Kymco Mongoose 250 User Manual

OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

Mongoose 250

OFF-ROAD

IMPORTANT NOTICES

READ THIS MANUAL CAREFULLY

Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this ATV should carefully read and understand the contents of this manual before riding the vehicle.

AGE RECOMMENDATION

The minimum recommended age for this ATV model is 16. Children under age 16 should never operate this vehicle.

RIDER TRAINING

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 is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this machine on any public street, road or highway.

This machine complies with all applicable OFF-ROAD noise level and spark arrester laws and regulation in effect at the time of manufacture.

Please check your local riding laws and regulations before operating this machine.

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.

WARNING

result if instructions are not followed.

CAUTION Indicates a possibility that equipment or property damage

could result if instructions are not followed.

Note: 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.

Indicates a strong possibility that serious injury or death may

PREFACE

Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a worldwide reputation for quality-in research, design, production and service.

For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.

This manual will provide you with a good basic understanding of the features and operation of this machine. This manual includes important safety information. It provides 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 maintenance of your machine, please consult a KYMCO dealer.

We wish you many years of safe and enjoyable riding.

While reading this manual, remember:

Indicates a strong possibility that serious injury or death may

WARNING

result if instructions are not followed.

All information in this publication is based on the latest product information available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD reserves the right to make changes at any time without notice and without incurring any obligation.

CONTENTS

Page Page

LOCATION OF THE WARNING AND

SPECIFICATION LABELS...........................1

SAFETY INFORMATION.............................4

DESCRIPTION AND MACHINE

IDENTIFICATION.....................................11

Key identification number.....................11

Frame and engineserialnumber............12

Model code.........................................12

Parts location.....................................13

CONTROL FUNCTIONS...........................17

Ignition switch.....................................17

Indicator lamps....................................18

Handlebar switches.............................20

Throttle lever......................................22

Speed limiter.......................................23

Front brake ........................................24

Rear brake .........................................24

Parking brake......................................25

Drive select lever.................................26

Fuel tank cap ......................................26

Fuel valve...........................................27

Starter (choke)....................................28

Seat...................................................29

Flag pole bracket.................................30

Storage compartment..........................30

(Cont'd)

Page Page

PRE-OPERATION CHECKS......................31

Drive select lever ................................32

Front and rear brakes..........................35

Fuel ...................................................36

Engine and transmission oil .................38

Chain ................................................39

Throttle lever......................................39

Fittings and fasteners..........................39

Lights ................................................39

Switches ............................................39

Tires ..................................................40

How to measure tire pressure ..............41

Tire wear limit .....................................42

Coolant .............................................42

OPERATION............................................44

Starting a cold engine..........................44

Starting 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

Accessories .......................................54

Riding Your ATV .......................................56

GETTING TO KNOW YOUR ATV .........57

RIDE WITH CARE AND

JUDGEMENT ..........................58

BE CAREFUL WHERE YOU RIDE .........69

TURNING YOUR ATV ..........................78

SLIDING AND SKIDDING.....................80

CLIMBING UPHILL..............................82

RIDING DOWNHILL.............................88

CROSSING A SLOPE ..........................90

RIDING OVER ROUGH TERRAIN .........92

CROSSING THROUGH

SHALLOW WATER..............................93

WHAT TO DO IF ..................................95

WHAT TO DO ......................................95

GOOD

(Cont'd)

Page Page

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

Front and rear brake shoe inspection

(Model code: LA50AB) .......................117

Brake fluid inspection.........................118

Cooling system inspection..................120

Drive chain slack check......................122

Drive chain slack adjustment...............122

Drive chain cleaning and

Lubrication.......................................124

Rear swing arm lubrication .................124

Draining the V-belt compartment.........125

Cable inspection and lubrication..........125

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

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

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

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

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

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

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

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

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

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

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

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

(cont'd)

Page

NOISE REGULATION.............................141

MAINTENANCE RECORD.......................142

INDEX...................................................143

LOCATION OF THE WARNING AND

SPECIFICATION LABELS

Warning information

Anyone who rides the vehicle should read and understand this information before riding. They contain important information for safe and proper operation of yourATV.

The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes hard to read, contact your KYMCO dealer for replacements.

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.

NEVER

under age 16.

operate this ATV if you are

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL. LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH. OPERATING TIRE PRESSURE : Set with tires cold

Recommended : FRONT : 25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi



REAR :

Never set tire pressure below recommended.



Maximum Vehicle Load: 100Kg. (220 lbs).



Including weight of operator, cargo and accessories.

25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi

CAUTION

Before shifting, you must stop the machine and return the throttle lever to its closed position until the engine speed to the specified idling speed.

Otherwise, the transmission may be damaged

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate :

Without proper training or 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 proper riding techniques to avoid vehicle



overturns on hills and rough terrain and in turns.

Avoid paved surfaces-pavement may seriously



affect handling and control. READ OWNER'S MANUAL, FOLLOW ALL INSTRUCTIONS AND WARNINGS.

SAFETY INFORMATION

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from

other vehicles including motorcycles and cars. An accident can occur quickly, even during routine maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:



Read this manual and all labels carefully and follow the operating procedures described.



Never operate an ATV without proper training or instruction.

Beginners should receive training from a certified instructor.



Always follow the age recommendation:

- A child under 16 years old should never operate an ATV with engine size greater than 90cc.



Never carry a passenger on an ATV.

Always avoid operating anATV on any paved surfaces, including sidewalks, driveways, parking



lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.



Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.



Never consume alcohol or drugs before or while operating thisATV.



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, jump, or other stunt.



Always inspect your ATV each time you use it to make sure it is in safe 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 ATV during operation.

Always follow proper procedures for turning as described in this manual. Practice turning at low

speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

Never operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to

changing terrain conditions when operating the ATV.



Always follow proper procedures for climbing hills as described in this manual. 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 suddenly. Never go over the top of a hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as described in this

manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down hill at an angle that would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as described in this manual.Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of theATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.



Never operate the ATV on hills too steep. Practice on smaller hills before attempting larger hills.



Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.



Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.



Never operate an ATV in fast flowing water or in water deeper than that recommended in this manual. 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.



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 surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.



Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly.

Always use the size and type tires specified in this manual. Always maintain proper tire pressure

as described in this manual.

Never modify an ATV through improper installation or use of accessories.



Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

WARNING

POTENTIAL HAZARD

Improper handling of gasoline.

WHAT CAN HAPPEN

Gasoline can catch fire and you could be burned.

HOW TO AVOID THE HAZARD

Always turn off the engine when refueling. Do not refuel right after the engine has been

running and is still very hot. Do not spill gasoline on the engine or exhaust

pipe/muffler when refueling. Never refuel while smoking, or while in the

vicinity of sparks, open flames, 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 the "OFF" position.

Otherwise, fuel may leak out of the carburetor or fuel tank.

WHAT CAN HAPPEN

Gasoline is poisonous and can cause injuries.

HOW TO AVOID THE HAZARD

If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately.

If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

WARNING

POTENTIAL HAZARD

Starting or running the engine in a closed area.

WHAT CAN HAPPEN Exhaust fumes are poisonous and may

cause loss of consciousness and death within a short time.

HOW TO AVOID THE HAZARD Always operate your machine in an area

with adequate ventilation.

DESCRIPTION AND MACHINE IDENTIFICATION

Identification number records

Record the key identification number, frame serial number, engine serial number and model code information for assistance when order replacement parts.

KEY NO.

FRAME NO.

ENGINE NO.

MODEL CODE

Key identification number

The key identification number is stamped on the hang tag as shown in the following illustration.

(1)

(1) Key identification number

Frame and engine serial number

The frame serial number is stamped on the front of the frame.

The engine serial number is stamped on the left crankcase.

Model code

MODEL CODE:

LA50AA (The rear brake is operated either

By depressing the brake pedal or by squeezing the rear brake lever)

LA50AB(The rear brake is operated by

depressing the brake pedal)

(1)

(1) Frame serial number (1) Engine serial number

(1)

Parts location

(01)(02)(03)(04)(05)

(01)

Headlight

(0 Headlight switch

Starter button Engine stop switch Passing signal switch

(03)

Drive select lever

(04)

Throttle lever

(05)

Seat

(10)(11) (12)

(06)(07)(09) (08)

(06) Front brake lever

) Fuel valve

(07 (08) Tool kit (09) Taillight/Stop light (10) Reservoir water tank (11) Rear brake pedal fluid r (12) Engine oil inspection window

eservoir

(15) (14) (13)

(13)

Exhaust system

) Choke knob

(14 (15) Rear brake lever (Mode code: LA50AA) (16) Front wheel (17) Rear wheel (18)

Seat lock lever

(18)(17)(16)

(19)

(20)(21)(22)

(18)

(18) Flat pole bracket

) Right operator footpeg

(19 (20) Rear brake pedal (21) Front parking brake (22) Ignition switch (23) Rear parking brake (24) Coolant temperature warning lamp

High beam indicator lamp Neutral indicator lamp

Reverse indicator lamp (25) Fuel fill cap (26) Left operator footpeg

NOTE:

The machine you have purchased may differ

(26)(23) (25)(24)

slightly from those shown in the figures of this manual.

CONTROL FUNCTIONS

Ignition switch

Functions of the respective switch positions are as follows:

OFF: All electrical circuits are switched off. The key

can be removed in this position.

ON ( :

)

The 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.

OFF

(1)

(1) Ignition switch (2) Key

(2)

Indicator lamps

(1)(2)(3)(4)

(1) Reverse indicator lamp (2) Neutral indicator lamp (3) High beam indicator lamp (4) Coolant temperature warning lamp

Reverse indicator lamp

The reverse indicator lamp will light when the transmission is in reverse and the ignition switch is ON () .

Neutral indicator lamp

The neutral indicator lamp will light when the transmission is in neutral and the ignition switch is ON (

High beam indicator lamp

The high beam indicator lamp will light when the headlight switch to select high beam ( )and the ignition switch is ON (

).

Coolant temperature warning lamp

When the coolant temperature reaches a specified level, this light comes on to warn that the coolant temperature is too hot. If the light comes on during operation, stop the engine as soon as it is safe to do so and allow the engine to cool down for about 10 minutes.

Coolant temperature warning lamp checking methed

Turn the ignition to " " and the engine stop switch " "

．

CAUTION:

1. The engine may overheat if the ATV is overloaded. If this happens, reduce the load to specification.

2. Restart after making sure that the light is out. Continuous use while the light is on may cause damage to the engine.

Coolant temperature warning lamp comes on momentarily.

Coolant temperature and electrical circuit are OK. Go ahead with riding.

Coolant temperature warning lamp does not come on.

Ask a KYMCO dealer to inspect the electrical circuit.

Handlebar switches

(1)

(2)

Stater button

To starter the engine, press the starter button, with the transmission in neutral, the ignition switch ON ( ) and the engine stop switch at RUN ( )



CAUTION:

See starting instructions prior to starting engine (see page 44 for details).

(1) Headlight switch (2) Starter button

Headlight switch

Turning the switch to the " " position to switch off the headlight and the taillight.

Turning the switch to the " " position to switch on the low beam and the taillight.

Turning the switch to the " " position to switch on the high beam and the taillight.

．

NOTE:

If the starter switch is pushed with the ignition switch " " and the engine stop switch " ", the starter motor will be activated but the engine will not start. To start the engine, be sure to position the engine stop switch at " ".

．

(2)

Engine stop switch

When the switch is in the RUN ( ) position, the 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.

(1)

(1)Engine stop switch (2) Passing signal switch

NOTE:

If you stop yourATV by turning the engine stop switch OFF ( ), be sure to turn the ignition switch OFF to prevent battery discharge.

Passing signal switch

When passing, if there are cars coming from the opposite direction, press and release the passing signal switch and the headlight will wink to warn the coming vehicles.

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