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1. 84 kg 185 Ibs Headlight Front turn signal light Rear turn signal light Tail Brake light Two stroke forced air cooled Speedometer light Reed valve Oil level 1 indicator light Turn signal indicator light 41 0 mm 1 614 in 37 4 mm 1 472 49 cri 3 0 cu in Trunk light eee 7 4 1 CAPACITIES SIDEDRAFT V V niai iess Polyurethane foam element Electric and kick HYOSUNG Engine oil tank Final gear oil Dry shoe automatic centrifugal type 2 815 0 866 Variable V belt drive Telescopic coil spring oil dampened Swingarm type coil spring oil damped 25 70 mm 2 75 45 right amp left 1 9 mm 6 2 ft 100 80 10 53J 100 80 10 53J Disc Internal expanding The specifications are subject to change without notice HYOSUNG CDI 23 B T D C at 4 000 r min GOLDEN BP6HS 12V 3Ah 10HR Magneto 10 12 15 15 2 12V 21 W 12V 10 W 12V 5 21 W 12V 3 4 Wx2 12V 1 7 W 12 1 7W 12V 2 W 4 8 L 1 3 1 1 US Imp ae gal 1 2 L 1 2 1 0 US Imp at 80 mi 2 7 2 8 US Imp gt oz
2. FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the SD 50 The SD 50 is a new type of motorcycle that has many technical features such as V belt drive automatic transmission Forced air cooling system Ignition system Electric starter system The SD 50 fits the needs of a wide variety of motorcycle users Those who will be servicing this motorcycle should carefully review this manual before performing any repair or services Information of this manual is up to date at the time of issue Major modification and changes incorporated later will be advised to HYOSUNG product distributor in each market Therefore if newest information is requested in the future please contact the local HYOSUNG distributor The SD 50 motorcycles distributed in your county might differ in minor respects from the standard specification and if they do it is because some minor modifications which are of quence in most cases as far as servicing is concemed has to be made to comply with the starutory requirements of your country GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE UP PROCEDURE ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION HYOSUNG MOTORS amp MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC Overseas Serv
3. ice GENERAL INFORMATION CONTENTS MODEL IDENTIFICATION FUEL AND OIL RECOMMENDATIONS 22222224 BREAKING IN PROCEDURE 33 PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIAL AA TERIAL SPECIFICATIONS ei a eee 1 1 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER The frame number or VIN is stamped on the right side of the under center in the frame ENGINE NUMBER The engine serial number 2 is stamped on the crankcase These numbers are required especially for registering the motorcycle and ordering spare parts FUEL AND OIL RECOMMENDATIONS Be sure to the specified fuel and oils The following are the specification FUEL Gasoline used should be graded 85 95 octane or higher An unleaded gasoline is recommended ENGINE OIL For the HYOSUNG system use of APOLLOIL or HYPOL HS is highly recommended but if they are not available a good quality two stoke oil non diuent type should be used FINAL GEAR OIL Use a good quality SAE 10W 40 multi grade motor oil BREAKING IN PROCEDURE During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and relia b
4. ility of the engine depends on the care and restraint exercised during its early life The general rules are as follow Keep to these breaking in speed limit Up to 1000 km 600 miles Less than 4 5 throttle Upon reaching an odometer reading of 1000km 600 miles you can subject the motorcycle to full throttle operation Do not maintain constant engine speed for an extended time period during any portion of the break in Try to vary the throttle position GENERAL INFORMATION 1 2 PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when disassembling and reassembling motorcycles Do not run engine indoors with litte or no ventilation Be sure to replace packing gaskets circlips O rings and cotter pins with new ones CAUTION Never reuse a circlip after it has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expend the end gap larger than required to slip the circlip over the shaft After installing a circlip always insure that it is completely seated in its groove and securely fitted When tightening cylinder head or a case torque the bolt or nut of larger thread diameter first and then proceed to that of smaller diameter They should also be tightened crosswise from inside to outside to the specified torque Use special tools where specified Use genuine parts and recommended oils Whe
5. n two or more persons work together pay attention to safety of each other After the reassembly check parts for tightness and operation Treat gasoline which is extremely flammable and highly exposive with greatest care Never use gaso line as cleaning solvent oOo Waming Caution and Note are included this manual occasionally describing the following contents WARNING parsonal safety of the rider may be involved Disregarding this information could result in injury to rider CAUTION 22 These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine NOTE This provides special information to make maintenance easier or important inst ructions clearer REPLACEMENT PARTS When you replace any parts use only genuine HYOSUNG replace ment parts or their equivalent Genuine HYOSUNG parts are high quality parts which are designed and built specifically for HYOSUNG vehicles CAUTION Use of replacement parts which are not equivalent in qual ity to genuine HYOSUNG parts can lead to performance problems and damage 1 3 GENERAL INFORMATION SPECIAL MATERIALS The materials shown are required for maintenance works on the Model SD 50 and should be kept on hand for ready use in addition such standard materials as cleaning fluids lubricants etc should also available Methods of u
6. se are discussed in the text of this manual on later pages Oil seal Reed valve securing screw Throttle grip 4 Crankshaft oil seal outer Speedometer cable F surface Oil pump drive driven gear Kick starter gear Kick starter shaft Movable driven face Fixed driven face Starter pinion Starter motor Wheel bearing THREAD LOCK GREASE G Brake camshaft 1342 Crankcase mating surface Front fork socket bolt Final gear cover THREE BOND THREAD LOCK No 1215 1324 99000 31110 99000 32030 Front brake caliper SILICONE GREASE 99000 25110 Magneto rotor nut THREAD LOCK SUPER 1322 99000 32110 GENERAL INFORMATION 1 4 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground clearance Dry mass ENGINE Type Intake system Number of cylinder Bore Stroke Piston displacement Corrected compression ratio Carburetor Air cleaner Starter system Lubrication system TRANSMISSION Clutch CHASSIS Front suspension Rear suspension Caster Trail Steering angle Turning radius Front tire size Rear tire size Front brake Rear brake ELECTRICAL Ignition type Ignition timing 1 780 mm 70 1 in 660 mm 26 0 in Spark plug 1 065 mm 41 9 in Battery 1 221 mm 48 1 112 4 4
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