GPX MOTO GPX300r TSE Owner's Handbook Manual
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GPX MOTO GPX300r TSE Owner's Handbook Manual

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GPX MOTO
GPX 300r TSE
Owners Handbook
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Summary of Contents for GPX MOTO GPX300r TSE

  • Page 1 GPX MOTO GPX MOTO GPX 300r TSE Owners Handbook WWW.GPXMOTO.COM WWW.GPXMOTOUK.COM - 1 - www.GPXMOTO.com + www.GPXMOTOUK.com...
  • Page 2 GPX MOTO 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.

  • Page 3: Symbols Used

    GPX MOTO improvement. The actual state of the motorcycle in questions should determine the overall level of maintenance required. 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.
  • Page 4 GPX MOTO 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.
  • Page 5 GPX MOTO Lessons learnt from a little time with the TSE 300 As is normal on dirt bikes , water can enter the air box when washing. It is imperative that the air filter is cleaned and oiled after every wash and every ride. This is the most important maintenance action you can complete to ensure the...
  • Page 6 GPX MOTO www.GPXMOTO.com + www.GPXMOTOUK.com - 12 -...
  • Page 7 GPX MOTO Name Name Front LED light Front brake caliper Handguard Petrol on off and reserve tap Hydraulic clutch lever Carburettor Switch gear Gear lever Coolant overflow tank Front sprocket Petrol filler cap wth vent Chain adjuster Petrol tank Seat...
  • Page 8 GPX MOTO Name Name Rear silencer Security rim lock Fast and slow speed compression Rear brake caliper Spring preload adjuster Rear shock rebound adjuster Radiator fan Rear brake master cylinder Hour meter Kick start Fork compression and spring preload Rear brake lever...

  • Page 9: Chassis Number

    GPX MOTO VIN CODE Vin code of the TSE 300r ,is located on the head stock. CHASSIS NUMBER Chassis Number of TSE 300r is located on the headstock/frame/chassis under the handlebars ENGINE NUMBER www.GPXMOTO.com + www.GPXMOTOUK.com - 15 -...
  • Page 10 GPX MOTO The engine number of TSE 300r is located on the engine case behind the cylinder block. www.GPXMOTO.com + www.GPXMOTOUK.com - 16 -...
  • Page 11 GPX MOTO PARAMETER DIMENSIONS AND SPECIFICATION - TSE 300R 2170×830×1285 L*W*H（mm） 1480mm Wheelbase（mm） 109kg Net weight（kg） Tire size F: 80/100-21；R: 110/100-18. Rear will accept a 140 80/90 18” Enduro or MX tyre. Comes fitted with off road tyre 960 mm.
  • Page 12 GPX MOTO High strength forged aluminium alloy structure Swingarm www.GPXMOTO.com + www.GPXMOTOUK.com - 18 -...
  • Page 13 GPX MOTO Competitive high-strength aluminium alloy fat bar (imported),，material Handlebar 7075 Φ28.6mm, with GPX special ultra-soft off-road grip 1.60×21, 2.15×18, 7050 high strength aluminium rim ， F/R rims forged CNC wheel hub Powerful Hydraulic alloy twin piston caliper with 260mm disc...

  • Page 14: Front Disc Brake

    GPX MOTO CONTROL CLUTCH The clutch is controlled by the clutch lever, which is fitted on the left side of the handlebar. By adjusting black plastic ribbed nut on the clutch lever it is possible to adjust the feel and operation of the clutch.
  • Page 15 GPX MOTO www.GPXMOTO.com + www.GPXMOTOUK.com - 21 -...

  • Page 16: Throttle Lever

    GPX MOTO THROTTLE LEVER The throttle lever is located on the right side of the handlebar. The throttle is very sensitive. Turn the throttle counter clockwise to increasing the engine speed and power output. The reverse will reduce the engine speed and power output. It will back to normal smoothly once you lease the handle.
  • Page 17 GPX MOTO FUEL TANK SWITCH The fuel tank switch is located on the bottom left side of the fuel tank. By turning the switch, you can control the entrance of the fuel into into the carburettor. fuel tank switch The meaning of symbols on the oil tank switch is shown as the left picture.

  • Page 18: Rear Disc Brake

    GPX MOTO REAR DISC BRAKE The rear brake pedal is located on the right side of the engine and is operate by pushing down on it gently using the right foot. The rear brake adopts a floating caliper disc brake. This is located on the right side of the rear wheel and fixed by a disc brake bracket.
  • Page 19 GPX MOTO www.GPXMOTO.com + www.GPXMOTOUK.com - 25 -...

  • Page 20: Preparing For Use

    GPX MOTO PREPARING FOR USE ADVICE ON FIRST USE 1. Before your first trip, read the entire operating instructions carefully, especially the section of “Controls” and “Riding Instructions”. 2. When driving, please carry out a standardized run-in period first. 3. If any parts problems are found during using, you can repair that according to this manual or contact GPX Dealers for professional aid.

  • Page 21: Riding Instructions

    GPX MOTO RIDING INSTRUCTIONS PREPARATION BEFORE RIDING 1. Check fuel level in fuel tank and replenish if necessary. 2. Check fluid level in front brake fluid reservoir and replenish if necessary. 3. Check fluid level in rear foot brake fluid reservoir and replenish if necessary.
  • Page 22 GPX MOTO PRECAUTIONS FOR TURNING 1. Take care to slow down in advance conditions when turning 2. Lower your centre of gravity to reduce the risk of side rolling when turning 3. Do not shift gears when turning PRECAUTIONS FOR ACCELERATION 1.
  • Page 23 GPX MOTO SUGGESTED INSPECTION TIME FOR ALL PARTS OF THE VEHICLE every 30 hours every 20 hours every 10 hours/after every race 1 hour after each ride Check and charge the battery ● ● ● Check the front disc brake ●...
  • Page 24 GPX MOTO ATTENTION：This table is for reference only. Please adjust the maintenance cycle of the motorcycle according to the specific model and use situation. WARNING：For the inspection, adjustment and replacement of the engine, please consult GPX Service Centre to avoid damage.

  • Page 25: Suspension System

    GPX MOTO SUSPENSION SYSTEM CHECK THE COMPRESSION AND REBOUND OF THE VEHICLE WITH THE RIDER ON BOARD To ensure the best driving characteristics of the vehicle and avoid damage to swingarm, shock absorbers, linkage and frame, the basic setting of the suspension components must match the driver's weight.
  • Page 26 GPX MOTO www.GPXMOTO.com + www.GPXMOTOUK.com - 32 -...
  • Page 27 GPX MOTO ADJUSTING THE REBOUND DAMPING OF THE REAR SHOCK ABSORBER You can adjust the rebound damping by adjusting the screw with a flat bladed screwdriver. Turn counter clockwise to decrease rebound damping(fast), or turn clockwise to increase rebound damping(slow)
  • Page 28 GPX MOTO MEASURE DISTANCE BETWEEN REAR WHEEL CENTER AND REAR FENDER IN DRIVING CONDITION The measurement procedure is as follows: 1. The driver rides the motorcycle (the engine does not start) 2. Up right the motorcycle so that the centre surface of the tire is perpendicular to the ground 3.
  • Page 29 GPX MOTO If it is difficult to rebound the front shock absorber, decrease the rebound damping appropriately. When the ambient temperature is high, the front shock absorber should also be properly bled of air using the bleed button on the top of the fork cap. Push the bleed button for 5 seconds to release all of the air.
  • Page 30 GPX MOTO VEHICLE MAINTENANCE PLACEMENT Raise you motorcycle on its centre stand always when carrying out the related maintenance. It is helpful to remove or install various parts. REMOVING OR INSTALLING THE DISC BRAKE COVER Removing steps are as follows: 1.
  • Page 31 GPX MOTO REMOVING OR INSTALLING THE FRONT BRAKE DISC CALIPER Removing Steps are as follow: 1. Remove the front brake fluid hose clamp from the left fork protection guard. 2. Remove the front brake master cylinder from the handlebars. 3. Remove the front disc brake caliper.
  • Page 32 GPX MOTO Removing Steps are as follows: 1. Remove the headlight 2. Remove the front wheel 3. Remove the front brake caliper 4. Remove both front forks 5. Remove the handlebars 6. Remove the lock nut and the punch bolt of the steering column as indicated 7.
  • Page 33 GPX MOTO CHECK THE FRONT STEERING Check the front steering steps are as follows: 1. Put the GPX on a stand lifting both wheels off the ground. 2. Turning the handlebars left to right to control . It should move smoothly and there should be no obstruction.
  • Page 34 GPX MOTO REMOVING OR INSTALLING FRONT HEADLIGHT Removing Steps are as follows: 1. Remove or loosen the rubber fixing strap on both the left and right fork suspension leg. 2. Remove the headlight 3. Pull out the connector between headlight and main...
  • Page 35 GPX MOTO Removing Steps are as follows: 1. Remove the 2 fixing screws. 2. Pull out the Front Fender. Installing Steps: The instalment should be carried out in the reverse order of removal. - 34 - www.GPXMOTO.com + www.GPXMOTOUK.com...
  • Page 36 GPX MOTO REMOVING OR INSTALLING THE REAR SHOCK ABSORBER Check the rear shock absorber to determine the performance of the unit. Please follow the steps below to removing the rear shock absorber: 1. Remove the seat 2. Remove the 2 small bolts that attach the radiator shrouds to the petrol tank 3.
  • Page 37 GPX MOTO REMOVING OR INSTALLING THE AIR FILTER HOUSING Removing Steps are as follows: 1. Place the left hand fingers behind the cover at position A. 2. Place the right hand fingers behind the cover at position B. 3. Pull smoothly but with good pressure.
  • Page 38 GPX MOTO CLEANING AND MAINTENANCE OF AIR FILTER - THIS IS THE MOST IMPORTANT CARE THAT YOU CAN PROVIDE YOUR MOTORCYCLE Before performing maintenance on the air filter parts, it is necessary to check the filter first. Follow this direction: 1.
  • Page 39 GPX MOTO REMOVING OR INSTALLING THE REAR SILENCER The exhaust pipe and the silencer can guide the gas emission and reduce the noise. If the exhaust pipe is rusty or ruptured or damaged by impact, please replace it with a new one immediately. If...
  • Page 40 GPX MOTO Removing steps as below: 1. Remove the seat . 2. Remove the left and right radiator shroud screws. 3. Unscrew the single central fuel tank installation screw. 4. Remove the fuel tank from the frame. Installing Steps: The instalment should be carried out in the reverse order of removal.
  • Page 41 GPX MOTO CHECK AND CLEAN THE CHAIN Checking the condition of the chain: 1. Observe the chain from the rear of the vehicle to check whether the chain is skewed as a whole 2. Rotate the rear wheel by hand and observe whether...
  • Page 42 GPX MOTO CHECK AND ADJUST THE CHAIN TENSION The chain transfers the power output from the engine to the wheels. It is therefore important that the chain is in good condition , is well lubricated and works correctly. It is an important part of the motorcycle. The chain needs frequent inspection and maintenance to ensure its normal use.
  • Page 43 GPX MOTO When checking the chain tension, you should also check the plastic chain guides, the chain split link and both front and rear sprocket for wear or damage . When the chain is over-used, or the stretch exceeds 2%, the chain should be replaced. Replace and change the relevant guide rail and both sprockets at the same time.
  • Page 44 GPX MOTO CHECK THE STRUCTURE OF THE REAR SPROCKET, ENGINE SPROCKET AND GUIDE CHAIN Check the condition of the swinging arm rubber and the chain guide as per the guide photos. Under normal circumstances, these two parts play a role in guiding the movement of the chain. If they are...
  • Page 45 GPX MOTO CHECK THE HANDLEBAR POSITION This setting is very personal to the operator. You should sit on the motorcycle and rest your hands on the handlebars naturally, and feel whether the position of the clutch grip and brake grip are comfortable or not.

  • Page 46: Maintenance Of The Brake System

    GPX MOTO MAINTENANCE OF THE BRAKE SYSTEM CHECK THE FREE-PLAY OF FRONT BRAKE LEVER Checking steps as below: 1. Rest your right hand on the right hand grip naturally 2. Use the index finger and middle finger of your right hand to check the free play.
  • Page 47 GPX MOTO CHECK THE DISC BRAKE Checking Steps are as follows: 1. Check whether there are cracks, dents and other damages on the surface 2. Measure the thickness of the rear disc and compare it with the limit thickness required.

  • Page 48: Check The Front Brake Pads

    GPX MOTO REFILL THE BRAKE FLUID LEVEL You should check/refuel the liquid level regularly. If the brake fluid is mixed with water, soil or other particles, the brake fluid should also be replaced. It is recommended to use DOT4 brake fluid.
  • Page 49 GPX MOTO In normal use,the free-play of the brake pedal is shown in the table below. Check the brake lever and pay attention to whether the stroke is correct. Model Free-Play 25～30mm www.GPXMOTO.com + www.GPXMOTOUK.com - 44 -...
  • Page 50 GPX MOTO CHECK THE REAR BRAKE DISK LIQUID LEVEL Check the Liquid level through the Observing Hole. The liquid level should higher than minimum level as required. You should refuel it if it is insufficient with DOT 4 brake fluid.
  • Page 51 GPX MOTO CHECK THE REAR BRAKE PADS After checking the thickness of the brake pads of the brake caliper, the thickness should not be less than 2 mm. If the thickness of the brake pads is lower than the minimum thickness, the entire set of brake pads should be replaced immediately.

  • Page 52: Tire Inspection

    GPX MOTO TIRE INSPECTION AND MAINTENANCE REMOVING OR INSTALLING THE FRONT WHEEL Removing Steps are as follows:  Lift the motorcycle off the ground and Stabilize it by using a motorcycle stand.  Remove front disc brake cover.  Loosen the 2 front wheel axle pinch bolts on each side.

  • Page 53: Check Tire Pressure

    GPX MOTO CHECK TIRE PRESSURE The tyres fitted to GPX motorcycles as standard are off road tyres only. Check the tire pressure by using a pressure gage. If it happens frequently with lower pressure problem, find out if there is a deflation or not and contact the GPX Dealer for help.
  • Page 54 GPX MOTO www.GPXMOTO.com + www.GPXMOTOUK.com - 48 -...

  • Page 55: Electrical System

    GPX MOTO ELECTRICAL SYSTEM REMOVING OR INSTALLING THE BATTERY Removing Steps are as follows: 1. Removing the passenger seat 2. Disconnect cable from the battery 3. Remove the screw on battery holder 4. Pull the battery up and out. Installing Steps: The instalment should be carried out in the reverse order of removal.

  • Page 56: Main Cable

    GPX MOTO MAIN CABLE GPX VEHICLE WIRING DIAGRAM www.GPXMOTO.com + www.GPXMOTOUK.com - 50 -...

  • Page 57: Cooling System

    GPX MOTO COOLING SYSTEM COOLING SYSTEM PROFILE The excess heat from the engine is captured by the water and antifreeze (coolant)within the cooling system. This coolant is circulated around the engine and through 2 radiators by a coolant pump that is mounted within the engine .
  • Page 58 GPX MOTO CHECK COOLANT/ANTI FREEZE LEVEL  Stop and stand the motorcycle upright on a horizontal surface.  Release the radiator cap when the engine is cool only .  Sway the motorcycle from side to side and then check the antifreeze level, which should be between Min and Max and should be less that 1 inch from the very top of the neck .

  • Page 59: Filling The Cooling System

    GPX MOTO FILLING THE COOLING SYSTEM You should change the coolant regularly to increase service lift. Main work:  Drain out the coolant. → p.50  Replace the bolt after draining the coolant completely.  Fill in a little of coolant through radiator tank.

  • Page 60: Installing The Engine

    GPX MOTO INTRODUCING ABOUT THE ENGINE STRUCTURE 1. COOLING SYSTEM The GPX uses coolant to cool the engine. The coolant enters the engine from the water tank through the radiators, takes away the heat of the engine, flows back to the water tank, and then exchanges heat with the air.
  • Page 61 GPX MOTO THE ENGINE ADJUSTMENT IDLE SPEED ADJUSTMENT OF CARBURETOR It is important that only people who are qualified in tuning make adjustments to the carburettor. The idle speed of the carburettor can be adjusted through the idle screw and air mixture screw.
  • Page 62 GPX MOTO DANGER: Driving a motorcycle with a damaged throttle cable is undoubtedly a very dangerous behaviour. The normal throttle cable should have a free stroke of at least 5mm. Start the engine and turn the handlebar left and right. If the engine stalls or accelerates due to the movement of the handlebar, the throttle cable may be improperly adjusted or damaged.
  • Page 63 GPX MOTO CHECK THE SHIFT LEVER POSITION The inspection steps are as follows: 1. Raise the whole vehicle so that the centre plane of the tire is perpendicular to the ground 2. The line of sight is level with the tread surface, and observe the position of the shift head 3.

  • Page 64: Lubricant Selection

    GPX MOTO LUBRICANT SELECTION Lubricating oil is an important factor affecting the performance and life of the engine. It must be selected according to regulations. It is forbidden to replace it with ordinary engine oil, gear oil, vegetable oil, etc.
  • Page 65 GPX MOTO LUBRICANT REPLACEMENT When replacing the lubricating oil, it should be done before the engine is warm and has not yet cooled, so as to ensure that the lubricating oil in the crankcase can be discharged quickly and completely. When replacing, place an oil pan under the engine and unscrew the oil bolt A to release the lubricating oil.
  • Page 66 GPX MOTO To adjust the mechanical power valve please follow these instructions. Always use a correctly sized tool to turn the power valve adjustment so that no damage is caused. This screw adjusts the engine speed at which point the power valve opens.

  • Page 67: Troubleshooting

    GPX MOTO TROUBLESHOOTING Troubleshooting for 2 and 4 stroke motorcycles. If the engine wants to be operated normally, it should meet the following four requirements: 1. Good fuel: There is a certain ratio of combustible mixture in the cylinder. 2. Good spark: The spark plug can emit a strong spark at the specified time.
  • Page 68 GPX MOTO or short-circuited The ignition switch is faulty The starting mechanism is slipping, Low Pressure and the engine cannot be turned Valve clearance is too small Valve opening blocked Cylinder or piston ring wear Test cylinder pressure Cylinder head gasket...
  • Page 69 GPX MOTO of the fine adjustment screw of the Correct carburettor plunger Deterioration of Air leak Carburettor seal ring Check whether the Loose carburettor carburettor gasket is leaking Damaged carburettor Airtight gasket The spark plug is faulty or carbon deposits...
  • Page 70 GPX MOTO Valve clearance is too Check whether there is Abnormal noise in the large abnormal noise in the valve valve Valve wear Piston and cylinder wear The small end holes of the piston pin and Check whether there is...
  • Page 71 GPX MOTO high, the viscosity is 40, 50 or Viscosity Compounding agent without ZDDP [2] with ZDDP Viscosity index improver Low molecular weight PIB [3] High molecular weight PIB Ash [4] High [1] Flash point: Flash is kind of fleeting flashing phenomenon. It is occurred when flammable gas, which is mixed gas of vapour produced on the surface and air, encounters a fire.

  • Page 72: Motorcycle Cleaning

    GPX MOTO MOTORCYCLE CLEANING The cleaning of the vehicle is also an important part of the daily use and maintenance of the motorcycle. Frequent cleaning of your motorcycle can keep your car in a good state of motion and prolong its service life. You can clean your motorcycle through the following steps: 1.

  • Page 73: Maintenance Points

    GPX MOTO NOTE: When applying anti-rust oil, please do not splash the oil on the brake and rubber parts, otherwise the rubber may be aged. PREPARING FOR USE AFTER LONG STORAGE After the motorcycle has been stored for a long time, please follow the steps below when it is put into use: 1.
  • Page 74 GPX MOTO check the battery The motorcycle has been stored Drain the old fuel and add new for a long time and the fuel has fuel deteriorated Clean or dry the spark plug, if Dirt or wet spark plug necessary, replace the spark plug...
  • Page 75 GPX MOTO Check and correct the exhaust Open exhaust valve valve Close the choke valve, clean the The engine can be started, Incorrect air supply fuel tank vent pipe, and adjust the will stop air filter duct immediately Lack of fuel...
  • Page 76 GPX MOTO gasket is ageing, replace the gasket White smoke from Change fuel The fuel contains water exhaust pipe Air filter is clogged Remove and clean the air filter Black smoke from exhaust The combustible mixture is too Adjust the carburettor valve...
  • Page 77 GPX MOTO Note: It is required to add the same kind of oil Change to fork oil with suitable Fork oil viscosity is too low viscosity Check whether the tires are Tire pressure is too low leaking, if the tires are complete,...
  • Page 78 GPX MOTO Disc brake disc wear Replace the disc brake Insufficient brake fluid Replenish brake fluid Deteriorating brake fluid Replace brake fluid Piston damaged Contact GPX Service Centre Brake failure Check the brake pads, if the thickness is less than the minimum...
  • Page 79 GPX MOTO www.GPXMOTO.com + www.GPXMOTOUK.com - 90 -...

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