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Summary of Contents for KYMCO UXV500
- 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 Your Side-by-Side vehicle can be hazardous to operate. A collision or a rollover can happen quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. For your safety, understand and follow all of the warnings contained in this Owner’s Manual and the labels applied to your vehicle. Keep this Owner’s Manual with your vehicle at all times.
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Page 3: Section 1 - Safety 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 UXV500 you should:... -
Page 4: Table Of Contents
TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 - SAFETY Fuel Tank Filler ..................52 INTRODUCTION ..................1 Seat ......................53 TABLE OF CONTENTS ................2 Seat Belts ....................53 UTV HAZARD WARNING ..............3 - 4 Head Cushions .................. -
Page 5: Utv Hazard Warning
Avoid going down a hill at an angle that would pery, or loose terrain. cause your UXV500 to lean sharply to one side. Go straight Always follow proper procedures for turning as described down the hill where possible. - Page 6 Never improperly install or improperly use accessories on uphill. Turn the vehicle around and reenter it following the pro- your UXV500. cedure described in this manual. Always wear the seat belt while driving this vehicle.
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Page 7: Serial Numbers
Your KYMCO UXV500 has two identification numbers: the Ve- case. hicle Identification Number (VIN), and the Engine Serial Num- The VIN and ESN are required by your KYMCO dealer to or- ber (ESN). der proper parts, perform service, and submit warranty claims. -
Page 8: Location Of Parts & Controls
LOCATION OF PARTS AND CONTROLS 1 Right Head Cushion 6 Left Tail/Brake Light AK Steering Wheel 2 Right Seat (passenger) 7 Seat Belts AL Canopy 3 Right Tail/Brake Light 8 Cargo Bed AM Grab Handles 4 Left Head Cushion 9 Headlights AN Bumper 5 Left Seat (driver) AT Battery... - Page 9 LOCATION OF PARTS AND CONTROLS AP Hood BL Choke Knob BQ Glove Box (locking storage) AQ Grab Handles BM Ignition Switch BR Auxiliary Power Outlet AR Seat Belts BN Steering Wheel BS Speedometer AS Fuel Tank Cap (gas cap) BO Brake Pedal CT Glove Box (open) BT Muffler &...
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Page 10: Hang Tags & Warning Labels
Anyone who drives the vehicle should read and under- stand this information before operation. The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer immediately for a replacement. WARNING LABELS On the vehicle’s dash... - Page 11 WARNING LABELS On the vehicle’s dash 3 3 3 3 3 Indicates a potential hazard that could result in serious injury or death.
- Page 12 WARNING LABELS On the vehicle’s chassis 5 5 5 5 5 4 4 4 4 4 6 6 6 6 6 5 5 5 5 5 6 6 6 6 6 4 4 4 4 4 Indicates a potential hazard that could result in serious injury or death.
- Page 13 WARNING LABELS On the vehicle’s chassis 7 7 7 7 7 8 8 8 8 8 8 8 8 8 8 7 7 7 7 7 9 9 9 9 9 AT AT AT AT AT 9 9 9 9 9 AK AK AK AK AK AT AT AT AT AT AK AK AK AK AK...
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Page 14: Epa Label & Hangtag
EPA LABEL & HANGTAG 1. EPA LABEL 2. EPA HANGTAG Indicates a potential hazard that could result in serious injury or death. -
Page 15: 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 16 HOW TO AVOID THIS HAZARD Never operate your UXV500 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 17 Operating your UTV at excessive speeds. WHAT CAN HAPPEN Operating your UXV500 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 UXV500 at a speed that is proper for the terrain, visibility, operating conditions and your experience.
- Page 18 HOW TO AVOID THIS HAZARD Do not drive your UXV500 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 19 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 UXV500 in reverse at slow speeds.
- Page 20 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 UXV500. 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 21 Never attempt to turn your UXV500 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 UXV500 on any hill, and avoid crossing the side of a steep hill, if possible.
- Page 22 Improperly driving your UTV over obstacles. WHAT CAN HAPPEN Improperly driving over obstacles may cause you to lose control of your UXV500 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 UXV500 in a new area, check for obstacles.
- Page 23 Operating your UTV through deep or fast flowing water. WHAT CAN HAPPEN Your UXV500’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 24 HOW TO AVOID THIS HAZARD Never exceed the stated load capacity of your UXV500 (as set forth in this Owner's Manual). Cargo should be properly distributed and secured. To aid in controlling your vehicle, 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.
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Page 25: Prevention
HELMET When riding or driving an off-road vehicle, PREVENTION is While your UXV500 is equipped with an overhead canopy, it the name of the game. "Had you only known" something could cannot take the place of a helmet. A helmet is an essential go wrong, you would have prevented it. -
Page 26: Condition Of The Utv
Side-by-Side vehicle before you drive it. Chances are your vehicle is by using the acronym "T-CLOC." good that you will be using your UXV500 in some rough ter- This acronym means: rain, and you do not want something to prevent you from en- joying your drive. - Page 27 Correct tire pressure is crucial to the proper operation of your Press down on the UXV500’s brake pedal. If the pedal does not UXV500. 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 28 CHASSIS CHASSIS CHASSIS Turn your UXV500’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.
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Page 29: First Aid And Survival
AND SUR AND SUR AND SURVIV VIVAL find yourself physically unable to safely operate your vehicle. Before driving your UXV500, you need to prepare for the unex- pected. Emergencies and accidents are traumatic, but the situa- IDENTIFICA IDENTIFICA IDENTIFICATION IDENTIFICA... -
Page 30: Active Driving
THE ENGINE THE ENGINE advance to the level of active driving. Always start your UXV500 when it is at rest on a flat, level surface. Carbon monoxide poisoning can kill you, so never run your These are your basic maneuvers: UXV500’s engine in an enclosed space. - Page 31 ACTIVE DRIVING An easy way to remember the starting procedure for your NOTE: If the engine is already warm or the weather is UXV500 is by using the acronym "BONE-C." hot (95 F, 35 C or more) do not use the choke.
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Page 32: Braking
BRAKING / STOPPING This KYMCO Side-by-Side vehicle is equipped with an automatic, Always allow plenty of room and time to stop your UXV500 safely. dual-range transmission with reverse capability. To shift your Be alert and prepared, as quick stops are inevitable. Whether you... -
Page 33: Driving & Parking The Utv
Before driving your UXV500, take time to familiarize yourself com- pletely with the operational information described in this Owner’s 4. Always try to park your UXV500 on level ground. If you have to Manual. Be prepared to practice operating the controls and driv- park on a hill, shift the vehicle’s transmission into low gear... -
Page 34: How To Handle The Utv
1. Ease off the accelerator as you approach the turn to slow NEVER DRIVE YOUR down UXV500 UP OR 2. Slowly rotate the steering wheel into the direction of the turn DOWN HILLS 3. Gradually increase your speed as you come out of the turn... - Page 35 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 backwards. Use the turning method on this page 1 1 1 1 1 for K-turns: 1.
- Page 36 ACTIVE DRIVING DRIVING DOWNHILL Use extreme caution accelerating as your swerve so you can Success in driving downhill depends on how familiar and skilled maintain better control of your vehicle. If you are in a situation you are with using your vehicle's brakes. Use care to balance where you feel you must swerve your vehicle, use this driving braking force and downhill speed so you don't lose control and method:...
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Page 37: Tips
REVERSING 1. If your UTV has not started rolling backwards yet, follow the Remember, it is difficult to see behind you as you back up your UXV500. procedure for the K-turn 1. Proceed slowly, using a slight amount of throttle (accelerator) 3. - Page 38 NOTE: Engine damage caused by water ingestion or im- DRIVING IN COLD WEATHER mersion will not be covered by your KYMCO warranty. NOTE: Check that all of the controls move freely. Make 1. Physically check the depth and current of the water, especially sure that the floorboards, gearshift lever, accelerator if you can't see the bottom.
- Page 39 ACTIVE DRIVING STOPPING YOUR UTV To stop your ATV, first release the accelerator pedal, then de- Do not attempt to free frozen brakes by pouring warm press the brake pedal smoothly. water on the brake pads, brake rotors or drums. STOPPING YOUR UTV’S ENGINE NOTE: After the brakes thaw, dry them by applying To stop your UTV's engine, turn the ignition switch key to the...
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Page 40: Sound Judgment
SOUND JUDGMENT 7. Do you thrive on the adrenaline rush you get from speeding and OVERVIEW dangerous situations? Human beings are not invincible: we need to use sound judg- ment to keep ourselves and others safe from harm. Knowing Never Sometimes Often that the first "S"... -
Page 41: Environment
SOUND JUDGMENT ENVIRONMENT NIGHT DRIVING The environment that you will operate your UTV in is often It is best to avoid driving your UTV at night when visibility harsh and sometimes dangerous if you don't take proper is limited. With little to no light, it is difficult to see what is precautions. -
Page 42: 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 43: Those Around You
SOUND JUDGMENT THOSE AROUND YOU People do all kinds of things that you can't predict or control. Take steps with your riding apparel choices and your actions to Be aware of others and their behavior, as it can affect your make yourself very visible. -
Page 44: Personal Choices
EQUIPMENT Cargo has such a significant affect on UTV handling that you The last thing you would expect is that your KYMCO UTV would need to adjust your speed to match your load. Even on level break down in the middle of a field. KYMCO products are usu-... -
Page 45: Load Capacity Ratings Chart
HOW TO AVOID THIS HAZARD Never exceed the stated load capacity of your UXV500 (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 46 SOUND JUDGMENT ALCOHOL AND DRUG CONSUMPTION THE EFFECTS OF ALCOHOL* Alcohol is related to over 30% of the motor vehicle accidents in The Number of Drinks that the United States. It is extremely dangerous to drink alcoholic Impair Mental and Physical Abilities beverages and drive a UTV.
- Page 47 SOUND JUDGMENT YOUR PHYSICAL CONDITION drivers use extra care and sound judgment to make sure that the Being physically exhausted is like being intoxicated. When fa- activities do not get out of hand. Being wise and responsible is the tigued, you will not be able to perform detail-oriented tasks and best way for you and your riding friends to avoid injury or even your coordination will be affected.
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Page 48: Supervision
SUPERVISION OVERVIEW EXPERIENCED/TRAINED DRIVERS When you allow others to drive your UTV you become respon- When anyone borrows your UTV, you become responsible to su- sible for their safety and their actions. The driving ability of your pervise them and control their actions. Before a guest drives your guests, their awareness of proper UTV operation, the terrain, and UTV, have them take a UTV training course and have them read the condition of your UTV must be factored into your decision to... -
Page 49: 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 accesso- ries have been engineered and approved to meet the standards and requirements of your KYMCO UTV. -
Page 50: Specifications
Engine Oil Capacity ....3.8 U.S. qt (3.6 L) with Parking Brake Differential Capacity ....F: 9.3 fl oz (275 ml) SAE#80 Carburetor type ..... Kymco CVK38 R: 8.45 fl oz (250 ml) SAE#80 Aif filter type ......Sponge element (oiled) ELECTRICAL Transmission type: .... -
Page 51: Features & Controls
FEATURES & CONTROLS ACCELERATOR PEDAL BRAKE PEDAL Your KYMCO UTV is equipped with front and rear hydraulic (Throttle pedal) brakes that are activated simultaneously by the brake pedal. Push the accelerator pedal 2 down to increase the engine’s Depress the brake pedal 1 to slow or stop the vehicle. -
Page 52: Parking Brake
2. Attempt to push the UTV 3 3 3 3 3 NOTE: The parking brake must lock the UTV’s wheels. If it does not, take your UXV500 to an authorized KYMCO dealer for service. Releasing the Parking Brake To release the parking brake, pull up on the handle and press the release button 5 (opposite page). - Page 53 8 8 8 8 8 DIFFERENTIAL LOCK LEVER & INDICATOR Your UXV500 is equipped with a lockable differential that allows you to chose between “open differential” or a “locked differential” NOTE: When the differential is locked, the “LOCK” lamp 8 8 8 8 8 will illuminate on the dash.
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Page 54: 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. 5. To replace the fuel filler cap, press it back into place on the fuel filler neck 6. -
Page 55: Seat
HEAD CUSHIONS Your UXV500 has head cushions for the driver and the passenger attached to the vehicle’s canopy. To adjust a cushion’s location, remove the three screws that se- cure the cushion to the canopy. -
Page 56: Tailgate & Cargo Bed
CARGO BED Tilting the Cargo Bed Opening & Closing the Tailgate Your UXV500’s cargo bed can tilt to aid in the removal of loose Your UXV500’s cargo bed has a tailgate which can be unlatched cargo, such as gravel. to ease the loading and unloading of cargo. -
Page 57: Hood
FEATURES & CONTROLS SWITCHES HOOD You can open the hood on your UXV500 to perform maintenance- Ignition Switch related tasks. The UXV500 ignition switch is a three-position, key-operated To open the hood, unhook the two rubber hood latches 3 and switch, The key can be removed from the switch when it is in release the six plastic fasteners 4. -
Page 58: Light Switch
FEATURES & CONTROLS 2WD / 4WD Button Light Switch The UXV500 is equipped with an remote, electric system to The UXV500 light switch is a four-position switch. The ignition shift the differential between two-wheel and four-wheel drive switch must be ON to power the light circuit. Rotate the switch modes. -
Page 59: Choke Knob
Follow accessory wiring instructions explic- knob. itly to prevent damage to your UXV500. If you need as- 7 7 7 7 7 sistance installing accessories properly, consult your KYMCO dealer. -
Page 60: Multifunction Meter (Speedometer)
LCD Indicator Icons & Meter Buttons MULTIFUNCTION METER The Liquid Crystal Display (LCD) portion of the multifunction Your UXV500 is equipped with a multifunction meter on its meter provides the driver with information such as vehicle dashboard that includes speedometer, odometer, indicator speed, total miles operated, trip mileage, fuel level, time and lamps and other operational information and alerts. - Page 61 FEATURES & CONTROLS Multifunction Meter Operation Speedometer: MPH -or- Km/H Display The UXV500’s multifunction meter can be programed to dis- To toggle the multifunction meter’s speed display between MPH play speed in MPH or Km/H, distance traveled (tripmeter) and and Km/H, press down the MODE button for two seconds. This time (clock).
- Page 62 FEATURES & CONTROLS Clearing the Tripmeter To clear the tripmeter’s mileage, select the trip meter you wish Once the clock display is flashing, you can set the hours and to clear, then press and hold the SET and MODE buttons si- the minutes.
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Page 63: General Maintenance
PERIODIC MAINTENANCE SCHEDULE Continued on following page... - Page 64 PERIODIC MAINTENANCE SCHEDULE Continued on following page...
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Page 65: Break-In Procedure
PERIODIC MAINTENANCE SCHEDULE BREAK-IN PROCEDURE New UTVs and renewed UTV engines require a "break-in" period. 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 UTV. During your UTV's first ten hours of operation, always use a light throttle, keeping engine RPM well below the maximum. - Page 66 UTV, to arrange for and pay for this initial service. Because of the technical ability and resources available to an authorized KYMCO dealer, it is best to take your UTV to the dealer for service rather than attempting to perform this initial service yourself.
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Page 67: Tool Kit
GENERAL MAINTENANCE TOOL KIT GASOLINE-OIL-LUBRICANT A tool has been supplied with your UXV500 for your conve- Recommended Gasoline nience. The tool kit is stored in the right glove box. The recommended fuel to use in your UTV is regular un- leaded gasoline with a 87 minimum octane rating. -
Page 68: Engine Oil Inspection & Replacement
GENERAL MAINTENANCE Engine Oil Level Inspection Engine Oil & Oil Filter Replacement To check the engine oil level, use this procedure: To replace the engine oil and oil filter, and clean the oil strainer use this procedure: 1. Park the UTV on level ground 1. - Page 69 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 5. Remove the oil filter cartridge 5 with a suitable oil filter wrench.
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Page 70: 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, take your ATV to an authorized KYMCO ATV dealer Do not overfill the fuel tank. for servicing. -
Page 71: Spark Plug
Do not at- tempt to diagnose such problems yourself. Instead, take AIR CLEANER your UTV to a KYMCO dealer. Air Cleaner Element Service You should periodically remove and inspect the spark plug be-... -
Page 72: Exhaust - Spark Arrestor Cleaning
3. Remove the air cleaner cover screws 3 4. Loosen the joint clamp 4 and remove the element from the The UXV500’s air cleaner element is a oiled foam type that air cleaner requires cleaning with an appropriate solvent and re-oil- ing so it will properly filter debris from the air that will enter the engine. -
Page 73: Coolant Level
Inspection Hard water, tap water, or salt water is harmful the engine Your UXV500 has a liquid-cooled engine and periodically you and the cooling system components. Always use distilled should inspect the level of the fluid in the coolant reservoir and water or pre-mixed coolant (50:50 ratio) when adding fluid the external condition of the radiator. -
Page 74: Brake Fluid
GENERAL MAINTENANCE BRAKES Brake Fluid Inspection POTENTIAL HAZARD Your UXV500 has hydraulically operated brakes and periodi- Brake fluid contacting the skin or eyes. cally you should inspect the level and condition of the fluid in WHAT CAN HAPPEN the brake fluid reservoir. -
Page 75: 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 main- Wheel Nut torque ..... 40 lb-ft (55 N-m) -
Page 76: Tires
Tire Tread Condition The use of worn-out tires on your UTV is very dangerous. A tire is Use only KYMCO approved tires on your UTV when re- considered to be worn-out when the depth of the tread is less placing tires. Failure to do so could result in unstable than 1/8 in (3 mm). -
Page 77: Battery
1 1 1 1 1 The battery is located in a compartment under the hood of your UXV500. After initial service, batteries require regular cleaning of 2 2 2 2 2 the terminals and recharging in order to deliver peak performance and maximum service life. -
Page 78: Fuses
Allow it to cool partment under the hood of your UXV500. The fuse box ac- before resuming charging. cepts small, blade-style fuses. To inspect or replace a fuse in the fuse box, follow this procedure: 8. - Page 79 GENERAL MAINTENANCE Fuse Identification The fuse box inner lid has a label which identifies the fuse’s circuit, its rating, and its location in the fuse box. 1 1 1 1 1 2 2 2 2 2 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 3 3 3 3 3 6 6 6 6 6 Fan motor ...
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Page 80: Preparation For Storage
4. Start the engine and allow it to idle, then spray KYMCO En- gine Preserver into the air filter opening for a period of ten to twenty seconds. Turn off the engine and reinstall the air filter... -
Page 81: Preparation After Storage
Make sure that the rivets holding components together are tight - re- ing. To take your UTV out of storage, KYMCO recommends using place any loose rivets the following procedure: 10. -
Page 82: Emission Control Information
Noise Exhaust Emission Control System The engine, intake and exhaust systems of your UXV500 were designed to comply with federal, state and local noise level requirements. Do not modify the engine ,intake or exhaust components, as doing so will affect compliance these noise level requirements. -
Page 83: Epa Emission Control Statement/Warranty Coverage (U.s.)
EPA EMISSION WARRANTY... -
Page 84: Maintenance Record
MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED & NOTES... - Page 85 MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED & NOTES...
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Page 86: Index
INDEX Accelerator Pedal ..........49 Gearshift Lever ............ 49 Sidehilling/Traversing Hills ........34 Accessories ............43 Handling the UTV ..........32 SIPDE ..............45 Active Driving ............28 Hangtags ............8 - 11 Skidding or Sliding ..........35 Air Filter ............69 - 70 Head Cushions ............ -
Page 87: Identification Numbers Record
The ignition switch key identification code is stamped on tab 1 supplied with 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 88 5 Stan Perkins Road Spartanburg, SC 29307 Telephone: (864) 327-4744 FAX: (864) 327-4745 Prepared May 2008 T200-UAA0AA-US-A5...
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