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GPX MOTO

GPX 250r TSE

Maintenance Manual

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Summary of Contents for 250r TSE

Page 1: ...GPX MOTO 1 www GPXMOTO com www GPXMOTOUK com GPX MOTO GPX 250r TSE Maintenance Manual WWW GPXMOTO COM WWW GPXMOTOUK COM...

Page 2: ...dited by GPXMOTO No part of this publication may be reproduced without authorization GPXMOTO reserves the right to make changes at any time without notice and without incurring any obligation The vehi...

Page 3: ...nd gloves at the bare minimum It is expected that the operator has a good knowledge of riding and maintaining motorcycles If you do not you should seeking specialised riding coaching and take your mot...

Page 4: ...GPX MOTO 4 www GPXMOTO com www GPXMOTOUK com GPX MOTO...

Page 5: ...18 CHANGING GEAR 18 REAR DISC BRAKE 19 SIDE STAND 19 NA 20 PREPARING FOR USE 21 ADVICE ON FIRST USE 21 RUNNING IN PROCESS 21 RIDING INSTRUCTIONS 22 PREPARATION BEFORE RIDING 22 PREPARATION FOR STARTI...

Page 6: ...THE TRIPLE TREES 30 CHECK THE FRONT STEERING 31 LUBRICATION AND INSTALLATION OF STEERING HEAD BEARING 31 REMOVING OR INSTALLING FRONT HEADLIGHT 32 REMOVING OR INSTALLING THE FRONT FENDER 32 REMOVING...

Page 7: ...47 ELECTRICAL SYSTEM 48 REMOVING OR INSTALLING THE BATTERY 48 CHANGING THE BATTERY 48 MAIN CABLE GPX VEHICLE WIRING DIAGRAM 49 COOLING SYSTEM 50 COOLING SYSTEM PROFILE 50 REMOVING OR INSTALLING THE RA...

Page 8: ...ON OF THE CLUTCH 68 INSTALLATION OF THE RIGHT CRANKCASE COVER 69 REMOVAL INSTALLATION OF THE SHIFT MECHANISM IN THE ENGINE 70 MAGNETO AND ELECTRIC ENGINE COMPONENTS 71 REMOVAL INSTALLATION OF STARTER...

Page 9: ...GPX MOTO 9 www GPXMOTO com www GPXMOTOUK com PREPARING FOR USE AFTER LONG STORAGE 84 MAINTENANCE POINTS 84 TORQUE SPECIFICATION TABLE FOR THE WHOLE VEHICLE 89...

Page 10: ...nt responsibility Please read this manual carefully Safety Messages preceded by a safety alert symbol and one of three signal words DANGER Indicates a danger that will immediately and invariably lead...

Page 11: ...or recommended by GPX and have them installed by an authorized GPX workshop GPX accepts no liability for any personal modification other products and any resulting damage or loss Our TSE series produc...

Page 12: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 11 APPEARANCE TSE 250R COMPONENTS AND POSITIONS...

Page 13: ...er 10 Front brake caliper 2 Headlight 11 Front shock 3 Handlebar 12 Fuel tank 4 Vent pipe 13 Carburettor 5 Fuel tank cap 14 Gear shift lever 6 Fuel tank petcock 15 Pedal 7 Air filter cover 16 Chain 8...

Page 14: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 13...

Page 15: ...rake caliper 20 Rear fender 29 Aluminium swinging arm 21 Exhaust silencer 30 Triangle rocker arm 22 Seat 31 U shape rocker arm 23 Rear shock 32 Rear brake oil cup 24 Upper clamp 33 Brake pedal 25 Cool...

Page 16: ...PXMOTO com www GPXMOTOUK com 15 VIN CODE Vin code of the TSE 250r is located on the head stock CHASSIS NUMBER Chassis Number of TSE 250r is located on the headstock frame chassis under the handlebars...

Page 17: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 16 The engine number of TSE 250r is located on the engine case behind the cylinder block...

Page 18: ...quality branded fully synthetic 2 stroke oil Displacement 224cc Max Power kw r min 39 8500 Max Torqu e NM r min 36 7500 Compression Ratio 6 5 1 Shift type Usually engaged two stage transmission six s...

Page 19: ...vailable after market L 950mm Rear shock Compression recovery dual adjustable nitrogen airbag rear shock L 480mm 300mm travel CRF general configuration Quality high performance unit with spring preloa...

Page 20: ...8 7050 high strength aluminium rim forged CNC wheel hub F brake system Powerful Hydraulic alloy twin piston caliper with 260mm disc R brake system Powerful Hydraulic alloy twin piston caliper with 240...

Page 21: ...ce between the clutch lever and handlebar to your preference FRONT DISC BRAKE The front disc brake is controlled by the hand brake lever which is fitted on the right side of the handlebar By adjusting...

Page 22: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 21...

Page 23: ...side of the handlebars near the throttle grip It is expected that you will only need to press this button for a maximum of 2 seconds to start the motorcycle Release the button as soon as the engine st...

Page 24: ...tank switch is shown as the left picture ON indicates that the switch is opened for petrol discharge OFF indicates that the switch is closed and the petrol discharge is stopped RES indicates that the...

Page 25: ...ng the right foot The rear brake adopts a floating caliper disc brake This is located on the right side of the rear wheel and fixed by a disc brake bracket SIDE STAND SUPPORT The GPX has a retractable...

Page 26: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 25...

Page 27: ...correct the working gap and form a good smooth friction surface that can withstand larger loads Only after standard running in can the engine have excellent performance and reliability The recommende...

Page 28: ...Check battery level 14 Check the thickness of the front disc brake 15 Check the thickness of the rear disc brake 16 Check the torque of each fastener 17 Check the rear sprocket to ensure the conditio...

Page 29: ...shifting gears 2 Do not rev the engine when shifting gears 3 Do not shift gears in the corner PRECAUTIONS FOR BRAKING 1 Use the rear brake as your first brake operation if necessary use hand brake as...

Page 30: ...ndlebars etc and check for smooth Check the front disc brake fluid level Check the free play of brake handlebar Check whether the steering head bearing for loose Check valve clearance Check clutch Rep...

Page 31: ...r 75 85KGS If the rider s weight is above or below the standard range the basic setting must be adjusted accordingly A small weight difference can be compensated by adjusting the rear shock absorber s...

Page 32: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 31...

Page 33: ...ed point on the side of the rear fender and mark it as point 1 3 Measure the distance from Point 1 to the centre of the rear axle and record it as A1 4 Remove the motorcycle from the rack MEASURE DIST...

Page 34: ...ower than the factory value you should decrease the spring preload appropriately Conversely increase the spring preload If D2 is far less than the factory value replace the spring with a softer one Co...

Page 35: ...DAMPING OF THE FRONT FORKS Adjusting Steps as follows 1 Check the front shock absorber to determine whether there is a need to adjust the rebound damping 2 Turn clockwise to increase rebound damping T...

Page 36: ...pad on the handlebar 2 Loosen the bolts securing the upper handlebar clamp so that the handlebar can be turned 3 Sit on the whole vehicle and hold the handlebar to the position where both hands are pl...

Page 37: ...mounting screws 3 Remove the disc brake cover Installing steps The instalment should be carried out in the reverse order of removal REMOVING OR INSTALLING THE FRONT FORK PROTECTION GUARDS Removing Ste...

Page 38: ...caliper Installing Steps The instalment should be carried out in the reverse order of removal REMOVING OR INSTALLING THE FRONT SHOCK ABSORBER Removing Steps as follows 1 Remove the front disc brake c...

Page 39: ...Remove both front forks 5 Remove the handlebars 6 Remove the lock nut and the punch bolt of the steering column as indicated 7 Remove the upper steering clamp 8 Remove the headstock bearings adjusting...

Page 40: ...GPX is feeling graunchy stiff or is loose with excessive movement please remove the top and bottom steering clamps to check that the bearing is both clean and greased and also that it is adjusted to...

Page 41: ...follows 1 Remove or loosen the rubber fixing strap on both the left and right fork suspension leg 2 Remove the headlight 3 Pull out the connector between headlight and main cable Installing Steps The...

Page 42: ...35 www GPXMOTO com www GPXMOTOUK com Removing Steps are as follows 1 Remove the 2 fixing screws 2 Pull out the Front Fender Installing Steps The instalment should be carried out in the reverse order o...

Page 43: ...bolts 3 Remove the bolt as indicated on the lower U shaped rocker arm 4 Remove the connecting bolts between the rear shock absorber and the triangular rocker arm 5 After confirming that there is no in...

Page 44: ...ut in the reverse order of removal but reapply grease on the locating pins to ease installation and removal NOTE GPX adopts a unique tool free maintenance design The side cover of the air filter can b...

Page 45: ...d perform maintenance as follows 1 Clean the inside of the air box so that no dirt remains on nay surfaces 2 Remove the sponge air filter and remove the frame from within it 3 Clean the sponge with ai...

Page 46: ...muffler tube please follow the steps below Unscrew the 2 mounting bolts of the silencer Unscrew the fixing bolts of the silencer Loosen the buckle at the connection between the silencer and the exhaus...

Page 47: ...as below 1 Remove the seat 2 Remove the left and right radiator shroud screws 3 Unscrew the single central fuel tank installation screw 4 Remove the fuel tank from the frame Installing Steps The inst...

Page 48: ...ure there is no dirt and that it is well lubricated Clean the Chain Use a special cleaning detergent to wash the chain links Wait until the chain is naturally air dried and then apply a layer of chain...

Page 49: ...ear of the chain guide pull the chain upwards so that it is taut The distance between the chain and the swinging arm should be 50 60mm 3 Be aware that sometimes the chain may become slightly more loos...

Page 50: ...ue to the harsh condition they operate in We repeat from an economic point of view it is worthwhile to replace the entire chain drive system at the same time At any time you should use the original pa...

Page 51: ...the surface of the frame is damaged or not 2 Check whether the fixed points of the frame are deformed or not especially the installation points of the engine swinging arm and rear shock absorber 3 Che...

Page 52: ...on the handlebars naturally and feel whether the position of the clutch grip and brake grip are comfortable or not If it does not feel comfortable adjust the components accordingly ADJUST THE POSITIO...

Page 53: ...e lever feels soft and pulls into the handlebar with little braking power it is possible that air has entered the hydraulic brake system You should check the entire brake system and take measures acco...

Page 54: ...to the limit thickness of the disc brake it must be replaced immediately The limit thickness table of disc brake is as follows Limit thickness of Limit thickness of Front Brake Disc Rear Brake Disc G...

Page 55: ...ke fluid NOTE You should change the brake fluid once a year even it has not used for a long time IMPORTANT _ The brake fluid is extremely corrosive and you should protect yourself from this The fluid...

Page 56: ...www GPXMOTO com www GPXMOTOUK com In normal use the free play of the brake pedal is shown in the table below Check the brake lever and pay attention to whether the stroke is correct Model Free Play G...

Page 57: ...e fluid NOTE Do not splash the brake fluid on the paint surface which may cause corrosion DANGER Please pay attention to check whether the brake fluid is leaking and whether the brake fluid pipe is da...

Page 58: ...be less than 2 mm If the thickness of the brake pads is lower than the minimum thickness the entire set of brake pads should be replaced immediately WARNING DANGER If it is found that the brake system...

Page 59: ...ried out in the reverse order of removal REMOVING OR INSTALLING THE REAR WHEEL Removing Steps are as follows Remove the chain Loosen the rear wheel axle bolts Holding the rear wheel with one hand with...

Page 60: ...for help Pressure advice Front Tire Rear Tire GPX 225kPa 280kPa NOTE Do the checking work only on cold tires i e when the temperature of the tires equals the ambient temperature CHECK SPOKE Use your f...

Page 61: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 48...

Page 62: ...Remove the screw on battery holder 4 Pull the battery up and out Installing Steps The instalment should be carried out in the reverse order of removal CHANGING THE BATTERY If you found bubble appears...

Page 63: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 50 MAIN CABLE GPX VEHICLE WIRING DIAGRAM...

Page 64: ...he cooling system from rust erosion or freezing the coolant must have the required level of antifreeze within it WARNING Antifreeze is a kind of chemical reagent and may cause problem to human body pl...

Page 65: ...eze level DRAIN OUT THE COOLANT You can drain the coolant out of the engine and cooling system through drain bolt Main work Stand the motorcycle upright and allow the engine and coolant system to cool...

Page 66: ...the coolant level if necessary Tighten the radiator cap WARNING DANGER OF SCALDING Do not remove the radiator cap screw or other cooling system components when the engine is hot Wait for the engine an...

Page 67: ...n it with nuts and bolts 3 Install the throttle cable and air filter the interface should be sealed and the clutch control cable should be installed 4 Install the transmission chain 5 Install the left...

Page 68: ...ew to reduce the engine speed as much as possible 4 Adjust the air screw to increase the engine speed as much as possible 5 Repeat the above steps until a satisfactory speed is obtained 6 Check whethe...

Page 69: ...r The cleaning steps as follows 1 Place a container under the carburettor for receiving fuel 2 Turn off the fuel tank switch 3 Unscrew the drain bolt of the carburettor and wait for the fuel to flow o...

Page 70: ...1 Loosen the fixing bolts of the shift lever 2 Remove the shift lever 3 Turn the shift lever to a suitable position and install the spline 4 Tighten the shift lever fixing bolt INSPECTION OR REPLACEM...

Page 71: ...lean it with washing kerosene before adding new lubricating oil according to the regulations The thermal engine system of this engine must be lubricated with two stroke special engine oil The engine o...

Page 72: ...an be discharged quickly and completely When replacing place an oil pan under the engine and unscrew the oil bolt A to release the lubricating oil Check the plug gasket for damage and replace it with...

Page 73: ...GPX MOTO www GPXMOTO com www GPXMOTOUK com 60...

Page 74: ...ck whether the impeller is damaged the cooling water seal is moving and the static ring sealing surface is abnormally worn or strained If it is damaged it needs to be replaced Check whether the end fa...

Page 75: ...uter diameter 66 752 66 767 66 602 Piston pin hole inner diameter 16 004 16 015 16 042 Width of the bottom of a ring groove 0 86 0 875 0 96 Width of the bottom of the second ring groove 1 21 1 23 1 31...

Page 76: ...it is easy to disassemble When doing this work avoid damaging the cylinder contact surface CYLINDER INSPECTION Check whether the cylinder is worn or damaged To measure the inner diameter of the cylin...

Page 77: ...TE When disassembling do not damage the piston ring Check whether the piston has abnormal wear or cracks and whether the piston ring groove has abnormal wear CLEANING AND INSPECTION OF CYLINDER HEAD C...

Page 78: ...outer diameter of the piston pin The standard value is 16 994 0 17 000 INSTALLATION OF PISTON RING The installation steps of the piston ring are as follows 1 Thoroughly clean the piston ring groove 2...

Page 79: ...LATION OF PISTON Install the piston piston pin and new piston retaining ring NOTE When installing the piston the side with the mark should be aligned with the direction of the exhaust pipe The end cle...

Page 80: ...stall the cylinder head gasket 5 Install the cylinder head The tightening torque of the cylinder head nut 24 2N m REMOVAL OR INSPECTION OF CLUTCH CLUTCH PARTS SPECIFICATIONS ITEM STANDARD mm REPAIR LI...

Page 81: ...emove the clutch friction plate pressure plate and pull rod 3 Loosen the clutch lock nut 4 Remove the clutch assembly 5 Remove the spline washer and clutch bushing 6 Remove the clutch cover 7 Remove t...

Page 82: ...H The clutch installation steps are as follows 1 Install driven gear and balance gear 2 Install driven tooth flat key and balance tooth flat key 3 Install balance tooth lock washer and driving tooth w...

Page 83: ...s 8N m NOTE When installing the lock nut gasket of the clutch the concave surface of the gasket should face the clutch INSTALLATION OF THE RIGHT CRANKCASE COVER The installation steps of the right cra...

Page 84: ...e fastening bolts of the stop plate 4 Remove the stop plate 5 Loosen the hexagon socket bolt 6 Remove the five star dial 7 Remove pins Installation is carried out in the reverse order of removal NOTE...

Page 85: ...SE COVER The disassembly and assembly steps of the left front cover are as follows 1 Remove the mounting bolts of the left front cover 2 Remove the left front cover 3 Remove the sealing paper pad 4 Re...

Page 86: ...ing gasket 3 Remove the rotor part of the magneto Installation is carried out in the reverse order of removal NOTE Clean the conical surface of the crankshaft and the oil in the cone hole of the rotor...

Page 87: ...e engine and place it on a clean workbench 2 Release the lubricating oil 3 Remove the right crankcase cover 4 Remove the clutch parts 5 Remove the left front cover 6 Remove the magneto parts 7 Remove...

Page 88: ...crankcase or tap the crankshaft REMOVAL OF THE TRANSMISSION MECHANISM The removal steps of the transmission mechanism are as follows 1 Remove the fork shaft A 2 Remove shift fork C 3 Remove variable...

Page 89: ...the shift fork plate A Standard value 4 93 5 0 Repair limit value 4 83 Check the fork pin diameter B Standard value 5 93 6 0 Check whether the rotation and axial sliding of the gears of the main and c...

Page 90: ...ork pin into the groove of the shift drum NOTE Do not install the wrong mark on the fork 7 Align the fork shaft holes of the fork 8 Insert the fork shaft 9 Rotate the main and auxiliary shafts to see...

Page 91: ...ence The tightening torque of the nut is 40 50N m and pry up at the flat side of the lock nut 4 The lock washer locks the nut 5 Install the piston parts 6 Install the cylinder block parts 7 Install th...

Page 92: ...ressure in the cylinder 4 Valve timing correct valve opening time After the engine malfunctions you can focus on the above four aspects to start check analyse the cause of the malfunction and eliminat...

Page 93: ...start The choke door is opened too much Improper adjustment of the carburettor fine tuning screw Engine does not ignite Air intake pipe leaks Incorrect ignition timing Remove the spark plug Wet spark...

Page 94: ...gine performs poorly at high speeds Check the ignition timing and valve clearance Incorrect The ignition controller is faulty Improper valve clearance adjustment The magneto is faulty Valve clearance...

Page 95: ...roduce abnormal noise Abnormal noise in the driving and driven gears Gear machining accuracy is not enough The gear teeth are worn The matching clearance between the driving and driven gears is too sm...

Page 96: ...r Polyisobutylene used as a thickener and used with other materials to improve adhesion flexibility aging resistance air tightness and electrical insulation 4 Ash content Ash content refers to the ino...

Page 97: ...e until the engine reaches the working temperature 8 Lubricate the chain and all other parts that need to be lubricated WARINING Never use high pressure water to clean the vehicle Avoid direct contact...

Page 98: ...hat need to be checked before daily driving 6 Routine lubrication for motorcycles MAINTENANCE POINTS In the following content we will enumerate the problems that occurred during your use find out the...

Page 99: ...ner should add new mixed fuel to the engine before the GPX can drive Because the moisture in the crankcase is difficult to completely evaporate the new fuel still contains a small amount of moisture T...

Page 100: ...damaged parts Ignition rotor is damaged Replace the rotor Water mixed in the fuel Empty the fuel then inject new fuel Insufficient engine power or poor acceleration Problems with fuel supply Clean fu...

Page 101: ...lace if necessary The selector position spring is damaged Replace the selector position spring Clutch slip Clutch disc wear Replace the clutch disc The clutch pressure plate spring is too soft or dama...

Page 102: ...the limit thickness replace it Damaged cylinder head Contact GPX Service Centre Brackets nuts and bolts are not tightly fastened Check and adjust the torque of the corresponding fasteners The gasket i...

Page 103: ...6 2 7 11 3 Steering column screw Aluminium silver 1 4 Upper pressure block mounting screws M8 30 4 20 32 5 Front disc brake rotor mounting bolt M6 16 6 7 11 6 Front axle mounting nut M16 1 5 H14 1 175...

Page 104: ...ll thread 1 7 11 28 High voltage package mounting bolt M6 20 2 7 11 29 Plastic mounting bolts M6 16 full thread 10 7 11 30 Igniter mounting bolt M6 16 full thread 2 7 11 31 Voltage stabilizer mounting...

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GPX 250r TSE, Maintenance Manual

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