This workshop service repair manual covers Mongoose 50, Mongoose 90, KXR 50, and KXR 90 models from 2004 through 2014. These ATVs are known for their reliable 4-stroke, air-cooled engines, available in 49.5 cc and 86.5 cc displacements, paired with an automatic CVT transmission. Designed for recreational use and targeting younger riders, the Mongoose and KXR lines are recognized for offering value-oriented performance. The vehicles feature dependable chassis, braking systems, and essential lighting, making them suitable for various off-road activities. This comprehensive manual provides in-depth guidance for all service and repair procedures. It includes detailed step-by-step instructions, clear illustrations, and diagnostic information for the engine, transmission, drivetrain, fuel, ignition, electrical, cooling, braking, suspension, and steering systems. Owners and technicians will find essential maintenance schedules, troubleshooting flowcharts, technical specifications, torque values, and wiring diagrams. The manual is designed to empower users to perform routine maintenance, complex repairs, and adjustments, ensuring the longevity and optimal performance of their ATV. 🏷️ Basic Information Identification Make: Kymco Model: Mongoose 50, Mongoose 90, KXR 50, KXR 90 Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Value Proposition: Enables users to perform their own repairs and save money, offering professional-level guidance for DIY enthusiasts and professional mechanics alike. Key Features Key Features: Detailed step-by-step instructions, clear illustrations and diagrams, comprehensive coverage of all models and years, downloadable for instant access and offline use, printable for convenient workspace use. 📋 Manual Details Coverage Applicable Years: 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 Model Variants Covered: All Models, Engines, Trim, and Transmission Types Format Format: Downloadable Delivery: Instant Email Delivery Software Requirements: Adobe Reader (or compatible PDF viewer) Language Language: English Manual Type Manual Type: Complete Workshop Service Repair Manual 📖 Manual Coverage Systems Systems Covered: Engine, Transmission, Drivetrain, Fuel System, Ignition System, Electrical System, Cooling System, Braking System, Suspension, Steering, Chassis, Bodywork, Pre-Delivery Inspection (PDI), Regular Maintenance, Troubleshooting Procedures Procedures Included: Step-by-step repair instructions, diagnostic procedures, maintenance schedules, component removal and installation, adjustments, specifications, torque values, wiring diagrams, troubleshooting flowcharts, overhaul procedures, routine checks Depth Technical Depth: Comprehensive (A-Z coverage for all service and repair procedures) 📊 Manual Specifications File Attributes File Format Details: PDF (Portable Document Format) Print Quality Print Quality: High Quality (suitable for printing individual pages, chapters, or the entire manual) Accessibility Accessibility Devices: PC, MAC, Tablets, Smartphones ⚙️ Engine Specifications Mongoose 90 Kxr 90 Engine Type: 4-stroke, Air-Cooled, SOHC Displacement: 86.5 cc Mongoose 50 Kxr 50 Engine Type: 4-stroke, Air-Cooled, SOHC Displacement: 49.5 cc Common Components Carburetor Type Spec: CV (Constant Velocity) carburetor, specific model to be detailed within the manual (e.g., Keihin or Mikuni) Ignition System Spec: CDI (Capacitor Discharge Ignition), details on timing and components will be covered. Maintenance Valve Lash Adjustment: Detailed procedure with specific clearances for intake and exhaust valves for both 50cc and 90cc models. 🔧 Transmission Drive Type Transmission Type: Automatic CVT (Continuously Variable Transmission) with Dry Clutch Features Clutch Type: Centrifugal Automatic Clutch Maintenance Belt Inspection Replacement Interval: Recommended interval for inspection and replacement of the CVT belt to ensure optimal performance and prevent failure. 📐 Dimensions General Vehicle Type: Scooter / ATV (Sport ATV) Weights Dry Weight Approximate: Figures vary slightly between 50cc and 90cc models, typically around 70-90 kg, detailed specifications available in manual. 🛡️ Safety Features Features Braking System: Front and Rear Drum Brakes or Front Disc/Rear Drum depending on specific model variant; manual will detail adjustments and maintenance. Lighting System: Headlight, Taillight, Brake Light, Turn Signals (where applicable), detailed wiring diagrams and bulb replacement procedures will be included. 💡 Technology Features Vehicle Systems Instrumentation: Includes speedometer, odometer, indicator lights (e.g., neutral, oil pressure, turn signals) with details on their function and diagnostics. Lighting Technology: Standard halogen or incandescent lighting systems; manual covers bulb types and replacement. 🔧 Maintenance Service Intervals Oil Change Interval: Typically recommended every 1000-2000 km or annually, with precise intervals and oil type specified in the manual. Spark Plug Replacement: Recommended replacement based on mileage or visual inspection, with specific spark plug types and gap settings provided. Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-40 or 15W-40 viscosity grade (specific recommendations will be in the manual). Gear Oil Type: Specific gear oil viscosity and capacity for the transmission/final drive unit will be detailed. Known Issues Common Wear Items: CVT Belt, brake pads, tires, and suspension components are common wear items that the manual will guide on inspection and replacement. Troubleshooting Guides Troubleshooting Approach: Systematic troubleshooting based on symptoms, covering common electrical, fuel, and mechanical issues. 📚 Vehicle History Brand Heritage Manufacturer: Kymco (Kwang Yang Motor Co., Ltd.) is a Taiwanese manufacturer known for producing a wide range of scooters, motorcycles, and ATVs. Model Evolution Model Series Positioning: The Mongoose and KXR lines represent Kymco's entry-level to mid-range sport ATVs, targeting...