HYOSUNG Sense SD-50 Service Manual
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HYOSUNG Sense SD-50 Service Manual

HYOSUNG Sense SD-50 Service Manual

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HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
99000-91201

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  • Page 1 HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL 99000-91201...
  • Page 2 Information of this manual is up-to-date at the time of issue. ELECTRICAL SYSTEM Major modification and changes incorporated later will be advised to HYOSUNG product distributor in each market. Therefore, if newest information is requested in the future, please contact the local HYOSUNG distributor.

  • Page 3: Table Of Contents

    GENERAL INFORMATION CONTENTS MODEL IDENTIFICATION FUEL AND OIL RECOMMENDATIONS BREAKING-IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIAL MATERIALS SPECIFICATIONS...

  • Page 4: Model Identification

    Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is recommended. ENGINE OIL For the HYOSUNG CCI system, use of “APOLLOIL BIKE-K”or “HYPOL HS”is highly recommended, but if they are not available, a good quality two-stoke oil (non-diuent type) should be used. FINAL GEAR OIL Use a good quality SAE 10W/40 multi-grade motor oil.

  • Page 5: Precautions And General Instructions

    ..... This provides special information to make maintenance easier or important inst- ructions clearer. REPLACEMENT PARTS When you replace any parts, use only genuine HYOSUNG replace- ment parts, or their equivalent. Genuine HYOSUNG parts are high quality parts which are designed and built specifically for HYOSUNG vehicles.

  • Page 6: Special Materials

    1-3 GENERAL INFORMA TION SPECIAL MATERIALS The materials shown are required for maintenance works on the Model SD-50 and should be kept on hand for ready use. in addition, such standard materials as cleaning fluids, lubricants, etc., should also available. Methods of use are discussed in the text of this manual on later pages.

  • Page 7: Specifications

    GENERAL INFORMA TION 1-4 SPECIFICATIONS ELECTRICAL Ignition type ………………… HYOSUNG “CDI” DIMENSIONS AND DRY MASS Ignition timing ……………… 23°B.T.D.C.at Overall length ……………… 1,780 mm(70.1 in) ………………………………… 4,000 r/min Overall width ……………… 660 mm(26.0 in) Spark plug ………………… GOLDEN: BP6HS Overall height ……………… 1,065 mm(41.9 in) Battery ………………………...
  • Page 8 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE 2- 1 MAINTENANCE AND TUNE-UP PROCEDURE 2- 2 BATTERY 2- 2 CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS 2- 3 CYLINDER HEAD AND CYLINDER 2- 3 SPARK PLUG 2- 4 FUEL LINE 2- 4 AIR CLEANER 2- 5...

  • Page 9: Periodic Maintenance Schedule

    2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 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. Mileages are expressed in terms of miles, kilometers and months. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 10: Maintenance And Tune-Up Procedure

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2 MAINTENANCE AND TUNE-UP PROCEDURE This section describes the servicing procedures for each item of the Periodic Maintenance requirements. BATTERY Inspect at Initially 1000km (600miles, 2momths), and Every 4000km (2400miles, 6months) thereafter ● Remove the battery cover ① from the leg shield mounting screws.

  • Page 11: Cylinder Head Nuts And Exhaust Pipe Bolts

    2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CYLINER HEAD NUT AND EXHAUST PIPE BOLTS T i g h t e n a t I n i t i a l l y 1 0 0 0 k m ( 6 0 0 m i l e s , 2 m o n t h s ) , a n d E v e r y 4 0 0 0 k m ( 2 4 0 0 m i l e s , 6 m o n t h s ) t h e r e a f t e r Cylinder head nuts, when they are not tightened to the specified torque, may result in leakage of the compressed mixture and reduce...

  • Page 12: Spark Plug

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4 SPARK PLUG C l e a n E v e r y 4 0 0 0 k m ( 2 4 0 0 m i l e s , 6 m o n t h s ) a n d R e p l a c e E v e r y 8 0 0 0 k m ( 4 8 0 0 m i l e s , 1 2 m o n t h s ) Neglecting the spark pulg maintenance eventually leads to difficult starting and poor performance.

  • Page 13: Air Cleaner

    2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER C l e a n E v e r y 4 0 0 0 k m ( 2 4 0 0 m i l e s , 6 m o n t h s ) If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption.

  • Page 14: Oil Pump

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6 ● Connect an electric tachometer to the connecting portion of the high tension lead. Use the selector key “C”position. 09900-26006 Tachometer ● Asjust the throttle stop screw to obtain the idle r/min as follows. Idle r/min 1800±50 r/min ●...

  • Page 15: Final Gear Oil

    2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES FINAL GEAR OIL I n s p e c t a t I n i t i a l l y 1 0 0 0 k m ( 6 0 0 m i l e s , 2 m o m t h s ) , a n d E v e r y 8 0 0 0 k m ( 4 8 0 0 m i l e s , 1 2 m o n t h s ) t h e r e a f t e r Inspect final gear oil periodically following procedure below.
  • Page 16 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-8 WARNING: Brake fluid, if it leaks, will interfere with safe running and immediatery discolor painted surfaces. Check the brake hoses for cracks and hose joints for leak- age before riding. BRAKE PADS Wearing condition of brake pads can be checked by observing the limit line ①...
  • Page 17 2-9 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES NOTE: Replenish the brake fluid reservoir as necessary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir. ● Close the bleeder valve, and disconnect the pipe. Fill the reser- voir to the upper end of the inspection window.

  • Page 18: Tires

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-10 TIRES I n s p e c t a t I n i t i a l l y 1 0 0 0 k m ( 6 0 0 m i l e s , 2 m o m t h s ) , a n d E v e r y 4 0 0 0 k m ( 2 4 0 0 m i l e s , 6 m o n t h s ) t h e r e a f t e r TIRE PRESSURE If the tire pressure is too high, the motorcycle will tend to ride...

  • Page 19: Front Suspension

    2-11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES FRONT SUSPENSION I n s p e c t a t I n i t i a l l y 1 0 0 0 k m ( 6 0 0 m i l e s , 2 m o m t h s ) , a n d E v e r y 8 0 0 0 k m ( 4 8 0 0 m i l e s , 1 2 m o n t h s ) t h e r e a f t e r Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary.
  • Page 20 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-12 ⑨ ① ⑩ ② ⑪ ③ ④ ⑥ ⑤ ⑫ ⑬ ⑧ ⑦...

  • Page 21: General Lubrications

    2-13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES GENERAL LUBRICATIONS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. The major lubrication points are indicated below. NOTE: * Lubricate expodes parts which are subject to rust with motor oil grease. * Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime.
  • Page 22 ENGINE CONTENTS ENGINE REMOVAL AND REMOUNTING 3- 1 ENGINE REMOVAL 3- 1 ENGINE REMOUNTING 3- 3 ENGINE DISASSEMBLY 3- 4 ENGINE COMPONENTS INSPECTION AND SERVICING 3-13 BEARINGS 3-13 OIL SEALS 3-13 CRANKSHAFT 3-13 AUTOMATIC CLUTCH INSPECTION 3-14 CYLINDER HEAD 3-16 CYLINDER 3-17 PISTON...

  • Page 23: Engine Removal And Remounting

    3-1 ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The procedure of engine removal is sequentially explained as follows. ● Remove the frame side covers. (Refer to page 6-3) ●...
  • Page 24 ENGINE 3-2 ● Disconnect the magneto lead wire and starter lead wire. ● Remove the rear brake cable ② by removing the bolt ①, bolt ③ and adjuster nut. ① ③ ② ● Remove the rear shock absorber mounting lower bolt. ●...

  • Page 25: Engine Remounting

    3-3 ENGINE ENGINE REMOUNTING The engine can be mounted in the reverse order of removal. Front side ● Install the damper to the crankcase bracket as shown in the ① “UP” mark illustration. 10mm ● With “UP”mark faced upward, install the crankcase bracket ① on the frame.

  • Page 26: Engine Disassembly

    ENGINE 3-4 ENGINE DISASSEMBLY MUFFLER ● Remove the muffler by removing the bolts and nuts. MAGNETO ② ● Remove the cooling fan. ① ● Remove the magneto rotor nut ① with the special tool. 09930-40113 Rotor holder ● Remove the magneto rotor with the special tool. 09930-30163 Rotor removerr Special tool...
  • Page 27 3-5 ENGINE CYLINDER ● Remove the cylinder cowling. ● Remove the cylinder head ① and cylinder ②. ② ① ④ PISTON ● Place a cloth beneath the piston and remove the circlip ① with ③ a pliers. ① ② ● Remove the piston pin ② and piston ③. ●...
  • Page 28 ENGINE 3-6 KICK STARTER DRIVEN GEAR ● Remove the E-ring ① with the long nose plier. ● Remove the spacer ②, spring ③ and kick starter driven gear ④. ④ ③ ② ① MOVABLE DRIVE FACE ● Remove the kick starter driven nut with the special tool. CAUTION: This nut has left-hand thread.
  • Page 29 3-7 ENGINE ● Loosen the clutch shoe nut with the special tool. 09930-40113 Rotor holder ● Remove the nut while holding down the clutch shoe assembly by both hands as shown in the illustration. ① WARNING: Gradually back off the clutch shoe assembly pressed down by hand to counter the clutch spring load.
  • Page 30 ENGINE 3-8 ● Remove the circlip �. � � � � ● Remove the bearing � with the special tool. 09941-50111 Wheel bearing remover Special tool CAUTION: The removed bearing should be replaced with a new one. TRANSMISSION ● Drain gear oil. ①...
  • Page 31 3-9 ENGINE ● Remove the circlip ④ and final driven gear ⑤. ● Remove the idle shaft ⑥. ④ ⑥ ⑤ ● Remove the drive shaft bearing ⑦. ① Special 09930-30102 Sliding shaft tool ⑦ 09921-20210 Bearing remover Special ② tool WHEEL, BRAKE ●...
  • Page 32 ENGINE 3-10 ● Remove the bearing ⑦ with the special tool. ⑦ Bearing remover Special tool 09913-75820 (Bearing installer) ● Remove the oil seal ⑧ with the special tool. 09913-50121 Oil seal remover ⑧ Special tool CENTER STAND ● Remove the return spring ①. ①...
  • Page 33 3-11 ENGINE ● Remove the crankshaft with the special tool. Crankshaft remover 09920-13120 (Crankcase separating tool) ● Remove the bearings, oil seals and bushing.
  • Page 34 ENGINE 3-12 ● Using two steel tubes of appropriate size, press out the engine mounting bushings on a vise as shown in the illustration. Bushing Front side 28.1 25.5 Bushing Crankcase Rear side Bushing Crankcase 22.3...

  • Page 35: Engine Components Inspection And Servicing

    3-13 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS Wash the bearing with cleaning solvent and lubricate with motor oil before inspecting. Turn the inner ring and check to see that the inner ring turns smoothly. If it does not turn lightly, quietly and smoothly, or if noise is heard, the bearing is defective and must be replaced with a new one.

  • Page 36: Clutch

    ENGINE 3-14 CONROD SMALL END BORE I.D. Measure the conrod small end diameter with a caliper gauge. Service limit 14.047 mm(0.5530 in) 09900-20605 Dial calipers AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch and variable ratio belt drive transmission. The engagement of the clutch is gov- erned by engine RPMs and centrifugal mechanism located in the clutch.
  • Page 37 3-15 ENGINE If the engine r/min does not coincide with the specified r/min range, then disassemble the clutch. Clutch shoe - inspect the shoes visually for chips, cracking, uneven wear and burning, and check the thickness of the shoes with vernier calipers.

  • Page 38: Cylinder Head

    ENGINE 3-16 ROLLER AND SLIDING SURFACE Inspect each roller and sliding surface for wear or damage. DRIVEN FACE SPRING Measure the free length of the driven face spring. If the length is shorter than the service limit, replace the spring with a new one. Service limit 104.5 mm(4.11 in) DRIVEN FACE PIN AND OIL SEAL...

  • Page 39: Cylinder

    3-17 ENGINE If the largest reading at any portion of the straightedge exceeds the limit, rework the surface by rubbing it against emery paper (of about # 400) laid flat on the surface plate in a lapping manner. The gasketed surface must be smooth and perfectly flat in order to secure a tight joint: a leaky joint can be the cause of reduced power output and increased fuel consumption.
  • Page 40 ENGINE 3-18 As a result of the above measurement, if the piston-to-cylinder clearance exceeds the following limit, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. The mea- surement for the bore diameter should be taken in the intake-to- exhaust port direction and at 20mm from the cylinder top surface.

  • Page 41: Reed Valve

    3-19 ENGINE PISTON RINGS Check each ring for end gap, reading the gap with a thickness gauge shown in the illustration. If the end gap is found to exceed the limit, indicated below, replace it with a new one. The end gap of each ring is to be measured with the ring fitted squarely into the cylinder bore and held at the least worn part near the cylinder bottom, as shown in the illustration.

  • Page 42: Engine Reassembly

    ENGINE 3-20 ENGINE REASSEMBLY Reassembly is generally performed in the reverse order of disas- sembly, but there are a number of reassembling steps that demand or deserve detailed explanation or emphasis. These steps will be taken up for respective parts and components. OIL SEALS Fit the oil seals to the crankcase following the procedure below.

  • Page 43: Bushings

    3-21 ENGINE BUSHINGS ② Using two steel tubes of appropriate size and a vise, press the mounting bushings ① and ② into the crankcase holes as shown in the illustration. NOTE: Knurled end ③ should face inside. Protruside � and � should be in the same dimension.

  • Page 44: Crankshaft

    ENGINE 3-22 CRANKSHAFT ①Crankshaft ②Crankcase(R) ③Oil seal ④Oil seal ⑤Oil pump drive gear ⑥Oil pump drive gear ⑦Oil ② ⑥ ③ ⑤ ⑦ ④ ① ● Deside the length between the webs referring to the figure at right when rebuilding the crankshaft. 35.0 ±...

  • Page 45: Crankcase

    3-23 ENGINE CRANKCASE ● Wipe the crankcase mating surfaces(both surfaces)with cleaning ③ solvent. ● Apply THREE BOND NO.1215 uniformly to the mating surface of the left half of the crankcase, and install the dowel pins. 99000-31110 THREAD BOND NO.1215 ● Install the two dowel pins. ●...

  • Page 46: Center Stand

    ENGINE 3-24 CENTER STAND ③ ④ ● Install the center stand ①. ① ● Install the shaft ②, washer ③ and cotter pin ④. ● Hook center stand spring ⑤ into the crankcase. ⑤ ⑥ ② ① ④ ③ ② ⑥...

  • Page 47: Rear Axle Shaft, Brake And Wheel

    3-25 ENGINE REAR AXLE SHAFT, BRAKE AND WHEEL ⑦ ⑨ ⑧ ⑤ ⑥ ② ③ ④ ①Rear axle shaft ②Rear brake cam ③Rear brake cam lever ④Rear brake cam lever bolt ⑤Rear brake shoe ⑥Brake shoe spring ⑦Rear wheel ① ⑧Rear wheel washer ⑨Rear wheel nut ●...
  • Page 48 ENGINE 3-26 ● When installing the cam lever ④ to the cam, align the punched Punched mark with the slit of cam lever. mark Slit ④ ● Tighten the cam lever nut ⑤ to the specified torque. 6-9 N∙m Tightening torque (0.6-0.9 kg-m, 4.5-6.5 lb-ft) ⑤...

  • Page 49: Transmission

    3-27 ENGINE TRANSMISSION ② ⑩ ⑦ ⑫ ⑮ ⑪ ① ⑨ ⑤ ④ ⑧ ① ⑤ ⑭ ⑥ ② ⑨Washer ①Rear axle shaft ⑩Gasket ②Circlip ③ ⑪Dowel pin ③Idle shaft ⑨ ⑫Gear box cover ⑭ ④Oil drain bolt ⑬Bearing ⑦ ⑤Washer ⑧...
  • Page 50 ENGINE 3-28 ● Install the new bearing ⑦ to the gear box cover ⑧ with the Special tool special tool. 09913-70610 Bearing installer ⑦ ⑧ ● Apply grease to the lip of the oil seal ⑨ and install it to the gear box cover with the special tool.

  • Page 51: Starter Driven Gear And Starter Motor

    3-29 ENGINE STARTER DRIVEN GEAR AND STARTER MOTOR ①Starter driven gear ②Starter motor ① ② ● Install the starter driven gear ① over the left crankshaft end. NOTE: The convex side of hub should face outside when installed in proper position. ①...

  • Page 52: Movable Driven And Clutch

    ENGINE 3-30 MOVABLE DRIVEN AND CLUTCH ①Fixed driven face ⑩O-ring ②Bearing ⑪Spring ③Circlip ⑫Clutch shoe assembly ④Needle roller bearing ⑬Clutch shoe nut ⑤Movable driven face ⑭Clutch housing ⑥Oil seal ⑮Clutch housing nut ⑦Oil seal �V-velt ③ ⑧Spacer ② ⑨Pin ⑨ ①...
  • Page 53 3-31 ENGINE ● Install the bearing with the special tool. Special tool 09943-88210 Bearing installer ④ ● Install the new oil seals (⑤, ⑥) to the movable driven face Oil seal Special tool with the special tool. 09913-76010 Bearing installer ⑥...
  • Page 54 ENGINE 3-32 ● Install the spring ⑫. ⑭ ● Install the clutch shoe assembly ⑬ and nut ⑭. ⑬ ⑫ ● Tighten the nut to the specified torque with the special tool. 09930-40113 Rotor holder 40-60 N∙m Tightening torque (4.0-6.0 kg-m, 29.0-43.5 lb-ft) Special tool ●...

  • Page 55: Movable Drive

    3-33 ENGINE MOVABLE DRIVE ⑥ ⑤ ④ ⑦ ③ ② ⑧ ① ①Movable drive face ⑨ ②Roller ③Movable drive plate ④Damper ⑤O-ring ⑥Movable drive face cover ⑦Spacer ⑧Fixed drive face ⑨Kick starter driven nut ⑪ ⑩Kick starter driven gear ⑫ ⑪Spring ⑬...
  • Page 56 ENGINE 3-34 ● Install the movable drive face cover ⑦. ⑦ NOTE: Spacer Make sure that the movable drive plate is fully positioned inside, or the weight roller may come off. ● Insert the spacer. ● Position the movable drive face subassembly on the crankshaft as shown in the photo.

  • Page 57: Kick Starter

    3-35 ENGINE ● Continue turning the fixed drive face ⑭ by hand until the belt is seated in and both the drive and driven faces ⑮ will move ⑮ together smoothly without slip. ● Fill the final gear box with engine oil up to the level hole. Oil Capacity 90 ml ●...

  • Page 58: Piston

    ENGINE 3-36 ● Install the clutch cover and kick starter lever ①. ① NOTE: Install the kick starter lever as shown in the illustra- tion. 13� ● Tighten the kick starter lever bolt to the specified torque. 8-12 N∙m Tightening torque (0.8-1.2 kg-m, 6.0-8.5 lb-ft) PISTON ②...
  • Page 59 3-37 ENGINE ● Install the piston rings on the piston. ∙1st - Keystone ring ∙2nd - Rectangular ring �Expander ring NOTE: Position the ring so that the marking is on upside. Locating pin ● It is extremely important that, when the piston is fed into the cylinder, each ring in place should be so positioned as to hug the locating pin as shown in the illustration.

  • Page 60: Oil Pump And Intake Pipe

    ENGINE 3-38 OIL PUMP AND INTAKE ② ① Apply grease ①Oil pump driven gear ②Oil pump ● Apply grease to the oil pump driven gear ① and install it to the crankcase. ① 99000-07000 Grease “G ” ● Install the oil pump ② and tighten it to the specified torque. ②...

  • Page 61: Magneto

    3-39 ENGINE MAGNETO ①Stator ②Key ③Magneto rotor ④Nut and washer ④ ⑤Fan case ③ ⑥Cooling fan ② ⑦Fan cover ① ⑤ ⑥ ⑦ ● Degrease the tapered portion of the crankshaft and also the ① magneto rotor. ● Install the stator ①. ●...

  • Page 62: Muffler

    ENGINE 3-40 ● Install the fan case ⑤. ● Install the magneto lead wire and starter motor lead wire. ⑤ ● Install the cooling fan ⑥. ⑥ ● Install the cooling fan cover ⑦. ⑦ MUFFLER ● Tighten the exhaust pipe bolts ① and muffler mounting bolts ② to the specified torque.
  • Page 63 FUEL AND LUBRICATION SYSTEM CONTENTS CARBURETOR 4- 1 REMOVAL 4- 1 DISASSEMBLY 4- 2 INSPECTION 4- 4 REASSEMBLY AND REMOUNTING 4- 4 FUEL TANK 4- 6 REMOVAL 4- 6 REMOUNTING 4- 7 OIL PUMP 4- 8...

  • Page 64: Carburetor

    4-1 FUEL AND LUBRICA TION SYSTEM CARBURETOR ①Carburetor chamber ②Float ③Main jet ④Throttle stop screw ⑤Needle jet ⑥Needle valve ⑦Pilot air screw ⑧Throttle valve ⑨Jet needle ④ ⑩E-ring ⑪Spring ⑤ ⑪ ⑫Thermoelement ⑫ ③ ⑦ ⑥ ② ⑩ ⑨ ⑧ ①...

  • Page 65: Disassembly

    FUEL AND LUBRICA TION SYSTEM 4-2 ● Remove the carburetor top cap ①, and disconnect the throttle cable ②. ② ① ③ ● Disconnect the carburetor hoses and oil hose. ⑤ Vacuum hose ③. Oil hose ④. Fuel hose ⑤. ④...
  • Page 66 4-3 FUEL AND LUBRICA TION SYSTEM ● Remove the float chamber ①. ① ● Remove the float ③ by removing the screw and pin ②. ② SCREW ③ ● Remove the needle valve ④. ④ ● Remove the throttle stop screw ⑤ and pilot air screw ⑥. NOTE: When removing the pilot air screw, record the revolu- tions until tighten completly.

  • Page 67: Inspection

    FUEL AND LUBRICA TION SYSTEM 4-4 INSPECTION Inspect the valve surface for worn. Check following items for any damage or clogging. ● Pilot jet ● Main jet Foreign ● Pilot air screw matter ● Needle jet air bleeding hole ● Float ●...

  • Page 68: Install Thermoelement/Carburetor Assembly

    4-5 FUEL AND LUBRICA TION SYSTEM ● Install the thermoelement assembly. ● Install the carburetor assembly. ● Install the vacuum hose ①, oil hose ② and fuel hose ③. ① ③ ② ● Install the carburetor top cap.

  • Page 69: Fuel Tank

    FUEL AND LUBRICA TION SYSTEM 4-6 FUEL TANK ① REMOVAL ● Remove the side covers. (Refer to page 6-3) ● Remove the rear center cover ①. ● Disconnect the fuel hose ②. NOTE: To prevent fuel flow, connect the suitable cap to the fuel tank outlet.

  • Page 70: Remounting

    4-7 FUEL AND LUBRICA TION SYSTEM REMOUNTING Remount the fuel tank in the reverse of removal. ①Fuel tank ②Fuel level gauge ③Fuel level gauge cap ③ ④Fuel tank cap ⑤Vacuum hose ② ⑥Inlet hose ④ ⑦Outlet hose No.1 ⑧⑨Cushion ⑩Fuel strainer ⑪Outlet hose No.2 ①...

  • Page 71: Oil Pump

    ● Remove the left side cover. ● Have the tool filled with HYOSUNG HYPOL OIL and connect it to the suction side of the pump. ● Run the engine at 3000 r/min.
  • Page 72 ELECTRICAL SYSTEM CONTENTS ELECTRICAL PARTS 5- 1 IGNITION/CHARGING SYSTEM 5- 2 IGNITION COIL 5- 2 STATOR COILS 5- 3 REGULATOR/RECTIFIER 5- 3 STARTER SYSTEM 5- 4 STARTER MOTOR INSPECTION 5- 5 STARTER RELAY INSPECTION 5- 5 FUEL LEVEL GAUGE 5- 6 OIL LEVEL CHECK LIGHT 5- 7 THERMOELEMENT...
  • Page 73 5-1 ELECTRICAL SYSTEM ELECTRICAL PARTS ① ① Ignition coil ② Thermolement assembly ③ Trunk box lamp ④ Fuel level gauge ⑤ Oil level gauge ② Turn signal relay Key set Starting motor relay ③ Rectifier M.F battery C.D.I Unit Horn ④...

  • Page 74: Electrical System

    ELECTRICAL SYSTEM 5-2 IGNITION/CHARGING SYSTEM Stator Regulator/Rectifier Ignition coil unit Battery Spark Lighting 12V 3AH plug switch (MF) Engine stop switch 15W×2 3.4W×2 IGNITION COIL ● Check the ignition coil with electro tester. ● Test the ignition coil for sparking performance. Test connection is as indicated.
  • Page 75 5-3 ELECTRICAL SYSTEM STATOR COILS ● Using a pocket tester, measure the resistance between the lead wire and ground. If the resistance checked is incorrect, replace the coil. Standard resistance Ground Lighting 0.6-1.4Ϊ Ground Charging 0.6-1.4Ϊ Ground Exciting 180-230Ϊ CHARGING OUTPUT CHECK Start the engine and keep it running at 5000 r/min with lighting switch turned ON.

  • Page 76: Starter System

    ELECTRICAL SYSTEM 5-4 STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch and battery. Depressing the starter button (on the right handlebar switch box) while squeezing the front or rear brake lever energizes the relay, causing the contact points to close which connects the starter motor to the battery.
  • Page 77 5-5 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be unable to pro- cedure sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically inspect the length of the brushes and replace them when they are too short or chipping.

  • Page 78: Fuel Gauge

    ELECTRICAL SYSTEM 5-6 FUEL GAUGE Fuel level gauge Fuel tank FUEL LEVEL METER/GAUGE FUEL METER INSPECTION To test the Fuel Meter two different checks may be used. The first, and simplest test will tell if the meter is operating but will not indicate the meters accuracy throughout the range.
  • Page 79 5-7 ELECTRICAL SYSTEM FUEL GUAGE SENDING UNIT INSPECTION ● Disconnect the lead wires coming out of the fuel gauge and check resistance of each position. Full ● If the resistance measured is incorrect, replace the fuel gauge assembly with a new one. ●...
  • Page 80 ELECTRICAL SYSTEM 5-8 OIL LEVEL CHECK LIGHT INSPECTION Disconnect the L/W and B/W lead connector ① of the oil level check light. ① Connect a jumper wire between L/W and B/W wires coming from the main wiring harness. With the ignition switch turned ON, the oil level check light should flash.
  • Page 81 5-9 ELECTRICAL SYSTEM SWITCHES LIGHTING SWITCH Inspect each switch for continuty with the pocket tester ○ ○ referring to the chart. If it is found any abnormality, replace the repective switch assembly with new one. STARTER BUTTON ○ ○ WIRE COLOR Black Green FRONT AND REAR BRAKE LIGHT SWITCH...
  • Page 82 ELECTRICAL SYSTEM 5-10 BATTERY SPECIFICATION Type designation YTX4L-BS Capacity 12V, 3AH/10HR Standard electrolyte S.G. 1.32 at 20 ℃(68℉) INITIAL CHARGING FILLING ELECTROLYTE ● Remove the aluminum tape ① sealing the battery electrolyte filler holes. ● Remove the caps ②. NOTE: A f t e r f i l l i n g t h e e l e c t r o l y t e c o m p l e t e l y , u s e t h e removed cap ②...
  • Page 83 Once install the caps to the battery, do not remove the caps. ● Using HYOSUNG pocket tester, measure the battery voltage. The tester should indicate more than 12.5-12.6 V(DC)as shown in the Fig. If the battery voltage is lower than the specification, charge the battery with a battery charger.
  • Page 84 ELECTRICAL SYSTEM 5-12 RECHARGING OPERATION ● Using the pocket tester, check the battery voltage. If the voltage reading is less than 12.0V(DC), recharge the battery with a bat- tery charger. CAUTION: When recharging the battery, remove the battery from the motorcycle.
  • Page 85 CHASSIS CONTENTS HANDLE BAR COVERS 6- 1 REMOVAL 6- 2 REMOUNTING 6- 2 LEG SHIELD AND SIDE COVERS 6- 3 REMOVAL 6- 4 REMOUNTING 6- 7 FRONT WHEEL 6- 8 REMOVAL AND DISASSEMBLY 6- 8 INSPECTION 6-10 REASSEMBLY AND REMOUNTING 6-10 FRONT BRAKE 6-13...
  • Page 86 6-1 CHASSIS HANDLEBAR COVERS...
  • Page 87 CHASSIS 6-2 REMOVAL HANDLEBAR FRONT COVER ● Remove the handlebar front cover by removing the mounting screws and disconnecting the lead wires. HANDLEBAR REAR COVER ● Disconnect the lead wire couplers and speedometer cable. ● Remove the handlebar rear cover by removing the mounting screws.
  • Page 88 6-3 CHASSIS LEG SHIELD AND SIDE COVERS...
  • Page 89 CHASSIS 6-4 REMOVAL FRONT LEG SHIELD UPPER ● Loosen the mounting screws. ● Remove the front leg shield upper by pull out it forward. FRONT LEG SHIELD LOWER ● Loosen the mounting screws. ● Remove the front leg shield lower.
  • Page 90 6-5 CHASSIS REAR CARRIER ● Open the seat. ● Remove the rear carrier by removing the bolts and screw. RIGHT SIDE COVER, RIGHT SIDE LEG SHIELD ● Loosen the mounting screws. ● Remove the right side cover and right side leg shield at the Side cover same time.
  • Page 91 CHASSIS 6-6 LEFT SIDE COVER, LEFT SIDE LEG SHIELD ● Loosen the mounting screws. ● Remove the handle grip ① by removing the bolts. ① ● Remove the left side cover and left side leg shield at the same Side cover time.
  • Page 92 6-7 CHASSIS REAR CENTER COVER ● Remove the rear center cover by removing the bolts. COVER LEG SHIELD REAR AND LEL SHIELD REAR ● Remove the ignition cap. ● Remove the battery cover by removing the screw. Battery cover ● Loosen the screw and bolts. ●...

  • Page 93: Front Wheel

    CHASSIS 6-8 FRONT WHEEL Tightening torque ① Item Nㆍm ㎏ㆍm lbㆍft ② ① 33-52 3.3-5.2 24.0-37.5 ⑩ 18-28 1.8-2.8 13.0-20.0 ③ ④ ⑥ ⑩ ⑤ ①Front axle nut ⑦ ②Speedometer gear box ③Wheel bearing(R) ⑧ ④Spacer ⑨ ⑤Wheel bearing(L) ⑥Disc plate ⑦Spacer ⑧Oil seal ⑨Front axle shaft...
  • Page 94 6-9 CHASSIS ● Remove the disc plate ① by removing the bolts. ① ● Remove the spacer. ② ● Remove the dust seal ③ with the special tool. 09913-50121 Oil seal remover ③ ● Drive out the both bearing with the special tool in the following procedures.
  • Page 95 CHASSIS 6-10 INSPECTION WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown. An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings. If bearing replace- ment fails to reduce the runout, replace the wheel.
  • Page 96 6-11 CHASSIS Right side Left side Bearing(R) Spacer Clearance Special tool Bearing(L) Bearing(L) OIL SEAL ● Install the oil seal ① with the special tool. ① 09922-55131 Oil seal installer ● Install the spacer ②. ② DISC PLATE ● Install the disc plate and tighten them to the specified torque. 18-28 Nㆍm Tightening torque (1.8-2.8 kgㆍm, 13-20 lb-ft)
  • Page 97 CHASSIS 6-12 SPEEDOMETER GEAR BOX ● When installing the speedometer gear box, align the two drive pawls � with the two recesses � of the wheel hub. � CAUTION: After touching the speedometer gear box � to the stopper � �, tighten the axle shaft.

  • Page 98: Front Brake

    6-13 CHASSIS FRONT BRAKE ⑤ Apply silicone grease ① ② ⑥ ③ ④ ⑦ ⑧ ⑨ ⑩ ①Master cylinder bolt ②Master cylinder ③Brake hose union bolt ④Brake hose ⑤Pad Tightening torque ⑥Air bleeder valve Item Nㆍm kgㆍm lb-ft ⑦Dust seal ①...
  • Page 99 CHASSIS 6-14 CALIPER REMOVAL AND DISASSEMBLY ● Remove the brake hose and catch the brake fluid in a suitable receptacle. CAUTION: Never re-use the brake fluid left over from the last servicing and stored long periods. ● Remove the caliper. ●...
  • Page 100 6-15 CHASSIS CALIPER INSPECTION Inspect the caliper cylinder bore wall for nicks, scratches or other damage. Inspect piston for damage and wear. Inspect each rubber part for damage and wear. CALIPER REASSEMBLY Apply grease Reassemble and remount the caliper in the reverse order of removal and disassembly, and also carry out the following steps.
  • Page 101 CHASSIS 6-16 DISC PLATE REMOVAL AND DISASSEMBLY ● Remove the front wheel(Refer to page 6-8) ● Remove the disc plate(Refer to page 6-9) ● Install the disc plate(Refer to page 6-11) DISC PLATE INSPECTION ● Check the disc for wear with a micrometer. Its thickness can be checked with disc and wheel in place.
  • Page 102 6-17 CHASSIS ● Remove the master cylinder. ● Remove the brake lever ① and brake switch ②. ② ① ● Remove the dust boot ③. ③ ● Remove the circlip ④ with the special tool. 09900-06108 Snapring pliers ④ ● Remove the piston/primary cup with return spring ⑤. ●...
  • Page 103 CHASSIS 6-18 MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for scratches or other damage. Inspect the primary cup and dust boot for wear or damage. MASTER CYLINDER REASSEMBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly, and also carry out the Boot...

  • Page 104: Front Fork

    6-19 CHASSIS FRONT FORK Tightening torque Item Nㆍm kgㆍm lb-ft ③ 35-55 3.5-5.5 22.5-40.0 ⑥ 25-35 2.5-3.5 16.0-25.5 ⑦ ⑫ 20-26 2.0-2.6 14.5-18.8 ③ ⑧ ⑨ ⑩ ① ⑪ ⑥ ② ①Steering stem ②Under bracket ④ ③Fork bolt ⑫ ④Cushion spring ⑤Pipe seat ⑥Fork lower clamp bolt ⑦Fork pipe...
  • Page 105 CHASSIS 6-20 ● Loosen the front fork bolt, then draw out the fork spring. ● Loosen the front fork lower clamp bolts. ● Invert the fork and stroke it several times to remove the oil. ● Hold the fork inverted for a few minutes. ●...
  • Page 106 6-21 CHASSIS INSPECTION Inspect pipe seat for wear and damage. Inspect fork pipe and bottom case sliding surfaces for any scuffing or flaws. CUSHION SPRING Measure the cushion spring free length, if it is shorter than the service limit, replace it. Service limit 240 mm(9.45 in) REASSEMBLY AND REMOUNTING...
  • Page 107 CHASSIS 6-22 STEERING ② REMOVAL AND DISASSEMBLY ① ● Remove the handlebar cover.(Refer to page 6-1) ● Remove the handlebar by removing the clamp bolt ① and set bolt ②. ● Loosen the steering stem lock nut ③ with the special tool. ③...
  • Page 108 6-23 CHASSIS ● Remove the upper and lower bearing inner race with a appropri- ate bar. INSPECTION Inspect the removed parts for the following abnormalities. ● Bearing race wear and brinelling. ● Worn and damaged steel balls. ● Distortion of steering stem or handlebar. REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem, handlebar and front fork in the reverse order of disassembly and removal, and also...
  • Page 109 CHASSIS 6-24 STEERING OUTER RACE NUT ● Tighten the steering outer race ① until resistance is felt, then loosen it 1/8-1/4 turn. NOTE: ① This adjustment will vary from motorcycle to motorcy- cle. Make sure that the steering turns smoothly and easily, left to right.
  • Page 110 6-25 CHASSIS REAR WHEEL AND BRAKE Tightening torque Item Nㆍm kgㆍm lb-ft ① 60-90 6.0-9.0 43.5-65.0 ⑨ 0.6-0.9 4.5-6.5 ①Rear axle nut ① ②Washer ② ③Rear wheel ④Brake shoe ⑤Spring ⑤ ⑥Rear brake camshaft ⑨ ⑦Indicate plate ⑧Brake cam lever ③...
  • Page 111 CHASSIS 6-26 WHEEL Refer to page 6-10. TIRE Refer to page 6-10. REASSEMBLY AND REMOUNTING ① Reassemble and remount the rear wheel and brake in the reverse order of removal, and diassembly. ② BRAKE CAM LEVER Brake cam lever ● When installing the brake cam lever, align the punched mark ① of camshaft with the slit ②...
  • Page 112 SERVICING INFORMATION CONTENTS SPECIAL TOOLS 7- 1 TIGHTENING TORQUE 7- 3 WIRING DIAGRAM 7- 5 WIRE ROUTING 7- 6 SERVICE DATA 7- 7 TROBLESHOOTING 7-11...

  • Page 113: Special Tools

    7-1 SERVICING INFORMA TION SPECIAL TOOLS PART No. PART NAME PART No. PART NAME 09900-00401 Hexagon wrench set 09910-20116 Conrod holder Snap ring pliers 09900-06107 09910-32812 Crank shaft installer (opening type) Snap ring pliers 09900-06108 09910-60611 Universal clamp wrench (closing type) 09900-09003 Impact driver set 09913-50121...
  • Page 114 SERVICING INFORMA TION 7-2 PART No. PART NAME PART No. PART NAME Bearing remover/ 09913-85210 09925-98220 Bearing installer installer Bearing remover/ 09914-05210-005 09930-30102 Sliding shaft installer 09920-13120 09930-30163 Rotor remover Crankcase separating tool 09921-20210 Bearing remover Rotor holder 09930-40113 Bearing remover 09923-73210 09941-34513 Bearing installer...

  • Page 115: Tightening Torque

    7-3 SERVICING INFORMA TION TIGHTENING TORQUE CHASSIS ⑧ ⑨ ④ ③ ⑭ ⑩ ⑦ ⑪ ⑬ ⑥ ⑤ ① ⑫ ② Item N∙m kg∙m lb-ft Front axle nut 3.3~5.2 33~52 24.0~37.5 Rear axle nut 6.0~9.0 60~90 43.5~65.0 Handle bar clamp nut 48~52 4.8~5.2 34.5~37.5...
  • Page 116 SERVICING INFORMA TION 7-4 ENGINE Item N∙m kg∙m lb-ft Spark plug 2.5~3.0 25~30 18.0~21.5 Magneto rotor nut 35~45 3.5~4.5 25.5~31.0 4.0~6.0 Kick starter driven nut 40~60 29.0~43.5 Clutch shoe nut 40~60 4.0~6.0 29.0~43.5 Clutch housing nut 40~60 4.0~6.0 29.0~43.5 Kick starter lever bolt 8~12 0.8~1.2 6.0~8.5...
  • Page 117 7-5 SERVICING INFORMA TION WIRING DIAGRAM...
  • Page 118 SERVICING INFORMA TION 7-6 WIRE, CABLE AND HOSE ROUTING...

  • Page 119: Service Data

    7-7 SERVICING INFORMA TION SERVICE DATA CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT 0.065-0.075 0.120 Piston to cylinder clearance (0.0047) (0.0026-0.0030) 41.005-41.020 41.07 Cylinder bore (1.6143-1.6120) (1.6169) Measure at 20(0.8) from the top surface 40.935-40.950 40.885 Piston diam...

  • Page 120: Electrical

    SERVICING INFORMA TION 7-8 CLUTCH Unit : mm (in) ITEM STANDARD LIMIT 110-110.15 110.35 Clutch Wheel I.D. (4.3307-4.3366) (4.344) Clutch shoe thickness (0.118) (0.08) Clutch engagement 3300±300 r/min Clutch lock-up 5800±500 r/min TRANSMISSION+DRIVE CHAIN Unit : mm (in) Except ratio ITEM STANDARD LIMIT...

  • Page 121: Fuse

    7-9 SERVICING INFORMA TION ITEM SPECIFICATION NOTE Spark performance Over 8(0.3) at 1 atm ㏀ Ignition coil resistance Secondary 14-20 Lighting 0.6-1.4Ϊ Y/W-Ground Magneto coil resistance W/R-Ground Charging 0.6-1.4Ϊ R/B-Ground Exciting 180-230Ϊ Regulated voltage 14-15V at 5000 r/min Starter motor brush length Limit: 4.0(0.15) Commutator under-cut Limit: 0.2(0.008)

  • Page 122: Fuel Tank

    SERVICING INFORMA TION 7-10 ITEM STANDARD LIMIT 30.230-30.306 Brake caliper cylinder bore Front (1.1902-1.1931 30.150-30.200 Brake caliper piston diam. Front (1.1870-1.1890 Axial (0.12) Wheel rim runout Radial (0.12) 0.25 Front Wheel axle runout (0.010) Front 100/80-10 53J Tire size 100/80-10 53J Rear Front (0.06)

  • Page 123: Troubleshooting

    7-11 SERVICING INFORMA TION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine does not Compression too low start, or is hard Replace. 1. Excessively worn cylinder or piston rings. to start. Refair or replace. 2. Stiff piston ring in place. Refair or replace.
  • Page 124 SERVICING INFORMA TION 7-12 Complaint Symptom and possible causes Remedy Engine runs 1. Excessively worn cylinder or piston rings. Replace. poorly in high- 2. Stiff piston ring in place. Replace. speed range. 3. Spark plug gaps to narrow. Adjust. 4. Ignition not advanced sufficiently due to poorly working CDI Replace.
  • Page 125 7-13 SERVICING INFORMA TION ELECTRICAL Complaint Symptom and possible causes Remedy 1. Defective CDI & Ignition coil unit. Replace. No sparking or Replace. 2. Defective spark plug. poor sparking. 3. Defective magneto stator coil. Replace. 4. Loose connection of lead wire. Connect/tighten.
  • Page 126 SERVICING INFORMA TION 7-14 CHASSIS Complaint Symptom and possible causes Remedy Handling feels 1. Steering stem nut overtightened. Adjust. 2. Broken bearing/race in steering stem. Replace. too heavy. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handle.
  • Page 127 7-15 SERVICING INFORMA TION Complaint Symptom and possible causes Remedy Excessive brake 1. Air entered into hydraulic system. Bleed air. lever stroke. 2. Insufficient brake fluid. Replenish fluid to narmal lever;bleed air. 3. Improper quality of brake fluid. Replace with correct fluid. 4.
  • Page 128 Prepared by HYOSUNG MOTORS & MACHINERY INC. Overseas Service 2nd Ed. APR. 1999 Manual No. 99000-91201 Printed in Korea...

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