Maintenance & Break-in Procedures

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Break-in Procedures

The first few rides with your new motorcycle are the most important. As with any air-cooled engine, heat is the major enemy you can encounter. Your engine cools as air flows past the cylinder fins and the oil circulates. Sitting still for extended periods of time – such as in heavy traffic – will prevent air from flowing past your engine. Oil temperature is a big concern with your new engine.

To avoid engine damage, the following guidelines MUST be adhered to if pistons have been fit to “Close Fit” tolerances.

  1. Do not allow engine to idle longer than absolutely necessary after initial start-up. Heat build-up can be excessive, resulting in engine damage. With carb jetting and ignition timing correct, ride motorcycle immediately to provide sufficient airflow and cooling. Avoid heavy stop and go traffic.


Overheating from excessive idling, poor ignition and carb tuning, etc. can cause engine damage not covered by warranty.
Operating engine prematurely at high RPM and/or lugging engine at low RPM may result in engine damage not covered by warranty.
  1. First 50 miles are most critical for new rings and pistons. Most engine wear occurs during this period. Always allow engine to warm before cracking throttle or putting under heavy load. Improper engine start-up or break-in procedure can cause head gasket failure and other engine damage. Once underway, vary speed. Keep heat down by not exceeding 2500 RPM, not lugging engine and avoiding heavy stop and go traffic. Do not exceed 50 mph (80 km/h)
  2. Change the engine oil at the 50-mile point.
  3. Next 500 miles should be spent operating engine no faster than 3500 RPM or about 60-70 mph, depending on gearing. Do not lug engine and continue to vary speed.
  4. Change the oil at 500 miles.
  5. For balance of first 1,000 miles (1,600 km), speed can be increased to approximately 70 mph, again depending on gearing. Continue to operate at different speeds including lower 45-mph ranges, but do not lug at low RPM. Avoid overheating the engine. Do not exceed 70 mph (115 km/h).
  6. Once you achieve 1,000 miles on the engine, verify the ignition and carburetor settings and change the oil.
  7. For the next 1,000 miles speed and RPM may slightly increase but there should be no racing, trailer towing, etc. It remains critical to avoid overheating and lugging engine.

500 Mile Maintenance

  • Drain oil tank through drain plug, and replace with fresh oil.
  • Drain transmission through drain plug and refill to level of filler opening with fresh oil. Use same grade oil used in engine.
  • Lubricate all points indicated for 1,000 mile attention in the regular service.
  • Visually inspect and service air cleaner if needed.
  • Inspect chain tension.
  • Inspect chain lubrication.
  • Inspect wheels and brakes.
  • Inspect battery terminals are clean and connections tight.
  • Check tire pressures and tread wear pattern.
  • Confirm brake operation.
  • Inspect front and rear wheel bearing play and grease.
  • Confirm carb/throttle response.
  • Visually inspect for leaks.

1,000 Mile maintenance

  • Drain oil tank and refill with fresh oil.
  • Check level of oil in transmission and add oil if needed
  • Visually inspect air cleaner.
  • Check adjustment of chains and adjust if necessary.
  • Check primary fluid level.
  • Check lubrication and condition of front chain.
  • Check lubrication and condition of rear chain.
  • Check battery. See that terminals are clean and connections tight.
  • Check circuit breaker condition.
  • Check brake adjustment.
  • Confirm clutch operation.
  • Check tire pressure and inspect tread.
  • Confirm operation of carb/throttle response.
  • Grease bearings front and rear.
  • Confirm operation of brakes.

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Posted On: April 10th 2018