User manual HYOSUNG COMET 250 SERVICE MANUAL

[. . . ] HYOSUNG MOTORS & MACHINERY INC. SERVICE MANUAL SERVICE MANUAL 99000-94710 FOREWORD This manual contains an introductory description on HYOSUNG GROUP INDEX GENERAL INFORMATION / and proce- 1 2 3 4 5 6 7 dures for its inspection/service and overhaul of its main components. 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. [. . . ] (Refer to page 6-1) Remove the fuel tank mounting bolt, and take off the hooks. Disconnect the fuel hose and remove the fuel tank. Remove the fuel cock. FUEL SYSTEM 4-2 FUEL PUMP ( REMOVAL Remove the front seat and fuel tank. Disconnect the fuel hoses Remove the fuel pump mounting bolts. Remove the fuel pump lead wire coupler . INSPECTION WARNING Gasolin is very explosive. Disconnect the fuel hose connect the suitable hose and insert the free end of the hose into a receptacle. Check the fuel flow when starting the engine for few seconds by pressing the starter switch. If the fuel flow is not found, check the fuel cock. If the fuel cock and hoses are not fault, replace the fuel pump. (Refer to page 5-21) REASSEMBLY Carry out the assembly procedure in the reverse order of disassembly. Connect the fuel pump lead wire coupler. FUEL HOSE ROUTING : Fuel hose (To fuel cock) Fuel hose (To carburetor) FUEL PUMP RELAY Remove the fuel pump relay mounting bolts and coupler. Disconnect the fuel hose and check the fuel flow when starting the engine for few seconds by pressing the starter switch. If the fuel pump are not fault, check the fuel pump relay. (Refer to page 5-21) 4-3 FUEL SYSTEM FUEL PUMP ( REMOVAL Remove the front seat and fuel tank. Disconnect the fuel hoses and vacuum hose INSPECTION WARNING Gasolin is very explosive. Disconnect the fuel hose , connect the suitable hose and insert the free end of the hose into a receptacle. Check the fuel flow when starting the engine for few seconds by pressing the starter switch. If the fuel flow is not found, check the fuel cock. If the fuel cock and hoses are not fault, replace the fuel pump. REASSEMBLY Carry out the assembly procedure in the reverse order of disassembly. Connect the fuel hoses and vacuum hose securely. FUEL HOSE ROUTING : Fuel hose (To fuel cock) Fuel hose (To carburetor) Vacuum hose (To intake pipe). FUEL SYSTEM 4-4 CARBURETOR 4-5 FUEL SYSTEM LOCATION OF CARBURETOR I. D. is stamped on the location on the carburetor as shown in the right photo. REMOVAL Remove the fuel tank. [. . . ] SPEEDOMETER 59266HM8100 CLAMP, BRAKE HOSE & SPEEDOMETER CABLE 59480HM8102 HOSE COMP. FRONT BRAKE FRONT IGNITION COIL VIEW A BATTERY MINUS 58410HM8102 CABLE COMP. STARTER 58200HM8101 CABLE ASS Y CLUTCH 09403H09304 CLUTCH CABLE WELDING CLAMP OIL COOLER HOSE RH 58300HM8102 CABLE ASS Y THROTTLE L/WIRE, STARTER MOTOR REAR BRAKE WELDING CLAMP L/WIRE STARTER MOTOR BATTERY MINUS Rr. BARKE S/W REAR BRAKE S/W 09404-06401 L/WIRE STARTER MOTOR STARTER MOTOR 09404-06401 L/WIRE STARTER MOTOR 09404-06401 L/WIRE STARTER MOTOR SERVICING INFORMATION 7-26 7-27 SERVICING INFORMATION WIRE AND CABLE ROUTING FUSE BOX TURN SIGLAL REALY BATTERY PLUS STARTER RELAY 09407-14408 HARNESS 09407-14408 HARNESS 45280-35000 CABLE COMP. [. . . ]