Page 1
3. INSPECTION/ADJUSTMENT
3-0
Mongoose/KXR 250
3
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INSPECTION/ADJUSTMENT
__________________________________________________________________________________
SERVICE INFORMATION -------------------------------------------- 3- 1
MAINTENANCE SCHEDULE ---------------------------------------- 3- 2
FUEL LINE/THROTTLE OPERATION/AIR CLEANER ---------- 3- 3
AIR FILTER FOR DRIVE BELT/ SPARK PLUG------------------- 3- 6
VALVE CLEARANCE/CARBURETOR IDLE SPEED ------------- 3- 7
IGNITION TIMING/CYLINDER COMPRESSION ----------------- 3- 8
ENGINE OIL ------------------------------------------------------------ 3- 9
TRANSMISSION OIL REPLACEMENT----------------------------- 3-10
DRIVE BELT/BRAKE PADS/BRAKE FLUID INSPECTION ----- 3-11
HEADLIGHT AIM/ STEERING SYSTEM INSPECTION --------- 3-12
TOE-IN ADJUSTMENT------------------------------------------------ 3-13
WHEELS/TIRES -------------------------------------------------------- 3-14
DRIVE CHAIN SLACK ADJUSTMENT ----------------------------- 3-16
DRIVE SELECT LEVER ADJUSTMENT --------------------------- 3-18
CABLE INSPECTION AND LUBRICATION ----------------------- 3-19
REAR SUSPENSION LUBRICATION ------------------------------- 3-19
COOLING SYSTEM ---------------------------------------------------- 3-20
3
Page 2
3. INSPECTION/ADJUSTMENT
3-1
Mongoose/KXR 250
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.
SPECIFICATIONS
ENGINE
Throttle grip free play : 1_ 4mm
Spark plug gap : 0.6_ 0.7mm
Spark plug: Standard : DPR7EA-9
Valve clearance : IN: 0.1mm
EX: 0.1mm
Idle speed : 1500±100rpm
Engine oil capacity:
At disassembly : 1.6 liter
At change : 1.4 liter
Gear oil capacity :
At disassembly : 400cc
At change : 300cc
Cylinder compression : 15±2kg/cm_
Ignition timing : BTDC 5°±1°/2000rpm
TIRE PRESSURE
1 Rider
Front
0.28kgf/cm_
Rear
0.28kgf/cm_
TIRE SIZE:
Front : 21*7-10
Rear : 20*11-9
TORQUE VALUES
Front wheel nut 5.0_ 6.0kgf-m
Rear wheel nut 5.0_ 6.0kgf-m
Page 3
3. INSPECTION/ADJUSTMENT
3-2
Mongoose/KXR 250
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. All service technicians should be familiar with this entire chapter.
Initial
Every
Item
Remarks
1
month
3
month
6
month
6
month
1
year
Valves
Check valve clearance. Adjust if
necessary.
°≥°≥°≥
°≥
Spark plug
Check condition. Adjust gap and
clean. Replace if necessary.
°≥°≥°≥°≥°≥
Air filter element (for
engine and drive belt
compartment)
Clean.
Replace if necessary.
Every 20~40
(more often in wet or dusty areas.)
Carburetor
Check idle speed/starter operation.
Adjust if necessary.
°≥°≥°≥
°≥
Fuel line
Check fuel hose for cracks or
damage. Replace if necessary.
°≥°≥°≥
Engine oil
Replace (Warm engine before
draining).
°≥°≥°≥
°≥
Coolant
Check coolant leakage.
Replace if necessary.
Replace coolant every 24 months.
°≥°≥°≥°≥°≥
Oil strainer
Clean.
Replace if necessary.
°≥°≥°≥
Drive chain
Check and adjust
slack/alignment/clean/lube.
°≥°≥°≥°≥°≥
Transmission oil
Check oil leakage. Replace every 12
months.
°≥
°≥
Brake system
Check operation and brake fluid.
Replace brake pad if necessary.
°≥°≥°≥°≥°≥
Drive belt
Check operation/replace if damage
or excessive wear.
°≥
°≥
Wheels
Check balance/damage/runout.
Replace if necessary.
°≥°≥°≥
°≥
Wheel bearings
Check bearing assembly for
looseness/damage. Replace if
damaged.
°≥°≥°≥
°≥
Steering system
Check operation/replace if damage.
Check toe-in/adjust if necessary.
°≥°≥°≥°≥°≥
Rear swing arm shafts
Lubricate every 6 months.
°≥°≥°≥
Fitting/Fasteners
Check all chassis fittings and
fasteners. Correct if necessary.
°≥°≥°≥°≥°≥
•In the interest of safety, we recommend these items should be serviced only by an authorized
KYMCO motorcycle dealer.
Page 4
3. INSPECTION/ADJUSTMENT
3-3
Mongoose/KXR 250
FUEL LINE
Check the fuel tubes and replace any parts,
which show signs of deterioration, damage
or leakage.
THROTTLE OPERATION
Check the throttle to swing for smooth
movement.
Measure the throttle to swing free play.
Free Play (A): 1_ 4mm
To adjust throttle free play:
Slide the rubber sleeve back to expose the
throttle cable adjuster.
Loosen the lock nut, then turn the adjuster
to obtain the correct free play. (1~4 mm or
0.04~0.16 in)
Tighten the lock nut and reinstall the sleeve.
AIR CLEANER
AIR CLEANER REPLACEMENT
Remove the seat. (See page 2-3)
Unlatch the four retainer clips and remove
the air cleaner housing cover.
Do not smoke or allow flames or sparks
in your working area.
°Ø
Fuel Filter
Fuel tubes
Lock nut
Retainer Clips
Air Cleaner Housing Cover
Cable adjuster
Rubber sleeve
Page 5
3. INSPECTION/ADJUSTMENT
3-4
Mongoose/KXR 250
Unscrew the clamp and remove the air
cleaner assembly from the air cleaner
housing.
Remove the screw and remove the air
cleaner assembly from the air cleaner holder.
Remove the air cleaner and air cleaner screen
from the air cleaner body.
Remove the air cleaner net from the air
cleaner.
Reassemble by reversing the disassembly
sequence.
Air Cleaner Assembly
Screw
Screw
Air Cleaner Holder
Air Cleaner
Air Cleaner screen
Air Cleaner body
Page 6
3. INSPECTION/ADJUSTMENT
3-5
Mongoose/KXR 250
CLEAN AIR FILTER ELEMENT
Wash the element gently, but throughly in
solvent.
Squeeze the excess solvent out of the
element and let dry.
Apply the engine oil.
Squeeze out the excess oil.
More frequent replacement is required when
riding in unusually dusty or rainy areas.
AIR CLEANER HOUSING DRAIN
Remove the drain tube by removing the clip.
Drain the deposits.
Reinstall the drain tube, securing it with the
clip.
Use parts cleaning solvent only. Never
use gasoline or low flash point solvents
which may lead to a fire or explosion.
°Ø
Do not twist or wring out the foam
element. This could damage the foam
material.
°Ø
The element should be wet but not
dripping.
°Ø
Air Cleaner Housing
Drain Tube
Clip
Page 7
3. INSPECTION/ADJUSTMENT
3-6
Mongoose/KXR 250
Gap, Wear, and Fouling Deposits
AIR FILTER FOR DRIVE BELT
To clean the air filter:
Remove the two screws attaching front
fender and remove air filter housing.
Remove the two screws and remove air filter
housing cover.
Remove the air filter from the housing.
Tap the air filter lightly to remove most of
the dust and dirt.
Blow out the remaining dirt with
compressed air.
If the element is damaged, replace it.
Reassemble by reversing the disassembly
sequence.
SPARK PLUG
Remove 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: DPR7EA-9
Measure the spark plug gap.
Spark Plug Gap: 0.6_ 0.7mm
Cracks, Damage
Washer Deformation
Screws
Air Filter Housing
Screw
Air Filter Cover
Air Filter
When installing, first screw in the spark
plug by hand and then tighten it with a
spark plug wrench.
°Ø
Ignition Coil Cap
Spark Plug
Page 8
3. INSPECTION/ADJUSTMENT
3-7
Mongoose/KXR 250
VALVE CLEARANCE
Remove the cylinder head cover. (See page
7-4)
Turn the flywheel clockwise so that the “T”
mark on the flywheel aligns with the index
mark on the right crankcase cover to bring
the round hole on the camshaft gear facing
up to the top dead center on the
compression stroke.
Inspect and adjust the valve clearance.
Valve Clearance: IN: 0.1mm
EX: 0.1mm
Loosen the lock nut and adjust by turning
the adjusting nut
Tappet adjuster E012
CARBURETOR IDLE SPEED
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed: 1500±100rpm
When the engine misses or run erratic, adjust
the air screw.
Inspect and adjust valve clearance while
the engine is cold (below 35¢J).
°Ø
• The engine must be warm for accurate
idle speed inspection and adjustment.
°Ø
Cylinder Head Cover
Round Hole
Valve Wrench
Throttle Stop Screw
Air Screw
“T” Mark
• Check the valve clearance again after
the lock nut is tightened.
°Ø
Special
Index Mark
Page 9
3. INSPECTION/ADJUSTMENT
3-8
Mongoose/KXR 250
IGNITION TIMING
Remove the timing hole cap.
Check the ignition timing with a timing light.
When the engine is running at idle speed, the
ignition timing is correct if the “F” mark on
the flywheel aligns with the index mark on
the right crankcase cover.
CYLINDER COMPRESSION
Warm up the engine before compression
test.
Remove the spark plug.
Insert a compression gauge.
Open the throttle valve fully and push the
starter button to test the compression.
Compression: 15±2kg/cm
2
If the compression is low, check for the
following:
- Leaky valves
- Valve clearance too small
- Leaking cylinder head gasket
- Worn piston rings
- Worn piston/cylinder
If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.
The ignition unit is not adjustable. If the
ignition timing is incorrect, check the
ignition system.
°Ø
Compression Gauge
Timing Hole
Timing Hole Cap
Index Mark
Page 10
3. INSPECTION/ADJUSTMENT
3-9
Mongoose/KXR 250
ENGINE OIL
OIL LEVEL
Place the machine on a level place.
Warm up the engine for several minutes and
stop it.
Check the oil level through the inspection
window.
The oil level should be between the
maximum (H) and minimum (L) marks. If
the level is low, add oil to raise it to the
proper level.
ENGINE OIL REPLACEMENT
Place the machine on a level place.
Warm up the engine for several minutes and
stop it.
Place a container under the engine.
Remove the oil fill cap and drain plug to
drain the oil.
Reinstall the drain plug and tighten the drain
plug to specification.
Torque: 2.0_ 3.0kgf-m
Fill the engine with oil and install the oil fill
cap.
Oil Capacity:At disassembly: 1.6L
At change: 1.4L
Inspection Window
Lower Level
Upper Level
Run the engine for 2_ 3 minutes and
check the oil level after the engine is
stopped for 2_ 3 minutes.
°Ø
Oil Fill Cap
Drain Plug
The engine oil will drain more easily
while the engine is warm.
°Ø
Page 11
3. INSPECTION/ADJUSTMENT
3-10
Mongoose/KXR 250
ENGINE OIL REPLACEMENT AND OIL
FILTER CLEANING
Place the machine on a level place.
Warm up the engine for several minutes and
stop it.
Place a container under the engine.
Remove the oil fill cap and oil filter cap to
drain the oil.
Clean the oil strainer with solvent.
Inspect the O-ring and replace if damaged.
Reinstall the O-ring, oil strainer,
compression spring and oil filter cap.
Tighten the oil filter cap to specification.
Torque: 1.0_ 2.0kgf-m
Fill the engine with oil and install the oil fill
cap.
Oil Capacity:At disassembly: 1.6L
At change: 1.4L
TRANSMISSION OIL
REPLACEMENT
Place the machine on a level place.
Place a container under the engine.
Remove the oil filler bolt and drain plug to
drain the oil.
Reinstall the drain plug and tighten to
specification.
Torque: 2.0_ 3.0kgf-m
Fill the engine with oil and install the oil
filler bolt.
Oil Capacity:At disassembly: 400cc
At change: 300cc
Start the engine and warm up for a few
minutes. While warming up, check for oil
leakage. If oil leakage is found, stop the
engine immediately and check for the cause.
Oil Filter Cap
O-ring
Compression Spring
Oil Strainer
Oil Filter Cap
Oil Filler Bolt
Drain Plug
Make sure that the sealing washer is in
good condition.
°Ø
Page 12
3. INSPECTION/ADJUSTMENT
3-11
Mongoose/KXR 250
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: 22mm
Replace the drive belt if out of specification.
BRAKE PADS INSPECTION
A wear indicator is provided on each brake.
The indicators allows checking of brake
pads wear. Check the position of the
indicator. If the indicator reaches the wear
limit line, to replace the pads.
BRAKE FLUID INSPECTION
Check if the fluid level is below the lower
level mark through the inspection window.
Drive Belt
Front Caliper
Rear Caliper
Inspection Window (R/L Brake Lever)
Page 13
3. INSPECTION/ADJUSTMENT
3-12
Mongoose/KXR 250
HEADLIGHT AIM
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.
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.
Replace the steering column bushings and or
bearings if excessive play
Check the tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then slightly move
the handlebar from left to right.
Replace the tie-rod ends if tie-rod end has
any vertical play.
Inspection Window (Rear Brake Pedal)
Adjust Screw
Tie-rod Ends
Page 14
3. INSPECTION/ADJUSTMENT
3-13
Mongoose/KXR 250
Raise the front end of the machine so that
there is no weight on the front wheels.
Check ball joints and/or wheel bearings.
Move the wheels lately back and froth.
Replace the front arms and/or wheel
bearings if excessive free play.
TOE-IN ADJUSTMENT
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.
Calculate the toe-in using the formula given
below.
Toe-in = B°– A
Toe-in: 0_ 10mm
If the toe-in is incorrect, adjust the toe-in
Adjust the toe-in step:
Mark both tie-rods ends.
This reference point will be needed during
adjustment.
Loosen the lock nuts (tie-rod end) of both
tie-rods
The same number of turns should be given
to both tie-rods right and left until the
specified toe-in is obtained, so that the
lengths of the rods will be kept the same.
Tighten the rod end locknuts of both tie-
rods
Torque: 2.5_ 3.5kgf-m
A
B
Tie-rod
Tie-rod End Nuts
Page 15
3. INSPECTION/ADJUSTMENT
3-14
Mongoose/KXR 250
WHEELS/TIRES
Check the tires for cuts, imbedded nails or
other damages.
Check the tire pressure.
TIRE PRESSURE
1 Rider
Front
0.28kgf/cm_
Rear
0.28kgf/cm_
TIRE SIZE
Front : 21*7-10
Rear : 20*11-9
Check the front axle nut for looseness.
Check the rear axle nut for looseness.
If the axle nuts are loose, tighten them to the
specified torque.
Torque: Front : 6.0_ 8.0kgf-m
Rear : 6.0_ 8.0kgf-m
Front Axle Nut
Rear Axle Nut
• Be sure that both tie-rod are
turned the same amount. If not, the
machine will drift tight or left even
though the handlebar is positioned
straight which may lead to mishandling
and accident.
• After setting the toe-in to
specification, run the machine slowly
for some distance with hands placed
lightly on the handlebar and check that
the handlebar responds correctly. If
not, turn either the right or left tie-rod
°Ø
Tire pressure should be checked when
tires are cold.
°Ø
Tie-rod
Tie-rod End Nuts
Page 16
3. INSPECTION/ADJUSTMENT
3-15
Mongoose/KXR 250
Inspect the tire surfaces.
Replace if wear or damage.
Tire wear limit: 3.0mm
WHEEL INSPECTION
Inspect the wheel.
Replace if damage or bends
Always balance the wheel when a tire or
wheel has been changed or replaced.
• Never attempt even small repairs
to the wheel.
• Ride conservatively after
installing a tire to allow it to seat itself
properly on the rim.
°Ø
It is dangerous to ride with a worn out
tire. When a tire wear is out of
specification, replace the tire
immediately.
°Ø
Page 17
3. INSPECTION/ADJUSTMENT
3-16
Mongoose/KXR 250
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. Check and/or adjust the chain slack
with the rear wheels in this “tightest”
position.
Place the machine on a level place.
Check drive chain slack.
Adjust if out of specification.
Drive chain slack (A): Approximately
30mm
Adjust drive chain slack:
Loosen the caliper holder bolt and two axle
hub holding bolt.
Provide a proper pin and pass the pin
through the axle hub and driven sprocket.
Bolt
Too little of chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
°Ø
Wheels should be on the ground without
the rider on it.
°Ø
Bolts
Driven Sprocket
Pin
Axle Hub
Page 18
3. INSPECTION/ADJUSTMENT
3-17
Mongoose/KXR 250
To tighten the chain, push the ATV
forward.
To loosen the chain, pull the ATV
backward.
Retighten the two axle hub holder bolt and
caliper holder bolt to the specification.
Torque:
Axle hub holding bolt: 3.5_ 4.5kgf-m
caliper holder bolt: 0.8_ 1.2kgf-m
Pull out the pin.
Bolt
Bolts
Pin
Page 19
3. INSPECTION/ADJUSTMENT
3-18
Mongoose/KXR 250
DRIVE SELECT LEVER
ADJUSTMENT
Turn the ignition switch is ON and make
sure the engine stop switch in the OFF
position.
Loosen the lock nuts of rod.
Shift the gear to neutral by moving the shift
lever and/or turn the rod. (The neutral
indicator lamp comes on.)
Provide standard/phillips screwdriver and
pass the standard/phillips screwdriver
through the shift arm into the index hole at
the transmission case cover.
Turn the rod clockwise or counterclockwise
until the drive select lever into the "N"
position of the shift guide and tighten the
lock nuts, then pull out the standard/phillips
screwdriver.
After adjustment, start the engine and test
to ride the ATV to be sure the drive select
lever is operating properly.
Lock Nuts
Rod
Standard/Phillips Screwdriver
Shift Arm
Index Hole
Drive Lever
Rod
Page 20
3. INSPECTION/ADJUSTMENT
3-19
Mongoose/KXR 250
CABLE INSPECTION AND
LUBRICATION
Inspect the cable sheath.
Replace if damage.
Check the cable operation.
Lubricate or replace if unsmooth operation.
LEVER LUBRICATION
Lubricate the pivoting parts of each lever.
REAR SUSPENSION
LUBRICATION
Inject grease into the nipples using a grease
gun until slight over flow is observed from
the thrust covers.
Nipple
Damaged cable sheath may cause
corrosion and interfere with the cable
movement. An unsafe condition may
result so replace such cable as soon as
possible.
°Ø
Wipe off the excess grease.
°Ø
Hold cable end high and apply several
drops of lubricant to cable.
°Ø
Page 21
3. INSPECTION/ADJUSTMENT
3-20
Mongoose/KXR 250
COOLING SYSTEM
COOLANT LEVEL INSPECTION
Place the machine on the level ground.
Check the coolant level in the coolant
reservoir when the engine is cold as the
coolant level will vary with engine
temperature. The coolant level should be
between the maximum and minimum marks.
If the level is low, remove the coolant
reservoir cap, and then add coolant or
distilled water to raise it to the specified
level.
Recommended Coolant: SIGMA Coolant
(Standard Concentration 30%)
COOLANT REPLACEMENT
Remove the front fender. (!2-5)
Remove the radiator cap.
Remove the drain bolt to drain the coolant.
Drain the coolant in the reserve tank.
Reinstall the drain bolt.
Coolant capacity: 1400cc
Radiator capacity: 1100cc
Reserve tank capacity: 300cc
Start the engine and check if there are no
bubbles in the coolant and the coolant level
is stable. Reinstall the radiator cap.
If there are bubbles in the coolant, bleed air
from the system.
Fill the reserve tank with the recommended
coolant up to the maximum mark.
The coolant level does not change no
matter the engine is warm or cold. Fill to
the maximum mark.
°Ø
Perform this operation when the engine
is cold.
°Ø
The coolant freezing point should be 5
°C lower than the temprature of the
riding area.
°Ø
Minimum Mark
Maximum Mark
Coolant Reservoir Cap
Drain Bolt
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