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250-300-Manual

1. Service Manual CHRISTINI AWD 300 CHRISTINI AWD 250 Christini Technologies Inc Veron 2015 1 tech christini com Guns TINI JR ieee Gore Pefeccucies HOW TO USE THIS MANUAL Read this Manual carefully You will find it contains all the necessary information for your safety and that of other per sons as well as guaranteeing the correct conservation and maintenance of the GAS GAS motorcycle that you have just acquired You will find all the necessary instructions for the correct riding and control of this vehicle are set out below Each message is preceded by a symbol with the following meaning WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or even death CAUTION This symbol identifies instructions or procedures which if not followed strictly could result in damage to or destruc tion of equipment NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Motorcycle riding if improperly conducted has the potential to cause environmental problems as well as conflicts with other people Responsible riding use of your motorcycle will ensure that these problems and conflicts do not develop TO PROTECT THE FUTURE OF YOUR SPORT MAKE SURE YOU USE YOUR MOTORCYCLE WHITHIN THE LAW SHOW CON CERNFOR THE ENVIRONMENT AND RESPECT THE R
2. FR tee Core CE Head Bearing Service Input Head Tube bearing Main Drive Shaft CB 6805 5 07 Taper Bearing Race part of CB 32908 Input Gear HT 04 Head Tube inner Bearing 543 Head Tube Cover HT 07 4 Head Tube Cover Bolts CH M amp 10 Picture above shows a head tube not welded to the frame for reference 101 Gurs TINI Summe Head Bearing Service Usea punch and remove the inner B543 bearings e If the taper bearing races are corroded or pitted remove them with a punch Clean the headset bearing surfaces with degreaser and apply a few drops of green Loctite Install the inner B543 bearings using a bearing punch nstall the taper bearing races using a bearing punch Page 102 Main Drive Shaft Installation 7272527 e Slide the input bearings onto the head tube gear e Slide the driveshaft partially through the frame and install the clutch hub Be sure the clutch retaining snap ring is on the driveshaft before sliding the clutch hub onto the driveshaft e Slide the driveshaft the rest of the way through the frame seating the input bearings and gear in the head tube and the clutch hub with the clutch basket Use a soft punch and lightly tap the gear to be sure it is fully seated e Move the clutch retaining snap ring into the groove closest to the clutch hub Page 103
3. incorporation or use of unsuitable attachments or parts Unsuitable use in an application for which the part was not designed Neglect Misuse Abuse Vandalism Failures caused by or related to any modification not approved by Christini Technologies Inc Failures caused by or related to any installation of any parts or kits designed for competition only use Use for the following activities which will VOID these warranties e Racing Competition e Rental L L L L LELOC U L 1 LNLOLULLLLULALAA LLLL ADO L OOooU AUOALULL LAL L AkXk4LAL LQLASAAAI Page 120 Coie Warranty Gurs TING LIMITED REMEDY Unless otherwise provided the sole remedy under the above warranty or any implied warranty is limited to the replacement of defective parts with those of equal or greater value at the sole discretion of CHRISTINI No cash refunds will be offered under this warranty and you will be responsible for labor costs associated with warranty replacements INNO EVENT WILL CHRISTINI AWD BE RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER BASED ON CONTRACT WARRANTY NEGLIGENCE OR STRICT PRODUCTS LIABILITY INCLUDING WITH OUT LIMITATION PERSONAL INJURY DAMAGES PROPERTY DAMAGE OR ECONOMIC LOSSES Note In those states that do not allow the exclusion or limitation of incidental or consequential damages the above limita tion or exclusion may not
4. up in nnmhuston chamber Inceerect octane er poor gasoline Damaged spark plug or incorrect specilicalians Detenoraied exhaust system gaskets White smoke coming out of the exhaust pipe Delenorated cylinder head waler leakage into Ine cylinder incorrect lhrdille valve cable adjusimarnt Brown smoke coming out of the Resticted air cleaner exhaust pipe Main jet set toc high di REMEDY Go fo a specialized workshop Go to specialized workshop Go specialized workshop Drain old fuel out of the tank With the fuel tank filled with new fuel the engine will start immediately Clean and dry or replace the spark plug n order te relieve the engine accelerate in max speed press the starter pedal 5 or 10 times Then start the engine as described above lf the engine fails ip start remove the spark plug and it Clean the fuel tank air vent Adjust the air cleaner duct Verity the exhaust valve and repair as necessary Close the starter Clean fuel tank air vent Adjust the air cleaner duct Fill up the fuel tank Fill up cooting liquid verify the refrigeration system wnatertightness Clean radiator fins or replace it Verify the spark plug condition and clean it accordingly tighten nr replace it Verify the spark plug cap condition Replace if deteriorated Replace the rater Drain the fuel tank and fal up wi
5. Grease the top and bottom taper bearings with Spectro SPL or equivalent waterproof grease Grease output gears with Shell grease e Check to make sure input head tube gear and bearings completely seated in the back of the head tube e Slide top triple clamp assembly into the head tube e Before seating the top triple clamp assembly make sure the output gear and input gear are beginning to mesh correctly Note If the two gears are not meshing it will not be possible to seat the top triple clamp correctly e Tap the top triple clamp with a plastic faced hammer to seat it completely Page 104 Triple Clamp Installation 7222274 e Slide the bottom triple clamp into the head tube Note Make sure bottom output gear is meshing with the input gear before fully seating the bottom triple clamp 1 ESI G TTTT ALL CBE d E Once gears are meshing correctly tap triple clamp with soft faced mallet to fully seat e Slide top triple clamp into head tube aligning preload bars Page 105 e Spin the left side sprocket driveshaft to align the bottom center I sprocket located inside the cavity with the steerer driveshaft Once turning the sprocket driveshaft also turns the top output gear everything is aligned correctly Spin drive shaft Uu Y N e Ensure the top output gear is meshing with the back input gear and tap top tri
6. 104 md HE bx Aih a w SE 2 INE 30 dd o E i 2 e i x 24 20 T 68 I i E 190 E i e 0 i amy 132 i CF 10 i 14 0 86 0 898 0 90 0 92 0 94 0 96 098 1 00 1 02 1 04 1 06 CORRECTION FACTOR REN NEEDLE POSITION AIR SCREW OPENING CORRECTION FACTOR 1 06 or HIGHER 1 06 1 02 1 02 0 98 0 98 0 94 0 94 pr LOWER NEEDLE LOWER CLIP 1 SAME SAME RAISE CLIP POSITION POSITION 1 POSITION AIR SCREW TIGHTEN 1 TURN 1 2 LOOSEN LOCGGEN OPENING TURN 1 2 TURN 1 TURIN Page 34 JT Storage STORAGE For extended storage of the motorcycle you must do the following Clean the motorcycle thoroughly Start the engine for about 5 minutes to warm up the transmission oil and then drain it refer to the transmission section Fill with new transmission oil Empty the fuel tank gasoline will deteriorate if left too long Disconnect the battery Lubricate the drive chain and all cables Cover all unpainted metal surfaces with a coat of oil to prevent rust do not apply oil to the brakes and rubber parts Cover the exhaust pipe with a plastic bag to prevent corrosion Place the motorcycle in such a position so that the wheels do not touch the ground if this is not possible place cardboards under the wheels Cover the motorcycle to protect it from dust an
7. Page 44 JR eee Gore Pefeccucies AWD Clutch Test e Place the bike on stand and make sure that the front wheel is not touching the ground e Shift the bike into gear e Turn the AWD switch to the on position and check to make sure the AWD is engaged e Grab the front wheel with two hands and try to spin it back wards The front wheel should spin backwards but require a large amount of effort to do so If the wheel will not break free the clutch is set too high If the wheel turns backwards very easily the clutch is set too low e If the clutch needs be adjusted pull the gas tank off the bike Loosen the set screw on the clutch locknut e Turn the locknut in or out a 1 2 turn at a time until the front wheel moves backward with the correct amount of force To keep driveshaft from spinning apply front brake e Make sure the set screw is positioned over a flat in the clutch hub and tighten the set screw down and reinstall the tank Page 45 27A 2 UNT Front Wheel Sprag Test Note Before performing this test make sure the AWD Clutch is set correctly e Place the bike on a stand and make sure that the wheels are not touching the ground e Turn the AWD switch to the on position and check to make sure the AWD is engaged Center the handlebars e Hold down the front and rear brakes e Turn handlebars to the left and back to center There should be steering res
8. Page 51 CHIS TINT AWD Engagement Installation Grease engagement retaining washer Insert washer into the back of the gearbox using a pick so it sits flush against the input gear retaining ring Insert the small fitting from the engagement cable through the center hole in the back of the gearbox and feed it through until it sticks out the front of the sidebar Page 52 Eee Se AWD Engagement Installation Grease the engagement spring and spline Feed the engagement cable through the spring and spline Insert the cable fitting onto the end of the cable and seat the fit ting into the engagement spline bearing Page 53 AWD Engagement Installation e Seatthe cable housing into the back of the gearbox e Slide the other end of the cable into the engagement switch e Line up the engagement spline with the input gear inside the gear box and push the spline into the gear Page 54 JR ieee Gore Pefeccucies AWD Engagement Installation Gums e Position the switch so the lever is positioned towards the rider and slide the housing into the end of the switch Note If there is not enough slack to seat the cable make sure the engagement spline is pushed all the way into the gearbox and the bar rel adjuster on the cable is turned in completely nsert the secondary sprocket into the sidebar and make sure it is fully seat
9. Liquid recommended Permanent type of antifreeze distilled water and ethylene glycol plus corrosion inhibitors for aluminum engines and radiators NOTE Initially at the factory a permanent type of antifreeze is installed in the cooling system It is colored green it contains a 5096 solution of ethylene glycol and has a freezing point of 35 C Page 14 Shee oo Cooling System 2673 TINI Coolant recommended Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level is low the engine overheats and may suffer severe damage Check the coolant level each day before riding the motorcycle Add liquid recommended if the level is low see next page WARNING To prevent severe scalding do not remove the radiator cap or try to change liquid when the engine is still hot Wait until it cools Coolant level Place the motorcycle in riding position Turn the radiator cap counterclockwise and wait a few sec onds until vapors inside are released Then push and turn it further in the same direction and remove the cap NOTE Check the level when the engine is cold Check the coolant level The coolant level should be just at a level below the cap rubber seal If the coolant level is low add the correct amount of coolant through the filler opening Total quantity Mix antifreeze and distilled water 1 1 distilled water 50 antifreeze 50 Cap
10. Page 122
11. 0 can be corrected tightening or loosening some spokes with the spoke adjusting wrench B If the wheel rim is curved or bent it must be re placed A Spoke adjusting wrench NOTE A welded area on the rim may indicate excessive run out Disregard this when measuring rim run out LLILLLALLLLALUL LLLIILLLA ULULALLLILLLILIL LLALILLLLeLELEILUILUIIII ILL L Page 27 Gums Washing Bike 1 Preparation for washing Before washing the motorcycle precautions must be taken to prevent water from entering the following parts of the motorcycle Exhaust Cover it with a plastic bag tightened with rubber bands Clutch and brake levers hand grips and engine stop button Cover these parts with plastic bags Air cleaner intake Cover the opening with tape or with a rag 2 Where to be careful Avoid spraying water with any great force near the following areas Brake calipers and brake pump piston Ignition coil or into the spark plug cap Front and rear wheel hubs Steering bearings Rear suspension system Swingarm bearings CAUTION To avoid excessive ageing of the plastic parts and other washable pieces of the motorcycle it is suggested that these items must be washed carefully If the washer applies water at high pressure and or tempera ture take the precaution of maintaining the washer outlet gun at a distance of 30 centimeters minimum this will ensure the correct gloss of the plastics and ma
12. Note that the hub inserts will only rotate in one direction in the hub Thread axle bolt back into the end of axle and tighten to 12ft Ib Tighten axle pinch bolts to 12 ft lb Note If wheel does not spin freely axle bolt is too tight Reinstall front brake caliper Guns 77 7 Page 57 Gury TINI Front Wheel Service Axle Seal Hub Insert Insert Bearing CS 20375 HS 03 CB 6808 Hub Insert O ring Axle Bearing CO 119 CB 6904 Sprag Bearing CB 6905 CB 2776 Orientation is different for each side of hub see following pages Page 58 Se Front Wheel Service 7 Warning Before taking hub make sure that you have a full set of spare sprag bearings Sprag bearings are likely to be damaged during the disassembly process and new ones may be required e Using a soft punch remove the hub inserts from either side of the hub Page 59 7272527 Front Wheel Service e Pry the insert seals out of the inserts using a flat bladed screwdriver e Remove the hub insert o rings with a pick e Punch the axle bearings out of the inserts using the ac cess holes in the back of the inserts Page 60 oo Front Wheel Service Gury ZANI e Using a bearing punch install the axle bearings into the hub inserts e Press the axle seals into the hub inserts e Install the hub insert o rings
13. Go to a specialized workshop Shock absorber set too hard Excessive front fork oil Pour excess oil until reaching the correct oil level Front fork oil viscosity too high Drain fork oil and fill with correct fork oil viscosity Bent front fork Replace the front fork Go to a specialized workshop Tire air pressure set too high Check tire air pressure Incorrect rear shock absorber adjustment Adjust rear shock absorber Shock absorber set too soft Insufficient front fork oil Fill with fork oil until reaching the correct oil level Front fork oil viscosity too low Drain fork oil and fill with correct fork oil viscosity Bent front fork Replace the front fork Go to a specialized workshop Tire air pressure too low Check tire air pressure Incorrect rear shock absorber adjustment Adjust the rear shock absorber Abnormal motorcycle noises Incorrect drive chain adjustment Adjust the drive chain Worn drive chain Replace the drive chain rear sprocket and the secondary transmission pinion Worn rear sprocket teeth Replace the rear sprocket Insufficient drive chain lubrication Lubricate with appropriate chain oil Incorrect rear wheel alignment Align the rear wheel Go to a specialized workshop Insufficient front fork oil Add front fork oil until reaching the correct level Weak or broken front fork spring Replace the front fork spring Worn disc brake Ch
14. HT 06 Triple Clamp Bearing cG 04 CB 6804 7 wo gt To Output Gears Triple Clamp Chain 1 1 Sprocket Snap Ring Bottom Center Sprocket HT 05 FD 03 HT 0B Triple Clamp Bearing Cover Seal CB 6804 CS 075 Shaft Sprocket R FD 01 Triple Clamp Bearing 6804 Page 86 72725270 A eee Gore Pefeccucies Triple Clamp Service Note To service the triple clamp chains sprockets and bearings it is recommended that you leave the bottom triple clamp attached to the bike This will make it easier to pull the cover off For servicing the steerer tube bearings or replacing the head tube gears the triple clamps will need to be removed For picture clarity the triple clamp was re moved from the bike Remove the forks and spline bearing assembly Remove the 4 cover bolts from the bottom of the triple clamp with a 6mm Allen wrench Carefully pull on the shaft sprockets and ease the cover down from the bottom triple clamp The Left shaft will pull down with the cover The right shaft will stay in place and the cover will slide down over it Page 87 Cours 7 Triple Clamp Service e Remove right shaft sprocket and the chain inside of triple clamp cavity e Pull center bottom sprocket off of the cover and remove the chain Pull both shaft sprockets out of cover Be careful of seal as it slides over snap ring grooves as it ca
15. Page 97 GHIS TINI AP ites Gove Moborcyctes Warning Replacing the taper bearing is a job for your dealer Do not attempt to do this on your own Loosen steerer set screw in triple clamp and remove the steerer tube Press taper bearing and seal off of steerer tube with an arbor or hydraulic press Note A new seal will be needed as it will be damaged when the taper bearing is pressed off the steerer Press new taper bearing and seal onto steerer tube Insert steerer tube into top triple clamp and tighten set screw to secure steerer tube Triple Clamp Service Page 98 IIRI G ZZ Triple Clamp Service e Slide the steerer tube bearing back onto the output gear e Press gear and bearing into top steerer tube 99 Cours 7 Main Drive Shaft Removal e Remove triples clamps as previously described e Remove the head tube cover from the front of the head tube e Slide the input head tube gear and main driveshaft out the head tube access port The driveshaft will need to slide out of the clutch hub e input bearings do not come out with the input gear and need to be replaced gently tap them out with a punch Make sure they do not get cocked as they are being tapped out Warning If any of the head tube gears are damaged and need to be replaced all of the head tube gears must be replaced together as a Set 100
16. cage B out of the air filter A Clean the filter using a soft bristle brush in a bath of filter cleaning fluid Squeeze it dry with a clean towel Do not wring the element or blow it dry since it can be damaged Inspect the filter for damage such as tears hardening or shrink age If damaged replace it or it will allow dirt into the carburetor Apply grease to all connections and screws in the air filter and intake ports Install the filter in the cage and pack the filter lip with grease A to ensure good sealing and prevent dirt entrance Install the air filter in the motorcycle and make sure it is correctly secured Page 20 Wee Core Motorcycles Throttle Carburetor Gurs TING THROTLE CABLE Check that the throttle grip turns smoothly Check that the throttle grip has 2 3 mm of free play If the free play is incorrect loosen the locknut on the upper end of the throttle cable and turn the adjuster to obtain the correct amount of free play Tighten the locknut again If the free play cannot be set by adjusting the cable re move the cable protector in the throttle body Make the necessary free play adjustments with the tensor at the ss end of the cable tighten the locknut and reinstallthe C Throttle grip protector CARBURETOR Idle speed adjustment Is carried out using the air screw A and idle screw B First turn in the air screw until it is l
17. contaminated during the service Loosen the housing cap from the linear bearing housing and un screw it completely e Slide the housing down off the sprocket driveshaft e Looser top and bottom triple clamp bolts Be sure to hold fork while loosening bolts so it does not fall out Slide fork out of triple clamps and remove Warning When fork is off the bike do not apply side pressure to spline Shafts as it is possible to bend them if enough force is applied Page 65 Gauris SP Seren ra Fork Installation e Carefully slide forks into triple clamps e Set desired fork height and torque triple clamp bolts to the follow Ing 15 ft los Lower 17ft los Upper e Slide the linear bearing housing over the drive sprocket shaft Tighten the housing cap down with 2 adjustable wrenches Page 66 Dropout Service Gurs 77 7 deei Drive Drive Carrier Bolts Drive Carrier Extemal Cover O ri CH M620H FG 03 cen ahi he i Drive Carrier Axle O Ring Drive Carrier O Ring Internal Cover O Ring 0 019 030 O 042 Cover Bolts Dropout Cover Cover Bearing Bevel Gear Right Shown Drive Insert Drive Insert Bearing CH M612H FP 10 CB 6808 Right FG 02 incl pinion FG 04 6906 Left FG 01 incl pinion Pinion Gear Right Shown Lower Pinion Bearing Top Pinion Bearing Pinion Shaf
18. not twisted in triple clamps Lube front spline shafts with grease If this does not help pull down dust boot and check spline shaft for damage Disassemble spline and check bearing for corrosion and damage Make sure front wheel axle bolt is not too tight and is not binding forks Front wheel is not pulling Make sure engagement switch is turned on and the en gagement spline is functioning properly Check clutch setting for proper torque using wheel check method Drive system is pulling to one side Perform Sprag bearing test as described in manual Check sprag bearings in hub to make sure neither side is slipping Make sure that drive shafts are free to spin smoothly Occasionally mud or other debris can hinder one drive shaft from spinning at the proper rate Clutch Basket has notches in it This is normal As long as the notches don t exceed 3 16 Replacement is not needed Cannot disengage system With bike in neutral rock it back and forth and use the lever to disengage the system Engagement cable has too much slack in it Use barrel adjuster to take slack out of cable Page 119 Gums Warranty CHRISTINI AWD LIMITED WARRANTY This LIMITED WARRANTY 15 a complete and exclusive statement of CHRISTINI s obligations to the ORIGINAL OWNER of a CHRISTINI AWD Motorcycle Kit CHRISTINI Technologies warrants ONLY The All Wheel Drive Components of the CHRISTINI AWD 450E Competition use Motorcycl
19. shown below must go in the disk side dropout Note the difference in the Spiral direction on each gear set Right Bevel Gear Set Left Bevel Gear Set FG 02 FG 01 Note Be sure dropout is clean before proceeding e insert top pinion bearings and seal into driveshaft bore at top of dropout using bearing driver Note be careful not to damage seal or nick chrome fork plating with hammer Use plastic faced hammer e Apply light grease to pinion seal e Insert bottom pinion bearing onto pinion gear WARNING black seal must be facing down towards gear teeth If bearing is not inserted correctly severe damage can occur Black seal facing down toward gear teeth e Slide bearing and pinion gear into bore Make sure bearing is fully seated Page 73 fd Dropout Service e f needed use hammer and soft punch to tap end of pinion gear to seat bearing e nsert axle o ring into dropout e nstall drive insert bearing and wedge small flat blade screwdriver in between pinion gear and inner bearing to keep pinion gear in place when the splined shaft is installed e Slide splined driveshaft onto pinion gear making sure to line up the set screw holes Lightly tap end of spline shaft with plastic faced hammer to slide it down onto pinion gear and line up set screw holes Page 74 A Meee Gore Pefeccucies Dropout Service Gurs ZAINI e Insert set screw with light dab of blue Loc
20. sleeve available from Christini Press new taper bearing and seal onto steerer tube e Coat mating surface of triple clamp and steerer tube with green Loctite Press steer tube into triple clamp Triple Clamp Service Page 92 Gore O Or Oy Eies Triple Clamp Service Gurs 27 7 Press steerer bearing into the top of the steerer tube Press steerer bearing into bottom of the steerer tube e install bottom output gear and tap sprocket back onto bottom of gear using a plastic faced hammer Sprocket is fully seated when the end of it is flush with the snap ring groove Replace snap ring Page 93 7272527 Gore Pefeccucies Install cover seals e Press cover bearings back into outer bores of cover Insert Teflon chain guides into cover if they were removed Note the wear pattern and be sure that the guides are placed on the same side as they were removed from Triple Clamp Service Page 94 JR eee Gore Pefeccucies Triple Clamp Service Gurs 27 7 nsert triple clamp bearing onto top of the right shaft sprocket It will be a slip fit e Wrap chain around top center sprocket and right shaft sprocket e insert shaft sprocket and bearing into bearing bore on triple clamp It will be a slip fit e nsert triple clamp bearing onto bottom center sprocket e Push left shaft sprocket through cover e Wrap the chain around the left shaft spr
21. to scratch inner bore e Remove top pinion bearings from upper bore by tapping them lightly tapping from inside the dropout with non marring punch e Pry axle o ring from dropout using small pick Page 69 7272527 e Remove 4 drive carrier bolts with 4mm Allen wrench The inner hardened bevel gear can be clamped with soft jaws in a vise or the drive carrier can be held with square bar stock to keep the assembly from moving as you unscrew the bolts e lightly tap the outside face of drive carrier with plastic hammer to break it free from gear and drive insert e Remove axle o ring from drive carrier with pick e Remove cover o rings and drive carrier o ring Dropout Service Page 70 A eee Gore Pefeccucies Dropout Service Guns ZAINI e Remove cover bearing with bearing removal punch Note o ring lip near inner race of bearing is easily damaged Only apply pressure to inner race of bearing e Remove drive insert from gear with hammer and bearing removal tool e Before reassembly of dropouts all parts must be cleaned and inspected individually for damage or wear Parts can be cleaned with solution no different then OEM fork Be sure to blow dry dropouts and parts prior to reassembly if cleaning solution is used e Pinion and bevel gear must be replaced as a set e f bearings are seized or hard to turn by hand they must be replaced or cleaned and repacked with
22. 242 e Red Loctite 262 e Green Loctite 609 Page 41 Guaisrin AWD Detail Illustration Headtube Gearbox Preload Bars i Top Triple Clamp Bottom Triple Clamps ih 2 if Clutch Assembly Linear Bearing Housing Main Gearbox behind Sidebar Spline Shaft Bellows Sidebar Cover AWD Hub Dropout Page 42 Warnings Do not adjust the choke while the bike is moving Do not over tighten the front axle as it can damage the inside Axle Clamp Bear Ings e Do not engage the AWD system while at high speeds Disengagement of the AWD system can occur at any speed Becautious when power washing bike especially around front drive hubs and AWD seals Spraying high pressure water into these areas can damage seals and bearings Page 43 fg EHIS TINI VEMETTITV poutine Maintenance Pre ride check list e Check secondary AWD chain tension Lube secondary AWD chain e Check clutch setting see AWD Clutch Test section Check front wheel for proper function see Front Wheel Sprag Test section e Check front wheel rim lock nut torque As Needed e Replace bearings if excessive noise or friction develops e Lubricate spline shafts through grease port with supplied grease gun and Shell grease e Replace worn or damaged seals and boots AVOID e Pressure washing the dropouts head tube area side bar and main gearbox
23. GCLONQAOIILUS bLL E 1 Page 77 7272527 Fork Spline Bearing Service Unscrew grease port from linear bearing housing e Remove set screw from housing e Slide housing sleeve off of housing e Remove linear bearing retaining ring Page 78 Fork Spline Bearing Service e Slide linear bearing out of housing and inspect If ball bearings inside of the case are corroded or worn replace linear bearing Warning Do not use hammer and punch to remove bearing as it may damage the bearing If bearing will not slide out apply pressure to the bearing lip with an 8mm nut driver to remove it e If shaft seal is damaged or worn pry it out and replace it with a new seal e Remove felt from housing sleeve and inspect If needed replace felt Note Dirt will pack up in felt The felt can be cleaned and reused Gurs F em Gore O Or Oy Eies Page 79 Cours 7 Fork Spline Bearing Service e Saturate felt with gear oil and place it back in housing sleeve e Reassembly of linear bearing housing is the reverse of disassembly Warning Use red Loctite on grease fitting or it may back out and cause the housing sleeve to slide down while riding Warning When sliding linear bearing housing back unto driveshaft carefully align the ball bearings with the grooves in the driveshaft Do not force the housing onto the driveshaft Groove should be approximately 90 degrees to the grease fitt
24. IGHTS OF OTHER PEOPLE Motorcycle riding is a wonderful sport and we hope you will enjoy it to the fullest Page 2 Table of contents srz General Bike Service Specifications 5 Location of Components 6 Fuel 7 Basic Operating Instructions 9 Maintenance Schedule 12 Ignition 13 Cooling System 14 Spark Plug 17 Transmission Oil 18 Air Filter 20 Throttle Cable 21 Carburetor 21 Clutch 22 Exhaust System 22 Primary Chain 23 Handlebar 25 Brakes 25 Wheels 27 Washing Bike 28 Nut and Bolt Tightening 29 Torque Values 30 Lubrication 31 Tune Up 32 Storage 35 Troubleshooting 36 Wiring Diagram 39 Page 3 CHRIS nee Table of Contents AWD Service Required tools 41 AWD detailed illustration 42 Routine maintenance schedule 44 AWD clutch test 45 AWD sprag test 46 AWD chain removal 47 AWD engagement switch 51 Front wheel removal 56 Front wheel service 58 Fork removal and installation 65 Dropout service 67 Fork spline bearing service 76 Boot Replacement 81 Triple clamp removal 83 Triple clamp service 85 drive shaft removal 100 Head tube bearing service 101 Main drive shaft installation 103 Triple Clamp Installation 104 Gearbox removal 108 Gearbox service 109 AWD clutch removal 114 AWD clutch Service 115 Troubleshooting 119 Warranty 120 Page 4 Specifications ENGINE 250 cc Engine Bore and stroke Displacement 300 cc Engine Bore and stroke Displacement Carburettor diameter of diff
25. Page 61 4 24 23 EINST Front Wheel Service Warning Sprag bearings must be installed in the correct orientation in the hub for the AWD sys tem to work properly If the sprag bearings are not installed correctly the AWD system can be damaged e Press CB 6905 bearing into the Hub Inner Race e sure that the bearing is seated completely e Insert sprag bearing into hub shell correct direction will be determined in next steps Lightly grease inside of sprag bearing with Shell grease Page 62 Service e Test fit hub insert into hub twisting as it is in serted Freewheels direction e Spin the hub insert and check to make sure it is free wheeling in the correct direction If it is not remove the hub insert and flip the sprag bearing around Recheck to verify that hub insert freewheels in the correct direc tion before moving on to next step Side Page 63 Re e Remove hub insert and press insert bearings into hub e Grease hub insert seal and slip hub insert into hub It may be required to tap hub insert into hub with a soft faced hammer e Grease axle seal e Repeat procedure for the other side of hub Page 64 FR Meee Gore Pefeccucies Fork Removal Warning If removing forks for rebuild service the fork dropouts must be disassembled so that the drive system parts are not
26. ace Make sure bearing is fully seated at the back of the gearbox nsert output gear and bearings into gearbox Make sure gears mesh correctly as you are pushing the output gear into place e Reinstall output snap ring Grease input and output gears using Shell Lithium grease e nstall output seals into gearbox making sure seals are installed markings facing out e Grease of seals and push clutch basket back onto output gear e Clean any excess grease off of clutch basket Page 113 CHRIS TANG Gore Pefeccucies e Remove chain cover and AWD chain see Cover chain removal section e Slide clutch snap ring up main driveshaft e Slide clutch up main driveshaft away from clutch basket Remove 4 shoulder connect gearbox from sidebar e Move gearbox out of the way e Slide clutch off main driveshaft Clutch Removal Page 114 Clutch Service Friction Pad Hub Plate Driven Spring Washers Locknut Set Screw CS 05 CS 04 CHW M22SW CH M22N CH M44S5 To Gearbox Basket Plate Drive Clutch Basket Clutch Hub 5 03 CS 02 CS 01 Page 115 7272527 Clutch Service oosen locknut set screw so it will not interfere with the hub threads Warning Failure to loosen set screw will damage threads in clutch hub Loosen locknut while clutch assembly is still on main driveshaft To keep driveshaft from sp
27. acity 1 11 250 300 Coolant Replacement Coolant should be changed periodically to ensure long engine life Wait for the engine to cool completely Place the motorcycle in riding position Remove the radiator cap Place a container under the coolant drain screw and drain the coolant from the radiator and engine by removing the drain screw B at the bottom of the water pump cover A Wash off immediately any coolant spilled on the chassis engine or wheels Page 15 7 WARNING If coolant gets on the tires will make them very slippery and can cause an accident Visually inspect the old coolant If whitish spots are observed in the liquid is a clear indication that the aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts of the system are rusting In both cases flush the cooling system Check the cooling system for damage leaks or missing gaskets in the cooling system Install the water pump cover drain screw with the specified torque values shown in the table Always re place the gasket with a new one Drain plug tightening torque refer to torque table Water pump screw 9 Nm Fill the radiator up to the edge of the cap with coolant and install the radiator cap Inspect the cooling system for leaks Start and warm up the engine then stop the engine Check the coolant level after the engine cools down Add coolant up to th
28. ange the disc brake Pad installed incorrectly or surface glazed Reinstall or replace pad Damaged cylinder Replace the damaged cylinder Improperly tightened brackets nuts bolts Verify and adjust to the correct torque values Handlebar vibration Worn tire and worn swingarm or its Replace worn parts with new ones needle bearings Wheel rim off centre Centre rim Incorrect wheel alignment Verify wheel spokes tension Readjust if necessary Page 37 Troubleshooting MALFUNCTION POSSIBLE CAUSE REMEDY Handlebar vibration Excessive steering axles tolerances Tighten steering bracket and steering stem locknut to the correct torque values Loose handlebar bracket and loose Tighten steering bracket and steering stem locknut to the handlebar stem locknut correct torque values Motorcycle pull to one side Bent chassis Replace the chassis Go to a specialized workshop Incorrect steering adjustment Adjust the steering Go to a specialized workshop Bent steering stem Replace the steering stem Go to a specialized workshop Bent front fork Replace the front fork Incorrect wheel alignment Align the wheels Brakes do not operate correctly Wom discs Replace the discs Leaking brake fluid Verify the brake circuits Replace the damaged or broken parts Deteriorated brake fluid Drain the brake fluid and fill with the new fluid recommended by the manufactur
29. ansmission oil deteriorated or contami nated can accelerate wear and tear and cause transmission Oil level inspection Wait a few minutes if the motorcycle has been operating Check the oil level through the inspection window in the lower right hand side of the engine A Oil level must be kept between the maximum and minimum marks If the lever is too high you have to remove the excess oil through the drain plug B If the level is low add the necessary quantity of oil by opening the plug C Use the same type and oil manufacturer used currently with the engine Transmission Oil Viscosity SAE 10W30 Capacity 900 cc EC250 300 Page 18 Transmission Oil TING Oil change NOTE The engine must be completely and then warm up the engine again for a few minutes to normal oper ating temperature to register the correct engine oil temperature and to obtain an accurate oil level meas urement The transmission oil should be changed periodically to ensure long engine life Warm up the engine for 5 minutes so any oil sediment will float Stop the engine and place an oil pan under the engine Remove the drain screw B and place the motorcycle in riding position to allow the oil to drain out Clean the drain screw magnet of any iron particles Tighten the oil drain screw with its O ring to 20 Nm Remove the oil filler opening plug C and pour 900 cc of new tra
30. apply to you EXCLUSIONS The above warranty or any implied warranty does not cover normal WEAR AND TEAR and all warranties are void if the motorcycle is used for other than normal activities including but not limited to the failure to follow the directions for as sembly the instructions warnings and advice found in the owner s manual or using the motorcycle for commercial activities or in competitive events including off road racing motocross racing stunt riding ramp jumping or similar activities and training for such activities or events This warranty does not cover any damage failure or loss caused by accident misuse abuse neglect improper assembly improper maintenance or use of parts or devices not consistent with the original intent for the product sold CHRISTINI TECHNOLOGIES MAKES NO OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED ALL IM PLIED WARRANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THAT OF THE EXPRESS WARRANTIES STATED ABOVE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you The warranty gives you specific legal rights and you may also have other rights which vary from state to state WHAT YOU SHOULD DO Always wear a helmet while riding Please remember to always ride safely and in control and within your capabili ties and limitations Even under normal riding motorcy
31. art remove any rusty spots with rust remover and wipe off any grease oil or dirt General lubrication Clutch lever A Front brake lever B Rear brake pedal C Rear brake bearing D Gearshift pedal E Use an aerosol with a tube for pressure lubrication and apply grease in side the gas cable A Drive Chain Lubrication Lubricate the drive chain after driving on wet terrain or when the chain looks dry A high viscosity oil is preferred rather than a lower viscosity because it will stick to the chain longer and lubricate the chain better Apply oil to the sides of the chain rollers for better oil penetration Wipe off any excess Page 31 Gums 1 CARBURETOR TUNE UP Mixture First step is to establish a basic knowledge on the identification and operation of carburetor components Change settings in accordance with the temperature Condition Change setting Dyar Lean Low altitude Standard standard High altitude Rich Lean NOTE The main jet should be increased or decreased 1 to 5 sizes and tested until the engine gives maximum power Main jet lt has a great overall effect The number stamped on lower part of the main jet indicates the size of the hole metering fuel A greater number corresponds to a bigger hole which supplies more fuel A Main jet WARNING Gasoline is extremely flammable and can be explosive under certain conditio
32. cles can be dangerous due to changing and variable riding conditions including known and unknown hazards WARRANTY CLAIM PROCEDURE e Jfa partis determined to be defective return said part to your dealership for verification of a defect Thedealer will verify whether the part is defective If the part is determined to be defective by the dealer the part will be replaced and the amount of the replacement part will be charged to the customers credit card until it is returned to Christini for verification Alternatively the dealer may opt to send the part in for verification before replacement Upon receipt of the defective part parts Christini will determine if the part is eligible for warranty compensation e Ifthe part is found to be defective the customer will be credited the full amount of the replacement part e This Warranty applies only to the Original Owner first retail purchaser from motorcycle dealer distributor or direct from Christini For Warranty service bring your AWD motorcycle along with your purchase receipt or other proof of the date of purchase to the dealer where you purchased the AWD Motorcycle Freight costs and any labor charges for part change overs assembly repair or disassembly are the responsibility of the Original Owner and this Warranty offers no cash refunds CHRISTINI AWD Motorcycles 421 N 7 Street Philadelphia PA 19123 Phone 215 351 9895 1 121 Guaisrin Warranty
33. clip to the top will provide a lean mixture Change the clip position one step at a Right section time The straight area of the needle affects throttle valve response in the small openings range Test runs with the motorcycle Warm up the engine with the carburetor at the standard setting and inspect the operating conditions of the spark plug Test ride the motorcycle with the throttle opened Symptoms of improper settings If your motorcycle exhibits one of the following symptoms the changes must be adjusted Before attempting any changes make sure that everything else is in good operating condition Check the condition of the spark plug make sure the ignition timing is correct service the air cleaner ele ment decarbonize the exhaust tube If your machine has run properly up to this point it is possible that the problem is elsewhere changing the carburetor settings in such a case would probably be a waste of time Spark plug condition insulator is dry amp lighttan Too lean White color insulator Replace the main jet to one __ Step larger Too rich Insulator is wet amp black color Replace the main jet to one step smaller Set the carburetor so that the engine delivers satisfactory power with the throttle valve opened If the air fuel mixture is too lean the engine tends to overheat and be seized On the other hand if it is too rich the spark plug easily gets wet and causes misfir
34. d dirt When starting off after an extended storage Remove the plastic bag from the exhaust pipe Tighten the spark plug Fill the fuel tank Check all points marked in the section Daily Inspection Before Riding General lubrication Connect the battery Page 35 CHIS TINT TROUBLESHOOTING NOTE Troubleshooting This is not an exhaustive list of malfunctions it only shows the most common problems MALFUNCTION POSSIBLE CAUSE Seized crankshaft Seized cylinder piston jornal bearing Seized transmission assembly Motorcycle inactive too lang 1 Engine does not crank Wet or fouled spark plug Flaoded engine Incorrect air fuel mixture Exhaust valve stuck open a Engine cranks but then stops 2 Incorrect air supply Na fuel 3 Engine overheating Insufficient cooing liquid in the circuit Radiatar is dirty or partially restricted 4 The engine operates irregularly Spark plug dirty or misadjusted Poor caniaoct with the spark plug nr cable loose in cap rator damaged Water in fuel The engine operates irregularly Engine lacks power or poor acceleration Fuel supply defective Dirty air cleaner Leaking nr deteriorated exhaust system Dirty carburetor jets Worn or damaged crankshaft bearings Clutch slips fgnibon problemi Overheating Abnormal engine noise Detonations from the exhaust pipe Carbon
35. djust as follows Adjustment Remove the magnetic flywheel cover Make sure that the mark on the stator plate is aligned with the mark on the crankcase f the marks are not aligned loosen the magnetic inertia wheel screws and turn it Tighten the screws securely Install the magnetic flywheel cover NOTE Engine tune up can be adjusted to match the rider s preferences and skills Remove the magnetic flywheel cover Loosen the stator screws Adjust the engine tune up by changing the position of the stator within prudent limits NOTE For the best engine performance it is very important to adjust the engine tune up within the set of limits described Tighten the stator screws Install the magnetic flywheel cover Test ride the motorcycle and readjust the engine tune up if necessary Page 13 7272527 Cooling System Radiator Hoses Check the radiator hoses for cuts or deterioration and the connections for looseness and leaks Radiator Check the radiator fins for obstructions insects or mud Remove any obstructions with a stream of low wa ter pressure CAUTION If high water pressure is used the radiator fins could be damaged and impair the radiator effectiveness Do not obstruct or deflect airflow through the radiator by installin unauthorized accessories Any interfer ence with the radiator airflow can lead to engine overheating and damage Coolant information To protect the cooling syste
36. e and all other original CHRISTINI AWD components including the fork machined parts front hub gear box and the components of the CHRISTINI All Wheel Drive AWD system including shafts and drive gears are warranted to be free of defects in ma terial and workmanship for a period of ONE 1 year from the date of Purchase for the Original Owner OTHER ORIGINAL COMPONENTS Any components not produced by CHRISTINI including the front suspension fork internal mechanisms bear their original manufacturer s own warranty and CHRISTINI reserves the right to direct any warranty request relating to those Other Original Components to said manufacturer s customer service department THESE WARRANTIES DO NOT COVER Failures or required services which are not due to a defect in material or factory workmanship e Replacement of expendable maintenance items including but not limited to Bearings including linear bearing e Seals and O Rings AWD Clutch Basket Plates and Friction Plates e Shaft Bellows AWD Engagement cable and housing Sprockets and Drive Chains Parts or accessories affected or damaged by Normal wear Finish including frame anodized machine parts and coatings on gears sprockets and driveshafts Improper maintenance including improper clutch settings of proper maintenance Improper installation e Deterioration from exposure to the elements Theunauthorized alteration of any part
37. e cap Page 16 VAN ieee foes CUE Spark Plug Gurs The standard spark plug is a shown in the table and should be tightened to 27 Nm Standard Spark Plug 250 300 cc Denso W24ESR U 0 7 0 8 OR The spark plug should be removed periodically to check its gap If the plug is oily or has carbon deposits clean it with a sandblaster After removing the abrasive particles the spark plug must be cleaned using a wire brush or a similar tool Measure the gap with a feeler gauge if incorrect adjust the gap by bending the side electrode If the spark plug electrodes are corroded or damaged or if insulator is cracked replace the plug NOTE Inspect every 30 hours and change every 60 hours To find out whether the right heat range plug is being used remove it and inspect the ceramic insulator around the center electrode If the ceramic is light brown the spark plug is correctly matched to engine temperature If the ceramic is white the spark plug should be replaced with the next colder plug If the ce ramic is black the spark plug should be replaced with the next hotter plug NOTE If the engine performance drops replace the spark plug first to recover its output Page 17 Transmission Oil Lire 7272527 For the transmission clutch to function properly maintain the transmission oil level at the optimum level and change it periodically A motorcycle with insufficient tr
38. e clutch lever is pulled the motorcycle can be started while in any gear 4 Start the motorcycle with kick start pedal C or push the start button D 5 Even after the engine starts keep the choke knob pulled up Stopping the engine 1 Shift the transmission into neutral 2 After racing the engine slightly close the throttle com pletely and depress the engine stop button E Page 9 7272527 Basic Operating Instructions Shifting Motorcycle The transmission is a 6 speed of the return shift type A return shift means that to go from first gear to third gear it must go first through the second gear that is to say that it upshifts gears one by one To engage first gear from neutral pull the clutch lever in and push down on the gearshift pedal A then release the gearshift pedal and gently release the clutch lever CAUTION When shifting gears press firmly on the gearshift pedal to ensure a positive shifting Careless incomplete shifts can cause the transmission to jump out of gear and cause engine damage Stopping Motorcycle For maximum deceleration close the throttle A and apply both front and rear brakes Disengage the clutch as the motorcycle comes to a stop Independent use of the front or rear brake may be advantageous under certain conditions Downshift progressively as speed is reduced to ensure good engine response when you want to accelerate Break In A break in period is
39. ed e Position the engagement lever towards the rider on and turn the barrel adjuster out until the engagement spline just starts to pull away from the stop snap ring Pushthe lever to the off position Make sure the secondary sprocket is fully seated Spin the secondary sprocket to verify that the spline has fully disengaged from the sprocket and it spins freely Page 55 Gams 77 7 JR ieee Gore Pefeccucies Note Due to AWD hub design front wheel removal and installation is aided by removing front caliper first e Remove front brake caliper note do not squeeze front brake lever while caliper is off Remove axle bolt from axle e Loosen axle pinch bolts on both sides of dropout e Slide axle through wheel and remove e Remove front wheel from dropouts Note The hub inserts will not fall out like the spacers on a normal hub They will also rotate independent of each other this is ok Front Wheel Removal Page 56 Front Wheel Installation Lightly grease dropout o rings and hub seals before installing the front wheel With brake caliper removed install front wheel into forks by care fully aligning right drive carrier on dropouts with hub inserts Once the right carriers are seated slide axle through to other end of hub Carefully align left carriers and slide axle completely through to the other side Note a flat blade screw may be needed to align hub insert with drive carrier
40. en unsealed for a long time Check for fluid leakage around the fittings Check for brake hose damage WARNING Do not mix different types of fluid Change the brake fluid in the reservoirs completely if the same type of brake fluid is not available Brake wear inspection If the thickness of either pad front and rear is less than 1 mm replace both pads as a set Pad replace ment should be carried out only by an authorized dealer Page 26 Wheels Gurs TINI WHEELS Tires Tire pressure affects traction and tire life Adjust the tire pressure to match road conditions and rider s preference but do not stray too far from the recommended pressure NOTE Tire pressure should be checked when the tires are cold before riding Road conditions When the road is wet muddy sandy or slippery reduce the tire pressure On gravel roads or hard terrain increase the tire pressure Spokes and wheel rims The spokes on both wheels must be tightened evenly and should not be allowed to have free play Unevenly tightened or loose spokes will cause wheel rim run out the other spokes will be stressed and might break Wheel rim run out Place a dial indicator at the rim side and spin the wheel by hand to measure the axial run out Place the dial indicator at the inner circumfer ence of the wheel and spin the wheel the differ ence between the highest and lowest quantities is the run out If the run out is not excessive it
41. er Broken pump piston Replace the pump piston Incorrect brake adjustment Adjust brakes Blown light bulbs Voltage regulator faulty Remove the seat and the fuel tank and check all connections check the voltage regulator and the fuses in the fuse box Lighting system does not Blown lighting relay fuse Remove the seat the fuse box cover and replace the operate fuse Page 38 Wiring Diagram En EB ius WIRING DIAGRAM Page 39 AWD Service AWD Service Section Page 40 ee fg Required Tools Guns ZINI The Tools You Will Need for Maintenance e Socket set metric e Pliers set Ball peen dead blow hammers Softtip metal punch brass aluminum e Screw driver set e AWD clutch wrench optional e Open ended wrenches metric e Allen key set metric e Snap ring pliers 45 or 90 degree e Bearing punch set Blind side bearing removal kit Motion Pro 08 0292 2 large adjustable wrenches Torque wrench 0 75 ft lbs e Split bearing puller Small pick or awe e Safety wire pliers e Safety wire 032 e Grease gun included with bike purchase customer must Supply grease below e Shell Albida Lithium grease do not substitute Spectro grease or equivalent Blue Loctite
42. es The proper mixture varies depending on at mospheric conditions Taking these conditions into consideration adjust the carburetor settings properly NOTE Keep in mind that the carburetor components that regulate fuel flow and the screw that control the flow of air must be tight Page 33 7272527 The standard competition measurements 250 are example UNLEADED Correction factors Throttle valve For altitude or temperature changes 1 Find the correction factor adjust the carburetor Main Jet Example 1000 meters altitude with an air temperature of 35 C The correction factor is 0 94 2 Using the correction factor select the correct slow jet and main jet Example For a correction factor of 0 94 multiply the jet size by that number Main jet 180 x 0 94 170 3 Find the correction factor on the Jet Needle Air Screw chart and change the jet needle clip position and air screw opening as indicated Jet needle clip setting from the 3rd groove to the 2nd groove Air screw opening 1 1 2 1 turn 2 1 2 turns out NOTE For the following recommendations to be accurate you must use the standard settings as a base line Also do not change any of the settings until you have determined what changes are necessary All specifications are based on the use of the fuel and oil specified ALTITUDE um d T lt re 40 wD i Ges fa gt
43. ged dented cracked or rusted replace it with a new one Replace the muffler fiber if the exhaust noise becomes too loud or if the engine per formance drops Muffler replacement Remove the retaining screws of the right side number posting cover Remove the retaining screws A of the muffler B and remove the muffler towards the rear Separate the silencer from the joint See arrow Replace the muffler and reinstall the assembly Changing the silencer packing Remove all three screws Remove the inside core of the muffler Replace the muffler fiber by wrapping it around the inner tube Reinstall the assembly A Screw B Silencer Page 22 Primary Chain 77 DRIVE CHAIN The drive chain must be checked adjusted and lubricated in accordance with the Maintenance Schedule If the chain is worn or adjusted incorrectly either too loose or too tight the chain could become loose or break Replace the chain if necessary WARNING A chain that breaks or becomes loose could snag on the engine or on the rear wheel severely damaging the motorcycle and causing it to go out of control Drive Chain Slack Inspection The space between the chain and the swingarm at the same height of the chain slider should be 30 50 mm Rotate the rear wheel to find the place where the chain is tighter Adjust the drive chain if it has too much or too little slack In addition to checking t
44. grease e Be sure to grease all o rings and gears during reassembly Page 71 7272527 Dropout Service e Install cover bearing into cover with bearing installation tools e Install internal and external cover O rings Note all O rings should be lightly coated with grease before being reassembled e Insert drive carrier o ring on drive carrier and insert drive carrier into cover and tap into place Note face of drive carrier should be flush with cover bearing and machined cover surface e Place drive insert on tooth side of bevel gear and line up all four threaded holes with clearance holes on gear e Set cover and drive carrier on top of bevel gear assembly with smooth side of gear facing the cover Line up 4 bolt holes and thread drive carrier bolts into drive insert Blue Loctite should be used on bolts Final tightening of bolts will require a square bar or soft jaws to keep gear from spinning Torque bolts to 8ft ft Ibs e Check that bevel gear spins freely on cover If it does not spin freely check to make sure all o rings and the cover bearing are properly seated If new o rings are used there may be more friction until o rings seat and break in e Insert axle o ring into drive carrier Page 72 72725270 JR ieee Gore Pefeccucies Dropout Service Warning Bevel gears are right and left hand specific and must be installed in the correct dropout or damage to the system can occur The Left Bevel Gear Set
45. he slack rotate the rear wheel to inspect for damaged roll ers loose pin and links unevenly or excessively worn teeth and damaged teeth INDEX LOCK NUT Drive Chain Slack Adjustment Loosen the rear axle nut A Turn the nuts on the chain adjusting tensors B until the drive chain has a gap of 30 50 mm between the chain and the swing arm To keep the chain and wheel aligned the left chain tensor should aligned with the right chain tensor ADJ USTING BOLT WARNING Misalignment of the wheel will result in abnormal wear may cause an unsafe riding condition NOTE Wheel alignment can also be checked using the string method Tighten the chain tensor nuts B Tighten rear axle nut to 98 Nm Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary Page 23 27727224 TING Primary Chain WARNING If the axle nut is not securely tightened an unsafe riding condition may result Drive chain chain guide chain slider and rear sprocket teeth When the chain is worn so much that it is more than 2 longer than when new it is no longer safe for use and should be replaced Whenever the chain is replaced inspect both the engine output pinion and rear sprocket teeth and replace them if necessary Worn sprocket teeth will cause a new chain to wear quickly NOTE When a part is worn replace it with a genuine part for maximum resistance and safet
46. he spring in the reverse selector mechanism mechanism Broken spring in the reverse selector Replace the spring in the reverse selector mechanism mechanism Broken gear drum Replace the gear drum Broken spring in the gear selector ratchet Replace the spring in the gear selector ratchet Jumps out of gear Shift fork worn at the gears Replace the shift fork Worn gear grooves Replace Go to a specialized workshop Worn gear dogs Replace Go to a specialized workshop Worn shift drum groove Replace Go to a specialized workshop Worn shift fork shaft Replace shaft Go to a specialized workshop Broken selector drum position spring Replace the spring Go to a specialized workshop Broken gears Go to a specialized workshop No clutch lever free play Go to a specialized workshop Worn clutch friction plate Replace the clutch friction plate Go to a specialized workshop Worn clutch center hub Replace the clutch center hub Broken or weak clutch spring Adjust or replace the clutch spring Unevenly worn clutch discs Replace the clutch discs Go to a specialized workshop The motorcycle is unstable Cable interferes with the handlebar turns Move or loosen the cable just a little Steering stem locknut too tight Loosen the steering stem locknut Damaged or worn steering bearings Replace the steering bearings Bent steering stem Replace the steering stem
47. hout spring Disc brake 260 mm 220 mm 1260 mm 2135 mm 610mm 940 mm 340 mm 1475 mm 9 5 7272527 Location of Components 1 Clutch lever 2 Stop Start 3 Fuel tank cap 4 Brake fluid reservoir 5 Front brake lever 6 Throttle 7 Clutch fluid reservoir 8 Choke trigger 9 Brake disc 10 Front brake caliper 11 Radiator 12 Shift pedal 13 Primary chain 14 Chain guard 15 Front suspension 16 Gasoline petcock 1 Gas tank 18 Carburetor behind AWD chain cover 19 Muffler behind panel 20 Seat 21 Rear shock 22 Rear brake caliper 23 Suspension linkage 24 Rear brake pedal 25 Kick start 26 Exhaust Page 6 Fuel Gums TING ee Sie The GAS GAS 2 cycle engines require mixture of gasoline and oil Use gasoline with an octane rating equal to or higher than that shown in the table OCTANE RATING METHOD MINIUM RATING Antiknock Index RON MON y2 Research Octane RON NOTE If knocking or pinging occurs try a different brand of gasoline or higher octane grade WARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Mixing oil inside the engine Oil must be mixed with gasoline to lubricate the piston cylinder crankshaft and connecti
48. ing Page 80 A eee Gore Pefeccucies Boot Replacement Guns TING Note To remove and replace the drive shaft boots it is not necessary to remove the forks The service can be done by removing the fork guards and following the instructions below Remove Fork Guard e Remove upper and lower boot clips with wire cutters e Pull up boot and loosen drive shaft set screw nsert screw drive in vent holes tap up on screwdriver e Slide shaft upwards Note Do not slide shaft down and remove from linear bearing Page 81 7272527 JR ieee Gore Pefeccucies Boot Replacement Remove old boot and slide new boot onto driveshaft e Add anew clip on the bottom of the shaft Insert driveshaft onto pinion gear and tighten set screw e Slide boot over bottom section of shaft and install set screw e Crimp the clamp around the boot and set screw e Pull top of boot over linear bearing housing and secure with low profile zip tie e Reinstall the fork guarda Page 82 A eee Gore Pefeccucies Triple Clamp Removal Note To service the triple clamp chains sprockets and bearings it is recommended that you leave the bottom triple clamp attached to the bike This will make it easier to pull the cover off For servicing the steerer tube bearings or replacing the head tube gears the triple clamps will need to be removed e Remove forks and front fender from triple clamp
49. inning apply front brake and put bike in gear e Remove clutch assembly from bike see Clutch Removal sec tion e Completely unscrew locknut Remove spring washers fiber pads and clutch plates and inspect for wear or damage Note If metal plates are not scored or warped they do not need to be replaced Simply replace fiber plates during standard rebuilt Page 116 72725270 A eee Gore Pefeccucies Clutch Service Reassemble clutch hub noting the order of the plates fibers and spring washers Be sure the spring washers are in the correct ori entation Apply anti seize compound to hub thread and thread locknut onto the hub by hand Note Use thread file to clean galled hub threads if needed Page 117 7272527 Clutch Installation Reinstall clutch on bike e Reinstall clutch basket and gearbox e Tighten locknut until it is approximately flush with the hub e Check clutch settings and adjust as necessary see AWD Clutch Test section e Adjust locknut so set screw hole lines up with the nearest flat sec tion on the hub and tighten set screw Warning Once set screw is tightened do try to turn locknut as this will damage the hub threads Page 118 fg AWD Troubleshooting 72725270 Problem Solution Front forks feel sticky Clean and lube fork seals Check to make sure forks are
50. intain adherence of the self adhesive labels that decorate the motorcycle 3 After washing Remove the plastic bags and clean the air cleaner intake Lubricate the points listed in the lubrication section Start the engine and let it run for 5 minutes Check the brakes before operating the motorcycle WARNING Never wax or lubricate the brake disc Loss of braking and an accident could result Clean the disc with trichloroethylene or acetone Page 28 em Gore O Or Oy Eies Nut and Bolt Tightening 27 7 Before each ride check the condition of the components below and make sure all bolts and nuts prop erly tightened 1 Front and rear wheel 2 Front fork 3 Handlebar 4 Clutch lever holder screw 5 Spark plug 6 Cylinder head bolt T Cylinder nuts 8 Swingarm shaft nut 9 Air box screw 10 Rear sprocket bolts 11 Chain adjuster nut 12 Chain guide bolts 13 Subframe bracket bolts 14 Gearshift pedal bolt 15 Engine holder bolts and nuts 16 Radiator bracket bolts 17 Front caliper bolts 18 Front axle nut 19 Spokes 20 Seat mounting bolts 21 Rear shock bolt 22 Subframe bolts 23 Brake lever bolt 24 Fork pinch bolts 25 Exhaust mounting bolts 26 Kick start bolt 2 Rear brake pedal bolt 28 Torque rod mounting bolt 29 Linkage mounting bolt 30 Rear axle bolt 29 E FAIRE TART Torque Values Torque Values Table Tighten all bolts and nut
51. isc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal ac tion So there are no parts that require adjustment on the brakes except brake lever free play and brake pedal position Front brake lever free pl A piay Adjust the front brake lever A to match your require ments To adjust loosen the nut B After adjustment L tighten it securely Then check that the brake response s 98 ET IS correct Rear brake pedal position When the brake pedal is in rest position there should be a free play of 10 mm Check the brake for good braking power and no brake drag A Brake pedal B 10 mm free play WARNING If the brake pedal feels spongy when it is applied there might be air trapped in the brake pump or the brake may be defective Since it is dangerous to operate the motorcycle under such conditions have the brake checked immediately Page 25 7272527 Brakes Brake fluid Inspect the brake fluid level and change it periodically The brake fluid should also be changed if it be comes contaminated with dirt or water Liquid recommended D O T 3 or D O T 4 Brake fluid level inspection The front A and rear B reservoirs must be kept more than half full with brake fluid If the brake fluid is insufficient add brake fluid CAUTION Do not spill brake fluid onto any painted surface Do not use fluid from a container that has been left open or that has be
52. istance from the AWD system when this is performed e Release brakes and center handlebars e Hold down front and rear brakes again and turn handlebars to the right and back to center There should be steering resistance from the AWD system e f no resistance is felt or there is only resistance in one direction check the front wheel to ensure the sprag bearings are not slip ping or damaged See Front Wheel Service section Page 46 Cover and Chain Removal 72725270 T L Chain Cover Bolts d P CH M610 Chain Tensioner Chain Tensioner Spring Block 08 06 05 05 Chain Tensioner Square Mut CH MB58S8W ie Chain Tensioner Chain Tensioner Shoulder Bolt Spring Washer CHS M820 ICH M158W Chain Cover 05 012 1 Page 47 x EAL LIM Lh Cover and Chain Removal Chain Cover Bearing External Engagement Engagement Spline Side Bar CB d Hub Snap Ring Hub Saal CSR 17B os Tom o0o00f 00 7 Chain ads Fral 25 24324 Enganaement Hub Sprocket Internal Engegrment Chain D 08 0515 1 8 05116 Hub Snap Ring Bearing CSR t 4B Cm 6905 Counter Shaft Adapler Bolts CH M612H o 5 Counter Shaft Drive Sprocket Counter Shaft Counter Shaft Snap Ring IDS 803 D5 0910 Adapter Sprocket CSR WSTTS 05 08 05 1073 051014 Page 48 Gurs F em Gore Pefeccucies Cover and Chain Removal e Remove the 6 cover bolts with an 8mm
53. m aluminum parts engine and radiator from rust and corrosion the use of cor rosion and rust inhibitors chemicals in the coolant is essential If rust inhibitors were not used over a pe riod of time the radiator will be corroded This will clog the tubes of the cooling system CAUTION Use of incorrect coolant solutions will cause engine and cooling system damage Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruc tions of the manufacturer WARNING Chemical liquids are harmful to the human body Follow manufacturer instructions CAUTION Distilled water must be used with corrosion inhibitors and the antifreeze in the cooling system If tap water is used in the system the cooling tubes can be clogged and reduce the cooling system efficiency If the lowest ambient temperature encountered falls below the freezing point of water protect the cooling system Use a permanent type of antifreeze in the cooling system distilled water and ethylene glycol and corrosion inhibitors for aluminum engines and radiators For the coolant mixture ratio under extreme con ditions choose the mixture ratio listed on the container for the lowest ambient temperature CAUTION Permanent types of antifreeze have anticorrosion and anti rust properties When it is diluted excessively it loses its antifreeze and anticorrosion properties Mix in accordance with the instructions of manufacturer
54. n tear the seal Page 88 A Meee Gore Pefeccucies Triple Clamp Service Gurs 27 7 e Remove cover bearings from cover with bearing puller if they need to be replaced e Remove cover seals and inspect Replace if needed Page 89 7272527 JR ieee Gore Pefeccucies e Remove sprocket snap ring e Remove sprocket and gear by tapping the gear through the sprocket with a plastic faced hammer and pulling it out the top of the steerer tube e Remove gear from steerer tube If bearing comes out with gear remove bearing from gear with split bearing puller if it does not slide off easily e bearing remains in steerer use a punch to remove it Triple Clamp Service Page 90 FRU eee Gore Pefeccucies Triple Clamp Service Gurs 77 7 e Tap the bottom output bearing from the bottom steerer tube e Inspect gears and bearing and replace any parts if needed Note Head tube gears must be replaced in sets Page 91 7272527 JR ieee Gore Pefeccucies Warning Replacing the taper bearing is a job for your dealer Do not attempt to do this on your own Remove the preload bars from the bottom triple clamp Press the steerer tube out of the bottom triple clamp with an arbor or hydraulic press The steering stops should be supporting the triple clamp as the steerer is pressed out Press the taper bearing and seal off of steerer tube with aluminum
55. necessary to ensure a smooth operation and obtain an optimum engine and the trans mission responses During the first hour or 20 km of operation run the engine at low and moderate speeds and revolutions per minute RPM NOTE slow riding necessary during the break in period may cause carbon deposits to build up on the spark plug and foul it AWD Engagement Switch Forward will switch OFF the AWD system You can do this at any speed Page 10 JT Basic Operating Instructions 7272527 If inspection of the spark plug shows this to be the case replace the standard spark plug with another of a higher heat range Perform the break in period following these steps 1 Start the engine and let it run at idle until the engine is warm 2 Stop and let the engine cool completely 3 Start the engine and ride for 10 minutes at moderate speed NEVER ACCELERATE HARD 4 Stop and let the engine cool completely Be sure to check and adjust chain slack and spoke tightness and carry out a general inspection 5 Start the engine and ride for 20 minutes at moderate speed NEVER ACCELERATE HARD 6 Stop and let the engine cool completely Check and adjust as needed Refer to the table of adjust ments f Install the removed parts 8 Fill the radiator with the recommended coolant Before starting the motorcycle bleed the air from the cooling system 9 Start the engine and ride for 30 minutes at modera
56. ng rod bearings Recommended oil 2 CYCLE SYNTHETIC Page 7 NOTE If the recommended oil is not available use only oil designed for racing with 2 cycle engines Gasoline and engine oil mixing proportions Synthetic oil 100 gasoline 50 engine oil 1 2 Semi synthetic oil gasoline 50 engine oil 1 2 Mineral oil gasoline 32 engine oil 1 3 627 294 Fuel CAUTION Do not mix vegetable and mineral based oils Too much oil will cause excessive smoking and spark plug fouling Too little oil will cause engine damage or premature wear CAUTION Below 0 do not use 100 synthetic oil To prepare the mixture first pour oil and half of the gasoline used into a container and stir the mixture thor oughly Then add the rest of the gasoline and stir the mixture well NOTE At low temperature oil will not easily mix with gasoline Take time to ensure a well blended mixture The lubrication quality of this mixture deteriorates rapidly use a fresh mixture for each day of operation Page 8 eam Gore O Or Oy eies Basic Operating Instructions Gurs ALLA 1 Make sure the motorcycle is in the neutral position 2 Turn the gasoline cock A clockwise to the ON position 3 If the engine is cold pull up the choke trigger NOTE When the engine is already warm or on hot days open the throttle instead of using the choke knob If the engine is flooded kick with the throttle fully open th
57. ns Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Idling nozzle and mixture adjustment screw Controls the mixture from the closed position to an opening of 1 8 of throttle range but has little effect on full throttle To adjust the mixture in this range the air screw can be turned to change the air flow through the circuit or the slow jet can be changed to provide more or less fuel Start by turning the air screw Screwing it in richens the mixture The air screw must be turned from a lightly seated position Make changes in 1 2 turn in crements If turning the screw between 1 and 2 5 turns does not give the desired results change the slow jet B one step and tune up with the air screw A B Page 32 72725270 JR eee Gore Pefeccucies Tune up Carburetor jet needle Clip position The jet needle and jet needle hole together have their greatest effect in the one a half throttle range The needle moves in and out of the jet needle hole since the needle is tapered its position in the jet determines the amount of fuel allowed gt to flow There are five grooves in the upper section of the needle where a T Jet needle circlip fits This clip locates the needle in the throttle valve and determines its number relative position in the jet needle hole and provides a rich mixture Moving the
58. nsmission oil for the models 250 300 Check the oil level after kicking the kick start pedal 3 or 4 times Install the oil filler opening plug Page 19 7272527 Air Filter A clogged air filter restricts the engine air intake increasing fuel consumption reducing engine power and causing spark plug fouling WARNING A clogged air filter may allow dirt and dust to enter the carburetor and stick the throttle open This could cause an accident A clogged air filter may allow dirt and dust to enter the engine causing excessive wear and tear and other damages Do not omit checking the element before and after each race or practice session Clean it if necessary Element Cleaning WARNING Clean the element in a well ventilated area and make sure that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline to clean the ele ment because could cause an explosion To access the air filter remove the seat by removing the bolt that secures it To access the air filter remove the seat by removing the bolt that secures it Remove the cover Remove the screw A and remove the filter B Place a lint free towel in the intake port of the carburetor so no dirt is allowed to enter the carburetor CAUTION Do not turn the filter since it can be easily damaged or torn Wipe out inside the air filter housing with a clean damp towel Pull the
59. ocket and bottom center sprocket nsert bottom center sprocket with bearing into the center cover hole e f needed grease chains with Shell grease e Slide cover and left shaft sprocket up into bottom triple clamp until the cover meets flush the lip of the bottom triple clamp If needed use a small screwdriver or pick to push the right chain away from the Teflon block as the cover slides into place Hint once the cover makes contact with the bottom triple clamp rotate the shaft sprockets as you are pushing the cover into its final position This helps to line everything up correctly Warning Left and right shaft sprockets must be installed on the correct side or severe damage to the AWD system can occur A simple rule to remember is that the lower shaft sprocket goes on the rider s left side ie Left Low Page 95 CHINS TINT When cover is in place screw down the cover bolts with a 6mm Allen wrench Note Use blue Loctite on cover bolts Torque bolts to 12 ft lbs Triple Clamp Service Page 96 oo Triple Clamp Service Gums e Pull top output gear and bearing out of top steerer If bearing does not come out with gear use blindside bearing puller to remove the bearing e f bearing is seized or hard to turn by hand it should be replaced Inspect output gear for wear If it needs to be replaced all gears the head tube must be replaced at the same time
60. on amp dus cover Every 2 years Brake caliper piston seal amp dust seal Every 2 years Brake hose and pipe Every 4 years Spoke tightness and rim runaut 1 fill up 1 fill up Lubricate drive chain 1 fill up chain 1 fill up p Drive chain wear Chain slider 5filups 6 fil ups B fill ups 1 Front fork 1 fill up When necessary When damaged When necessa Front fork ail 2 Nuts bolt fasteners 5 fill ups 5 fill ups 5 fl ups 7 fill ups ups Steering play 1 fill up Rear sprocket 5 fill ups Sfl ups 5 a fill ups 1D fill ups T0fillups 10 fill ups ee fill ups 5 fill ups 5 fill ups 5 fill ups 5 fill ups General lubrication Steering bearing Wheel bearing swingarm and linkages Rear shock absorber Every 2 years 2 years 2 years Bendix grease 10 fill ups x When me When necessary The maintenance and adjustments in this table are easy to follow and must be carried out to keep the mo torcycle in good running condition NOTE Inspect and carry out these operations only if it is necessary Page 12 A tee Gore Pefeccucies Electronic Ignition Gurs 77 7 This motorcycle uses a capacitor discharge ignition system CDI The ignition system should never require adjustment unless the stator of the magnetic flywheel was incorrectly installed during engine reassembly If necessary inspect and a
61. oose then tighten it 1 1 2 turns After thoroughly warming up the engine turn the idle adjusting screw to obtain the desired idle speed If there are no idle preferences turn the screw until the engine T h stops A Aii screw Tighten lightly the idle screw Open close the throttle a few times to make sure the idle speed does not change Readjust if neces sary With the engine idling turn the handlebar to each side If handlebar movement changes the idle speed the throttle cable may be improperly adjusted or routed incorrectly or it may be damaged Be sure to cor rect any of these conditions before riding WARNING Riding with a damaged throttle cable could be dangerous 21 27727224 TANT Clutch Exhaust CLUTCH The clutch lever should have a maximum play of 3 mm This margin increases with the wear on the clutch plate To adjust proceed as follows Use bolt A to adjust the lever s range of movement to the rider s convenience Adjust the play of the lever using bolt B WARNING Maintain the clutch lever with the play shown otherwise the performance and useful life of the clutch may be adversely affected This model uses mineral oil GRO ULTRA 5 for the clutch hydraulic circuit Tank C must not be filled with brake liquid EXHAUST SYSTEM The exhaust and the muffler reduce the noise and send gases away from the rider If the exhaust is badly dama
62. ple clamp into place with soft faced mallet until it is fully seated 0 Check Gear Mesh e Screw the preload bolts down until they are flush with the top triple clamp Page 106 RAF hee Drove A Triple Clamp Installation HEISE e Turn the preload bolts evenly until there is no play in the head tube bearings usually 1 2 3 4 of a turn 1 2 3 4 e Jdunnstessemove headset play e Tighten the preload bar pinch bolts Page 107 7272527 JR ieee Gore Pefeccucies e Remove chain cover chain and sprocket from frame see Cover chain removal section Remove cable and engagement spline from gearbox see AWD engagement cable section Slide clutch retaining snap ring up main drive shaft 6 inches or more e Slide clutch hub assembly up main driveshaft unit it clears the clutch basket Remove 4 shoulder bolts from sidebar with 4mm Allen wrench e With Shoulder bolts removed slide gearbox out of frame Gear Box Removal Page 108 pepe TIN Gear Box Service 72725270 Output Snap Ring Output Seal Output Bearings Output Goar Gear Box CSR 47B 5 37474 CB 6906 GB 03 GB 01 Orientation E Output Retaining Ring Input Bearing CSR 305 CB 6905 Input Gear Snap Ring G CSR 14H Input Gear GB 02 ALPAAOA OLLL OLLO IAOAA NU LaTA A AO VOLOL OAAIAUALO L
63. s e Loosen the two preload bar pinch bolts e Remove the preload bolts with 22mm Wrench e With a plastic faced hammer tap the bottom triple clamp to unseat it from the frame Page 83 272224 Triple Clamp Removal e Slide the bottom triple clamp out of the frame e Pull the top triple clamp assembly out of the frame Note It may be necessary to tap the underside of the top triple clamp with a plastic faced hammer to unseat it from the frame Page 84 T GHIS TINI JR eee Gore Triple Clamp Service Top Triple Clamp Pinch Bott CH M835 Preload Bolt FP 05 Headtube Seal Steerer Bearing Drive Shaft 25 32908 CB 6805 HT 045 qp Mm Steerer Sat Screw ia 4 1 ne Top Steerer Tube wm FP 06 Taper Bearing Tap Output Gear B 32908 02 Preload Bar Pinch CH ME20 Top Triple Clamp IFP 01 Headlight Mounting Bracket FP 11 Steerer Tube Bearing CB 6805 Bottom Steerer Tube Headtube Seal Bottom Output Gear FP OF CS 32908 HT 03 Bottom Triple Clamp 02 Preload Bar Taper Bearing C FP 04 CB 32908 Pretoad Bar O Ring CO 01 7 Jj Bottom Triple Clamp Pinch Bolt CH M amp 40 Page 85 Triple Clamp Service 7222470 Shaft Sprocket L FD 02 Chain Guides Top Center Sprocket
64. s to the proper torque using an adequate wrench A bolt or nut loose might damage the motorcycle or even cause an accident PART NAME Brake caliper mounting bolt Disc mounting screw 710 Engine mounting bot 36 Front axle bolt 11 51 Front brake hose mounting bot 6 Suspensionclampbot 15 Rearbrakepedalbot 9 Rear drive plate nt 29 Spokes 15 _Steerngstemnut Torqgerodbot 81 Rear linkage bolt 81 Cylinder head screws 258 Engiedranplug 202 Kick startpedalbolt 20 Kickstartpedalnut 25 Gearshift pedal bot 15 E Water pump cover drain plug 9 N screws 10 Starter pedal plate 8 ignition motor stator screws Ignition motor col Selector spring fixing screw 15 _ Pimaynt Valve control support screws 10 Valve controlnuts Reed screws 10_ Thermostat housing screws 10 Clutch housing screws 10 Valve housing screws 8 Ignition housing screws 10 sproket screws 60 Bendix cover screws 10 10 30 Lubrication TING LUBRICATION Lubricate the points shown here apply either engine oil or grease periodically or whenever the vehicle has been operated under wet or rainy conditions and especially after using high water pressure Before lubri cating each p
65. socket or t handle and pull cover off of the frame e To remove the chain pull the tensioner back with a flat blade screwdriver and pull the sprocket out with fingers or non marring pliers Remove the chain from countershaft sprocket e Check the following and replace if needed 1 Sidebar bearing and cover bearing should be smooth turn Ing 2 Check engagement spline action by engaging and disen gaging switch on handle bars 3 Sidebar seal and cover seal for wear 4 Excessive wear on chain tension block Warning Do not use an O ring chain as there is not enough clearance for one and it would rub the frame Page 49 Cover Chain Removal A ieee Gore Pefeccucies 7272527 e Reinstall chain and top sprocket e Adjust chain tensioner using a 4mm Allen wrench and by sliding the tensioner up the sidebar until the front side of the chain has roughly 10 15mm 0 4 0 of give when pressure is applied e Replace chain cover Torque sidebar cover bolts to 8 ft Ib Note If cover does not seat on the sidebar the top sprocket is not fully seated in the bearing Page 50 AS Se AWD Engagement TANI AWD Engagement Cable GB 09 Engagement Spring Engagement Spline Bearing GB 06 CB 685 M LLLI Ti PA M Il m Aue Engagement Spring Retaining Washer Engagement Spline Cable Fitting CHW MBGRW GB 04 GB 11 AWD Engagement Switch GB 10
66. t Seal Right FG 02 incl Bevel Gear CB 7001 CB 6901 CS 172586 Left FG 01 incl Bevel Gear Angular contact bearing Black seal must face towards pinion gear Page 67 7272527 Dropout Service e Remove the front wheel and front fork e Remove bellow clamp and bellow from spline driveshaft Pry gently with small flathead screw driver to undo clasp on clamp The clamps are not reusable e Remove set screw from driveshaft with 2 5mm Allen key e Remove driveshaft from pinion gear by lightly tapping lower driveshaft with a plastic hammer while pulling the driveshaft away from the dropout e Remove 6 cover bolts on the outside of the gearbox using a 4mm Allen wrench e Rotate the cover and pull it off of the dropout Page 68 Gurs F em Gore O Or Oy Eies Dropout Service e Remove drive insert bearing from inside of dropout Bearing is a slip fit so only light pressure from screw driver is required to remove e down on pinion gear with plastic face hammer After pinion is removed slide the bottom bearing out of dropout bore If bearing stays on pinion shaft remove by hand or with split bearing puller Note lower pinion bearing is angular contact so if pressure is applied in the wrong direction it may come apart If bearing comes apart it must be replaced e Remove top driveshaft seal from dropout using small flat blade screwdriver Be careful not
67. te speed 10 Stop and let the engine cool completely Check and adjust 11 After the break in procedure has been properly carried out the motorcycle is ready for regular opera tion CAUTION However avoid accelerating recklessly which can lead to engine failure Be careful to use the necessary skills and techniques while operating the motorcycle NOTE After the break in period install a new set of standard spark plugs A Page 11 Gums Tin 27 7 Maintenance Schedule Clutch At each fill up At each fill up At each fill up Discs 3 fill ups 3 fill ups 3 fill ups Throttie cable o Spark plug Air cleaner element When damaged Carburetor 1 fill up 1 fill un Transmission z 3 fill ups Piston and piston ring 3 fill ups 3 fill ups 3 fill up ylinder head yl amp exhaust valves fill ups 3 fill ups Exhaust i fill up 1 fill up Muffler gasket 10 fill ups 10 fill ups Piston bearing 3 fill ups fill ups fill ups 3 fill ups Kick start pedal and gearshift pedal i 1 fill up Exhaust pipe oting 3 fill ups Engine beanngs 10 till ups 10 fill ups 10 fill ups Coolant Radiator tube and connections 1 M E SE SE Brake adjustment 3 3hlup s3Wup Brake pads wear 3 Fill up 5 ups 5 fl ups Brake fluid level 3 fill ups Brake fluid Every 2 yaars Brake pup pist
68. th new fuel Clean the fuel system and verify iis operation Clean or replace the air cleaner Verify its operation Venty if the exhaust system damaged Replace ihe muffler fiberglass packing if necessary Disassembly the carburetor and clean all jets Replace the crankshafi bearings Verify the clutch operation Go ta a spennalzed workshop o to a specialized workshop Refer ta section 5 Clean the combustion chamber Drain all and fili up with a higher octane fuel Replace the spark plug with a new one of ihe correct type Verify if the exhaust system is damaged All gaskets must De In perlect conditions atherwisa replace than wilh mew ones if necessary Replace the cylindar head gaskel Go to specialized workshop Read uel the thretlia valve cable Clean or replace the air cleaner Go 1o specialized workshop Verily main tet operation Go lo specialized workshop Page 36 Troubleshooting CHII TING MALFUNCTION POSSIBLE CAUSE REMEDY Gears do not engage correctly Clutch does not disengage Go to a specialized workshop Bent or seized shift fork Replace the shift fork Gear seized at the transmission Go to a specialized workshop Damaged gearshift lever Replace the gearshift lever Broken or loose selector position spring Adjust or replace the selector position spring Broken spring in the reverse selector Replace t
69. tite When set screw is fully seated it will be slightly below the surface of driveshaft If not make sure that spline shaft is fully seated on pinion gear e Grease pinion gear and bevel gear with Shell Lithium grease e Insert cover bevel gear assembly onto dropout e Insert 6 cover bolts and tighten in a cross star pattern using a 4mm Allen wrench Tighten to Sft Ibs e Check that drive carrier spins freely and wipe excess grease from outside of dropout e Reinsert bellow and bellow clamp over spline shaft and crimp bellow down using crimping tool or vise grips WARNING The band of clamp must be over the set screw to ensure that the set screw can not back out e Lightly grease spline shaft with Shell Lithium grease Reinsert forks into triple clamps Page 75 Cours TINI Fork Spline Bearing Service Sleave Seal Housing Sleeve Grease Fitting Retaining Ring Housing Felt Linear Bearing 5 050 0 09 0 11 CSR 81B FD 10 CB LSAG12 Housing Cap Snap Ring Linear Bearing Housing FD 08 CO 116 CSR 75B 07 Page 76 227222274 Fork Spline Bearing Service e Cut Safety wire from boot and slide it off the housing e Remove forks from triple clamps see Fork Removal section e Slide housing assembly off of linear driveshaft POHILLEUT aBPEE EC ADLLLL LLLI AUTLICG UCT GOdTI SGAUIUUDGUGGIqJg 0GLULLL UUU 4UUULUAI
70. usor Lubrication system 100 Synthetic Mineral Oil Only USA Starting system Ignition system Ignition timing TRANSMISSION Transmission type Clutch type Secondary drive Gear ratio 250 cc 300 cc Primary reduction Final reduction Transmission oil Capacity Type CHASSIS Type Tire size Front Rear Suspension Front Rear Suspension stroke Front Rear Front fork oil Front fork cil level BRAKES Front Rear Effective disc diameter Front Hear DIMENSIONS Overall height Overall langth Overall width seat height Minimum height Wheelbase Fuel tank capacity Page 5 Gurs 77 7 Drive 2 cycles single cylinder crankcase intake liquid cooled 65 4 x 72 mm 249 3 cc 2 2 mm 204 7 cc 38 Mixture 50 1 296 32 1 3 Starting lever Electric start CDI system 1mm BTDC 6 speed in cascade Hydraulic operated multi plate in oil bath Chain driven 1st 2 071 29 14 2nd 1 625 26 16 3rd 1 333 24 18 4th 1 100 22 20 5th 0 913 21 23 6th 0 791 19 24 2 85 57 20 250 cc 300 cc 3 692 48 13 250 cc 300 cc 900 cc 250 cc 300 cc 10W30 API SF or SG Tubular semi double cradle EC 90 90 x 21 140 80 x 18 Inverted telescopic fork 45 mm Cross Country Inverted telescopic fork 48 mm 250 300 Progressive system with single multi adjustable shock 282 mm 320 mim SAE 5 7 5 110 mm compressed wit
71. y To minimize any chance of the master link coming apart the master link clip must be installed with the closed end of the U facing in the direction of the chain rotation Li T ection of i 8 lt Chain Guide Slider Visually inspect the upper and lower chain slider at the location of the swingarm If damaged or worn re place it with a new part Chain Guide Slider is the plastic piece that guides the chain into the countershaft sprocket Pinion Teeth Pinion Sprocket and Sprocket Wear Visually inspect the pinion teeth If they are worn or damaged replace the pinion or the sprocket Lubrication Lubrication is necessary after riding through rain or in the mud or any time that the chain appears dry A heavy oil is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication Apply oil to the sides of the chain rollers for better oil penetra tion Wipe off any excess oil Page 24 em Gore O Or Oy Eies Handlebar Brakes Gurs TINI HANDLEBAR To suit various riding positions the handlebar position can be adjusted front to rear Handlebar position adjustment Loosen the handlebar holder A screws B turn the handlebar and place it in the desired position Tighten the bolts front first and then the rear to 25 Nm of torque If the handlebar is installed correctly there will be an even gap at the front and rear after tightening A BRAKES D
72. yL L AOAOAO A A OIALAAAAAAOAOAAA IAIAAGSASA E OOAOAAAAAA uA OAaAeOOAA AN eALOGO 1 LLLIIZ Page 109 27727224 SINIT Gear Box Service Slide clutch basket off output gear Remove output seals from gear box Remove output snap ring Page 110 AE Eee Se Gear Box Service e Slide output gear and bearings out of gearbox Remove input gear and bearing from gearbox by tapping them out through the access holes in the back of the gearbox m Page 111 CHII S TINI YURI Box service Remove output retaining ring Use split bearing puller to press output bearings partially off of the gear After the bearings move away from the gear use press to remove bearings completely e Use same steps to remove input bearing from input gear Inspect gears and bearings and replace if needed Carefully press new output bearings onto driven gear and replace retaining ring Carefully press input bearing onto drive gear and replace engagement spline snap ring if it was removed Page 112 JR ieee Gore Pefeccucies Gearbox Service Note Make sure engagement spline snap ring is install on input gear before it is pressed into the gearbox Engagement Spline Snap Ring e Press input bearing onto gear and insert gear and bearing into gearbox e An aluminum punch and hammer may be needed to gently tap input bearing and drive gear back into pl

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