S&T Motors Co., Ltd. - Hyosung

1 SERVICE MANUAL99000-95610 SERVICE MANUALS&T Motors Co., This manual contains an introductory description onHYOSUNG & and procedures for its inspection / service andoverhaul of its main covers the differences from Carbure type andplease refer to the service manual of (99000-95310) , & (99000HR8310) and &(99000-94710) for others which are not covered inthis information considered as generally known isnot GENERAL INFORMATION section tofamiliarize yourself with outline of the vehicle andMAINTENANCE and other sections to use as a guidefor proper inspection and manual will help you know the vehicle better sothat you can assure your customers of your optimumand quick service.

2 ELECTRICAL SYSTEMGROUP INDEX GENERAL INFORMATION 1 FI SYSTEM DIAGNOSISFUEL SYSTEM AND THROTTLE BODY4-24-15 SERVICING INFORMATION7 This manual has been prepared on the basisof the latest specification at the time modification has been made since then,difference may exist between the content ofthis manual and the actual vehicle. Illustrations in this manual are used to showthe basic principles of operation and workprocedures. They may not represent the actual vehicleexactly in manual is intended for those who haveenough knowledge and skills for servicingHYOSUNG vehicles. Without such knowledge andskills, you should not attempt servicing by relyingon this manual , please contact your nearby authorizedHYOSUNG motorcycle dealer.

3 COPYRIGHT S&T Motors Co., Ltd. 2 HOW TO USE THIS MANUALTO LOCATE WHAT YOU ARELOOKING FOR :1. The text of this manual is divided into As the title of these sections are listed on the previouspage as GROUP INDEX, select the section where you are look-ing Holding the manual as shown at the right will allow you to find the first page of the section On the first page of each section, its contents are listed. Findthe item and page you in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them THREAD LOCK 1324 .Apply or use brake in voltage in resistance in current special in continuity test control beside it indicates specified oil.

4 Use engine oil unless otherwise SUPER GREASE A .Apply SILICONE MOLY BOND 1215 .Use fork SUPER GREASE C .3 AABDC : After Bottom Dead CenterAC: Alternating CurrentAPI : American Petroleum InstituteATDC: After Top Dead CenterBBBDC : Before Bottom Dead CenterBDC: Bettom Dead CenterBTDC : Before Top Dead CenterDDC : Direct CurrentDOHC : Double Over Head CamshaftEECU: Engine Control Unit, FI Control UnitET Sensor: Engine Temperature Sensor(ETS)FFI: Fuel Injection, Fuel InjectorFP : Fuel PumpFPR: Fuel Pressure RegulatorGGP Switch: Gear Position SwitchIIAP Sensor : Intake Air Pressure Sensor (IAPS)IAT Sensor : Intake Air Temperature Sensor(IATS)IG : IgnitionISC Solenoid: Idle Speed Control SolenoidLLCD : Liquid Crystal DisplayLED : Light Emitting DiodeLH : Left HandMMax.

5 MaximumMin : MinimumOO2 Sensor: Oxygen Sensor (O2S)RRH : Right HandSSAE : Society of Automotive EngineersSAV Solenoid : Secondary Air Valve SolenoidTTDC: Top Dead CenterTO Sensor: Tip Over Sensor (TOS)ABBREVIATIONS USED IN THIS MANUAL4BL: Black with Blue tracer BBr : Black with Brown tracerBG : Black with Green tracer BO: Black with Orange tracerBR : Black with Red tracer BW : Black with White tracerBY : Black with Yellow tracer LB : Blue with Black tracerLG : Blue with Green tracer LR : Blue with Red tracerLW : Blue with White tracer LY : Blue with Yellow tracerBrB: Brown with Black tracer BrW : Brown with White tracerGB : Green with Black tracer GR : Green with Red tracerGY : Green with Yellow tracer GrB : Gray with Black tracerGrR : Gray with Red tracer GrW : Gray with White tracerOB : Orange with Black tracer OL: Orange with Blue tracerOG : Orange with Green tracer OR : Orange with Red tracerOW : Orange with White tracer OY : Orange with Yellow tracerRB : Red with Black tracerRW : Red with White tracer WB : White with Black tracerWL : White with Blue tracer WR : White with Red tracerYB : Yellow with Black tracer YL : Yellow with Blue tracerYG : Yellow with Green tracer YR : Yellow with Red tracerB : Black Gr : Gray Sb : Light blueL : Blue Lg : Light green W : WhiteBr : Brown O : OrangeY.

6 YellowG: Green R : RedWIRE COLOR5 GENERAL INFORMATION SPECIFICATIONS ( , & )..6 (1-8)CONTENTS 1 61-8 GENERAL INFORMATION2,270 mm ( in)800 mm ( in)1,090 mm ( in)1,500 mm ( in)155 mm ( in)170 kg (375 lbs)2,080 mm ( in)760 mm ( in)1,120 mm ( in)1,455 mm ( in)180 mm ( in) Overall lengthOverall widthOverall heightWheelbaseGround clearanceMassITEMSPECIFICATIONS ( , & ) DIMENSIONS AND MASSFour-stroke, DOHC, air-cooled and oil-cooledV-2 mm ( in) mm ( in)249 ( in3)Fuel InjectionElectric starterWet sump TypeNumber of cylinderBoreStrokePiston displacementFuel systemStarter systemLubrication systemITEM ENGINEWet multi-plate type5-speed constant mesh1-down, 4-up , 116 links 520HO, 112 links ClutchTransmissionGearshift patternFinal reductionGear ratio, 1st2nd3rd4th5thDrive chainITEM TRANSMISSION2,060 mm ( in)655 mm ( in)1,125 mm ( in)1,435 mm ( in)130 mm ( in)185 kg (408 lbs)7 GENERAL INFORMATION 1-9 NOTEThe specifications are subject to change without typeSwingarm type40 (right & left)33 135 mm ( in)Disk brakeDrum brake110/90 - 16 59S150/80 - 15M/C 70S120 mm ( in) 33 (right & left) 85 mm ( in)

7 Disk brake110/70 - 17 54H150/70 - 17 69H 27 (right & left) 90 mm ( in)Double disk brake Front suspensionRear suspensionSteering angleCasterTrailFront brakeRear brakeFront tire size Rear tire sizeFront fork strokeITEM CHASSISITEM 1,450 1,500 1,800 250 400 cc Fuel tankEngine oilFront fork oil capacity(One side)Oil changeOil and filter changeEngine overhaulITEM CAPACITIESI gnition typeIgnition timingSpark plugBatteryFuseHead lampTurn signal lampBrake / Tail lampLicense plate lampIllumination lampHigh beam indicator lampTurn signal indicator lamp(right & left)Neutral indicator lampFuel meter lamp FI (Fuel Injection) check lampECU13 at 2,000 rpm and30 at 6,000 rpmCR8E12 V 12 Ah (MF)30 A & 15 A12 V - H4 : 60 W 112 V - H4 : 55 W 112 V - W5 W 112 V - RY10 W 412 V - P21/5 W 112 V - W5 W 112 V - W 212 V - W 112 V - W 212 V - W 112 V - W 1 LED type LED typeLED typeLED typeLED typeLED type (Level type) 12 V - H1 : 55 W 112 V - H3 : 55 W 1 HILOP osition 89 PRECAUTIONS IN (4-1-1)FI SYSTEM TECHNICAL (4-1-5)SELF-DIAGNOSIS FUNCTION ( ).

8 20 (4-1-11)SELF-DIAGNOSIS FUNCTION ( )..22 (4-1-13)FI SYSTEM (4-1-15)CUSTOMER COMPLAINT (4-1-15)SELF-DIAGNOSTIC PROCEDURES ( )..26 (4-1-17)SELF-DIAGNOSIS RESET PROCEDURE ( )..26 (4-1-17)MALFUNCTION CODE AND DEFECTIVE (4-1-18) C15 ET SENSOR CIRCUIT (4-1-20) C17 oorr C18 IAP SENSOR CIRCUIT (4-1-22) C21 IAT SENSOR CIRCUIT (4-1-24) C22 OXYGEN SENSOR CIRCUIT (4-1-26) C24 oorr C25 IGNITION COIL (4-1-26) C27 ISC SOLENOID RANGE (4-1-27) C32 oorr C33 FUEL INJECTOR CIRCUIT (4-1-28) C37 SAV SOLENOID MALFUNCTION ..39 (4-1-30) C41 FUEL PUMP RELAY CIRCUIT (4-1-31) C43 OXYGEN SENSOR HEATER CIRCUIT (4-1-32) (4-1-33)4 -1FI SYSTEM DIAGNOSISCONTENTS 10 PRECAUTIONS IN SERVICINGWhen handling the component parts or servicing theFI system, observe the following points for the safetyof the system.

9 ELECTRICAL PARTS CONNECTOR / COUPLER When connecting a connector, be sure to push itin until a click is felt. With a lock type coupler, be sure to release thelock when disconnecting, and push it in fully till theworks when connecting it. When disconnecting the coupler, be sure to holdthe coupler body and do not pull the lead wires. Inspect each terminal on the connector / couplerfor looseness or bending. Inspect each terminal for corrosion terminals must be clean and free of anyforeign material which could impede properterminal contact. Inspect each lead wire circuit for poor connectionby shaking it by hand lightly. If any abnormalcondition is found, repair or replace.

10 When taking measurements at electricalconnectors using a tester probe, be sure to insertthe probe from the wire harness side (backside) ofthe connector / FI SYSTEM DIAGNOSIS11FI SYSTEM DIAGNOSIS 4-1-2 When connecting meter probe from the terminalside of the coupler (connection from harness sidenot being possible), use extra care not to forceand cause the male terminal to bend or the femaleterminal to the probe as shown to avoid opening offemale push in the probe where male terminal issupposed to fit. Check the male connector for bend and femaleconnector for excessive opening. Also check thecoupler for locking (looseness), corrosion, dust,etc. FUSE When a fuse blows, always investigate the causeto correct it and then replace the fuse.