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)