Fantic XEF RALLY 2023 User Manual
  1. Manuals
  2. Brands
  3. Fantic Manuals
  4. Motorcycle
  5. XEF RALLY 2023
  6. User manual
Fantic XEF RALLY 2023 User Manual

Fantic XEF RALLY 2023 User Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

U S E R MAN UAL
e n
READ TH IS MANUA LE CA RE FULLY B E FO RE O P E RATI NG THI S VE HI C L E

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the XEF RALLY 2023 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Fantic XEF RALLY 2023

Summary of Contents for Fantic XEF RALLY 2023

  • Page 1 U S E R MAN UAL READ TH IS MANUA LE CA RE FULLY B E FO RE O P E RATI NG THI S VE HI C L E...
  • Page 2 RALLY - Edition 02 / 2023 INTRODUCTION Introduction FANTIC WANTS TO THANK YOU for choosing one of its products. We recommend that you read this manual before driving your vehicle. It contains information, advice and warnings on the vehicle maintenance and use. The instructions in this manual have been prepared to give you a simple and clear guide for use. We are sure that taking it into consideration you will gain confidence with your new vehicle, which you can use for a long time and with full satisfaction.
  • Page 3 Fantic Motor is constantly committed in improving its production. Any significant modifications and changes introduced with regard to vehicle characteristics and repair procedures will be brought to the attention of all Fantic Motor dealers and will be published in future editions of the manual.

  • Page 4: Table Of Contents

    USE AND MAINTENANCE MANUAL INDEX RALLY - Edition 02 / 2023 1. General information ..........................8 1.1 Warnings ............................... 8 1.2 Symbols used in the manual ........................10 1.3 Behaviour and driving ..........................11 Vehicle use ..............................11 Getting on ..............................11 Getting off ..............................

  • Page 5: Rally - Edition 02 / 2023 Index

    USE AND MAINTENANCE MANUAL INDEX RALLY - Edition 02 / 2023 Shift pedal ..............................46 Throttle grip ............................... 47 Front brake lever ............................47 Start button ..............................47 Rear brake pedal ............................47 Start knob (air valve) ..........................48 Sidestand ..............................48 Locking device ............................
  • Page 6 USE AND MAINTENANCE MANUAL INDEX RALLY - Edition 02 / 2023 Rear shock absorber sinking adjustment (SAG) ..................63 3.10 Chain tension ............................65 Chain tension check ..........................65 Chain tension adjustment ......................... 65 4. Maintenance ............................66 4.1 Engine oil ..............................66 Engine oil level check ..........................
  • Page 7 1. Warranty content ........................... 95 2. Effectiveness ............................96 3. Exclusions ............................... 96 4. Disputes ..............................96 FANTIC 3-MONTH OFF-ROAD COMMERCIAL WARRANTY ................96 5. Warranty content ........................... 96 6. Effectiveness ............................97 7. Exclusions ............................... 97 8. Disputes ..............................97 Intervention request ..........................
  • Page 8 USE AND MAINTENANCE MANUAL INDEX RALLY - Edition 02 / 2023...

  • Page 9: General Information

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1. General information 13 Motore 1.1 WARNINGS Carbon monoxide The exhaust fumes contain carbon monoxide, a poisonous gas that can cause death. Therefore, for certain operations, make sure you are in an open space, or in a suitable and well-ventilated room, never in enclosed spaces.
  • Page 10 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information The battery emits explosive gases, it is advisable to keep away flames, sparks and any other source of heat. Provide adequate ventilation when servicing or recharging the battery. Keep out of the reach of children.

  • Page 11: Symbols Used In The Manual

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore 1.2 SYMBOLS USED IN THE MANUAL Within this manual there will be technical warnings and annotations preceded by the following symbols according to the reference topic: Warning regarding the procedure described and the specific safety rules: indicates procedures that must be followed to prevent damage to the vehicle or possible injuries to vehicle repairers.

  • Page 12: Behaviour And Driving

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.3 BEHAVIOUR AND DRIVING Some safety tips are given below to avoid damage to people and/or things and to use your vehicle with an easier and safer drive. Vehicle use To use the vehicle it is necessary to meet all the law requirements.

  • Page 13: Frame Number

    CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Fantic Motor vehicles are equipped with frame and engine identification numbers. These numbers that identify the motorcycle model must be mentioned for the request for spare parts.

  • Page 14: Location Of Important Labels

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.6 LOCATION OF IMPORTANT LABELS 1. Pressurised gas hazard label 5. “Choke” symbol 2. Usable petrol quality label 6. Tyre pressure label 3. Chassis number punching 4.
  • Page 15 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information PETROL FUEL TYPE...

  • Page 16: Vehicle Component Location

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.7 VEHICLE COMPONENT LOCATION Handlebar components Ref. Component Clutch lever Left tablet control panel High beam / low beam light selector switch Turn signals warning light switch Horn button Left fuel filler cap High beam flasher button...

  • Page 17: Right And Left Side Components

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Right and left side components Ref. Component Ref. Component Rear brake pedal Cold start starter Radiator Oil filler cap Headlight Oil level sight glass Right fuel tank Gear pedal Central fuel tank cap...

  • Page 18: Technical Data

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.8 TECHNICAL DATA Technical Data Dato tecnico Valore/i Overall length 2310 mm (90.9 in) Overall width: Without handguards 800 mm (31.5 in) With handguards 885 mm (34.8 in) Overall height 1270 mm (50.0 in)
  • Page 19 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Dato tecnico Valore/i Primary reduction ratio 2.609 (60/23) Final drive Chain Secondary reduction ratio 3.692 (48/13) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio:...

  • Page 20: Tightening Torques

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.9 TIGHTENING TORQUES Engine tightening torques “◊” = marked portion shall be checked for torque tightening after break-in or before each race. Item Thread size Quantity Tightening torque Remarks Camshaft cap bolt 10 Nm (1.0 kgf•m, 7.4 lb•ft) Spark plug 13 Nm (1.3 kgf•m, 9.6 lb•ft) Cylinder head stud bolt (exhaust pipe)
  • Page 21 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Item Thread size Quantity Tightening torque Remarks Engine oil drain bolt 20 Nm (2.0 kgf•m, 15 lb•ft) Crankcase bolt 12 Nm (1.2 kgf•m, 8.9 lb•ft) Clutch cable holder bolt 10 Nm (1.0 kgf•m, 7.4 lb•ft) Crankshaft end accessing screw...
  • Page 22 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information : Cylinder head bolt (XEF 450 version) – First, tighten the cylinder head bolts to 40 N·m (4.0 kgf·m, 30 lb·ft) in the proper tightening sequence and remove them. –...

  • Page 23: Chassis Tightening Torques

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Chassis tightening torques “◊” = marked portion shall be checked for torque tightening after break-in or before each race. Item Thread size Quantity Tightening torque Remarks Upper bracket pinch bolt ◊ 21 Nm (2.1 kgf•m, 15 lb•ft) Lower bracket pinch bolt ◊...
  • Page 24 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Item Thread size Quantity Tightening torque Remarks Rear brake pad pin 17 Nm (1.7 kgf•m, 13 lb•ft) Rear brake pad pin plug 2.5 Nm (0.25 kgf•m, 1.8 lb•ft) Rear wheel axle nut ◊...
  • Page 25 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Item Thread size Quantity Tightening torque Remarks Upper tank central support screw 10 Nm (1.0 kgf•m, 7.4 lb•ft) Steering damper pivot bracket bolt 10 Nm (1.0 kgf•m, 7.4 lb•ft) Engine guard support central screw ◊...

  • Page 26: Electrical Tightening Torques (All Versions)

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Note : Fastening nut for instrument support block It is advisable to periodically check the tightening of bolts “A” of the instrument support block and if necessary, reset it to the prescribed torque. When checking the tightening of the instrument support block, special care should be taken not to exceed the prescribed torque.

  • Page 27: Maintenance Limits

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore 1.10 MAINTENANCE LIMITS Engine Elemento Standard Limite Cylinder head: Warp limit – 0.05 mm (0.0020 in) Cylinder: Bore size 97.000–97.010 mm (3.8189–3.8193 in) 97.060 mm (3.8213 in) Camshaft: Camshaft cap inside diameter...
  • Page 28 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Elemento Standard Limite Clutch: Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) – Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in) 2.82 mm (0.111 in) Plate quantity 6 pezzi –...

  • Page 29: Chassis

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Chassis Item Standard Limit Steering system: Steering bearing type Taper roller bearing – Front suspension: Front fork travel 310.0 mm (12.2 in) –...
  • Page 30 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Item Standard Limit Compression damping: Adjusting system Mechanical adjustable type Fast compression damping: Unit for adjustment Turn Adjustment value from the start position –...

  • Page 31: Electrical

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Item Standard Limit Rear brake: Brake pedal position 5.0 mm (0.20 in) – Disc outside diameter × thickness 245.0 × 4.0 mm (9.64 in × 0.16 in) –...

  • Page 32: Electrical System Diagram

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.11 ELECTRICAL SYSTEM DIAGRAM Cables colour coding The colour of a cable can be an “A” colour or two “B” colours. The cable which has two colours is identified by the first colour code (primary “C” or colour of the sheath) followed by the second colour code (secondary “D”): the codes are separated by a dash “-”. Examples: • case “A” : Blue = L ;...

  • Page 33: Main Wiring Diagram Component Legend

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Main wiring diagram component legend The following table lists all the components in the main electrical system diagram and their numbering. Number Description of the electrical component Engine control unit (CDI)
  • Page 34 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Number Description of the electrical component Speed sensor Race light Rear fuel pump control switch Engine map selector Front fuel tank reserve probe Rear fuel tank reserve probe Front fuel tank reserve interface Rear fuel tank reserve interface...

  • Page 35: Main Wiring Diagram

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Main wiring diagram PASS RIGHT LEFT HIGH BEAM 12V LUCI Vkey CAN L CAN H CONNETTORE AUX 7.5A INIEZIONE KEY ON 7.5A LUCI 7.5A...
  • Page 36 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information RUN / OFF CONNETTORE AUX INIEZIONE KEY ON LUCI VENTOLA...

  • Page 37: Service Wiring Harness Components Legend

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 13 Motore Service wiring harness components legend The following table lists all the components in the standard service wiring harness diagram and their numbering. Numero Descrizione del componente elettrico Roadbook tablet...

  • Page 38: Standard Services Wiring Harness Diagram

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Standard services wiring harness diagram GENERALE ROADBOOK/THORK ODOCAP/COMMANDER IRITRACK BACKUP FUSE...

  • Page 39: Lamps

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information 1.12 LAMPS The front and rear lights are LED type, therefore they do not require maintenance. The front and rear turn indicators are equipped with 12V - 6W halogen lamps.

  • Page 40: Recommended Lubricants And Liquids

    USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information The auxiliary fuse box “3” is accessible directly, next to the dashboard. 1.14 RECOMMENDED LUBRICANTS AND LIQUIDS Use lubricating and fluid products that meet the equivalent specifications, or higher than those prescribed. These same indications are also valid for topping up.

  • Page 41: Maintenance Intervals

    From 7000 km (4200 mi) or 9 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 3 months. Items marked with an asterisk (*) should be performed by a FANTIC dealer as they require special tools, data and technical skills.
  • Page 42 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Item Checks and maintenance jobs Initial / 1000 3000 km 5000 km km (600 mi) (1800 mi) or 3 (3000 mi) or 6 or 1 month months months...

  • Page 43: Maintenance Intervals For Competition Use

    (e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk (*) should be performed by a FANTIC dealer as they require special tools, data and technical skills.
  • Page 44 USE AND MAINTENANCE MANUAL CHAPTER 1 RALLY - Edition 02 / 2023 GENERAL INFORMATION 1. General information Item Routine After break-in Every Every Every As required 15 hours 30 hours 60 hours – Check the coolant passages for √ corrosion. –...

  • Page 45: Use Of The Vehicle

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 13 Motore 2.1 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points.

  • Page 46: Refuelling

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 2.3 REFUELLING The vehicle is equipped with three separate tanks (central, left side, and right side), each of which has its own filler cap. To refuel one of them, slide out the vent tube and remove cap “1”...

  • Page 47: Stop The Engine

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 2.5 STOP THE ENGINE With the throttle valve completely closed, press the “ENGINE STOP” button on the right handlebar. 2.6 MAIN COMPONENTS Engine stop switch The engine stop switch “1”...

  • Page 48: Throttle Grip

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle Throttle grip The throttle grip “1” is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you;...

  • Page 49: Start Knob (Air Valve)

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle Start knob (air valve) Starting a cold engine requires more air input, which is provided by the starter knob “1”. Pushing in the knob activates the starter, which increases the opening of the throttle valve.

  • Page 50: Dashboard

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 2.7 DASHBOARD Basic functions Maximum speed record Average speed record Tachometer ●Display range : ●Recording range : ●Display range : 0 ~ 10,000 RPM、0 ~ 12,000 RPM、0 ~ 15,000 RPM 0 ~ 360 km/h (0 ~ 225 mile) 0 ~ 360 km/h (0 ~ 225 MPH) Maximum RPM record...

  • Page 51: Meter Size

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 13 Motore Meter size 8 mm 120 mm 37 mm 20 mm Select button function instruction ●In the volt screen, press the Select ●In the volt screen.

  • Page 52: The Settings Screen Description

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle The settings screen description ●Total millage screen - Press and hold the Select + Adjust button for 3 seconds to enter setting screen. ●Press the Adjust button to select setting screen for Circumference and sensing pointsetting, RPM pulse setting, Fuel gauge resistance setting (Fuel level manual setting / Fuel level resistance auto detection setting...

  • Page 53: Rpm Pulse Setting

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 13 Motore RPM pulse setting ●Press the Select button to enter the ●Press the Select button to enter rpm RPM pulse setting screen.

  • Page 54: Oil Maintenance Mileage Setting

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle Oil maintenance mileage setting ●Press the Select button to enter the NOTE ●2-stroke motor oil millage is oil maintenance mileage setting indicated by external signal warning screen.

  • Page 55: Internal Odo

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 13 Motore Internal ODO ●Example：Current internal ODO is ●The main screen. 50,000 km. ●Press the Select button three seconds to go back to ODO screen.

  • Page 56: Other Electronic Devices

    USE AND MAINTENANCE MANUAL CHAPTER 2 RALLY - Edition 02 / 2023 USE OF THE VEHICLE 2. Use of the vehicle 2.8 OTHER ELECTRONIC DEVICES The standard XEF 450 Rally vehicle contains other integrated electronic devices. To access specific instructions for each of them, it is recommended to visit the relevant websites. List of available devices: –...

  • Page 57: Adjustments

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments 3.1 BRAKES Front brake adjustment Check brake lever position “A”. If it is different from the standard value, adjust it. Brake lever position “A”: Standard position: 100 mm (3.94 in) Adjustment point: 86-105 mm (3.39-4.13 in) Adjust the brake lever position as described below: –...

  • Page 58: Clutch

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments • Adjust the pedal height between the maximum “A” and the minimum “B” as shown. (In this adjustment, the bolt “3” end “b” should protrude out of the threaded portion “4” but not be less than 2 mm (0.08 in) “c” away from the brake pedal “5”). • After the pedal height adjustment, make sure that the rear brake does not drag. 3.2 CLUTCH Adjusting the clutch lever clearance Check the clutch lever clearance “A”.

  • Page 59: Throttle Control

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments 3.3 THROTTLE CONTROL Adjusting the throttle grip clearance Check the throttle control knob clearance “A”. If it is different from the standard value, adjust it. Throttle grip clearance “A”: 3.0–6.0 mm (0.12–0.24 in) Adjust the throttle control knob clearance as described...
  • Page 60 USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments Install the lower handlebar mounts so that the side with the longest distance “a” faces forward. By installing the lower mounts in the opposite direction, the amount of front-rear offset of the handlebar position can be changed.

  • Page 61: Fork Adjustment

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments 3.7 FORK ADJUSTMENT Rebound damping adjustment (return) – To adjust the rebound damping force of the fork, turn the adjustment device “1”. The device has a range of action of 20 clicks;...

  • Page 62: Relieving The Front Fork Internal Pressure

    Air bleed screw: 1.3 Nm (0.13 m•kg, 0.95 ft•lb) To improve the front fork performance, and adapt it to different road conditions, driving style and rider’s weight, Fantic features springs with different load coefficients which can be purchased from authorized dealers.

  • Page 63: Rear Shock Absorber Adjustment

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments 3.8 REAR SHOCK ABSORBER ADJUSTMENT Rebound damping adjustment (return) – To adjust the rebound damping force of the rear shock absorber, turn the adjustment device “1”. The device has a range of action of 30 clicks;...

  • Page 64: Compression Damping Adjustment (High Speed)

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments Compression damping adjustment (high speed) – To adjust the compression damping force at high speed, turn the adjustment device “1”. The device has a range of action of 2 turns, from fully closed, rotating counter- clockwise;...
  • Page 65 To improve the rear shock absorber performance, and adapt it to different road conditions, riding style and rider’s weight, Fantic features springs with different load coefficients that can be purchased from authorized dealers. Load factor...

  • Page 66: Chain Tension

    USE AND MAINTENANCE MANUAL CHAPTER 3 RALLY - Edition 02 / 2023 ADJUSTMENTS 3. Adjustments 3.10 CHAIN TENSION If the drive chain is too tight, it will overload the engine and other vital parts, and if it is too loose it may jump and damage the swingarm or cause an accident.

  • Page 67: Maintenance

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.1 ENGINE OIL Engine oil level check – Place the vehicle on a flat surface, in a vertical position by placing a suitable stand under the engine; –...

  • Page 68: Engine Oil Filling

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance If necessary, replace the oil filter: – Remove cover “7” and oil filter cartridge “5”; – Install a new oil filter cartridge “5” and a new O-Ring “6”; –...

  • Page 69: Coolant

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.2 COOLANT Checking the coolant level Do not remove the radiator cap “1”, drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.

  • Page 70: Air Filter

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.3 AIR FILTER Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. Never run the engine without the air filter element in place;...
  • Page 71 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Install gasket “7” on the filtering element; – Install guide “8” on the filtering element; – Install filtering element “9” on guide “10”; – Then install the guide/air filter assembly on the vehicle. Make sure that the two projections “A” at the rear side of the vehicle on the air filter guide are securely fitted into the two slots “B” in the air filter case.

  • Page 72: Camshafts

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.4 CAMSHAFTS Removal Remove: – Seat, air filter casing, left and right fuel tanks; – Remove the spark plug and valve cover; – Remove timing reference cap “1” and crankshaft access cap “2”.

  • Page 73: Installation

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Remove bolts “5” of the camshaft supports following a crossed pattern, starting from the outside to the inside; – Remove the camshaft supports “6” from the head. The camshaft cap bolts must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps.
  • Page 74 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Install the intake and exhaust camshafts in the head. – Install the timing chain “1” on the sprockets of both camshafts. Make sure that notches “c” of the exhaust and intake camshafts are aligned with plane “d”...
  • Page 75 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Release the screwdriver and check that the tensioner rod comes out smoothly and easily; – Install the gasket “4” and the timing chain tensioner cap “5”.

  • Page 76: Valve Clearance

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.5 VALVE CLEARANCE Make sure that the valve clearance is controlled and/or adjusted when the engine is cold (ambient temperature). While the valve clearance is checked and/or adjusted, ensure that the piston remains at the top dead centre (TDC).
  • Page 77 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance There are 25 types of adjusting pads, ranging from Last digit of pad number Rounded value 1.20 mm (0.0472 in) to 2.40 mm (0.0945 in), in increments of 0.05 mm (0.0020 in).

  • Page 78: Cylinder Head

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.6 CYLINDER HEAD Removal – Remove: Seat, left and right conveyors, air filter casing, fuel tank; – Remove the spark plug and valve cover; – Remove the camshafts (refer to chapter ”4.4 Camshafts” on page 71);...
  • Page 79 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance The head bolts tightening must be completed in four steps, as described below: 1st Phase – Tighten the head bolts to the specified torque by performing the operation in two/three steps, following the diagram shown in the figure.

  • Page 80: Cylinder And Piston

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.7 CYLINDER AND PISTON Removal – Remove the head (refer to section “4.6 Cylinder head” on page 77); – Remove cylinder bolts “1” on the timing chain side, then remove cylinder “2”...

  • Page 81: Piston Check

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance Piston check – Measure the outside diameter of piston “A” in measuring position “B” using the micrometer. Piston diameter: 96.955 – 96.970mm (3.8171 – 3.8177 in) Measuring point “B” (from the lower side of the piston skirt): 9.0mm (0.35 in)

  • Page 82: Soundproofing

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Install seeger “3” in the relative housings on the piston; Make sure that the end of the seeger “C” is not near the notches in the piston. – Install the centering pins, gasket and cylinder previously lubricated with engine oil;...

  • Page 83: Clutch

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.9 CLUTCH Clutch removal – Remove the clutch crankcase bolts “2” following a cross pattern, then remove the crankcase “1”; – Remove the clutch bolts and springs following a cross pattern;...

  • Page 84: Check The Clutch Elements

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Bend the tab of the clutch hub nut lock washer (XXF 450 / XEF 450 ONLY); – Lock the clutch hub “1” with the universal locking tool “2” and unscrew the nut “3”;...

  • Page 85: Clutch Installation

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Measure the free length “A” of the clutch springs. If not in accordance with specifications, replace the springs all together; Clutch spring free length: 48.00 mm (1.89 in) Minimum limit: 45.60 mm (1.80 in) –...
  • Page 86 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Install nut “1”, lock the clutch hub with universal locking tool “2” and tighten the nut to the specified torque; Nut (clutch boss): 75 Nm (7.5 m•kg, 55 ft•lb) Apply engine oil to the thread and contact surfaces of the clutch hub nut.
  • Page 87 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Install the thrust plate “1”; – Install the springs and bolts of the clutch and tighten them following a cross pattern; Bolt (clutch spring): 10 Nm (1.0 m•kg, 7.2 ft•lb) –...

  • Page 88: Steering Play Control And Adjustment

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.10 STEERING PLAY CONTROL AND ADJUSTMENT Steering play control – Place a stand under the engine to raise the front wheel off the ground; Securely support the vehicle so that there is no danger of it falling over.

  • Page 89: Fork

    MAINTENANCE 4. Maintenance 4.11 FORK For the maintenance of hydraulic components, contact an authorised Fantic workshop. – Regularly check the upper “1” and lower “2” fastening screws of both stems. If they are loose, tighten them to the specified torque.

  • Page 90: Wheel Check

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance Wheel check The following procedure applies to both wheels. – Place a stand under the engine, lift the wheel and turn it. Check the centering and alignment of the rim channel with respect to the wheel hub.

  • Page 91: Replace The Rear Brake Pads

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Remove the pad pin and brake pads “4”; – Install the brake pads “4” with their protrusions “A” in the recesses of the brake calliper “B”. Temporarily tighten the pads pin “2”;...
  • Page 92 USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance – Loosen the pad pin “3”, remove the rear wheel “4” and the brake calliper “5 “; – Remove the pad pin “6” and brake pads “7”; –...

  • Page 93: Tyres

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.15 TYRES – Check the tire while it is cold; Model/version Front tyre Rear tyre standard pressure standard pressure XEF 450 Rally with road use configuration 200 kPa (2.00 kgf/cm , 29 psi) 220 kPa (2.20 kgf/cm...

  • Page 94: Cleaning And Vehicle Storage

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 4.17 CLEANING AND VEHICLE STORAGE Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components. 1.

  • Page 95: Seat Frame (Only For My23 Vehicles)

    USE AND MAINTENANCE MANUAL CHAPTER 4 RALLY - Edition 02 / 2023 MAINTENANCE 4. Maintenance 13 Motore 4.19 SEAT FRAME (ONLY FOR MY23 VEHICLES) Surfaces cleaning and greasing Perform this operation at each disassembly- reassembly, or as needed. – Clean the surface of the inner faces “A” of the seat frame and apply new grease specifically for electrical contacts.

  • Page 96: Warranty And Service

    FANTIC 24-MONTH COMMERCIAL WARRANTY Fantic Motor S.p.A. located in via Tarantelli no. 7, 31030 Dosson di Casier-TV (hereinafter referred to as Fantic), although it is not the final seller to the consumer, intends to support the final seller’s responsibilities with its own warranty called Fantic Commercial Warranty, provided through its authorised technical assistance network under the conditions set out below.

  • Page 97: Effectiveness

    2.2. It is not possible to make use of the Fantic Commercial Warranty if more than 36 months have passed from the date of invoicing of the product by Fantic to the first purchaser. The end buyer will be responsible for checking with the seller whether the product can access the benefits of Fantic’s commercial warranty.

  • Page 98: Effectiveness

    It is not possible to make use of the Fantic Off-Road Commercial Warranty if more than 36 months have passed from the date of invoicing of the product by Fantic to the first purchaser. The end buyer will be responsible for checking with the seller whether the product can access the benefits of the Fantic Off-Road Commercial Warranty.
  • Page 99 USE AND MAINTENANCE MANUAL CHAPTER 5 RALLY - Edition 02 / 2023 WARRANTY AND SERVICE 5. Warranty and service 13 Motore Warnings for maintenance and care The purchaser is responsible for ensuring that maintenance work is carried out at the prescribed intervals and documented by means of completed, stamped and proof of purchase receipts.

  • Page 100: Warranty Data

    USE AND MAINTENANCE MANUAL CHAPTER 5 RALLY - Edition 02 / 2023 WARRANTY AND SERVICE 5. Warranty and service WARRANTY DATA VEHICLE DATA USER DATA Vehicle Type (PRODUCT CODE) Name and Surname (or Business Name) Engine Type (DISPLACEMENT) Address VEHICLE IDENTIFICATION NUMBER (V.I.N.) Zip Code - City - Country ENGINE NUMBER Phone Number...

  • Page 101: Service

    USE AND MAINTENANCE MANUAL CHAPTER 5 RALLY - Edition 02 / 2023 WARRANTY AND SERVICE 5. Warranty and service 13 Motore SERVICE Next service Registration of service Give the handbook to your dealer at each service. It is the responsability of the user to inform the Dealer of any maintenance carried out so that it is not repeated unnecessarily.
  • Page 102 USE AND MAINTENANCE MANUAL CHAPTER 5 RALLY - Edition 02 / 2023 WARRANTY AND SERVICE 5. Warranty and service Next service Next service Dealer’s stamp Dealer’s stamp Hours Date Hours Date Invoice No. Invoice No. Routine maintenance Main maintenance Routine maintenance Main maintenance Spark plug Air filter...

  • Page 103: Declarations Of Conformity

    Your vehicle is equipped with a range of radio equipment. The manufacturers of this radio equipment declare that these equipment complies with directive 2014/53/EU where required by law. The complete text of the EU declaration of conformity is available at the following web address: www.Fantic.com/RED Addresses of radio component manufacturers: All radio components must carry the manufacturer’s address according to the provisions of directive 2014/53/EU.
  • Page 104 FANTIC MOTOR S.P.A www.fantic.com - info@fanticmotor.it...

Table of Contents

Save PDF