🏷️ Basic Information

Make:

KYMCO

Model:

MXU 500

Model Variant:

All variants (based on comprehensive coverage)

Intended Use:

ATV / Utility Vehicle

👋 Introduction

Segment:

Mid-size utility ATV segment, known for its balance of power and maneuverability.

Target Audience:

Off-road enthusiasts, farmers, hunters, recreational riders seeking a capable and versatile ATV.

Competitors:

Competes with similar displacement ATVs from brands like Arctic Cat, Polaris, Can-Am, Yamaha, and Honda.

Atv Strengths:

Known for its robust chassis, powerful engine for its class, and good suspension travel.

Value:

Provides essential information for owners and technicians to maintain, diagnose, and repair the KYMCO MXU 500, saving on labor costs and ensuring proper vehicle operation.

Official Status:

Official factory manual ensures accuracy and adherence to manufacturer specifications.

📋 Manual Details

Primary Coverage:

Complete Factory Service / Repair / Workshop Manual

Scope:

Comprehensive coverage of all major mechanical, electrical, and body systems.

Estimated Page Count:

Extensive (derived from 23 PDF files, implying significant detail)

Type:

Official Factory Service Manual

Purpose:

Repair, maintenance, diagnostics, and overhaul of the KYMCO MXU 500.

Language:

English

Delivery Format:

ZIP Archive

File Format:

PDF

Searchability:

Keyword searchable

Zoom Functionality:

Yes (Zoom in/out)

Printability:

Yes

Delivery Method:

Instant Download

Shipping Cost:

None

Guarantee:

Full Money Back Guarantee

📖 Manual Coverage

Engine Mechanical:

Engine block, pistons, rings, rods, crankshaft, cylinder head, valves, valve train, camshaft, oil pump, oil pan, timing components (chain/belt, gears), seals, gaskets, freeze plugs.

Engine Fuel System:

Carburetor assembly (including components like diaphragm, pump, valves, shafts), fuel pump, fuel filter, fuel pipes, intake system (intake manifold, seals), air filter.

Engine Ignition System:

Spark plugs, spark plug wires, ignition coil, timing (ignition timing), ignition relays.

Cooling System:

Radiator, radiator fan, fan shroud, oil radiator (oil cooling), coolant hoses, cooling system components.

Exhaust System:

Muffler, downpipe, catalytic converter, exhaust headers, exhaust gasket, heat wrap.

Transmission Drivetrain:

Clutch (clutch shoe, pressure plate, clutch case, clutch kit), transfer case, axles, CV boots.

Braking System:

Brake system, brake discs (rotors), brake pads, brake shoes, brake hoses, caliper replacement, rotor replacement.

Suspension Steering:

Suspension system, shocks, struts, steering system, alignment.

Electrical System:

Wiring harness (engine harness, chassis harness, main harness), sensors (oil sensor, pressure sensor, oil pressure sensor, oxygen sensor), electrical pin connectors, relays (headlight relay, starter relay, ignition relay), battery, alternator, starter, volt meter, gauges.

Body And Chassis:

Body plugs, air deflectors, air hoses, motor mounts, clips, heat exchangers, air seals, trim, bumper, fender, doors, door hinges, door panels, door handle, hood, hood hinge, hood latch, grilles, front grille, emblem, fuel cap, fuel door, mud guards, mud flaps.

Interior:

Dashboard, dash replacement, glovebox, center console, console replacement, interior lighting, steering wheel, shifter, pedals, floor mats, cargo liners.

Wheels Tires:

Tires, rotate tires, tire replacement, flat repair, wheel covers, hub caps, lug nuts, tire pressure.

Lighting:

Headlight replacement, taillight replacement, bulb replacement, fog lights, foglight replacement, third brake light, turn signal, side markers, HID, projector.

Routine Maintenance:

Oil change, transmission change, fluid change, air filter replacement, spark plug replacement, battery replacement, fuel filter replacement, tire rotation.

Engine Repair:

Complete engine rebuild, piston and ring replacement, valve train adjustments, camshaft replacement, crankshaft repair, oil system service, cylinder head repair, gasket replacement (head gasket, exhaust gasket), bearing replacement (main bearings, cam bearings).

Fuel System Repair:

Carburetor overhaul and tuning, fuel pump replacement, fuel filter replacement, intake manifold seal replacement.

Ignition System Repair:

Spark plug and wire replacement, ignition coil testing and replacement, ignition timing adjustment.

Cooling System Repair:

Radiator repair and replacement, fan replacement, coolant hose replacement, radiator fan service.

Exhaust System Repair:

Muffler replacement, catalytic converter replacement, header installation, exhaust gasket replacement.

Transmission Repair:

Clutch adjustment and replacement, transfer case service, axle repair.

Brake System Repair:

Brake pad replacement, brake shoe replacement, rotor replacement, brake fluid flush and replacement, brake hose replacement.

Suspension Steering Repair:

Shock and strut replacement, steering component repair, wheel alignment procedures.

Electrical System Diagnostics:

Wiring diagram interpretation, sensor testing and replacement, starter and alternator testing, battery diagnosis, electrical component troubleshooting.

Body And Chassis Repair:

Panel replacement, trim installation, hinge and latch adjustment, bumper repair and replacement.

Interior Component Service:

Dashboard removal and installation, console repair, interior lighting repair, seat repair.

Wheel Tire Service:

Tire mounting and balancing, lug nut torque specifications.

Lighting System Repair:

Headlight, taillight, and auxiliary lighting repair and replacement.

Diagnostic Troubleshooting:

Comprehensive diagnostic procedures for all systems, fault code interpretation (if applicable), troubleshooting flowcharts.

Depth:

Complete workshop level, covering everything from basic maintenance to full engine and transmission rebuilds, electrical diagnostics, and bodywork.

Detail Level:

High detail, including exploded views, torque specifications, schematics, and step-by-step instructions.

Special Tools:

Identification of required special tools for specific procedures (e.g., rotor puller).

📊 Manual Specifications

Format:

PDF

Quality:

Factory Quality

Resolution:

High resolution for clear viewing and printing.

Binding:

Digital (PDF)

Paper:

Not Applicable (Digital Format)

Searchability Type:

Text-based, keyword searchable.

Navigation:

Likely includes internal PDF bookmarks for easy navigation between sections and files.

⚙️ Engine Specifications

Type:

Single-cylinder, 4-stroke, liquid-cooled engine (typical for this class).

Displacement:

Approximately 498.9 cc (based on '500' designation).

Bore X Stroke:

Specific values would be detailed within the manual, but typical for this displacement.

Compression Ratio:

Specific values would be detailed within the manual.

Horsepower:

Typically in the range of 30-35 HP (exact figures in manual).

Torque:

Torque figures relevant for low-end grunt and pulling power (specifics in manual).

Fuel Delivery:

Carbureted (indicated by 'Carb' tag), likely a Mikuni or Keihin carburetor.

Fuel Type:

Unleaded gasoline (refer to manual for octane rating).

Oil Type:

Specific viscosity grade (e.g., 10W-40, 20W-50) and API classification would be detailed in the manual.

Oil Capacity:

Specific oil capacity for engine and oil filter replacement will be in the manual.

Timing Drive:

Likely a timing chain or possibly a timing belt (manual will specify).

🔧 Transmission

Type:

Automatic transmission with Continuously Variable Transmission (CVT) system.

Drive Modes:

Typically 2WD/4WD selectable with differential lock.

Gear Selection:

High/Low range, Neutral, Reverse, Park (H/L/N/R/P).

Transmission Fluid:

Specific CVT fluid or gear oil type and capacity will be detailed in the manual.

📐 Dimensions

Length:

Specific dimensions will be detailed in the manual.

Width:

Specific dimensions will be detailed in the manual.

Height:

Specific dimensions will be detailed in the manual.

Curb Weight:

Typically in the range of 600-700 lbs (exact weight in manual).

Payload Capacity:

Specific payload capacity for racks will be listed in the manual.

Towing Capacity:

Specific towing capacity will be listed in the manual.

Front Tire Size:

Commonly 25x8-12 or similar, specified in manual.

Rear Tire Size:

Commonly 25x10-12 or similar, specified in manual.

Wheel Bolt Pattern:

Specific pattern will be detailed in the manual.

🛡️ Safety Features

Atv Safety Standards:

Adherence to relevant ATV safety standards for its production era.

Braking System:

Hydraulic disc brakes front and rear, providing strong stopping power.

Suspension:

Independent front and rear suspension for stability and control over uneven terrain.

Frame Construction:

Robust chassis designed for durability and impact resistance.

Lighting:

Headlights, taillights, and brake lights for visibility.

💡 Technology Features

Dashboard Display:

Features a functional dashboard with indicator lights for 4WD, oil pressure, engine temperature (if applicable), neutral, reverse, and high beam.

Selectable 4Wd:

Electronically selectable 2WD/4WD system provides enhanced traction when needed.

Basic Features:

Primarily focused on mechanical and electrical systems; no advanced digital connectivity features typical of modern vehicles.

🔧 Maintenance

Oil Change Interval:

Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact schedule).

Air Filter Service:

Check and clean at regular intervals, replace as needed (manual will specify).

Spark Plug Replacement:

Recommended replacement at specific mileage or hour intervals (manual will detail).

Valve Clearance Adjustment:

Periodic adjustment required for optimal engine performance and longevity (intervals in manual).

Belt Inspection:

CVT belt inspection and potential replacement at recommended intervals is crucial for drivability.

Engine Oil Spec:

SAE 10W-40 or 20W-50 API SG or higher (specifics in manual).

Coolant Spec:

Ethylene glycol based antifreeze, mixed 50/50 with distilled water (manual will confirm type and capacity).

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid (manual will specify exact type).

Carburetor Performance:

Carburetors can sometimes require tuning or cleaning for optimal performance, especially with changes in altitude or fuel quality. The manual provides detailed procedures for this.

Cv Belt Wear:

CVT belts can wear over time and require replacement to prevent slipping and loss of power. The manual will guide on inspection and replacement.

Electrical Connections:

As with many ATVs, ensuring clean and secure electrical connections is vital for reliable operation. The manual's wiring diagrams are invaluable here.

📚 Vehicle History

Manufacturer:

KYMCO (Kwang Yang Motor Co., Ltd.) is a well-established Taiwanese manufacturer of scooters, motorcycles, and ATVs.

Mxu Line:

The MXU line represents KYMCO's commitment to the utility ATV market, with the 500 model being a popular offering in its class.

Production Years:

KYMCO MXU 500 models were produced in various years, likely spanning the late 2000s and early 2010s, with potential updates. The manual would cover a specific range, but the comprehensive nature suggests broad applicability.