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Cleveland CycleWerks Misfit 250 Gen II, Service Manual

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Cleveland CycleWerks Misfit 250 Gen II Service Manual Download Page 80

 

 
 

80 

CRANKCASE/TRANSMISSION/CRANKSHAFT  

 

 

3. 

Install the 

3 x transmission forks

 into their 

grooves on the slider gears. The fork 
diameters will match the gear grooves, and 
all of the shift drum pins will be facing 
towards the shift drum location. 

 
 
 
 
 
 
 

4. 

Install the 

shift drum

 into the case. The 

shift forks will need to be moved to the side 
to allow the shift drum to drop down into 
the case. 

 
 
 
 
 
 

 

5. 

Align the 

fork pins

 into the 

drum grooves

 

and install the 

fork shaft

.  

 
 
 
 
 
 
 
 
 
 

6. 

Install the 

oil pump assembly

 in the right crank case 

as shown with a new gasket. Tighten the 

2 x M6 bolts 

to 11N-m.  

 
 
 
 
 

 

Fork shaft 

Fork pins 

Transmission 

forks installed 

in grooves 

Shift drum 

Move the shift forks to 

the side to allow the 

shift drum to drop in 

Tighten the 2 x M6 

bolts to 11N-m 

Summary of Contents for Misfit 250 Gen II

Page 1: ...1 2018 Cleveland CycleWerks Cleveland CycleWerks Misfit 250 Gen II REV 1 2018 11 25 SERVICE MANUAL OHV 250...

Page 2: ...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 REA...

Page 3: ...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 variet...

Page 4: ...s 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 con...

Page 5: ...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...

Page 6: ...ing 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 spe...

Page 7: ...tact 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...

Page 8: ...EM 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 FO...

Page 9: ...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...

Page 10: ...llion 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 tu...

Page 11: ...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 brak...

Page 12: ...09 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...

Page 13: ...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...

Page 14: ...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 Fr...

Page 15: ...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...

Page 16: ...lve 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...

Page 17: ...rom 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...

Page 18: ...arm 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 electrica...

Page 19: ...PARK 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 SYSTE...

Page 20: ...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...

Page 21: ...ment may be cleaned with compressed air Excessive air pressure will break down the fibers and clog the paper Do not use excessive air pressure Large amounts of dirt will require that the filter elemen...

Page 22: ...e throttle cable for free movement without binding Lubricate as necessary The throttle should close fully by itself when released Frayed kinked or rusted cables require replacement 2 Check that free p...

Page 23: ...d and rectify the running condition 4 Check the spark plug gap The spark plug gap should be 0 6 0 7 mm Always check the gap of a new spark plug before installation 5 Ensure all dirt has been cleaned f...

Page 24: ...the engine to be rotated easily 3 Remove the left side engine timing cap and crankshaft inspection cap Rotate the engine forward at the crankshaft counterclockwise as viewed from the left side of the...

Page 25: ...osen the lock nut and adjust the screw Tighten the lock nut to 15N m and measure the clearance again Tightening the lock nut may alter the final clearance so always measure again after the lock nut is...

Page 26: ...SO MA MA is Japanese Automotive Standards Organization 4 stroke motorcycle grade The chart below indicates recommended oil weight for common air temperatures Cleveland CycleWerks recommends 20W 50 ful...

Page 27: ...y 4 Clean the oil filter screen with a low flash point solvent 5 Reinstall the oil drain bolt with a new crush washer Tighten to 20N m 6 Reinstall the oil filter screen retention spring O ring and cov...

Page 28: ...ng surfaces of the cover and engine case Do not allow any gasket material to fall into the engine 4 Remove 3 x Phillips head screws and remove the centrifugal oil filter cover 5 Scrape off bulk contam...

Page 29: ...M 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 chok...

Page 30: ...e 20 mm 2 Inspect the drive chain for the following damaged rollers dry or rusted links kinked or binding links and excessive wear Replace a chain with excessive stretch or damage 3 Lubricate the driv...

Page 31: ...slack Push the wheel forward to be sure that the adjuster bolts are touching the swing arm 4 Make sure the right and left side are aligned the same Tighten the axle nut to 65N m Tighten the lock nuts...

Page 32: ...ge the battery The battery may be charged at a rate of between 0 5 2 0A h at a voltage of 13 8 14 5 volts to properly charge the AGM battery Inspect the battery for acid leaks corroded terminals or ot...

Page 33: ...and dry Any spilled fluid must be cleaned immediately 4 Add DOT 3 or 4 brake fluid to the reservoir until the UPPER level is reached DO NOT OVERFILL 5 Replace the diaphragm and cap Brake Pad Rotor Wea...

Page 34: ...tion will stop the engine if the transmission is in gear Check the following chassis fasteners for tightness Front and rear axle nuts Front and rear engine mount bolts Swing arm pivot bolt Fork clamp...

Page 35: ...d 2 From the front grasp the forks and turn the steering assembly from side to side and pull front to back The side movement should be smooth with no binding There should be no perceived front to back...

Page 36: ...ooth suspension action 2 Check the shock absorber for a bent damping rod or any oil leaks 3 Check the shock nuts for tightness 4 Check the swing arm bolts for tightness 5 Push the rear wheel from side...

Page 37: ...e parts Clean a dirty engine before disassembly Dirt and mud may be washed off with soap and water Oil and chain lube may be washed off with a water solvent engine degreaser or contact cleaner Park th...

Page 38: ...moval Tighten the 2 x M8 seat bolts to 23N m 1 Close the fuel valve Remove the fuel hose from the fuel valve petcock 2 Remove the 2 x M6 rear tank mount bolts 3 Lift the fuel tank up and to the rear t...

Page 39: ...round cables from the engine 3 Unplug the spark plug cap from the spark plug 1 Remove the front exhaust mount nuts 2 Remove the rear exhaust mount bolt and pillion rest bracket 3 Carefully lift off th...

Page 40: ...the battery box and move the battery box slightly to the rear inside the frame Unbolt the air box from the frame and move slightly to the rear inside the frame 3 Remove the choke cable 4 Unscrew the...

Page 41: ...removal 7 Support the front of the engine with a suitable wood block 8 Remove the front engine mount brackets 8 x M8 bolts in frame and 2 x M10 bolts in engine 9 Remove the 2 x M10 rear engine mount b...

Page 42: ...en to 39N m 3 8 x M8 engine bracket bolts tighten to 23N m 5 Install and adjust the drive chain shift lever and sprocket cover See page 30 6 Carburetor installation is the reverse of removal See page...

Page 43: ...ings and gears Gasket surfaces may not seal if damaged or if they have remaining old gasket material on them Do not use sealant on gaskets sealants are not required and may leave excess material insid...

Page 44: ...lve cover 3 x M6 bolts and spark plug 2 Remove the left crankshaft inspection plug and timing cap Rotate the engine forward counterclockwise as viewed from the left until both valves are closed This w...

Page 45: ...worn or damaged parts 6 Remove the 4 x M8 cylinder stud nuts and washers and the M8 bolt with copper washer and lift off the head Remove any gasket material from the head surface Do not scratch or dam...

Page 46: ...r or pitting Replace the valves if wear or damage is present The valve faces are hard coated and cannot be reground 12 Before inspecting the head decarbonize the combustion chamber and valve seats wit...

Page 47: ...through gaps will indicate that valves may be bent valve faces are worn or that the valve seats are worn 14 Measure the free length of the inner and outer valve springs Replace the springs if under th...

Page 48: ...act cleaner and blow dry with compressed air 4 Inspect the piston pin for wear galling or bluing indicating a need for replacement Insert the pin into the connecting rod it should move freely and have...

Page 49: ...r clearance wear limit is 0 25mm 1 Install the piston rings onto the piston Install the oil control spring ring first do not allow the ends to overlap The oil scraper rings are installed one above and...

Page 50: ...f the 2 x 10mm locating dowels over the cylinder studs Oil the cylinder bore with engine oil before installation Do not use force guide the piston rings into their grooves with a small screwdriver as...

Page 51: ...with engine oil and install into the guide Compress the valve springs with a valve spring compression tool and install the 2 x collets Verify that the collets are seated into the spring top after the...

Page 52: ...m follower arms will both be in a lowered position Install the 2 x push rods into the cam follower cups If the push rods fall into the cylinder they may be retrieved with a magnet 4 Install the rocker...

Page 53: ...oil Gasket surfaces may not seal if damaged or if they have remaining old gasket material on them Do not use sealant on gaskets sealants are not required and may leave excess material inside the engin...

Page 54: ...emove the13 x M6 bolts fastening the cover 2 Remove the right side engine cover Remove the cover gasket and any gasket material on the cover or crankcase Do not allow any material inside the engine Do...

Page 55: ...il filter housing cover nut and washer with solvent Inspect for galling of the oil through pipe and be sure that the pipe moved smoothly in the cover If the cover gasket is damaged replace 1 Lift out...

Page 56: ...ive notching wear on the tabs Replaced if scored or worn excessively 6 Inspect the 6 x metal clutch plates for scoring warping or bluing indicating a need for replacement Measure the thickness of the...

Page 57: ...ation is in the reverse order of disassembly Locate the detent on the shift drum with the locating pin on the drum Install the M6 bolt with medium strength blue thread lock Tighten to 11N m 5 Install...

Page 58: ...onto the clutch center Lubricate all plates with engine oil before assembly Alternate the metal and fiber plates during installation starting with a fiber plate against the clutch center Align the tab...

Page 59: ...p drive chain and sprocket onto the oil pump Fasten the sprocket with the M6 nut tighten the nut to 11N m Install the chain guard and fasten with the 2 x M6 bolts tighten to 11N m 2 Install the centri...

Page 60: ...against the spring pressure during installation Verify that the 2 x 10mm locating dowel pins are present in the crankcase Fasten with the 13 x M6 bolts Tighten the bolts progressively to 11N m The clu...

Page 61: ...gear cover shaft and thrust washers Inspect the O ring replace if damaged 3 Unbolt the 2 x M6 bolts fastening the starter motor and extract the starter motor to the right Inspect the O ring replace i...

Page 62: ...retainer and remove the spring 2 Extract the camshaft spindle and thrust washer from the left Lift out the camshaft Inspect the camshaft bushing for galling or excessive wear Inspect the cam lobe for...

Page 63: ...ing UP 5 Install the camshaft spindle retainer and spring Fasten with the M6 bolt Tighten to 11N m 1 Inspect the starter clutch outer for cracks The one way sprag clutch cams should allow the gear to...

Page 64: ...th thread lock and tighten the bolts to 23N m 1 Install the flywheel and starter clutch onto the crankshaft Align the key tighten the M10 bolt to 39N m Install the starter gear set with a thrust washe...

Page 65: ...Tighten the bolts to 11N m 4 Install the reduction gears and shaft with the 2 x thrust washers against the gears Lubricate the parts with engine oil before installation Position the locating pin into...

Page 66: ...excess material inside the engine that may clog oil passages Lubricate all parts with engine oil during assembly Replace the following with new parts upon assembly of the crankcase Crankcase gasket A...

Page 67: ...balance gear may be left installed to separate the cases 3 The cases may be separated If the cases do not separate easily small blows with a plastic dead blow hammer on the crank and transmission shaf...

Page 68: ...t solvent Clean all bearings with solvent and inspect for free turning without excessive wear 8 Clean the crankshaft and bearing with low flash point solvent Inspect the crankshaft for galling or heat...

Page 69: ...ssembly if the wear limit is reached 5 Measure the side clearance as shown with a feeler gauge and straight edge Standard 0 05 0 10mm Wear limit 0 15mm Replace the pump as an assembly if the wear limi...

Page 70: ...cks or damage to the gear teeth Inspect for galling or heat damage to the fork grooves Inspect the dogs for damage The stationary gears must spin freely and the slider gears must move side to side wit...

Page 71: ...tion the sharp edges towards the 4th gear 6 Install a spline washer onto the main shaft 7 Install main shaft 5th gear onto the main shaft Position the dogs towards 4th gear 8 Install main shaft gear 2...

Page 72: ...ter shaft gear 4th 22T 6 Spline washer 7 Circlip 8 Counter shaft gear 3rd 25T 9 Thrust washer 16 7 x 23 8 x 0 5 10 Bush 20 0 OD 11 Counter shaft gear 1st 32T 12 Bush 19 5 OD 13 Starter Idler Gear 14 T...

Page 73: ...circlip away from counter shaft gear 4th 7 Install slider counter shaft gear 3rd onto the counter shaft Position the gear teeth away from 4th gear 8 Install thrust washer 16 7 x 23 8 x 0 5 onto the c...

Page 74: ...sh 19 5 OD onto the counter shaft 13 Install the starter idler gear onto the counter shaft 14 Install thrust washer 15 2 x 29 8 x 1 0 onto the counter shaft The kick starter assembly may be disassembl...

Page 75: ...Ratchet piece 7 Circlip 8 Thrust washer 20 3 x26 8 x 0 5 9 Gear 10 Kick starter shaft 11 Conical washer 12 Return spring 13 Split collar 14 Thrust washer 16 2 x 29 8 x 1 0 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 76: ...shaft Position the arm around the boss as shown 7 Install the thrust washer 16 3 x 23 8 x 1 0 onto the shaft 8 Install the circlip into the shaft groove Position the sharp edges of the clip away from...

Page 77: ...kick starter shaft Insert the spring end into the shaft hole 12 Install the split collar onto the shaft Position the notch towards the gear 13 Install thrust washer 16 2 x 29 8 x 1 0 onto the shaft Co...

Page 78: ...pring to hook the case as shown 15 Position the return stop boss as shown 16 Locate the arm in the groove as shown Grip the shaft with locking pliers to aid case installation on the crank case The sha...

Page 79: ...sure that the bearing is seated fully into the case with no binding The crankshaft bearing should drop in with no force 2 Pair the two transmission shafts with gears and washers together during insta...

Page 80: ...e case The shift forks will need to be moved to the side to allow the shift drum to drop down into the case 5 Align the fork pins into the drum grooves and install the fork shaft 6 Install the oil pum...

Page 81: ...ce when all of the shafts and the shift drum are aligned Be sure that the cases seat fully before bolting together 8 Hand thread all crankcase bolts to be sure that the case gasket is aligned correctl...

Page 82: ...ty and to meet exhaust emissions standards to reduce air pollution Improper storage of the motorcycle water contamination or contaminated fuel may require the carburetor to be serviced to regain prope...

Page 83: ...attery box slightly to the rear inside the frame Unbolt the air box from the frame and move slightly to the rear inside the frame 8 Remove the choke cable 9 Unscrew the carburetor top and remove the t...

Page 84: ...s from the battery box and lay aside to the left of the frame 10 Remove the 4 x M6 battery box bolts and withdraw the battery box to the rear as shown 11 Disconnect the carburetor to air box rubber co...

Page 85: ...ring 2 Float bowl Remove the three screws 3 Float Push the float pin out to remove the float and float needle 4 Main jet emulsion tube and needle jet Press the needle jet down from the top 5 Pilot jet...

Page 86: ...ish or debris A small wire may be needed to clear blocked passages Do not enlarge the jet bores when cleaning 3 Clean the carburetor float bowl with cleaner and a soft brush Be sure that there is no l...

Page 87: ...mine the Viton float needle tip replace the needle if the tip is damaged Be sure that the float needle plunger is free to move and returns to the extended position when depressed 1 Install the needle...

Page 88: ...number of turns See Specifications page 12 4 Hold the float together with the float needle into position in the carb body The float needle retainer wire wraps around the float adjusting tab Install th...

Page 89: ...ocate the slide groove into the pin in the carb body Screw down the cap Carburetor installation is the reverse of removal See page 40 Inspect the manifold and carburetor mounting O rings for damage re...

Page 90: ...too tight or too loose may cause a crash in which the rider may be injured or killed Motorcycles are heavy do not take the risk of having the motorcycle fall on you during service Park the motorcycle...

Page 91: ...REMOVAL STEERING STEM DISASSEMBLY STEERING STEM FORK CLAMP ASSEMBLY CABLE ROUTING Front Wheel Removal 1 Support the motorcycle in a service stand and raise the front wheel 2 Unfasten the speedometer c...

Page 92: ...ension 4 Small adjustments to wheel true may be made by re tensioning the spokes large dents in the wheel rim require wheel replacement Front Fender Installation Install the front fender stays and fen...

Page 93: ...b on the right fork 2 Apply a thin film of grease to the axle prior to installing Install the front axle and nut Tighten the nut to 65N m Tighten the 4 x M6 axle pinch bolts to 11N m Spin the front wh...

Page 94: ...n the fork cap before removing from the fork clamps Loosen the top clamp bolt cover the fork cap with tape to protect the aluminum Loosen one turn 3 Loosen the two lower fork clamp bolts and remove th...

Page 95: ...pring and cartridge rod 2 Hold the cartridge rod nut to unscrew and remove the fork cap 3 Pull down on the spring and spring guide to remove the rod nut 4 Remove the spring guide and spring 5 Drain th...

Page 96: ...separate the fork The seals and fork bushes will be retained on the lower fork tube Several strikes may be required to separate the fork 9 Resume draining the fork oil from the cartridge into a tray 1...

Page 97: ...way more than 30 of the sliding area Oil seals must be replaced in all cases of disassembly Fork tubes may be rotated to check for bends Cartridge rod action must be smooth with no binding Fork Parts...

Page 98: ...thread lock Temperature measurements may be taken with an infrared thermometer Fork lower will be HOT Wear protective gloves to handle the fork 4 Use a steel rod 8mm x 200mm to press the lower tube fr...

Page 99: ...p from the cartridge tube with an impact gun 8 Remove the cartridge rod from the cartridge tube The rebound valve is installed on the cartridge rod 9 Remove the M6 bolt on the lower fork cap to disass...

Page 100: ...r All shims must lay flat check on a surface plate Inspect piston seal for excessive wear or damage Cartridge Internal Parts Identification 1 Cartridge rod 2 Shim collar 3 Check spring 4 Check shim 19...

Page 101: ...away from the shim stack 7 Install the M6 lock nut onto the cartridge rod Tighten to 11N m Check that the check shim moves freely and is held against the piston when at rest 8 Install a piston seal on...

Page 102: ...is away from the piston 8 Apply medium strength thread lock to the bolt install the valve assembly onto the lower fork cap Tighten to 11N m Check that the check shim moves freely with no binding A pic...

Page 103: ...l the cartridge into the lower fork tube Tighten to 20N m 2 Apply two beads of medium strength blue thread lock to the lower fork tube 3 Install the fork lower onto the lower fork tube Install the M10...

Page 104: ...er tube bush onto the lower fork tube Spread the lower fork bush slightly to install 7 Insert the lower fork tube into the upper fork tube Hold the seals and circlip away from the upper fork tube 8 Us...

Page 105: ...rclip groove 11 Seat the dust seal into the upper fork tube 12 Fill the fork with 270cc of 10W fork oil Pour slowly and stroke the cartridge rod to bleed out air from the cartridge Verify the correct...

Page 106: ...cap onto the cartridge rod Tighten to 23N m Wrap the fork cap with tape to protect the finish 15 Bring the upper tube to the fork cap and tighten to 15N m 1 To avoid possible damage remove the fuel t...

Page 107: ...8 bolts and spacers holding the headlight case Remove the headlight case 6 Disconnect the clutch cable from the handlebar perch Slacken the cable adjuster to release the cable 7 Disconnect the choke c...

Page 108: ...he stem nut and top fork clamp as an assembly with the instruments 12 Use a spanner wrench to remove the adjuster nut 13 Remove the steering stem and lower fork clamp as an assembly 14 Remove the top...

Page 109: ...racket 2 The lower steering bearing may be removed by pressing out the steering stem Proceed slowly and wear gloves and eye protection when using a hydraulic press Support the lower fork clamp with su...

Page 110: ...ny burrs or raised edges Lightly grease the bearing bores to aid installation of the bearing races Install the bearing races with a bearing driver tool to a fully seated position 2 Lightly grease the...

Page 111: ...em and seat with a bearing driver tool 5 Install the steering assembly into the frame Grease the top steering bearing and position in the top bearing race Install the top seal and adjuster nut 6 Insta...

Page 112: ...lamp bolts to 23N m 10 Tighten the steering stem nut to 65N m 11 Tighten the top fork clamp bolts to 23N m Rotate the steering and inspect for smooth operation with no binding There should be moderate...

Page 113: ...n switch 5 Turn signals 6 Tachometer 2 7 7 Speedometer 3 4 5 1 6 16 Position the wires as shown and install the head light by clipping the top of the bezel into the head light case and installing the...

Page 114: ...114 FRONT WHEEL STEERING Cable Routing Clutch cable Throttle cable Clutch cable Speedometer cable Clutch cable Front brake hose Choke cable...

Page 115: ...der may be injured or killed Motorcycles are heavy do not take the risk of having the motorcycle fall on you during service Park the motorcycle on a suitable service stand to remove the rear wheel rea...

Page 116: ...t to allow the left axle spacer to be removed 4 Disengage the rear brake caliper bracket from its locating tab and lay the caliper to the side The caliper may be covered with a shop towel and lay on t...

Page 117: ...pokes are evenly tensioned Loose spokes or spokes that are too tight must be adjusted accordingly Re check wheel true after adjusting spoke tension 5 Small adjustments to wheel true may be made by re...

Page 118: ...idges or burrs to allow the bearings to be installed 4 Lightly grease the bearing bores and install the bearings with a suitable bearing driver Install one bearing at a time to fully seated position b...

Page 119: ...Lightly grease the bearing bore and install the bearing with a suitable bearing driver 7 Install the dust seal Grease the dust seal lips after installation 1 Install the sprocket carrier into the rear...

Page 120: ...caliper bracket slot 6 Lightly grease the rear axle and install from the left Position the 20mm right side axle spacer during installation 7 Install the axle nut and adjust the chain slack to 20mm See...

Page 121: ...for oil leaks or damage to the damper rod The shocks are not serviceable and will need replacement if leaking or damaged Rear Shock Installation 1 Install the 2 x 12mm washers onto the shock mounts Li...

Page 122: ...ed with a clip master link the link may be removed If the drive chain has a rivet master link the chain may be withdrawn from around the front sprocket 6 Remove the swing arm pivot nut and withdraw th...

Page 123: ...age or excessive wear will require part replacement Swing Arm Bearing Parts Identification 1 Spacer 30 x 17 x 6 2 Inner dust seal 30 x 37 X 4 3 Thrust washer 4 Radial thrust bearing 34 5 x 22 x 6 5 Ne...

Page 124: ...ring thrust washers thrust bearing and center collar and install 4 Apply grease to the dust seals and install 5 Install the inner spacers 6 Install the chain guard and drive chain slider Tighten the M...

Page 125: ...er link was removed 9 Install the front sprocket cover and shift lever Verify that the engine wires are clamped secure and are not pinched during the cover installation Verify that the side stand swit...

Page 126: ...any spilled brake fluid immediately FRONT BRAKE FLIUD FLUSH BLEEDING OF AIR FRONT BRAKE MASTER CYLINDER REMOVAL DISASSEMBLY FRONT BRAKE MASTER CYLINDER INSPECTION FRONT BRAKE MASTER CYLINDER ASSEMBLY...

Page 127: ...and wipe clean of any fluid Clean the cap and diaphragm with contact cleaner and dry Any spilled fluid must be cleaned immediately 3 Drain the brake fluid from the reservoir with a commercial vacuum b...

Page 128: ...master cylinder banjo bolt and lay the brake hose aside Cover the hose end with a shop towel to prevent fluid spills 4 Remove the right side mirror and disconnect the front brake switch 5 Remove the...

Page 129: ...port holes are clear 3 Examine the piston for corrosion or damage Clean the piston as necessary Excessive damage will require that the master cylinder assembly be replaced 4 Examine the piston seals f...

Page 130: ...OTICE 1 Lubricate the piston seals with DOT 3 or 4 brake fluid from a sealed container 2 Install the piston seals onto the piston Verify correct direction and seating of the seals 3 Insert the piston...

Page 131: ...ealing washers and tighten to 20N m 11 Connect the brake switch wires to the switch 12 Install the mirror 13 Fill and bleed the brake system with DOT 3 or 4 brake fluid from a sealed container see pag...

Page 132: ...to allow the caliper to be installed around the brake rotor 7 Install the 2 x M10 caliper bolts and spacers Tighten the caliper bolts to 23N m 8 Pump the front brake lever and verify firm hydraulic p...

Page 133: ...liper banjo bolt and lay the brake hose aside Cover the brake hose end with a shop towel to prevent spills 4 Remove the M10 caliper bolts and spacers and remove the caliper 5 Remove the brake pad reta...

Page 134: ...istons 2 Bleed nipple 3 Piston seals 4 O rings 5 Caliper bodies 6 Caliper M8 bolts 1 1 2 3 4 3 4 5 5 6 6 Front Caliper Inspection 1 Clean all corrosion from the caliper bodies including the seal groov...

Page 135: ...caliper halves 3 Position the O rings into their recesses and bolt the caliper halves together Tighten the M8 caliper bolts to 23N m 4 Install the bleed nipple Tighten to 11N m 5 Insert the brake pads...

Page 136: ...e brake rotor 8 Install the 2 x M10 caliper bolts and spacers Tighten the caliper bolts to 23N m 9 Install the brake hose with the banjo bolt and 2 x sealing washers Tighten the banjo bolt to 20N m 10...

Page 137: ...e pedal to build and verify hydraulic pressure Typical movement at the pedal end is 30 40mm to build firm pressure 6 Set the fluid level in the reservoir to the top of the level mark and install the c...

Page 138: ...ess the spring slightly to allow the 2 x pins to be inserted Tighten the pins to 11N m Verify that the pad away from the piston is retained by the spring and the pad against the pistons is allowed to...

Page 139: ...nipple turn and drain the brake system of remaining brake fluid 3 Remove the brake pedal clevis pin Disconnect the rear brake switch at the wire harness 4 Remove the master cylinder banjo bolt and lay...

Page 140: ...nlet grommet 10 Use circlip pliers to remove the inlet circlip and remove the inlet pipe 11 Remove the inlet O ring 12 Use a pick tool to carefully remove the piston seals from the piston 13 Clean all...

Page 141: ...ny corrosion from the body 2 Verify that the compensation port hole and inlet port holes are clear 3 Examine the piston for corrosion or damage Clean the piston as necessary Excessive damage will requ...

Page 142: ...all onto the piston as shown Inspect the seals after installation for any damage or tears that may have happened during installation 4 Install the spring onto the piston as shown and insert the piston...

Page 143: ...n Tighten the banjo bolt rear brake switch to 15N m 11 Install the 6mm clevis pin washer and cotter pin as shown Adjust the brake pedal height as required by moving the clevis up or down on the rod Ti...

Page 144: ...2 x washers Cover the hose end with a shop towel to prevent brake fluid spills 4 Remove the 2 x M8 bolts and remove the caliper 5 Remove the 2 x pins and remove the brake pads 6 Extract the slide pins...

Page 145: ...on dust seal 6 Slide pins and bracket 7 Bleed nipple 1 2 3 4 5 6 7 Rear Caliper Inspection 1 Clean all corrosion from the caliper bodies including the seal grooves The piston bore and seal grooves mus...

Page 146: ...wn The pad away from the pistons remains fixed the pad against the pistons will slide against the spring 6 Install the brake pads as shown The pads will need to compress the spring slightly to allow t...

Page 147: ...feeds through the 15Amp blade fuse housed in the starter solenoid through the 4 pin connector and RED wire in the wire harness to the ignition switch The ignition switch connects the power to the BLAC...

Page 148: ...he gap Please note you may not see the spark in bright sunlight 1 Harness Inspect the wire harness connectors electric components and battery terminals for damage or corrosion Clean or repair connecto...

Page 149: ...TE wire with an Ohms meter to the negative battery terminal Ignition switch OFF 0 2 Ohms continuity to ground Ignition switch ON STOP switch STOP 0 2 Ohms continuity to ground Ignition switch ON STOP...

Page 150: ...WHITE wire is grounded the relay is activated to allow spark unless the STOP switch or ignition switch grounds the BLACK WHITE circuit If the side stand is DOWN the neutral switch activates the relay...

Page 151: ...oil is mounted inside the left engine cover and produces an AC voltage pulse to trigger the ignition spark The pulse is generated when the pole on the flywheel spins past the coil Disconnect the pulse...

Page 152: ...and starter motor cables must be clean and tight Activation of the solenoid will be heard and felt by an internal click of the relay If the relay does not activate check with a volt meter Negative at...

Page 153: ...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 The AGM bat...

Page 154: ...Inspect the wire harness and connectors for damage or corrosion Disconnect the stator connector and verify that the terminals are clean and not corroded or melted Verify that the battery cable from e...

Page 155: ...ire to YELLOW wire 11VAV 1500 RPM typical YELLOW wire to YELLOW wire 30VAC 3000 RPM typical Low voltage indicates a faulty stator and warrants replacement 4 Rectifier regulator Verify that sufficient...

Page 156: ...ng fuse The BROWN circuit powers Tail light Headlight Hi Low Parking light Tachometer and speedometer illumination lights The BLACK wire circuit powers Front rear brake lights circuits Electronic spee...

Page 157: ...ppears good check for power at the fuse holder with a volt meter BLACK wire ignition key on battery voltage typically 11 12 5VDC BROWN wire circuit to power the headlight Hi Low switch tail light mete...

Page 158: ...at for rear signals or in the headlight case for front signals 3 Brake lights The brake light circuits are powered by the BLACK wire circuit during ignition key on The BLACK wire circuit provides powe...

Page 159: ...r damaged instrument should be replaced as a unit Circuit description See schematic page 161 Power to each instrument is by the BLACK 12VDC wire circuit during key on and the GREEN ground wire The ill...

Page 160: ...nfasten the speedometer drive cable at the front wheel drive box 5 Remove the 2 x M6 ignition switch bolts to remove the instrument and bracket assembly 6 Remove 2 x screws to remove each instrument c...

Page 161: ...161 WIRE SCHEMATIC...

Page 162: ...d has a safety switch that will stop the ignition spark if the engine is in gear with the side stand down No Instrument lights Remove the seat and check that the battery cables are connected and tight...

Page 163: ...etor drain the float needle in the carburetor may be stuck closed Disassembly and cleaning of the carburetor is required The fuel tank is vented to the atmosphere through the EVAP System to allow fuel...

Page 164: ...exhaust or air intake Remove and disassemble the carburetor and inspect for varnish debris corrosion broken or worn parts If the previous running history is not known Remove and disassemble the carbur...

Page 165: ...ecessary Won t shift properly A transmission that will not change gears may indicate a broken shift shaft transmission drum or shift forks Jumping out of gears Ratcheting noise in the transmission may...

Page 166: ...full charge are resistant to freezing A battery low in voltage will freeze at a higher temperature causing permanent damage Squeaking brakes Inspect the caliper brake pads for thickness Some squeakin...

Page 167: ...167 NOTES...

Page 168: ...168...

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