CSC SG250 Owner's And Service Manual
SG250 Owner’s and Service Manual
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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
Fork Lock ....................................................................................................................................................... 9
Instruments ................................................................................................................................................... 9
Left and Right Handlebar Switchgear ........................................................................................................... 9
Fuel, Fuel Tank, Filler Cap, and Petcock ...................................................................................................... 10
Choke .......................................................................................................................................................... 11
Load Limits .................................................................................................................................................. 11
Tool Kit ........................................................................................................................................................ 12
Engine Break-In Procedure ......................................................................................................................... 12
Starting the Motorcycle .............................................................................................................................. 12
Operating the Motorcycle ........................................................................................................................... 13
Cleaning the Motorcycle ............................................................................................................................. 13
Storing the Motorcycle ............................................................................................................................... 14
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 Location ............................................................................................................................ 20
Front Brake Pad Inspection and Replacement ............................................................................................ 21
Rear Brake Pad Inspection and Replacement ............................................................................................. 22
Front Brake Rotor Inspection ...................................................................................................................... 23
Flushing and Replacing the Brake Fluid ...................................................................................................... 24
Bleeding the Brakes .................................................................................................................................... 24
Brake Troubleshooting ................................................................................................................................ 24
Power Transmission .................................................................................................................................... 25
Chain Drive System ..................................................................................................................................... 25
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SG250 Owner’s and Service Manual
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Chain Lubrication ........................................................................................................................................ 25
Chain Adjustment ....................................................................................................................................... 25
Sprocket and Chain Inspection ................................................................................................................... 27
Chain Drive Troubleshooting ...................................................................................................................... 28
Clutch Maintenance .................................................................................................................................... 28
Clutch Cable Installation and Adjustment .................................................................................................. 29
Clutch Replacement .................................................................................................................................... 30
Clutch Troubleshooting ............................................................................................................................... 39
Suspension .................................................................................................................................................. 40
Forks ............................................................................................................................................................ 40
Changing Fork Oil and Replacing Fork Seal ................................................................................................. 40
Swingarm and Rear Suspension .................................................................................................................. 44
Swingarm and Rear Suspension Troubleshooting ...................................................................................... 47
Steering System .......................................................................................................................................... 48
Steering Stem Bearing Adjustment ............................................................................................................. 48
Steering System Troubleshooting ............................................................................................................... 50
Wheels and Tires ......................................................................................................................................... 50
Front Wheel Removal ................................................................................................................................. 51
Rear Wheel Removal ................................................................................................................................... 52
Wheel and Tire Inspection .......................................................................................................................... 55
Wheel and Tire Troubleshooting ................................................................................................................ 55
Fixing Flat Tires ........................................................................................................................................... 55
Engine.......................................................................................................................................................... 58
Oil Change ................................................................................................................................................... 58
Spark Plug Removal and Installation ........................................................................................................... 62
Valve Adjustment ........................................................................................................................................ 62
Carburetor ................................................................................................................................................... 69
Air Filter Replacement ................................................................................................................................ 80
Exhaust System ........................................................................................................................................... 81
Engine Troubleshooting .............................................................................................................................. 83
Fuel System ................................................................................................................................................. 84
Fuel System Troubleshooting...................................................................................................................... 87
Control Cables ............................................................................................................................................. 88
Clutch and Throttle Cable Troubleshooting ................................................................................................ 88
Electrical System ......................................................................................................................................... 88
Battery......................................................................................................................................................... 93
Lighting and Turn Signals ............................................................................................................................ 95
Charging System .......................................................................................................................................... 97
Starting System ......................................................................................................................................... 100
Electrical System Troubleshooting ............................................................................................................ 105
Electrical Schematic .................................................................................................................................. 107
Appendix A - Service Checklists ................................................................................................................ 108
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SG250 Owner’s and Service Manual
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A Word From Steve
Thank you for purchasing this CSC San Gabriel 250 motorcycle. The SG250 is a great motorcycle and we
are very proud of it. The SG250 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 SG250 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
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SG250 Owner’s and Service Manual
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Foreword
The SG250 Owner’s and Service Manual provides information on operating and maintaining the CSC
SG250 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 SG250 motorcycle parts, and we recommend that you use only parts and
materials provided by us when servicing or maintaining your motorcycle.
The SG250 Owner’s and Service Manual is provided free to all who purchase a new CSC SG250
motorcycle.
Reproduction of the CSC SG250 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
info@CSCMotorcycles.com.
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.
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SG250 Owner’s and Service Manual
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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.
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SG250 Owner’s and Service Manual
General
Type
Dual sport
Designation
CSC San Gabriel 250
Colors
Mocha, White, Black, Blue
Fuel
87 octane
Fuel Capacity
4.0 US gallons
Top Speed
Dependent on gearing and rider weight; approximately 70 mph with 15T
countershaft sprocket and 50T rear sprocket. Other gear ratios available
from CSC.
Powertrain
Engine Configuration
Single cylinder, air cooled, 2 valve, carbureted, counterbalanced, choke
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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
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SG250 Owner’s and Service Manual
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
15T/50T
Chain Type
428
Brakes
Type
Hydraulic disk front, drum rear
Front Disk Diameter
9.00 inches
Rear Drum Diameter
6.50 inches
Wheels and Tires
Wheels
Aluminum, spoked
Front Tire
90/70/17
Rear Tire
120/70/17
Front & Rear Tire Pressure
36 psi front, 40 psi rear
Switchgear/Controls
Instrumentation
Speedometer, tachometer, odometer, tripmeter, neutral indicator, turn
signal indicator, high beam indicator, fuel gage
Dash Cluster
Keyed ignition switch
Left Handlebar
High/low beam, horn, turn signals, high beam flash, choke
Right Handlebar
Engine kill switch, starter
Chassis and Suspension
Ground Clearance
6.3 inches
Seat Height
26.0 inches
Handlebar Height
35.0 inches
Footpeg Height (rider)
10.0 inches
Footpeg Height (passenger)
16.0 inches
Helmet Lock
Left rear frame
Tool kit
Right frame under battery
Wheelbase
52.0 inches
Weight
273 lbs
Gross Vehicle Weight Rating
573 lbs
Frame
Tubular steel
Rear Suspension Travel
2.3 inches
Front Suspension Type
Telescopic fork, upper fork diameter 32mm, lower fork diameter 43mm
Front Suspension Travel
4.0 inches
Rake
27 degrees
Rear Suspension
Twin nitrogen-charged shocks
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SG250 Owner’s and Service Manual
SG250 Right Side View
SG250 Left Side View
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.
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Motorcycle Description
The CSC SG250 motorcycle is a 250cc street 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.
Vehicle Identification Number and Engine Number
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SG250 Owner’s and Service Manual
The motorcycle key operates the ignition lock. Insert the key and
turn it to the right to turn the ignition on. The ignition switch also
operates the parking light.
If you need additional keys, CSC stocks the key blanks for the SG250
motorcycle. Please call us at 909 445 0900 if you need to make
additional keys for your motorcycle.
The fork lock is located on the left side of the frame near the
steering yoke. To lock the forks, turn the forks all the way to the left.
Insert the ignition key, rotate it, and withdraw the key.
Warning! Do not attempt to ride the motorcycle with the forks in
the locked position.
SG250 instrumentation includes a speedometer, a
tachometer, an odometer, a fuel gage, turn signal
indicators, a high beam indicator, and a gear
indicator.
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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
Fork Lock
Instruments
Left and Right Handlebar Switchgear
Left handle switchgear includes the passing light, the high beam/low beam switch, the turn signals, and
the horn. The high beam/low beam flash switch momentarily activates the motorcycle’s high beam
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SG250 Owner’s and Service Manual
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when the low beam 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 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 must 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 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 starter switch is used to start the engine after the ignition switch is
turned on.
Fuel, Fuel Tank, Filler Cap, and Petcock
The SG250 fuel tank holds 4.0 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.
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SG250 Owner’s and Service Manual
Off
Normal Operation
Reserve Operation
Filler Cap
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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.
Load Limits
The SG250 motorcycle weighs 273 lbs. The gross vehicle weight rating is 573 lbs.
Warning! Do not overload or unevenly load the motorcycle or the handling will be adversely affected.
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SG250 Owner’s and Service Manual
The SG250 includes a tool kit stored in a container
on the right side of the motorcycle beneath the
battery. Pull up on the tab beneath the tool kit
cover and the cover will rotate up, providing access
to the tool kit.
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Tool Kit
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 cold weather, close the choke.
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.
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After the engine starts, allow it to warm for at least one minute. As the engine warms, open
the choke an intermediate position and then after the engine has warmed to the fully open
position (the choke lever should be all the way forward).
Operating the Motorcycle
Operate the motorcycle as outlined below:
After completing the pre-ride inspection in the Inspections Before Riding section and putting on
your riding gear (helmet, gloves, jacket, eye protection, and other protective riding apparel),
mount the motorcycle. Warning! Do not attempt to hold the motorcycle upright while putting
on your riding gear. You could drop the motorcycle and injure yourself. Put all of your riding
gear on before you get on the motorcycle.
Straddle the motorcycle.
Start the motorcycle as outlined above.
If the motorcycle is on the centerstand, push it forward to take it off the centerstand. If the
motorcycle is on the sidestand, lift the sidestand 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 sure 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. Caution! 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.
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SG250 Owner’s and Service Manual
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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. Caution! Do not spray lubricant directly into
the brakes.
Wax the motorcycle using a suitable wax.
Warning! When riding the motorcycle after cleaning it, actuate the brakes to make sure they
have not been degraded as a result of cleaning the motorcycle.
CSC stocks numerous cleaning and lubrication products; please call us at 909 445 0900 to order these
items.
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.
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SG250 Owner’s and Service Manual
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CSC stocks all the items described above. Please call us at 909 445 0900 to order any of the items
described above.
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SG250 Owner’s and Service Manual
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Section 2: Service Manual
Maintenance Cautions and Warnings
When you maintain or 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.
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SG250 Owner’s and Service Manual
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)
40/36 psi
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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 SG250 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 the specified gap. This Service Manual presents the procedure
for adjusting the motorcycle’s valve.
Tire pressure should be maintained at 40 psi for the front tire and 36 psi for the rear tire.
Recommended Tools
The CSC SG250 motorcycle includes a basic tool kit that is stored under the battery. 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
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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
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
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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
may be 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.
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SG250 Owner’s and Service Manual
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
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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 this
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 include the motorcycle’s steel frame, the seat, the body panels, the
sidestand, the Footpeg, the tool kit, and the fenders.
The tool kit is stored in a container under the battery.
The seat is held in place by two bolts. The rear seat can be removed to provide access to some of the
motorcycle’s electrical components.
Frame and body maintenance and troubleshooting guidelines are summarized below.
Frame and Body Maintenance and Troubleshooting
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SG250 Owner’s and Service Manual
Item
Cause
Symptom
Vehicle Effect
Maintenance Action
Sidestand
Deformation or
fracture
Sidestand cannot
return
Noise and compromised
parking
Correct or replace the
side support
Left or right
rear panel
Impact
Panel damaged
Compromised
appearance
Replace or repair the
panel
Left or right
tank panel
Impact
Panel damaged
Compromised
appearance
Replace or repair the
panel
Front fender
Impact
Deformation or
breakage
Compromised
appearance
Replace the front
fender
Rear fender
Impact
Deformation or
breakage
Compromised
appearance
Replace the rear
fender
Seat cushion
Impact
Seat cushion
damaged
Riding comfort
decreases
Replace the seat
Front footpeg
Impact
Deformation or
breakage
Compromised driving
safety
Replace the footpeg
Rear footpeg
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
Deformation
Compromised
placement of items
Replace the rear rack
The front brake master cylinder is located on the right
handlebar. It has a fluid level indicator on the master
cylinder that shows the “low” level. When the front master
cylinder fluid level is at the low mark, it is an indication that
the front brake pads should be replaced. Do not rely only
on this indication; you should check the pad thickness
regularly and replace them when they are worn below
acceptable limits (to be described below).
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Brakes
This section of the SG250 Owner’s and Service Manual covers the following topics:
Master cylinder locations
Inspecting and replacing the brake pads
Inspecting and replacing the brake disk
Flushing and replacing the brake fluid
Bleeding the brakes
Brake troubleshooting
Master Cylinder Location
20
SG250 Owner’s and Service Manual
The front brake caliper is located on the left side of the
motorcycle.
Loosen the front brake caliper’s two 5mm Allen pins.
Pull the caliper off the brake disk. You should not remove
the hydraulic, nor should you loosen it.
Completely remove the caliper’s two 5mm Allen pins, and
remove the two brake pads.
Note that one of the brake pads has a wear groove machined into the pad surface. When the pad is
worn such that the wear groove is no longer visible, replace both pads with new pads. CSC stocks
these pads, so call us at 909 445 0900 if you need to order a pair.
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Front Brake Pad Inspection and Replacement
It is possible to check the thickness on the front brake pads without removing the caliper from the
motorcycle, but it is difficult to do so and get an accurate indication of brake pad thickness. It is better to
remove the caliper to better see the pads.
21
Assembly is the reverse of disassembly. Install new front pads, place the caliper over the rotor, and
install the two caliper mounting bolts.
Rear Brake Pad Inspection and Replacement
The SG250 uses a mechanically-actuated drum brake in the rear. It is mechanically linked to the rear brake
pedal with a steel rod. The amount of free play in the rear brake pedal before the rear brake starts to
engage is adjusted via a threaded nut on the rear of the steel rod.
The rear brake caliper wear indicator is located on drum
(indicated by the upper arrow). As the rear brake wears,
free play is adjusted by turning the nut indicated by the
lower arrow. When the rear brake has reached the end of its
adjustment range, the brake shoes should be replaced. The
rear wheel must be removed to do this.
Place the motorcycle on the centerstand.
Remove the rear brake torque rod cotter pin and nut, and
disconnect the rear brake torque rod from the rear brake.
Remove the rear brake actuation rod nut and rotate the brake
actuator to disconnect the actuation rod from the rear brake.
SG250 Owner’s and Service Manual
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22
SG250 Owner’s and Service Manual
Remove the rear axle nut and remove the rear axle.
Caution! Support the rear wheel when removing the rear axle.
Remove the brake plate from the rear wheel to inspect the
brake shoes. When they are worn beyond the range allowed
for adjustability of the brake actuation rod (see above),
remove and replace both shoes.
The brake shoes are removed by rotating them away from
the brake plate, as shown here.
CSC stocks replacement brake shoes, so call us at 909 445 0900 if you need to order a pair.
Note that it is normal for the front brake pads to wear out much more quickly than the rear brake
shoes.
Assembly is the reverse of disassembly.
The front brake rotor is 4mm thick when new. When rotor
thickness drops below 3mm, the rotor should be replaced.
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Front Brake Rotor Inspection
23
The front brake rotor is each retained by Allen head bolts. Take care when removing these for the first
time; they are Loctited in place at the factory and it is easy to strip the Allen drive socket (we
recommend heating the head of the bolt first to soften the adhesive). CSC stocks replacement rotors
and Allen bolts; if you need a new rotor please call us at 909 445 0900.
It is a good idea to bleed the front brake every year, and to
flush and replace the brake fluid every two years. Use only
DOT4 brake fluid. We sell brake fluid suitable for use in your
SG250 motorcycle; if you need brake fluid please call us at
909 445 0900. Caution! Brake fluid can damage painted
components. Promptly wipe up spilled brake fluid.
To drain the system, open the master cylinder. Attach a
hose to the caliper bleed port and route it to a suitable
container. Open the caliper bleed port with an 8mm wrench
and allow the brake fluid to drain. Note that the drain hose
is not shown in the photo to allow clarity in identifying the
caliper bleed port.
After draining the brake fluid, add fluid to the master cylinder and bleed the brakes as described below.
Caution! Brake fluid can damage painted components. Promptly wipe up spilled brake fluid.
To bleed the brakes, attach a hose to the brake caliper bleed port and route it to a suitable container.
Open the master cylinder, taking care not to spill any brake fluid.
Open the caliper bleed port while applying the brake lever, and before releasing the brake lever, close
the bleed port. It’s important not to allow the bleed port to remain open while releasing the brake
lever or you will suck air into the system. Repeat this open-the-bleed-port, apply-the-brake-lever,
close-the-bleed-port, add-brake-fluid process until the master cylinder is full. Reinstall the brake
master cylinder cover.
Prior to taking the motorcycle on the street, operate it slowly and apply the brakes several times.
Flushing and Replacing the Brake Fluid
SG250 Owner’s and Service Manual
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Bleeding the Brakes
Brake Troubleshooting
Brake troubleshooting procedures are summarized below.
24
SG250 Owner’s and Service Manual
Item
Symptom
Cause
Vehicle Effect
Maintenance Action
Brake pad or brake
shoe
Reduced braking
force
Worn brake pads or
brake shoes
Longer stopping
distance, weaker
stopping
Replace brake pad
or brake shoe
Air in brake line
Reduced front
braking force
Air intrusion into
brake line
Longer stopping
distance
Bleed brake system
Pulsating brakes
Pulsating brake lever
Warped rotor disk
Pulsations; longer
stopping distance
Measure disk
runout, replace disk
rotor
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Front and Rear Brake Troubleshooting and Maintenance
Power Transmission
The SG250 uses a manually-operated wet clutch and a chain drive system.
Chain Drive System
This system consists of the clutch, the countershaft sprocket, the rear sprocket, the rear wheel, and the
drive chain.
Chain Lubrication
The drive chain should be lubricated approximately every 500 miles or more often if riding in rainy or
dusty conditions. Use only a quality wax-based or petroleum-based motorcycle chain lubricant. Ride
the motorcycle for at least 15 minutes to warm the chain, and apply the lubricant immediately after
stopping. Warning! Take care not to spray lubricant onto the tire or the rear brake. Do not use the
motorcycle for the next 15 minutes to allow the lubricant to seep into the chain.
Chain Adjustment
This section of the Owner’s and Service Manual addresses adjusting the SG250 motorcycle’s chain and
aligning the rear wheel.
You don’t have to get the rear wheel off the ground to adjust the SG250’s chain.
Adjusting the chain on a motorcycle consists of two jobs: Adjusting chain tension and aligning the rear
wheel.
You can check this adjustment easily, and you should perform this check on a regular basis. A lubricated
chain will require adjustment every 500 to 1000 miles once the motorcycle is broken in.
Adjusting the chain involves loosening (but not removing) the rear axle, loosening the adjustor nuts and
locknuts, using a screwdriver between the chain and the rear sprocket to remove all kinks, aligning the
rear wheel, tightening the rear axle, and tightening the adjustor nuts and locknuts.
25
SG250 Owner’s and Service Manual
If your chain requires adjustment, loosen the rear axle. The
rear axle is loosed by loosening the rear axle bolt and
nut. This photo shows the axle nut on the right side of the
SG250 motorcycle.
The left rear axle bolt head.
The rear axle adjustor nuts and locknuts are located behind
the adjustor plate on both sides of the swingarm. Loosen
both nuts on both sides of the swingarm.
The intent is to position and align the rear wheel such that the chain has 3/5 of an inch slack at its
midpoint. This is the amount of slack the chain should have with the motorcycle on the ground and
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 slack is
3/5 of an inch. If the rear wheel must move forward to increase chain slack, back off on the adjustor
nuts and locknuts and manually push the rear wheel forward. If the rear wheel must move rearward to
decrease chain slack, tighten the inner nuts as required on both sides of the swingarm to move the axle
to the rear.
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You should check the chain adjustment during your motorcycle’s first scheduled maintenance and at
every scheduled maintenance thereafter. The biggest adjustment will occur at the first service interval,
because chains do most of their stretching in their first several hundred miles of use. When the chain is
properly adjusted, it should have about 15mm (or 3/5 of an inch) slack at its midpoint.
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SG250 Owner’s and Service Manual
After moving the rear wheel, put a screwdriver between the
chain and the rear wheel sprocket (as shown below) and
sharply rotate the rear wheel. This will remove any kinks in
the chain. Note that this photo shows the TT250
motorcycle, but the procedure is the same for either the
TT250 or the SG250 motorcycle.
Check the alignment of the rear wheel by comparing the
scribe marks on the rear axle adjustors with the scribe marks
on the swingarm. This photo shows the right side of the
motorcycle and the scribe lines.
This photo shows the left side of the motorcycle and the
scribe lines.
You do not need to remove the rear axle to adjust the chain. Just loosen it and use the adjustor nuts to
move the wheel to its required location.
When the rear wheel is aligned and the chain slack is correct, tighten the rear axle to 35 ft-lb. Tighten
the rear axle adjustors’ positioning nuts, and then tighten the rear axle adjustors’ locknuts (the outer
nuts) to lock the adjustors in place.
Lube the chain every time it is adjusted. You can use either a wax-based or an oil-based chain lube; CSC
stocks both types. You can call us at 909 445 0900 if you need chain lube.
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Sprocket and Chain Inspection
The SG250 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 chain and sprockets will last much longer than they would if you
don’t maintain these items, but they still won’t last forever. You can expect the chain and sprockets to
wear more quickly if you ride in dusty environments or off road, or if you don’t lube the chain regularly.
Chains and sprockets should be replaced as a set. Do not replace one sprocket without replacing the
other or rapid wear will result.
27
SG250 Owner’s and Service Manual
Item
Symptom
Cause
Vehicle Effect
Maintenance Action
Rear
sprocket
Excessive wear
Inadequate lubrication,
misaligned rear wheel,
incorrect chain
adjustment
Chain skipping, chain
breakage
Replace chain and
both sprockets
Counter
shaft
sprocket
Excessive wear
Inadequate lubrication,
misaligned rear wheel,
incorrect chain
adjustment
Chain skipping, chain
breakage
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 sprockets
Excessive
tightness
Inadequate lubrication,
misaligned rear wheel,
incorrect chain
adjustment
Chain breakage, loss of
power, stiff rear
suspension
Adjust chain
Excessive
looseness
Improper adjustment of
chain’s tension
Chain skipping on
sprocket, excessive chain
slap
Adjust chain
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Remove the countershaft sprocket cover by removing the bolts that attach it to the engine. You don’t
have to remove the gear shift lever to remove the countershaft sprocket cover.
If the sprocket teeth are hooked or otherwise excessively worn, replace both sprockets. If the chain has
excessive stretch or if it has kinks that you cannot work out by manually rotating the links with respect to
each other, it’s time for a new chain.
The SG250 motorcycle chain does not have a master link. When you need to replace the original
equipment chain on your motorcycle, you have to cut it off.
Please call us at 909 445 0900 to order replacement chains and sprockets.
Chain Drive Troubleshooting
Troubleshooting and maintenance activities for the chain drive system are summarized in the table
below.
Chain Drive Troubleshooting and Maintenance
Clutch Maintenance
This section of the SG250 Owner’s and Service Manual addresses clutch cable installation, clutch
adjustment, and clutch replacement. Note that some of the photos in this portion of the Service Manual
show the TT250 motorcycle. The engines in the SG250 and TT250 motorcycles are identical.
28
Route the cable from the handlebar (without attaching it yet)
to the engine. Note that there is a loop welded on the left
front frame downtube through which you should route the
clutch cable.
Apply a small amount of grease to the lower clutch cable
attachment point and attach the lower end of the clutch
cable to the engine clutch arm. This is what it will look like
looking down at the attach point between the engine and
the 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 of the motorcycle as it can.
Pull back the handlebar clutch lever hood.
Clutch Cable Installation and Adjustment
SG250 Owner’s and Service Manual
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29
SG250 Owner’s and Service Manual
Screw the clutch lever adjustors into the clutch lever as far as
possible. After applying a small amount of grease to the
clutch cable barrel, route the clutch cable through the
adjustors and connect the clutch cable barrel.
After doing the above, position the handlebar clutch lever
adjustor so that the adjustor is in the middle of the
adjustment range. Note that there will still be considerable
slack in the clutch cable at this point.
Next, adjust the cable slack with the engine-mounted
adjustors. Use the adjustors shown here. Adjust these so
that there is approximately 3mm of slack on the handlebar
clutch lever.
Lock all the adjustor nuts (on the engine and on the handlebar clutch lever adjustor). Pull the rubber
adjustor hood over the adjustors at the handlebar clutch lever. All future 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.
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Clutch Replacement
If you change your oil regularly, if you use the right kind of oil, and if you don’t abuse your bike, your
clutch will last a long time. If you abuse your clutch it will wear prematurely. If the clutch is grabby or if
it slips and you can’t fix it by changing the oil or by adjusting the clutch, you need a new clutch.
Note that the photos in this portion of the SG250 Service Manual show the TT250 engine. The TT250
and SG250 engines are identical.
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