User manual HYOSUNG SENSE SD50 SERVICE REPAIR MANUAL

[. . . ] HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL SERVICE MANUAL 99000-91201 FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the SD-50. The SD-50 is a new type of motorcycle that has many technical features such as : ※ ※ ※ ※ V-belt drive automatic transmission Forced air-cooling system P. E Ignition system Electric starter system GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURE ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM 1 2 3 4 5 6 7 The SD-50 fits the needs of a wide variety of motorcycle users. Those who will be servicing this motorcycle should carefully review this manual before performing any repair or services. Major modification and changes incorporated later will be advised to HYOSUNG product distributor in each market. [. . . ] ④ ③ ① ⑤ ② ⑥ ① ③ ④ ② ⑥ ⑤ 3-25 ENGINE REAR AXLE SHAFT, BRAKE AND WHEEL ⑦ ⑨ ⑧ ⑤ ⑥ ② ③ ④ ①Rear axle shaft ②Rear brake cam ③Rear brake cam lever ④Rear brake cam lever bolt ⑤Rear brake shoe ⑥Brake shoe spring ⑦Rear wheel ⑧Rear wheel washer ⑨Rear wheel nut ① ● Install the rear axle shaft ① into the crankcase by tapping its end lightly. ● Apply engine oil on the left end of the rear axle shaft being inserted later in the reduction rear box cover. ① ● Apply grease lightly on the rear brake cam pivot part and install it to the crankcase. 99000-07000 Grease“G2” Brake cam ● Turn to position the cam where the punched mark on the end face is directed toward the axis of the rear axle shaft. Apply grease ENGINE 3-26 ● When installing the cam lever ④ to the cam, align the punched mark with the slit of cam lever. Punched mark Slit ④ ● Tighten the cam lever nut ⑤ to the specified torque. Tightening torque 6-9 N∙m (0. 6-0. 9 kg-m, 4. 5-6. 5 lb-ft) ⑤ ④ ● Install the brake shoes. ● Apply grease to the camshaft and pin before installing the brake shoes. 99000-07000 Grease“G2” CAUTION: Be careful not to apply too much grease to the camshaft and pin. If grease gets on the lining, brake effectiveness will be lost. ● Install the rear wheel and nut. Tightening torque 60-90 N∙m (6. 0-9. 0 kg-m, 43. 5-65. 0 lb-ft) 3-27 ENGINE TRANSMISSION ② ⑦ ⑩ ⑫ ⑮ ① ⑤ ⑨ ⑪ ④ ⑧ ⑭ ⑤ ① ② ⑥ ①Rear axle shaft ②Circlip ③Idle shaft ④Oil drain bolt ⑤Washer ⑥Final driven gear ⑦Circlip ⑧Driveshaft ⑨Washer ⑩Gasket ⑪Dowel pin ⑫Gear box cover ⑬Bearing ⑭Oil seal ⑮Oil level bolt Oil drain bolt ③ ⑧ ⑨ ⑭ ⑦ ⑬ ● Install the circlip ① on to the rear axle shaft ②. ● Assemble the idle shaft subassembly using the idle shaft ③ and thrust washer ④, then install the subsasembly on the gear box. ② ④ ③ ① ● Install the final driven gear ⑤ on the rear axle shaft using the circlip ⑥. Thrust ⑥ The center Circlip Rounded corner ⑤ ENGINE 3-28 ● Install the new bearing ⑦ to the gear box cover ⑧ with the special tool. 09913-70610 Bearing installer Special tool ⑦ ⑧ ● Apply grease to the lip of the oil seal ⑨ and install it to the gear box cover with the special tool. 99000-07000 09914-05210-005 Grease“G2” Bearing installer Oil seal Align face Special tool ⑨ ● Install the washer ⑩, new gasket and dowel pin ⑪. ⑫ ⑪ ⑪ ● Apply THREE BOND NO. 1215 at the hatched area shown in the illustration and install the gear box cover ⑬ on the crankcase. Hatched area 99000-31110 Three Bond No. 1215 ⑬ ● Tighten all the screws enenly one by one in a diagonal fashion. 3-29 ENGINE STARTER DRIVEN GEAR AND STARTER MOTOR ①Starter driven gear ②Starter motor ① ② ● Install the starter driven gear ① over the left crankshaft end. NOTE: The convex side of hub should face outside when installed in proper position. ① ● Install the starter motor ②. ② ENGINE 3-30 MOVABLE DRIVEN AND CLUTCH ③ ② ① ④ ⑨ ⑧ 그리스 ①Fixed driven face ②Bearing ③Circlip ④Needle roller bearing ⑤Movable driven face ⑥Oil seal ⑦Oil seal ⑧Spacer ⑨Pin ⑩O-ring ⑪Spring ⑫Clutch shoe assembly ⑬Clutch shoe nut ⑭Clutch housing ⑮Clutch housing nut V-velt ⑩ ⑦ ⑥ ⑤ ⑪ ⑫ ;; ;; ;; ;;;; ;;;; ⑬ ⑭ ⑮ ● Install the bearing ② in the fixed driven face ① with the special tool. 09943-88211 Bearing installer Special tool ② ① ● Install the circlip ③. ③ Thrust Rounded corner 3-31 ENGINE ● Install the bearing with the special tool. 09943-88210 Bearing installer Special tool ④ ● Install the new oil seals (⑤, ⑥) to the movable driven face with the special tool. 09913-76010 Bearing installer Oil seal Special tool ⑥ ⑤ ● Apply grease to the lip of oil seals and groove of inside of movable driven face. 99000-07000 Grease“G2” ● Install the movable driven ⑦ to the fixed driven face ⑧. NOTE: When reinstalling the movable face to the fixed face, make sure that the oil seal is positioned properly. ⑦ ⑧ ● Install the pin ⑨ at three places on the driven face hub. ⑩ Pin Spacer Grease ⑨ ● Install the movable driven face seat ⑪. ● Install the clutch shoe assembly ⑬ and nut ⑭. ⑭ ⑬ ⑫ ● Tighten the nut to the specified torque with the special tool. 09930-40113 Tightening torque Rotor holder 40-60 N∙m (4. 0-6. 0 kg-m, 29. 0-43. 5 lb-ft) Special tool ● Insert the V-belt between the driven faces as deep inside as possible while pulling the movable driven face all the way outside to provide the maximum belt clearance. CAUTION: The belt should be positioned so that the arrows on the belt periphery point the normal turning direction. The V-belt contact face on the driven faces should be thoroughly cleaned to be free from oil. ● Thoroughly clean the clutch housing ⑬ to be free from oil and position it over the clutch shoe assembly. ● Tighten the clutch housing nut ⑭ to the specified torque with the special tool. 09930-40113 Tightening torque Rotor holder 40-60 N∙m (4. 0-6. 0 kg-m, 29. 0-43. 5 lb-ft) ⑭ ⑬ Special tool 3-33 ENGINE MOVABLE DRIVE ⑥ ⑤ ④ ③ ② ①Movable drive face ②Roller ③Movable drive plate ④Damper ⑤O-ring ⑥Movable drive face cover ⑦Spacer ⑧Fixed drive face ⑨Kick starter driven nut ⑩Kick starter driven gear ⑪Spring ⑫Spacer ⑬E-ring ⑦ ① ⑧ ⑨ ⑪ ⑩ ⑫ ⑬ ● Install the roller ② to the movable drive face ①. [. . . ] 4. 8 L (1. 3/1. 1 US/lmp gal) Use APOLLOIL BIKE-K or HYPOL HS or an epuivalent good quality synthetic based 2-cycle oil. 1. 2 L (1. 2/1. 0 US/lmp qt) SAE 10W/40 80 ml (2. 7/2. 8 US/lmp oz) 90 ml (3. 0/3. 2 US/lmp oz) DOT4 NOTE 7-11 SERVICING INFORMA TION TROUBLESHOOTING ENGINE Complaint Engine does not start, or is hard to start. Worn or damaged bearings of drive shaft for rear axle shaft. Replace. Broken or damaged reed valve. SERVICING INFORMA TION 7-12 Complaint Engine runs poorly in highspeed range. [. . . ]