CSC TT250 Owner'S And Service Manual Download Page 36

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TT250

Owner’s

and

Service

Manual

www.CSCMotorcycles.com

Remove

the

clutch

actuation

rod

and

bushing.

Remove

the

clutch

throwout

bearing.

this

bearing

worn

does

not

operate

smoothly,

replace

with

new

bearing.

Summary of Contents for TT250

Page 1: ......

Page 2: ...k In Procedure 13 Starting the Motorcycle 13 Operating the Motorcycle 14 Cleaning the Motorcycle 14 Storing the Motorcycle 15 Section 2 Service Manual 16 Maintenance Cautions and Warnings 16 Component...

Page 3: ...54 Steering Stem Bearing Adjustment 54 Steering System Troubleshooting 56 Wheels and Tires 56 Front Wheel Removal 56 Rear Wheel Removal 59 Wheel and Tire Inspection 62 Wheel and Tire Troubleshooting...

Page 4: ...se decision I want you to know that we value the trust and confidence you have in CSC Our guiding principle will always be that our customers come first We wish you many miles of safe and enjoyable ri...

Page 5: ...ll TT250 motorcycle parts and we recommend that you use only parts and materials provided by us when servicing or maintaining your motorcycle The TT250 Owner s and Service Manual is provided free to a...

Page 6: ...n the motorcycle is running and after turning it off Do not touch these items Warning Always maintain appropriate tire pressure Operating the motorcycle with low tire pressure will adversely affect th...

Page 7: ...The front and rear brake levers have adequate free play The front and rear brakes operate The forks turn freely from side to side The rear view mirrors are adjusted appropriately The engine kill switc...

Page 8: ...tion Speedometer odometer tripmeter neutral indicator turn signal indicator high beam indicator fuel gage Dash Cluster Keyed ignition switch lockable cover lockable forks Left Handlebar High low beam...

Page 9: ...ransmission Major components are identified in the photographs below TT250 Right Side View TT250 Left Side View Vehicle Identification Number and Engine Number The vehicle identification number is loc...

Page 10: ...hanical cover to prevent access to the ignition switch It is operated by manually moving the cover to the closed position with the actuator knob located on the right front surface of the ignition swit...

Page 11: ...the starter switch The kill switch is used to shut all electrical power to the motorcycle Do not routinely use the kill switch to stop the engine use the ignition switch instead The accessories switch...

Page 12: ...as warmed open the choke fully by pushing the choke lever all the way down Choke Fully On Intermediate Choke Choke Fully Open Do not ride the motorcycle until the engine is fully warmed and the choke...

Page 13: ...g the slots located at the top of the forks and on lower portion of the rear shock absorber Turn the screw slots clockwise for more damping and counterclockwise for less damping Load Limits The TT250...

Page 14: ...il The oil change procedure is outlined in the Oil Change section of this Owner s and Service Manual Starting the Motorcycle After completing the pre ride inspection you can start the motorcycle using...

Page 15: ...shifting to Warning If you downshift too aggressively i e you downshift to too low a gear for your speed you can induce a skid Repeat the above process using engine braking and the front and rear brak...

Page 16: ...e the battery charge it and store it in a cool and dry environment Support the motorcycle on blocks to prevent tire damage Cover the motorcycle to protect it from dust moisture and other contaminants...

Page 17: ...while the engine is working make sure the area is well ventilated Warning Gas is flammable and combustible so do not smoke or provide ignition sources in the work area Warning The battery can liberate...

Page 18: ...this Service Manual The drive chain is adjusted by positioning and aligning the rear wheel The drive chain should have 3 5 inch of free play The drive chain adjustment procedure is explained in this S...

Page 19: ...l l Front and rear suspension l l l l l l l Nuts bolts fasteners l l l l l l l Front rear wheel bearings l l l l l l l The motorcycle should be maintained according to the schedule above The symbols a...

Page 20: ...rument panel readout Check oil level and tire pressure Confirm the motorcycle is in neutral Place the clutch in close the choke and start motorcycle Allow engine to warm Check brake and suspension fun...

Page 21: ...Impact Deformation or breakage Compromised driving safety Replace the footpeg Rearview mirror Impact Deformation or breakage Compromised driving safety Replace the rearview mirror Rear rack Impact De...

Page 22: ...mmet snaps The rubber grommets securing the rear panel are shown in the photo to the right The upper and lower fluid levels of the rear brake master cylinder are shown in the photo to the right Front...

Page 23: ...he two brake pads The front brake s pads are interchangeable left to right the rear brake s pads are not Note that the brake pads have wear grooves machined into the pad surface These are the three ve...

Page 24: ...two caliper mounting bolts The 5mm Allen pins should be torqued to 3 to 5 ft lbs The caliper mounting bolts should be torqued to 15 to 18 ft lbs Rear Brake Pad Inspection and Replacement The rear brak...

Page 25: ...way into the caliper Install new rear brake pads install the two 5mm Allen pins place the caliper over the rotor and install the two caliper mounting bolts The 5mm Allen pins should be torqued to 3 t...

Page 26: ...he caliper bleed port After draining the brake fluid add fluid to the master cylinder and bleed the brakes as described below Bleeding the Brakes Caution Brake fluid can damage painted components Prom...

Page 27: ...akes Pulsating brake lever Warped rotor disk Pulsations longer stopping distance Measure disk runout replace disk rotor Power Transmission The TT250 uses a manually operated wet clutch and a chain dri...

Page 28: ...he rear wheel tightening the rear axle and tightening the adjustor nuts and locknuts You should check the chain adjustment during your motorcycle s first scheduled maintenance and at every scheduled m...

Page 29: ...the rider on the bike If the bike is on a lift such that the rear wheel is off the ground you should increase the amount of slack when you adjust the chain such that when you are on the bike the slac...

Page 30: ...45 0900 if you need chain lube Sprocket and Chain Inspection The TT250 has a 428 chain a 17 tooth front sprocket and a 50 tooth rear sprocket If you keep your chain properly adjusted and lubed the cha...

Page 31: ...reakage Replace chain and both sprockets Drive chain Excessive wear Inadequate lubrication misaligned rear wheel incorrect chain adjustment Chain skipping chain breakage Replace chain and both sprocke...

Page 32: ...exhaust pipe Route the clutch cable through the adjustment mount on the engine and adjust the adjustor nuts to give the cable as much slack as possible The barrel should reach as far back to the rear...

Page 33: ...ture clutch adjustments should be made with the handlebar clutch lever adjustors You should not lubricate the clutch cable it has a Teflon sheath and is self lubricating Clutch Replacement If you chan...

Page 34: ...cles com 33 Remove the 13mm bolt securing the kick start lever and remove the kick start lever Loosen the handlebar clutch lever cable adjustor by screwing it all the way into the clutch lever casting...

Page 35: ...right engine cover to the engine Tap the right engine cover lightly with a soft mallet to loosen it Remove the right engine cover At this point you will see the engine internals on the right side of...

Page 36: ...r s and Service Manual www CSCMotorcycles com 35 Remove the clutch actuation rod and bushing Remove the clutch throwout bearing If this bearing is worn or does not operate smoothly replace it with a n...

Page 37: ...ch hub to back out evenly Remove the clutch hub to expose the clutch springs We recommend replacing the clutch springs when replacing the clutch Remove the Circlip that secures the clutch inner basket...

Page 38: ...cleaner Unscrew the three Phillips head screws on the centrifugal oil cleaner Remove the centrifugal oil cleaner cover On a motorcycle with much higher mileage packed sludge will accumulate around th...

Page 39: ...er portion of the centrifugal oil cleaner is secured by a castellated nut This nut is shown by the lower red arrow on the right in the photo Use a castellated nut driver like the one shown here to rem...

Page 40: ...At this point after removing the inner portion of the centrifugal oil cleaner the clutch inner basket and clutch components can be removed The clutch consists of six fiber plates and five steel plates...

Page 41: ...on which the clutch plates translate If the clutch inner basket has surface discontinuities or excessive wear replace it Similarly inspect the clutch outer basket for any surface discontinuities or ex...

Page 42: ...ing all components adjust the clutch as explained in the TT250 Clutch Adjustment section of this manual Clutch Troubleshooting Item Symptom Cause Vehicle Effect Maintenance Action Clutch cable Breaks...

Page 43: ...cosity fork oil to stiffen the forks please call CSC at 909 445 0900 to discuss which oil will best meet your needs Adjusting Ride Height The front forks can be raised and lowered in the fork upper tr...

Page 44: ...Service Manual for instructions on front wheel removal Actions shown here are on a motorcycle with the headlight removed removing the headlight provides easier access to the fork pinch bolts please se...

Page 45: ...eration after the fork leg has been removed We recommend that you do this after loosening the fork upper triple tee pinch bolt and before the fork lower triple tee pinch bolts have been loosened this...

Page 46: ...on the fork lowers If the shroud is removed dust and dirt will accelerate wear of the fork seals Loosen the fork upper triple tee pinch bolt with a 10mm socket or wrench Loosen the fork lower triple...

Page 47: ...cap over a suitable oil container Oil will begin to drain out of the fork leg when you do this Drain the oil from the fork leg Remove the 6mm Allen bolt at the bottom of the fork lower You can put the...

Page 48: ...oil After the fork legs have drained reassemble the forks and install them into the motorcycle without installing the fork cap Adjust height as described in the preceding section of the Owner s and Se...

Page 49: ...eplace only the leaking seal If the seal s leak due to age induced degradation you should to replace the seals on both fork legs Remove the affected fork leg s as described in the preceding section Re...

Page 50: ...tion Remove the 6mm Allen bolt at the bottom of the fork lower Remove the fork lower casting Remove the fork lower by lifting it up and out of the fork upper Examine the fork lower which is the part t...

Page 51: ...fter removing the fork seal the dust seal and the bushing examine these parts carefully for any cuts tears or degradation Replace the defective part s CSC stocks these parts please call us at 909 445...

Page 52: ...e rear shock absorber to the swingarm Rotate the lower portion of the rear shock absorber to clear the swingarm mounting bracket and remove the bushing from the rear shock absorber Unbolt the nuts sec...

Page 53: ...fit between the frame and the swingarm The next steps involve re greasing lubricating the swingarm pivot points We use Maxima waterproof grease which is a great lubricant We stock the full line of Max...

Page 54: ...de to side play in the swingarm and the swingarm pivots up and down with minimal drag Swingarm and Rear Suspension Troubleshooting Item Symptom Cause Vehicle Effect Maintenance Action Swingarm Deforme...

Page 55: ...ing in the steering head area Steering Stem Bearing Adjustment This section of the TT250 Owner s and Service Manual addresses steering stem bearing adjustment You only need to do this if there is free...

Page 56: ...wrench Loosen both the left and right pinch bolts Loosen the steering stem bolt It takes a 22mm wrench You don t need to remove the handlebars to do this but it is a tight fit for the wrench if you d...

Page 57: ...dirt crack and damage Contamination Sticky movement swing and shaking of handlebar while driving Replace whole set of steel ball and race Steering race balls Abrasion deformation damage Contamination...

Page 58: ...two 10mm bolts that secure it to the front fork Allow the caliper to hang by the hydraulic brake line Do not loosen or remove the hydraulic brake line Loosen the front axle by using a 17mm wrench on t...

Page 59: ...t the front wheel while removing the axle There is a bushing between the left side of the front hub and the left fork There is no bushing on the right side of the motorcycle The speedometer drive mech...

Page 60: ...front axle nut the front brake caliper and the speedometer drive cable The front axle should be torqued to 35 ft lbs The caliper bolts should be torqued to 22 ft lbs Check the front brake prior to ri...

Page 61: ...on the left side of the motorcycle Use a 19mm wrench on the left side of the motorcycle Unbolt the nut and withdraw the axle from the right side of the motorcycle It s a lot easier to get the rear whe...

Page 62: ...t side of the motorcycle The left side of the motorcycle has a bushing that fits between the rear wheel and the swingarm It is orientation insensitive it can be installed either way Rear wheel install...

Page 63: ...e wheels on a truing stand and inspect them for runout and ovality If either exceeds 1 0mm true the wheel by adjusting spoke tension Balance the wheel and tire on a dynamic balancer Wheel and Tire Tro...

Page 64: ...oken the bead spray the area between the bead and the rim with a rubber lubricant designed for tire mounting Using a tire iron you ll need two insert the tip between the tire and the bead and pull the...

Page 65: ...you reinstall the tube either one you ve patched or a new one reach in and gingerly feel around the inside of the tire Look for anything that might damage the tube when you reinstall it Warning Exerc...

Page 66: ...ection of the TT250 Owner s and Service Manual The TT250 engine has one oil fill port on the right side of the engine The TT250 engine has an oil viewport on the right side of the engine for assessing...

Page 67: ...gine Remove the oil drain plug underneath the engine and allow the oil to drain Hold the bike in the vertical position so all the oil drains The oil drain plug takes a 17mm wrench or socket Remove the...

Page 68: ...couple of oil changes as the engine is breaking in you will see more than a few metallic particles and plastic adhesive material the green stuff on the strainer This is normal Clean the strainer WD 40...

Page 69: ...L and H marks when the bike is vertical off the sidestand as you see here Start the engine let the bike warm up and then check the oil again You can also check the oil with the dipstick The proper way...

Page 70: ...bits symptoms consistent with spark plug failure missing under load no spark across the electrode etc Remove the lead from the spark plug The spark plug is on the right side of the motorcycle Unscrew...

Page 71: ...e exhaust valve but both the intake and the exhaust valve have similar valve trains The valve gap also referred to as the valve clearance is what the lower red arrow points to in the photo As the wear...

Page 72: ...m is not actuating the rocker arm We want the engine to have the piston at or very near top dead center which means the valves should be closed which is another way of saying the rocker arm is on the...

Page 73: ...e motorcycle Remove the seat It s secured by 10mm bolts on either side Once the bolts have been removed the seat slides to the rear Close the fuel petcock and remove the fuel hose from it Remove the h...

Page 74: ...ved the seat Remove the two screws that secure the left and right fuel tank body panels to the frame You do not need to remove the body panels from the fuel tank Slide the fuel tank to the rear After...

Page 75: ...on the carbon canister boss when you reinstall the fuel tank after adjusting the valves At this point we have what we want and that s access to the valve cover The valve cover is attached to the cyli...

Page 76: ...e motorcycle The valve cover seals to the cylinder head with an o ring type seal Place the valve cover where this seal will not be contaminated by dirt or debris Prior to reinstalling the valve cover...

Page 77: ...to rotate the engine it s why we removed the spark plug If you have the bike in the vertical position straight up and down only a tiny amount of oil will escape If the bike is on the sidestand more oi...

Page 78: ...tioned here for reference only Here s the mark we re interested in It s a scribe line with a T That shows when the piston is at top dead center which is where we want it to be for the valve adjustment...

Page 79: ...tate the engine two complete revolutions align the T mark and the scribe line again and check the clearance again Assembly is the reverse of disassembly CSC recommends inspecting the valve gap at 500...

Page 80: ...body panels from the frame you do not need to remove the body panels from the tank disconnecting the fuel line from the carburetor removing the fuel tank and disconnecting the fuel tank electrical co...

Page 81: ...securing the carburetor to the intake manifold It will be easier to access the left side carburetor mounting nut if you first detach the rear brake master cylinder Pull the carburetor away from the en...

Page 82: ...ice Manual www CSCMotorcycles com 81 Remove the carburetor float bowl Place the float bowl aside At this point when you invert the carburetor you can see the float the float valve the main jet the slo...

Page 83: ...valve is connected to the float by a wire clip Gently push the float pivot shaft out of the carburetor body Lift the float and the float valve from the carburetor body Take care not to drop the float...

Page 84: ...in jet You can then unscrew the main jet if you secure the main jet carrier with an 8mm wrench There is a brass bushing that fits in the bottom of the carburetor body It interfaces with the main jet c...

Page 85: ...eath the idle jet Carefully remove these from the carburetor body if they do not come out with the idle jet The idle jet the slow jet and the main jet components are shown below The idle jet is on the...

Page 86: ...body Clean all three jets using a suitable cleaning solvent and a jet cleaning tool to assure all passageways are open We stock these items please call us at 909 445 0900 if you need them This is a j...

Page 87: ...solvent Use a q tip to clean the interior of the float valve body Assembly is the reverse of disassembly When reinstalling the jets and the jet carriers do not overtighten them or you may strip the al...

Page 88: ...ight without assistance We use an Allen wrench to make sure this bushing is properly guided into its seat This is what the seat should look like viewed from the carburetor bore After the bushing is in...

Page 89: ...cts the float valve to the float come off the float Lowering the float valve into the carburetor body Guide the float pivot shaft through the carburetor body tangs drilled pivot points and the float R...

Page 90: ...50 does not have a tachometer we make the adjustment by sound Air Filter Replacement This section of the Owner s and Service Manual addresses removal and replacement of the TT250 air filter The TT250...

Page 91: ...hillips head screws Remove the screws and the airbox cover After removing the airbox cover the air filter and the air filter retainer will be visible If the air filter is dirty or clogged it should be...

Page 92: ...ervice Manual addresses the TT250 exhaust system Caution Do not operate your TT250 without all exhaust system components in place The exhaust header is secured to the cylinder head by two acorn nuts R...

Page 93: ...eneath the seat Remove the exhaust header crush gasket from the cylinder head Remove the mesh gasket between the exhaust header and the muffler Assembly is the reverse of disassembly CSC stocks all TT...

Page 94: ...ect Engine Poor engine performance See below See below See below Starter Difficult starting Clogged air filter carburetor not adjusted correctly valves too tight battery low Difficult to start engine...

Page 95: ...e of the motorcycle The fuel petcock is located on the left side of the fuel tank You can inspect the fuel filter to see if it is dirty or clogged if it is you should replace it You can remove the sed...

Page 96: ...Fuel hose kinked Starting difficulty insufficient power unstable idle speed Unkink fuel hose Fuel leaking Fuel hose leaking Leaking fuel insufficient power unstable idle speed Replace fuel hose fuel...

Page 97: ...tion of the Owner s and Service Manual explains the electrical system s main components their locations their functions and some suggestions in the unlikely event you ll ever need to troubleshoot the...

Page 98: ...m bolt on either side Remove these bolts and pull the seat to the rear to remove it Removing the tank involves Closing the fuel petcock Disconnecting the fuel line from the fuel petcock to the carbure...

Page 99: ...e steps below Remove the 10mm bolt from the rear of the fuel tank Disconnect the fairing front the motorcycle frame Remove this fastener to disconnect the fairing from the frame You do not need to rem...

Page 100: ...e vent line from the carbon canister Slide the fuel tank to the rear to remove it Disconnect the fuel gage connector plug The headlight is removed by unscrewing two Phillips head screws on either side...

Page 101: ...ated on the right side of the frame near the front of the motorcycle It is accessible without removing the fuel tank The connector from the fuel tank s fuel gage sending unit to the fuel gage is under...

Page 102: ...ounts to the frame beneath the fuel tank If this component is not working the battery will not charge properly or it may overcharge and boil over The red and green wires go to the battery to charge it...

Page 103: ...s only electrical fuse is located in a carrier behind the battery This pops open to provide access to the fuse If the motorcycle loses all electrical power there are several potential causes but the m...

Page 104: ...nted switch and they are provided as a convenient point for connecting accessories heated vests etc When the ignition is off power is cut to these connectors The engine ECU and turn signal controller...

Page 105: ...photos when troubleshooting any electrical problems Battery This section of the Owner s and Service Manual addresses TT250 battery maintenance You should keep the terminals clean keep the acid level w...

Page 106: ...th the green insulation on the lead and then disconnect the positive terminal Unhook the battery s rubber retention strap and remove the battery Check the acid level in the battery The level should be...

Page 107: ...Signals This section of the Owner s and Service Manual addresses the motorcycle s lighting including the headlight the taillight and brake light the instrumentation lights and the turn signals If you...

Page 108: ...her the brake light or the taillight filament is open CSC stocks these bulbs please call us at 909 445 0900 if you need a replacement The headlight and instrument lights are accessed by removing the h...

Page 109: ...bulbs after you have removed the headlight and its nacelle as described above After removing the headlight and its nacelle the instrument lights are accessible from beneath the dash cluster Isolate t...

Page 110: ...if you need a replacement Charging System This section of the Owner s and Service Manual addresses maintenance of the TT250 charging system You might have a charging system problem if the battery is d...

Page 111: ...tor shown above and measure the resistance between all three leads it should be approximately 0 5 ohms anything between 0 3 ohms and 0 6 ohms is acceptable If the resistance is outside the range menti...

Page 112: ...ill be necessary to remove the left engine crankcase cover to inspect and correct the anomalous condition Place a drip pan beneath the engine as oil will escape from the engine during this operation a...

Page 113: ...rter transfer gears Note their orientation the smaller gear is closest to the starter motor Note that there are small shims on either side of the gear cluster take care not to lose them Unbolt the 8mm...

Page 114: ...Use a rotor pulling tool to back the rotor off of the crankshaft We sell these please give us a call at 909 445 0900 if you need this tool Assembly is the reverse of disassembly Apply Loctite to the r...

Page 115: ...motorcycle s wiring and use a multimeter to identify any shorts to ground If the fuse is intact and the motorcycle does not crank next check the battery Please see our battery maintenance tutorial fo...

Page 116: ...e engine does not turn either the starter motor output gear is stripped or there is a problem in the starter gear train Remove the starter motor transfer gear train cover and examine the gears The sta...

Page 117: ...com 116 Remove the countershaft sprocket cover Remove the charging circuit harness retention clip Disconnect the charging circuit connector plug Unbolt the 8mm bolt inside the starter motor transfer...

Page 118: ...aced If the engine start drive gear is defective it must be replaced If you need replacement parts please call us at 909 445 0900 If you need to replace the engine start drive gear or the sprag clutch...

Page 119: ...ounting and countershaft cover bolts to 7 ft lbs Electrical System Troubleshooting Troubleshooting flow charts for electrical system problems are provided below in the following pages Item Symptom Cau...

Page 120: ...ed above isolate and correct open circuit Starter gear train failure Starter cranks but spins freely Check starter motor output gear check starter motor gear train as outlined above isolate and replac...

Page 121: ...TT250 Owner s and Service Manual www CSCMotorcycles com 120 Electrical Schematic...

Page 122: ...ck adjust intake and exhaust valves to 0 07mm Check adjust brake fluid levels Check throttle operation for free play and smoothness Check adjust clutch operation Check adjust wheel true and spoke tigh...

Page 123: ...ck brake light front and rear Check tail light Check auxiliary lights Check adjust front and rear brake fluid levels Check brake pads front and rear Check brake rotor wear front and rear Check brake h...

Page 124: ...ront and rear Check tail light Check auxiliary lights Check adjust front and rear brake fluid levels Check brake pads front and rear Check brake rotor wear front and rear Check brake hoses and connect...

Page 125: ...uid front and rear Check throttle cable for smooth operation Check adjust tire pressure 32 psi front and rear Check tire condition and tread depth Check lighting and signal systems Check drive chain t...

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CSC TT250, Owner'S And Service Manual

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