GPX 250r TSE User manual
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This service manual is edited by GPXMOTO
No part of this publication may be reproduced without authorization.
GPXMOTO reserves the right to make changes at any time without notice and without incurring
any obligation.
The vehicle pictured in this owner’s manual may not match your actual vehicle.
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PREFACE
Congratulations on your purchase of a GPX motorcycle. We believe that you have made an
excellent choice ,which will give you great and reliable performance.
This Handbook and Manual will give you an understanding of our product. It has detailed the
complete range of specialized maintenance and adjustment schedules as well as the procedures
required.
This document also explains extensive troubleshooting methods as well as a comprehensive technical
specification. To assist you there are many photographs and guides to assist you.
Please read this manual carefully and carry out maintenance according to a professional standard.
carrying out the correct maintenance at the required schedule will effectively prolong the service
life of each component, improve the motorcycle and engine performance as well as the reliability of
the vehicle.
Riding motorcycles is dangerous and the GPX should not be operated with out the rider wearing a
helmet , goggles ,boots and gloves at the bare minimum.
It is expected that the operator has a good knowledge of riding and maintaining motorcycles. If you
do not , you should seeking specialised riding coaching and take your motorcycle to a GPX dealer
when adjustments or work is required. This is a basic handbook and manual only. It expected that the
operator should have a much more comprehensive knowledge that this basic manual displays. If you
do not , then take your motorcycle to a GPX dealer.
For the sake of technical development, GPXMOTO will reserve the right of modifying motorcycle
structure, equipment, and spare parts without notice. Due to that different markets have different law’s
requirement, we’ve adjusted model accordingly, the model image in this manual maybe not match your
actual vehicle. In addition, if there is any question concerning this manual, please visit our website
www.GPXMOTO.COM or WWW.GPXMOTOUK.COM and consult our customer service.
Alternatively you can call your GPX dealer for advice and assistance.
The contents of this manual are subject to change without prior notice due to vehicle
improvement. The actual state of the motorcycle in questions should determine the overall
level of maintenance required.
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CONTENT
MEANINGS OF REPRESENTATION..................................................................................................9
SYMBOLS USED….......................................................................................................................9
DEGREES OF RISK AND SYMBOLS.........................................................................................9
ADVICE...............................................................................................................................................10
APPEARANCE....................................................................................................................................11
GPX COMPONENTS AND POSITIONS.................................................................................... 11
VIN CODE, CHASSIS NUMBER AND ENGINE NUMBER….......................................................13
VIN CODE…............................................................................................................................13
CHASSIS NUMBER................................................................................................................13
ENGINE NUMBER…................................................................................................................13
PARAMETER......................................................................................................................................14
DIMENSIONS AND SPECIFICATIONS................................................................................14
CONTROLS.........................................................................................................................................16
CLUTCH LEVER........................................................................................................................16
FRONT DISC BRAKE............................................................................................................16
THROTTLE LEVER............................................................................................................... 17
STARTING.................................................................................................................................. 17
STOPPING.................................................................................................................................. 17
FUEL TANK SWITCH................................................................................................................18
CHANGING GEAR…..............................................................................................................18
REAR DISC BRAKE…...............................................................................................................19
SIDE STAND…............................................................................................................................19
NA................................................................................................................................................ 20
PREPARING FOR USE...................................................................................................................... 21
ADVICE ON FIRST USE…........................................................................................................21
RUNNING-IN PROCESS............................................................................................................21
RIDING INSTRUCTIONS…...........................................................................................................22
PREPARATION BEFORE RIDING............................................................................................22
PREPARATION FOR STARTING.............................................................................................. 22
PREPARATION STOPPING....................................................................................................... 22
PREPARATION FOR TURNING................................................................................................23
PREPARATION FOR ACCELERATION…............................................................................23
PREPARATION FOR CHANGING GEAR............................................................................ 23
PREPARATION FOR BRAKING............................................................................................ 23
PREPARATION FOR STOPPING & PARKING............................................................. 23
SUGGESTED INSPECTION TIME FOR ALL PARTS OF THE VEHICLE.....................................24
SUSPENSION SYSTEM…................................................................................................................25
CHECK THE COMPRESSION AND REBOUND OF THE
VEHICLE…………………..25
ADJUSTING THE COMPRESSION DAMPING OF THE REAR SHOCK
ABSORBER..................................................................................................................................25
ADJUSTING THE REBOUND DAMPING OF THE REAR SHOCK
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ABSORBER..................................................................................................................................25
MEASURE THE SUSPENSION SAG …………………………………………………………26
MEASURE DISTANCE BETWEEN CENTER OF REAR WHEEL AND REAR
FENDER
UNDER NO LOAD......................................................................................................................26
MEASURE DISTANCE BETWEEN REAR WHEEL CENTER AND REAR
FENDER IN
DRIVING CONDITION...............................................................................................................27
ADJUSTING THE SPRING PRELOAD OF REAR SHOCK ABSORBER...............................27
CHECKING THE FRONT FORK SETTINGS............................................................................27
ADJUSTING THE COMPRESSION DAMPING OF FRONT FORKS.......................................28
ADJUSTING THE REBOUND DAMPING OF FRONT FORKS............................................. 28
ADJUSTING THE HANDLEBARS............................................................................................ 28
VEHICLE MAINTENANCE…..........................................................................................................29
PLACING THE MOTORCYCLE ON A RAISED STAND..................................................... 29
NA…............................................................................................................................................ 29
REMOVING OR INSTALLING THE FRONT FORK PROTECTION GUARDS…................29
REMOVING OR INSTALLING THE FRONT DISC BRAKE...............................................30
REMOVING OR INSTALLING THE FRONT SUSPENSION FORKS..............................30
REMOVING OR INSTALLING THE TRIPLE TREES.............................................................30
CHECK THE FRONT STEERING…..........................................................................................31
LUBRICATION AND INSTALLATION OF STEERING HEAD BEARING............................ 31
REMOVING OR INSTALLING FRONT HEADLIGHT…........................................................32
REMOVING OR INSTALLING THE FRONT FENDER...........................................................32
REMOVING OR INSTALLING THE REAR SHOCK ABSORBER..........................................33
REMOVING OR INSTALLING THE SEAT .............................................................................33
REMOVING OR INSTALLING THE AIR FILTER HOUSING.................................................34
REMOVING OR INSTALLING THE AIR FILTER....................................................................34
CLEANING AND MAINTENANCE OF AIR FILTER…...........................................................35
REMOVING OR INSTALLING THE EXHAUST PIPE….........................................................35
REMOVING OR INSTALLING THE EXHAUST SILENCER…...............................................36
REMOVING OR INSTALLING THE FUEL TANK…...............................................................36
CHECK AND CLEAN THE CHAIN….......................................................................................36
REMOVING OR INSTALLING THE CHAIN…........................................................................36
CHECK AND ADJUST THECHAIN TENSION........................................................................38
CHECK THE STRUCTURE OF THE REAR SPROCKET, FRONT SPROCKET AND CHAIN
GUIDE …………………………………………………………………………………………..39
CHECK THE FRAME..................................................................................................................39
CHECK THE FRONT SUSPENSION FORKS…....................................................................... 39
CHECK THE THROTTLE CABLE….........................................................................................39
CHECK THE HANDLEBARS…................................................................................................ 40
ADJUSTING THE CLUTCH LEVER.........................................................................................40
REPLACE THE TRANSMISSION OIL..................................................................................... 40
CHECK AND MAINTAIN THE BRAKE SYSTEM….....................................................................41
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CHECK THE FREE-PLAY OF FRONT BRAKE LEVER..........................................................41
CHECK THE FRONT BRAKE HOSE….................................................................................... 41
CHECK THE FRONT DISC …....................................................................................................42
CHECK THE FRONT BRAKE FLUID LEVEL...........................................................................42
REFILL THE FRONT BRAKE LIQUID LEVEL....................................................................... 43
CHECK THE FRONT BRAKE PADS.........................................................................................43
CHECK THE FREE-PLAY OF REAR BRAKE............................................................................43
CHECK THE REAR BRAKE DISK FLUID LEVEL.................................................................. 44
REFILL THE REAR BRAKE DISK FLUID LEVEL................................................................. 44
CHECK THE REAR BRAKE PADS............................................................................................45
TIRE INSPECTION AND MAINTENANCE.....................................................................................46
REMOVING OR INSTALLING THE FRONT WHEEL.............................................................46
REMOVING OR INSTALLING THE REAR WHEEL...............................................................46
TIRE INSPECTION......................................................................................................................46
CHECK TIRE PRESSURE...........................................................................................................47
CHECKING THE SPOKES...................................................................................................... 47
ELECTRICAL SYSTEM.....................................................................................................................48
REMOVING OR INSTALLING THE BATTERY.......................................................................48
CHANGING THE BATTERY.......................................................................................................48
MAIN CABLE
GPX VEHICLE WIRING DIAGRAM.........................................................................................49
COOLING SYSTEM...........................................................................................................................50
COOLING SYSTEM PROFILE...................................................................................................50
REMOVING OR INSTALLING THE RADIATOR AND GRILL............................................. 50
CHECK ANTIFREEZE LEVEL...................................................................................................51
DRAINING THE COOLANT...................................................................................................... 51
FILLING THE COOLING SYSTEM...........................................................................................52
ENGINE INTRODUCTION.........................................................................................................53
INSTALLING THE ENGINE.......................................................................................................53
ENGINE MAINTENANCE AND ADJUSTMENT..................................................................... 53
CHECK THE VALVE CLEARANCE..........................................................................................53
COMPRESSION PRESSURE CHECK........................................................................................54
ADJUSTMENT OF CLUTCH CONTROL SYSTEM.................................................................54
THE ENGINE ADJUSTMENT.......................................................................................................... 55
CARBURETOR IDLE SPEED ADJUSTMENT ..................................................................... 55
CLEANINING THE CARBURETOR......................................................................................... 55
CHECKING THE SHIFT LEVER POSITION.............................................................................56
ADJUSTING THE SHIFT LEVER POSITION.......................................................................... 56
INSPECTION OR REPLACEMENT OF THE SPARK PLUG....................................................56
LUBRICANT SELECTION.........................................................................................................57
LUBRICANT INSPECTION....................................................................................................... 57
LUBRICANT REPLACEMENT................................................................................................. 58
NA.................................................................................................................................................58
NA................................................................................................................................................ 59
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NA.................................................................................................................................................60
REMOVAL OF THE WATER COOLING PUMP.......................................................................60
INSTALLATION OF WATER COOLING PUMP...................................................................... 60
ENGINE CYLINDER BLOCK AND PISTON.................................................................................. 61
CYLINDER BLOCK AND PISTON PARTS SPECIFICATIONS...............................................61
REMOVAL OF CYLINDER ....................................................................................................... 62
CYLINDER INSPECTION.......................................................................................................... 62
REMOVAL OF PISTON...............................................................................................................62
PISTON AND PISTON RING INSPECTION............................................................................. 63
CLEANING AND INSPECTION OF CYLINDER HEAD.........................................................63
CHECK THE CLEARANCE BETWEEN CYLINDER AND PISTON......................................64
MEASURE THE DIAMETER OF PISTON PIN ....................................................................... 64
INSTALLATION OF PISTON RING...........................................................................................64
INSTALLATION OF PISTON......................................................................................................65
INSTALLATION OF CYLINDER............................................................................................... 66
REMOVAL / INSPECTION OF CLUTCH......................................................................................... 66
CLUTCH PARTS SPECIFICATIONS..........................................................................................66
REMOVAL OF THE RIGHT CRANKCASE COVER................................................................66
REMOVING THE CLUTCH........................................................................................................ 67
CLUTCH INSPECTION...............................................................................................................67
INSTALLATION OF THE CLUTCH.......................................................................................... 68
INSTALLATION OF THE RIGHT CRANKCASE COVER.......................................................69
REMOVAL / INSTALLATION OF THE SHIFT MECHANISM IN THE ENGINE.................. 70
MAGNETO AND ELECTRIC ENGINE COMPONENTS............................................................... 71
REMOVAL / INSTALLATION OF STARTER MOTOR............................................................ 71
REMOVAL / INSTALLATION OF LEFT CRANKCASE COVER........................................... 71
REMOVAL / INSTALLATION OF MAGNETO STATOR......................................................... 72
REMOVAL / INSTALLATION OF THE MAGNETO ROTOR.................................................. 72
REMOVAL / INSTALLATION OF ELECTRIC START GEAR................................................. 72
ENGINE CRANKSHAFT AND TRANSMISSION MECHANISM..................................................73
PREPARATIONS BEFORE REMOVING THE CRANKCASE.................................................73
SPECIFICATIONS OF CRANKSHAFT AND TRANSMISSION MECHANISM....................73
REMOVAL OF CRANKCASE....................................................................................................74
REMOVAL OF THE TRANSMISSION MECHANISM.............................................................74
CRANKSHAFT INSPECTION....................................................................................................74
TRANSMISSION MECHANISM INSPECTION....................................................................... 75
INSTALLATION OF TRANSMISSION MECHANISM.............................................................76
INSTALLATION OF REMAINING PARTS................................................................................77
ENGINE TIGHTENING TORQUE TABLE................................................................................78
TROUBLESHOOTING.......................................................................................................................78
ENGINE OIL SPECIFICATION........................................................................................................ 81
MOTORCYCLE CLEANING.............................................................................................................83
STORAGE........................................................................................................................................... 83
PREPARING FOR LONG STORAGE.........................................................................................83
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PREPARING FOR USE AFTER LONG STORAGE...................................................................84
MAINTENANCE POINTS..................................................................................................................84
TORQUE SPECIFICATION TABLE FOR THE WHOLE VEHICLE...............................................89
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MEANINGS OF REPRESENTATION
SYMBOLS USED
The meaning of specific symbols is described below
* All work marked with this symbol requires specialist knowledge and technical understanding. If
you do not have the confidence to perform that, you can go to an authorized GPX workshop or GPX
after-sale service point. There, your motorcycle will be optimally cared for by specially trained
experts using the specialist tools required.
→ Indicates a page reference (more information is provided on the specified page).
DEGREES OF RISK AND SYMBOLS
Your safety, and the safety of others, is very important. Operating this motorcycle safety is an
important responsibility. Please read this manual carefully.
Safety Messages preceded by a safety alert symbol and one of three signal words:
DANGER: Indicates a danger that will immediately and invariably lead to fatal or permanent injury
if the appropriate measures are not taken.
WARNING: Indicates a danger that is likely to lead to fatal or serious injury if the appropriate
measures are not taken.
CAUTION: Indicates a danger that may lead to minor injuries if the appropriate measures are not
taken.
Other important information:
Please note that it is not practical or possible to warn you about all hazards associated with operating
or maintaining a motorcycle.
Therefore, you must have basic mechanical safety knowledge and use your own good judgement.
If you cannot complete the process of operating or maintaining, please consult a more experienced
senior technician before operation.
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ADVICE
Most of off-road motorcycle fatalities are caused by head injuries. Without helmets, the chances of
serious injury or death caused by head injuries are much higher. Always wear an approved
motorcycle helmet and protective apparel such as goggles, gloves and boots while riding, which will
save your life at the critical moment.
This motorcycle was designed for off road racing , therefore there is no capacity to carry a
passenger .Please therefore do not use this motorcycle to carry any passengers. Ignoring this or order
rules could lead to serious injury or a fatality.
Do not use non-original parts to modify this motorcycle. If you need to replace any parts, please use
spare parts and accessory products that are approved and / or recommended by GPX and have them
installed by an authorized GPX workshop. GPX accepts no liability for any personal modification,
other products and any resulting damage or loss.
Our TSE series products are specially designed for off-road racing and riding.
Please take care of your vehicle and avoid any problem caused by improper use.
Please check your motorcycle carefully before riding and do the maintenance accordingly after use.
If you crash the motorcycle, check the condition of the motorcycle before you resume your journey.
Ignoring this advice could easily lead to an accident and endanger your own safety as well as others ,
as you may be riding a broken or faulting motorcycle .
When using this motorcycle, the temperature of the engine and exhaust pipe is very high, so it needs
to a period to cool down after parking. During this period, do not touch the engine or exhaust pipe as
you will scold yourself.
Do not wear shorts while riding, otherwise leg injuries may happen.
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No.
Name
No.
Name
1
Front fender
10
Front brake caliper
2
Headlight
11
Front shock
3
Handlebar
12
Fuel tank
4
Vent pipe
13
Carburettor
5
Fuel tank cap
14
Gear shift lever
6
Fuel tank petcock
15
Pedal
7
Air filter cover
16
Chain
8
Chain guide cover
17
Chain guide
9
Front disc brake cover
18
Rear sprocket
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No.
Name
No.
Name
19
Tail light
28
Rear brake caliper
20
Rear fender
29
Aluminium swinging arm
21
Exhaust silencer
30
Triangle rocker arm
22
Seat
31
U-shape rocker arm
23
Rear shock
32
Rear brake oil cup
24
Upper clamp
33
Brake pedal
25
Cooling water tank
34
Exhaust pipe
26
Lower clamp
35
Front disc brake
27
Rear disc brake
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PARAMETER
DIMENSIONS AND SPECIFICATION - TSE 250R
L*W*H（mm）
2180×820×1254
Wheelbase（mm）
1480mm
Net weight（kg）
110
Tire size
F: 80/100-21；R: 110/100-18. Rear will accept a 140 80/90 18” Enduro or
MX tyre
Seat height（mm）
939mm. This can be reduced by 55mm to 884mm by using the 2nd lower
shock bolt , at no expense.
Min ground clearance
（mm）
330mm
Tank volume（L）
9.4 litres
Engine Parameters
Engine type
Single cylinder, water cooled two stroke with power valve and counter
balancer.
Clutch type
Wet type, Multiple disk
Cylinder
diameter×stroke
66.8×64mm
Oil / ratio
During run in period 40/1. After run in period 50/1. On both occasions
always with quality branded fully synthetic 2 stroke oil
Displacement
224cc
Max. Power（kw/r/min）
39/8500
Max. Torqu（e NM/r/min）
36/7500
Compression Ratio
6.5:1
Shift type
Usually engaged two - stage transmission six - speed transmission,
International profile 1-N-2-3-4-5-6
Starting
12v Electric start with starter placement under engine and with direct
attachment to flywheel (No maintenance with no gears to wear) . Kick
start back up.
Fuel control system
PWK Flat side Mikuni copy carburettor
Battery
Stock 12v battery for high performance electric starting and reliable
electronics
Chain
#520, 12T/52T O ring
Frame/Shock/Brake/Wheel system Parameters
Frame type
Central double cradle type high-strength steel tube frame, GPX
International patent design
Front shock
SZC Front suspension. 310mm travel. Comprising of quality high
performance Telescopic, closed cartridge type units with adjustable
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compression and rebound. Seals , dust seal and range of springs available
(after market), L=950mm.
Rear shock
Compression recovery dual adjustable nitrogen airbag rear shock,
L=480mm, 300mm travel , CRF general configuration.Quality high
performance unit with spring preload, adjustable compression as well as
rebound damping
Swingarm
High strength forged aluminium alloy structure
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Handlebar
Competitive high-strength aluminium alloy fat bar (imported),，material
7075 Φ28.6mm, with GPX special ultra-soft off-road grip
F/R rims
F 1.60×21, R 2.15×18, 7050 high strength aluminium rim ，
forged CNC wheel hub
F brake system
Powerful Hydraulic alloy twin piston caliper with 260mm disc
R brake system
Powerful Hydraulic alloy twin piston caliper with 240mm disc
Others
Air filter type
Sponge filter core filter type
Fuel type
92# and above grade gasoline. 50/1 ratio premix with fully synthetic
quality oil
Motorcyclists
1 person（rider）
Maximum load weight
120kg
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