HYOSUNG Aquila 650 FI User manual

SERVICE MANUAL
99000-51310
SERVICE MANUAL
S&T Motors Co., Ltd.

FOREWORD
This manual contains an introductory description on
HYOSUNG &
and procedures for its inspection / service and
overhaul of its main components.
It covers the differences from Carbure type and
please refer to the service manual of

(99000 -
51210)
 ,  
(99000 -
94910)
 and  (99000
- 94810)

for others which are not covered in this manual.
Other information considered as generally known is
not included.
Read GENERAL INFORMATION section to
familiarize yourself with outline of the vehicle and
MAINTENANCE 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.
ELECTRICAL SYSTEM
GROUP INDEX
GENERAL INFORMATION 1
FI SYSTEM DIAGNOSIS
FUEL SYSTEM AND THROTTLE BODY
4-2
4-1
6
SERVICING INFORMATION 8
This manual has been prepared on the basis
of the latest specification at the time of
publication.
If modification has been made since then,
difference 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
procedures.
They may not represent the actual vehicle
exactly in detail.
WARNING
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 S&T Motors Co., Ltd.

2
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 you are look-
ing for.
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.
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.
Measure in continuity test range.
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.
Use fork oil.
DEFINITION
SYMBOL DEFINITIONSYMBOL
Apply SUPER GREASEC.

3
A
ABDC : After Bottom Dead Center
AC : Alternating Current
API : American Petroleum Institute
ATDC : After Top Dead Center
B
BBDC : Before Bottom Dead Center
BDC : Bettom Dead Center
BTDC : Before Top Dead Center
D
DC : Direct Current
DOHC : Double Over Head Camshaft
E
ECU : Engine Control Unit,
FI Control Unit
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
G
GP Switch : Gear Position Switch
I
IAP Sensor : Intake Air Pressure Sensor
(IAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
ISC Solenoid : Idle Speed Control Solenoid
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
LH : Left Hand
M
Max : Maximum
Min : Minimum
O
O2Sensor : Oxygen Sensor (O2S)
R
RH : Right Hand
S
SAE :
Society of Automotive Engineers
SAV Solenoid : Secondary Air Valve Solenoid
T
TDC : Top Dead Center
TO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
W
WT Sensor : Water Temperature Sensor
(WTS)
ABBREVIATIONS USED IN THIS MANUAL

4
BL : Black with Blue tracer BBr : Black with Brown tracer
BG : Black with Green tracer BO : Black with Orange tracer
BR : Black with Red tracer BW : Black with White tracer
BY : Black with Yellow tracer LB : Blue with Black tracer
LG : Blue with Green tracer LR : Blue with Red tracer
LW : Blue with White tracer LY : Blue with Yellow tracer
BrB : Brown with Black tracer BrW : Brown with White tracer
GB : Green with Black tracer GR : Green with Red tracer
GY : Green with Yellow tracer GrB : Gray with Black tracer
GrR : Gray with Red tracer GrW : Gray with White tracer
OB : Orange with Black tracer OL : Orange with Blue tracer
OG : Orange with Green tracer OR : Orange with Red tracer
OW : Orange with White tracer OY : Orange with Yellow tracer
RB : Red with Black tracer RW : Red with White tracer
WB : White with Black tracer WL : White with Blue tracer
WR : White with Red tracer YB : Yellow with Black tracer
YL : Yellow with Blue tracer YG : Yellow with Green tracer
YR : Yellow with Red tracer
B : Black Gr : Gray Sb : Light blue
L : Blue Lg : Light green W : White
Br : Brown O : Orange Y : Yellow
G : Green R : Red
WIRE COLOR

5
GENERAL INFORMATION
SPECIFICATIONS( & ) 6 (1-8-1)
SPECIFICATIONS( & )  8 (1-9-1)
CONTENTS
1

6
1-8-1 GENERAL INFORMATION
2,430 mm (95.7 in)
840 mm (33.1 in)
1,155 mm (45.5 in)
1,665 mm (65.6 in)
160 mm (6.3 in)
220 kg (485 lbs)
2,060 mm (81.1 in)
740 mm (29.1 in)
1,090 mm (42.9 in)
1,435 mm (56.5 in)
150 mm (5.9 in)
205 kg (451 lbs)
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Mass
ITEM
SPECIFICATIONS ( & )
DIMENSIONS AND MASS
Four-stroke, DOHC, Liquid-cooled
V-2 cylinder
81.5 mm (3.21 in)
62.0 mm (2.44 in)
647 (39.5 in3)
Fuel Injection
Electric starter
Wet sump








Type
Number of cylinder
Bore
Stroke
Piston displacement
Fuel system
Starter system
Lubrication system
ITEM
ENGINE
Wet multi-plate type
5-speed constant mesh
1-down, 4-up
2.79
2.46
1.78
1.38
1.13
0.96
-
Poly chain belt

6-speed constant mesh
1-down, 5-up
2.93
2.46
1.60
1.32
1.13
0.96
0.85
RK525XSO 108 links
Clutch
Transmission
Gearshift pattern
Final reduction
Gear ratio, 1st
2nd
3rd
4th
5th
6th
Drive belt / chain
ITEM
TRANSMISSION

Ignition type
Ignition timing
Spark plug
Battery
Fuse
Head lamp
Turn signal lamp
Brake / Tail lamp
Illumination lamp
License plate lamp
High beam indicator lamp
Turn signal indicator lamp(right & left)
Neutral indicator lamp
Fuel indicator lamp
Coolant temperature indicator lamp
“FI”(Fuel Injection) check lamp
Front suspension
Rear suspension
Steering angle
Caster
Trail
Front brake
Rear brake
Front tire size
Rear tire size
Front fork stroke


30(right & left)
25.5
85 mm (3.35 in)


120/60 - ZR 17 55W
160/60 - ZR 17 69W
120 mm (4.72 in)
Telescopic type
Swingarm type
35(right & left)
35
160 mm (6.3 in)
Double disk brake
Disk brake
120/70 - ZR 18 59W
180/55 - ZR 17 73W
130 mm (5.12 in)
7
GENERAL INFORMATION 1-8-2
NOTE
The specifications are subject to change without notice.
ITEM
CHASSIS
ECU
5B.T.D.C.at 1,500 rpm
CR8E
12 V 12 Ah (MF)
30 A
15 A
12 V - 60 W 1
12 V - 55 W 1
12 V - 10 W 4
LED type
-
12 V - 5 W 1
LED type
LED type
LED type
LED type (Level type)
LED type (Level type)
LED type






12 V - 60 W 1
12 V - 55 W 1
12 V - 10 W 4
12 V - 21 / 5 W 1
LED type
12 V - 5 W 1
LED type
LED type
LED type
LED type (Level type)
LED type (Level type)
LED type
ITEM
ELECTRICAL
Main
Head lamp
HI
LO
16.0 
3,000 
3,200 
3,400 
420 cc
17.0 



380 cc
Fuel tank
Engine oil, oil change
with filter change
overhaul
Front fork oil capacity(One side)
ITEM
CAPACITIES

8
1-9-1 GENERAL INFORMATION
2,060 mm (81.1 in)
740 mm (29.1 in)
1,125 mm (44.3 in)
1,435 mm (56.5 in)
150 mm (5.9 in)
215 kg (474 lbs)

655 mm (25.8 in)








130 mm (5.1 in)
220 kg (485 lbs)
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Mass
ITEM
SPECIFICATIONS ( & )
DIMENSIONS AND MASS
Four-stroke, DOHC, Liquid-cooled
V-2 cylinder
81.5 mm (3.21 in)
62.0 mm (2.44 in)
647  (39.5 in3)
Fuel Injection
Electric starter
Wet sump
















Type
Number of cylinder
Bore
Stroke
Piston displacement
Fuel system
Starter system
Lubrication system
ITEM
ENGINE
(Standard type)
(Standard type)
(Sport type)
(Sport type)
Wet multi-plate type
6-speed constant mesh
1-down, 5-up
2.93
2.46
1.60
1.32
1.13
0.96
0.85
RK525XSO 108 links






















Clutch
Transmission
Gearshift pattern
Final reduction
Gear ratio, 1st
2nd
3rd
4th
5th
6th
Drive chain
ITEM
TRANSMISSION
(Standard type) (Sport type)

Ignition type
Ignition timing
Spark plug
Battery
Fuse
Head lamp
Turn signal lamp
Brake / Tail lamp
Illumination lamp
License plate lamp
High beam indicator lamp
Turn signal indicator lamp(right & left)
Neutral indicator lamp
Fuel indicator lamp
Coolant temperature indicator lamp
“FI”(Fuel Injection) check lamp
9
GENERAL INFORMATION 1-9-2
NOTE
The specifications are subject to change without notice.
Telescopic type
Swingarm type
27(right & left)
25.5
74 mm (2.91 in)
Double disk brake
Disk brake
120/60 - ZR 17 55W
160/60 - ZR 17 69W
120 mm (4.72 in)




















Front suspension
Rear suspension
Steering angle
Caster
Trail
Front brake
Rear brake
Front tire size
Rear tire size
Front fork stroke
ITEM
CHASSIS
(Standard type) (Sport type)
ECU
5B.T.D.C.at 1,500 rpm
CR8E
12 V 12 Ah (MF)
30 A
15 A
12 V - H1 : 55 W 1
12 V - H3 : 55 W 1
12 V - 10 W 4
12 V - 21/5 W 1
LED type
12 V - 5 W 1
LED type
LED type
LED type
LED type (Level type)
LED type (Level type)
LED type




































ITEM
ELECTRICAL
(Standard type) (Sport type)
Main
Head lamp
HI
LO
17.0 
3,000 
3,200 
3,400 
380 cc










Fuel tank
Engine oil, oil change
with filter change
overhaul
Front fork oil capacity(One side)
ITEM
CAPACITIES
(Standard type) (Sport type)

10

11
PRECAUTIONS IN SERVICING  12 (4-1-1)
FI SYSTEM TECHNICAL FEATURES  16 (4-1-5)
SELF-DIAGNOSIS FUNCTION  22 (4-1-11)
FI SYSTEM TROUBLESHOOTING  25 (4-1-14)
CUSTOMER COMPLAINT ANALYSIS
 25 (4-1-14)
SELF-DIAGNOSTIC PROCEDURES
 27 (4-1-16)
SELF-DIAGNOSIS RESET PROCEDURE
 27 (4-1-16)
MALFUNCTION CODE AND DEFECTIVE CONDITION
 28 (4-1-17)
“ C12

PICK-UP COIL CIRCUIT MALFUNCTION  30 (4-1-19)

C14

TP SENSOR CIRCUIT MALFUNCTION  31 (4-1-20)

C15

WT SENSOR CIRCUIT MALFUNCTION  34 (4-1-23)

C17

C18

IAP SENSOR CIRCUIT MALFUNCTION  36 (4-1-25)

C21

IAT SENSOR CIRCUIT MALFUNCTION  38 (4-1-27)

C22

OXYGEN SENSOR CIRCUIT MALFUNCTION  40 (4-1-29)

C23

TO SENSOR CIRCUIT MALFUNCTION  41 (4-1-30)

C24

C25

IGNITION COIL MALFUNCTION  42 (4-1-31)

C31

GP SWITCH CIRCUIT MALFUNCTION  43 (4-1-32)

C32

C33

FUEL INJECTOR CIRCUIT MALFUNCTION  44 (4-1-33)

C41

FUEL PUMP RELAY CIRCUIT MALFUNCTION  46 (4-1-35)
SENSORS  47 (4-1-36)
4 -1
FI SYSTEM DIAGNOSIS
CONTENTS

12
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the
FI system, observe the following points for the safety
of the system.
ELECTRICAL PARTS
CONNECTOR / COUPLER
When connecting a connector, be sure to push it
in until a click is felt.
With a lock type coupler, be sure to release the
lock when disconnecting, and push it in fully till the
works when connecting it.
When disconnecting the coupler, be sure to hold
the coupler body and do not pull the lead wires.
Inspect each terminal on the connector / coupler
for looseness or bending.
Inspect each terminal for corrosion and
contamination.
The terminals must be clean and free of any
foreign material which could impede proper
terminal contact.
Inspect each lead wire circuit for poor connection
by shaking it by hand lightly. If any abnormal
condition is found, repair or replace.
When taking measurements at electrical
connectors using a tester probe, be sure to insert
the probe from the wire harness side (backside) of
the connector / coupler.
4-1-1 FI SYSTEM DIAGNOSIS

13
FI SYSTEM DIAGNOSIS 4-1-2
When connecting meter probe from the terminal
side of the coupler (connection from harness side
not being possible), use extra care not to force
and cause the male terminal to bend or the female
terminal to open.
Connect the probe as shown to avoid opening of
female terminal.
Never push in the probe where male terminal is
supposed to fit.
Check the male connector for bend and female
connector for excessive opening. Also check the
coupler for locking (looseness), corrosion, dust,
etc.
FUSE
When a fuse blows, always investigate the cause
to correct it and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use wire or any other substitute for the
fuse.
ECU / VARIOUS SENSORS
Since each component is a high-precision part,
great care should be taken not to apply any sharp
impacts during removal and installation.
Be careful not to touch the electrical terminals of
the ECU.
The static electricity from your body may damage
this part.

14
4-1-3 FI SYSTEM DIAGNOSIS
INCORRECT
When disconnecting and connecting the ECU,
make sure to turn “OFF” the ignition switch, or
electronic parts may get damaged.
Battery connection in reverse polarity is strictly
prohibited.
Such a wrong connection will damage the
components of the FI system instantly when
reverse power is applied.
Removing any battery terminal of a running
engine is strictly prohibited.
The moment such removal is made, damaging
counter electromotive force will be applied to the
ECU which may result in serious damage.
Before measuring voltage at each terminal, check
to make sure that battery voltage is 11V or higher.
Terminal voltage check at low battery voltage will
lead to erroneous diagnosis.

15
FI SYSTEM DIAGNOSIS 4-1-4
Never connect an ohmmeter to the ECU with its
coupler connected. If attempted, damage to ECU
or sensors may result.
Be sure to use a specified voltmeter / ohmmeter.
Otherwise, accurate measurements may not be
obtained and personal injury may result.
USING TESTERS
Use well-charged batteries in the tester.
Be sure to set the tester to the correct testing
range.
USING THE TESTER
Incorrectly connecting the and probes may
cause the inside of the tester to burnout.
If the voltage and current are not known, make
measurements using the highest range.
After using the tester, turn the power off.

16
4-1-5 FI SYSTEM DIAGNOSIS
FI SYSTEM TECHNICAL FEATURES
INJECTION TIME (INJECTION VOLUME)
The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of
intake air pressure, engine speed and throttle opening angle, and various compensations.
These compensations are determined according to the signals from various sensors that detect the engine and
driving conditions.
Intake Air Pressure Sensor
(IAP Sensor)
Intake air pressure signal
Basic
fuel
injection
time
Compensation
Ultimate
fuel
injection
time
Pick-up coil
Throttle Position Sensor
(TP Sensor)
Various Sensors
Injectors
Engine speed signal
Throttle opening signal
Various signals
Injection signal
ECU

17
FI SYSTEM DIAGNOSIS 4-1-6
COMPENSATION OF INJECTION TIME (VOLUME)
The following different signals are output from the respective sensors for compensation of the fuel injection time
(volume).
INJECTION STOP CONTROL
SIGNAL DESCRIPTION
WATER COOLANT TEMPERATURE
SENSOR SIGNAL
INTAKE AIR TEMPERATURE SENSOR
SIGNAL
BATTERY VOLTAGE SIGNAL
ENGINE RPM SIGNAL
STARTING SIGNAL
ACCELERATION SIGNAL /
DECELERATION SIGNAL
When engine coolant temperature is low, injection time (volume)
is increased.
When intake air temperature is low, injection time (volume) is
increased.
ECU operates on the battery voltage and at the same time, it
monitors the voltage signal for compensation of the fuel injection
time (volume). A longer injection time is needed to adjust
injection volume in the case of low voltage.
At high speed, the injection time (volume) is increased.
When starting engine, additional fuel is injected during cranking
engine.
During acceleration, the fuel injection time (volume) is increased
in accordance with the throttle opening speed and engine rpm.
During deceleration, the fuel injection time (volume) is
decreased.
SIGNAL DESCRIPTION
TIP OVER SENSOR SIGNAL
(FUEL CUT-OFF)
OVER-REV. LIMITER SIGNAL
When the motorcycle tips over, the tip over sensor sends a
signal to the ECU. Then, this signal cuts OFF current supplied to
the fuel pump, fuel injector and ignition coil.
The fuel injectors stop operation when engine rpm reaches rev.
limit rpm.

18
4-1-7 FISYSTEM DIAGNOSIS
FI SYSTEM PARTS LOCATION ( )
Speedometer
Fuel pump relay
Fuel injector, NO.1
TP sensor
IAT sensor
Fuel injector, NO.2
GP switch
Pick-up coil
Ignition coil, NO.1
EECCUU
3344
2266
55
77
88
99
11

19
FISYSTEM DIAGNOSIS 4-1-8
TO sensor
Ignition coil, NO.2
IAP sensor, NO.2
IAP sensor, NO.1
WT sensor
Oxygen sensor
EECCUU
1155
11221133
1111
1144
1100