KYMCO Mongoose 90, Mongoose 50-4T, MXER 70R, Mongoose 70, MXER 50R-4T Service Manual
...
By KWANG YANG Motor Co., Ltd.
First Edition, Dec 2006
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100LA0975
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Mongoose
90/70/50-4T/50-2T & MXER
90R/70R/50R-4T/50R-2T.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part,
starting from periodic maintenance.
Sections 4 through 17 give instructions
for disassembly, assembly and
inspection of engine, chassis frame and
electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
FRAME COVERS/EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE REMOVAL 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
DRIVE AND DRIVEN PULLEYS
9
FINAL REDUCTION/TRANSMISSION
SYSTEM
10
CRANKCASE/CRANKSHAFT
11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION/STEERING
SYSTEM
12
REAR WHEEL /SWING
ARM/HYDRAULIC BRAKE
13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM 15
STARTING SYSTEM 16
BULBS REMOVAL/INSTRUMENT/HORN 17
CHASSIS
ELECTRICAL
EQUIPMENT
ENGINE
The information and contents included in
this manual may be different from the
vehicle in case specifications are changed.
KYMCO reserves the right to make
changes at any time without notice and
without incurring any obligation.
1. GENERAL INFORMATION
1-0
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER---------------------------------------------------------- 1- 1
SPECIFICATIONS ---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS ------------------------------------------------ 1- 6
TORQUE VALUES --------------------------------------------------------- 1-14
SPECIAL TOOLS ----------------------------------------------------------- 1-16
LUBRICATION POINTS -------------------------------------------------- 1-17
CABLE & HARNESS ROUTING ---------------------------------------- 1-20
WIRING DIAGRAMS ------------------------------------------------------ 1-23
TROUBLESHOOTING----------------------------------------------------- 1-28
1
1. GENERAL INFORMATION
1-1
SERIAL NUMBER
Location of Engine Serial Numbe
r
(90cc/70cc/50cc-4T)
Location of Frame Serial Numbe
r
Location of Engine Serial Number (50cc-2T)
1. GENERAL INFORMATION
1-2
SPECIFICATIONS
Mongoose 90/MXER 90R
Model No. LA20
Overall length 1430 mm (57.2 in)
Overall width 905 mm (36.2 in)
Overall height 910 mm (36.4 in)
Wheel base 965 mm (38.6 in)
Engine type O.H.C.
Displacement 89.9 cc (5.5 cu-in)
Fuel Used
92# nonleaded gasoline
Front wheel 58 kg (127.6 lbs)
Rear wheel 56.5 kg (124.3 lbs)
Net weight
Total 114.5 kg (251.9 lbs)
Front wheel 61.5 kg (135.3 lbs)
Rear wheel 58.5 kg (128.7 lbs)
Gross
weight
Total 120 kg (264 lbs)
Front wheel 18*7-8
Tires
Rear wheel 18*9-8
Ground clearance 104 mm (4.16 in)
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
47X51.8 mm
(1.85X2.04 in)
Compression ratio 10:1
Compression pressure
1600 kPa (16
kgf/cm², 227.2 psi)
Intake Open 2° (ATDC)
(1mm) Close 26° (ABDC)
Exhaust Open 44° (BBDC)
Port
timin
g
(1mm) Close -17° (BTDC)
Intake 0.1 mm (0.004 in)
Valve
clearance
(cold)
Exhaust 0.1 mm (0.004 in)
Idle speed 1800 rpm
Lubrication type
Forced pressure &
Wet sump
Oil pump type
Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity
0.8 L (0.7 lmp qt,
0.85 US qt)
Lubrication System
Oil exchanging
capacity
0.7 L (0.62 lmp qt,
0.74 US qt)
Engine
Cooling Type Air cooling
Air cleaner type Sponge
Fuel capacity
5.5 L (12.1 lmp gal,
1.45 US gal)
Type PTE
Main jet No. #80
Venturi
dia.(mm)
φ16
Fuel System
Carburetor
Throttle type PISTON
Type CDI
Ignition timing 13°BTDC/1800rpm
Contact breaker Non-contact point type
Spark plug NGK CR7HSA
Ignition System
Spark plug gap
0.6～0.7 mm (0.024～
0.028 in)
Electrical Equipment
Battery Capacity 12V4AH
Clutch Type CVT
Type Helical gear
Transm
is-sion
Gear
Operation
Automatic centrifugal
Type
Type V-Belt
Primary
reduction
0.8~2.5
Power Drive System
Reduction
Gear
Final
reduction
9.255
FR/RR tire rolling
circumference
1436 mm (57.44 in)
Front
25 kPa (0.25 kg/cm²,
3.6 psi)
Tire pressure
Rear
25 kPa (0.25 kg/cm²,
3.6 psi)
Left 35°
Moving Device
Turning angle
Right 35°
RearDisk brake
Brake system type
Front Drum brake
Front
Swing axle
Damping
Device
Suspension
type
Rear
Swing arm
Frame type Steel tube frame
1. GENERAL INFORMATION
1-3
Mongoose 70/MXER 70R
Model No. LA15
Overall length 1415 mm (56.6 in)
Overall width 880 mm (35.2 in)
Overall height 910 mm (36.4 in)
Wheel base 965 mm (38.6 in)
Engine type O.H.C.
Displacement 69.4 cc (4.25 cu-in)
Fuel Used 92# nonleaded gasoline
Front wheel 53 kg (116.6 lbs)
Rear wheel 52 kg (114.4 lbs)
Net weight
Total 105 (231 lbs)
Front wheel 57 kg (125.4 lbs)
Rear wheel 54 kg (118.8 lbs)
Gross weight
Total 111 kg (244.2 lbs)
Front wheel 16*8-7
Tires
Rear wheel 16*8-7
Ground clearance 85 mm (3.4 in)
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
47X40 mm
(1.88X1.6 in)
Compression ratio 7.9:1
Compression pressure
1400 kPa (14 kgf/c
m
²,
200 psi)
Open 6° (ATDC)
Intake
(1mm)
Close 28° (ABDC)
Open 38° (BBDC)
Port
timin
g
Exhaust
(1mm)
Close -6° (BTDC)
Intake 0.04 mm (0.0016 in)
Valve
clearance
(cold)
Exhaust 0.04 mm (0.0016 in)
Idle speed 2000rpm
Lubrication
type
Forced pressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity
0.8 L (0.7 lmp qt,
0.85 US qt)
Lubrication System
Oil exchanging
capacity
0.7 L (0.62 lmp qt,
0.74 US qt)
Engine
Cooling Type Air cooling
Air cleaner type Sponge
Fuel capacity
5.5 L (12.1 lmp gal,
1.45 US gal)
Type PTE
Main jet No. #85
Venturi dia.(mm) φ16
Fuel S
y
stem
Carbureto
Throttle type PISTON
Type CDI
Ignition timing 13°BTDC/1800rpm
Contact breaker Non-contact point type
Spark plug NGK CR7HSA
Ignition System
Spark plug gap
0.6～0.7 mm
(0.024～0.028 in)
Electrical E
q
ui
p
ment
Battery Capacity 12V4AH
Clutch Type CVT
Type Helical gear
Transmission Gea
r
Operation
Automatic centrifugal
Type
Type V-Belt
Primary
reduction
0.8~3.1
Power Drive S
y
stem
Reduction
Gear
Final
reduction
27.257
FR/RR tire rolling
circumference
1266 mm (50.64 in)
Front
Tire pressure
Rear
25 kPa (0.25 kg/c
m
²,
3.6 psi)
Left 35°
Moving Device
Turning angle
Right 35°
Rear Disk brake
Brake system type
Front Drum brake
Front Swing axle
Damping Device
Suspension type
Rear Swing arm
Frame type Steel tube frame
1. GENERAL INFORMATION
1-4
Mongoose 50-4T /MXER 50R-4T
Model No. LB10
Overall length 1430 mm (58 in)
Overall width 870 mm (34.8 in)
Overall height 900 mm (37.8 in)
Wheel base 965 (38.6 in)
Engine type O.H.C.
Displacement 49.5 cc (3.01 cu-in)
Fuel Used 92# nonleaded gasoline
Front wheel
51 kg (132lbs)
Rear wheel
50 kg (132 lbs)
Net weight
Total
101 kg (264 lbs)
Front wheel
55 kg (138.6 lbs)
Rear wheel
53 kg (134.2 lbs)
Gross weight
Total
108 kg (272.8 lbs)
Front wheel 16*8-7
Tires
Rear wheel 16*8-7
Ground clearance 130 mm (7.6 in)
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
39X41.4 mm
(1.54X1.63 in)
Compression ratio 10:1
Compression pressure
1400 kPa (14 kgf/c
m
2
,
200 psi)
Open 2° (BTDC)
Intake
(1mm)
Close 26° (ABDC)
Open 44° (BBDC)
Port
timin
g
Exhaust
(1mm)
Close -17° (ATDC)
Intake
Valve
clearance
(cold)
Exhaust
0.04 mm (0.0016 in)
Idle speed (rpm) 2000rpm
Lubrication
type
Forced pressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity
0.8 L (0.7 lmp qt,
0.84US qt)
Lubrication System
Oil exchanging
capacity
0.7 L (0.62 lmp
qt,0.74US qt)
Engine
Cooling Type Air cooling
Air cleaner type Sponge
Fuel capacity
5.5 L (12.1 lmp gal,
1.45 US gal)
Type PTE
Main jet No. #80
Venturi dia.(mm) φ16
Fuel S
y
stem
Carbureto
Throttle type PISTON
Type CDI
Ignition timing 13°BTDC/2000rpm
Contact breaker Non-contact point type
Spark plug NGK CR7HSA
Ignition System
Spark plug gap
0.6～0.7 mm (0.024
～0.028 in)
Electrical E
q
ui
p
ment
Battery Capacity 12V4AH
Clutch Type CVT
Type Helical gear
Transmission Gea
r
Operation
Automatic centrifugal
Type
Type V-Belt
Primary
reduction
0.8~2.5
Power Drive S
y
stem
Reduction
Gear
Final
reduction
27.136
FR/RR tire rolling
circumference
1546/1514 mm
(61.84/60.56 in)
Front
Tire pressure
Rear
25 kPa (0.25 kgf/cm
2
,
3.6 psi)
Left 35°
Moving Device
Turning angle
Right 35°
Rear Disk brake
Brake system type
Front Drum brake
Front Swing axle
Damping Device
Suspension
type
Rear Swing arm
Frame type Steel tube frame
1. GENERAL INFORMATION
1-5
Mongoose 50-2T /MXER 50R-2T
Name & Model No. LA10
Overall length 1385 mm (55.4 in)
Overall width 875 mm (35 in)
Overall height 890 mm (35.6 in)
Wheel base 900 mm (36 in)
Engine type 2-stroke.
Displacement 49.4 cc (3.02 cu-in)
Fuel Used 92# nonleaded gasoline
Front wheel 49.6 kg (109.12 lbs)
Net weight Rear wheel 50.7 kg (111.54 lbs)
Total 100.3 kg (220.66 lbs)
Front wheel 54.6 kg (120.12 lbs)
Gross weight Rear wheel 55.7 kg (122.54 lbs)
Total 110.3 kg (242.66 lbs)
Front wheel 16*8-7
Tires
Rear wheel 16*8-7
Ground clearance 72 mm (2.88 in)
Starting system
Motor & Kick starte
r
Type Gasoline, 2-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement Reed valve & piston
Bore x stroke
39X41.4 mm
(1.56X1.656 in)
Compression ratio 7.2:1
Compression pressure
1200 kPa (12 kgf/c
m
2
,
170.4 psi)
Intake
Open Automatic controlled
Port
(1mm)
Close Automatic controlled
timin
g
Exhaust
Open ─
(1mm)
Close ─
Valve clearance
Intake ─
(cold)
Exhaust ─
Idle speed 2000 rpm
Lubrication type Separate type
Oil pump type Plunger type
Oil filter type Full-flow filtration
Engine
Cooling Type Air cooling
Air cleaner type & No Sponge
Fuel capacity
5.5 L (12.1 lmp gal, 1.45
US gal)
Type PB
Main jet No. 82
Venturi dia.(mm) φ14
Fuel System
Carburetor
Throttle type PISTON
Type CDI
Ignition timin
g
15°BTDC/1700r
pm
Contact breaker Non-contact point type
Spark plug NGK BR8HAS
Ignition System
Spark plug gap
0.6～0.7 mm
(0.024～0.028 in)
Electrical Equipment
Battery Capacity 12V4AH
Clutch Type CVT
Type Helical gear
Transmission Gear
Operation
Automatic centrifugal
Type
Type V-Belt
Primary
reduction
0.895~3.113
Power Drive System
Reduction
Gear
Final
reduction
11.05
FR/RR tire rolling
circumference
1247 mm (49.88 in)
Fron
t
Tire pressure
Rear
25 kPa (0.25 kgf/cm
2
,
3.6 psi)
Turning Left 35°
Moving Device
angle
Right 35°
Brake system
Rea
r
Drum brake
type Front Drum brake
Front
Swing axle
Damping
Suspension
type
Rear
Swing arm
Frame type Steel tube frame
1. GENERAL INFORMATION
1-6
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure
to use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
1. GENERAL INFORMATION
1-7
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for
proper tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-)
terminal before operation.
When using a spanner or other tools,
make sure not to damage the motorcycle
surface.
After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.
1. GENERAL INFORMATION
1-8
If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock
on the connector shall be released before
operation.
Hold the connector body when
connecting or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is
bending, protruding or loose.
Confir
m
Capacity
1. GENERAL INFORMATION
1-9
The connector shall be inserted
completely.
If the double connector has a lock,
lock it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check
for damaged terminal cover or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
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
1-10
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp
edges or corners. Avoid the projected
ends of bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !
1. GENERAL INFORMATION
1-11
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with
electrical tape or tube if they contact a
sharp edge or corner.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.
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
1-12
After routing, check that the wire
harnesses are not twisted or kinked.
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.
When a testing device is used, make sure
to understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
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
1-13
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
1-14
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque
N•m (kgf•m, lbf•ft)
Item
Torque
N•m (kgf•m, lbf•ft)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
5(0.5, 4)
10 (1, 7)
22 (2.2, 16)
35 (3.5, 25)
55 (5.5, 40)
70 (7, 50)
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
3 (0.3, 2)
4 (0.4, 3)
9 (0.9, 6.5)
12 (1.2, 9)
27 (2.7, 20)
40 (4, 29)
Torque specifications listed below are for important fasteners.
ENGINE (90cc/70cc/50cc-4T)
Item Q‘ty
Thread dia.
(mm)
Torque
N•m (kgf•m, lbf•ft)
Remarks
Stud bolt
Oil filter screen cap
L cover
Cam shaft holder nut (90cc)
Cam shaft holder nut
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 nut (90&70 cc)
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
4
2
1
2
1
7
1
1
1
1
1
1
1
1
1
2
2
3
4
8
30
6
8
7
5
6
6
6
8
8
12
10
28
24
10
10
10
3
6
8
5
6
9 (0.9, 6.5)
15 (1.5, 11)
12 (1.2, 9)
20 (2, 14)
14 (1.4, 10)
9 (0.9, 6.5)
10 (1, 7)
12 (1.2, 9)
4.5 (0.45, 3)
27 (2.7, 19)
18 (1.8, 13)
60 (6, 43)
40 (4, 29)
55 (5.5, 40)
55 (5.5, 40)
40 (4, 29)
12 (1.2, 9)
25 (2.5, 18)
2 (0.2 1.4)
9 (0.9, 6.5)
9 (0.9, 6.5)
10 (1, 7)
8 (0.8, 5.8)
Apply oil
Apply oil
Apply oil
Apply oil
1. GENERAL INFORMATION
1-15
ENGINE (50cc-2T)
Item Q‘ty
Thread dia.
(mm)
Torque
N•m (kgf•m,
lbf•ft)
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
10 (1, 7)
55 (5.5, 40)
40 (4, 29)
40 (4, 29)
40 (4, 29)
15 (1.5, 11)
55 (5.5, 40)
15 (1.5, 11)
FRAME
Item Q‘ty
Thread dia.
(mm)
Torque
N•m (kgf•m,
lbf•ft)
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 bolt
Front engine mounting bolt
Rear engine mounting bolt
Rear caliper bolt
Brake oil bolt
M/C holder
Exhaust muffler lock bolt
Exhaust muffler lock nut (90&70 cc)
Exhaust muffler lock nut (50 cc)
Rod-end nut
1
4
8
8
2
2
2
2
1
1
1
4
2
2
2
2
2
4
2
2
4
14
10
10
10
12
14
10
10
10
10
14
12
10
8
8
10
6
8
8
6
8
70 (7, 50)
45 (4.5, 32)
45 (4.5, 32)
45 (4.5, 32)
60 (6, 43)
80 (8, 58)
40 (4, 29)
40 (4, 29)
40 (4, 29)
40 (4, 29)
70 (7, 50)
70 (7, 50)
45 (4.5, 32)
32 (3.2, 23)
32 (3.2, 23)
35 (3.5, 25)
12 (1.2, 9)
35 (3.5, 25)
22 (2.2, 16)
10 (1, 7)
35 (3.5, 25)
1. GENERAL INFORMATION
1-16
SPECIAL TOOLS
90cc/70cc/50cc-4T
Tool Name Tool No.
Remarks Ref. Page
Clutch spring compressor A120E00034
Bearing puller A120E00037
Valve spring compressor A120E00040
Oil seal & bearing installer A120E00014
Tappet adjuster A120E00012
Long socket wrench A120E00015
Start clutch puller A120E00006
Flywheel puller A120E00001
Universal holder A120E00017
50cc-2T
Tool Name Tool No. Remarks Ref. Page
Flywheel puller A120E00001
Oil seal and bearing install A120E00014
Universal holder A120E00017
Clutch spring compressor A120E00034
Bearing puller A120E00037
Crankshaft install A120E00016
Crankshaft & crankcase install A120E00024
Crankcase puller A120E00026
Crankshaft Bearing puller A120E00030
1. GENERAL INFORMATION
1-17
LUBRICATION POINTS
ENGINE (90cc/70/50-4T)
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#
ENGINE (50cc-2T)
NO. Lubrication Points Lubricant
1 Crankcase sliding & movable KYMCO 2-STROKE OIL or QUIVALENT
2 Cylinder movable parts KYMCO 2-STROKE OIL or QUIVALENT
3 Transmission gear (final gear) SAE-90#
4 Kick starter spindle bushing Grease
5 Drive pulley movable parts Grease
6 Starter pinion movable parts Grease
1. GENERAL INFORMATION
1-18
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 Lowe
r
Front Swing Arm Bush
Front Swing Ar
m
Steering knuckle
Steering knuckle
1. GENERAL INFORMATION
1-19
Rear Axle Hub
Collar/Oil
Seal/Bearing
Driven Sprocket
Rear Swing Arm Axle
1. GENERAL INFORMATION
1-20
CABLE & HARNESS ROUTING
Headlight Wire Couple
r
Rear Brake Cable/Fluid Hose
Handlebar Switch Couple
r
Ignition Switch Couple
r
Harness Wire
Ignition Coil
Kill Switch (Safety)
Front Brake Cable
Front Stop Switch Wire
Throttle Cable
REG.REC Wire
Pilot Leads
(50cc-2T)
Rear Stop Switch Wire
Handlebar Switch Wire
Rear Stop Switch Wire
Kill Switch (Safety)
Front Stop Switch Wire
Front Brake Cable
Rear Brake Cable/Fluid Hose
REG.REC
1. GENERAL INFORMATION
1-21
Oil Outlet Tube
(50cc-2T)
Oil Level Switch Wire
(50cc-2T)
A.C.G. Wire
Ignition Coil
Ignition Coil Wire
Starter Motor Wire
1. GENERAL INFORMATION
1-22
Taillight Couple
r
Battery Positive (+)
Battery Negative (-)
Oil Pump Control Cable
(50cc-2T)
Ignition Coil Wire
Rear Brake Cable/Fluid Hose
Air Inlet Hose
Throttle Cable
Fuel Tube
Autobystarter Wire
Harness Wire
Resisto
r
1. GENERAL INFORMATION
1-23
WIRING DIAGRAMS
Mongoose 90/MXER 90R/Mongoose 50-4T OFF ROAD
G
1. GENERAL INFORMATION
1-24
MXER 90R ON ROAD
1. GENERAL INFORMATION
1-25
Mongoose 70
1. GENERAL INFORMATION
1-26
Mongoose 50-2T/MXER 50R-2T OFF ROAD
1. GENERAL INFORMATION
1-27
MXER 50R-2T ON ROAD
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