CSC RX3 User manual

MOTORCYCLES
MOTORCYCLES
RX3 SERVICE MANUAL

CSCRX3ServiceManual
www.CSCMotorcycles.com
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Contents
Foreword.......................................................................................................................................................3
MotorcycleDescription.................................................................................................................................4
MaintenanceCautionsandWarnings...........................................................................................................5
PartsandComponentsCleaning...................................................................................................................5
PartsInspection............................................................................................................................................6
MaintenanceAdjustments............................................................................................................................6
RecommendedTools....................................................................................................................................7
MotorcycleSpecifications.............................................................................................................................7
MotorcycleMaintenanceSchedule..............................................................................................................8
TorqueValues...............................................................................................................................................8
UnpackingandSetup....................................................................................................................................9
TopCaseInstallation.....................................................................................................................................9
RearviewMirrorInstallation.........................................................................................................................9
WindshieldInstallation.................................................................................................................................9
Fuel..............................................................................................................................................................10
Inspection....................................................................................................................................................10
FrameandBody..........................................................................................................................................11
Brakes..........................................................................................................................................................12
InspectingandReplacingtheBrakePads...................................................................................................12
ReplacingtheBrakeFluid............................................................................................................................13
BleedingtheBrakes....................................................................................................................................14
InspectingandReplacingtheBrakeDisks...................................................................................................15
BrakeTroubleshooting................................................................................................................................15
PowerTransmission....................................................................................................................................16
ChainDriveSystem.....................................................................................................................................16
ChainLubrication........................................................................................................................................16
ChainAdjustment.......................................................................................................................................16
LubingtheChain.........................................................................................................................................18
SprocketandChainInspection...................................................................................................................19
ChainDriveTroubleshooting......................................................................................................................20
ClutchMaintenance....................................................................................................................................20
ClutchCableReplacementandAdjustment...............................................................................................21
ClutchReplacement....................................................................................................................................23
ClutchTroubleshooting...............................................................................................................................24
Suspension..................................................................................................................................................26
Forks............................................................................................................................................................26
ChangingtheForkOil..................................................................................................................................26
RepairingaLeakingForkSeal......................................................................................................................28
RearShockAbsorber...................................................................................................................................31
SuspensionTroubleshooting.......................................................................................................................32
SteeringSystem..........................................................................................................................................32
SteeringSystemTroubleshooting...............................................................................................................32
Swingarm....................................................................................................................................................33

CSCRX3ServiceManual
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SwingarmTroubleshooting.........................................................................................................................33
WheelsandTires.........................................................................................................................................34
FrontWheelRemoval.................................................................................................................................34
RearWheelRemoval...................................................................................................................................35
WheelandTireInspection..........................................................................................................................36
WheelandTireTroubleshooting................................................................................................................37
FixingFlatTires...........................................................................................................................................37
Engine..........................................................................................................................................................40
EngineBreak‐InProcedure.........................................................................................................................40
OilChanges.................................................................................................................................................40
ValveAdjustment........................................................................................................................................45
EngineTroubleshooting..............................................................................................................................50
FuelSystem.................................................................................................................................................58
FuelSystemMaintenance...........................................................................................................................59
ElectronicFuelInjectionSystem.................................................................................................................61
FuelInjectionSystemOperatingPrinciples................................................................................................61
ElectronicFuelInjectionSystemTroubleshooting.....................................................................................63
IntakeandExhaustSystem.........................................................................................................................64
AirFilterMaintenance................................................................................................................................64
ExhaustSystem...........................................................................................................................................66
IntakeandExhaustSystemTroubleshooting..............................................................................................67
CoolingSystem............................................................................................................................................67
CheckingandAdjustingCoolingFluidLevels..............................................................................................68
FlushingandReplacingtheCoolingFluid...................................................................................................69
CoolingSystemTroubleshooting................................................................................................................71
ControlCables.............................................................................................................................................72
CableTroubleshooting................................................................................................................................73
Instruments.................................................................................................................................................74
InstrumentTroubleshooting.......................................................................................................................75
ElectricalSystem.........................................................................................................................................76
BatteryandBatteryInstallation..................................................................................................................77
AccessoriesConnections.............................................................................................................................78
ElectricalSystemComponentsandLocations............................................................................................78
ElectricalSystemTroubleshooting..............................................................................................................82
AccessoriesInstallation...............................................................................................................................92
MotorcycleGuardBarInstallation..............................................................................................................92
RearRackInstallation..................................................................................................................................94
RearMotorcycleGuardInstallation............................................................................................................94
TopCaseInstallation...................................................................................................................................96
PannierInstallation.....................................................................................................................................97
ElectricalSchematic....................................................................................................................................98
AppendixA‐ServiceChecklists..................................................................................................................99
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CSCRX3ServiceManual
www.CSCMotorcycles.com
3

Foreword

TheRX3ServiceManualprovidesinformationonmaintainingandservicingthemotorcycle.Itincludes
themotorcycle’stechnicalspecifications,performanceparameters,andmaintenanceandadjustment
data.
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Thetechnicalspecifications,performanceparametersandmaintenanceandadjustmentdatalabeledin
themanualarebasedonthelateststatus.

CSCMotorcyclesstocksallRX3motorcycleparts.CSCrecommendsthatyouuseonlypartsand
materialsprovidedbyCSCwhenservicingormaintainingyourmotorcycle.

ThismanualisprovidedfreetoallwhopurchaseanewCSCRXmotorcycle.

ReproductionoftheRX3ServiceManualorpostingitonlinewithoutCSC’spermissionisexpressly
prohibited.

Ifyouhaveanyquestions,pleasecontactCSCMotorcyclesat9094450900or
[email protected].
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CSCRX3ServiceManual
www.CSCMotorcycles.com
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MotorcycleDescription
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TheCSCRX3motorcycleisa250ccadventuretouringmotorcycle.Themotorcyclehasasingle‐cylinder,
4‐stroke,water‐cooledengineanda6‐speedtransmission.Majorcomponentlocationsareidentifiedin
thephotographsbelow.
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RightSide
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LeftSide
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CSCRX3ServiceManual
www.CSCMotorcycles.com
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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.
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Whenworkingonyourmotorcycle,youshouldfollowthisguidance:
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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.
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.
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Themeaningsofthesymbolsinthismanualareasfollows:

Warning

◆ Potentialdanger.Improperoperationmayleadtoinjuryordeath.

Caution

◆ Potentialdanger.Improperoperationmayleadtomotorcycledamage.
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PartsandComponentsCleaning
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Afterpartsaredisassembled,theymayneedtobecleaned.Cleaningmethodsvaryaccordingtothe
characteristicsoftheparts.
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Toremoveoilorgreasecontamination,CSCrecommendsusingSimpleGreenorothersimilar
degreasingagents.
Neverusegasolineasacleaningagent.
Toremovecarbondeposits,usemechanicalorchemicalmethods.Themechanicalmethoduses
awoodenorplasticscraperorbladetoclearthecarbondepositfirst,andthenrinsetheparts
withanappropriatecleaningagent.Thechemicalmethodistosoakthepartsinthecleaning

CSCRX3ServiceManual
www.CSCMotorcycles.com
6
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agentfirst,thencleanthemwithabrush,andthenrinsethemwithhotwater.
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PartsInspection

Partsshouldbeinspectedaftertheyarecleaned.Thepurposeofinspectionistocheckifthepartsneed
toberepairedorreplaced.Therearethreeinspectionmethods:Directinspection,measurement
inspection,anddetectioninspection.

Directinspectiondoesn’trequireanyinstrumentsorothertools.Itchecksandjudgescondition.
Measurementinspectioninspectsforsizechangesandshapechangesofthepartswithgages
andinstrumentstoconfirmtheirdimensions.Thismethodhashighaccuracy,butbeforethe
inspectionyoumustchecktheprecisionofthegagesandinstruments.
Detectioninspectioninvolvesinspectingforhiddendefects.Duringmaintenance,theoil‐
immersedhammeringmethodiscommonlyused,whichissimpleandconvenient.Soakthepart
intheoilforafewminutes,takeitoutandrubitssurfacedry,sprinkletalcumpowderevenly
overthesurface,andknockonitsnon‐workingsurfacegentlywithahammer.Iftheparthasany
cracks,theoilinsidethecrackwillwickoutanddyethetalcumpowderyellow.Ayellowlinewill
appearatthecrack.
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MaintenanceAdjustments
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TheCSCRX3motorcyclerequiresadjustmentsinthefollowingareas:
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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.
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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.
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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.
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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.
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Thevalvesshouldbeadjustedtoagapof0.04mmto0.08mm.ThisServiceManualpresents
theprocedureforadjustingtheRX3motorcycle’svalve.

Tirepressureshouldbemaintainedat33psiforthefronttire,and35psiforthereartire.
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CSCRX3ServiceManual
www.CSCMotorcycles.com
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RecommendedTools
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TheCSCRX3motorcycleincludesabasictoolkitthatisstoredundertherearseat.CSCviewsthese
toolsassuitableforemergencyrepairsonly.CSCsellscustomtoolkitswithprofessionalgradetools;
pleasecontactusat9094450900toordertheRX3customtoolkit.

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:386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, 262mm single disc
Rear Brake: Twin-piston caliper, 258mm single disc
Front Tire and Pressure: 100/90-18, 33 psi
RearTireandPressure:130/70‐17,35psi



CSCRX3ServiceManual
www.CSCMotorcycles.com
8

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RX3ServiceManual
www.CSCMotorcycles.com
9

UnpackingandSetup

WhenyourCSCmotorcycleisdelivered,themotorcycleiscompletelyassembledexceptforthe
windshield,themirrors,andthereartopcase.

Whenthemotorcycleisdelivered,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.

TopCaseInstallation

Securethetopcasetothetopcasemountingplatewiththree4mmAllenheadbolts.Tightenboltsand
installtopcasepadoverboltheadsinbottomoftopcase.


RearviewMirrorInstallation

Installleftandrightrearviewmirrorsonhandlebars.

WindshieldInstallation

ThewindshieldissecuredwithsixAllenheadboltsasshowninthephotobelow.Acapheadnutisused
ontheinsideofthewindshieldforeachAllenheadbolt.


CSCRX3ServiceManual
www.CSCMotorcycles.com
10


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.

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.

CSCRX3ServiceManual
www.CSCMotorcycles.com
11

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.

Theleftbodypanelcanberemovedtoprovideaccesstotheairfilter.

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
Frameisimpacted
andshockedbyroad
Framewelding
detachment
Shakeordrift Weldtheframe
SidesupportDeformationor
fracture
Sidesupportis
normal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
RearrackImpactDeformationor
weldingdetachment
Compromised
placementofitems
Weldorreplacethe
rearrack



CSCRX3ServiceManual
www.CSCMotorcycles.com
12

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single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RX3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andreardiskbrakesutilizedualpistoncalipers.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Allenboltsasshowninthephotosbelow.
Removetheboltssecuringthecalipertotheswingarm.Onetherearcaliperboltsareremoved,slidethe
caliperrearward,liftitoffofthediskrotor,andthenremovetheAllenboltsholdingthebrakepadsin
place.



OncethecaliperAllenboltsareremoved,thepadswillslideout.Notethatthepadsarenotidentical;
theymustbeinstalledinthecorrectorientation.Thepadwiththelargearm(showninthephotoabove)
isoppositethepistons;thepadwithoutthelargearmissituatedagainstthepistons.


CSCRX3ServiceManual
www.CSCMotorcycles.com
13

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.

ReinstalltheAllenboltsinthecaliper,positionthecaliperinitsappropriatelocation,andinstallthe
caliperboltstomountthecalipertotheswingarm.Tightenallfasteners.

Pumptherearbrakepedalseveraltimes.Operatethemotorcycletoassuresatisfactoryrearbrake
performance.

Theprocessforreplacingthefrontbrakepadsissimilartothatdescribedabovefortherearbrake
pads.LoosenthefrontbrakecaliperAllenbolts,andthenremovethefrontbrakecalipermounting
bolts.RemovethecaliperandthenremovetheAllenboltsfromthecaliper.Inspectthefrontbrake
padsandreplaceifnecessary.ReinstalltheAllenbolts,thefrontcaliper,andthecaliperbolts.Tighten
allfasteners.Pumpthefrontbrakeleverseveraltimes.Operatethemotorcycletoassuresatisfactory
frontbrakeperformance.

ReplacingtheBrakeFluid

Youshouldreplacethebrakefluidinthefrontandrear
mastercylindersevery2years.

UseonlyDOT4brakefluid.

WerecommendMaximabrakefluid.

Ifyouneedbrakefluid,callCSCat9094450900andwe
willshipacontainertoyou.

Theprocedureshownhereisfortherearmastercylinder;theprocedureforthefrontmastercylinderis
performedinasimilarmanner.

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.



CSCRX3ServiceManual
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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.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.


Addfreshbrakefluidtothemastercylinder.

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.


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.

Pumpthebrakepedalseveraltimes.Operatethemotorcycletoassuresatisfactorybrakeperformance.

BleedingtheBrakes

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.Again,useonlyDOT4brakefluid.

CSCRX3ServiceManual
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15


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.

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2mm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sixAllenbolts.UseblueLoctitewhenreinstallingtheboltsthatsecurethe
brakedisk.

BrakeTroubleshooting

Braketroubleshootingproceduresaresummarizedbelow.

FrontandRearBrakeTroubleshootingandMaintenance
ItemSymptom Cause VehicleEffectMaintenanceAction
BrakepadReducedbraking
force
Wornbrakepad(s) Longerstopping
distance
Replacebrakepad

CSCRX3ServiceManual
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
ItemSymptom Cause VehicleEffectMaintenanceAction
AirinbrakelinesReducedbraking
force
Airintrusioninto
brakeline
Longerstopping
distance
Bleedbrakes
PulsatingbrakesPulsatingbrakelever Warpedrotordisk Pulsations;longer
stoppingdistance
Measuredisk
runout,replacedisk
rotor
Incorrectrearbrake
leverfreeplay
Brakesappliedtoo
soonorexcessive
pedaltravel
Incorrectrearbrake
leveradjustment
Inadequateor
excessivebrake
pedaltravel
Adjustrearbrake
pedalfreeplay

PowerTransmission

TheRX3usesamanuallyoperatedwetclutchandachaindrivesystem.

ChainDriveSystem

Thissystemconsistsoftheclutch,thecountershaftsprocket,therearsprocket,therearwheel,thedrive
chain,thechainguard,therearaxleadjustors,andthecushdrive.

ChainLubrication

Thedrivechainshouldbelubricatedapproximatelyevery500miles,ormoreoftenifridinginrainyor
dustyconditions.Useonlyaqualitywax‐basedorpetroleumbasedmotorcyclechainlubricant.Ride
themotorcycleforatleast15minutestowarmthechain,andapplythelubricantimmediatelyafter
stopping.Takecarenottospraylubricantontothetireortherearbrake.Donotusethemotorcyclefor
thenext15minutestoallowthelubricanttoseepintothechain.

ChainAdjustment

Adjustingthechainonamotorcycleconsistsoftwojobs:Adjustingchaintensionandaligningtherear
wheel.

Youshouldcheckthechainadjustmentatyourmotorcycle’sfirstscheduledmaintenanceandevery
maintenancethereafter.Thebiggestneedforadjustmentwillmostlikelyoccuratthefirstservice
interval,becausechainsdomostoftheirstretchingintheirfirstseveralhundredmilesofuse.
Thefirststepistocheckchainslack.

Thechainshouldhavebetween¾ofaninchand1¼inchofslack.Measurethechaintensionbyflexing
thelowerportionofthechainupanddownonthebottomrun(betweenthefrontandrearsprockets)
andmeasuringtheamountof“play”fromtoptobottom.CSCrecommendsperformingthischeckwith
norideronthebikeandthemotorcycleonthesidestand.

Themeasurementapproachisshowninthephotosbelow.


CSCRX3ServiceManual
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
Toadjustthechaintension,loosen(butdonotremove)therearaxle,andloosenthechainadjustorson
bothaftendsoftheswingarm.Notethattherearaxleboltandnutaredifferentsizes.Theboltheadis
18mmontheleftsideofthebike,andtherearaxlenutis17mmontherightsideofthebike.


Next,loosenthechainadjustorsonbothsidesofthe
swingarm.

Theseadjustorseachhavetwo13mmnuts,oneoneachside
oftheadjustmentplate,asshowninthephotototheright.

Notethatinthephotototheright,therearaxleadjustornuts
havealreadybeenloosened.

Movetherearaxleeitherforwardorrearwardusingtherearaxleadjustornutswhilesimultaneously
positioningtherearaxlesuchthatthedesiredchaintensionisachieved,andrearwheelisaligned.Note
therearenowashersbetweentheinsidenutandwhereitbottomsagainsttheendoftheswingarm,and
thatthereisaflatwasherandalockwasherbetweentheoutsidenutandtheendoftheswingarm.

Toattaincorrectalignmentrearwheelalignment,therearetwoapproaches(measuringthedistance
betweentheswingarmpivotpointandtherearaxle,oraligningtherearaxleadjustorswithscribelines
ontheswingarm).


CSCRX3ServiceManual
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18

Tomeasurethedistancebetweenthecenteroftheswingarmpivotpointandthecenteroftherearaxle,
seethephotosbelow.


Toaligntherearaxleusingtheswingarm
scribelines,adjusttherearaxleadjustors
suchthattherearaxleadjustorsonboth
sidesofthemotorcycleareinthesame
positionwithrespecttotheswingarmscribe
lines.


Oncetherearaxleisalignedandchaintensionisadjusted,tightentherearaxlenutandallfourrearaxle
adjustornuts.

LubingtheChain

Youshouldlubricateyourchainapproximatelyevery500miles,orattheendofalongdayofriding.You
shouldlubethechainmoreoftenifyourideintherainorindustyconditions.Lubethechainassoonas
youstopridingwhilethechainisstillwarm,asthiswillallowthelubricanttowickintothechain.It’s
easiertolubethechainifyourRX3hastheoptionalcenterstand,butifitdoesn’t,it’sstilleasytodo.

Holdaragunderthelowerchainrunandspraythe
lubedirectlyontothechain.

Pushthebikebackwardafewfeettoexposemoreof
thechain(ifyourbikedoesnothavethecenterstand)
andlubethechain.

Ifyoubikehasthecenterstand,rotatetherearwheel
withthebikeonthecenterstandtoexposeallpartsof
thechainasyoulubeit.Lubetheentirechain.
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CSCRX3ServiceManual
www.CSCMotorcycles.com
19
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Don’tletthelubegetonthetire,anddon’tshootspraylubricantthroughthespokesandgetthelubeon
therearbrake.Don’tridethemotorcycleforatleast15minutesafterlubingthechain.Thatwillallow
thelubetoseepintothechain.
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CSCstocksbothwaxandpetroleumbasedchainlubes(callusat9094450900topurchasetheseitems).
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SprocketandChainInspection
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TheCSCRX3hasa520O‐ringtypechain,a14toothfrontsprocket,anda44toothrearsprocket.
Ifyoukeepyourchainproperlyadjustedandlubed,thechainandsprocketswilllastmuchlongerthan
theywouldifyoudon’tmaintaintheseitems,buttheystillwon’tlastforever.Youcanexpectthechain
andsprocketstowearmorequicklyifyourideindustyenvironmentsoroffroad.Chainsandsprockets
shouldbereplacedasaset.Donotreplaceonewithoutreplacingtheotherorrapidwearwillresult.
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Removethecountershaftsprocketcoverbyremovingthetwoboltsthatattachittotheengine.You
don’thavetoremovethegearshiftlevertoremovethecountershaftsprocketcover.
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TherearethreeAllenboltsthatsecurethechainguard.Twoarevisibleandeasilyaccessible;thethirdis
hiddenontheforwardportionofthechainguard(onthepartofthechainguardthatisbehindthe
chain).Undothethreeboltsandremovethechainguard.
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Afteryouhaveremovedtheseitems,youcanseethesprocketsandthechain.
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