CSC TT250 - Page 117

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TT250Owner’s andServiceManual

www.CSCMotorcycles.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case.

Gentlyremovetheleftenginecrankcasecover.

Main Page

Table of Contents2
Foreword5
Caution and Warning Symbols5
Section 1: Owner's Manual6
General Motorcycle Safety Guidance6
Inspections before Riding7
Motorcycle Specifications7
Motorcycle Description9
Controls10
Ignition Lock and Fork Lock10
Instruments10
Left and Right Handlebar Switchgear11
Fuel, Fuel Tank, Filler Cap, and Petcock11
Choke12
Helmet Lock12
Adjustable Front and Rear Suspension13
Load Limits13
Tool Kit14
Engine Break-In Procedure14
Starting the Motorcycle14
Operating the Motorcycle15
Cleaning the Motorcycle15
Storing the Motorcycle16
Section 2: Service Manual17
Maintenance Cautions and Warnings17
Component Cleaning17
Parts Inspection18
Maintenance Adjustments18
Recommended Tools18
Adjustment Specifications18
Motorcycle Maintenance Schedule19
Torque Values19
Unpacking20
Inspection20
Frame and Body20
Brakes21
Master Cylinder Locations21
Front Brake Pad Inspection and Replacement22
Rear Brake Pad Inspection and Replacement24
Front and Rear Brake Rotor Inspection25
Flushing and Replacing the Brake Fluid26
Bleeding the Brakes26
Chain Drive System27
Chain Lubrication27
Chain Adjustment27
Brake Troubleshooting27
Power Transmission27
Sprocket and Chain Inspection30
Chain Drive Troubleshooting31
Clutch Maintenance31
Clutch Cable Installation and Adjustment31
Clutch Replacement33
Clutch Troubleshooting42
Suspension43
Forks43
Adjusting Ride Height43
Changing Fork Oil44
Replacing Fork Seals and Bushings49
Swingarm and Rear Suspension51
Swingarm and Rear Suspension Troubleshooting54
Steering System55
Steering Stem Bearing Adjustment55
Steering System Troubleshooting57
Wheels and Tires57
Front Wheel Removal57
Rear Wheel Removal60
Wheel and Tire Inspection63
Wheel and Tire Troubleshooting63
Fixing Flat Tires63
Engine66
Oil Change66
Spark Plug Removal and Installation70
Valve Adjustment70
Carburetor79
Air Filter Replacement90
Exhaust System92
Engine Troubleshooting93
Fuel System95
Fuel System Troubleshooting96
Control Cables97
Clutch and Throttle Cable Troubleshooting97
Electrical System97
Battery105
Lighting and Turn Signals107
Charging System110
Starting System114
Electrical System Troubleshooting119
Electrical Schematic121
Appendix A - Service Checklists122

CSC TT250 - Page 117

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