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15.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake disk • Inspect the brake system before riding.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Rear Axle Nuts REAR WHEEL/AXLE/AXLE HUB REMOVAL AND INSPECTION Place the machine on a level place. Remove the rear caliper. (Refer to the “REAR BRAKE CALIPER REMOVAL” section in chapter 13) Use the nut wrench to loosen two rear axle nuts (inner and outer) of the rear axle. °ØNote that the rear axle nuts are left threaded.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Measure the wheel runout. Service Limit: Vertical: 2.0 mm Lateral: 2.0mm Out of specification _ Replace wheel. Remove the two rear axle nuts (outer and inner), washer and collar. Collar Washer Rear Axle Nuts Remove the rear brake disk.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Inspect the brake disk Cracks/damage _ Replace. Inspect the brake disk splines. Wear/damage _ Replace. Loosen the driven chain (refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in the chapter 3) and remove the two bolts at the drive sprocket (refer to the chapter 6), then disconnect the drive chain from the driven sprocket. Splines Drive Sprocket Cover Bolts Bolts Drive Sprocket Driven Sprocket Remove the rear axle from right side.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 REAR AXLE DISASSEMBLY Remove the driven sprocket clip at the rear axle and then remove the driven sprocket. Clip Remove the four nuts attaching the driven sprocket holder at the driven sprocket and then remove driven sprocket. Nuts Inspect the drive sprocket and driven sprocket. More than 1/4 teeth wear _ Replace. Bent teeth _ Replace.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Inspect the driven sprocket holder splines. Wear/damage _ Replace. Splines Inspect the rear axle. Scratched (excessively)/damage _ Replace. Inspect the splines and threads of the rear axle Wear/damage _ Replace. Measure the rear axle run out. Service limit: less than 1.5mm Out of specification _ Replace. °Ø Do not attempt to straighten a bent axle. REAR AXLE ASSEMBLY Reverse the “REAR AXLE DISASSEMBLY” procedures.
15. REAR WHEEL/AXLE/SUSPENSION Remove the circlip at the caliper holder and then remove the caliper holder and collar. Mongoose/KXR 250 Collar Circlip Caliper Holder Remove the rear axle hub from right side.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Inspect rear axle hub. Bearings allow play in the axle hub or the bearing turns roughly _ Replace. Oil seals is wear/damage _ Replace. Axle hub is cracks/bend/damage _ Replace. Dust Seal REAR AXLE HUB DISASSEMBLY Bearing and dust seal replacement steps: Clean the outside of the rear axle hub. Remove the dust seal by a flat-head screw driver. °Ø Place a wood block against the outer edge to protect this edge.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 INSTALLATION Reverse the “REAR WHEEL/AXLE/AXLE HUB REMOVAL AND INSPECTION” procedures. °Ø Apply grease onto the dust seal lips and bearings. Install the rear axle hub. °Ø At this time, the rear axle hub should not be tightened completely. Final tightening is done after the chain slack adjustment. Install the rear axle. Connect the drive chain. Install the rear brake disk, collar inner nut, washer and outer nut.
15. REAR WHEEL/AXLE/SUSPENSION Install the rear wheel and tighten the four nuts. Torque: 5.0_ 6.0kgf-m °ØBe sure the tapered side of the wheel nuts face the wheel rim. Tighten the two rear axle nuts (inner and outer). °ØNote that the rear axle nuts are left threaded. Special Nut wrench F010 Torque: 11.0_ 13.0kgf-m Adjust drive chain slack. (Refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 REAR FORK/SWIM ARM/SHOCK ABSORBER REMOVAL AND INSPECTION Place the machine on a level place. Elevate the rear wheels by placing a suitable stand under the rear of frame. °ØSupport the machine securely so there is no danger of it falling over. Remove the rear wheels, rear axle and rear hub. Refer to the “REAR WHEEL/AXLE/AXLE HUB REMOVAL AND INSPECTION” section in chapter 15. Remove the two bolts at the air cleaner case.
15. REAR WHEEL/AXLE/SUSPENSION Remove the two bolts attaching the rear swing arm at the rear fork and then remove the rear swing arm. Mongoose/KXR 250 Bolts Rear Swim Arm Bush Inspect the shock absorber rod. Bends/damage _ Replace the shock absorber assembly. Inspect the shock absorber. Oil leaks _ Replace the shock absorber assembly. Inspect the spring. Fatigue _ Replace the shock absorber assembly. Move the spring up and down. Inspect the bush. Wear/damage _ Replace.
. REAR WHEEL/AXLE/SUSPENSION Remove the dust seals and the bushes from the lower rear swing arm. Dust Seal Mongoose/KXR 250 Bushes Dust Seals Inspect the lower rear swing arm. Wear/damage _ Replace. Inspect the bush. Wear/damage _ Replace. Lower Rear Swing Arm Dust Seals Bush Inspect the needle bearings. Bring allow play in the lower rear swing arm or bearing turns roughly _ Replace. REAR SWING ARM ASSEMBLY Reverse the “REAR SWING ARM DISASSEMBLY” procedures.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Check the rear fork vertical movement by moving it up and down. If vertical movement is tight, binding or rough, check the inner collar, bearing, bushing and thrust cover, or adjust the shim. Band Remove the band and then disconnect the rear brake fluid tubes from the rear fork. Rear Fluid Tube Pivot Shaft Remove the nut and pivot shaft, then remove rear fork and drive chain. Remove the thrust covers.
15. REAR WHEEL/AXLE/SUSPENSION Mongoose/KXR 250 Thrust Covers Inspect the rear fork. Crack/bend/damage _ Replace. Roll the axle on a flat surface to inspect the pivot shaft. Bends _ Replace. °ØDo not attempt to straighten a bent axle. Inspect the thrust covers, collar and bushes. Wear/damage _ Replace. Collar Inspect the drive chain stiffness. Stiff _Clean and lubricate or replace.
15. REAR WHEEL/AXLE/SUSPENSION INSTALLATION Reverse the “REAR FORK/SWIM ARM/SHOCK ABSORBER REMOVAL AND INSPECTION” procedure. Apply grease onto the collar, bush, pivot shaft and thrust cover. Install the rear fork and tightening the nut and pivot shaft. Torque: 6.0_ 8.0kgf-m Install the rear swing arm and tightening the bolts. Torque: 3.5_ 4.5kgf-m Install the shock absorber and tightening the bolts. Torque: 3.5_ 4.5kgf-m Install the rear hub and rear wheels.
