CSC RC3 Owner's And Service Manual

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CSC RC3

Ow ner ' s and Ser v i c e

M anual

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Page 1 CSC RC3 Ow ner ’ s and Ser v i c e M anual...
Page 2: Table Of Contents
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Contents Foreword ............................... 4 Caution and Warning Symbols ........................ 4 Section 1: Owner’s Manual .......................... 5 General Motorcycle Safety Guidance ...................... 5 Inspections Before Riding .......................... 6 Motorcycle Description .......................... 7 Maintenance Cautions and Warnings ...................... 8 Parts and Components Cleaning ........................ 9 Maintenance Adjustments .......................... 9 Motorcycle Specifications ........................... 10 Motorcycle Maintenance Schedule ...................... 11 Torque Values ............................. 11 Unpacking and Setup .......................... 12 Rearview Mirror Installation ........................ 12 Fuel ................................ 12 Inspection .............................. 12 Frame and Body ............................ 13 Body Panel Removal ........................... 13 Brakes ................................ 15 ...
Page 3 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Rear Wheel Removal ........................... 35 Wheel and Tire Inspection .......................... 35 Wheel and Tire Troubleshooting ........................ 35 Fixing Flat Tires ............................ 36 Lifting the Motorcycle .......................... 37 Engine................................ 37 Engine Break‐In Procedure ......................... 37 Oil Changes .............................. 38 Valve Adjustment ............................ 42 Engine Troubleshooting .......................... 47 Fuel System .............................. 54 Fuel System Maintenance ........................... 55 Electronic Fuel Injection System ......................... 56 Electronic Fuel Injection System Troubleshooting .................. 58 Intake and Exhaust System ......................... 59 Air Filter Maintenance .......................... 59 Exhaust System ............................ 60 Intake and Exhaust System Troubleshooting .................... 62 Cooling System ............................ 62 Checking and Adjusting Cooling Fluid Levels .................... 63 Flushing and Replacing the Cooling Fluid .................... 64 Cooling System Troubleshooting ........................ 65 Control Cables ............................. 66 Cable Troubleshooting .......................... 66 ...
Page 4 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com A Word From Steve Thank you for purchasing this CSC RC3 motorcycle. The RC3 is a great motorcycle and we are very proud of it. The RC3 is easy to maintain, it’s reliable, and it’s fun. You’ve made a wise purchase decision. I want you to know that we value the trust and confidence you have in CSC. Our guiding principle will always be that our customers come first. We wish you many miles of safe and enjoyable riding on your new RC3 motorcycle. If there’s anything we can do to enhance your ownership experience, please let us know. Thank you again, Steve Seidner Founder and CEO CSC Motorcycles, LLC 1331 W. Foothill Boulevard Azusa, California 91702 909 445 0900 www.CSCMotorycles.com 3 ...
Page 5: Foreword
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Foreword The RC3 Owner’s and Service Manual provides information on operating and maintaining the CSC RC3 motorcycle. It includes the motorcycle’s technical specifications, performance parameters, and operating, maintenance, and adjustment data. This manual includes both the Owner’s Manual and the Service Manual. The Owner’s Manual is included in the first section of this document; the Service Manual in included in the second section of this document. CSC Motorcycles stocks all RC3 motorcycle parts, and we recommend that you use only parts and materials provided by us when servicing or maintaining your motorcycle. The RC3 Owner’s and Service Manual is provided free to all who purchase a new CSC RC3 motorcycle. Reproduction of the CSC RC3 Owner’s and Service Manual or posting it online without CSC’s permission is expressly prohibited. If you have any questions, please contact CSC Motorcycles by calling us at 909 445 0900 or via email at info@CSCMotorcycles.com. Caution and Warning Symbols Caution and warning symbols in this manual are as follows: The Caution! symbol indicates a condition that may lead to motorcycle damage. The Warning! symbol indicates a condition that may lead to injury or death. 4 ...
Page 6: Section 1: Owner's Manual
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Section 1: Owner’s Manual General Motorcycle Safety Guidance Warning! Do not attempt to ride this motorcycle on public roads if you do not have a motorcycle license. Warning! Do not attempt to ride this motorcycle if you do not know how to ride a motorcycle. Warning! Always wear appropriate motorcycle gear when riding your motorcycle. Never ride your motorcycle without wearing an approved helmet, a motorcycle jacket, eye protection, gloves, motorcycle pants, and boots. Warning! Always remain alert while operating your motorcycle. Pay attention to traffic conditions and the road surface. Adjust your speed and following distances taking these factors into consideration. Warning! Never operate your motorcycle while under the influence of drugs or alcohol, or when sleep deprived. Warning! The motorcycle’s cylinder, cylinder head, and exhaust system are hot when the motorcycle is running and after turning it off. Do not touch these items. Warning! Always maintain appropriate tire pressure. Operating the motorcycle with low tire pressure will adversely affect the motorcycle’s handling. Warning! Replace worn tires promptly. Warning! Never attempt to lubricate the chain by running the engine, putting the motorcycle in gear, and lifting the rear of the motorcycle. Lubricate the chain with the engine off. Warning! Make sure the choke is fully open when riding the motorcycle. Warning! Do not attempt to reach under the tank to open or close the choke while riding the motorcycle. Warning! Do not overload the motorcycle or load it unevenly. Warning! Do not attempt to carry more than one passenger (in addition to the rider). ...
Page 7: Inspections Before Riding
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Inspections Before Riding Before riding your motorcycle, you should check the following:  Both tires are appropriately inflated.  Neither tire has nails nor other foreign objects embedded in the tread or the sidewall.  The crankcase has oil. You can check the oil level using the crankcase viewing port.  The turn signals, the front and rear brake lights, the horn, and the headlight all operate when commanded to do so (the ignition switch must be in the ON position).  The front and rear brake levers have adequate free play.  The front and rear brakes operate.  The forks turn freely from side to side.  The rear view mirrors are adjusted appropriately.  The engine kill switch is in the RUN position.  The chain has appropriate slack.  Major threaded fasteners are tight. We always hand check the axle nuts, the exhaust header nuts and bolts, the muffler bolts and nuts (grab the muffler and check it for any side‐to‐side ...
Page 8: Motorcycle Description
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Motorcycle Description The CSC RC3 motorcycle is a 250cc sport motorcycle. The motorcycle has a single‐cylinder, 4‐stroke, water‐cooled engine and a 6‐speed transmission. The RC3 has hydraulic disk brakes at the front and rear wheels. The ignition and fork lock is located on the upper fork triple tee. The RC3 has a conventional chain drive. Major component locations are identified in the photographs below and in subsequent sections. The RC3 has a conventional motorcycle control layout, with the clutch and shifting lever on the left side of the motorcycle, the front and rear brakes operated from the right side of the motorcycle. The fuel filler cap is located on top of the fuel tank. It is operated with the motorcycle’s ignition switch. The instruments located in front of the upper triple tee, etc. Additional information on component locations is provided further in this Owner’s and Service Manual where such component locations are discussed in subsequent sections. Right Side 7 ...
Page 9: Maintenance Cautions And Warnings
Maintenance Cautions and Warnings When you repair the motorcycle, please use original components and parts, accessories, lubricating oil and other materials that are made or recognized by CSC Motorcycles. If you use any parts or components which are not recognized or recommended by our company, it may adversely affect the performance, reliability, or stability of your motorcycle. When working on your motorcycle, you should follow this guidance: ...
Page 10: Parts And Components Cleaning
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com  The battery can liberate hydrogen, which is flammable. Do not smoke, ignite or make sparks near the battery, especially when it is charging.  The electrolyte of the battery contains sulfuric acid. If your eyes, skin or clothes are splashed with electrolyte, rinse them thoroughly with water and seek immediate medical attention. Parts and Components Cleaning ...
Page 11: Motorcycle Specifications
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 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 6 speeds Spark plug model: RG6YC ...
Page 12: Motorcycle Maintenance Schedule
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Motorcycle Maintenance Schedule Maintenance Schedule Maintenance times Odometer (miles) 500 miles Every 2,500 miles Every 5,000 miles Maintenance item Fuel system Fuel filter R/ l R/ l Control system Air cleaner element Spark plug gap Valve lash ‐ Transmission chain Battery Brake pad wear Braking system Stop lamp switch Headlamp dimmer intensity Main stand and side support Front and rear shock absorbers l l l Nut/bolt/ fastener Front (rear) wheel bearings l l l The motorcycle should be maintained according to the schedule above. The symbols are defined below: ...
Page 13: Unpacking And Setup
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Unpacking and Setup When your CSC motorcycle is delivered, the motorcycle is completely assembled except for the rear view mirrors. Upon delivery, check the condition of the delivered crate. If there are any anomalies, stop and call CSC at 909 445 0900. Check the VIN numbers of the exterior of the crate. Compare these numbers to the documentation delivered to you. If the numbers don’t match, stop and call CSC at 909 445 0900. Rearview Mirror Installation Install left and right rearview mirrors on the motorcycle fairing and adjust them to provide a satisfactory rear view. Fuel Fill with the fuel tank with 87 octane (or higher) gasoline. Inspection Perform the following inspections when servicing the motorcycle.  Check to confirm all fasteners are properly tightened and all components are installed correctly and in an operational state.  Swing the handlebars from side to side to make sure motion is uninhibited.  Check chain tension and rear wheel alignment in accordance with the Chain Drive section of this Service Manual.  Insert ignition key and turn on. ...
Page 14: Frame And Body
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com  Check oil level and tire pressure.  Confirm motorcycle is in neutral.  Place clutch in and start motorcycle. Allow engine to warm.  Check brake and suspension function.  Test ride motorcycle to confirm operability. Detailed inspection checklists are included in Appendix A of this Shop Manual. Frame and Body The frame and body subsystem includes the motorcycle’s steel frame, the seat, the body panels, the sidestand, the footpegs, and the fenders. The rear seat is removable by inserting and twisting the ignition key in the left body panel beneath the seat. The tool kit is stored beneath the rear seat. The front seat is held in place by two 8mm bolts. The rear seat can be removed to provide access to the battery. Body Panel Removal The RC3 has several panels attached to the motorcycle with fasteners. These need to be removed to provide access to the engine, etc., for some of the maintenance activities described in this manual. Remove the fasteners securing the lower tank panels and remove the panels. 13 ...
Page 15 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Remove the fasteners securing the lower tank panels and remove the panels. Remove all of the fasteners securing the side and lower body panels. Remove all of the fasteners securing the side and lower body panels. Remove all of the fasteners securing the side and lower body panels. Frame and body maintenance and troubleshooting guidelines are summarized below. Frame and Body Maintenance and Troubleshooting Item Symptom Cause Vehicle Effect Maintenance Action Frame Frame is hit or falls Frame is curved or Drift Correct or replace the over deformed frame Frame is hit or falls Frame is cracked or Motorcycle cannot drive Weld or replace the over fractured frame 14 ...
Page 16: Brakes
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Item Symptom Cause Vehicle Effect Maintenance Action Frame is impacted Frame welding Shake or drift Weld the frame and shocked by road detachment Side support Deformation or Side support is Noise and compromised Correct or replace the fracture abnormal and cannot parking side support return Left side cover Impact Left side cover Compromised Replace or repair the damaged appearance left side cover Right side Impact Right side cover Compromised Replace or repair the cover damaged appearance right side cover ...
Page 17 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Once the caliper bolts are removed, the pads will slide out. Inspect the brake pads to determine if they are worn beyond their service limit (less than 1.5mm thick). If the pads are worn such that the grooves are gone (visible as vertical slots in the photo above), the pads should be replaced. Reassemble and reinstall the caliper. 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 bolts, and then remove the front brake caliper mounting bolts. 16 ...
Page 18 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Remove the caliper and then remove the bolts from the caliper. Inspect the front brake pads and replace if necessary. Reinstall the caliper bolts and the caliper. Tighten all fasteners. Pump the front brake lever several times. Operate the motorcycle to assure satisfactory front brake performance. 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. The procedure shown here is for the rear master cylinder; the procedure for the front master cylinder is performed in a similar manner. 17 ...
Page 19 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 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. Using a turkey baster or other suction device, remove as much of the brake fluid in the master cylinder as possible. Caution! Exercise caution to prevent any brake fluid spillage. If any spillage occurs, wipe up the spilled brake fluid immediately (it will damage painted or plastic surfaces). Remove the caliper bleed cap and attach a small diameter tube to the caliper bleed fitting. Route the tube to a receptacle. (Note: The photos shown here are for the RX3; the RC3 is similar.) 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. 18 ...
Page 20 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 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. Use only DOT 4 brake fluid. 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 2 mm thick, replace the disk. Use a dial indicator with the wheel off the ground to measure disk runout. Spin the wheel and measure ...
Page 21: Brake Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 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 Worn brake pad(s) Longer stopping Replace brake pad force distance Air in brake lines Reduced braking Air intrusion into Longer stopping Bleed brakes force brake line distance Pulsating brakes Pulsating brake lever Warped rotor disk Pulsations; longer Measure disk stopping distance runout, replace disk rotor Incorrect rear brake Brakes applied too Incorrect rear brake ...
Page 22: Lubing The Chain
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 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 the rear wheel is aligned. To attain correct alignment rear wheel alignment, align the rear axle adjustors such that they are equally aligned with the swingarm scribe marks shown in the above photos. Once the rear axle is aligned and chain tension is properly adjusted, tighten the rear axle nut and the tighten the rear axle adjustors. 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 RC3 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. Caution! Don’t let the lube get on the tire or 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. CSC stocks both wax and petroleum based chain lubes (please call us at 909 445 0900 to purchase these items). 21 ...
Page 23: Sprocket And Chain Inspection
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Sprocket and Chain Inspection The CSC RC3 has a 520 O‐ring type chain. 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. 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 mechanism to remove the countershaft sprocket cover. If the sprocket teeth are hooked or otherwise excessively worn, replace both sprockets. If the chain has excessive stretch or if it has kinks that you cannot work out by manually rotating the links with respect to each other, it’s time for a new chain. On a new RC3 motorcycle, the chain does not have a master link. When you need to replace the original equipment chain on your motorcycle, you will have to cut it off. A replacement 520 chain (call us at 909 445 0900 to order a replacement chain) has a master link that will allow you to install the new chain. Chain Drive Troubleshooting Troubleshooting and maintenance activities for the chain drive system are summarized in the table below. Chain Drive Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Rear Excessive wear Inadequate Chain skipping, chain Replace chain and sprocket lubrication, breakage both sprockets ...
Page 24: Clutch Maintenance
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Clutch Maintenance This section of the RC3 Service Manual addresses clutch cable replacement, clutch adjustment, and clutch replacement. Clutch Cable Replacement and Adjustment To disconnect the cable at the handlebar clutch lever, pull back the rubber grommet to expose the clutch lever knurled adjustment knob and knurled lock nut. Loosen the knurled lock nut, and then fully screw in the knurled adjustment knob. Align the slots in the knurled adjustment knob and the knurled lock nut, as you see in the photo below (note: the photos included here are for the RX3; the RC3 arrangement is similar). Locate the other end of the clutch cable where it attaches to the clutch lever on the engine case. It’s on the left side of the engine behind the cylinder and above the shift lever. Loosen the lock nuts on the threaded adjustment mechanism and move it forward to gain more slack in the cable. Once you have enough slack in the clutch cable, you can remove the cable sheath from the knurled adjustment knob at the handlebar end of the cable, and slide the clutch cable out. This will allow pulling the cable forward and sliding the cable head out of the clutch lever (as shown to the right). Disconnect the clutch cable at the engine end, as shown below. 23 ...
Page 25 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com At this point, the cable should be disconnected at both ends. Clutch cable installation is the reverse of removal. Reattach the clutch cable at both ends and adjust the clutch so that you have 10mm to 20mm of free play at the clutch lever tip. Clutch adjustment is covered in the clutch adjustment process section of this Service Manual below. There are two areas in which adjustments can be made to the clutch. These are the lower end of the clutch cable (where it attaches to the lever on the engine case), and the upper end of the clutch cable (where it attaches to the lever). The primary function of the lower end of the clutch cable adjusting mechanism is to remove most of the slack from the clutch cable. Adjust the lower end of the clutch cable adjusting mechanism so that it is about in the middle of its adjustment range. This will remove nearly all slack from the clutch cable. This is shown in the photo to the right. The final adjustment will be made at the handlebar clutch lever. Once you’ve done adjusted the lower end of the clutch cable, adjust the knurled adjustment know at the handlebar clutch lever such that there is about 10mm to 20mm of free play at the end of the clutch lever. When you’ve done that, lock the knurled adjustment knob in place with the knurled lock nut. Pull the rubber grommet back over the adjustment mechanism. Clutch Replacement If you change your oil regularly and you use the right kind of oil, and if you don’t abuse your bike, your clutch will last a long time. If you abuse your clutch it will wear prematurely. If the clutch is grabby or if it slips, and you can’t fix it by changing the oil or by adjusting the clutch, you need a new clutch. Drain the engine oil and remove the clutch cover by unbolting the five bolts securing it to the engine. This will provide access to the clutch internal components. (Note: The photos shown here are from the RX3; the RC3 clutch is identical to the RX3.) ...
Page 26 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Set the clutch cover aside, inside face up, so that you can use it as container for the parts to be removed next. Remove the six clutch pressure plate bolts. Each bolt has a machined keeper and a spring. Remove the clutch pressure plate. You may need to use a small pick to get behind it to coax it out. There’s a pusher behind the pressure plate that consists of a shaft, a roller bearing, and washer. You can see it in the photo above, and here are additional photos that show these components. 25 ...
Page 27: Clutch Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Inspect the roller bearing and washer. If either part is damaged, replace it. Remove the clutch plates. There are six friction plates and five steel plates. It’s best to use a small pick (as shown below) to do this. If the clutch slips due to the use of an unapproved oil (for example, an automotive oil with friction inhibitors), wash the plates to remove any remnants of the unapproved oil that induced the slippage. Caution! Soak the new clutch fiber plates in motorcycle engine oil for 24 hours prior to installation. If you do not, you may damage the new clutch plates. Replace the clutch plates (contact CSC at 909 445 0900 for replacement parts), and then reinstall the pressure plate, the clutch springs, the keepers, the bolts, and the clutch cover. Fill the engine to the correct level with approved motorcycle oil. Adjust the clutch as outlined above. Clutch Troubleshooting Clutch troubleshooting and maintenance actions are summarized in the table below. Clutch Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Clutch cable Breaks Wear, improper Clutch will not disengage Replace clutch cable adjustment, inadequate lubrication 26 ...
Page 28 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Item Symptom Cause Vehicle Effect Maintenance Action Clutch cable Sticks or grabs Wear, improper Difficult clutch operation Lubricate or replace adjustment, clutch cable inadequate lubrication Clutch Slips Incorrect engine oil, Loss of power Adjust clutch, check worn clutch plates, transmission, engine over engine oil, replace improper clutch revving clutch plates adjustment Clutch lever Too little or too much Incorrect clutch Clutch engages early, or Adjust clutch play at clutch lever adjustment, worn clutch slips clutch plates Difficult Transmission does Incorrect clutch ...
Page 29: Suspension
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Suspension The suspension subsystem includes the forks, the rear shock absorber, and the swingarm. Fork Maintenance The front forks of this motorcycle are an inverted hydraulic spring design. When the front wheel receives irregularities in the road and moves up, damping oil inside the forks flows upward through tiny holes. This provides damping. The RC3 has adjustable damping incorporated in its front forks. Check the performance of the forks and inspect for leaks. Prompt inspection and maintenance should be given to the forks when any abnormalities are found. If you wish to use a higher viscosity fork oil to stiffen the forks, please call CSC to discuss which oil will best meet your needs. Lift the front end of the motorcycle in accordance with the guidance provided in this Owner’s and Service Manual. Remove the front wheel and tire in accordance with the front wheel removal guidance provided in this Owner’s and Service Manual. Remove the four Allen bolts securing the front fender and remove the front fender. Loosen (but do not remove) the two Allen pinch bolts on the upper triple tee. 28 ...
Page 30 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Loosen (but do not remove) the Allen bolt securing the fork top clamp. While holding the fork, loosen (but do not remove) the lower triple tee Allen pinch bolts. Caution! When both are loose, the fork will be free to fall, so make sure you are holding it as these bolts are loosened. Carefully slide the fork from the triple tees. Caution! T ake care not to scratch the front fork anodizing. Using a small screwdriver, gently pry the lower fork seal away from the fork upper. Caution! T ake care not to scratch or gouge the fork upper. Fully unscrew the damping adjuster until it can no longer be turned. 29 ...
Page 31 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Unscrew the front fork cap assembly. Caution! We use a rag over the aluminum hex head and a socket one size larger to avoid marring the cap assembly. The fork contains oil, and when you remove the cap assembly, tilting the fork down will allow the oil to drain. Drain the oil into a receptacle. Next unscrew the fork cap assembly from the fork internal rod. This is made challenging by the fork spring and the lock nut arrangement securing the fork internal rod to the fork cap assembly. After unscrewing the fork cap assembly, remove the fork spring. Remove the inner clip securing the lower fork seal. 30 ...
Page 32: Rear Shock Absorber
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com At this point, the fork lower can be removed from the fork upper. Drain any remaining oil in the fork lower. Inspect the condition of the seals, the spring, the fork lower plated surfaces, and the bushings. If any parts are damaged, please contact CSC for replacements at 909 445 0900. The fork capacity is 270cc in each fork leg. We generally use 10W fork oil when replacing the fork oil. Please contact CSC at 909 445 0900 if you need fork oil. Assembly is the reverse of disassembly. Torque all fasteners in accordance with the torque table in the CSC RC3 Owner’s and Service Manual. Torque the fork cap assembly to 35 ft‐lbs, but do so after the upper and lower triple tees (but not the fork top clamp) pinch bolts have been tightened. Torque the fork top clamp pinch bolts after torqueing the fork cap assembly. After you’ve reassembled the forks, tighten all fasteners in accordance with the torque table in the CSC RC3 Service Manual torque specification table. Rear Shock Absorber The rear shock absorber is a hydraulic spring composite rear shock absorber, which consists of the upper connector, buffer rubber sheath, bushing, rear shock absorber spring, rear shock absorber lever, piston rod, damper, and lower connector. 31 ...
Page 33: Suspension Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com The rear shock absorber supports the rear of the motorcycle. When the motorcycle rear wheel receives impacts and shocks from the road and the rear shock absorber compresses or extends, hydraulic oil in the damper is forced to flow through damping holes, which reduce the motion of the rear shock absorber. The rear shock absorber has a damping adjustment shown in the photo below. Turning the screw clockwise increases damping; turning it counter‐ clockwise decreases the damping. (Note: The photo shown here is of the RX3 rear shock absorber; the RC3 unit is similar.) Suspension Troubleshooting Suspension maintenance and troubleshooting actions are summarized in the table below. Suspension Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Forks Fork has poor elastic force Spring excessively Poor comfort Replace fork spring or is broken soft Fork distorted Left and right forks Poor fork action, Adjust fork are not at same motorcycle pulls to ...
Page 34: Swingarm
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Steering Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Handlebar Bent Impact Drift Replace handlebar Steel ball race Excessive tightness Overtightened Sticky Adjust using a locking of adjusting nut movement wrench until steering column can rotate freely with no end play between steering column and frame Excessive abrasion, Contamination Sticky Replace whole set of pitting, dirt, crack movement, steel ball and race and damage swing and shaking of handlebar while driving Steering race balls Abrasion, Contamination Sticky ...
Page 35: Front Wheel Removal
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Both the front and rear wheel and tire should be dynamically balanced any time either tire is removed and reinstalled or when a new tire is installed. Front Wheel Removal Lift the front end of the motorcycle as addressed in the motorcycle lifting maintenance tutorial. Remove the bolts restraining the front brake caliper. Loosen (but do not remove yet) the front axle bolt. Loosen (but do not remove) the Allen pinch bolts at the bottom of the fork legs (there are two on each fork). Remove the front axle nut on the left side of the motorcycle and pull the axle out to the right. Note that there are two bushings (one of each side of the front wheel) between the front wheel and each front fork. 34 ...
Page 36: Rear Wheel Removal
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Reassembly is the reverse of disassembly. Torque all fasteners in accordance with the torque table provided in the RC3 Owner’s and Service Manual. Rear Wheel Removal Lift the motorcycle in accordance with the instructions in this manual for lifting the motorcycle. Remove the rear axle nut. It unbolts from the left side only; the right side uses and indexed Pull the rear axle out from the left side of the motorcycle. After removing the axle, push the rear wheel forward and lift the chain off the sprocket. You don’t have to remove the chainguard to get the chain off, and you don’t have to remove the rear brake caliper to get the wheel off. Once the chain is off the sprocket, roll the wheel out from under the motorcycle. At this point, you can remove the rear wheel from the motorcycle by rolling it to the rear. Wheel and Tire Inspection Check if the tire air pressure is within the specified range (33 psi front and 35 psi rear). Inspect the valve stems for lock nut installation, lock nut security, and valve stem condition. Do not operate the motorcycle without the valve stem cap in place. Inspect the tire condition. Replace any tire with tread that is worn down to the tread wear indicator (or if the tread remaining is less than 2mm), if the tire exhibits cupping, or if the tire has any other defects. Check the rims for dents, bends, or chips in the casting. If the rim is defective, it should be replaced. When the wheels are removed from the motorcycle, check the grease seals, the wheel bearings, and the rear wheel cush drive rubber cushion. If the grease seals are cut or torn, they should be replaced. If the wheel bearing inner races are loose, gritty when rotated, or noisy, replace the bearing. If the cush drive cushion is damaged or degraded, replace the cushion. Balance the wheel and tire on a dynamic balancer. Wheel and Tire Troubleshooting The table below summarizes wheel and tire troubleshooting and maintenance. Wheel and Tire Troubleshooting and Maintenance Item ...
Page 37: Fixing Flat Tires
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Fixing Flat Tires If your motorcycle has a flat tire, check for any obvious causes on the outside of the tire. Prior to lifting the bike to get the wheel with the flat tire off the ground, loosen the axle bolts (just loosen them, do not remove them). Caution! CSC does not recommend patching a tire with a puncture. CSC recommends replacing the tire if it is punctured. Remove the wheel with the flat tire in accordance with the instructions for doing so in this Owner’s and Service Manual. Place the wheel on its side, with the brake disk facing down. Let the air out of the tire. (Note: The photos shown here are from the RX3; the RC3 is comparable.) Break the bead around the tire. You only need to do this on one side of the tire. Usually, just stepping on the tire (as shown below) will unseat the tire from the rim. After you’ve broken the bead, spray the area between the bead and the rim with a rubber lubricant designed for tire mounting. Using a tire iron (you’ll need two), insert the tip between the tire and the bead, and pull the bead over the rim. Using the second tire iron, pick a location about 6 inches away (measured circumferentially on the rim) and do the same thing. Remove the first tire iron and repeat the process. Remove the tire from the wheel. 36 ...
Page 38: Lifting The Motorcycle
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Install the new tire on the rim using tire irons. Inflate the tire until it seats on the wheel rim. Liberal use of spray lubricant will help to seat the tire bead on the rim. Once the tire bead is seated on both sides of the wheel rim, deflate the tire. Reinstall the tire and wheel on the motorcycle. Adjust the tire to the proper pressure. Caution! Do not ride the motorcycle with under‐ or over‐inflated tires. The motorcycle’s handling will be adversely affected. Lifting the Motorcycle To lift the motorcycle from beneath the frame, it is necessary to remove the lower body panel (the body panel that is underneath the engine). Once the lower panel has been removed, add a support between the catalytic converter and the underside of the engine if the motorcycle lift is positioned beneath the catalytic converter. Caution! If you attempt to lift the motorcycle beneath the catalytic converter without adding a support between it and the engine, you may damage the motorcycle. Alternatively, you can remove the exhaust pipe to and lift the motorcycle by positioning the lift directly beneath the engine. Engine The RC3 engine is a water‐cooled, overhead cam, counterbalanced engine. Engine Break‐In Procedure Caution! When an internal combustion engine is new, it should not be subjected to hard acceleration, lugging, overheating, or running for long periods at a constant engine speed. You should avoid these situations during the first 500 miles of service. We recommend the first oil change when the motorcycle reaches between 200 and 500 miles. We recommend a second oil change at 1,000 miles, and every 2,500 miles thereafter. We recommend using only 10‐40W or 20‐50W motorcycle oil. Caution! Never use any oils intended for automotive use, 37 ...
Page 39: Oil Changes
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com or any oil that contains friction reducing additives (use of these oils will induce clutch slippage not covered by the CSC warranty). Use only non‐synthetic oils during the first 1000 miles of use. After that, you may wish to change to synthetic motorcycle oil. The oil change procedure is outlined in the next section. Oil Changes The following information applies to RC3 oil and oil changes.  The RC3 takes 1.7 quarts (55.4 ounces) of 5W‐40 or 10W‐40 motorcycle oil.  The RC3 has two cleanable and reusable oil strainers (one on the left side of the engine and one on the right side), and one oil filter (you should replace the oil filter with each oil change).  The RC3 has two oil fill ports (both on the right side of the engine), but you only need to use one or the other to replace the oil.  The RC3 has an oil viewport on the right side of the engine for assessing engine oil level, and the bike needs to be vertical to use it. The engine does not have a dipstick.  You’ll need a 17mm socket to remove the oil strainer caps and the oil drain plug.  You’ll need an 8mm socket to remove the oil filter cover nuts.  The RC3 tool kit includes a 17mm socket and an 8mm wrench, but we don’t recommend using them for changing the oil. The oil filter and oil strainer locations can be seen in the drawings below. This is what the strainer and filter caps look like on the engine. The oil strainer is the large 17mm bolt head, and the oil filter cover is held in place by two 8mm nut on the right, and the left oil strainer is 38 ...
Page 40 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com located on the left side of the engine. The left side oil strainer cover is the 17mm bolt head just beneath the shifter. (Note: The photos included here are of the RX3 engine; the RC3 engine is similar.) Use a 17mm socket with an extension to remove the oil strainer caps. Use an 8mm socket and an extension to remove the oil filter cover. We can provide these tools to you as part of an oil change service pack; we also sell the oil change tool kit separately if you do not have these tools. Place an oil pan under the motorcycle and remove either or both of the oil fill ports. The rearmost oil fill plug has a slot. It’s on the right side of the engine. A penny works well for removing it. There’s another fill port on the right side of the engine. You can remove that one by hand. You don’t need to remove both filler caps; either will allow in air when you drain the oil. Both access port covers have o‐rings; take care not to lose these parts or to allow the o‐rings to pick up dirt. After opening either or both of the oil fill ports, remove the oil drain plug. The oil drain plug is on the bottom of the crankcase. The oil drain plug also has a 17mm bolt head. The photos below show the socket on the drain plug and the drain plug after it has been removed. The oil drain plug has a copper gasket. It is not necessary to replace this unless oil leaks from around the drain plug. The drain plug has a magnetic core. Wipe it clean. 39 ...
Page 41 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com The next step is to remove the oil strainer covers. This requires a 17mm socket and an extension. The photos below show this on the left and right engine sides, and one of the covers after it has been removed. Set the oil strainer covers aside, taking care not to lose the o‐rings on the inside or put them where they could become dirty. Next, remove the oil filter cover. It is secured by two 8mm nuts. You can attempt to remove these with the 8mm wrench provided with the RC3 tool kit; a much better approach, though, is to use an 8mm socket with an extension. Remove the two 8mm nuts and the access port and set them aside, taking care not to lose the nuts. The oil filter cover also has an O‐ring. Take care not to get the O‐ring dirty or lose it. The spring inside the cover is orientation insensitive; it can be inserted either way. Once you have removed the filter cover, you’ll see the metal end of the oil filter, as shown in the photos below. Slide the oil filter out of the engine. The easiest way to do this is to take the magnetic drain plug, put the magnet end against the oil filter, and slide it out. The oil filter end with the rubber gasket goes into the engine first. Install a new oil filter with each oil change. Next remove and clean the oil strainers. Remember that there are two (one on each side of the engine). You can pull the oil strainers out of the engine using a pair of needle nose pliers. You can clean the oil strainer using WD40 or compressed air. 40 ...
Page 42 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com After removing the oil filter and the oil strainers, additional oil will drain from the engine. Hold the bike in the vertical position so that any remaining oil will drain from the crankcase. After all oil has drained from the engine, reinstall the oil strainers, the oil filter, the oil strainer covers, and the oil filter cover. The oil strainers are different on each end. Install the thin end of the oil strainer first. The thin end of the oil strainer is shown in the photo on the left (this end should go in first); the thick end of the oil strainer is shown in the photo on the right (it should point out). After installing the oil strainers, install the oil strainer covers on both sides of the engine. Next, install a new oil filter. Remember that the end with the black rubber gasket goes into the engine first. After inserting the oil filter in the engine, replace the oil filter cover and spring and secure it with the two 8mm nuts. Caution! Do not overtorque these nuts. Reinstall the oil drain plug. After the drain plug, the oil filter, the oil filter spring, the oil filter cover, the oil strainers, and the oil strainer covers have been installed, add new oil to the engine. The engine takes 1.7 quarts (55.4 ounces) of oil. Use a funnel to prevent spillage. After adding oil to the engine, start the engine and allow it to reach operating temperature. Stop the engine and wait one minute. The oil level should even with the upper mark on the viewport when the motorcycle is in the vertical position (straight up and down; not on the sidestand). The viewport is located on the right side of the engine. 41 ...
Page 43: Valve Adjustment
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Reinstall both oil fill caps (the one with the slot and the one with the extension for turning by hand). Start the motorcycle and let it run for a couple of minutes, and check for leaks. CSC Motorcycles can provide you with everything you need to change your oil, including recommended regular and synthetic oil. We offer a complete oil change service pack. Call us at 909 445 0900 to order these items. Valve Adjustment CSC recommends inspecting the valve gap at 500 miles, and adjusting the valves every 5000 miles. If the motorcycle is ridden aggressively or at high rpm for extended periods, you may need to increase the valve adjustment frequency. The CSC RC3 has a high performance, single overhead cam, 4‐valve engine. There are two exhaust valves and two intake valves. The CSC RC3 has a single camshaft with two lobes, and two rocker arms. One rocker arm actuates both intake valves; the other rocker arm actuates both exhaust valves. The cam’s lobes are what actuate the rocker arms. As the cam lobe lifts the rocker arm, the rocker arm pivots on its shaft. The rocker arm has one arm that follows the cam lobe up and down, and two arms that actuate its two valves. The engine opens the intake valves to admit the fuel/air mixture, and it opens the exhaust valves to expel the exhaust. When the engine is at the top of its compression stroke, all of the valves are closed. This allows for compression of the fuel air mixture, ignition, and the resulting high combustion pressures will drive the piston down. 42 ...
Page 44 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com If any leakage occurs around any of the valves while this is occurring, the engine will lose power and it could “burn” a valve if the combusting fuel/air mix escapes around the valve while it is still burning. When engineers design an engine, they want it to do the above, but they have to account for the thermal expansion that occurs as engine temperature increases during normal operation. In order to compensate for this thermal expansion, the engineers design in a gap in the cam lobe/rocker arm/valve train. As the engine warms, this gap approaches zero, and everything works the way it is supposed to. The valves close against the valve seat every time they go up and down. As the valve pounds against the seat when the engine runs, very small amounts of deformation occur in both the valve and the valve seat. It’s microscopic, but it grows over time as the engine runs. As this wear increases, it has the effect of reducing the valve gap (i.e., the clearance built into the valve train to account for the thermal expansion as the engine warms up). What happens is that as this wear occurs, the valve actually moves higher into the cylinder head and the valve gap decreases. If this wear goes beyond acceptable limits without adjusting the valves, the valve gap grows smaller and smaller. Ultimately, this wear will result in the valve being held off the seat when combustion occurs. When this condition exists, hot burning gases escape around the valve sealing area. Ultimately, these burning gases will destroy the valve and the seat. That’s what happens when a valve “burns.” This above undesirable condition is avoided by adjusting the valves. This keeps gaps in the valve train within an acceptable range over the life of an engine. As the valve and the valve seat wear, valve we keep everything adjusted so that when the engine is at operating temperature it still forms a good seal around the valve seat. Different engines use different approaches for adjusting the valves. The CSC RC3 uses the best approach for easy maintenance and high performance: It uses a threaded adjustor shaft with a lock nut to set and lock the valve gap. These adjustors are located in the ends of the rocker arms that interface directly with the valve stem. These are shown in the sketch above, and in the photos that follow. The CSC RC3 valve adjustment process consists of the following steps: 1. We gain access to the valve rocker arms and their adjustment screws. 2. We position the engine to be at a point in its rotation such that the rocker arm is on the cam’s base circle. This means the cam is not actuating the rocker arm. We want the engine to have ...
Page 45 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Remove the rear seat with the key lock, the front seat with its two 8mm bolts, all of the bodywork around the fuel tanks, and the fuel tank. If you do this when the fuel tank is low on fuel, it will make handling the fuel tank easier. Make sure you don’t spill any fuel, and make sure you put the fuel tank in a location where there are no ignition sources. Take care not to scratch any of the body work. (Note: The photos shown here are of the RX3 motorcycle; the RC3 is similar.) The next step is to unbolt the RC3’s radiator. You don’t have to disconnect the hoses or remove the radiator; you just want the radiator to be loose so that you’ll have access to the valve covers on top of the cylinder head. Unbolt the radiator but leave it in place…don’t disconnect the hoses. After you’ve done the above actions, remove the access port on the left side of the engine crankcase. It comes off with a 10mm Allen wrench, and inside of it, you’ll see another Allen receptacle. This is connected directly to the crankshaft, and it’s what we’ll use to manually rotate the engine. 44 ...
Page 46 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Next, remove the view cap on the left front of the engine crankcase, just forward of the port described above. This is the view port for viewing the stator cover, and this allows us to position the engine at top dead center. Next, remove the view caps on the left cylinder head. They can be removed with a 6mm Allen wrench. These view ports will allow determining that the engine is at top dead center. The next step is to pull the wire off of the spark plug and then remove the spark plug. Finally, remove the intake and exhaust valve covers. Each cover is secured with two 8mm bolts. Note that the covers are not interchangeable, and they are orientation sensitive. The rear valve cover is removed with a ratchet and an extension; the front valve cover is removed without the ratchet extension. 45 ...
Page 47 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Once the bike is opened up for valve adjustment as described above, the next step is to position the piston at top dead center. With the motorcycle in neutral, insert a 10mm Allen wrench through the crankcase port and turn the crankshaft until the alternator scribe line is aligned with the index register in the viewing port, as shown in the photo to the right. Align the scribe line with the index register in the center of the viewing port on the engine crankcase and the “L” and “R” marks are visible in the cylinder head viewing ports. There are scribe lines on the cam chain sprocket next to the “L” and “R” marks, these should be aligned with the machined marks in the viewing ports’ threaded regions as shown below. When these marks are aligned (as shown below), the scribe line will be visible in the crankcase viewing port. Once the engine is positioned as described above, insert a feeler gage between the valve and the threaded adjustor as shown above. This gap should be 0.04mm to 0.08mm. If the 0.08mm leaf slides in too easily, the valve gap is too large. That can result in noisy valves (valve tap). If the 0.04mm shim does not slide into this gap, the valve gap is too tight. When we adjust the valves, we always set them to 0.08mm. As the valves and valve seats wear, the wear will move the valve gap through the 0.04mm to 0.08mm adjustment range. The valves are adjusted by loosening the lock nut on each threaded adjustor (the lock nut is 8mm). Back the threaded adjustor out a bit with a flat blade screwdriver (see the photo below), insert the 0.08mm shim, and then screw in the adjustor until it’s just snug against the shim. There should just be a bit of drag on the shim when it is slid in and out When the gap is at the 0.08mm value, tighten the lock nut. Then check the gap with the shim again. 46 ...
Page 48: Engine Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Perform this same adjustment (and set each valve at the same gap) for all four of the RC3’s valves. Caution! Make sure you tighten the adjustor lock nuts. Failing to do so will allow the locknuts to back off of the valve adjustment mechanism and damage the engine. When finished, manually rotate the engine through two couple of revolutions and check the valve gap again. If it is not within specification, repeat the above process until it is. After completing the above, reassemble all components. Engine Troubleshooting The diagrams below outline procedures for troubleshooting engine anomalies. Engine diagnosis procedure: Smoke from exhaust. Dense blue‐white smoke from exhaust silencer of four‐stroke engine Yes No Inspect if the engine oil level in the crankcase exceeds the upper mark If the crankcase is filled with excess engine oil, the Start the engine, screw off the vernier scale at the unnecessary engine oil shall be discharged such that high‐speed operation and inspect if any smoke is the engine oil level is below the upper mark distributed from the oil inlet Yes [1] Inspect if the cylinder, the Inspect if the lash between valve and valve guide is piston and the piston ring are excessively big or not highly worn. [2] Inspect if the piston ring is Yes of sufficient elasticity or if it is stuck inside the slot. [3] Inspect if the opening of the Inspect if the valve and the ...
Page 49 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Engine diagnosis procedure: Engine idle speed. Poor idle speed of engine Higher idle speed of engine No idle speed of engine Unstable idle speed of engine Inspect compression Pull the throttle with hands and inspect Inspect if the ignition timing is pressure of cylinder if it is completely closed proper Yes No Inspect via the failure Check if the wire rope of the Turn off the ignition diagnostic tester accelerator operation cable switch, reset the idle is flexibly drawn in the cable speed step motor 10 wire cover and if the throttle seconds after the spring is excessively soft shutdown and restart No the step motor ① Inspect if the CDI Yes igniter fails If the idle speed is still high, inspect with the Inspect if the ② Inspect if magnetor failure diagnostic tester clearance between flywheel and the ...
Page 50 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Engine diagnosis procedure: Poor engine performance. Poor performance Erect the main stand, suspend the wheels and rotate the wheels with hands Free rotation of wheel Inflexible wheel rotation ① inspect if the brake is dragged Inspect the tire pressure ② Inspect if the wheel bearing is excessively worn or damaged Lower pressure ③ Inspect if the spacer brush of wheel hub is missed or if Normal pressure it is excessively short Remove the spark plug, block the spark plug thread hole with fingers, Inspect if the tire valve core is press start button leaked and if the tire is broken Feel the violently‐pushing gas and hear the Feel no violently‐pushing gas. It means the compression puff pressure of cylinder is insufficient Normal compression pressure Insufficient compression pressure ① Inspect if the external joint of engine has any Start the engine, slowly accelerate leakage and observe the change of engine ② Inspect if the valve timing mechanism works speed properly. ③ Inspect if the valve lash is excessively small. ④Inspect the airtightness between valve and The engine The engine speed does not valve seat. speed goes up go up with greater throttle ⑤ Inspect if the piston ring is fractured, ...
Page 51 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Engine diagnosis procedure: Difficult to start engine. Unable or hard to start engine Inspect the ignition system Yes No Remove the spark plug and inspect if the spark plug electrodes are connected via the carbon Remove the carbon deposition Conduct the spark‐over test Strong blue or bluish violet flame found between electrodes Weak or no flame between electrodes Inspect if the engine ignition is operational Screw off the spark plug cap and conduct the spark‐over test on the high‐voltage line No Yes 1. Inspect if the CDI igniter fails Ignite and start after Weak or Strong blue flame 2. Inspect if the magentor pulling out the injector. no flame flywheel and the triggering coil Inspect if the injected are loosened fuel is atomized Inspect spark plug, spark plug cap for Yes No trouble Inspect if the fuel tank is filled with gasoline Inspect the Inspect if the Inspect if the Inspect if the ...
Page 52 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Engine diagnosis procedure: Overheated engine. Overheated engine Yes Inspect if the operation and use is proper ① Inspect if the gasoline brand is wrong or the Inspect the cooling system gasoline is stored for a long time ② Inspect if the engine has been running at high Air cooling engine speed over a long period or been overloaded Yes Inspect if the radiation fin is polluted by the mud and sand or contains excess oil dirt No Cleaning No Yes Inspect if the engine is ignited at the correct time ① Inspect if the CDI ignition device fails Inspect if the clutch slides ② Inspect if the magnetor flywheel and the triggering coil are loosened Clutch slide No Process as per 1.6 Remove the spark plug, observe the color of spark plug insulation apron The spark plug insulation apron is dark black and the and judge the mixing proportion of black smoke or blowout is found in the exhaust combustible mixture according to silencer when the engine is rotated at intermediate different abnormalities. and low speed. The idle speed performance is poor, the idle speed is instable and it is easy to shut down. The spark plug insulation The engine is operational under high‐speed The spark plug ...
Page 53 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Engine diagnosis procedure: Excessive fuel consumption. Excessive fuel consumption No Yes Inspect if the operation and use method are correct ① Inspect if the motorcycle is running Erect the stand and rotate the wheels with hands with overloaded or running at the non‐ economic speed or low speed gear ② Inspect if the gasoline brand is correct Inflexible rotation of wheels Free rotation of wheels Normal pressure ① Inspect if the brake is dragged Check the tire pressure Check if the fuel tank, the oil delivery pipe ② Inspect if the wheel bearing is excessively worn and the like are leaked and if the oil pipe Excessively‐low pressure ③ Inspect if the middle hub is locked spacer bush of hub has any leakage or is excessively Fill the tire as per the provisions Yes No short Solve the problem according to the real conditions Inspect the mixing proportion of combustible mixture Normal mixing proportion of Dense combustible mixture Thin combustible mixture combustible mixture ...
Page 54 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Engine diagnosis procedure: Difficult gear shifting. Sticky gear shifting Yes No Start the engine and inspect if the engine idle speed is excessively high Adjust again Inspect if the gear shifting operation is coordinated Inspect if the clutch is completely disengaged Improve the operation method Yes No [1] Inspect if the clutch has uniform spring Inspect if the gear shifting shaft is deformed and if the elasticity gear shifting arm is deformed or excessively worn [2] Inspect if the driving hub tooth space and the driven hub tooth space are worn and shaped as Yes No the zigzag shape [3] Inspect if the clutch friction sheet iron is wrapped and deformed Replace [4] Inspect if the parts of the clutch operation mechanism is excessively worn [1] Inspect if the cam groove of gear shifting cam shaft is excessively worn or damaged [2] Inspect if the shifting fork is excessively worn [3] Inspect if the shifting fork is deformed [4] Inspect if the shifting fork shaft is deformed or excessively worn 53 ...
Page 55: Fuel System
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Fuel System The fuel supply system consists of the fuel tank, fuel pump, fuel injector, fuel filter and fuel hoses. Controlled by the ECU, the fuel injector sprays appropriate atomized fuel into the engine. The fuel supply pressure is 250kPa. The fuel should be 87 octane gasoline or higher. The fuel tank is stamped and welded from 0.8mm—l.0mm thick steel plate. There is a fuel filler port on the top of the tank, and the tank has a locking cap. To access the fuel pump and other parts of the fuel system, remove the rear seat with the ignition key, remove the rider seat, and then tilt the fuel tank up. Caution! It is best to do this with the fuel drank empty or nearly empty. Remove the fuel tank forward panel. The fuel tank forward panel is retained by two bolts. 54 ...
Page 56: Fuel System Maintenance
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com After removing the fuel tank forward panel, you will have access to two bolts securing the front of the fuel tank. Remove the two bolts. After removing the two forward fuel tank retaining bolts, you can tilt the fuel tank rearward to provide access to the fuel system components. Fuel System Maintenance Warning!  Disconnect the positive battery terminal when performing any work around the fuel system.  Fuel is a combustible material. 55 ...
Page 57: Electronic Fuel Injection System
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com  Smoking and open flames are strictly prohibited around any fuel system repairs.  Shut off the engine and operate in a well‐ventilated area whenever working on the fuel system.  If there is fuel leakage from the fuel tank cap, the fuel tank cap seal must be replaced.  Check for any fuel leakage from the tank.  If there is leakage, the tank must be repaired or replaced.  If the tank has any deformation due to the collision of external forces, such as pits, you can use a wood hammer to knock the pits up. If there are any cracks in the tank, you must replace the tank.  When you replace the fuel lines or fuel filter, you must shut off the ignition switch to stop the fuel pump to avoid spilling fuel.  Check for any fuel leakage or degradation in the fuel lines or if the fuel filter is blocked.  If there is any fuel leakage or degradation in the fuel lines, the fuel lines must be replaced.  When you drain the fuel, keep it away from combustion sources to avoid fire.  Drain the fuel before removing the pump, and keep it away from the combustion source to avoid the fire. ...
Page 58 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com The ECU is a single chip‐based microprocessor. The ECU recognizes working conditions of the engine after analyzing it through sensors installed on the engine and other locations. The ECU precisely controls the engine and corresponding systems. The engine rpm and crank angle sensor is a magneto‐electric sensor through which the system can determine the location and speed of the crankshaft. The crank angle sensor, which is installed on the clutch cover of the transmission, works with the gear of the flywheel. The MAP sensor is installed on the inlet pipe to measure the pressure. The ECU judges the air amount entered into the engine through this signal. The MAP sensor consists of a sealed elastic membrane and a ferromagnetic core, both of which are placed precisely inside the coil. When it senses pressure, the MAP will generate a 0～5V output signal in direct proportion to input pressure. The throttle plate position sensor, a linear variable resistor structure installed on the throttle valve body assembly, shares the same axle with throttle linkage and throttle valve and its slide end is driven by the throttle plate axle. The resistance signal given to the ECU from the sensor varies from throttle opening to throttle opening. The system will judge the engine’s real‐time loading and dynamic change according to the output signal value and the rate of change, giving precise control to the engine. The intake air temperature sensor is installed on the air intake system articulating pipe to detect the air temperature entered into the engine, and it also adopts negative temperature coefficient thermistors as its sensing elements. The air temperature change directly affects its density. Therefore, the intake air temperature sensor is one of the most important parameters to calculate the actual air amount entered into the cylinder. The injector nozzle is structurally an electromagnetic switch. Two poles of coil are connected to the ECU with engine wiring harness, and the coil, controlled by the ECU, will generate magnetic force against spring force after being energized; the magnetic force will disappear and the injector nozzle will shut down after the power being cut off. The top end of fuel injector, which uses a rubber seal ring, along with the fuel rail connector forms reliable pressure fuel seal; the lower end uses a rubber seal ring as well, and it forms an air seal along ...
Page 59: Electronic Fuel Injection System Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com The oxygen sensor is installed on the engine exhaust pipe, and is an important part of the closed loop fuel control system. The main sensitive material of the oxygen sensor is cobalt oxide. It becomes active after being heated by exhaust gas with a temperature over 300°C. When this occurs, oxygen ions will move through the cobalt oxide to reach the external electrodes. The cobalt oxide parts will sense the oxygen content in the engine exhaust, changing its output voltage value accordingly. The oxygen sensor uses Teflon‐insulated wires and preformed elements made of stainless steel. Reference air is input through these wires. As the air‐fuel ratio in the engine combustor becomes thinner, the oxygen content in the exhaust will become higher and the output voltage of the oxygen sensor will become lower; conversely, the output voltage value will become higher, thus giving the ECU feedback about the engine air‐fuel ratio. Electronic Fuel Injection System Troubleshooting The RC3 electronic fuel injection system is adjusted before it leaves the factory. A malfunction indicator light is fitted on the motorcycle instrument cluster. When starting the engine, the light will illuminate and then extinguish. If a malfunction occurs, the light will flash. If any malfunction occurs in the electronic fuel injection system, you can check the system by using the diagnostic tester. Please contact CSC Motorcycles at 909 445 0900 if you wish to purchase or rent the diagnostic tester. Replace any parts shown to be malfunctioning. Additionally, you should:  Check if the wire connections are intact. 58 ...
Page 60: Intake And Exhaust System
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com  Check if the voltage is above 9V.  Check if the fuel hoses are in good condition. If any of the fuel hoses are blocked, kinked, or otherwise damaged, replace the hose. Fuel System Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Fuel tank Rusty tank body Water intrusion Fuel leakage, clogged fuel Repair or replace filter the tank Fuel supply impeded Fuel cap vent Starting failure, engine Clean air vent clogged stalls Deformed tank Impact Poor appearance Repair or replace tank Fuel pump Fuel supply impeded Filter screen Starting difficulty, Clean filter blocked insufficient power, unstable idle speed ...
Page 61: Exhaust System
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Once the lid has been removed, the air filter will be accessible. Remove the air filter for cleaning or replacement. After repeated cleanings, or when the air filter element ages, it will ultimately need to be replaced. If you need replacement air filter elements, call CSC for a replacement element. After cleaning the air filter element (or replacing the air filter element), reinstall the air filter in the motorcycle and reinstall all components. Caution! Do not ride the motorcycle without the air filter element installed. Exhaust System Warning! The exhaust system components get very hot. Do not touch them while the engine is running. After stopping the engine, allow sufficient time for these components to cool before attempting any maintenance on or near these components. The exhaust system consists of the exhaust pipe, the muffler, a catalytic converter, a heat shield on the exhaust pipe, an oxygen sensor, an exhaust header gasket, and related mounting fasteners. These components are shown in the photos below. 60 ...
Page 62 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com The exhaust system functions are to discharge exhaust gas, to reduce noise, to eliminate flames or sparks from the exhaust, and to assist in the emissions control process. To remove the exhaust system, remove the fasteners from the muffler, the exhaust pipe, the muffler support, and the catalytic converter. Check the muffler suspension support and all other components for any cracks and repair or replace if necessary. Check the exhaust muffler seal and replace it if necessary. Replace the oxygen sensor if necessary. Check the muffler for any cracks or other damage, and repair or replace it if necessary. Caution! Do not operate the motorcycle without the muffler. Caution! Install a new exhaust header gasket when removing and reinstalling the exhaust pipe. 61 ...
Page 63: Intake And Exhaust System Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Intake and Exhaust System Troubleshooting Intake and exhaust system troubleshooting and maintenance actions are shown below. Intake and Exhaust System Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Intake system Hard starting, Excessive dust Poor performance, poor Clean or replace the air low power on the air idling, excessive fuel cleaner element cleaner consumption, dark smoke element exhaust Excessive intake Cracks or Poor performance, excessive Replace the air cleaner noise chaps on the intake noise shell air cleaner shell Exhaust system Excessive Cracks or Poor performance, excessive Replace defective ...
Page 64: Checking And Adjusting Cooling Fluid Levels
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Your RC3 motorcycle has a high performance aluminum engine and it needs a cooling fluid designed to work in this kind of engine. Use only cooling fluid designed for high performance aluminum engines. CSC stocks approved Coolanol by Maxima, a cooling fluid that is the right one for these engines. Please call us at 909 445 0900 if you wish to purchase coolant fluid. Checking and Adjusting Cooling Fluid Levels You can easily get to the radiator cap and the overflow container from the front of the motorcycle without removing the any body panels. 63 ...
Page 65: Flushing And Replacing The Cooling Fluid
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Check the coolant level in the overflow container. The overflow container should show a fluid level between the top and bottom of the container. It is normal for this level to vary as the motorcycle is operated and when the motorcycle is turned off. If you need to add fluid to the overflow container, unscrew the overflow container’s twist top. Use a funnel to avoid spilling fluid. When the engine is cold, the coolant level should not be below the lower mark on the coolant reservoir; when the engine is hot, the coolant level should not be above the upper mark on the coolant reservoir. Check the cooling fluid level in the radiator. Use caution opening the radiator cap, and only open it when the engine is cold. The fluid level should be even with the bottom lip in the radiator when the radiator cap is opened. Flushing and Replacing the Cooling Fluid Flush and replace the cooling fluid every 2 years. Open the cooling system drain plug on the right side of the engine just beneath the water pump (it has a copper gasket beneath the bolt head). (Note: The photos shown here are for the RX3; the RC3 is similar.) Allow the cooling fluid to completely drain from the radiator. Move the bike to a completely vertical orientation to allow the radiator to drain completely. Note that the temperature sensor has a rubber gasket to form a seal between it and the radiator. Take care not to damage this seal when removing and reinstalling the sensor. At this point, all cooling fluid should have drained from the motorcycle. Reinstall the cooling fluid drain plug (just beneath the water pump) and the temperature sensor. 64 ...
Page 66: Cooling System Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Add one liter of new cooling fluid to the radiator. Use a funnel to prevent spilling cooling fluid on the engine, and again, immediately wipe up any spilled cooling fluid. When the radiator fills to its neck, and with the radiator cap off, start the engine and allow it to run such that cooling fluid is pumped to the engine. Burp the system by gently squeezing the cooling system hoses to move fluid through them. Shut the engine off and add more cooling fluid to the radiator until it is filled to the bottom of the radiator cap opening. Repeat this process until the cooling system is full. When you are done, the cooling fluid should be even with the lower lip inside the radiator opening. Replace the radiator cap. Start and allow the motorcycle to run for several minutes to make sure the cooling system is operating normally. Next, remove the cap from the overflow container. Add cooling fluid to the overflow container such that the container is approximately half full. Remember that this is a reservoir and the cooling system will pull from the overflow container and return cooling fluid to it. Cooling System Troubleshooting Cooling system troubleshooting and maintenance are summarized in the table below. Cooling System Troubleshooting and Maintenance Item Symptom Cause Vehicle Effect Maintenance Action Leaking Fluid leakage Defective hose or hose Lowered cooling Identify source of cooling fluid connection, defective radiator, ...
Page 67: Control Cables
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Control Cables The CSC RC3 uses three control cables. These are the clutch cable, the throttle cable, and the rear seat release cable. The clutch and throttle cables are shown below. (Note: The photos below show the cables on the RX3; the RC3 is similar.) Access to the rear seat release cable requires removal of the rear seat with the ignition key in the release lock on the left side of the motorcycle. There is no adjustment for the rear seat release cable. The throttle cable should be adjusted such that there is 2 to 5 degrees of free rotation before the throttle is actuated. This accomplished through use of the adjustment mechanism underneath the right handlebar. Cable Troubleshooting The table below summarizes cable troubleshooting and maintenance actions. Cable Maintenance and Troubleshooting Item Symptom Cause Vehicle Effect Maintenance Action Rear seat cable Rear seat does Rear seat cable Cannot release rear seat Inspect or replace rear not release disconnects, rear seat seat cable cable seizes in sheath, rear seat cable breaks, rear seat cable not connected ...
Page 68: Instruments
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Item Symptom Cause Vehicle Effect Maintenance Action Throttle cable Throttle has no Seized or sticking Throttle does not Replace or adjust free play, idle throttle cable, operate, throttle sticks throttle cable speed too high, throttle cable open throttle does not adjustment incorrect, work throttle cable snaps Instruments The motorcycle instruments show the working condition of the motorcycle. The instrument cluster contains the following instruments:  Digital tachometer.  Digital speedometer.  Gear indicator (will show no gear indication when bike is in neutral).  Fuel gage.  Temperature gage. ...
Page 69: Instrument Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com light will illuminate. The fuel gage is calibrated to show that the fuel tank is empty when there is still a little more than a gallon remaining in the fuel tank. Instrument Troubleshooting Instrument maintenance actions are summarized in the table below. Instrument Maintenance and Troubleshooting Item Symptom Cause Vehicle Effect Maintenance Action Instrument Instrument lights do Disintegration of Indicator lamp not Replace indicator assembly not illuminate indicator lamp visible lamp, check signal to filament, no signal lamp to lamp No digital readout Damaged No digital readout, Replace speedometer or no tachometer instruments, check tachometer, no indication signals to signal to instruments ...
Page 70: Accessories Connections
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com When installing a new battery, add acid to the cells. Prior to installing the caps, charge the battery with a battery charging device with a charging rate that does not exceed 2 amps. We recommend using a Battery Tender charging device for this initial charge. We further recommend using the Battery Tender charging device to keep the motorcycle battery charged when the motorcycle is not in use for an extended period of time, as this will extend battery life. If you wish to purchase a Battery Tender, please contact CSC at 909 445 0900. After the battery is fully charged, install it in the motorcycle. The battery should be oriented so that the positive terminal faces the rear of the motorcycle, and the negative terminal faces the front of the motorcycle. Connect the red cable to the positive terminal, and the black cable to the negative terminal. Accessories Connections The CSC RC3 has two 12V electrical accessory outlets under the seat on the left side of the motorcycle. These are controlled by the right handlebar accessories switch. In the O position, no power is provided to the accessories outlets. In the A1 position, power is provided to one of the accessory outlets; in the A2 position, power is provided to the other accessory outlet. (Note: The pictures shown below are of the RX3; the RC3 installation is similar.) The RC3 motorcycle requires approximately 160 watts for normal operation. 140 watts are available for accessories beyond those provided with the motorcycle. You should make sure that the total electrical load for all accessories does not exceed 140 watts. Electrical System Components and Locations The control system includes the regulator, a flasher relay, the battery, a starter relay, an LED relay, ...
Page 71 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Warning! Disconnect the positive terminal of the battery prior to working on the electrical system. Do not wear any jewelry (rings, watches, necklaces, etc.) when working around the electrical system. To gain access to the electrical components mounted beneath the motorcycle seat, remove the rear seat with the ignition switch key. Remove the front seat by unbolting it from the frame. The plastic pan under the rear seat covers many of the electrical systems components, as will be seen below. After removing the seats, remove the cover over the battery. 70 ...
Page 72 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Once the cover has been removed, the components shown to the right are accessible. To get to other electrical system components, it is necessary to rotate the fuel tank to the rear. Remove the fuel tank upper body panel. Unbolt the fuel tank at its forward edge. Lift the fuel tank by rotating it at its rear hinge. It is best to do this with little fuel in the fuel tank. This will provide access to the fuel pump. 71 ...
Page 73: Electrical System Troubleshooting
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com There is compartment at the upper front of the frame that is directly beneath the fuel tank. Once the fuel tank has been rotated out of the way, this compartment is visible. Remove the compartment cover and the electrical system components shown in the photo to the right will be visible. The starter relay is located behind the engine cylinder, as shown in the photo to the right. The illumination and signal devices consist of headlamp, the turn signals, the tail light, the brake light, a license plate light, the instrument illumination lamps, and a horn. These are used for indicating the vehicle status for the driver and others, and for expressing driver intent via acoustical and visual signals. Electrical System Troubleshooting Troubleshooting flow charts for electrical system problems are provided below in the following pages. 72 ...
Page 74 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Battery charging. Charging failure of battery Disconnect the connector clip between the magnetor conductor bundle and the cable of the complete vehicle, measure if the resistance between the output conductor ends of charging coil is satisfactory with a mulimeter.
Page 75 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Poor battery charging performance. Poor charging performance of battery Inspect if the brake lamp is lighting normally Switch the ignition switch on, remove the cathode wire from the Adjust or replace the battery, connect the negative pen of the ampere meter on the...
Page 76 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Starter failure. Rotation failure of starting motor Switch on the ignition switch, pressing the horn button or push the turn light switch Loud sound output from the electric horn and bright lights from No sound or weak sound output of electric horn and dim...
Page 77 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Weak rotation of starting motor. Weak rotation of starting motor Switch on the ignition switch, press the horn button or pushing the turn light switch Loud sound output of electric horn and bright lights of turn No sound or weak sound of electric horn and dim lights of...
Page 78 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Failure of all headlamps. Failure of all headlamps Disconnect the connector clip between the magnetor conductor bundle and the complete -vehicle cables and inspect if the electricity is outputted from the output conduct of magentor illumination coil Open circuit or short circuit of...
Page 79 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Burnout of illumination lamp bulb. Easy burnout of head lamp bulb Replace variable voltage rectifier Operational Short circuit or poor contact of circuit Failure of variable voltage rectifier 78 ...
Page 80 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Weak headlight. Weak headlamp light Replace variable voltage rectifier Headlamp recovered Weak headlamp light Inspect if the magnetor Damaged variable voltage charging coil and the internal rectifier line of charging system are short circuited 79 ...
Page 81 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Troubleshooting procedure: Horn failure. Horn failure Check turn signal operation Turn signal anomaly Normal turn signals Check voltage at horn when horn switch Poor battery output or open circuit/short depressed circuit between battery and ignition switch Normal voltage Low or no...
Page 82 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Trouble‐shooting procedure: Brake light failure. Brake light failure Inspect bulb filament Open Filament intact Replace bulb Check operation with front brake applied Check operation with rear Front brake does not operate brake applied brake light, but rear brake does Neither brake operates brake...
Page 83: Electrical Schematic
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Electrical Schematic 82 ...
Page 84: Appendix A - Service Checklists
CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Appendix A ‐ Service Checklists 500‐Mile New Motorcycle First Service Customer Name: License: Odometer; Repair Order No: Date: Technician: Service Item Completion Comments Change engine oil and filter Check/adjust intake and exhaust valves to 0.08mm Check/adjust brake fluid levels Check throttle operation for freeplay and smoothness Check/adjust clutch operation Check/adjust wheel true and spoke tightness Check/adjust tire pressure (33 psi front; 35 psi rear) Check lighting and signal systems Check/adjust drive chain Check all chassis hardware Check/adjust steering bearing Install Lucas fuel injection treatment Test ride Notes ...
Page 85 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 2500‐Mile Motorcycle Service Customer Name: License: Odometer; Repair Order No: Date: Technician: Service Item Completion Comments Change engine oil and filter, clean screens Check engine mounts; tighter as required Inspect air filter, clean or replace as necessary Check throttle operation for freeplay and smoothness Check/adjust clutch operation Check/adjust seat cable operation Check high beam Check low beam Check turn signals Check brake light front and rear Check tail light Check auxiliary lights Check/adjust front and rear brake fluid levels Check brake pads front and rear Check brake rotor wear front and rear Check brake hoses and connections Check caliper bolts Check caliper pins Check front and rear tire wear (mm) Check/adjust tire pressure (33 psi front; 35 psi rear) Check/adjust front and rear wheel true ...
Page 86 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com 5000‐Mile Motorcycle Service Customer Name: License: Odometer; Repair Order No: Date: Technician: Service Item Completion Comments Change engine oil and filter, clean screens Check engine mounts; tighter as required Check intake/exhaust valve timing; adjust gap to 0.08mm Replace spark plug Inspect air filter, clean or replace as necessary Check throttle operation for freeplay and smoothness Check/adjust clutch operation Adjust clutch freeplay ...
Page 87 CSC RC3 Owner’s and Service Manual www.CSCMotorcycles.com Annual Motorcycle Service Customer Name: License: Odometer; Repair Order No: Date: Technician: Service Item Completion Comments Change engine oil and filter Change brake fluid front and rear Check throttle cable for smooth operation Check/adjust tire pressure (33 psi front; 35 psi rear) Check tire condition and tread depth Check lighting and signal systems Check drive chain tension Check battery condition Check coolant level Check radiator hose condition Check hose clamp tightness Check frame bolts for tightness Install Lucas fuel injection treatment Test ride Notes ...

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