TT250
Owner’s
and
Service
Manual
www.CSCMotorcycles.com
118
After
removing
the
rotor,
remove
the
engine
start
drive
gear
if
it
is
damaged.
To
do
so,
you
must
remove
the
small
Woodruff
key
that
indexes
the
engine
start
drive
gear
to
the
crankshaft.
Gently
tap
the
Woodruff
key
out
with
a
screwdriver
and
a
hammer.
Remove
the
engine
start
drive
gear.
If
you
need
a
replacement
engine
start
drive
gear,
please
call
us
at
909
445
0900.
Assembly
is
the
reverse
of
disassembly.
When
assembling
the
left
engine
cover
to
the
engine,
use
a
new
gasket
(please
call
us
at
909
445
0900
if
you
need
a
new
gasket).
Apply
Loctite
to
the
rotor
crankcase
bolt
and
torque
the
rotor
crankcase
bolt
to
45
ft
‐
lbs.
Torque
the
engine
cover
mounting
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
Cause
Vehicle
Effect
Maintenance
Action
Fuse
No
electrical
power
to
vehicle
Short
circuit
in
wiring
Cannot
operate
motorcycle
Check
electrical
system,
isolate
and
correct
any
short
circuits
to
ground,
replace
fuse
after
correcting
short
circuit
Battery
Low
or
no
output
Charging
failure
Cannot
operate
motorcycle
See
below
Battery
acid
low
Cannot
start
motorcycle
Add
distilled
water
Battery
plates
sulfated
Cannot
start
or
operate
motorcycle
Replace
battery
Does
not
charge
No
regulator
output
Cannot
start
or
operate
motorcycle
Check
regulator
output;
replace
regulator
if
defective
Open
circuit
in
charging
circuit
Cannot
start
or
operate
motorcycle.
Check
electrical
system,
isolate
and
correct
open
circuit
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