CSC TT250 Instruction Manual

TT250Owner’sandServiceManual
www.CSCMotorcycles.com
1

Contents
Foreword.......................................................................................................................................................4
CautionandWarningSymbols......................................................................................................................4
Section1:Owner’sManual..........................................................................................................................5
GeneralMotorcycleSafetyGuidance...........................................................................................................5
InspectionsBeforeRiding.............................................................................................................................6
MotorcycleSpecifications.............................................................................................................................6
MotorcycleDescription.................................................................................................................................8
Controls.........................................................................................................................................................9
IgnitionLockandForkLock...........................................................................................................................9
Instruments...................................................................................................................................................9
LeftandRightHandlebarSwitchgear.........................................................................................................10
Fuel,FuelTank,FillerCap,andPetcock......................................................................................................10
Choke..........................................................................................................................................................11
HelmetLock................................................................................................................................................11
AdjustableFrontandRearSuspension.......................................................................................................12
LoadLimits..................................................................................................................................................12
ToolKit........................................................................................................................................................13
EngineBreak‐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Cleaning...................................................................................................................................16
PartsInspection..........................................................................................................................................17
MaintenanceAdjustments..........................................................................................................................17
RecommendedTools..................................................................................................................................17
AdjustmentSpecifications..........................................................................................................................17
MotorcycleMaintenanceSchedule............................................................................................................
18
TorqueValues.............................................................................................................................................18
Unpacking...................................................................................................................................................19
Inspection....................................................................................................................................................19
FrameandBody..........................................................................................................................................19
Brakes..........................................................................................................................................................20
MasterCylinderLocations..........................................................................................................................20
FrontBrakePadInspectionandReplacement............................................................................................21
RearBrakePadInspectionandReplacement.............................................................................................23
FrontandRearBrakeRotorInspection......................................................................................................24
FlushingandReplacingtheBrakeFluid......................................................................................................25
BleedingtheBrakes....................................................................................................................................25
BrakeTroubleshooting................................................................................................................................26
PowerTransmission....................................................................................................................................26

TT250Owner’sandServiceManual
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ChainDriveSystem.....................................................................................................................................26
ChainLubrication........................................................................................................................................26
ChainAdjustment.......................................................................................................................................26
SprocketandChainInspection...................................................................................................................29
ChainDriveTroubleshooting......................................................................................................................30
ClutchMaintenance....................................................................................................................................30
ClutchCableInstallationandAdjustment..................................................................................................30
ClutchReplacement....................................................................................................................................32
ClutchTroubleshooting...............................................................................................................................41
Suspension..................................................................................................................................................42
Forks............................................................................................................................................................42
AdjustingRideHeight..................................................................................................................................42
ChangingForkOil........................................................................................................................................43
ReplacingForkSealsandBushings.............................................................................................................48
SwingarmandRearSuspension..................................................................................................................50
SwingarmandRearSuspensionTroubleshooting......................................................................................53
SteeringSystem..........................................................................................................................................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................................................................................................................62
FixingFlatTires...........................................................................................................................................62
Engine..........................................................................................................................................................65
OilChange...................................................................................................................................................65
SparkPlugRemovalandInstallation...........................................................................................................69
ValveAdjustment........................................................................................................................................69
Carburetor...................................................................................................................................................78
AirFilterReplacement................................................................................................................................89
ExhaustSystem...........................................................................................................................................91
EngineTroubleshooting..............................................................................................................................92
FuelSystem.................................................................................................................................................94
FuelSystemTroubleshooting.....................................................................................................................95
ControlCables.............................................................................................................................................96
ClutchandThrottleCableTroubleshooting................................................................................................96
ElectricalSystem.........................................................................................................................................96
Battery.......................................................................................................................................................104
LightingandTurnSignals..........................................................................................................................
106
ChargingSystem........................................................................................................................................109
StartingSystem.........................................................................................................................................113
ElectricalSystemTroubleshooting............................................................................................................118
ElectricalSchematic..................................................................................................................................120
AppendixA‐ServiceChecklists................................................................................................................121


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
3
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AWordFromSteve

ThankyouforpurchasingthisCSCTT250motorcycle.TheTT250isagreatmotorcycleandwearevery
proudofit.TheTT250iseasytomaintain,it’sreliable,andit’sfun.You’vemadeawisepurchase
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ridingonyournewTT250motorcycle.Ifthere’sanything
wecandotoenhanceyourownershipexperience,pleaseletusknow.

Thankyouagain,

SteveSeidner
FounderandCEO
CSCMotorcycles,LLC
1331W.FoothillBoulevard
Azusa,California91702
9094450900
www.CSCMotorycles.com


TT250Owner’sandServiceManual
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4

Foreword

TheTT250Owner’sandServiceManualprovidesinformationonoperatingandmaintainingtheCSC
TT250motorcycle.Itincludesthemotorcycle’stechnicalspecifications,performanceparameters,and
operating,maintenance,andadjustmentdata.ThismanualincludesboththeOwner’sManualandthe
ServiceManual.TheOwner’sManualisincludedinthefirstsectionofthisdocument;theService
Manualinincludedinthesecondsectionofthisdocument.

CSCMotorcyclesstocksall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allwhopurchaseanewCSCTT250
motorcycle.

ReproductionoftheCSCTT250Owner’sandServiceManualorpostingitonlinewithoutCSC’s
permissionisexpresslyprohibited.

Ifyouhaveanyquestions,pleasecontactCSCMotorcyclesbycallingusat9094450900orviaemailat
[email protected].


CautionandWarningSymbols

Cautionandwarningsymbolsinthismanualareasfollows:

TheCaution!symbolindicatesaconditionthatmayleadtomotorcycledamage.

TheWarning!symbolindicatesaconditionthatmayleadtoinjuryordeath.




TT250Owner’sandServiceManual
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5

Section1:Owner’sManual

GeneralMotorcycleSafetyGuidance

Warning!Donotattempttoridethismotorcycleonpublicroadsifyoudonothaveamotorcycle
license.

Warning!Donotattempttoridethismotorcycleifyoudonotknowhowtorideamotorcycle.

Warning!Alwayswearappropriatemotorcyclegearwhenridingyourmotorcycle.Neverrideyour
motorcyclewithoutwearinganapprovedhelmet,amotorcyclejacket,eyeprotection,gloves,
motorcyclepants,andboots.

Warning!Alwaysremainalertwhileoperatingyourmotorcycle.Payattentiontotrafficconditionsand
theroadsurface.Adjustyourspeedandfollowingdistancestakingthesefactorsintoconsideration.

Warning!Neveroperateyourmotorcyclewhileundertheinfluenceofdrugsoralcohol,orwhensleep
deprived.

Warning!Themotorcycle’scylinder,cylinderhead,andexhaustsystemarehotwhen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themotorcycle’shandling.

Warning!Replaceworntirespromptly.

Warning!Neverattempttolubricatethechainbyrunningtheengine,puttingthemotorcycleingear,
andliftingtherearofthemotorcycle.Lubricatethechainwiththeengineoff.

Warning!Makesurethechokeisfullyopenwhenridingthemotorcycle.

Warning!Donotattempttoreachunderthetanktoopenorclosethechokewhileridingthe
motorcycle.

Warning!Donotoverloadthemotorcycleorloaditunevenly.

Warning!Donotattempttocarrymorethanonepassenger(inadditiontotherider).

Warning!Donotattempttoperform“wheelies.”

Caution!Don’tparkyourmotorcyclefacingdownhillwithoutleavingthemotorcycleingear,oritmay
rollforwardandfalldown.

Caution!Neveroperateyourmotorcyclewithouttheairfilter,themuffler,andallemissions
componentsinplace.Doingsowillreduceperformance,damagetheengine,andvoidyourwarranty.

TT250Owner’sandServiceManual
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6

InspectionsBeforeRiding

Beforeridingyourmotorcycle,youshouldcheckthefollowing:

Bothtiresareappropriatelyinflated.

Neithertirehasnailsnorotherforeignobjectsembeddedinthetreadorthesidewall.

Thefueltankcontainsadequatefuel,andthefuelpetcockisintheONposition.Ifthefuel
petcockisintheRESERVEposition,fillthefueltankatthenextopportunity.

Thecrankcasehasoil.Youcanchecktheoillevelusingeitherthedipstickorthecrankcase
viewingport.

Theturnsignals,thefrontandrearbrakelights,thehorn,andtheheadlightalloperatewhen
commandedtodoso(theignitionswitchmustbeintheONposition).

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switchisintheRUNposition.

Thechainhasappropriateslack.

Majorthreadedfastenersaretight.Wealwayshandchecktheaxlenuts,theexhaustheader
nutsandbolts,themufflerboltsandnuts(grabthemufflerandcheckitforanyside‐to‐side
play),thesteeringstemnut,andthefrontandrearcaliperbolts.

MotorcycleSpecifications

General
TypeDualsport
DesignationCSCTT Special
ColorsCopper,black,white
Fuel 87octane
FuelCapacity2.9gallons
TopSpeedDependentongearingandriderweight;approximately70mphwith17T
countershaftsprocketand50Trearsprocket.Othergearratiosavailable
fromCSC.
Powertrain
EngineConfigurationSinglecylinder,aircooled,2valve,carbureted,counterbalanced,choke

TT250Owner’sandServiceManual
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7

BorexStroke66.5mmx66.2mm
Displacement229.9cc
CompressionRatio9.6:1
Horsepower16.1@7000rpm
Torque13.5ft‐lb
OilType10W40,motorcycletype
OilCapacity1.3quart
StartingElectricandkick
PrimaryTypeGeardriven
Transmission5speed,constantmesh
Front/RearSprockets17T/50T
ChainType428
Brakes
TypeHydraulicdiskfrontandrear,braidedstainlesssteelbrakelines
FrontDiskDiameter10.50inches
RearDiskDiameter8.63inches
WheelsandTires
WheelsSteel,spoked
FrontTire3.00x21knobby,DOTapproved
RearTire4.60x18knobby,DOTapproved
Front&RearTirePressure32psi,frontandrear
Switchgear/Controls
Instrumentation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,horn,turnsignals,highbeamflash,emergencyflashers
RightHandlebarOff/Accessory1/Accessory2,enginekillswitch,starter
ChassisandSuspension
GroundClearance11.5inches
SeatHeight34.0inches
HandlebarHeight44.5inches
FootpegHeight(rider)13.5inches
FootpegHeight(passenger)19.0inches
HelmetLockLeftrearframe
ToolkitLeftrearframe
Wheelbase55.0inches
Weight309lbs
GrossVehicleWeightRating639lbs
FrameTubularsteel
RearSuspensionTravel6.5inches
FrontSuspensionTypeInvertedtelescopicfork,anodizedgold,upperforkdiameter49mm,
lowerforkdiameter37mm.
FrontSuspensionTravel6.2inches
Rake28degrees
RearSuspensionSingleshock,adjustablepreloadanddamping



TT250Owner’sandServiceManual
www.CSCMotorcycles.com
8

MotorcycleDescription

TheCSCTT250motorcycleisa250ccdualsportmotorcycle.Themotorcyclehasasingle‐cylinder,4‐
stroke,air‐cooledengineanda5‐speedtransmission.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locatedonthe
rightsideofthesteeringstem,asshowninthe
photototheright.

Theengineserialnumberisshownonthelowerleft
sideoftheenginecrankcase(behindtheshift
lever),asshowninthephotototheright.

TT250Owner’sandServiceManual
www.CSCMotorcycles.com
9

Controls

Themotorcycleisoperatedwiththeignitionswitch,theinstruments,thethrottle,theclutch,thefront
brakelever,andtherearbrakelever.Youcanstartyourmotorcycleusingeitherthekickstarterorthe
electricstarter.Locationsfortheseitemsareshowninthephotosaboveandbelow.Operatingthe
motorcycleisexplainedbelow.

IgnitionLockandForkLock

YourTT250isequippedwithanignitionlock.Themotorcyclekeyoperatesthebasicignitionlock.
Insertthekeyandturnittotherighttoturntheignitionon.

TheTT250alsohasamechanical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switchmodule.Toopentheignitionswitchcover,insertthesideoftheplastic
keyuppersegmentintotherecessedcover,andusethekeyasalevertotwisttheovermechanism
open.

Theignitionswitchalsooperatestheforklock.Turntheforksallthewaytotheleft.Pushtheignition
keyintotheswitchandrotatethekeytothelefttolocktheforks.



Instruments

TT250instrumentationincludesaspeedometer,anodometer,atripmeter,afuelgage,turnsignal
indicators,ahighbeamindicator,andaneutralindicator.Youcanresetthetripmetertozeroby
rotatingtheknobontheleftsideoftheinstrumentcluster.


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
10

LeftandRightHandlebarSwitchgear

Lefthandleswitchgearincludesthepassinglight,thehighbeam/lowbeamswitch,theemergency
flasherswitch,theturnsignals,andthehorn.Thepassinglightmomentarilyactivatesthemotorcycle’s
highbeamwhenthelowbeamonlyison.Youcanuseittoalertavehicleyouareabouttopass.The
highbeam/lowbeamswitchisusedtoswitchbetweenthehighbeamandlowbeam.Theemergency
flasherswitchactivatesthemotorcycle’sflashers;whenitisintheONposition,allfourturnsignalswill
flash.Theturnsignalsareactivatedwhentheturnsignalispushedeithertotherightortotheleft.The
turnsignalsarenotself‐cancelling;youmightdepresstheturnsignalswitchsharplyinitscenterposition
toturntheturnsignaloff.Thehornbuttonsoundsthehorn.

Righthandlebarswitchgearincludestheenginekillswitch,theaccessoriesswitch,and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isusedtoprovide
12Velectricalenergytoeitheroftheaccessoryoutletsbeneaththeseat.Powertotheaccessories
outletsisprovidedonlywhentheignitionison.Thestarterswitchisusedtostarttheengineafterthe
ignitionswitchisturnedon.


Fuel,FuelTank,FillerCap,andPetcock

TheTT250fueltankholds2.9gallonsoffuel.Use87octaneorhigherfuel.

Thefuelpetcockislocatedonleftsideofthetank.TurnthepetcocktotheOFFpositionwhenyouare
notridingthemotorcycle.TurnthepetcocktotheRUNpositionpriortooperatingthemotorcycle.If
themotorcyclerunsoutoffuel,turnthepetcocktotheRESERVEposition.Findafuelstationandfill
themotorcycleassoonaspossibleafterthefuelpetcockswitchingtotheRESERVEposition.

Thefueltankfillercapisalockingcap.Toopenit,inserttheignitionkeyinthefueltankandturnit
clockwise.Afterfillingthefueltank,pushdownfirmlyonthefillercaptolockit.


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
11


OffNormalOperation ReserveOperation FillerCap

Choke

Thechokeislocatedontheleftsideofthecarburetorunderneaththefueltank.Whenthechokelever
isallthewaydown,thechokeisnotengaged.Whenthechokeisallthewayup,thechokeisfullyon.
Thereisanintermediatepositionhalfwaybetweenthechokeopenandfully‐chokedposition.

Whenstartingthemotorcyclewithacoldengine,pushthechokeleverallthewayuptothefully‐choked
position.Aftertheenginehaswarmedslightly,pushthechoketotheintermediateposition.Afterthe
enginehas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leverisinthefullyopen(all
thewaydown)position.

Warning!Donotattempttoactuatethechokeleverwhileridingthemotorcycle.

HelmetLock

Thehelmetlockislocatedonthemotorcycle’sleftrearframe.YoucanattachtheD‐ringonyour
helmetstraptothehelmetlocktosecureyourhelmetwhileyouarenotridingthemotorcycle.Toopen
thehelmetlock,inserttheignitionkeyandturnitcounterclockwise.Toclosethehelmetlock,push
downontheplungerabovethehelmetlock.

Warning!Donotoperateyourmotorcyclewithahelmetheldinplacebythehelmetlock.Alwayswear
yourhelmetwhenridingyourmotorcycle.


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
12


AdjustableFrontandRearSuspension

TheTT250’sfrontandrearsuspensiondampingcanbeadjustedbyturning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motorcycleweighs309lbs.Thegrossvehicleweightratingis639lbs.

Warning!Donotoverloadorunevenlyloadthemotorcycleorthehandlingwillbeadverselyaffected.


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
13

ToolKit

TheTT250includesatoolkitstoredinacontainer
ontheleftrearframe.
EngineBreak‐InProcedure

Whenaninternalcombustionengineisnew,itshouldnotbesubjectedtohardacceleration,lugging,
overheating,orrunningforlongperiodsataconstantenginespeed.Youshouldavoidthesesituations
duringthefirst500milesofservice.Caution!Donotviolatetheguidanceprovidedhere,oryoumay
damageyourmotorcycleengine.

Werecommendthefirstoilchangewhenthemotorcyclereachesbetween200and500miles.We
recommendasecondoilchangeat1,000miles,andevery2,500milesthereafter.Werecommend
usingonly10‐40Wmotorcycleoil.Caution!Neveruseanyoilsintendedforautomotiveuse,oranyoil
thatcontainsfrictionreducingadditives(useoftheseoilswillinduceclutchslippagenotcoveredbythe
CSCwarranty).

Useonlynon‐syntheticoilsduringthefirst1000milesofuse.Afterthat,youmaywishtochangeto
syntheticmotorcycleoil.

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eitherthekickstarterorthe
electricstarter.Followthestepslistedbelow:

PutthefuelpetcockintheRUNposition.
Incoolweather,closethechoke.Thisisaccomplishedbypushingthechokelever(mountedon
thecarburetorallthewayup.
InserttheignitionkeyandturnittotheONposition.Makesurethetransmissionisinthe
neutralposition.MakesuretheenginekillswitchisintheRUNposition.
Ifusingthekickstarter,vigorouslykicktheenginethroughacompressioncycle,whileopening
thethrottleslightly.
Ifusingtheelectricstarter,depressthestartbuttonwhileopeningthethrottleslightly.Donot
cranktheenginewiththeelectricstarterformorethanafewseconds.
Aftertheenginestarts,allowittowarmforatleastoneminute.Astheenginewarms,open
thechoketotheintermediateposition(partiallydown)andthen(aftertheenginehaswarmed)
tothefullyopenposition(thechokelevershouldbeallthewaydown).Warning!Donot
attempttoactuatethechokeleverwhileridingthemotorcycle.

TT250Owner’sandServiceManual
www.CSCMotorcycles.com
14

OperatingtheMotorcycle

Operatethemotorcycleasoutlinedbelow:

Aftercompletingthepre‐rideinspectionintheInspectionsBeforeRidingsectionandputtingon
allofyourridinggear(helmet,gloves,jacket,eyeprotection,andotherprotectiveriding
apparel),mountthemotorcycleandstanditupright.
Startthemotorcycleasoutlinedabove.
Liftthesidestandstandtotheretractedposition.Warning!Donotridethemotorcyclewiththe
sidestanddown.
Pullintheclutchandpushthegearshiftleverdowntoputthemotorcycleinfirstgear.
Openthethrottleslightlyandengagetheclutch.
Asthemotorcycleaccelerates,pullintheclutch,pulluponthegearshiftlever,andengage
secondgear.Repeattheaboveprocesstoengagethird,fourth,andfifthgear.
Whenyouneedtostop,allowthethrottletocloseandapplyboththefrontandrearbrakes.
Warning!Donotapplythebrakestooaggressively,asthiscaninduceaskid.Becognizantof
theroadsurfaceandadjustbrakingforceappropriately.
Asthemotorcycleslows,pullintheclutch,depressthegearshiftlevertoshifttoalowergear,
andreleasetheclutch.Matchyourspeedasyoudeceleratetothegearyouaredownshifting
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brakestoslowthe
motorcycle.Priortocomingtoacompletestop,pullintheclutch.Shiftthemotorcycleto
neutral.
Ifyouwishtoparkthemotorcycle,turnofftheignitionkey.Caution!Donotusethekillswitch
forroutinestopsandleavetheignitionkeyintheONpositionwhentheengineisnotrunning.
Thiswillrundownthebattery.
Deploythesidestandandleanthemotorcycletotheleft.Makethesidestandisfullyforward
priortoleaningthemotorcycletotheleft.Caution!Donotparkthemotorcyclewiththefront
endangleddownward;itcouldrollforward(offthesidestand)andfall.
Lockthefrontforks.Donotleavetheignitionkeywiththemotorcycle.

CleaningtheMotorcycle

Cleanyourmotorcyclewhenitbecomesdirtyasoutlinedbelow:

Washthemotorcyclewithlowpressurewatertoloosenandremovemud,insects,andother
debris.
Washthemotorcycleusingsoapywater.Rinsethemotorcycle.Caution!Donotspraywater
directlyintothemuffler.
Cleanthechainusingasuitablechaincleaner.
Drythemotorcyclewithatowelorachamois.
Lubricatethechainwithasuitablechainlubricant.
Waxthemotorcycleusingasuitablewax.

CSCstocksanumberofcleaningproducts;pleasecallusat9094450900toordertheseitems.

TT250Owner’sandServiceManual
www.CSCMotorcycles.com
15




StoringtheMotorcycle

Forstoragelongerthan60days,storethemotorcycleasoutlinedbelow:

Drainthefuelfromthefueltank,thefuellines,andthecarburetor.Closethefueltankcap.
Removethesparkplugandadd5ccofmotoroilintothecylinder.Reinstallthesparkplug.With
theignitionswitchintheOFFposition,cycletheengineseveraltimeswiththekickstarter.
Remove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.
Addfuelstabilizertothefueltopreventgumminginthetank,thecarburetor,orthefuellines.
Afterstorage,chargeandreinstallthebattery.Addfuel.Replacetheengineoilifthe
motorcyclehasbeeninstoragelongerthan6months.

Forshorterstorageintervals,werecommendattachingthemotorcycletoaBatteryTender.

CSCstocksalloftheitemsdescribedabove.Pleasecallusat9094450900toorderanyoftheitems
describedabove.


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
16

Section2:ServiceManual

MaintenanceCautionsandWarnings

Whenyourepairthemotorcycle,pleaseuseoriginalcomponentsandparts,accessories,lubricatingoil
andothermaterialsthataremadeorrecognizedbyCSCMotorcycles.Caution!Ifyouuseanypartsor
componentsotherthanthoserecommendedbyCSC,itmayadverselyaffecttheperformance,reliability,
stability,orwarrantyofyourmotorcycle.

Whenworkingonyourmotorcycle,youshouldfollowthisguidance:

Warning!Wheneverthemotorcycleistobereassembledafterdisassembly,washers,seals,and
cotterpinsneedtobereplaced.
Whenyoufastenaseriesofboltsornuts,youshoulddosoinadiagonalpattern.
Warning!Donotuseflammablecleaningfluidtocleancomponentsandparts.
Caution!Beforeassemblyoperations,addlubricatingoilorlubricatinggreasetolubricated
surfaces.
Warning!Afterassembly,makesureallpartsareproperlyassembledandtightened.
Warning!Stoptheenginewhenrepairingthemotorcycle.
Warning!Ifthemaintenanceoperationneedstobedone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hydrogen,whichisflammable.Donotsmoke,igniteormake
sparksnearthebattery,especiallywhenitischarging.
Warning!Theelectrolyteofthebatterycontainssulfuricacid.Ifyoureyes,skinorclothesare
splashedwithelectrolyte,rinsethemthoroughlywithwaterandseekimmediatemedical
attention.
Warning!Disconnectthenegativebatteryterminalwhenperforminganymaintenanceonthe
motorcycleengine,drivetrain,orfuelsystem.

ComponentCleaning

Afterpartsaredisassembled,theymayneedtobecleaned.Cleaningmethodsvaryaccordingtothe
characteristicsoftheparts.

Toremoveoilorgreasecontamination,CSCrecommendsusingSimpleGreenorothersimilar
degreasingagents.
Warning!Neverusegasolineasacleaningagent.
Toremovecarbondeposits,usemechanicalorchemicalmethods.Themechanicalmethoduses
awoodenorplasticscraperorbladetoclearthecarbondepositfirst,andthenrinsetheparts
withanappropriatecleaningagent.Thechemicalmethodistosoakthepartsinthecleaning
agentfirst,thencleanthemwithabrush,andthenrinsethemwithhotwater.


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
17


PartsInspection

Partsshouldbeinspectedaftertheyarecleaned.Thepurposeofinspectionistocheckifthepartsneed
toberepairedorreplaced.

MaintenanceAdjustments

TheTT250motorcyclerequiresadjustmentsinthefollowingareas:

Theclutchmustbeadjustedaccordingtothemaintenanceinstructionsincludedinthismanual.
Themainadjustmentfeatureistheclutchleverfreetravel(¼to½inch),andtheclutchcable
adjustingmechanism.ThisServiceManualpresentstheprocedureforclutchadjustment.
Thethrottlecableadjustmentisperformedatthethrottle.Thethrottleshouldhave2to5
degreesoffreerotation.Thisadjustmentispresentedin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Service
Manual.
Thevalvesshouldbeadjustedtoagapof0.04mmto0.08mm.ThisServiceManualpresents
theprocedureforadjustingthemotorcycle’svalve.
Tirepressureshouldbemaintainedat32psiforthefrontandreartiresforthereartire.

RecommendedTools

TheCSCTT250motorcycleincludesabasictoolkitthatisstoredundertherearseat.Thesetoolsare
suitableforemergencyrepairsonly.CSCsellscustomtoolkitswithprofessionalgradetools;please
contactusat9094450900toordertools.

AdjustmentSpecifications

ItemAdjustmentLimits
Clutchleverfreeplay(attip)¼to½inch
Throttlefreetravel2‐5degrees
Drivechain3/5inch
Valvegap(atTDC)0.04to0.08mm
Tirepressure(front/rear)32psi



TT250Owner’sandServiceManual
www.CSCMotorcycles.com
18

MotorcycleMaintenanceSchedule

Maintenance
Times

Maintenance
Item
Odometer(miles)
500
miles
2,500
miles
5,000
miles
7,500
miles
10,000
miles
12,500
miles
15,000
miles
FuelsystemI I I
FuelfilterIII I I II
AircleanerelementIII I I II
Sparkpluggaplll l l ll
Valvelashlll l l ll
OilchangeI/LI/L I/L I/L I/L I/LI/L
RearchainI/LI/L I/L I/L I/L I/LI/L
Batterylll l l ll
Brakepadwearlll l l ll
Brakingsystemlll l l ll
Stoplampswitchlll l l ll
Headlamp lll l l ll
Sidestand lll l l 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aredefinedbelow:

R‐rinsing
L‐lubrication
l‐inspection,cleaning,adjustment,lubricationorreplacement

Ifyouoperatethemotorcycleindustyareas,themaintenancecycleshouldbeshortened.

TorqueValues

Atableforgeneraltorquevaluesfollows.InvariousplacesinthisServiceManual,specifictorquevalues
areprovided,andyoushouldusethosewherespecified.Inallotherinstances,usethevaluesprovided
below.Thevaluesprovidedthroughoutareforclean,drythreads.

BoltSize(mm)Torque(ft‐lbs) BoltSize(mm) Torque(ft‐lbs)
63‐514 60
88‐1216 60‐94
1015‐2218 60‐130
123920 166‐188


TT250Owner’sandServiceManual
www.CSCMotorcycles.com
19

Unpacking

Whenthemotorcycleisdelivered,checktheconditionofthedeliveredcrate.Ifthereareany
anomalies,stopandcallCSCat9094450900.ChecktheVINnumbersontheexteriorofthecrate.
Comparethesenumberstothedocumentationdeliveredtoyoupriortothemotorcycle’sarrival.Ifthe
numbersdon’tmatch,stopandcallCSCat9094450900.

Inspection

Performthefollowinginspectionswhenservicingthemotorcycle.

Checktoconfirmallfastenersareproperlytightenedandallcomponentsareinstalledcorrectly
andinanoperationalstate.
Swingthehandlebarsfromsidetosidetomakesuremotionisuninhibited.
CheckchaintensionandrearwheelalignmentinaccordancewiththerequirementsofService
Manual.
Inserttheignitionkeyandturniton.
Checkhornfunction,turnsignals,headlighthighandlowbeam,brakelightsforfrontandrear
brakeactivation,andinstrument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function.
Testridemotorcycletoconfirmoperability.

DetailedinspectionchecklistsareincludedinAppendixAofthisServiceManual.

FrameandBody

Theframeandbodysubsystemincludesthemotorcycle’ssteelframe,theseat,thebodypanels,the
sidestand,thefootpegs,thetoolkit,andthefenders.

Thetoolkitisstoredinacontainerontheleftsideofthemotorcycle.

Theseatisheldinplacebytwobolts.Therearseatcanberemovedtoprovideaccesstothebattery.

Frameandbodymaintenanceandtroubleshootingguidelinesaresummarizedbelow.

FrameandBodyMaintenanceandTroubleshooting
ItemCauseSymptom VehicleEffect MaintenanceAction
Frame Frameishitorfalls
over
Frameiscurvedor
deformed
Drift Correctorreplacethe
frame
Frameishitorfalls
over
Frameiscrackedor
fractured
MotorcyclecannotdriveWeldorreplacethe
frame
Frameisimpacted
andshockedbyroad
Framewelding
detachment
Shakeordrift Weldtheframe