KYMCO Mongoose 90 Owner's Manual
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KYMCO Mongoose 90 Owner's Manual

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Mongoose 90 / Mongoose 90 R
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  • Page 1 Mongoose 90 / Mongoose 90 R off road Owner’s Manual...
  • Page 2 IMPORTANT NOTICES READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle. It is especially important that parents make sure their children fully understand and follow the information and procedures contained in the manual.
  • Page 3 NOTE TO PARENTS Parents should read the "Important Message to Parents" beginning on page 4 and the "Parents &Beginning riders" booklet received with the ATV and then decide whether their youngster is ready to ride. "Parents, Youngsters and ATVs" focuses on the beginning rider, and discusses how to evaluate your youngster's readiness to ride as well as showing you how to introduce your youngster to ATV riding.
  • Page 4 SPECIAL MESSAGES KYMCO provides many important safety messages both in this manual and on the vehicle. For your safety and the safety of others, pay special attention to all warnings preceded by this alert symbol . Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.
  • Page 5 PREFACE Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service. For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.

  • Page 6: Table Of Contents

    CONTENTS Page Page LOCATION OF THE WARNING AND CONTROL FUNCTIONS......20 SPECIFICATION LABELS......1 Ignition switch........20 Handlebar switches........21 SAFETY INFORMATION......4 Engine stop switch.......21 IMPORTANT MESSAGE TO PARENTS..4 Headlight switch........22 Stater button........22 Evaluate Riding Readiness ....4 Kick starter ..........23 Always Supervise Young Riders....7 Remote engine stop switch.
  • Page 7 Page Page PRE-OPERATION CHECKS......34 Riding Your ATV........49 Front and rear brakes......35 GETTING TO KNOW YOUR ATV....50 Fuel .............36 BEFORE RIDING ......50 Engine oil and Transmission oil ....38 RIDER PREPARATION .....50 Chain ...........39 RIDE WITH CARE AND GOOD Throttle lever.........39 JUDGEMENT.........51 Fittings and fasteners......39 Pre-operation checks ......52...
  • Page 8 Page Page SLIDING AND SKIDDING......75 Idle speed adjustment......107 Throttle lever adjustment......108 CLIMBING UPHILL.........77 Front brake shoe inspection....109 RIDING DOWNHILL .......83 Rear brake pads inspection....109 CROSSING A SLOPE ......85 Front brake lever free play adjustment..110 RIDING OVER ROUGH TERRAIN ...87 Brake fluid inspection......112 CROSSING THROUGH SHALLOW Drive chain slack check......114...
  • Page 9 Page CLEANING AND STORAGE.....126 A. Cleaning .........126 B. Storage ...........128 SPECIFICATIONS........130 NOISE REGULATION......134 MAINTENANCE RECORD.......135 INDEX...........136 Mongoose 90 Reverse version....142...

  • Page 10: Location Of The Warning And Specification Labels

    LOCATION OF THE WARNING AND SPECIFICATION LABELS DECAL OF EPA CERTIFICATE LABEL OF SVIA For US For Canada...
  • Page 11 The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements HANG TAG_GENERAL USE Reverse side...

  • Page 13: Safety Information

    SAFETY INFORMATION IMPORTANT MESSAGE TO PARENTS Your child's safety is very important to KYMCO. That's why we urge you to read this message before you let any young person ride this ATV. Off-road riding can be fun. However, an ATV is not a toy and it can be hazardous to operate. As with any...
  • Page 14 Physical size and ability are important considerations. To help determine whether a youngster is big enough for this ATV, have them stand up on the footboards and grasp the handgrips. While the youngster holds this position, check that they have at least three inches (8cm) of clearance between the ATV seat and the youngster's "seat of the pants".
  • Page 15 Athletic ability is another requirement for riding a ATV. Generally speaking, your youngster should be good at riding a bicycle before they get on an ATV. Can your youngster judge speeds and distances while riding a bicycle and react with proper hand and foot actions? Anyone who does not have good coordination, balance, and agility is not ready for this ATV.

  • Page 16: Always Supervise Young Riders

    Patience And Practice Even if a youngster takes a certified training course, it's up to you to ensure your youngster's safety. Remember, learning to ride a ATV is a gradual step-by-step process. It takes time, patience and practice. To help you regulate your youngster's rate of learning, your ATV was delivered with adjustable throttle limite .
  • Page 17 In Summay Children differ in skills, physical abilities, and judgement. Some children may not be able to operate an ATV safely. Parents should supervise their child's use of the ATV at all times. Parents should permit continued use only if they determine that the child has the ability to operate the ATV safely.

  • Page 18: Special Safety Messages

    SPECIAL SAFETY MESSAGES AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre- cautions.
  • Page 19 Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even a dirt or gravel one. Never operate an ATV without wearing an approved motorcycle helmet that fits porperly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
  • Page 20 Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain. Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 21 Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill.
  • Page 22 WARNING WHAT CAN HAPPEN Gasoline is poisonous and can cause injuries. POTENTIAL HAZARD HOW TO AVOID THE HAZARD Improper handling of gasoline. If you should swallow some gasoline or inhale WHAT CAN HAPPEN a lot of gasoline vapor, or get some gasoline in Gasoline can catch fire and you could be your eyes, see your doctor immediately.
  • Page 23 WARNING POTENTIAL HAZARD Starting or running the engine in a closed area. WHAT CAN HAPPEN Exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. HOW TO AVOID THE HAZARD Always operate your machine in an area with adequate ventilation.

  • Page 24: Description And Machine Identification

    DESCRIPTION AND MACHINE IDENTIFICATION Identification number records Key identification number Record the key identification number, frame The key identification number is stamped on serial number, engine serial number and the hang tag as shown in the following model code information for assistance when illustration.

  • Page 25: Frame And Engine Serial Number

    Frame and engine serial number Model code The frame serial number is stamped on the MODEL CODE: LA20AB front of the frame. The engine serial number is stamped on the left crankcase. (1) Frame serial number (1) Engine serial number...

  • Page 26: Parts Location

    Parts location (05) (04) (03) (02) (01) (1) Handlebar switch (2) Ignition switch (3) Speed limiter (4) Throttle lever (5) Seat...
  • Page 27 (08) (07) (06) (06) Remote engine stop switch (07) Storage compartment, containing Owner's manual Air pressure gauge Tool kit (08) Exhaust pipe (09) Taillight/Stop light (10) Rear wheel (11) Seat lock lever (12) Oil filler cap/dipstick (13) Front wheel (09) (10) (11) (12)
  • Page 28 (17) (16) (15) (14) (14) Flat pole bracket (15) Right footboard (16) Front brake lever (17) Parking brake (18) Rear brake lever (19) Fuel fill cap (20) Left footboard NOTE: The machine you have purchased may differ (18) (19) (20) slightly from those shown in the figures of this manual.

  • Page 29: Control Functions

    CONTROL FUNCTIONS Ignition switch Functions of the respective switch positions are as follows: OFF: All electrical circuits are switched off. The key can be removed in this position. ON ( The taillight can be turned on. With the engine stop switch at run ( ), the engine can be started.

  • Page 30: Handlebar Switches

    If you stop your ATV by turning the engine stop (1) Engine stop switch " " switch OFF ( ), be sure to turn the ignition " " switch OFF to prevent battery discharge. (2) Headlight switch (for genuine KYMCO accessories) (3) Start switch " "...

  • Page 31: Headlight Switch

    To starter the engine, press the starter button, you add the headlight equipment (using genuine with the ignition switch ON ( ) and the engine KYMCO accessories). stop switch at RUN ( Turning the switch to the " " position to CAUTION: switch off the headlight.

  • Page 32: Kick Starter

    Kick starter The kick starter cranks the engine when the kick starter is operated. CAUTION: See starting instructions prior to starting engine (see page 43 for details). NOTE: If the kick starter is operated with the ignition ． switch at " " and the engine stop switch " ", the engine will not start.

  • Page 33: Remote Engine Stop Switch

    Remote engine stop switch The ATV has a remote engine stop switch. This allows the supervisor to follow close behind and stop the engine by pulling a tethered core. Practice using it when your youngster first starts riding. NOTE: Make sure the tethered road lead is installed into the remote engine stop switch.

  • Page 34: Throttle Lever

    Check the operation of the throttle lever before you start the engine. If it does not work smoothly, check for the cause. Correct the problem before riding the ATV. Consult a KYMCO dealer if you can't find or solve the problem yourself. (1) Throttle lever...

  • Page 35: Speed Limiter

    Speed limiter The speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Screwing in the adjuster limits the maximum engine power available and decreases the maximum speed of the ATV. WARNING POTENTIAL HAZARD Improper adjustment of the speed limiter (1) Adjuster...

  • Page 36: Front Brake

    Front brake Rear brake The front brakes are operated by squeezing the The rear brakes are operated by squeezing the front brake lever. rear brake lever. (1) Front brake lever (1) Rear brake lever...

  • Page 37: Parking Brake

    Parking brake To set the parking brake, squeeze the front brake lever and lock it with the lock pin. Always set the parking brake when parking and before starting the engine. To unlock the parking brake, squeeze the front brake lever until the lock pin releases. Using the parking brake in freezing weather may cause the brakes to freeze in the locked position.

  • Page 38: Fuel Tank Cap

    Fuel tank cap WARNING After refueling, be sure to tighten the fuel tank POTENTIAL HAZARD cap. Improper use of the parking brake. TO refuel refer to page 36~37. WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine.

  • Page 39: Fuel Valve

    Fuel valve The fuel valve supplies fuel from the fuel tank to the carburetor. The fuel valve has three positions. OFF: With the lever and " " mark in this position fuel will not flow. Always turn the lever to this position when the engine is not running.

  • Page 40: Start (Choke)

    Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction (A) to turn on the starter (choke). Move in direction (B) to turn off the starter (choke). Refer to "starting a cold engine" for proper operation.

  • Page 41: Seat

    To install the seat, align the tabs on the seat with Seat the grommets on the frame and press the seat To remove the seat, pull upward the seat lock down until it locks. lever and pull up the seat at the rear. NOTE: Make sure that the seat is securely fitted.

  • Page 42: Flag Pole Bracket

    Flag pole bracket Storage compartment To mount a flag pole in the bracket. The storage compartment is located under the seat. To remove the seat, see page 32. NOTE: Be careful not to flood this area when washing Flag poles are required in some riding areas. Check local regulations before riding.

  • Page 43: Pre-Operation Checks

    PRE-OPERATION CHECKS Before using this machine, check the following points: ROUTINE PAGE ITEM Check operation, condition, free play (drum brake) and brake fluid level (disk brake). ～ ～ 35 36, 109 113 Brake Adjust (drum brake) if necessary. Fill with DOT 4 brake fluid (disk brake) if necessary.

  • Page 44: Front And Rear Brakes

    WHAT CAN HAPPEN feeling when the brake is applied. If not, have Increases the possibillty of an accident or the machine inspected by a KYMCO dealer. equipment damage. Disk brake HOW TO AVOID THE HAZARD Make sure there is no brake fluid leakage.

  • Page 45: Fuel

    Do not ride the ATV if you find any problem with the brakes. If a problem cannot be corrected by the adjustment procedures provided in this manual, have the ATV inspected by a KYMCO dealer. (1) Filler neck Recommended fuel: UNLEADED FUEL Fuel tank capacity: Total: 5.5L(1.16 lmp gal, 1.4 US gal)
  • Page 46 Your KYMCO engine has been designed to use WARNING regular unleaded gasoline with a pump octane POTENTIAL HAZARD number of 86 or higher, or research octane Improper care when refueling. number of 91 or higher. If knocking or pinging occurs, use a different brand of gasoline or WHAT CAN HAPPEN premium unleaded fuel.

  • Page 47: Engine Oil And Transmission Oil

    Engine and transmission oil CAUTION: Make sure the engine and transmission oil at the Be sure to use motor oils that do not specified level. Add oil as necessary. (See page contain anti-friction modifiers. Passenger 96~102.) car motor oils (often labeled "Energy Check for leaks.

  • Page 48: Chain

    Repair as necessary for proper operation. necessary for proper operation. Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the machine to a KYMCO dealer or refer to the Service Manual for correct tightening torque.

  • Page 49: Tires

    2.The tires should be set to the Tires recommended pressure: WARNING Recommended tire pressure POTENTIAL HAZARD Front: 25 kpa (0.25 kgf/cm , 3.6 psi) Operating this ATV with improper tires, or Rear: 25 kpa (0.25 kgf/cm , 3.6 psi) with improper or uneven tire pressure. Check and adjust tire pressures when the tires are cold.

  • Page 50: How To Measure Tire Pressure

    Set pressure tires cold. 4.Never set tire pressure over the Set tire pressures to the following recommended Front: 28 kpa (0.28 kgf/cm , 40 psi) Recommended Rear: 28 kpa (0.28 kgf/cm , 40 psi) Minimum Maximum pressure Higher pressures may cause the tire to 25 kpa 22 kpa 28 kpa...

  • Page 51: Tire Wear Limit

    Tire wear limit When the tire groove decreases to 4 mm (0.16 in) due to wear, replace the tire. A. 4mm (0.16 in)

  • Page 52: Operation

    KYMCO dealer. 1. Select a level surface and lock the parking brake (see page 28) before starting the engine.
  • Page 53 6.With the throttle closed, push the starter 5. Use the starter (choke) in reference to the button. Release the starter button as soon as figure: the engine starts. Position :Cold engine start-ambient temperature below 5C (40F). NOTE: Position :Cold engine start-ambient Do not use the electric starter for more than 5 temperature at 0C (30F)~30C(90F) seconds at a time.

  • Page 54: Starting A Warm Engine

    Warming up To start the engine without the electric starter. To get maximum engine life, always warm up the 1. Follow steps 1 through 5. engine before starting off. Never accelerate 2. With the throttle closed, operate the kick hard with a cold engine! To see whether or not starter with a rapid, continuous motion.

  • Page 55: Parking

    If any abnormality is noticed during this period, consult a KYMCO dealer. 1. 0~10 hours: Avoid continuous operation above half throttle. Allow a cooling off period of five to ten minutes after every hour of operation.

  • Page 56: Parking On A Slope

    Parking on a slope 1. Bring the machine to a stop by applying the brakes. WARNING 2. Stop the engine. POTENTIAL HAZARD 3. With the rear brake applied, apply the parking brake. Parking on a hill or other incline. WHAT CAN HAPPEN The ATV could roll out of control, increasing the chance of an accident.

  • Page 57: Accessories

    Choose only accessories designed for your difficult, an accessory that limits your ability to ATV. Your KYMCO dealer has a variety of move around on the seat, or one that limits genuine KYMCO accessories. Other your view.

  • Page 58: Riding Your Atv

    Riding Your ATV...

  • Page 59: Getting To Know Your Atv

    GETTING TO KNOW YOUR ATV BEFORE RIDING This ATV is for recreation use. This section, Before allowing your youngster to ride the ATV, riding your ATV, provides general ATV riding read "Important Message To Parents" instructions for recreational riding. The skills (beginning on page 4) carefully and decide and techniques described in this section, whether your youngster is ready to ride.

  • Page 60: Ride With Care And Good Judgement

    RIDE WITH CARE AND GOOD JUDGEMENT WHAT CAN HAPPEN If children use ATVs that are not recommended for their age, severe injury or Get training if you are inexperienced. death can result. Beginners should get training from a certified Even though a child may be within the age instructor.

  • Page 61: Pre-Operation Checks

    Pre-operation checks HOW TO AVOID THE HAZARD Always perform the pro-operation checks listed Become familiar with this ATV at slow on page 34 before riding for safety and proper speeds first, even if you are an experienced care of the machine. operator.

  • Page 62: Wight Limits

    Weight Limits This ATV is not designed to carry cargo or tow a WARNING trailer. Do not add a cargo rack or a trailer hitch. POTENTIAL HAZARD There are limits to how much weight can be Operating this ATV with improper tires, or carried on your ATV.

  • Page 63: Accessories

    WARNING Genuine KYMCO accessories have been specifically designed for and tested on this POTENTIAL HAZARD vehicle. Because KYMCO cannot test all other Overloading this ATV or carrying or towing accessories, you are personally responsible for cargo. properly selecting, installing, and using non- KYMCO accessories.

  • Page 64: No Modifications

    Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instruction. If you have question, consult...

  • Page 65: Safe Riding Rules

    SAFE RIDING RULES WHAT CAN HAPPEN Please note that the safe Riding Rules apply to Operating without an approved motorcycle all ATV riders. helmet increases your chances of a severe Even if you are an experienced rider, or after you head injury or death in the event of an become one continue to follow these guidelines accident.
  • Page 66 Do not operate after consuming alcohol or WARNING drugs. POTENTIAL HAZARD Operator's performance capability is reduced by Operating this ATV after consuming the influence of alcohol or drugs. alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception.
  • Page 67 This machine is designed to carry operator only-passengers prohibited. WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger.

  • Page 68: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This machine is designed for off-road use only. Riding on paved surfaces can cause loss of control. WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces. WHAT CAN HAPPEN ATV are designed for off-road use only. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control.
  • Page 69 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one.

  • Page 70: For Off-Road Use Only

    FOR OFF-ROAD USE ONLY Ride Only When Visibility Is Good Your ATV is not equipped with headlight. It is This vehicle is designed and manufactured for intended to be used only during the daytime. off-road use only. You should ride only when visibility is good. Plan to stop riding well before it gets sark.

  • Page 71: During Operation

    During operation WARNING Always keep your feet on the footboards during POTENTIAL HAZARD operation. Otherwise your feet may contact the Removing hands from handlebars or feet rear wheels. from footboards during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall a footboard, your foot or leg may come...
  • Page 72 Do not operate at speeds too fast your skills Speed limiter or the conditions. For riders inexperienced with this model, this model is equipped with a speed limiter in the WARNING throttle lever housing. The speed limiter limits the power and top speed of the machine. POTENTIAL HAZARD Turning the screw in decreases top speed, and Operating this ATV at speeds too fast for...
  • Page 73 Avoid wheelies and jumping. You may lose control of the machine or overturn. WARNING POTENTIAL HAZARD Attempting wheelies, jumps, and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps.
  • Page 74 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the machine to upset. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 75 WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary...
  • Page 76 When riding in an area where you might not WHAT CAN HAPPEN easily be seen, such as desert terrain, mount a You could be in a collision. You could be caution flag on the machine. DO NOT use the injured. flag pole bracket as a trailer hitch.

  • Page 77: Exhaust System

    Exhaust system The exhaust on the machine is very hot during and following operation. To prevent burns, avoid touching the exhaust system. Park the machine in a place where pedestrians or children are not likely to touch it. WARNING POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system...

  • Page 78: Riding

    RIDING Practice with the remote engine stop switch and For your initial riding practice, select a safe area throttle limiter adjusted as delivered until you free of obstacles with a level surface of dirt or are confident in braking and making turns. sand.
  • Page 79 Pull the tether after the ATV is moving. The ATV Speed limiter for new riders may continue to roll for some distance. Watch Your ATV has an adjustable throttle limiter. the distance until the ATV stops. Be aware that The screw and locknut in the lower throttle this distance must be included in the stopping housing can be adjusted to limit throttle lever space of the ATV and that this distance may...

  • Page 80: Braking

    BRAKING To adjust the throttle limiter: Practice starting and stopping at slow speeds. 1. Loosen the lock nut. Gradually work up to faster starts and stops. 2. Turn the throttle limiter screw clockwise to 1. Steer straight ahead. Close the throttle reduce throttle lever movement or completely, remove your thumb from the counterclockwise to increase throttle lever...
  • Page 81 Gradually increase the lever pressure as you When possible, reduce speed or brake before feel the brakes slowing your speed. The entering a turn. Closing the throttle or braking in pressure used depends on your speed and the mid-turn may cause wheel slippage which will condition of the terrain you are riding.

  • Page 82: Turning Your Atv

    TURNING YOUR ATV HOW TO AVOID THE HAZARD To achieve maximum traction while riding off- Always follow proper procedures for road, the two rear wheels are mounted solidly turning as described in this Owner's on one axle and turn together at the same Manual.
  • Page 83 Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves. Improper riding procedures such as abrupt throttle changes, or too much speed for the sharpness of the turn may cause the ATV to tip. If may also be necessary to the outside of the turn to avoid tipping over.

  • Page 84: Sliding And Skidding

    SLIDING AND SKIDDING If the rear wheels of your ATV start to slide sideways, control can usually be regained (if Care should be used when riding on loose or there is room to do so) by steering in the slippery surfaces since the ATV may slide. If direction of the slide.
  • Page 85 With practice, over a period of time, skill at WARNING controlled sliding can be developed. The terrain POTENTIAL HAZARD should be chosen carefully before attempting Skidding or sliding improperly. such maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should always be avoided on WHAT CAN HAPPEN extremely slippery surfaces such as ice, since...

  • Page 86: Climbing Uphill

    CLIMBING UPHILL WARNING Use proper riding techniques to avoid vehicle POTENTIAL HAZARD overturns on hills. Be sure that you can Operating on excessively steep hills. maneuver your ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
  • Page 87 An obstacle, a sharp drop, or another WARNING vehicle or person could be on the other POTENTIAL HAZARD side of the hill. Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause the ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Owner's Manual.
  • Page 88 If you are climbing a hill and you find that you When crossing the side of a hill: have not properly judged your ability to make it Always follow proper procedures as to the top, you should turn the ATV around while described in the Owner's Manual.
  • Page 89 If your ATV has stalled or stopped and you WARNING believe you can continue up the hill, restart POTENTIAL HAZARD carefully to make sure you do not lift the front Stalling, rolling backwards or improperly wheels which could cause you to lose control. If dismounting while climbing a hill.
  • Page 90 When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual.
  • Page 91 If the hill is not too steep and you have good footing, you may be able to walk the ATV back down the hill. Make sure your intended path is clear in case you lose control of the ATV . If you decide you can walk the ATV safely: 1.

  • Page 92: Riding Downhill

    RIDING DOWNHILL WARNING When riding your ATV downhill, shift your weight POTENTIAL HAZARD as far to the rear and uphill side of the ATV as Going down a hill improperly. possible. Move back on the seat and sit with your arms straight. Improper braking may cause WHAT CAN HAPPEN a loss of traction.

  • Page 94: Crossing A Slope

    CROSSING A SLOPE WARNING Traversing a sloping surface on your ATV POTENTIAL HAZARD requires you to properly position your weight to Improperly crossing hills or turning on maintain proper balance. Be sure that you have hills. learned the basic riding skills on flat ground before attempting to cross a sloping surface.
  • Page 95 Shift your weight to the uphill side of the ATV.

  • Page 96: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN WARNING Riding over rough terrain should be done with POTENTIAL HAZARD caution. Look out for obstacles which could Improperly operating over obstacles. cause damage to the ATV or could lead to an upset or accident. Be sure to keep your feet WHAT CAN HAPPEN firmly mounted on the footboards at all time.

  • Page 97: Crossing Through Shallow Water

    CROSSING THROUGH SHALLOW WATER Remember that wet brakes may have The ATV can be used to cross slow moving, reduced stopping ability. Test your brakes shallow water of up to a maximum of 20 cm (7.9 after leaving water. If necessary, apply inches) in depth.

  • Page 98: Parking

    Test your brakes after leaving the water. Do not PARKING continue to ride your ATV without verifying that you have regained proper braking ability. Always choose a level place to park. After bringing your ATV to a stop, hold the brakes while you shift into neutral.

  • Page 99: What To Do If

    WHAT TO DO IF If your ATV starts to slide sideways: This section is designed to be a reference guide Steer in the direction of the slide if you have the only. Be sure to read each section on riding room.
  • Page 100 If your ATV is traversing a sloping surface: Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain proper balance. If the ATV starts to tip, steer down the hill (if there are no obstacles in your way) to regain balance.

  • Page 101: Periodic Maintenance And Adjustment

    Have KYMCO dealer perform service if you PERIODIC MAINTENANCE AND are not familiar with machine service. ADJUSTMENT Periodic inspection, adjustment and lubrication Tool kit will keep your machine in the safest and most A tool kit is provide with your ATV.
  • Page 102 The tools in the kit are sufficient to perform WARNING routine maintenance and simple repairs. Any POTENTIAL HAZARD extensive work requiring additional tools should be performed by your authorized KYMCO Operating this ATV with improper dealer. modifications. The tool kit includes the following items:...

  • Page 103: Periodic Maintenance/Lubrication

    PERIODIC MAINTENANCE/LUBRICATION INITIAL EVERY ITEM ROUTINE year month months months months Replace (Warm engine before draining). Engine oil Clean. Oil strainer* Replace if necessary. Check oil level/oil leakage. Transmission oil Replace every 12 months. Check operation. V-belt* Replace if damage or excessive wear. Air filter element Clean.
  • Page 104 Lubricate every 6 months. Steering shaft* Check all chassis fittings and fasteners. Fittings and Fasteners* Correct if necessary. Spark arresterl Clean : It is recommended that these items be serviced by a KYMCO dealer. ** : Lithium soap base grease.

  • Page 105: Engine Oil

    Engine oil E. Remove the dipstick and inspect the oil level. 1.Engine oil level measurement F. The oil level should be between the maximum A. Place the machine on a level place. and minimum marks. If the level is low, add oil B.
  • Page 106 2-1. Engine oil replacement and oil filter CAUTION: cleaning ．Be sure no foreign material enters the A. Place the machine on a level place. crankcase. B. Warm up the engine for several minutes and stop it. ．When removing the drain plug, the C.
  • Page 107 H. Fill the engine with oil and install the oil filler 2-2. Engine oil replacement cap. A. Place the machine on a level place. B. Warm up the engine for several minutes Recommended oil: see page 131. and stop it. Oil quantity: C.
  • Page 108 Tightening torque: Drain plug (engine): 30 Nm (3.0 m-kg, 21.6 ft-lb) CAUTION: Be sure no foreign material enters the crankcase. Recommended oil: see page 131. Oil quantity: see page 131. (1) Drain plug E. Reinstall the drain plug and tighten the drain plug to specification.

  • Page 109: Transmission Oil

    Transmission oil 1. Transmission oil measurement A. Place the machine on a level place. B. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level.
  • Page 110 2. Transmission oil replacement A. Place the machine on a level place. B. Place a container under the engine. C. Remove the oil filler bolt and drain plug to drain the oil. D. Reinstall the drain plug and tighten to Specification.
  • Page 111 E. Fill the engine with oil and install the oil filler F. Start the engine and warm up for a few bolt. minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. Recommended oil : See page 131 Oil quantity: Periodic oil change:...

  • Page 112: Spark Plug Inspection

    Do not attempt to diagnose such problems yourself. Instead, take the machine to a KYMCO dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

  • Page 113: Air Filter Cleaning

    Air filter cleaning The air cleaner accumulates dust and must be cleaned periodically. If the ATV is ridden in dusty areas, the air cleaner must be cleaned at more frequent intervals than specified in the Maintenance Schedule. If the ATV is submerged in water, the air cleaner should be checked and water should be drained from the air cleaner housing before starting the...
  • Page 114 3. Remove the air filter element, and separate it WARNING from the box. POTENTIAL HAZARD Using low flash point solvents or gasoline to clean the air filter element. WHAT CAN HAPPEN Low flash point solvents or gasoline can catch fire or explode. HOW TO AVOID THE HAZARD Use parts cleaning solvent to clean the air filter element.

  • Page 115: Valve Clearance Adjustment

    To prevent this, the valve clearance must be adjusted regularly. This adjustment however, NOTE: should be left to a professional KYMCO service The element should be wet but not dripping. technician. 8. Reinstall the element to the air filter case 9.

  • Page 116: Idle Speed Adjustment

    Idle speed adjustment NOTE: A diagnostic tachometer must be used for this procedure. 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle.

  • Page 117: Throttle Lever Adjustment

    Throttle lever adjustment NOTE: Adjust the engine idling speed before adjusting the throttle lever free play. To adjust throttle free play: 1. Slide the rubber sleeves back to expose the throttle cable adjuster. 2. Loosen the lock nut, then turn the adjuster to obtain the correct free play.

  • Page 118: Front Brake Shoe Inspection

    Check the position of the indicator. If the replace the shoes as a set. These procedures indicator reaches the wear limit line, ask a should be performed by KYMCO dealer. KYMCO dealer to replace the pads. (1) Lining (A) Lining thickness...

  • Page 119: Front Brake Lever Free Play Adjustment

    Front brake lever free play adjustment The front brake lever free play should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. If the free play is incorrect, adjust as follows: (1) Upper locknut (2) Upper adjusting bolt (3) Lower locknut (4) Lower adjusting bolt 2.
  • Page 120 Make sure the brakes do not drag. Replacement of brake components requires (1) Cable joint ( A) Cable length professional knowledge. These procedures should be performed by KYMCO dealer. 6. Tighten the upper locknut.

  • Page 121: Brake Fluid Inspection

    Brake fluid inspection Check if the fluid level is below the lower level mark through the inspection window. WARNING POTENTIAL HAZARD Brake fluid contacting the skink or eyes. WHAT CAN HAPPEN May cause irritation. (1) Lower level mark (Hand Brake lever) HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes.
  • Page 122 (page 109), There is prevent accidental spilling. probably air in the brake system and it must Use only DOT 4 brake fluid from a sealed be bled. See your authorized KYMCO dealer container. for this service.

  • Page 123: Drive Chain Slack Check

    Drive chain slack check Drive chain slack adjustment Inspect the drive chain while all tires are 1.Loosen the upper and lower axle holding touching the ground. Check the slack at the bolts. position shown in the figure. The normal vertical deflection is approximately 10~20 mm (0.4~0.8in).
  • Page 124 2.Turn the adjusting nut, to decrease or increase 3.Retighten the upper and lower axle holding chain slack. bolts. Tightening torque: Axle holding bolts (upper): 70 Nm (7.0 m-kg, 48 ft-lb) (1) Adjust nut CAUTION: Too little of chain slack will overload the engine and other important parts.

  • Page 125: Drive Chain Cleaning And Lubrication

    Inspect cables frequently. Replace damaged cables. Lubricate the inner cables and the cable ends. If the cables do not operate smoothly, ask a KYMCO dealer to replace them. Recommended lubricant: 1. O-rings KYMCO chain and cable lube or SAE 10W40 motor oil...

  • Page 126: Brake Lever Lubrication

    Be sure to drive slowly until the (All-purpose grease) V-belt becomes dry. If slipping is noticed, ask a KYMCO dealer to inspect. Knuckle shaft and rear fork shaft lubrication Lubricate the pivot points using a grease gun.

  • Page 127: Wheel Removal

    Wheel removal 1. Elevate the wheel by placing a suitable stand under the frame. Wheel nut torque: 2. Remove the nuts from the wheel. Front: 40 Nm (4.0 m-kg, 30 ft-lb) 3. Remove the wheel assembly. Rear: 40 Nm (4.0 m-kg, 30 ft-lb) (1) Safe nut Wheel installation When installing the wheel, reverse the removal...

  • Page 128: Battery

    If battery. the battery seems weak, see your authorized KYMCO dealer for information on recharging or WHAT CAN HAPPEN Gases may explode and possibly cause replacement. If you replace the battery, choose one injury.
  • Page 129 Battery remove Battery installation 1. Make sure the ignition switch is OFF. 1. Install in the reverse order of removal. 2. Remove the seat (page 32) 2. Check all bolts and other fasteners are secure. 3. Remove the battery cover, by removing the mount 3.

  • Page 130: Fuse Replacement

    When frequent fuse failure occurs, it usually under the seat. indicates a short circuit or an overload in the The specified fuses are: 7A electrical system. See your authorized KYMCO dealer for repair. CAUTION: To prevent accidental short-circuiting, turn off the ignition switch before checking or replacing a fuse.
  • Page 131 1. Lift the seat. (See page 32) 3. Slide the old fuse out of the clips and discard 2. Open the fuse holders and lift out the fuse with the clips. (1) Fuse holder (2) Clip...

  • Page 132: Spark Arrester Cleaning

    Spark arrester cleaning (see page 139~140) 4. Slide the clips onto the ends of the new fuse, push them back into the fuse holder, and close the fuse holder. The spare fuse is on the battery cover. (1) Fuse holder (2) Clip CAUTION: ．...

  • Page 133: Troubleshooting

    The troubleshooting chart describes a WHAT CAN HAPPEN quick, easy procedure for making checks. If your Fuel can ignite or explode, causing severe machine requires any repair, take it to a KYMCO dealer. injury or property damage. HOW TO AVOID THE HAZARD...

  • Page 134: Troubleshooting Chart

    Check fluid, recharge, check connections. over slowly. Use electric starter. Engine turns Battery good. over quickly. Ask a KYMCO dealer to inspect. 3. Ignition Wipe clean with dry Adjust plug gap or cloth. Remove plug and No spark. replace plug.

  • Page 135: Cleaning And Storage

    CLEANING AND STORAGE CAUTION: Excessive water pressure may cause water A. CLEANING seepage and deterioration of wheel Frequent, thorough cleaning of your machine bearings, brakes, transmission seals and will not only enhance its appearance but will electrical devices. Many expensive repair improve its general performance and extend the bills have resulted from improper high useful life of many components.
  • Page 136 7. Clean the seat with a vinyl upholstery WARNING cleaner to keep the cover pliable and POTENTIAL HAZARD glossy. Operation with wet brakes after washing. 8. Automotive type wax may be applied to all painted and chrome plated surfaces. Avoid WHAT CAN HAPPEN combination cleaner-waxes.

  • Page 137: Storage

    B. STORAGE WARNING Before storing your ATV for an extended time, be POTENTIAL HAZARD sure you thoroughly check the vehicle for Refueling this ATV or handling fuel needed repairs and have them corrected. improperly. Otherwise, the repairs may be forgotten by the time you remove the vehicle from storage.
  • Page 138 4. Remove the battery (page 120) And store it in WARNING an area protected from freezing temperatures POTENTIAL HAZARD and direct sunlight and out of the reach of Prolonged contact of fuel with the skin. children, slow charge the battery once a Breathing fuel vapor.

  • Page 139: Specifications

    SPECIFICATIONS Mongoose 90 Model Dimension: Overall length 1430 mm (56.2 in) Overall width 905 mm (35.6 in) Overall height 910 mm (35.8 in) Seat height 650 mm (25.5 in) Wheel base 965 mm (37.9 in) Minimum ground clearance 104 mm (4.1 in)
  • Page 140 Model Mongoose 90 110 F Engine oil/transmission oil: Type SAE 5W － SAE 10W 30 Recommended engine oil classification: － SAE 10W 40 － SAE 20W 40 － SAE 20W 50 -1 0 40 C API Service SE, SF, SG type or higher...
  • Page 141 Mongoose 90 Model Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED FUEL Tank capacity 5.5 L (1.16 lmp gal, 1.40 US gal) Reserve amount 1.5 L (0.32 lmp gal, 0.38 US gal)
  • Page 142 Mongoose 90 Model Suspension: Front Swing axle Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Battery type 12V, 4AH Tire: Type Tubeless Size: Front 18X7-8 Rear 18X9-8...

  • Page 143: Noise Regulation

    NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 144: Maintenance Record

    MAINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.

  • Page 145: Index

    INDEX Page Page Accessories........48, 54 Draining the V-belt compartment....117 AGE RECOMMENDATION......A Drive chain cleaning and lubrication ..116 Air filter cleaning ........104 Drive chain slack adjustment....114 Drive chain slack check ......114 During operation........62 Brake fluid inspection......112 Brake lever lubrication......117 Engine break-in........45 Battery...........119 Engine and transmission oil ....
  • Page 146 Page Page Idle speed adjustment ......107 Fittings and fasteners....... 39 Ignition switch..........20 Flag pole bracket........33 IMPORTANT NOTICES......A Frame and engine serial number ....16 Front brake ..........27 Front brake lever free play adjustment ..110 Front brake shoe inspection......109 Key identification number ......
  • Page 147 Page Page No Modifications........55 Rear brake..........27 Rear brake pads inspection......109 Remote engine stop switch .......24 RIDING DOWNHILL........83 OPERATION ........... 43 RIDING OVER ROUGH TERRAIN ..... 87 Riding Your ATV........49 PARKING .......... 46, 89 Parking brake...........28 SAFETY INFORMATION......4 Parking on a slope ........47 Seat ............
  • Page 148 Page Throttle lever........25, 39 Throttle lever adjustment......108 Tires............40 Tire wear limit.......... 42 Tool kit.............92 Transmission oil ........100 Troubleshooting ........124 Troubleshooting chart ......125 TURNING YOUR ATV........73 Valve clearance adjustment..... 106 Warning information ........2 Wheel installation........118 Wheel removal........118 Weight limits ...........53...
  • Page 149 Spark arrester cleaning 2. Remove the tailpipe by pulling it out of the muffler. Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 3. Tap the tailpipe lightly, then use a wire brush to remove any carbon deposits from the spark 1.
  • Page 150 WARNING POTENTIAL HAZARD Improper cleaning of the spark arrester. WHAT CAN HAPPEN Could injure the eyes. Could cause burns. Could cause carbon monoxide poisoning, possibly leading to death. Could start a fire. HOW TO AVOID THE HAZARD When cleaning the spark arrester: Always let the exhaust system cool prior to touching exhaust components.

  • Page 151: Mongoose 90 Reverse Version

    WARNING Mongoose 90 reverse version The ATV version has a gear selector To change gears, stop the vehicle and To change gears, stop the vehicle and 1. -Forward gear with the engine idling, move the lever with the engine idling, move the lever Neutral gear to the desired gear.
  • Page 152 Shift lever 1 1.To shift into forward gear pull out and upward on the shift lever until the transmission engages in the forward gear. 2.To shift into reverse gear pull out and push downward on the shift lever until the transmission engages the reverse Gear .
  • Page 153 Shift lever 2 1.To shift into neutral from either for- ward or reverse gear ,push or pull the lever to the center position. When in the neutral with the ignition switch in the on position the neutral indicator light will illuminate. CAUTION: lways come to a complete stop with engine at idle before moving the shift...
  • Page 154 SPECIFICATIONS Mongoose 90 Reverse Model Dimension: Overall length 1440 mm (57.6 in) Overall width 905 mm (35.6 in) Overall height 925 mm (37.0 in) Seat height 650 mm (25.5 in) Wheel base 965 mm (37.9 in) Fra.Minimum ground clearance 150 mm (6.0 in) RR.Minimum ground clearance...
  • Page 155 Model Mongoose 90 Reverse 110 F Engine oil/transmission oil: Type SAE 5W － SAE 10W 30 Recommended engine oil classification: － SAE 10W 40 － SAE 20W 40 － SAE 20W 50 -1 0 40 C API Service SE, SF, SG type or higher...
  • Page 156 Mongoose 90 Reverse Model Air filter: for engine Wet type element for V-belt compartment Dry type element Fuel: Type UNLEADED FUEL Tank capacity 5.3 L (1.11 lmp gal, 1.38 US gal) Reserve amount 1.5 L (0.32 lmp gal, 0.38 US gal)
  • Page 157 Mongoose 90 Reverse Model Suspension: Front Single A-arm Rear Swing arm Shock absorber: Front Coil spring/Oil damper Rear Coil spring/Oil damper Electrical: Ignition system C.D.I. Generator system C.D.I. Magneto Battery type 12V, 4AH Tire: Type Tubeless Size: Front 18X7-8 Rear...
  • Page 158 KYMCO 90CC EPA HANGTAG FOR 2009 MODEL KYMCO 90CC EPA DECAL FOR 2009 MODEL...
  • Page 159 KWANG YANG MOTOR CO.,LTD. NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. Third Edition, OCT 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd.
  • Page 160 Do not remove this Owner’s Manual from the vehicle. Read this manual carefully before operating the vehicle as it contains important safety information. Version:T200-LE20AA-US-A5 C 2009 KYMCO. All rights reserved. Printed in Taiwan. www.kymco.com...

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