Fantic XEF 250 Use And Maintenance Manual Download

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13 Motore

4. Maintenance

USE AND MAINTENANCE MANUAL

CHAPTER 4

MAINTENANCE

XEF 250 - Rev01 / 2020

Summary of Contents for XEF 250

Page 1: ...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 v...

Page 2: ...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 model...

Page 3: ...23 Engine 23 Chassis 24 Electrical 27 1 11 Electrical system diagram 28 Cables colour coding 28 Key to the wiring diagram components 29 Wiring diagram 30 1 12 Lamps 32 1 13 Fuses 32 1 14 Recommended...

Page 4: ...ashboard setting values 49 3 Adjustments 50 3 1 Brakes 50 Front brake adjustment 50 Rear brake adjustment 50 3 2 Clutch 51 Adjusting the clutch lever position 51 Adjusting the clutch lever clearance 5...

Page 5: ...l 73 Cylinder check 73 Piston check 73 Installation 74 4 8 Soundproofing 75 4 9 Clutch 75 Clutch removal 75 Check the clutch elements 77 Clutch installation 78 4 10 Steering play control and adjustmen...

Page 6: ...F 250 Rev01 2020 6 Warranty period 89 Warranty conditions 89 Exclusions from the warranty 90 Additional warranty provisions 90 Request for intervention under warranty 90 Warnings for maintenance and c...

Page 7: ...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...

Page 8: ...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...

Page 9: ...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 name...

Page 10: ...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 deterge...

Page 11: ...e equipped with frame and engine identification numbers These numbers that identify the motorcycle model must be mentioned for the request for spare parts 1 4 FRAME NUMBER The frame number A is punche...

Page 12: ...E MANUAL CHAPTER 1 GENERAL INFORMATION XEF 250 Rev01 2020 12 2 1 5 4 3 6 1 6 LOCATION OF IMPORTANT LABELS 1 Pressurised gas hazard label 2 Usable petrol quality label 3 Chassis number punching 4 Vehic...

Page 13: ...NCE MANUAL CHAPTER 1 GENERAL INFORMATION XEF 250 Rev01 2020 13 1 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...

Page 14: ...13 5 7 1 7 VEHICLE COMPONENT LOCATION Handlebar components 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...

Page 15: ...2020 15 1 20 21 22 23 24 25 18 19 17 15 16 Right and left side components Ref Component 15 Headlight 16 Radiator 17 Rear brake pedal 18 Inspection window for oil level check 19 Coolant drain bolt 20 F...

Page 16: ...on oil Recommended type Periodic oil change With oil filter removal Total amount 10W 40 10W 50 15W 40 20W 50 API service SG type or higher JASO standard Ma 0 73 L 0 64 Imp qt 0 73 US qt 0 75 L 0 66 Im...

Page 17: ...I Wheels alternative sizes Front Rear Front inflation pressure road use Rear inflation pressure road use Front rear inflation pressure Racing use 80 100 21 140 80 18 120 90 18 2 bar 200 kPa 29 PSI 2 5...

Page 18: ...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 fa...

Page 19: ...h 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 Dr...

Page 20: ...lb ft Steering stem nut M24 1 145 Nm 14 5 kgf m 107 lb ft Upper handlebar holder bolt M8 4 28 Nm 2 8 kgf m 21 lb ft Lower handlebar holder nut M10 2 40 Nm 4 0 kgf m 30 lb ft Engine stop switch screw M...

Page 21: ...le nut M20 1 125 Nm 12 5 kgf m 92 lb ft Drive chain puller locknut M8 2 21 Nm 2 1 kgf m 15 lb ft Rear wheel sprocket nut M8 6 50 Nm 5 0 kgf m 37 lb ft Nipple spoke 72 2 5 Nm 0 25 kgf m 1 8 lb ft Bolt...

Page 22: ...nk M6 2 7 Nm 0 7 kgf m 5 2 lb ft Air scoop bolt radiator guard M6 4 7 Nm 0 7 kgf m 5 2 lb ft Front fender bolt M6 4 10 Nm 1 0 kgf m 7 4 lb ft Rear fender bolt front side M6 4 7 Nm 0 7 kgf m 5 2 lb ft...

Page 23: ...xhaust Valve stem runout 0 12 0 19 mm 0 0047 0 0075 in 0 17 0 24 mm 0 0067 0 0094 in 0 90 1 10 mm 0 0354 0 0433 in 0 90 1 10 mm 0 0354 0 0433 in 4 975 4 990 mm 0 1959 0 1965 in 4 460 4 475 mm 0 1756 0...

Page 24: ...uide bar 0 050 mm 0 0020 in Kickstarter type Kick clip friction force Kick and mesh P 7 80 11 80 N 0 80 1 20 kg 1 75 2 65 lb Air filter oil grade oiled filter Foam air filter oil or other quality foam...

Page 25: ...tment Adjustment value from the start position Soft Adjustment value from the start position STD Adjustment value from the start position Hard Mechanical adjustable type Click 20 11 0 Rear suspension...

Page 26: ...in 0 50 mm 0 02 in 0 50 mm 0 02 in Drive chain Type Number of links Chain slack Chain length 15 links DID520MXV5 114LL 114 58 0 68 0 mm 2 28 2 28 in 239 3 mm 9 42 in Front brake Front brake lever fre...

Page 27: ...at 5000 r min 0 368 0 552 Rectifier regulator Regulator type Regulated voltage DC Single phase 14 0 14 8 V Indicator light Fuel level warning light Engine trouble warning light 1 7 W 1 7 W Starter mot...

Page 28: ...o 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...

Page 29: ...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...

Page 30: ...AN L RS232 TX NEUTRAL CLUTCH COIL 2 COIL 1 MAP SENS VBATT FAN REL FUEL PUMP LAMB HEAT RPM OUT TPS SIDESTAND CANISTER MAIN REL LAMBDA INJ 2 ATS INJ PASS GND CAN L CAN H OBD CDI WiFi COM SERIAL Vbatt K...

Page 31: ...2020 31 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 F5 5A F4 7 5A F3 2A F2 7 5A F1 7 5A A B C D E H J...

Page 32: ...t 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 removi...

Page 33: ...bricant 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 supe...

Page 34: ...in any deposits Replace 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...

Page 35: ...ased 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 Re...

Page 36: ...irespecialtools 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 Ch...

Page 37: ...lter 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 Brak...

Page 38: ...hird 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 pres...

Page 39: ...up and 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 86 Lubrication Check for smooth...

Page 40: ...to the fuel during refuelling Avoid fuel 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 specif...

Page 41: ...lve completely closed press the ENGINE STOP button on the right handlebar Shift pedal The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the...

Page 42: ...ttle grip 1 is 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 butt...

Page 43: ...g a cold engine requires more air input which is provided by the starter knob 1 Pulling out the knob activates the starter which increases the opening of the throttle valve When the engine has warmed...

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Page 50: ...er 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...

Page 51: ...learance 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 inc...

Page 52: ...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 idli...

Page 53: ...upports 2 Install upper supports 3 and fastening bolts 4 without tightening them definitively Install the handlebar so that the projection A of the upper handlebar holders is positioned at the mark on...

Page 54: ...e 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...

Page 55: ...f 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...

Page 56: ...ternal pressure 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 styl...

Page 57: ...stment From all closed open by 11 clicks by turning towards S Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Compression damping adjustment low...

Page 58: ...rotate the device counter clockwise Standard adjustment From all closed open the register of 1 turn Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damag...

Page 59: ...e to remove all mud and dirt around the ring nut and lock nut If 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...

Page 60: ...ives can cause the clutch to slip Use only types of oil that meet the specifications and do not add additives Drain the engine oil by removing the drain bolt 3 Once all the engine oil in the crankcase...

Page 61: ...5 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 befor...

Page 62: ...ANTICORROSIVE FOR ALUMINIUM ENGINES up to the level previously indicated Coolant quantity 0 93 L 0 98 US qt 0 82 Imp qt Do not add additives or other substances and use the products recommended in the...

Page 63: ...se 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...

Page 64: ...ent 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...

Page 65: ...p 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...

Page 66: ...t to the frame using the metal wire Remove camshafts 9 and 10 from the head Installation Check that the top dead centre notch TDC A on the flywheel is aligned with the reference B on the left crankcas...

Page 67: ...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 con...

Page 68: ...at the movement is smooth and free of interference Check that the crankshaft and camshaft references are correctly aligned with the references on the left crankcase cover and cylinder head Refit the s...

Page 69: ...re valves is not within the standard values proceed with the adjustment Intake valve clearance 0 12 0 19mm 0 0047 0 0075 in Exhaust valve clearance 0 17 0 24mm 0 0067 0 0094 in Adjustment Check that t...

Page 70: ...ue 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...

Page 71: ...ide 4 Check 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...

Page 72: ...ad 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 sho...

Page 73: ...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 fin...

Page 74: ...in 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...

Page 75: ...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 maint...

Page 76: ...0 Rev01 2020 76 1 3 2 1 2 3 1 1 3 5 2 4 6 Remove the pressure plate 1 Remove the thrust bearing 1 the ball 2 and the thrust rod 3 Lock the clutch hub 1 with the universal locking tool 2 and unscrew th...

Page 77: ...the clutch housing and clutch hub for wear cracks damage 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...

Page 78: ...acer 2 the hub 3 and the conical washer 4 Install nut 1 lock the clutch hub with universal locking tool 2 and tighten the nut to the specified torque Nut clutch boss 95 Nm 9 5 m kg 70 ft lb Apply engi...

Page 79: ...discs 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 black x1 2 friction disc 2 identification co...

Page 80: ...1 3 5 2 4 6 Install a new gasket 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 the springs and bolts of the clu...

Page 81: ...head Check that the steering is working evenly by turning it fully to the right and left If play is present adjust the steering head Steering play adjustment Remove the front number plate the upper f...

Page 82: ...ase 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...

Page 83: ...nnel with respect 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 bearing...

Page 84: ...of the brake 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 previo...

Page 85: ...e 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 t...

Page 86: ...are damaged and or excessively worn replace them Always replace chain rim and pinion all together This will ensure uniform wear of the components and a longer service life of the components 4 15 TYRES...

Page 87: ...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 c...

Page 88: ...13 Motore 4 Maintenance USE AND MAINTENANCE MANUAL CHAPTER 4 MAINTENANCE XEF 250 Rev01 2020 88...

Page 89: ...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 pro...

Page 90: ...r 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 vehic...

Page 91: ...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 t...

Page 92: ...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...

Page 93: ...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 Invoic...

Page 94: ...13 Motore 5 Warranty and service USE AND MAINTENANCE MANUAL XEF 250 Rev01 2020 94...

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