Maico GM STAR 250 1986 Owner'S Manual Download Page 2

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CONTENTS

I Technical data

II Tightening torques

III Maintenance works - survey

IV Execution of maintenance works

V Suspension adjustments

VI Exploded view and part list engine

VII Engine Gear Box

VIII Exploded view and part list carburettor

IX Exploded view and part list chassis and frame

X Part list Enduro and Cross Country

IX Wiring Diagram

1986 MAICO Owners Manual

www.maicowerk.com

Courtesy of www.franklins.biz

Summary of Contents for GM STAR 250 1986

Page 1: ...1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 2: ...rks V Suspension adjustments VI Exploded view and part list engine VII Engine Gear Box VIII Exploded view and part list carburettor IX Exploded view and part list chassis and frame X Part list Enduro and Cross Country IX Wiring Diagram 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 3: ...10ES Rotor Inboard rotor External rotor PISTON DIAMETER LIST Standard 86 44 EDV Nr 6813 1st oversize 86 64 EDV Nr 6815 2nd oversize 86 84 EDV Nr 6816 3rd oversize 87 04 EDV Nr 6817 4th oversize 87 24 EDV Nr 6818 DRIVE Clutch 5 sintered 2 organic outer plates 6 inner plates Primary reduction ratio 1 970 65 33 1st Gear 1 875 30 16 2 285 32 14 2nd Gear 1 555 28 18 1 705 29 17 3rd Gear 1 300 26 20 4th...

Page 4: ...r security gear oil synthetic 100 FUEL CAPACITY Type Super also unleaded Lubrication 1 50 Klűber security motor oil 2T sport 1 100 Klűber security motor oil 2T synthetic WARNING Never mix mineral oil with synthetic oil never fuel when the motor is running never smoke whilst re fuelling THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD 1986 MAICO Owners Manual www maicowerk com Courte...

Page 5: ...d 66 97 EDV No 8370 1st oversize 67 37 EDV No 8373 DRIVE Clutch 5 sintered 2 organic outer plates 6 inner plates Primary reduction ratio 2 567 67 26 1st Gear 1 875 30 16 2 285 32 14 2nd Gear 1 555 28 18 1 705 29 17 3rd Gear 1 300 26 20 4th Gear 1 090 24 22 5th Gear 0 916 22 24 Secondary reduction ratio 4 000 52 13 3 250 52 16 Chain 5 8 x 1 4 116 links 114 links CARBURETTOR Type Bing 54 380 121 Bin...

Page 6: ...ber security motor oil 2T sport 1 100 Klűber security motor oil 2T synthetic WARNING Never mix mineral oil with synthetic oil never fuel when the motor is running never smoke whilst re fuelling THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD I TECHNICAL DATA continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 7: ... 0 4 at REAR SUSPENSION Construction Aluminium swinging fork made from rectangular pressed high resistant profile Afterwards tempered Shock absorber Öhlins Length 440 mm Travel 116 mm Rebound and compression damping Adjustable wheel at the end of the damper shaft Adjustable wheel at the reservoir Spring load Continuously controllable Suspension travel 350 mm BRAKES Front Hydraulic disc brake 235 d...

Page 8: ...security brake fluid DOT4 Brake system Rear About 35cc Klűber security brake fluid DOT4 In case of higher temperatures Klűber security brake fluid DOT5 THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz I TECHNICAL DATA continued ...

Page 9: ...crew for ignition system M5 5 Nm Engine mounting screws M8 25 Nm Screws for cylinder head support M8 25 Nm Front wheel axle M16 x 1 5 30 Nm Swing axle M14 x 1 5 30 Nm Rear wheel axle M20 x 1 5 90 Nm Hex screw for fixing of damper tube M18 x 1 20 Nm Hex screw for steering tube M27 x 1 No backlash Clamp screws for telescopic fork upper crosshead M10 45 Nm lower crosshead M8 20 Nm Clamp screw for fro...

Page 10: ...xhaust Look for easy movement of the slide valve check diaphragm for cracks Chassis After 0 5 1 hours testing time Before every race approx 60 miles Before every 3rd race approx 180 miles Steering head bearing Check tighten if required Cables Lubricate Lubricate check for damage and free movement Clutch free play Check adjust as necessary Brake pads Check wear Rear suspension linkage Lubricate the...

Page 11: ... dry Ensure proper fit PISTON RINGS The pistons rings have to turn freely in the notch and may only have limited free play COOLING WATER The cooling system is freeze protected down to 10ºC If necessary add anti freeze IMPORTANT Every time before starting the motorbike check the coolant level This level always must reach slightly beyond the filler neck If necessary refill IGNITION Adjustment of ign...

Page 12: ...se temperatures Air pressure and the oil volume should be set to meet individual body weight and travel requirements The oil volume can be changed by 20 mm to upper and lower reference point the air pressure by 0 2 at min air pressure 0 0 atmospheres max aIr pressure 0 4 atmospheres Telescopic fork characteristics normal fork oil quantity normal air pressure 0 0 2 at hard fork for sand big jumps h...

Page 13: ...t If this measurement is lower lessen the spring pretension If this measure higher increase the sprIng pretension THE RIGHT REBOUND 6 Turn the adjustment wheel by hand to the right until you come to a stop 7 Now turn 10 clickers to the left This is the right rebound On different tracks the rebound can be varied between and 2 to 3 clickers THE RIGHT COMPRESSION adjustment at the leading wheel of th...

Page 14: ...1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz VI ENGINE PARTS ...

Page 15: ...VI ENGINE PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 16: ...VI ENGINE PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 17: ...VI ENGINE PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 18: ...VII ENGINE GEAR BOX 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 19: ...VIII CARBURETTOR PARTS 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 20: ...IX CHASSIS AND FRAME PARTS 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 21: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 22: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 23: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 24: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 25: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 26: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 27: ...IX CHASSIS AND FRAME PARTS continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 28: ...X PARTS LIST ENDURO 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 29: ...X PARTS LIST ENDURO continued 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 30: ...X PARTS LIST CROSS COUNTRY 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 31: ...XI WIRING DIAGRAM MOTOPLAT 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

Page 32: ...XI WIRING DIAGRAM SEM 1986 MAICO Owners Manual www maicowerk com Courtesy of www franklins biz ...

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