Christini AWD 450 Wartungshandbuch

Service Manual CHRISTINI AWD 450 / 450DSCHRISTINI AWD 450 / 450DSCHRISTINI AWD 450 / 450DSCHRISTINI AWD 450 / 450DS Christini Technologies, Inc

Page 9 Basic Operating Instructions PRECAUTIONPRECAUTIONPRECAUTIONPRECAUTION For your safety, you must obey the following 9 rules while riding the

Page 99 • Slide the bottom triple clamp into the head tube. Note: Make sure Note: Make sure Note: Make sure Note: Make sure bottom output gear is me

Page 100 • Spin the left side sprocket driveshaft to align the bottom center sprocket (located inside the cavity) with the steerer driveshaft. Once t

Page 101 • Turn the preload bolts evenly until there is no play in the head tube bearings (usually 1/2-3/4 of a turn). • Tighten the preload bar

Page 102 • Remove chain cover, chain and sprocket from frame (see “Cover/ chain removal” section). • Remove cable and eng agement spline from gearbox

Page 103 Gear Box Service

Page 104 • Slide clutch basket off output gear. • Remove output seals from gear box. • Remove output snap ring. Gear B

Page 105 • Slide output gear and bearings out of gearbox. • Remove input gear and bearing from gearbox by tapping them out through the access

Page 106 • Remove output retaining ring. • Use split bearing puller to press output bearings partially off of the gear. After the bearings

Page 107 Note: Note: Note: Note: Make sure engagement spline snap ring is install on input gear before it is pressed into the gearbox • Press input b

Page 108 • Remove chain cover and AWD chain (see “Cover/chain removal” section). • Slide clutch snap ring up main driveshaft. • Slide clutch up ma

Page 10 Basic Operating Instructions PRE-RIDE INSPECTION Check the f ollowing before each ride. For enduro and motard version check below f or additi

Page 109 Clutch Service Clutch Service

Page 110 • Loosen locknut set screw so it will not interfere with the hub threads. Warning: Warning: Warning: Warning: Failure to loosen set screw

Page 111 • Reassemble clutch hub noting the order of the plates, fibers and spring washers. Be sure the spring washers are in the correct ori-entatio

Page 112 • Reinstall clutch on bike. • Reinstall clutch basket and gearbox. • Tighten locknut until it is approximately flush with the hub. •

Page 113 Front forks feel sticky • Clean and lube fork seals. • Check to make sure forks are not twisted in triple clamps. • Lube front spline shaft

Page 114 CHRISTINI AWD LIMITED WARRANTY This LIMITED WARRANTY is a complete and exclusive statement of CHRISTINI’s obligations to the ORIGINAL OWNE

Page 115 • Failures caused by or related to any installation of any parts or kits designed for “competition only” use • Use for the following activiti

Page 116 Bring your AWD kit or motorcycle along with your purchase receipt or other proof of the date of pur-chase to the dealer where you purchased t

Page 11 Basic Operating Instructions Start the engineStart the engineStart the engineStart the engine Shift the transmission into neutral and turn

Page 12 Basic Operating Instructions BREAKBREAKBREAKBREAK----ININININ During initial break-in newly machined surfaces will be in contact with each

Page 13 Maintenance The Maintenance Schedule specifies how often you should have your motorcycle served, and what things need attention. It is es-sent

Page 14 Maintenance Required Maintenance Schedule FREQUENCY-ITEMS Whatev er one first comes f irst First mai nte -na n ce The alternativ e time NOTE

Page 15 Maintenance SPECIAL MAINTENANCE SCHEDULE FREQUENCY ITEMS NOTE About 2.5hs About 7.5 hs About 15hs About 22.5hs About 30hs TH

Page 16 Maintenance ENGINE CHASSIS NOTE:NOTE:NOTE:NOTE: These parts and their possible replacement schedule are based upon average riding condit

Page 17 Maintenance FUEL LINEFUEL LINEFUEL LINEFUEL LINE • Inspect the fuel line for damage or leak, if necessary replace fuel line. FUEL

Page 18 Maintenance CHOKE LEVERCHOKE LEVERCHOKE LEVERCHOKE LEVER FREE PLAY: 2FREE PLAY: 2FREE PLAY: 2FREE PLAY: 2----3mm(1/83mm(1/83mm(1/83mm(1/8--

Page 19 Maintenance SPARK PLUGSPARK PLUGSPARK PLUGSPARK PLUG REMOVALREMOVALREMOVALREMOVAL • Remove the fuel tank and disconnect the spark plug

Page 20 Maintenance RADIATOR COOLANTRADIATOR COOLANTRADIATOR COOLANTRADIATOR COOLANT • Inspect the level of the radiator coolant should be between

Page 21 Maintenance SECONDARY AIR SUPPLY SYSTEMSECONDARY AIR SUPPLY SYSTEMSECONDARY AIR SUPPLY SYSTEMSECONDARY AIR SUPPLY SYSTEM • Remove the shoul

Page 22 Maintenance INTAKE VALVE: INTAKE VALVE: INTAKE VALVE: INTAKE VALVE: • Insert the feeler gauge between the valve lifter and the cam labe

Page 23 Maintenance Seventy-three different shim series are available from 1.2000mm to 3.000mm in intervals of 0.025mm. • Calculate the new shim thick

Page 24 Maintenance DECOMPRESSOR CLEARANCE INSPECTION / ADJUSTMENT:DECOMPRESSOR CLEARANCE INSPECTION / ADJUSTMENT:DECOMPRESSOR CLEARANCE INSPECTION /

Page 25 Maintenance ENGINE IDLE SPEEDENGINE IDLE SPEEDENGINE IDLE SPEEDENGINE IDLE SPEED The engine must be warm for an accurate idle inspection an

Page 26 Maintenance ENGINE OIL & FILTER CHANGE • Run the engine for 3 minutes. Stop the engine for 3 minutes and re-mov e the oil f ilter cap. •

Page 27 Maintenance TRANSMISSION OILTRANSMISSION OILTRANSMISSION OILTRANSMISSION OIL CHECKING OIL CHECKING OIL CHECKING OIL CHECKING OIL •

Page 28 Maintenance DRIVE CHAINDRIVE CHAINDRIVE CHAINDRIVE CHAIN The drive chain must be checked, adjusted, and lubricated in accordance with the M

Page 2 Introduction Congratulations for making the rig ht choice. The instruction in this book will provide a simple and understandable guide to your

Page 29 Maintenance DRIVE CHAIN SLIDERSDRIVE CHAIN SLIDERSDRIVE CHAIN SLIDERSDRIVE CHAIN SLIDERS Chain sliderChain sliderChain sliderChain slid

Page 30 Maintenance BRAKE FLUIDBRAKE FLUIDBRAKE FLUIDBRAKE FLUID Notice Notice Notice Notice • Avoid spilling fluid will damage the plastic or

Page 31 Maintenance BRAKE SYSTEM level position inspection The brake lev el position can be adjusted by loosening the lock nut and turning the adjuste

Page 32 Maintenance SWINGARM/SHOCK LINKAGESWINGARM/SHOCK LINKAGESWINGARM/SHOCK LINKAGESWINGARM/SHOCK LINKAGE • Raise the rear wheel off the ground

Page 33 Maintenance

Page 34 AWD Service SectionAWD Service SectionAWD Service SectionAWD Service Section AWD Service

Page 35 • Socket set, metric • Pliers set • Ball peen/ dead blow hammers • Soft tip metal punch (brass/aluminum) • Screw driver set • AWD clutch wrenc

Page 36 AWD Detail Illustration

Page 37 • Do not adjust the choke while the bike is moving! • Do not over tighten the front axle as it can damage the inside Axle Clamp Bear-ings. •

Page 38 Pre-ride check list: • Check secondary AWD chain tension. • Lube secondary AWD chain. • Check clutch setting (see “AWD Clutch Test” section).

Page 3 Table of Contents General Bike Service General Information 5 Lubricant System Specifications 7 Cooling System Specifications 7 Tire Specifi

Page 39 AWD Clutch Test • Place the bike on a stand and make sure that the front wheel is not touching the ground. • Shift the bike int o gear. • Turn

Page 40 Note: Note: Note: Note: Before performing this test, make sure the AWD Clutch is set correctly. • Place the bike on a stand and make sure th

Page 41 Cover and Chain Removal

Page 42 Cover and Chain Removal

Page 43 • Remove the 6 cover bolts with an 8mm socket or t-handle and pull cover off of the frame. • To remove the chain, pull the tensioner ba

Page 44 • Reinstall chain and top sprocket. • Adjust chain tensioner using a 4mm Allen wrench and by sliding the tensioner up the sidebar until the

Page 45 AWD Engagement

Page 46 • Grease engagement ret aining washer. • Insert washer into the back of the gearbox using a pick so it sits flush against the input ge

Page 47 AWD Engagement Installation • Grease the engagement spring and spline. • Feed the engagement cable through the spring and spline.

Page 48 • Seat the cable housing into the back of the gearbox. • Slide the other end of the cable into the engagement switch. • Line u

Page 4 Table of Contents AWD Service Required tools 35 AWD detailed illustration 36 Routine maintenance schedule 38 AWD clutch test 39 AWD sprag

Page 49 • Position the switch so the lever is positioned towards the rider (on) and slide the housing into the end of the switch. Note: If there i

Page 50 Note: Note: Note: Note: Due to AWD hub design, front wheel removal and installation is aided by removing front caliper first. • Remove

Page 51 • Lightly grease dropout o-rings and hub seals before installing the front wheel. • With brake caliper removed, install front wheel into for

Page 52 Front Wheel Service

Page 53 Front Wheel Service Warning: Warning: Warning: Warning: Before taking hub apart, make sure that you have a full set of spare sprag bearing

Page 54 Front Wheel Service • Pry the insert seals out of the inserts using a flat bladed screwdriver. • Remove the hub insert o-rings with a

Page 55 • Using a bearing punch, install the axle bearings into the hub inserts. • Press the axle seals into the hub inserts. • Ins

Page 56 Front Wheel Service Warning: Warning: Warning: Warning: Sprag bearings must be installed in the correct orientation in the hub for the AWD

Page 57 F • Test fit hub insert into hub, twisting as it is in-serted. • Spin the hub insert and check to make sure it is free-Spin the hub

Page 58 F• Remove hub insert and press insert bearings into hub. • Grease hub insert seal, and slip hub insert into hub. It may be requir

Page 5 I TEM TEC H NI C AL D ATA MOTOC R OSS EN D UR O MOTAR D D I MEN SI ON S OVER ALL LEN GTH 2175m m OVER ALL WI D TH 810m m OVER ALL H EI GH T

Page 59 Warning:Warning:Warning:Warning: If removing forks for rebuild service, the fork dropouts must be disassembled so that the drive system parts

Page 60 • Carefully slide forks into triple clamps. • Set desired fork height and torque triple clamp bolts to the follow-ing: 15 ft-lbs Lower 17f

Page 61 Dropout Service

Page 62 • Remove the front wheel and front fork. • Remove bellow clamp and bellow from spline driveshaft. Pry gently with small flathead screw driv

Page 63 • Remove drive insert bearing from inside of dropout. Bearing is a slip fit so only light pressure from screw driver is required to remove.

Page 64 • Remove 4 drive carrier bolts with 4mm Allen wrench. The inner hardened bevel gear can be clamped with soft jaws in a vise or the drive

Page 65 • Remove cover bearing with bearing removal punch. Note o-ring lip near inner race of bearing is easily damaged. Only apply pressure to inne

Page 66 • Install cover bearing into cover with bearing installation tools. • Install internal and external cover 0-rings. Note:Note:Note:Note: all

Page 67 Note: Note: Note: Note: Be sure dropout is clean before proceeding • Insert top pinion beari

Page 68 • If needed use hammer and soft punch to tap end of pinion gear to seat bearing. • Insert axle o-ring into dropout. • Install

Page 6 General Information RATED POWER 30. 5KW / 7000R PM MAX TORQUE 42. 5N M/ 6500R PM IDLE SPEED 1700±150 RPM FUEL CONSUMPTION 340 g/kW.h BORE X ST

Page 69 • Insert set screw with light dab of blue Loctite. When set screw is fully seated, it will be slightly below the surface of driveshaft. If n

Page 70 Fork Spline Bearing Service

Page 71 • Cut Safety wire from boot and slide it off the housing. • Remove forks from triple clamps (see “Fork Removal” section). • Slide housin

Page 72 • Unscrew grease port from linear bearing housing. • Remove set screw from housing. • Slide housing sleeve off of housing. •

Page 73 • Slide linear bearing out of housing and inspect. If ball bearings inside of the case are corroded or worn, replace linear bearing. Warning:

Page 74 • Saturate felt with gear oil and place it back in housing sleeve. • Reassembly of linear bearing housing is the reverse of disassembly.

Page 75 Boot Replacement • Remove Fork Guard • Remove upper and lower boot clips with wire cutters • Pull up boot and loosen drive shaft set scr

Page 76 Boot Replacement • Remove old boot and slide new boot onto driveshaft. • Add a new clip on the bottom of the shaft.

Page 77 Triple Clamp Removal • Remove forks and front fender from triple clamps. • Loosen the two preload bar pinch bolts. • Remove the pr

Page 78 Triple Clamp Removal • Slide the bottom triple clamp out of the frame. • Pull the top triple clamp assembly out of the frame

Page 7 General Information Lubrication System I TEM D ATA EN GI N E OI L 870m l APL SJ SAE10W -40 AT D R AIN IN G 670 m l AT F I LTER C H AN

Page 79 Triple Clamp Service

Page 80 Triple Clamp Service

Page 81 • Remove the forks and spline bearing assembly. • Remove the 4 cover bolts from the bottom of the triple clamp with a 6mm Allen wrench.

Page 82 • Remove the right shaft sprocket and the chain inside of triple clamp cavity. • Pull center bottom sprocket off of the cove

Page 83 • Remove cover bearings from cover with bearing puller if they need to be replaced. • Remove cover seals and inspect. Replace if nee

Page 84 • Remove sprocket snap ring . • Remove sprocket and gear by tapping the gear through the sprocket with a plastic faced hammer and pul

Page 85 • Tap the bottom output bearing from the bottom steerer tube. • Inspect gears and bearing and replace any parts if needed

Page 86 Warning: Warning: Warning: Warning: Replacing the taper bearing is a job for your dealer. Do not attempt to do this on your own. • Remov

Page 87 • Press steerer bearing into the top of the steerer tube. • Press steerer bearing into bottom of the steerer tube. • Install bo

Page 88 • Install cover seals. • Press cover bearings back into outer bores of cover. • Insert Teflon chain guides into cover if th

Page 8 General Information I TEM STAN D AR D S R EPAI R LI MI T C OLD TIR E PR ESSUR E 33/ 2. 3 (ps i/ bar) MA X LOAD F R ON T 430 / 195 (l

Page 89 • Insert triple clamp bearing onto top of the right shaft sprocket. It will be a slip fit. • Wrap chain around top center sprocket and right

Page 90 • 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. T

Page 91 • Pull top output gear and bearing out of top steerer. If bearing does not come out with gear, use blindside bearing puller to remove the bea

Page 92 Warning: Warning: Warning: Warning: Replacing the taper bearing is a job for your dealer. Do not attempt to do this on your own. • Loose

Page 93 • Slide the steerer tube bearing back onto the output gear. • Press gear and bearing into top steerer tube. T

Page 94 • Remove triples clamps as previously described. • Remove the head tube cover from the front of the head tube. • Slide the input hea

Page 95 Head Tube Bearing Service * Picture above shows a head tube not welded to the frame for reference. *

Page 96 • Use a punch and remove the inner B543 bearings. • If the taper bearing races are corroded or pitted, remove them with a punch.

Page 97 • Slide the input bearings onto the head tube gear. • Slide the driveshaft partially throug h the frame and install the clutch hub.

Page 98 • Grease the top and bottom taper bearings with Spectro SPL or equivalent waterproof grease. Grease output gears with Shell grease. • Check