2. FRAME COVERS/EXHAUST MUFFLER
2-0
Mongoose/KXR 250
2
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FRAME COVERS/EXHAUST MUFFLER
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SERVICE INFORMATION -------------------------------------------- 2- 2
TROUBLESHOOTING ------------------------------------------------- 2- 2
FRAME COVERS ------------------------------------------------------- 2- 3
EXHAUST MUFFLER REMOVAL ----------------------------------- 2- 7
2
2. FRAME COVERS/EXHAUST MUFFLER
2-1
Mongoose/KXR 250
2. FRAME COVERS/EXHAUST MUFFLER
2-2
Mongoose/KXR 250
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use special care not to pull them by force because the cover joint
claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Exhaust muffler lock bolt 3.2_ 3.8kgf-m
Exhaust muffler lock nut 1.8_ 2.2kgf-m
TROUBLESHOOTING
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Exhaust muffler air leaks
• Clogged exhaust muffler
2. FRAME COVERS/EXHAUST MUFFLER
2-3
Mongoose/KXR 250
FRAME COVERS
SEAT REMOVAL
Pull the lever right and pull up the seat at
the rear.
Remove the seat.
LEFT/RIGHT FRAME COVER
REMOVAL
Remove the seat. (See page 2-3)
Remove the screw and two bolts at the left
frame cover, then remove left frame cover.
Remove the screw and two bolts at the right
frame cover, then remove right frame cover.
REAR FENDER REMOVAL
Remove seat. (See page 2-3)
Remove right and left frame cover. (See page
2-3)
Remove battery. (See page 16-4)
Remove the fuse box.
Remove the screw attaching the ignition
unit/change gear control unit/starter relay
holder and remove holder.
Seat
Frame Left Cover
Bolts
Screw
Battery
Bolts
During removal, do not pull the joint
claws forcedly to avoid damage.
°Ø
Lever
Screw
Frame Right Cover
Screw and Holder
Fuse Box
2. FRAME COVERS/EXHAUST MUFFLER
2-4
Mongoose/KXR 250
Remove the three bolts at the rear fender.
Remove the two screws attaching the right
and left floor board.
Remove the two screws attaching the frame
body and three screws attaching the outlet
hose, then remove the rear fender.
HANDLEBAR COVER REMOVAL
Remove the two screws at the handlebar
cover.
Disconnect the indicator lamp coupler, then
remove the handlebar cover.
Bolts
Screws
Screws
Screws
Screws
During removal, do not pull the joint
claws forcedly to avoid damage.
°Ø
Outlet Hose
Indicator Lamp coupler
2. FRAME COVERS/EXHAUST MUFFLER
2-5
Mongoose/KXR 250
CENTER FRAME COVER REMOVAL
Remove the seat. (See page 2-3)
Remove the fuel fill cap.
Remove the four bolts at the center frame
cover, then remove the center frame cover.
FRONT FENDER REMOVAL
Remove the seat (See page 2-3), right and
left side frame cover (See page 2-3) and
center frame cover. (See page 2-5)
Remove the two bolts at the front fender
left side.
Remove the two screws attaching the inlet
hose.
Remove the two bolts at the front fender
right side.
Remove the screw, then remove the drive
select grip from the drive select lever.
Bolts
Bolts
Select Grip
Bolts
Screw
Screws
After remove, be sure to tighten the fuel
fill cap.
°Ø
Fuel Fill Cap
2. FRAME COVERS/EXHAUST MUFFLER
2-6
Mongoose/KXR 250
Disconnect headlight and ignition switch
couplers, then remove the front fender.
RIGHT AND LEFT FLOOR BOARD
REMOVAL
Remove the four screws at the floor board,
then remove the floor board.
FRONT CARRIER REMOVAL
Remove the four bolts at the front carrier,
then remove the front carrier.
Ignition Coupler
Headlight Coupler
Screws
Bolts
2. FRAME COVERS/EXHAUST MUFFLER
2-7
Mongoose/KXR 250
EXHAUST MUFFLER
REMOVAL
Remove the two exhaust pipe joint lock
nuts.
Remove the bolt at the exhaust muffler,
disconnect the exhaust pipe from the
exhaust muffler.
Inspect the gasket.
If the exhaust gas leaks, the gasket should be
replaced.
Install by reversing the removal sequence.
Torque:
Exhaust muffler lock bolt: 3.2_ 3.8kgf-m
Exhaust muffler lock nut: 1.8_ 2.2kgf-m
Remove the nut and bolt at the exhaust
muffler, then remove the exhaust muffler.
INSTALLATION
Install by reversing the removal sequence.
Torque:
Exhaust muffler lock bolt and nut:
3.2_ 3.8kgf-m
Nuts
Bolt
Gasket
Nut
Bolt
Be sure to install a new exhaust gasket.
°Ø
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