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4.13. FUEL TANK CAP

After refueling, be sure to tighten the fuel tank cap until it is

secure.

To refuel refer to CH 5.35.3.

4.13.1. Fuel System Troubleshooting

Engine would not start acceleration

Intake air leak

Fuel contaminated/deteriorated Pinched or clogged fuel hose.

Faulty fuel pump

Engine stall, hard to start, rough idling

Intake air leak

Fuel contaminated/deteriorated Pinched or clogged fuel hose

Idle speed mis-adjustment

Fail to perform TPS/ISC reset

Poor performance (drive ability) and poor fuel economy

Pinched or clogged fuel hose faulty injector

Содержание MXU 500i

Страница 1: ...3 4 ENGINE SERIAL NUMBER 3 3 3 5 PARTS LOCATIONS 3 4 4 CONTROL FUNCTIONS 4 1 4 1 IGNITION SWITCH 4 1 4 2 INSTRUMENTS AND INDICATOR 4 2 4 3 LEFT HANDLEBAR SWITCHES 4 15 4 4 Winch switch 4 18 4 5 EPS AB...

Страница 2: ...S 5 11 5 12 BATTERY CUT OFF SWITCH 5 11 5 13 TIRES 5 12 5 14 HOW TO MEASURE TIRE PRESSURE 5 13 5 15 TIRE WEAR LIMIT 5 14 5 16 COOLANT 5 14 6 OPERATION 6 1 6 1 STARTING A COLD ENGINE 6 1 6 2 STARTING A...

Страница 3: ...OL KIT TOOL KIT COMPARTMENT 8 2 8 2 PERIODIC MAINTENANCE LUBRICATION 8 4 8 3 ENGINE OIL 8 7 8 4 REAR GEAR BOX OIL 8 14 8 5 FRONT GEAR BOX OIL 8 16 8 6 SPARK PLUG INSPECTION 8 18 8 7 SPARK ARRESTER 8 1...

Страница 4: ...T 8 39 8 23 DRIVE SHAFT BOOTS 8 39 8 24 CABLE INSPECTION AND LUBRICATION 8 40 8 25 TROUBLESHOOTING 8 41 9 CLEANING AND STORAGE 9 1 9 1 CLEANING YOUR ATV 9 1 9 2 STORAGE 9 5 9 3 SPECIFICATIONS 9 7 9 4...

Страница 5: ...est service possible PROTECT YOUR SPORT Being able to use and enjoy your ATV requires you and your family to operate it in a responsible manner Before riding your ATV you should Learn and adhere to al...

Страница 6: ...UAL 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 befor...

Страница 7: ...eans 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...

Страница 8: ...ormation 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 maintenanc...

Страница 9: ...tand 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...

Страница 10: ...1 2 1 1 LABELS FOR T3b MODELS FOR PASSENGER SEAT ONLY...

Страница 11: ...1 3 MXU700i MXU550i...

Страница 12: ...1 4...

Страница 13: ...1 5...

Страница 14: ...e 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 AT...

Страница 15: ...lways 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 Alway...

Страница 16: ...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...

Страница 17: ...t 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 install...

Страница 18: ...gnition 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...

Страница 19: ...unning 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...

Страница 20: ...ion Switch Right Storage open and lock 3 2 IDENTIFICATION NUMBER RECORDS Record the keys identification number frame serial number and engine serial number information for assistance when order replac...

Страница 21: ...3 2 3 3 ENGINE SERIAL NUMBER The engine serial number is stamped on the left crankcase Engine Serial Number...

Страница 22: ...3 3 3 4 FRAME NUMBER The frame number is stamped on the right side of vehicle...

Страница 23: ...ly from your vehicle 01 Rearview mirrors 02 Position lights 03 High beam head light 04 Low beam headlight 05 Right turn signal light 06 Winch 07 Left turn signal light SOME MODELS ONLY NOTE The figure...

Страница 24: ...11 Central storage compartment 12 Tool storage 13 Taillights Brake lights 14 Right rear turn signal light 15 Spark arrester 16 Trailer hitch 17 License light 18 Trailer socket SOME MODELS ONLY NOTE Th...

Страница 25: ...ck 20 Battery Fuse Reservoir water tank 21 Rider Seat 22 Passenger Seat 23 Exhaust system 24 Rear cargo rack 25 Left foot peg SOME MODELS ONLY NOTE The figures of machine you purchased may differ slig...

Страница 26: ...cap 29 Accessory socket 30 Battery cut off switch 31 Brake pedal fluid reservoir 32 Right foot peg 33 Oil level inspection window 34 Rear brake pedal SOME MODELS ONLY NOTE The figures of machine you...

Страница 27: ...adlight dimmer switch Starter button Hazard switch Turn signal switch Horn switch 38 Rear parking brake lever 39 Ignition switch 40 2WD 4WD select switch and differential lock 41 Throttle Lever 42 Fro...

Страница 28: ...ective switch positions are as follows OFF All electrical circuits are switched off except hazard light The key can be removed in this position ON All electrical circuits are switched on The engine ca...

Страница 29: ...e Level Warning Indicator 1 Mode Button This button is used to switch km h mph km and mile This button is also used to adjust the time and reset the trip of meter 2 Engine Tachometer The electronic ta...

Страница 30: ...I system has fails 6 Neutral Gear Position Indicator The indicator light up when gear shifts to neutral gear position 7 Multi Function Display The display includes the following functions Digital cloc...

Страница 31: ...n during operation stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes 12 Brake Level Warning Indicator When the indicator light is on Check if the fl...

Страница 32: ...age 6 Fuel Gauge 7 Odometer Tripmeters Engine Running Time OPC 4 2 2 Change Units On ODO mode press and hold MODE button for more than 2 seconds to switch units The speed unit and mileage unit will be...

Страница 33: ...Turn the ignition switch ON b Press ADJ button to select ODO mode NOTE Digital clock can be adjusted in ODO mode only never select TRIP when you want to adjust your digital clock c Press and hold both...

Страница 34: ...4 7 d To set the hour press the ADJ button until the desired hour e Press the MODE button the minute display will start flashing...

Страница 35: ...4 8 f To set minute press the ADJ button until the desired minute g To end the adjustment Press and hold the MODE button and ADJ button in the same time until the digital clock stop flashing...

Страница 36: ...drive mode is in the 2WD Shows the drive mode isn t in the 4WD Differential lock indicator The front axle is equipped with a lockable differential that allows the operator to choose between an open d...

Страница 37: ...4 10 3 Gear Select Display Display the current gear position 4 Speedometer Display the riding speed in km h or mph 5 Battery Voltage Display the current battery voltage...

Страница 38: ...graduated display The normal operating fuel range is with the section between the segment F and segment E a Fuel indicator b Segment F c Segment E The fuel indicator and the last square start flashing...

Страница 39: ...hows the trip distance in Km or in mile There is tripmeters Press ADJ button to select ODO TRIP A TRIP B and Engine Running Time 0 1 6mins 1 1hr a Change Unit To change the unit on ODO mode press and...

Страница 40: ...4 13 b Reset Tripmeter Press ADJ select tripmeter Press and hold both the MODE button and ADJ button in the same time until the tripmeter is reset...

Страница 41: ...alarm signal and OPC appears on the gauge display when the any of following conditions is fulfilled Ignition is switched on or the engine is running below the 1800 rpm Thumb throttle is not actuated N...

Страница 42: ...to another lane The turn signal light will flash when the switch is operated and ignition switch is ON For turning to the left For turning to the right The instrument turn signal indicator light will...

Страница 43: ...rn on this switch when parking or there is a special condition After the hazard switch is turned on it will not reset automatically Be sure to reset it after use to avoid affecting the traffic safety...

Страница 44: ...gine stop switch is used to stop the engine in an emergency such as engine overturns or when the throttle cable is stuck If your ATV is stopped with the ignition switch ON and the engine stop switch O...

Страница 45: ...g the switch in starts the engine See starting instructions prior to starting engine 4 4 Winch switch To control cable in and out To determine the Cable OUT trigger to the OUT position To determine th...

Страница 46: ...ABS MODELS ONLY ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight The ABS automatically regulates brake force Intermittently gaining gr...

Страница 47: ...e has one 4 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...

Страница 48: ...r To select the drive mode push the button to switch to the desired position To check your present drive mode look at the multifunction display 4 6 2 Differential Lock Switch The Differential lock swi...

Страница 49: ...ver POTENTIAL HAZARD Malfunction 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 AVO...

Страница 50: ...ed of the ATV 1 Adjuster 2 Locknut 3 13mm 0 52in POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation...

Страница 51: ...by squeezing the front brake lever 4 9 2 Rear Brake Lever The rear brake is operated by squeezing the rear brake lever near left handgrip 1 Rear brake lever 2 Front brake lever 4 9 3 BRAKE PEDAL This...

Страница 52: ...er until the lock lever releases Using the parking brake in freezing weather may cause the brakes to freeze in the locked position 1 Lock lever 4 10 2 Rear parking brake To set the rear parking brake...

Страница 53: ...sing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely HOW TO AVOID THE HAZARD Always set the parking brake before start...

Страница 54: ...rive select lever is used to shift your ATV into the low high neutral reverse and park positions Refer to CH 5 1 1 for drive select lever adjustment and operation L Low R Reverse H High P Park N Neutr...

Страница 55: ...art acceleration Intake air leak Fuel contaminated deteriorated Pinched or clogged fuel hose Faulty fuel pump Engine stall hard to start rough idling Intake air leak Fuel contaminated deteriorated Pin...

Страница 56: ...evice and then clean off any abrasive particles The plug may also be to other suitable tool If the insulator is cracked replace the plug Use the standard plug 4 15 BATTERY INSPECTION Checking the batt...

Страница 57: ...align the tabs on the seat with the grommets on the frame and press the seat down until it locks 4 16 3 PASSENGER SEAT EPS MODELS ONLY To remove the seat pull the passenger seat lock lever upward and...

Страница 58: ...as Check local regulations before riding 1 Flag pole bracket 4 18 TRAILER HITCH SOME MODELS ONLY The trailer hitch is located on the rear axle housing To use the hitch you will need proper size ball a...

Страница 59: ...t 3 Right storage compartment 4 19 1 Cup Holder Cup holder is provided at the left side Some plastic bottle may not fit into the cup holder depending on their size and shape NOTE Never ride with any o...

Страница 60: ...should be stored in the plastic bag before store in the storage compartment Be careful not to flood this area when washing your ATV NOTE Do not put valuables inside the storage compartments 4 19 3 Ri...

Страница 61: ...ot to flood this accessory socket when washing your ATV To use the accessory socket 1 Turn the ignition switch ON and then start the engine 2 Turn the headlights OFF 3 Open the accessory socket cap 2...

Страница 62: ...ted at the rear side of the vehicle It is only allowed to provide vehicle lighting on the trailer 4 21 1 Socket Wiring Function Color 1 Brake Light G Y 2 LH Turn O 3 Fog Light Signal L 1 4 LH Indicato...

Страница 63: ...ry CH 5 3 ENGINE OIL FINAL GEAR DIFFERENTIAL GEAR OIL Check oil level Fill with oil if necessary Check for leakage CH 5 5 CH 5 6 CH 5 7 DRIVE SHAFT BOOTS Check for damage CH 5 4 THROTTLE Check for pro...

Страница 64: ...ures and schedules described in the Owner s Manual 5 1 DRIVE SELECT LEVER Before shifting you must stop the machine and return the throttle lever to its closed position until the engine speed to the s...

Страница 65: ...ting with improperly adjusted drive select lever WHAT CAN HAPPEN You may lose control of the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N po...

Страница 66: ...neutral and turn the ignition switch OFF and wait the engine cools down 2 Remove the seat 3 Remove the front cover 4 Remove five fasteners and then remove the central storage compartment cover and gea...

Страница 67: ...Verify the length of the shift rod is 341 5mm 0 5mm To adjust the length by loosening the lock nuts 1 and rotating the shift rod 2 until you achieve the proper length 150mm then tighten both locknuts...

Страница 68: ...to make sure they are working properly If the brakes do not provide proper braking performance inspect the brakes for wear POTENTIAL HAZARD Riding with improperly operating brakes WHAT CAN HAPPEN You...

Страница 69: ...esigned to use regular unleaded 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...

Страница 70: ...W TO AVOID 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 secur...

Страница 71: ...Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance ENGINE OIL QUANTITY Periodic oil change 3 0L 2 64 lm...

Страница 72: ...TITY Periodic oil change 0 23 L 0 20 Imp qt 0 243 US qt Total amount 0 25 L 0 22 Imp qt 0 265 US qt 5 7 FRONT GEAR CASE OIL Make sure the front gear case oil at the specified level Add oil as necessar...

Страница 73: ...torque 5 10 LIGHTS Check the headlight and taillight to make sure they are in working condition Repair as necessary for proper operation 5 11 SWITCHES Check the operation of the headlight switch engin...

Страница 74: ...AT25x10 12 Tubeless EPS Front AT26x8 14 Tubeless EPS Rear AT26x10 14 Tubeless 2 The tires should be set to the recommended pressure Recommended tire pressure Front 34 41 kpa 0 35 0 41 kgf cm 2 5 1 5 9...

Страница 75: ...m2 5 5 psi Rear 0 35kgf cm2 5 0 psi 0 32kgf cm2 4 7 psi 0 35kgf cm2 5 0 psi 5 14 HOW TO MEASURE TIRE PRESSURE Use the low pressure tire gauge Tool kit NOTE The low pressure tire gauge is included as s...

Страница 76: ...servoir tank when the engine is cold The coolant level will 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 a...

Страница 77: ...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 th...

Страница 78: ...nual carefully If there is a control or function you do not understand ask your KYMCO dealer 6 1 STARTING A COLD ENGINE POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You cou...

Страница 79: ...t ambient temperature below 18 C 0 F NOTE The engine 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 th...

Страница 80: ...ction system do not remove or install a battery wire when the ignition switch is at the ON position NOTE Do not allow water enter the right case See the engine break in section prior to operating engi...

Страница 81: ...e transmission may be damaged NOTE Apply the rear brake and shift the shift lever into P position before turning off the engine when parking the vehicle on an incline if you park on an incline with sh...

Страница 82: ...light should be on If the light does not come on ask a KYMCO dealer to inspect the machine 4 Check behind for people or obstacles and then release the rear brake pedal 5 Open the throttle lever gradua...

Страница 83: ...ottle 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 c...

Страница 84: ...pply 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 see CH 1 Locked position 2 Certainly locked position 3...

Страница 85: ...s If you must 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...

Страница 86: ...se a 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 c...

Страница 87: ...lbs Trailer Maximum towing capacity 150 kg 330 lbs Tongue weight 16kg 35 lbs 1 Front cargo rack 2 Rear cargo rack 6 7 2 One Rider with Passenger As originally equipped this ATV can carry cargo or tow...

Страница 88: ...carry the slower you should go Allow more braking distance A heavier vehicle takes longer to stop Avoid making sharp turns unless at very slow speeds Avoid hills and rough terrain Choose terrain care...

Страница 89: ...7 1 7 RIDING YOUR ATV...

Страница 90: ...s acquired through practice 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 provi...

Страница 91: ...more difficult maneuvers POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the AT...

Страница 92: ...hild under 16 should never operate an ATV with engine size greater than 90cc 7 4 NEVER CARRY PASSENGER ON THE CARGO RACKS POTENTIAL HAZARD Carrying a passenger on the cargo racks WHAT CAN HAPPEN Great...

Страница 93: ...the event 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 incr...

Страница 94: ...l or drugs 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...

Страница 95: ...s in safe operating 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 impr...

Страница 96: ...in an accident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience 7 8 1 Speed limiter For riders inexperienced with thi...

Страница 97: ...senger Maximum load Front cargo rack 52 kg 114 6 lbs Rear cargo rack 95 kg 209 5 lbs 7 9 4 Loading and operational guidelines Carrying cargo will affect how your ATV handles and greatly reduce its abi...

Страница 98: ...KYMCO 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 u...

Страница 99: ...ll parts 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 quest...

Страница 100: ...rds during 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 foot peg your foot or leg may come int...

Страница 101: ...of the machine 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 s...

Страница 102: ...rk the machine 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 cou...

Страница 103: ...pipe will be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position and shift the d...

Страница 104: ...corner or turn close the throttle fully and slow the ATV down by applying both front and rear brakes at the same time POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control ca...

Страница 105: ...e you to lose 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 T...

Страница 106: ...bing slopes as described in this Owner s Manual Always check the terrain carefully before you start up any slope Never climb slopes with excessively slippery or loose surfaces Shift your weight forwar...

Страница 107: ...cause loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any slope until you have mastered the turning technique as described in the Owner s M...

Страница 108: ...ou are in 2WD apply only the front brake When this ATV is in 4WD all wheels front and rear are interconnected by the drive train This means that applying either the front brake or the rear brake will...

Страница 109: ...position P after you are stopped 4 Lock parking brake If you begin rolling backwards Keep weight up slope 2WD Never apply the rear brake while rolling backwards Apply the front brake 4WD Apply both fr...

Страница 110: ...front brake lever 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 slope using the front brake lever to control sp...

Страница 111: ...scending a slope with loose or slippery surfaces Braking ability and traction may be adversely affected by these surfaces Improper braking may also cause a loss of traction When this ATV is in 4WD all...

Страница 112: ...se loss of control or cause the ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down slopes as described in this Owner s Manual Note a special technique is required w...

Страница 113: ...If your ATV doesn t turn when you want it to Bring the ATV to a stop and practice the turning maneuvers again Be sure you are putting your weight on the footboard to the outside of the turn Position y...

Страница 114: ...pection adjustment and lubrication are explained on the following pages POTENTIAL HAZARD Servicing an engine while it is running WHAT CAN HAPPEN Moving parts can catch clothing or parts of the body ca...

Страница 115: ...rm routine maintenance and simple repairs Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer The tool kit includes the following items 1 Tool bag 2 10 14...

Страница 116: ...ch in some situation could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should...

Страница 117: ...ck oil level oil leakage Replace every 12 months Differential gear oil Check oil level oil leakage Replace every 12 months Air filter element for engine and V belt compartment Clean More often in wet...

Страница 118: ...rake Check operation and brake fluid Replace brake pad if necessary Coolant Check coolant leakage Replace if necessary V belt Check operation Replace if damage or excessive wear Exhaust system Check l...

Страница 119: ...haft boots Check operation Replace if damaged Suspension Check operation Correct if necessary Brake Check operation and brake fluid Replace brake pad if necessary Knuckle shafts Steering shaft Lubrica...

Страница 120: ...m up the engine for several minutes and stop it C Check 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 r...

Страница 121: ...e for several minutes and stop 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 When removing...

Страница 122: ...oil and install the oil fill cap Recommended oil see CH 9 3 ENGINE OIL QUANTITY 550 700 Periodic oil change 3 0L 2 64 lmp qt 3 18 US qt 2 4 L 2 11 Imp qt 2 54 US qt After draining and oil filter cart...

Страница 123: ...replacement A Place the 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...

Страница 124: ...oil filter cartridge is not being replaced E Remove the two fasteners and then remove front cover F Remove the four fasteners and then remove the central storage cover G Remove the five fasteners and...

Страница 125: ...4 of the new oil filter cartridge NOTE An oil cartridge wrench is available at a nearby KYMCO dealer NOTE Make sure the O ring is seated properly J Install the new oil filter cartridge with an oil ca...

Страница 126: ...then install the engine oil filler cap and tighten it Recommended oil see CH 9 3 Oil quantity see CH 9 3 Be sure no foreign material enters the crankcase N Start the engine and warm it up for several...

Страница 127: ...e complete and rapid draining Rear gear box oil replacement To drain the oil first place an oil drain pan under the oil drain plug 1 1 Oil drain plug 2 Oil filler cap 3 Oil level check bolt washer 1 R...

Страница 128: ...4 Remove the oil level check bolt washer 3 Make sure the oil level reaches the oil level check hole 5 Install the oil filler cap and oil level check bolt Tightening Torque Oil filler cap 14 7 N m 1 5...

Страница 129: ...sure complete and rapid draining Front gear box oil replacement 1 To drain the oil first place an oil drain pan under the oil drain plug washer 1 2 Remove the oil filler bolt 2 1 Oil drain plug washer...

Страница 130: ...qt 0 265 US qt 6 Remove the oil level check bolt washer Make sure the oil level reaches the oil level check hole 7 Install the oil filler cap and oil level check bolt Tightening Torque Oil filler cap...

Страница 131: ...and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the p...

Страница 132: ...ESTER T3b MODELS ONLY 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 1 Bolts 2 Spark...

Страница 133: ...k arrester and the gasket in the muffler and tighten the three bolts securely POTENTIAL HAZARD Improper cleaning of the spark arrester Hot exhaust system WHAT CAN HAPPEN Could injure the eyes Could ca...

Страница 134: ...ance Schedule If the ATV is submerged 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 t...

Страница 135: ...ne or low flash point solvents for cleaning ATV parts WHAT CAN HAPPEN A fire or explosion could result HOW TO AVOID THE HAZARD Use only a nonflammable or high flash point solvent to cleanATV parts 6 S...

Страница 136: ...ding through 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 3...

Страница 137: ...4 16 2 Start the engine and 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 t...

Страница 138: ...lock nut 3 and then turn the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of...

Страница 139: ...3 FRONT BRAKE PADS The clearance between the brake pads and brake discs is adjusted automatically as the pads wear The only maintenance that is required is to replace brake pads when they become worn...

Страница 140: ...aler to have brake pads replaced 3 Reinstall the wheel and tighten the lug nuts to 61N m 8 15 BRAKE FLUID INSPECTION Check if the fluid level is below the lower level mark through the inspection windo...

Страница 141: ...e and the brake pads are not worn beyond the recommended limit CH 8 14 there is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service To prevent damage...

Страница 142: ...th engine temperature The coolant level should be between the maximum and minimum marks If the level is low remove the coolant reservoir cap and then add coolant or distilled water to raise it to the...

Страница 143: ...imum level mark NOTE 1 If water is added have a KYMCO dealer check the antifreeze content of the coolant as soon as possible 2 The radiator fan operation is completely automatic It is switched on or o...

Страница 144: ...teering recovers 2 Fuses in the harness may have blown There are several reasons that the fuses may blow Refer to the Fuse section in this chapter for details 3 Battery voltage has dropped Voltage dro...

Страница 145: ...pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over the cap Allow any remaining pressure to escape before completely removing the...

Страница 146: ...ts 8 19 2 INSTALLATION When 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 Wheel Nut Torqu...

Страница 147: ...direction of the wheel 1 Arrow mark Without arrow mark POTENTIAL HAZARD Installing wheels improperly WHAT CAN HAPPEN A wheel may come loose possibly leading to an accident HOW TO AVOID THE HAZARD Care...

Страница 148: ...ery cells as this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care POTENTIAL HAZARD Allowing open flames or sparks near the ba...

Страница 149: ...m the battery first and then disconnect the positive terminal lead 3 5 Remove the battery 8 20 2 Installation A Install in the reverse order of removal B After installing the battery check to see if t...

Страница 150: ...tion switch is OFF To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Fuse box 2 Remove the front cover 3 Open the fuse box cap 4 Pull the old fuse out...

Страница 151: ...r the seat 40A Fuse If the fuse is blown steering becomes heavy Replace the blown fuse with a fuse of the same specific amperage and type If a replaced fuse blows again there can be trouble with the E...

Страница 152: ...the ignition switch at ON position Turn on the dimmer switch Adjust the headlight aim by turning the headlight aim adjusting button 1 Adjusting button 8 23 DRIVE SHAFT BOOTS Check the protective boot...

Страница 153: ...es can also 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...

Страница 154: ...alership have 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...

Страница 155: ...8 42 8 25 1 Troubleshooting chart...

Страница 156: ...8 43 8 25 2 EPS EPS MODELS ONLY...

Страница 157: ...you and others to operate A Before cleaning the ATV a Block the end of the exhaust pipe to prevent water entry Use a commercially available tapered rubber plug or a plastic bag with a strong rubber b...

Страница 158: ...reaser off with a garden hose under normal pressure Use only enough water pressure to rinse the engine clean D Once the majority of the dirt has been rinsed off wash all of the surfaces with warm wate...

Страница 159: ...axes as they may contain abrasives which may mar the paint or protective finish K When finished start the engine and allow it to idle for several minutes to evaporate any residual moisture POTENTIAL H...

Страница 160: ...n the cover and then remove mud accumulated in the cover with water Where shall be careful Avoid spraying water in the electrical connectors Avoid spraying water with any great force near the followin...

Страница 161: ...fuel tank 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 i...

Страница 162: ...ter for a few seconds to distribute the oil and then reinstall the spark plug 4 Remove the battery and store it in an area protected from freezing temperatures and direct sunlight and out of the reach...

Страница 163: ...Overall Height 1250 mm 1340 mm Wheel Base 1297 mm 1297 mm Seat Height 880 mm 892 mm Minimum Ground Clearance 260 mm 272 mm Minimum Turning Radius 3450 mm 3450 mm Basic Weight With Oil and Full Fuel Ta...

Страница 164: ...ABS Displacement 501 cc 695 cc Bore x stroke 92X75 4 mm 102X85 mm Compression ratio 10 7 1 10 3 1 Starting System Electric starter Lubrication System Wet sump Engine oil Transmission oil Rear final g...

Страница 165: ...L 2 82 lmp qt 3 39 US qt 2 6 L 2 29 lmp qt 2 76 US qt Total Amount 3 6 L 3 17 lmp qt 3 82 US qt 2 9 L 2 64 Imp qt 3 07 US qt Front Gear Case Oil Quantity Front Gear box oil classification SAE 90 Peri...

Страница 166: ...filter Air filter element Oil coated paper element Fuel Type Unleaded fuel Tank capacity 21 L 4 62 lmp gal 5 55 US gal Reserve amount 5 L 1 1 lmp gal 1 32 US gal Fuel injection Type Throttle body Spa...

Страница 167: ...spension Front Dual A arm Rear Dual A arm Shock absorber Front Coil spring Oil damper Rear Coil spring Oil damper Electrical Ignition system ECU automatic control Generator system Battery type A C mag...

Страница 168: ...5 0 psi 0 38 kgf cm2 5 5 psi Rear tire pressure 0 32 kgf cm2 4 7 psi 0 35 kgf cm2 5 0 psi Bulb voltage wattage quantity Headlight 12V 35W 35W X2 Brake light 12V 21W X2 Taillight 12V 5W X2 Turn signal...

Страница 169: ...evice 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...

Страница 170: ...done in accordance 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...

Страница 171: ...g Taiwan Republic of China Telephone 886 7 3822526 FAX 886 7 3950021 By KWANG YANG Motor Co Ltd Third Edition Sep 2021 All rights reserved Any reproduction or unauthorized use without the written perm...

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