Fantic Caballero 500, Manual

Page 1: ...ormation 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 consider...

Page 2: ......

Page 3: ...ponents 11 Used engine and gearbox oil 12 Brake fluid 12 Electrolyte and hydrogen gas from the battery 13 Kickstand 13 Precautions and general warnings 13 FUNDAMENTAL SAFETY RULES 15 Behaviour and dri...

Page 4: ...53 Turn signal switch 54 Light switch 54 High beam flashing button 55 Start button 55 Engine stop button 56 ABS system 57 Saddle opening 59 Refuelling 60 Vehicle inactivity 61 Vehicle washing 62 MAIN...

Page 5: ...ions Rally version 78 Clutch lever and gearbox 83 Chain 84 Battery 86 Fuses and relays 87 Lights and turn signals 88 Rear view mirrors 89 MAINTENANCE TABLE 90 Scheduled maintenance table 90 Recommende...

Page 6: ......

Page 7: ...haracteristicsdescribedandillustratedherein Thispublication or part of it cannot be reduced or translated without the company s approval Reproduction of the contents used in this manual without the Ma...

Page 8: ......

Page 9: ...ur quickness of reflexes and agility but also on your knowledge of the vehicle its condition and your knowledge of the rules for safe driving We therefore recommend that you familiarize yourself with...

Page 10: ......

Page 11: ...If operating in enclosed spaces use an evacuation system for the exhaust fumes FUEL PETROL FUEL TYPE E5 E10 The fuel used is extremely flammable and can become explosive under certain conditions Refu...

Page 12: ...irst aid center indicating the cause and how the accident occurred In case of contact with clothing undress and wash thoroughly with soap and water Change the dirty cloths which must be specifically w...

Page 13: ...r fifteen minutes and promptly contact an eye specialist The battery emits explosive gases it is advisable to keep away flames sparks and any other source of heat Provide adequate ventilation when ser...

Page 14: ......

Page 15: ...isibility and weather In a situation not suitable for safe driving reduce the speed and drive carefully The braking effect in wet roads without ever having applied the brakes is initially less under t...

Page 16: ...cle is protected from the kickstand in case of imbalance or loss of balance The footboards must be extracted from the passenger and wait for him her to get on the vehicle The rider must instruct the p...

Page 17: ...Do not get off the vehicle jumping or by stretching the leg to touch the ground The stability and balance of the vehicle would be compromised Tilt the vehicle making the kickstand touch the ground Ge...

Page 18: ...ing the correct posture making sure that the kickstand is completely retracted Ifthekickstandislowered thevehiclecanbestarted only with the gearbox in neutral If you try to engage the gear the vehicle...

Page 19: ...ce Itisadvisabletowarmuptheenginewell proceeding for the first kilometres at reduced speed Do not start abruptly with the cold engine If the fuel reserve warning light comes on refuel as soon as possi...

Page 20: ...ually accelerate to allow the vehicle to move forward Starting After starting the vehicle and warming the engine well operate the clutch lever and engage the first gear pressing the gear lever downwar...

Page 21: ...rd to shift up and or down to shift down If you are a beginner in driving the vehicle it is important to familiarize yourself with the vehicle controls and its functions Shift one gear at a time Upshi...

Page 22: ...se the clutch too quickly or suddenly It could cause the engine to stop or an unintended wheelie of the vehicle Avoid sudden stops or sudden vehicle slow downs Engine stop To stop the vehicle and the...

Page 23: ...driving on mountain roads be careful not to force the engine brakes and suspension It is more suitable to travel on roads with moderate curves and hills where engine brakes and suspensions alternate...

Page 24: ...ing zone carefully and with attention It is very important to respect the road signs and the indications given below Do not park the vehicle placing it against the walls or laying it on the ground Mak...

Page 25: ...ng or parking the vehicle near places where there is dry brushwood Avoid places accessible to children and or people The silencer reaches high temperatures so avoid any kind of contact and pay the max...

Page 26: ......

Page 27: ...ers in the spaces indicated above in order to remind them in case of loss or damage Do not modify the identification data in order to avoid serious penal and administrative sanctions In addition the w...

Page 28: ...Engine number The engine number is punched on the left side of the crankcase Frame number The frame number is punched on the steering tube on the right side For the original spare parts supply this i...

Page 29: ...enger saddle 10 Rear handle 11 Rear fender 12 Tail light 13 License plate holder 14 License plate light 15 Left rear turn indicator 16 Left passenger footrest 17 Left rider footrest 18 Side kickstand...

Page 30: ...master cylinder 28 Front brake lever 29 Right front turn signal 30 Engine oil cap 31 Rear brake lever 32 Rear brake oil tank 33 Right rider footrest 34 Rear brake master cylinder 35 Right passenger f...

Page 31: ...and passenger saddle 10 Rear fender 11 Tail light 12 License plate holder 13 License plate light 14 Left rear turn indicator 15 Left passenger footrest 16 Left rider footrest 17 Side kickstand 18 Gea...

Page 32: ...r cylinder 27 Front brake lever 28 Right front turn signal 29 Engine oil M cap dipstick 30 Rear brake lever 31 Rear brake oil tank 32 Right rider footrest 33 Rear brake master cylinder 34 Right passen...

Page 33: ...ssenger saddle 10 Rear handle 11 Rear fender 12 Tail light 13 License plate holder 14 License plate light 15 Left rear turn indicator 16 Left passenger footrest 17 Left rider footrest 18 Side kickstan...

Page 34: ...linder 28 Front brake lever 29 Right front turn signal 30 Engine oil cap 31 Rear brake lever 32 Rear brake oil tank 33 Right rider footrest 34 Rear brake master cylinder 35 Right passenger footrest 36...

Page 35: ...e indicator light 6 ADJUST button 7 SELECT button 8 Turn signal indicator light 9 High beam light indicator 10 Engine indicator light 11 Engine oil indicator light not used 12 Neutral indicator light...

Page 36: ...Odometer Total trip distance recorder Partial trip distance recorder A Partial trip distance counter B Remaining Fuel Distance B Fuel level C Digital voltmeter D Tachometer E Clock F Speedometer G In...

Page 37: ...DJUST for three seconds to change the Odometer measurement units from kilometres km to miles mile and the speedometer measurement units from kilometres per hour km h to miles per hour MPH and vice ver...

Page 38: ...nce screen Press and hold the adjustment button ADJUST for three seconds to reset the partial trip distance counter B In the partial trip distance counter A screen press once the adjustment button ADJ...

Page 39: ...road conditions the vehicle conditions the type of driving and so on For these reasons the remaining distance is only a reference for the rider In the remaining fuel distance screen press once the ad...

Page 40: ...lay the RPM engine speed screen In the RPM engine speed screen press and hold the selection button SELECT to display to the remaining fuel distance screen and battery voltage screen Selection button i...

Page 41: ...ONSULTATION IT EN DE FR On the RPM screen engine revolutions When the remaining fuel level is at 1 the fuel symbol flashes as a warning When the remaining battery voltage level is at 1 the Battery sym...

Page 42: ...The settings screen has the following order of options input pulse setting RPM function tire circumference setting fuel resistance setting clock setting dashboard backlight setting total internal odo...

Page 43: ...ress and hold the selection SELECT and adjust ADJUST buttons simultaneously for three seconds to activate the Settings screen Input signal setting RPM Press the adjustment button ADJUST to change the...

Page 44: ...eed RPM is incorrect or not correctly displayed select another setting and try again It is advisable if the exact value is not known not to change the preset value In case of need contact an Authorize...

Page 45: ...ing A B 100 A Circumference of the new tire B Circumference of the original tire Setting values Scrambler version 2202 mm Flat Track version 2250 mm Check with the engine running idle if the RPM indic...

Page 46: ...ing press once and hold the selection button SELECT to display the next setting view Thenumberthatidentifiesthesettingflashesduring the modification operations Range displayed 300 2500 Unit of measure...

Page 47: ...eset value In case of need contact an Authorized Fantic Motor Center Press the adjustment butt o n ADJUST to change the setting Thenumberthatidentifiesthesettingflashesduring the modification operatio...

Page 48: ...NSULTATION After completing the setting press once and hold the selection button SELECT to display the next setting view When the fuel resistance value is changed the remaining distance is reset to 0...

Page 49: ...xt setting view Press the adjust button ADJUST to select another digit to change Clock setting Press and hold the selection button SELECT and release it when the desired digit is displayed During the...

Page 50: ...acklight setting Press and hold the adjustment button ADJUST and release it when the desired illumination value is selected Lighting values range from 1 5 darker to 5 5 lighter The brightness of the d...

Page 51: ...tion button SELECT until the desired digit is displayed Then press the adjust button ADJUST to change the digit to be changed Once the desired value has been set press once and hold the selection butt...

Page 52: ...ignition switch is located at the front of the vehicle near the dashboard The functions of the ignition switch are the following A The handlebar is locked and the vehicle cannot be started and the li...

Page 53: ...N Press to activate the horn STEERING LOCK ENGAGEMENT To insert the steering lock turn the handlebar completely to the left and turn the key to position A Press and turn the key anticlockwise and slow...

Page 54: ...d counterclockwise it activates the high beam To reactivate the low beam light operation turn the light switch clockwise TURN SIGNAL SWITCH Press the switch to the left or right to indicate the turn P...

Page 55: ...the flashing of the high beam It is usually used to indicate danger or emergency situations When the button is released the high beam flashing is deactivated START BUTTON With the key inserted and set...

Page 56: ...e engine It has the function of a safety or emergency switch Do not intervene on the switch when the vehicle is running this would cause the engine to stop This could result in loss of control of the...

Page 57: ...falling Do not exceed the physical road holding limits of the vehicle It is the rider s responsibility to ride at appropriate speeds always evaluating the weather and road conditions The ABS cannot c...

Page 58: ...system has been manually deactivated In case of failure of the ABS system the indicator light turns on the vehicle retains the characteristics of a traditional braking system Moderate the speed and g...

Page 59: ...and remove the saddle B Before reassembling the saddle make sure you have not forgotten the key in the area under the saddle Before riding check that the saddle has been correctly fixed SADDLE OPENIN...

Page 60: ...property and or persons Do not add additives or other substances to the fuel during refuelling Avoid fuel leakage during refuelling If you use a funnel make sure that it is perfectly clean It is recom...

Page 61: ...e ground using the appropriate supports and periodically check the tire pressure Lubricate the chain Cover the exhaust terminal with a well tied bag to prevent moisture from entering inside Cover the...

Page 62: ...bodywork Do not wash in the sun especially in summer with the body still warm as if the detergent dries before rinsing it could cause damage to the paintwork Do not use liquids at temperatures above...

Page 63: ...with caution and operate the brakes repeatedly Only after a scrupulous and thorough washing it is possible to proceed with the polishing phase with silicone waxes Do not use abrasive pastes on the ve...

Page 64: ......

Page 65: ...and check for leaks If necessary top up the brake fluid Throttle control Make sure that the knob rotation is smooth and fluid from both directions and that there are no jamming Engine oil Check the l...

Page 66: ...that there are no loose fasteners If necessary adjust and tighten Fuel tank Check the fuel level and refill if necessary Check the correct closing of the fuel cap and that there are no leaks in the c...

Page 67: ...y the engine oil level every 1 000 km 600 mi Check the engine oil level Periodically check the engine oil level The engine oil check must be carried out with hot engine Do not rest the vehicle on the...

Page 68: ...s not in the right parameters topping up is required Therefore remove the oil level plug and top up If you use a funnel or something else make sure of the perfect cleaning Do not add additives or othe...

Page 69: ...rator It is advisable to contact an Authorized Fantic Motor Center if you need to remove and replace the filter and the engine oil Amount of engine oil Total amount 1 6 l 0 35 UK gal 0 42 US gal Witho...

Page 70: ...icle may skid It is advisable if possible to always use the same pressure gauge to check the pressure so as not to measure incorrect values caused by the variability between different gauges TIRES For...

Page 71: ...osition where the chain is most taut Measure chain tension in the middle point of the lower branch with the motorcycle on the side stand and without any load on the vehicle Vertical oscillation must b...

Page 72: ...t is advisable to contact an authorized Fantic Motor Center or a tire specialist for the execution of certain operations The tires supplied are of the tubeless type and are mounted on spoked rims toge...

Page 73: ...refer to the SCHEDULED MAINTENANCE TABLE section under Air filter To disassemble check clean and replace the air filter contact an Authorized Fantic Motor Center COOLANT For the maintenance operation...

Page 74: ...horized Fantic Motor Service Center Refilling the brake system To top up the brake fluid do to an authorized Fantic Motor Service Centre BRAKING SYSTEM Check the front brake fluid level To check the f...

Page 75: ...with consequent metallic noise and sparks flying from the calliper braking efficiency safety and completeness of the disk would be affected If the groove has disappeared 1 5 mm 0 05 in friction materi...

Page 76: ...front brake lever push repeatedly on the handlebars making the fork compress The stroke must be gentle and there should be no traces of oil on the rods Check that all the front suspension components a...

Page 77: ...ment For different use needs it is possible to customize the setting To make changes it is recommended to wait until the engine is completely cold Adjust the spring preload according to the conditions...

Page 78: ...o to an authorized Fantic Motor Service Center Adjustment On this version it is possible to adjust the front suspensions SUSPENSIONS RALLY VERSION Front suspension Rally For the replacement of the fro...

Page 79: ...hestandardadjustmentofthefrontforkisdesigned to adapt to most driving styles and situations however it is possible to make custom adjustments The left stem adjustment is divided into two types compres...

Page 80: ...preload E Rear shock absorber spring F Preloaded shock absorber wheelbase Standard value 344 mm 13 54 in G Spring preload Standard value 176 mm 6 93 in The adjustment of the right stem consists only i...

Page 81: ...r of clicks A 24 from fully closed Adjustment The standard adjustment of the rear shock absorber is designed to adapt to most driving styles and situations however it is possible to make custom adjust...

Page 82: ...ring nut D to adjust the shock absorber spring preload E Screw in to increase the preload vice versa unscrew to decrease it After the adjustment tighten the locking ring nut C Do not force the rotatio...

Page 83: ...straight is not 2 mm 0 08 in Tighten the ring nut B keeping the adjuster C still Reposition the protective cowl A If the stroke of the C adjuster is not sufficient to guarantee the required clearance...

Page 84: ...orized Fantic Motor Center only Improper maintenance can cause premature chain wear and or damage the pinion and or crown Find the position where the chain is most taut Measure chain tension in the mi...

Page 85: ...not wash the chain with jets of water steam high pressure jets and solvents with a high degree of flammability For chain recommended lubrication and cleaning products refer to the RECOMMENDED PRODUCTS...

Page 86: ...itive pole from the battery Remove the battery When installing the battery insert it with the positive pole positioned as shown in the figure and connect the negative pole to the battery at the end If...

Page 87: ...it could cause a short circuit and consequently the risk of fire Fuses arrangement H Main fuse 30 A I Fuse box 1 Engine control unit fuse key operated power supply ABS control unit key operated power...

Page 88: ...of theprojector about9 10ofthetotalheight Tocarryoutthe vertical adjustment of the light beam position the vehicle in running position loosen the screws A on both sides of the vehicle and manually ad...

Page 89: ...or clockwise and remove it During reassembly before tightening the nut check that the mirror support rod is aligned with the handlebar Rear view mirror adjustment To adjust the rear view mirrors get o...

Page 90: ...nance operations we recommend going to an Authorized Fantic Motor Service Center Carry out maintenance operations more frequently if the vehicle is used in rainy dusty areas rough roads or in the case...

Page 91: ...Valves Check the valve clearance Adjust Cylinder head Check the cylinder head fastening bolts tightening Additional fuel filter Replace Every 10 000 km 6 000 mi Air filter Clean Replace Clutch Check...

Page 92: ...lace if necessary Check the air pressure Correct if necessary Wheel bearings Check that the bearings are not loose or damaged Swing arm Check its operation and excessive clearance Lubricate with lithi...

Page 93: ...htened Brake lever rotation pin Lubricate with silicone grease Brake pedal rotation pin Lubricate with lithium soap based grease Clutch lever rotation pin Lubricate with lithium soap based grease Side...

Page 94: ...ne oil filter Replace Cooling system Check the coolant level and the absence of oil leaks in the vehicle Coolant change Every 3 years Front brake and rear brake switches Check its operation Moving par...

Page 95: ...for bearings joints articulations and levers Lithium grease Coolant Antifreeze liquid based on ethylene glycol with organic additives Do not dilute with water Fork oil Fork oil gradation 15W Transmiss...

Page 96: ...r screw tightening torques Generic engine oil Lubricant for rubber oil seals and OR parts Lithium soap grease Battery poles White vaseline grease Vehicle wash Low pressure water at room temperature Ec...

Page 97: ......

Page 98: ...l base Flat Track 1423 mm 56 02 in Wheel base Rally 1432 mm 56 38 in Weight in running order 160 kg 337 30 lb Weight at full load vehicle rider baggage 330 kg 727 52 lb Engine type 4 stroke single cyl...

Page 99: ...920 6th gear ratio 21 27 0 778 Secondary transmission 48 13 3 692 Transmission ratios Flat Track Primary transmission 64 28 2 286 1st gear ratio 33 14 2 357 2nd gear ratio 31 17 1 824 3rd gear ratio...

Page 100: ...ggage 177 kg 390 21 lb Fuel system 40 mm single body Athena electronic injection singlepoint single injector Fuel 95 98 octane super lead free petrol Frame Closed double cradle frame in molybdenum chr...

Page 101: ...rber with tank positioned outside for convenient adjustment Stroke 76 2 mm 2 99 0 07 in Front brake Four piston calliper 28 mm 1 10 in 320 mm floating disk 12 59 in Rear brake One piston floating call...

Page 102: ...S system on two independent and disconnectable channels Spark plug NGK ER9EH 6N Battery 12 V 8 Ah Fuses Main fuse 30 A Secondary fuses 2 A 5 A 4 7 5 A 30 A Generator 12 V 300 W Turn signals 12 V 6 W H...