KYMCO Mongoose 250 User manual

OWNER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
Mongoose 250
OFF-ROAD

IMPORTANT NOTICES
READ THIS MANUAL CAREFULLY
AGE RECOMMENDATION
RIDER TRAINING
Your Owner's Manual contains important information on safety, operation, and
maintenance. Any one who operates this ATV should carefully read and
understand the contents of this manual before riding the vehicle.
The minimum recommended age for this ATV model is 16. Children under age 16
should never operate this vehicle.
Anyone who operates this vehicle should get proper instruction.
FOR OFF-ROAD USE ONLY
This vehicle is designed and manufactured for off-road use only. This machine is
designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to
operate this machine on any public street, road or highway.
This machine complies with all applicable OFF-ROAD noise level and spark
arrester laws and regulation in effect at the time of manufacture.
Please check your local riding laws and regulations before operating this
machine.
A

SPECIAL MESSAGES
KYMCO provides many important safety messages both in this manual and on the
vehicle. For your safety and the safety of others, pay special attention to all
warnings preceded by this alert symbol . Failure to follow the warnings
contained in this manual can result in SERIOUS INJURY or DEATH.
Indicates a strong possibility that serious injury or death may
result if instructions are not followed.
CAUTION Indicates a possibility that equipment or property damage
could result if instructions are not followed.
Note: Gives helpful information
The Owner's Manual should be considered a permanent part of your ATV. It should
remain with the vehicle at all times and stay with the ATV if it is sold.
B
WARNING

PREFACE
Congratulations on your purchase of the KYMCO ATV. KYMCO take pride in a
worldwide reputation for quality-in research, design, production and service.
For replacement parts and accessories, we recommend genuine KYMCO
products. They've been specially designed for your vehicle and manufactured to
meet KYMCO's demanding standards.
This manual will provide you with a good basic understanding of the features and
operation of this machine. This manual includes important safety information. It
provides information about special techniques and skills necessary to ride your
machine. It also includes basic maintenance and inspection procedures. If you
have any questions regarding the operation or maintenance of your machine,
please consult a KYMCO dealer.
We wish you many years of safe and enjoyable riding.
While reading this manual, remember:
Indicates a strong possibility that serious injury or death may
result if instructions are not followed.
All information in this publication is based on the latest product information
available at the time of approval for printing. KWANG YANG MOTOR CO.,LTD
reserves the right to make changes at any time without notice and without
incurring any obligation.
C
WARNING

CONTROL FUNCTIONS...........................17
Ignition switch.....................................17
Indicator lamps....................................18
Handlebar switches.............................20
Throttle lever......................................22
Speed limiter.......................................23
Front brake ........................................24
Rear brake .........................................24
Parking brake......................................25
Drive select lever.................................26
Fuel tank cap ......................................26
Fuel valve...........................................27
Starter (choke)....................................28
Seat...................................................29
Flag pole bracket.................................30
Storage compartment..........................30
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS...........................1
SAFETY INFORMATION.............................4
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................11
Key identification number.....................11
Frame and engine serial number............12
Model code.........................................12
Parts location.....................................13
Page Page
(Cont'd)
D

PRE-OPERATION CHECKS......................31
Drive select lever ................................32
Front and rear brakes..........................35
Fuel ...................................................36
Engine and transmission oil .................38
Chain ................................................39
Throttle lever......................................39
Fittings and fasteners..........................39
Lights ................................................39
Switches ............................................39
Tires ..................................................40
How to measure tire pressure ..............41
Tire wear limit .....................................42
Coolant .............................................42
OPERATION............................................44
Starting a cold engine..........................44
Starting a warm engine........................46
Warming up........................................46
Drive select lever operation and reverse
driving................................................47
Engine break-in...................................49
Parking ..............................................51
Parking on a slope ..............................52
Loading ..............................................53
Riding Your ATV .......................................56
GETTING TO KNOW YOUR ATV .........57
RIDE WITH CARE AND
BE CAREFUL WHERE YOU RIDE .........69
TURNING YOUR ATV ..........................78
CLIMBING UPHILL..............................82
RIDING DOWNHILL.............................88
CROSSING A SLOPE ..........................90
CROSSING THROUGH
SHALLOW WATER..............................93
WHAT TO DO IF ..................................95
WHAT TO DO ......................................95
JUDGEMENT ..........................58
Accessories .......................................54
GOOD
SLIDING AND SKIDDING.....................80
RIDING OVER ROUGH TERRAIN .........92
Page Page
(Cont'd)
E

PERIODIC MAINTENANCE AND
ADJUSTMENT.........................................97
Tool kit................................................97
PERIODIC MAINTENANCE/
LUBRICATION....................................99
Engine oil .........................................101
Transmission oil................................105
Spark plug inspection.........................107
Air filter cleaning................................108
Idle speed adjustment ........................113
Throttle lever adjustment....................114
Valve clearance adjustment................115
Front and rear brake shoe inspection
(Model code: LA50AA) .......................115
Brake fluid inspection.........................118
Cooling system inspection..................120
Drive chain slack check......................122
Drive chain slack adjustment...............122
Drive chain cleaning and
Lubrication.......................................124
Front and rear brake shoe inspection
(Model code: LA50AB) .......................117
Rear swing arm lubrication .................124
Draining the V-belt compartment.........125
Cable inspection and lubrication..........125
Spark arrest cleaning.........................130
Wheel removal.................................126
Wheel installation..............................126
Battery .............................................127
Fuse replacement..............................129
Headlight beam adjustment................130
Troubleshooting ...............................131
Troubleshooting chart........................132
CLEANING AND STORAGE.....................133
A. Cleaning ......................................133
B. Storage ........................................135
SPECIFICATIONS..................................137
Page Page
(cont'd)
F

NOISE REGULATION.............................141
MAINTENANCE RECORD.......................142
INDEX...................................................143
Page
G

LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1

Warning information
Anyone who rides the vehicle should read and understand this information before riding. They
contain important information for safe and proper operation of your ATV.
The labels should be considered as permanent parts of the vehicle. If a label comes off or becomes
hard to read, contact your KYMCO dealer for replacements.
Operating this ATV if you are under the
age of 16 increases your chance of
severe injury or death.
operate this ATV if you are
under age 16.
NEVER
2
WARNING
NEVER ride as a
passenger.
Passengers can cause a
loss of control, resulting
in SEVERE INJURY or
DEATH.
WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS
OF CONTROL.
LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH.
OPERATING TIRE PRESSURE : Set with tires cold
Recommended : FRONT : 25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi
REAR :
Never set tire pressure below recommended.
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2
25~32kpa, (0.25~0.32kgf/cm ), 3.5~4.5psi
Maximum Vehicle Load: 100Kg. (220 lbs).
Including weight of operator, cargo and accessories.
2
LOADING
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WARNING
3
Before shifting, you must stop the machine and
return the throttle lever to its closed position until
the engine speed to the specified idling speed.
Otherwise, the transmission may be damaged.
CAUTION

4
Improper ATV use can result in SEVERE
INJURY or DEATH.
ALWAYS USE AN
APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate :
Without proper training or instruction.
At speeds too fast for your skills or the
conditions.
On public roads-a collision can occur with
another vehicle.
With a passenger-passengers affect balance
and steering control.
ALWAYS :
Use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in
turns.
Avoid paved surfaces-pavement may seriously
affect handling and control.
READ OWNER'S MANUAL, FOLLOW ALL
INSTRUCTIONS AND WARNINGS.
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WARNING

SAFETY INFORMATION
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from
other vehicles including motorcycles and cars. An accident can occur quickly, even during routine
maneuvers such as turning and riding on hills or over obstacles, if you fail to take proper pre-
cautions.
SEVERE INJURY OR DEATH can result if you do not follow these instructions:
Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking
lots and streets.
Never operate an ATV on any public street, road or highway, even a dirt or gravel one.
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Read this manual and all labels carefully and follow the operating procedures described.
Never operate an ATV without proper training or instruction.
Beginners should receive training from a certified instructor.
Always follow the age recommendation:
- A child under 16 years old should never operate an ATV with engine size greater than 90cc.
Never carry a passenger on an ATV.
5

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Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or
jacket, and long pants.
Never consume alcohol or drugs before or while operating this ATV.
Never operate at speeds too fast for your skills or the conditions. Always go at a speed that is
proper for the terrain, visibility and operating conditions, and your experience.
Never attempt wheel, jump, or other stunt.
Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always
follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the ATV.
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Always follow proper procedures for turning as described in this manual. Practice turning at low
speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
Never operate on excessively rough, slippery or loose terrain until you have learned and practiced
the skills necessary to control the ATV on such terrain. Always be especially cautious on these
kinds of terrain.
6

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Always follow proper procedures for climbing hills as described in this manual. Check the terrain
carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward. Never open the throttle suddenly. Never go over the top of a hill at high
speed.
Never operate the ATV on hills too steep. Practice on smaller hills before attempting larger hills.
Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling,
maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed
straight uphill. Turn the ATV around and remount, following the procedure described in this
manual.
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Always follow proper procedures for going down hills and for braking on hills as described in this
manual. Check the terrain carefully before you start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going down hill at an angle that would cause the vehicle
to lean sharply to one side. Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid
hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
Never attempt to turn the ATV around on any hill until you have mastered the turning technique
described in this manual on level ground. Avoid crossing the side of a steep hill if possible.
7

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Always check for obstacles before operating in a new area. Never attempt to operate over large
obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating
over obstacles as described in this manual.
Never operate an ATV in fast flowing water or in water deeper than that recommended in this
manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several times to let friction dry out the linings.
Always be careful when skidding or sliding. Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of
control.
Always be sure there are no obstacles or people behind you when you operate in reverse. When it
is safe to proceed in reverse, go slowly.
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow
greater distance for braking.
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Always use the size and type tires specified in this manual. Always maintain proper tire pressure
as described in this manual.
Never modify an ATV through improper installation or use of accessories.
8

WARNING
POTENTIAL HAZARD
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
Improper handling of gasoline.
Gasoline can catch fire and you could be
burned.
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or exhaust
pipe/muffler when refueling.
Never refuel while smoking, or while in the
vicinity of sparks, open flames, or other
sources of ignition such as the pilot lights of
water heaters and clothes dryers.
When transporting the machine in another
vehicle, be sure it is kept upright and that the
fuel valve is in the "OFF" position.
Otherwise, fuel may leak out of the carburetor
or fuel tank.
WHAT CAN HAPPEN
HOW TO AVOID THE HAZARD
Gasoline is poisonous and can cause injuries.
If you should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gasoline in
your eyes, see your doctor immediately.
If gasoline spills on your skin, wash with soap
and water. If gasoline spills on your clothing,
change your clothes.
9

POTENTIAL HAZARD
Starting or running the engine in a closed
area.
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your machine in an area
with adequate ventilation.
10
WARNING
ON

Key identification number
The key identification number is stamped on
the hang tag as shown in the following
illustration.
DESCRIPTION AND MACHINE IDENTIFICATION
11
(1) Key identification number
Identification number records
Record the key identification number, frame
serial number, engine serial number and
model code information for assistance when
order replacement parts.
KEY NO.
FRAME NO.
ENGINE NO.
MODEL CODE
(1)