Mongoose 90 / Mongoose 90 R ATV off road Owner’s Manual
IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle. It is especially important that parents make sure their children fully understand and follow the information and procedures contained in the manual. AGE RECOMMENDATION This ATV is intended for use by children at least 10 years old.
NOTE TO PARENTS Parents should read the "Important Message to Parents" beginning on page 4 and the "Parents &Beginning riders" booklet received with the ATV and then decide whether their youngster is ready to ride. "Parents, Youngsters and ATVs" focuses on the beginning rider, and discusses how to evaluate your youngster's readiness to ride as well as showing you how to introduce your youngster to ATV riding. Your ATV was delivered with a speed restrictor for new riders.
SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol . Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH. WARNING Indicates a strong possibility that serious injury or death may result if instructions are not followed. To protect your vehicle from damage, pay attention to caution to cautions.
PREFACE Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service. For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards. This manual will provide you with a good basic understanding of the features and operation of this machine. This manual includes important safety information.
CONTENTS Page LOCATION OF THE WARNING AND SPECIFICATION LABELS...........................1 Page CONTROL FUNCTIONS........... ................20 Ignition switch...................................... .20 Handlebar switches................................21 Engine stop switch...............................21 Headlight switch.... ..............................22 Stater button.. . ...................................22 Kick starter ............ ..............................23 Remote engine stop switch. .......
Page Page PRE-OPERATION CHECKS......................34 Front and rear brakes.............................35 Fuel .....................................................36 Engine oil and Transmission oil ...............38 Chain ...................................................39 Throttle lever.........................................39 Fittings and fasteners.............................39 Lights ...................................................39 Switches .......................... ....................
Page Page SLIDING AND SKIDDING........................75 Idle speed adjustment.. ........................107 Throttle lever adjustment......................108 Front brake shoe inspection..................109 Rear brake pads inspection...................109 Front brake lever free play adjustment....110 Brake fluid inspection...........................112 Drive chain slack check.........................114 Drive chain slack adjustment.................114 Drive chain cleaning and Lubrication......
Page CLEANING AND STORAGE.....................126 A. Cleaning .........................................126 B. Storage ...........................................128 SPECIFICATIONS..................................130 NOISE REGULATION.............................134 MAINTENANCE RECORD.......................135 INDEX...................................................136 Mongoose 90 Reverse version.................
LOCATION OF THE WARNING AND SPECIFICATION LABELS DECAL OF EPA CERTIFICATE LABEL OF SVIA For US For Canada 1
WARNING INFORMATION Your ATV comes with a hang tag and several labels containing important safety information. Anyone who rides the vehicle should read and understand this information before riding. Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride. The labels should be considered as permanent parts of the vehicle.
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SAFETY INFORMATION IMPORTANT MESSAGE TO PARENTS Your child's safety is very important to KYMCO. That's why we urge you to read this message before you let any young person ride this ATV. Off-road riding can be fun. However, an ATV is not a toy and it can be hazardous to operate.
Physical size and ability are important considerations. To help determine whether a youngster is big enough for this ATV, have them stand up on the footboards and grasp the handgrips. While the youngster holds this position, check that they have at least three inches (8cm) of clearance between the ATV seat and the youngster's "seat of the pants".
Athletic ability is another requirement for riding a ATV. Generally speaking, your youngster should be good at riding a bicycle before they get on an ATV. Can your youngster judge speeds and distances while riding a bicycle and react with proper hand and foot actions? Anyone who does not have good coordination, balance, and agility is not ready for this ATV. Mental and emotional maturity are also necessary for safe riding.
Patience And Practice Even if a youngster takes a certified training course, it's up to you to ensure your youngster's safety. Remember, learning to ride a ATV is a gradual step-by-step process. It takes time, patience and practice. To help you regulate your youngster's rate of learning, your ATV was delivered with an adjustable throttle limite r . We recommend that all beginning riders start off with the throttle limiter adjusted as delivered.
In Summay Children differ in skills, physical abilities, and judgement. Some children may not be able to operate an ATV safely. Parents should supervise their child's use of the ATV at all times. Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely. Safe and responsible riding must be an on-going commitment - by you and your youngster.
SPECIAL SAFETY MESSAGES AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits porperly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. Never consume alcohol or drugs before or while operating this ATV.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. Never operate the ATV on hills too steep for the ATV or for your abilities.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area.
WARNING WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. HOW TO AVOID THE HAZARD If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. POTENTIAL HAZARD Improper handling of gasoline. WHAT CAN HAPPEN Gasoline can catch fire and you could be burned.
WARNING ON POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation.
DESCRIPTION AND MACHINE IDENTIFICATION Key identification number The key identification number is stamped on the hang tag as shown in the following illustration. Identification number records Record the key identification number, frame serial number, engine serial number and model code information for assistance when order replacement parts. KEY NO. FRAME NO. ENGINE NO.
Frame and engine serial number The frame serial number is stamped on the front of the frame. The engine serial number is stamped on the left crankcase.
Parts location (05) (04) (03) (02) (01) (1) Handlebar switch (2) Ignition switch (3) Speed limiter (4) Throttle lever (5) Seat 17
(08) (07) (06) (06) Remote engine stop switch (07) Storage compartment, containing Owner's manual Air pressure gauge Tool kit (08) Exhaust pipe (09) Taillight/Stop light (10) Rear wheel (11) Seat lock lever (12) Oil filler cap/dipstick (13) Front wheel (09) (10) (11) (12) (13) 18
(17) (16) (15) (14) (14) Flat pole bracket (15) Right footboard (16) Front brake lever (17) Parking brake (18) Rear brake lever (19) Fuel fill cap (20) Left footboard NOTE: (18) (19) The machine you have purchased may differ slightly from those shown in the figures of this manual.
CONTROL FUNCTIONS FF O Ignition switch Functions of the respective switch positions are as follows: (1) ON OFF: All electrical circuits are switched off. The key can be removed in this position. ON ( ) : The taillight can be turned on. With the engine stop switch at run ( engine can be started. (2) ), the (1) Ignition switch The key can not be removed.
Handlebar switches (2) Engine stop switch When the switch is in the RUN ( ) position, the engine will operate. When the switch is in OFF ( ) position, the engine will not operate. (1) This switch is intended primarily as a safety or emergency control, and it should normally remain in the RUN ( ) position. (3) NOTE: If you stop your ATV by turning the engine stop switch OFF ( ), be sure to turn the ignition switch OFF to prevent battery discharge.
Headlight switch The headlight switch should be operated when you add the headlight equipment (using genuine KYMCO accessories). Turning the switch to the " switch off the headlight. Turning the switch to the " on the low beam. Turning the switch to the " on the high beam. Stater button To starter the engine, press the starter button, with the ignition switch ON ( ) and the engine stop switch at RUN ( ) " position to CAUTION: See starting instructions prior to starting engine (see page 42 for details).
Kick starter The kick starter cranks the engine when the kick starter is operated. CAUTION: See starting instructions prior to starting engine (see page 43 for details). NOTE: If the kick starter is operated with the ignition switch at "．" and the engine stop switch " ", the engine will not start. To start the engine, be sure to position the engine stop switch at " ".
Remote engine stop switch The ATV has a remote engine stop switch. This allows the supervisor to follow close behind and stop the engine by pulling a tethered core. Practice using it when your youngster first starts riding. (2) NOTE: Make sure the tethered road lead is installed into the remote engine stop switch. When the tethered road lead is not installed, the engine will not operate.
Throttle lever It is operated by the thumb. Pressing the lever opens the throttle. When pressure is released, spring tension automatically closes the throttle. Regulate the speed of the machine by varying the throttle position. WARNING POTENTIAL HAZARD Malfunction of throttle. WHAT CAN HAPPEN The throttle could be hard to operate, making it difficult to speed up or slow down when you need to. This could cause an accident.
Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. (A) WARNING (2) POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle. WHAT CAN HAPPEN The throttle cable could be damaged. Improper throttle operation could result. You could lose control, have an accident or be injured.
Front brake The front brakes are operated by squeezing the front brake lever. Rear brake The rear brakes are operated by squeezing the rear brake lever.
Parking brake To set the parking brake, squeeze the front brake lever and lock it with the lock pin. Always set the parking brake when parking and before starting the engine. To unlock the parking brake, squeeze the front brake lever until the lock pin releases. Using the parking brake in freezing weather may cause the brakes to freeze in the locked position. (See page 46.
Fuel tank cap After refueling, be sure to tighten the fuel tank cap. TO refuel refer to page 36~37. WARNING POTENTIAL HAZARD Improper use of the parking brake. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine. This could cause loss of control or a collision. The brake could overheat if you ride the ATV without releasing the parking brake. You could lose braking performance which could cause an accident.
Fuel valve The fuel valve supplies fuel from the fuel tank to the carburetor. The fuel valve has three positions. RES (2) OFF OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this position when the engine is ON : not running. With the lever " " mark in this position, fuel flows to the carburetor. Normal riding RES: is done with the lever in this position. This indicates reserve. If you run out of fuel while riding, turn the lever " " mark to this position.
Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction (A) to turn on the starter (choke). Move in direction (B) to turn off the starter (choke). Refer to "starting a cold engine" for proper operation. (See page 43.) CAUTION: Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life of the engine.
To install the seat, align the tabs on the seat with the grommets on the frame and press the seat down until it locks. Seat To remove the seat, pull upward the seat lock lever and pull up the seat at the rear. NOTE: Make sure that the seat is securely fitted.
Flag pole bracket To mount a flag pole in the bracket. Storage compartment The storage compartment is located under the seat. To remove the seat, see page 32. NOTE: Be careful not to flood this area when washing your ATV or riding through water, and never put any electric conduction material in the storage compartment. Flag poles are required in some riding areas. Check local regulations before riding.
PRE-OPERATION CHECKS Before using this machine, check the following points: ITEM ROUTINE PAGE Brake Check operation, condition, free play (drum brake) and brake fluid level (disk brake). Adjust (drum brake) if necessary. Fill with DOT 4 brake fluid (disk brake) if necessary. Fuel Check fuel level. Fill with fuel if necessary. Engine oil and Transmission oil Check oil level. Fill with oil if necessary. 38, 96～102 Drive chain Check chain slack and condition. Adjust if necessary.
Front and rear brakes 1. Drum brake Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 110~111.) WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. Check operation of the levers. They should move smoothly and there should be a firm feeling when the brake is applied. If not, have the machine inspected by a KYMCO dealer. WHAT CAN HAPPEN Increases the possibillty of an accident or equipment damage.
Fuel Fill the fuel tank when necessary and make sure there is sufficient gasoline in the tank. Check for leaks. Fuel level should be below the filler neck. WARNING POTENTIAL HAZARD Riding with improperly operating brakes. WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. (1) HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride. Do not ride the ATV if you find any problem with the brakes.
Your KYMCO engine has been designed to use regular unleaded gasoline with a pump octane number of 86 or higher, or research octane number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost. Use unleaded fuel only because it produces fewer engine and spark plug deposits and extends the life of the exhaust system.
Engine and transmission oil Make sure the engine and transmission oil at the specified level. Add oil as necessary. (See page 96~102.) Check for leaks. 10 0 30 0 50 0 70 0 90 0 CAUTION: Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled "Energy Conserving") contain anti-friction additives which will cause starter clutch slippage, resulting in reduced component life and poor engine performance.
Chain Check the general condition of the chain and check the chain slack before every ride. Lubricate and adjust the chain as necessary. (See pages 114~116 for details.) Lights Check the headlight and taillight to make sure they are in working condition. Repair as necessary for proper operation. Throttle lever Check to see that the throttle lever operates correctly. It must open smoothly and spring back to idle position when released. Repair as necessary for proper operation.
2.The tires should be set to the recommended pressure: Recommended tire pressure Tires WARNING 2 POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. Front: 25 kpa (0.25 kgf/cm , 3.6 psi) Rear: 25 kpa (0.25 kgf/cm 2, 3.6 psi) Check and adjust tire pressures when the tires are cold. Tire pressures must be equal on both sides.
Set pressure tires cold. Set tire pressures to the following 4.Never set tire pressure over the recommended 2 Front: 28 kpa (0.28 kgf/cm , 40 psi) Recommended pressure Minimum Maximum Front 25 kpa 2 (0.25 kgf/cm , 3.6 psi) 22 kpa 2 (0.22 kgf/cm , 3.2 psi) 28 kpa 2 (0.28 kgf/cm , 4.0 psi) Rear 25 kpa 2 (0.25 kgf/cm , 3.6 psi) 22 kpa 2 (0.22 kgf/cm , 3.2 psi) 28 kpa (0.28 kgf/cm2, 4.0 psi) 2 Rear: 28 kpa (0.28 kgf/cm , 40 psi) Higher pressures may cause the tire to burst.
Tire wear limit When the tire groove decreases to 4 mm (0.16 in) due to wear, replace the tire. A. 4mm (0.
Starting a cold engine OPERATION WARNING WARNING POTENTIAL HAZARD Operating ATV without being familiar with all controls. POTENTIAL HAZARD Freezing control cables in cold weather. WHAT CAN HAPPEN You could be unable to control the ATV, which could lead to an accident or collision. WHAT CAN HAPPEN Loss of control, which could cause an accident or injury. HOW TO AVOID THE HAZARD When riding in cold weather, always make sure all control cables work smoothly before you begin riding.
6.With the throttle closed, push the starter button. Release the starter button as soon as the engine starts. 5. Use the starter (choke) in reference to the figure: Position Position Position :Cold engine start-ambient temperature below 5C (40F). :Cold engine start-ambient temperature at 0C (30F)~30C(90F) and warming up position. :Cold engine start-ambient temperature above 25C(80F) and warm engine start position. NOTE: Do not use the electric starter for more than 5 seconds at a time.
Warming up To get maximum engine life, always warm up the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, check if it responds to the throttle normally with the starter (choke) turned off. To start the engine without the electric starter. 1. Follow steps 1 through 5. 2. With the throttle closed, operate the kick starter with a rapid, continuous motion.
Parking When parking, stop the engine. Turn the fuel lock to "OFF" and apply the parking brake. During this period, prolonged full throttle operation or any condition which might result in excessive engine heating must be avoided. However, momentary (2~3 seconds maximum) full throttle operation under load does not harm the engine.
Parking on a slope 1. Bring the machine to a stop by applying the brakes. 2. Stop the engine. 3. With the rear brake applied, apply the parking brake. WARNING POTENTIAL HAZARD Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident. HOW TO AVOID THE HAZARD Avoid parking on hills or other inclines.
Accessories Accessories can affect the handling and control of your ATV. Keep the following in mind when considering an accessory or operating an ATV which has accessories. Choose only accessories designed for your ATV. Your KYMCO dealer has a variety of genuine KYMCO accessories. Other accessories may also be available on the market. However, it is not possible for KYMCO to test all non-KYMCO accessories, nor have any control over the quality or suitability of them.
Riding Your ATV 49
GETTING TO KNOW YOUR ATV This ATV is for recreation use. This section, riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
RIDE WITH CARE AND GOOD JUDGEMENT WHAT CAN HAPPEN If children use ATVs that are not recommended for their age, severe injury or death can result. Even though a child may be within the age group for which an ATV is recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. Get training if you are inexperienced. Beginners should get training from a certified instructor.
Pre-operation checks Always perform the pro-operation checks listed on page 34 before riding for safety and proper care of the machine. HOW TO AVOID THE HAZARD Become familiar with this ATV at slow speeds first, even if you are an experienced operator. Do not attempt to operate at maximum performance until you are totally familiar with the machine's handling and performance characteristics. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV.
Weight Limits This ATV is not designed to carry cargo or tow a trailer. Do not add a cargo rack or a trailer hitch. WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. There are limits to how much weight can be carried on your ATV. The following weight limit applies to standard equipment only. Modifying your ATV, using non-standard equipment or riding on terrain that is not flat and smooth could further reduce these limits.
Accessories Genuine KYMCO accessories have been specifically designed for and tested on this vehicle. Because KYMCO cannot test all other accessories, you are personally responsible for properly selecting, installing, and using nonKYMCO accessories. Always follow the loading instructions above, plus the following: WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo. WHAT CAN HAPPEN Could cause changes in vehicle handling, stability and braking which could lead to an accident. 1.
No Modifications Modifying this ATV or removing original equipment may render the vehicle unsafe or illegal. Spark arresters and mufflers are required in most areas. Don't modify your exhaust system or emission control system components. Remember, excessive noise bothers everyone and creates a bad image for off-road vehicles. WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
SAFE RIDING RULES WHAT CAN HAPPEN Please note that the safe Riding Rules apply to all ATV riders. Even if you are an experienced rider, or after you become one continue to follow these guidelines for your own safety and enjoyment. Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
Do not operate after consuming alcohol or drugs. Operator's performance capability is reduced by the influence of alcohol or drugs. WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
This machine is designed to carry operator only-passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers.
BE CAREFUL WHERE YOU RIDE This machine is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATV are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
FOR OFF-ROAD USE ONLY Ride Only When Visibility Is Good Your ATV is not equipped with headlight. It is intended to be used only during the daytime. You should ride only when visibility is good. Plan to stop riding well before it gets sark. Operation at night without lights may be illegal in some states. This vehicle is designed and manufactured for off-road use only. Do not ride in areas posted "no trespassing". Do not ride on private property without getting permission.
During operation Always keep your feet on the footboards during operation. Otherwise your feet may contact the rear wheels. WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footboard, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident.
Do not operate at speeds too fast your skills or the conditions. Speed limiter For riders inexperienced with this model, this model is equipped with a speed limiter in the throttle lever housing. The speed limiter limits the power and top speed of the machine. Turning the screw in decreases top speed, and turning it out increases top speed. WARNING POTENTIAL HAZARD Operating this ATV at speeds too fast for your skills or the conditions.
Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don't try to show off.
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the machine to upset. 58 68 WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.
WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.
When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the machine. DO NOT use the flag pole bracket as a trailer hitch. WHAT CAN HAPPEN You could be in a collision. You could be injured. HOW TO AVOID THE HAZARD Always mount a caution flag on the machine to make you more visible. Watch carefully for other vehicles. 58 WARNING POTENTIAL HAZARD Operating in areas where you might not be seen by other off-road vehicles.
Exhaust system The exhaust on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burned. HOW TO AVOID THE HAZARD Do not touch the hot exhaust system. Do not park the machine in a place where others might be likely to touch it.
RIDING For your initial riding practice, select a safe area free of obstacles with a level surface of dirt or sand. Practice with the remote engine stop switch and throttle limiter adjusted as delivered until you are confident in braking and making turns. WARNING Remote engine stop switch for new riders The ATV has a remote engine stop switch. This allows the supervisor to follow close behind and stop the engine by pulling a tethered core. Practice using it when your youngster first starts riding.
Speed limiter for new riders Your ATV has an adjustable throttle limiter. The screw and locknut in the lower throttle housing can be adjusted to limit throttle lever movement. Pull the tether after the ATV is moving. The ATV may continue to roll for some distance. Watch the distance until the ATV stops. Be aware that this distance must be included in the stopping space of the ATV and that this distance may increase with speed.
BRAKING Practice starting and stopping at slow speeds. Gradually work up to faster starts and stops. To adjust the throttle limiter: 1. Loosen the lock nut. 2. Turn the throttle limiter screw clockwise to reduce throttle lever movement or counterclockwise to increase throttle lever movement. 3. Hole the screw in place and tighten the lock nut. (2) (1) Adjuster 1. Steer straight ahead. Close the throttle completely, remove your thumb from the throttle lever. 2.
Gradually increase the lever pressure as you feel the brakes slowing your speed. The pressure used depends on your speed and the condition of the terrain you are riding. Slick , slippery or muddy ground requires gentler braking. When possible, reduce speed or brake before entering a turn. Closing the throttle or braking in mid-turn may cause wheel slippage which will reduce control of your ATV.
TURNING YOUR ATV To achieve maximum traction while riding offroad, the two rear wheels are mounted solidly on one axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed.
Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, or too much speed for the sharpness of the turn may cause the ATV to tip. If may also be necessary to the outside of the turn to avoid tipping over. Remember: Avoid higher speeds until you are thoroughly familiar with the operation of your ATV.
SLIDING AND SKIDDING Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an accident. To reduce the tendency for the front wheels to slide in loose or slippery conditions, positioning your weight over the front wheels will sometimes help. If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is room to do so) by steering in the direction of the slide.
With practice, over a period of time, skill at controlled sliding can be developed. The terrain should be chosen carefully before attempting such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on extremely slippery surfaces such as ice, since all control may be lost. WARNING POTENTIAL HAZARD Skidding or sliding improperly. WHAT CAN HAPPEN You may lose control of this ATV.
CLIMBING UPHILL Use proper riding techniques to avoid vehicle overturns on hills. Be sure that you can maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes. Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might cause you to lose control. WARNING POTENTIAL HAZARD Operating on excessively steep hills.
An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. 58 HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
If you are climbing a hill and you find that you have not properly judged your ability to make it to the top, you should turn the ATV around while you still have forward motion (provided you have the room to do so) and go down the hill. When crossing the side of a hill: Always follow proper procedures as described in the Owner's Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. If you start to roll backwards, DO NOT use the rear brake to stop.
When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual.
If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV . If you decide you can walk the ATV safely: 1. Stand with your body facing downhill, beside the vehicle so you can reach the rear brake liver with your left hand. 2. Be sure your legs are clear of the wheels. 3. Check your footing. 4.
RIDING DOWNHILL When riding your ATV downhill, shift your weight as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms straight. Improper braking may cause a loss of traction. Use caution while descending a hill with loose or slippery surfaces. Braking ability and traction may be adversely affected by these surfaces. Improper braking may also cause a loss of traction. Whenever possible, ride your ATV straight downhill.
58 OK 84
CROSSING A SLOPE Traversing a sloping surface on your ATV requires you to properly position your weight to maintain proper balance. Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your balance. WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn.
Shift your weight to the uphill side of the ATV.
RIDING OVER ROUGH TERRAIN Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on the footboards at all time. Avoid jumping the ATV as loss of control and damage to the ATV may result. WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn.
CROSSING THROUGH SHALLOW WATER The ATV can be used to cross slow moving, shallow water of up to a maximum of 20 cm (7.9 inches) in depth. Before entering the water, choose your path carefully. Enter where there is no sharp drop off, and avoid rocks or other obstacles which may be slippery or upset the ATV. Drive slowly and carefully. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the linings.
Test your brakes after leaving the water. Do not continue to ride your ATV without verifying that you have regained proper braking ability. PARKING Always choose a level place to park. After bringing your ATV to a stop, hold the brakes while you shift into neutral. Then set the parking brake and turn the ignition switch OFF. If you're through parking for the day, also turn the fuel valve OFF.
WHAT TO DO IF This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. If your ATV starts to slide sideways: Steer in the direction of the slide if you have the room. Applying the brakes or accelerating is not recommended until you have corrected the slide. (See pages 75~76.) WHAT TO DO.... If your ATV doesn't turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again.
If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance. If you discover that the ATV is going to tip over, dismount on the uphill side. (See pages 85~86) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles.
PERIODIC MAINTENANCE AND ADJUSTMENT Have KYMCO dealer perform service if you are not familiar with machine service. Periodic inspection, adjustment and lubrication will keep your machine in the safest and most efficient condition possible. Safety is an obligation of the machine owner. The most important points of machine inspection, adjustment and lubrication are explained on the following pages. Tool kit A tool kit is provide with your ATV.
The tools in the kit are sufficient to perform routine maintenance and simple repairs. Any extensive work requiring additional tools should be performed by your authorized KYMCO dealer. The tool kit includes the following items: (1) Air pressure gauge (2) Spark plug wrench (3) 10/12 mm wrench (4) Standard/Phillips screwdriver (5) Screwdriver handle (6) Tool bag (7) Rubber band (5) (4) (3) (2) (6) WARNING POTENTIAL HAZARD Operating this ATV with improper modifications.
PERIODIC MAINTENANCE/LUBRICATION ITEM Engine oil Oil strainer* Transmission oil V-belt* Air filter element (for engine and V-belt compartment) ROUTINE 1 month Replace (Warm engine before draining). Clean. Replace if necessary. Check oil level/oil leakage. Replace every 12 months. Check operation. Replace if damage or excessive wear. Clean. Replace if necessary. Every 20~40 hours (More often in wet or dusty areas.) Cylinder head cover breather system* Check operation and brake fluid/cable.
ITEM Valves* Exhaust system* Wheels* Wheel bearings* Steering system* ROUTINE Check valve clearance. Adjust if necessary. Check leakage. Retighten if necessary. Replace gasket if necessary. Check balance/damage/runout. Replace if necessary. Check bearing assembly for looseness/damage. Replace if damaged. Check operation. Replace if damaged. Check toe-in. Adjust if necessary. Knuckle shafts/ Steering shaft* Lubricate every 6 months.
Engine oil 1.Engine oil level measurement A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Remove right side cover. E. Remove the dipstick and inspect the oil level. F. The oil level should be between the maximum and minimum marks. If the level is low, add oil to raise it to the proper level. (1) (2) (3) (1) (1) Dipstick/oil filler cap (3) Minimum level mark (1) Right side cover D. Remove the dipstick and wipe it off with a clean rag.
2-1. Engine oil replacement and oil filter cleaning A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil filler cap and oil filter cap to drain the oil. CAUTION: ．Be sure no foreign material enters the crankcase. ．When removing the drain plug, the compression spring, oil strainer and Oring will fall out. Take care not to lose these parts. E. Clean the oil strainer with solvent. F.
H. Fill the engine with oil and install the oil filler cap. 2-2. Engine oil replacement A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil filler cap and drain plug to drain the oil. Recommended oil: see page 131. Oil quantity: Engine oil: Periodic oil change: 0.7 L (0.62 lmp qt, 0.74 US qt) Total amount: 0.8 L (0.70 lmp qt, 0.84 US qt) (1) CAUTION: Be sure no foreign material enters the crankcase. I.
Tightening torque: Drain plug (engine): 30 Nm (3.0 m-kg, 21.6 ft-lb) CAUTION: Be sure no foreign material enters the crankcase. (1) Recommended oil: see page 131. Oil quantity: see page 131. (1) Drain plug E. Reinstall the drain plug and tighten the drain plug to specification. F. Fill the engine with oil and install the oil filler cap. G. Warm up the engine for several minutes at idle speed. Check for oil leakage while warming up.
Transmission oil 1. Transmission oil measurement A. Place the machine on a level place. B. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level. C. Reinstall the oil filler bolt and tighten to specification. Tightening torque Oil filler bolt: 15 Nm (1.
2. Transmission oil replacement A. Place the machine on a level place. B. Place a container under the engine. C. Remove the oil filler bolt and drain plug to drain the oil. D. Reinstall the drain plug and tighten to Specification. (1) Tightening torque Drain plug: 15 Nm (1.
E. Fill the engine with oil and install the oil filler bolt. Recommended oil : See page 131 Oil quantity: Periodic oil change: 0.11 L (0.10 lmp qt, 0.12 US qt) Total amount: 0.12 L (0.11 lmp qt, 0.13 US qt) F. Start the engine and warm up for a few minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. (1) CAUTION: Be sure no foreign material enters the crankcase. Tightening torque Oil filler bolt: 15 Nm (1.
Spark plug inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. For example, a very white center electrode porcelain color could indicate an intake air leak or carburetion problem for that cylinder. Do not attempt to diagnose such problems yourself. Instead, take the machine to a KYMCO dealer.
Air filter cleaning The air cleaner accumulates dust and must be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule. If the ATV is submerged in water, the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine. To clean the air cleaner: 1. Remove the seat. (See page 32.) 2. Remove the air filter case cover.
3. Remove the air filter element, and separate it from the box. WARNING POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element. (1) (1) Air filter element 4. Wash the element gently but thoroughly in solvent. 5. Squeeze the excess solvent out of the filter and let it dry.
6. Inspect the element. If damaged, replace it. 7. Apply quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used. NOTE: The element should be wet but not dripping. Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional KYMCO service technician. 8.
Idle speed adjustment (1) NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Connect the tachometer and set the idle to the specified idling speed by adjusting the throttle stop screw. Turn the screw in to increase engine speed, and out to decrease engine speed.
Throttle lever adjustment (1) NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. (3) (4) ) (2) (A To adjust throttle free play: 1. Slide the rubber sleeves back to expose the throttle cable adjuster. 2. Loosen the lock nut, then turn the adjuster to obtain the correct free play. (3~5 mm or 0.12~0.2 in) 3. Tighten the locknut and reinstall the sleeve. (1) (1) Rubber sleeve (2) Cable adjuster (3) Locknut (4) Throttle lever (A) 3~5 mm (0.12~0.
Front brake shoe inspection The checking of brake shoe wear will disassemble the brake. If the lining thickness below to the wear limit 2.0mm (0.08in), to replace the shoes as a set. These procedures should be performed by KYMCO dealer. (A) (1) (1) (A ) (A (1) Lining Rear brake pads inspection A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator.
Front brake lever free play adjustment The front brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. If the free play is incorrect, adjust as follows: (2) (A) (1) (3) (1) Upper locknut (3) Lower locknut (2) Upper adjusting bolt (4) Lower adjusting bolt 2. Loosen the lower locknut. 3. Turn the lower adjusting bolt until specified free play is obtained. (A) Free play 10~20 mm (0.4~0.8 in) Specified free play: 10~20 mm (0.4~0.8 in) 1.
WARNING 5. While applying the front brake, turn out the upper adjusting bolt until the upper and lower cable lengths are equal. The cable joint will become vertical. POTENTIAL HAZARD Operating with improperly serviced or adjusted brakes. (A) (1) WHAT CAN HAPPEN You could lose braking ability, which could lead to an accident. HOW TO AVOID THE HAZARD After servicing: Make sure the brakes operate smoothly and that the free play is correct. Make sure the brakes do not drag.
Brake fluid inspection Check if the fluid level is below the lower level mark through the inspection window. (1) WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation. L (1) Lower level mark (Hand Brake lever) 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 doctor if your eyes were exposed.
NOTE: CAUTION: As the brake pads wear, brake fluid level drops, automatically compensating for wear. There are no adjustments to perform, but fluid level and pad wear must be inspected periodically. The system must be inspected frequently to ensure there are no fluid leaks. If the brake lever travel become excessive and the brake pads are not worn beyond the recommended limit (page 109), There is probably air in the brake system and it must be bled. See your authorized KYMCO dealer for this service.
Drive chain slack check Inspect the drive chain while all tires are touching the ground. Check the slack at the position shown in the figure. The normal vertical deflection is approximately 10~20 mm (0.4~0.8in). If the deflection exceeds 20 mm (0.8 in), adjust the chain slack. Drive chain slack adjustment 1.Loosen the upper and lower axle holding bolts. (2) (1) (1) Hub stopper nut (A) A. 10~20 mm (0.4~0.
2.Turn the adjusting nut, to decrease or increase chain slack. 3.Retighten the upper and lower axle holding bolts. Tightening torque: Axle holding bolts (upper): 70 Nm (7.0 m-kg, 48 ft-lb) (1) (1) Adjust nut CAUTION: Too little of chain slack will overload the engine and other important parts. Keep the slack within the specified limit.
Drive chain cleaning and lubrication The drive chain is equipped with rubber O-rings between the chain plates. Steam cleaning, highpressure washes, and certain solvents can damage these O-rings. Use only kerosene to clean the drive chain. Wipe it dry, and thoroughly lubricate it with SAE 30~50 motor oil. Do not use any other lubricants on the drive chain. They may contain solvents that could damage the O-rings. Cable inspection and lubrication WARNING POTENTIAL HAZARD Damaged control cables.
Brake lever lubrication Lubricate the pivoting parts of the brake levers. Recommended lubricant: Lithium-soap-based grease (All-purpose grease) Draining the V-belt compartment If water leaks into V-belt compartment such as when the machine is drive in water, remove the drain screw on the bottom of compartment and drain the water. Be sure to drive slowly until the V-belt becomes dry. If slipping is noticed, ask a KYMCO dealer to inspect.
Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. 2. Remove the nuts from the wheel. 3. Remove the wheel assembly. Wheel nut torque: Front: 40 Nm (4.0 m-kg, 30 ft-lb) Rear: 40 Nm (4.0 m-kg, 30 ft-lb) (1) (1) Safe nut Wheel installation When installing the wheel, reverse the removal procedure. Pay attention to the following.
Battery Your ATV battery is located in a compartment under the seat. The battery is sealed, so it is not necessary to check the electrolyte level or add distilled water. If the battery seems weak, see your authorized KYMCO dealer for information on recharging or replacement. If you replace the battery, choose one that is sealed and equivalent to the original. Be sure to read and follow all safety precautions indicated on the battery. WARNING POTENTIAL HAZARD Allowing open flames or sparks near the battery.
Battery remove 1. Make sure the ignition switch is OFF. 2. Remove the seat (page 32) 3. Remove the battery cover, by removing the mount bolts. 4. Disconnect the negative (-) terminal lead from the battery first, then disconnect the positive (+) terminal lead. 5. Remove the battery. Battery installation 1. Install in the reverse order of removal. 2. Check all bolts and other fasteners are secure. 3. After installing the battery, check to see if the battery cables are routed correctly.
Fuse replacement When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your authorized KYMCO dealer for repair. Fuse holder: The fuse holder is located in the storage box under the seat. The specified fuses are: 7A (1) CAUTION: To prevent accidental short-circuiting, turn off the ignition switch before checking or replacing a fuse. WARNING POTENTIAL HAZARD Using an improper fuse.
1. Lift the seat. (See page 32) 2. Open the fuse holders and lift out the fuse with the clips. 3. Slide the old fuse out of the clips and discard it.
Spark arrester cleaning (see page 139~140) 4. Slide the clips onto the ends of the new fuse, push them back into the fuse holder, and close the fuse holder. The spare fuse is on the battery cover. (1) (2) (1) Fuse holder (2) Clip CAUTION: ．Do not pry the clips open to get a fuse out; you could bend them and cause poor contact with the new fuse. A loose fuse could cause damage to the electrical system and even start a fire.
Troubleshooting Although KYMCO machines receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy procedure for making checks. If your machine requires any repair, take it to a KYMCO dealer. WARNING POTENTIAL HAZARD Checking the fuel system while smoking or near an open flame. WHAT CAN HAPPEN Fuel can ignite or explode, causing severe injury or property damage.
Troubleshooting chart 1. Fuel Check if there is fuel in the fuel tank. No fuel. Supply fuel. Some fuel. Turn the fuel valve to "RES". Restart engine. Turn the fuel valve to "OFF". Remove the fuel hose from the fuel valve. There is fuel. 2. Battery Use electric starter. Water or dirt mixed in fuel. Clean filter element and fuel tank. Turn the fuel valve to Check fuel flow. No fuel. Fuel valve Engine turns over slowly. Check fluid, recharge, check connections. Engine turns over quickly.
CLEANING AND STORAGE CAUTION: A. CLEANING Frequent, thorough cleaning of your machine will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the machine: A. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. B. Make sure the spark plug and all filler caps are properly installed. 2. If the engine case is excessively greasy, apply degreaser with a paint brush.
7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid combination cleaner-waxes. Many contain abrasives which may mar the paint or protective finish. When finished, start the engine and let it WARNING POTENTIAL HAZARD Operation with wet brakes after washing. WHAT CAN HAPPEN Wet brakes may have reduced stopping ability, increasing the chance of an accident.
B. STORAGE Before storing your ATV for an extended time, be sure you thoroughly check the vehicle for needed repairs and have them corrected. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage. In addition, extended storage requires that you take the following steps to reduce the effects of deterioration from non-use of the vehicle: WARNING POTENTIAL HAZARD Refueling this ATV or handling fuel improperly. WHAT CAN HAPPEN The fuel could explode or ignite.
4. Remove the battery (page 120) And store it in an area protected from freezing temperatures and direct sunlight and out of the reach of children, slow charge the battery once a month. WARNING POTENTIAL HAZARD Prolonged contact of fuel with the skin. Breathing fuel vapor. WARNING WHAT CAN HAPPEN The fuel can cause skin irritation. Fuel vapor could cause lung damage. POTENTIAL HAZARD Allowing open flames or sparks near the battery.
SPECIFICATIONS Mongoose 90 Model Dimension: Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance 1430 mm (56.2 in) 905 mm (35.6 in) 910 mm (35.8 in) 650 mm (25.5 in) 965 mm (37.9 in) 104 mm (4.1 in) Basic weight: With oil and full fuel tank 120kg (264 lbs) Engine: Type Cylinder arrangement: Displacement Bore x stroke Compression ratio Starting system Lubrication system: Air cooled 4-stroke, OHC Single cylinder 3 89.9 cm 47X51.8 10.
Model Mongoose 90 1 00 Engine oil/transmission oil: Type Recommended engine oil classification: 300 500 700 900 1100 F SAE 5W SAE 10W－30 SAE 10W－40 SAE 20W－40 SAE 20W－50 -1 00 00 100 200 300 0 40 C API Service SE, SF, SG type or higher Recommended transmission Oil classification: SAE#90 Quantity Engine oil: Periodic oil change Total amount Transmission oil: Periodic oil change Total amount 0.7 L (0.62 lmp qt, 0.74 US qt) 0.8 L (0.70 lmp qt, 0.84 US qt) 0.11 L (0.10 lmp qt, 0.12 US qt) 0.
Mongoose 90 Model Air filter: for engine for V-belt compartment Wet type element Dry type element Fuel: Type Tank capacity Reserve amount UNLEADED FUEL 5.5 L (1.16 lmp gal, 1.40 US gal) 1.5 L (0.32 lmp gal, 0.38 US gal) Carburetor: Type PB Spark plug: Type Gap NGK CR7HSA 0.6 ~ 0.7 mm (0.024 ~ 0.
Mongoose 90 Model Suspension: Front Rear Swing axle Swing arm Shock absorber: Front Rear Coil spring/Oil damper Coil spring/Oil damper Electrical: Ignition system Generator system Battery type C.D.I. C.D.I.
NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been remove
MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
INDEX Page Page A D Accessories........................................48, 54 AGE RECOMMENDATION..........................A Air filter cleaning ....................................104 Draining the V-belt compartment...............117 Drive chain cleaning and lubrication ........ 116 Drive chain slack adjustment................... 114 Drive chain slack check .......................... 114 During operation...................................... 62 B Brake fluid inspection..............................
Page Page F I Fittings and fasteners............................... 39 Flag pole bracket......................................33 Frame and engine serial number ............... 16 Front brake .............................................27 Front brake lever free play adjustment ..... 110 Front brake shoe inspection......................109 Fuel........................................................ 36 Fuse replacement...................................121 Fuel tank cap...................................
Page Page N R No Modifications...................................... 55 Rear brake...............................................27 Rear brake pads inspection......................109 Remote engine stop switch .......................24 RIDING DOWNHILL..................................83 RIDING OVER ROUGH TERRAIN ............. 87 Riding Your ATV........................................49 O OPERATION ........................................... 43 P PARKING ..........................................
Page T Throttle lever...................................... 25, 39 Throttle lever adjustment.........................108 Tires....................................................... 40 Tire wear limit.......................................... 42 Tool kit.....................................................92 Transmission oil .....................................100 Troubleshooting .................................... 124 Troubleshooting chart ............................ 125 TURNING YOUR ATV................
Spark arrester cleaning Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the bolt. 2. Remove the tailpipe by pulling it out of the muffler. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe. (1) (1) (1) Bolt (2) (1) Tailpipe (2) Spark arrester 4. Insert the tailpipe into the muffler and align the screw holes. 5. Install the bolt and tighten it.
WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components. Do not start the engine when cleaning the exhaust system.
WARNING Mongoose 90 reverse version The ATV version has a gear selector 1. F -Forward gear 2. N- Neutral gear 3. R -Reverse gear To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
Shift lever 1 1.To shift into forward gear pull out and upward on the shift lever until the transmission engages in the forward gear. 2.To shift into reverse gear pull out and push downward on the shift lever until the transmission engages the reverse Gear . When in the with the ignition switch in the ON position the reverse Indicator light will illuminate.
Shift lever 2 1.To shift into neutral from either forward or reverse gear ,push or pull the lever to the center position. When in the neutral with the ignition switch in the on position the neutral indicator light will illuminate. CAUTION: A lways come to a complete stop with engine at idle before moving the shift lever changing gears while moving or shifting from neutral with the engine above idle could.
SPECIFICATIONS Mongoose 90 Reverse Model Dimension: Overall length Overall width Overall height Seat height Wheel base Fra.Minimum ground clearance RR.Minimum ground clearance 1440 mm (57.6 in) 905 mm (35.6 in) 925 mm (37.0 in) 650 mm (25.5 in) 965 mm (37.9 in) 150 mm (6.0 in) 100 mm (4.0 in) Basic weight: With oil and full fuel tank 123kg (270.
Model Mongoose 90 Reverse 1 00 Engine oil/transmission oil: Type Recommended engine oil classification: 300 500 700 900 1100 F SAE 5W SAE 10W－30 SAE 10W－40 SAE 20W－40 SAE 20W－50 -1 00 00 100 200 300 0 40 C API Service SE, SF, SG type or higher Recommended transmission Oil classification: SAE#90 Quantity Engine oil: Periodic oil change Total amount Transmission oil: Periodic oil change Total amount 0.7 L (0.62 lmp qt, 0.74 US qt) 0.8 L (0.70 lmp qt, 0.84 US qt) 0.25 L (0.22 lmp qt, 0.
Mongoose 90 Reverse Model Air filter: for engine for V-belt compartment Wet type element Dry type element Fuel: Type Tank capacity Reserve amount UNLEADED FUEL 5.3 L (1.11 lmp gal, 1.38 US gal) 1.5 L (0.32 lmp gal, 0.38 US gal) Carburetor: Type PTE (Auto Bystarter) Spark plug: Type Gap NGK CR7HSA 0.6 ~ 0.7 mm (0.024 ~ 0.
Mongoose 90 Reverse Model Suspension: Front Rear Single A-arm Swing arm Shock absorber: Front Rear Coil spring/Oil damper Coil spring/Oil damper Electrical: Ignition system Generator system Battery type C.D.I. C.D.I.
KYMCO 90CC EPA HANGTAG FOR 2009 MODEL KYMCO 90CC EPA DECAL FOR 2009 MODEL
KWANG YANG MOTOR CO.,LTD. NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. Third Edition, OCT 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited.
Do not remove this Owner’s Manual from the vehicle. Read this manual carefully before operating the vehicle as it contains important safety information. C 2009 KYMCO. All rights reserved. Printed in Taiwan. www.kymco.
