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5. FUEL SYSTEM

5-0

Mongoose/KXR 250

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FUEL SYSTEM

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SERVICE INFORMATION -------------------------------------------- 5- 2

TROUBLESHOOTING ------------------------------------------------- 5- 3

FUEL TANK------------------------------------------------------------- 5- 4

FUEL VALVE REMOVAL -------------------------------------------- 5- 4

THROTTLE VALVE ----------------------------------------------------- 5- 7

CARBURETOR ---------------------------------------------------------- 5- 8

AIR CLEANER ---------------------------------------------------------- 5-12

Summary of content (13 pages)

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5. FUEL SYSTEM Mongoose/KXR 250 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. • Do not bend or twist control cables. Damaged control cables will not operate smoothly. • When disassembling fuel system parts, note the locations of O-rings. Replace them with new ones during reassembly.
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. FUEL SYSTEM Mongoose/KXR 250 FUEL TANK REMOVAL Warning • Keep sparks and flames away from the work area. • Wipe off any spilled gasoline. Remove the seat, right and left side frame cover (See page 2-3) and center frame cover (See page 2-5). Fuel Tube Fuel Valve Switch the fuel valve “OFF”. Disconnect the fuel tube from carburetor and remove two screws at the fuel valve holder. Nuts Screws Fuel Tank Remove the two bolts and two nuts at the fuel tank, then remove the fuel tank.
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5. FUEL SYSTEM DISASSEMBLY Remove the two screws on the retaining ring and then remove retaining ring. Remove the washer and control shaft. Mongoose/KXR 250 Screws Control Shaft Washer Retaining Ring Rubber Gasket Remove the rubber gasket from the fuel valve body. Fuel Valve Body INSPECTION Inspect the fuel valve body for dirt and clog. Clean if necessary. Replace the rubber gasket with new ones if they are damaged or deteriorated.
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5. FUEL SYSTEM Mongoose/KXR 250 Main Fuel Tube INSTALLATION Reverse the “FUEL VALVE REMOVEAL” procedures. Connect all fuel tube.
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5. FUEL SYSTEM Mongoose/KXR 250 Carburetor Cap THROTTLE VALVE DISAS SEMBLY Remove the fuel tank. (Refer to “FUEL TANK” section in the chapter 5) Remove the carburetor cap. Pull out the throttle valve. Throttle Valve Throttle Cable Compress the spring to disconnect the throttle cable by hand.
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5. FUEL SYSTEM Pry off the needle retainer and remove the jet needle. Check the throttle valve and jet needle for wear or damage. Mongoose/KXR 250 Needle Retainer Throttle Valve AS SEMBLY Reverse the “DISASSEMBLY” procedures. Jet Needle Clip Groove Install the throttle valve into the carburetor body. °ØAlign the groove in the throttle valve with the throttle stop screw on the carburetor body. Throttle Stop Screw CARBURETOR REMOVAL Remove the fuel tank and carburetor cap.
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5. FUEL SYSTEM Mongoose/KXR 250 Bolts Remove the two bolts at the air cleaner case. Loosen the air cleaner connecting tube band screw. Remove the two carburetor lock nuts attaching the inlet pipe. Remove the carburetor Band Nuts Float Chamber DIS AS S EMBLY Remove the float chamber attaching three screws and remove the float chamber. Screws Remove the jet holder. Jet Holder Pull out the float pin, then remove float and float valve.
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5. FUEL SYSTEM Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Remove the air screw and throttle stop screw. Mongoose/KXR 250 Throttle Stop Screw Slow Jet Main Jet Air Screw CAUTIONS! Spring Throttle Stop Screw °Ø• Be careful not to damage the jets and jet holder when removing them. • Before removal, turn the throttle stop screw and air screw in and count the number of turns until they seat lightly and then make a note of this.
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5. FUEL SYSTEM Mongoose/KXR 250 Spring Remove the spring, diaphragm and O-rings. Inspect the diaphragm and spring for wear or damage. Cover CARBURETOR CLEANING Blow compressed air through all passages of the carburetor body. Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float valve seat for wear or damage. Inspect the float for damage or fuel level inside the float chamber. Float Valve Seat FUEL RESERVOIR O-RING CHECK Remove the O-ring. INSPECTION Inspect the check the O-ring for damage.
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5. FUEL SYSTEM Mongoose/KXR 250 ASSEMBLY Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and air screw Install the spring, diaphragm and O-rings. °Ø• When installing the air screw, return it to the original position as noted during removal • After the carburetor is installed, be sure to perform the Exhaust Emission Test. Install the float valve, float and float pin.