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Summary of Contents for HYOSUNG RT 125 D
- Page 1 RX 125 D RX 125 SM RT 125 D Kun motor. Udgivet 2009 ServiceManual Holtvej 8-10, Høruphav 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 E-mail: info@scanmi.dk www.scanmi.dk CVR: 27 73 31 07...
- Page 2 WARNING 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.
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Page 3: How To Use This Manual
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 you are looking for. - Page 4 WIRE COLOR : Black : Gray : Light blue : Blue : Light green : White : Brown : Orange : Yellow : Green : Red : Black with Blue tracer : Black with Brown tracer : Black with Green tracer : Black with Orange tracer : Black with Red tracer : Black with White tracer...
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Page 6: Table Of Contents
GENERAL INFORMATION CONTENTS EXTERIOR PHOTOGRAPH ………………………………………… 6 (1-3) ₩ ₩ EXTERIOR ILLUSTRATION ………………………… 7 (1-7-1) EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ ……………………… 8 (1-7-2) EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ ……………………… 9 (1-7-3) SPECIFICATIONS ………………………………………………………10 (1-8) -
Page 7: Exterior Photograph
1-3 GENERAL INFORMATION EXTERIOR PHOTOGRAPH... -
Page 8: Exterior Illustration
GENERAL INFORMATION 1-7-1 EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ Rear turn signal lamp Brake / Tail lamp Rear License plate lamp reflector Front turn signal lamp Head lamp Passenger footrests 1,350 (WHEEL BASE) 2,085 (LENGTH) -
Page 9: Exterior Illustration
1-7-2 GENERAL INFORMATION EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ Brake / Tail lamp Rear reflector License plate lamp Rear turn signal lamp Front turn signal lamp Head lamp Passenger footrests 1,425 (WHEEL BASE) 2,190 (LENGTH) -
Page 10: Exterior Illustration
GENERAL INFORMATION 1-7-3 EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ Rear Brake / Tail lamp reflector Rear turn signal lamp License plate lamp Front turn signal lamp Head lamp Passenger footrests (WHEEL BASE) (LENGTH) -
Page 11: Specifications
1-8 GENERAL INFORMATION SPECIFICATIONS ⊙ ⊙ DIMENSIONS AND MASS I T E M Overall length 2,085 mm (82.1 in) 2,190 mm (86.2 in) 2,175 mm (85.6 in) 840 mm (33.1 in) ← ← Overall width Overall height 1,125 mm (44.3 in) 1,160 mm (45.7 in) 1,145 mm (45.1 in) Wheelbase... - Page 12 GENERAL INFORMATION 1-9 ⊙ ⊙ CHASSIS I T E M Front suspension Telescopic type ← ← Rear suspension Swingarm type ← ← Steering angle 47˚(right & left) 45˚(right & left) ← Caster 25˚ 27.5˚ 27˚ Trail 84 mm (3.31 in) 94 mm (3.70 in) 88 mm (3.47 in) Front brake...
- Page 14 PERIODIC MAINTENANCE CONTENTS MAINTENANCE PROCEDURES …………………………………14 (2-3) CYLINDER HEAD COVER BOLTS, CYLINDER HEAD & & CYLINDER BASE NUTS, EXHAUST PIPE NUTS AND MUFFLER BOLTS …………………14 (2-3) AIR CLEANER …………………………………………………………15 (2-5-1) VALVE CLEARANCE……………………………………………………18 (2-6-1) SPARK PLUG ……………………………………………………………20 (2-7) ENGINE OIL ……………………………………………………………21 (2-8) ENGINE OIL FILTER ……………………………………………………22 (2-9) CARBURETOR …………………………………………………………23 (2-10) COMPRESSION PRESSURE CHECK ………………………………24 (2-19)
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Page 15: 2-3 Periodic Maintenance
2-3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES This section describes the servicing procedures for each item. CYLINDER HEAD COVER BOLTS, CYLINDER HEAD & CYLINDER BASE NUTS, EXHAUST PIPE ① ① NUTS AND MUFFLER BOLTS Inspect Interval Tighten Initial at 1,000 km and Every 4,000 km thereafter. -
Page 16: Air Cleaner
: do not twist or wring the element or it will develop tears. ● Immerse the element in HYOSUNG genuine oil , and then squeeze out the excess oil leaving the element slightly wet. - Page 17 2-5-2 PERIODIC MAINTENANCE CAUTION Inspect the air cleaner element for tears. A torn element must be replaced. If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or with torn element.
- Page 18 PERIODIC MAINTENANCE 2-5-3 Clean the air cleaner element for the following : ● When the air cleaner element clean with the air gun, necessarily blow at the inside by compressed air. ● Carefully examine the air cleaner element for tears during cleaning.
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Page 19: Valve Clearance
2-6-1 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect Interval Inspect Initial 1,000 km and Every 4,000 km thereafter. Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification, if necessary. - Page 20 PERIODIC MAINTENANCE 2-6-2 ● Rotate the magneto rotor clockwise or counter- clockwise with a socket wrench to set the piston at TDC on the compression stroke. (Rotate the magneto rotor until the “T” index mark on the magneto rotor is aligned with the triangle mark ①...
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Page 21: Spark Plug
2-7 PERIODIC MAINTENANCE SPARK PLUG Inspect Interval Clean Initial 1,000 km and Every 4,000 km thereafter. Replace Every 8,000 km. ① ● Disconnect the spark plug cap ① and remove the spark plug. TYPE SPARK PLUG SPECIFICATION Hot type CR7E Standard type CR8E Cold type... -
Page 22: Engine Oil
PERIODIC MAINTENANCE 2-8 ● Insert the spark plug and finger tighten it to the cylinder head and then tighten it to the specified torque. Spark plug : 20 ~ 25 N· · m (2.0 ~ 2.5 kgf· · m) ENGINE OIL Inspect Interval Replace Initial 1,000 km and Every 4,000 km thereafter. -
Page 23: Engine Oil Filter
2-9 PERIODIC MAINTENANCE CAUTION Never operate the motorcycle if the engine oil level is below the “Lower line mark (L)”in the engine oil level lens. Never fill the engine oil above the “Upper line mark (F)” . Engine oil level being most suitable about 1 mm under the “Upper line mark (F)”of the engine oil level lens. -
Page 24: Carburetor
● Add new engine oil and check the engine oil level as described in the engine oil replacement procedure. CAUTION ONLY USE A GENUINE HYOSUNG MOTORCYCLE ENGINE OIL FILTER. Other manufacturer’s engine oil filters may differ filtering performance and durability which may lead to engine damage or oil leaks. -
Page 25: Compression Pressure Check
2-19 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK Low compression pressure can indicate some of the The compression of a cylinder is a good indicator of following conditions : its internal condition. ● Excessively worn cylinder wall The decision to overhaul the cylinder is often based ●... -
Page 26: Oil Pressure Check
PERIODIC MAINTENANCE 2-20 OIL PRESSURE CHECK Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 0.4 ~ 0.6 kgf/㎠ (at 60 ℃·3,000 rpm) If the engine oil pressure is lower or higher than the specification, the following causes may be considered. ■... - Page 28 ENGINE CONTENTS ENGINE REMOVAL AND REMOUNTING ……………………… 28 (3-5) ENGINE REMOUNTING ……………………………………………… 28 (3-5) UPPER END COMPONENTS OF ENGINE DISASSEMBLY 29 (3-6) UPPER END COMPONENTS OF ENGINE INSPECTION AND SERVICING ……………………………………………………… 34 (3-11) UPPER END COMPONENTS OF ENGINE REASSEMBLY 44(3-21) LEFT END COMPONENTS OF ENGINE DISASSEMBLY 54 (3-31) RIGHT END COMPONENTS OF ENGINE DISASSEMBLY...
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Page 29: Engine Removal And Remounting
3-5 ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOUNTING Remount the engine in the reverse order of removal. ● Temporarily fasten the engine mounting bracket ② before inserting the engine mounting bolts. ③ ● Tighten the engine mounting bolts and nuts to the specified torque. -
Page 30: Upper End Components Of Engine Disassembly
ENGINE 3-6 UPPER END COMPONENTS OF ENGINE DISASSEMBLY NOTE If only the upper end components of the engine is repaired, there is no necessary to remove the engine from the frame. ① Remove the seat and fuel tank so that the upper end components of the engine is disassemble. - Page 31 3-7 ENGINE ● Remove the cam chain tension adjuster ①. ① ● Remove the cam chain guide NO.2 ②. ② ● Remove the camshaft housings ③. ③ ③ ● Remove the dowel pins, intake camshaft and exhaust camshaft. NOTE Do not drop the dowel pins and cam chain into the crankcase.
- Page 32 ENGINE 3-8 ● Remove the camshaft C-rings ①. ① ● Loosen the three cylinder head bolts. ● Loosen the three cylinder head base nuts. ● Remove the cam chain guide NO.1.
- Page 33 3-9 ENGINE ● Remove the tappet and the shim. CAUTION Draw out the tappet and shim with the strong magnet not to be scratched. CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly.
- Page 34 ENGINE 3-10 ● Pull out the valve ① from the other side. ① ● Remove the two cylinder base nuts and the cylinder. CAUTION If tapping with the plastic hammer is necessary, pay attention to break the fins. ● Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase.
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Page 35: Upper End Components Of Engine Inspection And Servicing
3-11 ENGINE UPPER END COMPONENTS OF ENGINE INSPECTION AND SERVICING ⊙ ⊙ CYLINDER HEAD DISTORTION Decarbonize in combustion chamber. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance reading at several places as indicated. -
Page 36: Camshaft Runout
ENGINE 3-12 ⊙ ⊙ CAMSHAFT RUNOUT Support the camshaft using a V-blocks and measure the camshaft runout using the dial gauge. If the runout exceeds the service limit, replace the camshaft with a new one. Service limit Camshaft runout (IN. & EX.) 0.10 mm (0.004 in) Dial gauge : 09900-20606 Magnetic stand : 09900-20701... - Page 37 3-13 ENGINE ⊙ ⊙ TAPPET & SHIM WEAR When measuring the valve clearance, the clearance should be within the standard range. Standard (When cold) Valve clearance 0.1 ~ 0.2 mm Intake valve (0.004 ~ 0.008 in) 0.2 ~ 0.3 mm Exhaust valve (0.008 ~ 0.012 in) Thickness gauge : 09900-20806...
- Page 38 ENGINE 3-14 ⊙ ⊙ VALVE HEAD RADIAL RUNOUT Support the valve using a V-block and measure the valve head radial runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one. Service limit Cylinder head Valve head radial...
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Page 39: Valve Spring
3-15 ENGINE ⊙ ⊙ VALVE SPRING The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. -
Page 40: Piston Diameter
ENGINE 3-16 ⊙ ⊙ CYLINDER BORE Measure the cylinder bore diameter at six place. If any one of the measurements exceeds the limit, overhaul the cylinder and replace the cylinder. Standard Service limit Cylinder bore 57.000 ~ 57.015 mm 57.080 mm (2.2441 ~ 2.2447 in) (2.2472 in) Cylinder gauge set : 09900-20508... - Page 41 3-17 ENGINE ⊙ ⊙ PISTON RING TO GROOVE CLEARANCE INSPECTION Remove carbon deposit both from the piston ring and its groove. Fit the piston ring into the groove. With the ring com- pressed and lifted up, measure the clearance on the bottom side of the ring using a thickness gauge.
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Page 42: Piston Ring End Gap
ENGINE 3-18 ⊙ ⊙ PISTON RING FREE END GAP INSPECTION Before installing the piston rings, measure the free end gap of each ring using vernier calipers. If the gap is less than the service limit, replace the ring. Piston ring free end gap Service limit 5.7 mm (0.224 in) 4.6 mm (0.181 in) - Page 43 3-19 ENGINE ⊙ ⊙ PISTON PIN HOLE BORE Using a dial calipers, measure the piston pin hole bore both the vertical and horizontal directions. If the measurement exceeds the service limit, replace the piston with a new one. Service limit Piston pin hole bore 15.030 mm (0.5917 in)
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Page 44: Crankshaft Runout
ENGINE 3-20 ⊙ ⊙ CONROD DEFLECTION INSPECTION Wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod. Turn the conrod and see if it moves smoothly without play and noise. This method can also be used to check the extent of wear on the parts of the conrod’s big end. -
Page 45: Upper End Components Of Engine Reassembly
3-21 ENGINE UPPER END COMPONENTS OF ENGINE REASSEMBLY ① ⊙ ⊙ PISTON RING ● Install the oil ring first, the 2nd ring second, and the 1st ring last. NOTE ② The 1st ① ① and 2nd ② ② piston rings differ in shape. -
Page 46: Piston And Cylinder
ENGINE 3-22 ⊙ ⊙ PISTON AND CYLINDER ● Apply MOLY PASTE on the piston pin and small end of the conrod. MOLY PASTE ● Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase, and then fit the piston pin circlip with the long-nose pliers. - Page 47 3-23 ENGINE ⊙ ⊙ VALVE AND SPRING ● Apply MOLY PASTE to the valve as shown, and then insert them into the valve guides. MOLY PASTE CAUTION When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal. ●...
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Page 48: Cylinder Head
ENGINE 3-24 ● Install the dowel pins ① and new gasket. ① CAUTION Use a new cylinder head gasket to prevent gas leakage. ⊙ ⊙ CYLINDER HEAD ② ● Install the cylinder head ②. ● With the cylinder head snugly seated on the cylinder, secure it by tightening the bolts in diagonal stages. - Page 49 3-25 ENGINE CAUTION The tappet and shim should be installed at the Tappet original position when removed. If otherwise, it is difficult to adjust the valve clear- Shim ance. ● With pulling up the cam chain, align the “T”index mark of the magneto rotor into the triangle mark ①...
- Page 50 ENGINE 3-26 ⊙ ⊙ CAMSHAFT ASSEMBLY ● Distinguish the “EX”mark for the exhaust camshaft, the “IN” mark for the intake camshaft. ● Install the camshaft C-rings ①. ① ● When installing the camshaft and camshaft sprocket, apply a small quantity of the THREAD LOCK “1324”...
- Page 51 3-27 ENGINE ● With the “T” index mark on the magneto rotor is aligned with the triangle mark on the magneto ② ③ cover, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the 2↑...
- Page 52 ENGINE 3-28 NOTE The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft housings and cam chain tensioner are secured. 16 Pins ② ③ ① Notch mark EXHAUST INTAKE...
- Page 53 3-29 ENGINE ● Each camshaft housing is punched with “A” “ B” “C” “ D” . Put on the housing “A”to the “A”of head surface, the housing “B”to the “B” , the housing “C”to the “C”and the housing “D”to the “D”as that “A”...
- Page 54 ENGINE 3-30 ● Get out the pushrod for the front to turn the lock shaft handle of the cam chain tension adjuster in counter-clockwise ( ● Turn the crankshaft about 10 times clockwise or counter-clockwise on the basis of the magneto rotor.
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Page 55: Left End Components Of Engine Disassembly
3-31 ENGINE LEFT END COMPONENTS OF ENGINE DISASSEMBLY ● Disconnect the magneto couplers. ● Remove the engine guard ①. ● Remove the engine sprocket cover ②. ② ① ● Remove the magneto cover ③. ③ ● Remove the starter idle gear shaft ④ and starter idle gear ⑤. - Page 56 ENGINE 3-32 ● With the magneto rotor held immovable, loosen the rotor nut ①. ① ● Remove the magneto rotor ② by using the special tool. Rotor remover : 09930-30162 ② ● Remove the key. ③ ● Remove the starter clutch gear ③. ●...
- Page 57 3-33 ENGINE ● The starter one way clutch is constituted as shown in the right illustration. ● Separate the stator and magneto cover by removing the stator screws. ● Remove the gear position switch by removing the screws. ● Remove the switch contact ① and its spring ②. CAUTION Be careful not to lose the O-ring, switch contact and its spring.
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Page 58: Right End Components Of Engine Disassembly
ENGINE 3-34 RIGHT END COMPONENTS OF ENGINE DISASSEMBLY ● Drain the engine oil by removing the drain plug ① located on the bottom of the engine. ① ● Remove the engine guard ②. ● Remove the clutch cover bolts and oil filter cap nuts, and detach the clutch cover by tapping with a plastic hammer. - Page 59 3-35 ENGINE ● Remove the thrust washer ①, thrust bearing ②, clutch push piece ③ and clutch push rod ④. ④ ③ ② ① ● Flatten the lock washer ⑤. ● With the crankshaft held immovable, remove the primary drive gear nut ⑥. CAUTION ⑥...
- Page 60 ENGINE 3-36 ● Remove the circlip ① and oil pump driven gear ②. ● Remove the primary drive NO.2 gear ③ and primary drive gear. Primary drive gear Primary drive ③ NO.2 gear ① ② Spring ● Loosen the oil pump screws, and then remove the oil pump ④.
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Page 61: Lower End Components Of Engine Disassembly
3-37 ENGINE LOWER END COMPONENTS OF ENGINE DISASSEMBLY ① ⊙ ⊙ CRANKCASE ● Remove the oil strainer cap ①. ● Remove the gear shift cam stopper plug ②, washer ③, spring ④ and neutral cam stopper ⑤. ⑤ ② ④ ③... - Page 62 ENGINE 3-38 ⊙ ⊙ TRANSMISSION ● Remove the gear shift arm stopper spring ①. ① ● Draw out the gear shift fork shaft NO.1 & NO.2. ● Take off the gear shift cam ② and gear shift fork NO.1 & NO.2. ②...
- Page 63 3-39 ENGINE ⊙ ⊙ CRANKSHAFT ● Remove the crankshaft using the special tool. Crankcase separator : 09920-13120 ⊙ ⊙ OIL SEAL AND BEARING ● Remove the retainer, oil seals and bearings, right and left. ● Remove the clutch release camshaft.
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Page 64: Lower End Components Of Engine Inspection And Servicing
ENGINE 3-40 LOWER END COMPONENTS OF ENGINE INSPECTION AND SERVICING ⊙ ⊙ CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using the vernier calipers. If the clutch drive plate is not within the the service limit, replace the clutch plates as a set. - Page 65 3-41 ENGINE ⊙ ⊙ CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this bearing.
- Page 66 ENGINE 3-42 ⊙ ⊙ PRIMARY DRIVEN GEAR ③ ⑥ ① The primary driven gear is composed the following parts : ② ① Primary driven gear ④ Rivet ④ ② Plate ⑤ Washer ③ Clutch housing ⑥ Spring ⑤ If the tension of the inner spring of the primary driven gear is not working, get a play and noise between the gear and spring.
- Page 67 3-43 ENGINE LOWER END COMPONENTS OF ENGINE REASSEMBLY ⊙ ⊙ CRANKSHAFT ● Inspect the between the webs referring to the ● When mounting the crankshaft in the crankcase, it below figure when rebuilding the crankshaft. is necessary to pull its left end into the crankcase. Standard Crankshaft installer : 09910-32812 Width between webs...
- Page 68 ENGINE 3-44 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 CAUTION Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft.
- Page 69 3-45 ENGINE Washers and circlips thickness 1.2 mm 1.0 mm 1.0 mm 0.5 mm 1.0 mm NOTE When reassembling the bearing retainer, apply a small quantity of THREAD LOCK “ “ 1324 ” ” 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.
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Page 70: Gear Shift Cam And Fork
ENGINE 3-46 ⊙ ⊙ GEAR SHIFT CAM AND FORK ● Fit the gear shift cam on the crankcase. Position the gear shift cam as shown in the figure so that the gear shift fork can be installed easily. - Page 71 3-47 ENGINE CAUTION Two kinds of the gear shift forks, ① ① and ② ② , are used. They resemble each other very closely in external appearance and configuration. Carefully examine as shown in the illustration for correct installing positions and directions. ●...
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Page 72: Right End Components Of Engine Reassembly
ENGINE 3-48 ● If a large resistance is felt to rotation, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in the figure. RIGHT END COMPONENTS OF ENGINE REASSEMBLY ⊙ ⊙ GEAR SHIFT CAM DRIVEN GEAR ●... - Page 73 3-49 ENGINE ● 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 the oil pump mounting screws.
- Page 74 ENGINE 3-50 ⊙ ⊙ CLUTCH Assemble the clutch in the reverse order of disassembly. 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. ●...
- Page 75 3-51 ENGINE ● Install the clutch drive plates and driven plates Part without groove of primary driven gear one by one into the clutch sleeve hub. Clutch drive CAUTION plate groove The groove of the first installed clutch drive plate in five drive plates is inserted between the part without the groove of the primary driven gear.
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Page 76: Left End Components Of Engine Reassembly
ENGINE 3-52 ● Install the clutch cover, and tighten the clutch cover bolts securely. ⊙ ⊙ GEAR SHIFT CAM STOPPER PLUG ● Insert the cam neutral stopper ①, spring ② and washer ③. ● Tighten the gear shift cam stopper plug ④ to the specified torque. -
Page 77: Magneto Rotor
3-53 ENGINE ⊙ MAGNETO ROTOR ● Fit the key into the key slot on the crankshaft. ● With the magneto rotor, install the starter clutch on the crankshaft. ● Apply a small quantity of THREAD LOCK “1324”to the threaded parts of crankshaft. THREAD LOCK “1324”... - Page 78 ENGINE 3-54 ⊙ ⊙ DRIVESHAFT OIL SEAL Oil seal AND ENGINE SPROCKET O-ring 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 the figure, for correct position and direction.
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Page 80: Servicing Information
SERVICING INFORMATION CONTENTS TIGHTENING TORQUE ………………………………………………… 8 0 (7-11) SERVICE DATA …………………………………………………………… 8 1 (7-13) WIRING DIAGRAM ~ ~ ₩ ₩ ………………………………………8 8 (7-22-1) WIRING DIAGRAM ~ ~ ₩ ₩ & …………………8 9 (7-22-2) -
Page 81: Tightening Torque
7-11 SERVICING INFORMATION TIGHTENING TORQUE ⊙ ENGINE ITEM N·m kgf·m Camshaft sprocket bolt 10 ~ 12 1.0 ~ 1.2 Camshaft housing bolt 0.8 ~ 1.2 8 ~ 12 Cam chain tension adjuster mounting bolt 8 ~ 12 0.8 ~ 1.2 Clutch sleeve hub nut 3.0 ~ 5.0 30 ~ 50... -
Page 82: Service Data
SERVICING INFORMATION 7-13 SERVICE DATA ⊙ ⊙ VALVE + GUIDE Unit : mm (in) ITEM STANDARD LIMIT 22.0 (0.87) — — — Valve diam. 19.0 (0.75) — — — 0.1 ~ 0.2 (0.004 ~ 0.008) — — — Valve clearance (When cold) 0.2 ~ 0.3 (0.008 ~ 0.012) —... -
Page 83: Oil Pump
7-14 SERVICING INFORMATION ⊙ ⊙ CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT 14 ~ 16 kgf/cm Compression pressure 12 kgf/cm Piston to cylinder clearance 0.050 ~ 0.060 (0.0020 ~ 0.0024) 0.120 (0.0047) 57.000 ~ 57.015 (2.2441 ~ 2.2447) Cylinder bore 57.080 (2.2472) 56.945 ~ 56.960 (2.2419 ~ 2.2425) - Page 84 SERVICING INFORMATION 7-15 ⊙ ⊙ CLUTCH Unit : mm (in) ITEM STANDARD LIMIT Clutch cable play 4 (0.16) — — — Clutch drive plate thickness 2.9 ~ 3.1 (0.114 ~ 0.122) 2.6 (0.102) Clutch drive plate claw width 11.8 ~ 12.0 (0.465 ~ 0.472) 11.0 (0.433) Clutch driven plate distortion —...
- Page 85 7-16-1 SERVICING INFORMATION ⊙ ⊙ CARBURETOR ~ ~ ₩ ₩ Unit : mm (in) SPECIFICATION ITEM Carburetor type Piston valve type ф 24 Bore size Idle rpm 1,400 ~ 1,600 rpm Float height 12.5 (0.492) (M.J.) Main jet # 102 (M.A.J.) Main air jet # 100...
- Page 86 SERVICING INFORMATION 7-16-2 ⊙ ⊙ CARBURETOR ~ ~ ₩ ₩ & Unit : mm (in) SPECIFICATION ITEM Carburetor type Piston valve type ф 24 Bore size Idle rpm 1,400 ~ 1,500 rpm Float height 12.5 (0.492) (M.J.) Main jet # 98 (M.A.J.) Main air jet # 90...
- Page 87 7-16-3 SERVICING INFORMATION ⊙ ⊙ FUEL + OIL NOTE ITEM SPECIFICATION Gasoline used should be graded 91 octane or higher. Fuel type An unleaded gasoline is recommened. Fuel tank capacity ( 9.0 ℓ Fuel tank capacity 8.0 ℓ & Engine oil API Over SL (SAE 10W/40) Oil change 850 ㎖...
- Page 88 SERVICING INFORMATION 7-17 ⊙ ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE BTDC 6° / 1,900 rpm ~ 27° / 4,250 rpm Ignition timing Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E YTX7A-BS...
- Page 89 7-22-1 SERVICING INFORMATION WIRING DIAGRAM ~ ~ ₩ ₩...
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Page 90: Wiring Diagram
SERVICING INFORMATION 7-22-2 WIRING DIAGRAM ~ ~ ₩ ₩ &... - Page 93 Prepared by 1st Ed. JUN. 2009. Manual No. 99000HR7810 Printed in Korea...
- Page 94 S&T Motors Co., Ltd.