Polini X1R Manual Download Page 45 | Manualshive

Page: 45 / 46

background image

Page 45

V

I
I

2. WWW links

Action Racing & Polini

www.50ccminicross.com
www.poliniminicross.com
http://poliniminicross.com/forums/support_forum/ (Action Racing support forum)
www.polini.com

Sanctioning organizations

www.nemamx.com - New England Motocross Association
www.nemx.org
www.amadirectlink.com, www.ama-cycle.com AMA
www.mxnetwork.com (MD, TN, VA, NC, SC)
www.ahrma.org

Useful links

www.50ccperformance.com - aftermarket parts and service
www.airborncoatings.com - powder coating, exhaust coating, piston coatings
www.gsmxs.com - Gary Semics books, videos and riding schools
www.garybailey.com - Gary Bailey videos & riding schools
http://eric-gorr.com - technical information & services
www.motocross.com
www.dirtrider.net
www.minimotoxr.com - chatroom for minis

Manufacturer’s links

www.bobscycle.com - 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 supports
www. racerxill.com
www.scottusa.com

This manual is dedicated to the kids who ride the wheels off these things and give it their all.

This manual is for their dads (and moms), who make it all possible.

This manual was created exclusively for Action Racing by Bryan Patton of Patton Productions, Avon, CT - (860) 673-1957.

It was designed on a Power Macintosh G4 computer, using Quark XPress and Adobe Photoshop.

All photographs were taken digitally, using a Nikon Coolpix 800, 2 megapixel digital camera.

This manual is ©copyrighted, 2001, by Action Racing and can not be copied or distributed electronically or in print, in whole or in

part, except with the permission of Action Racing. The only exception is that owners of Polini motorcycles may make copies for

their own use.

acknowledgements

«
...
43
44
45
46
»

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...

Reviews:

No comments

Related manuals for X1R

F 850 GS Adventure 2019

Brand: BMW Motorrad Pages: 346

Brand: APRILIA Pages: 9

Brand: Suzuki Pages: 447

Stelvio 1200 MY11 2011

Brand: MOTO GUZZI Pages: 385

Venitex BARRIER

Brand: DELTA PLUS Pages: 2

Krauser 630.2516

Brand: hepco & becker Pages: 6

Brand: X-lite Pages: 96

640 LC4 Adventure

Brand: KTM Pages: 59

REACTOR 40 KICKER SUZUKI ADAPTER

Brand: Garmin Pages: 40

Brand: hepco & becker Pages: 6

Brand: Yamaha Pages: 82

Brand: Yamaha Pages: 84

Brand: Yamaha Pages: 90

Brand: Yamaha Pages: 83

Brand: Yamaha Pages: 148

Brand: Yamaha Pages: 96

Brand: Yamaha Pages: 108

Brand: Yamaha Pages: 190

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands