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Christini AWD, Service Manual

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                                                                                                                           Service Manual 

Page 23 

AWD  Troubleshooting 

 

Problem 

 

Solution 

 

Clutch plate squeaks when  
the rear wheel is rotating. 

Apply a chain lubricant such as Pro-
Gold to the face of the clutch plate. 

AWD Switch is tight. 

 

Apply heavy grease to the ball bearing 
holes in the switch body (see page 16). 

“Chainsuck” 

Bounce up and down on the bike to 
compress the suspension while back-
pedaling to remove the chain from be-
tween the chainstay. 

Clutch plate makes a clicking  
noise as the rear wheel rotates. 

AWD engagement switch needs to be 
adjusted.  Turn cable tension adjuster 
counterclockwise until clicking noise 
goes away and the ball bearings firmly 
seat in the switch body holes (see page 
17).  

Front Freewheel Hub squeaks 

Apply a light oil or grease to the roller 
bearings inside the hubshell (see page 
15). 

Summary of Contents for AWD

Page 1: ...Service Manual Page 1 Service Manual Christini Technologies Inc 421 N 7th Street Suite 200 Philadelphia PA 19123 215 351 9895 215 351 9896 fax info christini com Version 1 3 ...

Page 2: ...Service Manual Page 2 ...

Page 3: ...aintenance 8 AWD Drive Shaft Removal and Installation 10 AWD Engagement Clutch Detail 13 AWD Engagement Switch Detail 16 AWD Engagement Cam Detail 17 Rear Suspension Detail 18 AWD Bearing Maintenance 19 Routine Maintenance Schedule 20 General Notes 21 AWD Lubrication Guide 22 AWD Troubleshooting 23 Appendix Christini AWD Limited Warranty 24 Christini Owner s Registration Card 25 Front Hub Maintena...

Page 4: ...hed power to climb steep hills Simply stated when the rear wheel slips the front wheel grips Congratulations You own an All Wheel Drive Bicycle Allen Wrench Set 2 2 5 3 4 with short end supplied 5 6 millimeter wrenches Plastic faced hammer or a rubber mallet Large flat bladed screwdriver small flat bladed screwdriver Torx style wrench included with disk brake set 10 millimeter box wrench Pair of n...

Page 5: ...Service Manual Page 5 Page 5 AWD Detail Illustration ...

Page 6: ...Rear Wheel Remove Clutch Remove Rear Bevel Gear Remove Shock Remove Suspension Link Remove Front Drive Shaft Remove Rear Pinion Remove Rear Drive Shaft Remove Pivot Bolts Remove Rear Triangle All Wheel Drive Bike Disassembly Process Separate the Front and Rear Driveshafts Remove Headtube Gear and Sprocket Shaft Remove Power Transfer Chain Remove Front Driveshaft ...

Page 7: ...use the rounded Bohndus end of the Allen wrench when first loosening the bolts You will strip the hex head of these bolts After these three bolts have been removed the fork can be pushed down out of the head tube of the bicycle If necessary use a plastic hammer to tap the fork out Hit the hammer on the top of the brake arch to avoid damag ing the forks valves Please refer to the White Brother s AW...

Page 8: ...and slide on the splined portion of the drive shaft Remove the fork drive shaft capture bolt It is an M6 bolt on the end of the fork drive shaft located under the pinion gear To loosen the bolt use the supplied short end 4mm Allen wrench to hold the bolt in position while turning the hex piece of the driveshaft counterclockwise from the top of the fork looking down with a 10mm box wrench TIP If th...

Page 9: ...d slide the chain crown up into place Use removable threadlocker when re installing the crown cover screws Use removable threadlocker on the pinion bolt Removal Slide the two sections of the front drive shaft together The chain crown cover can slide off at this point The pinion gear can also be removed at this point Remove the floating cog and power transfer chain from the internal section of the ...

Page 10: ...mount bolt and the rear shock Removal Remove the M6 capture bolt from the rear pinion assembly on the rear bevel dropout Use the supplied short end Allen Wrench to hold the bolt while spinning the drive system by hand to remove the bolt If necessary use a 10mm wrench to spin the square spline section of the drive system to help loosen the bolt Remove the rear shock mount bolt and then slide the sh...

Page 11: ...he headtube Removal Remove the pivot bolt in the lower portion of the suspension link If necessary use an Allen wrench smaller than the internal threads to punch the female portion out Carefully lower the rear linkage until the bottom yoke is resting on the bottom bracket pivot casing The main drive shaft will separate at the square splined universal joint section Remove the plastic dirt cover fro...

Page 12: ...nto their respective frame tubes The front shaft will slide through the headtube support bearings and then firmly seat on the edge of the miter gear The rear shaft will slide through the sup port bearings but may not seat completely on the u joint section There may be a small gap between the u joint and the bearing the top yoke If necessary replace the rubber u joint boots Slide the square spline ...

Page 13: ... in the top of the rear bevel gear Slide the top sliding jaw of the clutch up and out of the guides in the gear assembly Installation Attach the clutch and gear assembly to the rear wheel see page 14 Make sure that the engagement cams are in the off position they should be flush with the surface of the dropout Re install the rear wheel making sure to seat the axle completely into the rear dropouts...

Page 14: ...s down on the plate 4 5mm and slightly rotate the plate until it does not spring back up Install the snap ring and make sure that the clutch is free to rotate when the sliding jaw is pressed in completely Removal Remove the circular wave spring Use a Torx wrench to remove the 6 disk brake bolts that attach the gear assembly to the disk brake hub Remove the gear assembly from the hub To remove the ...

Page 15: ...te The flat face of the gear side end cap should face outward Removal Loosen the set screws on the end caps and remove them from the axle With a plastic hammer tap the disc side axle to loosen the freewheel insert A punch may be needed to completely free the insert from the hubshell Remove the freewheel insert and axle from the hub Apply a light oil or grease to the roller bearings inside the hubs...

Page 16: ...sure that the cable adjuster faces forward Use 2mm Allen wrench to tighten the clamp bolt which secures the switch to the handlebars Apply grease through the holes in the side of the switch body directly to the ball bearings if the engagement switch becomes hard to move AWD Engagement Switch Detail ...

Page 17: ...n of the system using the cable adjuster on the AWD switch Press the engagement switch up and turn the cable ad juster counterclockwise until the lever begins to pull away from the switch body second pic ture from the top Turn the cable adjuster back 3 4 of a turn and make sure the ball bearings seat completely in the switch body holes AWD Engagement Cams Cam Removal To remove the cam system from ...

Page 18: ...the suspen sion pivot Remove the M8 bolts from the remaining con nection between the suspension link and the rear triangle There is a washer on either side of the suspension link that needs to be installed between the link and the rear triangle This washer fits through the threaded sec tion of upper suspension link bolts During re assembly use removable threadlocker on all pivot bolts Rear Triangl...

Page 19: ...otate smoothly Bearings should be replaced if they begin to make excessive noise or they feel notchy Bearings are sealed and do not require lubri cation Please contact Christini if you think a bearing needs to be replaced AWD Bearing Maintenance ...

Page 20: ...maged mud guards Monthly Tighten frame linkage bolts Check disk brake bolts Lubricate headtube gearset with grease Lubricate the front and rear bevel gears with chain lube Yearly Disassemble clean and inspect the rear bevel clutch assembly Apply lightweight oil lube to the front silent freewheel hub Routine Maintenance Schedule AVOID Water in the headtube Water inside the frame Mud dirt or sand in...

Page 21: ...s if they show signs of extreme wear U joints shrink wrap boot Square spline section round to square scraper Fork drive shaft rubber pinion bearing shield Headtube protective plastic cap over miter gear access hole For all questions regarding tuning or maintenance of the White Brother s Fork please see the separate White Brother s owner s manual For all questions regarding tuning or maintenance of...

Page 22: ... Gears Gears are coated with TEFNI2000 to provide lubrication and corrosion resistance Apply a light amount of Pro Gold chain lube if noise occurs AWD Switch Apply heavy grease to the ball bearing holes in the switch regularly especially if the switch becomes tight Front Silent Freewheel Hub Apply a lightweight oil lube if the hub friction increases or if it begins to squeak AWD Lubrication Guide ...

Page 23: ...ck Bounce up and down on the bike to compress the suspension while back pedaling to remove the chain from be tween the chainstay Clutch plate makes a clicking noise as the rear wheel rotates AWD engagement switch needs to be adjusted Turn cable tension adjuster counterclockwise until clicking noise goes away and the ball bearings firmly seat in the switch body holes see page 17 Front Freewheel Hub...

Page 24: ...ons caused dur ing riding transport or handling of the product are not considered defects OTHER ORIGINAL COMPONENTS Any components not produced by CHRISTINI including the front suspension fork internal mecha nisms 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 custome...

Page 25: ...nty is void if your bicycle is subjected to abuse or abnormal use 3 This Warranty applies only to the Original Owner first retail purchaser from bicycle dealer dis tributor or direct from Christini so we suggest you register your purchase with CHRISTINI at the time of purchase Because Proof of Purchase by the Original Owner is required for making any Warranty Claim taking this simple step will sav...

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