KYMCO UXV500 4x4 Owner's Manual
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KYMCO UXV500 4x4 Owner's Manual

4x4 offroad vehicle
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KWANG YANG MOTOR CO.,LTD.

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  • Page 1 KWANG YANG MOTOR CO.,LTD.
  • Page 3 Dear KYMCO UXV 500 Users: Thank you for purchasing this KYMCO UXV 500 and welcome to the family of KYMCO UXV500 riders. To enjoy safety and more pleasant riding, become thoroughly familiar with this owner manual before you ride the UXV 500. You safety depends not only on your own alertness and familiarity with the UXV 500 but also the UXV mechanical condition.

  • Page 4: Table Of Contents

    INDEX Auxiliary Outlet Differential Lock Lever And Indictor Air Cleaner Daily Safety Checks Driving Safety Battery remove Driving Downhill Brake Fluid Inspection Driving Uphill Brake Pedal Driving Reverse Cargo Bed 42-44 Emission Control System 55-56 Choke Knob Engine Oil 57-59 Crossing Water Cooling System Inspection Fuel Lever Inspection/Refilling...
  • Page 5 INDEX Gear Selector 26-31 Operation Instruction for Multi-Meter 77-79 PERIODIC MAINTENANCE/LUBRICATION Indicator Lights 24-25 Pillows Aduust Ignition Switch Parking Brake Release Ignition Switch Key Packing Light Switch Right Glove Compartment Key Location Of Parts 7-10 Serial Number Locations Start The Engine 49-50 Spark Arrestor Spark Plug Inspection...
  • Page 6 INDEX Throttle Pedal Tool Kit Under-Hood 45-46 2WD/4WD Switch Warning Labels Locaton 11-13 Warning Labels 14-22...
  • Page 7 This vehicle can be dangerous to operate. A impact or rollover can occur 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 the warnings contained in this Owner’s Manual and labels on this vehicle.
  • Page 8 This vehicle is not a toy and can be dangerous to operate. ●Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating this vehicle. ●Never operate on too rough, slippery, or loose terrain. ●Always follow proper procedures for turning as represent in this manual.
  • Page 9 Safety Watchful Always ● read the owner’s manual carefully and follow the operating procedures described. Pay special attention to the warnings contained In the manual and on all labels. Never ● operate this vehicle with the canopy frame removed. WARNING Always ●...

  • Page 10: Serial Number Locations

    Serial Number Locations This vehicle has 2 serial numbers:The frame number and Engine serial number. The frame number is located on the frame near right front wheel place. Frame Number...
  • Page 11 Serial Number Locations The engine serial number is located on the right side of the engine crankcase. Engine Serial Number...

  • Page 12: Fuel Cap Key

    Ignition Switch Key/Fuel Cap Key Right Glove Compartment Key Fore keys come with this vehicle. Keep the spare in the safe place. Fuel Cap Key Right Glove Compartment Key →2PCS Ignition Switch Key→2PCS...
  • Page 13 Location Of Parts (1) 1.Right Head Pillow 2.Right Seat 3.Right Tail /Brake Light 4.Left Head Pillow 5. Left Seat 6.Left Tail /Brake Light...
  • Page 14 Location Of Parts (2) 07.Seat Belts 08.Cargo Bed 09.Headlights 10.Battery 11.Steering Wheel 12.Cab Frame 13.hands Bars 14.Bumper 15.Tool or Parts Box...
  • Page 15 Location Of Parts (3) 16.Under-Hood 17.Hands Bars 18.Seat Belts 19.Fuel Tank Cap 20.Muffler& Spark Arrester 21. Latch Handles...
  • Page 16 Location Of Parts(4) 20.Right Glove Compartment 21. Auxiliary Outlet 22.Speedometer 23. Center Glove Compartment 24.Shifting The Automatic Transaxle 25. Choke Knob 26.Ignition Switch 27.Steering Wheel 28.Brake Pedal 29.Throttle Pedal...
  • Page 17 Warning Labels Location...
  • Page 18 Warning Labels Location...
  • Page 19 Warning Labels Location...
  • Page 20 Warning Labels...
  • Page 21 Warning Labels...
  • Page 22 Warning Labels...
  • Page 23 Warning Labels...
  • Page 24 Warning Labels...
  • Page 25 Warning Labels...
  • Page 26 Warning Labels...
  • Page 27 Warning Labels...
  • Page 28 Warning Labels...

  • Page 29: Fuel Lever Inspection/Refilling

    Features And Controls Fuel Lever Inspection/Refilling Check if fuel is sufficient. If the fuel gauge pointer is E(flash).refill nonleaded gasoline as soon as possible. (Refilling Method) 1.Turn the tank cap counterclockwise with hand to open the cap. OPEN CLOSE 2.Use only nonleaded gasoline. 3.Turn the fuel tank cap clockwise to tighten 4.Close the fuel tank cap in the reverse order of opening.

  • Page 30: Indicator Lights

    Features And Controls Indicator Lights The indicator lights on the console display: 1. Lower Gear 2. High Gear 3.Neutral Gear 4.Reverse Gear 5. Parking Brake 6. High Temperature Indicator Light 7.High Beam Indicator Light 7.Lock:( Differential Lock Indicator Light )

  • Page 31: Features And Controls

    Features And Controls Instruments and Indicators 1.Speedometer 2. Km/h or Mph 3. Clock 4.2WD OR 4WD 5.Fuel Gauge 6.ODO meter7. Adjust button...

  • Page 32: Operation Instruction For Multi-Meter

    Features And Controls Operation Instruction for Multi-meter Button A(MODE) Button B(SET)
  • Page 33 Features And Controls Operation Instruction for Multi-meter (1)Press and hold button A until 2 seconds. Shift the unit mph or km/h Button A(MODE)
  • Page 34 Features And Controls Operation Instruction for Multi-meter (1)Press and hold button B until 2 seconds. Shift function to ODO or TRIP(A) Once again Press and hold button B until 2 seconds change TRIP(B) Button B(SET)
  • Page 35 Features And Controls Operation Instruction for Multi-meter (1)Press and hold button A&B until 2 seconds. Simultaneously to reset to zero when at TRIP(A)or TRIP(B) function. Button B(SET) Button A(MODE)
  • Page 36 Features And Controls Operation Instruction for Multi-meter (1)Press and hold button A&B until 2 seconds . when at ODO function. than you can see clock position is flash word . Button B(SET) Button A(MODE)

  • Page 37: Operation Instruction For Multi-Meter

    Features And Controls Operation Instruction for Multi-meter When you seeing clock position is flash word . You can start setting hour item. Press button B adjust Correct hours than Press button A you can see the minute position is flash. adjust correct minute. Waiting for 2second .finish times setting.

  • Page 38: Choke Knob

    Features And Controls Auxiliary Outlet The 12-volt receptacle has spade Choke Knob connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console,under the hood. Choke Knob The choke knob located on the dashboard ,to the left of the steering shaft,provides a Auxiliary Outlet...

  • Page 39: Seat Removal

    Features And Controls Seat Removal Pull up on front of seat it toward the front of vehicle. Install the seat by sliding the tabs into the rear of the seat base.Push down firmly on the front of the pins are fully seated into the grommets.
  • Page 40 Features And Controls Pillows adjust If you want adjusting your pillows.remove the 3 screws then adjusting you need pillow position install the 3 screws.
  • Page 41 Features And Controls Maintaining shift linkage adjustment is Gear Selector important to assure proper 1.Lower Gear transmission function .See your dealer 2.High Gear if you experience any shifting 3.Neutral Gear problems. 4.Reverse Gear To change gears,stop the vehicle and with the engine idling, move the lever to the desired gear.
  • Page 42 Features And Controls Switches Ignition Switch The ignition switch is a 3-position,key- operated switch, The key can be removed from the switch when it is in the OFF position. Electrical circuits are on Electrical equipment can be used. OFF: Engine off .All electrical circuits are. off except Acc.12V START: Electrical starter is engaged by holding ignition switch key in this...
  • Page 43 Features And Controls Switches Light Switch The ignition switch key must be in the ON position to operate the headlights. The switch has 4 positions. 1:Light off -At this position , light is turn off. 2: Position light - At this position , light is turn off 3.LO Headlight Beam- When you select this position .the low beam will illuminate.

  • Page 44: Wd/4Wd Switch

    Features And Controls Switches 2WD/4WD Switch Pushing the switch to the 4WD position or to the 2WD position 1:2WD-At this position , LED speedometer will show 2wd word. 2:4WD-At this position , LED speedometer will show 4wd word.
  • Page 45 Features And Controls Differential Lock lever and indicator The front axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential in low traction situations. Pulling the lock lever up. To lock the differential on the 4WD, move the 4WD differential Button.

  • Page 46: Throttle Pedal

    Features And Controls Brake Pedal(1) Depress the brake pedal to slow or stop or stop the vehicle. Throttle Pedal(2) Push the pedal down to increase engine speed .Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine.

  • Page 47: Parking Brake Release

    Features And Controls Parking Brake Release(3) To release the parking brake, pull the release handle Spring pressure helps return the lever to the released position .make sure the parking brake lever is functioning properly before each operation.
  • Page 48 Features And Controls Cargo Bed (Lift and lower the cargo bed) To lift Push the cargo bed release lever to right side, then slowly lift up cargo bed until it stop. To lower Lower the cargo bed slowly to its original position and be sure the it is locked into place.
  • Page 49 Features And Controls Cargo Bed(Open and close the tailgate 1) To open---(1) Unlock the latches,and then lower the tailgate. Latch(x2) PULL...
  • Page 50 Features And Controls Cargo Bed(Open and close the tailgate 2) To close Please the tailgate in the original position ,and then hook the latches.
  • Page 51 Features And Controls Under-Hood (To Open) Unhook the hood latches and 3PU-screws,and then slowly tilt the hood up until it stops. Latch x2 PU- Screws x3...
  • Page 52 Features And Controls Under-Hood (To Close) Lower the hood slowly to its original position ,and then hook the hood latches and Screws. PU- Screws x3 Latch x2...

  • Page 53: Daily Safety Checks

    How to operate Daily Safety Checks Check the following items each day before operation. 1.Fuel→→→→→→→Enough fuel in tank,no leaks. 2.Engine Oil →→→→Oil lever between lever holes(when engine is cold),no leaks. 3.Air Cleaner→→→→Check the restriction gauge. 4.Tires →→→→→→→Air pressure(when cold)and check tires cracks, damage or abnormal wear.Check for any imbedded stones or other foreign particles in tread.
  • Page 54 How to operate Driving Safely(Driving procedures) 1.Sit in the driver’s seat and fasten the seat belt.: 2.After staring the engine and allowing it to warm up，shift　the transmission into gear. 3.Check your surroundings and determine your path of travel. 4.Release the parking brake. 5.Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving.Vehicle speed is controlled by the amount of throttle opening &...
  • Page 55 How to operate Start the engine Note: WARNING When the engine is already warm or the Never run the vehicle in a closed area, such as a garage Exhaust gases contain carbon monoxide, weather is hot. a colorless, odorless, poisonous gas. (35°C,95°F or more), do Breathing exhaust gas leads to carbon monoxide not use the choke.
  • Page 56 How to operate Start the engine CAUTION Do not run the starting attempt. The starter motor may overheat causing severe starter motor damage. Allow 15 seconds between starting attempts to allow the starter motor to cool. Braking/Stopping Always allow plenty of room and time to stop smoothly. Sometimes quick stops are inevitable’...

  • Page 57: Driving Downhill

    How to operate Parking Parking involves flowing the previous rules for braking;then : 1.After the vehicle stops,shift into neutral gear. 2.Set the parking brake. 3.Turn off the ignition key. 4.If you have to park on the hill,shift to low range,set the parking brake,and block the wheel on the downhill side.

  • Page 58: Driving Uphill

    How to operate Driving uphill whenever travel straight uphill, follow these precautions: 1.Always travel straight uphill. 2.Avoid steep hills(15° maximum) 3.Keep both feet on the floor. 4.Proceed at a steady rate of speed and throttle opening. NEVER OPERATE UP OR DOWN HILLS STEEPER THAN 15°...
  • Page 59 How to operate Crossing water UXV500 can only operate in water up to its floorboard.Stay away from fast moving rivers. This vehicle’s tires can be buoyant.In deep water,the vehicle may lose traction due to floating. 1.Physically check the depth and current of the water, especially if you can not see the bottom.Also,check for boulders,logs,or any other hidden obstacles.
  • Page 60 How to operate Driving in reverse Follow these guidelines when operating in reverse: 1.Back slowly. 2.Apply the brakes lightly for stopping. 3.Avoid turning at sharp angles. 4.Always avoid backing downhill. 5.Never open the throttle suddenly while backing. 6. Always inspect left and right fields of vision before backing.

  • Page 61: Emission Control System

    Emission Control System Crankcase Emission Control System This engine is equipped with a closed crankcase system . Blow-by gases forced back to the comb7ustion chamber by the intake s7ystem. The system does not allow the blow-b7y gases to enter the atmosphere. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design,including factory-set fuel delivery and ignition.KYMCO Exhaust...

  • Page 62: Emission Control System

    Emission Control System Spark Arrestor Your UXV 500 has a spark arrestor. The spark arrestor be installed and functional when the vehicle operated on public lands. Clean method Remove method Use the iron brush cleaning remove 3 screws carbon on the spark arrestor...

  • Page 63: Engine Oil

    Maintenance And Lubrication Engine Oil Always check and change the oil at the OWNER MANUAL standard intervals. The oil tank is located under the seat. 110 F 1.Position the vehicle on the surface. 2.Start the engine and let it idle for 20~30seconds. 3.Stop the engine and remove the seat.

  • Page 64: Maintenance And Lubrication

    Maintenance And Lubrication 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. If the level is low, add oil to raise it to the proper level.

  • Page 65: Engine Oil

    Maintenance And Lubrication (2) oil filter cap Engine oil replacement and oil filter cleaning 1. Place the machine on a level place. 2. Warm up the engine for several minutes and stop it. 3. Place a container under the engine. 4.
  • Page 66 Maintenance And Lubrication NOTE: Skip steps E to I if the oil filter cartridge is not being replaced. Remove the oil filter cartridge with an oil cartridge wrench. oil filter remove lock...
  • Page 67 Maintenance And Lubrication BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection window. WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation. HOW TO AVOID THE HAZARD (1) Lower level mark Avoid contacting brake fluid with the skin (2) Upper level mark...
  • Page 68 Maintenance And Lubrication Air Cleaner Remove the center cover screws and center cover Remove bolt. Shifting The Automatic Transaxle...
  • Page 69 Maintenance And Lubrication Air Cleaner Remove air cleaner cover screws. Remove air cleaner filter...
  • Page 70 Maintenance And Lubrication Air Cleaner Clean the air cleaner filter...

  • Page 71: Battery Remove

    Maintenance And Lubrication Battery remove 1. Make sure the ignition switch is OFF. 2. Remove the under-hood hook& pu bolts. 3. Remove the battery cover screws. 4. Disconnect the negative (-) terminal lead (1) from the battery first, then disconnect the positive (+) terminal lead (2).

  • Page 72: Fuse Replacement

    Maintenance And Lubrication Fuse Replacement (1) (2) (3) (4) (5) (6) The fuse box stored in the battery compartment. To replace a fuse: 1. Make sure the ignition switch is OFF. 2. Remove the under-hood hook& pu bolts 3. Open the fuse box cap. 4.
  • Page 73 Maintenance And Lubrication Cooling System Inspection NOTE: 1. If water is added, have a KYMCO dealer 1. Remove the under-hood hook& pu check the antifreeze content of the coolant bolts as soon as possible. 2. Check the coolant level in the 2.
  • Page 74 Maintenance And Lubrication WHEEL INSTALLATION WHEEL REMOVEL When reinstalling a wheel, tighten the wheel 1.Elevate the wheel by placing a suitable nuts in a crisscross(rather than a stand under the frame. circular)pattern.Be sure the tapered a side of the wheel nuts(1)face the wheel rim(2). 2.Remove the nuts from the wheel.
  • Page 75 Maintenance And Lubrication 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 76: Spark Plug Inspection

    Maintenance And Lubrication Be fo re i n sta l l i n g th e sp a rk p l u g , me a su re th e SPA R K PLU G IN SPEC TIO N e l e ctro d e g a p w i th a fe e l e r g a u g e a n d a d j u st to sp e ci fi ca ti o n .

  • Page 77: Tool Kit

    Maintenance And Lubrication Tool kit The tool kit put down location at Right Glove Compartment . The tool kit includes the following items: (1) Hexagon wrench (3) (5) (1) (2) (2) Spark plug wrench (3) 8/12；10/14；17/19 mm wrench (4) Screwdriver (5) Screwdriver handle (6) Tool bag (7)Air pressure gauge...

  • Page 78: Specifications

    Specifications MODEL UXV500(OFF ROAD) DIMENSIONS: OVERALL LENGTH 2870MM OVERALL WIDTH 1500MM OVERALL HEIGHT 1850MM SEAT HEIGHT 805MM WHEELBASE 1910MM GROUND CLEARANCE 310MM MINMUN. TURNING RADIUS 4060MM BASIC WEIGHT: WITH OIL AND FULL FUEL TANK 560KG MAX. CARGO BED LOAD 190KG DRY WEIGHT 525KG MAX.
  • Page 79 Specifications MODEL UXV500(OFF ROAD) ENGINE GEAR BOX: CAPICITY/EXCHANGE/TYPE 3.6L,5W-30 FRONT GEAR BOX: CAPICITY/EXCHANGE/TYPE 275ML,(SAE80#) REAR GEAR BOX CAPICITY/EXCHANGE/TYPE 250ML,(SAE80#) AIR FILTER: SPONGE ELEMENT FUEL: TYPE UNLEADED GASOLINE FUEL TANK CAPACITY CARBURETOR: TYPE/MANUFACTURER LEE8/KYMCO SPARK PLUG: TYPE/MANUFACTURER CR7E-NGK SPARK PLUG 0.9MM CLUTH TYPE: WET CENTRIFUGAL AUTOMATIC...
  • Page 80 Specifications MODEL UXV500(OFF ROAD) TRANSMISSION: V-BELT PRIMARY REDUCTION SYSTEM SHAFT DRIVE SECONDARY REDUCTION SYSTEM TRANSMISSION TYPE: V-BELT AUTOMATIC TIRE: TYPE TUBELESS SIZE(FRONT) 25x8-12 SIZE(REAR) 25x10-12 WHEEL MATERIAL STEEL PRESSURE FR/RR 0.7/0.98(kgf/cm2) OR 10/14 psi BRAKES: SYSTEM FRONT AND REAR UNIFIED TYPE(FRONT) DUAL DISC BRAKE TYPE(REAR)
  • Page 81 Specifications MODEL UXV500(OFF ROAD) WHEEL TRAVEL: FRONT WHEEL TRAVEL 190MM REAR WHEEL TRAVEL 190MM ELETRICAL: IGNITION SYSTEM DC, CDI GENERATOR SYSTEM A.C.MAGNETO BATTERY TYPE MF-VTX20L BATTERY CAPACITY 12V18AH HAEDLIGHT TYPE: BULB VOLTAGE WATTAGE X QUANTITY: HAEDLIGHT: 12V35/35W*2 NO.PLATE LIGHT NONE REAR LIGHT 12V21/5W*2 INDICATORS FR/RR DIRECTION NONE...

  • Page 82: Specifications

    Specifications MODEL UXV500(ON ROAD) SPECIFIED FUSES: MAIN FUSE FAN MOTER IGNITION LIGHT DC12VPOWER SPARE SPARE...
  • Page 83 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 84 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 85 INITIAL EVERY WHICHEVER COMES FIRST 1200 ITEM 1000 2000 ROUTINE MONTH *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 86 Maintenance Record...
  • Page 87 Maintenance Record...
  • Page 88 Maintenance Record...
  • Page 89 Maintenance Record...
  • Page 90 Maintenance Record...
  • Page 91 Maintenance Record...
  • Page 92 By KWANG YANG Motor Co., Ltd. Frist Edition, Oct 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T200-UAA0AA-US...
  • Page 93 KWANG YANG MOTER CO .,LTD NO.35 Wan Hsing Street,San Min District Kaohsiung, Taiwan, Republic Of China Telephone : 886-7-3822526 Fax : 886-7-3950021 Printed in Taiwan...

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