HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL SERVICE MANUAL 99000-94710 FOREWORD This manual contains an introductory description on HYOSUNG GROUP INDEX GENERAL INFORMATION / and proce- 1 2 3 4 5 6 7 dures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service. This manual has been prepared on the basis of the latest specification at the time of publication. If modification has been made since then, difference may exist between the content of this manual and the actual vehicle. Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail. PERIODIC MAINTENANCE ENGINE FUEL SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer. HYOSUNG MOTORS & MACHINERY INC. COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2002. HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where you are looking for. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. On the first page of each section, its contents are listed. Find the item and page you need. COMPONENT PARTS Example: Front wheel 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 Torque control required. Data beside it indicates specified torque. SYMBOL DEFINITION Apply THREAD LOCK 1324 . Apply oil. Use engine oil unless otherwise specified. Apply or use brake fluid. Apply SUPER GREASE A . Measure in voltage range. Apply SUPER GREASE C . Measure in resistance range. Apply SILICONE GREASE. Measure in current range. Apply MOLY PASTE. Use special tool. Apply BOND 1215 . NOTE Difference between photographs and actual motorcycles depends on the markets. GENERAL INFORMATION 1 CONTENTS INFORMATION LABELS GENERAL PRECAUTIONS SERIAL NUMBER LOCATION FUEL AND OIL RECOMMENDATIONS BREAK-IN PROCEDURES CYLINDER CLASSIFICATION EXTERIOR ILLUSTRATION SPECIFICATIONS 1-1 1-1 1-3 1-4 1-5 1-5 1-6 1-8 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. CAUTION Indicates a potential hazard that could result in vehicle damage. NOTE Indicates special information to make maintenance easier or instructions cleaner. Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS WARNING Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle. When 2 or more persons work together, pay attention to the safety of each other. When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all off the material manufacturer s instructions. Never use gasoline as a cleaning solvent. To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while after engine operation. After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks. GENERAL INFORMATION 1-2 WARNING 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. Be sure to use special tools when instructed. Make sure that all parts used in reassembly are clean, and also lubricated when specified. When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. When removing the battery, disconnect the negative cable first and then positive cable. When reconnecting the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the positive terminal. When performing service to electrical parts, if the service procedures do not require use of battery power, diconnect the negative cable at the battery. Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque. Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. Do not use self-locking nuts a few times over. Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil if a thread is smeared with them. After reassembly, check parts for tightness and operation. WARNING To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires. To protect Earth s natural resouces, properly dispose of used vehicles and parts. 1-3 GENERAL INFORMATION SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine serial number is located on the left upside of crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. FRAME SERIAL NUMBER ENGINE SERIAL NUMBER GENERAL INFORMATION 1-4 FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85~95 octane (Research Method) or higher. An unleaded gasoline type is recommended. ENGINE OIL ENGINE OIL SPECIFICATION Classification system API SAE Grade Over SG 10W/30 or 10W/40 If an SAE 10W/30 or 10W/40 motor oil is not available, select an alternative according to the following chart. Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. WARNING Don t mix the unrecommended oil. It could damage the engine. When refilling the oil tank, don t allow the dust to get inside. Mop the oil spilt. Don t put the patch on the cap. It could disturb the oil to be provided and damage the engine. BRAKE FLUID Specification and classification: DOT3 or DOT4 WARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil : TELLUS #22 1-5 GENERAL INFORMATION 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. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows: Keep to these break-in procedures: Initial 800km Up to 1,600km Less than 1/2 throttle Less than 3/4 throttle Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation. Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the throttle position. CYLINDER CLASSIFICATION The engine of / is composed of the two cylinder, is classified into the front cylinder and rear cylinder as basis of the motorcycle ahead. Rear cylinder Front cylinder FRONT GENERAL INFORMATION 1-6 EXTERIOR ILLUSTRATION 800 890 395 795 795 315 635 1,045 1,120 180 1,455 2,080 325 795 960 890 895 760 1-7 GENERAL INFORMATION EXTERIOR ILLUSTRATION GENERAL INFORMATION 1-8 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall width Overall height Wheelbase Ground clearance Unladen mass 2,080 mm (81.9 in) 760 mm (29.9 in) 1,120 mm (44.1 in) 1,455 mm (53.7 in) 180 mm (7.1 in) 170 kg (375 lbs) 167 kg (368 lbs) ENGINE Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Lubrication system Four-stroke, DOHC, air-cooled and oil-cooled V-2 cylinder 57.0 mm (2.24 in) 48.8 mm (1.92 in) 249 (15.2 in ) 3 44.0 mm (1.73 in) 41.0 mm (1.61 in) 124.7 (7.6 in3 ) BDS 26TYPE (DOUBLE) Electric starter Wet sump TRANSMISSION Clutch Transmission Gearshift pattern Final reduction Gear ratio, 1st 2nd 3rd 4th 5th Drive chain Wet multi-plate type 5-speed constant mesh 1-down, 4-up 3.286 2.462 1.556 1.190 0.957 0.840 520 HO 112 links 3.714 2.750 1.786 1.350 1.091 0.913 428 HO 136 links 1-9 GENERAL INFORMATION CHASSIS Front suspension Rear suspension Steering angle Caster Trail Front brake Rear brake Front tire size Rear tire size Front fork stroke Telescopic type Swingarm type 33 (right & left) 25.5 85 mm (3.35 in) Disk brake Disk brake 110/70 - 17 54H 150/70 - 17 69H 120 mm (4.72 in) 76 mm (2.29 in) ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Head lamp Turn signal lamp Brake / Tail lamp Speedometer lamp High beam indicator lamp Turn signal indicator lamp(right & left) License plate lamp Neutral indicator lamp CDI type 13 B.T.D.C.at 2,000 rpm and 30 B.T.D.C.at 6,000 rpm CR8E 12V 12Ah 15 A HI : 60 W LO : 55 W 10 W 21 / 5 W 1.7 W 3 1.7 W 1.7 W 2 5W 1.7 W HI : 35 W LO : 35 W CAPACITIES Fuel tank Engine oil, oil change with filter change overhaul Front fork oil (One side) 17.0 1,450 1,500 1,800 400 2.5 cc 1,650 262 cc NOTE The specifications are subject to change without notice. PERIODIC MAINTENANCE 2 CONTENTS PERIODIC MAINTENANCE SCHEDULE PERIODIC MAINTENANCE CHART LUBRICATION POINTS MAINTENANCE PROCEDURES VALVE CLEARANCE SPARK PLUG EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS AIR CLEANER CARBURETOR FUEL HOSE CLUTCH ENGINE OIL ENGINE OIL FILTER DRIVE CHAIN BRAKE SYSTEM STEERING FRONT FORK REAR SUSPENSION TIRE CHASSIS BOLTS AND NUTS COMPRESSION PRESSURE OIL PRESSURE 2- 1 2- 1 2- 2 2- 3 2- 3 2- 5 2- 5 2- 6 2- 7 2- 8 2- 8 2- 9 2-10 2-11 2-13 2-17 2-17 2-17 2-18 2-18 2-19 2-20 2 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 ENGINE Interval Item Air cleaner element Exhaust pipe nuts and muffler mounting bolts Valve clearance adjust Cylinder head nut Cylinder head & Cylinder Spark plug Fuel hose Engine oil filter Engine oil Throttle cable Idle speed Clutch Initial 1,000 km Every 4,000 km Every 8,000 km page 2- 6 2-5 2- 3 3-48 3-22 2- 5 2- 8 2-10 2- 9 2- 7 2- 7 2- 8 Clean every 3,000 km Tighten Inspect Tighten Clean Inspect Replace Replace Inspect Inspect Inspect Replace every 12,000 km Tighten Inspect Tighten Clean Inspect Replace every 4 years Replace Replace Inspect Inspect Inspect Remove carbon Replace CHASSIS Interval Item Drive chain Brake Brake hose Brake fluid Tires Steering Front forks Rear suspension Chassis bolts and nuts Initial 1,000 km Every 4,000 km Every 8,000 km page 2-11 2-13 2-13 2-13 2-18 2-17 2-1 ...