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1. GENERAL INFORMATION

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Mongoose/KXR 250

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GENERAL INFORMATION

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SERIAL NUMBER ------------------------------------------------------ 1- 1

SPECIFICATIONS ------------------------------------------------------ 1- 2

SERVICE PRECAUTIONS--------------------------------------------- 1- 3

TORQUE VALUES ----------------------------------------------------- 1-11

SPECIAL TOOLS ------------------------------------------------------- 1-12

LUBRICATION POINTS----------------------------------------------- 1-13

CABLE & HARNESS ROUTING ------------------------------------- 1-16

WIRING DIAGRAM ---------------------------------------------------- 1-19

TROUBLESHOOTING ------------------------------------------------- 1-21

Summary of content (27 pages)

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. GENERAL INFORMATION Mongoose/KXR 250 1 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION _________________________
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1. GENERAL INFORMATION Mongoose/KXR 250 Oil exchanging capacity Cooling Type SPECIFICATIONS Air cleaner type & No Sponge Fuel capacity 13 liters Type PD Float lever 14.8mm Venturi dia.
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1. GENERAL INFORMATION SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. n Use genuine parts and lubricants. n When servicing the motorcycle, be sure to use special tools for removal and installation. n After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.
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1. GENERAL INFORMATION Mongoose/KXR 250 n Apply or add designated greases and lubricants to the specified lubrication points. n After reassembly, check all parts for proper tightening and operation. n When two persons work together, pay attention to the mutual working safety. n Disconnect the battery negative (-) terminal before operation. n When using a spanner or other tools, make sure not to damage the motorcycle surface.
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1. GENERAL INFORMATION n If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. n After operation, terminal caps shall be installed securely. n When taking out the connector, the lock on the connector shall be released before operation. n Hold the connector body when connecting or disconnecting it. n Do not pull the connector wire. n Check if any connector terminal is bending, protruding or loose.
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1. GENERAL INFORMATION n The connector shall be inserted completely. n If the double connector has a lock, lock it at the correct position. n Check if there is any loose wire. Mongoose/KXR 250 Snapping! n Before connecting a terminal, check for damaged terminal cover or loose negative terminal. n Check the double connector cover for proper coverage and installation. n Insert the terminal completely. n Check the terminal cover for proper coverage. n Do not make the terminal cover opening face up.
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1. GENERAL INFORMATION Mongoose/KXR 250 n After clamping, check each wire to make sure it is secure. n Do not squeeze wires against the weld or its clamp. n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. n When fixing the wire harnesses, do not make it contact the parts which will generate high heat. n Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws.
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1. GENERAL INFORMATION n Route harnesses so they are neither pulled tight nor have excessive slack. Mongoose/KXR 250 Do not pull too tight! n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. n When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. n Do not break the sheath of wire. n If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it.
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1. GENERAL INFORMATION Mongoose/KXR 250 n After routing, check that the wire harnesses are not twisted or kinked. n Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. n When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
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1. GENERAL INFORMATION Mongoose/KXR 250 n Symbols: The following symbols represent the servicing methods and cautions included in this service manual. Engine Oil Grease : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. : Transmission Gear Oil (90#) Gear Oil Special : Use special tool.
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1. GENERAL INFORMATION Mongoose/KXR 250 TORQUE VALUES STANDARD TORQUE VALUES Item 5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut 14mm bolt and nut Torque (kgf-m) 0.45_ 0.6 0.8_ 1.2 1.8_ 2.5 3.0_ 4.0 5.0_ 6.0 6.0_ 8.0 Item 4mm screw 5mm screw 6mm screw, SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 10mm flange bolt and nut Torque (kgf-m) 0.2_ 0.4 0.35_ 0.5 0.7_ 1.1 1.0_ 1.4 2.4_ 3.0 3.5_ 4.
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1. GENERAL INFORMATION Mongoose/KXR 250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft right side oil seal Crankshaft one-way clutch movable part Oil pump drive chain Balance gear A.C.
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1. GENERAL INFORMATION Mongoose/KXR 250 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the ATV.
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1. GENERAL INFORMATION Mongoose/KXR 250 Temperature Sensor Wire Air Vent Tube Tail Light Cord REG.REC Cord Coolant Reservoir Breather Hose A.C.
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1. GENERAL INFORMATION Mongoose/KXR 250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Normal voltage Voltage does not increase Dead battery Faulty battery Measure resistance between AC generator coil terminals Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine ground and test voltage Faulty A.C.
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