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Kymco Maxxer Mongoose 250 300 MXER 250R ATV Service Repair Workshop Manual

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This manual covers the Maxxer, Mongoose, and MXER 250/300 series of All-Terrain Vehicles (ATVs). A Taiwanese company established in 1963, is recognized for its dependable and value-oriented powersports vehicles. The...
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Tipo: Atv
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SKU: 124055
Kymco Maxxer Mongoose 250 300 MXER 250R ATV Service Repair Workshop Manual
This manual covers the Maxxer, Mongoose, and MXER 250/300 series of All-Terrain Vehicles (ATVs). A Taiwanese company established in 1963, is recognized for its dependable and value-oriented powersports vehicles. The Maxxer and Mongoose lines represent a commitment to producing capable sport/utility ATVs designed for trail riding and light work, featuring robust liquid-cooled engines, automatic CVT transmissions, and durable chassis construction. These models have been updated over the years, with advancements including the integration of Electronic Fuel Injection (EFI) on some variants, enhancing performance and efficiency. This comprehensive Service Repair Workshop Manual provides detailed guidance for the maintenance, repair, and troubleshooting of these ATV models. It includes in-depth coverage of all major systems, such as the engine, transmission, chassis, electrical system, fuel system, and braking system. The manual offers step-by-step procedures for routine maintenance, component overhauls, and diagnostic processes, complete with troubleshooting guides, diagnostic flowcharts, and specific technical data like torque specifications and clearances. This resource is intended for ATV owners, DIY mechanics, independent repair shops, and dealerships seeking to ensure the optimal performance and longevity of their ATVs.
🏷️ Basic Information
Identification
Make:
Kymco
Model:
Maxxer Mongoose 250 300 MXER 250R ATV
Codes
Product Code:
KYMCO-MAX-MONG-MXER-250-300-250R-SRM
👋 Introduction
Market Position
Target User:
ATV owners, DIY mechanics, independent repair shops, dealerships
Competitive Analysis
Advantage Over Physical Manuals:
Instant delivery, searchable content, printable sections to keep original manuals clean, cost-effective digital format
Key Features
Content Source:
Official workshop manuals used by dealership technicians
Delivery Method:
Instant digital download, no physical shipping required
Accessibility:
Compatible with PC and Mac operating systems
📋 Manual Details
Coverage Areas
Models Covered:
Kymco Maxxer 250, Kymco Maxxer 300, Kymco Mongoose 250, Kymco Mongoose 300, Kymco MXER 250R, Kymco MX'er 250R
Related Models Mentioned:
Kymco Mongoose KXR 250, Kymco MXU 250, Kymco MXU 250R 300R
Page Count
Estimated Page Count:
Varies based on specific model variant and year (typically 300-600+ pages for comprehensive service manuals)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Adobe Acrobat PDF
📖 Manual Coverage
Systems Covered
Major Systems:
Engine, Transmission, Chassis, Electrical System, Fuel System, Lubrication System, Cooling System, Braking System, Steering System, Suspension System, Frame, Bodywork, Seats System, Locks
Specific Systems Detailed:
Clutch, Seats System, Locks, Frame, Fuel System, Battery, Lighting, Steering, Suspension, Brakes, Lubrication, Electrical, General Information, Engine, Transmission
Procedures Included
Repair Procedures:
Engine overhaul, carburetor/fuel injection tuning, transmission disassembly/reassembly, clutch service, suspension adjustments and rebuilds, brake system bleeding and repair, electrical diagnostics, wiring harness repair, frame inspection and repair, lubrication procedures, steering system overhaul
Maintenance Procedures:
Scheduled maintenance, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, battery maintenance, fluid level checks, tire pressure checks, general inspection procedures
Diagnostic Procedures:
Troubleshooting, fault finding, diagnostic flow charts for engine, electrical, and chassis issues.
Technical Depth
Diagnostic Capabilities:
Troubleshooting guides, diagnostic flowcharts, fault code interpretation, common problem identification and solutions
Rebuild Instructions:
Detailed step-by-step instructions for complete engine rebuilds, transmission overhauls, and component replacements
Specifications Detail:
Torque specifications for all fasteners, clearance measurements, tolerances, fluid capacities, and component dimensions.
📊 Manual Specifications
File Format
PDF Features:
Searchable text, bookmark navigation, high-resolution diagrams and illustrations
Print Quality
Printability:
Printable by section or entire manual for workshop use
Binding Type
Binding Recommendation:
Suitable for binding in 3-ring binders for easy reference and page insertion
Paper Type
Recommended Use Paper:
Standard printer paper recommended for printing specific sections to avoid damaging expensive original manuals
⚙️ Engine Specifications
Primary Engine
Engine Type 250Cc:
Liquid-cooled, 4-stroke, SOHC, 2-valve single-cylinder (typical for 250cc variants)
Engine Type 300Cc:
Liquid-cooled, 4-stroke, SOHC, 4-valve single-cylinder (typical for 300cc variants)
Performance
Bore Stroke 250Cc Approx:
e.g., 71.0 mm x 63.0 mm (exact specifications vary by specific engine code)
Bore Stroke 300Cc Approx:
e.g., 72.0 mm x 70.0 mm (exact specifications vary by specific engine code)
Horsepower 250Cc Approx:
Typically in the 15-20 HP range at around 7000-7500 RPM
Horsepower 300Cc Approx:
Typically in the 18-23 HP range at around 7000-7500 RPM
Fuel System
Fuel Delivery 250Cc:
Carburetor (e.g., Mikuni VM30 or similar) or Electronic Fuel Injection (EFI) depending on specific model year and variant
Fuel Delivery 300Cc:
Carburetor (e.g., Keihin CVK34 or similar) or Electronic Fuel Injection (EFI) depending on specific model year and variant
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition) or Electronic Ignition System
Cooling System
Cooling Method:
Liquid-cooled with fan assist
Lubrication
Oil Type Recommendation:
SAE 10W-40 API SG or higher (consult specific manual for exact specification)
Oil Capacity Approx:
Approx. 1.5-2.0 liters (including oil filter replacement)
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT)
Features
Drive System:
2WD or 4WD (selectable, depending on model variant)
Gearbox Type:
CVT with high/low range and reverse
Maintenance
Cvt Fluid Type:
Specific CVT fluid or engine oil meeting Kymco specifications (consult manual)
Cvt Fluid Capacity Approx:
Approx. 0.5-1.0 liters
📐 Dimensions
Exterior
Length Approx:
Approx. 1750-1850 mm
Width Approx:
Approx. 1000-1100 mm
Height Approx:
Approx. 1100-1150 mm
Weights
Dry Weight Approx:
Approx. 200-240 kg
Towing Capacity Approx:
Typically around 150-300 kg (check specific model for exact rating)
Tires
Front Tire Size Typical:
AT 22x7-10 or similar
Rear Tire Size Typical:
AT 22x10-10 or similar
Wheels
Wheel Bolt Pattern:
Typically 4x110 or 4x137 (verify for specific model)
🛡️ Safety Features
Passive Features
Lighting:
Halogen headlights, LED taillight/brake light
Active Features
Braking System:
Hydraulic disc brakes front and rear
Parking Brake:
Handlebar-mounted or lever-operated parking brake
💡 Technology Features
Infotainment
Display Features:
Digital instrument cluster typically includes speedometer, odometer, trip meter, fuel gauge, and indicator lights.
Driver Assistance
Efi Systems:
Later models may feature Electronic Fuel Injection (EFI) for improved throttle response, fuel economy, and emissions control.
Connectivity
Usb Charging Port:
Some newer models may include a 12V power outlet or USB charging port.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 1000 km or 6 months (whichever comes first, consult manual for precise interval)
Air Filter Cleaning:
Every 6 months or 1000 km, or more frequently in dusty conditions
Spark Plug Replacement Interval:
Every 24 months or 4000 km
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze/coolant, diluted 50/50 with distilled water
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Known Issues
Common Wear Items:
CVT belt, brake pads, ball joints, tie rod ends, wheel bearings (typical for ATVs of this era and class)
Carburetor Tuning Challenges:
Some carburetor-equipped models may require periodic fine-tuning or cleaning due to fuel quality variations or aging components.
Electrical Connector Corrosion:
In humid or wet environments, electrical connectors can be prone to corrosion, requiring inspection and cleaning.
📚 Vehicle History
Brand Heritage
Kymco Origin:
Kymco (Kwang Yang Motor Co., Ltd.) is a Taiwanese company established in 1963, known for its scooters, ATVs, and motorcycles.
Model Evolution
Maxxer Mongoose Lineage:
The Maxxer and Mongoose series are Kymco's popular sport/utility ATV line, designed for trail riding and light utility work. They evolved from earlier Kymco ATV platforms, incorporating improved engine technology and chassis design over various model years.
Production
Production Period Estimate:
Models like the Maxxer and Mongoose 250/300 have been in production for several years, with updates to engines (e.g., carburetor to EFI) and styling across different model years (e.g., mid-2000s to present).
🏆 Awards & Recognition
Recognitions
Market Reputation:
Kymco ATVs are generally well-regarded for offering a good balance of performance, features, and value for money in the mid-range ATV market.
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