Kymco MXU 500I IRS User Manual

KWANG YANG MOTOR CO.,LTD.

IMPORTANT NOTICES

READ THIS MANUAL CAREFULLY

AGE RECOMMENDATION

RIDER TRAINING

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

USE ATV

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.

WARNING

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.

Indicates a strong possibility that serious injury or death may

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:

WARNING

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.

CONTENTS

Page Page

LOCATION OF THE WARNING AND SPECIFICATION LABELS

SAFETY INFORMATION

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

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

DESCRIPTION AND MACHINE IDENTIFICATION

IDENTIFICATION NUMBER

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

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

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

ENGINE SERIAL NUMBER..................11

PARTS LOCATION.............................12

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

CONTROL FUNCTIONS....................17

IGNITION SWITCH..............................17

INSTRUMENTS AND INDICATOR........18

Multi-function display.......................20

LEFT HANDLEBAR SWITCHES...........27

Horn button.....................................27

Turn signal switch............................27

Headlight dimmer switch..................28

Hazard switch.................................29

Start switch.....................................30

RIGHT HANDLEBAR SWITCH

...............................................................31

2WD/4WD select switch .......31

TO JUMP START YOUR VEHICLE ......32

THROTTLE LEVER.............................33

SPEED LIMITER.................................34

(Cont'd)

Page Page

FRONT BRAKE LEVER.......................35

REAR BRAKE LEVER..........................35

BRAKE PEDAL...................................35

PARKING BRAKE...............................36

LOCKING STEERING.........................37

DRIVE SELECT LEVER.......................38

FUEL TANK ................................39

FUEL SYSTEM....................................39

SPARK PLUG INSPECTION...............41

BATTERY INSPECTION...........42

SEAT..................................................43

FLAG POLE BRACKET.......................44

TRAILER HITCH.................................44

OWNER’S MANUAL STORAGE

COMPARTMENT.................................45

ACCESSORY SOCKET........................46

PRE-OPERATION CHECKS.............47

DRIVE SELECT LEVER ......................48

Drive select lever adjustment............50

FRONT AND REAR BRAKES................52

FUEL...............................................53

DRIVE SHAFT BOOTS........................54

ENGINE OIL ......................................55

FINAL GEAR OIL................................56

DIFFERENTIAL GEAR OIL ...................56

THROTTLE LEVER.............................57

FITTINGS AND FASTENERS...............57

LIGHTS..............................................57

SWITCHES.........................................57

TIRES................................................58

How to measure tire pressure ..............59

Tire wear limit ....................................60

COOLANT..........................................60

(Cont'd)

Page Page

OPERATION........................................62

STARTING A COLD ENGINE...............62

STARTING A WARM ENGINE..............66

WARMING UP.....................................66

DRIVE SELECT LEVER OPERATION

AND REVERSE DRIVING....................67

ENGINE BREAK-IN.............................69

PARKING..........................................70

Parking on a slope............................71

ACCESSORIES ..................................72

LOADING ...........................................73

RIDING YOUR ATV ............................75

GETTING TO KNOW YOUR ATV .........76

RIDE WITH CARE AND

JUDGEMENT......................................77

APPAREL...........................................80

PRE-OPERATION CHECKS................82

LOADING AND ACCESSORIES..........84

Loading and operational guidelines...84

Accessories.....................................85

MODIFICATIONS................................86

No modifications..............................86

DURING OPERATION.........................87

EXHAUST SYSTEM............................89

PRACTICING......................................90

TURNING YOUR ATV ..........................91

CLIMBING UP SLOPE..........................92

RIDING DOWN SLOPE.........................98

PARKING...........................................99

WHAT TO DO IF .................................100

WHATTODO.....................................100

GOOD

(Cont'd)

PERIODIC MAINTENANCE AND ADJUSTMENT

TOOL KIT/

TOOLKIT COMPARTMENT.................101

PERIODIC MAINTENANCE/

LUBRICATION..................................103

ENGINE OIL .....................................106

FINAL GEAR OIL DIFFERENTIAL GEAR OIL ..115

SPARK PLUG INSPECTION..............117

SPARK ARRESTER...........................118

AIR FILTER CLEANING.....................120

AIR CLEANER HOUSING DRAIN

TUBE...............................................123

IDLE SPEED INSPECTION .............124

THROTTLE LEVER ADJUSTMENT....125

VALVE CLEARANCE ADJUSTMENT..126 FRONT BRAKE PADS INSPECTION...126

REAR BRAKE PADS INSPECTION......127

...................................101

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

Page Page

BRAKE FLUID INSPECTION..............127

COOLING SYSTEM INSPECTION......129

Engine overheating........................131

WHEEL REMOVAL............................132

WHEEL INSTALLATION.....................132

BATTERY..........................................134

Battery remove..............................135

Battery installation.........................135

FUSE REPLACEMENT......................136

HEADLIGHT BEAM ADJUSTMENT....137

DRIVE SHAFT BOOTS.......................137

CABLE INSPECTION AND

LUBRICATION..................................138

TROUBLESHOOTING .......................139

Troubleshooting chart...................140

(Cont'd)

Page

CLEANING AND STORAGE...........141

A. CLEANING ...................................141

B. STORAGE ....................................143

SPECIFICATIONS..................................145

NOISE REGULATION.............................149

MAINTENANCE RECORD.......................150

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.

(6)

(3)(2)(1)

(5)

(4)

(7)

(1)

(3)

WARNING

Never carry passenger

This carrier.

Maximum load 45 Kg (100 lbs)：

(2)

WARNING

Operating this ATV if you are under the age of 16 increases your changes of severe injury or death.

NEVER

under the age of 16.

operate this ATV if you are

CAUTION

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)

WARNING

Never carry passenger

This carrier.

Maximum load 85 Kg (187 lbs)：

(5)

(6)

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold

Recommended: FRONT:35 kpa,(0.35 0.03 kgf/cm ),5.0 0.4 psi REAR :32 3kpa,(0.32 0.03 kgf/cm ),4.5 0.4 psi

±± ±

Never set tire pressure over the recommended.

87505-LFE9-E01

(7)

WARNING

Exceeding vehicle towing limit could lead to an accident. Reduce speed when towing a trailer. Read owner's manual for details. MAXIMUM TOWING CAPACITY: 150kg (300lbs) TONGUE WEIGHT: 16kg (35 lbs)

Improper ATV use can result in SEVERE INJURY or DEATH.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER operate :



Without proper training or instruction.



At speeds too fast for your skills

the conditions.

Do not operate the vehicle after



consuming ALCOHOL OR DRUGS.

ALWAYS :



Use proper riding techniques to avoid

vehicle overturns on hills and rough terrain and in turns.



For your safety, wear gear to include

helmet gloves and foot protection.

Gasoline is flammable shut off engine,



avoid sparks and open flame when refueling.

LOCATE AND READ OPERATOR’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS

NEVER USE WITH

DRUGS

ALCOHOL

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. A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions.

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



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



Never operate an ATV 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 allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely.

Never operate an ATV 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 your ATV 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.



Never operate on excessively rough, slippery or loose terrain.



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 the ATV on hills.



Always follow proper procedures for climbing slopes as described in this manual. Check the terrain carefully before you start up any slope. Shift your weight forward. Never open the throttle suddenly. Never go over the top of a slope at high speed.

Always follow proper procedures for going down slopes and for braking on slopes as described in

this manual. Check the terrain carefully before you start down any slope. Shift your weight backward. Never go down a slope at high speed. Avoid going down slope at an angle that would cause the vehicle to lean sharply to one side. Go straight down the slope where possible.

Never attempt to turn the ATV around on any slope until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep slope if possible.



Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.



Always be careful when skidding or sliding. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.



Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.



Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.



Never modify an ATV through improper installation or use of accessories.



Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

WARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

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

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

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.

DESCRIPTION AND MACHINE IDENTIFICATION

IDENTIFICATION NUMBER RECORDS

Record the keys identification number, frame serial number and engine serial number information for assistance when order replacement parts.

IGNITION SWITCH KEY NO.

STEERING LOCK KEY NO.

KEYS IDENTIFICATION NUMBER

The keys identification number is stamped on the hang tag as shown in the following illustration.

FRAME NO.

ENGINE NO.

(1)

(1) Ignition switch key identification number (2) Steering lock key identification number

(2)

FRAME SERIAL NUMBER

The frame serial number is stamped on the rear of the frame.

(1) Frame serial number

ENGINE SERIAL NUMBER

The engine serial number is stamped on the left crankcase.

(1)

(1) Engine serial number

PARTS LOCATION

(04) (05) (06)

(01) Rear brake lever

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

(02) Headlights/Position lights (03) Front brake lever/Front parking brake (04) Right front turn signal light (05) Steering handlebar lock (06) Left front turn signal light ( A ) ATV Winch(LDA0AE version only)

(A)

(11) (09)

(10)(08) (08)(12) (07)

(15)(13) (16)

(14)

(07) Right rear turn signal light (08) Taillights/Brake lights (09) 2WD/4WD select switch and differential lock lever

(10) Instrument and indicators

Headlight dimmer switch

(11)

Starter button Hazard switch Turn signal switch

Horn switch (12) Left rear turn signal light (13) Spark arrester (14) Trailer hitch(LDA0AE /LDAOAD(FR)version only) (15) License light (16) Throttle lever

(22)

(19) (25)

(17)(18)

(17) Reservoir water tank (18) Front brake fluid reservoir (19) Right rearview mirror (20) Seat

Brake pedal fluid reservoir

(21)

Seat lock lever

(22)

Oil level inspection window

(23) (24) Tool storage (25) Left rearview mirror

(20)(21)

(23)(24)

(30) (26)(31) (27)(28)

(32) (33)

(29)

(26)

Exhaust system

) Battery/Fuse

(27 (28) Tool kit (29) Fuel pump (30)

Left rearview mirror (31) Rear brake fluid reservoir (32) Accessory socket seat (33)

Drive select lever

(37) (36)(39) (34)(38)

(35)

(34) Right footpeg (35) Owner’s manual storage (36) Front cargo rack (37) Ignition switch (38) Rear parking brake lever (39) Left footpeg (40) Rear cargo rack (41) Fuel fill cap (42) Rear brake pedal (43) Flag pole bracket

NOTE:

The machine you have purchased may differ slightly from those shown in the figures of this manual.

(41) (42) (43)(40)

CONTROL FUNCTIONS

IGNITION SWITCH

Functions of the respective switch positions are as follows:

OFF:

All electrical circuits are switched off except hazard light. The key can be removed in this position.

ON :

All electrical circuits are switched on. The engine can be started. The key can not be removed.

"“:

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.

(1)

OFF

(2)

(1) Ignition switch (2) Key

INSTRUMENTS AND INDICATOR

(12)

(14)

(11)

(13)

kmk

(5)

(8)

(7)(6)(9)(10)

(1) Multi-function display (2)

Right turn signal indicator/Left turn signal indicator

(3)

High beam indicator (4) Coolant temperature warning indicator (5)

Set button (6) Low-range indicator light “L” (7) High-range indicator light “H” (8) Neutral indicator light “N” (9) Reverse indicator light “N: (10) Park indicator light “P” (11)

Mode button

(12) EFIsystem

indicator (13) Differential lock indicator (14) Battery low voltage indicator light

(1) Multi-function display

(1)

The display includes the following functions: Speedometer

(2)

Odometer/Tripmeter Digital clock

(3)

(4)

4WD indicator Fuel gauge Engine tachometer

(2) Right turn signal indicator/Left turn signal indicator

Flashes when the right turn signal operates.

(3) High beam indicator

The ignition switch is at the " " position, the high beam indicator will light when the headlight switch to select High beam ( ).

(4) 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.

(5) 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 tripmeter.

(6) Low-range indicator light “L”

This indicator light comes on when the drive select lever is in the “L” position.

(7) High-range indicator light “H”

This indicator light comes on when the drive select lever is in the “H” position.

(8) Neutral indicator light “N”

This indicator light comes on when the drive select lever is in the “N” position.

(9) Reverse indicator light “R”

This indicator light comes on when the drive select lever is in the “R” position.

(10) Park indicator light “P”

This indicator light comes on when the drive select lever is in the “P” (park) position.

(11) Mode button

This button is used to select km/h, mph, km and mile. This button is also used to adjust the time and reset the trip meter.

(12)EFI system indicator

Engine check lamp bright or flashes when the EFI system has fails.

(13)Differential lock indicator

The front axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential in low traction situations. If the differential is in lock manner. The lock indicator will be activated.

Multi-function display

(4)

(1) Speedometer (2) 4WD indicator (3) Fuel gauge (4) Odometer/Tripmeter (5) Digital clock

(3)(2)(1)

(1) Speedometer

Shows riding speed in km/h or mph.

kmk

(5)

Press and hold MODE button for more than 2 seconds to select mph or km/h.

kmk

(2) 4WD indicator

Shows the drive mode is in the 4WD. Shows the drive mode isn’t in the 2WD.

(3) Fuel gauge

The fuel gauge shows the approximate fuel supply available in a graduated display. The normal operating fuel range is with the section between the segment F and segment E. When the segment E or the fuel indicator (3) flashes, fuel will be low and you should refill the tank as soon as possible.

(2)

(2) Segment E

(3)

(1)

(3) Fuel indicator(1) Segment F

+ 133 hidden pages