Fantic Motor TL 250 Workshop Manual
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Fantic Motor TL 250 Workshop Manual

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  • Page 1 WORKSHOP MANUAL...
  • Page 2  Fantic Motor reserves the right to amend or make changes, at any time and without prior notice, to the models described, to specifications and to design data, while this will not affect the essential features described and illustrated herein.
  • Page 3 WORKSHOP MANUAL TL 250...

  • Page 4: Table Of Contents

    8.1 Changing the headlight bulb on the carburettor model 8.2 Changing direction indicator light bulbs 9 Disassembling the forks 9.1 Casa Competizione fork TL 250 carburettor and injection 9.2 Casa Performance fork TL 250 carburettor 9.3 Changing fork oil 9.4 Disassembling the fork legs 10 Braking system 10.1 Front brake...
  • Page 5 14.3 Section 5 cooling system troubleshooting 15 Electrical devices 15.1 Location of fuses 15.2 Notes on the battery 15.3 Wiring diagram - TL 250 4-stroke 2016 15.4 Wiring diagram - TL injection 250 euro4 2018 15.5 OBD connectors 15.5.1 ECU 15.5.2 Fuel injector...
  • Page 6 WORKSHOP MANUAL TL 250 CONTENTS 16.8.1 Dim Headlight 16.8.2 Blown Bulb 16.8.3 Direction Indicators Not Flashing 16.8.4 Direction Indicators Stay On 16.8.5 Direction Indicators Flashing Too Slow 16.8.6 Direction Indicators Flashing Too Fast 16.8.7 Horn Does Not Work 17 Products 18 Engine 18.1 Removing the Engine Fully...
  • Page 7 WORKSHOP MANUAL TL 250 SAFETY CONTENTS RULES 18.5.20 Inspect the clutch spring 18.5.21 Inspect the clutch disc 18.5.22 Inspect the clutch basket 18.5.23 Inspect the drive gear 18.5.24 Inspect the freewheel 18.5.25 Inspect the primary starter gear 18.5.26 Inspect the oil pump on the right side of the engine case 18.5.27 Inspect the starter motor and step gear...

  • Page 8: Safety Rules

    WORKSHOP MANUAL TL 250 SAFETY CHAPTER 1 RULES Carbon monoxide Exhaust fumes contain carbon monoxide, a poisonous gas that can cause death. Consequently, when performing procedures with the engine running, make sure you are in the open air, or in a suitable, well-ventilated room, never in an enclosed space.
  • Page 9 WORKSHOP MANUAL TL 250 SAFETY CHAPTER 1 RULES Brakes Brake fluid can damage the vehicle's painted, plastic or rubber surfaces. Protect these parts with a clean rag when performing certain procedures. Always wear safety eyewear and, should brake fluid accidentally come into contact with eyes, flush immediately with plenty of cold, clean water, and seek immediate medical advice.
  • Page 10 WORKSHOP MANUAL TL 250 SAFETY CHAPTER 1 RULES Keep the work area tidy, so that you don't have items left lying around on the floor getting in the way of repair work. Wipe up any spilled oil, grease or other fluids on the floor in work areas to avoid people slipping on them.
  • Page 11 WORKSHOP MANUAL TL 250...

  • Page 12: Maintenance Rules

    RULES 2.1 MAINTENANCE  Always use original Fantic Motor spare parts, and lubricants recommended by the manufacturer. Non-original spare parts can damage the vehicle. Always use new gaskets, oil seals and O-rings during assembly. Following removal, clean parts with non-flammable solvents.

  • Page 13: Torque Settings

    WORKSHOP MANUAL TL 250 MAINTENANCE RULES CHAPTER 2 Keep all parts away from sources of heat. Do not lift the vehicle by its licence plate bracket, to avoid damage. Use suitable tools and cleaning products. 2.3 TORQUE SETTINGS STEERING STEM FASTENING SEQUENCE:...

  • Page 14: Vehicle Identification

    The chassis number can be found on the steering head. e11*168/2019*00256*00 ZFMTL250MGT000000 81.9 dB(A) 4125 minˉ� 9.7 kW max. 270 kg Engine identification number Each FANTIC MOTOR vehicle also has an engine ID number that can be found on the top left-hand side of the crankcase.

  • Page 15: Spare Parts

    SPARE CHAPTER 4 PARTS Use only original Fantic Motor spare parts; for all lubrication needs, use Fantic Motor-recommended grease and oil.  While other makes of product may look similar and do the same job, their quality may be inferior.

  • Page 16: Bodywork Removal

    WORKSHOP MANUAL TL 250 BODYWORK CHAPTER 5 REMOVAL To provide access to certain areas of the vehicle for inspection and work, you need to remove the relevant parts as follows: 5.1 REMOVING THE SEAT Remove the fastening screw (A) pictured and remove the seat by sliding it backwards to release it from the hook on the tank and the bracket (B).

  • Page 17: Removing The Radiator Shrouds

    WORKSHOP MANUAL TL 250 BODYWORK CHAPTER 5 REMOVAL 5.3 REMOVING THE RADIATOR SHROUDS Once you have unscrewed the two screws 5 securing the tank's rear mount, unscrew screws a,b,c,d, starting on the right side, followed by the left. 5.4 REMOVING THE FUEL TANK Unscrew screw F securing the tank to the frame, and the two mounting screws G;...

  • Page 18: Removing The Mud Flap

    WORKSHOP MANUAL TL 250 BODYWORK CHAPTER 5 REMOVAL 5.6 REMOVING THE MUD FLAP Unscrew the two screws "I" securing it to the mudguard. To make performing this procedure easier, it is best to remove the air filter (see sect. 6) so that you can tighten the nut located on the inside.

  • Page 19: Removing The Rear Subframe

    WORKSHOP MANUAL TL 250 BODYWORK CHAPTER 5 REMOVAL 5.9 REMOVING THE REAR SUBFRAME Unscrew the four screws N securing it to the frame (two each side) and the screw O connecting it to the silencer. 5.10 REMOVING THE KICKSTAND Remove spring P and unscrew screw Q securing the kickstand to the frame and remove the actual kickstand 5.11 REMOVING THE SWINGARM PIVOT BOLT...

  • Page 20: Dashboard

    WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 6.1 DASHBOARD TL 250 CARBURETTOR KOSO DB EX-O2 Speedometer Clock: 12/24 hour mode • Stopwatch: time taken to cover the set • Display range: 0-360 km/h (0-225 MPH) distance • Display unit: km/h or MPH •...

  • Page 21: How To Use The Select Button

    WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 • Pressing the Adjust button allows you to switch between displaying trip A and trip B. • Holding the Adjust button down for 3 seconds resets trip B. • Pressing the Adjust button allows you to switch between displaying trip B and the total hour meter.

  • Page 22: How To Use The Adjust + Select X 3 Button

    WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 • Pressing the Select button allows you to switch from the stopwatch function to the speed measuring function. • Holding the Select button down for 3 seconds resets the speed measuring device. NB: Average speed and maximum speed are shown in turns at 3-second intervals.

  • Page 23: Tyre Detection Point Setup

    WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 3.4 TYRE DETECTION POINT SETUP • Press the Select button to edit the digit, entering the number 1 NB: the detection point can be changed in the range 1 to 9. • Pressing the Adjust button takes you back to the tyre circumference and detection point menu 3.5 CLOCK SETUP...
  • Page 24 WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 • Press the Adjust button to enter stopwatch distance setup. In this example, we will be changing the distance from 300 to 350. • Press the Adjust button to go back to the stopwatch setup menu.

  • Page 25: Dashboard Koso Db-01Rn

    WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 Basic function instruction a ning Maximum speed record Tachometer Average speed record etting range ●Display range : 0 ~ 360 km/h (0 ~ 225 mile) ●Display range : 0 ~ 10,000 RPM、0 ~ 12,000 RPM、0 ~ 15,000 RPM ●Recording range :...
  • Page 26 WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 Meter size Meter size 8 mm 8 mm Meter size The settings s 120 mm 37 mm 20 mm 8 mm Select button function instruction 120 mm 37 mm 20 mm ●In the clock screen, press the Select ●In the fuel level screen, press the...
  • Page 27 WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 The settings screen description The settings screen description The settings screen description ●Total millage screen - Press and hold the Select + Adjust button for 3 seconds to enter setting screen. ●Total millage screen - Press and hold the Select + Adjust button for 3 seconds to ●Press the Adjust button to select setting screen for Circumference and sensing...
  • Page 28 WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 4-3-1 RPM pulse setting Fuel level man ●Press the Select button to enter the ●Press the Select button to enter rpm ●P RPM pulse setting screen. stage setting screen. ●EX. Setting from high wave (Hi-Act) to low wave (Lo-Act).
  • Page 29 WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 GENERAL CONTENT AND CONSULTATION ENERAL CONTENT AND CONSULTATION...
  • Page 30 WORKSHOP MANUAL TL 250 DASHBOARD CHAPTER 6 GENERAL CONTENT AND CONSULTATION...

  • Page 31: Air Filter Removal

    WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 AIR FILTER CHAPTER 7 REMOVAL To get to the filter, you will need to: - Remove the seat, see section 5.1. - Free the battery box by unscrewing the 4 screws S shown in the photo.

  • Page 32: Light Bulb Changing

    WORKSHOP MANUAL TL 250 LIGHT BULB CHAPTER 8 CHANGING 8.1 CHANGING THE HEADLIGHT BULB ON THE CARBURETTOR MODEL • Unplug light X from the connector • Remove the rubber cover Y installed to protect the bulb. • Turn the light assembly anticlockwise and remove the blown bulb.

  • Page 33: Disassembling The Forks

    TL 250 FORK CHAPTER 9 DISASSEMBLY Disassemble the fork parts in the order shown in the figure: 9.1 CASA COMPETIZIONE FORK TL 250 CARBURETTOR AND INJECTION 9.2 CASA PERFORMANCE FORK TL 250 CARBURETTOR MODELS UP TO 2018 CASA Q.O ml Q.O ml...

  • Page 34: Changing Fork Oil

    WORKSHOP MANUAL TL 250 FORK CHAPTER 9 DISASSEMBLY 9.3 CHANGING FORK OIL To change the oil, proceed as follows: 1. With the wheel removed, loosen the screws AA fastening the leg. 2. Slide out the leg and remove the top cap AB.

  • Page 35: Braking System

    WORKSHOP MANUAL TL 250 BRAKING CHAPTER 10 SYSTEM 10.1 FRONT BRAKE Check To check front brake wear, simply inspect the caliper, looking from the front of the bike, from where you should just be able to make out the ends of the two pads, which should have at least a 2mm-thick lining.

  • Page 36: Replacing The Brake Pads

    WORKSHOP MANUAL TL 250 BRAKE PAD CHAPTER 11 REPLACEMENT 11.1 FRONT BRAKE · Unscrew the bolts AC · Remove the pads from the caliper 11.2 REAR BRAKE · Remove the rear wheel. · Remove the pads from the caliper 11.3 FRONT OIL LEVEL Check for oil through the sight glass AD.

  • Page 37: Front Oil Level

    WORKSHOP MANUAL TL 250 BRAKE PAD CHAPTER 11 REPLACEMENT 11.4 REAR OIL LEVEL Check for oil through the oil reservoir AG. The oil level should never be allowed to drop below the minimum level mark on the reservoir AG. Top up oil as required through the filler cap AH.

  • Page 38: Adjusting The Brakes

    WORKSHOP MANUAL TL 250 BRAKE CHAPTER 12 ADJUSTMENT 12.1 ADJUSTING THE BRAKES 12.1.1 Front brake The front brake is a hydraulically operated disc model and hence does not require any adjustment. If you wish to adjust the position of the lever, use adjuster AO.

  • Page 39: Checking And Adjusting Steering Play

    WORKSHOP MANUAL TL 250 BRAKE CHAPTER 12 ADJUSTMENT 12.3 CHECKING AND ADJUSTING STEERING PLAY Check steering head play at regular intervals by pushing the forks forward and back as illustrated in the figure. If you notice any play, make the relevant adjustment by proceeding as follows: •...

  • Page 40: Headlight Beam

    WORKSHOP MANUAL TL 250 BRAKE CHAPTER 12 ADJUSTMENT 12.5 HEADLIGHT BEAM • The headlight beam is adjusted by hand • The height of the beam should be checked at regular intervals. It can be adjusted vertically only. • Place the vehicle (parallel to the ground, but not on its stand) 10 m from a vertical surface •...

  • Page 41: Removing The Engine From The Frame

    WORKSHOP MANUAL TL 250 ENGINE REMOVAL CHAPTER 13 FROM FRAME NOTE: THE HEAD, CYLINDER, CLUTCH AND IGNITION CAN BE REMOVED WITHOUT HAVING TO REMOVE THE ENGINE FROM THE FRAME. - CLEAN THE MOTORCYCLE THOROUGHLY BEFORE COMMENCING REMOVAL. - TO WORK ON THE MOTORCYCLE, SIT IT ON AN APPROPRIATE STAND •...
  • Page 42 WORKSHOP MANUAL TL 250 ENGINE REMOVAL CHAPTER 13 FROM FRAME • Clean up any trace of coolant that might have spilled onto the engine, frame or wheels. • Remove the screws and take off the drive sprocket guard BL. • Remove the sprocket and chain.
  • Page 43 WORKSHOP MANUAL TL 250 ENGINE REMOVAL CHAPTER 13 FROM FRAME Place the engine in a suitable position for removal and pull it out.

  • Page 44: Engine Maintenance

    Air filter paper PETROL FUEL TYPE premium petrol Fuel (octane n° min.98) Athena 34mm single-body electronic injection, TL 250 injection single-point injector. TL 250 Carburettor 36mm diameter constant vacuum carburettor Tank capacity (including reserve) 8.5 l/1 l Fuel reserve capacity...

  • Page 45: Vehicle Operation And Maintenance On Carburettor Version

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 14 MAINTENANCE 14.2 VEHICLE OPERATION AND MAINTENANCE ON CARBURETTOR VERSION 1. Check the oil level. When the average oil level drops below the bottom line marked on the sight glass, add lubricating oil. 2. Nominal weight: it is recommended that nominal weight not exceed 150 kg 3.
  • Page 46 WORKSHOP MANUAL TL 250 ENGINE CHAPTER 14 MAINTENANCE 11. Check the condition of the spark plug once the motorcycle has done 1000 km. Remove encrusted carbon deposits and check the gap between the two electrodes, which should usually be between 0.7 and 0.8 mm. The spark plug has a service life of 5000 km.

  • Page 47: Section 5 Cooling System Troubleshooting

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 14 MAINTENANCE 14.3 SECTION 5 COOLING SYSTEM TROUBLESHOOTING Symptoms: poor engine power, water temperature gauge indicator continually in the red, boiling coolant coming out of the radiator (to be expected when the indicator suddenly moves into the red) Causes of water overheating: 1.

  • Page 48: Electrical Devices

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.1 LOCATION OF FUSES The fuses BP are located under the seat and, to gain access to them, you will need to remove the seat as described in section 5.1. WARNING: Before replacing the blown fuse, identify and eliminate the fault causing it to blow.
  • Page 49 WORKSHOP MANUAL TL 250 49 49...

  • Page 50: Wiring Diagram - Tl 250 4-Stroke 2016

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.3 WIRING DIAGRAM - TL 250 4-STROKE 2016 50 50...
  • Page 51 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15...

  • Page 52: Wiring Diagram - Tl Injection 250 Euro4 2018

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.4 WIRING DIAGRAM - TL INJECTION 250 EURO4 2018...
  • Page 53 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 53 53...
  • Page 54 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 Main cable routing: rear, under-seat compartment, fuses and relays, ECU and tail lights...

  • Page 55: Obd Connectors

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5 O.B.D. connector  The OBD (On-Board Diagnostic) connector is the communication port used to connect the testers required for self-diagnostics. The OBD connector is located under the seat. Remove the seat to gain access to it.

  • Page 56: Ecu

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5.1 ECU The ECU (electronic injection) is located under the seat - refer to the procedures below: CHAPTER 10 WORKSHOP MANUAL 250 Rev00 / 2019 - Removing the seat ELECTRICAL SYSTEM AND DEVICES...
  • Page 57 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5.2 Rear ABS sensor The rear ABS sensor's connector is located in the middle of the vehicle, just above the engine case, and can be accessed directly.  To run instrumental tests, you may need to cut one or more cable clamps to release the connector from the frame.

  • Page 58: Fuses And Relays

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5.3 FUSES AND RELAYS To check fuses, set the ignition switch to OFF to avoid the risk of a short-circuit. Remove the seat and the fuse box cover. Remove one fuse at a time and check if the filament is broken.

  • Page 59: Stepper Motor

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5.4 Stepper motor The stepper motor is fitted on the throttle body: the stepper motor connector is located under the tank on the left-hand side of the vehicle and can be accessed directly.

  • Page 60: Lights Contactor

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5.5 Lights contactor The lights contactor is located under the seat. Remove the seat to gain access to it.  The contactor and its connector can be replaced individually. The contactor type is: 30A normally open.

  • Page 61: Lambda Sensor

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.5.7 Lambda sensor The lambda sensor connector is located under the tank, right behind the cylinder head cover, and can be accessed directly. Colour Function Lambda sensor heater control signal (-) WH-RD...

  • Page 62: Fuses And Relays

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.6 Fuses and relays To check fuses, set the ignition switch to OFF to avoid the risk of a short-circuit. Remove one fuse at a time and check if the filament is broken.

  • Page 63: Battery

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.7 Battery 15.7.1 Replacing the battery Remove: – Seat. Remove screw "A" and disconnect the negative cables. Remove screw "B" and disconnect the positive cables. Remove the battery.  Repeat the procedure in reverse to refit.

  • Page 64: Diagnostic Port And Instrument Connection

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.8 Diagnostic port and instrument connection To run diagnostics on the vehicle, you will need to access the diagnostic port and plug in a recognized diagnostic tester. The diagnostic port "A" is located under the seat, in the space between the battery and fuse box.

  • Page 65: Removing The Fuel Tank

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.9 Removing the fuel tank Remove the right- and left-hand radiator shrouds. Remove the seat. Remove the mudguard and side panels. Remove the battery. Remove the rear seat bracket securing the tank.
  • Page 66 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 Before refitting, check that the fuel line is positioned correctly, it should be unrestricted vertically. 15.9.4 Unscrew the four screws on the petrol pump flange.  The fuel strainer does not need replacing.

  • Page 67: Removing The Electronic Injection

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.10 REMOVING THE ELECTRONIC INJECTION 15.10.1 Removing the injector Remove the fastening screw "A" and disconnect the fuel injector from the flange on the engine. Unplug the fuel injector's connector "B". There may be some fuel left inside the injector and its line.

  • Page 68: Removing The Throttle Body

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 15.10.2 Removing the throttle body Disconnect the stepper motor's connector "A" and the TPS's connector "B". Loosen the metal clamps "C". Pull the throttle cable pin "D" out of the fitting "E" on the throttle body.

  • Page 69: Removing The Map Sensor

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES ELECTRICAL DEVICES CHAPTER 15 15.10.3 Removing the MAP sensor Remove the screw "A" and release the MAP sensor from its slot on the engine. Disconnect the connector "B" and the retaining bracket "C" from the MAP sensor.

  • Page 70: Error Code

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES ELECTRICAL DEVICES CHAPTER 15 CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS 11.2 ERROR CODES 15.11 ERROR ERROR CODE 15.11.1 11.2.1 Ignition module Error codes table P003F A Camshaft Profile Control Circuit Performance/Stuck Off - Bank 2...
  • Page 71 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES ELECTRICAL DEVICES CHAPTER 15 CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0084 P00B9 Exhaust valve control solenoid valve (bank 2) Low pressure fuel system pressure - Too low...
  • Page 72 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES ELECTRICAL DEVICES ELECTRICAL DEVICES CHAPTER 15 CHAPTER 15 CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0131 P0164 Oxygen sensor Oxygen heater control circuit high (bank 2 sensor 3)
  • Page 73 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES ELECTRICAL DEVICES ELECTRICAL DEVICES CHAPTER 15 CHAPTER 15 CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P020C P0261 Injection timing - Cylinder 3...
  • Page 74 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P02AB P032A Cylinder 5 balancing - Fuel trim at min limit Knock sensor 3 - circuit...
  • Page 75 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0370 P042A Timing Reference High Resolution Signal A Catalyst temperature sensor circuit P0371 P042B Timing Reference High Resolution Signal A Too Many Pulses...
  • Page 76 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0468 P0505 Evaporative emissions purge valve - signal too high Idle air stepper motor P0469...
  • Page 77 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0547 P0590 Exhaust Gas Temperature Sensor Circuit (bank 2 sensor 1) Cruise Control Multi-Function Input Circuit Stuck...
  • Page 78 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0628 P0661 Fuel Pump A Control Circuit Low Intake Manifold Tuning Valve Control Circuit Low (Bank 1)
  • Page 79 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P06A7 P0723 Sensor Reference Voltage B Circuit Range/Performance Output Speed Sensor Circuit Intermittent P06A8 P0724...
  • Page 80 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P0800 P0880 Transfer Case Control System (MIL Request) Transmission control module power input signal P0801...
  • Page 81 P209B Reductant Quality Sensor Circuit Range/Performance Reductant Inje WORKSHOP MANUAL P206C P209C Reductant Quality Sensor Circuit Low Reductant Inje TL 250 P206D P209D Reductant Quality Sensor Circuit High Reductant Inje P206E P209E Intake Manifold Runner Control Stuck Open (Bank 2)
  • Page 82 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P205B P208B Reductant Temperature Sensor Circuit Range/Performance Reductant Pump Control Range/Performance P205C P208C Reductant Tank Temperature Sensor Circuit Low...
  • Page 83 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P20BC P20F6 Reductant Heater A Control Circuit High Reductant Injection Valve Stuck Open (Bank 1 Unit 1)
  • Page 84 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P2138 P2179 Throttle/Pedal Position Sensor/Switch D/E Voltage Correlation System Too Lean Off Idle Bank 2...
  • Page 85 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P2235 P2288 Heated oxygen sensor heater (HO2S) Bank 2 Sensor 2 Injector Control Pressure Too High...
  • Page 86 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P2538 Exhaust Gas Temperature Sensor Circuit Range/Performance Bank 1 Ignition Switch Accessory Position Circuit High...
  • Page 87 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P2603 P2647 Coolant Pump A Control Circuit High A Rocker Arm Actuator System Stuck On Bank 1...
  • Page 88 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P2680 Torque Converter Clutch Pressure Control Solenoid Control Circuit Range/ Coolant Degassing Valve Control Circuit High...
  • Page 89 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ERROR ERROR CODE CODE P2A02 P3435 Oxygen Sensor Circuit Range/Performance (Bank 1, Sensor 3) Cylinder 5 Deactivation/Intake Valve Control Circuit Low...

  • Page 90: Abs Module Error Code Tablem

    WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS 15.11.2 11.2.2 ABS module error code table ERROR ERROR ADDITIONAL DESCRIPTION CODE C1013 Rear suction valve C1014 Internal error: solenoid valve relay fault...
  • Page 91 WORKSHOP MANUAL TL 250 ELECTRICAL DEVICES CHAPTER 15 CHAPTER 11 WORKSHOP MANUAL 250 Rev00 / 2019 11 Diagnostics DIAGNOSTICS ERROR ERROR ADDITIONAL DESCRIPTION CODE C1D91 Front speed sensor The signal changes intermittently C1D92 Front speed sensor The signal decays periodically...

  • Page 92: Troubleshooting

    WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 TROUBLESHOOTING CHAPTER 16 16.1 BIKE DOESN'T START/STARTING DIFFICULTY 16.1.1 FUEL SYSTEM CARBURETTOR VERSION Problem Specific Area Involved Cause Fuel tank � Empty � Tank breather clogged � Fuel deteriorated, contains water or contaminated...
  • Page 93 WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 TROUBLESHOOTING CHAPTER 16 Product Specific Area Involved Cause Cylinder and cylinder head � Spark plug loose � Cylinder head loose � Cylinder head gasket broken � Cylinder gasket broken � Cylinder worn, damaged or seized Piston and piston rings �...

  • Page 94: Poor Performance At Mid Range And High Speed

    WORKSHOP MANUAL TL 250 TROUBLESHOOTING CHAPTER 16 16.2 POOR PERFORMANCE AT MID RANGE AND HIGH SPEED Product Specific Area Involved Cause Ignition system � Spark plug fouled � Incorrect heat range � Ignition unit faulty � Pick-up coil faulty � Ignition coil faulty Fuel system �...

  • Page 95: Overheating Or Excessive Cooling

    WORKSHOP MANUAL TL 250 TROUBLESHOOTING CHAPTER 16 16.3 OVERHEATING OR EXCESSIVE COOLING Product Specific Area Involved Cause Ignition system � Incorrect gap between electrodes � Incorrect spark plug heat range � Ignition unit faulty Fuel system � Poor fuel mixture �...

  • Page 96: Front Fork Malfunctioning

    WORKSHOP MANUAL TL 250 TROUBLESHOOTING CHAPTER 16 16.5 FRONT FORK MALFUNCTIONING Product Specific Area Involved Cause OIL LEAKS FRONT FORK � Tube deformed, damaged or oxidized � Leg damaged or broken � Oil seals damaged � Hex bolt loose � Cap O-ring damaged �...

  • Page 97: Starter Motor Not Working

    WORKSHOP MANUAL TL 250 TROUBLESHOOTING CHAPTER 16 16.7 STARTER MOTOR NOT WORKING Product Specific Area Involved Cause Battery � Insufficient battery capacity � Battery faulty Fuse Blown, faulty connection Switches � ON/OFF switch faulty � Kickstand switch faulty � Front/rear brake switch faulty STARTER MOTOR IS NOT WORKING �...

  • Page 98: Direction Indicators Stay On

    WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 CHAPTER 16 TROUBLESHOOTING 16.8.4 DIRECTION INDICATORS STAY ON • Direction indicator relay faulty • Insufficient battery capacity (almost dead) • Bulb blown (front or rear) 16.8.5 DIRECTION INDICATORS FLASHING TOO SLOW • Direction indicator relay faulty •...

  • Page 99: Products

    WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 PRODUCTS CHAPTER 17  Use lubricating products and fluids that meet specifications that are equivalent or superior to those given. These directions also apply to any top-ups. Product Specifications Remarks 4-stroke engine and transmission oil SAE 10W30,10W40,15W40, 20W40, Do not use mineral oils.

  • Page 100: Engine

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.1 REMOVING THE ENGINE FULLY Place the vehicle on a central stand and support the weight at the back with straps and a hoist. Remove: – Seat – Tank – Exhaust system Remove the air hose "A" and clutch cable "B".
  • Page 101 WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Remove the neutral sensor "E". Remove the starter motor wire "F". Disconnect the pick-up and alternator connectors "G" and "H". Remove the spark plug boot "I".

  • Page 102: Changing Engine Oil And Engine Oil Filters

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Remove the three engine mounts "J" and swingarm bolt "K". Remove the engine from the vehicle. Torque settings: • M10 screws: 50 Nm (5.0 m•kg, 36 ft•lb) • M8 screws: 27 Nm (2.7 m•kg, 20 ft•lb) Repeat the procedure in reverse to refit.

  • Page 103: Engine Oil Level

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Remove the two M5 bolts "F" on the engine's right-hand side and remove the spring "G" and filter "H". This is a paper filter. Drain the oil for 5 min or wait until there is no more oil.

  • Page 104: Cylinder Head And Valve

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.4 CYLINDER HEAD AND VALVE 18.4.1 Remove the cylinder head cover Remove the four M6×20 bolts from the valve covers on the intake and exhaust sides respectively. Remove the valve covers from the cylinder head on the intake and exhaust sides respectively.

  • Page 105: Remove The Cylinder Head

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Remove the M6×25 bolt from the cylinder head and block. Remove the four M10×1.25 nuts and remove the four 10.5×2×20 washers belonging to the bolts. Remove the cylinder head. 18.4.3 Cylinder head cover disassembly Remove the two M14×1 bolts from the locating plate on the...

  • Page 106: Inspect The Valve And Valve Spring

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.4.5 Inspect the valve and valve spring Check that the valve is not bent or burned, and that the stem is not excessively worn, and measure the outside diameter of the stem. Service limit value: Ø 4.94 mm Seating surface width service limit: 1.5 mm.

  • Page 107: Inspect The Camshaft Parts

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.4.7 Inspect the camshaft parts Check the surface of the camshaft for wear or damage, and make sure that the bearings on both sides of the camshaft are not rotating slower than they should.

  • Page 108: Measure The Width Of The Valve Seating Surface

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.4.11 Measure the width of the valve seating surface Service limit value: 1.5 mm If the valve seat width "A" is inadequate or the seat is pitted, it must be lapped to ensure a proper seal.

  • Page 109: Assemble The Cylinder Head Cover

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.4.13 Assemble the cylinder head cover Insert the intake and exhaust rocker arms in the cylinder head cover in the direction shown by the arrows before pushing them through the cover, matching them up with the intake and exhaust rocker arm shaft holes.

  • Page 110: Adjusting Timing

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.4.15 Adjusting timing 1. Remove cap "D" from the left access hole, as well as cap "C". 2. Turn the magnet lock nut using the relevant spanner and check whether the timing index "-" on the rotor "E" (on the left) is lined up with the central index mark on the cover "F".

  • Page 111: Checking And Adjusting Tappets

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Adjust intake and exhaust valve clearance: 0.04 to 0.06 mm. Fit the valve cap on the cylinder head cover and tighten. Torque setting: Cylinder head cover fastening bolts 11 ~ 13 Nm (1.1 ~ 1.3 kgf·m, 8.1 ~ 9.6 lbf·ft) 18.4.17 Checking and adjusting tappets...

  • Page 112: Cylinder And Piston

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5 CYLINDER AND PISTON 18.5.1 Remove the cylinder Remove the chain tensioner and cylinder block. Using a scraper, scrape off any residues left by the gasket on the surface of the cylinder. Deposits are easier to remove after soaking in petrol. Be careful not to damage the cylinder's contact area when performing this job.

  • Page 113: Inspecting The Piston And Rings

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.4 Inspecting the piston and rings Remove the piston rings: Take care not to damage the piston rings during removal. Measure the piston ring-to-groove clearance. Service limit value: Top ring: 0.08 mm ring: 0.08 mm Oil ring: 0.08 mm...

  • Page 114: Install The Piston Rings

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Measure the outside diameter of the gudgeon pin. Service limit value: 15.99 mm Measure the piston-to-gudgeon pin clearance. Service limit value: 0.025 mm 18.5.5 Install the piston rings Clean the piston ring grooves.

  • Page 115: Install The Piston

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.7 Install the cylinder block Install the cylinder block locating bush and new cylinder gaskets. Coat the cylinder block, piston and piston ring with an even layer of oil. Set the gaps of all piston rings at a 120° angle to each other and lower the cylinder block into place.

  • Page 116: Remove The Clutch

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.11 Remove the clutch Remove the clutch pressure plate after unscrewing the bolts from the plate two at a time in diagonally opposite positions. Then remove the clutch push rod and friction plate.

  • Page 117: Remove The Starter Motor

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.15 Remove the starter motor Remove the screw fastening the starter motor and remove the motor. 18.5.16 Remove the gearshift Remove the screws fastening the shift star. Remove the shift lever components. Remove the screws fastening the index plate assembly and remove the washer and the index plate assembly.

  • Page 118: Inspect The Starter Shaft

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Tips for installing the water seal assembly, oil seal and water pump shaft: Apply a moderate amount of oil inside the water pump shaft hole, press and insert the oil seal using the special tool, while the outer side of the gasket faces out.

  • Page 119: Inspect The Clutch Disc

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.21 Inspect the clutch disc If there is anything wrong with the clutch disc, replace it. Measure the thickness of each disc. Service limit value: 2.85 mm Check the surface of the clutch disc for warp. Use a feeler gauge for inspection.

  • Page 120: Inspect The Drive Gear

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.23 Inspect the drive gear Check the drive gear for wear or damage. If there is significant notching, replace it. 18. 5.24 Inspect the freewheel Remove the circlip from the outer side of the freewheel and check the components for wear or damage.

  • Page 121: Inspect The Starter Motor And Step Gear

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.27 Inspect the starter motor and step gear. Check the starter motor's teeth for damage and check the step gear for wear or damage. 18.5.28 Inspect the gearshift Check the index plate roller for wear or for impeded movement.

  • Page 122: Install The Drive Gear

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.5.35 Install the drive gear Slide the drive gear onto the right end of the crankshaft. Fit the drive gear lock nut washer on the drive gear. Apply sealant to 3-4 threads of the drive gear lock nut.

  • Page 123: Generator, Crankshaft Balancing And Driven Gear

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.6 GENERATOR, CRANKSHAFT BALANCING AND DRIVEN GEAR 18.6.1 Remove the crankcase cover on the left side Remove the bolts fastening the cover on the front and left and remove the left side crankcase cover.

  • Page 124: Remove The Balancer Drive Gear And Driven Gear

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.6.5 Remove the oil pump on the left side Remove the 3 screws from the oil pump cover plate on the left side. Remove the oil pump cover plate and the oil pump rotor assembly on the left side.

  • Page 125: Inspect The Left Side Oil Pump

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.6.9 Inspect the left side oil pump Check the left side oil pump for wear or damage. Check the oil pump cover plate for wear or damage. 18.6.10 Install the left side oil pump Insert the oil pump in the relevant openings in the left side.

  • Page 126: Install The Generator Stator

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.6.13 Install the generator stator Secure the magnet stator assembly on the crankshaft on the left side by tightening the two M5×10 screws and M5×30 screws. Torque setting: Generator stator screws: 7 to 9 Nm.

  • Page 127: Inspect The Bearings On The Crankcase Left And Right Sides

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Measure the radial clearance of the connecting rod big end at two points in both the X- and Y-directions. Service limit value: 0.02 mm Use a feeler gauge to measure the connecting rod big end's side clearance.

  • Page 128: Inspect The Mainshaft Assembly And Countershaft Assembly

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Check the mainshaft and countershaft forks for wear, damage or warp, and measure the outside diameter. Mainshaft fork shaft service limit value: φ 11.95 mm Countershaft fork shaft service limit value: φ 13.95 mm Measure the thickness of the ends.

  • Page 129: Inspect The Oil Filters And Their Components

    WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 18.7.7 Inspect the oil filters and their components Check that oil filters and their components are clean: clean any fouled parts with clean petrol. The fine filter "A" is a paper filter: do not use petrol to clean it.
  • Page 130 WORKSHOP MANUAL TL 250 ENGINE CHAPTER 18 Insert the oil filter components in the relevant slots in the crankcase. When installing the oil filter, keep the opening facing the crankcase's left side. Install the filter cap on the pin and secure in place by tightening the two M5 nuts.

  • Page 131: Injection Maintenance Chart

    If you require technical advice or assistance from customer support, please contact an Authorized Fantic Motor Centre. Fantic Motor disclaims all civil or criminal liability for damage to the vehicle or property, and/or injury to persons, as a result of maintenance work carried out by the user.
  • Page 132 WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 MAINTENANCE CHAPTER 19 CHART Position Work 1,000 km 5,000 km 10,000 km 15,000 km 20,000 km (600 mi) (3,000 mi) (6,000 mi) (9,000 mi) (12,000 mi)   Brake hoses – Check for cracking or damage.
  • Page 133 WORKSHOP MANUAL WORKSHOP MANUAL TL 250 TL 250 MAINTENANCE CHAPTER 19 CHART Position Work 1,000 km 5,000 km 10,000 km 15,000 km 20,000 km (600 mi) (3,000 mi) (6,000 mi) (9,000 mi) (12,000 mi) Engine oil – Check the oil level and inspect the vehicle Every 1,000 km (600 mi).

  • Page 134: Carburettor Mainteinance Chart

    WORKSHOP MANUAL TL 250 MAINTENANCE CHAPTER 19 CHART 19.2 CARBURETTOR MAINTENANCE CHART  NOTE: Perform maintenance work at shorter intervals if the vehicle is used in rainy or dusty areas or on uneven ground.   Inspect and clean, adjust, lubricate, as necessary.
  • Page 135 WORKSHOP MANUAL TL 250 MAINTENANCE CHAPTER 19 CHART Parts End of running-in 500 km (321 mi) Every 2000 km (1250 mi) or Every 5000 km (3125 mi) or 12 months 12 months Braking systems    Brake fluid every 2 years ...
  • Page 136 WORKSHOP MANUAL TL 250...
  • Page 137 WORKSHOP MANUAL TL 250 MANUFACTURER'S DATA AND EDITION Fantic Motor SPA Via Tarantelli, 7 31030 Dosson di Casier (TV) Italy Tel. +39 0422 634192 Fax +39 0422 1830124 Email: info@fanticmotor.it www.fanticmotor.it Edition: 01/2019...
  • Page 138 FANTIC MOTOR S.P.A Fantic Motor SPA Via Tarantelli, 7 31030 Dosson di Casier (TV) Italy info@fanticmotor.it www.fanticmotor.it...

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