Kymco MO KXR 50 Service Manual - chap 03 (manutenzione)

3. INSPECTION/ADJUSTMENT

3-0

Mongoose/KXR 90/50

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INSPECTION/ADJUSTMENT

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SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 3 FUEL LINE/THROTTLE OPERATION------------------------------ 3- 4 AIR CLEANER ---------------------------------------------------------- 3- 5 SPARK PLUG/CYLINDER COMPRESSION ------------------------ 3- 7 VALVE CLEARANCE (Mongoose/KXR 90)------------------------- 3- 8 CARBURETOR IDLE SPEED ----------------------------------------- 3- 8 ENGINE OIL (Mongoose/KXR 90)------------------------------------ 3- 9 TRANSMISSION OIL -------------------------------------------------- 3-11 DRIVE BELT/BRAKE SHOES/BRAKE PADS/BRAKE FLUID -- 3-12 BRAKE LEVER FREE PLAY ----------------------------------------- 3-13 STEERING SYSTEM INSPECTION --------------------------------- 3-14 TOE-IN ADJUSTMENT------------------------------------------------ 3-15 WHEELS/TIRES -------------------------------------------------------- 3-16 DRIVE CHAIN SLACK ADJUSTMENT ----------------------------- 3-17 CABLE INSPECTION AND LUBRICATION ----------------------- 3-19 FRONT SUSPENSION LUBRICATION------------------------------ 3-19 HEADLIGHT BEAM ADJUSTMENT (ON ROAD ONLY) -------- 3-20 BRAKE PEDAL ADJUSTMENT (KXR 90 ON ROAD ONLY)---- 3-20 BRAKE FULID (KXR 90 ON ROAD ONLY)------------------------ 3-21

3. INSPECTION/ADJUSTMENT

3-1

Mongoose/KXR 90/50

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 (Mongoose/KXR 90)

ENGINE Throttle grip free play : 1_ 4mm Spark plug gap : 0.6_ 0.7mm Spark plug: Standard : NGK: C7HSA Valve clearance : IN: 0.1m

EX: 0.1m

Idle speed : 1700±100rpm Engine oil capacity: At disassembly : 0.8 liter At change : 0.7 liter Gear oil capacity : At disassembly : 120cc At change : 110cc Cylinder compression : 16kg/cm_ Ignition timing : BTDC 28°/4000rpm

CHASSIS Front brake free play: 10_ 20mm Rear brake free play: 10_ 20mm

TIRE PRESSURE

1 Rider

Front

0.22kgf/cm_

Rear

0.22kgf/cm_

TIRE SIZE: Front : 18*7-8 Rear : 18*9-8

TORQUE VALUES

Front wheel nut 4.0_ 5.0kgf-m Rear wheel nut 4.0_ 5.0kgf-m

3. INSPECTION/ADJUSTMENT

3-2

Mongoose/KXR 90/50

SPECIFICATIONS (Mongoose/KXR 50)

ENGINE Throttle grip free play : 1_ 4mm Spark plug gap : 0.6_ 0.7mm Spark plug: Standard : NGK: BR8HAS

Idle speed : 2000±100rpm Gear oil capacity : At disassembly : 120cc At change : 110cc Cylinder compression : 12kg/cm_ Ignition timing : BTDC 15°/1700rpm

CHASSIS Front brake free play: 10_ 20mm Rear brake free play: 10_ 20mm

TIRE PRESSURE

1 Rider

Front

0.22kgf/cm_

Rear

0.22kgf/cm_

TIRE SIZE: Front : 16*8-7 Rear : 16*8-7

TORQUE VALUES

Front wheel nut 4.0_ 5.0kgf-m Rear wheel nut 4.0_ 5.0kgf-m

3. INSPECTION/ADJUSTMENT

3-3

Mongoose/KXR 90/50

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 (Mongoose/KXR 50)

Check valve clearance. Adjust if necessary.

°≥°≥°≥

°≥

Spark plug

Check condition. Clean or replace if necessary.

°≥°≥°≥°≥°≥

Air clearance

Clean. Replace if necessary.

°≥°≥°≥

°≥

Carburetor

Check idle speed/starter operation. Adjust if necessary.

°≥°≥°≥

°≥

Fuel line

Check fuel hose for cracks or damage. Replace if necessary.

°≥°≥°≥

Engine oil (Mongoose/KXR 50)

Replace (Warm engine before draining).

°≥°≥°≥

°≥

Engine oil filter screen (Mongoose/KXR 50)

Clean. Replace if necessary.

°≥

Transmission oil

Check oil leakage. Replace every 12 months.

°≥

Brake system

Check operation. Adjust if necessary.

°≥°≥°≥°≥°≥

Drive belt

Check operation/replace if damage or excessive wear.

°≥

Wheels

Check balance/damage/runout. Replace if necessary.

°≥°≥°≥

°≥

Wheel bearings

Check bearings assembly for looseness/damage. Replace if damaged.

°≥°≥°≥

°≥

Steering system

Check operation/replace if damage. Check toe-in/adjust if necessary.

°≥°≥°≥°≥°≥

Knuckle 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

3-4

Mongoose/KXR 90/50

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: 1_ 4mm

To adjust throttle free play:

1. Slide the rubber sleeves back to expose the throttle cable adjuster.

2. Loosen the lock nut, then turn the adjuster to obtain the correct free play. (1~4 mm or 0.04~0.16 in)

3. Tighten the lock nut and reinstall the sleeve.

OIL PUMP ADJUSTMENT (Mongoose/KXR 50)

Open the throttle valve fully and check that the index mark on the pump body aligns with the aligning mark on the oil pump control lever. Reference tip alignment within 1mm of index mark on open side is acceptable. Start and idle the engine, then slowly open the throttle to increase engine rpm and check the operation of the oil pump control lever. If adjustment is necessary, adjust the oil pump control cable by loosening the control cable lock nut and turning the adjusting nut. After adjustment, tighten the lock nut.

Fuel Filter

Fuel Tubes

Rubber Sleeves

Lock Nut

Cable Adjuster

Throttle Lever

Adjust oil pump control cable after the throttle grip free play is adjusted.

°Ø

Control Lever Aligning Mark

Lock Nut

Adjusting Nut

Do not smoke or allow flames or sparks in your working area.

°Ø

3. INSPECTION/ADJUSTMENT

3-5

Mongoose/KXR 90/50

If the oil pump is not synchronized properly, the following will occur:

• Excessive white smoke or hard starting due

to pump control lever excessively open

• Seized piston due to pump control lever

insufficiently open

AIR CLEANER

AIR CLEANER REPLACEMENT/CLEANING

To replace the air cleaner (Mongoose/KXR 90):

1. Remove the seat. (See page 2-3.)

2. Remove the five screws and then remove air filter case cover.

3. Remove the air filter element, and separate it from the box.

Screws

Air Filter Case Cover

Air Filter Element

Reference tip alignment within 1mm of index mark on open side is acceptable. However, the aligning mark on the control lever must never be on the closed side of the index mark, otherwise engine damage will occur because of insufficient lubrication.

°Ø

3. INSPECTION/ADJUSTMENT

3-6

Mongoose/KXR 90/50

To replace the air cleaner (Mongoose/KXR 50):

1. Remove the five screws and air filter case cover.

2. Remove the air filter element, and separate it from the box.

To clean the air filter element:

1. Wash the element gently but thoroughly in solvent.

2. Squeeze the excess solvent out of the filter and let it dry.

3. Inspect the element. If damaged, replace it.

4. Apply quality foam air filter oil to the element. If foam air filter oil is not available, motor oil may be used.

5. Reinstall the element to the air filter case.

6. Reinstall the element assembly and parts removed for access.

Apply the engine oil.

Squeeze out the excess oil.

CHANGE INTERVAL

More frequent replacement is required when riding in unusually dusty or rainy areas.

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 Filter Element

Screws

Air Filter Case Cover

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