SERVICE MANUAL

HOW TO USE THIS MANUALTO LOCATE WHAT YOU ARELOOKING FOR:1. The text of this manual is divided into sections.2. As the title of these sections are listed on the previouspage as GROUP INDEX, select the section where whatyou are looking for belong.3. Holding the manual as shown at the right will allow you to findthe first page of the section easily.4. On the first page of each section, its contents are listed. Findthe item and page you need.COMPONENT PARTSExample: Rear wheel/Rear brake

SYMBOLListed in the table below are the symbols indicating instructions and other information necessary for servicing andmeaning associated with them respectively.SYMBOLDEFINITIONSYMBOLDEFINITIONTorque control required.Data beside it indicatesspecified torque.Apply THREAD LOCK “1324”.Apply oil. Use engine oil unlessotherwise 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”.

GENERAL INFORMATIONCONTENTS1INFORMATION LABELS 1-1GENERAL PRECAUTIONS 1-1SERIAL NUMBER LOCATION 1-3FUEL AND OIL RECOMMENDATIONS 1-3BREAK-IN PROCEDURES 1-4EXTERIOR ILLUSTRATION 1-5SPECIFICATIONS 1-6

1-1 GENERAL INFORMATIONWARNING / CAUTION / NOTEPlease read this manual and follow its instructions carefully. To emphasize special information, the symbol andthe words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messageshighlighted by these signal words.WARNINGIndicates a potential hazard that could result in death or injury.CAUTIONIndicates 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 potentialhazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTIONstated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform aparticular service operation, ask a more experienced mechanic for advice.GENERAL PRECAUTIONSWARNING● Proper service and repair procedures are important for the safety of the service machanic and the safetyand 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 wellventilatedand 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 whileafter engine operation.● After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system forleaks.

GENERAL INFORMATION 1-2CAUTION● 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 bereinstalled 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 reconnectingthe battery, connect the positive cable first and then negative cable, and replace the terminal cover on thepositive terminal.● When performing service to electrical parts, if the service procedures do not require use of batterypower, diconnect the negative cable at the battery.● Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smallerdiameter, from inside to outside diagonally, to the specified tightening torque.● Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, andcertain other parts as specified, be sure to replace them with new ones. Also, before installing these newparts, 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 thanrequired to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seatedin 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 oilif a thread is smeared with them.● After reassembly, check parts for tightness and operation.● 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 INFORMATIONHYOSUNG PRIMA (SF-50)RIGHT SIDELEFT SIDE* Difference between photographs and actual motorcycles depends on the markets.SERIAL NUMBER LOCATIONThe frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the frame under thefootboard. The engine serial number is located on the up side of the crankcase assembly.These numbers are required especially for registering the machine and ordering spare parts.FUEL AND OIL RECOMMENDATIONFUELGasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type isrecommended.TRANSMISSION OILMake sure that the transmission oil you use comes under APIclassification of SH, SG or SF and that its viscosity ratingis SAE 10W/30 or 10W/40. If an SAE 10W/30 or 10W/40 motoroil is not available, select an alternate according to the right chart.

GENERAL INFORMATION 1-4ENGINE OILSpecification and classification: APOLLOIL BIKE-K, HYPOL HSBRAKE FLUIDSpecification and classification: DOT4WARNINGSince the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do notuse 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 OILUse fork oil : TELLUS #37BREAK-IN PROCEDURESDuring manufacture only the best possible materials are used and all machined parts are finished to a very highstandard but it is still necessary to allow the moving parts to “BREAK-IN”before subjecting the engine to maximumstresses. The future performance and reliability of the engine depends on the care and restraint exercised during itsearly life. The general rules are as follows:● Keep to these break-in engine speed limits:Up to 1,000km(600miles): Less than 1/2 throttle.● Upon reaching an odometer reading of 1,000 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 thethrottle position.

1-5 GENERAL INFORMATIONEXTERIOR ILLUSTRATION5356901251,1109907403203506351,2701,825135Head lamp Rear reflector Tail/Brake lamp(Front) Turnsignal(Rear) Turnsignallamplamp600710

GENERAL INFORMATION 1-6SPECIFICATIONSDIMENSIONS AND DRY MASSOverall lengthOverall widthOverall heightWheelbaseGround clearanceDry mass1,825 mm (71.9 in)635 mm (25.0 in)1,110 mm (43.7 in)1,270 mm (50.0 in)125 mm (4.9 in)88 kg (194 lbs)ENGINETypeTwo-stroke, forced air cooledNumber of cylinder 1Bore41 mm (1.6 in)Stroke37.4 mm (1.5 in)Piston displacement49 cm3 (3.0 cu.in)CarburetorSIDE DRAFT VARIABLE VENTURI (PISTON)Air cleanerWet filter typeStarter systemKick/self starterCorrected compression ratio 7.4 : 1Intake systemReed valveTRANSMISSIONClutchDry shoe, automatic, centrifugal typeReduction ratio 2.997~0.813Drive systemV-belt driveCHASSISFront suspensionTelescopic typeRear suspensionCoil spring typeCaster 25。Trail75mm (2.95in)Steering angle45。(right & left)Front tire size110/70-12 47JRear tire size120/70-12 51JFront brakeDiscRear brakeDrum

PERIODIC MAINTENANCECONTENTSPERIODIC MAINTENANCE SCHEDULE 2- 1MAINTENANCE PROCEDURES 2- 32BATTERY 2- 3CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS 2- 4CYLINDER HEAD AND CYLINDER 2- 4SPARK PLUG 2- 4FUEL LINE 2- 5AIR CLEANER ELEMENT 2- 5THROTTLE CABLE PLAY 2- 6ENGINE IDLE SPEED 2- 7OIL PUMP 2- 7TRANSMISSION OIL 2- 8BRAKES 2- 8TIRES 2-10STEERING 2-11FRONT SUSPENSION 2-11REAR SUSPENSION 2-12CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2-12

2-1 PERIODIC MAINTENANCEPERIODIC MAINTENANCE SCHEDULEThe chart below lists the recommended intervals for all the required periodic service work necessary to keep themotorcycle operating at peak performance and economy.NOTE:More frequent servicing should be performed on motorcycles that are used under severe conditions.PERIODIC MAINTENANCE CHARTENGINEItemBatteryCylinder head nutsexhaust pipe nutsCylinder head, cylinder.Spark plugFuel lineAir cleaner elementThrottle cable playEngine idle speedOil pumpTransmission oilIntervalInitial 1,000 km Every 4,000 km Every 8,000 km pageInspectInspect-2-3InspectInspect-2-4--Clean2-4CleanCleanReplace2-4InspectInspect-Replace every 4 years2-5Clean every 3,000 km2-5InspectInspect-2-6InspectInspect-2-7InspectInspect-2-7Inspect-Inspect2-8CHASSISItemBrakesBrake hoseBrake fluidTiresSteeringFront suspensionRear suspensionChassis bolts and nutsIntervalInitial 1,000 km Every 4,000 km Every 8,000 km pageInspectInspect-2-9InspectInspect-Replace every 4 years2-9InspectInspect-Replace every 2 years2-9InspectInspect-2-10InspectInspect-2-11Inspect-Inspect2-11Inspect-Inspect2-12InspectInspect-2-12

PERIODIC MAINTENANCE 2-2LUBRICATION CHARTThe maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and iscalculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner.ItemThrottle cableThrottle gripBrake cableSpeedometer cableSpeedometer gear boxBrake camSteering stem bearingIntervalInitial and Every 4,000 kmEvery 8,000 kmMotor oil--GreaseMotor oil--Grease-Grease-GreaseGrease every 2 years or 20,000 kmWARNINGBe careful not to apply too much grease into the brake cam. If grease is on the linings, brake slippage willresult.Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle hasbeen operated under wet or rainy conditions.Before lubricating each part, clean off rusty sports and wipe off grease, oil, dirt or grime.

2-3 MAINTENANCE PROCEDUREMAINTENANCE PROCEDUREThis section describes the service procedures foreach section of the periodic maintenance.BATTERYNOTE:Inspect Initial 1,000 km and Every 4,000 km.● Remove the pillion seat for measure of battery voltage.● Remove the battery lead and then lead at thebattery terminls and remove the battery.● Using pocket tester, measure the battery voltage.If the tester reading is less than 12.0V, rechargethe battery with a battery charger. (Refer to page 5-13)Pocket tester : 09900-25002Bettery voltageMinimum 12.0VRechargeStandard charge 0.4A×5~10 HoursFast charge4A×30 MinutesCAUTION∙When recharging the battery removethe battery from motorcycle.Otherwise, regulator/rectifier unitshould be an obstacle.∙When recharging the battery, do notremove the caps.∙When recharging the battery, above thecharge electric current and time shouldbe kept as 12V.

MAINTENANCE PROCEDURE 2-6● Remove the air cleaner cover, separate the element.● Fill a washing pan of a proper size with non-flammablecleaning solvent. Immerse the element in the cleaningsolvent and wash them clean.● Squeeze the cleaning solvent out of the washed elementby pressing it between the palms of both hands:do not twist or wiring the element or if will developtears.● Immerse the element in Hyosung genuine oil, andsqueeze the oil out of the element leaving it slightlywet with oil.● Fit the elements to the cleaner case properly.CAUTIONInside∙Before and during the cleaning operation,inspect the element for tears. A torn elementmust be replaced.∙Be sure to position the element snugly and correctly,so that no incoming air will bypass it.Remember, rapid wear of piston rings andcylinder bore is often caused by a defective orpoorly fitted element.Non-flammablecleaning solventHyosunggenuine oilTHROTTLE CABLE PLAYNOTE:Inspect Initial 1,000 km and Every 4,000 km.● Loosen the lock nut 1 and adjust the cable play by turning adjuster 2 in or out to obtain the followingcable play. After adjusting play, tighten the lock nut.Throttle cable play0.5 ~ 1.0 mm21

2-7 MAINTENANCE PROCEDUREENGINE IDLE SPEEDNOTE:Inspect Initial 1,000 km and Every 4,000 km.CAUTIONMake this adjustment when the engine is hot.● start up the engine and set its speed at anywherebetween 1,750 and 1,850 rpm by turning the throttlestop screw 1.1Engine idle speed1,800 ± 50 rpmEngine tachometer : 09900-26006FixingOIL PUMPNOTE:Inspect Initial 1,000 km and Every 4,000 km.The engine oil is fed by the oil pump to the engine. Theamount of oil fed to it is regulated by engine speed andoil pump control lever which is controlled by amount ofthrottle opening.Check the oil pump in the following manner to confirmcorrect operation for throttle valve full closing position.● Fix the throttle grip. (The early idling condition)● Check whether the mark 2 on the oil pump controllever is aligned with the index mark 3 when thethrottle grip is fixed as above.● If the marks are not aligned, loosen lock nuts 4 andturn the adjuster 5 in or out to align the marks.● After aligning the marks, tighten the lock nuts 4.23CAUTIONOil pump cable adjustment must be done afterthrottle cable adjustment.54

MAINTENANCE PROCEDURE 2-10WARNINGHandle the brake fluid with care: the fluid reactschemically with paint, plastics, rubber materials, etc.15~25 mmREAR BRAKEAdjust by turning the adjusting nut 1 so that the play is 15~25 mm as shown in the illustration.핀Pin사용범위 RangePlay 여유가 is had 많아진다much여유가 Play is had 적어진다littleAdjuster 조정너트nut 1Brake lining wear limitThis motorcycle is equipped with the brake lining wearlimit indicator on the rear brake. As shown in the illustrationat right, at the condition of normal lining wear, anextended line from the index mark on the brakecamshaft should be within the range embossed on thecrankcase LH. To check wear of the brake lining, followthe steps below.● First check if the brake system is properly adjusted.● While operating the brake, check to see that theextension line from the index mark is within the rangeon the brake panel.FrontBrake lining wear limitIndex markThe extension line of the index mark is within the range.● If the index mark is outside the range as shown in theillustration at right, the brake shoe assembly shouldbe replaced to ensure safe operation.FrontIndex markBrake lining wear limitThe extension line of the index mark is outside of the range.TIRESNOTE:Inspect Initial 1,000 km and Every 4,000 km.TIRE PRESSUREIf the tire pressure is too high, the motorcycle will tend toride stiffly and have poor traction. Conversely, if the tirepressure is too low, stability will be adversely affected.Therefore, maintain the correct tire pressure for goodroadability and to prolong tire life.

2-11 MAINTENANCE PROCEDURECAUTIONThe standard tire fitted on this motorcycle is110/70-12 47J for front and 120/70-12 51J for rear.The use of a tire other than the standard maycause handling instability. It is highly recommendedto use a HYOSUNG Genuine Tire.COLD INFLATIONTIRE PRESSUREFRONTREARNORMAL RIDINGSOLO RIDING DUAL RIDINGkpa kg/cm2 kpa kg/cm21231961.252.001722211.752.25TIRE TREAD CONDITIONOperating the motorcycle with the excessively worn tireswill decrease riding stability and consequently invite adangerous situation. It is highly recommended toreplace the tire when the remaining depth of tire treadreaches the following specification.TREAD DEPTH SERVICE LIMITFRONT1.6 mmREAR1.6 mmOVER NORMAL SHORTSTEERINGNOTE:Inspect Initial 1,000 km and Every 4,000 km.Steering should be adjusted properly for smooth turningof handlebars and safe running. Too stiff steering preventssmooth turning of handlebars and too loose steeringwill cause poor stability.Check that there is no play in the front fork assembly bysupporting the machine so that the front wheel is off theground, with wheel straight ahead, grasp lower shockabsorber near the axle and pull forward. If play isfound, perform steering bearing adjustment.(Refer topage 6-21)FRONT SUSPENSIONNOTE:Inspect Initial 1,000 km and Every 8,000 km.Inspect the front shock absorber for oil leakage or otherdamage, and replace the defective parts, if necessary.

ENGINECONTENTSENGINE REMOVAL AND REMOUNTING 3- 1ENGINE REMOVAL 3- 1ENGINE REMOUNTING 3- 3ENGINE DISASSEMBLY 3- 4ENGINE COMPONENTS INSPECTION AND SERVICING 3-14BEARINGS 3-14OIL SEALS 3-14CRANKSHAFT 3-15AUTOMATIC CLUTCH INSPECTION 3-15CYLINDER HEAD 3-18CYLINDER 3-19PISTON 3-19REED VALVE 3-22ENGINE REASSEMBLY 3-22OIL SEALS 3-22BEARINGS 3-23BUSHINGS 3-23CRANKSHAFT 3-24CRANKCASE 3-25CENTER STAND 3-26REAR AXLE SHAFT, BRAKE AND WHEEL 3-27TRANSMISSION 3-29STARTER DRIVEN GEAR AND STARTING MOTOR 3-31MOVABLE DRIVEN AND CLUTCH 3-32MOVABLE DRIVE 3-36KICK STARTER 3-38PISTON 3-40OIL PUMP AND INTAKE PIPE 3-42MAGNETO 3-43MUFFLER 3-453

3-1 ENGINEENGINE REMOVAL ANDREMOUNTINGENGINE REMOVALBefore taking the engine out of the frame, thoroughlyclean the engine with a suitable cleaner. The procedureof engine removal is sequentially explained as follows.● Remove the low leg shield.● Remove the air cleaner by removing the mountingbolts 1 and clamp screw 2.21● Disconnect the ignition coil lead wires and spark plugcap.● Disconnect the oil pump cable 3 and the thermoelementlead coupler 4.● Disconnect the throttle cable. (Refer to page 4-2)34● Disconnect the vacuum hose 5, fuel hose 6 and oilhose 7.756

ENGINE 3-2● Disconnect the magneto lead wire and startingmoter lead wire .● Remove the rear brake cable 4 by removing the bolt1, bolt 2 and adjuster nut 3.1423● Remove the rear shock absorber mounting lowerbolt.

3-3 ENGINE● Remove the engine mounting shaft and remove theengine from the frame.ENGINE REMOUNTINGThe engine can be mounted in the reverse order ofremoval.● Install the damper to the crankcase bracket as shownin the illustration.● With “UP”mark faced upward, install the crankcasebracket 1 on the frame. Do not tighten the bracketbolt 2 at this stage. Pull up on the rear part ofcrankcase bracket and while holding it, tighten thebracket bolt 2 to specification. Tighten both the rearshock absorber bolt 4 and engine mounting bolt 3to specification.“UP” mark1Front side10mm8mmDamperEngine mounting bracket bolt: 48~72 N∙m (4.8~7.2 kg∙m)Engine mounting bolt: 40~60 N∙m (4.0~6.0 kg∙m)Rear shock absorber bolt: 22~35 N∙m (2.2~3.5 kg∙m)3 1 42

ENGINE 3-4● Install the magneto lead wire and starting motorlead wire correctly.After remounting the engine, route the wiring harnessproperly and following adjustments are necessary.Page∙Throttle cable play 2-6∙Idling adjustment 2-7∙Oil pump cable paly 2-7∙Rear brake cable adjustment 2-10∙Air bleeding at oil pump 4-9ENGINE DISASSEMBLYMUFFLER● Remove the muffler by removing the nuts.MAGNETO● Remove the cooling fan.● Remove the magneto rotor nut 1 with the specialtool.Rotor holder : 09930-401131

3-5 ENGINE● Remove the magneto rotor with the special tool.Rotor remover : 09930-30163Rotor remover sliding shaft : 09930-30102● Remove the magneto stator and key.REED VALVE● Remove the intake pipe 2 with reed valve 1.21OIL PUMP● Remove the oil pump 3.● Remove the oil pump driven gear 4.443CYLINDER● Remove the cylinder cowling.● Remove the cylinder head 5 and cylinder 6.56

ENGINE 3-6PISTON● Place a cloth beneath the piston and remove the pistoncirclip 1 with a long nose pliers.● Remove the piston pin 2 and piston 3.● Remove the piston pin bearing 4.3214KICK STARTER● Remove the kick starter lever 5.● Remove the clutch cover 6.56● Remove the kick starter shaft spring 7 and kickstarter shaft 8.87KICK STARTER DRIVEN GEAR● Remove the E-ring 9 with the long nose plier.● Remove the spacer 10, spring 11 and kick starterdriven gear 12.1211109

3-7 ENGINEMOVABLE DRIVE FACE● Remove the kick starter driven nut 1 with the specialtool.CAUTIONThis nut has left-hand thread.Conrod holder : 09910-20115● Remove the fixed drive face 2 and V-belt 3.● Disassemble the movable drive face 4.3421STARTER DRIVEN GEAR● Remove the starter driven gear 5.5MOVABLE DRIVEN FACE● Remove the clutch housing 6 with the special tool.Rotor holder : 09930-401136

ENGINE 3-8● Loosen the clutch shoe nut with the special tool.Rotor holder : 09930-40113● Remove the nut while holding down the clutch shoeassembly 2 by both hands as shown in the illustration.WARNINGGradually back off the clutch shoe assemblypressed down by hand to counter the clutchspring load. Releasing the hand suddenly maycause the parts to fly apart.● Remove the nut 1.● Remove the clutch shoe assembly 2.● Remove the spring 3.132;;;; ;;;; ;; ;;;; ;;;;12CAUTIONDo not attempt to diassemble the clutch shoeassembly.It is not serviceable.4● Using a thin blade screwdriver or the like, pry up themovable driven face spring guide 4.● Remove the pins 5, movable driven face 6 andfixed driven face 7.576

3-9 ENGINE● Remove the roller bearing with the special tools.Bearing remover(ф 17 mm) : 09923-73210Rotor remover sliding shaft : 09930-30102CAUTIONThe removed bearing should be replaced with anew one.● Remove the circlip .● Remove the bearing with the special tool.Wheel bearing remover : 09941-50111CAUTIONThe removed bearing should be replaced with anew one.TRANSMISSION● Drain transmission oil.● Remove the gear box cover 1.● Remove the driveshaft 2.12

ENGINE 3-10● Remove the oil seal 1 from the gear box cover withthe special tool.Oil seal remover : 09913-50121CAUTION1The removed oil seal should be replaced with anew one.● Remove the bearing 2 with the special tool.Bearing installer : 09913-76010CAUTION2The removed bearing should be replaced with anew one.● Remove the circlip 3 and final driven gear 4.● Remove the idle shaft 5.345● Remove the drive shaft bearing 6.Rotor remover sliding shaft : 09930-30102Bearing remover (ф 12 mm) : 09921-202106

3-11 ENGINEWHEEL, BRAKE● Remove the rear axle nut 1 and washer 2.● Remove the rear wheel 3.231● Remove the brake shoes 4 and rear axle shaft 5.454● Remove the bearing retainer 6.76● Remove the bearing 7 with the special tool.Bearing installer : 09913-758207

ENGINE 3-12● Remove the oil seal 1 with the special tool.Oil seal remover : 09913-501211CENTER STAND● Remove the return spring 2.2● Remove the cotter pin 3, washer 4 and shaft 5.● Remove the center stand 6.43526CRANKCASE● Remove the crankcase securing screws.CAUTIONLoosen the crankcase screws diagonally.Crankcase separater : 09920-13120

3-13 ENGINE● Remove the crankshaft with the special tool.Crankcase separater : 09920-13120● Remove the bearings, oil seals and bushings.

ENGINE 3-14● Using two steel tubes of appropriate size, press outthe engine mounting bushings on a vise as shown inthe illustration.BushingFront sideRear sideBushingBushingCrankcaseCrankcaseENGINE COMPONENTSINSPECTION AND SERVICINGBEARINGSWash the bearing with cleaning solvent and lubricatewith motor oil before inspecting.Turn the inner ring and check to see that the inner ringturns smoothly. If it does not turn lightly, quietly andsmoothly, or if noise is heard, the bearing is defectiveand must be replaced with a new one.OIL SEALDamage to the lip of the oil seal may result in leakage ofthe fuel-air mixture or oil. Inspect for damage and besure to replace the damaged seal if found.

3-15 ENGINECRANKSHAFTCRANKSHAFT RUNOUTSupport crankshaft by “V”blocks, with the dial gaugerigged to read the runout as shown.Crankshaft runoutService limit 0.08 mmExcessive crankshaft runout is often responsible forabnormal engine vibration. Such vibration shortensengine life.V-block(100 mm) : 09900-21304Magnetic stand : 09900-20701Dial gauge(1/100 mm) : 09900-20606WEAR AND CLEARANCE OF CONROD BIG ENDTurn the crankshaft with the conrod to feel the smoothnessof rotary motion in the big end. Move the rod upand down while holding the crankshaft rigidly to be surethat there is no rattle in the big end.Wear on the big end of the conrod can be estimated bychecking the movement of the small end of the rod. Thismethod can also check the extent of wear on the partsof the conrod’s big end.If wear exceeds the limit, conrod, crank pin and crankpin bearing should all be replaced.Conrod big end runoutService limit 3.0 mmCONROD SMALL END BORE I.D.Measure the conrod small end diameter with a calipergauge.Conrod small end bore I.D.Service limit 14.047 mmDial calipers : 09900-20605AUTOMATIC CLUTCH INSPECTIONThis motorcycle is equipped with an automatic clutchand variable ratio belt drive transmission. The engagementof the clutch is governed by engine RPMs andcentrifugal mechanism located in the clutch.To insure proper performance and longevity of theclutch assembly it is essential that the clutch engagessmoothly and gradually. Two inspection checks must beperformed to thoroughly check the operation of the drivetrain.Follow the procedures listed.

ENGINE 3-161. CLUTCH-IN INSPECTIONWarm up the motorcycle to normal operating temperature.Remove the right frame side cover.Connect an engine tachometer to the engine.Seated on the motorcycle with the motorcycle on levelground, increase the engine RPMs slowly and note theRPM at which the motorcycle begins to move forward.Engine tachometer : 09900-26006Clutch-in RPMStandardTolerance3,600 rpm± 200 rpm2. CLUTCH TIGHT INSPECTIONGrip the front and rear brake lever fully, and measurethe engine RPM when open the throttle.Warm the engine to normal operating temperatures.Connect an engine tachometer to the engine.Apply the rear brake as firm as possible.Briefly open the throttle fully and note the maximumengine RPMs sustained during the test cycle.CAUTIONDo not apply full power for more than 3 secondsor damage to the clutch or engine may occur.Clutch tight RPMStandardTolerance6,000 rpm± 200 rpmIf the engine RPM does not coincide with the specifiedRPM range, then disassemble the clutch.Clutch shoe - inspect the shoes visually for chips, cracking,uneven wear and burning, and check the thickness ofthe shoes with the vernier calipers. If the thickness is lessthan the following service limit, replace them as a set.Clutch springs - visually inspect the clutch springs forstretched coils or broken coils.Clutch shoe thicknessService limit 2.0 mm

3-17 ENGINECAUTIONClutch shoes or springs must be changed as aset and never individually.Clutch housing - inspect visually the condition of theinner clutch housing surface for scrolling, cracks, oruneven wear. Measure inside diameter of the clutchwheel with inside calipers. Measure the diameter at severalpoints to check for an in-of-round condition as wellas wear.Clutch housing I.D.Service limit 110.35 mmDRIVE V-BELTRemove the drive V-belt and check for cracks, wear andseparation. Measure the drive V-belt width with a verniercalipers. Replace it if the drive V-belt width is less thanthe service limit or any defect has been found.Drive V-belt widthService limit 15.3 mmCAUTIONAlways keep the drive belt away from any greasymater.DRIVE FACEInspect the V-belt contact surface of the drive faces forwear, scratches or any abnormality. If there is somethingunusual, replace the drive face with a new one.ROLLER AND MOVABLE DRIVE SURFACEInspect each roller and movable drive surface for wearor damage.

ENGINE 3-18MOVABLE DRIVEN SPRINGMeasure the free length of the movable driven spring. Ifthe length is shorter than the service limit, replace thespring with a new one.Movable driven spring free lengthService limit 135~153 mmMOVABLE DRIVEN FACE PIN AND OIL SEALTurn the movable driven faces and check to see that themovable driven faces turn smoothly.If not rotate smoothly, visually inspect the lip of oil seal,movable driven face sliding surface and sliding pins forwear or damage.MOVABLE DRIVEN FACEInspect the V-belt contacting surface of both drivenfaces for any scratches, wear and damage.Replace the movable driven face with new one if thereare any abnormality.CYLINDER HEADDecarbon the combustion chamber.Check the gasketed surface of the cylinder head for distortionwith a straightedge and thickness gauge, taking aclearance reading at several places.Thickness gauge : 09900-20806Cylinder head distortionService limit 0.1 mm

3-19 ENGINEIf the largest reading at any portion of the straightedgeexceeds the limit, rework the surface by rubbing itagainst emery paper (of about # 400) laid flat on the surfaceplate in a lapping manner. The gasketed surfacemust be smooth and perfectly flat in order to secure atight joint: a leaky joint can be the cause of reducedpower output and increased fuel consumption.CYLINDERDecarbon 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 diameterreading taken at 20 mm from the top of the cylinderwith a cylinder gauge. If the wear thus determinedexceeds the limit indicated below, rework the bore to thenext oversize by using a boring machine or replace thecylinder with a new one.Cylinder gauge set : 09900-20508Cylinder boreService limit 41.070 mmAfter reworking the bore to an oversize, be sure tochamfer the edges of ports and smooth the chamferededges with emery paper. To chamfer, use a scraper,taking care not to nick the wall surface.PISTONCYLINDER TO PISTON CLEARANCECylinder-to-piston clearance is the difference betweenpiston diameter and cylinder bore diameter. Be sure totake the maked diameter at right angles to the pistonpin. The value of elevation is prescribed to be 15 mmfrom the skirt end.Micrometer(25~50 mm) : 09900-20202Piston diameterService limit 40.885 mm

ENGINE 3-20As a result of the above measurement, if the piston-tocylinderclearance exceeds the following limit, overhaulthe cylinder and use an oversize piston, or replace bothcylinder and piston. The measurement for the borediameter should be taken in the intake-to-exhaust portdirection and at 20mm from the cylinder top surface.Cylinder borePiston diameterCylinder to piston clearanceStandard41.005~41.020 mm40.935~40.950 mm0.065~0.075 mmSerivice limit41.070 mm40.885 mm0.120 mmDE-CARBONINGDe-carbon the piston and piston ring grooves, as illustrated.After cleaning the grooves, fit the rings and rotatethem in their respective grooves to be sure that theymove smoothly.Carbon in groove is liable to cause the piston ring to getstuck in the groove, and this condition will lead toreduced engine power output.A piston whose sliding surface is badly grooved orscuffed due to overheating must be replaced. Shallowgrooves or minor scuff can be removed by grinding withemery paper of about # 400.PISTON PIN BORE I.D.Using a caliper gauge, measure the piston pin boreinside diameter. If reading exceeds the following servicelimit, replace it with a new one.Dial calipers : 09900-20605Piston pin bore I.D.Service limit 10.030 mm

3-21 ENGINEPISTON PIN O.D.Using a micrometer, measure the piston outside diameterat three positions.Micrometer(0~25 mm) : 09900-20201Piston pin O.D.Service limit 9.980 mmPISTON RINGSCheck each ring for end gap, reading the gap with athickness gauge shown in the illustration. If the end gapis found to exceed the limit, indicated below, replace itwith a new one.The end gap of each ring is to be measured with thering fitted squarely into the cylinder bore and held at theleast worn part near the cylinder bottom, as shown inthe illustration.Thickness gauge : 09900-20806Piston ring clearance(Assembly condition)Service Limit0.75 mmAs the piston ring wears, its end gap increases reducingengine power output because of the resultant blow bythrough the enlarged gap. Here lies the importance ofusing piston rings with end gaps within the limit.Measure the piston ring free end gap to check thespring tension.Piston ring clearance(Free condition)1st2ndService limit3.2 mm3.1 mmFix the piston ring in the piston ring groove, measure thering side clearance with the thickness gauge whilematching the sliding surfaces of piston and ring.Piston ring-ring groove clearance1st2ndStandard0.02~0.06 mm0.02~0.06 mm

ENGINE 3-22REED VALVEWhen reinstalling the reed valve and stopper plate tothe body, align the both cut on the reed valve and stopperplate.Apply THREAD LOCK “1324”to the stopper platesecuring screws.Thread Lock “1324”ENGINE REASSEMBLYReassembly is generally performed in the reverse orderof disassembly, but there are a number of reassemblingsteps that demand or deserve detailed explanation oremphasis. These steps will be taken up for respectiveparts and components.S hellA v lania3OIL SEALSFit the oil seals to the crankcase following the procedurebelow.Replace removed oil seals with new ones.● Coat SUPER GREASE “A”to the lip of the oil seals.Super Grease “A”● Be sure to apply THREAD LOCK “1324”to outersurfaces of right and left crankshaft oil seals to preventthem from moving.Thread Lock “1324”I ndustrialM ulti-purposeG rease● When fitting the oil seal in the crankcase, insert itslowly with the special tools.Oil seal installer : 09913-75830Bearing installer attachment : 09924-74510Bearing installer pilot : 09924-74540NOTE:Align the oil seal with edge of the crankcase asshown in the illustration.

3-23 ENGINEBEARINGSInstall new bearings with the special tool.Bearing installer : 09913-75810Bearing installer : 09913-76010BUSHINGSUsing two steel tubes of appropriate size and a vise,press the mounting bushings 1 and 2 into thecrankcase holes as shown in the illustration.21NOTE:Knurled end should face inside. Protrusion and should be in the same dimension.

ENGINE 3-24Bushing 2Bushing 1CrankcaseCrankcaseCRANKSHAFT1 Crank shaft2 Crankcase RH3 Oil seal4 Oil seal5 Oil pump drive gear6 Oil pump driven gear7 Oil seal2365741● Measure the length between the webs referring to thefigure at right when rebuilding the crankshaft.Width between websStandard 35.0±0.1 mm

3-25 ENGINE● When mounting the crankshaft into the crankcase, itis necessary to pull its left end into the crankcasewith the special tool.Crankshaft installer : 09910-32812Conrod holder : 09910-20116CAUTIONNever fit the crankshaft into the crankcase bydriving it with a plastic hammer. Always use thespecial tool, otherwise crankshaft alignmentaccuracy will be affected.CRANKCASE● Wipe the crankcase mating surfaces(bothsurfaces)with cleaning solvent.● Apply BOND “1215”uniformly to the mating surfaceof the left half of the crankcase, and install the dowelpins.BOND “1215”● Install the two dowel pins.● Tighten the crankcase screws securely.● Check if the crankshaft rotates smoothly.● Install the new oil seal 1 to the crankcase with thespecial tool.1NOTE:Align the oil seal with edge of the crankcase asshown in the illustration.Bearing installer : 09913-85210

ENGINE 3-26CENTER STAND● Install the center stand 1.● Install the shaft 2, washer 3 and cotter pin 4.43152● Hook the center stand spring 5 into the crankcase.5

3-27 ENGINEREAR AXLE SHAFT, BRAKE AND WHEEL● Install the rear axle shaft 1 into the crankcase bytapping its end lightly.● Apply engine oil on the left end of the rear axle shaftbeing inserted later in the reduction rear box cover.1● Apply SUPER GREASE “A”lightly on the rear brakecam pivot part and install it to the crankcase.Super Grease “A”● Turn to position the cam where the punched mark on the end face is directed toward the axis of the rearaxle shaft.Brakecam

ENGINE 3-28● When installing the cam lever 1 to the cam, align thepunched mark with the slit of cam lever.Punch markSlit1● Tighten the cam lever nut 2 to the specified torque.Rear brake cam lever nut : 6~9 N∙m (0.6~0.9 kg∙m)21● Install the brake shoes.● Apply SUPER GREASE “A”to the brake cam andpin before installing the brake shoes.Super Grease “A”CAUTIONBe careful not to apply too much grease to thebrake cam and pin. If grease gets on the lining,brake effectiveness will be lost.● Install the rear wheel and nut.Rear axle nut : 60~90 N∙m (6.0~9.0 kg∙m)

3-29 ENGINETRANSMISSION● Install the circlip 1 on to the rear axle shaft 2.● Assemble the idle shaft subassembly using the idleshaft 3 and thrust washer 4, then install the subassemblyon the gear box.2431● Install the final driven gear 5 on the rear axle shaftusing the circlip 6.5ThrustCenterCirclipRounded coner6

ENGINE 3-30● Install the new bearing 1, 3 to the gear box cover2 with the special tool.Bearing installer : 09913-76010312● Apply SUPER GREASE “A”to the lip of the oil seal4 and install it to the gear box cover with the specialtool.Super Grease “A”Bearing installer : 09913-70122Oil sealAlign face44● Install the washer, new gasket and dowel pin 5.● Install the driveshaft 6 to the gear box cover.56

3-31 ENGINE● Apply BOND “1215”at the hatched area shown inthe illustration and install the gear box cover 1 onthe crankcase.BOND “1215”● Tighten all the screws evenly one by one in a diagonalfashion.1STARTER DRIVEN GEAR AND STARTING MOTOR● Install the starter driven gear 2 over the leftcrankshaft end.NOTE:The convex side of hub should face outside wheninstalled in proper position.2

ENGINE 3-32● Install the starting motor 1.1MOVABLE DRIVEN AND CLUTCH;;;; ;;;; ;;;; ;;

3-33 ENGINE● Install the bearing 2 in the fixed driven face 1 withthe special tool.Bearing installer : 09943-88211CAUTION2Take care that hit inner race of the bearing.(Fall to ring in the bearing a case.)1● Install the circlip 3.CAUTIONInstert surely in the circlip groove.3ThrustRounded coner● Install the bearing 4 with the special tool.Bearing installer : 09943-88211CAUTIONA mark part of the bearing is pointed to the outside.4● Install the new oil seals (5, 6) to the movable drivenface with the special tool.Oil sealBearing installer : 09913-76010● Apply SUPER GREASE “A”to the lip of oil sealsand groove of movable driven face’s inside.Super Grease “A”Insert up to contactto the stopper.65

ENGINE 3-34● Install the movable driven face 1 to the fixed drivenface 2.CAUTIONWhen reinstalling the movable dirven face to thefixed dirven face, make sure that the oil seal ispositioned properly.Insert as guide the rim.12● Position the two O-ring 3.● Install the pin 4 at three places on the driven facehub.● Apply SUPER GREASE “A”lightly to the cam partwhere the pins are placed.Super Grease “A”3Pin4Spacer● Install the movable driven face seat 5.CAUTIONThe seat is installed rotatable naturally.The O-ring get damaged, in case of installed byforce.5● Install the spring 6.● Install the clutch shoe assembly 7 and nut 8.87 6

3-35 ENGINE● Tighten the clutch shoe nut to the specified torquewith the special tool.Rotor holder : 09930-40113Clutch shoe nut : 40~60 N∙m (4.0~6.0 kg∙m)● Insert the V-belt between the driven faces as deepinside as possible while pulling the movable drivenface all the way outside to provide the maximum beltclearance.CAUTIONThe V-belt should be positioned so that thearrows on the belt periphery point the normalturning direction.The V-belt contact face on the driven facesshould be thoroughly cleaned to be free from oil.● Thoroughly clean the clutch housing 1 to be freefrom oil and position it over the clutch shoe assembly.● Tighten the clutch housing nut 2 to the specifiedtorque with the special tool.Rotor holder : 09930-40113Clutch housing nut : 40~60 N∙m (4.0~6.0 kg∙m)12

ENGINE 3-36MOVABLE DRIVE● Install the roller 2 to the movable drive face 1.12● Mount the three dampers 4 on the movable driveplate 3 and install it on the movable drive face 5.● Position the O-ring 6 on the movable drive face.534446

3-37 ENGINE● Install the movable drive face cover 1.CAUTIONMake sure that the movable drive plate is fullypositioned inside, or the weight roller may comeoff.● Insert the spacer 2.12● Position the movable drive face subassembly on thecrankshaft as shown in the photo.CAUTIONThoroughly clean the V-belt contact to be from oil.34● Install the fixed drive face 3.● Tighten the kick starter driven nut 4 to the specifiedtorque with the special tool.Conrod holder : 09910-20115Kick starter driven nut : 40~60 N∙m (4.0~6.0 kg∙m)● Fill SUPER GREASE “A”in the groove providedinside sliding surface of the kick driven gear andinstall it on the end of the crankshaft. Wipe offexcess grease.Super Grease “A”● Install the spring and spacer .

ENGINE 3-38● Install the E-ring . ● Continue turning the fixed drive face 1 by hand untilthe belt is seated in and both the drive and drivenfaces 2 will move together smoothly without slip.● Fill the final gear box with engine oil up to the levelhole.2Transmission oil capacityReplaceOverhaul110 ml130 ml● Tighten the oil level bolt 3 to the specified torque.Oil level bolt : 9~15 N∙m (0.9~1.5 kg∙m)13KICK STARTER

3-39 ENGINE● Apply SUPER GREASE “A”lightly on the kickstarter shaft rolling surface and install it on thecrankcase cover.Super Grease “A”● Position the kick starter shaft return spring and hookthe spring end on the crankcase cover boss 1.1● Install the clutch cover and kick starter lever 2.CAUTIONInstall the kick starter lever as shown in the illustration.Concur with the mark.213● Tighten the kick starter lever bolt to the specifiedtorque.Kick starter lever bolt : 8~12 N∙m (0.8~1.2 kg∙m)

ENGINE 3-40PISTON● Install the piston rings on the piston.∙1st - Keystone ring∙2nd - Barrel face ring Expander ringPosition the ring so that the marking is on upside.CAUTIONPosition the ring so that the marking is on upside.Locating pin● It is extremely important that, when the piston is fedinto the cylinder, each ring in place should be sopositioned as to hug the locating pin as shown in theillustration.CORRECTINCORRECT

3-41 ENGINE● Apply engine oil on the piston pin and install the pistonto the conrod.CAUTIONThe arrow mark on the piston head shouldpoint the exhaust side.● The circlip should be mounted in such a position thatthe mating ends of the circlip do not coincide with thegroove portion of the piston.● Position the cylinder base gasket.● Apply engine oil on the piston and cylinder wall surfacesand install the cylinder over the piston carefully.● Install the cylinder head gasket and cylinder head.InsideOutside● Tighten the cylinder head nut to the specification, andtighten it diagonally several times as shown in theillustration.Cylinder head nut : 8~12 N∙m (0.8~1.2 kg∙m)

ENGINE 3-42OIL PUMP AND INTAKE PIPE● Apply SUPER GREASE “A”to the oil pump drivengear 1 and install it to the crankcase.Super Grease “A”1● Install the oil pump 2 and tighten it to the specifiedtorque.Oil pump bolt : 3~5 N∙m (0.3~0.5 kg∙m)2

3-43 ENGINE● Install the reed valve gasket 1, intake pipe gasket 2and intake pipe 4 with reed valve 3 to thecrankcase.4231MAGNETO● Degrease the tapered portion of the crankshaft andalso the magneto rotor.● Install the stator 1.● Install the key 2.21

ENGINE 3-44● Install the rotor 1.● Apply THREAD LOCK “1324”to the rotor nut 2 andtighten it to the specified torque with the special tool.Thread Lock “1324”Rotor holder : 09930-40113Magneto rotor nut : 35~45 N∙m (3.5~4.5 kg∙m)21● Install the fan case 3.● Install the magneto lead wire and starting motor leadwire.3● Install the cooling fan 4.4● Install the cooling fan cover 5.5

3-45 ENGINEMUFFLER● Tighten the exhaust pipe bolts and muffler mountingbolts 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)

FUEL SYSTEMCONTENTSCARBURETOR 4- 1REMOVAL 4- 1DISASSEMBLY 4- 2INSPECTION 4- 4REASSEMBLY AND REMOUNTING 4- 5FUEL TANK 4- 74REMOVAL 4- 7CLEANING 4- 8REMOUNTING 4- 8OIL PUMP 4- 8FUEL PUMP 4- 9

4-1 FUEL SYSTEMCARBURETORREMOVAL● Open the seat, and separate the helmet box byremoving the four lock nuts.● Remove the rear shock absorber mounting lower bolt.

FUEL SYSTEM 4-2● Remove the carburetor top cap 1, and disconnectthe throttle cable 2.21● Disconnect the air vent hose 3, oil hose 4, and fuelhose 5.345● Remove the carburetor by loosening the mountingbolts 6 and clamp screw 7.67DISASSEMBLY● Remove the thermoelement assembly.

4-3 FUEL SYSTEMCAUTIONDo not attempt to disassemble the thermoelementassembly.It is not serviceable.● Remove the float chamber 1.1● Remove the float 4 by removing the screw 2 andpin 3.432● Remove the needle valve 5.5

FUEL SYSTEM 4-4● Remove the throttle stop screw 1 and pilot air screw 2.CAUTIONWhen removing the pilot airscrew, record the revolutionsuntil tighten completly.2112● Remove the main jet 3 and needle jet 4.433,4INSPECTIONCheck following items for any damage or clogging.● Pilot jet● Main jet● Pilot air screw● Needle jet air bleeding hole● Float● Gasket● Pilot outlet and bypass holesInspect the valve surface for wornForeign matterNEEDLE VALVE INSPECTIONIf foreign matter is caught between the valve seat andthe needle, the gasoline will continue flowing and causeit to overflow. If the seat and needle are worn beyond thepermissible limits, similar trouble will occur. Conversely,if the needle sticks, the gasoline will not float chamber.Clean the float chamber and float parts with gasoline. Ifthe needle is worn as shown in the illustration, replace ittogether with a valve seat. Clean the fuel passage of themixing chamber with compressed air.

4-5 FUEL SYSTEMREASSEMBLY AND REMOUNTING● Reassemble following items.1 Pilot air screw2 Throttle stop screw3 Main jet4 Needle jet3 4 1 2● Install the needle valve 5 and float 6 on the carburetorbody.56● Install the float pin and tightened the screw 7.● Install the gasket and float chamber.7● Install the thermoelement assembly.

FUEL SYSTEM 4-6● Install the carburetor assembly.● Install the air vent hose 1, oil hose 2 and fuel hose 3.132● Install the carburetor top cap.

4-7 FUEL SYSTEMFUEL TANKREMOVAL● Remove the low leg shield 1.1● Disconnect the fuel hose 2.2● Disconnect the fuel level gauge lead wire 3.3● Remove the six fuel tank mounting bolt.

FUEL SYSTEM 4-8CLEANINGDust from the fuel tank tends to bulid up in the fuel filterwhich, when the fuel filter has been neglected for a longperiod, inhibits the flow of fuel.Remove the dust from, the fuel filter 1 using compressedair.1REMOUNTINGRemount the fuel tank in the reverse of removal.;; yy ; y;;; yyy; y;;; yyy;;; yyy;;; yyy;;;; yyyy;; yy ;;;; yyyy;; yyyyyy;;;;;;;; yyyy;;;; yyyyOIL PUMPAIR BLEEDINGWhenever evidence is noted of some air having leakedinto the oil pipe from the oil tank in a machine brought infor servicing, or if the oil pump has to be removed forservicing, be sure to carry out an air bleeding operatingwith the oil pump in place before returning the machineto the user.To bleed air, hold the machine in standstill condition.Loosen the air bleeding screw 1 to let out air and aftermaking sure that the trapped air has all been bled, tightenthe air bleeding screw completely.1

4-9 FUEL SYSTEMCHECKING OIL PUMPUse the special tool, to check the pump for capacity bymeasuring the amount of oil the pump draws during thespecified interval.● Remove the left side cover.● Have the CCI Oil gauge filled with HYOSUNG HYPOLOIL and connect it to the suction side of the pump.● Run the engine at 3,000 rpm.● Holding engine speed at the same 3,000 rpm, let thepump draw for 5 minutes. For this operation, thereading taken on the device should be 6 ml..CCI Oil gauge : 09900-21602Engine oildischarge amount1.0 ~ 1.2 ml(at 3,000 rpm for 5 minutes)CAUTIONDuring this inspection, strictly follow the followingpoints.∙The machine should be rested on the centerstand.∙Do not touch the rear wheel while running theengine.FUEL PUMPREPLACE● Remove the rear shock absorber, and support thecenter stand by a 70 mm wooden block.● Open the seat, and remove the trunk by loosing thefour nuts.● Remove the one lock nut of fuel pump.1 Disconnect the inlet hose.CAUTIONStop up an entrance of the hose, to prevent thatthe fuel leak out.2 Disconnect the vacuum hose and outlet hose.● Remount in the reverse of removal after replacing thefuel pump.

ELECTRICAL SYSTEMCONTENTSELECTRICAL PARTS 5- 1IGNITION/CHARGING SYSTEM 5- 2IGNITION COIL 5- 2STATOR COILS 5- 35REGULATOR/RECTIFIER 5- 4STARTER SYSTEM 5- 4STARTING MOTOR INSPECTION 5- 5STARTER RELAY INSPECTION 5- 6FUEL LEVEL GAUGE 5- 7OIL LEVEL CHECK LIGHT 5- 8THERMOELEMENT 5- 9SWITCHES INSPECTION 5-10BATTERY 5-11

5-1 ELECTRICAL SYSTEMELECTRICAL PARTS1 Ignition coil2 Thermolement assembly3 Fuel level gauge4 Oil level gauge1Front turn signalRH/LHHead LampWiringharnessSpeedometercableRegulatorTurn signal cableRear brakecableBrakehose234

ELECTRICAL SYSTEM 5-2IGNITION/CHARGING SYSTEMStatorRegulator/RectifierSparkpluglgnitioncoilCDIunitLightingswitchH/L T/L M/LBattery12V 3AH(MF)Engine stopswitch12V15W×212V5W12V1.7W×2IGNITION COIL● Check the ignition coil with electro tester.● Test the ignition coil for sparking performance. Testconnection is as indicated. Make sure that the threeneedlesparking distance is at least 8mm. Test it atleast for 5 minutes.Electro tester : 09900-28106Spark performanceOver 8 mmYellowRed(+)SparkBlackBlack(-)

5-3 ELECTRICAL SYSTEM● Check the ignition coil with the pocket tester.Pocket tester : 09900-25002Ignition coil resistancePrimary0.19 ~ 0.24 ΪB/RSecondary5.4 ~ 6.6 kΩC.D.I. UNIT● Using the pocket tester (R 1 range), measure theresistance between the lead wire in the following table.Pocket tester : 09900-25002Unit : kΩPlug capGround Probe of tester to :B/YW/BLB/RB/WWBr Probe of tester to :B/YW/BLB/RB/WWBr14~183~57~1112~1610~14∞∞∞∞∞∞7~103~4.56~85~7∞3~4∞25~351.2~2.5∞7~10∞3~4.55~8∞5~7∞1.2~2.527~37STATOR COILS● Using the pocket tester, measure the resistancebetween the lead wire and ground. If the resistancechecked is incorrect, replace the coil.Unit : ΪB/YB/WW/BLWB/RBrStator coil resistanceLead wire of tester (Red) (Black)Standard resistanceY/WGroundLighting coil0.54 ~ 0.80 ΪW/RGroundCharging coil0.69 ~ 1.03 ΪB/RGroundExciting coil220 ~ 260 ΪBrWPick-up coil90 ~ 110 ΪCHARGING OUTPUT CHECKStart the engine and keep it running at 5,000 rpm with lightingswitch turned “ON”.Measure the DC voltage between the battery terminal and with a pocket tester.If the tester reads under or over following specification, checkthe no-lead performance or replace the regulator/rectifier.CAUTIONWhen making this test, be sure that the battery isin fully-charged condition.Pocket tester : 09900-25002Engine tachometer : 09900-26006Standard charging output13.0 ~ 16.0 V (at 5,000 rpm)

ELECTRICAL SYSTEM 5-4NO-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 voltagebetween the three lead wire. If the tester reading is asfollows, magneto is in good condition.Standard no-load performanceof A.C. generatorMore than 17 V (at 5,000 rpm)REGULATOR/RECTIFIER● Disconnect the coupler.● Using the pocket tester(×1kΩ Range), measure theresistance between the terminals as shown in the followingtable. If the resistance checked is incorrect,replace the regulator/rectifier. Probe of tester to:Pocket tester : 09900-25002Unit : kΩ Probe of tester to:1 2 3 41 1 502 ~ 260 ∞3 ∞ 42 50 ~ 230∞ ∞3 ∞ ∞∞4 ∞ ∞ 10 ~ 100STARTER SYSTEMThe starter system is shown in the diagram below: namely, the starting motor, starter relay, starter switch and battery.Depressing the starter switch (on the right handlebar switch box) while squeezing the front or rear brake lever energizesthe relay, causing the contact points to close which connects the starting motor to the battery.Starter relayFuseIG switchRY/GStarter switchR/WPointStartermotorBrake switchBatteryW/B

5-5 ELECTRICAL SYSTEMSTARTING MOTOR REMOVAL AND DISASSEMBLYRemove the starting motor.Disassemble the starting motor as shown in the illustration.STARTING MOTOR INSPECTIONCARBON BRUSHESWhen the brushes are worn, the motor will be unable toprocedure sufficient torque, and the engine will be difficultto turn over. To prevent this, periodically inspect thelength of the brushes and replace them when they aretoo short or chipping.Carbon brushes wearService limit 4 mmCOMMUTATORIf the commutator surface is dirty, starting performancewill decrease. Polish the commutator with #400 or similarfine emery paper when it is dirty. After polishing wipethe commutator with a clean dry cloth.Measure the commutator under cut 1.Segment1Commutator under cutService limit 4 mm

ELECTRICAL SYSTEM 5-6ARMATURE COILUsing the pocket tester, check the coil for open andground by placing probe pins on each commutator segmentand rotor core (to test for ground)and on any twosegments at various places (to test for open), with thebrushes lifted off the commutator surface.If the coil is found to be open-circuited or grounded,replace the armature. Continuous use of a defectivearmature will cause the starting motor to suddenly fail.Pocket tester : 09900-25002STARTER RELAY INSPECTION● Disconnect the starter relay lead wire coupler.Check the coil for “open”, “ground”and ohmic resistance.The coil is in good condition, if the resistanceis as follows.Pocket tester : 09900-25002Starter relay standard resistance0 ~ 70 Ϊ

5-7 ELECTRICAL SYSTEMFUEL LEVEL GAUGEFuel level gaugeOB/WY/BFuel tankFUEL LEVEL METER/GAUGEFUEL METER INSPECTIONTo test the Fuel Meter two different checks may beused.The first, and simplest test will tell if the meter is operatingbut will not indicate the meters accuracy throughoutthe range. To perform this test, lift the seat and removethe right frame cover, then disconnect the B/W and Y/Blead connector of the fuel gauge sending unit. Connecta jumper wire between B/W and Y/B wires coming fromthe main wiring harness. With the ignition switch turnedON, the fuel meter should indicate “F”.The second test will check the accuracy of the meter inthe full and empty positions. Connect a 90 Ϊ resistorbetween the Y/B and B/W lead wires. The fuel meter isnormal if its pointer indicates the E(empty) positionwhen the specified voltage is applied to the circuit and ifits pointer indicates the F(full) position when the resistoris changed to 10 Ϊ.

ELECTRICAL SYSTEM 5-8If either one or both indications are abnormal, replacethe fuel meter with a new one.FUEL GUAGE SENDING UNIT INSPECTION● Disconnect the lead wires coming out of the fuelgauge and check resistance of each position.● If the resistance measured is incorrect, replace thefuel gauge assembly with a new one.● The relation between the position of the fuel gaugefloat and resistance is shown in the following table.FRelation between the position of the fuelgauge float and resistanceFloat positionResistance1/2F(Full)10 0- 6Ϊ1/2E(Empty)3890+ 100ΪΪEOIL LEVEL CHECK LIGHTOil level switchOil level check lightIG switchBattery

5-9 ELECTRICAL SYSTEMOIL LEVEL SWITCH INSPECTIONCheck the oil level switch for continuity between the leadwire. If the tester does not show the value of 0 ~ 1 Ϊwhen the switch ring is in bottom position, file the contactsurface or replace the unit.Pocket tester : 09900-25002SwitchOIL LEVEL CHECK LIGHT INSPECTIONDisconnect the L/W and B/W lead connector of the oillevel check light.Connect a jumper wire between L/W and B/W wirescoming from the main wiring harness. With the ignitionswitch turned ON, the oil level check light should flash.If there is no flash, check the wiring harness continuityand the bulb blown out.THERMOELEMENT BattaryPTCB/RRRegurator/RectifierY/W R/WMagneto

ELECTRICAL SYSTEM 5-10INSPECTION● Disconnect the thermoelement coupler 1.● Connect the thermoelement coupler 1 to a 12V batteryand touch the thermoelement 2 to check thetemperature being raised.The thermoelement 2 should become heated to atemperature more than that of human body withinfive minutes. If not, replace with new one.CAUTIONThis check should be carried out when the carburetoris cold.12SWITCHES INSPECTIONInspect each switch for continuity with the pocket testerreferring to the chart. If it is found any abnormality,replace the respective switch assembly with new one.Pocket tester : 09900-25002ONOFFSTARTER SWITCHW/B○Y/G○WIRE COLORBLGGrSbLgORWYB/RB/WW/BY/WY/GL/WONOFFBlackBlueGreenGrayLight blueLight greenOrangeRedWhiteYellowBlack with Red tracerBlack with White tracerWhite with Black tracerYellow with White tracerYellow with Green tracerBlue with White tracerLIGHTING SWITCHGrY/W○○FRONT AND REAR LAMP SWITCHOW/BONOFF○TURN SIGNAL LAMP SWITCH○Lg Sb BL∙○ ○R ○ ○HORN SWITCHB/WGONOFF○IGNITION SWITCH○B/W B/R R O L/WLOCK ○ ○OFF ○ ○ON○ ○C ○ ○ ○ ○ ○

5-11 ELECTRICAL SYSTEMBATTERYBATTERYTypeCapacityYT4L-BS12V, 3AH/10HRCapFilterSafety valveStandard electrolyte S.G.1.32(at 20℃)CAUTION OF BATERY ELECTROLYTETREATMENT● Pay attention that the battery electrolyte not be stainthe chasis or the humanbody.● If be stain the chasis or the humanbody, at oncewash a vast quantity of water.When it be stained, clothes should come into being ahole or painting should take off.Be cured from a doctor.● When the battery electrolyte was droped the surfaceof land, wash a vast quantity of water.Neutralize by hydroxide, bicarbonate of soda and soon. Pole plate Pole plateSeparator(fiberglass plate)INITIAL CHARGINGFILLING ELECTROLYTE● Remove the aluminum tape 1 sealing the batteryelectrolyte filler holes 2.● Remove the caps 3.CAUTION∙After filling the electrolyte completely, use theremoved cap as the sealed caps of battery-fillerholes.∙Do not remove or pierce the sealed areas 4 ofthe electrolyte container.

ELECTRICAL SYSTEM 5-12● Insert the nozzles of the electrolyte container into thebattery’s electrolyte filler holes, holding the containerfirmly so that it does not fall.CAUTION∙Take precaution not to allow any of the fluid tospill.∙The electrolyte container insert at right anglesso that it is not sloped.● Make sure air bubbles are coming up each electrolytecontainer, and leave in this position for aboutmore than 20 minutes.NOTE:If no air bubbles are coming up from a filler port, tap thebottom of the two or three times.Never remove the container from the battery.● After confirming that the electrolyte has entered thebattery completely, remove the electrolyte containersfrom the battery. Wait for around 20 minutes.● Insert the caps 1 into the filler holes, pressing infirmly so that the top of the caps do not protrudeabove the upper surface of the battery’s top cover.CAUTION∙Clean completely in case that the electrolyte isadhered at the filler hole.∙Once install the caps to the battery, do notremove the caps.

5-13 ELECTRICAL SYSTEM● Using the pocket tester, measure the battery voltage.The tester should indicate more than 12.5-12.6V(DC)as shown in the Fig. If the battery voltage islower than the specification, charge the battery with abattery charger.NOTE:Initial charging for a new battery is recommended if twoyears have elapsed since the date of manufacture.secondsTime(at 25℃)(Minutes)CAUTION OF BATTERY TREATMENTThe battery is needed attention generally as occur flammability gas.If does not, it should be explosion and severe accident.Pay attention to the following points.● Prohibit positively that come in contact with short, spark or firearms.● The battery recharge where be well-ventilated wide place.Prohibit positively at the shut tight room.RECHARGING OPERATION● Using the pocket tester, check the battery voltage. Ifthe voltage reading is less than 12.0V(DC), rechargethe battery with a battery charger.● When recharging the battery, remove the batteryfrom the motorcycle.● Do the battery by standard charging usually.BATTERY CHARGING CURRENTStandard0.4A × 5~10 HoursFast4A × 30 MinutesVoltage● After recharging, wait for more than 30 minutes andcheck the battery voltage with a pocket tester.● If the battery voltage is less than 12.0V, recharge thebattery again.● If the battery voltage is still less than 12.0V afterrecharging, replace the battery with a new one.NOTE:When a battery is left for a long term without using, it issubject to discharge. When the motorcycle is not usedfor more than 1 month(especially during the winter season),recharge the battery once a month at least.WARNINGVoltageTime(at 0~40℃)(Minutes)∙Charging equipment of this motorcycle isdesigned for the MF(Maintenance Free) battery.∙No use except the specificated battery.Battery charged condition

CHASSISCONTENTSFRONT WHEEL 6- 1FRONT BRAKE 6- 7FRONT FORK 6-14STEERING 6-18REAR WHEEL AND REAR BRAKE 6-226

6-1 CHASSISFRONT WHEELREMOVAL AND DISASSEMBLY● Remove the front brake caliper by removing themounting bolts 1.CAUTIONDo not operate the front brake lever while dismountingthe caliper.1

CHASSIS 6-2● Remove the front axle nut.● Support the motocycle by jack or wooden block.● Remove the front wheel and speedometer gear boxby removing the front axle shaft.● Remove the disc plate 1 by removing the bolts.1● Remove the spacer 2.2● Remove the oil seal 3 with the special tool.Oil seal remover : 09913-501213

6-3 CHASSISDrive out the both bearing with the special tool in the followingprocedures.● Insert the adapter into the bearing.● After inserting the wedge bar from the opposit side,lock the wedge bar in the slit of the adapter.● Drive out the bearing by knocking the wedge bar.Wheel bearing remover : 09941-50111CAUTIONThe removed dust seal and bearing should bereplaced with new ones.INSPECTIONWHEEL RIMMake sure that the wheel rim runout does not exceedthe service limit when checked as shown.An excessive runout is usually due to worn or loosewheel bearings and can be reduced by replacing thebearings. If bearing replacement fails to reduce therunout, replace the wheel.Wheel rim runout(Axle and Radial)Service limit 3.0 mmDial gauge(1/100 mm) : 09900-20606Magnetic stand : 09900-20701TIREInspect the tires for wear and damage, and check thetire tread depth as shown. Replace a badly worn or damagedtire. A tire with its tread worn down to the limit(interms of tread depth)must be replaced.

CHASSIS 6-4Tire depthservice limitTIRE PRESSURECold inflationFrontRear1.6 mm1.6 mmCheck the tire pressure, and examine the value for evidenceof air leakage.FrontRearNormal ridingSolo riding Dual ridingkg/cm21.252.00kPa123196kg/cm21.752.25kPa172221REASSEMBLY AND REMOUNTINGReassemble and remount the front wheel in the reverseorder diassembly and removal, and also carry out thefollowing steps.WHEEL BEARING● Apply SUPER GREASE“A”to the bearings beforeinstalling.Super Grease“A”● Install the wheel bearings by using the special tool.S hellA v lI ndustrialM ulti-purposeania3G reaseBearing installer set : 09924-84521CAUTIONFirst install the wheel bearing for left side.Right sideLeft sideBearing(R)SpacerBearing(L)ClearanceBearing(L)

6-5 CHASSISOIL SEAL● Install the oil seal 1 with the special tool.Oil seal installer : 09923-551311● Install the spacer 2.2DISC PLATE● Install the disc plate and tighten them to the specifiedtorque.Front brake disc bolt : 18 ~ 28 N∙m(1.8 ~ 2.8 kg∙m)SPEEDOMETER GEAR BOX● When installing the speedometer gear box, align thetwo drive pawls with the two recesses of thewheel hub.

CHASSIS 6-6CAUTIONAfter touching the speedometer gear box tothe stopper , tighten the axle shaft.FRONT WHEEL● Tighten the front axle nut to the specified torque.Front axle nut : 33 ~ 52 N∙m(3.3 ~ 5.2 kg∙m)● Tighten the caliper mounting bolts to the specifiedtorque.Front brake caliper mounting bolt: 18 ~ 28 N∙m(1.8 ~ 2.8 kg∙m)

6-7 CHASSISFRONT BRAKEBRAKE PAD REPLACEMENT● Remove the caliper by removing the brake calipermounting bolts 1.CAUTIONDo not operate the front brake lever while dismountingthe caliper.1

CHASSIS 6-8● Reassemble it after remove the brake pads 1.CAUTION1Replace the brake pads as a set, otherwise brakingperformance will be adversely affected.CALIPER REMOVAL AND DISASSEMBLY● Remove the brake hose 2 and catch the brake fluidin a suitable receptacle.● Remove the caliper mounting bolt 3.CAUTIONNever re-use the brake fluid left over from the lastservicing and stored long periods.32● Remove the caliper.● Remove the brake pads.● Remove the pad holder 4.4● Remove the spring 5.5

6-9 CHASSIS● Place a rag over the piston to prevent popping up.Force out the piston with a air gun.CAUTIONDo not use high pressure air to prevent pistondamage.● Remove the dust seal 1 and piston seal 2.12CALIPER INSPECTIONInspect the caliper cylinder bore wall for nicks, scratchesor other damage.Inspect piston for damage and wear.Inspect each rubber part for damage and wear.

CHASSIS 6-10CALIPER REASSEMBLYReassemble and remount the caliper in the reverseorder of removal and disassembly, and also carry out thefollowing steps.CAUTION{Wash the caliper components with fresh brakefluid before reassembly. Never use cleaning solventor gasoline to wash them. Apply brake fluidto the caliper bore and piston to be inserted intothe bore.{● Apply SILICONE GREASE to the caliper holder.Silicone GreaseItemSPECIFIED TORQUEN∙mkg∙m11218 ~ 2820 ~ 251.8 ~ 2.82.0 ~ 2.52WARNINGBleed the air from brake fluid circuit afterreassembling caliper.(Refer to page 2-9)DISC PLATE REMOVAL AND DISASSEMBLY● Remove the front wheel.(Refer to page 6-2)● Remove the disc plate.(Refer to page 6-2)● Install the disc plate.(Refer to page 6-4)DISC PLATE INSPECTION● Check the disc for wear with a micrometer. Its thicknesscan be checked with disc and wheel in place.Replace the disc if the thickness exceeds the servicelimit.Disc thicknessMicrometer(0 ~ 25mm) : 09900-20201Service limit 3.5 mm

6-11 CHASSIS● With the disc mounted on the wheel, check the discfor face runout with a dial gauge as shown. Replacethe disc if the runout exceeds the service limit.Dial gauge(1/100 mm) : 09900-20606Magnetic stand : 09900-20701Disc runoutService limit 0.3 mmMASTER CYLINDER REMOVAL ANDDISASSEMBLY● Remove the handlebar cover.● Disconnect the front brake lamp switch lead wires.● Place a cloth underneath the union bolt on the mastercylinder to catch spilled drops of brake fluid. Unscrewthe union bolt and disconnect the brake hose/mastercylinder joint.CAUTIONCompletely wipe off any brake fluid adhering toany part of motorcycle. The fluid reacts chemicallywith paint, plastics, rubber materials, etc.● Remove the master cylinder.

CHASSIS 6-12● Remove the brake lever 1 and brake switch 2.21● Remove the dust boot 3.3● Remove the circlip 4 with the special tool.Snapring pliers : 09900-061084● Remove the piston/primary cup with return spring 5.● Remove the reservoir cap 6 and diaphragm 7.● Drain brake fluid.67}5

6-13 CHASSISMASTER CYLINDER INSPECTIONInspect the master cylinder bore for any scratches orother damage.Inspect the piston surface for scratches or other damage.Inspect the primary cup and dust boot for wear or damage.MASTER CYLINDER REASSEMBLY ANDREMOUNTINGReassemble and remount the master cylinder in thereverse order of removal and disassembly, and alsocarry out the following steps.BootCAUTIONWash the master cylinder components with freshbrake fluid before reassembly. Never use cleaningsolvent or gasoline to wash them.Apply brake fluid to the cylinder bore and all theinternals to be inserted into the bore.spring PistonCirclipPrimary capSecond cap● Reassemble and remount the master cylinder.(Referto page 6-11)● When remounting the master cylinder on the handlebar,first tighten the clamp bolt for upside.CAUTIONUpsideMaster cylinderBleed air after remounting the master cylinder.HandlebarClearance

CHASSIS 6-14FRONT FORKREMOVAL AND DISASSEMBLY● Remove the front leg shield.● Remove the front brake caliper by removing themounting bolts.CAUTIONDo not operate the front brake lever while dismountingthe caliper.

6-15 CHASSIS● Remove the front axle nut.● Support the motorcycle by jack or wooden block.● Remove the front wheel by removing the front axleshaft.● Loosen the front fork bolt, then draw out the forkspring.● Loosen the front fork lower clamp bolts.● Invert the fork and stroke it several times to removethe oil.● Hold the fork inverted for a few minutes.● Remove the socket bolt 1 with the hexagon wrench.● Seperate the fork pipe 2 and pipe seat 3.231

CHASSIS 6-16● Remove the dust boot 1 and stopper ring 2.12● Remove the oil seal by using the special tool.CAUTIONThe oil seal removed should be replaced with anew oil seal.Oil seal remover : 09913-50121INSPECTION● Inspect pipe seat for wear and damage.● Inspect fork pipe and bottom case sliding surfaces forany scuffing or flaws.

6-17 CHASSISFORK SPRING● Measure the fork spring free length.Fork spring free lengthStandard 290.9 mm290.9REASSEMBLY AND REMOUNTINGReassemble and remount the fork in the reverse order ofremoval and disassembly, and also carry out the followingsteps.FRONT FORK BOLT● Apply BOND “1215”and THREAD LOCK “1324”tothe fork bolt and tighten the bolt with specified torque.}}Bond “1215”Thread Lock “1324”Front fork bolt : 35 ~ 55 Nㆍm(3.5 ~ 5.5 kgㆍm)FORK OIL● For the fork oil, be sure to use a front fork oil whoseviscosity rating meets specification below.Fork oil typeCapacityTELLUS # 3750 cc(One side)Up sideCUSHION SPRING● When installing the front fork spring, the close endshould position upside.

CHASSIS 6-18STEERINGREMOVAL AND DISASSEMBLY● Remove the handlebar cover.● Remove the handlebar by removing the clamp bolt 1and set bolt 2.12● Loosen the steering stem lock nut 3 with the specialtool.Clamp wrench : 09940-101223● Remove the front fork assembly by removing the lockwasher 4, steering outer upper race 5 and dust seal6.CAUTION4Do not drop the steering stem steel balls.56● Remove the steering outer lower race 7 with a chisel.7

6-19 CHASSIS● Remove the steering stem steel balls 1.Number of steel ballUpper22 pcsLower25 pcs11● Remove the upper and lower bearing inner race withan appropriate bar.INSPECTIONInspect 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 REMOUNTINGReassemble and remount the steering stem, handlebarand front fork in the reverse order of disassembly andremoval, and also carry out the following steps.2OUTER LOWER RACE● Press in the outer lower race 2.

CHASSIS 6-20INNER RACE● Press in the upper and lower inner races with the specialtool.Steering race installer : 09941-34513STEEL BALL● Apply SUPER GREASE “A”when installing theupper and lower steel balls.Super Grease “A”Number of steel ballUpper22 pcsLower25 pcsSTEERING OUTER UPPER RACE NUT● Tighten the steering outer upper race 1 until resistanceis felt, then loosen it 1/8 ~ 1/4 turn.CAUTION1Make sure that the steering turns smoothly andeasily, left to right.● Tighten the steering stem lock nut 2 with the specialtool.Clamp wrench : 09940-10122Steering stem lock nut: 60 ~ 100 Nㆍm(6.0 ~ 10.0 kgㆍm)2

6-21 CHASSIS● Install the handlebar and tighten the set bolt 1 andclamp bolt 2 to the specified torque.Handlebar set bolt : 22 ~ 28 Nㆍm(2.2 ~ 2.8 kgㆍm)Handlebar clamp bolt : 48 ~ 52 Nㆍm(4.8 ~ 5.2 kgㆍm)21● After install the front fork and steering stem, inspectthe following items.∙Lift the front fork.∙Inspect play of the front fork as that grasp lower ofthe front fork and shake it by the front and rear.∙By the handle turning the right or left, inspectwhether turning smoothly.∙Adjust the outer upper race, if the steering is comedheavy and tight.● Bleed air of the front brake.(Refer to page 2-9)

CHASSIS 6-22REAR WHEEL AND REAR BRAKEREMOVAL AND DISASSEMBLY● Place the motorcycle on level ground.● Remove the muffler.(Refer to page 3-4)● Remove the rear wheel by removing the axle nut 1.1

6-23 CHASSISINSPECTIONREAR BRAKE DRUMMeasure the brake drum I.D. to determine the extent ofwear and, if the limit is exceeded by the wear noted,replace the drum. The value of this limit is indicatedinside the drum.Rear brake drum I.DService limit 100.7 mmBRAKE SHOEUsing a vernier calipers, measure the brake shoe outsidediameter at the place as shown in the photo. If themeasurement is less than the limit, replace the brakeshoe.Brake shoe lining for thicknessCAUTIONService limit 96 mmReplace the brake shoe with a set, otherwisebraking performance will be adversely affected.WHEELRefer to page 6-3.TIRERefer to page 6-4.REASSEMBLY AND REMOUNTINGReassemble and remount the rear wheel and brake inthe reverse order of removal, and diassembly.BRAKE CAM LEVER● When installing the brake cam lever, align thepunched mark of camshaft with the slit on cam lever.Brake cam lever bolt : 6 ~ 9 Nㆍm(0.6 ~ 0.9 kgㆍm)FrontPunch markSlitFrontREAR BRAKE SHOE● Apply SUPER GREASE “A”to the camshaft and pinbefore installing the brake shoes.Super Grease “A”CAUTIONBe careful not to apply too much grease to thecamshaft and pin. If grease gets on the lining,brake effectiveness will be lost.

CHASSIS 6-24REAR AXLE NUT● Tighten the rear axle nut to the specified torque.Rear axle nut : 60 ~ 90 Nㆍm(6.0 ~ 9.0 kgㆍm)

SERVICING INFORMATIONCONTENTSTROUBLESHOOTING 7- 1SPECIAL TOOLS 7- 6TIGHTENING TORQUE 7-10SERVICE DATA 7-12WIRE AND CABLE ROUTING 7-18WIRING DIAGRAM 7-207

7-1 SERVICING INFORMATIONTROUBLESHOOTINGENGINEComplaint Symptom and possible causes RemedyEngine does notstart, or is hardto start.Engine stallseasily.Noisy engine.Slipping clutchEngine idlespoorly.Compression too low1. Excessively worn cylinder or piston rings.2. Stiff piston ring in place.3. Gas leaks from the joint in crankcase, cylinder or cylinder head.4. Damaged reed valve.5. Spark plug too loose.6. Broken, cracked or otherwise failed piston.Plug not sparking1. Damaged spark plug or spark plug cap.2. Dirty or wet spark plug.3. Defective CDI & Ignition coil unit or stator coil.4. Open or short in high-tension cord.5. Defective ignition switch.No fuel reaching the carburetor1. Clogged hole in the fuel tank cap.2. Clogged or defective fuel cock.3. Defective carburetor float valve.4. Clogged fuel hose or defective vacuum hose.1. Carbon deposited on the spark plug.2. Defective CDI & Ignition coil unit.3. Clogged fuel hose.4. Clogged jets in carburetor.5. Clogged exhaust pipe.Noise appears to come from piston1. Piston or cylinder worn down.2. Combustion chamber fouled with carbon.3. Piston pin, bearing or piston pin bore worn.4. Piston rings or ring grooves worn.Noise seems to come from crankshaft1. Worn or brunt crankshaft bearings.2. Worn or brunt conrod big-end bearings.Noise seems to come from final gear box1. Gears worn or rubbing.2. Badly worn splines.3. Worn or damaged bearings of drive shaft for rear axle shaft.1. Worn or damaged clutch shoes.2. Worn clutch drum.1. Excessively worn cylinder or piston rings.2. Stiff piston ring in place.3. Gas leaks from crankshaft oil seal.4. Spark plug gaps too wide.5. Defective CDI & Ignition coil unit.6. Defective magneto stator coil.7. Float-chamber fuel level out of adjustment in carburetor.8. Clogged jets in carburetor.9. Broken or damaged reed valve.Replace.Refair or replace.Refair or replace.Replace.Tighten.Replace.Replace.Clean and dry.Replace.Replace.Replace.Clean.Clean or replace.Replace.Clean or replace.Clean.Replace.Clean.Clean.Clean.Replace.Clean.Replace.Replace.Replace.Replace.Replace.Replace.Replace.Replace.Replace.Replace.Replace.Replace.Adjust or replace.Replace.Replace.Replace.Clean or adjust.Replace.

SERVICING INFORMATION 7-2Complaint Symptom and possible causes RemedyEngine runspoorly in highspeedrange.1. Excessively worn cylinder or piston rings.2. Stiff piston ring in place.3. Spark plug gaps to narrow.4. Ignition not advanced sufficiently due to poorly working CDI& Ignition coil unit.5. Defective magneto stator coil.6. Float-chamber fuel level too low.7. Clogged air cleaner element.8. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.9. Clogged fuel cock vacuum pipe.Replace.Replace.Adjust.Replace.Replace.Adjust or replace.CleanClean, and replace.Clean.Dirty or heavyexhaust smoke.Engine lackspower.Engine overheats.1. Too much engine oil to the engine.2. Use of incorrect engine oil.1. Excessively worn cylinder or piston rings.2. Stiff piston ring in place.3. Gas leaks from crankshaft oil seal.4. Spark plug gaps incorrect.5. Clogged jets in carburetor.6. Float-chamber fuel level out of adjustment.7. Clogged air cleaner element.8. Fouled spark plug.9. Sucking air from intake pipe.10. Slipping or worn V-belt.11. Damaged/worn rollers in the movable drive face.12. Weakened movable driven face spring.13. Too rich fuel/air mixture due to defective starter system.1. Heavy carbon deposit on piston crown.2. Defective oil pump or clogged oil circuit.3. Fuel level too low in float chamber.4. Air leakage from intake pipe.5. Use of incorrect engine oil.6. Use of improper spark plug.7. Clogged exhaust pipe/muffler.Check oil pump.Change.Replace.Replace.Replace.Adjust or replace.Clean.Adjust or replace.Clean.Clean or replace.Retighten or replace.Replace.Replace.Replace.Replace.Clean.Replace or clean.Adjust or replace.Retighten or replace.Change.Change.Clean or replace.CARBURETORComplaint Symptom and possible causes RemedyTrouble withstarting.1. Starter jet is clogged.2. Air leaking from a joint between starter body and carburetor.3. Air leaking from carburetor’s joint or vacuum hose joint.4. Starter plunger is not operating properly.Clean.Check starter body and carburetorfor tightness, and replace gasket.Check and replace.Check and replace.Idling or low-speedtrouble.Medium or highspeedtrouble.Overflow and fuellevel fluctuations.1. Pilot jet, pilot air jet are clogged or loose.2. Air leaking from carburetor’s joint, vacuum pipe joint, or starter.3. Pilot outlet is clogged.4. Starter plunger is not fully closed.1. Main jet or main air jet is clogged.2. Needle jet is clogged.3. Fuel level is improperly set.4. Throttle valve is not operating properly.5. Fuel filter is clogged.1. Needle valve is worn or damaged.2. Spring in deedle valve is broken.3. Float is not working properly.4. Foreign matter has adhered to needle valve.5. Fuel level is too high or low.Check and clean.Clean and replace.Check and clean.Check and replace.Check and clean.Check and clean.Check and replace.Check throttle valve for operation.Check and clean.Replace.Replace.Check and adjust.Clean.Adjust or replace.

7-3 SERVICING INFORMATIONELECTRICALComplaint Symptom and possible causes RemedyNo sparking orpoor sparking.1. Defective CDI & Ignition coil unit.2. Defective spark plug.3. Defective magneto stator coil.4. Loose connection of lead wire.Replace.Replace.Replace.Connect/tighten.Spark plug soonbecomes fouledwith carbon.Spark plugelectrodes overheator burn.Magneto does notcharge.Magneto charge,but charging rate isbelow the specifications.MagnetooverchargesUstable charging.Starter button isnot effective.1. Mixture too rich.2. Idling speed set too high.3. Incorrect gasoline.4. Dirty element in air cleaner.5. Spark plug too cold.6. Incorrect engine oil.1. Spark plug too hot.2. The engine overheats.3. Spark plug loose.4. Mixture too lean.5. Not enough engine oil.1. Open or short in lead wires, or loose lead connections.2. Shorted, grounded or open magneto coil.3. Shorted or open regulator/rectifier.1. Lead wires tend to get shorted or open-circuited orloosely connected at terminal.2. Grounded or open-circuited stator coils of magneto.3. Defective regulator/rectifier.4. Defective cell plates in the batttery.1. Internal short-circuit in the battery.2. Resistor element in the regulator/rectifier damaged or defective.3. Regulator.rectifier unit poorly grounded.1. Lead wire insulation frayed due to vibration,resulting in intermittent shorting.2. Magneto coil internally shorted.3. Defective regulator/rectifier.1. Battery run down.2. Defective switch contacts.3. Brushes not seating properly on commutator in starter motor.4. Defective starter relay.5. Defective starter pinion gears.6. Defective front or rear brake light switch circuit.Adjust carburetor.Adjust carburetor.Change.Clean.Replace by hot type plug.Replace.Replace by hot type plug.Turn up.Retighten.Adjust carburetor.Check oil pump.Repair, replace or retighten.Replace.Replace.Repair, or retighten.Replace.Replace.Replace the battery.Replace the battery.Replace.Clean and tighten groun connection.Repair or replace.Replace.Replace.Recharge or replace.Replace.Repair or replace.Replace.Replace.Replace or repair.BATTERYComplaint Symptom and possible causes RemedyBattery runs downquickly.Reversed batterypolarity.Battery dischargestoo rapidly.1. The charging method is not correct.2. Cell plates have lost much of their active material as a resultof over-charging.3. A short-circuit condition exists within the battery due toexcessive accumulation of sediments caused by the incorrectelectrolyte.4. Battery is too old.1. The battery has been connected the wrong way round in thesystem, so that it is being charged in the reverse direction.1. Dirty container top and sides.2. Battery is too old.Check the magneto and regulator/rectifiercircuit connections, and makenecessary adjustments to obtain specifiedcharging operation.Replace the battery, and correctthe charging system.Replace the battery.Replace the battery.Replace the battery and be sure toconnect the battery properly.Clean.Replace.

SERVICING INFORMATION 7-4CHASSISComplaint Symptom and possible causes RemedyHandling feelstoo heavy.Wobbly handle.Wobbly front wheel.Front suspensiontoo soft.Front suspensiontoo stiff.Noisy frontsuspension.Wobbly rear wheel.Rear suspensiontoo soft.Noisy rearsuspension.1. Steering stem nut overtightened.2. Broken bearing/race in steering stem.3. Distorted steering stem.4. Not enough pressure in tires.1. Loss of balance between right and left front suspension.2. Distorted front axle or crooked tire.1. Distorted wheel rim.2. Worn front wheel bearings.3. Defective or incorrect tire.4. Loose nut on axle.5. Loose nuts on the rear shock.6. Worn engine mounting bushing.7. Loose nuts or bolts for engine mounting.1. Weakened springs.2. Oil leakage of shock absorber.1. Not enough grease.2. Worn suspension arm spacer.1. Not enough grease.2. Loose nuts on suspension.1. Distorted wheel rim.2. Defective or incorrect tire.3. Loose nuts on the rear shock absorber.4. Worn engine mounting bushing.5. Loose nuts or bolts for engine mounting.1. Weakened spring.2. Oil leakage of rear shock absorber.1. Loosen nuts on shock absorber.2. Worn engine mounting bushing.Adjust.Replace.Replace.Adjust.Replace.Replace.Replace.Replace.Replace.Retighten.Retighten.Replace.Tighten.Replace.Replace.Refill.Replace.Refill.Retighten.Replace.Replace.Replace.Replace.Retighten.Replace.Replace.Retighten.Replace.BRAKESComplaint Symptom and possible causes RemedyInsufficient brakepower.1. Leakage of brake fluid from hydraulic system.2. Worn pad.3. Oil adhesion on engaging surface of pad.4. Worn disc.5. Air entered into hydraulic system.6. Worn shoe.7. Friction surfaces of shoes are dirty with oil.8. Excessively worn drum.9. Too much brake lever play.Repair or replace.Replace.Clean disc and pads.Replace.Bleed air.Replace.Replace.Replace.Adjust.Brake squeaking.1. Carbon adhesion on pad surface.2. Tilted pad.3. Damaged wheel bearing.4. Worn pad.5. Foreign substance entered into brake fluid.6. Clogged return ports of master cylinder.7. Brake shoe surface glazed.8. Loose front-wheel axle or rear-wheel axle nut.9. Worn shoe.Repair surface with sandpaper.Modify and fitting.Replace.Replace.Replace brake fluid.Disassemble and clean master cylinder.Repair surface with sandpaper.Tighten to specified torque.Replace.

7-5 SERVICING INFORMATIONComplaint Symptom and possible causes RemedyExcessive brakelever stroke.1. Air entered into hydraulic system.2. Insufficient brake fluid.3. Improper quality of brake fluid.4. Worn brake cam lever.5. Excessively worn shoes and/or drum.Bleed air.Replenish fluid to normal lever;bleedair.Replace with correct fluid.Replace.Replace.Leakage of brakefluid.Brake drags.1. Insufficient tightening of connection joints.2. Cracked hose.3. Worn piston seal.1. Rusty moving parts.Tighten to specified torque.Replace.Replace.Clean and lubricate.

SERVICING INFORMATION 7-6SPECIAL TOOLSSpecial toolsPart Number∙Part Name∙DescriptionSpecial toolsPart Number∙Part Name∙Description09900-00401“L”type hexagon wrench set09900-20205Micrometer(1/100mm, 0-25mm)Tighten hexagon boltMeasure outside diameter of piston pin09900-00410Hexagon wrench set09900-20508Cylinder gauge set(1/100mm, 40-80mm)Tighten hexagon boltMeasure inside diameter of cylinder09900-05108Snap ring pliers09900-20602Dial gauge(1/100mm, 1mm)Circlip remove and remountingMeasure inside diameter of cylinder09900-06105Snap ring pliers09900-20605Dial calipers(1/100mm, 10-34mm)Circlip remove and remountingMeasure width of conrod big-end09900-06107Snap ring pliers09900-20606Dial gauge(1/100mm, 10mm)Circlip remove and remountingMeasure run-out of wheel09900-0900309900-20701Impact driver setMagnetic standRemove and remounting of fixed screwUsed with Dial gauge09900-2010209900-20806Vernier calipersThickness gaugeMeasure thicknessMeasure clearance of piston ring09900-20202Micrometer(1/100mm, 25-50mm)09900-21304V-block setMeasure height of camUsed with Magnetic stand09900-20203Micrometer(1/100mm, 50-75mm)09900-21602CCI Oil gaugeMeasure outside diameter of pistonA gauge to inspect performance of oil pump

7-7 SERVICING INFORMATIONSpecial toolsPart Number∙Part Name∙DescriptionSpecial toolsPart Number∙Part Name∙Description09900-2230109913-60710Plastic gaugeBearing removerMeasure clearance of crankshaft thrustRemove bearing with the rotor remove sliding shaft09900-22401Small bore gauge(10-18mm)09913-75520Bearing installerMeasure inside diameter of conrod small-endUsed to drive bearing in09900-2500209913-75821Pocket testerBearing installerMeasure voltage, electric current, resistanceUsed to drive bearing in09900-2600609913-75830TachometerBearing installerMeasure rotational frequency of engineInstall rear axle shaft oil seal09900-2810709913-76010Electro testerBearing installerInspect ignition coilInstall crankshaft bearing09910-2011509915-63310Conrod holderCompression gauge adapterUsed to lock the crankshaftUsed with compression gauge09910-3281209915-64510Crankshaft installerCompression gaugeUsed to install the crankshaft in the crankcaseMeasure cylinder compression09913-1454109916-84511Fuel level gauge setTweezersMeasure height of carburetorRemove and remounting valve cotter pin.09913-5012109920-13120Oil seal removerCrankcase separaterUsed to remove the oil sealSeprate to crankcase

SERVICING INFORMATION 7-8Special toolsPart Number∙Part Name∙DescriptionSpecial toolsPart Number∙Part Name∙Description09921-2020009930-30163Bearing remover (10mm)Rotor removerRemove oil seal or bearingAttached to the top of sliding shaft when removing rotor09921-2021009930-32420Bearing remover (12mm)Rotor holderRemove oil seal or bearingRemove and remounting rotor09922-5513109930-40113Bearing installerRotor holderUsed to drive bearing inWidely used to lock rotary parts such as a flywheel magneto09923-7321009940-10122Bearing remover (17mm)Clamp wrenchRemove bearing with the rotor remove sliding shaftA hook wrench to adjust the steering head of motorcycle09923-7451009940-34520Bearing remover (20~35mm)T-handleRemove bearing with the rotor remove sliding shaftRemove and remounting front fork oil cylinder09924-8452109940-34561Bearing installerFront fork assembling tool attachment “D”Used to drive small bearing inUsed with T-handle09925-9822109940-50113Bearing installerFront fork oil seal installerUsed to drive bearing inInstall front fork oil seal09930-1012109941-34513Spark plug socket wrench setBearing installerRemove and remounting spark plugInstall steering outer race09930-3010209941-50110Rotor remove sliding shfatWheel bearing removerUsed to with bearing remover or rotor removerRemove wheel bearing

7-9 SERVICING INFORMATIONSpecial toolsPart Number∙Part Name∙Description09943-74111Front fork oil level gaugeUsed to drain the fork oil to the specified level09943-88211Bearing removerRemove rear axle shaft bearing09951-76010Bearing installerUsed to drive bearnig in

SERVICING INFORMATION 7-10TIGHTENING TORQUEENGINEITEMMagneto rotor nutMuffler mounting boltExhaust pipe nutSpark plugCylinder head nutEngine mounting boltEngine mounting bracket boltOil drain plugOil level boltOil pump boltClutch shoe nutClutch housing nutKick starter driven nutKick starter lever boltN∙m35 ~ 4518 ~ 288 ~ 1225 ~ 308 ~ 1240 ~ 6048 ~ 729 ~ 159 ~ 153 ~ 540 ~ 6040 ~ 6040 ~ 608 ~ 12kg∙m3.5 ~ 4.51.8 ~ 2.80.8 ~ 1.22.5 ~ 3.00.8 ~ 1.24.0 ~ 6.04.8 ~ 7.20.9 ~ 1.50.9 ~ 1.50.3 ~ 0.54.0 ~ 6.04.0 ~ 6.04.0 ~ 6.00.8 ~ 1.2

7-11 SERVICING INFORMATIONCHASSISITEMN∙mkg∙mRear brake cam lever bolt6 ~ 90.6 ~ 0.9Rear shock absorber bolt22 ~ 352.2 ~ 3.5Rear axle nut60 ~ 906.0 ~ 9.0Steering stem lock nut60 ~ 1006.0 ~ 10.0Front brake disc bolt18 ~ 281.8 ~ 2.8Front brake master cylinder bolt8 ~ 120.8 ~ 1.2Front brake air bleeder valve6 ~ 90.6 ~ 0.9Front brake caliper mounting bolt18 ~ 281.8 ~ 2.8Front brake hose union bolt20 ~ 252.0 ~ 2.5Front axle nut33 ~ 523.3 ~ 5.2Front fork bolt35 ~ 553.5 ~ 5.5Handlebar set bolt22 ~ 282.2 ~ 2.8Handlebar clamp nut48 ~ 524.8 ~ 5.2TIGHTENING TORQUE CHARTFor other bolts and nuts who’s torque is not listed, refer to this chart :Bolt Diameter(mm)Conventional or “4”marked boltN∙mkg∙mN∙m“7”marked boltkg∙m41.0 ~ 2.00.1 ~ 0.21.5 ~ 3.00.15 ~ 0.352.0 ~ 4.00.2 ~ 0.43.0 ~ 6.00.3 ~ 0.664.0 ~ 7.00.4 ~ 0.78.0 ~ 12.00.8 ~ 1.2810.0 ~ 16.01.0 ~ 1.618.0 ~ 28.01.8 ~ 2.81022.0 ~ 35.02.2 ~ 3.540.0 ~ 60.04.0 ~ 6.01235.0 ~ 55.03.5 ~ 5.570.0 ~ 100.07.0 ~ 10.01450.0 ~ 80.05.0 ~ 8.0110.0 ~ 160.011.0 ~ 16.01680.0 ~ 130.08.0 ~ 13.0170.0 ~ 250.017.0 ~ 25.018130.0 ~ 190.013.0 ~ 19.0200.0 ~ 280.020.0 ~ 28.0

SERVICING INFORMATION 7-12SERVICE DATACYLINDER + PISTON + PISTON RINGITEMPiston to cylinder clearanceSTANDARD0.065 ~ 0.075LIMIT0.120Unit : mmCylinder borePiston diam.Cylinder distortionCylinder head distortion41.005 ~ 41.02040.935 ~ 40.950Measure at 15mm from the skirt end41.0740.8850.10.1Piston ring clearance(Free condition)1st2ndApprox. 4.5Approx. 4.33.23.1Piston ring clearance(Assembling condition)1st2nd0.10 ~ 0.250.10 ~ 0.250.750.75Piston ring - ring groove clearance1st2nd0.02 ~ 0.060.02 ~ 0.06Piston pin bore I.D10.002 ~ 10.01010.030Piston pin O.D9.995 ~ 10.0009.980CONROD + CRANKSHAFTUnit : mmITEMSTANDARDLIMITConrod small end I.D.14.003 ~ 14.01114.047Conrod big end runout3.0Crank web to wed width35 ± 0.1Crankshaft runout0.08

7-13 SERVICING INFORMATIONOIL PUMPUnit : mmITEMSTANDARDOil pump reduction ratio 30.000(30/1)CLUTCHUnit : mmITEMClutch housing I.D.Clutch shoe thicknessClutch in rpmClutch tight rpmSTANDARD110.00 ~ 110.153.03,600 ± 200 rpm6,000 ± 200rpmLIMIT110.352.0TRANSMISSIONITEMFinal reduction ratioGear ratiosV-belt widthV-belt thicknessMovable drive face spring free lengthSTANDARD12.02.997 ~ 0.81316.5 ± 0.68.0 ± 0.6143.8Unit : mmLIMIT15.3135 ~ 153

SERVICING INFORMATION 7-14CARBURETORUnit : mmITEMSPECIFICATIONCarburetor typeMain bore sizeI.D. No.Idle rpmFuel levelMain jetMain air jetJet needleNeedle jetPilot jetThrottle valveBy-passValve seatStater jetPilot screwPilot outletThrottle cable play(M.J.)(M.A.J.)(J.N.)(N.J.)(P.J.)(T.V.)(B.P.)(V.S.)(G.S.)(P.S.)(P.O.)VM14ф 14HG 2661,800 ± 50 rpm24.5551.03E17-3E-2253.02.4 ± 0.051.2250.80.5 ~ 1.0

7-15 SERVICING INFORMATIONELECTRICALUnit : mmITEM SPECIFICATION NOTEIgnition timingSpark plugSpark performanceIgnition coil resistanceTypeGapPrimarySecondary20at 1,000 rpmBR8HSA0.6 ~ 0.7Over 8 mm0.19 ~ 0.24 Ϊ5.4 ~ 6.6 kΩLighting coil0.54 ~ 0.80 ΪY/W-GroundStator coil resistanceCharging coilExciting coil0.69 ~ 1.03 Ϊ220 ~ 260 ΪW/R-GroundB/R-GroundPick-up coil90 ~ 110 ΪBr-WRegulated voltageNo-load performance of A.C. generatorStarter relay resistanceType designation13.0 ~ 16.0 V at 5,000 rpmMore than 17V (at 5,000 rpm)0 ~ 70 ΪYT4L-BSBatteryFuseCapacityStandard electrolyte S.G.12V, 3AH1.32 at 20℃ (68℉)10 AWATTAGEITEMHead lamp bulbTail/Brake lamp bulbTurn signal lamp bulbTurn signal / Oil level check light pilot lampSpeedometer lamp bulbSPECIFICATION15W × 25 / 10W10W × 41.7W / 17W1.7W × 2Unit : WCAUTIONDo not use except the specified bulb (Wattage).

SERVICING INFORMATION 7-16BRAKE+WHEELUnit : mmITEMSTANDARDLIMITBrake lever playFrontRear5 ~ 2015 ~ 25Brake drum I.DRear100100.7Brake lining thicknessRear99.296Brake disc plate thicknessFront4.0 ± 0.23.5Brake disc plate runoutFront0.30Master cylinder bore I.D.Front11.000 ~ 11.04311.055Master cylinder piston diam.Front10.957 ~ 10.98410.945Brake caliper I.D.Front30.230 ~ 30.30630.315Brake caliper piston diam.Front30.150 ~ 30.20030.140Wheel rim runoutAxialRadial3.03.0Axle shaft runoutFront0.25Tire sizeFrontRear110/70-12 47J120/70-12 51JTire tread depthFrontRear1.61.6

7-17 SERVICING INFORMATIONSUSPENSIONUnit: mmITEM STANDARD LIMITFront fork strokeFront fork spring length(Free condition)Front fork oil specificationFront fork oil capacity(One side)Rear wheel travel75290.9TELLUS # 3750 cc66TIRE PRESSURECOLD INFLATIONTIRE PRESSUREFRONTREARSOLO RIDINGkPakg/cm21231.251962.00DUAL RIDINGkPakg/cm21721.752212.25FUEL + OILITEMFuel typeFuel tank capacityEngine oil typeEngine oil capacityEngine oil discharge amountTransmission oil typeTransmission oil capacityBrake fluid typeSPECIFICATIONGasoline used should be graded 85 ~ 95 octane or higher.An unleaded gasoline is recommended.4.8 lAPOLLOIL BIKE-K, HYPOL HS1.0 l1.0 ~ 1.2 ml(at 3,000 rpm for 5 minutes)SAE 10W/30 or 10W/40 multi-grade motor oilReplaceOverhaulDOT 4110 ml130 mlNOTEI.D 60ml/HrF.O 100ml/Hr

SERVICING INFORMATION 7-18WIRE AND CABLE ROUTINGRear turnsignal LREAR BRAKEBattery coverRear turnsignalR/LSwitch thermoStarter relayFuse caseRear turnsignal R 09407-22402Lamp assy, Tail & StopRear turnsignal R/L09407-22402Clamp09407-22402Starter motormagnetoEngine earthIgnition coilRear brakecableBrake cable

7-19 SERVICING INFORMATIONCABLEFrontRear turnsignal R/LLamp assy Tail & Stop coupleFuse caseBattery, , Oil level gaugeThrottle cableMaster cylinder hoseRear brake cableHarnessLamp assy Tail & Stop09407-22402Oil tank09407-22402Helmet boxSwitch thermoDRear turnsignal RH/LHShield leg lower rearHeater carburetorIgnition coilClampRear fenderShield leg lower rearP.T.CStarter motorHarnessREAR TURNSIGNAL LAMPFrontFrameStarter motorEngine earthStarter motormagnetoThrottle cableFrame earthRear brakecableHarnessVIEW BVIEW DFender, Front upperSteering lockCHarnessTurnsignal relayCDI unitSpeedometer cableHornRegulatorFront turnsignal RH/LHHead lampBClampHarnessThrottle cableBrake cableFuel tankFront turnsignal RH/LH RegulatorHead lampThrottle cableRear brakecableHarnessSpeedometercableBrakehoseVIEW C

SERVICING INFORMATION 7-20WIRING DIAGRAMSpeedometerFront turnsignal RHHead lampFront turnsignal LHRear turnsignalFront turnsignalOil pilot lampturnsignal pilot lampIlluminationRear combinationHead lmapLampTailStopDEST10101.71.71.7×251015×2Handle switch RHStarter LightingFront brake switchHornTurnsignal relayFuel gaugeFrame earthOil gaugeRegulatorThermo switchP.T.CCarburetor, HeaterRear turnsignal RHTail & StopRear turnsignal LHIgnition coil Starter relay BatteryEngine earthHornStarter motorTurnsignalHandle switch LHIgnition switchRear brakeswitchMagneto C.D.I unitSpark plugWIRE COLORB : Black Lg : Light green Y : Yellow RB : Red with Black tracerBr : Brown O : Orange BG : Black with Green tracer RW : Red with White tracerG : Green R : Red BW : Black with White tracer WB : White with Black tracerGr : Gray Sb : Light blue BR : Black with Red tracer WR : White with Red tracerL : Blue W : White LW : Blue with White tracer YB : Yellow with Black tracer

Prepared byHYOSUNG MOTORS & MACHINERY INC.2nd Ed. NOV. 1999Manual No. 99000-91310Printed in Korea