3.
13.
13. BRAKE SYSTEM Mongoose/KXR 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake pads and brake disk. • Drain the brake fluid from the hydraulic brake system before disassembly. • Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake disk with high-performance brake degreaser and replace the brake pads. • Do not use brake fluid for cleaning.
13. BRAKE SYSTEM FRONT HYDRAULIC BRAKE BRAKE PADS REMOVAL Remove the front wheel. (!14-3) Remove the two brake pad pins from the brake caliper. Remove the two bolts attaching the brake caliper and then remove brake caliper. Compress the brake caliper holder and remove brake pads. A wear indicator is provided on each brake. The indicators allows checking of brake pads wear. Check the position of the indicator. BRAKE DISK Measure the brake disk thickness. Service Limit: 3.
13. BRAKE SYSTEM Mongoose/KXR 250 FRONT BRAKE FLUID CHANGE/AIR BLEED BRAKE FLUID DRAINING Place the machine on the level ground and set the handlebar upright. Remove the two screws attaching the brake fluid reservoir cap. °ØUse shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose.
13. BRAKE SYSTEM BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake lever after continuously pull it several times. Then, loosen the bleed valve nut to bleed air from the brake system. Repeat these steps until the brake system is free of air. °ØWhen bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height.
13. BRAKE SYSTEM Mongoose/KXR 250 Remove the brake lever bolt and the brake lever. Remove the piston rubber cover and snap ring from the brake master cylinder. Snap Ring Snap Ring Pliers (Close) Remove the washer, main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid.
13. BRAKE SYSTEM Mongoose/KXR 250 ASSEMBLY Before assembly, apply brake fluid to all removed parts. °Ø• During assembly, the main piston and spring must be installed as a unit without exchange. • When assembling the piston, soak the cups in brake fluid for a while. • Install the cups with the cup lips facing the correct direction. Install the main piston, spring and snap ring. Install the rubber cover. Install the brake lever.
13. BRAKE SYSTEM Mongoose/KXR 250 FRONT BRAKE CALIPER REMOVAL Remove the front wheel. (!15-3) First drain the brake fluid from the hydraulic brake system. (!13-4) Remove the brake pad pins. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper. Brake Pad Pins Bolts Fluid Tube Bolt DISASSEMBLY Remove the brake pads. (!13-3) Remove the brake pad spring plate. Spring Plate Remove the piston from the brake caliper.
13. BRAKE SYSTEM Push the piston oil seal outward to remove it. Clean the seals groove with brake fluid. °ØBe careful not to damage the piston surface. INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper. ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the oil seal and dust seal.
13. BRAKE SYSTEM Mongoose/KXR 250 Install the caliper spring plate into the caliper. °ØMake sure that the boss on the caliper correctly engages with the locating slot on the caliper spring plate. INSTALLATION Reverse the “FRONT BRAKE CALIPER REMOVAL” procedures. °ØWhen installing the brake caliper, be sure to position the brake disk between the two brake pads. Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 1.8_ 2.
13. BRAKE SYSTEM Mongoose/KXR 250 Brake Pad Cover REAR HYDRAULIC BRAKE Cotter Pin REAR BRAKE PADS REMOVAL Remove the brake pads cover. Remove the cotter pin and then pull out the brake pad pin from the caliper. Brake Pad Pin Brake Pads Remove the brake spring plate and then remove brake pads. Spring Plate Spring Plate Big End INSTALLATION Reverse the “REAR BRAKE PADS REMOVAL” procedures. °Ø• Make sure put the spring plate big end on the rear caliper.
. BRAKE SYSTEM Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. Mongoose/KXR 250 Bleed Valve (Front Left Lever) Bleed Valve (Pedal) Bleed Valve (Front Left Lever) BRAKE FLUID REFILLING Connect a transparent hose and syringe to the brake caliper bleed valve and then loosen the bleed valve nut.
13. BRAKE SYSTEM Mongoose/KXR 250 REAR BRAKE MASTER CYLINDER (REAR BRAKE PEDAL) REAR MASTER CYLINDER ON THE LEFT HANDGRIP DISASSEMBLY Refer to the “FRONT BRAKE MASTER CYLINDER DISASSEMBLY” section in the chapter 13. ASSEMBLY Refer to the “FRONT BRAKE MASTER CYLINDER ASSEMBLY” section in the chapter 13. Upper Nut REAR MASTER CYLINDER ON THE REAR BRAKE PEDAL DISASSEMBLY Remove the brake reservoir cover. Drain the brake fluid from the hydraulic brake system. (!13-12) Loosen the upper and lower nuts.
13. BRAKE SYSTEM Remove the screw and remove the fluid inlet duct. Check the O-ring for wear or damage and replace if necessary. Mongoose/KXR 250 Screw Fluid Inlet Duct O-ring Seal Boot Remove the two nuts and remove the seal boot. Nuts Remove the circlip and then pull out the push rod, washer, piston and spring. Push Rod Circlip Washer Spring INSPECTION Check the cylinder inside wall, and spring for scratch, corrosion or other abnormal condition.
13. BRAKE SYSTEM Mongoose/KXR 250 ASSEMBLY Before assembly, apply brake fluid to all removed parts. °ØDuring assembly, the master cylinder, piston and spring must be installed as a unit without exchange. Washers Reverse the “MASTER CYLINDER ON THE REAR BRAKE PEDAL DISASSEMBLY” procedures. Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 1.8_ 2.5kgf-m Fill the brake reservoir with recommended brake fluid to the upper level.
13. BRAKE SYSTEM Mongoose/KXR 250 REAR BRAKE CALIPER REMOVAL Drain brake fluid of both the rear brake side and the combination brake side. (!13-12) °ØTo prevent brake fluid from splashing on the parts nearby, cover the parts with cloth. Remove the brake pads. (!13-11) Remove the caliper mounting bolts and remover the caliper. Bolts °ØSlightly loosen the caliper housing bolts before removing the caliper mounting bolts to facilitate later disassembly.
13. BRAKE SYSTEM INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper. BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0mm Measure the brake disk run out. Service Limit: 0.3mm ASSEMBLY Reassemble the caliper in the reverse order of disassembly procedures and observe the following points. °Ø Wash the caliper components with fresh brake fluid before assembly.
13. BRAKE SYSTEM Fit the O-ring. Install and tighten the caliper housing bolts. Torque: 1.8_ 2.5kgf-m INSTALLATION Install the rear caliper and tighten the two mounting bolts. With the tube ends contacted to the caliper and install the washers and tighten the fluid tube bolts. Torque: 1.8_ 2.5kgf-m Mongoose/KXR 250 O-ring Washers Washers Fill the system with brake fluid and bleed air.