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SERVICE MANUAL

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1. I g 2 0 Hato olo BO Aejas jeuBiswiny 90182 ond uos oms blag 1 0 A 94 8 Masa oe 5118 1 A 84 B MB 9 Jejeuiopeeds pesn eq pjnoys sseu xolui WIYS 99 07 5 3uesaJd 55904210 ullus pue 2 s eoueJeo o adde y ueuM 31d WVXa JO pue SSOUYOIU 10 eE UOZIJOY yey eoeds JO 4001 2 uesaud SSOUYOIU WIYS 99 INSLE N 7 pjoo ueuM jedde y ASN OL 024 9 SHOLOW 9 5 4 5 SV VE 0L 1 90 L S0 L 10 E 007 960 96 0 6 0 060 980 G8 0 18 0 08 0 92 0 92 0 12 0 0 70 990 022 4 2 90 00 590 1990 090 900 GL OL 007 667 99 0 19 0 02 GL 0 2 40 96 067 090 970 912 07 00 067 587 Sv 0 vO OL 0 007 96 98 0687 070 960 0 00 96 067 081192 S 0 1 0 00 S6 067 687 921 OZ 060 920
2. 5 11 ELECTRICAL SYSTEM STARTER SYSTEM The starter system is shown in the diagram below namely the starter motor relay switch starter switch and battery Depressing the starter switch on the right handdlebar switch box energizes the relay causing the contact points to close which connects the starter motor to the battery The motor draws about 80 amperes to start the engine Starter relay IAO S switch IG switch ON Starter motor 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 COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut 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 rep
3. FUEL SYSTEM CONTENTS FUEL TANK FUEL COCK kino consent vias eoe apt ancien vato cd sans Zot od ttt FUEL PUMP asset has ie ees ds S eue LS CARBURETOR diss ted CAUTION Gasoline must be handed carefully an area well ventilated and away from fire or sparks 4 1 FUEL SYSTEM FUEL TANK FUEL COCK 9 REMOVAL A 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 0 Remove the fuel tank Remove the fuel cock 9 INSPECTION FUEL COCK If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel cock for cracks REMOUNTING Remount the fuel tank and fuel cock in the reverse order of removal WARNING FUEL SYSTEM 4 2 lt Gaskets 1 and must be replaced with new ones to prevent fuel leakage lt Tighten the fuel cock bolts evenly FUEL PUMP REMOVAL Remove the left frame cover Refer to page 6 2 Turn the fuel cock to OFF Disconnect the fuel hoses 9
4. dwe esuaor dojs 9 Ie eqn1 0190 89 90790 70760 yn rao H7 YAMS TER 082 91040 asm pea 4 feje1 20760 20760 Ajquassy 0771 0960 10700 10760 yms U9 IMS Jeay U9 IAS 014 90771 0760 eyelq 4 20760 282 EUR eqe uoo 2 Jayawopseds emo ejpueH Fuel gauge 36818 3081 0 Tube Magneto Neutral switch Starter motor relay Battery plus SERVICING INFORMATION 7 22 Battery plus Wiring harness Welding clamp Starter motor relay Gearshift sw
5. Battery run down Defective switch contacts Brushes not seating properly on commutator in starter motor Defective starter relay Recharge or replace Replace Repair or replace Replace 7 5 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfation acidic white powdery substance or spots on surfaces of cell plates Not enough electrolyte 2 Battery case is cracked Battery has been left in a run down condition for a long time 4 Contaminated electrolyte Foreign matter has enters the battery and become mixed with the electrolyte e 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 Battery runs down quickly The charging method is not correct 2 Cell plates have lost much of their active material as a result of over charging 3 A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the high electrolyte specific gravity 4 Electrolyte specific gravity is too low 5 Contaminated electrolyte 6 Battery is too old
6. NN 7 gt 2 NA Tail Brake Poa lamp _ License plate lamp 1 lt us L C IL cB gt m ts d ae D o Je DA 9 lt 5 BOW RA Od E INO 8 AS ER y Turn signal lamp Rear Turn signal lamp Front 3 wes c v gl i 7 m Passenger footrests 1490 WHEEL BASE 4105 2200 LENGTH 1 7 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall t ese 2 200 mm Overall width sae 3 rc ere ce RR d 810 mm height 5 rete ee reete 1 070 mm Wheelbase P1 1 490 mm Ground clearance i 140 Unladen mass er Aden a 153 kg ENGINE TYPE abe sta dvr elie titi Four stroke DOHC air cooled and oil cooled Number of cylinder ertet 2 BOM fa cie et aee e P ORE TE 44 mm Stroken aiite eee Fee teca 41 mm Piston displacement 400 124 7 Carburetor BDS 26TYPE DOUBLE Dlarter SySlOM sceri eic ente mter Electric starter Lubrication system Wet sump
7. 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 F mark for front cylinder and the R mark for rear cylin der Remove the cam chain tensioner cylinder With the three bolts removed remove the cam chain guide NO 2 ENGINE 3 10 Remove the camshaft housing Remove the camshaft IN EX Remove the C ring Loosen the cylinder head base nuts 3 11 Loosen the four cylinder head stud bolts Remove the chain guide NO 1 Remove the tappet and the shim CAUTION Draw out the tappet and shim with the strong magnet not to be scratched CAUTION The tappet 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 09916HG5100 Take out the valve cotter from the valve stem Remove the valve spring retainer Pull out valve from the other side Remove the cylinder base nut and cylinder CAUTION ENGINE 3 12 If tapping with th
8. EN EE 2 w 1 0 1 10 5 E 0 1 100 1 100 5 8 4 5 100 00 1 100 5 00 00 00 00 00 0 50 o 4 100 1 30 ELECTRICAL SYSTEM 5 4 5 5 ELECTRICAL SYSTEM CAUTION Pay caution as the numerical value differs a little according to the tester Please remind that there may be defect which not be identified even though the measurement by using the tester indicates a low voltage lt The range of measurement adjust a x 1kQ unit 9 INSPECTION B IGNITION COIL Checking with Electro Tester Remove the ignition coil D 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 If no sparking or orange color sparking occures in the above conditions it may be caused by the defective coil Electro tester 09900 28107 Spark performance Over 8 mm 0 3 in Do not touch the wire clips to prevent an electric shock when testing CAUTION When using the electro tester follow the instruc tion manual B IGNITION COIL Checking with Pocket Tester A pocket tester or an ohm meter may be used instead of the electro tester In either cas
9. S6 067 98 0687 07 SOL 6020 00 jesseoeuun Jeo o 00 00 600 500 NOILO313S WIHS LaddVL 0 SSINYIHL WHS ON WIHS 700 000 12 l13ddVL NIYNSYIN pesn eq pjnous sseuyoiU WIUS 99 02 S jueseJd je sseuyoluj uius y pue 0 si adde 1 80UEJE9 O JO pue sseuxoluj 10 jejuozuou jeu ui eoeds 40071 sseuyoiuj WIYS 99 INSLE N Z pjoo ueuM 1edde y eunsea w ASN OL AMSNIHOVIN 9 SHOLOW ONNSOAH 419 001 9 0 1 907 50 007 960 02 96 0 6 0 022 SL 060 980 0 SL Ol 98 0 18 0 0 SL 0 6 906 08 0 92 0 GL OL 507 002 92 0 12 0 OL 9072 002 96 02 0 99 0 02 GO 0072 96 06 99 0 19 0 02 GL 007 96 06 68 090 940 0022 SL oLz G6 L 06 98 08 990 190 OL 50 06 68108 S
10. CAUTION Unless corrosion damage or other abnormal condition is found the bearing race need not be replaced 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 and a suitable wedge bar Bearing outer race remover 09941 54911 9 INSPECTION Check the steering stem and steering stem head for any damage Check the 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 CHASSIS 6 28 6 29 CHASSIS Press in the lower inner Bearing installer 09913 80112 Apply SUPER GREASE A to the upper bearing lower bearing and outer races prior to installing the steering stem SUPER GREASE A Install the upper inner race and dust cover Install the handlebar holders and tighten their nuts temporarily Install the steering stem Tighten the steering stem nut 9 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 L
11. 3 23 Lubricate each seal and drive them into position with the valve stem seal installer CAUTION Do not reuse the seals Valve guide installer and stem seal installer 09916 44910 9 VALVE SEAT WIDTH 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 correct the seat by ser vicing it as follows Standard Valve seat width 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 X75 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 Valve seat 3 24
12. CAUTION The standard drive chain is a 428HO Hyosung recommends that this standard drive chain should be used for the replacement PERIODIC MAINTENANCE 2 12 2 13 PERIODIC MAINTENANCE 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 BRAKE FLUID LEVEL CHECK 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 below 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 ning and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding 9 BRAKE PAD WEA
13. Dirty or heavy exhaust smoke Too much engine oil in the engine Worn piston rings or cylinder Worn valve guides Cylinder wall scored or scuffed Worn valves stems Defective stem seals Worn side rails Check with inspection win dow drain out excess oil Replace Replace Replace Replace Replace Replace 7 3 SERVICING INFORMATION Complaint Symptom and possible causes Engine lacks power 1 Loosen of valve clearance 2 Weakened valve springs 3 Valve timing out of adjustment 4 Worn piston ring or cylinder 5 Poor seating of valves 6 Fouled spark plug 7 Worn camshaft 8 Spark plug gap incorrect 9 Clogged jets in carburetor 10 Float chamber fuel level out of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe Adjust Replace Adjust Replace Repair or replace Clean or replace Replace Adjust or replace Clean Adjust Clean Drain out excess oil Retighten or replace Engine overheats 1 Heavy carbon deposit on piston head 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit Fuel level too low in float chamber Air leak from intake pipe Use of incrrect engine oil Defective oil cooler CARBURETOR Complaint Symptom and possible causes Clean Add oil Repair or clean Adjust Retighten or replace change Clean or repla
14. Tighten the engine sprocket nut to the specified torque V Engine sprocket nut 80 100 N m 8 0 10 0 kg m NOTE When tightening the engine sprocket nut depress the rear brake pedal Bend the lock washer securely ENGINE 3 6 3 7 Tighten the left footrest bolts to the specified torque V Footrest bolt 36 52 N m 3 6 5 2 kg 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 Clutch lever play nor temm sos Drive chain Refer to page 2 7 Refer to page 2 8 Refer to page 2 8 E Refer to page 2 11 Rear brake pedal height and free travel Gearshift lever height Engine oil level lt 1 Refer to page 2 16 Refer to page 2 9 Refer to page 2 9 3 8 ENGINE DISASSEMBLY STARTER MOTOR Remove the starter motor Remove the gear position switch Remove the contacts and springs CYLINDER HEAD COVER Remove the cylinder head cover 3 9 To set the piston at TDC Top Dead Center
15. With the damper rod held immovable with the gasket fitted tighten the damper rod bolt V Front fork damper rod bolt 15 25 N m 1 5 2 5 kg m THREAD LOCK 1324 CAUTION Replace the gasket with a new one ARAARAARAARARAEOAWSY NN o RETRAIT eM x 2222248 lt gt 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 Front fork oil level without spring Front fork oil level gauge 09943 74111 Install the front fork spring Install the spring guide front fork inner spacer 3 and O ring 4 Fit the O ring to the front fork upper bolt and apply SUPER GREASE A AH SUPER GREASE A CAUTION CHASSIS 6 24 Use a new O ring to prevent oil ieakage 6 25 CHASSIS Install the front fork to the motocycle Align the upper surface of the inner tube with the upper surface of the steering stem upper brack
16. 1 Insert with a slight rotation the solid pilot that gives 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 3 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 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 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 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 5 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
17. Replace with correct fluid Tighten to specified torque Replace Replace piston and or cup SERVICING INFORMATION 7 8 SPECIAL TOOLS Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09900 20101 09900 21109 Vernier Caliper r Torque wrench Used to conveniently measure various dimensions Measure torque of tightening 09900 20201 Micrometer 0 25mm Used for precise measurement 00 25mm measure ranges 09900 21304 V block With using magnetic stand 09900 20202 Micrometer 25 50mm Used for precise measurement 25 50mm measure ranges 09900 22301 Plastigauge Measure clearance of crankshaft thrust 09900 20203 Micrometer 50 75mm Used for precise measurement 50 75mm measure ranges 09900 22401 Small bore gauge Measure inside diameter of conrod small end 09900 20508 Cylinder gauge set Measure inside diameter of cylinder 09900 25002 Pocket tester Measure voltage electric current resistance 09900 20605 Dial calipers Meassure width of conrod big end 09900 26006 Engine tachometer Measure rotational frequency of engine 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 28107 Electro tester Inspect ignition coil 09900 20701 Magnetic stand With using dial gauge 09900 28500 Battery charger
18. 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 tubes 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 42 TIRE NOTE Inspect Initial 1 000 km and Every 4 000 km TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dan gerous situation It is highly recommended to replace a tire when the remaining depth of tire tread reaches the following specification Tire tread depth Service limit 1 6 mm 1 6 mm TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected
19. The carburetor D is stamped on the location on the carburetor as shown in the right photo REMOVAL Remove the fuel tank Refer to page 4 1 Remove the fuel hose Remove the throttle cables and choke cable Loosen the clamp screw and remove the carburetor 9 DISASSEMBLY Remove the diaphragm cover 4 FUEL SYSTEM 4 4 4 5 FUEL SYSTEM Remove the spring 4 and piston valve along with diaphragm Remove the jet needle cap spring retainer and jet needle 7 Remove the float chamber body Remove the float assembly 4 along with the needle valve by removing the pin Remove the valve seat 1 Remove the main jet jet holder and pilot jet Remove the throttle cable bracket Remove the pilot screw NOTE Count the number of turns required to lightly seat the screw This counted number is important when reassem bling pilot screw to original position 9 INSPECTION Check the following parts for damage and clogging Pilot jet Piston valve Main jet Starter jet Main air jet Gaskets and O rings Pilot air jet Pilot outlet and bypass Needle jet holder Float Needle valve Jet needle Valve seat If any abnormal condition is found wash the part clean If damage or clogging is found replace the part with a new one FUEL SYSTEM 4
20. 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 Reversed battery polarity The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction Replace the battery and be sure to connect the battery properly Battery sulfation 1 Charging rate too low or too high When not in use batteries should be recharged at least once a month to avoid sulfation 2 Battery electrolyte excessive or insufficient or its specific gravity too high or too low 3 The battery left unused for too long in cold climate 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 sulfated Battery discharges too rapidly 1 Dirty container top and sides 2 Impurities in the electrolyte or electrolyte specific gravity is too high Clean Change the electrolyte by consulting the battery maker s directions SERVICING INFORMATION 7 6 CHASSIS Complaint Symptom and possible causes Reme
21. 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 Filing electrolyte The battery is puted on even land remove the alu minum tape sealing 2 Remove the cap at the electrolyte container CAUTION Aluminum tape Do not remove the seal not prick with sharp thing Filler holes 5 17 ELECTRICAL SYSTEM 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 be case which t pour the elec trolyte if you put it into electrolyte container slopely 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 bubbles are coming up from filler port tap the button of the two or three times Air bubble 5 Separation of electrolyte container After confirming that you entered the electrolyte into bat tery completely remove the electrolyte containers from the battery
22. ONNSOAH HYOSUNG HYOSUNG MOTORS amp MACHINERY INC SERVICE MANUAL TIVONVW HOIASIHS 99000 95210 FOREWORD This manual contains an introductory description on HYOSUNG and procedures for its inspec tionlservice and overhaul of its main compo nents Other information considered as generally known is not included Read GENERAL INFORMATION section to familiar ize yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared on the basis of the latest specification at the time of publica tion If modification has been made since then dif ference may exist between the content of this manual and the actual vehicle lt Illustrations in this manual are used to show the basic principles of opertion and work pro cedures 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 knowedge and Skills you should not attempt servicing by relying on this manual only Instead please contact your nearby autho rized HYOSUNG motorcycle dealer GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL SYSTEM ELECTRICAL SYS
23. Used to charge the dischared battery 09900 20806 Thickness gauge Measure clearance of piston ring 09910 20115 Conrod stopper Used to lock the crankshaft 7 9 SERVICING INFORMATION Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09910 32812 09913 80112 S Y Crankshaft installer s Bearing installer Used to install the crankshaft in the crankcase Used to drive bearing in ss 09910 34510 ry ES 09915 63310 Li s Piston pin puller Compression gauge adapter Lo Use to remove the piston pin Used with compression gauge NR 09913 10760 09915 64510 Fuel level gauge Compression gauge M Measure height of carburetor Measure cylinder compression m 09913 50121 09915 74510 Oil seal remover Oil pressure gauge Used to remove the oil seal Measure oil pressure of 4 stroke engine 09913 70122 Bearing installer Used to drive bearing in 09915 74531 Oil pressure gauge hose attachment Used with oil pressure gauge 09913 75520 Bearing installer Used to drive bearing in 09916 14510 Valve spring compressor Used to remove and remounting valve stem 09913 75820 Bearing installer Used to drive bearing in 09916HG5100 Valve spring compressor attachment Used with valve spring compresso
24. sse High beam indicator lamp ene Turn signal indicator lamp right amp left License 0 Neutral indicator lamp sss CAPACITIES Euel tank d ice ri bre i c tef pene Engine oil oil change s with fiter change esee overhaul atout dde is Front fork oil One side eee The specifications are subject to change without notice GENERAL INFORMATION 1 8 Battery Ignition CDI 13 B T D C at 2 000 rpm and 30 B T D C at 5 000 rpm CR8E 12V 12Ah 15A HI 35W LO 35W 5W 14 0 1 1 450 1 500 ml PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE V Val eh a ded eee bog HONG Ns PERIODIC MAINTENANCE CHART LUBRICATION POINTS MAINTENANCE PROCEDURES diese ew VALVE CLEARANCE EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS AIR CLEANER uuu M DE ULM EN LESE FUEL HOSE ooo ENGINE ooo ENGINE OIL PIETER UM ese DRIVE CHAIN ooo o oo o o e BRAKE SYSTEM 23 25 ee ee STEERING net FRONT FORK REAR SUSPENSION o peeled CHASSIS BOLTS AND NUTS COMPRESSION PRESSURE es OVE PRESSURE oda Rl cite 2 1 PERIODIC MAINTENAN
25. 3 OPEL LOD ORE p rj I M Notch mark Intake Rear cylinder NOTE The camshaft housing should be installed in the same manner with the front engine 3 55 Each camshaft housing is punched with C Put on the housing A to the of head surface the housing B to the B the housing C to the and the housing D to the D as that B 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 If get damaged the head or 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 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 V camshaft housing bolt 8 12 N m 0 8 1 2 kg If turn the lock shaft handle in counter clockwise direction the p
26. A 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 ASSISTANCE RECHARGING Use the battery that is maded after 2 years as the main tenance free battery Use the battery at condition of the high temperature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric current or voltage when the battery discharged Do not assistance recharge except the right side table In times of recharging the battery please do it at the condition of removal of the lead wire A WARNING The firearm is strictly prohibited ELECTRICAL SYSTEM 5 18 Insert the caps firmly i Assistance Recharging Standard 1 2 A X 10 hours 4A X 3 hours CHASSIS CONTENTS EXTERIOR PARTS FRAME COVER REAR FRAME COVER FRONT WHEEL ooeec HANDLEBARS s FRONT FORK EE STEERING REE ro TERCER TE MATH EE EHE REAR WHEEL emt REAR BRAKE enr eir Rated REAR SHOCK ABSORBER dedo Aue AU M e cma e E pu cS MS rts RUD E M LA C VELA A E O ata SWIN
27. TRANSMISSION Wet multi plate type IMANSMISSION eo 6 speed constant mesh Gearshift patte sien Uh 1 down 5 up Final r dUctlon e aes 3 690 Gear Tatio 18b 25 iac RTT Ene drs 3 090 hie 1 790 H 1 350 AL sm scs ota shit bti eria iis 1 090 0 910 0 840 428 138 links CHASSIS on It e ie ies Telescopic type Rear SUSPENSION aote uen Up etate tenete Swingarm type Steering angle sson ede 40 right amp left GC M MEER 33 Trail e 135 Front Drake 2 Disk brake R ar brake amete itu He EG des Drum brake Front tlre size nde ti 110 90 16 59P or 110 90 17 55P 26 eet POR ERR RT Red 130 90 15M C 66P Front fork Stroke tta et tete 120 mm ELECTRICAL Ignition hal ate eit ads Ignition timing Aree ates a rari Puer Sparkcplug nu rate a attenti Batlely x ost aue RE eeu USC Head e e cta e Re ees Turn signal lamp enana ainina et Brake Tail lamp Speedometer lamp
28. Tighten lock nut while holding the adjuster in position The clutch cable should be lubricated with a light weight oil whenever it is adjusted Clutch cable play 4mm PERIODIC MAINTENANCE 2 8 2 9 PERIODIC MAINTENANCE GEARSHIFT LEVER HEIGHT ADJUSTMENT Loosen the lock nut With the link rod turned adjust the 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 ml Filter change 1 500 ml Overhaul engine 1 650 mf Engine oil type SAE 101 40 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 and drain plug 4 Tighten the drain plug to the specified torque and pour fresh oil through the oil filter Use an API classi fication of SF or SG oil with SAE 10W40 viscosity V Oil drain plug 18 20 N 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 ad
29. Valve spring free length Valve spring tension 30kgf length 27 95mm 30kgf at length 27 95mm CAMSHAFT CYLINDER HEAD Unit mm STANDARD Cam height 34 470 34 510 34 420 34 460 Camshaft journal holder 35 000 35 018 Cylinder head distortion Cylinder head cover distortion EE Cam chain pin Arrow 3 16th pin CYLINDER PISTON PISTON RING Compression pressure SERVICING INFORMATION 7 14 STANDARD 10 12 kg cm at 600 rpm Unit mm Piston to cylinder clearance 0 03 0 04 Cylinder bore 44 Piston diam 43 965 43 980 Measure at 11mm from the skirt end Cylinder or cylinder head distortion Piston ring free end gap 5 0 6 0 Piston ring end gap Assembly condition 0 10 0 25 0 25 0 40 Piston ring to groove clearance Piston ring to groove width 1 01 1 03 1 01 1 03 Piston ring thickness 2 01 2 03 0 970 0 990 0 970 0 990 Piston pin hall I D 8 9 9 1 Piston pin O D CONROD CRANKSHAFT ITEM STANDARD Conrod small end I D 13 006 13 014 Conrod deflection Conrod big end side clearance 0 15 0 40 Conrod big end width 15 95 16 00 Crank web to web width 72 0 1 Crankshaft runout OIL PUMP ITEM STANDARD Oil pressure 2 0 0 2 kg cm at 60 4 000 rpm Oil pump reduction r
30. and Remove the magneto cover plug and the timing inspection plug PERIODIC MAINTENANCE 2 4 Rotate the magneto rotor to set the front cylinder 5 piston at TDC Top Dead Center of 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 5 valve clearance insert the thickness gauge to the clearance between the camshaft and the tappet Valve clearance when cold IN 0 1 0 2 mm Thickness gauge 09900 20806 If 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 C 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 clearance as the same manner above In case that valve adjustment which 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 19
31. and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust 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 lt To avoid getting burned do not touch the engine engine oil or exhaust system during or for a while after engine operation After servicing fuel oil exhaust or brake systems check all lines and fittings related to the system for leaks GENERAL INFORMATION 1 2 CAUTION If parts replacement is necessary replace the parts with HYOSUNG Genuine Parts or their equivalent When removing parts that 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
32. 0 8 1 2 Oil cooler union bolt M10 20 25 2 0 2 5 Oil cooler union bolt M12 20 25 2 0 2 5 Spark plug 20 25 2 0 2 5 Neutral cam stopper plug 20 25 2 0 2 5 SERVICING INFORMATION 7 12 CHASSIS ITEM Rear brake cam lever bolt Rear shock absorber fitting nut Upper Rear shock absorber fitting nut Lower Rear sprocket nut Rear axle nut Rear torque link nut Front Rear torque link nut Rear 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 Valve diam 18 14 5 Valve clearance When cold 0 1 0 2 0 2 0 3 Valve guide to valve stem clearance 0 010 0 037 0 030 0 057 Valve stem deflection mm Valve guide 4 000 4 012 Valve stem O D 3 975 3 990 3 955 3 970 Valve stem runout Valve head thickness Valve seat width Valve seat angle Valve head radial runout
33. 6 Check for stopped wear Foreign substance Needle valve 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 20101 Float height 4 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 9 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 setting by turning the screw in until it lightly seats and then backing it out the same number of turns counted during disassembly Fit the seal rings securely to the float chamber and install the float chamber to the throttle body Install the eight screw 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 5 FUEL SYSTEM 4 8 4 9 F
34. 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 ENGINE 3 52 3 53 With pull up the camshaft drive chain align the F mark of magneto rotor into the punching mark of mag neto cover to turn the crankshaft Front cylinder CAUTION When adjusting the rear cylinder align the R 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 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
35. When using a jack take care not to cause scratches on the chassis Remove the front wheel by removing the front axle 6 7 CHASSIS Remove the brake disc 9 INSPECTION AND DISASSEMBLY For inspection of the tire Refer to page 2 17 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 Service limit 0 25 mm Axle shaft runout 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 Wheel runout Service limit axial and radial 2 0 mm E 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 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 or
36. 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 koten psi psi 172 1 75 25 172 1 75 25 7 196 2 00 29 221 2 25 32 CAUTION The standard tire on this motorcycle is 110 90 16 59P or 110 90 17 55P for front and 130 90 15M C 66P for rear The use of tires other than those specified may cause instability It is highly recom mended 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 tightened to their specified torque Refer to page 7 12 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 10 12 kg cm at 600 rpm Service limit 8 kg cm at 600 rpm PERIODIC MAINTENANCE 2 18 2 19 PERIODIC MAINTENANCE Low compression pressure can indicate any of the fol lowing conditions Excessively worn cylinder wall Worn down piston or piston rings Pi
37. 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 arrow 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 Notch mark 1 E T n wi T 4 E Intake Notch _ ENGINE 3 54 A 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 16 Pin 5 946 6664 949 696 I I I Notch mark Front cylinder 16 Pin
38. in the reassembly opera tion CAUTION Make sure to coat the rotating and sliding sec tions with engine oil 9 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 9 TRANSMISSION Install the transmission GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift NO 1 0 NO 2 NO 3 Install the gearshift cam and gearshift fork shaft G Install the oil pump idle gear shaft 7 Install the dowel pins 0 Before assembling the crankcase apply the engine oil to each gears and bearings Apply BOND 1215 to the right crankcase BOND 1215 CAUTION ENGINE 3 40 Application of BOND 1215 must be per formed within a short period of time lt Take extreme care not to let BOND 1215 enter into the oil hole or bearing Install the crankcase Install the crankcase bolts V Crankcase bolt 8 12 N 0 8 1 2 m 3 41 After the crankcase bolts been tightened make sure that the crankshaft countersh
39. 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 remover d 17mm 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 pply SUPER GREASE to the needle bearing and spacers AH SUPER GREASE Install the torque link and washer 0 tighten the torque link nut to the specified torque 9 Rear torque link nut Front 10 15 N 1 0 1 5 Install the new cotter 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 Install the rear shock absorber Refer to page 6 43 Install the rear wheel Refer to page 6 37 Adjust the following points Drive chain slack Refer to page 2 12 Rear brake pedal free travel Refer to page 2 16 CHASSIS 6 48 SERVICING INFORMATION CONTENTS IBOUBLESHOOTING expectata ras tardes SPECIAL T
40. 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 To minimize compression and oil leaks locate each piston ring end gap in the position as shown in the right illustration 2nd ring side rail Lower side 2 Side rail Upper side 1st ring spacer EX IN 9 PISTON Apply the 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 D CAUTION Replace the circlip with a new one Place a piece of rag under the piston when installing the circlip to prevent it from falling into the crankcase This motorcycle is equipped with the two cylinder engine which is composed of the two piston for the front and rear The classification is F for the front and R for the rear 9 CYLINDER Apply BOND 1215 to the parting line of crankcase BOND 1215 Place the dowel D 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
41. positive terminal When performing service to electrical parts if the service procedures do not require use of bat tery power diconnect the negative cable at the battery Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque 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 lt Never reuse 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 lt 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 lt After reassembly check parts for tightness and operation To protect environment do not unlawfully dispose of used motor oil and other fluids batteries and tires To protect Earth s natural resouces properly dispose of used vehicles and parts 1 3 GENERAL INFORMATION HYOSUNG Difference between photographs and actual motorc
42. that could pre vent the valve from sealing A WARNING Always use extreme caution when handling gaso line A CAUTION Be sure to adjust the valve clearance after reassem bling the engine 3 25 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 Valve spring free Service limit length IN amp EX 37 64 mm Venier calipers 09900 20101 Standard Valve spring tension 30 kgf at length 27 95 mm IN amp EX CYLINDER DISTORTION 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 Service limit Cylinder distortion 0 05 mm Thickness gauge 09900 20806 9 CYLINDER BORE Measure the cylinder bore diameter at six place If any one o
43. 0 and vacuum hose Remove the pump mounting bolts INSPECTION A WARNING Gasolin is very explosive Extreme care must be taken Disconnect the fuel hose connect the suitable hose and insert the free end of the hose into a recep tacle Check the fuel flow when starting the engine for few seconds by pressing the 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 replace the fuel pump 9 REASSEMBLY Carry out the assembly procedure in the reverse order of disassembly Tighten the fuel pump mounting bolts Connect the fuel hoses 0 and vacuum hose securely FUEL HOSE ROUTING Fuel hose To fuel cock Fuel hose 9 To carburetor Vacuum hose To intake pipe 4 3 FUEL SYSTEM CARBURETOR Carburetor type SPECIFICATION ITEM BDS 26 TYPE DOUBLE Needle jet SPECIFICATION Bore size 26 Pilot jet 1 0 NO 51 Throttle value Idle rpm 1 450 1 550 rpm By pass Pvt Float height 17 Valve seat V 1 2 Starter jet 20 20 Main jet M J 87 5 87 5 Pilot screw P S 2 1 8 2 1 8 Main air jet M A J 50 50 Pilot outlet P O 0 75 0 75 Jet needle 4FJ4 2 4DIX4 2 PV STROKE LOCATION OF CARBURETOR I D NO
44. 2x1 7W T10 12V 5x 17W Gr ILLUM ILLUM ILLUM ILLUN TURN R TURN L UTRAL FUEL YB FUEL o Lg TURN R o 006 6 o B TURN L Y H BEAM i Ay 5 B Y SIGNAL ELECTRICAL SYSTEM 5 16 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 9 CAUTION OF BATTERY ELECTROLYTE TREATMENT Pay attention for the battery electrolyte not to stain the chasis or the humanbody If be stain the chassis or the humanbody at once wash a vast quantity of water When it be stained clothes should come into being a hole or painting should take off Be cured from a doctor When the battery electrolyte was dropped to the surface of land wash a vast quantity of water Neutralize by hudroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape to seal the battery electrolyte filler hole untill use as battery of completely seal type
45. 4 000 km IDLE SPEED CAUTION Make this inspection when the engine is hot Connect engine tachometer to the high tension cord Start up the engine and set its speed at anywhere 1 450 1 550 rpm by turning throttle stop screw 0 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 and turn the adjuster 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 2 Inspect the fuel hoses for damage and fuel leakage If any defects are found the fuel hoses must be replaced 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 and screw the adjuster on the clutch lever holder all the way in Loosen clutch cable adjuster lock nut Turn the clutch cable adjuster in or out to acquire the specified play
46. 44 SWINGARM REMOVAL Remove the rear wheel Refer to page 6 32 Remove the exhaust pipe and mufflers Refer to page 3 2 6 45 CHASSIS Remove the engine sprocket cover Remove the rear shock absorber lower bolts and dis connect the rear shock absorber from swingarm Remove the swingarm pivot nut and washer Remove the swingarm by removing the pivot shaft Remove the rear torque link D from the swingarm CHASSIS 6 46 Remove the dust covers 0 washers 2 and spacers Remove the chain buffer from the swingarm 9 INSPECTION SWINGARM Inspect the swingarm for damage If any defects are found replace the swingarm with a 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 6 47 CHASSIS B 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 Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 Swingarm pivot shaft Service limit runout 0 6 mm 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
47. 5 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 CAUTION 4 Valve clearance should be checked when the engine is cold lt If you don t rotate the crankshaft about 10 times before measuring the valve clearance there is no meaning of valve clearance O 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 CR7E 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 brok
48. 606 Magnetic stand 09900 20701 Service limit Brake disc runout 0 3 mm If 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 Remove the master cylinder cap 6 15 CHASSIS Detach the dust seal boot and remove the circlip Pull out the piston cup set and spring 9 MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for any scratches or other damage 9 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 or DOT 4 NOTE When installing the circlip make sure that the sharp edge of the circlip fa
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50. CE 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 NOTE More frequent servicing should be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE Interval 1 000 Every 4 000 km Every 8 000 km page Air cleaner element Clean every 3 000 km 2 6 we We T Valve clearance adjust Inspect Inspect 2 3 Spark plug Clean Clean Replace 2 5 Inspect Inspect Replace every 4 years Engine oil filter Replace Replace 2 10 Engine oil Replace Replace 2 9 Throttle cable Inspect Inspect 2 8 Idle speed Inspect Inspect 2 7 Clutch Inspect Inspect 2 8 CHASSIS 26 Interval initial 1 000 km Every 4 000 km Every 8 000 page Drive chain Clean and lubricate every 1 000km 2 11 Brake Inspect Inspect 2 13 Inspect Inspect Brake hose 2 13 Replace every 4 years Inspect Inspect Replace every 2 years 6218 Tires Inspect Inspect 2 17 Steering Inspect Inspect 2 17 Front forks Inspect 2 17 Rear suspension Inspect 2 17 Chassis bolts and nuts Tighten Tighten 2 18 LUBRICATION POINT PERIODIC MAINTENANCE 2 2 Proper lubrication is important for smoot
51. FILTER REPLACEMENT Refer to page 2 10 DISASSEMBLY Remove the circlip and right crankshaft oil seal Oil seal remover 09913 50121 REASSEMBLY Drive in the oil seal using the special tool Bearing installer 09913 75820 Install the circlip 9 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 Vernier calipers 09900 20101 ENGINE 3 32 Clutch drive plate Standard Service limit thickness 2 9 3 1 2 6mm 3 33 Clutch drive plate Standard Service limit claw width 11 8 12 0 mm 11 0 mm 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 as a set Thickness gauge 09900 20806 Clutch driven plate Service limit distortion 0 1 mm 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 Vernier calipers 09900 20101 Clutch spring Service limit free length 29 5 mm CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality especially cracks When removing the bearing fro
52. G ARM esses ue ee dero ca Met MeebvaraaldsbuePeddveds pee sete ry pute dps steer tails 6 1 CHASSIS EXTERIOR PARTS FRONT FENDER With the bolts removed remove the front fender 9 FRONT SEAT Remove the front seat with the ignition key 9 REAR SEAT With the bolts removed remove the rear seat CHASSIS 6 2 RIGHT FRAME COVER Remove the screw With the hook 9 removed remove the right frame cover 6 3 CHASSIS 9 RIGHT REAR FRAME COVER Remove the right frame cover With the bolts 0 removed remove the right rear frame cover LEFT FRAME COVER Remove the screw Remove the hook 2 4 9 LEFT REAR FRAME COVER Remove the left frame cover With the bolts 9 removed remove the left rear frame cover CHASSIS 6 4 Remove the front and rear seats Remove the frame covers Remove the C D I unit and rectifier regulator 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 bolt Loosen the front axle Raise the front wheel off the ground with the center stand block or jack CAUTION
53. IVE GEAR Put in the oil pump driven gear and install the circlip ENGINE 3 42 3 43 CAUTION When installed 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 chain tensioner 2 tighten the cam chain tensioner bolt V Cam chain tensioner bolt 6 8 N m 0 6 0 8 kg m Install the cam chain 3 and key 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 Align the key groove and mark CAUTION Pay attention to the 2 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 Rotor holder 09930 44510 9 Primary drive gear nut 40 60 N 4 0 6 0 kg m 9 PRIMARY DIRVEN GEAR Install the spacer onto the countershaft NOTE Apply engine oil to the inside surface of the primary driven gear bearing Install the primary driven gear assembly ENGINE 3 44 3 45 CLUTCH Install the clutch sleeve hub D lock washer clutch sleev
54. L INFORMATION CONTENTS INFORMATION LABELS s GENERAL PRECAUTIONS ettet pita apttd o pde SERIAL NUMBER LOCATION e FUEL AND OIL RECOMMENDATIONS BREAK IN PROCEDURES e CYLINDER CLASSIFICATION EXTERIOR ILLUSTRA TION eee eO ope SPECIFICATIONS ertr erii renn aA RM RDUM Rd 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 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 If you 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
55. L PRESSURE TEST PROCEDURE Check the oil pressure in the following manner Install the oil pressure gauge with adaptor in the posi tion shown in the figure Connect an engine tachometer Warm up the engine as follows Summer 10 min at 2 000 rpm Winter 20 min at 2 000 rpm 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 PERIODIC MAINTENANCE 2 20 CONTENTS ENGINE REMOVAL AND REINS TALLA TION 222222 22 ENGINE REMOVAL te ENGINE REINSTALLATION e ENGINE DISASSEMBLY t nte ea sciiicet ape RUNS Usi STARTER MOTER ptg etd ttc NN CYLINDER HEAD COVER PISTON Utente MAGNETO COVER enone ROTOR Sv pu dite opu db duda CLUTCH COVER Mares ee ee UE ERU ME A PRIMARY DRIVE GEAR tet 9 GEARSHIFET SHAFT 2 ee eRe Gee NE e ENGINE COMPONENT INSPECTION AND SERVICE lt lt lt ENGINE REASSEMBLEY iiie e pta ioe CAUTION Mark an identification of assembly location on each removed part so that each will be restored to the original position during reasse
56. LL 090 970 0 2 0 00 S81 08 92 02 0 0 50 00 96 081570107149 070 960 007 667 067 7 0 7 59 097 S 0 1 0 eoueJee o peyioedg 060 020 Gl OL SO 002 96 OBL 98 O8 L OL SOL 0971 SSL OSL Sv V OV L Gel 0 L 60 60 OL GO 00 961 06 981 08 92 0 7 GOL 097 991 OS SVL OVV SEL 0 L 0 00 GZ X3 LYVHD 193735 WIHS 13ddV L 597 OS SVL OV L SEL E w GOL OC V SS30OHLINHS ON WIHS 60 0 S0 0 32NVHV319 13ddVL ONIMNSVSW T Prepared by HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department 2nd Ed Oct 2001 Manual No 99000 95210 Printed in Korea
57. NSPECTION 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 Pocket tester 09900 25002 Standard charge 13 5 16 0 V at 5 000 AC GENERATOR NO LOAD PERFORMANCE Disconnect the three lead wires from the AC 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 Regulator Rectifier 4 Standard NO load perfor 72 99 V at 5 000 rpm mance of AC generator REGULATOR RECTIFIER Using the pocket tester X 1 range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regulator rectifier Pocket tester 09900 25002 Unit kQ _ 2 3 4 5 OFF OFF OFF 2 7 3 oF OF 7 3 oF oF EE 4 7 8 OFF OFF OFF 5 7 8 7 8 7 8 ELECTRICAL SYSTEM 5 10
58. OOLS reiese UU et UR UN Nate D UMS TIGHTENING TORQUE i i STEREO ERN ERE EM M C EUH SERVICE DATA Soe se WIRE AND CABLE ROUTING s WIRING DIAGRAM atis dx cru a anota ne 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Engine will not start or is hard to start Compression too low Valve clearance out of adjustment Worn valve guides or poor seating of valves Valves mistiming Piston rings excessively worn Worn down cylinder bore Poor seating of spark plug 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 Adjust Repair or replace 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 Engine stalls easily 1 Fouled spark plug 2 Clogged fuel hose 3 Clogged jets in carburetor 4 Valve clearance out of adjustment Noisy engine Excessive valve chatter 1 Valve clearance too large 2 Weakened or broken valve springs 3 Worn down camshaft Nois
59. R The extend of brake pad wear can be checked by observing the grooved limit 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 PERIODIC MAINTENANCE 2 14 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 m 1 8 2 8 kg m 9 FRONT BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars 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 or DOT 4 Connect a clear hose 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 2 15 PERIODIC MAINTENANCE 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 N m 0 6 0 9 kg 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
60. TEM SERVICING INFORMATION HYOSUNG MOTORS amp MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 2000 Overseas Technical Department HOW USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 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 Y 4 pod ing for 3 Holding the manual as shown at the right will allow you to find l 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 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 V Data beside it indicates 472 Apply THREAD LOCK 1324 specified torque Apply oil Use engine oil unless Q aihenwiserspactied Apply or use brake fluid AGH Apply SUPER GREASE qa Measure in voltage range Apply SUPER GREASE Measure in resistance range AH Apply SILICONE GREASE i EX Measure in current range An Apply MOLY PASTE TOOL Use special tool Apply BOND 1215 GENERA
61. UEL SYSTEM CAUTION Never adjust CO adjust screw of the carbure tor If adjust at discretion have a 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 7 ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS IGNITION SYSTEM se TO E Cer poteet e deett CHARGING SYSTEM EE 5 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Turn signal relay 9 Fuse 2107 SS d Mo puce SS QI 5 Rear brake lamp switch Starter motor ELECTRICAL SYSTEM 5 2 4 Ignition coil NO 1 amp NO 2 C D I Unit 9 Regulator Rectifier Battery plus terminal Battery minus terminal CAUTION Be sure not to misassem ble the position of battery plus amp minus terminal 2 P 44 5 s ZI W S Magneto 3 Gear position switch 5 3 ELECTRICAL SYSTEM IGNITION SYSTEM Alqpailla is started as the battery discharged ignition system without a contact point The battery
62. able using special tool remove the clutch sleeve hub nut Clutch sleeve hub holder 09920 53710 Remove the clutch sleeve hub and primary driven gear assembly 3 PRIMARY DRIVE GEAR With the magneto rotor held immovable using special tool remove the primary drive gear nut Rotor holder 09930 44510 CAUTION This bolt has left hand thread Turning it counter clockwise it may cause damage Pay attention at the primary drive gear with two washer ENGINE 3 16 3 17 Remove the cam chain 1 Remove the cam chain tensioner 2 OIL PUMP Remove the circlip 3 and oil pump driven gear Remove the pin 4 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 lost the gearshift pawl pin spring with the cam driven gear removal Remove the oil strainer cap With the neutral cam stopper plug loosened remove the washer spring stopper Remove the crankcase securing bolts Separate the crankcase into 2 parts right and left with a special tool Crankcase separator 09920 13120 NOTE Fit the crankcase separater so that the tool arms parallel the side of the crankcase The crankshaft and
63. ace wears Measure the valve head If it is out of specification replace the valve with a new one Service limit Valve face wear 0 5 mm Vernier calipers 09900 20102 ENGINE 3 20 9 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 replace the valve Service limit Valve stem runout 0 05 mm Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 9 CAMSHAFT T D C The camshaft should be checked for runout and also for B T D C A T D C wear of cams and journals if the engine has been noted Intake open Exhaust close to produce abnormal noise or vibration or a lack of out put power Any of these abnormality could be caused by a worn camshaft B B D C Exhaust open A B D C Intake close B D C valve timing diagram CAMSHAFT 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 terms of cam height 8 which is to be measured with a micrometer Replace camshafts if found it worn down to the limit Micrometer 25 50 mm 09900 20202 Cam height Service limit 9 Tappet amp shim wear When measuring the valve clearance the clearance should be within the standard
64. aft and driveshaft rotate smoothly lt 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 GEARSHIFT CAM DRIVEN GEAR When installing the gearshift into the cam driven gear the big shoulder 4 face toward outside as shown in figure Install the cam guide and 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 shifting 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 9 PRIMARY DR
65. atio 70 20 X 14 20 2 45 7 15 SERVICING INFORMATION CLUTCH Clutch cable play STANDARD Unit mm Drive plate thickness Drive plate claw width Driven plate distortion Clutch spring free length TRANSMISSION DRIVE CHAIN ITEM STANDARD Unit mm Primary reduction ratio 3 5 70 20 Secondary reduction ratio 3 69 48 13 Gear ratio Shift fork to groove clearance 0 84 21 25 0 10 0 30 Shift fork groove width NO 1 amp NO 2 5 0 5 1 NO 3 5 5 5 6 Shift fork thickness NO 1 amp NO 2 4 8 4 9 NO 3 5 3 5 4 Drive chain Type 428 HO Links 138 LINKS 20 pitch length 254 0 Drive chain slack 20 30 CARBURETOR SERVICING INFORMATION 7 16 Unit mm SPECIFICATION Carburetor type Bore size BDS26TYPE DOUBLE 26 I D NO HG 51E Idle r p m 1 450 1 550 r p m Float height 17 Main jet Main air jet Jet needle Needle jet Pilot jet Throttle valve By pass 1 2 3 4 1 2 3 4 09 09 08 08 09 09 08 08 Valve seat 1 2 1 2 Starter jet Pilot screw 20 20 Pilot outlet PV Stroke 7 17 SERVICING INFORMATION ELECTRICAL STANDARD Unit mm Ignition timing Spark plug 13 2 000rpm 30 5 000rpm Type CR8E Gap 0 7 0 8 Hot type CR7E Standard type CR8E Cold typ
66. between the cylinder bore and outside diameter of the piston Piston to cylin Standard Service limit EIE 0 03 0 04 mm 0 1 mm 9 PISTON PIN 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 Service limit Piston pin hole bore 13 03 mm Dial calipers 09900 20605 9 PISTON PIN 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 the ser vice limit replace the pin Service limit Piston pin diameter 13 980 mm Micrometer 0 25 mm 09900 20201 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 sn standard Service limit 5 0 mm 4 0 mm 6 0 mm 4 8 mm Vernier calipers 09900 20101 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 piston ring Standard Service limit ENGINE 3 28 1st 0 10 0 25 mm 0 5mm 0 25 0 40 mm 0 5mm Thi
67. ce Trouble with Starter jet is clogged starting Starter pipe is clogged Starter plunger is not operating properly Air leaking from a joint between starter body and carburetor Clean Clean Check starter body and carburetor for tightness adjust and replace gasket Check and adjust Idling or low speed Pilot jet pilot air jet are clogged or loose trouble Pilot outlet or bypass is clogged Starter plunger is not fully closed Check and clean Check and clean Check and clean Medium or high Main jet or main air jet is clogged speed trouble Needle jet is clogged Throttle valve is not operating properly Filter is clogged Check and clean Check and clean Check throttle valve for operation Check and clean Overflow and fuel 1 Needle valve is worn or damaged level fluctuations 2 Spring in needle valve is borken 3 Float is not working properly 4 Foreign matter has adhered to needle valve 5 Fuel level is too high or low Replace Replace Check and adjust Clean Adjust float height SERVICING INFORMATION 7 4 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1 Defective ignition coil Replace sparking 2 Defective spark plug Replace 3 Defective CDI unit Replace Spark plug soon 1 Mixture too rich Adjust carburetor become fouled with 2 Idling speed set too high Adjust carburetor ca
68. ce Replace Transmission will not shift Broken gearshift cam Distorted gearshift forks Worn gearshift pawl Replace Replace Replace Transmission will not shift back Broken return spring on shift shaft Shift shafts are rubbing or sticky Distorted or worn gearshift forks Replace Repair Replace Transmission jumps out of gear Worn shifting gears on driveshaft or countershaft Distorted or worn gearshift forks Weakened stopper pawl spring on gearshift cam Worn gearshift pawl Replace Replace Replace Replace Engine idles poorly 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 Adjust Replace Replace Replace Adjust or replace Replace Adjust Clean Engine runs poorly in high speed range gt 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 Replace Adjust Replace Repair Replace Adjust Clean Clean or replace
69. ces outside When reinstalling the brake lamp switch align the projection on the switch with the hole in the master cylinder Apply SUPER GREASE to the brake lever pivot SUPER GREASE When remounting the master cylinder onto the han dlebars align the master cylinder holder s mating surface with punch mark the handlebar and tighten the upper clamp bolt first V Front brake master cylinder mounting bolt 5 8 N m 0 5 0 8 m Install the brake hose union tighten the union bolt to the specified torque V Front brake hose union bolt 20 25 N m 2 0 2 5 m CAUTION Bleed air from the brake system after reassem bling the master cylinder Refer to page 2 15 CHASSIS 6 16 Master cylinder Clearance 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 1 and grip 9 HANDLEBARS LEFT SIDE PARTS REMOVAL Remove the left handlebar switches Remove the handlebar balancer 3 and grip Remove the clutch lever holder Remove the clamp bolts and detach the handlebar holders Remove the handlebar REMOUNTING Perform the remounting work in the reverse order of
70. ckness Front 4 0 Brake disc runout Rear Master cylinder bore 12 700 12 743 Master cylinder piston diam 12 657 12 684 Brake caliper cylinder bore 25 4 Brake caliper piston diam 25 4 Brake fluid type DOT3 or DOT4 Brake drum 1 0 Rear Wheel rim runout Axial Radial Wheel axle runout Front Rear Wheel rim size Front Rear 7 19 SERVICING INFORMATION TIRE ITEM STANDARD Cold inflation tire pressure Solo riding 1 75 2 00 Cold inflation tire pressure Dual riding 1 75 2 25 Tire tread depth SEE FUEL OIL SPECIFICATION Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommened Fuel tank capacity Including reserve 14 0 1 Reserve 2 0 1 Engine oil type SAE 10W40 Engine oil capacity Change 1 450 m2 Filter change 1 500 m2 Overhaul 1 650 SERVICING INFORMATION 7 20 WIRE AND CABLE ROUTING plus 5 Oo Fuel hose Fuel pum Magneto 09404 08403 09407 18402 Rear ignition coil Fuel gauge Gear shift switch 5 Ro 5 E PAJAS E x ae co e Sege u SEER Lose c coo Speedometer Handle switch LH 7 21 SERVICING INFORMATION
71. ckness gauge 09900 20806 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 ring groove clearance Service limit 1st 0 180 mm Piston ring groove width Standard Piston ring thickness Standard Thickness gauge 09900 20806 Micrometer 0 25 mm 09900 20201 3 29 9 OVERSIZE RINGS E Oversize piston ring The following two types of oversize piston ring are used They bear the following identification numbers Oversize piston ring 1st 2nd 05 05 10 10 Oversize oil ring The following two types of oversize oil ring are used They bear the following identification marks Oversize oil ring Color classification 0 5mm Painted red 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 13 006 13 014 mm 13 040 mm Dial calipers 09900 20605 CONROD DEFLECTION INSPECTION Move the small end sideways while
72. cts are found the drive chain must be replaced NOTE When replacing the drive chain replace the drive chain and sprocket as a set Loose the axle nut Loose the rear torque link nuts Tense the drive chain fully by turning both chain adjusters D 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 Drive chain 20 pitch length 256 5 mm Loosen or tighten both chain adjusters until the chain has 20 30 mm of slack in the middle between the engine and rear sprockets The marks 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 its center stand for accurate adjustment After adjusting the drive chain tighten the axle nut and the torque link nuts to the specified torque Tighten both chain adjusters securely V Rear axle nut 50 80 N 5 0 8 0 kg m Torque link nut Rear 10 15 N m 1 0 1 5 kg m Recheck the drive chain slack after tightening the axle nut 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
73. d oil to F level If the level is above mark F drain oil to F level 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 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 Add new engine oil and check the oil level as described in the engine oil replacement procedure CAUTION PERIODIC MAINTENANCE 2 10 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 2 11 PERIODIC MAINTENANCE 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 center stand 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 defe
74. der of removal and disassembly Pay attention to the following points E WHEEL BEARING Apply SUPER GREASE A 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 B 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 and axle pinch bolt to the specified torque V Front axle 50 80 m 5 0 8 0 m Front axle pinch bolt 15 25 N m 1 5 2 5 m CHASSIS 6 10 A WARNING Do not mix with brake fluid of 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 lt Do not allow dirt and fluid to contact the brake disc o
75. dy Steering feels too 1 Steering stem nut overtightened Adjust heavy or stiff 2 Worn bearing or race in steering stem Replace 3 Distorted steering stem Replace 4 Not enough pressure in tires Adjust Steering 1 Loss of balance between right and left front suspensions Replace oscillation 2 Distorted front fork Repair or replace 3 Distorted front axle or crooked tire Replace Wobbling front wheel Distorted wheel rim Worn down wheel bearings Defective or incorrect tire Loosen nut on axle Replace Replace Replace Retighten Front suspension too soft Weakened springs Not enough fork oil Replace Refill Front suspension too stiff Fork oil too viscous Too much fork oil Replace Drain excess oil Noisy front suspension Not enough fork oil Loosen nuts on suspension Refill Retighten Wobbling rear wheel 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 Replace Replace Replace Retighten Replace Retighten Rear suspension too soft Weakened springs Rear suspension adjuster improperly set Replace Adjust Rear suspension too stiff Rear suspension adjuster improperly set Worn swing arm bushing or bearing Adjust Replace Noisy rear suspension Loo
76. e 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 Pocket tester 09900 25002 Ignition coil resistance Primary 0 19 0 24 Q Tester knob indication x 1 Qrange Secondary 5 4 6 6 Tester knob indication x 1kQrange Check to attached plug cap 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 Thickness gauge 09900 20806 ELECTRICAL SYSTEM 5 6 Spark plug 0 7 0 8 mm 5 7 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated 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 eee eee ee IG switch iiai A C generator F Controlunit Regulator Rectifier 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 incid
77. e CR9E Spark performance Ignition coil resistance Over 8mm Primary 0 19 0 34 Q Secondary 5 4 6 6k Q Magneto coil resistance Pick up coil 90 110 Q Charging coil 0 6 0 9 Q Generator no load voltage 72 99V 5 000rpm Regulated voltage 14 15V Battery standard charging voltage 13 5 16V 5 000rpm Battery Type CP12120 Capacity 12V 12Ah Standard electrolyte 5 0 1 320 at 20 C 60 F Fuse size WATTAGE 15A SPECIFICATION Unit W Head lamp 35W 35W 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 A CAUTION Do not use except the specified bulb Wattage SUSPENSION Front fork stroke SERVICING INFORMATION 7 18 STANDARD 120 Unit mm Front fork spring free length 269 2 Front fork oil type TELLUS 22 Front fork oil level 325 Front fork capacity each leg 250 Rear wheel travel 92 RU Swingarm pivot shaft runout 0 6 Rear shock absorber pre load position 1 5 position Rear shock absorber spring length 317 7 BRAKE WHEEL Unit mm ITEM STANDARD Rear brake pedal free travel 20 30 Rear brake pedal height 310 when one person riding from the ground Brake disc thi
78. e 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 Replace Replace Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Complaint Symptom and possible causes SERVICING INFORMATION 7 2 Noisy engine Noise seems to come from transmission 1 2 3 3 Gears worn or rubbing Badly worn splines Primary gears worn or rubbing Badly worn bearings Replace Replace Replace Replace Slipping clutch Clutch control out of adjustment or too much play Weakened clutch springs Worn or distorted pressure plate Distorted clutch plates driven and drive Adjust Replace Replace Replace Dragging clutch Clutch control out of adjustment or too much play 2 Weakened clutch springs Distorted clutch plates driven and drive Adjust Repla
79. e exhaust pipe bolts and muffler mounting bolts removed remove the exhaust pipes and muf flers ENGINE 3 2 3 3 9 ELECTRIC PARTS With take out the spark plug caps remove the spark plug Remove the starter motor lead wire 3 4 Remove the engine ground lead wire D Disconnect the magneto coupler 2 9 ENGINE SPROCKET Remove the engine sprocket cover Remove the breather hose 3 5 With the bolt removed disconnect the gearshift arm Remove the left footrest Flatten the lock washer Remove the engine sprocket nut 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 rear torque link nuts and chain adjusters to provide additional chain slack Refer to page 2 11 Support the engine using an engine jack Remove the engine mounting nuts and bolts Remove the engine from the frame 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 ENGINE SPOCKET Loosen the rear axle nut rear torque link nuts and chain adjusters Install the engine sprocket
80. e hub nut 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 m Bend the lock washer securely Install the clutch drive plates and driven plates Install the clutch release rack D bearing 2 and washer Install the clutch pressure plate 7 clutch springs and clutch spring mounting bolts 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 E CLUTCH COVER Install the two dowel pins and new gasket 5 Apply engine oil to each gears bearings and clutch plates Tighten the clutch cover bolts securely ONG ENGINE 3 46 3 47 Install the clutch release arm as following Turn the clutch release shaft toward This time mark on the shaft align outside contact line the stopper screw the right Install that the cable connecting center line of the clutch release arm align matching mark rightside of the case as shown the right figure 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 N m 2 0 2 5 OIL DRAIN PLUG Tighten the oil drain plug t
81. e 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 gt Front cylinder 3 13 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 MAGNETO COVER Remove the magneto cover Remove in the order of spacer shaft starter idle gear 9 3 14 With the magneto rotor held immovable using the special tool loosen the rotor nut Rotor holder 09930 44510 Remove the magneto rotor by using the special tool Rotor remover 09930 30162 Remove the key Remove the starter clutch gear Remove the cam chain tensioner and cam chain 3 15 CLUTCH COVER Remove the clutch release arm Remove the clutch cover bolts Remove the clutch cover 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 immov
82. en 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 PERIODIC MAINTENANCE 2 6 EXHAUSE PIPE NUT AND MUFFLER MOUNTING BOLT NOTE Tighten Initial 1 000 km and Every 4 000 km Tighten the exhaust pipe nuts D and muffler mount ing bolts 2 to the specified torque 9 Exhaust pipe nut 18 28 N m 1 8 2 8 kg m Muffler mounting bolt 20 30 N m 2 0 3 0 kg m AIR CLEANER NOTE Clean Every 3 000 km Remove the air cleaner box cover 2 7 PERIODIC MAINTENANCE With the three of air cleaner cap mounting bolts removed remove the air cleaner cap D Remove the air cleaner element 2 Clean the air cleaner element with the air gun CAUTION Always apply air pressure to the inside of the air cleaner element only 4 A torn air cleaner element will allow dirt to enter the engine and can damage the engine Carefully examine the air cleaner element for tears during cleaning Replace it with a new one if it is torn Failure to position the air cleaner element properly can allow dirt to bypass the air clean er element This will cause engine damage Be sure to properly install the air cleaner ele ment CARBURETOR NOTE Inspect Initial 1 000 km and Every
83. entally the generated current charges the battery directly pee Se ee eee ee ee ee ee oo IG switch o gt generator Regulator Rectifier ELECTRICAL SYSTEM 5 8 When the engine rpm become higher the generated voltage of the AC generator also becomes higher and the voltage between points and B 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 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 current 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 Controlunit generator Regulator Rectifier 5 9 ELECTRICAL SYSTEM 9 I
84. er 9 CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disas sembly procedures and observe the following points CAUTION lt 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 or DOT 4 Install the brake pad spring 6 13 CHASSIS Apply SILICONE GREASE to the brake caliper hold er AH SILICONE GREASE Install the brake pads Refer to page 2 14 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 15 Inspection after reassembly Refer to page 2 13 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 Micrometer 0 25 mm 09900 20201 Service limit Brake disc thickness 3 0 mm Measure the runout using the dial gauge Replace the brake disc if the runout exceeds the service limit Dial gauge 09900 20
85. et Tighten the front fork lower clamp bolts and front fork cap bolts 2 to the specified torque Tighten the front fork upper clamp bolts 9 to the specified torque V Front fork upper clamp bolt 22 35 N m 2 2 3 5 m Front fork lower clamp bolt 22 35 N m 2 2 3 5 m Front fork cap bolt 15 30N m 1 5 3 0 Install the turn signal lamp Install the front fender and tighten the mounting bolts temporarily Install the front brake caliper Refer to page 6 12 Install the front wheel Refer to page 6 8 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 using the special tool 09940 14911 Steering stem nut wrench 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 a chisel like
86. f the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replace the cylinder Standard Service limit Cylinder bore 44 mm 44 080 mm Cylinder gauge set 09900 20508 9 CHAIN TENSION ADJUSTER Check that the push rod slides smoothly with the lock shaft handle counter clockwise If it does not slide smoothly replace the cam chain ten sion adjuster with a new one CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner If it is worn or damaged replace it with a new one 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 the measurement is found less than the service limit replace the piston ENGINE 3 26 Service limit Piston diameter 43 890 mm Piston oversize 0 5 1 0 mm Micrometer 25 50 mm 09900 20202 11 mm 3 27 9 PISTON TO CYLINDER CLEARANCE To determine the piston to cylinder clearance calculate the difference
87. fied torque 9 Rear axle nut 50 80 N m 5 0 8 0 kg m Tighten both chain adjusting nuts securely Adjust the rear brake pedal free travel Refer to page 2 16 CHASSIS 6 38 9 DISASSEMBLY Remove the rear wheel Refer to page 6 32 Remove the brake panel 6 39 CHASSIS Remove the brake shoes Remove the rear brake cam lever 1 and rear brake cam by removing nut Remove the washer 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 Vernier calipers 09900 20101 Service limit Brake drum I D 130 7 mm CHASSIS 6 40 5 5 Check the brake shoe wear Refer to page 2 16 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 REASSEMBLY BRAKE CAMSHAFT When installing the brake camshaft apply SUPER GREASE A to the camshaft and cam face AH 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 the l
88. h operation and long life of each working part of the motorcycle Major lubrication points are indicated below MEAN Clutch lever holder Drive chain X 2 97 o If 2277 Center stand pivot and spring hook NOTE Side stand pivot and spring hook 5 Brake lever holder Brake pedal pivot 9 Motor oil 8 Grease 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 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
89. holding the big end immovable in 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 Service limit Conrod deflection 3 0mm 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 ENGINE 3 30 Conrod big end Standard Service limit E 0 15 0 40 mm 1 0 mm CRANKSHAFT RUNOUT INSPEC 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 Service limit Crankshaft runout 0 05 mm Magnetic stand 09900 20701 Dial gauge 09900 20606 V block 09900 21304 9 CRANKSHAFT REASSEBLY Measure the width between the webs referring to the figure below when rebuilding the crankshaft Standard 72 0 1 mm Width between webs 9 MAGNETO COVER MAGNETO INSPECTION Refer to page 5 4 DISASSEMBLY Remove the sta
90. ignition system is com posed a 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 Ignition coil Ignition coil Rear Front Ignition switch T Battery 7 77 Ignition amp Spark plug INSPECTION B 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 coil Y Y Approx 0 60 9 9 Pocket Tester 09900 25002 A 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 R Red W White Y Yellow B R Black with Red tracer L R Blue with Red tracer R G Red with Green tracer W G White with Green tracer W R White with Red tracer B CDI UNIT Using the pocket R 1kQ range measure the resis tance between the lead wires in the following table Pocket Tester 09900 25002 Unit kQ _ 00 110 300 10 500
91. ining 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 6 41 CHASSIS Tighten the brake cam lever nut to the specified torque 8 Rear brake cam lever nut 8 12 N m 0 8 1 2 kg m Install the rear wheel Refer to page 6 35 Adjust the rear brake pedal free travel Refer to page 2 16 CHASSIS 6 42 REAR SHOCK ABSORBER REMOVAL Remove the right and left rear frame cover Refer to page 6 2 Remove the right and left rear shock absorbers by removing their nuts 6 43 CHASSIS 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 9 Shock absorber mounting nut upper 20 30 N 2 0 3 0 kg m Shock absorber mounting nut lower 35 55 N m 3 5 5 5 kg m 9 SPRING PRE LOAD ADJUSTMENT Adjust the rear shock absorber spring pre load Rear shock absorber Standard spring length 317 7 mm Rear shock absorber Standard spring pre load 1 5 position Rear shock absorber 2 Pin spanner CHASSIS 6
92. inverted position for a few minutes to allow the fork oil to fully drain With the damper rod held immovable remove the damper rod bolt 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 CAUTION The removed seal and slide metal should be replaced with new ones 9 INSPECTION FRONT FORK SPRING Measure the free length of the front fork spring 4 If the length is found shorter than the service limit NND NARRA Service limit m Front fork spring free length 4 264 2 mm CHASSIS 6 22 B 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 REASSEMBLY Perform the reassembly and remounting work in the reverse order of the disassembly and removal procedures while observing the following instructions A CAUTION Thoroughly wash all the component parts being assembled Insufficient washing can result in oil leakage or premature wear of the parts lt When reassembling the front fork use new fo
93. itch Magneto C D I Unit Lead wire starter motor ms Battery Case Battery Battery Terminal VIEW Rectifier Regulator 7 23 SERVICING INFORMATION exelg Joyoui Ped Jeay L0790 vEr60 70781 20760 07 L 1060 Uoneulquioo pea AN 7 20760 954 snuiu ejo1 jeuBisuun 20760 20760 LOvSC 0v60 sseujeu DuulM HM yams yolIms ayeug Jeay UOIIMS 4 20760 U9JIMS JUL duiej SERVICING INFORMATION 7 24 WIRING DIAGRAM H7 5 8 dojs 9 4902 9 MOI 9A POY UJ AUM ORIG eyuM PUM UM poy WIM 8 49 B w E esueor 1 BM 19 9 Jojoul eja1 UUM isid J202 pay YIM 1
94. lace the starter motor with a new one Pocket tester 09900 25002 STARTER MOTOR REASSEMBLY Reassembly the starter motor Pay attention to the following points Reassembly the starter motor as shown in the illustration ELECTRICAL SYSTEM 5 12 Segment 4 f 5 13 ELECTRICAL SYSTEM Align the mark on the housing with the line on the housing end Apply SUPER GREASE A to the O ring and remount the starter motor SUPER GREASE SWITCHES Measure each switch for continuity using a tester If any abnormality is found replace the respective switch assemblies with new ones Pocket tester 09900 25002 IGNITION SWITCH ELECTRICAL SYSTEM 5 14 LAMP 2 HEADLAMP TAIL BRAKE LAMP 5 15 ELECTRICAL SYSTEM 9 COMBINATION METER Remove the combination meter Disassemble the combination meter as shown in the illustration B 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 CAUTION When making this test it is not necessary to remove the combination meter 12V
95. m 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 abnormal condition are found replace the primary driven gear 9 OIL PUMP Turn the oil pump shaft and check that rotation is smooth If any abnormal condition is found replace the oil pump with new one 9 GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture TRANSMISSION E 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 Thickness gauge 09900 20806 Vernier calipers 09900 20101 ENGINE 3 34 Shift fork groove Standard Service limit clearance 0 10 0 30mm 0 5mm 3 35 Shift fork groove width Standard NO 1 amp NO 2 5 0 5 1 mm 5 5 5 6 mm NO 1 amp NO 2 4 8 4 9 mm REASSEMBLY Assemble the countershaft and drivenshaft in the reverse order of disassembly Pay attention to follo
96. mbly 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 lt Check that each rotating or sliding part moves or operates smoothly after assembly lt Make sure to follow the bolt 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 3 1 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL NOTE If the engine is 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 9 Remove the right frame cover Refer to page 6 2 Disconnect the battery lead wire 9 AIR CLEANER With the two screw loosened remove the right air cleaner boxes Refer to page 2 6 Loosen the clamp screw With the bolt removed take out the center air cleaner box 9 CARBURETOR Remove the carburetor Refer to page 4 4 Disconnect the vacuum hoses from the intake pipe 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 th
97. n the crankcase Replace the bearing in the following procedure if there is anything unusual 3 37 DISASSEMBLY RIGHT CRANKCASE BEARING Remove the bearing retainer Remove the bearings 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 CRANKCASE BEARING Remove the oil seals and Oil seal remover 09913 50121 ENGINE 3 38 Remove the bearing retainer Remove the bearings 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 Bearing installer 09913 70122 Bearing installer 09913 76010 LEFT CRANKCASE BEARING Drive in the bearings 7 and 9 Bearing installer 09913 70122 Bearing installer 09913 76010 3 39 Install the seals 0 and 2 Apply SUPER GREASE A on the lip of oil seal AGH 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
98. o the specified torque 9 Engine oil drain plug 18 20 N m 1 8 2 0 kg m STATOR Apply a small quantity of THREAD LOCK 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 4324 V Starter clutch bolt 15 20 N m 1 5 2 0 m 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 LOCK 1324 Tighten the magneto rotor nut to the specified torque Rotor holder 09930 40113 V Magneto rotor nut 50 60 N m 5 0 6 0 kg m 9 STARTER IDLE GEAR AND MOTOR Install the starter idle gear shaft and spacer Install the starter motor ENGINE 3 48 3 49 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 71 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
99. of the pressure developed by the master cylinder and thus interferes with the full brak ing performance of the brake caliper The 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 insert 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 NOTE While bleeding the brake system replenish the brake fluid in the reservoir as necessary Make sure that there is always some fluid visible in the reservoir Close the air bleeder valve and di
100. oosen the steering stem nut of a turn 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 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 kg 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 m 2 2 3 5 kg 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 D spring and washer 3 Remove the cotter pin torque link nut and bolt Remove the rear axle nut Raise the rear wheel off the ground with a jack or
101. pecical tool Bearing remover 17mm 09923 73210 CAUTION removed bearing should be replaced with new one 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 A to the bearing before installation SUPER GREASE 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 SUPER GREASE REAR SPROCKET Tighten the rear sprocket nuts to the specified torque 9 Rear sprocket nut 20 30 N m 2 0 3 0 kg m Install the retainer to the mounting drum as shown CHASSIS 6 36 6 37 CHASSIS REAR WHEEL Tighten the rear torque link nut to the specified torque and install the new cotter pin V Rear torque link nut 10 15 N m 1 0 1 5 kg m Adjust the drive chain slack after installing the rear wheel Tighten the rear axle nut to the speci
102. r 09913 75830 Bearing installer Used to install rear axle shaft oil seal 09920 13120 Crankcase separater Separate to crankcase 09913 76010 Bearing installer Used to drive crankshaft bearing in Vx t 59 gt 09920 53710 Clutch sleeve hub holder Used to install or remove clutch sleeve hub nut SERVICING INFORMATION 7 10 Special tools Part Number Part Name Description Special tools Part Number Part Name Description fo 09921 20200 Bearing remover 10mm Used to remove oil seal or bearing 09930 44510 Rotor holder Widely used to lock rotary parts such as a flywheel magneto 09921 20210 Th 09940 10122 Bearing remover 12mm Clamp wrench Used to remove oil seal or bearing A hook wrench to adjust the steering head of motorcycle 09923 73210 09940 34520 Bearing remover 17mm i T handle rd Used to remove bearing with the rotor remove sliding shaft Remove and remounting front fork oil cylinder 09923 74510 Bearing remover 20 35mm Used to remove bearing with the rotor remove sliding shaft 09940 34561 Front fork assembling tool attachment D Used with T handle 09924 84521 Bearing installer Used to drive small bearing in 09940 50113 Front fork oil seal installer Install front fork oil seal 09930 10121 Spark plug socket wrench set U
103. r pad 6 11 CHASSIS CAUTION Do not allow brake fluid to contact the paint surface plastic rubber parts its chemical reaction can cause discoloration or crack 9 BRAKE FLUID REPLACEMENT For replacing procedure of brake fluid Refer to page 2 14 9 BRAKE PAD REPLACEMENT For replacing procedure of brake pad Refer to page 2 14 CALIPER DISASSEMBLY Drain brake fluid Refer to page 2 14 CAUTION To prevent brake fluid from splashing on the parts nearby cover the parts with cloth Remove the union bolt and caliper mounting bolts Remove the brake pad Refer to 2 14 Remove the brake caliper holder 3 Using an air gun push out the caliper piston Place rag over the piston to prevent it from popping out and flying and keeping hand off the piston lt Be careful of brake fluid which can possibly splash Do not use high pressure air but increase the pressure gradually Remove the dust seal and piston seal A CAUTION CHASSIS 6 12 Care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that have 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 calip
104. range Standard When cold Intake valve 0 1 0 2 mm Exhaust valve 0 2 0 3 mm 3 21 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 thickness 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 Service limit runout 0 03 mm 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 EX 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
105. rbon 3 Incorrect gasoline Change 4 Dirty element in air cleaner Clean or replace 5 Spark plug too cold Replace by hot type plug Spark plug become 1 Worn piston rings Replace fouled too soon 2 Pistons or cylinder worn Replace 3 Excessive clearance of valve stems in valve guides Replace 4 Worn stem oil seal Replace Spark plug 1 Spark plug too hot Replace by cold type plug electrodes 2 The engine overheats Tune up overheat or burn 3 Spark plug loose Retighten 4 Mixture too lean Adjust carburetor Generator charge Lead wires tend to get shorted or open circuited or loosely connected Repair or retighten but charging at terminals rate is below the 2 Grounded or open circuited stator coils of generator Replace specification 3 Defective regulator rectifier Replace 4 Not enough electrolyte in the battery Add distilled water between the level lines 5 Defective cell plates in the battery Replace the battery Generator 1 Internal short circuit in the battery Replace the battery overcharges 2 Resistor element in the regulator rectifier damaged or defective Replace 3 Regulator rectifier poorly grounded Clean and tighten ground connection Unstable 1 Lead wire insulation frayed due to vibration resulting in intermittent Repair or replace charging shorting 2 Generator internally shorted Replace 3 Defective regulator rectifier Replace Starter switch is not effective
106. replace the valve Valve stem diameter Standard 3 975 3 990 mm EX 3 955 3 970 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 and valve guide reamer handle 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 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 and valve guide installer attachment Valve guide installer and remover 09916 44910 Valve guide installer attachment 09916 44920 After fitting all valve guides re finish their guiding bores will a 4 0 mm valve guide reamer 9 and valve guide reamer handle 6 Be sure to clean and oil the guides after reaming 4 0 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 8 ENGINE 3 22
107. rk oil lt 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 ones On the inner tube assemble the following parts D Dust seal 2 Oil seal stopper ring seal Oil seal retainer 5 Slide metal Guide bushing CAUTION To prevent the lip of oil seal 3 from being dam aged cover the inner tube with vinyl sheet 4 dur ing installation With the oil lock piece fitted to the inner tube assem ble the inner tube to the outer tube 6 23 CHASSIS Apply SUPER GREASE A to the lip of the oil seal and install it into the outer tube using the front fork oil seal installer ASH 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 A CAUTION Make sure that the stopper ring is securely fitted into the groove on the outer tube Dust seal Oil seal stopper ring 9 Oil seal Oil seal retainer 5 Slide metal Fit the rebound spring on the damper and install them together to the inner tube Apply THREAD LOCK 1324 to the damper rod bolt
108. sconnect 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 D Rear brake pedal 310 mm height When one person ridding at the ground 9 REAR BRAKE ADJUSTING Adjust the free travel to 20 30 mm by turning the adjusting nut Rear brake pedal free travel 8 20 30 mm 9 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 from the index mark is within the range 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 38 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 PERIODIC MAINTENANCE 2 16 2 17 PERIODIC MAINTENANCE STEERING NOTE Inspect Initial 1 000 km and Every 4 000 km
109. sed to remove or remounting spark plug 09941 34513 Steering race installer Used to install steering outer race 09930 30102 Rotor remove sliding shaft Used to with bearing remover or rotor remover 09941 50111 Wheel bearing remover Used to remove wheel bearing 09930 30162 Rotor remover Attached to the top of sliding shaft when removing rotor 09943 74111 Front fork oil level gauge Used to drain the fork oil to the specified level 09930 40113 Rotor holder Widely used to lock rotary parts such as a flywheel magneto 7 11 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM kg m Magneto rotor nut 50 60 5 0 6 0 Magneto cover bolt 8 12 0 8 1 2 Muffler mounting bolt 20 30 2 0 3 0 Exhaust pipe nut 18 28 1 8 2 8 Starter clutch bolt 15 20 1 5 2 0 Cylinder head bolt 7 11 0 7 1 1 Cylinder head cover bolt 12 16 12 1 6 Cylinder head base nut 15 20 1 5 2 0 Engine sprocket nut 80 100 8 0 10 0 Engine oil drain plug 18 20 1 8 2 0 Engine mounting bolt 40 60 40 6 0 Cam chain sprocket bolt 10 13 1 0 1 3 Cam chain tensioner bolt 6 8 0 6 0 8 Cam chain tension adjuster bolt 8 12 0 8 1 2 Camshaft sprocket bolt 10 12 1 0 1 2 Crankcase bolt 8 12 0 8 1 2 Clutch sleeve hub nut 30 50 3 0 5 0 Primary drive gear nut 40 60 40 6 0 Camshaft housing bolt 8 12
110. sen nuts on suspension Worn swing arm bushing or bearing Retighten Replace 7 7 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking 1 Not enough brake fluid in the reservoir Refill to level mark FRONT and REAR 2 Air trapped in brake fluid circuit Bleed air out 3 Pads worn down Replace 4 Too much play on brake lever or pedal Adjust 5 Shoes worn down Replace Insufficient brake 1 Leakage of brake fluid from hydraulic system Repair or replace power 2 Worn pads Replace 3 Oil adhesion of engaging surface of pads Clean disk and pads 4 Worn disk Replace 5 Air in hydraulic system Bleed air Brake squeaking Excessive brake lever stroke Leakage of brake fluid 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 Worn brake lever cam Insufficient brake fluid Improper quality of brake fluid Insufficient tightening of connection joints Cracked hose Worn piston and or cup Repair surface with sandpaper Modify pad fitting Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Bleed air Replace brake lever Replenish fluid to specified level bleed air
111. ston 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 lt 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 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 gauge reading as the compres sion of that cylinder Compression gauge 09915 64510 OIL PRESSURE Check the oil pressure periodically This will give a good indication of the condition of the moving parts Standard Oil pressure 2 0 0 2 at 60 C 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 OI
112. 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 9 FRONT FORK OIL Use fork oil TELLUS 22 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 1 5 GENERAL INFORMATION 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 Alguuilla is composed of the two cylinder is classified into the front cylinder and rear cylinder as basis of the motorcycle ahead gt FRONT Rear cylinder Front cylinder EXTERIOR ILLUSTRATION GENERAL INFORMATION 1 6
113. the removal procedures while observing the following instructions Install the handlebars with the punch mark 5 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 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 A to the throttle cables and assemble them ASH SUPER GREASE CHASSIS 6 18 6 19 CHASSIS FRONT FORK 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 turn signal lamp Remove the front fork after loosening the front fork upper and lower clamp bolts NOTE Slightly loosen the front fork cap bolt 3 to facilitate later disassembly Remove the front fork upper bolt O ring 0 front fork inner spacer 5 and spring guide 6 Invert the front fork and stroke it several times to drain out the fork oil Hold the front fork in the
114. tor EN 72 0 1mm pe 3 31 STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven 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 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 Q Starter clutch bolt 15 20 N m 1 5 2 0 kg m STARTER DRIVEN GEAR STARTER DRIVEN GEAR BEARING Install the starter driven gear bearing D and gear onto the crankshaft and turn the starter driven gear by hand Inspect the starter driven gear bearing for smooth rotation and any abnormal noise If the bearing does not turn smoothly or there is any abnormal noise replace it 9 DISASSEMBLY Remove the bearing using the special tool Bearing remover 20 35 mm 09923 74510 CLUTCH COVER E OIL
115. transmission components must remain in the left crankcase half ENGINE 3 18 3 19 Remove the gearshift fork shaft and gearshift fork Remove the gearshift cam Remove the driveshaft assembly 0 countershaft assembly 6 Remove the oil pump idle gearshaft 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 No 1 cylinder No 2 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 Thickness gauge 09900 20806 Cylinder head Service limit distortion 0 05 mm 9 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 f
116. ushrod is inserted in Turn the mechanial spring continually until the handle is turned to the end Fix the adjuster into the cylinder block Lock shaft handle Get out the pushrod for the front to turn the lock shaft handle counterwise Turn the crankshaft about 10 times counter clock wise 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 0 1 0 2 mm 0 2 0 3 mm 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 Q Cylinder head cover bolt 12 16 N m 1 2 1 6 kg m ENGINE 3 56 3 57 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 pply SUPER GREASE to the O ring and install the gear postion switch A SUPER GREASE
117. wing points NOTE Always use new circlips NOTE Before installing the gears coat lightly engine oil to the driveshaft and CAUTION lt Never reuse circlip After circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to 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 Thrust SS LA ENGINE 3 36 TRANSMISSION GEARS AND RELATED PARTS Thickness for washers circlips and spacers 1 2mm 6 0mm 0 5mm 1 0mm E d JL CRANKCASE ll BEARING INSPECTION play i Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are i
118. with oil Install the cylinder 9 VALVE AND SPRING Insert the valve with their stems coated with MOLY PASTE Apply the oil to the lip of the stem seal A H MOLY PASTE Valve spring compressor 09916 14510 Valve spring compressor attachment 09916HG5100 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 ENGINE 3 50 pipe installation side pipe installation side Front piston Rear piston 3 51 Fit the cylinder head and tighten the stud bolts CAUTION Pay caution to prevent the cam chain from drop ping into the crankcase V Cylinder head bolt 7 11 m 0 7 1 1 m Tighten the cylinder head base nuts V Cylinder head base nut 15 20 N m 1 5 2 0 kg m Install the tappet and shim CAUTION With fit the tappet it should be replaced if turn not smoothly by the hand CAUTION 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 Front cylinder
119. wooden block Loosen the drive chain adjusters left and right Remove the rear axle Disengage the drive chain from the rear sprocket Remove the rear wheel Remove the rear brake panel Refer to page 6 39 Remove the spacer Remove the rear sprocket 9 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 sprocket damper 4 CHASSIS 6 34 Remove the rear sprocket from the rear sprocket mounting drum Remove the dust seal Oil seal remover 09913 50121 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 39 REAR SPROCKET DAMPER Inspect the rear sprocket dampers for wear and damage Replace the rear sprocket damper if there is anything unusual 6 35 CHASSIS SPROCKET Inspect the sprocket s teeth for wear If they are worn replace the sprocket and drive chain as a set Normal wear Excessive wear 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 REAR SPROCKET MOUNTING DRUM BEARING Remove the bearing by using s
120. ycles depends on the markets SERIAL NUMBER LOCATION The frame serial number or V I N 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 machine and ordering spare parts 1 4 FUEL AND OIL RECOMMENDATION 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 Grade SF or SG 10W 40 If an SAE 10W 40 motor oil is not available select an alternative according to the following chart Use a premium quality 4 stroke motor oil to ensure longer service life of your motorcycle WARNING Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside Mop the oil spilt Don t put the patch on the cap It could disturb the to be provided and damage the engine 9 BRAKE FLUID Specification and classification DOT3 DOT4 A WARNING Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the

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