Hyundai HYSG150, User Manual, Page: 13 / 28

5. ASSEMBLY
5.1. The assembly will be minimal and should be limited to mounting the handle bar,
brake and throttle levers.
5.2. Mounting the handle bars.
5.2.1. Take handlebar (1) and gasket (3) align them
and offer them to the machines base (4). Take
1 of the M12 x 35mm hex bolts (2) and pass it
through holes in the handlebar and gasket into
the base. Once you have one bolt through you
can pass 1 x 12mm spring washer (5) and 1 x
M12 hex locknut (6) over the protruding end of
bolt and screw it on loosely by hand. Repeat
the process for the rem a in in g three bolts,
spring washers and hex locknut's .
5.2.2. Once all nut/ bolts /washers are located you can fully
tighten them up.
5.3. Mounting the brake lever.
5.3.1. Take brake lever (1) and offer it up to handlebar then
pass 1 x M8 x 75mm bolt ( 4 ) and push it through
brake lever then through the handlebar and place 1
x M8 Hex locknut and 1 x M8 (2) spring washer (2)
over bolt ( 4 ) and tighten up by hand. Repeat for
second nut and bolt, once both fitted you can fully
tighten them both up.
5.3.2. Take the top end of the brake cable assembly (6) Pass
the bush (5) through hole at the end of the brake
cable then through the bottom end of the brake
lever. Once through you can push the cotter pin
through to secure the bush.
5.4. Brake drum connections (If required).
5.4.1. Firstly take the brake drum end of the
brake cable and undo 1 of the M12 hex
nuts (2), then pass the end of the brake
cable through the brake drum plate (4),
once through put the removed M12 hex
nut over the end of the cable and hand
tighten. Push the brake bolt (3) though hole
in brake drum plate them through end of
cable, once through secure bolt with
2mm x 20 cotter pin (5) . You will need to adjust and operate the brake lever
until the brake holds the machine firmly. Once completed you must fully
tighten the 2 x M12 hex nuts (2) onto the brake drum assembly.
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