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1.

Examine the Carburetor

- Be sure there is fuel flowing into the carburetor.

Is there fuel flowing into the carburetor?

No

- Clogged fuel hose/line or clogged fuel filter

- Clogged Fuel Valve
- Clogged fuel tank breather hose
- Sticking or stuck carburetor float

Yes

- SEE STEP 2

2.

Examine the Spark Plug

- Remove the spark plug and inspect. (see page 44)

Is the spark plug in good working condition?

No

- Flooded engine and/or carburetor

- Choke valve is closed

- Throttle is stuck open
- Dirty or clogged air filter
- Excessively worn piston rings (replace engine)

Yes

- SEE STEP 3

3.

Spark Test

- Test for ignition spark by removing the spark plug and inserting it into the spark plug cap. Place the open end of

the spark plug on a metal part of the engine and kick start the engine. You should see a nice blue spark on the end of the spark
plug. A faint spark will not start the engine.

Is there a good spark?

No

- Fouled or faulty spark plug

- Broken or shorted spark plug wire or spark plug cap
- Broken or shorted ignition coil
- Faulty ignition CDI Box
- Faulty or shorted magneto assembly
- Broken or shorted engine stop switch
- Loose or corroded wires and/or connectors (always clean bad electrical connections)

Yes

- SEE STEP 4

4.

Cylinder Compression Test

- Perform a simple compression test by kick starting the engine slowly. Be sure you have the spark

plug installed. While pushing down on the kick starter slowly, you should feel a very hard firmness that will abruptly soften as the
kick start lever moves further down. No hard firmness in the kick start lever means you have poor compression.

Is the compression normal?

No

- Valve stuck open/seized or improper valve timing (see your Xmotos dealer)

- Worn cylinder wall and/or piston rings (replace engine)
- Leaking or damaged cylinder head gasket (see your Xmotos dealer)

Yes

- SEE STEP 5

5.

Engine Start Condition

- Start the engine by using the normal starting procedure (see page 26)

Does the engine start but then stop quickly afterward?

Yes

- Improper choke operation

- Dirty or improperly adjusted carburetor (Contact your Xmotos Dealer)
- Intake manifold/pipe leak
- Improper ignition timing (see your Xmotos Dealer)
- Dirty or contaminated gasoline

DO NOT TOUCH THE SPARK PLUG OR PLUG CAP

WHILE TRYING TO START THE ENGINE. YOU WILL

RECEIVE AND ELECTRICAL SHOCK WHICH COULD

RESULT IN SERIOUS INJURY OR DEATH.

NOTICE

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Содержание XB21A 2018

Страница 1: ...1 OPERATING INSTRUCTION MANUAL XB21A OWNER S MANUAL DIRT BIKE VER 07 2018 XB21D XB27A PIT BIKE XB27B XB33 XB38 XB87 ENGINE DISPLACEMENT 110 125 FX1 ...

Страница 2: ...uld remain if it is resold This manual contains the latest product information available before printing Koolcnchet reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission 07 2018 Zhejiang Koolcnchet Industry Trade Co LTD ...

Страница 3: ...tos dealer for information IMPORTANT PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELYBEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOURBIKE PROPERLY CONSUMER INFORMATION FOR UNITED STATES Tampering with noise emissions control systems is prohibited Owners are warned that the law prohibits A The removal or rendering inoperative...

Страница 4: ...r warranty service Without limiting the above this warranty is Voided with respect to any product that has been used for rental or commercial purposes or that sustained the following damage Bent or broken frame or swing arm due to abuse Bent or broken wheels due to abuse Bent or broken plastic shrouds due to abuse Any sign of impact accident spin outs or roll over not caused by the condition for w...

Страница 5: ...TER THROTTLE SYSTEM ENGINE IDLE SPEED CLUTCH SYSTEM SPARK PLUG BRAKING SYSTEM BRAKE LEVER ADJUSTMENT BRAKE FLUID CHECK ADDING BRAKE FLUID BRAKE PADS BRAKE SYSTEM BLEEDING SUSPENSION SYSTEM FRONT SUSPENSION INSPECTION FRONT SUSPENSION ADJUSTMENT REAR SUSPENSION INSPECTION REAR SUSPENSION ADJUSTMENT RIMS TIRES SPOKES TIRE AIR PRESSURE TIRE INSPECTION TIRE AND TUBE REPLACEMENT NEW TIRE BREAK IN PERIO...

Страница 6: ... is preceded by a symbol This information is intended to help you avoid damage to your motorcycle and or property around you This manual covers basic maintenance procedures A detailed parts diagram manual is available and it can be purchased separately from Xmotos The parts manual will be helpful to those with the mechanical skills and tools required to service their own motorcycle Whenever you ri...

Страница 7: ...e You must use your own good judgment Safety information will come in a variety of different forms including Safety Labels on the Motorcycle Safety Messages preceded by a safety symbol and one of these signal words Below are the definitions of these three words You WILL be KILLED or SERIOUSLY INJURED if you do not follow instructions You CAN be KILLED or SERIOUSLY INJURED if you do not follow inst...

Страница 8: ...th lights turn signals horn and other features required to drive a motorcycle on public roads The tires are not designed for pavement and will make the motorcycle unstable if it is ridden on pavement If you have to cross a paved road dismount and walk the motorcycle across the road Ride Within Your Limits Never attempt to ride your motorcycle in a manner that is beyond your skill level It takes ti...

Страница 9: ...estions Does your child think through problems and come to logical conclusions Does your child obey your rules when they ride their bicycle If your child makes bad judgments takes un warranted risks and or does not obey your rules they should not ride this motorcycle If you have decided that your child is ready to ride please remember the following points and never let your child ride without a he...

Страница 10: ...You will find that some labels warn you of potential hazards Others will provide important safety and maintenance information Please read them carefully and do not remove them If your label wears off from riding or becomes hard to read contact your Xmotos dealer for a replacement ...

Страница 11: ...lutch brakes and other controls without stopping to look at them Please read this section carefully before you ride your motorcycle This section of the manual will show the location and operation of all the basic controls of your motorcycle Engine Stop Switch Front Brake Lever Throttle ...

Страница 12: ...12 Rear Brake Lever Spark Plug Kick Starter Fuel Cap FuelCCap Brake Drum Drive Chain Fuel Valve Air Filter Brake Disc Side Stand CDI Box Chain Guard ...

Страница 13: ...ite this number in the VIN box on page 3 Engine Model Serial Number The engine model number and serial number is stamped on the left side of the engine under the counter shaft sprocket Write this number is the Engine Number box on page 3 Hand Brake Lever Throttle The hand brake lever and throttle is mounted on the right side of the handlebar ZS154FMH 2 ...

Страница 14: ... installed Fuel Tap OFF In this position the fuel tap is closed No fuel can flow to the carburetor ON In this position the fuel tap in open This means fuel can flow to the carburetor With the lever in this position the tank will be emptied Choke Lever When pulling the choke lever fully toward the top a cylinder in the carburetor is opened Through this cylinder the engine can take in additional fue...

Страница 15: ...d on the right side of the engine Its basic operation is to apply the rear brake to slow or stop the motorcycle Kick Start Lever The kick start lever is mounted on the right side of the engine It is used to start the engine in case the electrical starter system is non functional Side Stand Push the side stand to the ground and tilt the motorcycle to the left Make sure the bike is on solid ground a...

Страница 16: ...Although complete protection is not possible wearing the proper gear can reduce the chance of and severity of injuries when you ride Helmets Eye Protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries A good helmet will be approved by a testing organization independent of the helmet manufacturer and will have a chin strap that ...

Страница 17: ...ructions on drive chain slack adjustment see the Servicing section of this manual Brake Hoses Inspect the brake hoses for leaks and replace if needed Nuts Bolts Inspect all accessible nuts and bolts Tighten then if it is needed Spark Plug Cap Check the spark plug for looseness Tighten if needed Be sure the cap is pushed on the spark plug and it is tight properly Check the following items after you...

Страница 18: ...wing the parts to cool Although it is essential to place some stress on the engine components during break in you must be careful not to load the engine too much Before riding this motorcycle be sure you have read this entire manual up to this point including the section titled Important Safety Information Pg 7 9 Before Riding pg 16 Even if you have ridden other motorcycles in the past take time t...

Страница 19: ...ady to go Starting When the Engine Is Warm 1 Repeat steps 1 2 3 5 6 7 and 8 in section Starting when the engine is cold Starting When the Engine Is Cold 1 Turn the key switch to the ON position 2 Make sure the transmission is in the neutral position 3 Turn the fuel tap to the ON position 4 Lift the choke lever up 5 Press and hold the brake lever on the right side of the handle bar 6 Open the throt...

Страница 20: ...nd push the engine stop switch on the left side of the handle bar For your safety avoid starting or operating the motorcycle in an enclosed area with poor ventilation such as a garage The motorcycle s exhaust gas contains poisonous carbon monoxide which can collect rapidly in an enclosed area and result in illness or death CAUTION DO NOT ride your motorcycle with full load and DO NOT rev up the en...

Страница 21: ... rpm gets too high in a gear you will feel the motorcycle stop accelerating This is another way to know when to up shift Downshift to a lower gear when you feel the engine lugging at a low rpm Downshifting is usually done when you slow down for a turn or when you stop the motorcycle Downshifting into a lower gear can help slow down your motorcycle especially when going down hill However down shift...

Страница 22: ...f this happens release the brake controls and steer straight ahead until you regain control of the motorcycle Once you have control reapply the brakes with less force Generally reduce your speed and complete your braking before you begin a turn Avoid braking or closing the throttle quickly while turning Either of these actions may cause one or both of the wheels to slip Any wheel slip will reduce ...

Страница 23: ... operate the engine 2 Burns From Hot Motorcycle Parts Let the engine and exhaust system cool off before you touch them 3 Injury From Moving Parts Do not run the engine unless instructed to do so Read all instructions before you begin a procedure Make sure you have all of the tools and skills required To help prevent the motorcycle from falling over park it on a firm level surface using the side st...

Страница 24: ...ty for your motorcycle Always perform the pre ride inspection described on page 24 at each scheduled maintenance interval Each item on the maintenance schedule requires some mechanical knowledge You will find that some items in the table marked and may require a higher level of mechanical skill and special tools If you do not feel capable of performing any procedure please consult your nearest Xmo...

Страница 25: ...asoline and be sure you are using the proper octane rating Use of unleaded fuel is recommended because it produces fewer engine deposits and extends the life of the engine and exhaust components Never use stale or contaminated gasoline Never use gasoline that has been mixed with oil Avoid getting dust dirt and water into the fuel tank 1 Before refueling your motorcycle check the fuel hoses for lea...

Страница 26: ... a support stand so that it is not leaning to either the right or left 4 Remove the oil filler cap wipe it clean and insert it back in to its place but DO NOT screw it back in 5 Check that the oil level is within the 1 2 hash marks on the dip stick as in Fig 1 6 If the oil level is at or near the upper mark 1 you do not need to add oil 7 If the oil level is at or near the lower mark 2 you need to ...

Страница 27: ...Install and tighten the drain bolt with a new sealing washer to 11ft lbs 15Nm 9 It is recommended to replace the oil after every 15 hours of riding 10 Fill the crankcase with the recommended oil only 11 Install the oil filler cap 12 Check the oil level by following the steps in Checking Adding Oil Improper disposal of drained fluids is harmful to the environment NOTICE Do Not dispose of drained oi...

Страница 28: ...er on to the carburetor 2 Once you have loosened the clamp take out the air filter 3 If the filter has a tear or break in the filter element it must be replaced 4 Once the filter is removed wash it clean with a non flammable cleaning solvent Then wash in hot soapy water rinse well Then allow the filter to dry well 5 When the filter is thoroughly dry spray the filter with a good quality air filter ...

Страница 29: ...play Turning the adjuster in the direction will increase free play 5 Operate the throttle to ensure that it is functioning smoothly and when released it returns completely from fully open to fully closed in all steering positions 6 Inspect the condition of the throttle cable from the throttle down to the carburetor If the cable is kinked or chafed it must be replaced 7 Lubricate the cable with a c...

Страница 30: ...or 3 5 minutes then shut it off 2 Connect a tachometer to the engine 3 Make sure the transmission is in neutral gear 4 Keep the motorcycle in an upright position 5 Adjust the idle speed with the stop screw 6 To increase the idle turn the screw to 7 To decrease the idle turn the screw to 8 The idle screw might look like and located on different sides of the motorcycle depending on which model you h...

Страница 31: ...e free play A second adjustment may be needed if the clutch is slipping or if the clutch will not engage Follow the steps below carefully to perform the adjustment If the clutch is slipping you will need to decrease the amount of clutch engagement If you squeeze the clutch lever all the way and the clutch still will not engage you need to increase the engagement Clutch Free play 10 15 mm 1 Loosen ...

Страница 32: ...hased at your local auto parts store The spark plug gap should be 0 5 0 8mm Always check the gap of anew spark plug before you install it 8 Be sure all dirt has been cleaned from the threads Install the spark plug by hand This will prevent stripping and or cross threading of the threads Use a5 8 in socket or wrench to securely tighten the spark plug Do not over or under tighten the spark plug When...

Страница 33: ...insert the brake lever back in to the coupler insert the pin and check the lever height If it is the desired height tighten the lock nut reinstall the pin and then the cotter pin Make sure the cotter pin is opened so that the pin does not fall out 1 Check the level of the brake fluid by looking in the sight glass periodically with the motorcycle in the upright position 2 The fluid level should not...

Страница 34: ...rake hose and brake caliper for leaks 1 Clean all dirt and dust from the master cylinder cap 2 Remove the cap screws with a Phillips head screwdriver 3 Remove the cap Be careful not to damage the diaphragm gasket that is seated under the cap 4 Add the required amount in to the master cylinder DO NOT OVERFILL Always use fresh fluid sealed bottle 5 Replace the cap and tighten the screws securely 6 P...

Страница 35: ...t your nearest Xmotos dealer for assistance or schedule your motorcycle for servicing Because the brake system utilizes fluid any air bubbles inside the brake system will cause you to lose braking efficiency Air generally enters the brake system when the motorcycle sits unused for long periods of time Air will also enter the system if you have a leaking brake hose brake caliper or master cylinder ...

Страница 36: ...e triple clamp bolts are tight 6 Examine the metal for any cracks wear or other damage 7 Be sure there is no free play in the steering head 1 On the top of the fork you will find a screw head or a clicker 2 It will have the writing S H meaning Soft Hard or the marks or This is the Compression Adjuster 3 If you turn the screw toward the H the downward action of the fork will harden Alternatively if...

Страница 37: ...tion Your Xmotos dealer is the most qualified to determine whether or not replacement parts or service is required Your motorcycle is new Break it in for about 2 hours with the original settings before attempting adjustments 1 Move the motorcycle by bouncing it up and down to check for smooth suspension action 2 Check for a broken or damaged spring 3 Check the shock absorber for a bent center shaf...

Страница 38: ...you are familiar with the settings on your suspension you can quickly and easily adjust them to suit different terrain For example you make the setting position for when you ride in the sand dunes But when you are riding on your local motocross track you know to tune it to a different setting A The rear shock absorber has one adjuster for both compression and rebound B By turning the adjuster cloc...

Страница 39: ... life and riding comfort Generally speaking under inflated tires will wear unevenly and adversely affect handling Under inflated tires are also more likely to fail from being overheated and can cause wheel damage on rocky terrain Overinflated tires will cause the motorcycle to ride harshly are prone to failure from surface hazards and wear unevenly Make sure the valve stem caps are secure if neede...

Страница 40: ...not have the same reliability as a new one and could fail while riding For more information on a temporary repair see the section titled Resolving the Unexpected Always use replacement tubes that are the same size as the original We recommend that you have tubes changed at your local Xmotos dealer or your local motorcycle shop Replacing a tube requires removal and installation of the wheel Anytime...

Страница 41: ... movement should measure between 08 10 mm 2 Repeat step 1 along several points of the drive chain The slack should remain constant through out If it is not some links may be kinked and binding Lubricating the chain will often stop this 3 Inspect the drive chain for the following damaged rollers loose pins dry or rusted links kinked or binding links and excessive wear Replace the chain loose pins o...

Страница 42: ...be replaced before your next ride 3 If the roller has been worn down then the roller must be replaced 4 If you cannot or do not know how to replace the roller take the motorcycle to an Xmotos dealer for service THE USE OF A NEW CHAIN ON A WORN SPROCKET WILL CAUSE RAPID CHAIN WEAR NOTICE NEVER RIDE YOUR MOTORCYCLE IF THE ROLLERS ARE WORN EXCESSIVELY CAUTION ALWAYS USE HIGH QUALITY LUBRICANT FOR THE...

Страница 43: ...wear limit has been reached Fig 3 it must be replaced 1 Check the guide slider for wear Fig 2 2 Replace the guide slider if it is worn to the bottom of the wear limit Fig 3 THE SLIDERS MUST BE REPLACED IF WORN DOWN TOO FAR NOTICE Fig 2 Fig 3 ...

Страница 44: ...ise to increase slack 4 Make sure the gap between the adjusting plate and swing arm are the same on both left and right sides 5 Tighten the axle nut to 85ft lbs 115 Nm 6 Re check chain slack and readjust if necessary Commercially prepared chain lubricants may be purchased at most motorcycle shops and should be used instead of motor oil Chain lube or gear oil 80w or 90w is recommended Saturate each...

Страница 45: ...ward wheel rotation 6 Lubricate the chain The master link is the most critical element of drive chain security Master links are reusable as long as they are in excellent condition We recommend installing a new master link when you install a new drive chain You may find it easier to install a new chain by connecting it to the old chain using a master link and pulling the old chain to position the n...

Страница 46: ...mbly Broken or shorted engine stop switch Loose or corroded wires and or connectors always clean bad electrical connections Yes SEE STEP 4 4 Cylinder Compression Test Perform a simple compression test by kick starting the engine slowly Be sure you have the spark plug installed While pushing down on the kick starter slowly you should feel a very hard firmness that will abruptly soften as the kick s...

Страница 47: ...tion Accelerate lightly Does the engine speed increase No Clogged air filter Restricted or clogged fuel line and or fuel filter Clogged muffler spark plug Choke valve is closed Clogged fuel tank breather hose Yes SEE STEP 5 5 Spark Plug inspection Remove the spark plug and inspect see page 44 Is the spark plug in good working condition No Spark plug is not serviced frequently enough Incorrect spar...

Страница 48: ... combustion chamber 11 Ignition Timing Inspection See your local Xmotos dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected Only attempt these procedures if you are qualified and have the proper tools needed Is the ignition timing normal Timing is non adjustable No Faulty CDI ignition box Faulty ignition pulse generator Yes SEE STEP 12 12 Lubricatio...

Страница 49: ...alified and have the proper tools needed Is the ignition timing normal Timing is non adjustable No Faulty CDI ignition box Faulty ignition pulse generator Yes See your Xmotos dealer to have your motorcycle serviced 1 Examine the Fuel Line Disconnect the fuel hose at the carburetor Is there fuel flowing freely No Clogged fuel hose line or clogged fuel filter Clogged Fuel Valve Clogged fuel tank bre...

Страница 50: ...xcessive wheel bearing play Bent Rim Improperly installed wheel hub Damaged swing arm Bent frame Loose or broken spokes Old tires with dry rot The motorcycle pulls to one side Front and rear wheels out of alignment Faulty shock absorber Damaged fork s Bent Swing arm Damaged axel Damaged frame Damaged upper or lower triple clamp ...

Страница 51: ...o make permanent repairs as soon as possible 3 Do not continue riding if you are hurt or if your motorcycle is not in safe riding condition Recommendations for specific problems follow If the engine was not making unusual noises before it quit running and it feels normal when you operate the kick starter you can probably rule out a major mechanical problem First check the fuel system 1 Make sure y...

Страница 52: ...nspect the motorcycle for damage Check the tightness of critical nuts and bolts such as the handle bars control levers brakes and wheels If there is minor damage or you are not sure about possible damage but decide to ride back to your base ride slowly and cautiously Sometimes crash damage is hidden or not immediately apparent Once you get home go over your motorcycle thoroughly and fix any proble...

Страница 53: ...53 ...

Страница 54: ...ear 60 7 45 2 Shock mount lower 48 6 36 1 Kick stand bolt 40 5 30 2 Connecting rod front 60 7 45 2 Linkage connection 64 8 48 2 Name Torque Notes N m ft lbs A Muffler Cover Bolts 24 4 18 2 B Seat Bolts 32 5 24 C Exhaust Mounting Bolt 24 4 18 2 D Sub Frame Bolt lower 33 8 25 2 E Shock Absorber Bolt 46 34 F Sub Frame Bolt upper 47 4 35 2 G Shroud Bolts upper 4 7 3 5 H Shroud Bolts lower 4 7 3 5 J Tr...

Страница 55: ...Apply loctite 243 liquid to threads 3 Apply grease to bolt NOT threads Name Torque Notes N m ft lbs A Engine mount front 35 26 2 B Oil drain cap 17 5 13 1 C Engine mount lower 40 5 30 2 D Sprocket bolts 16 2 12 2 E Swing arm nut 81 60 2 ...

Страница 56: ...eading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature Odometer or Hour Reading km hr Dealer Stamp Date Signature THE FIRST OIL CHANGE MUST BE DONE BEFORE THE FIRST INITIAL RIDE ...

Страница 57: ...You are responsible for presenting your vehicle to an authorized dealer as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days As the vehicle owner you should be aware that you may be denied your warranty coverage if your vehicle or a part has failed due to abuse neglect improper maintenance or unapproved modifications WARRANTY COV...

Страница 58: ...uggested retail price for all warranted parts replaced and labor charges based on the importer s recommend time allowance for the warranty repair and the geographically appropriate hourly labor rate The owner may reasonably be required to keep receipts and failed parts in order to receive compensation This Emission Control System Warranty is in addition to the standard Limited Warranty LIST OF EMI...

Страница 59: ...with an odometer or hour meter where the reading is altered so that actual mileage cannot be readily determined Repairs or replacement as a result of Accident Misuse Use of replacement parts or accessories not conforming to the original specifications which adversely affect performance Physical damage corrosion or defects caused by fire explosions or similar causes beyond the control of the import...

Страница 60: ...60 ...

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