The Kymco KXR 90 is a youth-oriented All-Terrain Vehicle (ATV) designed for entry-level sport riding. Produced between 2003 and 2007, this model offers a sporty appearance and manageable performance suitable for younger riders transitioning from smaller ATVs. A reputable Taiwanese manufacturer established in 1964, is known for its quality engineering and reliability across its range of powersports vehicles, including scooters, motorcycles, and ATVs. The KXR 90 exemplifies this dedication by providing a robust platform for recreational off-road exploration. This comprehensive workshop service manual provides detailed information for the maintenance and repair of the Kymco KXR 90 ATV, covering the production years from 2003 to 2007. The manual is structured to assist both DIY enthusiasts and professional mechanics, offering step-by-step instructions for all major systems, including the engine, fuel, ignition, transmission, suspension, steering, brakes, and electrical systems. It includes essential procedures such as disassembly, assembly, adjustments, cleaning, inspection, and troubleshooting, supported by technical specifications, wear limits, and torque values. The manual also features extensive use of illustrations and diagrams to ensure clarity and accuracy in all repair and maintenance tasks. 🏷️ Basic Information Identification Make: Kymco Model: KXR 90 Vehicle Type: All-Terrain Vehicle (ATV) Category: Youth/Entry-Level Sport ATV Generation Production Years: 2003-2007 Codes Model Code Reference: KXR 90 (specific VIN prefixes would typically denote year/assembly location, but are not provided) 👋 Introduction Market Position Target Audience: DIY enthusiasts and professional mechanics seeking to maintain and repair the Kymco KXR 90. Competitive Analysis Value Proposition: Provides comprehensive, detailed, and easily accessible repair information for a specific model range, enabling cost-effective maintenance and repairs. Key Features Instant Download: Available for immediate download upon purchase, eliminating shipping delays and costs. Completeness: Stated as 100% complete and intact, ensuring no missing or corrupt sections. Ease Of Use: Designed for simplicity with clear explanations, suitable for both experienced mechanics and beginners. 📋 Manual Details Coverage Areas Covered Models: Kymco KXR 90 Covered Years: 2003, 2004, 2005, 2006, 2007 Page Count Total Pages: 246 Manual Type Type: Workshop Service Manual / Repair Manual Language Primary Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, diagnosis, troubleshooting, adjustments, performance specifications. Fuel System: Carburetor, fuel lines, fuel tank, fuel pump (if applicable). Ignition System: Spark plug, CDI unit, ignition timing, troubleshooting. Transmission: Automatic transmission (likely CVT), clutch, drive system, removal, installation, inspection. Suspension: Front and rear suspension components, shock absorbers, A-arms, bushings, adjustments. Steering: Handlebars, steering column, tie rods, steering knuckles, adjustments, alignment. Brakes: Front and rear brake systems (likely drum or disc), brake fluid, calipers, master cylinder, bleeding procedures. Electrical System: Wiring diagrams, battery, starter, lighting, fuses, charging system. Chassis And Frame: Frame inspection, body panels, removal and installation. Wheels And Tires: Tire pressure, wheel removal and installation, bearing inspection. Procedures Included Maintenance: Regular maintenance, lubrication points, fluid changes, filter replacements. Troubleshooting: Systematic diagnosis of common problems and their solutions. Repair: Detailed step-by-step instructions for component repair and replacement. Disassembly: Complete breakdown of all major vehicle systems and components. Assembly: Reassembly procedures with specific torque values and sequences. Adjustments: Carburetor, throttle, brake, and other system adjustments. Cleaning And Inspection: Procedures for cleaning components and inspecting for wear or damage. Technical Depth Level Of Detail: Comprehensive, step-by-step procedures with detailed explanations and pictorial diagrams. Diagnostic Information: Included for various systems, aiding in problem identification. Pictorial Representation: Extensive use of illustrations, exploded diagrams, drawings, and photos. Special Tools: References and illustrations for specialized service tools required for specific operations. Wear Limits: Specifications for wear limits of critical components. Torque Specifications: Detailed torque values for all threaded connections and fasteners. 📊 Manual Specifications File Format Format: PDF Readability: High resolution, zoomable for clarity. Print Quality Printable: Yes, all pages are printable. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) Compatibility Operating Systems: Windows, Mac, Linux OS Required Software: Adobe Reader ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke (typical for this class, though not explicitly stated, the KXR 90 is known for this configuration) Displacement: Approximately 89cc (common for Kymco 90cc models) Cooling System: Air-cooled (typical for this displacement and ATV category) Performance Horsepower: Not specified, but generally in the 6-8 HP range for this class. Torque: Not specified. Fuel System Carburetor Type: Likely a Mikuni VM-series or similar small-bore carburetor (specific model not provided). Fuel Type: Unleaded gasoline (standard). Lubrication Oil Type: API SG or higher, SAE 10W-30 or 10W-40 motorcycle/ATV specific oil (refer to manual for exact specifications). Oil Capacity: Not specified, but typically around 0.8 - 1.0 liters for this engine size. 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with forward, neutral, and reverse (common for Kymco 90cc ATVs). Optional Optional Transmissions: N/A (CVT is standard). Features Drive System: Chain drive to rear axle. Clutch Type: Automatic centrifugal clutch (integrated with...