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12. COOLING SYSTEM

12-0

Mongoose/KXR 250

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COOLING SYSTEM

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SERVICE INFORMATION -------------------------------------------- 12- 1

TROUBLESHOOTING ------------------------------------------------- 12- 1

COOLING SYSTEM TESTING --------------------------------------- 12- 3

RADIATOR -------------------------------------------------------------- 12- 4

WATER PUMP ---------------------------------------------------------- 12- 6

THERMOSENSOR ------------------------------------------------------ 12-10

THERMOSTAT---------------------------------------------------------- 12-11

Summary of content (13 pages)

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12. COOLING SYSTEM Mongoose/KXR 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system. When the coolant temperature is over 100¢J, never remove the radiator cap to release the pressure because the boiling coolant may cause danger.
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12. COOLING SYSTEM Mongoose/KXR 250 SPECIFICATIONS Radiator cap relief pressure Begins to open Thermostat temperature Full-open Valve lift 075~1.05kg/cm_ 80±2¢J 90¢J 3.5_ 4.5mm 1100±20cc Total system 1400±20cc Radiator: Reserve tank: 300±20cc Coolant capacity COOLANT GRAVITY Temp. ¢J Coolant concentration 0 5 10 15 20 25 30 35 40 45 50 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 1.009 1.018 1.028 1.036 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100 1.009 1.107 1.027 1.035 1.044 1.
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12. COOLING SYSTEM Mongoose/KXR 250 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. Radiator Tester °ØApply water to the cap sealing surface before testing. Radiator Cap Relief Pressure: 0.75~1.05kg/cm_ Install the radiator tester onto the radiator and apply specified pressure to it. It must hold specified pressure for at least six seconds.
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12. COOLING SYSTEM Mongoose/KXR 250 Radiator RADIATOR RADIATOR INSPECTION Remove the front fender. (!2-5) Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins. Air Vent Tube Overflow Tube RADIATOR REMOVAL Drain the coolant. (!3-20) Remove the front fender. (!2-5) Disconnect the air vent tube from the radiator filler.
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12. COOLING SYSTEM RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan/shroud from the radiator. Check fan motor by battery. Mongoose/KXR 250 Bolts CHECK THERMOSTATIC SWITCH When coolant temperature lower then 85~90¢J the thermostatic switch OFF. When coolant temperature over 85~90¢J the thermostatic switch ON. RADIATOR ASSEMBLY Install the fan shroud on the radiator with the three bolts. RADIATOR INSTALLATION Reverse the “RADIATOR REMOVAL” procedures. Fill the radiator with coolant.
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12. COOLING SYSTEM Mongoose/KXR 250 WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal. Water Pump Telltale Hole Water Pump Cover WATER PUMP/IMPELLER REMOVAL Drain the coolant. (!3-20) Loosen the screw and disconnect the coolant inlet hose. Remove the four bolts and the water pump cover.
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12. COOLING SYSTEM Inspect the mechanical (water) seal and seal washer for wear or damage. Mongoose/KXR 250 Impeller Mechanical Seal °ØThe mechanical seal and seal washer must be replace as a set. Seal Washer (Porcelain) WATER PUMP SHAFT REMOVAL Remove the water pump impeller. (!12-6) Disconnect the water hose from the right crankcase cover. Remove the twelve bolts attaching the right crankcase cover. Remove the water pump bearing snap ring from the water pump assembly.
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12. COOLING SYSTEM Remove the water pump shaft outer bearing. Mongoose/KXR 250 Snap Ring Inner Bearing Washer Water Pump Shaft Outer Bearing MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Impeller Seal Washer Water Pump Assembly Mechanical Seal (Water Seal) Drive in a new mechanical seal using a mechanical seal driver.
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12. COOLING SYSTEM WATER PUMP S HAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside. Mongoose/KXR 250 Outer Bearing Water Pump Assembly Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten the twelve bolts to secure the right crankcase cover.
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12. COOLING SYSTEM Mongoose/KXR 250 THERMOSENSOR THERMOSENSOR REMOVAL Drain the coolant. (!3-20) Disconnect the thermosensor wire. Remove the thermosensor from the thermostat. Thermosensor Thermosensor Wire THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up. Temperature(¢J) 50 Resistance(W) 154 80 52 100 27 120 16 THERMOSENSOR INSTALLATION Apply 3-BOND No.
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. COOLING SYSTEM THERMOSTAT THERMOSTAT REMOVAL Drain the coolant. (!3-20) Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing. Disconnect the air vent tube from the thermostat housing. Remove the mounting bolt and the thermostat housing from the cylinder head. Remove the two screws and separate the thermostat housing halves.
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12. COOLING SYSTEM THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation. Technical Data Begins to open Mongoose/KXR 250 Thermostat Thermometer 80±2¢J Full-open 90¢J Valve lift 3.5_ 4.5mm °Ø• Do not let the thermostat touch the pan O-ring as it will give a false reading. • Replace the thermostat if the valve stays open at room temperature.