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being turned fully clockwise. (A click is approximately 

1

8

turn) See photo III.62. The compression circuit determines the rear wheels

resistance to moving quickly upwards, such as when hitting a high speed bump or landing from a jump. Stiffer compression settings
will help resist bottoming. However, too stiff settings will make the bike harsh and the rear wheel tend to wash out. Large jumps will
require stiffer settings. In the absence of unusual obstacles, the suspension would ideally be set so it just bottomed lightly on the hard-
est bump or landing on the track so the full range of suspension travel would be utilized. Tuning the suspension to work well for 80%
of the track will probably yield better lap times than tuning for the extreme 20% portion. Tire pressures will also affect the rear while
cornering and accelerating, tire pressure can be adjusted as needed as long as minimum pressure is maintained.

Rebound dampening is adjusted by turning the large rubber adjuster at the bottom of the shock spring retainer. Turning it counter-

clockwise as viewed from the top will increase the rebound dampening. The rebound dampening knob has 16 “click” positions total
and the standard setting is 8 clicks out from being turned fully clockwise. See photo III.61. The rebound dampening controls the speed
at which the wheel pushes downward after being pushed up by a bump. If the rebound dampening is set too light, the bike will tend to
bounce after a landing. The rear wheel will kick up when hitting bumps and leaving jump faces. If the rebound dampening is too
heavy, the wheel will not be able to return to its normal position quickly enough, and the bike will tend to run low with little suspen-
sion travel left after hitting the first bump in a series. Try decreasing the dampening setting 1 click at a time until the bike begins to
bounce or kick up a little, then increase the rebound setting slightly. Increasing shock spring preload will probably require increased
rebound dampening to compensate. 

In general, the compression adjuster will probably need more fine tuning than the rebound adjuster once it is properly set. If avail-

able, use a video camera to film the bike on various sections of track. Play the recording back at slow speed and determine if the tires
seem to be bouncing too much to maintain contact with the ground, or if the bike seems
to ride too high or too low. If the tires can’t react quickly enough to maintain contact
with the ground, reduce rebound and/or compression dampening. Adjust spring preload
to obtain proper level ride height.

Curnutt Shock (X3 model)

The shock “sag” must be adjusted for rider weight and ability. To measure sag, put

motorcycle on stand with rear wheel off the ground. Measure from center of rear axle
to side panel screw near rear of seat. Have rider with all riding gear sit on bike and
take measurement again. Sag is the difference between the two measurements. Set sag
to 2˝ minimum, 3˝ maximum by adjusting the spring preload as described below. 

Optional stiffer and softer springs are available for different rider weights and abili-

ties. Faster, heavier riders will likely need the stiffer spring, while lighter beginning
riders may need the softer spring. If the sag must be set to 2˝ or less to prevent bottom-
ing, purchase the stiffer spring. If using 3˝ of sag or more to make suspension soft
enough and bottoming is not a problem, the softer spring is indicated.

Adjusting Sag

- To adjust the sag, first clean and lubricate the shock body and threads.

Then, loosen the set screw on the spring seat 

1

4

turn using a 

1

8

” allen wrench. Adjust the

spring seat using a 

XXXX

tool. Turning the spring seat clockwise will preload the

spring more and decrease sag, counterclockwise will increase the amount of sag. Once
sag is set properly, tighten the set screw and apply a dab of silicone sealer to the set
screw to seal out dirt and water. Do not overtighten the set screw or damage will result.

The Curnutt shock is further tuned by utilizing air pressure in the shock reservoir. To

prevent damage never use less than 75 psi or more than 150 psi! Within this range, lower
pressures will yield softer dampening and higher pressure will yield firmer dampening. If
150 psi is required to prevent bottoming out, a stiffer spring may be necessary. If the sus-
pension still seems too stiff with 75 psi of pressure, a softer spring is required.

The supplied air pump can be used to adjust the air pressure in the shock. Begin with

changes of approximately 25 psi, then fine tune by 10 psi increments.

Adjusting Air Pressure

- Adjust air pressure when shock is cold and rear wheel is off

ground (shock is fully extended). Remove the cap from the valve on the shock reservoir
bottom. See photo III-64. Thread the pump onto the valve approximately 5 turns, or until
you feel it touch the top of the fitting. Once it touches, tighten 1 further turn (do not
overtighten to prevent damage). When pump is properly fitted, the shock pressure will
register on the pump gage. Stroke the pump a few times, the shock pressure should
increase slowly. If the pressure increases rapidly, the valve may not be open. In this
event, tighten the pump cautiously until valve opens. Pump air into shock to reached
desired setting (pressure must be between 75 and 150 psi). Remove pump and replace
valve cap.

Preload adjuster on Curnutt shock

Air reservoir fitting - Curnutt shock

III

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.63

III

III

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Summary of Contents for X1R

Page 1: ...URES 1 Notes warnings 10 2 Maintenance lubrication schedule chart 10 3 Maintenance preparation 10 4 Coolant 11 5 Air cleaner service 11 6 Transmission oil 11 7 Seat removal 12 8 Fuel tank gas filter 1...

Page 2: ...tion assembly 39 21 Final drive 39 chain adjustment and lubrication 39 Sprockets gearing 40 chain roller wear pads 41 22 Cleaning storage 41 23 Pre post between race maintenance 42 24 Special tools su...

Page 3: ...ges 4 6 assuming they have the size strength reflexes and maturity to operate a competition motorcycle Make sure your child can confidently ride a bicycle and understand and respond to your instruc ti...

Page 4: ...ll front number plate by inserting 3 fingers into holes in front fender then insert phillips M5x30 screw using metric spacer 5 5 x 12 x 20 Spread the grey plastic front brake cable guide over cable pu...

Page 5: ...st gently turn in until it stops then back out counting the turns to the desired setting The fuel metering screw can cause overall jetting to be too rich if it is turned out too far Note that the fuel...

Page 6: ...t the rear caliper Check the movement of the caliper arm it should be 5 10mm measured at the tip of the arm Adjust caliper as needed using the same procedure as for the front brake caliper see section...

Page 7: ...x 27oz Engine Ice antifreeze dual radiator models Carburetor model X1 Dell Orto PHBG19 19mm X1 models sleeved to 14mm for AMA compliance X3 21mm sleeved to 19mm X5 XX jet sizes X1 main 88 needle W3 2n...

Page 8: ...may not provide enough lubrication cause piston rings to stick cause heavy deposits in engine and foul spark plugs or separate from the gasoline The use of Maxima brand K2 premix oil is strongly recom...

Page 9: ...lider retaining bolt 20 ft lbs 27 1Nm Fuel tank screw snug by hand only Handlebar clamps 18 ft lbs 25 Nm Lower shock nut 33 ft lbs 45 Nm Rear axle nut 37 ft lbs 50 Nm seat bolt snug by hand only Spark...

Page 10: ...s check for worn or curved teeth each time chain is adjusted Chain roller wear pads check roller for free rotation when checking chain Make sure roller is not bent or damaged Check chain wear strips o...

Page 11: ...due 2 Next wash your filter twice with dish soap and hot water Rinse a third time Do not stretch or twist the filter Be careful not to dam age or crush the seams at the corners of the filter 3 Let fil...

Page 12: ...uel filter drain fuel and remove tank Remove two screws attaching fuel valve to bottom of tank using an 8mm socket Pull valve out of tank Clean fuel filter carefully do not attempt to remove filter fr...

Page 13: ...retaining bolts and torque to XX in lbs Install lever spring and caliper lever and loosely install nut to retain lever Push caliper onto mounting pins and reinstall front wheel Spread pads to insert d...

Page 14: ...weight of motorcycle A clean bike is easier to inspect and service However be very cautious if using a pressure washer The extremely high pressure water can cause considerable damage to wheel bearing...

Page 15: ...ting more difficult Always use new rings circlips 2 when replacing piston replacing rod bearing and pin with each new piston is also a good idea Use of a high quality synthetic or semi synthetic premi...

Page 16: ...ve cylinder nuts Remove 4 nuts on top of cylinder head using a 10mm wrench To pre vent warpage loosen nuts 1 4 turn at a time using a criss cross pattern until finger tight then remove Remove cylinder...

Page 17: ...ton There should be no noticeable slop Put rod bearing in end of rod and fit piston pin through bearing Lift straight up on pin to check for any play Replace bearing and pin when installing new piston...

Page 18: ...bustion chamber or cylinder into coolant passages Cylinder ID Iron cylinder 40 0 40 015mm new 40 030mm max Aluminum cylinder 40 180 40 220mm new 40 230mm max Piston to cylinder clearance 030mm min 070...

Page 19: ...olts to 10 Nm Guide expansion pipe through frame and insert rear of pipe into muffler Lubricate o ring on front of pipe then insert front of pipe into exhaust exten sion and twist pipe back and forth...

Page 20: ...haft is not free to move Inspect the gears shafts and bearings closely for damage bending or excessive wear Also check the cases for damage or cracks around the bear ing bores and the swingarm pivot b...

Page 21: ...e hook under the seal lips then pull the shaft of the tool outward to rotate the hook under seal Jerk handle firmly to remove seal See photo III 28 To install seals begin by lubricating both sides of...

Page 22: ...Regular oil changes and cleaning of the clutch will help prevent problems The Maxima MTL 75 transmission oil has special additives to prolong clutch life and is strongly recommended Three shoe clutch...

Page 23: ...arating from shoe Check spring washers for signs of abnormal wear or for flattening also examine shoulder bolts for any grooves or wear Check inside of clutch drum for scoring or uneven wear If clutch...

Page 24: ...hreadlocker on clutch nut Check end of crankshaft for wear Make sure starter gear will slide over end of shaft Remove any burrs as required with a file cov ering clutch and cases with a rag to make su...

Page 25: ...d a weaker early style kickstarter drive gear and driven gear See photos III 39 III 40 These parts can be upgraded but due to the thicker drive gear the clutch cover case will need to be machined to m...

Page 26: ...peration Shake float gently to make sure no fuel has entered float If the bike smokes alot and the plug seems fouled with oil the transmission seal behind the clutch assembly may be leaking oil into t...

Page 27: ...will have to put a piece of tape on the throttle housing by the grip Make a mark on the grip and mark the tape at the closed position Twist the grip fully open and mark the position on the tape Find a...

Page 28: ...ing the needle Adjust the clip position as needed by removing the small clip and snapping it into another groove The top groove will cause the needle to run leanest the bottom groove will cause the ne...

Page 29: ...uch float height will cause a lean condition In severe cases fuel can fill up the motor which can cause the piston to lock and create a fire hazard If you suspect the carburetor has overflowed do not...

Page 30: ...e squeezed together to fit into the center portion of rim so the tire will be loose enough to pry over the edge of the rim Squeezing tire into rim on one side insert a tire iron into tire on the oppos...

Page 31: ...ition Push the rim to one side and remove the rim from the spokes on the other side then work your way around to completely remove the rim Install the rim starting one one side making sure the angles...

Page 32: ...the X3 X5 models Lighter riders can try a 7wt oil or mix a 5 and 10wt oil to reduce dampening force Different brands of oil also have slightly different weights for the same specification Oil weight...

Page 33: ...e a spacer not shown at the top of the spring if the fork was adjusted for a heavier rider Remove the fork spring and invert the fork to drain oil Pump the fork a few times to remove most of the oil T...

Page 34: ...ing preload Use a spanner wrench to adjust the slotted adjusting nut Use of a screwdriver and hammer to turn nut may damage nut and shock threads Loosen the upper lock nut before adjusting the spring...

Page 35: ...The shock sag must be adjusted for rider weight and ability To measure sag put motorcycle on stand with rear wheel off the ground Measure from center of rear axle to side panel screw near rear of seat...

Page 36: ...n and side to side to check for excessive play or binding Loosen and remove the swingarm shaft nut on the left side of bike using a 19mm socket Prevent the bolt from turning by using a wrench or socke...

Page 37: ...den To install the grips it is best to use grip cement Follow the direc tions on the glue for best results Make sure the glue does not get onto the end of the throttle tube that goes into the housing...

Page 38: ...en tighten the screws Recheck the 0 measurement and the fir ing measurement and make any final adjustments Check to make sure the flywheel doesn t rub the stator if so insert 3 or 4 shims or feeler ga...

Page 39: ...or rag to remove heavy deposits of dirt Put the motorcycle on a stand with the rear wheel off the ground or lean the bike against the kickstand to pull the rear wheel off the ground Spray the oil on t...

Page 40: ...al gear ratio of the motorcycle Using more teeth on the front sprocket raises gearing while adding teeth to the rear sprocket lowers gearing The calculate the actual gear ratio divide the number of te...

Page 41: ...he next and so on Between moto maintenance Clean the bike as best you can between motos Inspect the bike for damage and repair it the best you can in the time you have In the event of more than minor...

Page 42: ...contains exploded parts diagrams part numbers main case splitter tool 144 695 001 needed to split main cases clutch puller set 2 3 shoe flywheel 99029 this tool is the most useful puller for the price...

Page 43: ...or piston Exhaust if power is down check for large dents blown out silencer packing or heavy carbon fouling Engine make sure motor mount bolts are tight Brakes are dragging or not working check for Mu...

Page 44: ...ed the circlip Consider powder coating parts for protection and appearance Exhaust pipe can be coated with high temperature ceramic coating for durability The piston can be dry film coated for longevi...

Page 45: ...discount gear www elineaccessories com www factoryconnection com www maximausa com Maxima lubricants www motocrossaction com www moto directory com www oneal com www promotorcyclesafety com neck suppo...

Page 46: ...ition 3 intake 15 jetting 26 29 kickstarter 25 maintenance schedule 10 muffler 13 needle 28 oil premix 8 oil transmission 11 operating instructions 5 optional parts 42 43 pads 13 parts 43 pipe 10 15 p...

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