KYMCO UXV 450i, Owner'S Manual

Page 1: ...KWANG YANG MOTOR CO LTD OFF ROAD UXV 450i...

Page 2: ...P indication Dangerous Alert CAUTION POTENTIAL HAZARD Operating your UTV in areas with tall or loose vegetation WHAT CAN HAPPEN Combustible materials such as tall grass or reeds exposed to the exhaust...

Page 3: ...nual before you ride the UXV 450i Your safety depends not only on your own alertness and familiarity with the UXV 450i but also the UXV mechanical condition A pre ride inspection before every outing a...

Page 4: ...ttery remove 62 Driving Downhill 47 Brake Fluid Inspection 59 Driving Uphill 48 Brake Pedal 34 Driving Reverse 50 C E Cargo Bed 36 38 Emission Control System 51 52 Engine Oil 53 56 Crossing Water 49 F...

Page 5: ...gnition Switch 29 Parking Brake 35 Ignition Switch Key 6 Parking 47 L R Light Switch 30 Right Glove Compartment Key 6 Location Of Parts 7 10 S Serial Number Locations 4 5 Start The Engine 45 46 Steeri...

Page 6: ...TABLE OF CONTENTS T Throttle Pedal 34 Tool Kit 68 W 2WD 4WD Switch 31 Warning Labels Locaton 11 15...

Page 7: ...s vehicle Keep this Owner s Manual with this vehicle at all times Failure to follow the warnings contained in this manual can result in serious injury or death Particularly important information is di...

Page 8: ...eeds Do not turn at intemperate speed Never operate on hills too steep for your abilities and cross the side of a hill Practice on smaller hills before attempting larger hills Always use proper proced...

Page 9: ...dirt or gravel one because you may not be able to avoid colliding with other vehicles Always avoid paved surfaces This vehicle isn t designed to be used on paved surfaces and may seriously affect han...

Page 10: ...Serial Number Locations This vehicle has 2 serial numbers The frame number and Engine serial number The frame number is located on the frame near right front wheel place Frame Number 4...

Page 11: ...Serial Number Locations The engine serial number is located on the left side of the engine crankcase Engine Serial Number 5...

Page 12: ...ight Glove Compartment Key There are two keys come with this vehicle Keep the spare in the safe place The key is for wheel steering lock ignition switch fuel cap and right glove compartment 1 Wheel st...

Page 13: ...Location Of Parts 1 5 1 2 6 1 Right Head Cushion 2 Left Head Cushion 3 Right Latch Handle 4 Left Latch Handle 5 Right Tail Brake Light 6 Left Tail Brake Light 7 4 3...

Page 14: ...Location Of Parts 2 07 Seat 08 Seat Belts 09 Battery Under the seat 10 Tool or Parts Box Under the seat 11 Steering Wheel 12 Headlights 13 Cargo Bed 14 Grab Handles 15 Canopy 9 12 14 15 8 7 8 13 10 11...

Page 15: ...Location Of Parts 3 16 Hood 17 Grab Handles 18 Fuel Tank Cap 19 Muffler Spark Arrestor 20 Cargo Bed Lever 16 19 18 9 17 20...

Page 16: ...Compartment 23 Auxiliary Outlet 24 Center Glove Compartment 25 Gear Shifter 26 Side Compartment 27 Rear differential lock switch Optional 28 Seat belt lamp 29 Light Switch 30 Ignition Switch 31 Parkin...

Page 17: ...Warning Labels Location 11 2 3 1...

Page 18: ...Warning Labels Location 12 6 4 5...

Page 19: ...13 Warning Labels Location 7 8 9 10...

Page 20: ...14 Warning Labels Location 11 12 13...

Page 21: ...Warning Labels Location 15 14...

Page 22: ...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...

Page 23: ...ise with hand to open the cap 2 Use only nonleaded gasoline 3 Turn the fuel tank cap clockwise to tighten it 4 Fill the fuel tank to the fuel level as shown 5 Close the fuel tank cap in the reverse or...

Page 24: ...Lower Gear 2 High Gear 3 Neutral Gear 4 Reverse Gear 5 Parking Gear 6 High Beam Indicator Light 7 FI System Indicator Light 8 Lock Differential Lock Indicator Light 9 Battery Low Voltage Indicator Lig...

Page 25: ...18 Features And Controls Instruments and Indicators 1 Speedometer 2 Km h or Mph 3 Clock 4 4WD 5 Fuel Gauge 6 ODO Meter 7 Adjust Button 8 Engine Tachometer 2 1 3 4 5 6 8 7...

Page 26: ...Features And Controls Operation Instruction for Multi meter 19 Button A MODE Button B SET...

Page 27: ...Features And Controls Operation Instruction for Multi meter Press and hold button A until 2 seconds over Shift the unit mph or km h Button A MODE 20...

Page 28: ...Features And Controls Operation Instruction for Multi meter Press and hold button B until 2 seconds over Shift function to ODO or TRIP 21 Button B SET...

Page 29: ...Features And Controls Operation Instruction for Multi meter Press and hold button A and B until 2 seconds over Simultaneously to reset to zero when at TRIP function 22 Button A MODE Button B SET...

Page 30: ...ures And Controls Operation Instruction for Multi meter Press and hold button A and B until 5 seconds over when at ODO function then you can see clock position is flash word 23 Button A MODE Button B...

Page 31: ...hen you seeing clock position is flash word You can start setting hour item Press button B adjust correct hours then Press button A you can see minute position is flash adjust correct minute Waiting f...

Page 32: ...l accessories or lights The connections are behind the console under the hood Auxiliary Outlet 25 Seat Belt Lamp Rear Differential Lock Switch Seat Belt Lamp The seat belt lamp would light on to warn...

Page 33: ...nt of the pins are fully seated into the grommets Seat Belts Your UXV450i is equipped with lap shoulder seat belts for the operator and passenger The seat belts should be used by the driver and passen...

Page 34: ...Features And Controls Pillows adjust If you want to adjust your pillow height Remove the four bolts and adjust pillow position you need Then tighten the bolts 27...

Page 35: ...not attempt to shift gears with engine speed above idle or while the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maint...

Page 36: ...e removed from the switch when it is in the OFF position ON Electrical circuits are on Electrical equipment can be used OFF Engine off All electrical circuits are off except Acc 12V START Electrical s...

Page 37: ...switch has 4 positions 1 Light off At this position light is turn off 2 Position light At this position light is turn off 3 LO Headlight Beam When you select this position low beam will illuminate 4...

Page 38: ...or normal riding on flat dry hard surfaces two wheels drive should be sufficient In situations when additional traction is necessary four wheel drive would be the desired choice To either engage or di...

Page 39: ...amage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differen...

Page 40: ...ng the differential Features And Controls Turf Version Model Front Left Right Wheels Rear Left Right Wheels 2WD Different speed when vehicle turning Same speed when vehicle turning Different speed whe...

Page 41: ...Brake Pedal 2 Step on the brake pedal to slow or stop or stop the vehicle Throttle Pedal 3 Step the pedal down slightly to increase engine speed Always check the throttle pedal in the original positi...

Page 42: ...ll the parking brake lever outward until resistance is felt Make sure the parking brake lever is functioning properly before each operation Note If you forget to release the parking brake when riding...

Page 43: ...ed To lift Push the cargo bed release lever to right side then slowly lift up cargo bed until it stop To lower Lower the cargo bed slowly to its original position and be sure the it is locked into pla...

Page 44: ...Features And Controls Cargo Bed Open and close the tailgate 1 To open Unlock the latches 1 and then lower the tailgate Latch x2 1 Pull 37...

Page 45: ...Features And Controls Cargo Bed Open and close the tailgate 2 To close Place the tailgate in the original position and then hook the latches 38...

Page 46: ...39 Features And Controls Hood To Open Pull up the hood from the front end Then remove the hood 1...

Page 47: ...sition then check tightness Features And Controls 3 3 2 2 The vehicle goes with additional tab accessory 4 customer can install the tab to strengthen the tightness if necessary Notice Install incorrec...

Page 48: ...Features And Controls Front Compartment To Open Release the latches and open the front compartment 41 Latches...

Page 49: ...e handle 1 and open the rear compartment Notice Install incorrectly could cause the latch loosen and the rear compartment opened 2 To install Pull the handle push ends of cover release and push the ha...

Page 50: ...al wear Check for any imbedded stones or other foreign particles in tread 04 Front wheel Air pressure 0 7kgf cm 10psi 05 Rear wheel Air pressure 0 98kgf cm 14psi 06 Headlight other indicate light Chec...

Page 51: ...4 Check your surroundings and determine the path of travel 5 Release the parking brake 6 Keeping both hands on the steering wheel slowly depress the throttle with your right foot and begin driving Ve...

Page 52: ...nd death WARNING 1 Fasten the seat belts helmets and eyes protections both operator and passenger 2 Set the parking brake 3 Put the gear shift lever in the N neutral position 4 Turn the ignition switc...

Page 53: ...e inevitable so always be prepared Whenever you are stopping quickly do this 1 Release the accelerator then press the foot brake pedal to apply the brake 2 If the wheels lock release them for a second...

Page 54: ...low gear set the parking brake and block the wheel on the downhill side Driving Downhill 1 Hold both hands on the steering wheel make the vehicle stable 2 Avoid steep hills 3 Before driving down the h...

Page 55: ...henever driving uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the floor 4 Proceed at a steady rate of speed and throttle opening NE...

Page 56: ...may lose traction due to floating 1 Physically check the depth and current of the water especially if you can not see the bottom Also check for boulders logs or any other hidden obstacles 2 Keep spee...

Page 57: ...when operating in reverse gear 1 Back slowly 2 Apply the brakes lightly for stopping 3 Avoid turning at sharp angles 4 Always avoid backing downhill 5 Never open the throttle suddenly while backing 6...

Page 58: ...ere Exhaust Emission Control System The emission from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition KYMCO Exhaust Emission Control System...

Page 59: ...rester Your UXV 450i has a spark arrester The spark arrester be installed and functional when the vehicle operated on public lands Remove method remove 3 bolts Clean method Use the iron brush cleaning...

Page 60: ...into the oil tank Make sure the engine oil at the specified level Add oil as necessary Check for leaks 53 Recommended engine oil classification API Service SJ type or higher SAE 20W 50 SAE 20W 40 SAE...

Page 61: ...up the engine for several minutes and stop it C Unscrew the dipstick filler cap and check the oil level should be within the standard range D Insert the dipstick and thread it in If the level is low...

Page 62: ...e 4 Remove the oil fill cap 1 and oil drain bolt 2 to drain the oil 5 Add oil to raise it to the proper level 6 Insert the dipstick and thread it in Be sure no foreign material enters the crankcase CA...

Page 63: ...Maintenance And Lubrication Skip steps E to I if the oil filter cartridge is not being replaced NOTE Remove the oil filter cartridge with an oil cartridge wrench oil filter cartridge 56 Lock Remove...

Page 64: ...emove the front gear box oil drain bolt 1 and front gear box oil filler bolt 2 4 Install the front gear box oil drain bolt 1 and then tighten it to the specified torque 5 Fill the front gear box oil w...

Page 65: ...r bolt 2 4 Install the rear gear box oil drain bolt 1 and then tighten it to the specified torque 5 Fill the rear gear box oil with recommended oil 6 Install the rear gear box oil filler bolt 2 58 2 M...

Page 66: ...acting the skink or eyes WHAT CAN HAPPEN May cause irritation HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes In case of contact flush thoroughly with water and call a docto...

Page 67: ...Maintenance And Lubrication Air Cleaner Remove the seat Loosen the air cleaner latches 60 Seat Latches 1...

Page 68: ...aintenance And Lubrication Air Cleaner Remove air cleaner cover Remove air filter element 61 Using high pressure air to clean air filter element Inspect the air filter element and replace it if damage...

Page 69: ...gative terminal lead 1 from the battery first then disconnect the positive terminal lead 2 5 Remove the battery Battery installation 1 Install in the reverse order of removal 2 After installing the ba...

Page 70: ...ap 3 Pull the old fuse out 4 Push the new fuse in to the fuse holder 5 Close the fuse box cap and install seat To prevent accidental short circuiting turn off the main switch when checking or replacin...

Page 71: ...and low marks 3 If the level is low remove the coolant reservoir cap and then add coolant or distilled water to raise it to the specified level 64 NOTE A permanent type of antifreeze is installed in...

Page 72: ...2 Remove the nuts from the wheel 3 Remove the wheel assembly Wheel Installation When reinstalling a wheel tighten the wheel nuts in a crisscross rather than a circular pattern Wheel nut torque Front...

Page 73: ...T CAN HAPPEN 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...

Page 74: ...inder Do not attempt to diagnose such problems yourself Instead take the machine to a KYMCO dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the sp...

Page 75: ...ol kit put down location at Right Glove Compartment The tool kit includes the following items 1 Hexagon wrench 2 Spark plug wrench 3 8 12 10 14 17 19 mm wrench 4 Screwdriver 5 Screwdriver handle 6 Too...

Page 76: ...Y WEIGHT MAX WEIGHT CAPACITY ENGINE ENGINE TYPE CYLINDER ARRANGEMENT BOREx STROKE ACTUAL DISPLACEMENT COMPRESSION RATIO STARING SYSTEM LUBRICATION SYSTEM Standard 515kg Turf Model 551kg 442 9cc SINGLE...

Page 77: ...GE TYPE REAR GEAR BOX CAPICITY EXCHANGE TYPE AIR FILTER FUEL TYPE FUEL TANK CAPACITY THROTTLE BODY TYPE MANUFACTURER SPARK PLUG TYPE MANUFACTURER SPARK PLUG CLUTH TYPE 0 7 0 8mm WET CENTRIFUGAL AUTOMA...

Page 78: ...E REAR WHEEL MATERIAL PRESSURE FR RR BRAKES SYSTEM FRONT AND REAR UNIFIED TYPE FRONT DUAL DISC BRAKE TYPE REAR SINGLE DISC BRAKE OPERATION FOOT OPERATION SUSPENSION FRONT SUSPENSION DUAL A ARM REAR SU...

Page 79: ...12V5W 2 POSITION LIGHT 12V5W 2 Max Wattage for Accessary limitation 10W Ferrite ACG model 190W Rare earth ACG model 172mm 176mm DC ECU AUTOMATIC CONTROL Note The limitation is just for reference usin...

Page 80: ...Specifications MODEL UXV450 i OFF ROAD SPECIFIED FUSES MAIN FUSE 30A FAN MOTER IGNITION LIGHT DC12VPOWER FUEL SPARE 10A 15A 15A 15A 15A 15A 73...

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Page 84: ...Maintenance Record...

Page 85: ...Maintenance Record...

Page 86: ...Maintenance Record...

Page 87: ...Maintenance Record...

Page 88: ...KWANG YANG Motor Co Ltd First Edition Apr 2014 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T200 UA90AA A...