HYOSUNG Aquila GT250 R Ej, Service Manual

Page 1: ...n 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 ServiceManual GT 125 R GT 250 R Euro 2 karburatormodel Se også FI Service Manual for indsprøjtnings delene og GT 250 Naked for øvrige service information ...

Page 2: ...nts It covers the differences from and please refer to the service manual of 99000 94710 for others which are not covered in this manual This page numbers on the top are ones which are in the service manual of and ones on the bottom are the page numbers in this manual Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outli...

Page 3: ...2 NOTE Difference between photographs and actual motorcycles depends on the markets ...

Page 4: ...tem and page you need 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 Use engine coolant Torque control required Data beside it indicates sp...

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Page 6: ...5 GENERAL INFORMATION EXTERIOR ILLUSTRATION 6 1 6 SPECIFICATIONS 7 1 8 CONTENTS 1 ...

Page 7: ... 6 GENERAL INFORMATION 6 EXTERIOR ILLUSTRATION Rear reflector Turn signal lamp Rear Tail Brake lamp License plate lamp Head lamp Turn signal lamp Front Passenger footrests HEIGHT WIDTH WHEEL BASE LENGTH ...

Page 8: ... Bore Stroke Piston displacement Carburetor Starter system Lubrication system I T E M ENGINE Wet multi plate type 5 speed constant mesh 1 down 4 up 3 290 2 460 1 560 1 190 0 960 0 840 520HO 112 links 3 690 2 750 1 790 1 350 1 090 0 910 428HO 136 links Clutch Transmission Gearshift pattern Final reduction Gear ratio 1st 2nd 3rd 4th 5th Drive chain I T E M TRANSMISSION 81 1 in 25 8 in 44 3 in 56 5 i...

Page 9: ...t 6 000 rpm CR8E 12V 12Ah MF 15 A 12V H1 55W 1 12V H3 55W 1 12V 5W 1 12V 10W 4 12V 21 5W 1 12V 1 7W 2 12V 5W 1 VFD VFD VFD VFD Level type 13 B T D C at 2 000 rpm and 30 B T D C at 5 000 rpm Ignition type Ignition timing Spark plug Battery Fuse Head lamp Position lamp Turn signal lamp Brake Tail lamp Illumination lamp License plate lamp High beam indicator lamp Turn signal indicator lamp right left...

Page 10: ...9 MAINTENANCE PROCEDURES CARBURETOR 10 2 7 CLUTCH 11 2 8 1 CONTENTS 2 2 PERIODIC MAINTENANCE ...

Page 11: ...e and set its speed at anywhere 1 400 and 1 500 rpm by turning throttle stop screw 1 400 1 500 rpm Engine idle speed Engine tachometer 09900 26006 MAINTENANCE PROCEDURES CARBURETOR IDLE SPEED Inspect Interval Inspect Initial 1 000 km and Every 4 000 km NOTE Make this inspection when the engine is hot ...

Page 12: ...remove the 8mm wrench bolts and install the bolts to the desired position by using the hexagon wrench 6mm are delivered from the factory on position WARNING When adjusting the footrest position the 8mm wrench bolts be torqued to the proper specification If they are not the footrest can come off unexpectedly Footrest mounting bolt 22 35 N m 2 2 3 5 kgf m CLUTCH ...

Page 13: ...S OPTIONAL PARTS When the footrests in position exchange the gearshift link rod for appropriate riding position Position or Install the gearshift link rod Position Install the gearshift link rod Optional parts NOTE The gearshift link rod is optional parts ...

Page 14: ...13 LAMP 14 5 16 1 ELECTRICAL SYSTEM 5 CONTENTS ...

Page 15: ...CAL SYSTEM 5 16 1 14 REPLACEMENT OF HEAD LAMP BULB Remove the under cowling Refer to page 6 1 2 3 Remove the body cowling Refer to page 6 1 4 5 Remove the head lamp coupler Remove the dust cover LAMP HEAD LAMP ...

Page 16: ...5 Remove the socket spring Remove the bulb and replace the new bulb Remove the head lamp HI bulb with the same manner of the head lamp LOW bulb removal Reinstall the head lamp bulb in the reverse order of head lamp bulb removal ...

Page 17: ...r as shown in the illustration INSPECTION Using the pocket tester check the continuity between lead wires in the following illustration If the continuity measured incorrect replace the respective part Pocket tester 09900 25002 CAUTION When making this test it is not necessary to remove the combination meter ...

Page 18: ...17 5 17 2 ELECTRICAL SYSTEM ...

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Page 20: ...19 CHASSIS EXTERIOR PARTS 20 6 1 1 HANDLEBARS 25 6 12 1 STEERING 29 6 27 CONTENTS 6 ...

Page 21: ...n key Remove the rear carrier mounting bolts and separate the rear carrier INSTALLATION Reassemble the rear carrier in the reverse order of removal To reinstall the rear seat slide the seat hook into the seat hook retainer and push down firmly until the seat snaps into the locked position ...

Page 22: ...CHASSIS 6 1 2 21 UNDER COWLING Under cowling RH Under cowling LH Under center cowling Under center cowling grill ...

Page 23: ...6 1 3 CHASSIS 22 REMOVAL Remove the under cowling screws at the rightside Remove the under cowling screws at the leftside ...

Page 24: ...Y COWLING Windscreen Meter panel Body side cowling RH Body side cowling LH Body side cowling inner RH Body side cowling lower RH Body side cowling lower LH Air duct cowling RH Air duct cowling LH Body center lower cowling ...

Page 25: ... screw at the rightside Remove the body cowling screw at the leftside Remove the two cowling brace bolts Remove the speedometer lead wire and head lamp lead wire REMOUNTING Tighten the two cowling brace bolts Cowling brace bolt 22 35 N m 2 2 3 5 kg m ...

Page 26: ... brake lamp switch lead wires and remove the master cylinder Refer to the service manual 99000 94710 page 6 10 Remove the handlebar balancer and grip Handlebar composition RH Handlebar composition LH Rear view mirror assembly RH Rear view mirror assembly LH Handlebar switch assembly RH Handlebar switch assembly LH ...

Page 27: ... and grip Remove the clutch lever holder Loosen the handlebar clamp bolts right and left Remove the steering stem upper bracket by removing the steering stem head nut Loosen the front fork upper clamp bolt right and left NOTE Place the rags under the steering stem upper bracket to prevent scratching the body cowling ...

Page 28: ...lamp bolts right and left REMOUNTING Remount the handlebar in the reverse order of removal Pay attention to the following point Install the handlebars temporary Install the steering stem upper bracket Tighten the steering stem head nut Steering stem head nut 80 100 N m 8 0 10 0 kg m Front fork upper clamp bolts 22 35 N m 2 2 3 5 kg m Handlebar clamp bolt 22 35 N m 2 2 3 5 kg m ...

Page 29: ...he clutch lever holder align the holder s mating surface with punch mark on the handlebar When remounting the front brake master cylinder onto the handlebar align the master cylinder holder s mating surface with punch mark on the handlebar and tighten the upper clamp bolt first as shown Upper Upper WARNING Bleed air from the brake fluid circuit after assembling master cylinder Refer to the service...

Page 30: ...e under cowling and body cowling Refer to page 6 1 2 5 Take off the front wheel Refer to the service manual 99000 94710 page 6 2 Remove the four bolts and front fender Take off the front fork Refer to the service manual 99000 94710 page 6 14 STEERING ...

Page 31: ... steering stem nut and draw out the steering stem Take off the steering stem lower bracket Remove the upper and lower bearings CAUTION Hold the steering stem lower bracket by hand to prevent from falling Remove the outer race fitted on the steering stem This can be done with a chisel Draw out the two inner races fitted to the top and bottom ends of the head pipe ...

Page 32: ...d to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering stem nut INSPECTION Inspect and check the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear Abnormality operation of bearing Worn or damaged races Distortion of steering stem REASSEMBLY Reassemble and remount the steering stem in the...

Page 33: ...32 Tighten the handlebar clamp bolts right and left Handlebar clamp bolts 22 35 N m 2 2 3 5 kg m 6 29 2 CHASSIS ...

Page 34: ...33 SERVICING INFORMATION SERVICE DATA 34 7 20 WIRING DIAGRAM 35 7 31 CONTENTS 7 ...

Page 35: ...cator lamp Turn signal indicator lamp Right left High beam indicator lamp Fuel indicator lamp 5W 5W 21 5W Front 10W 2 Rear 10W 2 1 7W 2 VFD VFD VFD H1 55W H3 55W VFD ITEM SPECIFICATION HI LO Level type WATTAGE Unit W CAUTION Do not use except the specified bulb Wattage NOTE VFD Vacuum Fluorescent Display Head lamp SERVICE DATA ...

Page 36: ...er Br Brown O Orange BG Black with Green tracer RW Red with White tracer G Green R Red BW Black with White tracer WB White with Black tracer Gr Gray Sb Light blue BR Black with Red tracer WR White with Red tracer L Blue W White LW Blue with White tracer YB Yellow with Black tracer WIRING DIAGRAM ...

Page 37: ...Prepared by HYOSUNG MOTORS MACHINERY INC 1st Ed JUL 2006 Manual No 99000HR8310 Printed in Korea ...