HYOSUNG Aquila 250 Service Manual
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HYOSUNG Aquila 250 Service Manual

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  • Page 1 SERVICE MANUAL...
  • Page 2 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. HYOSUNG MOTORS & MACHINERY INC. Overseas Technical Department � COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2000.

  • 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 look- ing 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. Apply THREAD LOCK “1324” . Data beside it indicates specified torque. Apply oil.

  • Page 6: Table Of Contents

    GENERAL INFORMATION CONTENTS 1 - 1 INFORMATION LABELS 1 - 1 GENERAL PRECAUTIONS 1 - 4 SERIAL NUMBER LOCATION 1 - 5 FUEL AND OIL RECOMMENDATIONS 1 - 6 BREAK-IN PROCEDURES CYLINDER CLASSIFICATION 1 - 6 EXTERIOR ILLUSTRATION 1 - 7 1 - 8 SPECIFICATIONS...

  • Page 7: General Precautions

    1-1 GENERAL INFORMATION WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. WARNING Indicates a potential hazard that could result in death or injury.
  • Page 8 GENERAL INFORMATION 1-2 CAUTION � If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent. � When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
  • Page 9 1-3 GENERAL INFORMATION HYOSUNG NOTE: Difference between photographs and actual motorcycles depends on the markets.

  • Page 10: Serial Number Location

    GENERAL INFORMATION 1-4 SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine seri- al number is located on the left upside of crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. ◉...

  • Page 11: Fuel And Oil Recommendations

    1- 5 GENERAL INFORMATION FUEL AND OIL RECOMMENDATION ◉ FUEL Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is recommended. ◉ ENGINE OIL ■ ENGINE OIL SPECIFICATION Classification system Grade SF or SG 10W-40 �...

  • Page 12: Break-In Procedures

    GENERAL INFORMATION 1- 6 BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN”before subjecting the engine to maximum stresses.

  • Page 13: Exterior Illustration

    1- 7 GENERAL INFORMATION EXTERIOR ILLUSTRATION Rear reflector Tail/Brake lamp License plate lamp Turn signal lamp(Rear) Turn signal lamp(Front) Passenger footrests Head lamp (WHEEL BASE) (LENGTH)

  • Page 14: Specifications

    GENERAL INFORMATION 1- 8 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2,270 mm Overall width ................800 mm Overall height ................1,090 mm Wheelbase ................1,500 mm Ground clearance ..............155 mm Unladen mass ................155 kg ENGINE Type ..................Four-stroke, DOHC, air-cooled and oil-cooled Number of cylinder ..............
  • Page 15 1- 9 GENERAL INFORMATION ELECTRICAL Ignition type ................Battery Ignition (CDI) Ignition timing ................13°B.T.D.C.at 2,000 rpm and 30°B.T.D.C.at 6,000 rpm Spark plug ................. CR8E Battery ..................12V 6Ah Fuse ..................15 A Head lamp .................. HI : 35W LO : 35W Position lamp ................
  • Page 16 PERIODIC MAINTENANCE CONTENTS 2 - 1 PERIODIC MAINTENANCE SCHEDULE 2 - 1 PERIODIC MAINTENANCE CHART LUBRICATION POINTS 2 - 2 MAINTENANCE PROCEDURES 2 - 3 2 - 3 VALVE CLEARANCE 2 - 5 SPARK PLUG 2 - 6 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2 - 6 AIR CLEANER 2 - 8...

  • Page 17: Spark Plug

    2-1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. CAUTION More frequent servicing should be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART ◉...

  • Page 18: Lubrication Points

    PERIODIC MAINTENANCE 2-2 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. ① Clutch lever holder ④ Brake lever holder ② Drive chain ⑤ Brake pedal pivot ③...

  • Page 19: Maintenance Procedures

    2-3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURE This section describes the service procedure for each section of the periodic maintenance. VALVE CLEARANCE NOTE: Inspect Initial 1,000 km and Every 4,000 km. CAUTION The clearance specification is for COLD state. The valve clearance specification is different for intake and exhause valves.
  • Page 20 PERIODIC MAINTENANCE 2-4 ● 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 21: Spark Plug

    2-5 PERIODIC MAINTENANCE ● Rotate the magneto rotor to set the rear cylinder’ s piston at TDC(Top Dead Center) of the compression stroke. (Rotate the rotor 285�counter-clockwise from the ｜ ｜ “ F”line, and until the “ R”line on the rotor is aligned with the center of hole on the crankcase.) ●...

  • Page 22: Air Cleaner

    PERIODIC MAINTENANCE 2-6 EXHAUSE PIPE NUTS AND MUFFLER MOUNTING BOLTS NOTE: Tighten Initial 1,000 km and Every 4,000 km. ● Tighten the exhaust pipe nuts ①, and muffler mount- ing bolts ② to the specified torque. ① Exhaust pipe nut : 18~28 N∙m (1.8~2.8 kg∙m) Muffler mounting bolt [ Front Cylinder ]...
  • Page 23 2-7 PERIODIC MAINTENANCE ● With the three of air cleaner cap mounting bolts ① removed, remove the air cleaner cap ①. ● Remove the air cleaner element ②. ② 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.

  • Page 24: Carburetor

    PERIODIC MAINTENANCE 2-8 CARBURETOR NOTE: Inspect Initial 1,000 km and Every 4,000 km. ◉ IDLE SPEED CAUTION Make this inspection when the engine is hot. ● Connect an engine tachometer to the high tension cord. Start up the engine and set its speed at anywhere ①...

  • Page 25: Clutch

    2-9 PERIODIC MAINTENANCE CLUTCH NOTE: Inspect Initial 1,000 km and Every 4,000 km. 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 26 PERIODIC MAINTENANCE 2-10 Oil should be changed while the engine is warm. Oil fil- ter replacement at the above intervals, should be together with the engine oil change. ● Keep the motorcycle upright. ● Place an oil pan below the engine, and drain the oil by removing the filter cap ①...

  • Page 27: Engine Oil Filter

    ◉ OIL FILTER INSTALLATION INSERTION DIRECTION CAUTION LUSTER MATERIAL When install the oil filter, necessarily, HYOSUNG character and 16510H05240 part s NO. install to- ward the outside, otherwise can damage the engine. WARNING HYOSUNG Engine oil and exhaust pipes can be hot enough to...

  • Page 28: Drive Chain

    TER only, since the other make s genuine filters and after-market parts may differ filtering perfor- mance and durability, which could cause engine damage or oil leaks. Hyosung motors genuine oil filter is also not usable for the motocycles. DRIVE CHAIN NOTE: Clean and Lubricate Every 1,000 km.
  • Page 29 2-13 PERIODIC MAINTENANCE ● Count out 21 pins (20 pitches) on the chain and mea- sure the distance between the two points. If the dis- tance exceeds the service limit, the chain must be replaced. Service limit Drive chain 20-pitch length 319.4 mm ●...

  • Page 30: Brake System

    PERIODIC MAINTENANCE 2-14 ● Wash the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. ● After washing and drying the chain, oil it with a engine oil. CAUTION � The standard drive chain is a RK-520DS Hyo- sung recommends that this standard drive chain should be used for the replacement.
  • Page 31 2-15 PERIODIC MAINTENANCE ◉ BRAKE PAD WEAR The extend of brake pad wear can be checked by observing the grooved limit � on the pad. When the wear exceeds the grooved limit, replace the pads with new ones. CAUTION Replace the brake pad as a set, otherwise braking �...
  • Page 32 PERIODIC MAINTENANCE 2-16 ● Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system. ● Close the air bleeder valve and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper line.
  • Page 33 2-17 PERIODIC MAINTENANCE NOTE: While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that Upper limit line there is always some fluid visible in the reservoir. ● Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the upper line.

  • Page 34: Steering

    PERIODIC MAINTENANCE 2-18 ◉ BRAKE LAMP SWITCH Adjust the rear brake lamp switch so that the brake lamp will come on just before pressure is felt when the brake pedal is depressed. STEERING NOTE : Inspect Initial 1,000 km and Every 4,000 km. Steering should be adjusted properly for smooth turning of handlebars and safe running.

  • Page 35: Tire

    150/80-15M/C 70S for rear. The use of tires other than those specified may cause instability. It is highly recommended to use a HYOSUNG Genuine Tire. CHASSIS BOLTS AND NUTS NOTE : Tighten Initial 1,000 km and Every 4,000 km.

  • Page 36: Compression Pressure

    PERIODIC MAINTENANCE 2-20 COMPRESSION PRESSURE The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compres- sion reading for each maintenance service.

  • Page 37: Oil Pressure

    2-21 PERIODIC MAINTENANCE OIL PRESSURE Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 1.3 ± 0.2 ㎏/㎠ (at 60 ℃∙4,000 rpm) If the oil pressure is lower or higher than the specification, the following causes may be considered. ◉...
  • Page 38 ENGINE CONTENTS ENGINE REMOVAL AND REINSTALLATION 3 - 1 ENGINE REMOVAL 3 - 1 3 - 6 ENGINE REINSTALLATION 3 - 8 ENGINE DISASSEMBLY 3 - 8 STARTER MOTER 3 - 9 CYLINDER HEAD COVER 3 - 13 PISTON 3 - 14 MAGNETO COVER MAGNETO ROTOR 3 - 14...

  • Page 39: Engine Removal And Reinstallation

    3-1 ENGINE ENGINE REMOVAL AND ① REINSTALLATION ENGINE REMOVAL NOTE: If the engine is dirtied, wash the machine with a suitable cleaner before removing the engine. ● Remove the front seat.(Refer to page 6-1) ● Remove the fuel tank.(Refer to page 4-1) ●...

  • Page 40: Clutch Cable

    ENGINE 3-2 ◉ CARBURETOR ● Remove the carburetor after removed the intake pipes. (Refer to page 4-4) ◉ CLUTCH CABLE ● Disconnect the clutch cable end out of clutch lever. ● Disconnect the clutch cable end out of clutch release arm.
  • Page 41 3-3 ENGINE [ Rear Cylinder ] ◉ ELECTRIC PARTS ● With take out the spark plug caps, remove the spark plug. [ Front Cylinder ] [ Rear Cylinder ] ● Remove the starter motor lead wire.
  • Page 42 ENGINE 3-4 ● Remove the engine ground lead wire ①. ① ● Disconnect the magneto coupler ②. ② ◉ ENGINE SPROCKET ● Remove the engine sprocket cover. ● Remove the breather hose.
  • Page 43 3-5 ENGINE ● With the bolt removed, disconnect the gearshift arm. ● Remove the left footrest. ● Flatten the lock washer. ● Remove the engine sprocket nut ① and washer. NOTE: When loosening the engine sprocket nut, depress the brake pedal. ①...

  • Page 44: Engine Reinstallation

    ENGINE 3-6 ● Support the engine using an engine jack. ● Remove the engine mounting nuts and bolts. ● Remove the engine from the frame. CAUTION Remove the carburetor when removing or installing the engine necessarily. When removing the carburetor , loosen the intake pipe mounting bolts at the same time.
  • Page 45 3-7 ENGINE ● Tighten the engine sprocket nut ① to the specified torque. Engine sprocket nut : 80~100 N∙m (8.0~10.0 kg∙m) NOTE: ① When tightening the engine sprocket nut, depress the rear brake pedal. ● Bend the lock washer securely. ●...

  • Page 46: Engine Disassembly

    ENGINE 3-8 ENGINE DISASSEMBLY STARTER MOTOR ● Remove the starter motor. ● Remove the gear position switch. ● Remove the contacts ① and springs ②. ② ① ● Remove the three union bolts.

  • Page 47: Cylinder Head Cover

    3-9 ENGINE CYLINDER HEAD COVER ● Remove the cylinder head cover. ● To set the piston at TDC(Top Dead Center). CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter-clockwise.
  • Page 48 ENGINE 3-10 ● With the three bolts removed, remove the cam chain guide NO.2. ● Remove the camshaft housing. ● Remove the camshaft (IN.∙EX.). ● Remove the C-ring.
  • Page 49 3-11 ENGINE ● Loosen the two cylinder head base cover nuts. ● Loosen the three cylinder head base nuts. ● Loosen the four cylinder head stud bolts. ● Remove the chain guide NO.1.
  • Page 50 ENGINE 3-12 ● 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 51: Piston

    3-13 ENGINE ● Remove the two cylinder base nuts and cylinder. CAUTION If tapping with the plastic hammer is necessary, do not break the fins. ● Remove the rear cylinder head and cylinder with the Rear cylinder same manner of the front cylinder head and cylinder removal.

  • Page 52: Magneto Cover

    ENGINE 3-14 MAGNETO COVER ● Remove the magneto cover. ● Remove in the order of spacer ①, shaft ②, starter idle gear ③. ① ② ③ MAGNETO ROTOR ● With the magneto rotor held immovable using the special tool, loosen the rotor nut. Conrod holder : 09910-20115 ●...

  • Page 53: Clutch Cover

    3-15 ENGINE ● Remove the key ①. ● Remove the starter driven gear ②. ① ② ● Remove the cam chain tensioner ③ and cam chain ④. ③ ④ CLUTCH COVER ● Remove the clutch release arm . ● Remove the clutch cover bolts. ●...

  • Page 54: Clutch

    ENGINE 3-16 CLUTCH ● With the primary drive gear held immovable, remove ① the clutch spring mounting bolts diagonally. ● Remove the disk pressure ①. ● Remove the clutch drive and driven plates. ● Flatten the lock washer ② ● With the clutch sleeve hub held immovable using special tool, remove the clutch sleeve hub nut.

  • Page 55: Primary Drive Gear

    3-17 ENGINE ● Remove the clutch sleeve hub and primary driven gear assembly ② . ① ② PRIMARY DRIVE GEAR ● With the magneto rotor held immovable using special tool, remove the primary drive gear nut. Conrod holder : 09910-20115 CAUTION This bolt has left-hand thread.

  • Page 56: Gearshift Shaft

    ENGINE 3-18 ● Remove the pin ● With the three screws loosened, remove the oil pump ① ② GEARSHIFT SHAFT ● Draw out the gearshift shaft ③ ● With the cam guide screws loosened, draw out the guide and lifter. ●...
  • Page 57 3-19 ENGINE ● Remove the crankcase securing bolts. ● Separate the crankcase into 2 parts, right and left, with a special tool. Crankcase separator : 09920-13120 CAUTION When separating the crankcase , necessarily, remove it after installed the special tool (Crankcase separator) on the side of clutch.

  • Page 58: Engine Component Inspection And Service

    ENGINE 3-20 ENGINE COMPONENT INSPEC- TION AND SERVICE CAUTION 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 origi- nal location during assembly.
  • Page 59 3-21 ENGINE ■ CAMSHAFT WEAR Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height �, which is to be measured with a micrometer.

  • Page 60: Valve Guide Installation

    ENGINE 3-22 ◉ 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 clearance Standard...
  • Page 61 3-23 ENGINE ● After fitting all valve guides, re-finish their guiding bores will a 4.5 mm valve guide reamer and valve guide reamer handle . Be sure to clean and oil the ② guides after reaming. 4.5 mm valve guide reamer : 09916-33210 ①...
  • Page 62 ENGINE 3-24 If either requirement is not met, correct the seat by ser- vicing it as follows. Standard Valve seat width � 0.9~1.1 mm ◉ VALVE SEAT SERVICING 0。 The valve seats for both intake and exhaust valves are 15。 angled to present two bevels, 15�and 45�...

  • Page 63: Valve Spring

    3-25 ENGINE 4. After the desired seat position and width is achieved, use be 45�cutter very lightly to clean up any burrs caused by the previous cutting operations. DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth fin- ish and not a highly polished or shiny finish.

  • Page 64: Cam Chain Tension Adjuster

    ENGINE 3-26 ◉ CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clear- ance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.
  • Page 65 3-27 ENGINE ◉ CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear, damage and kinked or bind- ing 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 66: Piston Ring End Gap Inspection

    ENGINE 3-28 ◉ 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...
  • Page 67 3-29 ENGINE 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 RINGS ■ Oversize piston ring The following two types of oversize piston ring are used. They bear the following identification numbers.
  • Page 68 ENGINE 3-30 ◉ CONROD DEFLECTION INSPECTION Move the small end sideways while holding the big end immovable in thrust direction. Measure the amount of deflection. Turn the conrod and see if it moves smoothly without play and noise. This method can check the extent of wear on the parts of the conrod’...

  • Page 69: Starter Clutch

    3-31 ENGINE ◉ MAGNETO COVER ■ MAGNETO INSPECTION(Refer to page 5-4) ① ■ DISASSEMBLY ● Remove the stator ①. ◉ 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).

  • Page 70: Starter Driven Gear

    ENGINE 3-32 ◉ STARTER DRIVEN GEAR ■ STARTER DRIVEN GEAR BUSHING Install the starter driven gear bushing ① and gear ② ② onto the crankshaft and turn the starter driven gear by ① hand. Inspect the starter driven gear bushing for smooth rotation and any abnormal noise.
  • Page 71 3-33 ENGINE ◉ 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...
  • Page 72 ENGINE 3-34 ◉ 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 73 3-35 ENGINE ◉ TRANSMISSION ■ INSPECTION ★ GEAR-SHIFTING FORK Using a thickness gauge, check the clearance between in the groove of its gear and shifting fork. The clearance for each of the three shifting forks plays an important role in the smoothness and positiveness of shifting action.
  • Page 74 ENGINE 3-36 CAUTION � Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded Thrust and a new circlip must be installed. � When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft.
  • Page 75 3-37 ENGINE ◉ CRANKCASE play play ■ 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. Replace the bearing in the following procedure if there is anything unusual.
  • Page 76 ENGINE 3-38 ★ LEFT CRANKCASE BEARING ● Remove the oil seals ① Oil seal remover : 09913-50121 ② ● Remove the bearing retainer. ● Remove the bearings ③, Bearing remover(17 mm) : 09923-73210 ④ Bearing remover(20~35 mm) : 09923-74510 ⑤ ③...

  • Page 77: Engine Reassembly

    3-39 ENGINE ★ LEFT CRANKCASE BEARING ● Drive in the bearings ① Bearing installer : 09913-70122 Bearing installer : 09913-76010 ② ③ ● Install the oil seals ● Apply SUPER GREASE “A”on the lip of oil seal. SUPER GREASE “A” ④...
  • Page 78 ENGINE 3-40 ◉ TRANSMISSION ● Install the transmission. ◉ GEARSHIFT CAM AND GEARSHIFT FORKS ● Install the gearshift NO.1 ①, NO.2 ②, and NO.3 ③. ⑤ ● Install the gearshift cam ④, and gearshift fork shaft ⑥ ⑤, ⑥. ● Install the oil pump idle gear shaft ⑦. ①...
  • Page 79 3-41 ENGINE ● Install the crankcase. ● Install the crankcase bolts. Crankcase bolt : 8~12 N∙m(0.8~1.2 kg∙m) NOTE : � After the crankcase bolts have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly. � If these shafts do not rotate smoothly, try to free it by tapping with a plastic hammer.
  • Page 80 ENGINE 3-42 ■ GEARSHIFT CAM DRIVEN GEAR ● When installing the gearshift into the cam driven gear, the big shoulder � face toward outside as shown in figure. ● Install the cam guide and pawl lifter. When installed, apply the THREAD LOCK “1324”to the securing screw.
  • Page 81 3-43 ENGINE ◉ PRIMARY DRIVE GEAR ● Put in the oil pump driven gear, and install the circlip. CAUTION When installing the oil pump to the crankcase, turn the pump gear and check that rotation is smooth by the hand. ◉...
  • Page 82 ENGINE 3-44 ● Install the primary drive gear and NO.2 gear to the crankshaft, put in the key to the key groove. Align the key groove and mark. CAUTION When installing the NO.2 gear, install so that the mark on the gear align the key groove as shown in figure.
  • Page 83 3-45 ENGINE CLUTCH ② ● Install the clutch sleeve hub ①, lock washer ② and clutch sleeve hub nut. ① ● Install the clutch sleeve hub nut, and tighten it to the specified torque using the special tool. Clutch sleeve hub holder : 09920-53710 Clutch sleeve hub nut : 30~50 N∙m(3.0~5.0 kg∙m) ●...
  • Page 84 ENGINE 3-46 ● Install the clutch release rack ①, bearing ② and washer ③. ② ③ ① ● Install the clutch pressure plate ④, clutch springs and clutch spring mounting bolts. ● Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern.
  • Page 85 3-47 ENGINE ● Install the clutch release arm as following: ① Turn the clutch release shaft toward(This time, Stopper screw mark on the shaft align outside contact line the stopper screw) the right. Clutch release Release camshaft ② Install that the cable connecting center line of the arm bolt notch mark clutch release arm align matching mark rightside of...
  • Page 86 ENGINE 3-48 ◉ MAGNETO ROTOR ● Fit the key in the key slot on the crankshaft. ● With the magneto rotor install the starter clutch, it install the crankshaft. ● Apply a small quantity of THREAD LOCK “1324”to the threaded parts of crankshaft. THREAD LOCK “1324”...

  • Page 87: Piston Ring

    3-49 ENGINE ◉ MAGNETO COVER ● Install the new gasket and dowel pin. ● Apply oil to the each gears, bearing and starter clutch. ● Install the magneto cover and tighten the magneto cover bolts. Magneto cover bolt : 8~12 N∙m(0.8~1.2 kg∙m) ◉...

  • Page 88: Cylinder Head

    ENGINE 3-50 ◉ CYLINDER ● Apply BOND “1215” to the parting line of crankcase. BOND “1215” ● Place the dowel pin ① and new gasket on the ① crankcase. CAUTION Make sure to replace the gasket with a new one. ●...
  • Page 89 3-51 ENGINE ● Tighten the cylinder head base nuts. Cylinder head base nut : 7~11 N∙m(0.7~1.1 kg∙m) ● Tighten the two cylinder head base cover nuts. ● Install the tappet and shim. CAUTION Tappet With fit the tappet, it should be replaced if turn not smoothly by the hand.
  • Page 90 ENGINE 3-52 ◉ CAMSHAFT ASSEMBLY ● Distinguish the “EX”mark for the exhaust camshaft, the “IN”mark for the intake camshaft. Be distinguished always each camshaft what has notch at the rightside end and leftside end of it. ● When installing the camshaft and cam sprocket, apply a small quantity THREAD LOCK “1324”...
  • Page 91 3-53 ENGINE ● The notch mark “─”of exhaust camshaft should be aligned with the plane of cylinder head. At that time, the “2” arrow of exhaust camshaft sprock- et should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into camchain.
  • Page 92 ENGINE 3-54 CAUTION The timing chain is installed to the all of three sprocket. Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely. 16 Pin Notch mark Exhaust Intake [Front cylinder] 16 Pin Notch mark Exhaust...
  • Page 93 3-55 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” “ B” “C”...
  • Page 94 ENGINE 3-56 ● Get out the pushrod for the front to turn the lock shaft handle in counter-clockwise ( ). ● Turn the crankshaft about 10 times counter-clock- wise ( ) on the basis of the magneto rotor. ● If the valve clearance is within standard after measured the valve clearance, begin the next operation.
  • Page 95 3-57 ENGINE ◉ SPARK PLUG ● Install the spark plug.(Refer to page 2-5) ● Install the rear cylinder head and cylinder with the same manner which installed the front cylinder head and cylinder. Front Cylinder Rear Cylinder ◉ GEAR POSITION SWITCH ●...

  • Page 96: Fuel System

    FUEL SYSTEM CONTENTS 4 - 1 FUEL TANK / FUEL COCK 4 - 2 FUEL PUMP 4 - 3 CARBURETOR CAUTION Gasoline must be handed carefully in an area well ventilated and away from fire or sparks.
  • Page 97 4-1 FUEL SYSTEM FUEL TANK / FUEL COCK ◉ REMOVAL WARNING Gasoline is very explosive. Extreme care must be taken. ● Remove the front seat. (Refer to page 6-1) ● Remove the fuel tank mounting nut and bolt, and take off the hooks. ●...

  • Page 98: Fuel Pump

    FUEL SYSTEM 4-2 ◉ REMOUNTING Remount the fuel tank and fuel cock in the reverse or- der of removal. WARNING � Gaskets ① and ② must be replaced with new ② ones to prevent fuel leakage. � Tighten the fuel cock bolts evenly. ①...
  • Page 99 4-3 FUEL SYSTEM CARBURETOR ITEM SPECIFICATION ITEM SPECIFICATION Carburetor type MIKUNI BDS 26 TYPE (DOUBLE) Needle jet (N.J.) ф 26 Bore size Pilot jet (P.J) I.D. NO. HJ82 Throttle value (TH.V.) # 1:0.9, # 2:0.9, # 1:0.9, # 2:0.9, Idle rpm 1,450�1,550 rpm By pass (B.P.)
  • Page 100 FUEL SYSTEM 4-4 ◉ LOCATION OF CARBURETOR I.D. The carburetor I.D. is stamped on the location ① on the carburetor as shown in the right photo. ① ◉ REMOVAL ● Remove the fuel tank. (Refer to page 4-1) ● Remove the fuel hose. ●...
  • Page 101 4-5 FUEL SYSTEM ● Remove the spring ① and piston valve ② along with diaphragm ③. ③ ② ① ● Remove the jet needle cap ④, spring ⑤, retainer ⑥, ④ and jet needle ⑦. ⑤ ⑥ ⑦ ● Remove the float chamber body ⑧. ⑧...
  • Page 102 FUEL SYSTEM 4-6 ● Remove the valve seat ①. ① ● Remove the main jet ②, jet holder ③ and pilot jet ④. ③ ④ ② ● Remove the throttle cable bracket ⑤. ⑤ ● Remove the pilot screw ⑥ with count and tighten the number of turn.

  • Page 103: Float Height Adjustment

    4-7 FUEL SYSTEM ◉ CLEANING ● Clean all jets by using compressed air. ● After cleaning, reassemble the carburetor with new seals and gaskets. ◉ FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Measure the float height � while the float arm is just contacting the needle valve using vernier calipers.
  • Page 104 FUEL SYSTEM 4-8 ● Fit the seal rings securely to the float chamber and ① install the float chamber to the throttle body. ● Install the eight screw ①. ● Install the jet needle with the pin ② on the spacer securely engaged with the hole ③...
  • Page 105 4-9 FUEL SYSTEM CAUTION Never adjust “CO adjust screw”� of the carbure- tor. If adjust at discretion, have a bad influence upon output of the engine as the two carburetor is disharmonious. � ● After the assembly and installation on the engine have been completed, perform the following adjus- ment.

  • Page 106: Electrical System

    ELECTRICAL SYSTEM CONTENTS 5 - 1 LOCATION OF ELECTRICAL COMPONENTS 5 - 3 IGNITION SYSTEM 5 - 7 CHARGING SYSTEM 5 - 11 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 5 - 15 SWITCHES 5 - 16 LAMP 5 - 18 BATTERY 5 - 21 FUEL SYSTEM...

  • Page 107: Location Of Electrical Components

    5-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS ① ③ ④ ② ① Battery ④ Front brake lamp switch ② Turn signal relay ③ Fuse ⑥ ⑤ ⑤ Rear brake lamp switch ⑥ Starter motor...
  • Page 108 ELECTRICAL SYSTEM 5-2 ⑦ ⑪ ⑩ ⑧ ⑨ ⑦ Ignition coil (NO.1 & NO.2) ⑧ C.D.I Unit ⑨ Regulator / Rectifier ⑩ Battery plus terminal CAUTION ⑪ Battery minus terminal Be sure not to misassem- ble the position of battery plus &...

  • Page 109: Ignition System

    5-3 ELECTRICAL SYSTEM IGNITION SYSTEM is started as the battery discharged ignition system without a contact point. The battery ignition system is composed a rotor with five rotor tip, the D.C CDI, the ignition coil and battery. Ignite after permit signal at ignition timing of pick-up as electric energy of this battery, occur the 1st electric current.
  • Page 110 ELECTRICAL SYSTEM 5-4 ◉ INSPECTION � MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. Pick-up coil G - L Approx 90�110 Ϊ Charging coil Y - Y Approx 0.6�0.9 Ϊ Pocket Tester : 09900 - 25002 CAUTION When mounting the stator on the magneto cover, apply a small quantily of THREAD LOCK “1324...
  • Page 111 5-5 ELECTRICAL SYSTEM CAUTION � Pay caution as the numerical value differs a little according to the tester. � Please remind that there may be defect which can not be identified even though the measurement by using the tester indicates a low voltage. ㏀...
  • Page 112 ELECTRICAL SYSTEM 5-6 � IGNITION COIL (Checking with Pocket Tester) ● A pocket tester or an ohm meter may be used, instead of the electro tester. In either case, the igni- tion coil is to be checked for continuity in both prima- ry and are secondary windings.

  • Page 113: Battery

    5-7 ELECTRICAL SYSTEM CHARGING SYSTEM The circuit of the charging system is indicated in figure, which is composed of the AC generator, regulator / rec- tifier unit and battery. The AC current generated from the AC generator is converted by the rectifier and is turned into the DC current, then it charges the battery.
  • Page 114 ELECTRICAL SYSTEM 5-8 When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and the voltage between points � and � of the regulator according becomes high, and when it reaches the adjusted voltage of the control unit, consequently the control unit becomes “ON”condition. On the “ON”condition of the control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become “ON”condition.
  • Page 115 5-9 ELECTRICAL SYSTEM ◉ INSPECTION � CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage between the battery terminal � and �. If the tester reads under 13.5 V or over 16.0 V, check the AC generator no-load performance and regulator / rectifier.
  • Page 116 ELECTRICAL SYSTEM 5-10 ★ REGULATOR / RECTIFIER Ϊ Using the pocket tester (X 1 range), measure the resistance between the lead wires in the following table. If the resistance checked is incorrect, replace the regulator / rectifier. ㏀ Unit : �...

  • Page 117: Starter System And Side Stand Ignition Interlock System

    5-11 ELECTRICAL SYSTEM 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 position swith, C.D.I unit, side stand switch, gear position 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 118 ELECTRICAL SYSTEM 5-12 � TRANSMISSION : Neutral - ON Side stand - Down ( OFF ) � TRANSMISSION : Neutral - OFF Side stand - Up ( ON ) is equipped with the side stand ignition interlock system. 1. If the transmission is in neutral, you can start the engine regardless of clutch lever and side stand. 2.

  • Page 119: Starter Motor Inspection

    5-13 ELECTRICAL SYSTEM ◉ STARTER MOTOR REMOVAL AND DISASSEMBLY ● Disconnect the starter motor lead wire ①. (Refer to page 3-3) ① ● With loosen the bolt ②, remove the starter motor. (Refer to page 3-8) ● Disassemble the starter motor. ②...
  • Page 120 ELECTRICAL SYSTEM 5-14 � STARTER MOTOR REASSEMBLY Reassembly the starter motor. Pay attention to the following points : ● Reassembly the starter motor as shown in the illustration. ● Align the mark ① on the housing with the line ② on the housing end.

  • Page 121: Switches

    5-15 ELECTRICAL SYSTEM ● Apply SUPER GREASE “A”to the O-ring ① and remount the starter motor. ① SUPER GREASE “ A ” SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respectiveswitch assemblies with new ones.

  • Page 122: ◉ Headlamp

    ELECTRICAL SYSTEM 5-16 LAMP ◉ HEADLAMP ◉ TURN SIGNAL LAMP ◉ TAIL / BRAKE LAMP...

  • Page 123: Combination Meter

    5-17 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 respec- tive part.

  • Page 124: Battery

    ELECTRICAL SYSTEM 5-18 BATTERY ◉ CAUTION OF BATTERY TREATMENT The battery should be well taken care of because it emits flammable gas. If you don’ t follow the instruction in the below, there may be a explosion and severe accident. Therefore, please pay attention to the following points.
  • Page 125 5-19 ELECTRICAL SYSTEM Seal ③ Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery’ s electrolyte filler holes, holding the container firmly so that it cloes not fall. Take precaution not to allow any of the fluid to spill. CAUTION There may be a case which can t pour the elec- trolyte if you put it into electrolyte container...

  • Page 126: Battery Installation

    ELECTRICAL SYSTEM 5-20 ⑤ Separation of electrolyte container After confirming that you entered the electrolyte into bat- tery completely, remove the electrolyte containers from the battery. CAUTION Draw the empty receptacle out slowly because there may be a chance which remaining elec- trolyte vaporize.

  • Page 127: Fuel System

    5-21 ELECTRICAL SYSTEM ◉ ASSISTANCE RECHARGING Use the battery that is maded after 2 years as the main- Assistance Recharging tenance free battery. Standard 0.7 A ×5~10 hours Use the battery at condition of the high temperature. Fast Assistance recharging to the following points. 3A ×...
  • Page 128 CHASSIS CONTENTS EXTERIOR PARTS 6- 1 FRAME COVER 6- 2 REAR FRAME COVER 6- 4 6 - 6 FRONT WHEEL FRONT BRAKE 6- 10 6 - 17 HANDLEBARS 6 - 19 FRONT FORK 6 - 26 STEERING REAR WHEEL 6- 32 REAR BRAKE 6- 39 REAR SHOCK ABSORBER...

  • Page 129: Exterior Parts

    6-1 CHASSIS EXTERIOR PARTS ◉ FRONT FENDER ● With the bolts removed, remove the front fender. ◉ FRONT SEAT ● Remove the front seat with the ignition key. ◉ REAR SEAT ● With the bolts removed, remove the rear seat.

  • Page 130: Frame Cover

    CHASSIS 6-2 FRAME COVER ◉ RIGHT FRAME COVER ● Remove the screw ①. ● With the hook ②, ③ removed, remove the right frame cover. ③ ② ①...
  • Page 131 6-3 CHASSIS ◉ RIGHT REAR FRAME COVER ● Remove the right frame cover. ● With the bolts ① removed, remove the right rear ① frame cover. ◉ LEFT FRAME COVER ④ ③ ● Remove the screw ②. ● Remove the hook ③, ④. ②...

  • Page 132: Rear Frame Cover

    CHASSIS 6-4 REAR FRAME COVER ● Remove the front and rear seats.(Refer to page 6-1) ● Remove the frame covers.(Refer to page 6-2 3) ● Remove the C.D.I unit ① and rectifier / regulator ②. ② ①...
  • Page 133 6-5 CHASSIS ● Disconnect the rear turn signal lamp couplers and rear combination lamp coupler. ● With the four bolts removed, remove the rear frame cover.

  • Page 134: Front Wheel

    CHASSIS 6-6 FRONT WHEEL ◉ REMOVAL ● Loosen the axle pinch bolt ①. ● Loosen the front axle ②. ② ● Raise the front wheel off the ground with a block or jack. CAUTION When using a jack, take care not to cause ①...
  • Page 135 6-7 CHASSIS ● Remove the brake disc. ◉ 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...
  • Page 136 CHASSIS 6-8 � WHEEL BEARING REMOVAL ● Remove the wheel bearing by using the special tool. Wheel bearing remover : 09941 - 50111 CAUTION The removed bearing should be replaced with new ones ◉ REASSEMBLY Reassemble the front wheel in the reverse order of removal and disassembly.
  • Page 137 6-9 CHASSIS ● Tighten the front axle ① and axle pinch bolt ② to the specified torque. ① 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) ②...

  • Page 138: Front Brake

    CHASSIS 6-10 FRONT BRAKE WARNING � 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 chil- dren.

  • Page 139: Brake Fluid Replacement

    6-11 CHASSIS CAUTION 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 2-15 ◉...

  • Page 140: Caliper Inspection

    CHASSIS 6-12 ● Remove the dust seal ① and piston seal ②. CAUTION � Care not to cause scratch on the cylinder bore. � Do not reuse the piston seal and dust seal that have been removed. ② ① ◉ CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages.

  • Page 141: Brake Disc Inspection

    6-13 CHASSIS ● Apply SILICONE GREASE to the brake caliper hold- SILICONE GREASE ● Install the brake pads. (Refer to page 2-15) ● Tighten the caliper mounting bolts ①. ● With the hose end seated to the stopper, tighten the union bolt ②.

  • Page 142: Master Cylinder Disassembly

    CHASSIS 6-14 ◉ MASTER CYLINDER DISASSEMBLY ● Drain brake fluid the master cylinder. ● Disconnect the brake lamp switch lead wire coupler. ● Remove the union bolt ①. ① CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts.

  • Page 143: Master Cylinder Inspection

    6-15 CHASSIS ● Detach the dust seal boot ① and remove the circlip. ● Pull out the piston/cup set ② and spring ③. ③ ② ① ◉ 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 144 CHASSIS 6-16 ● Apply SUPER GREASE “A”to the brake lever pivot. SUPER GREASE “ A ” ● When remounting the master cylinder onto the han- dlebars, align the master cylinder holder’ s mating ① surface ① with punch mark ② on the handlebar and tighten the upper clamp bolt first.

  • Page 145: Handlebars

    6-17 CHASSIS HANDLEBARS ◉ HANDLEBARS RIGHT SIDE PARTS REMOVAL ● Remove the right handlebar switches. ● Disconnect the brake lamp switch lead wires and ① remove the master cylinder. (Refer to page 6-14) ● Remove the handlebar balancer ① and grip ②. ②...
  • Page 146 CHASSIS 6-18 NOTE: The gap ① between the handlebar clamp and holder should be even. ① ① ● Align the mating face of clutch lever holders with the respective punch marks and tighten the bolt. ● Install the brake master cylinder. (Refer to page 6- 15).

  • Page 147: Front Fork

    6-19 CHASSIS FRONT FORK ◉ DISASSEMBLY ● Remove the front wheel. (Refer to page 6-6) ● Remove the brake caliper. (Refer to page 6-11) CAUTION Secure the brake caliper to the frame with a string etc., taking care not to bend the brake hose. ●...
  • Page 148 CHASSIS 6-20 ● Remove the front fork after loosening the front fork ③ upper ① and lower ② clamp bolts . ① NOTE: Slightly loosen the front fork upper bolt ③ to facili- tate later disassembly. ② ● Remove the front fork upper bolt ③, O-ring ④, front fork inner spacer ⑤...
  • Page 149 6-21 CHASSIS ● Remove the dust seal ① and oil seal stopper ring ②. ① ② ● Separate the inner tube from the outer tube. ● Remove the following parts. ③ Oil seal ④ Slide metal ⑤ Oil lock piece ③...
  • Page 150 CHASSIS 6-22 ◉ 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 � � 356 mm �...
  • Page 151 6-23 CHASSIS ● 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 152 CHASSIS 6-24 ● Apply THREAD LOCK “1324”to the damper rod bolt ②. ② ● With the damper rod held immovable, with the gasket fitted, tighten the damper rod bolt ②. ① Front fork damper rod bolt : 15~25 N∙m (1.5~2.5 kg∙m) THREAD LOCK “...
  • Page 153 6-25 CHASSIS ● Fit the O-ring to the front fork upper bolt and apply SUPER GREASE “A” . SUPER GREASE “ A ” CAUTION Use a new O-ring to prevent oil ieakage. ● Install the front fork to the motocycle. ●...

  • Page 154: Steering

    CHASSIS 6-26 STEERING ◉ DISASSEMBLY ● Remove the front wheel. (Refer to page 6-6) ● Remove the front fork. (Refer to page 6-19) ● Remove the cable guide.
  • Page 155 6-27 CHASSIS ● With the nuts removed, remove the headlamp hous- ing. ● Remove the handlebars. (Refer to page 6-17) ● Remove the steering stem head nut ①. ● Remove the steering stem upper bracket. ① ● Remove the steering stem nut ② using the special tool.
  • Page 156 CHASSIS 6-28 ● To remove the lower inner race, use a chisel like. CAUTION � 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 157 6-29 CHASSIS ● Press in the lower inner race ①. Bearing installer : 09913 - 80112 ① ● Apply SUPER GREASE “A”to the upper bearing, ② lower bearing and outer races prior to installing the ③ steering stem. SUPER GREASE A ●...
  • Page 158 CHASSIS 6-30 ● Turn the steering stem lower bracket about five or six times to the left and right. ● Loosen the steering stem nut ¼ ¼ - ½ ½ of a turn �. NOTE: � This adjustment will vary from motorcycle to motor- cycle.
  • Page 159 6-31 CHASSIS ● Install the cable guide. ● Install the front wheel. (Refer to page 6-8) NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose.

  • Page 160: Rear Wheel

    CHASSIS 6-32 REAR WHEEL ◉ REMOVAL ● Remove the drive chain cover.
  • Page 161 6-33 CHASSIS ● Remove the rear brake adjusting nut ①, spring ② and washer ③. ② ③ ① ● Raise the rear wheel off the ground with a jack or block. ● Loosen the drive chain adjuster , right and left. ●...
  • Page 162 CHASSIS 6-34 ● Remove the rear brake panel (Refer to page 6-39) ① ● Remove the spacer ● Remove the rear sprocket with mounting drum from the rear wheel. ② ④ NOTE: Before separating the rear sprocket and mounting drum, slightly loosen the rear sprocket bolts. ●...
  • Page 163 6-35 CHASSIS ◉ INSPECTION WHEEL AXLE : Refer to page 6-7 WHEEL : Refer to page 6-7 WHEEL BEARING : Refer to page 6-7 REAR SPOROCKET MOUNTING DRUM BEARING : Refer to page 6-7 BRAKE DRUM : Refer to page 6-40 �...
  • Page 164 CHASSIS 6-36 � REAR SPROCKET MOUNTING DRUM BEARING ● Remove the bearing by using specical tool. Bearing remover(17mm) : 09923 - 73210 CAUTION The removed bearing should be replaced with new one. ◉ REASSEMBLY Reassemble the rear wheel and rear brake in the reverse order of disassembly.
  • Page 165 6-37 CHASSIS � REAR SPROCKET ● Tighten the rear sprocket nuts to the specified torque. Rear sprocket nut : 22~35 N∙m (2.2~3.5 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 166 CHASSIS 6-38 ● After installing the drive chain to the rear sprocket, adjust the drive chain. ● Tighten both chain adjusting nuts securely. ● Adjust the rear brake pedal free travel. (Refer to page 2-17)

  • Page 167: Rear Brake

    6-39 CHASSIS REAR BRAKE ◉ DISASSEMBLY ● Remove the rear wheel. (Refer to page 6-32) ● Remove the brake panel.
  • Page 168 CHASSIS 6-40 ● Remove the brake shoes. ● Remove the rear brake cam lever ① and rear brake cam ② by removing nut. ② ① ● Remove the washer ③ and O-ring ④. ③ ④ ◉ INSPECTION � BRAKE DRUM Inspect the brake drum and measure the brake drum I.D.
  • Page 169 6-41 CHASSIS � BRAKE SHOES Check the brake shoe wear (Refer to page 2-17) and decide whether it should be replaced or not. CAUTION Replace the brake shoes as a set, otherwise brak- ing performance will be adversely affected. ◉ REASSEMBLY �...
  • Page 170 CHASSIS 6-42 ● Tighten the brake cam lever nut to the specified torque. Rear brake cam lever nut : 8~12 N∙m (0.8~1.2 kg∙m) ● Install the rear wheel. (Refer to page 6-36) ● Adjust the rear brake pedal free travel. (Refer to page 2-17)

  • Page 171: Rear Shock Absorber

    6-43 CHASSIS REAR SHOCK ABSORBER ◉ REMOVAL ● Remove the right and left rear frame cover. (Refer to page 6-2) ● Remove the right and left rear shock absorbers by removing their nuts.
  • Page 172 CHASSIS 6-44 ◉ 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. CAUTION Do not attempt to disassemble the rear shock absorber. It is unserviceable. ◉...

  • Page 173: Swingarm

    6-45 CHASSIS SWINGARM ◉ REMOVAL ● Remove the rear wheel. (Refer to page 6-32) ● Remove the exhaust pipe and mufflers. (Refer to page 3-2)
  • Page 174 CHASSIS 6-46 ● 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 ①...
  • Page 175 6-47 CHASSIS ● Remove the chain buffer ① from the swingarm. ① ◉ 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 176 CHASSIS 6-48 � 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 178: Servicing Information

    SERVICING INFORMATION CONTENTS 7 - 1 TROUBLESHOOTING 7 - 8 SPECIAL TOOLS 7 - 11 TIGHTENING TORQUE 7 - 13 SERVICE DATA 7 - 20 WIRE AND CABLE ROUTING WIRING DIAGRAM 7 - 24...

  • Page 179: Troubleshooting

    7-1 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard 1. Valve clearance out of adjustment. Adjust. to start. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
  • Page 180 SERVICING INFORMATION 7-2 Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from transmission 1. Gears worn or rubbing. Replace. 2. Badly worn splines. Replace. 3. Primary gears worn or rubbing. Replace. 3. Badly worn bearings. Replace. Slipping clutch.
  • Page 181 7-3 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. 1. Loosen of valve clearance. Adjust. 2. Weakened valve springs. Replace. 3. Valve timing out of adjustment. Adjust. 4. Worn piston ring or cylinder. Replace. 5. Poor seating of valves. Repair or replace.
  • Page 182 SERVICING INFORMATION 7-4 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective CDI unit. Replace. Spark plug soon 1. Mixture too rich. Adjust carburetor. become fouled with 2.
  • Page 183 7-5 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy “Sulfation” acidic 1. Not enough electrolyte. Add distilled water, if the battery white powdery has not been damaged and substance or spots “sulfation”has not advanced on surfaces of too far, and recharge. cell plates.
  • Page 184 SERVICING INFORMATION 7-6 CHASSIS Complaint Symptom and possible causes Remedy Steering feels too 1. Steering stem nut overtightened. Adjust. heavy or stiff. 2. Worn bearing or race in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust.
  • Page 185 7-7 SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Poor braking 1. Not enough brake fluid in the reservoir. Refill to level mark. (FRONT and REAR) 2. Air trapped in brake fluid circuit. Bleed air out. 3. Pads worn down. Replace.

  • Page 186: Special Tools

    SERVICING INFORMATION 7-8 SPECIAL TOOLS Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 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 187 7-9 SERVICING INFORMATION Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 09913-80112 09910-32812 Bearing installer Crankshaft 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 188 SERVICING INFORMATION 7-10 Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 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 189: Tightening Torque

    7-11 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N∙m kg∙m Magneto rotor nut 50 ~ 60 5.0 ~ 6.0 Magneto cover bolt 8 ~ 12 0.8 ~ 1.2 Muffler mounting bolt 20 ~ 30 2.0 ~ 3.0 Exhaust pipe nut 18 ~ 28 1.8 ~ 2.8 Starter clutch bolt 15 ~ 20...
  • Page 190 SERVICING INFORMATION 7-12 CHASSIS ITEM N∙m kg∙m Rear brake cam lever bolt 8 ~ 12 0.8 ~ 1.2 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 22 ~ 35 2.2 ~ 3.5...

  • Page 191: Service Data

    7-13 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 —...
  • Page 192 SERVICING INFORMATION 7-14 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 193 7-15 SERVICING INFORMATION CLUTCH Unit : mm ITEM STANDARD LIMIT — — — Clutch cable play Drive plate thickness 2.9~3.1 Drive plate claw width 11.8~12.0 11.0 — — — Driven plate distortion Clutch spring free length 38.2 36.2 TRANSMISSION + DRIVE CHAIN Unit : mm ITEM STANDARD...
  • Page 194 SERVICING INFORMATION 7-16 CARBURETOR Unit : mm ITEM SPECIFICATION MIKUNI BDS26TYPE(DOUBLE) Carburetor type ф 26 Bore size HJ 82 I.D. NO. 1,450~1,550 r.p.m. Idle r.p.m. Float height 0.5~1.0 Throttle cable play FRONT REAR 87.5 Main jet (M.J.) Main air jet (M.A.J.) Jet needle (J.N.)

  • Page 195: Brake/Tail Lamp

    7-17 SERVICING INFORMATION ELECTRICAL Unit : mm ITEM STANDARD NOTE 13� /2,000rpm ~ 30� /6,000rpm Ignition timing Type CR8E Spark plug 0.7~0.8 CR7E Hot type Standard type CR8E Cold type CR9E Spark performance Over 8mm Ignition coil resistance 0.19~0.34Ϊ Primary 5.4~6.6kΪ...
  • Page 196 SERVICING INFORMATION 7-18 SUSPENSION Unit : mm ITEM STANDARD LIMIT Front fork stroke — — — Front fork spring free length — — — Front fork oil type TELLUS #22 Front fork oil level — — — — — — Front fork oil capacity (each leg) 250cc —...

  • Page 197: Fuel Tank

    7-19 SERVICING INFORMATION TIRE ITEM STANDARD LIMIT Cold inflation tire pressure (Solo riding) — — — Front 1.75 — — — Rear 2.00 Cold inflation tire pressure (Dual riding) — — — Front 1.75 — — — Rear 2.25 Tire tread depth Front —...

  • Page 198: Wire And Cable Routing

    SERVICING INFORMATION 7-20 WIRE AND CABLE ROUTING...
  • Page 199 7-21 SERVICING INFORMATION...
  • Page 200 SERVICING INFORMATION 7-22...
  • Page 201 7-23 SERVICING INFORMATION Battery plus Fuel gauge 36818-30810(Tube) Wiring harness Magneto Neutral switch Fuel gauge Starter motor relay Battery plus Diode Fuel pump Welding clamp Starter motor relay Magneto Gearshift switch Lead wire, starter motor Fuel pump relay VIEW C Fuel pump Turnsignal lamp insert inside after installation VIEW D...

  • Page 202: Wiring Diagram

    SERVICING INFORMATION 7-24 WIRING DIAGRAM...
  • Page 206 Prepared by HYOSUNG MOTORS & MACHINERY INC. Overseas Technical Department 2nd Ed. MAY. 2001. Manual No. 99000-95310 Printed in Korea...

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Gv250Comet 250

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