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ATV250 01 (info generali) .pdf



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1. GENERAL INFORMATION

Mongoose/KXR 250

1

1
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GENERAL INFORMATION
__________________________________________________________________________________

SERIAL NUMBER -----------------------------------------------------SPECIFICATIONS -----------------------------------------------------SERVICE PRECAUTIONS--------------------------------------------TORQUE VALUES ----------------------------------------------------SPECIAL TOOLS ------------------------------------------------------LUBRICATION POINTS----------------------------------------------CABLE & HARNESS ROUTING ------------------------------------WIRING DIAGRAM ---------------------------------------------------TROUBLESHOOTING -------------------------------------------------

1- 1
1- 2
1- 3
1-11
1-12
1-13
1-16
1-19
1-21

1-0

1. GENERAL INFORMATION
SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number

1-1

Mongoose/KXR 250

1. GENERAL INFORMATION

Mongoose/KXR 250
Oil exchanging
capacity
Cooling Type

SPECIFICATIONS

Air cleaner type & No
Sponge
Fuel capacity
13 liters
Type
PD
Float lever
14.8mm
Venturi dia.(mm)
f22
Throttle type
PISTON
Type
CDI
Ignition timing
5°BTDC/2000rpm
Contact breaker Non-contact point type
Ignition System

Spark plug

Spark plug gap
Battery Capacity
Clutch Type
Transmis- Reduction
sion Gear Gear

Moving Device

Engine

Type

Type

Automatic centrifugal
Type
Chain drive

Reduction 1st
ratio
2nd
Reverse ratio

FR/RR tire rolling
circumference(mm)

Tire pressure Front
(kg/cm_)
Rear
Turning
Left
angle
Right
Rear
Brake system
type
Front
Damping
Device

Frame type

0.6_ 0.7mm
12V12AH
CVT
Helical gear/spur gear

Operation

Suspension
type

DPR7EA-9

24.7
9.33
47.4
1675/1596

0.28
0.28
40°
40°
Disk brake
Disk brake

Front

Double wishbone

Rear

Link suspension
Steel tube frame

System

Starting system
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C., chain drive
Bore x stroke (mm)
72.7 x 60
Compression ratio
10.3:1
Compression pressure
15.0
(kg/cm_)
Max. output (ps/rpm)
17/7000
Max. torque (kg m/rpm)
2.0/5500
Intake
Open
8.1° BTDC
Port (1mm) Close
41° ABDC
timin Exhaust Open
37° BBDC
g
(1mm) Close
7.9° ATDC
Valve clearance Intake
0.1
(cold) (mm)
Exhaust
0.1
Idle speed (rpm)
1500rpm
Forced
pressure &
Lubrication type
Wet sump
Oil pump type
Inner/outer rotor
type
Oil filter type
Full-flow filtration
Oil capacity
1.6 liter

Water cooling

Carburetor

2.865
Starting motor

Power Drive System

Min. turning radius (m)

Electrical

ance

Fuel System

Name & Model No.
LA50AA/AB
Motorcycle Name & Type
Mongoose/KXR
Overall length (mm)
1700
Overall width (mm)
1070
Overall height (mm)
1080
Wheel base (mm)
1180
Engine type
O.H.C.
Displacement (cc)
249
Fuel Used
92# nonleaded gasoline
Front wheel
93.1
Net weight (kg) Rear wheel
84.9
Total
178
Front wheel
100
Gross weight(kg) Rear wheel
91
Total
191
Front wheel
21*7-10
Tires
Rear wheel
20*11-9
Ground clearance (mm)
130
Breaking distance
29.27 below
Perform
(m)(30KPH)

1.4 liter

1-2

1. GENERAL INFORMATION
SERVICE PRECAUTIONS
n Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.

n When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

n Use genuine parts and lubricants.

n When servicing the motorcycle, be sure to
use special tools for removal and
installation.

n After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1-3

Mongoose/KXR 250

1. GENERAL INFORMATION

Mongoose/KXR 250

n Apply or add designated greases and
lubricants to the specified lubrication
points.

n After reassembly, check all parts for
proper tightening and operation.

n When two persons work together, pay
attention to the mutual working safety.

n Disconnect the battery negative (-)
terminal before operation.
n When using a spanner or other tools,
make sure not to damage the motorcycle
surface.

n After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
n When connecting the battery, the positive
(+) terminal must be connected first.
n After connection, apply grease to the
battery terminals.
n Terminal caps shall be installed securely.

1-4

1. GENERAL INFORMATION
n If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.

n After operation, terminal caps shall be
installed securely.

n When taking out the connector, the lock
on the connector shall be released before
operation.

n Hold the connector body when connecting
or disconnecting it.
n Do not pull the connector wire.

n Check if any connector terminal is
bending, protruding or loose.

1-5

Mongoose/KXR 250
Confirm
Capacity

1. GENERAL INFORMATION
n The connector shall be inserted
completely.
n If the double connector has a lock, lock
it at the correct position.
n Check if there is any loose wire.

Mongoose/KXR 250

Snapping!

n Before connecting a terminal, check for
damaged terminal cover or loose
negative terminal.

n Check the double connector cover for
proper coverage and installation.

n Insert the terminal completely.
n Check the terminal cover for proper
coverage.
n Do not make the terminal cover opening
face up.

n Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

1-6

1. GENERAL INFORMATION

Mongoose/KXR 250

n After clamping, check each wire to make
sure it is secure.

n Do not squeeze wires against the weld or
its clamp.

n After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.

n When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.

n Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
n Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.

1-7

No Contact !

1. GENERAL INFORMATION
n Route harnesses so they are neither
pulled tight nor have excessive slack.

Mongoose/KXR 250

Do not
pull too
tight!

n Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge
or corner.

n When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.

n Do not break the sheath of wire.
n If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.

n When installing other parts, do not press
or squeeze the wires.

Do not
press or
squeeze the
wire.

1-8

1. GENERAL INFORMATION

Mongoose/KXR 250

n After routing, check that the wire
harnesses are not twisted or kinked.

n Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

n When a testing device is used, make sure
to understand the operating methods
thoroughly and operate according to the
operating instructions.

Do you understand
the instrument? Is
the instrument set
correctly?

n Be careful not to drop any parts.

n When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.

1-9

Remove Rust
!

1. GENERAL INFORMATION

Mongoose/KXR 250

n Symbols:
The following symbols represent the
servicing methods and cautions included
in this service manual.

Engine Oil

Grease

: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for
lubrication.

: Transmission Gear Oil
(90#)
Gear Oil

Special

: Use special tool.

: Caution

: Warning

1-10

1. GENERAL INFORMATION

Mongoose/KXR 250

TORQUE VALUES
STANDARD TORQUE VALUES
Item
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut

Torque (kgf-m)
0.45_ 0.6
0.8_ 1.2
1.8_ 2.5
3.0_ 4.0
5.0_ 6.0
6.0_ 8.0

Item
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut

Torque (kgf-m)
0.2_ 0.4
0.35_ 0.5
0.7_ 1.1
1.0_ 1.4
2.4_ 3.0
3.5_ 4.5

Torque specifications listed below are for important fasteners.
ENGINE
Item
Stud bolt
Oil filter screen cap
Seat ball stopper bolt
L cover
Cam shaft holder
Tappet ADJ nut
Pivot tensioner bolt
Lifter tensioner bolt
Lifter tensioner cap
Mission case bolt
Mission fill bolt
Driver face nut
Clutch outer nut
Drive plate nut
Oneway clutch bolt
ACG flywheel nut
Spark plug
Water pump impeller
Drain plug
Oil pump screw
Head CYL stud bolt (IN pipe)
Head CYL stud bolt (EX pipe)
A.C.G Startor

1-11

Q‘ty Thread dia.(mm) Torque (kgf-m)
4
8
0.7_ 1.1
1
30
1.0_ 2.0
1
14
4.5_ 5.0
10
6
1.0_ 1.4
4
8
2.3_ 2.7
2
5
0.7_ 1.1
1
8
0.8_ 1.2
2
6
1.0_ 1.4
1
6
0.35_ 0.5
9
8
2.4_ 3.0
1
12
2.0_ 3.0
1
14
9.0_ 10.0
1
12
5.0_ 6.0
1
28
5.0_ 6.0
3
8
1.8_ 2.2
1
14
5.5_ 6.5
1
12
1.5_ 2.0
1
7
1.0_ 1.4
1
12
2.0_ 3.0
1
3
0.1_ 0.3
2
6
0.7_ 1.1
2
8
0.7_ 1.1
3
5
0.8_ 1.0

Remarks

Apply oil
Apply oil

Apply oil

Apply thread
lock

1. GENERAL INFORMATION

Mongoose/KXR 250

FRAME
Item
Steering stem nut
Front Swing arm nut
Front wheel nut
Rear wheel nut
Front wheel hub nut
Rear wheel hub nut
Front shock absorber upper mount bolt
Front shock absorber lower mount bolt
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Rear swing arm axle
Rear hub nut
Rear wheel shaft nut
Rear engine bracket upper bolt
Rear engine bracket lower bolt
Engine hanger bracket bolt
Exhaust muffler lock bolt (frame)
Exhaust muffler lock nut (engine)
Rod-end nut

Q‘ty Thread dia.(mm) Torque (kgf-m)
1
8
8
8
2
2
2
2
1
1
1
2
2
1
1
1
2
2
4

14
10
12
12
14
16
10
10
10
10
14
10
40
10
10
10
8
8
8

6.0_
4.0_
5.0_
5.0_
6.0_
6.0_
3.5_
3.5_
3.5_
3.5_
6.0_
3.5_
11.0_
3.5_
3.5_
3.5_
3.2_
1.8_
2.5_

Remarks

8.0
5.0
6.0
6.0
8.0
8.0
4.5
4.5
4.5
4.5
8.0
4.5
13.0
4.5
4.5
4.5
3.8
2.2
3.5

SPECIAL TOOLS
Tool Name
Flywheel puller
Valve adjuster
Valve spring compressor
Oil seal and bearing install
Universal holder
Flywheel holder
Clutch spring compressor
Bearing puller
Nut wrench

Tool No.
E003
E012
E040
E014
E017
E021
E034
E037
F010

Remarks Ref. Page

1-12

1. GENERAL INFORMATION

Mongoose/KXR 250

LUBRICATION POINTS
ENGINE
Lubrication Points

Lubricant

Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft right side oil seal
Crankshaft one-way clutch movable part
Oil pump drive chain
Balance gear
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip

•Genuine KYM CO Engine Oil (SAE15W-40)
•API SG Engine Oil

Transmission gear and movable parts

Gear oil: SAE90#

1-13

1. GENERAL INFORMATION

Mongoose/KXR 250

FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the ATV.

Throttle Cable

Front Swing Arm Bush

Steering Column Upper

Front Swing Arm Bush

Steering Column Lower

1-14

1. GENERAL INFORMATION

Mongoose/KXR 250

Rear Swing Arm
Axle

Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing

1-15

Driven Sprocket

1. GENERAL INFORMATION

Mongoose/KXR 250

CABLE & HARNESS ROUTING
Pilot Lamp Wire
Headlight Wire
Throttle Cable

Stop Switch Cord

Handlebar Switch Wire
Rear Brake Fluid Hose

Front Brake Fluid Hose
Thermostatic Sensor Wire
Ignition Switch Wire

Harness Wire
Motor Fan Cord
Thermostatic Switch Wire

Right Front Brake Fluid Hose
Left Front Brake Fluid Hose

1-16

1. GENERAL INFORMATION

Mongoose/KXR 250

Temperature Sensor Wire
Air Vent Tube

Tail Light Cord
REG.REC Cord
Coolant Reservoir
Breather Hose

A.C.G Cord

Start Motor Cable
Stop Switch Cord
Radiator Overflow Tube

Water Hose

Carburetor Drain Tube

Outlet Water Hose
Inlet Water Hose

1-17

1. GENERAL INFORMATION

Mongoose/KXR 250

Rear Brake Fluid Hose

Handlebar Switch Cord

Crankcase Breather Hose
Harness Wire
Blow By Hose

Battery Cable

Coil Cord
Motor Fan Cord

Start Motor Cable
Rear Brake Fluid Hose

Rear Brake Fluid Hose

1-18

1. GENERAL INFORMATION
WIRING DIAGRAM (OFF ROAD)

1-19

Mongoose/KXR 250

1. GENERAL INFORMATION

Mongoose/KXR 250

WIRING DIAGRAM (ON ROAD)

1-20

1. GENERAL INFORMATION

Mongoose/KXR 250

TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment

Symptom

Check if fuel reaches
carburetor by
loosening drain screw
Fuel reaches
carburetor

Fuel does not
reach carburetor

Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel valve passage

Weak or no spark

Faulty spark plug
Fouled spark plug
Faulty ignition unit
Faulty change gear control unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground
Spark jumps

Probable Cause

Test cylinder
compression
Normal
compression

Low or no
compression

Engine does not
fire

Engine fires but
does not start

Faulty starter clutch
Valve clearance too small
Valve stuck open
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket

Start engine by following normal starting
procedure
Air leaking through intake
pipe
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted air screw

Remove spark plug and
inspect again
Dry spark plug

1-21

Wet spark plug

Flooded carburetor
Clogged air cleaner
Throttle valve excessively
open

1. GENERAL INFORMATION

Mongoose/KXR 250

ENGINE LACKS POWER
Inspection/Adjustment

Symptom

Probable Cause

Start engine and accelerate
lightly for observation
Engine speed
increases

Engine speed does not
increase sufficiently

Check ignition timing
(using a timing light)
Correct timing

Incorrect timing

Correct

Incorrect

Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Carburetor fuel level too low
Faulty ignition unit
Faulty pulser coil

Check valve clearance

Test cylinder compression
Normal
compression

Abnormal
compression

Improper valve clearance
adjustment
Excessively worn valve seat
(protruded valve stem)
Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing

Check carburetor for
clogging

Not clogged

Clogged

Clean and unclog

Remove spark plug and
inspect
Plug not fouled or
discolored

Plug fouled or
discolored

Fouled spark plug
Incorrect heat range plug

Correct and not
contaminated

Incorrect or
contaminated

Oil level too high
Oil level too low
Oil not changed

Remove oil dipstick and
check oil level and condition

Remove cylinder head oil
pipe bolt and inspect
Valve train lubricated
properly

Valve train not
lubricated properly

Check if engine overheats
Engine does not
overheats

Engine overheats

Rapidly accelerate or run
at high speed
Engine does not knock

Engine knocks

Clogged oil line
Faulty oil pump
Coolant level too low
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon build-up in
combustion chamber
Ignition timing too early
Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early

1-22

1. GENERAL INFORMATION

Mongoose/KXR 250

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Correct timing

Incorrect timing

Faulty ignition unit
Faulty pulser coil

Check carburetor air
screw adjustment
Correctly adjusted

Incorrectly
adjusted

Mixture too rich (turn screw
out)
Mixture too lean (turn screw
in)

Check carburetor
gasket for air leaks

No air leak

Air leaks

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground
Good spark

1-23

Weak or intermittent spark

Deteriorated O-ring
Carburetor not securely
tightened
Damaged insulator rubber

Faulty or fouled spark plug
Faulty ignition unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch

1. GENERAL INFORMATION

Mongoose/KXR 250

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

Faulty ignition unit
Faulty pulser coil

Check valve clearance
Improperly adjusted valve
clearance
Worn valve seat

Check fuel pump for
fuel supply

Fuel flows freely

Fuel flow restricted

Not clogged

Clogged

Correct

Incorrect

Not weakened

Weak spring

Check carburetor jets
for clogging

Empty fuel tank
Clogged fuel tube or filter
Clogged Fuel tank cap breather
hole

Clean and unclog

Check valve timing

Cam timing gear aligning
marks not aligned

Check valve spring
tension
Faulty spring

1-24

1. GENERAL INFORMATION

Mongoose/KXR 250

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Inspection/Adjustment

Symptom

Probable Cause

Start engine and test
limit voltage of
battery terminals
Normal voltage

Voltage does not
increase

Dead battery
Faulty battery

Measure resistance
between AC generator
coil terminals

Connect battery (+)
wire to
regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage

Faulty A.C. generator coil
Broken yellow wire
Shorted pink and yellow
wires

Normal

Resistance too
high

Normal voltage

No voltage

Broken red wire

Normal

Abnormal

Faulty regulator/rectifier
Poorly connected coupler

Check
regulator/rectifier
coupler for loose
connection

Faulty A.C. generator

Overcharging
Inspection/Adjustment
Connect battery (+)
wire to
regulator/rectifier
coupler green wire and
battery (-) wire to engine
ground and test voltage

Symptom

Battery has
voltage with
ignition switch
“ON”

Probable Cause

Battery has no
voltage with
ignition switch
“ON”

Broken green wire

Check
regulator/rectifier
coupler for loose
connection
Normal

Abnormal

Poorly connected coupler
Faulty regulator/rectifier

1-25

1. GENERAL INFORMATION

Mongoose/KXR 250

NO SPARK AT SPARK PLUG
Inspection/Adjustment

Symptom

Probable Cause

Replace with a new
spark plug and inspect
again
Weak or no spark

Good spark

Not loose

Loose

Loose spark plug cap

Good

Good

Poorly connected coupler

Normal

Abnormal

Faulty spark plug

Check spark plug cap
and high-tension wire
for looseness

Check ignition unit
coupler for looseness

Measure resistance
between terminals of
ignition unit coupler

Check related parts

Normal

Abnormal

Faulty ignition switch
Weak battery
Faulty pulser coil
Faulty ignition coil
Faulty charging system
Broken wire harness
Poorly connected coupler

Check ignition unit
with a ignition unit
tester
Normal
Check ignition coil
with a ignition unit
tester

Abnormal

Abnormal

Faulty ignition unit
Faulty change gear control
unit

Faulty ignition coil

1-26


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