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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
Mongoose/KXR 250.
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 19 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/
BALANCE SHAFT
11
COOLING SYSTEM
12
BRAKE SYSTEM
13
FRONT WHEEL/FRONT
SUSPENSION/STEERING SYSTEM
14
REAR WHEEL/AXLE/SUSPENSION
15
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
16
IGNITION SYSTEM 17
STARTING SYSTEM 18
BULBSREMOVAL/INSTRUMENT/
HORN
19
The information and contents include
in this manual may be different from
the motorcycle in case specifications
are changed.
CHASSIS
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1. GENERAL INFORMATION
1-0
Mongoose/KXR 250
1
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GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER---------------------------------------------------------- 1- 1
SPECIFICATIONS---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS------------------------------------------------ 1- 3
TORQUE VALUES --------------------------------------------------------- 1-11
SPECIAL TOOLS ----------------------------------------------------------- 1-12
LUBRICATION POINTS -------------------------------------------------- 1-13
CABLE & HARNESS ROUTING ---------------------------------------- 1-16
WIRING DIAGRAM-------------------------------------------------------- 1-19
TROUBLESHOOTING----------------------------------------------------- 1-21
1
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1. GENERAL INFORMATION
1-1
Mongoose/KXR 250
SERIAL NUMBER
Location of Engine Serial Numbe
Location of Frame Serial Numbe
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1. GENERAL INFORMATION
1-2
Mongoose/KXR 250
SPECIFICATIONS
Name & Model No. LA50AA/AB
Motorcycle Name & Type Mongoose/KXR
Overall length (mm) 1700
Overall width (mm) 1070
Overall height (mm) 1080
Wheel base (mm) 1180
Engine type O.H.C.
Displacement (cc) 249
Fuel Used 92# nonleaded gasoline
Front wheel 93.1
Net weight (kg) Rear wheel 84.9
Total 178
Front wheel 100
Gross weight(kg) Rear wheel 91
Total 191
Front wheel 21*7-10
Rear wheel 20*11-9
Ground clearance (mm) 130
Perform-
Breakin
distance
(m)(30KPH)
29.27 below
ance
Min. turning radius (m) 2.865
Starting system
Starting motor
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke (mm) 72.7 x 60
Compression ratio 10.3:1
Compression pressure
(kg/cm²)
15.0
Max. output (ps/rpm) 17/7000
Max. torque (kg m/rpm) 2.0/5500
Intake
Open 8.1° BTDC
Port
(1mm)
Close 41° ABDC
timin
Exhaust
Open 37° BBDC
(1mm)
Close 7.9° ATDC
Valve clearance
Intake 0.1
(cold) (mm)
Exhaust 0.1
Idle speed (rpm) 1500rpm
Lubrication type
Forced
ressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 1.6 liter
Oil exchanging
capacity
1.4 liter
Cooling Type Water cooling
Air cleaner type & No Sponge
Fuel capacity 13 liters
Type PD
Float lever 14.8mm
Venturi dia.(mm) φ22
Throttle type PISTON
Type CDI
Ignition timing 5°BTDC/2000rpm
Contact breaker Non-contact point type
Spark plug DPR7EA-9
Spark plug gap 0.6~0.7mm
Battery Capacity 12V12AH
Clutch Type CVT
Type Helical gear/spur gear
Operation
Automatic centrifugal
Type
Type Chain drive
Reduction 1st
24.7
ratio
2nd
9.33
Reverse ratio
47.4
FR/RR tire rolling
circumference(mm)
1675/1596
Tire pressure
0.28
(kg/cm²)
Rear 0.28
Turning Left 40°
angle
Right 40°
Brake syste
Disk brake
type
Front Disk brake
Front
Double wishbone
Suspension
type
Rear
Link suspension
Frame type Steel tube frame
Tires
Engine
Lubrication
S
stem
Power Drive System
Transmis-
sion Gear
Reduction
Gear
Moving Device
Damping
Device
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1. GENERAL INFORMATION
1-3
Mongoose/KXR 250
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.
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1. GENERAL INFORMATION
1-4
Mongoose/KXR 250
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.
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1. GENERAL INFORMATION
1-5
Mongoose/KXR 250
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
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1. GENERAL INFORMATION
1-6
Mongoose/KXR 250
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!
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1. GENERAL INFORMATION
1-7
Mongoose/KXR 250
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.
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1. GENERAL INFORMATION
1-8
Mongoose/KXR 250
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 ti
ht!
Do not press
or squeeze
the wire.
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1. GENERAL INFORMATION
1-9
Mongoose/KXR 250
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 !
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1. GENERAL INFORMATION
1-10
Mongoose/KXR 250
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
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1. GENERAL INFORMATION
1-11
Mongoose/KXR 250
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
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
Item Q‘ty Thread dia.(mm) Torque (kgf-m) Remarks
Stud bolt
Oil filter screen cap
Seat ball stopper bolt
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
ACG flywheel nut
Spark plug
Water pump impeller
Drain plug
Oil pump screw
Head CYL stud bolt (IN pipe)
Head CYL stud bolt (EX pipe)
A.C.G Startor
4
1
1
10
4
2
1
2
1
9
1
1
1
1
3
1
1
1
1
1
2
2
3
8
30
14
6
8
5
8
6
6
8
12
14
12
28
8
14
12
7
12
3
6
8
5
0.7~1.1
1.0~2.0
4.5~5.0
1.0~1.4
2.3~2.7
0.7~1.1
0.8~1.2
1.0~1.4
0.35~0.5
2.4~3.0
2.0~3.0
9.0~10.0
5.0~6.0
5.0~6.0
1.8~2.2
5.5~6.5
1.5~2.0
1.0~1.4
2.0~3.0
0.1~0.3
0.7~1.1
0.7~1.1
0.8~1.0
Apply oil
Apply oil
Apply oil
Apply thread
lock
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1. GENERAL INFORMATION
1-12
Mongoose/KXR 250
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
Rear hub nut
Rear wheel shaft nut
Rear engine bracket upper bolt
Rear engine bracket lower bolt
Engine hanger bracket bolt
Exhaust muffler lock bolt (frame)
Exhaust muffler lock nut (engine)
Rod-end nut
1
8
8
8
2
2
2
2
1
1
1
2
2
1
1
1
2
2
4
14
10
12
12
14
16
10
10
10
10
14
10
40
10
10
10
8
8
8
6.0~8.0
4.0~5.0
4.0~5.0
4.0~5.0
6.0~8.0
9.0~11.0
3.5~4.5
3.5~4.5
3.5~4.5
3.5~4.5
6.0~8.0
3.5~4.5
11.0~13.0
3.5~4.5
3.5~4.5
3.5~4.5
3.2~3.8
1.8~2.2
2.5~3.5
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Flywheel puller E003
Valve adjuster E012
Valve spring compressor E040
Oil seal and bearing install E014
Universal holder E017
Flywheel holder E021
Clutch spring compressor E034
Bearing puller E037
Nut wrench F010
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1. GENERAL INFORMATION
1-13
Mongoose/KXR 250
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#
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1. GENERAL INFORMATION
1-14
Mongoose/KXR 250
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.
Steering Column Uppe
Throttle Cable
Steering Column Lowe
Front Swing Arm Bush
Front Swing Ar
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1. GENERAL INFORMATION
1-15
Mongoose/KXR 250
Sprocket hub/Rea
Axle Hub Collar/Oil
Seal/Bearing
Driven Sprocket
Rear Swing Ar
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1. GENERAL INFORMATION
1-16
Mongoose/KXR 250
CABLE & HARNESS ROUTING
Headlight Wire
Pilot Lamp Wire
Handlebar Switch Wire
Ignition Switch Wire
Rear Brake Fluid Hose
Harness Wire
Motor Fan Cor
Thermostatic Switch Wire
Left Front Brake Fluid Hose
Right Front Brake Fluid Hose
Thermostatic Sensor Wire
Front Brake Fluid Hose
Stop Switch Cor
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1. GENERAL INFORMATION
1-19
Mongoose/KXR 250
WIRING DIAGRAM (OFF ROAD)
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1. GENERAL INFORMATION
1-21
Mongoose/KXR 250
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 change gear control unit
Faulty pulser coil
Broken or shorted ignition 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 no
fire
Weak or no spark
Low or no
compression
Engine fires bu
does not start
Test cylinde
compression
Start engine by following normal starting
rocedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does no
reach carburetor
Wet spark plug
Dry spark plug
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1. GENERAL INFORMATION
1-22
Mongoose/KXR 250
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
Coolant level too low
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
Inspection/Adjustment
Symptom
Probable Cause
Engine speed
Check ignition timing
(using a timing light)
Test cylinder compression
Check carburetor fo
clogging
Rapidly accelerate or run
at hi
Remove spark plug and
inspec
Check if engine overheats
Check valve clearance
Correc
ression
Abnormal
compression
Remove oil dipstick and
check oil level and condition
Remove cylinder head oil
Engine overheats
Engine does no
overheats
Plug not fouled o
discolored
Correct and no
contaminated
Valve train lubricated
Engine does not knock
Engine knocks
Not clogged
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1. GENERAL INFORMATION
1-23
Mongoose/KXR 250
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 ignition 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
round
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor gaske
for air leaks
Check carburetor ai
screw adjustment
Correct timing
Incorrect timing
Correctly adjusted
No air leak
Air leaks
Good spark
Weak or inter-
mittent spark
Incorrectly adjusted
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1. GENERAL INFORMATION
1-24
Mongoose/KXR 250
POOR PERFORMANCE (AT HIGH SPEED)
Faulty ignition 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 fo
fuel supply
Correct timing
Incorrect timing
Check valve spring
tension
Check valve clearance
Fuel flows freely
Fuel flow restricted
Correc
Not clogged
Clogged
Correctly adjusted
Incorrectly adjusted
Not weakened
Weak spring
Check valve timing
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1. GENERAL INFORMATION
1-25
Mongoose/KXR 250
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead battery
Faulty battery
Faulty A.C. generator coil
Broken yellow wire
Shorted pink 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 tes
limit voltage of battery
terminals
Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
attery has voltage
with ignition
switch “ON”
attery has no
voltage with ignition
switc
“ON”
Resistance too high
Normal voltage No voltage
Measure resistance
between AC generator
coil terminals
Normal
Abnormal
Check regulator/rectifier
coupler for loose
connection
Normal
Abnormal
Connect battery (+) wire
to regulator/rectifier
coupler green wire and
battery (-) wire to engine
Check regulator/rectifier
coupler for loose
connection
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1. GENERAL INFORMATION
1-26
Mongoose/KXR 250
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 ignition unit
Faulty change gear control
unit
Faulty ignition coil
Replace with a new
spark plug and inspect
a
ain
Check ignition unit
coupler for looseness
Inspection/Adjustment Symptom
Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal
Abnormal
Abnormal
Measure resistance
between terminals of
i
Check related parts
Check ignition coil with
a ignition unit tester
Weak or no spark
Not loose
Good spark
Loose
Good
Good
Check spark plug cap
and high-tension wire
for looseness
Check ignition unit
with a ignition unit
teste
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2. FRAME COVERS/EXHAUST MUFFLER
2-0
Mongoose/KXR 250
2
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FRAME COVERS/EXHAUST MUFFLER
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SERVICE INFORMATION------------------------------------------------ 2- 2
TROUBLESHOOTING----------------------------------------------------- 2- 2
FRAME COVERS----------------------------------------------------------- 2- 3
EXHAUST MUFFLER REMOVAL-------------------------------------- 2- 7
2
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2. FRAME COVERS/EXHAUST MUFFLER
2-1
Mongoose/KXR 250