Christini AWD KTM Service Manual Download

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Service Manual

Christini Technologies, Inc.

Version 2011-1.0

CHRISTINI AWD KTM

Summary of Contents for AWD KTM

Page 1: ...Service Manual Christini Technologies Inc tech christini com Version 2011 1 0 CHRISTINI AWD KTM CHRISTINI AWD KTM CHRISTINI AWD KTM CHRISTINI AWD KTM ...

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Page 3: ...Page 2 Warnings Do not adjust the choke while the bike is moving ...

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Page 5: ...rvice 23 Fork spline bearing service 32 Triple clamp removal 39 Bottom triple clamp disassembly 41 Bottom taper bearing removal 48 Bottom triple clamp assembly 49 Top triple clamp disassembly 53 Top taper bearing removal 54 Top triple clamp assembly 55 Main drive shaft service 56 Headset bearing service 57 Gearbox removal 64 Gearbox Transfer Case Service 67 AWD clutch Service 81 Troubleshooting 85...

Page 6: ...punch set Blind side bearing removal kit Motion Pro 08 0292 2 large adjustable wrenches Torque wrench 0 75 ft lbs Split bearing puller Small pick or awe Safety wire pliers Safety wire 032 Grease gun included with frame kit Fill with Shell grease Shell Albida EP1 Lithium grease do not substitute Spectro SPL grease of equivalent Blue Loctite 242 Red Loctite 262 Green Loctite 609 The Tools You Will N...

Page 7: ...Page 6 AWD Detail Illustration ...

Page 8: ...ge Check front wheel rim lock nut torque As Needed Replace bearings if excessive noise or friction develops Lubricate spline shafts through grease port with supplied grease gun and Shell grease Replace worn or damaged seals and boots Routine Maintenance AVOID AVOID AVOID AVOID Pressure washing the dropouts head tube area side bar and main gearbox ...

Page 9: ...he gas tank off the bike Loosen the set screw on the clutch locknut and turn the locknut in or out a 1 2 turn at a time until the front wheel moves backward with the correct amount of force Make sure the set screw is posi tioned over a flat in the clutch hub and tighten the set screw down and reinstall the tank note picture shows clutch off the bike for clarity AWD Clutch Test There are two ways t...

Page 10: ...t sprocket Check the following 1 Sidebar bearing and cover bearing should be smooth turn ing 2 Check engagement spline action by engaging and disen gaging switch on handle bars 3 Sidebar seal and cover seal for wear 4 Excessive wear on chain tension block Warning Warning Warning Warning Do not use an O ring chain as there is not enough clearance for one and it would rub the frame Cover and Chain R...

Page 11: ...ween sides when pressure is applied If the gearbox is all the way forward and the chain is still too slack keep moving the set screw on the chain cover closer to the rub block until a good chain tension is created Replace chain cover Torque cover bolts to 8 ft lb Move jack bolt in until it touches the gearbox and tighten the lock nut Cover and Chain Removal ...

Page 12: ...sition Spin rear wheel of motorcycle and make sure that the front wheel is spinning as well it may take a few turns before AWD clicks in Push engagement switch forward to the off position Spin rear wheel and make sure front wheel is no longer moving If the front wheel is still moving Turn barrel adjuster on cable out until the AWD system disengages and front wheel is no longer moving ...

Page 13: ...o not squeeze front brake lever while caliper is off Remove axle bolt from axle Loosen axle pinch bolts on both sides of dropout Slide axle through wheel and remove Remove front wheel from dropouts Note Note Note Note The hub inserts will not fall out like the spacers on a normal hub They will also rotate independent of each other this is ok Front Wheel Removal ...

Page 14: ...ther end of hub Carefully align left carriers and slide axle completely through to the other side Note a flat blade screw may be needed to align hub insert with drive carrier Note that the hub inserts will only rotate in one direction in the hub Thread axle bolt back into the end of axle and tighten to 12ft lb Tighten axle pinch bolts to 12 ft lb Note Note Note Note If wheel does not spin freely a...

Page 15: ...Page 14 Front Wheel Service ...

Page 16: ...arings are likely to be damaged dur ing the disassembly process and new onesmay be required Using a soft punch remove the hub inserts from either side of the hub Carefully remove all bearings sprags and spacers from hub with a punch and hammer Be careful not to tap bearings out crooked as it may damage hub shell Front Wheel Service ...

Page 17: ...nsert seals out of the inserts using a flat bladed screw driver Remove the hub insert o rings with a pick Punch the axle bearings out of the inserts using the access holes in the back of the inserts Front Wheel Service ...

Page 18: ...Page 17 Front Wheel Service Using a bearing punch install new axle bearings into the hub in serts Press the axle seals into the hub inserts Install the hub insert o rings ...

Page 19: ...ct direction will be deter mined in next steps Lightly grease inside of sprag bearing with Shell grease Front Wheel Service Warning Warning Warning Warning Sprag bearings must be installed in the correct orientation in the hub for the AWD system to work properly If the sprag bearings are not installed correctly the AWD system can be damaged ...

Page 20: ...he hub insert and check to make sure it is freewheeling in Spin the hub insert and check to make sure it is freewheeling in the correct direction the correct direction the correct direction the correct direction If it is not remove the hub insert and flip the sprag bearing around Recheck to verify that hub insert free wheels in the correct direction before moving on to next step Front Wheel Servic...

Page 21: ...ress insert bearings into hub Grease hub insert seal and slip hub insert into hub It may be required to tap hub insert into hub with a soft faced hammer Grease axle seal Repeat procedure for the other side of hub Front Wheel Service ...

Page 22: ...inear bearing housing and un screw it completely Slide the housing down off the sprocket driveshaft Looser top and bottom triple clamp bolts Be sure to hold fork while loosening bolts so it does not fall out Slide fork out of triple clamps and remove Warning Warning Warning Warning When fork is off the bike do not apply side pressure to spline shafts as it is possible to bend them if enough force ...

Page 23: ...into the upper triple clamps Running the forks lower in the triple clamps may damage the lin ear spline bearings Set desired fork height and torque triple clamp bolts to the follow ing 15 ft lbs Lower 17ft lbs Upper Slide the linear bearing housing over the drive sprocket shaft Tighten the housing cap down with 2 adjustable wrenches Fork Installation ...

Page 24: ...Page 23 Dropout Disassembly ...

Page 25: ...The clamps are not reusable Remove set screw from driveshaft with 2 5mm Allen key Remove driveshaft from pinion gear by lightly tapping lower driveshaft with a plastic hammer while pulling the driveshaft away from the dropout Remove 6 cover bolts on the outside of the gearbox using a 4mm Allen wrench Rotate the cover and pull it off of the dropout Dropout Disassembly ...

Page 26: ...emove by hand or with split bearing puller Note lower pinion bearing is angular contact so if pressure is applied in the wrong direction it may come apart If bearing comes apart it must be replaced Remove top driveshaft seal from dropout using small flat blade screwdriver Be careful not to scratch inner bore Remove top pinion bearings from upper bore by tapping them lightly tapping from inside the...

Page 27: ...the drive carrier can be held with square bar stock to keep the assembly from moving as you unscrew the bolts Lightly tap the outside face of drive carrier with plastic hammer to break it free from gear and drive insert Remove axle o ring from drive carrier with pick Remove cover o rings and drive carrier o ring Dropout Disassembly ...

Page 28: ...uts all parts must be cleaned and inspected individually for damage or wear Parts can be cleaned with solution no different then OEM fork Be sure to blow dry dropouts and parts prior to reassembly if cleaning solution is used Pinion and bevel gear must be replaced as a set If bearings are seized or hard to turn by hand they must be replaced or cleaned and repacked with grease Be sure to grease all...

Page 29: ...ne up all four threaded holes with clearance holes on gear Set cover and drive carrier on top of bevel gear assembly with smooth side of gear facing the cover Line up 4 bolt holes and thread drive carrier bolts into drive insert Blue Loctite should be used on bolts Final tightening of bolts will require a square bar or soft jaws to keep gear from spinning Torque bolts to 8ft ft lbs Check that beve...

Page 30: ...to pinion gear WARNING WARNING WARNING WARNING black seal must be facing down towards gear teeth If bearing is not inserted correctly severe damage can occur Slide bearing and pinion gear into bore Make sure bearing is fully seated Dropout Assembly Warning Warning Warning Warning Bevel gears are right and left hand specific and must be installed in the correct dropout or damage to the system can o...

Page 31: ... small flat blade screwdriver in between pinion gear and inner bearing to keep pinion gear in place when the splined shaft is installed Slide splined driveshaft onto pinion gear making sure to line up the set screw holes Lightly tap end of spline shaft with plastic faced hammer to slide it down onto pinion gear and line up set screw holes Dropout Assembly ...

Page 32: ...rt 6 cover bolts and tighten in a cross star pattern using a 4mm Allen wrench Tighten to 8ft lbs Check that drive carrier spins freely and wipe excess grease from outside of dropout Reinsert bellow and bellow clamp over spline shaft and crimp bellow down using crimping tool or vise grips WARNING WARNING WARNING WARNING The band of clamp must be over the set screw to ensure that the set screw can n...

Page 33: ...Page 32 Fork Spline Bearing Service ...

Page 34: ...Page 33 Cut Safety wire from boot and slide it off the housing Remove forks from triple clamps see page 25 Slide housing assembly off of linear driveshaft Fork Spline Bearing Service ...

Page 35: ...Page 34 Unscrew grease port from linear bearing housing Slide housing sleeve off of housing Remove linear bearing retaining ring Fork Spline Bearing Service ...

Page 36: ...to remove bearing as it may damage the bearing If bearing will not slide out apply pressure to the bearing lip with an 8mm nut driver to remove it If shaft seal is damaged or worn pry it out and replace it with a new seal Remove felt from housing sleeve and inspect If needed replace felt Note Note Note Note Dirt will pack up in felt The felt can be cleaned and reused Fork Spline Bearing Service ...

Page 37: ... on grease fitting or it may back out and cause the housing sleeve to slide down while riding Warning Warning Warning Warning When sliding linear bearing housing back unto driveshaft carefully align the ball bearings with the grooves in the driveshaft Do not force the housing onto the driveshaft Groove should be approximately 90 degrees to the grease fitting Fork Spline Bearing Service ...

Page 38: ...oots it is not necessary to remove the forks The service can be done by removing the fork guards and following the instructions below Remove Fork Guard Remove Boot Clip with wire cutters Pull up boot and loosen Drive shaft set screw Insert screw drive in vent holes and tap screwdriver ...

Page 39: ...Old boot and replace with a new boot Be sure to add the clip on the bottom of the shaft Reinstall the drive shaft and tighten set screw Slide boot back over the bottom shaft and set screw Crimp the clamp around the boot and set screw and reinstall the fork guard ...

Page 40: ...d hammer tap the bottom triple clamp to unseat it from the frame Note Note Note Note To service the triple clamp chains sprockets and bearings it is recommended that you leave the bottom triple clamp attached to the bike This will make it easier to pull the cover off For servicing the steerer tube bearings or replacing the head tube gears the triple clamps will need to be removed ...

Page 41: ...al Slide the bottom triple clamp out of the frame Pull the top triple clamp assembly out of the frame Note It may be necessary to tap the underside of the top triple clamp with a plastic faced hammer to unseat it from the frame ...

Page 42: ...Page 41 Triple Clamp Service ...

Page 43: ...Page 42 Triple Clamp Service ...

Page 44: ...ight shaft will stay in place and the cover will slide down over it Bottom Triple Clamp Disassembly Note Note Note Note To service the triple clamp chains sprockets and bearings it is recommended that you leave the bottom triple clamp attached to the bike This will make it easier to pull the cover off For servicing the steerer tube bearings or replacing the head tube gears the triple clamps will n...

Page 45: ...hain inside of triple clamp cavity Pull center bottom sprocket off of the cover and remove the chain Pull both shaft sprockets out of cover Be careful of seal as it slides over snap ring grooves as it can tear the seal Bottom Triple Clamp Disassembly ...

Page 46: ...Page 45 Remove cover bearings from cover with bearing puller if they need to be replaced Remove cover seals and inspect Replace if needed Bottom Triple Clamp Disassembly ...

Page 47: ... a plastic faced hammer and pulling it out the top of the steerer tube Remove gear from steerer tube If bearing comes out with gear remove bearing from gear with split bearing puller if it does not slide off easily If top bearing remains in steerer use a punch to remove it Bottom Triple Clamp Disassembly ...

Page 48: ...Tap the bottom output bearing from the bottom steerer tube Inspect gears and bearing and replace any parts if needed Note Note Note Note Head tube gears must be replaced in sets Bottom Triple Clamp Disassembly ...

Page 49: ...om triple clamp with an arbor or hydraulic press The steering stops should be supporting the triple clamp as the steerer is pressed out Press the taper bearing and seal off of steerer tube with an aluminum sleeve available from Christini Press new taper bearing and seal onto steerer tube Coat mating surface of triple clamp and steerer tube with green Loctite Press steer tube into triple clamp Bott...

Page 50: ...steerer bearing into bottom of the steerer tube Install bottom output gear and tap sprocket back onto bottom of gear using a plastic faced hammer Sprocket is fully seated when the end of it is flush with the snap ring groove Replace snap ring Bottom Triple Clamp Assembly ...

Page 51: ...over bearings back into outer bores of cover Insert Teflon chain guides into cover if they were removed Note the wear pattern and be sure that the guides are placed on the same side as they were removed from Bottom Triple Clamp Assembly ...

Page 52: ... Slide cover and left shaft sprocket up into bottom triple clamp until the cover meets flush the lip of the bottom triple clamp If needed use a small screwdriver or pick to push the right chain away from the Teflon block as the cover slides into place Hint Hint Hint Hint once the cover makes contact with the bottom triple clamp rotate the shaft sprockets as you are pushing the cover into its final...

Page 53: ...Page 52 When cover is in place screw down the cover bolts with a 6mm Allen wrench Note Note Note Note Use blue Loctite on cover bolts Torque bolts to 12 ft lbs Bottom Triple Clamp Assembly ...

Page 54: ...r hard to turn by hand it should be replaced Inspect output gear for wear If it needs to be replaced all gears in all gears in all gears in all gears in the head tube must be replaced at the same time the head tube must be replaced at the same time the head tube must be replaced at the same time the head tube must be replaced at the same time Top Triple Clamp Disassembly ...

Page 55: ...nd remove the steerer tube Press taper bearing and seal off of steerer tube with an arbor or hydraulic press Note A new seal will be needed as it will be damaged when the taper bearing is pressed off the steerer Press new taper bearing and seal onto steerer tube Insert steerer tube into top triple clamp and tighten set screw to secure steerer tube Top Taper Bearing Removal ...

Page 56: ...Page 55 Slide the steerer tube bearing back onto the output gear Press gear and bearing into top steerer tube Top Triple Clamp Assembly ...

Page 57: ...ose the key when separating the driveshaft from the clutch hub not all models have key If the 3 input bearings do not come out with the input gear gently tap them out with a punch Make sure they do not get cocked as they are being tapped out Warning Warning Warning Warning If any of the head tube gears are damaged and need to be replaced all of the head tube gears must be replaced together as a se...

Page 58: ...Page 57 Headset Bearing Service Picture above shows a head tube not welded to the frame for reference ...

Page 59: ...g races are corroded or pitted remove them with a punch Clean the headset bearing surfaces with degreaser and apply a few drops of green Loctite Install the inner B543 bearings using a bearing punch Install the taper bearing races using a bearing punch Headset Bearing Service ...

Page 60: ...ear Slide the driveshaft the rest of the way through the frame seating the input bearings and gear in the head tube and the clutch hub with the clutch basket Use a soft punch and lightly tap the gear to be sure it is fully seated Main Drive Shaft Service ...

Page 61: ...head tube Slide top triple clamp assembly into the head tube Before seating the top triple clamp assembly make sure the output gear and input gear are beginning to mesh correctly Note If the two gears are not meshing it will not be possible to seat the top triple clamp correctly Tap the top triple clamp with a plastic faced hammer to seat it completely Triple Clamp Installation ...

Page 62: ...iple clamp partway into the head tube as you do the following Align the preload bars so they begin to slide into the top triple clamp Make sure the bottom output gear and input gear are meshing correctly Triple Clamp Installation ...

Page 63: ...ith the steerer driveshaft Once turning the sprocket driveshaft also turns the top output gear everything is aligned correctly Tap the bottom triple clamp with a plastic faced hammer to completely seat it in the frame Screw the preload bolts down until they are flush with the top triple clamp Triple Clamp Installation ...

Page 64: ...Page 63 Turn the preload bolts evenly until there is no play in the headset usually 1 2 3 4 of a turn Tighten the preload bar pinch bolts Triple Clamp Installation ...

Page 65: ... shaft 6 inches or more Slide clutch hub assembly up main driveshaft unit it clears the clutch basket If present certain models remove driveshaft key with needle nose pliers so it does not get lost Remove all 6 gearbox bolts retaining bolts 4 on top 2 on bottom and remove gearbox transfer case assembly from frame Gear Box Transfer Case Removal ...

Page 66: ...Page 65 AWD Switch Removal Switch Shown in off position ...

Page 67: ...e 66 Move switch to on position towards rider and pull cable forward and out of switch through the split Move switch to off position away from rider and remove cable end from the switch AWD Switch Removal ...

Page 68: ...Page 67 Gearbox Transfer Case Service ...

Page 69: ...Page 68 Gearbox Transfer Case Service ...

Page 70: ...Page 69 Remove 6 M6 bolts from the transfer case cover with a 8mm socket Remove transfer case cover Remove both sprockets and chain from transfer case Gearbox Transfer Case Service ...

Page 71: ...Page 70 Remove the 4 shoulder bolts from the transfer case with a 4mm allen wrench Separate the transfer case from the gearbox Gearbox Transfer Case Service ...

Page 72: ... Remove O ring from the back of the transfer case if it is damaged If the transfer case bearings need to be replaced remove them by tapping the bearings out with a socket or punch Gearbox Transfer Case Service ...

Page 73: ... case cover seal Remove the 6905 transfer case cover bearing with a socket or punch Remove the 6804 transfer case cover bearing with fingers It is a slip fit in the bore so it should come out easily Gearbox Transfer Case Service ...

Page 74: ...l the spline out from the gearbox and remove the cable fitting from the spline using a small flat blade screw driver With cable fitting removed Pull spline and spring out of input gear and pull the cable out the back of the gearbox Gearbox Transfer Case Service ...

Page 75: ...Page 74 Slide clutch basket off output gear Remove output seals from gear box Remove output snap ring Gearbox Transfer Case Service ...

Page 76: ...Page 75 Slide output gear and bearings out of gearbox Remove input gear and bearing from gearbox by tapping them out through the access holes in the back of the gearbox Gearbox Transfer Case Service ...

Page 77: ... press output bearings partially off of the gear After the bearings move away from the gear use press to remove bearings completely Use same steps to remove input bearing from input gear Inspect gears and bearings and replace if needed Gearbox Transfer Case Service ...

Page 78: ...x gears Be sure that the spring retaining post is facing up inside the input gear spline and is positioned on the middle ledge inside the spline Grease engagement spring and spline with Shell grease and reinstall with cable and fitting inside the gearbox Gearbox Transfer Case Service ...

Page 79: ...ent spline cable assembly does not fall out of gearbox Press engagement spline all the way into gearbox to take up spare cable slack Reinstall cable into the engagement switch Test switch and make sure it is moving the engagement spline in and out of gearbox Gearbox Transfer Case Service ...

Page 80: ...into top of transfer case Spin driveshaft and sprocket to make sure spline is fully disengaged If driveshaft and sprocket do not full disengage turn cable barrel adjuster until spline is completely disenagaged from driveshaft Test engagement by flipping switch back and forth a few times while spinning gearbox driveshaft and sprocket Gearbox Transfer Case Service ...

Page 81: ...einstall top and bottom transfer case sprockets and chain and grease chain with Shell grease Reinstall transfer case cover See chain cover removal section for reinstalling AWD chain Gearbox Transfer Case Service ...

Page 82: ...Page 81 Clutch Service ...

Page 83: ...ith the hub threads Warning Warning Warning Warning Failure to remove set screw will damage threads in clutch hub Remove locknut from clutch hub Remove spring washers fiber pads and clutch plates and inspect for wear or damage Note Note Note Note If metal plates are not scored or warped they do not need to be replaced Simply replace fiber plates during standard rebuilt Clutch Service ...

Page 84: ...ates fibers and spring washers Be sure the spring washers are in the correct orientation Use thread file to clean galled hub threads if needed Apply anti seize compound to hub thread and thread locknut onto the hub Tighten until locknut is approximately flush with the hub ...

Page 85: ...nd adjust as necessary see section AWD Clutch Test Adjust locknut so set screw hole lines up with the near est flat section on the hub and tighten set screw Warning Warning Warning Warning Once set screw is tightened do try to turn lock nut as this will damage the hub threads ...

Page 86: ... check method Drive system is pulling to oneside Check sprag bearings in hub to make sure neither side is slipping Make sure that drive shafts are free to spin smoothly Occasionally mud or other debris can hinder one drive shaft from spinning at the proper rate Clutch Basket has notches in it This is normal As long as the notches don t exceed 3 16 Replacement is not needed Cannot disengage system ...

Page 87: ...ght to direct any warranty request relating to those Other Original Components to said manufacturer s customer service department THESE WARRANTIES DO NOT COVER Failures or required services which are not due to a defect in material or factory workmanship Replacement of expendable maintenance items including but not limited to Bearings including linear bearing Seals and O Rings AWD Clutch Basket Pl...

Page 88: ...s on how long an implied warranty lasts so the above limitation may not apply to you The warranty gives you specific legal rights and you may also have other rights which vary from state to state WHAT YOU SHOULD DO Always wear a helmet while riding Please remember to always ride safely and in control and within your capabilities Always wear a helmet while riding Please remember to always ride safe...

Page 89: ...tment at CHRISTINI AWD 421 N 7th Street Suite 200 Philadelphia PA 19123 Phone 215 351 9895 Freight costs and any labor charges for part change overs assembly repair or disassembly are the responsibility of the Original Owner and this Warranty offers no cash refunds this Warranty offers no cash refunds this Warranty offers no cash refunds this Warranty offers no cash refunds Warranty ...

Page 90: ...Notes ...

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