9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 9 DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION ...........................................................9-2 LEFT CRANKCASE COVER/KICK STARTER..............................9-4 DRIVE PULLEY ..........................................................................9-7 9 CLUTCH/DRIVEN PULLEY.........................................................
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9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed in the frame. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS (Mongoose/KXR 90) Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D.
9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 TORQUE VALUES Drive face nut 5.5_ 6.5kgf-m (Mongoose/KXR 90) 3.5_ 4.5kgf-m (Mongoose/KXR 50) Clutch outer nut 3.5_ 4.5kgf-m Drive plat nut 5.0_ 6.
9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 Left Crankcase Cover LEFT CRANKCASE COVER/KICK STARTER REMOVAL Remove left foot board. (See page 2-7) Remove the eight left crankcase cover bolts and left crankcase cover. Remove the gasket and dowel pins. ＊ Use specified genuine parts for Bolts replacement. KICK STARTER DISASSEMBLY Remove the kick lever from the kick starter spindle. Remove the circlip and washer from the kick starter spindle.
9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 Spindle Return Spring INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage. Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage.
9. DRIVE AND DRIVEN PULLEYS Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown. Install the kick starter spindle cover and tighten three bolts. Mongoose/KXR 90/50 Friction Spring Kick Starter Spindle Cover ＊ Apply grease on to the driven gear shaft. Starter Driven Gear First install the washer and then install the circlip. Install the kick lever. Bolts Circlip Washer LEFT CRANKCASE COVER INSTALLATION First install the dowel pins.
9. DRIVE AND DRIVEN PULLEYS DRIVE PULLEY Mongoose/KXR 90/50 Starting Ratchet REMOVAL Remove the left crankcase cover. (Refer to the “LEFT CRANKCASE COVER REMOVAL” section in the chapter 9) Hold the drive pulley using a universal holder and remove the drive face nut and washer. Remove the drive pulley. Drive Pulley Nut Universal Holder Special Universal Holder E017 Remove the movable drive face assembly and drive pulley collar.
. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 15.4mm replace if below. Measure the movable drive face bushing I.D. Service Limit: Mongoose/KXR 90: 24.06mm over Mongoose/KXR 50: 20.06mm over ASSEMBLY Install the weight rollers into the movable drive face. Install the ramp plate. Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
9. DRIVE AND DRIVEN PULLEYS CLUTCH/DRIVEN PULLEY Mongoose/KXR 90/50 Clutch Outer Universal Holder REMOVAL Remove the left crankcase cover. (Refer to the “LEFT CRANKCASE COVER REMOVAL” section in the chapter 9) Remove the drive pulley. (Refer to the “DRIVE PULLEY REMOVAL” section in the chapter 9) Hold the clutch outer with the universal holder, then remove the clutch outer nut and clutch outer. Nut Special Universal Holder E017 Remove the clutch/driven pulley and drive belt.
9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 CLUTCH/DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Lock Nut Wrench, 39mm °ØBe sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor E034 Clutch Spring Compressor Set the clutch spring compressor in a vise and remove the clutch drive plate nut. Loosen the clutch spring compressor and disassemble the clutch/driven pulley assembly. Remove the seal collar.
9. DRIVE AND DRIVEN PULLEYS Measure the clutch lining thickness. Service Limit: Mongoose/KXR 90: 1.5mm replace if below Mongoose/KXR 50: 1.0mm replace if below INSPECTION Measure the driven face spring free length. Service Limit: Mongoose/KXR 90: 137.5mm below Mongoose/KXR 50: 92.8mm below Check the driven face for wear or damage. Measure the driven face O.D. Service Limit: 33.
9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm over DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. Inner Needle Bearing °ØDiscard the removed bearing and replace with a new one. Remove the snap ring and drive the outer bearing out of the driven face. °ØDiscard the removed bearing and replace with a new one.
9. DRIVE AND DRIVEN PULLEYS CLUTCH DISASSEMBLY Remove the circlips to disassemble the clutch. Mongoose/KXR 90/50 Circlip °ØKeep grease off the clutch linings.
9. DRIVE AND DRIVEN PULLEYS Mongoose/KXR 90/50 Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs. Set the circlips in the groove. Clean the driven pulley faces and remove any grease from them. Install the oil seal onto the moveable driven face. Apply grease onto the Oil seal and install them onto the moveable driven face. Install the movable driven face onto the driven face.
9. DRIVE AND DRIVEN PULLEYS INSTALLATION Install the clutch/driven pulley and driven belt onto the drive shaft. °ØKeep grease off the drive shaft. Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 3.5_ 4.
