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GV250 Owner Manual
GV250 Owner Manual
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Motorcycle reliability and performance depend service procedures or precautions
on special care and restraint exercised during that must be followed to avoid damag-
the break-in period. It is especially important that
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ing the machine.
you avoid operating the engine in a manner
which could expose the engine parts to exces-
NOTE: This provides special information
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sive heat.
to make maintenance easier or impor-
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1
FOREWORD
THANK YOU for choosing Hyosung. We at All information, illustrations photographs and
Hyosung have designed, tested and produced specifications contained in this manual are
this motorcycle using the most modern tech- based on the latest product information avail-
nology available to provide you with many able at the time of publication. Due to improve-
happy, enjoyable, safe riding. Motorcycling is ments or other changes, there may be some
one of the most exhilarating sports and insure discrepancies in this manual. Hyosung reserves
your riding enjoyment, you should become the right to make changes at any time.
throughly familiar with the information pre-
sented in this Owner’s Manual before riding the Please note that this manual applies to all speci-
motorcycle. fications for all respective destinations and
explains all equipments. Therefore, your model
The proper care and maintenance that your may have different standard features than shown
motorcycle requires are outlined in this manual. in this manual.
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By following these instructions explicitly you will
insure a long trouble-free operating life for your
motorcycle. Your Hyosung dealer has experi-
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HYOSUNG MOTORS & MACHINERY INC.
enced technicians that are trained to provide Overseas Technical Department
your machine with the best possible service with
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the right tools and equipment. � COPYRIGHT HYOSUNG MOTORS & MACHINERY INC.
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TABLE OF CONTENTS
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IGNITION KEY TOOL
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INSTRUMENT PANEL BATTERY
LEFT HANDLE SWITCH AIR CLEANER
RIGHT HANDLE SWITCH FUEL HOSE
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5. BRAKE-IN 15 9. SPECIFICATIONS 41
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oscillations in the front end and lead to
CONSUMER INFORMATION instability problems. Accessories added to
the machine should be as light as possible
and kept to a minimum.
ACCESSORY INSTALLATION AND 4. The motorcycle may be affected by a lifting con-
PRECAUTION SAFETY TIPS dition or by an instability in cross winds or when
being passed or passing large vehicles.
There are a great variety of accessories available to
Improperly mounted or poorly designed acces-
Hyosung owners. Hyosung can not have direct
sories can result in an unsafe riding condition,
control over the quality or suitability of accessories
therefore caution should be used when selecting
you may wish to purchase except genuine parts.
and installing all accessories.
The addition of unsuitable accessories can lead to
5. Certain accessories displace the rider from his or
unsafe operating conditions. It is not possible for
her normal riding position. This limits the free-
Hyosung to test each accessory on the market or
dom of movement of the rider and may limit his
combinations of all the available accessories, how-
or her control ability.
ever, your dealer can assist you in selecting quality
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6. Additional electrical accessories may over
accessories and installing them correctly.
load the existing electrical system. Severe
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overloads may damage the wiring harness or
Use extreme caution when selecting and installing the
create a dangerous situation due to the loss
accessories for your Hyosung. We have developed
of electrical power during the operation of
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some general guidelines which will aid you when
the motorcycle.
deciding whether, and how to equip your motorcycle.
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mounts can allow the shifting of the weight the motorcycle and fasten it securely.
and create a dangerous, unstable condition.
2. Inspect for proper ground clearance and bank MODIFICATION
angle. An improperly mounted load could criti- Modification of the motorcycle, or removal of
cally reduce these two safety factors. Also original equipment may render the vehicle
determine that the“load”does not interfere unsafe or illegal.
with the operation of the suspension steering
or other control operations. SAFE RIDING RECOMMENDATION
3. Accessories fitted to the handlebars or the FOR MOTORCYCLE RIDERS
front fork area can create serious stability
Motorcycle riding is great fun and an exciting
problems. This extra weight will cause the
sport. Motorcycle riding also requires that some
motorcycle to be less responsive to your
extra precautions be taken to ensure the safety of
steering control. The weight may also cause the rider and passenger. These precautions are:
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◉ WEAR A HELMET
SERIAL NUMBER LOCATION
Motorcycle safety equipment starts with a quality
safety helmet. One of the most serious injuries
The frame and/or engine serial numbers are
that can happen is a head injury. ALWAYS wear
used to register the motorcycle. They are
a properly approved helmet. You should also
also to assist your dealer in terms of ordering
wear a suitable eye protection.
parts or referring to special service infor-
mation.
◉ RIDING APPAREL
Loose fancy clothing can be uncomfortable and
unsafe in terms of riding your motorcycle.
Choose good quality motorcycle riding apparel
in terms of riding your motorcycle.
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manual. Do not forget to perform an entire safety TE
inspection to ensure the safety of the rider and
its passenger.
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◉ FAMILIARIZE YOURSELF WITH THE
MOTORCYCLE
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NAMES OF EACH PARTS
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� Tools
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� Air cleaner
� Rear brake pedal
� Rear brake lamp switch
� Engine oil filter
Engine oil drain plug
Engine oil filler cap
Engine oil level lens
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CONTROLS INSTRUMENT PANEL
IGNITION SWITCH
KEY
① TRIP METER
The trip meter is a resettable odometer located
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in the speedometer assembly. It can be used to
The ignition switch has three positions: indicate the distance traveled on short trip or
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between fuel stops. Pressing control button will
◉“OFF”POSITION
return the meter to zero.
All electrical circuits are cut off.
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The engine will not start. The key can be removed.
② ODOMETER
The odometer registers the total distance that
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◉“ON”POSITION
The ignition circuit is completed and the engine the motorcycle has been ridden.
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position and turn it to the“LOCK”position after It indicates the remaining fuel amount in the fuel
come up again and remove the key. All electrical
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⑤ TACHOMETER ◉“ ” : The headlamp low beam and tail-
The tachometer indicates the engine speed in lamp come on.
revolutions per minute(r/min).
⑧ HIGH BEAM INDICATOR LAMP ◉“�”Position : Flash the left turn signal
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The high beam indicator lamp will come on TE lamp.
when the headlamp high beam is turned on.
◉“�”Position : Flash the right turn signal
lamp.
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LEFT HANDLE SWITCH
CAUTION
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② DIMMER SWITCH
Change direction of headlamp light.
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① FRONT BRAKE LEVER With the ignition switch in the“ON”position, the
The front brake is applied by squeezing the engine stop switch in the“ ”position, and the
brake lever gently toward the throttle grip. transmission is in neutral, pull in the clutch lever
Front brake be anxious about motorcycle falling and push the starter switch to start the engine.
down when braking suddenly as disk brake sys-
tem. The brake lamp will come on when the CAUTION
lever is squeezed.
Do not engage the starter motor for more
② THROTTLE GRIP than five seconds at a time as it may over-
Engine speed is controlled by position of the heat the wiring harness and starter motor.
throttle grip. Turn it toward you to increase If the engine does not start after several
engine speed. Turn it away from you to attempts, check the fuel supply and igni-
tion system. (Refer to Page 40)
decrease the engine speed.
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◉“ ”Position : Using when dangerous con-
dition of falling down during
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drive and others or engine
stop suddenly. The ignition
circuit is off. The engine
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cannot start or run.
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The headlamp, position lamp, meter lamp and firmly with the key in the cap lock.
taillamp come on. If not start engine, do not
come on. WARNING
◉“ ”position Fuel and fuel vapor are highly flammable
The position lamp, meter lamp and taillamp and toxic. You can be burned or poisoned
come on. when refueling.
● Stop the engine and keep flames,
◉“ ”position sparks and heat sources away.
The headlamp, meter lamp and taillamp go off. ● Refuel only outdoors or in a well venti-
lated area.
⑤ STARTER SWITCH ● Do not smoke.
● Wipe up spills immediately.
Use this switch to operate the starter motor.
● Avoid breathing fuel vapor.
● Keep children and pets away.
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CARBURETOR CHOKE LEVER
◉“OFF”Position
Turn the lever to the“OFF”position whenever
stopping the engine for more than a few min-
The carburetor is equipped with a choke system utes.
to provide easy starting when the engine is cold.
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When starting the cold engine, turn the choke TE
lever all the way toward you. The choke works
best when the throttle is in the closed position.
When the engine warm, you do not need to use
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the choke system for starting.
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CAUTION
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◉“ON”Position
The normal operating position for the fuel cock
lever is in the“ON”position.
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CAUTION
After switching the fuel cock lever to the
“ RES ”position, it is advisable that the
tank be refilled at the closest gas station.
After refueling be sure to move the fuel
cock to the“ON”position.
Depressing the rear brake pedal will apply the has a 5-speed transmission
rear brake. which operates as shown.
The brake lamp will be illuminated when the rear To shift properly, pull the clutch lever and close
brake is operated. the throttle at the same time you operate the
gearshift lever. Each time that a gear is select-
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ed, the gearshift lever will return to its normal
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position ready to select the next gear.
Lift the gearshift lever to upshift and depress the
lever to downshift.
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Neutual is located between first and 2nd gear.
When neutral is desired, depress or lift the lever
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attention surely to occure accident of When down-shifting, the engine speed should
vehicle falling down. be increased before the clutch is engaged.
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CAUTION
When the transmission is in neutral the
green indicator lamp on the instrument
panel will be lit.
However, even though the light is illumi-
nated, cautiously release the clutch lever
slowly to determine whether the transmis-
sion is positively in neutral.
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STAND WARNING
Riding with the side stand incompletely
retracted can result in an accident when
you turn left.
SEAT LOCK
① Side stand
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is equipped with the side stand
ignition interlock system.
1. If the transmission is in neutral, you can start
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the engine regardless of clutch lever and side
stand.
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2. If the transmission is not in neutral, you can
only start the engine with pulling in clutch lever
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4 REAR SUSPENSION
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NOTE:
Neutral - Neutral switch (1)
Clutch - Clutch lever
- On or UP. (2)
- Off or Down
CAUTION
Before starting off, check that the side
stand is returned to fully upper position
and is not hanging down.
(1) Rear shock absorber (2) Pin spanner
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To adjust the spring pre-load, turn the adjuster ★ ENGINE OIL
clockwise or counter-clockwise to the desired
position with the pin spanner.
■ ENGINE OIL SPECIFICATION
Position 1 provides the softest spring pre-load Classification
and position 5 provides the stiffest. Grade Remarks
system
is delivered from the factory
API SF or SG
with its adjuster set on position 1.
SAE 10 W - 40
WARNING ※ If a SAE 10 W - 40 motor oil is not available,
Unequal suspension adjustment can select and alternative according to the follow-
cause poor handling and loss of stability. ing chart.
Adjust the right and left shock absorber
to the same settings. 20W50
15W40 15W50
ENGINE OIL
10W40 10W50
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℃ -30 -20 -10 0 10 20 30 40
FUEL AND OIL RECOMMENDA- Temperature
℉ -22 -4 14 32 50 68 86 104
TION
Using a premium quality four stroke motor oil will
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★ FUEL increase the service life of your motorcycle.
Use unleaded gasoline with an octane rating of
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91 or higher. WARNING
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Unleaded gasoline can extend spark plug life ● Don’t mix the unrecommended oil. It
and exhaust components life. could damage the engine.
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faces.
Be careful not to spill any fuel when filling disturb the oil to be provided and dam-
age the engine.
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WARNING
BREAK-IN
● When refueling, always shut the engine
off and turn the ignition key to the
“OFF”position. Never refuel near the The opening explains how important proper
flames, sparks and heat sources. break-in is to achieve maximum life and perfor-
● Do not overfill the fuel tank. Do not fill the
mance from your new Hyosung. The following
fuel tank above the entrance lower end.
guidelines explain proper break-in procedures.
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★ MAXIMUM THROTTLE OPENING REC-
OMMENDATIONS
WARNING
Failure to perform break-in of the tires
The table below shows the maximum throttle
could cause tire slip and loss of control.
opening recommendation during the break-in Use extra care when riding on new tire.
period. Perform proper break-in of the tire as
described in this section and avoid hard
Initial 800km (500miles) Less than 1/2 throttle acceleration, hard cornering, and hard
braking for the first 160km(100miles).
Up to 1,600km (1,000miles) Less than 3/4 throttle
★ ALLOW THE ENGINE OIL TO CIRCU-
LATE BEFORE RIDING
★ AVOID CONSTANT LOW SPEED
Allow sufficient idling time after warm or cold
Operating the engine at constant low speed engine start up before applying load or reviving
(light load) can cause parts to glaze and not the engine. This allows time for the lubricating
seat in.
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oil to reach all critical engine components.
Allow the engine to accelerate freely through the TE
gear, without exceeding the recommended max- ★ OBSERVE YOUR FIRST, AND MOST
imum limits. 1,000km SERVICE
Do not, however use full throttle for first 1,600km
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(1,000miles). The 1,000km (600miles) service is the most
important service your motorcycle will receive.
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★ VARY THE ENGINE SPEED During break-in procedures all of the engine
components will have worn in and all of the
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The engine speed should be varied and not held other parts will have seated in.
at a constant speed. All adjustments will be restored, all fasteners will
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This allows the parts to be“loaded”with pres- be tightened, and the dirty engine oil and engine
sure and then unloaded, allowing the parts to oil filter will be replaced.
cool. Timely performance of the 1,000km (600miles)
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This aids the mating process of the parts. It is service will ensure optimum service life and per-
essential that some stress be placed on the formance from the engine.
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◉ LUBRICATION POINTS
INSPECTION BEFORE RIDING Proper lubrication is important for smooth and
long life of each working part of your motorcycle
Before riding the motorcycle, be sure to check and also for safe riding. It is a good practice to
the follwing item. lubricate the motorcycle after a long rough ride or
Inspect every day once them before riding the after it gets wet in the rain or after washing it.
motorcycle. Major lubrication points are indicated as fol-
● Abnormal point of the previous day.
lows.
● Extra braking power of the brake lever.
substance (stone, nail and others) of Tire. Improper maintenance or failure to per-
● Adequate tread depth of Tire.
form recommended maintenance increas-
● Fluid measure of Engine oil.
es the chance of an accident or motorcy-
cle damage.
● Pollution degree inspect of Engine oil.
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● On and off condition or damage of Lamp,
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◉ ENGINE
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Throttle cable TEInspect Inspect ─
Idle speed Inspect Inspect ─
Clutch Inspect Inspect ─
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◉ CHASSIS
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Inspect Inspect ─
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Brake fluid
Replace every 2 years
Tire Inspect Inspect ─
Steering ★ Inspect Inspect ─
Front forks ★ ─ Inspect ─
Rear suspension ★ ─ Inspect ─
Chassis nuts and bolts ★ Tighten Tighten ─
CAUTION
More frequent servicing may be performed on motorcycles that are used under severe conditions.
NOTE
★ = Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.
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RIDING TIPS CAUTION
Running the engine too long without riding
may cause the engine to overheat.
STARTING THE ENGINE Overheating can result in damage to inter-
nal engine components and discoloration
of exhaust pipes.
Before attempting to start Shut the engine off if you cannot begin
the engine make sure: your ride promptly.
1. The transmission is in neutral.
2. The fuel cock lever is in the“ON”position.
3. The engine stop switch is in the“ ”pos-
ition.
STARTING OFF
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1. Turn the carburetor choke lever all the way Riding this motorcycle at excessive speed
toward you. increases your chances of losing control
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2. Close the throttle grip and push the starter of the motorcycle.
switch. This may result in an accident.
3. Immediately after the engine starter return the Always ride within the limits of your skills,
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choke lever halfway and warm up the engine. your motorcycle, and the riding condi-
tions.
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WARNING
◉ When the engine is warm :
Removing your hands from the handle-
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Operation of the carburetor choke system Always keep both hands on th handlebars
is not necessary when the engine is warm. and both feet on the footrests of your
motorcycle during operation.
WARNING
Running the engine indoors or in a garage WARNING
can be hazardous.
Exhaust gas contains carbon monoxide, a Sudden side winds, which can occur
gas that is colorless and odorless and can when being passed by large vehicles, at
cause death or severe injury. tunnel exits or in hilly areas, can upset
Only run the engine outdoors where there your control.
is a fresh air. Reduce your speed and be alert to side
winds.
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After moving the side stand to the fully upper
RIDING ON HILLS
position, pull the clutch lever in and pause
momentarily. Engage first gear by depressing
the gearshift lever downward. ● When climbing steep hills, the motorcycle
Turn the throttle grip toward you and at the may begin to slow down and show lack of
same time release the clutch lever gently and power. At this point you should shift to a lower
smoothly. As the clutch engages, the motorcycle gear so that the engine will again be operat-
will start moving forward. To shift to the next ing in its normal power range. Shift rapidly to
higher gear, accelerate gently, then close the prevent the motorcycle from losing momen-
throttle and pull the clutch lever in simultaneous- tum.
ly. Lift the gearshift lever upward to select the ● When riding down a steep hill, the engine
next gear and release the clutch lever and open may be used for braking by shifting to a lower
the throttle again. gear.
Select the gears in this manner until fifth gear is ● Be careful, however, not to allow the engine
reached. to overrev.
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USING THE TRANSMISSION STOPPING AND PARKING
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The transmission is provided to keep the engine 1. Turn the throttle grip away from you to close
operating smoothly in its normal operating the throttle completely.
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speed range. The gear ratios have been careful- 2. Apply the front and rear brakes evenly and at
ly chosen to meet the characteristics of the the same time.
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engine. The rider should always select the most 3. Downshift through the gears as road speed
suitable gear for the prevailing conditions. decreases.
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Downshifting when engine speed is too can be confirmed by observing the neutral
high can ; indicator lamp.
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WARNING INSPECTION AND REPAIR
Hard braking while turning may cause
wheel skid and loss of control.
TOOL
Brake before you begin to turn.
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3 12 × 14 mm open end wrench
WARNING 4 Spark plug wrench
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5 Combination screw driver
Following another vehicle too closely can
lead to a collision. As vehicle speeds 6 Screw driver handle
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increase, stopping distance increases 7 Pliers
progressively.
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WARNING ⑦
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BATTERY CAUTION
● Do not remove absolutely airtight cover
◉ INSPECTION OF BATTERY SOLUTION LEVEL as airtight type battery.
● Keep after separate at the motorcycle
MF(Maintenance Free) battery of airtight type is
used for this motorcycle. for the minimum of self electric dis-
charge and electric leakage when don t
It is not necessary to inspect or supplement bat-
use for a long time.
tery fluid. ● Remove the (-) negative terminal when
The battery is located behind the right frame keep intact at the motorcycle.
cover.
However, have your dealer check the charging
condition of battery periodically. ◉ CLEAN OF BATTERY TERMINAL
Clean the battery terminal when it is dusty or
rusted.
1. Set the ignition switch“OFF”position.
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2. Disassemble the battery cover, disassemble
the (+)positive battery wire after the (-)neg-
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ative battery wire.
Remove the battery.
3. Clean the terminal.
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If there is white dust, clean it with warm water.
4. Assemble the battery wires and grease the
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terminal lightly.
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◉ BATTERY INSTALLATION
CAUTION
’s battery installation order pay
● Keep the battery away from fires.
attention to following points : ● When disassemble the battery wire,
take off � terminal first with the ignition
switch“OFF”position.
When assemble, � terminal first.
● Fasten certainly the battery wires.
AIR CLEANER
(─) Lead wire
⇒ Front side If the air cleaner element has become clogged
with dust, intake resistance will increase with a
resultant decrease in power output and an
① Remove the seat, right frame cover and bat-
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increase in fuel consumption. If riding under ele-
tery support.
ment must be cleaned or replaced more fre-
② Lay down (+) positive terminal of the battery
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quently than maintenance schedule. Check and
at leftside of the battery case (on the motor-
clean the air cleaner element periodically
cycle).
according to the following procedure.
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③ Install (+) positive lead wire at the battery
terminal.
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⑥ Install the battery support and right frame smoke(black smoke). This appearence is
cover. occurred at first to clean the air cleaner ele-
ment and confirm.
CAUTION
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FUEL HOSE
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be replaced.
Replace the fuel hose every 4 years.
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SPARK PLUG
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CAUTION
More frequent servicing may be performed
on motorcycles that are used under severe
conditions, also clean the air cleaner ele-
ment when replacing the oil to prevent
damgae of the engine.
0.7~0.8mm
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Readjust the spark plug gap to 0.7~0.8 mm
(0.028~0.031 inch) by using a spark plug gap
thickness gauge.
CAUTION
CAUTION Never operate the motorcycle if the engine
oil level is below the“Lower line mark(L)”
● Do not over torque or cross thread the in the engine oil level gauge. Never fill the
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spark plug or the aluminum threads of engine oil above the“Upper line mark(F)”.
the cylinder head will be damaged. Engine oil level being most suitable about
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Do not allow contaminants to enter the 1mm under the“Upper line mark(F)”of the
engine through the spark plug holes engine oil lens. In case of the engine oil
when the plug is removed. pouring in excessively, the engine output
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● The standard spark plug for this motor- being made insufficient.
cycle has been carefully selected to Be careful not to pouring in the engine oil
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that other than a standard spark plug be ◉ ENGINE OIL LEVEL CHECK
used, it is best to consult your Hyosung
Follow the procedure below to inspect the
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ENGINE OIL CAPACITY
Replace 1,450 ㎖
CAUTION
In case of the engine oil pouring in exces-
sively, the engine output being made insuffi-
cient.
CAUTION
Be careful not to pouring in the engine oil Necessarily, confirm and clean the oil strain-
excessively. er � when replace the Engine oil(specially,
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when first replace ment).
1. Place the motorcycle on the center stand,
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jack or block.
CAUTION
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� �
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①
��
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3. Drain the oil by removing the drain plug ②
located on the bottom of the engine.
CAUTION
When install the oil fiter, necessarily,
“HYOSUNG”character and“16510H05240”
part’s NO. install toward the outside, other-
wise can damage the engine.
⑥ WARNING
Engine oil and exhaust pipes can be hot
enough to burn you.
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7 TE WARNING
New and used oil and solvent can be haz-
ardous. Children and pets may be harmed
by swallowing new or used engine oil or
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solvent. Continuous contact with used
engine oil has been found to cause skin
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Insert the filter so that surface of the filter away from children and pets.
● Wear a long-sleeve shirt and waterproof
hole turn toward the engine.
gloves.
● Wash with soaf if oil or solvent contact
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CAUTION CAUTION
Approximately 1,450 ㎖ of oil must be Never adjust“CO adjust screw”� of the
required when changing oil only without carburetor.
replacing the oil filter. If adjust optionally, exert a bad influence
upon output of the engine as the two car-
8. Replace the drain plug and tighten it securely. buretor is disharmonious.
Pour fresh oil through the filler hole.
Approximately 1,500㎖ of oil will be required.
CAUTION
�
In case of the engine oil pouring in exces-
sively, the engine output being made insuffi-
cient.
Be careful not to pouring in the engine oil
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excessively. TE
9. Operate the engine a few second by idling
speed. ◉ IDLE SPEED ADJUSTMENT
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Inspect to leak oil at the oil filter cap.
10. Confirm the oil level through the oil level lens
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◉ THROTTLE CABLE ADJUSTMENT
1 2
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(0.02~0.04in). ⑤ The cable adjuster
3. After adjusting the slack, tighten the lock nut. ⑥ The clutch cable adjuster lock nut
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If you find the play of the clutch incorrect,
CAUTION adjust it in the following way :
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After completing throttle cable adjust- ◉ CLUTCH CABLE
ment, check that handlebar movement
1. Loosen the lock nut ② and the clutch lever
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automatically.
Turn the cable adjuster ⑤ that the clutch
lever play ① should be 4mm(0.16in).
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At each maintenance interval, adjust the clutch ②, ⑥ and cover the rubber boot ④.
cable play by means of clutch cable adjuster.
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2 4mm
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WARNING CAUTION
Riding with the chain in poor condition or The two sprockets should be inspected
improperly adjusted can lead to an accident. for wear when a new chain is installed and
replace them if necessary.
Inspect, adjust, and maintain the chain
properly before each ride, according to
this section.
◉ DRIVE CHAIN ADJUSTMENT
Chain adjust in the following way.
◉ Insepcting the Drive Chain
When inspecting the chain, look for the follow-
ing:
● Loose pins
● Damaged rollers
● Dry or rusted links
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● Kinked or binding links
● Excessive wear
● Improper chain adjustment
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If you find something wrong with the drive chain
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condition or adjustment, correct the problem if
you know how. If necessary, consult your autho-
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Good Worn
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CAUTION BRAKES
The drive chain for this motorcycle is Properly operating the brake systems are vital to
made of the special material. safe riding. Be sure to perform the brake inspec-
The chain should be replaced with a tion requirements as schedules.
520DS.
The brakes should be inspected at periodic
Use of another chain may lead to prema-
ture chain failure. inspection by your authorized Hyosung dealer.
◉ FRONT BRAKE
● BRAKE FLUID
CAUTION Be sure to check the brake fluid level in the mas-
The drive chain should be inspected every ter cylinder. If the level was found to be lower
time before riding. than the lower mark while holding the motorcycle
Excessive chain slack could cause the upright, replenish with the proper brake fluid that
chain to come off the sprockets and result meets Hyosung’s requirements.
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in accident or serious engine damage. As the brake pads wear, the fluid level will drop to
compensate for the new position of barke pads.
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Replenishing the master cylinder to considered
WARNING normal periodic maintenance.
Be careful not to touch the muffler when it
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is hot : a hot muffler can burn you.
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WARNING
Brake fluid may be harmful or fated if
swallowed and harmful if it comes in con-
tact with skin or eyes. Contact your physi-
If the drive chain become dirty, the drive chain cian immediately. If swallowed induce
and the sprocket is wore easily. This times, vomiting. If brake fluid gets into the eye or
clean the drive chain with solvent and oil every in contact with the skin, it should be
1,000km with lubricating oil or motor oil. flushed thoroughly with plenty of water.
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Inspect every day in the following point at the
CAUTION brake system.
This motorcycle uses glycol-based brake ① Brake fluid leak of the front brake system.
fluid. Do not use or mix different types of ② Leak or damage of the brake hose.
brake fluid such as silicone-based or ③ Operating of the brake lever.
petroleum-based fluid, otherwise serious ④ Wear of the front brake pads.
damage will result in the brake system.
Use only DOT3 or DOT4. Do not spill any
brake fluid on painted or plastic surfaces CAUTION
as it will damage the surface severely.
The front brake system be replaced the
brake hose or the brake fluid according to
periodic inspection chart by your autho-
● BRAKE PADS
rized Hyosung dealer for safety as in
Inspect the front brake pads by nothing whether times of operating at high pressure.
or not the friction pads are worn down to the
grooved limit line. If a pad is worn to the grooved
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limit line it must be replaced with a new one by
your authorized Hyosung dealer or qualified ser-
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vice machanic. Riding with worn brake pads will reduce
braking performance and will increase your
chance of having accident. Inspect brake pad
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wear before each use. Ask your Hyosung
dealer or qualified mechanic to replace brake
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CAUTION
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◉ REAR BRAKE ● BRAKE LINING WEAR LIMIT
● REAR BRAKE ADJUSTMENT The motorcycle is equipped with the brake lining
wear limit indicators on the rear brakes.
WARNING To check wear of the brake lining, perform the
following :
Too much clearance in the rear brake
pedal can cause poor braking perfor-
mance and may lead to an accident. Too
little clearance may force brake shoes to IN IN
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NG
E LILI ITT
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① Check if the brake system is properly adjust-
① ed.
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② While fully applying the brake, check to see
that the extension line of the index mark is
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within the range on the brake panel.
③ If the extension line is beyond the range,
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tion.
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WARNING
Riding with worn brake shoe will reduce
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Operating the motorcycle with excessively worn
TIRE
tire will decrease riding stability and can lead to
loss of control.
Inspect the tire pressure and the tire thread
Inspect stortage of tire thread’s depth by the
depth periodically. 『tire wear indicator』.
Inspect frequently the tire pressure for the safety
Replace the front and rear tires at once when
and the tire life.
appear the『tire wear indicator』.
◉ TIRE PRESSURE
◉ TIRE REPLACEMENT
Insufficient air pressure in the tires not only has-
● FRONT TIRE REPLACEMENT
ten tire wear but also seriously affects the stabil-
1. Place the motorcycle on the center stand.
ity of the motorcycle.
Under-inflated tires make smooth cornering dif-
ficult and over-inflated tires decrease the
amount of tire in contact with the ground which
can lead to skids and loss of control. Be sure
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that the tire pressure is within the specified lim-
its at all times.
Tire pressure should only be adjusted when the
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tire is cold.
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TIRE PRESSURE NORMAL RIDING
(COLD INFLA-
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TION) SOLO RIDING DUAL RIDING 2. Remove the caliper from the front fork by
removing the mounting bolts ①.
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2.00 kg/㎠ 2.25 kg/㎠ Never squeeze the front brake lever with
REAR 196 kpa 221 kpa the caliper removed. It is very difficult to
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result.
◉ TIRE TREAD CONDITION
③�
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3. Loosen the front axle pinch bolt ②. ◉ REAR TIRE REPLACEMENT
4. Loosen the front axle ③. 1. Place the motorcycle on the center stand.
5. Carefully position a jack or block under
engine and raise until the front wheel is slight-
ly off the ground.
①
CAUTION
Improper jaking may cause damage to the
oil filter.
Do not apply the jack head to the oil filter
when jacking up the motorcycle.
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③
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②
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④�
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7. Pull the rear wheel assembly rearward.
WARNING 8. To replace the wheel, reverse the complete
A hot muffler can burn you. The muffler sequence listed.
will be hot enough to burn you for some
time after stopping the engine.
Wait until the muffler cools to avoid
CAUTION
burns. The standard tire on is
110/90-16 59S for front, and 150/80-15M/C
4. Loosen the drive chain adjuster ③, left and 70S for rear.
right, and disengage the drive chain from the The use of a tire other than standard may
rear sprocket. cause trouble. It is highly recommended
5. Remove the rear break hub from the swing to use the standard tire supplied by
arm. Hyosung.
6. Loosen the rear shock absorber lower bolt ④,
left and right, draw out the rear axle with the
rear wheel push to the bottom.
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TE REPLACE OF THE LAMP
the lamp.
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NAMES CAPACITY
HI 35 W
Head lamp
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LO 35 W
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Position lamp 5W
License lamp 5W
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◉ HEAD LAMP
CAUTION
The use of a lamp other than rules may
cause to occur the vehicle fire and to
damage at electric parts.
Surely use only the lamp of proper capaci-
ty.
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◉ TAIL/BRAKE LAMP
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4. After stick in the new lamp, assemble the lens.
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CAUTION
Overtightening the screws may cause the
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�
lens to crack.
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◉ FUSE
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The fuse box is located behind the right frame ③ If the ignition system is operating properly, a
cover. If the engine suddenly stops while run- blue spark should jump across the spark plug
ning or any electrical system fails to operate gap.
then the fuse must be checked. If there is no spark, consult your Hyosung
In case a fuse blows there is a 15A spare fuse. dealer for repairs.
CAUTION
Never use other than specified 15A fuse.
Installing a fuse of incorrect rating may seri-
ously damage the electrical system.
You should consult your Hyosung dealer or
a qualified service mechanic immediately.
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◉ TROUBLE SHOOTING
If the engine refuses to start, perform the follow-
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ing inspections to determine the cause.
WARNING
Do not hold the spark plug close to the
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● Fuel Supply Check
open spark plug hole in the cylinder head
① Is there enough fuel in the fuel tank? as gasoline vapor inside the cylinder
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② Is the fuel reaching the carburetor from the should be ignited, creating a fire hazard.
fuel cock?
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see if gasoline flows from the hole. ② Check the ignition system for intermittent
④ If it has been determined that fuel is reaching spark.
the carburetor, the ignition system should be ③ Check the engine idle speed.
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checked next.
CAUTION CAUTION
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● Ignition System Check 1. Supply enough the fuel in the fuel tank.
① Remove a spark plug and reattach to the 2. Do the fuel cock in the“OFF”position.
spark lead. 3. Do drain wholly the fuel in the carburetor.
② While holding the spark plug firmly against 4. Remove the battery from the motorcycle.
the engine, crank the engine with the ignition
switch in the“ON”switch.
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SPECIFICATIONS
ENGINE
Type Four-stroke, air-cooled and oil-cooled
Number of cylinder V-2 cylinder
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Bore 57.0mm(2.24in)
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Stroke 48.8mm(1.92in)
Piston displacement 249cm3 (15.2in3)
Corrected compression ratio 10.2 : 1
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Carburetor BDS 26 TYPE(DOUBLE)
Starter system ELECTRIC STARTER
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TRANSMISSION
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2nd : 1.560
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3rd : 1.190
4th : 0.960
5th : 0.840
Final 3.29
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CHASSIS
Front suspension Telescopic type
Rear suspension Swing arm type
Caster 33。
Trail 135mm(5.32in)
Steering angle 40。(right & left)
Front tire size 110/90-16 59S
Rear tire size 150/80-15M/C 70S
Front brake Disc
Rear brake Drum
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ELECTRICAL
Ignition type
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“CDI”type
Ignition timing 13。
B.T.D.C.at 2,000 rpm ~ 30。
B.T.D.C.at 6,000 rpm
Spark plug CR8E
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Battery 12V 6Ah (MF)
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Fuse 15A
Headlamp HI : 35 W ∙
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LO : 35 W
Position lamp 5W
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CAPACITIES
Fuel tank 14.0ℓ
Engine oil 1,450㎖ (Replace)
1,500㎖ (Oil filter replace)
1,800㎖ (Overhaul)
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Prepared by
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Printed in KOREA
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WARNING
Noise Control System (muffler assembly)
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
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carburetor may cause permanent damage to the catalyst and to the noise control system.
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CONSUMER INFORMATION
If you believe that your vehicle has a defect which could cause a crash or could cause
injury or death, you should immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Hyosung Motors & Machinery Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a
safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
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However, NHTSA cannot become involved in any individual problems between you, your
dealer, or Hyosung Motors & Machinery Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393
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( 366-0123 in Washington, D.C. area) or write to:
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NHTSA
U.S. DEPARTMENT of TRANSPORTATION
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You can also obtain other information about motor vehicle safety from the Hotline.
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