Cleveland FXR Owner's Manual
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Cleveland FXR Owner's Manual

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This   v ehicle   h as   a   m inimum   a ge   r equirement   o f   1 6   a nd   a   m aximum   w eight   c apacity   o f   1 90   l bs.   ( 86   k g.).    
Always   w eal   n ecessary   a nd   p roperly   f itting   p rotective   e quipment   w hen   o perating   t his   v ehicle.  
 
                   
 
 
 
 
To   r educe   t he   r isk   o f   i njury,   t he   u ser   m ust   r ead   a nd   u nderstand   t he   o perator's   m anual   b efore   u sing   t his   p roduct.
 
Obtain,   r eview   a nd   f ollow   p rovisional/municipal   g overnment   a cts   a nd   r egulations   p ertaining   t o   o wning   a nd  
operating   a n   o ff-­‐road   v ehicle   b efore   u sing   t his   p roduct.  
SAVE   T HIS   M ANUAL   F OR   F UTURE   R EFERENCE  
 
FXx   S tandard   /   F Xx   D eluxe   /   F X
OPERATOR'S INSTRUCTION MANUAL
    N OTICE  
                     
   
W ARNING
       
 
 
1  
 
R
 

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  • Page 1 FXx   S tandard   /   F Xx   D eluxe   /   F X   OPERATOR’S INSTRUCTION MANUAL     N OTICE     This   v ehicle   h as   a   m inimum   a ge   r equirement   o f   1 6   a nd   a   m aximum   w eight   c apacity   o f   1 90   l bs.   ( 86   k g.).     Always  ...
  • Page 2 • This manual contains the latest product information available before printing. Cleveland CycleWerks reserves the right to make changes at any time without notice and without incurring any obligation. • No part of this publication may be reproduced without written permission.
  • Page 3 B. The use of the vehicle after such devise or element of design has been removed or rendered inoperative by any person. 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: Important Warranty Information

    All warranties 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 5: Table Of Contents

      C ONTENTS   IMPORTANT WARRANTY INFORMATION SUSPENSION SYSTEM 41 - 44 INTRODUCTION FRONT SUSPENSION INSPECTION IMPORTANT SAFETY INFORMATION FRONT SUSPENSION ADJUSTMENT 10 - 13 SAFETY INFORMATION FOR PARENTS REAR SUSPENSION INSPECTION SAFETY LABEL INFORMATION REAR SUSPENSION ADJUSTMENT 43, 44 COMPONENT LOCATIONS 15 –...

  • Page 6: Introduction

      I NTRODUCTION   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 vehicle that you have chosen.
  • Page 7 WE ARE CLEVELAND   7  ...
  • Page 8 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 9   G ENERAL   I NFORMATION   WARRANTY   B OOKLET   Besides this Owner’s Manual, this vehicle is also accompanied by a warranty booklet that can be obtained through your distributor, containing important vehicle warranty & emissions warranty information. IMPORTANT Every time the vehicle is serviced by a dealer and/or service center, the owner must produce the warranty booklet so that the dealer can fill in the service information.

  • Page 10: Important Safety Information

    If you take responsibility for safety, properly maintain your motorcycle and understand the challenges you may encounter while riding, your Cleveland motorcycle will provide many years of use and enjoyment. Listed below are some important safety measures you should take when riding.
  • Page 11 Take caution when riding on wet roads as adhesion is greatly reduced. MODIFICATIONS   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, and relieves Cleveland CycleWerks of any liability.   11  ...
  • Page 12 The use of non-genuine parts and/or accessories can make the vehicle unsafe by reducing its handling, stability and the effectiveness of the braking system. For this reason, the installation of any non-genuine accessory makes the warranty void and relieves Cleveland CycleWerks of all liability.

  • Page 13: Safety Information For Parents

    As a parent it is your responsibility to be sure that the motorcycle is properly maintained and kept in safe operating condition. Modifying this motorcycle or using parts not manufactured by Cleveland CycleWerks can make your motorcycle unsafe. Before you consider making any modifications or adding an accessory, please read the following information carefully.

  • Page 14: Safety Label Information

    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. NOTE: Some labels may not be in exact location indicated.

  • Page 15: Component Locations 15 - 16

      C OMPONENT   L OCATIONS   When you ride a motorcycle, you need to be able to operate the throttle, clutch, brakes, and other controls without stopping to look at them. Please read this section carefully before you ride your motorcycle.
  • Page 16   C OMPONENT   L OCATIONS   Chassis   N umber   Fuel   V alve   Air   F ilter   Drive   C hain   Engine   N umber   Side   S tand   Shift   L ever   Fuel  ...

  • Page 17: Serial Number Locations

    VIN   N UMBER   –   E NGINE   N UMBER   L OCATIONS     S ERIAL   N UMBER   L OCATIONS   VIN – Chassis Number The VIN number is located in one of three places on the chassis.

  • Page 18: Handle Bar Lever Controls

    COMPONENT   L OCATIONS     H ANDLEBAR   L EVER   C ONTROLS   Clutch Lever / Hand Brake Lever Note: on 110cc models, the left lever is the front brake, this is NOT THE CLUTCH! On 125cc bikes, the clutch lever is located on the left side of the handlebar.

  • Page 19: Fuel Fill Cap

    COMPONENT   L OCATIONS     F UEL   F ILL   C AP   Fuel Fill Cap To Open: Turn counter-clockwise. To Close: Push down on the cap firmly, and turn clockwise until it is tight. Key Ignition Switch on 125cc Models The ignition key is used to supply power from the battery to the electrical components of the motorcycle in the “ON”...

  • Page 20: Operating Controls

    COMPONENT   L OCATIONS     O PERATING   C ONTROLS   Foot Brake Lever 125cc only. The brake lever is located on the right side of the motorcycle. Its basic operation is to apply the rear brake to slow or stop the motorcycle. NOTE: This is only on the 125cc version.

  • Page 21: Before Riding

      B EFORE   R IDING   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.

  • Page 22: Is The Motorcycle Ready To Ride

    A pre-ride inspection is a must because riding, especially in off road conditions (Cleveland roads) can be very tough on a motorcycle and you do not want to injure yourself, or breakdown far from help. A pre-ride inspection is essential!  ...

  • Page 23: Basic Operation & Riding

      B ASIC   O PERATION   &   R IDING   This section of the manual gives basic information on how to begin riding your motorcycle. In this section, we will cover how to start and stop the engine, how to use the throttle and brakes, how to use the clutch and shift gears, and tasks you need to perform when you are finished riding.

  • Page 24: Engine Starting Procedure

      B ASIC   O PERATION   &   R IDING     S TARTING   &   S TOPPING   T HE   E NGINE   Always follow the proper starting procedure as described below.   S TARTING   P ROCEDURE   ( KICK   S TART)   Cold Starting Procedure 1.

  • Page 25: Shifting Gears

      G ear   O peration   /   G ear   S hifting   This motorcycle has four (4) forward gears 110cc and five (5) forward gears for the 125cc. After the engine has been warmed up and the side stand raised: 4  ...

  • Page 26: Braking Technique

      B RAKING   T ECHNIQUE   This section will cover basic braking technique for your motorcycle. To slow or stop the motorcycle, squeeze and hold the clutch lever (125cc) and apply the front brake lever and rear brake pedal firmly and smoothly.

  • Page 27: Maintaining Your 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.

  • Page 28: Maintenance Schedule

    If you do not feel capable of performing any of the procedures described in this manual or if you need assistance, please contact your nearest 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 29   M AINTENANCE   S CHEDULE       29  ...

  • Page 30: Basic Maintenance Precedures

    87 (AKI USA) / 95 (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 a 87 (AKI USA) / 95 (RON/EU) or higher to ensure maximum performance and reliability.

  • Page 31: Engine Oil

    BASIC   M AINTENANCE   P ROCEDURES       E NGINE   O IL   Using proper oil, and regularly checking, adding and changing oil will help extend the service life of your engine. Even top quality oil wears out and becomes thinner. Changing oil helps get rid of dirt and deposits in the engine.

  • Page 32: Changing Oil & Filter

    BASIC   M AINTENANCE   P ROCEDURES       C HANGING   O IL   &   O IL   F ILTER   1. Start and run the engine at idle for 3-5 minutes, and then shut off the motor. 2.

  • Page 33: Changing Air Filter

    Always replace the air filter with a genuine Cleveland CycleWerks filter specifically designed for your model or a filter of equal quality. Failure to maintain the filter can/may cause engine wear or damage, expensive repairs, low engine power, low fuel mileage, carbon build up on valves and foul the spark plug.

  • Page 34: Engine Idle Speed

    Adjusting the idle will not solve or compensate for a fault elsewhere in the engine. If you are having trouble, please contact your Cleveland CycleWerks dealer. The engine must be at normal operating temperature for an accurate adjustment. 1. If the engine is cold, start it up and let it warm up for 3-5 minutes then shut it off.

  • Page 35: Clutch System

    BASIC   M AINTENANCE   P ROCEDURES       C LUTCH   S YSTEM   1 25cc   M otors   O nly     In order to ensure the best performance and durability from the clutch, always be sure you have proper clutch free-play.
  • Page 36 Fig.   1   and accelerate gradually. 6. If you cannot get the proper adjustment, see you Cleveland CycleWerks dealer or service center.   S HIFT   L EVER   1. The shift lever should not have any free play in it.

  • Page 37: Spark Plug

    Do not over or under tighten the spark plug. 9. We would like to extend an extra pre-caution to NOT over tighten the spark plug, all Cleveland CycleWerks motors are aluminum. Stripped threads can occur if they are torqued above recommended specification.

  • Page 38: Braking System

    BASIC   M AINTENANCE   P ROCEDURES       B RAKING   S YSTEM   Your motorcycle is equipped with hydraulic disc brakes on both the front and rear wheels. Hydraulic brakes require brake fluid for systems operation. Both front and rear brakes have a brake fluid reservoir built into the master cylinders.

  • Page 39: Adding Brake Fluid

    If one side has worn down more extensive than the other, consult your Cleveland CycleWerks dealer about the brake caliper, and its operational status. 4. If you are unsure how to replace the brake pads,...

  • Page 40: Brake System Bleeding

    The lever/pedal should feel hard and firm when you are complete.   B RAKE   P AD   C HANGE   Contact your Cleveland CycleWerks dealer and/or service center.     N OTICE  ...

  • Page 41: Suspension System

    Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Cleveland CycleWerks dealer for service and/or inspection. Your Cleveland CycleWerks dealer is qualified to determine whether or not replacement parts or service is required.

  • Page 42: Rear Suspension Inspection

    Loose, worn or damaged suspension components may affect the stability and handling of your motorcycle. If any of the suspension components seem to be worn or damaged, see your Cleveland CycleWerks dealer for service and/or inspection. Your Cleveland CycleWerks dealer is qualified to determine whether or not replacement parts or service is required.

  • Page 43: Rear Suspension Adjustment

    DO   N OT   T RY   T O   R EPAIR   T HE   S HOCK.   I F   R EPAIR   I S   NECESSARY,   T AKE   T HE   M OTORCYCLE   T O   A   CLEVELAND   C YCLEWERKS   D EALER.    ...
  • Page 44 DO   N OT   T RY   T O   R EPAIR   T HE   S HOCK.   I F   R EPAIR   I S   NECESSARY,   T AKE   T HE   M OTORCYCLE   T O   A   CLEVELAND   C YCLEWERKS   D EALER.    ...

  • Page 45: Rims & Tires

    Look for a wobble in the wheel. If a wobble is evident, the wheel is not “true”. See your Cleveland CycleWerks dealer or local motorcycle shop for inspection.

  • Page 46: Tire Inspection

    " Replace the valve stem anytime you replace a tire. " Have the wheel balanced after a new tire has been installed (on road bikes). " We recommend getting tires replaced by your Cleveland CycleWerks dealer or a qualified local motorcycle shop.

  • Page 47: New Tire Break-In Period

    This indicates that the chain is worn beyond its service limit. 5. Inspect the front and rear sprockets for excessive wear or damage. Refer to the illustration at the top of page 48. If needed, replace any worn or damaged sprockets. See your Cleveland CycleWerks dealer for assistance.

  • Page 48: Drive Sprocket Inspection

    4. If you cannot or do not know how, take the motorcycle to an Cleveland CycleWerks dealer for service.     C AUTION  ...

  • Page 49: Chain Slider Inspection

    BASIC   M AINTENANCE   P ROCEDURES         C HAIN   S LIDERS   CHAIN   S LIDER   I NSPECTION       1. Check the slider for wear. 2. If the wear limit has been reached, it must be replaced.

  • Page 50: Chain Removal & Replacement

    3. Inspect the drive chain for possible wear or damage. Replace the drive chain if it has any damaged rollers, loose fitting links, or otherwise appear unserviceable. 4. Inspect the sprockets for wear or damage. Cleveland CycleWerks recommends that you replace the sprockets when you install a new drive chain.

  • Page 51: Troubleshooting

    No hard / firmness in the kick start lever means you have poor compression. Is compression normal? - Valve stuck open/seized or improper valve timing (see your Cleveland CycleWerks dealer) - Worn cylinder wall and/or piston rings (replace) - Leaking or damaged cylinder head gasket (see your Cleveland CycleWerks dealer)
  • Page 52 7. Cylinder Compression Inspection - Check the cylinder compression. Is the engine compression normal? - Valve stuck open/seized or improper valve timing (see your Cleveland CycleWerks dealer) - Worn cylinder wall and/or piston rings (replace) - Leaking or damaged cylinder head gasket (see your Cleveland CycleWerks dealer) - SEE STEP 8  ...
  • Page 53 - Excessive carbon buildup in the combustion chamber Ignition Timing Inspection - See your local Cleveland CycleWerks dealer or motorcycle repair shop to have the ignition timing and engine lubrication system inspected. Only attempt these procedures if you are qualified and have the proper tools needed.
  • Page 54 Carburetor Air Screw Inspection – Dealer service only part, see your local Cleveland CycleWerks dealer. Ignition Timing Inspection - See your local Cleveland CycleWerks dealer or motorcycle repair shop to have the ignition timing inspected. Only attempt these procedures if you are qualified and have the proper tools needed.
  • Page 55 TROUBLESHOOTING         P OOR   H ANDLING   Steering is heavy - Steering stem nut is too tight - Damaged steering head bearings - Check tire pressure/tires low on air Either wheel has a Wobble (Weebles Wobble) - Excessive wheel bearing play - Bent Rim - Improperly installed wheel hub...

  • Page 56: Dealing With The Unexpected

    DEALING   W ITH   T HE   U NEXPECTED         G ENERAL   G UIDELINES   If you encounter trouble during a ride, the first thing you should do is stop as soon as possible in a safe area.
  • Page 57 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 58: Specifications

    SPECIFICATIONS   Standard Deluxe Engine Design Type Single Cylinder, 4-Stroke Single Cylinder, 4-Stroke Timing System SOHC 2-Valve SOHC 2-Valve Displacement 106.7 ml 106.7 ml Bore & Stroke 52.4 mm x 49.5 mm 52.4 mm x 49.5 mm Compression Ratio 9.7 : 1 9.7 : 1 Power Max.

  • Page 59: Specifications

    SPECIFICATIONS   Dimensions & Weight Wheelbase 128 cm (50.39 in) 128 cm (50.39 in) Overall Length 196 cm (77.16 in) 196 cm (77.16 in) Overall Width 74.5 cm (29.33 in) 74.5 cm (29.33 in) Overall Height 115 cm (45.27 in.) 115 cm (45.27 in.) Seat Height 84.5 cm (33.27 in.)

  • Page 60: Specifications

    SPECIFICATIONS   Brakes Front Brake Single 240mm diameter steel disc Single 240mm diameter steel disc Front Brake Caliper Dual piston caliper Dual piston caliper Rear Brake Single 240mm diameter steel disc Single 240mm diameter steel disc Rear Brake Caliper Dual piston caliper Dual piston caliper Wheels Front: Material/Size...

  • Page 61: Wiring Schematics

    WIRING   S CHEMATIC       61  ...

  • Page 62: Maintenance Records

    MAINTENANCE   S CHEDULE   R ECORD   Odometer or Hour Odometer or Hour Odometer or Hour Reading Reading Reading 00,000 Dealer Stamp Dealer Stamp Dealer Stamp Date Date Date Signature Signature Signature Odometer or Hour Odometer or Hour Odometer or Hour Reading Reading Reading...

  • Page 63: Notes

    NOTES     63  ...
  • Page 64 NOTES     64  ...
  • Page 65   65  ...

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