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KYMCO Mongoose/KXR 250 User Manual

KYMCO Mongoose/KXR 250
242 pages
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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
Mongoose/KXR 250.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part,
starting from periodic maintenance.
Sections 4 through 19 give instructions
for disassembly, assembly and
inspection of engine, chassis frame and
electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
FRAME COVERS/EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE REMOVAL 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
DRIVE AND DRIVEN PULLEYS
9
FINAL REDUCTION/TRANSMISSION
SYSTEM
10
CRANKCASE/CRANKSHAFT/
BALANCE SHAFT
11
COOLING SYSTEM
12
BRAKE SYSTEM
13
FRONT WHEEL/FRONT
SUSPENSION/STEERING SYSTEM
14
REAR WHEEL/AXLE/SUSPENSION
15
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
16
IGNITION SYSTEM 17
STARTING SYSTEM 18
BULBSREMOVAL/INSTRUMENT/
HORN
19
The information and contents include
d
in this manual may be different from
the motorcycle in case specifications
are changed.
CHASSIS
ELECTRICAL
EQUIPMENT
ENGINE

Table of Contents

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KYMCO Mongoose/KXR 250 Specifications

General IconGeneral
BrandKYMCO
ModelMongoose/KXR 250
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

Specifications

Details technical specifications for the engine, fuel system, electrical components, and chassis.

Service Precautions

Provides essential safety guidelines and procedures for maintenance and repair.

Torque Values

Lists specific torque specifications for important fasteners to ensure correct assembly.

Special Tools

Identifies specialized tools required for specific maintenance and repair procedures.

Wiring Diagram (Off Road)

Provides a schematic diagram of the ATV's electrical system for off-road configuration.

Wiring Diagram (On Road)

Provides a schematic diagram of the ATV's electrical system for on-road configuration.

Troubleshooting

Offers diagnostic procedures and solutions for common engine starting and performance issues.

Frame Covers and Exhaust Muffler

Exhaust Muffler Removal

Outlines the steps for safely removing and installing the exhaust muffler, including torque specifications.

Inspection and Adjustment

Maintenance Schedule

Provides a recommended schedule for routine inspections and maintenance tasks.

Valve Clearance and Carburetor Idle Speed

Explains how to inspect and adjust valve clearance and set the carburetor idle speed.

Ignition Timing and Cylinder Compression

Covers procedures for checking ignition timing and measuring cylinder compression.

Engine Oil Level and Replacement

Details how to check the engine oil level and perform oil and filter changes.

Drive Belt, Brake Pads, Brake Fluid Inspection

Covers inspection of the drive belt, brake pads, and brake fluid levels.

Drive Chain Slack Adjustment

Explains how to check and adjust the drive chain slack.

Lubrication System

Engine Oil/Oil Filter and Oil Pump Removal

Covers engine oil/filter checks and the removal procedure for the oil pump assembly.

Oil Pump Disassembly and Assembly

Details the disassembly, inspection, and assembly process for the oil pump.

Fuel System

Fuel Valve Disassembly and Inspection

Covers the disassembly, cleaning, and inspection of the fuel valve components.

Throttle Valve Disassembly

Explains the process for disassembling the throttle valve assembly.

Carburetor Removal

Details the removal procedure for the carburetor, including draining fuel and disconnecting cables.

Carburetor Disassembly

Covers the disassembly of the carburetor, including float chamber and jet holder removal.

Carburetor Cleaning and Float/Float Valve Inspection

Explains carburetor cleaning procedures and inspection of the float and float valve.

Carburetor Assembly and Float Level Inspection

Details the assembly of the carburetor and how to inspect and adjust the float level.

Engine Removal

Engine Removal Procedures

Step-by-step instructions for removing the engine, including disconnecting various hoses and wires.

Engine Removal Procedures (Continued)

Final steps for engine removal, involving mounting bolts and engine brackets.

Cylinder Head and Valves

Torque Values and Special Tools

Specifies torque values for cylinder head components and lists required special tools.

Camshaft/Camshaft Holder Removal

Explains how to remove the camshaft and camshaft holder assembly.

Camshaft Holder Inspection

Covers inspection of the camshaft holder and rocker arm shafts for wear and damage.

Cylinder Head Removal

Provides steps for removing the cylinder head, including associated components.

Cylinder Head Disassembly

Details the procedure for disassembling the cylinder head, including valve components.

Valve/Valve Guide Inspection

Explains how to inspect valves and guides for wear, damage, and proper clearance.

Cylinder Head Inspection

Covers checking the cylinder head for cracks and warpage.

Assembly

Step-by-step guide for assembling the cylinder head components.

Cylinder and Piston

Cylinder/Piston Removal

Details the procedure for removing the cylinder and piston assembly.

Piston Inspection

Covers inspection of the piston, rings, and ring-to-groove clearance.

Piston Ring Installation

Instructions for installing piston rings onto the piston, including proper orientation.

Drive and Driven Pulleys

Final Reduction and Transmission System

Crankcase, Crankshaft, and Balance Shaft

Cooling System

Brake System

Front Brake Fluid Change / Air Bleed

Explains the procedure for draining and refilling the front brake fluid and bleeding air.

Brake System Bleeding

Outlines the process for bleeding air from the brake system to ensure proper function.

Front Wheel, Front Suspension, and Steering System

Rear Wheel, Axle, and Suspension

Battery, Charging System, and A.C. Generator

Ignition System

Starting System

Troubleshooting

Lists common starting system problems like starter motor not turning or engine not starting.

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