Home

SERVICE MANUAL

1. SERVICING INFORMATION 7 12 TIGHTENING TORQUE ENGINE Cylinder head cover bolt Camshaft holder nut Camshaft sprocket center bolt Cylinder head nut Cylinder base nut Magneto rotor nut Primary drive gear nut Oil pump drive gear nut Clutch sleeve hub nut Engine oil drain plug Engine sprocket nut Engine mounting nut M10 Engine mounting nut M8 Exhaust pipe clamp nut Muffler clamp bolt Starter clutch bolt CHASSIS Front axle nut Front fork damper rod bolt Front fork lower clamp bolt Front fork upper bolt Steering stem head bolt Steering head cover bolt Swing arm pivot nut Rear torque link nut Rear shock absorber fitting nut Rear axle nut Rear sprocket nut Rear brake cam lever bolt Front brake caliper mounting bolt Front disc bolt Master cylinder mounting bolt Caliper bleeder bolt Front brake hose union bolt 7 13 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolt and nuts who s is not listed refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt mm N m kg m s kg m 4 1 0 20 0 1 0 2 0 15 0 3 5 20 40 0 2 0 4 3 0 6 0 0 3 0 6 6 40 7 0 0 4 0 7 8 0 12 0 0 8 1 2 8 10 0 16 0 1 0 1 6 18 0 28 0 1 8 28 10 22 0 350 22 35 40 0 60 0 40 60
2. 1 7 GENERAL INFORMATION part THREAD LOCK SUPER 1303B 99000 32030 2nd drive gear Starter clutch allen bolt THREAD LOCK CEMENT 99000 32040 Front fork damper rod bolts THREAD LOCK 99000 32050 Countershaft bearing retainer screws Gearshift cam guide and screws Engine oil pump mounting screws Pick up coil screws Stator mounting screws Starter motor securing screws THREAD LOCK SUPER 1305 99000 32100 Magneto rotor nut GENERAL INFORMATION 1 8 PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motorcycles Be sure to replace packings gaskets circlips O rings and cotter pins with new ones CAUTION Never reuse a circlip after a 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 insure that it is completely seated in its groove and securely fitted Tighten bolts and nuts from the ones of larger diameter to those of smaller diameter and from inside to out side diago nally with specified tightening torque Use special tools where specified Use specifide genuine parts and recommended oils When more than 2 persons perform work in cooperat
3. Segment 09900 25002 Pocket tester 5 11 ELECTRICAL SYSTEM STATER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to starter motor case align the protrusion D of the starter motor case with the notch 2 of the brush holder SECURING SCREWS Apply therad lock 1342 to starter motor securing screws 99000 32050 Thread Lock 1342 STARTER RELAY INSPECTION Disconnect lead wire of the starter motor at starter relay Turn on the ignition switch inspect the continuity between the terminals positive and negative when pushing the Starter button If the starter relay is in sound condition continuity is found 99000 25002 Pocket tester Check the coil for open ground and ohmic resis tance The coil is in good condition of the resistance is as follows 99000 25002 Pocket tester STD resistance Approx 3 4 2 ELECTRICAL SYSTEM 5 12 SPEEDOMETER ASSY Remove the speedometer assy See page 6 16 Disassemble the speedometer assy as shown in the illus tration INSPECTION Using the pocket tester check the continuity between lead wires in the following diagram If the continuity measured is incorrect replace the respec tive part 99000 25002 Pocket tester NOTE When making this test it is not necessary
4. The nuts and bolts listed are important parts and they must be in good condition for safety They must be retightened as necessary to the specified torque with a torque wrench Tightening torque ITEM N m kg m Front axle nut 36 52 36 52 Q Caliper mounting bolt 15 25 1 5 2 5 3 Brake hose union bolt 20 25 2 0 2 5 Master cylinder mounting bolt 5 8 0 5 0 8 Swing arm pivot nut 50 80 5 0 8 0 Rear shock absorber 20 30 2 0 3 0 Rear axle nut 50 80 5 0 8 0 Rear brake cam lever bolt 5 8 0 5 0 8 37 45 3 7 4 5 Engine mounting bolt 0 80 95 8 0 9 5 Rear touque link bolts 10 15 1 0 1 5 2 17 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES SERVICING ENGINE CONTENTS COMPRESSION PRESSURE AND OIL PERSSURE mH ENGINE REMOVE AND REMOUNTING mmm mmm nenne UPPER END COMPONENTS DISASSEMBLY HH Hmmm UPPER END COMPONENTS INSPECTION AND SERVICING gt 55555555555555 UPPER END COMPONENTS REASSEMBLY HH Hmmm LEFT ENGINE DISASSEMBLY n MM III RIGHT ENGINE DISASSEMBLY MM LOWER END COMPONENTS DISASSEMBLY LOWER END COMPONENTS INSPECTION AND SERVICING m LOWER END COMPONENTS MMRR Se 3 44 4 MM RIGHT ENGINE REASSEMBLY m III LEFT ENGINE REASSEMBLY n MM III 3 1 SERVICING E
5. 09900 20701 Magnetic stand 09900 20606 Dial gauge 1 100mm 09900 21304 V block 100mm Service limit 0 05mm 3 13 SERVICING ENGINE VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head and measure the valve head radial runout If it measures more than limit replace the valve Service limit 0 03mm VALVE GUIDE VALVE STEM CLEARANCE Measure the clearance in two directions X and perpendicular to each other by rigging up the dial gauge as shown If the clearance measured exceeds the limit Specified below then determine whether the valve or the guide should be replaced to reduce the clearance to with in the standard range Standard Service limit IN 0 010 0 037mm 0 35mm EX 0 030 0 057 mm 0 35mm VALVE STEM WEAR If the valve stem is worn down to the limit when mea sured with a micrometer and the clearance is found to be in excess of the limit previously indicated replace the valve if the stem is within the limit then replace the guige After replacing valve or guide be sure to recheck the clearance 09900 20205 Micrometer 0 25mm Valve stem O D Standard IN 4 915 4 990mn EX 4 955 4 970mn VALVE STEM CONDITION Inspect the valve stem end face for pitting and wear If pitting or wear of the stem end face are present the valve stem end may be resurfaced providi
6. 09900 20803 Thickness gauge Piston ring thickness Piston ring Standard Ist 0 970 0 990mm 2nd 0 970 0 990mm OVERSIZE RINGS Oversize piston rings The following two types of oversize piston rings are used They bear the following identification numbers SERVICING ENGINE 3 20 Piston ring Ist 2nd 0 5mm 50 50 1 0mm 100 100 Oversize oil rings The following two types of oversize oil ring are used They bear the following identification marks 0 5mm Painted red 1 0mm Painted yellow Oversize side rail Just measure outside diameter to identify the side rail as there is no mark or numbers on it PISTON PIN PIN BORE Using a caliper gauge measure the piston pin bore inside diameter and using a micrometer measure the piston pin outside diameter If the difference between these two measurements is more than the limits replace both pis ton and piston pin 09900 20205 Micrometer 0 25mm Piston pin bore Service limit 15 030mm Piston pin O D Service limit 14 980mm CONROD SMALL END Using a caliper gauge measure the conrod small end inside diameter Service limit 15 040mm f the conrod small end bore inside diameter exceeds the limit replace conrod 3 21 SERVICING ENGINE UPPER END COMPONENTS REASS
7. CHASSIS 6 14 STEERING STEM Tightening torque 35 55 3 5 5 5 35 55 3 5 5 5 25 35 2 5 3 5 12 20 1 2 2 0 REMOVE AND DISASSEMBLY Remove the front wheel Refer to Page 6 1 Remove the front fender Refer to Page 6 6 Remove the front fork Refer to Page 6 6 Loosen the headlamp screws and remove the lens 6 15 CHASSIS Disconnect the lead wire and remove the head lamp housing D Remove the steering head cover Loosen the steering stem bolt and remove the front fork upper bracket 2 Loosen the steering nut Remove the steering stem Remove the dust seal Remove the upper outer race Remove the upper and lower steel balls CHASSIS 6 16 Upper 22 pcs Number of balls Lower 18 pcs 6 17 CHASSIS Remove the outer race fitted on the steering stem This can be done with a chisel Dwaw out the two inner reces fitted to the top and bottom ends of the head pipe INSPECTION Inspect and check the removed parts for the following abnormalities Handlebars distortion Handlebars clamp wear Race wear and brinelling Worn or damaged steel balls Distortion of steering stem CHASSIS 6 18 REASSEMBLY Reassemble and remount the steering stem in the revers
8. Separate the inner tube from the outer tube Remove the oil seal stopper ring 6 9 CHASSIS Remove the oil seal by using the special tool 09913 50121 Oil seal remover CAUTION The oil seal removed should be replaced with a new one INSPECTION DAMPER ROD RING Inspect the damper rod for wear and damage INNER TUBE AND OUTER TUBE Inspect the inner tube and outer tube sliding surfaces for any scuffing or flaws FORK SPRING Measure the fork spring free length if it is shorter than the service limit replace it Service limit 454 5mm REASSEMBLY Reassemble and remount the front fork in the reverse order of disassembly and removal and also carry out the following steps DAMPER ROD BOLT Apply Three Bond No 1215 and Thread Lock Cement to the damper rod bolt and tighten the bolt with specified torque by using the 8mm hexagon wrench and special tools 99000 31110 Three Bond No 1215 99000 32040 Thread lock cement 09900 00401 L type hexagon wrench 6mm 20 26N m 2 0 2 6kg m Tightening torque OIL SEAL Install the oil seal to the outer tube by using the special tool as shown CHASSIS 6 10 Thread lock cement Three Bond 1215 09940 50112 Front fork oil seal installer FORK OIL For the fork oil be sure to use a
9. Tighten clutch sleeve hub nut using the special tool to the specified torque 09920 53710 Clutch sleeve hub holder Tightening torque 30 50N m 30 5 0kg m Be sure to lock the nut by firmly bending the tongue of the washer Install drive plates and driven plates to the sleeve hub Insert push rod in the countshaft Tighten clutch spring bolts diagonally Clutch release screw adjustment loosen the lock nut and turn in the release screw to feel high resistance From that position turn out the release screw 1 4 1 2 turn and tighten the lock nut SERVICING ENGINE 3 50 Cam sid Longer Is Push Piece side Shorter 3 51 SERVICING ENGINE LEFT ENGINE REASSEMBLY SRATOR Apply a small quantity of THREAD LOCK 1342 to the threaded parts of screws 99000 32050 Thread lock 1342 STARTER CLUTCH Locate the shim to the proper position Apply THREAD LOCK SUPER 1303B to allen bolts and tighten with specified torque 99000 32030 Thread lock super 1303B 09900 00401 L type hexagon wernch 5mm Tightening torque 15 20N m 1 5 20kg m MAGNETO ROTOR Fit key in the key slot on the crankshaft Install the magneto rotor Apply a small quantity of THREAD LOCK SUPER 1305 to the threaded parts of crankshaft Tighten magneto rotor nut to the
10. Spark plug too hot The engine overheats Spark plug loose Mixture too lean Replace by cold type plug Tune up Retighten Adjust carburetor Open or short in lead wires or loose lead connections Shorted grounded or open generator coils Shorted or panctured regulator rectifier Repair replace or retighten Replace Replace Generator charge but charging rate is below the Lead wires tend to get shorted or open circuited or loosely connected at terminals Grounded or open circuited stator coils of generator Defective regulator rectifier Not enough electrolyte in the battery Defective cell plates in the battery Repair or retighten Replace Replace Add distilled water between he level lines Replace the battery Internal short circuit in the battery Resistor element in the regulator rectifier damaged or defective Regulator rectifier poorly grounded Replace the battery Replace Clean and tighten ground connection Lead wire insulation frayed due to vibration resulting in intermittent shorting Generator internally shorted Defective regulator rectufier Repair or replace Replace Replace 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
11. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing SHIFTING FORK AND GEAR Using a thickness gauge check the shifting fork clearance in the groove of its gear If the clearance limit is exceed ed by any of the three gears determine whether the gear or the gear shifting fork should be replace by mea suring the thickness and groove width SERVICING ENGINE 3 38 09900 20803 Thickness gauge 09900 20101 Vernier calipers Item Standard Limit Shifting fork to 0 10 0 30mm 0 50mm groove clearance Shifting fork groove width No 1 amp 5 0 5 1mm t Standard NO 2 NO 3 5 5 5 6mm Shifting fork thickness No 1 amp 4 8 4 9 t Standard NO 2 NO 3 5 3 5 4mm Checking thickness 3 39 SERVICING ENGINE PRIMARY DRIVEN GEAR Primary driven gear is composed as shown D Primary driven gear Rivet Damper Clutch housing 5 Plate If the internal damper wears play is generated between gear and housing causing abnormal noise If the play is extreme replace the primary driven gear assembly with a new one CAM CHAIN 20 PITCH LENGTH Pull the chain tight to remove any slack then using vernier caliper measure the 20 pitch 21pins length of cam chain If it measure than the limits replace the cam chain Service limit 129 9mm C
12. W B W Y Y W Yellow Black with White Green with Blue tracer Red with Black tracer White with Black tracer White with Yellow tracer Yellow with Blue tracer Yellow with Green tracer Yellow with White tracer 5 15 ELECTRICAL SYSTEM BATTERY SPECIFICATIONS Type designation 12M8 3B Capacity 12V 9AH 10HR Standard electrolyte S G 1 280 at 20 C 68 F In fitting the battery to the motorcycle connect the breather tube to the battery vent INITIAL CHARGING Filling electrolyte Remove short sealed tube cap D before filling electroyte Fill battery with electrolyte dilute sulfuric acid solution with acid concentration of 35 0 by weight having a spe cific gravity of 1 28 at 20 C 68 F up to indicated UPPER LEVEL Filling electrolyte should be always cooled below 30 C 86 F before filling into battery Leave battery standing for half an hour after filling Add additonal electrolyte if nec essary Charge battery with current as described in the tables shown below Maximum charging current 0 8 Charging time The charging time for a new battery is determined by the number of months that have elasped since the date of manufacture Confirmation for date of manufacture Date of manufacture is indicated by a three part number as follows each indicating month data and year Near the end of charging period adjust the specific gravi ty of ele
13. f a large resistance is felt to rotation try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in Fig OIL SUMP FILTER Wash the sump filter with cleaning solvent and then blow compressed air through it to dry off solvent After mounting the sump filter fit the cap and tighten it NEUTRAL CAM STOPPER Put in the neutral stopper and spring Tighten the cam stopper plug SERVICING ENGINE 3 46 3 47 SERVICING ENGINE RIGHT ENGINE REASSEMBLY KICK START DRIVE GEAR AND IDLE GEAR Install kick starter idle gear and drive gear 09900 06107 Snap ring pliers GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driv en gear The large shoulder amp must face to the outside as shown Next install cam guide and pawl lifter Apply a samll quantity of THTEAD LOCK 1342 to the threaded parts of the screws 99000 32050 Thread lock 1342 GEAR SHIFTING 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 NOTE After the cam driven gear cam guide gear shift ing shaft and neutral cam stopper have been fit ted 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 installat
14. For less noise the INTAKE amp EXHAUST system and VALVE TRAIN system are redesigned in order to satisfy 71 db the strict 96 KOREA NOISE REGULATION 3 COMFORTABLE SEATING The seat is made out of two different hardness FOAM URETHANE in order to absorb shock which makes seating more com fortable THE TECHINICAL FEATURES 1 CYLINDER HEAD The best conbustion efficiency is done by the 4 VALVE seat system s connecting TWO IN ONE HOLE INTAKE AND EXHAUST to SPARK PLUG in Pentroof combustion chamber casted at the low pressure The silent chain is more closely united and the cylinder head wall is thickened more for decreasing chain noise By choosing ALUMINUM forging HOLDER gets lighter and stronger 2 PISTON CONNECTING ROD and CAM CHAIN PISTON high tension HI SILICON AC8A is FLAT type HEAD and T type SHORT SKIRT which is 57 suitble for high speeds and lightened for less vibration The part of CONNECTING ROD s small hole is 15 the PIN SIZE of large hole is 28 for enduring high engine power and PITCH is 99 8 CAM CHAIN is LINK PITCH 6 350 1 4 s endless type and gets TIMMING and less noise by adopting Borg warmer 92RH 1 3 GENERAL INFORMATION 3 CLUTCH MISSION The Primary Gear Ratio is improved from 3 47 to 3 50 in order to increase rotation For improving CLUTCH durability while long distance driving CLUTCH DAMPER is changed from rubber to steel Spring type 4 VALVE TRAIN The maximum power appears at 8500rpm
15. ONNSOAH HYOSUNG HYOSUNG MOTORS amp MACHINERY INC SERVICE MANUAL TIWANVW 99000 94200 FOREWORD The HYOSUNG GF 125 was designed to offer superior performance through light weight design and four stroke power The new GF 125 represents another major advance by HYOSUNG in four stroke motorcyles This service manual has been produced primarily for experienced mechanics whose job is to inspect adjust repair and service HYOSUNG Motorcycles Apprentice mechanics and do it yourself mechanics will also find this manual to be an extremely useful guide Model GF 125 manufactured to standard specifcations is the main subject matter of this manual However the GF 125 machines distributed in your country might differ in minor respects from the standard specifica tion GF 125 and if they do if is because some minor modifications Which are of no consequence in most cases as far as servicing is concerd had to be made to comply with the statutry requirments of your coun try This manual contains up to date information at the time of its issue Latermade modifications and changes will be explanied to each HYOSUNG distributor in respective markets to whom you are requested to make query about updated information if any HYOSUNG MOTORS amp MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES SERVIC
16. VICE DATA CRANKSHAFT RUNOUT Support the crankshaft with V blocks as shown with the two end joumals resting on the blocks Position the dial gauge as shown and rotate the crankshaft slowly to read the runout Correct or replace the crankshaft if the runout is greater than the limit Service limit 0 05 SERVICING ENGINE 3 36 3 37 SERVICING ENGINE CLUTCH DRIVE PLATE Measure the thickness and claw width of each drive plate with vernier calipers Replace drive plates found to have worn down to the limit 09900 20101 Vernier callipers Item Standard Limit Thickness 2 9 3 1mm 2 6mm Claw width 11 8 12 0mm 11 0mm CLUTCH DRIVEN PLATE Measure each driven plate for distortion with a thickness gauge Replace driven plates which Service limit 0 1mm 09916 20803 Thickness gauge CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with a vernier calipers and determine the elastic strength of each If any one of springs is not within springs at a time the limit replace all the Checking thickness WAN Checking claw width 09900 20101 Vernier calipers Service limit 29 5mm CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality parti calarly cracks to decide whether it can be reused or should be replaced
17. bling the engine 3 17 SERVICING ENGINE VALVE SPRINGS Check the springs for strength by measuring their free lengths and also the force required to compress them If the limit indicated below is exceeded by the free length reading or if the measured force does not fall within the range specified replace with a HYOSUNG spring as a set Valve spring free length Spring Service limit IN amp EX 4 65mm Valve spring tension Spring Standard IN amp EX 13 6 16 6k 36 6mm CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness guage 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 0 05mm CYLINDER BORE Measure the cylinder bore diameter at six places If any one of the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replace the cylinder 09900 20508 Oylinder guage set Service limit 57 080mm PISTON DIAMETER Using a micrometer measure the piston outside diameter at the place 15mm from the skirt end as shown in Fig If the measurement is less than the limit replace the pis ton 09900 20203 Micrometer 50 75mm Service limit 56 880mm Piston oversize 0 5
18. 12 35 0 550 35 755 70 0 100 0 10 10 0 14 50 0 80 0 5 0 8 0 110 0 160 0 11 0 16 0 16 80 0 130 0 8 0 13 0 170 0 250 0 17 0 25 0 18 130 0 190 0 13 0 19 0 200 0 280 0 20 0 28 0 m pe La quar 11 Conventional bolt A marked bolt marked bolt qur 0 SERVICING INFORMATION 7 14 SERVICE DATA VALVE GUIDE Unit mm STANDARD 22 19 7 4 1 1 ve clearance or tappet clearance P hen cold 0 10 0 13 ve diam ve lift 0 010 0 037 0 030 0 057 ve guide D f 5 000 5 012 4 915 4 990 4 955 4 970 ve stem runout ve guide to valve stem clearance ve stem O D ve head thickness ve stem end length 3 5 ve stem width 0 9 1 1 ve head radial runout ve spring free length 41 65 ve spring tension 13 6 16 6kg f 36 6mn CAMSHAFT CYLINDER HEAD Unit mm STANDARD 34 44 34 48 33 81 33 85 Cam chain 20 pitch length Camshaft runout Rocker arm 1 0 12 000 12 018 Rocker arm shaft O D 11 977 11 995 Cam height Cylinder head distortion Camshaft hold 7 15 SERVICING INFORMATION CYLINDER PISTON PISTON RING Unit mm STANDARD Compression pressure 12 07 15 0kg cri 8 0kg cri Piston to cylinder clearance 0 050 0 060 0 120 Oylinder bore 51 000 57 015 51 080 56 945 56 960 56 880 Measure st 15 from the skirt Oylinder
19. Piston rings or ring groove worn Replace Noise seems to come from timing chain 1 Stretched chain Replace 2 Worn sprockets Replace 3 Tension adjuster not working Repair or replace 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 4 Clutch dampers weakened Noise seems to come from crankshaft 1 Worn or burnt bearings 2 Big end bearings worn and burnt 3 Thrust clearance too large Replace Replace Replace Replace Replace Replace Replace Symptom and possible causes SERVICING INFORMATION 7 2 Noise seems to come from transmission Gears worn or rubbing Badly worn splines Primary gears worn or rubbing Badly worn bearings Replace Replace Replace Replace Slipping clutch Clutch contorl out of adjustment or loss of play Weakened clutch springs Worn or distorted pressure plate Distored clutch plates driven and drive Adjust Replace Replace Replace Clutch control out of adjustment or too much play Some clutch spring weakened while others are not Distorted pressure plate or clutch plates Adjust Replace Replace Transmission will not shift Broken gearshift cam Distorted gearshift forks Worn gearshift pawl Rep Transmission will not shift back Broken return spring on
20. e Turn the fuel lever to the OFF position Take off the fuel hose Disconnect the coupler 3 3 SERVING ENGINE Take off the clutch cable by removing the clutch release arm bolt Disconnect the lead wire of starter motor Take off the spark plug cap Disconnect the couplers and lead wire SERVICING ENGINE 3 4 Take off the breather pipe Remove the carburetor with intake pipe loosening the intake bolts and carburetor clamp screw Remove the engine sprocket cover Loosen the rear axle nut and chain adjuster nuts Take off the drive chain by removing the clip 3 5 SERVICING ENGINE Disconnect the ground wire from the crankcase Take off the gear shift lever by removing the bolt Remove the exhaust pipe bolts and muffler mounting bolt then take off the muffler Remove the swing arm pivot nut and remove the shaft D CAUTION Be careful not to draw out the swing arm pivot shaft completely from the left side swing arm pivot hole Remove the engine mounting nuts and bolts Remove the frame down tube by removing the mounting bolts Use both hands and lift the engine from the frame NOTE The engine must be taken out from the left side SERVICING ENGINE 3 6 ENGINE REMOUNTING After remounting the engine following adjustme
21. m Four strock air cooled OHC Number of cylinder eH eme 1 BO Gi Score misi tact et ec eror 57mm xo RETE 48 8mm Piston Hee 124 Compression ratio eem Hee 492 Carburetor PISTON VALVE Air cleaner eene Polyurethane foam element Starter system eee eene Kick and Electric LubriCation Wet Sump TRANSMISSION oct Peace rae e n edle eese ei gon ces Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern HH eee 1 down 4 up Primary reduction HH 3 500 Final reduction menn 3 357 Gear ratios LOW eee eene enne 2 150 PANE 1 785 CH EE EE 1 368 BED 1 045 I 0 913 Drive chain M 126 links ELECTRICAL Ignition type eee ere rere eee ee eee eee eee eee rere eee ee eee eee eee eee ee ee 09S Ignition timing Spark plug Battery 4440 000000 0 68 00800 86 Headlight Tail Brake light Turn signal light Neutral indicator light High beam indicator light Speedometer light Fuel
22. rubber materials etc PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 14 REAR BRAKE This is effected by turning the brake pedal stopper Be sure to tighten the lock nut securely after setting the bolt After adjusting the rear brake height adjust the brake pedal traval First set the pedal at position for comfort able riding by turning the brake pedal stopper D and then adjust the free travel to 20 30 mm If adjustment is necessary turn the rear brake adjuster 2 to obtain the specific play Brake pedal travel 20 30mm Brake lining wear limit This motorcycle is equipped with brake lining wear limit indicators on both rear brakes As shown in the illustra tion at right at the condition of normal lining wear an extended line from the index mark on the brake camshaft should be within the range embessed on the brake panel with the brake on To check wear of the brake lining fol low the steps below Fist check if the brake system is properly adjusted While operating the brake check to see that the range on the brake panel f the index mark is outside the range as shown in the illustration at right the brake shoe assembly should be replaced to ensure safe operation TIRES Inspect Initial 1 000km and Every 5 000km TREAD DEPTH SERVICE LIMIT FRONT 1 6mm Rear 1 6mm Check the tire pressure and examine the valve for evi
23. so that TORQUE is good enough to have a long distance driving or downtown driv ing The valve angle is 25 IN and 28 EX which are much narrower agles for ROCKER ARM 4 VALVE and TORQUE 1 02kg m is achieved by improving VOLUME EFFICIENCY The technical design is done through the enough simulation by the design SOFTWARE which our company have kept in order to not making trouble like JUMPING or SURGING 5 CAM SHAFT LOCK ARM and VALVE The material of CAM is CHILLED FC whose durability and safty is high For improving acceleration the inside of Cam Shaft is designed empty For improving durability BALL BEARING TYPE for CAM SHAFT is adopted and LOCK ARM is sur faced with HARD CROME COATING and LUBRITE For preventing the touching noise the contacted SPRING CAM is adopted The Valve IN 22 EX 19 is surfaced with TUFTLITE The left side of VALVE and TAPPET are surfaced with STELLITE especially the surface hardness is over HRC50 by surfacing STELLITE NO 1 so thatTAPPET s durability is improved by preventing wearing 7 Y A 2 2 GENERAL INFORMATION 1 4 IGNITION SYSTEM DESCRIPTION The GF 125 Engine is equipped with a new type ignition system This new system further reduces timing fluctuations It has an ignition timing control circuit wich accurately controls the advance curve and maintains consistent timing independent of high RPM fluctuation magnetic force temperature and air gap ADVANT
24. 50r min THROTTLE CABLE PLAY There shoule be 0 5 1 0mm 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 in obtained Secure the lock nuts while holding the adjuster in place Throttler cable play 0 5 1 0mm CLUTCH Inspect Initial 1 000km and Every 5 000km Clutch play should be 4mm 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 turn the adjuster in or out until the specified play in obtained Secure the lock nuts while holding the adjuster in place The clutch cable should be lubricated with a light weight oil whenever it is adjusted 2 11 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES DRIVE CHAIN Inspect and Clean Every 1 000km DRIVE CHAIN Visually inspect the drive chain for the belos listed possi ble malconditions Lift the rear sheel by placing the cen ter stand and turn the rear wheel slowly by hand with the transmission in NEUTRAL Inspect for 1 Loose pins 2 Damaged rollers 3 Rusted links 4 Twinsted or seized links 5 Excessive wear If any defects are found the drive chain must be replaced Wash the chain with ke
25. No 2 No 3 No 1 amp No 2 No 3 Countershaft length Low to 2nd Drive chain 126 links 20 pitch length Drive chain slack 20 35 7 17 SERVICING INFORMATION CARBURETOR ITEM SPECIFICATION Carburetor type PD 18F Bore size 24mm No 93BO Idle r min 1450 50rpm Float height 12 5mm Main jet M J 1 100 Main air jet M A J 80 Jet needle J N J29B Needle jet N J J6TC 3rd Pilot jet P J 38 Throttle valve T V 93C By pass B P 29 1 0 0 9 Valve seat V S 2 0mm Stater jet MAX 500 Pilot screw P S PRE SET 2 Pilot air jet P A J 150 ELECTRICAL Unit mm ITEM SPECIFICATION 15 BTDC Below 2250 300rpm and eon IRR 35 BTDC Above 4000 300rpm Spark plug Type C8EH 9 Gap 0 7 0 8 Spark performance Over 8mm at 1 atm Ignition coil resistance Primary B Ground Approx 0 5 1 5 Q Secondary Plug cap Ground Approx 4 7 5 57K Q Magneto coil resistance Pick up G W Approx 90 120 Q Power source HANKUK B R Approx 300 400 0 Power source PUNG SUNG B R Approx 400 600 0 Charging Y Y Y Approx 0 5 1 5 Q Generator no load voltage More than 70V AC at 5000r min Regulated voltage 13 5 16 0V at 5000r min Battery Capacity Standard electrolyte S G 1
26. PERIODIC MAINTENANCE AND TUNE UP PROCEDURES MAINTENANCE PROCEDURES This section describes the service procedures for each section of periodic Maintenance BATTERY Inspect Initial 1 000km and Every 5 000km The battery must be removed to check the electrolyte level and specific gravity Remove the seat Refer to page 3 2 Remove battery lead at the battery terminal Remove battery lead Remove battery from the frame Check electrolyte for level and specific gravity Add distilled water as necessary to keep the surface of the electrolyte above the LOWER level line but not above the UPPER level line For checking specific gravity use a hydrometer to deter mine the charged condition 09900 28403 Hydrometer Standard specific gravity 12V 1 28 at 20 C An S G reading of 1 22 at 20 C or under means that the battery needs recharging off the machine take it off and charge it from a recharger Charging the battery in place can lead to failure of the regulator rectifier To install the battery reverse the procedure described above WARNING When installing the battery lead wires fix the lead first and lead last Make sure that the breather pipe is tightly secured and undamaged and is routed as shown in the figure Breather pipe Battery PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 4 CYLINER HEAD NUTS CYLI
27. always insure that it is completely seated in its groove and securely fitted SERVICING ENGINE 3 42 Washers and circlips thickness 1 2mm 1 0mm 1 0mm 0 5mm 1 0mm 20 00 H NOTE When reassembling the bearing retainer apply a small quantity of THREAD LOCK 1342 to the threaded parts of the bearing retainer screws In reassembling the transmission attention must be given to the locations and positions of washers and cir clips The cross sectional view given here will serve as a reference for correctly mounting the gears washers and circlips COUNTERSHAFT Mounting 2nd drive gear Press fit 2nd drive gear into the countershaft Before reassembling coat the internal face of the 2nd drive gear with THREAD LOCK SUPER 1308B and install it so that the length is as shown in Fig Countershaft length 0 88 0 Low to 2nd oom 09920 32030 THREAD LOCK SUPER 1303B NOTE This procedure may be performed only twice before shaft replacement is required 3 43 SERVICING ENGINE GEAR SHIFTING CAM AND FORK Fit gear shifting cam on the crankcase Position the cam as shown in Fig so that the gear shifting fork can be installed easily SERVICING ENGINE 3 44 NOTE Two kinds of gear shifting forks D 2 are used They resembles each other very closely in exte
28. and replace gasket 4 Starter plunger in not operating properly Check and adjust Idling or low speed 1 Pilot jet pilot air jet are clogged or loose Check and clean trouble 2 Pilot outlet or bypass is clogged Check and clean 3 Starter plunger is not fully closed Check and clean Medium or high 1 Main jet or main air jet is clogged Check and clean speed trouble 2 Needle jet is clogged Check and clean 3 Throttle valve is not operating properly Check throttle valve for operation 4 Filter is clogged Check and clean Overflow and fuel 1 Needle valve is worn or damaged Replace level fluctuations 2 Spring in needle valve is broken Replace 3 Float is not working properly Check and adjust 4 Foreign matter has adhered to needle valve Clean 5 Fuel level is too high or low Adjust float height ELECTRICAL Symptom and possible causes SERVICING INFORMATION 7 4 Defective ignition coil Defective spark plug Defective pick up coil Defective CDI unit Replace Replace Replace Replace Mixture to rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Adjust carburetor Adjust carburetor Change Clean Replace by hot type plug Worn piston rings Pistons or cylinder worn Excessive clearance of valve stems in valve guides Worn stem oil seals
29. distortion 0 05 Aoorox 7 2 5 1 Aoorox 5 8 4 6 0 20 0 32 0 50 0 20 0 32 0 50 0 180 Piston diam Piston ring free end gap iston ring end gap iston ring to groove clearance iston ring to groove width 0 970 0 990 0 970 0 990 iston pin bore 15 002 15 008 iston pin O D 14 994 15 000 iston ring to thickness CONROD CRANKSHAFT Unit mm STANDARD Conrod small end 15 006 15 014 Conrod deflection zi Conrod big end side clearance 0 10 0 45 Conrod big end width 15 95 16 00 Crank web to web width 53 0 0 1 Crankshaft runout OIL PUMP ITEM STANDARD LIMIT 2 000 30 15 Oil pump reduction ratio SERVICING INFORMATION 7 16 Oil pressure at 60 C 140 F CLUTCH ITEM Clutch cable play 0 4 0 6kg cri at 3000r min Unit mm STANDARD 4 Clutch release screw Drive plate thickness 1 4 1 2 turn back 2 9 4 1 Driven plate thickness 1 60 05 Driven plate distortion Clutch spring free length TRANSMISSION DRIVE CHAIN Unit mm Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3 500 70 20 Final reduction ratio 3 357 47 14 2 750 33 12 1 785 25 14 Gear ratios 1 368 26 19 1 045 23 22 0 913 21 23 Shift fork to groove clearance 0 10 0 30 Shift fork to groove width Shift fork thickness No 1 amp
30. front fork oil whose vis cosity rating meets specifications below Fork oil type FORK OIL 15 Capacity each leg 175 ml 6 11 CHASSIS Hold the front vertical and adjust the fork oil level with the special tool c pem When adjusting oil level remove the fork spring and compress the inner tube fully i ies 09943 74111 Fork oil level gauge Y Oil level 185 mm FORK SPRING d Upside When installing the fork spring the close pitch end should T position upside a FORK BOLT Tighten the fork bolt with specified torque Tightening torque 18 28N m 1 8 2 8kg m REMOUNTING Tighten the fork upper clamp bolts with specificed torque Tightening torque 35 55N m 3 5 5 5kg m Tighten the lower clamp bolts with specificed torque Tightening torque 25 3bN m 2 5 3 5kg m Install the front fender Tighten the caliper mounting bolts with specificed torque CHASSIS 6 12 Tightening torque 15 25N m 1 5 2 5kg m Install the front wheel 6 13 CHASSIS SPEEDOMETER ASSY DISASSEMBLY Remove the speedometer cable Loosen the head lamp lens screw Disconnect the speedometer coupler Loosen the bolts and remove the speedometer
31. in a suitable receptacle Remove the caliper mounting bolts and take off the caliper CAUTOIN Never re use the brake fluid left over from the last servicing and stored for long peri ods Loosen the screw D and take off the housing cover Q take off the pads CHASSIS 6 24 Remove the caliper holer from the caliper Place a rag over the piston to prevent popping up Force out the piston by using air gun CAUTOIN Do not use high pressure air to prevent piston dam age Remove the piston piston boot and piston seal INSPECTION CALIPER CYLINDER Inspect the cylinder bore wall for nick scratches or other damage 6 25 CHASSIS PISTON Inspect the piston surface for any scratches or other damage RUBBER PARTS Inspect the each rubber part for damage and wear DISC Measure the disc thickness by using the micrometer 09900 20205 Micrometer 0 25mm Service limit 3 0 mm With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown 09900 20606 Dial gauge 1 100 Service limit 0 3 mm BRAKE PADS Wear condition of brake pads can be checked by observ ing the red limit line marked on the pad When the wear exceeds the limit line replace the pad
32. indicator light CHASSIS Front suspension Rear suspension Steering angle Caster Trail Front brake Rear brake 4848 9800406000000 00000666 00 6 6 00 66 606 6 6 Front tire size Rear tire size CAPACITIES Fuel tank including reserve Reserve 0000000000040 a Engine oil Front fork oil HH HHMHMHMHHHMHMHMHHHHHHHMHMHMHHHHHMHHSHHyyh es e The specification subject to change without notice GENERAL INFORMATION 1 1O CDI TYPE 15 B T D C below 2 250r min and 35 B T D C above 4 000r min 12V9Ah 35 35W 10 5W x2 Telescopic coil spring 42 right and left Disc brake single Internal expanding 2 15 18 4PR 3 00 18 6PR PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE m mm nme MAINTENANCE PROCEDURES m mme hmm nemen emen nnne 2 CYLINDER HEAD NUTS CYLINDER NUTS EXHASUST PIPE BOLTS AND NUTS em m e nemen nemen sheet enne AIR CLEANER ELEMENT m me enmmememe nehmen nente nennen VALVE CLEARANCE m n mmm emen nennen COMPRESSION PROSSURE mme e n meme nemen entente IO WM IHE FUEL STRAINER emm m Ie cR EE ENGINE OIL FILTER m m m mme eme he emn nhe nennen OIL PRESSURE meme heme hememen eene ene nemen nennen nennen OIL SUMP FILTER em
33. mme hmmm nemen nemen nennen CARBURETOR ee meme heme nehmen nemen temen nemen nente eene CLUTCH i AE FRONT FORK OIL e A III CHASSIS AND ENGINE BOLTS AND 6 2 1 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE an Interval Battery Initial 1 000km Inspect Every 5 000km Inspect Every 10 000km Oylinder head nuts cylinder nuts exhaust pipe bolts and nuts Inspect Inspect Air cleaner element Clean every 3 000 Valve clearance Inspect Inspect Compression pressure Inspect Inspect Spark plug Inspect Inspect Replace Fuel line Inspect Inspect Replace every 4 years Fuel strainer Clean Engine oil Change Change Engine oil filter Replace Replace Oil pressure Inspect Oil sump filter Carburetor Inspect Inspect Clutch CHASSIS Interval Item Inspect Initial 1 000km Inspect Every 5 000km Every 10 000km Drive chain Inspect and clean ever
34. on the piston head to exhaust side CYLINDER Before mounting the cylinder oil the big end and small end of the conrod and also the sliding surface of the pis ton Fit dowel pins D to crankcase and then fit gasket CAUTION To prevent oil leakage do not use the old gasket again always use new one Hold each piston ring with the piston rings properly Spaced and insert them into the cylinder Check to insure that the piston rings are properly inserted into the cylinder skirt NOTE When mounting the cylinder after attaching camshaft drive chain keep the camshaft drive chain taut The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated NOTE There is a holder for the bottom end of the cam chain guide cast in the crankcase Be sure that the guide is inserted properly or binding of the cam chain and guide may result SERVICING ENGINE 3 22 3 23 SERVICING ENGINE VALVE AND SPRING Insert the valves with their stems coated with HYOSUNG MOLY PASTE all around and along the full stem length without any break Similarly oil the lip of the stem seal 99000 25140 Hyosung moly paste CAUTION When inserting each valve take care not to damage the lip of the stem seal Insert valve springs making sure that the close pitch end D of each spring goes in first to rest
35. specified torque 99000 32100 Thread lock super 1305 09930 44511 Rotor holder Tightening torque 30 40N m 3 0 4 0kg m SERVICING ENGINE 3 52 STARTER IDLE GEAR AND MOTOR Install the starter idle gear Install the starter motor DRIVESHAFT OIL SEAL AND ENGINE SPROCKET CAUTION Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leak age Also grease the oil seal lip On installa tion refer to Fig for correct position and direction Replace O ring with a new one every disas sembly NOTE After reassembling the LOWER END COMPONENTS install the O ring and spacer 3 53 SERVICING ENGINE Tighten the engine sprocket nut to the specified torque and bend up the washer 09930 40113 Rotor and sprocket holder Tightening torque 80 100N m 8 0 10 0kg m GEAR POSITION SWITCH Install gear position switch FUEL AND LUBRICATION SYSTEM CONTENTS FUEL COGK staan setae Telia terete esses CARBURETOR ee 5 tese SPECIFICATION mm mmn REMOVAL DISASSEMBLY AND INSPECTION REASSEMBLY AND REMOUNTING e m nmm LUBRICATION SYS
36. stand 09900 21304 V block 100mm Service limit 0 25 mm WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown NOTE Worn or loose wheel bearing must be replaced before attempting to true a wheel rim Service limit 2 0 mm TIRE see page 2 14 SPROCET Inspect the sprocket teeth for wear If they are worn as illustrated replace the sprocket and drive chain a m i prm Normal wear Excessive wear REAR BRAKE DRUM Measure the brake drum 1 0 to determine the extent of wear and if the limit is exceed by the wear noted replace the drum the value of this limit is indicated inside the drum CHASSIS 6 34 Service limit 130 7 mm BRAKE SHOE Check the brake shoes and decide whether it should be replaced or not from the thickness of the brake shoe linings Service limit 1 5 mm CAUTION Replace the brake shoes as a set other wise braking performance will be adversely affected CUSHION Inspect the cushion for wear and damage REASSEMBLY Reassemble and remount the wear wheel and rear brake in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the bearing before installing 99000 07000 Grease G 6 35 CHASSIS Install the whe
37. to remove the speedometer ass y LIGHTS HEAD LIGHT 5 13 ELECTRICAL SYSTEM TURNSIGNAL LIGHT TAIL BRAKE LIGHT SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart If it is found any abnormality replace the respective switch assembly with new one 99000 25002 Pocket tester IGNITION SWITCH STARTER SWITCH R BR LIGHTING SWITCH Y W ON o o OFF O Y G OFF ON push O O FRONT BRAKE LIGHT SWITCH O W B OFF ON O O DIMMER SWITCH Y W Y W HI LO OS TURN SIGNAL LIGHT SWITCH B Sb Lg o o HORN SWITCH G B W OFF ON push O O REAR BRAKE LIGHT SWITCH W B OFF ON O O NEUTRAL INDICATOR LIGHT SWITCH Res L Ground OFF ON PASSING SWITCH Y OFF ON O ELECTRICAL SYSTEM 5 14 GEAR POSITION INDICATOR LIGHT SWITCH W Y L R B G L Y L Br R Ground Low O O Neutral 2nd WIRE COLOR B Black BI Blue Br Brown Q Green Sb Light blue Lg Light green O Orange R Red W White Y B W G BI R B
38. 0 cm Align the key groove on the camshaft so it is vertical with the surface of the cylinder head NOTE Do not rotate magneto rotor while doing this When the sprocket is not positioned correctly turn the sprocket Vertical 3 25 SERVICING ENGINE Install the camshaft lock C ring D CAMSHAFT HOLD Apply HYOSUNG MOLY PASTE to the rocker arm shafts Install the rocker arm spring rocker arm and inserting the shafts Fit the two dowel pins to the camshaft holder When fitting rocker arm spring hook part D of rocker arm spring onto rocker arm and hook part of rocker arm spring onto the dowel pins Dowel Pin Fit the two dowel pins and install the camshaft holder Tighten the camshaft holder nuts to the specified SERVICING ENGINE 3 26 Tightening torque 250 290kg cm CHAIN TENSIONER Remove the bolt and spring at the tensioner body Mount the tensioner body on the cylinder NOTE Racket side of tensioner is positioned cylinder head side Tightening torque 60 80keg cm Install the spring and bolts Tightening torque 60 80keg cm 3 27 SERVICING ENGINE VALVE CLEARANCE After tightening the camshaft holder lock nuts check and adjust the valve clearance Valve clearance specifications IN and EX 0 1
39. 0 0 13mm NOTE Valve clearance is to be checked when the engine is cold Both the intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compression stroke CYLINDER HEAD COVER Clean off oil from the surfaces of cylinder head and cover Fit the packing to the cylinder head cover Tighten the cylinder head cover bolts with hexagon wrench Tightening torque 120 160kg cm SERVICING ENGINE 3 28 LEFT ENGINE DISASSEMBLY MAGNETO ROTOR Remove gear change lever bolt Remove the frame down tube by removing the mounting bolts Remove sprocket cover bolts and detach sprocket Cover Remove magneto cover bolts and detach magneto Cover Detach magneto leadwire terminal Remove the starter idle gear Remove magneto rotor nut 09930 44511 Rotor holder NOTE Do not allow camshaft drive chain to be caught between crankcase and camshaft drive sprocket 3 29 SERVICING ENGINE Remove magneto rotor and key 09930 30162 Rotor remover Remove starter clutch gear Remove stator screw by using the impact drive and detach stator Remove roller D spring and push piece from stater clutch Clamp the rotor with a vise taking care not to damage it and r
40. 1 0mm NOTE Using a soft metal scraper decarbon the crown of the piston Clean the ring grooves similarly PISTON CYLINDER CLEARANCE As a result of the above measurement if the piston to cylinder clearance exceeds the limit shown in the table below overhaul the cylinder and use an oversize piston or replace both cylinder and piston SERVICING ENGINE 3 18 Service limit 0 120mm PISTON RING GROOVE CLEARANCE Using a thickness gauge measure the side clearance of the Ist and 2nd rings If any of the clearances exceeds the limit replace both piston and piston rings 09900 20803 Thickness gauge Piston ring groove clearance Piston ring Service limit Ist 0 180mm 2nd 0 150mm 3 19 SERVICING ENGINE Piston ring groove width Piston ring Standard Ist 1 01 1 03mm 2nd 1 01 1 03mn Oil 2 01 2 03mm PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings measure the free end gap of each ring using vernier calipers Next fit the ring in the cylinder and measure each ring end gap using a thickness gauge If any ring has an excess end gap replace the ring Piston ring free end gap R RIKEN Piston ring Service limit Ist 5 7mm 2nd 4 6mm 09900 20101 Vernier calipers Piston ring free end gap Piston ring Service limit Ist and 2nd 0 50mm
41. 2V9AH 10HR 1 280 at 20 C 68 F Fuse size 15A SERVICING INFORMATION 7 18 BRAKE WHEEL Unit mm STANDARD Front brake lever distance Rear brake pedal free travel Rear brake pedal height Brake drum D Rear wheel Brake lining thickness Rear wheel Brake disc thickness Front wheel Brake disc runout Front whee Master cylinder bore Front whee 12 700 12 743 Master cylinder piston diam Front whee 12 657 12 684 Brake caliper cylinder bore Front wheel 33 960 34 036 Brake caliper piston diam Front whee 33 884 33 934 Axis direction Wheel rim runout Circular direction 5 Front wheel Wheel axle runout Rear wheel Front wheel 2 15 18 4PR Rear wheel 3 00 18 6PR Front wheel 6 Tire size Tire tread depth Rear wheel 8 SUSPENSION Unit mm STANDARD Front fork stroke Front fork spring free length Front fork oil level Rear wheel travel Swing arm pivot shaft runout 7 19 SERVICING INFORMATION FUEL OIL Fuel type Gasoline u highter An unleaded or low lead type is recommended STANDARD sed should be graded 85 95 octane or Fuel tank including 13 7 1 reserve 1 6 1 Engine oil type SAE 10W 40 SF Engine oil capacity Change 850 ml Filter change 950 ml Overhaul 1300 ml Front fork oil type TELLUS 22 Front fork oil capacity eac
42. 5 Worn pads Replace 6 Foreign material in brake fluid Replace brake fluid and clean 7 Clogged return port of master cylinder Disassemble and clean Master cylinder Excessive brake 1 Air in hydraulic system Bleed air lever stroke 2 Worn brake lever cam Replace brake lever 3 Insufficient brake fluid Replenish fluid to specified level bleed air 4 Improper quality of brake fluid Replace with correct fluid Leakage of brake 1 Insufficient tightening of connection joints Tighten to specified torque fluid 2 Cracked hose Replace 3 Worn piston and or cup Replace piston and or cup SPECIAL TOOLS SERVICING INFORMATION 7 8 ITEM PART No PART NAME 1 09900 00401 L Type hexagon wrench set 2 09900 06107 Snap ring pliers opening type 3 09900 06108 Snap ring pliers closing type 4 09900 09003 Impact driver set 5 09900 20101 Vernier calipers 150mm 09900 20202 Micrometer 25 50mm 6 09900 20203 Micrometer 50 75mm 09900 20205 Micrometer 75 100mn 1 09900 20508 Cylinder gauge set 8 09900 20606 Dial gauge 1 100 9 09900 20701 Magnetic stand 10 09900 20803 Thickness gauge 09900 20804 Thickness gauge 11 09900 21304 V block 12 09900 25002 Poket tester 13 09900 28403 Hydrometer 14 09910 20116 Conrod holder 15 09910 32812 Crankshaft installer 16 09913 14511 Fuel level
43. 9 5 9 5 4 F 3 4 50 59 68 86 95 104 Check the reading as corrected to 20 C with chart to Temperature determine the recharging time in hours by constant cur rent charging at a charging rate of 0 9 amperes which is a tenth of the capacity of the present battery Be careful not to permit the electrolyte temperature to exceed 45 C 113 F at any time during the recharging operation Interrupt the operation as necessary to let the electrolyte cool down Recharge the battery to the specifi cation Electrolyte specific gravity 1 28 at 20 C 68 C 5 17 ELECTRICAL SYSTEM CAUTION Constant voltage charging otherwise called quick charging is not recommendable for it could shorten the life of the battery 09900 28403 Hydrometer SERVICE LIFE Lead oxide is applied to the poles plate of the battery which will come off gradually during the service When the bottom of the battery case becomes full of the sediment the battery cannot be used any more If the battery not charged for a long time lead sulfate is generated on the surface of the pole plates and will deteriorate the performance sulfation Replace the battery with new one in such a case When a battery is left for a long term without using it is apt to be subject to sulfation When the motorcycle is not used for more than 1 month especially during the win ter season recharge the battery
44. AGES OF CAPACITOR DISCHARGE IGNITION SYSTEM Trouble free operation due to elimination of contact breaker points which can become contaminated Ignition timing is maintained properly at all times and require no maintenance Free from arcing and provides the ignition coil with stable secondary voltage Excellent vibration and moisture resistance OPERATION When the magneto rotor rotates an electric current is generated in the power source coil L and this charges the capaci tor C via D On the other hand when the rotor tio on the magneto rotor passes the pick up coil the currents P and P are generated they flow to the ignition timing control circuit and they are converted into one ignition signal This signal is sent to the SCR the SCR becomes ON the circuit C SCR lg is formed and as the electric energy stored in capacitor C is discharged instantly a high voltage is induced in the ignition secondary coil Ig and a spark crosses over the spark plug gap When the engine is running slowly N r min or less Fig 3 control by the ignition timing control circuit is executed so that the ignition signal is generated at the time Fig 2 when the current P is generated and is sent to the SCR When the engine speed increases N to N r min control is executed so that the ignition signal is generated between P and P according to the engine speed At this time the advance angle is
45. At the time of high engine speed N r min and over control is executed so that the ignition signal is generated at the time when P is generated AT this time this advance angle becomes IGNITION SPARK MAGNETO CDI UNIT COIL Di Ci gt i I Power Source Coil Ig2 Y IGNITION TIMING A Rotor tip CONTROL CIRCUIT Mia ae Pick up Coll 7 P2 P Fig 1 1 5 GENERAL INFORMATION d LN Ye eo T T P2 P P Pick up Coil Current Signal current to SCR l 1 Engine speed DEI PY Below Between Ni and Ne R Fig 2 Engine speed r min Fig 3 GENERAL INFORMATION 1 6 SPECIAL MATERIALS The materials listed below are needed for maintenance work on the GF 125 and should be kept on hand for ready use These items supplement such standard materials as cleaning fluids lubricants emery cloth and the like How to use them and where to use them are described in the text of this manual Oil seals Wheel bearing Speedometer gear box Steering stem steel balls Brake cam Mounting drum Dust seal cover and spacer GREASE G2 99000 07000 Brake caliper holder SILICONE GREASE 99000 25100 Piston pin Valve stem Rocker arm shaft MOLY PASTE 99000 25140 Mating surfaces of left and right crankcase Front fork damper rod bolt BOND No 1215 99000 31110
46. EMBLY OIL RING Install spacer D into the bottom ring groove first Then install both side rails 2 one on each side of the spacer The spacer and side rails do not have a specific top or bottom when they are new When reassembling used parts install them in their original place and direction TOP RING AND 2ND RING Top ring and 2nd ring differ in the shape of ring face and the face of top ring is chrome plated whereas that of 2nd ring is not The color of 2nd ring appears darker than that of the top one Install expander ring into the 2nd ring groove Top and 2nd rings have the letter R or Y marked on the top Be sure to bring the marked side to the top when fitting them to the piston Position the gaps of the three rings as shown Before inserting piston into the cylinder check that the gaps are so located 9 1 Oil ring 9 2nd 2nd Side rail upper EX Side rail lower Top Spacer PISTON The following are reminders for piston installation Rub a small quantity of HYOSUNG MOLY PASTE onto the piston pin Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase and then fit the piston pin circlip with long nose pliers CAUTION Use a new piston pin circlip to prevent circlip failue which will occur with a bent one When fitting the piston turn arrow mark
47. 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 Initial 800km Below 4 500r min Up to 1 600km Below 5 500r min Over 1 600km Below 10 500r min Keep to these break in engine speed limits Upon reaching an odometer reading of 1 600km you can subject the motorcycle to full throttle operation However do not exceed 10 500r min at any time Do not maintain constant engine speed for an extend ed time period during any portion of the break in Try to vary the throttle position GENERAL INFORMATION 1 2 SPECIAL FEATURES HYOSUNG GF 125 is a improved model that has been revised from 2 valve evgine of GF 125 to 4 valve engine and has much more developed features as follows 1 IMPROVEMENT OF ENGINE POWER AT MIDDLE AND LOW SPEEDS In order to make long distance driving more comfortable and easier which is the best point of American Style the VALVE TIMING multi valve from 2 valve to 4 valve and the proper design of narrower angle VALVE port are done without losing TORQUE at high speeds 2 LESS VIBRATION AND NOISE In order to meet customer s demands for less vibration the VIBRATION with the body is prevented by making the engine strength higher and natural frequency high order AND the previous SYSTEM which prevents vibration transmissibility is get together
48. ING ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION GENERAL INFORMATION CONTENTS SERIAL NUMBER LOCATIONS 8 8 20 FUEL AND OIL RECOMMENDATIONS nennen BREAK IN PROCEDURE teo NR E us 1 1 SDE CIAL FEATURE S IN eL AB SPECIAL MATERIALS sss PRECAUTIONS AND GENERAL INSTRUCTIONS se SPEGIFIGA TIONS e tetto eda Ru D Re putida 1 1 GENERAL INFORMATION SERIAL NUMBER LOCATIONS The frame serial number is stamped on the rear end of the frame The engine serial number is located on the crankcase These numbers are required especially for registering the machine and ordering spare parts FUEL AND OIL RECOMMENDATIONS FUEL Gasoline used should be graded 85 95 octane or higher An unleaded or low lead gasoline type is recommended NOTE Unleaded and low lead gasoline will extend spark plug life ENGINE OIL Be sure that the engine oil you use comes under API Classification of SF or SG and that its vicosity rating is SAE 10W 40 If SAE 10w 40 motor oil is not avaliable select the oil viscosity according to the following chart FRONT FORK OIL TELLUS 22 BREAK IN PROCEDURE During manufacture only the best possible materials are used all machined parts are finished to a very high stan dard but it is still necessary to allow the moving parts to BREAK
49. INSPECTION Turn fuel cock to OFF position Remove the accelerator pump cable D Remove the choke cable Loosen the intake pipe bolts Loosen the clamp screw FUEL AND LUBRICATION SYSTEM 4 4 Loosen the carburetor top and disconnect throttle valve Remove throttle cable from the throttle valve and disconnect throttle cable Disconnect throttle valve spring and carburetor top from the throttle cable Draw out retainer clip and disconnect jet neddle D Inspect the jet needle and wear domage of throttle Separate the intake pipe form the carburetor Remove the carburetor drain screw and draw out in the carburetor WARNING Gasoline is highly explosive Extreme care must be taken 4 5 FUEL AND LUBRICATION SYSTEM Disconnect fuel tube and drain tube ACCELERATOR PUMP Loosen the screws and disconnect pump cover Disconnect spring and diaphragm Inspect the accelerator pump load and damage of diaphragm Clean the diaphragm When installing the diaphragm align the tongue D of the diaphragm with the groove of carburetor body Set up diaphragm and the float chamber Install the spring in the diaphragm and install the cover in the float chamber Adjust the accelerator pump FUEL AND LUBRICATION SYSTEM 4 6 FLOA
50. NDER NUTS EXHAUST PIPE BOLTS AND NUTS Inspect Initial 1 000km and Every 5 000km CYLINDER HEAD NUTS Remove the seat and fuel tank Refer to page 3 2 Remove the cylinder head cover Refer to page 3 7 Tighten the four nuts D and two nuts the specified torque with a torque wrench when engine is cold 25 29 25 29 kg m Tightening torque 6 8 N 06 08 kg m CYLINDER NUTS e Tighten the two 6mm nuts 3 to the specified torque Tightening torque 6 8 N m 0 6 0 8kg m EXHAUST PIPE BOLTS AND MUFFLER CLAMP BOLT Tighten the exhaust pipe bolts and muffler clamp bolt to the specdified torque Tightening torque Exhaust pipe bolts 9 12 Nem and muffler clamp bolt 0 9 1 2 kg m 2 5 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES AIR CLEANER ELEMENT Clean Every 3000km If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power out put and an increase in fuel consumption Check and clean the element in the following manner Remove the left frame cover Remove the screw and take out the cover Separate the polyurethane foam element from the ele ment frame Fill a washing pan of a proper size with nonflammable cleaning solvent Immerse the element in the cleaning solvent and wash it clean Squeeze the cleanin
51. NERY INC Ist Ed Jun 1997 Manual No 99000 94200 Printed in Korea
52. NGINE COMPRESSION PRESSURE AND OIL PRESSURE COMPRESSION PRESSURE NOTE Before inspecting for compression pressure make sure that the cylinder head nuts and bolts are tightend to specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing it O 09915 64510 Compression gauge 09915 74530 Adapter Remove spark plug Fit the compression gauge D and adapter to the plug hole taking care to make the connection abso lutely tight Twist the throttle grip into wide open position Crank the engine several times with the starter motor or kick starter and read the highest gauge indication as the compression of the cylinder Compression pressure Standard Limit 12 15 kg cm 8 kg cm A low compression pressure may indicate any of the fol lowing malfunction Excessively worn cylinder wall Worn piston or piston rings Piston rings stuck in the grooves Poor seating contact of valves Defective cylinder head gasket When the compression pressure noted is down to or below the limit indicated above the engine must be dis assembled inspected and repaired as required to over haul the engine with these five malconditions in mind OIL PRESSURE Install the oil pressure gauge in the position shown in the illustration Warm up the engine as follows Summer approx 10min a
53. ON Remove gear cam stopper spring Draw out gear shifting fork shafts and take off forks Remove clusters of gears and gear shifting cam KICK STARTER SHAFT Remove circlip spring guide and return spring Then pull out the kick starter shaft from the other side 3 35 SERVICING ENGINE CRANKSHAFT Remove crankshaft by using crankcase remover 09920 13111 Crankshaft remover OIL SEAL AND BEARING Remove retainer oil seals and bearings 09913 50121 Oil seal remover LOWER END COMPONENTS INSPECTION AND SERVICING CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the samll end of the rod This method can also check the extent of wear on the parts of the conrod s big end Service limit 3 0mm 09900 20701 Magnetic stand 09900 20606 Dial gauge 1 100mm 09900 21304 V block 100mm 09900 20803 Thickness gauge Push the big end of the conrod to one side and measure its side clearance with a thickness gauge Standard Service limit 0 10 0 45mm 1 00mm Where the limit is exceeded replace crankshaft assembly or reduce the deflection and the side clearance to within the limit by replacing the worn parts conrod big end bear ing crankpin and thrust washers etc Refer to the SER
54. OR Bl Blue G Green R Red W White Y Yellow B R Black with Red tracer BI R Blue with Red tracer R G Red with Green tracer W G White with Green tracer W R White with Red tracer 5 3 ELECTRICAL SYSTEM CDI UNIT Using the pocket Rx 1K range measure the resistance between the lead wires in the following table 09900 25002 Pocket tester Probe of tester R W R G BI R B W B Y B R OFF OFF OFF OFF ON OFF W e e e e OFF R G 99 s 02 40 OFF BI R 59 MPS AS OFF Probe of tester B W Mp vr re ps B Y ON OFF OFF OFF OFF OFF ARES BES APE 8 IGNITION COIL Check the ignition coil with electro tester Test the ignition coil for sparking performance Test connection is as indicated Make sure that the three needle sparking distance is at least 8mm Test it at least for 5 minutes 09900 28106 Electro teste STD Spark performance 8mm Check the ignition coil with pocket tester 09900 25002 Pocket tester WIRE COLOR B Black R Red W White B W Black with White tracer R Y Black with Yellow tracer BI G Blue with Green tracer R G Red with Green tracer IGNITION COIL RESISTANCE Bid B Ground Approx 0 5 1 5 Q Plug cap Grou
55. RANKCASE BEARING Inspect the play of crankcase bearing inner race by hand while fixing it in the case Rotate the inner race by hand to inspect for an abnormal noise and a smooth rotation Replace the bearing if there is something unusual STARTER CLUTCH BEARING Inspect the bearing for any abnormality particularly cracks to decide whether it can reused or should be replaced SERVICING ENGINE 3 40 LOWER END COMPONENTS REASSEMBLY CRANKSHAFT Decide the between the webs referring to the figure When mounting the crankshaft in the crankcase it is below when rebuilding the crankshaft necessary to pull its left end into the crankcase STD width between webs 53 0 0 1mm 09910 32812 Crankcase installer 09910 20116 Conrod holder ELT m noH 53 0 0 1mm 3 41 SERVICING ENGINE CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affect ed TRANSMISSION CAUTION Never reuse a circlip After a 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 cover the shaft After installing a circlip
56. S 2 8 FUEL LINE Inspect Initial 1 000 and Every 5 000km Replace every four years Inspect the fuel line and connections for damage and fuel leakage If any defects are found the fuel line must be replaced FUEL STRAINER Change Initial 1 000km Every 10 000km If the fuel strainer is dirty with sediment fuel will not flow smoothly and loss in engine power may result Clean the strainer cup with non flammable cleaning sol vent ENGINE OIL Change Initial 1 000km Every 5 000km The oil should be changed with the engine hot The procedure is follows Support the motorcycle by center stand Drain the oil by removing the drain plug and filler cap Fit drain plug securely and add fresh oil through the filler The engine will hold about 950ml of oil Use 10W 40 viscosity of oil under API classfication of SF or SG Start up the engine and allow it to run for several seconds at idling speed Turn off the engine and wait about one minute then check the oil level through the inspection window If the level is below mark add oil to that level 2 9 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES ENGINE OIL FILTER Replace Initial 1 000km and Every 5 000km Replace the oil filter in the following manner Drain engine oil by removing the drain plug Remove the three screws securing the filter cap Take off the ca
57. SERVICING INFORMATION Symptom and possible causes Remedy Not enough electrolyte Battery case is cracked Battery has been left in a run down condition for a long time Contaminated electrolyte Foreign matter has enters the battery and become mixed with the electrolyte 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 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 S G The charging method is not correct Cell plates have lost much of their active material as result of over charging A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the high electrolyte S G Electrolyte S G is too low Contaminated electrolyte Battery is too old Check the generator regulator rectifier and circuit connections and make necessary adjustment to obtain Specified charging operation Replace the battery and correct the charging system Replace the battery Recharge the battery fully and adjust electrolyte S G Replace the electrolyte recharge the battery and then adjust 5 0 Replace the battery The battery has been connected the wrong way round in the system So that it is bei
58. T AND NEEDLE VALVE Loosen the screws and remove the float chamber Pull out float arm pin D Remove the float and needle valve Inspect the needle valve and valve seat for wear Inspect the float for transformation JETS Remove the main jet D and needle jet Remove the pilot jet Remove pilot screw after record the revolutions until tighten completely NOTE Do not tighten the pilot screw by force otherwise can be damaged of seat 4 7 FUEL AND LUBRICATION SYSTEM Disconnect throttle stop screw Clean the jets with non flammable cleaning solvent Check following items for damage or clogging Main jet Pilot jet Pilot air screw Needle jet Clean the jets and body passage with compressed air REASSEMBLY AND REMOUNTING Install neddle jet main jet and pilot jet Install throttle stop screw and pilot screw NOTE Install pilot screw as revolutions to a case of disas semble Adjust the pilot screw when use a new pilot screw Install the needle valve D float float arm pin Main jet Pilot jet Pilot screw FLOAT ADJUSTMENT To check the float height invert the carburetor body holding the float arm pin so that the pin will not slip Off Check to be sure that the float moves freely Install the new O ring and floa
59. TE Do not tighten the pilot screw by force otherwise can be damaged of seat Start up the engine and set its speed at any where between 1 400 and 1 500 rpm by turning throttle stop Screw 8 Adjust the engine speed at hight position pilot screw left right turning Repeat again 3 5 Adjust standard engine idle speed by throttle stop Screw amp Look into the change idling revolution with snap light of continuously If the idling revolution is change repeat the LUBRICATION SYSTEM 4 11 FUEL AND LUBRICATION SYSTEM CAMSHAFT JOURNAL AND CAM FACE vd gan ROCKER ARM SHAFT mM vd CAM CHAIN CONROD SMALL END nn t vd gin CYLINDER WALL nn t CLUTCH RELEASE CAM Y DRIVESHAFT BEARING Y DRIVESHAFT AND GEARS vein p CONROD BIG END BEARING A COUNTERSHAFT SORTES BEARING OIL FILTER COUNTERSHAFT AND GEARS BY PASS OIL PUMP A PRIMARY DRIVEN GEAR SPACER SUMP FILTER CLUTCH PLATES A OIL PAN ELECTRICAL SYSTEM CONTENTS IGNITION SYSTEM m n mmm nemen hehehe hehehe tenentes CHARGING SYSTEM mm me n mmm nemen 00 STARTER SYSTEM e e
60. TEM em m n meme nemen hehehe tenente 4 1 FUEL AND LUBRICATION SYSTEM FUEL COCK Gasket DIASSEMBLY Remove the seat and frame covers Refer to page 3 2 e Turn fuel to OFF position and disconnect fuel hose from the fuel cock Place a clean oil pan under the fuel cock assembly turn fuel cock to ON position and drain the fuel WARINING Gasoline is highly explosive Extreme care must be taken Unscrew the fuel cock securing bolts and take off the fuel cock assemble CLEANING Rust from the fuel tank tends to build up in the filter which when the filter has been neglected for a long peri od inhibits the flow of fuel Remove the rust from the filter using compressed air WARINING Gasket must be replaced with a new one to prevent leakage CARBURETOR FUEL AND LUBRICATION SYSTEM 4 2 SPECIFICATIONS ITEM SPECIFICATION ITEM SPECIFICATION Carburetor type PD 18 F Needle jet N J JeTC 3rd Bore size 24mm Pilot jet P J 38 I D No 93 BO By pass B P 29 91 0 909 Idle r min 1450 50 r min Pilot air jet P A 150 Jet needle J N J 29 Valve seat V S 2 0mm Float height 12 5mm Starter jet MAX 500 Main jet M J 100 Pilot screw P S PRE SET 24 Main air jet M AJ 80 4 3 FUEL AND LUBRICATION SYSTEM REMOVAL DISASSEMBLY AND
61. UTION This is a left hand thread nut SERVICING ENGINE 3 32 Remove oil pump driven gear then remove primary drive gear and key OIL PUMP Remove oil pump mounting screws and take off oil pump body GEAR SHIFTER To remove cam driven gear first remove gear shifting shaft and loosen pawl lifter and cam guide screws D with an impact driver NOTE When removing cam driven gear do not lose gear shifting pawl 2 pin and spring KICK STARTER DRIVE GEAR AND IDLE GEAR Remove kick starter drive gear and kick starter idle gear 09900 06107 Snap ring pliers 3 33 SERVICING ENGINE LOW END COMPONENTS DISASSEMBLY CRANK CASE Remove sump filter cap and neutral cam stopper Remove sump filter Remove crankcase securing bolts Separte the crankcase into 2 parts right and left with crankcase separating tool 09920 13120 Crankcase separating tool Fit the crankcase separating tool so that the tool plate is parallel with the end face of the crankcase CAUTION The crankshaft and transmission compo nents must remain in the left crankcase half This is necessary because the gear shifting cam stopper is mounted on the left crankcase half and will be damaged if the transmission components remain in the right half SERVICING ENGINE 3 34 TRANSMISSI
62. ctrolyte to value specified After charging adjust the electrolyte level to the UPPER LEVEL with DISTILLED WATER Months after Within Within Within Over manufacturing 6 9 12 12 Necessary charging hours 20 30 40 60 Battery Breather pipe ELECTRICAL SYSTEM 5 16 Servicing Visually inspect the surface of the battery container If any signs of cracking or electrolyte or electolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery terminals are found to be coated with rust or an acidic white powdery substance then this can be cleaned away with sandpaper Check the electrolyte level and add distiled water as necessary to raise the electrolyte to each cells upper level Check the battery for proper charge by taking an electrolyte S G reading If the reading is 1 22 or less as corrected to 20 C 68 F it means that the battery is still in a run down con dition and needs recharging NOTE First remove the lead wire BASED ON S G READING RECHARGING OPERATION 30 To correct an S G reading 20 C 68 F use following table To read the S G on the hydrometer bring the electrolyte Recharge in the hydrometer to eye level and read the graduations on the float scale bordering on the meniscus curved up Specific gravity portion of electrolyte surface as shown in figure C 0 5 0 5
63. dence of air leakage TIRE PRESSURE COLD INFLATION NORMAL RIDING TIRE PRESSURE SOLO RIDING DULE RIDING kpa kg kpa kg cri FRONT 175 1 75 175 1 75 REAR 200 2 00 225 2 25 2 15 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES STEERING Inspect Initial 1 000km and Every 5 000km Steering stem bearings should be adjusted properly for smooth turning of the handlebars and safe running Steering which is too stiff prevents smooth movement of handlebars Steering which is too loose will cause vibration and dam age to the steering bearings Check to see that there is no play in the front fork attachment If the play is found perform steering bearing adjustment as described in pages 6 18 and 6 19 of this manual Tightening torque ITEM k m D Fork bolt 1 8 2 8 Steering stem head bolt 3 5 5 5 Front fork upper bolt 3 5 5 5 7 Front fork lower clamp bolt 2 5 3 5 FRONT FORK OIL Change Initial 1 000km and Every 10 000km Remove the front fork Refer to 6 6 Drain the fork oil Refer to 6 7 Pour specified amount of oil from the top of the inner tube Specified amonut for each leg 175ml Specification TELLUS 22 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 16 CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS Inspect Initial 1 000km and Every 5 000km
64. e order of disassembly and removal and also carry out the following steps INNER RACES Press in the upper and lower inner races using the spe cial tool 09941 34513 Steering race installer STEEL BALL Apply grease to the upper and lower inner races when installing the steel balls 99000 07000 Grease 02 Upper 22 Number of balls Bee Lower 18 pcs OUTER RACE Install the outer race to the steering stem by using the special tool j 09941 74910 Steering bearing installer ee STEERING STEM NUT Tighten the steering stem nut to 40 50 N m 4 0 5 0kg m by using the special tool 09940 14911 Steering nut socket wrench 6 19 CHASSIS Turn the steering stem right and left lock to lock five or six times to seat the steel ball bearings Turn back the stem nut by 1 4 1 2 turn NOTE This adjustment will vary from motorcycle to motorcycle Tighten the steering stem head bolt with specified torque Tightening torque 35 55N m 3 5 5 5kg m CAUTION After performing the adjustment and installing the steering stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly Finally check to be sure that the steering stem moves freely from left to right with its own
65. e specifications IN and EX 0 10 0 13mm if clearance is off the specification bring it into the Specified range by using the special tool 09917 14910 Valve adjust driver Reinstall spark plug cylinder head cover valve timing inspection plug and magneto cover cap NOTE Valve clearance is to be checked when the engine is cold Both the intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compression stroke COMPRESSION PRESSURE Inspect Initial 1 000km and Every 5 000km Refer to page 3 1 2 7 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES SPARK PLUG Inspect Initial 1 000km and 5 000km Replace Every 10 000km Remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0 7 0 8mm measuring with a thickness gauge When removing carbon deposits be sure to ovserve the appearance of the plug noting the color of the carbon deposits The color observed indicates whether the stan dard plug is suitable or not If the standard plug is apt to get wet a hotter plug should be used If the standard plug is apt to overheat porcelain is whitish in appear ance replace with a colder one TYPE SPARK PLUG SPECIFICATION Hot type GOLDEN C7EA 9 Standard GOLDEN C8EA 9 Cold type GOLDEN C9EA 9 PERIODIC MAINTENANCE AND TUNE UP PROCEDURE
66. e valve stem seal installer CAUTION Do not reuse the oil seals 09916 44910 Valve guide installer and stem seal installer 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 Valve seat width STD 0 0 9 1 1mm If either requirement is not met correct the seat by ser vicing it as follows VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are angled to present two bevels 15 and 45 09916 21110 Valve seat cutter set Use only for 15 of intake side 09916 24910 15 x 75 cutter N 212 09916 24480 Solid pilot N 140 5 5 NOTE The valve seat contact area must be inspected after each cut Valve seat 1 Insert with a slight rotation the solid pilot that gives a snug fit The shoulder on the pilot should be about 10 mm from the valve guide 2 Using the 45 cutter descale and cleanup the seat wit
67. el bearing by using the special tool NOTE First install wheel bearing for right side 09913 80112 Bearing installer MOUNTING DRUM Insert the bearing with retainer by using the special tool 09913 80112 Bearing installer SPROCKET After tightening the four nuts to specification bend the washers lock tabs Tightening torque 18 28N m 1 8 2 8kg m BRAKE CAM Apply grease to the brake cam 99000 07000 Grease Ce WARNING Be careful not to apply too much grease to the brake cam If grease gets on the lining brake slippage will result BRAKE CAM LEVER Install the brake cam lever and tighten the cam lever nut with specified torque CHASSIS 6 36 Tightening torque 5 8 N m 0 5 0 8kg m Apply grease to the mounting drum as shown 99000 07000 Grease G2 6 37 CHASSIS REAR SWING ARM Se Tightening torque Item kg m 50 80 5 0 8 0 10 15 1 0 1 5 REMOVAL AND DISASSEMBLY Remove the rear wheel See page 6 29 Remove the two bolts and take off the chain case CHASSIS 6 38 Remove the rear shock absorber nuts and take off the shock absorber units Remove the swing arm pivot nut and draw out the shaft Remove the swing arm Pull o
68. emove the three allen bolts using the 5mm L type hexagon wrench 09900 00401 L type hexagon 5mm GEAR POSITION SWITCH Remove the gear position indicator switch by removing the screws NOTE When removing gear position switch do not lose the O ring switch contact and spring ENGINE SPROCKET Remove the drive chain Refer to page 3 4 Flatten the lock washer then remove the sprocket nut by using the special tool 09930 40113 Rotor and sprocket holder RIGHT ENGINE DISASSEMBLY CLUTCH Remove the kick starter by removing bolt Remove the kick starter lever stopper by removing bolts SERVICING ENGINE 3 30 3 31 SERVICING ENGINE Remove clutch cover bolts and oil filter cap bolts and detach clutch cover by tapping with a plastic hammer Remove clutch spring mounting bolts diagonally while holding the primary driven gear and remove clutch pressure plate After removal of clutch drive and driven plates flatten the lock washer and remove the clutch sleeve hub by using the special tool 09920 53710 Clutch sleeve hub holder Take off the sleeve hub with the primary driven gear ass y OIL PUMP DRIVE GEAR DRIVEN GEAR AND PRIMARY DRIVE GEAR Flatten the lock washer then remove the nut lock washer and oil pump drive gear 09910 20116 Conrod holder CA
69. fork oil Replace Remove excess oil ot enough fork oil Loose nuts on suspension Refill Retighten Distorted wheel rim Worn down rear wheel bearings Defective or incorrect tire Loose nut on axle Worn swing arm bushing Loosen nuts on the rear shock Weakened springs Rear suspension adjuster improperly set Reti Rep Reti Replace Adjust Rear suspension adjuster improperly set Worn swing arm bushings Adjust Replace Loose nuts on suspension Worn swing arm bushing 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 Linings worn down Replace Insufficient brake 1 Leakage of brake fluid from hydraulic system Repair or replace power 2 Worn pads Replace 3 Oil adhesion on engaging surface of pads Clean disc and pads 4 Worn disc Replace 5 Air in hydraulic system Bleed air Brake squeaking 1 Carbon adhesion on pad surface Repair surface with sandpaper 2 Tilted pad Modify pad fitting 3 Damaged wheel bearing Replace 4 Loose front wheel axle or rear wheel axle Tighten to specified torque
70. g solvent out of the washed ele ment by pressing it between the palms of both hands Immerse the element in motor oil and squeeze the oil out of the element leaving it slightly wet with oil NOTE Do not twist or wring the element because it will tear or the individ ual cells of the element will be damaged CAUTION Inspect the element carefully for rips tom seams etc If any dam age is noted replace the element Non flammable cleaning solvent Motor oil ee PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 6 VALVE CLEARANCE Inspect Initial 1 000km and Every 5 000km Excessive valve clearance results in valve noise and insuf ficient valve clearance results in valve damage and reduced power At the distances indicated above check and adjust the clearance to the following specification The procedure for adjusting the valve clearance is as fol lows Remove spark plug cylinder head cover D and valve timing inspection plug Remove the magneto cover cap and rotate the mag neto rotor with the 14mm box wrench to set the piston at TDC of the compression stroke Rotate the rotor until the T line on the rotor is aligned with the center of hole on the crankcase Insert the thickness gauge to the valve stem end and the adjusting screw on the rocker arm 09900 20803 Thickness gauge Valve cleranc
71. gauge 17 09913 50121 Oil seal remover 18 09913 75820 Bearing installer 19 09913 80112 Bearing installer 20 09915 63310 Compression pressure adapter 21 09915 64510 Compression gauge 22 09915 74510 Oil pressure gauge 23 09916 14510 Valve spring compressor 24 09916H35C00 Attachment 25 09916 21110 Valve spring cutter set 26 09916 24480 Solid pilot N 140 5 5 21 09916 24910 Valve seat cutter 15 x 75 28 09916 34541 Reamer handle 29 09916 37571 5mm reamer 30 09916H34575 10 5mm reamer 31 09916 44910 Valve guide installer and remover 32 09916 44920 Valve guide installer attachment 33 09916 84510 Tweezers 34 09920 13111 Crankcase separating tool crankshaft remover 35 09920 13120 Crankcase separating tool crankshaft remover 36 09920 53710 Clutch sleeve hub holder 37 09923 73210 Bearing puller 7 9 SERVICING INFORMATION ITEM PART No PART NAME 38 09924 84510 Bearing installer set 39 09930 30102 Rotor remover slide shaft 40 09930 30162 Rotor remover 41 09930 40113 Rotor and sprocket holder 42 09930 44511 Rotor holder 43 09940 14911 Steering stem nut socket wrench 44 09940 50112 Fork oil seal installer 45 09941 34513 Steering race installer 46 09941 74910 Steering bearing installer 47 09943 74111 Fork oil level gauge SERVICING INFORMATION 7 10 7 11 SERVICING INFORMATION
72. h leg 175ml Brake fluid type TIRE PRESSURE COLD INFLATION TIRE PRESSURE SAE JI703 DOT OR DOT 4 NORMAL RIDING SOLO RIDING DUAL RIDING ke cai FRONT 1 75 REAR 2 25 SERVICING INFORMATION 7 20 WIRE AND CABLE ROUTING i 9 eAreN aM D W 7 21 SERVICING INFORMATION WIRING DIAGRAM 1530 01 J Yg UM M enq wor qs eng 1 oi NUI DIS L Je9en SHUM UM Je9en peu UM SHUM M Si JY USAID MM MOAPA OA SHUM WIM pu uo 9 ENT 271 19W00 UM MOA WWM emo 0 Jug ONISSVd Je9en eng YUM AUM IM MOJO 61 yorig g amp EN QV3H JHM 2 dWYT NOLLWNINATI WNOISNYNL 4313W0033dS 1 ONIAING WS 18088 Wn Ap eS unl WS WS Bussed 8 EJ 8 2 wow 085 H 8 4 m X 2005 L LLLI M Z Jde pear M EEEE EE Ee Ebr dE 3 1 4 40 ee x MOL 685 34 NOIL ee 7p 5 E2 Na 0 il 31 an mo Prepared by HYOSUNG MOTORS amp MACHI
73. h 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 SERVICING ENGINE 3 16 CAUTION Cut the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area If the contact area is too high or too wide use the 15 cutter to lower and narrow the contact area 4 After the desired seat position and width is achieved use he 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 that could prevent the valve from sealing WARNING Always use extreme caution when handling gasoline NOTE Be sure to adjust the valve clearance after reassem
74. he cap and diaphragm Drain brake fluid Remove the dust seal boot Remove the circlip by using the special tool 09900 06018 Snap ring pliers Remove the piston primary cup and spring INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston and cup surface for scratches or other damage Inspect the dust seal boot for wear or damage REASSEMBLY Reassemble and remount the master cylinder in the reverse orders of disassembly and removal and also carry out the following steps CHASSIS 6 28 CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all internal parts before inserting into the bore When remounting the master cylinder to the handle bars first tighten the clamp bolts for upside as shown Tightening torque 5 8N m 0 5 0 8kg m WARING Bleed air from the brake fluid circuit after reassembling master cylinder See page 2 13 Master oylinder Handle bar 6 29 CHASSIS REAR WHEEL AND REAR BRAKE Tightening torque Item N m kg m 9 50 80 5 8 5 8 0 5 0 8 18 28 1 8 2 8 REMOVAL AND DISASSEMBLY Support the machine by the center stand Remove the rea
75. ication Specification DOT3 DOT4 and Classification or SAE J1703 WARNING The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as sil cone based and petroleum based fluid for refilling the system other wise serious damage will be caused Do not use any brake fluid taken from old or used unsealed containers Never re use the breke fluid left over from the last servicing and stored for long periods WARNING Brake fluid if it leaks will interfere with safe running and immediate ly discolor painted surfaces Check the brake hoses for cracks and hose joint for leakage before riding Brake pads Wearing condition of brake pads can be checked by observing the red limit line D marked on the pad When the wear exceeds the limit line replace the pads with new ones refer to page 6 22 Brake light switch Replace the brake light switch with new one when brake light does not come on just before a pressure is felt when the brake lever is squeezed 2 13 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full brak ing performance of the caliper brake The presence of air is indicated by sponginess of the brake leve
76. ion pay attention to the safety of each other After the reassembly check parts for tightening condition and operation Treat gasoline which is extremely flammable and highly explosive with greatest care Never use gasoline as cleaning sol vent Warning caution and note are included in this manual occasionally describing the following contents WARNING Personal safety of the rider is involved and disregard of the information could result in injury CAUTION sesasssnsssssess For the protection of the motorcycle the instruction or rule must be strictly adhered to NOTE Advice calculated to facilitate the repair of the motorcycle is given under this heading USE OF GENUINE HYOSUNG PARTS To replace any part of the machine use a genuine HYOSUNG replacement part Imitation parts or parts sup plied from any other source than HYOSUNG if used to replace HYOSUNG parts can reduce the machine s per formance and even worse could induce costly mechani cal troubles 1 9 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length emm een 1 968mm Overall Wiata eseis nnne 763mm Overall height eee eee enn 1 073mm Wheel eee nnn nennen 1 292mm Ground clearance gt lt 195mm Dry mass eme eee eene 125kg ENGINE
77. ion of gear shifting fork is incorrect If this is the case disassemble and trace the mistake PRIMARY DRIVE GEAR AND OIL PUMP Fit key in the solt on the crankshaft and install the primary drive gear Before mounting the oil pump apply engine oil to the sliding surfaces of the case outer rotor inner rotor and shaft Apply samil quantity of THREAD LOCK 1342 to the threaded parts of oil pump mounting screws 99000 32050 Thread lock 1342 Tightening the oil pump mounting screws NOTE After mounting the oil pump in the crankcase rotate the pump gear by hand to see if it turns smoothy After checking the oil pump install the oil pump drive gear lock washer and nut tighten it with a torque wrench to the specified torque and bend up to the washer 09910 20116 Conrod holder NOTE This is a left hand thread nut Tightening torque 40 60N m 4 0 6 0kg m SERVICING ENGINE 3 48 3 49 SERVICING ENGINE CLUTCH Install the clutch camshaft by positioning the face to right side Install the oil seal by using 17mm socket Tighten the oil seal retainer screw Assemble the clutch in the reverse order of disassembly Pay attention to the following points When inserting spacer on countershaft apply a small quantity of engine oil to both inside and outside of the spacer
78. meme nemen nennen hehehe tenente tenens SPEEDOMETER ASSY LICHTS SUIT CHES EE Cuz 5 1 ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the capacitor discharged ignition system the electrical energy generated by the magento charges the capacitor This ener gy is released in a single surge at the specified ignition timing point and current flows through the pirmary side of the igni tion coil A high voltage current is induced in the secondary windings of the ignition coil resulting in strong spark between the spark plug gap MAGNETO C D I UNIT Green E Spark plug 77 CDI UNIT Ignition coil 4 77m A Yellow p Regulator Rectifier HI IGNITION COIL V INSPECTION MAGNETO Using the pocket tester measure the resistance between the lead wires in the following table ELECTRICAL SYSTEM 5 2 Pick up coil GW pas Approx 90 120 2 Power source R B HANKUK Approx 300 400 2 Power source Il R B PUNG SUNG Approx 400 600 2 Y Y Approx 0 5 1 5 9 09900 25002 Pocket tester NOTE When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1342 to the thereaded parts of screws 09900 32050 Thread Lock 1342 WIRE COL
79. n points and of regulator becomes high according and when it reaches the adjusted voltage of control unit control unit becomes ON condition consequently On the ON condition of 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 AC generator again At the end of this state since the AC current generated from AC generator flows into the point B reverse current tends to flow to SCR then the circuit of SCR turns to OFF mode and begins to charge the bat tery again Thus these repetitions maintain charging voltage to the battery constant and protect it from overcharging i Ig switch e e f o 3 e i Z e 2 9 T Battery o e scr Y scr Y Scr E 8 I Control g unit generator A f 9 9 e 5 9 T aad de dno Regulator rectifier 5 7 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5000r min Using the pocket tester measure the DC voltage between the battery terminal and If the tester reads under 13 5V or over 16 0V check the AC generator no load performance a
80. nd Secondary Approx 4 7 5 57 K SPARK PLUG Clean the plug with a wire brush and pin Use the pin to remove carbon taking care not to damage the porcelain Check the gap with a thickness gauge ELECTRICAL SYSTEM 5 4 e 09900 20804 Thickness gauge Spark plug gap 0 7 0 8mm 0 7 0 8mm 5 5 ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in figure which is composed of an AC generator regulator rectifier unit and battery The AC current generated from AC generator is converted by rectifier and is turned into DC current then it charges the bat tery Ig switch qu i i e e 2 e Battery SCR Y SCR SCR gt F Control 5 AC generator unit e e e e Regulator rectifier Function of regulator While the engine r min is low and the generated voltage of AC generator is lower than the adjusted voltage of regulator the regulator does not function incidentally the generated current charges the battery directly Ig switch So N 4 LAOD Control unit te A C generator Regulator rectifier ELECTRICAL SYSTEM 5 6 when the engine r min become higher the generated voltage of AC generator also becomes higher and the voltage betwee
81. nd while fixing it in the wheel hub Rotate the inner race by hand to inspect whether abnor mal noise occurs or rotating smoothy Replace the bearing if there is something unusual 6 3 CHASSIS AXLE SHAFT Using the special tools check the axle shaft for runout and replace it if the runout exceeds the limit 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand 09900 21304 V block 100mm Service 0 25mm WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown NOTE Worn or loose wheel bearings must be replaced before attempting to true a wheel rim 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand Service limit 20 Axial and Radial DM TIRE See page 2 14 OIL SEAL Inspect the lip of the oil seal for damage CHASSIS 6 4 REASSEMBLY Reassemble and remount the front wheel in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the bearing before installing 99000 07000 Grease C2 Install the wheel bearings by using the special tool 09913 75820 Bearing installer BRAKE DISC Make sure that the brake disc is clean and free of any grease matter After securing it in place by tightening its bolts be sure t
82. nd prime Replace Check with insection window drain out excess oil Replace Replace Replace Replace Replace Replace 7 3 SERVICING INFORMATION Symptom and possible causes Loss of valve clearance Weakened valve springs Valve timing out of adjustment Worn piston ring or cylinder Poor seating of valves Fouled spark plug Worn rocker arms or its shafts Spark plug gap incorrect Clogged jets in carburetor Float chamber fuel level out of adjustment Clogged air cleaner element Too much engine oil Suck air intake pipe Adjust Replace Adjust Replace Repair Clean or replace Replace Adjust or replace Clean Adjust Clean Drain out excess oil Retighten or replace Heavy carbon deposit on piston crown Not enough oil the engine Defective oil pump or clogged oil circuit Fuel level too low in float chamber Air leak from intake pipe Use of incorrect engine oil Defective oil cooler Clean Add oil Repair or clean Adjust Retighten or replace Change CARBURETOR Complaint Symptom and possible causes Remedy Trouble with 1 Starter jet is clogged Clean starting 2 Starter pipe is clogged Clean 3 Air leaking from a joint between starter body and carburetor Check starter body and carburetor for tighte ness adjust
83. nd regulator rectifier NOTE When making this test be sure that the battery is full charged condition STD charging output 13 0V 16 0V at 5 000r min 09900 25002 Pocket tester AC GENERATOR NO LOAD PERFORMANCE Disconnect the three lead wires from the AC generator terminal Start the engine and keep it running at 5000 r min Using the pocket tester measure the AC voltage between the three lead wires If the tester reads under 70V the AC generator is faulty IG switch Cay 2207 Regulator Rectifier zu Battery STD No load performance More than 7OV AC at 5000r min REGULATOR RECTIFIER Using the pocket tester x 14 range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regula tor rectifier ELECTRICAL SYSTEM 5 8 09900 25002 Pocket tester Unit Q Probe of tester R WB WR Y B W ZIR OFF OFF OFF OFF 5 wel 7 8 OFF OFF OFF WR 78 OFF OFF OFF y 78 OFF OFF OFF Few 3555 78 78 78 5 9 ELECTRICAL SYSTEM STARTER SYSTEM DESCRIPTION he starter system in shown in the diagram below namely the starter motor relay IG switch starter button and battery Depressing the starter button on the right handlebar
84. ng charged in the reverse direction Replace the battery and be sure to connect the battery properly 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 griavity too high or too low 3 The battery left usused for too long in cold climate Rep he battery Keep the electrolyte up to the prescribed level or adjust the S G by consulting the battery maker s directions Replace the battery if badly sulfated 1 Dirty container top and sides 2 Impurities in the electrolyte or electrolyte S G is too high Clean Charge the electrolyte by consulting the battery maker s directions CHASSIS Symptom and possible causes SERVICING INFORMATION 7 6 Steering stem nut overtightened Worn bearing or race in steering stem Distorted steering stem Not enough pressure in tires Adjust Replace Replace Adjust Loss of balance between right and left front suspensions Distorted front fork Distorted front axle or crooked tire Replace Repair or replace Replace Distorted wheel rim Worn down front wheel bearings Defective of incorrect tire Loose nut on axle Replace Replace Replace Retighten Weakened springs ot enough fork oil Rep Refill Fork oil too viscous Too much
85. ng that the length D will not be reduced to less than 3 8mm If this length becomes less than 3 8mm the valve must be replaced After installing a valve whose stem end has been ground off as above check to ensure that the face 2 of the valve stem end is above the cotters 3 VALVE GUIDE INSTALLATION Re finish the valve guide holes in cylinder head with a 10 5mm reamer and handle SERVICING ENGINE 3 14 09916H34575 10 5mm reamer 09916 34541 Handle 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 8 and valve guide installer attachment 4 Valve guide installer 09916 44910 Valve guide installer 09916 44920 Attachment After fitting all valve guides re finish their guiding bores will a 5 0mm reamer and handle Be sure to clean and oil the guides after reaming 09916 34571 5 0mm reamer 09916 34541 Reamer handle Install valve spring lower seat Be careful not to confuse the lower seat with the spring retainer 8 3 15 SERVICING ENGINE Lubricate each seal and drive them into position with th
86. nts are necessary The engine can be mounted in the reverse order of removal e Throttle cable Page 2 10 Temporarily fasten the engine mounting spacer before Clutch cable Page 2 10 inserting the engine mounting bolts Drive chain Page 2 11 Rear brake pedal Page 2 14 Idling speed Page 2 10 NOTE The engine mounting nuts are self lock nuts Once the nut has been removed it is no longer of any use Be sure to use new nuts and tighten them to the specified torque Tightening torque for engine mounting bolts 80 95N m 8 0 9 5kg m SIHEN m 37 498 m Tightening the exhaust pipe bolts and muffler mounting bolt to specified torque Tightening Torque 9 12N m 0 9 1 2kg m Pour 1300ml of engine oil SAE 10W 40 graded SF or SG into the engine after overhauling engine Start up the engine and allow it run for several sec onds at idle speed About one minute after stopping enine check oil level If the level is below the F mark add oil until the level reaches the Installing position for clutch release arm Align the release arm slit surface with the notch mark on the release cam shaft 3 7 SERVICING ENGINE UPPER END COMPONENTS DISASSEMBLY CYLINDER HEAD COVER CAMSHAFT Bring the piston to top dead center NOTE When removing cylinder head cover piston must be at top dead center on compression s
87. o lock with specified torque Tightening torque 15 25N m 1 5 2 5kg m NOTE Always use new lock washers Bend the washers to the bolts 6 5 CHASSIS SPEEDOMETER GEAR BOX Before installing the speedometer gear box grease it and align groove D on the wheel hub with two drive on the speedometer gear box 99000 07000 Grease Ce FRONT FORK Tightening torque Item N m kg m 18 28 1 8 2 8 20 26 2 0 2 6 CHASSIS 6 6 REMOVAL AND DISASSEMBLY Removal the front wheel See page 6 1 Remove the two bolts and take off the front caliper Remove the four bolts and take off the front fender Remove the two upper clamp bolts by using the 6 mm hexagon wrench 09900 00401 type hexagon wrench 6mm Loosen the front fork lower clamp bolts 6 7 CHASSIS Pull down right and left front forks Loosen the fork bolt Draw out the spacer and fork spring Invert the fork and stroke it several times to remove the oil Hold the fork inverted for a few minutes Remove damper rod bolt by using the special tools and 8mm hexagon wrench CHASSIS 6 8 09900 00401 L type hexagon wrench 6mm Remove the oil lock piece and damper rod with rebound spring
88. on the head The coil pitch is vary the pitch decreases from top to bottom as shown in the illustration Fit valve spring retainer compress spring with a valve lifter and insert cotters CYLINDER HEAD Fit dowel pins D to cylinder head and then attach new gasket to cylinder head Retainer Towards 1 TE Lower seat CAUTION Use a new cylinder head gasket to prevent oil leakage Do not use the old gasket Fit the cylinder head Tighten the cylinder base nuts D e Tighten the cylinder head base nuts Cylinder base nuts 80ke tightening Torque 60 80kg NOTE When mounting the cylinder after attaching camshaft drive chain keep the camshaft drive chain taut The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated SERVICING ENGINE 3 24 CAMSHAFT Align the mark on magneto rotor with the index mark on the crankcase keeping the camshaft drive chain pulled upward CAUTION If crankshaft is turned without drawing the camshaft drive chain upward the chain will be caught between crankcase and cam chain drive sprocket Install the key 2 cam sprocket and center bolt tighten it with a torque wrench to the specified torque NOTE This is a left hand thread bolt Tightening torque 250 30
89. once a month at least Hydrometer 4 f 3 4 4 H H H d Specific gravity at 20 C 6 8 10 1 2 4 L LLLI PT NET I 2 14 16 18 Charging time hour WARNING Before charging a battery remove the seal cap from each cell Keep fire and sparks away from a battery being charged When removing a battery from the motorcycle be sure to remove the terminal first CHASSIS CONTENTS FROM eoo DE PEAN STEI deut alee REAR WHEEL AND REAR BRAKE ettet REAR SWING ARM ee AH HH III 6 1 CHASSIS FRONT WHEEL Tightening torque Item kg m 36 52 3 6 5 2 9 15 25 1 5 2 5 REMOVAL AND DISASSEMBLY Support the machine by the center stand and jack or block Pull out the cotter pin and remove the axle nut Draw out the axle shaft and take off the front wheel CHASSIS 6 2 NOTE Do not operate the front brake lever while dismounting the front wheel Unlock the washers and remove the four bolts Separate the disc plate from the wheel CAUTION Do not reuse the lock washers Using the appropriate drift drive out the wheel bear ings INSPECTION WHEEL BEARING Inspect the play of wheel bearings inner race by ha
90. oo low hard to start 1 Valve clearance out of adjustment Adjust 2 Worn valve guides or poor seating of valves Repair or replace 3 Valves mistiming Adjust 4 Piston rings excessively worn Replace 5 Worn down cylinder bore Replace or rebore 6 Poor seating of spark plug Retighten 7 Starte motor cranks but too slowly Consult electrical complaints Plug not sparking 1 Fouled spark plug Clean or replace 2 Wet spark plug Clean and dry 3 Defective pick up coil Replace 4 Defective CDI unit Replace 5 Defective ignition coil Replace 6 Open or short circuit in high tension cord Replace 7 Open or short circuit of stator coil No fuel reaching the carburetor 1 Clogged hole in the fuel tank cap Clean 2 Clogged or defective fuel cock Clean or replace 3 Defective carburetor float valve Replace 4 Clogged fuel pipe Clean or replace Engine stalls 1 Foulded spark plug Clean easily 2 Defective pick up coil Replace 3 Defective C D I unit Replace 4 Clogged fuel pipe Clean 5 Clogged jets in carburetor Clean 6 Valve clearance out of adjustment Adjust Noisy engine Excessive valve chatter 1 Valve clearance too large Adjust 2 Weakened or broken valve springs Replace 3 Worn down rocker arm or rocker arm shaft Replace Noise appears to come from piston 1 Piston or cylinder worn down Replace 2 Combustion chamber fouled with carbon Clean 3 Piston pin or piston pin bore worn Replace 4
91. p and pull out the filter T Replace the filter with a new one Before installing on the filter check to be sure that the O ring in properly installed Before putting on the filter cap check to be sure that the filter spring and the O ring are installed correctly Install the filter cap and tighten the screws securely Pour in engine oil and check the level NOTE Pour about 950ml of engine oil into the engine only when changing oil and replacing oil filter at the same time When performing engine overhaul the amount of oil to be replen ished is 1300ml CAUTION When reassembling the oil filler make sure to check the oil filter installed as shown in illustration If the filter is installed improperly serious engine damage may result OIL PRESSURE Inspect Every 5 000km Refer to page 3 1 OIL SUMP FILTER Clean Every 10 000km Clean the sump filter screen to remove any foreign mat ter that may be collected there Inspect the screen to insure that it is free of any sign of damage PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 10 CARBURETOR Inspect Initial 1 000km and Every 5 000km IDLING ADJUSTMENT NOTE Make this adjustment when the engine is hot Start up the engine and set its speed at anywhere between 1400 and 1500r min by turning throttle stop screw Engine idle speed 14503
92. r 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 manner Fill up the master cylinder reservoir to the HIGH level line Replace the reservoir cap to prevent entry of dirt Attach a pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle Bleeder valve 6 9 tightening torque 0 6 0 9 kg m Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a trun so that the brake fluid runs into the receptacle this will remove the tension of te brake lever causing it to touch the handlebar grip Then close the valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bub bles NOTE Replenish the brake fluid reservoir as necessary while bleeding the brake system Make sure that there is always some fluid visible in the reservoir Close the bleeder valve and disconnect the pipe Fill the reservoir to the HIGH level line CAUTION Handle the brake fluid with care the fluid reacts chemically with paint plastics
93. r brake adjuster nut and disconnect the brake rod Pull out the cotter pin and remove the torque link nut and bolt CHASSIS 6 30 Remove the rear axle nut Loosen the chain adjuster lock nut and adjuster bolt right and left Remove the drive chain See page 3 4 Draw out the axle shaft and take off the rear wheel Separate the brake panel from the wheel Flatten the washers and remove the four nuts Take off the rear sprocket and mounting drum 6 31 CHASSIS Remove the oil seal Remove the bearing with retainer from the mounting drum Remove the cushion from the wheel Remove the right and left side wheel bearings from the wheel NOTE Remove the left side bearing first makes the job easier CHASSIS 6 32 Take off the brake shoes Remove the cam lever nut and bolt Pull off the brake cam shaft waaher O ring and cam lever INSPECTION WHEEL BEARING Play Inspect the wheel bearing for paly by hand 6 33 CHASSIS Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly Replace the bearing if there are any defects AXLE SHAFT Using the special tools check the axle shaft for runout exceeds the limit 09900 20606 Dial gauge 1 100 09900 20701 Magnetic
94. rnal appearance and configura tion Carefully examine the illustration for correct installing positions and directions After cam stopper and gear shifting forks have been fitted hook cam stopper spring into the crankcase KICK STARTER 3 45 SERVICING ENGINE When fitting the kick starter to the shaft be sure to align the punched marks Fit spring and washer on the shaft Then insert the kick starter shaft into crankcase Engage pawl D of kick starter guide When fitting kick return spring hook part D of return spring into crankcase turn it 1 2 a turn clockwise with pliers and fit part of return spring into hole of kick shaft Then fit spring guide and circlip CRANKCASE When reassembling the crankcase pay attention to the following Coat GREASE G 99000 07000 to the lip of oil seals Remove sealant material on the fitting surface of right and left halves of crankcase and thoroughly remove oil stains Fit dowel pins on the left half Apply engine oil to the big end of the crankshaft con rod and all parts of the transmission gears Apply THREE BOND No 1215 99000 31110 uniformly to the fitting surface of the left half of the crankcase and after waiting a few minutes fit the right half on the left half After the crankcase bolts have been tightened check if driveshaft and countershaft rotate smoothly
95. rosene If the chain tends to rust faster the interval must be stortened After washing and drying the chain lubricate it with chain lube or gear oil SAE 90 CHECKING Loosen axle nut Tense the drive chain fully to screw in the chain adjuster lock nuts 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 259 4 mm ADJUSTING Loosen both chain adjuster lock nuts until the chain has 15 25mm 0 6 1 0in of slack at the middle between engine and rear sprockets The mark on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctry aligned Drive chain slack 25 35 mm After adjusting the drive chain tighten the axle nut D securery 50 80 50 80 kg m PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 12 BRAKES Inspect Initial 1 000km and Every 5 000km Replace the hoses Every four years Change fluid hoses Every two years FRONT BRAKE Brake fluid level Support the motorcycle body on the center stand and place the handlebars straight Check the brake fluid level by observing the lower limit line on the brake fluid reservoir When the level is below the lower limit line replenish with brake fluid that meets the following specif
96. se amp A B D C T D C Exhaust close AT D C Exhaust open B B D C B D C Valve timing diagram CAMSHAFT CAM WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts if found it worn down to the limit SERVICING ENGINE 3 12 09900 20202 25 50mm Cam height height amp Service Intake cam 34 18mm Exhaust cam 33 55mm CYLINDER HEAD DISTORTION Decarbon combustion chamber Check the gasketed surface of the cylinder head for dis tortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Service limit 0 05mm VALVE FACE WEAR Measure the thickness D and if the thickness is found to have been reduced to the limit replace the valve NOTE Visually inspect each valve for wear of its seating face Replace any valve with an abnormally worn face Service limit 0 5mm VALVE STEM RUNOUT Support the valve with V blocks as shown and check its runout with a dial gauge The valve must be replaced if the runout exceeds the limit
97. shift shaft Shift shafts are rubbing or sticky Distorted or worn gearshift forks Rep Repai Rep Worn shifting gears on driveshaft or countershaft Distorted or worn gearshift forks Weakened stopper pawl spring on gearshift cam Worn gearshift pawl Engine idles poorly Valve clearance out of adjustment Poor seating of valves Defective valve guides Worn rocker arm or arm shaft Defective pick up coil Defective C D I unit Spark plug gap too wide Defective ignition coil resulting in weak sparking Float chamber fuel level out of adjustment in Carburetor Clogged jets o x o Adjust Replace Replace Replace Replace Replace Adjust or replace Replace Adjust Clean Valve springs weakend Valve timing out of adjustment Worn cams or rocker arms Spark plug gap too narrow Defective ignition coil Float chamber fuel level too low Clogged air cleaner element OMAN DOA Defective pick up coil C D I unit Too much engine oil in the engine Worn piston rings or cylinder Worn valve guides Oylinder wall scored or scuffed Worn valves stems Defective stem seals Worn side rails Clogged fuel pipe resulting in inadequate fuel supply to carburetor Replace Adjust Replace Repair Replace Adjust Clean Clean a
98. 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 S button lg switch ON OMNO Fuse Starter motor STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the starter motor Disassemble the starter motor as follows STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn the motor will be unable to produce sufficient torque and the engine will be difficult to turn over To prevent this periodically inspect the length of the brushes replacing them when they are too short or chipping ELECTRICAL SYSTEM 5 10 Service limit 3 5mm COMMUTATOR If the commutator surface is dirty starting performance decreases Polish the commutator with 400 or similar fine emery paper when it is dirty After polishing it wipe the commutator with a clean dry cloth Check the commutator under cut D Service limit 0 5mm ARMATURE COIL Using a pocket tester check the coil for open and ground by placing probe pins on each commutator segment and rotor core to test for ground and on any two segments at vari ous place of the commutator surface If the coil is found to be open circuited or grounded replace the armatrue Continuous use of a defective armature will cause the starter motor to suddenly fail
99. t 2000r min e Winter approx 20min at 2000r min After the warming up operation increase the engine speed to 3 000r min and read the oil pressure gauge NOTE Engine oil must be warmed up to 60 C 140 F when checking the oil pressure Oil pressure Above 0 4 kg cm Oil temp at 60 C Below 0 6 kg cm at 3 000rpm 09915 74510 Oil pressure gauge If the oil pressure is power or higher than the specifica tions several causes may be considered Low oil pressure is usually the result of a clogged oil filter oil leakage from the oil passageway damaged oil Seal a defective oil pump or a combination of these items High oil pressure is usually caused by a engine oil which is too heavy a weight a clogged oil passage improper installation of the oil filter or a combination of these items ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame thoroughly clean the engine with a suitable cleaner The proce dure of engine removal is sequentially explained in the following steps Take off the seat by opening the seat lock Take off the right and left frame covers Take off the right and left the frame head cover Disconnect the and lead wires of battery D SERVICING ENGINE 3 2 CAUTION First disconnect the lead wire Take off the fuel tank by removing the mounting bolts
100. t chamber groove Install the float chamber and screw ACCELERATOR PUMP ADJUSTMENT NOTE Do not adjust except for exchange adjust screw Adjust idling Refer to page 2 10 Adjust throttle grip Refer to page 2 10 Adjust clearance of accelerator pump rod after loosen the lock nut and turn the adjust screw 0 mm Tighten the lock nut Install the fuel tube and drain tube FUEL AND LUBRICATION SYSTEM 4 8 Lock nut 11 Adjust screw 4 9 FUEL AND LUBRICATION SYSTEM Replace a new O ring at the carburetor outlet side Install the jet needle and retainer clip into the throttle valve X Needle clip standard position 3rd groove Install the carburetor top and spring into the throttle cable Install the throttle cable into the throttle valve Install the carburetor top on the carburetor body Q Leaner Ist 1 2 Standard 3rd Richer 5th Install the carburetor between the cylinder and air cleaner out let tube tighten the intake pipe bolts and clamp screw Install the choke cable D Adjust play of throttle grip Refer to page 2 10 Install the accelerator pump cable PILOT SCREW ADJUSTMENT D Loosen as standard turn back revolutions after lock the pilot screw suitable Standard turn back revolutions 2 circle FUEL AND LUBRICATION SYSTEM 4 1O NO
101. troke Remove cam chain tensioner loosen the cylinder head cover bolts and detach the head cover loosen the camshaft holder lock nuts diagonally then detach the camshaft holder SERVICING ENGINE 3 8 Remove camshaft center bolt NOTE This is a left hand thread nut Remove C ring cam sprocket and camshaft CAUTION Do not drop camshaft drive chain key and sprocket into the crankcase CAMSHAFT HOLDER Take off the rocker arm spring from dowel pin Remove the dowel pin with long nose pliers 3 9 SERVICING ENGINE Install the bolt by the rocker arm shaft and pull out the rocker arm shaft CYLINDER HEAD Loosen the cylinder head nuts then detach the cylin der head NOTE If it is difficult to remove the cylinder head gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer Be careful not to break the fin Compress the valve spring by using the special tool 09916 14510 Valve lifter 09916H35C00 Attachment Take off the valve cotters from valve stem 09916 84510 Tweezers Take out the valve spring retainer and spring Pull out the valve from the other side Remove oil seal using long nose pliers NOTE Removed oil seal should be replaced with a ne
102. ut the cotter and remove the nut and bolt Remove the torque link Remove the dust seal covers and draw out the spac ers 6 39 CHASSIS INSPECTION BUSHING Inspect the bushing for wear and damage SWING ARM PIVOT SHAFT Using the special tools check the pivot shaft for runout and replace it if the runout exceeds the limit 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand 09900 21304 V block 100 mm Service limit 0 6 mm REASSEMBLY Reassemble and remount the swing arm in the reverse order of disassembly and removal and also carry out fol lowing steps SWING ARM BUSHINGS Force fit the bushings into the swing arm by using the special tool 09924 84510 Bearing installer set SPACER AND DUST SEAL COVER Apply grease to the spacer and dust seal cover when installing 54003700 SERVICING INFORMATION CONTENTS TROUBLESHOOTING m mm e e emen tenente tenens SPECIAL TOOLS i sess En EEEE ties sags TIGHTENING TORQUE m mnm hene nennen nne SERVING DATA mmm hem enn WIRE AND CABLE ROUTING e m m emen emen nemen WIRING DIAGRAM eem n m mmm heme emn nemen nemen ntes 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start or is Compression t
103. w one Take out the spring seat CYLINDER Remove cylinder base nuts and cylinder CAUTION If tapping with plastic hammer is necessary do not break the fins PISTON Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase and then remove the piston pin circlip with long nose pli ers Remove piston pin 09910 34510 Piston pin puller SERVICING ENGINE 3 1O 3 11 SERVICING ENGINE UPPER END COMPONENTS INSPECTION AND SERVICING CAMSHAFT HOLDER DISTORTION After removing oil from the fitting surface of the camshaft holder place the camshaft holder on a surface plate and check for distortion with a thickness gauge Check points are shown in Fig Service limit 0 05mm ROCKER ARM SHAFT O D Measure diameter of rocker arm shaft Standard 11 977 11 955mn ROCKER ARM When checking the valve rocker arm the inside diameter of the valve rocker arm and wear of the camshaft con tacting surface should be checked Standard 12 000 12 018mm CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of output power Any of these malconditions could be caused by a worn camshaft Inlet open B T D C gt Inlet clo
104. weight If play or stiffness is notice able readjust the steering stem nut Set the handlebars to match its punched mark to the mating face of the holder Tighten the handlebars clamp bolts See page 6 14 CHASSIS 6 20 TIGHTENING TORQUE Item kg m 35 55 3 5 5 5 35 55 3 5 5 5 25 35 2 5 3 5 6 21 CHASSIS FRONT BRAKE Tightening torque Item N m kg m 5 8 0 5 0 8 5 8 0 5 0 8 15 25 1 525 BRAKE PAD REPLACEMENT Remove the caliper mounting bolts and take off the caliper CAUTOIN Do not operate the brake lever while dismounting the caliper Push the piston and caliper holder all the way to the caliper when removing the pad Loosen the screw D and take off the housing cover Q Remove the pad CHASSIS 6 22 CAUTOIN Replace the brake with set otherwise braking performance will be adversely affected Apply the Silicone Grease to the caliper holder 39000 2510 Push in the piston and piston holder all the way to the caliper when remounting the caliper Tighten the caliper mounting bolts with specified torque Tightening torque 15 25N m 1 5 2 5kg m 6 23 CHASSIS CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose from the caliper and catch the brake fluid
105. with new ones CAUTION Replace the brake pad with a set otherwise braking performance will be adversely affected CALIPER REASSEMBLY Reassemble and remount the caliper in the reverse orders of disassembly and removal and also carry out the fol lowing steps CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gaso line to wash them Apply brake fluid to the caliper bore and all internal parts before inserting into the bore Apply Silicone Grease to the caliper holder 99000 25100 Silicone grease TIGHTENING TORQUE CHASSIS 6 26 Item N m kg m 6 9 0 6 0 9 20 25 2 0 2 5 9 15 25 1 5 2 5 WARNING Bleed the air from brake fluid circuit after reassembling caliper See page 2 13 6 27 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY Please a cloth underneath the union bolt on the mas ter cylinder to catch spilled drops of brake fluid Unscrew the union bolts and disconnect the brake hose from the master cylinder joint CAUTION Immediately and completely wipe off any brake fluid contacting any part of the motor cycle The fluid reacts chemically with paint plastics rubber materials etc and will damage them severely Remove the two clamp bolts and take off the master cylinder Remove the two fitting screws and separate t
106. y 1 000km Brakes Inspect Inspect Brakes hose Inspect Inspect Replace every 4 years Brakes fluid Change every 2 years Tires Inspect Inspect Steering Inspect Inspect Front fork oil Change Change Chassis bolts and nuts Inspect Inspect PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 2 LUBRICATION CHART The maintenance schedule which follows is based on this philosophy It is timed by odometer indication and is calculated to achieve the ultimate goal of motorcycle maintenance in the most ecomomical manner Interval Interval and Every 5 000km Every 10 000km Item Throttle cable Motor oil Throttle grip Grease Clutch cable Motor oil Brake cable Motor oil Speedometer cable Grease Speedometer gear box Grease Drive chain Motor oil every 1 000km Brake pedal Grease or oil Brake cam shaft Grease Steering stem bearings Grease every 2 years or 20 000km Swing arm bearings WARNING Be careful not to apply too much grease to the brake cam shaft If greases gets on the linings brake slip page will result Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motorcycle has been operat ed under wet or rainy conditions Before lubricating each part clean off any rusty sports and wipe off any grease oil dirt or grime 2 3

SERVICE MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents