Where Design Meets Engineering™
Product Installation Guide: Gravity Chain Oiling System™
For KTM DUKE 200, 390
Installation and User Guide Version: 1.0
Product Part Number: RLP-D2D3-GO
TABLE OF CONTENTS
WARNINGS AND CAUTION
MODEL SPECIFIC PACKAGE CONTENTS
USING ZIP TIES
GET SET GO!
THANK YOU for buying this REDLiNE+™ product.
This Gravity Chain Oiling System™ (hereafter referred to as GCOS) is manufactured by REDLiNE+™ from carefully selected components. We have used the finest of brass connectors for long life of the product.
DIY DIFFICULTY: Easy
QUALIFIED FITMENT: Due care should be taken during installation of the Gravity Chain Oiling System™. Improperly fitted oilers may hamper swingarm and or wheel movement. The installation can be performed if you have experience in DIY; else best to use an experienced mechanic. Inspect the Gravity Chain Oiling System™ assembly after installation to ensure there are no loose washers, nuts, bolts, zip ties and plumbing.
PERSONAL INJURY: Ensure that the bike has cooled down before installing or inspecting the Gravity Chain Oiling System™ to avoid personal injury. Ensure the bike is on a stable platform, ideally using a rear paddock stand. Ensure adequate lighting and ventilation is available for your own safety.
INDEMNITY: By purchasing this product, you agree that REDLiNE+™ will not and cannot be held responsible for any kind of damages arising to you or your vehicle by the installation and usage of this product. Carefully following the instruction in this guide will mitigate most risks.
Motorcycle manufacturers recommend that final drive chain be lubricated for optimal performance and life of the chain and sprockets. This translates to a lubrication interval of 500Kms under normal conditions.
The problem amplifies when touring for days together over long distances. Lubricating a chain with a fully loaded bike is not an easy task, especially with bikes without a centre stand.
The RedLine+ GCOS works on gravity and delivers a continuous supply of lubrication to the chain. Because the lubrication is continuous in nature, the 500 Km interval does not matter. A boon for tourers
- Expensive final drive chain
- Front and rear sprockets
- Suitable for Sealed O-ring and X-ring chains
- Works on gravity and atmospheric pressure
- No engine vacuum or electric motors
- Easy to fix, easy to use with provided zip ties
- No change in stock setup of the bike
- 30% extra zip ties provided for future use
- Recommended by most manufacturers for chain lubrication
- Very widely available
- System holds more than 50 ml of oil - sufficient for 1000 Km of use
- Supplied as an assembled ready to use k kit for specified motorcycle models
Oil container with lid
To hold the lubricating oil
Partially assembled Gravity Chain Oiling System™
The main part of the Oiling System
Clips (some motorcycle models only)
To hold the Oil container onto the motorcycle chassis
To fasten the Oil container to the clip or motorcycle chassis
Zip ties to hold the Gravity Chain Oiling System™
Black foam spacers strips (some motorcycle models only)
Spacers to use between the Gravity Chain Oiling System™ and the swingarm or delicate parts of the motorcycle to prevent scratching
Round steel retainer
To fasten the oil pipe to the oil container
MODEL SPECIFIC PACKAGE CONTENTS
- Zip ties (50% extra provided for future use)
- Z1 300mm - 7 pieces (5 required)
- Z2 200mm - 7 pieces (5 required)
- Z3 150mm - 9 pieces (6 required)
- Foam spacer strips (one size each)
- F1 4 cms - Above the front sprocket area
- F2 8 cms - Under the ball valve
- F3 6 cms - At the end of the swing arm under the nozzle pie brass connector
- Bolt - M5 30mm - 1 piece
- Washers - 4
- Mild Steel Clip - 1 piece
- Remove and inspect the contents against the above list
- Remove both the seats and make sufficient space by removing tools etc. This will also be a good time to dry and clean this area
USING ZIP TIES
- Choosing the right length
- Always check if the smallest length zip tie can be used, if not check the next longer length one and so on
- Eg: See if Z4 will fit for that step, if not try with Z3, if not Z2 and finally Z1
- The intention is to use the smallest zip tie wherever possible
- Ensure that the zip tie is fastened tightly and there is minimal play. Pull to tighten.
- After fastening, cut the tail of the zip tie. Cut using a sharp tool. Ensure no sharp edges are left. Ensure the tail is cut and does not get pulled into any movable parts or cause any obstruction
- The installation will be done from the rear sprocket end as shown below
- Lay the oiler system on the swing arm so that:
- The nozzle head will be aligned in such a way that oil can be delivered near to the sprocket edge
- The nozzle end face will be parallel to the sprocket surface (as in the above photo)
- Lay the pipeline as shown in the photos
- Lay the foam spacer strips as per their description in package contents list, do not stick them yet
- Now check the nozzle position and keep some play in the flexible nozzle pipe
- Adjust and stick the foam spacer strips as per their final position
- Zip tie the flexible nozzle pipe near the swingarm axle bolt - the nozzle head should remain flexible
- Continue the zip tie fastening all the way upto the oil container end
Notice the foam in the above photo
- Attach the oil container to the open tube end
- Fasten the bolt of the tube ring fastener
- Place the oiler on the chassis with the clip as shown below and bolt it using the left engine guard upper bolt
- If the tube is creating an obstruction anywhere in the line, unfasten the oil container, unfasten the tube ring, pull the tube out, cut the tube end a bit and repeat above steps
The system is now ready to pour oil.
- The oil will take a long time to reach the nozzle end because the tube is dry inside
- It takes a long time (couple of hours) for the system to get fully wet for the first time, so you can leave it overnight too
- Pour the specified oil with the valve in the open position
- Keep the flow of pouring low and try to pour into the oil container hole
- Once topped up, put the lid on lightly and allow the oil to flow and air to escape
- Keep topping the oil every 10-15 minutes to avoid air bubbles in the system and collect any oil at the nozzle end in a container to avoid spilling on the ground
- If any air bubbles appear, they will go away due to vibrations upon riding the motorcycle
Ensure the following after installation:
- There should be no leaking oil from any of the joints
- The rear tyre should be free of any oil marks - clean thoroughly if any oil spotted
- The entire assembly should have sufficient gap between itself and the rear foot peg. Means it should not touch any parts besides the swing arm
- Test the functioning of the valve
- Do a short ride to ensure there are no new noises or vibrations from the system
- After the first ~50 Kms, inspect all zip ties and entire system for tight fit. Repeat after first 200Kms.
Clean and lubricate the chain before using the oiler using the same grade of oil. The system works best when the chain is well lubricated. The system will keep topping up the oil layer on the entire chain and sprocket.
If the system is used on a dry chain, only the outer side of the chain will get lubricated. In this case manually lubricate the chain on both sides and then use the GCOS for normal results.
Sometimes the nozzle hole may get clogged due to muck or dirt. A sewing needle can be used to clean this. If that does not work, dip the nozzle head in diesel and try again.
While touring, do a quick visual inspection of the system to ensure there are no obstructions, leakages or other hazards.
The GCOS is not a replacement for proper chain and sprocket maintenance. For safety of the rider and long life of the chain and sprockets, the chain must be inspected, cleaned and lubricated manually as per the periodic maintenance schedule from the manufacturer.
The valve position must be controlled to adjust the flow. A very slight opening will provide a single drop every 10-15 minutes. This is a good setting for touring. A slightly larger opening will provide more flow for off road or wet conditions to provide more lubrication. You can experiment and find the best position that suits your preference.
Some notes from the Kawasaki User Manual:
- Lubrication: Lubrication is also necessary after riding through rain ir on wet roads, or any time that the chain appears dry. A heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication.
- Apply oil to the sides of the rollers so that it will penetrate to the rollers and bushings. Apply oil to the O-rings so that the O-rings will be coated with oil. Wipe off any excess oil.
- If the chain is specially dirty, clean it using diesel oil or kerosene and then apply oil as mentioned above.
GET SET GO!
Now you should be all set for amazing long rides without worrying about constant chain lubrication!
Enjoy riding your motorcycle safely!
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