5.
15.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • 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 disk • Inspect the brake system before riding.
15. REAR WHEEL/AXLE/SUSPENSION REAR WHEEL/AXLE/AXLE HUB MXU 250 Rear Axle Nuts REMOVAL AND INSPECTION Place the machine on a level place. Remove the rear caliper. (Refer to the “REAR BRAKE CALIPER REMOVAL” section in chapter 13) Use the nut wrench to loosen two rear axle nuts (inner and outer) of the rear axle. ＊ Note that the rear axle nuts are left threaded. Special Nut wrench F010 Remove four nuts attaching the rear wheel hub of the both rear wheels, then remove the both rear wheels.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Inspect the rear wheel hub. Cracks/damage → Replace. Inspect the rear wheel hub splines. Wear/damage → Replace. Splines Measure the wheel runout. Service Limit: Vertical: 2 mm (0.08 in) Lateral: 2 mm (0.08 in) Out of specification → Replace wheel. Remove the two rear axle nuts (outer and inner), washer and collar.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Remove the rear brake disk. Rear Brake Disk Inspect the brake disk Cracks/damage → Replace. Inspect the brake disk splines. Wear/damage → Replace. Splines Drive Sprocket Cover Bolts Loosen the driven chain (refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in the chapter 3) and remove the two bolts at the drive sprocket (refer to the chapter 6), then disconnect the drive chain from the driven sprocket.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Driven Sprocket Remove the rear axle from right side. ＊ Tap the axle and with a rubber hammer, this will avoid damage the axle thread.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Remove the driven sprocket clip at the rear axle and then remove the driven sprocket. Clip Remove the four nuts attaching the driven sprocket holder at the driven sprocket and then remove driven sprocket. Nuts Inspect the drive sprocket and driven sprocket. More than 1/4 teeth wear → Replace. Bent teeth → Replace.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Inspect the driven sprocket holder splines. Wear/damage → Replace. Splines Inspect the rear axle. Scratched (excessively)/damage → Replace. Inspect the splines and threads of the rear axle Wear/damage → Replace. Measure the rear axle run out. Service limit: less than 1.5 mm (0.06 in) Out of specification → Replace. ＊ Do not attempt to straighten a bent axle. REAR AXLE ASSEMBLY Reverse the “REAR AXLE DISASSEMBLY” procedures.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Bolts Remove the bolt at the rear caliper holder. Remove the two bolts attaching the rear axle hub at the rear fork. Bolt Collar Circlip Remove the circlip at the caliper holder and then remove the caliper holder and collar. Caliper Holder Inspect the O-ring for damage. Apply grease to the O-ring before the caliper holder is installed.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Remove the rear axle hub from right side. Rear Axle Hub Inspect rear axle hub. Bearings allow play in the axle hub or the bearing turns roughly → Replace. Dust seals is wear/damage → Replace. Axle hub is cracks/bend/damage → Replace. REAR AXLE HUB DISASSEMBLY Bearing and dust seal replacement steps: Clean the outside of the rear axle hub. Remove the dust seal by a flat-head screw driver.
15. REAR WHEEL/AXLE/SUSPENSION REAR AXLE HUB ASSEMBLY Install the new bearing and dust seal by reversing the previous steps. ＊ Dust Seal INSTALLATION Reverse the “REAR WHEEL/AXLE/AXLE HUB REMOVAL AND INSPECTION” procedures. Apply grease onto the dust seal lips and bearings. Install the rear axle hub. ＊ At this time, the rear axle hub should not be tightened completely. Final tightening is done after the chain slack adjustment. Install the rear axle. Connect the drive chain.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Install the rear wheel hub and tighten the nut. Torque: 10 kgf-m (100 Nm, 72 lbf-ft) Install cotter pin (new) ＊ Do not loosen the wheel hub nut after torque tightening. If the wheel hub nut groove is not aligned with the cotter pin hole, align groove with the hole by tightening up on the wheel hub nut. Always use a new cotter pin. Install the rear wheel and tighten the four nuts. Torque: 4.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 REAR SHOCK ABSORBER / REAR FORK REMOVAL AND INSPECTION Place the machine on a level place. Elevate the rear wheels by placing a suitable stand under the rear of frame. ＊ Support the machine securely so there is no danger of it falling over. Remove the rear wheels, rear axle and rear hub. Refer to the “REAR WHEEL/AXLE/AXLE HUB REMOVAL AND INSPECTION” section in chapter 15.
. REAR WHEEL/AXLE/SUSPENSION MXU 250 Check the rear fork side play by moving it from side to side. If side play noticeable, check the inner collar, bearing, bushing and thrust cover, or adjust the shim. Check the rear fork vertical movement by moving it up and down. If vertical movement is tight, binding or rough, check the inner collar, bearing, bushing and thrust cover, or adjust the shim. Remove the band and then disconnect the rear brake fluid tubes from the rear fork.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Pivot Shaft Remove the nut and pivot shaft, then remove rear fork and drive chain. Remove the four bolts from the lower guard and then remove the lower guard. Bolts Remove the thrust covers.
15. REAR WHEEL/AXLE/SUSPENSION MXU 250 Thrust Covers Inspect the rear fork. Crack/bend/damage → Replace. Roll the axle on a flat surface to inspect the pivot shaft. Bends → Replace. ＊ Do not attempt to straighten a bent axle. Inspect the thrust covers, collar and bushes. Wear/damage → Replace. Collar Inspect the drive chain stiffness. Stiff →Clean and lubricate or replace.
15. REAR WHEEL/AXLE/SUSPENSION INSTALLATION Reverse the “REAR FORK/SWIM ARM/SHOCK ABSORBER REMOVAL AND INSPECTION” procedure. Apply grease onto the collar, bush, pivot shaft and thrust cover. Install the rear fork and drive chain. Install the pivot shaft and tightening the nut and pivot shaft. Torque: 7 kgf-m (70 Nm, 50 lbf-ft) Install the shock absorber and tightening the bolts. Torque: 4 kgf-m (40 Nm, 29 lbf-ft) Install the rear hub and rear wheels. Refer to the “REAR WHEEL INSTALLATION” section.
