KYMCO MXU 700i User manual

TABLE OF CONTENTS
TABLE OF CONTENTS..........................................................- 1 -
IMPORTANT NOTICES................................................................I
YOUR ATV CAN BE HAZARDOUS TO OPERATE ....................II
PREFACE...................................................................................III
1. LOCATION OF THE WARNING AND SPECIFICATION
LABELS .......................................................................................1
2. SAFETY INFORMATION..................................................5
3. DESCRIPTION AND MACHINE IDENTIFICATION........11
3.1. IDENTIFICATION NUMBER RECORDS ..11
3.2. KEYS IDENTIFICATION NUMBER...........11
3.3. ENGINE SERIAL NUMBER ......................12
3.4. PARTS LOCATIONS.................................13
4. CONTROL FUNCTIONS.................................................18
4.1. IGNITION SWITCH ...................................18
4.2. INSTRUMENTS AND INDICATOR...........19
4.3. LEFT HANDLEBAR SWITCHES...............30
4.4. ELECTRICAL POWER STEERING ..........33
4.5. RIGHT HANDLEBAR SWITCH.................34
4.6. 2WD/4WD Select Switch...........................34
4.7. TO JUMP START YOUR VEHICLE..........35
4.8. THROTTLE LEVER ..................................36
4.9. SPEED LIMITER.......................................37
4.10. FRONT BRAKE LEVER............................38
4.11. REAR BRAKE LEVER..............................38
4.12. BRAKE PEDAL.........................................38
4.13. PARKING BRAKE.....................................39
4.14. LOCKING STEERING...............................40
4.15. DRIVE SELECT LEVER ...........................41
4.16. FUEL TANK CAP......................................42
4.17. FUEL SYSTEM.........................................42
4.18. SPARK PLUG INSPECTION....................43
4.19. BATTERY INSPECTION...........................43
4.20. SEAT.........................................................44
4.21. FLAG POLE BRACKET............................45
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4.22. TRAILER HITCH .......................................45
4.23. STORAGE COMPARTMENT....................46
4.24. ACCESSORY SOCKET............................47
5. PRE-OPERATION CHECKS ..........................................48
5.1. DRIVE SELECT LEVER............................49
5.2. FRONT AND REAR BRAKES...................53
5.3. FUEL .........................................................54
5.4. DRIVE SHAFT BOOTS.............................55
5.5. ENGINE OIL..............................................56
5.6. REAR GEAR CASE OIL............................57
5.7. FRONT GEAR CASE OIL .........................57
5.8. THROTTLE LEVER...................................58
5.9. FITTINGS AND FASTENERS...................58
5.10. LIGHTS......................................................58
5.11. SWITCHES................................................58
5.12. TIRES........................................................59
5.13. HOW TO MEASURE TIRE PRESSURE...60
5.14. TIRE WEAR LIMIT ....................................61
5.15. COOLANT.................................................61
6. OPERATION...................................................................63
6.1. STARTING A COLD ENGINE...................63
6.2. STARTING A WARM ENGINE .................66
6.3. WARMING UP ..........................................66
6.4. DRIVE SELECT LEVER OPERATION AND
REVERSE DRIVING........................................................66
6.5. ENGINE BREAK-IN ..................................69
6.6. PARKING..................................................70
6.7. ACCESSORIES........................................72
6.8. LOADING (One rider model).....................73
7. RIDING YOUR ATV........................................................75
7.1. GETTING TO KNOW YOUR ATV.............76
7.2. RIDE WITH CARE AND GOOD
JUDGEMENT77
7.3. APPAREL..................................................79
7.4. PRE-OPERATION CHECKS ....................81
7.5. LOADING AND ACCESSORIES ..............83
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7.6. MODIFICATIONS......................................85
7.7. DURING OPERATION..............................86
7.8. EXHAUST SYSTEM..................................88
7.9. PRACTICING ............................................89
7.10. TURNING YOUR ATV...............................90
7.11. CLIMBING UP SLOPE..............................91
7.12. RIDING DOWN SLOPE ............................97
7.13. PARKING ..................................................99
7.14. WHAT TO DO IF... ....................................99
8. PERIODIC MAINTENANCE AND ADJUSTMENT........100
8.1. TOOL KIT/TOOL KIT COMPARTMENT .101
8.2. PERIODIC MAINTENANCE/LUBRICATION
103
8.3. ENGINE OIL............................................106
8.4. REAR GEAR BOX OIL............................113
8.5. FRONT GEAR BOX OIL .........................115
8.6. SPARK PLUG INSPECTION ..................117
8.7. SPARK ARRESTER................................118
8.8. AIR FILTER CLEANING .........................120
8.9. IDLE SPEED INSPECTION....................124
8.10. THROTTLE LEVER ADJUSTMENT.......125
8.11. VALVE CLEARANCE ADJUSTMENT ....126
8.12. FRONT BRAKE PADS............................126
8.13. REAR BRAKE PADS..............................127
8.14. BRAKE FLUID INSPECTION..................127
8.15. COOLING SYSTEM INSPECTION.........129
8.16. ELECTRIC POWER STEERING SYSTEM
(EPS) 131
8.17. Engine overheating .................................132
8.18. WHEEL REMOVAL.................................133
8.19. WHEEL INSTALLATION.........................133
8.20. BATTERY................................................135
8.21. FUSE REPLACEMENT...........................137
8.22. POWER STEERING SYSTEM (EPS).....138
8.23. HEADLIGHT BEAM ADJUSTMENT.......139
8.24. DRIVE SHAFT BOOTS...........................139
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8.25. CABLE INSPECTION AND LUBRICATION
140
8.26. TROUBLESHOOTING ............................141
9. CLEANING AND STORAGE.........................................144
9.1. CLEANING YOUR ATV...........................144
9.2. STORAGE...............................................148
9.3. SPECIFICATIONS...................................150
9.4. NOISE REGULATION.............................154
9.5. MAINTENANCE RECORD......................155
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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 recommend age for this ATV model is 16. Children under age 16 should never operate this
vehicle.
RIDER TRAINING
Anyone who operates this vehicle should get proper instruction.
Use ATV
Please check your local riding law and regulations before operating this machine.
I

YOUR ATV CAN BE HAZARDOUS TO OPERATE
KYMCO provide many important many safety messages both in this manual and on the vehicle. For your
safety and the safety of others, pay special attention to all warning preceded by this alert symbol
.Failure to follow the warnings contained in this manual can result in SEROUS INJURY or DEATH.
The SAFETY ALERT symbol with the exclamation point in the triangle means
ATTENTION! BE ALERT! YOUR SAFETY CAN BE AFFECTED.
Failure to follow instructions associated with a WARNING symbol could result
in severe injury or death to the operator, a passenger, a bystander, or a
person inspecting or repairing the vehicle.
A CAUTION symbol indicates that special precautions must be taken to avoid
damaging the vehicle.
NOTE The NOTE symbol indicates key information about a procedure or to clarify
an operation.
The owner’s manual should be considered a permanent part of your vehicle. It should remain with the
vehicle at all times and stay with the ATV if it is sold.
II

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:
The warning symbol 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.
III

1. 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.
1

(1)
(2)
(3)
(4)
2

(5) (6)
3

(7)
(8)
(9)
(10)
4

2. 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.
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 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.
5

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.
Never operate on excessively rough, slippery or loose terrain.
6

Always follow proper procedures for turning as described in this manual. Practicing turns 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.
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.
7

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 that deeper than 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.
8

POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be burned.
HOW TO AVOID THE HAZARD
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
Gasoline is poisonous and can cause injuries.
HOW TO AVOID THE HAZARD
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.
9

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.
10

3. DESCRIPTION AND MACHINE IDENTIFICATION
3.1. 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.
______________________________________
RIGHT STORAGE COMPARTMENT
______________________________________
LOCK AND OPEN KEY NO.
______________________________________
FRAME NO.
______________________________________
ENGINE NO.
______________________________________
3.2. KEYS IDENTIFICATION NUMBER
The keys identification number is stamped on the
hang tag as shown in the following illustration.
(1) Ignition Switch Keys
(2) Right Storage
Compartment Lock And
Open Keys
11

3.3. ENGINE SERIAL NUMBER
The engine serial number is stamped on the left crankcase.
Engine Serial Number
12