Fantic Motor TL 250 Instruction manual
1
WORKSHOP MANUAL
EN
WORKSHOP MANUAL
TL 250
GENERAL WARNINGS
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Fantic Motor reserves the right to amend or make changes, at any time and without prior notice, to the models
described, to specications and to design data, while this will not affect the essential features described and
illustrated herein.
Operators are required to read this manual and to follow the instructions herein to the letter. The manufacturer
is not liable for injury to people and/or damage to property, and is not liable for damage incurred by the product
in the event of failure to observe the instructions featured herein.
No part of this publication may be reduced, reproduced and translated without the permission of Fantic Motor
None of the contents of this manual may be reproduced without the permission of the Manufacturer. Fantic
Motor cannot be held responsible for misprints or omissions. All rights reserved.
Warning concerning the procedure described and the specic safety rules: indicates procedures that must be
followed in order to avoid damage to the vehicle or possible injury to the person repairing the vehicle.
Note providing information on the procedure described and on the vehicle's characteristics: gives useful information
designed to help make the procedure easier and clearer.
Equipment: note advising the user of the need to use special tools for the procedure described.
Measurement: note illustrating the values of one or more measurements to be adhered to or to be checked for the
procedure described.
Torque setting: note illustrating one or more torque setting values referring to the procedure described.
Consumable: note illustrating names, types and/or quantity of consumables (such as oil, fuel, sealants, additives,
etc.) to be used for the procedure described.
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1. FOREWORD
This manual has been compiled by Fantic Motor for use by Fantic Motor dealers and their specialist personnel. It
is presumed that people using this documentation for repairing and servicing Fantic Motor vehicles have a basic
grasp of the principles and mechanical procedures involved in repairing vehicles.
If personnel are unfamiliar with these basics, the resulting repair work or servicing may be inadequate or unsafe.
Fantic Motor has an ongoing policy of product improvement. All Fantic Motor dealers will be notified of any
significant amendments or changes made to the vehicles' characteristics or repair procedures, which will be
published in future editions of the manual.
2. SYMBOL CONVENTIONS USED IN THE MANUAL
This manual features warnings and technical notes preceded by the following symbols depending on the warning's
contents:
The terms right or left always refer to the motorcycle's direction of travel, as though you were sitting on the bike.
WORKSHOP MANUAL
TL 250
WORKSHOP MANUAL
TL 250
CONTENTS
1 Safety rules
2 Maintenance rules
2.1 Maintenance
2.2 Preparation prior to work
2.3 Torque settings
3 Vehicle identication
4 Spare parts
5 Bodywork removal
5.1 Removing the seat
5.2 Removing the rear fender
5.3 Removing the radiator shrouds
5.4 Removing the fuel tank
5.5 Removing the headlight assembly
5.7 Removing the front mudguard
5.8 Removing the licence plate bracket
5.9 Removing the rear subframe
5.10 Removing the kickstand
5.11 Removing the swingarm pivot bolt
6 Dashboard
6.1 Dashboard TL 250 carburettor koso db ex-o2
2 Replacing the battery
3 Dashboard functions
3.1 How to use the Adjust button
3.2 How to use the Select button
3.3 How to use the Adjust + Select X 3 button
3.4 Tyre detection point setup
3.5 Clock setup
6.2 Dashboard koso db-01rn
7 Air lter removal
8 Light bulb changing
8.1 Changing the headlight bulb on the carburettor model
8.2 Changing direction indicator light bulbs
9 Disassembling the forks
9.1 Casa Competizione fork TL 250 carburettor and injection
9.2 Casa Performance fork TL 250 carburettor
9.3 Changing fork oil
9.4 Disassembling the fork legs
10 Braking system
10.1 Front brake
10.2 Rear brake
11 Replacing the brake pads
11.1 Front brake
11.2 Rear brake
11.3 Front oil level
11.4 Rear oil level
11.5 Bleeding the front brake
11.6 Bleeding the rear brake
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WORKSHOP MANUAL
TL 250
12 Adjusting the brakes
12.1 Adjusting the brakes
12.1.1 Front brake
12.1.1 Rear brake
12.2 Adjusting the clutch
12.3 Checking and adjusting steering play
12.4 Chain tensioning
12.5 Headlight beam
12.6 Carburettor
12.6.1 Idling (adjusting idling speed)
13 Removing the engine from the frame
14 Engine maintenance
14.2 Vehicle operation and maintenance on carburettor version
14.3 Section 5 cooling system troubleshooting
15 Electrical devices
15.1 Location of fuses
15.2 Notes on the battery
15.3 Wiring diagram - TL 250 4-stroke 2016
15.4 Wiring diagram - TL injection 250 euro4 2018
15.5 OBD connectors
15.5.1 ECU
15.5.2 Fuel injector
15.5.3 Fuses and relays
15.5.4 Stepper motor
15.5.5 Lights contactor
15.5.6 Radiator fan contactor
15.5.7 Lambda sensor
15.6 Fuses and relays
15.7 Battery
15.7.1 Replacing the battery
15.7.2 Notes on the Battery
15.8 Diagnostic Port and Instrument Connection
15.9 Removing the Fuel Tank
15.10 Removing the Electronic Injection
15.10.1 Removing the Injector
15.10.2 Removing the throttle body
15.10.3 Removing the MAP Sensor
15.11 Error Code
15.11.1 Ignition module Error code table
15.11.2 ABS module Error code tablem
16 Troubleshooting
16.1.1 Fuel System - Carburettor Version
16.2 Poor Performance at Mid Range And High Speed
16.3 Overheating or Excessive Cooling
16.4 Defective Braking/Poor Braking
16.5 Front Fork Malfunctioning
16.6 Steering Instability
16.7 Starter Motor Not Working
16.8 Faulty Indicator System and Lighting
CONTENTS
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TL 250
CONTENTS
16.8.1 Dim Headlight
16.8.2 Blown Bulb
16.8.3 Direction Indicators Not Flashing
16.8.4 Direction Indicators Stay On
16.8.5 Direction Indicators Flashing Too Slow
16.8.6 Direction Indicators Flashing Too Fast
16.8.7 Horn Does Not Work
17 Products
18 Engine
18.1 Removing the Engine Fully
18.2 Changing Engine Oil and Engine Oil Filters
18.3 Engine Oil Level
18.4 Cylinder Head and Valve
18.4.1 Remove the Cylinder Head Cover
18.4.2 Remove the Cylinder Head
18.4.3 Cylinder Head Cover Disassembly
18.4.4 Disassemble the Cylinder Head
18.4.5 Inspect the Valve and Valve Spring
18.4.6 Inspect the Rocker Arm and Rocker Arm Shaft
18.4.7 Inspect the Camshaft Parts
18.4.8 Inspect the Cylinder Head
18.4.9 Inspect and Lap the Valve Seat
18.4.10 Inspect the Valve Guide
18.4.11 Measure the Width of the Valve Seating Surface
18.4.12 Assemble the Cylinder Head
18.4.13 Assemble the Cylinder Head Cover
18.4.14 Install the Cylinder Head
18.4.15 Adjusting Timing
18.4.16 Install the Cylinder Head Cover
18.4.17 Checking and Adjusting Tappets
18.5 Cylinder and Piston
18.5.1 Remove the Cylinder
18.5.2 Inspect the Cylinder Block
18.5.3 Remove the Piston
18.5.4 Inspecting the Piston and Rings
18.5.5 Install the Piston Rings
18.5.6 Install the Piston
18.5.7 Install the cylinder block
18.5.8 Clutch, drive gear, freewheel, oil pump and gearshift
18.5.9 Remove the crankcase cover on the engine's right-hand side.
18.5.10 Remove the water pump shaft, the water seal assembly and the oil seal
18.5.11 Remove the clutch
18.5.12 Remove the drive gear, freewheel and starter gear
18.5.13 Remove the oil pump on the right side
18.5.14 Remove the step gear
18.5.15 Remove the starter motor
18.5.16 Remove the gearshift
18.5.17 Inspect the crankcase cover on the right side
18.5.18 Inspect the water pump shaft, impeller, water seal assembly and oil seal
18.5.19 Inspect the starter shaft
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WORKSHOP MANUAL
TL 250
CONTENTS
SAFETY
RULES
18.5.20 Inspect the clutch spring
18.5.21 Inspect the clutch disc
18.5.22 Inspect the clutch basket
18.5.23 Inspect the drive gear
18.5.24 Inspect the freewheel
18.5.25 Inspect the primary starter gear
18.5.26 Inspect the oil pump on the right side of the engine case
18.5.27 Inspect the starter motor and step gear
18.5.28 Inspect the gearshift
18.5.29 Assemble the kickstarter spindle
18.5.30 Assemble the step gear
18.5.31 Assemble the gearshift
18.5.32 Assemble the oil pump on the right side of the engine case
18.5.33 Assemble the freewheel
18.5.34 Install the primary gear and freewheel
18.5.35 Install the drive gear
18.5.36 Install the clutch
18.5.37 Assemble the starter motor
18.5.38 Install the crankcase cover on the right side
18.6 Generator, crankshaft balancing and driven gear
13.6.1 Remove the crankcase cover on the left side
18.6.2 Remove the generator stator
18.6.3 Remove the generator rotor
18.6.4 Remove the balancer drive gear and driven gear
18.6.5 Remove the oil pump on the left side
18.6.6 Inspect the crankcase cover on the left side
18.6.7 Inspect the generator rotor and stator
18.6.8 Inspect the balancer drive gear and driven gear
18.6.9 Inspect the left side oil pump
18.6.10 Install the left side oil pump
18.6.11 Install the balancer drive gear and driven gear
18.6.12 Install the generator rotor
18.6.13 Install the generator stator
18.6.14 Install the crankcase cover on the left side
18.7 Crankcase, crankshaft, gearbox and balancer shaft
18.7.1 Removing the crankcase
18.7.2 Remove the crankshaft, balancer shaft, mainshaft and countershaft
18.7.3 Inspect the crankshaft
18.7.4 Inspect the bearings on the crankcase left and right sides
18.7.5 Inspect the shift fork, fork shaft and shift drum
18.7.6 Inspect the mainshaft assembly and countershaft assembly
18.7.8 Assemble the gearbox, crankshaft and balancer shaft
19 Injection maintenance chart
19.1 Injection maintenance chart
19.2 Carburettor mainteinance chart
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WORKSHOP MANUAL
TL 250
CHAPTER 1
SAFETY
RULES
Carbon monoxide
Fuel
Hot parts
Spent engine and transmission oil
Exhaust fumes contain carbon monoxide, a poisonous gas that can cause death. Consequently, when performing
procedures with the engine running, make sure you are in the open air, or in a suitable, well-ventilated room,
never in an enclosed space. If you are working indoors, use an extraction system to remove exhaust fumes.
The fuel used is highly ammable and is explosive under certain conditions.
Perform refuelling and maintenance procedures in a properly ventilated area with the vehicle switched off. Do
not smoke while refuelling and when you are around fuel vapours: avoid contact with naked ames, sparks and
any other source that could cause fuel to ignite or explode.
Dispose of fuel responsibly and keep out of reach of children.
The engine and certain other parts get very hot and remain hot for some time even after the engine has been
switched off. Before performing any work around the engine or exhaust system, put on insulating gloves or wait
for the parts in question to cool down.
The engine and transmission oil used is harmful to health if breathed in or swallowed: it is also an irritant and
can have serious consequences if it comes into contact with skin.
Do not spill or release to the environment.
If swallowed, do not induce vomiting, instead seek emergency medical attention immediately, indicating the
cause and manner of the accident.
After contact with skin, wash the affected part immediately with soap and water, repeating the operation until
there is no trace of oil on the affected part.
After contact with eyes or ears, ush affected parts immediately with plenty of water: seek emergency medical
attention immediately, indicating the cause and manner of the accident.
After contact with clothing, remove any affected garments and wash parts of the body in contact with
contaminated clothing with plenty of soap and water. Put on new clothing and wash the affected clothing with
appropriate products as soon as possible.
Always use suitable hand protection when performing maintenance work.
Keep out of reach of children.
Spent engine and transmission oil must be placed in a sealed container and taken to the nearest service station
or to a waste oil collection centre, where authorized personnel will handle its disposal.
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WORKSHOP MANUAL
TL 250
CHAPTER 1
SAFETY
RULES
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Brakes
Battery electrolyte and hydrogen gas
Coolant
General precautions and warnings
Brake uid can damage the vehicle's painted, plastic or rubber surfaces. Protect these parts with a clean rag
when performing certain procedures.
Always wear safety eyewear and, should brake uid accidentally come into contact with eyes, ush
immediately with plenty of cold, clean water, and seek immediate medical advice. Keep out of reach of
children.
Clean break pads in a properly ventilated area, aiming the jet of compressed air so that you are not breathing
in dust produced by friction material wear. While said material does not contain asbestos, breathing in the
dust is still harmful.
Battery electrolyte is toxic and caustic. On contact with skin, it can cause burns as it contains sulphuric acid.
Wear gloves and protective clothing.
Should electrolyte liquid come into contact with skin, wash with plenty of cold water.
Protect eyes, as battery liquid can cause blindness. Should it come into contact with eyes, ush with water for
fteen minutes and seek the advice of an eye specialist without delay.
The battery gives off explosive gases: you are advised to keep ames, sparks and any other sources of heat well
away. When charging or performing maintenance on the battery, make sure the place where you are working is
sufciently ventilated.
Keep out of reach of children.
Battery liquid is corrosive. Do not spill it, especially on plastic parts.
Dispose of waste liquid regularly.
Under certain conditions, the ethylene glycol in engine coolant is combustible its ame is not visible. Should the
ethylene glycol ignite, you will not see any ame, but it can still cause severe burns.
Do not spill engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant
to ignite and burn without a visible ame. Coolant (ethylene glycol) can cause skin irritation and is poisonous
if swallowed. Keep out of reach of children. Do not remove the radiator cap while the engine is still hot. The
coolant is pressurized and could scald you.
Keep your hands and clothing well away from the cooling fan as it starts automatically.
Operators performing repair work must wear suitable clothing to avoid the risk of injury when working on
moving parts (for instance, loose clothing that can get caught).
Do not wear personal items (for instance, rings, wristwatches, etc.) while performing repair work on the vehicle,
especially on the electrical system.
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WORKSHOP MANUAL
TL 250
CHAPTER 1
SAFETY
RULES
Keep the work area tidy, so that you don't have items left lying around on the oor getting in the way of repair
work.
Wipe up any spilled oil, grease or other uids on the oor in work areas to avoid people slipping on them.
When compressing or releasing springs, only use strictly suitable tools to prevent the operator being injured in
the process.
Do not inhale vapours given off by cleaning uids: they can be highly toxic. Make sure the work area is suitably
ventilated.
Wear eye protection when using power tools, such as drills or grinders.
For each operation, use suitable cleaning products, making sure they are approved.
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WORKSHOP MANUAL
TL 250
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WORKSHOP MANUAL
TL 250
CHAPTER 2
MAINTENANCE
RULES
Always use original Fantic Motor spare parts, and lubricants recommended by the manufacturer. Non-original
spare parts can damage the vehicle.
Always use new gaskets, oil seals and O-rings during assembly.
Following removal, clean parts with non-ammable solvents.
Lubricate all work surfaces before assembly, except valve keepers.
All surfaces that have gaskets, oil seals or O-rings must be cleaned with special care.
Carefully inspect all circlips prior to retting them, replacing any that are misshapen. Only use new gudgeon pin
clips after each use.
Following reassembly, make sure that all parts have been installed correctly and are working perfectly.
Always use top-quality equipment. To lift the vehicle, use purpose-built, legally compliant equipment that
meets national and local standards.
When performing any work on the vehicle that involves the electrical system, make sure the electrical connections
have been made correctly, especially the earth and battery connections.
Only use the specic tools designed for this vehicle.
For removal, servicing and assembly procedures, use metric tools only.
Metric screws, nuts and pins are not interchangeable with imperial fasteners.
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2.2 PREPARATION PRIOR TO WORK
Prior to removal work, thoroughly clean parts in order to remove all traces of dirt, dust, mud or foreign matter.
When taking the vehicle apart, always keep mating parts together, namely gears, cylinders, pistons and other
parts that t together perfectly due to everyday wear. These mating parts must always be reused together, or
replaced altogether.
During work, keep tools close to hand, preferably in the order you will need them and, whatever the case, never
leave them on the vehicle or in a place that is hidden or awkward to reach.
Keep your zone area clean and tidy.
When taking the motorcycle apart, clean all parts and place them in containers in the order they are removed, so
as to make the assembly procedure easier and ensure all parts are tted correctly. Where necessary, mark parts
or locations that could get mixed up when it comes to reassembly.!
2.1 MAINTENANCE
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WORKSHOP MANUAL
TL 250
CHAPTER 2
MAINTENANCE RULES
Part Screw Torque seng Nm
Triple clamp screw M8 (08.8) 18
M8 (10.9) 25 + 243
Wheel axle M14 50
Rear wheel axle nut M17 80
M8 (08.8) 25
M8 (08.8) 25
M10 (08.8) 45
Clutch/Brake pump collars
Engine mounng screws diameter 10
Engine mounng screws diameter 8
M6 (10.9) 10
M10 45
M8 25
Swingarm pivot bolt M14 60
Linkage M12 50
Rear shock
Sprocket screws
M10 upper 40
M10 lower 40 + 243
M8 (10,9) 25
Front brake disc screws M8 25 + 243
Rear brake disc screws M6 10 + 243
Kickstand screw M8 (10.9) 25
Rear brake lever screw M10 (8.8) 40
STEERING STEM FASTENING SEQUENCE:
1. Tighten the ring nut to 25Nm;
2. Loosen the ring nut ½ a turn;
3. Reghten the ring nut to 8 Nm;
4. Fit the upper triple clamp;
5.
Tighten the top nut to 80 Nm.
NUT
RING NUT
Front brake caliper screws
Fork axle clamp screws
Handlebar bolts
Handlebar bolts
!Keep all parts away from sources of heat.
Do not lift the vehicle by its licence plate bracket, to avoid damage.
Use suitable tools and cleaning products.
2.3 TORQUE SETTINGS
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WORKSHOP MANUAL
TL 250
CHAPTER 3
VEHICLE
IDENTIFICATION
FANTIC MOTOR S.r.l
L3e-A1
e11*168/2019*00256*00
ZFMTL250MGT000000
81.9 dB(A) 4125 minˉ
9.7 kW max. 270 kg
numbers.
Vehicle identication number (VIN)
The chassis number can be found on the steering head.
Engine identication number
Each FANTIC MOTOR vehicle also has an engine ID number that
can be found on the top left-hand side of the crankcase.
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WORKSHOP MANUAL
TL 250
CHAPTER 4
SPARE
PARTS
Use only original Fantic Motor spare parts; for all lubrication needs, use Fantic Motor-recommended grease and oil.
While other makes of product may look similar and do the same job, their quality may be inferior.
!GASKETS, OIL SEALS AND O-RINGS
- When performing general repair work on the engine, replace all gaskets, O-rings and oil seals. In addition, clean all
mating surfaces and the edges of seals and O-rings.
- Prior to reassembly, lubricate mating parts and bearings with oil. Apply grease to the lips of seals.
WASHERS, LOCK PLATES AND COTTER PINS
When removing washers, lock plates and cotter pins, replace them with new parts. Locking tabs must be bent against
the surfaces of the relevant nut or bolt once they have been tightened correctly.
BEARINGS AND OIL SEALS
- Fit bearings and oil seals with the part numbers or brand markings facing out, namely turned to the visible side.
- To avoid damaging the rolling surfaces, do not dry bearings with compressed air.
CIRCLIPS
- Replace misshapen circlips when installing a new circlip.
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WORKSHOP MANUAL
TL 250
CHAPTER 5
BODYWORK
REMOVAL
A
B
C
D
5.1 REMOVING THE SEAT
Remove the fastening screw (A) pictured and remove the seat by sliding it
backwards to release it from the hook on the tank and the bracket (B).
5.2 REMOVING THE REAR FENDER
Once you have removed the seat as described in section 5.1 "Removing the seat",
unscrew the three fastening screws, two of which are on the left and right side of
the bike (marked C in the photo), and the central one D located under the seat.
To provide access to certain areas of the vehicle for inspection and work, you need to remove the relevant parts as follows:
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WORKSHOP MANUAL
TL 250
CHAPTER 5
BODYWORK
REMOVAL
FG
H
5.3 REMOVING THE RADIATOR SHROUDS
Once you have unscrewed the two screws 5 securing the tank's rear mount,
unscrew screws a,b,c,d, starting on the right side, followed by the left.
5.4 REMOVING THE FUEL TANK
Unscrew screw F securing the tank to the frame, and the two mounting screws G;
remove the fuel valve line and pull out the tank, turning it in the direction of the
fuel valve.
NB: You will need to have removed the radiator shrouds
.
5.5 REMOVING THE HEADLIGHT ASSEMBLY
Release the four cable clamps H and disconnect the headlight connector.
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CHAPTER 5
BODYWORK
REMOVAL
WORKSHOP MANUAL
TL 250
I
L
M
5.6 REMOVING THE MUD FLAP
Unscrew the two screws "I" securing it to the mudguard. To make performing
can tighten the nut located on the inside.
5.7 REMOVING THE FRONT MUDGUARD
Unscrew the four screws L securing the mudguard.
5.8 REMOVING THE LICENCE PLATE BRACKET
Once you have removed the rear fender, unscrew the four screws M
securing it to the rear subframe.
Unplug the tail lights from the connector and remove the licence plate
bracket.
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CHAPTER 5
BODYWORK
REMOVAL
WORKSHOP MANUAL
TL 250
N
O
Q
P
R
5.9 REMOVING THE REAR SUBFRAME
Unscrew the four screws N securing it to the frame (two each side) and the
screw O connecting it to the silencer.
5.10 REMOVING THE KICKSTAND
Remove spring P and unscrew screw Q securing the kickstand to the frame and
remove the actual kickstand
5.11 REMOVING THE SWINGARM PIVOT BOLT
Unscrew nut R and slide the bolt out from the side opposite the nut.
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WORKSHOP MANUAL
TL 250
CHAPTER 6
DASHBOARD
6.1 DASHBOARD TL 250 CARBURETTOR KOSO DB EX-O2
Speedometer
• Display range: 0-360 km/h (0-225 MPH)
• Display unit: km/h or MPH
Warning lights
• Full beam (Blue) Î
• Directional Indicators
(Green)
• 2-stroke oil level (Red)
• Neutral light (Green) N
SELECT button
• Pressing the SELECT button while on the
main screen allows you to switch between
the information displayed: 12/24 hour clock
mode, speedometer log, stopwatch and MAX.
record
Odometer
• Display range: 0-99,999 km (miles), automatic
reset after 99,999 km (miles)
• Display unit: 1 km (mile)Trip meter
• Display range: 0-999.9 km (miles), automatic
reset after 999.9 km (miles)
• Display unit: 0.1 km (mile)
ADJUST button
• Pressing the Select button while on the
main screen allows you to switch between
the information displayed: odometer, A/B
trip meter, total hour meter
and A/B trip hour meter
• Hold the key down for 3 seconds while on
the A/B trip screen to reset this hour meter.
• Hold the key down for 3 seconds while on
the A/B trip hour meter screen to reset this
hour meter.
Instrument battery level
• Display range: 4 levels.
Clock: 12/24 hour mode
• Stopwatch: time taken to cover the set
distance
• Speed log: logs the average speed and
maximum speed
2 REPLACING THE BATTERY
When the battery level is low, replace it by
proceeding as follows:
1. Remove the instrument from its mount by
unscrewing the two fastening screws (A).
2. Remove the battery cover (B), using a coin
(D) in its seat.
3 DASHBOARD FUNCTIONS
3.1 HOW TO USE THE ADJUST BUTTON
• Pressing the Adjust button while on the main screen allows you to toggle between the instrument's
speedometer and trip functions.
• Once you are on the trip screen, pressing the Adjust button allows you to switch between displaying trip A
and trip B.
• If you are on trip A, holding the Adjust button down for 3 seconds resets trip A.
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