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3. INSPECTION/ADJUSTMENT

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Mongoose/KXR 90/50

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INSPECTION/ADJUSTMENT

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SERVICE INFORMATION -------------------------------------------- 3- 1

MAINTENANCE SCHEDULE ---------------------------------------- 3- 3

FUEL LINE/THROTTLE OPERATION------------------------------ 3- 4

AIR CLEANER ---------------------------------------------------------- 3- 5

SPARK PLUG/CYLINDER COMPRESSION ------------------------ 3- 7

VALVE CLEARANCE (Mongoose/KXR 90)------------------------- 3- 8

CARBURETOR IDLE SPEED ----------------------------------------- 3- 8

ENGINE OIL (Mongoose/KXR 90)------------------------------------ 3- 9

TRANSMISSION OIL -------------------------------------------------- 3-11

DRIVE BELT/BRAKE SHOES/BRAKE PADS/BRAKE FLUID -- 3-12

BRAKE LEVER FREE PLAY ----------------------------------------- 3-13

STEERING SYSTEM INSPECTION --------------------------------- 3-14

TOE-IN ADJUSTMENT------------------------------------------------ 3-15

WHEELS/TIRES -------------------------------------------------------- 3-16

DRIVE CHAIN SLACK ADJUSTMENT ----------------------------- 3-17

CABLE INSPECTION AND LUBRICATION ----------------------- 3-19

FRONT SUSPENSION LUBRICATION------------------------------ 3-19

HEADLIGHT BEAM ADJUSTMENT (ON ROAD ONLY) -------- 3-20

BRAKE PEDAL ADJUSTMENT (KXR 90 ON ROAD ONLY)---- 3-20

BRAKE FULID (KXR 90 ON ROAD ONLY)------------------------ 3-21

Summary of content (22 pages)

PAGE 1
3.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 SERVICE INFORMATION GENERAL °I WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area.
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. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 SPECIFICATIONS (Mongoose/KXR 50) ENGINE Throttle grip free play : 1_ 4mm Spark plug gap : 0.6_ 0.7mm Spark plug: Standard : NGK: BR8HAS Idle speed : 2000±100rpm Gear oil capacity : At disassembly : 120cc At change : 110cc Cylinder compression : 12kg/cm_ Ignition timing : BTDC 15°/1700rpm CHASSIS Front brake free play: 10_ 20mm Rear brake free play: 10_ 20mm TIRE PRESSURE Front Rear 1 Rider 0.22kgf/cm_ 0.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 MAINTENANCE SCHEDULE This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service ad well as new vehicles that are being prepared for sale.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 Fuel Filter FUEL LINE Check the fuel tubes and replace any parts, which show signs of deterioration, damage or leakage. °ØDo not smoke or allow flames or sparks in your working area. Fuel Tubes Rubber Sleeves THROTTLE OPERATION Check the throttle to swing for smooth movement. Measure the throttle to swing free play. Free Play: 1_ 4mm To adjust throttle free play: 1. Slide the rubber sleeves back to expose the throttle cable adjuster. 2.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 °ØReference tip alignment within 1mm of index mark on open side is acceptable. However, the aligning mark on the control lever must never be on the closed side of the index mark, otherwise engine damage will occur because of insufficient lubrication.
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3. INSPECTION/ADJUSTMENT To replace the air cleaner (Mongoose/KXR 50): 1. Remove the five screws and air filter case cover. Mongoose/KXR 90/50 Screws Air Filter Case Cover 2. Remove the air filter element, and separate it from the box. To clean the air filter element: 1. Wash the element gently but thoroughly in solvent. °ØUse parts cleaning solvent only. Never use gasoline or low flash point solvents which may lead to a fire or explosion. Air Filter Element 2.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 SPARK PLUG Remove the ignition coil cap and spark plug. Check the spark plug for wear and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush. Specified Spark Plug: (Mongoose/KXR 90): NGK: C7HSA (Mongoose/KXR 50): NGK: BR8HAS Measure the spark plug gap. Spark Plug Gap: 0.6_ 0.
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3. INSPECTION/ADJUSTMENT VALVE CLEARANCE (Mongoose/KXR 90): Mongoose/KXR 90/50 Cylinder Head Cover °ØInspect and adjust valve clearance while the engine is cold (below 35¢J). Disconnect the oil recycle tube at the cylinder head cover. Remove the four bolts and cylinder head cover. Bolts Cooling Fan Cover Remove the two screws and two bolts, then remove the fan cover.
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3. INSPECTION/ADJUSTMENT ENGINE OIL (Mongoose/KXR 90) Mongoose/KXR 90/50 Bolts OIL LEVEL Remove the two bolts and right side cover. Place the machine on a level place. Warm up the engine for several minutes and stop it. Remove the dipstick and wipe it off with a clean rag. Insert the dipstick in the filler hole without screwing it in. °Ø Run the engine for 2_ 3 minutes and check the oil level after the engine is stopped for 2_ 3 minutes.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 ENGINE OIL REPLACEMENT AND OIL FILTER CLEANING A. Place the machine on a level place. B. Warm up the engine for several minutes and stop it. C. Place a container under the engine. D. Remove the oil filler cap and oil filter cap to drain the oil. °Ø°DBe sure no foreign material enters the crankcase. °DWhen removing the drain plug, the compression spring, oil strainer and O-ring will fall out. Take care not to lose these parts.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 Oil Filter Bolt/Measurement Hole TRANSMISSION OIL TRANSMISSION OIL MEASUREMENT Place the machine on a level place. Remove the oil filler bolt and check the oil level. It should be up to the brim of the hole. If the level is low, add oil to raise it to the proper level. Reinstall the oil filler bolt and tighten to specification. Torque: 1.0_ 2.0kgf-m TRANSMISSION OIL REPLACEMENT Place the machine on a level place. Place a container under the engine.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 Drive Belt DRIVE BELT Remove the left crankcase cover. Inspect the drive belt for cracks, scaling, chipping or excessive wear. Measure the V-belt width Service limit: Mongoose/KXR 90:16.5mm Mongoose/KXR 50:16.5mm Replace the drive belt if out of specification. BRAK SHOES The checking of brake shoes wear will disassemble the brake. If the lining thickness below to the wear limit (A) 2.0mm (0.08in), to replace the shoes as a set.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 BRAKEN LEVER FREE PLAY (DRUM BRAKE) The brake lever free play (A) should be adjusted to 10~20 mm (0.4~0.8 in) at the tip of the brake lever. FRONT BRAKE FREE PLAY ADJUSTMENT Loosen the upper lock nut and fully turn in the adjusting bolt. Loosen the lower lock nut. Turn the lower adjusting bolt until specified free play is obtained. Tighten the lower lock nut.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 °ØMake sure the cut-out on the adjusting nut Is seated on the brake arm pin after making final free play adjustment. Arm Pin Adjusting Nut STEERING SYSTEM INSPECTION Place the machine on a level place. Check the steering column bushings and bearings: Move the handlebar up and down, and/or back and forth.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 TOE-IN ADJUSTMENT A Place the machine on a level place. Measure the toe-in Adjust if out of specification. Toe-in measurement steps: Mark both front tire tread centers. Raise the front end of the machine so that there is no weight on the front tires. Fix the handlebar straight ahead. Measure the width A between the marks. Rotate the front tires 180 degrees until the marks come exactly opposite. Measure the width B between the marks.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. °ØTire pressure should be checked when tires are cold. TIRE PRESSURE 1 Rider Front 0.22kgf/cm_ Rear 0.22kgf/cm_ TIRE SIZE (Mongoose/KXR 90) Front : 18*7-8 Rear : 18*9-8 Front Axle Nut TIRE SIZE (Mongoose/KXR 50) Front : 16*8-7 Rear : 16*8-7 Rear Axle Nut Check the front wheel hub nut for looseness. Check the rear wheel hub nut for looseness.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 Inspect the wheel. Replace if damage or bends Always balance the wheel when a tire or wheel has been changed or replaced. °Ø• Never attempt even small repairs to the wheel. • Ride conservatively after installing a tire to allow it to seat itself properly on the rim. DRIVE CHAIN SLACK ADJUSTMENT Before checking and/or adjusting, rotate the rear wheels several revolutions and check slack at several points to find the tightest point.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 Turn the adjusting nut, to decrease or increase chain slack. Retighten the upper and lower axle holding bolts. Torque: 6.0_ 8.0kgf-m Adjusting Nut Drive chain cleaning and lubrication The drive chain is equipped with rubber Orings between the chain plates. Steam cleaning, high-pressure washes, and certain solvents can damage these O-rings. Use only kerosene to clean the drive chain. Wipe it dry, and thoroughly lubricate it with SAE 30~50 motor oil.
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3. INSPECTION/ADJUSTMENT Mongoose/KXR 90/50 CABLE INSPECTION AND LUBRICATION °ØDamaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result so replace such cable as soon as possible. Inspect the cable sheath. Replace if damage. Check the cable operation. Lubricate or replace if unsmooth operation. °ØHold cable end high and apply several drops of lubricant to cable. LEVER LUBRICATION Lubricate the pivoting parts of each lever.
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3. INSPECTION/ADJUSTMENT HEADLIGHT BEAM ADJUSTMENT (ON ROAD ONLY) Mongoose/KXR 90/50 Adjusting screw Vertical adjustment: Turn the ignition switch ON and start the engine. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting screw. Headlight BRAKE PEDAL ADJUSTMENT (KXR 90 ON ROAD ONLY) The brake pedal free play should be adjusted to 5~10 mm (0.2~0.4 in) at the brake pedal pivot. If the free play is incorrect, adjust as follows: Adjust: 1.
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3. INSPECTION/ADJUSTMENT 7. Loosen the locknut. (Brake pedal cable) 8. Turn the adjusting bolt until the specified free play is obtained. 9. Tighten the locknut. (Brake pedal cable) Mongoose/KXR 90/50 Brake Pedal Cable Adjusting Blot BRAKE FLUID (KXR 90 ON ROAD ONLY) Check if the fluid level is below the lower level mark through the inspection window.