KYMCO MXU500i-IRS-EFI Page 8 Owner'S Manual Download | Manualshive

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PERIODIC MAINTENANCE AND
ADJUSTMENT

...................................101

TOOL KIT/
TOOL KIT COMPARTMENT.................101
PERIODIC MAINTENANCE/
LUBRICATION..................................103
ENGINE OIL .....................................106

...............................113

D I F F E R E N T I A L

G E A R

O I L

. . 1 1 5

SPARK PLUG INSPECTION..............117
SPARK ARRESTER...........................118
AIR FILTER CLEANING.....................120
AIR CLEANER HOUSING DRAIN
TUBE...............................................123
IDLE SPEED INSPECTION .............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

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Summary of Contents for MXU500i-IRS-EFI

Page 1: ...KWANG YANG MOTOR CO LTD...

Page 2: ...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...

Page 3: ...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...

Page 4: ...s 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 maint...

Page 5: ...light dimmer switch 28 Hazard switch 29 Start switch 30 RIGHT HANDLEBAR SWITCH 31 2WD 4WD select switch 31 TO JUMP START YOUR VEHICLE 32 CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS SAFET...

Page 6: ...ACKET 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 DRIV...

Page 7: ...RATION 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 WHATTO DO 100 OPERATION 62 ST...

Page 8: ...ION 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...

Page 9: ...H CLEANING AND STORAGE 141 A CLEANING 141 B STORAGE 143 SPECIFICATIONS 145 NOISE REGULATION 149 MAINTENANCE RECORD 150 Page...

Page 10: ...he 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...

Page 11: ...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...

Page 12: ...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 7 Exceeding vehicle towing limit could...

Page 13: ...ar 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 ma...

Page 14: ...oth 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...

Page 15: ...is 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 s...

Page 16: ...ther 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 p...

Page 17: ...e 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 w...

Page 18: ...HINE 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 en...

Page 19: ...FRAME SERIAL NUMBER The frame serial number is stamped on the rear of the frame 10 1 Frame serial number...

Page 20: ...ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase 11 1 Engine serial number 1...

Page 21: ...lights Position lights 03 Front brake lever Front parking brake 04 Right front turn signal light 05 Steering handlebar lock 06 Left front turn signal light A ATV Winch LDA0AE version only 12 PARTS LOC...

Page 22: ...ial lock lever Headlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch 13 Spark arrester 14 Trailer hitch LDA0AE LDAOAD FR version only 15 License light 16 Throttle lever 1...

Page 23: ...er tank 18 Front brake fluid reservoir 19 Right rearview mirror 20 Seat Brake pedal fluid reservoir Seat lock lever Oil level inspection window 24 Tool storage 25 Left rearview mirror 21 22 23 22 23 2...

Page 24: ...15 26 Battery Fuse 28 Tool kit 29 Fuel pump 30 31 Rear brake fluid reservoir 32 Accessory socket seat 33 Exhaust system 27 Left rearview mirror Drive select lever 30 26 31 27 28 32 33 29...

Page 25: ...ition switch 38 Rear parking brake lever 39 Left footpeg 40 Rear cargo rack 41 Fuel fill cap 42 Rear brake pedal 43 Flag pole bracket 16 41 42 43 40 35 NOTE The machine you have purchased may differ s...

Page 26: ...t be removed The engine can be started OFF All electrical circuits are switched off except hazard light The key can be removed in this position All electrical circuits are switched on The ignition swi...

Page 27: ...ator 14 Battery low voltage indicator light 1 Multi function display The display includes the following functions Speedometer Odometer Tripmeter Digital clock 4WD indicator Fuel gauge Engine tachomete...

Page 28: ...s in the H position 8 Neutral indicator light N This indicator light comes on when the drive select lever is in the N position 9 Reverse indicator light R This indicator light comes on when the drive...

Page 29: ...riding speed in km h or mph Press and hold MODE button for more than 2 seconds to select mph or km h 4 3 2 1 5 E F 1 2 3 4 5 6 7 8 9 0 X1000 X1000 rpm rpm ODO ODO TRIP TRIP CLOCK CLOCK km h km h mph m...

Page 30: ...shows the approximate fuel supply available in a graduated display The normal operating fuel range is with the section between the segment F and segment E When the segment E or the fuel indicator 3 fl...

Page 31: ...d SET button for more than 2 seconds to select ODO TRIP Press and hold MODE button for more than 2 seconds to select mph or km E F 1 2 3 4 5 6 7 8 9 0 X1000 X1000 rpm rpm ODO ODO TRIP TRIP CLOCK CLOCK...

Page 32: ...he MODE button and SET button in the same time until the tripmeter is reset TRIP mile km E F 1 2 3 4 5 6 7 8 9 0 X1000 X1000 rpm rpm ODO ODO TRIP TRIP CLOCK CLOCK km h km h mph mph km km mile mile TRI...

Page 33: ...select ODO mode 3 Press and hold both the MODE button and SET button in the same time for more than 2 seconds The clock will be set in the adjust mode with the hour display flashing 24 Digital clock...

Page 34: ...e MODE button the minute display will start flashing 25 E F 1 2 3 4 5 6 7 8 9 0 X1000 X1000 rpm rpm ODO ODO TRIP TRIP CLOCK CLOCK km h km h mph mph km km mile mile E F 1 2 3 4 5 6 7 8 9 0 X1000 X1000...

Page 35: ...ent Press both the MODE button and SET button in the same time 26 E F 1 2 3 4 5 6 7 8 9 0 X1000 X1000 rpm rpm ODO ODO TRIP TRIP CLOCK CLOCK km h km h mph mph km km mile mile E F 1 2 3 4 5 6 7 8 9 0 X1...

Page 36: ...signal light will flash when the switch is operated and ignition switch is ON The instrument turn signal indicator light will also flash when the switch is operated Push the switch and it will release...

Page 37: ...running because it can drain the battery and without charging in this ATV s electrical system NOTE Headlight dimmer switch Turn the switch to the position to switch on the low beam Turn the switch to...

Page 38: ...ight will also flash when the switch is operated right and 1 Hazard switch 1 29 CAUTION Turn on this switch when parking or there is a special condition After the hazard switch is turned on it will no...

Page 39: ...art switch The start switch is used for starting the engine Pushing the switch in starts the engine See starting instructions prior to starting engine see page 62 for details CAUTION 1 1 Start switch...

Page 40: ...resent drive mode look at the Multi function display 1 31 2WD mode 2WD mode 4WD mode 4WD mode Multi funtion display Multi funtion display Without display Without display E F 1 2 3 4 5 6 7 8 9 0 X1000...

Page 41: ...has one Don t let the other end touch metal It to the positive terminal of the good battery Connect Use a remote positive terminal if the vehicle has one 5 Now connect the black negative cable to the...

Page 42: ...unction of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the o...

Page 43: ...ENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident...

Page 44: ...ront brake lever REAR BRAKE LEVER The rear brake is operated by squeezing the rear brake lever near left handgrip BRAKE PEDAL This ATV is equipped with a combined brake system Operating the brake peda...

Page 45: ...ke in freezing weather may cause the brakes to freeze in the locked position 1 1 Lock lever Rear parking brake To set the rear parking brake move the lever to position A To unlock the rear parking bra...

Page 46: ...ng brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a collision The brake could overheat...

Page 47: ...PEN The ATV could cause loss of control or overturn HOW TO AVOID THE HAZARD Always be sure you have released the locking steering handlebar and steering lock key is taken out before you begin to ride...

Page 48: ...it clicks Insert the breather tube into the meter cover hole To refuel refer to 1 Fuel tank cap 2 Breather tube 3 Meter cover hole 1 2 3 FUEL SYSTEM Engine would not start acceleration Intake air leak...

Page 49: ...dling Intake air leak Fuel contaminated deteriorated Pinched or clogged fuel hose Idle speed misadjustment Fail to perform TPS ISC reset FUEL SYSTEM Poor performance drive ability and poor fuel econom...

Page 50: ...s oily or has carbon built up it have it cleaned preferably in a sand blasting device and then clean off any abrasive particles The plug may also be to other suitable tool If the insulator is cracked...

Page 51: ...Battery Inspection Checking the battery voltage if the cold engine start ambient temperature below 18 C 0 F Refer to starting a cold engine for proper operation 0 0 See page 62 42...

Page 52: ...on the seat with the grommets on the frame and press the seat down until it locks Make sure that the seat is securely fitted NOTE SEAT To remove the seat pull the seat lock lever upward and pull up th...

Page 53: ...ions before riding 1 Flag pole bracket 44 TRAILER HITCH page 84 The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball as specified by the trailer manufa...

Page 54: ...or easy reference Store your owner s manual 1 in the storage compartment 2 at the right side of the front fender 1 1 Owner s manual 2 Storage compartment To open the compartment remove the lid 3 The o...

Page 55: ...ry socket when washing your ATV CAUTION To use the accessory socket 1 Turn the ignition switch ON then start the engine 2 Turn the headlights OFF 3 Open the accessory socket cap 2 and then insert the...

Page 56: ...y 52 126 128 48 51 FUEL Check fuel level Fill with fuel if necessary 53 54 Check oil level Fill with oil if necessary Check for leakage ENGINE OIL FINAL GEAR DIFFERENTIAL GEAR OIL 55 56 106 116 THROTT...

Page 57: ...schedules described in the Owner s Manual WARNING DRIVE SELECT LEVER Check operation of the lever before start the engine 1 Make sure moving the shift lever into the N position of the shift guide 2 T...

Page 58: ...operly adjusted drive select lever WHAT CAN HAPPEN You may lose the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N position and neutral indica...

Page 59: ...e the engine stop 2 Remove 3 fasteners 1 then remove the left side cover 2 50 2 1 Fasteners 2 Left side cover 3 Loosen the locknuts 3 of rod 4 Shift the gear to neutral by moving the shift lever and o...

Page 60: ...4 Turn the rod clockwise or counterclockwise until the drive select lever 5 into the N position of the shift guide and tighten the locknuts 51 5 Drive select lever N Neutral 5 N...

Page 61: ...If the brakes do not provide proper braking performance inspect the brakes for wear See page 126 128 FRONT AND REAR BRAKES 52 POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN Y...

Page 62: ...ded gasoline with a pump octane number of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel...

Page 63: ...OID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the fuel tank cap is closed securely Do...

Page 64: ...oftenlabeled EnergyConserving containanti frictionadditiveswhichwill causestarterclutchslippage resultingin reducedcomponentlifeandpoorengine performance CAUTION SAE 20W 50 SAE 20W 40 SAE 10W 40 SAE 1...

Page 65: ...115 116 Make sure the front gear case oil at the specified level Add oil as necessary Check for leaks Recommended final gear oil Type hypoid gear oil Viscosity SAE 80 56 Oil quantity Rear gear case o...

Page 66: ...hes Repair as necessary for proper operation THROTTLE LEVER Check to see that the throttle lever operates correctly It must open smoothly and spring back to idle position when released Repair as neces...

Page 67: ...29 0 35 kgf cm 4 1 4 9 psi Front 32 kpa 0 32 kgf cm 4 6 psi Rear 29 kpa 0 29 kgf cm 4 1 psi 2 2 2 2 POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHA...

Page 68: ...e low pressure tire gauge is included as standard equipment Make two measurements of the tire pressure and use the second reading Dust or dirt in the gauge could cause the first reading to be incorrec...

Page 69: ...l vary with engine temperature The coolant level is satisfactory if it is between the FULL and LOW marks on the tank If the coolant level is at or below the LOW level add tap water soft water to bring...

Page 70: ...WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the...

Page 71: ...TENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE HAZARD When riding in cold w...

Page 72: ...63 5 Checking the battery voltage if the cold engine start ambient temperature below 18 C 0 F 0 0...

Page 73: ...ne can be started in any gear if the brake lever is applied However it is recommended to shift into neutral or park before starting the engine When the select lever is in the neutral or park position...

Page 74: ...e engine Spark plug inspection If the engine fails to start release the start switch then push the start switch again Each cranking should be as short as possible to preserve battery energy Do not cra...

Page 75: ...er to the Starting a cold engine section The throttle should be opened slightly To get maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine To see...

Page 76: ...the specified idling speed Otherwise the transmission may be damaged CAUTION DRIVE SELECT LEVER OPERATION AND REVERSE DRIVING 1 Drive select lever R Reverse P Park L Low H High N Neutral 1 L H P R N N...

Page 77: ...e no obstacles or people behind you When it is safe to proceed go slowly NOTE Shifting neutral to reverse and reverse to park 1 Bring the machine to a complete stop and return the throttle lever to th...

Page 78: ...operation under load does not harm the engine Each full throttle acceleration sequence should be followed with a substantial rest period for the engine by cruising at lower r min so the engine can rid...

Page 79: ...the parking brake The front brake lever has three locked position that allow it to be used as a parking brake To set the front parking brake 3 1 2 1 Locked position 2 Lock lever 3 Certainly locked pos...

Page 80: ...st park on an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on slope that...

Page 81: ...genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are riding could...

Page 82: ...ollowing points in mind Never exceed the weight limit shown An overloaded ATV can be unstable Maximum load Rear cargo rack 85 kg 187 lbs Front cargo rack 45 kg 100 lbs Trailer Maximum towing capacity...

Page 83: ...he front and at the front of the rear Center the load from side to side cargo rack cargo rack Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load...

Page 84: ...RIDING YOUR ATV 75...

Page 85: ...ctice over a period of time Take the time to learn the basic techniques well before attempting more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of...

Page 86: ...ce until you are totally familiar with the machine s handling and performance characteristics POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is...

Page 87: ...ow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child u...

Page 88: ...ly reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger on the The is to allow th...

Page 89: ...of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your...

Page 90: ...s POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perceptio...

Page 91: ...rating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneve...

Page 92: ...ident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders inexperienced with this model this mo...

Page 93: ...s 16 kg 35 lbs Loading and operational guidelines Carrying cargo will affect how your ATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers Be sure to...

Page 94: ...MCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and usin...

Page 95: ...s and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction If you have question con...

Page 96: ...g operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footpeg your foot or leg may come into contact...

Page 97: ...achine or overturn POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts su...

Page 98: ...ine in a place where pedestrians or children are not likely to touch it POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burne...

Page 99: ...n riding and afterwards do not allow skin or clothing to come in contact with these components rough surfaces With the engine idling return the starter knob to the closed position and shift the drive...

Page 100: ...otboard to the outside of the turn opposite your desired direction and lean your upper body into the turn After completing the turn open the throttle gradually to accelerate the ATV 91 Support your we...

Page 101: ...se control POTENTIAL HAZARD Operating on excessively steep slopes WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep slopes than on level surfaces or small slopes HOW TO AVOID THE...

Page 102: ...pes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopels with excessively slippery or loose surfaces Shift your weight forward Never...

Page 103: ...ual Avoid slopes with excessively slippery or loose surfaces Shift your weight to the up of slope side of the ATV POTENTIAL HAZARD Improperly crossing slopes or turning on slopes WHAT CAN HAPPEN Could...

Page 104: ...rear brake will brake all wheels When descending slope using either brake lever or the brake pedal will brake the wheels on the downslope side Avoid sudden application of either the front or rear bra...

Page 105: ...4WD Apply both front and rear brakes gradually When fully stopped shift to the parking position P When fully stopped apply front brake as well and then lock parking brake Dismount on up slope side or...

Page 106: ...er with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the using the front brake lever to control speed 5 If you lose con...

Page 107: ...applying either the front brake or the rear brake will brake all wheels When descending slope using either brake lever or the brake pedal will brake the wheels on the downslope side Avoid sudden appl...

Page 108: ...turn the ignition switch OFF If you re through riding for the day also turn the fuel valve OFF Always check the terrain carefully before you start down any slope Shift your weight backward Never go d...

Page 109: ...utting your weight on the footboard to the outside of the turn Position your weight over the front wheels for better control If your ATV can t make it up a slope you are trying to climb Turn the ATV a...

Page 110: ...gine when performing maintenance unless otherwise specified PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient c...

Page 111: ...ter 1 2 3 4 5 6 7 8 POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling w...

Page 112: ...for cracks or damage Replace if necessary Check valve clearance Adjust if necessary Check condition Adjust gap and clean Replace if necessary Clean More often in wet or dusty areas Replace if necessa...

Page 113: ...ecessary Check operation Correct if necessary Check bearing assembly for looseness damage Replace if damaged Check operation Replace if damaged Check toe in Adjust if necessary Coolant Exhaust system...

Page 114: ...IAL EVERY ROUTINE Lubricate every 6 months Check all chassis fittings and fasteners Correct if necessary Knuckle shafts Steering shaft Fittings and Fasteners 1 6 12 MONTH It is recommended that these...

Page 115: ...heck the oil level through the inspection window D The oil level should be between the maximum H and minimum L marks If the level is low add oil to raise it to the proper level Wait a few minutes unti...

Page 116: ...it C Place a container under the engine D Remove the oil fill cap 1 and oil filter cap 2 to drain the oil Be sure no foreign material enters the crankcase CAUTION When removing the oil filter cap the...

Page 117: ...14 7 N m 1 5 kgf m 11 lbf ft CAUTION H Fill the engine with oil and install the oil fill cap Recommended oil see Oil quantity page 146 Periodic oil change 3 L 2 64 Imp qt 3 18 US qt After draining an...

Page 118: ...e machine on a level place B Warm up the engine for several minutes and stop it C Place a container under the engine D Remove the oil fill cap 1 and drain plug washer 2 to drain the oil Be sure no for...

Page 119: ...then remove right side cover 4 F Remove the oil filter cartridge 5 with an oil cartridge wrench 3 Fasteners 4 Right side cover 3 110 Skip steps E to I if the oil filter cartridge is not being replace...

Page 120: ...ll the new oil filter cartridge with an oil cartridge wrench and then tighten it to the specified torque 111 Make sure the O ring is seated properly NOTE Tightening torque Oil filter cartridge 10 N m...

Page 121: ...e 25 N m 2 5 kgf m 18 lbf ft Recommended oil see page 146 Oil quantity see page 146 Be sure no foreign material enters the crankcase CAUTION L Start the engine and warm it up for several minutes While...

Page 122: ...ox case when specified by the Maintenance Schedule Change the oil with the rear gear box warm and the ATV on level ground to assure complete and rapid draining Rear gear box oil replacement To drain t...

Page 123: ...il level check hole 6 Install the oil filler cap and oil level check bolt Tightening torque Drain plug 20 N m 2 kgf m 15 lbf ft 114 Recommended oil SAE 80 Oil quantity Periodic oil change 0 23 L 0 20...

Page 124: ...e oil with the front gear box warm and the ATV on level ground to assure complete and rapid draining Front gear box oil replacement 1 To drain the oil first place an oil drain pan under the oil drain...

Page 125: ...vel check hole 6 Install the oil filler bolt washer and oil level check bolt washer Tightening torque Drain plug 32 N m 3 2 kgf m 23 lbf ft 11 Recommended oil SAE 80 Oil quantity Periodic oil change 0...

Page 126: ...mportant engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an in...

Page 127: ...TER Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester 1 Remove the three bolts 1 the spark arrester 2 and the gasket 3 from the muffler 118 1 1 Bolts 2 Spark arrester 3...

Page 128: ...gasket in the muffler and tighten the three bolts securely 119 POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could cause burns Coul...

Page 129: ...d in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner 1 Remove the seat 2 Unlatch the six retainer c...

Page 130: ...air cleaner holder 8 7 Remove the inner air cleaner 9 and air cleaner screen 10 from the air cleaner guide 11 8 Remove the air cleaner screen from the inner air cleaner 6 6 Screw washer 7 8 9 10 11 7...

Page 131: ...il saturated then squeeze out the excess oil 11 Reassemble by reversing the disassembly sequence POTENTIAL HAZARD Using gasoline or low flash point solvents for cleaning ATV parts WHAT CAN HAPPEN A fi...

Page 132: ...ugh water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the drain tube 1 Remove the drain tube 1 by remov...

Page 133: ...d warm it up for a few minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 3 Connect the tacho...

Page 134: ...turn the adjuster to obtain the correct free play 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear that could cause stretching or failu...

Page 135: ...gularly This adjustment however should be left to a professional KYMCO service technician FRONT BRAKE PADS INSPECTION A wear indicator is provided on each brake The indicators allows checking of brake...

Page 136: ...tors allows checking of brake pads wear Check the position of the indicator If the indicator reaches the wear limit line ask a KYMCO dealer to replace the pads BRAKE FLUID INSPECTION Check if the flui...

Page 137: ...1 1 Lower level mark Foot brake pedal 2 Upper level mark Foot brake pedal 128 2...

Page 138: ...ee your authorized KYMCO dealer for this service page 126 127 To prevent damage to the brake system use only fluid from a sealed container Never allow contaminants dirt water etc to enter the brake fl...

Page 139: ...ee for details page 131 Hard water or salt water is harmful to the engine You may use distilled water if rou can not get soft water CAUTION 1 If water is added have a KYMCO dealer check the antifreeze...

Page 140: ...dealer when changing the coolant WARNING Engine overheating If your ATV overheat wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Restart the engine If th...

Page 141: ...reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Be sure the tapered side of the wheel nuts 1 face the wheel rim 2 Be sure the tapered side of the wheel nuts...

Page 142: ...EN 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 WARNING The arrow mark on the tire must point...

Page 143: ...s this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care NOTE When the ATV is to be stored for an extended period remove the ba...

Page 144: ...ery first then disconnect the positive terminal lead 3 5 Remove the battery 1 Install in the reverse order of removal 2 After installing the battery check to see if the battery cables are routed corre...

Page 145: ...se the fuse box cap and install seat page 43 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 136 POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPP...

Page 146: ...witch at position and start the engine Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting screws CAUTION 1 Adjusting screws 1 137 DRIVE SHAFT BOOTS Check the pro...

Page 147: ...become frayed or kinked Operation of controls could be restricted which could cause an accident or injury HOW TO AVOID THE HAZARD Inspect cables frequently Replace damaged cables Lubricate the inner...

Page 148: ...ve the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead t...

Page 149: ...ilter element and fuel tank Check fuel flow No fuel Fuel valve Clean fuel valve Turn the fuel valve to OFF Turn the fuel valve to RES Supply fuel 1 Fuel Remove the fuel hose from the fuel valve Check...

Page 150: ...les 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmissio...

Page 151: ...es which may mar the paint or protective finish When finished start the engine and let it idle for several minutes POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes m...

Page 152: ...and carburetor Be sure to drain the fuel in a well ventilated area not in a garage POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite HOW...

Page 153: ...o the cylinder Operate the starter for a few seconds to distribute the oil then reinstall the spark plug POTENTIAL HAZARD Prolonged contact of fuel with the skin Breathing fuel vapor WHAT CAN HAPPEN T...

Page 154: ...oil and full fuel tank Engine Type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system 145 335 kg 737 lbs Liquid cooled 4 stroke DOHC Single cylinder 4...

Page 155: ...l transmission oil rear final gear case oil Type Engine oil classification Front gear box oil classification Rear gear box oil classification Quantity Engine oil Periodic oil change After draining and...

Page 156: ...ve amount UNLEADED FUEL 16 5 L 3 47 lmp gal 4 29 US gal 2 3 L 0 48 lmp gal 0 6 US gal Throttle body Type Spark plug Type Gap CR7E NGK 0 6 0 7 mm 0 024 0 028 in Clutch Type Wet centrifugal automatic Br...

Page 157: ...amper Electrical Ignition system Generator system Battery type Tire Type Size Front Rear Bulb voltage wattage quantity Headlight Brake light Taillight Turn signal light Position light ECU automatic co...

Page 158: ...or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after...

Page 159: ...ccordance with the warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENACE INTERVAL DATE OF SERVIC...

Page 160: ...reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T200 LDA0AD IT A1 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kao...

Page 161: ......

Page 162: ......

Page 163: ...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...

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