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Mongoose 90
KYMCO Mongoose 90 Service Manual
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6. ENGINE REMOVAL/INSTALLATION
6-1
SERVICE INFORMATION
GENERAL INSTRUCTIONS
•
A floor jack or other adjustable support is required to support and maneuver the engine.
Be careful not to damage the machine body, cables and wires during engine rem
oval.
•
Use shop towels to protect the machine body during engine removal.
•
Parts requiring engine removal for servicing:
⎯
Crankcase
⎯
Crankshaft
104
106
Table of Contents
Preface
2
Table of Contents
2
General Information
3
Serial Number
4
General Information
4
Specifications
5
Service Precautions
9
Torque Values
17
Special Tools
19
Lubrication Points
20
Cable & Harness Routing
23
Wiring Diagrams
26
Troubleshooting
31
Frame Covers/Exhaust Muffler
37
Frame Covers/Exhaust Muffler
38
Service Information
39
Frame Covers
40
Exhaust Muffler Removal
44
Taillight Bulb
45
3. Inspection/Adjustment 3
46
Inspection/Adjustment
46
Inspection/Adjustment
47
Service Information
47
Maintenance Schedule
49
Fuel Line/Throttle Operation
50
Air Cleaner
51
Spark Plug/Cylinder Compression
53
VALVE CLEARANCE (90Cc/70Cc/50Cc-4T)
54
Carburetor Idle Speed
54
ENGINE OIL (90Cc/70Cc/50Cc-4T)
55
Transmission Oil
57
Drive Belt/Brake Shoes/Brake Pads/Brake Fluid
58
Brake Lever Free Play (Drum Brake)
59
Steering System Inspection
60
Toe-In Adjustment
61
Wheels/Tires
62
Drive Chain Slack Adjustment
63
Cable Inspection and Lubrication
65
Suspension Lubrication
65
Headlight Beam Adjustment (on Road Only)
66
Brake Pedal Adjustment (on Road Only)
66
Brake Fulid
67
4. Lubrication System 4
68
Lubrication System
68
Lubrication System
69
SERVICE INFORMATION (90Cc/70Cc/50Cc-4T)
71
SERVICE INFORMATION (50Cc-2T)
72
ENGINE OIL/OIL FILTER (90Cc/70Cc/50Cc-4T)
73
OIL PUMP (90Cc)
73
OIL PUMP (70Cc/50Cc-4T)
77
OIL PUMP BLEEDING (50Cc-2T)
83
OIL PUMP (50Cc-2T)
83
OIL FILTER CLEANING (50Cc-2T)
86
5. Fuel System 5
87
Fuel System
87
Fuel System
88
Service Information
89
Fuel Tank
91
Fuel Valve Removal
91
Throttle Valve
94
AIR CLEANER (90Cc/70Cc/50Cc-4T)
96
AIR CLEANER (50Cc-2T)
97
Carburetor
98
Engine Removal
104
Cylinder Head/Valves (90Cc/70Cc/50Cc-4T)
110
Default Chapter
110
Cylinder Head/Valves
110
Cylinder Head/Valves
111
(90Cc/70Cc/50Cc-4T)
112
Service Information
112
Camshaft/Camshaft Holder
115
Cylinder Head Cover
115
Cylinder Head
116
Cylinder/Piston
124
9.Drive and Driven Pulleys 9
143
Drive and Driven Pulleys
143
Service Information
145
Drive and Driven Pulleys
146
Left Crankcase Cover/Kick Starter
147
Drive Pulley
150
Clutch/Driven Pulley
152
Final Reduction/Transmission System
159
Crankcase/Crankshaft
166
Front Wheel/Front Brake/ Front Suspension\Steering System
179
Front Wheel/Front Brake/ Front Suspension/Steering
179
Front Wheel/Front Brake/Front Suspension/Steering System
180
Service Information
181
Front Wheel
183
Front Brake
187
Front Suspension
189
Steering System
192
Tie-Rod
196
13. Rear Wheel/Swing Arm/ Hydraulic Brake 13 13
198
Rear Wheel /Swing Arm/Hydraulic Brake
198
Service Information
200
Rear Wheel
200
Rear Swing Arm
200
Hydraulic Brake
201
Brake Pad/Disk
214
Brake Master Cylinder
215
Brake Caliper
218
Drum Brake
220
14. Battery/Charging System/ A.C. Generator 14
222
Batter/Charging System
223
A.C. Generator
224
Service Information
224
Battery Removal
226
Charging System
226
A.C. Generator
228
Battery/Charging System/A
228
Regulator/Rectifier
229
A.C. Generator
230
Generator Charging Coil
230
Generator Lighting Coil
230
Resistor Inspection
230
Ignition System
234
Ignition System
235
Service Information
237
CDI Unit Inspection
239
Ignition Coil
241
Pulser Coil
242
Ignition Timing Inspection
242
Starting System
243
Starter Motor
246
Bulbs Removal/Instrument/Horn
254
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KYMCO Mongoose 90 Specifications
General
Brand
KYMCO
Model
Mongoose 90
Category
Offroad Vehicle
Language
English
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