These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. Kymco Mongoose Factory Service Repair Manual meets all your information needs to repair or make some adjustments to your Kymco Mongoose This manual is intended as a handy, easy to read reference book for the mechanics and DIY persons.
Comprehensive explanations of all installation, removal,disassembly,assembly,repair and check procedures are laid out with the individual steps in sequential order. This manual is known in many names: Kymco Mongoose service manual Kymco Mongoose repair manual Kymco Mongoose workshop manual Kymco Mongoose shop manual.
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Contact us now! Contact us! Please enable JavaScript in your browser to complete this form. We will contact with you by email. This manual is specifically written for the do-it-yourselfer as well as the experienced mechanic. It provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide you through each service and repair procedure.
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It is clear, easy to use and printable I will definitely purchase from them again. Correct manual. Service Limit: 0. Install oil pump driven sprocket and drive chain, circlip and oil separator cover. Page Fuel System. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. Page Fuel Tank. Remove the seat See page , right and left side frame cover See page and fuel tank cover See page Remove the washer and control shaft.
Install rubber gasket, control shaft, washer and retaining ring. Page Throttle Valve. Throttle Valve Pull out the throttle valve. Compress the spring to disconnect the throttle cable by hand.
Check the throttle valve and jet needle for wear or damage. Page Carburetor. Replace with new ones if necessary. Screws Remove the baffle plate. Baffle plate Inspect the float for deformation or damage.
Screws Spring Diaphragm Remove the spring, diaphragm and O-rings. Inspect the diaphragm and spring for wear or damage. Inspect the float for damage or fuel level inside the float chamber. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and air screw Install the spring, diaphragm and O-rings. Page Air Cleaner Housing. Remove the side covers see page Remove the clip and disconnect the crankcase breather hose from the crankcase.
Loosen the carburetor-to-air cleaner connecting tube band screw. Page Pair Solenoid Valve. Disconnect air supply hose and vacuum hose from the air solenoid valve, then remove the air solenoid valve.
Page Engine Removal 6. Be careful not to damage the machine body, cables and wires during engine removal. Refer to chapter 3. Remove frame covers and exhaust pipe. Refer chapter 2. Remove the air cleaner housing and carburetor. Refer to chapter 5. Page 6. Remove the two mounting nuts and drive select shift. Drive Sprocket Cover Bolts Remove the three bolts at the drive sprocket cover and then remove the drive sprocket cover. Page Engine Removal Mxu Remove the starter motor wire nut for disconnect the starter motor wire.
Ground Wire Bolt Remove the bolt at the starter motor for disconnect the ground wire lead. Loosen the outlet hose band screw and then disconnect the outlet hose from the left crankcase cover. Page Engine Installation Mxu 6. The rear upper and lower engine mounting bolts and nuts loosely install, then tighten the engine mounting nuts to the specified torque.
Torque: 40 N-m 4 kgf-m, 29 lbf-ft Page Bolt Nuts Bolt Remove the bolt and thermostat. Generator, ignition pulse generator and gear change switch connectors. Inlet Hose Outlet Hose Loosen the inlet hose band screw and then disconnect the inlet hose from the left crankcase cover. Bolts Remove the rear upper mounting bolt and nut.
Bolt Remove the rear lower mounting bolt and nut. Bolt Remove the joint boot from the swingarm. Rise the engine front side and move the engine forward, then remove the engine Lower the cylinder head to turn the cylinder head to frame left side.
Intake Manifold Holder Plate Be careful not to damage choke knob cable and holder plate when the engine is moved. Check the joint boot for tears or other damage. Check the secondary driven bevel gear shaft splines and universal joint splines for wear or damage. Torque: 22 N-m 2. Page 7. Page Troubleshooting 7. Page Cylinder Head Cover. Refer to the chapter 5 Disconnect the crankcase breather hose and pair control valve hose from the cylinder head cover.
Refer to the chapter 6 Remove the four bolts at the cylinder head cover, then remove the cylinder head cover. Diagonally loosen the cylinder head nuts in 2 or 3 times. Remove the camshaft holder and dowel pins.
Remove the valve rocker arms, arm shafts and stop plate. Measure the I. Measure arm to shaft clearance. Replace as a set if out of specification. Service limits: 0. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. Install the washers and nuts and tighten the nuts. Page Cylinder Head. Remove the carburetor. Remove the two bolts and then remove the carburetor intake manifold.
If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O. Replace if out of specification. Standard: IN : Standard: IN : 0. Be sure to install new oil seal. Lubricate each valve with engine oil and insert the valves into the valve guides. Install the valve springs and retainers. Refer to the chapter 7 Remove the two dowel pins, cylinder head gasket and cam chain guide.
Towel Piston Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase. Press the piston pin out of the piston and remove the piston. Use the piston head to push each piston ring into the cylinder. Measure the piston ring end gap. Service Limit replace if over : Top: 0. Service Limit replace if over : 0. Apply engine oil to each piston ring. Be careful not to drop foreign matters into the crankcase.
Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. Remove the recoil starter cover. Recoil Starter Cover Gasket Remove the dowel pins and gasket. Dowel Pins Bolts Disconnect drive belt air inlet and outlet hose from left crankcase cover see page Roller Remove the six weight rollers. Measure each weight roller O.
Service Limit replace if below : Service Limit replace if over : Measure the drive belt width. Service Limit replace if below : 22 mm 0. Remove the seal collar. O-ring Guide Roller Pin Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Service Limit replace if below : 0. Service Limit replace if below : mm 5. Measure the movable driven face I. Apply grease to the driven face bore areas. Pack all bearing cavities with proper grease.
Install the retainer plate and secure with the circlips. Clean the driven pulley faces and remove any grease from them. Keep grease off the drive shaft. Install the clutch outer, collar. Hold the clutch outer with the flywheel holder. When installing the drive pulley face, compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened. Make sure the ratchet into the splines on the crankshaft when the ratchet is installed. Page Transmission Case Cover Mxu Remove the drive axle from the transmission case cover.
Remove the bearing circlip for remove the bearing. Inspect the bearing for allow play in the Page Transmission Mxu If any defects are found, replace the bearing with a new one. Remove the stopper plug. Plug Spring Shift Cam Remove shift cam. Shift Fork Remove the shift fork. Service Limit: Less than 0.
Shift Fork Cam Follower Inspect the shift fork cam follower and shift fork pawl. Inspect shift shaft. Shift Shaft Gear Remove the main axle. Inspect the mated dogs. Counter Axle Inspect the gear teeth. Refer to the chapter 9 Remove the oil seal, circlip, bolts and plates.
Page Fill the engine with oil and install the oil filler bolt. Remove the speedometer gear plug, washer and speedometer gear shaft. Plug Speedometer Gear Remove the transmission case cover see page If any defects are found, replace the oil seal with a new one.
Bolts Speedometer Gear Remove the speedometer gear plug, washer and speedometer gear. Plug Washer Clutch Outer Using a chisel, unlock the nut. Bolts Driveshaft Bearing Remove the countershaft bearing and driveshaft bearing with special tools.
Remove the snap ring. Outer Bearing Remove the outer bearing. Snap Ring Inner Bearing Remove the snap ring. Inspect the secondary driven bevel gear shaft for blue discoloration, pitting or wear. Inspect the bevel gears and speedometer gear Install the shim and driven bevel gear. Fit the universal joint onto the driven bevel gear shaft. Tighten the driven bevel gear nut to the specified torque. Install and tighten the bolts to the specified torque. Torque: 2.
Install the secondary driven bevel gear into the transmission case cover. Align the mark on the secondary bevel driven gear shaft case with the index mark on the transmission case cover. Page Transmission Mxu Fill the engine with oil and install the oil filler bolt.
Remove the upper shift fork. Remove the lower shift fork. Washer Plug Countershaft Driveshaft Remove the countershaft and driveshaft as an assembly. Clutch dog Check the gear dogs, gearshifter groove for wear or damage. Gear Dogs Clutch Dog Remove the snap ring, then remove washer Countershaft Inspect the teeth, spline grooves and sliding surfaces for abnormal wear or damage.
Washer Apply molybdenum oil solution to the gear and sliding surface and shift fork grooves to ensure initial lubrication. Remove the reverse gear. Reverse gear Inspect the dog holes and teeth for damage or wear. Low driven gear Inspect the dog holes and teeth for damage or wear. Apply molybdenum oil solution to the gear and sliding surface and shift fork grooves to ensure initial lubrication.
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