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Well, if you really cannot find the culprit, and you need the vehicle, make a direct line with an on/off switch from your battery or switched plus to the fan.

Yeah , but I don't want the fan running all the time , or have to figure when to turn it on , since the Camo/Limited Edition MXU500 doesn't have the Temp Gauge on the dash like the regular models do (makes no sense that the lesser models have the temp gauge but the Limited doesn't) , and the EMI Filter is in the system for a reason , so not sure I want to bypass any of that and overheat the fan , or anything  , just was wondering if anyone had the same issue and they figured it out , or happened to know where the ground source is on the frame other than at the battery ...  , but thanks for the reply ..

EDIT:
OK , I hooked a Ground plug to the existing ground plug on the Thermal Switch , basically tied it into the existing wiring plug , and just added another ground going to the front Rack bolt that is directly on the frame (the same spot where I did my testing using my Power Probe tool) , and the fan still didn't come on  , so this is confusing , since the EMI Filter is new and the Thermal Switch is new , and like I mentioned , I hooked the fan directly to power (using my Power Probe tool) and the fan works , so not sure what is going on , unless its not getting hot enough , when I'm testing to activate the Thermal Switch  , so maybe tomorrow I will go to Harbor Freight and get the handheld Temperature gun and see how hot its getting , so I know if it should be kicking on or not , or if I'm not letting it get hot enough , as it should work with everything I replaced , although just looking through the Service Manual again , I noticed it shows the EMI Filter but it does not mention it in Testing , it just mentions the Water Temperature Sensor on the engine , but nothing about the EMI Filter relay

EDIT EDIT: 8-3-2024 1:05pm Central Time
OK , I just checked it with the Thermal Temp Gun and I guess I wasn't letting it sit there and idle long enough  , it took a while to get up to temp even in 94 degree F outside temperatures , so I then disconnected the EXTRA ground I added and plugged it in just as its supposed to be OEM and the fan stayed running , then as soon as the fan ran for a couple minutes it shut off and the radiator temp was lower  , so its working as it should  , so it was either the Thermal Switch or the EMI Filter , not sure , but I replaced them both for under $100 , so that was good ...... , Either way , the problem is solved .....

OK i got a Email back from Kymco , and the Tech said to disconnect the light green/red wire that goes to the Instrument Cluster , if the light goes out then its the Clutch Diode  , so i did that and the light stayed on (with the gear selector in R , then H) , so its the Instrument Panel that is the issue   , so i cancelled the order for the Gear Selector Switch   , i will have to wait on the Panel as it is $98.00 , so it will have to wait , since there is no safety issue with the light being on (i will cover it with Electrical tape for the time being)

UPDATE:
I used my Power Probe and started tracing  wires   , what i found is that all the wires that go to the Gear Indicator Light Switch are Ground wires , as i could use the probe and get each light to light up (P,R,H,L) with the switch unplugged (at the source side not the switch side) and the ignition switch on , but it did nothing to the Neutral light which stayed on the entire time the ignition was on , , i found a "Clutch Diode" which seems to be some kind of relay , and traced the wires which are tied to the Neutral wire but even with the Diode unplugged , the light remained on as long as the ignition was on , and touching the Probe to it changed nothing

So from what i am gathering there seems to be a open ground or something causing the light to stay on , but using the Ground Function of the Power Probe , it changes nothing , which is confusing as it SHOULD have made the light go out when i hit the Ground button, but from looking at the wiring diagram the wire goes from the indicator light , to the Gear Indicator Switch , to the Clutch Diode , i have not figured out what the power source is yet , or where any other connection or junction linked to the Switch is other than what i listed

I did send a Email to Kymco to see if i can get some assistance from them directly as well

No one answered my post on jetting , but i hope someone can answer this

I have a 08 Limited Edition Camo MXU500 , i have had it since new and used to work at a Kymco Dealer , so i have the Factory Service Manual PDF  , i have searched thru it and cant find what i am looking for , so i am hoping someone here will have a answer for me

Symptoms:
Started doing this today:
I was riding and i had to back up and turn around , i stopped , and put it in Reverse , and backed up , stopped , and went to shift it to H , and right before i grabbed the shifter i heard this electric motor noise , it sounded like my Winch running or a small screw gun  , it was coming from about the front of the motor maybe even the front differential  but i could not locate it positively with all the plastics on , it was a whirring noise , it did it when in Neutral , but once in gear it went away , back to Neutral and it would do it again  , then i shifted to H and the H light came on (and it went in gear normally) , BUT the Neutral light remained on , so i rode up to my little shop and pulled it in

I pulled the side covers off , and after looking at my PDF manual , i found the Gear Indicator Light Switch , i turned on the Ignition  and put it in H , and unplugged the Gear Light Switch  , the H light went out , but the Neutral Light remained on  , i plugged it back in and the H light came on , so i went back to my manual and searched the wiring diagram and could not find a Neutral Switch , with the exception of where it showed the Gear Selector Switch it showed a P,R,N,H,L , but as i stated , when i unplugged the switch the light remains on as long as the key is on , regardless of what gear it is in , so if its in H , it shows N and H lit up when plugged in , but when unplugged , the N still remains on , so that leads me to believe it is separate somewhere not listed in the manual that i could find

I removed the Gear Light Switch and found that for the gear indicator light in the dash to remain on for P,R,H,L the switch had to be grounded (when it is in the Tranny it is then grounded) , but with the switch removed from the motor (still plugged in) none of the P,R,H,L lights would come on in the dash , but the Neutral light remains on as long as the ignition is on

Has anyone ever encountered this ?? , does anyone have a clue where the Neutral light gets its power ? or is it strictly thru the Gear Indicator Light Switch   

The Whirring noise seemed to be the trigger for the light malfunction , but i does not make the noise now and the light is still malfunctioning  , i dont know why the noise stopped since i got it in my shop , but i now can't trace the noise since it has not re-occurred , but it did it 4-5 times before i rode it to the shop

ANY help would be appreciated !!  , Thanks....Jim

Hi all !  , new here , and first post  , i have a 08 MXU500 Limited Edition Camo ATV

I have been searching the internet/Google (how i found this place) for jetting for elevation for my 500  and could not find anything  , i ride anywhere between 2000 - 6000 ft average , during the summer (around now) temps , i am usually in the 2000-2500 range  , in winter it can go from 2000 -8000  , i have not pulled the carb off yet so i am not sure what jetting is in there, BUT , i noticed since the weather is warming up (80+ degrees here in Idaho) that it is sluggish on top end ,  and if i open it up (like when traveling on a open dirt road) it seems like it takes forever to accelerate up to 40-50mph

So i am guessing that with the warmer weather its too rich now , i have not touched the Fuel Screw , because it idles and runs fine at lower RPM so i did not think the screw will help my situation since it seems to be top end which would mean Main Jet

Is there any Jetting Chart i can look at  or any suggestions for jetting for elevation and temp ??

I just want to get more response out of it  , it has about 1100 miles on it  , i bought it new in 08

Any help would be appreciated    Thanks   Jim