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HYOSUNG WOW90 User Manual

HYOSUNG WOW90
133 pages
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SERVICE MANUAL
99000-94310
SERVICE MANUAL
HYOSUNG MOTORS & MACHINERY INC.

Table of Contents

Questions and Answers:

HYOSUNG WOW90 Specifications

General IconGeneral
BrandHYOSUNG
ModelWOW90
CategoryOffroad Vehicle
LanguageEnglish

Summary

FOREWORD

GENERAL INFORMATION

INFORMATION LABELS

Information about labels on the vehicle.

GENERAL PRECAUTIONS

Important safety and handling precautions for servicing.

SERIAL NUMBER LOCATION

Location of frame and engine serial numbers.

FUEL AND OIL RECOMMENDATIONS

Recommended fuel and oil types and grades.

EXTERIOR ILLUSTRATION

Illustrations showing exterior views and dimensions.

SPECIFICATIONS

Technical specifications for engine, chassis, electrical, and capacities.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Schedule of recommended periodic service intervals for the vehicle.

PERIODIC MAINTENANCE CHART

Chart detailing maintenance items, intervals, and pages for service.

LUBRICATION POINTS

Identification of major lubrication points on the vehicle.

MAINTENANCE PROCEDURES

Step-by-step procedures for various maintenance tasks.

AIR CLEANER

Procedure for cleaning and maintaining the air cleaner element.

CYLINDER HEAD NUTS

Instructions for tightening cylinder head nuts to specified torque.

CYLINDER HEAD AND CYLINDER

Procedure for removing carbon deposits from cylinder head and cylinder.

SPARK PLUG

Inspection, cleaning, and replacement of the spark plug.

CARBURETOR

Maintenance procedures for the carburetor.

FUEL LINE

Inspection of the fuel line for leaks and replacement if necessary.

TRANSMISSION OIL

Procedure for changing the transmission oil and checking the oil level.

BRAKES

Inspection and adjustment procedures for front and rear brakes.

DRIVE CHAIN

Inspection, lubrication, and replacement of the drive chain.

TIRE

Inspection of tire pressure and tread condition.

STEERING

Inspection and adjustment of the steering system, including toe-in.

CHASSIS BOLTS AND NUTS

Checking chassis bolts and nuts for proper tightening.

ENGINE

ENGINE REMOVAL AND REINSTALLATION

Procedures for removing and reinstalling the engine assembly.

ENGINE DISASSEMBLY

Detailed steps for disassembling engine components.

ENGINE COMPONENTS INSPECTION AND SERVICING

Inspection and servicing of various engine parts.

BEARINGS

Inspection and servicing of engine bearings.

OIL SEALS

Inspection and servicing of engine oil seals.

CRANKSHAFT

Procedures for inspecting and servicing the crankshaft.

AUTOMATIC CLUTCH INSPECTION

Checks for proper operation of the automatic clutch system.

CYLINDER HEAD

Inspection and servicing of the cylinder head.

CYLINDER

Inspection and servicing of the cylinder.

PISTON

Inspection and servicing of the piston.

REED VALVE

Inspection and servicing of the reed valve.

ENGINE REASSEMBLY

Procedures for reassembling engine components after disassembly.

TRANSMISSION

Procedures for transmission assembly and related components.

MAGNETO

Installation of the magneto assembly.

FUEL SYSTEM

CARBURETOR

Procedures for carburetor removal, disassembly, inspection, and reassembly.

REASSEMBLY AND REMOUNTING

Steps for reassembling and remounting the carburetor.

FUEL TANK

Procedures for fuel tank removal, inspection, and remounting.

OIL PUMP

Procedures for air bleeding and checking the oil pump.

ELECTRICAL SYSTEM

IGNITION/CHARGING SYSTEM

Overview of the ignition and charging systems.

IGNITION COIL

Inspection of the ignition coil's primary and secondary resistance.

CDI UNIT

Resistance checks for the CDI unit.

STATOR COILS

Resistance checks for stator coils and charging output test.

REGULATOR/RECTIFIER

Resistance checks for the regulator/rectifier.

STARTER SYSTEM

Diagram and overview of the starter system components.

STARTING MOTOR REMOVAL AND DISASSEMBLY

Procedures for removing and disassembling the starting motor.

STARTING MOTOR INSPECTION

Inspection of carbon brushes and commutator of the starting motor.

STARTER RELAY INSPECTION

Inspection of the starter relay's resistance.

THERMOELEMENT

Inspection of the thermoelement's heating capability.

SWITCHES INSPECTION

Continuity checks for various switches.

BATTERY

Precautions and procedures for battery treatment, electrolyte handling, and recharging.

CHASSIS

FRONT WHEEL AND BRAKE

Procedures for front wheel and brake removal, inspection, and reassembly.

INSPECTION AND DISASSEMBLY

Inspection of wheel hub bearings and brake drum, disassembly steps.

REASSEMBLY AND REMOUNTING

Steps for reassembling and remounting the front wheel and brake.

STEERING AND FRONT SUSPENSION

Procedures for steering and front suspension removal, inspection, and reassembly.

REMOVAL AND DISASSEMBLY

Steps for removing and disassembling steering and front suspension components.

INSPECTION

Inspection of steering system parts like tie-rods and handlebar.

REASSEMBLY AND REMOUNTING

Steps for reassembling and remounting the steering system.

TOE-IN ADJUSTMENT

Procedure for adjusting the toe-in of the front wheels.

REAR WHEEL

Procedures for rear wheel removal, inspection, and remounting.

REAR BRAKE

Procedures for rear brake pad replacement and caliper disassembly/reassembly.

BRAKE PAD REPLACEMENT

Procedure for replacing rear brake pads.

CALIPER DISASSEMBLY

Steps for disassembling the rear brake caliper.

DISC PLATE INSPECTION

Inspection of the rear brake disc plate for wear and runout.

CALIPER REASSEMBLY

Steps for reassembling the rear brake caliper.

REAR AXLE HOUSING, AXLE SHAFT AND SHOCK ABSORBER

Procedures for removal, inspection, and reassembly of rear axle housing, shaft, and shock absorber.

INSPECTION AND DISASSEMBLY

Inspection of axle housing bearings and disassembly.

REASSEMBLY AND REMOUNTING

Steps for reassembling and remounting rear axle housing components.

SERVICING INFORMATION

TROUBLESHOOTING

Troubleshooting guide for common engine, electrical, and chassis issues.

SPECIAL TOOLS

List of special tools required for servicing, with part numbers and descriptions.

TIGHTENING TORQUE

Torque specifications for various engine and chassis fasteners.

SERVICE DATA

Technical data and specifications for engine and chassis components.

WIRE AND CABLE ROUTING

Diagrams showing the routing of wires and cables on the vehicle.

WIRING DIAGRAM

Electrical wiring diagram of the vehicle.

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