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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

14-0

Bet & Win 250

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STEERING HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

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SCHEMATIC DRAWING ---------------------------------------------- 14- 1

SERVICE INFORMATION -------------------------------------------- 14- 2

TROUBLESHOOTING ------------------------------------------------- 14- 3

STEERING HANDLEBAR--------------------------------------------- 14- 4

FRONT WHEEL--------------------------------------------------------- 14- 5

FRONT BRAKE --------------------------------------------------------- 14- 8

FRONT SHOCK ABSORBER------------------------------------------ 14-14

FRONT FORK ----------------------------------------------------------- 14-17

Summary of content (19 pages)

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4.
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14.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. • During servicing, keep oil or grease off the brake pads and brake disk.
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14.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. (!2-6) Remove the front and rear brake master cylinder attaching bolts. Remove the front upper cover. (!2-5) Remove the front lower cover. (!2-5) Remove the floor board. (!2-4) Remove the leg shield. (!2-5) Bolts Throttle Grip Remove the four screws attaching the right and left handlebar switches.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws. Bet & Win 250 Throttle Cable Throttle Grip ＊ • Adjust the throttle grip free play to the specified range of 2_ 6mm. Install the front and rear brake master cylinders.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. Bet & Win 250 Driver Handle ＊• Do not allow the bearings to tilt while driving them in. • Drive in the bearing squarely with the sealed end facing out. Special Tools Outer driver Driver handle Outer Driver Speedometer Gear Unit INSTALLATION Apply grease to the speedometer gear unit.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT BRAKE Bet & Win 250 Holder Bolts BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. (!2-6) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake master cylinder Remove the brake master cylinder.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.64mm Before assembly, inspect the lst and 2nd rubber cups for wear. ASSEMBLY Before assembly, apply brake fluid to all removed parts. Install the spring together with the 1st rubber cup.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Connect the front stop switch wire connector. Install the handlebar covers. (!2-6) BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm. Add DOT-3 brake fluid to the brake reservoir. Stop Switch Wire Connector ＊ • When bleeding, be careful not to allow air in the brake reservoir flowing into the brake system.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Bleed Valve BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper. Fluid Tube Bolt DISASSEMBLY Remove the two brake pads dowel pins from the brake caliper. Remove the brake pads. Dowel Pin Remove the piston from the brake caliper.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore. Service Limit: 25.45mm ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid.
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.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Brake Fluid Tube Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 24.5_ 34.3N-m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system. (!14-10) ＊ When installing the brake fluid tube, be sure to install the two sealing washers.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Front Fork FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover. (!2-5) Remove the front lower cover. (!2-5) Remove the front wheel. (!14-5) Remove the front brake caliper. (!14-11) Remove the front shock absorber upper mount bolts. Loosen the lower mount bolts to remove the front shock absorbers. Shock Absorber DISASSEMBLY Remove the dust boot. Remove the dust seal. Remove the circlip.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending, damage or wear •Weak front shock absorber spring •Damper and damper rod bending •Oil seal damage or wear Measure the front shock absorber spring free length.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube. Set the front shock absorber tube in a vise and then tighten the lock nut. ＊ When holding the shock absorber tube, place a shop towel to protect it and do apply too much force . Set the front shock absorber in a vise.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT FORK REMOVAL Remove the handlebar covers. (!2-6) Remove the steering handlebar. (!14-4) Remove the front upper cover. (!2-5) Remove the front lower cover. (!2-5) Remove the front inner fender. (!2-6) Remove the front wheel. (!14-5) Remove the front brake caliper. (!14-11) Hold the steering stem top cone race and remove the steering stem lock nut. Remove the top cone race and remove the front fork.
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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bet & Win 250 Outer Driver Drive in new ball races. ＊ Be sure to drive the ball races into place completely. Bottom Ball Race INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race. Then, install the front fork. Top Ball Race Apply grease to the top cone race and install it.