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Cleveland CycleWerks Misfit 250 Gen II Operator's Instruction Manual

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REV.2017-09-11
OPERATOR'S INSTRUCTION MANUAL
Cleveland CycleWerks Misfit 250 Gen II
SAVE THIS MANUAL FOR FUTURE REFERENCE
© 2017 Cleveland CycleWerks
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  • Page 1 REV.2017-09-11 OPERATOR’S INSTRUCTION MANUAL Cleveland CycleWerks Misfit 250 Gen II SAVE THIS MANUAL FOR FUTURE REFERENCE © 2017 Cleveland CycleWerks...
  • Page 2 Dear Customer, Thank you for choosing Cleveland CycleWerks. We know you have many choices of motorcycles that you could have chosen; your show of confidence in Cleveland is appreciated. Our designers, engineers and entire staff have placed a considerable amount of passion and knowledge into the development and manufacturing of the vehicle that you have chosen.
  • Page 3 Obtain, review and follow all laws and regulations pertaining to owning and operating a vehicle before using this product. Cleveland CycleWerks reserves the right to modify any equipment, technical specifications, colors, materials, services offered and rendered, and the like so as to adapt them to local conditions without previous announcement and without giving reasons, or to cancel any of the above items without substituting them with others.

  • Page 4: Table Of Contents

    CONTENTS IMPORTANT SAFETY INFORMATION CLUTCH MODIFICATIUONS IDLE SPEED ACESSORY INSTALLATION DRIVE CHAIN 37-39 FAMILIARIZE YOURSELF WITH THE VEHICLE BATTERY 40-41 SAFETY LABEL LOCATION BRAKE SYSTEM WARRANTY INFORMATION LIGHTING, HORN, SAFETY SWITCHES VEHICLE INDENTIFICATION NUTS, BOLTS. FASTENERS SERIAL NUMBER LOCATIONS WHEELS AND TIRES 12-13 COMPONENT LOCATIONS STEERING HEAD BEARINGS...

  • Page 5: Important Safety Information

    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.
  • Page 6 Even a crash at slow speed can result in a fatal head injury if you are not wearing a helmet. Cleveland CycleWerks strongly recommends wearing a helmet that has been certified for safety by helmet testing organizations that are independent from the helmet manufacturer.

  • Page 7: Modificatiuons

    Any modifications made to the motorcycle (alteration(s) and/or removal of components) can make the vehicle unsafe or unlawful. Modifying the motorcycle will immediately void the warranty offered and implied by your local distributor, and relieves Cleveland CycleWerks, and our distribution partners of any liability.

  • Page 8: Acessory Installation

    For this reason, the installation of any non-genuine accessory makes the warranty offered by your distributor void and relieves Cleveland CycleWerks and its distribution partner of all liability. FAMILIARIZE YOURSELF WITH THE VEHICLE The rider’s ability and their mechanical skills form the basis of riding safety.

  • Page 9: Safety Label Location

    Others will provide important safety and maintenance information. Please read them carefully and do not remove them. If your label wears off from riding or becomes hard to read, contact your Cleveland CycleWerks dealer for a replacement.

  • Page 10: Warranty Information

    All warranties are offered and have to go through the distributor in each respective country. Cleveland CycleWerks Distributor / Importer of Record, warrants that this product is free of defects in material and workmanship.

  • Page 11: Vehicle Indentification

    VEHICLE IDENTIFICATION SERIAL NUMBER LOCATIONS 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.

  • Page 12: Component Locations

    COMPONENT LOCATIONS COMPONENT OVERVIEW Adjustable Mirrors Fuel Cap Removable Seat Cowl Fuel Valve (Petcock): On / Off / Reserve Passenger Foot Pegs Horn Drive Chain Adjuster Engine Number Drive Chain Engine Oil Filter Side Stand Shift Lever Air Filter Underneath the Throttle Free Play Side Cover Adjuster...

  • Page 13: Handcontrols And Instruments

    COMPONENT LOCATIONS HAND CONTROLS AND INSTRUMENTS Trip Meter Odometer Tachometer Speedometer Front Brake Master Cylinder Clutch Free Play Adjuster & Reservoir Clutch Lever Front Brake Lever Headlight Flasher Switch Engine Stop / Run Switch Throttle Keyed Ignition Switch High Beam / Low Beam Switch Carburetor Choke Lever Engine Stop / Run Switch Horn Switch...

  • Page 14: Controls

    CONTROLS HANDLEBAR CONTROLS Choke Lever When the choke lever is forward, the choke is OFF. When the lever is in the rear position, the choke is ON. When pulled rearward, the butterfly valve in the carburetor is closed. The engine takes in additional fuel resulting in a rich fuel and air mixture ratio, which is needed for a cold start.

  • Page 15: Fuel Cap/Ignition/Fuel Valve

    CONTROLS FUEL CAP / IGNITION / PETCOCK Fuel Cap To Open: Insert ignition key and turn clockwise. To Close: Turn the key clockwise and push down on the cap, it should sit flush when closed completely. NOTE: Do not fill the gas tank to the top of the fuel cap.

  • Page 16: Foot Controls

    CONTROLS FOOT CONTROLS Foot Brake Pedal is located on the rider’s right side The brake Pedal of the motorcycle. Depress to apply the rear brake to slow or stop the motorcycle. Small adjustments to the height of the pedal may be made at the adjuster: Kick Start Lever The kick start lever is mounted on the right side of...

  • Page 17: Weight Capacity

    CONTROLS WEIGHT CAPACITY How much weight you put on your motorcycle, and how you load it, are important to your safety. Anytime you ride with a passenger or cargo, you should be aware of the following information. Maximum weight capacity: (Gross Vehicle weight Rating) GVWR 324Kg/ 714 lbs. Maximum weight capacity: 145kg.

  • Page 18: Before Riding

    BEFORE RIDING Before you ride, you must be absolutely sure that you and your motorcycle are ready to ride. To help you prepare, this section of the manual will discuss how to evaluate your riding readiness and how to perform our recommended pre-ride inspection of your motorcycle Are You Ready to Ride? Before you ride your motorcycle for the first time, we strongly recommend the following:...

  • Page 19: Pre Ride Inspection

    Brakes – Step on the rear brake pedal and pull in the front brake lever to be sure the brakes are working properly. Clutch – Check that the clutch lever disengages the transmission when pulled in towards the handle bar. Remember; be sure to correct any problems you find or have your Cleveland CycleWerks dealer correct it before you ride.

  • Page 20: Operation And Riding

    87 (AKI USA) / 91 (RON/EU) or higher for the best performance. Most service stations will display the octane rating above each pump. Cleveland CycleWerks recommends use of gasoline with an 87 (AKI USA) / 91 (RON/EU) or higher to ensure maximum performance and reliability.

  • Page 21: Running In A New Engine

    After the run in period (500miles/800km), a first service is required. This will include an oil change, inspection of the valve clearance, check of all adjustments and checking all fasteners for tightness. It is recommended that an authorized Cleveland CycleWerks Dealer perform this service. See the Inspection and Maintenance Schedule on page 27.

  • Page 22: Starting Procedure

    OPERATION & RIDING STARTING PROCEDURE Cold Starting Procedure 1. Turn the fuel valve (petcock) to the “ON” position. 2. Turn the key switch to the “ON” position 3. Be sure that the Stop switch on the right handle bar is in the RUN position. See Page 14. 4.

  • Page 23: Clutch And Shifting Gears

    OPERATION & RIDING CLUTCH AND SHIFTING GEARS This motorcycle has five (5) forward gears. After the engine has been warmed up and the side stand raised: 1. Close the throttle and pull in the clutch lever. This will disengage the transmission from the engine. 2.

  • Page 24: Braking Technique

    OPERATION & RIDING BRAKING TECHNIQUE (Good Road Conditions) To slow or stop the motorcycle, close the throttle and apply the front brake lever and rear brake pedal smoothly. To prevent the engine from stalling, always pull in and hold the clutch lever when slowing to a complete stop unless you are in neutral.

  • Page 25: Maintaining Your Cleveland Motorycle

    In this section you will also find important safety precautions, information on oils, and tips for keeping your Cleveland CycleWerks motorcycle in top shape. The service intervals in this section 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.

  • Page 26: Maintenance Schedule

    Cleveland CycleWerks dealer. If you decide to do your own maintenance, use only genuine replacement parts that you have purchased from a Cleveland CycleWerks distributor/dealer or parts purchased directly from Cleveland CycleWerks.

  • Page 27: Maintenance Schedule

    MAINTENANCE SCHEDULE Maintenance Schedule 300 Mile/ Every Every Every Item 500km First 1800Miles/ 3600Miles/ 5400Miles/ Service * 3000km 6000km 9000km Fuel System Fuel Cap and Gasket EVAP Control System Secondary Air System Spark Plug Valve Clearance Engine Oil Oil Filter Screen Centrifugal Oil Filter Air Cleaner Throttle Adjustment...

  • Page 28: Maintenance

    MAINTENANCE This section gives instructions for maintaining your motorcycle in top condition. FUEL SYSTEM 1. Inspect the fuel hoses, petcock and carburetor for fuel leaks. Repair as necessary. All fuel hoses should have a metal retaining clip on each end. Fuel leaks are a fire hazard; do not operate the motorcycle with a fuel leak.

  • Page 29: Spark Plug

    MAINTENANCE SPARK PLUG 1. Before removing the spark plug for inspection, clean any dirt from around spark plug base. Do not allow dirt or debris to fall into the engine. 2. Disconnect spark plug cap and remove the spark plug. 3.

  • Page 30: Valve Clearance

    MAINTENANCE VALVE CLEARANCE Valve clearances should be inspected and adjusted on a cool engine. The fuel tank may be left in place. Valve clearance inspection and adjustment 1. Remove the valve cover on top of the engine. It is held on by three screws. Wipe off any dirt or oil on the rubber gasket and the gasket surface of the engine.
  • Page 31 MAINTENANCE VALVE CLEARANCE 4. Measure the clearance between the valve tip and the adjuster screw with a feeler gauge. Intake should be 0.08mm, exhaust should be 0.13mm. If the clearance is too tight or loose, loosen the lock nut and adjust the screw. Tighten the lock nut to 15N-m, and measure the clearance again.

  • Page 32: Engine Oil

    MAINTENANCE ENGINE OIL Engine Oil Recommended: API classification SG or higher except oil labeled as energy conserving on the circular API service label JASO T 903 Standard MA SAE 20W- 50 The chart below indicates oil for regular air temperatures. Please use this oil/air temperature chart to help you choose the best oil for your climate.

  • Page 33: Checking & Adding Oil

    MAINTENANCE CHECKING & ADDING OIL Your motorcycle oil level can be checked by either the oil fill cap (dipstick) or by the inspection window. 1. The engine must be warm to properly check the oil level. If the engine is cold, start and run the engine at idle for 3-5 minutes, and then turn off the motor.

  • Page 34: Changing Oil & Cleaning Oil Filter

    MAINTENANCE CHANGING OIL & CLEANING OIL FILTER Changing the oil 1. Place an oil drain pan under the Oil filter screen engine. Retention spring 2. Remove the oil drain bolt and crush washer from the bottom of the motor. 3. Remove the oil filter screen cover, screen and retention spring.

  • Page 35: Air Filter

    MAINTENANCE AIR FILTER 1. Motorcycles equipped with a clamp-on screen air filter may have the filter removed and cleaned with a low flash-point solvent. 2. Motorcycles equipped with an airbox may have the filter element removed for service. If dirt is light, the pleated paper type element may be cleaned with compressed air.

  • Page 36: Carburetor Choke

    MAINTENANCE CARBURETOR CHOKE Choke inspection Note: Inspection of the carburetor choke system is important for the proper running of the engine. Choke enables the motorcycle to cold start more easily, yet excessive use of the choke will cause carbon fouled spark plugs, poor fuel mileage, and excessive exhaust emissions.

  • Page 37: Clutch

    MAINTENANCE CLUTCH A small amount of free play is necessary in the clutch cable to allow the clutch to fully engage. A clutch cable with no free play may allow the clutch to slip during riding and cause wear and overheating of the clutch plates.

  • Page 38: Drive Chain

    MAINTENANCE DRIVE CHAIN Before the drive chain is serviced, be sure the motorcycle is parked on a level surface and the engine is turned OFF. Be sure the transmission is in neutral. It is not necessary to remove or replace the chain to perform recommended maintenance service. Chain inspection 1.
  • Page 39 MAINTENANCE Chain slider inspection Chain slider minimum thickness 2mm Inspect the chain slider for wear. Minimum thickness is 2.0mm. Replace if worn down to minimum thickness. Chain adjustment Follow the procedure below to adjust the drive chain slack. Be sure that the motorcycle is parked on a level surface and the engine is turned OFF.

  • Page 40: Battery

    MAINTENANCE BATTERY The Misfit is equipped with an Absorbed Glass Mat (AGM) maintenance free battery. The battery electrolyte (acid) is filled at the time of battery commission and is not serviceable. Do not attempt to open an AGM battery and fill with electrolyte. Battery inspection/charging Remove the seat and check that the battery terminal bolts are tight and the cables not loose.
  • Page 41 MAINTENANCE Brake fluid inspection/filling-rear 1. Remove the right side motorcycle cover to access the rear brake fluid reservoir. Brake fluid level should be between the LOWER level and the UPPER level. Fluid should be a clear color. If the fluid is yellow or brown, this indicates that the fluid is contaminated and needs to be changed.

  • Page 42: Lighting, Horn, Safety Switches

    MAINTENANCE LIGHTING, HORN, SAFETY SWITCHES Inspect the functioning of the following electric components:  Headlight high beam, low beam, pilot (parking) lamp.  Turn signals, front and rear. Turn indicator light in the instruments.  Emergency (hazard) flasher, front and rear. ...

  • Page 43: Wheels And Tires

    Remember:  Replace the inner tube anytime you replace a tire.  Have the wheel balanced after a new tire has been installed.  We recommend getting tires replaced by your Cleveland CycleWerks dealer or a qualified local motorcycle shop.

  • Page 44: Steering Head Bearings

    MAINTENANCE STEERING HEAD BEARINGS Inspection and Adjustment Stem nut Tighten to 65N-m Stem adjustment nut Tighten to 45N-m, turn back ¼ turn. Fork clamp bolts Tighten to 23N-m 1. Support the motorcycle in a paddock stand or motorcycle service lift with the front wheel off the ground 2.

  • Page 45: Suspension

    MAINTENANCE SUSPENSION Loose, worn or damaged suspension components may affect the stability and handling of the motorcycle. Suspension Inspection Front 1. Check the fork operation by pulling in the front brake lever and holding it to lock the front wheel. 2.

  • Page 46: Troubleshooting

    TROUBLESHOOTING Before troubleshooting a problem, read and understand the operation of your motorcycle. Read the following sections: Controls Page 10 Before Riding Page 12 Operation and Riding Page 21 Maintenance Schedule Page 30 Maintenance Page 33 ENGINE DOES NOT START Engine will not crank (turn over) ...
  • Page 47 TROUBLESHOOTING Engine will crank (turn over) but will not start:  Cold engines require the choke to be ON to start. (Look at the carburetor and verify that the choke lever is UP).  Warm engines will foul the spark plug if run with the choke on, check that the choke is OFF (Lever is DOWN on the carburetor) ...

  • Page 48: Engine Starts But Runs Poorly

    TROUBLESHOOTING Check compression:  Crank the engine with the kick starter. (Spark plug in) You should feel a strong resistance as the engine spins past the compression stroke. This will indicate sufficient compression to start the engine. If strong compression is felt, and the engine still will not start, this may indicate clogged carburetor jets, problems with the cam timing, ignition timing, or other mechanical faults.

  • Page 49: Clutch Transmission

    TROUBLESHOOTING CLUTCH/TRANSMISSION Clutch slips:  A slipping clutch is indicated by engine speed increasing but not a corresponding road speed increase. Verify that there is free play in the clutch cable. The clutch lever should free for the first 3-5mm when pulled in, and then a stronger resistance as the clutch plates are disengaged.

  • Page 50: Electrical

    This may be a problem that needs attention, have your Cleveland CycleWerks dealer inspect the brakes and pads.  Inspect the rotor for galling. If the rotors are damaged or out of specification, they may need to be replaced.

  • Page 51: Dealing With The Unexpected

    Sometimes crash damage is hidden or not immediately apparent. Once you get home, go over your motorcycle thoroughly and fix any problems that you find. Also, be sure to have your Cleveland CycleWerks dealer inspect the frame and suspension after a serious crash.

  • Page 52: Dead Battery

    DEALING WITH THE UNEXPECTED DEAD BATTERY If the key is left ON after parking the Motorcycle, the battery may be jumped with a car battery to get the engine running. Remove the seat to access the battery. Proceed with caution when using jumper cables to avoid sparks.

  • Page 53: Specifications

    SPECIFICATIONS Dimensions Length 2110mm Width 780mm Height 1080mm Wheelbase 1400mm Seat height 775mm Ground clearance 150mm Curb/wet weight 144kg Max capacity (not including vehicle weight) 145kg 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...
  • Page 54 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-H18 tube type 6P.R. 62P Max.
  • Page 55 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 Rear sprocket Fuel Unleaded gasoline Minimum fuel octane 87 (R+M/2) 95(RON) Carburetor model KF PZ30...

  • Page 56: Fastening Torque

    FASTENING TORQUE Fastener torque Front axle 65N-m Rear axle 65N-m Swing arm pivot nut 65N-m Engine mount bolts M8 x 1.25 23N-m Steering stem top nut 65 N-m Steering stem bearing adjust nut 45 N·m then turn back 1/4 turn Fork clamp bolts M8 x 1.25 23N-m Front axle pinch bolts M6 x 1.0...

  • Page 57: Wiring Schematic

    WIRING SCHEMATIC...

  • Page 58: Maintenance Schedule Record

    MAINTENANCE SCHEDULE RECORD Odometer Reading Odometer Reading Odometer Reading Km/Miles Km/Miles Km/Miles Dealer Stamp Dealer Stamp Dealer Stamp Date Date Date Signature Signature Signature Odometer Reading Odometer Reading Odometer Reading Km/Miles Km/Miles Km/Miles Dealer Stamp Dealer Stamp Dealer Stamp Date Date Date Signature...

  • Page 59: Notes

    NOTES...

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