HYOSUNG Prima Service Manual Download Page 50

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ENGINE 3-22

S h

S h
A

v nia

ell

I ndu

M ulti-

pur

strial

pose

G rease

REED VALVE

When reinstalling the reed valve and stopper plate to
the body, align the both cut on the reed valve and stop-
per plate.
Apply

THREAD LOCK

“

1324

”

to the stopper plate

securing screws.

Thread Lock

“

1324

”

Thread Lock

“

1324

”

Super Grease

“

”

●

When fitting the oil seal in the crankcase, insert it
slowly with the special tools.

NOTE:
Align the oil seal with edge

�

of the crankcase as

shown in the illustration.

●

Be sure to apply

THREAD LOCK

“

1324

”

to outer

surfaces of right and left crankshaft oil seals to pre-
vent them from moving.

OIL SEALS

Fit the oil seals to the crankcase following the procedure
below.
Replace removed oil seals with new ones.

●

Coat

SUPER GREASE

“

”

to the lip of the oil seals.

ENGINE REASSEMBLY

Reassembly is generally performed in the reverse order
of disassembly, but there are a number of reassembling
steps that demand or deserve detailed explanation or
emphasis. These steps will be taken up for respective
parts and components.

Oil seal installer : 09913-75830
Bearing installer attachment : 09924-74510
Bearing installer pilot : 09924-74540

Summary of Contents for Prima

Page 1: ...SERVICE MANUAL 99000 91310 SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC ...

Page 2: ...r servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer COPYRIGHT HYOSUNG MOTORS MACHINERY INC 1999 HYOSUNG MOTORS MACHINERY INC FOREWORD This manual contains an introductory description on HYOSUNG PRIMA SF 50 and procedures for its inspec tion service and ...

Page 3: ...are listed on the previous page as GROUP INDEX select the section where what you are looking for belong 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS Example Rear wheel Rear brake ...

Page 4: ...LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool 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 DEFINITION SYMBOL DEFINITION SYMBOL Apply SUPER GREASE C ...

Page 5: ......

Page 6: ...NERAL INFORMATION INFORMATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 3 FUEL AND OIL RECOMMENDATIONS 1 3 BREAK IN PROCEDURES 1 4 EXTERIOR ILLUSTRATION 1 5 SPECIFICATIONS 1 6 CONTENTS 1 ...

Page 7: ...the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure...

Page 8: ...head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over m...

Page 9: ...rts FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85 95 octane Research Method or higher An unleaded gasoline type is recommended TRANSMISSION OIL Make sure that the transmission oil you use comes under API classification of SH SG or SF and that its viscosity rating is SAE 10W 30 or 10W 40 If an SAE 10W 30 or 10W 40 motor oil is not available select an alternate according to the ...

Page 10: ...odometer reading of 1 000 km you can subject the motorcycle to full throttle operation Do not maintain constant engine speed for an extended period during any portion of the break in Try to vary the throttle position Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum...

Page 11: ...1 5 GENERAL INFORMATION 320 635 740 1 110 990 125 535 690 Head lamp Rear reflector Tail Brake lamp Front Turnsignal lamp Rear Turnsignal lamp 600 710 1 825 135 1 270 350 EXTERIOR ILLUSTRATION ...

Page 12: ... 49 3 0 cu in Carburetor SIDE DRAFT VARIABLE VENTURI PISTON Air cleaner Wet filter type Starter system Kick self starter Corrected compression ratio 7 4 1 Intake system Reed valve TRANSMISSION Clutch Dry shoe automatic centrifugal type Reduction ratio 2 997 0 813 Drive system V belt drive CHASSIS Front suspension Telescopic type Rear suspension Coil spring type Caster 25 Trail 75mm 2 95in Steering...

Page 13: ...Fuse 10A Headlamp 15W 2 Turn signal lamp 10W 4 Tail Brake lamp 5 10W Speedometer lamp 1 7W 2 Oil level indicator lamp 1 7W Turn signal indicator lamp 1 7W CAPACITIES Fuel tank 4 8ℓ Engine oil tank 1 0ℓ Transmission oil 110cc Replace 130cc Overhaul 1 7 GENERAL INFORMATION NOTE The specifications are subject to change without notice ...

Page 14: ...YLINDER HEAD AND CYLINDER 2 4 SPARK PLUG 2 4 FUEL LINE 2 5 AIR CLEANER ELEMENT 2 5 THROTTLE CABLE PLAY 2 6 ENGINE IDLE SPEED 2 7 OIL PUMP 2 7 TRANSMISSION OIL 2 8 BRAKES 2 8 TIRES 2 10 STEERING 2 11 FRONT SUSPENSION 2 11 REAR SUSPENSION 2 12 CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2 12 CONTENTS 2 PERIODIC MAINTENANCE ...

Page 15: ...000 km Every 4 000 km Every 8 000 km page Interval Brakes Brake hose Brake fluid Tires Steering Front suspension Rear suspension Chassis bolts and nuts Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Replace every 4 years Replace every 2 years CHASSIS 2 9 2 9 2 9 2 10 2 11 2 11 2 12 2 12 PERIODIC MAINTENANCE SCHEDULE T...

Page 16: ...ngs brake slippage will result WARNING Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motorcycle has been operated under wet or rainy conditions Before lubricating each part clean off rusty sports and wipe off grease oil dirt or grime Item Initial and Every 4 000 km Every 8 000 km Interval Throttle cable Throttle grip Brake cable Speedometer cable Sp...

Page 17: ...he battery from motorcycle O t h e r w i s e r e g u l a t o r r e c t i f i e r u n i t should be an obstacle When recharging the battery do not remove the caps When recharging the battery above the charge electric current and time should be kept as 12V CAUTION NOTE Inspect Initial 1 000 km and Every 4 000 km Recharge Standard charge Fast charge 0 4A 5 10 Hours 4A 30 Minutes MAINTENANCE PROCEDURE...

Page 18: ...low of exhaust gases reducing the output Remove carbon deposits periodically CYLINDER HEAD AND CYLINDER Exhaust pipe nuts 8 12 N m 0 8 1 2 kg m EXHAUST PIPE NUTS Tighten the exhaust pipe nuts to the specified torque NOTE Remove carbon Every 8 000km NOTE Inspect Initial 1 000km and Every 4 000km Replace every 8 000km Neglecting the spark pulg maintenance eventually leads to difficult starting and p...

Page 19: ... kg m To check the spark plug first make sure that the fuel used is unleaded gasoline and if plug is either sooty with carbon or burnt white replace it Confirm the thread size and reach when replac ing the plug CAUTION If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power out put and an increase in fuel consumption Check and clean the elemen...

Page 20: ...htly wet with oil Fit the elements to the cleaner case properly Before and during the cleaning operation inspect the element for tears A torn element must be replaced Be sure to position the element snugly and cor rectly so that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element CAUTION Loosen the lock nut an...

Page 21: ...f oil fed to it is regulated by engine speed and oil pump control lever which is controlled by amount of throttle opening Check the oil pump in the following manner to confirm correct operation for throttle valve full closing position Fix the throttle grip The early idling condition Check whether the mark on the oil pump control lever is aligned with the index mark when the throttle grip is fixed ...

Page 22: ...luid reservoir When the level is bolow the middle line replenish with brake fluid that meets the following specification DOT4 Specification and classification The brake system of this motorcycle is filled with a glycolbased brake fluid Do not use or mix dif ferent type of fluid such as silicone based and petroleum based Do not use any brake fluid taken from old used or unsealed containners Never r...

Page 23: ...at this process until the fluid flowing into the receptacle no longer contains air bub bles Close the bleeder valve and disconnect the pipe Fill the reservoir to the upper end of the inspection win dow Bleeder valve 6 9 N m 0 6 0 9 kg m Replenish the brake fluid reservoir as necessary while bleeding the brake system Make sure that there is always some fluid visible in the reservoir CAUTION BLEEDIN...

Page 24: ... 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 핀 Pin Front Front Handle the brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc WARNING REAR BRAKE Adjust by turning the adjusting nut so that the play is 15 25 mm as shown in the illustration Brake lining wear limit This motorcycle is equipped with the brake lining wear limit indicator on the rear brake As shown in the i...

Page 25: ...aining depth of tire tread reaches the following specification Steering should be adjusted properly for smooth turning of handlebars and safe running Too stiff steering pre vents smooth turning of handlebars and too loose steer ing will cause poor stability Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground with wheel straight...

Page 26: ...D ENGINE MOUNTING BOLTS AND NUTS Front axle nut 33 52 N m 3 3 5 2 kg m Steering stem lock nut 60 100 N m 6 0 10 0 kg m Handlebar clamp nut 48 52 N m 4 8 5 2 kg m Handlebar set bolt 22 28 N m 2 2 2 8 kg m Front brake master cylinder bolt 8 12 N m 0 8 1 2 kg m Front brake hose union bolt 20 25 N m 2 0 2 5 kg m Front brake caliper mounting bolt 18 28 N m 1 8 2 8 kg m Front brake air bleeder valve 6 9...

Page 27: ...2 13 MAINTENANCE PROCEDURE ...

Page 28: ...YLINDER HEAD 3 18 CYLINDER 3 19 PISTON 3 19 REED VALVE 3 22 ENGINE REASSEMBLY 3 22 OIL SEALS 3 22 BEARINGS 3 23 BUSHINGS 3 23 CRANKSHAFT 3 24 CRANKCASE 3 25 CENTER STAND 3 26 REAR AXLE SHAFT BRAKE AND WHEEL 3 27 TRANSMISSION 3 29 STARTER DRIVEN GEAR AND STARTING MOTOR 3 31 MOVABLE DRIVEN AND CLUTCH 3 32 MOVABLE DRIVE 3 36 KICK STARTER 3 38 PISTON 3 40 OIL PUMP AND INTAKE PIPE 3 42 MAGNETO 3 43 MUF...

Page 29: ...ngine removal is sequentially explained as follows Remove the low leg shield Remove the air cleaner by removing the mounting bolts and clamp screw Disconnect the ignition coil lead wires and spark plug cap Disconnect the oil pump cable and the thermoele ment lead coupler Disconnect the throttle cable Refer to page 4 2 Disconnect the vacuum hose fuel hose and oil hose ...

Page 30: ...ENGINE 3 2 Disconnect the magneto lead wire and starting moter lead wire Remove the rear brake cable by removing the bolt bolt and adjuster nut Remove the rear shock absorber mounting lower bolt ...

Page 31: ...nstall the crankcase bracket on the frame Do not tighten the bracket bolt at this stage Pull up on the rear part of crankcase bracket and while holding it tighten the bracket bolt to specification Tighten both the rear shock absorber bolt and engine mounting bolt to specification Front side mark Damper UP 10mm 8mm Engine mounting bracket bolt 48 72 N m 4 8 7 2 kg m Engine mounting bolt 40 60 N m 4...

Page 32: ... following adjustments are necessary Page Throttle cable play 2 6 Idling adjustment 2 7 Oil pump cable paly 2 7 Rear brake cable adjustment 2 10 Air bleeding at oil pump 4 9 ENGINE DISASSEMBLY MUFFLER Remove the muffler by removing the nuts MAGNETO Remove the cooling fan Remove the magneto rotor nut with the special tool Rotor holder 09930 40113 ...

Page 33: ...gneto stator and key Rotor remover 09930 30163 Rotor remover sliding shaft 09930 30102 REED VALVE Remove the intake pipe with reed valve OIL PUMP Remove the oil pump Remove the oil pump driven gear CYLINDER Remove the cylinder cowling Remove the cylinder head and cylinder ...

Page 34: ...lever Remove the clutch cover PISTON Place a cloth beneath the piston and remove the pis ton circlip with a long nose pliers Remove the piston pin and piston Remove the piston pin bearing KICK STARTER DRIVEN GEAR Remove the E ring with the long nose plier Remove the spacer spring and kick starter driven gear ...

Page 35: ...ool Remove the fixed drive face and V belt Disassemble the movable drive face STARTER DRIVEN GEAR Remove the starter driven gear MOVABLE DRIVEN FACE Remove the clutch housing with the special tool This nut has left hand thread CAUTION Conrod holder 09910 20115 Rotor holder 09930 40113 ...

Page 36: ... 40113 Gradually back off the clutch shoe assembly pressed down by hand to counter the clutch spring load Releasing the hand suddenly may cause the parts to fly apart WARNING Remove the nut while holding down the clutch shoe assembly by both hands as shown in the illustration Remove the nut Remove the clutch shoe assembly Remove the spring Do not attempt to diassemble the clutch shoe assembly It i...

Page 37: ...ver Remove the driveshaft Remove the circlip Remove the bearing with the special tool Bearing remover ф 17 mm 09923 73210 Rotor remover sliding shaft 09930 30102 Wheel bearing remover 09941 50111 The removed bearing should be replaced with a new one CAUTION The removed bearing should be replaced with a new one CAUTION ...

Page 38: ... 09913 50121 Bearing installer 09913 76010 Rotor remover sliding shaft 09930 30102 Bearing remover ф 12 mm 09921 20210 The removed oil seal should be replaced with a new one CAUTION The removed bearing should be replaced with a new one CAUTION Remove the circlip and final driven gear Remove the idle shaft Remove the drive shaft bearing ...

Page 39: ... WHEEL BRAKE Remove the rear axle nut and washer Remove the rear wheel Remove the brake shoes and rear axle shaft Remove the bearing retainer Remove the bearing with the special tool Bearing installer 09913 75820 ...

Page 40: ...Remove the cotter pin washer and shaft Remove the center stand CENTER STAND Remove the return spring Oil seal remover 09913 50121 Crankcase separater 09920 13120 Loosen the crankcase screws diagonally CAUTION CRANKCASE Remove the crankcase securing screws ...

Page 41: ...3 13 ENGINE Remove the crankshaft with the special tool Crankcase separater 09920 13120 Remove the bearings oil seals and bushings ...

Page 42: ... in leakage of the fuel air mixture or oil Inspect for damage and be sure to replace the damaged seal if found BEARINGS Wash the bearing with cleaning solvent and lubricate with motor oil before inspecting Turn the inner ring and check to see that the inner ring turns smoothly If it does not turn lightly quietly and smoothly or if noise is heard the bearing is defective and must be replaced with a...

Page 43: ...nkshaft by V blocks with the dial gauge rigged to read the runout as shown Service limit 0 08 mm Crankshaft runout Service limit 3 0 mm Conrod big end runout Service limit 14 047 mm Conrod small end bore I D V block 100 mm 09900 21304 Magnetic stand 09900 20701 Dial gauge 1 100 mm 09900 20606 CONROD SMALL END BORE I D Measure the conrod small end diameter with a caliper gauge AUTOMATIC CLUTCH INSP...

Page 44: ... Warm the engine to normal operating temperatures Connect an engine tachometer to the engine Apply the rear brake as firm as possible Briefly open the throttle fully and note the maximum engine RPMs sustained during the test cycle Do not apply full power for more than 3 seconds or damage to the clutch or engine may occur CAUTION Service limit 2 0 mm Clutch shoe thickness If the engine RPM does not...

Page 45: ...ernier calipers Replace it if the drive V belt width is less than the service limit or any defect has been found DRIVE FACE Inspect the V belt contact surface of the drive faces for wear scratches or any abnormality If there is some thing unusual replace the drive face with a new one Clutch shoes or springs must be changed as a set and never individually CAUTION Always keep the drive belt away fro...

Page 46: ...er than the service limit replace the spring with a new one Service limit 135 153 mm Movabledrivenspringfreelength MOVABLE DRIVEN FACE Inspect the V belt contacting surface of both driven faces for any scratches wear and damage Replace the movable driven face with new one if there are any abnormality CYLINDER HEAD Decarbon the combustion chamber Check the gasketed surface of the cylinder head for ...

Page 47: ...cylinder with a cylinder gauge If the wear thus determined exceeds the limit indicated below rework the bore to the next oversize by using a boring machine or replace the cylinder with a new one After reworking the bore to an oversize be sure to chamfer the edges of ports and smooth the chamfered edges with emery paper To chamfer use a scraper taking care not to nick the wall surface PISTON CYLIND...

Page 48: ...of about 400 PISTON PIN BORE I D Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the following service limit replace it with a new one Cylinderbore Pistondiameter Cylindertopistonclearance Standard 41 005 41 020mm 40 935 40 950mm 0 065 0 075mm Serivice limit 41 070 mm 40 885 mm 0 120 mm As a result of the above measurement if the piston to cylinder clearance ex...

Page 49: ...mportance of using piston rings with end gaps within the limit Measure the piston ring free end gap to check the spring tension PISTON RINGS Check each ring for end gap reading the gap with a thickness gauge shown in the illustration If the end gap is found to exceed the limit indicated below replace it with a new one The end gap of each ring is to be measured with the ring fitted squarely into th...

Page 50: ...rankcase as shown in the illustration Be sure to apply THREAD LOCK 1324 to outer surfaces of right and left crankshaft oil seals to pre vent them from moving OIL SEALS Fit the oil seals to the crankcase following the procedure below Replace removed oil seals with new ones Coat SUPER GREASE A to the lip of the oil seals ENGINE REASSEMBLY Reassembly is generally performed in the reverse order of dis...

Page 51: ...aller 09913 75810 Bearing installer 09913 76010 BUSHINGS Using two steel tubes of appropriate size and a vise press the mounting bushings and into the crankcase holes as shown in the illustration NOTE Knurled end should face inside Protrusion and should be in the same dimension ...

Page 52: ... Oil seal Oil pump drive gear Oil pump driven gear Oil seal Bushing Crankcase Crankcase Bushing CRANKSHAFT Measure the length between the webs referring to the figure at right when rebuilding the crankshaft Standard 35 0 0 1 mm Width between webs ...

Page 53: ...t alignment accuracy will be affected CAUTION CRANKCASE Wipe the crankcase mating surfaces both surfaces with cleaning solvent Apply BOND 1215 uniformly to the mating surface of the left half of the crankcase and install the dowel pins Install the two dowel pins Tighten the crankcase screws securely Check if the crankshaft rotates smoothly Install the new oil seal to the crankcase with the special...

Page 54: ...ENGINE 3 26 Hook the center stand spring into the crankcase CENTER STAND Install the center stand Install the shaft washer and cotter pin ...

Page 55: ...pply engine oil on the left end of the rear axle shaft being inserted later in the reduction rear box cover Apply SUPER GREASE A lightly on the rear brake cam pivot part and install it to the crankcase Turn to position the cam where the punched mark on the end face is directed toward the axis of the rear axle shaft Super Grease A ...

Page 56: ...e Install the brake shoes Apply SUPER GREASE A to the brake cam and pin before installing the brake shoes Install the rear wheel and nut Rear brake cam lever nut 6 9 N m 0 6 0 9 kg m Rear axle nut 60 90 N m 6 0 9 0 kg m Super Grease A Be careful not to apply too much grease to the brake cam and pin If grease gets on the lining brake effectiveness will be lost CAUTION ...

Page 57: ...TRANSMISSION Install the circlip on to the rear axle shaft Assemble the idle shaft subassembly using the idle shaft and thrust washer then install the sub assembly on the gear box Install the final driven gear on the rear axle shaft using the circlip ...

Page 58: ...the driveshaft to the gear box cover Install the new bearing to the gear box cover with the special tool Apply SUPER GREASE A to the lip of the oil seal and install it to the gear box cover with the special tool Bearing installer 09913 76010 Bearing installer 09913 70122 Super Grease A ...

Page 59: ...e gear box cover on the crankcase Tighten all the screws evenly one by one in a diago nal fashion BOND 1215 Install the starter driven gear over the left crankshaft end NOTE The convex side of hub should face outside when installed in proper position STARTER DRIVEN GEAR AND STARTING MOTOR ...

Page 60: ...ENGINE 3 32 Install the starting motor MOVABLE DRIVEN AND CLUTCH ...

Page 61: ...hit inner race of the bearing Fall to ring in the bearing a case CAUTION Instert surely in the circlip groove CAUTION A mark part of the bearing is pointed to the out side CAUTION Install the bearing with the special tool Install the new oil seals to the movable driven face with the special tool Apply SUPER GREASE A to the lip of oil seals and groove of movable driven face s inside Super Grease A ...

Page 62: ...Apply SUPER GREASE A lightly to the cam part where the pins are placed When reinstalling the movable dirven face to the fixed dirven face make sure that the oil seal is positioned properly CAUTION The seat is installed rotatable naturally The O ring get damaged in case of installed by force CAUTION Super Grease A Install the spring Install the clutch shoe assembly and nut Insert as guide the rim ...

Page 63: ...ten the clutch housing nut to the specified torque with the special tool Tighten the clutch shoe nut to the specified torque with the special tool Rotor holder 09930 40113 Clutch shoe nut 40 60 N m 4 0 6 0 kg m Rotor holder 09930 40113 Clutch housing nut 40 60 N m 4 0 6 0 kg m The V belt should be positioned so that the arrows on the belt periphery point the normal turning direction The V belt con...

Page 64: ...INE 3 36 MOVABLE DRIVE Install the roller to the movable drive face Mount the three dampers on the movable drive plate and install it on the movable drive face Position the O ring on the movable drive face ...

Page 65: ...ecial tool Fill SUPER GREASE A in the groove provided inside sliding surface of the kick driven gear and install it on the end of the crankshaft Wipe off excess grease Install the spring and spacer Make sure that the movable drive plate is fully positioned inside or the weight roller may come off CAUTION Thoroughly clean the V belt contact to be from oil CAUTION Conrod holder 09910 20115 Kick star...

Page 66: ...eated in and both the drive and driven faces will move together smoothly without slip Fill the final gear box with engine oil up to the level hole Tighten the oil level bolt to the specified torque KICK STARTER 110 130 Replace Overhaul Transmission oil capacity Oil level bolt 9 15 N m 0 9 1 5 kg m ...

Page 67: ...cover Position the kick starter shaft return spring and hook the spring end on the crankcase cover boss Super Grease A Tighten the kick starter lever bolt to the specified torque Install the kick starter lever as shown in the illustra tion CAUTION Install the clutch cover and kick starter lever Kick starter lever bolt 8 12 N m 0 8 1 2 kg m ...

Page 68: ...he piston rings on the piston 1st Keystone ring 2nd Barrel face ring Expander ring It is extremely important that when the piston is fed into the cylinder each ring in place should be so positioned as to hug the locating pin as shown in the illustration Position the ring so that the marking is on upside CAUTION ...

Page 69: ...piston Position the cylinder base gasket Apply engine oil on the piston and cylinder wall sur faces and install the cylinder over the piston carefully Install the cylinder head gasket and cylinder head Tighten the cylinder head nut to the specification and tighten it diagonally several times as shown in the illustration The arrow mark on the piston head should point the exhaust side CAUTION Cylind...

Page 70: ...IL PUMP AND INTAKE PIPE Apply SUPER GREASE A to the oil pump driven gear and install it to the crankcase Install the oil pump and tighten it to the specified torque Super Grease A Oil pump bolt 3 5 N m 0 3 0 5 kg m ...

Page 71: ...Install the reed valve gasket intake pipe gasket and intake pipe with reed valve to the crankcase MAGNETO Degrease the tapered portion of the crankshaft and also the magneto rotor Install the stator Install the key ...

Page 72: ... tighten it to the specified torque with the special tool Thread Lock 1324 Rotor holder 09930 40113 Magneto rotor nut 35 45 N m 3 5 4 5 kg m Install the fan case Install the magneto lead wire and starting motor lead wire Install the cooling fan Install the cooling fan cover ...

Page 73: ...3 45 ENGINE MUFFLER Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Exhaust pipe bolt 8 12 N m 0 8 1 2 kg m Muffler mounting bolt 18 28 N m 1 8 2 8 kg m ...

Page 74: ...FUEL SYSTEM CARBURETOR 4 1 REMOVAL 4 1 DISASSEMBLY 4 2 INSPECTION 4 4 REASSEMBLY AND REMOUNTING 4 5 FUEL TANK 4 7 REMOVAL 4 7 CLEANING 4 8 REMOUNTING 4 8 OIL PUMP 4 8 FUEL PUMP 4 9 CONTENTS 4 ...

Page 75: ...4 1 FUEL SYSTEM REMOVAL Open the seat and separate the helmet box by removing the four lock nuts Remove the rear shock absorber mounting lower bolt CARBURETOR ...

Page 76: ...ect the air vent hose oil hose and fuel hose Remove the carburetor top cap and disconnect the throttle cable Remove the carburetor by loosening the mounting bolts and clamp screw DISASSEMBLY Remove the thermoelement assembly ...

Page 77: ...4 3 FUEL SYSTEM Do not attempt to disassemble the thermoelement assembly It is not serviceable CAUTION Remove the float chamber Remove the float by removing the screw and pin Remove the needle valve ...

Page 78: ...owing and cause it to overflow If the seat and needle are worn beyond the permissible limits similar trouble will occur Conversely if the needle sticks the gasoline will not float chamber Clean the float chamber and float parts with gasoline If the needle is worn as shown in the illustration replace it together with a valve seat Clean the fuel passage of the mixing chamber with compressed air INSP...

Page 79: ...le following items Pilot air screw Throttle stop screw Main jet Needle jet Install the needle valve and float on the carbu retor body Install the float pin and tightened the screw Install the gasket and float chamber Install the thermoelement assembly ...

Page 80: ...FUEL SYSTEM 4 6 Install the carburetor top cap Install the carburetor assembly Install the air vent hose oil hose and fuel hose ...

Page 81: ...4 7 FUEL SYSTEM FUEL TANK REMOVAL Remove the low leg shield Disconnect the fuel hose Disconnect the fuel level gauge lead wire Remove the six fuel tank mounting bolt ...

Page 82: ...e reverse of removal OIL PUMP AIR BLEEDING Whenever evidence is noted of some air having leaked into the oil pipe from the oil tank in a machine brought in for servicing or if the oil pump has to be removed for servicing be sure to carry out an air bleeding operating with the oil pump in place before returning the machine to the user To bleed air hold the machine in standstill condition Loosen the...

Page 83: ...e suction side of the pump Run the engine at 3 000 rpm Holding engine speed at the same 3 000 rpm let the pump draw for 5 minutes For this operation the reading taken on the device should be 6 1 0 1 2 at 3 000 rpm for 5 minutes Engine oil discharge amount Stop up an entrance of the hose to prevent that the fuel leak out CAUTION FUEL PUMP REPLACE Remove the rear shock absorber and support the cente...

Page 84: ... COIL 5 2 STATOR COILS 5 3 REGULATOR RECTIFIER 5 4 STARTER SYSTEM 5 4 STARTING MOTOR INSPECTION 5 5 STARTER RELAY INSPECTION 5 6 FUEL LEVEL GAUGE 5 7 OIL LEVEL CHECK LIGHT 5 8 THERMOELEMENT 5 9 SWITCHES INSPECTION 5 10 BATTERY 5 11 ELECTRICAL SYSTEM 5 CONTENTS ...

Page 85: ... SYSTEM Front turn signal RH LH Head Lamp Wiring harness Speedometer cable Brake hose Rear brake cable Turn signal cable Regulator ELECTRICAL PARTS Ignition coil Thermolement assembly Fuel level gauge Oil level gauge ...

Page 86: ...12V 5W 12V 1 7W 2 Spark Yellow Black Black Red IGNITION CHARGING SYSTEM Over 8 mm Spark performance Electro tester 09900 28106 IGNITION COIL Check the ignition coil with electro tester Test the ignition coil for sparking performance Test connection is as indicated Make sure that the three needle sparking distance is at least 8mm Test it at least for 5 minutes ...

Page 87: ...ween the battery terminal and with a pocket tester If the tester reads under or over following specification check the no lead performance or replace the regulator rectifier Pocket tester 09900 25002 Engine tachometer 09900 26006 Pocket tester 09900 25002 13 0 16 0 V at 5 000 rpm Standard charging output Pocket tester 09900 25002 Check the ignition coil with the pocket tester Primary Secondary 0 1...

Page 88: ...ter 09900 25002 REGULATOR RECTIFIER Disconnect the coupler Using the pocket tester 1 Range measure the resistance between the terminals as shown in the fol lowing table If the resistance checked is incorrect replace the regulator rectifier Probe of tester to Probe of tester to 1 2 3 4 1 2 3 4 50 230 50 260 10 100 1 2 3 4 STARTER SYSTEM The starter system is shown in the diagram below namely the st...

Page 89: ...brushes are worn the motor will be unable to procedure sufficient torque and the engine will be diffi cult to turn over To prevent this periodically inspect the length of the brushes and replace them when they are too short or chipping COMMUTATOR If the commutator surface is dirty starting performance will decrease Polish the commutator with 400 or simi lar fine emery paper when it is dirty After ...

Page 90: ...s places to test for open with the brushes lifted off the commutator surface If the coil is found to be open circuited or grounded replace the armature Continuous use of a defective armature will cause the starting motor to suddenly fail STARTER RELAY INSPECTION Disconnect the starter relay lead wire coupler Check the coil for open ground and ohmic resis tance The coil is in good condition if the ...

Page 91: ... disconnect the B W and Y B lead connector of the fuel gauge sending unit Connect a jumper wire between B W and Y B wires coming from the main wiring harness With the ignition switch turned ON the fuel meter should indicate F The second test will check the accuracy of the meter in the full and empty positions Connect a 90 Ϊ resistor between the Y B and B W lead wires The fuel meter is normal if it...

Page 92: ...OIL LEVEL CHECK LIGHT FUEL GUAGE SENDING UNIT INSPECTION Disconnect the lead wires coming out of the fuel gauge and check resistance of each position If the resistance measured is incorrect replace the fuel gauge assembly with a new one The relation between the position of the fuel gauge float and resistance is shown in the following table If either one or both indications are abnormal replace the...

Page 93: ...W and B W wires coming from the main wiring harness With the ignition switch turned ON the oil level check light should flash If there is no flash check the wiring harness continuity and the bulb blown out OIL LEVEL SWITCH INSPECTION Check the oil level switch for continuity between the lead wire If the tester does not show the value of 0 1 Ϊ when the switch ring is in bottom position file the con...

Page 94: ...dy within five minutes If not replace with new one Pocket tester 09900 25002 SWITCHES INSPECTION Inspect each switch for continuity with the pocket tester referring to the chart If it is found any abnormality replace the respective switch assembly with new one WIRE COLOR B Black L Blue G Green Gr Gray Sb Light blue Lg Light green O Orange R Red W White Y Yellow B R Black with Red tracer B W Black ...

Page 95: ...ting should take off Be cured from a doctor When the battery electrolyte was droped the surface of land wash a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on INITIAL CHARGING FILLING ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes BATTERY Type Capacity Standard electrolyte S G YT4L BS 12V 3AH 10HR 1 32 at 20 After filling the electrol...

Page 96: ...hat it does not fall NOTE If no air bubbles are coming up from a filler port tap the bottom of the two or three times Never remove the container from the battery Clean completely in case that the electrolyte is adhered at the filler hole Once install the caps to the battery do not remove the caps CAUTION After confirming that the electrolyte has entered the battery completely remove the electrolyt...

Page 97: ...shut tight room seconds Standard Fast BATTERY CHARGING CURRENT RECHARGING OPERATION Using the pocket tester check the battery voltage If the voltage reading is less than 12 0V DC recharge the battery with a battery charger When recharging the battery remove the battery from the motorcycle Do the battery by standard charging usually After recharging wait for more than 30 minutes and check the batte...

Page 98: ...CHASSIS FRONT WHEEL 6 1 FRONT BRAKE 6 7 FRONT FORK 6 14 STEERING 6 18 REAR WHEEL AND REAR BRAKE 6 22 CONTENTS 6 ...

Page 99: ...6 1 CHASSIS Do not operate the front brake lever while dis mounting the caliper CAUTION REMOVAL AND DISASSEMBLY Remove the front brake caliper by removing the mounting bolts FRONT WHEEL ...

Page 100: ...e motocycle by jack or wooden block Remove the front wheel and speedometer gear box by removing the front axle shaft Remove the disc plate by removing the bolts Remove the spacer Oil seal remover 09913 50121 Remove the oil seal with the special tool ...

Page 101: ...t Axle and Radial Service limit 3 0 mm INSPECTION WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel TIRE Inspect the tires for wear and damage and check the tire tread ...

Page 102: ... 25 2 00 kPa 123 196 kg 1 75 2 25 kPa 172 221 Front Rear Check the tire pressure and examine the value for evi dence of air leakage REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order diassembly and removal and also carry out the following steps WHEEL BEARING Apply SUPER GREASE A to the bearings before installing Install the wheel bearings by using the special too...

Page 103: ...23 55131 OIL SEAL Install the oil seal with the special tool Install the spacer DISC PLATE Install the disc plate and tighten them to the specified torque SPEEDOMETER GEAR BOX When installing the speedometer gear box align the two drive pawls with the two recesses of the wheel hub ...

Page 104: ...he stopper tighten the axle shaft CAUTION FRONT WHEEL Tighten the front axle nut to the specified torque Tighten the caliper mounting bolts to the specified torque Front axle nut 33 52 N m 3 3 5 2 kg m Front brake caliper mounting bolt 18 28 N m 1 8 2 8 kg m ...

Page 105: ...6 7 CHASSIS FRONT BRAKE Do not operate the front brake lever while dis mounting the caliper CAUTION BRAKE PAD REPLACEMENT Remove the caliper by removing the brake caliper mounting bolts ...

Page 106: ...move the brake pads Never re use the brake fluid left over from the last servicing and stored long periods CAUTION CALIPER REMOVAL AND DISASSEMBLY Remove the brake hose and catch the brake fluid in a suitable receptacle Remove the caliper mounting bolt Remove the caliper Remove the brake pads Remove the pad holder Remove the spring ...

Page 107: ...g over the piston to prevent popping up Force out the piston with a air gun Remove the dust seal and piston seal CALIPER INSPECTION Inspect the caliper cylinder bore wall for nicks scratches or other damage Inspect piston for damage and wear Inspect each rubber part for damage and wear ...

Page 108: ...CONE GREASE to the caliper holder DISC PLATE REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 6 2 Remove the disc plate Refer to page 6 2 Install the disc plate Refer to page 6 4 SPECIFIED TORQUE Item N m 18 28 20 25 kg m 1 8 2 8 2 0 2 5 Bleed the air from brake fluid circuit after reassembling caliper Refer to page 2 9 WARNING Disc thickness Service limit 3 5 mm Micrometer 0 25mm 0990...

Page 109: ... switch lead wires Dial gauge 1 100 mm 09900 20606 Magnetic stand 09900 20701 Disc runout Service limit 0 3 mm Completely wipe off any brake fluid adhering to any part of motorcycle The fluid reacts chemical ly with paint plastics rubber materials etc CAUTION Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect t...

Page 110: ... brake lever and brake switch Remove the dust boot Remove the circlip with the special tool Remove the piston primary cup with return spring Remove the reservoir cap and diaphragm Drain brake fluid Snapring pliers 09900 06108 ...

Page 111: ...semble and remount the master cylinder in the reverse order of removal and disassembly and also carry out the following steps Wash the master cylinder components with fresh brake fluid before reassembly Never use clean ing solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore CAUTION Bleed air after remounting the master cylinder...

Page 112: ...S 6 14 FRONT FORK Do not operate the front brake lever while dis mounting the caliper CAUTION REMOVAL AND DISASSEMBLY Remove the front leg shield Remove the front brake caliper by removing the mounting bolts ...

Page 113: ...removing the front axle shaft Loosen the front fork bolt then draw out the fork spring Loosen the front fork lower clamp bolts Invert the fork and stroke it several times to remove the oil Hold the fork inverted for a few minutes Remove the socket bolt with the hexagon wrench Seperate the fork pipe and pipe seat ...

Page 114: ...seal removed should be replaced with a new oil seal CAUTION Oil seal remover 09913 50121 INSPECTION Inspect pipe seat for wear and damage Inspect fork pipe and bottom case sliding surfaces for any scuffing or flaws Remove the oil seal by using the special tool ...

Page 115: ...the follow ing steps FRONT FORK BOLT Apply BOND 1215 and THREAD LOCK 1324 to the fork bolt and tighten the bolt with specified torque CUSHION SPRING When installing the front fork spring the close end should position upside Bond 1215 Thread Lock 1324 Front fork bolt 35 55 Nㆍm 3 5 5 5 kgㆍm TELLUS 37 50 cc One side Fork oil type Capacity FORK OIL For the fork oil be sure to use a front fork oil whos...

Page 116: ...the clamp bolt and set bolt Loosen the steering stem lock nut with the special tool Remove the front fork assembly by removing the lock washer steering outer upper race and dust seal Remove the steering outer lower race with a chisel Clamp wrench 09940 10122 Do not drop the steering stem steel balls CAUTION ...

Page 117: ...ing Worn and damaged steel balls Distortion of steering stem or handlebar REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem handlebar and front fork in the reverse order of disassembly and removal and also carry out the following steps OUTER LOWER RACE Press in the outer lower race Number of steel ball Upper Lower 22 pcs 25 pcs Remove the steering stem steel balls ...

Page 118: ...1 34513 Number of steel ball Upper Lower 22 pcs 25 pcs Make sure that the steering turns smoothly and easily left to right CAUTION STEERING OUTER UPPER RACE NUT Tighten the steering outer upper race until resis tance is felt then loosen it 1 8 1 4 turn Clamp wrench 09940 10122 Steering stem lock nut 60 100 Nㆍm 6 0 10 0 kgㆍm Tighten the steering stem lock nut with the special tool Super Grease A ...

Page 119: ...After install the front fork and steering stem inspect the following items Lift the front fork Inspect play of the front fork as that grasp lower of the front fork and shake it by the front and rear By the handle turning the right or left inspect whether turning smoothly Adjust the outer upper race if the steering is comed heavy and tight Bleed air of the front brake Refer to page 2 9 ...

Page 120: ...CHASSIS 6 22 REAR WHEEL AND REAR BRAKE REMOVAL AND DISASSEMBLY Place the motorcycle on level ground Remove the muffler Refer to page 3 4 Remove the rear wheel by removing the axle nut ...

Page 121: ...t on cam lever REAR BRAKE SHOE Apply SUPER GREASE A to the camshaft and pin before installing the brake shoes WHEEL Refer to page 6 3 TIRE Refer to page 6 4 Rear brake drum I D Service limit 100 7 mm INSPECTION REAR BRAKE DRUM Measure the brake drum I D to determine the extent of wear and if the limit is exceeded by the wear noted replace the drum The value of this limit is indicated inside the dr...

Page 122: ...CHASSIS 6 24 REAR AXLE NUT Tighten the rear axle nut to the specified torque Rear axle nut 60 90 Nㆍm 6 0 9 0 kgㆍm ...

Page 123: ...SERVICING INFORMATION TROUBLESHOOTING 7 1 SPECIAL TOOLS 7 6 TIGHTENING TORQUE 7 10 SERVICE DATA 7 12 WIRE AND CABLE ROUTING 7 18 WIRING DIAGRAM 7 20 CONTENTS 7 ...

Page 124: ...earing or piston pin bore worn 4 Piston rings or ring grooves worn Noise seems to come from crankshaft 1 Worn or brunt crankshaft bearings 2 Worn or brunt conrod big end bearings Noise seems to come from final gear box 1 Gears worn or rubbing 2 Badly worn splines 3 Worn or damaged bearings of drive shaft for rear axle shaft 1 Worn or damaged clutch shoes 2 Worn clutch drum Complaint Symptom and po...

Page 125: ... Clean Clean and replace Clean Check oil pump Change Replace Replace Replace Adjust or replace Clean Adjust or replace Clean Clean or replace Retighten or replace Replace Replace Replace Replace Clean Replace or clean Adjust or replace Retighten or replace Change Change Clean or replace Trouble with starting Idling or low speed trouble Medium or high speed trouble Overflow and fuel level fluctuati...

Page 126: ...ent in the regulator rectifier damaged or defective 3 Regulator rectifier unit poorly grounded 1 Lead wire insulation frayed due to vibration resulting in intermittent shorting 2 Magneto coil internally shorted 3 Defective regulator rectifier 1 Battery run down 2 Defective switch contacts 3 Brushes not seating properly on commutator in starter motor 4 Defective starter relay 5 Defective starter pi...

Page 127: ...n nuts on shock absorber 2 Worn engine mounting bushing Adjust Replace Replace Adjust Replace Replace Replace Replace Replace Retighten Retighten Replace Tighten Replace Replace Refill Replace Refill Retighten Replace Replace Replace Replace Retighten Replace Replace Retighten Replace CHASSIS Insufficient brake power Brake squeaking 1 Leakage of brake fluid from hydraulic system 2 Worn pad 3 Oil a...

Page 128: ...brake fluid 4 Worn brake cam lever 5 Excessively worn shoes and or drum 1 Insufficient tightening of connection joints 2 Cracked hose 3 Worn piston seal 1 Rusty moving parts Bleed air Replenish fluid to normal lever bleed air Replace with correct fluid Replace Replace Tighten to specified torque Replace Replace Clean and lubricate Complaint Symptom and possible causes Remedy ...

Page 129: ...sure height of cam 09900 20203 Micrometer 1 100mm 50 75mm Measure outside diameter of piston Special tools Part Number Part Name Description 09900 20205 Micrometer 1 100mm 0 25mm Measure outside diameter of piston pin 09900 20508 Cylinder gauge set 1 100mm 40 80mm Measure inside diameter of cylinder 09900 20602 Dial gauge 1 100mm 1mm Measure inside diameter of cylinder 09900 20605 Dial calipers 1 ...

Page 130: ...retor 09913 50121 Oil seal remover Used to remove the oil seal Special tools Part Number Part Name Description 09913 60710 Bearing remover Remove bearing with the rotor remove sliding shaft 09913 75520 Bearing installer Used to drive bearing in 09913 75821 Bearing installer Used to drive bearing in 09913 75830 Bearing installer Install rear axle shaft oil seal 09913 76010 Bearing installer Install...

Page 131: ...or remover Attached to the top of sliding shaft when removing rotor 09930 32420 Rotor holder Remove and remounting rotor 09930 40113 Rotor holder Widelyusedtolockrotarypartssuchasaflywheelmagneto 09940 34520 T handle Removeandremountingfrontforkoilcylinder 09921 20210 Bearing remover 12mm Remove oil seal or bearing 09922 55131 Bearing installer Used to drive bearing in 09923 73210 Bearing remover ...

Page 132: ... tools Part Number Part Name Description 09943 74111 Front fork oil level gauge Usedtodraintheforkoiltothespecifiedlevel 09943 88211 Bearing remover Remove rear axle shaft bearing 09951 76010 Bearing installer Used to drive bearnig in ...

Page 133: ...cket bolt Oil drain plug Oil level bolt Oil pump bolt Clutch shoe nut Clutch housing nut Kick starter driven nut Kick starter lever bolt 35 45 18 28 8 12 25 30 8 12 40 60 48 72 9 15 9 15 3 5 40 60 40 60 40 60 8 12 3 5 4 5 1 8 2 8 0 8 1 2 2 5 3 0 0 8 1 2 4 0 6 0 4 8 7 2 0 9 1 5 0 9 1 5 0 3 0 5 4 0 6 0 4 0 6 0 4 0 6 0 0 8 1 2 kg m N m TIGHTENING TORQUE ENGINE ...

Page 134: ...160 0 170 0 250 0 200 0 280 0 0 15 0 3 0 3 0 6 0 8 1 2 1 8 2 8 4 0 6 0 7 0 10 0 11 0 16 0 17 0 25 0 20 0 28 0 kg m N m kg m N m ITEM Rear brake cam lever bolt Rear shock absorber bolt Rear axle nut Steering stem lock nut Front brake disc bolt Front brake master cylinder bolt Front brake air bleeder valve Front brake caliper mounting bolt Front brake hose union bolt Front axle nut Front fork bolt H...

Page 135: ...4 3 0 10 0 25 0 10 0 25 0 02 0 06 0 02 0 06 Cylinder distortion Cylinder head distortion Piston ring clearance Free condition Piston ring clearance Assembling condition Piston ring ring groove clearance Piston pin bore I D Piston pin O D STANDARD LIMIT 1st 2nd 1st 2nd 1st 2nd CYLINDER PISTON PISTON RING Unit mm Unit mm CONROD CRANKSHAFT ITEM Conrod small end I D Conrod big end runout Crank web to ...

Page 136: ...110 15 3 0 3 600 200 rpm 6 000 200rpm 110 35 2 0 STANDARD LIMIT Unit mm OIL PUMP ITEM Oil pump reduction ratio 30 000 30 1 STANDARD Unit mm TRANSMISSION ITEM Final reduction ratio Gear ratios V belt width V belt thickness Movable drive face spring free length 12 0 2 997 0 813 16 5 0 6 8 0 0 6 143 8 15 3 135 153 STANDARD LIMIT ...

Page 137: ... rpm Fuel level Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot jet P J Throttle valve T V By pass B P Valve seat V S Stater jet G S Pilot screw P S Pilot outlet P O Throttle cable play Unit mm VM14 ф 14 HG 266 1 800 50 rpm 24 5 55 1 0 3E17 3 E 2 25 3 0 2 4 0 05 1 2 25 0 8 0 5 1 0 ...

Page 138: ...voltage No load performance of A C generator Starter relay resistance Ignition coil resistance Stator coil resistance Type designation Capacity Standard electrolyte S G Battery Fuse 0 19 0 24 Ϊ 5 4 6 6 0 54 0 80 Ϊ 0 69 1 03 Ϊ 220 260 Ϊ 90 110 Ϊ Y W Ground W R Ground B R Ground Br W 13 0 16 0 V at 5 000 rpm More than 17V at 5 000 rpm 0 70 Ϊ YT4L BS 12V 3AH 1 32 at 20 68 15W 2 5 10W 10W 4 1 7W 17W 1...

Page 139: ...iper I D Brake caliper piston diam Brake lever play Wheel rim runout Axle shaft runout Tire size Tire tread depth STANDARD LIMIT Front Rear Rear Rear Front Front Front Front Front Front Axial Radial Front Front Rear Front Rear 5 20 15 25 100 99 2 4 0 0 2 11 000 11 043 10 957 10 984 30 230 30 306 30 150 30 200 110 70 12 47J 120 70 12 51J 100 7 96 3 5 0 30 11 055 10 945 30 315 30 140 3 0 3 0 0 25 1 ...

Page 140: ...de Rear wheel travel 75 290 9 TELLUS 37 50 cc 66 Unit mm ITEM Fuel type FUEL OIL Gasoline used should be graded 85 95 octane or higher An unleaded gasoline is recommended 1 0 1 2 at 3 000 rpm for 5 minutes I D 60 Hr F O 100 Hr APOLLOIL BIKE K HYPOL HS SAE 10W 30 or 10W 40 multi grade motor oil 4 8 ℓ 1 0 ℓ Replace Overhaul 110 130 DOT 4 Fuel tank capacity Engine oil type Engine oil capacity Brake f...

Page 141: ...L Rear turnsignal R 09407 22402 Lamp assy Tail Stop Rear turnsignal R L Fuse case 09407 22402 Clamp Ignition coil Brake cable Rear brake cable Engine earth 09407 22402 Starter motor magneto Starter relay Switch thermo Battery cover REAR BRAKE WIRE AND CABLE ROUTING ...

Page 142: ...r Throttle cable Brake hose Rear brake cable Starter motor magneto Engine earth Starter motor Frame earth Frame Harness Throttle cable Rear fender Shield leg lower rear Harness Rear turnsignal RH LH Rear brake cable Starter motor Heater carburetor Shield leg lower rear Helmet box Ignition coil Clamp Switch thermo 09407 22402 Oil tank 09407 22402 Lamp assy Tail Stop Fuse case Battery Oil level gaug...

Page 143: ...eater Regulator Oil gauge Fuel gauge Horn Front brake switch Front turnsignal RH Head lamp Front turnsignal LH Horn Turnsignal Ignition switch Spark plug Starter motor Battery Engine earth Rear turnsignal LH Rear turnsignal RH Tail Stop Rear brake switch Handle switch LH Handle switch RH Speedometer Rear turnsignal Front turnsignal Oil pilot lamp turnsignal pilot lamp Illumination 10 10 1 7 1 7 1 ...

Page 144: ...Prepared by HYOSUNG MOTORS MACHINERY INC 2nd Ed NOV 1999 Manual No 99000 91310 Printed in Korea ...

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HYOSUNG Prima, Service Manual

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