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. Information of this manual is up-to-date at the time of issue. [. . . ] ⑪ ENGINE 3-32 ● Install the spring ⑫. ● 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. ① ② ● Mount the three dampers ④ on the movable drive plate ③ and install it on the movable drive face ⑤. ● Position the O-ring ⑥ on the movable drive face. ⑤ ③ ④ ④ ④ ⑥ ENGINE 3-34 ● Install the movable drive face cover ⑦. NOTE: Make sure that the movable drive plate is fully positioned inside, or the weight roller may come off. ⑦ Spacer ● Insert the spacer. ● Position the movable drive face subassembly on the crankshaft as shown in the photo. NOTE: Thoroughly clean the belt contact to be from oil. ● Install the fixed drive face ⑧. ● Tighten the nut ⑨ to the specified torque with the special tool. ⑧ 09910-20115 Tightening torque Conrod holder 40-60 N∙m (4. 0-6. 0 kg-m, 29. 0-43. 5 lb-ft) ⑨ ● Fill grease in the groove provided inside sliding surface of the kick driven gear and install it ⑩ on the end of the crankshaft. 99000-07000 ● Install the spring ⑪ and spacer ⑫. Grease“G2” ⑩ ⑫ ⑪ ⑬ ● Install the E-ring ⑬. Apply grease ⑩ ⑪ ⑫ ⑬ 3-35 ENGINE ● Continue turning the fixed drive face ⑭ by hand until the belt is seated in and both the drive and driven faces ⑮ will move together smoothly without slip. ● Fill the final gear box with engine oil up to the level hole. Oil Capacity 90 ml ⑭ ⑮ ● Tighten the oil level bolt to the specified torque. Tightening torque 9-15 N∙m (0. 9-1. 5 kg-m, 4. 5-11. 0 lb-ft) KICK STARTER ⑤ ⑧ ② ③ ④ ① ⑥ ⑦ ①Kick starter lever ②Kick starter shaft ③Kick starter shaft spring ④Circlip ⑤Crankcase cover LH ⑥Gasket ⑦Clutch cover ⑧Screw ● Apply grease lightly on the rolling surface and install it on the crankcase cover. 99000-07000 Grease“G2” ① ● Position the kick starter shaft return spring and hook the spring end on the crankcase cover boss ①. ● Install the dowel pin and crankcase cover ②. ② ENGINE 3-36 ● Install the clutch cover and kick starter lever ①. ① NOTE: Install the kick starter lever as shown in the illustration. 13 ● Tighten the kick starter lever bolt to the specified torque. 8-12 N∙m (0. 8-1. 2 kg-m, 6. 0-8. 5 lb-ft) Tightening torque PISTON ⑦ ⑤ ④ ⑥ ② Apply engine oil ① ⑧ ③ ⑦ ⑬ ⑪ ⑨ ⑩ ①Needle roller bearing ②Piston ③Piston ring ④1st ring ⑤2nd ring ⑥Expender ring ⑦Circlip ⑧Piston pin ⑨Cylinder gasket ⑩Cylinder ⑪Cylinder head gasket ⑫Cylinder head ⑬Cylinder head nut ⑫ 3-37 ENGINE ● Install the piston rings on the piston. ∙1st - Keystone ring ∙2nd - Rectangular ring Expander ring NOTE: Position the ring so that the marking is on upside. Locating pin ● It is extremely important that, when the piston is fed into the cylinder, each ring in place should be so positioned as to hug the locating pin as shown in the illustration. CORRECT INCORRECT ● Apply engine oil on the piston pin and install the piston to the conrod. NOTE: The arrow mark ① on the piston head should point the exhaust side. ① ● The circlip should be mounted in such a position ② that the mating ends of the circlip do not coincide with the groove portion of the piston. ● Apply engine oil on the piston and cylinder wall surfaces and install the cylinder over the piston carefully. ② Outside ● Tighten the cylinder head nut to the specification. Tightening torque 8-12 N∙m (0. 8-1. 2 kg-m, 6. 0-8. 5 lb-ft) ENGINE 3-38 OIL PUMP AND INTAKE ② ① Apply grease ①Oil pump driven gear ②Oil pump ● Apply grease to the oil pump driven gear ① and install it to the crankcase. 99000-07000 Grease“G2” ① ● Install the oil pump ② and tighten it to the specified torque. ② Tightening torque 3-5 N∙m (0. 3-0. 5 kg-m, 2. 0-3. 6 lb-ft) ● Install the gaskets (③, ④) and intake pipe ⑥ with reed valve ⑤ to the crankcase. ⑥ ④ ⑤ ③ 3-39 ENGINE MAGNETO ①Stator ②Key ③Magneto rotor ④Nut and washer ⑤Fan case ⑥Cooling fan ⑦Fan cover ④ ② ③ ① ⑤ ⑥ ⑦ ● Degrease the tapered portion of the crankshaft and also the magneto rotor. ● Install the rotor ③. ① ● Apply THREAD LOCK“1324”to the rotor nut ④ and tighten it to the specified torque with the special tool. [. . . ] Replace the battery, and correct the charging system. Cell plates have lost much of their active material as a result of over-charging. A short-circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte. The battery has been connected the wrong way round in the system, so that it is being charged in the reverse direction. [. . . ]