SERVICE MANUAL 99000-95610 SERVICE MANUAL

FOREWORD This manual contains an introductory description on HYOSUNG & and procedures for its inspection / service and overhaul of its main components. It covers the differences from Carbure type and please refer to the service manual of 『 (99000- 95310)』 , 『 & (99000HR8310)』and 『 & (99000- 94710)』 for others which are not covered in this manual. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service. ELECTRICAL SYSTEM GROUP INDEX GENERAL INFORMATION 1 FI SYSTEM DIAGNOSIS FUEL SYSTEM AND THROTTLE BODY 4-2 4-1 5 SERVICING INFORMATION 7 � 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. WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer. � COPYRIGHT S&T Motors Co., Ltd.

2 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previous page as GROUP INDEX, select the section where you are look- ing for. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. On the first page of each section, its contents are listed. Find the item and page you need. SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. Apply THREAD LOCK “1324” . Apply or use brake fluid. Measure in voltage range. Measure in resistance range. Measure in current range. Use special tool. Measure in continuity test range. Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply SUPER GREASE “A” . Apply SILICONE GREASE. Apply MOLY PASTE. Apply BOND “1215” . Use fork oil. DEFINITION SYMBOL DEFINITION SYMBOL Apply SUPER GREASE “C” .

3 A ABDC : After Bottom Dead Center AC : Alternating Current API : American Petroleum Institute ATDC : After Top Dead Center B BBDC : Before Bottom Dead Center BDC : Bettom Dead Center BTDC : Before Top Dead Center D DC : Direct Current DOHC : Double Over Head Camshaft E ECU : Engine Control Unit, FI Control Unit ET Sensor : Engine Temperature Sensor (ETS) F FI : Fuel Injection, Fuel Injector FP : Fuel Pump FPR : Fuel Pressure Regulator G GP Switch : Gear Position Switch I IAP Sensor : Intake Air Pressure Sensor (IAPS) IAT Sensor : Intake Air Temperature Sensor (IATS) IG : Ignition ISC Solenoid : Idle Speed Control Solenoid L LCD : Liquid Crystal Display LED : Light Emitting Diode LH : Left Hand M Max : Maximum Min : Minimum O O2 Sensor : Oxygen Sensor (O2S) R RH : Right Hand S SAE : Society of Automotive Engineers SAV Solenoid : Secondary Air Valve Solenoid T TDC : Top Dead Center TO Sensor : Tip Over Sensor (TOS) ABBREVIATIONS USED IN THIS MANUAL

4 BL : Black with Blue tracer BBr : Black with Brown tracer BG : Black with Green tracer BO : Black with Orange tracer BR : Black with Red tracer BW : Black with White tracer BY : Black with Yellow tracer LB : Blue with Black tracer LG : Blue with Green tracer LR : Blue with Red tracer LW : Blue with White tracer LY : Blue with Yellow tracer BrB : Brown with Black tracer BrW : Brown with White tracer GB : Green with Black tracer GR : Green with Red tracer GY : Green with Yellow tracer GrB : Gray with Black tracer GrR : Gray with Red tracer GrW : Gray with White tracer OB : Orange with Black tracer OL : Orange with Blue tracer OG : Orange with Green tracer OR : Orange with Red tracer OW : Orange with White tracer OY : Orange with Yellow tracer RB : Red with Black tracer RW : Red with White tracer WB : White with Black tracer WL : White with Blue tracer WR : White with Red tracer YB : Yellow with Black tracer YL : Yellow with Blue tracer YG : Yellow with Green tracer YR : Yellow with Red tracer B : Black Gr : Gray Sb : Light blue L : Blue Lg : Light green W : White Br : Brown O : Orange Y : Yellow G : Green R : Red WIRE COLOR

5 GENERAL INFORMATION SPECIFICATIONS ( , & ) …… 6 (1-8) CONTENTS 1

6 1-8 GENERAL INFORMATION 2,270 mm (89.4 in) 800 mm (31.5 in) 1,090 mm (42.9 in) 1,500 mm (59.1 in) 155 mm (6.1 in) 170 kg (375 lbs) 2,080 mm (81.9 in) 760 mm (29.9 in) 1,120 mm (44.1 in) 1,455 mm (57.3 in) 180 mm (7.1 in) ← Overall length Overall width Overall height Wheelbase Ground clearance Mass ITEM SPECIFICATIONS ( , & ) ◉ DIMENSIONS AND MASS Four-stroke, DOHC, air-cooled and oil-cooled V-2 cylinder 57.0 mm (2.24 in) 48.8 mm (1.92 in) 249 ㎤ (15.2 in 3 ) Fuel Injection Electric starter Wet sump ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Lubrication system ITEM ◉ ENGINE Wet multi-plate type 5-speed constant mesh 1-down, 4-up 3.290 2.460 1.560 1.190 0.960 0.840 520HO, 116 links ← ← ← ← ← ← ← ← ← 520HO, 112 links ← ← ← ← ← ← ← ← ← ← Clutch Transmission Gearshift pattern Final reduction Gear ratio, 1st 2nd 3rd 4th 5th Drive chain ITEM ◉ TRANSMISSION 2,060 mm (81.1 in) 655 mm (25.8 in) 1,125 mm (44.3 in) 1,435 mm (56.5 in) 130 mm (5.1 in) 185 kg (408 lbs)

7 GENERAL INFORMATION 1-9 NOTE The specifications are subject to change without notice. Telescopic type Swingarm type 40°(right & left) 33° 135 mm (5.32 in) Disk brake Drum brake 110/90 - 16 59S 150/80 - 15M/C 70S 120 mm (4.72 in) ← ← 33°(right & left) 25.5° 85 mm (3.35 in) ← Disk brake 110/70 - 17 54H 150/70 - 17 69H ← ← ← 27°(right & left) ← 90 mm (3.54 in) Double disk brake ← ← ← ← Front suspension Rear suspension Steering angle Caster Trail Front brake Rear brake Front tire size Rear tire size Front fork stroke ITEM ◉ CHASSIS ITEM ◉ ELECTRICAL 14.0 ℓ 1,450 ㎖ 1,500 ㎖ 1,800 ㎖ 250 cc 17.0 ℓ ← ← ← 400 ± 2.5 cc ← ← ← ← ← Fuel tank Engine oil Front fork oil capacity(One side) Oil change Oil and filter change Engine overhaul ITEM ◉ CAPACITIES Ignition type Ignition timing Spark plug Battery Fuse Head lamp Turn signal lamp Brake / Tail lamp License plate lamp Illumination lamp High beam indicator lamp Turn signal indicator lamp(right & left) Neutral indicator lamp Fuel meter lamp “FI”(Fuel Injection) check lamp ECU 13°B.T.D.C. at 2,000 rpm and 30°B.T.D.C. at 6,000 rpm CR8E 12 V 12 Ah (MF) 30 A & 15 A 12 V - H4 : 60 W ×1 12 V - H4 : 55 W ×1 12 V - W5 W ×1 12 V - RY10 W × 4 12 V - P21/5 W × 1 12 V - W5 W × 1 12 V - 1.7 W × 2 12 V - 1.7 W × 1 12 V - 1.7 W × 2 12 V - 1.7 W × 1 12 V - 1.7 W × 1 LED type ← ← ← ← ← ← ← ← ← ← ← LED type LED type LED type LED type LED type (Level type) ← ← ← ← ← ← 12 V - H1 : 55 W ×1 12 V - H3 : 55 W ×1 ← ← ← ← ← ← ← ← ← ← HI LO Position

9 PRECAUTIONS IN SERVICING ……………………………………… 10 (4-1-1) FI SYSTEM TECHNICAL FEATURES ……………………………… 14 (4-1-5) SELF-DIAGNOSIS FUNCTION ( ) ………………… 20 (4-1-11) SELF-DIAGNOSIS FUNCTION ( ) …………………… 22 (4-1-13) FI SYSTEM TROUBLESHOOTING ………………………………… 24 (4-1-15) CUSTOMER COMPLAINT ANALYSIS………………………………… 24 (4-1-15) SELF-DIAGNOSTIC PROCEDURES ( ) …………… 26 (4-1-17) SELF-DIAGNOSIS RESET PROCEDURE ( ) ……… 26 (4-1-17) MALFUNCTION CODE AND DEFECTIVE CONDITION …………… 27 (4-1-18) “C15 ” ET SENSOR CIRCUIT MALFUNCTION ……………………… 29 (4-1-20) “C17 ”or “C18 ” IAP SENSOR CIRCUIT MALFUNCTION …………… 31 (4-1-22) “C21 ” IAT SENSOR CIRCUIT MALFUNCTION ……………………… 33 (4-1-24) “C22 ” OXYGEN SENSOR CIRCUIT MALFUNCTION ……………… 35 (4-1-26) “C24 ”or “C25 ” IGNITION COIL MALFUNCTION …………………… 35 (4-1-26) “C27 ”ISC SOLENOID RANGE ABNORMAL ……………………… 36 (4-1-27) “C32 ”or “C33 ” FUEL INJECTOR CIRCUIT MALFUNCTION ……… 37 (4-1-28) “C37 ” SAV SOLENOID MALFUNCTION …………………………… 39 (4-1-30) “C41 ” FUEL PUMP RELAY CIRCUIT MALFUNCTION ……………… 40 (4-1-31) “C43 ” OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION …… 41 (4-1-32) SENSORS ………………………………………………………………… 42 (4-1-33) 4 -1 FI SYSTEM DIAGNOSIS CONTENTS