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KYMCO Mongoose 250 1999-2008 Service Repair Manual

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This manual covers the Mongoose 250 and MAXXER 250, along with the MAXXER 300 and MONGOOSE 300 models, produced between 1999 and 2008. These recreational ATVs were designed for agility...
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Tipo: Atv
Proveedor:
SKU: 143091
KYMCO Mongoose 250 1999-2008 Service Repair Manual
This manual covers the Mongoose 250 and MAXXER 250, along with the MAXXER 300 and MONGOOSE 300 models, produced between 1999 and 2008. These recreational ATVs were designed for agility and maneuverability, offering a balance of performance and comfort for trail riding and light utility. As part of the offering in the competitive 250cc to 300cc segment, these models were known for providing good value and capability, often compared to offerings from established Japanese manufacturers. They feature a four-stroke, liquid-cooled, single-cylinder engine with SOHC, paired with an automatic Continuously Variable Transmission (CVT) and 2WD drive. Safety features include hydraulic disc brakes, a throttle limiter on some models, and standard lighting. This comprehensive Factory Service Repair Manual provides detailed instructions for the maintenance, repair, and diagnostics of your Mongoose or MAXXER ATV. It covers all major systems, including the engine, fuel system, ignition, transmission, drivetrain, suspension, brakes, steering, and electrical system. You will find step-by-step repair procedures, routine maintenance schedules, troubleshooting guides, and essential technical specifications such as torque values and fluid capacities. This manual is an indispensable resource for owners and technicians alike, ensuring the proper upkeep and longevity of your vehicle.
🏷️ Basic Information
Identification
Make:
KYMCO
Model:
Mongoose 250
Model Variants:
MAXXER 300, MONGOOSE 300
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
Codes
Chassis Code Designation:
Typically varies by specific model year, often prefixed with 'LBB' for KYMCO ATVs.
👋 Introduction
Market Position
Segment:
Recreational ATV (All-Terrain Vehicle)
Target Audience:
Enthusiasts seeking trail riding, recreational sport, and light utility.
Competitive Analysis
Competitors:
Yamaha Wolverine, Honda FourTrax, Suzuki KingQuad, Polaris Sportsman (in their respective displacement classes).
Key Features
Vehicle Type:
Sport/Recreational ATV
Design Focus:
Agility, maneuverability, and a balance of performance and comfort for trail riding.
Manual Utility:
Provides factory-level repair and maintenance data, crucial for DIY mechanics and dealership technicians.
📋 Manual Details
Coverage Areas
Covered Years:
1999-2008
Covered Models:
KYMCO Mongoose 250, MAXXER 250, MAXXER 300, MONGOOSE 300
Page Count
Estimated Page Count:
Likely 500+ pages, typical for comprehensive factory service manuals.
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Primary Format:
PDF
Secondary Format:
WINRAR (for file compression/delivery)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, disassembly, assembly, tuning, diagnostics, specifications, and component identification.
Fuel System:
Carburetor (or fuel injection if applicable to specific variants), fuel pump, lines, filters, and troubleshooting.
Ignition System:
CDI unit, ignition coil, spark plug, wiring, timing, and diagnostics.
Transmission:
Clutch operation, gear shifting mechanisms, internal components, lubrication, and adjustment procedures.
Drivetrain:
Drive shafts, CV joints, differential (if applicable), chain/belt drive, and related components.
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, bushings, alignment, and adjustments.
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedures, and troubleshooting.
Steering:
Steering column, tie rods, steering knuckles, bearings, and adjustment/replacement procedures.
Electrical System:
Wiring diagrams, battery, charging system, starter, lighting, ignition switches, fuses, relays, and component testing.
Cooling System:
Radiator, fan, coolant, hoses, thermostat, and troubleshooting.
Exhaust System:
Muffler, pipes, heat shields, and gasket replacement.
Frame And Body:
Chassis inspection, frame straightening (if applicable), body panel removal/installation, and trim.
Procedures Included
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, chain/belt adjustments, and lubrication points.
Troubleshooting:
Comprehensive diagnostic flowcharts and common problem-solving guides for various systems.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly for all major vehicle systems.
Diagnostics:
Detailed procedures for diagnosing electrical and mechanical issues, including testing components.
Technical Specifications:
Essential data like torque values, fluid capacities, clearances, and specifications for accurate adjustments and repairs.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair or maintenance tasks.
Lubrication:
Detailed guidance on lubrication points, types of lubricants, and service intervals.
Cable Harness Routing:
Information on proper routing of electrical cables and harnesses to prevent damage and ensure correct function.
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine rebuilds and advanced diagnostics.
📊 Manual Specifications
File Format
Digital Format:
PDF, WINRAR
Searchability:
Complete searchable text
Bookmarking:
Completely bookmarked
Print Quality
Printability:
All pages are printable
Source Quality:
Real files, not scans
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Operating Systems:
Win95/98/ME/XP/vista/7/Linux/MAC
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, Single-cylinder, SOHC (Single Overhead Cam)
Displacement Mongoose 250:
Approximately 249cc (actual specification may vary slightly by year and sub-model)
Displacement Mongoose 300:
Approximately 292cc (actual specification may vary slightly by year and sub-model)
Cooling System:
Liquid-cooled
Performance
Horsepower 250Cc:
Estimated 17-20 HP (specific dyno figures vary)
Horsepower 300Cc:
Estimated 20-23 HP (specific dyno figures vary)
Torque 250Cc:
Estimated 15-18 lb-ft (specific figures vary)
Torque 300Cc:
Estimated 17-20 lb-ft (specific figures vary)
Fuel System
Carburetor Size 250Cc:
Typically a Mikuni BSR 32mm or similar (verify with manual for exact spec)
Carburetor Size 300Cc:
Typically a Mikuni BSR 34mm or similar (verify with manual for exact spec)
Fuel Type:
Unleaded gasoline (87 octane or higher recommended)
🔧 Transmission
Standard
Transmission Type:
Automatic Continuously Variable Transmission (CVT)
Drive Modes:
2WD (Rear Wheel Drive)
Features
Clutch Type:
Dry automatic clutch
Transmission Fluid Type:
Specific CVT fluid (e.g., recommended for wet clutch applications, check manual for exact type)
📐 Dimensions
Exterior
Overall Length:
Approx. 71-73 inches (varies by model year)
Overall Width:
Approx. 46-48 inches (varies by model year)
Overall Height:
Approx. 44-46 inches (varies by model year)
Weights
Dry Weight:
Approx. 450-500 lbs (varies by model year and configuration)
Ground Clearance:
Approx. 7-9 inches (varies by model year)
🛡️ Safety Features
Ratings
Safety Standards:
Conforms to ANSI/SVIA standards for recreational ATVs.
Active Features
Braking System:
Hydraulic disc brakes (front and rear), parking brake.
Throttle Limiter:
Adjustable throttle limiter for new riders (may be present on some models).
Passive Features
Lighting:
Headlights, taillight, brake light.
Handlebars:
ATV-specific handlebars with protective padding.
💡 Technology Features
Infotainment
Features:
Basic digital display for speed, odometer, trip meter, and possibly engine hour meter. No advanced infotainment systems.
Driver Assistance
Features:
Primarily mechanical features for rider control and safety; no electronic driver assistance systems like ABS or traction control.
Connectivity
Features:
No digital connectivity features.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 100 hours or 6 months, whichever comes first. Specific interval for break-in period is crucial.
Air Filter Cleaning:
Inspect and clean every 20-30 hours, replace as needed.
Spark Plug Replacement:
Check and clean every 100 hours, replace as per manual recommendation (e.g., 600 hours or annually).
Brake Fluid Flush:
Recommended every 1-2 years or as per manual instructions.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-40 motorcycle-specific oil is commonly recommended. Confirm with manual.
Engine Oil Capacity:
Approximately 1.5-1.7 Liters (check manual for exact capacity).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) is standard.
Known Issues
Common Wear Items:
CVT belt wear, carburetor jetting issues (especially with altitude changes), suspension bushings, and brake pad wear are common on ATVs of this era.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent faults.
📚 Vehicle History
Brand Heritage
Manufacturer:
KYMCO (Kwang Yang Motor Co., Ltd.) is a Taiwanese manufacturer known for scooters, motorcycles, and ATVs.
Model Evolution
Development:
The Mongoose series was KYMCO's offering in the popular 250cc to 300cc recreational ATV segment, competing with established Japanese brands.
Production
Production Period:
Manufactured and sold primarily from the late 1990s through the late 2000s.
🏆 Awards & Recognition
Recognitions
Industry Awards:
No specific widely publicized industry awards are noted for these models, but they were popular in their segment for value and capability.
Ratings
Consumer Reviews:
Generally reviewed as a solid, reliable, and capable entry-level to mid-range recreational ATV offering good value for the price.
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