KYMCO Mongoose 90 R Page 4 Owner'S Manual Download | Manualshive

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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.

Indicates a strong possibility that serious injury or death may
result if instructions are not followed.

CAUTION

Indicates a possibility that equipment or property damage

could result if instructions are not followed.

Note:

To protect your vehicle from damage, pay attention to caution to cautions.

Gives helpful information

The Owner's Manual should be considered a permanent part of your ATV. It should
remain with the vehicle at all times and stay with the ATV if it is sold.

WARNING

C

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Summary of Contents for Mongoose 90 R

Page 1: ...Owner s Manual ATV off road Mongoose 90 Mongoose 90 R...

Page 2: ...es contained in the manual This ATV is intended for use by children at least 10 years old Never allow children under the age of 10 to operate this ATV Anyone who operates this vehicle should get prope...

Page 3: ...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...

Page 4: ...RY or DEATH Indicates a strong possibility that serious injury or death may result if instructions are not followed CAUTION Indicates a possibility that equipment or property damage could result if in...

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: ...Headlight switch 22 Stater button 22 Kick starter 23 Remote engine stop switch 24 Start choke 31 CONTENTS LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 SAFETY INFORMATION 4 DESCRIPTION AND MACHI...

Page 7: ...arting a warm engine 45 Warming up 45 Parking 46 Parking on a slope 47 Accessories 48 Riding Your ATV 49 GETTING TO KNOW YOUR ATV 50 RIDE WITH CARE AND BE CAREFULWHERE YOU RIDE 59 JUDGEMENT 51 BEFORE...

Page 8: ...eed adjustment 107 Throttle lever adjustment 108 Front brake shoe inspection 109 Rear brake pads inspection 109 Front brake lever free play adjustment 110 Brake fluid inspection 112 Drive chain slack...

Page 9: ...H CLEANING AND STORAGE 126 A Cleaning 126 B Storage 128 SPECIFICATIONS 130 INDEX 136 NOISE REGULATION 134 MAINTENANCE RECORD 135 Mongoose 90 Reverse version 142 Page...

Page 10: ...LOCATION OF THE WARNING AND SPECIFICATION LABELS 1 CERTIFICATE LABEL OF SVIA For US For Canada DECAL OF EPA...

Page 11: ...is information before riding Parents of young riders should make sure their youngsters read and understand the hang tag and label information before allowing them to ride The labels should be consider...

Page 12: ...3...

Page 13: ...peed and skill such as bicycling or skateboarding poor judgement can result in injuries and we don t want that to happen You can help prevent accidents by making good decisions about if when and how y...

Page 14: ...o they can stand up for balance and comfort and to shift their body forward backward and from side to side Also make sure your youngster can comfortably reach and work all the controls For example can...

Page 15: ...ssary for safe riding Does your youngster think through problems and come to logical solutions On a bicycle does your youngster obey safe riding rules Be honest Young people who take unnecessary risks...

Page 16: ...ginner becomes more familiar with operating the ATV For adjustment and removal instructions see pages 69 Supervision is another important obligation of parents Even after youngsters have become skille...

Page 17: ...s use of the ATV at all times Parents should permit continued use if they determine that the child has the ability to operate the ATV safely must be an on going commitment by you and your youngster Wh...

Page 18: ...ne greater than 125cc A child under 16 years old should never operate an ATV with engine greater than 150cc Never carry cargo or tow a trailer A child under 10 years old should never operate this ATV...

Page 19: ...ATV Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experience Never attempt wheel...

Page 20: ...sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for...

Page 21: ...acles as described in this manual Always be careful when skidding or sliding Learn to safely control skidding or sliding by practicing at low speeds and on level smooth terrain On extremely slippery s...

Page 22: ...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 cock is in th...

Page 23: ...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 24: ...ing illustration DESCRIPTION AND MACHINE IDENTIFICATION 15 1 Key identification number Identification number records Record the key identification number frame serial number engine serial number and m...

Page 25: ...e serial number The frame serial number is stamped on the front of the frame The engine serial number is stamped on the left crankcase 1 1 1 Frame serial number 1 Engine serial number Model code MODEL...

Page 26: ...1 Handlebar switch 2 Ignition switch 3 Speed limiter 4 Throttle lever 5 Seat 17 01 03 04 05 02 Parts location...

Page 27: ...witch 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 13 Oil filler cap dipstick Front wheel 18...

Page 28: ...ight footboard 16 Front brake lever 17 Parking brake 18 Rear brake lever 19 Fuel fill cap 20 Left footboard The machine you have purchased may differ slightly from those shown in the figures of this m...

Page 29: ...ctive switch positions are as follows ON The taillight can be turned on With the engine stop switch at run the engine can be started The key can not be removed OFF All electrical circuits are switched...

Page 30: ...engine will operate When the switch is in OFF position the engine will not operate This switch is intended primarily as a safety or emergency control and it should normally remain in the RUN position...

Page 31: ...rated when you add the headlight equipment using genuine KYMCO accessories The USA model does not come equipped with headlights as standard equipment If the headlight is not equipped be sure to turn t...

Page 32: ...for details CAUTION If the kick starter is operated with the ignition switch at and the engine stop switch the engine will not start To start the engine be sure to position the engine stop switch at...

Page 33: ...d 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 When the te...

Page 34: ...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 35: ...the maximum speed of the ATV POTENTIAL HAZARD Improper adjustment of the speed limiter and throttle WHAT CAN HAPPEN The throttle cable could be damaged Improper throttle operation could result You co...

Page 36: ...1 Rear brake lever 1 Front brake lever Front brake The front brakes are operated by squeezing the front brake lever Rear brake The rear brakes are operated by squeezing the rear brake lever 1 1 27...

Page 37: ...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 br...

Page 38: ...not applied before starting the engine This could cause loss of control or a collision The brake could overheat if you ride the ATV without releasing the parking brake You could lose braking performan...

Page 39: ...in this 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...

Page 40: ...proper operation See page 43 1 Fully open 2 Half open 3 Closed A Starter choke 1 2 3 A B B CAUTION Extended use of the choke may impair piston and cylinder wall lubrication and shorten the life of the...

Page 41: ...at pull upward the seat lock lever and pull up the seat at the rear To install the seat align the tabs on the seat with the grommets on the frame and press the seat down until it locks Make sure that...

Page 42: ...ood this area when washing your ATV or riding through water and never put any electric conduction material in the storage compartment 33 1 Flag pole bracket Flag pole bracket To mount a flag pole in t...

Page 43: ...luid disk brake if necessary 35 36 109 113 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 96 102 Drive chain Chec...

Page 44: ...is incorrect adjust it See pages 110 111 Check operation of the levers They should move smoothly and there should be a firm feeling when the brake is applied If not have the machine inspected by a KY...

Page 45: ...blem 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 necessary and make sure...

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: ...ils often labeled Energy Conserving contain anti friction additives which will cause starter clutch slippage resulting in reduced component life and poor engine performance 38 CAUTION SAE 20W 50 SAE 2...

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: ...Other tire combinations are not recommended WARNING Size Type Front Rear Tires TUBELESS TUBELESS 18 7 8 18 9 8 40 2 The tires should be set to the recommended pressure Recommended tire pressure Front...

Page 50: ...the following 4 Never set tire pressure over the recommended Front 28 kpa 0 28 kgf cm 40 psi Rear 28 kpa 0 28 kgf cm 40 psi Higher pressures may cause the tire to burst Inflate the tires very slowly a...

Page 51: ...42 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: ...ZARD 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 HAZARD When riding in cold weather alw...

Page 53: ...F 30C 90F and warming up position Position Cold engine start ambient temperature above 25C 80F and warm engine start position 1 Fully open 3 Closed 2 Half open a Starter choke 7 If the engine is start...

Page 54: ...ollowing material Because the engine is brand new you must not put an excessive load on it for the first 20 hours the various parts in the engine wear and polish themselves to the correct operating cl...

Page 55: ...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 Vary the speed of the machine from ti...

Page 56: ...other inclines If you must park on 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...

Page 57: ...f them Choose a genuine KYMCO accessory or one that is equivalent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you a...

Page 58: ...Riding Your ATV 49...

Page 59: ...etely and understand the operation of the controls Pay particular attention to the safety information and special safety message on pages 4 14 Please also read all caution and warning labels on your A...

Page 60: ...e of t e ATV by a child If he or she does not have the abilities to operate it safely RIDE WITH CARE AND GOOD JUDGEMENT Get training if you are inexperienced Beginners should get training from a certi...

Page 61: ...erly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect tour ATV each time you use it to make sure the ATV is in safe...

Page 62: ...ehicle on pages40 42 Always maintain proper tire pressure as described in the Owner s Manual on page 41 WARNING Weight Limits This ATV is not designed to carry cargo or tow a trailer Do not add a carg...

Page 63: ...all other accessories you are personally responsible for properly selecting installing and using non KYMCO accessories Always follow the loading instructions above plus the following 1 Carefully insp...

Page 64: ...ies 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 author...

Page 65: ...a face shield gloves boots a long sleeved shirt or jacket and long pants 56 WHAT CAN HAPPEN Operating without an approved motorcycle helmet increases your chances of a severe head injury or death in...

Page 66: ...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 67: ...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 68: ...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 69: ...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 70: ...t ride on private property without getting permission Ride Only When Visibility Is Good Your ATV is not equipped with headlight It is intended to be used only during the daytime You should ride only w...

Page 71: ...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 into contact...

Page 72: ...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 73: ...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 74: ...ilure 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 or...

Page 75: ...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 76: ...lag 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 c...

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: ...new riders 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...

Page 79: ...ps Be aware that this distance must be included in the stopping space of the ATV and that this distance may increase with speed 1 1 Tethered cord Speed limiter for new riders Your ATV has an adjustabl...

Page 80: ...nt or counterclockwise to increase throttle lever movement 3 Hole the screw in place and tighten the lock nut BRAKING Practice starting and stopping at slow speeds Gradually work up to faster starts a...

Page 81: ...ondition of the terrain you are riding Slick slippery or muddy ground requires gentler braking Pulling one or both brake levers too hard may cause the front and or rear wheels to skid or slide out of...

Page 82: ...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 83: ...help to position more of your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Im...

Page 84: ...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 85: ...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 86: ...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 87: ...d 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 throttle...

Page 88: ...r 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 Could...

Page 89: ...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 90: ...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 91: ...brake liver 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 92: ...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 93: ...84 OK 58...

Page 94: ...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 95: ...86 Shift your weight to the uphill side of the ATV OK...

Page 96: ...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 97: ...wly 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 linings POTENTIAL HA...

Page 98: ...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 99: ...n to regain balance If necessary gradually let off the throttle and or steer to the outside of the turn See pages 73 74 If your ATV starts to slide sideways Steer in the direction of the slide if you...

Page 100: ...regain balance If you discover that the ATV is going to tip over dismount on the uphill side See pages 85 86 If your ATV encounters shallow water Ride slowly and carefully through slow moving water wa...

Page 101: ...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 102: ...uld be genuine KYMCO or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized KYMCO dealer 93 WARNIN...

Page 103: ...Brake Battery Check specific gravity Check breather hose for proper operation Correct if necessary Carburetor Check idle speed starter operation Adjust if necessary Cylinder head cover breather syste...

Page 104: ...Replace if necessary Wheel bearings Check bearing assembly for looseness damage Replace if damaged Steering system Check operation Replace if damaged Check toe in Adjust if necessary Knuckle shafts S...

Page 105: ...the filler hole without screwing it in 96 E Remove the dipstick and inspect the oil level F The oil level should be between the maximum and minimum marks If the level is low add oil to raise it to th...

Page 106: ...foreign material enters the crankcase When removing the drain plug the compression spring oil strainer and O ring will fall out Take care not to lose these parts CAUTION 1 Oil filter cap CAUTION 1 Tig...

Page 107: ...material enters the crankcase If oil leakage is found stop the engine immediately and check for the cause I Warm up the engine for several minutes at idle speed Check for oil leakage while warming up...

Page 108: ...h oil and install the oil filler cap G Warm up the engine for several minutes at idle speed Check for oil leakage while warming up Tightening torque Drain plug engine 30 Nm 3 0 m kg 21 6 ft lb Be sure...

Page 109: ...il 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 C Reinstall the oil filler bolt and tighten to specification...

Page 110: ...nt 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 Tighte...

Page 111: ...ck 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 0 11 L 0 10 lmp qt 0 12 US qt Total amount...

Page 112: ...and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive you should replace the spark plug with one of the p...

Page 113: ...leaned 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...

Page 114: ...w 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...

Page 115: ...stall the element assembly and parts removed for access air filter case The element should be wet but not dripping NOTE 106 Valve clearance adjustment The correct valve clearance changes with use resu...

Page 116: ...in 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...

Page 117: ...n the adjuster to obtain the correct free play 3 5 mm or 0 12 0 2 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 118: ...as a set These procedures should be performed by KYMCO dealer A A A 1 1 Lining A Lining thickness 2 1 1 Wear indicator 2 Rear brake Rear brake pads inspection A wear indicator is provided on each bra...

Page 119: ...of the brake lever 1 Loosen the upper locknut and fully turn in the adjusting bolt A Free play 10 20 mm 0 4 0 8 in A 1 Upper locknut 3 Lower locknut 2 Upper adjusting bolt 4 Lower adjusting bolt 1 2 3...

Page 120: ...ENTIAL HAZARD Operating with improperly serviced or adjusted brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD After servicing Make sure the...

Page 121: ...ark through the inspection window 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 e...

Page 122: ...ommended limit page 109 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 seal...

Page 123: ...ing bolt x 4 1 2 Drive chain slack check Inspect the drive chain while all tires are touching the ground Check the slack at the position shown in the figure The normal vertical deflection is approxima...

Page 124: ...rease chain slack 3 Retighten the upper and lower axle holding bolts Too little of chain slack will overload the engine and other important parts Keep the slack within the specified limit Tightening t...

Page 125: ...age the O rings 1 O rings Cable inspection and lubrication POTENTIAL HAZARD Damaged control cables WHAT CAN HAPPEN Corrosion can result when the outer covering of control cables becomes damaged Cables...

Page 126: ...the pivot points using a grease gun Recommended lubricant Lithium soap based grease 117 Draining the V belt compartment If water leaks into V belt compartment such as when the machine is drive in wat...

Page 127: ...he frame 2 Remove the nuts from the wheel 3 Remove the wheel assembly Wheel installation When installing the wheel reverse the removal procedure Pay attention to the following Wheel nut torque Front 4...

Page 128: ...s 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 the ba...

Page 129: ...negative terminal lead from the battery first then disconnect the positive terminal lead 5 Remove the battery 1 2 Battery installation 1 Install in the reverse order of removal 2 Check all bolts and o...

Page 130: ...r the seat The specified fuses are 7A To prevent accidental short circuiting turn off the ignition switch before checking or replacing a fuse POTENTIAL HAZARD Using an improper fuse WHAT CAN HAPPEN An...

Page 131: ...1 Lift the seat See page 32 2 Open the fuse holders and lift out the fuse with the clips 3 Slide the old fuse out of the clips and discard it 1 2 1 Fuse holder 2 Clip 122...

Page 132: ...er Do not pry the clips open to get a fuse out you could bend them and cause poor contact with the new fuse A loose fuse could cause damage to the electrical system and even start a fire After replaci...

Page 133: ...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 134: ...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 135: ...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 136: ...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 137: ...tank and carburetor Be sure to drain the fuel in a well ventilated area not in a garage POTENTIAL HAZARD Refueling this ATV or handling fuel improperly WHAT CAN HAPPEN The fuel could explode or ignite...

Page 138: ...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 POTENTIAL HAZARD Prolonged contact of fuel with the skin...

Page 139: ...in 905 mm 35 6 in 910 mm 35 8 in 650 mm 25 5 in 965 mm 37 9 in 104 mm 4 1 in Basic weight With oil and full fuel tank 120kg 264 lbs Engine Type Cylinder arrangement Displacement Bore x stroke Compress...

Page 140: ...l change Total amount Transmission oil Periodic oil change Total amount API Service SE SF SG type or higher SAE 90 0 7 L 0 62 lmp qt 0 74 US qt 0 8 L 0 70 lmp qt 0 84 US qt 0 11 L 0 10 lmp qt 0 12 US...

Page 141: ...eserve amount UNLEADED FUEL 5 5 L 1 16 lmp gal 1 40 US gal 1 5 L 0 32 lmp gal 0 38 US gal Carburetor Type PB Spark plug Type Gap NGK CR7HSA 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centrifugal automa...

Page 142: ...arm Shock absorber 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 4AH Tire Type Size Front Rear Tubeless 18X...

Page 143: ...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 144: ...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 145: ...NING 126 CLIMBING UPHILL 77 CONTENTS E CONTROL FUNCTIONS 20 CROSSING A SLOPE 85 CROSSING THROUGH SHALLOW WATER 88 Page Page Cont d D E Draining the V belt compartment 117 Drive chain cleaning and lubr...

Page 146: ...shoe inspection 109 Fuel 36 Fuse replacement 121 Fuel tank cap 29 Fuel valve 30 Handlebar switches 21 Headlight switch 22 Page Page Cont d I K L M Idle speed adjustment 107 Ignition switch 20 IMPORTAN...

Page 147: ...34 52 Page Page Cont d R S Rear brake 27 Rear brake pads inspection 109 Remote engine stop switch 24 RIDING DOWNHILL 83 RIDING OVER ROUGH TERRAIN 87 Riding Your ATV 49 SAFETY INFORMATION 4 Seat 32 SLI...

Page 148: ...djustment 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...

Page 149: ...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 150: ...uld 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...

Page 151: ...engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving To change gears stop the vehicle and with the engine idling...

Page 152: ...r 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 When in the with the ign...

Page 153: ...ral indicator light will illuminate A to the center position lways come to a complete stop with engine at idle before moving the shift lever changing gears while moving or shifting from neutral with t...

Page 154: ...5 mm 37 0 in 650 mm 25 5 in 965 mm 37 9 in 150 mm 6 0 in 100 mm 4 0 in Basic weight With oil and full fuel tank 123kg 270 6 lbs Engine Type Cylinder arrangement Displacement Bore x stroke Compression...

Page 155: ...nge Total amount Transmission oil Periodic oil change Total amount API Service SE SF SG type or higher SAE 90 0 7 L 0 62 lmp qt 0 74 US qt 0 8 L 0 70 lmp qt 0 84 US qt 0 25 L 0 22 lmp qt 0 265 US qt 0...

Page 156: ...ve amount UNLEADED FUEL 5 3 L 1 11 lmp gal 1 38 US gal 1 5 L 0 32 lmp gal 0 38 US gal Carburetor Type PTE Auto Bystarter Spark plug Type Gap NGK CR7HSA 0 6 0 7 mm 0 024 0 028 in Clutch Type Dry centri...

Page 157: ...Swing arm Shock absorber 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 4AH Tire Type Size Front Rear Tubeles...

Page 158: ...KYMCO 90CC EPA HANGTAG FOR 2009 MODEL KYMCO 90CC EPA DECAL FOR 2009 MODEL...

Page 159: ...reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T200 LE20AA US A5 KWANG YANG MOTOR CO LTD NO 35 Wan Hsing Street San Min District Kao...

Page 160: ...ner s Manual from the vehicle Read this manual carefully before operating the vehicle as it contains important safety information C 2009 KYMCO All rights reserved Printed in Taiwan www kymco com Versi...

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