GMX MOTORBIKES X Series, Assembly Manual

Page 1: ...ETURN TO STORE NOTE Manual illustrations are for demonstration purposes only Illustrations man not reflect exact appearance of actual procduct WWW GMXMOTORBIKES COM AU PH 1300 766 469 Chrisco Support www gmxmotorbikes com au chriscosupport GMX X SERIES DIRT BIKE 50cc 150cc 250cc ...

Page 2: ...g the packaging hand with caution CHECK LOOSE PARTS On most occasions your bike will come 90 assembled depending on the model Please go through all lose parts and check packaging that has been taken out to ensure no parts get thrown out so you can assemble your GMX Product READ MANUAL Ensure that you read and go over the manual and UNDERSTAND before assembling product PLEASE NOTE Minor assembly is...

Page 3: ...VE KEYS KEY REMOVAL WARNING Please use unleaded fuel 90 Octane or above UNLEADED FUEL ONLY WARNING This product is powered by a 4 stroke engine and comes with transport oil in the engine THE OIL NEEDS TO BE DRAINED AND REPLACED WITH MOTORCYCLE OIL 10W 40 or 10W 50 IS REQUIRED IF THE OIL CHANGE IS NOT PERFORMED YOU MAY INTERNALLY DAMAGE THE ENGINE AND CLUTCH AND VOID YOUR WARRANTY DO NOT USE MOTOR ...

Page 4: ...embly is required and in the interest of safety and warranty it is recommended that you have this product assembled by a qualified skilled small engine mechanic You may need to provide proof of being assembled by a skilled mechanic if not a report from a small engine mechanic advising of the issues to process your warranty claims The warranty is a parts replacement warranty and labor is not includ...

Page 5: ...orcycle across TAKE TIME TO LEARN AND PRACTICE Developing off road riding skills is a gradual step by step process Start by practicing at low speeds in a safe area and slowly build your skills Personal instruction from an experienced rider can also be valuable ALWAYS WEAR A HELMET It s a proven fact helmets significantly reduce the number and severity of head injuries It is required to wear an Aus...

Page 6: ...LITY is necessary for riding a motorcycle Generally speaking your youngster should be good at riding a bicycle before getting on a motorcycle Can your youngster judge speeds and distances while riding a bicycle and react with proper hand and foot actions Anyone who does not have good coordination balance and agility is not ready to ride this motorcycle To help your youngster build confidence as th...

Page 7: ...arts If you are unsure get advised by an experienced small engine mechanic or hobby shop technician BRAKE CHECK Check the brakes for correct functioning When you apply pressure to the hand brake you should have a positive braking action If not adjust the brake accordingly When you apply the brake with the accelerator on the brake cut off switch will stop the motor FRAME FORK AND HANDLEBARS Check f...

Page 8: ...it will lead to misalignment causing the chain to comeoff WARRANTY The dirt bikes are sold as off road or enduro competition motorcycles and they will require a high level of care and maintenance The dirt bikes due to their intended purpose being competition motorcycles become the same class as a competition rally car Therefore it is up to the individuals to establish which level of bike they need...

Page 9: ... person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to con...

Page 10: ...e chart Engineoil Spark plug Valve clearance Air filter Throttle grip Carburetor 8 8 10 11 12 13 14 15 15 16 17 18 18 20 22 25 26 27 28 30 Drive chain Handlebar Brakes Front brake pad replacement Rear brake pad replacement Steering Front and rear suspension Wheels and tyres Spokes and rims Tightening torques of nuts and bolts Cleaning of your motorcycle Lubrication STORAGE ASSEMBLY MAINTENANCE REC...

Page 11: ...8 GENERAL INFORMATION Location of parts 1 Clutch lever 2 Fuel tank cap 3 Front brake lever 4 Engine kill switch 5 Handlebar 6 Throttle grip ...

Page 12: ...ake disc 13 Front brake caliper 14 Left tank fin 15 Choke lever 16 Gear lever 17 Engine oil drainplug 18 Air filter 19 Chain guide 20 Silencer 21 Seat 22 Fuel tank 23 Right tank fin 24 Rear brake disc 25 Rear brake caliper 26 Rear shock 27 Kick start 28 Rear brake pedal 29 Engine guard 30 Carburetor ...

Page 13: ...heavy dust is blowing so that the fuel does not get contaminated Fuel tap The fuel tap has two positions ON A and OFF B For normal operation turn the fuel tap to the ON position Turn the fuel tap lever to the OFF position when the fuel tank is removed for maintenance and adjustments or when the motorcycle is left unused for lengthy periods ...

Page 14: ...The octane rating of a gasoline is a measure of its resistance to detonation or knocking The antiknock index is an average of the Research Octane Number RON and the motor Octane number MON CAUTION If engine knocking or pinging occurs use a different brand of petrol of a higher octane rating If this Condition is allowed to continue it can lead to severe engine damage Petrol quality is important Fue...

Page 15: ... the engine stops type A or pushed to the in position type B Starting the engine Shift the transmission into neutral by pushing the shift pedal down into neutral until the motorcycle rolls freely 140cc plus will start in gear with the clutch engaged fully Turn the fuel tap to the ON position Turn the ignition key to the ON position if your motorcycle is fitted with one Ensure your kill switch is n...

Page 16: ...ngines use the carburetor choke lever A lift upwards for choke ON Warm engine before riding Move choke lever downwards when the engine is warm for choke OFF Pull in the front brake lever then press the start button located on the left side of the handlebar Kick start can be used as a backup if required ...

Page 17: ... downwards with speed Moving off Geared models Engage clutch fully Shift into 1st gear Open the throttle slowly Release the clutch slowly Automatic models Open the throttle slowly Note When the engine is already warm or on a hot day open the throttle part way instead of using the choke lever ...

Page 18: ...s in certain circumstances Shift down progressively to ensure good engine response at all speeds 4 Speed 5 Speed 4 5 3 4 2 3 1 2 N N 1 WARNING When shifting down into a lower gear do not shift at such a high speed that the engine r min rpm jumps excessively Not only can this cause engine damage but the rear wheel may skid and cause an accident CAUTION When changing gears raise or press firmly on t...

Page 19: ...ct No leakage Tighten to correct torque Adjusted properly idle speed 1400 100 r min rpm Clean properly installed apply oil to air filter element Check not damaged Check overall condition wear cuts and other damage check tyre air pressure tighten the air valve cap securely Check for any loose spokes if necessary tighten Check overall condition lubricate the drive chain check drive chain tension is ...

Page 20: ...k acceleration or starting by using no more than 2 3 of the throttle NEVER pull the throttle back fully in this break in period and ride prudently The break in period should be carried out with normal riding and should not be carried out on a crate in a stationary position Once the motorcycle has completed its break in period it should then have its first service checks and maintenance carried out...

Page 21: ... motorcycle dealer Please note that we cannot assume any responsibility for damage resulting from incorrect or improper adjustment done by the owner Maintenance Proper maintenance is necessary to ensure that your motorcycle continues to run correctly This owner s manual contains maintenance operations recommended for your motorcycle As the owner of this motorcycle you have the responsibility to ma...

Page 22: ...tions mean that accelerating and braking is increased thus naturally causing more engine and braking wear You can rest assured that our motorcycles are happy to receive such a harsh life but with this comes a strict regular maintenance schedule this is implemented to ensure your motorcycle continues to serve you well Enduro motorcycles Enduro motorcycles still contain very much a similar specifica...

Page 23: ... D Fuel hose connections check Clutch check adjust CHASSIS Spoke tightness and rim run out check 38 Nuts bolts fasteners check 39 Drive sprockets and chain check 31 D Front fork inspect clean 37 D Front fork oil check 37 Steering play check 36 Steering stem bearing grease General lubrication perform 44 Side stand check D Wheel bearings check D Swing arm pivots check D Rear shock absorber check 37 ...

Page 24: ...lean replace D Fuel hose connections check Clutch check adjust CHASSIS Spoke tightness and rim run out check 38 Nuts bolts fasteners check 39 Drive sprockets and chain check 31 D Front fork inspect clean 37 D Front fork oil check 37 Steering play check 36 Steering stem bearing grease General lubrication perform 44 Side stand check D Wheel bearings check D Swing arm pivots check D Rear shock absorb...

Page 25: ...ed maintenance schedule will prolong the life of your motor and reduce wear and tear Recommended oil Semi synthetic motorcycle engine oil Viscosity SAE 10W 40 Type API SE SF or SG API SH or SJ with JASO MA WARNING The safe operation of your motorcycle will be impaired if proper engine oil maintenance is not carried out according to the maintenance schedule Utilising dirty or contaminated oil may r...

Page 26: ... the oil filler cap dipstick then thoroughly wipe it down with a rag 5 Stand the motorcycle into an upright position and ensure it is not leaning to the side 6 Re insert the dipstick until it seats but do not screw it in 7 Then remove the dipstick and inspect the oil level If the oil is at or near the upper oil boundary mark B do not add oil but if the oil is below or near the lower oil boundary m...

Page 27: ...sting on the side stand 7 Pour in new engine oil while continuously checkinglevels 8 To check oil levels the oil filler cap dip stick should be inserted fully but not screwed in then remove and inspect the dipstick levels top upaccordingly 9 Re install the oil fillercap dipstick 10 Start engine and let run for five minutes then stop engine and let it sit for three minutes 11 Re check oil level and...

Page 28: ... plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug The standard spark plug is shown in the table below Spark plug removal and installation Pull the spark plug cap off the sparkplug Apply a suitable wrench to the sparkplug Loosen and remove the spark p...

Page 29: ...ble motorcycle dealers mechanic following the instructions in the service manual Tappet clearance gap IN top EX bottom 0 05mm 0 10mm Valve clearance should be set at the following points 1st time 2nd time Onwards New PDI stage Upon 1st service See maintenance schedule CAUTION If valve clearance is left unadjusted wear will eventually cause the valves to remain partly open which lowers performances...

Page 30: ...w A 2 Remove air filter from the carburetor 3 Thoroughly wash the filter with dish soap Remove excess liquid and let dry for 24 hours prior to re installation 4 Visually examine the air filter If damaged replace with new airfilter 5 Once dry apply a thin layer of approved air filter oil Remove the excess oil 6 Re install the air filter by fastening the attaching clamp screw WARNING A clogged air f...

Page 31: ...no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play in accordance with the periodic maintenance chart and adjust the play if necessary Inspection Check that the throttle grip turns smoothly and there is 2 3 mm throttle grip play when lightly turning the throttle grip back and forth A Throttle grip B 2 3 mm If there is improper play adjust it...

Page 32: ...thly from full open to close and the throttle closes quickly by the return spring and operates completely in all steering positions If not check the throttle cable routing grip free play and cable damage Then lubricate the throttle cable With the engine idling turn the handlebar both ways and check if handlebar movement changes the idling speed If so the throttle cable may be improperly adjusted o...

Page 33: ...e If handlebar movement changes the idling speed the throttle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding Adjust the idling speed to 1400 100 r min rpm by turning the idling adjustingscrew WARNING Never run the motorcycle in a closed area such as a garage Exhaust gases contain carbon monoxide a colourless odou...

Page 34: ...on the clamps face thefront Ensure the handlebars are installed parallel to the forks Tighten all 4 clamp bolts and torque them to 25Nm Ensure the gap on the clamp is even on all four corners Chain slack inspection Set the motorcycle up on its sidestand Rotate the rear wheel to find the point where the chain is tightest Push up the chain midway point between the engine sprocket and the rear wheels...

Page 35: ...eath to catch oil 2 Refasten bleed screw Fill reservoir B with approved brake fluid 3 Connect clear plastic tube to caliper bleed screw and place other end in a container 4 Slowly engage brake lever or pedal 5 Pull in the lever or push down the pedal Continue to hold the lever or pedal in engaged position 6 Loosen the caliper bleed screw then allow the lever or pedal to reach its limit 7 Finally t...

Page 36: ... fork A 2 Take out large brake pad D and then small brake pad C 3 Place new small brake pad on piston 4 Place new larger brake pad on inner side of caliper 5 Place caliper assembly back into the correct position on fork and tighten caliper bolts whilst using thread lock WARNING Maintaining proper brake adjustment is crucial to safe operation of your motorcycle Improper adjustment may result in bra...

Page 37: ...e caliper assembly B 3 Remove two hex bolt pins from calliper rear 4 Take out brake pads B 5 Place new brake pads in correct position on piston 6 Refit two hex bolts into caliper 7 Place caliper assembly back into proper position 8 Refit rear wheel WARNING Maintaining proper brake adjustment is crucial to safe operation of your motorcycle Improper adjustment may result in brake assembly damage and...

Page 38: ...heel to check for brakedrag Operate the pedal a few times to see that it returns to its rest position immediately upon release Check brakingeffectiveness If the pedal has improper play adjustit WARNING Always maintain proper brake adjustment If the adjustment is incorrect this could cause overheating brake drag and further damage to the brake assembly This could possibly lock the wheel resulting i...

Page 39: ... rock the front fork back and forth as shown If play is felt the steering is too loose and needs to be adjusted Steering adjustment Raise the front wheel off the ground using a motorcycle jack special tool Remove the front number board or headlight Remove the handlebar clamp bolts and take out the handlebar Loosen the steering stem head nut and front fork upper clamp bolts Turn the steering stem l...

Page 40: ...uthorised dealer MAINTENANCE AND ADJUSTMENT Rear suspension The rear shock absorber inspection should be done in accordance with the periodic maintenance chart If there is any damage to the rear shock absorber it should be replaced by an authorised dealer WARNING This unit contains high pressure gas Keep away from fire or flame Do notdisassemble Note The installation and removal of the rear shock ...

Page 41: ...sult in spokebreakage Rim runout Set up a dial gauge on the side of the rim and rotate the wheel to measure its axial runout The difference between the highest and lowest readings is the amount of runout Set up the dial gauge on the inner circumference of the rim and rotate the wheel to measure its radial runout The difference between the highest and lowest dial readings is the amount of runout A ...

Page 42: ...rk mount bolts 3 Handlebar clamp bolts 4 Fin mount bolts 5 Engine mount bolts 6 Chain slider mountingbolts 7 Seat mount bolts 8 Front axle nut 9 Brake caliper bolt 10 Engine head bolts 11 Fuel tank mount bolts 12 Engine guard bolts 13 Engine oil drainplug 14 Footpeg engine mount bolts 15 Chain roller bolt 16 Rear shock mount bolt 17 Chain guide mount bolts 18 Rear sprocketbolts ...

Page 43: ... MAINTENANCE AND ADJUSTMENT 19 Silencer mounting bolt 20 Front brake lever bolt 21 Rear axle bolt 22 Chain adjusterbolts 23 Swing arm shaft bolt 24 Side stand bolt 25 Head stem nut 26 Front mudguard bolts ...

Page 44: ...3 35 6 Chain slider mount bolts 10 15 8 Nut for front axle 45 55 9 Front brake caliper bolts 20 25 10 Engine head bolts 10 12 13 Oil drain bolt 20 25 14 Foot peg engine mount bolt 33 35 16 Tightening nut for rear shock absorber 38 42 18 Rear sprocket bolts 25 30 19 Tightening nut for silencer 25 30 20 Front brake reservoir 8 12 21 Nut for rear axle 55 60 22 Chain adjuster bolts 20 25 23 Swing arm ...

Page 45: ... brake components electrical components silencer openings and fuel tankopenings Washing your motorcycle Rinse your bike with cold water from a garden hose to remove any loose dirt Mix a mild neutral detergent designed for motorcycles and water in bucket Use a soft cloth or sponge to wash your motorcycle If needed use a mild degreaser to remove any oil or grease build up After washing rinse your mo...

Page 46: ...cessories special care must be taken Use a leather cleaner treatment to clean and care for leather accessories Washing leather parts with detergent and water will damage them shortening their life Vinyl parts should be washed with the rest of the motorcycle and then treated with a vinyltreatment The sidewalls of tyres and other rubber components should be treated with a rubber protectant to help p...

Page 47: ...l to the following pivots Side Stand Front brake and clutch leverpoints Rear brake lever points Kick start points Cable lubrication Use an aerosol type cable lubrication with a pressure isolator on all cables Throttle cable Clutch cable Apply grease to the upper ends of both cables Drive chain lubrication Lubrication is also necessary after riding through rain or on wet tracks or any time that the...

Page 48: ...cycle on a box or stand so that both wheels are raised off the ground if this cannot be done put boards under the front and rear wheels to keep dampness away from the tyre rubber Place a plastic bag over the silencer and secure with a rubber band to prevent moisture fromentering Cover the motorcycle to keep dust and dirt away fromit It is advisable to connect any batteries to a motorcycle battery ...

Page 49: ...only as a guide to a professional and may not be exhaustive Each machine may require individual attention therefore ONLY qualified persons should carry out the following Tasks Tick Mount rear shock whereapplicable Ensure rear brake hose is inserted into the swing arm mount clips Mount front wheel ensure free rotation check for potential bearing and or brake drag Supermoto wheels see page 56 for wh...

Page 50: ...engine bolts frame must be hard tight against the engine chain tensioners rear shock bolts triple clamp bolts handlebars brake clutch throttle swing arm front rear sprocket front rear light It is suggested not to use thread lock at this stage Thread lock should be applied at the first service interval once further all parts have bedded in and nut and bolt adjustments have been made Once the engine...

Page 51: ... screws ifrequired Carburetor checks Pre delivery inspection PDI cont Tasks Tick Fuel the bike check for fuel leaks If fuel leaks from the carburetor overflow remove the carburetor adjust the float height Check for any debris which may be blocking the fuel shut offvalve Owners name address Owners telephone number Warranty start date Proof of PDI For warranty purposes to be completed by a reputable...

Page 52: ...ns name Dealers stamp Drain oil replace with semi synthetic 10w 40 4 stroke motorcycle engine oil do not use fully synthetic Working from front to rear check all nuts bolts tighten where necessary Apply thread locking compound where no nyloc nuts or spring washers are present and re tighten Check flywheel nut Re adjust valve tappet clearances seeoverleaf Check wheel spokes especially rear wheeldri...

Page 53: ...reputable motorcycle dealership ONLY Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp ...

Page 54: ...reputable motorcycle dealership ONLY Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp ...

Page 55: ...reputable motorcycle dealership ONLY Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp ...

Page 56: ...reputable motorcycle dealership ONLY Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp ...

Page 57: ...reputable motorcycle dealership ONLY Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp Motorcycle VIN number Date Company Company address Company telephone number Technicians name Dealers stamp ...

Page 58: ...f or start to hear valve bounce it is critical that you change up a gear or ease off thethrottle Do not stamp through the gears always use the clutch If you miss a gear do NOT stamp into gear from high engine revs Do not drop your clutch heavily or slip itunnecessarily Do not allow your air filter to fill with fuel this can occur by incorrect float height setting or the bike falling onto its side ...

Page 59: ...ompression feels low Spark plug loose valve clearance requires setting clutch requires adjustment Spark missing or weak Spark plug faulty spark plug cap poorly connected or shorted Fuel does not flow Not sufficient fuel in tank fuel hose blocked or kinked fuel tap blocked Engine flooded Starting techniqueincorrect Poor low speed performance Spark weak Spark plug faulty spark plug gap excessive Fue...

Page 60: ...ed correctly or faulty Poor handling or stability Handlebar hard to turn Steering stem locknut too tight tyre air pressure too low steering stem lubrication insufficient Handlebar vibrates or shakes Swing arm bent front fork bent frame bent wheel alignment incorrect pivot shaft warped right left front for oil level uneven warped brakedisc Shock absorption too hard Tyre air pressure toohigh Shock a...

Page 61: ...VEHICLE MAINTENANCE ...

Page 62: ...ck the fuel oil and coolant every time before use with the engine off Visually inspect Check for damaged or loose parts Check for fuel or oil leaks Wheels and Tyres Check tyres for damage Ensure tyre pressure is correct and even in each tyre Check wheel nuts Throttle Check the throttle operates smoothly across its range Accumulated mud and dirt can restrict cable movement and prevent the throttle ...

Page 63: ... oil leakage Look and feel for loose parts with the engine off Rough terrain will loosen chassis parts Steering Check the steering moves freely but without undue looseness Other checks required Maintenance actions required into operation Done Checked by Date VEHICLE MAINTENANCE BEFORE YOU RIDE CHECKLIST ...

Page 64: ... bike tyres Chassis and suspension Shock absorbers for leaks and wear Suspension operation Safety guards for looseness Handlebars foot decks and major fasteners use tension wrench Steering Smooth movement from lock to lock Linkages for wear Throttle operation Test while moving handlebars fully to the left and fully to the right Gear selectors Gear levers for damage and excessive slack Splines on g...

Page 65: ...adjustment as per the operator s manual Sprockets not worn Battery Battery terminals for corrosion and tightness Electrolyte levels Damaged casing Lever controls Check smoothness of operation Check for broken sharp or bent levers Other Check for attachment and condition of Load carriers Foot decks Seat Additional routine maintenance checks required On the back of this sheet list 1 Maintenance acti...

Page 66: ...VEHICLE MAINTENANCE ...

Page 67: ...ck the fuel oil and coolant every time before use with the engine off Visually inspect Check for damaged or loose parts Check for fuel or oil leaks Wheels and Tyres Check tyres for damage Ensure tyre pressure is correct and even in each tyre Check wheel nuts Throttle Check the throttle operates smoothly across its range Accumulated mud and dirt can restrict cable movement and prevent the throttle ...

Page 68: ... oil leakage Look and feel for loose parts with the engine off Rough terrain will loosen chassis parts Steering Check the steering moves freely but without undue looseness Other checks required Maintenance actions required into operation Done Checked by Date VEHICLE MAINTENANCE BEFORE YOU RIDE CHECKLIST ...

Page 69: ... bike tyres Chassis and suspension Shock absorbers for leaks and wear Suspension operation Safety guards for looseness Handlebars foot decks and major fasteners use tension wrench Steering Smooth movement from lock to lock Linkages for wear Throttle operation Test while moving handlebars fully to the left and fully to the right Gear selectors Gear levers for damage and excessive slack Splines on g...

Page 70: ...adjustment as per the operator s manual Sprockets not worn Battery Battery terminals for corrosion and tightness Electrolyte levels Damaged casing Lever controls Check smoothness of operation Check for broken sharp or bent levers Other Check for attachment and condition of Load carriers Foot decks Seat Additional routine maintenance checks required On the back of this sheet list 1 Maintenance acti...

Page 71: ...61 Notes ...