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HYOSUNG Aquil GV650, Service Manual

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HYOSUNG Aquil GV650 Service Manual Download Page 3

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing and 
meaning associated with them respectively.

Apply THREAD LOCK 

“

1324

”

.

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Use special tool.

Use engine coolant.

Torque control required.
Data beside it indicates specified torque.

Apply oil. Use engine oil unless otherwise
specified.

Apply SUPER GREASE 

“

A

”

.

Apply SILICONE GREASE.

Apply MOLY PASTE.

Apply BOND 

“

1215

”

.

Use fork oil.

DEFINITION

SYMBOL

DEFINITION

SYMBOL

Apply SUPER GREASE 

“

C

”

.

Summary of Contents for Aquil GV650

Page 1: ...ERY INC FOREWORD This manual contains an introductory description on HYOSUNG and procedures for its inspection service and overhaul of its main components Other information considered as generally kno...

Page 2: ...sections is listed on the previous page as GROUP INDEX select the section where you are look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section ea...

Page 3: ...r use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Use engine coolant Torque control required Data beside it indicates specified torque Ap...

Page 4: ...NOTE Difference between photographs and actual motorcycles depends on the markets...

Page 5: ...MATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 3 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS 1 4 BREAK IN PROCEDURES 1 6 CYLINDER CLASSIFICATION 1 6 EXTERIOR ILLUSTRATION 1 7 SPECI...

Page 6: ...t in vehicle damage WARNING Indicates a potential hazard that could result in death or injury NOTE Indicates special information to make maintenance easier or instructions cleaner WARNING Proper servi...

Page 7: ...r head and case bolts and nuts beginning with larger diameter and ending with small er diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaske...

Page 8: ...Number is stamped on the steering head tube The engine serial number is located on the left downside of crankcase assembly These numbers are required especially for registering the machine and orderin...

Page 9: ...ENGINE OIL SPECIFICATION WARNING Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside Mop the oil spilt Don t put the patch on the...

Page 10: ...rature in your area does not go down to freezing point Hyosung recommends the use of HYOSUNG COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an a...

Page 11: ...e position BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving pa...

Page 12: ...1 7 GENERAL INFORMATION EXTERIOR ILLUSTRATION...

Page 13: ...62 0 mm 2 44 in 647 39 5 in3 BDSR39 TYPE DOUBLE Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Lubrication system Wet multi plate type 5 sp...

Page 14: ...M Igniter type 5 B T D C at 1 500 rpm CR8E 12V 12Ah MF Main 30 A Head lamp 15 A HI 60 W LO 55 W 10 W 4 LED type 5 W Ignition type Ignition timing Spark plug Battery Turn signal lamp Brake Tail lamp Li...

Page 15: ...AND MUFFLER MOUNTING BOLTS 2 7 AIR CLEANER 2 8 CARBURETOR 2 9 FUEL HOSE 2 10 CLUTCH 2 10 ENGINE OIL 2 12 ENGINE OIL FILTER 2 14 DRIVE BELT 2 15 BRAKE SYSTEM 2 17 STEERING 2 21 FRONT FORK 2 21 REAR SU...

Page 16: ...pension Chassis bolts and nuts Inspect Inspect Inspect Inspect Inspect Tighten Inspect Inspect Inspect Inspect Inspect Inspect Inspect Tighten Inspect every 1 000km Replace every 4 years Replace every...

Page 17: ...TANK STAY has the fuel tank stay under the seat Use the fuel tank stay to inspect the engine or the other parts easily Remove the fuel tank mounting bolt Take the fuel tank stay off the tray upper the...

Page 18: ...ssenger footrests pivot Side stand pivot and spring hook Footrests pivot Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot O Motor oil G Grease NOTE Before lubricatin...

Page 19: ...to page 2 2 Remove the spark plug Refer to page 2 6 Remove the cylinder head cover and Remove the magneto cover plug and the tim ing inspection plug Rotate the magneto rotor counter clockwise to set...

Page 20: ...m selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 170 1 70 mm select 195 1 95 mm of the shim which 170 1 70 mm of the shim ad...

Page 21: ...and Every 6 000 km Replace Every 12 000 km Disconnect the spark plug caps Remove the spark plugs CAUTION Be careful not to damage the radiator fins Do not extract the radiator hose Remove the seat and...

Page 22: ...LTS Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Exhaust pipe bolt 18 28 N m 1 8 2 8 kg m Muffler mounting bolt 18 28 N m 1 8 2 8 kg m Inspect Interval Tighten Ini...

Page 23: ...e Be careful not to allow water to go inside the air clea ner element CAUTION More frequent servicing may be performed on mo torcycles that are used under severe condi tions also clean the air cleaner...

Page 24: ...ng the adjuster While holding the throttle grip at the fully closed posi tion slowly turn out the adjuster of the returning cable until resistance is felt Tighten the lock nut while holding the adjust...

Page 25: ...ay A basis adjustment be allowed by the clutch lever adjuster Loosen the clutch lever adjuster Screw the lock nut clockwise fully after finishing adjustment After end of adjustment tighten the lock nu...

Page 26: ...ion is delivered from the factory on position GEARSHIFT LINK ROD When the footrests in position exchange the gearshift link rod for appropriate riding position Position Install the gearshift link rod...

Page 27: ...e is warm Oil fil ter replacement at the above intervals should be together with the engine oil change Keep the motorcycle upright Place an oil pan below the engine and drain the oil by removing the f...

Page 28: ...low the Lower line mark L in the inspec tion window Never fill the engine oil above the Upper line mark F Engine oil level being most suitable about 1mm under the Upper line mark F of the engine oil l...

Page 29: ...YOSUNG character and 16510HN910 part s NO install to ward the outside otherwise can damage the engine WARNING Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug a...

Page 30: ...ing the drive belt replace the drive belt and pulleys as a set 2 15 PERIODIC MAINTENANCE Place the motorcycle on jack or block for accurate adjustment After adjusting the drive belt tighten the axle b...

Page 31: ...touch the muffler when it is hot a hot muffler can burn you CAUTION Never bend or twist when the drive belt is kept or installed If the drive belt was installed with driver forcedly damage the drive...

Page 32: ...e fluid on the brake pad of disk Front Brake L LO OW WE ER R BRAKE PAD WEAR The extend of brake pad wear can be checked by observing the grooved limit on the pad When the wear exceeds the grooved limi...

Page 33: ...Brake Right side of Front Brake Rear Brake FRONT AND REAR BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight Remove the master cylinder reservoir cap and...

Page 34: ...to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full brak ing performance of the brake caliper The presence of air is indicated by spongines...

Page 35: ...e the tension of the brake lever causing it to touch the handlebar grip Then close the air bleeder valve pump and squeeze the brake lever and open the valve Repeat this process until the fluid flowing...

Page 36: ...If play is found perform steering stem nut adjustment as described in page 7 30 of this manual FRONT FORK Inspect the front forks for oil leakage scoring or scratch es on the outer surface of the inne...

Page 37: ...ir specified torque Refer to page 8 13 COLD INFLATION TIRE PRESSURE Front Rear SOLO RIDING KPa 221 245 2 25 2 50 33 0 36 0 221 285 2 25 2 90 33 0 42 0 kgf cm2 psi DUAL RIDING KPa kgf cm2 psi TIRE PRES...

Page 38: ...capacity Reserve tank side Radiator side Engine side 230 430 940 WARNING Engine coolant is harmful if swallowed or if it comes in contact with skin or eyes Keep out of the reach of children and animal...

Page 39: ...escaping hot liquid or vapor WARNING You can be injured by scalding fluid or steam if you open the radiator cap when engine is hot After the engine cools wrap a thick cloth around cap and carefully r...

Page 40: ...adiator cap inlet Start up the engine and bleed air from the radiator cap inlet completely Add engine coolant up to the radiator cap inlet Repeat the above procedure until no air bleed from the radiat...

Page 41: ...The difference in compression pressure between two cylinder is more than 2kg All compression pressure readings are nearly 12kg even when they measure more than 12kg COMPRESSION TEST PROCEDURE Compress...

Page 42: ...pm Winter 20 min at 2 000 rpm After warming up increase the engine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge Engine tachometer 09900 26006 Oil pressure gauge 09915...

Page 43: ...identification of assembly location on each removed part so that each will be restored to the original position during reassembly Wash clean and dry the removed parts before inspecting and measuring...

Page 44: ...ove the seat Refer to page 7 1 Remove the fuel tank Refer to page 4 1 Remove the frame cover Refer to page 7 2 Disconnect the battery lead wire NOTE If the engine is dirtied wash the machine with a su...

Page 45: ...switch lead wire coupler Disconnect the radiator inlet hose Remove the four radiator cover mounting bolts Remove the radiator cover Disconnect the radiator outlet hose Remove the radiator mounting bo...

Page 46: ...lutch release arm EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts rear exhaust pipe connecting bolts and muffler mounting bolts removed remove the exhaust pipes and muffler CARBURETOR Remove the...

Page 47: ...ECTRIC PARTS By taking out the spark plug caps remove the spark plug Remove the starter motor lead wire Disconnect the engine coolant temperature sensor lead wire ENGINE 3 4 Front Cylinder Rear Cylind...

Page 48: ...ct the two magneto coupler Disconnect the neutral switch terminal Disconnect the side stand switch lead wire couper ENGINE PULLEY Remove the engine pulley cover Disconnect the front side of crankcase...

Page 49: ...rburetor when removing or installing the engine necessarily When removing the carburetor loosen the intake pipe mounting bolts at the same time Remove the gearshift arm Flatten the lock washer Remove...

Page 50: ...5 50 N m 3 5 5 0 kg m Tighten the frame down tube mounting bolts to the specified torque Frame down tube mounting bolt 22 35 N m 2 2 3 5 kg m CAUTION Set the part of engine mounting bolt align center...

Page 51: ...Install the breather hose and engine pulley cover Connect each electric parts and its couplers Refer to page 8 24 30 Install the exhaust pipes and mufflers Install the carburetor and air cleaner Refe...

Page 52: ...move the contacts and springs THERMOSTAT Remove the thermostat case along with the hose CAUTION Identify the position of each removed part Organize the parts in their respective groups so that they ca...

Page 53: ...er 2ND AIR VALVE Remove the 2nd air valve with the bracket CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter clockwise To set pi...

Page 54: ...emove the cam chain guide NO 2 Remove the camshaft housing Remove the camshaft IN EX NOTE Mark an identification of assembly location on each removed parts so that each will be restored to the origina...

Page 55: ...shim with the strong magnet not to be scratched ENGINE 3 12 Loosen the six cylinder head bolts Remove the chain guide NO 1 and cylinder head Loosen the cylinder head base bolt NOTE When loosening the...

Page 56: ...the valve cotter from the valve stem Remove the valve spring retainer Pull out valve from the other side CAUTION The tappet and shim should be lined so that each will be restored to the original posit...

Page 57: ...ankcase Remove the piston pin circlips with long nose pliers Piston pin puller 09910 34510 Remove the piston pin by using the special tool Remove the rear cylinder head and cylinder with the same mann...

Page 58: ...rod holder 09910 20115 Rotor remover 09930 30165 MAGNETO ROTOR With the magneto rotor held immovable using the special tool loosen the rotor nut Remove the magneto rotor by using the special tool Remo...

Page 59: ...OVER Remove the clutch release arm Remove the clutch cover bolts Remove the clutch cover Remove the cam chain tensioner NOTE When remove or inspect the clutch drive and driven plate remove only the cl...

Page 60: ...rod holder 09910 20115 Remove the disk pressure Remove the clutch drive plates NO 1 and driven plates Remove the spring washer and spring washer seat Remove the clutch drive plate NO 2 Flatten the loc...

Page 61: ...y Conrod holder 09910 20115 PRIMARY DRIVE GEAR With the crankshaft held immovable using special tool remove the primary drive gear nut Remove the water pump drive gear and primary drive gear CAUTION T...

Page 62: ...il pump GEARSHIFT SHAFT Draw out the gearshift shaft Remove the gearshift cam stopper Loosen the gearshift cam plate bolt Remove the gearshift cam stopper plate Remove the crankcase securing bolts rig...

Page 63: ...cial tool Crankcase separator 09920 13120 CAUTION When separating the crankcase necessarily remove it after installed the special tool Crankcase separator on the side of clutch In case separate opposi...

Page 64: ...E STEM RUNOUT Check the valve stem for abnormal wear or bend Place the valve on V blocks and measure runout If the service limit is exceeded or abnormal condi tion exists replace the valve Dial gauge...

Page 65: ...alve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts...

Page 66: ...tside diameter If the diameter measured exceeds the standard replace the valve VALVE GUIDE VALVE STEM CLEARANCE Measure the clearance in the valve guide valve stem by rigging up the dial gauge as show...

Page 67: ...on Inner Outer Standard 4 2 4 8 kgf 9 3 10 6 lbs at length 29 9 mm 1 18 in 17 0 19 6 kgf 37 5 43 2 lbs at length 33 4 mm 1 32 in Standard 81 500 81 515 mm 3 2087 3 2093 in Service limit 81 575 mm 3 21...

Page 68: ...d replace it with a new one CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear damage and kinked or bind ing links If any defects are found replace it with a new one Check the cam chain guide...

Page 69: ...ter measure the piston pin outside diameter at three position both the ends and the center If any of the measurements is founds less than the ser vice limit replace the pin Piston pin hole bore Servic...

Page 70: ...n Service limit 0 180 mm 0 007 in 0 150 mm 0 006 in Piston ring groove clearance 1st 2nd PISTON RING TO GROOVE CLEARANCE INSPECTION Remove carbon deposit both from the piston ring and its groove Fit t...

Page 71: ...conrod small end inside diameter both in vertical and horizontal directions If any of the measurements exceeds the service limit replace the conrod Standard 20 006 20 014 mm 0 7876 0 7880 in Service...

Page 72: ...With the right and left crank journals supported with V block turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds the service limit repla...

Page 73: ...replace the defective parts DISASSEMBLY With the magneto rotor held immovable remove the starter clutch bolts REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tigh...

Page 74: ...m 09923 74510 DISASSEMBLY Remove the bush using the special tool OIL JET REMOVAL Remove the oil jet from the right crankcase half Remove the oil jet from the left crankcase half NOTE If it is difficul...

Page 75: ...Fit the new O ring to each oil jets Install the oil jet to the oil hole of crankcase Apply engine oil to the O ring Oil seal remover 09913 50121 CLUTCH COVER OIL FILTER REPLACEMENT Refer to page 2 14...

Page 76: ...2 92 3 08 mm 0 115 0 121 in 3 42 3 58 mm 0 135 0 141 in NO 1 NO 2 Clutch drive plate thickness Vernier calipers 09900 20101 CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch driv...

Page 77: ...ng the bearing from the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing PRIMARY DRIVEN GEA...

Page 78: ...n important role in the smoothness and positiveness of shifting action If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Service limit 0 50 mm 0 020...

Page 79: ...ip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expand the end gap larger than requi...

Page 80: ...tation while the bearings are in the crankcase Replace the bearing in the following procedure if there is anything unusual DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer bolt and Remo...

Page 81: ...RING Remove the oil seals and CAUTION The removed bearing should be replaced with a new one Bearing remover 17 mm 09923 73210 Bearing remover 20 35 mm 09923 74510 Remove the bearings and Bearing insta...

Page 82: ...ing the special tool press the crankshaft into the left crankcase ENGINE REASSEMBLY The engine reassembly can be performed in the reverse order of disassembly procedures However the follow ing points...

Page 83: ...smission Install the gearshift cam and gearshift fork shaft GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift fork NO 1 NO 2 and NO 3 Install the dowel pins Before assembling the crankcase apply...

Page 84: ...215 must be per formed within a short period of time Take extreme care not to let BOND 1215 enter into the oil hole or bearing NOTE Tightening the crankcase bolts tighten each bolt little by little di...

Page 85: ...driveshaft spacer Install the oil seal retainer GEARSHIFT CAM STOPPER Apply a small quantity THREAD LOCK 1324 to the gearshift cam plate bolt Install the gearshift cam stopper plate and gearshift cam...

Page 86: ...nstall the circlip CAUTION After the cam driven gear cam guide gearshift shaft and neutral cam stopper have been fitted confirm that gear change is normal while turning the countshaft and driveshaft I...

Page 87: ...alling the NO 2 gear install so that the mark on the gear align the key groove as shown in figure With the crankshaft held immovable using special tool install the water pump drive gear and primary dr...

Page 88: ...urely Install the clutch sleeve hub nut and tighten it to the specified torque using the special tool Install the clutch drive plate NO 2 Install the spring washer seat and spring washer onto the clut...

Page 89: ...ng bolts Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern CLUTCH COVER Install the two dowel pins and new gasket Apply engine oil to each gears bear...

Page 90: ...own in the right figure THREAD LOCK 1324 STATOR Apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 STARTER CLUTCH When installing the starter clutch and rotor...

Page 91: ...tarter clutch on the crankshaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft Tighten the magneto rotor bolt to the specified torque STARTER IDLE GEAR AND MOTOR Instal...

Page 92: ...PISTON RING First install the piston ring in order of oil ring 2nd ring and 1st ring at the front cylinder PISTON Apply the MOLY PASTE to the piston pin When installing the piston turn the mark on the...

Page 93: ...sket on the crankcase Apply the engine oil to the conrod small end piston and the piston rings Coat the cylinder wall with oil Install the cylinder and tighten the cylinder base nuts Cylinder base nut...

Page 94: ...With the tappet fitted it should be replaced if it doesn t turn smoothly by the hand CAUTION The tappet and shim should be installed at the original position when removed If otherwise it is difficult...

Page 95: ...er head install first the exhaust camshaft following the intake camshaft The rear cylinder head install first the intake as the cam chain tensioner adjuster exist exhaust side CAUTION If turn the cran...

Page 96: ...st camshaft sprocket should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into cam chain The 1R arrow of intake camshaft sprocket should be toward t...

Page 97: ...ft until the two holder and cam chain tensioner adjuster are installed completely NOTE The camshaft housing should be installed in the same manner with the front engine 16 Pin 16 Link 1 Link Rotation...

Page 98: ...n the mechanical spring continually until the han dle is turned to the end Fix the adjuster into the cylinder block CAUTION The camshaft housing bolt is made of the special material This bolt is super...

Page 99: ...sis of the magneto rotor If the valve clearance is within standard after mea sured the valve clearance begin the next operation If it is out of stanadard adjust the valve clearance within standard lim...

Page 100: ...head and cylinder SUPER GREASE A GEAR POSITION SWITCH Install the spring and contact Apply SUPER GREASE A to the O ring and install the gear position switch THERMOSTAT Install the thermostat case alon...

Page 101: ...CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks FUEL SYSTEM FUEL TANK FUEL COCK 4 1 FUEL PUMP 4 2 CARBURETOR 4 3 CONTENTS 4...

Page 102: ...onnect the fuel hose and remove the fuel tank Remove the fuel cock INSPECTION FUEL COCK If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss of engine power may resul...

Page 103: ...order of disassembly Tighten the fuel pump mounting bolts Connect the fuel hoses and vacuum hose securely FUEL HOSE ROUTING Fuel hose To carburetor Fuel hose To fuel cock Vacuum hose To carburetor va...

Page 104: ...CARBURETOR 4 3 FUEL SYSTEM...

Page 105: ...the fuel hose LOCATION OF CARBURE TOR I D NO The carburetor I D is stamped on the location on the carburetor as shown in the right photo Remove the throttle cables and choke cable Loosen the clamp sc...

Page 106: ...the jet needle cap spring retainer and jet needle Remove the float chamber body Remove the float assembly along with the needle valve by removing the pin Remove the spring along with diaphragm 4 5 FUE...

Page 107: ...ts and O rings Pilot air jet Pilot outlet and bypass Needle jet holder Float Needle valve Jet needle Valve seat If any abnormal condition is found wash the part clean If damage or clogging is found re...

Page 108: ...and install the float chamber to the carburetor body Install the three screws Bend the float arm as necessary to bring the height to the specified level After adjustment check the float height and the...

Page 109: ...nt Refer to page 2 9 Idle speed adjustment Refer to page 2 9 Align the hole of the diaphragm with passage way on the carburetor body Install the two screws and diaphragm cover CAUTION Never adjust CO...

Page 110: ...ENGINE COOLANT 5 1 COOLING CIRCUIT 5 2 RADIATOR 5 2 COOLING FAN 5 5 COOLING FAN THERMO SWITCH 5 6 ENGINE COOLANT TEMPERATURE SENSOR 5 7 THERMOSTAT 5 8 WATER PUMP 5 10 COOLING SYSTEM 5 CONTENTS...

Page 111: ...n 50 Refer to Right figure Do not use a radiator anti leak additive 50 Engine coolant including reserve tank capacity Anti freeze Water 0 8 0 8 WARNING You can be injured by scalding fluid or steam if...

Page 112: ...the two mounting bolts removed remove the right front side cover Remove the radiator cap bolt Remove the radiator cover by the four mounting bolts Disconnect the radiator outlet hose RESERVE TANK RAD...

Page 113: ...be removed Use of compressed air is recommended for this clean ing Remove the radiator by the mounting bolts Disconnect the cooling fan thermo switch lead wire coupler Disconnect the radiator inlet h...

Page 114: ...g bolt 8 12 N m 0 8 1 2 kg m Pour engine coolant Refer to page 2 24 Bleed air from the cooling circuit Refer to page 2 25 COOLING SYSTEM 5 4 Fins bent down or dented can be repaired by straighten ing...

Page 115: ...ling fan to the radiator Cooling fan mounting bolt 8 12 N m 0 8 1 2 kg m Cooling fan motor mounting bolt 8 N m 0 8 kg m Install the radiator Route the radiator hoses properly Pour engine coolant Refer...

Page 116: ...nd read the column thermometer when the switch closes Multi circuit tester set 09900 25008 INSTALLATION Install a new O ring and apply engine coolant to the O ring Tighten the cooling fan thermo switc...

Page 117: ...d read the column thermometer and the ohmmeter 5 7 COOLING SYSTEM Temperature sensor specification Temperature 60 85 110 125 Standard resistance Approx 125 Approx 48 5 Approx 24 Approx 15 If the resis...

Page 118: ...e the thermostat in the WATER contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension Heat the water by placing the beaker on a stove and observe the risi...

Page 119: ...N Apply engine coolant to the rubber seal on the ther mostat Install the thermostat Install the thermostat case cap Tighten the thermostat case bolts to the specified torque Thermostat case bolt 10 N...

Page 120: ...the water hoses Remove the water pump case and clutch cover Refer to page 3 16 Remove the snap ring and water pump driven gear Remove the pin and washer NOTE Before draining engine oil and engine coo...

Page 121: ...Remove the water pump from the clutch cover Remove the O rings Remove the E ring from the impeller shaft Remove the impeller from the other side 5 11 COOLING SYSTEM...

Page 122: ...pect abnormal noise and smooth rotation Replace the bearing if there is anything unusual BEARING CASE Visually inspect the bearing case for damage Replace the water pump body if necessary REASSEMBLY A...

Page 123: ...Refer to page 2 24 Pour engine oil Refer to page 2 12 Apply SUPER GREASE A to the impeller shaft SUPER GREASE A Install the impeller to the water pump body Fix the impeller shaft with the E ring Fill...

Page 124: ...CATION OF ELECTRICAL COMPONENTS 6 1 IGNITION SYSTEM 6 3 CHARGING SYSTEM 6 7 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 6 11 SWITCHES 6 15 LAMP 6 16 BATTERY 6 18 ELECTRICAL SYSTEM 6 CONTEN...

Page 125: ...COMPONENTS 6 1 ELECTRICAL SYSTEM Engine coolant temperature sensor Thermostat Front brake lamp switch Side stand switch Rear brake lamp switch Starter motor Battery Head lamp relay Side stand relay C...

Page 126: ...ELECTRICAL SYSTEM 6 2 Regulator Rectifier Turn signal relay Cooling fan motor Cooling fan thermo switch Ignition coil NO 1 NO 2 Magneto Gear position switch Fuses Igniter...

Page 127: ...act point The battery ignition system is composed a rotor with four rotor tip the igniter the ignition coil and battery This system ignites after get signal from igni tion timing of pick up with the e...

Page 128: ...CK 1324 to the threaded parts of screws ELECTRICAL SYSTEM 6 4 WIRE COLOR L Blue G Green Y Yellow BY Black with Yellow tracer OB Orange with Black tracer Br Brown BW Black with White tracer WL White wi...

Page 129: ...indication 1 range Check the attached plug cap Ignition coil resistance Pocket tester 09900 25002 IGNITION COIL Pull out the spark plug Place it on the cylinder head after installing it at the plug ca...

Page 130: ...F OFF 200 300 210 310 21 5 32 5 11 1 16 7 14 3 21 5 OFF 25 7 38 5 15 4 23 14 2 21 2 14 6 21 8 11 2 16 8 39 59 20 4 30 6 4 7 7 1 13 7 20 5 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 18...

Page 131: ...usted voltage of the regulator the regulator does not function incidentally the generated current charges the battery directly CHARGING SYSTEM The circuit of the charging system is indicated in figure...

Page 132: ...SCR becomes conductive to the direction from point to point Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC...

Page 133: ...ee lead wires from the magneto terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC volt age between the three lead wires If the tester reads under 70 V th...

Page 134: ...ter 1 range measure the resistance between the terminals in the following table If the resistance checked is incorrect replace the regu lator rectifier 3 4 3 4 1 2 1 2 3 4 3 4 1 2 1 2 3 4 3 4 1 2 1 2...

Page 135: ...prevents the motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery and ignition coil The circuit consists of the igniter neutral...

Page 136: ...CAL SYSTEM 6 12 BATTERY IGNITION COIL IGNITION SWITCH ON IGNITION SW ON NEUTRAL INDICATOR LIGHT NEUTRAL SW ON DIODE NEUTRAL SW OFF NEUTRAL INDICATOR LIGHT DIODE SIDE STAND SW UP RIGHT POSITION SIDE ST...

Page 137: ...ature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Pocket tester 09900 25002 Segment STARTER MOTOR...

Page 138: ...g end SUPER GREASE A Apply SUPER GREASE A to the O ring and remount the starter motor STARTER MOTOR REASSEMBLY Reassemble the starter motor Pay attention to the following points Reassembly the starter...

Page 139: ...pective switch assemblies with new ones 6 15 ELECTRICAL SYSTEM R O BW BR ON OFF IGNITION SWITCH BBr BW ON OFF HORN SWITCH O WB ON OFF FRONT REAR BRAKE LAMP SWITCH O Y ON OFF PASS SWITCH OB YR ON OFF S...

Page 140: ...LAMP HEADLAMP TURN SIGNAL LAMP TAIL BRAKE LAMP ELECTRICAL SYSTEM 6 16...

Page 141: ...CTION Using the pocket tester check the continuity between lead wires Blue color coupler in the follow ing illustration If the continuity measured incorrect replace the respective part Pocket tester 0...

Page 142: ...water When they were stained clothes will come into being a hole or painting will take off Consult a doctor When the battery electrolyte was dropped to the surface of land wash it with a vast quantit...

Page 143: ...that it does not fall Take precaution not to allow any fluid to spill Confirmation of pour Make sure that air bubbles are coming up each electrolyte container and keep this position for more than abou...

Page 144: ...with rust or an acidic white powdery substance then this can be cleaned away with sandpaper RECHARGING OPERATION Using the pocket tester check the battery voltage If the voltage reading is less than...

Page 145: ...7 1 FRAME COVER 7 2 SEAT TAIL COVER SEAT TAIL COVER BRACE 7 4 FRONT WHEEL 7 6 FRONT BRAKE 7 10 HANDLEBARS 7 17 FRONT FORK 7 20 STEERING 7 28 REAR WHEEL 7 31 REAR BRAKE 7 36 REAR SHOCK ABSORBER 7 38 SW...

Page 146: ...htside and the two bolts for lelfside Remove the front fender SEAT To remove the seat remove the seat mounting bolt on the rearside of the seat To install the seat slide the seat hook into the seat ho...

Page 147: ...CHASSIS 7 2 FRAME COVER RIGHT DECORATION COVER With the right decoration cover mounting screw removed remove the right decoration cover...

Page 148: ...side cover LEFT FRONT SIDE COVER The left front side cover is used to inspect the fuses With the two mounting bolts removed remove the left front side cover RIGHT LEFT AIR DUCT REAR COVER Remove the...

Page 149: ...SEAT TAIL COVER BRACE Remove the seat Refer to page 7 1 Remove the rear shock absorber upper bolts inside of frame right and left Install the rear shock absorber upper bolts with the frame in the out...

Page 150: ...S Remove the battery and relay Disconnect the rear turn signal lamp coupler and rear combination lamp coupler Remove the two bolts With the two bolts removed remove the seat tail cover and seat tail c...

Page 151: ...the axle pinch bolt right and left Loosen the front axle Raise the front wheel off the ground with a block or jack Remove the front wheel by removing the front axle CAUTION When using a jack take care...

Page 152: ...axial and radial does not exceed the service limit when checked as shown An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If...

Page 153: ...earings as follows by using the special tools WHEEL BEARING Apply SUPER GREASE A to the wheel bearings WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel Rotate...

Page 154: ...pinch bolt 15 25 N m 1 5 2 5 kg m 7 9 CHASSIS BRAKE DISK Make sure that the brake disk is clean and free of any greasy matter Apply THREAD LOCK 1324 to the right and left disk mounting bolts and tight...

Page 155: ...ime To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children When filling brake fluid take care not to allow water or dirt to enter the system To...

Page 156: ...e right and left front brake union bolt and caliper mounting bolts Remove the brake pad Refer to page 2 18 Remove the brake pad mounting bolt CAUTION Do not allow brake fluid to contact the paint surf...

Page 157: ...an possibly splash Do not use high pressure air but increase the pressure gradually Remove the dust seal and piston seal CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scr...

Page 158: ...mounting bolts 18 28 N m 1 8 2 8 kg m Front brake hose union bolts 20 25 N m 2 0 2 5 kg m 7 13 CHASSIS CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disassembly procedures and obs...

Page 159: ...limit 0 3 mm 0 012 in Micrometer 0 25 mm 09900 20201 BRAKE DISK INSPECTION Check the brake disk for damage or cracks Measure the thickness using the micrometer Replace the brake disk if the thickness...

Page 160: ...age Inspect the piston surface for any scratches or other damage 7 15 CHASSIS Remove the two clamp bolts and take off the mas ter cylinder Remove the two fitting screws and separate the cap and diaphr...

Page 161: ...ion to the following points CAUTION Wash the master cylider components with new brake fluid before reassembly When washing the components use the speci fied brake fluid Never use different types of fl...

Page 162: ...ve the master cylinder Refer to page 7 15 Remove the handlebar balancer and grip HANDLEBARS LEFT SIDE PARTS REMOVAL Remove the left handlebar switches Remove the handlebar balancer and grip Remove the...

Page 163: ...ge 7 16 CHASSIS 7 18 Remove the handlebar mounting bolts right and left Remove the handlebar REMOUNTING Perform the remounting work in the reverse order of the removal procedures while observing the f...

Page 164: ...SIS Apply SUPER GREASE A to the throttle cables Install the throttle cable and returning cable to the throttle grip Throttle cable Returning cable SUPER GREASE A Throttle grip Throttle cable Rotation...

Page 165: ...CHASSIS 7 20 FRONT FORK...

Page 166: ...ISASSEMBLY Remove the front fender Refer to page 7 1 Take off the front wheel Refer to page 7 6 7 21 CHASSIS NOTE Slightly loosen the front fork cap bolt to facili tate later disassembly Remove the fr...

Page 167: ...ont fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil to hold it for a few time Remove the damper rod bolt Remove the inner rod dampe...

Page 168: ...new one INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and outer tube slide metal face for scratches If any defects are found replace them with a new one FORK SPRING Measure th...

Page 169: ...n fitted securely CAUTION Be careful not to damage the dust seal lip and the oil seal lip when installing the outer tube INNER ROD DAMPER ROD Move the inner rod by hand to examine it for smooth ness I...

Page 170: ...5 6 minutes Hold the front fork vertically and adjust fork oil level with the special tool NOTE Refill front fork oil up to the top of the outer tube to find bubbles while bleeding air NOTE Always ke...

Page 171: ...lower clamp bolts to the specified torque Front fork upper clamp bolt 22 35 N m 2 2 3 5 kg m Front fork lower clamp bolt 22 35 N m 2 2 3 5 kg m FRONT FORK INNER ROD LOCK NUT Adjust the height of the...

Page 172: ...n the adjuster will soften rebound damping force 2 Compression damping force To adjust the compression damping force turn in the adjuster fully for S or H direction Count the number of clicks from the...

Page 173: ...CHASSIS 7 28 REMOVAL AND DISASSEMBLY Take off the front wheel Refer to page 7 6 Remove the front fender Refer to page 7 1 Take off the front fork Refer to page 7 21 STEERING...

Page 174: ...ng stem head nut and take off the steering stem upper bracket Clamp wrench 09940 10122 Remove the steering stem nut and draw out the steering stem Take off the steering stem lower bracket Remove the u...

Page 175: ...stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering st...

Page 176: ...7 31 CHASSIS REAR WHEEL REMOVAL Raise the rear wheel off the ground with a jack or block With the four mounting bolts remove the engine pul ley cover...

Page 177: ...IS 7 32 With the four mounting bolts remove the drive belt cover Remove the rear axle bolt Remove the rear wheel Loosen the drive belt adjuster right and left Disengage the drive belt from the rear pu...

Page 178: ...g the special tool Remove the rear wheel shock absorber Remove the rear pulley from the rear pulley mounting drum NOTE Before separating the rear pulley and mounting drum slightly loosen the rear pull...

Page 179: ...lt 20 30 N m 2 0 3 0 kg m REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and dam age Replace the rear wheel shock absorber if there is any thing unusual REAR PULLEY Inspect t...

Page 180: ...7 35 CHASSIS After installing the drive belt to the rear pulley adjust the drive belt by turning both belt adjusters Tighten both belt adjuster lock nuts securely...

Page 181: ...long period To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children When filling brake fluid take care not to allow water or dirt to enter the...

Page 182: ...ment Refer to page 2 18 Brake pad replacement Refer to page 2 18 Disassembly of caliper Refer to page 7 11 Inspection of caliper Refer to page 7 12 Reassembly of caliper Refer to page 7 13 Inspection...

Page 183: ...CHASSIS 7 38 REMOVAL Remove the rear shock absorbers by removing their bolts and nuts REAR SHOCK ABSORBER...

Page 184: ...ING Install the rear shock absorber and tighten the bolts and nuts to the specified torque CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable Rear shock absorber spring...

Page 185: ...CHASSIS 7 40 REMOVAL AND DISASSEMBLY Remove the rear wheel Refer to page 7 31 Remove the exhaust pipes and muffler Refer to page 3 3 SWINGARM...

Page 186: ...over and drive belt cover With the rear shock absorber lower bolts removed disconnect the rear shock absorber from swingarm Remove the swingarm mounting lock nut Remove the swingarm pivot nut Remove t...

Page 187: ...s the service limit replace it with a new one Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 Swingarm pivot shaft runout Service limit 0 6 mm 0 024 in INSPECTION SWINGARM Inspec...

Page 188: ...ivot nut 50 70 N m 5 0 7 0 kg m Swingarm pivot shaft 15 30 N m 1 5 3 0 kg m Swingarm mounting lock nut M26 70 80 N m 7 0 8 0 kg m Engine mounting socket wrench M26 09940H35010 Install the rear wheel R...

Page 189: ...SERVICING INFORMATION TROUBLESHOOTING 8 1 SPECIAL TOOLS 8 9 TIGHTENING TORQUE 8 12 SERVICE DATA 8 14 WIRE AND CABLE ROUTING 8 24 WIRING DIAGRAM 8 30 CONTENTS 8...

Page 190: ...Valve clearance too large 2 Weakened or broken valve springs 3 Worn down camshaft Noise appears to come from piston 1 Piston or cylinder worn down 2 Weakened or broken valve springs 3 Worn down piston...

Page 191: ...kened stopper pawl spring on gearshift cam 4 Worn gearshift pawl 1 Valve clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Defective pick up coil 5 Spark plug gap too wid...

Page 192: ...ged jets in carburetor 10 Float chamber fuel level out of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe 1 Heavy carbon deposit on piston head 2 Not enou...

Page 193: ...is not fully closed Check and clean Check and clean Check and clean Overflow and fuel level fluctuations 1 Needle valve is worn or damaged 2 Spring in needle valve is borken 3 Float is not working pro...

Page 194: ...Defective regulator rectifier 4 Not enough electrolyte in the battery 5 Defective cell plates in the battery Repair or retighten Replace Replace Add distilled water between the level lines Replace th...

Page 195: ...ld Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the...

Page 196: ...eplace Replace Front suspension too soft 1 Weakened springs 2 Not enough fork oil 3 Wrong viscous fork oil 4 Improperly set front fork damping force adjuster Replace Refill Replace Adjust Front suspen...

Page 197: ...ed air Brake squeaking 1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Loosen front wheel axle or rear wheel axle 5 Worn pads 6 Foreign material in brake fluid 7 Clogged return...

Page 198: ...er 09900 20605 Dial calipers Meassure width of conrod big end 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 20701 Magnetic stand With using dial gauge 09900 2080...

Page 199: ...g in 09913 80112 Bearing installer Used to drive bearing in 09915 64510 Compression gauge Measure cylinder compression 09915 74510 Oil pressure gauge Measure oil pressure of 4 stroke engine Separate t...

Page 200: ...oil cylinder 09940 10122 Clamp wrench A hook wrench to adjust the steering head of motorcycle 09940 34561 Front fork assembling tool attachment D Used with T handle 09940H30010 Engine mounting socket...

Page 201: ...in tensioner bolt Cam chain tensioner adjuster bolt Clutch sleeve hub nut Primary drive gear nut Camshaft housing bolt Horn mounting bolt 1 8 1 1 1 4 0 8 1 2 0 8 1 3 0 8 1 2 11 0 17 0 1 0 1 8 2 8 1 8...

Page 202: ...t and Rear brake hose union bolt Front axle bolt Front axle pinch bolt Front fork damper rod bolt Front fork upper clamp bolt Front fork cap bolt Front fork lower clamp bolt Front fork inner rod lock...

Page 203: ...ength 33 4mm 1 32 in 1 2 1 7 0 047 0 067 IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX Inner Outer Inner Outer 0 35 0 014 0 05 0 002 0 50 0 02 0 03 0 0012 36 8 1 45 39 8 1 57 VALVE GUIDE...

Page 204: ...390 Approx 10 5 0 413 0 20 0 35 0 008 0 013 0 20 0 35 0 008 0 013 1 21 1 23 0 0476 0 0484 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 0 970 0 990 0 0382 0 0390 1 170 1 190 0 0461 0 0469 1st 2nd 1st 2n...

Page 205: ...ve plate thickness Drive plate claw width Driven plate distortion Clutch spring free length 2 62 0 103 3 12 0 123 15 1 0 595 15 1 0 595 0 1 0 004 51 2 008 CLUTCH 2 0 08 2 92 3 08 0 115 0 121 3 42 3 58...

Page 206: ...32 18 1 38 29 21 1 13 27 24 0 96 25 26 Poly chain belt 26 1 02 11 0 43 1st 2nd 3rd 4th 5th Type Width Pitch NO 1 NO 2 NO 3 NO 1 NO 2 NO 3 0 10 0 30 0 004 0 012 8 17 SERVICING INFORMATION Gear ratio Sh...

Page 207: ...t P J Throttle valve TH V By pass B P Valve seat V S Starter jet G S Pilot screw P S Pilot outlet P O PV Stroke P V BDSR39 TYPE DOUBLE 39 1 300 1 500 rpm 7 0 28 0 5 1 0 0 02 0 04 FRONT 125 45 6DH64 53...

Page 208: ...Engine coolant capacity Over 8mm 100 ITEM STANDARD LIMIT THERMOSTAT COOLING FAN COOLANT Valve opening Valve full open Valve closing 60 85 110 125 OFF ON ON OFF Reserve tank side Radiator side Engine s...

Page 209: ...20 Ignition timing Spark plug Spark performance Fuse size Ignition coil resistance Magneto coil resistance Magneto no load voltage Battery standard charging voltage CR8E 0 7 0 8 0 028 0 032 CR7E CR8E...

Page 210: ...470 18 5 TELLUS 32 215mm 8 5 in from end of outer tube when maximum compressed without spring 420cc 90 3 54 1 5 position 223 8 78 ITEM STANDARD LIMIT SUSPENSION STANDARD FRONT FORK DAMPING FORCE Rebo...

Page 211: ...12 700 12 743 0 5000 0 5017 15 827 15 854 0 6227 0 6242 12 657 12 684 0 4983 0 4994 25 4 1 00 25 4 1 00 DOT3 or DOT4 DOT4 120 70 ZR 18 59W 180 55 ZR 17 73W J18 MT3 50 J17 MT5 50 408 16 1 when one pers...

Page 212: ...ded 91 octane or higher An unleaded gasoline is recommened API Over SL SAE 10W 40 3 000 3 200 3 400 ITEM SPECIFICATION FUEL OIL Change Filter change Overhaul TIRE PRESSURE COLD INFLATION TIRE PRESSURE...

Page 213: ...RTH L WIRE BATTERY MINUS 36618 30610 TAIL STOP LAMP LICENSE LAMP RR TURN LAMP R L WELD CLAMP WELDING CLAMP WELDING CLAMP WELD CLAMP 1 TAPPING OF INSTALLATION BASIS RR IGNITION COIL COUP FUEL GAUGE COU...

Page 214: ...PING OF INSTALLATION BASIS RELAY 3EA LICENSE LAMP REFLEX REFLECTOR RR REFLEX REFLECTOR SIDE RR 2EA Exception of the application vehicle of European law WELD CLAMP WELD CLAMP L WIRE RR COMBI 09407 2040...

Page 215: ...NITOR COUP IGNITION S W 09407 20406 HANDLE S W Rh COUP HANDLE S W Rh Install inside of HEAD LAMP HOUSING LOCK STEERING IGNITION S W WELD CLAMP RR BRAKE S W RR BRAKE S W 09407 20406 L WIRE STARTER MOTO...

Page 216: ...ION 09407 20406 HANDLE S W 09407 20406 HANDLE S W CLUTCH LEVER S W 09407 20406 WIRING HARNESS FT TURN L HEAD LAMP COUP 09407 20406 FT TURN R 09404 06405 L WIRE FT TURN R L L WIRE C LEVER S W COUP HAND...

Page 217: ...SERVICING INFORMATION 8 28 VIEW A ENGINE EARTH INSTALLATION DIRECTION CRANK CASE R PIPE FRAME Lh SIDE L TOP WIRING HARNESS L WIRE BATTERY MINUS FRONT 1 MARK WELDING CLAMP PARTS 3EA VIEW...

Page 218: ...8 29 SERVICING INFORMATION FRONT CYLINDER REAR CYLINDER CAUTION FOR HIGHTENTION CORD INSTALLATION DIRECTION WELDING CLAMP OPERATION METHOD FRAME WELD CLAMP WIRING HARNESS...

Page 219: ...SIDE STAND RELAY HEAD LAMP RELAY DIODE 2 DIODE 1 FT IG COIL STARTER MOTOR STOP LAMP S W DIODE 3 IGNITION S W CLUTCH LEVER S W FT TURN R HEAD LAMP POSITION LAMP FT TURN L FREE ON STOP RUN OFF ON OFF ON...

Page 220: ...1 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 45 1 50 1 55 1 60 1 65...

Page 221: ...75 1 80 1 85 1 90 1 95 1 75 1 80 1 85 1 90 1 95 2 00 1 80 1 85 1 90 1 95 2 00 2 05 1 85 1 90 1 95 2 00 2 05 2 10 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 1 65 1 70 1 75 1 80 1 85 1...

Page 222: ...Prepared by HYOSUNG MOTORS MACHINERY INC 1st Ed JUL 2005 Manual No 99000 51210 Printed in Korea...

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