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TE 90 - Hyosung Motors America

1. A mS 6 11 REAR WHEEL 9 n emm 6 12 REMOVAL eH 6 12 INSPECTION ucc 7 dde 6 12 REMOUNTING 6 12 X IEEE 6 13 REPLACEMENT CH ere TT 6 13 CALIPER DISASSEMBLY 6 13 DISC PLATE INSPECTION ec ssa ee aes rasa eed ae 6 14 CALIPER REASSEMBLY Te rare eos re 6 14 REAR AXLE HOUSING AXLE SHAFT AND SHOCK ABSORBER 6 15 REMOVAL lt 6 15 INSPECTION AND DISASSEMBLY 6 16 REASSEMBLY AND REMOUNTING m 6 18 6 1 CHASSIS FRONT WHEEL AND BRAKE CHASSIS 6 2 REMOVAL Place the vehicle on level ground Remove the wheel center cap Remove the cotter pin and front axle nut Support the vehicle by jack or block and remove the front wheel Remove the brake shoe Remove the brake cam lever Remove the front brake plate 6 3 CHASSIS INSPECTION AND DISASSEMBLY 9 WHEEL HUB BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel hub Rotate the inner ring
2. HQ 050 37 4 in Ground clearance 22 2 2 2 2255 5 520202 222 22222 120 mm 4 7 in Front ant 658 25 9 in Rear track 658 25 9 in mn 95 kg 209 5 lbs ENGINE Type M Two stroke forced air cooled Intake system HP Reed valve Number of cylinder HE 1 Bore sc IPod ied ETE 52 5 mm 2 07 in X 41 4 mm 1 63 in Piston displacement ee Un Um OUR UN 89 5 43 in Corrected compression l alig mmn 66 1 11 hides tne reenter Polyurethane foam element TRANSMISSION Clutch Dry shoe automatic centrifugal type a 2 842 1 042 DIIVESYSIEM 428H 56 links CHASSIS Steering angle M M M 37 5 right amp left Trail adi eee Mee 15 mm 0 591 in Turning radius m Mlle e n n 9 2 595 mm 102 17 in Toe in M39 nne 8 mm 0 315 in Camber angle 1 Caster angle META 2 5 Drum Rear brake i ace SI eme Disk Front tire size me aT Tee MCE TET ree 18
3. White Y ad Yellow B R T Black with Red tracer B W Haale RE Vs Black with White tracer ENGINE STOP SWITCH E White with Black tracer BR BW YAN Pc Yellow With White tracer mM Oeo 0 YIG DEMEURE PETERE Yellow With Green tracer B ME Blue with White tracer FO 5 7 ELECTRICAL SYSTEM BATTERY 9 CAUTION OF BATTERY TREATMENT The battery should be well taken care of because it emits flammable gas If you don t follow the instruction in the below there may be a explosion and severe accident Therefore please pay attention to the following points Prohibit positively battery from contacting to short spark or firearms The recharge of battery should be done in the wide place where the wind is well ventilated Please don t recharge it at the sight of wind proof 9 CAUTION OF BATTERY ELECTROLYTE TREATMENT Q Pay attention for the battery electrolyte not to stain the chasis or the humanbody f it stain the chassis or the humanbody at once wash a vast quantity of water When it is stained clothes should come into being a hole or painting should take off Consult you with a doctor When the battery electrolyte was dropped to the surface of land wash a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on 9 CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the alum
4. DISASSEMBLY Remove the thermoelement assembly CAUTION Do not attempt to disassemble the thermoelement assembly It is not serviceable 4 3 FUEL SYSTEM Remove the throttle valve spring and jet needle DV NV Remove the float chamber Pull out the float pin and remove the float Remove the needle valve Remove the throttle stop screw pilot air screw 2 CAUTION When removing the pilot air screw record the revolutions until tighten completly Remove the pilot jet main jet 0 and needle jet 5 Check following items for any damage or clogging Pilot jet Main jet Pilot air screw Needle jet air bleeding hole Float Gasket Pilot outlet and bypass holes 9 NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle the gasoline will continue flowing and cause it to overflow If the seat and needle are worn beyond the permissible limits similar trouble will occur Conversely if the needle sticks the gasoline will not float chamber Clean the float chamber and float parts with gasoline If the needle is worn as shown in the illustration replace it together with a valve seat Clean the fuel passage of the mixing chamber with compressed air FUEL SYSTEM 4 4 Foreign matter 4 5 FUEL SYSTEM REASSEMBLY AND REMOUNTING Reassemble following item
5. yoejg uim ped gy 67 g 3HIM OLSNOW HOLON LYVLS H1 HOLIMS 3 TONVH 515 4 TIY SNIONS H3IHVIS YHALYVLS AV THH Coe s ed EE is 9A M B Md Md d Ma dd M8 H8 9A 8M MH SA d E Md NEN a M8 HH 9A SM VOL AON39H3NW3 WS M Ao o 14 T es ye NN DS a Em PUT ee 2 1 8d M ud M us M ud Ma M Md 8M 1g M Ne OTO INOHJ WS NOILINSI M S golvino3d x H18V3 ANIONS d3l3LLO3d I Prepared by HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department 1st Ed AUG 2001 Manual No 99000 94310 Printed in Korea
6. Regulator rectifier unit poorly grounded Lead wire insulation frayed due to vibration resulting in intermittent shorting Magneto coil internally shorted Defective regulator rectifier Battery run down Defective switch contacts Brushes not seating properly on commutator in starter motor Defective starter relay Defective starter pinion gears Defective front or rear brake light switch circuit Replace Replace Replace Connect tighten Adjust carburetor Adjust carburetor Change Clean Replace by hot type plug Replace Replace by hot type plug Turn up Retighten Adjust carburetor Check oil pump Repair replace or retighten Replace Replace Repair or retighten Replace Replace Replace the battery Replace the battery Replace Clean and tighten groun connection Repair or replace Replace Replace Recharge or replace Replace Repair or replace Replace Replace Replace or repair Complaint Symptom and possible causes Battery runs down quickly 1 The charging method is not correct 2 Cell plates have lost much of their active material as a result of over charging 3 A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte Check the magneto and regulator rec tifier circuit connections and make necessary adjustments to obtain spe cified char
7. Remove the front brake cables Remove the steering head cover bracket and handle bar by removing the mounting bolts Remove the tie rods by removing the cotter pins and nuts Remove the cotter pin and steering shaft lower nut CAUTION The removed cotter pins should be replaced with new ones 6 9 CHASSIS Separate the tie rod ends nuts and steering tie rods 4 4 CAUTION NU Inside lock nuts 2 are left hand thread Tu 7 S7 x Remove the cotter pins and remove the steering shaft holder bolts Remove the steering shaft holders and steering shaft INSPECTION Inspect the removed parts for the following abnormali ties Handlebar distortion Handlebar clamp wear 9 DUST SEAL Inspect the dust seals for damage TIE ROD Inspect the tie rod for distortion and the boot for wear STEERING SHAFT AND HOLDER Inspect the steering shaft for distortion or bend Inspect the two steering shaft holders for wear 9 SHOCK ABSORBER Inspect the shock absorber for oil leakage or other dam age REASSEMBLY AND REMOUNTING Reassemble and remount the steering system in the reverse order of removal and disassembly and also carry out the following steps Align the mating face of front brake holder with the respective punch mark and tighten the bolt 9 ROD Install the tie rod ends nuts 3 and steering tie rods 4 CAUTION Inside
8. to the rotor nut and tighten it to the specified torque with the special tool THREAD LOCK 1324 Conrod holder 09910 20115 9 Magneto rotor nut 35 45 3 5 4 5 kg m 3 39 PISTON Install the piston ring on the piston Position the ring so that the marking is on upside st Keystone ring 4 CAUTION Position the ring so that the marking is on upside Locating pin It is extremely important that when the piston is fed into the cylinder each ring in place should be so positioned as to hug the locating pin as shown in the illustration CORRECT INCORRECT 3 40 Apply engine oil the piston and install the pis ton to the conrod CAUTION The arrow mark on the piston head should point the exhaust side The circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the groove portion of the piston Position the cylinder base gasket Apply engine oil on the piston and cylinder wall sur faces and install the cylinder over the piston carefully Install the cylinder head gasket and cylinder head Tighten the cylinder head nut to the specification and tighten it diagonally several times as shown Inthe illustration Q Cylinder head nut 18 28 N m 1 8 2 8 kg m 3 41 OIL PUMP AND INTAKE PIPE Apply SUPER GREASE to the oil pump
9. PERIODIC MAINTENANCE 2 8 Index mark Brake lining wear limit The extension line of the index mark is within the range Brake lining wear limit Index mark The extension line of the index mark is outside of the range 2 9 PERIODIC MAINTENANCE BRAKE PAD WEAR The extend of brake pad wear can be checked by observ ing the grooved limit on the pad When the wear exceeds the grooved limit replace the pads with new ones CAUTION Replace the brake pad as a set otherwise braking performance will be adversely affected REAR BRAKE PAD REPLACEMENT Remove the brake caliper Remove the brake pads To reassmble reverse the above sequence V Rear brake caliper mounting bolt 5 0 7 0 N m 0 5 0 7 kg m DRIVE CHAIN NOTE Inspect and lubricate Every month Visually check the drive chain for the possible defects listed below Loosen pins 2 Damaged rollers 3 Dry or rusted links 4 Kinked or binding links Excessive wear If any defects are found the drive chain must be replaced 9 LUBRICATING THE DRIVE CHAIN Dirt hastens wear of drive chain and sprockets Lubricate the drive chain with chain lube or motor oil fre quently Every 1 month or more frequently wash the chain clean in a pool of solvent and lubricate it with chain lube or motor oil In a dusty area this service should be given at shorter intervals CAUTION When refitting the drive chain be sure to
10. Replace or replace Adjust tire pressure Replace Retighten Replace Replace or retighten Replace Replace Retighten Adjust tire pressure Adjust Replace Repair or replace Replace Adjust Replace Retighten 1 Worn or loosen wheel hub bearing Replace 2 Desturbed front wheel alignement Adjust 1 Loose bolt and nut 2 Broken or otherwise damaged wheel hub bearing 3 Poorly lubricated Retighten Replace Lubricate Front suspension too soft 1 Weakened spring Replace 2 Oil leakage of shock absorber Replace Front suspension 1 Worn wishbone arm related bushing too shift Noisy suspension 1 Loose bolt system Retighten 2 Worn wishbone arm related bushing Replace Rear wheel oscillation Rear suspension too soft Rear suspension too stiff Poor braking 1 Worn or4oose rear axle housing bearing 2 Defective or incorrect tire 3 Distorted wheel rim 4 Loose nut on wheel hub 5 Loose nut on axle shaft 1 Weakened spring 2 Rear shock absorber spring improperly set 3 Oil leakage of rear shock absorber 1 Rear shock absorber spring improperly set 2 Shock absorber shaft bent 3 Swingarm bent 4 Worn swingarm related bearing 1 Lining worn down 2 Too much play on brake lever and pedal Replace Replace Replace Retighten Retighten Replace Reset Replace Adjust Replace Replace
11. 28 _ 0 Fuel line 2 6 Replace every 4 years Transmission 27 2 Sprockets Inspect Inspect CHASSIS _ Inspect every month Check pressure each time ride Chassis bolts and nuts Tighten Tighten o 2a PERIODIC MAINTENANCE 2 2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the vehicle Major lubrication points are indicated below King pin 7 Front brake cable 2 Front wheel bearing Throttle cable 3 Steering shaft holder 9 Throttle lever 4 Drive chain Front brake cam shaft 5 Rear axle housing Rear brake cable 61 Motor oil Grease NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the vehicle has been operated under wet or rainy condition 2 3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES AIR CLEANER NOTE Clean at least Every month If the air cleaner is clogged with dust intake resis tance will increased with a resultant decrease in output and an increase in fuel consumption Check and clean the element in the following man ner Stand the vehicle in the standing position Remove the four bolts Remove the clamp screw 2 Remove the air cleaner case 5 Remove
12. Use of improper spark plug T Clogged exhaust pipe muffler CARBURETOR Complaint Symptom and possible causes Trouble with 1 Starter jet is clogged starting 2 Air leaking from a joint between starter body and carburetor 3 Air leaking from carburetor s joint or vacuum hose joint 4 Starter plunger is not operating properly Idling or low speed Pilot jet pilot air jet are clogged or loose trouble Air leaking from carburetor s joint vacuum pipe joint or starter Pilot outlet is clogged Starter plunger is not fully closed Medium or high Main jet or main air jet is clogged speed trouble Needle jet is clogged Fuel level is improperly set Throttle valve is not operating properly Fuel filter is clogged Overflow and fuel Needle valve is worn or damaged level fluctuations Spring in deedle valve is broken Float is not working properly Foreign matter has adhered to needle valve Fuel level is too high or low Replace Replace Replace Adjust or replace Clean Adjust or replace Clean Clean or replace Retighten or replace Replace Replace Replace Replace Clean Replace or clean Adjust or replace Retighten or replace Change Change Clean or replace Clean Check starter body and carburetor for tightness and replace gasket Check and replace Check and replace Check and clean Clean and replace Check and clean Check and replace
13. 8 2 8 N 1 84 2 86 xx 2 24 3 57 40 50 22 38 22 38 40 80 ISI A ASSEMBLING APPLY GREASE ASSEMBLING APPLY GREASE APPLY GREASE TO LIPS D APPLY GREASE EB ASSEMBLING APPLY GREASE 5 INFORMATION LABELS 1 1 GENERAL PRECAUTIONS enne 1 1 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATIONS me 1 5 EXTERIOR ILLUSTRATION e 1 6 SPECIFICATIONS 1 7 GENERAL INFORMATION 1 1 GENERAL INFORMATION WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions cleaner Please note however that the WARNING and CAUTION contained inthis manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the motorcycle In addition to the WARNING and CAUTION stated you must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS
14. Clutch tight RPM 200 rpm Engine tachometer 09900 26006 If the engine RPM does not coincide with the specified RPM range then disassemble the clutch Clutch shoe inspect the shoes visually for chips cracking uneven wear and burning and check the thickness of the shoes with vernier calipers If the thickness is less than the following service limit replace them as a set Clutch springs visually inspect the clutch springs for stretched coils or broken coils Clutch shoe thickness 2 0 mm 0 079 in CAUTION Clutch shoes or springs must be changed as a set and never individually Clutch housing inspect visually the condition of the inner clutch housing surface for scrolling cracks or uneven wear Measure inside diameter at several points to check for an out of round condition as well as wear Clutch housing I D 112 50 mm 4 429 in ENGINE 3 18 3 19 DRIVE V BELT Remove the drive V belt and check for cracks wear and separation Measure the belt width with a vernier calipers Replace it if the belt width is less than the ser vice limit or any defect has been found Drive V belt width 16 0 mm 0 630 in 4 CAUTION Always keep the belt away from any greasy material 9 DRIVE FACE Inspect the belt contact surface of the drive faces for wear scratches any abnormality If there is some thing unusual replace the drive face with a new one 9 ROL
15. Replace Replace Adjust 7 5 SERVICING INFORMATION SPECIAL TOOLS Part Number Part Name Description Special tools Part Number Part Name Description 09900 20101 09900 21109 Vernier Caliper c Torque wrench Used to conveniently measure various dimensions Measure torque of tightening 09900 20201 09900 21304 Micrometer 0 25mm V block Used for precise measurement 00 25mm measure ranges With using magnetic stand 09900 20202 SS 09900 21602 Micrometer 25 50mm oil gauge Used for precise measurement 20 50mm measure ranges i Q A gauge to inspect performance of oil pump 09900 20203 S 09900 22301 Micrometer 50 75mm Plastigauge Used for precise measurement 0 5mm measure ranges Measure clearance of crankshaft thrust 09900 20508 09900 22401 Cylinder gauge set Small bore gauge Measure inside diameter of conrod small end 09900 20605 09900 25002 Dial calipers We Pocket tester Meassure width of conrod big end Measure voltage electric current resistance 09900 20606 09900 26006 Dial gauge 5008 Engine tachometer Meassure oscillation of wheel with using magnetic stand SESE Measure rotational frequency of engine 09900 20701 eT 09900 28107 Magnetic stand ae Electro tester With using dial gauge Inspect ignition coil 09900 20806 09900 28500 Thickness gauge at Battery charger Used to charge the dischared battery SERVICING INFORMA
16. and with a pocket tester If the tester reads under or over following specification check the no load performance or replace the regula tor rectifier CAUTION When making this test be sure that the battery is in fully charged condition 13 0 16 0 V at 5 000 rpm Pocket tester 09900 25002 Engine tachometer 09900 26006 ELECTRICAL SYSTEM 5 2 5 3 ELECTRICAL SYSTEM 9 NO LOAD PERFORMANCE OF A C GENERATOR Disconnect the magneto lead wire coupler Start the engine and keep it running at 5 000 rpm Using a pocket tester measure the AC voltage between the three lead wire If the tester reading is as follows magneto is in good condition Standard no load performance of generator More than 17 0 V at 5 000 rpm REGULATOR RECTIFIER Disconnect the coupler Using the pocket tester x 1kQ Range measure the resistance between the terminals as shown in the fol lowing table If the resistance checked is incorrect replace the regulator rectifier Unit iQ Probe of tester to Probe of tester to Pocket tester 09900 25002 STARTER SYSTEM The starter system is shown in the diagram below namely the starting motor starter relay starter switch and battery Depressing the starter switch on the left handlebar switch box while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the
17. and possible causes Engine runs 1 Excessively worn cylinder or piston rings poorly in high 2 Stiff piston ring in place speed range 3 Spark plug gaps to narrow 4 Ignition not advanced sufficiently due to poorly working CDI amp Ignition coil unit 5 Defective magneto stator coil 6 Float chamber fuel level too low 7 Clogged air cleaner element 8 Clogged fuel hose resulting in inadequate fuel supply to carburetor 9 Clogged fuel cock vacuum pipe SERVICING INFORMATION 7 2 Replace Replace Adjust Replace Replace Adjust or replace Clean Clean and replace Clean Dirty or heavy 1 Too much engine oil to the engine Check oil pump exhaust smoke 2 Use of incorrect engine oil Change Engine lacks 1 Excessively worn cylinder or piston rings power 2 Stiff piston ring in place 3 Gas leaks from crankshaft oil seal 4 Spark plug gaps incorrect 5 Clogged jets in carburetor 6 Float chamber fuel level out of adjustment 7 Clogged air cleaner element 8 Fouled spark plug 9 Sucking air from intake pipe 10 Slipping or worn V belt 11 Damaged worn rollers in the movable drive face 12 Weakened movable driven face spring 13 Too rich fuel air mixture due to defective starter system Engine overheats 1 Heavy carbon deposit on piston crown 2 Defective oil pump or clogged oil circuit 3 Fuel level too low in float chamber 4 Air leakage from intake pipe 5 Use of incorrect engine oil 6
18. install the chain joint clip as shown the slit end faces counter to turning direction 9 DRIVE CHAIN REPLACEMENT The drive chain is checked when its slack between two sprockets is within 5 15 mm 0 197 0 591 in range 5 15mm 0 197 0 591 in Drive chain slack If the drive chain slack exceeds the specification the chain must be replaced PERIODIC MAINTENANCE 2 10 O gt 2 M NN 306 73 es 4 1 15 27 a 7 MS Zw 2 11 PERIODIC MAINTENANCE TIRE NOTE Inspect Every month Check pressure each time ride PRESSURE If the tire pressure is too high the vehicle will tend to ride stiffly have poor traction Conversely if the tire pressure is too low stability will be adversely affected Therefore maintain the correct tire pressure for good traction and prolonging tire life CAUTION The standard tire fitted on this is 18x 7 00 7 for front and rear The use of a tire other than the standard may cause handling instability It is high ly recommended to use a HYOSUNG Genuine Tire COLD INFLATION TIRE PRESSURE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dan gerous situation It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specifications 10 mm 0 394 in Front and rear tire t
19. motor to suddenly fail Pocket tester 09900 25002 STARTER RELAY INSPECTION Disconnect the starter relay lead wire coupler Check the coil for open ground and ohmic resis tance The coil is in good condition if the resistance is as follows Standard Starter relay standard resistance 80 150 Q Pocket tester 09900 25002 THERMOELEMENT R B W Oo o PTC Battary Regurator Rectifier ELECTRICAL SYSTEM 5 6 9 INSPECTION Disconnect the thermoelement coupler Connect the thermoelement coupler to a 12V bat tery and touch the thermoelement to check the temperature being raised The thermoelement 2 should become heated to a temperature more than that of human body within five minutes If not replace with new one 4 CAUTION This check should be carried out when the carbu retor is cold SWITCHES INSPECTION Inspect each switch for continuity with the pocket tester referring to the chart If it is found any abnormality STARTER SWITCH replace the respective switch assembly with new one w Pocket tester 09900 25002 WIRE COLOR B Gab tea Nain Black L nC MES Blue G OPTED Green Gr Gray Sb Loi se seen Light blue Lg Light green O R Red W
20. pin 8 Install the driveshaft to the gear box cover Install the gear box cover 0 on the crankcase Tighten all the screws evenly one by one a diago nal fashion ENGINE 3 30 STARTER PINION STARTER DRIVEN GEAR AND STARTER MOTOR Apply SUPER GREASE on the pinion shaft and install the starter pinion subassembly AZ SUPER GREASE Assemble the starter pinion subassembly Insert the two dowel pins the crankcase 3 31 Install the starter idle gear cap Install the starter driven gear 2 over the left crankshaft end NOTE The convex side of hub should face outside when installed in proper position Install the new O ring Install the starter motor 3 32 MOVABLE DRIVEN AND CLUTCH Install the bearing in the fixed driven face 1 with the special tool Bearing installer 09943 88211 3 33 Install the circlip A CAUTION Insert surely in the circlip groove Rounded coner Install the bearing with the special tool Bearing installer 09943 88211 CAUTION A mark part of the bearing is pointed to the outside Install the new O rings to the movable driven face 3 with the special tool Bearing installer 09913 76010 Apply SUPER GREASE to the groove of mov able driven face s inside AG SUPER GREASE ENGI
21. the element 4 from the cap 3 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 cleaning solvent out of the washed element by pressing it between the palms of both hands do not twist or wring the element or it will develop tears Immerse the element HYOSUNG genuine oil and squeeze the oil out of the element leaving it slightly wet with oil Fit the cleaner element to frame properly CAUTION Before and during the cleaning operation inspect the element for tears A torn element must be replaced Be sure to position the element snugly and cor rectly so that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element A Non flammable cleaning solvent 2 stroke engine oil CYLINDER HEAD NUTS NOTE Tighten Initial 1 month and Every 3 months Cylinder head nuts when they are not tightened to the specified torque may result in leakage of the compressed mixture and reduce output First loosen the nuts and tighten the 4 nuts evenly one by one in stages until each one is tightened to the specified torque Tighten the nuts in the order indicated V Cylinder head nut 18 28 N m 1 8 2 8 m CYLINDER HEAD AND CYLINDER NOTE Remove carbon Every 6 months Carbon deposits in the combustion chamber and t
22. x T 00 7 Rear tire size 18 x T 00 7 ELECTRICAL Ignition type Lund See Bin cient saa ME E CDI Type e 8 B T D C at 1 000 rpm and 20 B T D C at 4 000rpm Spark plug A BPR7HS CAPACITIES 4 Engine PY 17 Transmisstangl 80 mf Replace 90 ml Overhaul NOTE These specifications are subject to change without notice CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 1 PERIODIC MAINTENANCE CHART 2 4 LUBRICATION POINTS en 2 2 MAINTENANCE PROCEDURES n 2 3 AIR CLEANER tt ttn 2 3 CYLINDER HEAD NUTS tn 2 4 CYLINDER HEAD AND CYLINDER e 2 4 SPARK PLUG t ttt 2 5 CARBURETOR a eee 2 6 FUEL LINE ay Nee 2 6 TRANSMISSION OIL e 2 7 BRAKES mw 2 7 DRIVE CHAIN ese ee ce 2 10 2 11 STEERING M Woo 2 12 PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy CAUTION More frequent servicing should be performed on vehicles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE Air cleaner element Clean at least every month Cylinder head nuts Tighten Tighten 004 Carburetor Wa med
23. 0 0033 52 500 52 515 2 0669 2 0675 Measure at 20mm from the top surface 52 432 52 447 2 0643 2 0648 Measure at 20mm from the skirt end Approx 4 5 0 177 3 6 0 142 0705 0603 a N oe _ 030 st 4 5 0 6 0 eom 7 14 994 12 000 0 4722 0 6302 1 2 1 2 1 Unit mm in 16 004 16 008 0 6301 0 6302 oo oo T o oossoo NNNM o l o 7 11 SERVICING INFORMATION OIL PUMP ITEM STANDARD CLUTCH Unit mm in 112 00 112 50 Clutch housing 44095 4 4291 4 4095 45 0 lutch shoe thick Clutch shoe thickness 0 177 0 079 Clutch in rpm 3 900 200 rpm O Clutch tight rpm 5 900 200 rpm MEE TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD LIMIT Gum o 164 16 6 16 0 Drive V belt width 0 6457 0 6535 0 6299 136 4 130 0 Movable drive face spring free length 5 370 5 118 197 Drive chain 05 20 pitch length 254 10 000 259 10 197 Drive chain slack 5 15 0 197 0 591 Over 15 Over 0 591 SERVICING INFORMATION 7 12 CARBURETOR Unit mm in Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot jet Pilot outlet 0 8 0 032 Throttle cable play 0 5 1 0 0 020 0 039 7 13 SERVICING INFORMATION ELECTRICAL Unit mm in ITEM SPECIFICATION Ignition timing B T D C 8 at 1 000 rpm and B T D C 20 at 4 000 rpm Type BPR
24. 0 kg m 3 36 MOVABLE DRIVE Install the roller at six places to the movable drive face Mount the three dampers on the movable drive plate 3 and install it on the movable drive face Position the O ring on the movable drive face 3 37 Install the movable drive face cover 4 CAUTION Make sure that the movable drive plate is fully positioned inside or the weight roller may come off Insert the spacer 2 Position the movable drive face subassembly on the crankshaft as shown in the photo 4 CAUTION Thoroughly clean the V belt contact face to be from oil Install the fixed drive face 9 Tighten the fixed drive face nut 4 to the specified torque with the special tool Conrod holder 09910 20115 V Fixed drive face nut 40 60 N m 4 0 6 0 m Continue turning the fixed drive face 5 by hand until the V belt is seated in and both the drive and driven faces 6 will move together smoothly without slip Fill the final gear box with transmission oil up to the level hole Tighten the oil level bolt to the specified torque V Transmission oil level bolt 4 7 N m 0 4 0 7 kg m 3 38 Degrease the tapered portion of the crankshaft and also the magneto rotor Install the stator Install the key Install the rotor 3 Apply THREAD LOCK 1324
25. 20 3 21 CYLINDER Decarbon exhaust port and upper part of the cylinder taking care not to damage the cylinder wall surface The wear of the cylinder wall is determined from diame ter reading taken at 20mm from the top of the cylinder with a cylinder gauge If the wear thus determined exceeds the limit indicated below rework the bore to the next oversize by using a boring machine or replace the cylinder with a new one Service limit 52 590 mm 2 071 in Cylinder bore Cylinder gauge set 09900 20508 After reworking the bore to an oversize be sure to chamfer the edges of ports and smooth the chamfered edges with emery paper To chamfer use a scraper taking care not to nick the wall surface PISTON 9 CYLINDER TO PISTON CLEARANCE Cylinder to piston clearance is the difference between piston diameter and cylinder bore diameter Be sure to take the maked diameter at right angles to the piston pin The value of elevation 4 is prescribed to be 20mm from the skirt end Micrometer 50 75mm 09900 20203 Service limit 52 332 mm 2 060 in Piston diameter As result of the above measurement if the piston to cylinder clearance exceeds the following limit overhaul the cylinder and use an oversize piston or replace both cylinder and piston The measurement for the bore diameter should be taken in the intake to exhaust port direction and at 20mm from cylinder top surface Standard Se
26. 7HS 06 07 0 024 0 028 Spark plug Hot type BPR6HS NEM Standard type 5 EMEN Spark performance Over 8 0 3 at 1 atm Primary 0 19 0 24 Q Ignition coil resistance Secondary 54 6 6 kQ Lighting 0 54 0 80 Q YMW Ground Charging coil 0 69 1 03 0 W R Ground Stator coil resistance Exciting coil 146 220 B R Ground Regulated voltage 13 0 16 0 V at 5 000 rom No load performance of A C generator More than 17 0V at 5 000 rpm Starter motor carbon brush length S 3 _ 3 5 0 138 Starter motor commutator under cut S 0 2 0 008 Starter relay resistance 80 150 Q Type designation STX5L BS MF Battery 12V ANNYIOHR Standard electrolyte S G 1 32 at 20 C 68 F SERVICING INFORMATION 7 14 BRAKE WHEEL Unit mm in ITEM STANDARD LIMIT Brake lever play 5 15 0 197 0 591 Brake pedal play 15 25 0 591 0 984 mesema _ 1 o m 114 0 vm gt pom AN 12 _ LX 4 Us Tire tread depth 7 15 SERVICING INFORMATION SUSPENSION Unit mm in ITEM SPECIFICATION LIMIT Rear wheel travel 56 6 2 228 pe TIRE PRESSURE COLD INFLATION TIRE PRESSURE FUEL OIL ITEM SPECIFICATION NOTE Gasoline used should be graded 85 95 octane or higher An Fuel type n unleaded gasoline is recommended Fuel tank capacity Use HYOSUNG HY
27. CAUTION This nut has left hand thread Conrod holder 09910 20115 Remove the fixed drive face 2 and V belt Disassemble the movable drive face 4 3 9 9 MOVABLE DRIVEN FACE Remove the clutch housing STARTER DRIVEN GEAR Remove the starter driven gear 2 Remove the starter idle gear cap and starter motor pinion Remove the starter motor Loosen the clutch shoe nut with the special tool Rotor holder 09930 40113 Remove the nut while holding down the clutch shoe assembly by both hands as shown in the illustration WARNING Gradually back off the clutch shoe assembly pressed down by hand to counter the clutch spring load Releasing the hand suddenly may cause the parts to fly apart D Nut 2 Clutch shoe assembly 3 Spring CAUTION Do not attempt to disassemble the clutch shoe assembly It is not serviceable Using a thin blade screwdriver or the like pry up the movable driven face spring guide Remove the pins movable driven face and fixed driven face 0 ENGINE 3 10 3 11 ENGINE Remove the needle bearing 4 with the special tools Bearing remover 17mm 09923 73210 Rotor remover sliding shaft 09930 30102 4 CAUTION The removed bearing should be replaced with a new one Remove the circlip B 2 Ex 2 0100000 a Remove the bearing with the special tool Wheel be
28. Check and clean Check and clean Check and replace Check throttle valve for operation Check and clean Replace Replace Check and adjust Clean Adjust or replace 7 3 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes No sparking or poor sparking Spark plug soon becomes fouled with carbon Spark plug electrodes overheat or burn Magneto does not charge Magneto charge but charging rate is below the specific ations Magneto overcharges Unstable charging Starter switch is not effective BATTERY Defective CDI amp Ignition coil unit Defective spark plug Defective magneto stator coil Loose connection of lead wire Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Incorrect engine oil Spark plug too hot The engine overheats Spark plug loose Mixture too lean Not enough engine oil Open or short in lead wires or loose lead connections 2 Shorted grounded or open magneto coil Shorted or open regulator rectifier Lead wires tend to get shorted or open circuited or loosely connected at terminal Grounded or open circuited stator coils of magneto Defective regulator rectifier Defective cell plates in the batttery Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective
29. Confirm the thread size and reach when replac ing the plug PERIODIC MAINTENANCE 2 6 CARBURETOR NOTE Inspect Initial 1 month and Every 6 months 9 IDLE SPEED Adjust the throttle cable play Warm the engine up NOTE A warm engine means an engine has been run for 10 minutes l Remove the seat and cover in Adjust the throttle stop screw to obtain the idle speed as follows Engine idle speed 1 800 100 rom Engine tachometer 09900 26006 Finally adjust the throttle cable play 9 THROTTLE CABLE PLAY Loosen the lock nut and adjust the cable slack by turning adjuster 3 in or out to obtain the following cable play After adjusting play tighten the lock nut 0 5 1 0mm Throttle cable slack 0 020 0 039 in FUEL LINE NOTE Inspect Initial 1 month and Every 3 months Replace every 4 years Inspect leakage of the fuel line and connection part If abnormal replace it 2 7 PERIODIC MAINTENANCE TRANSMISSION OIL NOTE Inspect Initial 1 month and Every 6 months After a long period of use the transmission oil qual ities will deteriorate and quicken the wear of sliding and interlocking surfaces Replace the transmission oil periodically following the procedure below Start the engine to warm up the oil this will facilitate draining of oil Unscrew the oil filler cap and drain plug drain the oil completely Tighten the drai
30. INDER ly oni OUEST TEST 3 21 PISTON ee MEE MIRO ER 3 21 REED VALVE UM M eum 3 24 ENGINE REASSEMBLY DU 7 S Je 3 24 OIL SEALS 3 24 BEARINGS Toe CN mE 3 25 BUSHINGS E ES er tere 3 25 CRANKSHAFT RH 3 26 CRANKCASE 9 3 27 TRANSMISSION 3 28 STARTER PINION STARTER DRIVEN GEAR AND STARTER MOTOR 2 22 5 3 30 MOVABLE DRIVEN AND CLUTCH 2222222 3 32 MOVABLE DRIVE 2222 e 3 36 MAGNETO 22222222 2 2 3 28 PISTON 222222222122 2 2 3 39 OIL PUMP AND INTAKE PIPE oeie 3 41 COOLING FAN t 3 42 MUFFLER H 3 43 3 1 ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame thoroughly clean the engine with a suitable cleaner and drain trans mission oil etc The procedure of engine removal is sequentially explained in the following steps and engine reinstallation is effected by reversing the removal proce dure Place an oil pan under the engine and remove the oil filler cap and the oil drain plug to drain out transmis sion oil Remove the seat and frame cove
31. LER AND MOVABLE DRIVE FACE Inspect each roller and movable drive face for wear or damage MOVABLE DRIVEN SPRING Measure the free length of the movable driven spring If the length is shorter than the service limit replace the spring with a new one Movable driven spring free length 130 0 mm 5 118 in 130 0 mm 5 118 in 9 DRIVEN FACE AND OIL SEAL Turn the driven faces and check to see that the driven faces turn smoothly If any stickness or hitches are found visually inspect the lip of seal driven face sliding surface and sliding pins for wear or damage 9 DRIVEN FACE Inspect the belt contacting surface of both driven faces for any scratches wear and damage Replace driven face with new one if there are any abnormality CYLINDER HEAD Decarbon the combustion chamber Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places Cylinder head Service limit distortion 0 05 mm 0 002 in Thickness gauge 09900 20806 If the largest reading at any portion of the straight edge exceeds the limit rework the surface by rubbing it against emery paper of about 400 laid flat on the surface plate in a lapping manner The gasketed sur face must be smooth and perfectly flat in order to secure a tight joint a leaky joint can be the cause of reduced power output and increased fuel consump tion ENGINE 3
32. N Draw the empty receptacle out slowly because there may be a chance which remaining elec trolyte vaporize 6 Insert of the caps Insert the cap into the filler holes pressing it firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover 9 ASSISTANCE RECHARGING Use the battery that is made after 2 years as the main tenance free battery Use the battery at condition of the hightemperature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric current or voltage when the battery discharged Do not assistance recharge except the right side table In times of recharging the battery please do it at the condition of removal of the lead wire WARNING The firearm is strictly prohibited Insert the caps firmly Assistance Recharging Standard Fast CONTENTS FRONT WHEEL AND BRAKE 6 1 REMOVAL 6 2 INSPECTION AND DISASSEMBLY T rei 6 3 REASSEMBLY AND REMOUNTING TTE 6 4 STEERING AND FRONT SUSPENSION 6 6 REMOVAL AND DISASSEMBLY 6 6 INSPECTION ETT CO 6 9 REASSEMBLY AND REMOUNTING ea 6 10 TOE IN ADJUSTMENT
33. NE 3 34 Install the movable driven face to the fixed driven face CAUTION When reinstalling the movable driven face to the fixed driven face make sure that the O ring is positioned properly Install the spacer and 3 at three places on the driven face hub Apply SUPER GREASE A lightly to the cam part where the pins are placed A SUPER GREASE Position the two O rings 4 Install the movable driven face seat CAUTION The seat is installed rotatable naturally The O ring get damaged in case of installed by force 3 35 Install the spring Install the clutch shoe assembly and nut Tighten the nut to the specified torque with the spe cial tool Rotor holder 09930 40113 V Clutch shoe nut 40 60 N m 4 0 6 0 kg m Insert the V belt between the driven faces as deep inside as possible while pulling the movable driven face all the way outside to provide the maximum belt clearance CAUTION The V belt should be positioned so that the arrows on the belt periphery point the normal turning direction The V belt contact face on the driven faces should be thoroughly cleaned to be free from oil Thoroughly clean the clutch housing 4 to be free from oil and position it over the clutch shoe assem bly Tighten the clutch housing nut to the specified torque V Clutch housing nut 40 60 N m 4 0 6
34. OTORS amp MACHINERY INC Overseas Technical Department O COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 2001 HOW USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections are listed on the previous page as GROUP INDEX select the section where you look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUPER GREASE Apply SUPER GREASE Apply SILICONE GREASE Apply MOLY PASTE Apply BOND 1215 Apply THREAD LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit its exploded view is provided with work instruction and other service information such as the tightening torque lubricating points and looking agent points Example STEERING AND FRONT SUSPENSION 1
35. POL HS OIL or an equivalent good quality synthetic based 2 stroke engine 42 4 2 6 2 8 ml disch t at 3 000rpm for 5 minutes Transmission oil type SAE 10W 30 or 10W 40 multi grade motor oil Transmission oil capacity SERVICING INFORMATION 7 16 WIRE AND CABLE ROUTING SWITCH ASS Y STEERING CDI UNIT IGINTION COIL SWITCH ASS Y STOP FRONT SWITCH ASS Y HANDLE LH WIRE AND CABLE GUIDE 09407 14403 09407 14403 HARNESS REGULATOR BATTERY BATTERY STARTER RELAY 09407 14403 EMERGENCY SWITCH mmm Hil a 7 17 SERVICING INFORMATION EMERGENCY SWITCH CASE ul VITA SERVICING INFORMATION 7 18 STARTER RELAY 09407 14403 MAGNETO START MOTOR 7 19 SERVICING INFORMATION N 09407 14403 FRONT STOP SWITCH 09407 14403 HANDLE SWITCH LH 9 I lt Van HANDLE SWITCH LH STOP SWITCH CDI UNIT FRONT FENDER CDI UNIT ASSEMBLY POSITION SERVICING INFORMATION 7 20 WIRING DIAGRAM YOR G YIM GA SHU enig ANT SHUM M ng 1 UPM LUM HM poe YIM 34567 qS ID YOR G YM 9IIUAA J 9 1 UPM Jelg MG pod a uoo 9 Jo984 9JIUA Poy ANY JooeJ UBD 8 Og umoig Jg 199 U99JC YIM MOJISA DA
36. Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all off the material manufacturer 5 instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil or exhaust system during or for a while after engine operation After servicing fuel oil exhaust or brake systems check all lines and fittings related to the system for leaks GENERAL INFORMATION 1 2 A CAUTION If parts replacement is necessary replace the parts with HYOSUNG Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged an orderly manner so that they may be reinstalled in the proper order and orientation Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean and also lubricated when specified When use of a certain type of lubricant bond or sealant is specified be sure to use the specified type When removing the battery disconnect the negative cable first and then positive cable When ing the battery co
37. TION 7 6 Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09910 20115 TN 09913 76010 Conrod holder QU Bearing installer Used to drive crankshaft bearing in 09910 32812 09913 80112 Crankshaft installer Bearing installer Used to install the crankshaft in the crankcase 4 Used to drive bearing in 09910 34510 09915 63310 Piston pin puller Compression gauge adapter 09913 10760 09915 64510 Fuel level gauge Lo 4 Compression gauge Measure height of carburetor 09913 50121 6 09920 13120 Oil seal remover A AN Crankcase separater Used to remove the oil seal 09913 70122 09921 20200 Bearing installer Bearing remover 10mm Used to drive bearing in Used to remove oil seal or bearing 09913 75520 09921 20210 Bearing installer Bearing remover 12mm Used to remove oil seal or bearing 09913 75820 gm 09923 73210 Bearing installer Bearing remover 17mm Used to remove bearing with the rotor remove sliding shaft 09913 75830 p 09923 74510 Bearing installer Bearing remover 20 35mm Used to remove bearing with the rotor remove sliding shaft 7 7 SERVICING INFORMATION Special tools Part Number Part Description Special tools Part Number Part Description 09924 84521 lt lt 09930 30163 Bearing installer 09930 10121 09930 40113 Spark plug socket wrench set Rotor holder Widely used to lock rotary p
38. ank web to web width 40 0 0 1 mm 1 575 0 004 in When mounting the crankshaft into the crankcase it is necessary to pull its left end into the crankcase with the special tool Crankshaft installer 09900 32812 Conrod holder 09910 20116 CAUTION Never fit the crankshaft into the crankcase by driv ing it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affected CRANKCASE Wipe the crankcase mating surfaces both surfaces with cleaning solvent Apply BOND 1215 uniformly to the mating surface of the left half of the crankcase and install the dowel pins BOND 1215 Install the two dowel pins Tighten the crankcase screws securely Check if crankshaft rotates smoothly ENGINE 3 28 Install the new oil seal 1 to the crankcase with the special tool Bearing installer 09913 85210 NOTE Align the oil seal with edge amp of the crankcase as shown in the illustration TRANSMISSION 3 29 ENGINE Install the on to the rear axle shaft Assemble the idle shaft subassembly using the idle shaft and thrust washer 4 then install the sub assembly on the gear box Install the final driven gear on the rear axle shaft using the circlip Center Thrust Circlip T YN Rounded coner Install the idle thrust washer new gasket and dowel
39. aring remover 09941 50111 CAUTION The removed bearing should be replaced with a new one 3 12 TRANSMISSION Drain transmission oil Remove the gear box cover 0 Remove the drive shaft Remove the oil seal 3 from the gear box cover with the special tool Oil seal remover 09913 50121 CAUTION The removed oil seal should be replaced with new one Remove the bearing 4 with the special tool Bearing installer 09943 88211 CAUTION The removed bearing should be replaced with a new one Remove the circlip and final driven gear Remove the idle shaft 7 Remove the drive shaft bearing 8 and idle shaft bearing Rotor remover sliding shaft 09930 30102 Bearing remover 12mm 09921 20210 3 13 CRANKCASE Remove the crankcase securing screws Crankcase separater 09920 13120 NOTE Loosen the crankcase screws diagonally Remove the crankshaft with the special tool Crankcase separater 09920 13120 3 14 Remove the bushing Using two steel tubes of appropriate size press out the engine mounting bushings on a vise as shown in the illustration 3 15 ENGINE Bushing Crankcase Crankcase ENGINE COMPONENTS INSPEC TION AND SERVICING BEARINGS Wash the bearing with cleaning solvent and lubricate with motor oil before inspecting Turn the inner ring and c
40. arts such as a clutch shoe 09930 30102 09941 50111 Rotor remove sliding shaft SDN Wheel bearing remover Used to with bearing remover or rotor remover Used to remove wheel bearing SERVICING INFORMATION 7 8 TIGHTENING TORQUE ENGINE Magneto rotor nut 35 45 9 04 5 Muffler mounting bolt 18 28 1 8 2 8 Exhaust pipe bolt 0 8 1 2 0 aa 7 9 SERVICING INFORMATION CHASSIS Rear brake disc bolt 22 355 2273 5 Rear brake caliper mounting bolt 0 5 0 7 Front axle nut M14 50 80 5 0 8 0 Rear brake caliper lever bolt 68 0 6 0 8 TIGHTENING TORQUE CHART For other bolts and nuts who s torque is notdisted refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt wm Wm _ 1 0 1 6 18 0 28 0 1 8 2 8 s a SERVICE DATA CYLINDER PISTON PISTON RING ITEM Cylinder to piston clearance Cylinder bore Piston diam Cylinder distortion Cylinder head distortion Piston ring clearance Free condition Piston ring clearance Assembling condition Piston ring ring groove clearance Piston pin bore 1 0 Piston pin O D CONROD CRANKSHAFT ITEM Conrod small end bore I D Conrod big end runout Crank web to wed width Crankshaft runout SERVICING INFORMATION 7 10 Unit mm in LIMIT 0 120 0 0047 52 590 2 0705 52 332 2 0603 STANDARD 0 073 0 083 0 0029
41. by hand to inspect if any abnormal noise occurs or it rotates smoothly Replace the bearing if there is anything unusual Remove the spacer Remove the inner and outer dust seals with the spe cial tool Oil seal remover 09913 50121 CAUTION The removed dust seal should be replaced with new ones Drive out the both bearings with the special tool in the following procedures Wheel bearing remover 09941 50111 Insert the adapter into the bearing After inserting the wedge bar from the opposite side lock the wedge bar in the slit of the adapter Drive out the bearing by knocking the wedge bar 4 CAUTION The removed bearing should be replaced with new one TIRE Refer to page 2 11 92 BRAKE DRUM Measure the brake drum 1 0 to determine the extent of wear and if the limit is exceeded by the wear noted replace the brake drum The value of this limit is indicated inside of drum Brake drum I D 110 7 mm 4 358 in 9 BRAKE SHOE Check the brake shoe and decide whether it should be replaced or not from the thickness of brake lining Brake shoe lining thickness 2 mm 0 079 in CAUTION Replace the brake shoe as a set otherwise brak ing performance will be adversely affected REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel and brake in the reverse order of removal and disassembly and also carry out the following steps When installing the brak
42. driven gear and install it to the crankcase SUPER GREASE A Install the oil pump 2 and tighten it to the specified torque V pump bolt 3 5 N m 0 3 0 5 kg m ENGINE 3 42 Install the reed valve gasket 1 intake pipe gasket 2 and intake pipe with reed valve 3 to the crankcase COOLING FAN Install the cylinder cowling Install the fan case Install the magneto lead wire and starter motor lead wire 3 43 Install the cooling fan Install the cooling fan cover 2 MUFFLER Tighten the exhaust pipe bolts 3 and muffler mount ing bolts to the specified torque 9 Exhaust pipe bolt 6 12N m 0 8 1 2 m Muffler mounting bolt 18 28 m 1 8 2 8 m FUEL SYSTEM CONTENTS CARDURETOR EMI 4 1 REMOVAL Rm 4 1 7777 4 2 INSPECTION DM 4 4 REASSEMBLY AND REMOUNTING 4 5 R ER 8 4 7 REMOVAL 4 7 te 4 7 REMOUNTING 4 8 e E 4 8 1 FUEL SYSTEM 4 CARBURETOR REMOVAL Remove the front and rear fender FUEL SYSTEM 4 2 Remove the carburetor top cap and disconnect the throttle cable Disconnect the fuel hose Remove the carburetor by loosening the mounting bolts
43. e 5 5 THERMOELEMENT e 22 5 5 SWITCHES INSPECTION e 5 6 UU FEN Jmm 5 7 5 1 ELECTRICAL SYSTEM IGNITION CHARGING SYSTEM Stator Ignition 5 Engine stop pm IGNITION COIL Pull out the spark plug Place it on the cylinder head after installing it at the plug cap to obtain ground Push in the electric starter switch to rotate the start ing motor test sparking performance Spark performance Over 8 mm 0 3 in Check the ignition coil with the pocket tester Ignition coil resistance Primary 0 19 0 24 Q Pocket tester 09900 25002 Regulator Rectifier Plug cap Ground CDI UNIT Using the pocket tester R x 1kQ range measure the resistance between the lead wires in the following table Unit Probe of tester Cx pes rs e pese s fase ofr S ore ore een ore ee re eas Probe of tester Pocket tester 09900 25002 STATOR COILS Using the pocket tester measure the resistance between the lead wire and ground If the resistance checked 15 incorrect replace the coil Unite Q Stator coil resistance Standard Lighting coil 0 54 0 80 0 Y W Ground Charging coil 0 69 1 30 9 W R gt Ground Exciting coil 146 220 Q B R Ground Pick up coil 90 110 Q 9 CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Measure the DC voltage between the battery terminal CO
44. e camshaft apply SUPER GREASE to the camshaft and cam face AH SUPER GREASE Install the brake shoes with spring hooks faced inside CAUTION Be careful not to apply too much grease to the cam and pin If grease gets on the lining break slippage will result Install the brake cam lever to the brake camshaft Tighten the brake cam lever nut to the specified torque V Front brake cam lever nut 6 8 0 6 0 8 m CHASSIS 6 4 6 5 CHASSIS Apply BOND 1215 to the front brake plate as shown photo BOND 1215 Install the front brake drum and tire CHASSIS 6 6 STEERING AND FRONT SUSPENSION TIGHTENING TORQUE ASSEMBLING APPLY GREASE ASSEMBLING APPLY GREASE APPLY GREASE TO LIPS D APPLY GREASE ASSEMBLING APPLY GREASE REMOVAL AND DISASSEMBLY Remove the front fender Remove the front wheel and brake Refer to page 6 2 Remove the tie rod end nut Remove the steering knuckle 6 7 CHASSIS Remove the suspension arm mounting bolts and front shock absorber upper mounting bolt Remove the suspension arm with shock absorber 7 TUR Remove the shock absorber Remove the dust seals and spacer CHASSIS 6 8 Remove the handlebar switch Remove the throttle lever case Remove the front brake lever holder
45. ge Conrod small end bore 1 0 16 040mm 0 632 in Dial calipers 09900 20605 AUTOMATIC CLUTCH INSPECTION This vehicle is equipped with an automatic clutch and variable ratio belt drive transmission The engagement of the clutch is governed by engine RPMs and centrifu gal mechanism located in the clutch To insure proper performance and longevity of the clutch assembly it is essential that the clutch engages smoothly and gradually Two inspection checks must be performed to thoroughly check the operation of the driv etrain Follow the procedures listed CLUTCH IN INSPECTION Warm the engine to normal operating temperature Connect an engine tachometer to the engine Seated on the vehicle with the vehicle on level ground increase the engine RPMs slowly and note the RPM at which the vehicle begins to move forward Standard 3 900 rom Standard 200 rpm Engine tachometer 09900 26006 CLUTCH TIGHT INSPECTION Grip the front brake lever and depress rear brake pedal fully and measure the engine RPM when open the throttle Warm the engine to normal operating temperatures Connect an engine tachometer to the engine Apply the rear brake as firm as possible Briefly open the throttle fully and note the maximum engine RPMs sustained during the test cycle A CAUTION Do not apply full power for more than 3 seconds or damage to the clutch or engine may occur Standard 5 900 rom
46. ging operation Replace the battery and correct the charging system Replace the battery 4 Battery is too old Replace the battery Reversed battery 1 The battery has been connected the wrong way round in the Replace the battery and be sure to polarity system so that it is being charged in the reverse direction connect the battery properly Battery discharges 1 container top and sides E too rapidly 2 is too old E SERVICING INFORMATION 7 4 CHASSIS Complaint Symptom and possible causes Handling feels too heavy or stiff Steering oscillation Steering pulling to one side Shocks coming to steering uneven wear of tires Steering noise 1 Disturbed front wheel alignment 2 Poorly lubricated 3 Not enough pressure in tires 4 Tie rod ends tending to seize 5 Linkage connections tending to seize 1 Wheel tires inflated unequally 2 Wobbly wheels 3 Loose nut on wheel hub 4 Damaged or worn wheel hub bearing 5 Worn or loose tie rod ends 6 Defective or incorrect tires 7 Damaged wishbone arm bushing 8 Loosen bolts and nuts on chassis 1 Wheel tires unequally inflated 2 Disturbed front wheel alignment 3 Worn or broken wheel hub bearing 4 Distorted frame 5 Defective shock absorber 1 Tire inflating pressure too high 2 Worn steering linkage connections 3 Loose bolts on suspension system Adjust Lubricate Adjust Replace
47. he cylinder head will raise the compression ratio and may cause pre ignition or overheating Carbon deposited at the exhaust port of the cylinder will prevent the flow of exhaust gases reducing the output Remove carbon deposits periodically PERIODIC MAINTENANCE 2 4 2 5 PERIODIC MAINTENANCE SPARK PLUG NOTE Inspect Initial 1 month and Every 3 months Replace Every 6 months Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance If the spark plug is used for a long period the electrode grad ually burns away and carbon builds up along the inside part In accordance with the Periodic Inspection Chart the plug should be removed for inspection cleaning and resetting the gap Carbon deposits on the spark plug will prevent good sparking and cause misfiring Clean the deposits off periodically if the center electrode is fairly worn down the plug should be replaced and the plug gap set to the speci fied gap using a thickness gauge 0 6 0 7 mm Spark plug gap 0 024 0 028 in Thickness gauge 09900 20804 Q Check spark plug for burnt condition If abnormal replace the plug as indicated below 607mm 0 024 0 028 in SPARK PLUG SPECIFICATION V Spark plug 25 30 N m 2 5 3 0 kg m 4 CAUTION To check the spark plug first make sure that the fuel used is unleaded gasoline and if plug is either sooty with carbon or burnt white replace it
48. heck to see that the inner ring turns smoothly If it does not turn lightly quietly and smoothly or if noise is heard the bearing is defective and must be replaced with a new one OIL SEALS Damage to the lip of the oil seal may result in leakage of the fuel air mixture or oil Inspect for damage and be sure to replace the damaged seal if found CRANKSHAFT 9 CRANKSHAFT RUNOUT Support the crankshaft by the V blocks with the dial gauge rigged to read the runout as shown Service limit Crankshaft runout 0 05 mm 0 002 in V block 09943 21304 Magnetic stand 09900 20701 Dial gauge 09900 20606 Excessive the crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine life 9 WEAR AND CLEARANCE OF CONROD BIG END Turn the crankshaft with the conrod to feel the smooth ness of rotary motion in the big end Move the rod up and down while holding the crankshaft rigidly to be sure that there is no rattle in the big end Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod This method can also check the extent of wear on the parts of the conrod s big end If wear exceeds the limit conrod crank pin and crank pin bearing should all be replaced Service limit Conrod big end runout 3 0 mm 0 12 in ENGINE 3 16 3 17 9 CONROD SMALL END BORE I D Measure the conrod small end diameter with a caliper gau
49. icle Identification Number is stamped on the front frame member The engine seri al number is stamped on the right side of crankcase assembly These numbers are required especially for registering the machine and ordering spare parts FRAME SERIAL NUMBER 1 5 GENERAL INFORMATION FUEL AND OIL RECOMMENDATIONS FUEL Gasoline used should be graded 85 95 octane or higher An unleaded type gasoline is recommended If engine pinging is experienced substitute another brand as there are differences between brands 9 ENGINE OIL Use HYOSUNG HYPOL OIL HS If they are not available use a good quality TWO STROKE engine oil 9 TRANSMISSION OIL Use a good quality SAE 10W 30 or 10W 40 multigrade motor oil Classification system 10W 30 or 10W 40 SF or SG If an SAE 10W 40 motor oil is not available select an alternative according to the following chart 15W 40 15W 50 MULTIGRADE 10W 40 10W 50 30 20 10 O 10 20 30 40 TEMP F 22 4 14 32 50 68 86 104 GENERAL INFORMATION 1 6 EXTERIOR ILLUSTRATION at sj 670 9 uc 820 WIDTH VAN 865 HEIGHT 825 950 WHEEL BASE 1 355 LENGTH 1 7 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS overall lengit A eaa 1 355 mm 53 4 in eco rem 820 mm 32 3 in Overall height cc 865 mm 34 1 in Wheelbase
50. inum tape to seal the battery electrolyte filler hole untill use as battery of completely seal type Do not use it except the battery electrolyte When pour into the battery electrolyte necessarily use the electrolyte of the specified capacity Do not open the sealing cap after recharge the bat tery eletrolyte Filling electrolyte 0 The battery is put on even land remove the alu minum tape sealing 2 Remove the cap at the electrolyte container A CAUTION Aluminum tape Do not remove the seal not prick with sharp thing Filler holes ELECTRICAL SYSTEM 5 8 3 Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill CAUTION There may be a case which can t pour the elec trolyte if you put it into electrolyte container slopely Confirmation of pour Make sure that air bubbles are coming up each elec trolyte container and keep this position for about more than 20 minutes CAUTION If no air bubbles are coming up from a filler Air bubble port tap the bottom of the two or three times 5 9 ELECTRICAL SYSTEM 6 Separation of electrolyte container After confirming that you entered the electrolyte into bat tery completely remove the electrolyte containers from the battery 4 CAUTIO
51. lock nuts 2 are left hand thread 9 HANDLEBAR Install the handlebar with the punch mark aligned with the handlebar holder as shown Tighten the handlebar holder bolts to the specified torque V Handlebar holder bolt 18 4 28 6 N m 1 84 2 86 kg NOTE 5 between the handlebar holder should be even m 7 lt lt CHASSIS 6 10 6 11 CHASSIS ADJUSTMENT The procedure for adjusting the toe in as follows Place the vehicle on level ground and set the handle bar straight Make sure that all tires are inflated to the standard pressure COLD INFLATION TIRE PRESSURE Loosen the lock nuts 4 on each tie rod CAUTION Inside lock nuts 1 are left hand thread Measure the distances A and B of front wheels in illustration and adjust the tie rods right and left to within the specified range in 8 mm 0 315 in NOTE Temporarily tighten the four lock nuts Check that the distances in the illustration are equal If the distances C and D not equal readjust the tie rod right or left whichever makes the toe in value closer to the specification Check the toe in again by measuring the distances A and B f the toe in is not within specification repeat the adjustment as above until proper toe in value is obtained and at the same time the distances C and D become equal Tighten the f
52. ly and also carry out the following steps Tighten the brake lever bolt and caliper mounting bolts to the specified torque SPECIFIED TORQUE Rear brake caliper lever bolt Rear brake caliper mounting bolt CHASSIS 6 14 6 15 CHASSIS REAR AXLE HOUSING AXLE SHAFT AND SHOCK ABSORBER m ue REMOVAL Remove the rear wheel Refer to page 6 12 Remove the rear brake Refer to page 6 13 Remove the chain cover Remove the axle shaft with rear sprocket A ASSEMBLING APPLY GREASE Remove the shock absorber Remove the rear axle housing Remove the sprocket mounting flange by removing the nut INSPECTION AND DISASSEMBLY 9 AXLE HOUSING BEARING Inspect the play of bearing inner ring by hand while mounting in the axle housing Rotate the inner ring by hand to inspect if any abnormal noise occurs or it rotates smoothly Replace the bearing if there is anything unusual CHASSIS 6 16 6 17 CHASSIS Remove the dust seals with the special tool Oil seal remover 09913 50121 A CAUTION Replace the removed dust seals with new ones Remove the right and left bearings and spacer SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other damage REAR SPROCKET Inspect the sprocket s teeth for wear If they are worn as illustrated replace the sprocket and drive chain as a set Normal wear Excessive wear Rom
53. n plug Supply a good quality SAE 10W 30 or 10W 40 multi grade motor oil TRANSMISSION OIL CAPACITY Overhaul Check the oil level with the oil level screw 3 BRAKES NOTE Inspect Initial 1 month and Every months FRONT BRAKE BRAKE ADJUSTMENT Adjust the free play to 5 15mm 0 197 0 591 in by screwing in or out the front brake adjust nut 5 15mm 0 197 0 591 in Front brake lever play BRAKE LINING WEAR LIMIT This vehicle is equipped with the brake lining wear limit indicator on the front brake As shown in the illustration 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 embossed on the brake panel To check wear of the brake lining follow the steps below First check if the brake system is properly adjusted While operating the brake check to see that the extension line from the index mark is within the range on the brake panel If 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 REAR BRAKE BRAKE ADJUSTMENT Set the parking brake by pulling the lock lever 0 Rock the vehicle by pushing to see if the brake is sufficiently holding the wheels locked Adjust the brake if neces sary by turning the adjuster in or out 15 25 mm 0 591 0 984 Rear brake pedal play
54. nd start the engine After remounting the engine route wiring harness and cables properly by referring to the sections wire routing and cable routing and adjust the fol lowing items to the specification i Throtile Cablg Refer to page 2 6 Idling adjustment Refer to page 2 6 Front brake cable erste a abite Refer to page 2 7 4 Rear brake Refer to page 2 8 lt Drive chain e Refer to page 2 10 ENGINE 3 6 ENGINE DISASSEMBLY MUFFLER Remove the muffler removing the bolts 9 CYLINDER Remove the cylinder cowling Remove the cylinder head 1 and cylinder 2 9 PISTON Place a cloth beneath the piston and remove the pis ton pin circlip 3 with a long nose pliers Remove the piston pin and piston Remove the piston pin bearing 3 7 ENGINE 9 INTAKE PIPE AND OIL PUMP Remove the intake pipe and oil pump Remove the reed valve Remove the oil pump driven gear 4 MAGNETO Remove the cooling fan Remove the magneto rotor nut with the special tool Conrod holder 09910 20115 ENGINE 3 8 Remove the magneto rotor with the special tool Rotor remover sliding shaft 09930 30102 Rotor remover 09930 30163 Remove the magneto stator and key MOVABLE DRIVE FACE Remove the clutch cover Remove the fixed drive face nut with the special tool
55. ng be sure to carry out an air bleeding operating with the oil pump in place before returning the vehicle to the user To bleed air hold the vehicle in standstill condition Loosen the air bleeding screw to let out air and after making sure that the trapped air has all been bled tight en the air bleeding screw completely 9 CHECKING OIL PUMP Use the special tool to check the pump for capacity by measuring the amount of oil the pump draws during the specified interval Remove the frame cover Have the HYPOL Oil gauge filled with HYOSUNG HYPOL OIL HS and connect it to the suction side of the pump Run the engine at 3 000 rpm Holding engine speed at the same 3 000 rpm let the pump draw for 5 minutes For this operation the reading taken on the device should be 2 6 2 8 HYPOL Oil gauge 09900 21602 Engine oil 2 6 2 8m discharge amount at 3 000 rpm for 5 minutes CAUTION During this inspection strictly follow the follow ing points Do not touch the rear wheel while running the engine FUEL SYSTEM 4 8 ELECTRICAL SYSTEM CONTENTS IGNITIONICHARGING SYSTEM 2222222 2 122 e 5 1 IGNITION 222222 5 1 CDI UNIT 5 2 STATOR COILS oo e E 5 2 REGULATORIRECTIFIER c R 5 3 STARTER SYSTEM lt d 5 3 STARTING MOTOR REMOVAL AND DISASSEMBLY P 5 4 STARTING MOTOR INSPECTION 222 2 2 2 2 2 0015 5 4 STARTER RELAY INSPECTION
56. nnect the positive cable first and then negative cable and replace the terminal cover on the positive terminal When performing service to electrical parts if the service procedures do not require use of bat tery power diconnect the negative cable at the battery Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse circlip When installing a new circlip take care not to expand the end gap larger than required to slip the over the shaft After installing a circlip always ensure that it is completely seat ed in its groove and securely fitted Do not use self locking nuts a few times over Use a torque wrench to tighten fasteners to the torque values when specified Wipe off grease or oil if a thread is smeared with them After reassembly check parts for tightness and operation 1 3 GENERAL INFORMATION HYOSUNG NOTE Difference between photographs and actual vehicles depends on the markets GENERAL INFORMATION 1 4 SERIAL NUMBER LOCATION The frame serial number or V I N Veh
57. oONNSOAH HYOSUNG HYOSUNG MOTORS amp MACHINERY INC EMD SERVICE MANUAL TWANVIN E PII EE 99000 94310 This manual contains an introductory description on HYOSUNG J and procedures for its inspection GENERAL INFORMATION service and overhaul of its main components Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize PERIODIC MAINTENANCE yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so ENGINE that you can assure your customers of your optimum and quick service FUEL SYSTEM This manual has been prepared on the basis of the latest specification at the time of publica tion If modification has been made since then dif ference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the CARSSIS basic principles of operation and work proce dures They may not represent the actual vehicle exactly in detail This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer ELECTRICAL SYSTEM SERVICING INFORMATION el HYOSUNG M
58. our nuts 0 after adjustment of toe in is made V Tie rod lock nut 22 4 35 7 N m 2 24 3 57 kg FRONT CHASSIS 6 12 REAR WHEEL TIGHTENING TORQUE m em A ASSEMBLING APPLY GREASE ASSEMBLING APPLY LOCK TIGHT REMOVAL Place the vehicle on level ground Support the vehicle by jack or block Romove the wheel center cap Romove the cotter pin and rear hub nut INSPECTION TIRE Refer to page 2 11 REMOUNTING Remount the rear wheel in the reverse order of removal 6 13 CHASSIS REAR BRAKE TIGHTENING TORQUE ASSEMBLING APPLY GREASE BRAKE PAD REPLACEMENT For replacing procedure of brake pad Refer to page 2 9 CALIPER DISASSEMBLY Remove the brake lever bolt and caliper mounting bolts 2 Remove the caliper Remove the brake pad Refer to page 2 9 Remove the rear caliper lever return spring DISC PLATE INSPECTION Check the disc for wear with a micrometer Replace the disc if the thickness exceeds the service limit Disc thickness 2 5 mm 0 098 in Micrometer 0 25mm 09900 20201 Check the disc for face runout with a dial gauge as shown Replace the disc if the runout exceeds the service limit Service limit Disc runout 0 3 mm 0 012 in Dial gauge 09900 20606 Magnetic stand 09900 20701 CALIPER REASSEMBLY Reassemble and remount the caliper in the reverse order of removal and disassemb
59. ove the rear sprocket 9 REAR AXLE SHAFT Using a dial gauge check the axle shaft for runout and replace it if the runout exceeds the limit Rear axle shaft runout 0 5 mm 0 02 in REASSEMBLY AND REMOUNTING Reassemble and remount the rear axle housing inthe reverse order of removal and disassmbly 6 18 CHASSIS SERVICING INFORMATION CONTENTS TROUBLESHOOTING eee 7 1 SPECIAL TO LS EOM 7 5 TIGHTENING TORQUE een 7 8 SERVICE 7 10 WIRE AND CABLE ROUTING t 7 16 WIRING DIAGRAM 7 20 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Engine does not Compression too low start or is hard 1 Excessively worn cylinder or piston rings Replace to start 2 Stiff piston ring in place Refair or replace 3 Gas leaks from the joint in crankcase cylinder or cylinder head Refair or replace 4 Damaged reed valve Replace 5 Spark plug too loose Tighten 6 Broken cracked or otherwise failed piston Replace Plug not sparking 1 Damaged spark plug or spark plug cap Replace 2 Dirty or wet spark plug Clean and dry 3 Defective CDI amp Ignition coil unit or stator coil Replace 4 Open or short in high tension cord Replace 5 Defective ignition switch Replace No fuel reaching the carburetor Clogged hole in the fuel tank cap Clean Clogged or defective fuel cock Clean o
60. r Turn the fuel cock to OFF position Remove the fuel hoses from the fuel cock and remove the fuel tank by removing mounting bolts Remove the muffler and exhaust pipe 3 2 Remove the engine ground lead wire 0 Remove the spark plug cap 2 Remove the starter motor lead wire 3 Disconnect the magneto coil lead wire 4 3 3 Disconnect the thermoelement coupler Remove the air cleaner and air cleaner chamber 0 Remove the carburetor assembly from the intakepipe Disconnect the oil hose and oil pump cable from the pump T7 hn 3 4 Remove the chain case cover Remove the engine sprocket from the drive shaft by using the snap ring pliers Remove the drive chain Remove the seven engine mounting link bolts Remove the engine assembly from the frame with rear axle housing assembly 3 5 ENGINE REINSTALLATION For remounting engine reverse the order of engine removal and take the following additional steps Install the engine mounting link bolts Refer to page 3 4 V Engine mounting link bolt 70 100 N m 7 0 10 0 kg m Install 90ml of transmission oil SAE 10W 30 or 10W 40 multi grade motor oil when engine is over hauled check the oil level 225 clay oul 27 CR Set the fuel cock to position a
61. r replace Defective carburetor float valve Replace Clogged fuel hose Clean or replace Engine stalls Carbon deposited on the spark plug Clean easily Defective CDI amp Ignition coil unit Replace Clogged fuel hose Clean Clogged jets in carburetor Clean Clogged exhaust pipe Clean Noisy engine Noise appears to come from piston 1 Piston or cylinder worn down Replace 2 Combustion chamber fouled with carbon Clean Piston pin bearing or piston pin bore worn Replace 4 Piston rings or ring grooves worn Replace Noise seems to come from crankshaft 1 Worn or brunt crankshaft bearings Replace 2 Worn or brunt conrod big end bearings Replace Noise seems to come from final gear box 1 Gears worn or rubbing Replace 2 Badly worn splines Replace 3 Worn or damaged bearings of drive shaft for rear axle shaft Replace Slipping clutch 1 Worn or damaged clutch shoes Replace 2 Worn clutch drum Replace Engine idles 1 Excessively worn cylinder or piston rings Replace poorly 2 Stiff piston ring in place Replace 3 Gas leaks from crankshaft oil seal Replace 4 Spark plug gaps too wide Adjust or replace 5 Defective CDI amp Ignition coil unit Replace 6 Defective magneto stator coil Replace T Float chamber fuel level out of adjustment in carburetor Replace 8 Clogged jets in carburetor Clean or adjust 9 Broken or damaged reed valve Replace Complaint Symptom
62. read depth STEERING NOTE Inspect Initial 1 month and Every 3 months Steering system should be adjusted properly for smooth manipulation of handlebars and safe running Place the vehicle on the level ground Make sure that the tire pressure is within speci fication Refer to page 2 11 The front wheels are set in straight ahead position Measure the distance A and B in illustration of front wheels with a gauge as shown in illustra tion and calculate the difference between A and B 8 0 mm m 0 315 in if the toe in is off the specification bring it into the specified range Refer to page 6 11 CHASSIS BOLTS AND NUTS NOTE Tighten Initial 1 month and Every 3 months Check that all chassis bolts and nuts are tightened to their specified torque Refer to page 7 9 PERIODIC MAINTENANCE 2 12 CONTENTS ENGINE REMOVAL AND REINSTALLATION 21212222 3 1 ENGINE REMOVAL 3 1 ENGINE REINSTALLATION TELE CE 3 5 ENGINE DISASSEMBLY 222222222202212 2 3 6 ENGINE COMPONENTS INSPECTION AND SERVICING 3 16 BEARINGS M eepM Sener 3 16 OIL SEALS 3 16 CRANKSHAFT A Y OS 3 16 AUTOMATIC CLUTCH INSPECTION mM Sine Jm 3 17 CYLINDER HEAD uu 3 20 CYL
63. rts and components OIL SEALS Fit the oil seals to the crankcase following the proce dure below Replace removed oil seals with new ones Coat SUPER GREASE A to the lip of the oil seals AZ SUPER GREASE Be sure to apply THREAD LOCK 1324 to outer surfaces of right and left crankshaft oil seals to pre vent them from moving THREAD LOCK 1324 ENGINE 3 24 3 25 When fitting the oil seal the crankcase insert it slowly with the special tools Oil seal installer 09913 75830 Bearing installer attachment 09924 74510 Bearing installer pilot 09924 74540 NOTE Align the oil seal with edge of the crankcase as shown in the illustration BEARINGS Install new bearings D 2 3 with the special tool Bearing installer 09913 75810 Bearing installer 09913 76010 1 ea PE gt B P BUSHINGS Using two steel tubes of appropriate size and a vise press the mounting bushings and B into the crankcase holes as shown in the illustration ENGINE 3 26 Knurled end should face inside Protrusive and D should be in the same dimension Crankcase s def ushing Bushing A ECT 2 Crankcase CRANKSHAFT 3 27 Measure the length between the webs referring to the figure at right when rebuilding the crankshaft Standard Cr
64. rvice limit 52 500 52 515mm 52 590mm ALZA 9 0669 20675 in 2 0705 in 02 432 52 447mm 52 332mm 0643 2 0648 in 2 0603 in ean 0 0 3 0 083mm 0 120mm clearance 0 0029 0 0033 in 0 0047 in 9 DE CARBONING De carbon the piston and piston ring grooves as illus trated After cleaning the grooves fit the rings and rotate them in their respective grooves to be sure that they move smoothly Carbon in groove is liable to cause the piston ring to get stuck in the groove and this condition will lead to reduce engine power output A piston whose sliding surface is badly grooved or scuffed due to overheating must be replaced Shallow grooves or minor scuff can be removed by grinding with emery paper of about 400 9 PISTON PIN BORE I D Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the following ser vice limit replace it with a new one Service limit 12 030 mm 0 474 in Piston pin bore 1 0 Dial calipers 09900 20605 ENGINE 3 22 3 23 9 PISTON PIN O D Using a micrometer measure the piston pin outside diameter at three positions Service limit 11 980 mm 0 472 in Piston pin O D Micrometer 0 25mm 09900 20201 9 PISTON RINGS Check each ring for the clearance reading the clear ance with a thickness gauge shown in the illustration If the clearance is found to exceed the limit indicated below replace i
65. s Pilot air screw 2 Throttle stop screw 3 Pilot jet 4 Main jet 5 Needle jet Install the needle valve and float on the carbu retor body Insert the float 9 to the carburetor Install the gasket and float chamber Install the throttle valve spring and jet needle J Wifi t lt gt 2 4 D FUEL SYSTEM 4 6 Install the thermoelement assembly Install the carburetor assembly Install the fuel hose Install the carburetor top 4 7 FUEL SYSTEM FUEL TANK REMOVAL Remove the frame covers Refer to page 4 1 Remove the fuel tank mounting bolts Turn the fuel cock to OFF and disconnect the fuel hose 1 Remove the fuel tank Remove the fuel cock INSPECTION 9 FUEL COCK If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel filter with compressed air Also check the fuel cock for cracks REMOUNTING Remount the fuel tank and fuel cock in the reverse order of removal WARNING Gaskets and must be replaced with new ones to prevent fuel leakage Tighten the fuel cock bolts evenly OIL PUMP 9 AIR BLEEDING Whenever evidence is noted of some air having leaked into the oil pipe from the oil tank in a machine brought in for servicing or if the oil pump has to be removed for servici
66. starting motor to the battery Starter relay R YIG IG switch Starter switch Starter motor Brake switch Battery L lI ELECTRICAL SYSTEM 5 4 STARTING MOTOR REMOVAL AND DISASSEMBLY Remove the starting motor Disassemble the starting motor as shown in the illustration STARTING MOTOR INSPECTION CARBON BRUSHES When the brushes are worn the motor will be unable to procedure sufficient torque and the engine will be diffi cult to turn over To prevent this periodically inspect the length of the brushes and replace them when they are too short or chipping Service limit Carbon brushes wear 3 5 mm 0 138 in COMMUTATOR If the commutator surface is dirty starting performance will decrease Polish the commutator with 400 or simi lar fine emery paper when it is dirty After polishing wipe the commutator with a clean dry cloth Measure the commutator under cut Segment Service limit 0 2 mm 0 008 in Commutator under cut 5 5 ELECTRICAL SYSTEM 9 ARMATURE COIL Using the pocket tester check the coil for open and ground by placing probe pins on each commutator seg ment and rotor core to test for ground and on any two segments at various places to test for open with the brushes lifted off the commutator surface the coil is found to be open circuited or grounded replace the armature Continuous use of a defective armature will cause the starting
67. t with a new one The clearance of each ring is to be measured with the ring fitted squarely into the cylinder bore and held at the least worn part near the cylinder bottom as shown in the illustration Piston ring clearance Service limit Assembly condition 0 75 mm 0 030 Thickness gauge 09900 20806 As the piston ring wears its clearance increases reduc ing engine power output because of the resultant blow by through the enlarged clearance Here lies the impor tance of using piston rings with the clearance within the limit Measure the piston ring free clearance to check the spring tension Piston ring clearance Service limit Free condition 3 6 mm 0 142 in Fix the piston ring the piston ring groove measure the ring side clearance with the thickness gauge while matching the sliding surfaces of piston and ring Piston ring groove clearance 0 02 0 06 mm 0 0008 0 0024 in Standard 0 02 0 06 mm 0 0008 0 0024 in REED VALVE When reinstalling the reed valve and stopper plate to the body align the both cut on the reed valve and stop per plate Apply THREAD LOCK 1324 to the stopper plate securing screws THREAD LOCK 1324 ENGINE REASSEMBLY Reassembly is generally performed in the reverse order of disassembly but there are a number of reassembling steps that demand or deserve detailed explanation or emphasis These steps will be taken up for respective pa

TE 90 - Hyosung Motors America

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