Do not remove this Owner’s Manual from the vehicle. Read this manual carefully before operating the vehicle as it contains important safety information.
Your Side-by-Side vehicle can be hazardous to operate. A collision or a rollover can happen 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 of the warnings contained in this Owner’s Manual and the labels applied to your vehicle. Keep this Owner’s Manual with your vehicle at all times. FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
SECTION 1 - SAFETY INTRODUCTION FOREWORD Congratulations, and thank you for your purchase of a KYMCO Side-by-Side off-road vehicle (also known as a “UTV”). Built with American engineering and manufacturing knowledge, it is designed to provide a superior ride, great comfort, and strong utility capabilities. This Owner’s Manual was produced to ensure that you become aware of safe off-road vehicle operating procedures. It also includes information about the general care and maintenance of your UXV500.
TABLE OF CONTENTS SECTION 1 - SAFETY INTRODUCTION ........................................................................................ 1 TABLE OF CONTENTS ............................................................................. 2 UTV HAZARD WARNING ..................................................................... 3 - 4 SERIAL NUMBERS ................................................................................... 5 LOCATION OF PARTS & CONTROLS ...............................................
YOUR UTV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This Side-by-Side vehicle (UTV) handles differently from other vehicles, including motorcycles, ATVs and automobiles. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills and over obstacles if you fail to take proper precautions. Read this Owner’s Manual carefully and follow the operational procedures within. Pay special attention to the warnings in this manual and applied to your vehicle.
YOUR UTV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. 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. Exit the vehicle on the uphill side or to either side if pointed straight uphill. Turn the vehicle around and reenter it following the procedure described in this manual.
SERIAL NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBERS Your KYMCO UXV500 has two identification numbers: the Vehicle Identification Number (VIN), and the Engine Serial Number (ESN). The VIN 1 is located on the frame, behind the right, front wheel. 1 1 2 The ESN 2 is located on the rightside of the engine crankcase. The VIN and ESN are required by your KYMCO dealer to order proper parts, perform service, and submit warranty claims.
LOCATION OF PARTS AND CONTROLS 6 1 Right Head Cushion 6 Left Tail/Brake Light AK Steering Wheel 2 Right Seat (passenger) 7 Seat Belts AL Canopy 3 Right Tail/Brake Light 8 Cargo Bed AM Grab Handles 4 Left Head Cushion 9 Headlights AN Bumper 5 Left Seat (driver) AT Battery AO Tools & Spare Parts Box Indicates a potential hazard that could NOTE: Your vehicle may differ slightly in appearance images in this manual. result in serious from injury the or death.
LOCATION OF PARTS AND CONTROLS BL BM BQ BR BS CT BN BO CK BP AP Hood BL Choke Knob BQ Glove Box (locking storage) AQ Grab Handles BM Ignition Switch BR Auxiliary Power Outlet AR Seat Belts BN Steering Wheel BS Speedometer AS Fuel Tank Cap (gas cap) BO Brake Pedal CT Glove Box (open) BT Muffler & Spark Arrestor BP Throttle Pedal (accelerator) CK Transmission Shift Lever BK Latch Handles Indicates a potential hazard that could NOTE: Your vehicle may differ slightly the images in this
WARNING LABELS & HANGTAGS Your KYMCO UXV500 comes equipped with several labels and hangtags containing important safety information. Anyone who drives the vehicle should read and understand this information before operation. The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer immediately for a replacement.
WARNING LABELS On the vehicle’s dash 3 Indicates a potential hazard that could result in serious injury or death.
WARNING LABELS On the vehicle’s chassis 4 5 6 5 6 4 10 Indicates a potential hazard that could result in serious injury or death.
WARNING LABELS On the vehicle’s chassis 7 8 8 7 9 AT 9 AK AT AK Indicates a potential hazard that could result in serious injury or death.
EPA LABEL & HANGTAG 1. EPA LABEL 2. EPA HANGTAG 12 Indicates a potential hazard that could result in serious injury or death.
WARNINGS POTENTIAL HAZARD Operating this Side-by-Side vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if you do not know how to operate the vehicle properly in different situations and on different types of terrain. HOW TO AVOID THIS HAZARD Whether you are a beginning or experienced motorcycle, ATV rider or UTV driver, you should complete a certified training course directed at using this type of vehicle.
WARNINGS POTENTIAL HAZARD Operating your UTV on paved surfaces. WHAT CAN HAPPEN Your UXV500’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect vehicle handling and may result in your inability to control the vehicle. HOW TO AVOID THIS HAZARD Never operate your UXV500 on any paved surface, including, but not limited to, sidewalks, driveways, parking lots, or streets. POTENTIAL HAZARD Operating your UTV on public streets, roads, or highways.
WARNINGS POTENTIAL HAZARD Operating your UTV while under the influence of alcohol or drugs. WHAT CAN HAPPEN Consuming alcohol or drugs before or during the operation of your UTV can seriously affect your judgment. Consuming alcohol or drugs will cause you to react more slowly and will affect your balance and perception. Operating an UTV with these impairments may cause an accident resulting in injury or death. HOW TO AVOID THIS HAZARD Never operate your UXV500 while under the influence of alcohol or drugs.
WARNINGS POTENTIAL HAZARD Failure to inspect your UTV before operating it. Failure to properly maintain your UXV500. WHAT CAN HAPPEN By not keeping your vehicle in proper working order, you increase the possibility of an accident or damaging your UXV500. HOW TO AVOID THIS HAZARD Always inspect your UXV500 each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance schedules and procedures in this Owner's Manual.
WARNINGS POTENTIAL HAZARD Steering the UTV improperly. WHAT CAN HAPPEN You might lose control of your UXV500 and experience a rollover or collision. HOW TO AVOID THIS HAZARD Always follow proper procedures for steering your UXV500 as described in this Owner's Manual. Practice steering the vehicle at slow speeds before attempting to turn at faster speeds. Do not turn your UXV500 abruptly at excessive speeds. POTENTIAL HAZARD Operating your UTV on steep hills.
WARNINGS POTENTIAL HAZARD Climbing hills improperly with your UTV. WHAT CAN HAPPEN Climbing hills improperly may cause you to lose control of your UXV500 or cause the vehicle to overturn. HOW TO AVOID THIS HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces. Never accelerate suddenly as the vehicle might flip over backwards.
WARNINGS POTENTIAL HAZARD Improperly crossing hills or turning on hills while riding your UTV. WHAT CAN HAPPEN Improperly crossing hills or turning on hills may cause you to lose control of your UXV500 or cause the vehicle to overturn. HOW TO AVOID THIS HAZARD Never attempt to turn your UXV500 around on any hill until you have mastered the turning and steering techniques described in this Owner's Manual. Practice these maneuvers first on level ground.
WARNINGS POTENTIAL HAZARD Improperly driving your UTV over obstacles. WHAT CAN HAPPEN Improperly driving over obstacles may cause you to lose control of your UXV500 or cause a collision. A loss of control or a collision may cause the vehicle to overturn. HOW TO AVOID THIS HAZARD Before operating your UXV500 in a new area, check for obstacles. Never attempt to ride your vehicle over large obstacle: such as large rocks or fallen trees.
WARNINGS POTENTIAL HAZARD Operating your UTV through deep or fast flowing water. WHAT CAN HAPPEN Your UXV500’s tires may float, causing loss of traction and loss of control, which could lead to an accident. Water can also reduce the stopping capability of your vehicle’s braking system. HOW TO AVOID THIS HAZARD Never operate your UXV500 in fast flowing water, or in water deeper than the floorboard. Remember that wet brakes may have reduced stopping capability. Test your vehicle's brakes after leaving water.
WARNINGS POTENTIAL HAZARD Operating your UTV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modifications to your UXV500 may cause changes in handling which, in some situations, could lead to an accident. HOW TO AVOID THIS HAZARD Never modify your UXV500 or install accessories that are not specifically designed for your vehicle.
PREVENTION OVER VIEW OVERVIEW When riding or driving an off-road vehicle, PREVENTION is the name of the game. "Had you only known" something could go wrong, you would have prevented it. If you do not take notice of the current terrain and its specific conditions before driving your UTV, you increase the risk of losing control of the situation. Using prevention techniques will help you forecast potential hazards before they result in injury to you or damage to your Side-by-Side vehicle.
PREVENTION CONDITION OF YOUR UXV500 The second step in PREVENTION is checking the condition of your Side-by-Side vehicle before you drive it. Chances are good that you will be using your UXV500 in some rough terrain, and you do not want something to prevent you from enjoying your drive. Your best approach is to take steps to ensure that your vehicle is properly maintained so you can avoid equipment failure or a hazardous situation. You need to check the following items on your UXV500 before every ride.
PREVENTION TIRES AND WHEELS Correct tire pressure is crucial to the proper operation of your UXV500. Consult the values listed below or the SPECIFICATIONS section of this manual for tire pressure guidelines. Incorrect tire pressure can cause poor handling, instability, and could cause you to lose control of your vehicle. Front wheel air pressure: 10 psi (0.7 kgf/cm²) Rear wheel air pressure: 14 psi (0.98 kgf/cm²) Check: 1 . Tire pressure 2 . Tire surface (tread and sidewall) A.
PREVENTION LIGHTS AND ELECTRIC Turn your UXV500’s hi-beam and low-beam on and off to make sure they work. At the same time, check that the taillight and brake lights work. Also, check the status/warning indicators (reverse, neutral, and hi-lo beam) on the dash when you start the vehicle. Check the ignition switch operation. Do not drive your UXV500 unless all the systems are working properly. Check: 1. Headlight hi-beam 2. Headlight low-beam 3. Taillight/brake light 4.
PREVENTION FIRST -AID AND SUR VIV AL FIRST-AID SURVIV VIVAL Before driving your UXV500, you need to prepare for the unexpected. Emergencies and accidents are traumatic, but the situation can be worse if your are not prepared for it.
ACTIVE DRIVING OVER VIEW OVERVIEW "Active Driving" is the second part of "P.A.S.S." It involves an understanding of how your load weight, balance, gravity, and physical forces affect the handling of your UTV. For example, when you turn an automobile quickly into a sharp turn, your body is pulled to the outside of the vehicle by centrifugal force. While an automobile is comparatively stable and can tolerate harper turns, enough centrifugal force can cause an Side-by-Side vehicle to overturn.
ACTIVE DRIVING An easy way to remember the starting procedure for your NOTE: If the engine is already warm or the weather is UXV500 is by using the acronym "BONE-C." hot (95O F, 35O C or more) do not use the choke. This acronym means: 4.
ACTIVE DRIVING BRAKING / STOPPING Always allow plenty of room and time to stop your UXV500 safely. Be alert and prepared, as quick stops are inevitable. Whether you are stopping slowly or stopping quickly, follow these braking guidelines: 1. Press down on the brake pedal with your foot to apply the brakes 2. If your wheels lock, release the brake pedal for a second, then apply the brakes again. 3. Avoid prolonged application of the brakes.
ACTIVE DRIVING 3. Press down on the brake pedal and then shift the transmission into gear Always shift the transmission into LOW range when 4. Release the parking brake operating on wet or uneven terrain, when towing or pushing heavy loads, or when using a plow. Failure to 5. Keep both hands on the steering wheel, release the brake pedal follow this caution may result in premature V-belt failand slowly depress the accelerator pedal to begin driving ure or other damage to the drive system.
ACTIVE DRIVING HOW TO HANDLE A SIDE-BY-SIDE VEHICLE (Active Driving Techniques) Active driving involves being very aware of your vehicle’s dynamics as you maneuver it. You must learn how speed affects turning and the stability of your UTV. Unlike a motorcycle or an ATV where your can lean and shift your weight to aid in control of the vehicle, this type of vehicle requires balance between speed and steering. Your safety depends on using safe driving techniques.
ACTIVE RIDING K-TURNS Use the K-turn maneuver if you accidentally stall your UTV while driving uphill. Using a K-turn will enable you to point the vehicle downhill in a controlled manner and prevent it from rolling backwards. Use the turning method on this page for K-turns: 1. Stop where you are 1, apply the parking brake, and shift the transmission into neutral 2. Shut off the vehicle's engine 3. Exit the vehicle on the uphill side 4.
ACTIVE DRIVING DRIVING DOWNHILL Success in driving downhill depends on how familiar and skilled you are with using your vehicle's brakes. Use care to balance braking force and downhill speed so you don't lose control and flip your vehicle over. Use this method for riding downhill. 1. Select a low gear; stay out of neutral 2. Lightly apply the brakes and use very little throttle (accelerator pedal) Use extreme caution accelerating as your swerve so you can maintain better control of your vehicle.
ACTIVE DRIVING TIPS Driving a UTV and driving an automobile have some similarities; however, there are certain situations that require special attention: * Reversing * Skidding or Sliding * Parking on a Hill * Stalling on a Hill * Crossing Water * Crossing Roads * Riding in Cold Weather * Stopping the Vehicle * Stopping the Engine PARKING ON A HILL In the rare case you need to park your UTV on a hill: 1. Keep the UTV’s transmission in gear 2. Engage the parking brake 3.
ACTIVE DRIVING NOTE: Engine damage caused by water ingestion or immersion will not be covered by your KYMCO warranty. 1. Physically check the depth and current of the water, especially if you can't see the bottom. Look for boulders, logs, or other submerged obstacles that could impede your crossing 2. Keep your speed steady and slow 3. Make sure you have a way out on the other side of the water 4. If you get stuck in the sludge or mud, try rocking your UTV from side to side to free it 5.
ACTIVE DRIVING Do not attempt to free frozen brakes by pouring warm water on the brake pads, brake rotors or drums. STOPPING YOUR UTV To stop your ATV, first release the accelerator pedal, then depress the brake pedal smoothly. NOTE: After the brakes thaw, dry them by applying STOPPING YOUR UTV’S ENGINE To stop your UTV's engine, turn the ignition switch key to the them several times while riding slowly. OFF position.
SOUND JUDGMENT 7. Do you thrive on the adrenaline rush you get from speeding and OVERVIEW Human beings are not invincible: we need to use sound judg- dangerous situations? 1 2 3 ment to keep ourselves and others safe from harm. Knowing Never Sometimes Often that the first "S" in "P.A.S.S" stands for "Sound Judgment" 8. Do you hurt yourself because you try to do things that are beyond means you need to use yours when you operate your UTV.
SOUND JUDGMENT ENVIRONMENT NIGHT DRIVING The environment that you will operate your UTV in is often harsh and sometimes dangerous if you don't take proper It is best to avoid driving your UTV at night when visibility is limited. With little to no light, it is difficult to see what is precautions. around you. WEATHER You need to consider the weather when you participate in an If you must drive at night, proceed slowly and never ride at a outdoor activity such as driving an UTV.
SOUND JUDGMENT DRIVING ON TRAILS Use sound judgment when driving your UTV on trails. You should only drive on trails that suit your driving ability. If the trail is very rugged, it may be best to find another route to your destination. Make yourself visible to others by using your UTV's headlights and taillights. If you stop, pull completely off the trail in a way to protect yourself, your passenger, your UTV and the environment.
SOUND JUDGMENT THOSE AROUND YOU People do all kinds of things that you can't predict or control. Take steps with your riding apparel choices and your actions to Be aware of others and their behavior, as it can affect your make yourself very visible. Remember, if you can't see other vehicles coming, that means they cannot see you. enjoyment and safety when your drive your UTV. HIKERS Even though your UTV can take you to remote areas, don't assume that you are alone.
SOUND JUDGMENT EQUIPMENT The last thing you would expect is that your KYMCO UTV would break down in the middle of a field. KYMCO products are usually so reliable that sometimes you forget that your UTV, like any machine, has service needs and usage limitations. UTV MAINTENANCE You have to maintain your UTV for your safety, its operational integrity and to protect your investment. The General Maintenance section of this Owner's Manual tells you how to take care of your UTV.
SOUND JUDGMENT LOAD CAPACITY RATINGS KYMCO UTV Load Ca pacity R atings Capacity Ra Item Specifications Tongue Weight - Weight on trailer hitch. Tongue and Cargo Bed Weight - Total weight on trailer hitch plus the cargo bed load. Towing Capacity - Total weight of trailer and all cargo in the trailer. Max Load Capacity ......................................... 806 lb. (366 Kg) Cargo Bed - maximum .................................... 418 lb. (190 Kg) Tongue Weight ............................................
SOUND JUDGMENT ALCOHOL AND DRUG CONSUMPTION Alcohol is related to over 30% of the motor vehicle accidents in the United States. It is extremely dangerous to drink alcoholic beverages and drive a UTV. Alcohol, even in moderation, severely impairs your ability to control an UTV.
SOUND JUDGMENT YOUR PHYSICAL CONDITION Being physically exhausted is like being intoxicated. When fatigued, you will not be able to perform detail-oriented tasks and your coordination will be affected. This will severely inhibit your ability to drive your UTV safely. drivers use extra care and sound judgment to make sure that the activities do not get out of hand. Being wise and responsible is the best way for you and your riding friends to avoid injury or even death from a UTV accident.
SUPERVISION OVERVIEW When you allow others to drive your UTV you become responsible for their safety and their actions. The driving ability of your guests, their awareness of proper UTV operation, the terrain, and the condition of your UTV must be factored into your decision to allow others to operate your UTV. Additionally, you can be legally responsible for the actions your guests may take while driving your UTV.
SECTION 2 - OPERATION & MAINTENANCE PREFACE Thank you for choosing this quality KYMCO UTV. It has been designed and manufactured to provide you with reliable and enjoyable operation. This Owner's Manual should be considered a permanent part of your UTV and must remain with the vehicle in the event of a resale. If the UTV changes ownership, contact the KYMCO USA Customer Service Department for information on how to register the new owner.
UXV500 SPECIFICATIONS* ENGINE & DRIVE Engine type ........................... Four-Cycle/Water Cooled DOHC Bore x Stroke ........................ 92 mm x 75 mm (3.62 x 2.95 in.) Displacement ........................ 498.5 cc (30.42cu in.) Compression ratio ................. 10.5:1 Ignition type ........................... DC, CDI Spark Plug type ..................... NGK CR7E Spark Plug gap...................... 0.8 - 0.9 mm (0.03 - 0.04 in.) Brake type .............................
FEATURES & CONTROLS BRAKE PEDAL Your KYMCO UTV is equipped with front and rear hydraulic brakes that are activated simultaneously by the brake pedal. Depress the brake pedal 1 to slow or stop the vehicle. ACCELERATOR PEDAL (Throttle pedal) Push the accelerator pedal 2 down to increase the engine’s speed. Spring pressure will return the pedal to its original position when foot pressure is released. NOTE: Always check to make sure the accelerator pedal returns normally before starting the engine.
FEATURES & CONTROLS NOTE: Always turn off the engine, place the transmis- NOTE: The parking brake handle will click several times and lock as you pull the handle outward. When the parksion in gear and engage the parking brake whenever ing brake is engaged, the ! symbol 4 will illuminate you leave the UTV unattended. on the dash. NOTE: Maintaining proper gear sift linkage adjustment is required for proper transmission function. Contact your KYMCO dealer if you experience any shifting difficulty.
FEATURES & CONTROLS NOTE: Only use the differential lock when you need to maximize the tractive force to the UTV’s wheels. When the differentail lock is engaged steering effort will be increased. To engage the differential lock, pull the lock lever 6 up. To engage the differentail lock on the 4WD mode, rotate the 4WD button 7 while the lever in in the “up” position. 5 NOTE: The parking brake handle must fully retreat into its housing and the wheels must roll freely after the parking brake is released.
FEATURES & CONTROLS FUEL TANK FILLER To add fuel to your UXV500, follow this procedure: 1. Pull the fuel cap protective flap back to expose the key slot 2. Use the glove box/fuel cap key to unlock the cap 3. Turn the key counterclockwise to unlock the cap 4. Once unlocked, lift the cap from the fuel filler neck NOTE: Be careful where you place the removed fuel tank cap so dirt or other debris does not get onto the cap and ultimately into the fuel tank were it can contaminate the gasoline.
FEATURES & CONTROLS SEAT REMOVAL The seats on your UTV500 can be removed from the chassis for cleaning or service. To remove the seat, pull up on the front edge of the seat to release its location pins from the chassis grommets. Never drive your UTV without fastining your seat belt. Passengers should wear their seat belt any time the vehicle is in motion. The shoulder portion of the seat belt is designed to cross diagonally on the driver’s or passenger’s torso.
FEATURES & CONTROLS CARGO BED Opening & Closing the Tailgate Your UXV500’s cargo bed has a tailgate which can be unlatched to ease the loading and unloading of cargo. To open the tailgate, release both of the latches 1 by pulling the lever outward and disengage the wire hoop from the hook on the cargo bed. Once the latches are released, pull the top of the tailgate towards you (it is hinged on its bottom edge). 1 1 PULL To close the tailgate, lift it back up and secure both of the latches.
FEATURES & CONTROLS HOOD You can open the hood on your UXV500 to perform maintenancerelated tasks. To open the hood, unhook the two rubber hood latches 3 and release the six plastic fasteners 4. Press the center of the plastic fastener to release it and pull if from the hood and the fender. Lift on the back of the hood to raise it (it is hinged in the front). 4 3 3 To close the hood, carefully 4 lower it back into place on the chassis. Hook the rubber hood latches 3.
FEATURES & CONTROLS 2WD / 4WD Button The UXV500 is equipped with an remote, electric system to shift the differential between two-wheel and four-wheel drive modes. Press the 2WD/4WD button to select the desired drive mode. LIGHTS OFF 1: 2WD 5: In the position, the lights are In the position, the differential OFF. select 2WD mode (rear 6 will wheels only). The icon “2WD” POSITION LIGHT will display on the LCD speed5 ON 2: ometer. The lights are OFF (not a feature on US-market model).
FEATURES & CONTROLS CHOKE KNOB To aid cold-engine starting, the UXV500 is equipped with a manual choke. The choke knob is located on the dashboard to the left of the steering wheel. To start a cold engine, pull the choke knob 7 all the way out until it stops and hold it in place. Use the ignition switch to engage the starter motor. After starting, allow the engine to warm until the idle speed stabilizes and then release the choke knob.
FEATURES & CONTROLS MULTIFUNCTION METER Your UXV500 is equipped with a multifunction meter on its dashboard that includes speedometer, odometer, indicator lamps and other operational information and alerts. The multifunction meter becomes active when the ignition switch is in the ON position. Indicator Lights Indicator lights will provide you information about the operational status of several of the vehicles features and controls.
FEATURES & CONTROLS Multifunction Meter Operation The UXV500’s multifunction meter can be programed to display speed in MPH or Km/H, distance traveled (tripmeter) and time (clock). Use the MODE and SET buttons with procedures listed in the following sections to set and display the desired information. MODE button SET button Speedometer: MPH -or- Km/H Display To toggle the multifunction meter’s speed display between MPH and Km/H, press down the MODE button for two seconds.
FEATURES & CONTROLS Clearing the Tripmeter To clear the tripmeter’s mileage, select the trip meter you wish Once the clock display is flashing, you can set the hours and to clear, then press and hold the SET and MODE buttons si- the minutes. Press the MODE button to change the HOURS multaneously for two seconds. This will clear the mileage (“zero setting. Press the SET button to change the MINUTES setting. the tripmeter”) on the selected tripmeter display.
PERIODIC MAINTENANCE SCHEDULE Continued on following page...
PERIODIC MAINTENANCE SCHEDULE Continued on following page...
PERIODIC MAINTENANCE SCHEDULE BREAK-IN PROCEDURE New UTVs and renewed UTV engines require a "break-in" period. The first month is most critical to the life of your UTV's engine, and proper operation during this break-in period will help assure maximum life and performance from your UTV. During your UTV's first ten hours of operation, always use a light throttle, keeping engine RPM well below the maximum.
GENERAL MAINTENANCE BRAKE PADS MUST BE BEDDED-IN TO ACHIEVE FULL BRAKING EFFECTIVENESS. Braking distance will be greater until brake pads are properly bedded-in.
GENERAL MAINTENANCE GASOLINE-OIL-LUBRICANT TOOL KIT A tool has been supplied with your UXV500 for your conve- Recommended Gasoline The recommended fuel to use in your UTV is regular unnience. The tool kit is stored in the right glove box. leaded gasoline with a 87 minimum octane rating. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated fuels containing up to 10% ethanol, 5% methane, or MTBE are acceptable to use.
GENERAL MAINTENANCE Engine Oil Level Inspection To check the engine oil level, use this procedure: 1. Park the UTV on level ground 2. Warm up the engine for several minutes, then turn it off 3. Check the oil level at the inspection window 4. The oil level in the window 1 should be above the "L" mark but not higher than the "H" mark. Add oil through the filler cap 2 as required 2 1 NOTE: The UTV should be parked on level ground, with the engine off, when checking the engine oil level.
GENERAL MAINTENANCE NOTE: Skip step 5 and proceed to step 7 if you are not going to replace the oil filter cartridge. 5. Remove the oil filter cartridge 5 with a suitable oil filter wrench. Rotate the oil filter cartridge counterclockwise to remove it from the engine. Any oil used in place of the KYMCO recommended engine oil can cause serious engine damage. 10. Warm up the engine for several minutes, then turn it off 11. Check the oil level at the inspection window 12.
GENERAL MAINTENANCE Recommended Front Differential/Rear Drive Lubricant 5. After all the fluid has been drained, reinstall the drain plugs and The recommended lubricant for your KYMCO UTV (front diftighten them securely ferential and rear drive when applicable) is an SAE approved 6. Pour recommended oil into each filler hole 80W-90 Hypoid fluid. NOTE: If the gear case has a level plug, add fluid up to the threads of the level plug. If your UTV's gear case only has a fill plug, add fluid to within 1 in.
GENERAL MAINTENANCE SPARK PLUG Inspection & Replacement The spark plug is an important engine component and is easy to inspect. The condition the spark plug can indicate the condition of your UTV’s engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem. Do not attempt to diagnose such problems yourself. Instead, take your UTV to a KYMCO dealer.
GENERAL MAINTENANCE 3. Remove the air cleaner cover screws 3 4. Loosen the joint clamp 4 and remove the element from the air cleaner 4 The UXV500’s air cleaner element is a oiled foam type that requires cleaning with an appropriate solvent and re-oiling so it will properly filter debris from the air that will enter the engine. Consult with your KYMCO dealer about air cleaner element servicing products and procedures. 6.
GENERAL MAINTENANCE COOLING SYSTEM Inspection Hard water, tap water, or salt water is harmful the engine Your UXV500 has a liquid-cooled engine and periodically you and the cooling system components. Always use distilled should inspect the level of the fluid in the coolant reservoir and water or pre-mixed coolant (50:50 ratio) when adding fluid the external condition of the radiator. to the coolant reservoir.
GENERAL MAINTENANCE BRAKES Brake Fluid Inspection Your UXV500 has hydraulically operated brakes and periodically you should inspect the level and condition of the fluid in the brake fluid reservoir. Inspect and adjust the brake fluid level in the reservoir using the following procedure: 1. Open the hood 2. Check the brake fluid level; the brake fluid level should be between the FULL and LOW marks on the reservoir FULL LOW 3.
GENERAL MAINTENANCE WHEELS Wheel Removal & Installation To remove the wheels from your UTV, follow this procedure: 1. Elevate the UTV so the wheel comes off the ground by using a suitable jack and support stands 2. Remove the nuts from the wheel 3. Remove the wheel assembly NOTE: The arrow mark 4 4 on the tire must point towards the rotating direction of the wheel. To intall the wheels on your UTV, follow this procedure: 1. Place the wheel on the spindle 2.
GENERAL MAINTENANCE Tire Tread Condition The use of worn-out tires on your UTV is very dangerous. A tire is considered to be worn-out when the depth of the tread is less than 1/8 in (3 mm). Be sure to replace the tires on your UTV before reaching this minimum specification. Use only KYMCO approved tires on your UTV when replacing tires. Failure to do so could result in unstable UTV operation.
GENERAL MAINTENANCE BATTERY The battery is located in a compartment under the hood of your UXV500. After initial service, batteries require regular cleaning of the terminals and recharging in order to deliver peak performance and maximum service life. The procedures listed in this manual are recommended for cleaning and maintaining MF-sealed type batteries. Always read and follow instructions provided with battery chargers and battery products.
GENERAL MAINTENANCE NOTE: If the meter indicates the proper voltage, the battery may be reinstalled in the UTV (see step 10). NOTE: If the meter indicates the voltage is low, charge the battery using a automatic battery charge specially designed for use on MF-type batteries. When using an automatic battery charger, always follow the charger manufacturer's instructions. A battery overheated from improper charging could explode causing severe injury or death. Always monitor the battery charging carefully.
GENERAL MAINTENANCE Fuse Identification The fuse box inner lid has a label which identifies the fuse’s circuit, its rating, and its location in the fuse box. 1 2 3 4 5 6 6 Fan motor ........... 15A 5 Ignition ............... 15A 4 Light ................... 15A 3 Accessory .......... 15A 2 SPARE ................ 15A 1 SPARE ................
GENERAL MAINTENANCE PREPARATION FOR STORAGE Prior to storing your UTV, it should be properly serviced to prevent component rusting and deterioration. KYMCO recommends the procedures listed on this page to prepare your UTV for storage. If you lack the technical ability to prepare your UTV for storage, consult an authorized KYMCO dealer about performing this service. 1. Clean the seat and head cushions (cover and base) with a damp cloth and allow to the surfaces to dry 2.
GENERAL MAINTENANCE PREPARATION OF YOUR UTV FOR DRIVING AFTER STORAGE After storage, your UTV requires particular attention and adjustments to make sure you will enjoy many miles of trouble-free driving. To take your UTV out of storage, KYMCO recommends using the following procedure: 1. Clean your UTV thoroughly 2. Clean the engine. Remove the cloth from the exhaust system outlet 3. Check all control wires and cables for signs of wear or fraying. Replace any suspect items 4.
EMISSION CONTROL INFORMATION Crankcase Emission Control System Your UXV500’s engine is equipped with a closed crankcase system. Blow-by gases are routed back in to the combustion chamber via the intake system. This system does not allow the blow-by gases to enter the atmosphere. Exhaust Emission Control System The exhaust emissions from your UXV500 are controlled by engine design, factory-set fuel delivery, ignition settings, and exhaust system design.
EPA EMISSION WARRANTY 81
MAINTENANCE RECORD DATE 82 MILEAGE SERVICE PERFORMED & NOTES
MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED & NOTES 83
INDEX Accelerator Pedal ................................................ 49 Accessories ......................................................... 43 Active Driving ....................................................... 28 Air Filter ....................................................... 69 - 70 Alcohol (Effects) .................................................. 40 Auxiliary Power Outlet ......................................... 57 Battery .........................................................
Identification Numbers Record 3 1 2 4 1. IGNITION SWITCH KEY IDENTIFICATION NUMBER The ignition switch key identification code is stamped on tab 1 supplied with the key. If you require a replacement key, you will need this code to obtain a new key from your authorized KYMCO dealer. Record the key number in the box above. 2. GLOVEBOX & GAS CAP KEY IDENTIFICATION NUMBER The glovebox & gas cap key identification code is stamped on the key 2. Record the key number in the box above. 3.
5 Stan Perkins Road Spartanburg, SC 29307 Telephone: (864) 327-4744 FAX: (864) 327-4745 Prepared May 2008 T200-UAA0AA-US-A5
