Target Audience:
Owners, DIY mechanics, and professional technicians performing maintenance and repairs on Kymco Mongoose KXR50/KXR90 ATVs.
Value Proposition:
Provides comprehensive, in-depth technical information essential for maintaining and repairing the specified ATV models, saving time and money on service.
Competitor Manuals:
This manual offers a direct replacement for official Kymco service documentation, providing similar depth and accuracy.
Completeness:
Highly detailed, hundreds of pages covering all aspects of repair, maintenance, and rebuilding.
Accessibility:
PDF format ensures easy access and searchability across various devices.
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures for both KXR50 and KXR90 variants.
Fuel System:
Carburetor systems, fuel lines, fuel tank, fuel pump (if applicable), and associated components.
Ignition System:
Spark plug specifications, ignition coil testing, CDI unit, wiring diagrams, and troubleshooting.
Cooling System:
Air cooling system components, maintenance, and potential issues. (Note: Many small ATVs are air-cooled).
Exhaust System:
Exhaust pipe, muffler, heat shields, and gaskets. Diagnosis of leaks and performance issues.
Transmission Drive:
CVT (Continuously Variable Transmission) system, belt inspection and replacement, clutch assembly, and drive sprocket maintenance.
Chassis Frame:
Frame inspection, welding integrity, and component mounting points.
Suspension System:
Front and rear suspension components, shock absorber service, swingarm maintenance, and bushings.
Steering System:
Handlebar assembly, steering stem, tie rods, ball joints, and steering column service.
Braking System:
Front and rear brake systems (likely drum or disc brakes), brake shoe/pad replacement, caliper service, brake fluid flush, and adjustments.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system, and starter motor.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, and tire condition checks.
Bodywork Plastics:
Fairing removal and installation, seat maintenance, and plastic trim component servicing.
Routine Maintenance:
Oil change intervals, air filter cleaning/replacement, spark plug gap/replacement, drive belt inspection, and general lubrication.
Troubleshooting:
Systematic diagnostic procedures for common starting, running, braking, and electrical issues.
Component Rebuild:
Detailed instructions for rebuilding carburetors, brake calipers, and potentially the CVT clutch assembly.
Wiring Diagrams:
Comprehensive electrical schematics for accurate troubleshooting and component identification.
Torque Specifications:
Precise torque values for critical fasteners throughout the vehicle.
Adjustments:
Carburetor idle speed and mixture adjustments, brake lever free play, clutch engagement points.
Depth Level:
Comprehensive, covering everything from basic maintenance to major overhauls and diagnostics.
Diagnostic Procedures:
Detailed step-by-step diagnostic guides for identifying and resolving faults across all major systems.
Part Identification:
Illustrations and part numbers for easy identification of replacement components.
File Format:
PDF (Portable Document Format)
Searchable Text:
Likely searchable if digitally generated and not scanned as pure images, allowing for quick information retrieval.
Print Quality:
Assumed high quality suitable for printing, with clear diagrams and text.
Interactivity:
PDF format typically allows for bookmarking and navigation.
Binding Type:
Not applicable for PDF format (digital delivery).
Paper Type:
Not applicable for PDF format (digital delivery).
Engine Type:
4-stroke, Air-Cooled Single Cylinder
Kxr50 Displacement:
Approximately 49.5 cc (exact specification depends on model year and specific variant)
Kxr90 Displacement:
Approximately 89.6 cc (exact specification depends on model year and specific variant)
Bore Stroke Kxr50:
Specific bore and stroke figures would be detailed in the manual, e.g., 39mm x 41.4mm (typical for 50cc class).
Bore Stroke Kxr90:
Specific bore and stroke figures would be detailed in the manual, e.g., 47mm x 51.3mm (typical for 90cc class).
Compression Ratio:
Specifications would be included in the manual, typically in the range of 9.0:1 to 10.5:1.
Horsepower Kxr50:
Approximate figures are often around 3.0-3.5 HP. Precise output detailed in manual.
Horsepower Kxr90:
Approximate figures are often around 5.0-6.0 HP. Precise output detailed in manual.
Torque Kxr50:
Approximate figures are often around 2.5-3.0 Nm. Precise output detailed in manual.
Torque Kxr90:
Approximate figures are often around 5.0-6.0 Nm. Precise output detailed in manual.
Carburetor Type:
Likely a Keihin or similar Japanese brand CV-type carburetor, specific model number in manual.
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual).
Fuel Tank Capacity:
Typically around 3-5 liters. Exact capacity provided in manual.
Overall Length:
Approximate length would be in the 1400-1600mm range. Specific dimensions in manual.
Overall Width:
Approximate width would be in the 800-900mm range. Specific dimensions in manual.
Overall Height:
Approximate height would be in the 900-1000mm range. Specific dimensions in manual.
Dry Weight Kxr50:
Typically around 70-80 kg. Specific dry weight in manual.
Dry Weight Kxr90:
Typically around 75-85 kg. Specific dry weight in manual.
Curb Weight:
Curb weight including fluids would be provided in manual.
Ground Clearance:
Approximate ground clearance would be 100-150mm. Specific measurement in manual.
Safety Standards:
Manual will likely reference relevant ATV safety guidelines and standards.
Braking System Type:
Front and Rear Brakes (Specific type, e.g., drum or disc, will be detailed).
Throttle Limiter:
Many youth ATVs have adjustable throttle limiters; manual will cover this.
Lighting System:
Headlight, taillight, brake light functionality and maintenance.
Flag Mounting Point:
Manual may indicate recommended locations for safety flag mounting.
Engine Oil Change:
Typically every 1000-1500 km or 6 months. Specific interval in manual.
Air Filter Cleaning:
Frequent checks, cleaning every 50-100 hours of operation, replacement as needed. Specific intervals in manual.
Spark Plug Replacement:
Typically every 3000-5000 km or annually. Specific interval and gap in manual.
Brake Fluid Flush:
Recommended every 1-2 years. Manual will specify exact interval and fluid type.
Cv Belt Inspection:
Regular inspection for wear and damage, replacement interval based on mileage/usage. Detailed in manual.
Engine Oil Type:
Manual will specify SAE viscosity grade (e.g., 10W-40) and API service classification (e.g., SG or higher).
Engine Oil Capacity:
Specific oil capacity for KXR50 and KXR90 engines will be detailed in the manual.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, as specified by Kymco.
Common Wear Items:
CVT belt, brake pads/shoes, suspension bushings, and steering components are common wear items on ATVs.
Carburetor Cleaning:
Carburetors can become gummed up if the ATV is stored with fuel in it; manual will provide cleaning procedures.
