SERVICE MANUAL
Contents
1. POSITION GEARSHIFT LINK ROD FOR P 1 1 S OPTIONAL PARTS When the footrests in position exchange the gearshift link rod for appropriate riding position Position or Install the gearshift link rod 3 Position Install the gearshift link 4 NOTE The gearshift link rod 22 15 optional parts 15 PERIODIC MAINTENANCE 2 9 3 GE Optional parts 2 20 PERIODIC MAINTENANCE ENGINE COOLANT 9 SIDE COWLING INNER COMASS amp Corset anos A have the side cowling inner at the rightside Use the side cowling inner to operate the radiator cap 3 To disassemble the side cowling inner remove two screws 2 A WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor lt WY S CLOE 5 5 5 Be 18 6 6 echte 19 6 16 1 6 6 ELECTRICAL SYSTEM IGNITION SYSTEM IGNITER Using the pocket tester R x 1K range measure the resistance between the terminal in the following table CAUTION 4 Numerical value may differ a little according to the tester Please remind that there may be a defect which can not be identified even though the measurement by using the tester indicates a low v2. pee STOP LAMP SW 2 MH enm HEAD LAMP RELAY Eee o amp oo ons i B F Ft TURN R HEAD LAMP Ft TURNL ee E Heee eee eea I i pd LICENSE PLATE SR ES ES EES ER oii s il 2 lt Rh LL LEBER 4 gt 9 Br TURN Lh ee IHE 1 TE aE eoo e 59 S Ev horde 12V 12Ah 9 NN EARTH FUSEBOX FUSEBOX _BATTERY MF 15A 6 FREE Hi rece du _ RELAY puse LO HORN DIMMER PASS FUEL GAUGE Jr SIDESTAND SW E TURNSIGNAL M 2 NEUTRAL SW 20 Bw YB GR Bw G G L L Y Y Y R Bw Hw YR GR HANDLE SWITCH Lh MAGNETO STARTER MOTOR 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 Green 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 White LW Blue with White tracer Yellow with Black tracer 8 CH _TAIL amp STOP 80 8 NOILV
3. SON 09407 20406 WIRING HARNESS 09407 14403 59440HN910 WIRING HARNESS CLAMP COMP F T BRAKE HOSE L 42 09403 09301 59470 910 HOSE COMP FRONT BRAKE L 09360H10050 BOLT BRAKE FLUID PROP STAND S W ev 61610 810 GUIDE RR BRAKE HOSE 2 69480HM810 1 HOSE COMP REAR BRAKE 1324 Apply THREAD LOCK 1324 when install GUIDE NO 2 61510 810 GUIDE RR BRAKE HOSE NO 1 CYLINDER ASS Y R R MASTER 9 8 NOILVINHO3NI 5 TH CABLE RE CABLE C CABLE ST CABLE are routing into the bracket hole Each cable is no twisted 09407 14403 ENGINE EARTH MOTOR LEAD WIRE Rr STOP S W 09407 20406 LEAD WIRE STARTER MOTOR PIPE COMP 2ND AIR FRONT 76 58200HN910 CABLE ASS Y CLUTCH Q NOILVINHOANI ONIOIAUAS 0 9 8 SERVICING INFORMATION 8 27 1 09404 06401 Led m WIRING 55 WATER TEMP GAUGE FRONT CYLINDER REAR CYLINDER CAUTION FOR HIGHTENTION CORD INSTALLATION DIRECTION 8 27 2 SERVICING INFORMATION 09404 06429 MAGNETO GEAR SHIFT S W PROP STAND S W SPROCKET COVER 46 LV WATER TEMP HANDLE SWITCH Rh GAUGE Ji THERMO S W IGNITION S W LON 5 85 Lov S 2 jumaa 29 SIDE STAND RELAY 555
4. HYOSUNG CUK E c Q HYOSUNG MOTORS amp MACHINERY INC 2 ESO SERVICE MANUAL 99000 94910 FOREWORD GROUP INDEX This manual contains an introductory description on HYOSUNG amp Cometesoxe s and procedures for its inspection service and overhaul of its main components It covers the differences from and please PERIODIC MAINTENANCE refer to the service manual of 99000 94810 for others which are not covered in this manual This page numbers on the top are ones which are in the service manual of and ones on the bottom ELECTRICAL SYSTEM are the page numbers in this manual Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize CHASSIS yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service This manual will helo you know the vehicle better so that can assure your customers of your optimum quick service GENERAL INFORMATION 4 This manual has been prepared on the basis of the latest specification at the time of publication If modification has been made since then difference may exist between the content of this manual and the actual vehicle 4 Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual v
5. lt CC ee RLON 825 970 1 125 HEIGHT 645 710 780 1 435 WHEEL 330 2 060 LENGTH 1 7 3 INFORMATION EXTERIOR ILLUSTRATION zzz Turn signal lamp Rear Tail Brake lamp License plate lamp gt 510 655 Head lamp Turn signal lamp Front 4 DS A X 24 Passenger footrests c kos K dex rn 2 A A ZN 2 1 125 HEIGHT 825 1 435 WHEEL BASE 330 2 060 LENGTH 970 710 780 SPECIFICATIONS DIMENSIONS AND DRY MASS ITEM EQ Standard type GENERAL INFORMATION 1 8 Overall length Overall width 2 060 mm 81 1 in 740 mm 29 1 in COREL C50 FZ lt Overall height 1 125 mm 44 3 in Wheelbase 1 435 mm 56 5 in 655 mm 25 8 in lt lt lt Ground clearance 150 mm 5 9 in lt 130 mm 5 1 in Mass ENGINE 215 kg 474 Ibs ESQ Standard type 220 485 105 RO c Sport type Number of cylinder V 2 oylinder lt Bore Four stroke DOHC Liquid cooled 81 5 mm 3 21 in
6. 2 Screw the lock nut clockwise fully after finishing adjustment After finishing adjustment tighten the lock nut 1 and cover the rubber boot 5 f it is not adjusted by the adjuster 2 loosen the clutch cable adjuster lock nut 3 Turn the clutch cable adjuster in or out to acquire the specified play After finishing adjustment tighten the lock nut The clutch cable should be lubricated with a light weight oil whenever it is adjusted Clutch cable play 6 2 0 08 in 3 We _ e COA LOS Sports type 6 GEARSHIFT LEVER HEIGHT ADJUSTMENT Loosen the lock nut 6 With the link rod turned adjust the gearshift lever height Tighten the lock nut 13 PERIODIC MAINTENANCE 2 9 1 Standard K F TN M 1 T d 2 9 2 PERIODIC MAINTENANCE FOOTREST POSITION ADJUSTMENT gt 1 amp COME 1 have type of the footrest position right and left To change the position remove the 8mm wrench bolts D and install the bolts to the desired position by using the hexagon wrench 6mm 1 1 are delivered from the factory on position s WARNING When adjusting the footrest position the 8mm wrench bolts be torqued to the proper specification If they are not the footrest can come off unexpectedly Footrest mounting bolt 22 35 Nim 2 2 3 5 kgf m
7. 3 5 36 SERVICING INFORMATION CONTENTS GEDUIGE TT 38 8 20 WIRE AND CABLE ROUTING 39 8 24 1 WIRING DIAGRAM EE 47 8 28 37 8 20 SERVICING INFORMATION SERVICE DATA WATTAGE Unit W Head lamp E EN Neutral indicator lamp VFD Turn signal indicator lamp Right amp left VFD High beam indicator lamp VFD Fuel indicator lamp Level type Coolant temperature indicator lamp Level type A CAUTION Do not use except the specified bulb Wattage NOTE VFD Vacuum Fluorescent Display 38 6 09408 00002 CLIP T CABLE amp R CABLE ps d T 5 4 36618 30610 742 TUBE SPEEDOMETER LEAD WIRE 09407 2541 09407 20406 09407 20406 09407 20406 SPEED SENSOR 59460HN910 59470 910 HOSE COMP FRONT BRAKE HOSE COMP FRONT BRAKE L 51511HN910 22 JOINT FT BRAKE HOSE 8 NOILVINYOSNI 5 8 24 2 SERVICING INFORMATION YALYVLS 318 0 0 7 WS GNVLS 4 MWS WHLNAN WS QNV LS MWS WHLNAN ASSY 318VO D WS GNVIS dOud WS ALNIN OLSNOVN 1 OL3NOVIN SS3NHVH m 0 0760 DIN 60 0 60 LIVLSOWYSHL SS3N
8. Turn signal indicator lamp right left E Neutral indicator lamp VFD Fuel indicator lamp VFD Level type Coolant temperature indicator lamp VFD Level type CAPACITIES ITEM lt gt Standard type Sport type Fuel tank 17 0 2 Engine oil oil change 3 000 m with filter change 3 200 ml overhaul 3 400 m Front fork oil capacity One side 380 cc NOTE The specifications are subject to change without notice PERIODIC MAINTENANCE CONTENTS MAINTENANCE PROCEDURES CABBUBETORB EE 12 2 7 13 2 9 1 ENGINE COOLANT EE 16 2 20 2 7 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES CARBURETOR Inspect Interval Inspect Initial 1 000 km and Every 6 000 km IDLE SPEED NOTE Make this inspection when the engine is hot Connect an engine tachometer to the high tension cord Start up the engine and set its speed at anywhere 1 300 and 1 500 rom by turning throttle stop screw Engine idle speed 1 300 1 500 rom Engine tachometer 09900 26006 As V CONSU BI CLUTCH Inspect Interval Inspect Initial 1 000 km and Every 6 000 km Clutch play should be 2 0 08 in as measured at the clutch lever holder before the clutch begins to disengage If the play in the clutch 15 incorrect adjust it in the following way A basis adjustment can be done by the clutch lever adjuster 2 Loosen the clutch lever adjuster
9. bolts right and left Loosen the front fork upper clamp bolt right and left Remove the steering stem upper bracket by removing the steering stem head nut NOTE Place the rags under the steering stem upper bracket to prevent scratching the body cowling 30 Remove the handlebar holder right and left Draw out the handlebars to upward REMOUNTING Remount the handlebar in the reverse order of removal Pay attention to the following point Install the handlebars temporary Install the steering stem upper bracket Tighten the steering stem head nut 9 Steering stem head nut 80 100 N m 8 0 10 0 kg Tighten the front fork upper clamp bolt right and left V Front fork upper clamp bolts 22 35 2 2 3 5 kg m Tighten the handlebar clamp bolts right and left 9 Handlebar clamp bolt 22 35 2 2 3 5 kg 31 CHASSIS 7 14 1 7 14 2 CHASSIS When remounting the clutch lever holder align the holder snating surface with punch mark on the handlebar Clutch lever holder Handlebar When remounting the front brake master cylinder onto the handlebar align the master cylinder holder s mating surface with punch mark 0 the 1 handlebar and tighten the upper clamp bolt first as shown Handlebar WARNING Bleed air from the brake fluid circuit after cylinder holder assembling master cylinder Refer
10. inner RH D Air duct cowling LH Meter panel a Body side cowling lower RH a Body center lower cowling side cowling RH a side cowling lower LH side cowling LH D Airduct cowling RH 27 7 1 5 CHASSIS ST REMOVAL Remove the body cowling screw at the rightside Remove the body cowling screw at the leftside Remove the two cowling brace bolts Remove the speedometer lead wire and head lamp lead wire 5 REMOUNTING Tighten the two cowling brace bolts V Cowling brace bolt 22 35 2 2 3 5 kg 28 CHASSIS 7 13 1 6 dees e Standad type Refer to the service manual 99000 94810 page 7 13 14 O 220200207650 Sports type amp 22772670205 1 Handlebar composition RH 3 Rear view mirror assembly RH Handlebar switch assembly RH 2 Handlebar composition LH 4 Rear view mirror assembly LH Handlebar switch assembly LH HANDLEBAR RIGHT SIDE PARTS REMOVAL Remove the right handlebar switches Disconnect the brake lamp switch lead wires and remove the master cylinder Refer to the service manual amp zzzzezese 99000 94810 page 7 10 Remove the handlebar balancer 7 and grip 29 7 13 2 CHASSIS HANDLEBAR LEFT SIDE PARTS REMOVAL Remove the left handlebar switches Remove the handlebar balancer and grip Remove the clutch lever holder Loosen the handlebar clamp
11. HVH 0700 0760 e 1 _ 0760 QV3183 13AOQ33d 38011 Im oi S 01906 81996 RM WE ur D ISNA SSANYVH Y MWS 8015 d 60771 00760 1 0 L 2060 LINN 9 FIGVO 8 318V9 L MWS 015 28 HLHV3 diAV 19 9NIQTJM 20000 80760 0751 YOLOW dWY19 EN DM LINN TOH LNOO 3S1nd V3 SIS 1 Jeplo y 0 WS 4015 SSANYVH 60 0 60 WS 4015 FILLOYHL ASSY 318VO NYNLSY 31LLOHHI ASSY 318 0 056dH00989 d3ddn 1 4 3SCH 0 40 Lv CARBURETOR 55 58410 920 CABLE COMP STARTER 96 8 NOILVINHO3NI 5 8 25 2 SERVICING INFORMATION CD 225 09407 22402 CD ei 72 Slo co 82 lt lt O lt lt 9 2 2 Olio lt lt WIRING HARNESS WELDING CLAMP 09407 14403 HARNESS SPEED SENSOR 09407 254A1 09407 14403 FUSE Y FUSE 15A ut AC 2 ees 2 oC ei 07 p S 27
12. Stroke 62 0 mm 2 44 in Piston displacement Carburetor BDSR39 TYPE DOUBLE lt Starter system 647 39 5 in Electric starter Lubrication system TRANSMISSION Clutch Wet sump COPAS BB s Standard type Wet multi plate type a SL lt SC lt Ss Da c Sport type Transmission 6 speed constant mesh Gearshift pattern Final reduction 2 93 lt Gear ratio 1st 1 down 5 up 2nd 3rd Drive chain RK525XSO 108 links ____ ___ 1 9 GENERAL INFORMATION CHASSIS COS COLOLECSOS ITEM Standard type Sport type CUNA FZ Front suspension Telescopic type Rear suspension Swingarm type Steering angle 27 right amp left Caster 25 5 74 mm 2 91 in Front brake Double disk brake Rear brake Disk brake Front tire size 120 60 ZR 17 55W Rear tire size 160 60 ZR 17 69W Front fork stroke 120 mm 4 72 in ELECTRICAL COLLIE B c COLLIE BB c ITEM Standard type Sport type Ignition type Igniter type Ignition timing 5 B T D C at 1 500 rpm Spark plug CR8E Battery 12V 12Ah MF 30 A il Head lamp 12V H1 55W 1 12V 55W x 1 Turn signal lamp 12V 10W x 4 Head lamp Brake Tail lamp 12V 21 5W x 1 Illumination lamp 12V 1 7W x 2 e lamp 12V x 1
13. WNHOJNI SNIJIAH3S d HYOSUNG MOTORS amp MACHINERY INC 1st Ed APR 2005 Manual No 99000 94910 Printed in Korea
14. ehicle exactly in detail WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG 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 HYOSUNG MOTORS 8 MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 2005 Standard type Difference between photographs actual motorcycles depends on the markets HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections are listed on the previous page as GROUP INDEX select the section where you look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents 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 Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUPER GREASE Apply SUPER GREASE C Apply SILICONE GREASE Apply MOLY PASTE Apply BOND 1215 Use fo
15. ity between lead wires in the following illustration If the continuity measured incorrect replace the respective part Pocket tester 09900 25002 s CAUTION When making this test it is not necessary to remove the combination meter 21 6 17 2 ELECTRICAL SYSTEM amp 00000000 ol gt 1 DISPLAY VFD 12V 1 7W T6 5 N dWV1IGVSH M HEAD 1 22 5515 CONTENTS EXTERIOR ET 24 7 1 1 29 7 13 1 STEER NO E 33 7 23 23 7 1 1 CHASSIS EXTERIOR PARTS REAR CARRIER REMOVAL Open the rear seat with the ignition key Remove the rear carrier mounting bolts 0 and separate the rear carrier 2 INSTALLATION Reassemble the rear carrier in the reverse order of removal To reinstall the rear seat slide the seat hook into the seat hook retainer and push down firmly until the seat Snaps into the locked position 24 5515 7 1 2 3 Under center cowling 4 Under center cowling grill UNDER COWLING 1 Under cowling RH 2 Under cowling LH 25 7 1 3 CHASSIS REMOVAL Remove under cowling screws at the rightside Remove the under cowling screws at the leftside 26 5515 7 1 4 BODY COWLING a Windscreen Body side cowling
16. m This can be done with a chisel Draw out the two inner races fitted to the top and bottom ends of the head pipe 34 i i L L a a a rmm CHASSIS 7 25 1 INSPECTION Inspect and check the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear Abnormality operation of bearing Worn or damaged races Distortion of steering stem 6 REASSEMBLY and remount the steering stem in the reverse order of disassembly and removal and also carry out the following steps Apply SUPER GREASE Ai to the upper bearing and lower bearing 1 AH SUPER GREASE Tighten the steering stem nut 2 with the special tool Clamp wrench 09940 10122 9 Steering stem nut 80 100 N m 8 0 10 0 kg m Turn the steering stem right and left lock to lock five or six times Tighten the steering stem head nut 3 to the specified torque 9 Steering stem head nut 80 100 8 0 10 0 kg A CAUTION After performing the adjustment and installing the steering 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 stem nut 35 7 25 2 CHASSIS Tighten the handlebar clamp bolts right and left Q Handlebar clamp bolts 22 35 2 2
17. oltage The range of measurement adjust X 1 0 unit 910 Pocket Tester 09900 25002 Unit KQ 4 TESTER PROBE OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 22 4 33 6 x 29 5445 34 6 x 6 4 9 6 20 4 30 6 OFF OFF 50 5 75 5 48 72 bem se sa oF pen em er e me enm pem pen ne ae ra 170 260 180 270 5 e erue s oF ae 170 250 150 230 150 230 150 230 150 230 170260 165 245 1467219 4 7 3 5 ELECTRICAL SYSTEM 6 16 1 LAMP 6 HEAD LAMP REPLACEMENT OF HEAD LAMP BULB Remove the under cowling Refer to page 7 1 2 3 Remove the body cowling Refer to page 7 1 4 5 Remove the head lamp coupler Remove the dust cover 3 19 6 16 2 ELECTRICAL SYSTEM Remove the socket spring Remove the bulb and replace the new bulb Remove the head lamp HI bulb with the same manner of the head lamp LOW bulb removal Reinstall the head lamp bulb in the reverse order head lamp bulb removal 20 ELECTRICAL SYSTEM 6 17 1 COMBINATION METER Remove the combination meter Disassemble the combination meter as shown in the illustration m INSPECTION Using the pocket tester check the continu
18. rk Apply THREAD LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Use engine coolant GENERAL INFORMATION CONTENTS EXTERIOR ILLUSTRATION GDECIEICA __________ 1 7 1 GENERAL INFORMATION EXTERIOR ILLUSTRATION 5 Standard type Turn signal lamp Rear Tail Brake lamp Rear reflector S License plate lamp A 1 A A 1 T H 28 S SIS Sk 2 Y Y Head lamp Turn signal lamp Front A 2 jm Passenger footrests SEY RSS 1 A Y AF LLI lo 9 e v 4 i ARS ZO 92 Y 1 435 WHEEL BASE 330 2 060 LENGTH GENERAL INFORMATION 1 7 2 EXTERIOR ILLUSTRATION lt Sports Turn signal lamp Rear Tail Brake lamp Rear reflector License plate lamp A 1 785 810 880 510 655 WIDTH 710 790 KOR Turn signal lamp Front Passenger footrests ZACB ES VAS N AO VE LATAS RU CR CA A
19. to the service manual czzzezz 99000 94810 page 2 17 Apply SUPER GREASE A to the throttle cables A SUPER GREASE Ai Throttle grip e Install the throttle cable and returning cable to the throttle grip CD 1 Throttle cable 2 Returning cable Returning cable Throttle Rotation cable direction 32 5515 7 23 STEERING 6 2207227650 Standad type Refer to the service manual 12222220 99000 94810 7 23 25 5 Sports type amp COA EOR REMOVAL AND DISASSEMBLY Remove the under cowling and body cowling Camzateso Refer to page 7 1 2 5 Remove the body cowling Czzzzezesa Refer to page 7 1 4 5 Take off the front wheel gt Refer to the service manual amp zzzzezese 99000 94810 page 7 2 Remove the four bolts and front fender Take off the front fork Refer to the service manual 99000 94810 page 7 16 33 7 24 CHASSIS Remove the handlebar clamp bolts Remove the steering stem head nut 0 and take off the steering stem upper bracket 2 Remove the steering stem nut 3 and draw out the steering stem Clamp wrench 09940 10122 off the steering stem lower bracket 4 CAUTION Hold the steering stem lower bracket by hand to prevent from falling Remove the upper and lower bearings 5 Remove the outer race fitted on the steering ste
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