Kymco MO KXR 250 Service Manual - chap 03 (manutenzione)
3. INSPECTION/ADJUSTMENT
3-0
Mongoose/KXR 250
3
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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
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
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.
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
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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