KYMCO Mongoose 250 Owner'S Manual Download Page 8 | Manualshive

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PERIODIC MAINTENANCE AND
ADJUSTMENT.........................................97

Tool kit................................................97
PERIODIC MAINTENANCE/
LUBRICATION....................................99
Engine oil .........................................101
Transmission oil................................105
Spark plug inspection.........................107
Air filter cleaning................................108
Idle speed adjustment ........................113
Throttle lever adjustment....................114
Valve clearance adjustment................115
Front and rear brake shoe inspection
(Model code: LA50AA) .......................115

Brake fluid inspection.........................118
Cooling system inspection..................120
Drive chain slack check......................122
Drive chain slack adjustment...............122
Drive chain cleaning and
Lubrication.......................................124

Front and rear brake shoe inspection
(Model code: LA50AB) .......................117

Rear swing arm lubrication .................124
Draining the V-belt compartment.........125
Cable inspection and lubrication..........125

Spark arrest cleaning.........................130

Wheel removal.................................126

Wheel installation..............................126

Battery .............................................127

Fuse replacement..............................129

Headlight beam adjustment................130

Troubleshooting ...............................131

Troubleshooting chart........................132

CLEANING AND STORAGE.....................133

A. Cleaning ......................................133

B. Storage ........................................135

SPECIFICATIONS..................................137

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Summary of Contents for Mongoose 250

Page 1: ...OWNER S MANUAL KWANG YANG MOTOR CO LTD Mongoose 250 OFF ROAD...

Page 2: ......

Page 3: ...16 should never operate this vehicle Anyone who operates this vehicle should get proper instruction FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only This machine i...

Page 4: ...is manual can result in SERIOUS INJURY or DEATH Indicates a strong possibility that serious injury or death may result if instructions are not followed CAUTION Indicates a possibility that equipment o...

Page 5: ...information about special techniques and skills necessary to ride your machine It also includes basic maintenance and inspection procedures If you have any questions regarding the operation or mainten...

Page 6: ...5 Drive select lever 26 Fuel tank cap 26 Fuel valve 27 Starter choke 28 Seat 29 Flag pole bracket 30 Storage compartment 30 CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 SAFETY INFORMATI...

Page 7: ...tarting a warm engine 46 Warming up 46 Drive select lever operation and reverse driving 47 Engine break in 49 Parking 51 Parking on a slope 52 Loading 53 Riding Your ATV 56 GETTING TO KNOW YOUR ATV 57...

Page 8: ...system inspection 120 Drive chain slack check 122 Drive chain slack adjustment 122 Drive chain cleaning and Lubrication 124 Front and rear brake shoe inspection Model code LA50AB 117 Rear swing arm lu...

Page 9: ...NOISE REGULATION 141 MAINTENANCE RECORD 142 INDEX 143 Page G...

Page 10: ...LOCATION OF THE WARNING AND SPECIFICATION LABELS 1...

Page 11: ...be considered as permanent parts of the vehicle If a label comes off or becomes hard to read contact your KYMCO dealer for replacements Operating this ATV if you are under the age of 16 increases you...

Page 12: ...m 3 5 4 5psi REAR Never set tire pressure below recommended 2 25 32kpa 0 25 0 32kgf cm 3 5 4 5psi Maximum Vehicle Load 100Kg 220 lbs Including weight of operator cargo and accessories 2 LOADING WARNIN...

Page 13: ...instruction At speeds too fast for your skills or the conditions On public roads a collision can occur with another vehicle With a passenger passengers affect balance and steering control ALWAYS Use p...

Page 14: ...ctions 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 Re...

Page 15: ...fe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the handlebars and both feet on the footboards of the AT...

Page 16: ...de or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always follow proper procedures for going down hills and for braking on hill...

Page 17: ...skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or slid...

Page 18: ...es or other sources of ignition such as the pilot lights of water heaters and clothes dryers When transporting the machine in another vehicle be sure it is kept upright and that the fuel valve is in t...

Page 19: ...e 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 w...

Page 20: ...ing illustration DESCRIPTION AND MACHINE IDENTIFICATION 11 1 Key identification number Identification number records Record the key identification number frame serial number engine serial number and m...

Page 21: ...squeezing the rear brake lever LA50AB The rear brake is operated by depressing the brake pedal Frame and engine serial number The frame serial number is stamped on the front of the frame The engine s...

Page 22: ...Parts location 01 2 03 04 05 Headlight 0 Headlight switch Starter button Engine stop switch Passing signal switch Drive select lever Throttle lever Seat 01 02 03 04 05 13...

Page 23: ...06 07 09 08 10 11 12 06 Front brake lever Fuel valve 08 Tool kit 09 Taillight Stop light 10 Reservoir water tank 11 Rear brake pedal fluid r 12 Engine oil inspection window 07 eservoir 14...

Page 24: ...15 14 13 13 Choke knob 15 Rear brake lever Mode code LA50AA 16 Front wheel 17 Rear wheel 18 Exhaust system 14 Seat lock lever 18 17 16 15...

Page 25: ...this manual 18 Flat pole bracket Right operator footpeg 20 Rear brake pedal 21 Front parking brake 22 Ignition switch 23 Rear parking brake 24 Coolant temperature warning lamp High beam indicator lamp...

Page 26: ...the respective switch positions are as follows ON The headlight can be turned on With the engine stop switch at run and the transmission in neutral the engine can be started The key can not be removed...

Page 27: ...when the headlight switch to select high beam and the ignition switch is ON High beam indicator lamp Indicator lamps Reverse indicator lamp The reverse indicator lamp will light when the transmission...

Page 28: ...lamp checking methed Turn the ignition to and the engine stop switch Coolant temperature warning lamp comes on momentarily Coolant temperature and electrical circuit are OK Go ahead with riding Coolan...

Page 29: ...switch on the low beam and the taillight Turning the switch to the position to switch on the high beam and the taillight 20 1 2 1 Headlight switch 2 Starter button See starting instructions prior to s...

Page 30: ...mergency control and it should normally remain in the RUN position When passing if there are cars coming from the opposite direction press and release the passing signal switch and the headlight will...

Page 31: ...tion of throttle WHAT CAN HAPPEN The throttle could be hard to operate making it difficult to speed up or slow down when you need to This could cause an accident HOW TO AVOID THE HAZARD Check the oper...

Page 32: ...L HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You could lose control have an accident or b...

Page 33: ...ake The rear brake is operated either by depressing the brake pedal or by squeezing the rear brake lever near left handgrip Model code LA50AA Model code LA50AB The rear brake is operated by depressing...

Page 34: ...HAZARD Improper use of the parking brake WHAT CAN HAPPEN The ATV could start moving unexpectedly if the parking brake is not applied before starting the engine This could cause loss of control or a co...

Page 35: ...ect lever adjustment and operation Fuel tank cap After refueling be sure to tighten the fuel tank cap until it clicks Insert the breather tube into the handlebar cover hole TO refuel refer to page 36...

Page 36: ...position fuel flows to the carburetor Normal riding is done with the lever in this position This indicates reserve If you run out of fuel while riding turn the lever to this position THEN FILL THE FUE...

Page 37: ...proper operation See page 44 28 1 Fully open 2 Half open 3 Closed A Starter choke 1 2 3 A B CAUTION Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life of t...

Page 38: ...n the seat with the grommets on the frame and press the seat down until it locks Make sure that the seat is securely fitted 29 NOTE Seat To remove the seat pull the seat lock lever and pull up the sea...

Page 39: ...tions that come with the flag pole kit Storage compartment The storage compartment is located under the seat To remove the seat see page 29 The owner s manual should be stored in the storage compartme...

Page 40: ...35 36 115 119 32 35 Fuel Check fuel level Fill with fuel if necessary 36 37 Check oil level Fill with oil if necessary Engine oil and Transmission oil 38 101 106 Drive chain Check chain slack and cond...

Page 41: ...schedules described in the Owner s Manual WARNING Drive select lever Check operation of the lever before start the engine 1 Make sure moving the shift lever into the N position of the shift guide 2 Tu...

Page 42: ...improperly adjusted drive select lever WHAT CAN HAPPEN You may lose the gear shifting which lead to accident HOW TO AVOID THE HAZARD Make sure moving the shift lever into the N position and neutral in...

Page 43: ...ugh the shift arm into the index hole at the transmission case cover Turn the rod clockwise or counterclockwise until the drive select lever into the N position of the shift guide and tighten the lock...

Page 44: ...ve the machine inspected by a KYMCO dealer Brake operation Test the brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking performan...

Page 45: ...TV 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 Fuel Fill the fuel tank when n...

Page 46: ...em Never use stale or contaminated gasoline or an oil gasoline mixture Avoid getting dirt dust or water in the fuel tank POTENTIAL HAZARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill wh...

Page 47: ...motor oils often labeled Energy Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance Oil quantity Engine...

Page 48: ...ck the operation of the headlight switch engine stop switch and any other switches Repair as necessary for proper operation Throttle lever Check to see that the throttle lever operates correctly It mu...

Page 49: ...mbinations are not recommended 2 The tires should be set to the recommended pressure Recommended tire pressure Front 25 32 kpa 0 25 0 32 kgf cm 3 5 4 5 psi Rear Check and adjust tire pressures when th...

Page 50: ...Dust or dirt in the gauge could cause the first reading to be incorrect NOTE Recommended pressure Minimum Front Rear 28 kpa 0 28 kgf cm 3 92 psi 25 kpa 0 25 kgf cm 3 5 psi 32 kpa 0 32 kgf cm 4 5 psi 3...

Page 51: ...y with engine temperature The coolant level is satisfactory if it is between the FULL and LOW marks on the tank If the coolant level is at or below the LOW level add tap water soft water to bring the...

Page 52: ...ot WHAT CAN HAPPEN You could be burned by hot fluid and steam blown out under pressure HOW TO AVOID THE HAZARD Wait for the engine to cool before removing the radiator cap Always use a thick rag over...

Page 53: ...your KYMCO dealer WARNING POTENTIAL HAZARD Freezing control cables in cold weather WHAT CAN HAPPEN You could be unable to control the ATV which could lead to an accident or collision HOW TO AVOID THE...

Page 54: ...starter choke in reference to the figure Position Cold engine start ambient temperature below 5C 40F Position Cold engine start ambient temperature at 0C 30F 30C 90F and warming up position Position C...

Page 55: ...started with the starter choke in position keep the starter choke in this position to warm up the engine 8 Continue warming up the engine until it idles smoothly and return the starter choke to posit...

Page 56: ...op and return the throttle lever to the closed position B Shift the gear from neutral to forward by moving the shift lever along the shift guide C Open the throttle lever gradually 1 Shifting forward...

Page 57: ...person behind you resulting in serious injury HOW TO AVOID THE HAZARD When you shift into reverse make sure there are no obstacles or people behind you When it is safe to proceed go slowly 48 NOTE If...

Page 58: ...h might result in excessive engine heating must be avoided However momentary 2 3 seconds maximum full throttle operation under load does not harm the engine Each full throttle acceleration sequence sh...

Page 59: ...Avoid prolonged operation above 3 4 throttle Rev the machine freely through the gears but do not use full throttle at any time 3 After break in Avoid prolonged full throttle operation Vary speeds occ...

Page 60: ...rn the fuel lock to OFF and apply the parking brake The front brake lever has two locked position that allow it to be used as a parking brake To set the parking brake see page 25 51 1 2 1 2 1 Locked p...

Page 61: ...n an incline place the machine transversely across the incline apply the parking brake and block the front and rear wheels with rocks or other objects Do not park the ATV at all on hills that are so s...

Page 62: ...load from side to side MAXIMUM LOADING LIMIT Vehicle loading limit total weight of cargo rider and accessories 100 kg 220 lb Tie down cargo securely to the carriers Make sure cargo in the trailer cann...

Page 63: ...rol of your ATV Keep the following in mind when considering an accessory or operating an ATV which has accessories Choose only accessories designed for your ATV Your KYMCO dealer has a variety of genu...

Page 64: ...not limited to a heavy or bulky object attached to the handlebars which could make steering difficult an accessory that limits your ability to move around on the seat or one that limits your view Use...

Page 65: ...Riding Your ATV 56...

Page 66: ...more difficult maneuvers Riding your new ATV can be a very enjoyable activity providing you with hours of pleasure But it is essential to familiarize yourself with the operation of the ATV to achieve...

Page 67: ...ce until you are totally familiar with the machine s handling and performance characteristics POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is...

Page 68: ...ow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child HOW TO AVOID THE HAZARD A child u...

Page 69: ...of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident Operating without protective clothing increases your...

Page 70: ...s POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perceptio...

Page 71: ...AT 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 HOW TO AVOID THE HAZARD Never carry a passenger The lo...

Page 72: ...rating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneve...

Page 73: ...ident HOW TO AVOID THE HAZARD Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Speed limiter For riders inexperienced with this model this mo...

Page 74: ...a trailer use common sense Carrying cargo will affect how your ATV handles and greatly reduce its ability in accelerating braking and making turns and other maneuvers Be sure to observe the weight li...

Page 75: ...MCO accessories have been specifically designed for and tested on this vehicle Because KYMCO cannot test all other accessories you are personally responsible for properly selecting installing and usin...

Page 76: ...ccessories 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 an...

Page 77: ...ine in a place where pedestrians or children are not likely to touch it POTENTIAL HAZARD Hot exhaust system WHAT CAN HAPPEN Someone touching the exhaust system during or after operation could be burne...

Page 78: ...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...

Page 79: ...TIAL 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 high...

Page 80: ...Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning o...

Page 81: ...ss 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 a...

Page 82: ...flag pole bracket as a trailer hitch WHAT CAN HAPPEN You could be in a collision You could be injured HOW TO AVOID THE HAZARD Always mount a caution flag on the machine to make you more visible Watch...

Page 83: ...FOR OFF ROAD USE ONLY This vehicle is designed and manufactured for off road use only Do not ride in areas posted no trespassing Do not ride on private property without getting permission 74...

Page 84: ...ill be hot when riding and afterwards do not allow skin or clothing to come in contact with these components With the engine idling return the starter knob to the closed position and shift the drive s...

Page 85: ...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 footpeg your foot or leg may come into contact w...

Page 86: ...achine or overturn 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 su...

Page 87: ...collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Owner s Manual Practice turning at low speeds before attempting to turn at faster speeds...

Page 88: ...ce 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 excessive braking incorrect body mo...

Page 89: ...tendency for the front wheels to slide in loose or slippery conditions positioning your weight over the front wheels will sometimes help If the rear wheels of your ATV start to slide sideways control...

Page 90: ...ch as ice since all control may be lost POTENTIAL HAZARD Skidding or sliding improperly WHAT CAN HAPPEN You may lose control of this ATV You may also regain traction unexpectedly which may cause the A...

Page 91: ...lose control POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE...

Page 92: ...bed in this Owner s Manual Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the thrott...

Page 93: ...ner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Coul...

Page 94: ...rear brake to stop The ATV could easily tip over backwards Instead dismount the ATV immediately on the uphill side POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing...

Page 95: ...opped 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 Owne...

Page 96: ...t brake lever with your left hand 2 Be sure your legs are clear of the wheels 3 Check your footing 4 Then slowly and carefully back the ATV down the hill using the front brake lever to control speed 5...

Page 97: ...TV to tip or roll over Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could ca...

Page 98: ...89 OK...

Page 99: ...down hill If your ATV does begin to tip over gradually steer in the downhill direction if there are no obstacles in your path As you regain proper balance gradually steer again in the direction you w...

Page 100: ...91 Shift your weight to the uphill side of the ATV OK...

Page 101: ...the ATV as loss of control and damage to the ATV may result POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause the ATV to overt...

Page 102: ...and carefully Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads or lining POTENTIAL...

Page 103: ...t you have regained proper braking ability PARKING Always choose a level place to park After bringing your ATV to a stop hold the brakes while you shift into neutral Then set the parking brake and tur...

Page 104: ...to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 78 79 If your ATV starts to slide sideways Steer in the direction of the slide if you h...

Page 105: ...tip over dismount on the uphill side See pages 90 91 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let water drain from the...

Page 106: ...intenance unless otherwise specified PERIODIC MAINTENANCE AND ADJUSTMENT Periodic inspection adjustment and lubrication will keep your machine in the safest and most efficient condition possible Safet...

Page 107: ...D Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situation could lead t...

Page 108: ...areas Brake Check operation and brake fluid Replace brake pad if necessary Battery Check specific gravity Check breather hose for proper operation Correct if necessary Carburetor Check idle speed sta...

Page 109: ...k bearing assembly for looseness damage Replace if damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Knuckle shafts Steering shaft Lubricate every 6 months Fi...

Page 110: ...heck the oil level through the inspection window D The oil level should be between the maximum H and minimum L marks If the level is low add oil to raise it to the proper level Wait a few minutes unti...

Page 111: ...p it C Place a container under the engine D Remove the oil fill cap and oil filter cap to drain the oil Be sure no foreign material enters the crankcase CAUTION When removing the oil filter cap the co...

Page 112: ...Tightening torque Oil filter cap engine 14 7 Nm 1 5 m kg 10 6 ft lb CAUTION H Fill the engine with oil and install the oil fill cap Recommended oil see page 138 Oil quantity Periodic oil change 1 4L...

Page 113: ...d drain plug to drain the oil E Reinstall the drain plug and tighten the drain plug to specification F Fill the engine with oil and install the oil fill cap Be sure no foreign material enters the cran...

Page 114: ...n a level place 2 Place a container under the engine 3 Remove the oil filler bolt and drain plug to Drain the oil 4 Reinstall the drain plug and tighten to Specification 1 Drain plug 1 Oil filler bolt...

Page 115: ...e engine immediately and check for the cause 5 Fill the engine with oil and install the oil filler bolt Recommended oil See page 138 Oil quantity Periodic oil change 0 3 L 0 27 lmp qt 0 31 US qt Be su...

Page 116: ...portant engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine For example a very white center electrode porcelain color could indicate an int...

Page 117: ...ged in water the air cleaner should be checked and water should be drained from the air cleaner housing before starting the engine To clean the air cleaner 1 Remove the seat See page 29 2 Unlatch the...

Page 118: ...aner assembly from the air cleaner holder 5 Remove the air cleaner and air cleaner screen from the air cleaner guide 6 Remove the air cleaner net from the air cleaner 1 1 Screw 1 2 3 1 Air cleaner 2 A...

Page 119: ...il saturated then squeeze out the excess oil 9 Reassemble by reversing the disassembly sequence POTENTIAL HAZARD Using gasoline or low flash point solvents for cleaning ATV parts WHAT CAN HAPPEN A fir...

Page 120: ...rough water may require more frequent inspection If deposits can be seen in the drain tube the tube must be cleaned before starting the vehicle To clean the drain tube 1 Remove the drain tube by remov...

Page 121: ...air filter housing 2 3 Remove the two screws and remove air filter housing cover Remove the air filter from the housing 4 Tap the air filter lightly to remove most of the dust and dirt 5 Blow out the...

Page 122: ...Occasionally rev the engine to 4 000 to 5 000 r min The engine is warm when it quickly responds to the throttle 2 Connect the tachometer and set the idle to the specified idling speed by adjusting the...

Page 123: ...the adjuster to obtain the correct free play 1 4 mm or 0 04 0 16 in 3 Tighten the locknut and reinstall the sleeve Other checks Check the throttle cable for kinks and signs of wear that could cause s...

Page 124: ...is adjustment however should be left to a professional KYMCO service technician Front and rear brake pads inspection Model code LA50AA A wear indicator is provided on each brake The indicators allows...

Page 125: ...1 Rear brake pads cover Rear brake lever 2 Wear indicator Rear brake pads Rear brake lever 3 1 Rear brake pads cover Rear brake pedal 2 Wear indicator Rear brake pads Rear brake pedal 3 2 1 3 2 1 3 11...

Page 126: ...is provided on each brake The indicators allows checking of brake pads wear Check the position of the indicator If the indicator reaches the wear limit line ask a KYMCO dealer to replace the pads 1 We...

Page 127: ...ke lever L 1 UPPER LOWER 1 POTENTIAL HAZARD Brake fluid contacting the skink or eyes WHAT CAN HAPPEN May cause irritation HOW TO AVOID THE HAZARD Avoid contacting brake fluid with the skin or eyes In...

Page 128: ...mended limit page 115 117 There is probably air in the brake system and it must be bled See your authorized KYMCO dealer for this service To prevent damage to the brake system use only fluid from a se...

Page 129: ...aise it to the specified level 3 If your ATV overheats see page 121 for details FULL LOW 1 2 3 1 Coolant reservoir cap 2 Maximum level mark 3 Minimum level mark Hard water or salt water is harmful to...

Page 130: ...dealer when changing the coolant WARNING Engine overheating If your ATV overheat wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator Restart the engine If th...

Page 131: ...ion shown in the figure The normal vertical deflection is approximately 30 40 mm 1 18 1 6in If the deflection exceeds 40 mm 1 6in adjust the chain slack Drive chain slack adjustment 1 Loosen the hub s...

Page 132: ...pull the ATV backward 4 Retighten to the specification 5 Pull out the standard phillips screwdriver the two axle hub holder bolt and hub stopper bolt standard phillips screwdriver Tightening torque A...

Page 133: ...nd certain solvents can damage these O rings Use only kerosene to clean the drive chain Wipe it dry and thoroughly lubricate it with SAE 30 50 motor oil Do not use any other lubricants on the drive ch...

Page 134: ...AZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables can also become frayed or kinked Operation of controls could be restr...

Page 135: ...han a circular pattern Be sure the tapered side of the wheel nuts face the wheel rim Wheel nut torque Front 55 Rear 55 Nm 5 5 m kg 40 ft lb Nm 5 5 m kg 40 ft lb 126 1 Safe nut 1 POTENTIAL HAZARD Insta...

Page 136: ...ls as this may damage the battery Although the battery is sealed it vents explosive gases and should be handled with appropriate care NOTE When the ATV is to be stored for an extended period remove th...

Page 137: ...e battery first then disconnect the positive terminal lead 5 Remove the battery Battery installation 1 Install in the reverse order of removal 2 Check all bolts and other fasteners are secure 3 After...

Page 138: ...the new fuse in to the fuse holder 6 Close the fuse box cap and install seat To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 129 POTENTIAL HAZARD Usi...

Page 139: ...ustment Vertical adjustment Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting screw 130 CAUTION 1 Adjusting...

Page 140: ...ve the tools experience and know how to properly service your machine Imitation parts may look like KYMCO parts but they are often inferior Consequently they have a shorter service life and can lead t...

Page 141: ...an filter element and fuel tank Check fuel flow No fuel Fuel valve Clean fuel valve Turn the fuel valve to OFF Turn the fuel valve to RES Supply fuel 1 Fuel Remove the fuel hose from the fuel valve Ch...

Page 142: ...les 3 Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job Excessive water pressure may cause water seepage and deterioration of wheel bearings brakes transmissio...

Page 143: ...tain abrasives which may mar the paint or protective finish When finished start the engine and let it POTENTIAL HAZARD Operation with wet brakes after washing WHAT CAN HAPPEN Wet brakes may have reduc...

Page 144: ...and carburetor Be sure to drain the fuel in a well ventilated area not in a garage 135 POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite...

Page 145: ...r a few seconds to distribute the oil then reinstall the spark plug Make sure the engine stop switch is OFF before pressing the starter button 136 POTENTIAL HAZARD Prolonged contact of fuel with the s...

Page 146: ...0 mm 66 9 in 1070 mm 42 1 in 1080 mm 42 5 in 800 mm 31 5 in 1180 mm 46 5 in 130 mm 5 1 in 2865 mm 112 8 in Basic weight With oil and full fuel tank 191kg 420 lbs Engine Type Cylinder arrangement Displ...

Page 147: ...il Periodic oil change Total amount Transmission oil Periodic oil change Total amount API Service SE SF SG type or higher SAE 90 1 4 L 1 23 lmp qt 1 48 US qt 1 6 L 1 41 lmp qt 1 69 US qt 0 3 L 0 26 lm...

Page 148: ...L 2 78 lmp gal 3 34 US gal 1 8 L 0 4 lmp gal 0 47 US gal Carburetor Type PD Spark plug Type Gap DPR7EA 9 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automatic Brake Front brake type Operatio...

Page 149: ...rber Front Rear Coil spring Oil damper Coil spring Oil damper Electrical Ignition system Generator system Battery type C D I C D I Magneto 12V 12AH Tire Type Size Front Rear Tubeless 21X7 10 20X11 9 B...

Page 150: ...le 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...

Page 151: ...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 MAINTENACE INTERVAL DATE OF SERVICE MILEAGE...

Page 152: ...NS 17 Coolant 42 Coolant temperature warning lamp 19 Cooling system inspection 120 CROSSING A SLOPE 90 CROSSING THROUGH SHALLOW WATER 93 INDEX A B Accessories 54 66 AGE RECOMMENDATION A Air filter cle...

Page 153: ...alve 27 Handlebar switches 20 Headlight beam adjustment 130 Headlight switch 20 High beam indicator lamp 18 D E Draining the V belt compartment 125 Drive chain cleaning and lubrication 124 Drive chain...

Page 154: ...switch 21 PERIODIC MAINTENANCE LUBRICATION 99 PERIODIC MAINTENANCE AND ADJUSTMENT 97 PREFACE C PRE OPERATION CHECKS 31 63 I K L M Idle speed adjustment 113 Ignition switch 17 IMPORTANT NOTICES A Indic...

Page 155: ...AL MESSAGES B SPECIFICATIONS 137 Speed limiter 23 Starting a cold engine 44 Stater button 20 STORAGE 135 Storage compartment 30 Switches 39 Page 146 T W V Throttle lever 22 39 Throttle lever adjustmen...

Page 156: ...Remove the tailpipe by pulling it out of the muffler 3 Tap the tailpipe lightly then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe 4 Insert the tailpi...

Page 157: ...s 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...

Page 158: ...y reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4121 LBA7 U00 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kaohs...

Page 159: ......

Page 160: ...nstruction At speeds too fast for your skills or the conditions On public roads a collision can occur with another vehicle With a passenger passengers affect balance and steering control ALWAYS Use pr...

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