KYMCO MXU500i-IRS-EFI Owner's Manual
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KYMCO MXU500i-IRS-EFI Owner's Manual

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KWANG YANG MOTOR CO.,LTD.

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  • Page 1 KWANG YANG MOTOR CO.,LTD.

  • Page 2: Important Notices

    IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Anyone 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 All information in this publication is based on the latest product information available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD Reserves the right to make changes at any time without notice and without...

  • Page 5: Table Of Contents

    CONTENTS Page Page LOCATION OF THE WARNING AND CONTROL FUNCTIONS ....17 SPECIFICATION LABELS IGNITION SWITCH......17 ....1 INSTRUMENTS AND INDICATOR..18 Multi-function display.......20 LEFT HANDLEBAR SWITCHES...27 SAFETY INFORMATION ......4 Horn button........27 Turn signal switch......27 Headlight dimmer switch....28 Hazard switch.........29 DESCRIPTION AND MACHINE Start switch........30 IDENTIFICATION ........9...
  • Page 6 Page Page FRONT BRAKE LEVER.......35 PRE-OPERATION CHECKS.....47 DRIVE SELECT LEVER ......48 REAR BRAKE LEVER......35 Drive select lever adjustment....50 BRAKE PEDAL........35 FRONT AND REAR BRAKES....52 PARKING BRAKE.......36 FUEL..........53 LOCKING STEERING......37 DRIVE SHAFT BOOTS......54 DRIVE SELECT LEVER.......38 ENGINE OIL ........55 FINAL GEAR OIL........56 FUEL TANK ........39 DIFFERENTIAL GEAR OIL ....56...
  • Page 7 Page Page OPERATION RIDING YOUR ATV ........62 ......75 STARTING A COLD ENGINE....62 GETTING TO KNOW YOUR ATV ..76 RIDE WITH CARE AND GOOD STARTING A WARM ENGINE....66 JUDGEMENT........77 WARMING UP........66 APPAREL...........80 DRIVE SELECT LEVER OPERATION PRE-OPERATION CHECKS....82 AND REVERSE DRIVING....67 LOADING AND ACCESSORIES..84 ENGINE BREAK-IN......69 Loading and operational guidelines...84...
  • Page 8 Page Page PERIODIC MAINTENANCE AND BRAKE FLUID INSPECTION....127 COOLING SYSTEM INSPECTION..129 ADJUSTMENT ........101 Engine overheating......131 TOOL KIT/ WHEEL REMOVAL......132 TOOL KIT COMPARTMENT....101 PERIODIC MAINTENANCE/ WHEEL INSTALLATION.....132 LUBRICATION........103 BATTERY..........134 ENGINE OIL ........106 Battery remove......135 FINAL GEAR OIL .......113 Battery installation......135 D I F F E R E N T I A L G E A R O I L . . 1 1 5 SPARK PLUG INSPECTION....117 FUSE REPLACEMENT......136 SPARK ARRESTER......118...
  • Page 9 Page CLEANING AND STORAGE ...141 A. CLEANING ........141 B. STORAGE ........143 SPECIFICATIONS........145 NOISE REGULATION......149 MAINTENANCE RECORD.......150...

  • Page 10: Location Of The Warning And Specification Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS WARNING INFORMATION Anyone who rides the vehicle should read and understand this information before riding. They contain important information for safe and proper operation of your ATV. The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements.
  • Page 11 WARNING CAUTION Before shifting, you must stop the machine and Never carry passenger return the throttle lever to its closed position until This carrier. the engine speed to the specified idling speed. ： Maximum load 45 Kg (100 lbs) Otherwise, the transmission may be damaged WARNING WARNING Never carry passenger...
  • Page 12 WARNING Improper ATV use can result in SEVERE IMPROPER TIRE PRESSURE OR OVERLOADING INJURY or DEATH. CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE: Set with tires cold ALWAYS USE NEVER USE Recommended: WITH...

  • 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. A collision can occur quickly, even during routine maneuvers, if you fail to take proper pre-cautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.

  • Page 14: Final Gear Oild I F F E R E N T I A L G E A R O I

    Never consume alcohol or drugs before or while operating this ATV. Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is proper for the terrain, visibility and operating conditions, and your experience. Never attempt wheel, jump, or other stunt.
  • Page 15 Always follow proper procedures for going down slopes and for braking on slopes as described in this manual. Check the terrain carefully before you start down any slope. Shift your weight backward. Never go down a slope at high speed. Avoid going down slope at an angle that would cause the vehicle to lean sharply to one side.
  • 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 KEYS IDENTIFICATION NUMBER Record the keys identification number, frame The keys identification number is stamped on serial number and engine serial number the hang tag as shown in the following information for assistance when order illustration.

  • Page 19: Frame Serial Number

    FRAME SERIAL NUMBER The frame serial number is stamped on the rear of the frame. (1) Frame serial number...

  • Page 20: Engine Serial Number

    ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase. (1) Engine serial number...

  • Page 21: Parts Location

    PARTS LOCATION (01) Rear brake lever (02) Headlights/Position lights (03) (02) (02) (01) (03) Front brake lever/Front parking brake (04) Right front turn signal light (05) Steering handlebar lock (06) Left front turn signal light ( A ) ATV Winch(LDA0AE version only) (04) (05) (06)
  • Page 22 (12) (08) (11) (10) (09) (08) (07) (07) Right rear turn signal light (08) Taillights/Brake lights (09) 2WD/4WD select switch and differential lock lever (10) Instrument and indicators (11) Headlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch (12) Left rear turn signal light (13) Spark arrester (14) Trailer hitch(LDA0AE /LDAOAD(FR)version only)
  • Page 23 (22) (19) (25) (18) (17) (17) Reservoir water tank (18) Front brake fluid reservoir (19) Right rearview mirror (20) Seat (21) Brake pedal fluid reservoir (22) Seat lock lever (23) Oil level inspection window (24) Tool storage (25) Left rearview mirror (24) (21) (20)
  • Page 24 (31) (30) (29) (28) (27) (26) (26) Exhaust system ) Battery/Fuse (28) Tool kit (29) Fuel pump (30) Left rearview mirror (31) Rear brake fluid reservoir (32) Accessory socket seat (33) Drive select lever (32) (33)
  • Page 25 (39) (38) (37) (36) (35) (34) (34) Right footpeg (35) Owner’s manual storage (36) Front cargo rack (37) Ignition switch (38) Rear parking brake lever (39) Left footpeg (40) Rear cargo rack (41) Fuel fill cap (42) Rear brake pedal (43) Flag pole bracket NOTE: The machine you have purchased may differ...

  • Page 26: Control Functions Ignition Switch

    CONTROL FUNCTIONS IGNITION SWITCH Functions of the respective switch positions are as follows: OFF: All electrical circuits are switched off except hazard light. 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 27: Instruments And Indicator

    INSTRUMENTS AND INDICATOR (1) Multi-function display (13) The display includes the following functions: (12) Speedometer Odometer/Tripmeter Digital clock (14) 4WD indicator Fuel gauge Engine tachometer (2) Right turn signal indicator/Left turn signal indicator Flashes when the right turn signal operates. (11) (10) (7)(6)
  • Page 28 (4) Coolant temperature warning indicator (9) Reverse indicator light “R” When the coolant temperature reaches a This indicator light comes on when the drive specified level, this indicator comes on to select lever is in the “R” position. warn that the coolant temperature is too hot. (10) Park indicator light “P”...

  • Page 29: 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. (1) Speedometer (2) 4WD indicator (3) Fuel gauge (4) Odometer/Tripmeter (5) Digital clock...
  • Page 30 (2) 4WD indicator (3) Fuel gauge Shows the drive mode is in the 4WD. The fuel gauge shows the approximate fuel Shows the drive mode isn’t in the 2WD. supply available in a graduated display. The normal operating fuel range is with the section between the segment F and segment E.
  • Page 31 (4) Odometer/Tripmeter The odometer shows the total mileage in Km or in mph. The tripmeter shows the trip distance in Km or in mph. There is tripmeters. Press and hold SET button for more than 2 seconds to select ODO, TRIP Press and hold MODE button for more than 2 seconds to select mph or km.
  • Page 32 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 . SET button in the same time until the tripmeter is reset. TRIP TRIP mile mile...
  • Page 33 (5) Digital clock Show the time (hours and minutes) while the ignition is ON. To adjust the time manually, proceed as follows: 1. Turn the ignition switch ON. 2. Press and hold SET button for more than 2 seconds to select ODO mode. 3.
  • Page 34 4. To set the hour, press the SET button until the 5. Press the MODE button, the minute display will desired hour. start flashing.
  • Page 35 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.

  • Page 36: Left Handlebar Switches

    LEFT HANDLEBAR SWITCHES Turn signal switch Use the turn signal switch while turning to another direction or shifting to another lane. The turn signal light will flash when the switch is operated and ignition switch is ON. " " For turning to the " left ".

  • Page 37: Headlight Dimmer Switch

    Headlight dimmer switch Turn the switch to the " " position to switch on the low beam. Turn the switch to the " " position to switch on the high beam. Turn the switch to the " " position to switch off the headlight.

  • Page 38: Hazard Switch

    Hazard switch When the hazard switch is pressed, the right and left turn signal lights flash together. instrument turn signal indicator light will also flash when the switch is operated. When the hazard switch is pressed again, the right and left turn signal lights go out together.

  • Page 39: Start Switch

    Start switch " " The start switch is used for starting the engine. Pushing the switch in starts the engine. CAUTION: See starting instructions prior to starting engine (see page 62 for details). (1) Start switch...

  • Page 40: Right Handlebar Switch

    RIGHT HANDLEBAR SWITCH 2WD/4WD select switch This ATV is equipped with a 2WD/4WD select switch, which permits a choice between the “2WD” and “4WD” drive modes. Select a drive mode that is suitable for your riding. The 2WD/4WD select switch is located above the throttle lever.

  • Page 41: To Jump Start Your Vehicle

    TO JUMP START YOUR VEHICLE 5.Now connect the black negative(-) cable to the Remove the seat and locate the batteries. good battery’s negative(-) terminal . Find the positive(+)and negative(-)terminals on Don’t let the other end touch anything until the each battery. next step.

  • Page 42: Throttle Lever

    THROTTLE LEVER WARNING It is operated by the thumb. Pressing the lever POTENTIAL HAZARD opens the throttle. When pressure is released, Malfunction of throttle. spring tension automatically closes the throttle. WHAT CAN HAPPEN Regulate the speed of the machine by varying The throttle could be hard to operate, the throttle position.

  • Page 43: 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 44: Front Brake Lever

    FRONT BRAKE LEVER BRAKE PEDAL The front brake lever is next to the right This ATV is equipped with a combined brake handgrip. system. Operating the brake pedal applies the rear brake and a portion of the front brake. The front brakes are operated by squeezing the front brake lever.

  • Page 45: Parking Brake

    PARKING BRAKE Front parking brake Rear parking brake To set the front parking brake, squeeze the front To set the rear parking brake, move the lever to brake lever and lock it with the lock lever. Always position (A). set the parking brake when parking and before Always set the parking brake when parking and starting the engine.

  • Page 46: Locking Steering

    LOCKING STEERING WARNING Turn the steering handlebar left to full and turn POTENTIAL HAZARD the key clockwise, the steering handlebar is locked. Improper use of the parking brake. The key can be taken out. WHAT CAN HAPPEN Turn the key counterclockwise, the steering The ATV could start moving unexpectedly handlebar is released automatically.

  • Page 47: Drive Select Lever

    DRIVE SELECT LEVER WARNING The drive select lever is used to shift your ATV into the low, high, neutral, reverse and park POTENTIAL HAZARD positions. Refer to page 50 ~ 51 for drive select Improper use of the locking steering. lever adjustment and operation.

  • Page 48: Fuel Tank

    FUEL TANK CAP FUEL SYSTEM After refueling, be sure to tighten the fuel tank Engine would not start acceleration cap until it clicks. Intake air leak Insert the breather tube into the meter cover Fuel contaminated/deteriorated hole. Pinched or clogged fuel hose To refuel refer to page 53.
  • Page 49 FUEL SYSTEM FUEL SYSTEM Poor performance (drive ability) and poor Engine stall, hard to start, rough idling fuel economy Intake air leak Pinched or clogged fuel hose Fuel contaminated/deteriorated faulty injector Pinched or clogged fuel hose Idle speed misadjustment Fail to perform TPS/ISC reset...

  • Page 50: Spark Plug Inspection

    SPARK PLUG INSPECTION If the plug is oily or has carbon built up it, have it cleaned, preferably in a sand-blasting device, and then clean off any abrasive particles. The plug may also be to other suitable tool. If the insulator is cracked, replace the plug. Use the standard plug.

  • Page 51: B At T E R Y I N S P E C T I O

    Battery Inspection Checking the battery voltage if the cold engine start-ambient temperature below -18 C (0 F). Refer to "starting a cold engine" for proper operation. (See page 62.)

  • Page 52: 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 53: Flag Pole Bracket

    FLAG POLE BRACKET TRAILER HITCH 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. size ball as specified by the trailer manufacturer.

  • Page 54: 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 55: 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 56: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ROUTINE PAGE ITEM ～ Check the lever for proper operation. 48 51 DRIVE SELECT LEVER Check operation, condition, and brake fluid level. ～ 52, 126 128 BRAKE Fill with DOT 4 brake fluid if necessary. Check fuel level.

  • Page 57: 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 58 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 59: 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 60 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 61: Front And Rear Brakes

    FRONT AND REAR BRAKES WARNING 1. Make sure there is no brake fluid leakage. POTENTIAL HAZARD 2. Check operation of the levers and pedal. Riding with improperly operating brakes. They should move smoothly and there should be a firm feeling when the brake is applied. If WHAT CAN HAPPEN not, have the machine inspected by a You could lose braking ability, which could...

  • Page 62: 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 63: 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 64: 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 106~112.) 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 65: Final Gear Oil

    REAR GEAR CASE OIL FRONT GEAR CASE OIL Make sure the rear gear case oil at the specified Make sure the front gear case oil at the specified level. Add oil as necessary. (See page level. Add oil as necessary. (See page 115~116.) 113~114.) Check for leaks.

  • Page 66: Throttle Lever

    THROTTLE LEVER LIGHTS Check to see that the throttle lever operates Check the headlight and taillight to make sure correctly. It must open smoothly and spring back they are in working condition. Repair as to idle position when released. Repair as necessary for proper operation.

  • Page 67: Tires

    Tire pressures must be equal on both sides. 1.The tires listed below have been 3.Tire pressure below the minimum specified approved by Kwang Yang Motor Co., Ltd. could cause the tire to dislodge from the for this model. Other tire combinations rim under severe riding conditions.

  • Page 68: 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 69: 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 70 WARNING POTENTIAL HAZARD Removing the radiator cap when the engine and radiator are still hot. WHAT CAN HAPPEN FULL You could be burned by hot fluid and steam blown out under pressure. HOW TO AVOID THE HAZARD (1) Coolant reservoir cap Wait for the engine to cool before removing (2) Maximum level mark the radiator cap.

  • Page 71: Operation

    OPERATION STARTING A COLD ENGINE WARNING WARNING POTENTIAL HAZARD Operating ATV without being familiar with POTENTIAL HAZARD all controls. Freezing control cables in cold weather. WHAT CAN HAPPEN WHAT CAN HAPPEN Loss of control, which could cause an You could be unable to control the ATV, accident or injury.
  • Page 72 5. Checking the battery voltage if the cold engine start-ambient temperature below -18 C (0 F).
  • Page 73 NOTE: The engine can be started in any gear if the brake lever is applied. However, it is recommended to shift into neutral or park before starting the engine. When the select lever is in the neutral or park position, if either indicator light does not come on, ask a KYMCO dealer to inspect its electric circuit.
  • Page 74 NOTE: If the engine fails to start, release the start switch, then push the start switch again. Each cranking should be as short as possible to preserve battery energy. Do not crank the engine more than 10 seconds on each attempt. If the battery is discharged, Changing new one to start the engine.

  • Page 75: Starting A Warm Engine

    CAUTION: NOTE: See the "engine break-in" section prior to Do not allow water enter the right case. operating engine for the first time. STARTING A WARM ENGINE To start a warm engine, refer to the "Starting a cold engine" section. The throttle should be opened slightly.

  • Page 76: 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: Apply the rear brake and shift the shift lever into P position before turning off the engine (1) Drive select lever...
  • Page 77 Shifting: neutral to reverse and reverse to park 1. Bring the machine to a complete stop and return the throttle lever to the closed position. 2. Apply the brake pedal. 3. Shift from neutral to reverse or from reverse to park and vice versa by moving the drive select lever along the shift guide.

  • Page 78: Engine Break-In

    ENGINE BREAK-IN 1. 0~10 hours: There is never a more important period in the life Avoid continuous operation above half of your machine than the period between zero throttle. Allow a cooling off period of five to and 20 hours. ten minutes after every hour of operation.

  • Page 79: Parking

    PARKING When parking, stop the engine and shift into the To set the rear parking brake, see page 36 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.

  • Page 80: 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 slope or other incline. 4.

  • Page 81: Accessories

    ACCESSORIES Do not mount an accessory where it could Accessories can affect the handling and control interfere with your ability your to control the of your ATV. Keep the following in mind when ATV. Examples include (but are not limited to) considering an accessory or operating an ATV which has accessories.

  • Page 82: Loading

    LOADING As originally equipped, this ATV can carry cargo or tow a trailer, you must use common sense and good judgment. Keep the following points in mind: Never exceed the weight limit shown. An overloaded ATV can be unstable. Maximum load Rear cargo rack: 85 kg (187 lbs) Front cargo rack: 45 kg (100 lbs) Trailer:...
  • Page 83 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 84: Riding Your Atv

    RIDING YOUR ATV...

  • Page 85: 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 86: 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 87 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 88 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 89: 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 90 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 91: Pre-Operation Checks

    PRE-OPERATION CHECKS Always perform the pre-operation checks listed page 47 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 92 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 93: Loading And Accessories

    LOADING AND ACCESSORIES Use extra caution when riding the machine with Loading and operational guidelines additional loads, such as accessories or cargo. Carrying cargo will affect how your ATV handles The machine's handling may be adversely and greatly reduce its ability in accelerating, affected.

  • Page 94: Accessories

    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 95: Modifications

    MODIFICATIONS No modifications Modifying this ATV or removing original WARNING equipment may render the vehicle unsafe or illegal. Spark arresters and mufflers are POTENTIAL HAZARD required in most areas. Don't modify your Operating this ATV with improper exhaust system or emission control system modifications.

  • Page 96: 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 97 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 98: 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 99: Practicing

    PRACTICING With the engine idling, return the starter knob to Select a flat area to become familiar with your the closed position and shift the drive select ATV. Make sure that this area is free of lever into the forward position. Then release the obstacles and other riders.

  • Page 100: Turning Your Atv

    TURNING YOUR ATV To achieve maximum traction while riding on-road, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. When approaching a corner or turn, close the throttle fully, and slow the ATV down by applying both front and rear brakes at the same time.

  • Page 101: Climbing Up Slope

    CLIMBING UP SLOPE WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on slopes. Be sure that you can Operating on excessively steep slopes. maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
  • Page 102 WARNING POTENTIAL HAZARD An obstacle or a sharp drop could be on the Climbing slopes improperly other side of the slope. 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 slopes as described in this Owner's Manual.
  • Page 103 If you are climbing a slope 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 When crossing the side of a slope: the room to do so) and go down the slope.
  • Page 104 If your ATV has stalled or stopped and you WARNING believe you can continue up the slope, restart POTENTIAL HAZARD carefully to make sure you do not lift the front wheels which could cause you to lose control. If Stalling, rolling backwards or improperly you are unable to continue up the slope, dismounting while climbing a slope.
  • Page 105 If you begin rolling backwards: Keep weight up slope. 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”. When fully stopped, apply front brake as well, and then lock parking brake.
  • Page 106 If the slope is not too steep and you have good footing, you may be able to walk the ATV back down slope . 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 107: Riding Down Slope

    RIDING DOWN SLOPE When riding your ATV down slope, shift your Whenever possible, ride your ATV straight down weight as far to the rear and up slope side of the slope. Avoid sharp angles which could allow the ATV as possible. Move back on the seat and sit ATV to tip or roll over.

  • Page 108: Parking

    PARKING Always choose a level place to park. After Always check the terrain carefully before bringing your ATV to a stop, hold the brakes you start down any slope. while you shift into park position. Then set the Shift your weight backward. parking brake and turn the ignition switch OFF.

  • Page 109: What To Do If

    WHAT TO DO IF If your ATV can't make it up a slope you are This section is designed to be a reference guide trying to climb: only. Be sure to read each section on riding techniques completely. Turn the ATV around if you still have forward speed.

  • Page 110: 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 111 The tools in the kit are sufficient to perform WARNING routine maintenance and simple repairs. Any extensive work requiring additional tools should POTENTIAL HAZARD be performed by your authorized KYMCO Operating this ATV with improper dealer. modifications. The tool kit includes the following items: Air pressure gauge WHAT CAN HAPPEN Spark plug wrench(A)

  • Page 112: 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 113 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 114 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 115: 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 116 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 117 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 146 spring and oil filter cap. Tighten the oil filter Oil quantity: cap to specification.
  • Page 118 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/washer (2) to drain the oil.
  • Page 119 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 120 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 (5) O-ring cartridge wrench, and then tighten it to the specified torque.
  • Page 121 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/washer and tighten leakage. If oil leakage is found, turn the the drain plug to the specified torque. engine off immediately and check for the cause.
  • Page 122 Rear Gear Box Oil Change the oil in the rear gear box case when specified by the Maintenance Schedule. Change the oil with the rear gear box warm, and the ATV on level ground to assure complete and rapid draining. Rear gear box oil replacement To drain the oil, first place an oil drain pan under the oil drain plug (1).
  • Page 123 3. Remove the oil filler cap (2), then remove 7. Install the skid plate. the drain plug/washer. 4. After the oil has completely drained, CAUTION: reinstall the drain plug/washer. Be sure no foreign material enters the gear Tightening torque case. Drain plug: 20 N-m (2 kgf-m, 15 lbf-ft) 5.
  • Page 124 FRONT GEAR BOX OIL Change the oil in the front gear box when specified by the Maintenance Schedule. Change the oil with the front gear box warm, and the ATV on level ground to assure complete and rapid draining. Front gear box oil replacement 1.
  • Page 125 CAUTION: 3. Remove the drain plug. 4. After the oil has completely drained, Be sure no foreign material enters the gear reinstall the drain plug/washer. case. Tightening torque Drain plug: 32 N-m (3.2 kgf-m, 23 lbf-ft) 5. Fill the gear case with the recommended oil.

  • Page 126: Spark Plug Inspection

    Before installing the spark plug, measure the SPARK PLUG INSPECTION electrode gap with a feeler gauge and adjust to The spark plug is an important engine specification. component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine.

  • Page 127: Spark Arrester

    SPARK ARRESTER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the three bolts (1), the spark arrester (2) and the gasket (3) from the muffler. (1) Bolts (2) Spark arrester (3) Gasket...
  • Page 128 WARNING 2. 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 129: 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 130 (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 131 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 132: 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 133: Idle Speed Inspection

    IDLE SPEED INSPECTION NOTE: A diagnostic tachometer must be used for this procedure. 1. Remove the seat (see page 43) 2. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min.

  • Page 134: 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 135: Valve Clearance Adjustment

    VALVE CLEARANCE ADJUSTMENT FRONT BRAKE PADS INSPECTION The correct valve clearance changes with use, A wear indicator is provided on each brake. The resulting in improper fuel/air supply or engine indicators allows checking of brake pads noise. To prevent this, the valve clearance must wear.Check the position of the indicator.

  • Page 136: Rear Brake Pads Inspection

    REAR BRAKE PADS INSPECTION BRAKE FLUID INSPECTION A wear indicator is provided on each brake. The Check if the fluid level is below the lower level indicators allows checking of brake pads mark through the inspection window. wear.Check the position of the indicator. If the indicator reaches the wear limit line, ask a WARNING KYMCO dealer to replace the pads.
  • Page 137 (1) Lower level mark (Foot brake pedal) (2) Upper level mark (Foot brake pedal)

  • Page 138: Cooling System Inspection

    COOLING SYSTEM INSPECTION NOTE: Place the machine on the level ground. As the brake pads wear, brake fluid level Remove the two fasteners (1) and then drops, automatically compensating for wear. There are no adjustments to perform, but remove front cover (2). fluid level and pad wear must be inspected periodically.
  • Page 139 2. Check the coolant level in the coolant reservoir when the engine is cold as the coolant level will vary with engine temperature. The coolant level should be between the maximum and minimum marks. FULL 3. If the level is low, remove the coolant reservoir cap, and then add coolant or distilled water to raise it to the specified level.

  • Page 140: Engine Overheating

    Engine overheating WARNING If your ATV overheat, wait until the engine has POTENTIAL HAZARD cooled. Removing the radiator cap when the engine Check the coolant level in the reservoir tank and radiator are still hot. and/or radiator. WHAT CAN HAPPEN You could be burned by hot fluid and steam Level is low, check the cooling Level is OK.

  • Page 141: Wheel Removal

    WHEEL REMOVAL WHEEL INSTALLATION 1. Elevate the wheel by placing a suitable stand When reinstalling a wheel, tighten the wheel under the frame. nuts in a crisscross (rather than a circular) 2. Remove the nuts from the wheel. pattern. Be sure the tapered side of the wheel 3.
  • Page 142 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 143: Battery

    BATTERY WARNING Your ATV battery is located in a compartment under POTENTIAL HAZARD the seat. The battery is sealed, so it is not necessary Allowing open flames or sparks near the to check the electrolyte level or add distilled water. If battery.

  • Page 144: Battery Remove

    Battery remove 1. Make sure the ignition switch is OFF. 2. Remove the seat (page 43) 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 145: Fuse Replacement

    FUSE REPLACEMENT 2. Remove the seat (page 43) 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 146: Headlight Beam Adjustment

    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 147: Cable Inspection And Lubrication

    CABLE INSPECTION AND LUBRICATION WARNING POTENTIAL HAZARD Damaged control cables. WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged. Cables can also become frayed or kinked. Operation of controls could be restricted, which could cause an accident or injury. HOW TO AVOID THE HAZARD Inspect cables frequently.

  • Page 148: Troubleshooting

    TROUBLESHOOTING WARNING Although KYMCO machines receive a rigid POTENTIAL HAZARD inspection before shipment from the factory, Checking the fuel system while smoking or trouble may occur during operation. Any near an open flame. systems can cause poor starting and loss of power.

  • Page 149: Troubleshooting Chart

    Troubleshooting chart Water or dirt Clean filter element and fuel tank. mixed in fuel. 1. Fuel No fuel. Supply fuel. Turn the fuel Check if there is Check fuel flow. Turn the fuel valve to Restart engine. fuel in the fuel Some fuel.

  • Page 150: 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 151 WARNING 7. Clean the seat with a vinyl upholstery POTENTIAL HAZARD cleaner to keep the cover pliable and Operation with wet brakes after washing. glossy. 8. Automotive type wax may be applied to all WHAT CAN HAPPEN painted and chrome plated surfaces. Avoid Wet brakes may have reduced stopping combination cleaner-waxes.

  • Page 152: 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 153 4. Remove the battery (page 135) 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 154: Specifications

    SPECIFICATIONS Model MXU 500i IRS Dimension: 2203 mm (88.12 in) Overall length 1223 mm (48.92 in) Overall width 1243 mm (49.72 in) Overall height 887 mm (35.48 in) Seat height 1297 mm (51.88 in) Wheel base 241 mm (9.64 in) Minimum ground clearance Minimum turning radius Basic weight:...
  • Page 155 MXU 500i 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 API Service SJ type or higher SAE#80 Front gear box oil classification:...
  • Page 156 Model MXU 500 i IRS Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED FUEL Tank capacity 16.5 L (3.47 lmp gal, 4.29 US gal) Reserve amount 2.3 L (0.48 lmp gal, 0.6 US gal) Throttle body: PTA1/KYMCO Type...
  • Page 157 MXU 500i IRS Model Suspension: Dual A-arm Front Dual A-arm Rear Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system ECU automatic control Generator system A.C. magneto Battery type 12V, 18AH Tire: Type Tubeless Size: Front 25X8-12 Rear 25X10-12...

  • Page 158: 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 159: 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 160 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, JAN 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.
  • Page 163 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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