4. LUBRICATION SYSTEM
4-0
Mongoose/KXR 90/50
4
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LUBRICATION SYSTEM
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SERVICE INFORMATION (Mongoose/KXR 90)-------------------- 4- 3
SERVICE INFORMATION (Mongoose/KXR 50)-------------------- 4- 4
ENGINE OIL/OIL FILTER (Mongoose/KXR 90)-------------------- 4- 5
OIL PUMP BLEEDING (Mongoose/KXR 50)------------------------ 4- 9
OIL TANK (Mongoose/KXR 50)--------------------------------------- 4-10
OIL PUMP (Mongoose/KXR 50)--------------------------------------- 4-11
OIL FILTER CLEANING (Mongoose/KXR 50) --------------------- 4-12
4
4. LUBRICATION SYSTEM
4-1
Mongoose/KXR 90/50
LUBRICATION SYSTEM (Mongoose/KXR 90)
Oil Pump
Oil Filter Screen
Crankshaft
Rocker Arm Shaft
4. LUBRICATION SYSTEM
4-2
Mongoose/KXR 90/50
LUBRICATION SYSTEM (Mongoose/KXR 50)
4. LUBRICATION SYSTEM
4-3
Mongoose/KXR 90/50
SERVICE INFORMATION (Mongoose/KXR 90)
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
4. LUBRICATION SYSTEM
4-4
Mongoose/KXR 90/50
SERVICE INFORMATION (Mongoose/KXR 50)
GENERAL INSTRUCTIONS
• Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine
and oil line.
• Do not attempt to disassemble the oil pump.
• Bleed air from the oil pump if there is air between the oil pump and oil line.
• If the oil is disconnected, refill the oil line with motor oil before connecting it.
SPECIFICATIONS
• Recommended Motor Oil: SAE20W20# 2-stroke Motor Oil
• Oil Capacity : 1.0 liter
Light comes on : 0.25 liter
TROUBLESHOOTING
Excessive white smoke or carbon deposits on spark plug
• Oil pump not properly synchronized (excessive oil)
• Poor quality oil
Engine overheating
• Oil pump not properly adjusted (insufficient oiling)
• Poor quality oil
Seized piston
• No oil in tank or clogged oil line
• Oil pump not properly adjusted (insufficient oiling)
• Air in oil line
• Faulty oil pump
Oil not flowing out of tank to engine
• Clogged oil tank cap breather hole
• Clogged oil filter
4. LUBRICATION SYSTEM
4-5
Mongoose/KXR 90/50
Bolts
Right Crankcase Cover
Nut
Bolts
Oil Separator Cover
ENGINE OIL/OIL FILTER
(Mongoose/KXR 90)
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
Place a container under the engine.
Remove the drain plug to drain the oil. (!3-
9)
Remove the A.C. generator flywheel. (!14-
8)
Remove the A.C. generator stator and pulsar
coil. (!14-8)
Remove the eight right crankcase cover bolts
and the right crankcase cover.
Remove the two bolts and oil separator
cover.
Remove the oil pump driven gear nut.
Remove the oil pump driven gear and drive
chain.
Oil Pump Driven Gear
Drive Chain
4. LUBRICATION SYSTEM
4-6
Mongoose/KXR 90/50
Oil Pump
Bolts
Outer Rotor
Oil Pump Body
Screws
Remove the two oil pump mounting bolts
and the oil pump.
DISASSEMBLY
Remove the screw and disassemble the oil
pump.
INSPECTION
Measure the pump body-to-outer rotor
clearance.
Service Limit: 0.25mm
Oil Pump Body
4. LUBRICATION SYSTEM
4-7
Mongoose/KXR 90/50
Outer Rotor
Inner Rotor
Inner Rotor
Pump Cover
Outer Rotor
Measure the inner rotor-to-outer rotor
clearance.
Service Limit: 0.2mm
Measure the rotor end-to-pump body
clearance.
Service Limit: 0.12mm
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.
Insert the pump shaft by aligning the flat
on the shaft with the flat in the inner
rotor.
＊
4. LUBRICATION SYSTEM
4-8
Mongoose/KXR 90/50
Screws
Oil Pump
Arrow Mark
Pump Shaft
Tighten the screw to secure the pump cover.
Make sure that the pump shaft rotates
freely without binding.
INSTALLATION
Reverse the “OIL PUMP REMOVAL”
procedures.
Make sure that the pump shaft rotates
freely without binding.
Install the oil pump with the arrow on
the pump body facing up and fill the oil
pump with engine oil before installation.
＊
4. LUBRICATION SYSTEM
4-9
Mongoose/KXR 90/50
OIL PUMP BLEEDING
(Mongoose/KXR 50)
OIL INLET LINE/OIL PUMP BLEEDING
Fill the oil tank with recommended oil.
Place a shop towel around the oil pump.
Disconnect the oil inlet tube from the oil
pump and clip it.
Fill the oil pump with oil by squirting clean
oil through the joint. (About 3cc)
Fill the oil line with oil and connect it to the
oil pump.
OIL OUTLET LINE BLEEDING
1. Disconnect the oil outlet tube and bend it
into U shape. Force air out of the tube by
filling it with oil.
2. Start the engine and allow it to idle with
the oil control lever in the fully open
position. Visually check the oil flow.
3. If there is no oil flowing out within 1
minute, bleed air from the oil inlet tube
and oil pump.
• Air in the oil tubes will block oil flow
and result in severe engine damage.
• Bleed air from the oil tubes and oil
pump whenever the oil tubes or pump
have been removed or there is air in the
oil tubes.
°Ø
Bleed air from the oil inlet tube first,
then bleed air from the oil outlet line.
°Ø
• Never run the engine in a closed area.
• Do not increase the engine speed at
will.
°Ø
Oil Outlet Line
Oil Pump
Oil Outlet Line
4. LUBRICATION SYSTEM
4-10
Mongoose/KXR 90/50
OIL TANK (Mongoose/KXR 50)
OIL TANK REMOVAL
Remove the oil level switch connector.
Remove the two bolts attaching the oil tank.
Disconnect the oil inlet tube.
Drain the oil inside the oil tank into a clean
container.
Remove the oil tank.
The installation sequence is the reverse of
removal.
• Connect the oil tube properly.
• Bleed air from the oil pump after
installation. (See page 4-9)
• The oil tube clip (at the oil tank side)
must be locked from inside of the oil
tube joint.
°Ø
Oil Level Switch Connector
Bolts
Oil Inlet Tube
4. LUBRICATION SYSTEM
4-11
Mongoose/KXR 90/50
OIL PUMP (Mongoose/KXR 50)
REMOVAL
Disconnect the oil outlet tube from the oil
pump.
Disconnect the oil pump control cable from
the pump body.
Disconnect the oil inlet tube.
Remove the oil pump control cable plate
bolts.
Remove the oil pump from the crankcase.
OIL PUMP INSPECTION
Remove the oil pump and inspect the
following items:
• Weakened O-ring
• Damage to crankcase mating surface
• Damage to pump body
• Control lever operation
• Oil leaks through oil seals
• Worn or damaged pump pinion
Do not allow foreign matters to enter the
crankcase. Before removing the oil
pump, clean the oil pump and crankcase
surfaces.
°Ø
Do not disassemble the oil pump which
cannot be used after disassembly.
°Ø
O-ring
Gear
Control Lever
Oil Inlet Tube
Oil Pump Control Cable
Oil Pump Control Cable
Oil Outlet Tube
Before disconnecting the oil line, clip
the oil line to avoid oil flowing out and
then plug the oil line after it is
disconnected.
°Ø
Bolts
Oil Pump
Oil Pump Control
Cable Plate
4. LUBRICATION SYSTEM
4-12
Mongoose/KXR 90/50
OIL PUMP INSTALLATION
Install the oil pump into the crankcase.
Install the oil pump control cable plate.
Connect the oil inlet line and oil outlet tube
properly.
Connect the oil pump control cable.
Bleed air from the oil pump. (See page 4-9)
OIL FILTER CLEANING
(Mongoose/KXR 50)
Disconnect the oil tube at the oil pump side
and allow oil to drain into a clean container.
Remove the tube clip at the oil tank side and
disconnect the oil tube.
Remove the oil filter.
Clean the oil filter screen with compressed
air.
Install the oil filter in the reverse order of
removal and fill the oil tank with specified
oil up to the proper level.
Bleed air from the oil pump and oil lines.
• Lubricate the O-ring with grease or
engine oil before installation.
• Make sure that the oil pump is
inserted into the crankcase.
• Apply molybdenum disulfide or grease
to the pump pinion.
°Ø
Grease or Engine Oil
• Connect the oil tube properly.
• Bleed air from the oil pump after
installation.
• The oil tube clip (at the oil tank side)
must be locked from inside of the oil
tube joint.
°Ø
Filter Screen
Oil Filter
Clip
• Connect the oil tubes securely.
• Install the tube clip at the oil tank side
and also install the clip to the lower oil
tube that goes to the oil pump.
• Check for oil leaks.
°Ø
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