Page 1
4. LUBRICATION SYSTEM
4-0
Mongoose/KXR 250
4
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LUBRICATION SYSTEM
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SERVICE INFORMATION -------------------------------------------- 4- 2
TROUBLESHOOTING ------------------------------------------------- 4- 2
ENGINE OIL/OIL FILTER -------------------------------------------- 4- 3
OIL PUMP --------------------------------------------------------------- 4- 3
4
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4. LUBRICATION SYSTEM
4-1
Mongoose/KXR 250
LUBRICATION SYSTEM
Oil Pump
Oil Filter Screen
Crankshaft
Rocker Arm Shaft
Page 3
4. LUBRICATION SYSTEM
4-2
Mongoose/KXR 250
SERVICE INFORMATION
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.
SPECIFICATIONS
Item
Standard (mm)
Service Limit (mm)
Inner rotor-to-outer rotor clearance
0.15
0.20
Oil pump
Outer rotor-to-pump body clearance
0.15_ 0.20
0.25
Rotor end-to-pump body clearance
0.04_ 0.09
0.12
TROUBLESHOOTING
Oil level too low Poor lubrication pressure
• Natural oil consumption • Oil level too low
• Oil leaks • Clogged oil filter or oil passages
• Worn or poorly installed piston rings • Not use the specified oil
• Worn valve guide or seal
Page 4
4. LUBRICATION SYSTEM
4-3
Mongoose/KXR 250
Bolts
ENGINE OIL/OIL FILTER
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
REMOVAL
Remove the right crankcase cover and the
A.C. generator flywheel. (Refer to the “A.C.
GENERATOR/FLYWHEEL” section in the
chapter 16)
Remove the starter clutch gear. (Refer to the
“STARTER CLUTCH” section in the
chapter 18)
Remove the two bolts and oil separator
cover.
Pry the circlip off and remove the oil pump
driven gear, then remove the oil pump drive
chain and oil driven sprocket.
Oil Separator Cover
Circlip
Page 5
4. LUBRICATION SYSTEM
4-4
Mongoose/KXR 250
Screw
Pump Body
Remove the two oil pump bolts for remove
the oil pump.
OIL PUMP DISASSEMBLY
Remove the screw and disassemble the oil
pump.
INSPECTION
Measure the rotor end-to-pump body
clearance.
Service Limit: 0.12mm
Oil Pump Driven Sprocket
Oil Pump Drive Chain
Oil Pump Bolts
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4. LUBRICATION SYSTEM
4-5
Mongoose/KXR 250
Outer Rotor
Outer Rotor
Inner Rotor
Pump Body
Inner Rotor
Dowel Pin
Pump Cover
Measure the inner rotor-to-outer rotor
clearance.
Service Limit: 0.2mm
Measure the pump body-to-outer rotor
clearance.
Service Limit: 0.25mm
ASSEMBLY
Install the outer rotor, inner rotor and pump
shaft into the pump body.
Install the dowel pin.
Install the pump cover by aligning the hole
in the cover with the dowel pin.
Tighten the screw to secure the pump cover.
INSTALLATION
Reverse the “OIL PUMP REMOVAL”
procedures.
Outer Rotor
Oil Pump Bolts
Insert the pump shaft by aligning the flat
on the shaft with the flat in the inner
rotor.
°Ø
Install the oil pump with the arrow on
the pump body facing up and fill the oil
pump with engine oil before installation.
°Ø
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4. LUBRICATION SYSTEM
4-6
Mongoose/KXR 250
Pump Shaft
Make sure that the pump shaft rotates
freely without binding.
Install oil pump driven sprocket and drive
chain, circlip and oil separator cover.
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