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Lambretta X300 2023 Service Manual
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Lambretta X300 2023 Service Manual

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X300
Service manual
SERVICE MANUAL I ENG
Mod. # X300
1

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Summary of Contents for Lambretta X300 2023

  • Page 1 X300 Service manual SERVICE MANUAL I ENG Mod. # X300...
  • Page 2 X300 Service manual...

  • Page 3: Table Of Contents

    Table of contents X300 Service manual Preface How to use this manual Vehicle identification P.10 Pre-delivery inspection P.11 Technical Data P.13 Engine assembly P.17 Special Tools P.25 Maintenance P.27 Electrical system P.40 Removing the engine from the vehicle p.50 Troubleshooting P.77 Fuel system P 80...
  • Page 4 This manual details maintenance information,tools & special tools, disassembly and assembly procedures , inspection and adjustment methods, defected correction and technical specifications of the LAMBRETTA model X300. Due to continuous improvements of product we reserves the right to update this manual without prior notice.

  • Page 5: How To Use This Manual

    Only genuine Lambretta parts and manufacturer-recommended lubricants must be used. To prevent damage to the motorcycle. Use special tools that accurately match the vehicle model only to carry out repairs.
  • Page 6 Always use Lambretta Genuine Parts and recommended lubricants. from solvents and oils. Check these parts before installation to make Using parts not designed for Lambretta motorcycles may damage sure they are in good condition, replace them if necessary. the motorcycle.
  • Page 7 X300 Service manual external race). To avoid damage to the bearings, apply the same force to both species. Once the oil seal is installed, add grease to the groove, install the oil seal with the manufacturer's name facing the outside, check the Both of these examples may result in damage to the bearing.
  • Page 8 X300 Service manual contact with the body to prevent the circuit from short circuiting and Make sure the terminal pins are bent or loosened. generating sparks. Fully insert the connector. If there are two storage cabinets on the two connector sides, make sure the locker locks properly. Check if there is a loose wire.
  • Page 9 X300 Service manual Do not allow the harness to contact rotating, moving, or vibrating components to route the harness. Do not pinch or squeeze the strap as it does to install other components. Keep the strap away from hot parts. Do not allow the wiring harness to twist while installing.

  • Page 10: Vehicle Identification

    X300 Service manual Vehicle Identification Engine Number : The engine number (1) is stamped at the rear of the engine Frame Number (VIN) : Remove the rubber cover of the footrest. The frame number (2) is stamped on the frame.

  • Page 11: Pre-Delivery Inspection

    Pre-delivery inspection X300 Service manual Perform the following pre-delivery inspections before deliver to the customer. Check external conditions. Check general condition: Painting • Various plastic components and parts • Scratches • Dust, dirt stains • Check tightening torque Make sure that the color markings are made on the following points: Screws –...
  • Page 12 X300 Service manual Test Ride Push starting. • Check default reading of speedometer. • Check throttle and brake control. • Check engine and transmission operation. • Check front and rear suspension for smooth operation. • Check steering for smooth turning. •...

  • Page 13: Technical Data

    X300 Service manual Technical data 1370 mm. 1922 mm. Dimensions Length 1,922 mm (75.6in) Width 741 mm (29.1 in) Height 1,117 mm (43.9 in) Wheelbase 1,370 mm (53.9 in) Minimum ground clearance 153 mm (6.0in) Caster angle 26.5° Trail range 90°...

  • Page 14: Torque Value

    X300 Service manual Rear tire 130 / 70 - 12 56M tubeless Front tire pressure 28 PSI Rear tire pressure 32 PSI (34 PSI when there are passengers) Vehicle weight 160 Kg Maximum payload 160 Kg Battery YTZ10 12V, 9.1Ah (Yuasa) Liquid capacity Engine oil type 4 stroke JASO : MB, SAE : 5W-40, API : SG or higher...
  • Page 15 X300 Service manual Bolt securing the rear shock to the frame (top left) 18 – 22 Nm Bolt securing the rear shock (lower left) toBKT 37 – 43 Nm Bolt attaches right rear shock to frame (above). 37 – 43 Nm Bolt to secure rear right shock to swingarm (lower) 18 –...
  • Page 16 X300 Service manual Coolant hose clamps 3 - 5 Nm BKT attaches the water hose to the engine. 10-12 Nm Transmission unit Clutch mounting nut - belt drive wheel 45 - 50 Nm Drive pulley nut 75 - 83 Nm Transmission cover bolts 11 - 13 Nm Drive shaft fastening nut...

  • Page 17: Piston Pin

    X300 Service manual Engine assembly Assembly clearance Cylinder - piston assy. Cylinder - Piston Piston diameter (P) 74.967 ± 0.014 mm 75 + 0.038 + 0.01 mm Bore diameter (C) Caution The piston rings must be installed with the word <TOP> or the stamped mark racing upwards. Measure the outer diameter of the piston pin.
  • Page 18 X300 Service manual NoteN Measure the clearance by inserting the blade of the feeler Thickness gauge from the second seal side. Top piston ring – standard coupling clearance : 0.015 - 0.06 mm. (Top piston ring - maximum clearance allowed after use : 0.07 mm.) Middle piston ring –...
  • Page 19 X300 Service manual Crankcase - crankshaft - connecting rod Axial clearance between crankshaft and connecting rod Name Size Position Quantity Half-shaft, transmission side 16.6 +0-0.05 D = 0.20 - 0.50 Flywheel-side haft-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool...
  • Page 20 X300 Service manual Maximum admissible displacement 0.15 mm. 0.010 mm 0.010 mm 0.10 mm. Standard diameter Crankshaft – crankcase axial clearance <H> : 0.15 - 0.43 mm. Using a bore gauge, measure the connecting rod small end diameter. NoteNnote If the connecting rod small end diameter exceeds the standard diameter, Exhibits wear or Overheating, proceed to replace the crankshaft as described In the crankshaft chapter.
  • Page 21 X300 Service manual Note Because bearings will wear out with use, it is not necessary to measure the size on both sides of the bearing surface. Cylinder head Before doing anything, clean all contact surfaces of the cylinder head. Assemble the valve and valve spring to their original position. Use a a trued bar and a feeler thickness to measure wear.
  • Page 22 X300 Service manual Measuring the length of valve springs Standard Standard length:40.2 mm. Acceptable length after use:38.2 mm. Clean the soot from the valve seats. usePrussian blue checks the size of the valve seat contact area. as shown in figure<V> Standard value 1 - 1.3 mm.
  • Page 23 X300 Service manual Check the concentricity of the valve head by arranging a comparator at right angle relative to the valve head and rotate it on a "V" shaped abutment. Standard 0.03mm. Measure the size of the valve housing. Standard 5 +0.012 mm.
  • Page 24 X300 Service manual Camshaft tandard diameter Camshaft : standard diameter bearing A : 36.95 - 36.975 mm. Camshaft : standard diameter bearing B : 19.959 - 19.98 mm. Minimum Admissible diameter Camshaft : standard diameter bearing A : 36.94 mm. Camshaft : standard diameter bearing B : 19.950 mm.

  • Page 25: Special Tools

    X300 Service manual Special tools Name Pasts numbers pictures How to use Flywheel holder GZZ-NEXUS250-001 Timing system fixing GZZ-NEX US250-002 Piston assembling GZZ-NEXUS250-003 Front pulley nut fixing GZZ-NEXUS250-011 Cylinder head stud seal GZZ-NXS250-015 ring assembling 1 Cylinder head stud seal GZZ-NXS250-008 ring assembling 2 Cylinder head stud seal...
  • Page 26 X300 Service manual Pulley shaft oil seal GZZ-V125-006 assembling 2 Timing cover assembling GZZ-V125-007 Seal ring assembling GZZ-NEXUS-001...

  • Page 27: Radiator Coolant

    Maintenance X300 Service manual Periodic maintenance table Mileage / Km First 1,000 Every 4,000 Every 8,000 Every 12,000 Period inspection Inspection items Time / Month First 3 M Every 15 M Every 30 M Every 45 M Fuel system Fuel level display Throttle operation Air filter element Crankcase ventilation...
  • Page 28 X300 Service manual Specification of liquids Product introduction Type Details Grades Engine oil 5W-40 Synthetic base oil for engines 4 stroke SAE 5W - 40; JASO MB; API SL; ACEA A3 Transmission oil 80W - 90 Lubricating oil for gears and Transmission SAE 80W-90 API GL-4 Coolant Ready-mixed coolant typeEthylene Glycol...
  • Page 29 X300 Service manual Maintenance warning This function will remind you of scheduled maintenance. To turn the key to position<ON> each time the dashboard will perform a preliminary check. The maintenance warning symbol shows when it comes to maintenance This symbol will disappear when reset after completed servicing. Resetting the maintenance warning symbols Turn the key to the position<ON>...
  • Page 30 X300 Service manual Transmission oil Check the transmission oil level Put the vehicle on the main stand and level ground. Remove the dipstick and dry the tip of dipstick with clean cloth. Turn the dipstick in all the way down. Remove the dipstick.
  • Page 31 X300 Service manual Remove the LH footrest cover by loosen the screw and push down the lock pin behind the cover. Remove the RH footrest cover by loosen the screw and push down the lock pin behind the cover. Remove the 3 rubber floor strips on the left side. Pull out the left footrest by loosen 8 bolts (M6).
  • Page 32 X300 Service manual Loosen 4 bolts (M6) and loosen 3 bolts (M8) and Remove the fuel tank cap Remove the rubber plate Remove the drain hose Remove the plastic cover Loosen 2 bolts (M8) Remove the upper cover.
  • Page 33 X300 Service manual Loosen 2 screws. Remove the taillight rim. loosen 4 bolts (M6) to remove the LH side cover. Loosen 9 screws of air filter cover. Remove the air filter element. caution Replace the air filter element according to the maintenance schedule. If the vehicle is operated on rough or dusty roads.
  • Page 34 X300 Service manual Engine oil For 4-stroke engine, the lubricant is responsible for lubricating parts such as bearings, cylinder, piston, etc. Inadequate lubricant may damage the engine. In general the operation of a 4-stroke engine can degrade the lubricant and its properties, especially during the run-in period. The amount of engine oil decreases depending on operating conditions (e.g.
  • Page 35 X300 Service manual Caution The drained engine oil contains substances that are harmful to the environment. Measuring the engine oil level Must be checked while the engine is cold with the following steps : Put the vehicle on the center stand on level ground. Unscrew the dipstick.
  • Page 36 X300 Service manual Valve clearance adjustment Remove LH and RH side covers (refer to previous described procedures) Remove the LH engine cover. Remove the spark plug. Remove the plug of timing mark hole. turning drive pulley to align the mark “T” on the magneto wheel with reference mark on RH engine cover, as shown in the picture.
  • Page 37 X300 Service manual Engine cooling system The coolant level must be checked according to the maintenance schedule. and must be checked while the engine is cold. If the engine operating temperature is high, the warning light will appear in the dashboard. The engine must be stopped immediately and check the cooling system when the engine is cold Checking the coolant level Put the vehicle on the center stand on level ground.
  • Page 38 X300 Service manual Brake system Checking the brake fluid level Put the vehicle on level ground with the center stand holding the handlebars straight. Check the brake fluid level at the peephole. If the brake fluid level is low, add more brake fluid. If the brake fluid level at the peephole is full, it is normal.
  • Page 39 X300 Service manual Recommended Brake fluid Brake fluid : DOT4 SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4 Headlight adjustment Follow these steps: Adjust the vehicle position so that it is straight. Check that the tire pressure is within value according to specified standard, The vehicle is located on a level surface away from the screen or white wall about 10 meters.

  • Page 40: Electrical System

    X300 Service manual Electrical system Electrical system Location of electrical equipments...
  • Page 41 X300 Service manual Location of electrical equipments...
  • Page 42 X300 Service manual Location of electrical equipments...
  • Page 43 X300 Service manual Location of electrical equipments...
  • Page 44 X300 Service manual Location of electrical equipments...
  • Page 45 X300 Service manual Location of electrical equipments ABS Module Located inside the right front windscreen as shown in the picture. APK Antenna Located inside the right front windshield as shown in the picture. ECU box Located under U Box left side PDA connector Located under U Box on the left above ECU box Ignition coil...
  • Page 46 X300 Service manual Fuse box The ABS fuse box is located under the left luggage box. The main fuse box is located inside the right body cover, above the regulator. Regulator Located inside the right body cover. Under the main fuse box Magnetic wheel connector Located Inside the right body cover Under the regulator Key switch...
  • Page 47 X300 Service manual Left front turn signal assembly Located in the area of the left front windshield Set of front right turn signals Located in the area of the windshield on the right side fuel pump Locate under fuel tank 20.
  • Page 48 X300 Service manual Dashboard ① battery voltage gauge ⑩ Low fuel warning light ② speedometer ⑪ Warning lightEFI ③ coolant temperature gauge ⑫ high beam warning light ④ clock ⑬ right turn signal ⑤ tachometer ⑭ warning ligh taction Check distance ⑮...
  • Page 49 X300 Service manual Caution Procedure for resetting the warning lightactionCheckdistanceMust be done while the vehicle is stationary only. (speed equal to 0 km/hour) Section showing various functions Total distance 88888 This part of the screen will display the following information:actionCycle using the buttons MODE THIP 8888.8 Miles...

  • Page 50: Removing The Engine From The Vehicle

    X300 Service manual Removing the engine from the vehicle Removing the engine from the vehicle Put the vehicle on a suitable level surface. This operation must only be done while the engine is cold. Remove the luggage box. Remove the covers (Refer to the steps checking the ignition timing) Remove the battery terminals.
  • Page 51 X300 Service manual Remove 5 bolts (M6) mounting ABS sensor Slightly loosen 5 bolts (M8) mounting rear wheel. Remove 2 bolts (M6) air filter holder unplug the spark plug cap. Unplug the injector. Unplug Map sensor. Unplug the idle speed sensor. Unplug the temperature sensor.
  • Page 52 X300 Service manual Remove 2 bolts (M8) mounting rear brake caliper. Remove a bolt (M8) mounting rear shock absorber. Remove the nut mounting the engine and remove related bolt from opposite side. Remove the engine. Reinstall process vice versa and tightening procedures with the specified torque value. Warning When assembly is complete, please check the throttles operation and electrical equipments.
  • Page 53 X300 Service manual Disassemble of engine Remove LH cover Use a screw driver flat remove the front plastic cover. Use a special tool to lock the pulleys. special tools GZZ-F125-011 REAR PULLEY NUT FIXING Loosen the retaining nut and remove the retaining nut with the washer. Loosen bolts and remove belt cover fixing bolts.
  • Page 54 X300 Service manual Clutch shaft bearing assembly Use a hot air gun to blow the ball socket. Use a special tool to hammer the ball into the socket. Put the ball bearing lock ring back Removing the rear clutch assembly Remove the Clutch outer and clutch assembly.
  • Page 55 X300 Service manual Inspecting the clutch Check the thickness of the clutch cloth. Check that the clutch lining contact surfaces are free of grease or lubricant. If lubricant is found, check the seals. Note The thickness of the entire clutch clothThe 3 parts must not be too different. If the difference in thickness is too large it may cause the clutch to slip.or make a sound Standard value Minimum thickness:1 mm...
  • Page 56 X300 Service manual Inspection the driven sliding half-pulley Remove 2 washers and 2 O-rings. Measure the size bushing inside of the front pulley Check that the contact between the pulley and the belt is not damaged. joint check, pins, pivot points Check that the belt contact is consistent.
  • Page 57 X300 Service manual Drive-Belt Inspection Check that the belt is not damaged, torn or worn abnormally. The belt must have the correct width according to the standard value. Standard value Minimum belt width : 21.0 mm Check the wear condition of the belt especially visually. The belt groove may have cracks as shown.
  • Page 58 X300 Service manual Remove the washer, belt and drive pulley. Inspecting the rollers case Check the inside of the pulley slide bush rod must be free of damage. or abnormal wear and measure the inner diameter at position A. Measure the outer diameter of the bush slide axis at position B as shown in the figure. Inspect rollers must be free of damage or wear.
  • Page 59 X300 Service manual Assembling the belt cover Align the latch and belt cover gasket in position before assembling. Replace the belt cover and tighten the screws with the specified torque value. Reassemble the removal process Insert the pulley mounting nut accordingly, assemble the special tool and tighten with the required torque value. Torque value Belt cover screws : 11 - 13 Nm Pulley mounting bolts follow: 54 - 60 Nm...
  • Page 60 X300 Service manual Remove the wheel axle bearings Remove the bearing lock ring from the outside of the transmission housing. Place the transmission housing and use a special tool to remove the axle seal as shown. Remove the clutch shaft bearing To remove the clutch shaft bearing, remove the transmission housing and shaft seal.
  • Page 61 X300 Service manual Inspecting the final gear set Check 3 final gear teeth , bearing surfaces and oil seals for wear. If worn parts are found, replace them. Inspecting the rear gear Check that the surface is not worn or deformed. Check the bearing socket area.
  • Page 62 X300 Service manual Caution In assembling the bearing, a secondary device must be found to keep the bearing socket in a straight line. and assemble the ball bearings in alignment Assemble the lock ring and replace the seal from the pulley side. Assembling the transmission bearing Assemble all 3 shafts on the crankcase as shown in the picture.
  • Page 63 X300 Service manual cover RH engine Remove the RH engine cover Remove water pipe clamp on the pump . Remove the bolts and remove the RH engine cover. Remove the spring Remove the cover gasket. Remove magneto Remove the 2 screws on the CPS sensor and 3 mounting screws as shown. Remove the magneto and CPS sensor.
  • Page 64 X300 Service manual Remove flywheel and starter motor Remove starter motor Remove the positive wire on the starter motor. Remove 2 bolts and disconnect the ground wire. Remove the starter motor. Remove flywheel Remove the water pump shaft and the crankshaft sprocket lock clip . Use flywheel holder to hold the flywheel and loosen nut to remove the flywheel as shown in the picture.
  • Page 65 X300 Service manual Install flywheel Install the starter gear to the flywheel. Lubricate the starter gear with engine oil. Use the flywheel holder(GZZ-NEXUS250- 001 ) to install the flywheel tighten torque value. Torque value 94 - 102 Nm Install the starter motor Install the starter motor with the crankcase.
  • Page 66 X300 Service manual Cylinder and valve control mechanism assembly system Remove intake manifold Remove the throttle body and injector. Remove 3 bolts securing the intake manifold. Remove the intake manifold. remove the o-ring of intake manifold. Remove the cylinder head cover Remove 5 bolts as shown in the picture.
  • Page 67 X300 Service manual Remove a bolt and decompressor cover. Remove a bolt and remove the decompressor. Loosen the chain tensioner adjusting bolt. Remove the chain tensioner by loosen 2 mounting bolts. Remove the timing sprocket. Remove 3 screws securing the crankshaft gear holder on the LH crackcase.
  • Page 68 X300 Service manual Remove a bolt securing the chain tensioner pad and remove the timing chain Remove the camshaft Remove the camshaft by loosen 2 bolts. Remove rocker arm shafts and rocker arms. Remove cylinder head Remove the parts, refer to the procedure for removing the cylinder head cover timing chain sprocket .and camshaft Remove the spark plug.
  • Page 69 X300 Service manual Remove the valve Use a valve spring compressor to remove the valves. Use a valve stem seal plier to remove the valve stem seals. Remove the valve springs. cautions Remember the original position of each valve. Remove the cylinder and piston Remove the chain tensioner pad and chain guide.
  • Page 70 X300 Service manual Crankshaft seal Removing the left crankshaft cover Loosen the left crankshaft cover bolt. Remove the left crankshaft cover. Assembly of the left crankshaft cover Replace the crankshaft seal with a new one every time you assemble it. Lubricate the seal before assembly.
  • Page 71 X300 Service manual Remove the oil pressure relief valve. Remove the oil pump gear cover . Remove the bolt securing the oil pump gear . Remove the chain that drives the oil pump sprocket . and remove the oil pump gear Note It is recommended to make a mark or symbol on the chain for the process of assembling it back so that the chain rotates in the original direction.
  • Page 72 X300 Service manual Assembling the oil pump Check the rotor and pump housing for wear. Make sure the cover is not scratched. If worn or scratched parts are found, replace them. Assemble in reverse according to the disassembly procedure. Tighten the fixing screws with the specified torque. Note Make sure the gasket is positioned properly as shown in the picture.
  • Page 73 X300 Service manual Engine crankcase and crankshaft Remove the engine crankcase Remove 10 screws. Remove the crankcase on one side, with the crankshaft still attached to the other. Remove crankshaft Remove the oil strainer seal. Remove the oil filter. Check clearance of crankshaft and connecting rod. Check the size on the small end on the connecting rod.
  • Page 74 X300 Service manual Check and measure the various parts that are within the specified values. Assembling the engine crankcase The assembly process reverses the disassembly process. Cleaning contact surface of both side of crankcase. Replace the new crankcase gasket Place the gasket so that the holes align with where the screws are inserted. Assemble both sides of the engine crankcase together .
  • Page 75 X300 Service manual Checking engine oil pressure Remove the oil pressure sensor. Check that the pressure is between 0.5 - 1.2 bar. The engine is idling at 1,650 rpm at the engine's operating temperature. Check that the pressure is between 3.2 - 4.2 bar. While engine operates at 6,000 rpm at the operating temperature of the engine.
  • Page 76 X300 Service manual Remove the screw from the center of the chain tensioner and inspect the movement mechanism of the chain tensioner. If any wear is detected, replace it. Inspection of valve spring seats and valve cotter Check both valve spring seats and valve cotter for wear or abnormal conditions. If worn parts are found, replace them.

  • Page 77: Troubleshooting

    Troubleshooting X300 Service manual Excessive engine oil consumption / smoke from the exhaust pipe Causes Inspection and remedy Incorrect valve clearance Check and adjust the valve clearance to meet the standard values. Damaged valve , worn valve seat ? Replace cylinder head , valves / grind valves Cylinder - worn pistons , damaged or broken piston rings Replace cylinder , piston , piston ring Piston rings wear out , in the wrong position...
  • Page 78 X300 Service manual Can't start Problems that the ECU can detect RELAY PUMP , COIL , INJECTOR , RPM SENSOR Fuel system Fuel , fuel pump operation Fuel pressure (low), dirty injectors - ton Fire into the spark plug Coil wire insulation Parameter value Engine temperature , timing settings , injector settings while starting air temperature Compressive strength...
  • Page 79 X300 Service manual Spark plug Spark plugs , coil wires , ignition coils Intake system Air filter , leaking air filter , leaking intake system Check the parameters Engine temperature , air temperature , throttle position , ignition advance degree Fuel system Fuel level , fuel pressure , fuel filter , injector engine misfire (pre ignition)

  • Page 80: Fuel System

    X300 Service manual Fuel system Inspection process Before troubleshooting, check if there are any trouble codes in the system's memory. Do not disconnect the battery terminals before checking the code. The fuel system has a pressure of 3 bar. Be careful before removing the fuel line. No flammable objects or sparks, no smoking, and be careful not to get fuel in your eyes.
  • Page 81 X300 Service manual Fuel system The fuel system consists of Fuel pump , fuel filter , fuel pressure relief valve (regulator ) , fuel pipe , injector The fuel pump and regulator are mounted inside the fuel tank. Fuel Pump Light Circuit When the ignition key is turned to position (on), the fuel pump will operate for 2 seconds and stop When the engine is started, the ECU will keep the fuel pump running because of the engine revolution signal.
  • Page 82 X300 Service manual Electronic system information Fuel pump resistance ~ 1.5 ohms Normal current while the fuel pump is working is 1.4 - 1.8 amps. The current required to close the hydraulic circuit . ~ 2 amps Disconnect the fuel pump electrical connector. Turn the ignition switch to «ON».
  • Page 83 X300 Service manual Use air to dry the nozzle completely. Use a PDA to control the fuel pump. Check that there are no fuel leaks from the injectors. Ignition coil The ECU controls the operation of the injectors and ignition coils from two variables : Ignition advance degree By ordering the ignition at the right timing from the calculation of the engine's working load , engine rpm , temperature The duration of the magnetic field The magnetic field at the coil windings is controlled by the ECU .

  • Page 84: Suspension System

    X300 Service manual Suspension system Remove front shock absorber Put the vehicle on the center stand. Remove the lower rocker arm cover. Remove 2 bolts (M6). Remove the stud. Remove the lower rocker arm cover. Remove 4 nuts of LH and RH front shock absorbers. Loosen the bolt that holds the RH lower rocker arm.
  • Page 85 X300 Service manual Removing the front wheel and front wheel hub Park the vehicle with the center stand. Loosen 2 bolt (M8) Loosen the front axle nut Loosen the nut M6 Fasten the ABS sensor on the front wheel and remove it. Loosen a bolt (M8) Remove the front wheel lock nut.
  • Page 86 X300 Service manual Remove the handlebar Park with the center stand. Remove the headlight rim Loosen left handlebar cover screws . Loosen right handlebar cover screws . Remove the handlebar cover. Unwire the dashboard. Unplug the headlight. Remove the headlight adjusting bolt.
  • Page 87 X300 Service manual Remove the headlight mounting bolt and remove the headlight. Unplug the left-right handlebar switches. Unplug the brake switches on both the right and left. Loosen the mounting bolts of the left and right of master cylinder. Disconnect the throttle cables. Loosen the mounting screw to the throttle cable.
  • Page 88 X300 Service manual Remove the footrest. Loosen the bolts (M6). Remove the left and right bottom footrest covers. Remove the ignition key cover. Loosen 4 screws. Open the lid of USB. Remove the radiator cap. Remove the lock pin. Loosen 4 screws of leg shield cover. Loosen 2 screws.
  • Page 89 X300 Service manual Loosen 3 screws of lid lock. Remove the front legs shield cover. Loosen 2 screws of the legs shield. Unplug the left and right turn lights. Remove 3 screws and remove the legs shield. Loosen the handlebar nut.
  • Page 90 X300 Service manual Remove the handlebar and the lower handlebar cover. Remove the steering bearing put the vehicle on the center stand. Loosen the upper steering lock nut . Loosen steering adjusting nut. Warning Please be careful when performing this step. Remove the steering shaft.
  • Page 91 X300 Service manual Replace steering bearing Note Before replace steering balls, bearing races and seals must be replaced. Check the condition of the shaft to ensure that it is not crooked or deformed. If the steering shaft is found to be abnormal, replace it with a new one. Assembling the steering shaft Assembly reverses the disassembly process.
  • Page 92 X300 Service manual Remove the center stand Put a block support under the vehicle. Remove the nut securing the center stand as shown in the picture . Remove the center stand spring. Remove the center stand shaft. Remove the center stand. Assembling the center stand The assembly will be the reverse of the disassembly process.

  • Page 93: Brake System

    X300 Service manual Brake system ABS system Warning Removing the wheels for any service requires care not to damage the ABS disc. ABS braking system must be inspected by checking the ABS plate that there is no damage and having a test drive that the ABS braking system works normally.
  • Page 94 X300 Service manual Remove the bolts holding all 4 brake fluid pipes. Remove a bolt (M6) mounting lower bracket of ABS controller. Remove a bolt (M6) mounting upper bracket ABS controller. Disconnect the ground cable. Remove ABS controller unit. Assembling the ABS controller unit The assembly will be the reverse of the disassembly process.
  • Page 95 X300 Service manual Remove the rear brake disc Refer to the step of removing the engine from the vehicle that included rear wheel removal. Remove the rear brake caliper. Remove the rear wheel hub Remove 5 bolts holding the rear brake disc from the wheel hub. Rear brake disc assembly Reinstall brake disc to the wheel hub.
  • Page 96 X300 Service manual Remove the front brake pad Refer to step of front wheel removal and front wheel hub removal. Remove the dust cover. Slightly loosen the screws securing the brake pads. Remove the brake caliper. Remove the brake pads from the caliper . Caution Do not squeeze the brake lever after removed the brake pads.
  • Page 97 X300 Service manual Assembling the rear brake pad Assemble in reverse according to the disassembly procedure. Tighten the brake pad fixing screws to the specified torque . Torque value 35 – 40 Nm+ threadlocker 243 Brake pad inspection (front and rear) Check the thickness of the brake pads.

  • Page 98: Cooling System

    X300 Service manual Cooling system Warning Do not open the radiator cap while the engine is hot. Check coolant level Open the lid behind the leg shield, check coolant level of the reservoir, if require, top up the coolant while engine is cold. The normal coolant level while engine is cold should be between low and full level.
  • Page 99 X300 Service manual Put the rubber hose on the bleed screw. Loosen the bleed screw 3 turns. Bleed air from the system. Tighten the bleed screw to the specified torque . Torque value 3 Nm Add coolant to radiator until full. Run the engine at idle speed until fans operate.

  • Page 100: Default Code

    Default code X300 Service manual Components/Systems Fault type fault code Check the strategy description. Anomaly criteria P0262 Cylinder 1 Injector Circuit High Fuel injector P0261 Circuit check Cylinder 1 Injector Circuit Low P0201 Injector Circuit / open Cylinder 1 P0265 Cylinder 2 Injector Circuit High Fuel injector P0264...
  • Page 101 X300 Service manual Components/Systems Fault type fault code Check the strategy description. Anomaly criteria P2177 fuel trim high limits exceded System Too Lean Off Idle Fuel system cy1.1 P2178 fuel trim high limits exceded System Too Rich Off Idle P2179 fuel trim high limits exceded System Too Lean Off Idle Fuel system cy1.2...
  • Page 102 X300 Service manual Copyright ©2023 All rights reserved. This service manual is copyrighted. Copying in mechanical, electronic or any other form without the written permission of the manufacturer is prohibited.
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