Fantic Motor XXF 250 User Manual Download

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4. Maintenance

USE AND MAINTENANCE MANUAL

CHAPTER 4

MAINTENANCE

4-Strokes - Edition 00 / 2022

136

– Loosen the pad pin “3”, remove the rear wheel “4” and the

brake calliper “5 “;

– Remove the pad pin “6” and brake pads “7”;

– Install the brake pads “8” with the relative protrusions

“A” in the recesses “B” of the brake calliper. Temporarily

tighten the pads pin “3”.

– Install the brake caliper “5” and rear wheel “4”. Tighten

the pad pin “3” and install the pad pin plug. Installa the

protector “1”.

Summary of Contents for XXF 250

Page 1: ...USER MANUAL e n READ THIS MANUALE CAREFULLY BEFORE OPERATING THIS VEHICLE FOUR STROKE 250 FOUR STROKE 450 FOUR STROKE 250 FOUR STROKE 450 CODE 08695005 ...

Page 2: ...intenance and use The instructions in this manual have been prepared to give you a simple and clear guide for use We are sure that taking it into consideration you will gain confidence with your new vehicle which you can use for a long time and with full satisfaction MANUFACTURER DATA AND EDITION Fantic Motor Via Tarantelli 7 31030 Dosson di Casier TV Italy Tel 39 0422 634192 Fax 39 0422 1830124 E...

Page 3: ...t to the attention of all Fantic Motor dealers and will be published in future editions of the manual Fantic Motor reserves the right to modify and make changes at any time and without notice to the models described specifications and design data guaranteeing the essential characteristics described and illustrated in this manual Operators have the obligation to read the manual and to scrupulously ...

Page 4: ...50 XEF 450 26 1 9 Tightening torques 29 Engine tightening torques XEF 250 XEF 450 versions 29 Chassis tightening torques XEF 250 XEF 450 versions 32 Engine tightening torques XXF 250 version 35 Chassis tightening torques XXF 250 version 37 Engine tightening torques XXF 450 version 40 Chassis tightening torques XXF 450 version 42 Electrical tightening torques all versions 44 1 10 Maintenance limits...

Page 5: ...F 450 versions 75 Clutch lever 75 Shift pedal XXF 250 XEF 250 versions 75 Shift pedal XXF 450 XEF 450 versions 75 Throttle grip 76 Front brake lever 76 Start button XEF 250 XEF 450 versions 76 Start button XXF 250 XXF 450 versions 76 Launch traction control system XXF 250 XXF 450 versions 77 Engine mapping selection switch XXF 250 XXF 450 versions 77 Rear brake pedal 77 Start knob air valve 78 Sid...

Page 6: ...t 92 Rebound damping adjustment return 92 Compression damping adjustment low speed 92 Compression damping adjustment high speed 93 3 9 Setting the SAG 93 Rear shock absorber sinking adjustment SAG 93 3 10 Chain tension 95 Chain tension check 95 Chain tension adjustment 95 3 11 Engine mappings XXF 250 XXF 450 versions 96 3 12 Traction CONTROL mode XXF 250 XXF 450 versions 96 TRACTION CONTROL level ...

Page 7: ...XXF 450 XEF 450 versions 120 4 7 Cylinder and piston 122 Removal 122 Cylinder check 122 Piston check 123 Installation 124 4 8 Soundproofing 125 4 9 Clutch 125 Clutch removal 125 Check the clutch elements 127 Clutch installation 128 4 10 Steering play control and adjustment 132 Steering play control 132 Steering play adjustment 132 4 11 Fork 133 4 12 Shock absorber 133 4 13 Wheels 133 Spokes check ...

Page 8: ...5 Warranty and service 140 Warranty 140 Warranty period 140 Warranty conditions 140 Exclusions from the warranty 141 Additional warranty provisions 141 Request for intervention under warranty 141 Warnings for maintenance and care 141 Warranty data 142 Service 143 ...

Page 9: ... the operation until the affected part is free from residues In case of contact with eyes and ears immediately rinse the affected parts with plenty of water and urgently go to a first aid center indicating the cause and how the accident occurred In case of contact with clothing undress and wash thoroughly with soap and water Change the dirty cloths which must be specifically washes as soon as poss...

Page 10: ...cap when the engine is still hot Coolant is under pressure and may cause burns Keep hands and clothes away from the cooling fan as it starts automatically Precautions and general warnings The clothing of the operator performing the repair operations must be adequate to avoid the risk of injury when working on moving parts for example too wide clothes that can get caught Do not wear personal items ...

Page 11: ...ements to be complied with or verified for the procedure described Equipment note that informs the user of the need to use particular tools for the procedure described Consumable note that illustrates the names types and or quantities of consumables such as oil fuel sealants additives etc to be used for the procedure described All left or right indications refer to the direction of travel of the m...

Page 12: ...lly operate the brakes In case the vehicle is used on roads dirty with sand mud snow mixed with salt we recommend checking and if necessary cleaning the brake discs with special non aggressive detergents so as to prevent the formation of abrasive agglomerates inside the holes and an early wear of the brake pads The getting on and off from the vehicle must be in complete freedom of movement and wit...

Page 13: ...le model must be mentioned for the request for spare parts 1 4 FRAME NUMBER The frame number A is punched on the steering tube on the right side 1 5 ENGINE NUMBER XXF 250 XEF 250 versions The engine number B is punched on the left side of the engine crankcase XXF 450 XEF 450 versions The engine number C is punched on the right hand engine casing on the inside It is visible when looking at the insi...

Page 14: ... Strokes Edition 00 2022 13 1 2 1 5 4 3 6 1 6 LOCATION OF IMPORTANT LABELS 1 Pressurised gas hazard label 2 Usable petrol quality label XEF 250 XEF 450 ONLY 3 Chassis number punching 4 Vehicle data plate 5 Choke symbol XEF 250 XEF 450 ONLY 6 Tyre pressure label XEF 250 XEF 450 ONLY ...

Page 15: ...CE MANUAL CHAPTER 1 GENERAL INFORMATION 4 Strokes Edition 00 2022 14 5 90 90 21 80 100 21 140 80 18 130 90 19 ON ROAD USE OFF ROAD USE PRESSURE kPa AXLE SIZE 200 200 220 220 100 100 100 100 120 90 18 220 100 6 3 4 1 E5 E10 PETROL FUEL TYPE 2 ...

Page 16: ... 7 VEHICLE COMPONENT LOCATION Handlebar components XEF 250 version Ref Component 1 High beam flashing button 2 Clutch lever 3 SELECT button 4 ADJUST button 5 Engine stop switch 6 Front brake lever 7 Throttle grip 8 Radiator cap 9 Fuel tank cap 10 Speedlight switch 11 Horn button 12 Low beam high beam light switch 13 Starter switch 14 Dashboard ...

Page 17: ...3 24 27 25 18 19 17 26 15 16 Right and left side components XEF 250 version Ref Component 15 Headlight 16 Radiator 17 Rear brake pedal 18 Inspection window for oil level check 19 Coolant drain bolt 20 Front fork 21 Fuel tank Ref Component 22 Air filter 23 Taillight 24 Shift pedal 25 Drive chain 26 Oil filler cap 27 Starter knob ...

Page 18: ...4 Strokes Edition 00 2022 17 1 1 3 4 2 8 5 7 6 Handlebar components XXF 250 version Ref Component 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Starter switch 7 Launch traction control system mode control button 8 Engine mapping selector ...

Page 19: ...3 15 9 10 11 Right and left side components XXF 250 version Ref Component 9 Fuel tank cap 10 Launch traction control system display 11 Radiator 12 Rear brake pedal 13 Coolant drain bolt 14 Oil filler cap 15 Inspection window for oil level check Ref Component 16 Front fork 17 Fuel tank 18 Air filter 19 Shift pedal 20 Drive chain 21 Starter knob ...

Page 20: ... 10 9 8 13 5 7 Handlebar components XEF 450 version Ref Component 1 High beam flashing button 2 Clutch lever 3 SELECT button 4 ADJUST button 5 Engine stop switch 6 Front brake lever 7 Throttle grip 8 Radiator cap 9 Fuel tank cap 10 Speedlight switch 11 Horn button 12 Low beam high beam light switch 13 Starter switch 14 Dashboard ...

Page 21: ...3 24 25 19 26 27 18 15 16 17 Right and left side components XEF 450 version Ref Component 15 Headlight 16 Radiator 17 Rear brake pedal 18 Coolant drain bolt 19 Inspection window for oil level check 20 Front fork 21 Fuel tank Ref Component 22 Air filter 23 Taillight 24 Shift pedal 25 Drive chain 26 Oil filler cap 27 Starter knob ...

Page 22: ...4 Strokes Edition 00 2022 21 1 1 3 4 2 8 5 7 6 Handlebar components XXF 450 version Ref Component 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Starter switch 7 Launch traction control system mode control button 8 Engine mapping selector ...

Page 23: ...2 13 9 10 11 Right and left side components XXF 450 version Ref Component 9 Fuel tank cap 10 Launch traction control system display 11 Radiator 12 Rear brake pedal 13 Coolant drain bolt 14 Front fork 15 Fuel tank Ref Component 16 Air filter 17 Oil filler cap 18 Inspection window for oil level check 19 Shift pedal 20 Drive chain 21 Starter knob ...

Page 24: ...50 335 mm 13 19 in 320 mm 12 60 in Weight in running order XXF 250 XEF 250 105 kg 231 lb 115 kg 254 lb Weight at full load XXF 250 XEF 250 175 kg 385 8 lb 185 kg 407 8 lb Maximum allowable weight XXF 250 XEF 250 250 kg 551 2 lb 250 kg 551 2 lb Engine type Liquid cooled 4 stroke gasoline Cylinder arrangement Single cylinder Displacement 250 cm3 Bore stroke 77 0 x 53 6 mm 3 03 x 2 11 in Compression ...

Page 25: ... 10 US gal 2 0 L 0 44 Imp gal 0 53 US gal Fuel pump Pump type Maximum consumption amperage Electrical 2 4 A Fuel injector resistance 12 0 Throttle body XXF 250 XEF 250 B7B1 BAK1 Spark plug Type Manufacturer Gap NGK LMAR8E J 0 6 0 7 mm 0 024 0 028 in Clutch type Wet multiple disc Primary reduction system Gear Primary reduction ratio 3 353 57 17 Final drive Chain Secondary reduction ratio XXF 250 XE...

Page 26: ...ion pressure road use Front rear inflation pressure Racing use 80 100 21 130 90 18 120 90 18 2 bar 200 kPa 29 PSI 2 2 bar 220 kPa 32 PSI 1 bar 100 kPa 15 PSI Brake Front brake type Operation Rear brake type Operation Hydraulic single disc brake Right hand operation Hydraulic single disc brake Right foot operation Suspension Front suspension Rear suspension Telescopic fork Swingarm link suspension ...

Page 27: ...62 3 lb Weight at full load XXF 450 XEF 450 184 kg 405 6 lb 189 kg 416 6 lb Maximum allowable height XXF 450 XEF 450 250 kg 551 2 lb 250 kg 551 2 lb Engine type Liquid cooled 4 stroke gasoline Cylinder arrangement Single cylinder Displacement 450 cm3 Bore stroke 97 0 x 60 8 mm 3 82 x 2 39 in Compression ratio 13 0 1 Valve train DOHC Starting system Electric starter Lubrication system Wet sump Tran...

Page 28: ...tance 12 0 Throttle body XXF 450 XEF 450 BR91 B7R1 Spark plug Type Manufacturer Gap NGK LMAR8G 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Primary reduction system Gear Primary reduction ratio 2 609 60 23 Final drive Chain Secondary reduction ratio XXF 450 XEF 450 3 769 49 13 3 692 48 13 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio XXF 450 version 1a...

Page 29: ...cing use 80 100 21 130 90 18 120 90 18 2 bar 200 kPa 29 PSI 2 2 bar 220 kPa 32 PSI 1 bar 100 kPa 15 PSI Brake Front brake type Operation Rear brake type Operation Hydraulic single disc brake Right hand operation Hydraulic single disc brake Right foot operation Suspension Front suspension Rear suspension Telescopic fork Swingarm link suspension Shock absorber Front shock absorber Rear shock absorbe...

Page 30: ... drain bolt M6 1 10 Nm 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1 5 Nm 0 15 kgf m 1 1 lb ft Radiator bolt M6 4 10 Nm 1 0 kgf m 7 4 lb ft Radiator pipe joint bolt M6 1 10 Nm 1 0 kgf m 7 4 lb ft Radiator fan bolt M6 3 8 Nm 0 8 kgf m 5 9 lb ft Water pump housing cover bolt M6 4 10 Nm 1 0 kgf m 7 4 lb ft Water pump impeller M8 1 14 Nm 1 4 kgf m 10 lb ft Oil pump bolt M5 2 5 Nm 0 5 kgf m 3 7 ...

Page 31: ...ter clutch screw M6 8 12 Nm 1 2 kgf m 8 9 lb ft Primary drive gear nut M16 1 105 Nm 10 5 kgf m 77 lb ft Clutch spring bolt M6 6 10 Nm 1 0 kgf m 7 4 lb ft Clutch boss nut M20 1 95 Nm 9 5 kgf m 70 lb ft Stake Drive sprocket nut M18 1 75 Nm 7 5 kgf m 55 lb ft Use a lock washer Segment M8 1 30 Nm 3 0 kgf m 22 lb ft Shift guide bolt M6 2 10 Nm 1 0 kgf m 7 4 lb ft Stopper lever bolt M6 1 10 Nm 1 0 kgf m...

Page 32: ...d angle 60 Total tightening angle 60 60 120 The first and second time be sure to apply molybdenum disulfide oil to the bolt threads and seats as well as to both sides of the lock washers 3 2 4 1 FWD Tip Cylinder head bolt XEF 450 version First tighten the cylinder head bolts to 40 N m 4 0 kgf m 30 lb ft in the proper tightening sequence and remove them Retighten the cylinder head bolts to 23 N m 2...

Page 33: ...M5 2 3 8 Nm 0 38 kgf m 2 8 lb ft Clutch lever holder bolt M5 2 3 8 Nm 0 38 kgf m 2 8 lb ft Clutch lever nut M6 1 4 0 Nm 0 40 kgf m 3 0 lb ft Front brake master cylinder holder bolt M6 2 9 Nm 0 9 kgf m 6 6 lb ft Front brake master cylinder reservoir cap screw M4 2 1 5 Nm 0 15 kgf m 1 1 lb ft Front brake lever pivot bolt M6 1 6 Nm 0 6 kgf m 4 4 lb ft Front brake lever pivot nut M6 1 6 Nm 0 6 kgf m 4...

Page 34: ...ay arm side M14 1 80 Nm 8 0 kgf m 59 lb ft Connecting arm nut frame side M14 1 80 Nm 8 0 kgf m 59 lb ft Brake hose holder screw M5 4 3 5 Nm 0 35 kgf m 2 6 lb ft Drive chain tensioner bolt upper side M8 1 16 Nm 1 6 kgf m 12 lb ft Drive chain tensioner bolt lower side M8 1 16 Nm 1 6 kgf m 12 lb ft Bolt drive chain support M6 1 7 Nm 0 7 kgf m 5 2 lb ft Drive chain support nut M6 2 7 Nm 0 7 kgf m 5 2 ...

Page 35: ...ont brake hose guide and head light stay bolt M5 1 3 8 Nm 0 38 kgf m 2 8 lb ft Screw mud flap 2 1 3 Nm 0 13 kgf m 0 95 lb ft Frame ground bolt negative battery lead M5 1 7 Nm 0 7 kgf m 5 2 lb ft Tip Lower ring nut XEF 250 XEF 450 versions First tighten the lower ring nut approximately 38 Nm 3 8 kgf m 28 lb ft by using the steering nut wrench then loosen the lower ring nut one turn Retighten the lo...

Page 36: ...tor hose clamp screw M6 8 1 5 N m 0 15 kgf m 1 1 lb ft Radiator bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Radiator pipe joint bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Water pump housing cover bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Water pump impeller M8 1 14 N m 1 4 kgf m 10 lb ft Oil pump assembly bolt M5 2 5 N m 0 5 kgf m 3 7 lb ft Oil pump cover screw M4 1 2 0 N m 0 20 kgf m 1 5 lb ft Oil strainer bolt M6...

Page 37: ...05 N m 10 5 kgf m 77 lb ft Clutch spring bolt M6 6 10 N m 1 0 kgf m 7 4 lb ft Clutch boss nut M20 1 95 N m 9 5 kgf m 70 lb ft Stake Drive sprocket nut M18 1 75 N m 7 5 kgf m 55 lb ft Use a lock washer Segment M8 1 30 N m 3 0 kgf m 22 lb ft Shift guide bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stopper lever bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Shift pedal bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Generator r...

Page 38: ...h bolt M8 4 21 N m 2 1 kgf m 15 lb ft Steering stem nut M24 1 145 N m 14 5 kgf m 107 lb ft Upper handlebar holder bolt M8 4 28 N m 2 8 kgf m 21 lb ft Lower handlebar holder nut M10 2 40 N m 4 0 kgf m 30 lb ft Engine stop switch screw M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Start switch M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Mode switch M3 1 1 3 N m 0 13 kgf m 0 95 lb ft Lower ring nut M28 1 Vedere nota a p...

Page 39: ...ke pad pin plug M10 1 2 5 N m 0 25 kgf m 1 8 lb ft Rear wheel axle nut M22 1 135 N m 13 5 kgf m 100 lb ft Drive chain puller locknut M8 2 21 N m 2 1 kgf m 15 lb ft Rear wheel sprocket nut M8 6 42 N m 4 2 kgf m 31 lb ft Nipple spoke 72 2 5 N m 0 25 kgf m 1 8 lb ft Bolt rear brake disc cover M6 2 10 N m 1 0 kgf m 7 4 lb ft Rear brake caliper protector bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mount...

Page 40: ...6 lb ft Side cover bolt left M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt right M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt frame M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt fuel tank M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt radiator guard M6 4 7 N m 0 7 kgf m 5 2 lb ft Front fender bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Rear fender bolt front side M6 4 7 N m 0 7 kgf m 5 2 lb ft Rear fend...

Page 41: ...ain tensioner bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp screw M6 8 1 5 N m 0 15 kgf m 1 1 lb ft Radiator bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Radiator pipe joint bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Water pump housing cover bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Oil pump bolt M5 2 5 N m 0 5 kgf m 3 7 lb ft Oil pump cover screw M4 1 2 ...

Page 42: ...m 1 2 kgf m 8 9 lb ft Primary drive gear nut M20 1 80 N m 8 0 kgf m 59 lb ft Clutch spring bolt M6 6 10 N m 1 0 kgf m 7 4 lb ft Clutch boss nut M20 1 75 N m 7 5 kgf m 55 lb ft Use a lock washer Drive sprocket nut M20 1 90 N m 9 0 kgf m 66 lb ft Use a lock washer Segment M8 1 30 N m 3 0 kgf m 22 lb ft Shift guide bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Stopper lever bolt M6 1 10 N m 1 0 kgf m 7 4 lb f...

Page 43: ...t M8 4 28 N m 2 8 kgf m 21 lb ft Lower handlebar holder nut M10 2 40 N m 4 0 kgf m 30 lb ft Engine stop switch screw M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Lower ring nut M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Damper assembly front fork M3 1 1 3 N m 0 13 kgf m 0 95 lb ft Inner tube and Adjuster M28 1 Vedere nota a pagina 44 Base valve front fork M51 2 30 N m 3 0 kgf m 22 lb ft Adjuster damper assembly M22...

Page 44: ...N m 2 1 kgf m 15 lb ft Bolt rear brake disc cover M8 6 42 N m 4 2 kgf m 31 lb ft Rear brake caliper protector bolt 72 2 5 N m 0 25 kgf m 1 8 lb ft Engine mounting bolt upper side M6 2 10 N m 1 0 kgf m 7 4 lb ft Engine mounting bolt front side M6 2 7 N m 0 7 kgf m 5 2 lb ft Engine mounting bolt lower side M10 2 45 N m 4 5 kgf m 33 lb ft Engine bracket bolt upper side M10 1 55 N m 5 5 kgf m 41 lb ft...

Page 45: ...p bolt radiator guard M6 2 7 N m 0 7 kgf m 5 2 lb ft Front fender bolt M6 4 7 N m 0 7 kgf m 5 2 lb ft Rear fender bolt front side M6 4 10 N m 1 0 kgf m 7 4 lb ft Rear fender bolt rear side M6 4 7 N m 0 7 kgf m 5 2 lb ft Screw mud flap M6 2 16 N m 1 6 kgf m 12 lb ft Number plate bolt 2 1 3 N m 0 13 kgf m 0 95 lb ft Frame ground bolt negative battery lead M6 1 7 N m 0 7 kgf m 5 2 lb ft Bullone terra...

Page 46: ...uide inside diameter intake Valve guide inside diameter exhaust Valve stem to valve guide clearance intake Valve stem to valve guideclearance exhaust Valve stem runout 0 12 0 19 mm 0 0047 0 0075 in 0 17 0 24 mm 0 0067 0 0094 in 5 000 5 012 mm 0 1969 0 1973 in 4 500 4 512 mm 0 1772 0 1776 in 1 6 mm 0 06 in 1 6 mm 0 06 in 4 945 mm 0 1947 in 4 430 mm 0 1744 in 0 080 mm 0 0032 in 0 100 mm 0 0039 in 0 ...

Page 47: ...113 in 6 pcs 1 50 1 70 mm 0 059 0 067 in 7 pcs 44 00 mm 1 73 in 2 60 mm 0 102 in 2 62 mm 0 103 in 0 10 mm 0 004 in 41 80 mm 1 65 in 0 30 mm 0 012 in Trasmission Main axle deflection limit Drive axle deflection limit 0 08 mm 0 0032 in 0 08 mm 0 0032 in Shifter Shifting type Guide bar bending limit Cam drum and guide bar 0 050 mm 0 0020 in Kickstarter type Kick clip friction force Kick and mesh P 7 ...

Page 48: ...arance intake Valve stem to valve guideclearance exhaust Valve stem runout 0 10 0 17 mm 0 0039 0 0067 in 0 15 0 22 mm 0 0059 0 0087 in 5 500 5 512 mm 0 2165 0 2170 in 5 500 5 512 mm 0 2165 0 2170 in 1 5 mm 0 06 in 1 5 mm 0 06 in 5 445 mm 0 2144 in 5 435 mm 0 2140 in 0 080 mm 0 0032 in 0 100 mm 0 0039 in 0 020 mm 0 0008 in Valve spring Free length intake Free length exhaust 36 65 mm 1 44 in 35 55 m...

Page 49: ...21 in 6 pezzi 2 92 3 08 mm 0 115 0 121 in 2 pezzi 1 50 1 70 mm 0 059 0 067 in 7 pezzi 48 00 mm 1 89 in 2 82 mm 0 111 in 2 82 mm 0 111 in 0 10 mm 0 004 in 45 60 mm 1 80 in 0 10 mm 0 004 in Trasmission Main axle deflection limit Drive axle deflection limit 0 08 mm 0 0032 in 0 08 mm 0 0032 in Shifter Shifting type Guide bar bending limit Cam drum and guide bar 0 050 mm 0 0020 in Kickstarter type Kick...

Page 50: ...or adjustment Adjustment value from the start position Soft Adjustment value from the start position STD XXF 250 XXF 450 XEF 250 XEF 450 Adjustment value from the start position Hard Mechanical adjustable type Click 20 9 10 8 0 Damping in compression Adjusting system Unit for adjustment Adjustment value from the start position Soft Adjustment value from the start position STD XXF 250 XEF 250 XXF 4...

Page 51: ...djustment value from the start position Hard Mechanical adjustable type Turn 2 1 0 Slow compression damping Unit for adjustment Adjustment value from the start position Soft Adjustment value from the start position STD XXF 250 XEF 450 XEF 250 XXF 450 Adjustment value from the start position Hard Click 20 10 8 9 0 Swingarm Swingarm end free play limit radial Swingarm end free play limit axial 1 0 m...

Page 52: ...0 mm 25 40 mm 1 00 in 1 00 in DOT 4 1 0 mm 0 04 in Rear brake Brake pedal position Disc outside diameter thickness Brake disc thickness limit Brake disc runout limit as measured on wheel Master cylinder inside diameter Caliper cylinder inside diameter Specified brake fluid 5 0 mm 0 20 in 240 0 4 0 mm 9 45 in 0 16 in 3 5 mm 0 14 in 0 15 mm 0 0059 11 0 mm 0 43 in 25 40 mm 1 00 in DOT 4 1 0 mm 0 04 i...

Page 53: ...all length XXF 250 XEF 250 XXF 450 XEF 450 Brush spring force XXF 250 XEF 250 XXF 450 XEF 450 Mica undercut depth XXF 250 XEF 250 XXF 450 XEF 450 7 0 mm 0 28 in 11 0 mm 0 43 in 3 92 5 88 N 400 600 gf 14 11 21 17 oz 4 80 7 20 N 489 734 gf 17 28 25 92 oz 3 5 mm 0 14 in 5 5 mm 0 22 in 1 50 mm 0 06 in 2 40 mm 0 09 in Fuel injection sensor Crankshaft position sensor resistance Intake air temperature se...

Page 54: ...two colours is identified by the firstcolourcode primary C orcolourofthesheath followed by the second colour code secondary D the codes are separated by a dash Examples case A Blue L case B Red primary and Green secondary RV The following table shows the codes used in the wiring diagram to identify the colour of the cable Code Cables color A SKY BLUE B WHITE C ORANGE D DARK BLUE G YELLOW H GREY L ...

Page 55: ... air temperature sensor 22 Coolant temperature sensor 23 Throttle position sensor 24 Intake air pressure sensor 25 Engine stop switch 26 Gear position switch 27 Mode switch junction 28 Mode switch 29 Diode 3 30 Launch traction control button 31 Fuel injector preparation 2 32 Mode switch 33 ECU engine control unit secondary connector 34 Wi Fi interface 35 LC GPA Launch traction control display 36 O...

Page 56: ...BN BN RL BN BN B VG B VG R H M M M M M N N RL C R C M BN VG B VG B M BN M MB L N MB RG RG MB RB L RB R R R RB R R R R RB R LR LR M M N N N N R R N R B B B B B B B B N H H NL N R B H NL B N N N LV L LV M MB M LV LB LB RL R R RG RG RL R R M M BN VG B M S A GN S A LN LN LR LR LN LB LN N N N LN N NB NR NC N N N NL NL NL NL NL NL NL N RL NB NR NB RL NR N BL N BN N BN BN BN N N BR BL BL BL BR BR BR N B ...

Page 57: ...sensor 22 Coolant temperature sensor 23 Throttle position sensor 24 Intake air pressure sensor 25 Engine stop switch 26 Mode switch junction 27 Gear position switch 28 Unused system inhibition cap 29 Start switch 30 Diode 3 31 Fuel injector preparation 2 32 Mode switch 33 ECU engine control unit secondary connector 34 Wi Fi interface 35 LC GPA Launch traction control display 36 Launch traction con...

Page 58: ... VG H M M M M M M MB M LV LB MB RG RB R MB L N N N N R RB M LR RL RL RB R R R N N B B B B B B N H H NL B B H NL B B N R M M N N C R R C B VG BN M VG B M BN LR LR N N N L LV L RG RB MB L LV LV M R RL RL RL RL RG R RG RL RL RL RG R M B VG BN M M GN A S S GN A GN S A LN LN LR LR LN LB LB LN LN N N LN MR N CR CL NL MG S MR N CR CL MR N NL MG S N N NR NC NB RL NR N BL N BN N BN BN BN N N BR BL BL BL BR...

Page 59: ...ole 14 Positive battery pole 15 Starter remote control switch 16 Starter motor 17 Voltage regulator 18 Magnet flywheel 19 Pick Up 20 Engine control remote control switch 21 Neutral gear switch 22 Fan remote control switch 23 Radiator fan 24 Engine ground point 25 Frame ground point 26 Rear left turn signal 27 Tail light 28 Rear right turn signal 29 Rear brake light switch 30 Front brake light swit...

Page 60: ...1 GENERAL INFORMATION 4 Strokes Edition 00 2022 59 1 Number Description of the electrical component 46 Speed sensor 47 Serial communication interface 48 LC GPA module Launch Traction control optional 49 Fuel Injector 2 optional 50 Engine map selector optional ...

Page 61: ...OIL 2 COIL 1 MAP SENS VBATT FAN REL FUEL PUMP LAMB HEAT RPM OUT TPS MAP SW CANISTER MAIN REL LAMBDA INJ 2 ATS INJ1 PASS GND CAN L CAN H Vbatt K LINE VENTOLA LUCI KEY ON INIEZIONE CONNETTORE AUX GND HIGH BEAM RIGHT LEFT 12V LUCI 12V GND CAN H CAN L Vkey Rx GND Tx A B Rx GND SENS Tx 1k CAN H 12V GND INJ2 CAN L F5 5A F4 7 5A F3 2A F2 7 5A F1 7 5A A B C D E H J K L M N P R S Q F G 01 47 45 38 34 46 02...

Page 62: ...RMATION 4 Strokes Edition 00 2022 61 1 NEUTRAL MIL VKEY GND RIGHT LEFT HIGH BEAM SPEED RUN OFF VENTOLA LUCI KEY ON INIEZIONE CONNETTORE AUX OIL TACHO H20 VBATT FUEL LEVEL 1k A B C D E H J K L M N P R S Q F G 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30 50 31 32 33 27 ...

Page 63: ...ERSIONS ONLY The front and rear lights are LED type therefore they do not require maintenance The front and rear turn indicators are equipped with 12V 6W halogen lamps 1 13 FUSES The battery fuse 1 is accessible by removing the seat and the protective cover of the starter remote control switch Battery fuse 15 A The fuse box 2 is accessible by removing the seat ...

Page 64: ...in lubricant Spray grease for transmission chains Brake oil Synthetic Brake Fluid DOT 4 Olio per filtro aria Air Filter Special Oil Cleaner for electrical contacts Contact cleaner Fuel 95 or 98 octane super lead free petrol PETROL FUEL TYPE E5 E10 Paste for carter and engine covers coupling Three Bond N 1215 Safety lock medium tightening Medium threadlocker Safety lock strong tightening Strong thr...

Page 65: ...ny deposits Replace only for XEF 250 Every 2 years 6 Fuel injection Adjust engine idling speed 7 Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary 8 Engine oil Change warm engine before draining 9 Engine oil filter element Replace 10 Engine oil strainer Clean General maintenance and lubrication chart for XEF 250 XEF 450 versions only No Item Checks and maintenance...

Page 66: ...oap based grease all purpose grease lightly Every 30 hours 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil leakage Replace if necessary 18 Rear suspension link pivots Apply molybdenum disulfide grease lightly 19 Control cables A...

Page 67: ...Cdealerastheyrequirespecialtools dataandtechnical skills No Item Checks and maintenance jobs After break in Every race Every third race or 500 km Every fifth race or 1000 km As required 1 Engine oil Replace 2 Valve Check the valve clearances Check the valve seats and the valve stems for wear Replace 3 Valve spring Check the free length Replace 4 Valve lifter Check for scratches and wear Replace 5 ...

Page 68: ...r filter Clean and lubricate Replace 24 Oil filter Replace 25 Engine guard Replace 26 Frame Clean and inspect 27 Fuel tank fuel pump Clean and inspect 28 Fuel hose Inspect Replace Every four years 29 Brake s Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts caliper bolts master cylinder bolts and union bol...

Page 69: ...ry third race or 500 km Every fifth race or 1000 km As required 38 Sidestand Lubricate 39 Steering head Inspect free play and retighten Clean and lubricate Replace bearings 40 Tire wheels Inspect air pressure wheel runout tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate 41 Throttle control cable Check routing and connection Lubricate ...

Page 70: ...ataandtechnical skills No Item Checks and maintenance jobs After break in Every race about 2 5 hours Every third race about 7 5 hours Every fifth race about 12 5 hours As required 1 Valve Check the valve clearances Check the valve seats and the valve stems for wear Replace 2 Valve spring Check the free length Replace 3 Valve lifter Check for scratches and wear Replace 4 Camshaft Inspect the camsha...

Page 71: ...rk plug Inspect and clean Replace 20 Drive chain Lubricate and check slack alignment Replace 25 Cooling system Check coolant level and leakage Check radiator cap operation Replace coolant Every two years Inspect hoses 26 Engine guard Replace 27 Frame Clean and inspect 28 Fuel tank fuel pump Clean and inspect 29 Fuel hose Inspect Replace Every four years 30 Front fork s Clean Check and adjust Chang...

Page 72: ...ubricate Replace bearings 37 Tire wheels Inspect air pressure wheel runout tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate 38 Drive chain Lubricate and check for loosening alignment Replace 39 Chain guide Check for wear 40 Chain guide and drive chain support Replace 41 Cables Arrangement connection Check and lubricate with grease Check the throttle...

Page 73: ...d down Muffler Check that the muffler is tightly mounted and has no cracks Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose page 72 Lubrication Check for smooth operation Lubricate if necessary Bolts and nuts Check the chassis and engine for loose bolts and nuts Settings Is the machine set suitably for the condition of the racing course and weather or by taking i...

Page 74: ... leakage during refuelling If you use a funnel make sure that it is perfectly clean It is recommended to use the type of fuel indicated in the technical specifications of this manual Do not use different fuels they could damage the fuel system and compromise the operation of the engine Make sure that the tank cap is closed 2 4 STARTING THE ENGINE Starting a cold engine 1 Shift the transmission int...

Page 75: ...P button on the right handlebar XXF 250 XXF 450 versions Open the throttle valve slightly and start the engine by pressing the start button 2 2 6 MAIN COMPONENTS Engine stop switch XEF 250 XEF 450 versions The engine stop switch 1 is located on the right handlebar Press the engine stop switch until the engine stops XXF 250 XXF 450 versions With the throttle valve completely closed press the ENGINE...

Page 76: ...t disengages or engages the clutch Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth starts Shift pedal XXF 250 XEF 250 versions The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of ...

Page 77: ...located on the right handlebar it accelerates or decelerates the engine For acceleration turn the grip toward you for deceleration turn it away from you accelerate decelerate Start button XEF 250 XEF 450 versions The start button 1 is positioned on the right handlebar Press this button to start the engine using the starter motor Start button XXF 250 XXF 450 versions The start button 1 is positione...

Page 78: ...cated on the front mudguard through the screen it is possible to monitor the operation of the system and check the setting For the relevant settings refer to section 3 11 on page 96and section 3 12 on page 97 Engine mapping selection switch XXF 250 XXF 450 versions Using switch 1 on the left handlebar it is possible to select two different engine mappings that can be set via smartphone It is possi...

Page 79: ...ting a cold engine requires more air input which is provided by the starter knob 1 Pushing in the knob activates the starter which increases the opening of the throttle valve When the engine has warmed up pull it out to close the circuit When operating the starter knob be careful not to burn yourself with the exhaust pipe Locking device XEF 250 XEF 450 versions This device 1 operated by the vehicl...

Page 80: ...etro Range display DC 8 0 V 16 0 V Unità display 0 1V ODO interno ODO esterno Colore retroilluminazione dĞŶƐŝŽŶĞ ĞīĞƫǀĂ Range display 0 99999 9 km miglia non regolabile dall utente Unità display 0 1 km miglia Standard misuratore Dimensioni misuratore Peso misuratore Indicatori di direzione Folle spia verde Indicatore di direzione destro spia verde Temperatura acqua spia rossa Olio motore spia ross...

Page 81: ...trare nel display Ɣ Ɣ una volta per entrare nel display registrazione massima Ɣ Ɣ premere il una sola volta per accedere al display registrazione di Ɣ massima Ɣ Ɣ premere il una volta per Ɣ Ɣ una volta Ɣ contachilometri manutenzione Ɣ premere il una volta per tornare al display dell orologio Ɣ una sola volta per accedere al display del livello del carburante Ɣ per passare Ɣ il tasto per passare al...

Page 82: ...stazione circonferenza viene ŵŽĚŝĮĐĂƚĂ ĚĂ ϭ ϬϬϬ ŵŵ a ϭ ϯϬϬ ŵŵ 98J A Punto sensibile 1 20 Adesso il valore del numero da impostare sta lampeggiando භWƌĞŵĞƌĞ ŝů per selezionare il numero da impostare භ Ɛ KƌĂ ŝů ƉƵŶƚŽ ƐĞŶƐŽƌĞ ƐƚĂ ŝŵƉŽƐƚĂŶĚŽ da 1P ATTENZIONE per entrare nella schermata delle impostazioni 98J A 98J A භ per entrare nella schermata di impostazione භWƌĞŵĞƌe il per selezionare la schermata...

Page 83: ...Ğ del motore da P 1 a P 13 Durante il rilevamento del segnale ZWD ƐĞ Đ ğ ƋƵĂůĐŚĞ ĐĂƫǀŽ rilevamento o di interferenza si prega di selezionare un altra forma d onda di rilevamento RPM භ ƐĞŵƉŝŽ WĞƌ ŝŵƉŽƐƚĂƌĞ ŝů ǀĂůŽƌĞ Ěŝ ĨĂƐĞ rpm a 10 000 RPM භWƌĞŵĞƌĞ ŝů tasto Seleziona per selezionare il numero da impostare භ Ɛ ů ǀĂůŽƌĞ Ěŝ ĨĂƐĞ ƌƉŵ ĂƩƵĂůĞ ğ ϭϱ ϬϬϬ RPM භWƌĞŵĞƌĞ ŝů tasto Seleziona per entrare nella sc...

Page 84: ...ŝŽŶĞ ĐŚŝůŽŵĞƚƌĂŐŐŝŽ ŵĂŶƵƚĞŶǌŝŽŶĞ ŽůŝŽ භEsempio Per impostare il valore di chilometraggio dell olio motore su 4T භWƌĞŵĞƌĞ ŝů tasto Regola ƉĞƌ ƐĞůĞǌŝŽŶĂƌĞ ŝů ŶƵŵĞƌŽ ĚĂ ŝŵƉŽƐƚĂƌĞ භ Ɛ ĂƩƵĂůĞ ĐŚŝůŽŵĞƚƌĂŐŐŝŽ ŽůŝŽ ŵŽƚŽƌĞ ğ 2T භWƌĞŵĞƌĞ ŝů tasto Seleziona ƉĞƌ ĞŶƚƌĂƌĞ ŶĞůůĂ ƐĐŚĞƌŵĂƚĂ Ěŝ ŝŵƉŽƐƚĂǌŝŽŶĞ ĐŚŝůŽŵĞƚƌĂŐŐŝŽ ŽůŝŽ ŵŽƚŽƌĞ ϰd භ Ɛ ŵƉŽƐƚĂƌĞ ŝů ǀĂůŽƌĞ ĐŚŝůŽŵĞƚƌĂŐŐŝŽ ŽůŝŽ ŵŽƚŽƌĞ ĚĂ Ϯd Ă ϰd ƔWƌĞŵĞƌĞ ŝů tasto ...

Page 85: ...ŶĂ ĐĂŶĚĞůĂ Ěŝ ƟƉŽ Z භ ŽŶƚƌŽůůĂƌĞ ů ŝŵƉŽƐƚĂǌŝŽŶĞ ї ĂƌĞ ƌŝĨĞƌŝŵĞŶƚŽ Ăů ŵĂŶƵĂůĞ ϰͲϮ ŝŵƉŽƐƚĂǌŝŽŶĞ ĚĞŐůŝ ŝŵƉƵůƐŝ ZWD භ ƉŽƐƐŝďŝůĞ ĐŚĞ ŝů ĐĂďůĂŐŐŝŽ ĂůŝŵĞŶƚĂǌŝŽŶĞ ƉĞƌŵĂŶĞŶƚĞ ŶŽŶ ƐŝĂ ĐŽůůĞŐĂƚŽ ĐŽƌƌĞƩĂŵĞŶƚĞ ї ŽŶƚƌŽůůĂƌĞ ĐŚĞ ŝů ĐĂǀŽ ƉŽƐŝƟǀŽ ƌŽƐƐŽ ƐŝĂ ĐŽůůĞŐĂƚŽ ĐŽƌƌĞƩĂŵĞŶƚĞ භ ŽŶƚƌŽůůĂƌĞ ŝů ƐĞƌďĂƚŽŝŽ ĚĞů ĐĂƌďƵƌĂŶƚĞ භ ŽŶƚƌŽůůĂƌĞ ůĂ ŵĂƚĂƐƐĂ ĐĂǀŝ ї ů ĐĂǀŽ ğ ĐŽůůĞŐĂƚŽ ĐŽƌƌĞƩĂŵĞŶƚĞ භ ŽŶƚƌŽůůĂƌĞ ů ŝŵƉŽƐƚĂǌŝŽŶĞ ĚĞůůĞ...

Page 86: ...he brake lever cover Loosen the locknut 1 Turn the adjusting bolt 2 until the lever position A is within specified position Tighten the locknut 1 Reinstall the brake lever cover Be sure to tighten the locknut as it will cause poor brake performance Locknut 5 Nm 0 5 m kg 3 6 ft lb Rear brake adjustment Check the height of brake pedal A If it is different from the standard value adjust it Brake peda...

Page 87: ...r clearance A 7 0 12 0 mm 0 28 0 47 in Adjust the clutch lever clearance as described below Handlebar side Turn the adjuster 1 until the specified clutch lever free play is obtained Turning clockwise increases the clearance turning counter clockwise decreases it If the clutch lever free play cannot be obtained on the handlebar side use the adjuster on the clutch cable side Adjust the pedal height ...

Page 88: ...ottle grip free play the engine idling speed should be adjusted After adjusting the throttle grip free play turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change 3 3 THROTTLE CONTROL Adjusting the throttle grip clearance Check the throttle control knob clearance A If it is different from the standard value adjust it Throttle grip clear...

Page 89: ... with the longest distance a faces forward By installing the lower mounts in the opposite direction the amount of front rear offset of the handlebar position can be changed Lower handlebar support nut 40 Nm 4 0 m kg 30 ft lb First tighten the bolts on the front side 5 of the upper handlebar holder and then tighten the bolts 6 on the rear side Always install the upper handlebar mounts with the punc...

Page 90: ...ter clockwise and remove it then turn the right hand mirror clockwise and remove it During reassembly before tightening the nut check that the mirror support rod is aligned with the handlebar Rear view mirror adjustment To adjust the rear view mirrors get on the vehicle in the driving position and turn the rear view mirror according to your needs It is also possible to adjust the inclination of th...

Page 91: ...t of adjustment The adjuster may be damaged Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Compression damping adjustment To adjust the compression damping force of the fork turn the adjustment device 1 The device has a range of action of 20 clicks To increase the compression damping force harder thrust rotate the device clockwise ...

Page 92: ...ssure from the front fork Reinstall air purge screw 1 Air bleed screw 1 3 Nm 0 13 m kg 0 95 ft lb To improve the front fork performance and adapt it to different road conditions driving style and rider s weight Fantic features springs with different load coefficients which can be purchased from authorized dealers Load factor Part number XXF 250 XXF 450 XEF 250 XEF 450 4 1 N mm 07154005 4 2 N mm 07...

Page 93: ...justment XEF 450 From all closed open by 8 clicks by turning to S Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Compression damping adjustment low speed To adjust the compression damping force at low speed turn the adjustment device 1 The device has a range of action of 20 clicks To increase the compression damping force harder thrust rotate...

Page 94: ...dard adjustment XEF 250 When fully closed unscrew the adjuster by 1 turn Standard adjustment XXF 450 When fully closed unscrew the adjuster by 1 turn Standard adjustment XEF 450 When fully closed unscrew the adjuster by 1 turn Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged 3 9 SETTING THE SAG Rear shock absorber sinking adjustment SAG Place a...

Page 95: ... the vehicle is new and has run in the same spring length set may vary due to initial spring fatigue Therefore be sure to perform a new evaluation In case it is not possible to reach the standard value through ring nut adjustment replace the shock absorber spring with a spring having a different load coefficient If the ring nut is in the highest position lower preload but the sag value is lower th...

Page 96: ...sion 50 0 60 0mm 1 97 2 36 in Chain tension adjustment Place a kickstand or a stand under the engine to raise the rear wheel off the floor Place the gearshift in neutral Loosen the wheel axle nut 1 Loosen the locknut 2 on both sides Turntheadjustingbolt 3 onbothsides untilthespecified chain tension is achieved To maintain the correct alignment of the rear wheel carry out the adjustment by acting e...

Page 97: ...gs selectable using the Switch can be set using the WiGet app The WiGET App can be downloaded for both Apple and Android smartphones through the relevant AppStore To connect to the ECU and change its parameters refer to the instructions inside the App 3 12 TRACTION CONTROL MODE XXF 250 XXF 450 VERSIONS Approximately 1 second after starting the engine all LEDs will light up LED CHECK After approxim...

Page 98: ...his mode the lit MFL LED indicates a zero C T level 3 13 LAUNCH CONTROL MODE XXF 250 XXF 450 VERSIONS Activation of LAUNCH CONTROL It is possible to ACTIVATE the LAUNCH CONTROL only under 8 000 rpm and with the throttle valve open by a maximum of 10 Start the engine and wait for the LEDs to perform the initial CHECK After the CHECK the LEDs indicating the current C T level will remain lit Press an...

Page 99: ...ressed until the LEDs begin to flash at least 1 second With the LEDs flashing continue to press button 1 until only the LC LED flashes at least a further 2 seconds Release button 1 The LAUNCH CONTROL is active if the LC LED remains lit continuously To voluntarily deactivate the LAUNCH CONTROL press button 1 for at least 2 5 seconds and then release it The LAUNCH CONTROL will be deactivated and the...

Page 100: ...gnals can be displayed ENGINE RPM TOO LOW all LEDs are not lit accelerate for optimal starting speed ENGINE RPM TOO HIGH all the LEDs are flashing close the throttle just enough to return to the optimum condition next picture ENGINE RPM CORRECT all LED s are steady on optimal condition for starting After starting all LEDs will be off except for the LC LED which will flash ...

Page 101: ...ND MAINTENANCE MANUAL CHAPTER 3 ADJUSTMENTS 4 Strokes Edition 00 2022 100 TPS 30 Whenthethrottleposition TPS dropsbelow30 LAUNCH CONTROL is switched off and the TRACTION CONTROL is reactivated at the previously set level ...

Page 102: ... motor guard 1 if fitted Place the vehicle on a flat surface in a vertical position by placing a suitable stand under the engine Place a container under the engine Start the engine warm it up for several minutes then stop it and wait five minutes Remove the filler cap 2 Engine oil level check XXF 450 XEF 450 versions Place the vehicle on a flat surface in a vertical position by placing a suitable ...

Page 103: ...in bolt 3 Once all the engine oil in the crankcases has drained replace the copper gasket with a new one and install the drain bolt 3 Drain bolt 20 Nm 2 0 m kg 15 ft lb If necessary replace the oil filter Remove cover 4 and oil filter cartridge 5 Install a new oil filter cartridge 5 and a new O Ring 6 Then refit the cover 4 Cover bolt 10 Nm 1 0 m kg 7 4 ft lb ...

Page 104: ...ge replacement 0 75 L 0 79 US qt 0 66 Imp qt Filling after crankcase assembly 0 95L 1 00 US qt 0 48 Imp qt Check the engine oil pressure by loosening the control bolt 10 slightly Always loosen the control bolt 10 before starting the engine Start the engine and let it idle until the engine oil filters through the control bolt 10 Always keep the engine at idle speed only during the check If there is...

Page 105: ...ng it at idle and check the engine oil pressure Always keep the engine at idle speed only during the check Check through sight glass 1 that the engine oil is flowing and that the level is decreasing while the engine is running If the engine oil level does not drop after the engine has been started switch off the engine immediately to avoid seizure If when the engine is running the engine oil level...

Page 106: ...R ALUMINIUM ENGINES up to the level previously indicated Coolant quantity XXF 250 XEF 250 0 93 L 0 98 US qt 0 82 Imp qt Coolant quantity XXF 450 XEF 450 1 03 L 1 09 US qt 0 91 Imp qt Do not add additives or other substances and use the products recommended in the RECOMMENDED PRODUCTS TABLE section Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for alumi...

Page 107: ... cause rapid wear and possible engine damage Remove the initial part of the seat 1 Loosen the quick fastener screw 3 and remove the air filter case cover 2 Turn the plates 6 in direction A Remove the air filter guide 7 Remove the filtering element 8 from the air filter guide Remove the guide 9 from the filtering element Remove the gasket 10 from the filtering element Remove the two ribs 4 located ...

Page 108: ...g element Install guide 8 on the filtering element Install filtering element 9 on guide 10 Then install the guide air filter assembly on the vehicle Make sure that the two projections A at the rear side of the vehicle on the air filter guide are securely fitted into the two slots B in the air filter case Turn the plates 6 to the original position Install the filter casing cover 2 making sure that ...

Page 109: ...ver Align the top dead centre notch TDC A on the flywheel with the reference B on the left crankcase cover Align the notch C of the exhaust camshaft and the notch D of the intake camshaft with the cylinder head plane Align the crankshaft and camshaft references simultaneously It is possible to be in a situation where the crankshaft is aligned with the references while the camshafts are not In this...

Page 110: ...he frame using the metal wire Remove camshafts 9 and 10 from the head Installation XXF 250 XEF250 versions Check that the top dead centre notch TDC A on the flywheel is aligned with the reference B on the left crankcase cover If not align it by turning the crankshaft counter clockwise Remove bolts 5 of the camshaft supports following a crossed pattern starting from the outside to the inside Remove...

Page 111: ... the camshafts and timing the engine do not rotate the crankshaft Damage and or incorrect engine timing may occur Installthecamshaftbearingguidesandcamshaftsupports Apply engine oil to the threads and contact surfaces of the camshaft support bolts install them and tighten them to the specified torque Perform the tightening operation in two three steps following the diagram shown in the figure Theb...

Page 112: ... references are correctly aligned with the references on the left crankcase cover and cylinder head Refit the spark plug and valve cover Reassemble Fuel tank air filter casing right and left conveyors seat Removal XXF 450 XEF450 versions Remove Seat left and right conveyors air filter casing fuel tank Remove the spark plug and valve cover Remove timing reference cap 1 and crankshaft access cap 2 I...

Page 113: ...ft and camshaft references simultaneously It is possible to be in a situation where the crankshaft is aligned with the references while the camshafts are not In this case it is necessary to make the crankshaft move one more complete revolution Remove the timing chain tensioner cap 3 Remove the timing chain tensioner fixing screws 4 then remove the timing chain tensioner from the vehicle Remove bol...

Page 114: ...ockets and tie it to the frame using the metal wire Remove camshafts 9 and 10 from the head Installation XXF 450 XEF450 versions Check that the top dead centre notch TDC A on the flywheel is aligned with the reference B on the left crankcase cover If not align it by turning the crankshaft counter clockwise Install the intake and exhaust camshafts in the head Install the timing chain 1 on the sproc...

Page 115: ...oltsofthecamshaftsupportsmustbetightened evenly to prevent damage to the camshaft head or camshaft supports Camshaft support bolt 10 Nm 1 0 m kg 7 4 ft lb Install the timing chain tensioner operating as described below Press the tensioner rod with your fingers at the same time using a flat thin blade screwdriver turn the rod clockwise until it is in the fully closed position For XXF 450 version on...

Page 116: ... 4 ft lb Release the screwdriver and check that the tensioner rod comes out smoothly and easily Install the gasket 4 and the timing chain tensioner cap 5 Timing chain tensioner cap 6 Nm 0 6 m kg 4 4 ft lb Rotate the crankshaft counter clockwise for several turns checking that the movement is smooth and free of interference Check that the crankshaft and camshaft references are correctly aligned wit...

Page 117: ...lve clearance XXF 250 XEF 250 0 12 0 19mm 0 0047 0 0075 in Intake valve clearance XXF 450 XEF 450 0 10 0 17mm 0 0039 0 0067 in Exhaust valve clearance XXF 250 XEF 250 0 17 0 24mm 0 0067 0 0094 in Exhaust valve clearance XXF 450 XEF 450 0 15 0 22mm 0 0059 0 0087 in Adjustment Check that the crankshaft and camshaft references are correctly aligned with the references on the left crankcase cover and ...

Page 118: ...he value of the originally installed plates convert the last digit of the value according to the following table Example Plate number 148 Rounded value 150 Last digit of pad number Rounded value 0 0 1 0 2 0 4 5 5 5 6 5 8 10 9 10 Install the new adjustment plates 4 and valve lifters 5 on the relevant valves DO NOT force plates and or valve lifters into their housings during installation Apply molyb...

Page 119: ...eck XXF 250 XEF 250 versions Remove carbon deposits using a rounded scraper Take care to avoid damaging the spark plug threads Do not use a sharp instrument Avoid scratching the aluminum Check the head for damage and or cracks if any replace the head Check the water circuit if there is encrustation and or rust replace the head Measurethedeformationofthehead ifitdoesnotconform to specifications lev...

Page 120: ...The head bolts tightening must be completed in four steps as described below 1st Phase Tighten the head bolts to the specified torque by performing the operation in two three steps following the diagram shown in the figure Head bolts 1 4 30 Nm 3 0 m kg 22 ft lb 2nd Phase Remove a single bolt following the tightening order Apply molybdenum disulphide grease again to the thread and contact surface o...

Page 121: ...450 XEF 450 versions Remove carbon deposits using a rounded scraper Take care to avoid damaging the spark plug threads Do not use a sharp instrument Avoid scratching the aluminum Check the head for damage and or cracks if any replace the head Check the water circuit if there is encrustation and or rust replace the head Measurethedeformationofthehead ifitdoesnotconform to specifications level the h...

Page 122: ...ighten the bolt to the specified torque Head bolts 1 23 Nm 2 3 m kg 17 ft lb Using a marker pen mark a reference between bolt 1 and head 2 Tighten the bolt by turning it 90 in relation to the initial reference Head bolt 1 Specified angle 90 Repeat steps 2 operations for bolts 2 3 4 Perform the 2nd Phase operations one bolt at a time Remove the bolts in the order used for tightening then tighten th...

Page 123: ... Do not use a hammer to pull out the pin in case the operation is difficult to use a special puller Cylinder check Remove carbon deposits using a rounded scraper Do not use a sharp instrument Avoid scratching the aluminum Check the internal surface of the cylinder if damaged grind or replace Measure the cylinder bore in parallel D1 D3 D5 to and at right angles to the crankshaft D2 D4 D6 Then find ...

Page 124: ... 0 16 in Piston diameter XXF 450 XEF 450 96 955 96 970mm 3 8171 3 8177 in Measuring point B from the lower side of the piston skirt XXF 450 XEF 450 9 0mm 0 35 in If the diameter does not comply with the specifications replace the cylinder piston and segments all together Finally calculate the clearance between cylinder and piston Clearance Cylinder C bore Piston diameter Clearance between piston a...

Page 125: ...manufacturer s numbers are facing upwards Lubricate piston 1 and pin 2 then install them on the connecting rod Make sure that the piston reference A is facing the exhaust rear side of the vehicle Install seeger 3 in the relative housings on the piston Make sure that the end of the seeger C is not near the notches in the piston Install the centering pins gasket and cylinder previously lubricated wi...

Page 126: ...fing cartridge inside it Insert a new cartridge then replace the end cap on the silencer Refit the cover and secure the cover end cap silencer assembly with new breakstem rivets A correct and regular maintenance of the soundproofing element guarantees the best performance of the vehicle and allows it to be driven on the road and or in approved circuits 4 9 CLUTCH Clutch removal Remove the clutch c...

Page 127: ...ve the pressure plate 1 Remove the thrust bearing 1 the ball 2 and the thrust rod 3 Remove the plates from the clutch Bend the tab of the clutch hub nut lock washer XXF 450 XEF 450 ONLY Lock the clutch hub 1 with the universal locking tool 2 and unscrew the nut 3 Remove the clutch bolts and springs following a cross pattern ...

Page 128: ...ge replace them Check the driven gear of the primary transmission for circumferential clearance and or damage to the teeth If it has one or both defects replace it Measure the free length A of the clutch springs If not in accordance with specifications replace the springs all together Clutch spring free length XXF 250 XEF 250 44 00 mm 1 73 in Minimum limit 41 80 mm 1 65 in Clutch spring free lengt...

Page 129: ...F 450 Install nut 1 lock the clutch hub with universal locking tool 2 and tighten the nut to the specified torque Nut clutch boss XXF 250 XEF 250 95 Nm 9 5 m kg 70 ft lb Nut clutch boss XXF 450 XEF 450 75 Nm 7 5 m kg 55 ft lb Apply engine oil to the thread and contact surfaces of the clutch hub nut Measure the thickness of friction discs 1 and 2 If not in accordance with specifications replace the...

Page 130: ... discs 2 alternately on the clutch hub starting and ending with a friction disc Install the friction plates in the clutch hub aligning the grooves a on each friction plate with each other XEF 250 version ONLY Install friction discs and clutch discs 4 alternately on the clutch hub starting and ending with a friction disc Install friction discs in this order 1 friction disc 1 identification colour B...

Page 131: ...hub starting and ending with a friction disc Install friction discs in this order 1 friction disk 1 x3 2 friction disk 3 identification colour a violet x3 3 friction disk 1 x2 Apply engine oil to the friction and clutch discs Install thrust rod 1 the ball 2 and thrust bearing 3 Install the thrust plate 1 Install the springs and bolts of the clutch and tighten them following a cross pattern Bolt cl...

Page 132: ...MAINTENANCE 4 Strokes Edition 00 2022 131 4 1 2 1 Install the clutch crankcase 1 and bolts 2 Tighten them following a cross pattern Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb Install a new gasket 1 XXF 250 XEF 250 Install a new O ring 1 XXF 450 XEF 450 ...

Page 133: ...nd left If play is present adjust the steering head Steering play adjustment Remove the front number plate handlebars upper fork plate and the washer on the steering sleeve Loosen the lock nut 1 on the steering ring nut using a ring nut spanner 2 Start tightening the steering ring nut 3 with a ring nut spanner and a torque spanner 4 to the specified torque Initial clamping of the handlebar ring nu...

Page 134: ...nd grease the linkage bearings periodically 4 13 WHEELS Spokes check and tightening The following procedure applies to all spokes of both wheels Check that the spokes are not broken or deformed if they are they must be replaced Check the tension of the spokes by tapping on them with a screwdriver A well tightened spoke will emit a light tinkling tone whilealooseonewillemitadeaftone Inthecaseofaloo...

Page 135: ...ct to the wheel hub If there are any anomalies proceed with the correction by pulling the spokes Check that the wheel bearings do not have axial clearance If there is change the bearings If there are cracks or splits in the rim channels it is necessary to replace them Never try to repair the wheel rims 4 14 BRAKE PADS Replace the front brake pads Remove the pad pin plug 1 Loosen the pad pin 2 Unsc...

Page 136: ... calliper B Temporarily tighten the pads pin 2 Install the brake calliper 5 and tighten the relevant bolts to the specified torque Tighten the pad pin 2 and insert the relative cap previously removed Bolt brake caliper 28 Nm 2 8 m kg 20 ft lb Brake pad pin 17 Nm 1 7 m kg 13 ft lb Replace the rear brake pads Remove the protection 1 and the pad pin plug 2 Remove the pad pin and brake pads 4 ...

Page 137: ...emove the rear wheel 4 and the brake calliper 5 Remove the pad pin 6 and brake pads 7 Install the brake pads 8 with the relative protrusions A in the recesses B of the brake calliper Temporarily tighten the pads pin 3 Install the brake caliper 5 and rear wheel 4 Tighten the pad pin 3 and install the pad pin plug Installa the protector 1 ...

Page 138: ...nsure uniform wear of the components and a longer service life of the components 4 15 TYRES Check the tire while it is cold Model version Front tyre standard pressure Rear tyre standard pressure XXF 250 100 kPa 1 00 kgf cm2 15 psi 100 kPa 1 00 kgf cm2 15 psi XEF 250 with race use configuration 100 kPa 1 00 kgf cm2 15 psi 100 kPa 1 00 kgf cm2 15 psi XEF 250 with road use configuration 200 kPa 2 00 ...

Page 139: ...er towel and lubricate the chain to prevent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfaces Avoid combination cleanerwaxes as they may contain abrasives 9 After completing the above start the engine and allow it to idle for several minutes 4 18 LONG TIME VEHICLE INACTIVITY If your machine ...

Page 140: ...4 Maintenance USE AND MAINTENANCE MANUAL CHAPTER 4 MAINTENANCE 4 Strokes Edition 00 2022 139 4 ...

Page 141: ...ler strictly before the end of the warranty period If the last warranty day happens to be on Sunday or other holiday the last valid warranty day is to be considered the first available working day after the holiday All vehicles produced by FANTIC MOTOR are guaranteed without technical and production defects for the warranty period of 24 months with no limitation on mileage or operation hours This ...

Page 142: ... request the dispatch of the protested parts or to appoint a competent person There is no further warranty obligation for parts replaced free of charge or warranty services performed free of charge For components that have been replaced within the warranty period the warranty ends when the vehicle warranty expires Other forms of warranty established by the user with the dealer will not be recogniz...

Page 143: ...CE DATE AND NUMBER FIRST REGISTRATION DATE REGISTRATION PLATE NUMBER USER DATA Name and Surname or Business Name Address Zip Code City Country Phone Number E Mail Address Variation of User name address Keep the data in this handbook up to date Fill in any changes of address or change of user or owner of the vehicle If all the spaces are already used ask your Dealer for a new Warranty Manual Filled...

Page 144: ... Dealer s stamp Hours Date Invoice No Routine maintenance Main maintenance Spark plug Air filter Next service 3 Dealer s stamp Hours Date Invoice No Routine maintenance Main maintenance Spark plug Air filter Next service 4 Dealer s stamp Hours Date Invoice No Routine maintenance Main maintenance Spark plug Air filter Next service 5 Dealer s stamp Hours Date Invoice No Routine maintenance Main main...

Page 145: ...intenance Main maintenance Spark plug Air filter Next service 11 Dealer s stamp Hours Date Invoice No Routine maintenance Main maintenance Spark plug Air filter Next service 12 Dealer s stamp Hours Date Invoice No Routine maintenance Main maintenance Spark plug Air filter Next service 13 Dealer s stamp Hours Date Invoice No Routine maintenance Main maintenance Spark plug Air filter Next service 14...

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