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2. FRAME COVERS/EXHAUST MUFFLER

2-0

Mongoose/KXR 90/50

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FRAME COVERS/EXHAUST MUFFLER

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

FRAME COVERS ------------------------------------------------------- 2- 3

EXHAUST MUFFLER REMOVAL ----------------------------------- 2- 7

TAILLIGHT BULB ----------------------------------------------------- 2- 8

Summary of content (9 pages)

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2.
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. FRAME COVERS/EXHAUST MUFFLER 2-1 Mongoose/KXR 90/50
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 90/50 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt Exhaust muffler lock nut 3.2_ 3.8kgf-m 1.8_ 2.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 90/50 Bolts FRAME COVERS HANDLEBAR COVER REMOVAL Remove the two screws attaching the handlebar cover. Disconnect the oil level indicator leads (Mongoose/KXR 50). Remove the handlebar cover. INSTALLATION Reverse the “HANDLEBAR COVER REMOVAL” procedures. Handlebar Cover Seat Lock Lever SEAT REMOVAL To remove the seat, pull upward the seat lock lever and pull up the seat at the rear.
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2. FRAME COVERS/EXHAUST MUFFLER Front Brake Cables Disconnect the front brake cables. Disconnect the remote stop switch and front brake stop switch leads. Remote Engine Stop Switch Leads Remove the two screws and speed limiter cover. Disconnect the throttle cable. Remove the two bolts and handlebar cover holder. Remove the four bolts and upper handlebar holders. Remove the handlebar.
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2. FRAME COVERS/EXHAUST MUFFLER FRONT FENDER REMOVAL Remove the seat. (See page 2-3) Remove the handlebar. (See page 2-3) Mongoose/KXR 90/50 Screws Screws Remove the six screws and nuts attaching the front fender and right/left foot boards. Remove the four screws and two nuts attaching the front fender and rear fender at the right/left side. Screws Screws Bolts Remove the two bolts attaching front fender at the right/left side. Remover the fuel filler cap.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 90/50 INSTALLATION Reverse the “FRONT FENDER REMOVAL” procedures. °ØAfter remove, be sure to tighten the fuel filler cap. REAR FENDER REMOVAL Remove the front fender. (See page 2-5) Remove the battery. (See page 14-4) Starter Relay Ignition Unit Remove the starter relay and CDI unit. Remove the ten screws attaching the rear fender and foot boards at the right/left side. Screws Screws Bolts Remove the two screws attaching the rear fender at the rear.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 90/50 Bolts FOOT BOARD REMOVAL Remove front fender. (See page 2-5) Remover rear fender. (See page 2-6) Remove the four bolts attaching the right/left foot board. FRONT CARRIER REMOVAL Remove the four bolts attaching front carrier at the right/left side. Bolts EXHAUST MUFFLER REMOVAL Remove the two nuts attaching the exhaust pipe and cylinder head. Nuts Remove the three bolts attaching the exhaust muffler, then remove the exhaust muffler.
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2. FRAME COVERS/EXHAUST MUFFLER Mongoose/KXR 90/50 Inspect the gasket. If the exhaust gas leaks, the gasket should be replaced. Install by reversing the removal sequence. Torque: Exhaust muffler lock bolt: 3.2_ 3.8kgf-m Exhaust muffler lock nut: 1.8_ 2.2kgf-m °ØBe sure to install a new exhaust gasket. Gasket TAILLIGHT BULB REMOVAL Remove the two screws and taillight lens. Scresw Turn bulb and remove it.