Related Manuals for HYOSUNG Karion
Summary of Contents for HYOSUNG Karion
- Page 1 HYOSUNG MOTORS & MACHINERY INC. Part No. 99011HM5410 SEP. 2002. 1st Ed. Printed in KOREA...
- Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
- Page 3 Overseas Technical Department life for your motorcycle. Your Hyosung dealer has experienced technicians that are � COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. trained to provide your machine with the best possible service with the right tools and equipment.
- Page 4 Proper break-in operation during this time will help ensure maximum life and WARNING performance from your new motorcycle. Hyosung parts are manufactured of high The personal safety of the rider may be quality materials, and manufactured parts involved. Disregarding this information are finished to close tolerances.
- Page 5 WARNING Noise Control System(muffler assembly) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit : (a) The removal or rendering inoperative by any person other than for the purpose of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its any sale or delivery to the ultimate purchaser or while it is in use ;...
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Page 6: Consumer Information
HYOSUNG dealer is trained and ● ● Before the rider s first use of the equipped to perform this service. , make sure that he/she is ●... - Page 7 WARNING WARNING Keep both hands on the handgrips at all comes equipped with a times when riding. Removing your side stand safe device. hands from the handgrips reduces your This safe device is returned by itself. ability to control the motorcycle, and Push the side stand until it is in contact could result in an accident.
- Page 8 ◉ ◉ WEAR A HELMET ◉ ◉ FAMILIARIZE YOURSELF WITH THE MOTORCYCLE WARNING WARNING Motorcycle safety equipment starts with a quality safety helmet. One of the most Your riding skill and mechanical serious injuries that can happen is a knowledge form the foundation for safe head injury.
- Page 9 It and kept to a minimum. is not possible for Hyosung to test each 4. The motorcycle may be affected by a accessory on the market or combinations...
- Page 10 motorcycle. Balance the load between the left and right side of the motorcycle and fasten it securely. WARNING Modification of the motorcycle, or removal of original equipment may render the vehicle unsafe or illegal. 태...
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Page 11: Table Of Contents
TABLE OF CONTENTS 1. SERIAL NUMBER LOCATION ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 2. FUEL AND OIL RECOMMENDATION ∙∙∙∙∙∙∙∙∙∙∙∙∙ FUEL ENGINE OIL 3. NAMES OF EACH PARTS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 4. CONTROLS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ IGNITION SWITCH IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH CARBURETOR CHOKE LEVER FUEL COCK REAR BRAKE PEDAL KICK START LEVER... - Page 12 7. BREAK-IN ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 8. INSPECTION BEEORE RIDING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 9. PERIOPIC MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 10. INSPECTION AND REPAIR ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ TOOL ENGINE OIL GASOLINE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER FUEL HOSE SPARK PLUG CARBURETOR CLUTCH ADJUSTMENT DRIVE CHAIN...
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Page 13: Serial Number Location
Frame number : SERIAL NUMBER LOCATION Engine number : The frame and/or engine serial numbers are used to register the motorcycle. They are also to assist your dealer in terms of ordering parts or referring to special service information. FUEL AND OIL RECOMMENDATION F U E L Use unleaded gasoline with an octane... -
Page 14: Engine Oil
ENGINE OIL ■ ■ ENGINE OIL SPECIFICATION Classification Grade Remarks system Over SG 10 W/30 or 10W/40 ※ If a SAE 10 W/30 or 10W/40 motor oil is not available, select and alternative according to the following chart. 20W50 15W40 15W50 ENGINE OIL 10W40 10W50 10W30... -
Page 15: Names Of Each Parts
NAMES OF EACH PARTS 60 70 80 90 Clutch lever Front brake fluid reservoir Left handle switches Right handle switches Choke lever Front brake lever Speedometer Throttle grip Ignition switches Fuel tank cap 폽탐... - Page 16 Fuel cock Rear carrier Passenger footrests Side stand Footrests � Gearshift lever 폽탑...
- Page 17 � Kick starter lever � Engine oil filter cap � Engine oil filler cap & level gauge � Rear brake pedal � Footrests � Passenger footrests 폽탓...
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Page 18: Controls
IGNITION KEY CONTROLS comes equipped with a pair of IGNITION SWITCH identical ignition keys. Keep the spare key in a safe place. Your motorcycle ignition keys are stamped with an identifying number. This number is used when making replacement keys. Please write your key number in the box provided for your future reference. -
Page 19: Instrument Panel
INSTRUMENT PANEL LEFT HANDLE SWITCH � � � � � � � � � � � ODOMETER CLUTCH LEVER The odometer registers the total distance The coutch lever is used for disengaging that the motorcycle has been ridden. the drive to the rear wheel when starting the engine or shifting the transmission gear. -
Page 20: Right Handle Switch
WARNING RIGHT HANDLE SWITCH Set the dimmer switch when other vehicle is running in front or against. � � TURN SIGNAL SWITCH Using when left, right turn or change direction. ◉ � Position : Flash the left turn � signal lamp. �... - Page 21 STARTER SWITCH WARNING Use this switch to operate the starting motor. Apply the brake lightly and with great With the ignition switch in the ON care on slippery surfaces to avoid position, the engine stop switch in the skidding. position, and the transmission is in neutral, pull in the clutch lever and push the starter switch to start the engine.
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Page 22: Carburetor Choke Lever
CARBURETOR CHOKE LEVER FUEL COCK is equipped with a manually operated fuel cock. There are three position ON , OFF and RES . ◉ ◉ ON Position The normal operating position for the fuel cock lever is in the ON position. The carburetor is equipped with a choke system to provide easy starting when the engine is cold. -
Page 23: Rear Brake Pedal
◉ ◉ RES (RESERVE) Position WARNING If the fuel level in the tank is too low, turn the lever to the RES position to use the Apply the brake lightly and with great 1.5ℓ of reserve fuel supply. care on slippery surfaces to avoid skidding. -
Page 24: Gearshift Lever
Reduce the motorcycle speed before GEARSHIFT LEVER down-shifting. When down-shifting, the engine speed should be increased before the clutch is engaged. This will prevent unnecessary wear on the drive train components and the rear tire. CAUTION When the transmission is in neutral the green indicator lamp on the instrument panel will be lit. -
Page 25: Stand
STAND SEAT LOCK � To separate the seat, loosen two bolts Side stand that are united the rear fender and the frame below the seat. WARNING When assemble the seat, put up the seat at the frame and unite two bolts. comes equipped with a side stand safe device. -
Page 26: Rear Suspension
SUPPLY OF GASOLINE AND REAR SUSPENSION ENGINE OIL GASOLINE To adjust the spring pre-load, turn the adjuster clockwise or counter-clockwise to the desired position with the pin spanner. Position 1 provides the softest spring pre- load and position 5 provides the stiffest. To open the fuel tank cap, remove the end is delivered from the factory of vent tube from the vehicle body and turn... - Page 27 WARNING ENGINE OIL Gasoline is extremely flammable and Long engine life depends much on the toxic. Always observe the following precautions when refueling your selection of quality oil and the periodic changing of the oil. Daily oil level checks and periodic ●...
- Page 28 CAUTION CAUTION Never operate the motorcycle if the More frequent servicing may be performed on motorcycles that are used engine oil level is below the Lower line mark(L) in the engine oil level gauge. under severe conditions, inspect Never fill the engine oil above the Quantity of Engine oil, Pollution Upper line mark(F) .
- Page 29 INSERTION 3. Drain the oil by removing the drain LUSTER DIRECTION plug located on the bottom of the MATERIAL engine. HYOSUNG OUTSIDE 16510H05240 � CAUTION When install the oil fiter, necessarily, HYOSUNG character and 16510H05240 part s NO. install toward the outside, otherwise can damage the engine.
- Page 30 CAUTION WARNING Engine oil and exhaust pipes can be hot Approximately 950 of oil must be enough to burn you. required when changing oil only without Wait until the oil drain plug and exhaust replacing the oil filter. pipes are cool enough to touch with bare hands before draining oil.
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Page 31: Riding Tips
WARNING RIDING TIPS Running the engine indoors or in a garage can be hazardous. STARTING THE ENGINE Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and Before attempting to can cause death or severe injury. start the engine make Only run the engine outdoors where sure: there is a fresh air. -
Page 32: Starting Off
After moving the side stand to the fully STARTING OFF upper position, pull the clutch lever in and pause momentarily. Engage first gear by depressing the gearshift lever downward. WARNING Turn the throttle grip toward you and at the same time release the clutch lever Riding this motorcycle at excessive gently and smoothly. -
Page 33: Using The Transmission
USING THE TRANSMISSION RIDING ON HILLS The transmission is provided to keep the When climbing steep hills, the motorcycle engine operating smoothly in its normal may begin to slow down and show lack of operating speed range. The gear ratios power. -
Page 34: Stopping And Parking
WARNING STOPPING AND PARKING comes equipped with a 1. Turn the throttle grip away from you to side stand safe device. close the throttle completely. This safe device is returned by itself. 2. Apply the front and rear brakes evenly Push the side stand until it in contact and at the same time. - Page 35 160km(100miles). The opening explains how important proper break-in is to achieve maximum life and performance from your new Hyosung. WARNING The following guidelines explain proper break-in procedures. Failure to perform break-in of the tires could cause tire slip and loss of control.
- Page 36 CAUTION Service should may be peformed before 1,000km(600miles) on motorcycle that are used under severe conditions. CAUTION The 1,000km (600miles) service should be performed as outlined in the INSPECTION AND MAINTENANCE section of this Owner s Manual. Pay particular attention to the CAUTION and WARNING in that section.
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Page 37: Periodic Maintenance
RIDING For maximum safety we suggest that you have these items inspected and serviced by your authorized Hyosung dealer or a Before riding the motorcycle, be sure to qualified service mechanic. check the follwing item. - Page 38 Clutch lever holder Brake lever holder Drive chain Throttle cable Side stand pivot and spring hook Brake pedal pivot Speedometer gear box - Motor oil - Grease 텍 습 탉탔...
- Page 39 Front forks ★ Inspect ─ ─ Inspect Rear shock absorber ★ ─ Chassis nuts and bolts ★ Tighten Tighten N O T E ★ ★ = Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked. 탉탕...
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Page 40: Inspection And Repair
INSPECTION AND REPAIR ENGINE OIL Check if there is leakage from crankcase, TOOL oil hose. To assist you in the performance of periodic maintenance, a tool kit is supplied and is located under the right side cover. GASOLINE The tool kit consists of the following items. Check if there is leakage from fuel tank, NAME fule cock, hose, carburetor. -
Page 41: Front Fork
FRONT FORK ● Check if there is any noise by bend of front fork while moving the handle upward and downward. ● Inspect whether the steering stem is well assembled while moving front fork up/downwards and /or foreward/ backward. CAUTION REAR SHOCK ABSORBER ●... - Page 42 ◉ ◉ CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted. 1. Set the ignition switch OFF position. 2. Disassemble the battery cover, disassemble the ( )positive battery wire after the ( )negative battery wire. Remove the battery.
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Page 43: Air Cleaner
: do not twist or This appearence is occurred at first to wring the element or it will develop tears. clean the air cleaner element and 6. Immerse the element in HYOSUNG confirm. � genuine oil and squeeze the oil out of the element leaving it slightly wet with oil. -
Page 44: Spark Plug
FUEL HOSE � � CAUTION Inspect the fuel hose for damage and fuel ● ● Don t use the cleaning solvent leakage. If any defect are found the fuel whose flash point is low when hose must be replaced. cleaning the element. Replace the fuel hose every 4 years. - Page 45 Hyosung dealer before selecting an alternate plug or heat range. The selection of an improper spark plug can lead to severe engine damage.
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Page 46: Clutch Adjustment
◉ ◉ THROTTLE CABLE ADJUSTMENT � � � � � � (1) Loosen the lock nut (2) Adjust the cable slack by cable adjuster in or out to obtain the correct slack 0.5~1.0mm(0.02~0.04in). (3) After adjusting the slack, tighten the lock nut. -
Page 47: Drive Chain
Check the chain every 1,000km. WARNING If you find any of these problems with your sprocket, consult your Hyosung dealer. Riding with the chain in poor condition or improperly adjusted can lead to an accident. CAUTION... - Page 48 1. Place the motorcycle on the jack or block. ◉ ◉ DRIVE CHAIN CLEANING AND OILING 2. Loosen the axle nut 3. Adjust the slack in the drive chain by adjuster as the lock nut turning toward the left and right. 4.
- Page 49 Hyosung s requirements. the brake system. As the brake pads wear, the fluid level will Use only DOT3 or DOT4. Do not spill...
- Page 50 Hyosung dealer for safety as Hyosung dealer or qualified service in times of operating at high pressure.
- Page 51 ◉ ◉ REAR BRAKE CAUTION ● ● REAR BRAKE ADJUSTMENT Do not spill any brake fluid on painted or plastic surfaces as it will damage the WARNING surface severely. Too much clearance in the rear brake pedal can cause poor braking N O T E performance and may lead to an accident.
- Page 52 If the extension line is beyond the range, have the brake shoe assembly replaced by your Hyosung dealer to ensure safe operation. WARNING Riding with worn brake shoe will reduce braking performance and will increase your chance of having an accident.
- Page 53 TIRE Inspect the tire pressure and the tire thread depth periodically. Inspect frequently the tire pressure for the safety and the tire life. 테텍템텅탱텄 텝좼텍템호 텍죽턱템 ◉ ◉ TIRE PRESSURE Insufficient air pressure in the tires not CAUTION only hasten tire wear but also seriously affects the stability of the motorcycle.
- Page 54 CAUTION The standard tire on is 130/80-18 66p for front, and 180/80- 14M/C 78p for rear. The use of a tire other than standard may cause trouble. It is highly recommended to use the standard tire supplied by Hyosung. 탑탉...
- Page 55 REPLACEMENT OF THE LAMP Requirement electric power of the lamp shown in the following chart. � � When replace the damaged lamp, always use the equal capacity. The use of a lamp other than rules may cause to excessive at the electric system or to damage the lamp.
- Page 56 Installing a fuse of incorrect rating may seriously damage the electrical system. You should consult your Hyosung dealer or a qualified service mechanic immediately. 3. Push in the bulb, turn it to the counter- clock wise and pull it out.
- Page 57 When occur any trouble, the best way is away from any other fire or heat source. to consult your Hyosung dealer for repairs. ● ● Ignition System Check Remove a spark plug and reattach to the spark lead.
- Page 58 Use a garden hose at low pressure to CLEANING PROCEDURE remove the majority of dirt or other debris. Hand wash your motorcycle with a mild A thorough cleaning of your motorcycle is soap or detergent and water. Try to a necessary part of maintenance and will thoroughly remove all dirt and debris without help keep your motorcycle looking and excessive water pressure.
- Page 59 L A B E L 탑탕...
- Page 60 크 탑태...
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Page 61: Specifications
SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2,085mm (82.1 in) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Overall width 840mm (33.1 in) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Overall height 1,125mm (44.3 in) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Wheelbase 1,350mm (53.2 in) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Ground clearance 230mm (9.1 in) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Mass 135kg (298 lbs) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ ENGINE Type Four-stroke, air-cooled ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙... - Page 62 CHASSIS Front suspension Telescopic type ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Rear suspension Swing arm type ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Caster ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Trail 84mm ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Steering angle 47 (right & left) ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Front tire size 130/80-18 66P ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Rear tire size 180/80-14M/C 78P ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Front brake Disc ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ Rear brake Drum ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙...
- Page 63 Prepared by HYOSUNG MOTORS & MACHINERY INC. Overseas Technical Dept 1st Ed. SEP. 2002. Printed in KOREA...