HYOSUNG GF125 User manual
HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
SERVICE MANUAL
99000-94200
GF125
GF125
FOREWORD
HYOSUNG MOTORS & MACHINERY INC.
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES 2
SERVICING ENGINE 3
FUEL AND LUBRICATION SYSTEM 4
ELECTRICAL SYSTEM 5
CHASSIS 6
SERVICING INFORMATION 7
GENERAL INFORMATION
SERIAL NUMBER LOCATIONS 1-1
FUEL AND OIL RECOMMENDATIONS 1-1
BREAK-IN PROCEDURE 1-1
SPECIAL FEATURES 1-2
SPECIAL MATERIALS 1-6
PRECAUTIONS AND GENERAL INSTRUCTIONS 1-8
SPECIFICATIONS 1-9
CONTENTS 1
1-1 GENERAL INFORMATION
SERIAL NUMBER LOCATIONS
BREAK-IN PROCEDURE
ENGINE OIL
FRONT-FORK OIL
FUEL AND OIL
RECOMMENDATIONS
FUEL
NOTE:
Unleaded and low-lead gasoline will extend spark
plug life.
GENERAL INFORMATION 1-2
SPECIAL FEATURES
GF 125
1. IMPROVEMENT OF ENGINE POWER AT MIDDLE AND LOW SPEEDS
2. LESS VIBRATION AND NOISE
3. COMFORTABLE SEATING
THE TECHINICAL FEATURES
1. CYLINDER HEAD
2. PISTON, CONNECTING ROD and CAM CHAIN
1-3 GENERAL INFORMATION
3. CLUTCH MISSION
4. VALVE TRAIN
5. CAM SHAFT, LOCK ARM and VALVE
GENERAL INFORMATION 1-4
IGNITION SYSTEM
DESCRIPTION
ADVANTAGES OF CAPACITOR DISCHARGE IGNITION SYSTEM
�
�
�
�
OPERATION
P1P2
D1C1
SCR
lg1lg2
1-5 GENERAL INFORMATION
P2
P2
N2N1
P2
P2P1
P1
P1
(B.T.D.C.)
P1
Θ1
Θ2
Θ2
Θ2
③
②
①
360�
GENERAL INFORMATION 1-6
SPECIAL MATERIALS
Material page page
partpart
● Oil seals
● Wheel bearing
● Speedometer gear box
● Steering stem steel balls
● Brake cam
● Mounting drum
● Dust seal cover and spacer
3-45
6- 4
6-34
6- 5
6-18
6-35
6-36
6-39
6-22
6-26
● Brake caliper holder
3-22
3-23
3-25
● Piston pin
● Valve stem
● Rocker arm shaft
3-45
6-10
● Mating surfaces of left
and right crankcase
● Front fork damper rod bolt
GREASE “G2”
99000-07000
SILICONE
GREASE
99000-25100
MOLY PASTE
99000-25140
THREE
BOND No. 1215
99000-31110
Sh
Sh
Al
v
n
i
a
a
ell
3
Indu
Indu
Multi-
Multi-
pur
pur
strial
strial
pose
pose
G reaseGrease
1215
LiquidGasketGray.
SolventlessSilicone&Sagtype.
Excellentheat&gasolineresistance.
LiquidG asket
White.
ThreeBondCo,.Ltd.
Madeinjapan
MOLYPASTE
LiquidGasketWhite.
SolventlessSilicone&Sagtype.
Excellentheatresistance.
M OLY P ASTE
1-7 GENERAL INFORMATION
Material page page
partpart
● 2nd drive gear
● Starter clutch allen bolt
3-42
3-51
6-10● Front fork damper rod bolts
3-42
3-47
3-48
5-2
3-51
5-11
● Countershaft bearing
retainer screws
● Gearshift cam guide
and pawl screws
● Engine oil pump
mounting screws
● Pick up coil screws
● Stator mounting screws
● Starter motor securing
screws
3-51● Magneto rotor nut
THREAD LOCK
CEMENT
99000-32040
THREAD LOCK
SUPER “1305”
99000-32100
THREAD LOCK
“1342”
99000-32050
THREAD LOCK
SUPER “1303B”
99000-32030
GENERAL INFORMATION 1-8
PRECAUTIONS AND GENERAL INSTRUCTIONS
WARNING ................ Personal safety of the rider is involved, and disregard of the information could
result in injury.
CAUTION ................. For the protection of the motorcycle, the instruction or rule must be strictly
adhered to.
NOTE ..................... Advice calculated to facilitate the repair of the motorcycle is given under
this heading.
USE OF GENUINE HYOSUNG PARTS
CAUTION:
Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and a new circlip
must be installed.
When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the
circlip over the shaft.
After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
HYOSUNG
GENUINE PARTS
1-9 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
ENGINE
TRANSMISSION
GENERAL INFORMATION 1-10
ELECTRICAL
CHASSIS
CAPACITIES
PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE………………………………………………… 2- 1
MAINTENANCE PROCEDURES ………………………………………………………… 2- 3
BATTERY ………………………………………………………………………… 2- 3
CYLINDER HEAD NUTS , CYLINDER NUTS, EXHASUST PIPE
BOLTS AND NUTS ……………………………………………………………… 2- 4
AIR CLEANER ELEMENT ………………………………………………………… 2- 5
VALVE CLEARANCE ……………………………………………………………… 2- 6
COMPRESSION PROSSURE ……………………………………………………… 2- 7
SPARK PLUG …………………………………………………………………… 2- 8
FUEL LINE ……………………………………………………………………… 2- 8
FUEL STRAINER ………………………………………………………………… 2- 8
ENGINE OIL ……………………………………………………………………… 2- 9
ENGINE OIL FILTER ……………………………………………………………… 2- 9
OIL PRESSURE …………………………………………………………………… 2- 9
OIL SUMP FILTER ……………………………………………………………… 2- 9
CARBURETOR …………………………………………………………………… 2-10
CLUTCH…………………………………………………………………………… 2-10
DRIVE CHAIN …………………………………………………………………… 2-11
BRAKES…………………………………………………………………………… 2-12
TIRES……………………………………………………………………………… 2-14
STEERING ………………………………………………………………………… 2-15
FRONT FORK OIL………………………………………………………………… 2-15
CHASSIS AND ENGINE BOLTS AND NUTS……………………………………… 2-16
CONTENTS
2
2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
ENGINE
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
CHASSIS
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2
LUBRICATION CHART
WARNING:
Be careful not to apply too much grease to the brake cam shaft. If greases gets on the linings, brake slip-
page will result.
2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
BATTERY
MAINTENANCE PROCEDURES
Inspect Initial 1,000km and Every 5,000km
WARNING:
When installing the battery lead wires, fix the lead first and
lead last
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4
CYLINDER NUTS
CYLINER HEAD NUTS, CYLINDER
NUTS, EXHAUST PIPE BOLTS AND
NUTS
Inspect Initial 1,000km and Every 5,000km
EXHAUST PIPE BOLTS AND
MUFFLER CLAMP BOLT
Tightening torque
CYLINDER HEAD NUTS
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