Kymco MO KXR 250 Service Manual - chap 03 (manutenzione)

3. INSPECTION/ADJUSTMENT

3-0

Mongoose/KXR 250

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INSPECTION/ADJUSTMENT

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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. 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

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

month

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.

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

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

Air Cleaner Holder

Air Cleaner

Air Cleaner screen

Air Cleaner body

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

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

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