Barossa_motor_SANYANG_NCA250-WORKSHOP_MANUAL_ENGINE.pdf

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PREFACE
PREFACE
This shop manual describes the technical feature and
servicing procedures for the SANYANG NCA250.
All information, illustrations, directions and
specifications included in this publication are base on
SANYANG NCA250.
SANYANG reserves the right to make changes at any
time without notice and without incurring any
obligation whatever.
SANYANG INDUSTRY CO.,LTD.
SERVICE DIVISION
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CONTENTS
CONTENTS
GENERAL INFORMATION ..........................................................................1
INSPECTION/ADJUSTMENT.......................................................................2
LUBRICATION SYSTEM..............................................................................3
ENGINE REMOVAL/INSTALLATION ..........................................................4
CYLINDER HEAD/VALVE............................................................................5
CYLINDER/PISTON......................................................................................6
CLUTCH/OIL PUMP/GEAR SHIFT ..............................................................7
A.C. GENERATOR .......................................................................................8
CRANK SHAFT/CRANK CASE/TRANSMISSION .......................................9
CARBURETOR.............................................................................................10
HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ..........................11
REAR WHEEL/REAR SUSPENSION ..........................................................12
BATTERY/CHARGING SYSTEM .................................................................13
IGNITION SYSTEM.......................................................................................14
SWITCHES/HORN........................................................................................15
WIRING DIAGRAM.......................................................................................16
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1.GENERAL INFORMATION
SERVICE RULES ...............................1-1
SPECIFICATIONS..............................1-2
TORQUE VALUES ............................. 1-3
TROUBLE SHOOTING ...................... 1-4
SERVICE RULES:
(1)Use new packings, gaskets,O-rings and cotter
pins space and clipes whenever reassembling.
(5)Clean all removed parts in or with solvent, and
lubricate their sliding surfaces upon disassembly.
(2)When tightening bolts or nuts, begin on center or
larger diameter bolts and tighten them in criss-
cross pattern in two or more steps if necessary.
(6)Coat or fill parts with specified grease where
specified.
(3)Use genuine SANYANG parts and lubricants or
those equivalent. When parts are to be reused,
they must be inspected carefully to make sure they
are not damaged or deteriorated and in good
usable condition.
(7)Upon assembling, check every possible part for
proper installation and movement or operation.
(4)Use special tool when use of such a tool is
specified.
(8)Work safely and give your work your undivided
attention. Exchange signals as frequently as possi-
ble when a work involves two or more workers. Do
not run the engine unless the shop or working area
is well ventilated.
Symbol Marks:
:Apply engine oil.
NOTE: Things must be noticed.
CAUTION: Things that could cause damage to the
engine parts.
WARNING: Things that could cause damage to
the person or partner.
:Apply grease.
1-1
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1.GENERAL INFORMATION
SPECIFICATIONS
ITEM
NCA250
Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry weight
2180mm
960mm
1130mm
1480mm
160mm
175kg
DIMENSIONS
Type
Front suspension and travel
Rear suspension and travel
Front tire size and tire pressure
Rear tire size and tire pressure
Front brake
Rear brake
Fuel capacity
Fuel reserve capacity
Caster angle
Front fork oil capacity
Double pipe
Telescope 165mm
Swing arm 63mm
90/90-18 2.25Kg/C ꥏ
130/90-15 2.50Kg/C ꥏ
Disk
Drum
14 liter
2.0 liter
26 °
160c.c
FRAME
Type
Cylinder arrangement
Bore & stroke
Displacement
Compression ratio
Oil capacity
Intake valve opens
closes
Exhaust valve opens
closes
Valve clearance IN.
EX.
Idle speed
Air cooled 4 stroke O.H.C. engine
Double cylinders 15~ inclinde from vertical
53 x53mm
233.9c.c.
9.5:1
1.1 ~1.5 liter (1.3 liter for change)
0° BTDC
30 ° ABDC
35° BBDC
-5 ° ATDC
0.08mm
0.10mm
1500 rpm
ENGINE
Clutch
Transmission
Primary reduction ratio
Gear ratio I
II
III
IV
V
Final reduction ratio
Gearshift pattern
Wet muti-plate type
5-speed internationl
3.83
2.46
1.777
1.333
1.083
0.913
2.285
1 ꇺ N ꇺ 2 ꇺ 3 ꇺ 4 ꇺ 5
DRIVE TRAIN
Ignition system
Ignition timing "F" mark
Full advance
Starting system
Alternator
Battery capacity
Fuse
Spark plug
Spark plug gap
C.D.I. unit
BTDC 15° ꇀ 20° /1500rpm
BTDC 29.5° ꇀ 2° /4000rpm
Electrical motor starter
A.C. generator
12V 9AH
20A ꇁ 2/15A ꇁ 2/10A ꇁ 4
A6RTC
0.6~0.7mm
ELECTRICAL
1-2
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1.GENERAL INFORMATION
ENGINE
TIGHTEN LOCATION
Q'TY
THREAD DIA(mm)
TORQUE(kgf ꆤ cm)
Oil plate pan screw
Crank shaft bolt
Crank shaft nut
Cylinder head nut
Cylinder head cover
Cam shaft sprocket bolt
Crank case bolt
L crank case cover bolt
Fly wheel bolt
A.C.G. scocket bolt
Start motor bolt
R crank case cove bolt
Cam shaft holder nut
Primary drive gear nut
Oil pump flat bolt
Clutch lock nut
Shift durm stopper
Shift cam bolt
Cam chain adjuster screw
Drain oil bolt
Gear shift spindle bolt
3
5
1
3
2
2
10
7
1
3
4
10
8
1
3
1
1
1
1
1
1
6
8
7
6
6
7
6
6
10
5
6
6
8
16
6
16
6
6
6
12
8
80~120
180~220
70~110
80~120
80~120
80~120
80~120
80~120
400~500
50~70
80~120
80~120
180~220
400~500
80~120
400~500
80~120
80~120
80~120
150~250
100~150
FRAME
TIGHTEN LOCATION
Q'TY
THREAD DIA(mm)
TORQUE(kgf ꆤ cm)
Front wheel nut
Rear wheel nut
Rear fork pivot nut
Engine hanger nut
Handle pipe upper holder bolt
Steering stem nut
Front fork nut
Rear shock absorber
Rear brake torque link
Front fork top bridge
Rear fork bottom bridge
Final drive sprocket
Seat bolt
Drive sprocket bolt
1
1
1
3
4
1
1
4
1
2
2
4
2
2
14
14
14
10
8
22
22
10
8
7
8
10
8
6
600~800
1000~1200
800~1000
450~550
180~ 250
600~900
400~500
300~400
150~200
100~140
240~300
270~330
200~250
100~140
STANDARD TORQUE
TYPE
TORQUE(kgf·cm)
TYPE
TORQUE(kgf·cm)
5 mm bolt, nut
6 mm bolt, nut
8 mm bolt, nut
10 mm bolt, nut
12 mm bolt, nut
45~60
80~120
180~250
300~400
500~600
5 mm bolt
6 mm bolt
6 mm flange bolt, nut
8 mm flange bolt, nut
10 mm flange bolt, nut
35~50
70~110
100~140
240~300
350~450
1-3
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