HYOSUNG GV125, GV125C User Manual
FIG 1-1
1
9
8
2
12
13
12
13
12
13
12
13
3
4
5
14
14
14
15
15
15
16
18
20
16
7
6
7
6
21 - 3
7
7
6
6
11
10
8
19
17
14
15
10
10
10
21 - 2
21 - 1
21 - 4
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 11110SG5107HPA HEAD ASS'Y, cylinder 1
2 11171HG510203P COVER, cylinder head 1
3 11173HG5100 GASKET,cylinder head cover NO.1 1
4 13120HG5105 PIPE COMP, intake rear 1
5 09402-44207 CLAMP, carburetor 1
6 09390-35001 C-RING, camshaft 4
7 09206-08001 PIN, camshaft housing knock 8
8 01517-06128 BOLT, oil galley(M6*12) 4
9 09168H06019 GASKET, oil falley boit 2
10 09103-06013 BOLT,camshaft housing 8
11 09482-00456 PLUG, spark CR8E 1
12 09109H07018 BOLT, cylinder head cover 4
13 09161H11008 WASHER, cyitnder head cover 4
14 09103H08306 BOLT, cylinder head L =130 4
15 09168-08021 GASKET, cylinder head bolt 4
16 09119H06002 BOLT, intake pipe 2
17 12782HG5100 GUIDE, camchain NO.2 1
18 09280H32006 O-RING, intake pipe 1
19 11178-17E00 GASKET, cylinder head cover NO.2 1
20 01421-06258 BOLT, cylinder head stud(M6*25) 3
21-1 11121-35C00PCH HOUSING,camshaft No.1 1
21-2 11122-35C00PCH HOUSING,camshaft No.2 1
21-3 11123-35C00PCH HOUSING,camshaft No.3 1
21-4 11124-35C00PCH HOUSING,camshaft No.4 1
FIG 1-1. CYLINDER HEAD/(REAR)
FIG 1-2
1
20
20
20
2
3
12
12
12
12
13
13
13
13
14
15
8
4
7
5
17
7
21 - 1
16
16
18
6
9
11
19
10
8
14
15
14
15
14
15
7
6
10
7
6
10
7
6
10
21 - 2
21 - 4
21 - 3
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 11110SG5107HPA HEAD ASS'Y, cylinder 1
2 11171HG510203P COVER, cylinder head 1
3 11173HG5100 GASKET,cylinder head cover NO.1 1
4 13110HG5107 PIPE COMP, intake front 1
5 09402-44207 CLAMP, carburetor 1
6 09390-35001 C-RING, camshaft 4
7 09206-08001 PIN, camshaft housing knock 8
8 01517-06128 BOLT, oil galley(M6*12) 4
9 09168H06019 GASKET, oil galley boit 2
10 09103-06013 BOLT,camshaft housing 8
11 09482-00456 PLUG, spark CR8E 1
12 09109H07018 BOLT, cylinder head cover 4
13 09161H11008 WASHER, cyitnder head cover 4
14 09103H08306 BOLT, cylinder head L =130 4
15 09168-08021 GASKET, cylinder head bolt 4
16 09119H06002 BOLT, intake pipe 2
17 12782HG5100 GUIDE, camchain NO.2 1
18 09280H32006 O-RING, intake pipe 1
19 11178-17E00 GASKET, cylinder head cover NO.2 1
20 01421-06258 BOLT, cylinder head stud(M6*25) 3
21-1 11121-35C00PCH HOUSING,camshaft No.1 1
21-2 11122-35C00PCH HOUSING,camshaft No.2 1
21-3 11123-35C00PCH HOUSING,camshaft No.3 1
21-4 11124-35C00PCH HOUSING,camshaft No.4 1
FIG 1-2. CYLINDER HEAD /(FRONT)
FIG 2
Rear
1
5
6
7
3
14
10
2
8
16
8
12
4
9
15
11
13
15
16
15
Front
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 11220HG5107PCY CYLINDER COMP, rear 1
2 11141HG5110 GASKET, cylinder head 1
3 11241HG5103 GASKET, cylinder rear 1
4 04213-11169 PIN, cylinder head knock rear 2
5 11210HG5107PCY CYLINDER COMP, front 1
6 11141HG5110 GASKET, cylinder head front 1
7 11241HG5103 GASKET, cylinder front 1
8 04213-11149 KNOCK PIN, cylinder rear 2
9 04213-11149 KNOCK PIN, cylinder front 2
10 04213-11169 PIN, cylinder head knock front 2
11 11251HG510003P FIN, cylinder front 1
12 07110-05168 BOLT, cylinder fin rear(M5*16) 2
13 11251HG510003P FIN, cylinder rear 1
14 07110-05168 BOLT, cylinder fin rear(M5*16) 2
15 08316-16068 NUT, cylinder head(M6) 10
16 01421-06258 BOLT, cylinder stud(M6*25) 4
FIG 2. CYLINDER / FRONT, REAR
FIG 3
1
2
6
11
4
8
7
12
5
3
9
10
7
15
16
17
18
18
18
16
14
13
12
12
15
16
6
19
11
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 16810HG5104 GRILLE, oil cooler NO.1 1
2 16820HG5103 GRILLE, oil cooler NO.2 1
3 16600HG5102 COOLER, oil 1
4 16460HG5120 HOSE COMP, oil cooler NO.1 1
5 16470HG5101 HOSE COMP, oil cooler NO.2 1
6 09360H12007 BOLT, oil cooler hose union NO.2 2
7 09360H10034 BOLT, oil cooler hose union NO.1 2
8 09116-06010 BOLT, oil cooler 2
9 09320-10015 CUSHION, oil cooler 2
10 09180-06030 SPACER, oil cooler 2
11 09168-14011 GASKET, oil cooler NO.2 4
12 09161-10009 GASKET, oil cooler NO.1 4
13 11280HG5101 PIPE COMP, oil front 1
14 11290HG5101 PIPE COMP, oil rear 1
15 09360H10034 UNION BOLT, oil pipe upper 2
16 09161-10009 GASKET, oil pipe upper 4
17 15331HG5101 UNION BOLT, oil pipe lower 1
18 09161-10009 GASKET, oil pipe lower 3
19 09320-08013 CUSHION 2
FIG 3. OIL COOLER
1
2
5
6
0
6
3
12
13
7
8
4
9
11
10
10
9
9
9
10
10
10
9
9
FIG 4
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
0 11300HG5100HPA CRANKCASE ASS'Y 1
1 11321HG5103PCC CRANKCASE COMP, L 1
2 11310HG5107PCC CRANKCASE COMP, R 1
3 09364-12001 UNION, breather hose 1
4 09103H10022 BOLT, frame & engine (L=110) 3
5 08319-31106 NUT, frame & engine(M10) 3
6 04213-13189 PIN, crankcase 2
7 11319-05200 PLATE, oil gallery plug 1
8 01107-06106 BOLT, oil gallery plug plate(M6*10) 1
9 01547-06558 BOLT, crankcase(M6*55) 6
10 01547-06808 BOLT, crankcase(M6*80) 5
11 02112-06908 SCREW, crankcase(M6*90) 1
12 09401-14301 CLIP, breather drain cap 1
13 13870H29B00 CAP COMP, breather drain 1
FIG 4. CRANK CASE
5
6
7
8
9
9
3
1
13
FIG 5
17
17
19
18
16
161616
16
16
10
2
4
11
12
15
14
11
11
11
11
20
21
23
23
25
24
22
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 11340HG5102HPA COVER COMP, clutch 1
2 11351HG51020BF COVER, magneto 1
3 11482HG5102 GASKET, clutch cover (NA) 1
4 11483HG5102 GASKET, magneto cover 1
5 09247-14026 PLUG, oil check 1
6 09168H14003 GASKET, oil check plug 1
7 09259-2000903P PLUG, eng oil filler 1
8 09280-17003 O-RING, eng oil filler plug 1
9 04213-13189 PIN, clutch cover knock 2
10 04213-09129 PIN, magneto cover kmock 1
11 01547-06308 BOLT, magneto cover(M6*30) 7
12 01547-06558 BOLT, magneto cover(M6*55) 2
13 09403H09304 CLAMP, clutch cable 1
14 09259-2601503P PLUG, crankshaft hole 1
15 09280-22008 O-RING, cramkshaft hole plug 1
16 01547-06258 BOLT, clutch cover(M6*25) 6
17 01547-06358 BOLT, clutch cover(M6*35) 2
18 01547-06608 BOLT, clutch cover(M6*60) 1
19 01547-06758 BOLT, clutch cover(M6*75) 1
20 09247H12102 PLUG, TDC 1
21 09168H12003 GASKET, TDC plug 1
22 11360HG5104 COVER COMP, engine sprocket 1
23 01547-06308 BOLT, engine sprocket cover(M6*30) 2
24 01547-06508 BOLT, engine sprocket cover(M6*50) 1
25 08321-31068 WASHER, ENGINE SPROCKET COVER 3
FIG5. CRANK CASE COVER
15
32
33
34
20
21
22
19
18
16
17
18
11
12
14
13
30
34
10
9
8
1
5
24
25
26
26
6
7
FIG 6
27
28
29
23
2
31
31
3
4
3
31
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 12200HG5100HPA CRANK SHAFT ASS'Y 1
2 12161HG5100 ROD, connecting 1
3 09263-28027 BEARING, crank pin 2
4 12210HG5100 PIN, crank 1
5 12221HG5106CSA CRANK SHAFT, R 1
6 12261HG5104CSA CRANK SHAFT, L 1
7
09262H350A600AO BEARING, crank shaft, L(35*72*17) 1
8
09262H350A600AO BEARING, crank shaft, R(35*72*17) 1
9 21111HG5100 GEAR, primary drive 1
10 21112-35C00 GEAR, primary drive NO.2 1
11 09421-04004 KEY, primary drive gear 1
12 21114-35C00 SPRING, primary drive gear 1
13 09166H16021 WASHER, primary drive gear thrust 1
14 09140-16019 NUT, primary drive gear 1
15 09282-12001 SEAL, crank shaft oil RH 1
16 12112HG5100PPS PISTON, rear 1
17 12151HG5102 PIN, piston 1
18 09381-13001 CIRCLIP, piston pin 2
20 12141HG5101 RING, piston 1st 1
21 12142HG5101 RING, piston 2nd 1
22 12144HG5101 RING, piston oil 1
23 12161HG5100 ROD, connecting 1
24 12111HG5106PPS PLSTON, front 1
25 12151HG5102 PIN, piston 1
26 09381-13001 CIRCLIP, piston pin 2
27 12141HG5101 RING, piston 1st 1
28 12142HG5101 RING, piston 2nd 1
29 12144HG5101 RING, piston oil 1
30 09166H16031 WASHER, primary drive gear lock 1
31 09160H28001 WASHER,connrod thrust 3
FIG 6. CRANK SHAFT
15
32
33
34
20
21
22
19
18
16
17
18
11
12
14
13
30
34
10
9
8
1
5
24
25
26
26
6
7
FIG 6
27
28
29
23
2
31
31
4
3
31
3
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
32 11342HG5100 JET 1
33 11343HG5100 RETAINER 1
34 02112-06106 SCREW(M6*10) 2
FIG 6. CRANK SHAFT
FWD
FIG.7
9
4
11
8
12
1
3
2
10
6
7
5
13
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 12611HG5100 GEAR, starter idle 1
2 12612HG5100 SHAFT, starter idle gear 1
3 09180-13006 SPACE, starter idle gear 1
4 12620HG5101 GEAR COMP, starter clutch 1
5 09261-10003 ROLLER, starter clutch 3
6 09440-03004 SPRING, starter clutch release push 3
7 12633-05300 PIECE, starter clutch release push 3
8 09263-22031 BEARING, starter clutch gear 1
9 09106-06030 BOLT, starter clutch(M8*16) 3
10 12649-05300 SHIM, starter clutch hub 1
11 12630-29B00 HUB COMP, starter clutch 1
12 12622HG5101 GEAR, starter clutch 1 NOT SALE
13 12621HG5100 RACE, starter clutch inner 1 NOT SALE
FIG 7. STARTER CLUTCH
2
2
1
7
18
3
3
17
4
4
5
5
6
6
6
6
2
2
8
8
9
9
10
10
10
10
11
11
11
11
12
12
12
12
13
13
13
13
14
14
14
14
15
15
15
15
16
16
16
16
FIG 8-1
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 12711HG5102888 CAMSHAFT, intake rear 1
2 09262-17019 BEARING, camshaft rear 4
3 12742HG5100 SPROCKET, camshaft rear 2
4 12747-44B00 WASHER, sprocket rear 2
5 09261-05005 PIN, sprocket rear 2
6 09111-06032 BOLT, sprocket rear 4
7 12731HG5102888 CAMSHAFT, exhaust rear 1
8 12911HG5101 VALVE, intake rear 4
9 12912HG5101 VALVE, exhaust rear 4
10 12921HG5101 SPRING, valve rear 8
11 12931HG5100 RETAINER,valve spring rear 8
12 12932HG5100 COTTER, valve rear 16
13 REFERENCES.EN.BAS.DE.PAGE
14 12881H03000001 TAPPET,rear 8
15 09289H04003 SEAL, valve stem oil rear 8
16 12933HG5100 SEAT, valve spring rear 8
17 12720HG5100HPA CAMSHAFT ASS'Y,rear intake 1
18 12750HG5100HPA CAMSHAFT ASS'Y,rear exhaust 1
FIG 8-1. CAM SHAFT REAR
2
2
1
7
3
3
4
4
5
5
6
6
6
6
2
2
9
9
8
8
10
10
10
10
11
11
11
11
12
12
12
12
13
13
13
13
14
14
14
14
15
15
15
15
16
16
16
16
FIG 8-2
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 12711HG5102888 CAMSHAFT, intake front 1
2 09262-17019 BEARING, camshaft front 4
3 12741HG5101 SPROCKET, camshaft front 2
4 12747-44B00 WASHER, sprocket front 2
5 09261-05005 PIN, sprocket front 2
6 09111-06032 BOLT, sprocket front 4
7 12731HG5102888 CAMSHAFT, exhaust front 1
8 12911HG5101 VALVE, intake front 4
9 12912HG5101 VALVE, exhaust front 4
10 12921HG5101 SPRING, valve front 8
11 12931HG5100 RETAINER, valve spring front 8
12 12932HG5100 COTTER, valve front 16
13 REFERENCES.EN.BAS.DE.PAGE
14 12881H03000001 TAPPET,front 8
15 09289H04003 SEAL, valve stem oil front 8
16 12933HG5100 SEAT, valve spring front 8
17 12710HG5100HPA CAMSHAFT ASS'Y, front intake 1
18 12730HG5100HPA CAMSHAFT ASS'Y,front exhaust 1
FIG 8-2. CAM SHAFT FRONT
1
2
3
4
5
6
8
8
7
9
FIG 9
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
1 12760HG5100 CHAIN COMP, camshaft drive 2
2 12771HG5100 GUIDE, camchain NO.1 2
3 12811HG5101 TENSIONER, camchain 2
4 08211-06181 WASHER, camchain tensioner bolt 2
5 12812H35C00 BOLT, camchain tensioner 2
6 12837H31321 GASKET, tensioner adjuster 2
7 12830H31320 ADJUSTER ASS'Y, tensioner 2
8 07110-06208 BOLT, tensioner adjuster(M6*20) 4
9 12839-38200 PLUG, adjuster 2
FIG 9. CAM CHAIN
FIG.10
0
47
81
46
48
38
35
16
17
39
49
50
73
74
37
75
45
23
75
79
76
77
76
57
55
58
79
78
45
47
23
53
49
49
74
73
727169
70
727169
70
34
44
54
56
4
3
22
30
29
27
64
63
62
59
51
51
66
41
67
19
20
52
65
42
61
28
25
21
6
92785
33
69785
26
60
24
30
29
28
25
24
26
27
64
63
59
62
61
60
4
3
43
12
11
80
32
14
13
15
33-2
68
40
1
80
80
10
33
12
32
14
13
15
33-1
11
36
10
18
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
0 13200HG5100 CARBURETOR ASS'Y 1
1 13301HG5100 MIXING BODY ASS'Y 1 NOT SALE
2 13302HG5100 MIXING BODY ASS'Y 1 NOT SALE
3 13303HG5100 THROTTLE VALVE 2 NOT SALE
4 13304HG5100 .SCREW 4
5 13305HG5100 .PLUG 2
6 13306HG5100 .O-RING 2
7 13307HG5100 .SPRING(CO) 2
8 13308HG5100 .ADJUSTER 2
9 13309HG5100 .WASHER 2
10 13310HG5100 .DIAPHRAGM COVER 2
11 13311HG5100 .SPRING(CO) 2
12 13312HG5100 .SCREW 2
13 13313HG5100 .RING 2
14 13314HG5100 .SPRING(CO) 2
15 13315HG5100 .E-RING 2
16 13316HG5100 .RING 1
17 13317HG5100 .SEAL 1
18 13318HG5100 .BOLT 2
19 13319HG5100 .RING 1
20 13320HG5100 .SPRING(CO) 1
21 13321HG5100 .PACKING 1
22 13322HG5100 .SHAFT ASS'Y 1
23 13323HG5100 .O-RING 1
24 13324HG5100 MAIN JET #82.5 2 NOT SALE
25 13326HG5100 .PACKING 2
26 13327HG5100 SCREW 2 NOT SALE
27 13328HG5100 .WASHER 2
28 13329HG5100 .SCREW 2
29 13330HG5100 .WASHER 2
FIG 10. CARBURETOR ASS'Y
FIG.10
0
47
81
46
48
38
35
16
17
39
49
50
73
74
37
75
45
23
75
79
76
77
76
57
55
58
79
78
45
47
23
53
49
49
74
73
727169
70
727169
70
34
44
54
56
4
3
22
30
29
27
64
63
62
59
51
51
66
41
67
19
20
52
65
42
61
28
25
21
6
92785
33
69785
26
60
24
30
29
28
25
24
26
27
64
63
59
62
61
60
4
3
43
12
11
80
32
14
13
15
33-2
68
40
1
80
80
10
33
12
32
14
13
15
33-1
11
36
10
18
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
30 13331HG5100 NEEDLE (AB)(NL) 2 NOT SALE
31-1 13333HG5100 .JET NEEDLE(JN) 1
31-2 13334HG5100 .JET NEEDLE(JN) 1
32 13337HG5100 .RING 2
33 13338HG5100 .DIAPHRAGM ASS'Y 2
34 13339HG5100 .PLATE 1
35 13340HG5100 .LEVER ASS'Y 1
36 13341HG5100 .BRACKET ASS'Y 1
37 13342HG5100 .NUT 1
38 13343HG5100 .WASHER 1
39 13344HG5100 .SPRING(CO) 1
40 13345HG5100 .SHAFT ASS'Y 1
41 13346HG5100 THROTTLE SHAFT ASS'Y 1 NOT SALE
42 13347HG5100 .STARTER LEVER 1
43 13348HG5100 .E-RING 1
44 13349HG5100 .BRACKET ASS'Y 1
45 13350HG5100 .SCREW 2
46 13351HG5100 .ADJUST SCREW ASS'Y 1
47 13352HG5100 .FLOAT BODY ASS'Y 2
48 13353HG5100 .BRACKET 1
49 13354HG5100 .SCREW 8
50 13355HG5100 .PLATE 1
51 13356HG5100 .O-RING 4
52 13357HG5100 .NIPPLE 1
53 13358HG5100 .HOSE 1
54 13359HG5100 .THROTTLE SHAFT 1
55 13360HG5100 .NIPPLE 1
56 13361HG5100 .SPRING(CO) 1
57 13362HG5100 .HOSE 1
58 13363HG5100 .HOSE 1
FIG 10. CARBURETOR ASS'Y
FIG.10
0
47
81
46
48
38
35
16
17
39
49
50
73
74
37
75
45
23
75
79
76
77
76
57
55
58
79
78
45
47
23
53
49
49
74
73
727169
70
727169
70
34
44
54
56
4
3
22
30
29
27
64
63
62
59
51
51
66
41
67
19
20
52
65
42
61
28
25
21
6
92785
33
69785
26
60
24
30
29
28
25
24
26
27
64
63
59
62
61
60
4
3
43
12
11
80
32
14
13
15
33-2
68
40
1
80
80
10
33
12
32
14
13
15
33-1
11
36
10
18
REF. PARTS NAME Q`TY REMARKS
NO. MEU01
59 13364HG5100 .JET(PAJ) 1
60 13365HG5100 JET(PJ) 2 NOT SALE
61 13366HG5100 .CAP 2
62 13367HG5100 .GUIDE HOLDER 2
63 13368HG5100 .SPRING(CO) 2
64 13369HG5100 .PLUNGER ASS'Y 2
65 13370HG5100 .SCREW 1
66 13371HG5100 .SPRING(CO) 1
67 13372HG5100 .SPRING(CO) 1
68 13373HG5100 .SCREW 1
69 13374HG5100 .FILTER 2
70 13375HG5100 NEEDLE VALVE ASS'Y(VS) 2 NOT SALE
71 13376HG5100 O-RING 2 NOT SALE
72 13377HG5100 .SCREW 2
73 13378HG5100 .PIN 2
74 13379HG5100 .FLOAT ASS'Y 2
75 13380HG5100 .SCREW 2
76 13381HG5100 .HOSE 2
77 13382HG5100 .NIPPLE 1
78 13383HG5100 .HOSE 1
79 13384HG5100 .CLIP 2
80 13385HG5100 .SCREW 6
81 13386HG5100 .SPRING(CO) 1
FIG 10. CARBURETOR ASS'Y
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