HYOSUNG Prima Bedienungsanleitung

SERVICE MANUAL

99000-91310

SERVICE MANUAL

HYOSUNG MOTORS & MACHINERY INC.

CHASSIS

ELECTRICAL SYSTEM

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

ENGINE 3

FUEL SYSTEM 4

SERVICING INFORMATION 7

* 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, dif-

ference 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 proce-

dures.

They may not represent the actual vehicle exactly

in detail.

* 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.

�COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 1999

HYOSUNG MOTORS & MACHINERY INC.

FOREWORD

This manual contains an introductory description on

HYOSUNG PRIMA(SF-50) and procedures for its inspec-

tion/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 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.

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 are listed on the previous

page as GROUP INDEX, select the section where what

you are looking for belong.

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: Rear wheel/Rear brake

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.

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”.

DEFINITIONSYMBOL DEFINITIONSYMBOL

Apply SUPER GREASE

“C”

GENERAL INFORMATION

INFORMATION LABELS 1-1

GENERAL PRECAUTIONS 1-1

SERIAL NUMBER LOCATION 1-3

FUEL AND OIL RECOMMENDATIONS 1-3

BREAK-IN PROCEDURES 1-4

EXTERIOR ILLUSTRATION 1-5

SPECIFICATIONS 1-6

CONTENTS

1-1 GENERAL INFORMATION

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions cleaner.

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 perform a

particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

CAUTION

WARNING

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 meanings. Pay special attention to the messages

highlighted by these signal words.

●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 wellventilated

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 or exhaust system during or for a while

after engine operation.

●After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for

leaks.

WARNING

Indicates a potential hazard that could result in death or injury.

GENERAL INFORMATION 1-2

●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 negative cable first and then positive cable. When reconnect-

ing the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the

positive terminal.

●When performing service to electrical parts, if the service procedures do not require use of bat-

tery power, diconnect the negative cable 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 left over material 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 seat-

ed 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.

●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.

CAUTION

HYOSUNG PRIMA (SF-50)

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the frame under the

footboard. The engine serial number is located on the up side of the crankcase assembly.

These numbers are required especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATION

FUEL

Gasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type is

recommended.

TRANSMISSION OIL

Make sure that the transmission oil you use comes under API

classification of SH, SG or SF and that its viscosity rating

is SAE 10W/30 or 10W/40. If an SAE 10W/30 or 10W/40 motor

oil is not available, select an alternate according to the right chart.

* Difference between photographs and actual motorcycles depends on the markets.

RIGHT SIDE LEFT SIDE

1-3 GENERAL INFORMATION

GENERAL INFORMATION 1-4

FRONT FORK OIL

Use fork oil : TELLUS #37

BREAK-IN PROCEDURES

During manufacture only the best possible materials are used and all machined parts are finished to a very high

standard but it is still necessary to allow the moving parts to“BREAK-IN”before subjecting the engine to maximum

stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its

early life. The general rules are as follows:

●Keep to these break-in engine speed limits:

Up to 1,000km(600miles): Less than 1/2 throttle.

●Upon reaching an odometer reading of 1,000 km you can subject the motorcycle to full throttle operation.

●Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the

throttle position.

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not

use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the sys-

tem, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.

WARNING

ENGINE OIL

Specification and classification: APOLLOIL BIKE-K, HYPOL HS

BRAKE FLUID

Specification and classification: DOT4

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