KYMCO UXV500iG Owner's Manual
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KYMCO UXV500iG Owner's Manual

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Do not remove this Owner's Manual from the vehicle. Read this manual carefully
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Summary of Contents for KYMCO UXV500iG

  • Page 1 Do not remove this Owner’s Manual from the vehicle. Read this manual carefully before operating the vehicle as it contains important safety information.
  • Page 2 The NOTE symbol indicates key information about a procedure or to clarify an operation.      Carefully read the SAFETY PRECAUTIONS before operating your UXV500iG as a vehicle. See pages 2 - 49 for safety information related to vehicle operation.

  • Page 3: Table Of Contents

    Gearshift Lever ........................60 - 61 EMISSION CONTROL INFORMATION ..................102 Parking Brake ........................61 – 62 KYMCO USA LIMITED WARRANTY ..................103 Differential Lock & Indicator ......................62 U.S. EPA EMISSION CONTROL STATEMENT/WARRANTY ..........104 Fuel Tank Filler ..........................63 Seat ..............................

  • Page 4: Introduction

     Carefully read the GENERATOR SAFETY PRECAUTIONS before activating and using the generator functions of your UXV500iG. See pages 50 - 56 for safety information related to generator operation.  There are specific alerts within this manual. You, and anyone else who will use the UTV or operate its...

  • Page 5: Introduction

    Remember, only authorized KYMCO dealers have the knowledge and resources to provide you with the best service possible. PROTECT YOUR SPORT Being able to use and enjoy your KYMCO Side-by-Side vehicle requires you and your family to operate it in a responsible manner. Before riding your UXV500iG you should: Learn and adhere to all local and state off-road riding laws ...
  • Page 6 Avoid going down a hill at an angle that would pery, or loose terrain. cause your UXV500iG to lean sharply to one side. Go straight  Always follow proper procedures for turning as described down the hill where possible.
  • Page 7  Never improperly install or improperly use accessories on uphill. Turn the vehicle around and reenter it following the pro- your UXV500iG. cedure described in this manual.  Always wear the seat belt while driving this vehicle.

  • Page 8: Serial Numbers

    The VIN 1 is located on the frame, behind the right, front wheel. authorized KYMCO dealer for assistance. Warranty repairs will be declined by KYMCO if the VIN or ESN on 1 1 1 1 1 your ATV have been removed or altered in any way. If your ATV requires a repair that will replace the engine crankcase or the frame, ask your dealer to contact KYMCO to discuss the situation.

  • Page 9: Location Of Parts & Controls

    LOCATION OF PARTS AND CONTROLS (1/3) AT AT AT AT AT AK AK AK AK AK 3 3 3 3 3 4 4 4 4 4 9 9 9 9 9 AL AL AL AL AL 8 8 8 8 8 5 5 5 5 5 AM AM AM AM AM 2 2 2 2 2...
  • Page 10 LOCATION OF PARTS AND CONTROLS (2/3) AS AS AS AS AS BL BL BL BL BL AR AR AR AR AR BO BO BO BO BO AQ AQ AQ AQ AQ BN BN BN BN BN BT BT BT BT BT BM BM BM BM BM BK BK BK BK BK AP AP AP AP AP...

  • Page 11: Location Of Parts & Controls

    LOCATION OF PARTS AND CONTROLS (3/3) BO BO BO BO BO BP BP BP BP BP BN BN BN BN BN BL BL BL BL BL BM BM BM BM BM Controls to the left of the steering wheel: BL 2WD/4WD & Differential Lock Knob BQ BQ BQ BQ BQ BR BR BR BR BR BS BS BS BS BS...

  • Page 12: Hang Tags & Warning Labels

    WARNING LABELS On the vehicle’s dash (1/2) 1 1 1 1 1 Your KYMCO UXV500iG comes equipped with several labels and hangtags containing important safety informa- tion. Anyone who drives the vehicle should read and un- derstand this information before operation. The labels should be considered permanent parts of the vehicle.

  • Page 13: Warning Labels

    WARNING LABELS On the vehicle’s dash (2/2) 4 4 4 4 4 3 3 3 3 3 INDICATES A POTENTIAL HAZARD THAT COULD RESULT IN SERIOUS INJURY OR DEATH...
  • Page 14 WARNING LABELS On the vehicle’s chassis (1/3) 6 6 6 6 6 6 6 6 6 6 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 4 4 4 4 4 INDICATES A POTENTIAL HAZARD THAT COULD RESULT IN SERIOUS INJURY OR DEATH...
  • Page 15 WARNING LABELS On the vehicle’s chassis (2/3) 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 7 7 7 7 7 7 7 7 7 7 INDICATES A POTENTIAL HAZARD THAT COULD RESULT IN SERIOUS INJURY OR DEATH...
  • Page 16 WARNING LABELS On the vehicle’s chassis (3/3) AL AL AL AL AL AK AK AK AK AK AL AL AL AL AL AT AT AT AT AT AK AK AK AK AK AT AT AT AT AT INDICATES A POTENTIAL HAZARD THAT COULD RESULT IN SERIOUS INJURY OR DEATH...

  • Page 17: Epa Label & Hang Tag

    EPA LABEL & HANGTAG 1. EPA LABEL 2. EPA HANGTAG INDICATES A POTENTIAL HAZARD THAT COULD RESULT IN SERIOUS INJURY OR DEATH...

  • Page 18: Warnings

    WARNINGS POTENTIAL HAZARD Operating this Side-by-Side vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if you do not know how to operate the vehicle properly in different situations and on different types of terrain. HOW TO AVOID THIS HAZARD Whether you are a beginning or experienced motorcycle, ATV rider or UTV driver, you should complete a certified training course directed at using this type of vehicle.
  • Page 19 HOW TO AVOID THIS HAZARD Never operate your UXV500iG on a public street, road, highway, or even a dirt or gravel road. In many states it is illegal to operate this type of vehicle on public streets, roads, or highways.
  • Page 20 Operating your UTV at excessive speeds. WHAT CAN HAPPEN Operating your UXV500iG at excessive speeds increases your chances of losing control of the vehicle, which can result in an accident. HOW TO AVOID THIS HAZARD Always drive your UXV500iG at a speed that is proper for the terrain, visibility, operating conditions and your experience.
  • Page 21 HOW TO AVOID THIS HAZARD Do not drive your UXV500iG on rough, slippery, or loose terrain until you have learned and practiced the skills necessary to control the vehicle on these surfaces. Always be especially cautious when driving your UTV on rough, slippery, or loose terrain.
  • Page 22 You may hit an obstacle or person behind you with the vehicle, resulting in serious injury. HOW TO AVOID THIS HAZARD Before you engage reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, operate your UXV500iG in reverse at slow speeds.
  • Page 23 Always follow proper riding procedures for going down hills as described in this Owner's Manual. Always check the terrain carefully before you start down any hill on your UXV500iG. Never go downhill at a high speed. Avoid going down a hill at an angle that would cause your vehicle to lean sharply to one side.
  • Page 24 Never attempt to turn your UXV500iG around on any hill until you have mastered the turning and steering techniques described in this Owner's Manual. Practice these maneuvers first on level ground. Be very careful when turning your UXV500iG on any hill, and avoid crossing the side of a steep hill, if possible.
  • Page 25 Improperly driving your UTV over obstacles. WHAT CAN HAPPEN Improperly driving over obstacles may cause you to lose control of your UXV500iG or cause a collision. A loss of control or a collision may cause the vehicle to overturn. HOW TO AVOID THIS HAZARD Before operating your UXV500iG in a new area, check for obstacles.
  • Page 26 Operating your UTV through deep or fast flowing water. WHAT CAN HAPPEN Your UXV500iG’s tires may float, causing loss of traction and loss of control, which could lead to an accident. Water can also reduce the stopping capability of your vehicle’s braking system.

  • Page 27: Warnings

    Never modify your UXV500iG or install accessories that are not specifically designed for your vehicle. All parts and accessories added to your UXV500iG should be genuine KYMCO components designed for use on this type of vehicle, and should be installed and used according to the installation instructions.
  • Page 28 HELMET When riding or driving an off-road vehicle, PREVENTION is the name While your UXV500iG is equipped with an overhead canopy, it can- of the game. "Had you only known" something could go wrong, you not take the place of a helmet. A helmet is an essential piece of would have prevented it.
  • Page 29 Side-by-Side vehicle before you drive it. Chances are good that you will be using your UXV500iG. in some rough terrain, and you do not This acronym means: want something to prevent you from enjoying your drive. Your best...
  • Page 30 Correct tire pressure is crucial to the proper operation of your Press down on the UXV500iG’s brake pedal. If the pedal does not UXV500iG. Consult the values listed below or the SPECIFICATIONS feel firm, or if it feels soft or "weak," the brake system could be low section of this manual for tire pressure guidelines.
  • Page 31 CHASSIS CHASSIS CHASSIS Turn your UXV500iG’s hi-beam and low-beam on and off to make Grass, leaves and other debris can get entangled in your Side-by- sure they work. At the same time, check that the taillight and brake Side vehicle’s suspension and shocks. Keep the suspension arms, lights work.
  • Page 32 AND SURVIV VIVAL WATER Before driving your UXV500iG, you need to prepare for the unex- Water is so important that you need to carry it regardless of the pected. Emergencies and accidents are traumatic, but the situation duration of your drive. Heat exhaustion and heat stroke can occur can be worse if your are not prepared for it.

  • Page 33: Active Driving

    TING THE ENGINE THE ENGINE THE ENGINE Always start your UXV500iG when it is at rest on a flat, level sur- These are your basic maneuvers: face. Carbon monoxide poisoning can kill you, so never run your * Entering the Vehicle UXV500iG’s engine in an enclosed space.
  • Page 34 ACTIVE DRIVING An easy way to remember the starting procedure for your UXV500iG is by using the acronym "BONE-C." Allow 30 seconds between starting attempts to allow the This acronym means: starting motor to cool. Continuous starting attempts will result in overheating and damage to the starting motor.

  • Page 35: Braking

    ACTIVE DRIVING BRAKING / STOPPING SHIFTING Always allow plenty of room and time to stop your UXV500iG safely. This KYMCO Side-by-Side vehicle is equipped with an automatic, Be alert and prepared, as quick stops are inevitable. Whether dual-range transmission with reverse capability. To shift your...

  • Page 36: Shifting

    Before driving your UXV500iG, take time to familiarize yourself com- pletely with the operational information described in this Owner’s 4. Always try to park your UXV500iG on level ground. If you have Manual. Be prepared to practice operating the controls and driving to park on a hill, shift the vehicle’s transmission into low gear...

  • Page 37: Riding Uphill

    1. Ease off the accelerator as you approach the turn to slow down NEVER RIDE YOUR 2. Slowly rotate the steering wheel into the direction of the turn UXV500iG UP OR 3. Gradually increase your speed as you come out of the turn DOWN HILLS STEEPER ...

  • Page 38: Active Riding

    ACTIVE RIDING K-TURNS Use the K-turn maneuver if you accidentally stall your UTV while driving uphill. Using a K-turn will enable you to point the vehicle downhill in a controlled manner and prevent it from rolling back- wards. Use the turning method on this page for K-turns: 1 1 1 1 1 1.

  • Page 39: Riding Downhill

    ACTIVE DRIVING RIDING DOWNHILL Success in driving downhill depends on how familiar and skilled Use extreme caution accelerating as your swerve so you can main- you are with using your vehicle's brakes. Use care to balance brak- tain better control of your vehicle. If you are in a situation where you ing force and downhill speed so you don't lose control and flip your feel you must swerve your vehicle, use this driving method: vehicle over.

  • Page 40: Tips

    SKIDDING or SLIDING CROSSING WATER Your UXV500iG can only handle water up to its footrests. Crossing Be careful: it's easy to lose control of your UTV driving through water deeper than that risks engine damage and/or personal injury.

  • Page 41: Riding In Cold Weather

    RIDING IN COLD WEATHER      NOTE: Engine damage caused by water ingestion or immer- sion will not be covered by your KYMCO warranty.      NOTE: Check that all of the controls move freely. Make sure 1.

  • Page 42: Active Driving

    ACTIVE DRIVING STOPPING YOUR UTV      NOTE: After the brakes thaw, dry them by applying them To stop your UTV, first release the accelerator pedal, then depress several times while riding slowly. the brake pedal smoothly. ...

  • Page 43: Sound Judgment

    SOUND JUDGMENT OVERVIEW 7. Do you thrive on the adrenaline rush you get from speeding and Human beings are not invincible: we need to use sound judgment dangerous situations? to keep ourselves and others safe from harm. Knowing that the first "S"...

  • Page 44: Environment

    SOUND JUDGMENT ENVIRONMENT NIGHT RIDING The environment that you will operate your UTV in is often harsh It is best to avoid driving your UTV at night when visibility is limited. and sometimes dangerous if you don't take proper precautions. With little to no light, it is difficult to see what is around you.

  • Page 45: Driving On Trails

    SOUND JUDGMENT DRIVING ON TRAILS Use sound judgment when driving your UTV on trails. You should only drive on trails that suit your driving ability. If the trail is very rugged, it may be best to find another route to your destination. Make yourself visible to others by using your UTV's headlights and taillights.

  • Page 46: Those Around You

    SOUND JUDGMENT THOSE AROUND YOU People do all kinds of things that you can't predict or control. Be Take steps with your riding apparel choices and your actions to make aware of others and their behavior, as it can affect your enjoyment yourself very visible.

  • Page 47: Personal Choices

    Cargo has such a significant affect on UTV handling that you need The last thing you would expect is that your KYMCO UTV would break down in the middle of a field. KYMCO products are usually so to adjust your speed to match your load. Even on level ground, you...

  • Page 48: Accessory Installation

    HOW TO AVOID THIS HAZARD Never exceed the stated load capacity of your UXV500iG (as noted in this Owner's Manual). Cargo should be properly distributed and securely attached. To aid in controlling your UTV, reduce speed when carrying cargo or pulling a trailer, and allow greater distances for braking. Always follow the instructions and recommendations in this Owner's Manual for carrying cargo or pulling a trailer.
  • Page 49 SOUND JUDGMENT ALCOHOL AND DRUG CONSUMPTION THE EFFECTS OF ALCOHOL* Alcohol is related to over 30% of the motor vehicle accidents in the The Number of Drinks that United States. It is extremely dangerous to drink alcoholic bever- Impair Mental and Physical Abilities ages and drive a UTV.

  • Page 50: Sound Judgment

    SOUND JUDGMENT YOUR PHYSICAL CONDITION GROUP BEHAVIOR Being physically exhausted is like being intoxicated. When fatigued, It is a proven psychological fact that people will do irresponsible you will not be able to perform detail-oriented tasks and your coor- and riskier things in a group that they would never consider doing dination will be affected.

  • Page 51: Supervision

    SUPERVISION OVERVIEW EXPERIENCED/TRAINED DRIVERS When you allow others to drive your UXV500iG you become re- When anyone borrows your UTV, you become responsible to supervise them and control their actions. Before a guest drives sponsible for their safety and their actions. The driving ability of...

  • Page 52: Generator Safety

    GENERATOR SAFETY INFORMATION Your UXV500iG is a unique vehicle as it is a quality UTV equipped with a compact, onboard generator. The same engine that propels the UXV500iG as a vehicle also provides rotational force to the onboard generator so it can produce electricity.

  • Page 53: Generator Safety

    Never disassemble, modify or attempt to repair the vehicle or its generator system yourself. This could result in fire or an electrical shock. For any service or repair, contact a KYMCO ATV dealer for assistance. Never touch the generator control panel, any wiring or other electrical components on the vehicle with wet hands.
  • Page 54 10. Stop the generator immediately if an electrical shock affects a person or an object. 11. Never modify any portion of the generator system or the vehicle (see a KYMCO dealer for all repair needs). 12. Do not use the generator to power solid-state electronic devices (such as a computer, radio, television, and other personal electronics.)

  • Page 55: Location Precautions

    LOCATION PRECAUTIONS & FOR VEHICLE GENERATOR EQUIPMENT OPERATION Safety precautions for selecting a operating environment for your vehicle and its on-board generator system. When selecting an area for operating your UTV’s on-board gen- erator system, follow these safety recommendations: Select an operational area that is free of oil, fuel, oil fumes or fuel vapor. Avoid areas with soil that has a high salinity content, such as coastal area.

  • Page 56: Operational Precautions

    OPERATIONAL PRECAUTIONS & (1/2) FOR VEHICLE GENERATOR EQUIPMENT Safety precautions for operating your vehicle and its on-board generator system. When operating your UTV’s on-board generator system, follow these safety recommendations: Do not operate the on-board generator if the engine oil level is low. This vehicle is equipped with a warning system to alert the operator if the engine’s oil level is low.

  • Page 57: Operational Precautions

    If you are uncertain if the control panel is adequately dry enough to permit safe generator operation, contact your KYMCO dealer for assistance. If the generator, or any connected device, begins to operate abnormally press the emergency stop button immediately to stop the electrical output.

  • Page 58: Electrical Cord & Socket Precautions

    If the generator socket does not provide a snug fit to the male plug on an electrical cord in good condi- tion, do not use the generator and see your KYMCO dealer for repair of the socket. When connecting the electrical cord verify the voltage rating of the equipment. Be sure to properly choose between the 110V and 220V sockets before plugging in any electrical cord.

  • Page 59: Section 2 - Operation & Maintenance Preface

    PARTS AND ACCESSORIES When you need replacement parts, oil, or accessories for your KYMCO UTV, be sure to use only GENUINE KYMCO PARTS, OIL, AND ACCESSORIES. Genuine KYMCO parts, oil, and accessories have been engineered and approved to meet the standards and requirements of your KYMCO UTV.

  • Page 60: Specifications

    Brake type ......Hydraulic Front & Rear Unified Gasoline (Recommended) ..87 Octane with Parking Brake Regular Unleaded Intake system type ....KYMCO EFI Engine Oil (Recommended) ... SAE 5W-30 Air filter type ......Sponge element (oiled) Engine Oil Capacity ....3.8 U.S. qt (3.6 L) Transmission type: ....

  • Page 61: Specifications

    UXV500i-G SPECIFICATIONS* (2/2) ELECTRICAL GENERATOR Battery ........MF-VTX20l (12V18AH) Rated output ......4.5 KW @ 3,600 RPM Charging output ..... 310 W @ 5,000 RPM Type ........Capacitor, self-excited Capacitors ......50uF / 350 VAC EXCLUDES GENERATOR SYSTEM Headlight ....... 12V/35/35W (2) GFCI Taillight/Brakelight ....

  • Page 62: Brake Pedal

    ACCELERATOR PEDAL BRAKE PEDAL (Throttle pedal) Your KYMCO UTV is equipped with front and rear hydraulic brakes that are activated simultaneously by the brake pedal. Depress the Push the accelerator pedal 2 down to increase the engine’s speed. brake pedal 1 to slow or stop the vehicle.

  • Page 63: Parking Brake

    2. Attempt to push the UTV      NOTE: The parking brake must lock the UTV’s wheels. If it 3 3 3 3 3 does not, take your UXV500iG to an authorized KYMCO dealer for service. Releasing the Parking Brake o release the parking brake, pull up on the handle and press the release button 5 (opposite page).

  • Page 64: Parking Brake

         NOTE: The parking brake handle must fully retreat into its housing and the wheels must roll freely after the parking 6 6 6 6 6 brake is released. If it does not, take your UXV500iG to an authorized KYMCO dealer for service. 7 7 7 7 7 Always make sure that the parking brake has been disen- gaged before operating your UTV.

  • Page 65: Fuel Tank Filler

    Overfilling the fuel tank can cause gasoline to contaminate the vehicle Evaporative Emission System and may cause poor running. If this occurs, contact your KYMCO dealer. 2 2 2 2 2 4. To replace the fuel filler cap, press it back into place on the fuel filler neck 5.

  • Page 66: Seat

    FEATURES & CONTROLS SEAT REMOVAL The seats on your UXV500iG can be removed from the chassis for cleaning or service. Never drive your UTV without fastening your seat belt. Passengers should wear their seat belt any time the ve- To remove the seat, pull up on hicle is in motion.

  • Page 67: Cargo Bed

    CARGO BED Tilting the Cargo Bed Opening & Closing the Tailgate Your UXV500iG’s cargo bed can tilt to aid in the removal of loose Your UXV500iG’s cargo bed has a tailgate which can be unlatched cargo, such as gravel. to ease the loading and unloading of cargo.

  • Page 68: Hood

    FEATURES & CONTROLS SWITCHES HOOD Ignition Switch You can open the hood on your UXV500iG to perform maintenance- related tasks. The UXV500iG ignition switch is a three-position, key-operated switch, The key can be removed from the switch when it is in the To open the hood, unhook the two rubber hood latches 1 and re- OFF position.

  • Page 69: Light Switch

    In this position the high-beam of the headlights are ON. 2WD / 4WD Knob The UXV500iG is equipped with an remote, electric system to shift the differential between two-wheel and four-wheel drive modes. Rotate and then press the 2WD/4WD knob to select the desired drive mode (see images at right).

  • Page 70: Generator Emergency Button

    AUXILIARY POWER OUTLET The UXV500iG is equipped with a large, plunger-style button that Your UXV500iG is equipped with a SAE 12VDC power outlet (ciga- will emergency stop the onboard generator. The button 1 is lo- rette lighter socket) to provide power to electrical accessories.

  • Page 71: Multifunction Meter

    MULTIFUNCTION METER The Liquid Crystal Display (LCD) portion of the multifunction meter Your UXV500iG is equipped with a multifunction meter on its dash- provides the driver with information such as vehicle speed, total miles board that includes speedometer, odometer, indicator lamps and operated, trip mileage, fuel level, time and drive mode.

  • Page 72: Tripmeter

    FEATURES & CONTROLS Multifunction Meter Operation Speedometer: MPH -or- Km/H Display To toggle the multifunction meter’s speed display between MPH The UXV500i-G’s multifunction meter can be programed to display speed in MPH or Km/H, distance traveled (tripmeter) and time and Km/H, press down the MODE button 1 for two seconds. This (clock).

  • Page 73: Tripmeter

    FEATURES & CONTROLS Clearing the Tripmeter To clear the tripmeter’s mileage, select the trip meter you wish to Once the clock display is flashing, you can set the hours and the clear, then press and hold the MODE button 1 and SET button 2 minutes.

  • Page 74: Generator Control Panel

    GENERATOR OPERATION GENERATOR CONTROL PANEL COMPONENTS 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 7 7 7 7 7 8 8 8 8 8 9 9 9 9 9 AL AL AL AL AL...

  • Page 75: Generator Relay Panel

    GENERATOR OPERATION & GENERATOR RELAY PANEL COMPONENTS LABELS AK AK AK AK AK 3 3 3 3 3 4 4 4 4 4 1 1 1 1 1 2 2 2 2 2 5 5 5 5 5 KWANG YANG MOTOR CO., LTD 35, WAN HSING ST., SANMIN DIST., KAOHSIUNG, TAIWAN, R.O.C.

  • Page 76: Engaging The Generator

    GENERATOR OPERATION ENGAGING THE GENERATOR To start and operate the generator, follow this procedure: STEP 1 Stop vehicle and allow engine to idle. STEP 2 Move the gear shift lever to the "PARK" position (verify that the vehicle is in PARK via the icon on the dash). STEP 3 Engage the Parking Brake Lever.

  • Page 77: Stopping The Generator

    GENERATOR OPERATION STOPPING THE GENERATOR To stop the generator, follow this procedure: STEP 1 Turn “OFF” the GFCI switch (once the switch is “OFF” disconnect any electrical cords and equipment plugged into the generator’s output sockets). STEP 2 Press the V-Mode switch. STEP 3 Verify that the Output Indicator Light goes out and then rotate the keyed generator switch to the “OFF”...

  • Page 78: Powering Electrical Devices

    GENERATOR OPERATION POWERING ELECTRICAL DEVICES To use the generator’s AC voltage output to power electrical devices, follow these recommendations:      Verify that the generator operation is normal and the engine speed is constant without extreme variation. ...
  • Page 79 GENERATOR OPERATION POWER OUTLET SOCKET SPECIFICATIONS Power outlet socket use precautions:      Do not use a multi-socket adapter (a splitter to add more sockets).      Verify the polarity before using the generator’s to power an electrical device. Alternating Current (AC) has polarity designations, see the owner’s guide of the electrical device you intended to use.
  • Page 80 T here are anomalies or failures parts related to the generator. Stop using the show the fault codes - see the table on page 80 of this manual) generator immediately and return your vehicle to your KYMCO dealer for inspection.
  • Page 81 GENERATOR OPERATION (2/2) TROUBLESHOOTING MAJOR PROBLEMS - If any of the following phenomenons occur, contact your KYMCO dealer as soon as possible for technical assistance.:      A power cord has abnormal heat or odor.     ...
  • Page 82 Generator RPM sensor or generator clutch mechanism are faulty NOTE: If you encounter a fault that is not immediately and simply rectified by operating the vehicle or the generator as outlined in this manual, contact your KYMCO dealer for technical assistance.

  • Page 83: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE SCHEDULE SERVICE EVERY 100 HOURS (REGARDLESS OF MILEAGE OR TIME) SERVICE EVERY 100 HOURS (REGARDLESS OF MILEAGE OR TIME) Continued on following page...
  • Page 84 PERIODIC MAINTENANCE SCHEDULE Continued on following page...
  • Page 85 BREAK-IN PROCEDURE The engine in your new UXV500iG (or a engine that has been renewed) requires a "break-in" period. How the engine is operated during the first month is most critical to the life of your UTV's engine, and proper operation during this break-in period will help assure maximum life and performance from your UXV500iG.
  • Page 86 UTV, to arrange for and pay for this initial service. Because of the technical ability and resources available to an au- thorized KYMCO dealer, it is best to take your UTV to the dealer for service rather than attempting to perform this initial service your-...

  • Page 87: Tool Kit

    TOOL KIT GASOLINE-OIL-LUBRICANT Recommended Gasoline A tool kit has been supplied with your UXV500iG for your con- venience. The tool kit is stored in the right glove box. The recommended fuel to use in your UTV is regular unleaded gasoline with a 87 minimum octane rating. In many areas, oxygen- ates (either ethanol or MTBE) are added to the gasoline.

  • Page 88: Engine Oil Level Inspection

    To replace the engine oil and oil filter, and clean the oil strainer use this procedure: 1. Park your UXV500iG on level ground 2. Warm up the engine for several minutes, then turn it off 1. Park your UXV500iG on level ground 3.
  • Page 89      NOTE: Skip step 5 and proceed to step 7 if you are not going to replace the oil filter cartridge. Any oil used in place of the KYMCO recommended en- 5. Remove the oil filter cartridge 5 with a suitable oil filter gine oil can cause serious engine damage.

  • Page 90: Front Differential / Rear Drive Lubricant

    UTV is then moved to a warm area. Inspect the oil for any signs of metal filings or water. If found, Do not overfill the fuel tank. take your UTV to an authorized KYMCO dealer for servicing.

  • Page 91: Spark Plug

    Instead, take your UTV AIR CLEANER to a KYMCO dealer. Air Cleaner Element Service You should periodically remove and inspect the spark plug because The air cleaner element (air filter) requires periodic service because it...

  • Page 92: Air Cleaner

    Spark Arrestor Cleaning 3 3 3 3 3 Your UXV500iG is equipped with a spark arrestor in its muffler. The spark arrestor is required for you to operate your UTV on public lands. Periodically you will need to clean the spark arrestor’s screen The air cleaner element must be in serviceable condition.

  • Page 93: Coolant Level

    GENERAL MAINTENANCE COOLING SYSTEM Inspection Your UXV500iG has a liquid-cooled engine and periodically you Hard water, tap water, or salt water is harmful the engine should inspect the level of the fluid in the coolant reservoir and the and the cooling system components. Always use distilled external condition of the radiator.

  • Page 94: Brake Fluid

    GENERAL MAINTENANCE BRAKES Brake Fluid Inspection Your UXV500iG has hydraulically operated brakes and periodically you should inspect the level and condition of the fluid in the brake POTENTIAL HAZARD fluid reservoir. Brake fluid contacting the skin or eyes. Inspect and adjust the brake fluid level in the reservoir using the...

  • Page 95: Wheels

    Always use the size and type of tires specified for your 4. Torque the nuts to the specified torque KYMCO UTV. Refer to the specifications chart in this manual for tire-related information and always maintain Wheel Nut torque ..... 40 lb-ft (55 N-m)

  • Page 96: Tires

    Use only KYMCO approved tires on your UTV when replacing tires. Failure to do so could result in unstable UTV operation. Tubeless Tire Repair...

  • Page 97: Battery

    12.5 DC Volts ventilated. 7. If the meter indicates low voltage, charge the battery using the To remove the battery from your UXV500iG for service, follow guidelines on the following page this procedure: 1.

  • Page 98: Battery

    GENERAL MAINTENANCE      NOTE: If the meter indicates the proper voltage, the bat- tery may be reinstalled in the UTV (see step 10). Before installing the battery, make sure the UTV’s igni- tion switch is in the OFF position. ...

  • Page 99: Fuses

    UXV500iG. The fuse box ac- 1 1 1 1 1 2 2 2 2 2...

  • Page 100: Generator Maintenance

    GENERATOR MAINTENANCE The generator of your KYMCO UXV500iG has been engineered to be reliable and easy-to-maintain. The generator does not need period maintenance other than a monthly check of the GFCI switches. Please review this section for the basic care related to the generator components of your UTV.

  • Page 101: Generator Maintenance

    GENERATOR MAINTENANCE Cleaning the Generator’s Control Panel 1. Use a clean micro-fiber type cloth to remove light dirt or dust. 2. If the dirt is difficult to remove, you can lightly moisten the cloth with water and a mild detergent. 3.

  • Page 102: Preparation For Storage

    Make sure that the rivets holding components together are tight - re- pare your UXV500iG for storage. If you lack the technical ability to place all loose rivets prepare your UTV for storage, consult an authorized KYMCO dealer 8.
  • Page 103 Make sure that the rivets holding components together are tight - re- free driving. To take your UTV out of storage, KYMCO recom- place any loose rivets mends using the following procedure: 10.

  • Page 104: Emission Control Information

    EMISSION CONTROL INFORMATION Crankcase Emission Control System Your UXV500iG’s engine is equipped with a closed crankcase system. Blowby gases are routed back into the combustion chamber via the intake system. This system does not allow the blowby gases to enter the atmosphere.

  • Page 105: Kymco Usa Limited Warranty

    KYMCO USA LIMITED WARRANTY...
  • Page 106 EPA EMISSION WARRANTY...

  • Page 107: Maintenance Records

    MAINTENANCE RECORD In the event your UTV requires repairs that may be covered by the KYMCO Limited Warranty, you will be required to present records and documents chronicling the maintenance history for the vehicle. The chart below can help you organize your records and serves as a reminder of the essential maintenance intervals.

  • Page 108: Maintenance Records

    OTHER MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED & NOTES...
  • Page 109 REPAIR & OTHER SERVICE RECORD DATE MILEAGE SERVICE PERFORMED & NOTES...

  • Page 110: Cleaning The Control Panel

    Driving on Trails ..........43 INTRODUCTION ..........2 - 3 Tailgate & Cargo Bed .......... 65 Electrical Cord & Socket Precautions ....56 KYMCO USA LIMITED WARRANTY ....103 Taking Responsibility .......... 49 EMISSION CONTROL INFORMATION ..102 Light Switch ............67 Those around You ..........

  • Page 111: Identification Numbers Record

    The ignition switch key identification code 1 is stamped on blade of the key. If you require a replacement key, you will need this code to obtain a new key from your authorized KYMCO dealer. Record the key number in the box above.
  • Page 112 5 Stan Perkins Road Spartanburg, SC 29307 Telephone: (864) 327-4744 FAX: (864) 327-4745 Prepared July 2014 T200-UCA0AA-A7...

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