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SERVICE MANUAL

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1. 1085 A M89 9 1 095 19 woe 1 ode 1 5 P 40 j euBisuinj youms i O O E ojeuBejN 1 9xelq1U0H 29005 NM E duie 10jeopu Je ewopeeds T Prepared by HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department 1st Ed Feb 1999 Manual No 99000 97100 Printed in Korea
2. Wet filter type Starter system a eave Mese Ea dins Kick self starter Lubrication system e ttt Wet sump TRANSMISSION Clutch eene enema Wet multi plate type HH 5 speed constant mesh Gearshift pattern eee 1 down 4 up Final reduction mmm 3 357 Gear ratio LOW eee 2 15 2nd cs Mare aah EGET A BU p Na 1 785 1 368 4th ENA PEA EEES 1 045 seme ee eee eee eene 0 913 Drive chain HH HH 428H 132 links CHASSIS Front suspension Telescopic Rear suspension eee Swingarm type Steering angle caveat wee Via veda wr EQ 40 5 right amp left Caster 29 INCIDIT 125 mm 4 9 in Turning radius e 2 5 m 8 2 ft Front brake Disk brake Rear brake msnm Drum brake Front tire size mmm 2 15 21 45P Rear tire size aed arated diis T MINCE PI dE TE EA AE e 4 10 18 Front fork stroke EI EIS 250 mm 9 8 in GENERAL INFORMATION 1 6 ELECTRICAL Ignition type eine Battery Ignition CDI Ignition timing eem 15 B T D C at 2 250 rpm 35 B T D C at 4 000 rom Spark plug LY ANE uda
3. CAUTION There is a holder for the bottom end of the cam chain guide cast in the crankcase Be sure that the guide is inserted properly or binding of the cam chain and guide may result 3 22 VALVE AND SPRING Insert the valves with their stems coated with HYOSUNG MOLY PASTE all around and along the full stem length without any break Similarly oil the lip of the stem seal HYOSUNG MOLY PASTE CAUTION When inserting each valve take care not to damage the lip of the stem seal Insert valve springs making sure that the close pitch end D of each spring goes in first to rest on the head The coil pitch is vary the pitch decreases from top to bottom as shown in the illustration Fit valve spring retainer compress spring with a valve spring compressor and insert cotters 22 Valve spring compressor 09916 14510 CYLINDER HEAD Fit dowel pins to cylinder head and then attach new gasket to cylinder head CAUTION Use a new cylinder head gasket to prevent oil leakage Do not use the old gasket Retainer Towards rg Head Lower seat 3 23 Fit the cylinder head Tighten the cylinder base nuts D V Cylinder base nut 6 8 N m 0 6 0 8 kg m CAUTION When mounting the cylinder after attaching camshaft driv
4. 2 01 2 03 mm PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings measure the free end gap of each ring using vernier calipers Next fit the ring in the cylinder and measure each ring end gap using a thickness gauge If any ring has an excess end gap replace the ring Piston ring free end gap Free condition RIKEN Piston ring free end gap Service limit 5 7 2 4 6 Vernier calipers 09900 20101 Piston ring free end gap Assembly condition Piston ring free end gap Service limit and 2nd 0 50 mm Thickness gauge 09900 20803 Piston ring thickness Piston ring thickness Standard 184 0 970 0 990 2nd 0 970 0 990 mm 3 19 OVERSIZE RINGS Oversize piston rings The following two types of oversize piston rings are used They bear the following identification numbers Oversize piston ring 151 2nd 50 50 100 100 Oversize oil rings The following two types of oversize oil ring are used They bear the following identification marks Oversize oil ring Color classification 0 5 mm Painted red 1 0 mm Painted yellow Oversize side rail Just measure outside diameter to identify the side rail as there is no mark or numbers on it PISTON PIN PIN BORE Using a caliper gauge measure the
5. Description 09900 00401 I NE Micrometer rri L type hexagon wrench set 1 100mm 0 25 1 i Tighten hexagon Measure outside diameter of piston pin 09900 00410 09900 20508 4 a Cylinder gauge set Hexagon wrench set 1 100mm 40 80 J Tighten hexagon bolt Measure inside diameter of cylinder 09900 05108 09900 20602 Dial gauge P Snap ring pliers 1 100mm 1mm I Circlip remove and remounting Measure inside diameter of cylinder 09900 20605 Ue 09900 06105 Dial calipers ER Snap ring pliers 1 100mm 10 34mm A Circlip remove and remounting Measure width of conrod big end 09900 06107 09900 20606 h Dial gauge Snap ring pliers 1 100mm 10mm X Circlip remove and remounting Measure run out of wheel 09900 09003 Impact driver set Remove and remounting of fixed screw 09900 20701 Magnetic stand Used with Dial gauge 09900 20102 Vernier calipers Measure thickness 09900 20806 Thickness gauge Measure clearance of piston ring 09900 20202 Micrometer 1 100mm 25 50 Measure height of cam 09900 21304 V block set Used with Magnetic stand 09900 20203 Micrometer 1 100mm 50 75 Measure outside diameter of piston 09900 22301 Plastic gauge Measure clearance of crankshaft thrust
6. Used to drive bearing in u 9 Widely used to lock rotary parts such as a flywheel magneto 09923 73210 Bearing remover 17mm Remove bearing with the rotor remove sliding shaft 09940 34520 T handle Remove and remounting front fork oil cylinder 7 11 SERVICING INFORMATION Special tools Part Number Part Description 09940 34561 Front fork assembling tool attachment 09940 50113 Front fork oil seal installer i Used with T handle 7 Install front fork oil seal 09941 34513 Bearing installer Install steering outer race 09941 50110 Wheel bearing remover Remove wheel bearing 09943 74111 Front fork oil level gauge Used to drain the fork oil to the specified level 09943 88211 Bearing remover Remove rear axle shaft bearing 09951 76010 Bearing installer Used to drive bearnig in SERVICING INFORMATION 7 12 TIGHTENING TORQUE ENGINE Cylinder head cover bolt Camshaft sprocket bolt Cylinder head nut Cylinder base nut Magneto rotor nut primary drive gear oil pump drive gear nut Clutch sleeve hub nut Engine oil drain plug Engine sprocket nut Engine mounting bolt 17 mm Diam Engine mounting bolt 14 mm or 12 mm Diam Exhaust pipe clamp nut Muffler clamp bolt Starter clutch bolt 7 13 SERVICIN
7. CAUTION g Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new cir clip must be installed 02 When installing new circlip care must be taken not to expand the end gap larger than required to slip the circlip cover the shaft G After installing a circlip always insure that it is completely seated in its groove and securely fitted 3 40 Washers circlips thickness 1 0 mm 0 5 mm NOTE When reassembling the bearing retainer apply a small quantity of THREAD LOCK 41324 to the threaded parts of the bearing retainer screws In reassembling the transmission attention must be given to the locations and positions of washers and circlips The cross sectional view given here will serve as a referance for correctly mounting the gears washers and circlips COUNTERSHAFT Mounting 2nd drive gear Press fit 2nd drive gear into the countershaft Before reassembling coat the internal face of the 2nd drive gear with THREAD LOCK 1324 and install it so that the length is as shown in Fig Thread Lock 1324 Countshaft length 0 1 Low to 2nd CAUTION This procedure may be performed only twice before shaft replacement is required 3 41 GEAR SHIFTING AND FORK Fit the gear shifting cam on the crankcase Posit
8. cooler C D I Unit NE Throttle cable Starter motor lead wire Lead wire magneto Frame Lead wire neutral switch 09404 06401 View Engine sprocket cover Magneto cover View B 7 23 SERVICING INFORMATION WIRING DIAGRAM 1991 xoe g 19981 MI M eng 1 199 1 UM SUM Jeoen 1 6 qS 19 199 1 YOR UM SUM 19981 SWUM ues 9 J9981 SHUM MH YIM Og Jg gH MOII9A A usel6 y6q 61 weld HO IOO HHIM 1890 ayeiq uoyws d j H1 YoUms JOJOW 19215 is weds 0 A jeuDisuin 4 We 5 OF Oo ORO 1 19Je1S 330 N am Poe OTO 1 j i IT jeu6isuini 1u014 8 9 8 1f 4 wc Ec pact ws dE y jeu6isuin T T T T mat
9. Loosen the camshaft holder lock nuts diagonal ly then detach the camshaft holder Remove the camshaft center bolt CAUTION This is a left hand thread nut Remove the camshaft cam sprocket and A CAUTION Do not drop the camshaft drive chain key and sprocket into the crankcase CAMSHAFT HOLDER Take off the rocker arm spring from the dowel 4 Remove the dowel pin with the long nose pliers Install the bolt by the rocker arm shaft and pull out the rocker arm shaft Remove the rocker arm and spring Remove the rocker arm shaft by the same man ner at the opposite side ENGINE 3 8 3 9 CYLINDER HEAD Loosen the cylinder head nuts then detach the cylinder head CAUTION If it is difficult to remove the cylinder head gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer Be careful not to break the fin Compress the valve spring by using the special tool Value spring compressor 09916 14510 Value spring compressor attachment 09916 14910 Take off the valve cotters from the valve stem Tweezers 09916 84511 Take out the valve spring retainer and spring Pull out the valve from the other side CAUTION Do not compress the valve spring more than necessity for prevent damag
10. Before inspecting for compression pressure make sure that the cylinder head nuts and bolts are tightened to specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing it Compression gauae 09915 64510 Remove spark plug Fit the compression gauge to the plug hole taking care to make the connection absolutely tight Twist the throttle grip into wide open position Crank the engine several times with the starter motor or kick starter and read the highest gauge indication as the compression of the cylinder Compression pressure Compression pressure Standard 15 6 kg cm 500 rpm Compression pressure Limit 8 low compression pressure indicate of the following malfunction Excessively worn cylinder wall Worn piston or piston rings Piston rings stuck in the grooves Poor sealing contact of valves Defective cylinder head gasket When the compression pressure noted is down to or below the limit indicated above the engine must be disassembled inspected and repaired as required to overhaul the engine with these five abnormality in mind OIL PRESSURE Install the oil pressure gauge in the position shown in the illustration Warm up the engine as follows Summer approx 10 min at 2 000 rom Winter approx 20 min at 2 000 rom After the warming up operation increase the engi
11. Tighten clutch sleeve hub nut using the special tool to the specified torque Clutch sleeve hub holder 09920 53710 9 Clutch sleeve hub nut 30 50 N m 3 0 5 0 kg m Be sure to lock the nut by firmly bending the tongue of the washer Install the drive plates and driven plates to the sleeve hub Insert push rod in the countshaft Cam side Push piece side Shorter Tighten the clutch spring bolts diagonally Clutch release screw adjustment Loosen the lock nut and turn in the release screw to feel high resistance From that position turn out the release screw 1 4 1 2 turn and tighten the lock nut OIL SUMP FILTER Wash the sump filter with cleaning solvent and then bolw compressed air through it to dry off solvent After mounting the sump filter fit the cap and tighten it LEFT ENGINE REASSEMBLY NEUTRAL CAM STOPPER Put in the neutral stopper and spring Tighten the cam stopper plug ENGINE 3 48 3 49 STATOR Apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws Thread Lock 1324 STARTER CLUTCH Locate the shim to the proper position Apply THREAD LOCK 1324 to the bolts and tighten with the specified torque Thread Lock 1324 type hexagon wrench 09911 73730 9 Starter clutch 15 20 N m 1 5 2 0 kg m MAGNETO ROTOR Fit the key in the
12. o Valve seat cutter set 09916 21110 15 P Use only for 15 of intake side 2 45 15 x 75 Valve seat cutter 09916 24910 R Solid pilot N 140 5 5 09916 24480 29 Valve seat CAUTION 1 valve seat contact area must be inspected after each cut 1 Insert with a slight rotation the solid pilot that gives a snug fit The shoulder on the pilot should be about 10mm from the valve guide 2 Using the 45 cutter descale and cleanup the seat with one or two turns 3 Inspect the seat by the previous seat width measurement procedure If the seat is pitted or burned additional seat conditioning with the 45 cutter is required CAUTION ENGINE 3 16 Cut the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area If the contact area is too high or too wide use the 15 cutter to lower and narrow the contact area 4 After the desired seat position and width is achieved use be 45 cutter very lightly to clean up any burrs caused by the previous cutting operations DO NOT use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish
13. 22 19 7 4 Valve lift 7 1 Valve clearance or tappet clearance 0 08 0 13 when cold 0 010 0 037 Valve guide to valve stem clearance 0 030 0 057 Valve guide D 5 000 5 012 4 975 4 990 Valve stem O D 4 955 4 970 Valve stem runout Valve head thickness Valve stem end length Valve stem width Valve head radial runout Valve spring free length 41 65 Valve spring tension Assembling condition 13 6 16 6 kg at length 36 6 mm 7 15 SERVICING INFORMATION CAMSHAFT CYLINDER HEAD STANDARD Unit mm Cam height 34 44 34 48 33 81 33 85 Camshaft runout Cam chain 20 pitch length Rocker arm D Rocker arm shaft O D 12 000 12 018 11 977 11 995 Cylinder head distortion Cylinder head cover distortion CYLINDER PISTON PISTON ITEM RING STANDARD Unit mm Compression pressure 15 6 500 rpm Piston to cylinder clearance 0 050 0 060 Oylinder bore 57 000 57 015 Piston diam Cylinder distortion 56 945 56 960 Measure at 15 mm from the skirt end Approx 7 2 Piston ring free end gap Approx 5 8 0 20 0 32 Piston ring end gap Assembling condition 0 20 0 32 Piston ring to groove clearance 1 01 1 03 Piston ring groove width 1 01 1 03 2 01 2 03 0 970 0 990 Pi
14. OIL HOSE TET CAM CHAIN OIL COOLER A OIL HOSE A CLUTCH RELEASE CAM mu n t CONROD BIG END BEARING COUNTERSHAFT BEARING ad COUNTERSHAFT AND GEARS Y PRIMARY DRIVEN GEAR SPACER BY PASS OIL PUMP SUMP FILTER CLUTCH PLATES vd gin A OIL PAN FUEL SYSTEM 4 12 _ Oil cooler Start motor Cylinder head Crankcase Transmission ELECTRICAL SYSTEM CONTENTS IGNITION SYSTEM ERE CHARGING SYSTEM EET STARTER SYSTEM re 5 1 ELECTRICAL SYSTEM IGNITION SYSTEM RX 125 is started as the battery discharged ignition system without a contact point The battery ignition system is composed a rotor tip the D C CDI the igniton coil and battery Ignite after permit signal at ignition timing of pick up as electric energy of this battery occur the 1st electric current Therefore a high voltage current is induced in the secondary winding of the ignition coil resultion in strong spark between the spark plug gap MAGNETO C D I UNIT 2 IGNITION COIL AND SPARK PLUG Ignition switch CDI UNIT Ignition coil wv ASpark plug TMT AM LM ELECTRICAL SYSTEM 5 2 INSPECTION MAGNET
15. 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 Holding the manual as shown at the right will allow you to find the first page of the section easily 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 W Data beside it indicates 324 Apply THREAD LOCK 1324 specified torque Apply oil Use engine oil unless otherwise specified POPU OPISE Drake MUIH i AGH Apply SUPER GREASE A qsa Measure in voltage range Apply SUPER GREASE ja Measure in resistance range AH Apply SILICONE GREASE i EX Measure in current range Apply MOLY PASTE TOOL Use special tool Apply BOND 412157 GENERAL INFORMATION CONTENTS INFORMATION LABELS GENERAL PRE
16. Screws Thread Lock 1324 STARTER MOTOR RELAY INSPECTION Disconnect the lead wire of the starter motor at the starter motor relay Turn on the ignition switch inspect the continuity between the terminals positive and negative when pushing the starter button If the starter motor relay is in sound condition continuity is found Pocket tester 09900 25002 Check the coil for open ground and ohmic resistance The coil is in good condition of the resistance is as follows Pocket tester 09900 25002 Standard resistance Approx 3 40 LAMP ELECTRICAL SYSTEM 5 12 Lamp switch low beam Battery pop ERE 3 3 4lI Head lamp 12V 35 35W Tail lamp 12V 21 5W High beam Head lamp Tail lamp LAMP BULB REPLACEMENT AND INSPECTION After installing a new bulb check for continuity If the bulb does not light inspect the wiring for open or short circuit 5 13 ELECTRICAL SYSTEM SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart Pocket tester 09900 25002 ENGINE KILL SWITCH POSITIO COLOR B Y Frame Earth OFF O O RUN LAMP SWITCH POSITION 55 0 WIRE COLOR Black with yellow tracer ELECTRICAL SYSTEM 5 14 BATTERY CAUTION OF BATTERY TREATME
17. to point B Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC generator again At the end of this state since the AC current generated from the AC generator flows into the point reverse current tends to flow to SCR then the circuit of SCR turns to OFF mode and begins to charge the battery again Thus these repetitions maintain charging constant voltage to the battery and protect it from overcharging A ee ee i Ig switch h 7 i o i 3 EM 4 i lr i pp od i i Battery i SCR y SCA i i ai Q i 9 A C generator om m m GE NE NDS ED GR 6 ee mcm ia uem m Regulator Rectifier 5 7 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the DC voltage between the battery terminal and If the tester reads under 13 5 V or over 16 0 V check the AC generator no load performance and regulator rectifier CAUTION When making this test be sure that the battery is full charged condition Pocket tester 09900 25002 IG switch Standard charge 13 5 16 0 V at 5 000 rom Regula
18. 09900 20803 When the limit is exceeded replace crankshaft assem bly or reduce the deflection and the side clearance to within the limit by replacing the worn parts conrod big end bearing crankpin and thrust washers etc CRANKSHAFT RUNOUT Support the crankshaft with V blocks as shown with the two end journals resting on the blocks Position the dial gauge as shown and rotate the crankshaft slowly to read the run out Correct or replace the crankshaft if the runout is greater than the limit Crank shaft runout Service limit 0 05 mm CLUTCH DRIVE PLATE Measure the thickness and claw width of each drive plate with vernier calipers Replace the drive plates found to have worn down to the limit Vernier calipers 09900 20101 2 9 41mm 2 6mm ETAT Rege 1 0 12 0mm 11 0 mm Checking thickness Checking claw width 3 35 CLUTCH DRIVEN PLATE Measure each of the driven plate for distortion with a thickness gauge Replace the driven plates which Thickness gauge 09900 20803 Distortion of clutch Service limit driven plate 0 1 mm CLUTCH SPRING FREE LENGTH Measure the free length of each coil spring with a vernier calipers and determine the elastic strength of each If any one of springs is not within the limit replace all the springs at a time Vernier calipers 09900 20101 Checking disto
19. 4 Turn signal pilot lamp bulb 1 7 Hi beam pilot lamp bulb 1 7 CAUTION Do not use except the specified bulb Wattage 7 21 SERVICING INFORMATION WIRE AND CABLE ROUTING WIRING HARNESS 09404 06401 Magneto Neutral switch Tail stop lamp ez License plate lamp r uy Clutch cable Handle switch L H 14403 ul Neutral switch Bs Magneto g Starter relay 2 09407 14403 bs pe 1 License plate lamp SERVICING INFORMATION 7 22 CABLE Handle switch R H Font Drake hose 09407 14403 09407 14403 Handig switch L h Clutch cable Starter cable Throttle cable Speedometer cable Throttle cable 09407 254 1 92 5 9 5 Oil cooler Oil cooler 09407 14401 Clutch cable Rear brake 09403H930 switch Fuse assembly 9 t an ON 5 Battery lead wire Clamp Battery lead wir 3 Starter motor lead wire 09407 14403 O gt 09407 14403 JE Engine Magneto Neutral Switch oN 5 S Volt D View E 09404 06401 wisn hata Clutch cable 09497 11401 Clamp
20. 5 10 STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn the motor will be unable to produce sufficient torque and the engine will be difficult to turn over To prevent this odically inspect the length of the brushes ing them when they are too short or chipping deu sE Service limit 3 5 mm COMMUTATOR If the commutator surface is dirty starting perfor mance decreases Polish the commutator with 400 or similar fine emery paper when it is dirty pe After polishing it wipe the commutator with a clean d a dry cloth 2 i Check the commutator under cut T Under cut of commutator Service limit 0 5 mm 2 MICA ARMATURE COIL Using a pocket tester check the coil for open and ground by placing probe pins on each commutator segment and rotor core to test for ground and on any two segments at various place to test for open of the commutator surface If the coil is found to be open circuited or grounded replace the armature continuous use of a defective armature will cause the starter motor to suddenly fail Pocket tester 09900 25002 5 11 ELECTRICAL SYSTEM STATER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to starter motor case align the protrusion D of the starter motor case with the notch 2 of the brush holder SECURING SCREWS Apply thread lock 1324 to starter motor securing
21. UTR M E C8bEH 9 Battery nn 12V 6Ah IIIEE 15A Headlight eee M 12V 35 35 WX2 Turn signal light mmm 12V 1 7 Wx2 Tail Brake light mmm 12V 21 5 Wx2 Speedometer light e 14V 3 4W High beam indicator light mm tt 12V 1 7 W Turn signal indicator light mmm 12V 1 7 W License plate lens eee 12V 5W CAPACITIES Fuel tank mmn 9 0 2 Engine oil change eee 950 ml with filter change mmm 1 050 overhaul Vas deu aia qe D dO ir Gu s e cus 1 400 m Front fork oil One side 443 2 The specifications are subject to change without notice CONTENTS COMPRESSION PRESSURE AND OIL PRESSURE ENGINE REMOVE AND REMOUNTING EPIN EE ON N UPPER END COMPONENTS DISASSEMBLY UPPER END COMPONENTS INSPECTION AND SERVICING UPPER END COMPONENTS REASSEMBLY E LEFT ENGINE DISASSEMBLY mE RIGHT ENGINE DISASSEMBLY Fe COREE oR ETE Per SEA PESTER ET ees LOWER END COMPONENTS DISASSEMBLY IEEE LOWER END COMPONENTS INSPECTION AND SERVICING LOWER END COMPONENTS REASSEMBLY Paetus qune bxc GEAR SHIFTING CAM AND FORK dapat RIGHT ENGINE REASSEMBLY Peer EC IS UL RN LEFT ENGINE REASSEMBLY 3 1 COMPRESSION PRESSURE AND OIL PRESSURE COMEPRESSION PRESSURE CAUTION
22. bolt Fit the two dowel pins to the camshaft holder ENGINE 3 24 When fitting rocker arm spring hook part of rocker arm spring onto rocker arm and hook part of rocker arm spring onto the dowel pins 3 25 Fit the two dowel pins install the camshaft holder D Tighten the camshaft holder nuts diagonally to the specified 5 Camshaft holder nut 25 35 2 5 3 5 kg m CHAIN TENSIONER Mount the tensioner body on the cylinder Install the spring and bolts VALVE CLEARANCE After tightening the camshaft holder lock nuts check and adjust the valve clearance Valve clearance specifications IN and EX valve clearance 0 08 0 13 mm CAUTION Valve clearance is to be checked when the engine is cold Both the intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compression stroke ENGINE 3 26 CYLINDER HEAD COVER Clean off oil from the surfaces of cylinder head and cover Fit the packing to the cylinder head cover D Tighten the cylinder head cover bolts with the hexagon wrench 5 Cylinder head cover 12 16 m 1 2 1 6 kg m LEFT ENGINE DISASSEMBLY Remove the magneto rotor and key 8 Rotor remover 09930 30162 3 27 Remove the starter clutch gear Remove the sta
23. key slot on the crankshaft Install the magneto rotor Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft Thread Lock 1324 Tighten the magneto rotor nut to the specified torque Thread Lock 1324 Rotor holder 09930 40113 Rotor holder 09930 44511 V Magneto rotor nut 56 60 N m 5 6 6 0 kg m STARTER IDLE GEAR AND MOTOR Install the starter idle gear Install the starter motor DRIVESHAFT OIL SEAL AND ENGINE SPROCKET CAUTION Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leakage Also grease the oil seal lip On installation refer to Fig for correct posi tion and direction Replace ring with a new one every disassembly CAUTION After reassembling the LOWER END COMPO NENTS install the O ring and spacer ENGINE 3 50 3 51 Tighten the engine sprocket nut to the specified torque and bend up the washer Rotor holder 09930 40113 9 Engine sprocket nut 80 100 N m 8 0 10 0 m GEAR POSITION SWITCH Install the gear position switch FUEL SYSTEM CONTENTS FUEL COCK quunt EE e PUE THROTTLE VALVE 2066 66 ee vni asi ae CARBURETOR RUNE RR ACCELERATOR PUMP ADJUSTMENT PILOT SCREW ADJUST
24. of adjustment to start Worn valve guides or poor seating of valves Valves mistiming Piston rings excessively worn Worn down cylinder bore Poor seating of spark plug Starter motor cranks but too slowly Plug not sparking 1 Fouled spark plug 2 Wet spark plug 3 Defective ignition coil 4 Open or short circuit in high tension cord o fuel reaching the carburetor 1 Clogged hole in the fuel tank cap Clogged or defective fuel cock Defective carburetor float valve Clogged fuel pipe Adjust Repair or replace Adjust Replace Replace or rebore Retighten Consult electrical complaints Clean or replace Clean and dry Replace Replace Clean Clean or replace Replace Clean or replace Engine stalls Fouled spark plug easily 2 Clogged fuel hose 3 Clogged jets in carburetor 4 Valve clearance out of adjustment Noisy engine Excessive valve chatter 1 Valve clearance too large 2 Weakened or broken valve springs 3 Worn down rocker arm or rocker arm shaft Noise appears to come from piston 1 Piston or cylinder worn down 2 Weakened or broken valve springs 3 Worn down rocker arm or rocker arm shaft 4 Piston rings or ring groove worn Noise seems to come from timing chain 1 Stretched chain 2 Worn sprockets 3 Tension adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn
25. page 6 32 6 37 CHASSIS Remove swing arm pivot nut Draw out the pivot shaft and take off the swing arm Remove the chain case Remove the two spacers Remove the spacer by using the special tools Bearing remover 17 mm 09923 73210 Rotor remover sliding shaft 09930 30102 INSPECTION SWING ARM PIVOT SHAFT Using a dial gauge check the pivot shaft for runout and replace it if the runout exceeds the limit Dial gauge 1 100 09900 20606 Swing arm pivotshan Service limit 0 6 mm for runout REASSEMBLY Reassemble and remount the swing arm in the reverse order of disassembly and removal and also carry out the following steps SWING ARM SPACER Force fit the spacers into the swing arm by using the special tool Bearing installer set 09924 84510 CHASSIS 6 38 SPACER Apply grease to the spacer when installing Super grease SERVICING INFORMATION CONTENTS TROUBLESHOOTING eorex ermntoneneed SPECIAL TOOLS Gat onan EUR TIGHTENING TORQUE e Re ee SEBVICE ATA taste dim erase ena a WIRE AND CABLE ROUTING eir tele etl tcd WIRING DIAGRAM Ghoti dee ei eee eens 7 1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start or is hard Valve clearance out
26. teeth of cluth plates 3 Distorted clutch plates driven and drive Noise seems to come from crankshaft 1 Worn or broken bearings 2 Big end bearings worn and broken 3 Thrust clearance too large Adjust Replace Replace Rep Rep Rep Rep Replace Replace Repair or replace Rep Rep Rep Rep Rep Rep Complaint SERVICING INFORMATION 7 2 Symptom and possible causes Remedy Noisy engine Noise seems to come from transmission 1 2 3 3 Gears worn or rubbing Badly worn splines Primary gears worn or rubbing Badly worn bearings Slipping clutch Clutch control out of adjustment or too much play Weakened clutch springs Worn or distorted pressure plate Distorted clutch plates driven and drive Dragging clutch Clutch control out of adjustment or too much play Weakened clutch springs Distorted clutch plates driven and drive Transmission will not shift Broken gearshift cam Distorted gearshift forks Worn gearshift pawl Rep Rep Transmission will not shift back Broken return spring on shift shaft Shift shafts are rubbing or sticky Distorted or worn gearshift forks Replace Repair Replace Transmission jumps out of gear Worn shifting gears on driveshaft or countershaft Distorted or worn gearshift forks Weakened stopper pawl spring on gearshift cam Worn gearshift paw
27. the 20 21 pins length of cam chain If it measures than the limits replace the cam chain vam ehaln eo Service limit 129 9 mm length ENGINE 3 36 Checking groove width Checking thickness 123 19 20 21 Ub Ob Ob See eae he ah 3 37 CRANKCASE BEARING Inspect the play of crankcase bearing inner race by hand while fixing it in the case Rotate the inner race by hand to inspect for an abnormal noise and a smooth rotation Replace the bearing if there is something unusual STARTER CLUTCH BEARING Inspect the bearing for any abnormality particularly cracks to decide whether it can reused or should be replaced 3 38 LOWER END COMPONENTS REASSEMBLY CRANKSHAFT Inspect the between the webs referring to the When mounting the crankshaft in the crankcase below figure when rebuilding the crankshaft it is necessary to pull its left end into the crankcase Standard 53 0 0 1 mm Crankcase installer 09910 32812 Conrod holder 09910 20116 53 0 0 1 mm 3 39 A CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affected TRANSMISSION
28. washer then remove the nut lock washer and oil pump drive gear Conrod holder 09910 20116 CAUTION This is a left hand thread nut Remove the oil pump driven gear then remove the primary drive gear and key OIL PUMP Remove the oil pump mounting screws and take off the oil pump body GEAR SHIFTER To remove the cam driven gear first remove the gear shifting shaft and loosen the pawl lifter and cam guide screws with an impact driver CAUTION When removing the cam driven gear do not lose the gear shifting pawl D pin and spring 3 KICK STARTER DRIVE GEAR AND IDLE GEAR Remove the kick starter drive gear and kick starter idle gear Snap ring pliers 09900 06107 LOW END COMPONENTS DISASSEMBLY CRANK CASE Remove the sump filter cap and plug cam stopper Pull out the spring neutral stopper ENGINE 3 30 3 31 Remove the sump filter Remove the crankcase securing bolts Separate the crankcase into 2 part right and left with the crankcase separater Crankcase separater 09920 13120 Fit the crankcase separater so that the tool plate is parallel with the end face of the crankcase CAUTION The crankshaft and transmission components must remain in the left crankcase half This is necessary because the gear shifting cam stopper is mounted
29. 7 9 SERVICING INFORMATION Special tools Part Number Part Description Special tools Part Number Part Description 09900 22401 Small bore gauge 10 18 Measure inside diameter of conrod small end 09913 60710 Bearing remover Remove bearing with the rotor remove sliding shaft 09900 25002 Pocket tester Measure voltage electric current resistance 09913 75520 Bearing installer Used to drive bearing in 09900 26006 Tachometer Measure rotational frequency of engine 09913 75821 Bearing installer Used to drive bearing in 09900 28107 Electro tester Inspect ignition coil 09913 75830 Bearing installer Install rear axle shaft oil seal 09910 20116 Conrod holder Used to lock the crankshaft 09913 76010 Bearing installer Install crankshaft bearing 09910 32812 Crankshaft installer Used to install the crankshaft in the crankcase 09915 63310 Compression gauge adapter Used with compression gauge 09940 10122 09915 64510 lt gt Clamp wrench Compression gauge ka A hook wrench to adjust the steering head of motorcycle Y Measure cylinder compression TUS 09913 14541 09915 74510 SN a Fuel level gauge set Oil pressure gauge sy Measure height of carburetor Measure oil pressure of 4 stroke engine i 09913 50121 09915 74531 Oil seal remov
30. 7 mm BRAKE SHOE Check the brake shoes and decide whether it should be replaced or not from the thickness of the brake shoe linings CAUTION Replace the brake shoes as a set otherwise braking performance will be adversely affected OT brake Service limit 2 5 mm shoe linings REASSEMBLY Reassemble and remount the rear wheel and rear brake in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the bearings before installling Super grease Install the wheel bearings by using the special tool CAUTION First install the wheel bearing for right side Bearing installer set 09924 84510 SPROCKET After tightening the four nuts to specification bend the washers to lock nuts V Sprocket nut 20 30 m 2 0 3 0 m BRAKE Apply grease to the brake cam Super grease CAUTION CHASSIS 6 30 Be careful not to apply too much grease to the brake cam shaft If grease gets on the lining brake slippage will result BRAKE CAM LEVER Tighten the cam lever bolt with specified torque 9 Brake cam lever nut 8 12 N m 0 8 1 2 kg CAUTION Adjust the rear brake pedal play after installa tion of the rear wheel 6 31 CHASSIS SUSPENSIO
31. 9900 20806 Service limit 0 05 mm VALVE FACE WEAR Measure the thickness T and if the thickness is found to have been reduced to the limit replace the valve CAUTION Visually inspect each valve for wear of its seating face Replace any valve with an abnormally worn face Valve face wear Service limit 0 5 mm VALVE STEM RUNOUT Support the valve with V blocks as shown and check its runout with a dial gauge The valve must be replaced if the runout exceeds the limit Valve stem runout Service limit 0 05 mm 3 13 VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head and measure the valve head radial runout If it measures more than limit replace the valve Service limit 0 03 mm VALVE GUIDE VALVE STEM CLEARANCE Measure the clearance in two directions and Y perpendicular to each other by rigging up the dial gauge as shown If the clearance measured exceeds the limit specified below then determine whether the valve or the guide should be replaced to reduce the clearance to within the standard range Standard Service limit 000 007 mm 0 35 mm 0 030 0 057 mm 0 35 mm VALVE STEM WEAR If the valve stem is worn down to the limit when measured with a micrometer and the clearance is found to be in excess of the limit pr
32. 9900 28107 Spark performance Over 8 mm 0 3 in A WARNING Do not touch the wire clips to prevent an elec tric shock when testing CAUTION When using the electro tester follow the instruction manual IGNITION COIL Checking with Pocket Tester A pocket tester or an ohm meter may be used instead of the electro tester In either case the ignition coil is to be checked for continuity in both primary and secondary windings Exact ohmic readings are not necessary but if the windings are in sound condition their continuity will be noted with these approximate ohmic values Pocket tester 09900 25002 Ignition coil resistance Primary 0 19 0 24 Q Tester knob indication X 10 range Secondary 5 4 6 6 2 Tester knob indication X 1kQ range Check to attached plug cap SPARK PLUG Clean the plug with a wire brush and pin Use the pin to remove carbon taking care not to damage the porcelain Check the gap with a thickness gauge Thickness gauge 09900 20804 Spark plug gap 0 8 0 9 mm ELECTRICAL SYSTEM 5 4 T 3 i 0 8 0 9 mm 5 5 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated in figure which is composed of and the AC generator regulator rectifier unit and battery The AC cu
33. 9913 75820 6 5 CHASSIS Install the disk with four bolts as shown in photo Disk bolt 18 28 N m 1 8 2 8 kg m CHASSIS 6 6 FRONT BRAKE 6 7 CHASSIS BRAKE PAD REPLACEMENT Remove the caliper mounting bolts and take off the caliper CAUTION Do not operate the brake lever while dismount ing the caliper Push the piston and caliper holder all the way to the caliper when removing the pad Loosen the screw and take off the housing cover Remove the pad CAUTION Replace the brake pad with a set otherwise braking performance will be adversely affected Apply the silicone grease to the caliper holder AGH Silicone gerase Push in the piston and piston holder all the way to the caliper when remounting the caliper Tighten the caliper mounting bolts with specified torque V Caliper mounting bolts 18 28 m 1 8 2 8 kg m CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose from the caliper and catch the brake fluid in a suitable receptacle CAUTION Never re use the brake fluid left over from the last ser vicing and stored for long periods Remove the caliper mounting bolts and take off the caliper Loosen the screw 4 and take off the carrier Take off the caliper carrier Remove the caliper holder from the caliper CH
34. ASSEMBLY Reassemble and remount the master cylinder in the reverse orders of disassembly and removal 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 internal parts before inserting into the bore When remounting the master cylinder to the handlebars first tighten the clamp bolts for upside as shown WARNING Bleed air from the brake fluid circuit after reassembling master cylinder See page 2 12 Clearance Master Cylinder Handlebar CHASSIS 6 14 FRONT FORK 6 15 CHASSIS REMOVAL AND DISASSEMBLY Take off the front wheel See page 6 1 Loosen the front fork upper and lower clamp bolts Remove the front brake hose clamp Pull down right and left front forks Remove the front fork cap O ring D and seat lever A CAUTION remove the O ring D it will be necessary to push the seat lever inwards to remove spring pressure from the O ring removed O ring D should be replaced With a new one Straighten the fork and stroke it several times to remove the oil Hold the fork inverted for a few minutes Remove the damper rod bolt by using the 19 mm socket Separate the i
35. ASSIS 6 8 6 9 CHASSIS Place a rag over piston to prevent popping up Force out the piston by using air gun CAUTION Do not use high pressure air to prevent piston damage Remove the piston piston boot and piston seal INSPECTION CALIPER CYLINDER Inspect the cylinder bore wall for nick scratches or other damage PISTON Inspect the piston surface for any scratches or other damage RUBBER PARTS Inspect the each rubber part for damage and wear DISC Measure the disc thickness by using the micrometer V Micrometer 0 25 mm 09900 20205 Disc thickness Service limit 3 0 mm With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown V Dial gauge 1 100 09900 20606 CHASSIS 6 10 BRAKE PADS Wear condition of brake pads can be checked by observing the red limit line marked on the pad When the wear exceeds the limit line replace the pad with new ones CAUTION Replace the brake pad with a set otherwise braking performance will be adversely affected 6 11 CHASSIS CALIPER REASSEMBLY Reassemble and remount the caliper in the reverse orders of disassembly and removal 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 App
36. CAUTIONS 22222222224212 SERIAL NUMBER LOCATION ENE FUEL AND OIL RECOMMENDATIONS atte Sena ss ton aD ves BREAK IN PROCEDURES M RR SPECIFICATIONS oie des p E DR RR ERI 1 1 GENERAL INFORMATION WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words 4 WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates 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 If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together p
37. Drive chain slack 50 60 CARBURETOR ITEM SERVICING INFORMATION 7 18 SPECIFICATION Carburetor type Bore size PD 18F 24 I D No HG 58 Idle rom 1 450 100 rom Float height 12 5 Main jet 98 Main air jet Jet needle 90 429 Needle jet AIFC 2nd Pilot jet 38 Throttle valve 93 C By pass 2 9 1 0 0 9 Valve seat Stater jet 2 0 MAX 500 Pilot screw 2 Pilot air jet FUEL OIL 150 SPECIFICATION Fuel type Gasoline used should be graded 85 95 octane or higher An unleaded or low lead type is recommended Fuel tank including reserve 8 0 liter Reserve Engine oil type 1 0 liter SEA 10W 40 SF Engine oil capacity change 950 ml Filter change 1 050 ml Overhaul 1 400 ml Front fork oil type 558 Oil Front fork oil capacity each leg Brake fluid type SAE J 1703 DOT 3 or DOT 4 443 2 5 7 19 SERVICING INFORMATION BRAKE WHEEL Unit mm ITEM STANDARD Front brake lever distance 20 30 Rear brake pedal free travel 10 20 Rear brake pedal height 2 Brake disc thickness Brake disc runout Front wheel Master cylinder bore Front wheel 12 700 12 743 Master cylinder piston diam Front wheel 12 657 12 684 Brake caliper cylinder bore Front wheel 25 4 Brake caliper piston diam Front wheel 25 4 Brake d
38. G INFORMATION CHASSIS t axle bolt t axle pinch bolt t fork damper rod bolt Front fork lower clamp bolt Front fork upper clamp bolt Steering stem head bolt Handlebars clamp bolt Swing arm pivot nut Rear torque link nut Front and rear Rear shock absorber fitting nut Upper and lower Rear cushion lever center nut Rear cushion rod nut and bolt Upper and lower Rear axle nut Rear sprocket nut Rear brake cam lever bolt Front brake caliper mounting bolt Disc bolt Front brake mastet cylinder mounting bolt Brake hose union bolt Caliper bleeder bolt Oil cooler hose union bolt 10 M Oil cooler hose union bolt 12 M TIGHTENING TORQUE CHART SERVICING INFORMATION 7 14 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 mm kg N m kg 1 0 2 0 0 1 0 2 1 5 3 0 0 15 0 3 2 0 4 0 4 0 7 0 0 2 0 4 3 0 6 0 8 0 12 0 0 3 0 6 0 8 1 2 10 0 16 0 18 0 28 0 1 8 2 8 22 0 35 0 40 0 60 0 4 0 6 0 35 0 55 0 70 0 100 0 7 0 10 0 50 0 80 0 110 0 160 0 11 0 16 0 80 0 130 0 130 0 190 0 SERVICE DATA VALVE GUIDE 13 0 19 0 170 0 250 0 200 0 280 0 STANDARD 17 0 25 0 20 0 28 0 Unit Valve diam
39. LINDER BORE Measure the cylinder bore diameter at six places If any one of the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replace the cylinder Cylinder gauge set 09900 20508 Service limit 57 080 mm PISTON DIAMETER Using a micrometer measure the piston outside diameter at the place 15 mm from the skirt end as shown in Fig If the measurement is less than the limit replace the piston Micrometer 50 75 mm 09900 20203 0 5 SSS Piston diameter Service limit 56 880 mm Piston oversize 0 5 1 0 mm A CAUTION Using a soft metal scraper decarbon the crown of the piston Clean the ring grooves similarly PISTON CYLINDER CLEARANCE As aresult of the above measurement if the piston to cylinder clearance exceeds the limit shown in the table below overhaul the cylinder and use size piston or replace both cylinder and piston Service limit 0 120 mm PISTON RING GROOVE CLEARANCE Using a thickness gauge measure the side clearance of the 1st and 2nd rings If any of the clearances exceeds the limit replace both piston and piston rings Thickness gauge 09900 20803 ENGINE 3 18 Piston ring groove clearance Service limit 0 180 mm Piston ring groove width Standard
40. MENT ONSCOOLER d MR MR uh LUBRICATION SYSTEM 4 1 FUEL SYSTEM FUEL COCK DISASSEMBLY Turn the fuel cock to OFF position and dis connect the fuel hose from the fuel cock Place aclean oil pan under the fuel cock assembly turn the fuel cock to ON position and drain the fuel Unscrew the fuel cock securing bolts and take off the fuel cock assembly CLEANING Rust from the fuel tank tends to build up the filter which when the filter has been neglected for a long period inhibits the flow of fuel Remove the rust from the filter using compressed air WARNING Gasoline is highly explosive Extreme care must be taken WARNING Gasket must be replaced with a new one to prevent leakage CARBURETOR FUEL SYSTEM 4 2 SPECIFICATION ITEM SPECIFICATION Carburetor type PD 18F Needle jet N J AIFC 2nd Bore size 24 Pilot jet P J 38 I D NO HG58 By pass B P 2 9 6 1 0 0 9 Idel rom 1 450 100 rpm Pilot air jet P A J 150 Jet needle J N J 29 Valve seat V S 2 0 Float height 12 5 mm Starter jet MAX 500 Main jet M J 98 Pilot screw P S 2 Main air jet M A J 90 4 3 FUEL SYSTEM THROTTLE VALVE DISASSEMBLY Disconnect the s
41. MP Loosen the screws and disconnect the pump cover Disconnect the spring Inspect the accelerator pump load damage of the diaphragm Clean the diaphragm Set up the diaphragm and the float chamber Install the spring in the diaphragm and install the cover in the float chamber Adjust the accelerator pump FLOAT AND NEEDLE VALVE Loosen the screws and remove the float chamber Pull out the float arm pin Remove the float D and needle valve Inspect the valve and valve seat for wear Inspect the float for transformation FUEL SYSTEM 4 6 4 7 FUEL SYSTEM JETS Disconnect the main jet 0 needle jet holder and needle jet Disconnect the slow jet 3 Disconnect the pilot screw after record the revolutions until tighten completely CAUTION Do not tighten the pilot screw by force otherwise can be damaged of the seat Disconnect the throttle stop screw 9 Clean the jets with non flammable cleaning solvent Inspect the pilot screw 6 and pilot jets Clean the jets and body passage with compressed air Install the needle jet needle jet holder main jet and slow jet Install throttle stop screw and pilot screw CAUTION Install the pilot screw as revolutions to a case of disassemble Adjust the pilot screw when use a new pilot screw Install the needle valve
42. N Service limit 10 20 mm Service limit 10 20 mm Service limit 14 20 mm REMOVAL AND DISASSEMBLY Remove the seat and frame covers Remove the rear wheel See page 6 26 Loosen the four screws and remove the mud flap Remove the rear cushion rod fitting nuts and bolts Remove the rear cushion lever nut and bolt Remove the rear shock absorber fitting bolt Pull up the suspension from the chassis CHASSIS 6 32 6 33 CHASSIS Remove the rear cushion rod nut and bolt Remove the spacers from the rear cushion rod After drawing out the spacer remove the two bearings from the rear cushion lever by using the special tools Bearing remover 17 mm 09923 73210 Rotor remover sliding shaft 09930 30102 INSPECTION Inspect the dust seals if they are found to be damaged replace them with new seals SPACER Measure the inside diameter of the spacer with dial calipers CHASSIS 6 34 Service limit 14 20 mm Spacer Service limit 10 20 mm See page 6 31 6 36 If the inside diameter of the spacer exceeds the service limit or flaws are discovered replace the spacer and O rings REASSEMBLY Reassemble the suspension in the reverse order of disassembly and removal and also carry out the following steps CUSHION LEVER BEARINGS Install the right and left bearings by using the
43. NT 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 CAUTION OF BATERY ELECTROLYTE TREATMENT Pay attention that the battery electrolyte not be stain the chasis or the humanbody If be stain the chasis or the humanbody at once wash a vast quantity of water When it be stained clothes should come into being a hole or painting should take off Be cured from a doctor When the battery electrolyte was droped the surface of land wash a vast quantity of water Neutralize by hudroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATERY TREATMENT Do not remove the aluminum tape what sealing the battery electrolyte filler hole untill use as battery of completely seal type Do not use with the exception exclusive the bat tery electrolye When pour into the battery electrolyte sarily use the electrolyte of the rules capacity Do not open the sealing cap after recharge the battery eletrolyte Filling electrolyte The battery is puted on even land remove the aluminum tape sealing Remove the cap at the electrolyte container Aluminum tape 7 CAUTION Do not remove th
44. O Using the pocket tester measure the resistance between the lead wires in the following table Pick up coil G L Approx 90 110 Q Charging coil Y Y Approx 0 6 0 9 9 Pocket Tester 09900 25002 CAUTION When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws Thread Lock 1324 WIRE COLOR Blue Green R Red White a Yellow B R Black with Red tracer L R Blue with Red tracer R G Red with Green tracer G White with Green tracer R White with Red tracer CDI UNIT Using the pocket X 1kQ range measure the resis tance between the lead wires in the following table Pocket tester 09900 25002 5 3 ELECTRICAL SYSTEM ee 00 00 0 1 000 E 5 50 D E 2 1 10 gt 3 00 00 00 00 00 EM 4 550 o 0 oc 5 00 00 00 00 00 QD 6 10 1 000 o o 11 100 2 200 INSPECTION IGNITION COIL Checking with Electro Tester Remove the ignition coil D NOTE Make sure that the three needle sparking distance of the electro tester is set at 8 mm 0 3 in With the electro tester test the ignition coil for sparking performance If no sparking or orange color sparking occures in the above conditions it may be caused by the defective Electro tester 0
45. This will provide a soft surface for the final seating of the valve which will occur during the first few sec onds of engine operation 5 Clean and assemble the head and valve ponents Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealing A WARNING Always use extreme caution when handling gasoline CAUTION Be sure to adjust the valve clearance after reassembling the engine 3 17 VALVE SPRINGS Check the springs for strength by measuring their free lengths and also the force required to press them If the limit indicated below is ed by the free length reading or if the measured force does not fall within the range specified replace with a HYOSUNG spring as a set Valve spring free length Valve spring free length Service limit IN amp EX 41 65 mm Valve spring tension Assembly condition Valve spring tension Standard IN amp EX 13 6 16 6 kg 36 6 mm CYLINDER DISTORTION Check the gasketed surface of the cylinder for dis tortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Service limit 0 05 mm CY
46. arings inner race by hand while fixing it in the wheel hub Rotate the inner race by hand to inspect whether abnormal noise occurs or rotating smoothly Replace the bearing if there is something unusual Play CHASSIS 6 4 5 Using the special tools check the axle shaft for runout and replace it if the runout exceeds the limit Dial gauge 09900 20606 x 52 7 Runout of axle shaft Service limit 0 25 mm PEN If d 47 WHEEL RIM wo lu Make sure that the wheel rim runout does not exceed the service limit when checked as shown CAUTION Worn or loose wheel bearing must be replaced before attempting to true a wheel rim Dial gauge 1 100 09900 20606 Magnetic stand 09900 20701 Runout of wheel rim Axial and Radial Service limit 2 0 mm TIRE Inspect the tires for wear and damage Check the tire tread depth as shown Replace a badly worn or damaged tire A tire with its tread worn down to the limit in terms of tread depth must be replaced Tread depth Front 1 6 mm service limit Rear 1 6 mm REASSEMBLY Reassemble and remount the front wheel in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the bearing before installing Super grease Install the wheel bearings by using the special tool Bearing installer 0
47. ay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors When working with toxic or flammable materials make sure that the area you work in is 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 servicing fuel oil exhaust or brake systems check all lines and fittings related to the system for leaks GENERAL INFORMATION 1 2 CAUTION If parts replacement is necessary replace the parts with HYOSUNG Genuine Parts or their equivalent When removing parts that 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 or sealant is specified be sure to use the specified type When removing the battery disconnect the negative cable first and then positive cable When reconnecting the battery connect the positive cable first and then negative cable and replace the termi nal cover on the positive terminal When performing service to electrical parts if the servi
48. cam lever INSPECTION WHEEL BEARINGS Inspect the wheel bearings for play by hand Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly Replace the bearing if there are any defects 5 Using dial gauge check the axle shaft for runout and replace it if the runout exceeds the limit Dial gauge 1 100 09900 26006 Magnetic stand 09900 20701 V Block 09900 21304 CHASSIS 6 28 Axle shaft runout Service limit 0 25 mm WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown An excessive amount of runout is usually due to loosen spokes or a bent wheel rim If properly tightening the spokes will not correct the runout replace the wheel rim CAUTION Worn or loose wheel bearings must be replaced before attempting to true wheel rim Wheel rim runout Service limit Axial and Radial 2 0 mm SPROCKET Inspect the sprocket teeth for wear If they are worn as illustrated replace the sprocket and drive chain ee Normal wear Excessive wear 6 29 CHASSIS REAR BRAKE DRUM Measure the brake drum 1 D 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 130
49. ce procedures do not require use of battery ower disconnect the negative cable at the battery Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated 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 To protect environment do not unlawfully dispose of used motor oil and other fluids batteries and tires To protect Earth s natural resouces properly dispose of used vehicles and parts 1 3 GENERAL INFORMATION HYOSUNG RX125 RIGHT SIDE LEFT SIDE Difference between photographs and actual motorcycles depends on the markets SERIAL NUMBER LOCATION The frame ser
50. cial tool Bearing installer set 09924 84510 CAUTION When installing two bearings punch marked side of bearing comes on outside SPACER AND DUST SEAL Apply grease to the spacer and dust seal before installing as shown in the illustration Super grease 6 35 CHASSIS 9 amp Rear shock absorber nut Upper 40 60 4 0 6 0 m Rear cushion lever center nut 70 100 N 7 0 10 0 m O Rear cushion rod nut and bolt Lower 84 120 N m 8 4 12 0 m D Rear cushion rod nut and bolt Upper 684 120 m 8 4 12 0 9 m E Rear shock absorber nut Lower 40 60 4 0 6 0 m REAR SHOCK ABSORBER SPRING ADJUSTMENT PROCEDURE The procedure for adjusting the spring pre load is as follows Remove the seat and frame covers Remove the carburetor Remove thr air cleaner case Adjust the rear shock absorber by using the special tool Clamp wrench 09940 10122 Remount the air cleaner carburetor seat and frame cover CHASSIS 6 36 REAR SWING ARM Service limit 14 20 mm REMOVAL AND DISASSEMBLY Remove the rear wheel See page 6 26 Loosen the four screws and remove the mud flap See page 6 32 Remove the rear cushion rod fitting nuts and bolts See page 6 22 Remove the rear shock absorber fitting nut and bolt See
51. e chain keep the camshaft drive chain taut The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated CAMSHAFT Align the mark on magneto rotor with the index mark on the crankcase keeping the camshaft drive chain pulled upward CAUTION If crankshaft is turned without drawing the camshaft drive chain upward the chain will be caught between crankcase and cam chain drive sprocket Install the camshaft bearing and cam sprocket tighten it CAUTION This is left hand thread bolt Align the on the camshaft so it is vertical with the surface of the cylinder head CAUTION Do not rotate magneto rotor while doing this When the sprocket is not positioned correctly turn the sprocket Install the camshaft lock C ring A CAUTION Align the both end face of C ring and cylinder head face Apply HYOSUNG MOLY PASTE properly to the camshaft bearing and camshaft face CAMSHAFT HOLD Apply HYOSUNG MOLY PASTE to the rocker arm shafts G then inserting the camshaft hold Install the rocker arm spring 3 rocker arm 4 and inserting the camshaft hold CAUTION Pay attention to the exhaust side rocker arm that have not confused the groove at the intake side rocker arm so that avoid contact with stud Groove
52. e damaged of the seat Start up the engine and set its speed at any where between 1 450 100 rpm by turning the throttle screw 8 Adjust the engine speed at hight position as the pilot screw left right turning 0 Repeat again 3 Adjust the standard engine idle speed by the throttle stop screw 8 Look into the change idling revolution with snap light of continuously If the idling revolution is change repeat the OIL COOLER DISASSEMBLY Remove the oil cooler cover NOTE Draw out and push for face of the spring seat Remove the screws Remove the union bolts and detach the oil cooler NOTE When reassemble after remove the union bolt do not remove except special case that fold of the hose the others are affected according to assemble angle REMOUNTING Remounting the oil cooler by reversing the sequence of disassembling steps Loosen the union bolt D of the cylinder head and inspect the air bleeding and oil 8 Union bolt 20 25 N m 2 0 2 5 kg m FUEL SYSTEM 4 10 4 11 FUEL SYSTEM LUBRICATION SYSTEM vd CAMSHAFT JOURNAL AND CAM FACE 1 ven ROCKER ARM SHAFT n TET CONROD SMALL END CYLINDER WALL DRIVESHAFT BEARING DRIVESHAFT AND GEARS vd i
53. e new nuts and tighten them to the specified torque V Engine mounting bolt M 17 mm 48 72 4 8 7 2 m Engine mounting The others 22 33 2 2 3 3 m Exhaust pipe nuts 18 22 N m 1 8 2 2 m Muffler clamp bolts 9 16 m 0 9 1 6 kg m Pour 1 400 ml of engine SAE 10 W 40 graded SF or SG SH into the engine after overhauling the engine Start up the engine and allow it run for several seconds at idle speed About one minute after stopping the engine check the oil level If the level is below the top limit mark add the oil until the level reaches the top limit mark Installing position for clutch release am Align the release arm slit surface with the notch mark on the release cam shaft UPPER END COMPONENTS DISASSEMBLY CYLINDER HEAD COVER CAMSHAFT Bring the piston to top dead center CAUTION When removing the cylinder head cover the pis ton must be at top dead center on compression stroke ENGINE 3 6 After remounting the engine following adjust ments are necessary Throttle cable Clutch cable Page 2 9 Page 2 9 eS a Page 2 13 Page 2 9 lt Rear brake Idling speed lt Drive chain Page 2 10 3 7 Remove cam chain tensioner Loosen the cylinder head cover bolts and detach the head cover
54. e of the spring ten sion Remove the oil seal using the long nose pliers Take out the spring seat valve guide Decarbonate in the combustion chamber CAUTION Removed parts should be marked for install at the original position CYLINDER Remove the cylinder base nuts and cylinder A CAUTION If tapping with the plastic hammer is necessary do not break the fins ENGINE 3 10 PISTON Place a clean rag over the cylinder base to pre vent the piston pin circlip from dropping into the crankcase and then remove the piston pin cir clip with the long nose pliers Remove the piston pin Piston pin puller 09910 34510 Remove the knock pin with the long nose pliers 3 11 UPPER END COMPONENTS INSPECTION AND SERVICING CAMSHAFT HOLDER DISTORTION After removing the oil from the fitting surface of the camshaft holder place the camshaft holder on a surface plate and check for distortion with a thick ness gauge Check points are shown in Fig Service limit 0 05 mm f the distortion exceeds the service limit replace the camshaft holder ROCKER ARM SHAFT O D Measure the diameter of rocker arm shaft Standard 11 977 11 995mm ROCKER ARM 1 0 When checking the valve rocker arm the inside diameter of the valve rocke
55. e seal not prick with sharp Filler holes thing 5 15 ELECTRICAL SYSTEM 2 ff Na A A P d Seal 3 Pouring in battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it cloes not fall Take precaution not to allow any of the fluid to spill CAUTION In no case pouring into if put in slopely the electrolyte container 4 Confirm of pour Make sure that air bubbles are coming up each electrolyte container and leave in this position for about more than 20 minutes CAUTION If no air bubbles are coming up from afiller port tap the botton of the two or three times Air bubble 5 Separation of electrolyte container After confirming that the electrolyte has entered the battery completely remove the electrolyte ers from the battery CAUTION Draw out slowly otherwise in case of remain electrolyte vaporize 6 Insert of the caps Insert the cap 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 ASSISTANCE RECHARGING Use the battery that is maded after 2 years as the maintenance free battery Use the battery at condition of the high temp
56. eat and fuel tank See page 3 2 Looen the carburetor top D and disconnect the throttle valve Remove the throttle cable from the throttle valve and disconnect the throttle cable Disconnect the throttle valve spring and carburetor top from the throttle cable Draw out the retainer clip and disconnect the jet needle Inspect the jet needle and wear damage of the throttle valve Install the jet needle and retainer clip into the throttle valve Needle clip standard position 3rd groove Install the carburetor top and spring into the throttle cable Install the throttle cable into the throttle valve REASSEMBLY Following adjustments and inspection are necessary after installing the throttle valve Throttle cable play Refer to page 2 9 Idling adjustment Refer to page 2 9 CARBURETOR DISASSEMBLY Remove the seat and fuel tank Refer to page 3 2 Remove the carburetor top Refer to page 4 3 Remove the throttle cable Remove the carburetor drain screw and draw out in the carburetor A WARNING FUEL SYSTEM 4 4 Leaner 1st Standard 3rd Richer 5th Gasoline is highly explosive Extreme care must be taken Remove the choke cable 4 5 FUEL SYSTEM Loosen the carburetor nut and clamp screw Remove the carburetor DISASSEMBLY Disconnect the fuel tube and drain tube ACCELERATOR PU
57. er Oil pressure gauge adapter d Used to remove the oil seal Used with oil pressure gauge SERVICING INFORMATION 7 10 Special tools Part Number Part Description Special tools Part Number Part Description 09916 14510 Valve spring compressor Remove and remounting valve stem 09923 74510 Bearing remover 20 35mm Remove bearing with the rotor remove sliding shaft 09916 14910 Valve spring compressor attachment Used with valve spring compressor 09924 84521 Bearing installer Used to drive small bearing in 09916 84511 Tweezers Remove and remounting valve cotter pin 09925 98221 Bearing installer Used to drive bearing in 09917 14910 Tappet adjuster driver Control to valve clearance 09930 10121 Spark plug socket wrench set Remove and remounting spark plug 09920 13120 Crankcase separater Seprate to crankcase 09930 30102 Rotor remove sliding shfat Used to with bearing remover or rotor remover 09921 20200 09930 30162 Bearing remover 10mm S Rotor remover Remove oil seal or bearing amp Attached to the top of sliding shaft when removing rotor 09921 20210 09930 32420 Bearing remover 12mm b Rotor holder b ep k Remove oil seal or bearing Remove remounting rotor 09922 55131 09930 40113 3 Bearing installer s Rotor holder gt 4
58. erature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric rent or voltage when the battery discharged Do not assistance recharge except the right side table Do not remove when assistance recharge A WARNING The firearm is strictly prohibited ELECTRICAL SYSTEM 5 16 Insert the caps firmly Assistance Recharging Standard 0 7 A 5 10 hours CHASSIS CONTENTS FRONT WHEEL E FRONT BRAKE HH meme FRONT FORK re STEERING STEM C T M REAR WHEEL AND REAR BRAKE GUGDENGION nnd bites a donet NTA REAR SWING ARM eed d patada i bodas 6 1 CHASSIS FRONT WHEEL REMOVAL Support the machine by jack block or service stand Service stand 99000 99094 CHASSIS 6 2 Disconnect the speedo meter cable Disconnect the left side of the protector Disconnect the clamp Remove the brake hose Pull out the fixing bolt and remove the axle Draw out the front axle and take off the front wheel 6 3 CHASSIS DISASSEMBLY FRONT WHEEL Remove the front brake disk Using the special tool drive out the wheel bear ings Wheel bearing remover 09941 50110 INSPECTION WHEEL BEARING Inspect the play of the wheel be
59. eviously indicated replace the valve if the stem is within the limit then replace the valve guide After replacing valve or guide be sure to recheck the clearance Micrometer 0 25 mm 09900 20205 VALVE STEM O D Check face into end of valve stem and wear valve Standard 4 975 4 990 mm 4 955 4 970 mm CAUTION Inspect the valve stem end face for pitting and wear If pitting or wear of the stem end face are present the valve stem end may be resurfaced providing that the length 1 will not be reduced to less than 3 38 mm If this length becomes less than 3 38 mm the valve must be replaced After installing a valve whose stem end has been ground off as above check to ensure that the face 2 of the valve stem end is above the cotters 9 VALVE GUIDE INSTALLATION Re finish the vave guide holes in cylinder head with a 10 5 mm reamer 0 and handle 2 10 5 mm Reamer 09916H34575 Handle 09916 34541 Fit a ring to each valve guide Be sure to use new rings and valve guides Use of rings and valve guides removed in disassembly must be discarded Lubricate each valve guide and drive the guide into the guide hole using the valve guide installer handle and valve guide installer attachment 4 Valve guide installer and remover 0916 44910 Valve guide installer attachment 09916 44920 After fitting all valve guides re finish their
60. float float arm FLOAT ADJUSTMENT To check the float height invert the carburetor body holding the float arm pin so that the pin will not slip off Float height 12 5 mm Check to be sure that the float moves freely Install the new O ring and float chamber groove 4 Install the float chamber and screw ACCELERATOR PUMP ADJUSTMENT CAUTION Do not adjust except for exchange the adjust screw Adjust idling Refer to page 2 9 Adjust throttle grip Refer to page 2 9 Adjust clearance of the accelerator pump rod after loosen the lock nut and turn the adjust screw Tighten the lock nut Lock nut clearance 0 mm FUEL SYSTEM 4 8 Adjust screw 4 9 FUEL SYSTEM REASSEMBLY Install the fuel tube and drain tube Replace a new O ring at the carburetor outlet side Install the carburetor between the intake pipe and air cleaner outlet tube tighten the carburetor lock nut and clamp screw Connect the choke cable and throttle cable Adjust the choke cable Install the throttle valve Refer to page 4 4 Adjust play of the throttle grip Refer to page 2 9 PILOT SCREW ADJUSTMENT Loosen as standard turn back revolutions after lock the pilot screw suitable Standard turn back 2 Circle revolution of pilot screw A CAUTION Do not tighten the pilot screw by force otherwise can b
61. fuel tank ENGINE 3 2 3 3 Take off the clutch cable by removing the clutch lever bolts and adjuster lock nut Disconnect the lead wire of starter motor Take off the magneto Take off the spark plug cap 3 4 Take off the breather hose Loosen the two clamp screws bolt and take off the carburetor Remove the engine sprocket cover Take off the drive chain by removing the clip 3 5 Disconnect the ground wire from the crankcase Take off the gear shift lever by removing the bolt Remove the exhaust pipe nuts and muffler mounting bolt then take off the muffler Take out only one third of shaft after remove the swing arm pivot nut Remove engine mounting bolts D 0 after remove the swing arm pivot nut Use both hands and lift the engine from the frame NOTE The engine must be taken out from the right side CAUTION Take out only one third from the left side to the right side swing arm pivot nut ENGINE REMOUNTING The engine can be mounted in the reverse order of removal Temporarily fasten the engine mounting bracket before inserting the engine mounting bolts A CAUTION The engine mounting nuts are self lock nuts Once the nut has been removed it is no longer of any use Be sure to us
62. guiding bores will a 5 0 mm reamer and handle Be sure to clean and oil the guides after reaming 5 0 mm Reamer 09916 34571 Reamer handle 09916 34541 Install valve spring lower seat Be careful not to confuse the lower seat with the spring retainer 8 ENGINE 3 14 3 15 Lubricate each seal and drive them into tion with the valve stem seal installer CAUTION Do not reuse the oil seals Valve guide installer and stem seal installer 09916 44910 VALVE SEAT WIDTH Coat the valve seat with prussian blue uniformly Fit the valve and tap the coated seat with the valve face in a rotating manner in order to obtain a clear impression of the seating cotact In this operation use the valve lapper to hold the valve head The ring like dye impression left on the valve face must be continuous without any break In addition the width of the dye ring which is the visualized seat width must be within the specification Valve seat width Valve seat width Standard 0 9 1 1mm If either requirement is not met correct the seat by servicing it as follows VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are angled to present two bevels 15 and 45 0 c 15
63. he fitting sur face of the left half of the crankcase and after waiting a few minutes fit the right half on the left half BOND 1215 After the crankcase bolts have been tightened check if the driveshaft and countershaft rotate smoothly a large resistance is felt to rotation try to free the shafts by tapping the driveshaft or counter shaft with a plastic hammer as shown in Fig RIGHT ENGINE REASSEMBLY CLUTCH KICK START DRIVE GEAR AND IDLE GEAR Install the kick starter idle gear and drive gear Snap ring pliers 09900 06107 GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driven gear The large shoulder must face to the outside as shown Next install cam guide and pawl lifter Apply a quantity of THREAD LOCK 1324 to the threaded parts of the securing screws Thread Lock 1324 ENGINE 3 44 3 45 GAER SHIFTING SHAFT Install the gear shifting shaft Match the center teeth of the gear on the shifting shaft with the cen ter teeth on the shifting driven gear as shown CAUTION After the cam driven gear cam guide gear shifting shaft and neutral cam stopper have been fitted confirm that gear change is normal while turning the countshaft and driveshaft If gear change is not obtained it means that assembly of gears or installation of gear shifti
64. i Na HYOSUNG HYOSUNG MOTORS amp MACHINERY INC SERVICE MANUAL TWANVIN E Ot EE 99000 97100 FOREWORD This manual contains an introductory description on HYOSUNG RX 125 and procedures for its inspection service and overhaul of its main nents 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 helo 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 publi cation If modification has been made since then difference 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 procedures They may not represent the actual vehicle exactly in detail This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL SYSTEM ELECTRICAL SYSTEM
65. ial number or V I N Vehicle Identification Number is stamped on the right side of the steering head pipe The engine serial number is located on the left upside of the crankcase 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 ENGINE OIL Make sure that the engine oil you use comes under API classification of SH SG or SF and that its viscocity rating is SAE 10W 40 If an SAE 10W 40 motor oil is not available select an alternate according to the right chart GENERAL INFORMATION 1 4 BRAKE FLUID Specification and classification SAE J1703 DOT3 or DOT4 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 system 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 SS8 Oil 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 a
66. il Fork oil capacity Each leg 443 2 5 cc Hold the front fork vertical and adjust the fork oil level with the special too CAUTION When adjusting oil level remove the fork spring and compress the inner tube fully Front fork level gauge 09943 74111 Front fork oil level At outer tube 146 mm Without Spring STOPPER RING To install a new stopper ring it will be necessary to push the spring seat inward CAUTION Always use a new stopper ring After installing a stopper ring always insure that it is completely seated in its groove and securely fitted 6 19 CHASSIS REMOUNTING Maintain equally right and level height Standard for upside surface of the upper bracket 7 mm 1 mm Tighten the upper and lower clamp bolts Upper clamp bolts 22 35 m 2 2 3 5 m Lower clamp bolts 20 30 2 0 3 0 m CHASSIS 6 20 STEERING STEM 6 21 CHASSIS REMOVAL AND DISASSEMBLY Take off the front wheel See page 6 1 Take off the front fork See page 6 15 Remove the screws and the two headlight housing rubber packing Disconnect the lead wires Remove the two screws of the headlight housing Remove the four bolts and front fender Remove the handlebars clamp bolts Remove the steering stem head bolt and take off the steering ste
67. into the cylinder check that the gaps are so located ENGINE 3 20 Oil ring 2nd Side rail upper EX Side rail lower 3 21 PISTON The following are reminders for piston installation Rub asmall quantity of HYOSUNG MOLY PASTE onto the piston pin Place a clean rag over the cylinder base to vent piston pin circlip from dropping into crankcase and then fit the piston pin circlip with long nose pliers CAUTION Use a new piston pin circlip to prevent circlip failure which will occur with a bent one When fitting the piston turn arrow mark on the piston head to exhaust side CYLINDER Before mounting the cylinder oil the big end and small end of the conrod and also the sliding sur face of the piston Fit dowel pins D to crankcase and then fit gasket CAUTION To prevent oil leakage do not use the old gas ket again always use new one Hold each piston ring with the piston rings erly spaced and insert them into the cylinder Check to insure that the piston rings are properly inserted into the cylinder skirt CAUTION When mounting the cylinder after attaching camshaft drive chain keep the camshaft drive chain taut The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated
68. ion the cam as shown in Fig So that the gear shifting fork can be installed easily 3 42 CAUTION Two kinds of the gear shifting forks and 0 are used They resembles each other very closely in external appearance and configura tion Carefully examine the illustration for correct installing positions and directions After the cam stopper and gear shifting forks have been fitted hook the cam stopper spring into the crankcase KICK STARTER 3 43 When fitting the kick starter to the shaft be sure to align the punched marks Fit the spring and washer on the shaft Then insert the kick starter shaft into the crankcase Engage the pawl of kick starter guide 0 When fitting the kick return spring hook the part 9 of return spring into the crankcase turn it 1 2 a turn clockwise with the pliers and fit the part 0 of return spring into hole of the kick shaft Then fit the spring guide and circlip CRANKCASE When reassembling the crankcase pay attention to the following Coat SUPER GREASE A to the lip of oil seals Remove sealant material on the fitting surface of right and left halves of the crankcase and oughly remove oil stains Fit the dowel pins on the half Apply engine oil to the big end of the crankshaft conrod and all parts of the transmission gears Apply BOND 1215 uniformly to t
69. l Rep Rep Rep Rep Engine idles poorly gt Valve clearance out of adjustment Poor seating of valves Defective valve guides Worn rocker arm or arm shaft Spark plug gap too wide Defective ignition coil resulting in weak sparking Float chamber fuel level out of adjustment in carburetor Clogged jets Adjust Replace Replace Replace Adjust or replace Replace Adjust Clean Engine runs poorly in high speed range gt Valve springs weakened Valve timing out of adjustment Worn cams or rocker arms Spark plug gap too narrow Defective ignition coil Float chamber fuel level too low Clogged air cleaner element Clogged fuel pipe resulting in inadequate fuel supply to carburetor Replace Adjust Replace Repair Replace Adjust Clean Clean or replace Dirty or heavy exhaust smoke Too much engine oil in the engine Worn piston rings or cylinder Worn valve guides Cylinder wall scored or scuffed Worn valves stems Defective stem seals Worn side rails Check with inspection win dow drain out excess oil Replace Replace Replace Replace Replace Replace 7 3 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power 1 2 3 4 5 6 7 8 9 10 11 12 13 Loose
70. llow the moving parts to before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Initial 800km Below 5 000rpm Up to 1 600km Below 7 000rpm Over 1 600km Below 10 000rpm Keep to these break in engine speed limits Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation However do not exceed 10 000rpm at any time Do not maintain constant engine speed for an extended period during any portion of the break in Try to vary the throttle position 1 5 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length mmm eee 2 190 mm 86 2 in Overall width 800 mm 31 5 in Overall height eee 1 160 mm 45 7 in Wheelbase 1 425 56 1 in Ground clearance 295 mm 1 1 6 in Dry MASS eee 125 kg 276 lbs ENGINE e Four stroke SOHC Number of cylinder 1 lt 57 mm 2 24 in Stroke T E 48 8 mm 1 92 Piston displacement eee 124 7 6 cu in Carburetor semen PD18F Air cleaner
71. ly brake fluid to the caliper bore and all internal parts before inserting into the bore Apply the silicone grease to the caliper holder AGH Silicone grease TIGHTENING TORQUE 6 9 0 6 0 9 20 25 2 0 2 5 18 28 1 8 2 8 A WARNING Bleed the air from brake fluid circuit after reassembling the caliper See page 2 12 MASTER CYLINDER REMOVAL AND DISASSEMBLY Please a cloth underneath the union bolt on master cylinder to prevent spilled drops of the brake fluid Unscrew the union bolts and discon nect the brake hose from the master cylinder joint CAUTION Immediately and completely wipe off any brake fluid contacting any part of the motorcycle The fluid reacts chemically with paint plastics rubber materials etc and will damage them severely Remove the two clamp bolts and take off the master cylinder Remove the two fitting screws and separate the cap and diaphragm Drain brake fluid Remove the dust seal boot Remove the circlip by using the special tool Snap ring pliers 09900 06108 Remove the piston primary cup and spring INSPECTION Inspect the master cylinder bore for any scratches or other damage CHASSIS 6 12 6 13 CHASSIS Inspect the piston and cup surface for any scratches or other damage Inspect the dust seal boot for wear for damage RE
72. m upper nut Remove the steering stem nut and draw out the steering stem CAUTION Hold the steering stem lower bracket by hand to prevent from falling Remove the upper and lower bearing CHASSIS 6 22 6 23 CHASSIS Remove the outer race fitted on the steering stem This can be done with a chisel Draw out the two inner races fitted to the top and bottem ends of the head pipe INSPECTION Inspect and check the removed parts for the fol lowing abnormalities Handlebars distortion Handlebars clamp wear Abnormality operation of bearing Worn or damaged steel balls Distortion of steering stem REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal and also carry out the following steps INNER RACES Press in the upper and lower inner races using the special tool Steering race installer 09941 34511 CHASSIS 6 24 BEARING When press the bearing use the special tool STEERING STEM NUT Tighten the steering stem nut with the special tool Clamp wrench 09940 10122 9 steering stem nut 40 50 m 4 0 5 0kg m Turn the steering stem right and left lock to lock five or six times Tighten the steering stem head bolt to the ified torque F Steering stem head bolt 80 100 N m 8 0 10 0 kg m CAUTION After perf
73. n Too much play on brake lever or pedal Shoes worn down Refill to level mark Bleed air out Replace Adjust Replace Insufficient brake power i oe Leakage of brake fluid from hydraulic system Worn pads Oil adhesion of engaging surface of pads Worn disk Air in hydraulic system Repair or replace Replace Clean disk and pads Replace Bleed air Brake squeaking Excessive brake lever stroke Leakage of brake fluid i NOON BW Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Loosen front wheel axle or rear wheel axle Worn pads Foreign material in brake fluid Clogged return port of master cylinder Air in hydraulic system Worn brake lever cam Insufficient brake fluid Improper quality of brake fluid Insufficient tightening of connection joints Cracked hose Worn piston and or cup Repair surface with sandpaper Modify pad fitting Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Bleed air Replace brake lever Replenish fluid to specified level bleed air Replace with correct fluid ten to specified ue ace ace piston and or cup SPECIAL TOOLS SERVICING INFORMATION 7 8 Special tools Part Number Part Description Special tools Part Number Part
74. n of valve clearance Weakened valve springs Valve timing out of adjustment Worn piston ring or cylinder Poor seating of valves Fouled spark plug Worn rocker arms or its shafts Spark plug gap incorrect Clogged jets in carburetor Float chamber fuel level out of adjustment Clogged air cleaner element Too much enging oil Defective air intake pipe Adjust Replace Adjust Replace Repair or replace Clean or replace Replace Adjust or replace Clean Adjust Clean Drain out excess oil Retighten or replace Engine overheats CARBURETOR Complaint Heavy carbon deposit on piston head Not enough oil in the engine Defective oil pump or clogged oil circuit Fuel level too low in float chamber Air leak from intake pipe Use of incrrect engine oil Defective oil cooler Symptom and possible causes Clean Add oil Repair or clean Adjust Retighten or replace change Clean or replace Trouble with starting Starter jet is clogged Starter pipe is clogged Air leaking from a joint between starter body and carburetor Starter plunger is not operating properly Clean Clean Check starter body and carburetor for tightness adjust and replace gasket Check and adjust Idling or low speed trouble Pilot jet pilot air jet are clogged or loose Pilot outlet or bypass is clogged Starter plunge
75. ne speed to 3 000 rom and read the oil pres sure gauge NOTE Engline oil must be warmed up to 60 140 F when checking the oil pressure Oil pressure Oil pressure 0 4 0 6 at 60 C 3 000 rpm Oil pressure gauge 09915 74510 It the oil pressure is lower or higher than the speci fications several causes may be considered Low oil pressure is usually the result of a clogged oil damaged oil seal a defective oil pump or a combination of these items filter oil eakage from the oil passage damaged oil seal a defective oil pump or a combination of these items High oil pressure is usually caused by a engine oil which is too heavy a weight a clogged oil passage improper installation of the oil filter or a combination of these items ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame oughly clean the engine with a suitable cleaner The procedure of engine removal is sequentially explained in the following steps Take off the seat by loose two volts below seat Take off the right and left frame cover Take off the right and left fuel cover Disconnect and lead wires of battery D CAUTION First disconnect the O lead wire Take off the fuel tank by removing the mounting bolts Turn the fuel cock lever to the OFF position Take off the fuel hose Remove the
76. ng fork is incorrect If this is the case disassemble and trace the mistake PRIMARY DRIVE GEAR AND OIL PUMP Fit the key in the slot on the crankshaft and install the primary drive gear Before mounting the oil pump apply engine oil to the sliding surfaces of the case outer rotor inner rotor and shaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of oil pump mounting screws Thread Lock 1324 Tightening the oil pump mounting screws 3 46 CAUTION After mounting the oil pump in the crankcase rotate the pump gear by hand to see if it turns smoothy After checking the oil pump install the oil pump drive gear lock washer and nut tighten it with a torque wrench to the specified torque and bend up to the washer Conrod holder 09910 20116 CAUTION This is a left hand thread nut 9 Oil pump nut 40 60 N m 4 0 6 0 kg m CLUTCH 3 47 Install the clutch camshaft by positioning the face to right side Install the oill seal by using the 17 mm socket Tighten the oil seal retainer screw Assemble the clutch in the reverse order of disas sembly Pay attention to the following points When inserting the spacer on the countershaft apply a small quantity of engine oil to both inside and outside of the spacer
77. nner tube from outer tube Remove oil lock piece and damper rod with rebound spring Remove the snap ring by using the special tool Snap ring pliers 09900 06108 Remove the oil seal by using the special tool Oil seal remover 09913 50121 CAUTION CHASSIS 6 16 The oil seal removed should be replaced with a new oil seal 6 17 CHASSIS INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear and damage INNER TUBE AND OUTER TUBE Inspect the inner tube and outer tube sliding sur faces for any scuffing or flaws FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it Fork spring free length Service limit 555 mm REASSEMBLY Reassemble and remount the front fork in the reverse order of disassembly and removal and also carry out the following steps DAMPER ROD BOLT Apply Bond 1215 and Thread Lock 1324 to the damper rod bolt and tighten the bolt with specified torque by the 19 mm socket Bond 1215 Thread Lock 1324 CHASSIS 6 18 OIL SEAL Install the oil seal to the outer tube by using the special tool as shown Fork oil seal installer 09940 50112 FORK OIL For the fork oil be sure to use a front fork oil whose viscosity rating meets specifications below Fork oil type SS8 O
78. on the left crankcase half and will be damaged if the transmission components remain in the right half TRANSMISSION Remove the gear shifting cam stopper spring Draw out the gear shifting fork shafts and take off the forks Remove the clusters of gears and the gear shifting cam KICK STARTER SHAFT Remove the circlip spring guide and return spring Then pull out the kick starter shaft from the other side CRANKSHAFT Remove the crankshaft by using the crankcase separater Crankcase separater 09920 13120 ENGINE 3 32 3 33 OIL SEAL AND BEARING Remove the retainer oil seals and bearings Oil seal remover 09913 50121 LOWER END COMPONENTS INSPECTION AND SERVICING CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear the big end of the conrod can be estimat ed by checking the movement of the samll end of the rod This method can also check the extent of wear on the parts of the conrod s big end Wear limit on the big Service limit end of conrod 3 0 mm Magnetic stand 09900 20701 Dial gauge 1 100 mm 09900 20606 V block 09900 21304 3 34 Push the big end of the conrod to one side measure its side clearance with a thickness gauge Clearance standard on Service limit on big end big end of conrod of conrod 0 10 0 45 mm 1 00 mm Thickness gauge
79. orming the adjustment and installing the steering stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering stem nut HANDLEBARS Set the handlebars to match its punched mark to the mating face of the holder Secure the each handlebar clamp in such a way that the clearances ahead of and behind the handlebars should be equalized V Handlebars 18 28 m 1 8 2 8 m 6 25 CHASSIS REAR WHEEL AND REAR BRAKE P B 0 7 REMOVAL Support the machine by jack or block or service stand Service stand 99000 99094 Pull out the cotter and remove the torque link nut and bolt Remove the rear brake adjuster nut Remove the rear axle nut Draw out the axle shaft and take off the rear wheel Separate the rear wheel from rear brake panel DISASSEMBLY REAR WHEEL Flatten the washers and loosen the four nuts Separate the rear sprocket from the rear wheel CHASSIS 6 26 6 27 CHASSIS Remove the right and left side wheel bearings CAUTION Removing the left side bearing first makes the job easier REAR BRAKE Take off the brake shoes Loosen the cam lever nut Pull off the brake cam washer O ring and
80. piston pin bore inside diameter and using a micrometer measure the piston pin outside diameter If the difference between these two measurements is more than the limits replace both piston and piston pin Micrometer 0 25 mm 09900 20205 Piston pin bore Piston pin bore Service limit 15 030 mm Piston pin O D Piston pin O D Service limit 14 980 mm CONROD SMALL END 1 0 Using a caliper gauge measure the conrod small end inside diameter Greer Service limit 15 040 mm if the conrod small end bore inside diameter exceeds the limit replace conrod UPPER END COMPONENTS REASSEMBLY OIL RING Install spacer into the bottom ring groove first Then install both side rails 2 on each side of the spacer The spacer and side rails do not have a specific top or bottom when they are new When reassembling used parts install them in their original place and direction TOP RING AND 2ND RING Top ring and 2nd ring differ in the shape of ring face and the face of top ring is chrome plated whereas that of 2nd ring is not The color of 2nd ring appears darker than that of the top one Install expander ring into the 2nd ring groove Top and 2nd rings have the letter or Y marked on the top Be sure to bring the marked side to the top when fitting them to the piston Position the gaps of the three rings as shown Before inserting piston
81. r arm and wear of the camshaft contacting surface should be checked Rocker arm 1 0 Standard 12 000 12 018mm Dial caliper 09900 20605 CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of output power Any of these abnormality could be caused by a worn camshaft T D C Intake open B T D C Exhaust close A T D C Exhaust open Intake close B B D C A B D C B D C Valve timing diagram CAMSHAFT WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts if found it worn down to the limit Micrometer 25 50 mm 09900 20202 Can height ENGINE 3 12 Height Service limit Inspect the camshaft and the camshaft bearing wear damage or the oil hole is clogged CYLINDER HEAD DISTORTION Decarbonate in combustion chamber Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge tak ing clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Thickness gauge 0
82. r burn gt Spark plug too hot The engine overheats Spark plug loose Mixture too lean Replace by cold type plug Tune up Retighten Adjust carburetor Generator charge but charging Lead wires tend to get shorted or open circuited or loosely connected at terminals Repair or retighten rate is below the 2 Grounded or open circuited stator coils of generator Replace specification 3 Defective regulator rectifier Replace 4 Not enough electrolyte in the battery Add distilled water between the level lines 5 Defective cell plates in the battery Replace the battery Generator 1 Internal short circuit in the battery Replace the battery overcharges 2 Resistor element in the regulator rectifier damaged or defec Replace tive 3 Regulator rectifier poorly grounded Clean and tighten ground connection Unstable 1 Lead wire insulation frayed due to vibration resulting in inter Repair or replace charging mittent shorting 2 Generator internally shorted Replace 3 Defective regulator rectifier Replace Starter button is 1 Battery run down Recharge or replace not effective 2 Defective switch contacts Replace 3 Brushes not seating properly on commutator in starter motor Repair or replace 4 Defective starter relay Replace 7 5 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy Sulfa
83. r is not fully closed Check and clean Check and clean Check and clean Medium or high speed trouble Main jet or main air jet is clogged Needle jet is clogged Throttle valve is not operating properly Filter is clogged Check and clean Check and clean Check throttle valve for operation Check and clean Overflow and fuel level fluctuations Needle valve is worn or damaged Spring in needle valve is borken Float is not working properly Foreign matter has adhered to needle valve Fuel level is too high or low Replace Replace Check and adjust Clean Adjust float height SERVICING INFORMATION 7 4 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1 Defective ignition coil Replace sparking 2 Defective spark plug Replace 3 Defective CDI unit Replace Spark plug soon become fouled with carbon gt Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Adjust carburetor Adjust carburetor Change Clean or replace Replace by hot type plug Spark plug become fouled too soon gt Worn piston rings Pistons or cylinder worn Excessive clearance of valve stems in valve guides Worn stem oil seal Replace Replace Replace Replace Spark plug electrodes overheat o
84. r or replace 3 Distorted front axle or crooked tire Replace Wobbling front wheel Distorted wheel rim Worn down wheel bearings Defective or incorrect tire Loosen nut on axle Replace Replace Replace Retighten Front suspension too soft Weakened springs 2 Not enough fork oil Rep Refill Front suspension too stiff Fork oil too viscous Too much fork oil Replace Drain excess oil Noisy front suspension Not enough fork oil Loosen nuts on suspension Refill Retighten Wobbling rear wheel Distorted wheel rim Worn down rear wheel bearing Defective or incorrect tire Loose nut on axle Worn swing arm spacers Loosen nut on the rear shock Replace Replace Replace Retighten Replace Retighten Rear suspension too soft Weakened springs Rear suspension adjuster impromerly set Replace Adjust Rear suspension too stiff Rear suspension adjuster improperly set Worn swing arm spacers Adjust Replace Noisy rear suspension Loosen nuts on suspension Worn swing arm spacers Retighten Replace 7 7 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking FRONT and REAR i one Not enough brake fluid the reservoir Air trapped in brake fluid circuit Pads worn dow
85. rrent generated from the AC generator is converted by the rectifier and is turned into the DC current then it charges the battery H Ig switch cr o L 24 pu 1 Pa Ex oy 7 e Battery sca Ua h i 4 Controlunit generator 1 i i i F Regulator Rectifier Function of Regulator While the engine rom is low and the generated current of the AC generator is lower than the adjusted volt age of the regulator the regulator does not function incidentally the generated current charges the battery directly Ig switch oto i E I ta 1 1 1 ea i 1 H i 1 i i Battery 1 SCH So SUR x E LI 34 T 5 4 A C generator i Regulator Rectifier ELECTRICAL SYSTEM 5 6 When the engine rom become higher the generated voltage of the AC generator also becomes higher and the voltage between points and of the regulator according becomes high and when it reaches the adjusted volt age of the control unit consequently the control unit becomes ON condition On the ON condition of the trol unit signal will be sent to the SCR Thyristor gate probe and SCR will become ON condition Then the SCR becomes conductive to the direction from point
86. rter screw by using the impact drive and detach the stator Remove the roller spring and push piece 3 from the stater clutch Clamp the rotor with a vise taking care not to damage it and remove the three bolts using the 5 mm T type hexagon wrench T type hexagon wrench 5 mm 09911 73730 GEAR POSITION SWITCH Remove the gear position indicator switch by removing the screws CAUTION ENGINE 3 28 When removing gear position switch do not lose the O ring switch contact and its spring RIGHT ENGINE DISASSEMBLY ENGINE SPROCKET Flatten the lock washer then remove the sprocket nut by using the special tool Rotor holder 09930 40113 CLUTCH Remove the kick starter by removing the bolt Remove the clutch cover bolts and oil filter cap bolts and detach the clutch cover by tapping with a plastic hammer 3 29 Remove the clutch spring mounting bolts diago nally while holding the primary driven gear and remove the clutch pressure plate After removal of clutch drive and driven plates flatten the lock washer and remove the clutch sleeve hub by using the special tool Clutch sleeve hub holder 09920 53710 Take off the sleeve hub with the primary driven gear ass y This time well deposite the washer behind the hub OIL PUMP DRIVE GEAR DRIVEN GEAR AND PRIMARY DRIVE GEAR Flatten the lock
87. rtion Clutch spring Service limit free length 29 5 mm CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality particularly cracks to decide whether it can be reused or should be replaced Smooth engagement and disengagement of the clutch depends much on the condition of this ing SHIFTING FORK AND GEAR Using a thickness gauge check the shifting fork clearance in the groove of its gear If the clearance limit is exceeded by any of the three gears deter mine whether the gear or the gear shifting fork should be replace by measuring the thickness and groove width Thickness gauge 09900 20803 Vernier calipers 09900 20101 A Sd Checking clearance Shifting fork to groove Standard clearance 0 10 0 30 0 50 mm Standard NO 1 amp 2 5 0 5 1 mm NO 3 5 5 5 6 mm amp NO 2 4 8 4 9 mm NO 3 5 3 5 4 mm Shifting fork groove width Shifting fork thickness PRIMARY DRIVEN GEAR Primary driven gear is composed as shown Primary driven gear Rivet Damper 5 Clutch housing Plate 8 Spring If the internal damper wears play is generated between gear and housing causing abnormal noise If the play is extreme replace the primary driven gear assembly a new one CAM CHAIN 20 PITCH LENGTH Pull the chain tight to remove any slack then using vernier caliper measure
88. rum I D Rear wheel o 130 Brake lining thickness Rear wheel Axis direciton Wheel rim runout Circular direction Front wheel Wheel axle runout Rear whee Front whee 2 75 21 45 Rear whee 4 10 18 59 Front whee 7 0 Rear whee 10 0 Tire size Tire tread depth TIRE PRESSURE NORMAL RIDING SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE FRONT REAR SERVICING INFORMATION 7 20 SUSPENSION Unit mm ITEM STANDARD Front fork stroke 250 Front fork spring free length Front fork oil level Rear wheel travel 200 Swing arm pivot shaft runout ELECTRICAL Unit mm ITEM SPECIFICATION Ignition timing BTDC rpm 15 2 250 and 35 4 000 Type C8EH 9 Gap 0 8 0 9 Spark performance Over 8 mm Primary 0 19 0 24 Q 5 4 6 6 kQ my Pick up Approx 90 110 Q Charging Y Y Approx 0 6 0 9 Q Generator no load voltage 72 99 V 5 000 rpm Regulated voltage 14 15 V Capacity 6Ah Standard electrolyte specific gravity 1 320 at 20 C 600 F Spark plug Ignition coil resistance Magneto coil resistance Battery Fuse size Main 15A WATTAGE SPECIFICATION 35 35 Neutral lamp bulb 5 Tail stop lamp bulb 21 5 Turn signal lamp bulb Front 10 Rear 10 Head lamp bulb Speedo meter lamp bulb 3
89. ston ring thickness 0 970 0 990 Piston pin bore D 15 002 15 008 Piston O D 14 994 15 000 SERVICING INFORMATION 7 16 CONROD CRANKSHAFT ITEM STANDARD Unit mm Conrod small end D 15 006 15 014 Conrod deflection Conrod big end side clearance 0 10 0 45 Conrod big end width 15 95 16 00 Crank web to wed width Crankshaft runout OIL PUMP ITEM 53 0 0 1 Oil pump reduction ratio 2 000 30 15 Oil pressure at 60 C 140 F CLUTCH ITEM 0 4 0 6 kg cm at 3 000 rpm STANDARD Clutch cable play 4 Clutch release screw 1 4 1 2 turn back Drive plate thickness 2 9 4 1 Driven plate thickness 1 60 0 05 Driven plate distortion Clutch spring free length 7 17 SERVICING INFORMATION TRANSMISSION DRIVE CHAIN Unit mm except ratio ITEM STANDARD Primary reduction ratio 3 500 70 20 Final reduction ratio 3 357 47 14 2 750 33 12 2nd 1 785 25 14 Gear ratios 3rd 1 368 26 19 Ath 1 045 23 22 Top 0 913 21 23 Shift fork to groove clearance 0 10 0 30 No 1 NO 2 5 0 5 1 Shift fork groove width No 3 5 5 5 6 No 1 NO 2 4 8 4 9 3 5 3 5 4 Shift fork thickness 0 1 Countershaft length Low to 2nd 88 0 _ 02 428 H Drive chain 132 Links 20 pitch length
90. then adjust specific gravity Replace the battery Reversed battery polarity The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction Replace the battery and be sure to connect the battery properly Battery sulfation 1 Charging rate too low or too high When not in use batteries should be recharged at least once a month to avoid sulfa tion 2 Battery electrolyte excessive or insufficient or its specific gravity too high or too low 3 The battery left unused for too long in cold climate Replace the battery Keep the electrolyte up to the prescribed level or adjust the specific gravity by consulting the battery maker s directions Replace the battery if badly sulfated Battery discharges too rapidly Dirty container top and sides 2 Impurities in the electrolyte or electrolyte specific gravity is too high Clean Change the electrolyte by consulting the battery maker s directions SERVICING INFORMATION 7 6 CHASSIS Complaint Symptom and possible causes Remedy Steering feels too 1 Steering stem nut overtightened Adjust heavy or stiff 2 Worn bearing or race in steering stem Replace 3 Distorted steering stem Replace 4 Not enough pressure in tires Adjust Steering 1 Loss of balance between right and left front suspensions Replace oscillation 2 Distorted front fork Repai
91. tion acidic white powdery substance or spots on surfaces of cell plates Not enough electrolyte Battery case is cracked Battery has been left in run down condition for a long time Contaminated electrolyte Foreign matter has enters the battery and become mixed with the electrolyte Add distilled water if the battery has not been damaged and sulfation has not advanced too far and recharge Replace the battery Replace the battery or recharge If sulfation has not advanced far try to restore the battery by replacing the electrolyte recharing it fully with the battery detached from the motorcycle and then adjusting electrolyte specific gravity Battery runs down quickly The charging method is not correct Cell plates have lost much of their active material as a result of over charging A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the high electrolyte specific gravity Electrolyte specific gravity is too low Contaminated electrolyte Battery is too old Check the generator regula tor rectifier and circuit con nections and make neces sary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the battery Recharge the battery fully and adjust electrolyte spe cific gravity Replace the electrolyte recharge the battery and
92. tor Rectifier AC GENERATOR NO LOAD PERFORMANCE Disconnect the three lead wires from the AC erator terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC voltage between the three lead wires If the tester reads under 70 V the AC generator is faulty Standard NO load perfor 72 99 V mance of AC generator at 5 000 rom Y 9 REGULATOR RECTIFIER Using the pocket tester X 1 range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regulator rectifier Pocket tester 09900 25002 Probe of tester ELECTRICAL SYSTEM 5 8 5 9 ELECTRICAL SYSTEM STARTER SYSTEM The starter system is shown in the diagram below namely the starter motor relay G switch starter button and battery Depressing the starter button on the right handlebar switch box energizes the relay causing the contact points to close which connects the starter motor to the battery The motor draws about 80 amperes to start the engine Starter relay Fuse lg switch ON Starter motor STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the starter motor Disassemble the starter motor as follows MAC ELECTRICAL SYSTEM

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