KYMCO MXU 500 Owner's Manual
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KYMCO MXU 500 Owner's Manual

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See also: Owner's Manual , User Manual
MXU 500 / MXU 500 IRS
ATV
off road
Do not remove this Owner's Manual from the vehicle. Read this
manual carefully before operating the vehicle as it contains
important safety information.
Owner's Manual
Version:T200-LAAOCA-US-A5
C 2008 KYMCO. All rights reserved. Printed in Taiwan. www.kymco.com

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  • Page 1 MXU 500 / MXU 500 IRS off road Do not remove this Owner’s Manual from the vehicle. Read this manual carefully before operating the vehicle as it contains important safety information. Owner’s Manual Version:T200-LAAOCA-US-A5 C 2008 KYMCO. All rights reserved. Printed in Taiwan. www.kymco.com...

  • Page 2: Important Notices

    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.
  • Page 3 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.
  • Page 4 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.

  • Page 5: Table Of Contents

    CONTENTS Page Page LOCATION OF THE WARNING AND CONTROL FUNCTIONS ....16 SPECIFICATION LABELS IGNITION SWITCH......16 ....1 INSTRUMENTS AND INDICATOR..17 Multi-function display.......19 HANDLEBAR SWITCHES....26 SAFETY INFORMATION ......4 Headlight dimmer switch....26 Start button........26 Engine stop switch......27 Passing signal switch.......27 DESCRIPTION AND MACHINE RIGHT HANDLEBAR SWITCH.....28 IDENTIFICATION ........9...
  • Page 6 Page Page FRONT BRAKE LEVER.......32 PRE-OPERATION CHECKS.....43 DRIVE SELECT LEVER ......44 REAR BRAKE LEVER......32 Drive select lever adjustment....46 BRAKE PEDAL........32 FRONT AND REAR BRAKES....48 PARKING BRAKE.......33 FUEL..........49 DRIVE SELECT LEVER.......34 DRIVE SHAFT BOOTS......50 FUEL TANK CAP ........35 ENGINE OIL ........51 FINAL GEAR OIL........52 FUEL VALVE........35 DIFFERENTIAL GEAR OIL....52...
  • Page 7 Page Page OPERATION RIDING YOUR ATV ........58 ......71 STARTING A COLD ENGINE....58 GETTING TO KNOW YOUR ATV ..72 Using the recoil starter......61 RIDE WITH CARE AND GOOD STARTING A WARM ENGINE....62 JUDGEMENT........73 WARMING UP........62 APPAREL...........75 DRIVE SELECT LEVER OPERATION PRE-OPERATION CHECKS....79 AND REVERSE DRIVING ....63 Speed limiter........80 Shifting: neutral to high...
  • Page 8 Page Page RIDING DOWNHILL.......104 PERIODIC MAINTENANCE AND ADJUSTMENT CROSSING A SLOPE......106 ........113 TOOL KIT/ RIDING OVER ROUGH TERRAIN..108 TOOL KIT COMPARTMENT....113 CROSSING THROUGH SHALLOW PERIODIC MAINTENANCE/ WATER........109 LUBRICATION........115 PA R K I N G ........11 0 ENGINE OIL ........118 WHAT TO DO IF........111...
  • Page 9 Page Page COOLING SYSTEM INSPECTION..141 CLEANING AND STORAGE ...153 Engine overheating......143 A. CLEANING ........153 WHEEL REMOVAL......144 B. STORAGE ........155 WHEEL INSTALLATION.....144 BATTERY..........146 SPECIFICATIONS........157 Battery remove......147 Battery installation......147 NOISE REGULATION......161 FUSE REPLACEMENT......148 MAINTENANCE RECORD.......162 HEADLIGHT BEAM ADJUSTMENT..149 DRIVE SHAFT BOOTS.......149 INDEX...........163 CABLE INSPECTION AND LUBRICATION........150 TROUBLESHOOTING .......151...

  • Page 10: Location Of The Warning And Specification Labels

    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)
  • Page 11 Passengers can cause a ： Maximum load 85 Kg (187 lbs) loss of control, resulting in SEVERE INJURY or (6)-a(MXU 500) DEATH. 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.
  • Page 12 (6)-b(MXU 500 IRS) WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. Cold tire pressure: Front: psi ( kPa) Rear: psi ( kPa) Maximum weight capacity: 87505-LFE9-M35 WARNING Exceeding vehicle towing limit could lead to an accident.

  • Page 13: Safety Information

    SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. An accident can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre- cautions.
  • Page 14 Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions.
  • Page 15 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.
  • Page 16 WARNING POTENTIAL HAZARD WHAT CAN HAPPEN Improper handling of gasoline. Gasoline is poisonous and can cause injuries. WHAT CAN HAPPEN HOW TO AVOID THE HAZARD Gasoline can catch fire and you could be If you should swallow some gasoline or inhale burned.
  • Page 17 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation.

  • Page 18: Description And Machine Identification

    DESCRIPTION AND MACHINE IDENTIFICATION IDENTIFICATION NUMBER RECORDS KEY IDENTIFICATION NUMBER Record the key identification number, frame The key identification number is stamped on serial number, engine serial number and the hang tag as shown in the following model code information for assistance when illustration.

  • Page 19: Frame Serial Number

    FRAME SERIAL NUMBER ENGINE SERIAL NUMBER The frame serial number is stamped on the The engine serial number is stamped on the left front and rear of the frame. crankcase. (1) Frame serial number (1) Engine serial number...

  • Page 20: Parts Location

    PARTS LOCATION (03) (02) (02) (01) (01) Rear brake lever (02) Headlights/Position lights (03) Front brake lever...
  • Page 21 (05) 2WD/4WD select switch and differential lock lever (06) Instrument and indicators (07) Headlight dimmer switch Starter button Engine Stop Switch Passing signal switch (08) Spark arrester (09) Trailer hitch (MXU 500 version only (10) Throttle lever (10) (09) (08) MXU 500 IRS selectivity appurtenances (09)
  • Page 22 (23) (22) (21) (20) (19) (19) Exhaust system ) Battery/Fuse (21) Tool kit (22) Accelerating pump lever (23) Rear brake fluid reservoir (24) Accessory socket seat (25) Drive select lever (24) (25)
  • Page 23 (15) (14) (13) (12) (11) (11) Reservoir water tank (12) Front brake fluid reservoir (13) Fuel valve (14) Recoil starter (15) Seat (16) Brake pedal fluid reservoir (17) Seat lock lever (18) Oil level inspection window (16) (17) (18)
  • Page 24 (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.

  • Page 25: Control Functions

    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.

  • Page 26: Instruments And Indicator

    (3) Coolant temperature warning indicator 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)
  • Page 27 This button is also used to adjust the time and reset the trip meter. and reset the trip meter. (11)Differential lock indicator(MXU 500 IRS only) (5) Low-range indicator light “L” The front axle is equipped with a lockable This indicator light comes on when the drive differential that allows the operator to choose select lever is in the “L”...

  • Page 28: Multi-Function Display

    Multi-function display (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. TRIP mile TRIP mile MODE (1) Speedometer P R N H L (2) 2WD/4WD indicator (3) Fuel gauge (4) Odometer/Tripmeter (5) Digital clock...
  • Page 29 (2) 2WD/4WD indicator (3) Fuel gauge Shows the drive mode is in the 2WD or 4WD. 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.
  • Page 30 (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.
  • Page 31 To reset tripmeter: 1. Press and hold SET button for more than 2 2. Press and hold both the MODE button and seconds to select tripmeter A or tripmeter SET button in the same time until the tripmeter is reset. TRIP TRIP mile...
  • Page 32 (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 mile seconds to select ODO mode. MODE 3.
  • Page 33 4. To set the hour, press the SET button until the 5. Press the MODE button, the minute display will desired hour. start flashing. mile mile MODE MODE P R N H L P R N H L...
  • Page 34 6. To set minute, press the SET button until the 7. To end the adjustment, Press both the MODE desired minute. button and SET button in the same time. mile mile MODE MODE P R N H L P R N H L...

  • Page 35: Handlebar Switches

    LEFT HANDLEBAR SWITCHES (1) Headlight switch (2) Starter button Stater button Headlight dimmer switch To starter the engine, press the starter button, Turn the switch to the " " position to switch on with the transmission in neutral, the ignition the low beam.

  • Page 36: Engine Stop Switch

    (3)Engine stop switch (4) Passing signal switch Engine stop switch Passing signal switch When the switch is in the RUN ( ) position, the When passing, if there are cars coming from the engine will operate. When the switch is in OFF opposite direction, press and release the ) position, the engine will not operate.

  • Page 37: Right Handlebar Switch

    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) To check your present drive mode, look at the Multi-function display. 2WD mode...

  • Page 38: Recoil Starter

    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 (page 61) 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 39: Throttle Lever

    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. (1) Throttle lever(MXU 500 IRS version)

  • Page 40: Speed Limiter

    SPEED LIMITER The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed WARNING to the maximum. Screwing in the adjuster limits the maximum engine power available and POTENTIAL HAZARD decreases the maximum speed of the ATV. Improper adjustment of the speed limiter and throttle.

  • Page 41: Front Brake Lever

    FRONT BRAKE LEVER BRAKE PEDAL The front brake lever is next to the right Operating the brake pedal applies the rear handgrip. brake. 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.

  • Page 42: Parking Brake

    PARKING BRAKE WARNING To set the parking brake, squeeze the front POTENTIAL HAZARD brake lever and lock it with the lock lever. Always set the parking brake when parking and before Improper use of the parking brake. starting the engine. To unlock the parking brake, squeeze the front WHAT CAN HAPPEN brake lever until the lock lever releases.

  • Page 43: Drive Select Lever

    DRIVE SELECT LEVER The drive select lever is used to shift your ATV into the low, high, neutral, reverse and park positions. Refer to page 46 ~ 47 for drive select lever adjustment and operation. 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...

  • Page 44: Fuel Tank Cap

    FUEL TANK CAP FUEL VALVE After refueling, be sure to tighten the fuel tank The fuel valve supplies fuel from the fuel tank to cap until it clicks. the carburetor. The fuel valve has three positions. Insert the breather tube into the meter cover hole.
  • Page 45 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 " " mark in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

  • Page 46: Choke Knob

    (See page 58.) sticking, check the cable boot. The carburetor uses the automatic choke device in MXU 500 IRS version. (1) Fully open (2) Half open (3) Closed (A) ON position...

  • Page 47: Accelerating Pump Lever

    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.) MXU 500 IRS (1) Accelerating pump MXU 500 (1) Accelerating pump...

  • Page 48: Seat

    To install the seat, align the tabs on the seat with SEAT the grommets on the frame and press the seat To remove the seat, pull the seat lock lever down until it locks. upward and pull up the seat at the rear. NOTE: Make sure that the seat is securely fitted.

  • Page 49: Flag Pole Bracket

    Flag poles are optional equipment available The trailer hitch is located on the rear axle from your KYMCO dealer. To mount a flag pole housing. To use the hitch, you will need proper in the bracket to make you more visible.

  • Page 50: Owner's Manual Storage Compartment

    OWNER’S MANUAL STORAGE COMPARTMENT Your ATV provides storage for the owner’s To open the compartment, remove the lid (3). manual so you’ll have it with you for easy The owner’s manual should be stored in the reference. Store your owner’s manual (1) in the plastic bag.

  • Page 51: Accessory Socket

    ACCESSORY SOCKET The accessory socket (1) is attached to the left Be sure the engine is on and the headlights are side of the meter cover. You can use the turned off before using the accessory socket, accessory socket to power a trouble light, otherwise you may drain the battery.

  • Page 52: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ROUTINE PAGE ITEM ～ Check the lever for proper operation. 44 47 DRIVE SELECT LEVER Check operation, condition, and brake fluid level. ～ 48, 138 140 BRAKE Fill with DOT 4 brake fluid if necessary. Check fuel level.

  • Page 53: Drive Select Lever

    DRIVE SELECT LEVER WARNING CAUTION: POTENTIAL HAZARD Before shifting, you must stop the machine Failure to inspect the ATV before operating. and return the throttle lever to its closed position until the engine speed to the Failure to properly maintain the ATV. specified idling speed.
  • Page 54 WARNING POTENTIAL HAZARD Operating with improperly adjusted drive select lever. WHAT CAN HAPPEN You may lose control of 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.

  • Page 55: Drive Select Lever Adjustment

    Drive select lever adjustment 1. Turn the ignition switch is ON and make sure 3. Loosen the locknuts (3) of rod (4). Shift the the engine stop. gear to neutral by moving the shift lever and/or turn the rod. (The neutral indicator 2.
  • Page 56 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) Drive select lever (N) Neutral...

  • Page 57: Front And Rear Brakes

    If a problem performance, inspect the brakes for wear. cannot be corrected by the adjustment (See page 138~140.) procedures provided in this manual, have the ATV inspected by a KYMCO dealer.

  • Page 58: Fuel

    FUEL Fill the fuel tank when necessary and make sure Your KYMCO engine has been designed to use there is sufficient gasoline in the tank. regular unleaded gasoline with a pump octane Check for leaks. number of 86 or higher, or research octane number of 91 or higher.

  • Page 59: Drive Shaft Boots

    DRIVE SHAFT BOOTS Check the rubber drive shaft boots for damage or leaking grease. If necessary, have your KYMCO WARNING dealer replace them. POTENTIAL HAZARD Improper care when refueling. WHAT CAN HAPPEN Fuel can spill, which can cause a fire and severe injury.

  • Page 60: Engine Oil

    ENGINE OIL CAUTION: Make sure the engine oil at the specified level. Be sure to use motor oils that do not contain Add oil as necessary. (See page 118~124.) anti-friction modifiers. Passenger car motor Check for leaks. oils (often labeled "Energy Conserving") contain anti-friction additives which will cause starter clutch slippage, resulting in reduced component life and poor engine...

  • Page 61: Final Gear Oil

    Recommended rearl gear case oil: Recommended final gear oil: Type: hypoid gear oil Type: hypoid gear oil Viscosity: SAE# 80 Viscosity: SAE #80(MXU 500IRS)/SAE#90(MXU 500) Oil quantity: (MXU 500) Oil quantity: (MXU 500) Front gear case oil: Rear gear case oil:...

  • Page 62: Throttle Lever

    Always check the tightness of chassis fittings engine stop switch and any other switches. and fasteners before a ride. Take the machine to Repair as necessary for proper operation. a KYMCO dealer or refer to the Service Manual for correct tightening torque.

  • Page 63: Tires

    TIRES 2.The tires should be set to the recommended WARNING pressure: Recommended tire pressure POTENTIAL HAZARD Front: 25~32 kpa (0.25~0.32 kgf/cm , Operating this ATV with improper tires, or 3.5~4.5 psi) _MXU 500 with improper or uneven tire pressure. Rear: 25~32 kpa (0.25~0.32 kgf/cm , 3.5~4.5 psi) WHAT CAN HAPPEN...

  • Page 64: How To Measure Tire Pressure

    4.Higher pressures may cause the tire to How to measure tire pressure burst. Inflate the tires very slowly and Use the low-pressure tire gauge. (Tool kit) carefully. Fast inflation could cause the tire to burst. NOTE: The low-pressure tire gauge is included as Set pressure tires cold.

  • Page 65: Tire Wear Limit

    COOLANT Check the coolant level in the reservoir tank Tire wear limit when the engine is cold. (The coolant level will When the tire groove decreases to 4 mm (0.16 vary with engine temperature.) The coolant in) due to wear, replace the tire. level is satisfactory if it is between the "FULL"...
  • Page 66 (2) Maximum level mark the radiator cap. Always use a thick rag (3) Minimum level mark 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.

  • Page 67: Operation

    When riding in cold weather, always make is a control or function you do not sure all control cables work smoothly understand, ask your KYMCO dealer. before you begin riding. 1. Set the parking brake . 2. Turn the fuel valve to "ON".
  • Page 68 MXU 500 IRS 5. Use the accelerating pump if the cold engine start-ambient temperature below -15 C (0 F). Using the accelerating pump: Remove the seat (page 39) , then press the accelerating pump lever twice. (1) Accelerating pump MXU 500...
  • Page 69 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) 1.

  • Page 70: Using The Recoil Starter

    NOTE: Using the recoil starter If the engine fails to start, release the start The recoil starter is used to start the engine switch, then push the start switch again. when the battery is low. Each cranking should be as short as possible to preserve battery energy.

  • Page 71: Starting A Warm Engine

    CAUTION: To start the engine without the electric starter: See the "engine break-in" section prior to operating engine for the first time. 1. Follow steps 1 through 6. 2. With the throttle closed, grasp the starter grip firmly, then pull it out slowly until it seats STARTING A WARM ENGINE lightly.

  • Page 72: Drive Select Lever Operation And Reverse Driving

    DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING 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: (1) Drive select lever (L) Low Apply the rear brake and shift the shift lever...

  • Page 73: Shifting: Neutral To Reverse And Reverse To Park

    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. WARNING POTENTIAL HAZARD 4. Check behind for people or obstacles, then Improperly operation in reverse.

  • Page 74: Engine Break-In

    If any abnormality is noticed during this period, consult a KYMCO dealer.

  • Page 75: Parking

    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, see page 33 (1) Locked position...

  • Page 76: Parking On A Slope

    Parking on a slope 1. Bring the machine to a stop by applying the brakes. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the brake applied, shift the drive select lever into the park position Parking on a hill or other incline. 4.

  • Page 77: Accessories

    Choose only accessories designed for your difficult, an accessory that limits your ability ATV. Your KYMCO dealer has a variety of to move around on the seat, or one that limits genuine KYMCO accessories. Other your view.

  • Page 78: Loading

    (3) Trailer(MXU 500 ) Maximum towing capacity: 454 kg (1000 lbs) Tongue weight: 16kg (35 lbs) (3) Trailer (MXU 500 IRS has not this fittings) (1) Rear cargo rack (2) Front cargo rack (If you need this accessories. Please ask your dealers )
  • Page 79 Load cargo on the cargo racks as close to the WARNING center of the vehicle as possible. Put cargo at POTENTIAL HAZARD the rear of the front cargo rack and at the front Overloading this ATV or carrying or towing of the rear cargo rack .

  • Page 80: Riding Your Atv

    Riding Your ATV...

  • Page 81: Getting To Know Your Atv

    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 Before you begin to ride, be sure you have read section, riding your ATV, provides general ATV this Owner's manual completely and understand riding instructions for recreational riding.

  • Page 82: Ride With Care And Good Judgement

    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 HOW TO AVOID THE HAZARD Operating this ATV without proper Become familiar with this ATV at slow instruction.
  • Page 83 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.

  • Page 84: Apparel

    APPAREL WARNING POTENTIAL HAZARD Operating without protective clothing Operating this ATV without wearing an increases your chances of severe injury in approved motorcycle helmet, eye the event of an accident. protection and protective clothing. HOW TO AVOID THE HAZARD WHAT CAN HAPPEN Always wear an approved motorcycle Operating without an helmet that fits properly.
  • Page 85 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator's performance capability is reduced by Operating this ATV after consuming the influence of alcohol or drugs. alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.
  • Page 86 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.
  • Page 87 Never carry passenger on the cargo racks WARNING POTENTIAL HAZARD Carrying a passenger on the cargo racks 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.

  • Page 88: Pre-Operation Checks

    PRE-OPERATION CHECKS Always perform the pre-operation checks listed page 43 before riding for safety and proper WARNING care of the machine. POTENTIAL HAZARD Operating this ATV with improper tires, or WARNING with improper or uneven tire pressure. POTENTIAL HAZARD WHAT CAN HAPPEN Failure to inspect the ATV before operating.

  • Page 89: Speed Limiter

    Do not operate at speeds too fast your skills Speed limiter or the conditions. For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits WARNING the power and top speed of the machine. POTENTIAL HAZARD Turning the screw in decreases top speed, and Operating this ATV at speeds too fast for...

  • Page 90: Loading And Accessories

    LOADING AND ACCESSORIES Loading and Operational Guidelines Load Limits This ATV is not designed to carry or tow a trailer. There are limits to how much weight can be If you decide to add accessories to allow you to carried on your ATV. carry cargo or tow a trailer, use common sense.

  • Page 91: Accessories

    WARNING Genuine KYMCO accessories have been specifically designed for and tested on this POTENTIAL HAZARD vehicle. Because KYMCO cannot test all other Overloading this ATV or carrying or towing accessories, you are personally responsible for cargo improperly. properly selecting, installing, and using non- KYMCO accessories.

  • Page 92: Modifications

    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...

  • Page 93: Exhaust System

    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...

  • Page 94: Be Careful Where You Ride

    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.
  • Page 95 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.
  • Page 96 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the machine to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 97 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...
  • Page 98 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.

  • Page 99: For Off-Road Use Only

    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.
  • Page 100 Select a large, flat area off-road to become With the engine idling, return the starter knob to familiar with your ATV. Make sure that this area the closed position and shift the drive select is free of obstacles and other riders. You should lever into the forward position.

  • Page 101: During Operation

    DURING OPERATION WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the Removing hands from handlebars or feet rear wheels. from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg, your foot or leg may come...
  • Page 102 Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.

  • Page 103: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner's on one axle and turn together at the same Manual.
  • Page 104 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the turn may cause the ATV to tip. If the ATV begins to tip over to the outside while negotiating a turn, lean more to the inside.

  • Page 105: Sliding And Skidding

    SLIDING AND SKIDDING If the rear wheels of your ATV start to slide sideways, control can usually be regained (if Care should be used when riding on loose or there is room to do so) by steering in the slippery surfaces since the ATV may slide. If direction of the slide.
  • Page 106 With practice, over a period of time, skill at WARNING controlled sliding can be developed. The terrain POTENTIAL HAZARD should be chosen carefully before attempting Skidding or sliding improperly. such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on WHAT CAN HAPPEN extremely slippery surfaces such as ice, since...

  • Page 107: Climbing Uphill

    CLIMBING UPHILL WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on hills. Be sure that you can Operating on excessively steep hills. maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
  • Page 108 WARNING POTENTIAL HAZARD An obstacle, a sharp drop, or another Climbing hills improperly vehicle or person could be on the other side of the hill. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual.
  • Page 109 If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. WARNING When crossing the side of a hill: POTENTIAL HAZARD...
  • Page 110 If your ATV has stalled or stopped and you WARNING believe you can continue up the hill, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improperly wheels which could cause you to lose control. If dismounting while climbing a hill.
  • Page 111 If you begin rolling backwards: Keep weight uphill. 2WD: Never apply the rear brake while rolling backwards. Apply the front brake. 4WD: Apply both front and rear brakes gradually. When fully stopped, shift to the parking position “P”. Dismount on uphill side or to a side if pointed straight uphill.
  • Page 112 If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV . If you decide you can walk the ATV safely: 1.

  • Page 113: Riding Downhill

    RIDING DOWNHILL When riding your ATV downhill, shift your weight When this ATV is in 4WD, all wheels (front and as far to the rear and uphill side of the ATV as rear) are interconnected by the drive train. This possible.
  • Page 114 WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. Always follow proper procedures for going down hills as described in this Owner's Manual. Note: a special technique is required when braking as you go down a hill.

  • Page 115: Crossing A Slope

    CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV POTENTIAL HAZARD requires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you have hills. learned the basic riding skills on flat ground before attempting to cross a sloping surface.
  • Page 116 Shift your weight to the uphill side of the ATV.

  • Page 117: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet WHAT CAN HAPPEN firmly mounted on the footboards at all time.

  • Page 118: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other Remember that wet brakes may have obstacles which may be slippery or upset the reduced stopping ability.

  • Page 119: Pa R K I N

    Test your brakes after leaving the water. Do not PARKING continue to ride your ATV without verifying that Always choose a level place to park. After you have regained proper braking ability. bringing your ATV to a stop, hold the brakes while you shift into neutral.

  • Page 120: What To Do If

    WHAT TO DO IF If your ATV starts to slide sideways: This section is designed to be a reference guide Steer in the direction of the slide if you have the only. Be sure to read each section on riding room.
  • Page 121 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 122: Periodic Maintenance And Adjustment

    Have KYMCO dealer perform service if you PERIODIC MAINTENANCE AND are not familiar with machine service. ADJUSTMENT Periodic inspection, adjustment and lubrication TOOL KIT/TOOL KIT COMPARTMENT will keep your machine in the safest and most The tool kit is stored in the tool kit compartment efficient condition possible.
  • Page 123 Any routine maintenance and simple repairs. Any extensive work requiring additional tools should extensive work requiring additional tools should be performed by your authorized KYMCO be performed by your authorized KYMCO dealer. dealer. MXU 500 version...

  • Page 124: Periodic Maintenance/Lubrication

    PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH ! Replace (Warm engine before draining). Engine oil Clean. *Oil strainer Replace if necessary. Engine oil filter cartridge ! Replace Check oil level/oil leakage Final gear oil Replace every 12 months.
  • Page 125 INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH Check operation and brake fluid. *Brake Replace brake pad if necessary. Check coolant leakage. Replace if necessary. *Coolant Replace coolant every 24 months. Check operation. *V-belt Replace if damage or excessive wear. Check leakage.
  • Page 126 *Knuckle shafts/ ! Lubricate every 6 months. Steering shaft Check all chassis fittings and fasteners. *Fittings and Fasteners Correct if necessary. : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

  • Page 127: Engine Oil

    ENGINE OIL 1.Engine oil level measurement A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Check the oil level through the inspection window. D. The oil level should be between the maximum (H) and minimum (L) marks.
  • Page 128 2-1. Engine oil replacement and oil filter cleaning A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil fill cap (1) and oil filter cap (2) to drain the oil.
  • Page 129 H. Fill the engine with oil and install the oil fill E. Clean the oil strainer with solvent. cap. F. Inspect the O-ring and replace if damaged. G. Reinstall the O-ring, oil strainer, compression Recommended oil: see page 158 spring and oil filter cap. Tighten the oil filter Oil quantity: cap to specification.
  • Page 130 2-2. Engine oil replacement (with or without oil filter cartridge replacement) A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil fill cap (1) and drain plug (2) to drain the oil.
  • Page 131 NOTE: Skip steps E to I if the oil filter cartridge is not being replaced. E. Remove the three fasteners (3) and then remove right side cover (4). F. Remove the oil filter cartridge (5) with an oil cartridge wrench. (3) Fasteners (4) Right side cover (5) Oil filter cartridge...
  • Page 132 G. Apply a light coat of clean engine oil to the O-ring (6) of the new oil filter cartridge. NOTE: An oil cartridge wrench is available at a nearby KYMCO dealer NOTE: Make sure the O-ring is seated properly. H. Install the new oil filter cartridge with an oil...
  • Page 133 I. Install right side cover. L. Start the engine and warm it up for several minutes. While warming up, check for oil J. Reinstall the drain plug and tighten the leakage. If oil leakage is found, turn the drain plug to specification. engine off immediately and check for the cause.

  • Page 134: Final Gear Oil

    2.To drain the oil, first place an oil drain pan under the oil drain plug (4).(MXU 500 version) 3.To drain the oil, first place an oil drain pan under the oil drain plug (5).(MXU 500 IRS version) (4) Oil drain plug...
  • Page 135 Be sure no foreign material enters the gear Tightening torque case. Drain plug: 20 N-m (2 kgf-m, 15 lbf-ft) 5. Fill the gear case with the recommended MXU 500 IRS oil. Recommended oil : SAE 80 Oil quantity : Periodic oil change MXU 500/MXU500 IRS 0.13L(0.114...

  • Page 136: Differential Gear Oil

    1. To drain the oil, first place an oil drain pan (1) Oil drain plug/washer (2) Oil filler bolt/wahser under the oil drain plug/washer (1). 2. Remove the oil filler bolt/washer (2). MXU 500 IRS MXU 500 IRS (1) Oil drain plug/washer (2) Oil filler bolt/wahser...
  • Page 137 (2) Oil level check bolt Recommended oil : SAE 80 CAUTION: Oil quantity : Periodic oil change(MXU 500 /IRS) Be sure no foreign material enters the gear 0.3L(0.264lmp qt,0.318US qt / 0.25 L (0.22 lmp qt, 0.265 US qt) case.

  • Page 138: Spark Plug Inspection

    Do not attempt to diagnose such problems yourself. Instead, take the machine to a KYMCO dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 139: Spark Arrester

    SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolts. 2. Remove the three bolts (1), the spark arrester (2) and the gasket (3) from the muffler. (1) Bolts (2) Spark arrester (3) Gasket...
  • Page 140 WARNING 3. Use a brush to remove carbon deposits from POTENTIAL HAZARD the spark arrester screen. Be careful to avoid Improper cleaning of the spark arrester. damaging the spark arrester screen. The Hot exhaust system. spark arrester must be free of breaks and holes.

  • Page 141: Air Filter Cleaning

    AIR FILTER CLEANING The air cleaner accumulates dust and must be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule. If the ATV is submerged in water, the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine.
  • Page 142 (10) (11) 5. Remove the outer air cleaner (7). 6. Remove the screw/washers (6) and remove the air cleaner assembly from the air cleaner holder (8). 7. Remove the inner air cleaner (9) and air cleaner screen (10) from the air cleaner guide (11).
  • Page 143 9. Gently wash the air cleaner in clean, non- 10. Soak the air cleaner an equivalent (gear oil: flammable (high flash point) solvent such as SAE 80 - 90) until saturated, then squeeze out ─ kerosene not gasoline. Allow the air cleaner the excess oil.

  • Page 144: Air Cleaner Housing Drain Tube

    AIR CLEANER HOUSING DRAIN TUBE The air cleaner housing drain tube should be serviced in accordance with the Maintenance Schedule. (Riding through water may require more frequent inspection.) If deposits can be seen in the drain tube, the tube must be cleaned before starting the vehicle.

  • Page 145: Idle Speed Adjustment

    1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it (1) Idle adjusting screw (MXU 500) quickly responds to the throttle. 3. Connect the tachometer and set the idle to the specified idling speed by adjusting the idle adjusting screw.

  • Page 146: Throttle Lever Adjustment

    THROTTLE LEVER ADJUSTMENT NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. To adjust throttle free play: 1. Slide the rubber sleeve (1) back to expose the throttle cable adjuster (2). 2. Loosen the lock nut (3), then turn the adjuster to obtain the correct free play.

  • Page 147: Valve Clearance Adjustment

    If the be adjusted regularly. This adjustment however, indicator reaches the wear limit line, ask a should be left to a professional KYMCO service KYMCO dealer to replace the pads. technician. (1) Wear indicator...

  • Page 148: Rear Brake Pads Inspection

    If the indicator reaches the wear limit line, ask a WARNING KYMCO dealer to replace the pads. Wear indicator (2) Rear brakes MXU 500 version...
  • Page 149 (1) Lower level mark (Foot brake pedal) (1) Lower level mark (Hand brake lever) (2) Upper level mark (Foot brake pedal)

  • Page 150: Cooling System Inspection

    (page 138~139) , There is probably air in the brake system and it must be bled. See your authorized KYMCO dealer for this service. CAUTION: To prevent damage to the brake system, use (1) Fasteners only fluid from a sealed container.
  • Page 151 You may use distilled water if rou NOTE: can not get soft water. 1. If water is added, have a KYMCO dealer check the antifreeze content of the coolant as soon as possible. 2. The radiator fan operation is completely automatic.

  • Page 152: Engine Overheating

    Should be serviced by your authorized KYMCO dealer when changing the coolant. Restart the engine. If the engine overheats again, ask a KYMCO dealer to inspect and/or repair the cooling system NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it...

  • Page 153: Wheel Removal

    MXU 500 Front: 65 N-m (6.5 kgf-m, 46 lbf-ft) Rear: 65 N-m (6.5 kgf-m, 46 lbf-ft) Wheel nut torque:MXU 500 IRS Front: 55 N-m (5.5 kgf-m, 39.6 lbf-ft) Rear: 55 N-m (5.5 kgf-m, 39.6 lbf-ft) Be sure the tapered side of the wheel nuts (1) face the wheel rim (2).
  • Page 154 NOTE: WARNING The arrow mark on the tire must point POTENTIAL HAZARD toward the rotating direction of the wheel. Installing wheels improperly. WHAT CAN HAPPEN A wheel may come loose, possibly leading to an accident. HOW TO AVOID THE HAZARD Carefully follow the instructions in this Owner's Manual when installing.

  • Page 155: Battery

    If battery. the battery seems weak, see your authorized KYMCO dealer for information on recharging or WHAT CAN HAPPEN Gases may explode and possibly cause replacement. If you replace the battery, choose one injury.

  • Page 156: Battery Remove

    Battery remove 1. Make sure the ignition switch is OFF. 2. Remove the seat (page 39) 3. Release the rings and remove the rubber band (1). 4. Disconnect the negative (-) terminal lead (2) from the battery first, then disconnect the positive (+) terminal lead (3).

  • Page 157: Fuse Replacement

    FUSE REPLACEMENT 2. Remove the seat (page 39) The fuse box (1) stored in the battery 3. Open the fuse box cap (2). compartment under the seat. 4. Pull the old fuse out of the fuse holder. To replace a fuse: 5.

  • Page 158: Headlight Beam Adjustment

    DRIVE SHAFT BOOTS Check the protective boots for holes or tears. CAUTION: If any damage is found, have them replaced by a It is advisable to have a KYMCO dealer make KYMCO dealer this adjustment. To adjust: Turn the ignition switch at "...

  • Page 159: Cable Inspection And Lubrication

    Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a KYMCO dealer to replace them. Recommended lubricant: KYMCO chain and cable lube or SAE 10W40 motor oil...

  • Page 160: Troubleshooting

    The troubleshooting chart describes a WHAT CAN HAPPEN quick, easy procedure for making checks. If your Fuel can ignite or explode, causing severe machine requires any repair, take it to a KYMCO dealer. injury or property damage. HOW TO AVOID THE HAZARD...

  • Page 161: Troubleshooting Chart

    Check fluid, recharge, check connections. over slowly. Use electric starter. Engine turns Battery good. over quickly. Ask a KYMCO dealer to inspect. 3. Ignition Wipe clean with dry Adjust plug gap or cloth. Remove plug and No spark. replace plug.

  • Page 162: Cleaning And Storage

    CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend the bills have resulted from improper high useful life of many components.
  • Page 163 7. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after washing. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid WHAT CAN HAPPEN combination cleaner-waxes.

  • Page 164: Storage

    B. STORAGE WARNING Before storing your ATV for an extended time, be POTENTIAL HAZARD sure you thoroughly check the vehicle for Refueling this ATV or handling fuel needed repairs and have them corrected. improperly. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage.
  • Page 165 4. Remove the battery (page 147) And store it in WARNING an area protected from freezing temperatures POTENTIAL HAZARD and direct sunlight and out of the reach of Prolonged contact of fuel with the skin. children, slow charge the battery once a Breathing fuel vapor.

  • Page 166: Specifications

    SPECIFICATIONS MXU 500 /MUX500 IRS Model Dimension: 2203 mm (88.12 in) Overall length 1223 mm (48.92 in) Overall width 1240 mm (49.6 in)/1243 mm (49.72 in) Overall height 857mm(34.28in)/ 887 mm (35.48 in) Seat height 1293mm(51.72in)/ 1297 mm (51.88 in) Wheel base 235mm(9.4in)/241 mm (9.64 in)
  • Page 167 MXU 500/MXU 500 IRS Model 110 F Engine oil/transmission oil/ rear final gear case oil: SAE 5W － SAE 10W 30 Type － SAE 10W 40 Engine oil classification: － SAE 20W 40 － SAE 20W 50 -1 0 40 C...
  • Page 168 MXU 500 /MXU 500 IRS Model Air filter: for engine Wet type element Fuel: Type UNLEADED FUEL Tank capacity 17 L (3.57 lmp gal, 4.42 US gal) Reserve amount 2.3 L (0.48 lmp gal, 0.6 US gal) Carburetor: CVK/KYMCO CARBURETTOR (LFE9)
  • Page 169 Model MXU 500/MXU 500 IRS Suspension: Front Double wishbone/Dual A-arm Rear Swing arm/Dual A-arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system A.C. magneto Battery type 12V, 18AH MF Tire: Type Tubeless...

  • Page 170: Noise Regulation

    NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Some local laws and regulations prohibit the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 171: Maintenance Record

    MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

  • Page 172: Index

    INDEX Page Page ACCELERATING PUMP LEVER....38 CABLE INSPECTION AND ACCESSORIES......68, 81, 82 LUBRICATION........150 ACCESSORY SOCKET......42 CHOKE KNOB.........37 AGE RECOMMENDATION......A CLEANING..........153 AIR CLEANER HOUSING DRAIN CLIMBING UPHILL........98 TUBE............135 CONTENTS..........D AIR FILTER CLEANING ......132 CONTROL FUNCTIONS......16 APPAREL..........75 COOLANT..........56 Coolant temperature warning indicator..18 COOLING SYSTEM INSPECTION..141 BATTERY..........146...
  • Page 173 Page Page ENGINE BREAK-IN........65 IDLE SPEED ADJUSTMENT ....136 ENGINE OIL........51,118 IGNITION SWITCH........16 ENGINE OVERHEATING......143 IMPORTANT NOTICES......A ENGINE SERIAL NUMBER...... 10 INSTRUMENTS AND INDICATOR....17 ENGINE STOP SWITCH......27 EXHAUST SYSTEM.........84 HANDLEBAR SWITCHES.....26, 28 HEADLIGHT BEAM ADJUSTMENT ..149 Headlight dimmer switch......26 FINAL GEAR OIL........52, 125 High beam indicator.........
  • Page 174 Page Page KEY IDENTIFICATION NUMBER..... 9 Odometer ..........21 OPERATION ........... 58 OWNER’S MANUAL LIGHTS...........53 STORAGE COMPARTMENT......41 LOADING........... 69, 81 Low-range indicator light......18 LUBRICATION ........115, 150 Park indicator light........18 PARKING ......... 66, 110 PARKING BRAKE........33 MAINTENANCE RECORD.......162 Parking on a slope ........67 MODE BUTTON........18 PASSING SIGNAL SWITCH......27 MODIFICATIONS........83...
  • Page 175 Page Page THROTTLE LEVER......30, 53 RECOIL STARTER......29, 61 THROTTLE LEVER ADJUSTMENT..137 Reverse indicator light.......18 TIRES.............54 RIDING DOWNHILL........104 Tire wear limit.......... 56 RIDING YOUR ATV........71 RIGHT HANDLEBAR SWITCH....28 TOOL KIT..........113 2WD/4WD select switch......28 TRAILER HITCH........40 Tripmeter..........21 TROUBLESHOOTING ......151 Troubleshooting chart ......152 SAFETY INFORMATION......4 TURNING YOUR ATV........94 SEAT............
  • Page 176 KWANG YANG MOTOR CO.,LTD. NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. First Edition, DEC 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.

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