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with masking tape, and notice where any curves and creas-
es might occur. The curves and areas where the plastic
tapers in 2 directions will be the most difficult areas to
apply. When you’ve determined the best fit, tape one edge
of the decal securely in place, and remove the tape from
the opposite edge. Lift the decal up and spray a light mist
of water from a squirt bottle onto the entire plastic panel.
This will allow you to dampen the adhesive so it won’t
stick as well during the application of the decal and allow
repositioning if necessary without losing the the final bond. 

Carefully align the decal and lay it on the plastic. If the

graphic is not fitting the panel correctly, you can peel it
back up and start over. Start pressing down near the center
of the graphic to ‘work’ the water and any air away from
the center and toward the edges of the decal. Pay extra
attention to creases and irregular areas where the graphic
needs to conform to the plastic in unusual ways. Take your
time and work from the middle of the decal to the edges
pushing out any water and air as you go. The water will
weep out the side of the decal as you reach the edges. 

If you’re having trouble with an irregular area, use a blow dryer or heat gun to lightly warm up the decal in order to make it con-

form. The heat will soften the material, so that you can stretch or compress it as needed to make it fit. Use just enough heat to make
the material pliable without melting it. 

3. Pre-ride checks 

Initial startup

- When motorcycle is at operating temperature, adjust idle speed to the lowest speed at which the motorcycle will run

smoothly by using idle adjustment screw. See photo II-6. Then adjust fuel metering screw. Roll on the throttle rapidly. If the engine
bogs or hesitates, try rotating screw clockwise (leaner) in 

1

4

turn increments until hesitation ceases. If the engine surges or misfires,

rotate screw counterclockwise (richer) in 

1

4

turn increments until bike accelerate smoothly. If the fuel metering screw has to be less

than 1

1

2

for proper running, consider using a leaner pilot jet. If fuel metering screw is more than 2

1

2

-3 turns out, install a leaner pilot

jet. The fuel metering screw is normally set from 1

1

2

to 2

1

2

turns out from fully seated. Never tighten fuel metering screw, just 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 metering screw only affects the initial throttle response in conjunction with the
pilot jet until the needle jet takes over at 

1

4

throttle and above.

Regular pre-ride checklist

- Check chain tension and make sure chain is well lubricated and not worn. Check tire pressure, spokes,

all nuts & bolts, steering stem for binding or play, swingarm bolt, engine mounting bolts, oil & coolant levels and condition, lever
and throttle adjustment, & air cleaner. Look for broken or worn parts, leaking fluids, etc. Check brake calipers for proper freeplay
and accumulations of dirt. Clean and adjust as needed to provide proper function.

4. Basic operation & control functions

Engine startup - 

Make sure motorcycle has premix fuel, transmission oil and coolant. Make sure air cleaner is installed and proper-

ly oiled. Note that arrow on air cleaner and filter cover must point to front of motorcycle.

Turn fuel valve to ON position (vertical position). See photo II-3.

If engine is cold, lift the choke knob on carburetor and rotate about 

1

8

turn so it stays in the up position. See photo II-4.

Squeeze brake lever to prevent sudden movement upon starting. 

Motorcycle is always in gear and may move suddenly when started or whenever throttle is applied.

Push kickstarter down until slack is taken up, then kick briskly with throttle closed. If necessary, open throttle slightly and hold

while kicking. Motor should start readily. 

If adult is starting bike, use restraint not to damage kickstarter gears with excessive

force! If bike will not start, find and fix problems rather than just kicking harder!

As engine warms, turn choke knob to return

it to the closed position and apply throttle slightly until bike idles without stalling. 

To stop motor, depress kill switch until motor stops. If motorcycle will not start and there is a strong smell of fuel, the engine is

flooded. Turn off choke, open throttle fully and hold open, and kick motor approximately 10 times to clear engine of excess fuel.
Release throttle and try starting again. If engine still won’t start, remove sparkplug and inspect. If plug is wet with fuel, replace plug.
If plug seems to be dry, check fuel valve position and carburetor float and needle valve assembly for proper function.

Remove rubber cap, install vent tube onto vent fitting. 

remove & 

discard cap

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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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