Cleveland FXx Standard, FXx Deluxe, FXR, FR1000 Owner's Manual

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OPERATOR’S INSTRUCTION MANUAL

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FXx Standard / FXx Deluxe / FXR / FR1000

Owner’s Manual

• This manual should be considered a permanent part of the motorcycle

and should remain if it is resold.

• 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.

REV.1!01/2015

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Please write the serial numbers of your motorcycle in the boxes below

Chassis (VIN) Number

Engine Number

Dealer

Color Codes

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. It shall be acceptable to stop manufacturing a certain model without prior notice. In the event of such modifications, please ask your local Cleveland CycleWerks dealer for information.

IMPORTANT

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING

ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND

ADVICE, WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY.

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CONSUMER INFORMATION FOR UNITED STATES

Tampering with noise & emissions control systems is prohibited

Owners are warned that the law prohibits:

A. The removal or rendering inoperative by any person other than for purposes of

maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise and/or emissions control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

B. The use of the vehicle after such devise or element of design has been removed or

rendered inoperative by any person.

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Body

Frame

Swing Arm

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:IMPORTANT WARRANTY INFORMATION:

YOUR WARRANTY IS OFFERED AND SERVICED DIRECTLY BY THE IMPORTER / DISTRIBUTOR

WITHIN EACH COUNTRY. CLEVELAND CYCLEWERKS DOES NOT SERVICE OR EXTEND A

WARRANTY DIRECTLY TO CUSTOMERS, YOU MUST GO THROUGH YOUR DISTRIBUTOR.

WARRANTY PROCESS: CUSTOMER > CONTACT DEALER FIRST > DEALER CONTACT

DISTRIBUTOR.

This document does not express, extend, or imply that Cleveland CycleWerks is directly or indirectly offering a warranty for the product in your country. 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.

PLEASE REFERENCE YOUR WARRANTY AND SERVICE BOOKLET FOR

MORE INFORMATION & EMISSIONS WARRANTY

TO RECIEVE SERVICE: Contact your nearest Cleveland CycleWerks service center and/or dealer. The cost of transportation of the product to and from the service center and/or dealer must be paid by the owner.

No service center and/or dealer is authorized to modify this warranty.

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IMPORTANT WARRANTY INFORMATION

INTRODUCTION

IMPORTANT SAFETY INFORMATION

SAFETY INFORMATION FOR PARENTS

SAFETY LABEL INFORMATION

COMPONENT LOCATIONS

SERIAL NUMBER LOCATIONS

HANDLE BAR LEVER CONTROLS

FUEL FILL CAP

OPERATING CONTROLS

KEY IGNITION SWITCH

FUEL PET-COCK

BEFORE RIDING

PROTECTIVE GEAR & APPAREL

IS THE MOTORCYCLE READY TO RIDE

PRE-RIDE INSPECTION

BASIC OPERATION & RIDING

BREAK-IN PERIOD

SAFE RIDE PRECAUTIONS

ENGINE STARTING PROCEDURE

FLOODED ENGINE

STOPPING THE ENGINE

SHIFTING GEARS

BRAKING TECHNIQUE

PARKING & POST RIDE INSPECTION

MAINTAINING YOUR MOTORYCLE

IMPORTANT SAFETY PRECAUTIONS

MAINTENANCE SCHEDULE

BASIC MAINTENANCE PRECEDURES

FUEL, GASOLINE

REFUELING & INSPECTION

ENGINE OIL

CHECKING & ADDING OIL

CHANGING OIL & FILTER

CHANGING AIR FILTER

THROTTLE SYSTEM

ENGINE IDLE SPEED

CLUTCH SYSTEM

SPARK PLUG

BRAKING SYSTEM

BRAKE LEVER ADJUSTMENT

BRAKE FLUID CHECK

ADDING BRAKE FLUID

BRAKE PADS

BRAKE SYSTEM BLEEDING

SUSPENSION SYSTEM

FRONT SUSPENSION INSPECTION

FRONT SUSPENSION ADJUSTMENT

REAR SUSPENSION INSPECTION

REAR SUSPENSION ADJUSTMENT

RIMS & TIRES

TIRE AIR PRESSURE

TIRE INSPECTION

TIRE REPLACEMENT

NEW TIRE BREAK-IN PERIOD

DRIVE CHAIN SYSTEM

DRIVE CHAIN INSPECTION

DRIVE SPROCKET INSPECTION

CHAIN ROLLER INSPECTION

CHAIN SLIDER INSPECTION

CHAIN ADJUSTMENT

CHAIN LUBRICATION

CHAIN REMOVAL & REPLACEMENT

TROUBLESHOOTING

DEALING WITH THE UNEXPECTED

SPECIFICATIONS

WIRING SCHEMATICS

MAINTENANCE RECORDS

NOTES

51 - 55

56 - 57

58 – 60

61

62

63-64

47 - 50

47

48

49

50

45 - 47

45

46

47

41 - 44

41

42

43, 44

04

06

10 - 13

13

14

17

18

19

20

19

21

22

23 - 24

23

24

25

26

27

28, 29

30 - 50

30

31

32

33

34

35 - 36

37

38 - 40

38

39

40

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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.

We do our best to provide a trouble free and exceptional product from the factory. We recommend you to strictly follow the instructions given in this manual, paying close attention to the break-in period of this motor vehicle.

The instructions contained in this manual will help you make the most of your motorcycles performance and operational life. This manual provides useful information on how to take care of your vehicle, and also describes routine maintenance operations.

For any servicing or assistance you might need, please contact our authorized dealer and/or service centers.

Cleveland CycleWerks makes every attempt possible to verify the accuracy of our user manuals, we understand mistakes happen, as manuals are written during the development of the vehicle, specifications and variations do occur between writing the manual and production, we clearly state this and note that variations may happen between the manual and production. Every country has a unique set of laws and statutes, your countries model may vary slightly from the images or descriptions, due to each individual countries compliance regulations.

The information contained herein is valid at the time of printing. Cleveland CycleWerks reserves the right to make changes required by the future development of the above mentioned products. We do our best to verify the accuracy of this manual, but mistakes do happen, no liability is accepted for mistakes during the drafting of this manual.

For your safety and reliability of your vehicle, use original CLEVELAND CYCLEWERKS spare parts ONLY.

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WE ARE

CLEVELAND

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In addition to providing directions on operating and maintaining your motorcycle, this manual contains important safety information. Please read this manual over carefully before using your motorcycle.

Your personal safety, and the safety of those around you, is extremely important. Operating this motorcycle safely is an important responsibility. Cleveland CycleWerks has provided operating procedures and other information on labels in this manual to help you make informed decisions about safety. This information will alert you to potential hazards that could harm you or others.

It is not practical or possible to warn you about all possible hazards associated with operating and maintaining a motorcycle. You must use your own good judgment and common sense. In many cases “common sense” seems to be less and less common. Please use solid judgment, do not ride above your ability and respect the fact that you are a sack of water traveling through space at a high rate of speed. Respect the bike, respect the terrains and use caution.

Safety information will come in a variety of different forms, including:

! Safety Labels on the Motorcycle.

! Safety Messages preceded by a safety symbol and one of these signal words:

Sections of text in this manual which are particularly important in terms of safety or possible to the motorcycle are marked with the following symbols:

You CAN be KILLED or SERIOUSLY INJURED if you do not follow instructions.

You CAN be INJURED if you do not follow instructions.

! Safety Headings such as important safety reminders and/or precautions. ! Safety Section such as motorcycle safety. ! Instructions how to use the motorcycle properly and safely.

This manual is filled with important safety information - please read it carefully.

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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.

1. Frame Serial Number (VIN)

2. Engine Serial Number

The motorcycle is identified by the VIN number. When placing orders for spare parts, you are may be required to provide the VIN, engine serial number and the color code numbers.

We recommend you to write down all these numbers and keep them in a safe place with the Owners Manual and warranty booklet.

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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.

Before Riding. Carefully read this manual to familiarize yourself with the controls,

characteristics, functions and limits of the motorcycle,and your own ability.

Never attach a sidecar, a trailer or any other accessory to the motorcycle. Do Not modify the vehicle in any way. Failure to observe this prescription may make the vehicle unstable and cause serious accidents and/or injury.

Never Ride Without a Helmet. The following statement is a proven fact: “Helmets significantly reduce the number and severity of head injuries.” Never ride your motorcycle without a helmet. Even a crash at slow speed can result in a fatal head injury if you are not wearing a helmet. Cleveland CycleWerks strongly recommends wearing helmets that have been certified for safety by helmet testing organizations that are independent from the helmet manufacturer. We also recommend that you wear eye protection, boots, gloves, and other protective gear such as riding pants, and a chest protector if riding off road.

Never Carry a Passenger. This motorcycle has been designed for ONE rider only. There are no passenger pegs, footrests, hand holds or seat room for a passenger. Riding with a passenger can interfere with your ability to operate and/or control the motorcycle and may result in serious injury or death.

Ride Within Your Limits. Never attempt to ride your motorcycle in a manner that is beyond your skill level. It takes time to learn proper riding skills. Learn to ride your motorcycle step by step. Start by practicing in safe areas at slow speeds and gradually build your skill level. Instruction from an experienced rider(s) is highly recommended. Remember that alcohol, drug use, fatigue and ignorance can reduce your ability to make good decisions and ride safely.

Be Alert for Hazards. The terrain or road in which you ride can present many hazards. Always “scan” the terrain or road ahead of you continually. Watch for unexpected turns, drop-offs, ditches, rocks and other hazards. Always maintain a speed slow enough to allow you enough time to see and react to hazards.

Do Not Drink and Ride. Even one drink can impair your ability to ride a motorcycle safely. Each additional drink will make the impairment worse. Do not drink and ride. Do not let your friend’s drink and ride. Remember, in most states throughout the United States, you can be arrested and charged with Driving Under the Influence (DUI) if you are riding a motorcycle while intoxicated.

To ensure maximum reliability and maintain the motorcycle in perfect working condition, it is essential to perform the servicing detailed in the Scheduled Maintenance Table(s) and to follow all the direction provided in this manual. For further information, please contact your authorized dealer and/or service center that possess the necessary technical skills.

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! DO NOT use the motorcycle or try to service it if you do not possess the necessary

skills.

! Full control of the motorcycle is necessary for safe riding. Concentration and good

physical condition are essential for riding a motorcycle. The road and weather conditions must also be taken in to consideration; speed and steering can be affected.

! Always wear suitable clothes, especially when traveling at night. (Motorcycle garments

with reflective bands are recommended for night riding).

! ALWAYS wear a helmet, even if you go for a short ride.

! When traveling during daytime, keep the low beam light on if allowed by local laws.

! NEVER wear garments that could adversely affect control and handling of your

motorcycle.

! When refueling, switch off the engine, refrain from smoking, avoid spilling fuel onto the

tank and the exhaust pipe.

! When refueling, avoid inhaling harmful fuel vapors. If fuel comes in contact with skin or

clothes, immediately wash with water and change the contaminated garments.

! Some parts of the motorcycle become very hot during use. Avoid contact with these

parts and keep the motorcycle out of the reach of children, especially when hot.

! Always park the motorcycle safely and avoid leaving it unattended while the ignition

key is in the ignition, on the motorcycle.

! Park the motorcycle where it is visible, and not in danger of passing traffic. ! To prevent the vehicle from tipping over, never park on soft, or uneven ground. ! DO NOT start the motorcycle in an enclosed area. Exhaust fumes are toxic and can

quickly saturate the air causing death.

! Before starting the engine in a closed place, ensure that the area is well ventilated. ! While the vehicle is in motion, keep your feet on the appropriate foot pegs. ! While riding, keep both hands on the handlebars at all times. ! Maximum performance of the standard brake pads and tires is obtained on dry roads.

Take caution when riding on wet roads as adhesion is greatly reduced.

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.

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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.

The rider’s ability and his/her mechanical skills form the basis of riding safety. It is advisable to practice riding in a closed course, to familiarize yourself with the vehicle, it’s operation, and controls. Motorcycle riding is a learned skill, compounding over a long period of time. Valentino Rossi did not become “The Doctor” over night.

Remember: practice makes perfect, one solid turn leads to the next and in time you become a better rider.

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As a parent, your child’s safety is your first priority (Child meaning any rider under the legal age of adulthood and independence in their country). Riding a motorcycle is very fun. However, just like riding a bicycle, bad decisions can result in injury. As a parent, you can greatly prevent accidents by making informed decisions about if, when and how your child will ride. Always supervise your child when he/she is riding. We advise that no one under the legal riding age take part in riding any of our motorcycles.

Before you allow your child to ride, you need to decide if he/she is capable of riding. Riding readiness can vary tremendously from one person to another. Age and size are not the only factors that help determine one’s riding readiness. There are three other factors that you should consider before deciding if your child is ready to ride.

First, consider the physical ability of your child. Riders must be able to hold the motorcycle up, get on, and sit comfortably with both feet on the ground. The rider must also be able to reach all of the controls on the handlebars and work the brakes and clutch. Second, consider your child’s athletic ability. Your child should be good at riding a bicycle before riding a motorcycle. Determine if your child can judge speeds and distances while riding a bicycle and react with the proper hand and foot actions. Any person who does not have good coordination, balance, and agility should not ride this motorcycle.

Finally, determine your child’s level of mental maturity. It is imperative that you are honest with yourself when you ask yourself the following questions: Does your child think through problems and come to logical conclusions? Does your child obey your rules when they ride their bicycle? If your child makes bad judgments, takes un-warranted risks and/or does not obey your rules, they should not ride this motorcycle.

If you have decided that your child is ready to ride, please remember the following points and never let your child ride without a helmet. It is up to you (parent) to ensure your child’s safety, even if they learn to ride from another experienced adult. Never push your child to try things faster than they are willing or capable. Always supervise your child when they are riding and regularly remind them about safety rules. 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.

Improper accessories or modifications can cause a crash in which you can be seriously hurt or killed. Follow all instructions in this owner’s manual regarding and accessories.

Cleveland CycleWerks strongly recommends that you do not remove any original equipment or modify your motorcycle in any way that may alter the design and/or operation. Such a change could drastically impair the stability, handling, acceleration, and braking capabilities of the motorcycle and cause a crash. Do not make any modifications to the exhaust system, noise control system or

emission control components. This is illegal in almost every country we sell motor vehicles.

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This page will show you where to find the safety labels on your motorcycle. You will find that some labels warn

you of potential hazards. 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.

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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. This section of the manual will show the location and operation of all the basic controls of your motorcycle.

110cc version has an auto-clutch / hand brakes only

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Front!Brake!Lever!

Throttle!Adjuster!

!Throttle!

Front!Master!Cylinder!&!Reservoir!

Rear!Brake!Lever!

Engine!Stop!Switch!

Rear!Master!Cylinder!&!Reservoir!

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CDI!Box!

Fuel!Valve!

Kick!Starter!

Spark!Plug!

Engine!Number!

Side!Stand!

Shift!Lever!

Fuel!Cap! Drive!Chain!

Air!Filter!

Chassis!Number!

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VIN – Chassis Number

The VIN number is located in one of three places on the chassis.

1. Right Side of frame.

2. Left side of frame.

3. Steering head tube.

Write this number in the VIN box on page 3.

Engine Model & Serial Number

The engine model number and serial number is

stamped on the left side of the engine under the

countershaft sprocket.

Write this number is the Engine Number box on

page 3.

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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.

Choke Lever

When pulling the choke lever in the up position, the choke is ON. When the lever is in the down position, the choke is OFF. When pulled, the butterfly valve in the carburetor is closed. The engine takes in additional fuel resulting in a rich fuel and air mixture ratio, which is needed for a cold start. When releasing the choke lever, the cylinder is open again. This should be done, once the motor is warm. DO NOT RIDE WITH THE CHOKE ON!

Stop Switch / Button

The stop switch turns off the engine. When this button is pressed, the ignition circuit is turned off.

Hand Brake Lever & Throttle

The hand brake lever and throttle is mounted on the right side of the handlebar.

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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” position . Turn the switch to the “OFF” position when you are finished riding, or if you wish to stop the engine.

Ignition Kill Button on 110cc Models

Push and hold the kill button until the motor is no longer running.

Fuel Tap / Petcock

OFF - In this position, the fuel tap is closed. No fuel

flows from tank to the carburetor.

ON - In this position, the fuel tap in open. Fuel flows from the tank to the carburetor. The fuel tank empties down to the reserve level.

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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. 110cc has a left hand rear brake.

Kick Start Lever The kick start lever is mounted on the right side of

the engine. It is used to start the engine exclusively on the 110cc versions and in case the electrical starter system is non-functional on the FXR.

Shift Lever

The shift lever is on the left side of the motorcycle. The gear positions are shown in the illustration on page 24.

Side Stand Push the side stand to the ground and tilt the

motorcycle to the left. Make sure the bike is on solid ground and the position is secure.

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Cleveland FXx Standard, FXx Deluxe, FXR, FR1000 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual