KYMCO UXV 450i Owner's Manual
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KYMCO UXV 450i Owner's Manual

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KWANG YANG MOTOR CO.,LTD.
UXV 450i
OFF ROAD

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Summary of Contents for KYMCO UXV 450i

  • Page 1 KWANG YANG MOTOR CO.,LTD. UXV 450i OFF ROAD...
  • Page 2 's EFI or reeds .exposed to the exhaust system’s hot electrical system. Requires immediate components could result in a fire. inspection by a KYMCO dealer. HOW TO AVOID THIS HAZARD CELP indication Clear away plant debris or other materials away from the exhaust system Use care as the exhaust system can get very hot.
  • Page 3 Dear KYMCO UXV 450i Users: Thank you for purchasing this KYMCO UXV 450i and welcome to the family of KYMCO UXV 450i riders. To enjoy safety and more pleasant riding, become thoroughly familiar with this owner manual before you ride the UXV 450i.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Auxiliary Outlet Differential Lock Mode 32-33 Air Cleaner Daily Safety Checks Driving Safely Battery remove Driving Downhill Brake Fluid Inspection Driving Uphill Brake Pedal Driving Reverse Cargo Bed 36-38 Emission Control System 51-52 Engine Oil 53-56 Crossing Water Cooling System Inspection Fuel Lever Inspection/Refilling Fuse Replacement...
  • Page 5 TABLE OF CONTENTS Operation Instruction for Gear Selector 19-24 Hood 39-40 Periodic Maintenance/Lubrication 74-76 Indicator Lights Pillows Aduust Ignition Switch Parking Brake Ignition Switch Key Parking Light Switch Right Glove Compartment Key Location Of Parts 7-10 Serial Number Locations Start The Engine 45-46 Steering Wheel Adjuster Spark Arrestor...
  • Page 6 TABLE OF CONTENTS Throttle Pedal Tool Kit 2WD/4WD Switch Warning Labels Locaton 11-15...
  • Page 7 This vehicle can be dangerous to operate. An 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 in 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. 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 left side of the engine crankcase. Engine Serial Number...
  • Page 12 Wheel steering lock Key/ Ignition Switch Key/Fuel Cap Key Right Glove Compartment Key There are two keys come with this vehicle. Keep the spare in the safe place. The key is for wheel steering lock, ignition switch, fuel cap and right glove compartment.
  • Page 13 Location Of Parts (1) 1.Right Head Cushion 2.Left Head Cushion 3.Right Latch Handle 4.Left Latch Handle 5.Right Tail /Brake Light 6.Left Tail /Brake Light...
  • Page 14 Location Of Parts (2) 07.Seat 08.Seat Belts 09. Battery (Under the seat) 10.Tool or Parts Box (Under the seat) 11.Steering Wheel 12.Headlights 13.Cargo Bed 14.Grab Handles 15.Canopy...
  • Page 15 Location Of Parts (3) 16.Hood 17.Grab Handles 18.Fuel Tank Cap 19.Muffler& Spark Arrestor 20.Cargo Bed Lever...
  • Page 16 Location Of Parts(4) 21. Speedometer 22. Right Glove Compartment 23. Auxiliary Outlet 24. Center Glove Compartment 25.Gear Shifter 26. Side Compartment 27. Rear differential lock switch (Optional) 28. Seat belt lamp 29. Light Switch 30. Ignition Switch 31. Parking Brake Lever 32. Steering Wheel 33.
  • Page 17 Warning Labels Location...
  • Page 18 Warning Labels Location...
  • Page 19 Warning Labels Location...
  • Page 20 Warning Labels Location...
  • Page 21 Warning Labels Location...
  • Page 22 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...

  • Page 23: Features And Controls

    Features And Controls Fuel Level 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. 2. Use only nonleaded gasoline. 3.

  • Page 24: 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 Gear 6. High Beam Indicator Light 7. FI System Indicator Light 8.Lock:( Differential Lock Indicator Light )9.Battery Low Voltage Indicator Light 10. High Coolant Temperature Indicator Light 11.
  • Page 25 Features And Controls Instruments and Indicators 1.Speedometer 2. Km/h or Mph 3. Clock 4. 4WD 5.Fuel Gauge 6.ODO Meter 7. Adjust Button 8.Engine Tachometer...
  • Page 26 Features And Controls Operation Instruction for Multi-meter Button A (MODE) Button B (SET)
  • Page 27 Features And Controls Operation Instruction for Multi-meter Press and hold button A until 2 seconds over. Shift the unit mph or km/h Button A (MODE)
  • Page 28 Features And Controls Operation Instruction for Multi-meter Press and hold button B until 2 seconds over. Shift function to ODO or TRIP Button B (SET)
  • Page 29 Features And Controls Operation Instruction for Multi-meter Press and hold button A and B until 2 seconds over. Simultaneously to reset to zero when at TRIP function. Button B (SET) Button A (MODE)
  • Page 30 Features And Controls Operation Instruction for Multi-meter Press and hold button A and B until 5 seconds over . when at ODO function then you can see clock position is flash word . Button B (SET) Button A (MODE)
  • Page 31 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 then Press button A you can see minute position is flash. adjust correct minute. Waiting for 2second .finish times setting.

  • Page 32: Auxiliary Power Outlet

    Features And Controls Auxiliary Power Outlet The power outlet provides12-volt receptacle has spade 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. Seat Belt Lamp Auxiliary Outlet The seat belt lamp would light on to warn...

  • Page 33: 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 34 Features And Controls Pillows adjust If you want to adjust your pillow height. Remove the four bolts and adjust pillow position you need. Then tighten the bolts.

  • Page 35: Gear Selector

    Features And Controls Maintaining shift linkage adjustment is Gear Selector important to assure proper transmission 1.Lower Gear function . 2.High Gear See your dealer if you experience any 3.Neutral Gear shifting problems. 4.Reverse Gear 5.Parking Gear To change gears, stop the vehicle and with the engine idling, push the button and move the lever to the desired gear.

  • Page 36: Ignition Switch

    Features And Controls Switches Ignition Switch The ignition switch is a three-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...

  • Page 37: Light Switch

    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.
  • Page 38 Features And Controls Switches Drive Select Switch The 2WD/4WD allows the operator to operate the vehicle in either two-wheel drive (rear wheel) or four wheel drive(all wheels) For normal riding on flat, dry, hard surfaces, two-wheels drive should be sufficient. In situations when additional traction is necessary, four-wheel drive would be the desired choice.

  • Page 39: Differential Lock Mode

    Features And Controls Differential Lock mode The vehicle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential in low traction situations. Turf version of model is equipped with both front and rear differentials.
  • Page 40 Features And Controls Differential Lock mode Turf Front Left & Right Rear Left & Right Wheels Wheels Version Model Different speed when Same speed when vehicle turning. vehicle turning. Lock the rear differential Different speed when vehicle turning. Unlock the rear differential Different speed when Same speed when vehicle turning.

  • Page 41: Steering Wheel Adjuster

    Features And Controls Steering Wheel Adjuster (1) Pull steering wheel adjuster(1) to adjust the position of steering wheel. Brake Pedal (2) Step on the brake pedal to slow or stop or stop the vehicle. Throttle Pedal (3) Step the pedal down slightly to increase engine speed.

  • Page 42: Parking Brake

    Features And Controls Parking Brake(3) To engage the parking brake, pull the parking brake lever outward until resistance is felt. Make sure the parking brake lever is functioning properly before each operation. Note: If you forget to release the parking brake, when riding speed above 5 km/h, the alarm horn would be sounded to warn you.
  • Page 43 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 44 Features And Controls Cargo Bed(Open and close the tailgate 1) To open Unlock the latches (1) , and then lower the tailgate. Latch(x2) Pull...
  • Page 45 Features And Controls Cargo Bed(Open and close the tailgate 2) To close Place the tailgate in the original position ,and then hook the latches.
  • Page 46 Features And Controls Hood (To Open) Pull up the hood from the front end. Then remove the hood.
  • Page 47 Features And Controls Hood (To Install) Insert the tabs(1) and tap the tabs(2)(3) The vehicle goes with additional tab to correct position, then check tightness. accessory(4), customer can install the tab to strengthen the tightness if necessary. Notice: Install incorrectly could cause the hood loosen and fall off when vehicle being driven.
  • Page 48 Features And Controls Front Compartment (To Open) Release the latches and open the front compartment. Latches...
  • Page 49 Features And Controls Rear Compartment (To install) Pull the handle, push ends of cover, release and push the handle to make sure latches(2) engage with the grooves firmly. Notice: Install incorrectly could cause the latch loosen and the rear compartment opened.

  • Page 50: Daily Safety Checks

    How to operate Daily Safety Checks Check the following items each day before operation. 01.Fuel---------------------Enough fuel in tank, no leaks. 02.Engine Oil-------------Engine oil level is within the standard(when engine is cold),no leaks. 03.Tires --------------------Air pressure(when cold)and check tires crack, damage or abnormal wear.
  • Page 51 How to operate Driving Safely(Driving procedures) 1.Sit on the seat and fasten the seat belt. 2.Wear the helmet and eyes protection when driving. 3.After starting the engine and allowing it to warm up，shift the transmission into gear. 4.Check your surroundings and determine the path of travel. 5.Release the parking brake.
  • Page 52 How to operate Start the Engine WARNING Never run the vehicle in a closed area, such as a garage Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation, and death. 1.Fasten the seat belts, helmets and eyes protections.(both operator and passenger) 2.Set the parking brake.
  • Page 53 How to operate Start the Engine CAUTION Do not keep running the starter motor too long otherwise -- the starter motor may overheat causing severe damage. Braking/Stopping Always allow plenty of room and time to stop smoothly. Sometimes quick stops are inevitable’...

  • Page 54: Driving Downhill

    How to operate Parking Parking vehicle follows the rules below: 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 gear, set the parking brake, and block the wheel on the downhill side.

  • Page 55: Driving Uphill

    How to operate Driving Uphill whenever driving 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 56: Crossing Water

    How to operate Crossing Water UXV450i can only operate in water up to its floorboard. Stay away from fast flowing rivers. This vehicle 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.

  • Page 57: Driving In Reverse

    How to operate Driving in Reverse Follow these guidelines below when operating in reverse gear: 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 58: Emission Control System

    The system does not allow the blow-by gases to enter the atmosphere. Exhaust Emission Control System The emission from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. KYMCO Exhaust Emission Control System including catalytic converter system. Please do not change any kYMCO design.

  • Page 59: Spark Arrester

    Emission Control System Spark Arrester Your UXV 450i has a spark arrester. The spark arrester be installed and functional when the vehicle operated on public lands. Clean method Remove method Use the iron brush cleaning carbon on the remove 3 bolts...

  • Page 60: Engine Oil

    Maintenance And Lubrication Engine Oil Always check and change the oil at the OWNER MANUAL standard intervals. 1.Position the vehicle on the level ground. 110 F 2.Start the engine and let it idle for 20~30seconds. 4.Add fresh oil into the oil tank . SAE 5W －...

  • Page 61: Engine Oil

    Maintenance And Lubrication Engine Oil Engine oil level measurement A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Unscrew the dipstick/filler cap and check the oil level should be within the standard range.

  • Page 62: Engine Oil

    Maintenance And Lubrication Engine oil replacement 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. Remove the oil fill cap (1) and oil drain bolt (2) to drain the oil.

  • Page 63: Maintenance And Lubrication

    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. Lock Remove oil filter cartridge...
  • Page 64 Maintenance And Lubrication Changing the front gear box oil 1. Place the vehicle on the a level surface. 2. Place a container under the front gear box to collect the used oil. 3. Remove the front gear box oil drain bolt(1) and front gear box oil filler bolt (2).
  • Page 65 6. Install the rear gear box oil filler bolt(2). Tightening torque Drain bolt : 5 N-m (0.5 kgf-m) Recommended oil : SAE 80 Oil quantity : Periodic oil change 0.23L Note: UXV 450i TURF model equips rear differential same with front gear box.

  • Page 66: Brake Fluid Inspection

    Maintenance And Lubrication BRAKE FLUID INSPECTION BRAKE FLUID INSPECTION Check if the fluid level is between Check if the fluid level is below the lower level upper and lower level. mark through the inspection window. WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation.
  • Page 67 Maintenance And Lubrication Air Cleaner Remove the seat. Loosen the air cleaner latches. Seat Latches...

  • Page 68: Air Cleaner

    Maintenance And Lubrication Air Cleaner Remove air cleaner cover. Using high pressure air to clean air Remove air filter element. filter element . Inspect the air filter element and replace it if damaged.

  • Page 69: Battery Remove

    Maintenance And Lubrication Battery Remove 1. Make sure the ignition switch is OFF. 2. Remove the seat. 3. Remove the battery cover. 4. Disconnect the negative ( ) terminal lead (1) from the battery first, then disconnect the positive (+) terminal lead (2). 5.

  • Page 70: 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. Open the fuse box cap. 3. Pull the old fuse out. 4.
  • Page 71 Maintenance And Lubrication Cooling System Inspection NOTE: A permanent type of antifreeze is installed in the 1. Remove the hood. cooling system when shipped.It is colored green 2. Check the coolant level in the coolant and contains ethylene glycol.It is mixed.It is mixed reservoir when the engine is cold as the at 50% with water and has a freezing point of coolant level will vary with engine...

  • Page 72: Wheel Installation

    Maintenance And Lubrication Wheel Installation Wheel Removal When reinstalling a wheel, tighten the wheel nuts in 1.Elevate the wheel by placing a suitable a crisscross(rather than a circular)pattern. stand under the frame. Wheel nut torque: 2.Remove the nuts from the wheel. Front:55 N-m(5.5 kgf-m) 3.Remove the wheel assembly.
  • Page 73 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 74: 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 75: 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 76: Specifications

    Specifications MODEL UXV450 i (OFF ROAD) DIMENSIONS: OVERALL LENGTH 106 in(2700 mm) OVERALL WIDTH 56.69 in(1440 mm) OVERALL HEIGHT 72.84 in(1850 mm) SEAT HEIGHT 32.91 in(836 mm) 72.00 in(1829 mm) WHEELBASE GROUND CLEARANCE 10.00 in(254 mm) MINMUN. TURNING RADIUS 157.48 in(4000 mm) BASIC WEIGHT: WITH OIL AND FULL FUEL TANK Standard:515kg Turf Model:551kg...
  • Page 77 FRONT GEAR BOX: CAPICITY/EXCHANGE/TYPE 270ML/250ML/SAE80# REAR GEAR BOX CAPICITY/EXCHANGE/TYPE 250ML/230ML/SAE80# AIR FILTER: SPONGE ELEMENT FUEL: TYPE UNLEADED GASOLINE FUEL TANK CAPACITY 8.32 gal (32 L) THROTTLE BODY: TYPE/MANUFACTURER PTA1/KYMCO SPARK PLUG: CR6E-NGK TYPE/MANUFACTURER SPARK PLUG 0.7~0.8mm CLUTH TYPE: WET CENTRIFUGAL AUTOMATIC...
  • Page 78 Specifications MODEL UXV450 i (OFF ROAD) TRANSMISSION: V-BELT PRIMARY REDUCTION SYSTEM SHAFT DRIVE SECONDARY REDUCTION SYSTEM TRANSMISSION TYPE: TIRE: TYPE TUBELESS SIZE(FRONT) 25x 8-12 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 79 Specifications MODEL UXV450 i ( OFF ROAD) WHEEL TRAVEL: FRONT WHEEL TRAVEL 176mm REAR WHEEL TRAVEL 172mm ELETRICAL: IGNITION SYSTEM DC, ECU AUTOMATIC CONTROL GENERATOR SYSTEM 1. Rare earth A.C. generator or 2. Ferrite A.C.generator BATTERY TYPE MF-VTX20L BATTERY CAPACITY 12V18AH BULB VOLTAGE WATTAGE X QUANTITY:...

  • Page 80: Specifications

    Specifications MODEL UXV450 i (OFF ROAD) SPECIFIED FUSES: MAIN FUSE FAN MOTER IGNITION LIGHT DC12VPOWER FUEL SPARE...
  • Page 84 Maintenance Record...
  • Page 85 Maintenance Record...
  • Page 86 Maintenance Record...
  • Page 87 Maintenance Record...
  • Page 88 By KWANG YANG Motor Co., Ltd. First Edition, Apr. 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T200 –UA90AA –A7...

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