2003-2007 Kymco Mongoose KXR 90 KXR50 ATV Workshop Repair Service Manual Best Download PDF
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🏷️ Basic Information Identification Make: Kymco Model: Mongoose KXR 90 / KXR50 Model Variant: ATV Production Years Covered: 2003, 2004, 2005, 2006, 2007 👋 Introduction Market Position Target Audience: DIY enthusiasts, home mechanics, and professional technicians working on Kymco Mongoose KXR 90/50 ATVs. Competitive Analysis Value Proposition: Provides professional-level repair information in an accessible digital format, offering cost savings on repairs and maintenance. Key Features Download Access: Instant download provides immediate access to repair information. User Friendliness: Easy to use with no advanced computer skills required; information can be printed for practical use. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Service Manual Language: English Format: Digital Downloadable PDF Coverage Scope: Comprehensive repair, maintenance, rebuilding, refurbishing, and restoration 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for engine disassembly, inspection, repair, and reassembly. Engine Lubrication: Covers oil pump, lubrication passages, oil filter, and oil specifications. Engine Cooling: Details on the cooling system, coolant specifications, and fan operation. Engine Control System: Information on ignition system, CDI unit, and related sensors. Fuel System: Carburetor specifications, adjustments, fuel pump, and fuel lines. Exhaust System: Information on exhaust pipe, muffler, and emissions control (if applicable). Transmission Clutch: Details on clutch operation, adjustment, and replacement. Transmission Transaxle: Covers internal transmission components, gear shifting mechanisms, and lubrication. Driveline Axle: Front and rear axle assembly, bearings, and drive shafts. Suspension Front: Front shock absorbers, A-arms, ball joints, and steering knuckle assembly. Suspension Rear: Rear shock absorber, swingarm, and bearing assembly. Wheels Tires: Tire specifications, wheel mounting, and torque values. Brakes System: Front and rear brake caliper, brake pads, brake fluid, and bleeding procedures. Brakes Parking: Operation and adjustment of the parking brake mechanism. Steering System: Handlebars, steering stem, tie rods, and steering linkage. Restraints Seatbelts: While ATVs typically don't have seatbelts, this section may cover related safety features or be a placeholder from a generalized template. Restraints Srs: Supplemental Restraint System (Airbags) - Not applicable to this model, likely a generalized template. Body Locks Security: Frame, plastic body panels, seat mounting, and basic security features. Body Glasses Mirrors: Windshield (if equipped), mirrors, and lens components. Body Roof: Not applicable to this ATV model. Body Exterior Interior: Body panel removal and installation, grips, and dashboard components. Body Instrumental Panel: Speedometer, indicator lights, and associated wiring. Body Seat: Seat removal, installation, and upholstery care. Air Conditioner: Not applicable to this ATV model. Electrical Wiring Diagrams: Detailed electrical schematics for all systems. Electrical Starting Charging: Starter motor, battery, stator, and charging system testing. Electrical Lighting: Headlights, taillights, brake lights, and indicator lights. Electrical Driver Info: Instrument cluster and warning lights. Electrical Wiper Washer Horn: Horn operation and wiring. Electrical Body Control: Relays, fuses, and switches related to body functions. Electrical Lan System: Local Area Network (LAN) - Not typically applicable to this type of ATV. Electrical Audio Visual: Not applicable to this ATV model. Electrical Auto Cruise: Not applicable to this ATV model. Electrical Power Supply Ground: Battery terminals, ground points, and electrical circuit protection. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, lubrication, and component checks. Diagnostic Procedures: Troubleshooting guides, symptom analysis, and diagnostic flowcharts. Repair Procedures: Step-by-step instructions for component removal, repair, and reinstallation. Rebuilding Procedures: Detailed instructions for rebuilding major components like the engine and transmission. Technical Depth Depth Of Coverage: A-Z coverage, from basic maintenance to complex diagnostics and overhauls. Illustrations Diagrams: High-quality photos, illustrations, and detailed diagrams for clear understanding. Completeness Completeness Guarantee: 100% complete and intact, no missing or corrupt pages/sections. 📊 Manual Specifications File Format File Type: PDF Reader Requirement: PDF Reader Compatibility: All versions of Windows, Mac, and Linux Print Quality Printability: Printable for easy workshop use. Binding Type Binding Type: Digital (N/A for physical binding) Paper Type Paper Type: Digital (N/A for physical paper type) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 2-stroke or 4-stroke (model dependent, manual covers both if applicable) Displacement Kx50: Approximately 49cc (specifics in manual) Displacement Kx90: Approximately 89cc (specifics in manual) Performance Horsepower Kx90: Estimated 7-10 HP (manual will have precise figures) Torque Kx90: Estimated 5-7 lb-ft (manual will have precise figures) Fuel System Carburetor Type: Mikuni (likely VM series, specific model in manual) Fuel Type: Unleaded Gasoline (refer to manual for octane rating) Fuel Mixture: Oil/Gasoline mix ratio specified in manual for 2-stroke variants. 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Optional Optional Transmissions: N/A Features Drive System: Chain Drive to Rear Axle Clutch Type: Centrifugal Clutch 📐 Dimensions Exterior Length: Approx. 1440 mm (56.7 in) for KXR 90 (refer to manual for precise dimensions) Width: Approx. 900 mm (35.4 in) for KXR 90 (refer to manual for precise dimensions) Height: Approx. 930 mm (36.6 in) for KXR 90 (refer to manual for precise dimensions) Weights Dry Weight: Approx. 94 kg (207 lbs) for KXR 90 (refer to manual...
Approx. 1440 mm (56.7 in) for KXR 90 (refer to manual for precise dimensions)
Width:
Approx. 900 mm (35.4 in) for KXR 90 (refer to manual for precise dimensions)
Height:
Approx. 930 mm (36.6 in) for KXR 90 (refer to manual for precise dimensions)
Weights
Dry Weight:
Approx. 94 kg (207 lbs) for KXR 90 (refer to manual for precise specifications)
Payload Capacity:
Refer to manual for specific cargo carrying capacity.
Towing Capacity:
Typically not recommended for these models, refer to manual for confirmation.
🛡️ Safety Features
Ratings
Atv Safety Standards:
Meets industry standards for ATV safety; manual will detail specific warnings and precautions.
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Lighting System:
Headlights, taillight, and brake light for visibility.
Passive Features
Chassis Design:
Robust frame designed for off-road durability and rider support.
💡 Technology Features
Infotainment
Infotainment Features:
Basic instrumentation (speedometer, odometer, indicator lights). No advanced infotainment features.
Driver Assistance
Driver Assistance Systems:
None. Basic ATV design focused on utility and recreation.
Connectivity
Connectivity Options:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 100 hours or 6 months for engine oil (refer to manual for exact schedule).
Air Filter Cleaning:
Check and clean or replace every 20-30 hours or as needed based on operating conditions.
Spark Plug Replacement:
Inspect at regular intervals, replace as needed (manual will specify type and gap).
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grade (e.g., SAE 10W-40 or 20W-50) and API service classification.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Coolant Type:
Ethylene glycol-based antifreeze (refer to manual for type and mixture ratio).
Known Issues
Common Wear Items:
Brake pads, tires, drive chain/sprockets (if applicable), air filter, spark plug are common wear items. CVT belt may require replacement over time.
Carburetor Tuning:
Carburetors may require periodic cleaning and adjustment due to fuel variability or debris.
📚 Vehicle History
Brand Heritage
Kymco Heritage:
Kymco (Kwang Yang Motor Co., Ltd.) is a Taiwanese company known for producing a wide range of scooters, motorcycles, ATVs, and utility vehicles, often in partnership with other major manufacturers.
Model Evolution
Mongoose Kx Series:
The Mongoose KXR series represents Kymco's entry into the youth and entry-level sport ATV market, offering a balance of performance and affordability. The KXR 90 and KXR50 cater to different age groups and experience levels.
Production
Manufacturing Location:
Taiwan
🏆 Awards & Recognition
Recognitions
Atv Awards:
Specific awards for these particular models are not widely documented, but Kymco ATVs are generally recognized for their value and reliability in their segment.
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