HYOSUNG sense Service Manual Download

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CHASSIS 6-14

CALIPER REMOVAL AND DISASSEMBLY

● Remove the brake hose and catch the brake fluid in a suitable

receptacle.

● Remove the caliper.
● Remove the brake pads.

● Remove the pad holder ① and spring ②.

● Remove the dust seal ③ and piston seal ④.

● Place a rag over the piston to prevent popping up. Force out the

piston with a air gun.

①

②

③

④

CAUTION:
Never re-use the brake fluid left over from the last servicing
and stored long periods.

CAUTION:
Do not use high pressure air to prevent piston dam-
age.

Summary of Contents for sense

Page 1: ...SERVICE MANUAL 99000 91201 SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC ...

Page 2: ... be servicing this motorcycle should carefully review this manual before performing any repair or services Information of this manual is up to date at the time of issue Major modification and changes incorporated later will be advised to HYOSUNG product distributor in each market Therefore if newest information is requested in the future please contact the local HYOSUNG distributor The SD 50 motor...

Page 3: ...GENERAL INFORMATION MODEL IDENTIFICATION 1 1 FUEL AND OIL RECOMMENDATIONS 1 1 BREAKING IN PROCEDURE 1 1 PRECAUTIONS AND GENERAL INSTRUCTIONS 1 2 SPECIAL MATERIALS 1 3 SPECIFICATIONS 1 4 CONTENTS 1 ...

Page 4: ... allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and relia bility of the engine depends on the care and restraint exercised during its early life The general rules are as follow Keep to these breaking in speed limit Up to 1000 km 600 miles Less than 4 5 throttle Upon reaching an odometer reading of 1000km 600 miles you can subject the moto...

Page 5: ...ribing the following contents WARNING The parsonal safety of the rider may be involved Disregarding this information could result in injury to rider CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine NOTE This provides special information to make maintenance easier or important inst ructions clearer REPLACEMENT PARTS W...

Page 6: ... use Oil seal Throttle grip Speedometer cable Oil pump drive driven gear Kick starter gear Kick starter shaft Movable driven face Fixed driven face Starter pinion Starter motor Wheel bearing Brake camshaft Steering stem bearing Magneto rotor nut Crankcase mating surface Final gear cover Front brake caliper I ndu I ndu M ulti M ulti pur pur strial strial pose pose G rease G rease 1 215 L iquid G as...

Page 7: ...ve CHASSIS Front suspension Telescopic coil spring oil dampened Rear suspension Swingarm type coil spring oil damped Caster 25 Trail 70 mm 2 75 in Steering angle 45 right left Turning radius 1 9 mm 6 2 ft Front tire size 100 80 10 53J Rear tire size 100 80 10 53J Front brake Disc Rear brake Internal expanding ELECTRICAL Ignition type HYOSUNG CDI Ignition timing 23 B T D C at 4 000 r min Spark plug...

Page 8: ...NDER HEAD NUTS AND EXHAUST PIPE BOLTS 2 3 CYLINDER HEAD AND CYLINDER 2 3 SPARK PLUG 2 4 FUEL LINE 2 4 AIR CLEANER 2 5 THROTTLE CABLE 2 5 ENGINE IDLE SPEED 2 5 OIL PUMP 2 6 FINAL GEAR OIL 2 7 BRAKES 2 7 TIRES 2 10 STEERING 2 10 FRONT SUSPENSION 2 11 REAR SUSPENSION 2 11 CHASSIS BOLTS AND NUTS 2 11 GENERAL LUBRICATIONS 2 13 CONTENTS 2 ...

Page 9: ... oil Brakes Steering Brake fluid Brake hose Front suspension Rear suspension Tire Cylinder head nuts and exhaust pipe nuts Chassis bolts and nuts miles km months 2 Initial 600 Initial 1000 I I T l T C l C R C I I I I I I Replace every 4 years I I I I I Replace every 2 years I Replace every 4 years I I I I I I I I I I T T Every 2400 Every 4000 Every 4800 Every 8000 6 12 PERIODIC MAINTENANCE SCHEDUL...

Page 10: ...he battery voltage with the pocket tester If the voltage reading is below 12 0V this battery needs recharging Refer to page 5 10 MAINTENANCE AND TUNE UP PROCEDURE This section describes the servicing procedures for each item of the Periodic Maintenance requirements Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter Battery voltage Minimum 12 0V 09900 25002 P...

Page 11: ...mpressed mixture and reduce output Tighten the cylinder head nuts in the following procedure Remove the frame side cover Refer to page 6 3 Remove the spark plug cap Remove the cylinder head cover bolts Refer to page 3 5 Tighten the nuts evenly one by one in stages until each one is tightened to the specified torque Tighten the nuts in the order indicated CYLINER HEAD NUT AND EXHAUST PIPE BOLTS Tig...

Page 12: ...r electrode is fairly worn down the plug should be replaced and the plug gap set to the specified gap using a thickness gauge SPARK PLUG FUEL LINE Clean Every 4000km 2400miles 6months and Replace Every 8000km 4800miles 12months Tightening torque 25 30 N m 2 5 3 0 kg m 18 0 21 0 lb ft GOLDEN REMARKS BP5HS If the standard plug is apt to get wet replace with this plug If the standard plug is apt to g...

Page 13: ...case properly Non flammable cleaning solvent SAE 10W40 AIR CLEANER Loosen the lock nut and adjust the cable play by turning adjuster in or out to obtain the following cable play After adjusting play tighten the lock nut THROTTLE CABLE Clean Every 4000km 2400miles 6months Adjust at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter ENGINE IDLE SPEED Adjust at Initially ...

Page 14: ...he index mark when the throttle valve is posi tioned as above If the marks are not aligned loosen lock nuts and turn the adjuster in or out to align the marks After aligning the marks tighten the lock nuts OIL PUMP Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter CAUTION Oil pump cable adjustment must be done after throttle cable adjustment Connect an elec...

Page 15: ...erving the lower limit line on the brake fluid reservoir When the level is bolow the lower limit line replenish with brake fluid that meets the following specification BRAKES Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter Replace change brake fluid Every 2 years Replace brake hose Every 4 years WARNING The brake system of this motorcycle is filled with a...

Page 16: ...ke fluid circuit be purged of air in the following manner Fill up the master cylinder reservoir to the upper end of the inspection window Replace the reservoir cap to prevent entry of dirt Attach a pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle Bleed air from the bleeder valve Squeeze and release the brake lever several times in rapid suc cession and squeez...

Page 17: ...eps below First check if the brake system is properly adjusted While operating the brake check to see that the extension line from the index mark is within the range on the crankcase If the index mark is outside the range as shown in the illustra tion at right the brake shoe assembly should be replaced to ensure safe operation NOTE Replenish the brake fluid reservoir as necessary while bleeding th...

Page 18: ... bars and safe running Too stiff steering prevents smooth turning of handlebars and too loose steering 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 ahead grasp lower shock absorber near the axle and pull forward If play is found perform steering bearing adjustment Refer to pa...

Page 19: ... retightened to the specified torque with a torque wrench CHASSIS BOLTS AND NUTS Tighten at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter No Front axle nut 33 52 3 3 5 2 Steering stem lock nut 60 100 6 0 10 0 Handlebar clamp nut 48 52 4 8 5 2 Front brake master cylinder bolt 8 12 0 8 1 2 Front brake hose union bolt 20 25 2 0 2 5 Front brake air bleeder valve 18 28...

Page 20: ...PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 12 ...

Page 21: ...e cable Wheel bearing Center stand Engine mounting bracket pivoting portion Rear brake lever and cable Rear brake camshaft Grease Oil GENERAL LUBRICATIONS G G G G G G G G G G G O O WARNING Be careful not to apply too much grease to the rear break camshaft If grease gets on the linings brake slippage will result NOTE Lubricate expodes parts which are subject to rust with motor oil grease Before lub...

Page 22: ... 3 14 CYLINDER HEAD 3 16 CYLINDER 3 17 PISTON 3 17 REED VALVE 3 19 ENGINE REASSEMBLY 3 20 OIL SEALS 3 20 BEARINGS 3 20 BUSHINGS 3 21 CRANKSHAFT 3 22 CRANKCASE 3 23 CENTER STAND 3 24 REAR AXLE SHAFT BRAKE AND WHEEL 3 25 TRANSMISSION 3 27 STARTER DRIVEN GEAR AND STARTER MOTOR 3 29 MOVABLE DRIVEN AND CLUTCH 3 30 MOVABLE DRIVE 3 33 KICK STARTER 3 35 PISTON 3 36 OIL PUMP AND INTAKE PIPE 3 38 MAGNETO 3 ...

Page 23: ...tially explained as follows Remove the frame side covers Refer to page 6 3 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 thermoelement lead coupler Disconnect the throttle cable Refer to page 4 2 Disconnect the carburetor hoses and oil hose Vacuum hose Fuel hose Oil hose ...

Page 24: ...gneto lead wire and starter lead wire Remove the rear brake cable by removing the bolt bolt and adjuster nut Remove the rear shock absorber mounting lower bolt Remove the engine mounting shaft and remove the engine from the frame ...

Page 25: ...e holding it tighten the bracket bolt to specification Tighten both the rear shock absorber bolt and engine mounting bolt to specification Install the magneto lead wire and starter motor lead wire cor rectly After remounting the engine route the wiring harness properly Refer to page 6 and following adjustments are necessary Page Throttle cable play 2 5 Idling adjustment 2 5 Oil pump cable paly 2 6...

Page 26: ... 40113 Rotor holder MAGNETO Remove the cooling fan Remove the magneto rotor nut with the special tool 09930 30163 Rotor removerr Remove the magneto rotor with the special tool Remove the magneto stator and key REED VALVE Remove the intake pipe with reed valve OIL PUMP Remove the oil pump Remove the oil pump driven gear ...

Page 27: ...e the kick starter shaft spring and kick starter shaft Remove the crankcase left cover KICK STARTER Remove the kick starter lever Remove the clutch cover PISTON Place a cloth beneath the piston and remove the circlip with a pliers Remove the piston pin and piston Remove the piston pin bearing ...

Page 28: ...vable drive face STARTER DRIVEN GEAR Remove the starter driven gear MOVABLE DRIVEN FACE Remove the clutch housing with the special tool KICK STARTER DRIVEN GEAR Remove the E ring with the long nose plier Remove the spacer spring and kick starter driven gear CAUTION This nut has left hand thread 09910 20115 Conrod holder 09930 40113 Rotor holder ...

Page 29: ...oller bearing with the special tools Special tool Special tool Loosen the clutch shoe nut with the special tool 09930 40113 Rotor holder 09923 73210 Bearing remover 09930 30102 Sliding shaft WARNING 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 CAUTION Do not attempt to diassemble the ...

Page 30: ...t Remove the circlip Remove the bearing with the special tool Special tool Installer Special tool 09941 50111 Wheel bearing remover CAUTION The removed bearing should be replaced with a new one 09913 50121 Oil seal remover CAUTION The removed oil seal should be replaced with a new one 09943 88211 Bearing remover Bearing installer CAUTION The removed bearing should be replaced with a new one ...

Page 31: ... idle shaft Remove the drive shaft bearing 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 Special tool Special tool 09930 30102 Sliding shaft 09921 20210 Bearing remover ...

Page 32: ...r pin washer and shaft Remove the center stand CENTER STAND Remove the return spring CRANKCASE Remove the crankcase securing screws Special tool Special tool 09913 75820 Bearing remover Bearing installer 09913 50121 Oil seal remover NOTE Loosen the crankcase nuts diagonally 09920 13120 Crankcase separation tool ...

Page 33: ...3 11 ENGINE Remove the crankshaft with the special tool Remove the bearings oil seals and bushing 09920 13120 Crankshaft remover Crankcase separating tool ...

Page 34: ...12 Using two steel tubes of appropriate size press out the engine mounting bushings on a vise as shown in the illustration Front side Rear side Bushing Bushing Bushing 28 1 25 5 15 15 20 22 3 Crankcase Crankcase ...

Page 35: ...crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine life CONDITION OF BIG END BEARING Turn the crankshaft with the conrod to feel the smoothness of rotary motion in the big end Move the rod up and down while holding the crankshaft rigidly to be sure that there is no rattle in the big end Wear on the big end of the conrod can be estimated by checking ...

Page 36: ...Remove the right frame side cover Connect an electric tachometer to the engine Seated on the motorcycle with the motorcycle on level ground increase the engine RPMs slowly and note the RPM at which the motorcycle begins to move forward 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping Warm the engine to normal operating temperatures C...

Page 37: ... wheel with inside calipers Measure the diameter at several points to check for an out of round condition as well as wear DRIVE BELT Remove the drive belt and check for cracks wear and separation Measure the drive belt width with a vernier calipers Replace it if the belt width is less than the service limit or any defect has been found DRIVE FACE Inspect the belt contact surface of the drive faces...

Page 38: ... or hitches are found visually inspect the lip of oil seal driven face sliding surface and sliding pins for wear or dam age DRIVEN FACE Inspect the belt contacting surface of both driven faces for any scratches wear and damage Replace 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 distortion wi...

Page 39: ... the cylinder with a new one Oversize piston is available in one size 0 5 mm oversize 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 CYLINDER TO PISTON CLEARANCE Cylinder to piston clearance is the difference between piston diame ter and cylinder b...

Page 40: ...he piston to cylinder clearance exceeds the following limit overhaul the cylinder and use an oversize piston or replace both cylinder and piston The mea surement for the bore diameter should be taken in the intake to exhaust port direction and at 20mm from the cylinder top surface Unit mm PISTON PIN BORE Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the follo...

Page 41: ...e lies the importance 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 squa...

Page 42: ...Reassembly is generally performed in the reverse order of disas sembly 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 99000 07000 Grease G2 99000 32030 Thread Lock 1324 09913 75830 Oil seal installer 09924 74510 Oil seal installer handle 09913 75810 Bearing installer 09913 76010 B...

Page 43: ... 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 Protruside and should be in the same dimension ...

Page 44: ...into the crankcase with the special tool Crankshaft Crankcase R Oil seal Oil seal Oil pump drive gear Oil pump drive gear Oil Standard width between webs 35 0 1 0 mm 1 378 0 004 in 09910 32812 Crankshaft installer CAUTION Never fit the crankshaft into the crankcase by driving it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affected CRANKSHAFT ...

Page 45: ...he crankcase and install the dowel pins Install the two dowel pins Tighten the crankcase screws securely Check if crankshaft rotates smoothly Install the new oil seal to the crankcase with the special tool Special tool Apply grease 99000 31110 THREAD BOND NO 1215 09913 85210 Bearing installer NOTE Align the oil seal with edge of the crankcase as shown in the illustration ...

Page 46: ...ENGINE 3 24 CENTER STAND Install the center stand Install the shaft washer and cotter pin Hook center stand spring into the crankcase ...

Page 47: ...ly 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 REAR AXLE SHAFT BRAKE AND WHEEL Rear axle shaft Rear brake cam Rear brake cam lever Rear brake cam lever bolt Rear brake shoe Brake shoe spring Rear wheel Rear wheel washer Rear wheel nut Apply grease Brake cam 99000 ...

Page 48: ...ly grease to the camshaft and pin before installing the brake shoes Install the rear wheel and nut Punched mark Slit Tightening torque 6 9 N m 0 6 0 9 kg m 4 5 6 5 lb ft Tightening torque 60 90 N m 6 0 9 0 kg m 43 5 65 0 lb ft 99000 07000 Grease G2 CAUTION Be careful not to apply too much grease to the camshaft and pin If grease gets on the lining brake effectiveness will be lost ...

Page 49: ...stall the subsasembly on the gear box TRANSMISSION Rear axle shaft Circlip Idle shaft Oil drain bolt Washer Final driven gear Circlip Driveshaft Washer Gasket Dowel pin Gear box cover Bearing Oil seal Oil level bolt Oil drain bolt Thrust Rounded corner Circlip Install the final driven gear on the rear axle shaft using the circlip The center ...

Page 50: ... new gasket and dowel pin Install the driveshaft to the gear box cover Install the new bearing to the gear box cover with the special tool Hatched area Special tool Oil seal Align face Special tool Apply grease to the lip of the oil seal and install it to the gear box cover with the special tool 09913 70610 Bearing installer 99000 07000 Grease G2 99000 31110 Three Bond No 1215 09914 05210 005 Bear...

Page 51: ...tarter driven gear over the left crankshaft end STARTER DRIVEN GEAR AND STARTER MOTOR Starter driven gear Starter motor Install the starter motor NOTE The convex side of hub should face outside when installed in proper position ...

Page 52: ...clip MOVABLE DRIVEN AND CLUTCH Fixed driven face Bearing Circlip Needle roller bearing Movable driven face Oil seal Oil seal Spacer Pin 그리스 O ring Spring Clutch shoe assembly Clutch shoe nut Clutch housing Clutch housing nut V velt Special tool Thrust Rounded corner 09943 88211 Bearing installer ...

Page 53: ...ool Grease Pin Spacer Install the pin at three places on the driven face hub Apply grease lightly to the cam part where the pins are placed Position two O ring 09943 88210 Bearing installer 09913 76010 Bearing installer Apply grease to the lip of oil seals and groove of inside of mov able driven face 99000 07000 Grease G2 NOTE When reinstalling the movable face to the fixed face make sure that the...

Page 54: ...to be free from oil and position it over the clutch shoe assembly Tighten the clutch housing nut to the specified torque with the special tool Special tool Special tool 09930 40113 Rotor holder Tightening torque 40 60 N m 4 0 6 0 kg m 29 0 43 5 lb ft 09930 40113 Rotor holder Tightening torque 40 60 N m 4 0 6 0 kg m 29 0 43 5 lb ft CAUTION The belt should be positioned so that the arrows on the bel...

Page 55: ...le drive plate and install it on the movable drive face Position the O ring on the movable drive face MOVABLE DRIVE Movable drive face Roller Movable drive plate Damper O ring Movable drive face cover Spacer Fixed drive face Kick starter driven nut Kick starter driven gear Spring Spacer E ring ...

Page 56: ...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 Install the E ring Spacer Apply grease NOTE Make sure that the movable drive plate is fully positioned inside or the weight roller may come off NOTE Thoroughly clean the belt contact to be from oil 09910 20115 Conrod holder 99000 07000 Grea...

Page 57: ...ecified torque Kick starter lever Kick starter shaft Kick starter shaft spring Circlip Crankcase cover LH Gasket Clutch cover Screw Apply grease lightly on the rolling surface and install it on the crankcase cover Position the kick starter shaft return spring and hook the spring end on the crankcase cover boss Install the dowel pin and crankcase cover Oil Capacity 90 ml Tightening torque 9 15 N m ...

Page 58: ...ue Needle roller bearing Piston Piston ring 1st ring 2nd ring Expender ring Circlip Piston pin Cylinder gasket Cylinder Cylinder head gasket Cylinder head Cylinder head nut 13 Apply engine oil NOTE Install the kick starter lever as shown in the illustra tion Tightening torque 8 12 N m 0 8 1 2 kg m 6 0 8 5 lb ft PISTON ...

Page 59: ...he circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the groove por tion of the piston Position the cylinder base gasket Apply engine oil on the piston and cylinder wall surfaces and install the cylinder over the piston carefully Tighten the cylinder head nut to the specification Locating pin CORRECT INCORRECT Outside NOTE Position the ring so th...

Page 60: ...crankcase Install the oil pump and tighten it to the specified torque OIL PUMP AND INTAKE Oil pump driven gear Oil pump Apply grease Install the gaskets and intake pipe with reed valve to the crankcase 99000 07000 Grease G2 Tightening torque 3 5 N m 0 3 0 5 kg m 2 0 3 6 lb ft ...

Page 61: ...he key Install the rotor Stator Key Magneto rotor Nut and washer Fan case Cooling fan Fan cover Apply THREAD LOCK 1324 to the rotor nut and tighten it to the specified torque with the special tool 09930 40113 Rotor holder 99000 32030 THREAD LOCK 1324 Tightening torque 35 45 N m 3 5 4 5 kg m 25 5 31 0 lb ft MAGNETO ...

Page 62: ...1 2 kg m 6 0 8 5 lb ft Install the fan case Install the magneto lead wire and starter motor lead wire Install the cooling fan Install the cooling fan cover MUFFLER Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque ...

Page 63: ...FUEL AND LUBRICATION SYSTEM CARBURETOR 4 1 REMOVAL 4 1 DISASSEMBLY 4 2 INSPECTION 4 4 REASSEMBLY AND REMOUNTING 4 4 FUEL TANK 4 6 REMOVAL 4 6 REMOUNTING 4 7 OIL PUMP 4 8 CONTENTS 4 ...

Page 64: ... the absorber mounting lower bolt CARBURETOR Carburetor chamber Float Main jet Throttle stop screw Needle jet Needle valve Pilot air screw Throttle valve Jet needle E ring Spring Thermoelement Remove the side cover Refer to page 6 3 REMOVAL ...

Page 65: ...se Oil hose Fuel hose Remove the carburetor top cap and disconnect the throttle cable Remove the careburetor by loosening the mounting bolts and clamp screw DISASSEMBLY Remove the thermoelement assembly CAUTION Do not attempt to disassemble the thermoelement assembly It is not serviceable ...

Page 66: ...mber Remove the float by removing the screw and pin Remove the needle valve Remove the main jet and needle jet SCREW NOTE When removing the pilot air screw record the revolu tions until tighten completly Remove the throttle stop screw and pilot air screw ...

Page 67: ...at 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 INSPECTION Check following items for any damage or clogging Pilot jet Main jet Pilot air screw Needle jet air bleeding hole Float Gasket Pilot outlet and bypass holes REASSEMBLY AND REMOUNTING Reassemble f...

Page 68: ...4 5 FUEL AND LUBRICA TION SYSTEM Install the carburetor top cap Install the thermoelement assembly Install the carburetor assembly Install the vacuum hose oil hose and fuel hose ...

Page 69: ...ng lower bolt Remove the rear fender bolts then take off the rear fender CLEANING Dust from the fuel tank tends to bulid up in the fuel filter which when the fuel filter has been neglected for a long period inhibits the flow of fuel Remove the dust from the fuel filter using compressed air NOTE To prevent fuel flow connect the suitable cap to the fuel tank outlet Disconnect the fuel hose ...

Page 70: ...CA TION SYSTEM y y y Fuel tank Fuel level gauge Fuel level gauge cap Fuel tank cap Vacuum hose Inlet hose Outlet hose No 1 Cushion Fuel strainer Outlet hose No 2 REMOUNTING Remount the fuel tank in the reverse of removal ...

Page 71: ...w good and hare CAUTION During this inspection strictly follow the following points The machine should be rested on the center stand Do not touch the rear wheel while running the engine 09900 21602 CCI oil gauge Oil discharge amount 0 9 1 1 ml at 3000 r min for 5 minutes CHECKING OIL PUMP Use the special tool to check the pump for capacity by measuring the amount of oil the pump draws during the s...

Page 72: ...GING SYSTEM 5 2 IGNITION COIL 5 2 STATOR COILS 5 3 REGULATOR RECTIFIER 5 3 STARTER SYSTEM 5 4 STARTER MOTOR INSPECTION 5 5 STARTER RELAY INSPECTION 5 5 FUEL LEVEL GAUGE 5 6 OIL LEVEL CHECK LIGHT 5 7 THERMOELEMENT 5 8 SWITCHES 5 9 BATTERY 5 10 CONTENTS 5 ...

Page 73: ... ELECTRICAL SYSTEM ELECTRICAL PARTS Ignition coil Thermolement assembly Trunk box lamp Fuel level gauge Oil level gauge Turn signal relay Key set Starting motor relay Rectifier Horn C D I Unit M F battery ...

Page 74: ...or 5 minutes Check the ignition coil with pocket tester IGNITION COIL RESISTANCE IGNITION CHARGING SYSTEM Ignition coil Spark plug Engine stop switch CDI unit Stator Lighting switch Regulator Rectifier Battery 12V 3AH MF H L T L M L 12V 15W 2 12V 5W 12V 3 4W 2 Spark Y B B B R 그라운드 플러그 캡 R 09900 28106 Electro tester STD spark performance 8 mm 09900 25002 Pocket tester Primary Secondary W L Ground A...

Page 75: ...ion REGULATOR RECTIFIER Disconnect the coupler Using the pocket tester 1 range measure the resis tance between the terminals as shown in the following table If the resistance checked is incorrect replace the regulator rectifier Unit Approx Ground Ground Ground Y W W R B R Standard resistance Lighting Charging Exciting 0 6 1 4Ϊ 0 6 1 4Ϊ 180 230Ϊ NOTE When making this test be sure that the battery i...

Page 76: ...g the front or rear brake lever energizes the relay causing the contact points to close which connects the starter motor to the battery Starter relay IG switch Starter button Y G R Fuse Brake switch Battery W B Point R W Starter motor STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the starter motor Disassemble the starter motor as shown in the illustration Holder Pinion gear assembly Brush holder as...

Page 77: ...oth Measure the commutator under cut Service Limit 4mm 0 16in ARMATURE COIL Using the pocket tester check the coil for open and ground by placing probe pins on each commutator segment and rotor core to test for ground and on any two segments at various 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 armatu...

Page 78: ...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 ohm resistor between the Y B and B W lead wires The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the circuit ...

Page 79: ...ition of the fuel gauge float and resistance is shown in the following table Oil level switch IG switch Battery Oil level check light Float position F Full 1 2 E Empty Resistance Approx 10Ϊ Approx 38Ϊ Approx 90Ϊ 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 ohm when the switch ring is in bottom position file...

Page 80: ... minutes If not replace with new one Battery PTC REGURATOR RECTIFIER B R R Y W R W MAGNETO OIL LEVEL CHECK LIGHT INSPECTION Disconnect the L W and B W lead connector of the oil level check light Connect a jumper wire between L 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 c...

Page 81: ... 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 with White tracer W B White with Black tracer Y W Yellow with white tracer FRONT AND REAR BRAKE LIGHT SWITCH ON OFF O WB STARTER BUTTON ON OFF BW YG LIGHTING SWITCH ON OFF Gr YW DIMMER SWITCH LO HI W Y Gr TURN SIGNAL LIGHT SWITCH L R Lg B Sb HORN BUTTON ON OFF BW G IGNITION SWITCH LOCK O...

Page 82: ...g up each electrolyte container and leave in this position for about more than 20 minutes INITIAL CHARGING FILLING ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes Remove the caps Type designation YTX4L BS Capacity 12V 3AH 10HR Standard electrolyte S G 1 32 at 20 68 NOTE After filling the electrolyte completely use the removed cap as the sealed caps of battery fill...

Page 83: ...ry with a battery charger SERVICING Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery termi nals are found to be coated with rust or an acidic white powdery substance then this can be cleaned away with sandpaper CAUTION Never use anything except the spec...

Page 84: ...ge is still less than 12 5V after recharging replace the battery with a new one When a battery is left for a long term without using it is subject to discharge When the motorcycle is not used for more than 1 month especially during the winter season recharge the battery once a month at least CAUTION When recharging the battery remove the battery from the motorcycle CAUTION Be careful not to allow ...

Page 85: ...5 CALIPER REASSEMBLY 6 15 DISC PLATE REMOVAL AND DISASSEMBLY 6 16 DISC PLATE INSPECTION 6 16 MASTER CYLINDER REMOVAL AND DISASSEMBLY 6 16 MASTER CYLINDER INSPECTION 6 18 MASTER CYLINDER REASSEMBLY AND REMOUNTING 6 18 FRONT FORK 6 19 REMOVAL AND DISASSEMBLY 6 19 INSPECTION 6 21 REASSEMBLY AND REMOUNTING 6 21 STEERING 6 22 REMOVAL AND DISASSEMBLY 6 22 INSPECTION 6 23 REASSEMBLY AND REMOUNTING 6 23 R...

Page 86: ...6 1 CHASSIS HANDLEBAR COVERS Tightening torque 4 5 10 20 20 40 Handle rear cover Throttle grip Tightening torque 15 25 Tightening torque 10 20 Handle bar Headlight Handlebar front cover ...

Page 87: ...by removing the mounting screws and disconnecting the lead wires REMOUNTING Remount the handlebar covers in the reverse order of removal HANDLEBAR REAR COVER Disconnect the lead wire couplers and speedometer cable Remove the handlebar rear cover by removing the mounting screws ...

Page 88: ...IELD AND SIDE COVERS Tightening torque 4 5 6 10 20 20 40 40 70 Side cover R Center cover Side cover L Mat floor Battery cover Side leg shield L Front lower shield Front upper leg shield Leg shield cover Side leg shield R ...

Page 89: ...SIS 6 4 Remove the front leg shield lower REMOVAL FRONT LEG SHIELD UPPER Loosen the mounting screws Remove the front leg shield upper by pull out it forward FRONT LEG SHIELD LOWER Loosen the mounting screws ...

Page 90: ...n the seat Remove the rear carrier by removing the bolts and screw RIGHT SIDE COVER RIGHT SIDE LEG SHIELD Loosen the mounting screws Remove the right side cover and right side leg shield at the same time Side cover Side leg shield ...

Page 91: ... 6 6 LEFT SIDE COVER LEFT SIDE LEG SHIELD Loosen the mounting screws Remove the handle grip by removing the bolts Remove the left side cover and left side leg shield at the same time Side cover side leg shield ...

Page 92: ...ery cover by removing the screw REMOUNTING Remount the leg shield and side covers in the reverse orders of removal Remove the cover leg shield rear and leg shield rear at the same time REAR CENTER COVER Remove the rear center cover by removing the bolts Loosen the screw and bolts Battery cover ...

Page 93: ...ve the front wheel by removing the front axle shaft Front axle nut Speedometer gear box Wheel bearing R Spacer Wheel bearing L Disc plate Spacer Oil seal Front axle shaft Disc bolt CHASSIS 6 8 Tightening torque Item Nㆍm ㆍm lbㆍft 33 52 3 3 5 2 24 0 37 5 18 28 1 8 2 8 13 0 20 0 REMOVAL AND DISASSEMBLY Remove the front brake caliper by removing the mounting bolts ...

Page 94: ...ve the dust seal with the special tool Drive out the both bearing with the special tool in the following procedures Insert the adapter into the bearing After inserting the wedge bar from the opposit side lock the wedge bar in the slit of the adapter Drive out the bearing by knocking the wedge bar 09913 50121 Oil seal remover 09941 50110 Bearing remover ...

Page 95: ...rms of tread depth must be replaced Check the tire pressure and examine the value for evidence of air leakage TIRE DEPTH SERVICE LIMIT TIRE DEPTH SERVICE LIMIT NORMAL RIDING DUAL RIDING SOLD RIDING kPa 125 200 kPa kg 1 25 2 00 kg FRONT REAR COLD INFLATION TIRE PRESSURE WHEEL BEARING Apply grease to the bearings before installing 99000 07C00 Grease G2 Install the wheel bearings by using the special...

Page 96: ...em to the specified torque 09922 55131 Oil seal installer OIL SEAL Install the oil seal with the special tool Install the spacer Tightening torque 18 28 Nㆍm 1 8 2 8 kgㆍm 13 20 lb ft Special tool Right side Left side Bearing L Bearing R Spacer Clearance Bearing L ...

Page 97: ...the wheel hub FRONT WHEEL Tighten the front axle nut to the specified torque CAUTION After touching the speedometer gear box to the stopper tighten the axle shaft Tighten the caliper mounting bolts to the specified torque Tightening torque 33 52 Nㆍm 3 3 5 2 kgㆍm 24 38 lbㆍft Tightening torque 18 28 Nㆍm 1 8 2 8 kgㆍm 13 20 lbㆍft ...

Page 98: ...emove the brake pads CAUTION Replace the brake pads as a set otherwise braking perfor mance will be adversely affected Master cylinder bolt Master cylinder Brake hose union bolt Brake hose Pad Air bleeder valve Dust seal Piston Piston seal Caliper Apply silicone grease Tightening torque Item Nㆍm 8 12 20 25 6 9 kgㆍm 0 8 1 2 2 0 2 5 0 6 0 9 lb ft 6 0 8 5 14 5 18 0 4 5 6 5 ...

Page 99: ...r Remove the brake pads Remove the pad holder and spring Remove the dust seal and piston seal Place a rag over the piston to prevent popping up Force out the piston with a air gun CAUTION Never re use the brake fluid left over from the last servicing and stored long periods CAUTION Do not use high pressure air to prevent piston dam age ...

Page 100: ...lso carry out the following steps Apply silicone grease to the caliper holder Tighten the each bolts 99000 25100 Silicone grease Apply grease CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore WARNING Bleed the air from brake fluid circuit afte...

Page 101: ...he disc if the runout exceeds the service limit Service Limit 3 5 mm 0 14 in 09900 20205 Micrometer 0 25 mm Service Limit 0 3 mm 0 012 in 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handlebar cover Refer to page 6 1 Disconnect the front brake light switch lead wires Place a cloth underneath the union bolt on the master cylinder to c...

Page 102: ...ers Remove the master cylinder Remove the 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 ...

Page 103: ...mbly and also carry out the following steps Reassemble and remount the master cylinder Refer to page 6 13 When remounting the master cylinder on the handlebar first tighten the clamp bolt for upside Boot Circlip Second cap Piston Primary cap Spring CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fl...

Page 104: ...25 35 20 26 kgㆍm 3 5 5 5 2 5 3 5 2 0 2 6 lb ft 22 5 40 0 16 0 25 5 14 5 18 8 REMOVAL AND DISASSEMBLY Remove the front leg shield Refer to page 6 3 Remove the front brake caliper by removing the mounting bolts Remove the front axle nut Remove the motorcycle by jack or wooden block Remove the front wheel by removing the front axle shaft NOTE Do not operate the front brake lever while dismount ing th...

Page 105: ...s to remove the oil Hold the fork inverted for a few minutes Remove the scoket bolt with the hexagon wrench Seperate the fork pipe and pipe seat Remove the dust boot and stopper ring Remove the oil seal by using the special tool Loosen the front fork bolt then draw out the fork spring Loosen the front fork lower clamp bolts ...

Page 106: ...L For the fork oil be sure to use a front fork oil whose viscosity rating meets specification below REASSEMBLY AND REMOUNTING Reassemble and remount the fork in the reverse order of removal and disassembly and also carry out the following steps FRONT FORK BOLT Apply thread lock 1324 to the fork bolt and tighten the bolt with specified torque Service limit 240 mm 9 45 in 99000 32030 Thread lock 132...

Page 107: ... handlebar by removing the clamp bolt and set bolt Loosen the steering stem lock nut with the special tool Remove the steering stem steel balls Remove the lower bearing outer race with a chisel Number of steel balls Remove the front fork assembly by removing the lock washer steering outer upper race and dust seal CAUTION Do not drop the steering stem steel balls ...

Page 108: ...aring race wear and brinelling 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 INNER RACE Press in the upper and lower inner races with special tool STE...

Page 109: ...n the steering outer race until resistance is felt then loosen it 1 8 1 4 turn Tighten the steering stem lock nut with the special tool Install the handlebar and tighten the set bolt and clamp nut to the specified torque CAUTION After performing the adjustment and installing the handlebar rock the front wheel assembly for ward and backward to ensure that there is no play and that the procedure was...

Page 110: ... the drum BRAKE SHOE Using a vernier calipers measure the brake shoe outside diameter at the place as shown in the photo If the measurement is less than the limit replace the brake shoe Service Limit 100 7 mm 3 96 in Service Limit 96 6 mm 3 78 in CAUTION Replace the brake shoe with a set otherwise braking performance will be adversely affected Rear axle nut Washer Rear wheel Brake shoe Spring Rear...

Page 111: ...camshaft with the slit on cam lever BRAKE SHOE Apply grease to the camshaft and pin before installing the brake shoes REAR AXLE NUT Tighten the rear axle nut to the specified torque 99000 07C00 Grease G2 CAUTION Be careful not to apply too much grease to the camshaft and pin If grease gets on the lining brake effectiveness will be lost Brake cam lever Tightening torque 6 9 Nㆍm 0 6 0 9 kgㆍm 4 5 6 5...

Page 112: ...SERVICING INFORMATION SPECIAL TOOLS 7 1 TIGHTENING TORQUE 7 3 WIRING DIAGRAM 7 5 WIRE ROUTING 7 6 SERVICE DATA 7 7 TROBLESHOOTING 7 11 CONTENTS 7 ...

Page 113: ...pe Impact driver set Thickness gauge Tire depth gauge CCI oil gauge Pocket tester Tachometer Universal clamp wrench Crank shaft installer Oil seal remover Bearing remover installer Bearing remover installer Bearing remover installer Bearing remover installer Bearing remover installer PART NAME 09910 20116 09910 60611 09913 50121 09913 75810 09913 75820 09913 75830 09910 32812 09913 76010 09913 845...

Page 114: ... 74910 09943 88211 PART No PART NAME FIG PART No PART NAME FIG Bearing remover installer Bearing remover installer Crankcase separating tool Bearing remover Bearing remover Bearing remover Bearing installer handle Bearing installer attachment Bearing installer set Bearing installer Sliding shaft 09930 30163 Rotor remover Rotor holder Bearing installer Bearing remover Bearing installer Bearing inst...

Page 115: ...r bleeder valve Rear brake cam lever nut Front brake disc bolt Steering stem lock nut 3 3 5 2 33 52 60 90 48 52 22 28 40 60 48 72 20 30 8 12 20 25 18 28 6 9 6 9 18 28 60 100 24 0 37 5 43 5 65 0 34 5 37 5 16 0 20 0 29 0 43 5 34 5 52 0 14 5 21 5 6 0 8 5 14 5 18 0 13 0 20 0 4 5 6 5 4 5 6 5 13 0 20 0 43 5 72 5 6 0 9 0 4 8 5 2 2 2 2 8 4 0 6 0 4 8 7 2 2 0 3 0 0 8 1 2 2 0 2 5 1 8 2 8 0 6 0 9 0 6 0 9 1 8 ...

Page 116: ... 9 1 5 0 8 1 2 0 8 1 2 0 8 1 2 kg m lb ft N m TIGHTENING TORQUE CHART For other bolts and nuts not listed in the preceding page refer to this chart Conventional or 4 marked bolt Bolt Diameter mm 7 marked bolt 1 2 0 1 0 2 0 7 1 5 1 5 3 0 15 0 3 1 0 2 0 2 0 4 5 6 0 8 5 13 0 20 0 29 0 43 5 50 5 72 5 79 5 115 5 123 0 181 0 144 5 202 5 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 28 ...

Page 117: ...LATOR P T C REAR TURN SIGNAL LIGHT R TAIL BRAKE LIGHT REAR TURN SIGNAL LIGHT L BATTERY STARTER MOTOR STARTER RELAY C D I MAGNETO REAR BRAKE LIGHT SWITCH IGNITION SWITCH TURN SIGNAL LIGHT SWITCH HORN DIMMER SWITCH FRONT TURN SIGNAL LIGHT R FRONT TURN SIGNAL LIGHT L HEAD LIGHT SPARK PLUG IGNITION COIL HORN 7 5 SERVICING INFORMA TION WIRING DIAGRAM WIRE COLOR B Black Lg Light green Y Yellow WL White ...

Page 118: ...Engine ground Screw Guide rear brake cable Base mark white tape Regulator Ignition switch Starter relay To turn signal L Regulator Horn Turn signal relay To turn signal R Battery C D I unit Starter relay To battery wire C D I unit Top Oil To the rear turn signal light L To the tail brake light To the rear turn signal light R Oil tank VI E W A HANDLE BAR WIRE ROUNTING VIEW B ENGINE GROUND DETAIL DE...

Page 119: ...004 0 1 0 004 3 7 0 15 3 5 0 14 0 75 0 030 10 036 0 4079 9 980 0 3929 Unit mm in Unit mm in 1st 2nd 1st 2nd R Piston diam Cylinder distortion Cylinder head distortion Piston ring free end gap Piston pin bore Piston pin O D Piston ring end gap Piston ring groove clearance Cylinder bore STANDARD LIMIT CONROD CRANKSHAFT ITEM Conrod small end I D Conrod deflection Crank web to wed width Crankshaft run...

Page 120: ...lt width 16 5 0 650 110 0 4 33 Driven face spring free length 15 3 0 602 104 5 4 11 STANDARD LIMIT Unit mm in ELECTRICAL ITEM SPECIFICATION NOTE CARBURETOR ITEM SIDERAFT VARIABLE VENTURI 14 mm PA35E 1800 50 rpm 1 0mm 76 ф2 0 J68A 2 ф2 1 3 5 3 5 0 5 1 0mm 0 02 0 04in SPECIFICATION Carburetor type Bore size I D No Idle r min Pilot air jet P A T Main jet M J Main air jet M A J Jet needle J N Pilot je...

Page 121: ...ry Lighting Charging Exciting WATTAGE ITEM Headlight Front turn signal light Rear turn signal light 3 2 EA 15 2 EA 5 21 21 10 3 4 2 EA 1 7 1 7 2 Unit W Tail Brake light LO POSITION Speedemeter light Oil level indicator light Turn signal indicator light Trunk light SPECIFICATION Unit mm in BRAKE WHEEL ITEM Brake lever play Brake drum I D Brake lining thickness Brake disc thickness Brake disc runout...

Page 122: ...raded 85 95 octane or higher An unleaded gasoline is recommended Use APOLLOIL BIKE K or HYPOL HS or an epuivalent good quality synthetic based 2 cycle oil 4 8 L 1 3 1 1 US lmp gal 1 2 L 1 2 1 0 US lmp qt SAE 10W 40 80 ml 2 7 2 8 US lmp oz Change Overhaul 90 ml 3 0 3 2 US lmp oz DOT4 Fuel tank capacity Engine oil type Engine oil tank capacity Final gear oil type Final gear oil capacity Brake fluid ...

Page 123: ...mbustion chamber fouled with carbon 3 Piston pin bearing 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...

Page 124: ...eplace Adjust Replace Replace Adjust or replace Clean Clean and prime 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 sp...

Page 125: ...l short circuit in the battery 2 Resistor element 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 ...

Page 126: ...en nuts on shock absorber 2 Worn engine mounting bushing Complaint Symptom and possible causes Remedy 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 ...

Page 127: ... 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 Complaint Symptom and possible causes Remedy Bleed air Replenish fluid to narmal lever bleed air Replace with correct fluid Replace Replace Tighten to specified torque Replace Replace Clean and lubricate ...

Page 128: ...Prepared by HYOSUNGMOTORS MACHINERYINC Overseas Service 2nd Ed APR 1999 Manual No 99000 91201 Printed in Korea ...

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