CSC SG250 Mode d’emploi

SG250 Owner’s and Service Manual

www.CSCMotorcycles.com

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

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

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

SG250 Owner’s and Service Manual

www.CSCMotorcycles.com

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.

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.

SG250 Owner’s and Service Manual

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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

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

SG250 Owner’s and Service Manual

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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

SG250 Owner’s and Service Manual

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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.

SG250 Right Side View

SG250 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.

SG250 Owner’s and Service Manual

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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

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.

Fork Lock

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.

Instruments

SG250 instrumentation includes a speedometer, a

tachometer, an odometer, a fuel gage, turn signal

indicators, a high beam indicator, and a gear

indicator.

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

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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