SERVICE MANUAL 49ccScoot Com

Service Manual 49ccscoot Com-Free PDF

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FOREWORD GROUP INDEX, This manual contains an introductory description on. HYOSUNG PRIMA SF 50 and procedures for its inspec GENERAL INFORMATION 1. tion service and overhaul of its main components, Other information considered as generally known is. not included,Read GENERAL INFORMATION section to familiarize. PERIODIC MAINTENANCE 2,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,FUEL SYSTEM 4,This manual has been prepared on the basis of. the latest specification at the time of publica,If modification has been made since then dif. ELECTRICAL SYSTEM 5,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,They may not represent the actual vehicle exactly.
SERVICING INFORMATION 7,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,HYOSUNG MOTORS MACHINERY INC. COPYRIGHT HYOSUNG MOTORS MACHINERY INC 1999,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. Listed in the table below are the symbols indicating instructions and other information necessary for servicing and. meaning associated with them respectively,SYMBOL DEFINITION SYMBOL DEFINITION.
Torque control required,Data beside it indicates Apply THREAD LOCK 1324. specified torque,Apply oil Use engine oil unless,Apply or use brake fluid. otherwise specified,Apply SUPER GREASE A Measure in voltage range. Apply SUPER GREASE C Measure in resistance range,Apply SILICONE GREASE Measure in current range. Apply MOLY PASTE Use special tool,Apply BOND 1215,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 6,1 1 GENERAL INFORMATION. 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, Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in vehicle damage. 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, 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. 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. 1 3 GENERAL INFORMATION,HYOSUNG PRIMA SF 50,RIGHT SIDE LEFT SIDE.
Difference between photographs and actual motorcycles depends on the markets. 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, 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. GENERAL INFORMATION 1 4,ENGINE OIL, Specification and classification APOLLOIL BIKE K HYPOL HS. BRAKE FLUID,Specification and classification DOT4, 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. 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,1 5 GENERAL INFORMATION,EXTERIOR ILLUSTRATION.
Head lamp Rear reflector Tail Brake lamp,Front Turnsignal Rear Turnsignal. GENERAL INFORMATION 1 6,SPECIFICATIONS,DIMENSIONS AND DRY MASS. Overall length 1 825 mm 71 9 in,Overall width 635 mm 25 0 in. Overall height 1 110 mm 43 7 in,Wheelbase 1 270 mm 50 0 in. Ground clearance 125 mm 4 9 in,Dry mass 88 kg 194 lbs.
Type Two stroke forced air cooled,Number of cylinder 1. Bore 41 mm 1 6 in,Stroke 37 4 mm 1 5 in,Piston displacement 49 3 0 cu in. Carburetor SIDE DRAFT VARIABLE VENTURI PISTON,Air cleaner Wet filter type. Starter system Kick self starter,Corrected compression ratio 7 4 1. Intake system Reed valve,TRANSMISSION,Clutch Dry shoe automatic centrifugal type.
Reduction ratio 2 997 0 813,Drive system V belt drive. Front suspension Telescopic type,Rear suspension Coil spring type. Trail 75mm 2 95in,Steering angle 45 right left,Front tire size 110 70 12 47J. Rear tire size 120 70 12 51J,Front brake Disc,Rear brake Drum. 1 7 GENERAL INFORMATION,ELECTRICAL,Ignition type CDI type.
Ignition timing 20 B T D C at 1 000 rpm,Spark plug BR8HSA. Battery 12V 3Ah 10HR,Generator Magneto,Headlamp 15W 2. Turn signal lamp 10W 4,Tail Brake lamp 5 10W,Speedometer lamp 1 7W 2. Oil level indicator lamp 1 7W,Turn signal indicator lamp 1 7W. CAPACITIES,Fuel tank 4 8,Engine oil tank 1 0,Transmission oil 110cc Replace.
130cc Overhaul, The specifications are subject to change without notice. PERIODIC MAINTENANCE,PERIODIC MAINTENANCE SCHEDULE 2 1 2. MAINTENANCE PROCEDURES 2 3,BATTERY 2 3,CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS 2 4. CYLINDER HEAD AND CYLINDER 2 4,SPARK PLUG 2 4,FUEL LINE 2 5. AIR CLEANER ELEMENT 2 5,THROTTLE CABLE PLAY 2 6,ENGINE IDLE SPEED 2 7.
OIL PUMP 2 7,TRANSMISSION OIL 2 8,BRAKES 2 8,TIRES 2 10. STEERING 2 11,FRONT SUSPENSION 2 11,REAR SUSPENSION 2 12. CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2 12,2 1 PERIODIC MAINTENANCE. PERIODIC MAINTENANCE SCHEDULE, The chart below lists the recommended intervals for all the required periodic service work necessary to keep the. motorcycle operating at peak performance and economy. More frequent servicing should be performed on motorcycles that are used under severe conditions. PERIODIC MAINTENANCE CHART, Initial 1 000 km Every 4 000 km Every 8 000 km page.
Battery Inspect Inspect 2 3,Cylinder head nuts,Inspect Inspect 2 4. exhaust pipe nuts,Cylinder head cylinder Clean 2 4. Spark plug Clean Clean Replace 2 4,Inspect Inspect. Fuel line 2 5,Replace every 4 years,Air cleaner element Clean every 3 000 km 2 5. Throttle cable play Inspect Inspect 2 6,Engine idle speed Inspect Inspect 2 7.
Oil pump Inspect Inspect 2 7,Transmission oil Inspect Inspect 2 8. Initial 1 000 km Every 4 000 km Every 8 000 km page. Brakes Inspect Inspect 2 9,Inspect Inspect,Brake hose 2 9. Replace every 4 years,Inspect Inspect,Brake fluid 2 9. Replace every 2 years,Tires Inspect Inspect 2 10,Steering Inspect Inspect 2 11. Front suspension Inspect Inspect 2 11,Rear suspension Inspect Inspect 2 12.
HYOSUNG motorcycle dealer COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 1999 HYOSUNG MOTORS amp 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

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