Hyosung RX 125 Manual de Reparatie WWW - Manualedereparatie.info

HYOSUNG MOTORS & MACHINERY INC.
RX 125
SERVICE MANUAL
RX 125
SERVICE MANUAL
99000-97100
FOREWORD
This manual contains an introductory description on HYOSUNG RX 125 and procedures for its inspection/service and overhaul of its main comonents. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service. * This manual has been prepared on the basis of the latest specification at the time of publication. If modification has been made since then, difference may exist between the content of this manual and the actual vehicle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail. * This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer.
GROUP INDEX
GENERAL INFORMATION
1 2 3 4 5 6 7
PERIODIC MAINTENANCE
ENGINE
FUEL SYSTEM
ELECTRICAL SYSTEM
CHASSIS
SERVICING INFORMATION
COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 1999
HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where what you are looking for belong. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. On the first page of each section, its contents are listed. Find the item and page you need.
COMPONENT PARTS
Example: Rear wheel/Rear brake
;;;; ;;;; ;;;;
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. SYMBOL DEFINITION Apply THREAD LOCK1324 .
Apply or use brake fluid.
Apply SUPER GREASEA .
Measure in voltage range.
Apply SUPER GREASEC .
Measure in resistance range.
Apply SILICONE GREASE.
Measure in current range.
Apply MOLY PASTE.
Use special tool.
Apply BOND1215 .
GENERAL INFORMATION
1
CONTENTS
INFORMATION LABELS GENERAL PRECAUTIONS SERIAL NUMBER LOCATION FUEL AND OIL RECOMMENDATIONS BREAK-IN PROCEDURES SPECIFICATIONS 1-1 1-1 1-3 1-3 1-4 1-5
1-1 GENERAL INFORMATION
WARNING / CAUTION / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
NOTE: Indicates special information to make maintenance easier or instructions cleaner.

Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
WARNING
Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle. When 2 or more persons work together, pay attention to the safety of each other. When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all off the material manufacturer s instructions. Never use gasoline as a cleaning solvent. To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while after engine operation. After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks.
GENERAL INFORMATION 1-2
CAUTION
If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. Be sure to use special tools when instructed. Make sure that all parts used in reassembly are clean, and also lubricated when specified. When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. When removing the battery, disconnect the negative cable first and then positive cable. When reconnecting the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the positive terminal. When performing service to electrical parts, if the service procedures do not require use of battery ower, disconnect the negative cable at the battery. Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque. Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. Do not use self-locking nuts a few times over. Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil if a thread is smeared with them. After reassembly, check parts for tightness and operation.
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.
HYOSUNG RX125
RIGHT SIDE
LEFT SIDE
* Difference between photographs and actual motorcycles depends on the markets.
SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head pipe. The engine serial number is located on the left upside of the crankcase. These numbers are required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION

FUEL
Gasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type is recommended.
ENGINE OIL
Make sure that the engine oil you use comes under API classification of SH, SG or SF and that its viscocity rating is SAE 10W/40. If an SAE 10W/40 motor oil is not available, select an alternate according to the right chart.
BRAKE FLUID
Specification and classification: SAE J1703, DOT3 or DOT4
WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL

Use fork oil : SS8 Oil
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts toBREAK-INbefore subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows: Initial 800km Up to 1,600km Over 1,600km Below 5,000rpm Below 7,000rpm Below 10,000rpm
Keep to these break-in engine speed limits: Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation. However, do not exceed 10,000rpm at any time. Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the throttle position.
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length 2,190 mm(86.2 in) Overall width 800 mm(31.5 in) Overall height 1,160 mm(45.7 in) Wheelbase 1,425 mm(56.1 in) Ground clearance 295 mm(11.6 in) Dry mass 125 kg(276 lbs)
ENGINE
Type Four-stroke, SOHC Number of cylinder 1 Bore 57 mm(2.24 in) Stroke 48.8 mm(1.92 in) Piston displacement 124.5(7.6 cu.in) Carburetor PD18F Air cleaner Wet filter type Starter system Kick/self starter Lubrication system Wet sump
TRANSMISSION
Clutch Wet multi-plate type Transmission5-speed constant mesh Gearshift pattern 1-down, 4-up Final reduction 3.357 Gear ratio, Low 2.75 2nd 1.785 3rd 1.368 4th 1.045 Top 0.913 Drive chain428H 132 links
CHASSIS
Front suspensionTelescopic Rear suspension Swingarm type Steering angle 40(right & left) Caster 29 Trail 125 mm(4.9 in) Turning radius 2.5 m(8.2 ft) Front brake Disk brake Rear brake Drum brake Front tire size 2.75-21 45P Rear tire size 4.10-18 59P Front fork stroke 250 mm(9.8 in)
ELECTRICAL
Ignition type Battery Ignition (CDI) Ignition timing 15B.T.D.C.at 2,250 rpm and 35B.T.D.C.at 4,000 rpm Spark plug C8EH-9 Battery12V 6Ah Fuse 15 A Headlight 12V 35/35 W2 Turn signal light 12V 1.7 W2 Tail/Brake light 12V 21/5 W2 Speedometer light 14V 3.4 W High beam indicator light 12V 1.7 W Turn signal indicator light 12V 1.7 W License plate lens 12V 5 W
CAPACITIES
Fuel tank 9.0 Engine oil, oil change 950 with filter change 1,050 overhaul1,400 Front fork oil (One side) 443cc2.5cc The specifications are subject to change without notice.
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE MAINTENANCE PROCEDURES BATTERY CYLINDER HEAD NUTS, CYLINDER NUTS, EXHAUST PIPE BOLT AND NUTS AIR CLEANER ELEMENT VALVE CLEARANCE COMPRESSION PRESSURE SPARK PLUG FUEL LINE ENGINE OIL ENGINE OIL FILTER OIL PRESSURE OIL SUMP FILTER CARBURETOR CLUTCH DRIVE CHAIN BRAKES TIRES STEERING FRONT FORK OIL CHASSIS AND ENGINE BOLTS AND NUTS 2- 3 2- 4 2- 5 2- 6 2- 6 2- 7 2- 7 2- 8 2- 8 2- 8 2- 9 2- 9 2-10 2-11 2-13 2-14 2-14 2-15 2- 1 2- 3 2- 3
2-1 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy.
NOTE: More frequent servicing should be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

ENGINE Interval Item Battery Cylinder head nuts, cylinder nuts, exhaust pipe bolts and nuts Air cleaner element Cam drive chain tensioner Valve clearance Compression pressure Spark plug Fuel line Engine oil Engine oil filter Oil pressure Oil sump filter Carburetor Clutch CHASSIS Interval Item Drive chain Brakes Brakes fluid (Disk Brake) Tires Steering Front fork oil Chassis bolts and nuts Inspect Inspect Change Inspect Initial 1,000 km Every 4,000 km Every 8,000 km page 2-10 Change 2-11 2-11 2-13 2-14 2-14 2-15 Inspect Inspect Inspect Inspect Change Replace Inspect Inspect Initial 1,000 km Inspect Inspect Every 4,000 km Inspect Inspect Clean every 3,000 km Adjust at initial and every 3,000 km Inspect Inspect Inspect Inspect Replace every 4 years Change Replace Inspect Inspect Inspect Clean Replace Every 8,000 km page 2-3 2-3 2-4 3-25 2-5 3-1 2-6 2-7 2-7 2-8 3-1 2-8 2-9 2-9
Inspect and clean every 1,000 km Inspect Inspect Change every 2 years Inspect Inspect Inspect
PERIODIC MAINTENANCE 2-2
LUBRICATION CHART
The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner. Interval Item Throttle cable Throttle grip Clutch cable Brake cable Speedometer cable Speedometer gear box Drive chain Brake pedal Brake cam shaft Steering stem bearing Swing arm bearing Interval and Every 4,000 km Motor oil Motor oil Motor oil Motor oil every 1,000 km Grease or oil Motor oil Grease Grease every 2 years or 20,000 km Every 8,000 km Grease Grease Grease
WARNING
Be careful not to apply too much grease into the brake camshaft. If grease is on the linings, brake slippage will result.
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has been operated under wet or rainy conditions. Before lubricating each part, clean off rusty sports and wipe off grease, oil, dirt or grime.
MAINTENANCE PROCEDURE
This section describes the service procedures for each section of the periodic maintenance.
BATTERY
NOTE: Inspect Initial 1,000 km and Every 4,000 km.
Remove the seat for measure of battery voltage. Using pocket tester, measure the battery voltage. If the tester reading is less than 12.8V, recharge battery by a battery charger. Voltage Less than 11.5V Between 11.5~12.8V More than 12.8V
CAUTION
When recharging the battery remove the battery from motorcycle. Otherwise, regulator/rectifier unit should be an obstacle. When recharging the battery, do not remove the caps. When recharging the battery, above the charge electric current and time should be kept as 12V.
How to charge Charge 20Hour as 0.7A Charge 5~10Hour as 0.7A No charge
CYLINDER HEAD NUTS, CYLINDER NUTS, EXHAUST PIPE BOLTS AND NUTS
CYLINDER HEAD NUTS Remove the seat and fuel tank. (Refer to page 3-2) Remove the cylinder head cover. Tighten the four 12 mm nuts and two 10 mm nuts to the specified torque with a torque wrench, when engine is cold.
Cylinder head nut (12mm) : 25~29 Nm (2.5~2.9 kgm) Cylinder base nut (10mm) : 6~8 Nm (0.6~0.8 kgm)
When installing cylinder head cover, the rubber packing is reached the mating surface of cylin der head cover.
CYLINDER NUTS Tighten the two 10 mm nuts to the specified torque.

Cylinder base nut (10mm) : 6~8 Nm (0.6~0.8 kgm)
EXHAUST PIPE NUTS AND MUFFLER CLAMP BOLT Tighten the exhaust pipe nuts and muffler clamp bolt to the specified torque.
Exhaust pipe nuts : 18~22 Nm (1.8~2.2 kgm) Muffler clamp bolt : 9~16 Nm (0.9~1.6 kgm)
AIR CLEANER ELEMENT

NOTE: Clean Every 3,000 km, Replace Every 12,000 km.
If the air cleaner is clogged with dust, intake resistance will be increased resulting with decrease in power output and increasing fuel consumption. Check and clean the element in the following manner. Remove the upside frame cover. Remove the screw and take out the cover. Separate the element from the element cover.
Fill a washing pan of a proper size with nonflammable cleaning solvent. Immerse the elements in the cleaning solvent and wash them clean. Squeeze the cleaning solvent out of the washed element by pressing it under the palms of both hands : do not twist or wring the element or it will develop tears. Immerse the element in Hyosung genuine oil, and squeeze the oil out of the element leaving it slightly wet with oil. Fit the elements to the cleaner case properly.
CAUTION
Before and during the cleaning operation, inspect the element for tears. A torn element must 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 and cylinder bore is often caused by a defective or poorly fitted element.
Non-flammable Cleaning solvent
Hyosung genuine oil
VALVE CLEARANCE
Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. At the distances indicated above, check and adjust the clearance to the following specification. The procedure for adjusting the valve clearance is as follows : Remove the seat and fuel tank.
Remove spark plug, cylinder head cover , and valve timing inspection plug . Remove the magneto cover cap and rotate the magneto rotor with the 14 mm box wrench to set the piston at (TDC) of the compression stroke. (Rotate the rotor until theTline on the rotor is aligned with the center of hole on the crankcase.) Insert the thickness gauge to the valve stem end and the adjusting screw on the rocker arm.
Thickness gauge : 09900-20803
Valve clearance specifications Valve clearance of IN. and EX. 0.08~0.13 mm
If clearance is off the specification, bring it into the specified range by using the special tool.
Tappet adjust driver : 09917-13210
Reinstall spark plug, cylinder head cover, valve timing inspection plug and magneto cover cap.
CAUTION
Valve clearance should be checked when the engine is cold. Both the intake and exhaust valves must be checked and adjusted when the piston is at TopDead-Center (TDC) of the compression stroke.
COMPRESSION PRESSURE
(Refer to page 3-1)
SPARK PLUG
NOTE: Inspect lnitial 1,000 km and 4,000 km,. Replace Every 8,000 km.
Remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0.8~0.9 mm, measuring with a thickness gauge. When removing carbon deposits, be sure to abserve the appearance of the plug, the color of the carbon deposits. The color observed indicates whether the standard plug is suitable or not. If the
standard plug is apt to get wet, a hotter plug should be used. If the standard plug is apt to overheat (porcelain is whitish in appearance), replace with a colder one. TYPE Hot type Standard Cold type SPARK PLUG SPECIFICATION N.G.K C7EH-9 N.G.K C8EH-9 N.G.K C9EH-9
0.8~0.9mm
FUEL LINE
NOTE: Inspect lnitial 1,000 km and Every 4,000 km, Replace every four years.
Inspect the fuel line and connections for damage and fuel leakage. If any defects are found, the fuel line must be replaced.
ENGINE OIL
NOTE: Change lnitial 1,000 km and Every 4,000 km.
The oil should be changed with the engine hot. The procedure is as follows : Support the motorcycle by side stand. Drain the oil by removing the drain plug and filler cap . Fit drain plug securely and add fresh oil through the filler. The engine will be held about 950 of oil. Use SAE 10W/40 viscosity of oil under API classification of SF or SG, SH. Start up the engine and allow it to run for several seconds at idling speed. Shut down the engine and wait about one minute. Then check the oil level in the oil level gauge. The motorcycle must be in a level. Upright position for accurate measurement. If the level is below the top limit mark, add oil until the level reaches the top limit mark.
ENGINE OIL FILTER

NOTE: Replace lnitial 1,000 km and Every 4,000 km.
Replace the filter in the following manner. Drain engine oil by removing the drain plug. Remove the three screws securing the filter cap. Take off the cap, and pull out the filter ,
Replace the filter with a new one. Before installing on the filter, check to be sure that the O-ring is properly installed. Before putting on the filter cap, check to be sure that the filter spring and the O-ring are installed correctly. Install the filter cap and tighten the screws securely. Pour in engine oil and check the level.
CAUTION
Pour about 950 of engine oil into the engine only when changing oil and about 1,050 of it when replacing oil filter. When performing engine overhaul, the amount of oil to be replenished is 1,400 .
WARNING
When reassembling the oil filter, make sure to check the oil filter installed as shown in illustration. If the filter is installed improperly, serious engine damage may result.
OIL PRESSURE
NOTE: Inspect Every 4,000 km.
(Refer to page 3-1.)
OIL SUMP FILTER

NOTE: Clean Every 8,000 km.
Clean the sump filter screen to remove any foreign matter that may be collected there. Inspect the screen to insure that it is free of any sign of damage.
CARBURETOR
NOTE: Inspect lnitial 1,000 km and Every 4,000 km.
IDLING ADJUSTMENT
NOTE: Make this adjustment when the engine is hot.

Start up the engine and set its speed at anywhere between 1,400 and 1,500 rpm by turning throttle stop screw . Enginge idle speed THROTTLE CABLE PLAY There should be 0.5~1.0 mm play on the throttle cable. To adjust the throttle cable play. Tug on the throttle cable to check the amount of play. Loosen the lock nut and turn the adjuster in or out until the specified play is obtained. Secure the lock nuts while holding the adjuster in place. Throttle cable play 0.5~1.0 mm 1,450100 rpm
CLUTCH
NOTE: Inspect lnitial 1,000 km and Every 4,000 km
Clutch play should be 4 mm as measured at the clutch lever holder before the clutch begins to disengage. If the play in the clutch is incorrect, adjust it in the following way : Loosen the lock nut and screw the adjuster on the clutch lever holder all the way in. Loosen clutch cable adjuster lock nut . Turn the clutch cable adjuster in or out to acquire the specified play. Tighten lock nut while holding the adjuster in position. The clutch cable should be lubricated with a light weight oil whenever it is adjusted.
DRIVE CHAIN
NOTE: Inspect and Clean Every 1,000 km.
Visually inspect the drive chain for the below listed possible abnormality. (Lift the rear wheel by placing the jack or block, and turn the rear wheel slowly by hand, with the transmission in NEUTRAL.) Inspect for : 1. Loose pins 2. Damaged rollers 3. Rusted links 4. Twisted or seized links 5. Excessive wear If any defects are found, the drive chain must be replaced. Wash the chain with kerosene. If the chain tends to rust faster, the interval must be shortened. After washing and drying the chain, lubricate it with chain lube or gear oil SAE # 90. Check the drive chain for wear and adjust the chain tension as follows. Loosen axle nut after pulling out cotter pin and loosen the lock nut . Adjust the drive chain carefully by tightening the adjuster . CHAIN SAG Loosen the adjuster until the chain 50~60 mm of sag at the middle between engine and rear sprockets. The mark on both chain adjusters must be the same position on the scale to ensure that the front and rear wheels are correctly aligned. After adjusting the drive chain, tighten the axle nut securely and lock with cotter pin. Always use a new cotter pin. CHAIN WEAR Count out 21 pins on the chain and measure the distance between 20-pitch. If the distance exceeds 259.4 mm, the chain must be replaced. Drive chain 20-pitch length Service Limit 259.4 mm
50~60 mm
BRAKE
NOTE: Inspect lnitial 1,000 km and Every 4,000 km,. Replace the hoses Every four years,. Replace the brake fluid Every two years.
FRONT BRAKE Brake fluid level Upright position of the motorcycle, and place the handlebars straight. Check the brake fluid level by observing the lower limit line on the brake fluid reservoir. When the level is below the lower limit line, replenish with brake fluid that meets the following specification. Specification and Classification DOT3, DOT4 or SAE J1703
HYOSUNG Brake fluid : 99000-07100
WARNING
The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as siliconebased and petroleum-based fluid for refilling the system, otherwise serious damage will be caused. Do not use any brake fluid taken from old or used unsealed containers. Never re-use the brake fluid left over from the last servicing and stored for long periods.
WARNING
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses for cracks and hose joint for leakage before riding.
Brake pads Wearing condition of brake pads can be checked by observing the red limit line marked on the pad. When the wear exceeds the limit line, replace the pads with new ones. Brake light switch Adjust the brake light switch with new one when brake light dose not come on just before a pressure is felt when the brake lever is squeezed.
AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the caliper brake. The presence of air is indicated by sponginessof the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit should be purged of air in the following manner. Fill up the master cylinder reservoir to the HIGHlevel line. Replace the reservoir cap to prevent entry of dirt. Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle.
Bleeder valve : 6~9 Nm (0.6~0.9 kgm)
Squeeze and release the brake lever several times in rapid succession, and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning quarter of it so that the brake fluid runs into the receptacle ; this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this process untill the fluid flowing into the receptacle no longer contains air bubbles.
CAUTION
Replenish the brake fluid reservoir as necessary while bleeding the brake system. Make sure that there is always some fluid visible in the reservoir.
Close the bleeder valve, and disconnect the pipe. Fill the reservoir to theHIGHlevel line.
WARNING
Handle the brake fluid with care : the fluid reacts chemically with paint, plastics, rubber materials, etc.
REAR BRAKE This is effected by turning the brake pedal stopper. Be sure to tighten the lock nut securely after setting the bolt. After adjusting the rear brake height, adjust the brake pedal traval, First set the pedal at position for comfortable riding by turning the brake pedal stopper, and then adjust the free travel to 10~20 mm. If adjustment is necessary, trun the rear brake adjuster to obtain the specific play. Brake pedal travel 10~20 mm
BRAKE LINING WEAR LIMIT This motorcycle is equipped with brake lining wear limit indicators on both rear brakes. As shown in the illustration at right, at the condition of normal lining wear, an extended line from the index mark on the brake camshaft should be within the range embossed on the brake panel with the brake on. To check wear of the brake lining, follow the steps below. First check if the brake system is properly adjusted. While operating the brake, check to see that the range on the brake panel. If the index mark is outside the range as shown in the illustration at right, the brake shoe assembly should be replaced to ensure safe operation.
TIRES
TREAD DEPTH SERVICE LIMIT Front Rear 1.6 mm 1.6 mm
The extension line of the index mark is within the range.
Check the tire pressure, and examine the valve for evidence of air leakage. TIRE PRESSURE COLD INFLATION TIRE PRESSURE NORMAL RIDING SOLO RIDING kpa FRONT REAR 172 197 kg/ 1.75 2.00 DUAL RIDING kpa 172 221 kg/ 1.75 2.25
STEERING
Steering stem bearings should be adjusted properly for smooth turning of the handlebars and safe running. steering which is too stiff prevents smooth movement of handlebars. Steering which is too loose will cause vibration and damage to the steering bearings. Check to see that there is no play in the front fork attachment. If the play is found, perform steering bearing adjustment as described in page 6-24 of this manual. Tightening torque
Fork top cap bolt() : 30~40 Nm (3.4~4.0 kgm) Steering stem head bolt() : 80~100 Nm (8.0~10.0 kgm) Fork top clamp bolt() : 22~30 Nm (2.2~3.0 kgm) Front fork lower clamp bolt() : 20~30 Nm (2.0~3.0 kgm)
FRONT FORK OIL

NOTE: Change lnitial 1,000 km and 8,000 km.
Remove the front fork. Drain the fork oil. Pour specified amount of oil from the top of the inner tube. Specified amount(for each leg) Specification 443 cc2.5 cc SS8 Oil
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be retightened, as necessary, to the specified torque with a torque wrench.
Front axle bolt() : 50~80 Nm (5.0~8.0 kgm) Caliper mounting bolt () : 18~28 Nm (1.8~2.8 kgm) Brake hose union bolt() : 20~25 Nm (2.0~2.5 kgm) Master cylinder bolt() : 5~8 Nm (0.5~0.8 kgm) Swing arm pivot nut() : 50~80 Nm (5.0~8.0 kgm) Rear shock absorber fitting nut() : 40~60 Nm (4.0~6.0 kgm) Rear axle nut() : 50~80 Nm (5.0~8.0 kgm) Rear brake cam lever bolt() : 8~12 Nm (0.8~1.2 kgm) Engine mounting bolt() : 22~33 Nm (2.2~3.3 kgm) Engine mounting bolt() : 48~72 Nm (4.8~7.2 kgm)
ENGINE
CONTENTS
COMPRESSION PRESSURE AND OIL PRESSURE ENGINE REMOVE AND REMOUNTING UPPER END COMPONENTS DISASSEMBLY UPPER END COMPONENTS INSPECTION AND SERVICING UPPER END COMPONENTS REASSEMBLY LEFT ENGINE DISASSEMBLY RIGHT ENGINE DISASSEMBLY LOWER END COMPONENTS DISASSEMBLY LOWER END COMPONENTS INSPECTION AND SERVICING LOWER END COMPONENTS REASSEMBLY GEAR SHIFTING CAM AND FORK RIGHT ENGINE REASSEMBLY LEFT ENGINE REASSEMBLY 3- 1 3- 2 3- 6 3-10 3-20 3-26 3-28 3-30 3-33 3-38 3-41 3-44 3-48
3-1 ENGINE
COMPRESSION PRESSURE AND OIL PRESSURE

COMEPRESSION PRESSURE
CAUTION
Before inspecting for compression pressure, make sure that the cylinder head nuts and bolts are tightened to specified torque values and valves are properly adjusted. Have the engine warmed up by idling before testing it. Compression gauae : 09915-64510
OIL PRESSURE
Install the oil pressure gauge in the position shown in the illustration. Warm up the engine as follows. Summer approx. 10 min. at 2,000 rpm. Winter approx. 20 min. at 2,000 rpm. After the warming up operation, increase the engine speed to 3,000 rpm, and read the oil pressure gauge.
NOTE: Engline oil must be warmed up to 60 (140) when checking the oil pressure.
Oil pressure Oil pressure 0.4 ~ 0.6 kg/ (at 60 3,000 rpm)
Remove spark plug. Fit the compression gauge to the plug hole, taking care to make the connection absolutely tight. Twist the throttle grip into wide-open position. Crank the engine several times with the starter motor or kick starter, and read the highest gauge indication as the compression of the cylinder. Compression pressure Compression pressure (Standard) Compression pressure (Limit) 15.6 kg/ (500 rpm) 8 kg/
Oil pressure gauge : 09915-74510
A low compression pressure may indicate any of the following malfunction : Excessively worn cylinder wall. Worn piston or piston rings. Piston rings stuck in the grooves. Poor sealing contact of valves. Defective cylinder head gasket When the compression pressure noted is down to or below the limit indicated above, the engine must be disassembled, inspected and repaired as required to overhaul the engine, with these five abnormality in mind.
It the oil pressure is lower or higher than the specifications, several causes may be considered. Low oil pressure is usually the result of a clogged oil damaged oil seal, a defective oil pump or a combination of these items, filter, oil leakage from the oil passage, (damaged oil seal, a defective oil pump or a combination of these items.) High oil pressure is usually caused by a engine oil which is too heavy a weight, a clogged oil passage, improper installation of the oil filter or a combination of these items.
ENGINE 3-2
ENGINE REMOVAL AND REMOUNTING

ENGINE REMOVAL
Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The procedure of engine removal is sequentially explained in the following steps. Take off the seat by loose two volts below seat. Take off the right and left frame cover. Take off the right and left fuel cover.
Disconnect the and lead wires of battery .

CAUTION
First, disconnect the lead wire.
Take off the fuel tank by removing the mounting bolts .
Turn the fuel cock lever to theOFFposition. Take off the fuel hose. Remove the fuel tank.
3-3 ENGINE
Take off the clutch cable by removing the clutch lever bolts and adjuster lock nut.
Disconnect the lead wire of starter motor.
Take off the magneto. Take off the spark plug cap.
ENGINE 3-4
Take off the breather hose.
Loosen the two clamp screws, bolt and take off the carburetor.
Remove the engine sprocket cover.
Take off the drive chain by removing the clip.
3-5 ENGINE
Disconnect the ground wire from the crankcase. Take off the gear shift lever by removing the bolt.
Remove the exhaust pipe nuts and muffler mounting bolt, then take off the muffler.
Take out only one third of shaft after remove the swing arm pivot nut. Remove engine mounting bolts , , , , after remove the swing arm pivot nut. Use both hands, and lift the engine from the frame.
NOTE: The engine must be taken out from the right side.
CAUTION
Take out only one third from the left side to the right side swing arm pivot nut.
ENGINE 3-6
ENGINE REMOUNTING
The engine can be mounted in the reverse order of removal. Temporarily fasten the engine mounting bracket before inserting the engine mounting bolts.
CAUTION
The engine mounting nuts are self-lock nuts. Once the nut has been removed, it is no longer of any use. Be sure to use new nuts and tighten them to the specified torque. Engine mounting bolt (M : 17 mm) : 48~72 Nm (4.8~7.2 kgm) Engine mounting bolt (The others) : 22~33 Nm (2.2~3.3 kgm) Exhaust pipe nuts : 18~22 Nm (1.8~2.2 kgm) Muffler clamp bolts : 9~16 Nm (0.9~1.6 kgm)
After remounting the engine, following adjustments are necessary. Throttle cable Clutch cable Drive chain Rear brake pedal Idling speed (Page : 2-9) (Page : 2-9) (Page : 2-10) (Page : 2-13) (Page : 2-9)
Pour 1,400 of engine oil SAE 10 W/40 graded SF or SG, SH into the engine after overhauling the engine. Start up the engine and allow it run for several seconds at idle speed. About one minute after stopping the engine, check the oil level. If the level is below thetop limitmark, add the oil until the level reaches thetop limitmark
Installing position for clutch release arm

Align the release arm slit surface with the notch mark on the release cam shaft.
Slit
Notch Mark
UPPER END COMPONENTS DISASSEMBLY

CYLINDER HEAD COVER-CAMSHAFT
Bring the piston to top dead center.
CAUTION
When removing the cylinder head cover, the piston must be at top dead center on compression stroke.
3-7 ENGINE
Remove the cam chain tensioner.
Loosen the cylinder head cover bolts and detach the head cover.
Loosen the camshaft holder lock nuts diagonally, then detach the camshaft holder.
Remove the camshaft center bolt.

CAUTION
This is a left-hand thread nut.
ENGINE 3-8
Remove the camshaft , cam sprocket and C-ring

CAUTION
Do not drop the camshaft drive chain, key and sprocket into the crankcase.
CAMSHAFT HOLDER
Take off the rocker arm spring from the dowel pin .
Remove the dowel pin with the long-nose pliers.
Install the bolt by the rocker arm shaft and pull out the rocker arm shaft. Remove the rocker arm and spring Remove the rocker arm shaft by the same manner at the opposite side.
3-9 ENGINE
CYLINDER HEAD
Loosen the cylinder head nuts, then detach the cylinder head.
CAUTION
If it is difficult to remove the cylinder head, gently pry it off while tapping the finless portion of the cylinder head with a plastic hammer. Be careful not to break the fin.
Compress the valve spring by using the special tool.

Value spring compressor : 09916-14510 Value spring compressor attachment : 09916-14910
Take off the valve cotters from the valve stem.

Tweezers : 09916-84511
Take out the valve spring retainer and spring. Pull out the valve from the other side.
CAUTION
Do not compress the valve spring more than necessity for prevent damage of the spring tension.
Remove the oil seal, using the long-nose pliers. Take out the spring seat, valve guide. Decarbonate in the combustion chamber.
CAUTION
Removed parts should be marked for install at the original position.
ENGINE 3-10
CYLINDER
Remove the cylinder base nuts and cylinder.
CAUTION
If tapping with the plastic hammer is necessary, do not break the fins.
PISTON
Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase and then, remove the piston pin circlip with the long-nose pliers.
Remove the piston pin.

Piston pin puller : 09910-34510
Remove the knock pin with the long-nose pliers.
3-11 ENGINE
UPPER END COMPONENTS INSPECTION AND SERVICING

CAMSHAFT HOLDER DISTORTION
After removing the oil from the fitting surface of the camshaft holder, place the camshaft holder on a surface plate and check for distortion with a thickness gauge. Check points are shown in Fig. Camshaft holder distortion Service limit 0.05 mm
If the distortion exceeds the service limit, replace the camshaft holder.
ROCKER ARM SHAFT O.D.

Measure the diameter of rocker arm shaft. Rocker arm shaft O.D. Standard 11.977~11.995mm
ROCKER ARM I.D.

When checking the valve rocker arm, the inside diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked. Rocker arm I.D. Standard 12.000~12.018mm
Dial caliper : 09900-20605
CAMSHAFT
The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of output power. Any of these abnormality could be caused by a worn camshaft.
(T.D.C) Intake open (B.T.D.C)
44 37
Exhaust close (A.T.D.C)
Intake close (A.B.D.C)
52
65
Exhaust open (B.B.D.C)
(B.D.C) Valve timing diagram
ENGINE 3-12
CAMSHAFT CAM WEAR

Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height , which is to be measured with a micrometer. Replace camshafts if found it worn down to the limit.
Micrometer (25~50 mm) : 09900-20202
Can height Height Intake cam Exhaust cam Service limit 34.18 mm 33.55 mm
Inspect the camshaft and the camshaft bearing wear, damage, or the oil hole is clogged.
CYLINDER HEAD DISTORTION

Decarbonate in combustion chamber. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.
Cylinder head distortion
Service limit 0.05 mm
VALVE FACE WEAR

Measure the thickness and, if the thickness is found to have been reduced to the limit, replace the valve.
CAUTION
Visually inspect each valve for wear of its seating face. Replace any valve with an abnormally worn face.
Valve face wear
VALVE STEM RUNOUT

Support the valve with V blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. Valve stem runout Service limit 0.05 mm
3-13 ENGINE
VALVE HEAD RADIAL RUNOUT

Place the dial gauge at right angles to the valve head, and measure the valve head radial runout. If it measures more than limit, replace the valve. Valve head radial runout Service limit 0.03 mm
VALVE GUIDE-VALVE STEM CLEARANCE

Measure the clearance in two directions,XandY , perpendicular to each other, by rigging up the dial gauge as shown. If the clearance measured exceeds the limit specified below, then determine whether the valve or the guide should be replaced to reduce the clearance to within the standard range: valve IN EX Standard 0.010~0.037 mm 0.030~0.057 mm Service limit 0.35 mm 0.35 mm
VALVE STEM WEAR

If the valve stem is worn down to the limit, when measured with a micrometer, and the clearance is found to be in excess of the limit previously indicated, replace the valve, if the stem is within the limit, then replace the valve guide. After replacing valve or guide, be sure to recheck the clearance.
Micrometer (0~25 mm) : 09900-20205
VALVE STEM O.D.

Check face into end of valve stem and wear. valve IN EX
CAUTION
Inspect the valve stem end face for pitting and wear. If pitting or wear of the stem end face are present, the valve stem end may be resurfaced, providing that the length will not be reduced to less than 3.38 mm. If this length becomes less than 3.38 mm, the valve must be replaced. After installing a valve whose stem end has been ground off as above, check to ensure that the face of the valve stem end is above the cotters .
Standard 4.975~4.990 mm 4.955~4.970 mm
ENGINE 3-14
VALVE GUIDE INSTALLATION

Re-finish the vave guide holes in cylinder head with a 10.5 mm reamer and handle .
10.5 mm Reamer : 09916H34575 Handle : 09916-34541
Fit a ring to each valve guide. Be sure to use new rings and valve guides. Use of rings and valve guides removed in disassembly must be discarded.
Lubricate each valve guide and drive the guide into the guide hole using the valve guide installer handle and valve guide installer attachment .
Valve guide installer and remover : 0916-44910 Valve guide installer attachment : 09916-44920
After fitting all valve guides, re-finish their guiding bores will a 5.0 mm reamer and handle . Be sure to clean and oil the guides after reaming.
5.0 mm Reamer : 09916-34571 Reamer handle : 09916-34541
Install valve spring lower seat . Be careful not to confuse the lower seat with the spring retainer .
3-15 ENGINE
Lubricate each seal, and drive them into position with the valve stem seal installer .
CAUTION
Do not reuse the oil seals. Valve guide installer and stem seal installer : 09916-44910
VALVE SEAT WIDTH

Coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating cotact. In this operation, use the valve lapper to hold the valve head.
The ring-like dye impression left on the valve face must be continuous-without any break. In addition, the width of the dye ring, which is the visualized seatwidth , must be within the specification. Valve seat width Valve seat width Standard 0.9~1.1mm
If either requirement is not met, correct the seat by servicing it as follows.
VALVE SEAT SERVICING

The valve seats for both intake and exhaust valves are angled to present two bevels, 15and 45 .
Valve seat cutter set : 09916-21110
15 0 15 45 45 Valve seat
Use only for 15of intake side

15 75 Valve seat cutter : 09916-24910 Solid pilot (N-140-5.5) : 09916-24480
CAUTION
The valve seat contact area must be inspected after each cut.
ENGINE 3-16
1. Insert with a slight rotation, the solid pilot that gives a snug fit. The shoulder on the pilot should be about 10 from the valve guide. 2. Using the 45cutter, descale and cleanup the seat with one or two turns. 3. Inspect the seat by the previous seat width measurement procedure. If the seat is pitted or burned, additional seat conditioning with the 45cutter is required.
CAUTION
Cut the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle.
If the contact area is too low or too narrow, use the 45cutter to raise and widen the contact area. If the contact area is too high or too wide, use the 15cutter to lower and narrow the contact area. 4. After the desired seat position and width is achieved, use be 45cutter very lightly to clean up any burrs caused by the previous cutting operations. DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few sec onds of engine operation. 5. Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing.
WARNING
Always use extreme caution when handling gasoline.
CAUTION
Be sure to adjust the valve clearance after reassembling the engine.
3-17 ENGINE
VALVE SPRINGS
Check the springs for strength by measuring their free lengths and also the force required to compress them. If the limit indicated below is exceeded by the free length reading or if the measured force does not fall within the range specified, replace with a HYOSUNG spring as a set. Valve spring free length Valve spring free length IN. & EX. Service limit 41.65 mm
Valve spring tension(Assembly condition) Valve spring tension IN. & EX. Standard 13.6~16.6 kg / 36.6 mm
CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder. Cylinder distortion Service limit 0.05 mm
CYLINDER BORE
Measure the cylinder bore diameter at six places. If any one of the measurements exceeds the limit, overhaul the cylinder and replace the piston with an oversize, or replace the cylinder.
Cylinder gauge set : 09900-20508
Cylinder bore diameter
PISTON DIAMETER
Using a micrometer, measure the piston outside diameter at the place 15 mm from the skirt end as shown in Fig. If the measurement is less than the limit, replace the piston.
Micrometer (50~75 mm) : 09900-20203
Piston diameter Piston oversize

CAUTION
Service limit 56.880 mm 0.5, 1.0 mm
15 mm
Using a soft-metal scraper, decarbon the crown of the piston. Clean the ring grooves similarly.
ENGINE 3-18
PISTON-CYLINDER CLEARANCE
As a result of the above measurement, if the piston to cylinder clearance exceeds the limit shown in the table below, overhaul the cylinder and use an oversize piston, or replace both cylinder and piston. Piston cylinder clearance Service limit 0.120 mm
PISTON RING-GROOVE CLEARANCE

Using a thickness gauge, measure the side clearance of the 1st and 2nd rings. If any of the clearances exceeds the limit, replace both piston and piston rings.
Piston ring-groove clearance 1st 2nd Piston ring-groove width 1st 2nd Oil
Service limit 0.180 mm 0.150 mm Standard 1.01~1.03 mm 1.01~1.03 mm 2.01~2.03 mm
PISTON RING FREE END GAP AND PISTON RING END GAP
Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring. Piston ring free end gap(Free condition)
R : (RIKEN)
Piston ring free end gap 1st 2nd R RN
Service limit 5.7 mm 4.6 mm
Vernier calipers : 09900-20101
Piston ring free end gap(Assembly condition) Piston ring free end gap 1st and 2nd Service limit 0.50 mm
Piston ring thickness Piston ring thickness 1st 2nd Standard 0.970~0.990 mm 0.970~0.990 mm
3-19 ENGINE
OVERSIZE RINGS
Oversize piston rings The following two types of oversize piston rings are used. They bear the following identification numbers. Oversize piston ring 0.5 mm 1.0 mm 1st 50 100 2nd 50 100
Oversize oil rings The following two types of oversize oil ring are used. They bear the following identification marks. Oversize oil ring 0.5 mm 1.0 mm Color classification Painted red Painted yellow
Oversize side rail Just measure outside diameter to identify the side rail as there is no mark or numbers on it.
PISTON PIN-PIN BORE

Using a caliper gauge, measure the piston pin bore inside diameter, and using a micrometer measure the piston pin outside diameter. If the difference between these two measurements is more than the limits, replace both piston and piston pin.
Micrometer (0~25 mm) : 09900-20205
Piston pin bore Piston pin bore Piston pin O.D. Piston pin O.D. Service limit 14.980 mm Service limit 15.030 mm
CONROD SMALL END I.D.

Using a caliper gauge, measure the conrod small end inside diameter. Conrod small end I.D. Service limit 15.040 mm
If the conrod small end bore inside diameter exceeds the limit, replace conrod.
ENGINE 3-20
UPPER END COMPONENTS REASSEMBLY

OIL RING
Install spacer into the bottom ring groove first. Then install both side rails , one on each side of the spacer. The spacer and side rails do not have a specific top or bottom when they are new. When reassembling used parts, install them in their original place and direction.
Oil ring
TOP RING AND 2ND RING

Top ring and 2nd ring differ in the shape of ring face and the face of top ring is chrome-plated whereas that of 2nd ring is not. The color of 2nd ring appears darker than that of the top one.
Top
2nd
Install expander ring into the 2nd ring groove. Top and 2nd rings have the letterRorYmarked on the top. Be sure to bring the marked side to the top when fitting them to the piston.
Position the gaps of the three rings as shown. Before inserting piston into the cylinder, check that the gaps are so located.
EX. 2nd Side rail, upper
120
Side rail, lower
120 120
IN.
Top ring, Spacer
3-21 ENGINE
PISTON
The following are reminders for piston installation: Rub a small quantity of HYOSUNG MOLY PASTE onto the piston pin. Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase, and then fit the piston pin circlip with long-nose pliers.
CAUTION
Use a new piston pin circlip to prevent circlip failure which will occur with a bent one.
When fitting the piston, turn arrow mark on the piston head to exhaust side.
CYLINDER
Before mounting the cylinder, oil the big end and small end of the conrod and also the sliding surface of the piston. Fit dowel pins to crankcase and then fit gasket.
CAUTION
To prevent oil leakage, do not use the old gasket again, always use new one.
Hold each piston ring with the piston rings properly spaced and insert them into the cylinder. Check to insure that the piston rings are properly inserted into the cylinder skirt.
CAUTION
When mounting the cylinder, after attaching camshaft drive chain, keep the camshaft drive chain taut. The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated.
CAUTION
There is a holder for the bottom end of the cam chain guide cast in the crankcase. Be sure that the guide is inserted properly or binding of the cam chain and guide may result.
ENGINE 3-22
VALVE AND SPRING

Insert the valves, with their stems coated with (HYOSUNG MOLY PASTE) all around and along the full stem length without any break. Similarly oil the lip of the stem seal.
HYOSUNG MOLY PASTE
CAUTION
When inserting each valve, take care not to damage the lip of the stem seal.
Insert valve springs, making sure that the closepitch end of each spring goes in first to rest on the head. The coil pitch is vary: the pitch decreases from top to bottom, as shown in the illustration.
Retainer Towards
Head
Lower seat
Fit valve spring retainer, compress spring with a valve spring compressor and insert cotters.
Valve spring compressor : 09916-14510
CYLINDER HEAD
Fit dowel pins to cylinder head, and then attach new gasket to cylinder head.
CAUTION
Use a new cylinder head gasket to prevent oil leakage. Do not use the old gasket.
3-23 ENGINE
Fit the cylinder head. Tighten the cylinder base nuts , .

Cylinder base nut : 6~8 Nm (0.6~0.8 kgm)
CAUTION
When mounting the cylinder, after attaching camshaft drive chain, keep the camshaft drive chain taut. The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated.
CAMSHAFT
Align the mark on magneto rotor with the index mark on the crankcase keeping the camshaft drive chain pulled upward.
CAUTION
If crankshaft is turned without drawing the camshaft drive chain upward, the chain will be caught between crankcase and cam chain drive sprocket.
Install the camshaft , bearing and cam sprocket , tighten it.

CAUTION
This is a left-hand thread bolt.
Align the key-groove on the camshaft so it is vertical with the surface of the cylinder head.
CAUTION
Do not rotate magneto rotor while doing this. When the sprocket is not positioned correctly, turn the sprocket.
ENGINE 3-24
Install the camshaft lock C-ring .

CAUTION
Align the both end face of C-ring and cylinder head face.
Apply HYOSUNG MOLY PASTE properly to the camshaft bearing and camshaft face.
CAMSHAFT HOLD
Apply HYOSUNG MOLY PASTE to the rocker arm shafts , then inserting the camshaft hold. Install the rocker arm spring , rocker arm and inserting the camshaft hold .
CAUTION
Pay attention to the exhaust side rocker arm that have not confused, the groove at the intake side rocker arm so that avoid contact with stud bolt.
IN. EX.
Groove
Fit the two dowel pins to the camshaft holder.
When fitting rocker arm spring, hook part of rocker arm spring onto rocker arm and hook part of rocker arm spring onto the dowel pins .
3-25 ENGINE
Fit the two dowel pins and install the camshaft holder .
Tighten the camshaft holder nuts diagonally to the specified.

Camshaft holder nut : 25~35 Nm (2.5~3.5 kgm)
CHAIN TENSIONER
Mount the tensioner body on the cylinder.
Install the spring and bolts.
ENGINE 3-26
VALVE CLEARANCE
After tightening the camshaft holder lock nuts, check and adjust the valve clearance. Valve clearance specifications IN and EX. valve clearance
CAUTION
Valve clearance is to be checked when the engine is cold. Both the intake and exhaust valves must be checked and adjusted when the piston is at TopDead-Center(TDC) of the compression stroke.
0.08~0.13 mm
CYLINDER HEAD COVER

Clean off oil from the surfaces of cylinder head and cover. Fit the packing to the cylinder head cover .
Tighten the cylinder head cover bolts with the hexagon wrench.
Cylinder head cover : 12~16 Nm (1.2~1.6 kgm)
LEFT ENGINE DISASSEMBLY

Remove the magneto rotor and key.
Rotor remover : 09930-30162
3-27 ENGINE
Remove the starter clutch gear.
Remove the starter screw by using the impact drive and detach the stator.
Remove the roller, spring and push piece from the stater clutch.
Clamp the rotor with a vise taking care not to damage it and remove the three bolts using the 5 mmTtype hexagon wrench.
Ttype hexagon wrench (5 mm) : 09911-73730
ENGINE 3-28
GEAR POSITION SWITCH

Remove the gear position indicator switch by removing the screws.
CAUTION
When removing gear position switch, do not lose the O-ring, switch contact and its spring.
RIGHT ENGINE DISASSEMBLY

ENGINE SPROCKET
Flatten the lock washer, then remove the sprocket nut by using the special tool.
Rotor holder : 09930-40113
CLUTCH
Remove the kick starter by removing the bolt.
Remove the clutch cover bolts and oil filter cap bolts, and detach the clutch cover by tapping with a plastic hammer.
3-29 ENGINE
Remove the clutch spring mounting bolts diagonally while holding the primary driven gear, and remove the clutch pressure plate.
After removal of clutch drive and driven plates, flatten the lock washer and remove the clutch sleeve hub by using the special tool.
Clutch sleeve hub holder : 09920-53710
Take off the sleeve hub with the primary driven gear ass y This time well deposite the washer behind the hub.
OIL PUMP DRIVE GEAR, DRIVEN GEAR AND PRIMARY DRIVE GEAR
Flatten the lock washer, then remove the nut, lock washer and oil pump drive gear.
Conrod holder : 09910-20116
CAUTION
This is a left-hand thread nut.
Remove the oil pump driven gear, then remove the primary drive gear and key.
ENGINE 3-30
OIL PUMP
Remove the oil pump mounting screws and take off the oil pump body.
GEAR SHIFTER
To remove the cam driven gear, first remove the gear shifting shaft, and loosen the pawl lifter and cam guide screws with an impact driver.
CAUTION
When removing the cam driven gear, do not lose the gear shifting pawl , pin and spring .
KICK STARTER DRIVE GEAR AND IDLE GEAR

Remove the kick starter drive gear and kick starter idle gear.
Snap ring pliers : 09900-06107
LOW END COMPONENTS DISASSEMBLY

CRANK CASE
Remove the sump filter cap and plug cam stopper. Pull out the spring, neutral stopper.
3-31 ENGINE
Remove the sump filter.
Remove the crankcase securing bolts.
Separate the crankcase into 2 part, right and left with the crankcase separater.
Crankcase separater : 09920-13120
Fit the crankcase separater so that the tool plate is parallel with the end face of the crankcase.
CAUTION
The crankshaft and transmission components must remain in the left crankcase half. This is necessary because the gear shifting cam stopper is mounted on the left crankcase half and will be damaged if the transmission components remain in the right half.
TRANSMISSION
Remove the gear shifting cam stopper spring.
ENGINE 3-32
Draw out the gear shifting fork shafts and take off the forks.
Remove the clusters of gears and the gear shifting cam.
KICK STARTER SHAFT

Remove the circlip, spring guide and return spring. Then, pull out the kick starter shaft from the other side.
CRANKSHAFT
Remove the crankshaft by using the crankcase separater.
Crankcase separater : 09920-13120
3-33 ENGINE
OIL SEAL AND BEARING

Remove the retainer, oil seals and bearings.
Oil seal remover : 09913-50121
LOWER END COMPONENTS INSPECTION AND SERVICING

CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE
Wear on the big end of the conrod can be estimated by checking the movement of the samll end of the rod. This method can also check the extent of wear on the parts of the conrod s big end. Wear limit on the big end of conrod Service limit 3.0 mm
Magnetic stand : 09900-20701 Dial gauge (1/100 mm) : 09900-20606 V-block : 09900-21304
ENGINE 3-34
Push the big end of the conrod to one side and measure its side clearance with a thickness gauge. Clearance standard on big end of conrod 0.10~0.45 mm Service limit on big end of conrod 1.00 mm
When the limit is exceeded, replace crankshaft assembly or reduce the deflection and the side clearance to within the limit by replacing the worn parts-conrod, big end bearing, crankpin and thrust washers, etc.
CRANKSHAFT RUNOUT
Support the crankshaft withVblocks as shown, with the two end journals resting on the blocks. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the run out. Correct or replace the crankshaft if the runout is greater than the limit. Crank shaft runout Service limit 0.05 mm
CLUTCH DRIVE PLATE

Measure the thickness and claw width of each drive plate with vernier calipers. Replace the drive plates found to have worn down to the limit.
Standard Serivice limit Thickness of clutch drive plate 2.9~4.1 mm 2.6 mm

Checking thickness
Claw width of clutch drive plate 11.8~12.0 mm 11.0 mm
Checking claw width
3-35 ENGINE
CLUTCH DRIVEN PLATE

Measure each of the driven plate for distortion with a thickness gauge. Replace the driven plates which.
Distortion of clutch driven plate
Checking distortion
CLUTCH SPRING FREE LENGTH

Measure the free length of each coil spring with a vernier calipers, and determine the elastic strength of each. If any one of springs is not within the limit, replace all the springs at a time.
Clutch spring free length
CLUTCH RELEASE BEARING

Inspect the release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing.
SHIFTING FORK AND GEAR

Using a thickness gauge, check the shifting fork clearance in the groove of its gear. If the clearance limit is exceeded by any of the three gears, determine whether the gear or the gear shifting fork should be replace by measuring the thickness and groove width.
Thickness gauge : 09900-20803 Vernier calipers : 09900-20101
Checking clearance
ENGINE 3-36
Shifting fork to groove clearance
Standard Serivice limit 0.10~0.30 mm 0.50 mm Standard NO.1 & NO.2 5.0~5.1 mm NO.3 5.5~5.6 mm Standard NO.1 & NO.2 4.8~4.9 mm NO.3 5.3~5.4 mm
Checking groove width
Shifting fork groove width
Shifting fork thickness
Checking thickness
PRIMARY DRIVEN GEAR

Primary driven gear is composed as shown. Primary driven gear Damper Plate Rivet Clutch housing Spring
If the internal damper wears, play is generated between gear and housing, causing abnormal noise. If the play is extreme, replace the primary driven gear assembly a new one.
CAM CHAIN 20-PITCH LENGTH

Pull the chain tight to remove any slack, then using vernier caliper, measure the 20-pitch (21 pins) length of cam chain. If it measures than the limits, replace the cam chain. Cam chain 20-pitch length Service limit 129.9 mm
3-37 ENGINE
CRANKCASE BEARING
Inspect the play of crankcase bearing inner race by hand while fixing it in the case. Rotate the inner race by hand to inspect for an abnormal noise and a smooth rotation. Replace the bearing if there is something unusual.
Play Play
STARTER CLUTCH BEARING

Inspect the bearing for any abnormality, particularly cracks, to decide whether it can reused or should be replaced.
ENGINE 3-38
LOWER END COMPONENTS REASSEMBLY

CRANKSHAFT
Inspect the between the webs referring to the below figure when rebuilding the crankshaft. Width between webs Standard 53.00.1 mm
When mounting the crankshaft in the crankcase, it is necessary to pull its left end into the crankcase.
Crankcase installer : 09910-32812 Conrod holder : 09910-20116
53.0 0.1 mm
3-39 ENGINE
CAUTION
Never fit the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise crankshaft alignment accuracy will be affected.
TRANSMISSION
CAUTION
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip cover the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
ENGINE 3-40
Washers and circlips thickness. 1.2 mm 1.0 mm 1.0 mm 0.5 mm 1.0 mm
NOTE: When reassembling the bearing retainer, apply a small quantity of THREAD LOCK1324to the threaded parts of the bearing retainer screws. In reassembling the transmission, attention must be given to the locations and positions of washers and circlips. The cross sectional view given here will serve as a referance for correctly mounting the gears, washers and circlips.
COUNTERSHAFT
Mounting 2nd drive gear Press-fit 2nd drive gear into the countershaft. Before reassembling, coat the internal face of the 2nd drive gear with THREAD LOCK1324and install it so that the length is as shown in Fig.
Thread Lock1324
Countshaft length (Low to 2nd)

CAUTION
88.0
+0.1 mm -0.2
This procedure may be performed only twice before shaft replacement is required.
3-41 ENGINE
GEAR SHIFTING CAM AND FORK
Fit the gear shifting cam on the crankcase. Position the cam as shown in Fig. So that the gear shifting fork can be installed easily.
ENGINE 3-42
CAUTION
Two kinds of the gear shifting forks, and , are used. They resembles each other very closely in external appearance and configuration. Carefully examine the illustration for correct installing positions and directions.
After the cam stopper and gear shifting forks have been fitted, hook the cam stopper spring into the crankcase.
KICK STARTER
3-43 ENGINE
When fitting the kick starter to the shaft, be sure to align the punched marks..
Fit the spring and washer on the shaft. Then, insert the kick starter shaft into the crankcase. Engage the pawl of kick starter guide .
When fitting the kick return spring, hook the part of return spring into the crankcase, turn it 1/2 a turn clockwise with the pliers and fit the part of return spring into hole of the kick shaft. Then, fit the spring guide and circlip.
CRANKCASE
When reassembling the crankcase pay attention to the following. Coat SUPER GREASEAto the lip of oil seals. Remove sealant material on the fitting surface of right and left halves of the crankcase and thoroughly remove oil stains. Fit the dowel pins on the half. Apply engine oil to the big end of the crankshaft conrod and all parts of the transmission gears. Apply BOND1215uniformly to the fitting surface of the left half of the crankcase, and after waiting a few minutes, fit the right half on the left half.
BOND1215
ENGINE 3-44
After the crankcase bolts have been tightened, check if the driveshaft and countershaft rotate smoothly.
If a large resistance is felt to rotation, try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in Fig.
RIGHT ENGINE REASSEMBLY

CLUTCH
KICK START DRIVE GEAR AND IDLE GEAR Install the kick starter idle gear and drive gear.
GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driven gear. The large shoulder must face to the outside as shown. Next, install cam guide and pawl lifter. Apply a samll quantity of THREAD LOCK1324to the threaded parts of the securing screws.
Thread Lock1324
3-45 ENGINE
GAER SHIFTING SHAFT Install the gear shifting shaft. Match the center teeth of the gear on the shifting shaft with the center teeth on the shifting driven gear as shown.
CAUTION
After the cam driven gear, cam guide, gear shifting shaft and neutral cam stopper have been fitted, confirm that gear change is normal while turning, the countshaft and driveshaft. If gear change is not obtained, it means that assembly of gears or installation of gear shifting fork is incorrect. If this is the case, disassemble and trace the mistake.
PRIMARY DRIVE GEAR AND OIL PUMP Fit the key in the slot on the crankshaft, and install the primary drive gear.
Before mounting the oil pump, apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft. Apply a small quantity of THREAD LOCK1324 to the threaded parts of oil pump mounting screws.
Thread Lock1324
Tightening the oil pump mounting screws.
ENGINE 3-46
CAUTION
After mounting the oil pump in the crankcase, rotate the pump gear by hand to see if it turns smoothy.
Bend up
After checking the oil pump, install the oil pump drive gear, lock washer and nut, tighten it with a torque wrench to the specified torque and bend up to the washer.
Conrod holder : 09910-20116
CAUTION
This is a left-hand thread nut. Oil pump nut : 40~60 Nm (4.0~6.0 kgm)
CLUTCH
3-47 ENGINE
Install the clutch camshaft by positioning the face to right side. Install the oill seal by using the 17 mm socket.
Tighten the oil seal retainer screw.
Assemble the clutch, in the reverse order of disassembly. Pay attention to the following points. When inserting the spacer on the countershaft, apply a small quantity of engine oil to both inside and outside of the spacer. Tighten clutch sleeve hub nut using the special tool to the specified torque.
Clutch sleeve hub holder : 09920-53710 Clutch sleeve hub nut : 30~50 Nm (3.0~5.0 kgm)
Be sure to lock the nut by firmly bending the tongue of the washer. Install the drive plates and driven plates to the sleeve hub. Insert push rod in the countshaft.
Cam side
Push piece side
Longer
Shorter
ENGINE 3-48
Tighten the clutch spring bolts diagonally.
Clutch release screw adjustment Loosen the lock nut, and turn in the release screw to feel high resistance. From that position, turn out the release screw 1/4-1/2 turn, and tighten the lock nut.
OIL SUMP FILTER Wash the sump filter with cleaning solvent, and then bolw compressed air through it to dry off solvent. After mounting the sump filter, fit the cap and tighten it.
LEFT ENGINE REASSEMBLY

NEUTRAL CAM STOPPER
Put in the neutral stopper and spring. Tighten the cam stopper plug.
3-49 ENGINE
STATOR Apply a small quantity of THREAD LOCK1324to the threaded parts of screws.
Thread Lock1324
STARTER CLUTCH Locate the shim to the proper position
Apply THREAD LOCK1324to the bolts and tighten with the specified torque.
Thread Lock1324 Ttype hexagon wrench : 09911-73730 Starter clutch : 15~20 Nm (1.5~2.0 kgm)
MAGNETO ROTOR
Fit the key in the key slot on the crankshaft. Install the magneto rotor. Apply a small quantity of THREAD LOCK1324 to the threaded parts of crankshaft.
Thread Lock1324
ENGINE 3-50
Tighten the magneto rotor nut to the specified torque.
Thread Lock1324 Rotor holder : 09930-40113 Rotor holder : 09930-44511 Magneto rotor nut : 56~60 Nm (5.6~6.0 kgm)
STARTER IDLE GEAR AND MOTOR

Install the starter idle gear.
Install the starter motor.
DRIVESHAFT OIL SEAL AND ENGINE SPROCKET

CAUTION
Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leakage. Also grease the oil seal lip. On installation, refer to Fig, for correct position and direction. Replace O ring with a new one every disassembly.
Oil seal O-ring
CAUTION
After reassembling the LOWER END COMPONENTS, install the O-ring and spacer.
3-51 ENGINE
Tighten the engine sprocket nut to the specified torque and bend up the washer.
Rotor holder : 09930-40113 Engine sprocket nut : 80~100 Nm (8.0~10.0 kgm)
GEAR POSITION SWITCH

Install the gear position switch.
FUEL SYSTEM
CONTENTS
FUEL COCK CARBURETOR THROTTLE VALVE CARBURETOR ACCELERATOR PUMP ADJUSTMENT PILOT SCREW ADJUSTMENT OIL COOLER LUBRICATION SYSTEM 4- 1 4- 2 4- 3 4- 4 4- 8 4- 9 4-10 4-11
4-1 FUEL SYSTEM
FUEL COCK
CLEANING Rust from the fuel tank tends to build up the filter, which, when the filter has been neglected for a long period, inhibits the flow of fuel. Remove the rust from the filter using compressed air.
DISASSEMBLY Turn the fuel cock toOFFposition and dis connect the fuel hose from the fuel cock.
WARNING
Gasoline is highly explosive. Extreme care must be taken.
WARNING
Place a clean oil pan under the fuel cock assembly, turn the fuel cock toONposition and drain the fuel. Unscrew the fuel cock securing bolts, and take off the fuel cock assembly.
Gasket must be replaced with a new one to prevent leakage.
FUEL SYSTEM 4-2
CARBURETOR
ITEM Carburetor type Bore size I.D. NO. Idel rpm Jet needle(J.N.) Float height Main jet(M.J.) Main air jet(M.A.J.)
SPECIFICATION PD 18 F 24 HG58 1,450100 rpm J 29 B 12.5 mm # 98 # 90
ITEM Needle jet(N.J) Pilot jet(P.J) By pass(B.P.) Pilot air jet(P.A.J) Valve seat(V.S.) Starter jet Pilot screw(P.S.)
SPECIFICATION AIFC-2nd # 38 2.9, 1.0, 0.9 # 150 2.0 MAX # 500 (2)
4-3 FUEL SYSTEM
THROTTLE VALVE
DISASSEMBLY Disconnect the seat and fuel tank. (See page 3-2) Looen the carburetor top and disconnect the throttle valve.
Remove the throttle cable from the throttle valve and disconnect the throttle cable.
Disconnect the throttle valve spring and carburetor top from the throttle cable.
Draw out the retainer clip and disconnect the jet needle . Inspect the jet needle and wear, damage of the throttle valve .
FUEL SYSTEM 4-4
Install the jet needle and retainer clip into the throttle valve. Needle clip standard position : 3rd groove Install the carburetor top and spring into the throttle cable. Install the throttle cable into the throttle valve.
Leaner 1st (Standard) 3rd Richer 5th
REASSEMBLY Following adjustments and inspection are necessary after installing the throttle valve. Throttle cable play. (Refer to page 2-9) Idling adjustment. (Refer to page 2-9)
CARBURETOR
DISASSEMBLY Remove the seat and fuel tank. (Refer to page 3-2) Remove the carburetor top. (Refer to page 4-3) Remove the throttle cable. Remove the carburetor drain screw and draw out in the carburetor.
WARNING
Gasoline is highly explosive. Extreme care must be taken.
Remove the choke cable.
4-5 FUEL SYSTEM
Loosen the carburetor nut and clamp screw. Remove the carburetor.
DISASSEMBLY Disconnect the fuel tube and drain tube.
ACCELERATOR PUMP Loosen the screws and disconnect the pump cover.
Disconnect the spring. Inspect the accelerator pump load damage of the diaphragm. Clean the diaphragm.
FUEL SYSTEM 4-6
Set up the diaphragm and the float chamber. Install the spring in the diaphragm and install the cover in the float chamber. Adjust the accelerator pump.
FLOAT AND NEEDLE VALVE Loosen the screws and remove the float chamber.
Pull out the float arm pin. Remove the float and needle valve .
Inspect the valve and valve seat for wear. Inspect the float for transformation.
4-7 FUEL SYSTEM
JETS Disconnect the main jet , needle jet holder and needle jet. Disconnect the slow jet . Disconnect the pilot screw after record the revolutions until tighten completely.
CAUTION
Do not tighten the pilot screw by force, otherwise can be damaged of the seat.
Disconnect the throttle stop screw . Clean the jets with non-flammable cleaning solvent. Inspect the pilot screw and pilot jets.
Clean the jets and body passage with compressed air.
Install the needle jet , needle jet holder , main jet and slow jet . Install throttle stop screw and pilot screw.
CAUTION
Install the pilot screw as revolutions to a case of disassemble.
Adjust the pilot screw, when use a new pilot screw.
FUEL SYSTEM 4-8
Install the needle valve , float float arm pin .
FLOAT ADJUSTMENT To check the float height, invert the carburetor body, holding the float arm pin so that the pin will not slip off. Float height 12.5 mm
Check to be sure that the float moves freely.
Install the new O-ring and float chamber groove . Install the float chamber and screw.
ACCELERATOR PUMP ADJUSTMENT

CAUTION
Do not adjust except for exchange the adjust screw.
Adjust screw
Adjust idling. (Refer to page 2-9) Adjust throttle grip. (Refer to page 2-9) Adjust clearance of the accelerator pump rod after loosen the lock nut and turn the adjust screw. Tighten the lock nut. Lock nut clearance 0 mm
4-9 FUEL SYSTEM
REASSEMBLY Install the fuel tube and drain tube.
Replace a new O-ring at the carburetor outlet side. Install the carburetor between the intake pipe and air cleaner outlet tube, tighten the carburetor lock nut and clamp screw. Connect the choke cable and throttle cable. Adjust the choke cable. Install the throttle valve. (Refer to page 4-4) Adjust play of the throttle grip. (Refer to page 2-9)
PILOT SCREW ADJUSTMENT

Loosen as standard turn back revolutions after lock the pilot screw suitable. Standard turn back revolution of pilot screw
CAUTION
Do not tighten the pilot screw by force, otherwise can be damaged of the seat.
2 Circle
Start up the engine and set its speed at any where between 1,450100 rpm by turning the throttle screw . Adjust the engine speed at hight position as the pilot screw left-right turning. Repeat again - . Adjust the standard engine idle speed by the throttle stop screw. Look into the change idling revolution with snap light of continuously. If the idling revolution is change, repeat the - .
FUEL SYSTEM 4-10
OIL COOLER
DISASSEMBLY Remove the oil cooler cover.
NOTE: Draw out and push for face of the spring seat.
Remove the screws.
Remove the union bolts and detach the oil cooler.
NOTE: When reassemble after remove the union bolt, do not remove except special case that fold of the hose, the others, are affected according to assemble angle.
REMOUNTING Remounting the oil cooler by reversing the sequence of disassembling steps. Loosen the union bolt of the cylinder head, and inspect the air bleeding and oil.
Union bolt : 20~25 Nm (2.0~2.5 kgm)
4-11 FUEL SYSTEM
LUBRICATION SYSTEM
CAMSHAFT JOURNAL AND CAM FACE
CONROD SMALL END
OIL HOSE ROCKER ARM SHAFT OIL COOLER CAM CHAIN
CYLINDER WALL
OIL HOSE
CONROD BIG END BEARING
CLUTCH RELEASE CAM
COUNTERSHAFT BEARING DRIVESHAFT BEARING COUNTERSHAFT AND GEARS OIL FILTER
BY-PASS OIL PUMP
DRIVESHAFT AND GEARS
PRIMARY DRIVEN GEAR SPACER
SUMP FILTER
CLUTCH PLATES
OIL PAN
FUEL SYSTEM 4-12
Oil cooler
Piston Cylinder Start motor
Cylinder head Crankcase Transmission
ELECTRICAL SYSTEM 5-1
ELECTRICAL SYSTEM
CONTENTS
IGNITION SYSTEM CHARGING SYSTEM STARTER SYSTEM LAMP SWITCHES BATTERY 5- 1 5- 5 5- 9 5-12 5-13 5-14
5-1 ELECTRICAL SYSTEM
IGNITION SYSTEM
RX 125 is started as the battery discharged ignition system without a contact point. The battery ignition system is composed a rotor tip, the D.C CDI, the igniton coil and battery. Ignite after permit signal at ignition timing of pick-up as electric energy of this battery, occur the 1st electric current. Therefore a high voltage current is induced in the secondary winding of the ignition coil resultion in strong spark between the spark plug gap.
MAGNETO C.D.I UNIT
IGNITION COIL AND SPARK PLUG
Ignition switch
Ignition coil
CDI UNIT Battery
Spark plug
INSPECTION
MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. Pick-up coil Charging coil G-L Approx 90~110 Y-Y Approx 0.6~0.9
Pocket Tester : 09900-25002
CAUTION
When mounting the stator on the magneto cover, apply a small quantity of THREAD LOCK1324 to the threaded parts of screws. Thread Lock1324
WIRE COLOR L : Blue G : Green R : Red W : White Y : Yellow B / R : Black with Red tracer L / R : Blue with Red tracer R / G : Red with Green tracer W / G : White with Green tracer W / R : White with Red tracer
CDI UNIT Using the pocket (R1 range), measure the resistance between the lead wires in the following table.
Pocket tester : 09900-25002
Probe of tester 1 Probe of tester 1 2 3 4 5 6 5~500 5~500 10~1,000 2 3 4 1~50 1~100 5 1~100 1~100 2~200 6 5~500 10~1,000
INSPECTION
IGNITION COIL (Checking with Electro Tester) Remove the ignition coil .
NOTE: Make sure that the three-needle sparking distance of the electro tester is set at 8 mm (0.3 in).
With the electro tester, test the ignition coil for sparking performance.
If no sparking or orange color sparking occures in the above conditions, it may be caused by the defective coil.
Electro tester : 09900-28107
cord cord cord cord
Spark performance
Over 8 mm (0.3 in)
WARNING
Do not touch the wire clips to prevent an electric shock when testing.
8 mm
CAUTION
When using the electro tester, follow the instruction manual.
Spark
IGNITION COIL (Checking with Pocket Tester) A pocket tester or an ohm meter may be used, instead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secondary windings. Exact ohmic readings are not necessary, but, if the windings are in sound condition, their continuity will be noted with these approximate ohmic values.
Ignition coil resistance Primary Secondary 0.19~0.24 Tester knob indication 1 range 5.4~6.6 Tester knob indication 1 range Check to attached plug cap
SPARK PLUG Clean the plug with a wire brush and pin. Use the pin to remove carbon, taking care not to damage the porcelain.
Check the gap with a thickness gauge.

Spark plug gap
0.8~0.9 mm
0.8~0.9 mm
CHARGING SYSTEM
The circuit of the charging system is indicated in figure, which is composed of and the AC generator, regulator / rectifier unit and battery. The AC current generated from the AC generator is converted by the rectifier and is turned into the DC current, then it charges the battery.
Ig. switch
Battery Controlunit LOAD Ig. switch Battery Controlunit A. C generator LOAD
A. C generator
Regulator / Rectifier
Function of Regulator While the engine rpm is low and the generated current of the AC generator is lower than the adjusted voltage of the regulator, the regulator does not function, incidentally the generated current charges the battery directly.
When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and the voltage between points and of the regulator according becomes high, and when it reaches the adjusted voltage of the control unit, consequently the control unit becomesONcondition. On theONcondition of the control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become ONcondition. Then the SCR becomes conductive to the direction from point to point . Namely at the state of this, the current generated from the AC generator gets through SCR without charging the battery and returns to the AC generator again. At the end of this state, since the AC current generated from the AC generator flows into the point , reverse current tends to flow to SCR, then the circuit of SCR turns toOFFmode and begins to charge the battery again. Thus these repetitions maintain charging constant voltage to the battery and protect it from overcharging.
Ig. switch
Battery Controlunit A. C generator LOAD
INSPECTION
CHARGING OUTPUT CHECK Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the DC voltage between the battery terminal and . If the tester reads under 13.5 V or over 16.0 V, check the AC generator no-load performance and regulator / rectifier.
CAUTION
When making this test, be sure that the battery is full-charged condition. Pocket tester : 09900-25002
IG. switch
Standard charge
13.5~16.0 V at 5,000 rpm

Regulator Rectifier Battery DCV
AC GENERATOR NO-LOAD
PERFORMANCE Disconnect the three lead wires from the AC generator terminal. Start the engine and keep it running at 5,000 rpm. Using the pocket tester, measure the AC voltage between the three lead wires. If the tester reads under 70 V the AC generator is faulty. Standard NO-load performance of AC generator 72~99 V at 5,000 rpm
REGULATOR / RECTIFIER Using the pocket tester ( 1 range), measure the resistance between the lead wires in the following table. If the resistance checked is incorrect, replace the regulator / rectifier.
Unit : Probe of tester 1 Probe of tester 1 2 3 4 5 7~8 7~8 7~8 2 OFF OFF OFF 3 OFF OFF OFF 7~8 4 OFF OFF OFF 7~8 5 OFF OFF OFF OFF -
35~55 7~8
STARTER SYSTEM
The starter system is shown in the diagram below : namely, the starter motor, relay, IG switch, starter button and battery. Depressing the starter button (on the right handlebar switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery. The motor draws about 80 amperes to start the engine.
Starter relay
Fuse
S. button Starter motor Ig. switch ON
STARTER MOTOR REMOVAL AND DISASSEMBLY. Remove the starter motor. Disassemble the starter motor as follows.
STARTER MOTOR INSPECTION

CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically, inspect the length of the brushes, replacing them when they are too short or chipping. Wear of carbon brushes Service limit 3.5 mm
COMMUTATOR If the commutator surface is dirty, starting performance decreases. Polish the commutator with # 400 or similar fine emery paper when it is dirty. After polishing it, wipe the commutator with a clean dry cloth. Check the commutator under cut . Under cut of commutator Service limit 0.5 mm
SEGMENT
MICA
ARMATURE COIL Using a pocket tester, check the coil for open and ground by placing probe pins on each commutator segment and rotor core (to test for ground) and on any two segments at various place (to test for open) of the commutator surface. If the coil is found to be open-circuited or grounded, replace the armature, continuous use of a defective armature will cause the starter motor to suddenly fail.
STATER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to starter motor case, align the protrusion of the starter motor case with the notch of the brush holder.
SECURING SCREWS Apply thread lock1324to starter motor securing screws.

Thread Lock1324
STARTER MOTOR RELAY INSPECTION Disconnect the lead wire of the starter motor at the starter motor relay. Turn on the ignition switch, inspect the continuity between the terminals, positive and negative, when pushing the starter button. If the starter motor relay is in sound condition, continuity is found.
Check the coil foropen ,groundand ohmic resistance. The coil is in good condition of the resistance is as follows.
Standard resistance
Approx. 3~4
LAMP
Lamp switch
low beam Battery
High beam Head lamp
Tail lamp
Head lamp : 12V 35/35W Tail lamp : 12V 21/5W
LAMP BULB REPLACEMENT AND INSPECTION

After installing a new bulb, check for continuity. If the bulb does not light, inspect the wiring for open or short circuit.
SWITCHES
Inspect each switch for continuity with the pocket tester referring to the chart.
ENGINE KILL SWITCH

POSITION OFF RUN COLOR B/Y Frame Earth
LAMP SWITCH
POSITION OFF ON COLOR Gr O
WIRE COLOR
Gr B/Y O Gray Black with yellow tracer Orange.
BATTERY
CAUTION OF BATTERY TREATMENT
The 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.
CAUTION OF BATERY ELECTROLYTE TREATMENT

Pay attention that the battery electrolyte not be stain the chasis or the humanbody. If be stain the chasis or the humanbody, at once wash a vast quantity of water. When it be stained, clothes should come into being a hole or painting should take off. Be cured from a doctor. When the battery electrolyte was droped the surface of land, wash a vast quantity of water. Neutralize by hudroxide, bicarbonate of soda and so on.
CAUTION OF MAINTENANCE FREE BATTERY TREATMENT

Do not remove the aluminum tape what sealing the battery electrolyte filler hole untill use as battery of completely seal type. Do not use with the exception exclusive the battery electrolye. When pour into the battery electrolyte, necessarily use the electrolyte of the rules capacity. Do not open the sealing cap after recharge the battery eletrolyte.
Filling electrolyte. The battery is puted on even land, remove the aluminum tape sealing Remove the cap at the electrolyte container.
CAUTION
Do not remove the seal, not prick with sharp thing.
Aluminum tape
Filler holes
Cap
Seal
Pouring in battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes, holding the container firmly so that it cloes not fall. Take precaution not to allow any of the fluid to spill.
CAUTION
In no case pouring into if put in slopely the electrolyte container.
Confirm of pour Make sure that air bubbles are coming up each electrolyte container, and leave in this position for about more than 20 minutes.
CAUTION
If no air bubbles are coming up from afiller port, tap the botton of the two or three times.
Air bubble
Separation of electrolyte container. After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery.
CAUTION
Draw out slowly otherwise in case of remain electrolyte vaporize.
Insert of the caps Insert the cap into the filler holes, pressing in firmly so that the top of the caps do not protrude above the upper surface of the battery s top cover.
Insert the caps firmly
ASSISTANCE RECHARGING
Use the battery that is maded after 2 years as the maintenance free battery. Use the battery at condition of the high temperature. Assistance recharging to the following points. The main principle of assistance recharging. Assistence recharging from rule of electric current or voltage, when the battery discharged. Do not assistance recharge except the right side table. Do not remove, when assistance recharge.
WARNING
The firearm is strictly prohibited.
Assistance Recharging Standard Fast 0.7 A 5~10 hours 3A 30 minutes.
CHASSIS
CONTENTS
FRONT WHEEL FRONT BRAKE FRONT FORK STEERING STEM REAR WHEEL AND REAR BRAKE SUSPENSION REAR SWING ARM 6- 1 6- 6 6-14 6-20 6-25 6-31 6-36
6-1 CHASSIS
FRONT WHEEL
REMOVAL Support the machine by jack, block or service stand.

Service stand : 99000-99094
CHASSIS 6-2
Disconnect the speedo meter cable. Disconnect the left side of the protector.
Disconnect the clamp. Remove the brake hose.
Pull out the fixing bolt and remove the axle .
Draw out the front axle and take off the front wheel.
6-3 CHASSIS
DISASSEMBLY
FRONT WHEEL Remove the front brake disk.
Using the special tool, drive out the wheel bearings.

Wheel bearing remover : 09941-50110
INSPECTION
WHEEL BEARING Inspect the play of the wheel bearings inner race by hand while fixing it in the wheel hub. Rotate the inner race by hand to inspect whether abnormal noise occurs or rotating smoothly. Replace the bearing if there is something unusual.
Play Play
CHASSIS 6-4
AXLE SHAFT Using the special tools, check the axle shaft for runout and replace it if the runout exceeds the limit.
Dial gauge : 09900-20606
Runout of axle shaft
WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown.
CAUTION
Worn or loose wheel bearing must be replaced before attempting to true a wheel rim. Dial gauge(1/100) : 09900-20606 Magnetic stand : 09900-20701
Runout of wheel rim (Axial and Radial)
TIRE Inspect the tires for wear and damage. Check the tire tread depth as shown. Replace a badly worn or damaged tire. A tire with its tread worn down to the limit(in terms of tread depth) must be replaced. Tread depth service limit Front Rear 1.6 mm 1.6 mm
REASSEMBLY
Reassemble and remount the front wheel in the reverse order of disassembly and removal, and also carry out the following steps : WHEEL BEARING Apply grease to the bearing before installing.
: Super greaseA
Install the wheel bearings by using the special tool.

Bearing installer : 09913-75820
6-5 CHASSIS
Install the disk with four bolts as shown in photo.

Disk bolt : 18~28 Nm (1.8~2.8 kgm)
CHASSIS 6-6
FRONT BRAKE
yy ;; ;;; yyy ;; yy ;;; yyy ;;; yyy ; y ;;; yyy ; y
6-7 CHASSIS
BRAKE PAD REPLACEMENT

Remove the caliper mounting bolts and take off the caliper.
CAUTION
Do not operate the brake lever while dismounting the caliper.
Push the piston and caliper holder all the way to the caliper when removing the pad. Loosen the screw and take off the housing cover.
Remove the pad.

CAUTION
Replace the brake pad with a set, otherwise braking performance will be adversely affected.
Apply the silicone grease to the caliper holder.

Silicone gerase.
Push in the piston and piston holder all the way to the caliper when remounting the caliper. Tighten the caliper mounting bolts with specified torque.
Caliper mounting bolts : 18~28 Nm (1.8~2.8 kgm)
CHASSIS 6-8
CALIPER REMOVAL AND DISASSEMBLY

Disconnect the brake hose from the caliper and catch the brake fluid in a suitable receptacle.
CAUTION
Never re-use the brake fluid left over from the last servicing and stored for long periods.
Remove the caliper mounting bolts and take off the caliper. Loosen the screw and take off the carrier .
Take off the caliper carrier.
Remove the caliper holder from the caliper.
6-9 CHASSIS
Place a rag over piston to prevent popping up. Force out the piston by using air gun.
CAUTION
Do not use high pressure air to prevent piston damage.
Remove the piston, piston boot and piston seal.
INSPECTION
CALIPER CYLINDER Inspect the cylinder bore wall for nick, scratches or other damage.
PISTON Inspect the piston surface for any scratches or other damage.
CHASSIS 6-10
RUBBER PARTS Inspect the each rubber part for damage and wear.
DISC Measure the disc thickness by using the micrometer.

Micrometer (0~25 mm) : 09900-20205
Disc thickness
With the disc mounted on the wheel check the disc for face runout with a dial gauge, as shown.
Dial gauge (1/100) : 09900-20606
Disc runout
BRAKE PADS Wear condition of brake pads can be checked by observing the red limit line marked on the pad When the wear exceeds the limit line, replace the pad with new ones.
CAUTION
Replace the brake pad with a set, otherwise braking performance will be adversely affected.
6-11 CHASSIS
CALIPER REASSEMBLY
Reassemble and remount the caliper in the reverse orders of disassembly and removal, and also carry out the following steps.
CAUTION
Wash the caliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the caliper bore and all internal parts before inserting into the bore.
Apply the silicone grease to the caliper holder.

Silicone grease.
TIGHTENING TORQUE Item

WARNING
Bleed the air from brake fluid circuit after reassembling the caliper. (See page 2-12)
Nm 6-9 20-25 18-28
kgm 0.6-0.9 2.0-2.5 1.8-2.8
MASTER CYLINDER REMOVAL AND DISASSEMBLY

Please a cloth underneath the union bolt on the master cylinder to prevent, spilled drops of the brake fluid. Unscrew the union bolts and disconnect the brake hose from the master cylinder joint.
CAUTION
Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc., and will damage them severely.
CHASSIS 6-12
Remove the two clamp bolts and take off the master cylinder.
Remove the two fitting screws and separate the cap and diaphragm. Drain brake fluid.
Remove the dust seal boot. Remove the circlip by using the special tool.
Remove the piston, primary cup and spring.
INSPECTION
Inspect the master cylinder bore for any scratches or other damage.
6-13 CHASSIS
Inspect the piston and cup surface for any scratches or other damage. Inspect the dust seal boot for wear for damage.
REASSEMBLY
Reassemble and remount the master cylinder in the reverse orders of disassembly and removal, and also carry out the following steps :
CAUTION
Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and all internal parts before inserting into the bore.
When remounting the master cylinder to the handlebars, first tighten the clamp bolts for upside as shown.
WARNING
Bleed air from the brake fluid circuit after reassembling master cylinder. (See page 2-12)
Up
Master Cylinder
Handlebar
Clearance
CHASSIS 6-14
FRONT FORK
6-15 CHASSIS
REMOVAL AND DISASSEMBLY

Take off the front wheel. (See page 6-1) Loosen the front fork upper and lower clamp bolts.
Remove the front brake hose clamp.
Pull down right and left front forks.
Remove the front fork cap, O-ring , and seat lever.

CAUTION
To remove the O-ring , it will be necessary to push the seat lever inwards, to remove spring pressure from the O-ring. The removed O-ring should be replaced with a new one.
CHASSIS 6-16
Straighten the fork and stroke it several times to remove the oil. Hold the fork inverted for a few minutes.
Remove the damper rod bolt by using the 19 mm socket. Separate the inner tube from outer tube. Remove oil lock piece and damper rod with rebound spring.
Remove the snap ring by using the special tool.

Remove the oil seal by using the special tool.

Oil seal remover : 09913-50121
CAUTION
The oil seal removed should be replaced with a new oil seal.
6-17 CHASSIS
INSPECTION
DAMPER ROD RING Inspect the damper rod ring for wear and damage.
INNER TUBE AND OUTER TUBE Inspect the inner tube and outer tube sliding surfaces for any scuffing or flaws.
FORK SPRING Measure the fork spring free length. If it is shorter than the service limit, replace it. Fork spring free length Service limit 555 mm
REASSEMBLY
Reassemble and remount the front fork in the reverse order of disassembly and removal, and also carry out the following steps : DAMPER ROD BOLT Apply Bond1215and Thread Lock1324to the damper rod bolt and tighten the bolt with specified torque by the 19 mm socket.
Bond1215 Thread Lock1324
CHASSIS 6-18
OIL SEAL Install the oil seal to the outer tube by using the special tool as shown.
Fork oil seal installer : 09940-50112
FORK OIL For the fork oil, be sure to use a front fork oil whose viscosity rating meets specifications below. Fork oil type Fork oil capacity SS8 Oil Each leg 4432.5 cc
Hold the front fork vertical and adjust the fork oil level with the special too.
CAUTION
When adjusting oil level, remove the fork spring and compress the inner tube fully. Front fork level gauge : 09943-74111
Front fork oil level
At outer tube 146 mm (Without Spring)
STOPPER RING To install a new stopper ring, it will be necessary to push the spring seat inward.
CAUTION
Always use a new stopper ring. After installing a stopper ring, always insure that it is completely seated in its groove and securely fitted.
6-19 CHASSIS
REMOUNTING
Maintain equally right and level height. (Standard for upside surface of the upper bracket : 7 mm1 mm) Tighten the upper and lower clamp bolts.
Upper clamp bolts : 22~35 Nm (2.2~3.5 kgm) Lower clamp bolts : 20~30 Nm (2.0~3.0 kgm)
CHASSIS 6-20
STEERING STEM
6-21 CHASSIS

Take off the front wheel. (See page 6-1) Take off the front fork. (See page 6-15) Remove the screws and the two headlight housing rubber packing .
Disconnect the lead wires.
Remove the two screws of the headlight housing.
Remove the four bolts and front fender.
CHASSIS 6-22
Remove the handlebars clamp bolts.
Remove the steering stem head bolt and take off the steering stem upper nut.
Remove the steering stem nut and draw out the steering stem.
CAUTION
Hold the steering stem lower bracket by hand to prevent from falling.
Remove the upper and lower bearing.
6-23 CHASSIS
Remove the outer race fitted on the steering stem. This can be done with a chisel.
Draw out the two inner races fitted to the top and bottem ends of the head pipe.
INSPECTION
Inspect and check the removed parts for the following abnormalities. Handlebars distortion. Handlebars clamp wear. Abnormality operation of bearing. Worn or damaged steel balls. Distortion of steering stem.
REASSEMBLY
Reassemble and remount the steering stem in the reverse order of disassembly and removal, and also carry out the following steps : INNER RACES Press in the upper and lower inner races using the special tool.
Steering race installer : 09941-34511
CHASSIS 6-24
BEARING When press the bearing, use the special tool.
STEERING STEM NUT Tighten the steering stem nut with the special tool.
Clamp wrench : 09940-10122 steering stem nut : 40~50 Nm (4.0~5.0kgm)
Turn the steering stem right and left, lock-tolock, five or six times. Tighten the steering stem head bolt to the specified torque.
Steering stem head bolt : 80~100 Nm (8.0~10.0 kgm)
CAUTION
After performing the adjustment and installing the steering stem upper bracket,rockthe front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly. If play is noticeable, re-adjust the steering stem nut.
HANDLEBARS Set the handlebars to match its punched mark to the mating face of the holder.
Secure the each handlebar clamp in such a way that the clearances ahead of and behind the handlebars should be equalized.
Handlebars : 18~28 Nm (1.8~2.8 kgm)
6-25 CHASSIS
REAR WHEEL AND REAR BRAKE
;;;; ;;;; ;;;;
REMOVAL
Support the machine by jack or block or service stand.
Service stand : 99000-99094
CHASSIS 6-26
Pull out the cotter pin and remove the torque link nut and bolt. Remove the rear brake adjuster nut.
Remove the rear axle nut.
Draw out the axle shaft and take off the rear wheel. Separate the rear wheel from rear brake panel.
DISASSEMBLY
REAR WHEEL Flatten the washers and loosen the four nuts. Separate the rear sprocket from the rear wheel.
6-27 CHASSIS
Remove the right and left side wheel bearings.

CAUTION
Removing the left side bearing first makes the job easier.
REAR BRAKE Take off the brake shoes.
Loosen the cam lever nut. Pull off the brake cam, washer, O-ring and cam lever.
INSPECTION
WHEEL BEARINGS Inspect the wheel bearings for play by hand. Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly. Replace the bearing if there are any defects.
Play Play
CHASSIS 6-28
AXLE SHAFT Using a dial gauge, check the axle shaft for runout and replace it if the runout exceeds the limit.
Dial gauge(1/100) : 09900-26006 Magnetic stand : 09900-20701 VBlock : 09900-21304
Axle shaft runout
WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to loosen spokes or a bent wheel rim. If properly tightening the spokes will not correct the runout, replace the wheel rim.
CAUTION
Worn or loose wheel bearings must be replaced before attempting to true wheel rim.
Wheel rim runout (Axial and Radial)
SPROCKET Inspect the sprocket teeth for wear. If they are worn as illustrated, replace the sprocket and drive chain.
Normal wear
Excessive wear
6-29 CHASSIS
REAR BRAKE DRUM Measure the brake drum I. D. to determine the extent of wear and, if the limit is exceeded by the wear noted, replace the drum. The value of this limit is indicated inside the drum. Rear brake drum I. D. Service limit 130.7 mm
BRAKE SHOE Check the brake shoes and decide whether it should be replaced or not from the thickness of the brake shoe linings.
CAUTION
Replace the brake shoes as a set, otherwise braking performance will be adversely affected.
Thickness of brake shoe linings
REASSEMBLY
Reassemble and remount the rear wheel and rear brake in the reverse order of disassembly and removal, and also carry out the following steps : WHEEL BEARING Apply grease to the bearings before installling
Super greaseA
Install the wheel bearings by using the special tool.

CAUTION
First install the wheel bearing for right side. Bearing installer set : 09924-84510
SPROCKET After tightening the four nuts to specification, bend the washers to lock nuts.
Sprocket nut : 20~30 Nm (2.0~3.0 kgm)
CHASSIS 6-30
BRAKE CAM Apply grease to the brake cam.

Super greaseA
CAUTION
Be careful not to apply too much grease to the brake cam shaft. If grease gets on the lining, brake slippage will result.
BRAKE CAM LEVER Tighten the cam lever bolt with specified torque.
Brake cam lever nut : 8~12 Nm (0.8~1.2 kgm)
CAUTION
Adjust the rear brake pedal play after installation of the rear wheel.
6-31 CHASSIS
SUSPENSION
(Service limit 10.20 mm)
CHASSIS 6-32

Remove the seat and frame covers. Remove the rear wheel. (See page 6-26) Loosen the four screws and remove the mud flap.
Remove the rear cushion rod fitting nuts and bolts.
Remove the rear cushion lever nut and bolt.
Remove the rear shock absorber fitting bolt. Pull up the suspension from the chassis.
6-33 CHASSIS
Remove the rear cushion rod nut and bolt.
Remove the spacers from the rear cushion rod.
After drawing out the spacer, remove the two bearings from the rear cushion lever by using the special tools.
Bearing remover (17 mm) : 09923-73210 Rotor remover sliding shaft : 09930-30102
INSPECTION
Inspect the dust seals, if they are found to be damaged, replace them with new seals.
CHASSIS 6-34
SPACER Measure the inside diameter of the spacer with dial calipers. Spacer Service limit 14.20 mm Service limit 10.20 mm
(, See page 6-31, 6-36) If the inside diameter of the spacer exceeds the service limit or flaws are discovered, replace the spacer and O-rings.
REASSEMBLY
Reassemble the suspension, in the reverse order of disassembly and removal, and also carry out the following steps : CUSHION LEVER BEARINGS Install the right and left bearings by using the special tool.
Bearing installer set : 09924-84510
CAUTION
When installing two bearings, punch marked side of bearing comes on outside.
SPACER AND DUST SEAL

Apply grease to the spacer and dust seal before installing, as shown in the illustration.
Super greaseA
6-35 CHASSIS
Rear shock absorber nut(Upper) : 40~60 Nm (4.0~6.0 kgm) Rear cushion lever center nut : 70~100 Nm (7.0~10.0 kgm) Rear cushion rod nut and bolt(Lower) : 84~120 Nm (8.4~12.0 kgm) Rear cushion rod nut and bolt(Upper) : 84~120 Nm (8.4~12.0 kgm) Rear shock absorber nut(Lower) : 40~60 Nm (4.0~6.0 kgm)
REAR SHOCK ABSORBER SPRING ADJUSTMENT PROCEDURE

The procedure for adjusting the spring pre-load is as follows. Remove the seat and frame covers. Remove the carburetor. Remove thr air cleaner case. Adjust the rear shock absorber by using the special tool.
Clamp wrench : 09940-10122
Remount the air cleaner, carburetor, seat and frame cover.
CHASSIS 6-36
REAR SWING ARM

Remove the rear wheel. (See page 6-26) Loosen the four screws and remove the mud flap. (See page 6-32) Remove the rear cushion rod fitting nuts and bolts. (See page 6-32) Remove the rear shock absorber fitting nut and bolt. (See page 6-32)
6-37 CHASSIS
Remove the swing arm pivot nut. Draw out the pivot shaft and take off the swing arm.
Remove the chain case. Remove the two spacers. Remove the spacer by using the special tools.
Bearing remover (17 mm) : 09923-73210 Rotor remover sliding shaft : 09930-30102
INSPECTION
SWING ARM PIVOT SHAFT Using a dial gauge, check the pivot shaft for runout and replace it if the runout exceeds the limit.
Dial gauge (1/100) : 09900-20606
Swing arm pivot shaft for runout
REASSEMBLY
Reassemble and remount the swing arm in the reverse order of disassembly and removal, and also carry out the following steps: SWING ARM SPACER Force-fit the spacers into the swing arm by using the special tool.
Bearing installer set : 09924-84510
CHASSIS 6-38
SPACER Apply grease to the spacer when installing.

Super greaseA
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING SPECIAL TOOLS TIGHTENING TORQUE SERVICE DATA WIRE AND CABLE ROUTING WIRING DIAGRAM 7- 1 7- 8 7-12 7-14 7-21 7-23
7-1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Engine will not start, or is hard to start. Symptom and possible causes Compression too low 1. Valve clearance out of adjustment. 2. Worn valve guides or poor seating of valves. 3. Valves mistiming 4. Piston rings excessively worn. 5. Worn-down cylinder bore. 6. Poor seating of spark plug. 7. Starter motor cranks but too slowly. Plug not sparking 1. Fouled spark plug. 2. Wet spark plug. 3. Defective ignition coil. 4. Open or short circuit in high tension cord. No fuel reaching the carburetor 1. Clogged hole in the fuel tank cap. 2. Clogged or defective fuel cock. 3. Defective carburetor float valve. 4. Clogged fuel pipe. Remedy
Adjust. Repair or replace. Adjust. Replace. Replace or rebore. Retighten. Consult electrical complaints
Clean or replace. Clean and dry. Replace. Replace..
Clean. Clean or replace. Replace. Clean or replace.
Engine stalls easily.
1. 2. 3. 4.
Fouled spark plug. Clogged fuel hose. Clogged jets in carburetor. Valve clearance out of adjustment.
Clean. Clean. Clean. Adjust.
Noisy engine.
Excessive valve chatter 1. Valve clearance too large. 2. Weakened or broken valve springs. 3. Worn down rocker arm or rocker arm shaft. Noise appears to come from piston 1. Piston or cylinder worn down. 2. Weakened or broken valve springs. 3. Worn down rocker arm or rocker arm shaft. 4. Piston rings or ring groove worn. Noise seems to come from timing chain 1. Stretched chain. 2. Worn sprockets. 3. Tension adjuster not working. Noise seems to come from clutch 1. Worn splines of countershaft or hub. 2. Worn teeth of cluth plates. 3. Distorted clutch plates, driven and drive. Noise seems to come from crankshaft 1. Worn or broken bearings. 2. Big-end bearings worn and broken. 3. Thrust clearance too large.
Adjust. Replace. Replace.
Replace. Replace. Replace. Replace.
Replace. Replace. Repair or replace.
Replace. Replace. Replace.
Replace. Replace. Replace.
SERVICING INFORMATION 7-2
Complaint Noisy engine.
Symptom and possible causes Noise seems to come from transmission 1. Gears worn or rubbing. 2. Badly worn splines. 3. Primary gears worn or rubbing. 3. Badly worn bearings. 1. 2. 3. 4. Clutch control out of adjustment or too much play. Weakened clutch springs. Worn or distorted pressure plate. Distorted clutch plates, driven and drive.
Remedy
Replace. Replace. Replace. Replace. Adjust. Replace. Replace. Replace. Adjust. Replace. Replace.
Slipping clutch.
Dragging clutch.
1. Clutch control out of adjustment or too much play. 2. Weakened clutch springs. 3. Distorted clutch plates, driven and drive.
Transmission will not shift.
1. Broken gearshift cam. 2. Distorted gearshift forks. 3. Worn gearshift pawl. 1. Broken return spring on shift shaft. 2. Shift shafts are rubbing or sticky. 3. Distorted or worn gearshift forks.
Replace. Replace. Replace. Replace. Repair. Replace.
Transmission will not shift back.
Transmission jumps out of gear.
1. 2. 3. 4.
Worn shifting gears on driveshaft or countershaft. Distorted or worn gearshift forks. Weakened stopper pawl spring on gearshift cam. Worn gearshift pawl.
Replace. Replace. Replace. Replace.
Engine idles poorly.
1. 2. 3. 4. 5. 6. 7. 8.
Valve clearance out of adjustment. Poor seating of valves. Defective valve guides. Worn rocker arm or arm shaft. Spark plug gap too wide. Defective ignition coil resulting in weak sparking. Float-chamber fuel level out of adjustment in carburetor. Clogged jets.
Adjust. Replace. Replace. Replace. Adjust or replace. Replace. Adjust. Clean.
Engine runs poorly in high speed range.
1. 2. 3. 4. 5. 6. 7. 8.
Valve springs weakened. Valve timing out of adjustment. Worn cams or rocker arms. Spark plug gap too narrow. Defective ignition coil. Float-chamber fuel level too low. Clogged air cleaner element. Clogged fuel pipe, resulting in inadequate fuel supply to carburetor.
Replace. Adjust. Replace. Repair. Replace. Adjust . Clean. Clean or replace. Check with inspection window, drain out excess oil. Replace. Replace. Replace. Replace. Replace. Replace.
Dirty or heavy exhaust smoke.
1. Too much engine oil in the engine. 2. 3. 4. 5. 6. 7. Worn piston rings or cylinder. Worn valve guides. Cylinder wall scored or scuffed. Worn valves stems. Defective stem seals. Worn side rails.
Complaint Engine lacks power.
Symptom and possible causes 1. Loosen of valve clearance. 2. Weakened valve springs. 3. Valve timing out of adjustment. 4. Worn piston ring or cylinder. 5. Poor seating of valves. 6. Fouled spark plug. 7. Worn rocker arms or its shafts. 8. Spark plug gap incorrect. 9. Clogged jets in carburetor. 10. Float-chamber fuel level out of adjustment. 11. Clogged air cleaner element. 12. Too much enging oil. 13. Defective air intake pipe. 1. 2. 3. 4. 5. 6. 7. Heavy carbon deposit on piston head. Not enough oil in the engine. Defective oil pump or clogged oil circuit. Fuel level too low in float chamber. Air leak from intake pipe. Use of incrrect engine oil. Defective oil cooler.
Remedy Adjust. Replace. Adjust. Replace. Repair or replace. Clean or replace. Replace. Adjust or replace. Clean. Adjust. Clean. Drain out excess oil. Retighten or replace. Clean. Add oil. Repair or clean. Adjust. Retighten or replace. change. Clean or replace.
Engine overheats.
CARBURETOR
Complaint Trouble with starting. Symptom and possible causes 1. Starter jet is clogged. 2. Starter pipe is clogged. 3. Air leaking from a joint between starter body and carburetor. Remedy Clean. Clean. Check starter body and carburetor for tightness, adjust and replace gasket. Check and adjust. Check and clean. Check and clean. Check and clean. Check and clean. Check and clean. Check throttle valve for operation. Check and clean. Replace. Replace. Check and adjust. Clean. Adjust float height.
4. Starter plunger is not operating properly. Idling or low-speed trouble. 1. Pilot jet, pilot air jet are clogged or loose. 2. Pilot outlet or bypass is clogged. 3. Starter plunger is not fully closed. 1. Main jet or main air jet is clogged. 2. Needle jet is clogged. 3. Throttle valve is not operating properly. 4. Filter is clogged. Overflow and fuel level fluctuations. 1. 2. 3. 4. 5. Needle valve is worn or damaged. Spring in needle valve is borken. Float is not working properly. Foreign matter has adhered to needle valve. Fuel level is too high or low.
Medium-or high speed trouble.
ELECTRICAL
Complaint No sparking or poor sparking. Symptom and possible causes 1. Defective ignition coil. 2. Defective spark plug. 3. Defective CDI unit. 1. 2. 3. 4. 5. 1. 2. 3. 4. 1. 2. 3. 4. Mixture too rich. Idling speed set too high. Incorrect gasoline. Dirty element in air cleaner. Spark plug too cold. Worn piston rings. Pistons or cylinder worn. Excessive clearance of valve stems in valve guides. Worn stem oil seal. Spark plug too hot. The engine overheats. Spark plug loose. Mixture too lean. Replace. Replace. Replace. Adjust carburetor. Adjust carburetor. Change. Clean or replace. Replace by hot type plug. Replace. Replace. Replace. Replace. Replace by cold type plug. Tune up. Retighten. Adjust carburetor. Repair or retighten. Replace. Replace. Add distilled water between the level lines. Replace the battery. Replace the battery. Replace. Clean and tighten ground connection. Repair or replace Replace. Replace. Recharge or replace. Replace. Repair or replace. Replace. Remedy
Spark plug soon become fouled with carbon.
Spark plug become fouled too soon.
Spark plug electrodes overheat or burn.
Generator charge, but charging rate is below the specification.
1. Lead wires tend to get shorted or open-circuited or loosely connected at terminals. 2. Grounded or open-circuited stator coils of generator. 3. Defective regulator/rectifier. 4. Not enough electrolyte in the battery. 5. Defective cell plates in the battery.
Generator overcharges.
1. Internal short-circuit in the battery. 2. Resistor element in the regulator/rectifier damaged or defective. 3. Regulator/rectifier poorly grounded.
Unstable charging.
1. Lead wire insulation frayed due to vibration resulting in intermittent shorting. 2. Generator internally shorted. 3. Defective regulator/rectifier. 1. 2. 3. 4. Battery run down. Defective switch contacts. Brushes not seating properly on commutator in starter motor. Defective starter relay.
Starter button is not effective.
BATTERY
Complaint Sulfationacidic white powdery substance or spots on surfaces of cell plates. Symptom and possible causes 1. Not enough electrolyte. Remedy Add distilled water, if the battery has not been damaged and sulfation has not advanced too far, and recharge. Replace the battery. 2. Battery case is cracked. 3. Battery has been left in a run-down condition for a long Replace the battery or recharge. time. sulfation has not advanced 4. Contaminated electrolyte. (Foreign matter has enters the If far, try to restore the battery by battery and become mixed with the electrolyte.) replacing the electrolyte, recharing it fully with the battery detached from the motorcycle and then adjusting electrolyte specific gravity. 1. The charging method is not correct. Check the generator, regulator/rectifier and circuit connections, and make necessary adjustments to obtain specified charging operation. Replace the battery, and correct the charging system. Replace the battery.
Battery runs down quickly.
2. Cell plates have lost much of their active material as a result of over-charging. 3. A short-circuit condition exists within the battery due to excessive accumulation of sediments caused by the high electrolyte specific gravity. 4. Electrolyte specific gravity is too low.
5. Contaminated electrolyte.
6. Battery is too old. Reversed battery polarity. The battery has been connected the wrong way round in the system, so that it is being charged in the reverse direction.
Recharge the battery fully and adjust electrolyte specific gravity. Replace the electrolyte, recharge the battery and then adjust specific gravity. Replace the battery. Replace the battery and be sure to connect the battery properly. Replace the battery.
Batterysulfation
1. Charging rate too low or too high. (When not in use, batteries should be recharged at least once a month to avoid sulfation.) 2. Battery electrolyte excessive or insufficient, or its specific gravity too high or too low.
3. The battery left unused for too long in cold climate.
Keep the electrolyte up to the prescribed level, or adjust the specific gravity by consulting the battery maker s directions. Replace the battery, if badly sulfated. Clean. Change the electrolyte by consulting the battery maker s directions.
Battery discharges too rapidly.
1. Dirty container top and sides. 2. Impurities in the electrolyte or electrolyte specific gravity is too high.
CHASSIS
Complaint Steering feels too heavy or stiff. 1. 2. 3. 4. Symptom and possible causes Steering stem nut overtightened. Worn bearing or race in steering stem. Distorted steering stem. Not enough pressure in tires. Adjust. Replace. Replace. Adjust. Replace. Repair or replace. Replace. Replace. Replace. Replace. Retighten. Replace. Refill. Replace. Drain excess oil. Refill. Retighten. Replace. Replace. Replace. Retighten. Replace. Retighten. Replace. Adjust. Adjust. Replace. Retighten. Replace. Remedy
Steering oscillation.
1. Loss of balance between right and left front suspensions. 2. Distorted front fork. 3. Distorted front axle or crooked tire. 1. 2. 3. 4. Distorted wheel rim. Worn-down wheel bearings. Defective or incorrect tire. Loosen nut on axle.
Wobbling front wheel.
Front suspension too soft. Front suspension too stiff. Noisy front suspension. Wobbling rear wheel.
1. Weakened springs. 2. Not enough fork oil. 1. Fork oil too viscous. 2. Too much fork oil. 1. Not enough fork oil. 2. Loosen nuts on suspension. 1. 2. 3. 4. 5. 6. Distorted wheel rim. Worn-down rear wheel bearing. Defective or incorrect tire. Loose nut on axle. Worn swing arm spacers. Loosen nut on the rear shock.
Rear suspension too soft. Rear suspension too stiff. Noisy rear suspension.
1. Weakened springs. 2. Rear suspension adjuster impromerly set. 1. Rear suspension adjuster improperly set. 2. Worn swing arm spacers. 1. Loosen nuts on suspension. 2. Worn swing arm spacers.
BRAKES
Complaint Poor braking (FRONT and REAR) 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. Symptom and possible causes Not enough brake fluid in the reservoir. Air trapped in brake fluid circuit. Pads worn down. Too much play on brake lever or pedal. Shoes worn down. Leakage of brake fluid from hydraulic system. Worn pads. Oil adhesion of engaging surface of pads. Worn disk. Air in hydraulic system. Remedy Refill to level mark. Bleed air out. Replace. Adjust. Replace. Repair or replace. Replace. Clean disk and pads. Replace. Bleed air. Repair surface with sandpaper. Modify pad fitting. Replace. Tighten to specified torque. Replace. Replace brake fluid. Disassemble and clean master cylinder. Bleed air. Replace brake lever. Replenish fluid to specified level ; bleed air. Replace with correct fluid. Tighten to specified torque. Replace. Replace piston and/or cup.
Insufficient brake power.
Brake squeaking.
1. Carbon adhesion on pad surface. 2. 3. 4. 5. 6. 7. Tilted pad. Damaged wheel bearing. Loosen front-wheel axle or rear-wheel axle. Worn pads. Foreign material in brake fluid. Clogged return port of master cylinder.
Excessive brake lever stroke.
1. Air in hydraulic system. 2. Worn brake lever cam. 3. Insufficient brake fluid. 4. Improper quality of brake fluid.
Leakage of brake fluid.
1. Insufficient tightening of connection joints. 2. Cracked hose. 3. Worn piston and/or cup.
SPECIAL TOOLS
Special tools Part NumberPart NameDescription 09900-00401 Ltype hexagon wrench set Tighten hexagon bolt 09900-00410 Hexagon wrench set Tighten hexagon bolt 09900-05108 Snap ring pliers Circlip remove and remounting 09900-06105 Snap ring pliers Circlip remove and remounting 09900-06107 Snap ring pliers Circlip remove and remounting 09900-09003 Impact driver set Remove and remounting of fixed screw 09900-20102 Vernier calipers Measure thickness 09900-20202 Micrometer (1/100mm, 25-50mm) Measure height of cam 09900-20203 Micrometer (1/100mm, 50-75mm) Measure outside diameter of piston Special tools Part NumberPart NameDescription 09900-20205 Micrometer (1/100mm, 0-25mm) Measure outside diameter of piston pin 09900-20508 Cylinder gauge set (1/100mm, 40-80mm) Measure inside diameter of cylinder 09900-20602 Dial gauge (1/100mm, 1mm) Measure inside diameter of cylinder 09900-20605 Dial calipers (1/100mm, 10-34mm) Measure width of conrod big-end 09900-20606 Dial gauge (1/100mm, 10mm) Measure run-out of wheel 09900-20701 Magnetic stand Used with Dial gauge 09900-20806 Thickness gauge Measure clearance of piston ring 09900-21304 V-block set Used with Magnetic stand 09900-22301 Plastic gauge Measure clearance of crankshaft thrust
Special tools
Part NumberPart NameDescription 09900-22401 Small bore gauge (10-18mm) Measure inside diameter of conrod small-end 09900-25002 Pocket tester Measure voltage, electric current, resistance 09900-26006 Tachometer Measure rotational frequency of engine 09900-28107 Electro tester Inspect ignition coil 09910-20116 Conrod holder Used to lock the crankshaft 09910-32812 Crankshaft installer Used to install the crankshaft in the crankcase 09940-10122 Clamp wrench A hook wrench to adjust the steering head of motorcycle 09913-14541 Fuel level gauge set Measure height of carburetor 09913-50121 Oil seal remover Used to remove the oil seal
Special tools
Part NumberPart NameDescription 09913-60710 Bearing remover Remove bearing with the rotor remove sliding shaft 09913-75520 Bearing installer Used to drive bearing in 09913-75821 Bearing installer Used to drive bearing in 09913-75830 Bearing installer Install rear axle shaft oil seal 09913-76010 Bearing installer Install crankshaft bearing 09915-63310 Compression gauge adapter Used with compression gauge 09915-64510 Compression gauge Measure cylinder compression 09915-74510 Oil pressure gauge Measure oil pressure of 4-stroke engine 09915-74531 Oil pressure gauge adapter Used with oil pressure gauge.
Special tools
Part NumberPart NameDescription 09916-14510 Valve spring compressor Remove and remounting valve stem 09916-14910 Valve spring compressor attachment Used with valve spring compressor 09916-84511 Tweezers Remove and remounting valve cotter pin. 09917-14910 Tappet adjuster driver Control to valve clearance. 09920-13120 Crankcase separater Seprate to crankcase 09921-20200 Bearing remover (10mm) Remove oil seal or bearing 09921-20210 Bearing remover (12mm) Remove oil seal or bearing 09922-55131 Bearing installer Used to drive bearing in 09923-73210 Bearing remover (17mm) Remove bearing with the rotor remove sliding shaft
Special tools
Part NumberPart NameDescription 09923-74510 Bearing remover (20~35mm) Remove bearing with the rotor remove sliding shaft 09924-84521 Bearing installer Used to drive small bearing in 09925-98221 Bearing installer Used to drive bearing in 09930-10121 Spark plug socket wrench set Remove and remounting spark plug 09930-30102 Rotor remove sliding shfat Used to with bearing remover or rotor remover 09930-30162 Rotor remover Attached to the top of sliding shaft when removing rotor 09930-32420 Rotor holder Remove and remounting rotor 09930-40113 Rotor holder Widely used to lock rotary parts such as a flywheel magneto 09940-34520 T-handle Remove and remounting front fork oil cylinder
Special tools
Part NumberPart NameDescription 09940-34561 Front fork assembling tool attachment D Used with T-handle 09940-50113 Front fork oil seal installer Install front fork oil seal 09941-34513 Bearing installer Install steering outer race 09941-50110 Wheel bearing remover Remove wheel bearing 09943-74111 Front fork oil level gauge Used to drain the fork oil to the specified level 09943-88211 Bearing remover Remove rear axle shaft bearing 09951-76010 Bearing installer Used to drive bearnig in
TIGHTENING TORQUE
ENGINE
ITEM
Cylinder head cover bolt Camshaft sprocket bolt Cylinder head nut Cylinder base nut Magneto rotor nut primary drive gear/oil pump drive gear nut Clutch sleeve hub nut Engine oil drain plug Engine sprocket nut Engine mounting bolt 17 mm Diam. Engine mounting bolt 14 mm or 12 mm Diam. Exhaust pipe clamp nut Muffler clamp bolt Starter clutch bolt
Nm
12-16 25-30 25-29 6-8 56-60 40-60 30-50 25-30 80-100 48-72 22-33 18-22 9-16 15-20
kgm
1.2-1.6 2.5-3.0 2.5-2.9 0.6-0.8 5.6-6.0 4.0-6.0 3.0-5.0 2.5-3.0 8.0-10.0 4.8-7.2 2.2-3.3 1.8-2.2 0.9-1.6 1.5-2.0
CHASSIS
ITEM
Front axle bolt Front axle pinch bolt Front fork damper rod bolt Front fork lower clamp bolt Front fork upper clamp bolt Steering stem head bolt Handlebars clamp bolt Swing arm pivot nut Rear torque link nut (Front and rear) Rear shock absorber fitting nut (Upper and lower) Rear cushion lever center nut Rear cushion rod nut and bolt (Upper and lower) Rear axle nut Rear sprocket nut Rear brake cam lever bolt Front brake caliper mounting bolt Disc bolt Front brake mastet cylinder mounting bolt Brake hose union bolt Caliper bleeder bolt Oil cooler hose union bolt (10 M) Oil cooler hose union bolt (12 M)
Nm
50-80 15-25 30-40 20-30 22-35 80-100 18-28 50-80 10-15 40-60 70-100 84-120 50-80 20-30 8-12 18-28 18-28 5-8 20-25 6-9 20-25 20-25
kgm
5.0-8.0 1.5-2.5 3.0-4.0 2.0-3.0 2.2-3.5 8.0-10.0 1.8-2.8 5.0-8.0 1.0-1.5 4.0-6.0 7.0-10.0 8.4-12.0 5.0-8.0 2.0-3.0 0.8-1.2 1.8-2.8 1.8-2.8 0.5-0.8 2.0-2.5 0.6-0.9 2.0-2.5 2.0-2.5
TIGHTENING TORQUE CHART

For other bolts and nuts who s torque is not listed, refer to this chart :
Bolt Diameter (mm)

4 5 6 8 10 12 14 16 18
Conventional or4marked bolt Nm

1.0-2.0 2.0-4.0 4.0-7.0 10.0-16.0 22.0-35.0 35.0-55.0 50.0-80.0 80.0-130.0 130.0-190.0
7marked bolt Nm
1.5-3.0 3.0-6.0 8.0-12.0 18.0-28.0 40.0-60.0 70.0-100.0 110.0-160.0 170.0-250.0 200.0-280.0
kgm
0.1-0.2 0.2-0.4 0.4-0.7 1.0-1.6 2.2-3.5 3.5-5.5 5.0-8.0 8.0-13.0 13.0-19.0
kgm
0.15-0.3 0.3-0.6 0.8-1.2 1.8-2.8 4.0-6.0 7.0-10.0 11.0-16.0 17.0-25.0 20.0-28.0
SERVICE DATA
VALVE + GUIDE
ITEM Valve diam. IN. EX. IN. Valve lift EX. IN. & EX. IN. EX. IN. & EX. IN. Valve stem O.D. Valve stem runout Valve head thickness Valve stem end length Valve stem width Valve head radial runout Valve spring free length Valve spring tension(Assembling condition) EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. IN. & EX. STANDARD 22 19 7.4 7.1 0.08-0.13 0.010-0.037 0.030-0.057 5.000-5.012 4.975-4.990 4.955-4.970 3.5 0.9-1.1 41.65 13.6-16.6 kg at length 36.6 mm Unit : mm LIMIT 0.35 0.35 0.05 0.5 3.38 0.03 -
Valve clearance or tappet clearance (when cold) Valve guide to valve stem clearance Valve guide I.D.
CAMSHAFT + CYLINDER HEAD

ITEM Cam height Camshaft runout Cam chain 20-pitch length Rocker arm I.D. Rocker arm shaft O.D. Cylinder head distortion Cylinder head cover distortion IN. EX. IN. & EX. IN. & EX. STANDARD 34.44-34.48 33.81-33.85 12.000-12.018 11.977-11.995 -
Unit : mm LIMIT 34.18 33.55 0.10 129.9 0.05 0.05
CYLINDER + PISTON + PISTON RING

ITEM Compression pressure Piston to cylinder clearance Cylinder bore Piston diam. Cylinder distortion Piston ring free end gap 1st 2nd 1st 2nd 1st 2nd 1st Piston ring groove width 2nd Oil 1st Piston ring thickness Piston pin bore I.D Piston pin O.D 2nd R RN STANDARD 15.6 kg/ (500 rpm) 0.050-0.060 57.000-57.015 56.945-56.960 Measure at 15 mm from the skirt end Approx. 7.2 Approx. 5.8 0.20-0.32 0.20-0.32 1.01-1.03 1.01-1.03 2.01-2.03 0.970-0.990 0.970-0.990 15.002-15.008 14.994-15.000
Unit : mm LIMIT 8.0 kg/ 0.120 57.080 56.880 0.05 5.7 4.6 0.50 0.50 0.180 0.150 15.030 14.980
Piston ring end gap(Assembling condition)
Piston ring to groove clearance
CONROD + CRANKSHAFT
ITEM Conrod small end I.D. Conrod deflection Conrod big end side clearance Conrod big end width Crank web to wed width Crankshaft runout STANDARD 15.006-15.014 0.10-0.45 15.95-16.00 53.00.1 -
Unit : mm LIMIT 15.040 3.0 1.00 0.05
OIL PUMP
ITEM Oil pump reduction ratio Oil pressure (at 60, 140 ) STANDARD 2.000(30/15) 0.4~0.6 kg/ (at 3,000 rpm)
Unit : mm LIMIT -
CLUTCH
ITEM Clutch cable play Clutch release screw Drive plate thickness Driven plate thickness Driven plate distortion Clutch spring free length STANDARD 4 1/4-1/2 turn back 2.9-4.1 1.600.05 -
Unit : mm LIMIT 2.6 0.10 29.5
TRANSMISSION+DRIVE CHAIN
ITEM Primary reduction ratio Final reduction ratio Low 2nd Gear ratios 3rd 4th Top Shift fork to groove clearance Shift fork groove width No. 1, NO. 2 No. 3 No. 1, NO. 2 No. 3 88.0 Type Drive chain Links STANDARD 3.500 (70/20) 3.357 (47/14) 2.750 (33/12) 1.785 (25/14) 1.368 (26/19) 1.045 (23/22) 0.913 (21/23) 0.10-0.30 5.0-5.1 5.5-5.6 4.8-4.9 5.3-5.4 + 0.1 - 0.2 428 H 132 Links 20 pitch length Drive chain slack 50-60
Unit : mm except ratio LIMIT 0.50 259.4 -
Shift fork thickness
Countershaft length(Low to 2nd)
CARBURETOR
ITEM Carburetor type Bore size I.D. No. Idle rpm Float height Main jet Main air jet Jet needle Needle jet Pilot jet Throttle valve By-pass Valve seat Stater jet Pilot screw Pilot air jet (P.S.) (P.A.J.) (M.J.) (M.A.J.) (J.N.) (N.J.) (P.J.) (T.V.) (B.P.) (V.S.) SPECIFICATION PD 18F 24 HG 58 1,450100 rpm 12.5 # 98 # 90 J 29 B AIFC-2nd # 38 93 C 2.9, 1.0, 0.9 2.0 MAX # 500 2 # 150
FUEL + OIL
ITEM Fuel type Fuel tank (including reserve) Reserve Engine oil type change Engine oil capacity Front fork oil type Front fork oil capacity(each leg) Brake fluid type Filter change Overhaul SS8 Oil 4432.5 cc SAE J 1703, DOT 3 or DOT 4 SPECIFICATION Gasoline used should be graded 85-95 octane or higher. An unleaded or low-lead type is recommended. 8.0 liter 1.0 liter SEA 10W/40 SF 950 ml 1,050 ml 1,400 ml SG, SH NOTE
BRAKE+WHEEL
ITEM Front brake lever distance Rear brake pedal free travel Rear brake pedal height Brake disc thickness Brake disc runout Master cylinder bore Master cylinder piston diam Brake caliper cylinder bore Brake caliper piston diam Brake drum I.D Brake lining thickness Wheel rim runout Wheel axle runout Tire size Tire tread depth Front wheel Front wheel Front wheel Front wheel Front wheel Front wheel Rear wheel Rear wheel Axis direciton Circular direction Front wheel Rear wheel Front wheel Rear wheel Front wheel Rear wheel STANDARD 20-30 10-20 2 4.0 12.700-12.743 12.657-12.684 25.4 25.4 130 4 2.75-21 45P 4.10-18 59P 7.0 10.0 -
Unit : mm LIMIT
3.0 0.30 130.7 2.5 2.0 2.0 0.25 0.25 1.6 1.6
TIRE PRESSURE
NORMAL RIDING COLD INFLATION TIRE PRESSURE kPa FRONT REAR 172 197 SOLO RIDING kg/ 1.75 2.00 psi 25 29 kPa 172 221 DUAL RIDING kg/ 1.75 2.25 psi 25 32
SUSPENSION
ITEM Front fork stroke Front fork spring free length Front fork oil level Rear wheel travel Swing arm pivot shaft runout STANDARD 250 146 200 -
Unit: mm LIMIT 555 0.6
ELECTRICAL
ITEM Ignition timing (BTDC/rpm) Spark plug Spark performance Ignition coil resistance Primary Secondary Pick-up Magneto coil resistance Charging Generator no-load voltage Regulated voltage Battery Fuse size Capacity Main Type Gap SPECIFICATION 15 /2,250 and 35 /4,000 C8EH-9 0.8-0.9 Over 8 mm 0.19-0.24 5.4-6.6 G-L Approx. 90-110 Y-Y Approx. 0.6-0.9 72-99 V/5,000 rpm 14-15 V 6Ah 15A
Unit : mm
Standard electrolyte specific gravity 1.320 at 20 (600)
WATTAGE
ITEM Head lamp bulb Neutral lamp bulb Tail/stop lamp bulb Turn signal lamp bulb Speedo meter lamp bulb Turn signal pilot lamp bulb Hi-beam pilot lamp bulb
CAUTION
Do not use except the specified bulb(Wattage)
Unit : W SPECIFICATION HI LO 35 35 5 21/5 Front:10, Rear:10 3.4 1.7 1.7
WIRE AND CABLE ROUTING

WIRING HARNESS
Clutch cable
Tail stop lamp 09407-254A1 Air vent hose License plate lamp Starter cable Breather hose 09404-06401 Magneto Neutral switch
C.D.I Unit
Handle switch R/H Front brake hose
09407-14403
Neutral switch Magneto Starter relay
09407-14403 Air vent hose
License plate lamp
Clutch cable Handle switch L/H
CABLE
Handle switch R/H
Front brake hose
09407-14403 09407-14403
Handle switch L/H
Clutch cable Throttle cable Starter cable
09407-14403
View P
Speedometer cable 09407-254A1 Throttle cable
Oil cooler 09407-14401 Rear brake switch Fuse assembly Battery lead wire Starter motor lead wire 09407-14403 09407-14403 Magneto Neutral switch Battery lead wire Clamp 09403H9304 Oil cooler Clutch cable
Engine
Volt
View E
09404-06401 Wiring horn 09497-11401 Oil cooler C.D.I Unit Throttle cable Starter motor lead wire Lead wire magneto Lead wire neutral switch 09404-06401 Frame Clutch cable Clamp Engine
View D
View A
Magneto cover
Engine sprocket cover
View B
Speedometer Indicator lamp Starter Front brake switch Horn Turnsignal relay Rectifier/Regulator Magneto C.D.I. Unit
Handle switch RH
WIRING DIAGRAM
Engine kill
Rear turnsignal, R
Front turnsignal, R
License plate
Head lamp Fuse(15A)
Tail & stop lamp
Front turnsignal,L
Rear turnsignal, L
Starter relay Lighting Ignition coil Spark plug Battery(MF) Engine earth Starter motor
Horn
Turnsignal
Dimmer
Handle switch LH Ignition switch Rear brake switch Gear position
WIRE COLOR Lg O R Sb W : Light green : Orange : Red : Light blue : White Y BG BW BR LW : Yellow : Black with Green tracer : Black with White tracer : Black with Red tracer : Blue with White tracer RB RW WB WR YB : Red with Black tracer : Red with White tracer : White with Black tracer : White with Red tracer : Yellow with Black tracer
B Br G Gr L
: Black : Brown : Green : Gray : Blue
Prepared by

Overseas Technical Department 1st Ed. Feb. 1999 Manual No. 99000-97100 Printed in Korea

Hyosung RX 125 Manual de Reparatie WWW - Manualedereparatie.info

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HYOSUNG MOTORS & MACHINERY INC.

HYOSUNG MOTORS & MACHINERY INC.

COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 1999

HOW TO USE THIS MANUAL

;;;; ;;;; ;;;;

Apply or use brake fluid.

Apply SUPER GREASEA .

Measure in voltage range.

Apply SUPER GREASEC .

Measure in resistance range.

Apply SILICONE GREASE.

Measure in current range.

Apply MOLY PASTE.

Use special tool.

1-1 GENERAL INFORMATION

WARNING / CAUTION / NOTE

NOTE: Indicates special information to make maintenance easier or instructions cleaner.

GENERAL INFORMATION 1-2

1-3 GENERAL INFORMATION

* Difference between photographs and actual motorcycles depends on the markets.

SERIAL NUMBER LOCATION

FUEL AND OIL RECOMMENDATION

GENERAL INFORMATION 1-4

FRONT FORK OIL

1-5 GENERAL INFORMATION

GENERAL INFORMATION 1-6

2-1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE CHART

PERIODIC MAINTENANCE 2-2

2-3 PERIODIC MAINTENANCE

How to charge Charge 20Hour as 0.7A Charge 5~10Hour as 0.7A No charge

PERIODIC MAINTENANCE 2-4

CYLINDER NUTS Tighten the two 10 mm nuts to the specified torque.

AIR CLEANER ELEMENT

2-5 PERIODIC MAINTENANCE

Non-flammable Cleaning solvent

Hyosung genuine oil

PERIODIC MAINTENANCE 2-6

Valve clearance specifications Valve clearance of IN. and EX. 0.08~0.13 mm

2-7 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-8

ENGINE OIL FILTER

OIL SUMP FILTER

2-9 PERIODIC MAINTENANCE

NOTE: Make this adjustment when the engine is hot.

PERIODIC MAINTENANCE 2-10

2-11 PERIODIC MAINTENANCE

HYOSUNG Brake fluid : 99000-07100

PERIODIC MAINTENANCE 2-12

2-13 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-14

FRONT FORK OIL

2-15 PERIODIC MAINTENANCE

CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

PERIODIC MAINTENANCE 2-16

COMPRESSION PRESSURE AND OIL PRESSURE

Oil pressure gauge : 09915-74510

ENGINE REMOVAL AND REMOUNTING