1. GENERAL INFORMATION
1-0
Mongoose/KXR 90/50
1
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GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER ------------------------------------------------------ 1- 1
SPECIFICATIONS ------------------------------------------------------ 1- 2
SERVICE PRECAUTIONS--------------------------------------------- 1- 4
TORQUE VALUES ----------------------------------------------------- 1-12
SPECIAL TOOLS ------------------------------------------------------- 1-14
LUBRICATION POINTS----------------------------------------------- 1-15
CABLE & HARNESS ROUTING ------------------------------------- 1-18
WIRING DIAGRAM ---------------------------------------------------- 1-21
TROUBLESHOOTING ------------------------------------------------- 1-25
1
1. GENERAL INFORMATION
1-1
Mongoose/KXR 90/50
SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
Location of Engine Serial Number
1. GENERAL INFORMATION
1-2
Mongoose/KXR 90/50
SPECIFICATIONS
(Mongoose/KXR 90)
Name & Model No.
LA20AB
Motorcycle Name & Type
Mongoose/KXR 90
Overall length (mm)
1430
Overall width (mm)
905
Overall height (mm)
910
Wheel base (mm)
965
Engine type
O.H.C.
Displacement (cc)
89.9
Fuel Used
92# nonleaded gasoline
Front wheel
58
Net weight (kg)
Rear wheel
56.5
Total
114.5
Front wheel
61.5
Gross weight(kg)
Rear wheel
58.5
Total
120
Front wheel
18*7-8
Rear wheel
18*9-8
Ground clearance (mm)
104
Breaking distance
(m)(ANSI)
20.6 below
Starting system
Motor & Kick
starter
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C., chain drive
Bore x stroke (mm)
47X51.8
Compression ratio
10.0:1
Compression pressure
(kg/cm_)
16.0
Max. output (ps/rpm)
6.3/6500
Max. torque (kg m/rpm)
0.7/5500
Intake
Open
2°
Port
(1mm)
Close
26°
timin
g
Exhaust
Open
44°
(1mm)
Close
-17°
Valve clearance
Intake
0.1
(cold) (mm)
Exhaust
0.1
Idle speed (rpm)
1700rpm
Lubrication type
Forced pressure &
Wet sump
Oil pump type
Inner/outer rotor
type
Oil filter type
Full-flow filtration
Oil capacity
0.8 liter
Oil exchanging
capacity
0.7 liter
Cooling Type
Air cooling
Air cleaner type & No
Sponge
Fuel capacity
5.5 liters
Type
PB
Main jet No.
#100
Venturi dia.(mm)
f14
Throttle type
PISTON
Type
CDI
Ignition timing
28°BTDC/4000rpm
Contact breaker
Non-contact point type
Spark plug
NGK C7HSA
Spark plug gap
0.6_ 0.7mm
Battery
Capacity
12V4AH
Clutch
Type
CVT
Type
Helical gear
Operation
Automatic centrifugal
Type
Type
V-Belt
Primary
reduction
0.8~2.5
Final
reduction
9.255
FR/RR tire rolling
circumference(mm)
1436/1436
Tire pressure
Front
0.25
(kg/cm_)
Rear
0.25
Turning
Left
35°
angle
Right
35°
Brake system
Rear
Disk brake
type
Front
Drum brake
Front
Swing axle
Suspension
type
Rear
Swing arm
Frame type
Steel tube frame
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis-
sion Gear
Reduction
Gear
Moving Device
Damping
Device
1. GENERAL INFORMATION
1-3
Mongoose/KXR 90/50
SPECIFICATIONS
(Mongoose/KXR50)
Name & Model No.
LA10BA
Motorcycle Name & Type
Mongoose/KXR 50
Overall length (mm)
1385
Overall width (mm)
875
Overall height (mm)
890
Wheel base (mm)
900
Engine type
2-stroke.
Displacement (cc)
49.4
Fuel Used
92# nonleaded gasoline
Front wheel
49.6
Net weight (kg)
Rear wheel
50.7
Total
100.3
Front wheel
54.6
Gross weight(kg)
Rear wheel
55.7
Total
110.3
Front wheel
16*8-7
Rear wheel
16*8-7
Ground clearance (mm)
72
Breaking distance
(m)(ANSI)
20.6 below
Starting system
Motor & Kick
starter
Type
Gasoline, 2-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
Reed valve & piston
Bore x stroke (mm)
39X41.4
Compression ratio
7.2:1
Compression pressure
(kg/cm_)
12.0
Max. output (ps/rpm)
4.6/6000
Max. torque (kg m/rpm)
0.55/5500
Intake
Open
Automatic controlled
Port
(1mm)
Close
Automatic controlled
timin
g
Exhaust
Open
_
(1mm)
Close
_
Valve clearance
Intake
_
(cold) (mm)
Exhaust
_
Idle speed (rpm)
2000rpm
Lubrication type
Separate type
Oil pump type
Plunger type
Oil filter type
Full-flow filtration
Cooling Type
Air cooling
Air cleaner type & No
Sponge
Fuel capacity
5.5 liters
Type
PB
Main jet No.
82
Venturi dia.(mm)
f14
Throttle type
PISTON
Type
CDI
Ignition timing
15°BTDC/1700rpm
Contact breaker
Non-contact point type
Spark plug
NGK BR8HAS
Spark plug gap
0.6_ 0.7mm
Battery
Capacity
12V4AH
Clutch
Type
CVT
Type
Helical gear
Operation
Automatic centrifugal
Type
Type
V-Belt
Primary
reduction
0.895~3.113
Final
reduction
11.05
FR/RR tire rolling
circumference(mm)
1247/1247
Tire pressure
Front
0.25
(kg/cm_)
Rear
0.25
Turning
Left
35°
angle
Right
35°
Brake system
Rear
Drum brake
type
Front
Drum brake
Front
Swing axle
Suspension
type
Rear
Swing arm
Frame type
Steel tube frame
Tires
Engine
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis-
sion Gear
Reduction
Gear
Moving Device
Damping
Device
1. GENERAL INFORMATION
1-4
Mongoose/KXR 90/50
SERVICE PRECAUTIONS
n Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
n When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
n Use genuine parts and lubricants.
n When servicing the motorcycle, be sure to
use special tools for removal and
installation.
n After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
1. GENERAL INFORMATION
1-5
Mongoose/KXR 90/50
n Apply or add designated greases and
lubricants to the specified lubrication
points.
n After reassembly, check all parts for
proper tightening and operation.
n When two persons work together, pay
attention to the mutual working safety.
n Disconnect the battery negative (-)
terminal before operation.
n When using a spanner or other tools,
make sure not to damage the motorcycle
surface.
n After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
n When connecting the battery, the positive
(+) terminal must be connected first.
n After connection, apply grease to the
battery terminals.
n Terminal caps shall be installed securely.
1. GENERAL INFORMATION
1-6
Mongoose/KXR 90/50
n If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.
n After operation, terminal caps shall be
installed securely.
n When taking out the connector, the lock
on the connector shall be released before
operation.
n Hold the connector body when connecting
or disconnecting it.
n Do not pull the connector wire.
n Check if any connector terminal is
bending, protruding or loose.
Confirm
Capacity
1. GENERAL INFORMATION
1-7
Mongoose/KXR 90/50
n The connector shall be inserted
completely.
n If the double connector has a lock, lock
it at the correct position.
n Check if there is any loose wire.
n Before connecting a terminal, check for
damaged terminal cover or loose
negative terminal.
n Check the double connector cover for
proper coverage and installation.
n Insert the terminal completely.
n Check the terminal cover for proper
coverage.
n Do not make the terminal cover opening
face up.
n Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Snapping!
1. GENERAL INFORMATION
1-8
Mongoose/KXR 90/50
n After clamping, check each wire to make
sure it is secure.
n Do not squeeze wires against the weld or
its clamp.
n After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.
n When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
n Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
n Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !
1. GENERAL INFORMATION
1-9
Mongoose/KXR 90/50
n Route harnesses so they are neither
pulled tight nor have excessive slack.
n Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge
or corner.
n When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
n Do not break the sheath of wire.
n If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.
n When installing other parts, do not press
or squeeze the wires.
Do not pull too
tight!
Do not press
or squeeze the
wire.
1. GENERAL INFORMATION
1-10
Mongoose/KXR 90/50
n After routing, check that the wire
harnesses are not twisted or kinked.
n Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
n When a testing device is used, make sure
to understand the operating methods
thoroughly and operate according to the
operating instructions.
n Be careful not to drop any parts.
n When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !
1. GENERAL INFORMATION
1-11
Mongoose/KXR 90/50
n Symbols:
The following symbols represent the
servicing methods and cautions included
in this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for
lubrication.
: Transmission Gear Oil
(90#)
: Use special tool.
: Caution
: Warning
Engine Oil
Grease
Gear Oil
Special
1. GENERAL INFORMATION
1-12
Mongoose/KXR 90/50
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kgf-m)
Item
Torque (kgf-m)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
0.45_ 0.6
0.8_ 1.2
1.8_ 2.5
3.0_ 4.0
5.0_ 6.0
6.0_ 8.0
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
0.2_ 0.4
0.35_ 0.5
0.7_ 1.1
1.0_ 1.4
2.4_ 3.0
3.5_ 4.5
Torque specifications listed below are for important fasteners.
ENGINE (Mongoose/KXR 90)
Item
Q‘ty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Stud bolt
Oil filter screen cap
L cover
Cam shaft holder
Tappet ADJ nut
Pivot tensioner bolt
Lifter tensioner bolt
Lifter tensioner cap
Mission case bolt
Mission fill bolt
Driver face nut
Clutch outer nut
Drive plate nut
Oneway clutch bolt
Oneway clutch nut
ACG flywheel nut
Spark plug
Drain plug
Oil pump screw
Head CYL stud bolt (IN pipe)
Head CYL stud bolt (EX pipe)
A.C.G Startor
Fan
4
1
8
4
2
1
2
1
7
1
1
1
1
3
1
1
1
1
1
2
2
3
4
8
30
6
8
5
6
6
6
8
8
12
10
28
6
24
10
10
10
3
6
8
5
6
0.7_ 1.1
1.0_ 2.0
1.0_ 1.4
1.8_ 2.2
0.7_ 1.1
0.8_ 1.2
1.0_ 1.4
0.35_ 0.5
2.4_ 3.0
1.0_ 2.0
5.5_ 6.5
3.5_ 4.5
5.0_ 6.0
1.0_ 1.4
5.0_ 6.0
3.5_ 4.5
1.0_ 1.4
2.0_ 3.0
0.1_ 0.3
0.7_ 1.1
0.7_ 1.1
0.8_ 1.0
0.6_ 1.0
Apply oil
Apply oil
Apply oil
Apply thread
lock
1. GENERAL INFORMATION
1-13
Mongoose/KXR 90/50
ENGINE (Mongoose/KXR 50)
Item
Q‘ty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Cylinder head bolt
Clutch drive plate nut
Drive face nut
Clutch outer nut
ACG flywheel nut
Mission fill bolt
Drive plate nut
Spark plug
4
1
1
1
1
1
1
1
6
28
10
10
10
8
28
14
0.8_ 1.2
5.0_ 6.0
3.5_ 4.5
3.5_ 4.5
3.5_ 4.5
1.0_ 2.0
5.0_ 6.0
1.1_ 1.7
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Steering stem nut
Front Swing arm nut
Front wheel nut
Rear wheel nut
Front wheel hub nut
Rear wheel hub nut
Front shock absorber upper mount bolt
Front shock absorber lower mount bolt
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Rear swing arm axle hub bolt
Rear axle hub nut
Front engine bracket bolt
Rear engine bracket bolt
Rear caliper bolt
Brake oil bolt
M/C holder
Exhaust muffler lock bolt (frame)
Exhaust muffler lock nut (engine)
Rod-end nut
1
4
8
8
2
2
2
2
1
1
1
4
2
2
2
2
2
2
2
4
14
10
10
10
12
14
10
10
10
10
14
12
10
8
8
10
6
8
8
8
6.0_ 8.0
4.0_ 5.0
4.0_ 5.0
4.0_ 5.0
5.5_ 6.5
6.0_ 8.0
3.5_ 4.5
3.5_ 4.5
3.5_ 4.5
3.5_ 4.5
6.0_ 8.0
6.0_ 8.0
4.0_ 5.0
2.0_ 2.4
2.9_ 3.5
3.0_ 4.0
1.0_ 1.4
3.2_ 3.8
1.8_ 2.2
2.5_ 3.5
1. GENERAL INFORMATION
1-14
Mongoose/KXR 90/50
SPECIAL TOOLS (Mongoose/KXR 90)
Tool Name
Tool No.
Remarks Ref. Page
Clutch spring compressor
E034
Bearing puller
E037
Valve spring compressor
E040
Oil seal & bearing installer
E014
Tappet adjuster
E036
Long socket wrench
E015
Start clutch puller
E006
Flywheel puller
E001
Universal holder
E017
Float level gauge
SPECIAL TOOLS (Mongoose/KXR 50)
Tool Name
Tool No.
Remarks Ref. Page
Flywheel puller
E001
Oil seal and bearing install
E014
Universal holder
E017
Clutch spring compressor
E034
Bearing puller
E037
Crankshaft install
E016
Crankshaft & crankcase install
E024
Crankcase puller
E026
Crankshaft Bearing puller
E030
Float level gauge
1. GENERAL INFORMATION
1-15
Mongoose/KXR 90/50
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft right side oil seal
Crankshaft one-way clutch movable part
Oil pump drive chain
Balance gear
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE15W-40)
•API SG Engine Oil
Transmission gear and movable parts
Gear oil: SAE90#
1. GENERAL INFORMATION
1-16
Mongoose/KXR 90/50
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the ATV.
Throttle Cable
Steering Column Lower
Front Swing Arm Bush
Front Swing Arm Bush
Steering knuckle
Steering knuckle
1. GENERAL INFORMATION
1-17
Mongoose/KXR 90/50
Rear Axle Hub
Collar/Oil
Seal/Bearing
Driven Sprocket
Rear Swing Arm Axle
1. GENERAL INFORMATION
1-18
Mongoose/KXR 90/50
CABLE & HARNESS ROUTING
Headlight Wire Coupler
Rear Brake Cable/Fluid Hose
Handlebar Switch Coupler
Ignition Switch Coupler
Harness Wire
Ignition Coil
Kill Switch Wire (Safety)
Front Brake Cable
Front Stop Switch Wire
Throttle Cable
REG.REC Wire
Pilot Leads
(Mongoose/KXR 50)
Rear Stop Switch Wire
Handlebar Switch Wire
Rear Stop Switch Wire
Kill Switch Wire (Safety)
Front Stop Switch Wire
Front Brake Cable
Rear Brake Cable/Fluid Hose
REG.REC
1. GENERAL INFORMATION
1-19
Mongoose/KXR 90/50
Oil Outlet Tube
(Mongoose/KXR 50)
Oil Level Switch Wire
(Mongoose/KXR 50)
A.C.G. Wire
Ignition Coil
Ignition Coil Wire
Starter Motor Wire
1. GENERAL INFORMATION
1-20
Mongoose/KXR 90/50
Taillight Coupler
Battery Positive (+)
Battery Negative (-)
Oil Pump Control Cable
(Mongoose/KXR 50)
Ignition Coil Wire
Rear Brake Cable/Fluid Hose
Air Inlet Hose
Throttle Cable
Fuel Tube
Autobystarter Wire
Harness Wire
Resistor
Rear Brake Cable/Fluid Hose
1. GENERAL INFORMATION
1-21
Mongoose/KXR 90/50
WIRING DIAGRAM (Mongoose/KXR 90 OFF ROAD)
G
1. GENERAL INFORMATION
1-22
Mongoose/KXR 90/50
WIRING DIAGRAM (KXR 90 ON ROAD)
1. GENERAL INFORMATION
1-23
Mongoose/KXR 90/50
WIRING DIAGRAM (Mongoose/KXR 50 OFF ROAD)
1. GENERAL INFORMATION
1-24
Mongoose/KXR 90/50
WIRING DIAGRAM (KXR 50 ON ROAD)
1. GENERAL INFORMATION
1-25
Mongoose/KXR 90/50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel valve passage
Faulty spark plug
Fouled spark plug
Faulty ignition unit
Faulty pulser coil
Broken or shorted ignit ion coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery
Faulty starter clutch
Valve clearance too small
Valve stuck open
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket
Air leaking through intake
pipe
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted air screw
Flooded carburetor
Clogged air cleaner
Throttle valve excessively
open
Check if fuel reaches
carburetor by
loosening drain screw
Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground
Inspection/Adjustment
Probable Cause
Spark jumps
Normal
compression
Engine does not
fire
Weak or no spark
Low or no
compression
Engine fires but
does not start
Test cylinder
compression
Start engine by following normal starting
procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does not
reach carburetor
Wet spark plug
Dry spark plug
1. GENERAL INFORMATION
1-26
Mongoose/KXR 90/50
ENGINE LACKS POWER
Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Carburetor fuel level too low
Faulty ignition unit
Faulty pulser coil
Improper valve clearance
adjustment
Excessively worn valve seat
(protruded valve stem)
Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing
Clean and unclog
Fouled spark plug
Incorrect heat range plug
Oil level too high
Oil level too low
Oil not changed
Clogged oil line
Faulty oil pump
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon build-up in
combustion chamber
Ignition timing too early
Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early
Start engine and accelerate
lightly for observation
Inspection/Adjustment
Symptom
Probable Cause
Engine speed
increases
Correct timing
Engine speed does not
increase sufficiently
Incorrect timing
Check ignition timing
(using a timing light)
Test cylinder compression
Check carburetor for
clogging
Rapidly accelerate or run
at high speed
Remove spark plug and
inspect
Check if engine overheats
Check valve clearance
Correct
Incorrect
Normal
compression
Abnormal
compression
Remove oil dipstick and
check oil level and condition
Remove cylinder head oil
pipe bolt and inspect
Engine overheats
Engine does not
overheats
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not
contaminated
Incorrect or
contaminated
Valve train lubricated
properly
Valve train not
lubricated properly
Engine does not knock
Engine knocks
Not clogged
Clogged
1. GENERAL INFORMATION
1-27
Mongoose/KXR 90/50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty ignition unit
Faulty pulser coil
Mixture too rich (turn screw
out)
Mixture too lean (turn screw
in)
Deteriorated O-ring
Carburetor not securely
tightened
Damaged insulator rubber
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
Check carburetor
gasket for air leaks
Check carburetor air
screw adjustment
Correct timing
Incorrect timing
Correctly adjusted
No air leak
Air leaks
Good spark
Weak or inter mittent spark
Incorrectly
1. GENERAL INFORMATION
1-28
Mongoose/KXR 90/50
POOR PERFORMANCE (AT HIGH SPEED)
Faulty CDI unit
Faulty pulser coil
Improperly adjusted valve
clearance
Worn valve seat
Empty fuel tank
Clogged fuel tube or filter
Clogged Fuel tank cap breather
hole
Clean and unclog
Cam timing gear aligning
marks not aligned
Faulty spring
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
Check carburetor jets
for clogging
Check fuel pump for
fuel supply
Correct timing
Incorrect timing
Check valve spring
tension
Check valve clearance
Fuel flows freely
Fuel flow restricted
Correct
Incorrect
Not clogged
Clogged
Correctly adjusted
Incorrectly adjusted
Not weakened
Weak spring
Check valve timing
1. GENERAL INFORMATION
1-29
Mongoose/KXR 90/50
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead battery
Faulty battery
Faulty A.C. generator coil
Broken yellow wire
Shorted white and yellow
wires
Broken red wire
Faulty regulator/rectifier
Poorly connected coupler
Faulty A.C. generator
Overcharging
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
Start engine and test
limit voltage of
battery terminals
Connect battery (+)
wire to
regulator/rectifier
coupler red wire and
batt ery (-) wire to engine
ground and test voltage
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
Battery has
voltage with
ignition switch
Normal
Voltage does not
increase
Battery has no
voltage with
ignition swit ch
Resistance too
Normal voltage
No voltage
Measure resistance
between AC generator
coil terminals
Normal
Abnormal
Check
regulator/rectifier
coupler for loose
Normal
Abnormal
Connect battery (+)
wire to
regulator/rectifier
coupler green wire and
batt ery (-) wire to engine
ground and test voltage
Check
regulator/rectifier
coupler for loose
1. GENERAL INFORMATION
1-30
Mongoose/KXR 90/50
NO SPARK AT SPARK PLUG
Faulty spark plug
Loose spark plug cap
Poorly connected coupler
Faulty ignition switch
Weak battery
Faulty pulser coil
Faulty ignition coil
Faulty charging system
Broken wire harness
Poorly connected coupler
Faulty CDI unit
Faulty ignition coil
Replace with a new
spark plug and inspect
again
Check CDI unit
coupler for looseness
Inspection/Adjustment
Symptom
Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal
Abnormal
Abnormal
Measure resistance
between terminals of
CDI unit coupler
Check related parts
Check ignition coil
with a CDI unit tester
Weak or no spark
Not loose
Good spark
Loose
Good
Good
Check spark plug cap
and high-tension wire
for looseness
Check CDI unit with a
CDI unit tester
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