KYMCO Mongoose 90 R User manual

Owner’s Manual
ATV off road
Mongoose 90 / Mongoose 90 R

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.
It is especially important that parents make sure their children fully understand
and follow the information and procedures contained in the manual.
This ATV is intended for use by children at least 10 years old. Never allow children
under the age of 10 to operate this ATV.
Anyone who operates this vehicle should get proper instruction.
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

NOTE TO PARENTS
Parents should read the "Important Message to Parents" beginning on page 4 and
the "Parents &Beginning riders" booklet received with the ATV and then decide
whether their youngster is ready to ride.
"Parents, Youngsters and ATVs" focuses on the beginning rider, and discusses
how to evaluate your youngster's readiness to ride as well as showing you how to
introduce your youngster to ATV riding.
Your ATV was delivered with a speed restrictor for new riders. Please refer to page
7 for more information
B

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:
To protect your vehicle from damage, pay attention to caution to cautions.
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.
WARNING
C

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.
D
WARNING

E
CONTROL FUNCTIONS........... ................20
Ignition switch...................................... .20
Handlebar switches................................21
Throttle lever... .....................................25
Speed limiter.... .....................................26
Front brake .......... . ...............................27
Rear brake ............................................27
Parking brake. ......................................28
Fuel tank cap .. ......................................29
Fuel valve . .......................................... 30
Seat......................................................32
Flag pole bracket................................... 33
Storage compartment . ..........................33
Engine stop switch...............................21
Headlight switch.... ..............................22
Stater button.. . ...................................22
Kick starter ............ ..............................23
Remote engine stop switch. ....................24
Start (choke)......................................... 31
CONTENTS
LOCATION OF THE WARNING AND
SPECIFICATION LABELS...........................1
SAFETY INFORMATION.............................4
DESCRIPTION AND MACHINE
IDENTIFICATION.....................................15
IMPORTANT MESSAGE TO PARENTS......4
Evaluate Riding Readiness ....................4
Always Supervise Young Riders..............7
SPECIAL SAFETY MESSAGES........... .....9
Key identification number.. .....................15
Frame and engine serial number..............16
Model code............................................16
Parts location........................................ 17
Page Page
(Cont'd)

F
PRE-OPERATION CHECKS......................34
Front and rear brakes.............................35
Fuel .....................................................36
Engine oil 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
OPERATION............................................43
Starting a cold engine.............................43
Engine break-in.....................................45
Starting a warm engine...........................45
Warming up...........................................45
Parking .. ..............................................46
Parking on a slope .................................47
Accessories ..........................................48
Riding Your ATV........................................49
GETTING TO KNOW YOUR ATV........ ......50
RIDE WITH CARE AND
BE CAREFULWHERE YOU RIDE .............59
JUDGEMENT.........................................51
BEFORE RIDING ..............................50
RIDER PREPARATION .....................50
GOOD
Pre-operation checks .............................52
Wight limits ...........................................53
Accessories ..........................................54
No Modifications ....................................55
SAFE RIDING RULES .............................56
FOR OFF-ROAD USE ONLY ....................61
Ride Only When Visibility Is Good .............61
During operation ....................................62
Exhaust system....................................68
RIDING .................................................69
BRAKING ..............................................71
TURNING YOUR ATV .............................73
Page Page
(Cont'd)

G
SLIDINGAND SKIDDING........................75
CLIMBING UPHILL.................................77
RIDING DOWNHILL ...............................83
CROSSING A SLOPE .............................85
RIDING OVER ROUGH TERRAIN ...........87
CROSSING THROUGH SHALLOW
WATER................................................88
PARKING ............................................89
WHAT TO DO IF ..................................90
WHAT TO DO ......................................90
Engine oil..............................................96
Transmission oil...................................100
Spark plug inspection............................103
Air filter cleaning..................................104
Valve clearance adjustment..................106
PERIODIC MAINTENANCE AND
ADJUSTMENT.........................................92
Tool kit...................................................92
PERIODIC MAINTENANCE/
LUBRICATION.......................................94
Idle speed adjustment.. ........................107
Throttle lever adjustment......................108
Front brake shoe inspection..................109
Rear brake pads inspection...................109
Front brake lever free play adjustment....110
Brake fluid inspection...........................112
Drive chain slack check.........................114
Drive chain slack adjustment.................114
Drive chain cleaning and Lubrication......116
Cable inspection and lubrication...........116
Brakeleverlubrication...........................117
Knuckle shaft and rear fork shaft
Lubrication..........................................117
Draining the V-belt compartment ........... 117
Wheel removal.....................................118
Wheel installation.................................118
Battery .............................................119
Fuse replacement................................121
Spark arrester cleaning.........................123
Troubleshooting ...............................124
Troubleshooting chart........................125
Page Page
(Cont'd)

H
CLEANING AND STORAGE.....................126
A. Cleaning .........................................126
B. Storage ...........................................128
SPECIFICATIONS..................................130
INDEX...................................................136
NOISE REGULATION.............................134
MAINTENANCE RECORD.......................135
Mongoose 90 Reverse version.................142
Page

LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1
CERTIFICATE LABEL OF SVIA
For US
For Canada
DECAL OF EPA

WARNINGINFORMATION
YourATV comes with a hang tag and several labels
containing important safety information. Anyone
who rides the vehicle should read and understand
thisinformation before riding.
Parents of young riders should make sure their
youngsters read and understand the hang tag and
labelinformation before allowing themtoride.
The labels should be considered as permanent
parts of the vehicle. If a label comes off or
becomes hard to read, contact your KYMCO
dealerfor replacements
2
HANG TAG_GENERAL USE
Front Reverse side

3

SAFETY INFORMATION
IMPORTANT MESSAGE TO PARENTS
Your child's safety is very important to KYMCO. That's why we urge you to read
this message before you let any young person ride this ATV. Off-road riding can be
fun. However, an ATV is not a toy and it can be hazardous to operate. As with any
youth activity involving speed and skill-such as bicycling or skateboarding-poor
judgement can result in injuries and we don't want that to happen! You can help
prevent accidents by making good decisions about if, when, and how your
youngster rides this ATV.
The first decision you'll need to make is whether your youngster is ready to ride.
Riding readiness varies widely from one person to another, and while the minimum
age recommended for this ATV is 10 years old, there are other factors that you
should consider.
Evaluate Riding Readiness
4

Physical size and ability are important considerations. To help determine whether
a youngster is big enough for this ATV, have them stand up on the footboards and
grasp the handgrips. While the youngster holds this position, check that they have
at least three inches (8cm) of clearance between the ATV seat and the youngster's
"seat of the pants". A rider needs at least three inches (8cm) of clearance so they
can stand up for balance and comfort, and to shift their body forward, backward and
from side to side.
Also make sure your youngster can
comfortably reach and work all the
controls. For example, can they turn the
handlebars all the way to the right and
left? Can they easily use their feet to work
the brake pedal and gearshift lever? Can
they operate the throttle and brake levers
while they hold onto the handgrips? If not,
the youngster is not physically ready to
ride this ATV.
Before you let a youngster ride an ATV, decide whether they are physically,
mentally and emotionally ready to ride.
5

Athletic ability
Mental and emotional maturity
is another requirement for riding a ATV. Generally speaking, your
youngster should be good at riding a bicycle before they get on an ATV. Can your
youngster judge speeds and distances while riding a bicycle and react with proper
hand and foot actions? Anyone who does not have good coordination, balance, and
agility is not ready for this ATV.
are also necessary for safe riding. Does your
youngster think through problems and come to logical solutions? On a bicycle,
does your youngster obey safe riding rules? Be honest! Young people who take
unnecessary risks, make bad judgments and don't obey rules are not ready to ride
this ATV.
If you decide that your youngster is ready to safely operate this ATV, make sure
both of you first carefully read and understand the instructions and warnings in this
Owner's Manual. Also be sure that your youngster always wears a helmet and other
appropriate riding equipment when operating or sitting on the ATV. (see page 55)
6

Patience And Practice
Always Supervise Young Riders
Even if a youngster takes a certified training course, it's up to you to ensure your
youngster's safety. Remember, learning to ride a ATV is a gradual step-by-step
process. It takes time, patience and practice.
To help you regulate your youngster's rate of learning, your ATV was delivered with
an r We recommend that all beginning riders start off
with the throttle limiter adjusted as delivered. The limiter may be adjusted to
gradually increase maximum speed as the beginner becomes more familiar with
operating the ATV. For adjustment and removal instructions, see pages 69
Supervision is another important obligation of parents. Even after youngsters have
become skilled off-road riders, make sure they always have adult supervision while
riding. It also helps to regularly remind young riders to follow the instructions and
warnings in this manual. And remember, it's the parent's responsibility to see that
the ATV is properly maintained and kept in safe operating condition.
If you choose to lend your ATV, do make sure that any riders under 16 years old will
have adult supervision. Your youngster should understand that the decision to lend
the ATV is yours.
adjustable throttle limite .
7

In Summay
Children differ in skills, physical abilities, and judgement. Some children may not
be able to operate an ATV safely. Parents should supervise their child's use of the
ATV at all times. Parents should permit continued use if they determine that
the child has the ability to operate the ATV safely.
must be an on-going commitment - by you and your
youngster. When you both put safety first, you can enjoy more peace of mind, and
your youngster can enjoy many hours of safe off- road riding.
only
Safe and responsible riding
8

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.An ATV handles differently from
other vehicles including motorcycles and cars. A collision 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 follow the age recommendation:
- A child under 14 years old should never operate an ATV with engine greater than 125cc.
- A child under 16 years old should never operate an ATV with engine greater than 150cc.
-.
Never carry cargo or tow a trailer.
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A child under 10 years old should never operate this ATV
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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.
Never allow a child under age 16 to operate an ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she does not have the abilities to operate it safely.
Never carry a passenger on an ATV.
9
SPECIAL SAFETY MESSAGES

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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.
Never operate an ATV without wearing an approved motorcycle helmet that fits porperly. 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.
10

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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.
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 the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
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.
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.
11