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SER VICE MANUAL - Hyosung Motors America

1. Rr TURN Rh BW Gr Gr lg gt Lg BW D B8W L 4 LICENSE LAMP Ft TURN Rh is Gr Gr BW BW BW HEAD LAMP TAIL amp STOP Gime BW i Gr Gr Bw 9 POSITION LAMP Bd q 8 g iii FUSE BOX Be SVAN th gt BW BW xim m BWG Lg B Sb W Y YW Rr TURN Lh Y Y Y L BW GR G L Y Y Y BW Br GR 12V 12Ah 7 i L ENGINE EARTH OFF OFF HORN TURN SIGNAL DIMMER a STARTER MOTOR HANDLE SWITCH LH Z i SIDE STAND S W LEVER S W MAGNETO NEUTRAL DIODE IGNITION S W WIRING HARNESS _ 30001 H J8254 GV 250 36610HJ8254 GL NI AMANIHOWW 9 SHOLOW 61 pS pesn eq pinoys 022 WIYS eu 0 si jueseud sseuxotuj ulus 022 80100 pue ww z o SI eoueJeo o Jodde ueuM 066 SV 0 90 00 022 972 902 ooz 596060 10 eui pue 55 10 0027 06906 006 96 060980 je3u0ZiJ0U Ul eoeds JO 40071 022
2. License plate lamp 4 x th 1 i E i is 5 Qr z 14 Is OO D a ae ES LO 2 Y gt Y Y Turn signal lamp Rear Turn signal lamp Front Passenger footrests A 4 2 a T 9 O 9 LO y Y Y p 1 500 WHEEL BASE J 465 2 270 LENGTH SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height acta Ground clearance Unladen mass ENGINE Type Number of cylinder BOO Piston displacement equ M Starter system Lubrication system TRANSMISSION ec E Se Transmission d NA Gearshift pattern Final reduction Gear ratio 1st 2nd Drive chain CHASSIS Front suspension Rear suspension Steering angle Caster PR Front brake mic DIAKO M Front tire size Poarte SIZE Front fork stroke GENERAL INFORMATION 1 8 BDS 26TYPE DOUBLE Electric starter Wet sump Wet multi plate type 5 constant mesh 1 down 4 up 3 290 Telescopic type Swingarm type 40 right amp left 33 7 135 Disk brake Drum brake 110 90 16 59S 150 80 15M C 705 120 mm 1 9 GENERAL INFORMATION ELECTRICAL fe eq Battery Ignition CDI Ignition timing
3. 5 11 IGNITION INTERLOCK SYSTEM SWITCHES ME ors 5 15 E 5 16 N 5 18 5 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS D Battery 2 Turn signal relay 3 Fuse 5 Rear brake lamp switch Starter motor ELECTRICAL SYSTEM 5 2 C D I Unit 9 Regulator Rectifier Battery plus terminal 1 Battery minus terminal Be sure not to misassem P ble the position of battery CT plus amp minus terminal 3 Gear position switch 5 3 ELECTRICAL SYSTEM IGNITION SYSTEM 250 is started as the battery discharged ignition system without a contact point The battery ignition system is composed a rotor with five rotor tip the D C CDI the ignition coil and battery Ignite after permit signal at ignition timing of pick up as electric energy of this battery occur the 1st electric current Therefore a high voltage current is induced in the secondary winding of the ignition coil resulting in strong spark between the spark plug gap Magneto C D I Unit SPARK PLUG PLUG CAP FRONT IGNITION COIL IGNITION SWITCH MAGNETO ASS Y ae CDI REG BATTERY M REAR IGNITION COIL 2 Dy SIDE STAND SWITHC NEUTRAL SWITCH T1 Ignition coil amp Spark plug ELECTRICAL SYSTEM 5
4. FRONT FORK OIL Use fork oil TELLUS 22 GENERAL INFORMATION 1 6 BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving 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 early life The general rules are as follows Keep to these break in procedures Initial 800km Less than 1 2 throttle Up to 1 600km Less than 3 4 throttle Upon reaching an odometer reading of 1 600 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 CYLINDER CLASSIFICATION The engine of 250 is composed of the two cylinder is classified into the front cylinder and rear cylinder as basis of the motorcycle ahead Rear cylinder Front cylinder ame Uo 5 gt est TY 49 iq en C 1521 ay 555 6 1 7 GENERAL INFORMATION EXTERIOR ILLUSTRATION Rear reflector gJ N D Sy Tail Brake lamp 7
5. SEL 10 jesseoeuun jueuusn py payloads LO tO lt EN ve 8 SHOLOW SNASOAH 5 6 022 9 0 02 04 WOS eq 5590910 06 9 60 ulus y 1 1uesaeJd 55904210 6 soz 0121 90 y pue si y ueuM 52212 dE 501 101 922 101 DUE SSBUYOSIU JO on 100000 ulus 99 7 0272 912 oF Z 502 002 96 1 061 98 06 0 38 0 pjoo Jadde y eunseow 022 9 2 orz so z 007 567 06 981 58 07 80 1NVHO ISN OL MOH 022 912 01 002 961 067 987 081 080 9 0 567 063 52 NC ise 10 vo vo vo vo 9 NT jesseoeuun DUET Sd 02 0 02 0 9 2 902 007 967 061 ce 081 92 oz fegi 091 951 081 oF Z soz nz se ost sm oer sri ors O9 e ori sev oy sc 1000 502 002 56 061 581 081 5 4 02 897 09 ear 061 Ovi oer 9 Poe s 600 8070 006 6 010 6 650201 002 6611061 581108115 11 07 6501091 65601001 9711 0 71165 611
6. 01696 00066 SADIAYAS SERVICE MANUAL 8 SHOLOIN 5 Q 2 2 gt FOREWORD This manual contains an introductory description on HYOSUNG 250 and procedures for its inspection service and overhaul of its main components Other information considered as generally known 15 not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared the basis of the latest specification at the time of publica tion If modification has been made since then dif ference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of operation and work proce dures They may not represent the actual vehicle exactly in detail This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and Skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE FUEL SYSTEM ELECTRICAL SYSTEM CH
7. Rear brake pedal free travel 8 20 30 mm 4 ore PJ REAR BRAKE SHOE WEAR This motorcycle is equipped with brake lining wear limit indicator on the rear brake To check brake lining wear perform the following steps Make sure that the rear brake is properly adjusted Depress the rear brake pedal Make sure that the extension line 3 from the index mark is within the range 4 embossed on the brake panel If the extension line goes beyond the range the brake shoe assembly should be replaced with a new set of shoes Refer to page 6 39 9 BRAKE LAMP SWITCH Adjust the rear brake lamp switch so that the brake lamp will come on just before pressure is felt when the brake pedal is depressed STEERING NOTE Inspect Initial 1 000 km and Every 4 000 km Steering should be adjusted properly for smooth turning of handlebars and safe running Overtight steering pre vents smooth turning of the handlebars and too loose steering will cause poor stability Check that there is no play in th steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the ground with the wheel straight ahead and pull forward If play is found perform steering bearing adjustment as described in page 6 30 of this manual FRONT FORK NOTE Inspect Every 4 000 km Inspect the front forks for oil leakage scoring or scratch es on the outer surface of the inner tu
8. WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnormal noise and smooth rotation Replace the bearing in the following procedure if there is anything unusual E WHEEL BEARING REMOVAL Remove the wheel bearing by using the special tool Wheel bearing remover 09941 50111 CAUTION The removed bearing should be replaced with new ones 9 REASSEMBLY Reassemble the front wheel in the reverse order of removal and disassembly Pay attention to the following points E WHEEL BEARING Apply SUPER GREASE to the wheel bearings AH SUPER GREASE Install the wheel bearings as follows by using the special tools Steering race installer 09941 34513 CAUTION First install the right wheel bearing then install the left wheel bearing BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Apply THREAD LOCK 1324 to the disc mounting bolts and tighten them to the specified torque V Brake disc bolt 18 28 N m 1 8 2 8 kg m THREAD LOCK 1324 CHASSIS 6 8 6 9 CHASSIS Tighten the front axle D and axle pinch bolt to the specified torque V Front axle 50 80 N m 5 0 8 0 m Front axle pinch bolt 15 25 N m 1 5 2 5 m CHASSIS 6 10 FRONT BRAKE WARNING Do not mix with brake fluid of
9. Install the rear shock absorber Refer to page 6 44 Install the rear wheel Refer to page 6 37 Adjust the following points Drive chain slack Refer to page 2 13 Rear brake pedal free travel Refer to page 2 17 CHASSIS 6 48 SERVICING INFORMATION CONTENTS TROUBLESHOOTING 7 1 CBE CIAL TOOLS 7 8 TIGHTENING TORQUE 7 11 SERBUIGE DATA AE 7 13 WIRE AND CABLE ROUTING 7 20 WIRING DIAGRAM 7 24 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Engine will not Compression too low start or is hard 1 Valve clearance out of adjustment Adjust to start 2 Worn valve guides or poor seating of valves Repair or replace Engine stalls easily Noisy engine 3 Valves mistiming 4 Piston rings excessively worn 5 Worn down cylinder bore 6 Poor seating of spark plug 7 Starter motor cranks but too slowly Plug not sparking 1 Fouled spark plug 2 Wet spark plug 3 Defective ignition coil 4 Open or short circuit in high tension cord No fuel reaching the carburetor 1 Clogged hole in the fuel tank cap 2 Clogged or defective fuel cock 3 Defective carburetor float valve 4 Clogged fuel pipe 1 Fouled spark plug 2 Clogged fuel hose 3 Clogged jets in car
10. PISTON af Nae MAGNETO COVER MAGNETO ROTOR o tette CLUTCH COVER ae Nee CLUTCH eee PRIMARY DRIVE GEAR 6 MEE GEARSHIFT SHA PAG ttt ENGINE COMPONENT INSPECTION AND SERVICE 2 ENGINE RE ASSEMBLY oeenn CAUTION Mark an identification of assembly location on each removed part so that each will be restored to the original position during reassembly Wash clean and dry the removed parts before inspecting and measuring Oil the rotating or sliding parts before assembly Make sure to use the correct type of lubricant where specified Check that each rotating or sliding part moves or operates smoothly after assembly Make sure to follow the tightening order where specified If the correct length of the bolt is confused when tightening the crankcase or cover insert all the bolts and check that the tightening margin is equal in each bolt ENGINE 3 1 ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL NOTE If the engine 15 dirtied wash the machine with a suitable cleaner before removing the engine Remove the front seat Refer to page 6 1 Remove the fuel tank Refer to page 4 1 Drain the engine oil Refer to page 2 10 Remove the right frame cover Refer to page 6 2 Disconnect the battery lead wire Remove the the four support mounting bolts 2 Remove the spark plug R
11. Bearing remover 12mm Used to remove oil seal or bearing 09923 73210 Bearing remover 17mm Used to remove bearing with the rotor remove sliding shaft 09923 74510 Bearing remover 20 35mm Used to remove bearing with the rotor remove sliding shaft 09924 84521 Bearing installer 09930 10121 Spark plug socket wrench set Used to remove or remounting spark plug 09930 30102 Rotor remove sliding shaft Used to with bearing remover or rotor remover 09930 30164 Rotor remover 09930 40113 Rotor holder Widely used to lock rotary parts such as a flywheel magneto SERVICING INFORMATION 7 10 Special tools Part Number Part Name Description 09930 44510 Rotor holder Widely used to lock rotary parts such as a flywheel magneto 09940 10122 Clamp wrench A hook wrench to adjust the steering head of motorcycle 09940 34520 T handle Remove and remounting front fork oil cylinder 09940 34561 Front fork assembling tool attachment D Used with T handle 09940 50113 Front fork oil seal installer Install front fork oil seal 09941 34513 Steering race installer 09941 50111 VTS Wheel bearing remover Used to remove wheel bearing 09943 74111 Front fork oil level gauge Used to drain the fork oil to the specified level 7 11 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM kym Magneto rotor nut Magneto cover bolt Muffler mounting bolt Exhaust pip
12. ENGINE 3 18 Remove the pin With the three screws loosened remove the oil pump GEARSHIFT SHAFT Draw out the gearshift shaft With the cam guide screws loosened draw out the guide and lifter Remove the cam driven gear CAUTION Pay attention to not gearshift pawl pin spring with the cam driven gear removal With the neutral cam stopper plug loosened remove the washer spring stopper 3 19 ENGINE Remove the crankcase securing bolts Separate the crankcase into 2 parts right and left with a special tool Crankcase separator 09920 13120 CAUTION When separating the crankcase necessarily remove it after installed the special tool Crankcase separator on the side of clutch In case separate oppositely the gearshift cam stopper will be damaged in the side of magneto CAUTION The crankshaft and transmission components must remain in the right crankcase half This is necessary because the gearshift cam stopper is mounted on the right crankcase half and will be damaged if the trans mission components remain in the left half 79 8 mg Fit the crankcase separater so that the tool arms adi parallel the side of the crankcase The crankshaft and transmission components must remain in the left crankcase half Remove the gearshift fork shaft 0 and gearshift fork 2 Remove the gearshift 3 Remove th
13. m 1 5 3 0 kg m Install the front fender and tighten the mounting bolts temporarily Install the front wheel Refer to page 6 8 Install the front brake caliper Refer to page 6 12 Move the front fork up and down several times Tighten the front fender mounting bolts securely CHASSIS 6 26 STEERING 9 DISASSEMBLY Remove the front wheel Refer to page 6 6 Remove the front fork Refer to page 6 19 Remove the cable guide 6 27 CHASSIS With the nuts removed remove the headlamp hous ing Remove the handlebars Refer to page 6 17 Remove the steering stem head nut Remove the steering stem upper bracket Remove the steering stem nut 2 using the special tool Clamp wrench 09940 10122 Draw out the steering stem lower bracket NOTE Hold the steering stem lower bracket to prevent it from falling Remove the handlebar holders by removing the nuts To remove the lower inner race use chisel CAUTION Unless corrosion damage or other abnormal condition is found the bearing race need not be replaced 4 Once the lower inner race has been removed replace it with a new one Drive out the steering stem bearing outer races using the special tools 0 and a suitable wedge bar 2 Bearing outer race remover 1 09941 54911 9 INSPECTION Check the steering stem and steering stem head for any damage Check the
14. 0 7 A 5 10 hours 30 minutes CHASSIS CONTENTS EXTERIOR 6 1 COVER ee 6 2 REAR FRAME ices eee 6 4 FRONT WEERE erat ee 6 6 FRONT BRAKE ee 6 10 eee ere 6 17 FRONT FORK 6 19 6 26 gt topped 6 32 REAR BRAKE Nen 6 39 REAR SHOCK ABSORBER Seu s 6 43 SWING ARM Tc 520 dH Tm 6 45 6 1 CHASSIS EXTERIOR PARTS FRONT FENDER With the bolts removed remove the front fender FRONT SEAT Remove the front seat with the ignition key REAR SEAT With the bolts removed remove the rear seat CHASSIS 6 2 O pes gt 13 gt Q 1e lt lt o RIGHT FRAME COVER Remove the screw 1 FRAME COVER gt O O uc 6 3 CHASSIS RIGHT REAR FRAME COVER Remove the right frame cover With the bolts removed remove the right rear frame cover LEFT FRAME COVER Remove the screw 2 Remove the hook 3 4 LEFT REAR FRAME COVER Remove the left frame cover With the bolts removed remove the left rear frame CHASSIS 6 4 REAR FRAME COVER REAR VIEW co
15. Align the key groove and mark CAUTION Pay attention to the two washer to lower end of the primary drive gear nut in times of assemblage With the magneto rotor held immovable using special tool tighten the primary drive gear nut Conrod holder 09910 20115 9 Primary drive gear nut 40 60 N 4 0 6 0 m PRIMARY DIRVEN GEAR NOTE Apply engine oil to the inside surface of the primary driven gear bearing Install the primary driven gear assembly 3 45 ENGINE CLUTCH Install the clutch sleeve hub lock washer and clutch sleeve hub nut 75 2 1 AN S D JA X Install the clutch sleeve hub nut and tighten it to the specified torque using the special tool Clutch sleeve hub holder 09920 53710 V Clutch sleeve hub nut 30 50 N m 3 0 5 0 kg m Bend the lock washer securely Install the clutch drive plates and driven plates ENGINE 3 46 Install the clutch release rack 0 bearing 2 and washer 3 Install the clutch pressure plate clutch springs and clutch spring mounting bolts 9 NEL Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern NOTE Make sure that the clutch pressure plate is installed correctly CLUTCH COVER Install the two dowel pins and new gasket 9 Apply engine oil to
16. Measure the runout using the dial gauge Replace the brake disc if the runout exceeds the service limit Brake disc runout Dial gauge 09900 20606 Magnetic stand 09900 20701 f either measurement exceeds the service limit replace the brake disc Refer to page 6 7 CHASSIS 6 14 MASTER CYLINDER DISASSEMBLY Drain brake fluid the master cylinder Disconnect the brake lamp switch lead wire coupler Remove the union bolt CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts Remove the master cylinder Remove the brake lamp switch and brake lever 3 lt O Remove the master cylinder 6 15 CHASSIS Detach the dust seal boot 0 and remove the circlip Pull out the piston cup set and spring 3 MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for any scratches or other damage 2 MASTER CYLINDER REASSEMBLY Reassemble the master cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylider components with new brake fluid before reassembly When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Specification and Classification DOT 3 DOT 4 NOTE When installing th
17. O c 84 a co O 4 84 75 2 O O C gt gt c Remove the front and rear seats Remove the frame covers 6 5 CHASSIS Disconnect the rear turn signal lamp couplers and rear combination lamp coupler With the four bolts removed remove the rear frame cover CHASSIS 6 6 FRONT WHEEL REMOVAL Loosen the axle pinch Loosen the front axle 2 Raise the front wheel off the ground with a block or jack CAUTION When using a jack take care not to cause scratches on the chassis Remove the front wheel by removing front axle 2 6 7 CHASSIS Remove the brake disc 9 INSPECTION AND DISASSEMBLY B TIRE For inspection of the tire Refer to page 2 19 FRONT AXLE Measure the front axle runout using the dial gauge If the runout exceeds the limit replace the front axle Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 WHEEL Make sure that the wheel runout axial and radial does not exceed the service limit when checked as shown An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the wheel Axle shaft runout
18. 3 MAGNETO ROTOR With the magneto rotor held immovable using the special tool loosen the rotor nut Conrod holder 09910 20115 Remove the magneto rotor by using the special tool Rotor remover 09930 30164 3 15 ENGINE Remove the key Remove the starter driven gear 2 Remove the cam chain tensioner 3 and cam chain 0 CLUTCH COVER Remove the clutch release arm Remove the clutch cover bolts Remove the clutch cover ENGINE 3 16 CLUTCH With the primary drive gear held immovable remove the clutch spring mounting bolts diagonally Remove the disk pressure 1 Remove the clutch drive and driven plates Flatten the lock washer With the clutch sleeve hub held immovable using special tool remove the clutch sleeve hub nut Clutch sleeve hub holder 09920 53710 3 17 ENGINE Remove the clutch sleeve hub and primary driven gear assembly 2 PRIMARY DRIVE GEAR With the magneto rotor held immovable using special tool remove the primary drive gear nut Conrod holder 09910 20115 CAUTION This bolt has left hand thread If turning it counter clockwise it may cause damage Pay attention at the primary drive gear with two washer Remove the key and cam chain Remove the cam chain tensioner OIL PUMP Remove the circlip and oil pump driven gear 4 a t e 4 min d
19. Q if no sparking or orange color sparking occures in the above conditions it may be caused by the defective coil Spark performance Over 8 mm 0 3 in Electro tester 09900 28107 WARNING Do not touch the wire clips to prevent an electric shock when testing CAUTION When using the electro tester follow the instruc tion manual A CAUTION The ignition coil is marked the F front and the R forrear If otherwise it may occure severe damage to the engine Spark ELECTRICAL SYSTEM 5 6 B IGNITION COIL Checking with Pocket Tester A pocket tester or an ohm meter may be used instead of the electro tester In either case the igni tion coil is to be checked for continuity in both prima ry and are secondary windings Exact ohmic readings are not necessary but if the windings are in sound condition their continuity will be noted with approxi mate ohmic values Ignition coil resistance Primary 0 19 0 246 Tester knob indication x 1 Grange 5 4 6 6 Tester knob indication x 1kQrange Check to attached plug cap Pocket tester 09900 25002 B SPARK PLUG Clean the plug with a wire brush and pin Use the pin to remove carbon taking care not to damage the porce lain Check the gap with a thickness gauge Spark plug gap 0 7 0 8mm Thickness gauge 09900 20806 5 7 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated
20. 06115011001 WHS 19 1 ONIYNSVAW LYWHOD NOILO313S WIHS LaddVL LO 35 P 6L 0 810 scr DD o E _____ ____ _____ ____ OO 001960 960160 060980 0 0809 0 0 Hor fen wes CE 090980 990190 _ 2 sowo ___ ___ _____ ___ 060070 0 D eroso XN ooo 90050 Prepared by HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department 2nd Ed MAY 2001 Manual No 99000 95310 Printed in Korea
21. 2 Remove the right and left rear shock absorbers by removing their nuts 9 INSPECTION Inspect the rear shock absorber for damage and oil leakage If any defects are found replace the rear shock absorber with a new one CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable 9 REMOUNTING Install the rear shock absorber and tighten the nuts to the specified torque V Shock absorber mounting nut upper 20 30 N m 2 0 3 0 kg m Shock absorber mounting nut lower 35 55 3 5 5 5 m SPRING PRE LOAD ADJUSTMENT Adjust the rear shock absorber spring pre load Rear shock absorber Standard spring length 199 8 mm Rear shock absorber Standard spring pre load 1 5 position 0 Rear shock absorber 2 Pin spanner CHASSIS 6 44 6 45 CHASSIS SWINGARM REMOVAL Remove the rear wheel Refer to page 6 32 Remove the exhaust pipe and mufflers Refer to page 3 2 CHASSIS 6 46 Remove the engine sprocket cover Remove the swingarm pivot nut and washer Remove the swingarm by removing the pivot shaft Remove the rear brake hub from the swingarm Remove the dust covers 0 washers 2 and spacers 8 6 47 CHASSIS Remove the chain buffer 1 from the swingarm 9 INSPECTION SWINGARM Inspect the swingarm for damage If any defects are found replace the swingarm with a
22. 4 INSPECTION E MAGNETO Using the pocket tester measure the resistance between the lead wires in the following table Pick up coil G L Approx 90 110 Q Charging Y Y Approx 0 6 0 9 Q Pocket Tester 09900 25002 CAUTION When mounting the stator on the magneto cover apply a small quantily of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 WIRE COLOR L Blue G Green Br Brown B Y Black with Yellow tracer O B Orange with Black tracer G W Green with White tracer B W Black with White tracer W L White with Blue tracer B CDI UNIT Using the pocket R x 1kQ range measure the resis tance between the lead wires in the following table Unit kQ Probe of tester llus o0 gt um Pocket Tester 09900 25002 5 5 ELECTRICAL SYSTEM A CAUTION Pay caution as the numerical value differs a little according to the tester Please remind that there be defect which can not be identified even though the measurement by using the tester indicates a low voltage The range of measurement adjust a x 1kQ unit INSPECTION B IGNITION COIL Checking with Electro Tester Remove the ignition coil 1 2 Make sure that the three needle sparking distance of the electro tester is set at 8 mm 0 3 in With the electro tester test the ignition coil for spark ing performance
23. 4 490 O n 4 455 4 470 NENNEN 12 1 13 9kgf at length 33 7mm SS 12 1 13 9kgf at length 33 7mm NO NO Valve diam gt Valve clearance When cold gt Valve guide to stem clearance Valve stem deflection Valve guide I D Valve stem O D gt Valve stem runout Valve head thickness ETES Valve seat width Valve seat angle Valve head radial runout Valve spring free length gt Z Valve spring tension CAMSHAFT CYLINDER HEAD Unit mm STANDARD LIMIT 34 470 34 510 34 170 34 420 34 460 34 120 Cam height Camshaft journal holder I D IN amp EX 35 000 35 018 Cylinder head cover distortion Cam chain pin Arrow 3 16th pin SERVICING INFORMATION 7 14 CYLINDER PISTON PISTON RING Unit mm Piston diam 56 945 56 960 56 880 Measure 15mm from the skirt end Cylinder cylinder head distortion Piston ring free end gap 1st Piston ring end gap Assembly condition 1st Piston ring to groove clearance 1st 1st Piston ring to groove width S 0 970 0 990 Piston ring thickness 1st 2nd 0 970 0 990 Piston pin hall 1 0 15 002 15 008 Piston pin O D 14 994 15 000 CONROD CRANKSHAFT Unit mm ITEM STANDARD 15 006 15 014 2nd Oil 2 01 2 03 N N 9 OIL PUMP Unit mm ITEM STANDARD NOTE Oil pressure 1 3 0 2 kg cm at 6
24. 50 2 002 96 06 480800000 ueseJd je sseuxolu WIYS 99 027 Sc 0L Z 902 002 OBL 0222 08097000000 02 jedde eu eunseeJv 022 soz 007 set 06 981 084 0 1 0 LYVH9 ASN OL 10272 972 orzi 907 007 96 06 Set 087 921 02 0 99 0 0061 soc 002 965 061 9841084 92 021 590 190 022 972 90 007 96 061 S8 og i SEV OL V 591 090 9570 022 90 0072 66 06 981 091 92 1 02 991 091 550 150 06 8814085 9 71 02 991 091 G6 1 050 970 02 002 591067 joe 991 INT LO 0 9 0 960 160 060 9600 GC 0 16 0 06 0 010 soz 661 e oe sz or BB 091657 os ev or sen sev zv 600506 52 0071561 067 981 081 sr 023 st 09 ss ost sri ors So 3ONVSV3T SANYOHL WHS ONIYNSVAN NI LYWHOD NOILO313S WIHS LaddVL LO srt NC 22 122 5 502 002581 os se 0 so onn 551 922 5 5 soz 002 581 se or 511100 591 oon 551 061 22 5 0 2 502 002 581 061951081 os soz ooz srt LC 0661916 011 90 1002196 1 06 98 08 871107 659 09 5
25. Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clear ance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Thickness gauge 09900 20806 CYLINDER BORE Measure the cylinder bore diameter at six place If any one of the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replace the cylinder Cylinder bore 57 000 57 015 mm 57 080 mm Cylinder gauge set 09900 20508 9 CAM CHAIN TENSION ADJUSTER Check that the push rod slides smoothly with the lock shaft handle clockwise x If it does not slide smoothly replace the chain ten sion adjuster with a new one 9 CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner If itis worn or damaged replace it with a new one ENGINE 3 26 4 3 27 ENGINE 9 CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear damage and kinked or bind ing links If any defects are found replace it with a new one Check the cam chain guide for wear and damage If it is found to be damaged replace it with a new one 9 PISTON DIAMETER INSPECTION Measure the outside diameter of piston in the direction per pendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer If
26. DO NOT use lapping compound after the final cut is made The finished valve seat should have a velvety smooth fin ish and not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation Clean and assemble the head and valve components Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could pre vent the valve from sealing 4 WARNING Always use extreme caution when handling gaso line CAUTION Be sure to adjust the valve clearance after reassem bling the engine 9 VALVE SPRING The force of the coil spring keeps the valve seat tight A weakened spring results in reduced engine power out put and often accounts for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by measur ing their free length and also by the force required to compress them If the spring length is less than the ser vice limit or if the force required to compress the spring does not fall within the specified range replace both the inner and outer springs as a set Service limit 37 80 mm Valve spring free length IN amp EX Venier calipers 09900 20101 Standard 12 1 13 9 kgf at length 33 7 mm Valve spring tension IN amp EX 9 CYLINDER DISTORTION
27. Remove the combination meter Disassemble the combination meter as shown in the illustration E INSPECTION Using the pocket tester check the continuity between lead wires in the following illustration If the continuity measured incorrect replace the respec tive part Pocket tester 09900 25002 A CAUTION When making this test it is not necessary to remove the combination meter 12V 7 X 1 7W T6 5 wies ILLUM ILLUM ILLUM TURN TURN L NELITRAL TACHD METER 5I BNAL OX YB FUEL o 4 L NEUTRAL 3 Gr ILLUM amp o Lg TURN R B TURN L B Y SIGNAL ELECTRICAL SYSTEM 5 18 BATTERY CAUTION OF BATTERY TREATMENT The battery should be well taken care of because it emits flammable gas If you don t follow the instruction in the below there may be a explosion and severe accident Therefore please pay attention to the following points Prohibit positively battery from contacting to short spark or firearms The recharge of battery should be done in the wide place where the wind is well ventilated Please don t recharge it at the sight of wind proof CAUTION OF BATTERY ELECTROLYTE TREATMENT Pay attention for the battery electrolyte not to stain the chasis or the humanbogy If be stain the chassis or the humanbody at once wash a vast quantity of water When it be stained clothes should come into being a hole o
28. Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09910 32812 09913 80112 Crankshaft installer lt Bearing installer Used to install the crankshaft in the crankcase J Used to drive bearing in 09910 34510 09915 63310 Piston pin puller Compression gauge adapter Used with compression gauge 09913 10760 09915 64510 Fuel level gauge Lac Compression gauge Measure cylinder compression 09913 50121 09915 74510 Oil seal remover Oil pressure gauge Measure oil pressure of 4 stroke engine 09913 70122 lt 09915 74531 Bearing installer EN Oil pressure gauge hose attachment Used to drive bearing in Used with oil pressure gauge 09913 75520 09916 14510 Bearing installer Valve spring compressor Used to drive bearing in Used to remove and remounting valve stem 09913 75820 09916H35C00 Bearing installer Valve spring compressor attachment Used to drive bearing in Used with valve spring compressor 09913 75830 5 09920 13120 Bearing installer LA NN Crankcase separater Used to install rear axle shaft oil seal Separate to crankcase 09913 76010 09920 53710 Bearing installer Clutch sleeve hub holder Used to drive crankshaft bearing in Used to install or remove clutch sleeve hub nut Special tools Part Number Part Name Description 09921 20200 Bearing remover 10mm Used to remove oil seal or bearing 09921 20210
29. Tighten the steering stem head nut temporarily Install the handlebars Refer to page 6 17 Tighten the handlebar holder nuts to the specified torque V Handlebar holder lower nut 40 60 N m 4 0 6 0 m Align the upper surface of the front fork inner tube with the upper surface of the steering stem upper bracket Tighten the upper front fork clamp bolts to the speci fied torque V Front fork upper clamp bolt 22 35 N m 2 2 3 5 m Tighten the steering stem head nut to the specified torque V Steering stem head nut 80 100 N m 8 0 10 0 kg m CHASSIS 6 30 6 31 CHASSIS Install the cable guide Install the front wheel Refer to page 6 8 NOTE Hold the front fork legs move them back and forth and make sure that the steering is not loose CHASSIS 6 32 REAR WHEEL REMOVAL Remove the drive chain cover 6 33 CHASSIS Remove the rear brake adjusting nut spring and washer 3 Raise the rear wheel off the ground with a jack or block Loosen the drive chain adjuster right and left Disengage the drive chain from the rear sprocket Loosen the rear shock absorber upper bolt 6 right and left Draw out the rear axle with the rear wheel push to the bottom Pull the rear wheel assembly rearward CHASSIS 6 34 Remove the rear brake panel Refer to page 6 39 Remove the spac
30. With the damper rod held immovable remove the damper rod bolt Q Remove the damper rod and rebound spring from the inner tube CHASSIS 6 20 6 21 CHASSIS Remove the dust seal and oil seal stopper ring Separate the inner tube from the outer tube Remove the following parts 3 Oil seal 4 Slide metal Oil lock piece 77 8 CAUTION The removed oil seal and slide metal should be replaced with new ones Remove the front fork cover bolt CHASSIS 6 22 9 INSPECTION FRONT FORK SPRING Measure the free length of the front fork spring If the length is found shorter than the service limit replace the spring CC Front fork spring free length 356 mm E INNER TUBE AND OUTER TUBE Check the sliding of the inner tube outer tube and damper rod ring for scratch wear bending or other abnormal condition 0 REASSEMBLY Perform the reassembly and remounting work in the reverse order of the disassembly and removal procedures while observing the following instructions CAUTION Thoroughly wash all parts being assembled Insufficient washing can result in oil leakage or premature wear of the parts When reassembling the front fork use new fork oil Use the specified fork oil for the front fork When reassembling replace the slide metals oil seal dust seal and damper rod bolt gasket with new o
31. abnormal condition are found replace the primary driven gear tation is place the Turn the oil pump shaft and check t smooth If any abnormal condition is fo oil pump with new one 9 GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture ENGINE 3 34 3 35 ENGINE 9 TRANSMISSION INSPECTION GEAR SHIFTING FORK Using a thickness gauge check the clearance between in the groove of its gear and shifting fork The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Shift fork groove Standard clearance 0 10 0 30 mm Thickness gauge 09900 20806 Vernier calipers 09900 20101 Shift fork groove width Standard NO 1 amp NO 2 5 0 5 1 mm 5 0 5 1 mm Shift fork thickness Standard NO 1 amp NO 2 48 49 mm 4 8 4 9 mm REASSEMBLY Assemble the countershaft and drivenshaft in the reverse order of disassembly Pay attention to following points NOTE Always use new circlips NOTE Before installing the gears coat lightly engine oil to the driveshaft and countershaft ENGINE 3 36 CAUTION Never reuse Circlip After circlip has been removed from a shaft it should be discarded Thrust and a new circlip must be installed When installing a new circl
32. bearing before installation AH SUPER GREASE Q Press fit the bearing to the wheel using the special tools Steering race installer 09941 34513 CAUTION First install the right wheel bearing then left wheel bearing REAR SPROCKET MOUNTING DRUM BEARING Install the rear sprocket mounting drum bearing and dust seal using the special tool Steering race installer 09941 34513 NOTE Apply grease to the bearing and dust seal lip before assembling the rear sprocket mounting drum AH SUPER GREASE CHASSIS 6 36 6 37 CHASSIS REAR SPROCKET Tighten the rear sprocket nuts to the specified torque V Rear sprocket nut 22 35 N 2 2 3 5 kg m Install the retainer to the mounting drum as shown REAR WHEEL After the rear wheel install tighten the rear axle nut 0 to the specified torque V Rear axle 90 140 N m 9 0 14 0 kg m Tighten the rear shock absorber upper bolt right and left CHASSIS 6 38 After installing the drive chain to the rear sprocket adjust the drive chain Tighten both chain adjusting nuts securely Adjust the rear brake pedal free travel Refer to page 2 17 6 39 CHASSIS REAR BRAKE 9 DISASSEMBLY Remove the rear wheel Refer to page 6 32 Remove the brake panel CHASSIS 6 40 Remove the brake shoes Remove the rear brake cam lever and rear brake cam 2 by removing
33. come from transmission 1 2 3 3 Gears worn or rubbing Badly worn splines Primary gears worn or rubbing Badly worn bearings Clutch control out of adjustment or too much play Weakened clutch springs Worn or distorted pressure plate Distorted clutch plates driven and drive Clutch control out of adjustment or too much play 2 Weakened clutch springs Distorted clutch plates driven and drive Broken gearshift cam Distorted gearshift forks Worn gearshift pawl Broken return spring on shift shaft 2 Shift shafts are rubbing or sticky Distorted or worn gearshift forks Worn shifting gears on driveshaft or countershaft Distorted or worn gearshift forks Weakened stopper pawl spring on gearshift cam Worn gearshift pawl CON O14 Valve clearance out of adjustment Poor seating of valves Defective valve guides Defective pick up coil Spark plug gap too wide Defective ignition coil resulting in weak sparking Float chamber fuel level out of adjustment in carburetor Clogged jets Valve springs weakened Valve timing out of adjustment Worn cams Spark plug gap too narrow Defective ignition coil Float chamber fuel level too low Clogged air cleaner element Clogged fuel hose resulting in inadequate fuel supply to carburetor Too much engine oil in the engine Worn piston r
34. each gears bearings and clutch plates Tighten the clutch cover bolts securely 3 47 ENGINE Install the clutch release arm as following 0 Turn the clutch release shaft toward This time mark on the shaft align outside contact line the stopper screw the right Stopper screw 2 Install that the cable connecting center line of the arm bolt clutch release arm align matching mark rightside of the case as shown the right figure Clutch release arm Crankcase matching mark NEUTRAL CAM STOPPER Put in the neutral cam stopper spring and washer tighten the cam stopper plug to the specified torque V Cam stopper plug 20 25 m 2 0 2 5 kg m 9 OIL DRAIN PLUG Tighten the oil drain plug to the specified torque Q Engine oil drain plug 18 20 N m 1 8 2 0 kg m STATOR Apply a small quantity of THREAD 1324 to the threaded parts of screws THREAD LOCK 1324 9 STARTER CLUTCH When installing the starter clutch and rotor apply the THREAD LOCK 1324 to the bolts and tighten to the specified torque THREAD LOCK 1324 V Starter clutch bolt 15 20 N 1 5 2 0 kg m Release camshaft notch mark MAGNETO ROTOR Fit the key in the key slot on the crankshaft With the magneto rotor install the starter clutch it install the crankshaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft THREAD LOC
35. ee 13 B T D C at 2 000 rpm and 30 B T D C at 6 000 rpm CR8E sul 12V 6Ah PUSO 15 HI 35W 35W uen u oW Tum signallamp me 10 W Brake lamp 21 5W Speedometer 1 7 Wx3 High beam indicator lamp 1 7 W Turn signal indicator lamp right 1 7 WX2 License plate lamp oW Neutral indicator 1 7 W CAPACITIES FIST TAIN 14 0 2 Engine oil oil change 1 450 m with filter change 2 2 1 500 m overhaul 1 800 m Front fork oil One side 250 cc NOTE The specifications are subject to change without notice 5 PERIODIC MAINTENANCE SCHEDULE 2 4 PERIODIC MAINTENANCE CHART 2 1 LUBRICATION POINTS cd uid 2 2 MAINTENANCE PROCEDURES 2 3 VALVE CLEARANCE 2 3 SPARK PLUG c S 2 5 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2 6 4 2 6 CARBURETOR sections eee 2 8 EUEL xen ee 2 8 GEUICH 2 9 ENGINE OIL 4 44 2 9 ENGIN
36. ee ee ae 4 3 A CAUTION Gasoline must be handed carefully in an area well ventilated and away from fire or sparks 4 1 FUEL SYSTEM FUEL TANK FUEL COCK 9 REMOVAL WARNING Gasoline is very explosive Extreme care must be taken Remove the front seat Refer to page 6 1 Remove the fuel tank mounting nut and bolt and take off the hooks Turn the fuel cock to OFF and disconnect the fuel hose 1 Remove the fuel tank Remove the fuel cock INSPECTION B FUEL COCK If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel cock for cracks 9 REMOUNTING Remount the fuel tank and fuel cock in the reverse or der of removal WARNING Gaskets 1 and must be replaced with new ones to prevent fuel leakage Tighten the fuel cock bolts evenly FUEL PUMP 9 REMOVAL Q Remove the left frame cover Refer to page 6 3 Turn the fuel cock to OFF Disconnect the fuel hoses 3 Remove the fuel pump mounting bolts Remove the fuel pump lead wire coupler 5 INSPECTION A WARNING Gasolin is very explosive Extreme care must be taken Disconnect the fuel hose 3 connect the suitable hose and insert the free end of the hose into recep tacle Check the fuel flow when starting the engine for few seconds by pressing th
37. gauge reading as the compres sion of that cylinder Compression gauge 09915 64510 PERIODIC MAINTENANCE 2 20 2 21 PERIODIC MAINTENANCE OIL PRESSURE Check the oil pressure periodically This will give a good indication of the condition of the moving parts Standard Oil pressure 1 3 0 2 kg a at 60 4 000 rpm If the oil pressure is lower or higher than the specification the following causes may be considered 9 LOW OIL PRESSURE Oil leakage from the oil passage Damaged O ring Defective oil pump Combination of above items 9 HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items 9 OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner Remove the oil check plug and install the adapter of oil pressure gauge at the removed position Connect an engine tachometer Warm up the engine as follows summer 10 min at 2 000 rpm Winter 20 min at 2 000 rpm Q After warming up increase the engine speed to 4 000 rpm with the engine tachometer and read the oil pressure gauge Oil pressure gauge 09915 74510 Engine tachometer 09900 26006 5 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL UEM EUN ENGINE REINS TALLA TION 2222222222 ENGINE DISASSEMBLY ee STARTER al CYLINDER HEAD COVER
38. in figure which is composed of the AC generator regulator rec tifier unit and battery The AC current generated from the AC generator is converted by the rectifier and is turned into the DC current then it charges the battery IG switch Controlunit 4 generator GEM e Regulator Rectifier 9 FUNCTION OF REGULATOR While the engine rpm is low and the generated current of the AC generator is lower than the adjusted voltage of the regulator the regulator does not function incidentally the generated current charges the battery directly IG switch LI TJ mm NR hom PON P 4 Controlunit A C generator Regulator Rectifier ELECTRICAL SYSTEM 5 8 When the engine rom become higher the generated voltage of the AC generator also becomes higher and the voltage between points 4 and 8 of the regulator according becomes high and when it reaches the adjusted voltage of the control unit consequently the control unit becomes ON condition On the ON condition of the control unit signal will be sent to the SCR Thyristor gate probe and SCR will become ON condition Then the SCR becomes conductive to the direction from point to point 8 Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC generator again At the end of this state since the AC cur
39. new one CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are found replace the chain buffer with a new one E SWINGARM PIVOT SHAFT Measure the pivot shaft runout using the dial gauge If the pivot shaft exceeds the service limit replace it with a new one Swingarm pivot shaft a Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 E SWINGARM PIVOT SPACERS AND DUST SEALS Inspect the swingarm pivot spacers and dust seals for damage If any defects are found replace the spacer with a new one SWINGARM NEEDLE BEARINGS Insert the spacers into the needle bearings rotate the spacer and check for abnormal noise and smooth rota tion If there is anything usual replace the bearing s with a new one Remove the swingarm needle bearings using the special tool Bearing 17 09923 73210 CAUTION The removed bearings should be replaced with new ones 9 REASSEMBLY Reassemble the swingarm and rear shock absorber in the reverse order of disassembly Pay attention to the following points Press the needle bearings into the swingarm pivot using the special tool Steering race installer 09941 34513 Apply SUPER GREASE to the needle bearing and spacers AH SUPER GREASE Install the swingarm and tighten the swingarm pivot nut to the specified torque V Swingarm pivot nut 45 70 N m 4 5 7 0 kg m
40. of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all off the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil or exhaust system during 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 A 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 t
41. oil level being most suitable about 1mm under the Upper line mark F of the engine oil lens In case of the engine oil pouring in excessively the engine output being made insufficient Be careful not to pouring in the engine oil exces sively 4 CAUTION Necessarily confirm and clean the oil strainer 3 when replace the Engine oil specially when first replacement 4 CAUTION More frequent servicing may be performed on mo torcycles that are used under severe conditions PERIODIC MAINTENANCE 2 10 2 11 PERIODIC MAINTENANCE ENGINE OIL FILTER NOTE Replace Initial 1 000 km and Every 4 000 km Drain the engine oil as described in the engine oil replacement procedure Remove the oil filter cap Remove the oil filter Install the new O ring 2 Install the new oil filter Install the new O ring and spring to the oil filter cap Install the oil filter cap NOTE Before installing the oil filter cap apply engine oil lightly to the new O ring 3 9 OIL FILTER INSTALLATION 4 CAUTION When install the oil filter necessarily HYOSUNG character and 16510H05240 part s NO install to ward the outside otherwise can damage the engine WARNING Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before drain ing oil INSERTION DIRECTION 16510H05240
42. pro vide additional chain slack Refer to page 2 12 Remove the oil cooler ENGINE 3 6 Support the engine using an engine jack Remove the engine mounting nuts and bolts Remove the engine from the frame CAUTION Remove the carburetor when removing or installing the engine necessarily When removing the carburetor loosen the intake pipe mounting bolts at the same time ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal Install the engine mounting bolts and nuts Tighten the engine mounting bolts and nuts to the specified torque 9 ENGINE SPOCKET Loosen the rear axle nut and chain adjusters Install the engine sprocket 3 7 ENGINE Tighten the engine sprocket nut to the specified torque V Engine sprocket nut 80 100 N m 8 0 10 0 m NOTE When tightening the engine sprocket nut depress the rear brake pedal Bend the lock washer securely Tighten the left footrest bolts to the specified torque V Footrest bolt 36 52 N m 3 6 5 2 kg m Install the gearshift arm and adjust the gearshift lever height Refer to page 2 9 Connect each electric part and its couplers Refer to page 7 20 23 Install the exhaust pipes and mufflers Install the carburetor and air cleaner Refer to page 4 7 After remounting the engine the following adjust ments are necessary Engine idling speed Refer to pag
43. rings and valve guides removed in disassembly must be discarded Lubricate each valve guide and drive the guide into the guide hole using the valve guide installer handle 3 and valve guide installer attachment 4 Valve guide installer and remover 09916 44910 Valve guide installer attachment 09916 44920 ENGINE 3 22 3 23 ENGINE After fitting all valve guides re finish their guiding bores will a 4 5 mm valve guide reamer and valve guide reamer handle Be sure to clean and oil the guides after reaming 4 5 mm valve guide reamer 09916 33210 Valve guide reamer handle 09916 34541 Install valve spring lower seat Be careful not to confuse the lower seat with the spring retainer Lubricate each seal and drive them into position with the valve stem seal installer CAUTION Do not reuse the oil seals Valve guide installer and stem seal installer 09916 44910 9 VALVE SEAT WIDTH Q Coat the valve seat with prussian blue uniformly Fit the valve and tap the coated seat with the valve face in a rotating manner in order to obtain a clear impression of the seating contact In this operation use the valve lapper to hold the valve head The ring like dye impression left on the valve face must be continuous without any break In addition the width of the dye ring which is the visualized seat width must be within the specification If either requirement is not met correc
44. stud bolts CAUTION Pay caution to prevent the cam chain from drop ping into the crankcase V Cylinder head bolt 21 25 N m 2 1 2 5 kg m ENGINE 3 50 Head direction Narrow pitch part N 3 51 ENGINE Tighten the cylinder head base nuts V Cylinder head base nut 7 11 N m 0 7 1 1 kg m Tighten the two cylinder head base cover nuts Install the tappet and shim CAUTION With fit the tappet it should be replaced if turn not smoothly by the hand CAUTION The tappet and shim should be installed at the Original position when removed If otherwise it is difficult to adjust the valve clear ance Fit the chain guide Cylinder Fit the C ring CAMSHAFT ASSEMBLY Distinguish the EX mark for the exhaust camshaft the IN mark for the intake camshaft Be distinguished always each camshaft what has notch at the rightside end and leftside end of it When installing the camshaft and cam sprocket apply a small quantity THREAD LOCK 1324 to the bolts and tighten with the specified torque THREAD LOCK 1324 V Camshaft sprocket bolt 10 12 N m 1 0 1 2 kg m Apply the engine oil to the camshaft bearings With pull up the camshaft drive chain align the F mark of magneto rotor into the punching mark of mag neto cover to turn crankshaft F
45. the measurement is found less than the service limit replace the piston Piston diameter 56 880 mm Piston oversize 0 5 1 0 mm Micrometer 50 75 mm 09900 20203 9 PISTON TO CYLINDER CLEARANCE To determine the piston to cylinder clearance calculate the difference between the cylinder bore and outside diameter of the piston Piston to cylin Standard 0 05 0 06 mm 0 120 mm 9 PISTON HOLE BORE Using a dial calipers measure the piston pin hole bore both in the vertical and horizontal directions If the measurement exceeds the service limit replace the piston Piston pin hole bore 15 030 mm Dial calipers 09900 20605 15mm 9 PISTON DIAMETER INSPECTION Using a micrometer measure the piston pin outside diameter at three position both the ends and the center If any of the measurements is founds less than ser vice limit replace the pin Piston pin diameter 14 980 mm Micrometer 0 25 mm 09900 20201 9 PISTON RING FREE END GAP INSPECTION Before installing piston rings measure the free end gap of each ring using vernier calipers If the gap is less than the service limit replace the ring mte Standard Vernier calipers 09900 20101 9 PISTON RING END GAP INSPECTION Insert the piston ring squarely into the cylinder using the piston head Measure the end gap with a thickness gauge If the gap exceeds the service limit replace the pis
46. the reverse direction Charging rate too low or too high When not in use batteries should be recharged at least once a month to avoid sulfation Battery electrolyte excessive or insufficient or its specific gravity too high or too low The battery left unused for too long in cold climate Dirty container top and sides 2 Impurities in the electrolyte or electrolyte specific gravity is too high Add distilled water if the battery has not been damaged and sulfation has not advanced too far and recharge Replace the battery Replace the battery or recharge If sulfation has not advanced far try to restore the battery by replacing the electrolyte recharing it fully with the battery detached from the motorcycle and then adjusting electrolyte specific gravity Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the battery Recharge the battery fully and adjust electrolyte specific gravity Replace the electrolyte recharge the battery and then adjust specific gravity Replace the battery Replace the battery and be sure to connect the battery properly Replace the battery Keep the electrolyte up to the prescribed level or adjust the specific gravity by consulting the battery maker s directions Replace the battery if badly sulf
47. with carbon Spark plug become fouled too soon Spark plug electrodes overheat or burn Generator charge but charging rate is below the specification Generator overcharges Unstable charging Starter switch is not effective Defective ignition coil 2 Defective spark plug Defective CDI unit Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Worn piston rings Pistons or cylinder worn Excessive clearance of valve stems in valve guides Worn stem oil seal Spark plug too hot The engine overheats Spark plug loose Mixture too lean Lead wires tend to get shorted open circuited or loosely connected at terminals Grounded or open circuited stator coils of generator Defective regulator rectifier Not enough electrolyte in the battery Defective cell plates in the battery Internal short circuit in the battery Resistor elementin the regulator rectifier damaged or defective Regulator rectifier poorly grounded Lead wire insulation frayed due to vibration resulting in intermittent shorting Generator internally shorted Defective regulator rectifier Battery run down Defective switch contacts Brushes not seating properly on commutator in starter motor Defective starter relay Replace Replace Replace Adjust carburetor Adjust carbureto
48. 0 C 4 000 rpm Oil pump reduction ratio 98 19 X 14 20 2 137 7 15 SERVICING INFORMATION CLUTCH Unit mm ITEM STANDARD LIMIT Drive plate thickness 2 9 3 1 Drive plate claw width 11 8 12 0 Driven distortion _ 4 TRANSMISSION DRIVE CHAIN Unit mm ITEM STANDARD LIMIT Primary reduction ratio 3 05 58 19 O reduction ratio 3 29 46 14 Lm Jes 19052 4h h 0960223 B m jV __ Shift fork to groove clearance 01 03 0 10 0 30 Shift fork groove width 18 2 Shift fork thickness NO 3 8 4 _ SERVICING INFORMATION 7 16 CARBURETOR Unit mm Main jet Throttle valve By pass 7 17 SERVICING INFORMATION ELECTRICAL Unit mm OMwe COE Ignition coil resistance Primary 019 038 Secondary 54 600 Battery standard charging voltage 5M ov5O0pm 1 320 at 20 60 Fuse size 15A WATTAGE Unit W SPECIFICATION Position lamp License lamp Brake Tail lamp Turn signal lamp Speedometer lamp Neutral lamp Turn signal indicator lamp Right amp left High beam indicator lamp CAUTION Do not use except the specified bulb Wattage SERVICING INFORMATION 7 18 SUSPENSION Unit mm Front fork stroke 120 Front fork spring free length 361 356 Front fork oil level 325 SS Front fork oil capacit
49. 20101 Bend the float arm as necessary to bring the height to the specified level After adjustment check the float height and the fuel level again REASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly When reassembling carefully observe the following instructions After cleaning reinstall the pilot screw to the original number of turn that is recorded during disassembly FUEL SYSTEM 4 8 Fit the seal rings securely to the float chamber and install the float chamber to the throttle body Install the eight screw 1 Install the jet needle with the pin on the spacer securely engaged with the hole on the piston valve Align the hole of the diaphragm with passage way on the carburetor body Install the eight screw 4 9 FUEL SYSTEM CAUTION Never adjust CO adjust screw of the carbure tor If adjust at discretion have bad influence upon output of the engine as the two carburetor is disharmonious After the assembly and installation on the engine have been completed perform the following adjus ment Throttle cable adjustment Refer to page 2 8 Idle speed adjustment Refer to page 2 8 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS 5 1 IGNITION SYSTEM cee UM NN UNUM INE 5 3 CHARGING SYSTEM usen URNA 5 7 STARTER SYSTEM AND SIDE STAND
50. 4 11024 kejau 7 071 0060 8077 20760 9 7 21 SERVICING INFORMATION V ear 201 20760 6071 0760 0 90 70760 YOUMS 000 1 20760 jan EUN 5 is ek a Jo aur ye 08 duiej dojs 9 peo 8 EL SI IQUOI Je9J Je9 j 3 9 d 65 27 _ jeuDisuum Je9 snid j e 8J JaJe S uoniuDi 4e8J jon 0780 7060 0796 0960 ojeuDe N 1 01908 81996 Jang YOIN D YOHMS BPIS H7 U9IIMS sseuJeu 80 0 60 HT YMS d SERVICING INFORMATION 7 22 8 JOJOW pea 0790 6760 2078 0760 ayelg ES 0 7 0760 7 5 7 A 6 SN Je Ajquiasse WOH JOU SI asoy 13 009 9509 19009 10 9 qeo uoini alll UJOH 7 aa YOUMS Je9 fat _ ES 0771 20260 6 NSF FAS WV 951
51. 4 Aayeg jeuBisuJn Ott L 10160 L 10760 LOvS2 20760 UJOH AN U9IIMS gt ayelg o gt 2 exeJq 4014 K 8071 20760 Yo IMs 9 qe 9 oJu exeJq 1u0JJ 94049 7 23 SERVICING INFORMATION Battery plus Fuel gauge 36818 30810 Tube Wiring harness Magneto Neutral switch Fuel gauge Starter motor relay Battery plus Diode Fuel pump 57 Weldingsclamp Starter motor relay Magneto Gearshift switch Lead wire starter motor Fuel pump relay VIEW C oV 7o Fuel pump Turnsignal lamp insert inside after installation with the wiring be comed out VI EW SERVICING INFORMATION 7 24 WIRING DIAGRAM 998 UM POY UM AUM 1908 YOR G UM 1998 YOR G eufu3 away iva HJ dois 9 Ie eds joo 5 109 uous uoy 1 MS Ad da anj pe g Jo9 4 YUM PUM Jo9 J 9IIUM U9
52. 5 25 N m 1 5 2 5 m THREAD LOCK 1324 CAUTION Replace the gasket with a new one FRONT FORK OIL With the inner tube in fully compressed position pour the specified amount of fork oil and stroke the tube several times to expel air Front fork oil specification TELLUS 22 Each leg Front fork oil capacity 250 cc With the front fork held in vertical position compress the inner tube all the way Wait until the fluid level stabilizes measure and adjust the level to specification using the special tool 325 mm without spring Front fork oil level Front fork oil level gauge 09943 74111 Install the front fork spring 3 Install the spring guide 4 front fork inner spacer 6 and O ring CHASSIS 6 24 6 25 CHASSIS Fit the O ring to the front fork upper bolt and apply SUPER GREASE SUPER GREASE A CAUTION Use a new O ring to prevent oil ieakage Install the front fork to the motocycle Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket Tighten the front fork lower clamp bolts front fork upper bolts 2 to the specified torque Tighten the front fork upper clamp bolts 3 to the specified torque V Front fork upper clamp bolt 22 35 N 2 2 3 5 m Front fork lower clamp bolt 22 35 m 2 2 3 5 m Front fork upper bolt 15 30 N
53. 9JC YM YOIN D JMS puejs apis yun ra o U9JAS go TM PUM cg oDuelJQ A 14611 1299 Yous 1014 M ng 1 95 JIS S G _ 21 ic deos duue dois Ier S UMOJg Jg uoneuluuny Jejeuiopeeds 61 g jeubisuin jeuBisuin weay jeuBisuung 1u0J4 esuoeor uonisog 5 yanna WNOISNUNL eed ALLE CL HJ BE 7 H m ad uonisog HJ HeLa Augg 1 E Ex 52 Jouejs USIWS SjpUeH HANDLE SWITCH RH Rr BRAKE S W Ft IGNITION COIL Rr IGNITION COIL Ft BRAKE S W FUEL_GAUGE TURNSIG RELAY HORN ON OFF oe 3 C D I UNIT REC amp REG BY 1 WL ow WB 3 S YB BW L BYOB Br G BWWL 2 2 E WB Sb e 6 WB YB BW 2 Z Lg 418 Bw 4 Z BW
54. ASSIS SERVICING INFORMATION HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 2000 HOW USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections are listed on the previous page as GROUP INDEX select the section where you are look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS Example Front wheel r 21 L r 1 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply THREAD LOCK 1324 Apply oil Use engine oil unless otherwise specified Apply or use brake fluid Apply SUPER GREASE A Measure in voltage range Apply SUPER GREASE Measure in resistance range Apply SILICONE GREASE Measure in current range Apply MOLY PASTE Use special tool Apply BOND 1215 5 INFORMATION LABELS 1 1 GENERAL PRE
55. CAUTIONS eene 1 1 SERIAL NUMBER LOCATION RR 1 4 FUEL AND OIL RECOMMENDATIONS 1 5 BREAK IN PROCEDURES 1 6 CYLINDER CLASSIFICATION ttt 1 6 EXTERIOR ILLUSTRATION ams 1 7 SPECIFICATIONS ES PT OT 1 8 GENERAL INFORMATION 1 1 GENERAL INFORMATION WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions cleaner Please note however that the warning and 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 Ifyou are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety
56. E OIL EIETERL ree 2 11 DRIVE CHAIN 2 12 BRAKE 2 14 STEERER O a 2 18 FRONT OOE E EEA E 2 18 REAR SUSPENSION aero niaii iii 2 18 TRE 2 19 CHASSIS BOLTS AND NUTS e 2 19 COMPRESSION PRESSURE e 2 20 OIL PRESSURE 2 21 PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy CAUTION More frequent servicing should be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE Air Aircleanerelement element Clean every 3 000 km Replace every 12 000 km nuts and igh Tigh med wes Fuel hose Replace every 4 years Few CHASSIS Drivechain e chain Clean and lubricate every 1 000km 22 12 spect Replace every 4 years ws me Brake fluid Replace every 2 years Chassis bolts and nuts Tighten Tighten CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and shorten its useful life Use only genuine Hyoung replacement parts or their equivalent PERIODIC MAINTENANCE 2 2 LUBRICATION POINT Proper lubrication is important for smooth operation and l
57. K 1324 Tighten the magneto rotor nut to the specified torque Conrod holder 09910 20115 V Magneto rotor nut 50 60 N m 5 0 6 0 kg m STARTER IDLE GEAR AND MOTOR Install the starter idle gear shaft and spacer Install the starter motor ENGINE 3 48 3 49 ENGINE MAGNETO COVER Install the new gasket and dowel pin Apply oil to the each gears bearing and starter clutch Install the magneto cover and tighten the magneto cover bolts V Magneto cover bolt 8 12 N m 0 8 1 2 kg m 9 PISTON RING Install the piston ring in order of oil ring 2nd ring and 1st ring at first at the front cylinder CAUTION Be careful not to cause scratch on the piston when inserting the piston ring to the piston Also do not expand the piston ring more than necessary as the ring can break When all the piston rings have been assembled check that each can turn smoothly Q To minimize compression and oil leaks locate each piston ring end gap in the position as shown in the right illustration 1 2nd ring side rail Upper side 2 Side rail Lower side 3 1st ring spacer 9 PISTON Apply MOLY PASTE to the piston pin MOLY PASTE When installing the piston turn the mark on the piston head to exhaust side After the piston pin has been inserted through the conrod install the circlip CAUTION Replace the circlip with a new one Pla
58. LUSTER MATERIAL OUTSIDE Add new engine oil and check the oil level as described in the engine oil replacement procedure 4 CAUTION Use HYOSUNG MOTORCYCLE GENUINE OIL FIL TER only since the other make s genuine filters and after market parts may differ filtering perfor mance and durability which could cause engine damage or oil leaks Hyosung motors genuine oil filter is also not usable for the motocycles DRIVE CHAIN NOTE Clean and Lubricate Every 1 000 km Visually check the drive chain for the possible defects listed below Support the motorcycle by the jack or block turn the rear wheel slowly by hand with the trans mission shifted to Neutral Loose pins Excessive wear Damaged rollers Improper chain adjustment Dry or rusted links Kinked or binding links If any defects are found the drive chain must replaced NOTE When replacing the drive chain replace the drive chain and sprocket as a Loose the axle nut 1 Tense the drive chain fully by turning both chain adjusters 2 3 PERIODIC MAINTENANCE 2 12 2 13 PERIODIC MAINTENANCE Count out 21 pins 20 pitches on the chain and mea sure the distance between the two points If the dis tance exceeds the service limit the chain must be replaced Service limit 319 4 mm Drive chain 20 pitch length Loosen or tighten both chain adjusters 1 until the chain has 20 30 mm of slack in th
59. MMUTATOR Inspect the commutator for discoloration abnormal wear or undercut 4 If the commutator is abnomally worn replace the arma ture When surface is discolored polish it with 400 sand paper and clean it with dry cloth ARMATURE COIL INSPECTION Check for continuity between each segment Check for continuity between each segment and the armature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Pocket tester 09900 25002 Segment ELECTRICAL SYSTEM 5 14 STARTER MOTOR REASSEMBLY Reassembly the starter motor Pay attention to the following points Reassembly the starter motor as shown the illustration Align the mark 1 on the housing with the line 2 on the housing end 2 5 15 ELECTRICAL SYSTEM Apply SUPER GREASE A to the O ring and remount the starter motor AH SUPER GREASE SWITCHES Measure each switch for continuity using a tester If any abnormality is found replace the respectiveswitch assemblies with new ones Pocket tester 09900 25002 IGNITION SWITCH ENGINE STOP SWITCH HEADLAMP SWITCH FRONT REAR BRAKE LAMP SWITCH o 00 __ 2 or ELECTRICAL SYSTEM 5 16 LAMP HEADLAMP TURN SIGNAL LAMP 9 TAIL BRAKE LAMP 5 17 ELECTRICAL SYSTEM 9 COMBINATION METER
60. Put on the housing to the of head surface the housing to the the housing to the and the housing D to the D as that is punched also to the cylinder head upper surface Fix the four camshaft bearing holder by tightening of the bolt in order Install each bolt diagonally by using the wrench pulling the shaft down Tighten the bolt of each camshaft bearing holder with the same torque CAUTION 0 Or OUO 4 If get damaged the head surface of camshaft bearing housing thrust produce an result that the bearing housing not was tightened Tighten the camshaft housing bolt with the specified torque CAUTION The camshaft housing bolt is made of the special material This bolt is superior at the degree of hardness more than the different high tension bolt Pay special caution that the different type of bolt should not be used This bolt head is punched the 9 mark Lock shaft handle V Camshaft housing bolt 86 12 N m 0 8 1 2 m If turn the lock shaft handle in clockwise gt direction the pushrod is inserted in Turn the mechanial spring continually until the handle is turned to the end Fix the adjuster into the cylinder block Get out the pushrod for the front to turn the lock shaft handle in counter clockwise 4 Turn the crankshaft about 10 times counte
61. ad wires in the following table If the resistance checked is incorrect replace the regulator rectifier Probe of tester Probe of tester 5 11 ELECTRICAL SYSTEM STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components the starter motor starter relay clutch lever position swith C D I unit side stand switch gear position switch starter switch engine stop switch ignition switch and battery Pressing the starter switch on the right handlebar switch energizes the starter relay causing the contact points to close thus completing the circuit from the starter motor to the battery CLUTCH LEVER ENGINE STOP IGNITION SWITCH SWITCH SWITCH FUSE CDI E gt START SWITCH START RELAY suff c NEUTRAL INDICATOR LIGHT 27 GEAR POSITION Z 7 SWITCH START MOTOR 9 SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION This side stand ignition interlock system prevents the motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery and ignition coil The circuit consists of the C D l unit neutral indicator light and switches The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whe ther the side stand is either up or down The gear positoin and side stand switches work together in this syste
62. am 2 and gearshift fork shaft Install the oil pump idle gear shaft Install the dowel pins 8 Before assembling the crankcase apply the engine oil to each gears and bearings Apply BOND 1215 to the right crankcase BOND 1215 CAUTION Application of BOND 1215 must be formed within a short period of time lt Take extreme care not to let BOND 1215 enter into the oil hole or bearing ENGINE 3 40 3 41 ENGINE Install the crankcase Install the crankcase bolts 9 Crankcase bolt 8 12 N m 0 8 1 2 m NOTE After the crankcase bolts have been tightened make sure that the crankshaft countershaft and driveshaft rotate smoothly If these shafts do not rotate smoothly try to free it by tapping with a plastic hammer Apply the SUPER GREASE to the driveshaft O ring and oil seal lip Install the driveshaft spacer SUPER GREASE Install the oil seal retainer CAM DRIVEN GEAR When installing the gearshift into the cam driven gear the big shoulder face toward outside as shown in figure Install the cam guide and pawl lifter When installed apply the THREAD LOCK 1324 to the securing screw THREAD LOCK 1324 GEARSHIFT SHAFT Install the gear shifting shaft Match the center teeth of the gear on the shifting shaft with the center teeth on the shif
63. ated Clean Change the electrolyte by consulting the battery s directions SERVICING INFORMATION 7 6 CHASSIS Complaint Symptom and possible causes Steering feels too heavy or stiff Steering oscillation Wobbling front wheel Front suspension too soft Front suspension too stiff Noisy front suspension Wobbling rear wheel Rear suspension too soft Rear suspension too stiff Noisy rear suspension Steering stem nut overtightened Worn bearing or race in steering stem Distorted steering stem Not enough pressure in tires Loss of balance between right and left front suspensions Distorted front fork Distorted front axle or crooked tire Distorted wheel rim Worn down wheel bearings Defective or incorrect tire Loosen nut on axle Weakened springs Not enough fork oil Fork oil too viscous Too much fork oil Not enough fork oil Loosen nuts on suspension Distorted wheel rim Worn down rear wheel bearing Defective or incorrect tire Loose nut on axle Worn swing arm bushing or bearing Loosen nut on the rear shock Weakened springs Rear suspension adjuster improperly set Rear suspension adjuster improperly set Worn swing arm bushing or bearing Loosen nuts on suspension Worn swing arm bushing or bearing Adjust Replace Replace Adjust Replace Repair or replace Replac
64. bbles are coming up from a filler port tap the button of the two or three times ei Air bubble ELECTRICAL SYSTEM 5 20 5 Separation of electrolyte container After confirming that you entered the electrolyte into bat tery completely remove the electrolyte containers from the battery CAUTION Draw the empty receptacle out slowly because there may be a chance which remaining elec trolyte vaporize Insert of the caps Insert the cap into the filler holes pressing it firmly so that the top of the caps do not protrude above the up per surface of the battery stop cover inser 9 BATTERY INSTALLATION 250 s battery installation order pay attention to following points D Romove the seat right frame battery support 2 Lay down positive terminal of the battery at leftside of the battery case on the motorcycle 3 Install positive lead wire at the battery terminal 4 Put on the rubber cap positive terminal of the battery 5 5 Install negative lead wire the battery terminal UN Frontside 6 Install the battery support and right frame cover t AMAN A ms CAUTION If install first the lead wire at the battery then lay down at the battery case will be installed the opposite direction positive terminal face on the rightside of the motorcycle as that length of the lead wire has no somethi
65. bearing and race for corrosion nick or other damage 9 REASSEMBLY Reassembly can be performed in reverse order of disas sembly procedures However operate the work taking care for the following points Press in the upper and lower outer race using the special tool Steering race installer 09941 34513 C X 4 H a H 4 4 a 4 H a 4 2 4 E 1 H s A 4 4 z 4 H H e x Ti CHASSIS 6 28 6 29 CHASSIS Press in the lower inner race Bearing installer 09913 80112 Apply SUPER GREASE to the upper bearing lower bearing and outer races prior to installing the steering stem SUPER GREASE A Install the upper inner 2 and dust cover 3 Install the handlebar holders and tighten their nuts temporarily Install the steering stem Tighten the steering stem nut V Steering stem nut 40 50 N m 4 0 5 0 kg m Clamp wrench 09940 10122 Turn the steering stem lower bracket about five or six times to the left and right Loosen the steering stem nut of a turn 4 NOTE This adjustment will vary from motorcycle to motor cycle Make sure that the steering turns smoothly and easily in both directions without play Install the steering stem upper bracket D and washer 2
66. bes Replace any defective parts if necessary REAR SUSPENSION NOTE Inspect Every 4 000 km Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage Replace any defective parts if neces sary Refer to page 6 43 PERIODIC MAINTENANCE 2 18 2 19 PERIODIC MAINTENANCE TIRE NOTE Inspect Initial 1 000 km and Every 4 000 km 9 TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and can lead to loss of control Inspect stortage of tire thread s depth by the tire wear indicator Replace the front and rear tires at once when appear the tire wear indicator 9 TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore maintain the correct tire pressure for good roadability or shorter tire life will result Cold inflation tire pressure is as follows COLD INFLATION SOLD RIDING DUAL RIDING TIRE PRESSURE KPa ZEE 0 005 51725 5 200 29 231 526 32 4 CAUTION The standard tire on 250 is 110 90 16 595 for front and 150 80 15M C 705 for rear The use of tires other than those specified may cause instability It is highly recommended to use a HYOSUNG Genuine Tire CHASSIS BOLTS AND NUTS NOTE Tighten Initial 1 000 km and Every 4 000 km Check that all chassis bolts and nuts are tighte
67. buretor 4 Valve clearance out of adjustment Excessive valve chatter 1 Valve clearance too large 2 Weakened or broken valve springs 3 Worn down camshaft Noise appears to come from piston 1 Piston or cylinder worn down 2 Weakened or broken valve springs 3 Worn down piston pin or piston pin bore 4 Piston rings or ring groove worn Noise seems to come from timing chain 1 Stretched chain 2 Worn sprockets 3 Tension adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of cluth plates 3 Distorted clutch plates driven and drive Noise seems to come from crankshaft 1 Worn or broken bearings 2 Big end bearings worn and broken 3 Thrust clearance too large Adjust Replace Replace or rebore Retighten Consult electrical complaints Clean or replace Clean and dry Replace Replace Clean Clean or replace Replace Clean or replace Adjust Replace Replace Replace Replace Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Complaint Symptom and possible causes Noisy engine Slipping clutch Dragging clutch Transmission will not shift Transmission will not shift back Transmission jumps out of gear Engine idles poorly Engine runs poorly in high speed range Dirty or heavy exhaust smoke Noise seems to
68. ce a piece of rag under the piston when installing the circlip to prevent it from falling into the crankcase 9 CYLINDER Apply BOND 1215 to the parting line of crankcase BOND 1215 Place the dowel pin and new gasket on the crankcase CAUTION Make sure to replace the gasket with a new one Apply the engine oil to the conrod big end piston and the piston rings Coat the cylinder wall with oil Install the cylinder This cylinder is different from the front and rear With the cam chain groove of cylinder face the left side it is the front cylinder when the cam chain tension adjuster be existed at the back 9 VALVE AND SPRING Insert the valve with their stems coated with MOLY PASTE Apply the oil to the lip of the stem seal MOLY PASTE The narrow pitch side of each spring face to the head when the valve spring install The pitch of inside Spring and outside spring is changed The pitch of spring is decreased from the upper side to the lower side Valve spring compressor 09916 14510 Valve spring compressor attachment 09916H35C00 9 CYLINDER HEAD Put in the valve spring and retainer install the cotter with compressed the spring by using the valve spring compressor CAUTION After installed the valve cotter tap the valve stem end by using the plastic hammer at 2 3 times for assembly of the valve and cotter Fit the cylinder head and tighten the
69. ch cable should be lubricated with a light weight oil whenever it is adjusted Clutch cable play 4mm 9 GEARSHIFT LEVER HEIGHT ADJUSTMENT Loosen the lock nut 5 With the link rod turned adjustthe gearshift lever height ENGINE OIL NOTE Replace Initial 1 000 km and Every 4 000 km Necessary amount of engine oil Oil change 1 450 m Filter change 1 500 m Overhaul engine 1 800 m Engine oil type SAE 10W40 API SF or SG Oil should be changed while the engine is warm Oil fil ter replacement at the above intervals should be together with the engine oil change Keep the motorcycle upright Place an oil pan below the engine and drain the oil by removing the filter cap 1 and drain plug 2 Tighten the drain plug to the specified torque and pour fresh oil through the oil filter Use an classi fication of SF or SG oil with SAE 10W40 viscosity V Oil drain plug 18 20 N m 1 8 2 0 kg m Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about three minutes then check the oil level through the inspection win dow If the level is below mark F add oil to F level If the level is above mark F drain oil to F level 4 CAUTION Never operate the motorcycle if the engine oil level is below the Lower line mark L in the engine oil level gauge Never fill the engine oil above the Up per line mark F Engine
70. ckness was installed with standard at present Refer to page 7 25 26 E SHIM KIND There are 41 kinds of shim which thickness is increased by each 0 025 mm from 1 20 mm to 2 20 mm 9 VALVE HEAD RADIAL RUNOUT Place a dial gauge as shown and measure valve head radial runout If the service limit is exceeded replace the valve Valve head radial Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 9 VALVE GUIDE VALVE STEM CLEAR ANCE Measure the clearance in the valve guide valve stem by rigging up the dial gauge as shown If the clearance is measured exceeds the limit specified below then deter mine whether the valve or the guide should be replaced to reduce the clearance to within the standard range Valve guide valve stem clearance Standard 0 010 0 037 mm 0 030 0 057 mm Dial gauge 09900 20606 Magnetic stand 09900 20701 9 VALVE STEM DIAMETER Measure the valve stem outside diameter If the diameter measured exceeds the standard replace the valve Valve stem diameter Standard 4 475 4 490 mm 4455 4 470 mm Micrometer 0 25 mm 09900 20201 9 VALVE GUIDE INSTALLATION Re finish the valve guide holes in cylinder head with a 11 3 mm valve guide reamer 0 and valve guide reamer handle 2 11 3 mm valve guide reamer 09916 34561 Valve guide reamer handle 09916 34542 Fit a ring to each valve guide Be sure to use new rings and valve guides Use of
71. clogged oil circuit Repair or clean 4 Fuel level too low in float chamber Adjust 5 Air leak from intake pipe Retighten or replace 6 Use of incrrect engine oil change 7 Defective oil cooler Clean or replace CARBURETOR Complaint Symptom and possible causes Trouble with 1 Starter jet is clogged Clean starting Starter pipe is clogged Clean Air leaking from jointbetween starter body and carburetor Check starter body and carburetor for tightness adjust and replace gasket Starter plunger is not operating properly Check and adjust Idling or low speed Pilot jet pilot air jet are clogged or loose Check and clean trouble 2 Pilot outlet or bypass is clogged Check and clean Starter plunger is not fully closed Check and clean Medium or high Main jet or main air jet is clogged Check and clean speed trouble Needle jet is clogged Check and clean Throttle valve is not operating properly Check throttle valve for operation Filter is clogged Check and clean Overflow and fuel Needle valve is worn or damaged Replace level fluctuations Spring in needle valve is borken Replace Float is not working properly Check and adjust Foreign matter has adhered to needle valve Clean Fuel level is too high or low Adjust float height SERVICING INFORMATION 7 4 ELECTRICAL Complaint Symptom and possible causes No sparking or poor sparking Spark plug soon become fouled
72. different brand Do not use a brake fluid kept in an open container or stored for long period of time To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of chil dren When filling brake fluid take care not to allow water or dirt to enter the system To wash the brake system parts use brake fluid and not any other material Do not allow dirt and fluid to contact the brake disc or pad 6 11 CHASSIS CAUTION 0 BRAKE FLUID REPLACEMENT For replacing procedure of brake fluid Refer to page 2 15 0 BRAKE PAD REPLACEMENT For replacing procedure of brake pad Refer to page 2 15 9 CALIPER DISASSEMBLY Drain brake fluid Refer to page 2 15 CAUTION To prevent brake fluid from splashing on the parts nearby cover the parts with cloth Remove the union bolt D and caliper mounting bolts 2 Remove the brake pad Refer to page 2 15 Remove the brake caliper holder Using an air gun push out the caliper piston WARNING Place rag over the piston to prevent it from popping out and flying and keeping hand off the piston Be careful of brake fluid which can possibly splash Do not use high pressure air but increase the pressure gradually Remove the dust seal 1 and piston seal 2 CAUTION Care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that hav
73. dlebars straight Remove the master cylinder reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and Classification DOT 3 DOT 4 Connect a clear hose 1 to the air bleeder valve and insert the other end of the hose into a receptacle Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper line V Front brake caliper air bleeder valve 6 9 m 0 6 0 9 m 9 AIR BLEEDING OF THE BRAKE FLUID CIRCUIT Air trapped in the brake 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 presence of 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 brake fluid circuit be purged of air in the following man ner Fill the master cylider reservoir to top of the inspec tion window Replace the reservoir cap to prevent dirt from entering it Attach a hose to the air bleeder valve and in
74. e Replace Replace Replace Retighten Replace Refill Replace Drain excess oil Refill Retighten Replace Replace Replace Retighten Replace Retighten Replace Adjust Adjust Replace Retighten Replace 7 7 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Poor braking FRONT and REAR Insufficient brake power Brake squeaking Excessive brake lever stroke Leakage of brake fluid Not enough brake fluid in the reservoir Air trapped in brake fluid circuit Pads worn down Too much play on brake lever or pedal Shoes worn down Leakage of brake fluid from hydraulic system Worn pads Oil adhesion of engaging surface of pads Worn disk Air in hydraulic system Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Loosen front wheel axle or rear wheel axle Worn pads Foreign material in brake fluid Clogged return port of master cylinder Air in hydraulic system 2 Worn brake lever cam Insufficient brake fluid Improper quality of brake fluid Insufficient tightening of connection joints Cracked hose Worn piston and or Refill to level mark Bleed air out Replace Adjust Replace Repair or replace Replace Clean disk and pads Replace Bleed air Repair surface with Sandpaper Modify pad fitting Replace Tighten to specified tor
75. e 2 8 Throttle cable Play Refer to page 2 8 Refer to page 2 9 Drive chain mme Refer to page 2 12 Rear brake pedal height and free travel Refer to page 2 17 Gearshift lever height Refer to page 2 9 Engine eum Refer to page 2 10 ENGINE DISASSEMBLY STARTER MOTOR Remove the starter motor Remove the gear position switch Remove the contacts 0 and springs 2 Remove the three union bolts ENGINE 3 8 3 9 ENGINE CYLINDER HEAD COVER Remove the cylinder head cover To set the piston at TDC Top Dead Center CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter clockwise To set piston at TDC Top Dead Center of the compression stroke as align the mark for front cylinder and the R mark for rear cylin der Remove the cam chain tensioner ENGINE 3 10 E Ben O O JC gt e gt C C N O Z 5 Remove the camshaft housing Remove the camshaft IN EX C T O C gt gt c 3 11 ENGINE Loosen the two cylinder head base cover nuts NS lt d f s f f Ce 7 J j v Loosen the three cylinder head base n
76. e been removed 9 CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages If any abnormal condition is noted replace the caliper 9 CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disas sembly procedures and observe the following points CAUTION Wash the caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid after washing the components Replace the piston seal and dust seal with new ones with brake fluid applied Brake fluid specification and classification DOT 3 DOT 4 Install the brake pad spring CHASSIS 6 12 6 13 CHASSIS Apply SILICONE GREASE to the brake caliper hold er SILICONE GREASE Install the brake pads Refer to page 2 15 Tighten the caliper mounting bolts With the hose end seated to the stopper tighten the union bolt V Front brake caliper mounting bolts 18 28 N m 1 8 2 8 m Front brake hose union bolts 20 25 N m 2 0 2 5 m Fill the system with brake fluid and bleed air Refer to page 2 16 Inspection after reassembly Refer to page 2 14 9 BRAKE DISC INSPECTION Check the brake disc for damage or cracks Measure the thickness using the micrometer Replace the brake disc if the thickness is less than the service limit or if damage is found Brake disc thickness Micrometer 0 25 mm 09900 20201
77. e circlip make sure that the sharp edge of the circlip faces outside When reinstalling the brake lamp switch align the projection on the switch with the hole in the master cylinder CHASSIS 6 16 Apply SUPER GREASE to the brake lever pivot a SUPER GREASE When remounting the master cylinder onto the han dlebars align the master cylinder holder s mating surface 0 with punch mark on the handlebar tighten the upper clamp bolt first V Front brake master cylinder mounting bolt 5 8 N m 0 5 0 8 m Master cylinder Handlebar Clearance Install the brake hose union tighten the union to the specified torque V Front brake hose union bolt 20 25 N m 2 0 2 5 kg m CAUTION Bleed air from the brake system after reassem bling the master cylinder Refer to page 2 16 6 17 CHASSIS HANDLEBARS HANDLEBARS RIGHT SIDE PARTS REMOVAL Remove the right handlebar switches Disconnect the brake lamp switch lead wires and remove the master cylinder Refer to page 6 14 Remove the handlebar balancer 0 and grip 2 9 HANDLEBARS LEFT SIDE PARTS REMOVAL Remove the left handlebar switches Remove the handlebar balancer 3 and grip 4 Remove the clutch lever holder Remove the clamp bolts and detach the handlebar holders Remove the handlebar 9 REMOUNTING Perform the remounting work in the
78. e driveshaft assembly 4 countershaft assembly 6 Remove the oil pump idle gearshaft 6 Remove the crankshaft by using the special tool Crankcase separator 09920 13120 ENGINE COMPONENT INSPEC TION AND SERVICE CAUTION Be sure to identify each removed part as to its loca tion and lay the parts out in groups designated as Front cylinder Rear cylinder Exhaust Intake so that each will be restored to the origi nal location during assembly 9 CYLINDER HEAD DISTORTION Decarbonate in combustion chamber Check the gasketed surface of the cylinder head for dis tortion with a straightedage and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Cylinder head distortion 0 05 mm Thickness gauge 09900 20806 VALVE FACE WEAR Visually inspect each valve face for wear Replace any valve with an abnormally worn face The thickness of the valve face decreases as the face wears Measure the valve head D If it is out of specification replace the valve with a new one Service limit Valve face wear 0 5 mm Vernier calipers 09900 20101 VALVE STEM RUNOUT Check the valve stem for abnormal wear or bend Place the valve on V blocks and measure runout If the service limit is exceeded or abnormal condition exists replac
79. e middle between the engine and rear sprockets The marks 3 4 on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned Drive chain slack 20 30mm Place the motorcycle on jack or block for accurate adjustment After adjusting the drive chain tighten the axle nut to the specified torque Tighten both chain adjusters 1 2 securely V Rear axle 90 140 m 9 0 14 0 kg m Recheck the drive chain slack after tightening the axle nut 123 192021 Yo cXo oo oXo ako glo eXo YL p T i 1 5 ARE t Wash the drive chain with kerosine If the drive chain tends to rust quickly the intervals must be shortened After washing and drying the chain oil it with a engine oil CAUTION The standard drive chain is a RK 520DS sung recommends that this standard drive chain should be used for the replacement BRAKE SYSTEM NOTE BRAKE Inspect Initial 1 000 km and Every 4 000 km BRAKE HOSE amp BRAKE FLUID Inspect Initial 1 000 km and Every 4 000 km Replace the brake hoses Every 4 years Replace the brake fluid Every 2 years 9 BRAKE FLUID LEVEL CHECK Q Keep the motorcycle upright and place the handle bars straight Check the brake fluid level by observing the lower limit line LOWER on the front brake fluid reservoir When the level is belo
80. e nut Starter clutch bolt Cylinder head bolt Cylinder head cover bolt Cylinder head stud bolt Cylinder head base nut Engine sprocket nut Engine oil drain plug Engine mounting bolt Cam chain sprocket bolt Cam chain tensioner bolt Cam chain tension adjuster bolt Camshaft sprocket bolt Crankcase bolt Clutch sleeve hub nut Primary drive gear nut Camshaft housing bolt Oil cooler union bolt M10 Oil cooler union bolt M12 Spark plug Neutral cam stopper plug 8 0 10 0 SERVICING INFORMATION 7 12 CHASSIS ITEM o km Rear brake cam lever bolt 8 12 Rear shock absorber fitting nut Upper 20 30 Rear shock absorber fitting nut Lower 3555 22 35 90 140 45 70 40 50 80 100 1828 5 8 8 28 20 25 50 80 15 25 15 25 22 35 15 30 22 35 36 52 18 28 40 60 Rear sprocket nut Rear axle nut Swing arm pivot nut Steering stem nut Steering stem head nut Front brake disc bolt Front brake master cylinder mounting bolt Front brake caliper air bleeder valve Front brake caliper mounting bolt Front brake hose union bolt Front axle Front axle pinch bolt Front fork damper rod bolt Front fork upper clamp bolt Front fork upper bolt Front fork lower clamp bolt Front footrest bolt Handlebar clamp bolt Handlebar holder lower nut 7 13 SERVICING INFORMATION SERVICE DATA VALVE GUIDE Unit mm STANDARD LIMIT 0 010 0 037 _ __ 0 030 0 057 0 4 500 4 512 4 475
81. e starter switch If the fuel flow is not found check the fuel cock Refer to page 4 1 If the fuel cock and hoses are not fault check the fuel pump Refer to page 5 21 REASSEMBLY Carry out the assembly procedure in the reverse order of disassembly Connect the fuel pump lead wire coupler 5 Tighten the fuel pump mounting bolts Connect the fuel hoses 3 4 securely FUEL HOSE ROUTING Fuel hose 3 To fuel cock Fuel hose 4 To carburetor 9 FUEL PUMP RELAY Remove the fuel pump relay mounting bolts and coupler Disconnect the fuel hose and check the fuel flow when starting the engine for few seconds by pressing the starter switch If the fuel pump are not fault check the fuel pump relay Refer to page 5 21 FUEL SYSTEM 4 2 4 3 FUEL SYSTEM CARBURETOR ITEM SPECIFICATION ITEM SPECIFICATION V S G S ZO ME T UEM Pilot outlet FUEL SYSTEM 4 4 LOCATION OF CARBURETOR I D NO The carburetor D is stamped on the location 1 on the carburetor as shown in the right photo 9 REMOVAL Q Remove the fuel tank Refer to page 4 1 Remove the fuel hose Remove the throttle cables 2 and choke cable 3 Loosen the clamp screw and remove the carburetor 9 DISASSEMBLY Remove the diaphragm cover 4 4 5 FUEL SYSTEM Re
82. e the valve Valve stem runout Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 2 CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of out put power Any of these abnormality could be caused by a worn camshaft ENGINE 3 20 250 3 C A 6 6 EDO B T D C ees Intake open 192 327 A T D C Exhaust close A B D C Intake close B B D C 38 Exhaust open B D C Valve timing diagram 3 21 ENGINE CAMSHAFT WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height 8 which is to be measured with a micrometer Replace camshafts if found it worn down to the limit Intake 34 170 mm Exhaust 34 120 Micrometer 25 50 mm 09900 20202 Tappet amp shim wear When measuring the valve clearance the clearance should be within the standard range Valve clearance Standard When cold Intake valve Exhaust valve Inspect the tappet for wear and scratch If modification or scratch is present replace the tap pet The shim has various size Replace the thin shim to valve clearance is narrow or the thick shim to valve clearance is wide as that shim thi
83. efer to page 3 3 9 AIR CLEANER With the two screw loosened remove the right air cleaner case Refer to page 2 6 Loosen the clamp screw With the bolt removed take out the air cleaner chamber CARBURETOR Remove the carburetor after removed the intake pipes Refer to page 4 4 CLUTCH CABLE Disconnect the clutch cable end out of clutch lever Disconnect the clutch cable end out of clutch release arm 9 EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts and muffler mounting bolts removed remove the exhaust pipes and muf flers ENGINE 3 2 3 3 ENGINE 9 ELECTRIC PARTS With take out the spark plug caps remove the spark plug Remove the starter motor lead wire ENGINE 3 4 Remove the engine ground lead wire Disconnect the magneto coupler 2 ENGINE SPROCKET Remove the engine sprocket cover y 5 gt re Log gt oa 9 Ar 0 1 i 4 7 uL Ay NL A 7 ha Remove the breather hose 3 5 ENGINE With the bolt removed disconnect the gearshift arm Remove the left footrest Flatten the lock washer Remove the engine sprocket nut 1 and washer NOTE When loosening the engine sprocket nut depress the brake pedal Remove the engine sprocket NOTE If it is difficult to remove the engine sprocket loosen the rear axle nut chain adjusters 2 3 to
84. er Remove the rear sprocket with mounting drum from the rear wheel NOTE Before separating the rear sprocket and mounting drum slightly loosen the rear sprocket bolts Remove the rear wheel shock absorber Remove the rear sprocket 5 from rear sprocket mounting drum Remove the dust seal Oil seal remover 09913 50121 6 35 CHASSIS 9 INSPECTION WHEEL AXLE Refer to page 6 7 WHEEL Refer to page 6 7 WHEEL BEARING Refer to page 6 7 REAR SPOROCKET MOUNTING DRUM BEARING Refer to page 6 7 BRAKE DRUM Refer to page 6 40 REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and damage Replace the rear wheel shock absorber if there is any thing unusual SPROCKET Inspect the sprocket s teeth for wear If they are worn replace the sprocket and drive chain as a set Normal wear E WHEEL BEARING REMOVAL Remove the bearing by using the special tool Wheel bearing remover 09941 50111 CAUTION The removed bearing should be replaced with new one Excessive wear REAR SPROCKET MOUNTING DRUM BEARING Remove the bearing by using specical tool Bearing remover 17mm 09923 73210 CAUTION The removed bearing should be replaced with new one 9 REASSEMBLY Reassemble the rear wheel and rear brake in the reverse order of disassembly Pay attention to the following points E WHEEL BEARING Apply SUPER GREASE to the
85. ery power diconnect the negative cable at the battery Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seat ed in its groove and securely fitted Do not use self locking nuts a few times over Use a torque wrench to tighten fasteners to the torque values when specified Wipe off grease or oil if a thread is smeared with them After reassembly check parts for tightness and operation 1 3 GENERAL INFORMATION HYOSUNG 250 NOTE Difference between photographs and actual motorcycles depends on the markets GENERAL INFORMATION 1 4 SERIAL NUMBER LOCATION The frame serial number or Vehicle Identification Number is stamped on the steering head tube The engine seri al number is located on the left upside of crankcase assembly These numbers are required especially for registering the machi
86. ings or cylinder Worn valve guides Cylinder wall scored or scuffed Worn valves stems Defective stem seals Worn side rails SERVICING INFORMATION 7 2 Replace Replace Replace Replace Adjust Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace Repair Replace Replace Replace Replace Replace Adjust Replace Replace Replace Adjust or replace Replace Adjust Clean Replace Adjust Replace Repair Replace Adjust Clean Clean or replace Check with inspection win dow drain out excess oll Replace Replace Replace Replace Replace Replace 7 3 SERVICING INFORMATION Complaint Symptom and possible causes Engine lacks power 1 Loosen of valve clearance Adjust 2 Weakened valve springs Replace 3 Valve timing out of adjustment Adjust 4 Worn piston ring or cylinder Replace 5 Poor seating of valves Repair or replace 6 Fouled spark plug Clean or replace 7 Worn camshaft Replace 8 Spark plug gap incorrect Adjust or replace 9 Clogged jets in carburetor Clean 10 Float chamber fuel level out of adjustment Adjust 11 Clogged air cleaner element Clean 12 Too much enging oil Drain out excess oil 13 Defective air intake pipe Retighten or replace Engine overheats 1 Heavy carbon deposit on piston head Clean 2 Not enough oil in the engine Add oil 3 Defective oil pump or
87. ip care must be taken 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 seated in its groove and securely fitted When installing a new circlip pay attention to the direction of the circlip Fit it to the side where the thrust is as shown in figure TRANSMISSION GEARS AND RELATED PARTS Thickness for washers circlips and spacers 1 0mm D 1 0mm 1 2mm 1 0mm 0 5mm Z XH on RH m la n ii 2 pe VR 1 LI 7 1 2 T MONA _ LANA O6 9 3 37 ENGINE CRANKCASE BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase Replace the bearing in the following procedure if there is anything unusual a play play DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer Remove the bearings 0 and 2 Bearing remover 17 mm 09923 73210 Bearing remover 20 35 mm 09923 74510 Remove the bearing Bearing installer 09913 76010 CAUTION The removed bearing should be replace with a new one LEFT BEARING Remove the oil seals and Oil seal remover 09913 50121 Remove the bearing retai
88. iven gear by hand the gear turns in only one direction The starter driven gear should turn smoothly If excessive resistance is felt while turning the starter driven gear inspect the starter clutch Also inspect the surface of the starter driven gear which con tacts the starter clutch for wear or damage If any wear or damage is found replace the defective part s DISASSEMBLY Hold the magneto rotor with the rotor holder and remove the starter clutch bolts Rotor holder 09930 44510 ll REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tighten them to the speci fied torque while holding the rotor holder Thread Lock 1324 Rotor holder 09930 44510 9 Starter clutch bolt 15 20 m 1 5 2 0 m 0 STARTER DRIVEN GEAR STARTER DRIVEN GEAR BUSHING Install the starter driven gear bushing and gear 2 onto the crankshaft and turn the starter driven gear by hand Inspect the starter driven gear bushing for smooth rotation and any abnormal noise If the bushing does not turn smoothly or there is any abnormal noise replace it DISASSEMBLY Remove the bushing using the special tool Bearing 20 35 mm 09923 74510 CLUTCH COVER OIL FILTER REPLACEMENT Refer to page 2 11 DISASSEMBLY Remove the circlip and right crankshaft oihseal Oil seal remover 09913 50121 ll REASSEMBLY Drive in the oil seal using the special to
89. km and Every 4 000 km Tighten the exhaust pipe nuts 4 and muffler mount ing bolts 2 to the specified torque V Exhaust pipe nut 18 28 N m 1 8 2 8 m Muffler mounting bolt 20 30 N m 2 0 3 0 kg m AIR CLEANER NOTE Clean Every 3 000 km Replace Every 12 000 km Remove the air cleaner case cover 3 PERIODIC MAINTENANCE 2 6 2 7 PERIODIC MAINTENANCE With the three of air cleaner cap mounting bolts removed remove the air cleaner cap 1 Remove the air cleaner element 2 Clean the air cleaner element for the following When the air cleaner element clean with the air gun necessarily blow at the inside by compressed air Carefully examine the air cleaner element for tears during cleaning Replace it with a new one if it is torn Assemble the element completely severely the engine Be careful not to allow waterto go inside the air clea ner element CAUTION More frequent servicing may be performed on mo torcycles that are used under severe conditions also clean the air cleaner element when replacing the oil to prevent damage of the engine CARBURETOR NOTE Inspect Initial 1 000 km and Every 4 000 km IDLE SPEED 4 CAUTION Make this inspection when the engine is hot Connect an engine tachometer to the high tension cord Start up the engine and set its speed at anywhere 1 450 and 1 550 rpm by turning thro
90. m The ignition coil work only in two situations as follows IGNITION ENGINE STOP FUSE SWITCH SWITCH IGNITION COIL NEUTRAL INDICATOR LIGHT BATTERY POSITION SWITCH 7 DOWN POSITION GEAR SIDE STAND SWITCH ELECTRICAL SYSTEM 5 12 TRANSMISSION Neutral ON Side stand Down OFF IGNITION SWITCH ON IGNITION COIL NEUTRAL INDICATOR LIGHT SIDE STAND SWITCH DOWN POSITION TRANSMISSION Neutral OFF Side stand Up ON IGNITION SWITCH ON BATTERY lt IGNITION COIL NEUTRAL INDICATOR LIGHT GEAR POSITIONY SIDE STAND SWITCH SWITCH OFF UP POSITION 250 is equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in clutch lever and side stand up Possible Possible Impossible Impossible NOTE 6 On or Up A Off or Down 5 13 ELECTRICAL SYSTEM 9 STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire 1 Refer to page 3 3 With loosen the bolt remove the starter motor Refer to page 3 8 Disassemble the starter motor 9 STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushes for abnormal wear crack or smoothness in the brush holder If the brush has failed replace the brush sub assy CO
91. move the spring 1 and piston valve 2 along with diaphragm 3 Q Remove the jet needle 4 spring retainer and jet needle 7 Remove the float chamber body 8 Q Remove the float assembly 40 along with the needle valve 9 by removing the pin FUEL SYSTEM 4 6 Remove the valve seat 1 Remove the main jet 2 jet holder 3 and pilot jet 4 a hs E4 22 Remove the throttle cable bracket 5 Remove the pilot screw with count and tighten the number of turn NOTE Record the number of turn for the pilot screw when install to confer INSPECTION Check the following parts for damage and clogging Check for stopped wear Pilot jet Piston valve Main jet Starter jet Main air jet Gaskets and O rings Pilot air jet Pilot outlet and bypass 4 Foreign Needle jet holder Float s bstance Needle valve Jet needle Valve seat If any abnormal condition is found wash the part clean Needle valve If damage or clogging is found replace the part with a new one 4 7 FUEL SYSTEM 9 CLEANING Clean all jets by using compressed air After cleaning reassemble the carburetor with new seals and gaskets 9 FLOAT HEIGHT ADJUSTMENT To check the float height turn the carburetor upside down Measure the float height while the float arm is just contacting the needle valve using vernier calipers Vernier calipers 09900
92. ne and ordering spare parts 9 FRAME SERIAL NUMBER 1 5 GENERAL INFORMATION FUEL AND OIL RECOMMENDATION 9 FUEL Gasoline used should be graded 91 octane Research Method or higher An unleaded gasoline type is recommended 9 ENGINE OIL ENGINE OIL SPECIFICATION Classification system SF or SG 10W 40 If an SAE 10W 40 motor oil is not available select an alternative according to the following chart 15W 40 15W 50 10W 40 10W 50 gt 30 20 10 O 10 20 30 40 TEMP F 22 4 14 32 50 68 86 104 MULTIGRADE Use a premium quality 4 stroke motor oil to ensure longer service life of your motorcycle 4 WARNING Don t mix unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside gt Mop the oil spilt Don t put the patch on the cap It could disturb oil to be provided and damage the engine 9 BRAKE FLUID Specification and classification DOT3 or DOT4 WARNING Since the brake system of this motorcycle is filled with 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
93. ne is cold 2 NG 6 a On at_ LZ If you don t rotate the crankshaft about 10 times before measuring the valve clearance there is no meaning of valve clearance 2 5 PERIODIC MAINTENANCE Rotate the magneto rotor to set the rear cylinder s piston at TDC Top Dead Center of the compression stroke Rotate the rotor 285 counter clockwise from the F line and until the R line on the rotor is aligned with the center of hole on the crankcase Inspect the rear cylinder s valve clearance with the same manner of the front cylinder SPARK PLUG NOTE Clean Initial 1 000 km and Every 4 000 km Replace Every 8 000 km Disconnect the spark plug caps Remove the spark plugs TYPE SPARK PLUG SPECIFICATION Hot type Standard type CR8E Cold type CR9E Remove the carbon deposite with wire or pin and adjust the spark plug gap to 0 7 0 8 mm measuring with a thickness gauge Spark plug gap 0 7 0 8 mm Thickness gauge 09900 20806 Check to see the worn or burnt condition of the elec trodes If it is extremly worn or burnt replace the plug And also replace the plug if it has a broken insulator damaged thread etc Install the spark plug and then tighten it to specified torque V Spatk plug 20 25 N m 2 0 2 5 kg m 0 7 0 8 mm EXHAUSE PIPE NUTS AND MUFFLER MOUNTING BOLTS NOTE Tighten Initial 1 000
94. ned to their specified torque Refer to page 7 12 Tire wear indicator COMPRESSION PRESSURE The compression of a cylinder is a good indicator of its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic maintenance records kept at your dealership should include compres sion reading for each maintenance service Compression pressure Standard 14 16 kg cm at 600 rpm Low compression pressure can indicate any of the fol lowing conditions Excessively worn cylinder wall Worn down piston or piston rings Piston rings stuck in grooves Poor seating of valves Ruptured or otherwise defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pres sure make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing Be sure that the battery used is in fully charged condition Remove the parts concerned and test the compression pressure in the following manner Loosen the oil cooler mounting bolts from the frame Remove all the spark plug Fit the compression gauge in one of the plug holes while taking care that the connection is tight Keep the throttle grip in full open position Crank the engine a few seconds with the starter and record the maximum
95. ner Remove the bearings 3 and Bearing remover 17 mm 09923 73210 Bearing remover 20 35 mm 09923 74510 ll REASSEMBLY Assemble the crankcase in the reverse order of disas sembly Pay attention to the following points RIGHT CRANKCASE BEARING Drive in the bearings 7 and amp Bearing installer 09913 70122 Bearing installer 09913 76010 ENGINE 3 38 3 39 ENGINE LEFT CRANKCASE BEARING Drive in the bearings D and 3 Bearing installer 09913 70122 Bearing installer 09913 76010 Install the oil seals and 5 Apply SUPER GREASE on the lip of oil seal SUPER GREASE ENGINE REASSEMBLY The engine reassembly can be performed in the reverse order of disassembly procedures However the follow ing points must be observed in the reassembly tion CAUTION Make sure to coat the rotating and sliding sec tions with engine oil 0 CRANKSHAFT Using the special tool press in the crankshaft into the left crankcase Crankshaft installer 09910 32812 Conrod holder 09910 20115 CAUTION Never fit the crankshaft into crankcase by striking it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affected TRANSMISSION Install the transmission GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift NO 1 NO 2 and NO 3 Install the gearshift c
96. nes On the inner tube assemble the following parts 0 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal retainer 5 Slide metal 6 Guide bushing CAUTION To prevent the lip of oil seal 3 from being dam aged cover the inner tube with vinyl sheet dur ing installation 6 23 CHASSIS With the oil lock piece fitted to the inner tube assem ble the inner tube to the outer tube Apply SUPER GREASE to the lip of the oil seal A and install it into the outer tube using the front fork oil seal installer AH SUPER GREASE Front fork oil seal installer set 09940 52861 CAUTION Wash and clean the front fork oil seal installer before using If dirt is on the installer the inner tube may possibly be damaged during press fit ting work Fit the stopper ring and dust seal CAUTION Make sure that the stopper ring is securely fitted into the groove on the outer tube 1 Dust seal 2 Oil seal stopper ring 3 Oil seal 4 Oil seal retainer 5 Slide metal Fit the rebound spring 7 on the damper rod and install them together to the inner tube f E xE a 1 1 Apply THREAD LOCK 1324 to the damper rod bolt 2 With the damper held immovable with the gasket D fitted tighten the damper 2 V Front fork damper rod bolt 1
97. ng extra This time the battery could not lay down per fectly and to occur the short circuit etc if the battery install the opposite direction 5 21 ELECTRICAL SYSTEM 9 ASSISTANCE RECHARGING Use the battery that is maded after 2 years as the main tenance free battery Use the battery at condition of the high temperature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric current or voltage when the battery discharged Do not assistance recharge except the right side table times of recharging the battery please do it at the condition of removal of the lead wire WARNING The firearm is strictly prohibited FUEL SYSTEM 9 FUEL PUMP Q Remove the left frame cover Refer to page 6 3 Q Remove the fuel pump lead wire coupler 9 Refer to page 4 2 Using the pocket tester X 142 range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the fuel pump Fuel pump resistance 1 0 10 0 Q BW BG Pocket tester 09900 25002 9 FUEL PUMP RELAY Q Remove the fuel pump relay coupler 8 Refer to page 4 2 Using the pocket tester X 192 range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the fuel pump relay Unit Q Probe of tester Assistance Recharging Standard
98. nut Remove the washer 3 and O ring INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I D to determine the extent of wear Replace the brake drum if the measurement exceeds the service limit The value of this limit is indicated inside the brake drum Brake drum I D 160 7 mm Vernier calipers 09900 20101 6 41 CHASSIS BRAKE SHOES Check the brake shoe wear Refer to page 2 17 and decide whether it should be replaced or not CAUTION Replace the brake shoes as a set otherwise brak ing performance will be adversely affected 9 REASSEMBLY E BRAKE CAMSHAFT When installing the brake camshaft apply SUPER GREASE to the camshaft and cam face A SUPER GREASE Install the brake shoes with spring hooks faced inside CAUTION Be careful not to apply too much grease to the cam and pin If grease gets on lining break slippage will result BRAKE CAM LEVER Install the new O ring and washer Install the brake cam lever to the brake camshaft as shown CHASSIS 6 42 Tighten the brake cam lever nut to the specified torque V Rear brake cam lever nut 8 12 N m 0 8 1 2 kg m Install the rear wheel Refer to page 6 36 Adjust the rear brake pedal free travel Refer to page 2 17 6 43 CHASSIS REAR SHOCK ABSORBER REMOVAL Remove the right and left rear frame cover Refer to page 6
99. ol Bearing installer 09913 75820 Install the circlip ENGINE 3 32 3 33 ENGINE CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers If a clutch drive plate is not within the service limit replace the clutch plates as a set Clutch drive plate Standard Service limit thickness 2 9 3 1 mm 2 6 mm Vernier calipers 09900 20101 Clutch drive plate Standard Service limit claw width 11 8 12 0 mm 11 0 mm gt CLUTCH DRIVEN PLATES Measure each clutch driven plates for distortion using the thickness gauge If a clutch driven plate is not within the service limit replace the clutch plates set Clutch driven plate Service limit distortion 0 1 mm Thickness gauge 09900 20806 9 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers If any spring is not within the service limit replace all of the spring Service limit 36 2 mm Clutch spring free length Vernier calipers 09900 20101 gt CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality especially cracks When removing the bearing from the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing 9 PRIMARY DRIVEN GEAR Inspect the primary driven gear bearing for any damage If any
100. ong life of each working part of the motorcycle Major lubrication points are indicated below D Clutch lever holder 2 Drive chain 3 Side stand pivot and spring hook 4 Brake lever holder 5 Brake pedal pivot 6 Motor oil 2 Grease NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motorcycle has been operated under wet or rainy condition 2 3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURE This section describes the service procedure for each section of the periodic maintenance VALVE CLEARANCE NOTE Inspect Initial 1 000 km and Every 4 000 km 4 CAUTION The clearance specification is for COLD state The valve clearance specification is different for intake and exhause valves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshaft is disturbed by removing it for servicing Remove the spark plug Refer to page 2 5 Remove the right air cleaner box Remove the fuel tank Refer to page 4 1 Remove the cylinder head cover 1 and 2 Remove the magneto cover plug and the timing inspection plug 4 PERIODIC MAINTENANCE 2 4 Rotate the magneto rotor to set the front cylinder s piston at TDC Top Dead Center of
101. que Replace Replace brake fluid Disassemble and clean master cylinder Bleed air Replace brake lever Replenish fluid to specified level bleed air Replace with correct fluid Tighten to specified torque Replace Replace piston and or cup SERVICING INFORMATION 7 8 SPECIAL TOOLS Part Number Part Name Description 09900 20101 Vernier Caliper Special tools Part Number Part Name Description 09900 21109 Torque wrench Measure torque of tightening Used to conveniently measure various dimensions 09900 20201 Micrometer 0 25mm Used for precise measurement 00 25mm measure ranges 09900 20202 Micrometer 25 50mm Used for precise measurement 25 50mm measure ranges 09900 20203 Micrometer 50 75mm Used for precise measurement 50 75mm measure ranges 09900 20508 Cylinder gauge set Measure inside diameter of cylinder 09900 20605 Dial calipers Meassure width of conrod big end 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 20701 Magnetic stand With using dial gauge 09900 20806 Thickness gauge 512 09900 21304 V block With using magnetic stand 09900 22301 Plastigauge 09900 22401 Small bore gauge 09900 25002 Pocket tester 09900 26006 Engine tachometer 09900 28107 Electro tester 09900 28500 Battery charger 09910 20115 Conrod holder 7 9 SERVICING INFORMATION
102. r Change Clean or replace Replace by hot type plug Replace Replace Replace Replace Replace by cold type plug Tune up Retighten Adjust carburetor Repair or retighten Replace Replace Add distilled water between the level lines Replace the battery Replace the battery Replace Clean and tighten ground connection Repair or replace Replace Replace Recharge or replace Replace Repair or replace Replace 7 5 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Sulfation acidic white powdery substance or spots on surfaces of cell plates Battery runs down quickly Reversed battery polarity Battery sulfation Battery discharges too rapidly Not enough electrolyte Battery case is cracked Battery has been left in a run down condition for a long time Contaminated electrolyte Foreign matter has enters the battery and become mixed with the electrolyte The charging method is not correct Cell plates have lost much of their active materialas a result of over charging A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the high electrolyte specific gravity Electrolyte specific gravityis too low Contaminated electrolyte Battery is too old The battery has been connected the wrong way round in the system so that it is being charged in
103. r clock wise lt gt on the basis of the magneto rotor If the valve clearance is within standard after measured the valve clearance begin the next operation If it is out of stanadard adjust the valve clearance within standard limit after disassembled the camshaft and replaced the proper shim Valve clearance Standard 0 1 0 2 mm 0 2 0 3 mm Adjust the valve clearance of rear cylinder with the same manner of the front cylinder Refer to page 2 5 CAUTION If you don t turn the crankshaft about 10 times before measured the valve clearance there is no meaning in valve clearance Apply BOND 1215 to the surface of cylinder head cover packing block BOND 1215 Tighten the cylinder head cover bolts with the speci fied torque 9 Cylinder head cover bolt 12 16 N m 1 2 1 6 kg m ENGINE 3 56 3 57 ENGINE 9 SPARK PLUG Install the spark plug Refer to page 2 5 Install the rear cylinder head and cylinder with the Same manner which installed the front cylinder head and cylinder 9 GEAR POSITION SWITCH Install the spring and contact Apply SUPER GREASE to O ring and instal the gear postion switch AH SUPER GREASE Em soe A uw 5 55 N E v 24 lt Wy FUEL SYSTEM CONTENTS FUEL TANK FUEL COCK 4 1 FUEL PUMP ED D 4 2 CARBURETOR etat nn
104. r painting should take off Be cured from a doctor When the battery electrolyte was dropped to the surface of land wash vast quantity of water Neutralize by hudroxide bicarbonate of soda and so on 9 CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape to seal the battery electrolyte filler hole untill use as battery of completely seal type Do not use it except the battery electrolyte When pour into the battery electrolyte necessarily use the electrolyte of the specified capacity Do not open the sealing cap after recharge the bat tery eletrolyte Filling electrolyte 1 The battery is puted on even land remove the alu minum tape sealing 2 Remove the cap at the electrolyte container A CAUTION Aluminum tape Do not remove the seal not prick with sharp Filler holes thing 5 19 ELECTRICAL SYSTEM 3 Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it cloes not fall Take precaution not to allow any of the fluid to spill CAUTION There may be a case which can t pour the elec trolyte if you put it into electrolyte container slopely 4 Confirmation of pour Make sure that air bubbles are coming up each elec trolyte container and keep this position for about more than 20 minutes CAUTION If no air bu
105. rent generated from the AC generator flows into the point 8 reverse current tends to flow to SCR then the circuit of SCR turns to OFF mode and begins to charge the battery again Thus these repetitions maintain charging constant voltage to the battry and protect it from overcharging IG switch ontrolunit Regulator Rectifier A C generator P 5 9 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the DC voltage between the battery terminal and If the tester reads under 13 5 V or over 16 0 V check the AC generator no load performance and regulator rectifier CAUTION When making this test be sure that the battery is full charged condition 13 5 16 0 V at 5 000 rpm Pocket tester 09900 25002 Standard charge AC GENERATOR NO LOAD PERFORMANCE Disconnect the three lead wires from gener ator terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC voltage between the three lead wires If the tester reads under 72V the AC generator is faulty NO I for Standard NO load perfor 72 99 V at 5 000 rpm mance of AC generator Regulator Rectifier ELECTRICAL SYSTEM 5 10 REGULATOR RECTIFIER Using the pocket tester X 1Q range measure the resistance between the le
106. reverse order of the removal procedures while observing the following instructions Install the handlebars with the punch mark aligned with the handlebar clamp as shown Tighten the handlebar clamp bolts to the specified torque V Handlebar clamp bolt 18 28 N m 1 8 2 8 kg m The 1 between the handlebar clamp and holder should be even Align the mating face of clutch lever holders with the respective punch marks and tighten the bolt Install the brake master cylinder Refer to page 6 15 Apply SUPER GREASE to the throttle cables and assemble them AH SUPER GREASE CHASSIS 6 18 6 19 CHASSIS FRONT FORK 9 DISASSEMBLY Remove the front wheel Refer to page 6 6 Remove the brake caliper Refer to page 6 11 CAUTION Secure the brake caliper to the frame with a string etc taking care not to bend the brake hose Remove the front fender Refer to page 6 1 Remove the front fork after loosening the front fork upper 1 and lower 2 clamp bolts NOTE Slightly loosen the front fork upper bolt 3 to facili tate later disassembly Remove front fork upper bolt 3 O ring 4 front fork inner spacer and spring guide Invert the front fork and stroke it several times to drain out the fork oil Hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain
107. ront cylinder CAUTION When adjusting the rear cylinder align the mark of magneto rotor into turn counter clock wise 285 at the postion of front cylinder CAUTION If turn the crankshaft without pulling up the camshaft drive chain the chain may be fallen off between the crankcase and cam chain drive sprocket The front cylinder head install first the exhaust camshaft following the intake camshaft The rear cylinder head install first the intake as the cam chain tension adjuster exist exhaust side ENGINE 3 52 3 53 ENGINE The notch mark of exhaust camshaft should be aligned with the plane of cylinder head At that time the 2 arrow of exhaust camshaft sprock et should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into camchain The notch mark of intake camshaft should be toward the outside and aligned with the plane of cylinder head At that time the 3 arrow of intake camshaft sprocket should be in a vertical position to the plane of cylinder head when the intake camshaft sprocket was geared into the camchain Gear into the chain at the 3 arrow of intake sprock et that count the 16th of chain roller pin from the roller pin on the 2 arrow of exhaust sprocket to the intake camshaft CAUTION The rear cylinder gear into that count the 16th of chain roller pin from the 3 ar
108. row of intake sprocket to the 2 arrow of exhaust sprocket Install the 3 arrow punching mark of intake camshaft sprocket with the surface of cylinder head vertically The camshaft sprocket use the intake and exhaust the front and rear is different in common but use to dis tinguish according as installation with the camshaft For example Front exhaust Camshaft exhaust Front sprocket Install the camshaft pin atthe marking hole Rear intake Camshaft intake sprocket Install the camshaft pin at the RI marking hole Exhaust Intake mark 7 Ji Exhaust Intake Front Cylinder Exhaust Pin installation Intake Rear Cylinder ENGINE 3 54 CAUTION The timing chain is installed to the all of three sprocket Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely Notch mark Exhaust Intake 7 Front cylinder bp OC 3 2 1 1 1 aN N a Notch mark Exhaust Intake Rear cylinder NOTE The camshaft housing should be installed in the same manner with the front engine 3 55 ENGINE Each camshaft housing is punched with A B C
109. sert the free end of the hose into a receptacle Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and sqeeze 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 air bleeder valve pump and squeeze the brake lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles PERIODIC MAINTENANCE 2 16 Upper limit line 2 17 PERIODIC MAINTENANCE NOTE While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that mE there is always some fluid visible in the reservoir Upper limit line Close the air bleeder valve and disconnect the hose Fill the reservoir with brake fluid to the upper line V Front brake caliper air bleeder valve 6 9 N m 0 6 0 9 m CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc 9 REAR BRAKE PEDAL HEIGHT Loosen the lock nut Adjust the brake pedal height by turning the adjuster 1 Rear brake pedal 310 mm height When one person ridding at the ground 9 REAR BRAKE ADJUSTING Adjust the free travel 8 to 20 30 mm by turning the adjusting nut 2
110. t the seat by vicing it as follows Standard Valve seat width W 0 9 1 1 mm 9 VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are angled to present two bevels 15 and 45 Valve seat cutter set 09916 21110 Use only for 15 of intake side 15 x 75 Valve seat cutter 09916 24910 Solid pilot N 140 5 5 09916 24480 CAUTION The valve seat contact area must be inspected after each cut 1 Insert with a slight rotation the solid pilot that gives a snug fit The shoulder on the pilot should be about 10 mm from the valve guide 2 Using the 45 cutter descale and cleanup the seat with one or two turns Inspect the seat by the previous seat width measure ment procedure If the seat is pitted or burned addi tional seat conditioning with the 45 cutter is required CAUTION Cut the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area If the contact area is too high or too wide use the 15 cut ter to lower and narrow the contact area 15 4 Valve seat ENGINE 3 24 3 25 ENGINE 4 After the desired seat position and width is achieved use be 45 cutter very lightly to clean up any burrs caused by the previous cutting operations
111. the compression stroke Rotate the rotor until F line on the rotor is aligned with the center of hole on the crankcase To inspect the front cylinder s valve clearance insert the thickness gauge to the clearance between the camshaft and the tappet Valve clearance when cold Thickness gauge 09900 20806 the clearance is out of specification first remove the cam chain tensioner camshaft housing camshaft To install the tappet shim at original position record the shim NO and clearance with A B D mark on the cylinder head as the illustration Select the tappet that agree with tappet clearance vertical line and shim NO horizontal line as refer to the tappet shim selection chart Refer to page 7 25 26 Adjust valve timing install the camshaft housing and the tensioner After the crankshaft rotate about 10 times measure the valve clearance If the clearance be not agree adjust the standard clea rance as the same manner above case that valve adjustmentwhich there is no the tappet shim selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 170 1 70 mm select 195 1 95 mm of the shim which 170 1 70 mm of the shim add up the excess clearance 0 25 mm when adjust with the standard 0 15 as the intake standard clearance 0 1 0 2 mm 4 CAUTION 4 Valve clearance should be checked when the engi
112. thrust direction Measure the amount of deflection Turn the conrod and see if it moves smoothly without play and noise This method can check the extent of wear on the parts of the conrod s big end Conrod deflection Magnetic stand 09900 20701 Dial gauge 09900 20606 V block 09900 21304 9 CONROD BIG END SIDE CLEARANCE INSPECTION Using a thickness gauge measure the side clearance at the conrod big end If the measurement is out of stan dard value measure the conrod big end and the crank pin widths individually to determine which one is to be replaced Standard 40 0 85 mm Thickness gauge 09900 20806 CRANKSHAFT RUNOUTANSPEC TION With the right and left crank journals supported with V block turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds the service limit replace the crankshaft Crankshaft runout Magnetic stand 09900 20701 Dial gauge 09900 20606 V block 09900 21304 CRANKSHAFT REASSEBLY Measure the width between the webs referring to the fi gure below when rebuilding the crankshaft Standard Width between webs 72 0 1 mm 72504mm ENGINE 3 30 3 31 ENGINE MAGNETO COVER MAGNETO INSPECTION Refer to page 5 4 DISASSEMBLY Remove the stator STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter dr
113. ting driven gear as shown CAUTION After the cam driven gear cam guide gear shift shaft and neutral cam stopper have been fitted confirm that gear change is normal while turning the countshaft and driveshaft If gear change is not obtained it means that assembly of gears or installation of gear shifting fork is incorrect In this case disassemble and trace the mistake 9 OIL PUMP Before installing the oil pump apply the engine oil to the contact face of case outer rotor inner rotor and shaft Apply a small quantity THREAD LOCK 1324 to the oil pump securing screws THREAD LOCK 1324 Tighten the oil pump securing screws e ENGINE 3 42 3 43 ENGINE PRIMARY DRIVE GEAR Put in the oil pump driven gear and install the circlip CAUTION When installing the oil pump to the crankcase turn the pump gear and check that rotation is smooth by the hand 9 CAM CHAIN TENSIONER Install the washer and cam 2 tighten the cam chain tensioner bolt 9 Cam chain tensioner bolt 6 8 N m 0 6 0 8 m Install the cam chain and key FS 4 gt pe 999 H ENGINE 3 44 Install the primary drive gear and NO 2 gear to the crankshaft put in the key to the key groove CAUTION When installing the NO 2 gear install so that the mark on the gear align the key groove as shown in figure
114. ton ring 0 20 0 32 mm 0 20 0 32 mm Thickness gauge 09900 20806 9 PISTON RING TO GROOVE CLEAR ANCE INSPECTION Remove carbon deposit both from the piston ring and its groove Fit the piston ring into the groove With the ring com pressed and lifted up measure the clearance on the bottom side of the ring using a thickness gauge Piston clearance Service limit 0 180 mm 0 150 mm ENGINE 3 28 3 29 ENGINE Piston ring groove width Piston ring thickness Standard 0 970 0 990 mm 0 970 0 990 mm Thickness gauge 09900 20806 Micrometer 0 25 mm 09900 20201 9 OVERSIZE RINGS Oversize piston ring The following two types of oversize piston ring are used They bear the following identification numbers Oversize piston ring Oversize oil ring The following two types of oversize oil ring are used They bear the following identification marks Oversize oil ring Color classification Painted red Painted yellow CONROD SMALL END INSIDE DIAM ETER INSPECTION Using a dial calipers measure the conrod small end inside diameter both in vertical and horizontal directions If any of the measurements exceeds the service limit replace the conrod Conrod small Standard Service limit Eu 15 006 15 014 mm 15 040 Dial calipers 09900 20605 CONROD DEFLECTION INSPECTION Move the small end sideways while holding the big end immovable in
115. ttle stop screw 1 Engine idle speed 1 450 1 550 rpm Engine tachometer 09900 26006 9 THROTTLE CABLE PLAY There should be 0 5 1 0 mm play on the throttle cable To adjust the throttle cable play Tug on the throttle cable to check the amount of play Loosen the lock nut 2 and turn the adjuster 3 in or out until the specified play is obtained Secure the lock nuts while holding the adjuster in place Throttle cable play 0 5 1 0 mm FUEL HOSE NOTE Inspect Initial 1 000 km and Every 4 000 km Replace every 4 years Remove the left frame cover Refer to page 6 3 Inspect the fuel hoses for damage and fuel leakage If any defects are found the fuel hoses must be replaced 31 BC gt 24 l gt 3 52 Su T 4 Y PERIODIC MAINTENANCE 2 8 5 Mey ti Ny lig 2 9 PERIODIC MAINTENANCE CLUTCH NOTE Inspect Initial 1 000 km and Every 4 000 km Clutch play should be 4 mm as measured at the clutch lever holder before the clutch begins to disengage If the play in the clutch is incorrect adjust it in the following way Loosen the lock nut 1 and screw the adjuster 2 on the clutch lever holder all the way in Loosen clutch cable adjuster lock nut 3 Turn the clutch cable adjuster in or out to acquire the specified play Tighten lock nut while holding the adjuster in position The clut
116. uts Loosen the four cylinder head stud bolts Remove the chain guide NO 1 ENGINE 3 12 Remove the tappet and the shim CAUTION Draw out the tappet and shim with the strong magnet not to be scratched CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly Compress the valve spring by using the special tool Valve spring compressor 09916 14510 Valve spring compressor attachment 09916H35C00 Take out the valve cotter from the valve stem Remove the valve spring retainer Pull out valve from the other side 3 13 ENGINE Remove the two cylinder base nuts and cylinder CAUTION If tapping with the plastic hammer is necessary do not break the fins Remove the rear cylinder head and cylinder with the Same manner of the front cylinder head and cylinder removal Front cylinder N X 1 PISTION Place a clean rag over the cylinder base to prevent piston pin circlips from dropping into crankcase Remove the piston pin circlips with long nose pliers Remove the piston pin by using the special tool Piston pin puller 09910 34510 NOTE Make an identification on each piston head so that confirmed the cylinder ENGINE 3 14 MAGNETO COVER Remove the magneto cover Remove in the order of spacer shaft starter idle gear
117. w the lower limit line LOWER replenish with brake fluid that meets the following specification Specification and Classification DOT 3 or DOT 4 CAUTION The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix dif ferent types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing or stored for a long period CAUTION Brake fluid if it leaks will interfere with safe run ning and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding PERIODIC MAINTENANCE 2 14 AEN A 7 ZA OXO O NG VAS SE ARRAN 2 15 PERIODIC MAINTENANCE 9 BRAKE PAD WEAR The extend of brake pad wear can be checked by observing the grooved limit amp on the pad When the wear exceeds the grooved limit replace the pads with new ones CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affected 9 FRONT BRAKE PAD REPLACEMENT Remove the brake caliper Remove tne brake pads To reassmble reverse the above sequence V Brake caliper mounting bolt 18 28 N 1 8 2 8 kg m 9 FRONT BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the han
118. y each leg o 28966 0 Swingarm pivot shaft runout Rear shock absorber pre load position position 0 Rear shock absorber spring length 195 BRAKE WHEEL Unit mm Rear brakepedalfreetravel 2080 310 when one person riding from the ground Master cylinder piston diam 12657 1264 0 Brake caliper cylinder bore Re 29 5 _ 3948 7 19 SERVICING INFORMATION TIRE Cold inflation tire pressure Solo riding Front 0 29 Cold inflation tire pressure Dual riding Front 15 0 Re 3m _ me 8 FUEL OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane higher unleaded gasoline is recommened Fuel tank capacity Including reserve 14 0 1 Revove 5 721 _ _ Pee _ SERVICING INFORMATION 7 20 WIRE AND CABLE ROUTING 7 TN un HT YAMS ssouJeu E N 8077 1060 A T rT o 9 qeo uon 44 1969 yN A ig Y A y woe V HI _ 24 91095 t Jeyeuopeedg sseuJeu juod Aquessy _ LOvGC 10v60 J 20760 Pes Ped 20760 Qs eyeiq 8182910014

SER VICE MANUAL - Hyosung Motors America

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