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SERVICE MANUAL - Hyosung

1. HYOSUNG HYOSUNG MOTORS amp MACHINERY INC SERVICE MANUAL 99000 91310 FOREWORD This manual contains an introductory description on HYOSUNG PRIMA SF 50 and procedures for its inspec tion service and overhaul of its main components Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared 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 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 forsservicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE FUEL SYSTEM ELECTRICAL SYSTEM CHASSIS
2. Lu 7 a _ Front turn signal KS Regulator RH LH SS Head Lamp Turn signal cable 74 cable Wiring harness Speedometer cable hose Sh ELECTRICAL SYSTEM 5 2 IGNITION CHARGING SYSTEM Stator Regulator Rectifier Ignition coil Lighting switch LHL Engine stop switch mr 1777 12V 12V 12V 15Wx2 SW 1 7WX2 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 Electro tester 09900 28106 Zi 5 3 ELECTRICAL SYSTEM Check the ignition coil with the pocket tester Pocket tester 09900 25002 Ignition coil resistance C D I UNIT Using the pocket tester R x 1 range measure the ms resistance between the lead wire in the following table m Plug cap Pocket tester 09900 25002 Unit kQ OO o 9 2 o pum STATOR COILS Using the pocket tester measure the resistance between the lead wire and ground If the resistance checked is incorrect replace the coil Unit Stator coil resistance Lead wire of tester Standard resistance Black Lighting coil 0 54 0 80 0 Chargifi
3. Z 7 Engine oil capacity 1 0 1 Acne wil 1 0 1 2 mp I D 60ml Hr E A at 3 000 rpm for 5 minutes F O 100m Hr Transmission oil type SAE 10W 30 or 10W 40 multi grade motor oil Transmission oil capacity Brake fluid type DOT 4 SERVICING INFORMATION 7 18 WIRE AND CABLE ROUTING REAR BRAKE Rear turnsignal L Rear turnsignal R L Fuse case 09407 22402 Starter motor magneto Rear t ianal R 09407 22402 Lamp assy Tail amp Stop Rear turnsignal R L 09407 22402 Engine earth Ignition coil Rear brake cable Brake cable 7 19 SERVICING INFORMATION M3lA amas 8 M3lA SSouJeH 9 qeo 9 qeo di 1 4 um il yes d 9 qeo Geo epoJu
4. Position the two O ring 3 Install the pin at three places on the driven face hub Apply SUPER GREASE lightly to the cam part where the pins are placed AG Super Grease Install the movable driven face seat CAUTION The seat is installed rotatable naturally The O ring get damaged in case of installed by force Install the spring Install the clutch shoe assembly 7 and nut 8 ENGINE 3 34 3 35 ENGINE Tighten the clutch shoe nut to the specified torque with the special tool Rotor holder 09930 40113 V Clutch shoe nut 40 60 N m 4 0 6 0 kg 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 D to be free from oil and position it over the clutch shoe assem bly Tighten the clutch housing the specified torque with the special tool Rotor holder 09930 40113 V Clutch housing nut 40 60 N Am 4 0 6 0 kg m ENGINE 3 36 MOVABLE DRIVE Install the roller 2 to the movable drive face 1 Mount the three dampers on the movabl
5. o qeo owed 11024 9 qe5 JOJOW J91J2 S eo WP ait S IVNSISNSNL 3 V3 p JOJOW exyeJg U Je91 peius 5 E JejeaH 102 uoniub juoJ4 9 qeo exyeJq sseuJeH 9 qeo epoJu L 9 qeo Jojeuiopeedg sseuJeH jeuDisuJn yoo 9 Jeddn juoJ4 epueJ 1 2 8500 Jepur A9 D Jamo cOvcc L0v60 9 Asse due ene 9522 asn4 ejdnoo 0016 9 Asse due jeuBisuun 1693 SERVICING INFORMATION 7 20 WIRING DIAGRAM Jane YOR UM GA ANT SHUM M ng 1 4902 POY
6. Remove the bearing 2 with the special tool Bearing installer 09913 76010 CAUTION The removed bearing should be replaced with a new one Remove the circlip 3 and final driven gear 4 Remove the idle shaft 6 Remove the drive shaft bearing Rotor remover sliding shaft 09930 30102 Bearing remover 12 mm 09921 20210 ur T B T E ENGINE 3 10 3 11 ENGINE WHEEL BRAKE Remove the rear axle nut and washer 2 Remove the rear wheel 3 Remove the brake shoes 4 and rear axle shaft 5 Remove the bearing retainer Remove the bearing 7 with the special tool Bearing installer 09913 75820 ENGINE 3 12 Remove the oil seal 1 with the special tool Oil seal remover 09913 50121 CENTER STAND Remove the return spring Remove the cotter pin washer and shaft Remove the center stand 6 CRANKCASE Remove the crankcase securing screws CAUTION Loosen the crankcase screws diagonally Crankcase separater 09920 13120 3 13 ENGINE Remove the crankshaft with the special tool Crankcase separater 09920 13120 Remove the bearings oil seals and bushings ENGINE 3 14 Using two steel tubes of appropriate size press out the engine mounting bushings on a vise as shown in the illustration ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS
7. 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 or replace Defective carburetor float valve Replace Clogged fuel hose or defective vacuum hose Clean or replace Engine stalls easily Carbon deposited on the spark plug Clean 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 3 Piston pin bearing 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
8. Capacity 12V 3AH 10HR Standard electrolyte S G 1 32 at 20 C CAUTION OF BATERY ELECTROLYTE TREATMENT Pay attention that the battery electrolyte not be stain the chasis or the humanbody if be stain the chasis the humanbody at once wash a vast quantity of water When it be stained clothes should come into being a hole or painting should take off Be cured from a doctor When the battery electrolyte was droped the surface of land wash a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on INITIAL CHARGING FILLING ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes Remove the caps A CAUTION After filling the electrolyte completely use removed cap as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 4 of the electrolyte container Filter Safety valve Pole plate Pole plate Separator fiberglass plate Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall CAUTION Take precaution not to allow any of the fluid to spill The electrolyte container insert at right angles so that it is not sloped Make sure air bubbles are coming up each elec trolyte container and leave in this position for about more than 20 minutes NOTE If no air bubbles are comi
9. Measure the conrod small end diameter with a caliper gauge Service limit 14 047 mm Dial calipers 09900 20605 AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch and variable ratio belt drive transmission The engage ment of the clutch is governed by engine RPMs and centrifugal 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 1 CLUTCH IN INSPECTION Warm up the motorcycle to normal operating tempera ture Remove the right frame side cover Connect an engine tachometer to the engine Seated on the motorcycle with the motorcycle on level ground increase the engine RPMs slowly and note the RPM at which the motorcycle begins to move forward Engine tachometer 09900 26006 Standard 3 600 rom Clutch in RPM 2 CLUTCH TIGHT INSPECTION Grip the front and rear brake lever 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 CAUTION Do not apply full power for more than 3
10. aged tire A tire with its tread worn down to the limit in terms of tread depth must be replaced CHASSIS 6 4 Tire depth service limit Check the tire pressure and examine the value for evi dence of air leakage Normal riding TIRE PRESSURE Cold inflation 9500 riding Dual riding kPa REASSEMBLY AND REMOUNTING Reassemble and remount the front wheel in the reverse order diassembly and removal and also carry out the following steps WHEEL BEARING Apply SUPER GREASE to the bearings before installing Super Grease Install the wheel bearings by using the special tool Bearing installer set 09924 84521 CAUTION First install the wheel bearing for left side Right side Left side Bearing R Spacer WA jaj v Clearance Bearing L Bearing L 6 5 CHASSIS OIL SEAL Install the oil seal D with the special tool Oil seal installer 09923 55131 Install the spacer 2 DISC PLATE Install the disc plate and tighten them to the specified torque 9 Front brake disc bolt 18 28 NMS 2 8 kg m SPEEDOMETER GEAR BOX When installing the speedometer gear box align the two drive pawls 4 with the two recesses B of the wheel hub CHASSIS 6 6 A CAUTION After touching the speedometer gear box to the stopper 0 tighten the axle shaft FRONT WHEEL Tighten the front axl
11. 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 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
12. av Bearing installer Install rear axle shaft oil seal 09900 28107 09913 76010 Electro tester ae Bearing installer Install crankshaft bearing 09910 20115 XM 09915 63310 Conrod holder Compression gauge adapter q i a Used with compression gauge 09910 32812 09915 64510 Crankshaft installer Compression gauge Measure cylinder compression 09913 14541 09916 84511 Fuel level gauge set Tweezers Remove and remounting valve cotter pin 09913 50121 09920 13120 Oil seal remover Crankcase separater Seprate to crankcase SERVICING INFORMATION 7 8 Part Number Part Name Description Special tools Part Number Part Name Description 09921 20200 09930 30163 Bearing remover 10mm Rotor remover Remove oil seal or bearing Attached to the top of sliding shaft when removing rotor 09921 20210 09930 32420 Bearing remover 12mm x Rotor holder Remove oil seal or bearing Remove and remounting rotor 09922 55131 09930 40113 Bearing installer 2 Rotor holder Widely used to lock rotary parts such as a flywheel magneto 09923 73210 09940 10122 Bearing remover 17mm M Clamp wrench Remove bearing with the rotor remove sliding shaft wrench to adjust the steering head of motorcycle 09923 74510 09940 34520 Bearing remover 20 35mm F T handle Remove bearing with the rotor remove sliding shaft 0992
13. 09910 20116 CAUTION Never fit the crankshaft into the crankcase by driving 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 the crankshaft rotates smoothly Install the new oil seal to the crankcase with the special tool NOTE Align the oil seal with edge of the crankcase as shown in the illustration Bearing installer 09913 85210 ENGINE 3 26 CENTER STAND Install the center stand Install the shaft 2 washer 3 and cotter pin 2 Hook the center stand spring into the crankcase 3 27 ENGINE REAR AXLE SHAFT BRAKE AND WHEEL Install the rear axle shaft into the crankcase by tapping its end lightly Apply engine oil on the left end of the rear axle shaft being inserted later in the reduction rear box cover Apply SUPER GREASE lightly on the rear brake cam pivot part and install it to the crankcase Super Grease Turn to position the cam where the punched mark on the end face is directed toward the axis of the rear axle shaft ENGINE 3 28 When installi
14. 8 1 2 m Muffler mounting 18 28 N m 1 8 2 8 kg m FUEL SYSTEM CONTENTS ____ ______________ 4 1 REMOVAL MEME EM MEDIE 4 1 Blk yz dt e 4 2 INSPECTION 4 4 REASSEMBLY AND REMOUNTING n 4 5 FOF TANK EIC S Imm 4 7 REMOVAL uim d c 4 7 CLEANING Noo ON c 4 8 REMOUNTING ea e n e 4 8 4 8 FUEL PUMP etat dorso 4 9 1 FUEL SYSTEM 4 CARBURETOR COON gt gt lt Q E lt lt C 0 0 Bez REMOVAL 0 2 lt O 2 2 lt lt C E 2 Remove the rear shock absorber mounting lower bolt Remove the carburetor top cap 0 and disconnect the throttle cable 2 Disconnect the air vent hose 3 oil hose and fuel hose 5 Remove the carburetor by loosening the mounting bolts and clamp screw DISASSEMBLY Remove the thermoelement assembly FUEL SYSTEM 4 2 4 3 FUEL SYSTEM CAUTION Do not attempt to disassemble the thermoelement assembly It is not serviceable Remove the float chamber Remove the float by removing the screw and pin 3 Remove the needle valve FUEL SYSTEM 4 4 Rem
15. CRANKCASE M EE 3 25 STAND 3 26 AXLE SHAFT BRAKE AND WHEEL 3 27 TRANSMISSION 3 29 STARTER DRIVEN GEAR AND STARTING MOTOR 3 31 MOVABLE DRIVEN AND CLUTCH 3 32 MOVABLE DRIVE wan 3 36 KICK STARTER X 3 38 PISTON 3 40 OIL PUMP AND INTAKE PIPE 3 42 eter cee ee 3 43 3 45 3 1 ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame thoroughly clean the engine with a suitable cleaner The procedure of engine removal is sequentially explained as follows Remove the low leg shield Remove the air cleaner by removing the mounting bolts and clamp screw Disconnect the ignition coil lead wires and spark plug cap Disconnect the oil pump cable 3 and the thermoele ment lead coupler 4 Disconnect the throttle cable Refer to page 4 2 Disconnect the vacuum hose 5 fuel hose and oil hose 7 ENGINE 3 2 Disconnect the magneto lead wire and starting moter lead wire Remove the rear brake cable 4 by removing the bolt D bolt an
16. Loosen the lock nut D and adjust the cable play by turning adjuster 2 in or out to obtain the following cable play After adjusting play tighten the lock nut 0 5 1 0 mm Throttle cable play MAINTENANCE PROCEDURE 2 6 Inside cleaning solvent 2 7 MAINTENANCE PROCEDURE ENGINE IDLE SPEED NOTE Inspect Initial 1 000 km and Every 4 000 km CAUTION Make this adjustment when the engine is hot start up the engine and set its speed at anywhere between 1 750 and 1 850 rpm by turning the throttle stop screw Engine idle speed 1 800 50 rpm Engine tachometer 09900 26006 OIL PUMP NOTE Inspect Initial 1 000 km and Every 4 000 km The engine oil is fed by the oil pump to the engine The amount of oil fed to it is regulated by engine speed and oil pump control lever which is amount of throttle opening Check the oil pump in the following manner to confirm correct operation for throttle valve full closing position Fix the throttle grip The early idling condition Check whether the mark on the oil pump control lever is aligned with the index mark when the throttle grip is fixed as above if the marks are not aligned loosen lock nuts and turn the adjuster in or out to align the marks After aligning the marks tighten the lock nuts CAUTION Oil pump cable adjustment must be done after throttle cable adjustmen
17. Place cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose master cylinder joint 4 CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid reacts chemical ly with paint plastics rubber materials etc Remove the master cylinder CHASSIS 6 12 Remove the brake lever D and brake switch Remove the dust boot 3 Remove the circlip with the special tool Snapring pliers 09900 06108 Remove the piston primary cup with return spring Remove the reservoir cap 6 and diaphragm 7 Drain brake fluid 6 13 CHASSIS MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for scratches or other dam age Inspect the primary cup and dust boot for wear or dam age MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly and also carry out the following steps CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use clean ing solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore Reassemble and remount the master cylinder Refer to page 6 11 When remounting the master cylinder on the h
18. SERVICING INFORMATION HYOSUNG MOTORS amp MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 1999 HOW TO 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 what you are looking for belong 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS Example Rear wheel Rear brake SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates Apply THREAD LOCK 1324 specified torque Apply oil Use engine oil unless otherwise specified Apply or use brake fluid Apply SUPER GREASE Measure in voltage range Apply SUPER GREASE Measure in resistance range Apply SILICONE GREASE Measure in current range Apply MOLY PASTE Use special tool Apply BOND 1215 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 s
19. 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 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
20. lever align the punched mark of camshaft with the slit on cam lever Q Brake cam lever bolt 6 9 m 0 6 0 9 m REAR BRAKE SHOE Apply SUPER GREASE A to the camshaft and pin before installing the brake shoes ARGH Super Grease A CAUTION Be careful not to apply too much grease to the camshaft and pin If grease gets on the lining brake effectiveness will be lost Front Punch mark CHASSIS 6 24 REAR AXLE NUT Tighten the rear axle nut to the specified torque V Rear axle nut 60 90 N m 6 0 9 0 m SERVICING INFORMATION CONTENTS TROUBLESHOOTING _ 7 1 TOOLS 7 6 TIGHTENING TORQUE 7 10 SERBUIGE DATA 7 12 WIRE AND CABLE ROUTING tt 7 18 WIRING DIAGRAM 7 20 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Engine does not start or is hard to start Compression too low 1 Excessively worn cylinder or piston rings Replace 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
21. seconds or damage to the clutch or engine may occur Standard 6 000 rpm Clutch tight RPM If the engine RPM does not coincide with the specified RPM range then disassemble the clutch Clutch shoe inspect the shoes visually for chips crack ing uneven wear and burning and check the thickness of the shoes with the 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 Service limit 2 0 mm ENGINE 3 16 3 17 ENGINE 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 of the clutch wheel with inside calipers Measure the diameter at sev eral points to check for an in of round condition as well Clutch housing I D Service limit 110 35 mm DRIVE V BELT Remove the drive V belt and check for cracks wear and separation Measure the drive V belt width with a vernier calipers Replace it if the drive V belt width is less than the service limit or any defect has been found Drive V belt width Service limit 15 3 mm CAUTION Always keep the drive belt away from any greasy mater DRIVE FACE Inspect the V belt contact surface of the drive faces for wear scratches or any abnormalit
22. the hatched area shown in the illustration and install the gear box cover on the crankcase BOND 1215 Tighten all the screws evenly one by one in a diago nal fashion STARTER DRIVEN GEAR AND STARTING MOTOR Install the starter driven gear over the left crankshaft end NOTE The convex side of hub should face outside when installed in proper position ENGINE 3 32 Install the starting motor 1 MOVABLE DRIVEN AND CLUTCH 3 33 ENGINE Install the bearing in the fixed driven face D with the special tool Bearing installer 09943 88211 A CAUTION Take care that hit inner race of the bearing Fall to ring in the bearing a case Install the circlip 3 A CAUTION Instert 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 out side Install the new oil seals 6 to the movable driven face with the special tool Bearing installer 09913 76010 Apply SUPER GREASE to the lip of oil seals and groove of movable driven face s inside Super Grease Insert up to contact to the stopper Install the movable driven face to the fixed driven face 0 CAUTION When reinstalling the movable dirven face to the fixed dirven face make sure that the oil seal is positioned properly
23. to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seat ed in its groove and securely fitted Do not use self locking nuts a few times over Use a torque wrench to tighten fasteners to the torque values when specified Wipe off grease or oil if a thread is smeared with them After reassembly check parts for tightness and operation 1 3 GENERAL INFORMATION HYOSUNG PRIMA SF 50 RIGHT SIDE LEFT SIDE Difference between photographs and actual motorcycles depends on the markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number is stamped on the right side of the frame under the footboard The engine serial number is located on the up side of the crankcase assembly These numbers are required especially for registering the machine and ordering spare parts FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85 95 octane Research Method or higher An unleaded gasoline type is recommended TRANSMISSION OIL Make sure that the transmission oil you use comes under API classification of SH SG or SF and that its viscosity rating Jove at TOW DO is SAE 10W 30 or 10W 40 If an SAE 10W 30 or 10W 40 motor oil is not a
24. turning of handlebars and too loose steer ing will cause poor stability Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground with wheel straight ahead grasp lower shock absorber near the axle and pull forward If play is found perform steering bearing adjustment Refer to page 6 21 FRONT SUSPENSION NOTE Inspect Initial 1 000 km and Every 8 000 km Inspect the front shock absorber for oil leakage or other damage and replace the defective parts if necessary NORMAL REAR SUSPENSION NOTE Inspect Initial 1 000 km and Every 8 000 km Inspect the rear shock absorber for oil leak and the mounting rubbers including engine mountings for wear and damage Replace the defective part if necessary MAINTENANCE PROCEDURE 2 12 CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS NOTE Inspect Initial 1 000 km and Every 4 000 km These bolts and nuts listed below are important safety parts They must be loosened first and retightened to the specified torque with a torque wrench 9 9 9 9 9 9 1 9 9 7 9 9 9 Front axle nut D 33 52 N 3 3 5 2 kg m Steering stem lock nut 60 100 N m 6 0 10 0 kg m Handlebar clamp nut 48 52 N m 4 8 5 2skg m Handlebar set bolt 4 22 28 N m 2 2 2 8 kg Front brake master cylinder bolt 8 12 m 0 8 1 2 m
25. 4 84521 09940 34561 Bearing installer Front fork assembling tool attachment 09925 98221 09940 50113 Bearing installer Front fork oil seal installer 09930 10121 Spark plug socket wrench set 09930 30102 o x Rotor remove sliding shfat b Wheel bearing remover 7 9 SERVICING INFORMATION Special tools Part Number Part Name Description 09943 74111 Front fork oil level gauge Used to drain the fork oil to the specified level 09943 8821 1 Bearing remover 09951 76010 Bearing installer SERVICING INFORMATION 7 10 TIGHTENING TORQUE ENGINE Magneto rotor nut Muffler mounting bolt Exhaust pipe nut Spark plug Cylinder head nut Engine mounting bolt Engine mounting bracket bolt Oil drain plug Oil level bolt Oil pump bolt Clutch shoe nut Clutch housing nut Kick starter driven nut Kick starter lever bolt 35 45 18 28 8 12 25 30 8 12 40 60 48 72 7715 ge 19 Jag 40 60 40 60 40 60 8 12 3 5 4 5 19729 7 11 SERVICING INFORMATION CHASSIS wm wm _ Front brake master cylinder bolt 0 8 1 2 Front brake air bleeder valve 0 6 0 9 TIGHTENING TORQUE CHART For other bolts and nuts who s torque is not listed refer to this chart Bolt Diameter Conventional or 4 marked bolt 7 marked bolt om 1300 190 0 130 190 s SERVICING INFORMAT
26. 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 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 1 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 Ustable charging Starter button 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 conn
27. EM MB OMA 8 41D 0495 M1 U d G D 9 67 44 9145 MA zl G Y MB MS JA t AU MA T Q 5 330 dg AL BK yea awed Q SO UJ 7 are S jan4 fejeJjeuDisuun H yuo 4 459 18 E H H H Jojeungye 19 SjpueH jejeuopeeds i Prepared by HYOSUNG MOTORS amp MACHINERY INC 2nd Ed NOV 1999 Manual No 99000 91310 Printed in Korea
28. Front brake hose union bolt 6 20 25 N m 2 0 2 5 kg m Front brake caliper mounting bolt 18 28 m 1 8 2 8 kg m Front brake air bleeder valve 8 6 9 N m 0 6 0 9 kg m Rear axle nut 9 60 90 N m 6 0 9 0 kg m Rear shock absorber bolt upper and 40 22 35 2 2 3 5 m Rear brake cam lever nut 699 N 0 6 0 9 kg m Engine mounting bracket bolt 12 48 72 N m 4 8 7 2 m Engine mounting 43 40 60 N m 4 0 6 0 m 2 13 MAINTENANCE PROCEDURE CONTENTS ENGINE REMOVAL AND REMOUNTING 3 1 ENGINE REMOVAL ooe 3 1 ENGINE REMOUNTING ee neee 3 3 ENGINE DISASSEMBLY e aie 3 4 ENGINE COMPONENTS INSPECTION AND SERVICING 3 14 BEARINGS af 3 14 OI SEALS M 3 14 CRANKSHAFT E e 3 15 AUTOMATIC CLUTCH INSPECTION CMM CEDE Sonne Tere re 3 15 CYLINDER HEAD 3 18 CYLINDER v os pada E 3 19 PISTON 3 19 REED VALVE 3 22 ENGINE REASSEMBLY TERT WA oam DEINER 3 22 OIL SEALS 3 22 BEARINGS ON 3 23 BUSHINGS gun Uh 3 23 5 NM 3 24
29. INE 3 8 Loosen the clutch shoe nut with the special tool Rotor holder 09930 40113 Remove the nut while holding down the clutch shoe assembly 2 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 Remove the nut D Remove the clutch shoe assembly 0 Remove the spring 9 CAUTION Do not attempt to diassemble the clutch shoe assembly It is not serviceable Using a thin blade screwdriver or the like pry up the movable driven face spring guide 4 Remove the pins 5 movable driven face and fixed driven face 7 3 9 ENGINE Remove the roller bearing with the special tools Bearing remover 17 mm 09923 73210 Rotor remover sliding shaft 09930 30102 A CAUTION The removed bearing should be replaced with a new one Remove the circlip B Remove the bearing with the special tool Wheel bearing remover 09941 50111 CAUTION The removed bearing should be replaced with a new one TRANSMISSION Drain transmission oil Remove the gear box cover 1 Remove the driveshaft 0 Remove the oil seal 1 from the gear box cover with the special tool Oil seal remover 09913 50121 CAUTION The removed oil seal should be replaced with a new one
30. ION 7 12 SERVICE DATA CYLINDER PISTON PISTON RING Unit mm ITEM STANDARD LIMIT Piston to cylinder clearance 0 065 0 075 0 120 Cylinder bore 41 005 41 020 41 07 40 935 40 950 Piston diam Measure at 15mm from the skirt end 40 885 Piston ring clearance 18 4 5 Piston ring clearance 0 10 0 25 05 Assembling condition 010 025 05 Piston ring ring groove clearance Piston pin bore 1 0 10 002 10 010 10 030 Piston pin O D 9 995 10 000 9980 CONROD CRANKSHAFT Unit mm ITEM STANDARD Conrod small end I D 14 003 14 011 Conrod big end runout Crank web to wed width Crankshaft runout 7 13 SERVICING INFORMATION OIL PUMP Unit mm ITEM STANDARD Oil pump reduction ratio 30 000 30 1 CLUTCH Unit mm TRANSMISSION Unit mm ITEM STANDARD Gear ratios 2 997 0 813 V belt width 16 5 0 6 V belt thickness 8 0 0 6 Movable drive face spring free length 143 8 135 153 SERVICING INFORMATION 7 14 CARBURETOR Unit mm Main jet Main air jet QS lt Throttle valve By pass Valve seat WM U Stater jet N c Pilot screw Pilot outlet D Throttle cable play 7 15 SERVICING INFORMATION ELECTRICAL Unit mm ITEM SPECIFICATION Ignition timing 20 at 1 000 rpm BEEN Type BR8HSA Spark plug Gap 0 6 0 7 Spark performance Omm 0000 ___ Ignition coil resistance Secondary 5 4 6 6 kQ DEMENS Lightin
31. Inspect Initial 1 000 km and Every 4 000 km Replace every four years Inspect leakage of the fuel line and connection part If abnormal replace it AIR CLEANER ELEMENT NOTE Clean Every 3 000km and Replace Every 12 000km 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 air cleaner cover by removing the eight screw Remove the air cleaner cover separate the element Fill a washing pan of a proper size with non flammable cleaning solvent Immerse the element in the cleaning solvent and wash them clean Squeeze the cleaning solvent out of the washed ele ment by pressing it between the palms of both hands do not twist or wiring the element or if will develop tears Immerse the element in Hyosung genuine oil and squeeze the oil out of the element leaving it slightly wet with oil Fit the elements to the cleaner case 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 THROTTLE CABLE PLAY NOTE Inspect Initial 1 000 km and Every 4 000 km
32. SEMBLY Reassemble and remount the caliper in the reverse order of removal and disassembly and also carry out the following steps CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning sol vent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore Apply SILICONE GREASE to the caliper holder ARGH Silicone Grease SPECIFIED TORQUE 0 18 28 1 8 2 8 2 20 25 2 0 2 5 WARNING Bleed the air from brake fluid circuit after reassembling caliper Refer to page 2 9 DISC PLATE REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 6 2 Remove the disc plate Refer to page 6 2 Install the disc plate Refer to page 6 4 DISC PLATE INSPECTION Check the disc for wear with a micrometer Its thick ness can be checked with disc and wheel in place Replace the disc if the thickness exceeds the service limit Disc thickness Service limit 3 5 mm Micrometer 0 25mm 09900 20201 CHASSIS 6 10 6 11 CHASSIS With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown Replace the disc if the runout exceeds the service limit Dial gauge 1 100 mm 09900 20606 Magnetic stand 09900 20701 Disc runout Service limit 0 3 mm MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handlebar cover Disconnect the front brake lamp switch lead wires
33. UEL SYSTEM FUEL TANK REMOVAL Remove the low leg shield Disconnect the fuel hose 2 Disconnect the fuel level gauge lead wire 3 Remove the six fuel tank mounting bolt CLEANING Dust from the fuel tank tends to bulid up in the fuel filter which when the fuel filter has been neglected for a long period inhibits the flow of fuel Remove the dust from the fuel filter using com pressed air REMOUNTING Remount the fuel tank in the reverse of removal OIL PUMP 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 servicing be sure to carry out an air bleeding operating with the oil pump in place before returning the machine to the user To bleed air hold the machine 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 FUEL SYSTEM 4 8 4 9 FUEL SYSTEM 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 left side cover Have the Oil gauge filled with HYOSUNG HYPOL OIL 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 pum
34. Wash the bearing with cleaning solvent and lubricate with motor oil before inspecting Turn the inner ring and check 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 SEAL 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 3 15 ENGINE CRANKSHAFT CRANKSHAFT RUNOUT Support crankshaft by V blocks with the dial gauge rigged to read the runout as shown Crankshaft runout Service limit 0 08 mm Excessive crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine life V block 100 mm 09900 21304 Magnetic stand 09900 20701 Dial gauge 1 100 mm 09900 20606 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 Conrod big end runout Service limit 3 0 mm CONROD SMALL END BORE 1 0
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36. all 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 in the illustration V Cylinder head nut 8 12 N 0 8 1 2 kg m ENGINE 3 42 OIL PUMP AND INTAKE PIPE Apply SUPER GREASE to the oil pump driven gear 1 and install it to the crankcase Super Grease Install the oil pump and tighten it to the specified torque V Oil pump bolt 3 5 N m 0 3 0 5 3 43 ENGINE Install the reed valve gasket 1 intake pipe gasket 2 and intake pipe with reed valve 3 to the crankcase MAGNETO Degrease the tapered portion of the crankshaft and also the magneto rotor Install the stator D Install the key 2 ENGINE 3 44 Install the rotor D Apply THREAD LOCK 1324 to the rotor nut and tighten it to the specified torque with the special tool Thread Lock 1324 Rotor holder 09930 40113 V Magneto rotor nut 35 45 N m 3 5 4 5 m Install the fan case 3 Install the magneto lead wire and starting motor lead wire Install the cooling fan 4 Install the cooling fan cover 3 45 ENGINE MUFFLER Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque V Exhaust pipe 8 12 N m 0
37. all the front fork and steering stem inspect the following items Lift the front fork Inspect play of the front fork as that grasp lower of the front fork and shake it by the front and rear By the handle turning the right or left inspect whether turning smoothly Adjust the outer upper race if the steering is comed heavy and tight Bleed air of the front brake Refer to page 2 9 CHASSIS 6 22 REAR WHEEL AND REAR BRAKE REMOVAL AND DISASSEMBLY Place the motorcycle on level ground Remove the muffler Refer to page 3 4 Remove the rear wheel by removing the axle nut 6 23 CHASSIS INSPECTION REAR 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 drum The value of this limit is indicated inside the drum Rear brake drum I D Service limit 100 7 mm BRAKE SHOE Using a vernier calipers measure the brake shoe out side diameter at the place as shown in the photo If the measurement is less than the limit replace the brake shoe SIC Service limit 96 mm CAUTION Replace the brake shoe with a set otherwise braking performance will be adversely affected WHEEL Refer to page 6 3 TIRE Refer to page 6 4 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and brake in the reverse order of removal and diassembly BRAKE CAM LEVER When installing the brake cam
38. andle bar first tighten the clamp bolt for upside CAUTION Bleed air after remounting the master cylinder Boot co spring Piston V Primary cap m Clearance Circlip Second cap Master cylinder CHASSIS 6 14 FRONT FORK REMOVAL AND DISASSEMBLY Remove the front leg shield C gt gt O gt Q is O Q gt uc gt gt c 0 Ee C E gt 2 m lt O lt Do not operate the front brake lever while dis mounting the caliper 6 15 CHASSIS Remove the front axle nut Support the motorcycle by jack or wooden block Remove the front wheel by removing the front axle shaft Loosen the front fork bolt then draw out the fork spring Loosen the front fork lower clamp bolts a Invert the fork and stroke it several times to remove the oil Hold the fork inverted for a few minutes Remove the socket bolt D with the hexagon wrench Seperate the fork pipe and pipe seat CHASSIS 6 16 Remove the dust boot D and stopper ring 2 Remove the oil seal by using the special tool CAUTION The oil seal removed should be replaced with a new oil seal Oil seal remover 09913 50121 INSPECTION Inspect pipe seat for wear and damage Inspect fork pipe a
39. balls Number of steel ball Remove the upper and lower bearing inner race with an appropriate bar INSPECTION Inspect the removed parts for the following abnormali ties Bearing race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem handlebar and front fork in the reverse order of disassembly and removal and also carry out the following steps OUTER LOWER RACE Press in the outer lower race 2 INNER RACE Press in the upper and lower inner races with the spe cial tool Steering race installer 09941 34513 STEEL BALL 6 Apply SUPER GREASE A when installing the upper and lower steel balls AGH Super Grease Number of steel ball STEERING OUTER UPPER RACE NUT Tighten the steering outer upper race until resis tance Is felt then loosen it 1 8 1 4 turn A CAUTION Make sure that the steering turns smoothly and easily left to right Tighten the steering stem lock nut with the special tool Clamp wrench 09940 10122 Q Steering stem lock nut 60 100 N m 6 0 10 0 m CHASSIS 6 20 6 21 CHASSIS Install the handlebar and tighten the set bolt and clamp bolt 2 to the specified torque 9 Handlebar set 22 28 N m 2 2 2 8 kg m Handlebar clamp 48 52 N m 4 8 5 2 kg m After inst
40. both indications are abnormal replace the fuel meter with a new one FUEL GUAGE SENDING UNIT INSPECTION Disconnect the lead wires coming out of the fuel gauge and check resistance of each position if the resistance measured is incorrect replace the fuel gauge assembly with a new one The relation between the position of the fuel gauge float and resistance is shown in the following table Relation between the position of the fuel gauge float and resistance Float Resistance OIL LEVEL CHECK LIGHT Oil level switch IG switch ELECTRICAL SYSTEM 5 8 Oil level check light 5 9 ELECTRICAL SYSTEM OIL LEVEL SWITCH INSPECTION Check the oil level switch for continuity between the lead wire If the tester does not show the value of 0 1 Q when the switch ring is in bottom position file the contact surface or replace the unit Pocket tester 09900 25002 OIL LEVEL CHECK LIGHT INSPECTION Disconnect the L W and B W lead connector of the oil level check light Connect a jumper wire between L W and B W wires coming from the main wiring harness With the ignition switch turned ON the oil level check light should flash If there is no flash check the wiring harness continuity and the bulb blown out THERMOELEMENT Magneto INSPECTION Disconnect thermoelement coupler Connect the thermoelement coupler to a 12V bat tery and touch the thermoelement to check the tempe
41. ch set p 1 100mm 40 80mm Tighten hexagon bolt 09900 05108 09900 20602 Dial gauge oy 1 100mm 1mm Circlip remove and remounting Measure inside diameter of cylinder 09900 06105 gt 09900 20605 EI Dial calipers 1 100 10 34mm A Circlip remove and remounting Measure width of conrod big end 09900 06107 09900 20606 BAT Dial gauge anap rng 1 100mm 10mm Circlip remove and remounting 09900 09003 09900 20701 Impact driver set Magnetic stand Used with Dial gauge 09900 20102 os 09900 20806 Vernier calipers Thickness gauge Measure clearance of piston ring gt 09900 21304 1 100mm 25 50mm V block set Measure height of cam Used with Magnetic stand d 09900 21602 Micrometer QN 1 100mm 50 75mm NUN CCI Oil gauge Agauge to inspect performance of oil pump 7 7 SERVICING INFORMATION Special tools Part Number Part Name Description Special tools Part Number Part Description 09900 22301 09913 60710 Plastic gauge Bearing remover Measure clearance of crankshaft thrust ay Remove bearing with the rotor remove sliding shaft 09900 22401 09913 75520 Small bore gauge E 10 18mm Bearing installer Used to drive bearing in 09900 25002 09913 75821 Pocket tester b Bearing installer Used to drive bearing in 09900 26006 09913 75830 Tachometer
42. d adjuster nut 3 Remove the rear shock absorber mounting lower bolt 3 3 ENGINE Remove the engine mounting shaft and remove the engine from the frame ENGINE REMOUNTING The engine can be mounted in the reverse order of removal Install the damper to the crankcase bracket as shown in the illustration With UP mark faced upward install the crankcase bracket 1 on the frame Do not tighten the bracket bolt 2 at this stage Pull up on the rear part of crankcase bracket and while holding it tighten the Damper bracket bolt to specification Tighten both the rear shock absorber bolt and engine mounting bolt 3 to specification Front side UP mark Io V Engine mounting bracket bolt 40 72 m 4 8 7 2 kg m 9 Engine mounting bolt 40 60 4 0 6 0 m Q Rear shock absorber bolt 22 35 m 2 2 3 5 m ENGINE 3 4 Install the magneto lead wire and starting motor lead wire B correctly After remounting the engine route the wiring harness properly and following adjustments are necessary Page Throttle cable play eco 2 6 Idling adjustment 2 7 pump cable paly 2 7 Rear brake cable adjustment m 2 10 Air bleeding at oil DUMP 4 9 ENGINE DISASSEMBLY MUFFLER Remove the muffler by removing the nuts MAGNETO Remove the cooling fa
43. de the range as shown in the illustration at right the brake shoe assembly should be replaced to ensure safe operation TIRES NOTE Inspect Initial 1 000 km and Every 4 000 km TIRE PRESSURE If the tire pressure is too high the motorcycle will tend to ride stiffly and have poor traction Conversely if the tire pressure is too low stability will be adversely affected Therefore maintain the correct tire pressure for good roadability and to prolong tire life MAINTENANCE PROCEDURE 2 10 The extension line of the index mark is within the range Index mark Brake lining wear limit 2 11 MAINTENANCE PROCEDURE CAUTION The standard tire fitted on this motorcycle is 110 70 12 47J for front and 120 70 12 51J for rear The use of a tire other than the standard may cause handling instability It is highly recom mended to use a HYOSUNG Genuine Tire COLD INFLATION NORMAL RIDING TIRE SOLO RIDING DUAL RIDING TIRE TREAD CONDITION Operating the motorcycle with the excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specification TREAD DEPTH SERVICE LIMIT STEERING NOTE Inspect Initial 1 000 km and Every 4 000 km Steering should be adjusted properly for smooth turning of handlebars and safe running stiff steering pre vents smooth
44. e drive plate 3 and install it on the movable drive face Position the O ring on the movable drive face 3 37 ENGINE Install the movable drive face cover 1 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 A CAUTION Thoroughly clean the V belt contact to be from oil Install the fixed drive face 3 Tighten the kick starter driven nut to the specified torque with the special tool Conrod holder 09910 20115 V Kick starter driven nut 40 60 m 4 0 6 0 kg Fill SUPER GREASE in the groove provided inside sliding surface of the kick driven gear and install it on the end of the crankshaft Wipe off excess grease Super Grease Install the spring B and spacer ENGINE 3 38 Install the E ring Continue turning the fixed drive face D by hand until the belt is seated in and both the drive and driven faces 2 will move together smoothly without slip Fill the final gear box with engine oil up to the level hole Replace 110 m Transmission oil capacity Replace 110m Tighten the oil level bolt 3 to the specified torque V Oil level bolt 9 15 N 0 9 1 5 m KICK STARTER 3 39 ENGINE Apply SUPER GREASE lig
45. e nut to the specified torque V Front axle nut 33 52 N m 3 3 5 2 m Tighten the caliper mounting bolts to the specified torque V Front brake caliper mounting bolt 18 284 m 1 8 2 8 m 6 7 CHASSIS FRONT BRAKE 7 om er BRAKE PAD REPLACEMENT Remove the caliper by removing the brake caliper mounting bolts CD CAUTION Do not operate the front brake lever while dis mounting the caliper CHASSIS 6 8 Reassemble it after remove the brake pads CAUTION Replace the brake pads as a set otherwise brak ing performance will be adversely affected CALIPER REMOVAL AND DISASSEMBLY Remove the brake hose 2 and catch the brake fluid in a suitable receptacle Remove the caliper mounting bolt CAUTION Never re use the brake fluid left over from the last servicing and stored long periods Remove the caliper Remove the brake pads Remove the pad holder Remove the spring 6 9 CHASSIS Place a rag over the piston to prevent popping up Force out the piston with a air gun CAUTION Do not use high pressure air to prevent piston damage Remove the dust seal 0 and piston seal CALIPER INSPECTION Inspect the caliper cylinder bore wall for nicks scratches or other damage Inspect piston for damage and wear Inspect each rubber part for damage and wear CALIPER REAS
46. eals 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 When fitting the oil seal in 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 ENGINE 3 22 3 23 ENGINE BEARINGS Install new bearings with the special tool Bearing installer 09913 75810 Bearing installer 09913 76010 BUSHINGS Using two steel tubes of appropriate sizevand a vise press the mounting bushings D and 2 into the crankcase holes as shown in the illustration NOTE Knurled end should face inside Protrusion and should be in the same dimension ENGINE 3 24 Bushing 2 Crankcase a CRANKSHAFT 1 Crank shaft 2 Crankcase RH 3 Oil seal 4 Oil seal 5 Oil pump drive gear 6 Oil pump driven gear 7 Oil seal Measure the length between the webs referring to the figure at right when rebuilding the crankshaft Width between webs Standard 35 0 0 1 mm 3 25 ENGINE When mounting the crankshaft into the crankcase it is necessary to pull its left end into the crankcase with the special tool Crankshaft installer 09910 32812 Conrod holder
47. ections Shorted grounded or open magneto coil Shorted or open regulator rectifier 1 Lead wires tend to get shorted or open circuited or loosely connected at terminal 2 Grounded or open circuited stator coils of magneto 3 Defective regulator rectifier 4 Defective cell plates in the batttery 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier unit poorly grounded 1 Lead wire insulation frayed due to vibration resulting in intermittent shorting 2 Magneto coil internally shorted 3 Defective regulator rectifier 1 Battery run down 2 Defective switch contacts 3 Brushes not seating properly on commutator in starter motor 4 Defective starter relay 5 Defective starter pinion gears 6 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 possib
48. er switch on the right handlebar switch box while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the starting motor to the battery Starter relay R IG switch Starter switch Starter 4 motor Brake switch 9 5 ELECTRICAL SYSTEM 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 Carbon brushes wear Service limit 4 mm 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 Commwutator under cut Service limit 4 mm 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 If the coil is found to be open circuited or grounded replace
49. exhaust port of the cylinder will prevent the flow of exhaust gases reducing the output Remove carbon deposits periodically SPARK PLUG NOTE Inspect Initial 1 000km and Every 4 000km Replace every 8 000km Neglecting the spark pulg maintenance eventually leads to difficult starting and poor performance If the spark plug is used for a long period the electrode gradually 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 to reset the gap Carbon deposits on the spark plug will prevent good sparking and cause misfiring Clean the deposits off periodically MAINTENANCE PROCEDURE 2 4 2 5 MAINTENANCE PROCEDURE f 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 Thickness gauge 09900 20804 Spark plug gap 0 6 0 7 mm Check the spark plug for burnt condition If abnormal replace the plug as indicated in the chart TYPE SPARK PLUG SPECIFICATION Standard BR8HSA Tighten the spark plug to the specification V Spark plug 25 30 N m 2 5 3 0 kg m 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 Confirm the thread size and reach when replac ing the plug FUEL LINE NOTE
50. g coil 069 103 0 Exciting coil 220 260 2 CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm with lighting switch tumed Measure the DC voltage between the battery terminal and with a pocket tester If the tester reads under or over following specification check the no lead performance or replace the regulator rectifier CAUTION When making this test be sure that the battery is in fully charged condition Pocket tester 09900 25002 Engine tachometer 09900 26006 13 0 16 0 V at 5 000 rpm ELECTRICAL SYSTEM 5 4 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 A C generator More than 17 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 Pocket tester 09900 25002 Unit kQ Probe of tester to Probe of tester to STARTER SYSTEM The starter system is shown in the diagram below namely the starting motor starter relay starter switch and battery Depressing the start
51. g coil 0 54 0 80 Q Y W Ground Charging coil 0 69 1 03 0 W R Ground Stator coil resistance Exciting coil 220 260 B R Ground Pickup 90271186 Regulated voltage 13 0 16 0 V at 5 000 rpm No load performance of A C generator More than 17V at 5 000 rpm Starter relay resistance 70 So Type designation YT4L BS Battery Capacity 12V Standard electrolyte S G 1 32 at 20 68 F a S Yo WATTAGE Unit W ITEM SPECIFICATION Head lamp bulb 15W x 2 Tail Brake lamp bulb 5 10W Turn signal lamp bulb 10W x 4 Turn signal Oil level check light pilot lamp 1 7W Speedometer lamp bulb 1 7W 2 CAUTION Do not use except the specified bulb Wattage SERVICING INFORMATION 7 16 BRAKE WHEEL Unit mm ITEM STANDARD LIMIT Brake lever play Brake disc plate thickness 40 0 2 Master cylinder bore I D 11 000 11 043 11 055 Master cylinder piston diam 10 957 10 984 10 945 Brake caliper 1 0 30 230 30 306 30 315 Brake caliper piston diam 30 150 30 200 30 140 a Wheel rim runout 3 0 Radial Tire size Tire tread depth iw 7 17 SERVICING INFORMATION SUSPENSION Unit mm ITEM STANDARD Front fork stroke 5 Front fork spring length Free condition 290 9 Front fork oil specification TELLUS 37 Front fork oil capacity One side 50 cc Rear wheel travel TIRE PRESSURE FUEL OIL LONE ANN gasoline is recommended LT 00040210
52. htly on the kick starter shaft rolling surface and install it on the crankcase cover Super Grease Position the kick starter shaft return spring and hook the spring end on the crankcase cover boss 1 Install the clutch cover and kick starter lever 0 4 CAUTION Install the kick starter lever as shown in the illustra tion Tighten the kick starter lever bolt to the specified torque V Kick starter lever 8 12 N m 0 81 2 m We N Z Concur withithe mark 7 ENGINE 3 40 PISTON Install the piston rings on the piston 1st Keystone ring 2nd Barrel face ring L Expander ring CAUTION Position the ring so that the marking is on upside Position the ring so that the marking is on upside 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 41 ENGINE Apply engine oil on the piston pin and install the pis ton to the conrod CAUTION The arrow mark on the piston head should point the exhaust side The 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 inst
53. ine mounting bushing 7 Loose nuts or bolts for engine mounting Adjust Replace Replace Adjust Replace Replace Replace Retighten Retighten Replace Tighten Front suspension 1 Weakened springs Replace too soft 2 Oil leakage of shock absorber Replace Front suspension 1 Not enough grease Refill too stiff 2 Worn suspension arm spacer Replace Noisy front 1 Not enough grease Refill suspension 2 Loose nuts on suspension Retighten Wobbly rear wheel 1 Distorted wheel rim Replace 2 Defective or incorrect tire Replace 3 Loose nuts on the rear shock absorber Replace 4 Worn engine mounting bushing Replace 5 Loose nuts or bolts for engine mounting Retighten Rear suspension 1 Weakened spring Replace too soft 2 Oil leakage of rear shock absorber Replace Noisy rear 1 Loosen nuts on shock absorber Retighten suspension 2 Worn engine mounting bushing Replace BRAKES Complaint Symptom and possible causes Insufficient brake Leakage of brake fluid from hydraulic system Repair or replace power Worn pad Replace Oil adhesion on engaging surface of pad Clean disc and pads Worn disc Replace Air entered into hydraulic system Bleed air Worn shoe Replace Friction surfaces of shoes are dirty with oil Replace Excessively worn drum Replace Too much brake lever play Adjust gt Brake squeaking Carbon adhesio
54. ing fitted squarely into the cylinder bore and held at the least worn part near the cylinder bottom as shown in the illustration Thickness gauge 09900 20806 Piston ring clearance Service Limit Assembly condition 0 75 mm As the piston ring wears its end gap increases reducing engine power output because of the resultant blow by through the enlarged gap Here lies the importance of using piston rings with end gaps within the limit Measure the piston ring free end gap to check the spring tension Piston ring clearance Free condition Fix the piston ring in the piston ring groove measure the ring side clearance with the thickness gauge while matching the sliding surfaces of piston and ring Piston ring ring groove clearance Standard 0 02 0 06 mm 0 02 0 06 mm 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 parts and components OIL SEALS Fit the oil seals to the crankcase following the procedure below Replace removed oil seals with new ones Coat SUPER GREASE to the lip of the oil s
55. l times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handlebar grip Then close the 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 CAUTION 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 upper end of the inspection win dow WARNING REAR BRAKE Adjust by turning the adjusting nut D so that the is 15 25 mm as shown in the illustration Brake lining wear limit This motorcycle is equipped with the brake lining wear limit indicator on the rear brake 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 embossed on the crankcase LH 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 f the index mark is outsi
56. le 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 4 Battery is too old Check the magneto and regulator rec tifier circuit connections and make necessary adjustments to obtain spe cified charging operation Replace the battery and correct the charging system Replace the battery 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 Dirty container top and sides Clean too rapidly 2 Battery is too old Replace CHASSIS SERVICING INFORMATION 7 4 Complaint Symptom and possible causes Handling feels 1 Steering stem nut overtightened too heavy 2 Broken bearing race in steering stem 3 Distorted steering stem 4 Not enough pressure in tires Wobbly handle 1 Loss of balance between right and left front suspension Replace 2 Distorted front axle or crooked tire Replace Wobbly front wheel 1 Distorted wheel rim 2 Worn front wheel bearings 3 Defective or incorrect tire 4 Loose nut on axle 5 Loose nuts on the rear shock 6 Worn eng
57. move the front brake caliper by removing the mounting bolts CD A CAUTION Do not operate the front brake lever while dis mounting the caliper Remove the front axle nut Support the motocycle by jack or wooden block Remove the front wheel and speedometer gear box by removing the front axle shaft Remove the disc plate by removing the bolts Remove the spacer Remove the oil seal with the special tool Oil seal remover 09913 50121 CHASSIS 6 2 6 3 CHASSIS Drive out the both bearing with the special tool in the fol lowing procedures Insert the adapter into the bearing After inserting the wedge bar from the opposit side lock the wedge bar in the slit of the adapter Drive out the bearing by knocking the wedge bar Wheel bearing remover 09941 50111 CAUTION The removed dust seal and bearing should be replaced with new ones INSPECTION WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Wheel rim runout Service limit 3 0 mm Axle and Radial Dial gauge 1 100 mm 09900 20606 Magnetic stand 09900 20701 TIRE Inspect the tires for wear and damage and check the tire tread depth as shown Replace a badly worn or dam
58. n Remove the magneto rotor nut with the special tool Rotor holder 09930 40113 3 5 ENGINE Remove the magneto rotor with the special tool Rotor remover 09930 30163 Rotor remover sliding shaft 09930 30102 Remove the magneto stator and key REED VALVE Remove the intake pipe with reed valve D OIL PUMP Remove the oil pump 3 Remove the oil pump driven gear 4 CYLINDER Remove the cylinder cowling Remove the cylinder head 5 and cylinder 6 PISTON Place a cloth beneath the piston and remove the pis ton circlip D with a long nose pliers Remove the piston pin and piston 3 Remove the piston pin bearing KICK STARTER Remove the kick starter lever 5 Remove the clutch cover 6 Remove the kick starter shaft spring and kick starter shaft 6 KICK STARTER DRIVEN GEAR Remove the E ring 9 with the long nose plier Remove the spacer 40 spring 4 and kick starter driven gear 2 ENGINE 3 6 3 7 ENGINE MOVABLE DRIVE FACE Remove the kick starter driven nut with the special tool CAUTION This nut has left hand thread Conrod holder 09910 20115 Remove the fixed drive face and V belt 3 Disassemble the movable drive face 4 STARTER DRIVEN GEAR Remove the starter driven gear MOVABLE DRIVEN FACE Remove the clutch housing with the special tool Rotor holder 09930 40113 ENG
59. n on pad surface Tilted pad Modify and fitting Damaged wheel bearing Replace Worn pad Replace Repair surface with sandpaper Foreign substance entered into brake fluid Clogged return ports of master cylinder Brake shoe surface glazed Repair surface with sandpaper Loose front wheel axle or rear wheel axle nut Tighten to specified torque Worn shoe Replace Replace brake fluid Disassemble and clean master cylinder 7 5 SERVICING INFORMATION Complaint Symptom and possible causes Excessive brake 1 Air entered into hydraulic system Bleed air lever stroke 2 Insufficient brake fluid Replenish fluid to normal lever bleed air 3 Improper quality of brake fluid Replace with correct fluid 4 Worn brake cam lever Replace 5 Excessively worn shoes and or drum Replace Leakage of brake 1 Insufficient tightening of connection joints Tighten to specified torque fluid 2 Cracked hose Replace 3 Worn piston seal Replace Brake drags 1 Rusty moving parts Clean and lubricate SERVICING INFORMATION 7 6 SPECIAL TOOLS Special tools Part Number Part Description Special tools Part Number Part Name Description 09900 00401 09900 20205 Micrometer L type hexagon wrench set 1 100mm 0 25mm Tighten hexagon bolt c Measure outside diameter of piston pin 09900 00410 Pu 09900 20508 Cylinder gauge set Hexagon wren
60. nd bottom case sliding surfaces for any scuffing or flaws 6 17 CHASSIS FORK SPRING Measure the fork spring free length Fork spring free length Standard 290 9 mm REASSEMBLY AND REMOUNTING Reassemble and remount the fork in the reverse order of removal and disassembly and also carry out the follow ing steps FRONT FORK BOLT Apply BOND 1215 and THREAD LOCK 1324 to the fork bolt and tighten the bolt with specified torque Bond 1215 Thread Lock 1324 Front fork 35 55 N m 3 5 5 5 kg m FORK OIL For the fork oil be sure to use a front fork oil whose viscosity rating meets specification below Fork oil type TELLUS 37 Capacity 50 cc One side CUSHION SPRING When installing the front fork spring the close end should position upside 1324 1215 _ em E M CHASSIS 6 18 STEERING REMOVAL AND DISASSEMBLY Remove the handlebar cover Remove the handlebar by removing the clamp bolt 4 and set bolt 2 Loosen the steering stem lock nut with the special tool Clamp wrench 09940 10122 Remove the front fork assembly by removing the lock washer 2 steering outer upper 5 dust seal 6 CAUTION Do not drop the steering stem steel balls Remove the steering outer lower race with a chisel 6 19 CHASSIS Remove the steering stem steel
61. ng the cam lever D to the cam align the punched mark with the slit of cam lever Tighten the cam lever nut to the specified torque V Rear brake cam lever nut 6 9 N m 0 6 0 9 kg m Install the brake shoes Apply SUPER GREASE to the brake cam and pin before installing the brake shoes Super Grease CAUTION Be careful not to apply too much grease to the brake cam and pin If grease gets on the lining brake effectiveness will be lost Install the rear wheel and nut V Rear axle nut 60 90 N m 6 0 9 0 m 3 29 ENGINE TRANSMISSION Install the circlip D on to the rear axle shaft 2 Assemble the idle shaft subassembly using the idle shaft 3 and thrust washer 4 then install the sub assembly on the gear box Install the final driven gear 5 on the rear axle shaft using the circlip 8 Center Thrust Circlip AP if 8 gt Rounded coner Install the new bearing D 3 to the gear box cover 2 with the special tool Bearing installer 09913 76010 Apply SUPER GREASE to the lip of the oil seal 4 and install it to the gear box cover with the special tool Super Grease Bearing installer 09913 70122 Install the washer new gasket and dowel 5 Install the driveshaft to the gear box cover ENGINE 3 30 3 31 ENGINE Apply BOND 1215 at
62. ng up from a filler port bottom of the two or three times Never remove the container from the battery After confirming that the electrolyte has entered the battery completely remove the electrolyte containers from the battery Wait for around 20 minutes Insert the caps into the filler holes pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover CAUTION Clean completely in case that the electrolyte is adhered at the filler hole Once install the caps to the battery do not remove the caps ELECTRICAL SYSTEM 5 12 9 13 ELECTRICAL SYSTEM Using the pocket tester measure the battery voltage The tester should indicate more than 12 5 12 6 V DC as shown in the Fig If the battery voltage is lower than the specification charge the battery with a battery charger NOTE Initial charging for a new battery is recommended if two years have elapsed since the date of manufacture CAUTION OF BATTERY TREATMENT The battery is needed attention generally as occur flammability gas If does not it should be explosion and severe accident Pay attention to the following points Prohibit positively that come in contact with short spark or firearms The battery recharge where be well ventilated wide place Prohibit positively at the shut tight room RECHARGING OPERATION Using the pocket tester check the battery voltage the v
63. o secure a tight joint a leaky joint can be the cause of reduced power output and increased fuel consumption 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 20 mm 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 Cylinder gauge set 09900 20508 Cylinder bore Service limit 41 070 mm 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 scraper taking care not to nick the wall surface PISTON 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 is prescribed to be 15 mm from the skirt end Micrometer 25 50 mm 09900 20202 Piston diameter Service limit 40 885 mm IL rnm As a 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 direc
64. oltage reading is less than 12 0V DC recharge the battery with a battery charger When recharging the battery remove the battery from the motorcycle Do the battery by standard charging usually BATTERY CHARGING CURRENT Standard x 5 10 Hours x 30 Minutes After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester f the battery voltage is less than 12 0V recharge the battery again if the battery voltage is still less than 12 0V after recharging replace the battery with a new one NOTE When a battery is left for a long term without using it is subject to discharge When the motorcycle is not used for more than 1 month especially during the winter sea son recharge the battery once a month at least A WARNING Charging equipment of this motorcycle is designed for the MF Maintenance Free battery No use except the specificated battery vr iz LL J seconds Li 2 amp 10 Minutes e 20 30 40 50 6D Minutes Time at 0 40 C 101 25 K Battery charged condition CHASSIS CONTENTS WHEEL suem ette tEUUUM 6 1 6 7 FERONT FORK a a orc 6 14 STEERING ___ ______ 0 09_ 6 18 REAR WHEEL AND REAR BRAKE e 6 1 CHASSIS FRONT WHEEL REMOVAL AND DISASSEMBLY Re
65. ove the battery lead and then lead at the battery terminls and remove the battery Using pocket tester measure the battery voltage If the tester reading is less than 12 0V recharge the battery with a battery charger Refer to page 5 13 Pocket tester 09900 25002 Bettery voltage Minimum 12 0V Recharge Standard charge 0 4A x 5 10 Hours Fast charge 4A x 30 Minutes CAUTION When recharging the battery remove the battery from motorcycle Otherwise regulator rectifier unit should be an obstacle When recharging the battery do not remove the caps When recharging the battery above the charge electric current and time should be kept as 12V CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS NOTE Inspect Initial 1 000 km and Every 4 000 km CYLINDER HEAD NUTS Remove the personal trunk Remove the spark plug cap Remove the cylinder head cover bolt Refer to page 3 5 Tighten the four nuts to the specified torque with a torque wrench when engine is cold V Cylinder head nut 8 12 N m 0 8 1 2 kg m EXHAUST PIPE NUTS Tighten the exhaust pipe nuts to the specified torque V Exhaust pipe nuts 8 12 N m 0 8 1 2 kg CYLINDER HEAD AND CYLINDER NOTE Remove carbon Every 8 000km Carbon deposits in the combustion chamber and the cylinder head will raise the compression ratio and may cause preignition or overheating Carbon deposited at the
66. ove the throttle stop screw and pilot air screw A CAUTION When removing the pilot air screw record the revolu tions until tighten completly Remove the main jet and needle jet INSPECTION 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 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 4 5 FUEL SYSTEM REASSEMBLY AND REMOUNTING Reassemble following items Pilot air screw 2 Throttle stop screw 3 Main jet 4 Needle jet Install the needle valve and float on the carbu retor body Install the float pin and tightened the screw 7 Install the gasket and float chamber Install the thermoelement assembly FUEL SYSTEM 4 6 Install the carburetor assembly Install the air vent hose oil hose and fuel hose 3 Install the carburetor top cap 4 7 F
67. p draw for 5 minutes For this operation the reading taken on the device should be 6 md CCI Oil gauge 09900 21602 Engine oil 1 0 1 2 mp discharge amount at 3 000 for 5 minutes CAUTION During this inspection strictly follow the follow ing points The machine should be rested on the center stand Do not touch the rear wheel while running the engine FUEL PUMP REPLACE Remove the rear shock absorber and support the center stand by a 0 mm wooden block Open the seat and remove the trunk by loosing the four nuts Remove the one lock nut of fuel pump D Disconnect the inlet hose CAUTION Stop up an entrance of the hose to prevent that the fuel leak out 2 Disconnect the vacuum hose and outlet hose Remount in the reverse of removal after replacing the fuel pump CONTENTS ELECTRICAL PARTS ttn 5 1 IGNITIONICHARGING SYSTEM 5 2 5 2 COIS pect ore eee ee eee aes 5 3 REGULATORIRECTIFIER cn 5 4 STARTER SYSTEM eee P Na 5 4 STARTING MOTOR INSPECTION 5 5 5 STARTER RELAY INSPECTION Rem 5 6 FUEL LEVEL GAUGE 5 7 OIL LEVEL CHECK LIGHT eA ANN 5 8 THERMOELEMENT eem 5 9 SWITCHES INSPECTION 5 10 BATTERY Ae 5 11 ELECTRICAL SYSTEM 9 1 ELECTRICAL SYSTEM ELECTRICAL PARTS Ignition coil 2 Thermolement assembly 3 Fuel level gauge 4 Oil level gauge
68. pecial meanings Pay special attention to the messages highlighted by these signal words WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions cleaner Please note however that the warning and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the motorcycle In addition to the WARNING and CAUTION stated you must use good judgement and basic mechanical safety principles Ifyou are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors When working with toxic flammable materials make sure that the area you work in is wellventilated and that you follow all off the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil or exhaust system during or for a while after engine operation After
69. pm Spark Mii BR8HSA 12V 3Ah 10HR ETT a a a Magneto E 10A 15W x2 10Wx4 TalBrake lanp ene 5 10 17Wx2 Oil ____________ 170 Turn signal indicator lamp 1 7N CAPACITIES IUe eee 4 84 Engine oil tank nnt 102 Transmission oil Ee 1106c Replace 130cc Overhaul NOTE The specifications are subject to change without notice CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 4 MAINTENANCE PROCEDURES 222222022222 2 3 BATTERY ooe 2 3 CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS 2 4 CYLINDER HEAD AND CYLINDER 2 4 SPARK PLUG 2 4 FUEL LINE o e oa 2 5 AIR CLEANER ELEMENT 5 2 5 THROTTLE CABLE PLAY 2 6 ENGINE IDLE SPEED 2 7 OIL PUMP e Neal 2 7 TRANSMISSION OIL 5e m 2 8 BRAKES m B 2 8 TIRES Meet 2 10 STEERING Lee 2 11 FRONT SUSPENSION 2 11 REAR SUSPENSION 2 12 CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 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 motorcycle operating at peak performance and economy NOTE More frequent servicing should be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE Battery Inspect Cylinder head nuts Inspect Inspec
70. rature 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 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 replace the respective switch assembly with new one Pocket tester 09900 25002 WIRE COLOR B Black L n Blue G P Green Gr Sb Light blue Lg OO Light green O E E R Red W EE White Y Yellow B R TE Black With Red tracer B W eae Black with White tracer White with Black tracer YIN OT Yellow with White tracer Y G Yellow with Green tracer Blue with White tracer LIGHTING SWITCH o ce ON 2 oor ELECTRICAL SYSTEM 5 10 HORN SWITCH o w or IGNITION SWITCH Few uw flock or PON _ OO 0 09 I 9 11 ELECTRICAL SYSTEM BATTERY BATTERY YTAL BS
71. servicing fuel oil exhaust or brake systems check all lines and fittings related to the system for leaks GENERAL INFORMATION 1 2 A CAUTION If parts replacement is necessary replace the parts with HYOSUNG Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean and also lubricated when specified When use of a certain type of lubricant bond sealant is specified be sure to use the specified type When removing the battery disconnect the negative cable first and then positive cable When reconnect ing the battery connect the positive cable first and then negative cable and replace the terminal cover on the positive terminal When performing service to electrical parts if the service procedures do not require use of bat 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
72. t TRANSMISSION OIL NOTE Inspect Initial 1 000 km and Every 8 000 km Inspect transmission oil periodically following procedure below Remove the low leg shield Remove the clutch cover Refer to page 3 6 Remove the oil level bolt 0 and inspect oil level If the level is below the level hole add oil until oil flows from the level hole Tighten the oil level bolt to the specified torque 9 Oil level bolt 9 15 N m 0 91 5 kg m BRAKES NOTE Inspect Initial 1 000 km and Every 4 000 km Replace the hose Every four years Replace the brake fluid Every two years FRONT BRAKE FLUID LEVEL Keep the motorcycle upright and place the handlebar straight Check brake fluid level by observing the middle line on the brake fluid reservoir When the level is bolow the middle line replenish with brake fluid that meets the following specification Specification and classification DOT4 HYOSUNG Brake fluid 99000 23021 WARNING The brake system of this motorcycle is filled with a glycolbased brake fluid Do not use or mix dif ferent type of fluid such as silicone based and petroleum based Do not use any brake fluid taken from old used or unsealed containners Never re use the brake fluid left over from the last servicing and stored for long periods MAINTENANCE PROCEDURE 2 8 Oil drain glug Middle lin A WARNING Brake fluid if it leaks
73. t exhaust pipe nuts Fuel line 2 5 Replace every 4 years Air cleaner element Clean every 3 000 km 2 5 Transmission oil CHASSIS he NE ital 1 000 km Every 4000 Every 8000 km mma _ Brake hose 2 9 Replace every 4 years Brake fluid Replace every 2 years PERIODIC MAINTENANCE 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 economical manner m Mt ital and Every 4 000 Every 8000 km Grease Grease Grease Grease every 2 years or 20 000 km Throttle grip Brake cable Motor oil Speedometer cable Speedometer gear box Brake cam Steering stem bearing WARNING Be careful not to apply too much grease into the brake cam If grease is on the linings brake slippage will result Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motorcycle has been operated under wet or rainy conditions Before lubricating each part clean off rusty sports and wipe off grease oil dirt or grime 2 3 MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE This section describes the service procedures for each section of the periodic maintenance BATTERY NOTE Inspect Initial 1 000 km and Every 4 000 km Remove the pillion seat for measure of battery voltage Rem
74. the armature Continuous use of a defective armature will cause the starting 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 Pocket tester 09900 25002 Starter relay standard resistance 0 70 Q ELECTRICAL SYSTEM 5 6 5 7 ELECTRICAL SYSTEM FUEL LEVEL GAUGE Fuel level gauge Fuel tank FUEL LEVEL METER GAUGE FUEL METER INSPECTION To test the Fuel Meter two different checks may be used The first and simplest test will tell if the meter is operat ing but will not indicate the meters accuracy throughout the range To perform this test lift the seat and remove the right frame cover then disconnect the B W and Y B lead connector of the fuel gauge sending unit Connect a jumper wire between B W and Y B wires coming from the main wiring harness With the ignition switch turned ON the fuel meter should indicate F The second test will check the accuracy of the meter in the full and empty positions Connect 90 2 resistor between the Y B and B W lead wires The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the circuit and if its pointer indicates the F full position when the resistor is changed to 10 9 If either one or
75. tion and at 20mm from the cylinder top surface BENI Standard Serivice limit Cylinder bore 41005 41020 mm 41 070 mm Piston diameter 40 935 40 950 mm 40 885 mm 21 060 0 0 omm 0 120 mm 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 reduced 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 PISTON PIN BORE 1 0 Using a caliper gauge measure the piston pin bore inside diameter If reading exceeds the following service limit replace it with a new one Dial calipers 09900 20605 Piston pin bore 1 0 Service limit 10 030 mm ENGINE 3 20 3 21 ENGINE PISTON PIN O D Using a micrometer measure the piston outside diame ter at three positions Micrometer 0 25 mm 09900 20201 Piston pin O D Service limit 9 980 mm PISTON RINGS Check each ring for end gap reading the gap with a thickness gauge shown in the illustration If the end gap is found to exceed the limit indicated below replace it with a new one The end gap of each ring is to be measured with the r
76. ttle position 1 5 GENERAL INFORMATION EXTERIOR ILLUSTRATION Head lamp Front Turnsignal lamp Rear reflector Rear Turnsignal lamp 600 ZS LZZIL ASS 7 EN Tail Brake lamp EN 4 di 710 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground clearance Dry mass ENGINE Type Number of cylinder Bore Stroke Piston displacement Carburetor Air cleaner Starter system Corrected compression ratio Intake system TRANSMISSION Clutch Reduction ratio Drive system CHASSIS Front suspension Rear suspension Caster Steering angle Front tire size Rear tire size Front brake Rear brake GENERAL INFORMATION 1 6 1 825 mm 71 9 in 635 mm 25 0 in 1 110 mm 43 7 in 1 270 mm 50 0 in 125 mm 4 9 in 88 kg 194 1 5 Two stroke forced aif cooled 41 mm 1 6 in 37 4 mm 1 5 in 49 3 0 cu in SIDE DRAFT VARIABLE VENTURI PISTON Wet filter type Kick self starter T 4 11 Reed valve Dry shoe automatic centrifugal type 2 997 0 813 V belt drive Telescopic type Coil spring type 7omm 2 95in 45 right amp left 110 70 12 47J 120 70 12 51J Disc 1 7 GENERAL INFORMATION ELECTRICAL Ignition CDI type Ignition timing 20 B T D C at 1 000 r
77. vailable select an alternate according to the right chart GENERAL INFORMATION 1 4 ENGINE OIL Specification and classification APOLLOIL BIKE K HYPOL HS BRAKE FLUID Specification and classification DOT4 4 WARNING Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the sys tem otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never re use brake fluid left over from a previous servicing which has been stored for a long period FRONT FORK OIL Use fork oil TELLUS 37 BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Up to 1 000km 600miles Less than 1 2 throttle Upon reaching an odometer reading of 1 000 km you can subject the motorcycle to full throttle operation Do not maintain constant engine speed for an extended period during any portion of the break in Try to vary the thro
78. will interfere with safe run ning and immediately discolor painted surfaces Check the brake hoses for cracks and hose joints for leakage before riding 2 9 MAINTENANCE PROCEDURE BRAKE PADS Wearing condition of brake pads can be checked by observing the limit line marked on the pad When the wear exceeds the limit mark replace the pads with new ones BRAKE LAMP SWITCH For the brake lamp come on after the brake lever is pulled adjust the brake lamp switch BLEEDING AIR FROM 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 brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped air exposes the machine and rider it is essential that after remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the following man ner Fill up the master cylinder reservoir to the upper end of the inspection window 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 9 Bleeder valve 6 9 m 0 6 0 9 kg Bleed air from the bleeder valve Squeeze and release the brake lever severa
79. y If there is some thing unusual replace the drive face with a new one co ROLLER AND MOVABLE DRIVE SURFACE Inspect each roller and movable drive surface 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 Service limit 135 153 mm MOVABLE DRIVEN FACE PIN AND OIL SEAL Turn the movable driven faces and check to see that the movable driven faces turn smoothly If not rotate smoothly visually inspect the lip of oil seal movable driven face sliding surface and sliding pins for wear or damage MOVABLE DRIVEN FACE Inspect the V belt contacting surface of both driven faces for any scratches wear and damage Replace the movable 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 dis tortion with a straightedge and thickness gauge taking a clearance reading at several places Thickness gauge 09900 20806 Cylinder head distortion Service limit 0 1 mm ENGINE 3 18 3 19 ENGINE If the largest reading at any portion of the straightedge exceeds the limit rework the surface by rubbing it against emery paper of about 400 laid flat on the sur face plate in a lapping manner The gasketed surface must be smooth and perfectly flat in order t

SERVICE MANUAL - Hyosung

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