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 2-17 2-17 2-18 Clean and lubricate every 1,000km Inspect Inspect Inspect Inspect Inspect Inspect Inspect Replace every 4 years Inspect Replace every 2 years Inspect Inspect Inspect Inspect Tighten Tighten CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and shorten its useful life. Use only genuine Hyoung replacement parts or their equivalent. 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. Clutch lever holder Drive chain Side stand pivot and spring hook Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot O - Motor oil, G - Grease NOTE Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has been operated under wet or rainy condition. 2-3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURE This section describes the service procedure for each section of the periodic maintenance. VALVE CLEARANCE Inspect Interval 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. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is disturbed by removing it for servicing. Remove the spark plug. (Refer to page 2-5) Remove the fuel tank. (Refer to page 4-1) Remove the cylinder head cover and . Remove the magneto cover plug and the timing inspection plug . [ FRONT CYLINDER ] [ REAR CYLINDER ] 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.) To inspect the front cylinder s valve clearance, insert the thickness gauge to the clearance between the camshaft and the tappet. Valve clearance (when cold) IN. EX. 0.1 0.2 0.2 mm (0.004~0.008 in) 0.3 mm (0.008~0.012 in) Thickness gauge : 09900-20806 PERIODIC MAINTENANCE 2-4 If the clearance is out of specification, first remove the cam chain tensioner, camshaft housing, camshaft. To install the tappet shim at original position, record the shim NO. and clearance with A , B , C , D mark on the cylinder head as the illustration. Select the tappet that agree with tappet clearance (vertical line) and shim NO.(horizontal line) as refer to the tappet shim selection chart. (Refer to page 7-33 34) Adjust valve timing, install the camshaft housing and the tensioner. After the crankshaft rotate about 10 times, measure the valve clearance. If the clearance be not agree, adjust the standard clearance as the same manner above. In case that valve adjustment which there is no the tappet shim selection chart, please follow instructions of example in the below. For example, the intake clearance is 0.4 and the shim is 170 (1.70 mm), select 195 (1.95 mm) of the shim which 170 (1.70 mm) of the shim add up the excess clearance 0.25 mm when adjust with the standard 0.15 as the intake standard clearance 0.1 0.2 mm. CAUTION Valve clearance should be checked when the engine is cold. If you don t rotate the crankshaft about 10 times before measuring the valve clearance, there is no meaning of valve clearance. 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.) Inspect the rear cylinder s valve clearance with the same manner of the front cylinder. 2-5 PERIODIC MAINTENANCE SPARK PLUG Inspect Interval Clean Initial 1,000 km and Every 4,000 km, Replace Every 8,000 km. Disconnect the spark plug caps. Remove the spark plugs. TYPE Hot type Standard type Cold type SPARK PLUG SPECIFICATION CR7E CR8E CR9E Remove the carbon deposite with wire or pin and adjust the spark plug gap to 0.7 0.8 mm, measuring with a thickness gauge. Spark plug gap 0.7 0.8 mm (0.028~0.032 in) Thickness gauge : 09900-20806 Check to see the worn or burnt condition of the electrodes. If it is extremly worn or burnt, replace the plug. And also replace the plug if it has a broken insulator, damaged thread, etc. Install the spark plug, and then tighten it to specified torque. Spark plug : 20~25 N m (2.0~2.5 kg m) 0.7 0.8mm (0.028 0.032 in) EXHAUSE PIPE NUTS AND MUFFLER MOUNTING BOLTS Inspect Interval Tighten Initial 1,000 km and Every 4,000 km. Tighten the exhaust pipe nuts , and muffler mounting bolts to the specified torque. Exhaust pipe nut : 18~28 N m (1.8~2.8 kg m) Muffler mounting bolt : 20~30 N m (2.0~3.0 kg m) [ Front Cylinder ] PERIODIC MAINTENANCE 2-6 [ Rear Cylinder ] AIR CLEANER Inspect Interval Clean Every 3,000 km, Replace Every 12,000 km. The air cleaner is located under the fuel tank. Remove the fuel tank. Remove the four screw Pull up the air cleaner cover and the air cleaner element 2-7 PERIODIC MAINTENANCE 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. Carefully examine the air cleaner element for tears during cleaning. Replace it with a new one if it is torn. Assemble the element completely or damage severely the engine. Be careful not to allow water to go inside the air cleaner element. CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions, also clean the air cleaner element when replacing the oil to prevent damage of the engine. CARBURETOR Inspect Interval 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 1,450 and 1,550 rpm by turning throttle stop screw . Engine idle speed 1,450 1,550 rpm Engine tachometer : 09900-26006 THROTTLE CABLE PLAY There should be 0.5 1.0 mm play on the throttle cable. To adjust the throttle cable play. Tug on the throttle cable to check the amount of play. Loosen the lock nut and turn the adjuster in or out until the specified play is obtained. Secure the lock nuts while holding the adjuster in place. Throttle cable play 0.5 1.0 mm (0.02~0.04 in) PERIODIC MAINTENANCE 2-8 FUEL HOSE Inspect Interval Inspect Initial 1,000 km and Every 4,000 km, Replace every 4 years. Remove the front and rear seat. (Refer to page 6-1) Inspect the fuel hoses for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced. [ ] [ ] CLUTCH Inspect Interval 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 : Loosen the lock nut and screw the adjuster on the clutch lever holder all the way in. Loosen clutch cable adjuster lock nut . Turn the clutch cable adjuster in or out to acquire the specified play. Tighten lock nut while holding the adjuster in position. The clutch cable should be lubricated with a light weight oil whenever it is adjusted. Clutch cable play 4 mm (0.16 in) 2-9 PERIODIC MAINTENANCE GEARSHIFT LEVER HEIGHT ADJUSTMENT Loosen the lock nut With the link rod turned, adjust the gearshift lever height. ENGINE OIL Inspect Interval Replace Initial 1,000 km and Every 4,000 km. Necessary amount of engine oil Oil change Filter change Overhaul engine Engine oil type 1,450 1,500 1,800 1,450 1,500 1,650 SAE 10W/30 or 10W/40 API Over SG Oil should be changed while the engine is warm. Oil filter 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 filler cap and drain plug . Tighten the drain plug to the specified torque, and pour fresh oil through the oil filler. Use an API classification of Over SG oil with SAE 10W/30 or 10W/40 viscosity. Oil drain plug : 18~20 N m (1.8~2.0 kg m) Start up the engine and allow it to run for several minutes at idling speed. Turn off the engine and wait about three minutes, then check the oil level through the inspection window. If the level is below mark F , add oil to F level. If the level is above mark F , drain oil to F level. PERIODIC MAINTENANCE 2-10 CAUTION Never operate the motorcycle if the engine oil level is below the Lower line mark(L) in the inspection window. Never fill the engine oil above the Upper line mark(F) . Engine oil level being most suitable about 1mm under the Upper line mark(F) of the engine oil lens. In case of the engine oil pouring in excessively, the engine output being made insufficient. Be careful not to pouring in the engine oil excessively. CAUTION Necessarily, confirm and clean the oil strainer when replace the engine oil (specially, when first replacement). CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions. ENGINE OIL FILTER Inspect Interval Replace Initial 1,000 km and Every 4,000 km. Drain the engine oil as described in the engine oil replacement procedure. Remove the oil filter cap . Remove the oil filter. Install the new O-ring . Install the new oil filter. Install the new O-ring and spring cap. Install the oil filter cap. to the oil filter CAUTION Before installing the oil filter cap, apply engine oil lightly to the new O-ring . 2-11 PERIODIC MAINTENANCE OIL FILTER INSTALLATION INSERTION DIRECTION CAUTION When install the oil filter, necessarily, HYOSUNG character and 16510H05240 part s NO. install toward the outside, otherwise can damage the engine. HYOSUNG LUSTER MATERIAL WARNING Engine oil and exhaust pipes can be hot enough to burn you. Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil. 16510H05240 OUTSIDE Add new engine oil and check the oil level as described in the engine oil replacement procedure. CAUTION Use HYOSUNG MOTORCYCLE GENUINE OIL FILTER only, since the other make s genuine filters and after-market parts may differ filtering performance and durability, which could cause engine damage or oil leaks. Hyosung motors genuine oil filter is also not usable for the motocycles. DRIVE CHAIN Inspect Interval Clean and Lubricate Every 1,000 km. Visually check the drive chain for the possible defects listed below. (Support the motorcycle by the jack or block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.) Loose pins Excessive wear Damaged rollers Improper chain adjustment Dry or rusted links Kinked or binding links If any defects are found, the drive chain must be replaced. PERIODIC MAINTENANCE 2-12 NOTE When replacing the drive chain, replace the drive chain and sprocket as a set. Loose the axle nut . Tense the drive chain fully by turning both chain adjusters , . Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced. Service limit Drive chain 20pitch length 319.4 mm (12.58 in) 256.5 mm (10.10 in) Loosen or tighten both chain adjusters , until the chain has 20 30 mm of slack in the middle between the engine and rear sprockets. The marks , on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned. Drive chain slack 20 30 mm (0.79 ~ 1.18 in) 2-13 PERIODIC MAINTENANCE Place the motorcycle on jack or block for accurate adjustment. After adjusting the drive chain, tighten the axle nut to the specified torque. Tighten both chain adjusters , securely. Rear axle nut : 90~140 N m (9.0~14.0 kg m) Recheck the drive chain slack after tightening the axle nut. 20~30mm (0.79~1.18 in) 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 or chain lubricating oil. CAUTION The drive chain for this motorcycle is made of the special material. The chain should be replaced with a 520HO for and 428SO for Use of another chain may lead to premature chain failure. BRAKE SYSTEM Inspect Interval [ BRAKE ] Inspect Initial 1,000 km and Every 4,000 km. [ BRAKE HOSE & BRAKE FLUID ] Inspect Initial 1,000 km and Every 4,000 km. Replace the brake hoses Every 4 years, Replace the brake fluid Every 2 years. PERIODIC MAINTENANCE 2-14 BRAKE FLUID LEVEL CHECK Keep the motorcycle upright and place the handlebars straight. Check the brake fluid level by observing the lower limit line (LOWER) on the front brake fluid reservoir. When the level is below the lower limit line (LOWER), replenish with brake fluid that meets the following specification. Specification and Classification : DOT 3 or DOT 4 LOWER LIMIT LINE CAUTION The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period. [ Front Brake ] CAUTION Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding. [ Rear Brake ] 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 performance will be adversely affected. FRONT AND REAR BRAKE PAD REPLACEMENT Remove the brake caliper. Remove the brake pads. To reassmble, reverse the above sequence. Front brake caliper mounting bolt : 18~28 N m (1.8~2.8 kg m) Rear brake caliper mounting bolt : 18~28 N m (1.8~2.8 kg m) [ Front Brake ] 2-15 PERIODIC MAINTENANCE FRONT AND REAR BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handlebars straight. Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Specification and Classification : DOT 3 or DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle. [ Rear Brake ] 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. Replace the rear brake s fluid with the same manner of the front brake. Front brake caliper air bleeder valve :6~9 N m (0.6~0.9 kg m) Rear brake caliper air bleeder valve :6~9 N m (0.6~0.9 kg m) PERIODIC MAINTENANCE 2-16 AIR BLEEDING OF THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by sponginess of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner : Fill the master cylider reservoir to top of the inspection window. Replace the reservoir cap to prevent dirt from entering it. Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle. Bleed air from the brake system. Squeeze and release the brake lever several times in rapid succession and sqeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the brake lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles. NOTE While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir. Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the upper line. Bleed the rear brake s air with the same manner of front brake. Front brake caliper air bleeder valve : 6~9 N m (0.6~0.9 kg m) Rear brake caliper air bleeder valve : 6~9 N m (0.6~0.9 kg m) CAUTION Handle brake fluid with care : the fluid reacts chemically with paint, plastics, rubber materials, etc. 2-17 PERIODIC MAINTENANCE FRONT BRAKE LAMP SWITCH The front brake lamp switch is located beneath the front brake lever. Loosen the switch fitting screws and adjust the timing by moving the switch body forward or backward. REAR 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 Inspect Interval Inspect Initial 1,000 km and Every 4,000 km. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the steering stem while grasping the lower fork tubes by supporting the machine so that the front wheel is off the ground, with the wheel straight ahead, and pull forward. If play is found, perform steering bearing adjustment as described in page 6-29 of this manual. FRONT FORK Inspect Interval Inspect Every 4,000 km. Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. REAR SUSPENSION Inspect Interval Inspect Every 4,000 km. Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage. Replace any defective parts, if necessary.(Refer to page 6-36) PERIODIC MAINTENANCE 2-18 TIRE Tire wear indicator Inspect Interval Inspect Initial 1,000 km and Every 4,000 km. TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and can lead to loss of control. Inspect shortage of tire thread s depth by the tire wear indicator . Replace the front and rear tires at once when appear the tire wear indicator . Tire wear indicator mark TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good roadability or shorter tire life will result. Cold inflation tire pressure is as follows. COLD INFLATION SOLD RIDING DUAL RIDING TIRE PRESSURE KPa kgf/cm2 psi KPa kgf/cm2 psi Front Rear 196 2.00 29.0 196 2.00 29.0 221 2.25 32.0 245 2.50 36.0 CAUTION The standard tire on is 110/70-17 54H for front and 150/70-17 69H 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 Inspect Interval Tighten Initial 1,000 km and Every 4,000 km. Check that all chassis bolts and nuts are tightened to their specified torque.(Refer to page 7-12) 2-19 PERIODIC MAINTENANCE 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 compression reading for each maintenance service. Compression pressure Standard Service limit 14~16 kg/cm (at 500 rpm) 12 kg/cm2 (at 500 rpm) 2 Compression pressure Standard Service limit 11~13 kg/cm2 (at 500 rpm) 10 kg/cm2 (at 500 rpm) Low compression pressure can indicate any of the following conditions : Excessively worn cylinder wall Worn-down piston or piston rings Piston rings stuck in grooves Poor seating of valves Ruptured or otherwise defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. Have the engine warmed up by idling before testing. Be sure that the battery used is in fullycharged condition. Remove the parts concerned and test the compression pressure in the following manner. Loosen the oil cooler mounting bolts from the frame. Remove all the spark plug. Fit the compression gauge in one of the plug holes, while taking care that the connection is tight. Keep the throttle grip in full-open position. Crank the engine a few seconds with the starter, and record the maximum gauge reading as the compression of that cylinder. Compression gauge : 09915-64510 PERIODIC MAINTENANCE 2-20 OIL PRESSURE Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 2.0 (at 65 0.5 / 3,000 rpm) Oil pressure Standard 0.9 1.1 / (at 65 3,000 rpm) If the oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE Oil leakage from the oil passage Damaged O-ring Defective oil pump Combination of above items HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Check the oil pressure in the following manner. Remove the oil check plug and install the adapter of oil pressure gauge at the removed position. Connect an engine tachometer. Warm up the engine as follows : Summer : 10 min. at 2,000 rpm. Winter : 20 min. at 2,000 rpm. After warming up, increase the engine speed to 3,000 rpm. (with the engine tachometer), and read the oil pressure gauge. Oil pressure gauge : 09915-74510 Engine tachometer : 09900-26006 ENGINE CONTENTS ENGINE REMOVAL AND REINSTALLATION ENGINE REMOVAL ENGINE REINSTALLATION ENGINE DISASSEMBLY STARTER MOTER CYLINDER HEAD COVER PISTON MAGNETO COVER MAGNETO ROTOR CLUTCH COVER CLUTCH PRIMARY DRIVE GEAR OIL PUMP GEARSHIFT SHAFT ENGINE COMPONENT INSPECTION AND SERVICE ENGINE REASSEMBLY 3- 1 3- 1 3- 5 3- 7 3- 7 3- 8 3-12 3-13 3-13 3-14 3-15 3-16 3-16 3-17 3-19 3-36 3 CAUTION Mark an identification of assembly location on each removed part so that each will be restored to the original position during reassembly. Wash clean and dry the removed parts before inspecting and measuring. Oil the rotating or sliding parts before assembly. Make sure to use the correct type of lubricant where specified. Check that each rotating or sliding part moves or operates smoothly after assembly. Make sure to follow the bolt tightening order where specified. If the correct length of the bolt is confused when tightening the crankcase or cover, insert all the bolts and check that the tightening margin is equal in each bolt. 3-1 ENGINE ENGINE REMOVAL AND 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) Drain the engine oil.(Refer to page 2-9) Disconnect the battery lead wire . CAUTION First, disconnect the lead wire. AIR CLEANER With the two screw loosened, remove the air cleaner case. Loosen the clamp screw. CARBURETOR Remove the carburetor after removed the intake pipes. (Refer to page 4-5) ) Disconnect the vacuum hoses . ( ENGINE 3-2 CLUTCH CABLE Disconnect the clutch cable end out of clutch lever. Disconnect the clutch cable end out of clutch release arm. EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts and muffler mounting bolts removed, remove the exhaust pipes and mufflers. [ Front Cylinder ] [ Rear Cylinder ] 3-3 ENGINE ELECTRIC PARTS With take out the spark plug caps, remove the spark plug. [ Front Cylinder ] Remove the starter motor lead wire. [ Rear Cylinder ] Remove the engine ground lead wire . Disconnect the magneto coupler . ENGINE 3-4 ENGINE SPROCKET Remove the engine sprocket cover. Remove the breather hose. Loosen the bolt and remove the link rod. Flatten the lock washer. Remove the engine sprocket nut and washer. NOTE When loosening the engine sprocket nut, depress the brake pedal. Remove the engine sprocket. NOTE If it is difficult to remove the engine s p r o c k e t , loosen the rear axle nut, c h a i n to provide additional chain adjusters slack.(Refer to page 2-11) 3-5 ENGINE Remove the oil cooler. 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. ENGINE REINSTALLATION Reinstall the engine in the reverse order of engine removal. Install the engine mounting bolts and nuts. Tighten the engine mounting bolts and nuts to the specified torque. Engine mounting bolt : 40 60 N m (4.0 6.0 kg m) ENGINE 3-6 ENGINE SPOCKET Loosen the rear axle nut and chain adjusters, left and right. Install the engine sprocket. Tighten the engine sprocket nut torque. to the specified Engine sprocket nut : 80~100 N m (8.0~10.0 kg m) NOTE When tightening the engine sprocket nut, depress the rear brake pedal. Bend the lock washer securely. Install the gearshift arm and adjust the gearshift lever height.(Refer to page 2-9) Connect each electric part and its couplers.(Refer to page 7-23~30) Install the exhaust pipes and mufflers. Install the carburetor and air cleaner. After remounting the engine, the following adjustments are necessary. Engine idling speed Throttle cable play Clutch cable play Drive chain Gearshift lever height Engine oil level Refer to page 2-7 Refer to page 2-7 Refer to page 2-8 Refer to page 2-11 Refer to page 2-9 Refer to page 2-9 3-7 ENGINE ENGINE DISASSEMBLY STARTER MOTOR Remove the starter motor. Remove the gear position switch. Remove the contacts and springs . Remove the three union bolts. ENGINE 3-8 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. To set piston at TDC(Top Dead Center) of the F mark for compression stroke as align the R mark for rear cylinfront cylinder and the der. Remove the cam chain tensioner. [ Front Cylinder ] [ Rear Cylinder ] 3-9 ENGINE 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. ENGINE 3-10 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 and cylinder head. 3-11 ENGINE 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. Compress the valve spring by using the special tool. Valve spring compressor : 09916-14510 Valve spring compressor attachment : 09916H35C00 Valve spring compressor attachment : 09916H5100 Take out the valve cotter from the valve stem. Remove the valve spring retainer. Pull out valve from the other side. ENGINE 3-12 Remove the two cylinder base nuts and cylinder. CAUTION If tapping with the plastic hammer is necessary, pay attention to break the fins. Remove the rear cylinder head and cylinder with the same manner of the front cylinder head and cylinder removal. Rear Cylinder Front Cylinder PISTION Place a clean rag over the cylinder base to prevent piston pin circlips from dropping into crankcase. Remove the piston pin circlips with long-nose pliers. Remove the piston pin by using the special tool. Piston pin puller : 09910-34510 NOTE Make an identification on each piston head so that confirmed the cylinder. 3-13 ENGINE MAGNETO COVER Remove the magneto cover. Remove in the order of spacer idle gear . , shaft , starter MAGNETO ROTOR With the magneto rotor held immovable using the special tool, loosen the rotor nut. Conrod holder : 09910-20115 Remove the magneto rotor by using the special tool. Rotor remover : 09930-30164 Rotor remover : 09930-30162 Rotor remove sliding shaft : 09930-30102