KYMCO MXU 500 User manual

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
MXU 500
ON-ROAD
Issued: 01.31.2006

A
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 ON-ROAD USE ONLY
This machine is designed and manufactured for ON-ROAD use only. It is illegal and unsafe to
operate this machine on any hills and rough or loose terrain.
This machine complies with all applicable ON-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.

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....................17
IGNITION SWITCH..............................17
INSTRUMENTS AND INDICATOR........18
Multi-function display.......................20
LEFT HANDLEBAR SWITCHES...........27
Horn button.....................................27
THROTTLE LEVER.............................33
SPEED LIMITER.................................34
Turn signal switch............................27
Headlight dimmer switch..................28
Hazard switch.................................29
Start switch.....................................30
RIGHT HANDLEBAR SWITCH...........31
2WD/4WD select switch....................31
RECOIL STARTER..............................32
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..................11
PARTS LOCATION.............................12
Page Page
(Cont'd)

E
FRONT BRAKE LEVER.......................35
REAR BRAKE LEVER..........................35
BRAKE PEDAL...................................35
PARKING BRAKE...............................36
LOCKING STEERING.........................37
DRIVE SELECT LEVER.......................38
FUEL TANK CAP ................................39
FUEL VALVE......................................39
CHOKE KNOB....................................41
ACCELERATING PUMP LEVER...........42
SEAT..................................................43
FLAG POLE BRACKET.......................44
TRAILER HITCH.................................44
OWNER’S MANUAL STORAGE
COMPARTMENT.................................45
ACCESSORY SOCKET........................46
PRE-OPERATION CHECKS.............47
DRIVE SELECT LEVER ......................48
Drive select lever adjustment............50
FRONT AND REAR BRAKES................52
FUEL...............................................53
DRIVE SHAFT BOOTS........................54
ENGINE OIL ......................................55
FINAL GEAR OIL................................56
DIFFERENTIAL GEAR OIL..................56
THROTTLE LEVER.............................57
FITTINGS AND FASTENERS...............57
LIGHTS..............................................57
SWITCHES.........................................57
TIRES................................................58
How to measure tire pressure ..............59
Tire wear limit ....................................60
COOLANT..........................................60
Page Page
(Cont'd)

F
RIDING YOUR ATV ............................75
GETTING TO KNOW YOUR ATV .........76
RIDE WITH CARE AND
APPAREL...........................................80
PRE-OPERATION CHECKS................82
LOADING AND ACCESSORIES..........84
Loading and operational guidelines...84
Accessories.....................................85
MODIFICATIONS................................86
DURING OPERATION.........................87
EXHAUST SYSTEM............................89
PRACTICING......................................90
TURNING YOUR ATV ..........................91
CLIMBING UP SLOPE..........................92
RIDING DOWN SLOPE.........................98
JUDGEMENT......................................77
GOOD
No modifications..............................86
PARKING...........................................99
WHAT TO DO IF .................................100
WHATTODO.....................................100
OPERATION........................................62
STARTING A COLD ENGINE...............62
Using the recoil starter......................65
STARTING A WARM ENGINE..............66
WARMING UP.....................................66
DRIVE SELECT LEVER OPERATION
AND REVERSE DRIVING....................67
ENGINE BREAK-IN.............................69
ACCESSORIES ..................................72
PARKING..........................................70
Parking on a slope............................71
LOADING ...........................................73
Page Page
(Cont'd)

G
PERIODIC MAINTENANCE AND
ADJUSTMENT...................................101
TOOL KIT/
TOOL KIT COMPARTMENT.................101
PERIODIC MAINTENANCE/
LUBRICATION..................................103
ENGINE OIL .....................................106
...............................113
DIFFERENTIAL GEAR OIL.................115
SPARK PLUG INSPECTION..............117
SPARK ARRESTER...........................118
AIR FILTER CLEANING.....................120
AIR CLEANER HOUSING DRAIN
TUBE...............................................123
IDLE SPEED ADJUSTMENT .............124
THROTTLE LEVER ADJUSTMENT....125
VALVE CLEARANCE ADJUSTMENT..126
FRONT BRAKE PADS INSPECTION...126
REAR BRAKE PADS INSPECTION......127
FINAL GEAR OIL
BRAKE FLUID INSPECTION..............127
COOLING SYSTEM INSPECTION......129
Engine overheating........................131
BATTERY..........................................134
Battery remove..............................135
Battery installation.........................135
FUSE REPLACEMENT......................136
HEADLIGHT BEAM ADJUSTMENT....137
DRIVE SHAFT BOOTS.......................137
CABLE INSPECTION AND
LUBRICATION..................................138
TROUBLESHOOTING .......................139
Troubleshooting chart...................140
WHEEL REMOVAL............................132
WHEEL INSTALLATION.....................132
Page Page
(Cont'd)

H
CLEANING AND STORAGE...........141
A. CLEANING ...................................141
B. STORAGE ....................................143
SPECIFICATIONS..................................145
INDEX...................................................151
NOISE REGULATION.............................149
MAINTENANCE RECORD.......................150
Page

LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1
(6) (5)
(4)
(3)(2)(1)
(7)
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.

2
(2)
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
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.
(3)
CAUTION
Never carry passenger
This carrier.
Maximum load 45 Kg (100 lbs)：
on
(1)
WARNING
(4)
Never carry passenger
This carrier.
Maximum load 85 Kg (187 lbs)：
on
WARNING

3
(6)
NEVER operate :
Without proper training or instruction.
At speeds too fast for your skills
the conditions.
consuming ALCOHOL OR DRUGS.
ALWAYS :
Use proper riding techniques to avoid
vehicle overturns on hills and rough
terrain and in turns.
For your safety, wear gear to include
helmet gloves and foot protection.




Do not operate the vehicle after
or
Gasoline is flammable shut off engine,
avoid sparks and open flame when refueling.


Improper ATV use can result in SEVERE
INJURY or DEATH.
NEVER USE
WITH
ALCOHOL
DRUGS
OR
ALWAYS USE
AN
APPROVED
HELMET AND
PROTECTIVE
GEAR
LOCATE AND READ OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS
WARNING
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.


2
25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi
2
WARNING
(5)
(7)
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

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:
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.
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.





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:
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
4







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.




Never operate on excessively rough, slippery or loose terrain.
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 the ATV on hills.
Always follow proper procedures for climbing slopes as described in this manual. Check the
terrain carefully before you start up any slope. Shift your weight forward. Never open the throttle
suddenly. Never go over the top of a slope at high speed.
5



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. Go straight down the slope where possible.
Never attempt to turn the ATV around on any slope until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep slope if possible.






Always check for obstacles before operating in a new area. Never attempt to operate over large
obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating
over obstacles as described in this manual.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of
control.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
Always use the size and type tires specified in this manual. Always maintain proper tire pressure
as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow
greater distance for braking.
6

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

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.
8
ON
WARNING

KEYS IDENTIFICATION NUMBER
The keys identification number is stamped on
the hang tag as shown in the following
illustration.
DESCRIPTION AND MACHINE IDENTIFICATION
(1) Ignition switch key identification number
(2) Steering lock key identification number
IDENTIFICATION NUMBER RECORDS
Record the keys identification number, frame
serial number and engine serial number
information for assistance when order
replacement parts.
IGNITION SWITCH KEY NO.
STEERING LOCK KEY NO.
FRAME NO.
ENGINE NO.
(1) (2)
9

FRAME SERIAL NUMBER
The frame serial number is stamped on the
rear of the frame.
(1) Frame serial number
10
(1)