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6. ENGINE REMOVAL

6-0

Mongoose/KXR 250

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ENGINE REMOVAL

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SERVICE INFORMATION -------------------------------------------- 6- 1

ENGINE REMOVAL --------------------------------------------------- 6- 2

Summary of content (8 pages)

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6.
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6. ENGINE REMOVAL/INSTALLATION Mongoose/KXR 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the machine body, cables and wires during engine removal. • Use shop towels to protect the machine body during engine removal.
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6. ENGINE REMOVAL Mongoose/KXR 250 ENGINE REMOVAL Drain engine oil and transmission oil. (Refer to chapter 3) Remove frame covers and exhaust pipe. (Refer chapter 2) Remove the carburetor. (Refer to chapter 5) Disconnect the oil recycle tube at the cylinder head cover. Oil Recycle Tube Disconnect the water hose from water pump cover. Remove the bolt at the thermostat and disconnect the thermosensor wire, then disconnect the thermostat from the cylinder head.
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6. ENGINE REMOVAL/INSTALLATION Disconnect the speedometer cable (ON ROAD only). Remove the three bolts at the drive sprocket cover and then remove the drive sprocket cover. Remove the two bolts on the drive sprocket. Remove the drive sprocket and washer. Speedometer Cable Drive Sprocket Cover Bolts Slide the rubber sleeve back to expose the starter motor wire nut. Remove the starter motor wire nut for disconnect the starter motor wire.
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6. ENGINE REMOVAL Mongoose/KXR 250 Gear Change Switch coupler Remove the A.C.Generator, pulser and gear change switch couplers. Pulser coupler A.C.Generator coupler Disconnect the spark plug cap. Spark Plug Cap Bolts Remove the three bolts and remove the outlet hose cover. Outlet Hose Cover Unscrew the clamp and then disconnect the outlet hose from the left crankcase cover. Outlet Hose Inlet Hose Unscrew the clamp and then disconnect the inlet hose from the left crankcase cover.
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. ENGINE REMOVAL/INSTALLATION Mongoose/KXR 250 Bolts Remove the two bolts at the left foot peg attaching the left floor board holder and remove the nut at the left floor board holder, then remove the left floor board holder. Nut Remove the two bolts at the right foot peg attaching the right floor board holder. Remove the nut at the right floor board holder and bolt attaching the reservoir protection cover, then remove the right floor board holder.
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6. ENGINE REMOVAL Remove the rear lower mounting bolt and nut. Remove the rear upper mounting bolt and nut. Remove the front mounting bolts and nuts. Mongoose/KXR 250 Mounting Bolt and Nut Mounting Bolt and Nut Mounting Bolt and Nut Brackets Remove the four bolts for remove the left and right engine brackets. Bolts Remove the engine assembly to the left side of the machine.
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