User manual HYOSUNG COMET 125 SERVICE MANUAL

[. . . ] HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL SERVICE MANUAL 99000-94710 FOREWORD This manual contains an introductory description on HYOSUNG GROUP INDEX GENERAL INFORMATION / and proce- 1 2 3 4 5 6 7 dures for its inspection/service and overhaul of its main components. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service. This manual has been prepared on the basis of the latest specification at the time of publication. [. . . ] Gear into the chain at the 3 arrow of intake sprocket that count the 16th of chain roller pin from the roller pin on the 2 arrow of exhaust sprocket to the intake camshaft. EX IN Exhaust 16Pin Intake CAUTION The rear cylinder gear into that count the 16th of chain roller pin from the 3 arrow of intake sprocket to the 2 arrow of exhaust sprocket. Notch mark Notch mark Install the 3 arrow punching mark of intake camshaft sprocket with the surface of cylinder head vertically. The camshaft sprocket use the intake and exhaust (the front and rear is different) in common, but use to distinguish according as installation with the camshaft. For example, Front exhaust : Camshaft exhaust + Front sprocket (Install the camshaft pin at the E marking hole. ) Rear intake : Camshaft intake + Rear sprocket (Install the camshaft pin at the RI marking hole. ) Pin installation Exhaust Intake [ Front Cylinder ] Exhaust Pin installation Intake [ Rear Cylinder ] 3-51 ENGINE CAUTION The cam chain is installed to the all of three sprocket. Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely. 16 Pin Notch mark Exhaust Intake [Front cylinder] 16 Pin Notch mark Exhaust Intake [Rear cylinder] NOTE The camshaft housing should be installed in the same manner with the front engine. ENGINE 3-52 Each camshaft housing is punched with A B C D. Put on the housing A to the A of head surface, the housing B to the B , the housing C to the C and the housing D to the D as that A B C D is punched also to the cylinder head upper surface. Fix the four camshaft bearing holder and cam chain guide by tightening of the bolt in order. Install each bolt diagonally by using the wrench pulling the shaft down. Tighten the bolt of each camshaft bearing holder with the same torque. CAUTION If get damaged the head or surface of camshaft bearing housing thrust, produce an result that the bearing housing not was tightened. Tighten the camshaft housing bolt with the specified torque. CAUTION The camshaft housing bolt is made of the special material. This bolt is superior at the degree of hardness more than the different high tension bolt. Pay special caution that the different type of bolt should not be used. Camshaft housing bolt : 8~12 N m(0. 8~1. 2 kg m) If turn the lock shaft handle in clockwise ( ) direction, the pushrod is inserted in. Turn the mechanial spring continually until the handle is turned to the end. Fix the adjuster into the cylinder block. Lock shaft handle 3-53 ENGINE Get out the pushrod for the front to turn the lock shaft handle in counter-clockwise ( ). Turn the crankshaft about 10 times counter-clockwise ( ) on the basis of the magneto rotor. If the valve clearance is within standard after measured the valve clearance, begin the next operation. If it is out of stanadard, adjust the valve clearance within standard limit after disassembled the camshaft and replaced the proper shim. Standard 0. 1~0. 2 mm 0. 2~0. 3 mm Adjust the valve clearance of rear cylinder with the same manner of the front cylinder. (Refer to page 2-3) CAUTION If you don t turn the crankshaft about 10 times before measured the valve clearance, there is no meaning in valve clearance. BOND 1215 Tighten the cylinder head cover bolts with the specified torque. Cylinder head cover bolt : 12~16 N m(1. 2~1. 6 kg m) ENGINE 3-54 SPARK PLUG Install the spark plug. (Refer to page 2-5) Install the rear cylinder head and cylinder with the same manner which installed the front cylinder head and cylinder. Rear Cylinder Front Cylinder GEAR POSITION SWITCH Install the spring and contact . Apply SUPER GREASE A to the O-ring and install the gear postion switch. SUPER GREASE A FUEL SYSTEM CONTENTS FUEL TANK / FUEL COCK FUEL PUMP CARBURETOR 4- 1 4- 2 4- 4 4 CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks. 4-1 FUEL SYSTEM FUEL TANK / FUEL COCK REMOVAL WARNING Gasoline is very explosive. (Refer to page 6-1) Remove the fuel tank mounting bolt, and take off the hooks. Disconnect the fuel hose and remove the fuel tank. Remove the fuel cock. FUEL SYSTEM 4-2 FUEL PUMP ( REMOVAL Remove the front seat and fuel tank. [. . . ] Brake caliper cylinder bore Brake caliper piston diam Brake fluid type Wheel runout Axial Radial Wheel axle runout Front Rear Wheel rim size Front Rear Tire tread depth Front Rear J17 MT3. 00 J17 MT4. 00 4. 6 (0. 18) 6. 3 (0. 25) Front Rear Front Rear Front Rear Front Rear Front Rear 12. 700 ~ 12. 743 (0. 5000 ~ 0. 5017) 12. 657 ~ 12. 684 (0. 4983 ~ 0. 4994) 25. 4 (1. 00) 25. 4 (1. 00) DOT3 or DOT4 4. 0 (0. 16) 4. 3 (0. 17) Unit : mm (in) LIMIT 3. 0 (0. 12) 3. 0 (0. 12) 0. 3 (0. 012) 2. 0 (0. 08) 2. 0 (0. 08) 0. 25 (0. 01) 0. 25 (0. 01) 1. 6 (0. 06) 1. 6 (0. 06) FUEL + OIL ITEM Fuel type SPECIFICATION Gasoline used should be graded 85~95 octane or higher. Including reserve Reserve Engine oil type Engine oil capacity 17 3 NOTE Fuel tank capacity API Over SG (SAE 10W/30 or 10W/40) Change Filter change Overhaul 1, 450 1, 500 1, 800 1, 450 1, 500 1, 650 Engine oil capacity Change Filter change Overhaul 7-23 SERVICING INFORMATION WIRE AND CABLE ROUTING HEAD LAMP RELAY TURN SIGLAL RELAY FUSE BOX 09407-22402 HARNESS 45280-35000 CABLE COMP. SEAT LOCK STARTER RELAY 09407-22402 HARNESS BATTERY PLUS 09407-22402 HARNESS REAR BRAKE S/W WELDING CLAMP L/WIRE STARTER MOTOR BATTERY MINUS C. D. I UNIT REGULATOR BATTERY MINUS ENGINE EARTH Rr. SPARK PLUG CAP 09407-22402 HARNESS DIODE HANDLE S/W RH 09407-22402 HARNESS 58300HM8102 CABLE ASS Y THROTTLE 09407-14408 HARNESS HANDLE S/W R. L HANDLE S/W LH CLUTCH LEVER S/W 58200HM8101 CABLE ASS Y. [. . . ]