Christini AWD 250 Service Manual Download Page 37

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Page 36

Troubleshooting

TROUBLESHOOTING

NOTE

This is not an exhaustive list of malfunctions, it only shows the most common problems.

Summary of Contents for AWD 250

Page 1: ...Service Manual CHRISTINI AWD 300 250 CHRISTINI AWD 300 250 CHRISTINI AWD 300 250 CHRISTINI AWD 300 250 Christini Technologies Inc tech christini com Version 2012 1 ...

Page 2: ......

Page 3: ...t correctly followed could result in per sonal injury or even death CAUTION CAUTION CAUTION CAUTION This symbol identifies instructions or procedures which if not followed strictly could result in damage to or destruc tion of equipment NOTE NOTE NOTE NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Motorcycle riding if improperly conducted h...

Page 4: ...ition 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 Lubrication 31 Tune Up 32 Storage 35 Nut and Bolt Tightening 29 Torque Values 30 Troubleshooting 36 Wiring Diagram 39 Table of Contents ...

Page 5: ...rvice 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 Main drive shaft removal 100 Head tube bearing service 101 Triple Clamp Installation 104 Gearbox removal 108 Gearbox service 109 AWD clutch removal 114 AWD clutch Service 115 Troubleshooting 119 Warranty 120 Main drive shaft installation 10...

Page 6: ...Page 5 Specifications ...

Page 7: ... 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 17 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 8: ...any source of flame or sparks this includes any appliance with a pilot light Mixing oil inside the engine Mixing oil inside the engine Mixing oil inside the engine Mixing oil inside the engine Oil must be mixed with gasoline to lubricate the piston cylinder crankshaft and connecting rod bearings Recommended oil Recommended oil Recommended oil Recommended oil 2 CYCLE SYNTHETIC NOTE NOTE NOTE NOTE I...

Page 9: ... 0 ºC 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 NOTE NOTE 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 ...

Page 10: ...flooded kick with the throttle fully open If the 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 Stopping the engine Stopping the engine Stopping the engine 1 Shift the transmission into neutral 2 After racing the engine s...

Page 11: ...engine damage Stopping Motorcycle Stopping Motorcycle Stopping Motorcycle 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 ...

Page 12: ...E HARD 6 Stop and let the engine cool completely Check and adjust as needed Refer to the table of adjust ments 7 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 moderate speed 10 Stop and let the engine cool completely Check and adjust 11 After the break in ...

Page 13: ...ce Schedule 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 14: ...ned loosen the magnetic inertia wheel screws and turn it Tighten the screws securely Install the magnetic flywheel cover NOTE NOTE NOTE 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 NOTE NOTE NOTE For the best engi...

Page 15: ...ith the instruc tions of the manufacturer WARNING WARNING WARNING WARNING Chemical liquids are harmful to the human body Follow manufacturer instructions CAUTION CAUTION CAUTION 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 lo...

Page 16: ...OTE NOTE NOTE Check the level when the engine is cold Check the level when the engine is cold Check the level when the engine is cold 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 Total quantity Total quantit...

Page 17: ...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 Drain plug tightening torque refer to torque table Drain plug tightening torque refer to torque table Drain plug tightening torque refer to torque table Water pump screw 9 Nm Water pump screw 9 Nm Water pump...

Page 18: ...g NOTE NOTE NOTE NOTE Inspect every 30 hours and change every 60 hours Inspect every 30 hours and change every 60 hours Inspect every 30 hours and change every 60 hours 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 co...

Page 19: ...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...

Page 20: ...g 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 trans...

Page 21: ...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 CAUTION CAUTION CAUTION Do not turn the filter since it can be easily damaged or to...

Page 22: ... adjustment Idle speed adjustment Idle speed adjustment Is carried out using the air screw A and idle screw B First turn in the air screw until it is loose 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 stops Tighten lightly the idle screw Open and clo...

Page 23: ... the muffler reduce the noise and send gases away from the rider If the exhaust is badly damaged 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 Muffler replacement Muffler replacement Muffler replacement Remove the retaining screws of the right side number posting cover Remov...

Page 24: ...lack rotate the rear wheel to inspect for damaged rollers loose pin and links unevenly or excessively worn teeth and damaged teeth Drive Chain Slack Adjustment Drive Chain Slack Adjustment Drive Chain Slack Adjustment 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...

Page 25: ... 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 Chain Guide Slider Chain Guide Slider Chain Guide Slider Chain Guide Slider Visually inspect the upper and lower chain slider at the location of the swingarm If damaged or worn replace it with a new part A Chain Guide Slider B Swingarm Pinion Teeth Pinion Spro...

Page 26: ...ment on the brakes except brake lever free play and brake pedal position Front brake lever free play Front brake lever free play Front brake lever free play Front brake lever free play Adjust the front brake lever A to match your require ments To adjust loosen the nut B After adjustment tighten it securely Then check that the brake response is correct Rear brake pedal position Rear brake pedal pos...

Page 27: ...ll with brake fluid If the brake fluid is insufficient add brake fluid CAUTION CAUTION CAUTION 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 been unsealed for a long time Check for fluid leakage around the fittings Check for brake hose damage WARNING WARNING WARNING WARNING Do not mix different types of fluid Change ...

Page 28: ...oth 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 Wheel rim run out Wheel rim run out 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 c...

Page 29: ...reas 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 CAUTION CAUTION 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...

Page 30: ...4 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 27 Rear brake pedal bolt 28 Torque rod mounting bolt 29 Linkage mounting bolt 30 Rear axle bolt Before each ride check the ...

Page 31: ...orque Values Table Torque Values Table Torque Values Table Torque Values Table Tighten all bolts and nuts to the proper torque using an adequate wrench A bolt or nut loose might damage the motorcycle or even cause an accident ...

Page 32: ... 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 Drive Chain Lubrication Drive Chain Lubrication 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 l...

Page 33: ...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 Idling nozzle and mixture adjustment screw Idling nozzle and mixture adjustment screw Idling nozzle and mixture adjustment screw Idling nozzle and mixture adjustment screw Controls the mixture from the closed position to...

Page 34: ...he 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 carburet...

Page 35: ...0 94 2 2 2 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 3 3 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 o...

Page 36: ... 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 and dirt When starting off after an extended storage When starting off after an extended storage When ...

Page 37: ...haustive list of malfunctions it only shows the most common problems This is not an exhaustive list of malfunctions it only shows the most common problems This is not an exhaustive list of malfunctions it only shows the most common problems This is not an exhaustive list of malfunctions it only shows the most common problems ...

Page 38: ...Page 37 Troubleshooting ...

Page 39: ...Page 38 Troubleshooting ...

Page 40: ...Page 39 Wiring Diagram ...

Page 41: ...Page 40 AWD Service AWD Service Section AWD Service Section AWD Service Section AWD Service Section ...

Page 42: ...et Blind side bearing removal kit Motion Pro 08 0292 2 large adjustable wrenches Torque wrench 0 75 ft lbs Split bearing puller Small pick or awe Safety wire pliers Safety wire 032 Grease gun included with bike purchase customer must supply grease below Shell Albida EP1 Lithium grease do not substitute Spectro SPL grease or equivalent Blue Loctite 242 Red Loctite 262 Green Loctite 609 The Tools Yo...

Page 43: ...Page 42 AWD Detail Illustration ...

Page 44: ...e the inside Axle Clamp Bear ings Do not engage the AWD system while at high speeds Disengagement of the AWD system can occur at any speed Be cautious when power washing bike especially around front drive hubs and AWD seals Spraying high pressure water into these areas can damage seals and bearings Warnings ...

Page 45: ...e Front Wheel Sprag Test section Check front wheel rim lock nut torque As Needed Replace bearings if excessive noise or friction develops Lubricate spline shafts through grease port with supplied grease gun and Shell grease Replace worn or damaged seals and boots Routine Maintenance AVOID AVOID AVOID AVOID Pressure washing the dropouts head tube area side bar and main gearbox ...

Page 46: ...nt 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 If the clutch needs to be adjusted pull the gas tank off the bike Loosen the set screw on the clutch locknut 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 ...

Page 47: ...ars to the left left left left and back to center There should be steering resistance from the AWD system when this is performed Release brakes and center handlebars Hold down front and rear brakes again and turn handlebars to the right right right right and back to center There should be steering resistance from the AWD system If no resistance is felt or there is only resistance in one direction ...

Page 48: ...Page 47 Cover and Chain Removal ...

Page 49: ...Page 48 Cover and Chain Removal ...

Page 50: ...in from countershaft sprocket 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 Warning Warning Warning Do not use an O ring chain as there is not enough clearance for one and...

Page 51: ...nsioner up the sidebar until the front side of the chain has roughly 10 15mm 0 4 0 6in of give when pressure is applied Replace chain cover Torque sidebar cover bolts to 8 ft lb Note Note Note Note If cover does not seat on the sidebar the top sprocket is not fully seated in the bearing Cover and Chain Removal ...

Page 52: ...Page 51 AWD Engagement ...

Page 53: ... 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 AWD Engagement Installation ...

Page 54: ...ent 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 55: ...using into the back of the gearbox Slide the other end of the cable into the engagement switch Line up the engagement spline with the input gear inside the gear box and push the spline into the gear AWD Engagement Installation ...

Page 56: ...s turned in completely Insert the secondary sprocket into the sidebar and make sure it is fully seated 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 Push the lever to the off position Make sure the secondary sprocket is fully seated Spin the secondary sprocket to verify that the splin...

Page 57: ...o not squeeze front brake lever while caliper is off Remove axle bolt from axle Loosen axle pinch bolts on both sides of dropout Slide axle through wheel and remove Remove front wheel from dropouts Note Note Note 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 58: ...ther 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 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 lb Tighten axle pinch bolts to 12 ft lb Note Note Note Note If wheel does not spin freely a...

Page 59: ...Page 58 Front Wheel Service ...

Page 60: ...ning Before taking hub apart 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 Using a soft punch remove the hub inserts from either side of the hub ...

Page 61: ...el Service Pry the insert seals out of the inserts using a flat bladed screwdriver Remove the hub insert o rings with a pick Punch the axle bearings out of the inserts using the ac cess holes in the back of the inserts ...

Page 62: ...Page 61 Using a bearing punch install the axle bearings into the hub inserts Press the axle seals into the hub inserts Install the hub insert o rings Front Wheel Service ...

Page 63: ...D sys tem to work properly If the sprag bearings are not installed correctly the AWD system can be damaged Press CB 6905 bearing into the Hub Inner Race Be sure that the bearing is seated completely Insert sprag bearing into hub shell correct direction will be determined in next steps Lightly grease inside of sprag bearing with Shell grease ...

Page 64: ...k to make sure it is free Spin the hub insert and check to make sure it is free wheeling in the correct direction wheeling in the correct direction wheeling in the correct direction 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 Front Wheel Se...

Page 65: ...press insert bearings into hub 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 Grease axle seal Repeat procedure for the other side of hub Front Wheel Service ...

Page 66: ...inear bearing housing and un screw it completely Slide the housing down off the sprocket driveshaft 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 Warning Warning 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 ...

Page 67: ...lamps Set desired fork height and torque triple clamp bolts to the follow ing 15 ft lbs Lower 17ft lbs Upper Slide the linear bearing housing over the drive sprocket shaft Tighten the housing cap down with 2 adjustable wrenches Fork Installation ...

Page 68: ...Page 67 Dropout Service ...

Page 69: ...p The clamps are not reusable Remove set screw from driveshaft with 2 5mm Allen key Remove driveshaft from pinion gear by lightly tapping lower driveshaft with a plastic hammer while pulling the driveshaft away from the dropout Remove 6 cover bolts on the outside of the gearbox using a 4mm Allen wrench Rotate the cover and pull it off of the dropout Dropout Service ...

Page 70: ... 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 Remove top driveshaft seal from dropout using small flat blade screwdriver Be careful not to scratch inner bore Remove top pinion bearings from upper bore by tapping them lightly tapping from inside t...

Page 71: ...r the drive carrier can be held with square bar stock to keep the assembly from moving as you unscrew the bolts Lightly tap the outside face of drive carrier with plastic hammer to break it free from gear and drive insert Remove axle o ring from drive carrier with pick Remove cover o rings and drive carrier o ring Dropout Service ...

Page 72: ...pouts 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 Pinion and bevel gear must be replaced as a set If bearings are seized or hard to turn by hand they must be replaced or cleaned and repacked with grease Be sure to grease a...

Page 73: ...line up all four threaded holes with clearance holes on gear 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 lbs Check that be...

Page 74: ...to pinion gear WARNING WARNING WARNING WARNING black seal must be facing down towards gear teeth If bearing is not inserted correctly severe damage can occur Slide bearing and pinion gear into bore Make sure bearing is fully seated Dropout Service Warning Warning Warning Warning Bevel gears are right and left hand specific and must be installed in the correct dropout or damage to the system can oc...

Page 75: ...e small flat blade screwdriver in between pinion gear and inner bearing to keep pinion gear in place when the splined shaft is installed 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 Dropout Service ...

Page 76: ...ert 6 cover bolts and tighten in a cross star pattern using a 4mm Allen wrench Tighten to 8ft lbs Check that drive carrier spins freely and wipe excess grease from outside of dropout Reinsert bellow and bellow clamp over spline shaft and crimp bellow down using crimping tool or vise grips WARNING WARNING WARNING WARNING The band of clamp must be over the set screw to ensure that the set screw can ...

Page 77: ...Page 76 Fork Spline Bearing Service ...

Page 78: ...Page 77 Cut Safety wire from boot and slide it off the housing Remove forks from triple clamps see Fork Removal section Slide housing assembly off of linear driveshaft Fork Spline Bearing Service ...

Page 79: ...Page 78 Unscrew grease port from linear bearing housing Remove set screw from housing Slide housing sleeve off of housing Remove linear bearing retaining ring Fork Spline Bearing Service ...

Page 80: ...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 If shaft seal is damaged or worn pry it out and replace it with a new seal Remove felt from housing sleeve and inspect If needed replace felt Note Note Note Note Dirt will pack up in felt The felt can be cleaned and reused Fork Spline Bearing Service ...

Page 81: ... on grease fitting or it may back out and cause the housing sleeve to slide down while riding Warning Warning Warning 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 fitting Fork Spline Bearing Service ...

Page 82: ...Do not slide shaft down and remove Note Do not slide shaft down and remove Note Do not slide shaft down and remove Note Do not slide shaft down and remove from linear bearing from linear bearing from linear bearing from linear bearing Note Note Note 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 follo...

Page 83: ... the bottom of the shaft Insert driveshaft onto pinion gear and tighten set screw Slide boot over bottom section of shaft and install set screw Crimp the clamp around the boot and set screw Pull top of boot over linear bearing housing and secure with low profile zip tie Reinstall the fork guard ...

Page 84: ...d hammer tap the bottom triple clamp to unseat it from the frame Note Note Note 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 ...

Page 85: ...al Slide the bottom triple clamp out of the frame 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 86: ...Page 85 Triple Clamp Service ...

Page 87: ...Page 86 Triple Clamp Service ...

Page 88: ...The right shaft will stay in place and the cover will slide down over it Note Note Note 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 pictu...

Page 89: ... the chain inside of triple clamp cavity 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 can tear the seal Triple Clamp Service ...

Page 90: ...Page 89 Remove cover bearings from cover with bearing puller if they need to be replaced Remove cover seals and inspect Replace if needed Triple Clamp Service ...

Page 91: ...t with a plastic faced hammer and pulling it out the top of the steerer tube 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 If top bearing remains in steerer use a punch to remove it Triple Clamp Service ...

Page 92: ...ge 91 Tap the bottom output bearing from the bottom steerer tube Inspect gears and bearing and replace any parts if needed Note Note Note Note Head tube gears must be replaced in sets Triple Clamp Service ...

Page 93: ...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 an aluminum sleeve available from Christini Press new taper bearing and seal onto steerer tube Coat mating surface of triple clamp and steerer tube with green Loctite Press steer tube into triple clamp ...

Page 94: ...ess steerer bearing into bottom of the steerer tube 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 Triple Clamp Service ...

Page 95: ...ss 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 96: ...ease 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 Hint Hint Hint once the cover makes contact with the bottom triple clamp rotate the shaft sprockets as you are pushing the cover into its f...

Page 97: ...Page 96 When cover is in place screw down the cover bolts with a 6mm Allen wrench Note Note Note Note Use blue Loctite on cover bolts Torque bolts to 12 ft lbs Triple Clamp Service ...

Page 98: ...ed or hard to turn by hand it should be replaced Inspect output gear for wear If it needs to be replaced all gears in all gears in all gears in all gears in the head tube must be replaced at the same time the head tube must be replaced at the same time the head tube must be replaced at the same time the head tube must be replaced at the same time Triple Clamp Service ...

Page 99: ... 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 100: ...Page 99 Slide the steerer tube bearing back onto the output gear Press gear and bearing into top steerer tube Triple Clamp Service ...

Page 101: ...aft will need to slide out of the clutch hub If the 3 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 Warning Warning 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 Main Drive Shaft...

Page 102: ...Page 101 Head Tube Bearing Service Picture above shows a head tube not welded to the frame for reference ...

Page 103: ... 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 Install the taper bearing races using a bearing punch Head Tube Bearing Service ...

Page 104: ...ng the clutch hub onto the driveshaft driveshaft before sliding the clutch hub onto the driveshaft driveshaft before sliding the clutch hub onto the driveshaft driveshaft before sliding the clutch hub onto the driveshaft 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 ligh...

Page 105: ...seated in the back of the head tube Slide top triple clamp assembly into the head tube 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 Tap the top triple clamp with a plastic faced hammer to seat it completely Triple Clamp Instal...

Page 106: ...ore fully bottom output gear is meshing with the input gear before fully bottom output gear is meshing with the input gear before fully seating the bottom triple clamp seating the bottom triple clamp seating the bottom triple clamp seating the bottom triple clamp Once gears are meshing correctly tap triple clamp with soft faced mallet to fully seat Slide top triple clamp into head tube aligning pr...

Page 107: ... turning the sprocket driveshaft also turns the top output gear everything is aligned correctly Ensure the top output gear is meshing with the back input gear and tap top triple clamp into place with soft faced mallet until it is fully seated Screw the preload bolts down until they are flush with the top triple clamp Triple Clamp Installation ...

Page 108: ...Page 107 Turn the preload bolts evenly until there is no play in the head tube bearings usually 1 2 3 4 of a turn Tighten the preload bar pinch bolts Triple Clamp Installation ...

Page 109: ... from gearbox see AWD engagement cable section Slide clutch retaining snap ring up main drive shaft 6 inches or more Slide clutch hub assembly up main driveshaft unit it clears the clutch basket Remove 4 shoulder bolts from sidebar with 4mm Allen wrench With Shoulder bolts removed slide gearbox out of frame Gear Box Removal ...

Page 110: ...Page 109 Gear Box Service ...

Page 111: ...Page 110 Slide clutch basket off output gear Remove output seals from gear box Remove output snap ring Gear Box Service ...

Page 112: ...Page 111 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 Gear Box Service ...

Page 113: ...e gear use press to remove bearings completely 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 Gear Box Service ...

Page 114: ...k into place Make sure bearing is fully seated at the back of the gearbox Insert output gear and bearings into gearbox Make sure gears mesh correctly as you are pushing the output gear into place Reinstall output snap ring Grease input and output gears using Shell Lithium grease Install output seals into gearbox making sure seals are installed markings facing out Grease lip of seals and push clutc...

Page 115: ...Cover chain removal section Slide clutch snap ring up main driveshaft Slide clutch up main driveshaft away from clutch basket Remove 4 shoulder connect gearbox from sidebar Move gearbox out of the way Slide clutch off main driveshaft Clutch Removal ...

Page 116: ...Page 115 Clutch Service ...

Page 117: ... on main driveshaft To keep driveshaft from spinning apply front brake and put bike in gear Remove clutch assembly from bike see Clutch Removal sec tion Completely unscrew locknut Remove spring washers fiber pads and clutch plates and inspect for wear or damage Note Note Note Note If metal plates are not scored or warped they do not need to be replaced Simply replace fiber plates during standard r...

Page 118: ...ates 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 Note Note Note Use thread file to clean galled hub threads if needed Clutch Service ...

Page 119: ...he hub Check clutch settings and adjust as necessary see AWD Clutch Test section Adjust locknut so set screw hole lines up with the nearest flat sec tion on the hub and tighten set screw Warning Warning Warning Warning Once set screw is tightened do try to turn locknut as this will damage the hub threads Clutch Installation ...

Page 120: ... 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...

Page 121: ...ght 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 Replacement of expendable maintenance items including but not limited to Bearings including linear bearing Seals and O Rings AWD Clutch Basket Pl...

Page 122: ...ns 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 capabilities Always wear a helmet while riding Please remember to always ride saf...

Page 123: ...ce Department at CHRISTINI AWD 421 N 7th Street Suite 200 Philadelphia PA 19123 Phone 215 351 9895 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 this Warranty offers no cash refunds this Warranty offers no cash refunds this Warranty offers no cash refunds Warranty ...

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Christini AWD 250, Service Manual

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