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1. General information

USE AND MAINTENANCE MANUAL

CHAPTER 1

GENERAL INFORMATION

2-Strokes - Edition 01 / 2023

90/90-21

80/100-21

120/90-18
140/80-18

ON-ROAD USE OFF-ROAD USE

PRESSURE [kPa]

AXLE

SIZE

200
200
220
220

100
100
100
100

E10

PETROL FUEL TYPE

Summary of Contents for XX 125

Page 1: ...manuale di uso e manutenzione e n READ THIS MANUALE CAREFULLY BEFORE OPERATING THIS VEHICLE CODE 10288005...

Page 2: ...ntenance 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 ve...

Page 3: ...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 mo...

Page 4: ...bles XX 125 and XE 125 versions 26 Tightening torque tables XX 250 version 30 1 10 Maintenance limits 34 Engine XX 125 and XE 125 versions 34 Engine XX 250 version 36 Chassis XX 125 and XE 125 version...

Page 5: ...ock XX 125 XX 250 versions 71 Fuel cock XE 125 version 71 Starter knob choke 71 Sidestand only for XE 125 version 71 Locking device only for XE 125 version 72 2 7 Dashboard only XE 125 version 73 Inst...

Page 6: ...92 Relationship with throttle opening XE 125 version 93 Carburetor setting parts XE 125 version 93 Jet needle adjustment XX 250 version 95 Relationship with throttle opening XX 250 version 95 Carbure...

Page 7: ...installation XX 250 version 124 Exhaust valve installation XX 125 XE 125 versions 126 Cylinder installation XX 250 version 127 Cylinder installation XX 125 XE 125 versions 128 Head installation 129 4...

Page 8: ...n 146 Fantic 24 month commercial warranty 146 1 Warranty content 146 2 Effectiveness 147 3 Exclusions 147 4 Disputes 147 FANTIC 3 MONTH OFF ROAD COMMERCIAL WARRANTY 147 5 Warranty content 147 6 Effect...

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 indica...

Page 10: ...ap 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 11: ...ments 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...

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 deterge...

Page 13: ...are 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 punc...

Page 14: ...TION 2 Strokes Edition 01 2023 13 1 5 1 2 3 4 6 1 6 LOCATION OF IMPORTANT LABELS 1 Pressurised gas hazard label 2 Usable petrol quality label ONLY XE 125 3 Chassis number punching ONLY XE 125 4 Vehicl...

Page 15: ...AINTENANCE MANUAL CHAPTER 1 GENERAL INFORMATION 2 Strokes Edition 01 2023 14 5 90 90 21 80 100 21 120 90 18 140 80 18 ON ROAD USE OFF ROAD USE PRESSURE kPa AXLE SIZE 200 200 220 220 100 100 100 100 6...

Page 16: ...INFORMATION 2 Strokes Edition 01 2023 15 1 1 2 6 5 7 3 4 1 7 VEHICLE COMPONENT LOCATION Handlebar components XX 125 version Ref Component 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Thro...

Page 17: ...14 18 15 16 17 19 8 9 10 13 11 12 Right and left side components XX 125 version Ref Component 8 Kickstarter lever 9 Fuel tank 10 Radiator 11 Coolant drain bolt 12 Check bolt Transmission oil level 13...

Page 18: ...4 10 11 12 9 8 5 7 6 Handlebar components XE 125 version Ref Component 1 High beam flashing button 2 Clutch lever 3 ADJUST button 4 SELECT button 5 Engine stop switch 6 Front brake lever 7 Throttle g...

Page 19: ...0 21 22 24 13 14 15 18 16 17 Right and left side components XE 125 version Ref Component 13 Kickstarter lever 14 Fuel tank 15 Radiator 16 Coolant drain bolt 17 Check bolt Transmission oil level 18 Rea...

Page 20: ...APTER 1 GENERAL INFORMATION 2 Strokes Edition 01 2023 19 1 1 2 7 6 5 3 4 Handlebar components XX 250 version Ref Component 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Rad...

Page 21: ...15 16 17 19 8 9 10 13 11 12 Right and left side components XX 250 version Rif Componente 8 Kickstarter lever 9 Fuel tank 10 Radiator 11 Coolant drain bolt 12 Check bolt Transmission oil level 13 Rear...

Page 22: ...ase XX 125 XE 125 1445 mm 56 9 in 1485 mm 58 5 in Minimum ground clearance XX 125 XE 125 365 mm 14 37 in 320 mm 12 6 in Weight in running order XX 125 XE 125 94 kg 207 0 lb 100 kg 220 6 lb Weight at f...

Page 23: ...5 XE 125 Reserve amount XE 125 Premium unleaded gasoline only E10 acceptable 8 0 L 1 76 Imp gal 2 11 US gal 9 0 L 1 98 Imp gal 2 38 US gal 2 0 L 0 44 Imp gal 0 53 US gal Carburetor Type Manufacturer X...

Page 24: ...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 2 bar 200 kPa 29 PSI 2 5 bar 250 kPa 36 PSI 1 bar 100...

Page 25: ...66 4 x 72 0 mm 2 61 x 2 83 in Compression ratio XX 250 8 9 10 6 1 Starting system Kickstarter Lubrication system Premix 30 1 Mixture oil Premix 30 1 API TC JASO FD ISO L EGD Transmission oil Recommen...

Page 26: ...inal equipment Front Rear Front rear inflation pressure 80 100 21 PIRELLI MX 32 MID SOFT 110 90 19 PIRELLI MX32 MID SOFT 1 bar 100 kPa 10 15 PSI Brake Front brake type Operation Rear brake type Operat...

Page 27: ...1 lb ft Air filter element M6 1 2 0 N m 0 20 kgf m 1 5 lb ft Carburetor joint bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Carburetor joint clamp M4 1 2 3 N m 0 23 kgf m 1 7 lb ft Air filter case joint clamp...

Page 28: ...ng ring nut M28 1 Refer to TIP Damper assembly front fork M51 2 30 N m 3 0 kgf m 22 lb ft Inner tube and adjuster M22 2 55 N m 5 5 kgf m 41 lb ft Base valve front fork M42 2 29 N m 2 9 kgf m 21 lb ft...

Page 29: ...de M10 1 64 N m 6 4 kgf m 47 lb ft Engine bracket nut upper side M8 2 34 N m 3 4 kgf m 25 lb ft Engine bracket nut lower side M8 1 34 N m 3 4 kgf m 25 lb ft Pivot shaft nut M16 1 85 N m 8 5 kgf m 63 l...

Page 30: ...25 only M10 1 25 N m 2 5 kgf m 18 lb ft TIP Steering ring nut 1 First tighten the steering ring nut approximately 38 N m 3 8 kgf m 28 lb ft by using the steering nut wrench then loosen the steering ri...

Page 31: ...f m 7 4 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Radiator guard bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp M6 8 1 5 N m 0 15...

Page 32: ...kgf m 8 9 lb ft Neutral switch screw M5 2 4 0 N m 0 40 kgf m 3 0 lb ft Chassis marked portion shall be checked for torque tightening after break in or before each race Elemento Filettatura Quantit Cop...

Page 33: ...m 1 1 lb ft Rear brake hose union bolt M10 2 30 N m 3 0 kgf m 22 lb ft Rear wheel axle nut M20 1 125 N m 12 5 kgf m 92 lb ft Rear wheel sprocket nut M8 6 42 N m 4 2 kgf m 31 lb ft Nipple sproke 72 2...

Page 34: ...5 2 lb ft Fuel tank bracket bolt M6 4 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 19 N m 1 9 kgf m 14 lb ft Side cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Air scoop bolt fuel tank M6 4 7 N m 0 7 kgf m 5...

Page 35: ...Lateral piston ring clearance 0 035 0 070 mm 0 0014 0 0028 in 1 20 mm 0 0472 in 0 10 mm 0 0039 in Crankshaft Crankshaft assembly width 55 90 55 95 mm 2 201 2 203 in 0 030 mm 0 0012 in Clutch Clutch le...

Page 36: ...Main jet M J Approved version Racing configuration version Full throttle air jet Taper pin Approved version Racing configuration version Taper jet Notch Idle throttle outlet Idle throttle jet Bypass...

Page 37: ...earance 0 030 0 065 mm 0 0012 0 0026 in 0 030 0 065 mm 0 0012 0 0026 in 0 70 mm 0 0276 in 0 10 mm 0 0039 in 0 70 mm 0 0276 in 0 10 mm 0 0039 in Crankshaft Crankshaft assembly width 59 95 60 00 mm 2 36...

Page 38: ...opening turns Valve seat size Starter jet 1 Booster jet Float height Throttle grip clearance PWK38 x 1 1P86 40 190 200 N3 EW 3 2 9 6 7 0 8 55 1 5 2 and 1 4 3 8 85 50 6 5 mm 0 26 in 3 0 5 0 mm 0 12 0 2...

Page 39: ...position STD XX 125 XE 125 Adjustment value from the start position Hard Mechanical adjustable type Click 20 11 10 0 Compression damping Adjusting system Unit for adjustment Adjustment value from the...

Page 40: ...125 XE 125 Adjustment value from the start position Hard Click 20 12 14 0 Swingarm Swingarm free play limit End Side clearance 1 0 mm 0 04 in 0 2 0 9 mm 0 01 0 04 in Wheel Front wheel type Rear wheel...

Page 41: ...diameter Pump plunger inside diameter left Brake fluid type 0 15 mm 0 0059 in 9 52 mm 0 37 in 25 4 mm 25 4 mm 1 in 1 in DOT 4 2 5 mm 0 10 in 1 0 mm 0 04 in Rear disc brake Brake pedal position Brake...

Page 42: ...start position STD XX 250 Adjustment value from the start position Hard Mechanical adjustable type Click 20 12 0 Compression damping Adjusting system Unit for adjustment Adjustment value from the sta...

Page 43: ...n Hard Click 20 12 0 Swingarm Swingarm free play limit End Side clearance 1 0 mm 0 04 in 0 2 0 9 mm 0 01 0 04 in Wheel Front wheel type Rear wheel type Front rim size material Rear rim size material X...

Page 44: ...up coil resistance Charge coil resistance 1 Charge coil resistance 2 CDI Capacitive Discharge Ignition 0 50 mm 0 02 in 248 0 372 0 720 0 1080 0 44 0 66 0 Ignition coil Primary winding resistance Seco...

Page 45: ...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 prima...

Page 46: ...X 125 version The following table lists all the components in the wiring diagram and their numbering Number Description of the electrical component 1 Engine stop switch 2 CDI unit 3 Ignition coil 4 Ma...

Page 47: ...LINE 12V GND Killswitch Sel MAP RPM Out Pickup POS Phase HV Phase LV 1 Pickup NEG Phase LV 2 Quickshifter V ref TPS H2O Temp Neutral Solenoid COIL 1 2 3 GND OBD CDI 4 12V 5 6 K LINE N NB N R S S R N...

Page 48: ...tive battery pole 6 Fuse 1 7 5 A 7 Fuse 2 5 A 8 Capacitor 9 Voltage regulator 10 Magnet flywheel 11 Pick Up 12 Lights remote control switch 13 Speed sensor 14 Rear right turn signal 15 Tail light 16 R...

Page 49: ...ion 01 2023 48 25 27 1 2 28 29 30 31 3 24 21 32 22 23 26 A B C D E G H F J K K LINE CAN H CAN L VBATT GND CAN L CAN H K LINE COIL KILL PICKUP GND GND 12V LIGHT RELAY MIL TPS V_REF MAP SEL POWERJET V_R...

Page 50: ...ND MAINTENANCE MANUAL CHAPTER 1 GENERAL INFORMATION 2 Strokes Edition 01 2023 49 1 4 5 SPEED GND NEUTRAL MIL 12V GND RIGHT LEFT HIGH BEAM 24 9 11 8 7 6 12 13 14 15 16 17 18 19 20 10 A B C D E G H F J...

Page 51: ...ponents XX 250 version The following table lists all the components in the wiring diagram and their numbering Number Description of the electrical component 1 Engine stop switch 2 CDI unit 3 Ignition...

Page 52: ...LINE 12V GND Killswitch Sel MAP RPM Out Pickup POS Phase HT Phase LT 1 Pickup NEG Phase LT 2 NEUTRAL TPS V ref H2O Temp Quickshifter Solenoid COIL 1 2 3 GND OBD CDI 4 12V 5 6 K LINE N L N R S S R N L...

Page 53: ...nd 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 XE 125 VERSION ONLY The system protection fus...

Page 54: ...t Transmission chain 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 Fu...

Page 55: ...reference to the list below The timely execution of the service and the relevant documentation is necessary for the correct use of the warranty Maintenance table XX 125 version Item After break in Ev...

Page 56: ...fiber When the exhaust sound becomes louder or when a performance drop is felt Crankshaft Inspect and clean Check the crankshaft for carbon deposits and damage Carburetor Inspect adjust and clean Spa...

Page 57: ...e oil Replace oil seal Replace dust seal Rear shock absorber Inspect and adjust Lubricate after rain ride Molybdenum disulfide grease Retighten Drive chain guide and rollers Inspect Check for wear or...

Page 58: ...lace Cylinder head Inspect carbon deposits and eliminate them Inspect and clean Check gasket Retighten Cylinder Inspect and clean Inspect score marks Replace Inspect wear YPVS Inspect and clean Inspec...

Page 59: ...ses Outside nuts and bolts Retighten Air filter Clean and lubricate Use the Air Filter Special Oil for foam air filters Replace Frame Clean and inspect Fuel tank cock Clean and inspect Brakes Adjust l...

Page 60: ...num disulfide grease Sidestand version XE 125 Racing Lubricate Lithium base grease Relay arm connecting rod Inspect lubricate and retighten Molybdenum disulfide grease Steering head Inspect free play...

Page 61: ...and leakage Inspect hoses Check radiator cap operation Replace coolant every two years Outside nuts and bolts Retighten Retighten Air filter Clean lubricate Clean lubricate Replace Frame Clean inspect...

Page 62: ...rs As required Tire wheels Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket...

Page 63: ...place Piston pin small end bearing Inspect Replace Cylinder head Inspect carbon deposits and eliminate them Inspect and clean Check gasket Retighten Replace Replace the gasket Cylinder Inspect and cle...

Page 64: ...r carbon deposits and damage Carburetor Inspect adjust and clean Spark plug Inspect and clean Replace Drive chain Use chain lube Lubricate slack alignment Chain slack 48 0 58 0 mm 1 89 2 28 in Replace...

Page 65: ...hock absorber Inspect and adjust Lubricate after rain ride Molybdenum disulfide grease Retighten Drive chain guide and rollers Inspect Check for wear or damage and replace if necessary Swingarm Inspec...

Page 66: ...1 General information USE AND MAINTENANCE MANUAL CHAPTER 1 GENERAL INFORMATION 2 Strokes Edition 01 2023 65 1...

Page 67: ...age page 138 Cables wires Check that the clutch and throttle cables move smoothly Check that they are not caught when the handlebars are turned or when the front forks travel up and down Muffler Check...

Page 68: ...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 th...

Page 69: ...ebar Continue pushing the engine stop switch till the engine comes to a stop 2 6 MAIN COMPONENTS Engine stop switch XX 125 XX 250 versions The engine stop switch 1 is located on the left handlebar Con...

Page 70: ...ore starting Shift pedal XX 250 version The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine...

Page 71: ...on Switch XX 125 XX 250 versions By means of switch 1 on the right handlebar it is possible to select two different engine mappings which modify the throttle response and the performance of the vehicl...

Page 72: ...will not flow Always return the lever to this position when the engine is not running 2 ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this po...

Page 73: ...THE VEHICLE 2 Strokes Edition 01 2023 72 1 Locking device only for XE 125 version This device 1 operated by the vehicle keys allows the rotation of the rim so it can be mechanically locked It is recom...

Page 74: ...3 Speedometer Display range 0 360km h 0 225 MPH 4 Speedometer Display unit km h MPH 5 Odo meter Display range 0 99999 km mile automatically reset after 99999 km mile Display unit 1 km mile 6 Trip met...

Page 75: ...e Select button while on main screen to switch from Clock to Stopwatch Press and hold the Select button for 3 seconds to alternate 12 24 hour modes If 24 hour mode is chosen then the AM PM symbol will...

Page 76: ...from odometer to trip A While on odometer screen press and hold the Adjust button for 3 seconds to change the speed unit Press the Adjust button to switch from trip A to trip B Press and hold the Adju...

Page 77: ...our meter to hour meter A Press the Adjust button to switch from hour meter A to hour meter B Press and hold the Adjust button for 3 seconds to reset the hour meter A Press the Adjust button to exit f...

Page 78: ...ng 1000 mm Use the valve stem as the starting point and the terminal point to measure the wheel circumference with a measuring tape Example the tire circumference setting is changed from 1000 mm to 13...

Page 79: ...value and sensing point setting screen From switch to screen Press the Select button to enter the clock Hour setting The clock hour setting Example the hours have to be set to 14 Press the Select but...

Page 80: ...al thumb switch If Auto option is chosen press Adjust button to exit the Stop watch setup Default value AUTO If Manual mode SW switch option is chosen press Adjust button to enter the menu then Select...

Page 81: ...oil light setting Press the Adjust button to move the cursor to the digit to be set If OFF is chosen then press the Adjust button to exit the maintenace oil light setting From switch to screen Press...

Page 82: ...le USE AND MAINTENANCE MANUAL CHAPTER 2 USE OF THE VEHICLE 2 Strokes Edition 01 2023 81 2 Back to the main screen Then press and hold both the Adjust and Select buttons 3 seconds to exit and go back t...

Page 83: ...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 l...

Page 84: ...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...

Page 85: ...HROTTLE 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 clearance A 3 0 5 0 mm 0 12 0 20 in...

Page 86: ...and thoroughly warm it up Turn the throttle stop screw 1 until the engine runs at the lowest possible speed Screwing it in increases idle speed unscrewing it decreases XX 250 Version Start the engine...

Page 87: ...hemintheoppositedirection itispossible to change the front rear off set of the handlebar position By installing the lower mounts in the opposite direction the amount of front rear offset of the handle...

Page 88: ...nd engine seizure may occur If the mixture is too rich the spark plugs will get wet with oil making it impossible to use the engine at full rpm or in the worst case the engine may stop The richness of...

Page 89: ...rburettor and normal spark plug run two or three laps of the circuit and check the smooth running of the engine and the spark plug colour Colour Condition of spark plug Normal Insulator is dry and bur...

Page 90: ...t Standard carburation setting XE 125 version with Racing configuration Pilot jet 60 07868005 Main jet 162 07917005 Jet needle NYCF 2 09013001 2 of 5 notches Pilot air screw 1 turns open Power Jet 35...

Page 91: ...n setting XX 125 version Pilot jet 62 07867005 Main jet 162 07917005 Jet needle NYCF 09013001 3 of 5 notches Pilot air screw 1 turns open Power jet 35 08995001 Standard carburation setting XX 250 vers...

Page 92: ...larger jet size produces a richer mixture while a smaller size produces a leaner mixture Standard Power Jet XX 125 version 35 XX 250 version 50 Adjusting the pilot air screw The air fuel mixture rati...

Page 93: ...groove position Should the engine be hard to run smoothly at intermediate speeds the jet needle 1 must be adjusted If the mixture is too rich or too lean at intermediate speed operation irregular engi...

Page 94: ...the clip Therefore the fuel flow is balanced at each stage of the throttle opening by a combination of the diameter of the straight portion of the taper pin the initial position of the taper and the p...

Page 95: ...3 Size Part number Rich Standard 4 0 05810005 Lean 4 25 05811005 Jet needle Jet needle 4 Size Part number Rich NYEH 09003001 NYDH 09004001 NYCH 09005001 NYFH 09006001 NYEG 09007001 NYDG 09008001 NYCG...

Page 96: ...t D 0 5 groove variation Relationship with throttle opening XX 250 version The flow of fuel through the main system of the carburettor is controlled by the full jet and then further regulated by the a...

Page 97: ...7908005 Standard 190 07907005 Rich 195 08673005 Pilot jet Pilot jet Size Part number Lean 38 07876005 40 07875005 42 07874005 45 07873005 48 07872005 50 07871005 52 07866005 Standard 55 07870005 58 07...

Page 98: ...t D 0 5 groove variation Relationship with throttle opening XX 125 version The flow of fuel through the main system of the carburettor is controlled by the full jet and then further regulated by the a...

Page 99: ...07914005 172 07913005 Rich 175 07912005 Pilot jet Pilot jet Size Part number Lean 50 07871005 52 07866005 55 07870005 58 07869005 60 07868005 62 07867005 65 08988001 68 08989001 70 08990001 72 0899100...

Page 100: ...USTMENTS 2 Strokes Edition 01 2023 99 3 Jet needle Size Part number NYFG 09010001 NYEF 09011001 NYDF 09012001 NYCF 09013001 NYFF 09014001 NYEE 09015001 NYDE 09016001 NYCE 09017001 NYFE 09018001 NYED 0...

Page 101: ...Lower jet needle clip position 1 groove down The clip position is the jet needle groove onwhichtheclipisinstalled Thepositions are numbered from the top If a change in the clip position 1 groove is ef...

Page 102: ...3 Adjustments USE AND MAINTENANCE MANUAL CHAPTER 3 ADJUSTMENTS 2 Strokes Edition 01 2023 101 3...

Page 103: ...ustment 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 compr...

Page 104: ...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 105: ...rd setting From all closed open 10 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 106: ...n the register of 1 1 2 1 6 turns XE 125 version standard setting From all closed open the register of 1 5 8 1 6 turns XX 250 version standard setting From all closed open the register of 1 3 8 1 6 tu...

Page 107: ...he distance B between the centre of the rear wheel axle and the reference on the rear mudguard Standard value 90 100mm Rear shock absorber sinking adjustment SAG XX 125 XX 250 version Place a kickstan...

Page 108: ...ard 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...

Page 109: ...ightening the wheel axle nut push the wheel forward to ensure that there is no clearance between the adjusters and the wheel axle plates Rear wheel axle nut 125 Nm 12 5 m kg 92 ft lb Chain adjusters l...

Page 110: ...3 Adjustments USE AND MAINTENANCE MANUAL CHAPTER 3 ADJUSTMENTS 2 Strokes Edition 01 2023 109 3...

Page 111: ...dholdituponupright position by placing the suitable stand under the engine Check the transmission oil level by removing control bolt 1 If oil leaks the level is correct while if it does not add oil fr...

Page 112: ...oil removing the drain bolt 1 and the filler cap 2 Install a new aluminium washer to the drain bolt 1 and install it in its housing Fill the crankcase from the appropriate opening with transmission o...

Page 113: ...ed Coolant quantity XX 125 XE 125 versions 0 90 L 0 95 US qt 0 79 Imp qt Coolant quantity XX 250 version 1 20 L 1 27 US qt 1 06 Imp qt Do not add additives or other substances and use the products rec...

Page 114: ...filter support Grasp the air filter support and pull it outwards to disconnect the second anchor point Remove the complete air filter support 4 3 AIR FILTER Proper air filter maintenance is the bigges...

Page 115: ...rtridge and blowing it with compressed air Apply air filter oil to the cartridge press it to remove the excess oil The cartridge must be damp but not wet Assemble the air filter on the support by carr...

Page 116: ...nce of the spark plug electrodes A using a thickness gauge If different from the standard value proceed with the adjustment Standard spark plug electrodes gap A 0 6 0 7 mm 0 024 0 028 in Clean the gas...

Page 117: ...Remove the cylinder nuts 1 in sequence and following a crossed pattern then remove the cylinder from the crankcases Remove a pin seeger 2 then remove the pin 3 the piston and roller bearing of the co...

Page 118: ...25 versions Remove the spark plug Remove the engine bracket 1 the bracket fastening bolts 2 and the engine fastening bolt 3 Remove the head nuts and the copper washers in sequence and following a cros...

Page 119: ...eger cover the crankcase with a clean cloth to prevent the seeger from falling into it Do not use a hammer to pull out the pin in case the operation is difficult to use a special puller Head check Rem...

Page 120: ...n 66 345 66 355 mm 2 6120 2 6124 in XX 250 version Cylinder check Remove carbon deposits using a rounded scraper Do not use a sharp instrument Avoid scratching the aluminum Check the internal surface...

Page 121: ...0 0018 in XX 125 XE 125 versions 0 100 mm 0 0039 in 0 040 0 060 mm 0 0016 0 0024 in XX 250 versione Checking the piston and cylinder combination Check the notch on cylinder A Check the notch on pisto...

Page 122: ...e the clearance between the ends of the segments if it is not in accordance with the specifications replace the segments all together Standard Limit Distance between ends of piston rings installed 0 7...

Page 123: ...rbon deposits check for wear and or damage if present replace the components Remove carbon deposits from the surfaces of the exhaust valve seats Do not use a sharp instrument Avoid scratching the alum...

Page 124: ...ng bushings 3 a new cylinder gasket 1 and the connecting rod head roller bearing 2 Apply the engine oil onto the bearing crankshaft and connecting rod and connecting rod big end washers Install the ga...

Page 125: ...exhaust valve 1 Install the secondary exhaust valve bracket 2 and bolts 3 Valves bracket fastening bolt 6 Nm 0 6 m kg 4 4 ft lb Install the exhaust valve with notch a facing upwards Apply molybdenum...

Page 126: ...eys Main valve support screw 4 Nm 0 4 m kg 3 0 ft lb Secondary valve pulley screw 4 Nm 0 4 m kg 3 0 ft lb Install new O rings 1 Install the secondary valve cover 2 on the right and left sides Tighten...

Page 127: ...5 8 ft lb Install the spring 1 on lever 2 Then install the spring lever assembly in the cylinder with the retainer A facing inwards Install the collar 3 the valve stem 4 the valve holder 5 and the lev...

Page 128: ...Nm 0 5 m kgf 3 7 ft lb Install the cover screws 3 Install the YPVS vent with the opening of clamp B facing back Cylinder installation XX 250 version Apply engine oil to piston 1 piston rings 2 and cy...

Page 129: ...ocking pin to avoid damaging the exhaust valve components Pushrod nut 4 5 Nm 0 45 m kg 3 3 ft lb Install a new exhaust valve cover gasket Install the exhaust valve cover 1 and the related fastening bo...

Page 130: ...od bolt 4 Install a new exhaust valve cover gasket Install the exhaust valve cover 1 and the related fastening bolts Bolt power valve housing 4 Nm 0 4 m kg 2 9 ft lb Head installation Install the new...

Page 131: ...ylinder head XX 250 version 25 Nm 2 5 m kg 18 ft lb Nut cylinder head XX 125 XE 125 versions 28 Nm 2 8 m kg 20 ft lb Install the engine bracket 1 upper bolts 2 and lower bolt 3 Engine bracket upper bo...

Page 132: ...3 131 4 1 3 5 2 4 1 2 1 2 XX 125 XE 125 1 1 2 XX 250 Remove bolts 1 and springs 2 of the clutch following a cross pattern Remove the pressure plate 1 XX 125 XE 125 versions Remove the thrust bearing 1...

Page 133: ...the clutch elements Check 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 te...

Page 134: ...h XX 250 version 50 00 mm 1 97 in Minimum limit 48 00 mm 1 89 in Measure the thickness of the driving plates If not in accordance with the specifications replace the plate Friction plate thickness 2 9...

Page 135: ...tool 3 and tighten the nut 2 Nut clutch boss XX 125 XE 125 versions 80 Nm 8 0 m kg 58 ft lb Nut clutch boss XX 250 version 75 Nm 7 5 m kg 55 ft lb Straighten the lock washer tab 1 Install alternately...

Page 136: ...XE 125 versions Install the push rod 1 ball 2 and thrust bearing 3 XX 250 version Install the push rod 1 and the thrust bearing 2 Install the pushrod with the smaller end a facing yourself Install the...

Page 137: ...2 4 6 1 2 2 1 1 XX 125 XE 125 1 XX 250 XX 250 version Install a new O ring 1 on the clutch housing Install the clutch crankcase 1 and bolts 2 Tighten them following a cross pattern Bolt clutch cover 1...

Page 138: ...to the right and left If play is present adjust the steering head Steering play adjustment Remove the front number plate the upper fork plate and the handlebar Loosen the lock nut 1 of the steering ri...

Page 139: ...ighten them to the specified torque To ensure the best operation and durability of the rear shock absorber linkage it is recommended to check clean and grease the linkage bearings periodically Nut 2 5...

Page 140: ...ench to the specified torque Spokes XX 125 and XE 125 versions 2 5 Nm 0 25 m kg 1 8 ft lb Spokes XX 250 version 2 5 Nm 0 25 m kg 1 8 ft lb Be sure to tighten the spokes before and after the running in...

Page 141: ...he pad pin 2 unscrew the fixing bolts then remove the brake caliper 3 from the fork Remove the pad pin and brake pads 4 Install the brake pads 4 with their protrusions A in the recesses of the brake c...

Page 142: ...iper 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...

Page 143: ...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...

Page 144: ...t of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 12 BRAKE FLUID Check the front b...

Page 145: ...he pinion and crown teeth If they 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...

Page 146: ...event rust 11 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 12 Automotive wax may be applied to all painted or chromed surfaces Avoid combination cleanerwaxes as...

Page 147: ...y in which the purchase took place in the European territory in compliance with EU Directive n 2019 771 1 Warranty content 1 1 Fanticwarrantsthequality theabsenceofdefectsandtheproperoperationofitspro...

Page 148: ...roduct see http fantic com 3 Exclusions 3 1 The following are excluded from this warranty Routine maintenance Malfunctions due to normal wear and tear tyres inner tubes chain brake discs brake pads ru...

Page 149: ...ular maintenance if required has not been carried out by a Fantic Service Centre If product serial numbers or VIN have been removed or tampered with from the product 6 5 During the warranty period the...

Page 150: ...work allow the motorcycle to cool down to avoid burns Self locking nuts once removed must be replaced by new nuts When removing bolts and nuts secured with threadlocking fluid these must be refitted...

Page 151: ...E 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...

Page 152: ...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 153: ...ntenance 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 Dat...

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Fantic XX 125, Use And Maintenance Manual

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Summary of Contents for XX 125

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