Cleveland CycleWerks Misfit 250 Gen II User manual

1
© 2018 Cleveland CycleWerks
Cleveland CycleWerks Misfit 250 Gen II
REV.1 –2018-11-25
SERVICE MANUAL OHV 250

2
GUIDE TO THE MANUAL
GUIDE TO THE MANUAL
3
VEHICLE IDENTIFICATION
9
SPECIFICATIONS
10
TIGHTENING TORQUE
14
MAINTENANCE SCHEDULE
15
EMISSIONS CONTROL SYSTEMS
16
MAINTENANCE
18
SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALLATION
37
HEAD/CYLINDER
43
CLUTCH/ALTERNATOR/STARTER CLUTCH
53
CRANKCASE/TRANSMISSION/CRANKSHAFT
66
FUEL/AIR SYSTEM
82
FRONT WHEEL/STEERING
90
REAR WHEEL/SUSPENSION
115
BRAKES
126
IGNITION/STARTING SYSTEM
147
CHARGING SYSTEM/BATTERY
153
LIGHTING/HORN/INSTRUMENTS
156
WIRING SCHEMATIC
161
TROUBLESHOOTING
162

3
GUIDE TO THE MANUAL
Your personal safety, and the safety of those around you, is extremely important. Operating this
motorcycle safely is an important responsibility. Cleveland CycleWerks has provided operating
procedures and other information on labels in this manual to help you make informed decisions
about safety. This information will alert you to potential hazards that could harm you or others.
It is not practical or possible to warn you about all possible hazards associated with operating and
maintaining a motorcycle. You must use your own good judgment and common sense. In many
cases “common sense” seems to be less and less common. Please use solid judgment, do not
ride above your ability and respect the fact that you are a sack of water traveling through space at
a high rate of speed. Respect the bike, respect the terrain and use caution.
Safety information will come in a variety of different forms, including:
Safety Labels on the Motorcycle.
Safety Messages preceded by a safety symbol and one of these signal words below:
Sections of text in this manual, which are particularly important in terms of safety or possible
damage to the motorcycle are marked with the following symbols:
You CAN be KILLED or SERIOUSLY INJURED if you do not follow instructions.
You CAN be KILLED or SERIOUSLY INJURED if you do not follow instructions.
You CAN be INJURED if you do not follow instructions.
Safety Headings such as important safety reminders and/or precautions.
Safety Section such as motorcycle safety.
Instructions how to use the motorcycle properly and safely.
Safety Symbols

4
GUIDE TO THE MANUAL
Operating, servicing and maintaining a passenger vehicle can expose you to chemicals such as
lead, phthalates, engine exhaust and carbon monoxide that are known to the State of California
cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid
breathing exhaust, service your vehicle in a well-vented area and wear gloves or wash your
hands frequently when servicing your vehicle.
For more information go to:
www.P65Warnings.ca.gov/PassengerVehicle.
Proper service, maintenance and repair are mandatory to operate any motor vehicle safely.
Keeping your motorcycle in good operating condition is absolutely essential to your safety. It is
essential to ensure your motorcycles longevity. Proper maintenance will ensure you are achieving
maximum performance, avoid breakdowns, and will ultimately have more fun.
The service intervals in this manual are based on average riding conditions. More frequent service
is needed if you subject your motorcycle to severe use, or ride in unusually wet and dusty areas.
Frequent checks of the air cleaner are very important to help you avoid engine damage.
The information contained herein is valid at the time of printing. Cleveland CycleWerks reserves
the right to make changes required by the future development of the above mentioned products.
We do our best to verify the accuracy of this manual, but mistakes do happen, no liability is
accepted for mistakes during the drafting of this manual.
For your safety and reliability of your vehicle, use original
CLEVELAND CYCLEWERKS spare parts ONLY.
!!! DO NOT use the motorcycle or try to service it if you do not possess the
necessary skills, if you have never turned a wrench, please entrust your safety to a
motorcycle service professional!!!
Important Safety Precautions
This vehicle has a minimum age requirement of 16
Always wear necessary and properly fitting protective gear when operating this vehicle.
NOTICE
WARNING
Obtain, review and follow provisional/municipal government laws and regulations pertaining to
owning and operating an on-road vehicle before using this product

5
GUIDE TO THE MANUAL
Make sure the engine is off before you begin any maintenance or repairs. This will help eliminate
the following hazards:
1. Carbon Monoxide Poisoning From Engine Exhaust –Be sure you have adequate ventilation
whenever you operate the engine.
2. Burns From Hot Motorcycle Parts –Let the engine and exhaust system cool before you touch them.
3. Injury From Moving Parts –Do not run the engine unless your hands and body parts are clear from
danger or risk of injury.
Read all instructions before you begin a procedure. Make sure you have all of the tools and skills required.
To help prevent the motorcycle from falling over, park it on a firm, level surface, using the side stand or a
maintenance stand to provide support. To reduce the chance of a fire or explosion, be careful when
working around gasoline. Use only a non-flammable (high flash point) solvent such as mineral spirits to
clean parts. Keep cigarettes, sparks, and flames away from all fuel related parts.
Cleveland CycleWerks LLC., and our authorized Distributor are pleased to explain the emission
control system warranty on your Motorcycle. New motor vehicles must be designed, built and
equipped to meet the state and national emissions laws for which they are certified for. Distributor
must warrant the emission control system on your vehicle for 30 months or 5,000 km, whichever
comes first, provided that there has been no abuse, neglect or improper maintenance of your
vehicle.
Your emission control system includes the carburetor, the ignition system, catalytic converters and
engine control unit. Also included are hoses, connectors and other emission-related assemblies.
Where a warrantable condition exists, Distributor will repair your vehicle at no cost to you,
including diagnosis, parts and labor.
If an emission-related part on your vehicle is defective, the part will be repaired or replaced by
Distributor. This is your emission control system DEFECTS WARRANTY.
The following warranty applies to the noise control system and is in addition to the general
Cleveland CycleWerks Authorized Distributor warranty and the emission control warranty.
Cleveland CycleWerks Authorized Distributor warrants to the first, and each subsequent owner,
that the vehicle was designed and built so as to conform, at the time of sale, with the regulations
at the time of manufacture, was free from defects in materials and workmanship which would
cause the motorcycle not to meet the noise control system warranty extends for a period of six (6)
calendar months starting from the date of purchase. Same warranty applies to a demonstration
motorcycle or company motorcycle.
WE RECOMMEND THAT ONLY FACTORY GENUINE CLEVELAND CYCLEWERKS PARTS
BE USED FOR MAINTENANCE REPAIR OR REPLACEMENT OF THE NOISE CONTROL
SYSTEM.
Emissions Warranty
Noise Control System

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GUIDE TO THE MANUAL
If Non-Factory Genuine Parts are used
to repair your motorcycle,
warranty claims may be denied.
Owners are warned that the law prohibits:
(A)The removal or rendering inoperative by any person other than for purposes of maintenance,
repair or replacement, of any device or element of design incorporated into any new vehicle
for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it
is in use;
(B)The use of the vehicle after such devise or element of design has been removed or
rendered inoperative by any person.
Acts which are likely to constitute tampering include the following;
1. Removal or tampering with the muffler’s, baffles or header pipes or any other component,
which conducts exhaust gases.
2. Removal of or puncturing of any part of the air intake system.
3. Failure to carry out maintenance as prescribed in the owner’s manual.
4. Replacing any part of the exhaust or air intake system with parts other than those specified by
Cleveland CycleWerks.
The following items are not covered by the noise control system warranty;
1. Failures, which arise through misuse, alterations or accident damage.
2. Replacing, removing or modifications of any part of the noise control system (consisting of the
exhaust system and air intake system) with parts not certified to be noise legal for street use.
3. Cleveland CycleWerks Authorized Distributor shall not be liable for loss of use,
inconvenience, lost time, commercial losses or other incidental or consequential damages.
This motorcycle should be checked for repair or
replacement if the motorcycle noise has increased
significantly through use, otherwise the owner may
become subject to penalties under state and local laws
NOTICE
Tampering With Noise Control System

7
GUIDE TO THE MANUAL
As the motorcycle owner, you are responsible for the performance of the required maintenance
listed in your owner’s manual.
Cleveland CycleWerks recommends that you retain all receipts covering maintenance on your
motorcycle, but Cleveland CycleWerks Authorized Distributor cannot deny warranty solely for the
lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
You are responsible for presenting your motorcycle to a Cleveland CycleWerks dealer as soon as
a problem exists. The warranty repairs should be completed in a reasonable amount of time, not
to exceed 30 days.
As the motorcycle owner, you should also be aware that Cleveland CycleWerks Authorized
Distributor may deny you warranty coverage if your motorcycle or a part has failed due to abuse,
neglect, improper maintenance or unapproved modifications.
NOTICE! Use of any Cleveland CycleWerks brand vehicle in any type of competitive
event completely and absolutely voids this and all other warranties offered by Cleveland
CycleWerks Authorized Distributor.
If you have any questions regarding your warranty right and responsibilities, you should contact
Cleveland CycleWerks or Cleveland CycleWerks authorized Distributor.
A. Is designed, built and equipped so as to conform at the time of initial retail purchase with all
applicable regulations of the state and country in which they are authorized to be sold.
B. Is free from defects in material and workmanship which cause such vehicle to fail to
conform to applicable regulations.
C. Coverage: Warranty defects shall be remedied during customary business hours at any
authorized Cleveland CycleWerks dealer and/or service center. Any part or parts replaced
under this warranty shall become the property of Cleveland CycleWerks Authorized
Distributor.
. This Emission Control System Warranty shall not cover any of the following:
A. Repair or replacement as a result of
1. Accident(s)
2. Misuse
3. Repairs improperly performed or replacement parts improperly installed
4. Use of replacement parts or accessories which are not genuine Cleveland CycleWerks
replacement parts which adversely affect performance and/or
5. Use in competitive racing or related events.
B. Inspections, replacement of parts and other services and adjustments required for required
maintenance.
C. Any vehicle equipped with an odometer or hour meter on which the odometer mileage or
hour meter reading has been changed so that the actual mileage cannot be readily
determined.
Owner’s Warranty Responsibility

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GUIDE TO THE MANUAL
D. Limited Liability
A. The liability of Cleveland CycleWerks Authorized Distributor, under this
Emission Control System Warranty is limited solely to the remedying of
defects in material or workmanship by an authorized Cleveland CycleWerks
dealer at its place of business during customary business hours. This
warranty does not cover inconvenience or loss of use of the vehicle or
transportation of the vehicle to or from the Cleveland CycleWerks dealer.
CLEVELAND CYCLEWERKS AUTHORIZED DISTRIBUTOR SHALL NOT
BE LIABLE FOR ANY OTHER EXPENSES, LOSS OR DAMAGE,
WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY
ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY
TO USE THE CLEVELAND CYCLEWERKS VEHICLE FOR ANY PURPOSE.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE
LIMITATIONS MAY NOT APPLY TO YOU.
B. NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY
CLEVELAND CYCLEWERKS AUTHORIZED DISTRIBUTOR, EXCEPT AS
SPECIFICALLY SET FORTH HEREIN. ANY EMISSION CONTROL SYSTEM
WARRANTY IMPLIED BY LAW, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED
TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED
IN THIS WARRANTY. THE FOREGOING STATEMENTS OF WARRANTY ARE
EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES. SOME STATES DO NOT
ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE
ABOVE LIMITATIONS MAY NOT APPLY TO YOU.
C. No dealer is authorized to modify this Cleveland CycleWerks Authorized Distributor
Limited Emission Control System Warranty.
E. LEGAL RIGHTS. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU
MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
F. THIS WARRANT IS IN ADDITION TO THE CLEVELAND CYCLEWERKS AUTHORIZED
DISTRIBUTOR LIMITED ON ROAD VEHICLE WARRANTY.
G. ADDITIONAL INFORMATION. Any replacement part that is equivalent in
performance and durability may be used in the performance of any maintenance or
repairs. However, Cleveland CycleWerks Authorized Distributor is not liable for these
parts. The owner is responsible for the performance of all required maintenance.
Such maintenance may be performed at a service establishment or by any individual.
The warranty period begins in the date the motorcycle is delivered to an ultimate
purchaser.

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VEHICLE IDENTIFICATION
VIN –Chassis Number
The VIN number identifies the motorcycle. When placing
orders for spare parts, you may be required to provide
the VIN, engine serial number and the color of the
motorcycle.
The VIN number is located in one of three places on the
chassis.
1. Right side of frame on compliance sticker.
2. Left side of frame on compliance sticker.
3. Steering head tube right side of frame.
Engine Model & Serial Number
The engine model number and serial number is stamped
on the left side of the engine below the countershaft
sprocket.

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SPECIFICATIONS
Dimensions
Length
2150mm
Width
780mm
Height
1080mm
Wheelbase
1400mm
Seat height
770mm
Ground clearance
150mm
Curb/wet weight
144kg
Max capacity (not including vehicle weight)
180kg
Chassis
Seat
Rider/pillion seat with pillion strap
Removable pillion seat cover
Foot rests
Spring loaded rider foot rests
Folding pillion foot rests
Frame type
Tubular backbone, double cradle
High carbon steel
Rake
25 degree
Trail
114mm
Swing arm
Large diameter tubular arms.
Needle roller axial bearings
Needle roller side thrust bearings
Fork clamps
Billet CNC 6061 aluminum
Handle bar
7/8" Tubular steel
Handle bar clamp
Billet CNC 6061 aluminum black anodized
Stem bearings
Tapered needle caged bearings
25mm x 47mm x 15mm

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SPECIFICATIONS
Front suspension
Inverted forks, 38mm stanchions
Cartridge type damping
Shim stack valving for rebound and
compression
Fork seals 33 x 45 x 10.5
Rear suspension
Twin coil over, oil damped shocks
325mm length eye to eye
Spring pre load adjustable 5 stage
Rear wheel travel
90mm
Front wheel travel
110mm
Front wheel
2.50" x 18" steel
Front tire
Kingstone 100/90-18 tube type 6P.R. 62P
Max. load 583 lbs.
Max. load 265 Kg.
Tire pressure front
200kPa (29psi)
Front axle diameter
15mm
Rear wheel
2.75" x 18" steel
Full floating cush sprocket carrier
Rear tire
Kingstone 120/90-18 tube type 6P.R. 71M
Max. load 759 lbs.
Max. load 345 Kg.
Tire pressure rear
265kPa (38psi)
Rear axle diameter
17mm
Front brake
Single 320mm full floating wave rotor
4 piston radial mount caliper
Braided and bonded DOT stainless steel brake
hose
Rear brake
220mm wave rotor
2 piston slide caliper
Braided and bonded DOT stainless steel brake
hose
Engine
Type
CCWCG250
OHV single cylinder four stroke push rod
Air cooled
Counter balanced
Bore
67.0mm
Stroke
65.0mm
Displacement
229.0cc
Compression ratio
9.2:1
Maximum power
11.5 kW /15.4 HP @7000RPM
Maximum torque
16.0 N-m @6000 RPM
Maximum speed
8500RPM
Idle speed
1500±100RPM

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SPECIFICATIONS
Minimum fuel consumption
≤354g/kW-h
Starting
Electric and kick
Ignition type
CDI
Ignition advance
15° @1500RPM
Spark plug
DR8EA, DPR8EA-9, Torch D8TC
Spark plug gap
0.6-0.8mm
Intake Valve Open (BTDC)
10°
Exhaust Valve Open (BBDC)
40°
Intake Valve Closed (ABDC)
40°
Exhaust Valve Closed (ATDC)
10°
Intake valve clearance (cold)
0.08mm
Exhaust valve clearance (cold)
0.13mm
Clutch
Wet multi-plate
Clutch lever free play
3-5mm at ball end
Transmission
Constant mesh, five-speed
Primary Reduction 21/70
3.333
First gear ratio 11/32
2.909
Second gear ratio 15/28
1.867
Third gear ratio 19/25
1.316
Fourth gear ratio 23/23
1.000
Fifth gear ratio 24/20
0.833
Final drive
520 roller chain
Front sprocket
13T
Rear sprocket
36T
Fuel
Unleaded gasoline
Minimum fuel octane
87 (R+M/2), 95(RON)
Carburetor model 2016-2017
Sheng Wey PZ30 with accelerator pump
Main jet #98
Pilot jet #40
Needle #145S1
Mixture screw 2.5 turns
Float height 14mm
Carburetor model 2018
KF PZ30
Main jet #100
Pilot jet #38
Needle #K140+washer
Mixture screw 1.5 turns
Float height 14mm
Air filter
Stainless steel mesh (clamp filter)
Pleated paper element (air box)
Exhaust emission system
3 x three way catalyst in muffler
PAIR air injection
Engine lubrication
Pressure-splashed
Oil Pump Type
Inner/outer rotor

13
SPECIFICATIONS
Electrical
Battery
YTX9-BS AGM maintenance free
Battery capacity
12V /9 Amp/hour
Generator
Three-phase A.C. generator
Generator output
160 watts.
Main fuse
15A
Secondary fuse
15A
Headlight
H4 35/35W
High/low/passing
Brake/Tail light
12V 21/5W
Speedometer
Cable driven
Electronic stepper motor needle
LCD odometer/trip meter
Tachometer
Electronic stepper motor needle
Emergency lighting
Four way flasher
Side stand safety switch
Stops engine if driven with side stand down
Turn signal light
12V 21W
License plate light
12V 5W
Neutral indicator light
12V LED
High beam indicator light
12V LED
Turn signal indicator lights
12V LED
Capacities
Fuel tank capacity including reserve
15L
Engine oil capacity
1200ml
Engine oil
SAE10W-40, 15W-50, 20W-50
API SF/SG or SH/SJ with JASO MA
Fork oil capacity
270cc per fork
10W fork oil
Air gap level 115mm

14
TIGHTENING TORQUE
Chassis
Front axle
65N-m
Front axle pinch bolts M6 x 1.0
11N-m
Rear axle
65N-m
Rear axle adjuster nuts M8 x 1.25
20N-m
Swing arm pivot nut
65N-m
Rear shock nuts M10 x 1.25
39N-m
Front brake caliper bolt M10 x 1.25
39N-m
Rear brake caliper bolt M8 x 1.25
23N-m
Front brake rotor bolt M8 x 1.25
23N-m use thread lock
Rear brake rotor bolt M8 x 1.25
23N-m use thread lock
Engine mount bolts M8 x 1.25
23N-m
Engine mount bolts M10 x 1.25
39N-m
Steering stem top nut
65N-m
Steering stem bearing adjust nut
30N-m then turn back 1/4 turn
Handle bar clamp bolts M8 x 1.25
20N-m
Fork clamp bolts M8 x 1.25
20N-m
Fork cartridge bolt M10 x 1.50
39N-m
Fork top
20N-m
Rider footrest bolts M10 x 1.25
39N-m
Pillion rest bolt M10 x 1.25
39 N-m
Seat bolts M8 x 1.25
23N-m
Rear sprocket nut M8 x 1.25
23N-m use thread lock
Front sprocket retainer bolt M6 x 1.0
11N-m
Engine
Spark plug
18N-m
Oil filter screen cover
20N-m
Oil drain bolt M12 x
20N-m use a new aluminum crush washer
Valve clearance adjusting screw lock-nut
15N-m
Cylinder head nut M8 x 1.25
37N-m
Rocker arm holder bolts M8 x 1.25
23N-m
Cylinder base bolts M6 x 1.0
11N-m
Flywheel bolt M10 x 1.25
39N-m
Shift drum detent bolt M6 x 1.0
11N-m use thread lock
Clutch spring bolts M6 x 1.0
11N-m
Centrifugal oil filter nut M12 x 1.25
32N-m use 24mm OD nut tool
Crank case bolts M6 x 1.0
11N-m
Engine side cover bolts M6 x 1.0
11N-m
Exhaust nuts M8 x 1.25
23N-m
Kick starter bolt M8 x 1.25
23N-m

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MAINTENANCE SCHEDULE
Please use this guide as reference to the maintenance schedule mileage chart:
I = Inspect condition and clean, adjust, lubricate, or replace as necessary. Replace more
frequently under extreme conditions, heavy use, or in wet or dusty environment.
C= Clean
R = Replace
L= Lubricate
A= Adjust
*First Service is critical and required for Warranty.
Maintenance Schedule
Item
300 Mile/
500km First
Service *
Every
1800Miles/
3000km
Every
3600Miles/
6000km
Every
5400Miles/
9000km
Fuel Hose
I
I
I
R
Petcock Sediment Bowl
C
C
C
Fuel Cap and Gasket
I
I
I
I
EVAP Control System
I
I
Secondary Air System
I
I
Spark Plug
I
I
R
Valve Clearance
I/A
Engine Oil
R
R
R
R
Oil Filter Screen
C
C
C
C
Centrifugal Oil Filter
C
Air Cleaner
C
C
C
R
Throttle Adjustment
I
I
I
I
Carburetor Choke
I
I
I
I
Clutch
I
I
I
I
Idle Speed
I
I
I
I
Drive Chain
I/L
I/L Every 300 miles/ 500Km.
Battery
I
I
I
I
Brake Pad/Disc Wear
I
I
I
I
Brake Fluid
I
I
I
R
Headlight Aim
I
I
I
I
Brake Switches, Horn, Side
Stand Switch
I
I
I
I
Bolts, Nuts, Fasteners
I
I
I
I
Tire Pressure
I/A
I/A
I/A
I/A
Wheels, Spokes
I
I
I
I
Steering Head Bearings
I
I
I
A
Suspension
I
I
I
I

16
EMISSIONS CONTROL SYSTEMS
Secondary Air Injection System
Catalyst Exhaust
The pulsed secondary air injection system allows atmospheric air to enter the exhaust
system and mix with the exhaust gas to promote complete burning of excess
hydrocarbons. The pulsed air injection (PAIR) valve contains a one way reed valve and an
air cut diaphragm valve. During normal engine operation, negative pressure periods in the
exhaust head pipes draws fresh air through the one way reed valve into the exhaust.
During engine deceleration, manifold vacuum closes the diaphragm valve and prevents air
from entering the reed valve and the exhaust.
The exhaust system is equipped with metal substrate three-way catalysts to convert
pollutants in the exhaust gas to less toxic pollutants.

17
EMISSIONS CONTROL SYSTEMS
EVAP/ Crankcase Emissions Control System
The Cleveland CycleWerks motorcycle is equipped with an evaporative emissions control
system (EVAP) to prevent fuel and oil vapors from escaping into the atmosphere and
polluting the environment. Fuel vapors evaporating in the fuel tank and oil vapors from the
crankcase are collected in the charcoal canister when the motorcycle is not being ridden.
The vapors in the fuel tank are vented through the vent hose into the canister. During
normal operation of the motorcycle, vacuum from the intake manifold opens a diaphragm
valve to allow engine vacuum to purge the vapors collected in the canister to be burned in
the engine.
Combustion blow by and oil vapors generated in the crankcase during engine operation
are directed into the air box and therefore burned in the engine.

18
MAINTENANCE
Introduction
Routine maintenance of your motorcycle is required to keep it running well and keep it in top condition.
Lack of proper lubrication will let parts wear or rust prematurely; dirt or salt will harm paint and plated parts.
Washing your motorcycle when it becomes dirty will prevent dirt from abrading the paint and keep it looking
good. A mild sop with water is recommended. Oiled surfaces may be washed with an engine degreaser,
rinsed with plenty of water. Do not wash your motorcycle when hot, or in the direct sun. Soaps may harm
the finishes if it is allowed to dry on the motorcycle, rinse the motorcycle with water if the soap is drying. Do
not pressure-wash the motorcycle or spray direct water into the air filter, electrical connectors or air box.
The first service at about 300 mi /500 km is critical as this is when the engine is run-in and parts bed in.
All service procedures are recommended with the engine cool to the touch. Park the motorcycle on
the side stand on level firm ground or in a service stand. Motorcycle are heavy, do not take the risk
of having the motorcycle fall on you during maintenance!
Note: The service intervals are based on average riding conditions. Service the motorcycle more
frequently in harsh, dirty conditions or if the motorcycle is run hard.

19
MAINTENANCE
Maintenance Table of Contents
FUEL HOSES/FUEL FILTER
AIR FILTER
EVAP CONTROL SYSTEM
SECONDARY AIR INJECTION SYSTEM
THROTTLE OPERATION
SPARK PLUG
VALVE CLEARANCE
ENGINE OIL/OIL FILTER SCREEN
CENTRIFUGAL OIL FILTER
ENGINE IDLE SPEED
CARBURETOR CHOKE
DRIVE CHAIN
BATTERY
BRAKE SYSTEM
ELECTRICAL COMPONENTS/SIDE STAND SWITCH/LIGHTING SYSTEM
BOLTS/NUTS/FASTENERS
WHEELS/SPOKES/TIRES
STEERING HEAD BEARINGS
SUSPENSION
CLUTCH SYSTEM
20
21
21
22
22
23
24
26
28
29
29
30
32
32
34
34
34
35
35
36

20
MAINTENANCE
Fuel Hoses/Fuel Filter
1. Inspect the fuel hoses, petcock and carburetor for fuel leaks. Repair as necessary. All fuel
hoses should have a metal retaining clamp on each end. Fuel leaks are a fire hazard; do
not operate the motorcycle with a fuel leak.
2. The petcock features a sediment bowl on the bottom. Remove the bowl and clean of water or
dirt. Replace the bowl O-ring if it is damaged.
3. The fuel filter is a plastic screen inside the fuel tank. Excessive debris caused by poor fuel or
rust in the fuel tank may clog the fuel flow. If fuel flow is restricted, the tank may be removed,
drained of fuel and the petcock removed to clean or replace the filter screen as necessary.
See page 38 for fuel tank removal.
4. Replace the fuel hoses at 5400 mi /9000 km with the original fuel-resistant type.
Sediment bowl
Fuel filter