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HYOSUNG Aquil GV650, Руководство по обслуживанию

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CAUTION

�

Numberical value may differ a little according
to the tester.

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Please  remind  that  there  may  be  a  defect
which  can  not  be  identified  even  though  the
measurement  by  using  the  tester  indicates  a
low voltage.

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The  range  of  measurement  adjust  a  [ 

X

1

㏀

]

unit.

ELECTRICAL SYSTEM  6-6

▣

IGNITER

Using the pocket tester(R 

×

1

㏀

range), measure the

resistance between the terminal in the following table.

Unit : kΪ

Pocket Tester : 09900-25002

①

②

③

④

⑤

⑥

⑦

⑧

⑨

⑩

⑪

⑫

⑬

⑭

⑮

�

� TESTER PROBE

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

250~370

250~380

18~27

22~33

OFF

9.2~13.8

37~55

23.6~35.4 21.6~32.4 22.4~33.6

18~27

53~79

29.5~44.5 9.2~13.8 21.3~31.9

180~270

180~270

2.9~4.4

2.8~4.2

OFF

8.4~12.6

9.6~14

3.8~5.8

2.7~4.1

3~4.6

0

46~69

6.4~9.6 7.1~10.4

2.2~3.4

180~270

180~270

9.6~14

2.8~4.2

OFF

9.6~14

12.2~18.2

2.6~4

1.4~2

1.8~2.6

2.8~4.2

49~73

9.1~13.7

8.6~13

0.9~1.3

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

200~300

210~310 21.5~32.5 11.1~16.7 14.3~21.5

OFF

25.7~38.5 15.4~23 14.2~21.2 14.6~21.8 11.2~16.8

39~59

20.4~30.6 4.7~7.1 13.7~20.5

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

180~270

190~280 11~16.4

3.8~5.7

2.6~4

OFF

10.8~16.2 13.6~20.4

2.4~3.6

0.9~1.3

3.9~5.9 50.5~75.5 10.4~15.6 9.6~14

1.8~2.8

180~270

190~280

9.6~14

2.5~3.8

1.4~2

OFF

8.7~13.1

12~18

2.4~3.6

1.4~2

2.6~3.8

48~72

8.8~13.2

8~12

0.6~0.8

180~270

180~270

10~15

3.1~4.7

1.7~2.5

OFF

9.6~14

12.5~18.7 0.9~1.3

1.5~2.3

3.1~4.7 49.5~74.5

9.6~14

8.8~13.2

1~1.4

170~260

180~270

7~10.4

0

2.8~4.2

OFF

8.5~12.7

9.6~14

3.9~5.9

2.6~4

3~4.6

46.5~69.5 6.4~9.6 7.2~10.8

2.3~3.5

330~490

330~500 180~270

150~230

80~120

OFF

170~250

190~280 150~230 150~230 150~230

150~230

170~260 165~245

146~219

200~300

180~270 17.5~26.5 8.6~12.8 7.3~10.9

OFF

17.5~26.5 21.2~31.8 8.2~12.4

7~10.6

7.3~10.9 8.6~12.8

69~103

16.3~24.5 6.4~9.6

200~300

210~310 16.5~24.5

7.4~11

10~15

OFF

4.6~7

20.8~31.2 11.4~17

10~15

10.4~15.6 7.3~10.9

34~51

15.6~23.4

9.6~14

170~260

180~270

9~13.5

2.3~3.5

0.9~1.3

OFF

8.8~13.2

11.4~17

1.8~2.8

0.6~1

0.9~1.3

2.3~3.5

48~72

8.6~13

8.1~12.1

①
②
③
④
⑤
⑥
⑦
⑧
⑨
⑩
⑪
⑫
⑬
⑭
⑮
�

�

T
E
S
T
E

R 

P
R

O

B
E

Содержание Aquil GV650

Страница 1: ...ERY INC FOREWORD This manual contains an introductory description on HYOSUNG and procedures for its inspection service and overhaul of its main components Other information considered as generally kno...

Страница 2: ...sections is listed on the previous page as GROUP INDEX select the section where you are look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section ea...

Страница 3: ...r use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Use engine coolant Torque control required Data beside it indicates specified torque Ap...

Страница 4: ...NOTE Difference between photographs and actual motorcycles depends on the markets...

Страница 5: ...MATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 3 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS 1 4 BREAK IN PROCEDURES 1 6 CYLINDER CLASSIFICATION 1 6 EXTERIOR ILLUSTRATION 1 7 SPECI...

Страница 6: ...t in vehicle damage WARNING Indicates a potential hazard that could result in death or injury NOTE Indicates special information to make maintenance easier or instructions cleaner WARNING Proper servi...

Страница 7: ...r head and case bolts and nuts beginning with larger diameter and ending with small er diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaske...

Страница 8: ...Number is stamped on the steering head tube The engine serial number is located on the left downside of crankcase assembly These numbers are required especially for registering the machine and orderin...

Страница 9: ...ENGINE OIL SPECIFICATION WARNING Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside Mop the oil spilt Don t put the patch on the...

Страница 10: ...rature in your area does not go down to freezing point Hyosung recommends the use of HYOSUNG COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an a...

Страница 11: ...e position BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving pa...

Страница 12: ...1 7 GENERAL INFORMATION EXTERIOR ILLUSTRATION...

Страница 13: ...62 0 mm 2 44 in 647 39 5 in3 BDSR39 TYPE DOUBLE Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Lubrication system Wet multi plate type 5 sp...

Страница 14: ...M Igniter type 5 B T D C at 1 500 rpm CR8E 12V 12Ah MF Main 30 A Head lamp 15 A HI 60 W LO 55 W 10 W 4 LED type 5 W Ignition type Ignition timing Spark plug Battery Turn signal lamp Brake Tail lamp Li...

Страница 15: ...AND MUFFLER MOUNTING BOLTS 2 7 AIR CLEANER 2 8 CARBURETOR 2 9 FUEL HOSE 2 10 CLUTCH 2 10 ENGINE OIL 2 12 ENGINE OIL FILTER 2 14 DRIVE BELT 2 15 BRAKE SYSTEM 2 17 STEERING 2 21 FRONT FORK 2 21 REAR SU...

Страница 16: ...pension Chassis bolts and nuts Inspect Inspect Inspect Inspect Inspect Tighten Inspect Inspect Inspect Inspect Inspect Inspect Inspect Tighten Inspect every 1 000km Replace every 4 years Replace every...

Страница 17: ...TANK STAY has the fuel tank stay under the seat Use the fuel tank stay to inspect the engine or the other parts easily Remove the fuel tank mounting bolt Take the fuel tank stay off the tray upper the...

Страница 18: ...ssenger footrests pivot Side stand pivot and spring hook Footrests pivot Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot O Motor oil G Grease NOTE Before lubricatin...

Страница 19: ...to page 2 2 Remove the spark plug Refer to page 2 6 Remove the cylinder head cover and Remove the magneto cover plug and the tim ing inspection plug Rotate the magneto rotor counter clockwise to set...

Страница 20: ...m selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 170 1 70 mm select 195 1 95 mm of the shim which 170 1 70 mm of the shim ad...

Страница 21: ...and Every 6 000 km Replace Every 12 000 km Disconnect the spark plug caps Remove the spark plugs CAUTION Be careful not to damage the radiator fins Do not extract the radiator hose Remove the seat and...

Страница 22: ...LTS Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque Exhaust pipe bolt 18 28 N m 1 8 2 8 kg m Muffler mounting bolt 18 28 N m 1 8 2 8 kg m Inspect Interval Tighten Ini...

Страница 23: ...e Be careful not to allow water to go inside the air clea ner element CAUTION More frequent servicing may be performed on mo torcycles that are used under severe condi tions also clean the air cleaner...

Страница 24: ...ng the adjuster While holding the throttle grip at the fully closed posi tion slowly turn out the adjuster of the returning cable until resistance is felt Tighten the lock nut while holding the adjust...

Страница 25: ...ay A basis adjustment be allowed by the clutch lever adjuster Loosen the clutch lever adjuster Screw the lock nut clockwise fully after finishing adjustment After end of adjustment tighten the lock nu...

Страница 26: ...ion is delivered from the factory on position GEARSHIFT LINK ROD When the footrests in position exchange the gearshift link rod for appropriate riding position Position Install the gearshift link rod...

Страница 27: ...e is warm Oil fil ter replacement at the above intervals should be together with the engine oil change Keep the motorcycle upright Place an oil pan below the engine and drain the oil by removing the f...

Страница 28: ...low the Lower line mark L in the inspec tion window Never fill the engine oil above the Upper line mark F Engine oil level being most suitable about 1mm under the Upper line mark F of the engine oil l...

Страница 29: ...YOSUNG character and 16510HN910 part s NO install to ward the outside otherwise can damage the engine WARNING Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug a...

Страница 30: ...ing the drive belt replace the drive belt and pulleys as a set 2 15 PERIODIC MAINTENANCE Place the motorcycle on jack or block for accurate adjustment After adjusting the drive belt tighten the axle b...

Страница 31: ...touch the muffler when it is hot a hot muffler can burn you CAUTION Never bend or twist when the drive belt is kept or installed If the drive belt was installed with driver forcedly damage the drive...

Страница 32: ...e fluid on the brake pad of disk Front Brake L LO OW WE ER R BRAKE PAD WEAR The extend of brake pad wear can be checked by observing the grooved limit on the pad When the wear exceeds the grooved limi...

Страница 33: ...Brake Right side of Front Brake Rear Brake FRONT AND REAR BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight Remove the master cylinder reservoir cap and...

Страница 34: ...to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full brak ing performance of the brake caliper The presence of air is indicated by spongines...

Страница 35: ...e the tension of the brake lever causing it to touch the handlebar grip Then close the air bleeder valve pump and squeeze the brake lever and open the valve Repeat this process until the fluid flowing...

Страница 36: ...If play is found perform steering stem nut adjustment as described in page 7 30 of this manual FRONT FORK Inspect the front forks for oil leakage scoring or scratch es on the outer surface of the inne...

Страница 37: ...ir specified torque Refer to page 8 13 COLD INFLATION TIRE PRESSURE Front Rear SOLO RIDING KPa 221 245 2 25 2 50 33 0 36 0 221 285 2 25 2 90 33 0 42 0 kgf cm2 psi DUAL RIDING KPa kgf cm2 psi TIRE PRES...

Страница 38: ...capacity Reserve tank side Radiator side Engine side 230 430 940 WARNING Engine coolant is harmful if swallowed or if it comes in contact with skin or eyes Keep out of the reach of children and animal...

Страница 39: ...escaping hot liquid or vapor WARNING You can be injured by scalding fluid or steam if you open the radiator cap when engine is hot After the engine cools wrap a thick cloth around cap and carefully r...

Страница 40: ...adiator cap inlet Start up the engine and bleed air from the radiator cap inlet completely Add engine coolant up to the radiator cap inlet Repeat the above procedure until no air bleed from the radiat...

Страница 41: ...The difference in compression pressure between two cylinder is more than 2kg All compression pressure readings are nearly 12kg even when they measure more than 12kg COMPRESSION TEST PROCEDURE Compress...

Страница 42: ...pm Winter 20 min at 2 000 rpm After warming up increase the engine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge Engine tachometer 09900 26006 Oil pressure gauge 09915...

Страница 43: ...identification of assembly location on each removed part so that each will be restored to the original position during reassembly Wash clean and dry the removed parts before inspecting and measuring...

Страница 44: ...ove the seat Refer to page 7 1 Remove the fuel tank Refer to page 4 1 Remove the frame cover Refer to page 7 2 Disconnect the battery lead wire NOTE If the engine is dirtied wash the machine with a su...

Страница 45: ...switch lead wire coupler Disconnect the radiator inlet hose Remove the four radiator cover mounting bolts Remove the radiator cover Disconnect the radiator outlet hose Remove the radiator mounting bo...

Страница 46: ...lutch release arm EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts rear exhaust pipe connecting bolts and muffler mounting bolts removed remove the exhaust pipes and muffler CARBURETOR Remove the...

Страница 47: ...ECTRIC PARTS By taking out the spark plug caps remove the spark plug Remove the starter motor lead wire Disconnect the engine coolant temperature sensor lead wire ENGINE 3 4 Front Cylinder Rear Cylind...

Страница 48: ...ct the two magneto coupler Disconnect the neutral switch terminal Disconnect the side stand switch lead wire couper ENGINE PULLEY Remove the engine pulley cover Disconnect the front side of crankcase...

Страница 49: ...rburetor when removing or installing the engine necessarily When removing the carburetor loosen the intake pipe mounting bolts at the same time Remove the gearshift arm Flatten the lock washer Remove...

Страница 50: ...5 50 N m 3 5 5 0 kg m Tighten the frame down tube mounting bolts to the specified torque Frame down tube mounting bolt 22 35 N m 2 2 3 5 kg m CAUTION Set the part of engine mounting bolt align center...

Страница 51: ...Install the breather hose and engine pulley cover Connect each electric parts and its couplers Refer to page 8 24 30 Install the exhaust pipes and mufflers Install the carburetor and air cleaner Refe...

Страница 52: ...move the contacts and springs THERMOSTAT Remove the thermostat case along with the hose CAUTION Identify the position of each removed part Organize the parts in their respective groups so that they ca...

Страница 53: ...er 2ND AIR VALVE Remove the 2nd air valve with the bracket CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter clockwise To set pi...

Страница 54: ...emove the cam chain guide NO 2 Remove the camshaft housing Remove the camshaft IN EX NOTE Mark an identification of assembly location on each removed parts so that each will be restored to the origina...

Страница 55: ...shim with the strong magnet not to be scratched ENGINE 3 12 Loosen the six cylinder head bolts Remove the chain guide NO 1 and cylinder head Loosen the cylinder head base bolt NOTE When loosening the...

Страница 56: ...the valve cotter from the valve stem Remove the valve spring retainer Pull out valve from the other side CAUTION The tappet and shim should be lined so that each will be restored to the original posit...

Страница 57: ...ankcase Remove the piston pin circlips with long nose pliers Piston pin puller 09910 34510 Remove the piston pin by using the special tool Remove the rear cylinder head and cylinder with the same mann...

Страница 58: ...rod holder 09910 20115 Rotor remover 09930 30165 MAGNETO ROTOR With the magneto rotor held immovable using the special tool loosen the rotor nut Remove the magneto rotor by using the special tool Remo...

Страница 59: ...OVER Remove the clutch release arm Remove the clutch cover bolts Remove the clutch cover Remove the cam chain tensioner NOTE When remove or inspect the clutch drive and driven plate remove only the cl...

Страница 60: ...rod holder 09910 20115 Remove the disk pressure Remove the clutch drive plates NO 1 and driven plates Remove the spring washer and spring washer seat Remove the clutch drive plate NO 2 Flatten the loc...

Страница 61: ...y Conrod holder 09910 20115 PRIMARY DRIVE GEAR With the crankshaft held immovable using special tool remove the primary drive gear nut Remove the water pump drive gear and primary drive gear CAUTION T...

Страница 62: ...il pump GEARSHIFT SHAFT Draw out the gearshift shaft Remove the gearshift cam stopper Loosen the gearshift cam plate bolt Remove the gearshift cam stopper plate Remove the crankcase securing bolts rig...

Страница 63: ...cial tool Crankcase separator 09920 13120 CAUTION When separating the crankcase necessarily remove it after installed the special tool Crankcase separator on the side of clutch In case separate opposi...

Страница 64: ...E STEM RUNOUT Check the valve stem for abnormal wear or bend Place the valve on V blocks and measure runout If the service limit is exceeded or abnormal condi tion exists replace the valve Dial gauge...

Страница 65: ...alve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts...

Страница 66: ...tside diameter If the diameter measured exceeds the standard replace the valve VALVE GUIDE VALVE STEM CLEARANCE Measure the clearance in the valve guide valve stem by rigging up the dial gauge as show...

Страница 67: ...on Inner Outer Standard 4 2 4 8 kgf 9 3 10 6 lbs at length 29 9 mm 1 18 in 17 0 19 6 kgf 37 5 43 2 lbs at length 33 4 mm 1 32 in Standard 81 500 81 515 mm 3 2087 3 2093 in Service limit 81 575 mm 3 21...

Страница 68: ...d replace it with a new one CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear damage and kinked or bind ing links If any defects are found replace it with a new one Check the cam chain guide...

Страница 69: ...ter measure the piston pin outside diameter at three position both the ends and the center If any of the measurements is founds less than the ser vice limit replace the pin Piston pin hole bore Servic...

Страница 70: ...n Service limit 0 180 mm 0 007 in 0 150 mm 0 006 in Piston ring groove clearance 1st 2nd PISTON RING TO GROOVE CLEARANCE INSPECTION Remove carbon deposit both from the piston ring and its groove Fit t...

Страница 71: ...conrod small end inside diameter both in vertical and horizontal directions If any of the measurements exceeds the service limit replace the conrod Standard 20 006 20 014 mm 0 7876 0 7880 in Service...

Страница 72: ...With the right and left crank journals supported with V block turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds the service limit repla...

Страница 73: ...replace the defective parts DISASSEMBLY With the magneto rotor held immovable remove the starter clutch bolts REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tigh...

Страница 74: ...m 09923 74510 DISASSEMBLY Remove the bush using the special tool OIL JET REMOVAL Remove the oil jet from the right crankcase half Remove the oil jet from the left crankcase half NOTE If it is difficul...

Страница 75: ...Fit the new O ring to each oil jets Install the oil jet to the oil hole of crankcase Apply engine oil to the O ring Oil seal remover 09913 50121 CLUTCH COVER OIL FILTER REPLACEMENT Refer to page 2 14...

Страница 76: ...2 92 3 08 mm 0 115 0 121 in 3 42 3 58 mm 0 135 0 141 in NO 1 NO 2 Clutch drive plate thickness Vernier calipers 09900 20101 CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch driv...

Страница 77: ...ng the bearing from the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing PRIMARY DRIVEN GEA...

Страница 78: ...n important role in the smoothness and positiveness of shifting action If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Service limit 0 50 mm 0 020...

Страница 79: ...ip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expand the end gap larger than requi...

Страница 80: ...tation while the bearings are in the crankcase Replace the bearing in the following procedure if there is anything unusual DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer bolt and Remo...

Страница 81: ...RING Remove the oil seals and CAUTION The removed bearing should be replaced with a new one Bearing remover 17 mm 09923 73210 Bearing remover 20 35 mm 09923 74510 Remove the bearings and Bearing insta...

Страница 82: ...ing the special tool press the crankshaft into the left crankcase ENGINE REASSEMBLY The engine reassembly can be performed in the reverse order of disassembly procedures However the follow ing points...

Страница 83: ...smission Install the gearshift cam and gearshift fork shaft GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift fork NO 1 NO 2 and NO 3 Install the dowel pins Before assembling the crankcase apply...

Страница 84: ...215 must be per formed within a short period of time Take extreme care not to let BOND 1215 enter into the oil hole or bearing NOTE Tightening the crankcase bolts tighten each bolt little by little di...

Страница 85: ...driveshaft spacer Install the oil seal retainer GEARSHIFT CAM STOPPER Apply a small quantity THREAD LOCK 1324 to the gearshift cam plate bolt Install the gearshift cam stopper plate and gearshift cam...

Страница 86: ...nstall the circlip CAUTION After the cam driven gear cam guide gearshift shaft and neutral cam stopper have been fitted confirm that gear change is normal while turning the countshaft and driveshaft I...

Страница 87: ...alling the NO 2 gear install so that the mark on the gear align the key groove as shown in figure With the crankshaft held immovable using special tool install the water pump drive gear and primary dr...

Страница 88: ...urely Install the clutch sleeve hub nut and tighten it to the specified torque using the special tool Install the clutch drive plate NO 2 Install the spring washer seat and spring washer onto the clut...

Страница 89: ...ng bolts Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern CLUTCH COVER Install the two dowel pins and new gasket Apply engine oil to each gears bear...

Страница 90: ...own in the right figure THREAD LOCK 1324 STATOR Apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 STARTER CLUTCH When installing the starter clutch and rotor...

Страница 91: ...tarter clutch on the crankshaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft Tighten the magneto rotor bolt to the specified torque STARTER IDLE GEAR AND MOTOR Instal...

Страница 92: ...PISTON RING First install the piston ring in order of oil ring 2nd ring and 1st ring at the front cylinder PISTON Apply the MOLY PASTE to the piston pin When installing the piston turn the mark on the...

Страница 93: ...sket on the crankcase Apply the engine oil to the conrod small end piston and the piston rings Coat the cylinder wall with oil Install the cylinder and tighten the cylinder base nuts Cylinder base nut...

Страница 94: ...With the tappet fitted it should be replaced if it doesn t turn smoothly by the hand CAUTION The tappet and shim should be installed at the original position when removed If otherwise it is difficult...

Страница 95: ...er head install first the exhaust camshaft following the intake camshaft The rear cylinder head install first the intake as the cam chain tensioner adjuster exist exhaust side CAUTION If turn the cran...

Страница 96: ...st camshaft sprocket should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into cam chain The 1R arrow of intake camshaft sprocket should be toward t...

Страница 97: ...ft until the two holder and cam chain tensioner adjuster are installed completely NOTE The camshaft housing should be installed in the same manner with the front engine 16 Pin 16 Link 1 Link Rotation...

Страница 98: ...n the mechanical spring continually until the han dle is turned to the end Fix the adjuster into the cylinder block CAUTION The camshaft housing bolt is made of the special material This bolt is super...

Страница 99: ...sis of the magneto rotor If the valve clearance is within standard after mea sured the valve clearance begin the next operation If it is out of stanadard adjust the valve clearance within standard lim...

Страница 100: ...head and cylinder SUPER GREASE A GEAR POSITION SWITCH Install the spring and contact Apply SUPER GREASE A to the O ring and install the gear position switch THERMOSTAT Install the thermostat case alon...

Страница 101: ...CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks FUEL SYSTEM FUEL TANK FUEL COCK 4 1 FUEL PUMP 4 2 CARBURETOR 4 3 CONTENTS 4...

Страница 102: ...onnect the fuel hose and 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 of engine power may resul...

Страница 103: ...order of disassembly Tighten the fuel pump mounting bolts Connect the fuel hoses and vacuum hose securely FUEL HOSE ROUTING Fuel hose To carburetor Fuel hose To fuel cock Vacuum hose To carburetor va...

Страница 104: ...CARBURETOR 4 3 FUEL SYSTEM...

Страница 105: ...the fuel hose LOCATION OF CARBURE TOR I D NO The carburetor I D is stamped on the location on the carburetor as shown in the right photo Remove the throttle cables and choke cable Loosen the clamp sc...

Страница 106: ...the jet needle cap spring retainer and jet needle Remove the float chamber body Remove the float assembly along with the needle valve by removing the pin Remove the spring along with diaphragm 4 5 FUE...

Страница 107: ...ts and O rings Pilot air jet Pilot outlet and bypass Needle jet holder Float Needle valve Jet needle Valve seat If any abnormal condition is found wash the part clean If damage or clogging is found re...

Страница 108: ...and install the float chamber to the carburetor body Install the three screws Bend the float arm as necessary to bring the height to the specified level After adjustment check the float height and the...

Страница 109: ...nt Refer to page 2 9 Idle speed adjustment Refer to page 2 9 Align the hole of the diaphragm with passage way on the carburetor body Install the two screws and diaphragm cover CAUTION Never adjust CO...

Страница 110: ...ENGINE COOLANT 5 1 COOLING CIRCUIT 5 2 RADIATOR 5 2 COOLING FAN 5 5 COOLING FAN THERMO SWITCH 5 6 ENGINE COOLANT TEMPERATURE SENSOR 5 7 THERMOSTAT 5 8 WATER PUMP 5 10 COOLING SYSTEM 5 CONTENTS...

Страница 111: ...n 50 Refer to Right figure Do not use a radiator anti leak additive 50 Engine coolant including reserve tank capacity Anti freeze Water 0 8 0 8 WARNING You can be injured by scalding fluid or steam if...

Страница 112: ...the two mounting bolts removed remove the right front side cover Remove the radiator cap bolt Remove the radiator cover by the four mounting bolts Disconnect the radiator outlet hose RESERVE TANK RAD...

Страница 113: ...be removed Use of compressed air is recommended for this clean ing Remove the radiator by the mounting bolts Disconnect the cooling fan thermo switch lead wire coupler Disconnect the radiator inlet h...

Страница 114: ...g bolt 8 12 N m 0 8 1 2 kg m Pour engine coolant Refer to page 2 24 Bleed air from the cooling circuit Refer to page 2 25 COOLING SYSTEM 5 4 Fins bent down or dented can be repaired by straighten ing...

Страница 115: ...ling fan to the radiator Cooling fan mounting bolt 8 12 N m 0 8 1 2 kg m Cooling fan motor mounting bolt 8 N m 0 8 kg m Install the radiator Route the radiator hoses properly Pour engine coolant Refer...

Страница 116: ...nd read the column thermometer when the switch closes Multi circuit tester set 09900 25008 INSTALLATION Install a new O ring and apply engine coolant to the O ring Tighten the cooling fan thermo switc...

Страница 117: ...d read the column thermometer and the ohmmeter 5 7 COOLING SYSTEM Temperature sensor specification Temperature 60 85 110 125 Standard resistance Approx 125 Approx 48 5 Approx 24 Approx 15 If the resis...

Страница 118: ...e the thermostat in the WATER contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspension Heat the water by placing the beaker on a stove and observe the risi...

Страница 119: ...N Apply engine coolant to the rubber seal on the ther mostat Install the thermostat Install the thermostat case cap Tighten the thermostat case bolts to the specified torque Thermostat case bolt 10 N...

Страница 120: ...the water hoses Remove the water pump case and clutch cover Refer to page 3 16 Remove the snap ring and water pump driven gear Remove the pin and washer NOTE Before draining engine oil and engine coo...

Страница 121: ...Remove the water pump from the clutch cover Remove the O rings Remove the E ring from the impeller shaft Remove the impeller from the other side 5 11 COOLING SYSTEM...

Страница 122: ...pect abnormal noise and smooth rotation Replace the bearing if there is anything unusual BEARING CASE Visually inspect the bearing case for damage Replace the water pump body if necessary REASSEMBLY A...

Страница 123: ...Refer to page 2 24 Pour engine oil Refer to page 2 12 Apply SUPER GREASE A to the impeller shaft SUPER GREASE A Install the impeller to the water pump body Fix the impeller shaft with the E ring Fill...

Страница 124: ...CATION OF ELECTRICAL COMPONENTS 6 1 IGNITION SYSTEM 6 3 CHARGING SYSTEM 6 7 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 6 11 SWITCHES 6 15 LAMP 6 16 BATTERY 6 18 ELECTRICAL SYSTEM 6 CONTEN...

Страница 125: ...COMPONENTS 6 1 ELECTRICAL SYSTEM Engine coolant temperature sensor Thermostat Front brake lamp switch Side stand switch Rear brake lamp switch Starter motor Battery Head lamp relay Side stand relay C...

Страница 126: ...ELECTRICAL SYSTEM 6 2 Regulator Rectifier Turn signal relay Cooling fan motor Cooling fan thermo switch Ignition coil NO 1 NO 2 Magneto Gear position switch Fuses Igniter...

Страница 127: ...act point The battery ignition system is composed a rotor with four rotor tip the igniter the ignition coil and battery This system ignites after get signal from igni tion timing of pick up with the e...

Страница 128: ...CK 1324 to the threaded parts of screws ELECTRICAL SYSTEM 6 4 WIRE COLOR L Blue G Green Y Yellow BY Black with Yellow tracer OB Orange with Black tracer Br Brown BW Black with White tracer WL White wi...

Страница 129: ...indication 1 range Check the attached plug cap Ignition coil resistance Pocket tester 09900 25002 IGNITION COIL Pull out the spark plug Place it on the cylinder head after installing it at the plug ca...

Страница 130: ...F OFF 200 300 210 310 21 5 32 5 11 1 16 7 14 3 21 5 OFF 25 7 38 5 15 4 23 14 2 21 2 14 6 21 8 11 2 16 8 39 59 20 4 30 6 4 7 7 1 13 7 20 5 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 18...

Страница 131: ...usted voltage of the regulator the regulator does not function incidentally the generated current charges the battery directly CHARGING SYSTEM The circuit of the charging system is indicated in figure...

Страница 132: ...SCR becomes conductive to the direction from point to point Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC...

Страница 133: ...ee lead wires from the magneto terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC volt age between the three lead wires If the tester reads under 70 V th...

Страница 134: ...ter 1 range measure the resistance between the terminals in the following table If the resistance checked is incorrect replace the regu lator rectifier 3 4 3 4 1 2 1 2 3 4 3 4 1 2 1 2 3 4 3 4 1 2 1 2...

Страница 135: ...prevents the motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery and ignition coil The circuit consists of the igniter neutral...

Страница 136: ...CAL SYSTEM 6 12 BATTERY IGNITION COIL IGNITION SWITCH ON IGNITION SW ON NEUTRAL INDICATOR LIGHT NEUTRAL SW ON DIODE NEUTRAL SW OFF NEUTRAL INDICATOR LIGHT DIODE SIDE STAND SW UP RIGHT POSITION SIDE ST...

Страница 137: ...ature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Pocket tester 09900 25002 Segment STARTER MOTOR...

Страница 138: ...g end SUPER GREASE A Apply SUPER GREASE A to the O ring and remount the starter motor STARTER MOTOR REASSEMBLY Reassemble the starter motor Pay attention to the following points Reassembly the starter...

Страница 139: ...pective switch assemblies with new ones 6 15 ELECTRICAL SYSTEM R O BW BR ON OFF IGNITION SWITCH BBr BW ON OFF HORN SWITCH O WB ON OFF FRONT REAR BRAKE LAMP SWITCH O Y ON OFF PASS SWITCH OB YR ON OFF S...

Страница 140: ...LAMP HEADLAMP TURN SIGNAL LAMP TAIL BRAKE LAMP ELECTRICAL SYSTEM 6 16...

Страница 141: ...CTION Using the pocket tester check the continuity between lead wires Blue color coupler in the follow ing illustration If the continuity measured incorrect replace the respective part Pocket tester 0...

Страница 142: ...water When they were stained clothes will come into being a hole or painting will take off Consult a doctor When the battery electrolyte was dropped to the surface of land wash it with a vast quantit...

Страница 143: ...that it does not fall Take precaution not to allow any fluid to spill Confirmation of pour Make sure that air bubbles are coming up each electrolyte container and keep this position for more than abou...

Страница 144: ...with rust or an acidic white powdery substance then this can be cleaned away with sandpaper RECHARGING OPERATION Using the pocket tester check the battery voltage If the voltage reading is less than...

Страница 145: ...7 1 FRAME COVER 7 2 SEAT TAIL COVER SEAT TAIL COVER BRACE 7 4 FRONT WHEEL 7 6 FRONT BRAKE 7 10 HANDLEBARS 7 17 FRONT FORK 7 20 STEERING 7 28 REAR WHEEL 7 31 REAR BRAKE 7 36 REAR SHOCK ABSORBER 7 38 SW...

Страница 146: ...htside and the two bolts for lelfside Remove the front fender SEAT To remove the seat remove the seat mounting bolt on the rearside of the seat To install the seat slide the seat hook into the seat ho...

Страница 147: ...CHASSIS 7 2 FRAME COVER RIGHT DECORATION COVER With the right decoration cover mounting screw removed remove the right decoration cover...

Страница 148: ...side cover LEFT FRONT SIDE COVER The left front side cover is used to inspect the fuses With the two mounting bolts removed remove the left front side cover RIGHT LEFT AIR DUCT REAR COVER Remove the...

Страница 149: ...SEAT TAIL COVER BRACE Remove the seat Refer to page 7 1 Remove the rear shock absorber upper bolts inside of frame right and left Install the rear shock absorber upper bolts with the frame in the out...

Страница 150: ...S Remove the battery and relay Disconnect the rear turn signal lamp coupler and rear combination lamp coupler Remove the two bolts With the two bolts removed remove the seat tail cover and seat tail c...

Страница 151: ...the axle pinch bolt right and left Loosen the front axle Raise the front wheel off the ground with a block or jack Remove the front wheel by removing the front axle CAUTION When using a jack take care...

Страница 152: ...axial and radial does not exceed the service limit when checked as shown An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If...

Страница 153: ...earings as follows by using the special tools WHEEL BEARING Apply SUPER GREASE A to the wheel bearings WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel Rotate...

Страница 154: ...pinch bolt 15 25 N m 1 5 2 5 kg m 7 9 CHASSIS BRAKE DISK Make sure that the brake disk is clean and free of any greasy matter Apply THREAD LOCK 1324 to the right and left disk mounting bolts and tight...

Страница 155: ...ime To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children When filling brake fluid take care not to allow water or dirt to enter the system To...

Страница 156: ...e right and left front brake union bolt and caliper mounting bolts Remove the brake pad Refer to page 2 18 Remove the brake pad mounting bolt CAUTION Do not allow brake fluid to contact the paint surf...

Страница 157: ...an possibly splash Do not use high pressure air but increase the pressure gradually Remove the dust seal and piston seal CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scr...

Страница 158: ...mounting bolts 18 28 N m 1 8 2 8 kg m Front brake hose union bolts 20 25 N m 2 0 2 5 kg m 7 13 CHASSIS CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disassembly procedures and obs...

Страница 159: ...limit 0 3 mm 0 012 in Micrometer 0 25 mm 09900 20201 BRAKE DISK INSPECTION Check the brake disk for damage or cracks Measure the thickness using the micrometer Replace the brake disk if the thickness...

Страница 160: ...age Inspect the piston surface for any scratches or other damage 7 15 CHASSIS Remove the two clamp bolts and take off the mas ter cylinder Remove the two fitting screws and separate the cap and diaphr...

Страница 161: ...ion to the following points CAUTION Wash the master cylider components with new brake fluid before reassembly When washing the components use the speci fied brake fluid Never use different types of fl...

Страница 162: ...ve the master cylinder Refer to page 7 15 Remove the handlebar balancer and grip HANDLEBARS LEFT SIDE PARTS REMOVAL Remove the left handlebar switches Remove the handlebar balancer and grip Remove the...

Страница 163: ...ge 7 16 CHASSIS 7 18 Remove the handlebar mounting bolts right and left Remove the handlebar REMOUNTING Perform the remounting work in the reverse order of the removal procedures while observing the f...

Страница 164: ...SIS Apply SUPER GREASE A to the throttle cables Install the throttle cable and returning cable to the throttle grip Throttle cable Returning cable SUPER GREASE A Throttle grip Throttle cable Rotation...

Страница 165: ...CHASSIS 7 20 FRONT FORK...

Страница 166: ...ISASSEMBLY Remove the front fender Refer to page 7 1 Take off the front wheel Refer to page 7 6 7 21 CHASSIS NOTE Slightly loosen the front fork cap bolt to facili tate later disassembly Remove the fr...

Страница 167: ...ont fork and stroke the inner rod several times to let out fork oil Under the inverted condition of front fork drain oil to hold it for a few time Remove the damper rod bolt Remove the inner rod dampe...

Страница 168: ...new one INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and outer tube slide metal face for scratches If any defects are found replace them with a new one FORK SPRING Measure th...

Страница 169: ...n fitted securely CAUTION Be careful not to damage the dust seal lip and the oil seal lip when installing the outer tube INNER ROD DAMPER ROD Move the inner rod by hand to examine it for smooth ness I...

Страница 170: ...5 6 minutes Hold the front fork vertically and adjust fork oil level with the special tool NOTE Refill front fork oil up to the top of the outer tube to find bubbles while bleeding air NOTE Always ke...

Страница 171: ...lower clamp bolts to the specified torque Front fork upper clamp bolt 22 35 N m 2 2 3 5 kg m Front fork lower clamp bolt 22 35 N m 2 2 3 5 kg m FRONT FORK INNER ROD LOCK NUT Adjust the height of the...

Страница 172: ...n the adjuster will soften rebound damping force 2 Compression damping force To adjust the compression damping force turn in the adjuster fully for S or H direction Count the number of clicks from the...

Страница 173: ...CHASSIS 7 28 REMOVAL AND DISASSEMBLY Take off the front wheel Refer to page 7 6 Remove the front fender Refer to page 7 1 Take off the front fork Refer to page 7 21 STEERING...

Страница 174: ...ng stem head nut and take off the steering stem upper bracket Clamp wrench 09940 10122 Remove the steering stem nut and draw out the steering stem Take off the steering stem lower bracket Remove the u...

Страница 175: ...stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering st...

Страница 176: ...7 31 CHASSIS REAR WHEEL REMOVAL Raise the rear wheel off the ground with a jack or block With the four mounting bolts remove the engine pul ley cover...

Страница 177: ...IS 7 32 With the four mounting bolts remove the drive belt cover Remove the rear axle bolt Remove the rear wheel Loosen the drive belt adjuster right and left Disengage the drive belt from the rear pu...

Страница 178: ...g the special tool Remove the rear wheel shock absorber Remove the rear pulley from the rear pulley mounting drum NOTE Before separating the rear pulley and mounting drum slightly loosen the rear pull...

Страница 179: ...lt 20 30 N m 2 0 3 0 kg m REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and dam age Replace the rear wheel shock absorber if there is any thing unusual REAR PULLEY Inspect t...

Страница 180: ...7 35 CHASSIS After installing the drive belt to the rear pulley adjust the drive belt by turning both belt adjusters Tighten both belt adjuster lock nuts securely...

Страница 181: ...long period To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children When filling brake fluid take care not to allow water or dirt to enter the...

Страница 182: ...ment Refer to page 2 18 Brake pad replacement Refer to page 2 18 Disassembly of caliper Refer to page 7 11 Inspection of caliper Refer to page 7 12 Reassembly of caliper Refer to page 7 13 Inspection...

Страница 183: ...CHASSIS 7 38 REMOVAL Remove the rear shock absorbers by removing their bolts and nuts REAR SHOCK ABSORBER...

Страница 184: ...ING Install the rear shock absorber and tighten the bolts and nuts to the specified torque CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable Rear shock absorber spring...

Страница 185: ...CHASSIS 7 40 REMOVAL AND DISASSEMBLY Remove the rear wheel Refer to page 7 31 Remove the exhaust pipes and muffler Refer to page 3 3 SWINGARM...

Страница 186: ...over and drive belt cover With the rear shock absorber lower bolts removed disconnect the rear shock absorber from swingarm Remove the swingarm mounting lock nut Remove the swingarm pivot nut Remove t...

Страница 187: ...s the service limit replace it with a new one Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 Swingarm pivot shaft runout Service limit 0 6 mm 0 024 in INSPECTION SWINGARM Inspec...

Страница 188: ...ivot nut 50 70 N m 5 0 7 0 kg m Swingarm pivot shaft 15 30 N m 1 5 3 0 kg m Swingarm mounting lock nut M26 70 80 N m 7 0 8 0 kg m Engine mounting socket wrench M26 09940H35010 Install the rear wheel R...

Страница 189: ...SERVICING INFORMATION TROUBLESHOOTING 8 1 SPECIAL TOOLS 8 9 TIGHTENING TORQUE 8 12 SERVICE DATA 8 14 WIRE AND CABLE ROUTING 8 24 WIRING DIAGRAM 8 30 CONTENTS 8...

Страница 190: ...Valve clearance too large 2 Weakened or broken valve springs 3 Worn down camshaft Noise appears to come from piston 1 Piston or cylinder worn down 2 Weakened or broken valve springs 3 Worn down piston...

Страница 191: ...kened stopper pawl spring on gearshift cam 4 Worn gearshift pawl 1 Valve clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Defective pick up coil 5 Spark plug gap too wid...

Страница 192: ...ged jets in carburetor 10 Float chamber fuel level out of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe 1 Heavy carbon deposit on piston head 2 Not enou...

Страница 193: ...is not fully closed Check and clean Check and clean Check and clean Overflow and fuel level fluctuations 1 Needle valve is worn or damaged 2 Spring in needle valve is borken 3 Float is not working pro...

Страница 194: ...Defective regulator rectifier 4 Not enough electrolyte in the battery 5 Defective cell plates in the battery Repair or retighten Replace Replace Add distilled water between the level lines Replace th...

Страница 195: ...ld Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the...

Страница 196: ...eplace Replace Front suspension too soft 1 Weakened springs 2 Not enough fork oil 3 Wrong viscous fork oil 4 Improperly set front fork damping force adjuster Replace Refill Replace Adjust Front suspen...

Страница 197: ...ed air Brake squeaking 1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Loosen front wheel axle or rear wheel axle 5 Worn pads 6 Foreign material in brake fluid 7 Clogged return...

Страница 198: ...er 09900 20605 Dial calipers Meassure width of conrod big end 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 20701 Magnetic stand With using dial gauge 09900 2080...

Страница 199: ...g in 09913 80112 Bearing installer Used to drive bearing in 09915 64510 Compression gauge Measure cylinder compression 09915 74510 Oil pressure gauge Measure oil pressure of 4 stroke engine Separate t...

Страница 200: ...oil cylinder 09940 10122 Clamp wrench A hook wrench to adjust the steering head of motorcycle 09940 34561 Front fork assembling tool attachment D Used with T handle 09940H30010 Engine mounting socket...

Страница 201: ...in tensioner bolt Cam chain tensioner adjuster bolt Clutch sleeve hub nut Primary drive gear nut Camshaft housing bolt Horn mounting bolt 1 8 1 1 1 4 0 8 1 2 0 8 1 3 0 8 1 2 11 0 17 0 1 0 1 8 2 8 1 8...

Страница 202: ...t and Rear brake hose union bolt Front axle bolt Front axle pinch bolt Front fork damper rod bolt Front fork upper clamp bolt Front fork cap bolt Front fork lower clamp bolt Front fork inner rod lock...

Страница 203: ...ength 33 4mm 1 32 in 1 2 1 7 0 047 0 067 IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX Inner Outer Inner Outer 0 35 0 014 0 05 0 002 0 50 0 02 0 03 0 0012 36 8 1 45 39 8 1 57 VALVE GUIDE...

Страница 204: ...390 Approx 10 5 0 413 0 20 0 35 0 008 0 013 0 20 0 35 0 008 0 013 1 21 1 23 0 0476 0 0484 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 0 970 0 990 0 0382 0 0390 1 170 1 190 0 0461 0 0469 1st 2nd 1st 2n...

Страница 205: ...ve plate thickness Drive plate claw width Driven plate distortion Clutch spring free length 2 62 0 103 3 12 0 123 15 1 0 595 15 1 0 595 0 1 0 004 51 2 008 CLUTCH 2 0 08 2 92 3 08 0 115 0 121 3 42 3 58...

Страница 206: ...32 18 1 38 29 21 1 13 27 24 0 96 25 26 Poly chain belt 26 1 02 11 0 43 1st 2nd 3rd 4th 5th Type Width Pitch NO 1 NO 2 NO 3 NO 1 NO 2 NO 3 0 10 0 30 0 004 0 012 8 17 SERVICING INFORMATION Gear ratio Sh...

Страница 207: ...t P J Throttle valve TH V By pass B P Valve seat V S Starter jet G S Pilot screw P S Pilot outlet P O PV Stroke P V BDSR39 TYPE DOUBLE 39 1 300 1 500 rpm 7 0 28 0 5 1 0 0 02 0 04 FRONT 125 45 6DH64 53...

Страница 208: ...Engine coolant capacity Over 8mm 100 ITEM STANDARD LIMIT THERMOSTAT COOLING FAN COOLANT Valve opening Valve full open Valve closing 60 85 110 125 OFF ON ON OFF Reserve tank side Radiator side Engine s...

Страница 209: ...20 Ignition timing Spark plug Spark performance Fuse size Ignition coil resistance Magneto coil resistance Magneto no load voltage Battery standard charging voltage CR8E 0 7 0 8 0 028 0 032 CR7E CR8E...

Страница 210: ...470 18 5 TELLUS 32 215mm 8 5 in from end of outer tube when maximum compressed without spring 420cc 90 3 54 1 5 position 223 8 78 ITEM STANDARD LIMIT SUSPENSION STANDARD FRONT FORK DAMPING FORCE Rebo...

Страница 211: ...12 700 12 743 0 5000 0 5017 15 827 15 854 0 6227 0 6242 12 657 12 684 0 4983 0 4994 25 4 1 00 25 4 1 00 DOT3 or DOT4 DOT4 120 70 ZR 18 59W 180 55 ZR 17 73W J18 MT3 50 J17 MT5 50 408 16 1 when one pers...

Страница 212: ...ded 91 octane or higher An unleaded gasoline is recommened API Over SL SAE 10W 40 3 000 3 200 3 400 ITEM SPECIFICATION FUEL OIL Change Filter change Overhaul TIRE PRESSURE COLD INFLATION TIRE PRESSURE...

Страница 213: ...RTH L WIRE BATTERY MINUS 36618 30610 TAIL STOP LAMP LICENSE LAMP RR TURN LAMP R L WELD CLAMP WELDING CLAMP WELDING CLAMP WELD CLAMP 1 TAPPING OF INSTALLATION BASIS RR IGNITION COIL COUP FUEL GAUGE COU...

Страница 214: ...PING OF INSTALLATION BASIS RELAY 3EA LICENSE LAMP REFLEX REFLECTOR RR REFLEX REFLECTOR SIDE RR 2EA Exception of the application vehicle of European law WELD CLAMP WELD CLAMP L WIRE RR COMBI 09407 2040...

Страница 215: ...NITOR COUP IGNITION S W 09407 20406 HANDLE S W Rh COUP HANDLE S W Rh Install inside of HEAD LAMP HOUSING LOCK STEERING IGNITION S W WELD CLAMP RR BRAKE S W RR BRAKE S W 09407 20406 L WIRE STARTER MOTO...

Страница 216: ...ION 09407 20406 HANDLE S W 09407 20406 HANDLE S W CLUTCH LEVER S W 09407 20406 WIRING HARNESS FT TURN L HEAD LAMP COUP 09407 20406 FT TURN R 09404 06405 L WIRE FT TURN R L L WIRE C LEVER S W COUP HAND...

Страница 217: ...SERVICING INFORMATION 8 28 VIEW A ENGINE EARTH INSTALLATION DIRECTION CRANK CASE R PIPE FRAME Lh SIDE L TOP WIRING HARNESS L WIRE BATTERY MINUS FRONT 1 MARK WELDING CLAMP PARTS 3EA VIEW...

Страница 218: ...8 29 SERVICING INFORMATION FRONT CYLINDER REAR CYLINDER CAUTION FOR HIGHTENTION CORD INSTALLATION DIRECTION WELDING CLAMP OPERATION METHOD FRAME WELD CLAMP WIRING HARNESS...

Страница 219: ...SIDE STAND RELAY HEAD LAMP RELAY DIODE 2 DIODE 1 FT IG COIL STARTER MOTOR STOP LAMP S W DIODE 3 IGNITION S W CLUTCH LEVER S W FT TURN R HEAD LAMP POSITION LAMP FT TURN L FREE ON STOP RUN OFF ON OFF ON...

Страница 220: ...1 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 45 1 50 1 55 1 60 1 65...

Страница 221: ...75 1 80 1 85 1 90 1 95 1 75 1 80 1 85 1 90 1 95 2 00 1 80 1 85 1 90 1 95 2 00 2 05 1 85 1 90 1 95 2 00 2 05 2 10 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 1 65 1 70 1 75 1 80 1 85 1...

Страница 222: ...Prepared by HYOSUNG MOTORS MACHINERY INC 1st Ed JUL 2005 Manual No 99000 51210 Printed in Korea...

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