Do not remove this Owner’s Manual from the vehicle. Read this
manual carefully before operating the vehicle as it contains
important safety information.
MXU 500 / MXU 500 IRS
ATV off road
Owner’s Manual
C 2008 KYMCO. All rights reserved. Printed in Taiwan. www.kymco.com
Version:T200-LAAOCA-US-A5
IMPORTANT NOTICES
READ THIS MANUAL CAREFULLY
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.
AGE RECOMMENDATION
The minimum recommended age for this ATV model is 16. Children under age 16
should never operate this vehicle.
RIDER TRAINING
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.
A
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.
B
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.
C
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..................10
PARTS LOCATION.............................11
..................................9
CONTROL FUNCTIONS....................16
IGNITION SWITCH..............................16
INSTRUMENTS AND INDICATOR........17
Multi-function display.......................19
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
THROTTLE LEVER.............................30
SPEED LIMITER.................................31
(Cont'd)
D
Page Page
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
(Cont'd)
E
Page Page
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
PARKING..........................................66
Parking on a slope............................67
ACCESSORIES ..................................68
LOADING ...........................................69
RIDING YOUR ATV ............................71
GETTING TO KNOW YOUR ATV .........72
RIDE WITH CARE AND
JUDGEMENT......................................73
APPAREL...........................................75
PRE-OPERATION CHECKS................79
Speed limiter...................................80
LOADING AND ACCESSORIES..........81
Load Limits......................................81
Loading and operational guidelines...81
Accessories.....................................82
MODIFICATIONS................................83
No modifications..............................83
EXHAUST SYSTEM............................84
BE CAREFUL WHERE YOU RIDE........85
FOR OFF-ROAD USE ONLY.................90
DURING OPERATION.........................92
TURNING YOUR ATV ..........................94
SLIDING AND SKIDDING....................96
CLIMBING UPHILL.............................98
GOOD
(Cont'd)
F
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
PERIODIC MAINTENANCE AND
ADJUSTMENT
TOOL KIT/
TOOL KIT COMPARTMENT.................113
PERIODIC MAINTENANCE/
LUBRICATION..................................115
ENGINE OIL
FINAL GEAR OIL...............................125
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
BRAKE FLUID INSPECTION..............139
...................................113
......................................118
Page
(cont'd)
G
Page
COOLING SYSTEM INSPECTION......141
Engine overheating........................143
WHEEL REMOVAL............................144
WHEEL INSTALLATION.....................144
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
Page
CLEANING AND STORAGE...........153
A. CLEANING ...................................153
B. STORAGE ....................................155
SPECIFICATIONS..................................157
NOISE REGULATION.............................161
MAINTENANCE RECORD.......................162
INDEX...................................................163
H
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.
(A) (US version only)
(2)
/MXU500IRS
(B) (US version only)
(4)(3)(1)
(5)
(7)
(B) (A)
1
(6)-a or (6)-b
(8)
(1)
(3)
WARNING
Never carry passenger
This carrier.
Maximum load 45 Kg (100 lbs)：
on
(2)
WARNING
NEVER ride as a
passenger.
Passengers can cause a
loss of control, resulting
in SEVERE INJURY or
DEATH.
(4)
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
(5)
WARNING
Never carry passenger
This carrier.
Maximum load 85 Kg (187 lbs)：
(6)-a(MXU 500)
.
on
2
(6)-b(MXU 500 IRS)
WARNING
Improper tire pressure or overloading
cancauselossofcontrol.
Loss of control can result in severe
injury or death.
Cold tire pressure:
Front: psi ( kPa)
5.0 35
Rear: psi ( kPa)
Maximum weight capacity: lbs
4.5 32
485
(kg)
220
87505-LFE9-M35
(7)
(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
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 precautions.
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 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.
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.
4
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 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 go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
5
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.
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.
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.
6
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.
7
WARNING
POTENTIAL HAZARD
ON
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.
8
DESCRIPTION AND MACHINE IDENTIFICATION
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
KEY IDENTIFICATION NUMBER
The key identification number is stamped on
the hang tag as shown in the following
illustration.
(1)
(1) Key identification number
9
FRAME SERIAL NUMBER
The frame serial number is stamped on the
front and rear of the frame.
(1)
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left
crankcase.
(1)
(1) Frame serial number
(1) Engine serial number
10
PARTS LOCATION
(01)(02)(02)(03)
(01) Rear brake lever
(02) Headlights/Position lights
(03) Front brake lever
11
(07) (05)
(06)(04) (04)
(04) Taillights/Brake lights
(05) 2WD/4WD select switch and differential lock lever
(06) Instrument and indicators
Headlight dimmer switch
(07)
Starter button
Engine Stop Switch
Passing signal switch
(08) Spark arrester
(09) Trailer hitch (MXU 500 version only
(10) Throttle lever
)
(08)
(09)
(10)
(09)
MXU 500 IRS selectivity appurtenances
12
(22)
(24) (25)
(19)(23) (20)(21)
(19)
Exhaust system
) Battery/Fuse
(20
(21) Tool kit
(22) Accelerating pump lever
(23) Rear brake fluid reservoir
(24) Accessory socket seat
(25)
Drive select lever
14
(13)
(14) (11)(12)
(15)
(11) Reservoir water tank
(12) Front brake fluid reservoir
(13) Fuel valve
(14) Recoil starter
(15) Seat
Brake pedal fluid reservoir
(16)
(17) Seat lock lever
(18) Oil level inspection window
(16) (17)
(18)
13
(29) (28)(30) (26)
(27)
(26 Right footpeg
)
(27) Owner’s manual storage
(28) Front cargo rack
(29) Ignition switch
(30) Left footpeg
(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)
NOTE:
The machine you have purchased may differ
slightly from those shown in the figures of this
manual.
(32) (33) (34)(31)
(35)
(36)
15
CONTROL FUNCTIONS
IGNITION SWITCH
Functions of the respective switch positions
are as follows:
OFF:
All electrical circuits are switched off . 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.
ON
(1)
OFF
(2)
(1) Ignition switch (2) Key
16
INSTRUMENTS AND INDICATOR
(1)
2WD
4WD
(2)
(3)
MODE
AB
TRIPODO
mile
PM
km
P R N H L
SET
(11)
(10)
(7)
(6) (5)(8)(9)
(4)
(1) Multi-function display
(2)
High beam indicator
(3) Coolant temperature warning indicator
(4)
Set button
(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)
Mode button
(11) Differential lock indicator(MXU 500 IRS version only)
(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 ( ).
17
(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”
This indicator light comes on when the drive
select lever is in the “L” position.
(6) High-range indicator light “H”
This indicator light comes on when the drive
select lever is in the “H” position.
(7) Neutral indicator light “N”
This indicator light comes on when the drive
select lever is in the “N” position.
(8) Reverse indicator light “R”
This indicator light comes on when the drive
select lever is in the “R” position.
(9) Park indicator light “P”
This indicator light comes on when the drive
select lever is in the “P” (park) position.
(10) 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.
(11)Differential lock indicator(MXU 500 IRS only)
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.
Pulling the lock lever to the left.
To lock the differential on the 4WD, move the
4WD differential Button.
18
Multi-function display
2WD
4WD
AB
TRIPODO
(4)
(1) Speedometer
(2) 2WD/4WD indicator
(3) Fuel gauge
(4) Odometer/Tripmeter
(5) Digital clock
mile
km
PM
(5)
(1)(2)(3)
(1) Speedometer
Shows riding speed in km/h or mph.
Press and hold MODE button for more than 2
seconds to select mph or km/h.
2WD
4WD
AB
TRIPODO
mile
PM
MODE
km
P R N H L
SET
19
(2) 2WD/4WD indicator
Shows the drive mode is in the 2WD or 4WD.
2WD
4WD
(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)
(3)
(3) Fuel indicator(1) Segment F
(2) Segment E
(1)
20
(4) Odometer/Tripmeter
The odometer shows the total mileage in Km or in miles.
The tripmeter shows the trip distance in Km or in miles.
There are two tripmeters, tripmerer A and tripmeter B
Press and hold SET button for more than 2 seconds to select ODO, TRIP A or TRIP B.
Press and hold MODE button for more than 2 seconds to select mile or km.
MODE
2WD
4WD
AB
TRIPODO
mile
PM
km
P R N H L
2WD
4WD
AB
TRIPODO
mile
PM
SET
MODE
km
SET
P R N H L
TRIPODO
AB
mile
km
21
To reset tripmeter:
1. Press and hold SET button for more than 2
seconds to select tripmeter A or tripmeter
B.
2. Press and hold both the MODE button and
SET button in the same time until the
tripmeter is reset.
MODE
2WD
4WD
AB
TRIP
mile
PM
km
P R N H L
TRIP
AB
mile
km
2WD
4WD
AB
TRIP
mile
PM
SET
MODE
TRIP
km
P R N H L
A
SET
mile
km
22
(5) Digital clock
Show the time (hours and minutes) while the
ignition is ON.
To adjust the time manually, proceed as follows:
1. Turn the ignition switch ON.
2. Press and hold SET button for more than 2
seconds to select ODO mode.
3. Press and hold both the MODE button and
SET button in the same time for more than 2
seconds. The clock will be set in the adjust
mode with the hour display flashing.
NOTE:
Digital clock can be adjust in ODO mode only,
never select TRIP A or TRIP B mode when you
want to adjust your digital clock.
23
ODO
MODE
PM
2WD
4WD
mile
PM
km
P R N H L
SET
4. To set the hour, press the SET button until the
desired hour.
5. Press the MODE button, the minute display will
start flashing.
ODO
MODE
2WD
4WD
mile
km
P R N H L
2WD
4WD
ODO
SET
MODE
mile
km
SET
P R N H L
24
6. To set minute, press the SET button until the
desired minute.
7. To end the adjustment, Press both the MODE
button and SET button in the same time.
ODO
MODE
2WD
4WD
mile
km
P R N H L
2WD
4WD
ODO
SET
MODE
mile
km
SET
P R N H L
25
LEFT HANDLEBAR SWITCHES
(1)
(2)
(1) Headlight switch
Headlight dimmer switch
Turn the switch to the " " position to switch on
the low beam.
Turn the switch to the " " position to switch on
the high beam.
Turn the switch to the " " position to switch off
the headlight.
(2) Starter button
Stater button
To starter the engine, press the starter button,
with the transmission in neutral, the ignition
switch ON and the engine stop switch
At RUN ( )
CAUTION:
See starting instructions prior to starting
engine (see page 58 for details).
26
(3)
(4)
(3)Engine stop switch
Engine stop switch
When the switch is in the RUN ( ) position, the
engine will operate. When the switch is in OFF
( ) position, the engine will not operate.
This switch is intended primarily as a safety or
emergency control, and it should normally
remain in the RUN ( ) position.
NOTE:
If you stop your ATV by turning the engine stop
switch OFF ( ), be sure to turn the ignition
switch OFF to prevent battery discharge.
(4) Passing signal switch
Passing signal switch
When passing, if there are cars coming from the
opposite direction, press and release the
passing signal switch and the headlight will wink
to warn the coming vehicles.
27
RIGHT HANDLEBAR SWITCH
(1)
2WD/4WD select switch
This ATV is equipped with a 2WD/4WD select
switch, which permits a choice between the
“2WD” and “4WD” drive modes. Select a drive
mode that is suitable for your riding.
The 2WD/4WD select switch is located above
the throttle lever. To select the drive mode,
push the 2WD/4WD select switch to the
desired position.
(1) 2WD/4WD select switch(MXU 500)
2WD mode2WD mode
4WD mode4WD mode
2WD
TRIPODO
4WD
TRIPODO
AB
AB
mile
km
mile
km
PM
PM
Multi-funtion displayMulti-funtion display
To check your present drive mode, look at the
Multi-function display.
(1) 2WD/4WD
Select switch
(1)
MXU 500 IRS versionMXU 500 IRS version
28
(1)
RECOIL STARTER
The recoil starter is on the right side of the ATV.
It is used to start the engine when the battery is
low.
See using the recoil starter .
1. Pull the grip up briskly and fully.
2.After the engine starts, put the grip back to
original position and seal the hole.
(page 61)
(1) Recoil starter
NOTE:
Do not allow water enter the right case,
a.lways put the recoil starter to original
position and seal the hole
29
THROTTLE LEVER
It is operated by the thumb. Pressing the lever
opens the throttle. When pressure is released,
spring tension automatically closes the throttle.
Regulate the speed of the machine by varying
the throttle position.
WARNING
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate,
making it difficult to speed up or slow down
when you need to. This could cause an
accident.
(1)
(1) Throttle lever(MXU 500 version)
(1)
(1) Throttle lever(MXU 500 IRS version)
HOW TO AVOID THE HAZARD
Check the operation of the throttle lever
before you start the engine. If it does not
work smoothly, check for the cause.
Correct the problem before riding the ATV.
Consult a KYMCO dealer if you can't find or
solve the problem yourself.
30
SPEED LIMITER
The speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed
to the maximum. Screwing in the adjuster limits
the maximum engine power available and
decreases the maximum speed of the ATV.
WARNING
POTENTIAL HAZARD
Improper adjustment of the speed limiter
and throttle.
(1)
(2)
(A)
(1) Adjuster (2) Locknut (A) 13mm(0.52in)
WHAT CAN HAPPEN
The throttle cable could be damaged.
Improper throttle operation could result.
You could lose control, have an accident or
be injured.
HOW TO AVOID THE HAZARD
Do not turn the speed adjuster out more
than 13 mm (0.52 in). Always make sure the
throttle lever free play is adjusted to 3~5
mm (0.12~0.2 in). See page 137.
31
FRONT BRAKE LEVER
The front brake lever is next to the right
handgrip.
The front brakes are operated by squeezing the
front brake lever.
REAR BRAKE LEVER
The rear brake is operated by squeezing the
rear brake lever, near left handgrip.
BRAKE PEDAL
Operating the brake pedal applies the rear
brake.
(1)
(1) Rear brake pedal
(2)
(1) Front brake lever
(1)
(2) Rear brake lever
32
PARKING BRAKE
To set the parking brake, squeeze the front
brake lever and lock it with the lock lever. Always
set the parking brake when parking and before
starting the engine.
To unlock the parking brake, squeeze the front
brake lever until the lock lever releases.
Using the parking brake in freezing weather may
cause the brakes to freeze in the locked
position.
(See page 66.)
(1)
WARNING
POTENTIAL HAZARD
Improper use of the parking brake.
WHAT CAN HAPPEN
The ATV could start moving unexpectedly
if the parking brake is not applied before
starting the engine. This could cause loss
of control or a collision.
The brake could overheat if you ride the
ATV without releasing the parking brake.
You could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
HOW TO AVOID THE HAZARD
Always set the parking brake before
starting the engine.
Always be sure you have released the
parking brake before you begin to ride.
(1) Lock lever
33
DRIVE SELECT LEVER
The drive select lever is used to shift your ATV
into the low, high, neutral, reverse and park
positions. Refer to for drive select
lever adjustment and operation.
page 46 ~ 47
(1)
(L)
(H)
NOTE:
Apply the rear brake and shift the shift lever
into P position before turning off the engine
when parking the vehicle on an incline if you
park on an incline with shift lever in H, L or R
position, vehicle weight will make it difficult to
shift into neutral.
(N)
(R)
(P)
(1) Drive select lever
(L) Low
(H) High
(N) Neutral
(R) Reverse
(P) Park
34
FUEL TANK CAP
After refueling, be sure to tighten the fuel tank
cap until it clicks.
Insert the breather tube into the meter cover
hole.
To refuel refer to
page 49.
FUEL VALVE
The fuel valve supplies fuel from the fuel tank to
the carburetor. The fuel valve has three
positions.
(1)
(1) Fuel tank cap
(2) Breather tube
(3) Meter cover hole
(2)
(1)
(3)
(1) Fuel valve
35
OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this
position when the engine is not running.
ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with
""mark
the lever in this position.
RES: This indicates reserve. If you run out of fuel while riding, turn the lever to this
""mark
position. THEN FILL THE FUEL TANKAT THE FIRST OPPORTUNITY. After refueling, return
the fuel valve lever to the "ON" position.
NOTE:
After refueling, do not operate the ATV with the fuel valve in the RES position. If you run out of fuel,
there will be no reserve supply.
OFF RESON
RES
ON
RES
ON
36
RES
ON
CHOKE KNOB(MXU 500 version only)
Starting a cold engine requires a richer air-fuel
mixture. A separate starter circuit supplies this
mixture.
Move in direction (A) to turn on the choke knob.
Move in direction (B) to turn off the choke knob.
Refer to "starting a cold engine" for proper
operation.
(See page 58.)
CAUTION:
Extended use of the choke may impair piston
and cylinder wall lubrication and shorten the
life of the engine.
Pushing the choke knob too hard to the OFF
position may dislodge the choke cable boot.
If this happens, water and dirt may enter the
choke cable and cause corrosion. If the
choke is hard to actuate, or feels like it is
sticking, check the cable boot.
(1)
(2)
(3)
(B)
(1) Fully open (2) Half open
(A) ON position (B) OFF position
(A)
The carburetor uses the automatic choke
device in MXU 500 IRS version.
(3) Closed
37
ACCELERATING PUMP LEVER
The accelerating pump lever is on the carburetor right side under the seat.
Starting a cold engine start-ambient temperature below -15 C (0 F) requires a richer air-fuel
00
mixture.
When the pump lever is pressed, the pump send the necessary amount of fuel to the fuel pipe for
correcting fuel.
Refer to "starting a cold engine" for proper operation.
(See page 59.)
38
MXU 500 IRS
(1) Accelerating pump
MXU 500
(1) Accelerating pump
(1)
(1)
SEAT
To remove the seat, pull the seat lock lever
upward and pull up the seat at the rear.
(1)
(1) Seat lock lever
To install the seat, align the tabs on the seat with
the grommets on the frame and press the seat
down until it locks.
NOTE:
Make sure that the seat is securely fitted.
39
FLAG POLE BRACKET
Flag poles are optional equipment available
from your KYMCO dealer. To mount a flag pole
in the bracket to make you more visible.
NOTE:
Flag poles are required in some riding areas.
Check local regulations before riding.
(1)
(1) Flag pole bracket
(1) Flag pole bracket
TRAILER HITCH
The trailer hitch is located on the rear axle
housing. To use the hitch, you will need proper
size ball as specified by the trailer
manufacturer.
To attach the ball and properly hook up a trailer,
follow the trailer manufacturer's instructions.
For load limits and operational guidelines, see
page 81
.
(1)
(1)
(1) Trailer(MXU 500 version only)
(MXU 500 IRS has not this fittings)
(If you need this accessories. Please ask your dealers )
40
OWNER’S MANUAL STORAGE
COMPARTMENT
Your ATV provides storage for the owner’s
manual so you’ll have it with you for easy
reference. Store your owner’s manual (1) in the
storage compartment (2) at the right side of the
front fender.
(2)
(1)
To open the compartment, remove the lid (3).
The owner’s manual should be stored in the
plastic bag.
Be careful not to flood this area when washing
your ATV
(3)
(1) Owner's manual
(2) Storage compartment
(3) Lid
41
ACCESSORY SOCKET
The accessory socket (1) is attached to the left
side of the meter cover. You can use the
accessory socket to power a trouble light,
spotlight, radio, or cell phone, etc.
CAUTION:
Do not plug in any heat-generating accessory
such as an automobile cigarette lighter
because it can damage the socket.
Be carful not to flood this accessory socket
when washing yourATV.
Be sure the engine is on and the headlights are
turned off before using the accessory socket,
otherwise you may drain the battery.
The accessory socket’s rated capacity is DC
12V, 120 Watts (10A) or less. If you exceed this
limit, you may blow a fuse.
When you are done using an accessory, unplug
it, and cover the socket with the cap.
To use the accessory socket:
1. Turn the ignition switch ON, then start the
engine.
2. Turn the headlights OFF.
3. Open the accessory socket cap (2), and then
insert the accessory power plug into the
socket.
(1) Accessory socket
(2) Cap
42
(1)
(2)
PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM
DRIVE SELECT LEVER
BRAKE
FUEL
ENGINE OIL, FINAL GEAR
AND DIFFERENTIAL GEAR OIL
DRIVE SHAFT BOOTS
THROTTLE
WHEELS AND TIRES
FITTINGS AND
FASTENERS
SWITCHES
LIGHTS
COOLANT
ROUTINE
Check the lever for proper operation.
Check operation, condition, and brake fluid level.
Fill with DOT 4 brake fluid if necessary.
Check fuel level.
Fill with fuel if necessary.
Check oil level.
Fill with oil if necessary.
Check for leakage
Check for damage.
Check for proper throttle cable operation.
Check tire pressure, wear and damage.
Check all fitting and fasteners.
Check for proper function.
Check for proper operation.
Check coolant leakage.
Fill with coolant if necessary.
PAGE
44 47～
48, 138 140～
49 50～
51 52, 118 128～～
50
53
54 56, 144 145～～
53
53
53, 149
56 57, 141 143～～
43
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibillty of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and
maintenance procedures and schedules
described in the Owner's Manual.
DRIVE SELECT LEVER
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.
Check operation of the lever before start the
engine.
1. Make sure moving the shift lever into the "N"
position of the shift guide.
2. Turn the ignition switch to "ON" and check the
neutral indicator lamp comes on.
3. If the neutral indicator lamp does not come
on, then see for adjustment.page 46~47
44
WARNING
POTENTIAL HAZARD
Operating with improperly adjusted drive
select lever.
(1)
(1) Drive select lever
(N) Neutral
(N)
WHAT CAN HAPPEN
You may lose the gear shifting,
which lead to accident.
HOW TO AVOID THE HAZARD
Make sure moving the shift lever into the
"N" position and neutral indicator lamp
comes on before start the engine.
45
control of
Drive select lever adjustment
1. Turn the ignition switch is ON and make sure
the engine stop.
2. Remove 3 fasteners (1), then remove the left
side cover (2).
3. Loosen the locknuts (3) of rod (4). Shift the
gear to neutral by moving the shift lever
and/or turn the rod. (The neutral indicator
lamp comes on.)
(2)
(1) Fasteners
(2) Left side cover
(1)
(4)
(3)
(3) Lock nuts
(4) Rod
46
4.Turn the rod clockwise or counterclockwise
until the drive select lever (5) into the "N"
position of the shift guide and tighten the
locknuts.
(5)
(N)
(5) Drive select lever
(N) Neutral
47
FRONT AND REAR BRAKES
1. Make sure there is no brake fluid leakage.
2. Check operation of the levers and pedal.
They should move smoothly and there should
be a firm feeling when the brake is applied. If
not, have the machine inspected by a
KYMCO dealer.
WARNING
POTENTIAL HAZARD
Riding with improperly operating brakes.
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
3. Brake operation
Test the brakes at slow speed after starting
out to make sure they are working properly. If
the brakes do not provide proper braking
performance, inspect the brakes for wear.
(See page 138~140.)
HOW TO AVOID THE HAZARD
Always check the brakes at the start of
every ride. Do not ride the ATV if you find
any problem with the brakes. If a problem
cannot be corrected by the adjustment
procedures provided in this manual, have
the ATV inspected by a KYMCO dealer.
48
FUEL
Fill the fuel tank when necessary and make sure
there is sufficient gasoline in the tank.
Check for leaks.
(1)
(1) Fuel neck
Recommended fuel:
UNLEADED FUEL
Fuel tank capacity:
Total: 17L(3.57 lmp gal, 4.42 US gal)
Reserve: 2.3L(0.48 lmp gal, 0.6 US gal)
Your KYMCO engine has been designed to use
regular unleaded gasoline with a pump octane
number of 86 or higher, or research octane
number of 91 or higher. If knocking or pinging
occurs, use a different brand of gasoline or
premium unleaded fuel. Unleaded fuel will give
you longer spark plug life and reduced
maintenance cost.
Use unleaded fuel only because it produces
fewer engine and spark plug deposits and
extends the life of the exhaust system. Never
use stale or contaminated gasoline or an
oil/gasoline mixture.
Avoid getting dirt, dust or water in the fuel tank.
49
WARNING
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and
severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine.
DRIVE SHAFT BOOTS
Check the rubber drive shaft boots for damage or
leaking grease. If necessary, have your KYMCO
dealer replace them.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not
to spill fuel, especially on the engine or
exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely.
Do not refuel right after the engine has
been running and is still very hot.
(1)
(1) Drive shaft boots
50
ENGINE OIL
Make sure the engine oil at the specified level.
Add oil as necessary.
(See page 118~124.)
Check for leaks.
10030
0
50
0
70
0
90
0
0
110 F
SAE 5W
CAUTION:
Besuretousemotoroilsthat do not contain
anti-frictionmodifiers.Passengercarmotor
oils(oftenlabeled"EnergyConserving")
containanti-frictionadditiveswhichwill
causestarterclutchslippage,resultingin
reducedcomponentlifeandpoorengine
performance.
SAE 10W 30－
SAE 10W 40－
SAE 20W 40－
SAE 20W 50－
-1 0
0
0
0
10
0
20
0
30
0
0
40 C
Recommended engine oil classification: API
Service SJ type or higher
Oil quantity:
Engine oil:
Periodic oil change:
3L(2.64Impqt,3.18USqt)
Total amount:
3.6L(3.17Impqt,3.82USqt)
51
REAR GEAR CASE OIL
Make sure the rear gear case oil at the specified
level. Add oil as necessary.
(See page
125~126.)
Check for leaks.
FRONT GEAR CASE OIL
Make sure the front gear case oil at the specified
level.Add oilas necessary.
(Seepage 127~128.)
Checkfor leaks.
Recommended rearl gear case oil:
Type: hypoid gear oil
Viscosity: SAE# 80
Oil quantity:
(MXU 500)
Rear gear case oil:
Periodic oil change:
0.13 L (0.114 Imp qt, 0.138 US qt)
Total amount:
0.15 L (0.132 Imp qt, 0.159 US qt)
Oil quantity:
(MXU 500 IRS)
Rear gear case oil:
Periodic oil change:
0.23 L (0.20 Imp qt, 0.243 US qt)
Total amount:
0.25 L (0.22 Imp qt, 0.265 US qt)
Recommended final gear oil:
Type: hypoid gear oil
Viscosity:
Oil quantity:
SAE #80(MXU 500IRS)/SAE#90(MXU 500)
(MXU 500)
Front gear case oil:
Periodic oil change:
0.30 L (0.264 Imp qt, 0.318 US qt)
Total amount:
0.30 L (0.264 Imp qt, 0.318 US qt)
Oil quantity:
(MXU 500 IRS)
Front gear case oil:
Periodic oil change:
0.25 L (0.22 Imp qt, 0.265 US qt)
Total amount:
0.27 L (0.238 Imp qt, 0.286 US qt)
52
THROTTLE LEVER
Check to see that the throttle lever operates
correctly. It must open smoothly and spring back
to idle position when released. Repair as
necessary for proper operation.
LIGHTS
Check the headlight and taillight to make sure
they are in working condition. Repair as
necessary for proper operation.
FITTINGS AND FASTENERS
Always check the tightness of chassis fittings
and fasteners before a ride. Take the machine to
a KYMCO dealer or refer to the Service Manual
for correct tightening torque.
SWITCHES
Check the operation of the headlight switch,
engine stop switch and any other switches.
Repair as necessary for proper operation.
53
TIRES
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or
operation of this ATV with improper or
uneven tire pressure, may cause loss of
control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
1.The tires listed below have been
approved by Kwang Yang Motor Co., Ltd.
for this model. Other tire combinations
are not recommended.
Front
Rear
Size
25X8-12
25X10-12
Type
Tubeless
Tubeless
2.The tires should be set to the recommended
pressure:
Recommended tire pressure
Front: 25~32 kpa (0.25~0.32 kgf/cm ,
3.5~4.5 psi)
Rear:
25~32 kpa (0.25~0.32 kgf/cm ,
3.5~4.5 psi)
Front:32~38 kpa (0.32~0.38 kgf/cm ,
4.6~5.4 psi)_MXU 500 IRS
Rear: 29~35 kpa (0.29~0.35 kgf/cm ,
4.1~4.9 psi)
Check and adjust tire pressures when the
2
_MXU 500
2
2
2
tires are cold.
Tire pressures must be equal on both sides.
3.Tire pressure below the minimum specified
could cause the tire to dislodge from the
rim under severe riding conditions.
The following are minimums:
Front:25 kpa (0.25 kgf/cm , 3.5 psi)
Rear: 25 kpa (0.25 kgf/cm , 3.5 psi)
Front:32 kpa (0.32 kgf/cm , 4.6 psi)_MXU 500 IRS
Rear: 29 kpa (0.29 kgf/cm , 4.1 psi)
2
2
2
2
_MXU 500
54
4.Higher pressures may cause the tire to
burst. Inflate the tires very slowly and
carefully. Fast inflation could cause the
tire to burst.
Set pressure tires cold.
Set tire pressures to the following
MXU
500
Front
Rear
Recommended
pressure
28 kpa
(0.28 kgf/cm ,
3.92 psi)
28 kpa
(0.28 kgf/cm ,
3.92 psi)
2
2
Minimum
25 kpa
(0.25 kgf/cm ,
3.5 psi)
25 kpa
(0.25 kgf/cm ,
3.5 psi)
2
2
Maximum
32 kpa
(0.32 kgf/cm ,
4.5 psi)
32 kpa
(0.32 kgf/cm ,
4.5 psi)
How to measure tire pressure
Use the low-pressure tire gauge. (Tool kit)
NOTE:
The low-pressure tire gauge is included as
standard equipment. Make two
measurements of the tire pressure and use
the second reading. Dust or dirt in the gauge
could cause the first reading to be incorrect.
2
(1)
2
MXU
500 IRS
Front
Rear
Recommended
pressure
35 kpa
(0.35 kgf/cm ,
5.0 psi)
32 kpa
(0.32 kgf/cm ,
4.5 psi)
2
2
Minimum
32 kpa
(0.32 kgf/cm ,
4.6 psi)
29 kpa
(0.29 kgf/cm ,
4.1 psi)
2
2
Maximum
38 kpa
(0.38 kgf/cm ,
5.4 psi)
35 kpa
(0.35 kgf/cm ,
4.9 psi)
2
(1) Low-pressure tire gauge
2
55
Tire wear limit
When the tire groove decreases to 4 mm (0.16
in) due to wear, replace the tire.
A. Standard: 4mm (0.16 in)
COOLANT
Check the coolant level in the reservoir tank
when the engine is cold. (The coolant level will
vary with engine temperature.) The coolant
level is satisfactory if it is between the "FULL"
and "LOW" marks on the tank. If the coolant
level is at or below the "LOW" level, add tap
water (soft water) to bring the level up to
"FULL". Change the coolant every two years.
(See for details.)page 141~143
CAUTION:
Hard water or salt water is harmful to the
engine. You may use distilled water if you
can not get soft water.
56
(1)
(2)
(3)
WARNING
POTENTIAL HAZARD
Removing the radiator cap when the engine
and radiator are still hot.
(1) Coolant reservoir cap
(2) Maximum level mark
(3) Minimum level mark
FULL
LOW
WHAT CAN HAPPEN
You could be burned by hot fluid and steam
blown out under pressure.
HOW TO AVOID THE HAZARD
Wait for the engine to cool before removing
the radiator cap. Always use a thick rag
over the cap. Allow any remaining pressure
to escape before completely removing the
cap.
Should be serviced by your authorized
KYMCO dealer when changing the coolant.
57
OPERATION
WARNING
STARTING A COLD ENGINE
POTENTIAL HAZARD
Operating ATV without being familiar with
all controls.
WHAT CAN HAPPEN
Loss of control, which could cause an
accident or injury.
HOW TO AVOID THE HAZARD
Read the Owner's Manual carefully. If there
is a control or function you do not
understand, ask your KYMCO dealer.
WARNING
POTENTIAL HAZARD
Freezing control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always make
sure all control cables work smoothly
before you begin riding.
1. Set the parking brake .
2. Turn the fuel valve to "ON".
3. Turn the ignition switch to "ON" position and
the engine stop switch to “ “
4. Shift the drive select lever into the neutral or
park position.
58
5. Use the accelerating pump if the cold engine
00
start-ambient temperature below -15
C(0 F).
Using the accelerating pump:
Remove the seat , then press the
(page 39)
accelerating pump lever twice.
MXU 500 IRS
(1) Accelerating pump
MXU 500
(1)
(1)
(1) Accelerating pump
59
NOTE:
The engine can be started in any gear if the
brake lever is applied. However, it is
recommended to shift into neutral or park
before starting the engine.
When the select lever is in the neutral or
park position, if either indicator light does
not come on, ask a KYMCO dealer to inspect
its electric circuit.
6. Use the choke knob in reference to the figure:
(MXU 500 version only)
Position :Cold engine start-ambient
temperature below 5 C (40 F).
Position :Cold engine start-ambient
temperature at 0 C
000
(30 F)~30 C(90 F) and warming up
position.
Position :Cold engine start-ambient
temperature above 25 C(80 F) and
warm engine start position.
00
0
00
1. Fully open
3. Closed
2. Half open
a. Choke knob
7. Completely close the throttle lever and start
the engine by pushing the start switch.
8. The carburetor uses the automatic choke
device in MXU 500 IRS version.
60
60
NOTE:
If the engine fails to start, release the start
switch, then push the start switch again.
Each cranking should be as short as
possible to preserve battery energy. Do not
crank the engine more than 10 seconds on
each attempt.
If the battery is discharged, pull the recoil
starter to start the engine.
8. If the engine is started with the choke knob in
position 1, the choke knob should be
returned to position 2 to warm up the engine.
If the engine is started with the choke knob in
position 2, keep the choke knob in this
position to warm up the engine.
9. Continue warming up the engine until it idles
smoothly and return the choke knob to
position 3 before riding.
Using the recoil starter
The recoil starter is used to start the engine
when the battery is low.
(1)
(1) Recoil starter
61
To start the engine without the electric starter:
1. Follow steps 1 through 6.
2. With the throttle closed, grasp the starter grip
firmly, then pull it out slowly until it seats
lightly.
3. Pull the grip up briskly and fully.
4. After the engine starts, allow the starter grip to
return slowly.
CAUTION:
See the "engine break-in" section prior to
operating engine for the first time.
STARTING A WARM ENGINE
To start a warm engine, refer to the "Starting a
cold engine" section. The choke knob should not
be used. The throttle should be opened slightly.
NOTE:
Do not allow water enter the right case,
a.lways put the recoil starter to original
position and seal the hole
5. Follow steps 8 through 9.
WARMING UP
To get maximum engine life, always warm up the
engine before starting off. Never accelerate
hard with a cold engine! To see whether or not
the engine is warm, check if it responds to the
throttle normally with the choke knob turned off.
62
DRIVE SELECT LEVER OPERATION AND
REVERSE DRIVING
(1)
(L)
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.
NOTE:
Apply the rear brake and shift the shift lever
into P position before turning off the engine
when parking the vehicle on an incline if you
park on an incline with shift lever in H, L or R
position, vehicle weight will make it difficult to
shift into neutral.
Shifting: Neutral to high and high to low
1. Bring theATV to a complete stop and return
the throttle lever to the closed position.
2. Apply the brakes, then shift by moving the
drive select lever along the shift guide.
(1) Drive select lever
(H) High (N) Neutral
(R) Reverse (P) Park
(L) Low
NOTE:
Make sure that the drive select lever is
completely shifted into position.
63
(H)
(N)
(R)
(P)
Shifting: neutral to reverse and reverse to
park
1. Bring the machine to a complete stop and
return the throttle lever to the closed position.
2. Apply the brake pedal.
3. Shift from neutral to reverse or from reverse
to park and vice versa by moving the drive
select lever along the shift guide.
(L)
(H)
(N)
(R)
NOTE:
When in reverse, the reverse indicator light
should be on. If the light does not come on, ask
a KYMCO dealer to inspect the machine.
4. Check behind for people or obstacles, then
release the rear brake pedal.
5. Open the throttle lever gradually and continue
to watch to the rear while backing.
(P)
WARNING
POTENTIAL HAZARD
Improperly operation in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind
you, resulting in serious injury.
HOW TO AVOID THE HAZARD
When you shift into reverse, make sure
there are no obstacles or people behind
you. When it is safe to proceed, go slowly.
64
ENGINE BREAK-IN
There is never a more important period in the life
of your machine than the period between zero
and 20 hours.
For this reason, we ask that you carefully read
the following material. Because the engine is
brand new, you must not put an excessive load
on it for the first 20 hours, the various parts in
the engine wear and polish themselves to the
correct operating clearances.
During this period, prolonged full throttle
operation or any condition which might result in
excessive engine heating must be avoided.
However, momentary (2~3 seconds maximum)
full throttle operation under load does not harm
the engine.
Each full throttle acceleration sequence should
be followed with a substantial rest period for the
engine by cruising at lower r/min so the engine
can rid itself of the temporary build up of heat.
If any abnormality is noticed during this period,
consult a KYMCO dealer.
1. 0~10 hours:
Avoid continuous operation above half
throttle. Allow a cooling off period of five to
ten minutes after every hour of operation.
Vary the speed of the machine from time to
time. Do not operate it at full throttle position.
2. 10~20 hours:
Avoid prolonged operation above 3/4 throttle.
Rev the machine freely through the gears but
do not use full throttle at any time.
3. After break-in
Avoid prolonged full throttle operation. Vary
speeds occasionally.
65
PARKING
When parking, stop the engine and shift into the
park position. Turn the fuel valve to "OFF" and
apply the parking brake.
The front brake lever has three locked position
that allow it to be used as a parking brake.
To set the parking brake, .
(1) Locked position
(2) Lock lever
see page 33
(1)
(3)
(2)
(3) Certainly locked position
66
Parking on a slope
WARNING
POTENTIAL HAZARD
Parking on a hill or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, increasing
the chance of an accident.
HOW TO AVOID THE HAZARD
Avoid parking on hills or other inclines. If
you must park on an incline, place the
machine transversely across the incline,
apply the parking brake, and block the front
and rear wheels with rocks or other objects.
Do not park the ATV at all on hills that are so
steep you could not walk up them easily.
1. Bring the machine to a stop by applying the
brakes.
2. Stop the engine.
3. With the brake applied, shift the drive select
lever into the park position
4. Apply the parking brake.
67
ACCESSORIES
Accessories can affect the handling and control
of your ATV. Keep the following in mind when
considering an accessory or operating an ATV
which has accessories.
Choose only accessories designed for your
ATV. Your KYMCO dealer has a variety of
genuine KYMCO accessories. Other
accessories may also be available on the
market. However, it is not possible for KYMCO
to test all non-KYMCO accessories, nor have
any control over the quality or suitability of
them. Choose a genuine KYMCO accessory,
or one that is equivalent in design and quality.
Accessories should be rigidly and securely
mounted. An accessory which can shift
position or come off while you are riding could
affect your ability to control the ATV.
Do not mount an accessory where it could
interfere with your ability your to control the
ATV. Examples include (but are not limited to)
a heavy or bulky object attached to the
handlebars which could make steering
difficult, an accessory that limits your ability
to move around on the seat, or one that limits
your view.
Use extra caution when riding an ATV with
accessories. The ATV may handle differently
than it does without accessories.
68
LOADING
As originally equipped, this ATV can carry cargo
or tow a trailer, you must use common sense and
good judgment. Keep the following points in
mind:
Never exceed the weight limit shown. An
overloaded ATV can be unstable.
Maximum load
Rear cargo rack: 85 kg (187 lbs)
Front cargo rack: 45 kg (100 lbs)
Trailer
Maximum towing capacity: 454 kg (1000 lbs)
Tongue weight: 16kg (35 lbs)
(1)(2)
(1) Rear cargo rack (2) Front cargo rack
(3)
(3) Trailer(MXU 500 )
(3)
(3) Trailer
(MXU 500 IRS has not this fittings)
(If you need this accessories. Please ask your dealers )
69
Load cargo on the cargo racks as close to the
center of the vehicle as possible. Put cargo at
the rear of the front and at the front
of the rear . Center the load from
side to side.
Tie down cargo securely to the carriers. Make
sure cargo in the trailer cannot move around.
A shifting load can cause an accident.
Make sure the load does not interfere with
controls or your ability to see where you are
going.
Ride more slowly than you would without a
load. The more weight you carry, the slower
you should go.
Allow more braking distance. A heavier
vehicle takes longer to stop.
Avoid making sharp turns unless at very slow
speeds.
Avoid hills and rough terrain. Choose terrain
carefully. Added weight affects the stability
and handling of the ATV.
Never carry passenger on the cargo racks.
．
cargo rack
cargo rack
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing
cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling
which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this ATV.
Cargo should be properly distributed and
securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance for
braking.
70
Riding Your ATV
71
WARNING
Indicates a potential hazard that could result
in serious injury or death.
GETTING TO KNOW YOUR ATV
This ATV is for recreation and utility use. This
section, riding yourATV, provides generalATV
riding instructions for recreational riding. The
skills and techniques described in this section,
however, are appropriate for all types of riding.
Riding your ATV requires special skills acquired
through practice over a period of time. Take the
time to learn the basic techniques well before
attempting more difficult maneuvers.
Riding your newATV can be a very enjoyable
activity, providing you with hours of pleasure.
But it is essential to familiarize yourself with the
operation of theATV to achieve the skill
necessary to enjoy riding safely.
Before you begin to ride, be sure you have read
this Owner's manual completely and understand
the operation of the controls. Pay particular
attention to the safety information on
. Please also read all caution and warning
4~8
labels on yourATV.
pages
72
RIDE WITH CARE AND GOOD JUDGEMENT
Get training if you are inexperienced.
Beginners and inexperienced riders should get
proper instruction on how to operate this ATV.
WARNING
POTENTIAL HAZARD
Operating this ATV without proper
instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased
if the operator does not know how to
operate the ATV properly in different
situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Become familiar with this ATV at slow
speeds first, even if you are an experienced
operator.
Do not attempt to operate at maximum
performance until you are totally familiar
with the machine's handling and
performance characteristics.
Riding your machine requires skills acquired
through practice over a period of time.
Take the time to learn the basic techniques well
before attempting more difficult maneuvers.
73
Not recommended for children under 16 year
of age.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations
for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not
recommended for their age can lead to
severe injury or death of the child.
HOW TO AVOID THE HAZARD
A child under 16 should never operate an
ATV with engine size greater than 90cc.
74
APPAREL
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an
approved motorcycle helmet, eye
protection and protective clothing.
WHAT CAN HAPPEN
Operating without an
approved motorcycle
helmet increases your
chances of a severe
head injury or death in
the event of an
accident.
Operating without eye
protection can result in
an accident and
increases your chances
of a severe injury in the
event of an accident.
Operating without protective clothing
increases your chances of severe injury in
the event of an accident.
HOW TO AVOID THE HAZARD
Always wear an approved motorcycle
helmet that fits properly.
You should also wear:
eye protection(goggles or face shield)
gloves
boots
long-sleeved shirt or jacket
Long pants
75
Do not operate after consuming alcohol or
drugs.
Operator's performance capability is reduced by
the influence of alcohol or drugs.
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming
alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or
while driving this ATV.
76
This machine is designed to carry operator
only-passengers prohibited.
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and
control this ATV. Could cause an accident,
resulting in harm to you and/or your
passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to
allow the operator to shift position as
needed during operation. It is not for
carrying passengers.
77
Never carry passenger on the .cargo racks
WARNING
POTENTIAL HAZARD
Carrying a passenger on the .
WHAT CAN HAPPEN
Greatly reduces your ability to balance and
control this ATV. Could cause an accident,
resulting in harm to you and/or your
passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger on the
. The is to allow the
racks cargo racks
operator to carry cargo. It is not for
carrying passengers.
cargo racks
cargo
78
PRE-OPERATION CHECKS
Always perform the pre-operation checks listed
page 43
on before riding for safety and proper
care of the machine.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or
equipment damage.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or
operation of this ATV with improper or
uneven tire pressure, may cause loss of
control, increasing your risk of an
accident.
HOW TO AVOID THE HAZARD
Always inspect tour ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and
maintenance procedures and schedules
described in the Owner's Manual.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified
in the Owner's Manual for this vehicle on
pages 54~56.
Always maintain proper tire pressure as
described in the Owner's Manual on
page55.
79
Do not operate at speeds too fast your skills
or the conditions.
WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast for
your skills or the conditions.
Speed limiter
For riders inexperienced with this model, this
model is equipped with a speed limiter in the
throttle lever housing. The speed limiter limits
the power and top speed of the machine.
Turning the screw in decreases top speed, and
turning it out increases top speed.
WHAT CAN HAPPEN
Increases your chances of losing control of
the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always go at a speed that is proper for the
terrain, visibility and operating conditions,
and your experience.
(1)
(2)
(1) Adjuster (2) Locknut
80
LOADING AND ACCESSORIES
Load Limits
There are limits to how much weight can be
carried on yourATV.
NOTE:
The following weight limits apply to standard
equipment only. Modifying your ATV, using nonstandard equipment or riding on terrain that is
not flat and smooth could further reduce these
limits.
MAXIMUM WEIGHT CAPACITY:
220 kg (485 lbs)
(Combined weight of rider, all accessories
and all cargo)
MAXIMUM TOWING CAPACITY:
454 kg (1000 lbs)
TONGUE WEIGHT:
16 kg (35 lbs)
MAXIMUM LOADING LIMIT:
REAR CARGO RACK: 85 kg (187 lbs)
FRONT CARGO RACK: 45 kg (100 lbs)
Loading and Operational Guidelines
This ATV is not designed to carry or tow a trailer.
If you decide to add accessories to allow you to
carry cargo or tow a trailer, use common sense.
Carrying cargo will affect how your ATV handles
and greatly reduce its ability in accelerating,
braking and making turns and other maneuvers.
Be sure to observe the weight limits and follow
these guidelines:
1. Never ride with a passenger.
2. Do not tow another vehicle.
3. Make sure all cargo is secured before riding.
4. Allow extra room for starting, stopping and
turning whenever you carry cargo or pull a
trailer.
5. Avoid riding on steep slopes when carrying
cargo or pilling a trailer.
6. Never cross a slope when toeing a trailer.
81
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing
cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling,
stability and braking which could lead to an
accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this ATV.
Cargo should be properly distributed and
securely attached.
Reduce speed when carrying cargo or
pulling a trailer. Allow greater distance for
braking.
Always follow the instructions in your
Owner's Manual for carrying cargo or
pulling a trailer.
Accessories
Genuine KYMCO accessories have been
specifically designed for and tested on this
vehicle. Because KYMCO cannot test all other
accessories, you are personally responsible for
properly selecting, installing, and using nonKYMCO accessories. Always follow the loading
instructions above, plus the following:
1. Carefully inspect the accessory to make sure
it does not block any lights, reduce ground
clearance, or limit suspension travel, steering
travel, or other controls.
2. Make sure the accessory does not interfere
with your ability to shift body position on the
seat or operate hand and foot controls.
3. Do not add electrical equipment that will
exceed the vehicle's electrical system
capacity. A blown fuse could cause a loss of
lights or engine power.
82
MODIFICATIONS
WARNING
POTENTIAL HAZARD
Operating this ATV with improper
modifications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some
situations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper
installation or use of accessories. All parts
and accessories added to this vehicle
should be genuine KYMCO or equivalent
components designed for use on this ATV
and should be installed and used according
to instruction. If you have question, consult
an authorized ATV dealer.
No Modifications
Modifying this ATV or removing original
equipment may render the vehicle unsafe or
illegal. Spark arresters and mufflers are
required in most areas. Don't modify your
exhaust system or emission control system
components. Remember, excessive noise
bothers everyone and creates a bad image for
off-road vehicles.
83
EXHAUST SYSTEM
The exhaust on the machine is very hot during
and following operation. To prevent burns, avoid
touching the exhaust system. Park the machine
in a place where pedestrians or children are not
likely to touch it.
WARNING
POTENTIAL HAZARD
Hot exhaust system
WHAT CAN HAPPEN
Someone touching the exhaust system
during or after operation could be burned.
HOW TO AVOID THE HAZARD
Do not touch the hot exhaust system.
Do not park the machine in a place where
others might be likely to touch it.
84
BE CAREFUL WHERE YOU RIDE
This machine is designed for off-road use only.
Riding on paved surfaces can cause loss of
control.
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
ATV are designed for off-road use only.
Paved surfaces may seriously affect
handling and control of the ATV, and may
cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.
85
Do not ride on any public road, street, or
highway.
Riding on public roads can result in collisions
with other vehicles.
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads
or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street,
road or highway, even a dirt or gravel one.
In many states it is illegal to operate ATVs
on public streets, roads and highways.
86
Know the terrain where you ride. Ride cautiously
in unfamiliar areas. Stay alert for
or roots other hidden
hazards
in the terrain, and
which may cause the machine to upset.
holes, rocks,
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating
this ATV on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps,
or holes, without enough time to react.
Could result in the ATV overturning or
going out of control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when
operating on unfamiliar terrain.
Always be alert to changing terrain
conditions when operating the ATV.
66
87
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on
excessively rough, slippery or loose
terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle
control, which could result in an accident,
including an overturn.
HOW TO AVOID THE HAZARD
Do not 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.
88
When riding in an area where you might not
easily be seen, such as desert terrain, mount a
caution flag on the machine. DO NOT use the
flag pole bracket as a trailer hitch.
WARNING
POTENTIAL HAZARD
Operating in areas where you might not be
seen by other off-road vehicles.
WHAT CAN HAPPEN
You could be in a collision. You could be
injured.
HOW TO AVOID THE HAZARD
Always mount a caution flag on the
machine to make you more visible. Watch
carefully for other vehicles.
89
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for
off-road use only.
Do not ride in areas posted "no trespassing". Do
not ride on private property without getting
permission.
90
Select a large, flat area off-road to become
familiar with yourATV. Make sure that this area
is free of obstacles and other riders. You should
practice control of the throttle, brakes, shifting
before trying more difficult terrain.
Always avoid riding on paved surfaces: the ATV
is designed for off-road use only, and handling
maneuvers are more difficult to perform on
pavement.
With the engine idling, return the starter knob to
the closed position and shift the drive select
lever into the forward position. Then release the
parking brake. Apply the throttle slowly and you
will start to accelerate. If the throttle is applied
too abruptly, the front wheels may lift off the
ground resulting in a loss of directional control.
Avoid higher speeds until you are thoroughly
familiar with the operation of your ATV.
Set the parking brake and follow the instruction
on page 58~62 to start the engine. Once it has
warmed up you are ready to begin riding your
ATV. Remember that the engine and exhaust
pipe will be hot when riding and afterwards; do
not allow skin or clothing to come in contact with
these components.
When slowing down or stopping, release the
throttle and apply the brakes smoothly and
evenly. Improper use of the brakes can cause
the tires to lose traction, reducing control and
increasing the possibility of an accident.
91
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