HYOSUNG WOW90 Service Manual Download | Manualshive

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1-1 GENERAL INFORMATION

Indicates a potential hazard that could result in vehicle damage.

NOTE :
Indicates special information to make maintenance easier or instructions cleaner.

Please note, however, that the

WARNING

and

CAUTION

contained in this manual cannot possibly cover all potential

hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the

WARNING

and

CAUTION

stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

CAUTION

WARNING

WARNING / CAUTION / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
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 that exhaust gas is forced outdoors.

�

When working with toxic or flammable materials, make sure that the area you work in is well-ventilated

and that you follow all off the material manufacturer

’

s instructions.

�

Never use gasoline as a cleaning solvent.

�

To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while

after engine operation.

�

After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for

leaks.

WARNING

Indicates a potential hazard that could result in death or injury.

COPYRIGHTED

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Summary of Contents for WOW90

Page 1: ...SERVICE MANUAL 99000 94310 SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC ...

Page 2: ...G 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 2001 HYOSUNG MOTORS MACHINERY INC Overseas Technical Department F FO OR RE EW WO OR RD D This manual contains an introductory description on HYOSUNG and procedures for its inspecti...

Page 3: ... are listed Find the item and page you need SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively Apply THREAD LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Torque control required Data beside it indicates...

Page 4: ...ing torque lubricating points and looking agent points Example STEERING AND FRONT SUSPENSION TIGHTENING TORQUE ITEM N m 18 28 18 4 28 6 1 84 2 86 22 4 35 7 40 50 80 100 22 35 22 35 40 60 ASSEMBLING APPLY GREASE ASSEMBLING APPLY GREASE APPLY GREASE TO LIPS APPLY GREASE ASSEMBLING APPLY GREASE 1 8 2 8 2 24 3 57 4 0 5 0 8 0 10 0 2 2 3 5 2 2 3 5 4 0 6 0 kg m C O P Y R I G H T E D ...

Page 5: ...C O P Y R I G H T E D ...

Page 6: ... L I IN NF FO OR RM MA AT TI IO ON N INFORMATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATIONS 1 5 EXTERIOR ILLUSTRATION 1 6 SPECIFICATIONS 1 7 CONTENTS 1 C O P Y R I G H T E D ...

Page 7: ...RNING 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 that exhaus...

Page 8: ...se 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 material fro...

Page 9: ...1 3 GENERAL INFORMATION HYOSUNG NOTE Difference between photographs and actual vehicles depends on the markets C O P Y R I G H T E D ...

Page 10: ...Identification Number is stamped on the front frame member The engine seri al number is stamped on the right side of crankcase assembly These numbers are required especially for registering the machine and ordering spare parts FRAME SERIAL NUMBER ENGINE SERIAL NUMBER C O P Y R I G H T E D ...

Page 11: ...ed should be graded 85 95 octane or higher An unleaded type gasoline is recommended If engine pinging is experienced substitute another brand as there are differences between brands ENGINE OIL Use HYOSUNG HYPOL OIL HS If they are not available use a good quality TWO STROKE engine oil TRANSMISSION OIL Use a good quality SAE 10W 30 or 10W 40 multigrade motor oil 1 5 GENERAL INFORMATION C O P Y R I G...

Page 12: ...EXTERIOR ILLUSTRATION GENERAL INFORMATION 1 6 HEIGHT WIDTH WHEEL BASE LENGTH 658 670 820 865 658 825 120 645 950 1 355 C O P Y R I G H T E D ...

Page 13: ...6 1 Carburetor PB11M Air cleaner Polyurethane foam element TRANSMISSION Clutch Dry shoe automatic centrifugal type Transmission 2 842 1 042 Drive system 428H 56 links CHASSIS Steering angle 37 5 right left Trail 15 mm 0 591 in Turning radius 2 595 mm 102 17 in Toe in 8 mm 0 315 in Camber angle 1 Caster angle 5 Front brake Drum Rear brake Disk Front tire size 18 7 00 7 Rear tire size 18 7 00 7 ELEC...

Page 14: ... CLEANER 2 3 CYLINDER HEAD NUTS 2 4 CYLINDER HEAD AND CYLINDER 2 4 SPARK PLUG 2 5 CARBURETOR 2 6 FUEL LINE 2 6 TRANSMISSION OIL 2 7 BRAKES 2 7 DRIVE CHAIN 2 10 TIRE 2 11 STEERING 2 12 CHASSIS BOLTS AND NUTS 2 12 C CO ON NT TE EN NT TS S 2 P PE ER RI IO OD DI IC C M MA AI IN NT TE EN NA AN NC CE E C O P Y R I G H T E D ...

Page 15: ...pect Inspect Tighten Lubricate Inspect every month Check pressure each time ride CHASSIS 2 7 2 12 2 11 2 12 2 2 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy PERIODIC MAINTENANCE CHART ENGINE Clean at least every month More frequent servicing should be ...

Page 16: ...er wet or rainy condition PERIODIC MAINTENANCE 2 2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the vehicle Major lubrication points are indicated below King pin Front wheel bearing Steering shaft holder Drive chain Rear axle housing Rear brake cable Front brake cable Throttle cable Throttle lever Front brake cam shaft O Motor oil G ...

Page 17: ...cleaning solvent and wash it clean Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands do not twist or wring the element or it will develop tears Immerse the element in HYOSUNG genuine oil and squeeze the oil out of the element leaving it slightly wet with oil Fit the cleaner element to frame properly Before and during the cleaning operation inspec...

Page 18: ... until each one is tightened to the specified torque Tighten the nuts in the order indicated Cylinder head nut 18 28 N m 1 8 2 8 kg m CYLINDER HEAD AND CYLINDER NOTE Remove carbon Every 6 months Carbon deposits in the combustion chamber and the cylinder head will raise the compression ratio and may cause pre ignition or overheating Carbon deposited at the exhaust port of the cylinder will prevent ...

Page 19: ...d carbon builds up along the inside part In accordance with the Periodic Inspection Chart the plug should be removed for inspection cleaning and resetting the gap Carbon deposits on the spark plug will prevent good sparking and cause misfiring Clean the deposits off periodically If the center electrode is fairly worn down the plug should be replaced and the plug gap set to the speci fied gap using...

Page 20: ...k IDLE SPEED Adjust the throttle cable play Warm the engine up NOTE Inspect Initial 1 month and Every 6 months NOTE A warm engine means an engine has been run for 10 minutes Remove the seat and cover Adjust the throttle stop screw to obtain the idle speed as follows Finally adjust the throttle cable play THROTTLE CABLE PLAY Loosen the lock nut and adjust the cable slack by turning adjuster in or o...

Page 21: ...g and drain the oil completely Tighten the drain plug Supply a good quality SAE 10W 30 or 10W 40 multi grade motor oil BRAKES NOTE Inspect Initial 1 month and Every 3 months FRONT BRAKE BRAKE ADJUSTMENT Adjust the free play to 5 15mm 0 197 0 591 in by screwing in or out the front brake adjust nut TRANSMISSION OIL NOTE Inspect Initial 1 month and Every 6 months TRANSMISSION OIL CAPACITY 80 90 Chang...

Page 22: ...ake camshaft should be within the range embossed on the brake panel To check wear of the brake lining follow the steps 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 brake panel If the index mark is outside the range as shown in the illustration at right the brake shoe assembly...

Page 23: ...ceeds the grooved limit replace the pads with new ones REAR BRAKE PAD REPLACEMENT Remove the brake caliper Remove the brake pads To reassmble reverse the above sequence Replace the brake pad as a set otherwise braking performance will be adversely affected CAUTION Rear brake caliper mounting bolt 5 0 7 0 N m 0 5 0 7 kg m C O P Y R I G H T E D ...

Page 24: ...oil fre quently Every 1 month or more frequently wash the chain clean in a pool of solvent and lubricate it with chain lube or motor oil In a dusty area this service should be given at shorter intervals DRIVE CHAIN REPLACEMENT The drive chain is checked when its slack between two sprockets is within 5 15 mm 0 197 0 591 in range When refitting the drive chain be sure to install the chain joint clip...

Page 25: ...oo high the vehicle will tend to ride stiffly have poor traction Conversely if the tire pressure is too low stability will be adversely affected Therefore maintain the correct tire pressure for good traction and prolonging tire life Front Rear COLD INFLATION TIRE PRESSURE The standard tire fitted on this ATV is 18 7 00 7 for front and rear The use of a tire other than the standard may cause handli...

Page 26: ...to their specified torque Refer to page 7 9 TOE IN Place the vehicle on the level ground Make sure that the tire pressure is within speci fication Refer to page 2 11 8 0 mm 0 315 in Toe in The front wheels are set in straight ahead position Measure the distance A and B in illustration of front wheels with a gauge as shown in illustra tion and calculate the difference between A and B If the toe in ...

Page 27: ...C O P Y R I G H T E D ...

Page 28: ...ATIC CLUTCH INSPECTION 3 17 CYLINDER HEAD 3 20 CYLINDER 3 21 PISTON 3 21 REED VALVE 3 24 ENGINE REASSEMBLY 3 24 OIL SEALS 3 24 BEARINGS 3 25 BUSHINGS 3 25 CRANKSHAFT 3 26 CRANKCASE 3 27 TRANSMISSION 3 28 STARTER PINION STARTER DRIVEN GEAR AND STARTER MOTOR 3 30 MOVABLE DRIVEN AND CLUTCH 3 32 MOVABLE DRIVE 3 36 MAGNETO 3 38 PISTON 3 39 OIL PUMP AND INTAKE PIPE 3 41 COOLING FAN 3 42 MUFFLER 3 43 CON...

Page 29: ...lained in the following steps and engine reinstallation is effected by reversing the removal proce dure Place an oil pan under the engine and remove the oil filler cap and the oil drain plug to drain out transmis sion oil Remove the seat and frame cover Turn the fuel cock to OFF position Remove the fuel hoses from the fuel cock and remove the fuel tank by removing mounting bolts Remove the muffler...

Page 30: ...ENGINE 3 2 Remove the engine ground lead wire Remove the spark plug cap Remove the starter motor lead wire Disconnect the magneto coil lead wire C O P Y R I G H T E D ...

Page 31: ...move the carburetor assembly from the intakepipe Disconnect the oil hose and oil pump cable from the oil pump Disconnect the thermoelement coupler Remove the air cleaner and air cleaner chamber C O P Y R I G H T E D ...

Page 32: ...ting link bolts Remove the engine assembly from the frame with rear axle housing assembly Remove the chain case cover Remove the engine sprocket from the drive shaft by using the snap ring pliers Remove the drive chain C O P Y R I G H T E D ...

Page 33: ...the following additional steps Install the engine mounting link bolts Refer to page 3 4 Install 90ml of transmission oil SAE 10W 30 or 10W 40 multi grade motor oil when engine is over hauled check the oil level Set the fuel cock to ON position and start the engine After remounting the engine route wiring harness and cables properly by referring to the sections wire routing and cable routing and ad...

Page 34: ...he bolts CYLINDER Remove the cylinder cowling Remove the cylinder head and cylinder PISTON Place a cloth beneath the piston and remove the pis ton pin circlip with a long nose pliers Remove the piston pin and piston Remove the piston pin bearing 7 C O P Y R I G H T E D ...

Page 35: ...ump driven gear Remove the reed valve MAGNETO Remove the cooling fan Remove the magneto rotor nut with the special tool Conrod holder 09910 20115 INTAKE PIPE AND OIL PUMP Remove the intake pipe and oil pump C O P Y R I G H T E D ...

Page 36: ...he movable drive face Remove the fixed drive face nut with the special tool This nut has left hand thread CAUTION Conrod holder 09910 20115 Remove the magneto rotor with the special tool Remove the magneto stator and key Rotor remover sliding shaft 09930 30102 Rotor remover 09930 30163 C O P Y R I G H T E D ...

Page 37: ...NGINE STARTER DRIVEN GEAR Remove the starter driven gear Remove the starter idle gear cap and starter motor pinion Remove the starter motor MOVABLE DRIVEN FACE Remove the clutch housing C O P Y R I G H T E D ...

Page 38: ...ch shoe nut with the special tool Rotor holder 09930 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 Using a thin blade screwdriver or the like pry up the movable driven face spring guide Do not attempt to disassemble the clutch shoe assembly It is not serviceable CAUTION C...

Page 39: ...eedle bearing with the special tools Remove the circlip Remove the bearing with the special tool Wheel bearing remover 09941 50111 The removed bearing should be replaced with a new one CAUTION Bearing remover 17mm 09923 73210 Rotor remover sliding shaft 09930 30102 C O P Y R I G H T E D ...

Page 40: ... Bearing remover 12mm 09921 20210 Remove the drive shaft bearing and idle shaft bearing Remove the oil seal from the gear box cover with the special tool Oil seal remover 09913 50121 The removed oil seal should be replaced with a new one CAUTION Remove the bearing with the special tool Bearing installer 09943 88211 The removed bearing should be replaced with a new one CAUTION C O P Y R I G H T E D...

Page 41: ...nkcase separater 09920 13120 Remove the crankshaft with the special tool CRANKCASE Remove the crankcase securing screws Crankcase separater 09920 13120 NOTE Loosen the crankcase screws diagonally C O P Y R I G H T E D ...

Page 42: ...ENGINE 3 14 Using two steel tubes of appropriate size press out the engine mounting bushings on a vise as shown in the illustration Remove the bushing Bushing C O P Y R I G H T E D ...

Page 43: ...3 15 ENGINE Front side Rear side Bushing Bushing Crankcase Crankcase C O P Y R I G H T E D ...

Page 44: ...as shown Service limit 0 05 mm 0 002 in Crankshaft runout Excessive the crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine life WEAR AND CLEARANCE OF CONROD BIG END Turn the crankshaft with the conrod to feel the smooth ness 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 ratt...

Page 45: ...ON Warm the engine to normal operating temperature Connect an engine tachometer to the engine Seated on the vehicle with the vehicle on level ground increase the engine RPMs slowly and note the RPM at which the vehicle begins to move forward CLUTCH TIGHT INSPECTION Grip the front brake lever and depress rear brake pedal fully and measure the engine RPM when open the throttle Warm the engine to nor...

Page 46: ...oils Clutch housing inspect visually the condition of the inner clutch housing surface for scrolling cracks or uneven wear Measure inside diameter at several points to check for an out of round condition as well as wear Do not apply full power for more than 3 seconds or damage to the clutch or engine may occur CAUTION Engine tachometer 09900 26006 Clutch tight RPM 5 900 rpm 200 rpm Standard Tolera...

Page 47: ...f there is some thing unusual replace the drive face with a new one ROLLER AND MOVABLE DRIVE FACE Inspect each roller and movable drive face for wear or damage MOVABLE DRIVEN SPRING Measure the free length of the movable driven spring If the length is shorter than the service limit replace the spring with a new one Always keep the belt away from any greasy material CAUTION Drive V belt width Servi...

Page 48: ...EN FACE PIN AND OIL SEAL Turn the driven faces and check to see that the driven faces turn smoothly If any stickness or hitches are found visually inspect the lip of seal driven face sliding surface and sliding pins for wear or damage 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 ...

Page 49: ...wear of the cylinder wall is determined from diame ter reading taken at 20mm from the top of the 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...

Page 50: ...n ring to get stuck in the groove and this condition will lead to reduce engine power output A piston whose sliding surface is badly grooved or scuffed due to overheating must be replaced Shallow grooves or minor scuff can be removed by grinding with emery paper of about 400 PISTON PIN BORE I D Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the following ser v...

Page 51: ...easured with the ring fitted squarely into the cylinder bore and held at the least worn part near the cylinder bottom as shown in the illustration Service limit 0 75 mm 0 030 in Piston ring clearance Assembly condition Service limit 3 6 mm 0 142 in Piston ring clearance Free condition Thickness gauge 09900 20806 As the piston ring wears its clearance increases reduc ing engine power output because...

Page 52: ... from moving 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 Fix the piston ring in the piston ring groove measure the ring side clearance with the thickness gauge while matching the sliding sur...

Page 53: ...al installer 09913 75830 Bearing installer attachment 09924 74510 Bearing installer pilot 09924 74540 Bearing installer 09913 75810 Bearing installer 09913 76010 BEARINGS Install new bearings with the special tool 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 C O P Y R I G H T E D ...

Page 54: ...ENGINE 3 26 CRANKSHAFT Bushing Bushing Crankcase Crankcase Bushing NOTE Knurled end should face inside Protrusive and should be in the same dimension C O P Y R I G H T E D ...

Page 55: ...ankcase with the special tool Never fit the crankshaft into the crankcase by driv ing it with a plastic hammer Always use the special tool otherwise crankshaft 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 Instal...

Page 56: ...NOTE Align the oil seal with edge of the crankcase as shown in the illustration Bearing installer 09913 85210 TRANSMISSION Install the new oil seal to the crankcase with the special tool 12 16 C O P Y R I G H T E D ...

Page 57: ...embly on the gear box Install the final driven gear on the rear axle shaft using the circlip Thrust Rounded coner Circlip Center Install the idle thrust washer new gasket and dowel pin Install the driveshaft to the gear box cover Install the gear box cover on the crankcase Tighten all the screws evenly one by one in a diago nal fashion C O P Y R I G H T E D ...

Page 58: ...R DRIVEN GEAR AND STARTER MOTOR Apply SUPER GREASE A on the pinion shaft and install the starter pinion subassembly Assemble the starter pinion subassembly Insert the two dowel pins on the crankcase SUPER GREASE A C O P Y R I G H T E D ...

Page 59: ... ring Install the starter motor Install the starter driven gear over the left crankshaft end NOTE The convex side of hub should face outside when installed in proper position Install the starter idle gear cap C O P Y R I G H T E D ...

Page 60: ...ENGINE 3 32 Bearing installer 09943 88211 Install the bearing in the fixed driven face with the special tool MOVABLE DRIVEN AND CLUTCH C O P Y R I G H T E D ...

Page 61: ...bearing with the special tool Bearing installer 09913 76010 Install the new O rings to the movable driven face with the special tool Apply SUPER GREASE A to the groove of mov able driven face s inside A mark part of the bearing is pointed to the outside CAUTION Thrust Rounded coner SUPER GREASE A C O P Y R I G H T E D ...

Page 62: ...three places on the driven face hub Apply SUPER GREASE A lightly to the cam part where the pins are placed Position the two O rings Pin Spacer SUPER GREASE A Install the movable driven face to the fixed driven face When reinstalling the movable driven face to the fixed driven face make sure that the O ring is positioned properly CAUTION Insert as guide the rim C O P Y R I G H T E D ...

Page 63: ...and position it over the clutch shoe assem bly Tighten the clutch housing nut to the specified torque Insert the V belt between the driven faces as deep inside as possible while pulling the movable driven face all the way outside to provide the maximum belt clearance The V belt should be positioned so that the arrows on the belt periphery point the normal turning direction The V belt contact face ...

Page 64: ...he roller at six places 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 MOVABLE DRIVE C O P Y R I G H T E D ...

Page 65: ... the fixed drive face by hand until the V belt is seated in and both the drive and driven faces will move together smoothly without slip Fill the final gear box with transmission oil up to the level hole Tighten the oil level bolt to the specified torque 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 f...

Page 66: ...45 N m 3 5 4 5 kg m Install the rotor Apply THREAD LOCK 1324 to the rotor nut and tighten it to the specified torque with the special tool Degrease the tapered portion of the crankshaft and also the magneto rotor Install the stator Install the key MAGNETO C O P Y R I G H T E D ...

Page 67: ...on 1st 2nd 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 7 PISTON Locating pin Position the ring so that the marking is on upside CORRECT INCORRECT Keystone ring C O P Y R I G H T E D ...

Page 68: ...er 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 Cylinder head nut 18 28 N m 1 8 ...

Page 69: ... A Apply SUPER GREASE A to the oil pump driven gear and install it to the crankcase Oil pump bolt 3 5 N m 0 3 0 5 kg m Install the oil pump and tighten it to the specified torque OIL PUMP AND INTAKE PIPE C O P Y R I G H T E D ...

Page 70: ...eed valve gasket intake pipe gasket and intake pipe with reed valve to the crankcase Install the fan case Install the magneto lead wire and starter motor lead wire COOLING FAN Install the cylinder cowling C O P Y R I G H T E D ...

Page 71: ... fan cover 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 Tighten the exhaust pipe bolts and muffler mount ing bolts to the specified torque MUFFLER Install the cooling fan C O P Y R I G H T E D ...

Page 72: ... FU UE EL L S SY YS ST TE EM M 4 CARBURETOR 4 1 REMOVAL 4 1 DISASSEMBLY 4 2 INSPECTION 4 4 REASSEMBLY AND REMOUNTING 4 5 FUEL TANK 4 7 REMOVAL 4 7 INSPECTION 4 7 REMOUNTING 4 8 OIL PUMP 4 8 CONTENTS C O P Y R I G H T E D ...

Page 73: ...4 1 FUEL SYSTEM REMOVAL Remove the front and rear fender CARBURETOR C O P Y R I G H T E D ...

Page 74: ...nect the throttle cable Disconnect the fuel hose Remove the carburetor by loosening the mounting bolts Remove the thermoelement assembly DISASSEMBLY Do not attempt to disassemble the thermoelement assembly It is not serviceable CAUTION C O P Y R I G H T E D ...

Page 75: ...4 3 FUEL SYSTEM Remove the float chamber Pull out the float pin and remove the float Remove the needle valve Remove the throttle valve spring and jet needle C O P Y R I G H T E D ...

Page 76: ...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 INSPECTION...

Page 77: ...Pilot air screw Throttle stop screw Pilot jet Main jet Needle jet Install the needle valve and float on the carbu retor body Insert the float pin to the carburetor Install the gasket and float chamber Install the throttle valve spring and jet needle C O P Y R I G H T E D ...

Page 78: ...FUEL SYSTEM 4 6 Install the carburetor top cap Install the carburetor assembly Install the fuel hose Install the thermoelement assembly C O P Y R I G H T E D ...

Page 79: ...fuel cock to OFF and disconnect the fuel hose Remove the fuel tank Remove the fuel cock INSPECTION FUEL COCK If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel cock for cracks C O P Y R I G H T E D ...

Page 80: ... completely Gaskets and must be replaced with new ones to prevent fuel leakage Tighten the fuel cock bolts evenly WARNING During this inspection strictly follow the follow ing points Do not touch the rear wheel while running the engine CAUTION HYPOL Oil gauge 09900 21602 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 81: ...C O P Y R I G H T E D ...

Page 82: ...LS 5 2 REGULATOR RECTIFIER 5 3 STARTER SYSTEM 5 3 STARTING MOTOR REMOVAL AND DISASSEMBLY 5 4 STARTING MOTOR INSPECTION 5 4 STARTER RELAY INSPECTION 5 5 THERMOELEMENT 5 5 SWITCHES INSPECTION 5 6 BATTERY 5 7 ELECTRICAL SYSTEM 5 C CO ON NT TE EN NT TS S C O P Y R I G H T E D ...

Page 83: ...n coil Spark plug Engine stop switch CDI unit Stator Regulator Rectifier Battery 12V 4AH MF IGNITION CHARGING SYSTEM Over 8 mm 0 3 in Spark performance IGNITION COIL Pull out the spark plug Place it on the cylinder head after installing it at the plug cap to obtain ground Push in the electric starter switch to rotate the start ing motor test sparking performance C O P Y R I G H T E D ...

Page 84: ...CAUTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Measure the DC voltage between the battery terminal and with a pocket tester If the tester reads under or over following specification check the no load performance or replace the regula tor rectifier Pocket tester 09900 25002 Engine tachometer 09900 26006 13 0 16 0 V at 5 000 rpm Standard charging output Pocket tester...

Page 85: ...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 B 50 230 50 260 10 100 1 2 3 4 STARTER SYSTEM The starter system is shown in the diagram below namely the starting mot...

Page 86: ...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 87: ...ny 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 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 ...

Page 88: ...e 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 STARTER SWITCH B W B R R O OFF ON 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 wi...

Page 89: ...ity of water When it is stained clothes should come into being a hole or painting should take off Consult you with a doctor When the battery electrolyte was dropped to the surface of land wash a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape to seal the battery electrolyte filler hole untill...

Page 90: ...e precaution not to allow any of the fluid to spill There may be a case which can t pour the elec trolyte if you put it into electrolyte container slopely CAUTION Confirmation of pour Make sure that air bubbles are coming up each elec trolyte container and keep this position for about more than 20 minutes If no air bubbles are coming up from a filler port tap the bottom of the two or three times C...

Page 91: ... upper surface of the battery s top cover ASSISTANCE RECHARGING Use the battery that is made after 2 years as the main tenance free battery Use the battery at condition of the high temperature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric current or voltage when the battery discharged Do not assistance recharge...

Page 92: ...D REMOUNTING 6 10 TOE IN ADJUSTMENT 6 11 REAR WHEEL 6 12 REMOVAL 6 12 INSPECTION 6 12 REMOUNTING 6 12 REAR BRAKE 6 13 BRAKE PAD REPLACEMENT 6 13 CALIPER DISASSEMBLY 6 13 DISC PLATE INSPECTION 6 14 CALIPER REASSEMBLY 6 14 REAR AXLE HOUSING AXLE SHAFT AND SHOCK ABSORBER 6 15 REMOVAL 6 15 INSPECTION AND DISASSEMBLY 6 16 REASSEMBLY AND REMOUNTING 6 18 C CO ON NT TE EN NT TS S 6 C O P Y R I G H T E D ...

Page 93: ...6 1 CHASSIS FRONT WHEEL AND BRAKE C O P Y R I G H T E D ...

Page 94: ...he brake cam lever Remove the front brake plate REMOVAL Place the vehicle on level ground Remove the wheel center cap Remove the cotter pin and front axle nut Support the vehicle by jack or block and remove the front wheel C O P Y R I G H T E D ...

Page 95: ...rake drum I D to determine the extent of wear and if the limit is exceeded by the wear noted replace the brake drum The value of this limit is indicated inside of drum Oil seal remover 09913 50121 Drive out the both bearings with the special tool in the following procedures Insert the adapter into the bearing After inserting the wedge bar from the opposite side lock the wedge bar in the slit of th...

Page 96: ... the camshaft and cam face Install the brake shoes with spring hooks faced inside Install the brake cam lever to the brake camshaft Tighten the brake cam lever nut to the specified torque SUPER GREASE A Be careful not to apply too much grease to the cam and pin If grease gets on the lining break slippage will result CAUTION Replace the brake shoe as a set otherwise brak ing performance will be adv...

Page 97: ...6 5 CHASSIS BOND 1215 Apply BOND 1215 to the front brake plate as shown photo Install the front brake drum and tire C O P Y R I G H T E D ...

Page 98: ... Remove the tie rod end nut Remove the steering knuckle TIGHTENING TORQUE ITEM N m 18 28 18 4 28 6 1 84 2 86 22 4 35 7 40 50 80 100 22 35 22 35 40 60 ASSEMBLING APPLY GREASE ASSEMBLING APPLY GREASE APPLY GREASE TO LIPS APPLY GREASE ASSEMBLING APPLY GREASE 1 8 2 8 2 24 3 57 4 0 5 0 8 0 10 0 2 2 3 5 2 2 3 5 4 0 6 0 kg m C O P Y R I G H T E D ...

Page 99: ... Remove the suspension arm mounting bolts and front shock absorber upper mounting bolt Remove the suspension arm with shock absorber Remove the shock absorber Remove the dust seals and spacer C O P Y R I G H T E D ...

Page 100: ...Remove the front brake cables Remove the steering head cover bracket and handle bar by removing the mounting bolts Remove the tie rods by removing the cotter pins and nuts Remove the cotter pin and steering shaft lower nut The removed cotter pins should be replaced with new ones CAUTION C O P Y R I G H T E D ...

Page 101: ...stortion and the boot for wear STEERING SHAFT AND HOLDER lnspect the steering shaft for distortion or bend lnspect the two steering shaft holders for wear Separate the tie rod ends nuts and steering tie rods Remove the cotter pins and remove the steering shaft holder bolts Remove the steering shaft holders and steering shaft Inside lock nuts are left hand thread CAUTION Tire side C O P Y R I G H T...

Page 102: ...ont brake holder with the respective punch mark and tighten the bolt TIE ROD Install the tie rod ends nuts and steering tie rods Inside lock nuts are left hand thread CAUTION HANDLEBAR Install the handlebar with the punch mark aligned with the handlebar holder as shown Tighten the handlebar holder bolts to the specified torque NOTE The gap between the handlebar holder should be even Handlebar hold...

Page 103: ...re left hand thread CAUTION NOTE A B Toe in Toe in 8 mm 0 315 in Temporarily tighten the four lock nuts Check that the distances C and D in the illustration are equal If the distances C and D are not equal readjust the tie rod right or left whichever makes the toe in value closer to the specification Check the toe in again by measuring the distances A and B If the toe in is not within specificatio...

Page 104: ...er cap Romove the cotter pin and rear hub nut INSPECTION TIRE Refer to page 2 11 REMOUNTING Remount the rear wheel in the reverse order of removal TIGHTENING TORQUE ITEM N m 60 90 20 30 2 0 3 0 22 35 22 35 120 150 6 0 9 0 2 2 3 5 2 2 3 5 12 0 15 0 kg m ASSEMBLING APPLY GREASE ASSEMBLING APPLY LOCK TIGHT C O P Y R I G H T E D ...

Page 105: ...re of brake pad Refer to page 2 9 CALIPER DISASSEMBLY Remove the brake lever bolt and caliper mounting bolts Remove the caliper Remove the brake pad Refer to page 2 9 TIGHTENING TORQUE ITEM N m 2 4 6 8 0 6 0 8 0 2 0 4 kg m ASSEMBLING APPLY GREASE C O P Y R I G H T E D ...

Page 106: ... following steps Tighten the brake lever bolt and caliper mounting bolts to the specified torque Check the disc for face runout with a dial gauge as shown Replace the disc if the runout exceeds the service limit Remove the rear caliper lever return spring Micrometer 0 25mm 09900 20201 Disc thickness Service limit 2 5 mm 0 098 in Disc runout Service limit 0 3 mm 0 012 in N m kg m Item SPECIFIED TOR...

Page 107: ...R REMOVAL Remove the rear wheel Refer to page 6 12 Remove the rear brake Refer to page 6 13 Remove the chain cover Remove the axle shaft with rear sprocket TIGHTENING TORQUE ITEM N m 40 50 40 60 4 0 6 0 4 0 5 0 kg m ASSEMBLING APPLY GREASE C O P Y R I G H T E D ...

Page 108: ...while mounting in the axle housing Rotate the inner ring by hand to inspect if any abnormal noise occurs or it rotates smoothly Replace the bearing if there is anything unusual Remove the shock absorber Remove the rear axle housing Remove the sprocket mounting flange by removing the nut C O P Y R I G H T E D ...

Page 109: ... as a set SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other damage Normal wear Excessive wear 6 17 CHASSIS Remove the right and left bearings and spacer Remove the dust seals with the special tool Replace the removed dust seals with new ones CAUTION Oil seal remover 09913 50121 C O P Y R I G H T E D ...

Page 110: ...e check the axle shaft for runout and replace it if the runout exceeds the limit REASSEMBLY AND REMOUNTING Reassemble and remount the rear axle housing in the reverse order of removal and disassmbly Service limit 0 5 mm 0 02 in Rear axle shaft runout C O P Y R I G H T E D ...

Page 111: ...C O P Y R I G H T E D ...

Page 112: ...SERVICING INFORMATION TROUBLESHOOTING 7 1 SPECIAL TOOLS 7 5 TIGHTENING TORQUE 7 8 SERVICE DATA 7 10 WIRE AND CABLE ROUTING 7 16 WIRING DIAGRAM 7 20 C CO ON NT TE EN NT TS S 7 C O P Y R I G H T E D ...

Page 113: ...re 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 possible causes Remedy Re...

Page 114: ...n 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 fluctuations 1 Start...

Page 115: ... 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 pinion gears...

Page 116: ... bearing 2 Desturbed front wheel alignement 1 Loose bolt and nut 2 Broken or otherwise damaged wheel hub bearing 3 Poorly lubricated 1 Weakened spring 2 Oil leakage of shock absorber 1 Worn wishbone arm related bushing 1 Loose bolt on suspension system 2 Worn wishbone arm related bushing 1 Worn or loose rear axle housing bearing 2 Defective or incorrect tire 3 Distorted wheel rim 4 Loose nut on wh...

Page 117: ...Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 20701 Magnetic stand With using dial gauge 09900 20806 Thickness gauge Measure clearance of piston ring 09900 21304 V block 09900 21109 Torque wrench With using magnetic stand Measure torque of tightening 09900 21602 CCI oil gauge A gauge to inspect performance of oil pump 09900 22301 Plastigauge Measure clearance of cranksha...

Page 118: ...ive bearing in 09913 75830 Bearing installer Used to install rear axle shaft oil seal 09913 80112 Bearing installer 09913 76010 Bearing installer Used to drive bearing in Used to drive crankshaft bearing in Used with compression gauge 09915 64510 Compression gauge Separate to crankcase Measure cylinder compression 09920 13120 Crankcase separater 09915 63310 Compression gauge adapter 09923 74510 Be...

Page 119: ...sed to drive small bearing in 7 7 SERVICING INFORMATION Special tools Part Number Part Name Description Part Number Part Name Description Used to remove wheel bearing 09941 50111 Wheel bearing remover 09930 30163 Rotor remover Special tools Attached to the top of sliding shaft when removing rotor 09930 40113 Rotor holder Widely used to lock rotary parts such as a clutch shoe C O P Y R I G H T E D ...

Page 120: ...0 5 4 0 6 0 4 0 6 0 4 0 6 0 kg m N m ITEM Magneto rotor nut Muffler mounting bolt Exhaust pipe bolt Spark plug Cylinder head nut Engine mounting link engine joint bolt Engine mounting link frame joint bolt Transmission oil drain plug Transmission oil level bolt Oil pump bolt Clutch shoe nut Clutch housing nut Fixed drive face nut TIGHTENING TORQUE ENGINE C O P Y R I G H T E D ...

Page 121: ...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 Front brake cam lever nut Front shock absorber bolt nut Rear sprocket nut Rear shock absorber bolt Rear axle nut M28 Rear brake caliper lever bolt Rear brake disc bolt Rear brake caliper mounting bolt Front axle nut M14 Handlebar holder bolt Tie rod lock nut Steering shaft bolt M8 Steerin...

Page 122: ... 177 Approx 4 5 0 177 0 10 0 25 0 004 0 010 0 10 0 25 0 004 0 010 0 02 0 06 0 0008 0 0024 0 02 0 06 0 0008 0 0024 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 in Unit mm in CON...

Page 123: ...ratio TRANSMISSION DRIVE CHAIN ITEM Final reduction ratio 1 33 428H 56 259 10 197 254 10 000 5 15 0 197 0 591 Over 15 Over 0 591 8 62 Gear ratio Transmission Drive V belt width 2 842 1 042 16 4 16 6 0 6457 0 6535 136 4 5 370 Type Links 20 pitch length Drive chain Drive chain slack 16 0 0 6299 130 0 5 118 STANDARD LIMIT Movable drive face spring free length OIL PUMP ITEM Oil pump reduction ratio 30...

Page 124: ... 0 039 45 18 0 8 0 032 0 5 1 0 0 020 0 039 SPECIFICATION Carburetor type Bore size I D No Idle rpm Fuel level Main jet Main air jet Jet needle Pilot jet Needle jet Pilot air jet Throttle valve By pass Valve seat Starter jet Pilot screw Pilot outlet Throttle cable play M J M A J J N N J P A J P J T V B P V S G S P S P O C O P Y R I G H T E D ...

Page 125: ...er motor carbon brush length Starter motor commutator under cut Starter relay resistance Battery Capacity Type designation Standard electrolyte S G Fuse size No load performance of A C generator B R Ground Br W Y W Ground W R Ground Over 8 0 3 at 1 atm 5 4 6 6 0 19 0 24Ϊ 0 69 1 03Ϊ 0 54 0 80Ϊ 146 220Ϊ 90 110 Ϊ 13 0 16 0 V at 5 000 rpm 3 5 0 138 0 2 0 008 80 150 Ϊ STX5L BS MF 12V 4Ah 10HR 10A More ...

Page 126: ...30 110 0 4 330 4 0 0 158 3 0 0 118 2 595 102 165 1 8 0 0 315 15 0 591 5 15 0 197 0 591 15 25 0 591 0 984 106 0 4 173 2 0 0 079 110 7 4 358 2 5 0 098 0 3 0 012 STANDARD LIMIT Front Rear Front Front Front Rear Rear Caster Trail Wheel rim runout Wheel axle shaft runout Tire size Tire tread depth 5 18 7 00 7 18 7 00 7 1 2 0 047 1 2 0 047 0 5 0 020 10 0 394 10 0 394 Axial Radial Rear Front Rear Front R...

Page 127: ... 000rpm for 5 minutes SAE 10W 30 or 10W 40 multi grade motor oil 80 Change Overhaul 90 Fuel tank capacity Engine oil type Engine oil tank capacity Engine oil discharge amount Transmission oil capacity Transmission oil type SPECIFICATION NOTE TIRE PRESSURE SUSPENSION COLD INFLATION TIRE PRESSURE FRONT REAR kPa kgf psi 25 25 0 25 0 25 3 6 3 6 ITEM SPECIFICATION LIMIT Front wheal travel Rear wheel tr...

Page 128: ... 14403 09407 14403 09407 14403 WIRE AND CABLE GUIDE SWITCH ASS Y HANDLE LH SWITCH ASS Y STOP FRONT SWITCH ASS Y STEERING IGINTION COIL CDI UNIT 09407 14403 SEPARATING POINT BATTERY BATTERY FUSE HARNESS REGULATOR MAGNETO P T C STARTER RELAY ENGINE EARTH C O P Y R I G H T E D ...

Page 129: ...7 17 SERVICING INFORMATION B A EMERGENCY SWITCH CASE 09407 18401 C O P Y R I G H T E D ...

Page 130: ...SERVICING INFORMATION 7 18 BATTERY FUSE STARTER RELAY 09407 14403 VIEWA VIEWB MAGNETO START MOTOR C O P Y R I G H T E D ...

Page 131: ...7 19 SERVICING INFORMATION 09407 14403 09407 14403 HANDLE SWITCH LH FRONT STOP SWITCH HANDLESWITCHLH STOPSWITCH CDIUNITASSEMBLYPOSITION CDI UNIT FRONT FENDER C O P Y R I G H T E D ...

Page 132: ...NGINE KILL HANDLE SWITCH LH BW Y GB R R BW YG RW R BW RECTIFIER REGULATOR ENGINE EARTH BATTERY 12V WIRING DIAGRAM WIRE COLOR B Black Lg Light green Y Yellow RB Red with Black tracer Br Brown O Orange BG Black with Green tracer RW Red with White tracer G Green R Red BW Black with White tracer WB White with Black tracer Gr Gray Sb Light blue BR Black with Red tracer WR White with Red tracer L Blue W...

Page 133: ...Prepared by HYOSUNG MOTORS MACHINERY INC Overseas Technical Department 1st Ed AUG 2001 Manual No 99000 94310 Printed in Korea C O P Y R I G H T E D ...

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