KYMCO 2006 MXU 500 Off-Road User manual

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 500
OFF-ROAD
Issued: 03.09.2006

IMPORTANT NOTICES
READ THIS MANUAL CAREFULLY
AGE RECOMMENDATION
RIDER TRAINING
Your Owner's Manual contains important information on safety, operation, and
maintenance. Any one who operates this ATV should carefully read and
understand the contents of this manual before riding the vehicle.
The minimum recommended age for this ATV model is 16. Children under age 16
should never operate this vehicle.
Anyone who operates this vehicle should get proper instruction.
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only. This machine is
designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark
arrester laws and regulation in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this
machine.
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B
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.
Indicates a strong possibility that serious injury or death may
result if instructions are not followed.
CAUTION Indicates a possibility that equipment or property damage
could result if instructions are not followed.
Note: Gives helpful information
The Owner's Manual should be considered a permanent part of your ATV. It should
remain with the vehicle at all times and stay with the ATV if it is sold.
WARNING

C
PREFACE
Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a
worldwide reputation for quality-in research, design, production and service.
For replacement parts and accessories, we recommend genuine KYMCO
products. They've been specially designed for your vehicle and manufactured to
meet KYMCO's demanding standards.
This manual will provide you with a good basic understanding of the features and
operation of this machine. This manual includes important safety information. It
provides information about special techniques and skills necessary to ride your
machine. It also includes basic maintenance and inspection procedures. If you
have any questions regarding the operation or maintenance of your machine,
please consult a KYMCO dealer.
We wish you many years of safe and enjoyable riding.
While reading this manual, remember:
Indicates a strong possibility that serious injury or death may
result if instructions are not followed.
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
incurring any obligation.
WARNING

D
CONTROL FUNCTIONS....................16
IGNITION SWITCH..............................16
INSTRUMENTS AND INDICATOR........17
Multi-function display.......................19
THROTTLE LEVER.............................30
SPEED LIMITER.................................31
HANDLEBAR SWITCHES....................26
Headlight dimmer switch..................26
Start button.....................................26
Engine stop switch...........................27
Passing signal switch.......................27
RIGHT HANDLEBAR SWITCH...........28
2WD/4WD select switch....................28
RECOIL STARTER..............................29
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
SAFETY INFORMATION
DESCRIPTION AND MACHINE
IDENTIFICATION
...................1
......................4
..................................9
IDENTIFICATION NUMBER
RECORDS...........................................9
KEY IDENTIFICATION NUMBER............9
FRAME SERIAL NUMBER...................10
ENGINE SERIAL NUMBER..................10
PARTS LOCATION.............................11
Page Page
(Cont'd)

E
FRONT BRAKE LEVER.......................32
REAR BRAKE LEVER..........................32
BRAKE PEDAL...................................32
PARKING BRAKE...............................33
DRIVE SELECT LEVER.......................34
FUEL TANK CAP ................................35
FUEL VALVE......................................35
CHOKE KNOB....................................37
ACCELERATING PUMP LEVER .........38
SEAT..................................................39
FLAG POLE BRACKET.......................40
TRAILER HITCH.................................40
OWNER’S MANUAL STORAGE
COMPARTMENT.................................41
ACCESSORY SOCKET........................42
PRE-OPERATION CHECKS.............43
DRIVE SELECT LEVER ......................44
Drive select lever adjustment............46
FRONT AND REAR BRAKES................48
FUEL...............................................49
DRIVE SHAFT BOOTS........................50
ENGINE OIL ......................................51
FINAL GEAR OIL................................52
DIFFERENTIAL GEAR OIL..................52
THROTTLE LEVER.............................53
FITTINGS AND FASTENERS...............53
LIGHTS..............................................53
SWITCHES.........................................53
TIRES................................................54
How to measure tire pressure ..............55
Tire wear limit ....................................56
COOLANT..........................................56
Page Page
(Cont'd)

F
RIDING YOUR ATV ............................71
GETTING TO KNOW YOUR ATV .........72
RIDE WITH CARE AND
APPAREL...........................................75
PRE-OPERATION CHECKS................79
LOADING AND ACCESSORIES..........81
Loading and operational guidelines...81
Accessories.....................................82
MODIFICATIONS................................83
EXHAUST SYSTEM............................84
BE CAREFUL WHERE YOU RIDE........85
TURNING YOUR ATV ..........................94
SLIDING AND SKIDDING....................96
JUDGEMENT......................................73
GOOD
Speed limiter...................................80
Load Limits......................................81
No modifications..............................83
FOR OFF-ROAD USE ONLY.................90
DURING OPERATION.........................92
CLIMBING UPHILL.............................98
OPERATION........................................58
STARTING A COLD ENGINE...............58
Using the recoil starter......................61
STARTING A WARM ENGINE..............62
WARMING UP.....................................62
DRIVE SELECT LEVER OPERATION
AND REVERSE DRIVING ....................63
Shifting: neutral to high
and high to low .................................63
Shifting: neutral to reverse
and reverse to park...........................64
ENGINE BREAK-IN.............................65
ACCESSORIES ..................................68
PARKING..........................................66
Parking on a slope............................67
LOADING ...........................................69
Page Page
(Cont'd)

G
PERIODIC MAINTENANCE AND
ADJUSTMENT...................................113
TOOL KIT/
TOOL KIT COMPARTMENT.................113
PERIODIC MAINTENANCE/
LUBRICATION..................................115
......................................118
DIFFERENTIAL GEAR OIL.................127
SPARK PLUG INSPECTION..............129
SPARK ARRESTER...........................130
AIR FILTER CLEANING.....................132
AIR CLEANER HOUSING DRAIN
TUBE...............................................135
IDLE SPEED ADJUSTMENT .............136
THROTTLE LEVER ADJUSTMENT....137
VALVE CLEARANCE ADJUSTMENT..138
FRONT BRAKE PADS INSPECTION...138
REAR BRAKE PADS INSPECTION.....139
ENGINE OIL
FINAL GEAR OIL...............................125
BRAKE FLUID INSPECTION..............139
(cont'd)
Page
RIDING DOWNHILL.......................104
CROSSING A SLOPE.........................106
RIDING OVER ROUGH TERRAIN.......108
CROSSING THROUGH SHALLOW
WATER........................................109
PARKING....................................110
WHAT TO DO IF..................................111
WHAT TO DO....................................111
Page

H
CLEANING AND STORAGE...........153
A. CLEANING ...................................153
B. STORAGE ....................................155
SPECIFICATIONS..................................157
INDEX...................................................163
NOISE REGULATION.............................161
MAINTENANCE RECORD.......................162
Page
COOLING SYSTEM INSPECTION......141
Engine overheating........................143
BATTERY..........................................146
Battery remove..............................147
Battery installation.........................147
FUSE REPLACEMENT......................148
HEADLIGHT BEAM ADJUSTMENT....149
DRIVE SHAFT BOOTS.......................149
CABLE INSPECTION AND
LUBRICATION..................................150
TROUBLESHOOTING .......................151
Troubleshooting chart...................152
WHEEL REMOVAL............................144
WHEEL INSTALLATION.....................144
Page

LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1
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.
(7) (6)
(5)
(4)(3)(1)
(8)
(2)
(B) (A)
(B) (USA only)
(A) (USA only)

2
(3)
Operating this ATV if you are under
the age of 16 increases your changes
of severe injury or death.
operate this ATV if you are
under the age of 16.
NEVER
WARNING
Never carry passenger
This carrier.
Maximum load 45 Kg (100 lbs)：
on
(1)
WARNING
NEVER ride as a
passenger.
Passengers can cause a
loss of control, resulting
in SEVERE INJURY or
DEATH.
WARNING
(2)
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.
(4)
CAUTION
(5)
Never carry passenger
This carrier.
Maximum load 85 Kg (187 lbs)：
on
WARNING

3
IMPROPER TIRE PRESSURE OR OVERLOADING
CAN CAUSE LOSS OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE
INJURY OR DEATH.
OPERATING TIRE PRESSURE : Set with tires cold
Recommended :
FRONT : 25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi
REAR :
Never set tire pressure below recommended.
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2
25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi
Maximum Vehicle Load: 220 Kg. (485 lbs).
Including weight of operator, cargo and accessories.
2
LOADING

WARNING
(6)
(8)
Exceeding vehicle towing limit could lead to an
accident. Reduce speed when towing a trailer.
Read owner's manual for details.
MAXIMUM TOWING CAPACITY: 454kg (1000lbs)
TONGUE WEIGHT: 16kg (35 lbs)
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH.
ALWAYS USE AN
APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate :
Without proper training or instruction.
At speeds too fast for your skills or the
conditions.
On public roads-a collision can occur with
another vehicle.
With a passenger-passengers affect balance
and steering control.
ALWAYS :
Use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in
turns.
Avoid paved surfaces-pavement may seriously
affect handling and control.
READ OWNER'S MANUAL, FOLLOW ALL
INSTRUCTIONS AND WARNINGS.
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WARNING
(7)

4
SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from
other vehicles including motorcycles and cars. An accident can occur quickly, even during routine
maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-
cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
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




Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or instruction.
Beginners should receive training from a certified instructor.
Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
Never carry a passenger on an ATV.

5
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




Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. 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.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.


Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced
the skills necessary to control the ATV on such terrain. Always be especially cautious on these
kinds of terrain.

6
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

Always follow proper procedures for climbing hills as described in this manual. Check the terrain
carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high
speed.
Never operate the ATV on hills too steep. Practice on smaller hills before attempting larger hills.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,
maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed
straight uphill. Turn the ATV around and remount, following the procedure described in this
manual.


Always follow proper procedures for going down hills and for braking on hills as described in this
manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

POTENTIAL HAZARD
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
Improper handling of gasoline.
Gasoline can catch fire and you could be
burned.
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or exhaust
pipe/muffler when refueling.
Never refuel while smoking, or while in the
vicinity of sparks, open flames, or other
sources of ignition such as the pilot lights of
water heaters and clothes dryers.
When transporting the machine in another
vehicle, be sure it is kept upright and that the
fuel cock is in the "OFF" position.
Otherwise, fuel may leak out of the carburetor
or fuel tank.
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
Gasoline is poisonous and can cause injuries.
If you should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immediately.
If gasoline spills on your skin, wash with soap
and water. If gasoline spills on your clothing,
change your clothes.
7
WARNING

8
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.
ON
WARNING

KEY IDENTIFICATION NUMBER
The key identification number is stamped on
the hang tag as shown in the following
illustration.
DESCRIPTION AND MACHINE IDENTIFICATION
(1) Key identification number
IDENTIFICATION NUMBER RECORDS
Record the key identification number, frame
serial number, engine serial number and
model code information for assistance when
order replacement parts.
KEY NO.
FRAME NO.
ENGINE NO.
MODEL CODE
(1)
9

10
ENGINE SERIAL NUMBER
The engine serial number is stamped on the left
crankcase.
(1) Engine serial number
(1)
FRAME SERIAL NUMBER
The frame serial number is stamped on the
front and rear of the frame.
(1) Frame serial number
(1)