Kymco MO KXR 50 Service Manual - chap 01 (info generali)

1. GENERAL INFORMATION

1-0

Mongoose/KXR 90/50

1

__________________________________________________________________________________

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

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

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.