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4. LUBRICATION SYSTEM

4-0

Mongoose/KXR 90/50

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LUBRICATION SYSTEM

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SERVICE INFORMATION (Mongoose/KXR 90)-------------------- 4- 3

SERVICE INFORMATION (Mongoose/KXR 50)-------------------- 4- 4

ENGINE OIL/OIL FILTER (Mongoose/KXR 90)-------------------- 4- 5

OIL PUMP BLEEDING (Mongoose/KXR 50)------------------------ 4- 9

OIL TANK (Mongoose/KXR 50)--------------------------------------- 4-10

OIL PUMP (Mongoose/KXR 50)--------------------------------------- 4-11

OIL FILTER CLEANING (Mongoose/KXR 50) --------------------- 4-12

Summary of content (13 pages)

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. LUBRICATION SYSTEM Mongoose/KXR 90/50 SERVICE INFORMATION (Mongoose/KXR 90) GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line. • Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it reaches its service limit. • After the oil pump is installed, check each part for oil leaks.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 SERVICE INFORMATION (Mongoose/KXR 50) GENERAL INSTRUCTIONS • Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. • Do not attempt to disassemble the oil pump. • Bleed air from the oil pump if there is air between the oil pump and oil line. • If the oil is disconnected, refill the oil line with motor oil before connecting it.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 ENGINE OIL/OIL FILTER (Mongoose/KXR 90) OIL LEVEL AND OIL CHANGE Refer to the “ENGINE OIL” section in the chapter 3 to check the oil level and replacement and oil filter cleaning. OIL PUMP Right Crankcase Cover REMOVAL Place a container under the engine. Remove the drain plug to drain the oil. (!39) Remove the A.C. generator flywheel. (!148) Remove the A.C. generator stator and pulsar coil.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 Oil Pump Remove the two oil pump mounting bolts and the oil pump. Bolts Oil Pump Body DISASSEMBLY Remove the screw and disassemble the oil pump. Screws INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.
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4. LUBRICATION SYSTEM Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.2mm Mongoose/KXR 90/50 Outer Rotor Inner Rotor Measure the rotor end-to-pump body clearance. Service Limit: 0.12mm Inner Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor. Install the dowel pin. Install the pump cover by aligning the hole in the cover with the dowel pin.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 Screws Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding. Arrow Mark INSTALLATION Reverse the “OIL PUMP REMOVAL” procedures. Make sure that the pump shaft rotates freely without binding. ＊ Install the oil pump with the arrow on the pump body facing up and fill the oil pump with engine oil before installation.
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4. LUBRICATION SYSTEM OIL PUMP BLEEDING (Mongoose/KXR 50) Mongoose/KXR 90/50 Oil Pump °Ø • Air in the oil tubes will block oil flow and result in severe engine damage. • Bleed air from the oil tubes and oil pump whenever the oil tubes or pump have been removed or there is air in the oil tubes. Oil Outlet Line OIL INLET LINE/OIL PUMP BLEEDING Fill the oil tank with recommended oil. Place a shop towel around the oil pump. Disconnect the oil inlet tube from the oil pump and clip it.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 OIL TANK (Mongoose/KXR 50) OIL TANK REMOVAL Remove the oil level switch connector. Remove the two bolts attaching the oil tank. Bolts Oil Level Switch Connector Oil Inlet Tube Disconnect the oil inlet tube. Drain the oil inside the oil tank into a clean container. Remove the oil tank. The installation sequence is the reverse of removal. °Ø• Connect the oil tube properly. • Bleed air from the oil pump after installation.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 Oil Inlet Tube OIL PUMP (Mongoose/KXR 50) REMOVAL °ØDo not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Disconnect the oil outlet tube from the oil pump. Disconnect the oil pump control cable from the pump body. Disconnect the oil inlet tube.
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4. LUBRICATION SYSTEM Mongoose/KXR 90/50 OIL PUMP INSTALLATION °Ø • Lubricate the O-ring with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion. Install the oil pump into the crankcase. Install the oil pump control cable plate. Connect the oil inlet line and oil outlet tube properly. Connect the oil pump control cable. Bleed air from the oil pump.