Christini AWD 450E Service Manual Download Page 60 | Manualshive

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Page 59

Warning: If removing forks for rebuild service, the fork dropouts must
be disassembled so that the drive system parts are not contaminated
during the service.

•

Loosen the housing cap from the linear 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 —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.

Fork Removal

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Summary of Contents for AWD 450E

Page 1: ...Service Manual CHRISTINI AWD 450E Christini Technologies Inc tech christini com Version 2015 1 ...

Page 2: ......

Page 3: ... YOU USE YOUR BIKE LEGALLY SHOW CONCERN FOR THE ENVIRONMENT AND RESPECT THE RIGHTS OF OTHER PEOPLE This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator We reserve the right to amend this motorcycle service manual due to periodic improvements and upgrades WARNING This warning symbol ...

Page 4: ...ations 7 Tire Specifications 8 Battery Specifications 8 Spark Plug Specifications 8 Basic Operating Instructions 9 Precaution 9 Pre Ride Inspection 10 Starting Stopping Engine 11 Break In 12 Maintenance 13 General Service Information 13 Maintenance Schedule 13 Service Information 16 General Specifications 5 Wiring Diagram 33 ...

Page 5: ...al 50 Front wheel service 52 Fork removal and installation 59 Dropout service 61 Fork spline bearing service 70 Boot Replacement 75 Triple clamp removal 77 Triple clamp service 79 Main drive shaft removal 94 Head tube bearing service 95 Triple Clamp Installation 98 Gearbox removal 102 Gearbox service 103 AWD clutch removal 108 AWD clutch Service 109 Troubleshooting 113 Warranty 114 Main drive shaf...

Page 6: ... TWI N SPAR F R ON T TI R E SIZ E 80 100 21 80 100 21 110 70 17 R EAR TIR E SI Z E 110 90 19 110 100 18 140 70 17 F R ON T SU SPEN SI ON I N VER TED C AR TR ID GE F OR K WI TH R E BOU N D C OMPR ESSI ON D AMPI N G ADJ U ST R EAR SU SPEN SI ON MON OSH OC K WI TH SPRI N G PR ELOAD R E BOU N D AND C OMPR ESSI ON D AMPIN G AD J U ST F U EL TAN K C APAC I TY 8 0L WI TH R ESER VE VALVE EN GI N E TYPE SI...

Page 7: ...VALVE CLEARANCE COOL INTAKE VALVE 0 16 0 03 mm EXHAUST VALVE 0 28 0 03 mm DECOMPRESS CLEARANCE EX VALVE CLEARANCE 0 28mm 0 15mm 0 43mm SPARK PLUG TYPE DENSO IK24 IK27 DIMENSION 350mm 297mm 423 mm DRIVE TYPE CHAIN DRIVE SPROCKET 13T CLUTCH TYPE MANUAL MULTI WET TRANSMISSION TYPE CONSTANT MESH 5 SPEED LEFT FOOT OPERATED PRIMARY ADJUCTION RATIO 2 739 63 23 GEAR RATIO 1ST 2 230 29 13 2ND 1 625 26 16 3...

Page 8: ...er D I SASSEMBLY 1 20 lit er AN TI FR EEZ E H I GH QU ALI TY ETHY LEN E GLY C OL AN TIF R EEZ E C ON TAI NI N G SI LI C ATE FR EE C ORR OSI ON I N H I BI TOR S STAN D AR D S C OOLAN T C ON C EN TR A TI ON 1 1 MI XTU R E WI TH D I STI LLED W ATER Coolant System WARNING Low Oil level in Transmission can cause transmission failure Warranty Void if transmission oil is not kept at mandatory level Failu...

Page 9: ...F R ON T 430 195 lbs k gs R EAR 548 265 lbs k gs Tire Specifications I TEM D ATA BATTER Y C APAC I TY 12V 6Ah C UR R EN T C ON SU MPTI ON MA X 0 1m A VOLTAGE 200 680 F F U LL 13 0 13 2V Battery Specifications I TEM D ATA SPAR K PLU G STAN D AR D S D EN SO I K24 OPTI ON AL N GK I FR 8H 11 Spark Plug Specifications ...

Page 10: ...cles to master riding skills Get to know the speed limit of safe riding The motorcycle s safe riding speed depends on the ground condition and your riding skills Knowing the speed limit based on your riding ability can avoid accidents Do not ride after drinking or taking medicine This bike is designed for adultoperators only Be sure you are allowed to ride this kind of motorcycle based on your loc...

Page 11: ...g head is tight Brake Inspect for free trav el of pedal and lev er and that there is f ull braking power Tire Check tire pressure and inspect tires for cracks Spokes Inspect and tighten loose spokes if necessary Other Bolts and Parts Inspect attachment points and other bolts to ensure they are tight Exhaust muffler Inspect for loose bolts and the exhaust is secure WARNING You should practice drivi...

Page 12: ...e engine is started let the EFI go through the high idle warm up for 10 20 seconds Then pull and release throttle grip repeatedly to run engine idle until engine is heated and close choke lever completely If engine warming up takes time run the engine idle with the choke lever slightly closed Stop the engine Shift the transmission into neutral Push the stop button 4 or push the engine start stop s...

Page 13: ...intenance the machine per the maintenance schedule After the break in procedure has been properly carried out the motorcycle is readyfor regular operation However since premature high r min rpm will lead to engine trouble take care to use the necessary skill and technique in operating the motorcycle Never run theengine with full throttle at low speed operation This rule is applicable not only duri...

Page 14: ...tening bolts and nuts begin with larger diameter or inner bolt first Then tighten to specified torque diagonally in incre mental steps unless a particular sequence is specified Clean parts in cleaning solvent upon disassembly lubricate and sliding surface before assembly Always inspect all parts for proper installation andoperation after reassemble Route all electrical wires cables and harness rou...

Page 15: ...TION I I I I I I I CRANKCASE BREATHER NOTE 2 I I I I I I I COOLING SYSTEM I I I I I I I SECONDAY AIR SUPPLY NOTE 2 I I I I I I I DECOMPRESSOR SYSTEM I I I I I I I ENGINE IDLE SPEED NOTE 4 I I I I I I I DRIVE CHAIN NOTE1 I L I L I L I L I L I L I L DRIVE CHAIN SLIDER NOTE1 I I I I I I I BRAKE FLUID NOTE3 I I I I I I I BRAKE PAD WEAR I I I I I I I BRAKE SYSTEM I I I I I I I HEADLIGHT FOCUS I I I I I...

Page 16: ...DECOMPRESSOR NOTE4 I ENGINE OIL NOTE3 I R ENGINE OIL FILTER NOTE3 R TANSMISSION OIL I R ENGINE IDLE SPEED I PISTON AND RING R PISTON PIN R DRIVE CHAIN I L R DRIVE CHAIN SLIDER I DRIVE CHAIN ROLLER I DRIVE DRIVEN SPROCKET I BRAKE FLUID NOTE2 I BRAKE PADS WEAR I BRAKE SYSTEM I CLUTCH SYSTEM NOTE5 I CONTROL CABLES I L EXHAUST PIPE MUFFLER I SUSPENSION I SWING ARM SHOCK LINKAGE L FORK OIL FORK TUBE SL...

Page 17: ...nev er disassembled Replace whenev er disassembled ITEM CAUSE REMARKS Front rear tire Front rear brake pad Sub f rame mounting bolts Chain guide plate Side cov er Front number plate Front rearf ender Clutch lev er holder Brake lev er Air throttle lever Handlebar Throttle housing Grip rubber Gearshif t pedal Brake pedal Chain adjuster bolt Air cleaner wear wear Fatigue or damage Wear or damage Dama...

Page 18: ...ll closing in all steering positions Check the throttle cable and replace them if they are deteriorated kinked or damaged Lubricate the throttle cable if throttleoperation is not smooth Measure the free play at the throttle grip flange FREE PLAY 3 5mm 1 8 3 16in Throttle grip free play can be adjusted at either end of the throttle cable Minor adjustments are made with the upper adjuster Remove the...

Page 19: ...ing liquid soap Clean the inside of the air cleaner housing After cleaning be sure there is no dirt or sand trapped between the inner and outer layer of the cleaner Wash again if necessary Allow the air cleaner to dry thoroughly After drying soak the air filter in clean Foam FilterOil or an equivalent Apply air filter oil to the entire surface of the air filter and rub it with both hands to satura...

Page 20: ... is contaminated Replace the plug if the center electrode is rounded as shown in the pic ture Always use the specified spark plugs on this motorcycle RECOMMENDED SPARK PLUG OR EQUIVALENT Standard DENSO IK24 Optional DENSO IK27 Check the gap between the center and side electrodes with a wire Type feeler gauge To prevent damaging the iridium center electrode use a wire type Feeler gauge to check the...

Page 21: ...then reinstall the cap Recommended antifreeze Professional coolant or an equivalent high quality ethylene glycol antifreeze containing silicate free corrosion inhibitors COOLING SYSTEM Remove the radiator grills Check the radiator air passage for clogs or damage Inspect the hoses for cracks and deteriorations Use low pressure water and a soft brush to wash off any dirt that may be stuck in the rad...

Page 22: ...elow35 950f Remove the cylinder head cover Remove the crankshaft hole cap and O ring Turn the crankshaft clockwise to align the punch mark with the index mark on the right crankcase cover Make sure the piston is at TDC Top Dead Center on the compression stroke Check that the index line on the cam sprocket aligns with the mark on the cam holder ...

Page 23: ...ker arm and shim Check the valve clearance for the exhaust valves using a feeler gauge Valve clearance Ex 0 28 0 03mm VALVE CLEANCE ADJUSTMENT Remove the camshaft holder assembly The shims my stick to the inside of the valve lifter Do not allow the shims to fall into the crankcase The shims can be easily removed with tweezers or a magnet Clean the valve shim contact area in the valve lifter with c...

Page 24: ... D old shim thickness Make sure of the correct shim thickness by measuring the shim using a micrometer Reface the valve seat if carbon deposits result in a calculated dimension of over 3 000mm Install the valve lifters into the camshaft holder assembly Install the camshaft holder assembly With the valve clearance adjusted check and adjust the decompressor clearance Reinstall the cap and hand tight...

Page 25: ... CLEARANCE 0 15mm EXAMPLE If measured right exhaust valve clearance is 0 28mm decompressor clearance is 0 28mm 0 15mm 0 43mm If decompressor clearance needs adjustment see following procedure Measure the right exhaust valve clearance by inserting a feeler gauge between the right side rocker arm and shim VALVE CLEARANCE EX 0 28mm 0 03mm Pull out the feeler gauge between the rocker arm and shim Inse...

Page 26: ...t the motorcycle in an upright position on a level surface Remove theoil filter cap dipstick and wipe the oil with clean cloth Insert the dipstick without screw in take it out and check theoil level If the oil level is lower or near the lower level line on the stick add recom mended oil to the upper level line through the hole Reinstall theengine oil filter cap otherviscositiesshowninthechartmaybe...

Page 27: ...ling washer Tighten the engine oil drain bolt to the specif ied torque TORQUE 16N m Apply grease to thef ilter side of the spring end Install the spring into the oil filter as shown Install the oil filter with the OUT SIDE mark f acing out Installing the oil f ilter backwards will result in sev ere engine damage Apply engine oil to a new O ring and install it to the oil filter cover Install the oi...

Page 28: ...el or filling install the oil check bolt with a new sealing washer tighten the oil check bolt and oil filler cap CHANGING ENGINE OIL Run the engine to let it get hot before draining oil Support the motorcycle in an upright position on a level surface and re move the engine oil filler cap from the right crankcase cover Place an oil drain pan under the engine to catch the oil Then remove the drain b...

Page 29: ...rear wheel to inspect the drive chain and sprockets for damaged rollers loose pin and links unevenly or excessively worn or damaged teeth ADJUSTMENT Adjust the chain if the slack is too much or too little Loosen the axle nut and adjuster lock nuts and turn the adjusting bolts Check that the chain adjuster index marks are in the same position on both sides then tighten the axle nut Tighten the adju...

Page 30: ...rive chain roller for excessive wear or binding Service limit Minimum roller O D Upper 39mm Lower 35mm Replace the roller if necessary and tighten the roller bolt nut to the specified torque The sign means installing the drive chain roller outside Torque Upper bolt 12N m Lower nut 12N m DRIVE DRIVEN SPROCKETS Inspect the drive and driven sprocket teeth for wear or damage and re place if necessary ...

Page 31: ...s If the brake pads are worn the caliper piston is pushed out and this accounts for a low reservoir level If the brake pads are not worn and the fluid level is low check the entire system for leaks Front brake Position the site level in the horizontal position If the level is near the low level line check the brake pad wear Rear brake Support the motorcycle in an upright position on a level surfac...

Page 32: ...unterwork wise mov es the brake lev er closer the grip After adjustment hold the adjuster and tighten the lock nut to the specif ied torque Torque 5 9N m If the brake lev er f ree play exceeds 20mm there is air in the system that must be bled Brake pedal height Adjust the brake pedal to the desired height by loosening the lock nut and turning the pedal height adjusting bolts Standard height 79 6mm...

Page 33: ... wheel off the ground Grab the bottom of front suspension and rock the front wheel on both sides to check whether the front wheel axle is loose Grab the rocker and rock the rear wheel on both sides to check whether the rear wheel axle has problem Check the tires for cuts embedded nails or other damage Check the cold tire pressure Remember to do it when the tire is cold Check the rims and spoke for...

Page 34: ...Page 33 Maintenance ...

Page 35: ...Page 34 AWD Service Section AWD Service ...

Page 36: ...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 37: ...Page 36 AWD Detail Illustration ...

Page 38: ...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 39: ...nction see 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 Pressure washing the dropouts head tube area side bar and main gearbox ...

Page 40: ...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 41: ...n handlebars to the 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 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 check the front wheel to...

Page 42: ...Page 41 Cover and Chain Removal ...

Page 43: ...Page 42 Cover and Chain Removal ...

Page 44: ...move the chain 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 Do not use an O ring chain as there is not enough clearance for one and it would ru...

Page 45: ...g the tensioner 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 If cover does not seat on the sidebar the top sprocket is not fully seated in the bearing Cover and Chain Removal ...

Page 46: ...Page 45 AWD Engagement Disengaged AWD System Pull and Push with one finger to Engage Engaged AWD System ...

Page 47: ... 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 48: ...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 49: ...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 50: ...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 51: ...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 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 52: ...ugh 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 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 If wheel does not spin freely axle bol...

Page 53: ...Page 52 Front Wheel Service ...

Page 54: ...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 55: ...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 56: ...Page 55 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 57: ... 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 58: ... 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 Front Wheel Service ...

Page 59: ...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 60: ...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 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 Fork Removal ...

Page 61: ...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 62: ...Page 61 Dropout Service ...

Page 63: ...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 64: ... 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 65: ...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 66: ...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 67: ...r 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 bevel gear spins ...

Page 68: ...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 Slide bearing and pinion gear into bore Make sure bearing is fully seated 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 sho...

Page 69: ...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 70: ... dropout Insert 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 The band of clamp must be over the set screw to ensure that the set screw can not back out...

Page 71: ...Page 70 Fork Spline Bearing Service ...

Page 72: ...Page 71 Cut Black Zip Tie 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 73: ...Page 72 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 74: ...emove 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 Dirt will pack up in felt The felt can be cleaned and reused Fork Spline Bearing Service ...

Page 75: ... 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 fitting Fork Spline Bearing Service ...

Page 76: ...ft set screw Insert screw drive in vent holes and tap up on screwdriver Slide shaft upwards Note Do not slide shaft down and remove from linear bearing 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 ...

Page 77: ... 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 78: ...ic faced hammer tap the bottom triple clamp to unseat it from the frame 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 79: ...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 80: ...Page 79 Triple Clamp Service ...

Page 81: ...Page 80 Triple Clamp Service ...

Page 82: ...e cover The right shaft will stay in place and the cover will slide down over it 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 clar...

Page 83: ... 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 84: ...Page 83 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 85: ...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 86: ...Page 85 Tap the bottom output bearing from the bottom steerer tube Inspect gears and bearing and replace any parts if needed Note Head tube gears must be replaced in sets Triple Clamp Service ...

Page 87: ...e 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 Triple Clamp...

Page 88: ...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 89: ...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 90: ...chains with Shell grease 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 ...

Page 91: ...Page 90 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 92: ...not come out with gear use blindside bearing puller to remove the bearing If 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 in the head tube must be replaced at the same time Triple Clamp Service ...

Page 93: ...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 94: ...Page 93 Slide the steerer tube bearing back onto the output gear Press gear and bearing into top steerer tube Triple Clamp Service ...

Page 95: ...The driveshaft 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 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 Service ...

Page 96: ...Page 95 Head Tube Bearing Service Picture above shows a head tube not welded to the frame for reference ...

Page 97: ... 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 98: ...veshaft 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 lightly tap the gear to be sure it is fully seated Move the clutch retaining snap ring into the groove closest to the clutch hub Main Drive Shaft Removal ...

Page 99: ...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 100: ...re bottom output gear is meshing with the input gear before fully 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 preload bars Triple Clamp Installation ...

Page 101: ... 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 102: ...Page 101 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 103: ... 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 104: ...Page 103 Gear Box Service ...

Page 105: ...Page 104 Slide clutch basket off output gear Remove output seals from gear box Remove output snap ring Gear Box Service ...

Page 106: ...Page 105 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 107: ...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 108: ...lace 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 clutch basket...

Page 109: ...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 110: ...Page 109 Clutch Service Clutch Service ...

Page 111: ...ain 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 If metal plates are not scored or warped they do not need to be replaced Simply replace fiber plates during standard rebuilt Clutch Servic...

Page 112: ...f 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 Clutch Service ...

Page 113: ...flush with the 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 Once set screw is tightened do try to turn locknut as this will damage the hub threads Clutch Installation ...

Page 114: ... setting for proper torque using wheel check method Drive system is pulling to oneside 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 ...

Page 115: ...t 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 Plates and Friction Plates Shaft Bellows AWD Engagement cable and housing Sprockets and Drive Chains Parts or accessories affected...

Page 116: ...PLIED ALL IM PLIED WARRANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THAT OFTHE 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 st...

Page 117: ...Page 116 Warranty ...

Page 118: ......

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