Fantic Motor TZ 300 2011 User manual
WARNING
It is recommended, after the first hours of use, to check all the torques with particular attention to:
A Front / Rear brake caliper
B Wheels axle
C Rear sprocket
D Engine bolts
E Rear suspension mounting nuts
F Wheels spokes
G Rear frame
The vehicle is equipped by catalytic exhaust (accredited Euro3) that can catch up high temperatures. Absolutely avoid the contact with body parts,
clothes inflammable materials !
WARNING
If necessary consult a FANTIC MOTOR dealer.
The technical information and specifications for maintenance contained in this handbook were correct at the time of going to press. FANTIC MOTOR
reserves the right to change the specifications, design data and necessary equipment at any time without notice. No part of this publication may be
abridged or translated without the manufacturer’s approval. FANTIC MOTOR cannot be held liable for any errors or omissions. All rights reserved.
3
This handbook is an integral part of the vehicle and must accompany it if resold.
FANTIC MOTOR reserves the right to make changes to the models described in this handbook without notice, while guaranteeing the essential features
described and shown herein.
No part of this handbook may be reproduced without the prior permission of the Manufacturer.
FANTIC MOTOR cannot be held liable for any copying or printing errors in this handbook.
GENERAL CONTENTS AND CONSULTATION
All the specifications and helpful instructions for normal use and maintenance of the vehicle are given in the handbook.
It is advisable to contact our Authorised Dealers for maintenance and any repairs, since they guarantee a prompt and precise service and always use
original spare parts.
MANUFACTURER’S DATA AND EDITION
FANTIC MOTOR
via Al Bigonzo, 15
31030 – Dosson di Casier (TV) Italy
Tel. +39 0422 634192/490636
Fax +39 0422 630491/490620
E-mail: info@fanticmotor.it
www.fanticmotor.it
Edition: 01/2011
FOREWORD
4
HOW TO USE THIS MANUAL
Read this Manual carefully. You will nd it contains all the necessary informa-
tion for your safety, and that of other persons, as well as guaranteeing the cor-
rect conservation and maintenance of the FANTIC MOTOR motorcycle that
you have just acquired.
You will nd all the necessary instructions for the correct riding and control
of this vehicle are set out below. Each message is preceded by a symbol with
the following meaning.
WARNING
This warning symbol identies special instructions or procedures which, if
not correctly followed, could result in personal injury or even death.
CAUTION
This symbol identies instructions or procedures which, if not followed
strictly, could result in damage to or destruction of equipment.
NOTE
This note symbol indicates points of particular interest for more ecient
and convenient operation.
Motorcycle riding, if improverly conducted, has the potential to cause envi-
ronmental problems as well as conicts with other people. Responsible riding
use of your motorcycle will ensure that these problems and conicts do not
develop.
5
TABLE OF CONTENTS
Warning...................................................................................................... 2
Foreword ................................................................................................... 3
How to use this manual ....................................................................... 4
Table of contents.................................................................................... 5
Specications........................................................................................... 6
Location of components...................................................................... 8
Side Stand ................................................................................................. 10
Fuel .............................................................................................................. 10
Serial Number.......................................................................................... 12
Homologation Plate .............................................................................. 12
Starting the engine................................................................................ 12
Shifting gears........................................................................................... 13
Stopping the motorcycle..................................................................... 14
Riding during the Break-In Period.................................................... 14
Maintenance Schedule......................................................................... 15
Electronic Ignition.................................................................................. 17
Cooling System ....................................................................................... 17
Spark Plug ................................................................................................. 20
Transmission ............................................................................................ 20
Air Cleaner................................................................................................. 22
Throttle Cable .......................................................................................... 23
Carburetor................................................................................................. 23
Clutch.......................................................................................................... 24
Exhaust System ....................................................................................... 24
Drive Chain Guide.................................................................................. 25
Handlebar ................................................................................................. 27
Brakes ......................................................................................................... 28
Steering...................................................................................................... 29
Steering blockage.................................................................................. 30
Steering plate .......................................................................................... 31
Front Fork.................................................................................................. 32
Rear suspension...................................................................................... 35
Wheels........................................................................................................ 37
Cleaning..................................................................................................... 37
Bolts and nuts tightening.................................................................... 39
Lubrication................................................................................................ 41
Tune-Up (Carburetor and Suspension).......................................... 41
Final recommendatios.......................................................................... 50
Homologation ......................................................................................... 51
Preparation for competition............................................................... 52
Storage....................................................................................................... 53
FANTIC MOTOR Multifunction Instructions .................................. 54
Troubleshooting ..................................................................................... 60
Electric Schemas..................................................................................... 64
Warranty Manual.................................................................................... 66
Fast guide.................................................................................................. 69
Lubricants table ...................................................................................... 70
6
SPECIFICATIONS
ENGINE 2 cycles, single cylinder, crankcase intake, liquid cooled
Engine 125 cc
Bore and stroke 54 x 54,5 mm
Displacement 124 cc
Engine 200 cc
Bore and stroke 62,5 x 65 mm
Displacement 199,4 cc
Engine 250 cc
Bore and stroke 66,4 x 72 mm
Displacement 249,3 cc
Engine 300 cc
Bore and stroke 72 x 72 mm
Displacement 294,7 cc
Carburettor, diameter of diusor 38 (125 cc : 36)
Lubrication system Mixture
100% Synthetic Oil 50 : 1 = 2 %
Mineral Oil (Only USA) 32 : 1 = 3 %
Starting system Starting lever / Electric ( 250cc - 300cc )
Ignition system CDI system
Ignition timing 1 mm BTDC
TRANSMISSION
Transmission type 6 speed in cascade
Clutch type Hydraulic operated multi-plate in oil bath
Secondary drive Chain driven
Gear ratio (200 cc, 250 cc, 300 cc) 1ª 2,071 (29/14)
(125 cc)
1ª 2,308 (30/13)
2ª 1,625 (26/16) 2ª 1,867 (28/15)
3ª 1,333 (24/18) 3ª 1,529 (26/17)
4ª 1,100 (22/20) 4ª 1,286 (27/21)
5ª 0,913 (21/23) 5ª 1,130 (26/23)
6ª 0,791 (19/24) 6ª 1,000 (24/24)
7
Primary reduction 2,85 (57/20) (250 cc, 300 cc); 3,32 (63/19) (125cc)
Final reduction 3,692 (48/13) (125 cc, 250 cc, 300 cc); 3,667 (44/12) (200cc)
Transmission oil Capacity 750 cc (125 cc)
900 cc (200 cc / 250 cc / 300 cc)
Type 10W30 (125 cc) / 10W50 (200 cc / 250 cc / 300 cc)
CHASSIS
Type Tubular, semi-double cradle
Tire size Front 90/90 x 21 (120/60 x17 motard version)
Rear 140/80 x 18 (150/60 x17 motard version)
Suspension Front USD fork ø 45 mm (125)
Inverted USD fork ø 50 mm (200, 250, 300)
Rear System shock absorber with progressive
Suspension stroke Front 282 mm
Rear 320 mm
Front fork oil 7,5
5 - 7,5
Front fork oil level 110 mm (compressed, without spring)
BRAKES
Type Front, Rear Disc brake
Eective disc diameter Front 260 mm
Rear 220 mm
DIMENSIONS
Overall height 1260 mm
Overall length 2135 mm
Overall width 810 mm
Seat height 940 mm
Minimum height 340 mm
Wheelbase 1475 mm
Fuel tank capacity 9,5 liters
8
LOCATION OF COMPONENTS
1 7 43 65
2
1 - Clutch lever
2 - Steering, lights, horn and headlamp controls
3 - Fuel tank cap
4 - Brake uid reservoir
5 - Front brake lever
6 - Throttle grip
7 - Clutch uid reservoir
9
8 - Skid plate
9 - Brake disc
10 - Front suspension
11 - Fuel tank
12 - Carburetor
13 - Rear shock absorber
14 - Brake caliper
914 15 17 12 13 22 21
10 11 27 16
14 23 24 25 826 20
18 19 20
15 - Radiator
16 - Gasoline cock
17 - Shift pedal
18 - Muer
19 - Seat
20 - Front axe puller
21 - Chain guide
22 - Chain
23 - Suspension linkage and swingarm
24 - Rear brake pedal
25 - Kick-start pedal
26 - Exhaust
27 - CDI switch
10
SIDE STAND
To set the side stand only turn it until it contacts the stopper, then the side
stand will be parallel to the ground and rest securely.
The side stand will return to its original position by means of the double
spring. The function of the double spring insures that, when the side stand is
down, the rest position is stable and above all secure; moreover, it also returns
the side stand to its original position.
(A)
(B)
(EC)
(A) - Side stand.
(B) - Double spring.
NOTE
Do not start the engine or ride the motorcycle when the side stand is
down.
FUEL
The FANTIC MOTOR EC models have 2-cycle engines that require a mixture of
gasoline and oil.
Gas Tank Capacity : 9,5 l
(A)
(B)
(A) - Fuel tank cap.
(B) - TVapor outlet tube.
The fuel tank cap is of the quick-release type.
To open the fuel tank cap, lift the plated latch and turn cap counter-clockwise.
To close it, turn the cap clockwise and lower the latch.
NOTE
It is recommended that the rubber seal should be checked thoroughly to
insure it is airtight.
11
RECOMMENDED FUEL
Use gasoline with an octane rating equal to or higher than that shown in the
table.
OCTANE RATING METHOD MINIUM RATING
Antiknock Index (RON+MON)/2 90
Research Octane No. (RON) 98
NOTE
If knocking or pinging occurs, try a dierent brand of gasoline or higher
octane grade.
WARNING
Gasoline is extremely ammableandcan be explosive under certain condi-
tions. Always stop the engine and do not smoke. Make sure the area is well
ventilated and free from any source of ame or sparks; this includes any
appliance with a pilot light.
Mixing oil inside the engine
Oil must be mixed with gasoline to lubricate the piston, cylinder, crankshaft,
and connecting rod bearings.
Recommended oil: 2-CYCLE SYNTHETIC (see table lubricants pag. 70)
Gasoline and engine oil mixing proportions:
Synthetic oil 100%: gasoline 50, engine oil 1 = 2%
Semi-synthetic oil: gasoline 50, engine oil 1 = 2%
Mineral oil: gasoline 32, engine oil 1 = 3%
CAUTION
Do not mix vegetable and mineral based oils.
Too much oil will cause excessive smoking and spark plug fouling. Too little
oil will cause engine damage or premature wear.
CAUTION
Below 0 ºC do not use 100% synthetic oil.
To prepare the mixture, rst pour oil and half of the gasoline used into a con-
tainer and stir the mixture thoroughly. Then add the rest of the gasoline and
stir the mixture well.
NOTE
At low temperature, oil will not easily mix with gasoline. Take time to en-
sure a well-blended mixture.
The lubrication quality of this mixture deteriorates rapidly; use a fresh
mixture for each day of operation.
12
SERIAL NUMBER (A)
It is stamped on the steering pipe. It indicates the frame number registered
for this motorcycle.
HOMOLOGATION PLATE (B)
This motorcycle carries its corresponding homologation plate where it also
shows the serial number, and this data must match the information registered
in the motorcycle documents.
(A)
(B)
STARTING THE ENGINE
1. Make sure the motorcycle is in the neutral position.
2. Turn the gasoline cock (A) clockwise to the“ON” position.
ON
Open
OFF
Close
RES
Reserve
(A)
3. If the engine is cold, pull up the choke trigger (B).
13
SHIFTING GEARS
The transmission is a 6-speed, of the return shift type. A return shift means
that to go from rst gear to third gear it must go rst through the second
gear, that is to say that it upshifts gears one by one. To engage rst gear from
neutral, pull the clutch lever in and push down on the gearshift pedal, then
release the gearshift pedal and gently release the clutch lever.
CAUTION
When shifting gears, press rmly on the gearshift pedal to ensure a positive
shifting. Careless, incomplete shifts can cause the transmission to jump out
of gear and cause engine damage.
(A)
(A) - Gearshift pedal.
NOTE
- When the engine is already warm or on hot days, open the throttle
instead of using the choke knob.
- If the engine is ooded, kick with the throttle fully open.
- If the clutch lever is pulled, the motorcycle can be started while in
any gear.
(C)
(E)
4. Start the motorcycle with kick-start pedal (C) or press the start button (E)
(only model 200, 250, 300 cc).
5. Even after the engine starts, keep the choke knob pulled up.
STOPPING THE ENGINE
1. Shift the transmission into neutral.
(D)
2. After racing the engine slightly, close the throttle completely and depress
the engine stop button (D).t
14
STOPPING THE MOTORCYCLE
For maximum deceleration, close the throttle (A) and apply both front and
rear brakes. Disengage the clutch as the motorcycle comes to a stop. Inde-
pendent use of the front or rear brake may be advantageous under certain
conditions.
Downshift progressively as speed is reduced to ensure good engine response
when you want to accelerate.
RIDING DURING THE BREAK-IN PERIOD
A break-in period is necessary to ensure a smooth operation and obtain an
optimum engine and the transmission responses. During the rst hour or 20
km of operation, run the engine at low and moderate speeds and revolutions
per minute (RPM).
NOTE
The slow riding necessary during the break-in period may cause carbon
deposits to build up on the spark plug and foul it. If
inspection of the spark plug shows this to be the case, replace the stand-
ard spark plug with another of a higher heat range.
Perform the break-in period following these steps:
1. Start the engine and let it run at idle until the engine is warm.
2. Stop and let the engine cool completely.
3. Start the engine and ride for 10 minutes at moderate speed -NEVER AC-
CELERATE HARD.
4. Stop and let the engine cool completely. Be sure to check and adjust chain
slack and spoke tightness and cxarry out a general inspection.
5. Start the engine and ride for 20 minutes at moderate speed. - NEVER AC-
CELERATE HARD.
6. Stop and let the engine cool completely. Check and adjust as needed (Re-
fer to the table of adjustments).
7. Install the parts removed.
8. Fill the radiator with the recommended coolant. Before starting the mo-
torcycle, bleed the air from the cooling system.
9. Start the engine and ride for 30 minutes at moderate speed.
10. Stop and let the engine cool completely. Check and adjust.
11. After the break-in procedure has been properly carried out, the motorcy-
cle is ready for regular operation.
CAUTION
However, avoid accelerating recklessly that can lead to engine failure. Be
careful to use the necessary skills and techniques while operating the mo-
torcycle.
NOTE
After the break-in period, install a new set of standard spark plugs.
15
MANTENANCE SCHEDULE
ITEM CHECK / INSPECT ADJUST CHANGE / REPLACE CLEAN APPLY GREASE / LUBRICATE
Clutch At each ll up At each ll up At each ll up (*) - At each ll up
Discs 3 ll ups 3 ll ups (*) 3 ll ups (*) - -
Throttle cable - 1 ll up - - -
Spark plug - - - 1 ll up -
Air cleaner element - - When damaged 1 ll up -
Carburetor 1 ll up 1 ll up - - -
Transmission oil - - 3 ll ups - -
Piston and piston ring 3 ll ups 3 ll ups (*) 3 ll ups (*) 3 ll ups -
Cylinder head, cyl. & exhaust valves 3 ll ups 3 ll ups (*) 3 ll ups (*) - -
Exhaust 1 ll up 1 ll up (*) 1 ll up (*) 1 ll up -
Muer gasket - 10 ll ups (*) 10 ll ups - -
Piston bearing 3 ll ups 3 ll ups (*) 10 ll ups - 3 ll ups
Kick-start pedal and gearshift pedal - - - - 1 ll up
Exhaust pipe o’ring - - 3 ll ups - -
Engine bearings 10 ll ups 10 ll ups (*) 10 ll ups (*) - -
Coolant 3 ll ups 3 ll ups (*) 3 ll ups (*) - -
Radiator tube and connections 1 ll up 1 ll up (*) 1 ll up (*) - -
Brake adjustment 3 ll ups 3 ll ups (*) 3 ll ups(*) - -
Brake pads wear 5 ll ups 5 ll ups (*) 5 ll ups (*) - -
Brake uid level 3 ll ups 3 ll ups (*) 3 ll ups (*) - -
Brake uid - - Every 2 years - -
Brake pump piston & dust cover - - Every 2 years - -
The maintenance and adjustments in this table are easy to follow and must be carried out to keep the motorcycle in good running condition.
NOTE: (*) Inspect and carry out these operations only if it is necessary.
16
ITEM CHECK / INSPECT ADJUST CHANGE / REPLACE CLEAN
APPLY GREASE / LUBRICATE
Brake caliper piston seal & dust seal
- - Every 2 years - -
Brake hose and pipe - - Every 4 years - -
Spoke tightness and rim runout 1 ll up 1 ll up (*) 1 ll up (*) - -
Lubricate drive chain - - - - 1 ll up
Drive chain 1 ll up - - - -
Drive chain wear - 5 ll ups (*) 5 ll ups - -
Chain slider 5 ll ups 5 ll ups (*) 5 ll ups (*) - -
Front fork 1 ll up When necessary When necessary When damaged -
Front fork oil - - Every year - -
Nuts, bolt, fasteners 5 ll ups 5 ll ups (*) 5 ll ups (*) - -
Fuel hose 7 ll ups 7 ll ups (*) 7 ll ups When necessary -
Fuel system - - 10 ll ups - -
Steering play 1 ll up - - - -
Rear sprocket 5 ll ups 5 ll ups (*) 5 ll ups (*) - -
General lubrication 5 ll ups - - - 5 ll ups
Steering bearing - - - - 10 ll ups
Wheel bearing 10 ll ups 10 ll ups (*) 10 ll ups (*) - -
Swingarm and linkages 5 ll ups 5 ll ups (*) 5 ll ups (*) - 5 ll ups
Rear shock absorber oil Every 2 years Every 2 years Every 2 years (*) - -
The maintenance and adjustments in this table are easy to follow and must be carried out to keep the motorcycle in good running condition.
NOTE: (*) Inspect and carry out these operations only if it is necessary.
17
ELECTRONIC IGNITION
This motorcycle uses a capacitor discharge ignition system (CDI). The ignition
system should never require adjustment unless the stator of the magnetic y-
wheel was incorrectly installed during engine reassembly.
If necessary, inspect and adjust as follows:
Adjustment
- Remove the magnetic ywheel cover (A).
- Make sure that the mark on the stator plate is aligned with the mark on
the crankcase.
(A)
125cc
200 / 250 / 300 cc
- If the marks are not aligned, loosen the magnetic inertia wheel screws and
turn it.
- Tighten the screws securely.
- Install the magnetic ywheel cover.
NOTE
Engine tune-up can be adjusted to match the rider´s preferences and
skills.
- Remove the magnetic ywheel cover.
- Loosen the stator screws.
- Adjust the engine tune-up by changing the position of the stator within
prudent limits
NOTE
For the best engine performance, it is very important to adjust the en-
gine tune-up within the set of limits described.
- Tighten the stator screws.
- Install the magnetic ywheel cover.
- Test ride the motorcycle and readjust the engine tune-up, if necessary.
COOLING SYSTEM
Radiator Hoses
Check the radiator hoses for cuts or deterioration, and the connections for
looseness and leaks.
Radiator
Check the radiator ns for obstructions (insects or mud). Remove any obstruc-
tions with a stream of low water pressure.
18
CAUTION
If high water pressure is used the radiator ns could be damaged and impair
the radiator eectiveness.
Do not obstruct or deect airow through the radiator by installing unau-
thorized accessories. Any interference with the radiator airow can lead to
engine overheating and damage.
Coolant information
To protect the cooling system aluminum parts (engine and radiator) from rust
and corrosion, the use of corrosion and rust inhibitors chemicals in the cool-
ant is essential. If rust inhibitors were not used, over a period of time the radia-
tor will be corroded. This will clog the tubes of the cooling system.
CAUTION
Use of incorrect coolant solutions will cause engine and cooling system
damage.
Use coolant containing corrosion inhibitors made specically for aluminum
engines and radiators in accordance with the instructions of the manufac-
turer.
CAUTION
Chemical liquids are harmful to the human body. Follow manufacturer in-
structions.
CAUTION
Distilled water must be used with corrosion inhibitors and the antifreeze in
the cooling system. If tap water is used in the system, the cooling tubes can
be clogged and reduce the cooling system eciency.
If the lowest ambient temperature encountered falls below the freezing point
of water, protect the cooling system. Use a permanent type of antifreeze in
the cooling system (distilled water and ethylene glycol and corrossion inhibi-
tors for aluminium engines and radiators).
For the coolant mixture ratio under extreme conditions, choose the mixture
ratio listed on the container for the lowest ambient temperature.
CAUTION
Permantent types of antifreeze have anticorrosion and anti-rust properties.
When it is diluted excessively, it loses its antifreeze and anticorrosion prop-
erties. Mix in accordance with the instructions of manufacturer.
Liquid recommended
Permanent type of antifreeze (distilled water and ethylene glycol) plus cor-
rossion inhibitors for aluminium engines and radiators. (see table lubricants
pag. 70)
NOTE
Initially, at the factory a permanent type of antifreeze is installed in the
cooling system. It is colored green, it contains a 50% solution of ethylene
glycol, and has a freezing point of –35 ºC.
Coolant recommended
Coolant absorbs excessive heat from the engine and transfers it to the air at
the radiator. If the coolant level is low, the engine overheats and may suer se-
vere damage. Check the coolant level each day before riding the motorcycle.
Add liquid recommended if the level is low.
19
WARNING
To prevent severe scalding do not remove the radiator cap or try to change
liquid, when the engine is still hot. Wait until it cools.
Coolant level
- Place the motorcycle in riding position.
- Turn the radiator cap (A) counterclockwise and wait a few seconds until
vapors inside are released.Then push and turn it further in the same direc-
tion and remove the cap.
A
NOTE
Check the level when the engine is cold.
- Check the coolant level. The coolant level should be just at a level below
de cap rubber seal.
- If the coolant level is low, add the correct amount of coolant through the
ller opening.
Total quantity
Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze 50%).
Capacity: 1,1L.
Coolant Replacement
Coolant should be changed periodically to ensure long engine life.
- Wait for the engine to cool completely.
- Place the motorcycle in riding position.
- Remove the radiator cap.
- Place a container under the coolant drain screw, and drain the coolant
from the radiator and engine by removing the drain screw (B) at the
bottom of the water pump cover (A). Wash oimmediately any coolant
spilled on the chassis, engine, or wheels.
(A)
(B)
200/250/300
125 cc.
(A)
(B)
20
WARNING
If coolant gets on the tires will make them very slippery and can cause an
accident.
- Visually inspect the old coolant. If whitish spots are observed in the liquid
is a clear indication that the aluminum parts in the cooling system are cor-
roded. If the coolant is brown, iron or steel parts of the system are rusting.
In both cases, ush the cooling system.
- Check the cooling system for damage, leaks or missing gaskets in the
cooling system.
- Install the water pump cover drain screw with the specied torque values
shown in the table. Always replace the gasket with a new one.
Drain plug tightening torque
Water pump screw: 9 Nm
- Fill the radiator up to the edge of the cap with coolant, and install the
radiator cap.
- Inspoect the cooling system for leaks.
- Start and warm up the engine, then stop the engine.
- Check the coolant level after the engine cools down. Add coolant up to
the cap.
SPARK PLUG
The standard spark plug is a shown in the table and should be tightened to
27 Nm.
Standard Spark Plug
125 cc = Denso W27ESR-U 0,7-0,8 mm O NGK BR9EG
200 / 250 / 300 cc = Denso W24ESR-U 0,7-0,8 mm O NGK BR8EG
The spark plug should be removed periodically to check its gap. If the plug
is oily or has carbon deposits, clean it with a sandblaster. After removing the
abrasive particles, the spark plug must be cleaned using a wire brush or a
similar tool. Measure the gap with a feeler gauge, if incorrect adjust the gap
by bending the side electrode. If the spark plug electrodes are corroded or
damaged, or if insulator is cracked, replace the plug.
NOTE
Inspect every 30 hours and change every 60 hours.
To nd out whether the right heat range plug is being used, remove it and
inspect the ceramic insulator around the center electrode. If the ceramic is
light brown, the spark plug is correctly matched to engine temperature. If the
ceramic is whie, the spark plug should be replaced with the next colder plug.
If the ceramic is black, the spark plug should be replaced with the next hotter
plug.
NOTE
If the engine performance drops, replace the spark plug rst to recover
its output.
TRANSMISSION
For the transmission and clutch to function properly, maintain the transmis-
sion oil level at the optimum level and change it periodically. A motorcycle
with insucient transmission oil, deteriorated or contaminated can acceler-
ate wear and tear and cause transmission damages.
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