HYOSUNG GV125S Service Manual
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HYOSUNG GV125S Service Manual

HYOSUNG GV125S Service Manual

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GV125S
SERVICE MANUAL
维修手册
99000HB8110

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Summary of Contents for HYOSUNG GV125S

  • Page 1 GV125S SERVICE MANUAL 维修手册 99000HB8110...
  • Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on GENERAL INFORMATION HYOSUNG 『 GV125S 』 and procedures for its inspection / service and overhaul of its main components. PERIODIC MAINTENANCE Other information considered as generally known is not included.
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : The text of this manual is divided into sections. 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 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. Use fork oil. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise Apply THREAD LOCK.
  • Page 5 ABBREVIATIONS USED IN THIS MANUAL ABDC : After Bottom Dead Center : Liquid Crystal Display : Alternating Current : Light Emitting Diode : American Petroleum Institute : Left Hand ATDC : After Top Dead Center : Maximum BBDC : Before Bottom Dead Center : Minimum : Bettom Dead Center BTDC...
  • Page 6 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...

  • Page 7: Table Of Contents

    1-1 GENERAL INFORMATION GENERAL INFORMATION CONTENTS INFORMATION LABELS………………………………………………………………………… 1 - 2 1 - 3 GENERAL PRECAUTIONS……………………………………………………………………… 1 - 4 EXTERIOR PHOTOGRAPH……………………………………………………………………… 1 - 5 FUNCTION OF EI SENSOR……………………………………………………………………… SERIAL NUMBER LOCATION…………………………………………………………………… 1 - 6 FUEL AND OIL RECOMMENDATIONS………………………………………………………… 1 - 7 BREAK-IN PROCEDURES………………………………………………………………………...

  • Page 8: Information Labels

    GENERAL INFORMATION 1-2 INFORMATION LABELS 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. Indicates a potential hazard that could result in death or injury.

  • Page 9: General Precautions

    After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks. ❖ 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.

  • Page 10: Exterior Photograph

    GENERAL INFORMATION 1-4 EXTERIOR PHOTOGRAPH N O T E Difference between photographs and actual motorcycles depends on the markets.

  • Page 11: Function Of Ei Sensor

    1-5 GENERAL INFORMATION FUNCTION OF EI SENSOR ★ ECU (Engine Control Unit, EI Control Unit) : ECU decide the fuel injection volume and ignition time to adjust the fuel injector opening and closing rate which is considered the engine speed, intake air pressure, intake air volume, engine temperature, oxygen volume and throttle opening angle, etc.

  • Page 12: Serial Number Location

    GENERAL INFORMATION 1-6 ★ WT sensor (Water Temperature Sensor : WTS) : WT sensor is located on the cylinder block’s water jacket, the intake pipe or the cylinder head coolant passage’s thermostat part for contact with the coolant. WT sensor is the NTC (Negative Temperature Coefficient) resister that measure the coolant temperature and inform ECU.

  • Page 13: Fuel And Oil Recommendations

    1-7 GENERAL INFORMATION FUEL AND OIL RECOMMENDATION ◉ FUEL Gasoline used should be graded 92 octane (Research Method) or higher. An unleaded gasoline type is recommended. ◉ ENGINE OIL ENGINE OIL SPECIFICATION Grade Classification system Over SL 10W-40  If an SAE 10W-40 motor oil is not available, select an alternative according to the following chart.
  • Page 14 GENERAL INFORMATION 1-8 ◉ FRONT FORK OIL Use fork oil : TELLUS #22 ◉ ANTIFREEZE Antifreeze selection: 1. Antifreeze must not be mixed using. 2.The freezing point of antifreeze is normally lower than the local minimum ambient temperature 5-10 degrees. 3.

  • Page 15: Break-In Procedures

    Do not maintain constant engine speed for an extended period during any portion of the throttle position. break-in. Try to vary the CYLINDER CLASSIFICATION The engine of is composed of the two cylinder, is classified into the front GV125S cylinder and rear cylinder as basis of the motorcycle ahead.

  • Page 16: Exterior Illustration

    GENERAL INFORMATION 1-10 EXTERIOR ILLUSTRATION...

  • Page 17: Specifications

    1-11 GENERAL INFORMATION SPECIFICATIONS ⊙ DIMENSIONS AND MASS ITEM GV125S Overall length 2080 mm Overall width 750 mm Overall height 1050 mm Wheelbase 1425 mm Minimum ground clearance 175 mm Turning clearance circle diameter 6120mm Overall mass 165 kg ⊙ ENGINE...
  • Page 18 GENERAL INFORMATION 1-12 CHASSIS ITEM GV125S Front spark plug model Spring oil damping Rear spark plug model Spring oil damping ≤48° (right & left) Steering angle Caster 29° Front brake Disk brake Rear brake Disk brake Front tire size 120/80-16...
  • Page 19 1-13 GENERAL INFORMATION CAPACITIES ITEM GV125S Fuel tank capacity Including reserve 12.5 L Reserve 1.2 L Engine oil capacity Change 1,100 ml Filter change 1,300 ml Overhaul 1,400 ml Antifreeze First add liquid antifreeze 0.75L Replacement and maintenance 0.7L 170±2 ml...
  • Page 20 2-1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE………………………………………………………… 2 - 2 PERIODIC MAINTENANCE CHART……………………………………………………………… 2 - 2 LUBRICATION POINTS…………………………………………………………………………… 2 - 4 MAINTENANCE PROCEDURES………………………………………………………………… 2 - 5 VALVE CLEARANCE……………………………………………………………………………… 2 - 5 SPARK PLUG……………………………………………………………………………………… 2 - 8 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS…………………………………...

  • Page 21: Periodic Maintenance Schedule

    PERIODIC M AINTENANCE 2-2 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. More frequent servicing should be performed on motorcycles that are used under severe conditions.
  • Page 22 2-3 PERIODIC MAINTENANCE ◉ CHASSIS Interval Item Every 8,000 km Initial 1,000 km Every 4,000 km Drive chain Clean and lubricate every 1,000km ─ Brake Inspect Inspect ─ Inspect Inspect Brake hose Replace every 4 years ─ Inspect Inspect Brake fluid Replace every 2 years ─...

  • Page 23: Lubrication Points

    PERIODIC M AINTENANCE 2-4 LUBRICATION POINT Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. - Motor oil, - Grease ① ② Clutch lever holder Drive chain ③...

  • Page 24: Maintenance Procedures

    2-5 PERIODIC MAINTENANCE MAINTENANCE PROCEDURE This section describes the service procedure for each section of the periodic maintenance. VALVE CLEARANCE N O T E Inspect Initial 1,000 km and Every 4,000 The clearance specification is for COLD state. The valve clearance specification is different for intake and exhause valves.
  • Page 25 PERIODIC M AINTENANCE 2-6 ● Rotate the magneto rotor to set the front cylinder’s piston at TDC (Top Dead Center) of the compression stroke. (Rotate the rotor until “F” line on the rotor is aligned with the center of hole on the crankcase.) ●...
  • Page 26 2-7 PERIODIC MAINTENANCE ● In case that valve adjustment which there is no the tappet shim selection chart, please follow instructions of example in the below. For example, the intake clearance is 0.4 and the shim is 170 (1.70 mm), select 195 (1.95 mm) of the shim which 170 (1.70 mm) of the shim add up the excess clearance 0.25 mm when adjust with the standard 0.15 as the...

  • Page 27: Spark Plug

    PERIODIC M AINTENANCE 2-8 SPARK PLUG N O T E Clean Initial 1,000 km and Every 4,000 km, Replace Every 8,000 km. ● Disconnect the spark plug caps. ● Remove the spark plugs. SPARK PLUG TYPE SPECIFICATION Hot type CR7E Standard type CR8E CR9E...

  • Page 28: Exhaust Pipe Nuts And Muffler Mounting Bolts

    2-9 PERIODIC MAINTENANCE EXHAUSE PIPE NUTS MUFFLER MOUNTING BOLTS N O T E Tighten Initial 1,000 km and Every 4,000 ● Tighten the exhaust pipe nuts ①, and muffler mounting bolts ② to the specified torque. Exhaust pipe nut : 18~28 N·m (1.8~2.8 kg·m) Muffler mounting bolt : 20~30 N·m (2.0~3.0 kg·m)

  • Page 29: Air Cleaner

    PERIODIC M AINTENANCE 2-10 AIR CLEANER N O T E Clean Every 3,000 km, Replace Every 12,000 km. ● Remove the air cleaner case cover ①. ● With the three of air cleaner cap mounting bolts removed, remove the air cleaner cap ②.

  • Page 30: Fuel Hose

    2-11 PERIODIC MAINTENANCE FUEL HOSE N O T E Inspect Initial 1,000 km and Every 4,000 km, Replace every 4 years. ● Remove the left frame cover. (Refer to page 6-3) Inspect the fuel hoses for damage and fuel any defects are found, the fuel leakage.

  • Page 31: Clutch

    PERIODIC M AINTENANCE 2-12 CLUTCH N O T E Inspect Initial 1,000 km and Every 4,000 Clutch play should be 4 mm as measured at the clutch lever holder before the clutch begins to disengage. If the play in the clutch is incorrect, adjust it in the following way: ●...

  • Page 32: Engine Oil

    2-13 PERIODIC MAINTENANCE ENGINE OIL Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. ● Don’t mix the unrecommended oil. It could damage the engine. ● ⊙ ENGINE OIL SPECIFICATION When refilling the oil, don’t allow the dust to get inside.
  • Page 33 PERIODIC M AINTENANCE 2-14 ⊙ ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level. 1. Start up the engine and allow it to run for several minutes at idling speed. 2. Turn off the engine and wait about three minutes, then check the oil level through the inspection window.
  • Page 34 2-15 PERIODIC MAINTENANCE Necessarily, confirm and clean the oil strainer when replace the Engine oil Operating the motorcycle with an (specially, when first replacement). incorrect amount of engine oil can damage your motorcycle. Too little or too much engine oil can damage your engine.
  • Page 35 PERIODIC M AINTENANCE 2-16 ⊙ ENGINE OIL AND FILTER CHANGE More frequent servicing may be performed on motorcycles that are used under severe conditions, inspect ① Quantity of Engine oil, ② Pollution degree of Engine oil before riding motorcycle then supplement and replace at any time to prevent damage of the engine.
  • Page 36 2-17 PERIODIC MAINTENANCE 1. Hold the motorcycle vertically using the center stand. N O T E Place the motorcycle on firm and flat ground. 2.Place a drain pan under the engine. ①. 3.Remove the engine oil filler plug 4.Drain the engine oil by removing the engine oil ②...
  • Page 37 PERIODIC M AINTENANCE 2-18 New and used oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals. Brief contact with used oil may irritate skin.
  • Page 38 Approximately 1,450 your motorcycle. of the engine oil will be required. Engine damage may occur if you use the engine oil that does not meet Hyosung’s specifications. Be sure to use the engine oil specified in the FUEL AND OIL RECOMMENDATION...
  • Page 39 “O”-ring / gasket damage. If you find any leaks or are not sure that the engine oil filter cap/ drain plug has been properly installed, have the motorcycle inspected your Hyosung dealer or qualified mechanic.

  • Page 40: Engine Oil Filter

    2-21 PERIODIC MAINTENANCE ENGINE OIL FILTER INSTALLATION When install the oil filter, necessarily, HYOSUNG character NO. install to ward the outside, otherwise can damage the engine. Engine oil and exhaust pipes can be hot enough to burn you. Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil.

  • Page 41: Antifreeze

    PERIODIC M AINTENANCE 2-22 ANTIFREEZE This motorcycle engine is water cooling system. During motorcycle running, the antifreeze is high temperature and high pressure in the cooling system. So, it is strictly forbidden opening the radiator cap in this state, avoiding burn. The antifreeze must be added in a timely manner and sufficient amount to prevent damaging the engine.
  • Page 42 2-23 PERIODIC MAINTENANCE Antifreeze replacement Carry out this work on about 10000 km running or when using the motorcycle for a year. The operation is following: 1. Please stand the motorcycle on a level ground with stand, take a container and put under the draining bolt③, then remove the bolt③, so antifreeze is outflow.
  • Page 43 PERIODIC M AINTENANCE 2-24 Common fault of cooling system: 4.Tighten the radiator cover, start the engine, Check the makeup water tank, radiator, repeated acceleration and deceleration of the fan, water pump, rubber water pipe and engine in place until the fan of cooling system antifreeze.

  • Page 44: Drive Chain

    2-25 PERIODIC MAINTENANCE DRIVE CHAIN N O T E Clean and Lubricate Every 1,000 km. Visually check the drive chain for the possible defects listed below. (Support the motorcycle by the jack or block, turn the rear wheel slowly by hand with the trans- mission shifted to Neutral.) ●...
  • Page 45 PERIODIC M AINTENANCE 2-26 ● Count out 21 pins (20 pitches) on the chain and mea- sure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Service limit Drive chain 20-pitch length 254 mm ●...
  • Page 46 ● After washing and drying the chain, oil it with a engine oil. The standard drive chain is a 428HO Hyosung recommends that this standard drive chain should be used for the replacement.

  • Page 47: Brake System

    [ BRAKE HOSE & BRAKE FLUID ] If the brake pad’s wear condition is good, replenish Inspect Initial 1,000 km and Every 4,000 km. with the proper brake fluid that meets Hyosung’s Replace the brake hoses Every 4 years, requirements.
  • Page 48 If a pad is worn to the grooved limit line it must be replaced with a new one by your authorized Hyosung dealer or qualified Brake fluid may be harmful if swallowed service mechanic.
  • Page 49 Hyosung dealer for safety as they operate at high pressure. Riding with worn brake pads will reduce braking performance and will increase your chance of having accident. Inspect brake pad wear before each use. Ask...
  • Page 50 2-31 PERIODIC MAINTENANCE ⊙ BRAKE DISK INSPECTION Check the brake disk for damage or cracks. FRONT BRAKE ◉ BRAKE FLUID LEVEL CHECK ● Keep the motorcycle upright and place the handle bars straight. ● Check the brake fluid level by observing the lower limit line (LOWER) on the front brake fluid reservoir.
  • Page 51 PERIODIC M AINTENANCE 2-32 ◉ FRONT BRAKE FLUID REPLACEMENT ● Place the motorcycle on a level surface and handlebars straight. keep the ● Remove the master cylinder reservoir cap and diaphragm. ● Suck up the old brake fluid as much as possible.
  • Page 52 2-33 PERIODIC MAINTENANCE ◉ AIR BLEEDING OF THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper.
  • Page 53 PERIODIC M AINTENANCE 2-34 N O T E Upper limit line While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. ● Close the air bleeder valve, and disconnect the hose.
  • Page 54 2-35 PERIODIC MAINTENANCE ◉ BRAKE LAMP SWITCH Adjust the front and rear brake light switches so that when the front brake handle is clenched or the brake pedal is pressed, the brake light will light up before the pressure is felt. Front brake lamp switch Rear brake lamp switch...

  • Page 55: Steering

    PERIODIC M AINTENANCE 2-36 STEERING N O T E Inspect Initial 1,000 km and Every 4,000 km. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering pre- vents smooth turning of the handlebars and too loose steering will cause poor stability.

  • Page 56: Rear Suspension

    2-37 PERIODIC MAINTENANCE REAR SUSPENSION N O T E Inspect Every 4,000 km. Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage. Replace any defective parts, if necessary.

  • Page 57: Tire

    PERIODIC M AINTENANCE 2-38 TIRE N O T E Inspect Initial 1,000 km and Every 4,000 km. Inspect the tire pressure and the tire thread depth periodically. Inspect frequently the tire pressure for the safety and the tire life. Failure to follow these warnings may result in an accident due to tire failure.
  • Page 58 2-39 PERIODIC MAINTENANCE The standard tire on GV125S is 120/80-16 or front and 150/80-15 for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a HYOSUNG Genuine Tire. ◉ TIRE PRESSURE...

  • Page 59: Chassis Bolts And Nuts

    PERIODIC M AINTENANCE 2-40 ⊙ CRACKS AND CUTS CHASSIS BOLTS AND NUTS Check if 1) There are visible cracks and cuts. N O T E 2) There are abnormal wears. Tighten Initial 1,000 km and Every 4,000 km. Check that all chassis bolts and nuts are tightened to SCREW, their specified torque.
  • Page 60 2-41 PERIODIC MAINTENANCE ◉ COMPRESSION TEST PROCEDURE N O T E Before testing the engine for compression pres- sure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. Have the engine warmed up by idling before testing.

  • Page 61: Oil Pressure

    PERIODIC MAINTENANCE 2-42 OIL PRESSURE Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 1.4 ± 0.2 kg/cm (at 60 ℃·4,000 rpm) If the oil pressure is lower or higher than the specification, the following causes may be considered.
  • Page 62 3-1 ENGINE ENGINE CONTENTS 3 - 2 BRIEF DESCRIPTION……………………………………………………………………………… ENGINE AND THE CHASSIS SEPARATION…………………………………………………… 3 - 3 ENGINE COMPONENT INSPEC- TION AND SERVICE……………………………………… 3 - 23...
  • Page 63 ENGINE 3-2 BRIEF DESCRIPTION Engine and the chassis separation: 1. Remove the seat and fuel tank (Tubing and trachea and power cord coupler). 2. Drain the engine oil and antifreeze. Remove the small sprockets and accessories. Disconnect the battery lead wire and magneto coupler and gear display switch. 3.
  • Page 64 Engine and the chassis separation: ● With left and right bolts removed, remove the seat. ● Remove fixed bolts on the left and right sides of the tank. ● Gently lift the rear of the tank, remove the injection pump tubing 1, trachea 2, oil pump power supply 3, fuel sensor 4.
  • Page 65 ● Drain the engine oil by removing the engine oil drain plug located on the bottom of the engine. ENGINE OIL CAPACITY 1,100ml Oil change 1,300ml Oil and filter change 1,400ml Engine overhaul ● Remove the lower water pipe. Drain the antifreeze. First add liquid antifreeze is about 0.75L, replacement and maintenance add at about 0.7 L.
  • Page 66 ● Remove the Gear display switch. ● Remove the contacts and springs . ● Remove the battery bracket comp 1, Disconnect the battery lead wire 2. ● Remove the starter motor lead wire 1 . gnition switch line 2, gear display power cord 3, side stand switch 4, Link by number of wires, color, and interface shape during installation, otherwise you cannot...
  • Page 67 ● Remove the gear shift cam lever. ● Remove the left footrest. ● Remove the starting motor. ● Remove the starter motor lead wire.
  • Page 68 ● Remove the left frame head cover. ● decoration cover. Remove the ● Remove the fuel hose joint 1 ● Remove the front cylinder fuel hose 2, ● Remove the rear cylinder fuel hose 3 and hose 4. ● Disconnect the injector and ignition coil coupler and horn.
  • Page 69 ● Remove the intake air temperature sensor (IATS) ● Remove the thermostat power cord. ● With the four screw loosened, remove the cleaner case. right air ● With the four screw and a nut loosened. Remove the air filter case comp.
  • Page 70 ● Remove the idle speed control solenoid throttle position sensor (TPS)2, Remove the throttle cable, ● Remove the idle speed control solenoid bolt. Remove the idle speed control solenoid. ● Disconnect the clutch cable en d out of clutch release arm bolt 1 and 2. Remove the clutch wire cable ●...
  • Page 71 ● With the exhaust pipe bolts and muffler bolts removed, remove the mounting exhaust pipes and mufflers. ● cover Remove the muffler and exhaust pipe ● Remove the muffler and exhaust pipe bolt. Remove the exhaust pipe. ● front cylinder oxygen sensor 1, Remove the rear cylinder oxygen sensor 2.
  • Page 72 ● Oxygen sensor separation white lock plate outward pull out. ● Remove three fixed bolts from the rear of: the engine assembly ● Rear swing arm pivot upper ● Rear swing arm pivot lower ● A bolt 1 below the front of the engine.
  • Page 73 ● Lift the engine from the left side of the body: remove the 2 bolts on the fixed bracket of the ignition coil. ● Loosen the front and rear cylinder inlet bending pipe locking clamp, Remove the throttle body. ● Remove the front cylinder inlet interface 1, rear cylinder inlet interface 2;...
  • Page 74 ● Remove the front cylinder head cover 1, rear cylinder head cover 2. ● Remove the cylinder head side cover. ● Remove the crankshaft hole plug, ， urn the crankshaft 1 counterclockwise, so that the timing mark "F" Alignment arrow 2; the cylinder head is marked as a straight line 3.
  • Page 75 ● Remove the sprocket and remove the positioning pin 1. ● Remove cylinder head fixing Bolts 2. ● Note that the torque is 25 Nm when assembling. ● Remove the chain tensioning device. ● Remove the cylinder head. ● Remove the cylinder 1. ●...
  • Page 76 ● Remove the rear cylinder head. Cylinder and Piston: The steps are the same as the front cylinder. Note: Turn the magnetic motor rotor counterclockwise, rotate the 300° (Fig. 1), Mark the "R" Alignment arrow (Figure 2), and mark the cylinder head on the alignment (Fig.
  • Page 77 ● Remove 9 bolts and remove the magnetic motor cover; Note that the stator coil is fixed on the inside; ● Stator Coil fixing. ● Remove the crankshaft nut; ● Torque 50-60N·m when mounting nuts; ● Remove the rotor with special tools.
  • Page 78 ● Remove the oil filter; ● Remove the semicircle key 1 ● Starter idle gear 2 ● Electric start clutch 3 ● Remove the bolt and remove the camchain guide. ● Remove 11 right cover bolts and remove the right cover; ●...
  • Page 79 ● Remove 5 clutch press plate fixing bolts ● Note: Diagonal fastening torque requirements during installation 6-10Nm ● Remove the clutch friction sheet. ● Disassembly clutch Large hub fixing nut 1 ● Mounting torque 30-50Nm ● Remove the drive gear fixing nut 2; ●...
  • Page 80 ● Remove 3 bolts from the pump and remove the oil pump 1 ● Remove the variable camshaft bezel 2 bolts and remove the bezel 2 ● Remove the variable camshaft holder 2 bolts and remove the cage 3 ● Remove two gear shift fork the variable camshaft ●...
  • Page 81 ● Separation of Engine crankcase: Installation of special tools (crankcase separators) on the side of the right clutch. With crankshaft as the center, three key points are found, the separator is installed, and the center bolt of the separator is rotated to separate the box. ●...
  • Page 82 ● Cylinder head combination decomposition; ● Intake valve clearance (When cold): 0.1~0.2mm ● Exhaust valve clearance (When cold): 0.2~0.3mm ● Remove the camshaft limit plate 1; ● Remove the exhaust valve spring, Intake valve arm, bushing 2; ● Remove the exhaust valve spring, exhaust valve arm 3 ●...
  • Page 83 ● See if the valve room is carbon-accumulating. ● 1 Exhaust valve, slightly larger in diameter, ● 2 Intake valve, slightly smaller in diameter. ● Exhaust valve Installation combination 1 ● Intake valve Installation combination 2 ● Pressurized gas door lock disassembly device, remove the lock plate, remove the valve base, valve oil seal;...
  • Page 84 ● Cylinder head; ● When the piston ring is installed, 3 ring openings are staggered 120° respectively; ● Note that the two gas ring marks the top notch of the upper piston at the time of installation corresponds to the valve chamber. ●...
  • Page 85 ● Engine assembly Considerations: ● Reverse operation in the above order; ● The disassembled engine must be cleaned clean; ● When the left and right box is merged, apply the sealant evenly and the fixing bolt diagonally according to the torque requirement to lock;...
  • Page 86 ENGINE COMPONENT INSPEC- TION AND SERVICE Be sure to identify each removed part as to its loca- tion, and lay the parts out in groups designated as “Front cylinder”, “Rear cylinder”,“Exhaust”, “Intake”, so that each will be restored to the original location during assembly.
  • Page 87 ◉ VALVE STEM RUNOUT Check the valve stem for abnormal wear or bend. Place the valve on V-blocks and measure runout. If the service limit is exceeded or abnormal condition exists, replace the valve. Service limit Valve stem runout 0.05 mm Dial gauge : Magnetic stand : ◉...
  • Page 88 ◉ Valve rocker arm If the engine produces abnormal noise or vibration or the output power decreases, the valve rocker arm should be checked, and any of these anomalies may be caused by the worn valve arm. Exhaust valve 1 Inlet valve 2...
  • Page 89 ◉ Tappet & shim wear When measuring the valve clearance, the clearance should be within the standard range. Valve clearance Standard(When cold) Intake valve 0.1~0.2mm Exhaust valve 0.2~0.3mm ● Inspect the tappet for wear and scratch. If modification or scratch is present, replace the tap pet. ●...
  • Page 90 ◉ VALVE HEAD RADIAL RUNOUT Place a dial gauge as shown and measure valve head radial runout. If the service limit is exceeded, replace the valve. Service limit Valve head radial runout 0.03 mm Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304...
  • Page 91 ◉ VALVE GUIDE-VALVE STEM CLEAR- ANCE Measure the clearance in the valve guide-valve stem, by rigging up the dial gauge as shown. If the clearance is measured exceeds the limit specified below, then deter- mine whether the valve or the guide should be replaced to reduce the clearance to within the standard range: Valve guide-valve stem...
  • Page 92 ◉ VALVE SPRING The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power out- put 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 93 ◉ CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion 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.
  • Page 94 ◉ CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear, damage and kinked or binding links. If any defects are found, replace it with a new one. Check the cam chain guide for wear and damage. If it is found to be damaged, replace it with a new one.
  • Page 95 ◉ PISTON DIAMETER INSPECTION Measure the outside diameter of piston in the direction perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer. If the measurement is found less than the service limit, replace the piston.
  • Page 96 ◉ PISTON PIN DIAMETER INSPECTION Using a micrometer, measure the piston pin outside diameter at three position, both the ends and the center. If any of the measurements is founds less than the ser- vice limit, replace the pin. Service limit Piston pin diameter 14.980 mm Micrometer(0~25 mm) : 09900-20201...
  • Page 97 Piston ring-groove clearance Service limit 0.180 mm 0.150 mm Piston ring-groove width Standard 1.01~1.03 mm 1.01~1.03 mm 2.01~2.03 mm Piston ring thickness Standard 0.970~0.990 mm 0.970~0.990 mm Thickness gauge : 09900-20806 Micrometer(0~25 mm) : 09900-20201 ■ Oversize oil ring The following two types of oversize oil ring are used. They bear the following identification marks.
  • Page 98 ◉ CONROD BIG END SIDE CLEARANCE INSPECTION Using a thickness gauge, measure the side clearance at the conrod big end. If the measurement is out of stan- dard value, measure the conrod big end and the crank pin widths individually to determine which one is to be replaced.
  • Page 99 ◉ MAGNETO COVER ■ MAGNETO INSPECTION(Refer to page 5-4) ■ DISASSEMBLY ● Remove the stator. ◉ STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand(the gear turns in only one direction). The starter driven gear should turn smoothly.
  • Page 100 ■ REASSEMBLY ● Apply a small quantity of THREAD LOCK“1324” to the starter clutch bolts and tighten them to the speci- fied torque while holding the rotor holder. Thread Lock “1324” Rotor holder : 09930-44510 Starter clutch bolt 23~28 N∙m(2.3~2.8 kg∙m) ◉...
  • Page 101 ◉ CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. Standard Service limit Clutch drive plate thickness 2.9~3.1 mm 2.6 mm...
  • Page 102 ◉ CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the spring. Service limit Clutch spring free length 29.5mm Vernier calipers : 09900-20101 ◉...
  • Page 103 ◉ OIL PUMP Turn the oil pump shaft and check that rotation is smooth. If any abnormal condition is found, replace the oil pump with new one. ◉ GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture. ◉...
  • Page 104 Thickness gauge : 09900-20806 Vernier calipers : 09900-20101 Shift fork groove width Standard NO.1 & NO.2 5.0~5.1 mm NO.3 5.5~5.6 mm Shift fork thickness Standard NO.1 & NO.2 4.8~4.9 mm NO.3 5.3~5.4 mm ◉ CRANKCASE ■ BEARING INSPECTION Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while the bearings are in the crankcase.
  • Page 105 ■ DISASSEMBLY ★ RIGHT CRANKCASE BEARING ● Remove the bearing retainer. ● Remove the bearings ① and ②. Bearing remover(17 mm) : 09923-73210 Bearing remover(20~35 mm) : 09923-74510 Bearing installer : 09913-76010 The removed bearing should be replace with a new one.
  • Page 106 ● Remove the bearing retainer. ● Remove the bearings 3,4 and 5. Bearing remover(17 mm) : 09923-73210 Bearing remover(20~35 mm) : 09923-74510...
  • Page 107 EI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ………………………………………………………………………… 4 - 1 EI SYSTEM TECHNICAL FEATURES ………………………………………………………………… 4 - 5 4 - 10 SELF-DIAGNOSIS FUNCTION ………………………………………………………………………… EI SYSTEM TROUBLE SHOOTING …………………………………………………………………… 4 - 19 CUSTOMER COMPLAINT ANALYSIS 4 - 19 …………………………………………………………… 4 - 21 SELF-DIAGNOSTIC PROCEDURES ………………………………………………………………...

  • Page 108: Precautions In Servicing

    4-1 EI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the EI system, observe the following points for the safety of the system. ⊙ELECTRICAL PARTS ▣ CONNECTOR / COUPLER ● When connecting a connector, be sure to push it in until a click is felt.
  • Page 109 EI SYSTEM DIAGNOSIS 4-2 ● When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open.
  • Page 110 4-3 EI SYSTEM DIAGNOSIS ● When disconnecting and connecting the ECU, make sure to turn “OFF” the ignition switch, or electronic parts may get damaged. ● Battery connection in reverse polarity is strictly INCORRECT prohibited. Such a wrong connection will damage the components of the EI system instantly when reverse power is applied.
  • Page 111 EI SYSTEM DIAGNOSIS 4-4 ● Never connect an ohmmeter to the ECU with its coupler connected. If attempted, damage to ECU or sensors may result. ● Be sure to use a specified voltmeter / ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.

  • Page 112: Ei System Technical Features

    4-5 EI SYSTEM DIAGNOSIS EI SYSTEM TECHNICAL FEATURES EI SYSTEM’S CONTROL DIAGRAM IAP&T Sensor (Temperature function) FUEL TANK AIR CLEANER ISC Solenoid TP Sensor FUEL PUMP THROTTLE BODY IAP&T Sensor (Pressure function) INTAKE PIPE FUEL INJECTOR WT Sensor CYLINDER Pick-up Coil Sensor EXHAUST PIPE : Electrical signal flow...
  • Page 113 EI SYSTEM DIAGNOSIS 4-6 ⊙ INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.
  • Page 114 4-7 EI SYSTEM DIAGNOSIS ⊙ COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION WATER COOLANT TEMPERATURE When engine temperature is low, injection time (volume) is increased.
  • Page 115 EI SYSTEM DIAGNOSIS 4-8 EI SYSTEM PARTS LOCATION ① Speedometer ② Ignitioncoil,NO.1 ③ Ignitioncoil,NO.2 ④ Pick-up coil ⑤ GP switch ⑥ Fuel injector, NO.1 ⑦ Fuel injector, NO.2 ⑧ IAP&T SENSOR...
  • Page 116 4-9 EI SYSTEM DIAGNOSIS ⑨ ISC solenoid ⑩ RO switch ⑪ Fuel pump relay ⑫ TP SENSOR ⑬ WT SENSOR ⑭ Oxygen sensor, NO.1 ⑮ Oxygen sensor, NO.2...

  • Page 117: Self-Diagnosis Function

    EI SYSTEM DIAGNOSIS 4-10 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECU. The function has two modes, “USER MODE” and “DEALER MODE”. ” A The user can only be notified by the engine warning lamp “ To check the function of the individual EI system devices, the dealer mode is prepared. In this check, the special tool and additional operations is necessary to read the code of the malfunction items.
  • Page 118 4-11 EI SYSTEM DIAGNOSIS ⊙ DEALER MODE The defective function is memorized in the ECU. The memorized malfunction code is displayed on the odometer screen B or by blinks signal of the engine warning ” A lamp “ Malfunction means that the ECU does not receive signal from the devices or fault signal received. These affected devices are indicated in the code form on the odometer screen B or displayed by blinks signal ”...
  • Page 119 EI SYSTEM DIAGNOSIS 4-12 ❖ Confirm the malfunction code after turning the ignition switch “ON” position and starting the engine separately. ❖ The dealer mode coupler of the wiring harness is located Left side cover. ODOMETERSCR ENGINE INDICATION CLASSIFICATION MALFUNCTI WARNING LAMP MODE INDICATION B...
  • Page 120 4-13 EI SYSTEM DIAGNOSIS A. ENGINE WARNING LAMP ” A: To confirm the memorized malfunction code through the engine warning lamp “ 1. Turn the ignition switch alternately, “ON” and “OFF” position, for 2 seconds by three times. Take special care when operating above procedure. If the ignition switch is turned alternately, “ON”...
  • Page 121 EI SYSTEM DIAGNOSIS 4-14 B CODE A CODE MALFUNCTION PART REMARKS ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐ P0031 For NO.1 cylinder NO.1 O₂S heater Circuit Low Voltage ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐ P0032 NO.1 O₂S heater Circuit High Voltage For NO.1 cylinder ▐▐▐▐▐▐▐▐▐▐...
  • Page 122 4-15 EI SYSTEM DIAGNOSIS B CODE A CODE MALFUNCTION PART REMARKS ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ P0117 WTS Circuit Low Voltage ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐ P0118 WTS Circuit High Voltage or Open ▐▐▐▐▐▐▐▐▐▐...
  • Page 123 EI SYSTEM DIAGNOSIS 4-16 B CODE A CODE MALFUNCTION PART REMARKS ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐ P0171 Injection Fuel Shortage ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐ P0172 Injection Fuel Excess ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐ P0201 NO.1 Fuel injector Circuit Malfunction For NO.1 cylinder...
  • Page 124 4-17 EI SYSTEM DIAGNOSIS B CODE A CODE MALFUNCTION PART REMARKS ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐ P0500 Speed Sensor Malfunction ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐ P0505 ISC Error ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐ ▐▐ P0562 Battery Voltage Low ▐▐▐▐▐▐▐▐▐▐...
  • Page 125 EI SYSTEM DIAGNOSIS 4-18 A. ENGINE WARNING LAMP INDICATION In the engine warning lamp“ ”A the malfunction code is displayed by blinking the signal in order of occurrence. B. ODOMETER SCREENINDICATION In the odometer screen B, the malfunction code is indicated in order of occurrence.

  • Page 126: Ei System Troubleshooting

    4-19 EI SYSTEM DIAGNOSIS EI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 127 EI SYSTEM DIAGNOSIS 4-20 MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition 口 Fair 口 Cloudy 口 Rain 口 Snow 口 Always 口 Other Weather Temperature 口 Hot 口 Warm 口 Cool 口 Cold ( °C) 口 Always °F / Frequency 口...

  • Page 128: Self-Diagnostic Procedures

    4-21 EI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDURES Don’t disconnect couplers from ECU, battery cable from battery, ECU ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. the memorized malfunction code is displayed in the code form on the odometer screen B or by blinks signal of the engine ”...
  • Page 129 EI SYSTEM DIAGNOSIS 4-22 ODOMETER SCREEN INDICATION Refer to page [4-11] ENGINE WARNING LAMP INDICATION Refer to page [4-13]...

  • Page 130: Malfunction Code And Defective Condition

    EI SYSTEM DIAGNOSIS 4-24 MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT noEr After engine running, if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 Low Voltage times test cycle, the code 0031 is indicated.
  • Page 131 4-25 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE The sensor voltage should be the following. 0.1 V ≤Sensor output voltage P0117 Without the above rangefor6.25sec.and more,0117is indicated. Low Voltage Water temperature sensor, lead wire / coupler connection. The sensor voltage should be the following.
  • Page 132 EI SYSTEM DIAGNOSIS 4-26 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, rate of fuel calibration remains less than Injection standard value (1.3) for 10 sec. and more, the code P0171 is P0171 Fuel indicated. Fuel Shortage Injection ECU, O2 sensor, Fuel pump, Fuel hose line...
  • Page 133 4-27 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR Motorcycle speed＜10km/h Water temperature＜20℃ IAP&TS pressure＞40kpa 20%＜TPS open angle＜100% P0500 2,000rpm＜Engine speed ＜6,000rpm Speed sensor If the above conditions are maintained for 32.5sec.and more, Malfunction The code P0500 is indicated Speedo sensor, wiring/coupler connection to ECU After engine running, if idle speed is different to 500 rpm from the specified range in 25 seconds test cycle, the code 0505 is...

  • Page 134: P0031","P0032","P0037"Or"P0038"Oxygen Sensor Heater Circuit

    EI SYSTEM DIAGNOSIS 4-28 “P0031”, “P0032”, “P0037” or “P0038” OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION & “0131”, “0132”, “0137” or “0138” OXYGEN SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐ P0031 ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐ P0032 ▐▐▐▐▐▐▐▐▐▐...
  • Page 135 4-29 EI SYSTEM DIAGNOSIS ▣ INSPECTION 1) The connectors of two oxygen sensors are located in the frame head left cover lower, and another the right side cover inside. 2) Turn the ignition switch to the “OFF” position. 3) Check the Oxygen sensor coupler for loose or poor contacts.

  • Page 136: P0107"Or"P0108"Iap&T(Pressure Function)Sensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-30 “ P0107” or “P0108 IAP&T(Pressure function)SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐ P0107 ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ P0108 DETECTED CONDITION POSSIBLE CAUSE ● Clogged vacuum passage between throttle body ☞...
  • Page 137 4-31 EI SYSTEM DIAGNOSIS Is the input voltage OK? Go to Step 2. ● Loose or poor contacts on the ECU coupler. ● Open or short circuit in the OB wire or GR wire. ◈ Step 2 1) Connect the IAP&T(Pressure function) sensor coupler ①.

  • Page 138: P0112"Or"P0113"Iap&T(Temperature Function) Sensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-32 “P0112” or “P0113”IAP&T(Temperature function)SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐ P0112 1 1 2 1 1 2 ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ P0113 POSSIBLE CAUSE DETECTED CONDITION...
  • Page 139 4-33 EI SYSTEM DIAGNOSIS IAP&T(Temperature function) Sensor resistance Intake Air Temp. Resistance ㏀ -20 ℃ (-40 ℉ ) Approx 14.541 ㏀ -0 ℃ (32 ℉ ) Approx 5.627 ㏀ 20 ℃ (68 ℉ ) Approx 2.429 ㏀ 40 ℃ (104 ℉ ) Approx 1.155 ㏀...

  • Page 140: P0117"Or"P0118"Wtsensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-34 “P0117” or “P0118” WT SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐ ▐▐▐▐ P0117 ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐ ▐▐▐▐▐▐▐▐ ▐▐ P0118 DETECTED CONDITION POSSIBLE CAUSE ●...
  • Page 141 4-35 EI SYSTEM DIAGNOSIS WT sensor resistance Engine Coolant Resistance (To ECU) Temp. -40 ℃ (-40 ℉ ) Approx. 48.140 K Ω 0 ℃ (32 ℉ ) Approx.5.790 K Ω 20 ℃ (68 ℉ ) Approx. 2.450 K Ω 40 ℃ (104 ℉ ) Approx.

  • Page 142: P0122"Or"P0123"Tpsensor Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-36 “P0122” or “P0123” TP SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐ P0122 ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐ ▐▐▐ ▐▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐ ▐▐▐ ▐▐▐▐▐▐▐▐▐▐ P0123 DETECTED CONDITION POSSIBLE CAUSE ●...
  • Page 143 4-37 EI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch to the “OFF” position. 2) Disconnect the TP sensor coupler. ○ 3) Check the continuity between (LY) and ground. ∞ Ω (Infinity) TP sensor continuity (A- Ground) Tester knob indication : Resistance ( Ω ) Is the continuity OK? Go to Step 3.
  • Page 144 EI SYSTEM DIAGNOSIS 4-38 ● OB, LY or GR wire open or shorted to ground, or poor B16 ,B12 or B10 connection of ECU coupler. ● If wire and connection are OK, intermittent trouble or faulty ECU. ● Recheck each terminal and Gray Black wire harness for open circuit...

  • Page 145: P0171" Or"P0172" Fuel Injection Circuit Malfunction

    4-39 EI SYSTEM DIAGNOSIS “ P0171” or “P0172” FUEL INJECTOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐ ▐▐▐▐ P0171 ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐ ▐▐ ▐ ▐ P0172 DETECTED CONDITION POSSIBLE CAUSE ●...

  • Page 146: P0201"Or"P0202"Fuelinjector Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-40 “P0201” or “P0202” FUEL INJECTOR CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐ P0201 ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐ P0202 DETECTED CONDITION POSSIBLE CAUSE ● Injector circuit open or short. ●...
  • Page 147 4-41 EI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch to the “ON” position. 2) Measure the injector voltage between YL(NO.1 & NO.2) wire and ground. Battery voltage NO.2 Ground, Injector voltage NO.2 Ground) Tester knob indication: Voltage (—) N O T E Injector voltage can be detected only 3 seconds after ignition switch is turned “ON”...

  • Page 148: P0230"Or"P0232"Fuel Pump Relay Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-42 “P0230” or “P0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION P0230 P0232 DETECTED CONDITION POSSIBLE CAUSE ● Fuel pump relay circuit open or short. ● Fuel pump relay malfunction. ☞ Refer to page [4-26] ●...

  • Page 149: P0336"Or"P0337" Pick-Up Coilcircuit Malfunction

    4-43 EI SYSTEM DIAGNOSIS “P0336” or “P0337” PICK-UP COIL CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐▐▐ ▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐▐▐ ▐▐▐▐ P0336 ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐▐▐ ▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐ ▐▐▐ ▐▐ P0337 DETECTED CONDITION POSSIBLE CAUSE ● Metal particles or foreign materiel being attached on the pick-up coil and rotor tip.
  • Page 150 EI SYSTEM DIAGNOSIS 4-44 Are the resistance and continuity OK? ● L or G wire open or shorted to ground, or poor B13 or B4 connection of ECU coupler. ● If wire and connection are OK, intermittent trouble or faulty ECU. ●...

  • Page 151: P0351"Or"P0352"Ignition Coil Malfunction

    4-45 EI SYSTEM DIAGNOSIS “P0351” or “P0352” IGNITION COIL MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION P0351 P0352 ☞ Refer to the IGNITION COIL for details.

  • Page 152: P0500" Speedo Sensor Malfunction

    EI SYSTEM DIAGNOSIS 4-46 “P0500” SPEEDO SENSOR MALFUNTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐ P0500 DETECTED CONDITION POSSIBLE CAUSE ● Speedo sensor circuit open and short ● Speedo sensor malfunction. ☞ Refer to page [4-27] ●...

  • Page 153: P0505" Isc Solenoid Range Abnormal

    4-47 EI SYSTEM DIAGNOSIS “P0505” ISC SOLENOID RANGE ABNORMAL LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐ P0505 DETECTED CONDITION POSSIBLE CAUSE ● ISC solenoid malfunction. ● ISC solenoid’s step is out of the specified range. ☞...

  • Page 154: P0562" Or "P0563" Battery Voltag Emalfunction

    EI SYSTEM DIAGNOSIS 4-48 “ 0562” or “ 0563” BATTERY VOLTAGE MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐ ▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐ P0562 ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐ ▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐ P0563 DETECTED CONDITION POSSIBLE CAUSE ● Battery voltage circuit open and short. ●...

  • Page 155: P0601" Ecu Fault Malfunction

    4-49 EI SYSTEM DIAGNOSIS “P0601” ECU FAULT LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION P0601 DETECTED CONDITION POSSIBLE CAUSE ● ECU error ☞ Refer to page [4-27]...

  • Page 156: P0650"Engine Warning Lamp Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-50 “P0650” ENGINE WARNING LAMP CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐ ▐▐▐▐▐ P0650 POSSIBLE CAUSE DETECTED CONDITION ● Engine warming lamp circuit open and short. ☞ Refer to page [4-27] ●...

  • Page 157: P0850"Gporclutch Lever Switch Circuit Malfunction

    4-51 EI SYSTEM DIAGNOSIS “P0850” GP or CLUTCH LEVER SWITCH CIRCUIT MALFUNCTION LCD (DISPLAY)INDICATION ENGINE WARING LAMP INDICATION ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐ ▐▐▐▐▐ ▐▐▐▐▐▐▐▐▐▐ ▐▐▐▐▐▐▐▐ ▐ P0850 DETECTED CONDITION POSSIBLE CAUSE ● GP switch circuit open or short. ● GP switch malfunction. ●...
  • Page 158 EI SYSTEM DIAGNOSIS 4-52 1) Disconnect the clutch lever switch coupler ② and then check the continuity between GR wire and Br wire when the squeezing the clutch lever. Ω Clutch lever switch continuity Tester knob indication: Resistance ( Ω ) 1) Measure the voltage between G18 of the ECU and the LY wire of the wiring harness’s GP switch coupler, and measure the voltage between G18 of the...

  • Page 159: Sensors

    SENSORS ⊙ PICK-UP COIL INSPECTION The pick-up coil ① is installed in the magneto cover. (Refer to page [4-43]) ⊙PICK-UP COIL REMOVAL AND INSTALLATION ● Remove the magneto cover. ● Install the magneto cover in the reverse order of removal. ⊙...
  • Page 160 ⊙ WT SENSOR INSPECTION ① The engine temperature (WT) sensor is installed at the thermostat case. (Refer to page [4-34]) ⊙WT SENSOR REMOVAL AND INSTALLATION ● Remove the WT sensor. ● Install the WT sensor in the reverse order of removal.
  • Page 161 5-1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM 5 - 2 ……………………………………………………………………………………… 5 - 2 REMOVAL AND DISASSEMBLY…………………………………………………………………… 5 - 3 REASSEMBLY AND INSTALLATION…………………………………………………………… 5 - 4 FUEL PRESSURE INSPECTION…………………………………………………………………… 5 - 4 FUEL PUMP RELAY INSPECTION………………………………………………………………… 5 - 6 FUEL MESH FILTER INSPECTION AND CLEANING…………………………………………………...

  • Page 162: Fuel System

    FUEL S YSTEM AND THROTTLE BODY 5-2 FUEL SYSTEM Gasoline must be handed carefully in an area well ventilated and away from fire or sparks.

  • Page 163: Removal And Disassembly

    5‐3    FUEL SYSTEM AND THROTTLE BODY      REMOVAL AND DISASSEMBLY        Gasoline  i s  v ery  e xplosive.  E xtreme  c are  m ust  b e  taken.       ● Drain the fuel. ● Remove the fuel tank mounting bolts. ● Disconnect the fuel injector hose①. ● Disconnect the fuel pump lead wire coupler② and fuel sender gauge coupler wire coupler③.

  • Page 164: Reassembly And Installation

    FUEL SYSTEM AND THROTTLE BODY 5-4 ● Remove the fuel tank. As gasoline leakage may occur in this operation, keep away from fire and sparks. ● Remove the fuel sensors mounting bolts. ● Remove the fuel sensor. ● Remove the fuel pump mounting screws. ●...

  • Page 165: Fuel Pressure Inspection

    ❖ Gasoline is highly flammable and explosive. Keep heat, sparks and flame away. FUEL PUMP RELAY INSPECTION GV125S’s fuel pump relay is located inside the right side cover. ● Remove the right side cover. ●...

  • Page 166: Fuel Mesh Filter Inspection And Cleaning

    FUEL SYSTEM AND THROTTLE BODY 5-6 First, check the insulation between ① and ②terminals with the pocket tester. Then apply 12 volts to ③ and ④ terminals, to ③ and ① ③ to ④, and check the continuity between ① and ②. If there is no continuity, replace it with a new one.

  • Page 167: Throttle Body

    5-7 FUEL SYSTEM AND THROTTLE BODY THROTTLE BODY...

  • Page 168: Removal

    REMOVAL ● Remove the fuel tank. ● Remove the air cleaner chamber. ● Disconnect the fuel hoses. ● Remove the all couplers connected to the throttle body. ● Loosen the throttle body clamp screws. ● Disconnect the throttle cables from their drum. ●...

  • Page 169: Cleaning

    LEANING  Clean all passageways with a spray-type throttle body cleaner and blow dry with compressed air. Some throttle body cleaning chemicals, especially dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow chemical manufacturer’s instructions on proper use, handling and storage.

  • Page 170: Installation

    FUEL SYSTEM AND THROTTLE BODY 5-10 INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points : Never operate the idle nuts ① and ② to avoid variations of the ECU setting.  Connect the throttle cable to the throttle cable drum.
  • Page 171 6-1 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS COMPONENTS………………………………………………………… 6 - 2 LOCATION OF ELECTRICAL 6 - 4 IGNITION SYSTEM…………………………………………………………………………………… 6 - 8 CHARGING SYSTEM…………………………………………………………………………………… 6 - 12 STARTER SYSTEM AND SIDE STAND………………………………………………………………… 6 - 4 IGNITION INTERLOCK SYSTEM……………………………………………………………………… 6 - 16 SWITCHES………………………………………………………………………………………………...

  • Page 172: Location Of Electrical Components

    ELECTRICAL SYSTEM 6-2 LOCATION OF ELECTRICAL COMPONENTS ① ② ③ Fuse Front brake lamp switch ④ ⑤ Rear brake lamp switch Starter motor...
  • Page 173 6-3 ELECTRICAL SYSTEM ① ② ③ Ignition coil (NO.1 FRONT) Ignition coil (NO.2 REAR) Side stand relay ④ ⑤ ⑥ Main relay (RO) switch Head lamp relay ⑦ ⑧ ⑨ Fan relay Fuel pump relay Turn signal relay ⑩ ⑪ ⑫...

  • Page 174: Ignition System

    ELECTRICAL SYSTEM 6-4 IGNITION SYSTEM □ INSPECTION □ MAGNETO □ Using the pocket tester, measure the resistance between the lead wires in the following table. If the resistance is not within the specified □ value, replace the stator coil, with a new one.
  • Page 175 6-5 ELECTRICAL SYSTEM IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION ● Remove the fuel tank and frame cover. ● Disconnect the two spark plug caps. ● spark With the spark plug cap connected, place a new plug on the engine to ground it. N O T E ❖...
  • Page 176 ELECTRICAL SYSTEM 6-6 IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION ● Remove the fuel tank and frame cover. ● Disconnect the two spark plug caps. ● spark With the spark plug cap connected, place a new plug on the engine to ground it. N O T E ❖...
  • Page 177 6-7 ELECTRICAL SYSTEM While testing, do not touch the tester probes and spark plugs to prevent receiving an electric shock. If the peak voltage is lower than the specified values, inspect the ignition coil. (Refer to the next page.) ■ I GNITION COIL RESISTANCE INSPECTION ●...
  • Page 178 ■ SPARK PLUG ▷ CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it with a spark plug cleaner machine or carefully use a tool with a pointed end. ▷ SPARK PLUG GAP Measure the spark plug gap with a thickness gauge.

  • Page 179: Charging System

    CHARGING 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 If the voltage is not within the specified value, check the magneto no-load performance and regulator / rectifier. When making this test, be sure that the battery is full-charged condition.
  • Page 180 6-9 ELECTRICAL SYSTEM MAGNETO NO-LOAD PERFORMANCE Disconnect the three lead wires from the magneto 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 voltage is under the specified value, replace the magneto with a new one.

  • Page 181: Starter System And Side Stand

    ELECTRICAL SYSTEM 6-10 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM ⊙ STARTER SYSTEM DESCRIPTION The starter system consists of the following components : the starter motor, starter relay, clutch lever switch, side stand switch, GP switch, starter switch, engine stop switch, ignition switch and battery. Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact points to close, thus completing the circuit from the starter motor to the battery.
  • Page 182 GP SWITCH “OFF” SIDE STAND GV125S are equipped with the side stand ignition interlock system. If the transmission is in neutral or side stand up, you can only start the engine with pulling the clutch lever. NO Neutral switch Clutch lever Side stand Engine Start △...
  • Page 183 6-12 ELECTRICAL SYSTEM STARTER MOTOR REMOVAL DISASSEMBLY ● Disconnect the starter motor lead wire ①. (Refer to page 3-6) ● With loosen the bolt ②, remove the starter motor. (Refer to page 3-6) ● Disassemble the starter motor. ◉ STARTER MOTOR INSPECTION □...
  • Page 184 ELECTRICAL SYSTEM 6-14 □ STARTER MOTOR REASSEMBLY Reassembly the starter motor. Pay attention to the following points : ● Reassembly the starter motor as shown in the illustration.
  • Page 185 6-15 ELECTRICAL SYSTEM  Align the mark ① on the housing with the line on the housing end.  Apply GREASE to the O-ring ① and remount the starter motor.

  • Page 186: Switches

    ELECTRICAL SYSTEM 6-16 SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Pocket tester : 09900 - 25002...

  • Page 187: Lamp

    6-17 ELECTRICAL S YSTEM LAMP If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. ◉ HEADLAMP ◉ TURN SIGNAL LAMP...
  • Page 188 ELECTRICAL SYSTEM 6-18 ◉ TAIL / BRAKE LAMP...
  • Page 189 6-19 ELECTRICAL SYSTEM COMBINATION METER Remove the combination meter. Disassemble the combination meter as shown in the illustration. INSPECTION Using the pocket tester, check the continuity between lead wires in the following illustration. If the continuity measured incorrect, replace the respective part. Pocket tester : 09900 - 25002 When making this test, it is not necessary to remove the combination meter.

  • Page 190: Battery

    BATTERY Use only the genuine Hyosung battery on GV125S. ◉ CAUTION OF BATTERY TREATMENT The battery needs attention generally as it occur flammability gas. If you don’t follow the instruction in the below, there may be a explosion and severe accident.
  • Page 191 6-21 ELECTRICAL S YSTEM...
  • Page 192 ELECTRICAL SYSTEM 6-22...
  • Page 193 ● When the vehicle is not used for a long period, check the battery every 1 month to prevent the battery discharge. ◉ BATTERY INSTALLATION GV125S battery installation order pay attention to following points : ① Remove the seat, left frame cover ② Orient the battery's positive terminal toward the right side of the battery case ③...
  • Page 194 CHASSIS CONTENTS EXTERIOR PARTS 7- 1 FRAME COVER 7- 2 REAR FRAME COVER 7- 4 7 - 6 FRONT WHEEL FRONT BRAKE 7- 10 7 - 17 HANDLEBARS 7 - 19 FRONT FORK 7 - 26 STEERING REAR WHEEL 7- 32 REAR BRAKE 7- 39 REAR SHOCK ABSORBER...
  • Page 195 7-1 CHASSIS EXTERIOR PARTS ◉ FRONT FENDER ● With the bolts removed, remove the front fender. ◉ SEAT ● With the bolts removed, remove the seat.
  • Page 196 FRAME COVER ◉ LEFT FRAME COVER ● Remove the screw ①. ● With the hook ②, ③ removed, remove the left frame cover.
  • Page 197 ◉ RIGHT FRAME COVER ● Remove the screw ①. ● With the hook ②, ③ removed, remove the right frame cover. ◉ DECORATION COVER ● Remove the two screw④. ● Remove the decoration cover. ◉ MAIN KEY COVER ● Remove the two screw ⑤. ●...
  • Page 198 ◉ LEFT AND RIGHT FRAME HEAD COVER ● Remove the left frame head cover with mounting screws①. ● Remove the right frame head cover with two mounting screws②. ● With the hook ③ removed, remove the left and right frame head cover. ●...
  • Page 199 ◉ LEFT AND RIGHT DECORATION FRAME CENTER COVER ● Remove the upper screw ①. ● Remove the left screw ②. ● Remove the left decoration frame center cover ● Remove the right screw ③. ● Remove the right decoration frame center cover...
  • Page 200 REAR FRAME COVER ● Remove the seats. ● Remove the frame covers. ● Remove the left pillion rider grip comp mounting nut.
  • Page 201 ● Remove the right pillion rider grip comp mounting nut. ● Disconnect the rear turn signal lamp couplers and rear combination lamp coupler. ● With the bolts removed, remove the rear fender.
  • Page 202 FRONT WHEEL REMOVAL ● Loosen the axle pinch bolt ①. ● Loosen the front axle ②. ● Raise the front wheel off the ground with a block or jack. When using a jack, take care not to cause scratches on the chassis.
  • Page 203 ◉ INSPECTION AND DISASSEMBLY □ TIRE For inspection of the tire : Refer to page 2-19. □ FRONT AXLE Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle. Service limit Axle shaft runout 0.25 mm Dial gauge : 09900 - 20606...
  • Page 204 □ WHEEL BEARING REMOVAL ● Remove the wheel bearing by using the special tool. Wheel bearing remover : 09941 - 50111 The removed bearing should be replaced with new ones ◉ REASSEMBLY Reassemble the front wheel in the reverse order of removal and disassembly.
  • Page 205 ● Tighten the front axle ① and axle pinch bolt ② to the specified torque. Front axle : 50~80 N∙m (5.0 ~8.0 kg∙m) Front axle pinch bolt : 15~25 N∙m (1.5 ~2.5 kg∙m)
  • Page 206 FRONT BRAKE AND REAR BRAKE ❖ Do not mix with brake fluid of different brand. ❖ Do not use a brake fluid kept in an open container or stored for long period of time. ❖ To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of children.
  • Page 207 Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause discoloration or crack. ◉ BRAKE FLUID REPLACEMENT ● For replacing procedure of brake fluid : Refer to page 2-28 ◉ BRAKE PAD REPLACEMENT ●...
  • Page 208 ● Remove the front brake caliper pad comp ①. ● Remove the front brake caliper spring sheet ②.
  • Page 209 ● Using an air gun, push out the caliper piston. ❖ Place a rag over the piston to prevent it from popping out and flying and keeping hand off the piston. ❖ Be careful of brake fluid which can possibly splash.
  • Page 210 CALIPER REAR BRAKE DISASSEMBLY ● Remove the rear brake union bolt ① and caliper ②. mounting bolts ● Remove the rear brake caliper friction sheet ⑤ fixing screws ③ and washer ④. ● Remove the spring slice ⑥. ● Remove the caliper combination bolt ⑦ of the rear brake caliper and separate the left and right caliper body.
  • Page 211 ● Using an air gun, push out the caliper piston. ❖ Place a rag over the piston to prevent it from popping out and flying and keeping hand off the piston. ❖ Be careful of brake fluid which can possibly splash.
  • Page 212 ◉ CALIPER REASSEMBLY Reassemble the caliper in the reverse order of disas- sembly procedures and observe the following points. ❖ Wash the caliper components with fresh brake fluid before reassembly. Do not wipe off brake fluid after washing the components. ❖...
  • Page 213 ● Tighten the caliper mounting bolts ① front and rear caliper mounting bolts ②. ● With the hose end seated to the stopper, tighten the union bolt ③ and ④. Front brake caliper mounting bolts :18~28 N∙m (1.8~2.8 kg∙m) Front brake hose union bolts :20~25 N∙m (2.0~2.5 kg∙m) Rear brake caliper mounting bolts :18~28 N∙m (1.8~2.8 kg∙m)
  • Page 214 ◉ MASTER CYLINDER DISASSEMBLY ● Drain brake fluid the master cylinder. ● Disconnect the brake lamp switch lead wire coupler. ● Remove the union bolt ①. Place a rag under the union bolt so that brake fluid can not contact the parts. ●...
  • Page 215 ● Detach the dust seal boot and remove the circlip. ● Pull out the piston/cup set ①and spring ②. ◉ MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage.
  • Page 216 ● Apply SUPER GREASE “A”to the brake lever pivot ①. SUPER GREASE “ A ” ● When remounting the master cylinder onto the han- dlebars, align the master cylinder holder’ s mating surface with punch mark on the handlebar and tighten the upper clamp bolt first.
  • Page 217 HANDLEBARS HANDLEBARS RIGHT SIDE PARTS REMOVAL ● Remove the rearview mirror ①. ● Remove the front master cylinder set. ● Disconnect the brake lamp switch lead wires and remove the master cylinder. ● Remove the brake lever. ● Remove the right handlebar switches.
  • Page 218 ● Remove the throttle cable. ● Remove the handlebar grip ①. HANDLEBARS LEFT SIDE PARTS REMOVAL ● Remove the rearview mirror ①. ● Remove the clutch lever rear holder.
  • Page 219 ● Disconnect the clutch switch lead wires. ● Remove the clutch cable. ● Remove the clutch lever. ● Remove the left handlebar switches. ● Remove the handlebar grip.
  • Page 220 ● Remove the clamp bolts and detach the handlebar holders. ● Remove the handlebar. REMOUNTING Perform the remounting work in the reverse order of the removal procedures while observing the following instructions. ● Install the handlebars with the punch mark ① with the handlebar clamp as shown.
  • Page 221 ● Apply SUPER GREASE“A”to the throttle cables and assemble them. SUPER GREASE “ A ” ● Align the mating face ① of right handle switch with the respective punch marks ② and tighten the bolt. ● Install the brake master cylinder.
  • Page 222 FRONT FORK ◉ DISASSEMBLY ● Remove the front wheel. ● Remove the front brake caliper. Secure the brake caliper to the frame with a string etc., taking care not to bend the brake hose. ● Remove the front fender. ● Remove the turn signal lamp.
  • Page 223 ● Remove the front fork after loosening the front fork upper ① and lower clamp bolts② . ● N O T E Slightly loosen the front fork upper bolt ③ to facili- tate later disassembly. ● Remove the front fork upper bolt ③, O-ring ④, front fork inner spacer ⑤...
  • Page 224 ● Remove the dust seal ① and oil seal stopper ring ②. ② ● Separate the inner tube from the outer tube. ● Remove the following parts. ③ Oil seal ④ Slide metal ③ ⑤ Oil lock piece ④ The removed oil seal and slide metal should be replaced with new ones.
  • Page 225 ◉ INSPECTION □ FRONT FORK SPRING Measure the free length of the front fork spring. If the length is found shorter than the service limit, replace the spring. Service limit Front fork spring free length L 356 mm □ INNER TUBE AND OUTER TUBE Check the sliding of the inner tube, outer tube and damper rod ring for scratch, wear, bending, or other abnormal condition.
  • Page 226 ● With the oil lock piece fitted to the inner tube, assem- ble the inner tube to the outer tube. ● Apply SUPER GREASE“A”to the lip of the oil seal and install it into the outer tube using the front fork oil seal installer.
  • Page 227 ● Apply THREAD LOCK“1324”to the damper rod bolt ② ② ● With the damper rod held immovable, with the gasket ① ① fitted, tighten the damper rod bolt ②. Front fork damper rod bolt : 15~25 N∙m (1.5~2.5 kg∙m) THREAD LOCK “ 1324 ” Replace the gasket with a new one.
  • Page 228 ● Fit the O-ring to the front fork upper bolt and apply SUPER GREASE“A” . SUPER GREASE “ A ” Use a new O-ring to prevent oil leakage. ● Install the front fork to the motorcycle. ● Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket.
  • Page 229 STEERING      ...
  • Page 230 ◉ DISASSEMBLY ● Remove the front wheel. ● Remove the front fork. ● Remove the head lamp ①. ● Remove the steering lock ②and speedometer bracket ③. ● Remove the brake hose guide.
  • Page 231 ● With the nuts removed, remove the headlamp hous- ing. ● Remove the handlebars. ● Remove the steering stem head nut ①. ● Remove the steering stem upper bracket. ● Remove the steering stem nut ② using the special tool. ②...
  • Page 232 ● To remove the lower inner race, use a chisel like. ❖ Unless corrosion, damage or other abnormal condition is found, the bearing race need not be replaced. ❖ Once the lower inner race has been removed, replace it with a new one. ●...
  • Page 233 ● Press in the lower inner race ①. Bearing installer : 09913 - 80112 ● Apply SUPER GREASE“A”to the upper bearing, ② lower bearing and outer races prior to installing the ③ steering stem. SUPER GREASE A ● Install the upper inner race ② and dust cover ③. ●...
  • Page 234 ● Turn the steering stem lower bracket about five or six times to the left and right. ● Loosen the steering stem nut ¼ - ½ of a turn . N O T E This adjustment will vary from motorcycle to motor- cycle.
  • Page 235 ● Install the front wheel. N O T E Hold the front fork legs, move them back and forth and make sure that the steering is not loose.
  • Page 236 REAR WHEEL ◉ REMOVAL ● Remove the drive chain cover.
  • Page 237 ● Remove the rear brake caliper. ● Raise the rear wheel off the ground with a jack or block. ● Loosen the right drive chain adjuster nut ① and left drive chain adjuster nut ②. ● Disengage the drive chain from the rear sprocket. ●...
  • Page 238 ● Remove the rear brake panel ①. ● Remove the spacer ②. ● Remove the rear sprocket ③ with mounting drum from the rear wheel. N O T E Before separating the rear sprocket and mounting drum, slightly loosen the rear sprocket bolts. ●...
  • Page 239 ◉ INSPECTION WHEEL AXLE : Refer to page 7-9 WHEEL : Refer to page 7-9 WHEEL BEARING : Refer to page 7-9 □ REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and damage. Replace the rear wheel shock absorber if there is any- thing unusual.
  • Page 240 □ REAR SPROCKET MOUNTING DRUM BEARING ● Remove the bearing by using specical tool. Bearing remover(17mm) : 09923 - 73210 The removed bearing should be replaced with new one. ◉ REASSEMBLY Reassemble the rear wheel and rear brake in the reverse order of disassembly.
  • Page 241 □ REAR SPROCKET ● Tighten the rear sprocket nuts to the specified torque. Rear sprocket nut : 20~30 N∙m (2.0~3.0 kg∙m) ● Install the retainer to the mounting drum as shown. □ REAR WHEEL ● After the rear wheel install, tighten the rear axle nut ① to the specified torque.
  • Page 242 ● After installing the drive chain to the rear sprocket, adjust the drive chain. ● Tighten the right drive chain adjuster nut ① and left ● drive chain adjuster nut ②. ● Adjust the rear brake pedal free travel.
  • Page 243 REAR SHOCK ABSORBER ◉ REMOVAL ● Remove the right and left rear frame cover. ● Remove the right and left rear shock absorbers by removing their nuts.
  • Page 244 ◉ INSPECTION Inspect the rear shock absorber for damage and oil leakage. If any defects are found, replace the rear shock absorber with a new one. Do not attempt to disassemble the rear shock absorber. It is unserviceable. ◉ REMOUNTING ●...
  • Page 245 ◉ SPRING PRE-LOAD ADJUSTMENT ① ● Adjust the rear shock absorber spring pre-load. ② Rear shock absorber Standard spring length 199.8 mm Rear shock absorber Standard 1/5 position spring pre-load ① Rear shock absorber ② Pin spanner...
  • Page 246 SWINGARM ◉ REMOVAL ● Remove the rear wheel. ● Remove the exhaust pipe and mufflers.
  • Page 247 ● Remove the engine sprocket cover. ● Remove the swingarm pivot nut and washer. ● Remove the swingarm by removing the pivot shaft. ● Remove the rear brake hub from the swingarm. ● Remove the dust covers ①, washers ② and spacers ③.
  • Page 248 ● Remove the chain buffer ① from the swingarm. ◉ INSPECTION □ SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one. □ CHAIN BUFFER Inspect the chain buffer for wear and damage. If any defects are found, replace the chain buffer with a new one.
  • Page 249 □ SWINGARM PIVOT SPACERS AND DUST SEALS Inspect the swingarm pivot spacers and dust seals for damage. If any defects are found, replace the spacer with a new one. □ SWINGARM NEEDLE BEARINGS Insert the spacers into the needle bearings, rotate the spacer and check for abnormal noise and smooth rota- tion.
  • Page 250 8-1 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING 8 - 2 ……………………………………………………………………… SPECIAL TOOLS 8 - 16 ……………………………………………………………………………… TIGHTENING TORQUE 8 - 19 ……………………………………………………………………… SERVICE DATA 8 -21 ………………………………………………………………………………… WIRING DIAGRAM 8 -30 ……………………………………………………………………………...

  • Page 251: Troubleshooting

    SERVICING INFORMATION 8-2 TROUBLESHOOTING ⊙ MALFUNCTION CODE AND DEFECTIVECONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE NO FAULT noEr After engine running, if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 times test cycle, the code 0031 is indicated.
  • Page 252 8-3 SERVICING INFORMATION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE The sensor voltage should be the following. 0.1 V ≤Sensor output voltage Without the above rangefor6.25sec.and more,0117is indicated. Low Voltage P0117 Water temperature sensor, lead wire / coupler connection. Circuit sensor voltage...
  • Page 253 SERVICING INFORMATION 8-4 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, rate of fuel calibration remains less than Injection standard value (1.3) for 10 sec. and more, the code P0171 is Fuel P0171 Fuel indicated. Injection Shortage ECU, O2 sensor, Fuel pump, Fuel hose line Circuit...
  • Page 254 8-5 SERVICING INFORMATION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CHECK FOR CODE Motorcycle speed＜10km/h Water temperature＜20℃ IAP&TS pressure＞40kpa 20%＜TPS open angle＜100% Speedo sensor P0500 2,000rpm＜Engine speed ＜6,000rpm Malfunction If the above conditions are maintained for 32.5sec.and more, The code P0500 is indicated Speedo sensor, wiring/coupler connection to ECU After engine running, if idle speed is different to 500 rpm from the specified range in 25 seconds test cycle, the code 0505...
  • Page 255 SERVICING INFORMATION 8-6 ⊙ ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start or is hard Adjust. Tappet clearance out of adjustment. to start. Repair or replace. Worn valve guides or poor seating of valves. Adjust.
  • Page 256 8-7 SERVICING INFORMATION Complaint Symptom and possible causes Remedy 1. Tappet clearance out of adjustment. Adjust. Engine idles Poor seating of valves. Replace or repair. poorly. Defective valve guides. Replace. Worn down camshafts. Replace. Too wide spark plug gaps. Adjust or replace. Defective ignition coils.
  • Page 257 SERVICING INFORMATION 8-8 Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter Too large tappet clearance. Adjust. Weakened or broken valve springs. Replace. Worn tappet or cam surface. Replace. Worn and burnt camshaft journal. Replace. Noise seems to come from piston Worn down pistons or cylinders.
  • Page 258 8-9 SERVICING INFORMATION Remedy Complaint Symptom and possible causes Defective engine internal / electrical parts Engine runs Replace. Weakened valve springs. poorly Replace. Worn camshafts. high speed Adjust. Valve timing out of adjustment. range. Adjust. Too narrow spark plug gaps. Replace ECU.
  • Page 259 SERVICING INFORMATION 8-10 Complaint Symptom and possible causes Remedy Defective engine internal / electrical parts Engine Adjust. Loss of tappet clearance. lacks Replace. Weakened valve springs. power. Adjust. Valve timing out of adjustment. Replace. Worn piston rings or cylinders. Repair. Poor seating of valves.
  • Page 260 8-11 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Check with inspection Too much engine oil in the engine. Dirty or window, drain out excess oil. heavy Replace. Worn piston rings or cylinders. exhaust Replace. Worn valve guides. smoke. Replace. Cylinder wall scored or scuffed.
  • Page 261 SERVICING INFORMATION 8-12 ⊙ ELECTRICAL Complaint Symptom and possible causes Remedy Defective ignition coils or spark plug caps. Replace. No sparking or poor Defective spark plugs. Replace. sparking. Defective pick-up coil. Replace. Defective ECU. Replace. Defective RO switch. Replace. Open-circuited wiring connections. Check and repair.
  • Page 262 8-13 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy “Sulfation” acidic Not enough electrolyte. Add distilled water, if the battery has white powdery been damaged substance or spots “sulfation”has not advanced too on surfaces of cell far, and recharge. plates.
  • Page 263 SERVICING INFORMATION 8-14 CHASSIS Complaint Symptom and possible causes Remedy Steering feels too Adjust. Steering stem nut overtightened. heavy or stiff. Worn bearing or race in steering stem. Replace. Distorted steering stem. Replace. Not enough pressure in tires. Adjust. Steering oscillation. Replace.
  • Page 264 8-15 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking Refill to level mark. Not enough brake fluid in the reservoir. (FRONT and Air trapped in brake fluid circuit. Bleed air out. REAR) Pads worn down. Replace. Too much play on brake lever or pedal. Adjust.

  • Page 265: Special Tools

    SERVICING INFORMATION 8-16 SPECIAL TOOLS Special tools Part Number∙Part Name∙Description Part Number∙Part Name∙Description Special tools 09900-20101 09900-21109 Vernier Caliper Torque wrench Used to conveniently measure various dimensions. Measure torque of tightening. 09900-20201 09900-21304 Micrometer(0~25mm) V-block Used for precise measurement (00~25mm measure ranges). With using magnetic stand.
  • Page 266 8-17 SERVICING INFORMATION Part Number∙Part Name∙Description Part Number∙Part Name∙Description Special tools Special tools 09910-32812 09913-80112 Crankshaft installer Bearing installer Used to install the crankshaft in the crankcase. Used to drive bearing in. 09910-34510 09915-63310 Piston pin puller Compression gauge adapter Use to remove the piston pin.
  • Page 267 SERVICING INFORMATION 8-18 Part Number∙Part Name∙Description Part Number∙Part Name∙Description Special tools Special tools 09921-20200 09930-44510 Bearing remover(10mm) Rotor holder Used to remove oil seal or bearing. Widely used to lock rotary parts such as a flywheel magneto. 09921-20210 09940-10122 Bearing remover(12mm) Clamp wrench Used to remove oil seal or bearing.

  • Page 268: Tightening Torque

    8-19 SERVICING INFORMATION TIGHTENING TORQUE ENGINE STRENGTH N·m kgf·cm ITEM POSITION Remark (Ø) Spark plug (150 ~ 200) Crankcase bolt(M8) (180 ~ 280) Initial Cylinder head bolt(M8) Final Cylinder head bolt no.2(M8) Cylinder head cover bolt(M8) (180 ~ 280) Starter clutch bolt (230 ~ 280) Engine sprocket nut (800 ~ 1000)
  • Page 269 SERVICING INFORMATION 8-20 CHASSIS N∙m kg∙m ITEM Rear shock absorber fitting nut (Upper) 20 ~ 30 2.0 ~ 3.0 Rear shock absorber fitting nut (Lower) 35 ~ 55 3.5 ~ 5.5 Rear sprocket nut 20 ~ 30 2.0 ~ 3.0 Rear axle nut 90 ~ 140 9.0 ~ 14.0...
  • Page 270 8-21 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit : mm ITEM STANDARD LIMIT ——— Valve diam. ——— 19.0 ——— Valve clearance (When cold) 0.1~0.2 0.2~0.3 ——— ——— Valve guide to valve stem clearance 0.010~0.037 ——— 0.030~0.057 Valve stem deflection IN.
  • Page 271 SERVICING INFORMATION 8-22 CYLINDER + PISTON + PISTON RING Unit : mm ITEM STANDARD LIMIT Compression pressure 14~16 kg/cm (at 600 rpm) 12 kg/cm Piston to cylinder clearance 0.050~0.060 0.120 Cylinder bore 57.000~57.015 57.080 Piston diam. 56.945~56.960 56.880 (Measure at 15mm from the skirt end) ———...
  • Page 272 8-23 SERVICING INFORMATION CLUTCH Unit : mm ITEM STANDARD LIMIT Clutch cable play ——— Drive plate thickness 2.9~3.1 Drive plate claw width 11.8~12 11.0 ——— Driven plate distortion Clutch spring free length 29.5 TRANSMISSION + DRIVE CHAIN Unit : mm ITEM STANDARD LIMIT...

  • Page 273: Service Data

    SERVICING INFORMATION 8-24 SERVICE DATA ⊙ EI SENSORS SPECIFICATION ITEM IAP&T (Pressure function) sensor input voltage 4.9 ~ 5.1V IAP&T (Pressure function) sensor output voltage Approx. 1.5V at. idle speed TP sensor input voltage 4.8 ~ 5.2V TP sensor output voltage Closed Approx.
  • Page 274 8-25 SERVICING INFORMATION ⊙ THROTTLE BODY ITEM SPECIFICATION NOTE I.D. No. 13400H88 Bore size Idle rpm 1,500 ~ 1,700 rpm Throttle cable play 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) ⊙ FUEL INJECTOR + FUEL PUMP ITEM SPECIFICATION NOTE Ω...
  • Page 275 SERVICING INFORMATION 8-26 ⊙ ELECTRICAL Unit : mm (in) ITEM SPECIFICATION NOTE BTDC 10°/ 2,000 rpm and 28°/ 6,000 rpm Ignition timing Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Hot type CR7E Spark plug Standard type CR8E Cold type CR9E More than 8 (0.32) Spark performance...
  • Page 276 8-27 SERVICING INFORMATION WATTAGE Unit : W ITEM SPECIFICATION Head lamp 12VㅡH4 : 55W/60W Position lamp 12V – W5W License lamp LED TYPE Brake/Tail lamp LED TYPE Turn signal lamp 12V 10W x 4 Speedometer lamp LED TYPE Engine warning lamp LED TYPE LED TYPE Turn signal indicator lamp...
  • Page 277 SERVICING INFORMATION 8-28 SUSPENSION Unit : mm ITEM STANDARD LIMIT Front fork stroke ——— Front fork spring free length Front fork oil type ISO VIG46, JSK2001 ——— Front fork oil level ——— 170±2 ml Front fork oil capacity (each leg) ———...
  • Page 278 8-29 SERVICING INFORMATION TIRE ITEM STANDARD LIMIT Front 200Kpa(29psi) 200Kpa(33psi) Cold inflation tire pressure (Solo riding) Rear 200Kpa(29psi) 200Kpa(33psi) Front 200Kpa(29psi) 200Kpa(33psi) Cold inflation tire pressure (Dual riding) Rear 200Kpa(29psi) 200Kpa(33psi) Front ——— Tire tread depth Rear ——— FUEL + OIL NOTE ITEM SPECIFICATION...
  • Page 279 SERVICING INFORMATION 8-30 WIRING AND CABLE ROUTING...
  • Page 280 8-31 SERVICING INFORMATION...
  • Page 281 SERVICING INFORMATION 8-32...
  • Page 282 8-33 SERVICING INFORMATION...
  • Page 283 SERVICING INFORMATION 8-34...
  • Page 284 8-35 SERVICING INFORMATION...
  • Page 285 SERVICING INFORMATION 8-36...

  • Page 286: Wiring Diagram

    8-37 SERVICING INFORMATION WIRING DIAGRAM...
  • Page 287 1nd Ed.Dec.2020...

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