Kymco MXU 500 User Manual

0 (0)

ATV off road

MXU 500 / MXU 500 IRS

Owner’s Manual

Version:T200-LAAOCA-US-A5

Do not remove this Owner’s Manual from the vehicle. Read this

manual carefully before operating the vehicle as it contains

important safety information.

IMPORTANT NOTICES

READ THIS MANUAL CAREFULLY

AGE RECOMMENDATION

RIDER TRAINING

Your Owner's Manual contains important information on safety, operation, and

maintenance. Any one who operates this ATV should carefully read and

understand the contents of this manual before riding the vehicle.

The minimum recommended age for this ATV model is 16. Children under age 16

should never operate this vehicle.

Anyone who operates this vehicle should get proper instruction.

FOR OFF-ROAD USE ONLY

This vehicle is designed and manufactured for off-road use only. This machine is

designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to

operate this machine on any public street, road or highway.

This machine complies with all applicable OFF-ROAD noise level and spark

arrester laws and regulation in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this

machine.

SPECIAL MESSAGES

KYMCO provides many important safety messages both in this manual and on the

vehicle. For your safety and the safety of others, pay special attention to all

warnings preceded by this alert symbol . Failure to follow the warnings

contained in this manual can result in SERIOUS INJURY or DEATH.

Indicates a strong possibility that serious injury or death may

result if instructions are not followed.

CAUTION Indicates a possibility that equipment or property damage

could result if instructions are not followed.

Note: Gives helpful information

The Owner's Manual should be considered a permanent part of your ATV. It should

remain with the vehicle at all times and stay with the ATV if it is sold.

WARNING

PREFACE

Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a

worldwide reputation for quality-in research, design, production and service.

For replacement parts and accessories, we recommend genuine KYMCO

products. They've been specially designed for your vehicle and manufactured to

meet KYMCO's demanding standards.

This manual will provide you with a good basic understanding of the features and

operation of this machine. This manual includes important safety information. It

provides information about special techniques and skills necessary to ride your

machine. It also includes basic maintenance and inspection procedures. If you

have any questions regarding the operation or maintenance of your machine,

please consult a KYMCO dealer.

We wish you many years of safe and enjoyable riding.

While reading this manual, remember:

Indicates a strong possibility that serious injury or death may

result if instructions are not followed.

All information in this publication is based on the latest product information

available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD

Reserves the right to make changes at any time without notice and without

incurring any obligation.

WARNING

CONTROL FUNCTIONS....................16

IGNITION SWITCH..............................16

INSTRUMENTS AND INDICATOR........17

Multi-function display.......................19

THROTTLE LEVER.............................30

SPEED LIMITER.................................31

HANDLEBAR SWITCHES....................26

Headlight dimmer switch..................26

Start button.....................................26

Engine stop switch...........................27

Passing signal switch.......................27

RIGHT HANDLEBAR SWITCH.............28

2WD/4WD select switch....................28

RECOIL STARTER..............................29

CONTENTS

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

SAFETY INFORMATION

DESCRIPTION AND MACHINE

IDENTIFICATION

...................1

......................4

..................................9

IDENTIFICATION NUMBER

RECORDS...........................................9

KEY IDENTIFICATION NUMBER............9

FRAME SERIAL NUMBER...................10

ENGINE SERIAL NUMBER..................10

PARTS LOCATION.............................11

Page Page

(Cont'd)

FRONT BRAKE LEVER.......................32

REAR BRAKE LEVER..........................32

BRAKE PEDAL...................................32

PARKING BRAKE...............................33

DRIVE SELECT LEVER.......................34

FUEL TANK CAP ................................35

FUEL VALVE......................................35

CHOKE KNOB....................................37

ACCELERATING PUMP LEVER .........38

SEAT..................................................39

FLAG POLE BRACKET.......................40

TRAILER HITCH.................................40

OWNER’S MANUAL STORAGE

COMPARTMENT.................................41

ACCESSORY SOCKET........................42

PRE-OPERATION CHECKS.............43

DRIVE SELECT LEVER ......................44

Drive select lever adjustment............46

FRONT AND REAR BRAKES................48

FUEL...............................................49

DRIVE SHAFT BOOTS........................50

ENGINE OIL ......................................51

FINAL GEAR OIL................................52

DIFFERENTIAL GEAR OIL..................52

THROTTLE LEVER.............................53

FITTINGS AND FASTENERS...............53

LIGHTS..............................................53

SWITCHES.........................................53

TIRES................................................54

How to measure tire pressure ..............55

Tire wear limit ....................................56

COOLANT..........................................56

Page Page

(Cont'd)

RIDING YOUR ATV ............................71

GETTING TO KNOW YOUR ATV .........72

RIDE WITH CARE AND

APPAREL...........................................75

PRE-OPERATION CHECKS................79

LOADING AND ACCESSORIES..........81

Loading and operational guidelines...81

Accessories.....................................82

MODIFICATIONS................................83

EXHAUST SYSTEM............................84

BE CAREFUL WHERE YOU RIDE........85

TURNING YOUR ATV ..........................94

SLIDING AND SKIDDING....................96

JUDGEMENT......................................73

GOOD

Speed limiter...................................80

Load Limits......................................81

No modifications..............................83

FOR OFF-ROAD USE ONLY.................90

DURING OPERATION.........................92

CLIMBING UPHILL.............................98

OPERATION........................................58

STARTING A COLD ENGINE...............58

Using the recoil starter......................61

STARTING A WARM ENGINE..............62

WARMING UP.....................................62

DRIVE SELECT LEVER OPERATION

AND REVERSE DRIVING ....................63

Shifting: neutral to high

and high to low .................................63

Shifting: neutral to reverse

and reverse to park...........................64

ENGINE BREAK-IN.............................65

ACCESSORIES ..................................68

PARKING..........................................66

Parking on a slope............................67

LOADING ...........................................69

Page Page

(Cont'd)

PERIODIC MAINTENANCE AND

ADJUSTMENT

...................................113

TOOL KIT/

TOOL KIT COMPARTMENT.................113

PERIODIC MAINTENANCE/

LUBRICATION..................................115

......................................118

DIFFERENTIAL GEAR OIL.................127

SPARK PLUG INSPECTION..............129

SPARK ARRESTER...........................130

AIR FILTER CLEANING.....................132

AIR CLEANER HOUSING DRAIN

TUBE...............................................135

IDLE SPEED ADJUSTMENT .............136

THROTTLE LEVER ADJUSTMENT....137

VALVE CLEARANCE ADJUSTMENT..138

FRONT BRAKE PADS INSPECTION...138

REAR BRAKE PADS INSPECTION.....139

ENGINE OIL

FINAL GEAR OIL...............................125

BRAKE FLUID INSPECTION..............139

(cont'd)

Page

RIDING DOWNHILL.......................104

CROSSING A SLOPE.........................106

RIDING OVER ROUGH TERRAIN.......108

CROSSING THROUGH SHALLOW

WATER........................................109

PARKING....................................110

WHAT TO DO IF..................................111

WHAT TO DO....................................111

Page

CLEANING AND STORAGE...........153

A. CLEANING ...................................153

B. STORAGE ....................................155

SPECIFICATIONS..................................157

INDEX...................................................163

NOISE REGULATION.............................161

MAINTENANCE RECORD.......................162

Page

COOLING SYSTEM INSPECTION......141

Engine overheating........................143

BATTERY..........................................146

Battery remove..............................147

Battery installation.........................147

FUSE REPLACEMENT......................148

HEADLIGHT BEAM ADJUSTMENT....149

DRIVE SHAFT BOOTS.......................149

CABLE INSPECTION AND

LUBRICATION..................................150

TROUBLESHOOTING .......................151

Troubleshooting chart...................152

WHEEL REMOVAL............................144

WHEEL INSTALLATION.....................144

Page

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

WARNING INFORMATION

Anyone who rides the vehicle should read and understand this information before riding. They

contain important information for safe and proper operation of your ATV.

The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes

hard to read, contact your KYMCO dealer for replacements.

(7)

(6)-a or (6)-b

(5)

(4)(3)(1)

(8)

(2)

(B) (A)

(B) (US version only)

(A) (US version only)

/MXU500IRS

(3)

Never carry passenger

This carrier.

Maximum load 45 Kg (100 lbs)：

(1)

WARNING

NEVER ride as a

passenger.

Passengers can cause a

loss of control, resulting

in SEVERE INJURY or

DEATH.

WARNING

(2)

Before shifting, you must stop the machine and

return the throttle lever to its closed position until

the engine speed to the specified idling speed.

Otherwise, the transmission may be damaged

(4)

CAUTION

(5)

Never carry passenger

This carrier.

Maximum load 85 Kg (187 lbs)：

WARNING

(6)-a(MXU 500)

(6)-b(MXU 500 IRS)

(8)

Exceeding vehicle towing limit could lead to an

accident. Reduce speed when towing a trailer.

Read owner's manual for details.

MAXIMUM TOWING CAPACITY: 454kg (1000lbs)

TONGUE WEIGHT: 16kg (35 lbs)

WARNING

(7)

WARNING

Improper tire pressure or overloading

cancauselossofcontrol.

Loss of control can result in severe

injury or death.

Cold tire pressure:

Front: psi ( kPa)

Rear: psi ( kPa)

Maximum weight capacity: lbs

(kg)

5.0 35

4.5 32

485

220

87505-LFE9-M35

SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from

other vehicles including motorcycles and cars. An accident can occur quickly, even during routine

maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-

cautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking

lots and streets.

Never operate anATV on any public street, road or highway, even a dirt or gravel one.



Read this manual and all labels carefully and follow the operating procedures described.

Never operate anATV without proper training or instruction.

Beginners should receive training from a certified instructor.

Always follow the age recommendation:

- A child under 16 years old should never operate an ATV with engine size greater than 90cc.

Never carry a passenger on an ATV.



Never operate anATV without wearing an approved motorcycle helmet that fits properly. You

should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or

jacket, and long pants.

Never consume alcohol or drugs before or while operating this ATV.

Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is

proper for the terrain, visibility and operating conditions, and your experience.

Never attempt wheel, jump, or other stunt.

Always inspect yourATV each time you use it to make sure it is in safe operating condition. Always

follow the inspection and maintenance procedures and schedules described in this manual.

Always keep both hands on the handlebars and both feet on the footboards of the ATV during

operation.

Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when operating the ATV.



Always follow proper procedures for turning as described in this manual. Practice turning at low

speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

Never operate on excessively rough, slippery or loose terrain until you have learned and practiced

the skills necessary to control the ATV on such terrain. Always be especially cautious on these

kinds of terrain.



Always follow proper procedures for climbing hills as described in this manual. Check the terrain

carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high

speed.

Never operate theATV on hills too steep. Practice on smaller hills before attempting larger hills.

Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,

maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special

procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed

straight uphill. Turn the ATV around and remount, following the procedure described in this

manual.



Always follow proper procedures for going down hills and for braking on hills as described in this

manual. Check the terrain carefully before you start down any hill. Shift your weight backward.

Never go down a hill at high speed. Avoid going down hill at an angle that would cause the vehicle

to lean sharply to one side. Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid

hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

Never attempt to turn the ATV around on any hill until you have mastered the turning technique

described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

POTENTIAL HAZARD

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Improper handling of gasoline.

Gasoline can catch fire and you could be

burned.

Always turn off the engine when refueling.

Do not refuel right after the engine has been

running and is still very hot.

Do not spill gasoline on the engine or exhaust

pipe/muffler when refueling.

Never refuel while smoking, or while in the

vicinity of sparks, open flames, or other

sources of ignition such as the pilot lights of

water heaters and clothes dryers.

When transporting the machine in another

vehicle, be sure it is kept upright and that the

fuel cock is in the "OFF" position.

Otherwise, fuel may leak out of the carburetor

or fuel tank.

WHAT CAN HAPPEN

HOW TO AVOID THE HAZARD

Gasoline is poisonous and can cause injuries.

If you should swallow some gasoline or inhale

a lot of gasoline vapor, or get some gasoline in

your eyes, see your doctor immediately.

If gasoline spills on your skin, wash with soap

and water. If gasoline spills on your clothing,

change your clothes.

WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed

area.

WHAT CAN HAPPEN

Exhaust fumes are poisonous and may

cause loss of consciousness and death

within a short time.

HOW TO AVOID THE HAZARD

Always operate your machine in an area

with adequate ventilation.

WARNING

KEY IDENTIFICATION NUMBER

The key identification number is stamped on

the hang tag as shown in the following

illustration.

DESCRIPTION AND MACHINE IDENTIFICATION

(1) Key identification number

IDENTIFICATION NUMBER RECORDS

Record the key identification number, frame

serial number, engine serial number and

model code information for assistance when

order replacement parts.

KEY NO.

FRAME NO.

ENGINE NO.

MODEL CODE

(1)

ENGINE SERIAL NUMBER

The engine serial number is stamped on the left

crankcase.

(1) Engine serial number

(1)

FRAME SERIAL NUMBER

The frame serial number is stamped on the

front and rear of the frame.

(1) Frame serial number

(1)

(01) Rear brake lever

(03) Front brake lever

(02) Headlights/Position lights

PARTS LOCATION

(01)(02)(02)(03)

(04) Taillights/Brake lights

(05) 2WD/4WD select switch and differential lock lever

Headlight dimmer switch

Starter button

Engine Stop Switch

Passing signal switch

(08) Spark arrester

(09) Trailer hitch (MXU 500 version only

(10) Throttle lever

(06) Instrument and indicators

(07)

)

(06)(04) (04)

(08)

(09)

(10)

(07) (05)

MXU 500 IRS selectivity appurtenances

(09)

(19)

) Battery/Fuse

(21) Tool kit

(23) Rear brake fluid reservoir

(24) Accessory socket seat

(25)

Exhaust system

(20

(22) Accelerating pump lever

Drive select lever

(19)(23) (20)(21)

(24) (25)

(22)

(11) Reservoir water tank

(12) Front brake fluid reservoir

(13) Fuel valve

Brake pedal fluid reservoir

(17) Seat lock lever

(18) Oil level inspection window

(14) Recoil starter

(15) Seat

(16)

(13)

(15)

(16) (17)

(14) (11)(12)

(18)

(26 Right footpeg

(27) Owner’s manual storage

(31) Rear cargo rack

(32) Fuel fill cap

(33) Choke knob

(34) Rear brake pedal

(35) Flag pole bracket

(36) Tool storage(MXU 500 IRS version only)

)

(28) Front cargo rack

(29) Ignition switch

(30) Left footpeg

(32) (33) (34)(31)

(27)

NOTE:

The machine you have purchased may differ

slightly from those shown in the figures of this

manual.

(35)

(29) (28)(30) (26)

(36)

(2)

OFF

(1)

CONTROL FUNCTIONS

(1) Ignition switch (2) Key

IGNITION SWITCH

ON :

Functions of the respective switch positions

are as follows:

The key can not be removed.

The engine can be started.

OFF:

"“:

All electrical circuits are switched off . The key

can be removed in this position.

All electrical circuits are switched on.

The ignition switch is ON while the position

light and taillight will light.

All electrical circuits are switched on.

The engine can be started.

The key can not be removed.

INSTRUMENTS AND INDICATOR

(1) Multi-function display

(2)

(4)

(5) Low-range indicator light “L”

(6) High-range indicator light “H”

(7) Neutral indicator light “N”

(8) Reverse indicator light “R”

(9) Park indicator light “P”

(10)

High beam indicator

(3) Coolant temperature warning indicator

Set button

Mode button

(11) Differential lock indicator(MXU 500 IRS version only)

(10)

(2)

(3)

(4)

(7)

(1) Multi-function display

The display includes the following functions:

Speedometer

Odometer/Tripmeter

Digital clock

2WD/4WD indicator

Fuel gauge

(2) High beam indicator

The ignition switch is at the " " position, the

high beam indicator will light when the headlight

switch to select High beam ( ).

(1)

(6) (5)(8)(9)

TRIPODO

mile

2WD

4WD

SET

MODE

P R N H L

(11)

(3) Coolant temperature warning indicator

When the coolant temperature reaches a

specified level, this indicator comes on to

warn that the coolant temperature is too hot.

If the indicator comes on during operation,

stop the engine as soon as it is safe to do so

and allow the engine to cool down for about

10 minutes.

(4) Set button

This button is used to select ODO, TRIP A

and TRIP B.

This button is also used to adjust the time

and reset the trip meter.

(5) Low-range indicator light “L”