HYOSUNG WOW90 Service Manual
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HYOSUNG WOW90 Service Manual

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HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
99000-94310

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Summary of Contents for HYOSUNG WOW90

  • Page 1 HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL 99000-94310...

  • Page 2: General Information

    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. 2001.
  • Page 3 H H O O W W T T O O U U S S E E T T H H I I S S M M A A N N U U A A L L TO LOCATE WHAT YOU ARE LOOKING FOR: 1.
  • Page 4 COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, its exploded view is provided with work instruction and other service information such as the tightening torque, lubricating points and looking agent points. Example : STEERING AND FRONT SUSPENSION TIGHTENING TORQUE N∙...

  • Page 6: Table Of Contents

    G G E E N N E E R R A A L L I I N N F F O O R R M M A A T T I I O O N N CONTENTS 1 - 1 INFORMATION LABELS 1 - 1 GENERAL PRECAUTIONS...

  • 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 vehicles 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 front frame member. The engine seri- al number is stamped on the right side of crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. ◉...

  • Page 11: Fuel And Oil Recommendations

    Gasoline used should be graded 85~95 octane or higher. An unleaded type gasoline is recommended. If engine pinging is experienced, substitute another brand as there are differences between brands. ◉ ENGINE OIL Use HYOSUNG HYPOL OIL HS. If they are not available, use a good quality TWO-STROKE engine oil. ◉ TRANSMISSION OIL Use a good quality SAE 10W/30 or 10W/40 multigrade motor oil.

  • Page 12: Exterior Illustration

    GENERAL INFORMATION 1- 6 EXTERIOR ILLUSTRATION (WHEEL BASE) 1,355 (LENGTH)

  • Page 13: Specifications

    1- 7 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 1,355 mm (53.4 in) Overall width 820 mm (32.3 in) Overall height 865 mm (34.1 in) Wheelbase 950 mm (37.4 in) Ground clearance 120 mm (4.7 in) Front track 658 mm (25.9 in) Rear track 658 mm (25.9 in)
  • Page 14 P P E E R R I I O O D D I I C C M M A A I I N N T T E E N N A A N N C C E E C C O O N N T T E E N N T T S S 2 - 1 PERIODIC MAINTENANCE SCHEDULE 2 - 1...

  • Page 15: Periodic Maintenance Schedule

    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 vehicle operating at peak performance and economy. CAUTION More frequent servicing should be performed on vehicles that are used under severe conditions. PERIODIC MAINTENANCE CHART ◉...

  • Page 16: Lubrication Points

    PERIODIC MAINTENANCE 2-2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the vehicle. Major lubrication points are indicated below. ① King pin ⑦ Front brake cable ② Front wheel bearing ⑧ Throttle cable ③...

  • Page 17: Maintenance Procedures

    : do not twist or wring the element or it will develop tears. ● Immerse the element in HYOSUNG genuine oil and squeeze the oil out of the element leaving it slightly wet with oil.

  • Page 18: Cylinder Head Nuts

    PERIODIC MAINTENANCE 2-4 CYLINDER HEAD NUTS NOTE : Tighten Initial 1 month and Every 3 months. Cylinder head nuts, when they are not tightened to the specified torque, may result in leakage of the compressed mixture and reduce output. First loosen the nuts and tighten the 4 nuts evenly one by one in stages until each one is tightened to the specified torque.

  • Page 19: Spark Plug

    2-5 PERIODIC MAINTENANCE SPARK PLUG NOTE : Inspect Initial 1 month and Every 3 months, Replace Every 6 months. Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is used for a long period, the electrode grad- ually burns away and carbon builds up along the inside part.

  • Page 20: Carburetor

    PERIODIC MAINTENANCE 2-6 CARBURETOR NOTE : Inspect Initial 1 month and Every 6 months. ◉ IDLE SPEED ● Adjust the throttle cable play. ● Warm the engine up. NOTE : A warm engine means an engine has been run for 10 minutes.

  • Page 21: Transmission Oil

    2-7 PERIODIC MAINTENANCE TRANSMISSION OIL NOTE : Inspect Initial 1 month and Every 6 months. After a long period of use, the transmission oil qual- ities will deteriorate and quicken the wear of sliding and interlocking surfaces. Replace the transmission oil periodically following the procedure below.
  • Page 22 PERIODIC MAINTENANCE 2-8 ■ ■ BRAKE LINING WEAR LIMIT This vehicle is equipped with the brake lining wear limit indicator on the front brake. As shown in the illustration at right, at the condition of normal lining wear, an extended line from the index mark on the brake camshaft should be within the range embossed on the brake panel.
  • Page 23 2-9 PERIODIC MAINTENANCE ■ ■ BRAKE PAD WEAR The extend of brake pad wear can be checked by observ- ing 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 performance will be adversely affected.

  • Page 24: Drive Chain

    PERIODIC MAINTENANCE 2-10 DRIVE CHAIN NOTE : Inspect and lubricate Every month. Visually check the drive chain for the possible defects listed below. 1. Loosen pins 2. Damaged rollers 3. Dry or rusted links 4. Kinked or binding links 5. Excessive wear If any defects are found, the drive chain must be replaced.

  • Page 25: Tire

    The standard tire fitted on this 『 『 ATV』 』 is 18×7.00 - 7 for front and rear. The use of a tire other than the standard may cause handling instability. It is high- ly recommended to use a HYOSUNG Genuine Tire. COLD INFLATION TIRE PRESSURE kgf/㎠...

  • Page 26: Steering

    PERIODIC MAINTENANCE 2-12 STEERING NOTE : Inspect Initial 1 month and Every 3 months. Steering system should be adjusted properly for smooth manipulation of handlebars and safe running. ◉ TOE-IN ● Place the vehicle on the level ground. ● Make sure that the tire pressure is within speci- fication.(Refer to page 2-11) ●...
  • Page 28 E E N N G G I I N N E E CONTENTS 3 - 1 ENGINE REMOVAL AND REINSTALLATION 3 - 1 ENGINE REMOVAL 3 - 5 ENGINE REINSTALLATION 3 - 6 ENGINE DISASSEMBLY 3 - 16 ENGINE COMPONENTS INSPECTION AND SERVICING 3 - 16 BEARINGS 3 - 16...

  • Page 29: Engine Removal And Reinstallation

    3-1 ENGINE ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner and drain trans- mission oil, etc. The procedure of engine removal is sequentially explained in the following steps, and engine reinstallation is effected by reversing the removal proce- dure.
  • Page 30 ENGINE 3-2 ● Remove the engine ground lead wire ①. ● Remove the spark plug cap ②. ● Remove the starter motor lead wire ③. ● Disconnect the magneto coil lead wire ④.
  • Page 31 3-3 ENGINE ● Disconnect the thermoelement coupler ①. ● Remove the air cleaner ② and air cleaner chamber ③. ● Remove the carburetor assembly from the intakepipe. ● Disconnect the oil hose and oil pump cable from the oil pump.
  • Page 32 ENGINE 3-4 ● Remove the chain case cover. ● Remove the engine sprocket from the drive shaft by using the snap ring pliers. ● Remove the drive chain. ● Remove the seven engine mounting link bolts. ● Remove the engine assembly from the frame with rear axle housing assembly.

  • Page 33: Engine Reinstallation

    3-5 ENGINE ENGINE REINSTALLATION F o r r e m o u n t i n g e n g i n e , r e v e r s e t h e o r d e r o f engine removal and take the following additional steps.

  • Page 34: Engine Disassembly

    ENGINE 3-6 ENGINE DISASSEMBLY ◉ MUFFLER ● Remove the muffler removing the bolts. ◉ CYLINDER ● Remove the cylinder cowling. ● Remove the cylinder head ① and cylinder ②. ② ① ◉ PISTON ● Place a cloth beneath the piston and remove the pis- ton pin circlip ③...
  • Page 35 3-7 ENGINE ◉ INTAKE PIPE AND OIL PUMP ● Remove the intake pipe ① and oil pump ②. ② ● Remove the reed valve ③. ● Remove the oil pump driven gear ④. ④ ◉ MAGNETO ● Remove the cooling fan. ●...
  • Page 36 ENGINE 3-8 ● Remove the magneto rotor with the special tool. Rotor remover sliding shaft : 09930-30102 Rotor remover : 09930-30163 ● Remove the magneto stator and key. ◉ MOVABLE DRIVE FACE ● Remove the clutch cover. ● Remove the fixed drive face nut ① with the special tool.
  • Page 37 3-9 ENGINE ◉ MOVABLE DRIVEN FACE ● Remove the clutch housing ①. ◉ STARTER DRIVEN GEAR ● Remove the starter driven gear ②. ● Remove the starter idle gear cap and starter motor pinion. ● Remove the starter motor.
  • Page 38 ENGINE 3-10 ● Loosen the clutch shoe nut with the special tool. Rotor holder : 09930 - 40113 ● Remove the nut while holding down the clutch shoe assembly by both hands as shown in the illustration. WARNING Gradually back off the clutch shoe assembly pressed down by hand to counter the clutch spring load.
  • Page 39 3-11 ENGINE ● Remove the needle bearing � with the special tools. Bearing remover(17mm) : 09923 - 73210 � Rotor remover sliding shaft : 09930 - 30102 CAUTION The removed bearing should be replaced with a new one. ● Remove the circlip �. �...
  • Page 40 ENGINE 3-12 ◉ TRANSMISSION ● Drain transmission oil. ● Remove the gear box cover ①. ● Remove the drive shaft ②. ● Remove the oil seal ③ from the gear box cover with the special tool. Oil seal remover : 09913-50121 CAUTION The removed oil seal should be replaced with a new one.
  • Page 41 3-13 ENGINE ◉ CRANKCASE ● Remove the crankcase securing screws. Crankcase separater : 09920-13120 NOTE : Loosen the crankcase screws diagonally. ● Remove the crankshaft with the special tool. Crankcase separater : 09920-13120...
  • Page 42 ENGINE 3-14 ● Remove the bushing. ● Using two steel tubes of appropriate size, press out the engine mounting bushings on a vise as shown Bushing in the illustration.
  • Page 43 3-15 ENGINE Front side Bushing Crankcase Rear side Bushing Crankcase...

  • Page 44: Engine Components Inspection And Servicing

    ENGINE 3-16 ENGINE COMPONENTS INSPEC- TION 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 45: Automatic Clutch Inspection

    3-17 ENGINE ◉ CONROD SMALL END BORE I.D. Measure the conrod small end diameter with a caliper gauge. Service limit Conrod small end bore I.D. 16.040mm (0.632 in) Dial calipers : 09900-20605 AUTOMATIC CLUTCH INSPECTION This vehicle is equipped with an automatic clutch and variable ratio belt drive transmission.
  • Page 46 ENGINE 3-18 CAUTION Do not apply full power for more than 3 seconds or damage to the clutch or engine may occur. Standard 5,900 rpm Clutch tight RPM ±200 rpm Tolerance Engine tachometer : 09900-26006 If the engine RPM does not coincide with the specified RPM range, then disassemble the clutch.
  • Page 47 3-19 ENGINE ◉ DRIVE V-BELT Remove the drive V-belt and check for cracks, wear and separation. Measure the belt width with a vernier calipers. Replace it if the belt width is less than the ser- vice limit or any defect has been found. Service limit Drive V-belt width 16.0 mm (0.630 in)

  • Page 48: Cylinder Head

    ENGINE 3-20 ◉ DRIVEN FACE PIN AND OIL SEAL Turn the driven faces and check to see that the driven faces turn smoothly. If any stickness or hitches are found, visually inspect the lip of seal, driven face sliding surface and sliding pins for wear or damage.

  • Page 49: Cylinder

    3-21 ENGINE CYLINDER Decarbon exhaust port and upper part of the cylinder, taking care not to damage the cylinder wall surface. The wear of the cylinder wall is determined from diame- ter reading taken at 20mm from the top of the cylinder with a cylinder gauge.
  • Page 50 ENGINE 3-22 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 measurement for the bore diameter should be taken in the intake- to-exhaust port direction and at 20mm from cylinder top surface.
  • Page 51 3-23 ENGINE ◉ PISTON PIN O.D. Using a micrometer, measure the piston pin outside diameter at three positions. Service limit Piston pin O.D. 11.980 mm (0.472 in) Micrometer(0~25mm) : 09900 - 20201 ◉ PISTON RINGS Check each ring for the clearance, reading the clear- ance with a thickness gauge shown in the illustration.

  • Page 52: Reed Valve

    ENGINE 3-24 Fix the piston ring in the piston ring groove, measure the ring side clearance with the thickness gauge while matching the sliding surfaces of piston and ring. Piston ring - groove Standard clearance 0.02~0.06 mm (0.0008 ~ 0.0024 in) 0.02~0.06 mm (0.0008 ~ 0.0024 in) REED VALVE...

  • Page 53: Bearings

    3-25 ENGINE ● When fitting the oil seal in the crankcase, insert it slowly with the special tools. Oil seal installer : 09913-75830 Bearing installer attachment : 09924-74510 Bearing installer pilot : 09924-74540 NOTE : � � of the crankcase as Align the oil seal with edge shown in the illustration.

  • Page 54: Crankshaft

    ENGINE 3-26 NOTE : Knurled end � � should face inside. Protrusive � � and � � should be in the same dimension. � Bushing � � � � Bushing Bushing Crankcase Crankcase � � � CRANKSHAFT...

  • Page 55: Crankcase

    3-27 ENGINE ● Measure the length between the webs referring to the figure at right when rebuilding the crankshaft. Standard 40.0 ± 0.1 mm Crank web to web width (1.575 ± 0.004 in) ● When mounting the crankshaft into the crankcase, it is necessary to pull its left end into the crankcase with the special tool.

  • Page 56: Transmission

    ENGINE 3-28 ● Install the new oil seal ① to the crankcase with the special tool. Bearing installer : 09913-85210 NOTE : Align the oil seal with edge � � of the crankcase as shown in the illustration. � TRANSMISSION...
  • Page 57 3-29 ENGINE ● Install the circlip ① on to the rear axle shaft ② . ● Assemble the idle shaft subassembly using the idle shaft ③ and thrust washer ④, then install the sub- assembly on the gear box. ④ ③...

  • Page 58: Starter Pinion, Starter Driven Gear And Starter Motor

    ENGINE 3-30 STARTER PINION, STARTER DRIVEN GEAR AND STARTER MOTOR ● Apply SUPER GREASE“A”on the pinion shaft and install the starter pinion subassembly. SUPER GREASE “A” ● Assemble the starter pinion subassembly ①. ● Insert the two dowel pins ② on the crankcase.
  • Page 59 3-31 ENGINE ● Install the starter idle gear cap ①. ● Install the starter driven gear ② over the left crankshaft end. NOTE : The convex side of hub should face outside when installed in proper position. ● Install the new O-ring ③. ●...

  • Page 60: Movable Driven And Clutch

    ENGINE 3-32 MOVABLE DRIVEN AND CLUTCH ● Install the bearing ② in the fixed driven face ① with the special tool. Bearing installer : 09943-88211...
  • Page 61 3-33 ENGINE ● Install the circlip ①. CAUTION Insert surely in the circlip groove. Thrust � Rounded coner ● Install the bearing ② with the special tool. Bearing installer : 09943-88211 CAUTION A mark part of the bearing is pointed to the outside. ●...
  • Page 62 ENGINE 3-34 ● Install the movable driven face ① to the fixed driven face ②. CAUTION Insert as guide the rim. When reinstalling the movable driven face to the fixed driven face, make sure that the O-ring is positioned properly. ●...
  • Page 63 3-35 ENGINE ● Install the spring ①. ● Install the clutch shoe assembly ② and nut ③. ● Tighten the nut to the specified torque with the spe- cial tool. Rotor holder : 09930-40113 Clutch shoe nut : 40~60 N ∙ ∙ m (4.0~6.0 kg ∙ ∙ m) ●...

  • Page 64: Movable Drive

    ENGINE 3-36 MOVABLE DRIVE ● Install the roller ② at six places to the movable drive face ①. ● Mount the three dampers ④ on the movable drive plate ③ and install it on the movable drive face ⑤ . ●...
  • Page 65 3-37 ENGINE ● Install the movable drive face cover ①. CAUTION Make sure that the movable drive plate is fully positioned inside, or the weight roller may come off. ● Insert the spacer ②. ● Position the movable drive face subassembly on the crankshaft as shown in the photo.

  • Page 66: Magneto

    ENGINE 3-38 MAGNETO ● Degrease the tapered portion of the crankshaft and also the magneto rotor. ● Install the stator ①. ● Install the key ②. ● Install the rotor ③ . ● Apply THREAD LOCK “ “ 1324” ” to the rotor nut ④ and tighten it to the specified torque with the special tool.

  • Page 67: Piston

    3-39 ENGINE PISTON ● Install the piston ring on the piston. Position the ring so that the marking is on upside. ∙ 1st Keystone ring ∙ 2nd CAUTION Position the ring so that the marking is on upside. Locating pin ●...
  • Page 68 ENGINE 3-40 ● Apply engine oil on the piston pin and install the pis- ton to the conrod. CAUTION � The arrow mark � � on the piston head should point the exhaust side. ● The circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the groove portion of the piston.

  • Page 69: Oil Pump And Intake Pipe

    3-41 ENGINE OIL PUMP AND INTAKE PIPE ● Apply SUPER GREASE “ “ A” ” to the oil pump driven gear ① and install it to the crankcase. SUPER GREASE “A” ● Install the oil pump ② and tighten it to the specified torque.

  • Page 70: Cooling Fan

    ENGINE 3-42 ● Install the reed valve gasket ①, intake pipe gasket ② and intake pipe ④ with reed valve ③ to the crankcase. COOLING FAN ● Install the cylinder cowling ⑤. ● Install the fan case ⑥. ● Install the magneto lead wire and starter motor lead wire.

  • Page 71: Muffler

    3-43 ENGINE ● Install the cooling fan ①. ● Install the cooling fan cover ②. MUFFLER ● Tighten the exhaust pipe bolts ③ and muffler mount- ing bolts ④ to the specified torque. Exhaust pipe bolt : 8~12 N∙m (0.8~1.2 kg∙m) Muffler mounting bolt : 18~28 N∙m (1.8~2.8 kg∙m)
  • Page 72 FUEL SYSTEM 4-4 4 F F U U E E L L S S Y Y S S T T E E M M CONTENTS 4 - 1 CARBURETOR 4 - 1 REMOVAL 4 - 2 DISASSEMBLY 4 - 4 INSPECTION 4 - 5 REASSEMBLY AND REMOUNTING...

  • Page 73: Fuel System 4-4

    4-1 FUEL SYSTEM CARBURETOR REMOVAL ● Remove the front and rear fender.

  • Page 74: Disassembly

    FUEL SYSTEM 4-2 ● Remove the carburetor top cap ①, and disconnect the throttle cable ②. ● Disconnect the fuel hose ③. ● Remove the carburetor by loosening the mounting bolts ④ . DISASSEMBLY ● Remove the thermoelement assembly. CAUTION Do not attempt to disassemble the thermoelement assembly.
  • Page 75 4-3 FUEL SYSTEM ● Remove the throttle valve, spring and jet needle. ● Remove the float chamber ①. ● Pull out the float pin ② and remove the float ③. ● Remove the needle valve ④.

  • Page 76: Inspection

    FUEL SYSTEM 4-4 ● Remove the throttle stop screw ① and pilot air screw ② . CAUTION When removing the pilot air screw, record the revolutions until tighten completly. ① ② ● Remove the pilot jet ③, main jet ④ and needle jet ⑤.

  • Page 77: Reassembly And Remounting

    4-5 FUEL SYSTEM REASSEMBLY AND REMOUNTING ● Reassemble following items. ① Pilot air screw ② Throttle stop screw ③ Pilot jet ④ Main jet ⑤ Needle jet ● Install the needle valve ⑥ and float ⑦ on the carbu- retor body. ●...
  • Page 78 FUEL SYSTEM 4-6 ● Install the thermoelement assembly. ● Install the carburetor assembly. ● Install the fuel hose ① . ● Install the carburetor top cap ②.

  • Page 79: Fuel Tank

    4-7 FUEL SYSTEM FUEL TANK REMOVAL ● Remove the frame covers. (Refer to page 4-1) ● Remove the fuel tank mounting bolts. ● Turn the fuel cock to “OFF”and disconnect the fuel hose ①. ● Remove the fuel tank. ● Remove the fuel cock. INSPECTION ◉...

  • Page 80: Remounting

    ● Remove the frame cover. ● Have the HYPOL Oil gauge filled with HYOSUNG HYPOL OIL HS and connect it to the suction side of the pump. ● Run the engine at 3,000 rpm.
  • Page 82 ELECTRICAL SYSTEM C C O O N N T T E E N N T T S S 5 - 1 IGNITION/CHARGING SYSTEM 5 - 1 IGNITION COIL 5 - 2 CDI UNIT 5 - 2 STATOR COILS 5 - 3 REGULATOR/RECTIFIER 5 - 3 STARTER SYSTEM...

  • Page 83: Ignition/Charging System

    5-1 ELECTRICAL SYSTEM IGNITION/CHARGING SYSTEM Stator lgnition Regulator unit coil Rectifier Battery Spark 12V 4AH plug (MF) Engine stop switch IGNITION COIL ● Pull out the spark plug. ● Place it on the cylinder head after installing it at the plug cap to obtain ground.

  • Page 84: Cdi Unit

    ELECTRICAL SYSTEM 5-2 CDI UNIT ㏀ × 1 Using the pocket tester (R range), measure the resistance between the lead wires in the following table. ㏀ Unit : � Probe of tester 14~18 7.5~9.5 5.5~6.5 3.6~4.4 2~2.5 8~10 12.5~15.5 27~33 29~35 10.5~13.5 2~2.5...

  • Page 85: Regulator/Rectifier

    5-3 ELECTRICAL SYSTEM ◉ ◉ NO-LOAD PERFORMANCE OF A.C. GENERATOR ● Disconnect the magneto lead wire coupler. ● Start the engine and keep it running at 5,000 rpm. ● Using a pocket tester, measure the AC voltage between the three lead wire. If the tester reading is as follows, magneto is in good condition.

  • Page 86: Starting Motor Removal And Disassembly

    ELECTRICAL SYSTEM 5-4 STARTING MOTOR REMOVAL AND DISASSEMBLY Remove the starting motor. Disassemble the starting motor as shown in the illustration. STARTING MOTOR INSPECTION ◉ ◉ CARBON BRUSHES When the brushes are worn, the motor will be unable to procedure sufficient torque, and the engine will be diffi- cult to turn over.

  • Page 87: Starter Relay Inspection

    5-5 ELECTRICAL SYSTEM ◉ ◉ ARMATURE COIL Using the pocket tester, check the coil for open and ground by placing probe pins on each commutator seg- ment and rotor core (to test for ground) and on any two segments at various places (to test for open), with the brushes lifted off the commutator surface.

  • Page 88: Switches Inspection

    ELECTRICAL SYSTEM 5-6 ◉ ◉ INSPECTION ● Disconnect the thermoelement coupler ① . ● Connect the thermoelement coupler ① to a 12V bat- tery and touch the thermoelement ② to check the temperature being raised. The thermoelement ② should become heated to a temperature more than that of human body within five minutes.

  • Page 89: Battery

    5-7 ELECTRICAL SYSTEM 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 90 ELECTRICAL SYSTEM 5-8 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 does not fall. Take precaution not to allow any of the fluid to spill. CAUTION There may be a case which can’...
  • Page 91 5-9 ELECTRICAL SYSTEM 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 92 CHASSIS C C O O N N T T E E N N T T S S 6 - 1 FRONT WHEEL AND BRAKE 6 - 2 REMOVAL 6 - 3 INSPECTION AND DISASSEMBLY 6 - 4 REASSEMBLY AND REMOUNTING 6 - 6 STEERING AND FRONT SUSPENSION 6 - 6...

  • Page 93: Front Wheel And Brake

    6-1 CHASSIS FRONT WHEEL AND BRAKE...

  • Page 94: Removal

    CHASSIS 6-2 REMOVAL ● Place the vehicle on level ground. ● Remove the wheel center cap. ● Remove the cotter pin and front axle nut. ● Support the vehicle by jack or block and remove the front wheel. ● Remove the brake shoe. ●...

  • Page 95: Inspection And Disassembly

    6-3 CHASSIS INSPECTION AND DISASSEMBLY ◉ ◉ WHEEL HUB BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel hub. Rotate the inner ring by hand to inspect if any abnormal noise occurs or it rotates smoothly. Replace the bearing if there is anything unusual.

  • Page 96: Reassembly And Remounting

    CHASSIS 6-4 ◉ ◉ BRAKE SHOE Check the brake shoe and decide whether it should be replaced or not from the thickness of brake lining. Service limit Brake shoe lining thickness 2 mm (0.079 in) CAUTION Replace the brake shoe as a set, otherwise brak- ing performance will be adversely affected.
  • Page 97 6-5 CHASSIS ● Apply BOND “1215”to the front brake plate as shown photo. BOND “1215” ● Install the front brake drum and tire.

  • Page 98: Steering And Front Suspension

    CHASSIS 6-6 STEERING AND FRONT SUSPENSION TIGHTENING TORQUE N∙ ∙ m kg∙ ∙ m ITEM ① 18 ~ 28 1.8 ~ 2.8 ① ② 18.4 ~ 28.6 1.84 ~ 2.86 ③ 22.4 ~ 35.7 2.24 ~ 3.57 ④ 40 ~ 50 4.0 ~ 5.0 ⑤...
  • Page 99 6-7 CHASSIS ● Remove the suspension arm mounting bolts and front shock absorber upper mounting bolt. ● Remove the suspension arm with shock absorber. ● Remove the shock absorber. ● Remove the dust seals and spacer.
  • Page 100 CHASSIS 6-8 ● Remove the handlebar switch. ● Remove the throttle lever case. ● Remove the front brake lever holder. ● Remove the front brake cables. ● Remove the steering head cover bracket and handle- bar by removing the mounting bolts. ●...

  • Page 101: Inspection

    6-9 CHASSIS ● Separate the tie-rod ends ①, nuts ②, ③ and steering tie-rods ④. Tire side CAUTION Inside lock nuts ② ② are left-hand thread. ② ① ④ ③ ① ● Remove the cotter pins ⑤, and remove the steering shaft holder bolts ⑥...

  • Page 102: Reassembly And Remounting

    CHASSIS 6-10 ◉ ◉ SHOCK ABSORBER lnspect the shock absorber for oil leakage or other dam- age. REASSEMBLY AND REMOUNTING Reassemble and remount the steering system in the reverse order of removal and disassembly, and also carry out the following steps : ●...

  • Page 103: Toe-In Adjustment

    6-11 CHASSIS TOE-IN ADJUSTMENT The procedure for adjusting the toe-in as follows. ● Place the vehicle on level ground and set the handle- bar straight . Tire side Make sure that all tires are inflated to the standard pressure. ① COLD INFLATION TIRE PRESSURE kgf/㎠...

  • Page 104: Rear Wheel

    CHASSIS 6-12 REAR WHEEL TIGHTENING TORQUE N∙ ∙ m kg∙ ∙ m ITEM ① 60 ~ 90 6.0 ~ 9.0 ② ② 20 ~ 30 2.0 ~ 3.0 ① ③ 22 ~ 35 2.2 ~ 3.5 ④ 22 ~ 35 2.2 ~ 3.5 ⑤...

  • Page 105: Rear Brake

    6-13 CHASSIS REAR BRAKE � ① ② TIGHTENING TORQUE N∙ ∙ m kg∙ ∙ m ITEM 2 ~ 4 0.2 ~ 0.4 ① ② 6 ~ 8 0.6 ~ 0.8 � : ASSEMBLING APPLY GREASE BRAKE PAD REPLACEMENT ● For replacing procedure of brake pad : Refer to page CALIPER DISASSEMBLY ●...

  • Page 106: Disc Plate Inspection

    CHASSIS 6-14 ● Remove the rear caliper lever return spring . DISC PLATE INSPECTION ● Check the disc for wear with a micrometer. Replace the disc if the thickness exceeds the service limit. Service limit Disc thickness 2.5 mm (0.098 in) Micrometer(0~25mm) : 09900 - 20201 ●...

  • Page 107: Rear Axle Housing, Axle Shaft And Shock Absorber

    6-15 CHASSIS REAR AXLE HOUSING, AXLE SHAFT AND SHOCK ABSORBER ① � ② ① � TIGHTENING TORQUE N∙ ∙ m kg∙ ∙ m ITEM ① 40 ~ 50 4.0 ~ 5.0 ② 40 ~ 60 4.0 ~ 6.0 � : ASSEMBLING APPLY GREASE REMOVAL ●...

  • Page 108: Inspection And Disassembly

    CHASSIS 6-16 ● Remove the shock absorber. ● Remove the rear axle housing. ● Remove the sprocket mounting flange by removing the nut. INSPECTION AND DISASSEMBLY ◉ ◉ AXLE HOUSING BEARING Inspect the play of bearing inner ring by hand while mounting in the axle housing.
  • Page 109 6-17 CHASSIS ● Remove the dust seals with the special tool. Oil seal remover : 09913 - 50121 CAUTION Replace the removed dust seals with new ones. ● Remove the right and left bearings and spacer. ◉ ◉ SHOCK ABSORBER Inspect the rear shock absorber for oil leakage or other damage.
  • Page 110 6-18 CHASSIS ● Romove the rear sprocket. ◉ ◉ REAR AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit. Service limit Rear axle shaft runout 0.5 mm (0.02 in) REASSEMBLY AND REMOUNTING Reassemble and remount the rear axle housing in the reverse order of removal and disassmbly.
  • Page 112 SERVICING INFORMATION C C O O N N T T E E N N T T S S 7 - 1 TROUBLESHOOTING 7 - 5 SPECIAL TOOLS 7 - 8 TIGHTENING TORQUE 7 - 10 SERVICE DATA 7 - 16 WIRE AND CABLE ROUTING WIRING DIAGRAM 7 - 20...

  • Page 113: Troubleshooting

    7-1 SERVICING INFORMATION 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. 2. Stiff piston ring in place. Refair or replace. 3.
  • Page 114 SERVICING INFORMATION 7-2 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 115 7-3 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy 1. Defective CDI & Ignition coil unit. Replace. No sparking or 2. Defective spark plug. Replace. poor sparking. 3. Defective magneto stator coil. Replace. 4. Loose connection of lead wire. Connect/tighten.
  • Page 116 SERVICING INFORMATION 7-4 CHASSIS Complaint Symptom and possible causes Remedy Handling feels 1. Disturbed front wheel alignment. Adjust. too heavy or stiff. 2. Poorly lubricated. Lubricate. 3. Not enough pressure in tires. Adjust. 4. Tie-rod ends tending to seize. Replace. 5.

  • Page 117: Special Tools

    7-5 SERVICING INFORMATION 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 118 SERVICING INFORMATION 7-6 Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 09913-76010 09910-20115 Bearing installer Conrod holder Used to lock the crankshaft. Used to drive crankshaft bearing in. 09910-32812 09913-80112 Crankshaft installer Bearing installer Used to install the crankshaft in the crankcase. Used to drive bearing in.
  • Page 119 7-7 SERVICING INFORMATION Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description 09930-30163 09924-84521 Rotor remover Bearing installer Attached to the top of sliding shaft when removing rotor. Used to drive small bearing in. 09930-10121 09930-40113 Spark plug socket wrench set Rotor holder Widely used to lock rotary parts such as a clutch shoe.

  • Page 120: Tightening Torque

    SERVICING INFORMATION 7-8 TIGHTENING TORQUE ENGINE kg∙ ∙ m N∙ ∙ m ITEM Magneto rotor nut 35 ~ 45 3.5 ~ 4.5 Muffler mounting bolt 18 ~ 28 1.8 ~ 2.8 Exhaust pipe bolt 8 ~ 12 0.8 ~ 1.2 Spark plug 25 ~ 30 2.5 ~ 3.0...

  • Page 121: Tightening Torque Chart

    7-9 SERVICING INFORMATION CHASSIS N∙ ∙ m kg∙ ∙ m ITEM Front brake cam lever nut 6 ~ 8 0.6 ~ 0.8 Front shock absorber bolt & nut 40 ~ 50 4.0 ~ 5.0 Rear sprocket nut 22 ~ 35 2.2 ~ 3.5 Rear shock absorber bolt 40 ~ 50...

  • Page 122: Service Data

    SERVICING INFORMATION 7-10 SERVICE DATA CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT Cylinder to piston clearance 0.073 ~0.083 (0.0029 ~ 0.0033) 0.120 (0.0047) 52.500 ~ 52.515 (2.0669 ~2.0675) Cylinder bore 52.590 (2.0705) Measure at 20mm from the top surface 52.432 ~ 52.447 (2.0643 ~2.0648) Piston diam.
  • Page 123 7-11 SERVICING INFORMATION OIL PUMP ITEM STANDARD Oil pump reduction ratio 30 : 1 CLUTCH Unit : mm (in) ITEM STANDARD LIMIT 112.00 112.50 Clutch housing I.D. (4.4095) (4.4291) Clutch shoe thickness (0.177) (0.079) 3,900 ± 200 rpm Clutch in rpm Clutch tight rpm 5,900 ±...
  • Page 124 SERVICING INFORMATION 7-12 CARBURETOR Unit : mm (in) ITEM SPECIFICATION Carburetor type PB11M Bore size 16.0 (0.630) I.D. No. HL41 Idle rpm 1,800 ± 100 rpm Fuel level 8.0 (0.315) # 70 Main jet (M.J.) Main air jet ф 2.1 (M.A.J.) Jet needle (J.N.)
  • Page 125 7-13 SERVICING INFORMATION ELECTRICAL Unit : mm (in) ITEM SPECIFICATION NOTE B.T.D.C. 8� at 1,000 rpm and B.T.D.C. 20� at 4,000 rpm Ignition timing Type BPR7HS 0.6 ~ 0.7 (0.024 ~ 0.028) BPR6HS Hot type Spark plug BPR7HS Standard type BPR8HS Cold type Spark performance...
  • Page 126 SERVICING INFORMATION 7-14 Unit : mm (in) BRAKE + WHEEL ITEM STANDARD LIMIT Front Brake lever play 5 ~15 (0.197 ~ 0.591) Brake pedal play Rear 15 ~25 (0.591 ~ 0.984) 110.0 110.7 Brake drum I.D. Front (4.330) (4.358) 110.0 106.0 Brake shoe lining O.D.

  • Page 127: Tire Pressure

    Gasoline used should be graded 85 ~ 95 octane or higher. An Fuel type unleaded gasoline is recommended. Fuel tank capacity ℓ Use HYOSUNG HYPOL HS OIL or an equivalent good quality Engine oil type synthetic based 2-stroke engine oil. 1.0 ℓ Engine oil tank capacity 2.6 ~ 2.8 ㎖...

  • Page 128: Wire And Cable Routing

    SERVICING INFORMATION 7-16 WIRE AND CABLE ROUTING...
  • Page 129 7-17 SERVICING INFORMATION...
  • Page 130 SERVICING INFORMATION 7-18 VIEW A BATTERY STARTER RELAY FUSE VIEW B 09407-14403 MAGNETO START MOTOR...
  • Page 131 7-19 SERVICING INFORMATION 09407-14403 FRONT STOP SWITCH 09407-14403 HANDLE SWITCH LH HANDLE SWITCH LH / STOP SWITCH CDI UNIT FRONT FENDER CDI UNIT ASSEMBLY POSITION...

  • Page 132: Wiring Diagram

    SERVICING INFORMATION 7-20 WIRING DIAGRAM...
  • Page 133 Prepared by HYOSUNG MOTORS & MACHINERY INC. Overseas Technical Department 1st Ed. AUG. 2001. Manual No. 99000-94310 Printed in Korea...

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