Target Audience:
Recreational and utility ATV riders; DIY owners and service technicians working on the MXU 500.
Segment:
Mid-size 4x4 utility ATV
Competitors:
Honda FourTrax Rancher, Suzuki KingQuad 450, Polaris Sportsman 450
Advantage:
Liquid-cooled 499cc engine with independent rear suspension at a lower price point than Japanese rivals.
Engine:
499cc liquid-cooled single-cylinder four-stroke
Drivetrain:
Selectable 2WD/4WD with shaft drive
Suspension:
Independent double wishbone front and rear
Coverage:
All models and repairs A to Z, mechanical and electrical
Page Count:
N/A - not specified for this manual
Manual Type:
Workshop service / repair manual
Delivery Method:
Instant digital download
Printing:
All pages printable - print only what you need
Illustrations:
Detailed pictures, diagrams, schematics and exploded views included
Engine:
Complete teardown, inspection and rebuild procedures for the 499cc engine
Fuel System:
Carburetor, fuel pump, throttle body and fuel tank service
Cooling System:
Radiator, coolant replacement, thermostat and fan testing
Lubrication:
Oil change procedures, oil pump and pressure testing
Electrical System:
Wiring diagrams, charging system, ignition, starter and lighting circuits
Ignition System:
CDI unit, ignition coil, spark plug and timing checks
Transmission:
CVT drive system, clutch, gearbox and shift mechanism service
Final Drive:
Front and rear differential and shaft drive inspection and repair
Brakes:
Hydraulic disc brake service, pad replacement, caliper and master cylinder rebuilds
Suspension:
Front and rear A-arm, shock and ball joint removal and installation
Steering:
Steering stem, tie rods and handlebar alignment
Wheels & Tires:
Wheel removal, tire service, bearings and torque specs
Frame & Body:
Frame inspection, plastic body panels, racks and fenders
Procedures & Technical Depth
Diagnostic Procedures:
Step-by-step troubleshooting charts for no-start, charging, fueling and drive issues
Torque Specifications:
Factory torque values for fasteners throughout the machine
Special Tools:
Tool requirements and part numbers for specialized operations
Tightening Sequence:
Head, cylinder and fastener sequences included
Depth Level:
Full workshop level - complete disassembly and rebuild, not an owners manual
Parts Diagrams:
Exploded views for component identification
Part Numbers:
Factory part numbers referenced throughout procedures
Fluid Capacities:
Engine oil, coolant and gear oil capacities specified
Wear Limits:
Service limits for brakes, bearings, clutches and engine components
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Type:
4-stroke, single-cylinder, SOHC, liquid-cooled
Bore x Stroke:
91.0 x 77.0 mm
Compression Ratio:
Approximately 10.0:1
Fuel Delivery:
Carburetor (Keihin CVK type)
Fuel Type:
Regular unleaded gasoline
Fuel Tank Capacity:
Approximately 4.5 gallons (17 liters)
Ignition:
CDI electronic ignition
Standard Transmission:
CVT automatic (H-L-N-R) with centrifugal clutch
Drive Method:
Shaft drive to front and rear differentials
Drive Modes:
Selectable 2WD / 4WD
Gearing:
High, Low, Neutral and Reverse range selection
Final Drive:
Sealed differential units with gear oil
Wheelbase:
Approximately 49.4 inches (1255 mm)
Length:
Approximately 86.2 inches (2190 mm)
Width:
Approximately 46.5 inches (1180 mm)
Seat Height:
Approximately 34.3 inches (870 mm)
Curb Weight:
Approximately 653 lbs (296 kg)
Ground Clearance:
Approximately 10.2 inches (260 mm)
Payload / Towing:
N/A - not specified for this model
Passive & Active Features
Brakes:
Hydraulic disc brakes front and rear
Lighting:
Headlight, taillight and brake light
Engine Stop:
Handlebar-mounted kill switch
Parking Brake:
Mechanical parking brake lock
Guarding:
Footwells and heat shielding for rider protection
Crash Test Ratings:
N/A - ATVs are not crash tested by standard vehicle rating programs
Certification:
N/A - not specified for this model
Instrumentation & Electrical
Display:
Digital LCD instrument panel with speedometer and odometer
Starting:
Electric start with recoil backup
Charging:
12-volt system with battery and alternator
Infotainment & Assistance
Audio System:
N/A - no audio system on this ATV
Driver Assistance:
N/A - not applicable to this vehicle type
Engine Oil:
Change after first 20 hours, then every 100 hours or 6 months
Oil Filter:
Replace with every engine oil change
Air Filter:
Inspect frequently; clean/replace per schedule, more often in dusty conditions
Valve Clearance:
Check at scheduled intervals per manual
Coolant:
Replace every 2 years
Engine Oil:
SAE 10W-40 API SF/SG or higher, JASO MA-rated for wet clutch
Gear Oil:
SAE 80W-90 API GL-5 in differentials
Brake Fluid:
DOT 4 hydraulic brake fluid
Common Wear Items:
CVT drive belt, brake pads, ball joints and CV boots are typical wear points
