SR250S Owner`s Manual
Contents
1. Damage Damage 15 As long as disassemble to be replaced As long as disassemble to be replaced Minimum tread height 8mm Minimum thickness 1mm Chain adjuster bolts Air filter 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 m runt LINE Check the oil tube ageing if necessary should replace it see Figure 5 1 a Sixth Oil filter mesh Figure 5 1 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 16 FUEL LINES FUEL JOINT FUEL FILTER Figure 6 1 Figure 6 2 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 5bmm Eighth Cold start 17 Check the cold start grip if necessary lubricate IL check the cables if these are damaged replaced Ensure the cold start grip free travel in 2 3mm See the F2. 3 Elertrical 6 11 P34 4 Product warranty description P35 1 Resume Maintenance rules 1 3 Front wheel Suspension Handle description eseese 1 6 Brief 1 3 wheel Suspensiondescription 1 7 Lubrication system description 1 9 Battery Charging system 1 7 Fuel system description 1 6 Ignition system description 888 1 7 Cooling system description 1 6 Maintenance Regulation 1 Mustto 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 Should use the metric tool bolt nuts and screws to maintain vehicle it s not can be interchanged with British system If rebuild the vehicle should change the new gaskets O rings split pins and retainer rings 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 Dredge all the cables and wi
3. low water pressure to get rid of small insects mud or blockages if the air circulation restricted radiating over 20 should replace the radiator See Figure 12 1 Check the radiator pipe if it gets fissure or ageing if necessary with a new radiator replacement Check all of the water pipes clamps and hoops tightness See the Figure 12 2 5 4 RADIATOR HOSES mm ASE Beer Figure12 2 Figure 12 1 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 21 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 vm 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 038mm Figure 13 3 Exhaust valve side Put the feeler gague between the rocker arm stud and valve measure the exhaust side valve clearance Exhaust valve cleara
4. shift Primaryr reduction ratio 2 91 First gear 2 58 Second gear 1 8 Third gear 1 33 Fouth gear 1 1 Fifth gear 0 96 Sixth gear 0 88 DCDI Electric amp Kick 15s Lubrication system Engine lubricat oil capacity 1600ml Oil brand APL SJ SAE10W 40 Fuel system Oil brand 97 Capacity 8 0L Tank capacity 1 4L Cooling system Cooling liquid Replacement 1 11L capacity Disassembly 1 20L Recommended antifreeze Coolant or the same mass of ethylene glycol antifreeze Standard coolant concentration Mixed 1 1 with distilled water Front wheel Suspension Operate specification Cooling wheel pression 32 2 25 Psi Bar Rear wheel Suspension specification Cooling wes pression sean ____ _ maoa ___ _ Battery Charging system Capacity 12V 6Ah Battery Current consumption Max 0 1 Voltage 20 68 F Fully charged 13 0 13 2V Ignition system Items Description Spark plug Standard CHAMPION RG 6YC 2 Maintenance First tpa es 2 9 Fourteenth Engine oil oil 2 23 Second Technique maintenace 2 10 Fifteenth Engineidle speed 2 26 Third Racing technique maintenance 2 12 Sixteenth Drive 2 27 Fourth Frequently changed additional issues 2 14 Seventeenth Drive chain slider 2 27 Fifth Oil 555555555555 2 15 Eighteenth Drive ch
5. t check and adjust drive chain Review the middle of the chain measure the chain relaxation on this See Figure 16 Figure 16 Chain relaxation 25 35mm 5 0 mm 0 2 in Al Notes If chain relaxed too much 50mm more it will damage chassis Chain type 520 chain Seventeenth Drive chain slider Chain slider CHAIN SLIDER ge Check the drive chain slider to see if it s abraded Figure 17 1 Figure17 1 Maintenance limited 5 0mm from the top surface INSPECTION WINDOW CHAIN GUIDE RA HO Notes If chain slider was abrade the chain will abrade rocker destroy the chain and rocker Check the chain guide and slider to see if these are rank well abrade or damaged Figure17 2 28 Figure 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 Remove the side frame check the drive chain rotor to see if its excessed the wear or clamping stagnation Maintanace limited The minimum outside diameter of rotor 35mm If need to replace the rotor please screw the rotor bolts nuts to Figure18 the special torque this mark outward to install drive chain rotor Figure 18 Torque 12N m Nineteenth Drive driven sprocket Check the drive driven sprocket gear to see if these were wear or damaged If necessary replace it Figure 19 Don t install the new drive chain on the wear
6. LI 1 LL 1 t id foa O 3 LLL fnew wwie pisse 1 _ i 13 Front shock absorber Note 3 oil Nuts Bolts Fastener Wheels Tires Front tube bearing 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 3 If replace the clutch plate and baffle should replace the transmission oil Fourth Additional items should be changed frequently Engine Cylinder head gasket Leakage of a crush As long as disassemble to be replaced Clutch pressure plate Abrasion or rust 14 Head gasket Right side cover sealing Chassis Items Reason Remarks F R wheels F R Brake plate Assembly bolts on the frame Chain sliding plate Side guard plate Front covering parts Front and rear fender Clutch handle stay Brake handle Kick start bar Handlebar The throttle handle Grip Shift lever Leakage Damage Abrasion Abrasion Strain or abrasion Abrasion or damage Damage Damage Damage Excessive gap or damage Excessive gap or damage Excessive gap or damage Deformation or fissure Damage
7. 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 Don t ride when feel sick or take medicine Strickly prohibit drunk driving and driving without linence Be sure to wear the protective equipment 6 The driver must be adults over the age 18 2 In the drive 1 This vehicle not belongs to on road type please don t ride on the street 2 Keep a good mood and psychological qualities pay all attention on driving Reduce the rapid acceleration and suddenly brake times to prevent the emergencies 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 should be soft to avoid locking fall down company reserves it s rights to make changes due to product updates Introduction 1 seeees 2 7 2 Maintenance P8 P33
8. ain 2 28 Sixth Oll filter Screen 2 16 Ninteenth Active driven sprocket 2 28 Seventh Accelerator 0088 n8 2 17 Twentieth Brake fluid 2 29 Eighth Hot start 2 17 Twenty first Brake block 2 30 Nineth Air 2 18 Twenty second Brake system 2 30 Tenth Spark plug 2 19 Twenty third Rocker arm Vibration coupling 2 31 Eleventh Radiator 2 19 Twenty fourth 5 2 32 Twelfth Cooling system 2 20 Twenty fifth Front tube bearing 2 33 Thirteen Valve clearance Decompression device system 2 21 First Maintenance date Summary Before maintenance put motorcycle on the level ground Ensure the maintenance of a well ventilated environment Prepare the work table under the engine and tools 1 2 3 4 If exhaust system not cooling enough before to disaccemble spare parts or maintenance it will make a serious scald 5 Must replace the exhaust pipe gasket when take off exhaust pipe from Engine 6 Must check the exhaust system for leak after installition is complete Second Technique maintenance I Check and clean adjust if necessary lubricate or replace C Clean Replace A Adjust L Lubricate First time
9. e blocl wear Check the brake block to see if it was wear 3l If any one brake plate was wear to the wear limited mark bottom please replace the brake block Maintenance limited 1 0mm Twenty second Brake system Front brake hand lever inspection Loosing the locknut to roll the adjuster can adjust the front brake hand lever Rolling the adjuster on the clockwise direction to make the brake hand lever away from vehicle handbar Rolling the adjuster on anticlockwise direction to make the brake hand lever closed to the vehicle handbar When adjust over screw the locknut to special torque The touch surface of adjusting bolt and piston should add grease Torque 5 9N m Figure 22 1 If the brake hand lever free travel is exceed 20mm the air will enter this system it need to discharge Brake pedal height 32 LOCKNUT ADJUSTER LESS THAN 20 mm 0 8 in Figure 22 1 ADJUSTING BOLT 79 6mm LOCK NUT 9 Eg RE Figure22 2 Loosen the locknut and roll the pedal height to adjust bolt Adjust the brake pedal height to 79 6mm or what you need height Figure22 2 Twenty third Rocker arm rocker arm fork Put the support under engine make the rear wheel off ground Catch the rocker arm shaking left and right to check if there is something wrong with rocker arm bearing Figure 23 1 If bearing wear excessive replace a new one Inspect rocker arm fork replace all dama
10. el surface to ensure complete drainage clean Put an oil pan under the engine to access oil Remove the engine oil drain bolt and aluminum gasket Drop the engine oil completely Figure 14 4 After close the engine stop switch Kick the engine start lever 5 times or more times Figure14 4 25 This menthod can drop the engine oil completely Remowve the bolts oil filter cover and O Ring Figure 14 5 Remove the oil filter Figure14 6 Figure14 6 Install the engine oil drain screw use the special Torque 20N m to tightening the engine drain bolt Figure 14 3 26 Notes If install the oil filter anti direction it will seriously damage the engine Grease engine oil on the new O Ring Put it on the oil filter cover Install the oil filter cover Tightening the bolt Put the recommended machine oil enter engine Re check the engine oil level See Figure 14 1 ensure there is no leakage Fifteenth Engine idle speed Preheat the engine 10 minutes after use the correct method to check and adjust the idle speed put the gear in neutral righting the vehicle according to the specification to install the counter adjusting the bolt to make a suitable idling speed Figure 15 Idel speed 1500 100rpm PRAM yyy s Idling adjusting screw p Figure 15 21 Sixteenth Drive chain Drive chain relaxation tests Put the vehicle on the workbench make the rear wheel off ground When engine working please don
11. ge needle bearing It should disassemble when every time works 7 5 hours Clean inspect rocker arm and rocker arm fork center bearing and all of the related sealing element Add lubricant and reassemble Twenty fourth Wheels tires Put support under the engine make the front wheel off ground Catch the bottom of front brake shaking front wheel check if there is something wrong with the front wheel bearing Figure 24 1 Figure24 1 33 Catch the rocker arm shaking the rear wheel to check if there is something wrong with rear wheel bearing Figure 24 2 Inspect wheel to see if there is split nails or other damage Inspect the cold tires pressure carefully It should be measure when tires cold Figure 24 3 Tire pressure Front tire 32 2 25 Psi Bar Rear tire 32 2 25 Psi Bar 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 valve nuts Torque front wheel rim 3 68N m Rear wheel rim 3 7N m Cycle valve nut 13N m Figure 24 4 34 Twenty fifth Front tube bearing Put the support under engine make the front wheel off ground Inspect the direction hand lever to see if turning left and right flexible Ensure the main wire harness is not interference the direction hand lever rotation If the direction hand lever rotate not smoothly it has block or shaft radial pla please check the front tube bear
12. igure 8 1 tightening lock nuts and install the dust cover See the Figure 8 2 DUST COVER ADJUSTER Ji LOCK NUT 905985 8 2 Figure 8 1 AIR CLEANER ASSEMBLY Nineth Air Cleaner 23658 M 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 RETAINING BOLT ig BRE 18 AIR CLEANER ELEMENT AE be entered squeeze the excess oil Reinstall the air cleaner x zr E W L Notes Ifthe air cleaner assembly install incorrectness the dirt or dust will enter the engine causing the piston rings and cylinder early period abrasion HOLDER 2H fF 3c 2 MI RS RETAINING BOLT Squeeze S dz SEC Dry gt gt 227 Wash 5 non flammable Clean Foam Filter solvent Oil or equivalent TET T 3 BEL VIE E Mh FATA PHBE BY yF 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 n
13. ing If the activity clearance too large please check the direction column nut if the nut loose or there is a crack on the front tube 35 3 Electrical element diagram Front brake Rear 1 Side stand Gear switch Diode Clutch switch ight switch light switch Starting button Stop switch switch stop switch CDI coi sle 499 puo e To LILI CELE CLL l Blt 191 011 HHH E A uu o X MAARNECH L J Instrument gt gt gt AS 5222 22 18 __ Turn signal indication nim s Turn signal indication zu ly lanp indication QE 9 Rear turn signal 12 10 Front turn sip on SESH in signal lano Ox tt i BEN E Headlarp 12V 35v 39V Aad gt 24 24 4 Flasher Front position la 8 2 1 fo L A Horn Storting molor Starting relay Rectifier Magneto I2V 9 ET eie CI j e etrere 01 4 fel 11 191111 fet lee le Lighting switch Dimmer switch Horn button Turn signal switch ch 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 Because of th
14. is vehicle NC250 special performance from the purchase date it will be free to repair or replace the bad quality parts 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 cylinder body and one set of engine gaskets etc Quality guarantee description Cause of the non normal operate to result fault is not include quality guarantee if the fault need repair the company authorized service station will take a suitable parts charge 37 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 SHANDONG ASTAWING MOTORS CO LTD Address Taian City Shandong Province PC 271000 Tel 0538 6366706 6366708 Fax 0538 6366702 38 Packing list XM5 5 120 P _ This packing list page printed separated 39
15. nce 0 05mm Figure13 4 Figure 13 4 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 MEE SAE 20W 50 SAE 20W 40 SAE 10W 40 SAE 10W 30 0 20 40 60 80 100 Figure14 1 20 10 0 10 20 40 C Figure14 2 Recommended engine SJ 4 stroke oil containing the molybdenum additives or the similar higher lever engine oil JASO 903 Standard or MB Viscosity SAE 10W 40 24 Fuel capacity 1 6L Figure14 2 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 Motorcycle on a lev
16. o mess enter the combustor According to the technique maintenance Figure10 1 19 list to check and replace Check Check the following spare parts if necessary replacement If heat guard is damaged 1 electrode is abraded Combustion condition tinting II 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 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 20 Twelfth Cooling system Disassemble fuel tank and radiator fan blades and check the radiator fan blades if those are blocked or damaged Make the bending fan blades straight use compressed air or
17. ring harness 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 Length 2180mm Measurement width 830mm Chassis Height Wheelbase Seat height Minimum ground clearance Whole weight Material Front wheel size Rear wheel size Maximum power Rotate speed Maxmum torque Rotate speed Idle speed Minimum fuel consumption Bore X Stroke Displacement Compression ratio Intake type Lubricating system and pump type 1280mm 1486mm 960mm 310mm 135kg Alloy 80 100 21 110 100 18 or 110 90 19 25177 The type number remarks upper the left axle box Single cylinder 4 stroke water cooling 19 5 kw 9000 r min 23 N m 7000 r min 1500 100 r min x 367g kw h 77X53 6mm 249 6 ml 11 5 1 SOHC 4 valves Pressure splash Ignition advance angle Valve clearance cold Spark plug type Measurement Net weight Transmission type Clutch type Gearshift type Reduction ratio Electrical Ignition type equipment Starting system Starting performance BTDC 127 3000r min Intake valve 0 03 mm Exhaust valve 0 05mm CHAMR10N RG6YC 370mm 315mm 415 mm 30 kg Chain Manual Wet muiti plate Five gears international type two levels of transmission 6 gears
18. sprocket The chain and sprocket should be in good condition otherwise it Figure19 20 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 Twentieth Brake fluid Notes The spilling fluid will damage the color plastic or rubber parts When repair this system put some pieces of rag on these parts Don t mix the different types fluid because they not compatible ONERE e E uie e When add the brake fluid don t allow other things enter this system Fluid surface inspection When fluid surface lower check the brake block to see if this was wear The brake block wear will make the fluid surface lower If the brake block not wear but the fluid surface lower please check the system to see if this system leakage Figure 20 1 30 Front brake Turn the hand lever to make the inspection line with the fluid level at the same line check the front brake fluid level Figure 20 1 If the fluid level is closed to the horizontal line check the brake block to see if this was wear j M B Y ey gt n lt Er 2 Rear brake 4 Put the motorcycle upright on the horizontal line inspect the rear brake fluid level Figure 20 2 If the fluid level is closed to horizontal line please check the brake block to see if it was wear Figure20 2 Twenty first Brak
19. to Trip distance or Date Month c c Fule filter screen _ _ Note 1 o cep 1 pe e SERERE 10 Decompression device Coolant fluid Note 3 Secondary air system Transmission oil Drive chain 500 Or 3 months Per 500km Or 3 months ote 1 Nuts Bolts m m Chain slider Note 1 m KH e Fasteners 11 Ces oce Please go to our authorized dealers for repair unless the owners have special tools and maintenance of data and is qualified mechanic To be safe we recommend all of these items should go to our authorized dealers for repair Remarks 1 If driving on the wet and dusty road should maintain frequently 22 Repalce per 2 years with technique skill Third Racing technique maintenance Check all items before racing I Check and clean adjust if necessary lubricate or replace C Clean Replace A Adjust L Lubricate About 2 5 Abouy 7 5 About 15 0 About 22 5 About 30 IL _ L _ Crankcase breather pipe Dune 01 12 Coolant fluid Note 2 i Valve Decompression Note 4 device Duas Wes 1111 haw 1 0 1 LX LE Priston in SP LL Iw us a E IL CL
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