ATV250 11 (carter e controalbero) .pdf



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11.CRANKSCASE/CRANKSHAFT/
BALANCE SHAFT

Mongoose/KXR 250

11
__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CRANKCASE/CRANKSHAFT/BALANCE SHAFT
__________________________________________________________________________________

SERVICE INFORMATION -------------------------------------------- 11- 2
TROUBLESHOOTING ------------------------------------------------- 11- 2
CRANKCASE/CRANKSHAFT/BALANCE SHAFT----------------- 11- 3

11
11-0

11.CRANKCASE/CRANKSHAFT/
BALANCE SHAFT

11-1

Mongoose/KXR 250

11.CRANKSCASE/CRANKSHAFT/
BALANCE SHAFT

Mongoose/KXR 250

SERVICE INFORMATION
GENERAL INSTRUCTIONS
• This section covers crankcase separation to service the crankshaft. The engine must be removed
for this operation.
• The following parts must be removed before separating the crankcase.
-Cylinder head (!Chapter 7)
-Cylinder/piston (!Chapter 8)
-Drive and driven pulleys (!Chapter 9)
-A.C. generator (!Chapter 16)
-Starter clutch (!Chapter 18)
-Oil pump (!Chapter 4)

SPECIFICATIONS
Item
Connecting rod big end side clearance
Crankshaft Connecting rod big end radial clearance
Run out
TORQUE VALUES
Crankcase bolt
Cam chain tensioner slipper bolt
Cam chain cover bolt

Standard (mm)
0.05_ 0.4
0_ 0.008
æ

Service Limit (mm)
0.6
0.05
0.10

0.8_ 1.2kgf-m
0.8_ 1.2kgf-m
0.8_ 1.2kgf-m

TROUBLESHOOTING
Excessive engine noise
Excessive bearing play

11-2

11.CRANKCASE/CRANKSHAFT/
BALANCE SHAFT

CRANKCASE/CRANKSHAFT/BA
LANCE SHAFT

Mongoose/KXR 250
Timing Chain

REMOVAL
Remove the timing chain from right
crankcase.

Bolts

Remove the left and right crankcase
attaching bolts.
Separate the left and right crankcase halves.

°ØDo not damage the crankcase gasket
surface.

Remove the gasket and dowel pins.
Crankshaft

Remove the crankshaft from the left
crankcase.

11-3

11.CRANKSCASE/CRANKSHAFT/
BALANCE SHAFT

Remove balance shaft from the left
crankcase.

Mongoose/KXR 250
Balance Shaft

Clean off all gasket material from the
crankcase mating surfaces.

°ØAvoid damaging the crankcase mating
surfaces.

Inspect the balance shaft gear teeth.
Burrs/chips/roughness/wear _ Replace.

CRANKSHAFT INSPECTION
Inspect the crankshaft gear teeth.
Burrs/chips/roughness/wear _ Replace.
Measure the connecting rod small end I.D.
Service Limit: 17.06 mm replace if over

11-4

11.CRANKCASE/CRANKSHAFT/
BALANCE SHAFT

Mongoose/KXR 250

Measure the connecting rod small end free
play (A).
Out of specification (0.8 ~ 1.0 mm) _
Replace the crankshaft.

A
B

B

Measure the crankshaft run out (B).
Service Limit: 0.10mm replace if over
C
D

Measure the connecting rod big end side
clearance (C).
Service Limit: 0.05mm replace if over
Measure the crank width (D).
Out of specification (55.15 ~ 55.2 mm) _
Replace the crankshaft.

Turn the crankshaft bearings and check for
excessive play.
Measure the crankshaft bearing play.
Service Limit:
Axial : 0.20mm replace if over
Radial : 0.05mm replace if over

Play
Play

Axial

11-5

Radial

11.CRANKSCASE/CRANKSHAFT/
BALANCE SHAFT

CRANKCASE/BALANCER
INSTALLATION
Install the balance shaft and crankshaft into
the left crankcase.

Mongoose/KXR 250
Mark (Crankshaft)

°ØAlign the mark on the balance shaft with
the mark on the crankshaft.

Install the dowel pins and new gasket.
Install the right crankcase and tighten the
crankcase attach bolts.
Install the timing chain.

Mark (Balancer)

11-6


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