HYOSUNG RT 125 D Service Manual Download Page 3

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SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing.
The meaning of each symbol is also included in the table.

Apply THREAD LOCK

“

1324

”

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Use special tool.

Measure in continuity test range.

Measure in diode test range.

Torque control required.
Data beside it indicates specified torque.

Apply oil.
Use engine oil unless otherwise specified.

Apply SUPER GREASE

“

”

Apply SILICONE GREASE.

Apply MOLY PASTE.

Apply BOND

“

1215

”

Use fork oil.

DEFINITION

SYMBOL

DEFINITION

SYMBOL

Apply SUPER GREASE

“

”

Summary of Contents for RT 125 D

Page 1: ...ServiceManual RX 125 D RX 125 SM RT 125 D Kun motor Udgivet 2009 Holtvej 8 10 Høruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 ...

Page 2: ...omers of your optimum and quick service SERVICING INFORMATION GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE ENGINE 3 2 7 This manual has been prepared on the basis of the latest specification at the time of publication If modification has been made since then difference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the ba...

Page 3: ...L Listed in the table below are the symbols indicating instructions and other information necessary for servicing The meaning of each symbol is also included in the table Apply THREAD LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Measure in continuity test range Measure in diode test range Torque control required D...

Page 4: ...cer GY Green with Yellow tracer GrB Gray with Black tracer GrR Gray with Red tracer GrW Gray with White tracer OB Orange with Black tracer OL Orange with Blue tracer OG Orange with Green tracer OR Orange with Red tracer OW Orange with White tracer OY Orange with Yellow tracer RB Red with Black tracer RW Red with White tracer WB White with Black tracer WL White with Blue tracer WR White with Red tr...

Page 5: ...4 ...

Page 6: ...5 GENERAL INFORMATION EXTERIOR PHOTOGRAPH 6 1 3 EXTERIOR ILLUSTRATION 7 1 7 1 EXTERIOR ILLUSTRATION 8 1 7 2 EXTERIOR ILLUSTRATION 9 1 7 3 SPECIFICATIONS 10 1 8 CONTENTS 1 ...

Page 7: ...6 1 3 GENERAL INFORMATION EXTERIOR PHOTOGRAPH ...

Page 8: ...USTRATION 390 315 840 940 945 1 125 1 060 230 1 350 2 085 405 790 660 715 725 800 865 Rear reflector Brake Tail lamp Rear turn signal lamp License plate lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WIDTH ...

Page 9: ...USTRATION 875 720 295 810 410 1 010 1 065 1 160 1 100 1 425 2 190 320 840 865 124cm 3 Rear reflector Brake Tail lamp Rear turn signal lamp License plate lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WIDTH ...

Page 10: ...GENERAL INFORMATION 1 7 3 EXTERIOR ILLUSTRATION Rear reflector Brake Tail lamp Rear turn signal lamp License plate lamp Front turn signal lamp Passenger footrests Head lamp HEIGHT WHEEL BASE LENGTH WIDTH ...

Page 11: ... oil cooled 1 cylinder 57 0 mm 2 24 in 48 8 mm 1 92 in 124 5 7 6 in3 Carburetor Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Lubrication system I T E M ENGINE Wet multi plate type 5 speed constant mesh 1 down 4 up 3 500 2 750 1 786 1 368 1 046 0 913 428SO 130 links 428H 132 links 428H 130 links Clutch Transmission Gearshift pattern Re...

Page 12: ...HASSIS I T E M ELECTRICAL 9 0 ℓ 850 950 1 200 215 2 5 cc 8 0 ℓ 443 2 5 cc Fuel tank Engine oil Front fork oil capacity One side Oil change Oil and filter change Engine overhaul I T E M CAPACITIES Ignition type Ignition timing Spark plug Battery Fuse Head lamp Turn signal lamp Brake Tail lamp License plate lamp Illumination lamp High beam indicator lamp Turn signal indicator lamp right left Neutral...

Page 13: ...12 ...

Page 14: ... BOLTS CYLINDER HEAD CYLINDER BASE NUTS EXHAUST PIPE NUTS AND MUFFLER BOLTS 14 2 3 AIR CLEANER 15 2 5 1 VALVE CLEARANCE 18 2 6 1 SPARK PLUG 20 2 7 ENGINE OIL 21 2 8 ENGINE OIL FILTER 22 2 9 CARBURETOR 23 2 10 COMPRESSION PRESSURE CHECK 24 2 19 OIL PRESSURE CHECK 25 2 20 CONTENTS ...

Page 15: ...er Exhaust pipe nut 18 28 N m 1 8 2 8 kgf m Muffler connecting bolt 18 28 N m 1 8 2 8 kgf m Muffler mounting bolt 18 28 N m 1 8 2 8 kgf m Cylinder head cover bolt 12 16 N m 1 2 1 6 kgf m CYLINDER HEAD COVER BOLT Tighten the cylinder head base buts and cylinder base nuts to the specified torque Cylinder head base nut 7 11 N m 0 7 1 1 kgf m Cylinder base nut 7 11 N m 0 7 1 1 kgf m CYLINDER HEAD CYLI...

Page 16: ... the air cleaner element for the follwing Fill a washing pan of a proper size with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it Gently squeeze the air cleaner element between the palms of both hands to remove the excess solvent do not twist or wring the element or it will develop tears Immerse the element in HYOSUNG genuine oil and then squee...

Page 17: ...ement or with torn element Make sure that the air cleaner element is in good condition at all times Life of the engine depends largely on this component 8 8 Remove the seat The air cleaner is located under the seat Remove the four air cleaner element bolts Pull up the air cleaner element AIR CLEANER OIL DRAIN TUBE Inspect the air cleaner oil drain tube and drain water and oil at the periodic inter...

Page 18: ...e element completely or damage severely the engine Be careful not to allow water to go inside the air clea ner element CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions also clean the air cleaner element when replacing the engine oil to prevent damage of the engine AIR CLEANER OIL DRAIN TUBE Inspect the air cleaner oil drain tube and drain water ...

Page 19: ...d Every 4 000 km thereafter Remove the cylinder head cover The valve clearance specification is different for both intake and exhaust valves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshafts are removed for servicing Remove the magneto cover plug and valve timing inspection plug NOTE The pist...

Page 20: ...e cylinder head Select the tappet that agree with tappet clearance vertical line and shim NO horizontal line as refer to the tappet shim selection chart Refer to page 90 91 Adjust valve timing install the camshaft housing and the cam chain tension adjuster After the crankshaft rotate about 10 times measure the valve clearance If the clearance be not correct adjust the standard clearance as the sam...

Page 21: ... km and Every 4 000 km thereafter Replace Every 8 000 km SPARK PLUG GAP Measure the spark plug gap using a thickness gauge If the spark plug gap is out of specification adjust the gap ELECTRODE Check to see the worn or burnt condition of the elec trodes If it is extremly worn or burnt replace the spark plug with a new one And also replace the spark plug if it has a broken insulator damaged thread ...

Page 22: ...rain the engine oil by removing the engine oil filler plug and drain plug Reinstall the drain plug gasket and engine oil drain plug Tighten the drain plug to the specified torque and pour fresh engine oil through the engine oil filler hole Use an engine oil that meets the API service classification of Over SL and that has a viscosity rating of SAE 10W 40 Install the engine oil filler plug Start up...

Page 23: ...N Necessarily confirm and clean the oil strainer when replace the engine oil specially when first replacement CAUTION More frequent servicing may be performed on mo torcycles that are used under severe conditions ENGINE OIL FILTER Drain the engine oil as described in the engine oil replacement procedure Remove the oil filter cap by removing the three nuts Remove the oil filter Install the new O ri...

Page 24: ...d check the engine oil level as described in the engine oil replacement procedure CAUTION ONLY USE A GENUINE HYOSUNG MOTORCYCLE ENGINE OIL FILTER Other manufacturer s engine oil filters may differ filtering performance and durability which may lead to engine damage or oil leaks Connect an engine tachometer to the high tension cord Start up the engine and set its speed at anywhere of the specified ...

Page 25: ...MPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic maintenance records kept at your dealership should include compression reading for each maintenance service NOTE Before testing the engine for compression pressure make sure that the cylinder head bol...

Page 26: ... 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 74511 LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage way Damaged O ring Defective oil pump Combination of the above items OIL PRESSURE CHECK Check the engine oil pressure periodically Thi...

Page 27: ...26 ...

Page 28: ...F ENGINE REASSEMBLY 71 3 48 LEFT END COMPONENTS OF ENGINE REASSEMBLY 75 3 52 3 CONTENTS CAUTION Mark an 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 Oil the rotating or sliding parts before assembly Make sure to use the correct type of lubricant ...

Page 29: ...unting bolts and nuts to the specified torque INSTALLING POSITION FOR CLUTCH RELEASE ARM Align the clutch release arm slit surface with the notch mark on the clutch release camshaft Engine mounting bolt M10 48 72 N m 4 8 7 2 kgf m Engine mounting bolt M8 22 33 N m 2 2 3 3 kgf m Tighten the engine mounting bracket bolts and nuts to the specified torque Engine mounting bracket bolt M8 22 33 N m 2 2 ...

Page 30: ...y removing the four wrench bolts Bring the piston at TDC Top Dead Center NOTE If only the upper end components of the engine is repaired there is no necessary to remove the engine from the frame Remove the seat and fuel tank so that the upper end components of the engine is disassemble CAUTION Align the T index mark on the magneto rotor with the triangle mark on the magneto cover as turn the crank...

Page 31: ...ove the cam chain tension adjuster Remove the cam chain guide NO 2 Remove the camshaft housings Remove the dowel pins intake camshaft and exhaust camshaft NOTE Do not drop the dowel pins and cam chain into the crankcase ...

Page 32: ...31 ENGINE 3 8 Remove the camshaft C rings Loosen the three cylinder head bolts Loosen the three cylinder head base nuts Remove the cam chain guide NO 1 ...

Page 33: ...m the valve stem Remove the valve spring retainer CAUTION Draw out the tappet and shim with the strong magnet not to be scratched CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly Valve spring compressor 09916 14510 Valve spring compressor attachment 09916H35C00 ...

Page 34: ...n rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase Remove the piston pin circlips with the long nose pliers Remove the piston pin by using the special tool CAUTION If tapping with the plastic hammer is necessary pay attention to break the fins Piston pin puller 09910 34510 ...

Page 35: ...mal wear is found replace the respective valve with a new one The thickness of the valve face decreases as the face wears Measure the valve head thickness If the valve head thickness is not within the specified value replace the valve with a new one Cylinder head distortion Valve head thickness IN EX Service limit 0 5 mm 0 02 in Vernier calipers 09900 20101 VALVE STEM RUNOUT Check the valve stem f...

Page 36: ...al noise or vibration or a lack of out put power Any of these abnormality could be caused by a worn camshaft VALVE TIMING DIAGRAM Cam height Intake cam Exhaust cam 34 12 mm 1 343 in 34 17 mm 1 345 in Service limit CAMSHAFT WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in term...

Page 37: ... the tappet for wear and scratch If modification or scratch is present replace the tappet When you checked the valve clearance if the valve clearance is wide please replace the present shim into thick one if the valve clearance is narrow please replace the present shim into thin shim Refer to page 90 91 SHIM KIND There are 41 kinds of shim which thickness is increased by each 0 025 mm from 1 20 mm...

Page 38: ...VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two directions X and Y perpendicular to each other Position the dial gauge as shown If the deflection exceeds the service limit determine whether the valve or the guide should be replaced with a new one EX IN Dial gauge 09900 20606 Magnetic stand 09900 20701 VALVE STEM DIAMETER Measure...

Page 39: ...he force required to compress them If the spring length is less than the service limit or if the force required to compress the valve spring is not within specification replace the valve spring Vernier calipers 09900 20101 12 1 13 9 kgf 26 68 30 64 lbs at length 33 7 mm 1 33 in 3 15 ENGINE Cylinder distortion Service limit 0 05 mm 0 002 in CYLINDER DISTORTION Check the gasketed surface of the cyli...

Page 40: ... in the direction perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer If the measurement is found less than the service limit replace the piston PISTON TO CYLINDER CLEARANCE To determine the piston to cylinder clearance calculate the difference between the cylinder bore and outside diameter of the piston 15 mm 0 6 in 0 120 mm 0 0047 in ...

Page 41: ...nd lifted up measure the clearance on the bottom side of the ring using a thickness gauge If any clearance reading exceeds the service limt replace both the piston and piston rings Standard Piston ring thickness Standard Piston ring groove width Oil 2nd 1st 2 01 2 03 mm 0 079 0 080 in 1 01 1 03 mm 0 040 0 041 in 1 01 1 03 mm 0 040 0 041 in 2nd 1st 0 970 0 990 mm 0 0382 0 0390 in 0 970 0 990 mm 0 0...

Page 42: ...he piston ring squarely into the cylinder using the piston head Measure the end gap with a thickness gauge If the gap exceeds the service limit replace the piston ring with a new one Piston ring end gap Assembly condition 1st 2nd Service limit 0 50 mm 0 020 in 0 50 mm 0 020 in Piston ring end gap Assembly condition 1st 2nd Standard Thickness gauge 0990 20806 Service limit Piston ring free end gap ...

Page 43: ...pers measure the piston pin hole bore both the vertical and horizontal directions If the measurement exceeds the service limit replace the piston with a new one Dial calipers 09900 20605 Piston pin hole bore Service limit 15 030 mm 0 5917 in Piston pin diameter Service limit 14 980 mm 0 5898 in PISTON PIN DIAMETER INSPECTION Using a micrometer measure the piston pin outside diameter at three posit...

Page 44: ...auge If the clearance exceeds the service limit replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts conrod big end bearing crankshaft crank pin etc with new ones Standard 1 00 mm 0 040 in Conrod big end side clearance Thickness gauge 09900 20806 0 10 0 45 mm 0 004 0 018 in Service limit CRANKSHAFT RUNOUT...

Page 45: ...ide rails The spacer and side rails do not have a designated top and bottom They can be installed in any position CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove Position the piston ring gaps as shown Before inserting the piston into its cylinder check that the gaps are properly positioned 2nd ring and lower side rail Upper side rail 1st ring and sp...

Page 46: ...ing sections positioned correctly and put it into the cylinder Make sure that the piston rings are caught by the cylinder skirt Tighten the cylinder base nut to the specified torque MOLY PASTE NOTE Install the piston with the punch mark on the piston head facing toward the exhaust side NOTE When mounting the cylinder after attaching the cam chain keep the cam chain taut The cam chain must not be c...

Page 47: ... sure that the rounded lip of the cotter fits snugly into the groove in the stem end Install the valve spring with the smaller pitch facing the cylinder head CAUTION When inserting each valve into the valve guides make sure not to damage the lip of the oil seal MOLY PASTE Cylinder head direction Valve spring compressor 09916 14510 Valve spring compressor attachment 09916H35C00 CAUTION After instal...

Page 48: ...ly engine oil to the threaded parts of the cylinder head bolts and its washers Be sure to install the washer with rounded side facing up Pay caution to prevent the cam chain from dropping into the crankcase Cylinder head bolt 21 25 N m 2 1 2 5 kgf m After tightening the cylinder head bolts to the specification tighten the cylinder head base nuts to the specified torque Cylinder head base nut 7 11 ...

Page 49: ...valve clear ance With pulling up the cam chain align the T index mark of the magneto rotor into the triangle mark of the magneto cover to turn the crankshaft Fit the cam chain guide NO 1 CAUTION If turn the crankshaft without pulling up the cam chain the cam chain may be fallen off between the crankcase and cam chain drive sprocket 3 25 ENGINE ...

Page 50: ...4 to the thread portion of the camshaft sprocket bolts Camshaft sprocket bot 10 12 N m 1 0 1 2 kgf m THREAD LOCK 1324 CAMSHAFT ASSEMBLY Distinguish the EX mark for the exhaust camshaft the IN mark for the intake camshaft IN EX Apply the engine oil to the camshaft bearings Install the exhaust camshaft first following the intake camshaft CAUTION Do not rotate the magneto rotor while doing this opera...

Page 51: ...r to the following photograph and illustrations 3 27 ENGINE With the T index mark on the magneto rotor is aligned with the triangle mark on the magneto cover hold the camshaft steady and lightly pull up the cam chain to remove any slack between the cam chain sprocket and exhaust camshaft sprocket The exhaust camshaft sprocket has an arrow marked 1 Turn the exhaust camshaft so that the arrow marked...

Page 52: ... ENGINE 3 28 16 Pins Notch mark EXHAUST INTAKE NOTE The cam chain should now be on all three sprockets Be careful not to move the crankshaft until the camshaft housings and cam chain tensioner are secured ...

Page 53: ...ace the housing B to the B the housing C to the C and the housing D to the D as that A B C D is punched also to the cylinder head upper surface Fix the four camshaft housing and cam chain guide NO 2 by tightening of the bolt in order Install each bolt diagonally by using the wrench pulling the shaft down Tighten the bolt of each camshaft housing with the same torque CAUTION If get damaged the cyli...

Page 54: ...imes clockwise or counter clockwise on the basis of the magneto rotor If the valve clearance is within standard after measured the valve clearance begin the next operation If it is out of standard adjust the valve clearance within standard limit after disassembled the camshaft and replaced the proper shim CAUTION If you don t rotate the crankshaft about 10 times before measuring the valve clearanc...

Page 55: ...ONENTS OF ENGINE DISASSEMBLY Disconnect the magneto couplers Remove the engine guard Remove the engine sprocket cover Remove the magneto cover Remove the starter idle gear shaft and starter idle gear 54 3 31 ENGINE ...

Page 56: ... With the magneto rotor held immovable loosen the rotor nut Remove the magneto rotor by using the special tool Remove the key Remove the starter clutch gear Remove the starter one way clutch Rotor remover 09930 30162 ...

Page 57: ... cover by removing the stator screws Remove the gear position switch by removing the screws Remove the switch contact and its spring Flatten the lock washer and then remove the engine sprocket nut Remove the engine sprocket CAUTION Be careful not to lose the O ring switch contact and its spring 56 3 33 ENGINE ...

Page 58: ...ve the clutch cover bolts and oil filter cap nuts and detach the clutch cover by tapping with a plastic hammer Remove the clutch spring mounting bolts diagonally while holding the primary driven gear and remove the clutch pressure plate Remove the clutch drive plates and driven plates RIGHT END COMPONENTS OF ENGINE DISASSEMBLY ...

Page 59: ...ut Flatten the lock washer With the clutch sleeve hub held immovable using the special tool remove the clutch sleeve hub nut Remove the clutch sleeve hub and thrust washer Take off the primary driven gear assembly CAUTION The primary drive gear nut has a left hand thread If turning it counter clockwise it may cause damage Clutch sleeve hub holder 09920 53710 3 35 ENGINE ...

Page 60: ...hen remove the oil pump Draw out the gearshift shaft Loosen the four screws and then remove the gear shift pawl lifter and gear shift cam guide Take off the gear shift cam driven gear CAUTION When removing the gear shift cam driven gear be careful not to lose the gear shift pawl pin and return spring Primary drive gear Primary drive NO 2 gear Spring ...

Page 61: ...the crankcase bolts NOTE Fit the crankcase separator so that the tool arms are in parallel with the side of crankcase The crankshaft and transmission components should remain in the left crankcase half This is necessary because the gear shift cam stopper is mounted on the left crankcase half and will be damaged if the transmission components remain in the right half Crankcase separator 09920 13120...

Page 62: ...8 Remove the gear shift arm stopper spring Draw out the gear shift fork shaft NO 1 NO 2 Take off the gear shift cam and gear shift fork NO 1 NO 2 Remove the driveshaft assembly and countershaft assembly TRANSMISSION ...

Page 63: ...ve the crankshaft using the special tool CRANKSHAFT Remove the retainer oil seals and bearings right and left Remove the clutch release camshaft OIL SEAL AND BEARING Crankcase separator 09920 13120 3 39 ENGINE ...

Page 64: ... FREE LENGTH Measure the free length of each clutch spring using the vernier calipers If any spring is not within the service limit replace all of the spring Vernier calipers 09900 20101 Service limit Clutch spring free length 29 5 mm 1 161 in CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using the vernier calipers If the clutch drive plate is not within the t...

Page 65: ...ork The clearance for each of the three gear shift forks plays an important role in the smoothness and positiveness of shifting action If the checked clearance is noted to exceed the limit specified replace the fork or its gear or both Service limit 0 50 mm 0 020 in Standard 0 10 0 30 mm 0 004 0 012 in Vernier calipers 09900 20101 Thickness gauge 09900 20806 Shift fork groove clearance Shift fork ...

Page 66: ...he cam chain tight to remove any slack then using the vernier caliper measure the 20 pitch 21 pins length of the cam chain If it measures than the limits replace the cam chain STARTER CLUTCH BEARING Inspect the bearing for any abnormality particularly cracks to decide whether it can reused or should be replaced 129 9 mm 5 11 in Cam chain 20 pitch length CRANKCASE BEARING Rotate the bearing inner r...

Page 67: ...he below figure when rebuilding the crankshaft When mounting the crankshaft in the crankcase it is necessary to pull its left end into the crankcase 53 0 0 1 mm 2 087 0 004 in Width between webs Crankshaft installer 09910 32812 Conrod holder 09910 20115 53 0 0 1 mm 2 087 0 004 in 3 43 ENGINE Standard ...

Page 68: ... accuracy will be affected CAUTION Never reuse a circlip 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 do not expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always insure that it is completely seated in its groove and securely fitted ...

Page 69: ...NOTE When reassembling the bearing retainer apply a small quantity of THREAD LOCK 1324 to the threaded parts of the bearing retainer screws In reassembling the transmission attention must be given to the locations and positions of washers and circlips The cross sectional view shows the correct position of the gears washers and circlips CAUTION This procedure may be performed only twice before shaf...

Page 70: ...69 ENGINE 3 46 Fit the gear shift cam on the crankcase Position the gear shift cam as shown in the figure so that the gear shift fork can be installed easily GEAR SHIFT CAM AND FORK ...

Page 71: ... material on the fitting surface of right and left halves of the crankcase and thoroughly remove the oil stains Fit the dowel pins on the left side of the crankcase Apply the engine oil to the big end of the crankshaft conrod and all parts of the transmission gears Apply BOND 1215 uniformly to the fitting surface of the left side of the crankcase and after waiting a few minutes fit the right half ...

Page 72: ...ation try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in the figure GEAR SHIFT CAM DRIVEN GEAR When installing the gear shift pawls into the gear shift cam driven gear the large shoulder must face to the outside as shown Next install the gear shift cam guide and gear shift pawl lifter Apply a small quantity of THREAD LOCK 1324 to the threaded parts o...

Page 73: ...a small quantity of THREAD LOCK 1324 to the threaded parts of the oil pump mounting screws Tightening the oil pump mounting screws to the specified toruqe THREAD LOCK 1324 Fit the oil pump driven gear and install the circlip CAUTION After mounting the oil pump in the crankcase rotate the oil pump driven gear by hand to see if it turns smoothly CAUTION When installing the primary drive NO 2 gear al...

Page 74: ...ershaft apply a small quantity of engine oil to both inside and outside of the spacer Tighten the clutch sleeve hub nut using the special tool to the specified torque Clutch sleeve hub holder 09920 53710 Clutch sleeve hub nut 30 50 N m 3 0 5 0 kgf m With the clutch sleeve hub held immovable install the primary drive gear washer and nut tighten the primary drive gear nut to the specified torque and...

Page 75: ...d in the countershaft Install the clutch push piece thrust bearing and thrust washer to the countershaft Install the clutch pressure plate Tighten the clutch spring set bolts CAUTION Insert the longer side of the clutch push rod toward the inside NOTE Tighten the clutch spring set bolts diagonally CLUTCH RELEASE ADJUSTER SCREW Loosen the adjuster nut and turn clutch release adjuster screw to feel ...

Page 76: ...rain plug to the specified torque LEFT END COMPONENTS OF ENGINE REASSEMBLY STATOR Apply a small quantity of THREAD LOCK 1324 to the thread parts of screws Engine oil drain plug 25 30 N m 2 5 3 0 kgf m Gear shift cam stopper plug 20 25 N m 2 0 2 5 kgf m THREAD LOCK 1324 THREAD LOCK 1324 STARTER CLUTCH When installing the starter clutch and rotor apply the THREAD LOCK 1324 to the bolts and tighten t...

Page 77: ... clutch on the crankshaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft Hold the magneto rotor and tighten the magneto rotor bolt to the specified torque STARTER IDLE GEAR AND MOTOR Install the starter idle gear Install the starter motor Magneto rotor bolt 56 60 N m 5 6 6 0 kgf m 3 53 ENGINE ...

Page 78: ... cover Install the engine guard Tighten the engine sprocket nut to the specified torque and bend up the lock washer Rotor holder 09930 40113 Engine sprocket nut 80 100 N m 8 0 10 0 kgf m CAUTION Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leakage Also grease the oil seal lip On installation refer to the figure for correct position and direction Replace th...

Page 79: ...78 ...

Page 80: ...79 SERVICING INFORMATION TIGHTENING TORQUE 80 7 11 SERVICE DATA 81 7 13 WIRING DIAGRAM 88 7 22 1 WIRING DIAGRAM 89 7 22 2 CONTENTS 7 ...

Page 81: ...Exhaust pipe nut Gear shift cam stopper plug Magneto rotor nut Muffler connecting bolt Muffler mounting bolt Oil cooler bolt Oil pump mounting screw Primary drive gear nut Spark plug Starter clutch bolt 1 0 1 2 0 8 1 2 0 8 1 2 3 0 5 0 0 9 1 3 0 7 1 1 2 1 2 5 1 2 1 6 0 7 1 1 4 8 7 2 2 2 3 3 2 2 3 3 2 5 3 0 8 0 10 0 1 8 2 8 2 0 2 5 5 6 6 0 1 8 2 8 1 8 2 8 2 0 2 5 0 5 0 7 4 0 6 0 2 0 2 5 1 5 2 0 kgf ...

Page 82: ... IN EX IN EX 0 35 0 014 0 05 0 002 0 50 0 02 0 03 0 0012 37 80 1 488 37 80 1 488 Valve diam Valve clearance When cold Valve guide to valve stem clearance Valve stem deflection Valve guide I D Valve stem O D Valve stem runout Valve head thickness Valve seat width Valve seat angle Valve head radial runout Valve spring free length Valve spring tension ITEM STANDARD LIMIT Camshaft runout Cylinder head...

Page 83: ...0390 1st 2nd 1st 2nd 1st 2nd 1st 2nd Oil 1st 2nd Compression pressure Piston to cylinder clearance Cylinder bore Piston diameter Cylinder distortion Piston ring free end gap Piston ring end gap Assembly condition Piston ring to groove clearance Piston ring groove width Piston ring thickness Piston pin hole bore Piston pin O D CYLINDER PISTON PISTON RING Unit mm in Oil pressure Oil pump reduction r...

Page 84: ...thickness Drive chain Drive chain Drive chain Drive chain slack Drive chain slack 3 500 70 20 5 00 5 10 0 197 0 201 5 50 5 60 0 217 0 221 4 80 4 90 0 189 0 193 5 30 5 40 0 209 0 213 20 30 0 79 1 18 50 60 1 97 2 36 0 5 0 020 256 5 10 10 256 5 10 10 256 5 10 10 ITEM STANDARD LIMIT TRANSMISSION DRIVE CHAIN 2 750 33 12 1 786 25 14 1 368 26 19 1 046 23 22 0 913 21 23 428SO 130 LINKS 254 0 10 00 1st 2nd...

Page 85: ...492 102 100 A1FC ф 2 6 38 3 ф 0 9 ф 2 0 MAX 500 120 0 5 1 0 0 02 0 04 SPECIFICATION Carburetor type Bore size Idle rpm Float height Main jet M J M A J J N N J P J TH V V S P A J Main air jet Jet needle Pilot jet Throttle valve Pilot outlet Valve seat Starter jet Pilot air jet Throttle cable play Needle jet ...

Page 86: ...92 98 90 ф 2 6 A1FC 2nd 38 3 ф 0 9 ф 2 0 MAX 500 150 0 5 1 0 0 02 0 04 SPECIFICATION Carburetor type Bore size Idle rpm Float height Main jet M J M A J J N N J P J TH V V S P A J Main air jet Jet needle Pilot jet Throttle valve Pilot outlet Valve seat Starter jet Pilot air jet Throttle cable play Needle jet ...

Page 87: ...ty Fuel tank capacity Engine oil Engine oil capacity 9 0 ℓ 8 0 ℓ API Over SL SAE 10W 40 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommened 850 950 1 200 ITEM SPECIFICATION FUEL OIL Oil change Oil and filter change Engine overhaul ...

Page 88: ...rd electrolyte S G ELECTRICAL CR8E 0 7 0 8 0 028 0 032 CR7E CR8E CR9E YTX7A BS 12V 6Ah 15A ITEM STANDARD BTDC 6 1 900 rpm 27 4 250 rpm NOTE 1 320 at 20 68 Unit mm in Ignition timing Spark plug Battery Fuse size Type Gap Hot type Standard type Cold type ...

Page 89: ...88 7 22 1 SERVICING INFORMATION WIRING DIAGRAM ...

Page 90: ...89 SERVICING INFORMATION 7 22 2 WIRING DIAGRAM ...

Page 91: ... 10 2 15 2 20 2 20 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 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 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 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2...

Page 92: ...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 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 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 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 80 1 85 1 90 1 95 2 00 2 05 ...

Page 93: ...Prepared by 1st Ed JUN 2009 Manual No 99000HR7810 Printed in Korea ...

Page 94: ...SERVICE MANUAL S T Motors Co Ltd ...

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