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SD 50

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1. HH Sgt 3 27 STARTER DRIVEN GEAR AND STARTER MOTOR en 3 29 MOVABLE DRIVEN AND CLUTCH E 3 30 MOVABLE Eli RA AE ae erai 3 33 KICK STARTER sem ee Re GE oi EE eb EG Ee ee DEM 3 35 PISTON J 3 36 OIL PUMP AND INTAKE PIPE e 3 38 MACN TO RE EE ae ee 3 39 REESEN 3 40 3 1 ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame thoroughly clean the engine with a suitable cleaner The procedure of engine removal is sequentially explained as follows e Remove the frame side covers Refer to page 6 3 e Remove the air cleaner by removing the mounting bolts and clamp screw e Disconnect the ignition coil lead wires and spark plug cap e Disconnect the oil pump cable and the thermoelement lead coupler 4 e Disconnect the throttle cable Refer to page 4 2 O Disconnect the carburetor hoses and oil hose Vacuum hose 6 Fuel hose Oil hose D ENGINE 3 2 e Disconnect the magneto lead wire and starter lead wire O Remove the rear brake cable by removing the bolt D bolt S and adjuster nut Remove the rear shock absorber mounting lower bolt O Remove the engine mounting shaft and remove the engine from the frame 3 3 ENGINE ENGINE REMOUNTING The engine can be mounted in the reverse order of removal Front side O Install the dam
2. ONNSOAH HYOSUNG HYOSUNG MOTORS amp MACHINERY INC d Q n d Q SEHVICE MANUAL TVANYIN 3983S 99000 91201 FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the SD 50 The SD 50 is a new type of motorcycle that has many technical features such as X V belt drive automatic transmission x Forced air cooling system P E Ignition system Electric starter system The SD 50 fits the needs of a wide variety of motorcycle users Those who will be servicing this motorcycle should carefully review this manual before performing any repair or services Information of this manual is up to date at the time of issue Major modification and changes incorporated later will be advised to HYOSUNG product distributor in each market Therefore if newest information is requested in the future please contact the local HYOSUNG distributor The SD 50 motorcycles distributed in your county might differ in minor respects from the standard specification and if they do it is because some minor modifications which are of no conse quence in most cases as far as servicing is concemed has to be made to comply with the starutory requirements of your country GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE UP PROCEDURE ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INF
3. The convex side of hub should face outside when installed in proper position e Install the starter motor 2 ENGINE 3 30 MOVABLE DRIVEN AND CLUTCH Fixed driven face DO ring Bearing Spring Circlip Clutch shoe assembly Needle roller bearing Clutch shoe nut Movable driven face Clutch housing Oil seal Clutch housing nut OI seal 6V velt Spacer Pin Install the bearing in the fixed driven face with the special tool Special tool 1 09943 8821 1 Bearing installer W e g yu Foy ES Ea De n RH a 1 a Ip KR l m F e Install the circlip 3 Rounded corner 3 31 ENGINE O Install the bearing with the special tool 09943 88210 Bearing installer Special tool e Install the new oil seals to the movable driven face with the special tool 09913 76010 Bearing installer Apply grease to the lip of oil seals and groove of inside of mov able driven face 39000 0700 Oil seal e Install the movable driven to the fixed driven face 8 NOTE When reinstalling the movable face to the fixed face make sure that the oil seal is positioned properly e Install the pin 9 at three places on the driven face hub O Apply grease lightly to the cam part where the pins are placed e Position two O ring 00 Spacer O Install the movable driven face seat D O Install the spring O Install the clutch shoe assembly 3 and nut
4. Tighten to specified torque Replace 7 15 SERVICING INFORMATION Excessive brake 1 Air entered into hydraulic system Bleed air lever stroke 2 Insufficient brake fluid Replenish fluid to narmal lever bleed air 3 Improper quality of brake fluid Replace with correct fluid 4 Worn brake cam lever Replace 5 Excessively worn shoes and or drum Replace Leakage of brake 1 Insufficient tightening of connection joints Tighten to specified torque fluid 2 Cracked hose Replace 3 Worn piston seal Replace Brake drags 1 Rusty moving parts Clean and lubricate d Prepared by HYOSUNG MOTORS amp MACHINERY INC Overseas Service 2nd Ed APR 1999 Manual No 99000 91201 Printed in Korea
5. CYLINER HEAD AND CYLINDER Remove carbon Every 8000km 4800miles 12months Carbon deposits in the combustion chamber and the cylinder head will raise the compression ratio and may cause preignition or over heating 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 AND TUNE UP PROCEDURES 2 4 SPARK PLUG Clean Every 4000km 2400miles 6months and Replace Every 8000km 4800miles 12months Neglecting the spark pulg maintenance eventually leads to difficult starting and poor performance If the spark plug is used for a long period the elec trode gradually 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 e Carbon deposits on the spark plug will prevent good sparking and cause misfiring Clean the deposits off periodically e if the center electrode is fairly worn down the plug should be replaced and the plug gap set to the specified gap using a thickness gauge 09900 20804 Thickness gauge pot Spark plug gap 0 6 0 7 mm 0 024 0 028 in 0 024 0 028in O Check the spark plug for burnt condition If abnormal replace the plug as indicated in the chart GOLDEN REMARKS If the standard plug is apt to get wet BP5HS replace with this plug BP6HS standard If th
6. Defective oil pump or clogged oil circuit Fuel level too low in float chamber Air leakage from intake pipe Use of incorrect engine oil Use of improper spark plug Clogged exhaust pipe muffler Starter jet is clogged Air leaking from a joint between starter body and carburetor Air leaking from carburetor s joint or vacuum hose joint Starter plunger is not operating properly Pilot jet pilot air jet are clogged or loose Air leaking from carburetor s joint vacuum pipe joint or starter Pilot outlet is clogged Starter plunger is not fully closed Main jet or main air jet is clogged Needle jet is clogged Fuel level is improperly set Throttle valve is not operating properly Fuel filter is clogged Needle valve is worn or damaged Spring in deedle valve is broken Float is not working properly Foreign matter has adhered to needle valve Fuel level is too high or low SERVICING INFORMATION 7 12 Replace Replace Adjust Replace Replace Adjust or replace Clean Clean and prime Clean Check oil pump Change Replace Replace Replace Adjust or replace Clean Adjust or replace Clean Clean or replace Retighten or replace Replace Replace Replace Replace Clean Replace or clean Adjust or replace Retighten or replace Change Change Clean or replace Clean Check starter body and carburetor for tight
7. O Remove the shock absorber mountingslower bolt O Remove the rear fender bolts then take off the rear fender CLEANING Dust from the fuel tank tends to bulid up in the fuel filter which when the fuel filter has been neglected for a long period inhibits the flow of fuel Remove the dust from the fuel filter 1 using compressed air FUEL AND LUBRICATION SYSTEM 4 6 4 7 FUEL AND LUBRICATION SYSTEM REMOUNTING Remount the fuel tank in the reverse of removal Fuel tank Fuel level gauge Fuel level gauge cap Fuel tank cap GVacuum hose lnlet hose Outlet hose No 1 amp Cushion Fuel strainer pOutlet hose No 2 OIL PUMP AIR BLEEDING Whenever evidence is noted of some air having leaked into the oll 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 machine to the user To bleed air hold the machine in standstill condition Loosen the screw D to let out air and after making sure that the trapped air has all been bled tignten the screw good and hare 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 O Remove the left side cover O Have the tool filled with HYOSUNG HYPOL OIL and connect it to the suction side of the pump e Run the engine
8. inside or the weight roller may come off e Insert the spacer O Position the movable drive face subassembly on the crankshaft as shown in the photo NOTE Thoroughly clean the belt contact to be from oil e Install the fixed drive face 8 e Tighten the nut to the specified torque with the special tool 09910 20115 Conrod holder Tightening torque aan Ti 4 0 6 0 kg m 290 435 Ib ft e Fill grease in the groove provided inside sliding surface of the kick driven gear and install it on the end of the crankshaft Wipe off excess grease 39000 0700 e Install the spring and spacer 2 e Install the E ring 3 Apply grease 3 35 ENGINE e Continue turning the fixed drive face by hand until the belt is seated in and both the drive and driven faces 59 will move together smoothly without slip e Fil the final gear box with engine oil up to the level hole Oil Capacity e Tighten the oil level bolt to the specified torque 9 15 N m Tightening torque ME TEN 09 15 kem 45 110 lb f KICK STARTER DKick starter lever Kick starter shaft kick starter shaft spring Circlip GCrankcase cover LH Gasket Clutch cover Screw Apply grease lightly on the rolling surface and install it on the crankcase cover 39000 0700 e Position the kick starter shaft return spring and hook the spring end on the crankcase cover boss D e Install the dowel pin and crankcase cover Q
9. mE 6 9N m Tightening torque 06 09 ke m 45 65 Ib ft CAUTION Handle the brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc REAR BRAKE Adjust by turning the adjusting nut D so that the play 9 is 15 25 mm 0 6 1 0 in as shown in the illustration 2 15 25mm Brake lining wear limit This motorcycle is equipped with the brake lining wear limit indicator on the rear brake As shown in the illustration at right at the con dition of normal lining wear an extended line from the index mark on the brake camshaft should be within the range embossed on the Brake lining crankcase To check wear of the brake lining follow the steps wear limit below e First check if the brake system is properly adjusted e While operating the brake check to see that the extension line from the index mark is within the range on the crankcase e If the index mark is outside the range as shown in the illustra tion at right the brake shoe assembly should be replaced to ensure safe operation Brake lining wear limit The extension line of the index mark is outside of the range PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 10 TIRES Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter TIRE PRESSURE If the tire pressure is too high the motorcycle will tend to ride stiffly and have poor traction Conversely if the tire p
10. 002 10 010 10 036 Piston pin bore 0 3938 0 3941 0 4079 9 995 10 000 9 980 Piston pin O D 0 3935 0 3937 0 3929 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT 14 003 14 011 14 047 Conrod small end 1D i KA ed ird Crank web to wed width om i Lem inii ite OIL PUMP ITEM STANDARD Oil pump reduction ratio 30 000 30 1 0 9 1 1 ml F T 0 030 0 032 0 037 0 039 US Imp OZ EE for 5 minutes at 3000 r min CCl pump discharge rate SERVICING INFORMATION 7 8 CLUTCH Unit mm in 110 110 15 110 35 Clutch Wheel 1D ouen Wee iD 4 3307 4 3366 4 344 Clutch shoe thickness 0 2 0 0 118 0 08 Clutch engagement 3300 300 r min o Clutch lock up 5800 500 r min TEN TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD LIMIT Drive belt width Bo d Driven face spring free length 7 X ben CARBURETOR SEET ELECTRICAL Unit mm in ITEM SPECIFICATION NOTE Ignition timing B T D C 23 at 4000 r min Spark plug SE 0224 0028 7 9 SERVICING INFORMATION ams 1 meas tram 1 MT aam LI Swwwe mmm sg N z Standard electrolyte S G 1 32 at 20 C 68 F wae Unit W BRAKE WHEEL Unit mm in ITEM STANDARD LIMIT 5 20 02 08 AA Brake lever play saag Brake drum ID E Brake lining thickness CUT cum pem 5 5 EN GEE MR EE emer rem Qnae EA f quee IL SERVICING INFORMATION 7 10 w Whee
11. 1 8 2 8 kg m 13 20 lb ft SPEEDOMETER GEAR BOX When installing the speedometer gear box align the two drive pawls with the two recesses of the wheel hub CAUTION After touching the speedometer gear box to the stopper O tighten the axle shaft FRONT WHEEL e Tighten the front axle nut to the specified torque 33 52 N m Tightening torque 3 3 5 2 kg m lt 24 38 Ib ft e Tighten the caliper mounting bolts to the specified torque 18 28 N m Tightening torque 1 8 2 8 kg m 13 20 Ib ft CHASSIS 6 12 6 13 CHASSIS FRONT BRAKE Master cylinder bolt Master cylinder Brake hose union bolt Brake hose Pad Air bleeder valve Dust seal Piston Piston seal OCaliper BRAKE PAD REPLACEMENT O Remove the caliper by removing the mounting bolts D NOTE Do not operate the front brake lever while dismounting the caliper O Remove the brake pads CAUTION Replace the brake pads as a set otherwise braking perfor mance will be adversely affected Tightening torque CALIPER REMOVAL AND DISASSEMBLY O Remove the brake hose and catch the brake fluid in a suitable receptacle CAUTION Never re use the brake fluid left over from the last servicing and stored long periods O Remove the caliper Remove the brake pads O Remove the pad holder D and spring O Place a rag over the piston to prevent popping up Force out the pisto
12. 2400miles 6months thereafter The engine oil is fed by the oil pump to the engine The amount of oil fed to it is regulated by engine speed and oil pump control lever which is controlled by amount of throttle opening Check the oil pump in the following manner to confirm correct oper ation for throttle valve full opening position e Turn the throttle grip full open e Check whether the marke on the oil pump control lever is aligned with the index mark when the throttle valve is posi tioned as above e f the marks are not aligned loosen lock nuts and turn the adjuster in or out to align the marks O After aligning the marks tighten the lock nuts CAUTION Oil pump cable adjustment must be done after throttle cable adjustment 2 7 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES FINAL GEAR OIL Inspect at Initially 1000km 600miles 2momths and Every 8000km 4800miles 12months thereafter Inspect final gear oil periodically following procedure below Remove the side cover Refer to page 6 3 Remove the clutch cover Refer to page 3 5 O Remove the oil level bolt D and inspect oil level If the level is below the level hole add oil until oil flows from the level hole e Tighten the oil level bolt to the specified torque mE 9 15 N m Tightening torque 09 15 kem 65 110 lb ft BRAKES Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafte
13. 4 EUEEL EINE oa NE aM oon a 2 4 AIR CLEANER sussies sesse Nei eremi 2 5 THROTTLE CABLE n eeaeee 2 5 ENGINE IDLE SPEED n Nene 2 5 OIL PUMP affe 2 6 FINAL GEAR OIL oe Me eee 2 7 BEAKES seers Oe ER RE crete 2 7 TIRES som 4 ON AE OE EE EE eee 2 10 GTEERINGS N N esse Ek ee EE 2 10 FRONT SUSPENSION eee 2 11 PEAR SUSPENSION RM 2 11 CHASSIS BOLTS AND NUTS en 2 11 GENERAL LUBRICATIONS eee 2 13 2 1 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy Mileages are expressed in terms of miles kilometers and months NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART mis Initial 600 Every 2400 Every 4800 EAS This Nee judged D odometer read Initial 1000 Every 4000 Every 8000 ing or month whichever comes first ENE EE ee mm OA Fuel line Replace every 4 years Air cleaner Throttle cable play Engine idle rpm Final gear oil Brakes Brake hose Replace every 4 years Brake fluid Replace every 2 years Tire Steering Front suspension Rear suspension Chassis bolts and nuts NOTE Inspect and clean adjust lubricate or replace if necessary A Adjust C Clean R Replace T Tighten PERIODIC MAINTENANCE AND TUNE UP PROCED
14. LI E Sg 8M 0 HOLMS 1HON dyad 1NOH4 NOLING WILIS fam ONILHON W313W0033dS SERVICING INFORMATION 7 6 WIRE CABLE AND HOSE ROUTING y e s WN ol ejes jeusis win MINN 33M D I SON JIM pea Vue og on 9JIM Pla Jalewiopaads fela1 Janes yams UORIUS Jaena yun rag am Donen oL k 1 Ies um oJ keal Ee 91M pea YAMS 9yeJq 1013 M A D yeu geg KE Dei a a Apel Jeugis uny W130 GNNOYD ANIONS o qeo oye Pai aping Y f Re Malos y punoJg euigu3 SPOED Par as D mee l Ere i ol e ly ul ll TIE H V duen a A Td e V NGA E WS r A ade aqu peu eseg dee i do l i punoJ8 aulguy q ugew Oo HAS j CIE ENA de o TS 1431 3210 18 an OL 7 W DES um 1691 ey OL 7 7 SERVICING INFORMATION SERVICE DATA CYLINDER PISTON PISTON RING Unit mm in 0 065 0 075 0 120 Piston to cylinder clearance ee bee di 41 005 41 020 4107 Cylinder bore 1 6143 1 6120 1 6169 Measure at 20 0 8 from the top surface i 40 935 40 950 Piston diam 1 6116 1 6122 e Measure at 20 0 8 from the skirt end i Cylinder distortion i m Apporox 4 5 0 18 3 7 0 15 Apporox 4 3 0 17 35 0 14 EM 0 10 0 25 Piston ring end gap 0 004 0 010 ia 0 02 0 06 mE P 0 0008 0 0024 Piston ring groove clearance TEN 0
15. Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore O Reassemble and remount the master cylinder Refer to page 6 13 e When remounting the master cylinder on the handlebar first tighten the clamp bolt for upside CAUTION Bleed air after remounting the master cylinder Refer to page 2 8 CHASSIS 6 18 Piston A ee Primary cap Second cap 6 19 CHASSIS FRONT FORK ET tordue E kg m Ib ft 95255 so 22 5 40 0 25 35 noob 16 0 25 5 20 26 2 0 2 6 14 5 18 8 DSteering stem Under bracket Fork bolt Cushion spring 5Pipe seat amp Fork lower clamp bolt DFork pipe Dust boot Stopper ring Oil seal Bottom case 2Socket bolt REMOVAL AND DISASSEMBLY O Remove the front leg shield Refer sto page 6 3 e Remove the front brake caliper y removing the mounting bolts NOTE Do not operate the front brake lever while dismount ing the caliper O Remove the front axle nut O Remove the motorcycle by jack or wooden block O Remove the front wheel by removing the front axle shaft CHASSIS 6 20 O Loosen the front fork bolt then draw out the fork spring O Loosen the front fork lower clamp bolts OI O Invert the fork and stroke it several times to remove the oil e Hold the fork inverted for a few minutes O Remove the scoket bolt with the hexagon wrench O Seperate the fork
16. O Install the clutch cover and kick starter lever D NOTE Install the kick starter lever as shown in the illustra tion e Tighten the kick starter lever bolt to the specified torque PISTON Apply engine oil DNeedle roller bearing Piston SPiston ring Mist ring 2nd ring amp Expender ring Circlip Piston pin Cylinder gasket OQ Cylinder Cylinder head gasket Cylinder head 3Cylinder head nut ENGINE 3 36 3 37 ENGINE O Install the piston rings on the piston Ist Keystone ring 2nd Rectangular ring L Expander ring NOTE Position the ring so that the marking is on upside O t 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 e Apply engine oil on the piston pin and install the piston tothe conrod NOTE The arrow mark D on the piston head should point the exhaust side e The circlip should be mounted In such a position that the mating ends of the circlip do not coincide with the groove por tion of the piston e Position the cylinder base gasket e Apply engine oil on the piston and cylinder wall surfaces and i s M fe aw install the cylinder over the piston carefully oe TL BUE i Ze Te m N e lighten the cylinder head nut to the specification 8 12 Ne m Tightening torque 0 8 1 2 em 6 0 8 5
17. bearings and can be reduced by replacing the bearings If bearing replace ment fails to reduce the runout replace the wheel Service limit Axle and Radial 3 D mm 0 12 in TIRE Inspect the tires for wear and damage and check the tire tread depth as shown Replace a badly worn or damaged tire A tire with its tread worn down to the limit in terms of tread depth must be replaced TIRE DEPTH SERVICE LIMIT Front amp Rear 1 6 mm 0 064 in Check the tire pressure and examine the value for evidence of air leakage TIRE DEPTH SERVICE LIMIT COLD INFLATION NORMAL RIDING TIRE PRESSURE SOLD RIDING DUAL RIDING KPa kg cri kPa Kg cni FRONT 125 1 25 E REAR 200 2 00 REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order diassembly and removal and also carry out the following steps WHEEL BEARING O Apply grease to the bearings before installing 39000 0700 e Install the wheel bearings by using the special tool 09924 84520 Bearing installer CAUTION First install the wheel bearing for left side CHASSIS 6 10 6 1 CHASSIS dE Right side N Left B Bearing R Spacer Special tool Fi Bearing L OIL SEAL e Install the oil seal D with the special tool 09922 55131 Oil seal installer e Install the spacer DISC PLATE e Install the disc plate and tighten them to the specified torque i 18 28 N m Tightening torque
18. brake effectiveness will be lost O Install the rear wheel and nut Tightening torque aii eed 60 90 kg m 435 650 lb ft 3 27 ENGINE TRANSMISSION Rear axle shaft Washer Circlip Gasket ldle shaft Dowel pin Oil drain bolt Gear box cover S Washer 3Bearing Oil seal Final driven gear SOU level bolt Ge Oil drain bolt e Install the circlip on to the rear axle shaft Assemble the idle shaft subassembly using the idle shaft and thrust washer then install th subsasembly on the gear box e Install the final driven gear 6 on the rear axle shaft using the circlip Rounded corner ENGINE 3 28 O Install the new bearing to the gear box cover with the special tool 09913 70610 Bearing installer Special tool Apply grease to the lip of the oil seal and install it to the gear box cover with the special tool UNE Oil seal 39000 07000 09914 05210 005 Bearing installer e Install the washer 0 newsgasket and dowel pin D e Install the driveshaft 2 to the gear box cover O Apply THREE BOND NO 1215 at the hatched area shown in the illustration and install the gear box cover 43 on the crankcase 99000 31110 Three Bond No 1215 e Tighten all the screws enenly one by one in a diagonal fashion 3 29 ENGINE STARTER DRIVEN GEAR AND STARTER MOTOR Starter driven gear Starter motor e Install the starter driven gear over the left crankshaft end NOTE
19. e Tighten the nut to the specified torque with the special tool 09930 40113 Rotor holder Tightening torque 40 60 N m 4 0 6 0 kg m 29 0 43 5 Ib ft O Insert the V belt between the driven faces as deep inside as possible while pulling the movable driven face all the way out side to provide the maximum belt clearance CAUTION The belt should be positioned so that the arrows on the belt periphery point the normal turning direction The V belt contact face on the driven faces should be thoroughly cleaned to be free from oil e Thoroughly clean the clutch housing to be free from oil and position it over the clutch shoe assembly e Tighten the clutch housing nut to the specified torque with the special tool 09930 40113 Rotor holder Tightening torque 40 60 N rm 4 0 6 0 kg m 29 0 435 Ib ft ENGINE 3 32 Special tool 3 33 ENGINE MOVABLE DRIVE DMovable drive face Roller Movable drive plate Damper 0 ring Movable drive face cover DSpacer amp Fixed drive face kKick starter driven nut Kick starter driven gear Spring Spacer 3E ring e Install the roller 2 to the movable drive face D e Mount the three dampers on the movable drive plate and install it on the movable drive face 5 e Position the O ring on the movable drive face ENGINE 3 34 e Install the movable drive face cover 7 NOTE Make sure that the movable drive plate is fully positioned
20. es em sr o epe poem or ome oes os EE AN EE EE EE EE 9 oe oe pee oem oem D sem o omm owe xem mem nem mese o oum owe meo mem mem mem o omm meme ems mem acm arms Conventional bolt 4 marked bolt T marked bolt 7 5 SERVICING INFORMATION WIRING DIAGRAM 139 11 MOIE UHM Poy du J998J SHYUM UHM MOIISA MA Joe n UBBID UUM MOJA OA 139 11 YOR G YUM MOJISA HA Jooe n eniH UHM SHUM IM OMd YHYdS 199811 498lg UHM NUM EM 199811 Pay UUM SHUM UM 19911 SHUM UHM 498lg Ma 199811 Doud UHM yoejg Hg MO ISA A HOLMS 1HON AM uv38 aniq 1ysI7 SHUM pay ogueJQ Useds 1UBI1 HOLMS NOLLINOI as ng 7 M AEIO JO H Loo y O UMOJg JIG ER yoelq g HO lOO JHM YOLOW HALLS NALA M TALHOM TWNOIS VU DCH Lee pei mee EN EEEEEEER AN l i LE P 2 SE ER WEN WS EEN ER RR RR Seen N ND D 1HOFl MAL H H H R te e tHe 3 MY Bi E BEER S 4 1HOIT VNOS M DH e 1 M 8A M8 uM i Wi i as 9 Na GA i H T INV DO BU ND NaOH UNOS NEAL HOI 1038 Be BAI IO XO8 YNDHL a HHS TT ENE EE IE elle HOLIMS HON Se E NOS NIU Li oae ETE LI E CHER avo SI ELI IT LM 1 HOLMS HANG 09 8 3 MI O H HA Ma M O H Ud Ma l J 1 HOM TWNOIS NANL IN H ITT WEE NEAL LNO 81 8 Md Ma H
21. lb ft ENGINE 3 38 OIL PUMP AND INTAKE Apply grease DOil pump driven gear Oil pump e Apply grease to the oil pump driven gear D and install it tothe crankcase 99000 07000 e Install the oil pump and tighten H Io the specified torque Tightening torque 323 N m 0 3 0 5 kg m 2 0 36 Ib ft e Install the gaskets D and intake pipe with reed valve 5 to the crankcase 3 39 ENGINE MAGNETO DStator Key Magneto rotor Nut and washer Fan case amp Cooling fan Fan cover O Degrease the tapered portion of the crankshaft and also the magneto rotor e Install the stator e Install the key e Install the rotor Appl THREAD LOCK 1324 to the rotor nut OD and tighten it to the specified torque with the special tool 99000 32030 THREAD LOCK 1324 09930 40113 Rotor holder i i 35 45 N m Tightening torque 35 45 kg m 25 5 31 0 lb ft ENGINE 3 40 e Install the fan case 6 O Install the magneto lead wire and starter motor lead wire e Install the cooling fan e Install the cooling fan cover D MUFFLER e Tighten the exhaust pipe bolts D and muffler mounting bolts to the specified torque i 8 12 Nem Tightening torque 0 8 1 2 em 60 85 lb ft FUEL AND LUBRICATION SYSTEM CONTENTS CARBURETOR EE EE aaa 4 1 sisie MED m 4 1 DISASSEMBLY sonara eee 4 INSPECTION ME RE EE EE EE d REASSEMBLY AND REMOUNTI
22. pipe and pipe seat O Remove the dust boot and stopper ring O Remove the oil seal by using the special tool CAUTION The oil seal removed should be replaced with a new oil seal 6 21 CHASSIS INSPECTION Inspect pipe seat for wear and damage Inspect fork pipe and bottom case sliding surfaces for any scuffing or flaws CUSHION SPRING Measure the cushion spring free length if it is shorter than the service limit replace it 240 mm 9 48 in REASSEMBLY AND REMOUNTING Reassemble and remount the fork in the reverse order of removal and disassembly and also carry out the following steps FRONT FORK BOLT e Apply thread lock 1324 to the fork bolt and tighten the bolt with specified torque Thread lock 1324 Tightening torque 35 55 N m 35 55 kg m 253 400 loft FORK OIL e For the fork oil be sure to use a front fork oil whose viscosity rating meets specification below Fork oil type TELLUS 22 Capady FORK SPRING e When installing the front fork spring the close end should posi tion upside Kegel Thread lock 1324 Threebond 1215 STEERING REMOVAL AND DISASSEMBLY e Remove the handlebar cover Refer to page 6 1 O Remove the handlebar by removing the clamp bolt and set bolt O Loosen the steering stem lock nut with the special tool 09910 6061 1 Universal clamp wrench O Remove the front fork assembly by removing the lock washer steering
23. read the runout as shown TA Excessive crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine life 09900 21304 V block 100 mm 09900 20701 Magnetic stand 09900 20206 Dial gauge 1 100 mm CONDITION OF BIG END BEARING Turn the crankshaft with the conrod to feel the smoothness 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 OA CONROD SMALL END BORE LD Measure the conrod small end diameter with a caliper gauge 14047 mm 0 5530 in 09900 20605 Dial calipers AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch and variable ratio belt drive transmission The engagement of the clutch is gov erned by engine RPMs and centrifugal 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 opera tion of the drivetrain Follow the procedures listed 1 INITIAL ENGAGEMENT INSPECTION Warm up the motorcycle to norm
24. test lift the seat and remove the right frame cover then dis connect the B W and Y B lead connector of the fuel gauge sending unit Connect a jumper wire between B W and Y B wires coming from the main wiring harness With the ignition switch turned ON the fuel meter should indicate F The second test will check the accuracy of the meter in the full and empty positions Connect a 90 ohm resistor between the Y B and B W lead wires The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the circuit and if its pointer indicates the F full position when the resistor is changed to 10 ohms If either one or both indications are abnormal replace the fuel meter with a new one 5 7 ELECTRICAL SYSTEM FUEL GUAGE SENDING UNIT INSPECTION O Disconnect the lead wires coming out of the fuel gauge and check resistance of each position e f the resistance measured is incorrect replace the fuel gauge assembly with a new one e The relation between the position of the fuel gauge float and resistance is shown in the following table Es Te F Full Approx 109 E Empty Approx 909 OIL LEVEL CHECK LIGHT Oil Oil level check light level switch IG switch OIL LEVEL SWITCH INSPECTION inui i P X Check the oil level switch for continuity between the lead wire If the BER aa A tester does not show the value of 0 1 ohm when the switch ring is E Ka in bottom posi
25. the disc if the runout exceeds the service limit 0 3 mmn 0 012 in 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand MASTER CYLINDER REMOVAL AND DISASSEMBLY O Remove the handlebar cover Refer to page 6 1 e Disconnect the front brake light switch lead wires O Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose master cylinder joint CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid reacts chemically with paint plastics rubber materials etc CHASSIS 6 16 6 17 CHASSIS O Remove the master cylinder O Remove the brake lever D and brake switch O Remove the dust boot Gi O Remove the circlip withthe special tool 09900 06108 Snapring pliers O Remove the piston primary cup with return spring O Remove the reservoir cap and diaphragm D e Drain brake fluid MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for scratches or other damage Inspect the primary cup and dust boot for wear or damage MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly and also carry out the following steps CAUTION Wash the master cylinder components with fresh brake fluid before reassembly
26. the handlebar and tighten the set bolt and clamp nut to the specified torque O Tightening torque 22 28 Ng 22 28 kg m 159 203 lb ft D Tightening torque 532 EN 48 52 kg m 345 375 lot CAUTION After performing the adjustment and installing the handlebar rock the front wheel assembly for ward and backward to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable readjust the steering outer race nut 6 25 CHASSIS REAR WHEEL AND BRAKE o 69 osos 4565 DRear axle nut Washer SRear wheel Brake shoe Spring Rear brake camshaft MIndicate plate Brake cam lever Brake cam lever nut Brake cam lever bolt REMOVAL AND DISASSEMBLY e Place the motorcycle on level ground e Remove the muffler Refer to page 3 4 O Remove the rear wheel by removing the axle nut INSPECTION BRAKE DRUM Measure the brake drum I D to determine the extent of wear and if the limit is exceeded by the wear noted replace the drum The value of this limit is indicated inside the drum EE BRAKE SHOE Using a vernier calipers measure the brake shoe outside diameter at the place as shown in the photo If the measurement is less than the limit replace the brake shoe 356 GT n CAUTION Replace the brake shoe with a set otherwise braking performance will be adversely affected WHEEL Refer to page 6 10 TIRE Refer to pa
27. tracer white lead wire and ground If the tester reading is as follows magneto is in good condition More than 100 V AC at STD No load performance 5000 r min REGULATOR RECTIFIER e Disconnect the coupler Using the pocket tester x1K range measure the resis tance between the terminals as shown in the following table If the resistance checked is incorrect replace the regulator rectifier 09900 25002 Pocket tester Unit Approx K I D AD ide L le Es e a D ELECTRICAL SYSTEM 5 4 STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below namely the starter motor relay starter switch and battery Depressing the starter button on the right handlebar switch box while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the Starter motor to the battery Starter relay R Fuse mph e vo IG switch Starter button B m motor LE P Brake switch TT Battery do ki 2 STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the starter motor Disassemble the starter motor as shown in the illustration D Holder 2 Pinion gear assembly Brush holder assembly Amateur Starting motor cover 5 5 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn the motor will be unable to pro cedure sufficient torque and the engine will be difficult to turn over To prevent this
28. wires HANDLEBAR REAR COVER e Disconnect the lead wire couplers and speedometer cable e Remove the handlebar rear cover by removing the mounting screws REMOUNTING O Remount the handlebar covers in the reverse order of removal 6 3 CHASSIS LEG SHIELD AND SIDE COVERS CA J9A09 19 U9 7 49 00 APIS CS ZZ J9 09 pjeius 397 pjeius Bal Jeddn 1U044 enbi10 Suruoe1usl J S N pJolys JOMO UOJ CHASSIS 6 4 REMOVAL FRONT LEG SHIELD UPPER O Loosen the mounting screws O Remove the front leg shield upper by pull out it forward FRONT LEG SHIELD LOWER O Loosen the mounting screws O Remove the front leg shield lower 6 5 CHASSIS REAR CARRIER O Open the seat Remove the rear carrier by removing the bolts and screw RIGHT SIDE COVER RIGHT SIDE LEG SHIELD O Loosen the mounting screws O Remove the right side cover and right side leg shield at the same time Side cover CHASSIS 6 6 LEFT SIDE COVER LEFT SIDE LEG SHIELD O Loosen the mounting screws O Remove the handle grip by removing the bolts Remove the left side cover and left side leg shield at the same time Side cover 6 7 CHASSIS REAR CENTER COVER Remove the rear center cover by removing the bolts COVER LEG SHIELD REAR AND LEL SHIELD REAR Remove the ignition cap O Remove the battery cover by removing the screw O Loosen th
29. ER BUTTON AA w veo ON ER BATTERY SPECIFICATION Type designation YTX4L BS Capacity 12V 3AH 10HR Standard electrolyte S G 1 32 at 20 C 68 F INITIAL CHARGING FILLING ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes O Remove the caps NOTE After filling the electrolyte completely use the removed cap as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 9 of the electrolyte container O Insert the nozzels 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 e Make sure air bubbles are coming up each electrolyte container and leave in this position for about more than 20 minutes ELECTRICAL SYSTEM 5 1O Fults Stopp Terrin Upper cower e EI broathes e BC CS 4 Cathode Er ug L Salety valve plapes sce oa pred des AL Cri hoj fiberglass plate Anode plates Electrolyte containers Insert in filler holes Air bubbles 5 11 ELECTRICAL SYSTEM NOTE If no air bubbles are coming up from a filler port tap the bottom of the two or three times Never remove the container from the battery After confirming that the electrolyte has entered the battery completely remove the electrolyte containers from the battery Wait for around 20 minutes O Insert the ca
30. G SYSTEM Stator Regulator Rectifier Engine stop se IGNITION COIL Check the ignition coil with electro tester e 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 09900 28106 Electro tester STD spark performance 8 mm O Check the ignition coil with pocket tester 09900 25002 Pocket tester IGNITION COIL RESISTANCE W L Ground Primary Approx 0 15 0 28 Q Plug cap Ground 5 3 ELECTRICAL SYSTEM STATOR COILS O Using a pocket tester measure the resistance between the lead wire and ground If the resistance checked is incorrect replace the coil po Standard resistance Lighting 06 149 CHARGING OUTPUT CHECK Start the engine and keep it running at 5000 r min with lighting switch turned ON Measure the DC voltage between the battery terminal and with a pocket tester If the tester reads under or over following specification check the no lead performance or replace the regulator rectifier NOTE When making this test be sure that the battery is in fully charged condition 09900 25002 Pocket tester 03900 26006 14 15V at 5000 r min SID charging output NO LOAD PERFORMANCE e Disconnect the magneto lead wire coupler O Start the engine and keep it running at 5000 r min e Using a pocket tester measure the AC voltage between the White with Red
31. NG m 4 REMOVAL tetendit entume sape NBC cre IN ene 4 BEMOUNTIN Q isis eani n cr eet 4 s r gt T oO N OO A A N OIL PUMP eE e nn E O CTS 4 4 1 FUEL AND LUBRICATION SYSTEM CARBURETOR DCarburetor chamber Float Main jet Throttle stop screw GNeedle jet amp Needle valve DPilot air screw Throttle valve 9Jet needle DE ring Spring Thermoelement REMOVAL Remove the side cover Refer to page 6 3 O Remove the absorber mounting lower bolt e Remove the carburetor top cap D and disconnect the throttle cable O Disconnect the carburetor hoses and oil hose Vacuum hose Oil hose Fuel hose O Remove the careburetor by loosening the mounting bolts 6 and clamp screw D DISASSEMBLY e Remove the thermoelement assembly CAUTION Do not attempt to disassemble the thermoelement assembly It is not serviceable FUEL AND LUBRICATION SYSTEM 4 2 4 3 FUEL AND LUBRICATION SYSTEM O Remove the float chamber D O Remove the float by removing the screw and pin O Remove the needle valve 1 O Remove the throttle stop screw 5 and pilot air screw NOTE When removing the pilot air screw record the revolu tions until tighten completly O Remove the main jet D and needle jet 8 FUEL AND LUBRICATION SYSTEM 4 4 INSPECTION Inspect the valve surface Check following items for any da
32. ORMATION HYOSUNG MOTORS amp MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC Overseas Service GENERAL INFORMATION CONTENTS MODEL IDENTIFICATION ee ee ee ee 1 1 FUEL AND OIL RECOMMENDATIONS Imm 1 1 BREAKING IN PROCEDURE pue 1 1 PRECAUTIONS AND GENERAL INSTRUCTIONS 1 2 SPECIAL MATERIALS nectit titii asa 1 3 SPECIFICATIONS sean eee 1 4 1 1 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER The frame number or VIN is stamped on the right side of the under center in the frame ENGINE NUMBER The engine serial number is stamped on the crankcase These numbers are required especially for registering the motorcycle and ordering spare parts FUEL AND OIL RECOMMENDATIONS Be sure to the specified fuel and oils The following are the specification FUEL Gasoline used should be graded 85 95 octane or higher An unleaded gasoline is recommended ENGINE OIL For the HYOSUNG CCI system use of APOLLOIL BIKE K or HYPOL HS is highly recommended but if they are not available a good quality two stoke oil non diuent type should be used FINAL GEAR OIL Use a good quality SAE 10W 40 multi grade motor oil BREAKING IN PROCEDURE During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The futu
33. Su 3 09913 75820 oa e TELS JA an Bearing installer wu La M a A SL l n kr Remove the oil seal with the special tool ESA WK Special tool CENTER STAND O Remove the return spring D O Remove the cotter pin washer and shaft O Remove the center stand 6 CRANKCASE O Remove the crankcase securing screws NOTE Loosen the crankcase nuts diagonally 09920 13120 Crankcase separation tool 3 11 ENGINE O Remove the crankshaft with the special tool Crankshaft remover 09920 13120 Crankcase separating tool O Remove the bearings oil seals and bushing ENGINE 3 12 Using two steel tubes of appropriate size press out the engine mounting bushings on a vise as shown in the illustration Crankcase e Bushing Em Crankcase H 3 13 ENGINE ENGINE COMPONENTS INSPECTION 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 ne O OIL SEAL 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 crankshaft by V blocks with the dial gauge rigged to
34. Th An MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPECTION EE OE RE EE EARN MASTER GYLINDER REASSEMBLY AND REMOUNTING FRONT FORK LE dIE EE GE N N N A N NEST REMOVAL AND DISASSEMBLY EE HE EE EE RE OE KO INSPECTION EO OE RR OE REASSEMBLY AND HREMOUNTING STEERING H REMOVAL AND DISASSEMBLY T H M n P INSPECTION T ON NE REASSEMBLY AND REMOUNTING P REAR WHEEL AND BRAKE sa es Fetters P O m REMOVAL AND DISASSEMBLY e E E INSPECTION e E e EE REASSEMBL Y AND REMOUNTING A O 6 1 CHASSIS HANDLEBAR COVERS Handle rear cover y XA o MR Y SS Q X cm E LO NI 5 LO Q E gt E E d oF E i E 7 E q e E 4 Si Y e x Iz a Gl t l OU o ZX S O X Se d N f S e i YOR DA Et l CP Si N EN N E 7 X N E T slc P O o C M DG E S eo eo oe ot Sele o DION E JESP S ms D c ie OI OL CHASSIS 6 2 REMOVAL HANDLEBAR FRONT COVER O Remove the handlebar front cover by removing the mounting screws and disconnecting the lead
35. UP PROCEDURES FRONT SUSPENSION Inspect at Initially 1000km 600miles 2momths and Every 8000km 4800miles 12months thereafter Inspect the front shock absorber for oil leakage or other damage and replace the defective parts if necessary REAR SUSPENSION Inspect at Initially 1000km 600miles 2momths and Every 8000km 4800miles 12months thereafter Inspect the rear shock absorber for oil leak and the mounting rub bers including engine mountings for wear and damage Replace the defective part if necessary CHASSIS BOLTS AND NUTS Tighten at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter These bolts and nuts listed below are important safety parts They must be loosened first and retightened to the specified torque with a torque wrench wp CSC BCEE OMITA EEN 5 Fen wate mf omo OMITE o Fom ate cpr mowing bot Fr ate ar bew we S leeu ooo a Fear aa etre bat pe and ove o Fearne amie nt soen Eeer 60 100 48 52 22 28 8 12 20 25 18 28 60 90 22 35 48 12 40 60 24 0 31 5 43 5 2 5 34 5 31 5 16 0 20 0 608 145 18 0 13 0 20 0 4 5 6 5 43 5 65 0 16 0 25 5 4 5 6 5 34 5 52 0 29 0 43 5 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 12 2 13 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES GENERAL LUBRICATIONS Proper lubrication is important for smooth operation and long life of each wo
36. URES 2 2 MAINTENANCE AND TUNE UP PROCEDURE This section describes the servicing procedures for each item of the Periodic Maintenance requirements BATTERY Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter O Remove the battery cover from the leg shield mounting SCrews e Remove the battery lead and then lead at the battery ter minals and remove the battery O Check the battery voltage with the pocket tester If the voltage reading is below 12 0V this battery needs recharging Refer to page 5 10 Battery voltage Minimum 12 0V 09900 25002 Pocket tester 2 3 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CYLINER HEAD NUT AND EXHAUST PIPE BOLTS Tighten at Initially 1000km 600miles 2months and Every 4000km 2400miles 6months thereafter Cylinder head nuts when they are not tightened to the specified torque may result in leakage of the compressed mixture and reduce output Tighten the cylinder head nuts in the following procedure O Remove the frame side cover Refer to page 6 3 O Remove the spark plug cap O Remove the cylinder head cover bolts Refer to page 3 5 e Tighten the nuts evenly one by one in stages until each one is tightened to the specified torque Tighten the nuts in the order indicated Tightening torque 8 12 N m pannel Meee Nt 08 12 kg m 60 85 Ib ft Exhaust pipe nut 8 12 EU dd 0 8 1 2 kg m 6 0 8 5 Ib ft
37. al operating temperature Remove the right frame side cover Connect an electric tachometer to the engine Seated on the motorcycle with the motorcycle on level ground increase the engine RPMs slowly and note the RPM at which the motorcycle begins to move forward 3900 2600 ENGAGEMENT R MIN STD 3300 r min 300 r min 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping Warm the engine to normal operating temperatures Connect an electric 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 CAUTION Do not apply full power for more than 10 seconds or damage to the clutch or engine may occur LOCK UP R MIN STD 5800 r min 500 r min ENGINE 3 14 3 15 ENGINE If the engine r min does not coincide with the specified r min 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 2 0 mm 0 08 in CAUTION Clutch shoes or springs must be changed as a set and never individually Clutch wheel inspect visually the condition of
38. areful not to allow the charging current to exceed 4A at any time in mp oo 25 Bartery charped condition e After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester e H the battery voltage is less than 12 5V recharge the battery again e f the battery voltage is still less than 12 5V after recharging replace the battery with a new one e When a battery is left for a long term without using it is subject to discharge When the motorcycle is not Used for more than 1 month especially during the winter season recharge the battery once a month at least CHASSIS CONTENTS HANDLE BAR COVERS P REMOVAL ree Text E REMOUNTING IE EER ON NL EE NE EE LEG SHIELD AND SIDE COVERS EN REMOVAL A AAA AAA A E REMOUNTING A EMEND PAR FRONT WHEEL EE OE EE OE AE OE GEE OE A oo MA REMOVAL AND DISASSEMBLY ER N N TR EET INSPECTION U F EES AAA REASSEMBLY AND REMOUNTING eo n UU AA FRONT BRAKE Tr EA Were ON of BRAKE PAD REPLACEMENT E AO CALIPER REMOVAL AND DISASSEMBLY MEE OE KO ATTE CALIPER INSPECTION A V EEN ols Sis eae etd A EN EEN CALIPER REASSEMBLY n WE TEE E Mc Er DISC PLATE REMOVAL AND DISASSEMBLY Ho DISC PLATE INSPECTION
39. at 3000 r min Holding engine speed at the same 3000 r min let the pump draw for 5 minutes For this operation the reading taken on the device should be 0 9 1 1 ml 09900 21602 CCI oil gauge MN 0 9 1 1 ml at 3000 r min Oil discharge amount for 5 minutes CAUTION During this inspection strictly follow the following points The machine should be rested on the center stand x Do not touch the rear wheel while running the engine FUEL AND LUBRICATION SYSTEM 4 8 ELECTRICAL SYSTEM CONTENTS ELECTRICAL TT EE 5 1 IGNITION CHARGING SYSTEM eene 5 2 IGNITION COM soap 5 2 STATOR COLS nas ope 5 3 REGULATOR RECTIFIER ten 5 3 STARTER SYSTEM mes sine eb ei n car MB cares 5 4 STARTER MOTOR INSPECTION e Re 5 5 STARTER RELAY INSPECTION ee 5 5 FUEL LEVEL GAUGE aa Rene 5 6 OIL LEVEL CHECK LIGHT Mr Ma Ne 5 7 THERMOELEMENT essa litte tpe 5 8 SWITCHES e eessssssssssssssssssessssssssensnesnnenenenennennenennennncnncneneeeeee 5 9 BATTERY ol N N SEE AE EE EE boe 5 10 5 1 ELECTRICAL SYSTEM ELECTRICAL PARTS D Ignition coil 2 Thermolement assembly 8 Trunk box lamp Fuel level gauge 5 Oil level gauge Turn signal relay m ae m BR L B EE i m T di nm f i ig Rectifier Ve MAL ir h J ii E A XP N E I Ae amp d orb em Je ME Batter e E a IN 07 77 CD Unit th ks Horn i ELECTRICAL SYSTEM 5 2 IGNITION CHARGIN
40. ate size and a vise press the mounting bushings and into the crankcase holes as shown in the illustration NOTE Knurled end S should face inside Protruside and should be in the same dimension Bushuing 11 Crankcase l q Bushing 2 i i i We ZU mm e 1 H IE i A 20 mm ENGINE 3 22 CRANKSHAFT Crankshaft Crankcase R Oil seal DOil seal Oil pump drive gear Oil pump drive gear MOil O Deside the length between the webs referring to the figure at right when rebuilding the crankshaft 35 0 1 0 mm Standard width between webs 1 378 0 004 in e When mounting the crankshaft into the crankcase it is necessary to pull its left end into the crankcase with the special tool 09910 32812 Crankshaft installer CAUTION Never fit the crankshaft into the crankcase by driving it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affected 3 23 ENGINE CRANKCASE O Wipe the crankcase mating surfaces both surfaces with cleaning solvent Apply THREE BOND NO 1215 uniformly to the mating surface of the left half of the crankcase and install the dowel pins 99000 31110 THREAD BOND NO 1215 O Install the two dowel pins e Tighten the crankcase screws securely O Check if crankshaft rotates smoothly O Install the new oil seal D to the crankcase with the special tool NOTE Align the oil seal with edge of t
41. e screw and bolts O Remove the cover leg shield rear and leg shield rear at the same time REMOUNTING O Remount the leg shield and side covers in the reverse orders of removal CHASSIS 6 8 FRONT WHEEL Tightening torque 3 3 5 2 240 375 13 0 20 0 Front axle nut Speedometer gear box Wheel bearing R Spacer Wheel bearing L amp Disc plate DSpacer Oil seal Front axle shaft Disc bolt REMOVAL AND DISASSEMBLY O Remove the front brake caliper by removing the mounting bolts NOTE Do not operate the front brake lever while dismount ing the caliper O Remove the front axle nut O Support the motocycle by jack or wooden block O Remove the front wheel by removing the front axle shaft 6 9 CHASSIS O Remove the disc plate D by removing the bolts O Remove the spacer O Remove the dust seal with the special tool ESE e Drive out the both bearing with the special tool in the following procedures O Insert the adapter into the bearing e After inserting the wedge bar from the opposit side lock the wedge bar in the slit of the adapter e Drive out the bearing by knocking the wedge bar 09841 50110 CAUTION The removed dust seal and bearing should be replaced with new ones INSPECTION WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown An excessive runout is usually due to worn or loose wheel
42. e standard plug Je ant to get overheat BP7HS replace with this plug e Tighten the spark plug to the specification Spark plug 25 30N m Tightening torque 25 30 kg m 180 210 lb ft NOTE To check the spark plug first make sure that the fuel used is unlead ed gasoline and if plug is either sooty with carbon or bumt white replace it Confirm the thread size and reach when replacing the plug FUEL LINE Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter Replace Every 4 years 2 5 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES AIR CLEANER Clean Every 4000km 2400miles 6months If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the element in the following manner O Remove the frame side cover Refer to page 6 3 O Remove the cleaner cover by removing the screw O Remove the element O Fill a washing pan of a proper size with non flammable cleaning solvent Immerse the element in the cleaning solvent and wash them clean O Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands do not twist or wiring the element or if will develop tears O Immerse the element in SAE 10 W40 oil and squeeze the oil out of the element leaving it slightly wet with oil O Fit the elements to the cleane
43. e text of this manual on later pages Reed valve securing screw Throttle grip e Crankshaft oil seal outer Speedometer cable 1 surface Oil pump drive driven gear Kick starter gear Kick starter shaft Movable driven face Fixed driven face Starter pinion Starter motor Wheel bearing THREAD LOGK Brake camshaft 1342 Steering stem bearing 99000 32050 GREASE G 99000 07C00 Crankcase mating surface Front fork socket bolt Final gear cover THREE BOND THREAD LOCK No 1215 4324 99000 31110 99000 32030 e Front brake caliper SILICONE GREASE 99000 25110 Magneto rotor nut THREAD LOCK SUPER 1322 99000 32110 SPECIFICATIONS DIMENSIONS AND DRY M Overall length e Overall width Overall height Wheelbase Ground clearance en Dry mass ENGINE Type Me Intake system Number of cylinder e Bore Stroke Piston displacement Corrected compression ratio Nhan Carburetor a RD RR Air cleaner Starter system Lubrication system TRANSMISSION Clutch Reduction ratio ASS 1 780 mm 70 1 in 660 mm 26 0 in 1 065 mm 41 9 in 1 221 mm 48 1 in 112 mm 4 4 in 84 kg 185 Ibs Two stroke forced air cooled Reed valve 1 41 0 mm 1 614 in 37 4 mm 1 472 in 49 cri 3 0 cu in TAN SIDEDRAFT V V Polyurethane foam element Electric and kick HYOSUNG CCI Dry shoe automatic ce
44. earing remover urn 09900 20805 Tire depth gauge ERAN 09913 75820 g Wyre installer Bearing remover k 09900 21602 CCI oil gauge 09913 75830 d MEE installer Sea Bearing remover ao NS 09900 25002 Pocket tester 09913 76010 l 8 Ta installer NI Bearing remover 09900 26006 Tachometer 09913 84510 installer SERVICING INFORMATION 7 2 PART No PART NAME PART No PART NAME de Bearing remover 09913 85210 8 09925 98220 Bearing installer i installer E ie Bearing remover gt 8 Petale 09930 30102 Sliding shaft 09920 13120 Crankcase separating tool bw 09930 30163 09921 20210 Bearing remover 09930 40113 Rotor holder d 09923 73210 Bearing remover 09941 34513 Bearing installer 09923 74510 Bearing remover M F 09941 50110 Bearing remover earing i er 09924 74510 Seale oe 09941 74910 Bearing installer handle Er Bearing installer T attachment 09943 88211 earing installer Bearing installer 09924 84520 set 7 3 SERVICING INFORMATION TIGHTENING TORQUE CHASSIS D e XT Ow ow SERVICING INFORMATION 7 4 ENGINE eld ENE TEEN e fomm em om ars OCOT o reraman es A sw o orem ES ume eem ele me END er oem 11 Exhaust pipe nut 0 8 1 2 6 0 8 5 TIGHTENING TORQUE CHART For other bolts and nuts not listed in the preceding page refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt LL er D
45. esence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the dan ger to which such trapped air exposes the machine and rider it is essectial that after remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the following manner e Fil up the master oylinder reservoir to the upper end of the inspection window Replace the reservoir cap to prevent entry of dirt Attach a pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle e Bleed air from the bleeder valve O Squeeze and release the brake lever several times in rapid suc cession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handlebar grip Then close the valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the recep tacle no longer contains air bubbles 2 9 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES NOTE Replenish the brake fluid reservoir as necessary while bleeding the brake system Make sure that there is always some fluid visible in the reservoir e Close the bleeder valve and disconnect the pipe Fill the reser voir to the upper end of the inspection window Bleeder valve
46. ge 6 10 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and brake in the reverse order of removal and diassembly BRAKE CAM LEVER e When installing the brake cam lever align the punched mark D of camshaft with the slit on cam lever 6 9 N m Tightening torque ME 06 03 kg m 45 65 lb ft BRAKE SHOE Apply grease to the camshaft and pin before installing the brake shoes 39000 0100 CAUTION Be careful not to apply too much grease to the camshaft and pin If grease gets on the lining brake effectiveness will be lost REAR AXLE NUT e Tighten the rear axle nut to the specified torque i i 60 90 N m Tightening torque Trento 60 90 kg m 435 650 lb ft CHASSIS 6 26 Brake cam lever SERVICING INFORMATION CONTENTS SPECIAL TOOLS 0000 ee ee ee ee 7 1 TIGHTENING TORQUE EE 7 3 WIRING DIAGRAM ee 7 5 WIRE ROUTING nn 7 6 SERVICE DATA tette 7 7 TROBLESHOOTING eee 7 11 7 1 SERVICING INFORMATION SPECIAL TOOLS PART No PART NAME PART No PART NAME 09900 00401 Hexagon wrench set v i 09910 20116 Conrod holder Snap ring pliers 09900 06107 EE e 09910 32812 Crank shaft installer opening type ie 09900 06108 BMAP ring pliers 09910 60611 Universal clamp wrench closing type M Es E 09900 09003 Impact driver set S 09913 50121 Oil seal remover N 05 7 k L Bearing remover 09900 20804 Thickness gauge j 09913 75810 l installer AA AE B
47. guide 4 O Remove the pins 5 movable driven face and fixed driven face D O Remove the roller bearing with the special tools Q 09923 73210 Special tool Special too X i A j mu 09930 30102 Sliding shaft l Zei e 4 CAUTION The removed bearing should be replaced with a new one C LN al ENGINE 3 8 O Remove the circlip O Remove the bearing with the special tool 09941 50111 Wheel bearing remover CAUTION The removed bearing should be replaced with a new one TRANSMISSION e Drain gear oil O Remove the gear box cover D e Remove the driveshaft O Remove the oil seal from the gearbox cover with the special tool ESE CAUTION The removed oil seal should be replaced with a new one Remove the bearing with the special tool Bearing remover 09943 8821 1 E Bearing installer CAUTION The removed bearing should be replaced with a new Installer one 3 9 ENGINE O Remove the circlip and final driven gear Remove the idle shaft O Remove the drive shaft bearing D Special d7 09930 30102 Sliding shaft Ne d 09921 20210 ay oficial 5 or sd wy WHEEL BRAKE O Remove the rear axle nut D and washer O Remove the rear wheel 3 O Remove the brake shoes 6 and rear axle shaft O Remove the bearing retainer ENGINE 3 10 O Remove the bearing 7 with the special tool Bearing remover Special tool
48. he crankcase as shown in the illustration 09913 85210 Bearing installer O r n y E D Apply grease Special tool ENGINE 3 24 CENTER STAND O Install the center stand e Install the shaft washer and cotter pin O Hook center stand spring 5 into the crankcase 3 25 ENGINE REAR AXLE SHAFT BRAKE AND WHEEL DRear axle shaft Rear brake cam SRear brake cam lever DRear brake cam lever bolt Rear brake shoe Brake shoe spring Rear wheel Rear wheel washer Rear wheel nut O Install the rear axle shaft D into the crankcase by tapping its end lightly e Apply engine oil on the left end of the rear axle shaft being inserted later in the reduction rear box cover Apply grease lightly on the rear brake cam pivot part and install it to the crankcase 39000 0700 e Turn to position the cam where the punched mark 9 on the end face is directed toward the axis of the rear axle shaft ENGINE 3 26 e When installing the cam lever to the cam align the punched mark with the slit of cam lever Punched mark e Tighten the cam lever nut to the specified torque Tightening torque m UE Oie 0 6 0 9 kg m 4 5 6 5 Ib ft e Install the brake shoes e Apply grease to the camshaft and pin before installing the brake shoes 39000 0700 CAUTION Be careful not to apply too much grease to the camshaft and pin If grease gets on the lining
49. istor element in the regulator rectifier damaged or defective Regulator rectifier unit poorly grounded Lead wire insulation frayed due to vibration resulting in intermittent shorting Magneto coil internally shorted Defective regulator rectifier Battery run down Defective switch contacts Brushes not seating properly on commutator in starter motor Defective starter relay Defective starter pinion gears Defective front or rear brake light switch circuit Replace Replace Replace Connect tighten Adjust carburetor Adjust carburetor Change Clean Replace by hot type plug Replace Replace by hot type plug Turn up Retighten Adjust carburetor Check oil pump Repair replace or retighten Replace Replace Repair or retighten Replace Replace Replace the battery Replace the battery Replace Clean and tighten groun connection Repair or replace Replace Replace Recharge or replace Replace Repair or replace Replace Replace Replace or repair BATTERY Battery runs down 1 The charging method is not correct Check the magneto and regulator rec quickly tifier circuit connections and make necessary adjustments to obtain spe cified charging operation Replace the battery and correct the charging system Replace the battery Cell plates have lost much of their active material as a result of over charging A short circuit co
50. l due to seizure or similar abnormalities can be corrected by f grinding the flaws off with fien grain emery paper If e the flaws are deep grooves or otherwise persist the 1 0 1 5 mm LJ ft mm cylinder must be reworked with a boring machine to the next oversize PISTON CYLINDER TO PISTON CLEARANCE Cylinder to piston clearance is the difference between piston diame ter and cylinder bore diameter Be sure to take the maked diameter at right angles to the piston pin The value of elevation is pre scribed to be 15 mm from the skirt end 09900 20202 Micrometer 25 50 mm EE 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 mea surement for the bore diameter should be taken in the intake to exhaust port direction and at 20mm from the cylinder top surface Unit mm Cylinder 41 005 41 020 41 070 40 935 40 950 40 885 Cylinder to piston 0 065 0 075 0 120 pT Sewelmt DE CARBONING De carbon the piston and piston ring grooves as illustrated After cleaning the grooves fit the rings and rotate them in their respec tive 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 A piston whose sliding surface is badly grooved or scuffed due t
51. l rim runout Radial a 100 80 10 53 Tire size 100 80 10 53 Front Tire tread depth SUSPENSION Unit mm in ITEM SPECIFICATION LIMIT NOTE TIRE PRESSURE COLD INFLATION DUAL RIDING PUA RIDING RN cht 15 5 J gw Rm f Nm ae 8 FUEL OIL ITEM SPECIFICATION NOTE Gasoline used should be graded 85 95 octane or higher An unleaded gasoline is recommended 4 8 L Fuel tank capacity 1 3 1 1 US Imp gal EE Use APOLLOIL BIKE K or HYPOL HS or an epuivalent good quality synthetic based 2 cycle oil Fuel type Engine oil type Engine oil tank capacity 1 2 1 nee qt Ma Final gear oil Final gear oil type SAE EAN Final gear oil capacity mp oz Overhaul 30 mi 3 0 3 2 US Imp oz Brake fluid type DOT4 7 11 SERVICING INFORMATION TROUBLESHOOTING ENGINE Engine does not start or is hard to start Compression too low Excessively worn cylinder or piston rings Replace Stiff piston ring in place Refair or replace Gas leaks from the joint in crankcase cylinder or cylinder head Refair or replace Damaged reed valve Replace Spark plug too loose Tighten Broken cracked or otherwise failed piston Replace Plug not sparking 1 Damaged spark plug or spark plug cap Replace 2 Dirty or wet spark plug Clean and dry 3 Defective CDI amp Ignition coil unit or stator coil Replace 4 Open or short in high tensi
52. mage or clogging Fi for worn A Pilot jet ge Main jet Pilot air screw Needle jet air bleeding hole Float Gasket Pilot outlet and bypass holes NEEDLE 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 REASSEMBLY AND REMOUNTING O Reassemble following items Pilot air screw Throttle stop screw Main jet Needle jet e Install the needle and float on the carburetor body e Install the float pin and tightened the screw D e Install the gasket and float chamber 4 5 FUEL AND LUBRICATION SYSTEM O Install the thermoelement assembly O Install the carburetor assembly e Install the vacuum hose D oil hose and fuel hose O Install the carburetor top cap US n y dy FUEL TANK REMOVAL Remove the side covers Refer to page 6 3 Remove the rear center cover e Disconnect the fuel hose NOTE To prevent fuel flow connect the suitable cap to the fuel tank outlet e Disconnect the oil gauge lead wire
53. mmended oils When two or more persons work together pay attention to safety of each other After the reassembly check parts for tightness and operation Treat gasoline which is extremely flammable and highly exposive with greatest care Never use gaso line as cleaning solvent OO D Waming Caution and Note are included in this manual occasionally describing the following contents WARNING The parsonal safety of the rider may be involved Disregarding this information could result in injury to rider CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine NOTE H This provides special information to make maintenance easier or important inst ructions clearer REPLACEMENT PARTS When you replace any parts use only genuine HYOSUNG replace ment parts or their equivalent Genuine HYOSUNG parts are high quality parts which are designed and built specifically for HYOSUNG vehicles CAUTION Use of replacement parts which are not equivalent in qual ity to genuine HYOSUNG parts can lead to performance problems and damage 1 3 GENERAL INFORMATION SPECIAL MATERIALS The materials shown are required for maintenance works on the Model SD 50 and should be kept on hand for ready use in addition such standard materials as cleaning fluids lubricants etc should also available Methods of use are discussed in th
54. n with a air gun CAUTION Do not use high pressure air to prevent piston dam age O Remove the dust seal and piston seal CHASSIS 6 14 6 15 CHASSIS CALIPER INSPECTION Inspect the caliper cylinder bore wall for nicks scratches or other damage Inspect piston for damage and wear Inspect each rubber part for damage and wear CALIPER REASSEMBLY Reassemble and remount the caliper in the reverse order of removal and disassembly and also carry out the following steps Apply grease CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore O Apply silicone grease to the caliper holder 39000 2510 e Tighten the each bolts WARNING Bleed the air from brake fluid circuit after reassem bling caliper See page 2 8 DISC PLATE REMOVAL AND DISASSEMBLY O Remove the front wheel Refer to page 6 8 O Remove the disc plate Refer to page 6 9 e Install the disc plate Refer to page 6 11 DISC PLATE INSPECTION O Check the disc for wear with a micrometer lts thickness can be checked with disc and wheel in place Replace the disc if the thickness exceeds the service limit Service Limit 3 5 mm 0 14 in 09900 20205 Micrometer 0 25 mm e With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown Replace
55. ndition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte Battery is too old Replace the battery 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 1 Dirty container top and sides Clean too rapidly 2 Battery is too old Replace SERVICING INFORMATION 7 14 CHASSIS Handling feels too heavy Wobbly handle Wobbly front wheel Front suspension too soft Front suspension too stiff Noisy front suspension Wobbly rear wheel Rear suspension too soft Noisy rear suspension BRAKES Steering stem nut overtightened Broken bearing race in steering stem Distorted steering stem Not enough pressure in tires Loss of balance between right and left front suspension Distorted front axle or crooked tire Distorted wheel rim Worn front wheel bearings Defective or incorrect tire Loose nut on axle Loose nuts on the rear shock Worn engine mounting bushing Loose nuts or bolts for engine mounting Weakened springs Oil leakage of shock absorber Not enough grease Worn suspension arm spacer Not enough grease Loose nuts on suspension Distorted wheel rim Defective or incorrect tire Loose nuts on the rear shock abso
56. ness and replace gasket Check and replace Check and replace Check and clean Clean and replace Check and clean Check and replace Check and clean Check and clean Check and replace Check throttle valve for operation Check and clean Replace Replace Check and adjust Clean Adjust or replace 7 13 SERVICING INFORMATION ELECTRICAL No sparking or poor sparking Spark plug soon becomes fouled with carbon Spark plug electrodes overheat or burn Magneto does not charge Magneto charge but charging rate is below the specific ations Magneto overcharges Ustable charging Defective CDI amp Ignition coil unit Defective spark plug Defective magneto stator coil Loose connection of lead wire Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Incorrect engine oil Spark plug too hot The engine overheats Spark plug loose Mixture too lean Not enough engine oil Open or short in lead wires or loose lead connections Shorted grounded or open magneto coil Shorted or open regulator rectifier Lead wires tend to get shorted or open circuited or loosely connected at terminal Grounded or open circuited stator coils of magneto Defective regulator rectifier Defective cell plates in the batttery Internal short circuit in the battery Res
57. ntrifugal type 2 815 0 866 Variable Drive system CHASSIS Front suspension 0 os i Rear suspension Caster Trail Steering angle Turning radius Front tire size Rear tire size Front brake Rear brake V belt drive Telescopic coil spring oil dampened Swingarm type coil spring oil damped 25 70 mm 2 75 in 45 right A left 1 9 mm 6 2 ft 100 80 10 DA 100 80 10 DA Disc Internal expanding The specifications are subject to change without notice GENERAL INFORMATION 1 4 ELECTRICAL Ignition timing Spark plug Battery Generator Fuse Headlight Front turn signal light en Rear turn signal light Tail Brake light Speedometer light Oil level indicator light Turn signal indicator light Trunk light CAPACITIES Fuel tank HYOSUNG CDI 23 B T D C at 4 000 r min GOLDEN BP6HS 12V 3Ah 10HR Magneto 10A 12V 15 15 Wx2 12V 21 W 12V 10 W 12V 5 21 W 12V 3 4 Wx2 12V 1 7 W 12V 1 7W 12 2 W 4 8 L 1 3 1 1 US Imp gal Engine oil tank 1 2 L 1 2 1 0 US Imp qt Final gear oil 80 mi 2 7 2 8 US Imp Oz PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE e 2 1 MAINTENANCE AND TUNE UP PROCEDURE RR 2 2 BATTERY ano 2 2 CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS 2 3 CYLINDER HEAD AND CYLINDER ee 2 3 SPARK PLUG e A leen 2
58. o overheating must be replaced Shallow grooves or minor scuff can be removed by grinding with emery paper of about 400 PISTON PIN BORE Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the following service limit replace it with a new ne 09900 20605 Dial calipers 10 036 mm 0 4079 in O PISTON PIN O D Using a micrometer measure the piston outside diameter at three positions 09900 20205 Micremeter 0 25 mm 9 980 mm 0 3929 in ENGINE 3 18 E cnmoothernanm the siding surface with emery paper 3 19 ENGINE PISTON RINGS Check each ring for end gap reading the gap with a thickness gauge shown in the illustration If the end gap is found to exceed the limit indicated below replace it with a new one The end gap 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 09900 20803 Thickness gauge Service limit 0 75 mm 0 030 in As the piston ring wears its end gap increases reducing engine power output because of the resultant blow by through the enlarged gap Here lies the importance of using piston rings with end gaps within the limit Measure the piston ring free end gap to check the spring tension Ist 3 7 mm 0 15 in Service Limit 2nd 3 5 mm 0 14 in Fix the piston ring in the piston ring groove measure the ring side clearance with the thicknes
59. oil Replace 7 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 Engine runs poorly in high speed range Dirty or heavy exhaust smoke Engine lacks power Engine overheats CARBURETOR Trouble with starting Idling or low speed trouble Medium or high speed trouble Overflow and fuel level fluctuations Excessively worn cylinder or piston rings Stiff piston ring in place Spark plug gaps to narrow Ignition not advanced sufficiently due to poorly working CDI amp Ignition coil unit Defective magneto stator coil Float chamber fuel level too low Clogged air cleaner element Clogged fuel hose resulting in inadequate fuel supply to carburetor Clogged fuel cock vacuum pipe Too much engine oil to the engine Use of incorrect engine oil Excessively worn cylinder or piston rings Stiff piston ring in place Gas leaks from crankshaft oil seal Spark plug gaps incorrect Clogged jets in carburetor Float chamber fuel level out of adjustment Clogged air cleaner element Fouled spark plug Sucking air from intake pipe Slipping or worn V belt Damaged worn rollers in the movable drive face Weakened movable driven face spring Too rich fuel air mixture due to defective starter system Heavy carbon deposit on piston crown
60. on cord Replace 5 Defective ignition switch Replace No fuel reaching the carburetor 1 Clogged hole in the fuel tank cap Clean Clogged or defective fuel cock Clean or replace 2 3 Defective carburetor float valve Replace 4 Clogged fuel hose or defective vacuum hose Clean or replace Engine stalls Carbon deposited on the spark plug Clean easily Defective CDI amp Ignition coil unit Replace Clogged fuel hose Clean Clogged jets in carburetor Clean 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 c
61. ormality 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 09900 20803 Thickness gauge 0 1 mm 0 004 in ENGINE 3 16 M i V 3 17 ENGINE If the largest reading at any portion of the straightedge exceeds the limit rework the surface by rubbing it against emery paper of about it 400 laid flat on the surface plate in a lapping manner The gasketed surface 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 consumption 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 diameter reading taken at 20 mm from the top of the cylinder with a cylinder gauge If the wear thus determined exceeds the limit indicated below rework the bore to the next oversize by using a boring machine or replace the cylinder with a new one Oversize piston is available in one size 0 5 mm oversize 09900 20508 Cylinder gauge set 41 070 mm gie ni 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 20 mm NOTE Minor surface flaws on the cylinder wal
62. outer upper race G and dust seal CAUTION Do not drop the steering stem steel balls O Remove the lower bearingouter race D with a chisel O Remove the steering stem steel balls Number of steel balls CHASSIS 6 22 6 23 CHASSIS O Remove the upper and lower bearing inner race with a appropri ate bar INSPECTION Inspect the removed parts for the following abnormalities O Bearing race wear and brinelling e Worn and damaged steel balls Distortion of steering stem or handlebar REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem handlebar and front fork in the reverse order of disassembly and removal and also carry out the following steps OUTER LOWER RACE O Press in the outer lower race INNER RACE O Press in the upper and lower inner races with special tool 09941 34513 Steering inner race installer STEEL BALL O Apply grease when installing the upper and lower steel balls 39000 07609 Number of steel balls i CHASSIS 6 24 STEERING OUTER RACE NUT e Tighten the steering outer race until resistance is felt then loosen it 1 8 1 4 turn NOTE This adjustment will vary from motorcycle to motorcy cle Make sure that the steering turns smoothly and easily left to right e Tighten the steering stem lock nut with the special tool Tightening torque eli ightening torqu 60 100 k g m 435 725 bt 09910 6061 1 Universal clamp wrench e Install
63. per to the crankcase bracket as shown in the UP mark d illustration k e With UP mark faced upward install the crankcase bracket D Dil on the frame Do not tighten the bracket bolt at this stage Pull up on the rear part of crankcase bracket and while holding it tighten the bracket bolt to specification Tighten both the rear shock absorber bolt and engine mounting bolt to specification Tightening torque up Nm Kem bt O Install the magneto lead wire and starter motor lead wire cor rectly After remounting the engine route the wiring harness properly Refer to page 6 and following adjustments are necessary Page Throttle cable play 225 Idling lei SCC OS 2 5 SOI UO o eaters 2 6 Rear brake cable E 2 9 AF bleeding at oil pump ebe 4 8 ENGINE 3 4 ENGINE DISASSEMBLY MUFFLER O Remove the muffler by removing the bolts and nuts MAGNETO O Remove the cooling fan O Remove the magneto rotor nut D with the special tool 09930 40113 Rotor holder O Remove the magneto rotor with the special tool 09930 30163 e Remove the magneto stator and key REED VALVE O Remove the intake pipe with reed valve OIL PUMP O Remove the oil pump D O Remove the oil pump driven gear 3 5 ENGINE CYLINDER O Remove the cylinder cowling O Remove the cylinder head D and cylinder PISTON O Place a cloth beneath the piston and remove the circlio with a plie
64. periodically inspect the length of the brushes and replace them when they are too short or Service Limit 4mm 0 16in e 2 O 5 Qo COMMUTATOR If the commutator surface is dirty starting performance will decrease Polish the commutator with 400 or similar fine emery paper when it is dirty After polishing wipe the commutator with a clean dry cloth Measure the commutator under cut Service Limit 4mm 0 16in ARMATURE COIL Using the pocket tester check the coil for open and ground by placing probe pins on each commutator segment 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 starter motor to suddenly fail 09900 25002 Pocket tester STARTER RELAY INSPECTION e Disconnect the starter relay lead wire coupler Check the coil for open ground and ohmic resistance The coil is in good condition if the resistance is as follows 09000 25002 Pocket tester STD resistance 0 70 Q ELECTRICAL SYSTEM 5 6 FUEL GAUGE Fuel level gauge FUEL LEVEL METER GAUGE FUEL METER INSPECTION To test the Fuel Meter two different checks may be used The first and simplest test will tell if the meter is operating but will not indicate the meters accuracy throughout the range To perform this
65. ps into the filler holes pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover CAUTION Never use anything except the specified battery Once install the caps to the battery do not remove the caps e Using HYOSUNG pocket tester measure the battery voltage The tester should indicate more than 125 126 V DC as shown in the Fig If the battery voltage is lower than the specification charge the battery with a battery charger NOTE Initial charging for a new battery is recommended if two years have elapsed since the date of manufac ture SERVICING Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery termi nals are found to be coated with rust or an acidic white powdery substance then this can be cleaned away with sandpaper insert Us caps firmly LU Portes ELECTRICAL SYSTEM 5 12 RECHARGING OPERATION Charging pared Using the pocket tester check the battery voltage If the voltage de Ergo chime ity reading is less than 12 0V DC recharge the battery with a bat KE tery charger CAUTION When recharging the battery remove the battery from the motorcycle NOTE Do not remove the sealing cap off the battery top while recharging T i 0 4A for hours or AI E 40A for half an hour CAUTION Be c
66. r Replace change brake fluid Every 2 years Replace brake hose Every 4 years FRONT BRAKE FLUID LEVEL O Keep the motorcycle upright and place the handlebar straight O Check brake fluid level by observing the lower limit line on the brake fluid reservoir e When the level is bolow the lower limit line replenish with brake fluid that meets the following specification DOTA WARNING The brake system of this motorcycle is filled with a glycolbased brake fluid Do not use or mix different type of fluid such as silicone based and petroleum based Do not use any brake fluid taken from old used or unsealed containners Never re use the brake fluid left over from the last servicing and stored for long periods Lower limit line PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 8 WARNING Brake fluid if it leaks will interfere with safe running and immediatery discolor painted surfaces Check the brake hoses for cracks and hose joints for leak age before riding BRAKE PADS Wearing condition of brake pads can be checked by observing the limit line marked on the pad When the wear exceeds the limit mark replace the pads with new ones Refer to page 6 13 BLEEDING AIR FROM THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The pr
67. r case properly CAUTION o Before and during the cleaning operation inspect the element for tears A torn element must be replaced o Be sure to position the element snugly and correct ly 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 SAE 10W40 THROTTLE CABLE Adjust at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter e Loosen the lock nut D and adjust the cable play 9 by turning adjuster in or out to obtain the following cable play After adjusting play tighten the lock nut Cable play 05 1 0 mm 0 020 0 040 in ENGINE IDLE SPEED Adjust at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter e Adjust the throttle cable play O Remove the frame side cover Refer to page 6 3 e Warm up the engine NOTE A warm engine means an engine that has been run for 10 minutes PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 6 e Connect an electric tachometer to the connecting portion of the high tension lead Use the selector key C position 09900 26006 e Asjust the throttle stop screw to obtain the idle r min as follows Idle r min 1800 50 r min e Finally adjust the throttle cable play OIL PUMP Inspect at Initially 1000km 600miles 2momths and Every 4000km
68. rber Worn engine mounting bushing Loose nuts or bolts for engine mounting Weakened spring Oil leakage of rear shock absorber Loosen nuts on shock absorber Worn engine mounting bushing Adjust Replace Replace Adjust Replace Replace Replace Replace Replace Retighten Retighten Replace Tighten Replace Replace Refill Replace Refill Retighten Replace Replace Replace Replace Retighten Replace Replace Retighten Replace Insufficient brake power Brake squeaking OO OO OO POND cO OO J On OOI BOON Leakage of brake fluid from hydraulic system Worn pad Oil adhesion on engaging surface of pad Worn disc Air entered into hydraulic system Worn shoe Friction surfaces of shoes are dirty with oil Excessively worn drum Too much brake lever play Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Worn pad Foreign substance entered into brake fluid Clogged return ports of master cylinder Brake shoe surface glazed Loose front wheel axle or rear wheel axle nut Worn shoe Repair or replace Replace Clean disc and pads Replace Bleed air Replace Replace Replace Adjust Repair surface with sandpaper Modify and fitting Replace Replace Replace brake fluid Disassemble and clean master oylinder Repair surface with sandpaper
69. re performance and relia bility of the engine depends on the care and restraint exercised during its early life The general rules are as follow Keep to these breaking in speed limit Up to 1000 km 600 miles Less than 4 5 throttle e Upon reaching an odometer reading of 1000km 600 miles you can subject the motorcycle to full throttle operation O Do not maintain constant engine speed for an extended time period during any portion of the break in Try to vary the throttle position GENERAL INFORMATION 1 2 PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motorcycles O Do not run engine indoors with little or no ventilation O Be sure to replace packing gaskets circlips O rings and cotter pins with new ones CAUTION Never reuse a circlip after it has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expend the end gap larger than required to slip the circlip over the shaft After installing a circlip always insure that it is completely seated in its groove and securely fitted D When tightening cylinder head or a case torque the bolt or nut of larger thread diameter first and then proceed to that of smaller diameter They should also be tightened crosswise from inside to outside to the specified torque Use special tools where specified Use genuine parts and reco
70. ressure is too low stability will be adversely affected Therefore maintain the cor rect tire pressure for good roadability and to prolong tire life CAUTION The standard tire fitted on this motorcycle is 100 90 10 56J for front and rear The use of a tire other than the standard may cause handling instability It is highly recommended to use a HYOSUNG Genuine Tire NORMAL COLD INFLATION SOLO RIDING DUAL RIDING TO mw a e 7 MESE TEE TIRE TREAD CONDITION Operating the motorcycle with the excessively worn tires will decrease riding stability and consequently invite a dangerous situa tion It is highly recommended to replace the tire when the remain ing depth of tire tread reaches the following specification Front and Rear 1 6 mm 0 064 in 09900 20805 Tire depth gauge STEERING Inspect at Initially 1000km 600miles 2momths and Every 4000km 2400miles 6months thereafter Steering should be adjusted properly for smooth turning of handle bars and safe running Too stiff steering prevents smooth turning of handlebars and too loose steering will cause poor stability Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground with wheel straight ahead grasp lower shock absorber near the axle and pull forward If play is found perform steering bearing adjustment Refer to page 6 24 2 11 PERIODIC MAINTENANCE AND TUNE
71. rking part of the motorcycle The major lubrication points are indicated below NOTE Lubricate expodes parts which are subject to rust with motor oil grease Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt of grime WARNING Be careful not to apply too much grease to the rear break camshaft If grease gets on the linings brake slippage will result D Steering stem bearing Speedometer cable and drive gear box 8 Throttle grip Throttle cable 5 Wheel bearing 6 Center stand Engine mounting bracket pivoting portion Rear brake lever and cable 9 Rear brake camshaft t Grease 9 oi ENGINE CONTENTS ENGINE REMOVAL AND REMOUNTING ese esse ees 3 1 ENGINE REMOVAL essa ee NU mE 3 1 ENGINE REMOUNTINQA instaret itane uut 3 3 ENGINE DISAS SEDE Ve iese responce ete ee 3 4 ENGINE COMPONENTS INSPECTION AND SERVICING en 3 13 INC eet 3 13 OIL SEALS OE er OE A Bio 3 13 CRANKSHAFT ona AF N AR 3 13 AUTOMATIC CLUTCH INSPECTION As ME ee ee 3 14 CYLINDER HEAD ac Mee 3 16 CYLINDER ens etae tret 3 17 DIGTON coastal o o 3 17 BEED VALVE suse NBC insta 3 19 ENGINE REASSEMBLY 4 WA ee 3 20 EE JUR ROO om 3 20 BEARINGS cece eee 3 20 BUSHINGS N GE 3 21 VI EIS so DE 3 29 ei EE Mead m ewe eet te 3 23 CENTER STAND ER 3 24 REAR AXLE SHAFT BRAKE AND WHEEL 3 25 TRANSMISSION
72. rs O Remove the piston pin and piston O Remove the piston pin bearing 6 KICK STARTER O Remove the kick starter lever O Remove the clutch cover O Remove the crankcase Jett cover 8 O Remove the kick starter shaft spring and kick starter shaft KICK STARTER DRIVEN GEAR O Remove the E ring D with the long nose plier O Remove the spacer 2 spring and kick starter driven gear p MOVABLE DRIVE FACE O Remove the kick starter driven nut with the special tool CAUTION This nut has left hand thread 09910 20115 Conrod holder O Remove the fixed drive face and V belt 3 O Disassemble the movable drive face STARTER DRIVEN GEAR O Remove the starter driven gear D MOVABLE DRIVEN FACE O Remove the clutch housing with the special tool 09930 40113 Rotor holder ENGINE 3 6 3 7 ENGINE O Loosen the clutch shoe nut with the special tool 09930 40113 Rotor holder O Remove the nut while holding down the clutch shoe assembly by both hands as shown in the illustration 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 D Nut 2 Clutch shoe assembly S Spring CAUTION Do not attempt to diassemble the clutch shoe assembly It is not serviceable e Using a thin blade screwdriver or the dike pry u the movable driven face spring
73. s gauge while matching the sliding sur faces of piston and ring 0 020 0 060 mm pi eda 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 stopper plate Apply Thread Lock 1324 to the stopper plate securing screws 99000 32030 Thread Lock 1324 ENGINE REASSEMBLY Reassembly is generally performed in the reverse order of disas sembly 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 procedure below Replace removed oil seals with new ones Apply grease to the lip of the oil seals 99000 07000 Grease Ge e Be sure to apply Thread Lock 1324 to outer surfaces of right and left crankshaft oil seals to prevent them from moving 99000 32030 Thread Lock 1324 e When fitting the oil seal in the crankcase insert it slowly with the special tools 09913 75830 Oil seal installer 09924 74510 Oil seal installer handle 09924 74540 Oil seal installer attachment NOTE Align the oil seal withfedge Ai of the crankcase as shown in the illustration BEARINGS Install new bearings with the special tool 09913 75810 Bearing installer 09913 76010 Bearing installer ENGINE 3 20 3 21 ENGINE BUSHINGS Using two steel tubes of appropri
74. the inner clutch wheel surface for scrolling cracks or uneven wear Measure inside diameter of the clutch wheel with inside calipers Measure the diameter at several points to check for an out of round condition as well as wear 11035 mm A344 V DRIVE BELT Remove the drive belt and check for cracks wear and separation Measure the drive belt width with a vernier calipers Replace it if the belt width is less than the service limit or any defect has been found 153 mm 0 602 in CAUTION Always keep the drive belt away from any greasy mater DRIVE FACE Inspect the belt contact surface of the drive faces for wear scratch es or any abnormality If there is something unusual replace the drive face with a new one Measuring clutch wheel D ROLLER AND SLIDING SURFACE Inspect each roller and sliding surface for wear or damage DRIVEN FACE SPRING Measure the free length of the driven face spring If the length is shorter than the service limit replace the spring with a new one 104 5 mm 4 11_ in DRIVEN FACE PIN AND OIL SEAL Turn the driven faces and check to see that the driven faces turn smoothly If any stickness or hitches are found visually inspect the lip of oil seal driven face sliding surface and sliding pins for wear Or dam age 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 abn
75. tion file the contact surface or replace the unit K H te Switch j E 09900 25002 Pocket tester Ka ELECTRICAL SYSTEM 5 8 OIL LEVEL CHECK LIGHT INSPECTION Disconnect the L W and B W lead connector of the oil level check light Connect a jumper wire between L W and B W wires coming from the main wiring harness With the ignition switch turned ON the oil level check light should flash If there is no flash check the wiring harness continuity and the bulb blown out THERMOELEMENT MAGNETO INSPECTION e Disconnect the thermoelement coupler e Connect the thermoelement coupler OD mp a 12V battery and touch the thermoelement to check the temperature being raised The thermoelement should become heated to a temperature more than that of human body within five minutes If not replace with new one NOTE This check should be carried out when the carburetor is cold 5 9 ELECTRICAL SYSTEM SWITCHES Inspect each switch for continuty with the pocket tester referring to the chart If it is found any abnormality replace the repective switch assembly with new one WIRE COLOR E it eee Black cT Green QP ee Gray c RUM Light blue Lg eee Light green asia cis Orange R EE UIE OD Red W EE EE EK White Y EE Yellow B R EE Black with Red tracer B W Black with White tracer W B A OE T White with Black tracer Y AN DETENER Yellow with white tracer LIGHTING SWITCH START

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