KYMCO UXV500, Owner'S Manual

Page 1: ...Do not remove this Owner s Manual from the vehicle Read this manual carefully before operating the vehicle as it contains important safety information ...

Page 2: ...this manual by the following icons and notations WARNING CAUTION NO NO NO NO NOTE TE TE TE TE The SAFETY ALERT symbol with the exclamation point in the triangle means ATTENTION BE ALERT YOUR SAFETY CAN BE AFFECTED Failure to follow instructions associated with a WARNING symbol could result in severe injury or death to the operator a passenger a bystander or a person inspecting or repairing the veh...

Page 3: ... the best service possible SECTION 1 SAFETY INTRODUCTION FOREWORD PROTECT YOUR SPORT Being able to use and enjoy your KYMCO Side by Side vehicle requires you and your family to operate it in a responsible manner Before riding your UXV500 you should Learn and adhere to all local and state off road riding laws Respect your vehicle and its capabilities and limitations Respect the environment and the ...

Page 4: ... Brake Pedal 49 Accelerator Pedal 49 Gearshift Lever 49 Parking Brake 50 51 Fuel Tank Filler 52 Seat 53 Seat Belts 53 Head Cushions 53 Tailgate Cargo Bed 54 Hood 55 Ignition Switch 55 Light Switch 56 2WD 4WD Switch 56 Choke Knob 57 Accessory Power Outlet 57 Multifunction Meter Speedometer 58 60 GENERAL MAINTENANCE 61 79 Maintenance Schedule 61 63 Break in Procedure 63 64 Tool Kit 65 Gasoline Oil L...

Page 5: ...ate this vehicle on a public road even a dirt or gravel road as you may not be able to avoid a collision with another vehicle YOUR UTV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE Avoid paved surfaces with your UXV500 This vehicle is not designed to be driven on paved surfaces as its handling and control will be seriously affected Always follow proper procedures for climbing hills as de scribed in...

Page 6: ...an the floor boards Remember that wet brakes may reduce stopping capability Test your brakes after leaving wa ter If necessary apply them lightly several times to let friction dry out the pads Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Always be sure there are no obstacles or people behind you when you operate your U...

Page 7: ...aler to or der proper parts perform service and submit warranty claims Always provide your vehicle s year model VIN and ESN when contacting an authorized KYMCO dealer for assistance Warranty repairs will be declined by KYMCO if the VIN or ESN on your ATV have been removed or altered in any way If your ATV requires a repair that will replace the engine crankcase or the frame ask your dealer to cont...

Page 8: ...ght Tail Brake Light 4 Left Head Cushion 5 Left Seat driver LOCATION OF PARTS AND CONTROLS 6 Left Tail Brake Light 7 Seat Belts 8 Cargo Bed 9 Headlights AT Battery AK Steering Wheel AL Canopy AM Grab Handles AN Bumper AO Tools Spare Parts Box NOTE Your vehicle may differ slightly in appearance from the images in this manual ...

Page 9: ...p BT Muffler Spark Arrestor BK Latch Handles BL Choke Knob BM Ignition Switch BN Steering Wheel BO Brake Pedal BP Throttle Pedal accelerator BQ Glove Box locking storage BR Auxiliary Power Outlet BS Speedometer CT Glove Box open CK Transmission Shift Lever CK CT BS BR BQ BP BO BN BM BL NOTE Your vehicle may differ slightly in appearance from the images in this manual ...

Page 10: ...ant safety information Anyone who drives the vehicle should read and under stand 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 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 2 2 2 2 2 1 1 1 1 1 See following page ...

Page 11: ...9 Indicates a potential hazard that could result in serious injury or death WARNING LABELS 3 3 3 3 3 On the vehicle s dash ...

Page 12: ...10 Indicates a potential hazard that could result in serious injury or death WARNING LABELS 5 5 5 5 5 6 6 6 6 6 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 On the vehicle s chassis ...

Page 13: ...tential hazard that could result in serious injury or death WARNING LABELS On the vehicle s chassis 7 7 7 7 7 7 7 7 7 7 8 8 8 8 8 9 9 9 9 9 AT AT AT AT AT AT AT AT AT AT 8 8 8 8 8 9 9 9 9 9 AK AK AK AK AK AK AK AK AK AK ...

Page 14: ...12 Indicates a potential hazard that could result in serious injury or death 2 EPA HANGTAG 1 EPA LABEL EPA LABEL HANGTAG ...

Page 15: ...nual POTENTIAL HAZARD Allowing anyone under 16 years of age to operate this vehicle WHAT CAN HAPPEN Use of a Side by Side vehicle by children can lead to severe injury or death Children under 16 years of age may lack the skills abilities or judgment to operate the vehicle safely and may be involved in a serious accident HOW TO AVOID THIS HAZARD A child under 16 years of age should never operate th...

Page 16: ...ENTIAL HAZARD Operating your UTV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THIS HAZARD Never operate your UXV500 on a public street road highway or even a dirt or gravel road In many states it is illegal to operate this type of vehicle on public streets roads or highways WARNINGS POTENTIAL HAZARD Operating your UTV without wearing eye pro...

Page 17: ...ile under the influence of alcohol or drugs POTENTIAL HAZARD Operating your UTV at excessive speeds WHAT CAN HAPPEN Operating your UXV500 at excessive speeds increases your chances of losing control of the vehicle which can result in an accident HOW TO AVOID THIS HAZARD Always drive your UXV500 at a speed that is proper for the terrain visibility operating conditions and your experience POTENTIAL ...

Page 18: ... HAPPEN Driving your UXV500 on rough slippery or loose terrain can cause loss of traction or control which could result in an accident including a rollover HOW TO AVOID THIS HAZARD Do not drive your UXV500 on rough slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on these surfaces Always be especially cautious when driving your UTV on rough...

Page 19: ...HAZARD Operating your UTV on steep hills WHAT CAN HAPPEN This type of vehicle can overturn more easily on steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate your UXV500 on hills that are too steep for the vehicle or for your abilities Practice driving on smaller hills before attempting to drive on larger hills POTENTIAL HAZARD Improperly operating your UTV in r...

Page 20: ...lerate suddenly as the vehicle might flip over backwards Never go over the top of any hill at high speed as an obstacle a sharp drop or another vehicle or person might be on the other side of the hill POTENTIAL HAZARD Going down a hill improperly on your UTV WHAT CAN HAPPEN Going down a hill improperly could cause you to lose control of your UXV500 or cause the vehicle to overturn HOW TO AVOID THI...

Page 21: ...g procedures as described in this Owner s Manual Avoid hills with slippery or loose surfaces WARNINGS POTENTIAL HAZARD Stalling rolling backwards or improperly exiting the vehicle while climbing a hill on your UTV WHAT CAN HAPPEN Stalling rolling backwards or improperly exiting could result in the vehicle overturning HOW TO AVOID THIS HAZARD Select the proper transmission gear and maintain a stead...

Page 22: ...tremely slippery surfaces such as ice go slowly and be very cautious to reduce the chance of skidding or sliding your vehicle out of control 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 Aloss of control or a collision may cause the vehicle to overturn HOW TO A...

Page 23: ...rakes may have reduced stopping capability Test your vehicle s brakes after leaving water If necessary apply the brakes smoothly several times to dry the pads drums and rotors WARNINGS POTENTIAL HAZARD Operating your UTV with improper tires or with tires that have improper or uneven tire pressure WHAT CAN HAPPEN Using the wrong tires on your UXV500 or driving your vehicle with improper or uneven t...

Page 24: ...he installation instructions Never alter the hand and foot controls of this vehicle If you have questions about personalizing your UXV500 consult an authorized KYMCO dealer POTENTIAL HAZARD Overloading your UTV or carrying loads or towing cargo improperly WHAT CAN HAPPEN Improper loading and towing will cause changes to the vehicle s handling characteristics and may lead to an accident HOW TO AVOI...

Page 25: ...ventionissimpleandmaypreventthepainofinjuryandtheincon venience damage to your UTV It is also important to take into account specific climate and weather conditions where you will be riding Wear a liner under your helmet and layers of clothing dur ingcoolerweatherandlighter protectiveclothingwhenitiswarmer The following sections review the minimum protective gear you will need to wear during each ...

Page 26: ...h is to take steps to en sure 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 1 Brakes 2 Throttle accelerator pedal 3 Tires and Wheels 4 Fluids 5 Lights 6 Electrical 7 Controls and Cables 8 Chassis and Suspension 9 Miscellaneous Items An easy way to remember what items you ne...

Page 27: ...rake pedal 2 Parking brake Check 1 Free smooth range of motion 2 The pedal returns after it is released B B B B B Acceler Acceler Acceler Acceler Accelera a a a ator tor tor tor tor YourUXV500 sacceleratorpedalshouldhaveafree smoothrange of motion If it seems to stick at any point or does not return when released refer to the GENERAL MAINTENANCE section of this manual for instructions Driving your...

Page 28: ...round the vehicle Watch the engine temperature indicator on the dash to ensure the engine coolant level is adequate Check 1 Gas 2 Oil 3 Fluid leaks CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS Grass leaves and other debris can get entangled in your Side by Sidevehicle ssuspensionandshocks Keepthesuspensionarms shock springs and fenders clean and free of debris Check the steering smoothness by rotating ...

Page 29: ...ormation Put your I D in your pocket before you ride Without it you are anonymous CELL CELL CELL CELL CELLULAR ULAR ULAR ULAR ULAR TELEPHONE TELEPHONE TELEPHONE TELEPHONE TELEPHONE Itmaybenecessarytomakeanurgentphonecallortoalertfriends and family where you are MAPS GPS MAPS GPS MAPS GPS MAPS GPS MAPS GPS Global Positioning System Maps may be unnecessary when you are familiar with the area but whe...

Page 30: ...tive driving These are your basic maneuvers Entering the Vehicle Starting the Engine Starting a Cold Engine Braking Stopping Shifting Parking ENTERING THE VEHICLE Use care when entering your UXV500 While your UXV500 is a four wheel vehicle you still must use care to not upset the chassis when mounting it To get seated 1 Make sure the Parking Brake is engaged 2 From the left side of the vehicle gra...

Page 31: ...will be illuminated on the dash display 2 Pull the choke knob all the way out and hold it in that position 3 Rotatetheignitionswitchkeytothesecondposition START to activate the starter motor Do not hold the switch in the START position for more than eight seconds Allow 30 seconds between starting attempts to allow the starting motor to cool Continuous starting attempts will result in overheating a...

Page 32: ...luidandprematurebrakepadwearwhichcancause unexpected loss of braking ability Use only KYMCO approved brake fluid Never substitute or mix different types or grades of brake fluid as unex pectedlossofbrakingabilitycanresult Checkthevehicle s brake fluid level and pad wear before each use The loss of braking ability may result in severe injury or even death SHIFTING ThisKYMCOSide by Sidevehicleisequi...

Page 33: ... safely drive your UXV500 1 Sit in the driver s seat and fasten the seat belt 2 Start the engine and allow it to warm up NOTE Vehicle speed is controlled by the amount of throttle applied to the engine via the accelerator pedal The transmission shifting is automatic 3 Press down on the brake pedal and then shift the transmis sion into gear 4 Release the parking brake 5 Keepbothhandsonthesteeringwh...

Page 34: ...2 Slowly rotate the steering wheel into the direction of the turn 3 Gradually increase your speed as you come out of the turn If your UTV s tires are coming off the ground during a turn you are driving the vehicle at too high of a speed to initiate a turn Reduce speed in these situations as a vehicle rollover could cause serious injury or death NOTE If the terrain you are driving on is not level y...

Page 35: ...ng brake and shift the transmission into neutral 2 Shut off the vehicle s engine 3 Exit the vehicle on the uphill side 4 If you are to the left of the vehicle rotate the steering wheel all the way to the left 5 Release the parking brake but lightly press on the brake pedal so you can control the vehicle rolling 6 Let the vehicle roll slowly to your right side until it faces slightly downhill 2 2 2...

Page 36: ...acle avoidance swerve is complete and you have regained full control of your ve hicle 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 ...

Page 37: ... mud or water Follow these suggestions on controlling a skid or slide 1 Turn your steering wheel into the direction of the slide 2 Avoid using the brakes until you are out of the skid STALLING ON A HILL CROSSING WATER 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 Find something to block the rear tires Your UXV500 can only ha...

Page 38: ...e ice CROSSING ROADS Crossing paved roads can be dangerous and should be avoided However if you must cross a road follow these guidelines 1 Before crossing stop completely on the shoulder of the road 2 Check both directions for oncoming traffic 3 Do not cross near a blind corner or intersection because the lack of visibility is dangerous 4 Ride straight across the road to the opposite shoulder 5 B...

Page 39: ...ving on snow covered or ice covered trails 5 Pay attention to how your UTV responds to steering and brak ing on the type of terrain you will encounter on your trail ride NOTE After riding through water mud snow or slush it is important to dry the brake system before parking your UTV Ride slowly and be extra careful when riding on snow covered or ice covered terrain Always be alert to changing terr...

Page 40: ... it has a major problem with the brakes tires or engine 1 Never 2 Sometimes 3 Often 1 Never 2 Sometimes 3 Often 7 Do you thrive on the adrenaline rush you get from speeding and dangerous situations 8 Do you hurt yourself because you try to do things that are beyond your abilities 1 Never 2 Sometimes 3 Often 9 Do you tailgate other drivers when you think they re driving too slow 1 Never 2 Sometimes...

Page 41: ...an be constructed and excava tions dug in a short period of time Weather climate and de velopment take their toll as well as erosion and other changes that can affect your UTV s ability to drive smoothly and surely Because terrain can constantly change in configuration you may not know how it has changed until you get there Whether it s familiar or not check out your surroundings before and during...

Page 42: ...rself your passenger your UTV and the environment Outsloped trails trails that slant to allow rain to run off make driving on trails more challenging To drive on outsloped trails keep the UTV steered towards the uphill of the slope Proceeding slowly with your vehicle aimed towards the slope will help you from sliding off the trail Be aware of the rules and the laws that govern the area in which yo...

Page 43: ...TVs ATVs motorcycles bicycles or large motor vehicles on roadsandtrails Respectthepresenceofautomobilesandother vehicles if you re crossing roads or riding in public areas Take steps with your riding apparel choices and your actions to make yourself very visible Remember if you can t see other vehicles coming that means they cannot see you HIKERS Even though your UTV can take you to remote areas d...

Page 44: ...ngs identified in the chart on the following page So if you your passenger and your load weighs over 771 lb 350 kg leave some of that extra cargo at home The com bined weight limit including you your passenger your UTV s bed cargo and your trailer is a specific amount so consult the UTV Load Capacity Ratings Chart and adjust your load accordingly SOUND JUDGMENT Cargo has such a significant affect ...

Page 45: ...ached To aid in controlling your UTV reduce speed when carrying cargo or pulling a trailer and allow greater distances for braking Always follow the instructions and recommendations in this Owner s Manual for carrying cargo or pulling a trailer NOTE Use extra caution when operating your UTV with additional loads such as accessories and or cargo Handling of your UTV may be adversely af fected Reduc...

Page 46: ...need to take medications before you plan to drive your UTV Illegal drugs not only inhibit your judgment and ability to drive your UTV but there can be severe legal consequences if you are confronted by law enforcement authorities The same is true for excessive alcohol use so never use alcohol or drugs before or during your UTV drive SOUND JUDGMENT THE EFFECTS OF ALCOHOL The Number of Drinks that I...

Page 47: ...u can legally drive in the proposed area Be a good off road citizen Illegal or irresponsible driving will cause authorities and landowners to close the area GROUP BEHAVIOR It is a proven psychological fact people will do irresponsible and riskier things in a group that they would never consider doing when they are alone When you are driving your UTV with other drivers use extra care and sound judg...

Page 48: ...mal training course that would have educated them about safe UTV operation As the vehicle owner it is your responsibility to keep uneducated guests especially children or those who lack a automobile operator s license out of your UTV EXPERIENCED TRAINED DRIVERS When anyone borrows your UTV you become responsible to su pervise them and control their actions Before a guest drives your UTV have them ...

Page 49: ...understand the entire Owner s Manual before operating your KYMCO UTV to ensure safe and proper use Always oper ate your UTV within your level of skill and current terrain conditions At the time of publication all of the information and illustra tions in this manual are technically correct Some illustra tions herein are used to best represent a certain procedure or item and are not intended to depi...

Page 50: ... Width Overall 150 mm 59 0in Dry Weight Approx 1157 Ib 525 kg Suspension Travel 190 mm 7 5 in Wheelbase 1910 mm 75 2in Tire Size Front 25 x 8 12 Tire Size Rear 25 x 10 12 Tire Inflation Pressure F 10 0 psi 0 7 kg cm2 R 14 0 psi 0 98 kg cm2 FLUIDS Gas Tank Capacity 8 45 U S Gal 32 L Gasoline Recommended 87 Octane Regular Unleaded Engine Oil Recommended SAE 5W 30 Engine Oil Capacity 3 8 U S qt 3 6 L...

Page 51: ...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 Make sure there is adequate accelerator pedal free play before starting the engine LOW range HIGH range Neutral Reverse GEAR SHIFT LEVER To change gears stop the vehicle and allow the engine to idle then move ...

Page 52: ...g the Parking Brake To engage the parking brake pull the handle 3 outward until resistance is felt indicating that locking pressure is being ap plied to the brakes NOTE The parking brake handle will click several times and lock as you pull the handle outward When the park ing brake is engaged the symbol 4 4 4 4 4 will illuminate on the dash Use the following procedure to verify that the parking br...

Page 53: ...n 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 NOTE When the differential is locked the LOCK lamp 8 8 8 8 8 will illuminate on the dash 6 6 6 6 6 7 7 7 7 7 Always make sure that the parking brake has been disen ...

Page 54: ...the gasoline Donotaddgasolinetothevehicleiftheengineisrunning Stoptheengine and turn off the ignition before fueling Gasoline is highly flammable and should be kept away from sparks flame and other ignition sources Do not overfill the fuel tank Stop the fuel level at the reference plate near the top of the fuel filler neck Overfilling the fuel tank can cause gasoline to contaminate the vehicle Eva...

Page 55: ...t belt insert the end tab into the latch until you feel the latch mechanism click as it secures the tab To release the seat belt press the release button on the seat belt latch and pull the tab from the latch Never drive your UTV without fastining your seat belt Passengers should wear their seat belt any time the ve hicle is in motion The shoulder portion of the seat belt is designedtocrossdiagona...

Page 56: ...bed Once the latches are released pull the top of the tail gate towards you it is hinged on its bottom edge 1 1 1 1 1 1 1 1 1 1 PULL To close the tailgate lift it back up and secure both of the latches Tilting the Cargo Bed Your UXV500 s cargo bed can tilt to aid in the removal of loose cargo such as gravel To tilt the cargo bed slide the release lever 2 to the right and lift up on the forward edg...

Page 57: ...h andthefenderextensions Set the fastener by pressing the center pin down so it is flush withthefastener sbuttonhead 4 4 4 4 4 3 3 3 3 3 SWITCHES Ignition Switch The UXV500 ignition switch is a three position key operated switch The key can be removed from the switch when it is in the OFF position OFF Engineisoff Allelectricalcircuits areoff exceptaccessorycircuit ON The engine can run as the ig n...

Page 58: ...ghts are ON HIGH BEAM HEAD LIGHT ON 3 3 3 3 3 In this position the high beam of the headlights are ON 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 2WD 5 5 5 5 5 In the position the differential will select 2WD mode rear wheels only The icon 2WD will display on the LCD speed ometer 4WD 6 6 6 6 6 In the position the differential will select 4WD mode all wheels are driven The icon 4WD will display on the ...

Page 59: ...et cigarette lighter socket to provide power to electrical acces sories This power outlet 8 provides fused power 15A at all times Additional spade type connectors are available on the outlet on the back side of the dash to provide a more permanent source of accessory electrical power No not use items that will exceed the amperage capac ity of the auxiliary power outlet or connectors The maxi mum c...

Page 60: ...ear 4 Neutral LCD Indicator Icons Meter Buttons The Liquid Crystal Display LCD portion of the multifunction meter provides the driver with information such as vehicle speed total miles operated trip mileage fuel level time and drive mode There are two buttons that control other functions of the multi function meter the MODE and SET buttons These buttons allow programming of certain multifunction m...

Page 61: ...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 This will shift the display between MPH or Km H Tripmeter Selecting Odometer Trip A or Trip B To toggle the multifunction meter s odometer and tripmeter dis play press hold the SET button for two seconds and...

Page 62: ...es Press the MODE button to change the HOURS setting Press the SET button to change the MINUTES setting FEATURES CONTROLS Setting the Clock To set the clock s time cycle the odometer tripmeter until the odometer mileage is displayed Then press and hold the SET and MODE buttons simultaneously until the clock display be gins to flash Once you have set the desired time press and hold the SET and MODE...

Page 63: ...61 PERIODIC MAINTENANCE SCHEDULE Continued on following page ...

Page 64: ...62 PERIODIC MAINTENANCE SCHEDULE Continued on following page ...

Page 65: ...PM during the break in period allows the engine and transmission components to mate together so they will operate smoothly in the future Applying some higher engine RPM s and other loads during the break in period is not detrimental when done in moderation Do not pull a trailer or haul very heavy cargo loads during the break in period When the engine starts allow it to warm up properly Permit the ...

Page 66: ...Accelerate to 30 mph then depress the brake pedal to decelerate to 0 5 mph Repeat procedure five times After the completion of the break in period your UTV s engine oil and oil filter should be changed Other maintenance after break in should include checking of all prescribed adjustments and tightening of all fasteners It is your responsibility as the owner and driver of your UTV to arrange for an...

Page 67: ...commended fuel to use in your UTV is regular un 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 etha nol 5 methane or MTBE are acceptable to use When using ethanol blended gasoline it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in ...

Page 68: ...e window 1 should be above the L mark but not higher than the H mark Add oil through the filler cap 2 as required 1 1 1 1 1 2 2 2 2 2 Engine Oil Oil Filter Replacement To replace the engine oil and oil filter and clean the oil strainer use this procedure 1 Park the UTV on level ground 2 Warm up the engine for several minutes then turn it off 3 Place a suitable container under the engine capable of...

Page 69: ...ten it securely 9 Add the appropriate amount of engine oil 5 5 5 5 5 OIL QUANTITY Without oil filter 3 18 US qt 3 0 L With oil filter change 3 82 US qt 3 6 L NOTE The UTV should be parked on level ground with the engine off when checking the engine oil level Wait approximately one minute after running for the oil level to stabilize before checking 7 7 7 7 7 7 7 7 7 7 Do not overfill the engine wit...

Page 70: ...cularly if the tank is filled with cold gasoline and the UTV is then moved to a warm area Do not overfill the fuel tank Front Differential and Rear Drive Gear Lubricant Inspecting Changing Inspect and change the gear lubricants in your UTV according to the Maintenance Schedule When changing the lubricant only use the approved SAE 80W 90 hypoid type fluid and use the following procedure 1 Park your...

Page 71: ... NOTE Before installing the spark plug measure the electrode gap with a feeler gauge and adjust to specifi cation When installing the spark plug always clean the gasket surface and use a new spark plug if the seal ing gasket is pressed flat Always tighten the spark plug to the specified torque Spark plug type CR7E NGK Tightening torque 73 lb ft 17 2 N m Electrode gap 0 028 0 028 in 0 9 mm AIR CLEA...

Page 72: ... 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 5 5 5 5 5 6 After cleaning reinstall the air cleaner element and the cov ers in reverse order of disassembly EXHAUST Spark Arrestor Cleaning Your UXV500 is equipped with a spark arrestor in its muffler The spark arrestor is required f...

Page 73: ...ways use distilled water or pre mixed coolant 50 50 ratio when adding fluid to the coolant reservoir NOTE If you have to add water to your UTV s coolant have your KYMCO dealer inspect the coolant as soon as possible to determine if it is in good condition NOTE Dirtanddebrismustbecleanedfromtheradiator s fins regularly to ensure proper engine oil cooling Operating your UTV with high engine temperat...

Page 74: ... Brake fluid contacting the skin or eyes WHAT CAN HAPPEN The fluid will cause irritation HOW TO AVOID THIS HAZARD Avoid brake fluid contact with skin or eyes In case of con tact flush the affected area thoroughly with water and call a doctor if your eyes were affected SHOCK ABSORBERS Each shock absorber on your UTV should be visibly checked weeklyforexcessivefluidleakage somesealleakageisnormal cr...

Page 75: ...2 2 2 2 2 WRONG OK 3 Tighten the wheel nuts in a criss cross pattern 3 4 Torque the nuts to the specified torque Wheel Nut torque 40 lb ft 55 N m 4 4 4 4 4 NOTE The arrow mark 4 on the tire must point towards the rotating direction of the wheel POTENTIAL HAZARD Install the wheels improperly WHAT CAN HAPPEN A wheel may come loose possibly leading to an accident HOW TO AVOID THIS HAZARD Carefully fo...

Page 76: ...e wheel be extremely careful not to damage the inner wheel surface or the tire bead Tubeless Tire Repair Should a leak or flat tire occur due to a puncture the tire may be repaired using a plug type repair If the damage is from a cut or if the puncture cannot be repaired using a plug the tire must be replaced When riding your UTV in areas where transportation or service facilities are not readily ...

Page 77: ...off the ignition switch and open the hood 2 Remove the battery compartment cover 3 Disconnect the battery cables Disconnect the negative cable 1 first then disconnect the positive cable 2 4 Remove the battery from the battery compartment Then thor oughly wash thebatteryandthecompartmentwithsoapandwater ToremovethebatteryfromyourUTVforservice followthisproce dure 2 2 2 2 2 1 1 1 1 1 NOTE If the bat...

Page 78: ...oltage 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 Connecting the battery cables in reverse positive to negative and negative to positive can cause serious damage to the electrical system Battery acid is harmful if it contacts eyes skin or clo...

Page 79: ...abel which identifies the fuse s circuit its rating and its location in the fuse box 6 6 6 6 6 Fan motor 15A 5 5 5 5 5 Ignition 15A 4 4 4 4 4 Light 15A 3 3 3 3 3 Accessory 15A 2 2 2 2 2 SPARE 15A 1 1 1 1 1 SPARE 30A 1 1 1 1 1 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 3 3 3 3 3 2 2 2 2 2 ...

Page 80: ...e with a damp cloth and allow to the surfaces to dry 2 Clean your UTV thoroughly by washing dirt oil grass and other debris from the entire vehicle Allow the UTV to dry thor oughly DO NOT get water into the engine air intake or ex haust 3 Drain the gas tank completely or add a fuel stabilizer to the fuel in the gas tank Remove the air filter housing cover and air filter 4 Start the engine and allo...

Page 81: ...OUR UTV FOR DRIVING AFTER STORAGE 6 Inspect the brake system Verify the good condition of the brake fluid pads and the controls 7 Verify the proper operation and adjustment of all controls head lights taillight brakelight adjustorreplaceitemsasnecessary 8 Check the tire pressures inflate the tires to the recommended pressure Before installing the battery make sure the ignition switch is in the OFF...

Page 82: ...ry ignition settings and exhaust system design This system also includes a secondary air supply system and a catalyzer in the exhaust system Noise Exhaust Emission Control System The engine intake and exhaust systems of your UXV500 were designed to comply with federal state and local noise level requirements Do not modify the engine intake or exhaust components as doing so will affect compliance t...

Page 83: ...81 EPA EMISSION WARRANTY ...

Page 84: ...82 MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED NOTES ...

Page 85: ...83 MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED NOTES ...

Page 86: ...68 Lubrication General 65 Maintenance General 42 Maintenance Record 82 83 Maintenance Schedule 61 63 Muffler Spark Arrester 70 Oil and Filter 66 67 Oil Level Window 63 Oil Engine Transmission 65 Operation Maintenance 47 Parking 31 35 Parking Brake 50 51 Parts Accessories 47 Parts and Controls Locations 6 7 Passengers 41 Responsibility 46 Reversing 35 Riding Downhill 34 Riding Uphill 32 35 Safety A...

Page 87: ...d Engine Serial Number 4 in the boxes above for future reference to assist you in ordering parts from your authorized KYMCO dealer or for reference in case the vehicle is stolen Identification Numbers Record 1 IGNITION SWITCH KEY IDENTIFICATION NUMBER 3 VEHICLE IDENTIFICATION NUMBER VIN 4 ENGINE SERIAL NUMBER ESN 2 GLOVEBOX GAS CAP KEY IDENTIFICATION NUMBER The glovebox gas cap key identification ...

Page 88: ...5 Stan Perkins Road Spartanburg SC 29307 Telephone 864 327 4744 FAX 864 327 4745 Prepared May 2008 T200 UAA0AA US A5 ...