CSC RX3 Service Manual

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RX3 SERVICE MANUAL

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Page 1 MOTORCYCLES RX3 SERVICE MANUAL...
Page 2: Table Of Contents
CSC RX3 Service Manual www.CSCMotorcycles.com Contents Foreword ............................... 3 Motorcycle Description .......................... 4 Maintenance Cautions and Warnings ...................... 5 Parts and Components Cleaning ........................ 5 Parts Inspection ............................ 6 Maintenance Adjustments .......................... 6 Recommended Tools ............................ 7 Motorcycle Specifications .......................... 7 Motorcycle Maintenance Schedule ...................... 8 Torque Values ............................... 8 Unpacking and Setup ............................ 9 Top Case Installation ............................. 9 Rearview Mirror Installation ......................... 9 Windshield Installation .......................... 9 Fuel ................................ 10 Inspection .............................. 10 Frame and Body ............................ 11 Brakes ................................ 12 ...
Page 3 CSC RX3 Service Manual www.CSCMotorcycles.com Swingarm Troubleshooting ......................... 33 Wheels and Tires ............................ 34 Front Wheel Removal .......................... 34 Rear Wheel Removal ........................... 35 Wheel and Tire Inspection .......................... 36 Wheel and Tire Troubleshooting ........................ 37 Fixing Flat Tires ............................ 37 Engine................................ 40 Engine Break‐In Procedure ......................... 40 Oil Changes .............................. 40 Valve Adjustment ............................ 45 Engine Troubleshooting .......................... 50 Fuel System .............................. 58 Fuel System Maintenance ........................... 59 Electronic Fuel Injection System ......................... 61 Fuel Injection System Operating Principles .................... 61 Electronic Fuel Injection System Troubleshooting .................. 63 Intake and Exhaust System ......................... 64 Air Filter Maintenance .......................... 64 Exhaust System ............................ 66 Intake and Exhaust System Troubleshooting .................... 67 Cooling System ............................ 67 Checking and Adjusting Cooling Fluid Levels .................... 68 Flushing and Replacing the Cooling Fluid .................... 69 ...
Page 4: Foreword
CSC RX3 Service Manual www.CSCMotorcycles.com Foreword The RX3 Service Manual provides information on maintaining and servicing the motorcycle. It includes the motorcycle’s technical specifications, performance parameters, and maintenance and adjustment data. The technical specifications, performance parameters and maintenance and adjustment data labeled in the manual are based on the latest status. CSC Motorcycles stocks all RX3 motorcycle parts. CSC recommends that you use only parts and materials provided by CSC when servicing or maintaining your motorcycle. This manual is provided free to all who purchase a new CSC RX motorcycle. Reproduction of the RX3 Service Manual or posting it online without CSC’s permission is expressly prohibited. If you have any questions, please contact CSC Motorcycles at 909 445 0900 or info@CSCMotorcycles.com. 3 ...
Page 5: Motorcycle Description
CSC RX3 Service Manual www.CSCMotorcycles.com Motorcycle Description The CSC RX3 motorcycle is a 250cc adventure touring motorcycle. The motorcycle has a single‐cylinder, 4‐stroke, water‐cooled engine and a 6‐speed transmission. Major component locations are identified in the photographs below. Right Side Left Side 4 ...
Page 6: 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 7: Parts Inspection
CSC RX3 Service Manual www.CSCMotorcycles.com agent first, then clean them with a brush, and then rinse them with hot water. Parts Inspection Parts should be inspected after they are cleaned. The purpose of inspection is to check if the parts need to be repaired or replaced. There are three inspection methods: Direct inspection, measurement inspection, and detection inspection.  Direct inspection doesn’t require any instruments or other tools. It checks and judges condition.  Measurement inspection inspects for size changes and shape changes of the parts with gages and instruments to confirm their dimensions. This method has high accuracy, but before the inspection you must check the precision of the gages and instruments.  Detection inspection involves inspecting for hidden defects. During maintenance, the oil‐ immersed hammering method is commonly used, which is simple and convenient. Soak the part in the oil for a few minutes, take it out and rub its surface dry, sprinkle talcum powder evenly over the surface, and knock on its non‐working surface gently with a hammer. If the part has any cracks, the oil inside the crack will wick out and dye the talcum powder yellow. A yellow line will appear at the crack. Maintenance Adjustments The CSC RX3 motorcycle requires adjustments in the following areas:  The clutch must be adjusted according to the maintenance instructions included in this manual. The main adjustment features the clutch handle free travel (¼ to ½ inch), and the clutch cable adjusting mechanism. This Service Manual presents the procedure for clutch adjustment.  Adjustment of the electric horn affects volume and tone. The volume of the electric horn is 95 to 105 dB. If the volume or tone is too high or too low, you can adjust the horn with the adjusting screw at its back, as explained in this Service Manual.  The throttle cable adjustment is performed at the throttle. The throttle should have 2 to 5 ...
Page 8: Recommended Tools
CSC RX3 Service Manual www.CSCMotorcycles.com Recommended Tools The CSC RX3 motorcycle includes a basic tool kit that is stored under the rear seat. CSC views these tools as suitable for emergency repairs only. CSC sells custom tool kits with professional grade tools; please contact us at 909 445 0900 to order the RX3 custom tool kit. Motorcycle Specifications Adjustment Specifications Item Adjustment Limits Clutch lever free play (at tip) ¼ to ½ inch Throttle free travel 2‐5 degrees Drive chain ¾ to 1 ¼ inch Valve gap (at TDC) 0.04 to 0.08 mm Tire pressure (front/rear) 33 psi front, 35 psi rear Major Technical Specifications Model: single cylinder, 4‐stroke, water cooling, SOHC, inclined, 4‐valve Major performance parameters: a. 24.8 hp @ 9,000 rpm b. 16.6 ft‐lb @ 7,000 rpm c. Idle speed: 1,5000 rpm Bore × stroke: 77 mm × 53.6 mm Displacement: 249.6 cc Compression ratio: 11.1:1 Ignition mode: Capacitive energy storage Spark advance angle: 8° BTDC@2,200 rpm, 37°@7,000 rpm Lubricating method: Pressure plug splash...
Page 9: Motorcycle Maintenance Schedule
CSC RX3 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 10: Unpacking And Setup
CSC RX3 Service Manual www.CSCMotorcycles.com Unpacking and Setup When your CSC motorcycle is delivered, the motorcycle is completely assembled except for the windshield, the mirrors, and the rear top case. When the motorcycle is delivered, check the condition of the delivered crate. If there are any anomalies, stop and call CSC at 909 445 0900. Check the VIN numbers of the exterior of the crate. Compare these numbers to the documentation delivered to you. If the numbers don’t match, stop and call CSC at 909 445 0900. Top Case Installation Secure the top case to the top case mounting plate with three 4mm Allen head bolts. Tighten bolts and install top case pad over bolt heads in bottom of top case. Rearview Mirror Installation Install left and right rearview mirrors on handlebars. Windshield Installation The windshield is secured with six Allen head bolts as shown in the photo below. A cap head nut is used on the inside of the windshield for each Allen head bolt. 9 ...
Page 11: Fuel
CSC RX3 Service Manual www.CSCMotorcycles.com Fuel Fill with the fuel tank with 87 octane (or higher) gasoline. Inspection Perform the following inspections when servicing the motorcycle.  Check to confirm all fasteners are properly tightened and all components are installed correctly and in an operational state.  Swing the handlebars from side to side to make sure motion is uninhibited.  Check chain tension and rear wheel alignment in accordance with the Chain Drive section of this Service Manual.  Insert ignition key and turn on.  Check horn function, turn signals, headlight high and low beam, brake lights for front and rear brake activation, and instrument panel readout.  Check oil level and tire pressure.  Confirm motorcycle is in neutral.  Place clutch in and start motorcycle. Allow engine to warm.  Check brake and suspension function. ...
Page 12: Frame And Body
CSC RX3 Service Manual www.CSCMotorcycles.com Frame and Body The frame and body subsystem includes the motorcycle’s steel frame, the seat, the body panels, the sidestand, the footpegs, and the fenders. The rear seat is removable by inserting and twisting the ignition key in the left body panel beneath the seat. The tool kit is stored beneath the rear seat. The front seat is held in place by two 8mm bolts. The rear seat can be removed to provide access to the battery. The left body panel can be removed to provide access to the air filter. Frame and body maintenance and troubleshooting guidelines are summarized below. Frame and Body Maintenance and Troubleshooting Item Symptom Cause Vehicle Effect Maintenance Action Frame Frame is hit or falls 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 Frame is impacted Frame welding ...
Page 13: Brakes
CSC RX3 Service Manual www.CSCMotorcycles.com Brakes The main function of the brakes is to slow or stop the motorcycle. The brakes consist of the front and rear brakes and their controls. Both front and rear brakes are hydraulically‐actuated single disk brakes. The front brake is operated by the right hand and the rear brake is operated by the right foot. This section of the RX3 Service Manual covers the following topics:  Inspecting and replacing the brake pads.  Replacing the brake fluid.  Bleeding the brakes.  Inspecting and replacing the brake disks. Inspecting and Replacing the Brake Pads The front and rear disk brakes utilize dual piston calipers. You should replace the brake pads when either one has less than 1.5mm of pad thickness left, or if the brake pads are worn such that the groove in the pad is no longer visible. CSC stocks the brake pads (call us at 909 445 0900). To remove the rear brake pads, loosen the rear brake caliper Allen bolts as shown in the photos below. Remove the bolts securing the caliper to the swingarm. One the rear caliper bolts are removed, slide the caliper rearward, lift it off of the disk rotor, and then remove the Allen bolts holding the brake pads in place. Once the caliper Allen bolts are removed, the pads will slide out. Note that the pads are not identical; they must be installed in the correct orientation. The pad with the large arm (shown in the photo above) is opposite the pistons; the pad without the large arm is situated against the pistons. 12 ...
Page 14 CSC RX3 Service Manual www.CSCMotorcycles.com Inspect the brake pads to determine if they are worn beyond their service limit (less than 1.5mm thick). If the pads are worn such that the grooves are gone (visible as vertical slots in the photo above), the pads should be replaced. Reinstall the Allen bolts in the caliper, position the caliper in its appropriate location, and install the caliper bolts to mount the caliper to the swingarm. Tighten all fasteners. Pump the rear brake pedal several times. Operate the motorcycle to assure satisfactory rear brake performance. The process for replacing the front brake pads is similar to that described above for the rear brake pads. Loosen the front brake caliper Allen bolts, and then remove the front brake caliper mounting bolts. Remove the caliper and then remove the Allen bolts from the caliper. Inspect the front brake pads and replace if necessary. Reinstall the Allen bolts, the front caliper, and the caliper bolts. Tighten all fasteners. Pump the front brake lever several times. Operate the motorcycle to assure satisfactory front brake performance. Replacing the Brake Fluid You should replace the brake fluid in the front and rear master cylinders every 2 years. Use only DOT 4 brake fluid. We recommend Maxima brake fluid. If you need brake fluid, call CSC at 909 445 0900 and we will ship a container to you. The procedure shown here is for the rear master cylinder; the procedure for the front master cylinder is performed in a similar manner. Open the master cylinder by unscrewing the two screws securing the master cylinder cover. Remove the master cylinder cover and place it in an area where it will not become contaminated. 13 ...
Page 15 CSC RX3 Service Manual www.CSCMotorcycles.com Using a turkey baster or other suction device, remove as much of the brake fluid in the master cylinder as possible. Exercise caution to prevent any brake fluid spillage. If any spillage occurs, wipe up the spilled brake fluid immediately (it will damage painted or plastic surfaces). Remove the caliper bleed cap and attach a small diameter tube to the caliper bleed fitting. Route the tube to a receptacle. Add fresh brake fluid to the master cylinder. Open the caliper bleed fitting by unscrewing it slightly (turn it counterclockwise to do so) and depress the brake lever to pump brake fluid out through the caliper bleed fitting. Prior to allowing the brake lever to return, close the caliper bleed fitting by turning it clockwise. Repeat the process until fresh brake fluid exits the caliper. Close the caliper bleed fitting and replace the caliper bleed fitting cap. Add brake fluid to the master cylinder such that the upper level is within 1/8‐ inch of the top (do not overfill the master cylinder). Replace the master cylinder cover and the screws securing it to the master cylinder. Tighten the screws. Pump the brake pedal several times. Operate the motorcycle to assure satisfactory brake performance. Bleeding the Brakes If air gets into the brake lines, braking performance will be diminished. You should bleed the brakes once every year, any time the brakes feel spongy or soft, or if the brake fluid drops below the level of the master cylinder view port. Again, use only DOT 4 brake fluid. 14 ...
Page 16: Brake Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com 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 runout. If the runout exceeds 0.3mm, replace the disk. You only need to do this if the disk appears to be visibly warped (which is not likely) or if the brakes pulsate when applied. You will have to remove the wheel in order to replace the disk. The procedure for wheel removal is explained elsewhere in this Service Manual. Each disk is secured with six Allen bolts. Use blue Loctite when reinstalling the bolts that secure the brake disk. ...
Page 17: Power Transmission
CSC RX3 Service Manual www.CSCMotorcycles.com Item Symptom Cause Vehicle Effect Maintenance Action 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 Inadequate or Adjust rear brake lever free play soon or excessive lever adjustment excessive brake pedal free play pedal travel pedal travel Power Transmission ...
Page 18 CSC RX3 Service Manual www.CSCMotorcycles.com To adjust the chain tension, loosen (but do not remove) the rear axle, and loosen the chain adjustors on both aft ends of the swingarm. Note that the rear axle bolt and nut are different sizes. The bolt head is 18mm on the left side of the bike, and the rear axle nut is 17mm on the right side of the bike. Next, loosen the chain adjustors on both sides of the swingarm. These adjustors each have two 13mm nuts, one on each side of the adjustment plate, as shown in the photo to the right. Note that in the photo to the right, the rear axle adjustor nuts have already been loosened. Move the rear axle either forward or rearward using the rear axle adjustor nuts while simultaneously positioning the rear axle such that the desired chain tension is achieved, and rear wheel is aligned. Note there are no washers between the inside nut and where it bottoms against the end of the swingarm, and that there is a flat washer and a lockwasher between the outside nut and the end of the swingarm. To attain correct alignment rear wheel alignment, there are two approaches (measuring the distance between the swingarm pivot point and the rear axle, or aligning the rear axle adjustors with scribe lines on the swingarm). 17 ...
Page 19: Lubing The Chain
CSC RX3 Service Manual www.CSCMotorcycles.com To measure the distance between the center of the swingarm pivot point and the center of the rear axle, see the photos below. To align the rear axle using the swingarm scribe lines, adjust the rear axle adjustors such that the rear axle adjustors on both sides of the motorcycle are in the same position with respect to the swingarm scribe lines. Once the rear axle is aligned and chain tension is adjusted, tighten the rear axle nut and all four rear axle adjustor nuts. Lubing the Chain You should lubricate your chain approximately every 500 miles, or at the end of a long day of riding. You should lube the chain more often if you ride in the rain or in dusty conditions. Lube the chain as soon as you stop riding while the chain is still warm, as this will allow the lubricant to wick into the chain. It’s easier to lube the chain if your RX3 has the optional centerstand, but if it doesn’t, it’s still easy to do. Hold a rag under the lower chain run and spray the lube directly onto the chain. Push the bike backward a few feet to expose more of the chain (if your bike does not have the centerstand) and lube the chain. If you bike has the centerstand, rotate the rear wheel with the bike on the centerstand to expose all parts of the chain as you lube it. Lube the entire chain. 18 ...
Page 20: Sprocket And Chain Inspection
CSC RX3 Service Manual www.CSCMotorcycles.com Don’t let the lube get on the tire, and don’t shoot spray lubricant through the spokes and get the lube on the rear brake. Don’t ride the motorcycle for at least 15 minutes after lubing the chain. That will allow the lube to seep into the chain. CSC stocks both wax and petroleum based chain lubes (call us at 909 445 0900 to purchase these items). Sprocket and Chain Inspection The CSC RX3 has a 520 O‐ring type chain, a 14 tooth front sprocket, and a 44 tooth rear sprocket. If you keep your chain properly adjusted and lubed, the chain and sprockets will last much longer than they would if you don’t maintain these items, but they still won’t last forever. You can expect the chain and sprockets to wear more quickly if you ride in dusty environments or off road. Chains and sprockets should be replaced as a set. Do not replace one without replacing the other or rapid wear will result. Remove the countershaft sprocket cover by removing the two bolts that attach it to the engine. You don’t have to remove the gear shift lever to remove the countershaft sprocket cover. There are three Allen bolts that secure the chainguard. Two are visible and easily accessible; the third is hidden on the forward portion of the chainguard (on the part of the chainguard that is behind the chain). Undo the three bolts and remove the chainguard. After you have removed these items, you can see the sprockets and the chain. 19 ...
Page 21: Chain Drive Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com 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 RX3 motorcycle, the chain does not have a master link. When you need to replace the original equipment chain on your motorcycle, you 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. When you install the master link, the closed end should always face the direction the chain rotates. 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 misaligned rear wheel, incorrect chain adjustment Counter Excessive wear Inadequate Chain skipping, chain ...
Page 22: Clutch Cable Replacement And Adjustment
CSC RX3 Service Manual www.CSCMotorcycles.com 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. 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. 21 ...
Page 23 CSC RX3 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 ¼ to ½ inch 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. 22 ...
Page 24: Clutch Replacement
CSC RX3 Service Manual www.CSCMotorcycles.com 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. 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. 23 ...
Page 25: Clutch Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com 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. 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. Soak the new clutch fiber plates in motorcycle engine oil for 24 hours prior to installation. 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. 24 ...
Page 26 CSC RX3 Service Manual www.CSCMotorcycles.com 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 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 ...
Page 27: Suspension
CSC RX3 Service Manual www.CSCMotorcycles.com Suspension The suspension subsystem includes the forks, the rear shock absorber, and the swingarm. Forks 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. 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. Changing the Fork Oil The first step in working on the forks is to remove the front wheel. Please see the front wheel removal portion of this Service Manual for instructions front wheel removal. After the front wheel has been removed, remove the ignition switch shroud to gain access to the upper fork yoke pinch bolts. The next step is to remove the speedometer cable from the right fork leg (if you are removing the right fork leg). There’s a composite clamp that secures it. Unscrew the clamp screw and detach the speedometer cable from the fork leg. 26 ...
Page 28 CSC RX3 Service Manual www.CSCMotorcycles.com Remove the front fender by removing the four bolts that secure it to the forks. The front fender can be maneuvered through the forks so that it can be removed after the bolts securing it have been removed. Loosen the two upper yoke pinch bolts if you have not done so already. You don’t need to remove them; they just need to be loose. Loosen the lower yoke pinch bolts, and be prepared for the fork leg to drop as soon you loosen the last pinch bolt. Hold the fork leg with one hand while loosening the last pinch bolt. You can get to the lower yoke pinch bolts from beneath the body panels, and you don’t need to remove the body panels to gain access to the lower yoke pinch bolts. Unscrew the fork cap from the fork using an impact wrench. Keep the fork in a vertical orientation. The fork contains oil, and if tilted, oil will spill out. Tilt the fork over a container and pour the oil out of the fork. Each fork leg contains 330 cc (or 11.2 US fluid ounces). You will need to pump all of the oil out of the dampening rod by moving the dampening rod in and out of the fork. You will know all of the oil is out when you feel no dampening when pumping the dampeners. When installing new oil, pump the dampeners to eliminate any air in the dampeners. The stock fork oil is a fairly light oil, which provides a comfortable ride. If you desire a firmer ride, you can use heavier fork oil. 27 ...
Page 29: Repairing A Leaking Fork Seal
CSC RX3 Service Manual www.CSCMotorcycles.com Reassemble the forks in the same manner as they were disassembled, leaving the fork caps loose so that you can add new fork oil. Add 11.2 ounces to each fork using a funnel. Replace the fork caps. Tighten all fasteners. Repairing a Leaking Fork Seal If the fork seal leaks because it was damaged by grit or some other attributable cause, you need to replace only the leaking seal. If the seal started leaking due to age‐induced degradation, you should to replace the seals on both sides of the forks. Put a wrench on the bolt head inside the fork spring, and unscrew the fork cap from the fork rod that runs through the center of the fork spring. The fork cap and its washer will separate from the fork rod. Pull the fork spring completely out of the fork. Note that the fork spring is a compound spring. The more tightly wound coils always go toward the lower end of the fork, as shown in the photo below. At this point, put a shop rag or a paper towel in the opening at the top of the fork (where the fork cap was). There will still be residual oil in the fork and this will prevent spillage. 28 ...
Page 30 CSC RX3 Service Manual www.CSCMotorcycles.com The next step is to remove the dust seal using a light touch. Use a fine bladed screwdriver (or something similar) and gently tap the dust seal away from the fork upper tube. Work gently around the periphery of the dust seal. Take care not to gouge the fork or damage the dust seal. Once the dust seal has been removed, you need to reach inside the fork upper with a pick to release the clip that secures the fork seal in place. Gently place the pick inside the raised area of the clip, and push inward and toward the opening. The clip will release. Remove the clip from the fork. 29 ...
Page 31 CSC RX3 Service Manual www.CSCMotorcycles.com Pull the fork lower out of the fork upper. Use the fork lower as a jack hammer. Pull it sharply away from the fork upper while holding the fork upper. Repeat this motion several times to get the fork lower out of the fork upper. After you have separated the fork lower from the fork upper, it will look like this. Note that there are two circular flat clips around the diameter of the fork lower. These are bushings. Each bushing has a slit in it to allow expanding the bushing so that it can be removed from the fork lower. The red arrow points to the slit in the upper bushing. It’s barely visible and it is a fine slit. The upper bushing (the black one) rests in an annular groove machined into the fork lower. Expand this bushing diametrically to get it off the fork lower. Use a fine‐bladed screwdriver to start the expansion process, and then insert a larger screwdriver. Remove the bushing from the fork lower machined annular groove and take if off the fork lower. Take care not to scratch the fork lower or over‐expand the bushing. After removing the upper clamp, slide the lower clamp off. At this point, the fork lower will look like the photos below. 30 ...
Page 32: Rear Shock Absorber
CSC RX3 Service Manual www.CSCMotorcycles.com Remove the dust seal and the fork seal from the fork lower. Take care not to damage either seal. The edges of the fork lower’s annual groove are sharp and these edges can damage the seals. After removing the fork seal and the dust seal, examine both carefully for any cuts, tears, or degradation. Replace the defective part(s). Examine the fork lower (which is the part that slides through the dust seal and the fork seal). If there are any scratches, gouges, or surface imperfections on the portion of the fork lower that slides through the seals, polish the imperfections out or replace the fork lower. After you’ve reassembled the forks, tighten all fasteners in accordance with the torque table in the CSC RX3 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 RX3 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. 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 level one side ...
Page 34: Swingarm
CSC RX3 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: Wheels And Tires
CSC RX3 Service Manual www.CSCMotorcycles.com Wheels and Tires The CSC RX3 uses a 17‐inch steel rimmed wire wheel at the rear of the motorcycle, and an 18‐inch steel rimmed wire wheel at the front of the motorcycle. Both the front and rear wheels use inner tubes. The recommended front tire size is 100/90/‐18. The front tire should be inflated to 33 psi. The recommended rear tire size is 130/70‐17. The rear tire should be inflated to 35 psi. Under‐inflation or over‐inflation of either tire will adversely affect the motorcycle’s handling characteristics. 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 The first step in removing the front wheel is to remove the front axle bolt. It’s on the left side of the motorcycle. The axle won’t come out yet (it’s secured by the pinch bolts on the right side of the motorcycle). The next step is to lift the front end of the bike off the ground. If you have our accessory centerstand, the front wheel will be off the ground when the bike is on the centerstand. If you do not have a centerstand, you need a bike lift or some means of safely lifting the front wheel off the ground. Once the front wheel is off the ground, loosen the two pinch bolts on the right side of the motorcycle. 34 ...
Page 36: Rear Wheel Removal
CSC RX3 Service Manual www.CSCMotorcycles.com Slide the front axle out on the right side of the motorcycle. Roll the front wheel forward a short distance and remove the speedometer drive from the right side of the front wheel hub. You can now remove the front wheel. Note that there is only one bushing, and that is installed on the left side of the front wheel hub (it is captured between the left fork and the wheel hub). Front wheel installation is the reverse of front wheel removal. When reinstalling the speedometer drive unit, make sure that the tab in it fits into the slot on the front wheel. Rear Wheel Removal Remove the rear axle nut (the rear axle nut is 17mm; the bolt head on the other side is 18mm). Pull the rear axle out from the left side of the motorcycle. 35 ...
Page 37: Wheel And Tire Inspection
CSC RX3 Service Manual www.CSCMotorcycles.com 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. On the rear wheel, there are two bushings (one on either side of the wheel). The thicker bushing goes on the right side of the motorcycle, and the thinner bushing goes on the left side of 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, 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. Inspect the spokes on both the front and the rear wheel. If any spokes are loose, tighten them and check for wheel trueness. If any spokes are missing, do not replace single spokes as a long term fix. The entire wheel should be relaced at the next available opportunity. Check the rims for dents. If the rim is dented, 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. 36 ...
Page 38: Wheel And Tire Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com Place the wheels on a truing stand and inspect them for runout and ovality. If either exceeds 1.0mm, true the wheel by adjusting spoke tension. 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 Symptom Cause Vehicle Effect Maintenance Action Wheel and Vibration Deformation, out of balance Drift, True wheel, check bearings, check Tire condition, worn tire, wheel handlebar inflation pressure, check tire trueness or ovality outside of shake, condition, balance tire and wheel, spec limits, worn bearing, vibration check for proper loading of motorcycle load motorcycle Tire Premature Out of balance, misaligned rear ...
Page 39 CSC RX3 Service Manual www.CSCMotorcycles.com 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. You usually only need to do this once and the tire will pop off the rim on the side you’re working. You do not need to remove the tire from the rim; you only have to get it off the wheel on one side. 38 ...
Page 40 CSC RX3 Service Manual www.CSCMotorcycles.com Push the valve stem back into the rim so that it is no longer passes through the rim. Remembering where the puncture occurred on the tire (if you were able to identify the puncture location), pull the tube out of the tire (you’ll be pulling it out between the tire and the rim on the side where you separated the tire from the rim). Carefully inspect the tube in the area adjacent to the tire puncture location and inspect for the source of the leak. If you find it and if it is small (they almost always are), you can most likely patch it as a temporary fix. If the tear is more extensive, you should replace the tube. If you can’t find the leak, partially inflate the tube and listen for hissing. You may have to put the partially inflated tube near your ear and rotate it until you find the leak. If you are near water, you can immerse the tube and look for bubbles to locate the leak. If you hear it but can’t see it, you can rub spit around the general area and look for the leak. Before you reinstall the tube (either one you’ve patched or a new one), reach in and gingerly feel around the inside of the tire. Look for anything that might damage the tube when you reinstall it. Exercise caution (if there is something sticking into the tire, don’t cut yourself on it). If you find anything, remove it. Gently insert either the patched or a new tube into the tire. Position it so that the valve stem is aligned with the hole in the rim. Push the valve stem through the hole in the rim and then reinstall the 10mm nut on the valve stem to lock the valve stem in place. Gently tuck the tube completely in to the tire. Reinstall the tire on the rim using tire irons. Take care not to pinch the tube between the tire and the rim (and don’t damage the tube with the tire irons) when reseating the tire. Liberal use of spray lubricant will help. Reinstall the tire and wheel on the motorcycle before you inflate the tube. This is the reverse of the process I described above. After accomplishing the above, inflate the tire and to seat it on the rim. CSC advises keeping a patch kit, a tire repair kit, and a source of compressed air with you, especially if you ride in remote locations (as was the RX3 motorcycle design intent). If you need these items, please call CSC at 909 445 0900. ...
Page 41: Engine
CSC RX3 Service Manual www.CSCMotorcycles.com Engine The RX3 engine is a water‐cooled, overhead cam, counterbalanced engine. Engine Break‐In Procedure 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 motorcycle oil. Never use any oils intended for automotive use, 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 RX3 oil and oil changes.  The RX3 takes 1.7 quarts (55.4 ounces) of 5W‐40 or 10W‐40 motorcycle oil.  The RX3 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 RX3 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 RX3 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. ...
Page 42 CSC RX3 Service Manual www.CSCMotorcycles.com 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 located on the left side of the engine. The left side oil strainer cover is the 17mm bolt head just beneath the shifter. The RX3 tool kit is located under the rear seat cushion (you need to unlock the rear seat with the key lock on the left side of the motorcycle beneath the seat to get to it). Like most motorcycle tool kits, these should be considered emergency tools only. 41 ...
Page 43 CSC RX3 Service Manual www.CSCMotorcycles.com 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 just behind the exhaust pipe. 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. Removing the motorcycle’s skid plate is not necessary. 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. 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. 42 ...
Page 44 CSC RX3 Service Manual www.CSCMotorcycles.com 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 RX3 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. 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. 43 ...
Page 45 CSC RX3 Service Manual www.CSCMotorcycles.com 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. 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. 44 ...
Page 46: Valve Adjustment
CSC RX3 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 RX3 has a high performance, single overhead cam, 4‐valve engine. There are two exhaust valves and two intake valves. The CSC RX3 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. 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. ...
Page 47 CSC RX3 Service Manual www.CSCMotorcycles.com 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 RX3 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 RX3 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 the piston at top dead center on the compression stroke, which means the valves should be closed (which is another way of saying the rocker arm is on the cam’s base circle). 3. With the engine in this position, we want to loosen the threaded adjustor lock nuts, we want to set the valve gaps to the specified gap of 0.04mm to 0.08mm, and we want to tighten the lock nuts to lock the threaded adjustors at this gap. 4. When we’ve completed the above, we want to put everything back together. When you adjust the valves, you have to start with a cold engine. Let your RX3 cool completely. ...
Page 48 CSC RX3 Service Manual www.CSCMotorcycles.com The next step is to unbolt the RX3’s twin radiators. You don’t have to disconnect the hoses or remove the radiators; you just want the radiators to be loose so that you’ll have access to the valve covers on top of the cylinder head. Unbolt the radiators but leave them 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. 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. 47 ...
Page 49 CSC RX3 Service Manual www.CSCMotorcycles.com 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. 48 ...
Page 50 CSC RX3 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. Finding the scribe line on the alternator cover may be a bit challenging, as you have to get down low enough to see it. Wear safety glasses when you do this, as oil may spit out of this hole. This step is complicated by the fact that even though you’ve removed the sparkplug, the rotating the crankshaft will feel as though the engine still has compression. This is due to the valve springs acting to rotate the engine as the crankshaft is turned. 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. 49 ...
Page 51: Engine Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com 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. Perform this same adjustment (and set each valve at the same gap) for all four of the RX3’s valves. 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. 50 ...
Page 52 CSC RX3 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 53 CSC RX3 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 54 CSC RX3 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 55 CSC RX3 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 56 CSC RX3 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 57 CSC RX3 Service Manual www.CSCMotorcycles.com 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 The valve oil seal is piston rings are staggered by a valve guide are highly worn damaged 120°angle 56 ...
Page 58 CSC RX3 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 57 ...
Page 59: Fuel System
CSC RX3 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. The fuel tank capacity is 16L, or 4.2 gallons without any of the fuel tank’s internal components installed (fuel pump and fuel gage sending unit). As assembled (with the fuel pump and the fuel gage sending unit), fuel capacity is 3.9 gallons. The fuel pump assembly consists of the fuel pump, fuel pump support, and fuel pressure regulator. The fuel pump is turbo‐type single‐stage fuel pump driven by a 12V DC motor and controlled by the ECU through the pump relay. On the pump discharge, there is a check valve so that the fuel in the tube will not flow back to the tank when the engine is not working and Fuel Pump engine starting will not be affected. ...
Page 60: Fuel System Maintenance
CSC RX3 Service Manual www.CSCMotorcycles.com The fuel filter is between the electric fuel pump and the fuel injector to filter fuel and avoid the nozzle blocking. If the filter is blocked, it must be cleaned or replaced. Check the fuel filter Fuel System Maintenance Warning ◆ Fuel is a combustible material. 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. ...
Page 61 CSC RX3 Service Manual www.CSCMotorcycles.com Remove the side covers and the seats. Then remove the fuel tank bolts and remove the fuel tank. Remove the 6 M5×16 bolts from the fuel pump. Remove the fuel pump. Use an appropriate cleaning agent to clear any fuel residue and water in the tank. Remove the fuel tank Check for any degradation, cracks or fuel intrusion in the silicon seal of the fuel pump. If there is, replace the silicon seal. Check the silicon seal Check if the motor of the fuel pump works, and rinse or replace the fuel filter screen. Take out the fuel pump The fuel filter should be replaced every 5,000 miles, or more frequently if the motorcycle is operated in dusty conditions. ...
Page 62: Electronic Fuel Injection System
CSC RX3 Service Manual www.CSCMotorcycles.com Electronic Fuel Injection System The main function of the electronic fuel injection system is to atomize and inject fuel into the combustion chamber. Fuel Injection System Operating Principles The electronic fuel injection system consists of the ECU, injector nozzle, throttle valve assembly, intake air temperature, integration pressure sensor, engine temperature sensor, ignition coil, crankshaft position sensor, oil pump assembly and oxygen sensor. The engine electronic fuel injection management system precisely controls the mixture ratio of air and fuel conducted into the engine cylinder, the combustion process and the exhaust gas conversion to optimize engine performance. The system controls also controls emission levels. 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 ...
Page 63 CSC RX3 Service Manual www.CSCMotorcycles.com 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 with the engine inlet pipe. The injector nozzle injects fuel to the inlet valve. The throttle valve body, installed in front of the inlet pipe, consists of the valve body, throttle plate position sensor, idle control valve etc. with a main function of controlling the air input when the engine is in working condition. It is the channel for dialogue between the electronic control system and the driver. 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. 62 ...
Page 64: Electronic Fuel Injection System Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com Electronic Fuel Injection System Troubleshooting The RX3 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.  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 ...
Page 65: Intake And Exhaust System
CSC RX3 Service Manual www.CSCMotorcycles.com Intake and Exhaust System The air intake system consists of the air cleaner, the inlet pipe, and other related components. The main functions are to conduct air, to filter air, and to reduce intake noise. Air Filter Maintenance You should clean the air filter every 2,500 miles, or more often if you ride in dusty environments. The air filter is located beneath the seat. To gain access, remove the seats. The rear seat is removed with the ignition key in the left side body panel and the front seat is secured with two bolts at the rear. Remove the left side body panel. Once the body panel has been removed, hold the electrical harnesses away from the cover to gain access to the five screws securing it. Take care not to pull on the harnesses, as this can break the electrical connections. Remove the five screws securing the air filter cover and remove the cover. After removing the air filter cover, remove the air filter element subassembly by pulling it out. 64 ...
Page 66 CSC RX3 Service Manual www.CSCMotorcycles.com The air filter element subassembly consists of four pieces (the lower screen, the filter element, the upper frame, and the screw that holds these three items together. Remove the screw to separate the four pieces. The air filter element is a serviceable item. We recommend cleaning the air filter element with Maxima Air Filter Cleaner, and then applying a light coat of Maxima Air Filter Oil. You can purchase these items from us by calling 909 445 0900. 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 and oiling the air filter element (or replacing the air filter element), reinstall the air filter subassembly in the motorcycle and reinstall all components. Do not ride the motorcycle without the air filter element installed. 65 ...
Page 67: Exhaust System
CSC RX3 Service Manual www.CSCMotorcycles.com Exhaust System The exhaust system consists of the exhaust pipe, the muffler, heat shields on the muffler and the exhaust pipe, a gasket, and related mounting fasteners. These components are shown in the photos below. 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. The muffler contains an integral catalytic converter. The exhaust pipe is made of a curved steel tube. It transports exhaust gas from the engine to the muffler. To remove the exhaust system, remove the fasteners from the muffler, the exhaust pipe, and the muffler support. Check the muffler suspension support for any cracks and repair or replace if necessary. Check the exhaust muffler seal and replace it if necessary. Check the muffler for any cracks or other damage, and repair or replace it if necessary. Do not operate the motorcycle without the muffler. Install a new seal washer when assembling and disassembling the muffler. 66 ...
Page 68: Intake And Exhaust System Troubleshooting
CSC RX3 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 69: Checking And Adjusting Cooling Fluid Levels
CSC RX3 Service Manual www.CSCMotorcycles.com intended for use in aluminum engines. The RX3 cooling system consists of the following components:  Two radiators located under the fuel tank.  Two fans (one for each radiator).  Hoses connecting the radiators and the engine.  A water pump.  Cooling fluid. The system coolant capacity is 1.0 liter.  A temperature sensor (located on the bottom of the left radiator).  An overflow container located to the left of the right radiator.  A thermostat located on the top right of the cylinder (it’s where the cooling system hose attaches to the engine). Your RX3 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. Access to the coolant system is provided via the radiator cap on top of the right side radiator. As mentioned above, when opening the radiator cap, always place a rag over it and open it slowly. Checking and Adjusting Cooling Fluid Levels ...
Page 70: Flushing And Replacing The Cooling Fluid
CSC RX3 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, as shown below. 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). 69 ...
Page 71 CSC RX3 Service Manual www.CSCMotorcycles.com Allow the cooling fluid to completely drain from the right radiator. Move the bike to a completely vertical orientation to allow the radiator to drain completely. Next, drain the left radiator. Place a drain pan underneath the left radiator. Remove the electrical plug from the temperature sensor, unscrew the temperature sensor, and allow the cooling fluid to drain from the radiator. Immediately wipe any spilled cooling fluid from the motorcycle. 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. 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. As you are adding cooling fluid, you will notice that the radiator will not take the entire liter of cooling fluid. That’s because the cooling fluid needs to flow to the other radiator, the hoses, and the engine. 70 ...
Page 72: Cooling System Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com When the right 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 and the left radiator. 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 right radiator. 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 right radiator opening. Replace the radiator cap on the right radiator. 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, fluid levels, leak and replace or ...
Page 73: Control Cables
CSC RX3 Service Manual www.CSCMotorcycles.com Control Cables The CSC RX3 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. 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, removal of the plastic tray covering the electrical components beneath the rear seat, and removal of the left side body panel. 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. 72 ...
Page 74: Cable Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com 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 and lube or not release disconnects, rear seat replace rear seat cable cable seizes in sheath, rear seat cable breaks, rear seat cable not connected Clutch cable See Clutch section of this Service Manual 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, ...
Page 75: Instruments
CSC RX3 Service Manual www.CSCMotorcycles.com Instruments The motorcycle instruments show the working condition of the motorcycle. The instrument cluster contains the following instruments:  Analog tachometer.  Digital speedometer.  Gear indicator (will show no gear indication when bike is in neutral).  Fuel gage.  Temperature gage.  Trip meter.  Odometer.  Clock.  Push button to toggle between kilometers and miles.  Push button to toggle between trip meter and odometer. The instrument layout is shown in the photograph below. Other than replacing the indicator light bulbs, the instruments are not designed to be repairable. If any of the instruments fails, the instrument cluster must be replaced. Although the fuel tank capacity is 4.2 gallons, the fuel level should never go below 1.0 gallon remaining in the fuel tank (this remaining fuel serves to cool the fuel pump). When the fuel tank should be refilled, an orange indicator light on the right side of the instrument cluster will also illuminate. The fuel gage is 74 ...
Page 76: Instrument Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com 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 or tachometer speedometer or no tachometer instruments, check output tachometer, no indication signals to ...
Page 77: Electrical System
CSC RX3 Service Manual www.CSCMotorcycles.com Electrical System The function of the electrical system is to supply electric energy for starting and running the motorcycle. The electrical system consists of power supply parts, power utilization parts, and control parts. The power supply system consists of the stator and battery. When the engine drives the stator to reach a certain speed, the stator will output electrical energy. This energy powers the electrical equipment and charges the battery. The battery uses its stored energy for starting, illumination, signaling, and other purposes. The power utilization portion of the electrical system uses electrical energy for lighting, starting, signaling, accessories, and applications. The control portion of the electrical system consists of the electronic control unit (ECU), the rectifier, the starter relay, the fuse, the control switch gear, and the main electrical harness. Your motorcycle has a 300‐watt stator, a 12V lead acid battery, a main harness to conduct electrical energy to various motorcycle components, a regulator, connectors, flashers, an ECU for controlling engine functions, a starter motor, fuses for overload protection, and other components. Most of the motorcycle’s main electrical components are located beneath the rear seat. After removing the seats and the plastic cover beneath the rear seat, the components are accessible. The electrical component locations are identified in the photo below. 76 ...
Page 78: Battery And Battery Installation
CSC RX3 Service Manual www.CSCMotorcycles.com Note that the manufacturer moved the regulator location in early 2015 from under the left rear body panel to a new location under the left forward body panel. This is shown in the photos below under the Electrical Components Location section. Battery and Battery Installation The battery is located under the seat on the right side of the motorcycle. It is accessible by removing the right body panel underneath the seat. It is not necessary to remove the seat to gain access to the battery. It will be easier to work around the battery, however, if you remove both seats. The red harness is the positive side of the motorcycle electrical circuit; the black terminal is the negative side of the motorcycle electrical circuit. 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. Secure the rubber retention strap around the battery, and reinstall the body panel. 77 ...
Page 79: Accessories Connections
CSC RX3 Service Manual www.CSCMotorcycles.com Accessories Connections The CSC RX3 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. The RX3 motorcycle requires 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, a starter relay, an LED relay, two fuse sets (two 20A fuses for the battery power circuit and two 15A fuses for other electrical components), control switches, the main harness, connectors, lights, the horn, and other parts. These components and their locations are primarily located beneath a cover under the rear seat. To gain access to these ...
Page 80 CSC RX3 Service Manual www.CSCMotorcycles.com The plastic pan under the rear seat covers many of the electrical systems components, as will be seen below. The ECU controls the fuel injection system and engine electrical management. It is located directly beneath the cover under the rear seat. The starter relay is located under the rider’s seat to the left of the battery. This electrical connector is located under the rider’s seat outboard of the left side of the frame. This circuit provides energy from the voltage regulator to the battery. If this connector is not mated properly, the motorcycle will not charge the battery. This electrical connector is the main electrical connector from the stator to the voltage regulator. It is located under the rider’s seat outboard of the left side of the frame. If this connector is not mated properly, the motorcycle will not charge the battery. 79 ...
Page 81 CSC RX3 Service Manual www.CSCMotorcycles.com This is the relay that controls power to the fuel pump. It is located under the plastic cover under the passenger seat, inboard of the frame, in front of the 15A fuse box on the left side of the motorcycle. The motorcycle’s two 15A fuses are in a fuse box located under the plastic cover under the passenger seat, inboard of the frame, on the left side of the motorcycle. One fuse is a spare; the other is the fuse for the ignition and the fuel pump. The motorcycle’s two 20A fuses are in a fuse box located under the plastic cover under the passenger seat, inboard of the frame, on the right side of the motorcycle. One fuse is a spare; the other is the fuse for between the battery and the rest of the motorcycle. If this fuse is open, no power is provided to anything on the motorcycle. This small processor controls the motorcycle’s turn signals. It is located under the plastic cover under the passenger seat, inboard of the frame, on the right side of the motorcycle behind the main fuse. The horn is attached to the frame behind the headlight. 80 ...
Page 82 CSC RX3 Service Manual www.CSCMotorcycles.com The left side switches are located on the left handlebar. These switches operate high/low beam, the turn signals, the emergency flashers, the high beam flash, and the horn. The right side switches are located on the right handlebar. These switches operate the accessory outlets, the starter button, and the kill switch. The ignition switch is located immediately forward of the upper fork yoke. The headlight is located at the front of the motorcycle. The taillight and brake light are located at the rear of the motorcycle. 81 ...
Page 83: Electrical System Troubleshooting
CSC RX3 Service Manual www.CSCMotorcycles.com The turn signals are located on the left and right sides of the motorcycle. The starter motor is located immediately behind the cylinder on top of the engine case. 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. 82 ...
Page 84 CSC RX3 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 85 CSC RX3 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 86 CSC RX3 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 87 CSC RX3 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 88 CSC RX3 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 89 CSC RX3 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 88 ...
Page 90 CSC RX3 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 89 ...
Page 91 CSC RX3 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 92 CSC RX3 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 93: Accessories Installation
CSC RX3 Service Manual www.CSCMotorcycles.com Accessories Installation The North American RX3 configuration is delivered fully assembled except for the windshield, the mirrors, and the top case. All other accessories provided with the motorcycle are already installed when the motorcycle is delivered. For reference, installation instructions for the guard bars, the rear rack, the top case, and the panniers are included here. Motorcycle Guard Bar Installation Install the forward guards first. The forward motorcycle guard bar layout and required fasteners are shown below. Start by installing the upper portion beneath the front fender. It attaches with a single M8×16 flange bolt as shown in the photos below. 92 ...
Page 94 CSC RX3 Service Manual www.CSCMotorcycles.com Install the lower portion of the forward motorcycle guard. Install the guard with two bushings to the lower portion of the guard and two M8×50 flange bolts. Install the U‐bolt and attach to the frame using two M8 flanged self‐locking nuts. Install two M8×45 flange bolts to connect the upper and lower portion of the forward motorcycle guards. Tighten all fasteners. When finished, the forward motorcycle guards should appear as shown in the photo to the right, with red arrows indicating bolt attach points. 93 ...
Page 95: Rear Rack Installation
CSC RX3 Service Manual www.CSCMotorcycles.com Rear Rack Installation Carefully install rear rack over rear body panels (exercise caution to not scratch the rear body panels). Although shown in this photo, do not install the rear rack screws that go through the body panels yet. Rear Motorcycle Guard Installation The rear motorcycle guards and their components are shown in the photo below. 94 ...
Page 96 CSC RX3 Service Manual www.CSCMotorcycles.com The photo to the right shows the rear engine guards assembled off the motorcycle. This photo is provided only for the purpose of clarifying the relative position of the parts in the assembled condition. Do not attempt to assemble the guards prior to installation on the motorcycle. Position the right rear motorcycle guard on the right side of the motorcycle. Insert Bolt A through the right rear motorcycle guard and the rack and hand tighten to frame. Do the same on the left side of the motorcycle. Insert Bolts B through the right and left rear motorcycle guards and into frame beneath rear fender. Note that Bolts B go through both the left and right rear motorcycle guards beneath the rear fender. Insert Bolts D and E through both the right and left rear motorcycle subguards. The upper portion of the subguard secures to the rear motorcycle guard with Bolt D; the lower portion of the subguard secures to the rear footpeg bracket with Bolt E. 95 ...
Page 97: Top Case Installation
CSC RX3 Service Manual www.CSCMotorcycles.com Install the strut to the left and right rear motorcycle guards with Bolts C. After completing all steps above for the rear rack, top case platform, and rear motorcycle guards, tighten all bolts. Top Case Installation Place the trunk connecting plate bushing beneath the top case support, and install one M8×85 flange bolt. Install top case support plate with two truss head Allen bolts M6×20 and two truss head bolts M6×35. Tighten all fasteners. Secure the top case to the top case mounting plate with three 4mm Allen head bolts. Tighten bolts and install top case pad over bolt heads in bottom of top case. 96 ...
Page 98: Pannier Installation
CSC RX3 Service Manual www.CSCMotorcycles.com Pannier Installation Each pannier is secured to the rear motorcycle guard with four M8×20 flange bolts and a flanged washer. The annular step on the washer faces toward the motorcycle and centers the bolt in the rear motorcycle guard bushing. Install all four bolts and tighten. Repeat on left side of motorcycle. 97 ...
Page 99: Electrical Schematic
CSC RX3 Service Manual www.CSCMotorcycles.com Electrical Schematic 98 ...
Page 100: Appendix A - Service Checklists
CSC RX3 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 101 CSC RX3 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 102 CSC RX3 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 103 CSC RX3 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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