Page 2: Table Of Contents
GUIDE TO THE MANUAL GUIDE TO THE MANUAL VEHICLE IDENTIFICATION SPECIFICATIONS TIGHTENING TORQUE MAINTENANCE SCHEDULE EMISSIONS CONTROL SYSTEMS MAINTENANCE SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALLATION HEAD/CYLINDER CLUTCH/ALTERNATOR/STARTER CLUTCH CRANKCASE/TRANSMISSION/CRANKSHAFT FUEL/AIR SYSTEM FRONT WHEEL/STEERING REAR WHEEL/SUSPENSION BRAKES IGNITION/STARTING SYSTEM CHARGING SYSTEM/BATTERY LIGHTING/HORN/INSTRUMENTS WIRING SCHEMATIC TROUBLESHOOTING...
Page 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.
Page 4 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.
Page 5 Keep cigarettes, sparks, and flames away from all fuel related parts. Emissions Warranty 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.
Page 6 3. Cleveland CycleWerks Authorized Distributor shall not be liable for loss of use, inconvenience, lost time, commercial losses or other incidental or consequential damages.
Page 7 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.
Page 8 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...
Page 9: Vehicle Identification
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.
Page 10: Specifications
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...
Page 11 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...
Page 12 SPECIFICATIONS ≤354g/kW-h Minimum fuel consumption Starting Electric and kick Ignition type 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°...
Page 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 Secondary fuse 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...
Page 14: Tightening Torque
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...
Page 15: Maintenance Schedule
MAINTENANCE SCHEDULE Maintenance Schedule 300 Mile/ Every Every Every Item 500km First 1800Miles/ 3600Miles/ 5400Miles/ Service * 3000km 6000km 9000km Fuel Hose Petcock Sediment Bowl Fuel Cap and Gasket EVAP Control System Secondary Air System Spark Plug Valve Clearance Engine Oil Oil Filter Screen Centrifugal Oil Filter Air Cleaner...
Page 16: Emissions Control Systems
EMISSIONS CONTROL SYSTEMS Secondary Air Injection System 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.
Page 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.
Page 18: Maintenance
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.
Page 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...
Page 20: Fuel Hoses/Fuel Filter
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.
Page 21: 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 air box may have the filter element removed for service. If dirt is light, the pleated paper type element may be cleaned with compressed air.
Page 22: Secondary Air Injection System
MAINTENANCE Secondary Air Injection System See “Secondary Air Injection System” page 16, for more information. Inspect the hoses for damage. Inspect the vacuum hoses for damage or leaks, replace components if damaged. Vacuum hose to intake manifold Air hose to engine Throttle Operation Idle speed is controlled by the speed screw on the carburetor.
Page 23: 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 24: 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 25 MAINTENANCE 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. When inserting the feeler gauge, pull up on the rocker arm adjust screw to take up the clearance slack of the push rod. A slight drag on the feeler gauge is best.
Page 26: Engine Oil/Oil Filter Screen
MAINTENANCE Engine Oil/Oil Filter Screen Engine Oil Recommended: SAE 10W-40, 15W-50, 20W-50, (Society of Automotive Engineers: viscosity) API SF/SG, (American Petroleum Institute: service code for gasoline, grade) API SH/SJ with JASO MA (MA is Japanese Automotive Standards Organization 4-stroke motorcycle grade) The chart below indicates recommended oil weight for common air temperatures.
Page 27 MAINTENANCE 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 28: Centrifugal Oil Filter
MAINTENANCE Centrifugal Oil Filter The centrifugal oil filter is located behind the right crankcase cover. Drain oil before servicing. Recommended service is every 5400 mi/9000 km. Centrifugal Oil Filter Service 1. Remove the kick starter. 2. Remove 13 x M6 hex head bolts from the right crankcase cover and remove the cover.
Page 29: Engine Idle Speed
MAINTENANCE Engine Idle Speed Idle speed (RPM) of the engine is best set after regular service is performed. Valve clearance out of specifications, stale/dirty fuel, varnish or contaminants in the carburetor, dirty air filter, fouled spark plug or tight throttle cable can all adversely affect the engine idle speed.
Page 30: 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 31 MAINTENANCE Chain Slider Inspection Chain slider minimum Inspect the chain slider for wear. Minimum thickness is thickness 2mm 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 32: 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 33 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 34: Electrical Components/Side Stand Switch/Lighting System
MAINTENANCE Electric Components/Side Stand Switch/Lighting System Inspect the functioning of the following electric components:  Headlight high beam, low beam, pilot (parking) lamp.  Turn signals, front and rear. Indicator light in the instruments.  Emergency (hazard) flasher, front and rear. ...
Page 35: Steering Head Bearings
MAINTENANCE Tire Replacement Cleveland CycleWerks does not recommend patching inner tubes. A repaired inner tube may not have the same reliability as a new one and could fail while riding. Always use replacement tires that are the same size and type as the original. Balance the wheel after a new tire has been installed.
Page 36: 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 37: Seat/Tank/Exhaust/Engine Removal/Installation
SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALL Introduction Seat Removal Engine removal from the chassis is required to service the following: Crankcases, crankshaft, balance shaft and transmission. The following may be serviced with the engine in the chassis: Head and cylinder Left case cover and alternator Right case cover, oil filter, oil pump and clutch Notes on engine removal ...
Page 38: Seat Removal/Installation
SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALL Seat Removal/Installation Seat Removal 1. Remove the rear seat bolts/turn signal brackets from the frame. 2. Lift the rear of the seat slightly. 3. Pull the seat backwards to disengage the front of the seat from the frame. Do not lift up on the rear of the seat fully without pulling backwards, or the front seat mounting tab may break.
Page 39: Disconnect Wire Harness
SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALL Disconnect Wire Harness 1. Remove both motorcycle side covers by slowly pulling outward from the rubber grommets. 2. Disconnect the following, cut fastening ties as required. Battery cables from the battery. Pulser wires Stator wires Pulser wires Neutral indicator wire (G, B/W) Starter and Chassis ground cables from the engine.
Page 40: Carburetor Removal
SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALL Carburetor Removal 1. Place a suitable container or shop towel Unscrew under the drain hose of the carburetor. carburetor top Unscrew the drain screw at the bottom of to remove slide the carburetor 2 turns to drain of fuel. and cable Choke cable...
Page 41 SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALL 4. Unbolt the right foot rest bracket to lower the foot rest. 5. Unbolt the rear brake master cylinder and tie the brake pedal away for clearance. 6. Cover the frame tubes with shop towels and tape to protect the frame paint and engine during removal.
Page 42: Engine Installation
SEAT/TANK/EXHAUST/ENGINE REMOVAL/INSTALL Engine Installation Engine installation is the reverse of removal. Follow these guidelines during installation. 1. Cover the frame tubes with tape and shop towels to avoid damaging the frame paint. 2. Engine is installed from the right side of the 4 x M10 bolts and frame.
Page 43: Head/Cylinder
HEAD/CYLINDER Introduction An improperly assembled engine or motorcycle may fail while being ridden, causing possible injury or harm to the rider. Do not service or assemble an engine unless the mechanic is certain of his skills and uses proper assembly procedure. If the mechanic is in doubt, find assistance from a trained professional! ...
Page 44 HEAD/CYLINDER Head Removal and Inspection The head and cylinder may be removed with the engine in the chassis. For the purposes of illustration, the following procedures are shown with the engine on a work bench. To remove the head and cylinder in the chassis, remove the seat, fuel tank, exhaust and carburetor first.
Page 45 HEAD/CYLINDER 5. The rockers, rocker pins and push rods may be inspected for wear or damage. Galling, rough surfaces, or bluing indicate excessive wear or overheating. Inspect the push rods for straightness or loose and worn ends. Replace worn or damaged parts. 6.
Page 46 HEAD/CYLINDER 9. Remove the valves, springs, spring seats and valve stem seals. Note the order of installation; each spring will have a spring seat washer underneath, and each valve will have the paint mark in the top position. 10. Before inspection, decarbonize the valves with a wire wheel.
Page 47 HEAD/CYLINDER 13. Inspect the vale guides for wear. With the valve lifted 10mm off the seat, the valve should move 0.1-0.6mm side to side and front to back. The valves should move freely without binding or tight spots. Excessive movement indicates worn guides and requires a head replacement.
Page 48 HEAD/CYLINDER 2. Inspect the cam followers for wear, galling or bluing, indicating overheating and a need for replacement. Cam followers 3. Cover the crankcase opening with shop towels. Remove the piston circlip and Remove piston push the piston pin out. Lift off the circlip piston.
Page 49 HEAD/CYLINDER 6. Inspect the cylinder bore for galling and excessive wear, indicating a need for replacement. Measure the bore diameter with a dial bore gauge. Replace the cylinder if the bore measures larger than the wear limit. Cylinder bore wear limit: 67.10mm Note: Nominal piston to cylinder clearance is 0.06mm Piston to cylinder clearance wear limit is 0.25mm Cylinder and Piston Installation...
Page 50 HEAD/CYLINDER 3. Cover the crankcase opening with shop IN mark facing the rear towels to prevent a circlip from falling into the engine. Lubricate the piston pin with engine oil and install the piston onto the connecting rod. Orient the piston with the “IN” mark facing the rear.
Page 51 HEAD/CYLINDER Head Assembly 1. Install new valve stem seals onto the valve guides; lubricate the seals with Valve stem seal engine oil before installation. Installing one valve at a time, install the valve spring seats, inner and outer, the valve springs and valve spring top.
Page 52 HEAD/CYLINDER Head Installation 1. Refer to page 42 to install the cylinder, piston, head gasket, dowels and O-ring. 4x M8 head nuts Tighten to 37N-m 2. Install the head onto the cylinder and hand thread the 4 x M8 head nuts and washers and M8 bolt with copper sealing washer M8 bolt Tighten into the head.
Page 53: Clutch/Alternator/Starter Clutch
CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH Introduction The clutch, centrifugal oil filter, oil pump, starter motor and alternator may be serviced with the engine in the chassis, or with the engine on a work bench. For the purposes of illustration, this manual shows the clutch and alternator service with the head and cylinder removed. An improperly assembled engine or motorcycle may fail while being ridden, causing possible injury or harm to the rider.
Page 54 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH Centrifugal Oil Filter and Oil Pump Drive Removal and Inspection 1. Drain the engine oil if removing the right side engine cover (clutch cover). Remove the kick starter. Remove 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.
Page 55 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 5. Remove the M6 nut holding the oil pump drive sprocket. Remove the sprocket and chain. 6. Clean the centrifugal oil 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.
Page 56 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 3. Remove the clutch center circlip with circlip pliers. 4. Lift off the clutch center, pressure plate Clutch pressure plate and clutch plates. Lift off the thrust washer and clutch basket. Thrust washer Clutch center Clutch basket 5.
Page 57 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH Shifter Arm and Shift Detent Removal and Installation 1. Clean any dirt or chain lube from the shift shaft before removal. The shift shaft is exposed to dirt and chain lube from the drive chain (left side of engine). Lift out the shift shaft and arm from the crankcase.
Page 58 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH Clutch Installation 1. Install the counter balancer drive gear Counter balancer and the crankshaft gear. Time the drive gear counter balancer drive gear with the counter balancer gear. Align the marks. Lubricate the gears with engine oil during assembly.
Page 59 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 5. Install the 6 x clutch springs into the Tighten M6 clutch. Install the spring plate and fasten bolts to 11N-m with the 6 x M6 bolts. Tighten the bolts progressively to 11N-m; the springs will clamp the clutch plates tightly between the pressure plate and the clutch center.
Page 60 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 4. Install the oil filter cover and gasket; fasten with the 3 x Phillips screws. 5. Be sure that the gasket sealing surfaces are clean and flat. Install the right side engine cover with a new gasket. Hold the clutch lifter arm in the position shown (against the spring pressure) during installation.
Page 61 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH Left Engine Cover and Starter Motor Removal and Inspection 1. Remove the crankshaft inspection cover by unbolting the 4 x M6 bolts. Remove the 3 x bolts fastening the starter reduction gear cover. Inspection cover removed Starter reduction gear cover 2.
Page 62 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 5. Remove the M10 flywheel bolt. Remove the flywheel and starter clutch with a 16mm x 1.5mm RH thread removal tool. Camshaft Removal and Inspection 1. Unbolt the camshaft retainer and remove the spring. Camshaft retainer and spring 2.
Page 63 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH Camshaft Installation and Timing 4. Lubricate the camshaft and spindle with engine oil before installation. Position the Cam gear thrust washer on the spindle before timing mark inserting into the crankcase from the left. The cam gear is timed with the crankshaft at top dead center (key is pointing UP) and the gear mark pointing UP.
Page 64 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 2. To remove the starter clutch from the flywheel, remove the 3 x M8 bolts and separate the flywheel. 3. The starter clutch, cams and gear with Medium strength hub should be replaced as an assembly. Insert the cams and friction ring into the thread lock clutch outer as shown.
Page 65 CLUTCH/ALTERNATOR/STARTER CLUTCH cclutCLUTCCLUCLUCLUTCHCLUTCH 3. Insert the starter motor from the right, oil the O-ring to aid installation; fasten the motor with 2 x M6 bolts. Tighten the bolts O-ring to 11N-m. 4. Install the reduction gears and shaft with the 2 x thrust washers against the gears. Locating pin Lubricate the parts with engine oil before installation.
Page 66: Crankcase/Transmission/Crankshaft
CRANKCASE/TRANSMISSION/CRANKSHAFT Introduction An improperly assembled engine or motorcycle may fail while being ridden, causing possible injury or harm to the rider. Do not service or assemble an engine unless the mechanic is certain of his skills and uses proper assembly procedure. If the mechanic is in doubt, find assistance from a trained professional! ...
Page 67: Crankcase Disassembly
CRANKCASE/TRANSMISSION/CRANKSHAFT Crankcase Disassembly 1. Prior to separating the crankcases, remove the following parts from the right crank case. A. Shift shaft B. Detent arm and spring C. Shift drum detent D. Crank shaft gear Remove the countershaft sprocket from the left side.
Page 68: Oil Pump Inspection
CRANKCASE/TRANSMISSION/CRANKSHAFT 7. The transmission shafts may be removed together. Note the position of the thrust washers. Remove the crankshaft. Remove any gasket material from the crankcases. Do not scratch or damage the gasket sealing surfaces. Clean the cases of dirt and oil with low flash point solvent. Clean all bearings with solvent and inspect for free turning without excessive wear.
Page 69 CRANKCASE/TRANSMISSION/CRANKSHAFT 3. Measure the body side clearance as shown with a feeler gauge. Standard 0.15-0.20mm Wear limit: 0.25mm Replace the pump as an assembly if the wear limit is reached. 4. Measure the tip clearance as shown with a feeler gauge. Wear limit 0.20mm Replace the pump as an assembly if the wear limit is reached.
Page 70: Transmission Shafts Disassembly
CRANKCASE/TRANSMISSION/CRANKSHAFT Transmission Shafts Disassembly The transmission shaft assemblies may be disassembled, if required. Use internally expanding circlip pliers to remove the circlips. Clean the transmission parts with a low flash point solvent and dry. Inspect the gears for cracks or damage to the gear teeth. Inspect for galling or heat damage to the fork grooves.
Page 71 CRANKCASE/TRANSMISSION/CRANKSHAFT 1. Install Main shaft gear 3 onto the 2. Spline washer 1. Main shaft 3 gear main shaft. The dogs face away from the main shaft 1 gear integral to the main shaft. 2. Install a spline washer against the gear.
Page 72: Counter Shaft Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT Counter Shaft Assembly Counter Shaft Parts Identification 1. Thrust washer 20.2 x 26.8 x 1.0 2. Counter shaft gear 2 3. Counter shaft gear 5 4. Counter shaft NOTICE 5. Counter shaft gear 4 LUBRICATE ALL TRANSMISSION PARTS WITH ENGINE 6.
Page 73 CRANKCASE/TRANSMISSION/CRANKSHAFT 3. Install thrust washer 20.2 x 26.8 x 1.0 onto the counter shaft. 3. Thrust washer 20.2 x 26.8 x 1.0 4. Install counter shaft gear 4 onto the 4. Counter shaft gear 4 counter shaft. Position the dogs away from gear.
Page 74: Kick Starter Dissassembly
CRANKCASE/TRANSMISSION/CRANKSHAFT 11. Install thrust washer 16.7 x 23.8 x 0.5 onto 11. Thrust washer the counter shaft. 16.7 x 23.8 x 0.5 12. Install bush Ø19.5 OD onto the counter shaft. 12. Bush Ø19.5 13. Starter idler gear 13. Install the starter idler gear onto the counter shaft.
Page 75: Kick Starter Shaft Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT Kick Starter Shaft Assembly Kick Starter Shaft Assembly Parts Identification 1. Thrust washer 12.2 x 17.8 x 1.0 2. Circlip 3. Thrust washer 16.3 x 23.8 x 1.0 4. Arm NOTICE 5. Coil spring LUBRICATE ALL KICK STARTER PARTS WITH ENGINE 6.
Page 76 CRANKCASE/TRANSMISSION/CRANKSHAFT 4. Install the ratchet piece onto the kick starter shaft. Align the marks on the arm and shaft. 4. Ratchet piece Position the ratchet teeth towards the gear. Align marks 5. Install the coil spring onto the shaft. 6. Arm 6.
Page 77 CRANKCASE/TRANSMISSION/CRANKSHAFT 10. Install the conical washer onto the kick starter shaft. Position the recess side towards the gear. 11. Install the return spring onto the kick starter shaft. Insert the spring end into the shaft hole. 11. Return spring in hole 10.
Page 78 CRANKCASE/TRANSMISSION/CRANKSHAFT 14. Install the kick starter assembly into the right clutch cover. Position the return spring to hook the case as shown. 14. Spring location 15. Position the return stop boss as shown. 15. Return stop boss position 16. Locate the arm in the groove as shown. Grip the shaft with locking pliers to aid case installation on the crank case.
Page 79: Crankcase Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT Crankcase Assembly 1. Engine cases must be clean of dirt or Crankshaft material that can clog oil passages. Lubricate the bearings with engine oil. Support the left case Prepare to assemble the transmission and with wood blocks crankshaft into the left engine case. The case may be supported with two suitable wood blocks.
Page 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. Transmission forks installed in grooves 4.
Page 81 CRANKCASE/TRANSMISSION/CRANKSHAFT 7. Install a new crank case gasket. Be sure that the 2 x locating dowel pins are in place. Hold the kick starter shaft as shown against the spring pressure during assembly. Install the right case onto the left crankcase.
Page 82: Fuel/Air System
FUEL/AIR SYSTEM Introduction The Misfit 250 is equipped with a single PZ30 slide valve carburetor. The airflow is manually operated by opening or closing the slide via the cable operated throttle. The carburetor features a manually operated choke butterfly valve to aid cold starting. Depending on the market, the carburetor may be equipped with an accelerator pump that adds a small additional squirt of fuel during quick throttle openings.
Page 83: Carburetor Removal
FUEL/AIR SYSTEM Carburetor Removal 6. Place a suitable container or shop towel Unscrew under the drain hose of the carburetor. carburetor top Unscrew the drain screw at the bottom of to remove slide the carburetor 2 turns to drain of fuel. and cable Choke cable...
Page 84 FUEL/AIR SYSTEM 7. Remove the 2 x M8 bolts mounting the center of the rear fender and remove the rear fender. Remove 2 x M8 fender bolts Remove 4 x M6 8. Unbolt the rectifier/ regulator and battery box bolts lay aside.
Page 85: Carburetor Disassembly
FUEL/AIR SYSTEM Carburetor Disassembly After removing the carburetor (see page 23), disassemble the carburetor in the following sequence: 1. Slide valve top, including slide, slide spring and slide needle. Unscrew the top and extract the slide with needle and spring. 2.
Page 86: Carburetor Cleaning And Inspection
FUEL/AIR SYSTEM Carburetor Cleaning and Inspection Fuel and carburetor cleaners can absorb into the skin and are dangerous to health. Wear chemical resistant gloves, eye protection and work in a well ventilated area. Fuel and cleaning chemicals are highly flammable. Avoid sparks, flames and smoking when working on the fuel system and components.
Page 87: Carburetor Assembly
FUEL/AIR SYSTEM 6. Examine the float needle seat. The bore of the seat should be shiny brass in color with no varnish deposits. Polish the bore with a roll of 2000 grit wet/dry sandpaper to clean. Float needle seat 7. Examine the Viton float needle tip; replace the needle if the tip is damaged.
Page 88 FUEL/AIR SYSTEM 3. Install the idle mixture screw as an assembly; spring, washer and O-ring installed on the mixture screw prior to inserting into the carb body. Screw into a lightly seated position, and then unscrew to the specified number of turns. See Specifications page 12.
Page 89: Carburetor Installation
FUEL/AIR SYSTEM 7. Install the float bowl. Be sure that the accelerator pump cam arm is in the UP position. Install the three float bowl screws. Cam arm in the UP position 8. The slide is installed with the cutaway facing the intake. Locate the slide groove into the pin in the carb body.
Page 90: Front Wheel/Steering
FRONT WHEEL/STEERING Introduction Proper operation of the front wheel, forks and steering are critical for safe riding.  Wheels that are out of round or unbalanced can cause wobbles or shaking that can cause a crash, in which the rider can be injured or killed. ...
Page 91: Front Wheel Removal
FRONT WHEEL/STEERING Table of Contents Seat Removal FRONT WHEEL REMOVAL FRONT WHEEL INSPECTION FRONT WHEEL/FENDER INSTALLATION FRONT FORK REMOVAL FORK DISASSEMBLY FORK INSPECTION CARTIDGE REMOVAL/DISASSEMBLY CARTIDGE INSPECTION CARTIDGE ASSEMBLY- REBOUND VALVE CARTIDGE ASSEMBLY- COMPRESSION VALVE FORK ASSEMBLY STEERING STEM/FORK CLAMP REMOVAL STEERING STEM DISASSEMBLY STEERING STEM/ FORK CLAMP ASSEMBLY CABLE ROUTING...
Page 92: Front Wheel Inspection
FRONT WHEEL/STEERING Front Wheel Inspection 1. Wheel true may be measured on a truing stand using a dial indicator. 2. Measure total side to side movement and total up-down movement at the rim. Maximum permissible runout: 2.0mm. 3. Check that the spokes are evenly tensioned. Loose spokes or spokes that are too tight must be adjusted accordingly.
Page 93 FRONT WHEEL/STEERING Front Wheel Installation 1. Apply grease to the left side dust seal prior to installing the left side axle spacer. Engage the Apply grease to the dust seal. speedometer drive box in the notches on the right side of the wheel. Align the speedometer drive box notch with the tab on the right fork.
Page 94: Front Fork Removal
FRONT WHEEL/STEERING Front Fork Removal Tape wrap for 1. Remove the front wheel and fender. See page protection 2. If forks are to be serviced, loosen the fork cap before removing from the fork clamps. Loosen the top clamp bolt; cover the fork cap with tape to protect the aluminum.
Page 95: Fork Disassembly
FRONT WHEEL/STEERING Front Fork Disassembly Wrap cap with 1. Unscrew the fork cap and lower the upper fork tube to tape expose the spring and cartridge rod. 2. Hold the cartridge rod nut to unscrew and remove the fork cap. 3.
Page 96 FRONT WHEEL/STEERING Pry around the 6. Pry away the dust seal from the fork tube. Use a thin flat tube slowly screwdriver, work slowly around the fork. Do not damage the seal or tube. 7. Pry out the seal circlip with a hook pick. Hook pick used to remove the circlip...
Page 97: Fork Inspection
FRONT WHEEL/STEERING Fork Inspection  Wash the fork parts in a low flash point solvent and dry.  Inspect the lower tube for scratches, rust or damage.  Lower fork chrome may be lightly polished clean with 1500 grit oiled sandpaper. Do not sand excessively! ...
Page 98: Cartidge Removal/Disassembly
FRONT WHEEL/STEERING Cartridge Removal/ Disassembly Note: cartridge removal is not necessary for regular fork maintenance, fork seal change or fork oil change. 1. Disassemble the fork as per page 95. 2. Remove the M10 bolt, flat washer and lock washer from the fork lower.
Page 99 FRONT WHEEL/STEERING 6. The lower tube cap may be removed with an impact gun. The cartridge is attached to the lower fork cap and the cartridge will be removed with the lower fork cap. Extract the cartridge from the lower fork tube. Lower tube cap 7.
Page 100: Cartidge Inspection
FRONT WHEEL/STEERING Cartridge Inspection  Wash the cartridge parts in a low flash point solvent and dry.  Inspect the cartridge tube for dents, out of round or damage.  Inspect the cartridge rod for bends or excessive wear.  All shims must lay flat, check on a surface plate. ...
Page 101: Cartidge Assembly- Rebound Valve
FRONT WHEEL/STEERING Cartridge Assembly- Rebound Valve Recess towards 1. Install a shim collar onto the cartridge rod. The base flange is towards the rod shoulder. collar 2. Install a check spring onto the shim collar. The spring should move without binding. 3.
Page 102: Cartidge Assembly- Compression Valve
FRONT WHEEL/STEERING Cartridge Assembly- Compression Valve 1. Install the M6 flat and lock washer onto the compression valve M6 bolt. 2. Install a shim collar onto the bolt. The base flange is towards the bolt head. 3. Install a check spring onto the shim collar. The spring should move freely with no binding.
Page 103: Fork Assembly
FRONT WHEEL/STEERING Fork Assembly Note- if the fork lower or cartridge have NOT been disassembled, proceed to page 104, step 4 for assembly instructions. Tighten cap to 20N-m 1. Install the cartridge into the lower fork tube. Tighten to 20N-m. 2.
Page 104: Front Wheel Removal
FRONT WHEEL/STEERING 4. Wrap the lower fork tube with vinyl tape to protect Wrap with tape the seals from damage during installation. for protection 5. Install the dust seal, circlip and oil seal onto the lower fork tube. Apply grease to the groove of the oil seal.
Page 105: Support The Motorcycle In A Service Stand And Raise The
FRONT WHEEL/STEERING 9. Seat the oil seal with the fork seal driver. Hold the dust seal and circlip away when striking down with the seal driver. The oil seal is seated when the circlip groove is exposed for circlip installation. Check that the circlip groove is exposed after seating the oil seal...
Page 106: Steering Stem/Fork Clamp Removal
FRONT WHEEL/STEERING 13. Install the fork spring, spring guide and washer. Hold down the spring guide to install the cartridge rod M10 nut. Screw the nut down to the bottom of the threads. Hold down the spring guide to install the nut 14.
Page 107 FRONT WHEEL/STEERING 3. Remove the headlight lens and bezel as an assembly. M8 headlight bolts Remove the 2 x M5 shouldered screws from the bezel and release the headlight assembly from the top tab in the headlight case. 4. Unplug the electrical connectors in the headlight case and withdraw the wires from the headlight case.
Page 108 FRONT WHEEL/STEERING 9. Open the right handlebar switch and release the throttle cable from the throttle pipe. The right switch may hang away on the throttle cable. Release the throttle cable 10. Remove the 4 x M8 bolts and handlebar clamp. Remove the handlebar as an assembly with left switch, mirrors, clutch perch, front brake assembly and throttle pipe.
Page 109: Steering Stem Disassembly
FRONT WHEEL/STEERING Steering Stem Disassembly 1. Remove the two M8 bolts holding the headlight bracket. Remove the headlight bracket. Remove 2 x M8 bolts to remove the headlight bracket 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.
Page 110: Steering Stem/Fork Clamp Assembly
FRONT WHEEL/STEERING 3. Remove the lower steering bearing, washer, seal and steering stem. 4. Remove the steering bearing races with a drift. Remove the races evenly; tap out in a circular pattern. Clean and inspect the bearing races for wear and damage. Remove the races evenly Steering Stem/Fork Clamp Assembly If the steering stem has not been disassembled,...
Page 111 FRONT WHEEL/STEERING 3. Clean and inspect the bearings and seals for wear and damage. Grease the bearings with waterproof grease prior to installation. 1. Seal. 2. Washer. 3. Bearing 32005X. 4. Adjuster nut 4. Install the seal and washer on the steering stem. Install the steering bearing over the steering stem and seat with a bearing driver tool.
Page 112 FRONT WHEEL/STEERING 8. Install the top fork clamp. Position the 2 x head light bracket rubber collars into their respective holes in the top fork clamp. Install the stem washer and nut. Tighten the stem nut by hand, to allow the forks to be inserted.
Page 113 FRONT WHEEL/STEERING 13. Feed the wire harness, switch wires and turn signal wires through the head light case. 14. Install the head light case with the 2 x M8 bolts and spacers. 15. Connect the following wires: 1. Right handle bar switch 2.
Page 114: Cable Routing
FRONT WHEEL/STEERING Cable Routing Clutch cable Choke cable Clutch cable Front brake hose Throttle cable Clutch cable Speedometer cable...
Page 115: Rear Wheel/Suspension
REAR WHEEL/ SUSPENSION Introduction Seat Removal Proper operation of the rear wheel, rear shocks and swing arm are critical for safe riding.  Wheels that are out of round or unbalanced can cause wobbles or shaking that can cause a crash, in which the rider can be injured or killed.
Page 116: Rear Wheel Removal
REAR WHEEL/ SUSPENSION Rear Wheel Removal 1. Support the motorcycle in a suitable service stand and raise the rear wheel. 2. Remove the rear axle nut and withdraw the axle. 3. Remove the right side axle spacer, and move the wheel to the right to allow the left axle spacer to be removed.
Page 117: Rear Wheel Inspection
REAR WHEEL/ SUSPENSION Rear Wheel Inspection Cush drive 1. Remove the sprocket carrier and inspect for wear rubber or damage to the cush drive rubber. Inspect the wheel bearings for smooth operation and without excessive play. Sprocket carrier 2. Wheel true may be measured on a truing stand using a dial indicator. 3.
Page 118: Wheel Bearing Replacement
REAR WHEEL/ SUSPENSION Wheel Bearing Replacement Wheel Hub Bearings 1. Remove the 2 x dust seals from the rear wheel hub. 2. The bearings may be removed with a suitable drift punch. Move the hub center collar slightly to the side to gain purchase on the bearings.
Page 119: Rear Wheel Installation
REAR WHEEL/ SUSPENSION 4. Install the spacer collar into the bearing with a Inspect the bearing suitable bearing driver. bore for burrs 5. Inspect the bearing bores of the sprocket carrier for wear or burrs. Smooth any ridges or burrs to allow the bearing to be installed.
Page 120 REAR WHEEL/ SUSPENSION 3. Insert the 15mm long left axle spacer in position on the sprocket carrier. 4. Apply grease to the right side dust seal and install the 24mm axle spacer. 15mm left axle spacer 5. Move the wheel to the left to install the rear brake caliper with bracket.
Page 121: Rear Shocks
REAR WHEEL/ SUSPENSION Rear Shocks Rear Shock Removal 1. Support the motorcycle in a suitable service stand and raise the rear wheel. 2. Remove 2 x M10 nuts with washers per shock. 3. Remove the shock. Remove 2 x M10 nuts and washers Rear Shock Inspection Inspect the shock for smooth...
Page 122: Swing Arm Removal
REAR WHEEL/ SUSPENSION Swing Arm Removal Swing Arm Removal 1. Support the motorcycle in a suitable service stand and raise the rear wheel. 2. Remove the rear wheel. See page 116 3. Remove the rear shocks. See page 121 4. Remove the shift lever and front sprocket cover. Swing arm 5.
Page 123: Swing Arm Bearing Inspection
REAR WHEEL/ SUSPENSION Swing Arm Bearing Inspection  Wash the bearing parts in a low flash point solvent and dry.  Inspect the bearings for rust, pitting, broken rollers, or damage.  Inspect the bearing collar for excessive wear.  Inspect the dust seals for excessive wear or damage. ...
Page 124 REAR WHEEL/ SUSPENSION Bearing depth is 6mm ±1mm. 3. Grease the needle bearing, thrust washers, thrust bearing and center collar and install. 4. Apply grease to the dust seals and install. 5. Install the inner spacers. Apply grease to the dust seal lips 6.
Page 125 REAR WHEEL/ SUSPENSION 7. Position the swing arm assembly between the frame Tighten swing and around the engine carriage. Lightly grease the arm nut to 65N- swing arm bolt and install. Install the swing arm pivot bolt nut and tighten to 65N-m. Operate the swing arm and verify smooth operation.
Page 126: Brakes
BRAKES Introduction Seat Removal Proper operation of the front and rear brakes are critical for safe riding.  Brakes that are inoperable or defective can cause a crash, in which the rider can be injured or killed.  Brake fluid leaks onto the brake pads may impede brake function, causing a crash in which the rider may be injured or killed.
Page 127: Seat Removal
BRAKES Front Brake Flush/Bleeding Of Air Seat Removal 1. Move the handlebars until the front brake master cylinder is level. Cover the master cylinder as shown to catch fluid spills. Remove the 2 x screws and remove the cap, diaphragm plate and diaphragm. 2.
Page 128: Front Brake Master Cylinder Removal/Disassembly
BRAKES Front Brake Master Cylinder Removal/Disassembly Cover the brake Seat Removal Disconnect the hose end to prevent 1. Remove the reservoir cap, diaphragm plate and brake switch brake fluid spills diaphragm and drain the reservoir with a vacuum bleeder. 2. Connect a commercial vacuum bleeder to the caliper bleed nipple and apply vacuum.
Page 129: Front Brake Master Cylinder Inspection
BRAKES Front Brake Master Cylinder Inspection Seat Removal Swing Arm Bearing Parts Identification 1. Dust boot 2. Circlip 3. Piston seal outer 4. Piston 5. Piston seal inner 6. Piston spring 7. Master cylinder body Compensation 1. Examine the master cylinder reservoir for corrosion port Inlet port or damage.
Page 130: Front Brake Master Cylinder Assembly/Installation
BRAKES Front Brake Master Cylinder Assembly/Installation Seat Removal 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.
Page 131: Front Brake Pad Replacement
BRAKES 7. Install the lever, pivot and lock nut. Tighten the M6 lock nut to 11N-m. Tighten M6 lock 8. Install the brake light switch. nut to 11N-m Brake light switch 9. Install the master cylinder assembly onto the handle Tighten banjo bars.
Page 132 BRAKES 4. Replace the brake pads. 5. Position the pad spring as show and install the pad retaining pin. Tighten the pin to 11N-m. Tighten the pin to 11N-m 6. Pry the pads apart to allow the caliper to be installed around the brake rotor.
Page 133: Front Brake Caliper Removal/Disassembly
BRAKES Front Brake Caliper Removal/Disassembly Seat Removal 1. Remove the reservoir cap, diaphragm plate and diaphragm and drain the reservoir with a vacuum bleeder. 2. Connect a commercial vacuum bleeder to the caliper bleed nipple and apply vacuum. Open the bleed nipple ¼ turn and drain the brake system of remaining brake fluid.
Page 134: Front Brake Caliper Inspection
BRAKES 9. The piston seals may be removed with a hook pick. O-rings 10. Clean all parts with contact cleaner and dry with compressed air. Piston seals Front Brake Caliper Inspection Seat Removal Front Brake Caliper Parts Identification 1. Pistons 2.
Page 135: Front Brake Caliper Assembly/Installation
BRAKES Front Brake Caliper Assembly/Installation Seat Removal 1. New piston seals and O-rings are required to assemble the calipers. Lubricate the piston seals and install into the seal grooves. 2. Insert the pistons into the caliper halves. Piston seal Piston 3.
Page 136 BRAKES 7. Pry the pads apart to allow the caliper to be installed around the brake rotor. 8. Install the 2 x M10 caliper bolts and spacers. Tighten the caliper bolts to 23N-m. Tighten the M10 9. Install the brake hose with the banjo bolt and 2 x bolts to 23N-m sealing washers.
Page 137: Rear Brake Pad Replacement
BRAKES Vacuum bleed from the bleed nipple 4. Connect the vacuum bleeder to the front brake caliper bleed nipple and apply vacuum. Open the bleed nipple ¼ turn to allow the vacuum to pull brake fluid down from the master cylinder and through the caliper.
Page 138: Rear Brake Fluid Flush/Bleding Of Air
BRAKES 4. Clean dirt from the spring and around the pistons. Inspect the exposed surface of the piston for damage to the chrome or excessive corrosion, which would indicate that the caliper may need to be serviced. See page 144 5.
Page 139: Rear Brake Master Cylinder Removing/Disassembly
BRAKES Rear Brake Master Cylinder Removal/Disassembly Seat Removal 1. Remove the reservoir cap, diaphragm plate and diaphragm and drain the reservoir with a vacuum bleeder. 2. Connect a commercial vacuum bleeder to the caliper bleed nipple and apply vacuum. Open the bleed nipple ¼ turn and drain the brake system of remaining brake fluid.
Page 140 BRAKES 8. Remove the piston circlip and withdraw the rod, washer, piston and spring. 9. Remove the inlet grommet. Inlet grommet 10. Use circlip pliers to remove the inlet circlip and remove the inlet pipe. 11. Remove the inlet O-ring. Inlet pipe Inlet O-ring 12.
Page 141: Rear Brake Master Cylinder Inspection
BRAKES Rear Brake Master Cylinder Inspection Seat Removal Rear Brake Master Cylinder Parts Identification 1. Spring 9. Inlet pipe 2. Outer piston seal 10. Inlet circlip 3. Piston 11. Inlet O-ring 4. Inner piston seal 12. Piston rod 5. Washer 13.
Page 142: Rear Brake Master Cylinder Assembly/Installation
BRAKES Rear Brake Master Cylinder Assembly/Installation Seat Removal 1. Install the inlet O-ring and inlet pipe into the rear brake master cylinder. Lube the O-ring prior to assembly with brake fluid. 2. Install the inlet pipe circlip. Be sure that the circlip is seated fully into its groove.
Page 143 BRAKES 8. Install the M8 nut and clevis onto the rod. M8 nut and clevis 9. Install the master cylinder onto the chassis. Tighten the 2 x M6 bolts to 11N-m. 10. Using 2 x new crush washers, install the rear brake hose as shown.
Page 144: Rear Brake Caliper Removal/Disassembly
BRAKES Rear Brake Caliper Removal/Disassembly Seat Removal 1. Remove the reservoir cap, diaphragm plate and diaphragm and drain the reservoir with a vacuum bleeder. 2. Connect a commercial vacuum bleeder to the caliper bleed nipple and apply vacuum. Open the bleed nipple ¼ turn and drain the brake system of remaining brake fluid.
Page 145: Rear Brake Caliper Inspection
BRAKES Rear Brake Caliper Inspection Seat Removal Rear Brake Caliper Parts Identification 1. Pistons 2. Slide pin boot 3. Slide pin boot 4. Piston seal 5. Piston dust seal 6. Slide pins and bracket 7. Bleed nipple Rear Caliper Inspection 1.
Page 146: Rear Brake Caliper Assembly/Installation
BRAKES Rear Brake Caliper Assembly/Installation Piston seals Seat Removal 1. Lubricate the piston seals with brake fluid and install in the seal grooves. 2. Install the slide pin boots if removed. Lubricate the inside of the boots with waterproof grease to allow the slide pins to move freely.
Page 147: Ignition/Starting System
IGNITION/STARTING SYSTEM System Description The Misfit 250 is equipped with a Direct Current Capacitive Discharge Ignition system (DC CDI). The ignition system is all electronic and provides a strong ignition spark with automatic advance and retard of the ignition timing to suit the engine speed (RPM). Refer to the following wire schematic for the system description: 1.
Page 148 IGNITION/STARTING SYSTEM 3. The engine STOP circuit is activated by grounding the BLACK/WHITE wire circuit connected to the CDI. If this circuit is grounded, the ignition spark is stopped. The BLACK/WHITE stop circuit may be grounded by:  The Ignition switch in the “OFF” position. ...
Page 149 IGNITION/STARTING SYSTEM  BLACK wire: battery voltage. (typically 11-12.5VDC) If the voltage is substantially lower than the battery voltage, inspect the ignition switch wire connector and switch contacts for continuity. 5. STOP Circuit Remove the positive battery cable from the battery and lay aside.
Page 150 IGNITION/STARTING SYSTEM 7. Side stand relay The side stand relay activates to turn ON the spark during ignition key-on. If the side stand is DOWN, and the engine is in gear, the relay deactivates and spark is stopped. Activation of the relay disconnects the BLACK/WHITE pulser wire from ground, allowing the pulser signal to the CDI and allowing spark (unless the STOP switch or ignition switch grounds the BLACK/WHITE circuit)
Page 151 IGNITION/STARTING SYSTEM  Disconnect the BLACK/YELLOW wire and Primary resistance measure the resistance of the primary (low 0.4 Ohms voltage) side of the coil with an Ohms meter. Typical resistance 0.4 Ohms. Reconnect the wire after testing.  Measure the resistance of the secondary (high voltage) side of the coil with an Ohms meter.
Page 152 IGNITION/STARTING SYSTEM Starter System Description The Misfit 250 starter motor is activated by a solenoid relay located under the battery box. During key-on, +12VDC power is supplied to the starter button switch on the right handle bar through the BLACK wire circuit. The YELLOW/RED wire provides +12VDC to the solenoid when the starter button is pressed.
Page 153: Charging System/Battery
CHARGING SYSTEM/BATTERY System Description The Misfit 250 charging system features a permanent magnet flywheel spinning around stator windings of wire to produce an AC (Alternating Current) voltage output. The AC voltage is converted to DC (Direct Current) voltage by a rectifier/regulator to charge the battery. The Misfit is equipped with an Absorbed Glass Mat (AGM) maintenance free battery.
Page 154 CHARGING SYSTEM/BATTERY 1. Battery Inspection/Charging Remove the seat and Check that the battery terminal bolts are tight and the cables not loose. Measure the battery voltage, ignition off, with a volt meter. Normal static battery voltage should be 12.6VDC minimum. If below this voltage, charge 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.
Page 155 CHARGING SYSTEM/BATTERY Stop the engine and reconnect the stator wire connector. Measure the AC voltage at the connector.  YELLOW wire 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.
Page 156: Lighting/Horn/Instruments
LIGHTING/HORN/INSTRUMENTS System Description The BROWN wire circuit is energized by the BLACK wire circuit at ignition key-on through the 15Amp lighting fuse. The BROWN circuit powers:  Tail light  Headlight Hi/Low  Parking light  Tachometer and speedometer illumination lights The BLACK wire circuit powers: ...
Page 157 LIGHTING/HORN/INSTRUMENTS The following wire connectors may be accessed inside the head light case: 1. Right handle bar switch 2. Left handle bar switch 3. Head light 4. Ignition switch 5. Turn signals 6. Tachometer 7. Speedometer Lighting System Inspection 1. Headlight The Misfit headlight is an always-on for safety during daylight riding.
Page 158 LIGHTING/HORN/INSTRUMENTS 2. Turn signals The turn signals are powered by the BLACK wire circuit through the flasher relay under the right side cover. The relay is load-sensitive, and will blink fast if one signal bulb is burnt out. If no left or right blinking occurs when signaling, disconnect the relay from its connector, and jumper a wire between the terminals in the connector.
Page 159 LIGHTING/HORN/INSTRUMENTS Horn Inspection The horn is powered by the BLACK wire circuit at ignition key-on, and is sounded by grounding the opposed horn terminal by the LIGHT GREEN wire through the horn switch on the left handle bar. If the horn does not sound, check for power (typically 11.0-12.5VDC) at the BLACK wire terminal at the horn.
Page 160 LIGHTING/HORN/INSTRUMENTS Instruments Removal/Installation 1. Remove the 2 x M5 headlight bezel screws and remove the headlight. 2 x M5 screws 2. Disconnect the instrument wire connectors in the headlight case. Instrument 3. Remove the 2 x M8 headlight bolts and spacers connectors and lower the headlight case.
Page 161: Wiring Schematic
WIRE SCHEMATIC...
Page 162: Troubleshooting
TROUBLESHOOTING Before troubleshooting a problem, read and understand the operation of your motorcycle as described in the Misfit 250 Gen 2 Owner’s Manual. Engine Does Not Start Engine will not crank (turn over)  Turn on the ignition key: The headlight and instrument lights should illuminate. The transmission needs to be in neutral with the green neutral light on.
Page 163 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 164 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 165 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 166 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 167 NOTES...

Cleveland CycleWerks Misfit 250 Gen II Service Manual

Guide to the Manual

Maintenance

Seat/Tank/Exhaust/Engine Removal/Install

Crankcase/Transmission/Crankshaft

Fuel/Air System

Front Wheel/Steering

Rear Wheel/ Suspension

Brakes

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