GPX 250r TSE User manual

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GPX MOTO
GPX 250r TSE
Maintenance Manual
WWW.GPXMOTO.COM
WWW.GPXMOTOUK.COM

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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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GPX MOTO

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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.