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12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the machine frame covers before removing the front wheel. Jack the machine front wheel off the ground and be careful to prevent the machine from falling down. • During servicing, keep oil or grease off the brake drum and brake linings. • Inspect the brake system before riding. SPECIFICATIONS Item Radial Axial Front wheel rim run out Front brake drum I.
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12. FRONT WHEEL/FRONT BRAKE/FRONT Mongoose/KXR 90/50 SUSPENSION/STEERING SYSTEM FRONT WHEEL REMOVAL Place the machine on a level place. Remove four nuts attaching the wheel panel and front wheel. Elevate the front wheels by placing a suitable stand under the frame. °ØSupport the machine securely so there is no danger of it falling over. Nuts Nut Cover Pin Remove the nut cover. Remove the cotter pin. Remove nut attaching the wheel hub and washer. Washer Hub Nut Remove the collar and wheel hub.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM INSPECTION Measure the wheel run out. Replace wheel or check bearing play if out of specification Rim run out limits: Vertical: 2.0mm Lateral: 2.0mm Inspect the front wheel hub. Replace it if cracks or damage. Inspect the front brake drum. Measure the front brake drum I.D. Service limits: 84mm °ØKeep oil or grease off the brake drum. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
12. FRONT WHEEL/FRONT BRAKE/FRONT Mongoose/KXR 90/50 SUSPENSION/STEERING SYSTEM Side Collar FRONT WHEEL HUB DISASSEMBLY Remove the side collar. Remove the dust seal of each side. Dust Seal Remove the front wheel hub bearings and distance collar.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 ASSEMBLY Apply grease to a new dust seal lip and install the dust seal. Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. °Ø• Do not allow the bearings to tilt while driving them in. • Drive in the bearing squarely with the sealed end facing out. Special Oil seal and bearing install E014 INSTALLATION Reverse the “FRONT WHEEL REMOVAL” procedures.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 Brake Cable FRONT BRAKE REMOVAL Remove the wheel hub. (See page 12-4) Pull brake shoe plate out from steering knuckle. Disconnect the front brake cable from brake cam lever and remove the brake shoe plate. Brake Shoe Plate Brake Cam Lever INSPECTION Measure the front brake lining thickness (A). Service limit: 2.0mm replace it if below DISASSEMBLY Remove return ring. Remove the brake shoes.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 Install the brake shoe plate. °ØMake sure that the boss on the knuckle correctly engages with the locating slot on the brake shoe plate. Install front wheel. (See page 12-7) Adjust the front brake cable free play. Refer to the “BRAKE LEVER FREE PLAY” section in the CHAPTER 3.
12. FRONT WHEEL/FRONT BRAKE/FRONT Mongoose/KXR 90/50 SUSPENSION/STEERING SYSTEM FRONT SUSPENSION Upper Bolt Shock Absorber REMOVAL Elevate the front wheels by placing a suitable stand under the frame. °Ø Support the machine securely so there is no danger of it falling over. Remove the front wheel, wheel hub, brake shoe plate. (Refer to chapter 12) Remove the upper and lower bolt, then remove the shock absorber.
. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 Check the front arm brackets of the frame. If bent, cracked or damaged, repair or replace the frame. Check the tightening torque of the front arms securing nuts. Torque: 4.0_ 5.0kgf-m Check the dust seal. If wear or damage, replace the dust seal. Check the front arm side play by moving it from side to side. If side play noticeable, replace the bushings.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Inspect the front arm. Replace if cracks, bends or damage. Mongoose/KXR 90/50 Bushes °Ø Do not attempt to straighten a bent arm, this may dangerously weaken the arm. Inspect bushes. Replace if wear or damage. Bushes INSTALLATION Reverse the “REMOVAL” procedures. °Ø Apply the grease onto the bushes. Install the front arm onto the frame and tighten the bolts and nut. Torque: 4.0_ 5.0kgf-m °Ø Apply the grease onto the bushes.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 STEERING SYSTEM HANDLEBAR REMOVAL Remove the following parts: Handlebar and Front fender. Refer to the “FRAME COVER” section in the CHAPTER 2 INSPECTION Inspect the handlebar. Replace if cracks, bends or damage. INSTALLATION Install handlebar and handlebar holder, then tighten the four bolts. Torque: 1.8_ 2.5kgf-m °Ø• Align the mark on the handlebar with the lower handlebar holder surface.
12. FRONT WHEEL/FRONT BRAKE/FRONT Mongoose/KXR 90/50 SUSPENSION/STEERING SYSTEM Nut STEERING COLUMN REMOVAL Remove handlebar. (Refer to “FRAME COVER” section in chapter 2) Remove the cotter pins and nuts attaching the tie-rods, then remove tie-rods. Remove the cotter pin and nut attaching the steering column, then remove steering column and collar. Nut Remove the two bolts to remove the steering bracket and rubber collar. Remove steering column and collar.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Dust Seals Remove the dust seal of each frame side. Remove the snap ring. Remove the bearing. Snap Ring INSTALLATION Apply grease to a new dust seal lip and install the dust seal (under frame). Pack bearing cavities with grease. Drive in the bearing and install snap ring. Apply grease to a new dust seal lip and install the dust seal. °Ø• Do not allow the bearings to tilt while driving them in.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 Apply the grease onto the rubber collar and then install the rubber collar. Install the steering bracket and tighten the two bolts. Torque: 1.8_ 2.5kgf-m Install the tie rods and tighten the nuts. Torque: 2.0_ 3.0kgf-m Install the cotter pin and band ends of cotter pin. °Ø Always use a new cotter pin. Apply the grease onto the end of the throttle cable and end of the brake cable.
12. FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION/STEERING SYSTEM Mongoose/KXR 90/50 Nut TIE-ROD REMOVAL Remove the cotter pin and nut at the steering knuckle. Remove the cotter pin and nut at the steering column. Remove the tie-road. Nut Cotter Pin Cotter Pin INSPECTION Inspect the tie-rod. Replace if bend or damage. Check the tie-rod end movement. Replace it if the tie-rod end exists free play or turns roughly. Check the tapered surface of the tie-rod end. Replace it if pitting, wear or damage.
12. FRONT WHEEL/FRONT BRAKE/FRONT Mongoose/KXR 90/50 SUSPENSION/STEERING SYSTEM Set the rod-end (steering column side) in an angle where the indentation surface of the tie-rod is parallel to the rod-end shaft, and then tighten the lock nut. Torque: 2.0_ 3.0kgf-m Set the other rod-end (knuckle arm side) in an angle as shown (right-hand tie-rod and left-had tie-rod), and then tighten the lock nut. Rod-end (tie rod) angle (A): 15º±3º Torque: 2.0_ 3.
