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SF50 Service Manual
SF50 Service Manual
SERVICE MANUAL
SERVICE MANUAL
99000-91310
FOREWORD GROUP INDEX
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* This manual has been prepared on the basis of
the latest specification at the time of publica-
ELECTRICAL SYSTEM 5
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tion.
If modification has been made since then, dif-
ference may exist between the content of this
manual and the actual vehicle.
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CHASSIS
* Illustrations in this manual are used to show the
basic principles of operation and work proce-
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dures.
They may not represent the actual vehicle exactly SERVICING INFORMATION 7
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in detail.
* This manual is intended for those who have
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COMPONENT PARTS
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Example: Rear wheel/Rear brake H
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SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and
meaning associated with them respectively.
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Apply SUPER GREASE“C”. Measure in resistance range.
Apply BOND“1215”.
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GENERAL INFORMATION
1
CONTENTS
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SPECIFICATIONS 1-6
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1-1 GENERAL INFORMATION
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions cleaner.
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Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.
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GENERAL PRECAUTIONS
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WARNING
● Proper service and repair procedures are important for the safety of the service machanic and the safety
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● When working with toxic or flammable materials, make sure that the area you work in is wellventilated
and that you follow all off the material manufacturer’s instructions.
● Never use gasoline as a cleaning solvent.
● To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while
after engine operation.
● After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for
leaks.
GENERAL INFORMATION 1-2
CAUTION
● If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
● When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and orientation.
● Be sure to use special tools when instructed.
● Make sure that all parts used in reassembly are clean, and also lubricated when specified.
● When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
● When removing the battery, disconnect the negative cable first and then positive cable. When reconnect-
ing the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the
positive terminal.
● When performing service to electrical parts, if the service procedures do not require use of bat-
tery power, diconnect the negative cable at the battery.
● Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to outside diagonally, to the specified tightening torque.
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● Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and
certain other parts as specified, be sure to replace them with new ones. Also, before installing these new
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parts, be sure to remove any left over material from the mating surfaces.
● Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seat-
ed in its groove and securely fitted.
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● Do not use self-locking nuts a few times over.
● Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil
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if a thread is smeared with them.
● After reassembly, check parts for tightness and operation.
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● To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.
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● To protect Earth’s natural resouces, properly dispose of used vehicles and parts.
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1-3 GENERAL INFORMATION
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* Difference between photographs and actual motorcycles depends on the markets.
TRANSMISSION OIL
Make sure that the transmission oil you use comes under API
classification of SH, SG or SF and that its viscosity rating
is SAE 10W/30 or 10W/40. If an SAE 10W/30 or 10W/40 motor
oil is not available, select an alternate according to the right chart.
GENERAL INFORMATION 1-4
ENGINE OIL
Specification and classification: APOLLOIL BIKE-K, HYPOL HS
BRAKE FLUID
Specification and classification: DOT4
WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not
use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the sys-
tem, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
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FRONT FORK OIL
Use fork oil : TELLUS #37
BREAK-IN PROCEDURES TE
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During manufacture only the best possible materials are used and all machined parts are finished to a very high
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standard but it is still necessary to allow the moving parts to“BREAK-IN”before subjecting the engine to maximum
stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its
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● Upon reaching an odometer reading of 1,000 km you can subject the motorcycle to full throttle operation.
● Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the
throttle position.
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1-5 GENERAL INFORMATION
EXTERIOR ILLUSTRATION
350
635
320
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1,110
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990
740
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125
1,270
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1,825
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135
710
600
535
GENERAL INFORMATION 1-6
SPECIFICATIONS
ENGINE
Type Two-stroke, forced air cooled
Number of cylinder 1
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Bore 41 mm (1.6 in)
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Stroke 37.4 mm (1.5 in)
Piston displacement 49 ㎤ (3.0 cu.in)
Carburetor SIDE DRAFT VARIABLE VENTURI (PISTON)
Air cleaner Wet filter type
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Starter system Kick/self starter
Corrected compression ratio 7.4 : 1
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Intake system Reed valve
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TRANSMISSION
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ELECTRICAL
Ignition type “CDI”type
Ignition timing 20。B.T.D.C. at 1,000 rpm
Spark plug BR8HSA
Battery 12V 3Ah/10HR
Generator Magneto
Fuse 10A
Headlamp 15W×2
Turn signal lamp 10W×4
Tail/Brake lamp 5/10W
Speedometer lamp 1.7W×2
Oil level indicator lamp 1.7W
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Turn signal indicator lamp 1.7W
CAPACITIES
Fuel tank
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4.8ℓ
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Engine oil tank 1.0ℓ
Transmission oil 110cc (Replace)
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130cc (Overhaul)
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NOTE:
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CONTENTS
BATTERY 2- 3
SPARK PLUG 2- 4
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FUEL LINE 2- 5
2- 6
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ENGINE IDLE SPEED 2- 7
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OIL PUMP 2- 7
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TRANSMISSION OIL 2- 8
BRAKES 2- 8
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TIRES 2-10
STEERING 2-11
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NOTE:
More frequent servicing should be performed on motorcycles that are used under severe conditions.
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Cylinder head nuts
Inspect Inspect - 2-4
exhaust pipe nuts
Cylinder head, cylinder.
Spark plug
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Clean
Inspect
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Clean
Inspect
Clean
Replace
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2-4
2-4
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Fuel line 2-5
Replace every 4 years
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Air cleaner element Clean every 3,000 km 2-5
Throttle cable play Inspect Inspect - 2-6
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Interval
Initial 1,000 km Every 4,000 km Every 8,000 km page
Item
Brakes Inspect Inspect - 2-9
Inspect Inspect -
Brake hose 2-9
Replace every 4 years
Inspect Inspect -
Brake fluid 2-9
Replace every 2 years
Tires Inspect Inspect - 2-10
Steering Inspect Inspect - 2-11
Front suspension Inspect - Inspect 2-11
Rear suspension Inspect - Inspect 2-12
Chassis bolts and nuts Inspect Inspect - 2-12
PERIODIC MAINTENANCE 2-2
LUBRICATION CHART
The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is
calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner.
Interval
Initial and Every 4,000 km Every 8,000 km
Item
Throttle cable Motor oil -
Throttle grip - Grease
Brake cable Motor oil -
Speedometer cable - Grease
Speedometer gear box - Grease
Brake cam - Grease
Steering stem bearing Grease every 2 years or 20,000 km
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WARNING
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Be careful not to apply too much grease into the brake cam. If grease is on the linings, brake slippage will
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result.
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Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has
been operated under wet or rainy conditions.
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Before lubricating each part, clean off rusty sports and wipe off grease, oil, dirt or grime.
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2-3 MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
This section describes the service procedures for
each section of the periodic maintenance.
BATTERY
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
● Remove the pillion seat for measure of battery voltage.
● Remove the battery � lead and then � lead at the
battery terminls and remove the battery.
● Using pocket tester, measure the battery voltage.
If the tester reading is less than 12.0V, recharge
the battery with a battery charger. (Refer to page 5-13)
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Pocket tester : 09900-25002
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Bettery voltage Minimum 12.0V
Recharge
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Standard charge 0.4A×5~10 Hours
Fast charge 4A×30 Minutes
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CAUTION
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∙W h e n r e c h a r g i n g t h e b a t t e r y r e m o v e
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EXHAUST PIPE NUTS
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● Tighten the exhaust pipe nuts ② to the specified
torque.
Exhaust pipe nuts : 8~12 N∙m (0.8~1.2 kg∙m) ②
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NOTE:
Remove carbon Every 8,000km.
Carbon
Carbon deposits in the combustion chamber and the
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SPARK PLUG
NOTE:
Inspect Initial 1,000km and Every 4,000km,
Replace every 8,000km.
Neglecting the spark pulg maintenance eventually leads to
difficult starting and poor performance. If the spark plug is
used for a long period, the electrode 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.
● Carbon deposits on the spark plug will prevent good
sparking and cause misfiring. Clean the deposits off
periodically.
2-5 MAINTENANCE PROCEDURE
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CAUTION
FUEL LINE
NOTE:
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NOTE:
Clean Every 3,000km and Replace Every 12,000km.
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solvent and wash them clean.
● Squeeze the cleaning solvent out of the washed ele-
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ment by pressing it between the palms of both hands:
do not twist or wiring the element or if will develop
tears.
● Immerse the element in Hyosung genuine oil, and
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squeeze the oil out of the element leaving it slightly
wet with oil.
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● Fit the elements to the cleaner case properly.
Inside
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CAUTION
genuine oil
poorly fitted element.
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
CAUTION
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OIL PUMP
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NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
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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
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CAUTION
⑤ ④
MAINTENANCE PROCEDURE 2-8
TRANSMISSION OIL
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
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flows from the level hole.
● Tighten the oil level bolt to the specified torque.
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Oil drain plug
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BRAKES
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NOTE:
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straight.
● Check brake fluid level by observing the middle line
on the brake fluid reservoir.
● When the level is bolow the middle line, replenish
with brake fluid that meets the following specification.
Specification and classification DOT4
WARNING
HYOSUNG Brake fluid : 99000-23021
Brake fluid, if it leaks, will interfere with safe run-
WARNING ning and immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joints
The brake system of this motorcycle is filled with
for leakage before riding.
a glycolbased brake fluid. Do not use or mix dif-
ferent 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.
2-9 MAINTENANCE PROCEDURE
BRAKE PADS
Wearing condition of brake pads can be checked by
observing the limit line ① marked on the pad. When the
wear exceeds the limit mark, replace the pads with new
ones.
①
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 brak-
ing performance of the brake caliper. The presence of
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air is indicated by“sponginess”of the brake lever and
also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider,
it is essential that, after remounting the brake and
restoring the brake system to the normal condition, the TE
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brake fluid circuit be purged of air in the following man-
ner:
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● Fill up the master cylinder reservoir to the upper end
of the inspection window. Replace the reservoir cap
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Do original position
rapid succession, and squeeze the lever fully without
releasing it. Loosen the bleeder valve by turning it a
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CAUTION
WARNING
15~25 mm
Handle the brake fluid with care: the fluid reacts
�
chemically with paint, plastics, rubber materials, etc.
REAR BRAKE
Adjust by turning the adjusting nut ① so that the play � 사용범위
사용범위
사용범위
사용범위
사용범위
사용범위
사용범위
Range
사용범위
사용범위
사용범위
사용범위
사용범위
사용범위
is 15~25 mm as shown in the illustration. 핀
핀
핀
P
핀
핀
핀in
여유가
여유가
여유가
여유가
여유가
여유가
Play
여유가
여유가
여유가 적어진다
적어진다
적어진다
적어진다
적어진다
is 적어진다
had
적어진다little
적어진다
적어진다
여유가
여유가
여유가
Play
여유가
여유가
여유가
여유가
여유가
여유가 많아진다
많아진다
많아진다
is had much
많아진다
많아진다
많아진다
많아진다
많아진다
많아진다 조정너트
조정너트
조정너트
Adjuster
조정너트
조정너트
조정너트
조정너트
조정너트 nut ①
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limit indicator on the rear brake. As shown in the illustra- Index mark
tion at right, at the condition of normal lining wear, an
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extended line from the index mark on the brake
camshaft should be within the range embossed on the Brake lining wear limit
crankcase LH. To check wear of the brake lining, follow
the steps below.
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● First check if the brake system is properly adjusted.
● While operating the brake, check to see that the
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extension line from the index mark is within the range
The extension line of the index mark is within the range.
on the brake panel.
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TIRES
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
TIRE PRESSURE
If the tire pressure is too high, the motorcycle will tend to
ride stiffly and have poor traction. Conversely, if the tire
pressure is too low, stability will be adversely affected.
Therefore, maintain the correct tire pressure for good
roadability and to prolong tire life.
2-11 MAINTENANCE PROCEDURE
CAUTION
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TIRE TREAD CONDITION
Operating the motorcycle with the excessively worn tires
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will decrease riding stability and consequently invite a
dangerous situation. It is highly recommended to
replace the tire when the remaining depth of tire tread
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reaches the following specification.
1.6 mm
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STEERING
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
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FRONT SUSPENSION
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
REAR SUSPENSION
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
Inspect the rear shock absorber for oil leak and the
mounting rubbers including engine mountings for wear
and damage. Replace the defective part if necessary.
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NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
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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.
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Front axle nut(①) : 33~52 N∙m (3.3~5.2 kg∙m)
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Steering stem lock nut (②) : 60~100 N∙m (6.0~10.0 kg∙m)
Handlebar clamp nut(③) : 48~52 N∙m (4.8~5.2 kg∙m)
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Rear shock absorber bolt(upper and lower)(⑩) : 22~35 N∙m (2.2~3.5 kg∙m)
Rear brake cam lever nut(⑪) : 6~9 N∙m (0.6~0.9 kg∙m)
Engine mounting bracket bolt(⑫) : 48~72 N∙m (4.8~7.2 kg∙m)
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①
2-13 MAINTENANCE PROCEDURE
⑩
③
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⑥
⑤
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⑧
⑫
⑬
⑨
ENGINE
CONTENTS
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OIL SEALS 3-14
CRANKSHAFT 3-15
AUTOMATIC CLUTCH INSPECTION
CYLINDER HEAD TE 3-15
3-18
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CYLINDER 3-19
PISTON 3-19
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BEARINGS 3-23
BUSHINGS 3-23
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CRANKSHAFT 3-24
CRANKCASE 3-25
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ENGINE REMOVAL
②
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.
● Remove the low leg shield.
● Remove the air cleaner by removing the mounting
bolts ① and clamp screw ②. ①
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③
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④ ②
③
ENGINE REMOUNTING
The engine can be mounted in the reverse order of
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removal.
Front side
● Install the damper to the crankcase bracket as shown “UP”mark ①
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in the illustration.
● With“UP”mark faced upward, install the crankcase 10mm
②
③ ①
④
ENGINE 3-4
�
�
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Page
∙Throttle cable play 2-6
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∙Idling adjustment 2-7
∙Oil pump cable paly 2-7
∙Rear brake cable adjustment 2-10
∙Air bleeding at oil pump 4-9
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ENGINE DISASSEMBLY
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MUFFLER
● Remove the muffler by removing the nuts.
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MAGNETO
● Remove the cooling fan.
● Remove the magneto rotor nut ① with the special
tool. ①
Rotor holder : 09930-40113
3-5 ENGINE
REED VALVE
● Remove the intake pipe ② with reed valve ①.
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②
①
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OIL PUMP
● Remove the oil pump ③.
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④
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④
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CYLINDER
● Remove the cylinder cowling.
● Remove the cylinder head ⑤ and cylinder ⑥.
⑥
ENGINE 3-6
PISTON
● Place a cloth beneath the piston and remove the pis-
ton circlip ① with a long nose pliers.
● Remove the piston pin ② and piston ③.
● Remove the piston pin bearing ④. ③
②
①
KICK STARTER
● Remove the kick starter lever ⑤.
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● Remove the clutch cover ⑥.
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⑤
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⑥
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⑧ ⑦
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⑨
⑩
3-7 ENGINE
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ENGINE 3-8
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● Remove the clutch shoe assembly ②. ①
● Remove the spring ③.
;;
;;;;
② TE
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;;;;
①
③
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②
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CAUTION
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⑥
3-9 ENGINE
CAUTION
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�
� TE
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�
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CAUTION
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new one.
TRANSMISSION
● Drain transmission oil.
● Remove the gear box cover ①.
● Remove the driveshaft ②. ①
②
ENGINE 3-10
● Remove the oil seal ① from the gear box cover with
the special tool.
Oil seal remover : 09913-50121
CAUTION ①
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CAUTION ②
③
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WHEEL, BRAKE
● Remove the rear axle nut ① and washer ②.
● Remove the rear wheel ③.
①
③
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④
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④
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CENTER STAND
● Remove the return spring ②.
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②
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⑥
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CRANKCASE
● Remove the crankcase securing screws.
CAUTION
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Bushing
Bushing
Crankcase
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Crankcase
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ENGINE COMPONENTS
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BEARINGS
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Turn the inner ring and check to see that the inner ring
turns smoothly. If it does not turn lightly, quietly and
smoothly, or if noise is heard, the bearing is defective
and must be replaced with a new one.
OIL 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.
3-15 ENGINE
CRANKSHAFT
CRANKSHAFT RUNOUT
Support crankshaft by“V”blocks, with the dial gauge
rigged to read the runout as shown.
Crankshaft runout Service limit 0.08 mm
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Turn the crankshaft with the conrod to feel the smooth-
ness of rotary motion in the big end. Move the rod up
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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
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method can also check the extent of wear on the parts
of the conrod’s big end.
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If wear exceeds the limit, conrod, crank pin and crank
pin bearing should all be replaced.
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1. CLUTCH-IN INSPECTION
Warm up the motorcycle to normal operating tempera-
ture.
Remove the right frame side cover.
Connect an engine 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.
Engine tachometer : 09900-26006
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2. CLUTCH TIGHT INSPECTION
Grip the front and rear brake lever fully, and measure
the engine RPM when open the throttle.
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Warm the engine to normal operating temperatures.
Connect an engine tachometer to the engine.
Apply the rear brake as firm as possible.
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CAUTION
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CAUTION
DRIVE V-BELT
Remove the drive V-belt and check for cracks, wear and
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separation. Measure the drive V-belt width with a vernier
calipers. Replace it if the drive V-belt width is less than
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the service limit or any defect has been found.
Drive V-belt width Service limit 15.3 mm
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CAUTION
DRIVE FACE
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movable driven faces turn smoothly.
If not rotate smoothly, visually inspect the lip of oil seal,
movable driven face sliding surface and sliding pins for
wear or damage.
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CYLINDER HEAD
Decarbon the combustion chamber.
Check the gasketed surface of the cylinder head for dis-
tortion with a straightedge and thickness gauge, taking a
clearance reading at several places.
Thickness gauge : 09900-20806
CYLINDER
Decarbon exhaust port and upper part of the cylinder,
taking care not to damage the cylinder wall surface.
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ter 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. TE
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Cylinder gauge set : 09900-20508
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Cylinder bore Service limit 41.070 mm
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PISTON
CYLINDER TO PISTON CLEARANCE
Cylinder-to-piston clearance is the difference between
piston diameter and cylinder bore diameter. Be sure to
take the maked diameter at right angles to the piston
pin. The value of elevation � is prescribed to be 15 mm
from the skirt end.
Micrometer(25~50 mm) : 09900-20202
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DE-CARBONING
De-carbon the piston and piston ring grooves, as illus-
trated. After cleaning the grooves, fit the rings and rotate
them in their respective grooves to be sure that they
move smoothly. TE
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Carbon in groove is liable to cause the piston ring to get
stuck in the groove, and this condition will lead to
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reduced engine power output.
A piston whose sliding surface is badly grooved or
scuffed due to overheating must be replaced. Shallow
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PISTON RINGS
Check each ring for end gap, reading the gap with a
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thickness gauge shown in the illustration. If the end gap
is found to exceed the limit, indicated below, replace it
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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
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the illustration.
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Thickness gauge : 09900-20806
Fix the piston ring in the piston ring groove, measure the
ring side clearance with the thickness gauge while
matching the sliding surfaces of piston and ring.
Piston ring-ring groove clearance Standard
1st 0.02~0.06 mm
2nd 0.02~0.06 mm
ENGINE 3-22
REED VALVE
When reinstalling the reed valve and stopper plate to
the body, align the both cut on the reed valve and stop-
per plate.
Apply THREAD LOCK“ 1324 ”to the stopper plate
securing screws.
Thread Lock“1324”
ENGINE REASSEMBLY
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Reassembly is generally performed in the reverse order
of disassembly, but there are a number of reassembling
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steps that demand or deserve detailed explanation or
emphasis. These steps will be taken up for respective
parts and components.
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I ndustrial e ase
purpos
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M ulti-
OIL SEALS
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Thread Lock“1324”
NOTE:
Align the oil seal with edge � of the crankcase as
shown in the illustration.
3-23 ENGINE
BEARINGS
Install new bearings with the special tool.
Bearing installer : 09913-75810
Bearing installer : 09913-76010
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BUSHINGS ②
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NOTE:
Knurled end � should face inside. Protrusion � and �
should be in the same dimension.
ENGINE 3-24
Bushing ②
Bushing ①
Crankcase
Crankcase
CRANKSHAFT
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① Crank shaft
② Crankcase RH
③ Oil seal
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④ Oil seal
⑤ Oil pump drive gear
⑥ Oil pump driven gear
⑦ Oil seal
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CRANKCASE
● Wipe the crankcase mating surfaces(both
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surfaces)with cleaning solvent.
● Apply BOND“1215”uniformly to the mating surface
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of the left half of the crankcase, and install the dowel
pins.
BOND“1215”
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● Install the two dowel pins.
● Tighten the crankcase screws securely.
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NOTE:
Align the oil seal with edge � of the crankcase as
shown in the illustration.
Bearing installer : 09913-85210
�
ENGINE 3-26
CENTER STAND
● Install the center stand ①. ④
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● Install the shaft ②, washer ③ and cotter pin ④. ③
①
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⑤
3-27 ENGINE
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�
ENGINE 3-28
Slit
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CAUTION
TRANSMISSION
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②
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④
③ ①
Center
Thrust
� Circlip
⑥
Rounded coner
ENGINE 3-30
①
②
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tool.
Super Grease“A” Oil seal
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④
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⑥
3-31 ENGINE
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②
ENGINE 3-32
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;;
;;;;
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;;;;
3-33 ENGINE
CAUTION ②
Take care that hit inner race of the bearing.
(Fall to ring in the bearing a case.)
CAUTION
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Instert surely in the circlip groove. ③
Thrust
�
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Rounded coner
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where the pins are placed.
Super Grease“A”
Pin
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③
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Spacer
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CAUTION
⑤
The seat is installed rotatable naturally.
The O-ring get damaged, in case of installed by
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force.
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⑦
⑥
3-35 ENGINE
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face all the way outside to provide the maximum belt
clearance.
CAUTION
②
ENGINE 3-36
MOVABLE DRIVE
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①
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②
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④
⑥
3-37 ENGINE
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CAUTION
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Thoroughly clean the V-belt contact to be from oil. H
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③ ④
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� � �
ENGINE 3-38
�
�
�
�
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faces ② will move together smoothly without slip.
● Fill the final gear box with engine oil up to the level
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hole.
Replace 110 ㎖
Transmission oil capacity
Overhaul 130 ㎖
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● Tighten the oil level bolt ③ to the specified torque.
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Oil level bolt : 9~15 N∙m (0.9~1.5 kg∙m) ① ③
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KICK STARTER
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3-39 ENGINE
Super Grease“A”
● Position the kick starter shaft return spring and hook
the spring end on the crankcase cover boss ①.
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Install the kick starter lever as shown in the illustra- ②
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tion.
Concur with the mark.
13�
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torque.
Kick starter lever bolt : 8~12 N∙m (0.8~1.2 kg∙m)
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ENGINE 3-40
PISTON
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Locating pin
CORRECT INCORRECT
3-41 ENGINE
● Apply engine oil on the piston pin and install the pis-
ton to the conrod.
CAUTION
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groove portion of the piston.
● Position the cylinder base gasket.
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● Apply engine oil on the piston and cylinder wall sur- Inside Outside
faces and install the cylinder over the piston carefully.
● Install the cylinder head gasket and cylinder head.
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Super Grease“A”
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①
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②
3-43 ENGINE
④
②
③
MAGNETO
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①
ENGINE 3-44
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wire.
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MUFFLER
● Tighten the exhaust pipe bolts and muffler mounting
bolts to the specified torque.
Exhaust pipe bolt : 8~12 N∙m (0.8~1.2 kg∙m)
Muffler mounting bolt : 18~28 N∙m (1.8~2.8 kg∙m)
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FUEL SYSTEM
CONTENTS
CARBURETOR 4- 1
REMOVAL 4- 1
DISASSEMBLY 4- 2
INSPECTION 4- 4
4- 5
REASSEMBLY AND REMOUNTING
4
FUEL TANK 4- 7
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REMOVAL 4- 7
CLEANING
REMOUNTING TE 4- 8
4- 8
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OIL PUMP 4- 8
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FUEL PUMP 4- 9
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4-1 FUEL SYSTEM
CARBURETOR
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REMOVAL
● Open the seat, and separate the helmet box by
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③ ④
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DISASSEMBLY
● Remove the thermoelement assembly.
4-3 FUEL SYSTEM
CAUTION
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③
②
⑤
FUEL SYSTEM 4-4
CAUTION
②
When removing the pilot air
screw, record the revolu-
tions until tighten completly.
① ②
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④
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INSPECTION
PY
Check following items for any damage or clogging. Inspect the valve surface for worn
● Pilot jet
● Main jet
● Pilot air screw
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● Gasket
● Pilot outlet and bypass holes
③ ④ ① ②
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● Install the air vent hose ①, oil hose ② and fuel hose ③.
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①
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③
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FUEL TANK
①
REMOVAL
● Remove the low leg shield ①.
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②
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CLEANING
Dust from the fuel tank tends to bulid up in the fuel filter
①
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 com-
pressed air.
REMOUNTING
Remount the fuel tank in the reverse of removal.
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yyy ;
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yyyy
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yyyy
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yyyy;;;;
yyyy
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yyyy
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OIL PUMP
AIR BLEEDING
Whenever evidence is noted of some air having leaked ①
into the oil pipe from the oil tank in a machine brought in
for servicing, or if the oil pump has to be removed for
servicing, be sure to carry out an air bleeding operating
with the oil pump in place before returning the machine
to the user.
To bleed air, hold the machine in standstill condition.
Loosen the air bleeding screw ① to let out air and after
making sure that the trapped air has all been bled, tight-
en the air bleeding screw completely.
4-9 FUEL SYSTEM
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CAUTION
FUEL PUMP
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REPLACE
● Remove the rear shock absorber, and support the
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four nuts.
● Remove the one lock nut of fuel pump.
① Disconnect the inlet hose.
CAUTION
CONTENTS
ELECTRICAL PARTS 5- 1
IGNITION/CHARGING SYSTEM 5- 2
IGNITION COIL 5- 2 5
STATOR COILS 5- 3
REGULATOR/RECTIFIER 5- 4
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STARTER SYSTEM 5- 4
5- 7
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OIL LEVEL CHECK LIGHT 5- 8
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THERMOELEMENT 5- 9
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BATTERY 5-11
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5-1 ELECTRICAL SYSTEM
ELECTRICAL PARTS
① Ignition coil ①
② Thermolement assembly
③ Fuel level gauge
④ Oil level gauge
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Front turn signal Regulator ②
RH/LH
Turn signal cable
Head Lamp
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Rear brake
cable
Wiring
harness
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Speedometer
cable
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Brake
hose
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④
ELECTRICAL SYSTEM 5-2
IGNITION/CHARGING SYSTEM
Stator Regulator/Rectifier
lgnition CDI
coil unit
Spark Lighting Battery
plug switch 12V 3AH
H/L T/L M/L (MF)
Engine stop
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switch
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12V 12V 12V
15W×2 5W 1.7W×2
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IGNITION COIL
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Yellow Red(+)
Spark
Black
Black(-)
5-3 ELECTRICAL SYSTEM
C.D.I. UNIT
● Using the pocket tester (R 1 range), measure the Ground
resistance between the lead wire in the following table. Plug cap
Pocket tester : 09900-25002
Unit : ㏀
� Probe of tester to :
B/Y W/BL B/R B/W W Br
B/Y ∞ ∞ ∞ ∞ ∞
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� Probe of tester to :
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B/R 3~5 ∞ ∞ ∞ ∞
B/W 7~11 ∞ 3~4.5 3~4.5 1.2~2.5
W 12~16 ∞ 6~8 25~35 27~37
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Br 10~14 ∞ 5~7 1.2~2.5 5~8 B/W W Br
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STATOR COILS
● Using the pocket tester, measure the resistance
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REGULATOR/RECTIFIER
● Disconnect the coupler.
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● Using the pocket tester(×1㏀ Range), measure the
resistance between the terminals as shown in the fol-
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lowing table. If the resistance checked is incorrect,
replace the regulator/rectifier.
1 1 502~ 260 ∞3 ∞ 4
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2 50 ~ 230 ∞ ∞
3 ∞ ∞ ∞
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4 ∞ ∞ 10 ~ 100
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STARTER SYSTEM
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The starter system is shown in the diagram below: namely, the starting motor, starter relay, starter switch and battery.
Depressing the starter switch (on the right handlebar switch box) while squeezing the front or rear brake lever energizes
the relay, causing the contact points to close which connects the starting motor to the battery.
Starter relay
R R/W
Fuse
Y/G
IG switch Starter switch
Point
Starter
motor
Brake switch
W/B
Battery
5-5 ELECTRICAL SYSTEM
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CARBON BRUSHES
When the brushes are worn, the motor will be unable to
procedure sufficient torque, and the engine will be diffi-
cult to turn over. To prevent this, periodically inspect the
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COMMUTATOR
If the commutator surface is dirty, starting performance
will decrease. Polish the commutator with #400 or simi-
lar fine emery paper when it is dirty. After polishing wipe Segment
①
the commutator with a clean dry cloth.
Measure the commutator under cut ①.
Commutator under cut Service limit 4 mm
ELECTRICAL SYSTEM 5-6
ARMATURE COIL
Using the pocket tester, check the coil for open and
ground by placing probe pins on each commutator seg-
ment and rotor core (to test for ground)and on any two
segments at various places (to test for open), with the
brushes lifted off the commutator surface.
If the coil is found to be open-circuited or grounded,
replace the armature. Continuous use of a defective
armature will cause the starting motor to suddenly fail.
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Check the coil for“open”,“ground”and ohmic resis-
tance. The coil is in good condition, if the resistance
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is as follows.
Pocket tester : 09900-25002
O B/W
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Y/B
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Fuel tank
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the right frame cover, then disconnect 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”.
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float and resistance is shown in the following table. F
IG switch
Battery
5-9 ELECTRICAL SYSTEM
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level check light.
Connect a jumper wire between L/W and B/W wires
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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.
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THERMOELEMENT
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R
B/R
Y/W R/W
� �
Battary Regurator/Rectifier Magneto
PTC
ELECTRICAL SYSTEM 5-10
INSPECTION
● Disconnect the thermoelement coupler ①.
● Connect the thermoelement coupler ① to a 12V bat- ①
tery and touch the thermoelement ② to check the
temperature being raised. ②
The thermoelement ② should become heated to a
temperature more than that of human body within
five minutes. If not, replace with new one.
CAUTION
SWITCHES INSPECTION
STARTER SWITCH
D
Inspect each switch for continuity with the pocket tester W/B Y/G
referring to the chart. If it is found any abnormality,
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ON ○ ○
replace the respective switch assembly with new one.
OFF
Pocket tester : 09900-25002
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FRONT AND REAR LAMP SWITCH
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O W/B
ON ○ ○
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OFF
WIRE COLOR
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B Black
L Blue TURN SIGNAL LAMP SWITCH
G Green Lg Sb B
Gr Gray
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Sb Light blue L ○ ○
Lg Light green ∙
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O Orange R ○ ○
R Red
W White
Y Yellow HORN SWITCH
B/R Black with Red tracer B/W G
B/W Black with White tracer
W/B White with Black tracer ON ○ ○
Y/W Yellow with White tracer OFF
Y/G Yellow with Green tracer
L/W Blue with White tracer
IGNITION SWITCH
OFF
ON ○ ○
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5-11 ELECTRICAL SYSTEM
BATTERY
BATTERY
Type YT4L-BS Filter
Cap Safety valve
Capacity 12V, 3AH/10HR
Standard electrolyte S.G. 1.32(at 20℃)
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wash a vast quantity of water.
When it be stained, clothes should come into being a
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hole or painting should take off.
Be cured from a doctor. � Pole plate
● When the battery electrolyte was droped the surface � Pole plate
of land, wash a vast quantity of water. Separator
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Neutralize by hydroxide, bicarbonate of soda and so (fiberglass plate)
on.
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INITIAL CHARGING
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FILLING ELECTROLYTE
● Remove the aluminum tape ① sealing the battery
electrolyte filler holes ②.
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CAUTION
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more than 20 minutes.
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NOTE:
If no air bubbles are coming up from a filler port, tap the
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CAUTION
NOTE:
Initial charging for a new battery is recommended if two
years have elapsed since the date of manufacture.
(Minutes)
Time
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If does not, it should be explosion and severe accident.
Pay attention to the following points.
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● Prohibit positively that come in contact with short, spark or firearms.
● The battery recharge where be well-ventilated wide place.
Prohibit positively at the shut tight room.
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RECHARGING OPERATION
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CONTENTS
FRONT WHEEL 6- 1
FRONT BRAKE 6- 7
STEERING 6-18
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6-1 CHASSIS
FRONT WHEEL
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③
6-3 CHASSIS
Drive out the both bearing with the special tool in the fol-
lowing procedures.
● Insert the adapter into the bearing.
● After inserting the wedge bar from the opposit side,
lock the wedge bar in the slit of the adapter.
● Drive out the bearing by knocking the wedge bar.
CAUTION
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replaced with new ones.
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INSPECTION
WHEEL RIM
PY
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
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TIRE
Inspect the tires for wear and damage, and check the
tire tread depth as shown. Replace a badly worn or dam-
aged tire. A tire with its tread worn down to the limit(in
terms of tread depth)must be replaced.
CHASSIS 6-4
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order diassembly and removal, and also carry out the
following steps.
WHEEL BEARING
● Apply SUPER GREASE“A”to the bearings before
installing. TE ell
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Super Grease“A”
ase
CAUTION
Clearance
Bearing(L) Bearing(L)
6-5 CHASSIS
OIL SEAL
● Install the oil seal ① with the special tool.
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DISC PLATE
● Install the disc plate and tighten them to the specified
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torque.
Front brake disc bolt : 18 ~ 28 N∙m(1.8 ~ 2.8 kg∙m)
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�
CHASSIS 6-6
CAUTION
FRONT WHEEL
● Tighten the front axle nut to the specified torque.
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Front axle nut : 33 ~ 52 N∙m(3.3 ~ 5.2 kg∙m)
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FRONT BRAKE
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in a suitable receptacle.
● Remove the caliper mounting bolt ③.
CAUTION
Never re-use the brake fluid left over from the last TE ②
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servicing and stored long periods. ③
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CALIPER INSPECTION
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CALIPER REASSEMBLY
Reassemble and remount the caliper in the reverse
order of removal and disassembly, and also carry out the
following steps.
{
CAUTION
{
fluid before reassembly. Never use cleaning sol-
vent or gasoline to wash them. Apply brake fluid
to the caliper bore and piston to be inserted into
the bore.
Silicone Grease
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SPECIFIED TORQUE
①
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Item N∙m kg∙m
① 18 ~ 28 1.8 ~ 2.8
② 20 ~ 25 2.0 ~ 2.5 ②
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WARNING
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● Remove the handlebar cover.
● Disconnect the front brake lamp switch lead wires.
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CAUTION
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⑦ ⑤
6-13 CHASSIS
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Reassemble and remount the master cylinder in the
Boot
reverse order of removal and disassembly, and also
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carry out the following steps.
CAUTION
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Wash the master cylinder components with fresh spring Piston Circlip
brake fluid before reassembly. Never use clean- Primary cap Second cap
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ing solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all the
internals to be inserted into the bore.
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CAUTION Upside
Handlebar
Clearance
CHASSIS 6-14
FRONT FORK
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● Loosen the front fork bolt, then draw out the fork
spring.
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● Loosen the front fork lower clamp bolts.
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①
CHASSIS 6-16
①
②
CAUTION
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The oil seal removed should be replaced with a
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new oil seal.
INSPECTION
● Inspect pipe seat for wear and damage.
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FORK SPRING
● Measure the fork spring free length.
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removal and disassembly, and also carry out the follow-
ing steps.
FORK OIL
● For the fork oil, be sure to use a front fork oil whose
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CUSHION SPRING
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STEERING
REMOVAL AND DISASSEMBLY
● Remove the handlebar cover.
● Remove the handlebar by removing the clamp bolt ①
and set bolt ②.
①
②
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Clamp wrench : 09940-10122
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CAUTION ④
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⑦
6-19 CHASSIS
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INSPECTION
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INNER RACE
● Press in the upper and lower inner races with the spe-
cial tool.
Steering race installer : 09941-34513
STEEL BALL
● Apply SUPER GREASE“ A ”when installing the
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upper and lower steel balls.
Super Grease“A”
Upper
Number of steel ball
22 pcs TE
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Lower 25 pcs
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∙Lift the front fork.
∙Inspect play of the front fork as that grasp lower of
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the front fork and shake it by the front and rear.
∙By the handle turning the right or left, inspect
whether turning smoothly.
∙Adjust the outer upper race, if the steering is comed
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heavy and tight.
● Bleed air of the front brake.(Refer to page 2-9)
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CHASSIS 6-22
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INSPECTION
REAR 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.
Rear brake drum I.D Service limit 100.7 mm
BRAKE SHOE
Using a vernier calipers, measure the brake shoe out-
side diameter at the place as shown in the photo. If the
measurement is less than the limit, replace the brake
shoe.
Brake shoe lining for thickness Service limit 96 mm
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CAUTION
Reassemble and remount the rear wheel and brake in Front Front
the reverse order of removal, and diassembly.
Punch mark
BRAKE CAM LEVER
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SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 7- 1
SPECIAL TOOLS 7- 6
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7-1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
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5. Defective ignition switch. Replace.
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1. Clogged hole in the fuel tank cap. Clean.
2. Clogged or defective fuel cock. Clean or replace.
3. Defective carburetor float valve. Replace.
4. Clogged fuel hose or defective vacuum hose. Clean or replace.
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Engine stalls 1. Carbon deposited on the spark plug. Clean.
easily. 2. Defective CDI & Ignition coil unit. Replace.
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3. Clogged fuel hose. Clean.
4. Clogged jets in carburetor. Clean.
5. Clogged exhaust pipe. Clean.
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Dirty or heavy 1. Too much engine oil to the engine. Check oil pump.
exhaust smoke. 2. Use of incorrect engine oil. Change.
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4. Spark plug gaps incorrect. Adjust or replace.
5. Clogged jets in carburetor. Clean.
6. Float-chamber fuel level out of adjustment. Adjust or replace.
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7. Clogged air cleaner element. Clean.
8. Fouled spark plug. Clean or replace.
9. Sucking air from intake pipe. Retighten or replace.
10. Slipping or worn V-belt. Replace.
11. Damaged/worn rollers in the movable drive face. Replace.
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12. Weakened movable driven face spring. Replace.
13. Too rich fuel/air mixture due to defective starter system. Replace.
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Engine overheats. 1. Heavy carbon deposit on piston crown. Clean.
2. Defective oil pump or clogged oil circuit. Replace or clean.
3. Fuel level too low in float chamber. Adjust or replace.
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CARBURETOR
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Idling or low-speed 1. Pilot jet, pilot air jet are clogged or loose. Check and clean.
trouble. 2. Air leaking from carburetor’s joint, vacuum pipe joint, or starter. Clean and replace.
3. Pilot outlet is clogged. Check and clean.
4. Starter plunger is not fully closed. Check and replace.
Medium or high- 1. Main jet or main air jet is clogged. Check and clean.
speed trouble. 2. Needle jet is clogged. Check and clean.
3. Fuel level is improperly set. Check and replace.
4. Throttle valve is not operating properly. Check throttle valve for operation.
5. Fuel filter is clogged. Check and clean.
ELECTRICAL
Complaint Symptom and possible causes Remedy
Spark plug 1. Spark plug too hot. Replace by hot type plug.
electrodes overheat 2. The engine overheats. Turn up.
or burn. 3. Spark plug loose. Retighten.
4. Mixture too lean. Adjust carburetor.
5. Not enough engine oil. Check oil pump.
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Magneto does not 1. Open or short in lead wires, or loose lead connections. Repair, replace or retighten.
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charge. 2. Shorted, grounded or open magneto coil. Replace.
3. Shorted or open regulator/rectifier. Replace.
Magneto charge, 1. Lead wires tend to get shorted or open-circuited or Repair, or retighten.
but charging rate is loosely connected at terminal.
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below the specific- 2. Grounded or open-circuited stator coils of magneto. Replace.
ations. 3. Defective regulator/rectifier. Replace.
4. Defective cell plates in the batttery. Replace the battery.
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Ustable charging. 1. Lead wire insulation frayed due to vibration, Repair or replace.
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BATTERY
Complaint Symptom and possible causes Remedy
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.
2. Cell plates have lost much of their active material as a result Replace the battery, and correct
of over-charging. the charging system.
3. A short-circuit condition exists within the battery due to Replace the battery.
excessive accumulation of sediments caused by the incorrect
electrolyte.
4. Battery is too old. Replace the battery.
Reversed battery 1. The battery has been connected the wrong way round in the Replace the battery and be sure to
polarity. system, so that it is being charged in the reverse direction. connect the battery properly.
CHASSIS
Complaint Symptom and possible causes Remedy
Handling feels 1. Steering stem nut overtightened. Adjust.
too heavy. 2. Broken bearing/race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Wobbly handle. 1. Loss of balance between right and left front suspension. Replace.
2. Distorted front axle or crooked tire. Replace.
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too soft. 2. Oil leakage of shock absorber. Replace.
Front suspension
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1. Not enough grease. Refill.
too stiff. 2. Worn suspension arm spacer. Replace.
BRAKES
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Brake squeaking. 1. Carbon adhesion on pad surface. Repair surface with sandpaper.
2. Tilted pad. Modify and fitting.
3. Damaged wheel bearing. Replace.
4. Worn pad. Replace.
5. Foreign substance entered into brake fluid. Replace brake fluid.
6. Clogged return ports of master cylinder. Disassemble and clean master cylinder.
7. Brake shoe surface glazed. Repair surface with sandpaper.
8. Loose front-wheel axle or rear-wheel axle nut. Tighten to specified torque.
9. Worn shoe. Replace.
7-5 SERVICING INFORMATION
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SERVICING INFORMATION 7-6
SPECIAL TOOLS
Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description
09900-00401 09900-20205
Micrometer
“L”type hexagon wrench set (1/100mm, 0-25mm)
09900-00410 09900-20508
Cylinder gauge set
Hexagon wrench set (1/100mm, 40-80mm)
09900-05108 09900-20602
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Dial gauge
Snap ring pliers (1/100mm, 1mm)
09900-06105
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09900-20605
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Dial calipers
Snap ring pliers (1/100mm, 10-34mm)
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09900-06107 09900-20606
Dial gauge
Snap ring pliers
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(1/100mm, 10mm)
09900-09003 09900-20701
Impact driver set Magnetic stand
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09900-20102 09900-20806
Vernier calipers Thickness gauge
09900-20202 09900-21304
Micrometer
(1/100mm, 25-50mm) V-block set
09900-20203 09900-21602
Micrometer
(1/100mm, 50-75mm) CCI Oil gauge
Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description
09900-22301 09913-60710
Plastic gauge Bearing remover
Measure clearance of crankshaft thrust Remove bearing with the rotor remove sliding shaft
09900-22401 09913-75520
Small bore gauge
(10-18mm) Bearing installer
09900-25002 09913-75821
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Pocket tester Bearing installer
09900-26006
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09913-75830
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Tachometer Bearing installer
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Measure rotational frequency of engine Install rear axle shaft oil seal
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09900-28107 09913-76010
Electro tester Bearing installer
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09910-20115 09915-63310
Conrod holder Compression gauge adapter
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09910-32812 09915-64510
Crankshaft installer Compression gauge
09913-14541 09916-84511
Fuel level gauge set Tweezers
09913-50121 09920-13120
Oil seal remover Crankcase separater
Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description
09921-20200 09930-30163
Bearing remover (10mm) Rotor remover
Remove oil seal or bearing Attached to the top of sliding shaft when removing rotor
09921-20210 09930-32420
Bearing remover (12mm) Rotor holder
09922-55131 09930-40113
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Bearing installer Rotor holder
09923-73210
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09940-10122
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Bearing remover (17mm) Clamp wrench
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Remove bearing with the rotor remove sliding shaft A hook wrench to adjust the steering head of motorcycle
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09923-74510 09940-34520
Bearing remover (20~35mm) T-handle
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Remove bearing with the rotor remove sliding shaft Remove and remounting front fork oil cylinder
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09924-84521 09940-34561
Bearing installer Front fork assembling tool attachment“D”
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09925-98221 09940-50113
Bearing installer Front fork oil seal installer
09930-10121 09941-34513
Spark plug socket wrench set Bearing installer
09930-30102 09941-50110
Rotor remove sliding shfat Wheel bearing remover
09943-74111
Front fork oil level gauge
09943-88211
Bearing remover
09951-76010
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Bearing installer
TIGHTENING TORQUE
ENGINE
ITEM N∙m kg∙m
Magneto rotor nut 35 ~ 45 3.5 ~ 4.5
Muffler mounting bolt 18 ~ 28 1.8 ~ 2.8
Exhaust pipe nut 8 ~ 12 0.8 ~ 1.2
Spark plug 25 ~ 30 2.5 ~ 3.0
Cylinder head nut 8 ~ 12 0.8 ~ 1.2
Engine mounting bolt 40 ~ 60 4.0 ~ 6.0
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Engine mounting bracket bolt 48 ~ 72 4.8 ~ 7.2
Oil drain plug 9 ~ 15 0.9 ~ 1.5
Oil level bolt
Oil pump bolt TE 9 ~ 15
3~5
0.9 ~ 1.5
0.3 ~ 0.5
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Clutch shoe nut 40 ~ 60 4.0 ~ 6.0
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Clutch housing nut 40 ~ 60 4.0 ~ 6.0
Kick starter driven nut 40 ~ 60 4.0 ~ 6.0
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CHASSIS
ITEM N∙m kg∙m
Rear brake cam lever bolt 6~9 0.6 ~ 0.9
Rear shock absorber bolt 22 ~ 35 2.2 ~ 3.5
Rear axle nut 60 ~ 90 6.0 ~ 9.0
Steering stem lock nut 60 ~ 100 6.0 ~ 10.0
Front brake disc bolt 18 ~ 28 1.8 ~ 2.8
Front brake master cylinder bolt 8 ~ 12 0.8 ~ 1.2
Front brake air bleeder valve 6~9 0.6 ~ 0.9
Front brake caliper mounting bolt 18 ~ 28 1.8 ~ 2.8
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Front brake hose union bolt 20 ~ 25 2.0 ~ 2.5
Front axle nut
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33 ~ 52 3.3 ~ 5.2
Front fork bolt 35 ~ 55 3.5 ~ 5.5
Handlebar set bolt 22 ~ 28 2.2 ~ 2.8
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Handlebar clamp nut 48 ~ 52 4.8 ~ 5.2
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SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit : mm
ITEM STANDARD LIMIT
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2nd Approx. 4.3 3.1
ITEM STANDARD
CLUTCH Unit : mm
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Clutch tight rpm 6,000 ± 200rpm
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TRANSMISSION Unit : mm
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ITEM STANDARD LIMIT
Final reduction ratio 12.0
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CARBURETOR Unit : mm
ITEM SPECIFICATION
Carburetor type VM14
Main bore size ф 14
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Needle jet (N.J.) E-2
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Pilot jet (P.J.) 25
Throttle valve (T.V.) 3.0
By-pass (B.P.) 2.4 ± 0.05
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Valve seat (V.S.) 1.2
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Stater jet (G.S.) 25
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ELECTRICAL Unit : mm
ITEM SPECIFICATION NOTE
Ignition timing 20�at 1,000 rpm
Type BR8HSA
Spark plug
Gap 0.6 ~ 0.7
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Exciting coil 220 ~ 260 Ϊ B/R-Ground
Pick-up coil 90 ~ 110 Ϊ Br-W
Regulated voltage
No-load performance of A.C. generator
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13.0 ~ 16.0 V at 5,000 rpm
More than 17V (at 5,000 rpm)
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Starter relay resistance 0 ~ 70 Ϊ
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Type designation YT4L-BS
Fuse 10 A
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WATTAGE
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Unit : W
ITEM SPECIFICATION
Head lamp bulb 15W × 2
Tail/Brake lamp bulb 5 / 10W
Turn signal lamp bulb 10W × 4
Turn signal / Oil level check light pilot lamp 1.7W / 17W
Speedometer lamp bulb 1.7W × 2
CAUTION
BRAKE+WHEEL Unit : mm
ITEM STANDARD LIMIT
Front 5 ~ 20
Brake lever play
Rear 15 ~ 25
Brake drum I.D Rear 100 100.7
Brake lining thickness Rear 99.2 96
Brake disc plate thickness Front 4.0 ± 0.2 3.5
Brake disc plate runout Front 0.30
Master cylinder bore I.D. Front 11.000 ~ 11.043 11.055
Master cylinder piston diam. Front 10.957 ~ 10.984 10.945
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Brake caliper I.D. Front 30.230 ~ 30.306 30.315
Brake caliper piston diam. Front 30.150 ~ 30.200 30.140
Front 1.6
Tire tread depth
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Rear 1.6
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7-17 SERVICING INFORMATION
SUSPENSION Unit: mm
ITEM STANDARD LIMIT
Front fork stroke 75
Front fork spring length(Free condition) 290.9
Front fork oil specification TELLUS # 37
Front fork oil capacity(One side) 50 cc
Rear wheel travel 66
TIRE PRESSURE
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COLD INFLATION SOLO RIDING DUAL RIDING
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TIRE PRESSURE kPa kg/㎠ kPa kg/㎠
FRONT 123 1.25 172 1.75
REAR 196 2.00 221 2.25
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FUEL + OIL
ITEM SPECIFICATION NOTE
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REAR BRAKE
Rear turnsignal L
Battery cover
Rear turnsignal
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R/L
Switch thermo
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Starter relay
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Fuse case
09407-22402 09407-22402
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Rear turnsignal R Starter motor
Lamp assy, Tail & Stop 09407-22402
Rear turnsignal R/L magneto
Clamp
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Engine earth
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Ignition coil
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Rear brake
cable
Brake cable
CABLE
Front
Fender, Front upper
Switch thermo
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Ignition coil
B
Shield leg lower rear
Rear turnsignal RH/LH Heater carburetor Clamp Clamp
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Rear fender P.T.C
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Shield leg lower rear H Harness
Throttle cable
Brake cable
Starter motor
Harness
Fuel tank
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Starter motor
REAR TURNSIGNAL LAMP Regulator
Engine earth Front turnsignal RH/LH
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Starter motor Throttle cable
magneto Head lamp
Front Rear brake
Frame
cable
Harness
Throttle cable
Frame earth
Speedometer
Rear brake cable
cable Harness Brake
hose
VIEW B
VIEW D
VIEW C
Speedometer Handle switch RH
Starter Lighting Oil gauge Carburetor, Heater
Regulator
Front brake switch Fuel gauge Thermo switch
Horn Turnsignal relay P.T.C
Frame earth
WIRING DIAGRAM
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Front turnsignal RH
Rear turnsignal RH
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Tail & Stop
Head lamp
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G Rear turnsignal LH
Front turnsignal LH H
Ignition coil Starter relay Battery
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Engine earth
Horn D Starter motor
Turnsignal
Rear brake Magneto C.D.I unit
Spark plug
Handle switch LH Ignition switch switch
Rear turnsignal 10
Front turnsignal 10
WIRE COLOR
Oil pilot lamp 1.7
turnsignal pilot lamp 1.7 B : Black Lg : Light green Y : Yellow RB : Red with Black tracer
Illumination 1.7×2
Br : Brown O : Orange BG : Black with Green tracer RW : Red with White tracer
Tail 5
Rear combination G : Green R : Red BW : Black with White tracer WB : White with Black tracer
Stop 10
Head lmap 15×2 Gr : Gray Sb : Light blue BR : Black with Red tracer WR : White with Red tracer
Lamp DEST L : Blue W : White LW : Blue with White tracer YB : Yellow with Black tracer
SERVICING INFORMATION 7-20
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Prepared by
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HYOSUNG MOTORS & MACHINERY INC.
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