EasyManua.ls Logo

HYOSUNG GF125 User Manual

HYOSUNG GF125
180 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
SERVICE MANUAL
99000-94200
GF125
GF125

Table of Contents

Questions and Answers:

HYOSUNG GF125 Specifications

General IconGeneral
Fuel SystemCarburetor
Rear BrakeDrum
Seat Height780 mm
Width760 mm
Height1, 070 mm
Ground Clearance160 mm
Engine TypeAir cooled, 4 stroke, single cylinder
Transmission5-speed
Front SuspensionTelescopic fork
Front BrakeDisc
Rear SuspensionTwin shock absorbers

Summary

General Information

Serial Number Locations

Identifies the locations of the frame and engine serial numbers for registration and parts ordering.

Fuel and Oil Recommendations

Specifies the recommended octane rating for gasoline and the appropriate engine oil classification and viscosity.

Break-In Procedure

Provides guidelines for the initial period of motorcycle operation to ensure proper engine component seating and longevity.

Special Features

Highlights key improvements and unique aspects of the GF 125 model, focusing on engine performance and rider comfort.

Technical Features

Details the specific engineering aspects of the engine's cylinder head, piston, connecting rod, and cam chain.

Clutch Mission

Explains improvements to the primary gear ratio and clutch durability for enhanced driving performance.

Valve Train

Describes the valve angles, rocker arm, and overall valve train design for optimal power and efficiency.

Cam Shaft, Lock Arm and Valve

Details the materials and design features of the camshaft, lock arm, and valves for durability and performance.

Ignition System

Explains the operation and advantages of the new capacitor discharge ignition system for consistent timing.

Special Materials

Lists and describes specific materials and lubricants required for maintenance and repair procedures.

Precautions and General Instructions

Outlines essential safety precautions and general instructions to be followed during disassembly and reassembly.

Specifications

Provides detailed technical specifications for dimensions, mass, engine, transmission, and more.

Periodic Maintenance and Tune-Up Procedures

Periodic Maintenance Schedule

Lists recommended intervals for all periodic service work to maintain peak performance and economy.

Battery Maintenance

Details procedures for inspecting, checking electrolyte level, and maintaining the motorcycle battery.

Cylinder Head, Nuts, Bolts, and Exhaust Pipe

Covers tightening procedures for cylinder head nuts, cylinder nuts, and exhaust pipe bolts and nuts.

Air Cleaner Element

Provides instructions for cleaning the air cleaner element to maintain engine performance and fuel efficiency.

Valve Clearance Adjustment

Explains how to check and adjust valve clearance for optimal engine operation and to prevent damage.

Compression Pressure Check

Details the procedure for measuring cylinder compression pressure to diagnose engine health.

Spark Plug Maintenance

Covers spark plug inspection, cleaning, gap adjustment, and replacement recommendations.

Fuel Line Inspection

Instructs on inspecting the fuel line and connections for damage and fuel leakage.

Fuel Strainer Cleaning

Provides steps for cleaning the fuel strainer to ensure smooth fuel flow and prevent power loss.

Engine Oil Change

Details the procedure for changing the engine oil, including draining, refilling, and level checking.

Engine Oil Filter Replacement

Explains the process for replacing the engine oil filter to maintain lubrication system integrity.

Oil Pressure Check

Describes how to check the engine oil pressure to diagnose lubrication system issues.

Oil Sump Filter Cleaning

Provides instructions for cleaning the oil sump filter to remove foreign matter.

Carburetor Maintenance

Covers carburetor inspection, including idling adjustment and throttle cable play.

Clutch Adjustment

Explains how to inspect and adjust the clutch play for proper engagement and disengagement.

Drive Chain Maintenance

Details procedures for inspecting, checking slack, cleaning, and lubricating the drive chain.

Brake System Maintenance

Covers inspection of front brake fluid level, pads, and brake light switch.

Brake Fluid Air Bleeding

Explains the procedure for purging air from the front brake fluid circuit to restore braking performance.

Rear Brake Adjustments

Covers adjustments for rear brake pedal travel and inspection of brake lining wear.

Tire Inspection

Details inspection of tire tread depth and pressure for safe operation.

Steering System Inspection

Explains how to inspect steering stem bearings for proper adjustment and smooth handlebar movement.

Front Fork Oil Change

Provides instructions for changing the front fork oil, including draining and refilling.

Chassis and Engine Mounting Bolts

Lists tightening torques for various chassis and engine mounting bolts for safety and structural integrity.

Servicing Engine

Compression and Oil Pressure Checks

Details procedures for measuring engine compression and oil pressure to diagnose performance issues.

Engine Removal and Remounting

Step-by-step guide for safely removing and reinstalling the engine from the motorcycle frame.

Upper End Components Disassembly

Instructions for disassembling the engine's upper end components, including the cylinder head and camshaft.

Upper End Components Inspection and Servicing

Covers inspection and servicing procedures for camshaft holder, rocker arms, and valves.

Upper End Components Reassembly

Details the process for reassembling the engine's upper end components, including piston rings and cylinder.

Left Engine Disassembly

Step-by-step instructions for disassembling the left side of the engine, including the magneto rotor.

Right Engine Disassembly

Step-by-step instructions for disassembling the right side of the engine, including the clutch and engine sprocket.

Lower End Components Disassembly

Instructions for disassembling the engine's lower end components, focusing on the crankcase and transmission.

Lower End Components Inspection and Servicing

Covers inspection and servicing of crankshaft runout, conrod deflection, and big end side clearance.

Lower End Components Reassembly

Details the reassembly process for the engine's lower end components, including crankshaft and transmission.

Fuel and Lubrication System

Fuel Cock Maintenance

Covers removal, cleaning, and inspection of the fuel cock assembly to ensure proper fuel flow.

Carburetor Specifications

Lists detailed specifications for the carburetor, including jet sizes, float height, and idle speed.

Carburetor Removal, Disassembly, and Inspection

Provides step-by-step instructions for removing, disassembling, and inspecting the carburetor.

Accelerator Pump Servicing

Details the procedure for inspecting, cleaning, and adjusting the accelerator pump diaphragm and components.

Float and Needle Valve Inspection

Covers inspection of the float, needle valve, and valve seat for wear and proper function.

Carburetor Jet Servicing

Explains how to remove, clean, and inspect the carburetor jets for damage or clogging.

Carburetor Reassembly and Remounting

Provides instructions for reassembling and remounting the carburetor, including jet and screw installation.

Float Adjustment

Details the procedure for checking and adjusting the float height for correct fuel level in the carburetor.

Accelerator Pump Adjustment

Explains how to adjust the accelerator pump rod clearance after component replacement.

Pilot Screw Adjustment

Covers the procedure for adjusting the pilot screw to set the correct engine idle speed.

Lubrication System Overview

Illustrates the engine's lubrication system, showing oil flow paths to various components.

Electrical System

Ignition System Operation

Explains the capacitor discharged ignition system, its components, and how it generates a spark.

Magneto Inspection

Details how to measure resistance of magneto coils (pick-up, power source, charging) using a pocket tester.

CDI Unit Resistance Check

Provides a table and instructions for measuring resistance between CDI unit lead wires.

Ignition Coil Inspection

Covers checking the ignition coil for sparking performance and resistance.

Ignition Coil Resistance Values

Lists the primary and secondary resistance values for the ignition coil.

Spark Plug Checks

Covers cleaning, checking gap, and testing spark plug performance.

Charging System Overview

Illustrates the charging system circuit, including AC generator, regulator/rectifier, and battery.

Charging Output Check

Details how to measure DC voltage at the battery terminals to verify charging system output.

AC Generator No-Load Performance

Explains how to test AC generator performance by measuring AC voltage between lead wires.

Regulator/Rectifier Resistance Check

Provides a table for measuring resistance values of the regulator/rectifier using a pocket tester.

Starter System Operation

Describes the starter system components and how depressing the starter button activates the starter motor.

Starter Motor Removal and Disassembly

Step-by-step guide for removing and disassembling the starter motor for inspection or repair.

Starter Motor Inspection

Covers inspection of starter motor carbon brushes, commutator, and armature coil.

Starter Motor Reassembly

Details the process for reassembling the starter motor, including brush holder and housing alignment.

Starter Relay Inspection

Explains how to inspect the starter relay for continuity and coil resistance.

Speedometer Assembly Inspection

Covers inspection of the speedometer assembly for continuity between lead wires.

Lights System

Details the various lights on the motorcycle, including headlights and turn signals.

Head Light Servicing

Provides information on the headlight assembly and its components.

Turn Signal Light Maintenance

Covers inspection and replacement of turn signal lights.

Tail and Brake Light Maintenance

Covers inspection and replacement of tail and brake lights.

Switches Inspection

Details how to inspect various switches for continuity using a pocket tester.

Dimmer Switch Function

Explains the operation of the dimmer switch for controlling headlight beam.

Gear Position Indicator Light Switch

Covers inspection of the gear position indicator light switch.

Turn Signal Light Switch Operation

Explains the function and inspection of the turn signal light switch.

Horn Switch Function

Covers the operation and inspection of the horn switch.

Rear Brake Light Switch Function

Explains the operation and inspection of the rear brake light switch.

Neutral Indicator Light Switch

Covers the operation and inspection of the neutral indicator light switch.

Passing Switch Function

Explains the operation and inspection of the passing switch.

Battery Specifications

Provides technical specifications for the motorcycle battery, including type, capacity, and electrolyte S.G.

Battery Initial Charging

Details the procedure for filling electrolyte and the initial charging process for a new battery.

Battery Servicing and Recharging

Covers battery servicing, checking electrolyte level, and recharging based on specific gravity readings.

Battery Service Life

Provides information on battery service life, factors affecting it, and maintenance for long-term storage.

Chassis

Front Wheel Removal and Disassembly

Step-by-step guide for removing and disassembling the front wheel, including bearings and brake disc.

Front Fork Servicing

Covers removal, disassembly, inspection, and reassembly of the front fork assembly.

Steering Stem Maintenance

Details the removal, disassembly, inspection, and reassembly of the steering stem and bearings.

Front Brake System Maintenance

Covers the entire front brake system, including caliper, pads, disc, and master cylinder servicing.

Rear Wheel and Rear Brake Servicing

Provides procedures for removing, disassembling, inspecting, and reassembling the rear wheel and brake system.

Rear Swing Arm Maintenance

Details the removal, disassembly, inspection, and reassembly of the rear swing arm and related components.

Servicing Information

Troubleshooting Guide

A comprehensive guide to diagnosing and resolving common engine, electrical, and chassis problems.

Special Tools List

Lists all special tools required for performing maintenance and repair procedures on the motorcycle.

Tightening Torque Specifications

Provides essential torque values for various engine and chassis fasteners to ensure proper assembly and safety.

Tightening Torque Chart

A general chart for determining tightening torques based on bolt diameter and type.

Service Data Reference

Contains critical technical data and specifications for engine, transmission, and chassis components.

Wire and Cable Routing Guide

Illustrates the correct routing for all wires and cables to prevent damage and ensure proper function.

Wiring Diagram

A detailed schematic showing the electrical system connections, wire colors, and component layout.

Related product manuals