CSC RC3 Instruction Manual

CSC RC3
Ow ner’s and Service
M anual

CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
1

Contents
Foreword.......................................................................................................................................................4
CautionandWarningSymbols......................................................................................................................4
Section1:Owner’sManual..........................................................................................................................5
GeneralMotorcycleSafetyGuidance...........................................................................................................5
InspectionsBeforeRiding.............................................................................................................................6
MotorcycleDescription.................................................................................................................................7
MaintenanceCautionsandWarnings...........................................................................................................8
PartsandComponentsCleaning...................................................................................................................9
MaintenanceAdjustments............................................................................................................................9
MotorcycleSpecifications...........................................................................................................................10
MotorcycleMaintenanceSchedule............................................................................................................11
TorqueValues.............................................................................................................................................11
UnpackingandSetup..................................................................................................................................12
RearviewMirrorInstallation.......................................................................................................................12
Fuel..............................................................................................................................................................12
Inspection....................................................................................................................................................12
FrameandBody..........................................................................................................................................13
BodyPanelRemoval...................................................................................................................................13
Brakes..........................................................................................................................................................15
InspectingandReplacingtheBrakePads...................................................................................................15
ReplacingtheBrakeFluid............................................................................................................................17
BleedingtheBrakes....................................................................................................................................19
InspectingandReplacingtheBrakeDisks...................................................................................................19
BrakeTroubleshooting................................................................................................................................20
PowerTransmission....................................................................................................................................20
ChainAdjustment.......................................................................................................................................20
LubingtheChain.........................................................................................................................................21
SprocketandChainInspection...................................................................................................................22
ChainDriveTroubleshooting......................................................................................................................22
ClutchMaintenance....................................................................................................................................23
ClutchCableReplacementandAdjustment...............................................................................................23
ClutchReplacement....................................................................................................................................24
ClutchTroubleshooting...............................................................................................................................26
Suspension..................................................................................................................................................28
ForkMaintenance.......................................................................................................................................28
RearShockAbsorber...................................................................................................................................31
SuspensionTroubleshooting.......................................................................................................................32
SteeringSystem..........................................................................................................................................32
SteeringSystemTroubleshooting...............................................................................................................32
Swingarm....................................................................................................................................................33
SwingarmTroubleshooting.........................................................................................................................33
WheelsandTires.........................................................................................................................................33
FrontWheelRemoval.................................................................................................................................34

CSCRC3Owner’sandServiceManual
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RearWheelRemoval...................................................................................................................................35
WheelandTireInspection..........................................................................................................................35
WheelandTireTroubleshooting................................................................................................................35
FixingFlatTires...........................................................................................................................................36
LiftingtheMotorcycle.................................................................................................................................37
Engine..........................................................................................................................................................37
EngineBreak‐InProcedure.........................................................................................................................37
OilChanges.................................................................................................................................................38
ValveAdjustment........................................................................................................................................42
EngineTroubleshooting..............................................................................................................................47
FuelSystem.................................................................................................................................................54
FuelSystemMaintenance...........................................................................................................................55
ElectronicFuelInjectionSystem.................................................................................................................56
ElectronicFuelInjectionSystemTroubleshooting.....................................................................................58
IntakeandExhaustSystem.........................................................................................................................59
AirFilterMaintenance................................................................................................................................59
ExhaustSystem...........................................................................................................................................60
IntakeandExhaustSystemTroubleshooting..............................................................................................62
CoolingSystem............................................................................................................................................62
CheckingandAdjustingCoolingFluidLevels..............................................................................................63
FlushingandReplacingtheCoolingFluid...................................................................................................64
CoolingSystemTroubleshooting................................................................................................................65
ControlCables.............................................................................................................................................66
CableTroubleshooting................................................................................................................................66
Instruments.................................................................................................................................................67
InstrumentTroubleshooting.......................................................................................................................68
ElectricalSystem.........................................................................................................................................68
BatteryandBatteryInstallation..................................................................................................................68
AccessoriesConnections.............................................................................................................................69
ElectricalSystemComponentsandLocations............................................................................................69
ElectricalSystemTroubleshooting..............................................................................................................72
ElectricalSchematic....................................................................................................................................82
AppendixA‐ServiceChecklists..................................................................................................................83
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

CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
3

AWordFromSteve

ThankyouforpurchasingthisCSCRC3motorcycle.TheRC3isagreatmotorcycleandweareveryproud
ofit.TheRC3iseasytomaintain,it’sreliable,andit’sfun.You’vemadeawisepurchasedecision.

IwantyoutoknowthatwevaluethetrustandconfidenceyouhaveinCSC.Ourguidingprinciplewill
alwaysbethatourcustomerscomefirst.

WewishyoumanymilesofsafeandenjoyableridingonyournewRC3motorcycle.Ifthere’sanything
wecandotoenhanceyourownershipexperience,pleaseletusknow.

Thankyouagain,

SteveSeidner
FounderandCEO
CSCMotorcycles,LLC
1331W.FoothillBoulevard
Azusa,California91702
9094450900
www.CSCMotorycles.com


CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
4

Foreword

TheRC3Owner’sandServiceManualprovidesinformationonoperatingandmaintainingtheCSCRC3
motorcycle.Itincludesthemotorcycle’stechnicalspecifications,performanceparameters,and
operating,maintenance,andadjustmentdata.ThismanualincludesboththeOwner’sManualandthe
ServiceManual.TheOwner’sManualisincludedinthefirstsectionofthisdocument;theService
Manualinincludedinthesecondsectionofthisdocument.

CSCMotorcyclesstocksallRC3motorcycleparts,andwerecommendthatyouuseonlypartsand
materialsprovidedbyuswhenservicingormaintainingyourmotorcycle.

TheRC3Owner’sandServiceManualisprovidedfreetoallwhopurchaseanewCSCRC3motorcycle.

ReproductionoftheCSCRC3Owner’sandServiceManualorpostingitonlinewithoutCSC’spermission
isexpresslyprohibited.

Ifyouhaveanyquestions,pleasecontactCSCMotorcyclesbycallingusat9094450900orviaemailat
[email protected].


CautionandWarningSymbols

Cautionandwarningsymbolsinthismanualareasfollows:

TheCaution!symbolindicatesaconditionthatmayleadtomotorcycledamage.

TheWarning!symbolindicatesaconditionthatmayleadtoinjuryordeath.




CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
5

Section1:Owner’sManual

GeneralMotorcycleSafetyGuidance

Warning!Donotattempttoridethismotorcycleonpublicroadsifyoudonothaveamotorcycle
license.

Warning!Donotattempttoridethismotorcycleifyoudonotknowhowtorideamotorcycle.

Warning!Alwayswearappropriatemotorcyclegearwhenridingyourmotorcycle.Neverrideyour
motorcyclewithoutwearinganapprovedhelmet,amotorcyclejacket,eyeprotection,gloves,
motorcyclepants,andboots.

Warning!Alwaysremainalertwhileoperatingyourmotorcycle.Payattentiontotrafficconditionsand
theroadsurface.Adjustyourspeedandfollowingdistancestakingthesefactorsintoconsideration.

Warning!Neveroperateyourmotorcyclewhileundertheinfluenceofdrugsoralcohol,orwhensleep
deprived.

Warning!Themotorcycle’scylinder,cylinderhead,andexhaustsystemarehotwhenthemotorcycleis
runningandafterturningitoff.Donottouchtheseitems.

Warning!Alwaysmaintainappropriatetirepressure.Operatingthemotorcyclewithlowtirepressure
willadverselyaffectthemotorcycle’shandling.

Warning!Replaceworntirespromptly.

Warning!Neverattempttolubricatethechainbyrunningtheengine,puttingthemotorcycleingear,
andliftingtherearofthemotorcycle.Lubricatethechainwiththeengineoff.

Warning!Makesurethechokeisfullyopenwhenridingthemotorcycle.

Warning!Donotattempttoreachunderthetanktoopenorclosethechokewhileridingthe
motorcycle.

Warning!Donotoverloadthemotorcycleorloaditunevenly.

Warning!Donotattempttocarrymorethanonepassenger(inadditiontotherider).

Warning!Donotattempttoperform“wheelies.”

Caution!Don’tparkyourmotorcyclefacingdownhillwithoutleavingthemotorcycleingear,oritmay
rollforwardandfalldown.

Caution!Neveroperateyourmotorcyclewithouttheairfilter,themuffler,andallemissions
componentsinplace.Doingsowillreduceperformance,damagetheengine,andvoidyourwarranty.

CSCRC3Owner’sandServiceManual
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6

InspectionsBeforeRiding

Beforeridingyourmotorcycle,youshouldcheckthefollowing:

Bothtiresareappropriatelyinflated.

Neithertirehasnailsnorotherforeignobjectsembeddedinthetreadorthesidewall.

Thecrankcasehasoil.Youcanchecktheoillevelusingthecrankcaseviewingport.

Theturnsignals,thefrontandrearbrakelights,thehorn,andtheheadlightalloperatewhen
commandedtodoso(theignitionswitchmustbeintheONposition).

Thefrontandrearbrakelevershaveadequatefreeplay.

Thefrontandrearbrakesoperate.

Theforksturnfreelyfromsidetoside.

Therearviewmirrorsareadjustedappropriately.

TheenginekillswitchisintheRUNposition.

Thechainhasappropriateslack.

Majorthreadedfastenersaretight.Wealwayshandchecktheaxlenuts,theexhaustheader
nutsandbolts,themufflerboltsandnuts(grabthemufflerandcheckitforanyside‐to‐side
play),thesteeringstemnut,andthefrontandrearcaliperbolts.




CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
7

MotorcycleDescription

TheCSCRC3motorcycleisa250ccsportmotorcycle.Themotorcyclehasasingle‐cylinder,4‐stroke,
water‐cooledengineanda6‐speedtransmission.TheRC3hashydraulicdiskbrakesatthefrontand
rearwheels.Theignitionandforklockislocatedontheupperforktripletee.TheRC3hasa
conventionalchaindrive.Majorcomponentlocationsareidentifiedinthephotographsbelowandin
subsequentsections.

TheRC3hasaconventionalmotorcyclecontrollayout,withtheclutchandshiftingleverontheleftside
ofthemotorcycle,thefrontandrearbrakesoperatedfromtherightsideofthemotorcycle.

Thefuelfillercapislocatedontopofthefueltank.Itisoperatedwiththemotorcycle’signitionswitch.

Theinstrumentslocatedinfrontoftheuppertripletee,etc.

AdditionalinformationoncomponentlocationsisprovidedfurtherinthisOwner’sandServiceManual
wheresuchcomponentlocationsarediscussedinsubsequentsections.

RightSide






CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
8

LeftSide



MaintenanceCautionsandWarnings

Whenyourepairthemotorcycle,pleaseuseoriginalcomponentsandparts,accessories,lubricatingoil
andothermaterialsthataremadeorrecognizedbyCSCMotorcycles.Ifyouuseanypartsor
componentswhicharenotrecognizedorrecommendedbyourcompany,itmayadverselyaffectthe
performance,reliability,orstabilityofyourmotorcycle.

Whenworkingonyourmotorcycle,youshouldfollowthisguidance:

Wheneverthemotorcycleistobereassembledafterdisassembly,washers,seals,andcotter
pinsneedtobereplaced.
Whenyoufastenaboltoranut,youshoulddoitinadiagonalpattern.
Donotuseflammablecleaningfluidtocleancomponentsandparts.
Beforeassemblyoperations,addlubricatingoilorlubricatinggreasetolubricatedsurfaces.
Afterassembly,makesureallpartsareproperlyassembledandtightened.
Stoptheenginewhenrepairingthemotorcycle.
Ifthemaintenanceoperationneedstobedonewhiletheengineisworking,makesurethearea
iswell‐ventilated.
Gasisflammableandcombustible,sodonotsmokeorprovideignitionsourcesintheworkarea.

CSCRC3Owner’sandServiceManual
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9

Thebatterycanliberatehydrogen,whichisflammable.Donotsmoke,igniteormakesparks
nearthebattery,especiallywhenitischarging.
Theelectrolyteofthebatterycontainssulfuricacid.Ifyoureyes,skinorclothesaresplashed
withelectrolyte,rinsethemthoroughlywithwaterandseekimmediatemedicalattention.

PartsandComponentsCleaning

Afterpartsaredisassembled,theymayneedtobecleaned.Cleaningmethodsvaryaccordingtothe
characteristicsoftheparts.

Toremoveoilorgreasecontamination,CSCrecommendsusingSimpleGreenorothersimilar
degreasingagents.
Warning!Neverusegasolineasacleaningagent.

MaintenanceAdjustments

TheCSCRC3motorcyclerequiresadjustmentsinthefollowingareas:

Theclutchmustbeadjustedaccordingtothemaintenanceinstructionsincludedinthismanual.
Themainadjustmentfeaturestheclutchhandlefreetravel(¼to½inch),andtheclutchcable
adjustingmechanism.ThisServiceManualpresentstheprocedureforclutchadjustment.

Adjustmentoftheelectrichornaffectsvolumeandtone.Thevolumeoftheelectrichornis95
to105dB.Ifthevolumeortoneistoohighortoolow,youcanadjustthehornwiththe
adjustingscrewatitsback,asexplainedinthisServiceManual.

Thethrottlecableadjustmentisperformedatthethrottle.Thethrottleshouldhave2to5
degreesoffreerotation.ThisadjustmentispresentedinthisServiceManual.

Thedrivechainisadjustedbypositioningandaligningtherearwheel.Thedrivechainshould
have¾to1¼inchoffreeplay.Thedrivechainadjustmentprocedureisexplainedinthis
ServiceManual.

Thevalvesshouldbeadjustedtoagapof0.04mmto0.08mm.ThisServiceManualpresents
theprocedureforadjustingtheRC3motorcycle’svalve.

Tirepressureshouldbemaintainedat33psiforthefronttire,and35psiforthereartire.



CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
10

MotorcycleSpecifications

AdjustmentSpecifications
ItemAdjustmentLimits
Clutchleverfreeplay(attip)¼to½inch
Throttlefreetravel2‐5degrees
Drivechain¾to1¼inch
Valvegap(atTDC)0.04to0.08mm
Tirepressure(front/rear)33psifront,35psirear

MajorTechnicalSpecifications
Model:singlecylinder,4‐stroke,watercooling,SOHC,inclined,4‐valve
Majorperformanceparameters:
a. 24.8hp@9,000rpm
b. 16.6ft‐lb@7,000rpm
c. Idlespeed:1,5000rpm
Bore×stroke:77mm×53.6mm
Displacement:249.6cc
Compressionratio:11.1:1
Ignitionmode:Capacitiveenergystorage
Sparkadvanceangle:8°BTDC@2,200rpm,37°
@
7,000 rpm
Lubricatingmethod:Pressureplugsplash
Intake&exhaustvalvelash:0.04mmto0.08 mm(coldstate)
Clutchtype:Manual,wetmulti‐plate
Transmission:Constantmeshtwo‐stagedrivewith6speeds
Sparkplugmodel:RG6YC
Fuel:Minimum87octane
Oil:5W40or10W40;useonlymotorcycleoils
Oilcapacity:1.7qt;55.4ounces
Motorcycleweight:335lbs
CoolantSpecification:Ethyleneglycolmixsuitableforaluminumblockengines
Coolantcapacity:2liters
Thermostatopeningtemperature:60±2Ԩ;wideopentemperature:72±2Ԩ
Front Brake: Twin-piston caliper
Rear Brake: Single-piston caliper
Front Tire: 110/70R17
RearTire:140/70R17



CSCRC3Owner’sandServiceManual
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11

MotorcycleMaintenanceSchedule

MaintenanceSchedule
Maintenancetimes

Maintenanceitem
Odometer(miles)
500milesEvery2,500milesEvery5,000miles
Fuelsysteml l
FuelfilterAR/lR/l
Controlsysteml l l
AircleanerelementA/R R R
Sparkpluggapl l l
Valvelashl‐l
TransmissionchainI/L I/L I/L
Batteryl l l
Brakepadwearl l l
Brakingsysteml l l
Stoplampswitchl l l
Headlampdimmerintensityl l l
Mainstandandsidesupportl l l
Frontandrearshockabsorberslll
Nut/bolt/fastenerl l l
Front(rear)wheelbearingslll

Themotorcycleshouldbemaintainedaccordingtothescheduleabove.Thesymbolsaredefinedbelow:

R‐rinsing
A‐inspection
L‐lubrication
l‐inspection,cleaning,adjustment,lubricationorreplacement
Ifyouoperatethemotorcycleindustyareas,themaintenancecycleshouldbeshortened.

TorqueValues

TorqueValues
ItemBoltTorque(ft‐lb)
HandlebarfixedboltM10×1.25 33‐40
FrontwheelaxlenutM14×1.552‐59
RearwheelaxlenutM14×1.5 52‐59
EnginesuspensionboltM10×1.25 33‐40
RearshockabsorberfixingnutM10 33‐40
RearrockershaftnutM12×1.2537‐44
ForkshaftnutM12×1.25 41‐48
ForkshaftnutM10×1.25 33‐40



CSCRC3Owner’sandServiceManual
www.CSCMotorcycles.com
12

UnpackingandSetup

WhenyourCSCmotorcycleisdelivered,themotorcycleiscompletelyassembledexceptfortherear
viewmirrors.

Upondelivery,checktheconditionofthedeliveredcrate.Ifthereareanyanomalies,stopandcallCSC
at9094450900.ChecktheVINnumbersoftheexteriorofthecrate.Comparethesenumberstothe
documentationdeliveredtoyou.Ifthenumbersdon’tmatch,stopandcallCSCat9094450900.

RearviewMirrorInstallation

Installleftandrightrearviewmirrorsonthemotorcyclefairingandadjustthemtoprovideasatisfactory
rearview.


Fuel

Fillwiththefueltankwith87octane(orhigher)gasoline.

Inspection

Performthefollowinginspectionswhenservicingthemotorcycle.

Checktoconfirmallfastenersareproperlytightenedandallcomponentsareinstalledcorrectly
andinanoperationalstate.

Swingthehandlebarsfromsidetosidetomakesuremotionisuninhibited.

CheckchaintensionandrearwheelalignmentinaccordancewiththeChainDrivesectionofthis
ServiceManual.

Insertignitionkeyandturnon.

Checkhornfunction,turnsignals,headlighthighandlowbeam,brakelightsforfrontandrear
brakeactivation,andinstrumentpanelreadout.

CSCRC3Owner’sandServiceManual
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13


Checkoillevelandtirepressure.

Confirmmotorcycleisinneutral.

Placeclutchinandstartmotorcycle.Allowenginetowarm.

Checkbrakeandsuspensionfunction.

Testridemotorcycletoconfirmoperability.

DetailedinspectionchecklistsareincludedinAppendixAofthisShopManual.

FrameandBody

Theframeandbodysubsystemincludesthemotorcycle’ssteelframe,theseat,thebodypanels,the
sidestand,thefootpegs,andthefenders.

Therearseatisremovablebyinsertingandtwistingtheignitionkeyintheleftbodypanelbeneaththe
seat.Thetoolkitisstoredbeneaththerearseat.

Thefrontseatisheldinplacebytwo8mmbolts.Therearseatcanberemovedtoprovideaccesstothe
battery.

BodyPanelRemoval

TheRC3hasseveralpanelsattachedtothemotorcyclewithfasteners.Theseneedtoberemovedto
provideaccesstotheengine,etc.,forsomeofthemaintenanceactivitiesdescribedinthismanual.

Removethefastenerssecuringthelowertankpanelsand
removethepanels.

CSCRC3Owner’sandServiceManual
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14

Removethefastenerssecuringthelowertankpanelsand
removethepanels.
Removeallofthefastenerssecuringthesideandlowerbody
panels.
Removeallofthefastenerssecuringthesideandlowerbody
panels.
Removeallofthefastenerssecuringthesideandlowerbody
panels.

Frameandbodymaintenanceandtroubleshootingguidelinesaresummarizedbelow.

FrameandBodyMaintenanceandTroubleshooting
ItemSymptom Cause VehicleEffect MaintenanceAction
Frame Frameishitorfalls
over
Frameiscurvedor
deformed
Drift Correctorreplacethe
frame
Frameishitorfalls
over
Frameiscrackedor
fractured
MotorcyclecannotdriveWeldorreplacethe
frame

CSCRC3Owner’sandServiceManual
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15

ItemSymptom Cause VehicleEffect MaintenanceAction
Frameisimpacted
andshockedbyroad
Framewelding
detachment
Shakeordrift Weldtheframe
SidesupportDeformationor
fracture
Sidesupportis
abnormalandcannot
return
Noiseandcompromised
parking
Correctorreplacethe
sidesupport
LeftsidecoverImpactLeftsidecover
damaged
Compromised
appearance
Replaceorrepairthe
leftsidecover
Rightside
cover
ImpactRightsidecover
damaged
Compromised
appearance
Replaceorrepairthe
rightsidecover
FrontfenderImpactDeformationor
breakage
Motorcycledriveswitha
noise
Replacethefront
fender
RearfenderImpactDeformationor
breakage
Motorcycledriveswitha
noise
Replacetherear
fender
Frontandrear
seatcushion
ImpactSeatcushion
damaged
Ridingcomfortableness
decreases
Replacethefrontand
rearseatcushion
FrontfootpegImpactDeformationor
breakage
Compromiseddriving
safety
Replacethefootpeg
RearfootpegImpactDeformationor
breakage
ComfortReplacethefootpeg
Rearview
mirror
ImpactDeformationor
breakage
Compromiseddriving
safety
Replacetherearview
mirror

Brakes

Themainfunctionofthebrakesistosloworstopthemotorcycle.Thebrakesconsistofthefrontand
rearbrakesandtheircontrols.Bothfrontandrearbrakesarehydraulically‐actuateddiskbrakes.The
frontbrakeisoperatedbytherighthandandtherearbrakeisoperatedbytherightfoot.

ThissectionoftheRC3ServiceManualcoversthefollowingtopics:

Inspectingandreplacingthebrakepads.
Replacingthebrakefluid.
Bleedingthebrakes.
Inspectingandreplacingthebrakedisks.

InspectingandReplacingtheBrakePads

Thefrontdiskbrakeutilizesdualpistoncalipers;thereardiskbrakeusesasinglepistoncaliper.You
shouldreplacethebrakepadswheneitheronehaslessthan1.5mmofpadthicknessleft,orifthebrake
padsarewornsuchthatthegrooveinthepadisnolongervisible.CSCstocksthebrakepads(callusat
9094450900).Toremovetherearbrakepads,loosentherearbrakecaliperbolts.Removethebolts
securingthecaliper.Oncetherearcaliperboltsareremoved,liftthecaliperoffofthediskrotor,and
thenremovetheboltsholdingthebrakepadsinplace.


CSCRC3Owner’sandServiceManual
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16
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Oncethecaliperboltsareremoved,thepadswillslideout.Inspectthebrakepadstodetermineifthey
arewornbeyondtheirservicelimit(lessthan1.5mmthick).Ifthepadsarewornsuchthatthegrooves
aregone(visibleasverticalslotsinthephotoabove),thepadsshouldbereplaced.
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Reassembleandreinstallthecaliper.Tightenallfasteners.
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Pumptherearbrakepedalseveraltimes.Operatethemotorcycletoassuresatisfactoryrearbrake
performance.
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Theprocessforreplacingthefrontbrakepadsissimilartothatdescribedabovefortherearbrake
pads.Loosenthefrontbrakecaliperbolts,andthenremovethefrontbrakecalipermountingbolts.


CSCRC3Owner’sandServiceManual
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17
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Removethecaliperandthenremovetheboltsfromthecaliper.Inspectthefrontbrakepadsand
replaceifnecessary.Reinstallthecaliperboltsandthecaliper.Tightenallfasteners.Pumpthefront
brakeleverseveraltimes.Operatethemotorcycletoassuresatisfactoryfrontbrakeperformance.
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ReplacingtheBrakeFluid
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Youshouldreplacethebrakefluidinthefrontandrear
mastercylindersevery2years.
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UseonlyDOT4brakefluid.
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WerecommendMaximabrakefluid.
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Ifyouneedbrakefluid,callCSCat9094450900.
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Theprocedureshownhereisfortherearmastercylinder;theprocedureforthefrontmastercylinderis
performedinasimilarmanner.

CSCRC3Owner’sandServiceManual
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18
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Openthemastercylinderbyunscrewingthetwo
screwssecuringthemastercylinder
cover.Removethemastercylindercoverand
placeitinanareawhereitwillnotbecome
contaminated.
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Usingaturkeybasterorothersuctiondevice,removeasmuchofthebrakefluidinthemastercylinder
aspossible.Caution!Exercisecautiontopreventanybrakefluidspillage.Ifanyspillageoccurs,wipeup
thespilledbrakefluidimmediately(itwilldamagepaintedorplasticsurfaces).Removethecaliperbleed
capandattachasmalldiametertubetothecaliperbleedfitting.Routethetubetoareceptacle.(Note:
ThephotosshownherearefortheRX3;theRC3issimilar.)
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Addfreshbrakefluidtothemastercylinder.
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Openthecaliperbleedfittingbyunscrewingitslightly(turnitcounterclockwisetodoso)anddepress
thebrakelevertopumpbrakefluidoutthroughthecaliperbleedfitting.Priortoallowingthebrake
levertoreturn,closethecaliperbleedfittingbyturningitclockwise.
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

CSCRC3Owner’sandServiceManual
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Repeattheprocessuntilfreshbrakefluidexitsthecaliper.Closethecaliperbleedfittingandreplacethe
caliperbleedfittingcap.Addbrakefluidtothemastercylindersuchthattheupperleveliswithin1/8‐
inchofthetop(donotoverfillthemastercylinder).Replacethemastercylindercoverandthescrews
securingittothemastercylinder.Tightenthescrews.
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Pumpthebrakepedalseveraltimes.Operatethemotorcycletoassuresatisfactorybrakeperformance.
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BleedingtheBrakes
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Ifairgetsintothebrakelines,brakingperformancewillbediminished.Youshouldbleedthebrakes
onceeveryyear,anytimethebrakesfeelspongyorsoft,orifthebrakefluiddropsbelowthelevelofthe
mastercylinderviewport.UseonlyDOT4brakefluid.
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Theprocedureissimilartotheprocedureforreplacingthebrakefluid.Openthemastercylinderby
unscrewingthetwoscrewssecuringthemastercylindercover.Removethemastercylindercoverand
placeitinanareawhereitwillnotbecomecontaminated.Removethecaliperbleedcapandattacha
smalldiametertubetothecaliperbleedfitting.Routethetubetoareceptacle.Openthecaliper
bleedfittingbyunscrewingitslightly(turnitcounterclockwisetodoso)anddepressthebrakeleverto
pumpbrakefluidoutthroughthecaliperbleedfitting.Priortoallowingthebrakelevertoreturn,close
thecaliperbleedfittingbyturningitclockwise.Addbrakefluidtothemastercylinderas
necessary.Repeattheprocessuntilthebrakefluidexitingthecaliperisfreeofairbubbles.Closethe
caliperbleedfittingandreplacethefittingcap.Addbrakefluidtothemastercylindersuchthatthe
upperleveliswithin1/8‐inchofthetop(donotoverfillthemastercylinder).Replacethemaster
cylindercoverandthescrewssecuringittothemastercylinder.
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Aftercompletingtheabove,pumptherearbrakepedal(ifyouarebleedingtherearbrake)oroperate
thefrontbrakelever(ifyouarebleedingthefrontbrake)severaltimes.Operatethemotorcycleto
assuresatisfactorybrakeperformance.

InspectingandReplacingtheBrakeDisks

Youshouldreplaceanybrakediskthatiswornbelowservicewearlimitsorifthediskiswarped.You
canmeasurediskthicknessandstraightnesswithoutremovingthewheelfromthemotorcycle.Youwill
needtoremovethewheelifyoureplacethebrakedisk.

Measurethediskthickness.Ifthediskislessthan2mmthick,replacethedisk.

Useadialindicatorwiththewheeloffthegroundtomeasurediskrunout.Spinthewheelandmeasure
runout.Iftherunoutexceeds0.3mm,replacethedisk.Youonlyneedtodothisifthediskappearsto
bevisiblywarped(whichisnotlikely)orifthebrakespulsatewhenapplied.

Youwillhavetoremovethewheelinordertoreplacethedisk.Theprocedureforwheelremovalis
explainedelsewhereinthisServiceManual.

EachdiskissecuredwithAllenbolts.UseblueLoctitewhenreinstallingtheboltsthatsecurethebrake
disk.