HYOSUNG Prima User manual

CHASSIS
ELECTRICAL SYSTEM
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FUEL SYSTEM 4
5
6
SERVICING INFORMATION 7
* This manual has been prepared on the basis of
the latest specification at the time of publica-
tion.
If modification has been made since then, dif-
ference 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 proce-
dures.
They may not represent the actual vehicle exactly
in detail.
* 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 HYOSUNG MOTORS & MACHINERY INC. 1999
HYOSUNG MOTORS & MACHINERY INC.
FOREWORD
This manual contains an introductory description on
HYOSUNG PRIMA(SF-50) and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read GENERAL INFORMATION section to familiarize
yourself with outline of the vehicle and MAINTE-
NANCE 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.

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 what
you are looking for belong.
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.
COMPONENT PARTS
Example: Rear wheel/Rear brake

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.
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”.
DEFINITIONSYMBOL DEFINITIONSYMBOL
Apply SUPER GREASE
“C”
.

GENERAL INFORMATION
INFORMATION LABELS 1-1
GENERAL PRECAUTIONS 1-1
SERIAL NUMBER LOCATION 1-3
FUEL AND OIL RECOMMENDATIONS 1-3
BREAK-IN PROCEDURES 1-4
EXTERIOR ILLUSTRATION 1-5
SPECIFICATIONS 1-6
CONTENTS
1

1-1 GENERAL INFORMATION
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions cleaner.
Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
CAUTION
WARNING
WARNING / CAUTION / NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages
highlighted by these signal words.
●Proper service and repair procedures are important for the safety of the service machanic and the safety
and reliability of the vehicle.
●When 2 or more persons work together, pay attention to the safety of each other.
●When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
●When working with toxic or flammable materials, make sure that the area you work in is wellventilated
and that you follow all off the material manufacturer’s instructions.
●Never use gasoline as a cleaning solvent.
●To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while
after engine operation.
●After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for
leaks.
WARNING
Indicates a potential hazard that could result in death or injury.

GENERAL INFORMATION 1-2
●If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
●When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and orientation.
●Be sure to use special tools when instructed.
●Make sure that all parts used in reassembly are clean, and also lubricated when specified.
●When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
●When removing the battery, disconnect the negative cable first and then positive cable. When reconnect-
ing the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the
positive terminal.
●When performing service to electrical parts, if the service procedures do not require use of bat-
tery power, diconnect the negative cable at the battery.
●Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to outside diagonally, to the specified tightening torque.
●Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and
certain other parts as specified, be sure to replace them with new ones. Also, before installing these new
parts, be sure to remove any left over material from the mating surfaces.
●Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seat-
ed in its groove and securely fitted.
●Do not use self-locking nuts a few times over.
●Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil
if a thread is smeared with them.
●After reassembly, check parts for tightness and operation.
●To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.
●To protect Earth’s natural resouces, properly dispose of used vehicles and parts.
CAUTION

HYOSUNG PRIMA (SF-50)
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the frame under the
footboard. The engine serial number is located on the up side of the crankcase assembly.
These numbers are required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL
Gasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type is
recommended.
TRANSMISSION OIL
Make sure that the transmission oil you use comes under API
classification of SH, SG or SF and that its viscosity rating
is SAE 10W/30 or 10W/40. If an SAE 10W/30 or 10W/40 motor
oil is not available, select an alternate according to the right chart.
* Difference between photographs and actual motorcycles depends on the markets.
RIGHT SIDE LEFT SIDE
1-3 GENERAL INFORMATION

GENERAL INFORMATION 1-4
FRONT FORK OIL
Use fork oil : TELLUS #37
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high
standard but it is still necessary to allow the moving parts to“BREAK-IN”before subjecting the engine to maximum
stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its
early life. The general rules are as follows:
●Keep to these break-in engine speed limits:
Up to 1,000km(600miles): Less than 1/2 throttle.
●Upon reaching an odometer reading of 1,000 km you can subject the motorcycle to full throttle operation.
●Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the
throttle position.
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not
use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the sys-
tem, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
WARNING
ENGINE OIL
Specification and classification: APOLLOIL BIKE-K, HYPOL HS
BRAKE FLUID
Specification and classification: DOT4

1-5 GENERAL INFORMATION
320
635
740
1,110
990
125
535
690
Head lamp Rear reflector Tail/Brake lamp
(Front)Turnsignal
lamp
(Rear)Turnsignal
lamp
600
710
1,825
135
1,270
350
EXTERIOR ILLUSTRATION

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length 1,825 mm (71.9 in)
Overall width 635 mm (25.0 in)
Overall height 1,110 mm (43.7 in)
Wheelbase 1,270 mm (50.0 in)
Ground clearance 125 mm (4.9 in)
Dry mass 88 kg (194 lbs)
ENGINE
Type Two-stroke, forced air cooled
Number of cylinder 1
Bore 41 mm (1.6 in)
Stroke 37.4 mm (1.5 in)
Piston displacement 49 ㎤(3.0 cu.in)
Carburetor SIDE DRAFT VARIABLE VENTURI (PISTON)
Air cleaner Wet filter type
Starter system Kick/self starter
Corrected compression ratio 7.4 : 1
Intake system Reed valve
TRANSMISSION
Clutch Dry shoe, automatic, centrifugal type
Reduction ratio 2.997~0.813
Drive system V-belt drive
CHASSIS
Front suspension Telescopic type
Rear suspension Coil spring type
Caster 25。
Trail 75mm (2.95in)
Steering angle 45。 (right & left)
Front tire size 110/70-12 47J
Rear tire size 120/70-12 51J
Front brake Disc
Rear brake Drum
GENERAL INFORMATION 1-6

ELECTRICAL
Ignition type “CDI”type
Ignition timing 20。B.T.D.C. at 1,000 rpm
Spark plug BR8HSA
Battery 12V 3Ah/10HR
Generator Magneto
Fuse 10A
Headlamp 15W×2
Turn signal lamp 10W×4
Tail/Brake lamp 5/10W
Speedometer lamp 1.7W×2
Oil level indicator lamp 1.7W
Turn signal indicator lamp 1.7W
CAPACITIES
Fuel tank 4.8ℓ
Engine oil tank 1.0ℓ
Transmission oil 110cc (Replace)
130cc (Overhaul)
1-7 GENERAL INFORMATION
NOTE:
The specifications are subject to change without notice.