Maico GM STAR 250 1986, GM STAR 500 1986, GM STAR 250 E 1986, GM STAR 500 E 1986 Owner's Manual

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1986 MAICO Owners Manual

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CONTENTS

I Technical data

II Tightening torques

III Maintenance works - survey

IV Execution of maintenance works

1986 MAICO Owners Manual

V Suspension adjustments

VI Exploded view and part list engine

VII Engine Gear Box

VIII Exploded view and part list carburettor

IX Exploded view and part list chassis and frame

X Part list Enduro and Cross Country

IX Wiring Diagram

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I. TECHNICAL DATA

GM500 and GME500

ENGINE

Type

2-stroke liquid cooled

2-stroke liquid cooled/air cooled

System

Reed valve

Displacement

488 cc

Bore/Stroke

86.5/83

Performance (kW/PS)

44.9 /61 @7000

Max. Torque

62 @6600

Compression ratio

12:1

Combustion space

54 cc

X-distance

0.5 mm

IGNITION

System

SEM/Motoplat pointless Ignition advance

1.8 mm btdc

Spark plug

NGK B9ES (B10ES)

Rotor

Inboard rotor

External rotor

PISTON DIAMETER LIST

Standard

86.44 EDV-Nr. 6813

1st oversize

86.64 EDV-Nr. 6815

2nd oversize

86.84 EDV-Nr. 6816

3rd oversize

87.04 EDV-Nr. 6817

4th oversize

87.24 EDV-Nr. 6818

DRIVE

Clutch

5 sintered, 2 organic outer plates, 6 inner plates

Primary reduction ratio

1.970 (65/33)

1st Gear

1.875 (30/16)

2.285 (32/14)

2nd Gear

1.555 (28/18)

1.705 (29/17)

3rd Gear

1.300 (26/20)

4th Gear

1.090 (24/22)

5th Gear

0.916 (22/24)

Secondary reduction ratio

4.000 (52/13)

3.000 (48/16)

Chain

5/8” x 1/4” 116 links

1986 MAICO Owners Manual

GM500

ignition

GME500

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CARBURETTOR

GM500

GME500

Main jet

195

145

Needle jet

280-2

280

Idle air jet

Jet needle/position

6D2/M

6G1/M

Air screw opening

1 1/2

Venturi tube

Slide

2103

594

OIL CAPACITY

Gearbox

700 cc

Grade

Klűber security gear-oil synthetic 100

FUEL CAPACITY

Type

Super (also unleaded)

Lubrication

1:50 Klűber security motor oil 2T sport

1:100 Klűber security motor oil 2T synthetic

WARNING

Never mix mineral oil with synthetic oil, never fuel when the motor is running, never smoke whilst re-fuelling.

I. TECHNICAL DATA (continued)

1986 MAICO Owners Manual

Type

THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD

Bing 54/40/113

Bing 84/32/130A

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GM250 and GME250

GM250

GME250

ENGINE

Type

2-stroke liquid cooled

System

Reed valve

Displacement

247 cc

Bore/Stroke

67/70

Performance (kW/PS)

36 /49 @8000

Max. Torque

40 @7400

Compression ratio

14.7:1

Combustion space

20.5 ccm

X-distance

0.5 mm

System

Motoplat pointless ignition

SEM/Motoplat pointless ignition

Ignition advance

0.4 mm btdc

2.0 mm btdc

Spark plug

NGK B9ES (B10ES)

Rotor

Inboard rotor

External rotor

PISTON DIAMETER LIST

Standard

66.97 EDV-No. 8370

1st oversize

67.37 EDV-No. 8373

DRIVE

Clutch

5 sintered, 2 organic outer plates, 6 inner plates

Primary reduction ratio

2.567 (67/26)

1st Gear

1.875 (30/16)

2.285 (32/14)

2nd Gear

1.555 (28/18)

1.705 (29/17)

3rd Gear

1.300 (26/20)

4th Gear

1.090 (24/22)

5th Gear

0.916 (22/24)

Secondary reduction ratio

4.000 (52/13)

3.250 (52/16)

Chain

5/8” x 1/4” 116 links

114 links

Type

Bing 54/380/121

Main jet

195

135

Needle jet

280-2

278-2

Idle air jet

Jet needle/position

6D2/M

Air screw opening

0.5 - 1

Slide

2103

I. TECHNICAL DATA (continued)

IGNITION

1986 MAICO Owners Manual

CARBURETTOR

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OIL CAPACITY

Gearbox

GM250

750 cc

GME250

Grade

Klűber security gear-oil

Grade FUEL CAPACITY

Type

Super (also unleaded)

Type

Lubrication

1:50 Klűber security motor oil 2T sport

1:100 Klűber security motor oil 2T synthetic

WARNING

Never mix mineral oil with synthetic oil, never fuel when the motor is running, never smoke whilst re-fuelling.

I. TECHNICAL DATA (continued)

1986 MAICO Owners Manual

synthetic 100

THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD

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GM/GME 250 and 500 (all models)

CHASSIS

Overall length

2145 – 2175 mm

Overall width

850 mm

Overall height

1235 mm

Seat height

960 mm

Ground clearance

386 mm

Fuel tank capacity

8.7 litre (GME air cooled 10.2 litre)

Weight

98 kg (250), 102 kg (500)

Construction

Rigid chrome moly single tube frame with double yoke trussing tube.

Castor angle

63° Castor

121 mm

Wheelbase

1480 mm

TELESCOPIC FORK

Telescopic

Maico 42mm diameter

Spring

3.6 N/mm

Suspension travel, front

305 mm

Air support

0 - 0.4 at

REAR SUSPENSION

Construction

Aluminium swinging fork made from rectangular

Shock absorber

Öhlins

Length

440 mm

Travel

116 mm

Rebound and compression damping

Adjustable wheel at the end of the damper shaft / Spring load

Continuously controllable.

Suspension travel

350 mm

BRAKES

Front

Hydraulic disc brake 235 diameter carbon steel.

Rear

Hydraulic disc brake 235 diameter carbon steel. TYRES

Front

3.00 x 21”

Rear

4.10 x 18” (250) 5.10 x 18” (500)

I. TECHNICAL DATA (continued)

FRAME

1986 MAICO Owners Manual

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pressed, high resistant profile. Afterwards tempered.

Adjustable wheel at the reservoir.

Hydraulic ratio Ǿ 38 : Ǿ 11

Hydraulic ratio Ǿ 38 : Ǿ 16

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FLUID CAPACITY

Telescopic fork

560 cc Klűber security fork fluid 5-20 sport

Brake system Front

About 40cc Klűber security brake fluid DOT4

Brake system Rear

About 35cc Klűber security brake fluid DOT4

In case of higher temperatures: Klűber security

I. TECHNICAL DATA (continued)

brake fluid DOT5

THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD

1986 MAICO Owners Manual

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II. TIGHTENING TORQUES

Nut for primary sprocket on crankshaft

M20 x 1

105 Nm

Nut for clutch body

M16 x 1

50 Nm

Clutch pressure screws

8 Nm

Nut for ignition system

M12 x 1

70 Nm

Bolt for cylinder head

M10

25 Nm

Nut for cylinder head

25 Nm

Bolt for cylinder base

20 Nm

Nut for cylinder base - 500

M10

20 - 25 Nm

Nut for cylinder base - 250

20 - 25 Nm

Guide screw (pin)

M14 x 1.5

30 Nm

Oil drain screw (pin)

M14 x 1.5

30 Nm

Engine housing and cover screws (not applied to right side cover)

9 Nm

Cover for ignition

3 Nm

Fixing screw for ignition system

5 Nm

Engine mounting screws

25 Nm

Screws for cylinder head support

25 Nm

Front wheel axle

M16 x 1.5

30 Nm

Swing axle

M14 x 1.5

30 Nm

Rear wheel axle

M20 x 1.5

90 Nm

Hex screw for fixing of damper tube

M18 x 1

20 Nm

Hex screw for steering tube

M27 x 1

No backlash

Clamp screws for telescopic fork:

upper crosshead

M10

45 Nm

lower crosshead

20 Nm

Clamp screw for front axle

9 Nm

Calliper support rear

9 Nm

Pan head screw for protector clamping

9 Nm

Twin Link system

M12

70 Nm

Calliper clamping

25 Nm

Brake disc clamping

12 Nm

Sheet metal screw for protector clamping

B5.5

1 Nm

SCREW AND NUT TORQUES (engine cold)

1986 MAICO Owners Manual

THE IGNITION ROTOR NUT ON THE CRANKSHAFT HAS A LEFT HAND THREAD

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Page 10

III. MAINTENANCE SCHEDULE

Engine

After 0.5 – 1 hours testing time

Before every race (approx. 60 miles)

Before every 3rd race (approx. 180 miles)

Gear oil

change

Check oil level

change

Air filter

clean/oil, check fitting

Spark plug

Check gap and condition, clean/reset/replace as necessary

Piston

Check, examine rings for free movement

Engine mounting screws

Check, tighten if required

Coolant

Check, top up if required

Reeds

Check for cracks

Ignition advance

Check

Inlet manifold and airbox boot

Check for leaks Carburettor

Clean if necessary

Exhaust

Look for easy movement

Chassis

After 0.5 – 1 hours testing time

Before every race (approx. 60 miles)

Before every 3rd race (approx. 180 miles)

Steering head bearing

Check, tighten if required

Cables

Lubricate

Lubricate, check for

movement

Clutch free play

Check, adjust as necessary

Brake pads

Check wear

Rear suspension linkage

Lubricate the three grease nipples

Dismantle, clean and grease.

Spokes

Check, tighten if required

Silencer

Repack if required.

Tank fuel filter

Clean if necessary.

Drive chain

Check, tighten or replace as necessary.

Sprockets

Replace as necessary.

Fork oil

Change

Fork seals

Check

1986 MAICO Owners Manual

of the slide valve, check diaphragm for cracks

damage and free

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1986 MAICO Owners Manual

IV. EXECUTION OF MAINTENANCE WORKS

GEAR OIL - CHECK

Pull motorbike vertical on both wheels. Unscrew the white plastic screw, situated in the clutch cover. The oil level is correct when the oil is just about coming out of the hole. N.B: Oil level has to be checked with engine hand warm. Don't tilt the motorcycle prior to checking the oil level, because a wrong result in measuring might occur.

GEAR OIL - CHANGE

Remove oil filler screw in the clutch cover (Allen screw 10mm) and oil draining screw (right-hand screw seen in driving direction). Drain oil completely. Check the oil drain magnet for metallic particles and screw it in (do not forget the sealing ring), fill oil slowly in order to avoid overfilling, re-install oil filler screw. N.B: An oil change has to be executed with hand-warm engine.

AIR FILTER:

Was h out in fuel, wring out or dry with compressed air, oil it. Grease head-sided sealing surface freely. IMPORTANT: The air filter must never be dry. Ensure proper fit.

PISTON RINGS:

The pistons rings have to turn freely in the notch and may only have limited free play.

COOLING WATER:

The cooling system is freeze protected down to – 10ºC. If necessary, add anti- freeze. IMPORTANT: Every time before starting the motorbike, check the coolant level. This level always must reach slightly beyond the filler neck. If necessary refill.

IGNITION:

Adjustment of ignition:

Use a gauge to correctly adjust the ignition advance. The gauge has to be turned into the spark plug thread by using a gauge holder at first. Then the crankshaft is turned back anti-clockwise by 45 º. Upon turning the crankshaft clockwise, the adjustment mark of rotor and stator has to align with the corresponding values. In order to increase the ignition advance turn the stator against the engine's running direction. When all the screws are fixed, the ignition advance has to be measured again, as by fixing the screws it might have moved.

REMARK: Under difficult circumstances (high outer temperatures, sand, etc.) we recommend the use of NGKB 10 ES spark plugs.

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-10°C to + 10°C

+10°C to + 20°C

Over + 20°C

SAE 5W

SAE 7.5W

SAE 10W

1986 MAICO Owners Manual

V. SUSPENSION ADJUSTMENT

TELESCOPIC FORK:

The fork oil:

The viscosity of the fork oil has to be varied to suit the corresponding ambient temperature.

Therefore we recommend the following settings:

By using the newly developed Klüber fork oil5-20 sport, changing the oil for different temperatures is not necessary as this fluid works well over all these temperatures.

Air pressure and the oil volume should be set to meet individual body weight and travel requirements.

The oil

volume can be changed by 20 mm to upper and lower reference point, the air

pressure by 0.2 at (min. air pressure 0.0 atmospheres, max. aIr pressure 0.4 atmospheres).

Telescopic fork characteristics:

normal fork: oil quantity normal, air pressure 0 – 0.2 at.

hard fork: (for sand, big jumps, heavy rider, etc.) oil quantity higher, air pressure up to

0.4 at. lift up spring pretension.

soft fork: oil quantity lower, air pressure 0 at.

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1986 MAICO Owners Manual

V. SUSPENSION ADJUSTMENT (continued)

REAR WHEEL SUSPENSION:

The right spring tension:

1. Put motorcycle upon a base with the rear wheel hanging free in the aIr.

2. Measure the distance between wheel axle and the seat mount bolt.

3. Take motorbike off the stand.

4. Driver has to sit on the motorbike as normal

5. Measure dIstance agaln.

For correct sprIng pretension this measurement has to be about 90 to 100 mm lower than during the previous measurement. If this measurement is lower, lessen the spring pretension. If this measure higher increase the sprIng pretension.

THE RIGHT REBOUND:

6. Turn the adjustment wheel by hand to the right until you come to a stop.

7. Now turn 10 clickers to the left. This is the right rebound. On different tracks the

rebound can be varied between

THE RIGHT COMPRESSION: (adjustment at the leading wheel of the reservoir).

8. Adjustment wheel has to be turned to the left. This is the right compression.

During different tracks the pressure rebound can be varied up to clickers.

+ and – 2 to 3 clickers.

+ and - 4

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VI. ENGINE PARTS

1986 MAICO Owners Manual

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VI. ENGINE PARTS (continued)

1986 MAICO Owners Manual

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VI. ENGINE PARTS (continued)

1986 MAICO Owners Manual

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VI. ENGINE PARTS (continued)

1986 MAICO Owners Manual

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VII. ENGINE GEAR BOX

1986 MAICO Owners Manual

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VIII. CARBURETTOR PARTS

1986 MAICO Owners Manual

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IX. CHASSIS AND FRAME PARTS

1986 MAICO Owners Manual

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