Kymco Mongoose 300 Factory Service Repair Manual

KYMCO SERVICE MANUAL MAXXER 300/250 MONGOOSE 300/250 Issued: 10.JUN.2005

By KWANG YANG Motor Co., Ltd. First Edition, Jun 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-ATV250-S00

PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO ATV 300/250. 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 20 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 BULBS REMOVAL/INSTRUMENT/ HORN 19 WIRING DIAGRAMS 20 CHASSIS ELECTRICAL EQUIPMENT ENGINE The information and contents included in this manual may be different from the ATV 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 ATV 300/250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER---------------------------------------------------------- 1- 1 SPECIFICATIONS (MAXXER 250/MONGOOSE 250) -------------- 1- 2 SPECIFICATIONS (MAXXER 300/MONGOOSE 300) -------------- 1- 3 SERVICE PRECAUTIONS ------------------------------------------------ 1- 4 TORQUE VALUES --------------------------------------------------------- 1-12 SPECIAL TOOLS ----------------------------------------------------------- 1-14 LUBRICATION POINTS -------------------------------------------------- 1-15 CABLE & HARNESS ROUTING ---------------------------------------- 1-18 TROUBLESHOOTING----------------------------------------------------- 1-21 1

1. GENERAL INFORMATION 1-1 ATV 300/250 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number

1. GENERAL INFORMATION 1-2 ATV 300/250 Model No. LA50 ATV Name & Type MXER 250R MAXXER 250 Overall length 1705 mm (68.2 in) Overall width 1020 mm (40.1 in) Overall height 1110 mm (43.3 in) Wheel base 1175 mm (46.2 in) Engine type O.H.C. Displacement 249 cm 3 (15.2 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 93.1 kg (204.8 lbs) Dry weight Rear wheel 84.9 kg (186.8 lbs) Total 178 kg (391.6 lbs) Front wheel 100 kg (220 lbs) Gross weight Rear wheel 91 kg (200.2 lbs) Total 191 kg (420.2 lbs) Front wheel 21*7-10 Tires Rear wheel 20*11-9 Ground clearance 130 mm (5.1 in) 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 72.7 x 60 mm (2.9 x 2.4 in) Compression ratio 10.3:1 Compression pressure 15 kgf/cm 2 (1500 kPa, 213 psi) Open 8.1° BTDC Intake valve Close 41° ABDC Open 37° BBDC Exhaust valve Close 7.9° ATDC Intake 0.1 mm (0.004 in) Valve clearance (cold) Exhaust 0.1 mm (0.004 in) Idle speed 1500 rpm Lubrication type Forced pressure & Wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 1.6 L (1.4 lmp qt, 1.7 US qt) Oil exchanging capacity 1.4 L (1.23 lmp qt, 1.48 US qt) Cooling Type Liquid cooling Air cleaner type & No Sponge Fuel capacity 13 L (2.73 lmp gal, 3.38 US gal) Type PTG Main jet NO. 98 Venturi dia. φ22 mm (φ0.88 in) Throttle type PISTON Type Full transistor digital ignition Ignition timing 5°BTDC/1000 rpm Spark plug DPR7EA-9 Spark plug gap 0.6～0.7 mm (0.002～0.003 in) Battery Capacity 12V12AH Clutch Type Dry, centrifugal automatic Clutch operation system Automatic (V-belt) Primary reduction system Helical gear/spur gear Secondary reduction system Chain drive Primary reduction ratio 26.5 Secondary reduction ratio 10.02 Reverse ratio 50.9 FR/RR tire rolling circumference 1675/1596 mm 67/63.8 in) Front Tire pressure Rear 0.28 kgf/cm 2 (28 kPa, 3.2 psi) Turning Left 40° angle Right 40° Rear Disk brake Brake system type Front Disk brake Front Double wishbone Suspension type Rear Link suspension Frame type Steel tube frame Lubrication System Fuel System Carburetor Electrical Equipment Ignition System Moving Device Engine Drive System SPECIFICATIONS (MAXXER 250/MONGOOSE 250)

1. GENERAL INFORMATION 1-3 ATV 300/250 Model No. LA60 ATV Name & Type MAXXER 300 Overall length 1700 mm (68 in) Overall width 1050 mm (42 in) Overall height 1150 mm (46 in) Wheel base 1170 mm (46.8 in) Engine type O.H.C. Displacement 270 cm 3 (16.2 cu-in) Fuel Used 92# nonleaded gasoline Front wheel 103 kg (226.6 lbs) Dry weight Rear wheel 102 kg (224.4 lbs) Total 205 kg (451 lbs) Front wheel 110 kg (242 lds) Gross weight Rear wheel 105 kg (231 lbs) Total 215 kg (473 lbs) Front wheel 21*7-10 Tires Rear wheel 20*11-9 Ground clearance 130 mm (5.1 in) 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 72.7 x 65.2 mm (2.9 x 2.608 in) Compression ratio 10.3:1 Compression pressure 16 kgf/cm 2 (1600 kPa, 227 psi) Open 5° BTDC Intake valve Close 41° ABDC Open 37° BBDC Exhaust valve Close 5° ATDC Intake 0.1 mm (0.004 in) Valve clearance (cold) Exhaust 0.1 mm (0.004 in) Idle speed 1600 rpm Lubrication type Forced pressure & Wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 1.6 L (1.4 lmp qt, 1.7 US qt) Oil exchanging capacity 1.4 L (1.23 lmp qt, 1.48 US qt) Cooling Type Liquid cooling Air cleaner type & No Sponge Fuel capacity 13 L (2.73 lmp gal, 3.38 US gal) Type PTG Main jet NO. 98 Venturi dia. φ22 mm (φ0.88 in) Throttle type PISTON Type Full transistor digital ignition Ignition timing 5°BTDC/1500 rpm Spark plug DPR7EA-9 Spark plug gap 0.6～0.7 mm (0.002～0.003 in) Battery Capacity 12V12AH Clutch Type Dry, centrifugal automatic Clutch operation system Automatic (V-belt) Primary reduction system Helical gear/spur gear Secondary reduction system Chain drive Primary reduction ratio 26.5 Secondary reduction ratio 10.02 Reverse ratio 50.9 FR/RR tire rolling circumference 1675/1596 mm 67/63.8 in) Front Tire pressure Rear 0.28 kgf/cm 2 (28 kPa, 3.2 psi) Turning Left 40° angle Right 40° Rear Disk brake Brake system type Front Disk brake Front Double wishbone Suspension type Rear Link suspension Frame type Steel tube frame Lubrication System Fuel System Carburetor Electrical Equipment Ignition System Drive System Moving Device SPECIFICATIONS (MAXXER 300/MONGOOSE 300) Engine

1. GENERAL INFORMATION 1-4 ATV 300/250 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.

1. GENERAL INFORMATION 1-5 ATV 300/250 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.

1. GENERAL INFORMATION 1-6 ATV 300/250 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. Confirm Capacity

Kymco Mongoose 300 Factory Service Repair Manual

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