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TE 50 - Hyosung Motors America

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1. MB H8 M8 1 1 515 m 540 30 NO No SSY WS 8 A SSY M S TO ANS NOLLINDI YOLVINDAY HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department 1st Ed MAR 2001 Manual No 99000 93110 Printed in Korea
2. V Spark plug 25 30 m 2 5 3 0 kg m CAUTION To check the spark plug first make sure that the fuel used is unleaded gasoline and if plug is either sooty with carbon or burnt white replace it Confirm the thread size and reach when replac ing the plug 0 6 0 7 mm 0 024 0 028 in CARBURETOR NOTE Inspect Initial 1 month and Every 6 months 9 IDLE SPEED Adjust the throttle cable play Warm the engine up NOTE A warm engine means an engine has been run for 10 minutes Remove the seat and cover Adjust the throttle stop screw 0 to obtain the idle speed as follows Engine tachometer 09900 26006 PERIODIC MAINTENANCE 2 6 Engine idle speed 1 800 50 rpm Finally adjust the throttle cable play THROTTLE CABLE PLAY Loosen the lock nut 2 and adjust the cable slack by turning adjuster 3 in or out to obtain the following cable play After adjusting play tighten the lock nut 0 5 1 0 mm Throttle cable slack 0 020 0 039 in FUEL LINE NOTE Inspect Initial 1 month and Every 3 months Replace every 4 years Inspect leakage of the fuel line and connection part If abnormal replace it 2 7 PERIODIC MAINTENANCE TRANSMISSION OIL NOTE Inspect Initial 1 month and Every 6 months After a long period of use the transmission
3. Remove the brake cam lever Remove the front brake plate 6 3 CHASSIS INSPECTION AND DISASSEMBLY 9 WHEEL HUB BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel hub Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly Replace the bearing if there is anything unusual Remove the spacer Remove the inner and outer dust seals with the spe cial tool Oil seal remover 09913 50121 CAUTION The removed dust seal should be replaced with new ones Drive out the both bearings with the special tool in the following procedures Wheel bearing remover 09941 50111 Insert the adapter into the bearing After inserting the wedge bar from the opposite side lock the wedge bar in the slit of the adapter Drive out the bearing by knocking the wedge bar CAUTION The removed bearing should be replaced with new one 9 TIRE Refer to page 2 11 9 BRAKE DRUM Measure the brake drum 1 0 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 Service limit 110 7 mm 4 358 in Brake drum AN 555 9 BRAKE SHOE Check the brake shoe and decide whether it should be replac
4. ASSEMBLING APPLY GREASE BRAKE PAD REPLACEMENT For replacing procedure 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 CHASSIS 6 14 Remove the rear caliper lever return spring o DISC PLATE INSPECTION Check the disc for wear with a micrometer Replace the disc if the thickness exceeds the service limit Service limit 2 5 mm 0 098 in Micrometer 0 25mm 09900 20201 Check the disc for face runout with a dial gauge as shown Replace the disc if the runout exceeds the service limit Service limit 0 3 mm 0 012 in Dial gauge 09900 20606 Magnetic stand 09900 20701 CALIPER REASSEMBLY Reassemble and remount the caliper in the reverse order of removal and disassembly and also carry out the following steps Tighten the brake lever bolt and caliper mounting bolts 2 to the specified torque SPECIFIED TORQUE Rear brake lever bolt 6 8 0 6 0 8 Rear brake caliper 5 7 0 5 0 7 mounting bolt 6 15 CHASSIS REAR AXLE HOUSING AXLE SHAFT AND SHOCK ABSORBER TIGHTENING TORQUE 6 ASSEMBLING APPLY GREASE REMOVAL Remove the rear wheel Refer to page 6 12 Remove the rear brake Refer to page 6 13 Remove the c
5. Bearing installer 09913 76010 Apply SUPER GREASE to the lip of the oil seal and install it to the gear box cover with the spe cial tool Super Grease A Bearing installer 09913 70122 ENGINE 3 28 Oil seal Align face 3 29 ENGINE Install the washer new gasket and dowel pin Install the driveshaft 2 to the gear box cover Apply BOND 1215 at the hatched area shown in the illustration and install the gear box cover 3 on the crankcase 125 BOND 1215 Tighten all the screws evenly one by one in a diago nal fashion ENGINE 3 30 STARTER DRIVEN GEAR AND STARTER MOTOR 6 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 motor 3 31 MOVABLE DRIVEN AND CLUTCH Install the bearing 2 in the fixed driven face D with the special tool Bearing installer 09943 88211 Install the circlip CAUTION ENGINE 3 32 Insert surely in the circlip groove Install the bearing 2 with the special tool Bearing installer 09943 88211 A CAUTION Rounded coner A mark part of the bearing is pointed to the outside Install t
6. 7 19 SERVICING INFORMATION HOLIMS 401 H1 H LIMS HO LIMS 3015 HV3H H1HOLIAS 0vVvL Z0vV60 HOLIMS dOLS LNOYS 0brtL Z20v60 SERVICING INFORMATION 7 20 Jeoe4 pe g YPM SIIUA YM MI IUM M eng 1 AUM pes qs 19 JUM usan 9 4302 SUM 49028 USAID 9g U99JC YUM MOI 9A Jooenxoelg pod gH A 0140 1 64 TAMA rao 42 HTHOLIMS 18915 9015 3NION3 15 T O1O HIHV33NION3 18915 7M 0 MH DA 0 1 5 B Abi vli dii 1 HUM gt A m asna gt DA 0 VOL WIRING DIAGRAM AJNJOHIWI SSV H LIMS as 4 I ug 4 4 4 4
7. 0 5A X 5 hours 5A X 30 minutes CONTENTS FRONT WHEEL AND BRAKE REMOVAL 222272727272727 22727772722777727722 INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNT ING STEERING AND FRONT SUSPENSION REMOVAL AND DISASSEMBLY INSPECTION REASSEMBLY AND REMOUNTING TOE IN ADJUSTMENT tte s cute quac Lp uta REAR WHEEL ultus REMOVAL diode Kangan Ua der Eu INSPECTION EO S i S AGA Nm PEMOUNTING EA BRAKE PAD REPLACEMENT CALIPER DISASSEMBLY rotten tna gana angen gana agi an rana DISC PLATE INSPECTION GANS iiu UND ped CALIPER REASSEMBLYV eain vu qct rte ics tiM REAR AXLE HOUSING AXLE SHAFT AND SHOCK ABSORBER REMOVAL a abane ana a naba aa aana INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING 6 1 CHASSIS FRONT WHEEL AND BRAKE Op 7 2 is lt E dio 96 O gt CHASSIS 6 2 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 Remove the brake shoe
8. ONNSOAH HYOSUNG HYOSUNG MOTORS amp MACHINERY INC You SERVICE MANUAL 99000 93110 FOREWORD This manual contains an introductory description on HYOSUNG WOW50 1 and procedures for its inspection Iservice and overhaul of its main components Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared on the basis of the latest specification at the time of publica tion If modification has been made since then dif ference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of operation and work proce dures They may not represent the actual vehicle exactly in detail lt 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 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE FUEL SYSTEM 4 SERVICI
9. measure the resistance between the terminals as shown in the fol D 3 4 lowing table If the resistance checked is incorrect replace the regulator rectifier Pocket tester 09900 25002 c3 Unit Q Probe of tester to 3 E D STARTER SYSTEM The starter system is shown in the diagram below namely the starting motor starter relay starter switch and battery Depressing the starter switch on the left handlebar switch box while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the starting motor to the battery Starter relay RW IG switch Starter switch N Point Starter motor Brake switch B W Battery Ha I ELECTRICAL SYSTEM 5 4 STARTING MOTOR REMOVAL AND DISASSEMBLY Remove the starting motor Disassemble the starting motor as shown in the illustration STARTING MOTOR INSPECTION 9 CARBON BRUSHES When the 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 Service limit Carbon brushes wear 4 0 mm 0 158 in 9 COMMUTATOR If the commutator surface is dirty starting performance will decre
10. 4 Clogged jets in carburetor Clean 5 Clogged exhaust pipe Clean Noisy engine Noise appears to come from piston 1 Piston or cylinder worn down Replace 2 Combustion chamber fouled with carbon Clean 3 Piston pin bearing or piston pin bore worn Replace 4 Piston rings or ring grooves worn Replace Noise seems to come from crankshaft 1 Worn or brunt crankshaft bearings Replace 2 Worn or brunt conrod big end bearings Replace Noise seems to come from final gear box 1 Gears worn or rubbing Replace 2 Badly worn splines Replace 3 Worn or damaged bearings of drive shaft for rear axle shaft Replace Slipping clutch 1 Worn or damaged clutch shoes Replace 2 Worn clutch drum Replace Engine idles 1 Excessively worn cylinder or piston rings Replace poorly 2 Stiff piston ring in place Replace 3 Gas leaks from crankshaft oil seal Replace 4 Spark plug gaps too wide Adjust or replace 5 Defective CDI amp Ignition coil unit Replace 6 Defective magneto stator coil Replace T Float chamber fuel level out of adjustment in carburetor Replace 8 Clogged jets in carburetor Clean or adjust 9 Broken or damaged reed valve Replace SERVICING INFORMATION 7 2 Complaint Symptom and possible causes Engine runs poorly in high speed range 1 Excessively worn cylinder or piston rings 2 Stiff piston ring in place 3 Spark plug gaps to narrow 4 Ignition not advanced sufficiently due t
11. Make sure that air bubbles are coming up each elec trolyte container and keep this position for about more than 20 minutes CAUTION If no air bubbles are coming up from a filler port tap the buttom of the two or three times Air bubble 5 9 ELECTRICAL SYSTEM 5 Separation of electrolyte container After confirming that you entered the electrolyte into bat tery completely remove the electrolyte containers from the battery CAUTION Draw the empty receptacle out slowly because there may be a chance which remaining elec trolyte vaporize 6 Insert of the caps Insert the cap into the filler holes pressing it firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover ASSISTANCE RECHARGING Use the battery that is maded 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 except the right side table In times of recharging the battery please do it at the condition of removal of the lead wire A WARNING The firearm is strictly prohibited Insert the caps firmly Assistance Recharging Standard
12. Rear brake lever blot 6 8 0 6 0 8 Rear brake disc bolt 22 35 22 35 Rear brake caliper mounting bolt 5 7 0 5 0 7 Front axle nut M14 50 80 5 0 8 0 Handlebar holder bolt 18 4 28 6 1 84 2 86 Tie rod lock nut 22 4 35 7 2 24 3 57 Steering shaft bolt M8 18 28 1 8 2 8 Steering shaft lower nut 22 4 35 7 2 24 3 57 TIGHTENING TORQUE CHART For other bolts and nuts who s torque is not listed refer to this chart Conventional or 4 marked bolt 7 marked bolt Bolt Diameter mm N m kg m N m kg 1 0 2 0 0 1 0 2 1 5 3 0 0 15 0 3 2 0 4 0 0 2 0 4 3 0 6 0 0 3 0 6 4 0 7 0 0 4 0 7 8 0 12 0 0 8 1 2 10 0 16 0 1 0 1 6 18 0 28 0 1 8 2 8 22 0 35 0 2 2 3 5 40 0 60 0 4 0 6 0 35 0 55 0 3 5 5 5 70 0 100 0 7 0 10 0 50 0 80 0 5 0 8 0 110 0 160 0 11 0 16 0 80 0 130 0 8 0 13 0 170 0 250 0 17 0 25 0 130 0 190 0 13 0 19 0 200 0 280 0 20 0 28 0 SERVICE DATA SERVICING INFORMATION 7 10 CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm in LIMIT Cylinder to piston clearance 0 065 0 075 0 0026 0 0030 0 120 0 0047 Cylinder bore 41 005 41 020 1 6144 1 6150 Measure at 20mm fr
13. Tire inflating pressure too high Adjust steering 2 Worn steering linkage connections Replace 3 Loose bolts on suspension system Retighten Rapid wear or 1 Worn or loosen wheel hub bearing Replace uneven wear of tires 2 Desturbed front wheel alignement Adjust Steering noise 1 Loose bolt and nut Retighten 2 Broken or otherwise damaged wheel hub bearing Replace 3 Poorly lubricated Lubricate Front suspension 1 Weakened spring Replace too soft 2 Oil leakage of shock absorber Replace Front suspension 1 Worn wishbone arm related bushing Replace too shift Noisy suspension 1 Loose bolt on suspension system Retighten 2 Worn wishbone arm related bushing Replace Rear wheel 1 Worn or loose rear axle housing bearing Replace oscillation 2 Defective or incorrect tire Replace 3 Distorted wheel rim Replace 4 Loose nut on wheel hub Retighten 5 Loose nut on axle shaft Retighten Rear suspension 1 Weakened spring Replace too soft 2 Rear shock absorber spring improperly set Reset 3 Oil leakage of rear shock absorber Replace Rear suspension 1 Rear shock absorber spring improperly set Adjust too stiff 2 Shock absorber shaft bent Replace 3 Swingarm bent Replace 4 Worn swingarm related bearing Replace Poor braking 1 Lining worn down Replace Too much play on brake lever and pedal Adjust 7 5 SERVICING INFORMATION SPECIAL TOOLS Special tools Part Number Part Na
14. available select an alternative according to the following chart MULTIGRADE 10W 40 10W 50 10W 30 30 20 10 0 10 20 30 40 TEMP F 22 4 14 32 50 68 86 104 GENERAL INFORMATION 1 6 EXTERIOR ILLUSTRATION SPECIFICATIONS DIMENSIONS AND length Overall width Overall height Wheelbase Ground clearance Front track Rear track Mass DRY MASS ENGINE Type Intake system X Number of cylinder Bore x Stroke Piston displacement Corrected compression ratio Carburetor Air cleaner TRANSMISSION Clutch Reduction ratio Drive system CHASSIS Steering angle Trail Turning radius Toe in Camber angle Caster angle menm Front brake Rear brake Front tire size Rear tire size ELECTRICAL Ignition type Ignition timing Spark plug CAPACITIES Fuel tank Engine oil tank Transmission oil NOTE These specifications are subject to change without notice GENERAL INFORMATION 1 7 1 250 mm 49 2 in 780 mm 30 7 in 825 mm 32 5 in 915 mm 36 0 in 80 mm 3 2 in 630 mm 24 8 in 630 mm 24 8 in 85 kg 187 5 Ibs Two stroke forced air cooled Reed valve 1 41 0 mm 1 61 in X 37 4 mm 1 47 in 49 3 9 cu in 74 1 Piston valve Polyurethane foam element Dry shoe automatic centrifugal type 2 818 0 87
15. mm in Except ratio ITEM STANDARD LIMIT Final reduction ratio 1 33 Gear ratio 2 818 0 870 1 16 5 0 6 153 PING DOE 06496 0 024 0 6023 8 0 0 6 110 0 Movable drive face spring free length 4 331 Type SLC 428H Drive chain Links 50 20 pitch length 259 10 197 Drive chain slack 5 15 0 197 0 591 over 15 over 0 591 SERVICING INFORMATION 7 12 CARBURETOR Unit mm in ITEM SPECIFICATION Carburetor type PISTON VALVE Bore size o 14 10 No HK31 Idle rpm 1 800 50 rpm Fuel level 16 Main jet JJ 75 Main air jet AJ 2 0 Jet needle N J68A 2 Needle jet J N 2 1 Pilot air jet P A J 3 0 Pilot jet P J 35 Throttle valve 83 5 By pass B P 0 8 Valve seat V S 1 4 Starter jet G S 45 Pilot screw 5 2 0 Pilot outlet 0 8 Throttle cable play 0 5 1 0 0 020 0 039 7 13 SERVICING INFORMATION ELECTRICAL Unit mm in ITEM SPECIFICATION NOTE Ignition timing B T D C 23 at 4 000 rpm Type BPR6HS Spark plu Ca 0 6 0 7 0 024 0 028 Hottype BPR5HS Standard type BPR6HS Cold type BPR7HS Spark performance Over 8 0 3 at 1 atm Ignition coil resistance pimay Secondary 54 6 6 kQ Magneto coil resistance Exciting 220 260 B R Ground Regulated volta
16. one ENGINE 3 20 Service limit Cylinder bore 41 070 mm 1 617 in Cylinder gauge set 09900 20508 After reworking the bore to an oversize be sure to chamfer the edges of ports and smooth the chamfered edges with emery paper To chamfer use a scraper taking care not to nick the wall surface PISTON CYLINDER TO PISTON CLEARANCE Cylinder to piston clearance is the difference between piston diameter and cylinder bore diameter Be sure to take the maked diameter at right angles to the piston pin The value of elevation is prescribed to be 15mm from the skirt end Micrometer 20 50mm 09900 20202 Service limit Piston diameter 40 885 mm 1 610 in 3 21 As a result of the above measurement if the piston to cylinder clearance exceeds the following limit overhaul the cylinder and use an oversize piston or replace both cylinder and piston The measurement for the bore diameter should be taken in the intake to exhaust port direction and at 20mm from cylinder top surface Standard Service limit 41 005 41 020 41 070mm 1 6144 1 6150 in 1 6169 in Cylinder bore 40 935 40 950mm 40 885 Piston diameter 1 6116 1 6122 in 1 6097 in 0 065 0 075mm 0 120mm clearance 0 0026 0 0030 in 0 0047 in DE CARBONING De carbon the piston and piston ring grooves as illu
17. 0 SLC 428H 50 links 37 5 right amp left 8 5 mm 0 335 in 2 450 mm 96 46 in 6 mm 0 236 in 1 3 Drum Disk 145 70 6 x 2 145 70 6 x 2 HYOSUNG CDI 23 B T D C at 4 000 rpm BPR6HS 41 12 80 m Replace 90 m Overhaul PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE Rea reer errr er cen IHRE HERR PEOR tree MAINTENANCE PROCEDURES cue RENE CYLINDER HEAD AND CYLINDER SPARK PLUG CARBURETOR FUEL LINE gt aana aaa TRANSMISSION BREAKS 2 1 PERIODIC MAINTENANCE 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 CAUTION More frequent servicing should be performed on vehicles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE item Initial 1 month Every 3 months Every 6 months page Air cleaner element Clean at least every month 2 3 Cylinder head nuts Tighten Tighten 2 4 Cylinder head and cylinder Remove carbon 2 4 Carburetor Inspect Inspect 2 6 Spark plug Clean Clean Replace 2 5 Inspect Inspect Replace every 4 years dn Transmission oil Inspe
18. 8 12 N m 0 8 1 2 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 the flow of exhaust gases reducing the output Remove carbon deposits periodically PERIODIC MAINTENANCE 2 4 2 5 PERIODIC MAINTENANCE SPARK PLUG NOTE Inspect Initial 1 month and Every 3 months Replace Every 6 months Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance If the spark plug is used for a long period the electrode grad ually burns away and carbon builds up along the inside part In accordance with the Periodic Inspection Chart the plug should be removed for inspection cleaning and to reset the gap Carbon deposits on the spark plug will prevent good sparking and cause misfiring Clean the deposits off periodically 6 the center electrode is fairly worn down the plug should be replaced and the plug gap set to the speci fied gap using a thickness gauge Thickness gauge 09900 20804 0 6 0 7 mm Spark plug gap 0 024 0 028 in au Check spark plug for burnt condition If abnormal replace the plug as indicated below TYPE SPARK PLUG SPECIFICATION Hot type BPR5HS Standard type BPR6HS Cold type BPR7HS
19. E VALVE INSPECTION If foreign matter is caught between the valve seat and the needle the gasoline will continue flowing 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 FUEL SYSTEM 4 4 Inspect the valve surface for worn N Foreign matter 4 5 FUEL SYSTEM REASSEMBLY AND REMOUNTING Reassemble following items Pilot air screw 2 Throttle stop screw 3 Main jet 4 Needle jet Install the needle valve and float on the carbu retor body Install the float pin and tightened the screw Install the gasket and float chamber Install the thermoelement assembly E later i emi FUEL SYSTEM 4 6 Install the carburetor assembly Install the fuel hose Install the carburetor top cap WMD S 4 7 FUEL SYSTEM FUEL TANK REMOVAL Remove the frame covers Refer to page 4 1 Remove the fuel tank mounting bolts Turn the fuel cock to OFF and disconnect the fuel hose D Remove the fue
20. EINSTALLATION For remounting engine reverse the order of engine removal and take the following additional steps Install the engine mounting bolts Refer to page 3 3 V Engine mounting bolt 40 60 4 0 6 0kg m Install 90ml of transmission oil SAE 10W 40 multi grade motor oil when engine is overhauled check the oil level Transmission oil capacity 90 ml when overhauling engine 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 adjust the fol lowing items to the specification 4 Throttle cable e e Idling adjustment lt Front brake cable lt Rear brake cable Refer to page 2 Refer to page 2 Refer to page 2 Refer to page 2 Refer to page 2 1 ON DD ENGINE DISASSEMBLY 9 MUFFLER Remove the muffler removing the bolts 9 CYLINDER Remove the cylinder cowling Remove the cylinder head and cylinder ENGINE 3 6 PISTON Place a cloth beneath the piston and remove the pis ton pin circlip 3 with a long nose pliers Remove the piston pin and piston Remove the piston pin bearing 6 3 7 ENGINE MAGNETO Remove the cooling fan Remove the magneto rotor nut with the special tool Conrod hol
21. GINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame thoroughly clean the engine with a suitable cleaner and drain trans mission oil etc The procedure of engine removal is sequentially explained 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 muffler and exhaust pipe Remove the air cleaner and air cleaner chamber Refer to page 2 3 ENGINE 3 2 Remove the engine ground lead wire Remove the spark plug cap 2 Remove the starter motor lead wire 3 Disconnect magneto coil lead wire 0 3 3 ENGINE Remove the carburetor assembly and intake manifold from the crankcase Disconnect the oil hose from the oil pump Remove the chain case cover Remove the engine sproket from the drive shaft by using the snap ring pliers Remove the drive chain Remove the six engine mounting bolts Remove the engine assembly from the frame with rear axle housing assembly ENGINE 3 4 3 5 ENGINE ENGINE R
22. ION 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 lt 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 is forced outdoors lt 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 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 GENERAL INFORMATION 1 2 CAUTION lt If parts replacement is necessary replace the parts with HYOSUNG Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation lt Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean and also lubricate
23. NG INFORMATION HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 2001 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 are 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 SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque z w Apply THREAD LOCK 1324 Apply oil Use engine oil unless otherwise specified E gt Apply or use brake fluid Apply SUPER GREASE jm Measure in voltage range Apply SUPER GREASE Measure in resistance range Apply SILICONE GREASE a EX Measure in current range Apply MOLY PASTE Use special tool 18088 48 1215 COMPONENT PARTS AND WORK TO DONE Under the name of each system or unit its exploded view is provided with work instru
24. ON Inside lock nuts are left hand thread Measure the distances A and B of front wheels in illustation and adjust the tie rods right and left to within the specified range NOTE A B Toe in Sm 02861 Temporarily tighten the four lock nuts Check that the distances C and D in 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 6 If the toe in is not within specification repeat the adjustment as above until proper toe in value is obtained and at the same time the distances C and D become equal Tighten the four nuts after adjustment of toe in is made V Tie rod lock nut 224 357 2 24 3 57 kg m CHASSIS 6 12 REAR WHEEL TIGHTENING TORQUE 60 90 6 0 9 0 20 30 22 35 22 35 2 2 3 5 120 150 12 0 15 0 6 ASSEMBLING APPLY GREASE ASSEMBLING APPLY LOCK TIGHT REMOVAL Place the vehicle on level ground Support the vehicle by jack or block Romove the wheel center cap Romove the cotter pin and rear hub nut INSPECTION 9 TIRE Refer to page 2 11 REMOUNTING Remount the rear wheel in the reverse order of removal 6 13 CHASSIS REAR BRAKE 0 ic t e TIGHTENING TORQUE
25. ON CONTENTS TROUBLESHOOTING SPECIAL TOOLS scan DA UN MEI NER M UAM TIGHTENING TORQUE SERVICE DATA aga aa ies WIRE AND CABLE ROUTING e ane ana anana ene nenen eee WIRING DIAGRAM M mH mmm mmn 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine does not start or is hard to start Compression too low 1 Excessively worn cylinder or piston rings 2 Stiff piston ring in place 3 Gas leaks from the joint in crankcase cylinder or cylinder head 4 Damaged reed valve 5 Spark plug too loose 6 Broken cracked or otherwise failed piston Plug not sparking 1 Damaged spark plug or spark plug cap 2 Dirty or wet spark plug 3 Defective CDI amp Ignition coil unit or stator coil 4 Open or short in high tension cord 5 Defective ignition switch No fuel reaching the carburetor 1 Clogged hole in the fuel tank cap 2 Clogged or defective fuel cock 3 Defective carburetor float valve 4 Clogged fuel hose or defective vacuum hose Replace Refair or replace Refair or replace Replace Tighten Replace Replace Clean and dry Replace Replace Replace Clean Clean or replace Replace Clean or replace Engine stalls 1 Carbon deposited on the spark plug Clean easily 2 Defective CDI amp Ignition coil unit Replace 3 Clogged fuel hose Clean
26. OVAL AND DISASSEMBLY Remove the front fender Remove the front wheel and brake Refer to page 6 2 Remove the tie rod end nut Remove the steering knuckle 6 7 CHASSIS 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 PPR ECan CHASSIS 6 8 Remove handlebar switch Remove the throttle lever case Remove the brake lever holder Remove the front brake cables Remove the steering head cover bracket and handle bar by removing the mounting bolts Remove tie rods by removing the cotter pins and nuts Remove the cotter pin and steering shaft lower nut CAUTION The removed cotter pins should be replaced with new ones 6 9 CHASSIS Separate the tie rod ends nuts 3 and steering tie rods 9 CAUTION Inside lock nuts 2 left hand thread Remove the cotter pins and remove the steering shaft holder bolts Remove the steering shaft holders and steering shaft INSPECTION Inspect the removed parts for the following abnormali ties Handlebar distortion Handlebar clamp wear 9 DUST SEAL Inspect the dust seals for damage 9 TIE ROD Ins
27. Piston ring clearance Service limit Assembly condition 0 75 mm 0 030 in As the piston ring wears its clearance increases reduc ing engine power output because of the resultant blow by through the enlarged clearance Here lies the impor tance of using piston rings with the clearance within the limit Measure the piston ring free clearance to check the spring tension Piston ring claerance Free condition Service limit 1st 3 2 mm 0 126 in 3 1 mm 0 122 in 3 23 ENGINE Fix the piston ring in the piston ring groove measure the ring side clearance with the thickness gauge while matching the sliding surfaces of piston and ring Piston ring clearance Standard 0 02 0 06 mm in 0 0008 0 0024 in 0 02 0 06 mm 0 0008 0 0024 in REED VALVE When reinstalling the reed valve and stopper plate to the body align the both cut on the reed valve and stop per plate Apply THREAD LOCK 1324 to the stopper plate securing screws 4323 Thread Lock 1324 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 OIL SEALS Fit the oil seals to the crankcase following the proce dure below Replace removed oil seals with new
28. Use of improper spark plug 7 Clogged exhaust pipe muffler Symptom and possible causes Clean Replace or clean Adjust or replace Retighten or replace Change Change Clean or replace Remedy Trouble with starting 1 Starter jet is clogged 2 Air leaking from a joint between starter body and carburetor 3 Air leaking from carburetor s joint or vacuum hose joint 4 Starter plunger is not operating properly Clean Check starter body and carburetor for tightness and replace gasket Check and replace Check and replace Idling or low speed trouble 1 Pilot jet pilot air jet are clogged or loose 2 Air leaking from carburetor s joint vacuum pipe joint or starter 3 Pilot outlet is clogged 4 Starter plunger is not fully closed Check and clean Clean and replace Check and clean Check and replace Medium or high speed trouble 1 Main jet or main air jet is clogged 2 Needle jet is clogged 3 Fuel level is improperly set 4 Throttle valve is not operating properly 5 Fuel filter is clogged Check and clean Check and clean Check and replace Check throttle valve for operation Check and clean Overflow and fuel level fluctuations 1 Needle valve is worn or damaged 2 Spring in deedle valve is broken 3 Float is not working properly 4 Foreign matter has adhered to needle valve 5 Fuel level is too high or low Replace Replace Ch
29. ace Replace Replace the battery Magneto overcharges 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier unit poorly grounded Replace the battery Replace Clean and tighten groun connection Unstable charging 1 Lead wire insulation frayed due to vibration resulting in intermittent shorting 2 Magneto coil internally shorted 3 Defective regulator rectifier Repair or replace Replace Replace Starter switch is not effective BATTERY Complaint 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 6 Defective front or rear brake light switch circuit Symptom and possible causes Recharge or replace Replace Repair or replace Replace Replace Replace or repair Remedy Battery runs down quickly 1 The charging method is not correct 2 Cell plates have lost much of their active material as a result of over charging 3 A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte 4 Battery is too old Check the magneto and regulator rec tifier circuit connections and make necessary adjustments to obtain spe cified charging operation Replace the battery and correc
30. anged as set and never individually 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 Service limit Clutch housing 1 0 110 35 mm 4 344 in DRIVE V BELT Remove the drive V belt and check for cracks wear and separation Measure the belt width with a vernier calipers Replace it if the belt width is less than the ser vice limit or any defect has been found ENGINE 3 18 Service limit Drive V belt width 15 3 mm 0 602 in CAUTION Always keep the belt away from any greasy mater DRIVE FACE Inspect the belt contact surface of the drive faces for wear scratches or any abnormality If 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 Movable driven spring Standard free length 110 0 mm 4 331 in 110 0 mm 4 331 in 3 19 ENGINE ll DRIVEN FACE PIN AND OIL SEAL Turn the driven faces and check to see that the driven fac
31. arger Used to charge the dischared battery SERVICING INFORMATION 7 6 Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09910 20115 09913 76010 Conrod holder Bearing installer Used to lock the crankshaft Used to drive crankshaft bearing in 09910 32812 Crankshaft installer Used to install the crankshaft in the crankcase 09913 80112 Bearing installer Used to drive bearing in 09910 34510 Piston pin puller Use to remove the piston pin 09915 63310 Compression gauge adapter Used with compression gauge 09913 10760 Fuel level gauge Measure height of carburetor 09915 64510 Compression gauge Measure cylinder compression 09913 50121 Oil seal remover Used to remove the oil seal 09920 13120 Crankcase separater Separate to crankcase 09913 70122 Bearing installer Used to drive bearing in 09921 20200 Bearing remover 10mm Used to remove oil seal or bearing 09913 75520 Bearing installer Used to drive bearing in 09921 20210 Bearing remover 12mm Used to remove oil seal or bearing 09913 75820 Bearing installer Used to drive bearing in 09923 73210 Bearing remover 17mm Used to remove bearing with the rotor remove sliding shaft 09913 75830 Bearing installer Used to install rear axle shaft o
32. arts for tightness and operation 9 To protect environment do not unlawfully dispose of used motor oil and other fluids batteries and tires To protect Earth s natural resouces properly dispose of used vehicles and parts 1 3 GENERAL INFORMATION HYOSUNG 90000 NOTE Difference between photographs and actual vehicles depends on the markets GENERAL INFORMATION 1 4 SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number is stamped on the front frame member The engine seri al number is stamped on the left side of crankcase assembly These numbers are required especially for registering the machine and ordering spare parts 9 FRAME SERIAL NUMBER Y Km 5 Qi AES 22 an 17 rj p ak 1818 ELT a im 2 ggo 2 f ERE 9 ENGINE SERIAL NUMBER 1 5 GENERAL INFORMATION FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85 95 octane or higher An unleaded type gasoline is recommended If engine pinging is experiened 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 9 TRANSMISSION OIL Use a good quality SAE 10W 40 multigrade motor oil Classification system Grade 10W 40 9 If an SAE 10W 40 motor oil is not
33. ase Polish the commutator with 400 or simi lar fine emery paper when it is dirty After polishing wipe Segment the commutator with a clean dry cloth j Measure the commutator under cut Service limit Commutator under cut 0 2 mm 0 008 in 5 5 ELECTRICAL SYSTEM 9 ARMATURE COIL Using the pocket tester check the coil for open and ground by placing probe pins on each commutator seg ment and rotor core to test for ground and on any two segments at various places to test for open with the brushes lifted off the commutator surface If the coil is found to be open circuited or grounded replace the armature Continuous use of a defective armature will cause the starting motor to suddenly fail Pocket tester 09900 25002 STARTER RELAY INSPECTION Disconnect the starter relay lead wire coupler Check the coil for open ground and ohmic resis tance The coil is in good condition if the resistance is as follows Pocket tester 09900 25002 Standard 0 70 Q Starter relay standard resistance THERMOELEMENT RW Regurator Rectifier Magneto 9 INSPECTION Disconnect the thermoelement coupler Connect the thermoelement coupler to a 12V bat tery and touch the thermoelement 2 to check the temperature being raised The thermoelement should become heated to a temp
34. ause handling instability It is high ly recommended to use a HYOSUNG Genuine Tire COLD INFLATION TIRE PRESSURE kPa psi Front 25 025 36 Rear 25 0 25 3 6 TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dan gerous situation It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specifications Service limit 4 mm 0 16 in Front and rear tire tread depth PERIODIC MAINTENANCE 2 12 STEERING NOTE Inspect Initial 1 month and Every 3 months Steering system should be adjusted properly for smooth manipulation of handlebars and safe running TOE IN Place the vehicle on the level ground Make sure that the tire pressure is within speci fication Refer to page 2 11 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 and B 0 236 in 1 If the toe in is off the specification bring it into Forward the specified range Refer to page 6 11 CHASSIS BOLTS AND NUTS NOTE Tighten Initial 1 month and Every 3 months Check that all chassis bolts and nuts are tightened to their sp
35. ct E Inspect 2 T Drive chain Inspect and lubricate every month 2 10 Sprockets Inspect Inspect 6 17 CHASSIS Initial 1 month Every 3 months Every 6 months page Brakes Inspect Inspect 2 7 Steering Inspect Inspect 2 12 Tire Inspect every month Check pressure each time ride 2 11 Chassis bolts and nuts Tighten Tighten 2 12 General lubrication Lubricate 2 2 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 brake cable 2 Front wheel bearing Throttle cable 3 Steering shaft holder 9 Throttle lever 4 Rear brake cable Front brake cam shaft 5 Rear axle housing 6 Drive chain 9 Motor oil Grease NOTE lt Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime lt Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the vehicle has been operated under wet or rainy condition 2 3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES AIR CLEANER NOTE Clean at least Every month If the air cleaner is clogged with dust intake resis tance will increased with a resultant decrease in output and an increase in fuel consumption Check and clean the element in the following man ner Stand the vehicle in the sta
36. ct 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 Standard 3 600 rpm Tolerance 200 rpm Engine tachometer 09900 26006 2 CLUTCH TIGHT INSPECTION Grip the front and rear lever fully and measure the engine RPM when open the throttle Warm the engine to normal operating temperatures Connect an engine tachometer to the engine Apply the rear brake as firm as possible Briefly open the throttle fully and note the maximum engine RPMs sustained during the test cycle 3 17 ENGINE CAUTION Do not apply full power for more than 3 seconds damage to the clutch or engine may occur Standard 4 500 rpm Clutch tight RPM Tolerance 200 rpm Engine tachometer 09900 26006 If the engine RPM does not coincide with the specified RPM range then disassemble the clutch Clutch shoe inspect the shoes visually for chips cracking uneven wear and burning and check the thickness of the shoes with vernier calipers If the thickness is less than the following service limit replace them as a set Clutch springs visually inspect the clutch springs for stretched coils or broken coils Service limit Clutch shoe thick CAUTION Clutch shoes or springs must ch
37. ction and other service information such as the tightening torque lubricating points and looking agent points Example STEERING AND FRONT SUSPENSION TIGHTENING TORQUE kg 18 28 1 8 2 8 18 4 28 6 1 84 2 86 224 35 7 2 24 3 57 6 ASSEMBLING APPLY GREASE B ASSEMBLING APPLY GREASE O APPLY GREASE TO LIPS D APPLY GREASE ASSEMBLING APPLY GREASE GENERAL INFORMATION CONTENTS INFORMATION LABELS GENERAL PRECAUTIONS MM mmm SERIAL NUMBER LOCATION I HR Hmm FUEL AND OIL RECOMMENDATIONS EXTERIOR ILLUSTRATION SPECIFICATIONS eerte ti nter pe reet I eie 1 1 GENERAL INFORMATION 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 WARNING Indicates a potential hazard that could result in death or injury CAUTION 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 CAUT
38. d when specified lt When use of a certain type of lubricant bond or sealant is specified be sure to use the specified type When removing the battery disconnect the negative cable first and then positive cable When reconnect ing the battery connect the positive cable first and then negative cable and replace the terminal cover on the positive terminal lt When performing service to electrical parts if the service procedures do not require use of bat tery power diconnect the negative cable at the battery Tighten cylinder head and case 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 from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seat ed in its groove and securely fitted Do not use self locking nuts a few times over lt Use a torque wrench to tighten fasteners to the torque values when specified Wipe off grease or oil if a thread is smeared with them After reassembly check p
39. der 09910 20115 Remove the magneto rotor with the special tool Rotor remover sliding shaft 09930 30102 Rotor remover 09930 30163 Remove the magneto stator and key 9 REED VALVE Remove the intake pipe and reed valve 9 OIL PUMP Remove the oil pump Remove the oil pump driven gear 2 9 MOVABLE DRIVE FACE Remove the fixed drive face nut with the special tool CAUTION ENGINE 3 8 This nut has left hand thread Conrod holder 09910 20115 Remove the fixed drive face 2 and V belt 3 Disassemble the movable drive face 0 9 MOVABLE DRIVEN FACE Remove the clutch housing 5 with the special tool Rotor holder 09930 40113 9 STARTER DRIVEN GEAR Remove the starter driven gear 3 9 ENGINE Loosen the clutch shoe nut with the special tool Rotor holder 09930 40113 Remove the nut while holding down the clutch shoe assembly by both hands as shown in the illustration A WARNING Gradually back off the clutch shoe assembly pressed down by hand to counter the clutch spring load Releasing the hand suddenly may cause the parts to fly apart Nut 2 Clutch shoe assembly 3 Spring CAUTION Do not attempt to disassemble the clutch shoe assembly It is not serviceable Usi
40. e normal turning direction The V belt contact face on the driven faces should be thoroughly cleaned to be free from oil Thoroughly clean the clutch housing 2 to be free from oil and position it over the clutch shoe assem bly Tighten the clutch housing nut to the specified torque with the special tool Rotor holder 09930 40113 9 Clutch housing nut 40 60 N m 4 0 6 0 kg m ENGINE 3 34 3 35 ENGINE MOVABLE DRIVE Install the roller to the movable drive face D Mount the three dampers 2 on the movable drive plate 3 and install it on the movable drive face 5 Position the O ring on the movable drive face Install the movable drive face cover 1 CAUTION Make sure that the movable drive plate is fully positioned inside or the weight roller may come off Insert the spacer 2 Position the movable drive face subassembly on the crankshaft as shown in the photo CAUTION Thoroughly clean the V belt contact face to be from oil Install the fixed drive face Tighten the fixed drive face nut 0 to the specified torque with the special tool Conrld holder 09910 20115 V Fixed drive face nut 40 60 N m 4 0 6 0 kg Continue turning the fixed drive face 5 by hand until the V belt is seated in and both the drive and driven faces 8
41. ecified torque Refer to page 7 8 CONTENTS ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL ENGINE REINS TALL ATION ettet tecta 3 ENGINE DISASSEMBLY ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS riening eh ah praeh ang ng a BAN put OIL SEALS CRANKSHAFT et i YE E AUTOMATIC CLUTCH INSPECTION CYLINDER HEAD tasks CYLINDER RS VAR UH RAS gt gt PISTON M REED VALVE thon ica oria pee M MESURE REOR natal RM ODE co ARENA ENGINE REASSEMBLY esee cnn teni Ud e OIL SEALS BEARINGS so kei BUSHINGS __ AAN a pest E CRANKSHAFT ore UND an CRANKCASE apad aia phat ud qq en eth op andi TRANSMISSION e STARTER DRIVEN GEAR AND STARTER MOTOR MOVABLE DRIVEN AND CLUTCH MOVABLE DRIVE ionis as E naa pan aaa e a gg i used MAGNETO asana eaaa ataga NUR ga aaa PISTON OIL PUMP AND INTAKE PIPE s COOLING FAN innie HR RIEN MUFF ER 22 3 1 EN
42. eck and adjust Clean Adjust or replace 7 3 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes No sparking or poor sparking Defective CDI amp Ignition coil unit Defective spark plug Defective magneto stator coil Loose connection of lead wire Replace Replace Replace Connect tighten Spark plug soon becomes fouled with carbon Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Incorrect engine oil Adjust carburetor Adjust carburetor Change Clean Replace by hot type plug Replace Spark plug electrodes overheat or burn Spark plug too hot The engine overheats Spark plug loose Mixture too lean Not enough engine oil Replace by hot type plug Turn up Retighten Adjust carburetor Check oil pump Magneto does not charge Open or short in lead wires or loose lead connections Shorted grounded or open magneto coil Shorted or open regulator rectifier Repair replace or retighten Replace Replace Magneto charge but charging rate is below the specific ations 1 Lead wires tend to get shorted or open circuited or loosely connected at terminal 2 Grounded or open circuited stator coils of magneto 3 Defective regulator rectifier 4 Defective cell plates in the batttery Repair or retighten Repl
43. ecommended Fuel tank capacity 4 0 4 Use HYOSUNG HYPOL HS OIL or an equivalent good quality synthetic based 2 stroke engine oil Engine oil tank capacity 10 4 0 9 1 10 disch t cum at 3 000rpm for 5 minutes Transmission oil type SAE 10W 40 multi grade motor oil Change 80 me Transmission oil capacity Overhaul 90 mb SERVICING INFORMATION 7 16 WIRE AND CABLE ROUTING 1 HOLOW 18915 Ed 287 EEE 0771 10760 e or l SSF fu 50771 70760 3 5 102 0vt 60 28 HOLOW 18915 ANIOd 5NILVHVd3S o SS3NHVH 3 5071 10560 goes 2 2 NOILNIDI 2 lt Woivino3u 50771 10760 AWAY H31HVIS 5 H1HV3 ONIHSHIS SSY HOLIMS 7 3snd LINN 109 11083 dOLS SSY HOLIMS HOLMS ANISH 50771 10760 AHSILVH A SSV HOLIMS 7 17 SERVICING INFORMATION 0961 2060 8575 HOLIMS SERVICING INFORMATION 7 18 VIEW A VIEW
44. ed or not from the thickness of brake lining CHASSIS 6 4 Brake shoe lining Service limit thickness 2 mm 0 079 in A CAUTION Replace the brake shoe as a set otherwise brak ing performance will be adversely affected REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel and brake in the reverse order of removal and disassembly and also carry out the following steps When installing the brake camshaft apply SUPER GREASE A to the camshaft and cam face AW Super Grease Install the brake shoes with spring hooks faced inside A CAUTION Be careful not to apply too much grease to the cam and pin If grease gets on the lining break slippage will result Install the brake cam lever to the brake camshaft Tighten the brake cam lever nut to the specified torque V Front brake cam lever nut 6 8N 0 6 0 8 kg m 6 5 CHASSIS Apply BOND 1215 to the front brake plate as shown photo BOND 1215 Install the front brake drum and tire CHASSIS 6 6 STEERING AND FRONT SUSPENSION TIGHTENING TORQUE kg 18 28 1 8 2 8 18 4 28 6 1 84 2 86 224 35 7 2 24 3 57 40 50 4 0 5 0 6 ASSEMBLING APPLY GREASE ASSEMBLING APPLY GREASE APPLY GREASE TO LIPS D APPLY GREASE E ASSEMBLING APPLY GREASE REM
45. erature more than that of human body within five minutes If not replace with new one A CAUTION This check should be carried out when the carbu retor is cold 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 Pocket tester 09900 25002 WIRE COLOR Y Yellow Black with Red tracer White with Black tracer YIW os Yellow with White tracer Y G 77 Yellow with Green tracer ELECTRICAL SYSTEM 5 6 STARTER SWITCH OFF B W B R R OFF GINE ON SUME 5 7 ELECTRICAL SYSTEM BATTERY 9 CAUTION OF BATTERY TREATMENT The battery should be well taken care of because it emits flammable gas If you don t follow the instruction in the below there may be a explosion and severe accident Therefore please pay attention to the following points Prohibit positively battery from contacting to short spark or firearms The recharge of battery should be done in the wide place where the wind is well ventilated Please don t recharge it at the sight of wind proof 9 CAUTION OF BATTERY ELECTROLYTE TREATMENT Pay attention for the battery electrolyte not to stain the chasis or the humanbody If be stain the chassis or the humanbody at once wash a vas
46. es 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 CYLINDER HEAD Decarbon the combustion chamber Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places Thickness gauge 09900 20806 Cylinder head Service limit distortion 0 1 mm 0 004 in If the largest reading at any portion of the straight edge exceeds the limit rework the surface by rubbing it against emery paper of about 400 laid flat on the surface plate in a lapping manner The gasketed sur face must be smooth and perfectly flat in order to Secure a tight joint a leaky joint can be the cause of reduced power output and increased fuel consump tion CYLINDER Decarbon exhaust port and upper part of the cylinder taking care not to damage the cylinder wall surface The 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
47. ex mark is outside the range as shown in the illustration at right the brake shoe assembly should be replaced to ensure safe operation 2 REAR BRAKE BRAKE ADJUSTMENT Set the parking brake by squeezing the rear brake lever and then pressing the lock knob D Rock the vehicle by pushing to see if the brake is sufficiently holding the wheels locked Adjust the brake if necessary by turning the adjuster 2 in or out PERIODIC MAINTENANCE 2 8 Index mark Brake lining wear limit The extension line of the index mark is within the range 5 15mm Rear brake lever play 0 197 0 591 in 2 9 PERIODIC MAINTENANCE BRAKE PAD WEAR The extend of brake pad wear can be checked by observ ing the grooved limit amp on the pad When the wear exceeds the grooved limit replace the pads with new ones CAUTION Replace brake pad as set otherwise braking performance will be adversely affected REAR BRAKE PAD REPLACEMENT Remove the brake caliper Remove the brake pads To reassmble reverse the above sequence V Rear brake caliper mounting bolt 5 0 7 0 m 0 5 0 7 kg m Inspect and lubricate Every month Visually check the drive chain for the possible defects listed below 1 Loosen pins 2 Damaged rollers 3 Dry or rusted links 4 Kinked or bindin
48. g links 5 Excessive wear If any defects are found the drive chain must be replaced 9 LUBRICATING THE DRIVE CHAIN Dirt hastens wear of drive chain and sprockets Lubricate the drive chain with chain lube or motor 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 A CAUTION PERIODIC MAINTENANCE 2 10 When refitting the drive chain be sure to install the chain joint clip as shown the slit end faces counter to turning direction 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 5 15mm Drive chain slack 0 197 0 591 in If the drive chain slack exceeds the specification the chain must be replaced 2 11 PERIODIC MAINTENANCE TIRE NOTE Inspect Every month Check pressure each time ride 9TIRE PRESSURE If the tire pressure is too 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 to prolong tire life CAUTION The standard tire fitted on this is 145 70 6 for front and rear The use of a tire other than the standard may c
49. ge 14 0 15 0 V at 5 000 rpm Starter motor carbon brush length 4 0 0 158 Starter motor commutator under cut 0 2 0 008 Starter relay resistance 0 70 Q Type designation STX5L BS MF Battery Capacity 12V 4Ah 10HR Standard electrolyte 5 0 1 32 at 20 C 68 F Fuse size 10A No load performance of A C generator More than 17 0V at 5 000 rpm SERVICING INFORMATION 7 14 BRAKE WHEEL LIMIT Front 5 15 0 197 0 591 Brake lever play Rear 5 15 0 197 0 591 Brake drum Front 590 4 358 Brake shoe lining O D Front di Brake shoe thickness Front 0 A Brake disc thickness Rear Brake disc runout Rear hee Tuming radius fives Camber 1 A 6 0 Toe in 0 236 85 Trail 0 335 Caster 3 0 5 Wheel rim runout 8 0 Wheel axle shaft runout Rear 0 315 aom Front 145 70 6 X 2 Tire size Rear 145 70 6 X 2 4 Front Tire tread depth S Rear 0 1 6 7 15 SERVICING INFORMATION SUSPENSION Unit mm in ITEM SPECIFICATION Front wheal travel 55 2 165 Rear wheel travel 60 2 362 TIRE PRESSURE COLD INFLATION TIRE PRESSURE FRONT REAR FUEL OIL ITEM SPECIFICATION NOTE Gasoline used should be graded 85 95 octane or higher An Fuel type 223 unleaded gasoline is r
50. h the pocket tester Pocket tester 09900 25002 Ignition coil resistance Secondary 5 4 6 6 kQ STATOR COILS Using the pocket tester measure the resistance between the lead wire and ground If the resistance checked is incorrect replace the coil Unit Stator coil resistance Standard Charging coil 0 69 1 03 0 Exciting coil 220 260 2 9 CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Measure the DC voltage between the battery terminal CO and O with a pocket tester If the tester reads under or over following specification check the no lead performance or replace the regula tor rectifier CAUTION When making this test be sure that the battery is in fully charged condition Pocket tester 09900 25002 Engine tachometer 09900 26006 Keine 14 0 15 0 V at 5 000 rpm ELECTRICAL SYSTEM 5 2 Ground Plug cap 5 3 ELECTRICAL SYSTEM 9 NO LOAD PERFORMANCE OF A C GENERATOR Disconnect the magneto lead wire coupler Start the engine and keep it running at 5 000 rpm Using a pocket tester measure the AC voltage between the three lead wire If the tester reading is as follows magneto is in good condition W R A Standard no load performance of A C generator More than 17 0 V at 5 000 rpm REGULATOR RECTIFIER Disconnect the coupler Using the pocket tester X 1kQ Range
51. hain cover Remove the axle shaft with rear sprocket CHASSIS 6 16 Remove the shock absorber Remove the rear axle housing Remove sprocket mounting flange by removing the nut INSPECTION AND DISASSEMBLY 9 AXLE HOUSING BEARING Inspect the play of bearing inner ring by hand while mounting in the axle housing Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly Replace the bearing if there is anything unusual 6 17 CHASSIS Remove the dust seals with the special tool Oil seal remover 09913 50121 CAUTION Replace removed dust seals with new ones Remove the right and left bearings and spacer SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other damage 9 REAR SPROCKET Inspect the sprocket s teeth for wear If they are worn as illustrated replace the sprocket and drive chain as a set 4 Normal wear Excessive wear Romove the rear sprocket 9 REAR AXLE SHAFT Using a dial gauge check the axle shaft for runout and replace it if the runout exceeds the limit CHASSIS 6 18 Rear axle shaft Service limit runout 8 0 mm 0 315 in REASSEMBLY AND REMOUNTING Reassemble and remount the rear axle housing in the reverse order of removal and disassmbly SERVICING INFORMATI
52. he new oil seals 0 to the movable driv en face 3 with the special tool Bearing installer 09913 76010 Apply SUPER GREASE to the lip of oil seals and groove of movable driven face s inside AGH Super Grease A Oil seal Insert up to contact to the stopper 3 33 ENGINE Install the movable driven face D to the fixed driven face 2 CAUTION When reinstalling the movable driven face to the fixed driven face make sure that the oil seal is positioned properly Position the two O rings 3 Install the pin at three places on the driven face hub Apply SUPER GREASE lightly to the cam part where the pins are placed Super Grease Install the movable driven face seat 6 CAUTION The seat is installed rotatable naturally The O ring get damaged in case of installed by force Install the spring Install the clutch shoe assembly 2 and nut 3 Tighten the nut to the specified torque with the spe cial tool Rotor holder 09930 40113 V Clutch shoe nut 40 60 N m 4 0 6 0 kg m 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 CAUTION The V belt should be positioned so that the arrows on the belt periphery point th
53. il seal 09923 74510 Bearing remover 20 35mm Used to remove bearing with the rotor remove sliding shaft 7 7 SERVICING INFORMATION Special tools Part Number Part Name Description 09924 84521 Bearing installer Used to drive small bearing in Special tools Part Number Part Name Description 09930 30163 Rotor remover Attached to the top of sliding shaft when removing rotor 09930 10121 Spark plug socket wrench set Used to remove or remounting spark plug 09930 40113 Rotor holder Widely used to lock rotary parts such as a clutch shoe 09930 30102 Rotor remove sliding shaft Used to with bearing remover or rotor remover 09941 50111 Wheel bearing remover Used to remove wheel bearing SERVICING INFORMATION 7 8 TIGHTENING TORQUE ENGINE Magneto rotor nut Muffler mounting bolt Exhaust pipe bolt Spark plug Cylinder head nut Engine mounting bolt Engine mounting bracket bolt Transmission oil drain plug Transmission oil level bolt Oil pump bolt Clutch shoe nut Clutch housing nut Fixed drive face nut 7 9 SERVICING INFORMATION CHASSIS Front brake cam lever nut Front shock absorber blot amp nut Rear sprocket nut Rear shock absorber bolt 40 50 4 0 5 0 Rear axle nut M28 120 150 12 0 15 0
54. l tank Remove the fuel cock INSPECTION 9 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 REMOUNTING Remount the fuel tank and fuel cock in the reverse order of removal WARNING FUEL SYSTEM 4 8 lt Gaskets 1 and 2 must be replaced with new ones to prevent fuel leakage lt Tighten the fuel cock bolts evenly OIL PUMP 9 AIR BLEEDING Whenever evidence is noted of some air having leaked into the oil pipe from the oil tank in a machine brought in for servicing or if the oil pump has to be removed for servicing be sure to carry out an air bleeding operating with the oil pump in place before returning the vehicle to the user To bleed air hold the vehicle in standstill condition Loosen the air bleeding screw D to let out air and after making sure that the trapped air has all been bled tight en the air bleeding screw completely CHECKING OIL PUMP Use the special tool to check the pump for capacity by measuring the amount of oil the pump draws during the specified interval Remove the frame cover Have the Oil gauge filled with HYOSUNG HYPOL OIL HS and connect it to the suction side of the pump Run the engine at 3 000 rpm Holding engine speed the same 3 000 rpm let
55. lt 8 12 m 0 8 1 2 kg m Muffler mounting bolt 18 28 m 1 8 2 8 kg FUEL SYSTEM CONTENTS CARBURETOR RR re ana aaa REASSEMBIYANDRBEMOUNTING n 4 1 FUEL SYSTEM CARBURETOR REMOVAL Remove the front and rear fender Remove the carburetor top cap D and disconnect the throttle cable 2 Disconnect the fuel hose 3 Remove the carburetor by loosening the mounting bolts DISASSEMBLY Remove the thermoelement assembly FUEL SYSTEM 4 2 4 3 FUEL SYSTEM CAUTION Do not attempt to disassemble the thermoelement assembly It is not serviceable Remove the float chamber Remove the float 2 by removing the screw 3 and pin Remove the needle valve 5 Remove the throttle stop screw 0 and pilot air screw 2 CAUTION When removing the pilot air screw record the revolutions until tighten completly w Remove the main jet and needle jet 9 INSPECTION Check following items for any damage or clogging Pilot jet Main jet Pilot air screw Needle jet air bleeding hole Float Gasket Pilot outlet and bypass holes NEEDL
56. me Description Special tools Part Number Part Name Description 09900 20101 Vernier Caliper Used to conveniently measure various dimensions SS 09900 21109 Torque wrench Measure torque of tightening 09900 20201 Micrometer 0 25mm Used for precise measurement 00 25 measure ranges 09900 21304 V block With using magnetic stand 09900 20202 Micrometer 25 50mm Used for precise measurement 25 50mm measure ranges 09900 21602 oil gauge A gauge to inspect performance of oil pump 09900 20203 Micrometer 50 75mm Used for precise measurement 50 7 5mm measure ranges 09900 22301 Plastigauge Measure clearance of crankshaft thrust 09900 20508 Cylinder gauge set Measure inside diameter of cylinder 09900 22401 Small bore gauge Measure inside diameter of conrod small end 09900 20605 Dial calipers Meassure width of conrod big end 09900 25002 Pocket tester Measure voltage electric current resistance 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 26006 Engine tachometer Measure rotational frequency of engine 09900 20701 Magnetic stand With using dial gauge 09900 28107 Electro tester Inspect ignition coil 09900 20806 Thickness gauge Measure clearance of piston ring 09900 28500 Battery ch
57. nding position Remove the four bolts D Remove the clamp screw Remove the air cleaner case Remove the element from the cap Fill a washing pan of a proper size with nonflammable cleaning solvent Immerse the element in the 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 CAUTION Before and during the cleaning operation inspect the element for tears A torn element must be replaced Be sure to position the element snugly and cor rectly so that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element Non flammable cleaning solvent 2 stroke engine oil CYLINDER HEAD NUTS NOTE Tighten Initial 1 month and Every 3 months Cylinder head nuts when they are not tightened to the specified torque may result in leakage of the compressed mixture and reduce output First loosen the nuts and tighten the 4 nuts enenly one by one in stages until each one is tightened to the specified torque Tighten the nuts in the order indicated 9 Cylinder head nut
58. ng a thin blade screwdriver or the like pry up the movable driven face spring guide 9 Remove the pins 5 movable driven face and fixed driven face D ENGINE 3 10 Remove the roller bearing with the special tools Bearing remover 17mm 09923 73210 Rotor remover sliding shaft 09930 30102 CAUTION The removed bearing should be replaced with a new one Remove the circlip 8 Remove the bearing with the special tool Wheel bearing remover 09941 50111 CAUTION The removed bearing should be replaced with a new one 9 TRANSMISSION Drain transmission oil Remove the gear box cover Remove the drive shaft 3 11 ENGINE Remove the oil seal 1 from the gear box cover with the special tool Oil seal remover 09913 50121 CAUTION The removed oil seal should be replaced with a new one Remove the bearing 2 with the special tool Bearing installer 09943 88211 CAUTION The removed bearing should replaced with a new one Remove the circlip 3 and final driven gear 9 Remove the shaft Remove the drive shaft bearing Rotor remover sliding shaft 09930 30102 Bearing remover 12mm 09921 20210 ENGINE 3 12 CRANKCASE Remove the cra
59. nkcase securing screws Crankcase separater 09920 13120 NOTE Loosen the crankcase screws diagonally Remove the crankshaft with the special tool Crankcase separater 09920 13120 3 13 Remove the bearings oil seals and bushing Using two steel tubes of appropriate size press out the engine mounting bushings on a vise as shown in the illustration ENGINE 3 14 Front side Bushing Crankcase Rear side Crankcase 3 15 ENGINE COMPONENTS INSPEC TION AND SERVICING BEARINGS Wash the bearing with cleaning solvent and lubricate with motor oil before inspecting Turn the inner ring and check to see that the inner ring turns smoothly If it does not turn lightly quietly and smoothly or if noise is heard the bearing is defective and must be replaced with a new one OIL SEALS Damage to the lip of the oil seal may result in leakage of the fuel air mixture or oil Inspect for damage and be sure to replace the damaged seal if found CRANKSHAFT CRANKSHAFT RUNOUT Support the crankshaft by the V blocks with the dial gauge rigged to read the runout as shown Service limit Crankshaft runout 0 08 mm 0 003 in Excessive the crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine life V block 09943 21304 Magnetic
60. o poorly working CDI amp Ignition coil unit 5 Defective magneto stator coil 6 Float chamber fuel level too low 7 Clogged air cleaner element 8 Clogged fuel hose resulting in inadequate fuel supply to carburetor 9 Clogged fuel cock vacuum pipe Replace Replace Adjust Replace Replace Adjust or replace Clean Clean and replace Clean Dirty or heavy exhaust smoke 1 Too much engine oil to the engine 2 Use of incorrect engine oil Check oil pump Change Engine lacks power 1 Excessively worn cylinder or piston rings 2 Stiff piston ring in place 3 Gas leaks from crankshaft oil seal 4 Spark plug gaps incorrect 5 Clogged jets in carburetor 6 Float chamber fuel level out of adjustment 7 Clogged air cleaner element 8 Fouled spark plug 9 Sucking air from intake pipe 10 Slipping or worn V belt 11 Damaged worn rollers in the movable drive face 12 Weakened movable driven face spring 13 Too rich fuel air mixture due to defective starter system Replace Replace Replace Adjust or replace Clean Adjust or replace Clean Clean or replace Retighten or replace Replace Replace Replace Replace Engine overheats CARBURETOR Complaint 1 Heavy carbon deposit on piston crown 2 Defective oil pump or clogged oil circuit 3 Fuel level too low in float chamber 4 Air leakage from intake pipe 5 Use of incorrect engine oil 6
61. oil qual ities will deteriorate and quicken the wear of sliding and interlocking surfaces Replace the transmission oil periodically following the procedure below Start the engine to warm up the oil this will facilitate draining of oil Unscrew the oil filler cap and drain plug and drain the oil completely Tighten the drain plug Supply a good quality SAE 10W 40 multi grade motor oil TRANSMISSION OIL CAPACITY 80 n Check the oil level with the oil level screw 3 BRAKES NOTE Inspect Initial 1 month and Every 6 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 6 Front brake lever play 0 in BRAKE LINING WEAR LIMIT This vehicle is equipped with the brake lining wear limit indicator on the front brake As shown in the illustration at right at the condition of normal lining wear an extended line from the index mark on the brake 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 ind
62. om the top surface 41 070 1 6169 Piston diam 40 935 40 950 1 6116 1 6122 Measure at 15mm from the skirt end 40 885 1 6097 Cylinder distortion 0 004 Cylinder head distortion Piston ring clearance Free condition Approx 4 5 0 177 Approx 4 3 0 169 0 1 0 1 3 2 0 126 3 1 0 122 Piston ring clearance Assembling condition 0 10 0 25 0 004 0 010 0 75 0 030 0 10 0 25 0 004 0 010 0 75 0 030 Piston ring ring groove clearance 181 0 02 0 06 0 0008 0 0024 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 1 0 Piston pin O D CONROD CRANKSHAFT ITEM 10 002 10 010 0 3938 0 3941 9 995 10 000 0 3935 0 3937 STANDARD 10 030 0 3949 9 980 0 3929 Unit mm in LIMIT Conrod small end bore I D 14 003 14 011 0 5513 0 5516 14 047 0 5530 Conrod big end runout 3 0 0 12 Crank web to wed width 35 0 1 1 378 0 004 Crankshaft runout 0 08 0 003 7 11 SERVICING INFORMATION OIL PUMP ITEM STANDARD Oil pump reduction ratio 30 1 CLUTCH Unit mm in ITEM STANDARD LIMIT 110 00 410 15 110 35 4 3307 4 3366 4 3444 30 20 Clutch shoe thickn DTE NUES 0 118 0 079 Clutch in rpm 3 600 200 rpm Clutch tight rpm 4 500 200 rpm TRANSMISSION DRIVE CHAIN Unit
63. ones Coat SUPER GREASE to the lip of the oil seals Super Grease A Be sure to apply THREAD LOCK 1324 to outer surfaces of right and left crankshaft oil seals to pre vent them from moving Thread Lock 1324 When fitting the oil seal in the crankcase insert it Slowly with the special tools Oil seal installer 09913 75830 Bearing installer attachment 09924 74510 Bearing installer pilot 09924 74540 NOTE Align the oil seal with edge of the crankcase as shown in the illustration BEARINGS Install new bearings with the special tool Bearing installer 09913 75810 Bearing installer 09913 76010 BUSHINGS Using two steel tubes of appropriate size and a vise press the mounting bushings 0 and 2 into the crankcase holes as shown in the illustration ENGINE 3 24 3 25 ENGINE NOTE Knurled end should face inside Protrusive and 8 should be in the same dimension Bushing 2 t 2 24 B CRANKSHAFT Crankshaft Crankcase R Oil seal Oil seal 5 Oil pump drive gear 6 Oil pump driven gear Oil seal m ME Measure the length between the webs referring to the figure at right when rebuilding the crankshaft ENGINE 3 26 Standard Crank web to web width 35 0 0 1 mm 1 378 0 004 in When moun
64. pect the tie rod for distortion and the boot for wear 9 STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bend Inspect the two steering shft holders for wear 35 gt 9 SHOCK ABSORBER Inspect the shock absorber for oil leakage or other dam age REASSEMBLY AND REMOUNTING Reassemble and remount the steering system in the reverse order of removal and disassembly and also carry out the following steps Aline the mating face of rear brake holder with the respective punch mark and tighten the bolt 9 TIE ROD Install the tie rod ends nuts and steering tie rods 0 CAUTION Inside lock nuts 0 are left hand thread 9 HANDLEBAR Install the handlebar with the punch mark aligned with the handlebar holder as shown Tighten the handlebar holder bolts to the specified torque V Handlebar holder bolt 18 4 28 6 m 1 84 2 86 kg m NOTE The gap 5 between the handlebar holder should be even CHASSIS 6 10 6 11 CHASSIS TOE IN ADJUSTMENT The procedure for adjusting the toe in as follows Place the vehicle on level ground and set the handle bar straight Make sure that all tires are inflated to the standard pressure kPa psi 25 0 25 3 6 25 0 25 3 6 Loosen the lock nuts on each tie rod CAUTI
65. piston head should point the exhaust side The circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the groove portion of the piston Position the cylinder 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 9 Cylinder head nut 8 12 N m 0 8 1 2 kg m Inside Outside ENGINE 3 40 OIL PUMP AND INTAKE PIPE Apply SUPER GREASE to the oil pump driven gear and install it to the crankcase AH SUPER GREASE Install the oil pump 2 and tighten it to the specified torque V Oil pump bolt 3 5 m 0 3 0 5 kg m 3 41 ENGINE Install the reed valve gasket 0 intake pipe gasket 2 and intake pipe with reed valve to the crankcase COOLING FAN Install the fan case Install the magneto lead wire and starter motor lead wire Install the cooling fan ENGINE 3 42 Install the cooling fan cover D MUFFLER Tighten the exhaust pipe bolts and muffler mount ing bolts 3 to the specified torque 9 Exhaust pipe bo
66. s trated After cleaning the grooves fit the rings and rotate them in their respective grooves to be sure that they move smoothly Carbon in groove is liable to cause the piston ring to get stuck in the groove and this condition will lead to reduced engine power output piston whose sliding surface is badly grooved scuffed due to overheating must be replaced Shallow grooves or minor scuff can be removed by grinding with emery paper of about 400 PISTON BORE 1 0 Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the following ser vice limit replace it with a new one Dial calipers 09900 20605 Service limit 10 030 mm 0 395 in Piston pin bore I D PISTON PIN O D Using a micrometer measure the piston pin outside diameter at three positions Micrometer 0 25mm 09900 20201 Service limit 9 980 mm 0 393 in Piston pin O D PISTON RINGS Check each ring for the clearance reading the clear ance with a thickness gauge shown in the illustration If the clearance is found to exceed the limit indicated below replace it with a new one The clearance of each ring is to be measured 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 Thickness gauge 09900 20806 ENGINE 3 22
67. stand 09900 20701 Dial gauge 09900 20606 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 rattle in the big end Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check the extent of wear on the parts of the conrod s big end If wear exceeds the limit conrod crank pin and crank pin bearing should all be replaced Service limit Conrod big end runout 3 0mm 0 12 in CONROD SMALL END 1 0 Measure the conrod small end diameter with a caliper gauge ENGINE 3 16 Service limit Conrod small end bore I D 14 047mm 0 553 in Dial calipers 09900 20605 AUTOMATIC CLUTCH INSPECTION This vehicle is equipped with an automatic clutch and variable ratio belt drive transmission The engagement of the clutch is governed by engine RPMs and centrifu gal mechanism located in the clutch To insure proper performance and longevity of the clutch assembly it is essential that the clutch engages smoothly and gradually Two inspection checks must be performed to thoroughly check the operation of the driv etrain Follow the procedures listed 1 CLUTCH IN INSPECTION Warm the engine to normal operating temperature Conne
68. t the charging system Replace the battery Replace the battery Reversed battery polarity 1 The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction Replace the battery and be sure to connect the battery properly Battery discharges too rapidly 1 Dirty container top and sides 2 Battery is too old Clean Replace SERVICING INFORMATION 7 4 CHASSIS Complaint Symptom and possible causes Remedy Handling feels 1 Disturbed front wheel alignment Adjust too heavy or stiff 2 Poorly lubricated Lubricate 3 Not enough pressure in tires Adjust 4 Tie rod ends tending to seize Replace 5 Linkage connections tending to seize Replace or replace Steering oscillation 1 Wheel tires inflated unequally Adjust tire pressure 2 Wobbly wheels Replace 3 Loose nut on wheel hub Retighten 4 Damaged or worn wheel hub bearing Replace 5 Worn or loose tie rod ends Replace or retighten 6 Defective or incorrect tires Replace 7 Damaged wishbone arm bushing Replace 8 Loosen bolts and nuts on chassis Retighten Steering pulling to 1 Wheel tires unequally inflated Adjust tire pressure one side 2 Disturbed front wheel alignment Adjust 3 Worn or broken wheel hub bearing Replace 4 Distorted frame Repair or replace 5 Defective shock absorber Replace Shocks coming to 1
69. t quantity of water When it be stained clothes should come into being a hole or painting should take off Be cured from 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 use as battery of completely seal type Do not use it except the battery electrolyte When pour into the battery electrolyte necessarily use the electrolyte of the specified capacity Do not open the sealing cap after recharge the tery eletrolyte Filing electrolyte D The battery is puted on even land remove the alu minum tape sealing 2 Remove the cap at the electrolyte container CAUTION Aluminum tape Do not remove the seal not prick with sharp thing Filler holes ELECTRICAL SYSTEM 5 8 8 Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill A CAUTION There may be a case which can t pour the elec trolyte if you put it into electrolyte container slopely 4 Confirmation of pour
70. the pump draw for 5 minutes For this operation the reading taken on the device should be 0 9 1 1 CCI Oil gauge 09900 21602 Engine oil 0 9 1 100 discharge amount at 3 000 rpm for 5 minutes A CAUTION During this inspection strictly follow the follow ing points Do not touch the rear wheel while running the engine ELECTRICAL SYSTEM CONTENTS IGNITIONICHARGING SYSTEM tetti IGNITION ann STATOR COILS REGULATORIRECTIFIER e STARTER SYSTEM ccrte terii Giotto STARTING MOTOR REMOVAL AND DISASSEMBLY gt STARTING MOTOR INSPECTION STARTER RELAY INSPECTION THERMOELEMENT SWITCHES INSPECTION BATTERY a eei dame eee iude Md EM UE 5 1 ELECTRICAL SYSTEM IGNITION CHARGING SYSTEM Stator Spark plug Ignition coil Regulator Rectifier CDI unit 1 Engine stop 1 switch T Battery 12V 4AH MF IGNITION COIL Check the ignition coil with electro tester Test the ignition coil for sparking performance Test connection is as indicated Make sure that the three needle sparking distance is at least 8mm Test it at least for 5 minutes Electro tester 09900 28106 Spark performance Over 8 mm 0 3 in 0 3 in Spark Check the ignition coil wit
71. ting the crankshaft into the crankcase it is necessary to pull its left end into the crankcase with the special tool Crankshaft installer 09900 32812 Conrod holder 09910 20116 CAUTION 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 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 BOND 1215 Install the two dowel pins Tighten the crankcase screws securely Check if crankshaft rotates smoothly 3 27 ENGINE Install the new oil seal to the crankcase with the special tool NOTE Align the oil seal with edge 2 of the crankcase as shown in the illustration Bearing installer 09913 85210 TRANSMISSION Install the circlip 0 on to rear axle shaft Assemble the idle shaft subassembly using the idle shaft 3 and thrust washer then install the sub assembly on the gear box Install the final driven gear on the rear axle shaft using the circlip Center Circlip NX Install the new bearing 2 8 to gear box cover 9 with the special tool Thrust Rounded coner
72. will move together smoothly without slip Fill the final gear box with transmission oil up to the level hole Transmission Replace 80 m oil capacity Overhaul 90 ml Tighten the oil level bolt 7 to the specified torque V Transmission oil level bolt 9 15 N m 0 91 5 kg m ENGINE 3 36 3 37 ENGINE MAGNETO Degrease the tapered portion of the crankshaft and also the magneto rotor Install the stator D Install the key Install the rotor 6 Apply THREAD 1 1324 to the rotor nut and tighten it to the specified torque with the special tool JE THREAD LOCK 1324 Conrod holder 09910 20115 9 Magneto rotor nut 35 45 m 3 5 4 5 m ENGINE 3 38 PISTON Install the piston ring on the piston 1st Keystone ring 2nd Barrel face ring Expander ring A CAUTION Position the ring so that the marking is on upside Position the ring so that the marking is on upside Locating pin 6 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 CORRECT INCORRECT 3 39 ENGINE Apply engine oil on the piston pin and install the pis ton to the conrod CAUTION The arrow mark 9 on the

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