Christini AWD Service manual

Service Manual
Service Manual
Christini Technologies, Inc.
421 N. 7th Street Suite 200
Philadelphia, PA 19123
215.351.9896 fax
Version 1.6
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Service Manual
Due to the design of the gears, front and
rear international standard disk brakes
must be reversed on the Christini bikes.
The front brake must be mounted on the
rear triangle, and the rear brake must be
mounted on the front fork.
To Ensure proper gear alignment, use a
sealed cartridge bearing rear hub or be sure
the distance between the end of the axle
and the disc mount is the universal standard of 15mm (loose ball bearing hubs are
often out of spec. due to the floating nature
of the axle during assembly).
The entire service manual, as well as technical videos can be downloaded from the following web site:
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Service Manual
Table of Contents
Introduction; Tools you’ll need
AWD Bike Detail Illustration
Bike Disassembly Flowchart
White Brothers AWD Fork Removal
White Brothers AWD Fork Drive Shaft Maintenance
AWD Drive Shaft Removal and Installation
AWD Engagement Clutch Detail
Front Hub Maintenance
AWD Engagement Switch Detail
AWD Engagement Cam Detail
Rear Suspension Detail
AWD Bearing Maintenance
Routine Maintenance Schedule
General Notes
AWD Lubrication Guide
AWD Troubleshooting
Christini AWD Limited Warranty
Christini Owner’s Registration Card
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Service Manual
Congratulations! You own an All Wheel Drive Bicycle
The CHRISTINI AWD consists of a patented lightweight, internalized, shaft-driven system that allows the rider to engage
both wheels for additional power when there is "wheel slip".
With the simple flip of a handlebar-mounted switch, the AWD
system provides increased control, traction and stability on
slippery or loose surfaces and unmatched power to climb
steep hills.
Simply stated, when the rear wheel slips — the front wheel
The Tools You Will Need for Maintenance
Allen Wrench Set
2, 2.5, 3, 4 with short end (supplied), 5, 6 millimeter
Plastic faced hammer or a rubber mallet
Large flat bladed screwdriver & small flat bladed screwdriver
T-25 torx wrench
10 millimeter box wrench
Pair of needle-nose pliers
Thread Retaining Compound:
“Blue” Loc-tite 242 Removable Strength
“Red” Loc-tite 262 Permanent Strength
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Service Manual
AWD Detail Illustration
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Service Manual
Bike Disassembly Flowchart
All Wheel Drive Bike
Disassembly Process
Rear Wheel
Front Wheel
Remove Front
Bevel Gear
Remove Shock
Remove Chain
Crown Cover
Remove Rear
Bevel Gear
Transfer Chain
Separate the
Front and Rear
Remove Fork
Remove Front
Drive Shaft
Gear and
Sprocket Shaft
Remove Front
Remove Pivot
Remove Rear
Remove Front
Remove Rear
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Remove Rear
Drive Shaft
Service Manual
Custom White Brothers AWD Fork Removal
Remove the front wheel. The fork legs may
need to be pulled apart slightly, since there is
a 1 mm indent on the non-disc brake side of
the front hub axle. This indent locates the
front bevel gear and provides support during
heavy AWD loading.
Remove the front disk brake cable at the
lever—or remove the front disk brake caliper.
Remove the three M6 bolts, located just
above the headtube on the front plate, that
attach the steering link to the upper steering
Warning—DO NOT use the rounded Bohndus
end of the Allen wrench when first loosening
the bolts. You will strip the hex head of these
After these three bolts have been removed,
the fork can be pushed down out of the headtube of the bicycle. If necessary, use a plastic
hammer to tap the fork out. Remove the valve
cover on the top of the fork (non-driveshaft
side) and tap the top of the crown, being careful not to strike the schrader valve itself.
Please refer to the White Brother’s AWD Fork
Owner’s Manual to service or adjust the front
suspension. (If lost see
for details)
• Slide Lower steering tube into the support bearings in the headtube.
• Tap the fork into place with a plastic hammer.
Do not tap the crown cover.
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Service Manual
Fork Driveshaft Maintenance
Remove the four countersunk M4 screws under the
crown of fork which hold the crown cover plate in
Remove the Crown-Cover plate. Slide the Upper
Front driveshaft and the crown cover plate down, as
shown, towards the dropouts. The Upper Front
Driveshaft will compress and slide on the splined
portion of the drive shaft.
Remove the fork drive shaft capture bolt. It is an M6 bolt
on the end of the fork drive shaft located under the pinion gear.
To loosen the bolt, use the supplied short-end 4mm Allen
wrench to hold the bolt in position while turning the hex piece
of the driveshaft counterclockwise (from the top of the fork
looking down), with a 10mm box wrench.
▪ TIP: If the driveshaft is stuck in the gear, loosen the bolt
halfway and then gently tap the blot head with a hammer to
free the driveshaft.
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Service Manual
Fork Driveshaft Maintenance
Slide the two sections of the front drive shaft together.
The chain crown cover can slide off at this point.
The pinion gear can also be removed at this point.
Remove the floating cog and power transfer chain from
the internal section of the chain crown.
Use your thumbs to press the center sprocket up through
the lower steering tube.
Carefully pull the drive shaft out of the steering tube.
Insert the drive shaft into the steering tube, sprocket first,
until the miter gear is fully seated on its sealed bearing
Loop the chain around the shaft sprocket and the floating
cog. Press the cog into the bearing.
Press the upper hex portion of the driveshaft into the cog
and slide the chain crown up into place.
Use removable threadlocker when re-installing the crown
cover screws.
Use removable threadlocker on the pinion bolt.
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Service Manual
AWD Frame Drive-system Maintenance
Remove the M6 capture bolt from the rear pinion assembly on
the rear bevel dropout. Use the supplied short-end Allen Wrench to
hold the bolt while spinning the drive system by hand to remove the
If necessary, use a 10mm wrench to spin the square spline
section of the drive system to help loosen the bolt.
Remove the rear shock mount bolt, and then slide the shock
out from between the Top Yoke, as shown.
TIP: Be careful not to chip the frame paint with the suspension
link when the rear triangle swings backward.
▪ Slide the rear pinion into the slot and then drop the rear
drive shaft down into the female spline on the pinion.
Apply removable threadlocker to the M6 bolt and tighten
by holding the bolt with a wrench and then spin the drive
system clockwise to tighten.
Install the rear shock mount bolt and the rear shock.
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Service Manual
AWD Frame Drive-system Maintenance
Remove the pivot bolt in the lower portion of the
suspension link. If necessary, use an Allen wrench smaller
than the internal threads to punch the female portion out.
Carefully lower the rear linkage until the bottom yoke is
resting on the bottom bracket pivot casing.
The main drive-shaft will separate at the square splined
universal joint section.
Remove the plastic dirt cover from the front of the
headtube access hole.
• Gently tap the round female slider section with a flat head
screwdriver and push the front drive shaft, which is attached
to the driving miter gear, out through the access hole in the
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Service Manual
AWD Frame Drive-System Maintenance
The entire driveshaft will push through the
support bearings located in the headtube.
To remove the rear driveshaft, pull it forward
through the support bearings by gripping the
universal joint section.
The rear drive pinion will slide out from the
dropout slot.
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Slide the rear and front drive-shafts into their
respective frame tubes. The front shaft will
slide through the headtube support bearings
and then firmly seat on the edge of the miter
gear. The rear shaft will slide through the support bearings but may not seat completely on
the u-joint section. There may be a small gap
between the u-joint and the bearing in the top
If necessary, replace the rubber u-joint boots
(only applies to some models).
Slide the square spline section into the round
female section before you begin to re-attach
the suspension link and the shock.
Service Manual
AWD Clutch Maintenance
Remove the rear wheel and quick release skewer.
Push down of the top clutch plate and rotate the bevel
gear until the clutch plate does not spring back up.
Remove the clutch snap ring from the groove in the top
of the rear bevel gear.
Slide the top “sliding jaw” of the clutch up and out of the
guides in the gear assembly.
Attach the clutch and gear assembly to the rear wheel
(see page 14).
Make sure that the engagement cams are in the off
position, they should be flush with the surface of the dropout.
Re-install the rear wheel, making sure to seat the axle
completely into the rear dropouts.
Test the engagement and disengagement of the clutch.
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Service Manual
AWD Clutch Maintenance
Remove the circular wave spring.
Use a Torx wrench to remove the 6 disk brake bolts that
attach the gear assembly to the disk brake hub.
Remove the gear assembly from the hub.
To remove the “locked jaw” turn over the gear assembly,
and remove the 4 M3 countersunk bolts that attach the large
diameter clutch bearing to the gear.
Press or tap out the locked jaw section from the bearing.
Press the clutch bearing and locked jaw into the gear.
Install the circular wave spring into the locked jaw section
making sure that the broken “tabs” are facing away from
the hub are lined up with a sliding jaw guide slot (top left
Install the sliding clutch plate by lining up the 6 guides
into the appropriate slots, then press down on the plate 45mm and slightly rotate the plate until it does not spring
back up.
Install the snap ring and make sure that the clutch is free
to rotate when the sliding jaw is pressed in completely.
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Service Manual
Front Hub Maintenance
Loosen the set screws on the end caps and remove them
from the axle.
With a plastic hammer, tap the disc side axle to loosen
the freewheel insert. A punch may be needed to
completely free the insert from the hubshell.
Remove the freewheel insert and axle from the hub.
Apply a light oil or grease to the roller bearings inside the
Note: It is not necessary to remove the bevel gear or the
brake rotor to service the freewheel.
Press the axle and freewheel insert back into the hub
shell until the insert is flush with the hubshell bearing. A
plastic hammer may be needed to tap the insert back into
Insert the end caps onto the axle and tighten the set
Note: The flat face of the gear side end cap should face
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Service Manual
AWD Engagement Switch Detail
Install the switch on the left side of the handlebars between the shifter and the brake lever.
Use a 2mm Allen wrench to tighten the clamp bolt
which secures the switch to the handlebars.
The drivesystem is engaged when it is in the position
shown in figure 1.
To disengage the system, push the lever forward as far
as it will go. To engage the system again push on the
engagement button (figures 2 and 3).
Figure 1
Figure 2
Figure 3
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Service Manual
AWD Engagement Cams
Cable Adjustment:
Cam Removal:
To remove the cam system from the
dropouts, loosen the hex set screw on
the long cam.
Slide the short cam and hex shaft out
from the dropout.
Page 17
To attach the cable from the switch to the engagement cams, loosen the set screw located
in the top of the long cam and slide the cable
Install the rear wheel and clutch assembly in
the dropouts.
To adjust the cams, make sure the switch is in
the engaged positions, pull the cable taunt
and tighten the set screw.
Once the slack is taken out of the cable, no
further adjustment is needed.
Service Manual
Rear Triangle Detail
Page 18
Disassemble the shock by removing the upper
shock bolt using a 5mm Allen wrench and an
10mm box wrench.
Remove the large bolts where the rear triangle
and the front triangle connect at the suspension pivot.
Remove the M8 bolts from the remaining connection between the suspension link and the
rear triangle.
There is a washer on either side of the
suspension link that needs to be installed
between the link and the rear triangle.
This washer fits through the threaded section of upper suspension link bolts.
During re-assembly—use removable
threadlocker on all pivot bolts.
Service Manual
AWD Bearing Maintenance
Page 19
All bearings should rotate smoothly.
Bearings should be replaced if they begin to
make excessive noise or they feel “notchy”.
Bearings are sealed and do not require lubrication.
Please contact Christini if you think a bearing
needs to be replaced.
Service Manual
Routine Maintenance Schedule
As Needed
Wash exposed drive system parts with
soap and water or a bike cleaner.
Replace bearings if excessive noise or
friction develops.
Lubricate all spline shafts if suspension performance is effected.
Replace worn or damaged mud
Tighten frame linkage bolts.
Check disk brake bolts.
Lubricate headtube gearset with
Lubricate the front and rear bevel
gears with chain lube.
Water in the headtube.
Water inside the frame.
Mud, dirt, or sand in the u-joints or
gear sets for extended periods.
Disassemble, clean and inspect the
rear bevel clutch assembly.
Apply lightweight oil lube to the front
“silent freewheel” hub.
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Service Manual
General Notes:
During re-assembly of the frame and fork apply grease to all bolts
that aren’t specified to be assembled with Loc-tite threadlocker.
The Christini AWD bike comes with several devices to provide dirt
and mud protection. Replace any of these protective devices if they
show signs of extreme wear:
U-joints—shrink-wrap boot (only applies to some models)
Square spline section—round to square scraper
Headtube—protective plastic cap over miter gear access hole
For all questions regarding tuning or maintenance of the White
Brother’s Fork please see the separate White Brother’s owner’s
For all questions regarding tuning or maintenance of the Rear
Shock please see the separate Rear Shock owner’s manual.
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Service Manual
AWD Lubrication Guide
Spline Shafts
Apply chain lube regularly.
During operation in muddy conditions,
clean and lube the front fork spline
and the rear shock spline as often as
Spiral Bevel Gears
Gears are coated with TEFNI2000 to
provide lubrication and corrosion
Apply a light amount of Pro-Gold chain
lube if noise occurs.
Front “Silent” Freewheel Hub
Apply a lightweight oil lube if the hub
friction increases or if it begins to
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Service Manual
AWD Troubleshooting
Clutch plate squeaks when
the rear wheel is rotating.
Apply a chain lubricant such as ProGold to the face of the clutch plate.
Clutch plate makes a clicking
noise as the rear wheel rotates.
AWD engagement switch lever needs
to be pushed farther forward (see page
Slack needs to be taken out of the
switch cable (see page 17)
Front Freewheel Hub squeaks
Apply a light oil or grease to the roller
bearings inside the hubshell (see page
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Service Manual
CHRISTINI Technologies / CHRISTINI AWD Limited Warranty
This LIMITED WARRANTY is a complete and exclusive statement of CHRISTINI’s obligations to the ORIGINAL OWNER of a CHRISTINI bicycle product.
CHRISTINI Technologies warrants:
1. All aluminum suspension and rigid frames to be free from defects in material and workmanship for a period of five (5) years from the date of purchase for the Original Owner.
2. All other original CHRISTINI AWD components, including the fork machined parts (excludes
suspension fork slider tubes and internal suspension mechanisms, see below), the front wheel
free-hub, and the components of the CHRISTINI All Wheel Drive (AWD) system including
clutch, shafts, and drive gears are warranted to be free of defects in material and workmanship
for a period of two (2) years from the date of Purchase for the Original Owner.
3. All CHRISTINI AWD system bearings and any CHRISTINI AWD brand replacement parts are
warranted to be free of defects in material and workmanship for a period of one (1) year from
the date of Purchase for the Original Owner.
Any finish applied by CHRISTINI (paint, decals, etc.) are warranted against any manufacturing defect for a period of one (1) year from the date of purchase. Scratches, dings, abrasions caused during riding, transport, or handling of the product are not considered defects.
Any components not produced by CHRISTINI, including the front suspension fork internal mechanisms, bear their original manufacturer’s own warranty and CHRISTINI reserves the right to direct
any warranty request relating to those Other Original Components to said manufacturer’s customer
service department.
Unless otherwise provided, the sole remedy under the above warranty or any implied warranty is
limited to the replacement of defective parts with those of equal or greater value at the sole discretion of CHRISTINI. No cash refunds will be offered under this warranty and you will be responsible for labor costs associated with warranty replacements. IN NO EVENT WILL CHRISTINI
Note: In those states that do not allow the exclusion or limitation of incidental or consequential
damages, the above limitation or exclusion may not apply to you.
The above warranty, or any implied warranty, does not cover normal WEAR AND TEAR, and all
warranties are void if the bicycle is used for other than normal activities, including, but not limited
to, the failure to follow the directions for assembly, the instructions, warnings and advice found in
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Service Manual
the owner's manual or using the bicycle for commercial activities or in competitive events, including bicycle racing, bicycle motocross racing, stunt riding, ramp jumping or similar activities and
training for such activities, or events. This warranty does not cover any damage, failure, or loss
caused by accident, misuse, abuse, neglect, improper assembly, improper maintenance, or use of
parts or devices not consistent with the original intent for the product sold.
allow limitations on how long an implied warranty lasts so the above limitation may not apply to
you. The warranty gives you specific legal rights, and you may also have other rights, which vary
from state to state.
1) Always wear a helmet while riding. Please remember to always ride safely and in control and
within your capabilities and limitations. Even under normal riding, bicycles and mountain bikes
can be dangerous due to changing and variable riding conditions including known and unknown
2) This Warranty is void if your bicycle is subjected to abuse or abnormal use.
3) This Warranty applies only to the Original Owner (first retail purchaser from bicycle dealer, distributor, or direct from Christini) so we suggest you register your purchase with CHRISTINI at the
time of purchase. Because Proof of Purchase by the Original Owner is required for making any
Warranty Claim, taking this simple step will save you time looking for the receipt later. Please
fill out and return the Warranty Registration section below.
4) Bring your bicycle along with your purchase receipt or other proof of the date of purchase to the
store where you purchased the bicycle or write to the Warranty Service Department at:
421 N. 7th Street, Suite 200
Philadelphia, PA 19123
Phone: (215) 351 9895
5) Freight costs and any labor charges for part change overs, assembly, repair, or disassembly are
the responsibility of the Original Owner and this Warranty offers no cash refunds.
Original Owner Name:
Date Purchased:
Purchase Price:
Store Where Purchased:
Product Model:
City / State:
Bottom Bracket Serial Number:
Would you like to receive CHRISTINI AWD product information and updates?
Would you be willing to participate in the CHRISTINI AWD one-year and two year surveys?
Please detach and save a copy of this Registration Form and return original to: Christini Purchase
Registration, Christini Technologies, 421 North 7th Street, Suite 200, Philadelphia PA 19123
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