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2. FRAME COVERS/EXHAUST MUFFLER

2-0

Mongoose/KXR 250

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FRAME COVERS/EXHAUST MUFFLER

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SERVICE INFORMATION -------------------------------------------- 2- 2

TROUBLESHOOTING ------------------------------------------------- 2- 2

FRAME COVERS ------------------------------------------------------- 2- 3

EXHAUST MUFFLER REMOVAL ----------------------------------- 2- 7

Summary of content (8 pages)

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2.
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. FRAME COVERS/EXHAUST MUFFLER 2-1 Mongoose/KXR 250
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt Exhaust muffler lock nut 3.2_ 3.8kgf-m 1.8_ 2.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 250 FRAME COVERS Seat Lever SEAT REMOVAL Pull the lever right and pull up the seat at the rear. Remove the seat. LEFT/RIGHT FRAME COVER REMOVAL Remove the seat. (See page 2-3) Frame Left Cover Bolts Remove the screw and two bolts at the left frame cover, then remove left frame cover. Screw Remove the screw and two bolts at the right frame cover, then remove right frame cover.
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2. FRAME COVERS/EXHAUST MUFFLER Bolts Remove the three bolts at the rear fender. Screws Remove the two screws attaching the right and left floor board. Remove the two screws attaching the frame body and three screws attaching the outlet hose, then remove the rear fender. Mongoose/KXR 250 Screws Screws °ØDuring removal, do not pull the joint claws forcedly to avoid damage. Outlet Hose HANDLEBAR COVER REMOVAL Remove the two screws at the handlebar cover.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 250 Bolts CENTER FRAME COVER REMOVAL Remove the seat. (See page 2-3) Remove the fuel fill cap. Remove the four bolts at the center frame cover, then remove the center frame cover. °ØAfter remove, be sure to tighten the fuel fill cap. Fuel Fill Cap FRONT FENDER REMOVAL Remove the seat (See page 2-3), right and left side frame cover (See page 2-3) and center frame cover. (See page 2-5) Bolts Remove the two bolts at the front fender left side.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 250 Disconnect headlight and ignition switch couplers, then remove the front fender. Ignition Coupler Headlight Coupler RIGHT AND LEFT FLOOR BOARD REMOVAL Remove the four screws at the floor board, then remove the floor board. Screws FRONT CARRIER REMOVAL Remove the four bolts at the front carrier, then remove the front carrier.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 250 EXHAUST MUFFLER REMOVAL Remove the two exhaust pipe joint lock nuts. Remove the bolt at the exhaust muffler, disconnect the exhaust pipe from the exhaust muffler. Nuts Bolt Gasket Inspect the gasket. If the exhaust gas leaks, the gasket should be replaced. Install by reversing the removal sequence. Torque: Exhaust muffler lock bolt: 3.2_ 3.8kgf-m Exhaust muffler lock nut: 1.8_ 2.2kgf-m °ØBe sure to install a new exhaust gasket.