NC250 Motorcycle Maintenance Guide
NC250 Motorcycle Maintenance Guide
0
User’s Safety Statement
Dear customer, please don’t ride the motorcycle before you are not reading this handbook or unknown this
motorcycle performance, also don’t borrow to anybody who don’t know how to use.
Driver’s attention:
1、Before driving
1 Check motorcycle condition careful,don’t ride if get ill; ②Don’t ride when feel sick or take medicine;③Strickly prohibit drunk driving and
2 Keep a good mood and psychological qualities, pay all attention on driving; ③Reduce the rapid acceleration and suddenly brake
3 Should slowly when driving detour road to prevent skid(Prohibit use the front brake,otherwise the vehile will easy to fly out) ;
⑥ When rainy or snowin, the ground friction is small and brake distance will be longer,the vehicle should be slowly and brake operation
1
The company reserves it’s rights to make any changes due to product updates。
Introduction
1、Resume………………………………………………………………………………………P 2~P 7
2、Maintenance…………………………………………………………………………………P8~P33
1、Resume
2
Maintenance Regulation
1. Must to use this company or this company recommend spare parts or lubricants;Not to suits to this company designing
parts or lubricants ,may damage the vehicle .
2. Should use the metric tool, bolt, nuts and screws to maintain vehicle, it’s not can be interchanged with British system.
3. If rebuild the vehicle should change the new gaskets, O-rings, split pins and retainer rings.
4. When tighten bolts and nuts,first starting with the big diameter or from the inner bolts. And then increase the number of
steps by diagonal unless specified special order to tighten to the specified torque.
5. After decomposition,should clean the spare parts in the cleaner solvent; lubricating every smooth surface before
assembly .
6. After assembly,check all spare parts installation and operation, if all these are right.
7. Dredge all the cables and wiring harness.
8. Please go to our authorized dealers for repair, unless the owners have special tools and maintenance of data and is a
qualified mechanic.
Brief (Technical specification) : Motorcycle running-in period is 1000km, then at the range of 1000Km, the speed
should not exceed 50km/h.
It e m s De s c r i p t i o n
Le n g t h 21 8 0 m m
Me a s u r e m e n t
wi d t h 83 0 m m
3
He i g h t 12 8 0 m m
Wh e e l b a s e 14 8 6 m m
Se a t he i g h t 96 0 m m
Mi n i m u m gr o u n d cl e a r a n c e 31 0 m m
Wh o l e we i g h t 13 5 kg
Ma t e r i a l Al l o y
Ch a s s i s Fr o n t wh e e l si z e 80 / 1 0 0 - 2 1 ’’
Re a r wh e e l si z e 11 0 / 1 0 0 - 1 8 ’’ or 11 0 / 9 0 - 1 9 ’’
Type ZS177 ( The type number remarks upper the left axle
box )
Single cylinder, 4-stroke, water-cooling
Maximum power / Rotate speed 19.5 kw / 9000 r / min)
Maxmum torque / Rotate speed 23 N.m /(7000 r / min)
En g i n e Idle speed 1500±100 r/min
Minimum fuel consumption ≤367g/kw.h
Bore×Stroke 77×53.6mm
Displacement 249.6 ml
Compression ratio 11.5:1
Intake type SOHC、4 valves
Lubricating system and pump type Pressure splash
4
Ignition advance angle BTDC 12° [3000r/min]
Valve clearance(cold) Intake valve: 0.03 mm
Exhaust valve: 0.05mm;
Spark plug type CHAMR10N RG6YC
Measurement 370mm×315mm×415 mm
Net weight 30 kg
Transmission type Chain
Clutch type Manual、Wet muiti-plate
Gearshift type Five gears international type, two levels of transmission 6
gears shift
Primaryr reduction ratio:2.91
First gear:2.58
Reduction ratio
Second gear:1.8
Third gear:1.33
Fouth gear:1.1
Fifth gear:0.96
Sixth gear:0.88
El e c t r i c a l Ignition type DCDI
eq u i p m e n t Starting system Electric & Kick
Starting performance ≤15 s
5
Lu b ri cati o n syst em
It e m s
En g i n e lu b r i ca t oi l ca p a c i t y 16 0 0 m l Oi l br a n d : APL SJ SAE10W-40
Fu el syst em
It e m s De s c r i p t i o n
Oil brand 97#
Ca p a c i t y 8. 0 L
Tan k ca p a c i t y 1. 4 L
Co ol i ng syst em
It e m s De s c r i p t i o n
Co o l i n g li q u i d Re p l a c e m e n t 1. 11 L
ca p a c i t y Di s a s s e m b l y 1. 2 0 L
Re co m m e n d e d an t i f r e e z e Co o l a n t or th e sa m e ma s s of et h y l e n e gl yc o l an t i f r e e z e
St a n d a r d co o l a n t co n c e n t r a t i o n Mi x e d 1: 1 wi t h di s t i l l e d wa t e r
6
Fro n t wh eel /S usp en si on / Oper ate sp eci fi cati o n
It e m s St a n d a r d Ma i n t e n a n c e li m i t e d
Co o l i n g wh e e l pr e s s i o n 32 / 2 . 2 5 ( Ps i / B a r ) -
Ma x lo a d 45 5 / 2 0 6 ( Lb s/ K g s ) -
7
Ig ni t io n syst em
It e m s De s c r i p t i o n
Sp a r k pl u g St a n d a r d CH A M P I O N RG 6Y C
2. Maintenance
First: Maintance date………………………………2-9 Fourteenth: Engine oil/oil filter………2-23
8
Tenth: Spark plug………………………2-19 Twenty-third: Rocker arm/Vibration coupling……2-31
9
Second: Technique maintenance
I:Check and clean,adjust,if necessary lubricate or replace C:Clean R:Replace A:Adjust L:Lubricate
Frequency First
No matter which one time to Trip distance or Date
Items maintain
first Minutes 100 600 1200 1800 2400
received Kilometers 150 1000 2000 3000 4000
Note Month 1 6 12 18 24
* Oil-way I I
* * Fule filter screen C C
10
* Accelerator I I
Air filter (Note 1) C C C C
Crankcase
(Note 2) I I I I
breather pipe
Spark plug I I I I
* Air valve I I I I I
Machine oil R R R R R
Oil filter R R R R R
Decompression
* I I I I I
device
* Idling I I I I I
Coolant fluid (Note 3) I R
* Cooling system I I I I I
Secondary air
* (Note2) I I
system
Transmission oil R R R R R
Drive chain (Note 1) I,L I,L:Per 500km Or 3 months
Chain slider (Note 1) I I,L:Per 500km Or 3 months
Brake fluid (Note 3) I I I I
11
Brake block I I I I
Brake system I I I I I
* Lights I I
Clutch system I I I I I
Side stay I I
* F/R damping I I
Nuts 、 Bolts 、
* I I I
Fasteners
* * Wheels/tires I I I I I
* * Front tube bearing I I I
9. * Please go to our authorized dealers for repair, unless the owners have special tools and maintenance of data and is a
qualified mechanic.
* *To be safe,we recommend all of these items should go to our authorized dealers for repair .
Remarks: 、If driving on the wet and dusty road ,should maintain frequently .
(1)
(2)、Repalce per 2 years with technique skill.
12
Items Frequency About 2.5 Abouy 7.5 About 15.0 About 22.5 About 30
Notes
hours hours hours hours hours
Accelarator I
Choke valve I
Air filter (Note 1) C
Crankcase breather
I
pipe
Spark plug I
Coolant fluid (Note 2) I
Valve/Decompression
(Note 4) I
device
Machine oil (Note 3) I R
Oil filter (Note 3) R
Idling I
Piston and piston rings R
Piston pin R
Cooling system I
Drive chain I,L R
Chain slider I
13
Drive chain rotor I
Active/driven sprocket I
Brake fluid (Note 2) I
Brake block I
Brake system I
Clutch system (Note 5) I
Control cable I,L
Exhaust pipe/Silencer I
F/R Damping I
Rear fork/ Rocker arm L
Front shock absorber
(Note 3) R
oil
Nuts、Bolts、Fastener I
Wheels/Tires I
Front tube bearing I
This maintenance schedule is base on the driving average condition.The vehicle must be checked according to this
maintenance list .
Remarks: 1、First time to riding in the dirty environment should clean the vehicle .
2、Should check the vehicle after the first time no-race ride .
14
3、If replace the clutch plate and baffle ,should replace the transmission oil .
15
Front and rear fender Damage
Clutch handle/stay Excessive gap or damage
Brake handle Excessive gap or damage
Kick start bar Excessive gap or damage
Handlebar Deformation or fissure
The throttle handle Damage
Grip Damage
Shift lever Damage
Brake pedal Damage
Chain adjuster/bolts Damage
Air filter Damage
Notes:
·These spare parts and maintenance list are base on the average riding environment
·Vehicle must be checked strictly according to the user manual .
Fifth: Oil tuble
Check the oil tube ageing,if necessary should replace it, see Figure 5-1
Figure 5-1
16
Sixth: Oil filter mesh
Disassemble fuel tank: first drop the oil into container, remove the tubing,bolts and oil switch, then clean the oil filter ,ensure
the O-ring in a good condition and install it to oil switch ,re-install in reverse order with the disassemble, install the fuel
tank (Make sure there is no leakage after installation). See Figure 6-1, Figure 6-2
Figure 6-1
Figure 6-2
17
Seventh: Accelerator operation
Check the throttle grip, it should be rotate smoothly and freely return; Check the throttle cable, if it’s ageing or damage
should be replaced; If throttle operate not smoothly should lubricate the cable;The free rotation distance of adjust throttle
grip is in 3-5mm.
Check the cold start grip, if necessary lubricate it ; check the cables,if these are damaged, replaced ;Ensure the cold
start grip free travel in 2-3mm( See the Figure 8-1),tightening lock nuts and install the dust cover ( See the Figure 8-2 )
18
Nineth: Air Cleaner
Open the air cleaner side cover, remove the retaining bolts.Remove the
filter element from bracket, put it into clean cleaner to wash, and then get it
from that cleaner to the hot soup-sudz to wash; Clean the air filter inner room
to ensure there is no mess; When the air cleaner and filter are completely dry,
put filter to the special filter oil, use hand rubbing the filter ensure the oil can
be entered, squeeze the excess oil.Reinstall the air cleaner.
Notes: If the air cleaner assembly install incorrectness, the dirt or dust
will enter the engine causing the piston rings and cylinder early period abrasion.
19
Tenth: Spark plug
Disassembly
Disassemble fuel tank, remove the spark plug cover from cylinder head,
disassemble spark plug,and check it to see if it is damage (See Figure 10-1).(Before
disassemble,use the compression air to clean the spark plug, ensure there is no mess
enter the combustor.) According to the technique maintenance list to check and replace.
Check
Check the following spare parts, if necessary replacement.
Figure10-1
·If heat guard is damaged
·If electrode is abraded
·Combustion condition、tinting;
If electrode was contaminated by carbon or other dirt,please replace the spark plug.
Rrcommended spark plug : Standard CHAMPION:RG6YC
In order to prevent damage the center electrod, use the feeler gaugeto check the spark plug clearance. Don’t adjust
thespark plug clearance. If the clearance exceed the standard, with a new spark plug replacement .
Spark plug clearance standard:0.65mm
Installation: usd hand screw the spark plug to cylinder head,and then screw the spark plug to the specified
torque. Torque:22N.m
Eleventh: Radiator coolant
20
Check the coolant level before start the engine or after the engine flameout 5 minutes, if can’t see the liquid
surface,please add the recommended coolant;
Remove the cover, add the mixed liquid which mixed with distilled water and antifreeze 1:1,the distance from liquid
surface to cover is 5-10mm, then install the radiator cover .
Recommended antifreeze: coolant liquid or the same qulity ethylene glycol antifreeze containing silicate
preservatives .
Figure12-2
Figure 12-1
21
Thirteenth: Valves clearance
Check valves clearance
Disassemble cylinder head cover; check and adjust the valve clearance after the engine is cooled;
Disassemble crankcase cover and O-ring.(See the Figure 13-1)
Figure 13-1
Rotating the magnator mark on clockwise direction to make it with the left crankcase cover scale mark on the same line,
ensure the piston on the compression stroke top dead center.
Otherwise,rotating the crankshaft one whole circle on the clockwise direction,and make the magnator mark with the left
crankcase cover scale mark on the same line again ;
Check the cam sprocket indicatrix, make it with the camshaft bracket“_”mark on the same line(Figure13-2)
Figure 13-2
22
Intake side:
Put the feeler gague between the rocker arm stud and valve, measure the
intake side valve clearance
Intake valve clearance : 0.03mm (Figure 13-3) Figure13-3
Rotating the crankshaft a few times on the clockwise direction,make the crankshaft to piston compression top dead
center,check the valve clearance .
Put the O-Ring on the crankshaft timing screw with oil( check the O-Ring,if necessary with a new O-Ring replacement),
Put the grease on Crankshaft hole cap thread .
Install the crankshaft hole cap and screw it to the special torque.
Torque:15N.m
23
Fourteenth:Engine oil / oil filter
Oil surface inspection
Starting engine idling 3 minutes, waiting 3 minutes after the engine flameout .
Put the motorcycle vertical support in the horizontal plane, if the oil horizontal plane is low or close to the low level of the
oil ruler line, through the filling hole add the recommended engine oil to a third above the horizontal line.(Figure14-1)
Figure14-2
Figure14-1
Recommended engine oil:API SJ
4-stroke oil containing the molybdenum additives or the similar higher-lever
engine oil
JASO T 903 Standard:MA or MB Figure14-3
Viscosity:SAE 10W-40
Fuel capacity:1.6L(Figure14-2)
24
Figure14-4
Engine oil and oil filter replacement
Remove the engine cover,
Starting engine idling 3 minutes,
Waiting 3 minutes after engine flameout.
put motorcycle vertical support in the horizontal plane,
Stop the engine,
Remove the oil nut off(Figure 14-3)
25
Remove the bolts, oil filter cover and O-Ring( Figure 14-5 )
Figure14-6
Remove the oil filter(Figure14-6),
Install the engine oil drain screw, use the special Torque 20N.m to tightening the engine drain bolt(Figure 14-3).
Notes:If install the oil filter anti-direction,it will seriously damage the engine,
26
Grease engine oil on the new O-Ring,
Put it on the oil filter cover,
Install the oil filter cover
Tightening the bolt.
Figure 15
27
Sixteenth: Drive chain Figure 16
Drive chain relaxation tests
Put the vehicle on the workbench, make the rear wheel off
ground .
( When engine working, please don’t check and adjust drive
chain)
Review the middle of the chain, measure the chain relaxation on this. (S e e Fi g u r e 16 )
Chain relaxation:25-35mm
Notes:If chain relaxed too much, 50mm or more,it will damage chassis.
Chain type:520 chain
Figure17-1
Seventeenth: Drive chain slider
Chain slider
Check the drive chain slider, to see if it’s abraded.(F i g u r e 17 - 1 )
Maintenance limited:5.0mm from the top surface
Notes:
If chain slider was abrade, the chain will abrade rocker, destroy the
Figure17-2
chain and rocker.
Check the chain guide and slider, to see if these are rank well 、abrade
28
or damaged.
(F i g u r e 17 - 2 )
If damaged or abraded,replace the chain guide.
If the slider was wear to the special wear marker bottom,replace the chain guide slider.
Eighteenth: Drive chain rotor
Figure18
Remove the side frame, check the drive chain rotor, to see if
it’s excessed the wear or clamping stagnation.
Maintanace limited:
The minimum outside diameter of rotor:35mm
29
Don’t install the new drive chain on the wear sprocket.
The chain and sprocket should be in good condition,otherwise it will wear the new chain quickly.
Check the bolts and nuts on the drive and driven sprockets.
If there is any loose, tighten them.
Torque:drive sprocket bolts:31N.m
Driven sprocket nuts:32N.m
Rear brake:
Put the motorcycle upright on the horizontal line, inspect
the rear brake fluid level.
Figure20-2
(Figure 20-2)
If the fluid level is closed to horizontal line, please check
the brake block, to see if it was wear.
31
Twenty-first: Brake blocl wear
Check the brake block ,to see if it was wear.
If any one brake plate was wear to the wear limited mark bottom, please replace the brake block .
Maintenance limited:1.0mm
Figure22-2
32
enter this system, it need to discharge.
33
Catch the bottom of front brake, shaking front wheel, check if there is something wrong with the front wheel bearing;
(Figure 24-1)
Catch the rocker arm, shaking the rear wheel to check if there is
something wrong with rear wheel bearing.,
(Figure 24-2) Figure24-2
Check all of the rims and spokes, to see if there were damage
(Figure 24-4)
According to the special torque to screw all of the loose rims and cycle
Figure 24-4
34
valve nuts.
Torque: front wheel rim:3.68N.m
Rear wheel rim:3.7N.m
Cycle valve nut:13N.m
35
3、 Electrical element diagram
36
4、 Maintenance Warranty instruction
Dear user:
Thanks for using our vehicle NC250 type, in order to protect your benefits, please read this manual instruction and according to it to
use.
After-sale service
1. Because of this vehicle NC250 special performance, from the purchase date,it will be free to repair or replace the bad quality
parts.
2. Specific to this product using performance, the main quick-wear parts are not include to the maintenance range, the detail
quick-wear parts information as follows: out/inner tires、spoke、chain、chain upper/down slider、wire roll pull、hand lever
grip、lights、plastic parts、air filter、oil tube、water tube、clutch、fuel filter、spark plug、piston、piston ring、piston pin、
cylinder body and one set of engine gaskets etc.
1. Cause of the non-normal operate to result fault is not include quality guarantee, if the fault need repair, the company or
authorized service station will take a suitable parts charge.
37
2. User should comply with this manual to maintain 、 replace the quick-wear parts on schedule, if don’t do like this, all of the
damage will not include the free after-sale service; User should on schedule to maintain and the service station should record the
maintanace report actually, if don’t have this report, it’s not suit to the warranty condition.
38
Packing list
NO. Name Quantity Remarks
1 Handbar 1 Set
2 Front wheel assy 1 Set
3 Packing list detail:
(1) Battery 1 Piece
(2) Battery cable tie 1 Piece
(3) Headlamp assy 1 Set
(4) Headlamp install bolts 1 Set
(5) Rear lamp assy 1 Set
(6) Front brake shield 1 Pair
(7) Front brake shield install bolts 1 Set
(8) Tank cover(Left/Right) 1 Set
(9) Rear cover(Left/Right) 1 Set
(10) Appearance parts install bolts 1 Set
(11) Tool:Spark plug sleeve 1 Pcs
(12) Sticker 1 Set
39