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1
BATTERY INITIAL CHARGING
2. BATTERY INSTALLATION
① Fill the electrolyte to the battery.
② Leave the battery for 30 minutes.
③ Charge the battery by standard charging. This is necessary for reliability of the
battery.
④ Install the battery to the motorcycle.
CAUTION
Do not use the battery without the battery initial charging.
Otherwise the battery service life may be shortened.
WARNING
The 『 』 uses a battery ignition system.
Do not permit to start or operate the motorcycle without the battery otherwise the
electrical system will be damage.
Always start or ride the motorcycle with the correct battery installed and connected.
CAUTION
Use only the genuine Hyosung battery on the 『 』.
If use a non genuine battery, as poor performance for low temperature of the battery,
the engine could not start because the ECU is not running by lower battery moment
voltage than 7V when pushing the starter switch.
2
FOREWORD
THANK YOU for choosing a Hyosung All information, illustrations photographs
m o t o r c y c l e . We a t H y o s u n g h a v e and specifications contained in this manual
designed, tested and produced this are based on the latest product information
motorcycle using the most modern available at the time of publication. Due to
technology available to provide you with improvements or other changes, there may
much happy, enjoyable, safe riding. be some discrepancies between
Motorcycling is one of the most exhilarating information in this manual and your
sports and to ensure your riding enjoyment, motorcycle.
you should become thoroughly familiar with Hyosung reserves the right to make
the information presented in this Owner's changes at any time, without notice and
Manual before riding the motorcycle. without incurring any obligation to make the
same or similar changes to motorcycles
The proper care and maintenance that previously built or sold.
your motorcycle requires is outlined in this
manual. Please note that this manual applies to all
By following these instructions explicitly you specifications for all respective destinations
will ensure a long trouble-free operating life and explains all equipments. Therefore,
for your motorcycle. Your Hyosung dealer your model may have different standard
has experienced technicians that are features than shown in this manual.
trained to provide your machine with the
best possible service with the right tools
and equipment.
3
IMPORTANT
BREAK-IN INFORMATION WARNING / CAUTION /
FOR YOUR MOTORCYCLE NOTE
The first 1,600 km (1,000 miles) are the Please read this manual and follow its
most important in the life of your instructions carefully.
motorcycle. To emphasize special information the
Proper break-in operation during this time words 『WARNING』, 『CAUTION』 and
will help ensure maximum life and 『NOTE』 have special meanings.
performance from your new motorcycle. Information following these signal words
Hyosung parts are manufactured of high should be carefully reviewed.
quality materials, and manufactured parts
are finished to close tolerances. Proper WARNING
break-in operation allows the machined
surfaces to polish each other and mate The personal safety of the rider may be
smoothly. involved. Disregarding this information
could result in injury to the rider.
Motorcycle reliability and performance
depend on special care and restraint
exercise during the break-in period. It is
especially important that you avoid
CAUTION
operating the engine in a manner which These instructions point out special
could expose the engine parts to excessive service procedures or precautions that
heat. must be followed to avoid damaging
the machine.
Please refer to the BREAK-IN section for
specific break-in recommendations.
N O T E
This provides special information to
make maintenance easier or important
instructions clearer.
4
WARNING
Noise Control System (muffler assembly)
MAINTENANCE :
The exhaust system of this motorcycle requires no periodic maintenance.
The engine should be adjusted to the manufacture’ s specifications and
the spark plug should be kept in good condition. Running the engine with
incorrectly operating spark plug or misadjusted fuel injection system may
cause permanent damage to the catalyst and to the noise control system.
5
CONSUMER WARNING
INFORMATION ● B efore each use, perform daily
inspections with the rider. Specific
SAFE RIDING items to check are listed in the
RECOMMENDATION INSPECTION BEFORE RIDING
section on page 55 of this owner’s
FOR MOTORCYCLE RIDERS manual.
Motorcycle riding is great fun and an ●M ake sure the rider wears a helmet,
exciting sport. Motorcycle riding also eye protection, and protective
requires he/she to take some extra clothing (gloves, leather or heavy
precautions to ensure the safety of the rider cloth pants, long sleeved shirt or
and passenger. jacket, boots).
●P ermit use only by two persons.
These precautions are : The motorcycle is designed for use
only by one rider and one passenger.
WARNING ●D o not permit anyone to operate the
『 』 under the influence of
●B e f o r e f i r s t u s e o f t h e
alcohol or other drugs. It may cause
『 』, r e a d t h i s o w n e r ’s
damage to the motorcycle and alter
manual carefully to become familiar
handling characteristics.
with the motorcycle features, and
●O bserve periodic maintenance
safety and maintenance
requirements. Your authorized
requirements. Review all instructions,
HYOSUNG dealer is trained and
requirements and warnings.
equipped to perform this service.
Keep the owner’s manual in the
●Drain gasoline from the fuel tank
owner ’s manual storage
prior to transporting the
compartment located under the rear
『 』.
seat.
● Caution the rider and others near the
●Before the rider’s first use of the
『 』 not to get close to or
『 』, make sure that he / she
touch any moving parts or any
is familiar with the location and
heated areas such as the engine and
operation of all controls, and has
exhaust system.
been instructed in the proper
● Do not make any modifications to
operation of the motorcycle.
the 『 』.
● F o r f i r s t u s e o f t h e
M odifications may make the
『 』, find a level, open area
motorcycle unsafe or illegal in your
for the rider to use to become familiar
state.
with the operation of controls and the
operating and handling
characteristics of the motorcycle.
6
WARNING WARNING
The 『 』 is equipped with the Keep both hands on the handgrips at all
side stand ignition interlock system. times when riding. Removing your
If the transmission is in neutral or the hands from the handgrips reduces your
side stand up, you can only start the ability to control the motorcycle and
engine by squeezing the clutch lever. could result in an accident.
This side stand ignition interlock
system prevents the motorcycle from
being started with side stand down. WARNING
Make sure that the side stand ignition
While operating the 『 』, the
interlock system is working properly
rider should keep both feet on the
before riding.
footrests at all times to avoid injuries
resulting from accidents. Moving the
CAUTION rider’s feet from the footrests reduces
the rider ’s ability to control the
The position lamp, meter lamp, tail lamp motorcycle and could lead to an
and license plate lamp on this motorcycle accident.
always comes on when the ignition
switch is turned to the “ON” position.
The head lamp is always lit when starting CAUTION
the engine.
WHEN STORING FOR LONG PERIOD :
1. D rain the fuel in the fuel tank.
WARNING 2. R emove the battery from the
motorcycle.
●Do not run the engine indoors or
where there is little or no ventilation.
Exhaust gases contain carbon
monoxide, a potentially lethal gas CAUTION
that is colorless and odorless. ●T he trunk could be heated.
● Never leave the motorcycle running Don’t keep anything that doesn’t
while unattended, even for a short endure heat.
time. ●D on’t keep the fragile.
●C heck if it is locked.
WARNING ● The unlocking of rear seat could
cause serious accident.
Always open the throttle gradually to ● Don’t allow water to get inside the
prevent front wheel lifting. Failure to trunk or it could damage.
observe this precaution may result in ●D on’t keep the valuables in the trunk
loss of control and an accident. when leaving unattended.
●L oading limit of trunk : 2 kg (4.4 lbs)
7
⊙ RIDING APPAREL
WARNING
Do not turn the ignition switch to its WARNING
“OFF” or “LOCK” position or the Loose clothing can be uncomfortable
engine stop switch to its “ ” position and unsafe when riding a motorcycle.
while riding the motorcycle. Use good quality motorcycle riding
apparel when riding your motorcycle.
WARNING WARNING
Motorcycle safety equipment starts with Review thoroughly the instructions in
a quality safety helmet. One of the most the “INSPECTION BEFORE RIDING”
serious injuries that can happen is a section of this manual. Do not forget to
head injury. ALWAYS wear a properly perform an entire safety inspection to
approved helmet. You should also wear ensure the safety of the rider and its
a suitable eye protection. passenger.
8
⊙ FAMILIARIZE YOURSELF WITH ⊙B
E EXTRA SAFETY CONSCIOUS
THE MOTORCYCLE ON BAD WEATHER DAYS
WARNING WARNING
Your riding skill and mechanical Riding on bad weather days, especially
knowledge from the foundation for safe wet ones, requires extra caution.
riding practices. Braking distances double on a rainy
We suggest that you practice riding day. Stay off of the painted surface
your motorcycle in a non-traffic marks, manhole covers and greasy
situation until you are thoroughly appearing areas as they can be
familiar with your machine and its especially slippery.
controls. Use extreme caution at railway
Remember practice makes perfect. crossings and on metal gratings and
bridges.
Whenever you have a doubt about road
condition, slow down!
WARNING
Ride within the boundaries of your own
skill at all times. Knowing these limits
and staying within them will help you to
avoid accidents.
9
1. In case that additional weight or
aerodynamic affecting accessories are
ACCESSORY installed, they should be mounted as
INSTALLATION AND low as possible, as close to the
motorcycle and as near the center of
PRECAUTION SAFETY TIPS gravity as is feasible. The mounting
brackets and other attachment
There are a great variety of accessories hardware should be carefully checked
available to Hyosung owners. Hyosung to ensure that it provides for a rigid,
can not have direct control over the quality nonmovable mount. Weak mounts can
or suitability of accessories you may wish allow the shifting of the weight and
to purchase except genuine parts. create a dangerous, unstable
The addition of unsuitable accessories condition.
can lead to unsafe operating conditions. It
is not possible for Hyosung to test each 2. Inspect for proper ground clearance
accessory on the market or combinations and bank angle. An improperly
of all the available accessories, however, mounted load could critically reduce
your dealer can assist you in selecting these two safety factors. Also
quality accessories and installing them determine that the “load” does not
correctly. interfere with the operation of the
suspension, steering or other control
Use extreme caution when selecting and operations.
installing the accessories for your
Hyosung. We have developed some 3. Accessories fitted to the handlebars or
general guidelines which will aid you when the front fork area can create serious
deciding whether, and how to equip your stability problems. This extra weight will
motorcycle. cause the motorcycle to be less
responsive to your steering control.
The weight may also cause oscillations
WARNING in the front end and lead to instability
problems. Accessories added to the
Improper accessories or modifications
machine should be as light as possible
can make your motorcycle unsafe and
and kept to a minimum.
can lead to an accident.
4. The motorcycle may be affected by a
Never modify the motorcycle with
lifting condition or by an instability in
improper or poorly installed
cross winds or when being passed or
accessories. Follow all instructions in
passing large vehicles. Improperly
this owner ’s manual regarding
mounted or poorly designed
accessories and modifications.
accessories can result in an unsafe
Use genuine Hyosung accessories or
riding condition, therefore caution
equivalent designed and tested for your
should be used when selecting and
motorcycle. Consult your Hyosung
installing all accessories.
dealer if you have any questions.
10
5. Certain accessories displace the rider
from his or her normal riding position.
This limits the freedom of movement of
the rider and may limit his or her control MODIFICATION
ability.
Modification of the motorcycle, or removal of
6. Additional electrical accessories may original equipment may render the vehicle
damage the existing electrical system. unsafe or illegal.
Severe overloads may damage the Obey all applicable equipment regulations in
wiring harness or create a dangerous your area.
situation due to the loss of electrical
power during the operation of the
motorcycle.
11
TABLE OF CONTENTS
6. RIDING TIPS··························47
STARTING THE ENGINE
STARTING OFF
USING THE TRANSMISSION
RIDING ON HILLS
STOPPING AND PARKING
7. BREAK-IN· ························· 52
12
8. INSPECTION BEFORE RIDING·················55
9. PERIODIC MAINTENANCE·················· 57
11. TROUBLESHOOTING·····················85
16. SPECIFICATIONS·······················94
13
Please write down the numbers in the box
SERIAL NUMBER provided below for your future reference.
LOCATION
Frame number :
The frame and/or engine serial numbers
are used to register the motorcycle. They
Engine number :
are also to assist your dealer in terms of
ordering parts or referring to special
service information.
GD250-000010
14
FUEL, ENGINE OIL AND ENGINE OIL
ENGINE COOLANT Oil quality is a major contributor to your
RECOMMENDATION engine’s performance and life.
Always select good quality engine oil.
● When
refueling, always shut the ℃ -30 -20 -10 0 10 20 30 40
Temperature
engine off and turn the ignition key ℉ -22 -4 14 32 50 68 86 104
to the “OFF” position.
Never refuel near the flames, sparks Use the chart to select a viscosity rating
and heat sources. based on temperature range in your area.
● Do not overfill the fuel tank.
Do not fill gasoline above the fuel
tank entrance lower end.
N O T E
In very cold weather [below -15 C (5
F)], use SAE 5W/30 for good starting
and smooth operation.
15
WARNING ENGINE COOLANT
● Don’t mix the unrecommended oil.
SOLUTION
It could damage the engine. Use an engine coolant that is compatible
● When refilling the oil, don’t allow the with aluminum radiator, mixed with distilled
dust to get inside. water only at a 50 : 50 mixture ratio for
● Wipe the spilled oil up immediately. engine coolant solution.
An engine coolant mixture other than
50 : 50 can affect cooling efficiency or rust
inhibiting peformance.
WARNING
Engine coolant is harmful or fatal if
swallowed or inhaled.
CAUTION
Spilled engine coolant can damage
painted surfaces.
16
⊙ ENGINE COOLANT ⊙ COOLANT RESERVOIR TANK
The engine coolant performs as rust ☞ Refer to 45 page.
inhibitor and water pump lubricant as well
as anti-freeze.
Therefore the engine coolant should be
used at all times even though the
atmospheric temperature in your area does
not go down to freezing point.
Water 0.615 ℓ
50%
Engine coolant 0.615 ℓ
N O T E
This 50 % mixture will protect the
cooling system from freezing at
temperatures above -31℃.
If the motorcycle is to be exposed to
temperature below -31℃this mixing
ratio should be increased up to 55 %
(-40℃) or 60 % (-55℃).
The mixing ratio should not exceed 60
%.
17
NAMES OF EACH PARTS
② ②
③
④ ⑤ ⑥
① ⑦
⑧
⑨
⑩
18
⑭ ⑰ ⑱
⑮ ⑯ ⑲
⑬ ⑳
⑫
⑪
N O T E
“ ” : means the invisable parts.
19
N O T E
“ ” : means the invisable parts.
20
CONTROLS
IGNITION SWITCH
STEERING
LOCK
KEY
STEERING
LOCK
⊙ “OFF” POSITION
In this position the ignition circuit is
interrupted, a running engine stops, and a
non-running engine will not start.
The key can be removed.
21
To lock the steering :
ⓐ Turn the handlebars all the way to the IGNITION KEY
left.
ⓑ Turn the ignition key to the “OFF” This motorcycle come equipped with two
position. ignition keys.
ⓒ Push down the ignition key from the Keep the spare key in a safe place.
“OFF” position, come up again and turn
it to the “LOCK” position.
ⓓ Remove the ignition key.
WARNING
Turning the ignition switch to the
“OFF”or “LOCK” position while the
motorcycle is moving can be
hazardous. Moving the motorcycle while
the steering is locked can be hazardous.
You could lose your balance and fall, or
you could drop the motorcycle.
N O T E
Start the engine after turning the key to
the “ON” position, or the battery will
lose power due to consumption by the
lamp.
22
INSTRUMENT PANEL
❶
❾
❷ ❸ ❹ ❺ ❻ ❼
WARNING CAUTION
Operating the display while riding can To adjust brightness of the instrument
be hazardous. Removing a hand from panel display, push the switch ⑭ (in
the handlebars can reduce your ability the Normal mode) for 0.6 ~ 1 seconds
to control the motorcycle. while you want to change.
23
① TACHOMETER ③ “FI ” (Fuel Injection) CHECK
The tachometer indicates the engine LAMP
speed in revolutions per minutes (rpm).
The “FI” check lamp ③ comes on and
CAUTION remains lit when the ignition switch is set to
Revving the engine into the black zone “ON” position with the engine stopped as a
of the tachometer can cause severe test of injection system operation.
engine damage.
Never allow the engine to rev into the As soon as the engine starts, the “FI”
black zone of the tachometer in any check lamp ③ should go out.
gear.
If the fuel injection system fails, the “FI”
check lamp ③ comes on and remains lit.
CAUTION
If the “FI” check lamp does not come
on when the ignition switch is set to
“ON” position with the engine stopped
or fail to go out after the engine start,
contact an authorized Hyosung dealer.
CAUTION
Riding the motorcycle with the “FI”
check lamp lit after starting the engine
can damage the engine and
transmission.
24
④COOLANT TEMPERATURE ⑤ NEUTRAL INDICATOR LAMP
WARNING LAMP The green neutral indicator lamp will
The red coolant temperature warning come on when the transmission is in
lamp will come on when the coolant gets neutral.
too hot while operating. The lamp will go out when you shift into
When coolant temperature is higher than any gear other than neutral.
113℃ (235.4℉), the coolant temperature
warning lamp comes on.
CAUTION
Operating the motorcycle while the
coolant temperature warning lamp is lit
can damage your motorcycle. ⑥ HIGH BEAM INDICATOR
Continued operation of the motorcycle LAMP
with high engine coolant temperature The blue high beam indicator lamp will
may result in engine damage or come on when the head lamp high beam is
premature wear. turned on.
If the coolant temperature warning lamp
comes on, stop the engine and allow it
to cool before restarting.
Refer to the note below.
N O T E
● H igh engine speed, low vehicle
speeds, or heavy load can ⑦ TURN SIGNAL INDICATOR
increase engine coolant LAMP
temperature. When the turn signals are being operated
Decrease engine speed, reduce either to the right or to the left, the green
load and select an appropriate indicator will flash at the same time.
transmission gear to lower the
temperature.
● D ebris or mud in front of the
engine or packed between the
radiator fins can reduce cooling
ability.
R e m o v e a n y d e b r i s o r m u d
preventing air flow to the engine.
25
⑧ ODOMETER / TRIP METER
/ CLOCK
The display in it has four functions, the Odometer
odometer, two trip meters and clock.
The display changes the odometer, trip
meter or clock, as indicated before turning
the ignition switch off.
Trip meter A
26
4. Adjust the minutes display by pushing the
switch ⑭ (in the Minutes reset mode) for
0.6 ~ 1 seconds.
5. Push the switch ⑬ (in the Minutes reset
mode) for 2 seconds to resume as the
Clock display of the Normal mode.
CLOCK ADJUSTMENT
Mode Switch Push it for Adjustment
27
⑨ FUEL METER ⑩ COOLANT TEMPERATURE
METER
Ⓐ
Ⓑ
The 『 』’s fuel meter is LCD
(Liquid Crystal Display) type, it indicates The 『 』’s coolant temperature
the remaining fuel amount in the fuel tank. meter is LCD (Liquid Crystal Display) type,
The fuel meter displays all 6 segments it indicates the coolant temperature.
when the fuel tank is full. The coolant temperature meter displays
[ The “F”(Full) mark indicates the fuel tank all 9 segments when the coolant
is full.] temperature is hot.
The “E”(Empty) mark indicates the fuel [ The “H”(Hot) mark indicates the coolant
tank is empty or nearly so. temperature is hot.]
When the remaining fuel is approximately When the coolant temperature is higher
4.0 ℓ, the indicator Ⓐ of the last column than 113℃(235.4℉), the “H” (Hot) mark Ⓑ
blinks only. blinks.
Fill the fuel tank before the indicator Ⓐ of The “C”(Cool) mark indicates the coolant
the last column blinks only. temperature is cool.
The fuel tank capacity is 11.0 ℓ.
CAUTION
CAUTION Running the engine with high engine
Before the indicator Ⓐ of the last coolant temperature can cause serious
column blinks only, you should add engine damage.
fuel to the fuel tank at the first If the “H” mark Ⓑ on the engine
opportunity to avoid running out of coolant temperature meter blinks, stop
fuel. the engine to let it cool.
CAUTION
For checking the fuel meter, hold the
motorcycle vertically and the ignition
switch “ON”.
28
⑪ SPEEDOMETER
N O T E
● H igh engine speed, low vehicle
speeds, or heavy load can
increase engine coolant
temperature.
Decrease engine speed, reduce
load and select an appropriate
transmission gear to lower the
temperature.
● D ebris or mud in front of the
engine or packed between the
radiator fins can reduce cooling
ability.
R e m o v e a n y d e b r i s o r m u d
preventing air flow to the engine.
WARNING
Obey the speed limit and traffic
regulation at all times.
29
⑫ GEAR POSITION INDICATOR ⑭ RESET SWITCH
This indicator is displayed gear position as Use this switch to adjust the following :
N, 1, 2, 3, 4, 5 and 6.
If revving the engine into the black zone of ■ in the Normal mode
the tachometer, the displayed gear position
is blinked. Push it for Adjustment
30
LEFT HANDLE SWITCHES ③ DIMMER SWITCH
Change the direction of the head lamp
light.
❸
❶ ❷ ■“ ” : T he head lamp high beam
comes on.
The high beam indicator lamp
also comes on.
■ “ ” : T he head lamp low beam
comes on.
❺ ❹ WARNING
Set the dimmer switch “ ” when
other vehicle is running in front or
① CLUTCH LEVER
against.
The clutch lever is used for disengaging
the drive to the rear wheel when starting
the engine or shifting the transmission ④ TURN SIGNAL SWITCH
gear. Using when left, right turn or change
Squeezing the lever disengages the direction.
clutch.
■“ ” Position :F lash the left turn
CAUTION ■“
signal lamp.
” Position : F lash the right turn
Use the clutch correctly. signal lamp.
Otherwise, the clutch may be worn ■ “ △ ” (OFF) : P
ushing the “△”
quickly. position will stop the turn
signal lamp to operate.
31
RIGHT HANDLE SWITCHES WARNING
Apply the brake lightly and with great
❶ ❷
care on slippery surfaces to avoid
skidding.
③ THROTTLE GRIP
Engine speed is controlled by position of
the throttle grip. Turn it toward you to
❸
❺ ❹
increase engine speed. Turn it away from
you to decrease the engine speed.
CAUTION
② FRONT BRAKE LEVER Turn off the hazard warning switch
The front brake is applied by squeezing promptly after use.
the brake lever gently toward the throttle If the motorcycle is ridden with the
grip. hazard warning switch turned on, it
The front brake is a powerful disk brake may confuse other drivers.
system. Do not brake excessively so as to The battery will eventually become
cause the front wheel to lock up or skid. depleted if the hazards warning
The brake lamp will come on when the remains on for a period of time without
lever is squeezed. the engine running.
32
⑤ STARTER SWITCH
Use this switch to operate the starting
CAUTION
motor. ● R e l e a s e t h e s t a r t e r s w i t c h
With the ignition switch in the “ON” immediately after the motorcycle
position, the engine stop switch in the “ ” has started.
position, and the transmission is in neutral, ●D o not engage the starting motor for
squeeze the clutch lever and the side stand more than five seconds at a time as
up and push the starter switch to start the it may overheat the wiring harness
engine. and starting motor.
If the engine does not start after
When the ignition switch is set to “ON” several attempts, check the fuel
position with the engine stopped, the meter supply and ignition system.
lamp will come on and the segments of the (Refer to Page 85)
tachometer will turn on once to the end as
a test of electric system operation.
Push the starter switch after all the
segments of the tachometer turn off.
WARNING
The 『 』 is equipped with the
CAUTION side stand ignition interlock system.
If the transmission is in neutral or the
Do not attempt the start the engine until side stand up, you can only start the
all the segments of the tachometer turn engine by squeezing in the clutch lever.
on and then turn off again otherwise This side stand ignition interlock
the engine will start badly. system prevents the motorcycle from
If the engine does not start or runs being started with side stand down.
badly, turn the ignition switch to the Make sure that the side stand ignition
“OFF” position. After 8 seconds, turn interlock system is working properly
the ignition switch on, allow all the before riding.
segments of the tachometer turn on
and turn off again and then attempt to
restart.
This allows the ISC (Idling Speed CAUTION
Control) solenoid to be initialized. The position lamp, meter lamp, tail
lamp and license plate lamp on this
motorcycle always comes on when the
ignition switch is turned to the “ON”
position.
The head lamp is always lit when
starting the engine.
33
FRONT BRAKE LEVER REAR BRAKE PEDAL
ADJUSTMENT
Depressing the rear brake pedal will
apply the rear brake.
Ⓐ The brake lamp will be illuminated when
the rear brake is operated.
WARNING
Never attempt to change the front brake
lever position while riding, or you may
lose control.
34
It is not possible to upshift or downshift
GEARSHIFT LEVER more than one gear at a time.
CAUTION
When the transmission is in neutral, the
green indicator lamp on the instrument
panel will be lit.
However, even though the light is
illuminated, cautiously release the
The 『 』 has a 6-speed clutch lever slowly to determine
transmission which operates as shown. whether the transmission is positively
in neutral.
To shift properly, squeeze the clutch lever
and close the throttle at the same time you
operate the gearshift lever.
35
FOOTRESTS ❹
⊙ FOOTREST POSITION ADJUST-
MENT
The 『 』 has 2 type of the ❺F
L
❸ ❶
❷
❺
F
L
❸ [ POSITION Ⓑ ]
❶
The 『 』 is delivered from the
factory on position Ⓐ.
❸
WARNING
When adjusting the footrest position,
❷ the M10 mounting bolts be torqued to
the proper specification.
[ POSITION Ⓐ ] If they are not, the footrest can come off
unexpectedly.
TIGHTEN TORQUE
Footrest mounting 4.0 ~ 5.0 kgf·m
bolt (40 ~ 50 N·m)
36
⊙ GEARSHIFT LINK ROD SIDE STAND
When the footrests in position Ⓑ,
exchange the gearshift link rod for
appropriate riding position.
■ Position Ⓐ GD250-000010
50-000010
2 △ ● ● Possible
❼ 3 ● △ △ Impossible
4 △ ● △ Impossible
5 △ △ ● Impossible
N O T E
● On or Up
△ Off or Down
37
WARNING SEAT LOCK
Make sure that the side stand ignition
interlock system is working properly
before riding.
38
TRUNK REAR SHOCK ABSORBER
F
L
CAUTION
● The trunk could be heated. The length of the long spring provides the
Don’t keep anything that doesn’t soft spring preload and the length of the
endure heat. short spring provides the stiff spring
● Don’t keep the fragile. preload.
● Check if it is locked.
● The unlocking of rear seat could
cause serious accident.
● Don’t allow water to get inside the
trunk or it could damage.
● Don’t keep the valuables in the trunk
when leaving unattended.
39
SUPPLY OF GASOLINE, WARNING
ENGINE OIL AND Gasoline is extremely flammable and
toxic.
ENGINE COOLANT Always observe the following
precautions when refueling your
「 」.
GASOLINE
● Never permit motorcycle refueling by
anyone other than an adult.
● Refuel in a well ventilated area.
● Make sure the engine is off and
avoid spilling fuel on a hot engine.
● Do not smoke, and make sure there
are no open flames or sparks in the
area.
● Avoid prolonged contact with skin
and breathing of gasoline vapors.
● Keep children and pets away during
refueling.
To open the fuel tank cap, insert the
ignition key into the cap lock and turn it
clockwise. With the key inserted, pull back
the fuel tank cap.
WARNING
Do not overfill the fuel tank. Stop adding
fuel when the fuel level reaches the
bottom of the filler neck. If you fill the
tank beyond this level, fuel may
overflow when it expands due to engine
heat or heating by the sun.
40
ENGINE OIL
N O T E
Engine oil expands and oil level
⊙ ENGINE OIL LEVEL CHECK increases when the engine oil is hot.
Follow the procedure below to inspect the Check and adjust engine oil level when
engine oil level. the engine oil is not hot.
1. Start the engine and run it for a few
minutes.
2. Stop the engine and wait three minutes.
CAUTION
WARNING Be sure to use the engine oil specified
in the FUEL, ENGINE OIL AND ENGINE
The engine and the components of the COOLANT RECOMMENDATION
exhaust system become very hot and section.
remain hot for some time after the
engine has been stopped. Before
handling these components, wear
insulating gloves or wait until the
engine and the exhaust system have
CAUTION
cooled down. Operating the motorcycle with an
incorrect amount of engine oil can
damage your motorcycle.
3. Hold the motorcycle vertically.
Too little or too much engine oil can
N O T E damage your engine.
Position the motorcycle on firm and flat Place the motorcycle on level ground.
ground. Check the engine oil level with the
engine oil level lens before each use of
4. Inspect the engine oil level through the the motorcycle.
engine oil level lens on the right side on
the engine.
41
Change the engine oil and filter, after first
CAUTION running 1,000 km and every running 4,000
Never operate the motorcycle if the km.
engine oil level is below the “Lower line The engine oil should always be changed
mark (L)” in the engine oil level lens. when the engine is hot so that the engine
Never fill the engine oil above the oil will be drained thoroughly from the
“Upper line mark (F)”. Engine oil level engine.
being most suitable about 1 mm under
the “Upper line mark (F)” of the engine The procedure is as follows.
oil level lens. In case of the engine oil ENGINE OIL CAPACITY
pouring excessively, the engine output
being made insufficient. Oil change 1,100 ㎖
Be careful not to pour the engine oil
Oil and filter change 1,300 ㎖
excessively.
Engine overhaul 1,500 ㎖
CAUTION
In case of the engine oil being over
filled, the engine output will be reduced.
Be careful not to over fill the engine oil.
CAUTION
Improper jacking may cause damage to
the frame or engine.
CAUTION
More frequent servicing may be ❶
performed on motorcycles that are
used under severe conditions, inspect
① Quantity of Engine oil,
② Pollution degree of Engine oil
before riding the motorcycle and then
supplement and replace at any time to
F
L
42
4. Drain the engine oil by removing the drain
plug ② located on the left downside of the WARNING
engine. ● The engine oil temperature may be
high enough to burn you when the
drain plug is loosened. Wait until the
drain plug is cool enough to touch
with bare hands before draining oil.
GD250-000010 ● Do not touch the hot muffler, or the
❷ hot muffler can burn you.
CAUTION
Remove, inspect and clean the oil
strainer Ⓐ by removing the engine oil
WARNING strainer cap Ⓑ when replacing the
Engine oil (specially, when first
New and used oil can be hazardous. replacing).
43
GD250-0000
CAUTION
When replacing the engine oil filter, it is
highly recommended that you use a
genuine HYOSUNG oil filter designed
for your motorcycle, as other filters may
Ⓑ have different design and thread
specifications which could cause
engine damage or oil leaks.
5. Reinstall the engine oil drain plug ②
9. Screw on the new engine oil filter by
securely, but do not overtighten them.
hand until the filter gasket contacts the
mounting surface (a small resistance will
be felt).
And, tighten the new engine oil filter with
a 30mm socket wrench.
F
❸
L
CAUTION
To tighten the engine oil filter properly, it
is important to accurately identify the
position at which the oil filter gasket first
contacts the mounting surface.
CAUTION
Approximately 1,100 ㎖ of the engine
oil must be required when changing
the engine oil only without replacing
6. Loosen the engine oil filter ③ counter-
the engine oil filter.
clockwise and remove it with a 30mm
socket wrench.
7. Wipe off the mounting surface on the
engine where the new engine oil filter will CAUTION
be seated with a clean rag. In case of the engine oil being over
8. S mear a little engine oil around the filled, the engine output will be reduced.
rubber gasket of the new engine oil filter. Be careful not to over fill the engine oil.
44
CAUTION ENGINE COOLANT
Failure to use the correct oil can
⊙ COOLANT LEVEL
damage your motorcycle.
11. Install the engine oil filler plug ① . The coolant should be kept between the
12. Start the engine and allow it idle for a “F”(FULL) and “L”(LOW) level lines in the
few minutes. Check to see that no the reservoir tank at all times.
engine oil is leaking from the engine oil Inspect the level every time before riding
filter ③ and engine oil drain plug ② . while the motorcycle vertically. If the
13. Check the engine oil level according to coolant is found lower than the “L” level
Engine Oil Level Check procedure. line, add properly mixed coolant in the
following way :
CAUTION If the reservoir tank is emptied, pour the
engine coolant to the reservoir tank and
Engine oil leaks from around the engine radiator.
oil filter or drain plug indicate incorrect
installation or the gasket damage. If you
find any leaks or are not sure that the
WARNING
engine oil filter / drain plug has been Wait for the engine to cool down before
properly installed, have the motorcycle checking or topping up coolant level.
inspected by your Hyosung dealer or
qualified mechanic.
N O T E
Position the motorcycle on firm and flat
ground.
45
1. Remove the right side radiator cover ② 4. Install the coolant reservoir tank filler cap
by loosening the two mounting bolts ①. ③.
CAUTION
❶ If coolant level drops too quickly or
the reservoir tank is empty, check the
cooling circuit for leaks.
Have the repair carried out at an
authorized Hyosung dealer.
❷ WARNING
2. Remove the coolant reservoir tank filler Engine coolant is harmful or fatal if
cap ③ by turning it counter-clockwise. swallowed or inhaled.
N O T E
About 1.23 ℓof coolant will required
when filling the radiator and reservoir
tank.
46
RIDING TIPS WARNING
The 『 』 is equipped with the
side stand ignition interlock system.
STARTING THE ENGINE If the transmission is in neutral or the
side stand up, you can only start the
efore attempting to
B engine by squeezing in the clutch lever.
start the engine make This side stand ignition interlock
sure : system prevents the motorcycle from
1. Inspect every day once before riding being started with the side stand down.
the motorcycle. Make sure that the side stand ignition
2. The transmission is in neutral. interlock system is working properly
3. The ignition switch is in the “ON” before riding.
position.
4. The engine stop switch is in the “ ”
position.
5. Moving the side stand to the fully CAUTION
upper position.
The position lamp, meter lamp, tail
6. Squeeze the clutch lever.
lamp and license plate lamp on this
motorcycle always comes on when the
WARNING ignition switch is turned to the “ON”
position.
Running the engine indoors or in a The head lamp is always lit when
garage can be hazardous. starting the engine.
Exhaust gas contains carbon
monoxide, a gas that is colorless and
odorless and can cause death or severe
injury. CAUTION
Only run the engine outdoors where
there is a fresh air. ● R e l e a s e t h e s t a r t e r s w i t c h
immediately after the motorcycle
has started.
CAUTION ● Avoid pressing the starter switch
when the engine is running, or the
Running the engine too long without starting motor damage.
riding may cause the engine to ● Do not engage the starting motor for
overheat. more than five seconds at a time as
Overheating can result in damage to it may overheat the wiring harness
internal engine components and and starting motor.
discoloration of exhaust pipes. If the engine does not start after
Shut the engine off if you cannot begin several attempts, check the fuel
your ride promptly. supply and ignition system.
(Refer for Page 85)
47
When the ignition switch is set to “ON”
position with the engine stopped, the meter CAUTION
lamp will come on and the segments of the The “FI” check lamp ① comes on and
tachometer will turn on once to the end as remains lit when the ignition switch is
a test of electric system operation. set to “ON” position with the engine
Push the starter switch after all the stopped as a test of injection system
segments of the tachometer turn off. operation.
As soon as the engine starts, the “FI”
CAUTION check lamp ① should go out.
Do not attempt the start the engine until If the fuel injection system fails, the “FI”
all the segments of the tachometer turn
check lamp ① comes on and remains
on and then turn off again otherwise
lit.
the engine will start badly.
If the engine does not start or runs
Riding the motorcycle with the “FI”
badly, turn the ignition switch to the
check lamp lit after starting the engine
“OFF” position. After 8 seconds, turn
can damage the engine and
the ignition switch on, allow all the
transmission.
segments of the tachometer turn on
and turn off again and then attempt to Whenever the “FI” check lamp is lit
restart. while riding the motorcycle, have your
This allows the ISC (Idling Speed authorized Hyosung dealer or a
Control) solenoid to be initialized. qualified mechanic inspect the electric
fuel injection system as soon as
possible.
CAUTION
If the “FI” check lamp does not come
on when the ignition switch is set to
“ON” position with the engine stopped
or fail to go out after the engine start,
contact an authorized Hyosung dealer.
48
❶
49
Squeeze the clutch lever and pause
momentarily. Engage first gear by USING THE TRANSMISSION
depressing the gearshift lever downward.
Turn the throttle grip toward you and at The transmission is provided to keep the
the same time release the clutch lever engine operating smoothly in its normal
gently and smoothly. As the clutch operating speed range. The gear ratios
engages, the motorcycle will start moving have been carefully chosen to meet the
forward. characteristics of the engine. The rider
should always select the most suitable
To s h i f t t o t h e n e x t h i g h e r g e a r, gear for the prevailing conditions.
accelerate gently, then close the throttle
and squeeze the clutch lever
simultaneously. Lift the gearshift lever WARNING
upward to select the next gear and release
Downshifting when engine speed is too
the clutch lever and open the throttle again.
high can ;
●c ause the rear wheel to skid and lose
Select the gears in this manner until sixth
traction due to increased engine
gear is reached.
braking, resulting in an accident ; or
● force the engine to overrev in the
WARNING lower gear, resulting in engine
Do not turn for the ignition switch to its damage.
“OFF ” or “LOCK ” position or the
engine stop switch to its “ ” position
while riding the motorcycle. WARNING
Shifting incorrectly can be hazardous.
WARNING Engine and drive chain damage can
Opening the throttle suddenly can be occur if you do not shift correctly.
hazardous.
The front wheel can lift off the ground Slow down before downshifting and
and cause loss of control of the always release the throttle every time
motorcycle. you shift gears.
Always open the throttle gradually
when you accelerate.
CAUTION
WARNING Revving the engine into the black zone
of the tachometer can cause severe
Downshifting while the motorcycle is engine damage.
leaned over in a corner may cause rear
wheel skid and loss of control. Never allow the engine to rev into the
Reduce your speed and downshift black zone of the tachometer in any
before entering corner. gear.
50
RIDING ON HILLS STOPPING AND PARKING
When climbing steep hills, the 1. Turn the throttle grip away from you to
motorcycle may begin to slow down and close the throttle completely.
show lack of power. At this point, you 2. Apply the front and rear brakes evenly at
should shift to a lower gear so that the the same time.
engine will again be operating in its normal 3. Downshift through the gears as road
power range. Shift gear rapidly to prevent speed decreases.
the motorcycle from losing momentum. 4. S elect neutral with the clutch lever
When riding down a steep hill, the squeezed towards the grip (disengaged
engine may be used for braking by shifting position) just before the motorcycle
to a lower gear. stops. Neutral position can be confirmed
Be careful, however, not to allow the by observing the neutral indicator lamp.
engine to overrev.
WARNING WARNING
Inexperienced riders tend to
Operating this motorcycle on steep hills underutilize the front brake. This can
can be hazardous. cause excessive stopping distance and
Never operate this motorcycle on steep lead to a collision. Using only the front
hills. or rear brake can cause skidding and
loss of control.
WARNING
Hard braking while turning may cause
wheel skid and loss of control.
WARNING
Hard braking on wet, loose, rough, or
other slippery surfaces can cause
wheel skid and loss of control.
51
WARNING BREAK-IN
Following another vehicle too closely
can lead to a collision. As vehicle This section explains how important
speeds increase, stopping distance proper break-in is to achieve maximum life
increases progressively. and performance from your new Hyosung.
The following guidelines explain proper
Be sure you have a safe stopping break-in procedures.
distance between you and the vehicle in
front of you.
★ MAXIMUM THROTTLE
5. P ark the motorcycle on a firm, flat OPENING
surface where it will not fall over. RECOMMENDATIONS
WARNING The table below shows the maximum
throttle opening recommendation during
A hot muffler can burn you. The muffler the break-in period.
will be hot enough to burn you for
some time after stopping the engine. Initial 800 km (500 miles) Less than 1/2 throttle
Park the motorcycle where pedestrians Up to 1,600 km (1,000 miles) Less than 3/4 throttle
or children are not likely to touch the
muffler.
52
★ VARY THE ENGINE SPEED ★ ALLOW THE ENGINE OIL
The engine speed should be varied and TO CIRCULATE BEFORE
not held at a constant speed.
This allows the parts to be “loaded” with RIDING
pressure and then unloaded, allowing the Allow sufficient idling time after warm or
parts to cool. cold engine start up before applying load
This aids the mating process of the parts. or revving the engine. This allows time
It is essential that some stress be placed for the lubricating oil to reach all critical
on the engine components during break-in engine components.
to ensure this mating process.
Do not, though, apply excessive load on
the engine.
WARNING
Failure to perform break-in of the tires
could cause tire slip and loss of control.
Use extra care when riding on new tire.
Perform proper break-in of the tire as
described in this section and avoid hard
acceleration, hard cornering, and hard
braking for the first 160 km (100 miles).
53
★ OB SERVE YOUR FIRST, CAUTION
AND MOST IMPORTANT The 1,000 km (600 miles) service
1,000 km SERVICE should be performed as outlined in the
The 1,000 km (600 miles) service is the INSPECTION AND MAINTENANCE
most important service your motorcycle section of this Owner’s Manual.
will receive. Pay particular attention to the
『CAUTION』 and 『WARNING』 in that
During break-in procedures, all of the
section.
engine components will have worn in
and all of the other parts will have seated
in.
All adjustments will be restored, all
fasteners will be tightened, and the dirty
engine oil and engine oil filter will be
replaced.
Timely performance of the 1,000 km
(600 miles) service will ensure optimum
service life and performance from the
engine.
CAUTION
Service should may be peformed
before 1,000 km (600 miles) on
motorcycle that are used under severe
conditions.
54
INSPECTION BEFORE WARNING
RIDING Operating this motorcycle with improper
modifications can be hazardous.
Failure to inspect and maintain your Never modify this motorcycle through
motorcycle increases the chances of an improper installation or use of
accident or equipment damage. accessories.
55
WHAT TO
WARNING CHECK CHECK FOR :
56
PERIODIC WARNING
MAINTENANCE Running the engine indoors or in a
garage can be hazardous.
The chart indicates the intervals between Exhaust gas contains carbon monoxide,
periodic service in kilometers. a gas that is colorless and odorless and
At the end of each interval, be sure to can cause death or severe injury.
inspect, check, lubricate and service as Only run the engine outdoors where
instructed. there is fresh air.
If your motorcycle is used under high
stress conditions such as continuous full
throttle operation, or is operated in a dusty
climate, certain services should be CAUTION
performed more often to ensure reliability of Using poor quality replacement parts
the machine as explained in the can cause your motorcycle to wear
maintenance section. more quickly and may shorten its
Your Hyosung dealer can provide you useful life.
with further guide lines. Use only genuine Hyosung
Steering components, suspensions and replacement parts or their equivalent.
require very special and careful servicing.
For maximum safety we suggest that you
have these items inspected and serviced by
your authorized Hyosung dealer or a N O T E
qualified service mechanic.
The MAINTENANCE CHART specifies
WARNING the minimun requirements for
maintenance. If you use your
Improper maintenance or failure to motorcycle under severe conditions,
perform recommended maintenance perform maintenance more often than
increases the chance of an accident or shown in the chart. If you have any
motorcycle damage. questions regarding maintenance
Always follow the inspection and intervals, consult your Hyosung dealer
maintenance recommendations and or a qualified mechanic.
schedules in this owner’s manual.
Ask your Hyosung dealer or a qualified
mechanic to do the maintenance items
marked with a pentagram (★).
You may perform the unmarked
maintenance items by referring to the
instructions in this section, if you have
mechanical experience.
If you are not sure how to do any of the
jobs, have your Hyosung dealer or a
qualified mechanic do them.
57
★ LUBRICATION POINTS
Proper lubrication is important for smooth and long life of each working part of your
motorcycle and also for safe riding.
It is a good practice to lubricate the motorcycle after a long rough ride or after it gets wet in
the rain or after washing it.
Major lubrication points are indicated as follows.
CAUTION
Lubricating switches can damage the switches.
Do not apply grease and oil to the switches.
❶ ❷ ❸
❻ ❺ ❹
58
❼
❷
❽
N O T E
“ ” : means the invisable parts.
59
★ ENGINE
Interval First Every Every
Item 1,000 km 4,000 km 8,000 km
Air cleaner element Clean every 3,000 km·Replace every 12,000 km
Exhaust pipe nuts and muffler mounting bolts ★ Tighten Tighten -
Valve clearance adjust ★ Inspect Inspect -
Cylinder head bolt ★ Tighten Tighten -
Spark plug Clean Clean Replace
Inspect Inspect -
Fuel hose
Replace every 4 years
Engine oil Replace Replace -
Engine oil filter Replace Replace -
Throttle cable Inspect Inspect -
Idle speed ★ Inspect Inspect -
Clutch ★ Inspect Inspect -
Engine coolant ★ Replace every 2 years
- Inspect -
Radiator hose ★
Replace every 4 years
★ CHASSIS
Interval First Every Every
Item 1,000 km 4,000 km 8,000 km
Drive chain ★ Clean and lubricate every 1,000 km
Brake ★ Inspect Inspect -
Inspect Inspect -
Brake hose ★
Replace every 4 years
Inspect Inspect -
Brake fluid ★
Replace every 2 years
Tire Inspect Inspect -
Steering ★ Inspect Inspect -
Front forks ★ - Inspect -
Rear shock absorber ★ - Inspect -
Chassis nuts and bolts ★ Tighten Tighten -
General lubrication Lubricate Lubricate -
N O T E
“★” : Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.
60
INSPECTION AND
MAINTENANCE
❾
❽
ENGINE OIL
❼
Check if there is leakage from crankcase.
❻
❺
❹ FUEL HOSE
❸ Inspect the fuel hoses for damage and
fuel leakage. If any defect are found the fuel
hoses must be replaced.
❷ Replace the fuel hoses every 4 years.
GASOLINE
Check if there is leakage from fuel tank,
fuel pump, hoses and electric fuel injection
system.
61
ENGINE COOLANT RUBBER CAP OF CABLES
Check if there is leakage from the radiator, Wipe them up with a cloth or towel when
coolant hose. washing.
Rubber cap
Always check the status of the cable's
rubber cap assembly and must be
assembled in the correct position.
Check the location of the cable's rubber
cap after adjusting the throttle cable play.
RADIATOR
Check if there is damage from the radiator.
Inspection Inspection
part Rubber cap part
RADIATOR HOSE
Check to see the radiator hoses for crack,
damage or engine coolant leakage.
If any defects are found, replace the
radiator hoses with new ones.
Replace the radiator hoses every 4 years.
62
EXHAUST PIPE AND REAR-VIEW MIRROR
MUFFLER Check if the mirror shows the rear and/or
Inspect the exhaust pipe and muffler joint side views.
for loosening.
CAUTION
In the event of malfunction or if the
suspension needs expert servicing,
contact an authorised Hyosung dealer.
63
⊙ CHECK AND CLEAN OF
BATTERY BATTERY TERMINAL
⊙ INSPECTION OF BATTERY Clean the battery terminal when it is dusty
or rusted.
SOLUTION LEVEL 1. Set the ignition switch “OFF” position.
The battery is located under the front 2. Remove the front seat.
seat. 3. Check the battery lead wire and terminal.
MF (Maintenance Free) battery of airtight 4. If necessary : disconnect the negative
type is used for this motorcycle. ⊖ battery wire first, then disconnect the
It is not necessary to inspect or positive ⊕ battery wire.
supplement battery fluid. Remove the battery.
However, have your dealer check the 5. Clean the terminal.
charging condition of the battery If there is white dust, clean it with warm
periodically. water.
6. Connect the battery wires and grease the
CAUTION W
terminal lightly.
hen reinstalling the battery, be sure to
● Do not remove airtight cover as it is connect the positive ⊕ battery wire first,
a permanently sealed type battery. then connect the negative ⊖ battery
● Keep separate from the motorcycle wire.
if not used for a long time to reduce
electric discharge and electric
leakage.
● Remove the ⊖ negative terminal
when storing the motorcycle.
WARNING
Never invert the battery cables.
Ensure that the ignition switch is in
position “OFF” before connecting or
disconnecting the battery, otherwise
some components might damage.
64
CAUTION AIR CLEANER
● Keep the battery away from fires.
The air cleaner is located under the front
● When disconnecting the battery
center cover.
wire, be sure to remove the negative
⊖ battery wire first with the ignition
If the air cleaner element has become
switch “OFF” position, then remove
clogged with dust, intake resistance will be
the positive ⊕ battery wire.
increased, with a resultant decrease in
power output and an increase in fuel
When reinstalling the battery, be
consumption.
sure to connect the positive ⊕
If riding under severe conditions must be
battery wire first, then connect the
cleaned or replaced more frequently than
negative ⊖ battery wire.
maintenance schedule. Check and clean
● Ensure the battery wires are
the air cleaner element periodically
fastened tightly.
according to the following procedure.
● Incorrect installation of the battery
will reverse the terminal position
resulting in possible electrical CAUTION
system damage due to incorrect Never operate the engine without the
battery lead connection. element in position.
The red lead wire must go to the Operating the engine without the air
positive ⊕ terminal and the black (or cleaner element will increase engine
black with white tracer) lead wire wear. Always be sure that the air
must go to the negative ⊖ terminal. cleaner element is in excellent
● Never charge a battery while still in operational condition.
the machine as damage may result The life of the engine depends largely
to the battery or regulator / rectifier. on this single component.
CAUTION
If the air cleaner element is polluted it
will result in starting difficulty, engine
output reduced, combustion efficiency
decline, and sooty smoke (black
smoke). At this time, inspect and clean
the air cleaner element and confirm.
65
To remove the air cleaner element : 4.Clean the air cleaner element for the
following :
1. Remove the front center cover ①.
1) When the air cleaner element clean
with the air gun, necessarily blow at
the inside by compressed air.
2) C arefully examine the air cleaner
element for tears during cleaning.
Replace it with a new one if it is torn.
❶ 3) Assemble the element completely or
damage severely the engine.
4) Be careful not to allow water to go
inside the air cleaner element.
❸
CAUTION
●W hen the air cleaner element is not
installed correctly, dust can go
inside and severely damage the
engine.
● Be careful not to allow water to go
into the element while washing.
WARNING
Operating the engine without the air
cleaner element in place can be
hazardous.
66
CAUTION SPARK PLUG
More frequent servicing may be
Check the spark plug every time a
performed on the motorcycle that are
scheduled maintenance service is
used under severe conditions, also
performed.
clean the air cleaner element when
replacing the oil to prevent damage of
the engine.
67
getting into the engine. Change the
spark plug if it shows cracks on the CAUTION
insulating material, corroded electrodes The spark plug must be tightened
or excessive deposits. firmly, otherwise the engine may
overheat and severe damage may
occur.
TIGHTENING TORQUE
15 ~ 20 N·m
SPARK PLUG
(1.5 ~ 2.0 kgf·m)
68
IDLING ADJUSTMENT
This engine features EFI (electronic fuel
injection). The idle speed is not adjustable.
❶
CAUTION ❷
(0.02 ~ 0.04 in)
Do not attempt to make any adjustment
to the idle speed as it may permanently
damage the EFI system. ● Position the motorcycle on firm and flat
ground.
● Withdraw the protection.
● Loosen the lock nut ①.
● Rotate the adjuster ② until achieving the
specified free play.
● When finished, tighten the lock nut ①
and check free play again.
● Refit the protection.
WARNING
Inadequate throttle cable play can cause
engine speed to rise suddenly when you
turn the throttle grip. This can lead to
loss of rider control.
WARNING
When finished, turn the handlebars to
make sure its movement does not affect
the engine idle rpm and check that the
throttle grip - when opened and then
THROTTLE CABLE PLAY released - returns smoothly to the
closed position.
ADJUSTMENT
There should be 0.5 ~ 1.0 mm (0.02 ~
0.04 in) free play in the throttle cable.
If this is not the case, proceed as
follows :
69
CLUTCH CABLE ⊙ CLUTCH CABLE PLAY
ADJUSTMENT
ADJUSTMENT ● A basis adjustment be allowed by the
At each maintenance interval, adjust the clutch lever adjuster ③.
clutch cable play by means of clutch cable ● Uncover the rubber boot ④.
adjuster. ● L o o s e n t h e l o c k n u t ② c o u n t e r -
The cable play should be 4 mm (0.16 in) clockwise.
as measured at the clutch lever holder ● Turn the clutch lever adjuster ③ in or out
before the clutch begins to disengage. to acquire the specified play.
● After end of adjustment, tighten the lock
nut ② clockwise fully and cover the
❹ ❸ rubber boot ④.
● If not adjust by the clutch lever adjuster
③, adjust by the clutch cable adjuster ⑤.
● Loosen the clutch cable adjuster lock nut
⑥.
● Turn the clutch cable adjuster ⑤ in or
4mm out to acquire the specified play.
❷ ❶ ● After end of adjustment, tighten the lock
nut ⑥.
● The clutch cable should be lubricated
❺ with a light weight oil whenever it is
adjusted.
70
DRIVE CHAIN
Good Excessive
wear
The chain may require more frequent
adjustment that it is with periodic
maintenance depending upon your riding
conditions.
Check the chain every 1,000 km.
WARNING
If you find any of these problems with your
Riding with the chain in poor condition
sprocket, consult your Hyosung dealer.
or improperly adjusted can lead to an
accident.
CAUTION
Inspect, adjust, and maintain the chain The two sprockets should be inspected
properly before each ride, according to for wear when a new chain is installed
this section. and replace them if necessary.
71
CAUTION
The drive chain should be inspected
every time before riding.
20 ~ 30 mm (0.79 ~ 1.18 in) Excessive chain slack could cause the
chain to come off the sprockets and
result in accident or serious engine
damage.
CAUTION WARNING
The drive chain for this motorcycle is Kerosene can be hazardous. Kerosene
made of the special material. is flammable. Children or pets may be
The chain should be replaced with a harmed from contact with kerosene.
RK520STX for 『 』.
Use of another chain may lead to Keep flames and smoking materials
premature chain failure. away from kerosene. Keep children and
pets away from kerosene.
If swallowed, do induce vomiting. Call a
physician immediately.
Dispose of used kerosene properly.
72
CAUTION BRAKES
Cleaning the chain with gasoline or The 『 』 utilizes front and rear
commercial cleaning solvents can disk brakes.
damage “O-rings” and ruin the chain. Properly operating the brake systems are
vital to safe riding. Be sure to perform the
Clean the drive chain with kerosene brake inspection requirements as
only. schedules.
The brakes should be inspected at
2. After thoroughly washing the chain and periodic inspection by your authorized
allowing it to dry, oil the links with a Hyosung dealer.
Hyosung chain lube or an equivalent.
WARNING
Failure to properly inspect and maintain
your motorcycle brake systems can be
hazardous.
73
⊙ BRAKE FLUID
WARNING Be sure to check the brake fluid level in
Operating the motorcycle in harsh the master cylinder. If the level was found
condition can be hazardous if you do to be lower than the lower mark holding
not inspect brake wear often. the motorcycle upright, inspect the brake
pad’s wear condition.
Operating in mud, water, sand, or other If the brake pad’s wear condition is
extreme conditions can cause good, replenish with the proper brake fluid
accelerated brake wear. This could lead that meets Hyosung’s requirements.
to an accident.
[Front Brake]
[Rear Brake]
74
As the brake pads wear, the fluid level will ⊙ BRAKE PADS
drop to compensate for the new position of Inspect the front and rear brake pads to
barke pads. determine whether or not the friction pads
Replenishing the master cylinder to are worn down to the grooved limit line. If a
considered normal periodic maintenance. pad is worn to the grooved limit line it must
be replaced with a new one by your
WARNING authorized Hyosung dealer or qualified
service mechanic.
Brake fluid may be harmful if
swallowed or if it comes in contact with The rate at which brake pads will wear
skin or eyes. Contact your doctor depends on motorcycle usage, riding style
immediately if brake fluid is swallowed and road surface condition.
and induce vomiting. If brake fluid gets
into the eyes or in contact with the skin,
flush thoroughly with plenty of water.
CAUTION
This motorcycle uses glycol-based
brake fluid.
Do not use or mix different types of
brake fluid, otherwise serious damage [Front Brake]
will result in the brake system.
Use Only DOT4 brake fluid.
Do not spill any brake fluid on painted
or plastic surfaces as it will damage the
surface severely.
Never use any brake fluid that has been
stored in a used or unsealed container.
Never reuse brake fluid left over from
the last servicing and stored for long
period as it absorbs moisture from the
air.
[Rear Brake]
75
Limit line
WARNING
If brake pads are allowed to wear down
to the metal substrate, metal-to-metal
contact with the brake disk would lead
to noise and the brake caliper sparking ;
this would result in loss of braking and
brake disk damage, cousing a
dangerous riding condition.
Riding with worn brake pads will Replace both pads together.
reduce braking performance and will
increase your chance of having
accident. Inspect brake pad wear before
each use. Ask your Hyosung dealer or
qualified mechanic to replace brake
pads if any pad is worn to the limit.
76
⊙ BRAKE DISK INSPECTION ⊙ REAR BRAKE FLUID SUPPLY
Check the brake disk for damage or cracks. 1. Place the motorcycle on a level surface
and keep the handlebars straight.
2.C lean the rear brake fluid reservior
around not to allow dust to get inside of it.
3. Turn the cap to the counter - clockwise.
4. Replenish with brake fluid to the upper
line.
N O T E
The recommended brake fluid : DOT4
N O T E
The recommended brake fluid : DOT4
CAUTION
● Don’t replenish with brake fluid over
the limit line. It will leak out of the
brake fluid reservoir.
● Be careful not to allow dusts or
water to go inside when it is
replenished. ⊙ REAL BRAKE LAMP SWITCH
● D on’t use the unrecommended The rear brake lamp switch is located at
brake fluid. right-side of the engine.
● Brake fluid can damage severely the Move the switch up or down to adjust it
plastics or rubbers. When it is spilt until the switch operates and turns on the
on the parts, wipe them up brake lamp after the brake pedal begins to
immediately. be depressed.
77
TIRE TIRE PRESSURE NORMAL RIDING
(COLD INFLATION) SOLO RIDING DUAL RIDING
Inspect the tire pressure and the tire 2.00 kgf/㎠ 2.00 kgf/㎠
thread depth periodically. FRONT 200 kPa 200 kPa
Inspect frequently the tire pressure for the 29.0 psi 29.0 psi
safety and the tire life. 2.11 kgf/㎠ 2.25 kgf/㎠
REAR 211 kPa 225 kPa
WARNING 30.0 psi 32.0 psi
78
⊙ CRACKS AND CUTS ⊙ TIRE TREAD CONDITION
TWI
TW
TWI
I
SCREW,
FOREIGN
TWI
MATERIAL
79
⊙ TIRE REPLACEMENT ■ REAR TIRE REPLACEMENT
■ FRONT TIRE REPLACEMENT 1. P
lace the motorcycle on the jack or block
1. Place the motorcycle on the jack or block vertically.
vertically.
CAUTION
CAUTION Improper jacking may cause damage to
Improper jacking may cause damage to the frame or engine.
the frame or engine.
2. Loosen the four front axle pinch bolts ① 2. Loosen the rear axle nut ①.
(right and left).
3. Loosen the front axle nut ② .
❶
❶
❶ ❷
3. Carefully position a jack or block under
engine and raise until the rear wheel is
4. Carefully position a jack or block under slightly off the ground.
engine and raise until the front wheel is
slightly off the ground.
5. Draw out the front axle .
WARNING
6. Slide the front wheel forward. A hot muffler can burn you.
7. To reinstall the front wheel assembly, The muffler will be hot enough to burn
reverse the sequence as described. yor for some time after stopping the
engine.
Wait until the muffler cools to avoid
burns.
80
BULBS ⊙ INSPECTION OF LAMPS
● Check if the position lamp, meter lamp,
tail lamp and license plate lamp work
WARNING well when the ignition switch was turned
to the “ON” position.
Keep fuel and other flammable
substances away from electric Check if the head lamp work well when
components. starting the engine.
●C heck if the brake lamp work well when
the front brak lever or rear brake pedal
was operated.
CAUTION ●C heck if the turn signal lamp work well
when the turn signal switch was
Before changing a bulb, set the ignition
operated.
switch to position “OFF” and allow a
● Check if the head lamp, tail lamp, turn
few minutes for the bulb to cool down.
signal lamp and brake lamp are dusty or
Wear clean gloves or use a clean, dry
damaged.
cloth to handle the new bulb.
Do not put your fingerprints on the
bulb, as this may lead to overheating
and failure.
If you have handled the bulb with bare Head lamp
hands, clean it with alcohol to avoid &
any damage. Position
lamp
DO NOT PULL ON THE WIRES.
N O T E
Before changing a bulb, check the Brake / Tail lamp
fuses.
License
plate lamp
81
⊙ HEAD LAMP’S BULB
CAUTION REPLACEMENT
The position lamp, meter lamp, tail 1. R
emove the two bolts ① (right and left)
lamp and license plate lamp on this and the head lamp assembly.
motorcycle always comes on when the
ignition switch is turned to the “ON”
position .
The head lamp is always lit when
starting the engine.
CAUTION
Using a lamp bulb with the wrong 6. To reinstall the head lamp, reverse the
wattage rating can cause electrical above sequence.
system damage or shorten bulb life.
82
⊙ TURN SIGNAL LAMP’S BULB ⊙ BRAKE / TAIL LAMP’S BULB
REPLACEMENT REPLACEMENT
1. R emove the lens by removing the
screw.
2. While pushing the bulb, turn it to the
counter-clockwise and pull it out.
❸ ❶
❷
83
⊙ FUSE BOX The fuse box is located under the front
seat.
The fuses are designed to open when the
circuit overload exists in individual electrical
system circuits.
If any electrical system fails to work, then
the fuses must be checked.
● 30A REC. / REG. / IGN fuse protects the
rectifier / regulator and ignition switch
circuits.
● 20A ECU / M.RELAY fuse protects all
electrical circuits including the ECU.
● 10A HEAD L. / METER fuse protects the
head lamp low beam and instrument
panel circuits.
ZWh yljUGylnU ZWh zwhyl ● 10A HEAD H. fuse protects the head
pnu
YWh yljUGylnU
ZWh lj| YWh zwhyl
ZWh zwhyl
lamp high beam circuits.
YWh
pnu
tUGylsh
lj| XWh zwhyl
YWh
● 10A S.STAND / STARTER / CLUTCH
XWh olhkGsU zwhyl
tUGylsh
tl{ly
XWh olhkGsU XWh wvzp{pvu
XWh zwhyl
fuse protects the side stand switch,
tl{ly {hps
spjluU
XWh wvzp{pvu
starter switch and clutch lever switch
XWh olhkGoU mhu
{hps
spjluU circuits.
XWh zUGz{huk XWh mhu
XWh olhkGoU {|yu
z{hy{ly
XWh zUGz{huk
z{vw ● 10A POSITION / TAIL / LICEN. / FAN
js|{jo XWh {|yu
ovyu
z{hy{ly
js|{jo
z{vw
zUGzluz
ovyu fuse protects the position lamp, tail lamp,
zUGzluz
licence plate lamp and cooling fan
circuits.
● 10A TURN / STOP / HORN / S.SENS
fuse protects the turn signal lamp, brake
lamp, horn and speedo sensor circuits.
● 30A SPARE / 20A SPARE / 10A SPARE
fuse are each spare fuse.
ZWh
ZWh ZWh
ZWh
CAUTION
XX XW
XW
YY
YWh
YWh ``
YWh
YWh
Installing a fuse of incorrect rating or
XWh
XWh XWh
XWh
ZZ __
using aluminum foil or wire instead of a
XWh
XWh XWh
XWh fuse may seriously damage the
[ ^
[ ^
electrical system.
\
XWh
XWh ]
XWh
XWh
\ ]
Always replace a blown fuse with a
fuse of the same type and rating. If the
new fuse blows in a short time, consult
your Hyosung dealer or a qualified
mechanic immediately.
84
TROUBLESHOOTING ★W
HEN THE ENGINE
REFUSES TO START
This troubleshooting guide is provided to ⊙ IGNITION SYSTEM CHECK
help you find the cause of some common
complaints. 1. R
emove the spark plug and reattach it to
the spark plug lead.
CAUTION
Failure to troubleshoot a problem
correctly can damage your motorcycle.
Improper repairs or adjustments may
damage the motorcycle instead of
fixing it. Such damage may not be
covered under warranty.
If you are not sure about the proper
action, consult your Hyosung dealer
about the problem. 2. Put the engine stop switch in the “ ”
position and the ignition switch in the
“ON” position. Holding the spark plug
base firmly against the engine, the
transmission in neutral, the side stand
up, the clutch disengaged and push the
electric starter switch.
I f the ignition system is operating
properly, a blue spark should jump
across the spark plug gap.
85
4. If there is still no spark, consult your ★ ENGINE STALLING
Hyosung dealer for repairs.
1. C
heck the fuel supply in the fuel tank.
2. C
heck the ignition system for intermittent
WARNING spark.
3. C
heck the idle speed.
Performing the spark test improperly
can be hazardous. CAUTION
You could get a high voltage electrical When occur any trouble, the best way
shock or an explosion if you are not is to consult your Hyosung dealer for
familiar with this procedure. repairs.
Do not perform this check if you are not
familiar with the procedure.
86
● Place the motorcycle on firm and level
TRANSPORT ground.
● Stop the engine and wait until it has
cooled down.
WARNING ● Prepare a container large enough to
hold the fuel in the tank and place it on
Before transporting the motorcycle, it is
the floor on the left side of the
necessary to empty the fuel tank
motorcycle.
completely, making sure that it is
● Remove the fuel tank cap.
completely dry.
● Drain fuel using a manual tank or similar
During transport, the motorcycle must
system.
be firmly secured in an upright position
D o not damage the fuel tank assembly
to avoid fuel and oil leaks.
(fuel level gauge accommodated inside
the tank).
WARNING
Refit the fuel tank cap after draining all
fuel.
WARNING
Keep the fuel tank away from fires.
Allow some time for the engine and
muffler to cool down completely.
Fuel vapours are harmful to human
health.
Ensure the area is well ventilated before
proceeding.
Do not inhale fuel vapours.
Do not smoke, nor use naked flames.
87
★ WASHING YOUR
CLEANING PROCEDURE
MOTORCYCLE
A thorough cleaning of your motorcycle is With some care, your motorcycle can be
a necessary part of maintenance and will washed in a similar manner to washing an
help keep your motorcycle looking and automobile.
performing its best. Proper cleaning can
also extend the life of your motorcycle.
It is important to clean and inspect your N O T E
motorcycle after every ride if it is used in Avoid spraying or allowing water to
mud, brush, grass, water, salt water, or very flow over the following places :
dusty conditions. ● Ignition switch
The build-up of mud, brush, grass, etc, ● Spark plug
especially on the engine and exhaust ● Fuel tank cap
system, can reduce engine cooling, conceal ● Electric fuel injection system
damage, or increase wear of certain parts. ● Brake master cylinders
It is important to remove all debris during ● Radiator fins
cleaning. ● Snorkel air intake for air cleaner
CAUTION
High pressure washers can damage CAUTION
your motorcycle (especially the radiator Do not use parts cleaner to throttle
pin). body and electric fuel injection
High pressure washers such as those sensors.
found at coin-operated car washes
have enough pressure to damage the
parts of your motorcycle. It may cause Use a garden hose at low pressure to
rust, corrosion and increase wear. remove the majority of dirt or other debris.
Do not use high pressure washers to Wash your motorcycle by hand with a mild
clean your motorcycle. soap or detergent and water. Try to
thoroughly remove all dirt and debris
without excessive water pressure. Cloth
rags, washing mitts or cleaning brushes can
be used, be careful with brushes as they
may scratch plastic or painted surfaces.
Rinse the motorcycle thoroughly with clean
water.
Dry all areas using a chamois or soft
absorbent cloth.
88
★ WAXING THE ★ INSPECTION AFTER
MOTORCYCLE CLEANING
After washing the motorcycle, waxing and Remove the rags or wrapping from the
polishing are recommended to further exhaust pipe. For extended life of your
protect and beautify the paint. motorcycle, lubricate according to
● Only use waxes and polishes of good “LUBRICATION POINTS” section.
quality.
● W hen using waxes and polishes, WARNING
observe the precautions specified by the
manufacturers. Operating the motorcycle with wet
brakes can be hazardous.
Wet brakes may not provide as much
stopping power as dry brakes. This
could lead to an accident.
Test your brakes after washing
motorcycle, riding at slow speed. If
necessary, apply brakes several times
to let friction dry out the pads.
89
STORAGE PROCEDURE ★ EXTERNAL
·Spray all vinyl and rubber parts with
rubber protectant.
If you don’t plan on using your motorcycle ·Spray the unpainted surfaces with rust
for a long time, it will need special servicing preventative.
requiring appropriate materials, equipment ·Coat the painted surfaces with car wax.
and skill. For this reason, Hyosung
recommends that you trust this maintenance ★ MAINTENANCE DURING
work to your dealer. If you wish to service the
machine for storage yourself, follow the STORAGE
general guidelines below : Once a month, recharge the battery.
90
LAB E L
❷
❹
❶
NOTE :
“ ” = means the invisable parts.
91
❶
92
❸
93
SPECIFICATIONS
★ DIMENSIONS AND DRY MASS
★ ENGINE
Four-stroke, DOHC,
Type
Liquid-cooled
Number of cylinder 1 cylinder
Bore 73.0 mm (2.87 in)
Stroke 59.6 mm (2.35 in)
Piston displacement 249.5 cm3 (15.2 in3)
Fuel system Electric fuel injection
Starter system ELECTRIC STARTER
★ TRANSMISSION
94
★ CHASSIS
★ ELECTRICAL
★ CAPACITIES
95
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