Christini AWD Service Manual

Service Manual CHRISTINI AWD 450DS Christini Technologies, Inc. [email protected] Version 2015.1

Page 9 Basic Operating Instructions PRECAUTION For your safety, you must obey the following 9 rules while riding the motorcycle: - Wear your helmet: S

Page 99 • Slide the bottom triple clamp into the head tube. Note: Make sure bottom output gear is meshing with the input gear before fully seating

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 engagement 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: Make sure engagement spline snap ring is install on input gear before it is pressed into the gearbox • Press input bearing onto gear a

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 following before each ride. For Enduro and Super Moto Models version check below f

Page 109 Clutch Service Clutch Service

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

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 LIMITED REMEDY Unless otherwise provided, the sole remedy under the above warranty or any implied warranty is limited to the replacement of d

Page 116 Warranty

Page 11 Basic Operating Instructions Starting the engine — EFI Models Shift the transmission into neutral. Pull in the clutch lever when starting the

Page 12 Basic Operating Instructions BREAK-IN During initial break-in newly machined surfaces will be in contact with each other and these surfaces w

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 Maintenance Schedule in Kilometers ITEMS NOTE km 150 1500 3500 6000 9000 1200

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

Page 16 Maintenance ENGINE CHASSIS NOTE: These parts and their possible replacement schedule are based upon average riding conditions. Machines sub

Page 17 Maintenance FUEL LINE • Inspect the fuel line for damage or leak, if necessary replace fuel line. FUEL FILTER SURFACE • Remove the fuel tank.

Page 18 Maintenance AWD Lever FREE PLAY: 2-3mm(1/8-3/16in) • Check for smooth Lever operation and lubricate the cable if required. • Inspect the cable

Page 19 Maintenance SPARK PLUG REMOVAL • Remove the fuel tank and disconnect the spark plug cap. Remove The spark plug and inspect it for damage • Cl

Page 20 Maintenance RADIATOR COOLANT • Inspect the level of the radiator coolant should be between “upper” and “lower” when the motorcycle running und

Page 21 Maintenance VALVE CLEANCE / DECOMPRESSOR SYSTEM VALVE CLEARANCE INSPECTION • Inspect and adjust the valve cleanse while the engine is cold (

Page 22 Maintenance INTAKE VALVE: • Insert the feeler gauge between the valve lifter and the cam labe. • Check the valve clearance for the intake

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: • Inspect and adjust the decompressor clearance while the engine is cold (below 35

Page 25 Maintenance ENGINE IDLE SPEED The engine must be warm for an accurate idle inspection and adjustment. Ten minutes of stop and go riding is suf

Page 26 Maintenance ENGINE OIL & FILTER CHANGE • Run the engine for 3 minutes. Stop the engine for 3 minutes and re-move the oil filter cap. • Re

Page 27 Maintenance TRANSMISSION OIL CHECKING OIL • Run the engine at Idle for 3minutes, turn off engine and wait 3 minutes. • Support the motorcycl

Page 28 Maintenance DRIVE CHAIN The drive chain must be checked, adjusted, and lubricated in accordance with the Maintenance Schedule. If the chain be

Page 2 Introduction Congratulations for making the choice to become and AWD rider! The instructions in this book will provide a simple and understanda

Page 29 Maintenance DRIVE CHAIN SLIDERS Chain slider • Inspec t t h e d r ive c h a i n s l i d e r for ex cess i v e wear. Service limit:

Page 30 Maintenance BRAKE FLUID Notice • Avoid spilling fluid will damage the plastic or rubber parts. Place a rag over these parts whenever the sys

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

Page 32 Maintenance SWINGARM/SHOCK LINKAGE • Raise the rear wheel off the ground by placing a work stand or equiva-lent under the engine. • Check for

Page 33 Maintenance

Page 34 AWD 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 into gear. • Turn

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

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 Disengaged AWD System ———>>> Pull and Push with one finger to Engage. ——>>>> Engaged AWD System

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

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: Due to AWD hub design, front wheel removal and installation is aided by removing front caliper first. • Remove front brake caliper (n

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: Before taking hub apart, make sure that you have a full set of spare sprag bearings. Sprag bearings are likely

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: Sprag bearings must be installed in the correct orientation in the hub for the AWD sys-tem to work properly. If

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-wheeling in t

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 ITE M TEC HNI C A L DA T A OFFRO A D DUAL SP O R T MOTA R D DI MEN S I O N S OVERALL L E N G T H 2175 m m OVERALL W I D TH 810m m OVERAL

Page 59 Warning: If removing forks for rebuild service, the fork dropouts must be disassembled so that the drive system parts are not contaminated dur

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 car

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: all 0-rings should

Page 67 Note: Be sure dropout is clean before proceeding • Insert top pinion bearings and seal into driveshaft bore at top of dropout us

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 /7 0 0 0 R P M MAX TORQUE 42.5N M / 6 5 0 0 RP M IDLE SPEED 1700±150 RPM FUEL CONSUMPTION ≤340 g/kW.h BO

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 Black Zip Tie from boot and slide it off the housing. • Remove forks from triple clamps (see “Fork Removal” section). • Slide hous

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 ITE M DA TA EN GIN E O I L 8 7 0 ml API S G o r h i g h er SAE10W-40 A T D RAI N I N G 670 m l A

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: Replacing the taper bearing is a job for your dealer. Do not attempt to do this on your own. • Remove the preload bars from the bo

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 ITE M S TAN DA R D S REPAIR L I MI T COLD TI R E P R E SS U R E 33/2.3 ( p s i / b a r ) MAX LO A D FRON T 430 / 1 9

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: Use blue Loctite on cover bolts. Torque bolts to 12 ft-

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: Replacing the taper bearing is a job for your dealer. Do not attempt to do this on your own. • Loosen steerer set screw in triple

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 through 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