2007-2012 Hyosung Ms3 125 250 Scooter Service & Repair Manual

ELECTRICAL SYSTEM COOLING SYSTEM GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FI SYSTEM DIAGNOSIS 4 FUEL SYSTEM AND THROTTLE BODY 5 6 7 CHASSIS 8 SERVICING INFORMATION 9 � COPYRIGHT S&T Motors Co., Ltd. FOREWORD This manual contains an introductory description on HYOSUNG and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiar- ize 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. 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. � This manual has been prepared on the basis of the latest specification at the time of publica- tion. 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. COPYRIGHTED

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 is listed on the previous page as GROUP INDEX, select the section where you are looking for. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. On the first page of each section, its contents are listed. Find the item and page you need. COMPONENT PARTS Example : Front wheel COPYRIGHTED

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. Use engine coolant. 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” . Measure in continuity test range. COPYRIGHTED

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 F FI : Fuel Injection, Fuel Injector FP : Fuel Pump 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) TP Sensor : Throttle Position Sensor (TPS) W WT Sensor : Water Temperature Sensor (WTS) ABBREVIATIONS USED IN THIS MANUAL COPYRIGHTED

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 COPYRIGHTED

NOTE Difference between photographs and actual motorcycles depends on the markets. COPYRIGHTED

GENERAL INFORMATION INFORMATION LABELS ………………………………………………… 1- 1 GENERAL PRECAUTIONS …………………………………………… 1- 2 SERIAL NUMBER LOCATION ………………………………………… 1- 3 FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS …… 1- 4 BREAK-IN PROCEDURES……………………………………………… 1- 6 EXTERIOR ILLUSTRATION …………………………………………… 1- 7 SPECIFICATIONS ………………………………………………………… 1- 8 CONTENTS 1 COPYRIGHTED

1-1 GENERAL INFORMATION 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 per- form a particular service operation, ask a more experienced mechanic for advice. 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 mean- ings. Pay special attention to the messages highlighted by these signal words. CAUTION Indicates a potential hazard that could result in vehicle damage. WARNING Indicates a potential hazard that could result in death or injury. NOTE Indicates special information to make maintenance easier or instructions cleaner. COPYRIGHTED

GENERAL INFORMATION 1-2 GENERAL PRECAUTIONS WARNING � Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle. � When 2 or more persons work together, pay attention to the safety of each other. � When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. � When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all off the material manufacturer’s instructions. � Never use gasoline as a cleaning solvent. � To avoid getting burned, do not touch the engine, engine oil, exhaust system or radiator during or for a while after engine operation. � After servicing fuel, oil, engine coolant, exhaust or brake systems, check all lines and fittings related to the system for leaks. WARNING � If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent. � When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. � Be sure to use special tools when instructed. � Make sure that all parts used in reassembly are clean, and also lubricated when specified. � When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. � When removing the battery, disconnect the � battery lead wire first and then the � battery lead wire. When reconnecting the battery, connect the � battery lead wire first and then the � battery lead wire. Finally, cover the � battery terminal with the terminal cover. � When performing service to electrical parts, if the service procedures do not require use of battery power, diconnect the � battery lead wire 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 material left over from the mating surfaces. � Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. � Do not use self-locking nuts a few times over. � Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil if a thread is smeared with them. � After reassembly, check parts for tightness and operation. WARNING � To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires. � To protect Earth’s natural resouces, properly dispose of used vehicles and parts. COPYRIGHTED

1-3 GENERAL INFORMATION SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right downside frame. The engine serial number is stamped on the left rearside of the crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts. ◉ FRAME SERIAL NUMBER ◉ ENGINE SERIAL NUMBER COPYRIGHTED

2007-2012 Hyosung Ms3 125 250 Scooter Service & Repair Manual

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