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Summary of Contents for HYOSUNG GV 650 EFI
- Page 1 WARNING This owner’s manual contains important safety information. Please read it carefully.
- 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 informa- tion and instructions which should be read carefully before operating the motorcycle.
- Page 3 Motorcycling is one of be some discrepancies in this manual. the most exhilarating sports and insure your Hyosung reserves the right to make riding enjoyment, you should become thor- changes at any time. oughly familiar with the information present-...
- Page 4 Information following these signal words mance from your new motorcycle. should be carefully reviewed. Hyosung parts are manufactured of high quality materials, and manufactured parts are finished to close tolerances. Proper WARNING break-in operation allows the machined sur-...
- 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 ele- ment 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 ;...
- Page 6 ● ● Observe periodic maintenance the owner’s manual in the owner’s requirements your authorized manual storage compartment located HYOSUNG dealer is trained and under the seat. equipped to perform this service. ● ● Before the rider’s first use of the ●...
- Page 7 WARNING WARNING Keep both hands on the handgrips at all is equipped with the side stand ignition interlock system. times when riding. Removing your If the transmission is in neutral or side hands from the handgrips reduces your stand up, you can only start the engine ability to control the motorcycle, and with pulling in the clutch lever.
- Page 8 ◉ ◉ FAMILIARIZE YOURSELF WITH WARNING THE MOTORCYCLE Do not operate the ignition switch in the WARNING “OFF” position, the steering lock to lock or the engine stop switch in the “ ” Your riding skill and mechanical knowl- position while driving at one’s pleasure. edge from the foundation for safe riding practices.
- Page 9 2. Inspect for proper ground clearance can lead to unsafe operating conditions. It and bank angle. An improperly mount- is not possible for Hyosung to test each ed load could critically reduce these accessory on the market or combinations two safety factors. Also determine that...
- Page 10 This limits the freedom of movement of the rider and may limit his or her control ability. 6. Additional electrical accessories may damage the existing electrical system. Severe overloads may damage the wiring harness or create a dangerous situation due to the loss of electrical power during the operation of the motorcycle.
- Page 11 TABLE OF CONTENTS 1. SERIAL NUMBER LOCATION ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 2. FUEL , ENGINE OIL AND COOLANT RECOMMENDATION ∙∙ FUEL ENGINE OIL ENGINE COOLANT SOLUTION 3. NAMES OF EACH PARTS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 4. CONTROLS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ IGNITION SWITCH STEERING LOCK IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH REAR BRAKE PEDAL...
- Page 12 7. BREAK-IN ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 8. INSPECTION BEFORE RIDING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 9. PERIODIC MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 10. INSPECTION AND MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙ TOOL ENGINE OIL GASOLINE FUEL HOSE ENGINE COOLANT RADIATOR RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER SPARK PLUG IDLING ADJUSTMENT...
- Page 13 Please write down the numbers in the box SERIAL NUMBER LOCATION provided below for your future reference. Frame number : The frame and/or engine serial numbers are used to register the motorcycle. They are also to assist your dealer in terms of Engine number : ordering parts or referring to special ser- vice information.
- Page 14 FUEL, ENGINE OIL AND ENGINE OIL COOLANT RECOMMENDATION ◉ ◉ ENGINE OIL SPECIFICATION Classification F U E L Grade Remarks system Over SL Use unleaded gasoline with an octane rating of 91 or higher. 10W/40 Unleaded gasoline can extend spark plug life and exhaust components life.
- Page 15 ◉ ◉ ENGINE COOLANT ENGINE COOLANT SOLUTION The engine coolant performs as rust inhibitor and water pump lubricant as well Use an engine coolant that is compatible as anti-freeze. with aluminum radiator, mixed with distilled Therefore the engine coolant should be water only at a 50 : 50 mixture ratio for used at all times even though the atmos- engine coolant solution.
- Page 16 NAMES OF EACH PARTS ① ⑤ Clutch lever Right handle switches ② ⑥ Left handle switches Front brake lever ③ ⑦ Instrument panel Throttle grip ④ ⑧ Front brake fluid reservoir Fuel tank cap...
- Page 17 ⑨ ⑮ Spark pulg (Front) Coolant reserve tank ⑩ � Fuses Engine oil drain plug ⑪ � Spark pulg (Rear) Footrests ⑫ � Seat lock bolt Gearshift lever ⑬ � Passenger footrests Ignition coil (Front) ⑭ Side stand N O T E ”...
- Page 18 � � Muffler Rear brake fluid reservoir � � Seat Radiator � Battery Cooling fan and motor � ECU (Engine Control Unit) Rear brake pedal � Tools Rear brake lamp switch � Ignition coil (Rear) Engine oil filter � Front brake fluid reservoir Water pump �...
- Page 19 WARNING CONTROLS Turning the ignition switch to the “OFF” position while the motorcycle is moving IGNITION SWITCH can be hazardous. have the ignition switch at the rightside. The ignition switch has two positions : ◉ ◉ “OFF” POSITION All electrical circuits are cut off. The engine will not start.
- Page 20 STEERING LOCK IGNITION KEY has the steering lock below comes equipped with a pair the steering head tube. of 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.
- Page 21 ③ ③ NEUTRAL INDICATOR LAMP INSTRUMENT PANEL The neutral indicator lamp will come on when the transmission is in neutral. � � The lamp will go out when you shift into � � any gear other than neutral. � � ④...
- Page 22 ⑤ ⑤ FUEL METER ⑥ ⑥ ODOMETER / TRIP METER The display in it has three functions, odometer and two trip meters. The display changes odometer or trip meter, as indicated before turning the igni- tion switch off. ’s the speedometer is LCD(Liquid Crystal Display) type, it indi- cates the remaining fuel amount in the fuel tank.
- Page 23 ⑦ ⑦ CLOCK The clock indicates 12-hour mode. Follow the procedure below to adjust the clock. 1. Push the switch ⑧ (in the normal mode) for 2 seconds until the hour and minutes To reset the trip meter to zero, push the display blink.
- Page 24 ⑧ ⑧ ⑩ ⑩ SELECT SWITCH SPEEDOMETER Use this switch to adjust the following : In the normal mode ● Push it for Adjustment To adjust the light of 0.6 ~ 1 speedometer display seconds (100% → 75% → 50% → 25% → 100%) Normal mode 2 seconds →...
- Page 25 Whenever the “FI” check lamp is lit and the display panel indicates “FI” have your authorized Hyosung dealer or a � qualified mechanic inspect the fuel � injection system as soon as possible.
- Page 26 WARNING RIGHT HANDLE SWITCH Set the dimmer switch “ ” when other vehicle is running in front or against. � � ④ TURN SIGNAL SWITCH Using when left, right turn or change direction. ◉ “ � ” Position : Flash the left turn sig- �...
- Page 27 CAUTION WARNING Apply the brake lightly and with great Do not engage the starting motor for care on slippery surfaces to avoid skid- more than five seconds at a time as it ding. may overheat the wiring harness and starting motor. If the engine does not start after several attempts, check the fuel supply and igin- ③...
- Page 28 REAR BRAKE PEDAL GEARSHIFT LEVER Depressing the rear brake pedal will apply the rear brake. The brake lamp will be illuminated when the rear brake is operated. WARNING Apply the brake lightly and with great care on slippery surfaces to avoid skid- ding.
- Page 29 Reduce the motorcycle speed before FOOTRESTS down-shifting. When down-shifting, the engine speed should be increased before the clutch is ◉ ◉ FOOTREST POSITION ADJUSTMENT engaged. has 2 type of the footrest This will prevent unnecessary wear on position, right and left. the drive train components and the rear tire.
- Page 30 ◉ ◉ GEARSHIFT LINK ROD When the footrests in position � , exchange the gearshift link rod for appropri- ate riding position. ● ● Position � � : Install the gearshift link rod ④ ● ● Position � � : Install the gearshift link rod ⑤ �...
- Page 31 WARNING SIDE STAND Make sure that the side stand ignition interlock system is working properly before riding. � is equipped with the side stand ignition interlock system. If the transmission is in neutral or side stand up, you can only start the engine with pulling in the clutch lever.
- Page 32 SEAT LOCK REAR SHOCK ABSORBER � � To remove the seat, remove the seat ① Rear shock absorber mounting bolt on the rearside of the seat. ② Pin spanner To install the seat, slide the seat hook into the seat hook retainer and install the seat WARNING mounting bolt.
- Page 33 The rebound and compression damping FRONT FORK force can be individually adjusted by turn- ing the respective adjusters. The rebound damping force adjuster ① is located at the The standard settings of front forks are top of the front fork. The compression selected to meet various riding conditions damping force adjuster ②...
- Page 34 3. Remove the fuel tank mounting bolt ② . FUEL TANK STAY 4. Take the fuel tank stay ③ off the tray upper the battery. has the “fuel tank stay” under the seat. Use the “fuel tank stay” to inspect the engine or the other parts easily.
- Page 35 SUPPLY OF GASOLINE, WARNING ENGINE OIL AND COOLANT Gasoline is extremely flammable and toxic. Always observe the following pre- cautions when refueling your GASOLINE ● Never permit motorcycle refueling by anyone other than an adult. ● Refuel in a well ventilated area. ●...
- Page 36 CAUTION ENGINE OIL Never operate the motorcycle if the Long engine life depends much on the engine oil level is below the “Lower line selection of quality oil and the periodic mark(L)” in the engine oil level lens. changing of the oil. Never fill the engine oil above the Daily oil level checks and periodic “Upper line mark(F)”.
- Page 37 CAUTION CAUTION More frequent servicing may be per- Necessarily, confirm and clean the oil formed on motorcycles that are used � strainer when replace the Engine oil ① (specially, when first replacement). under severe conditions, inspect ② Quantity of Engine oil, Pollution degree of Engine oil before riding the motorcycle and then supplement and...
- Page 38 Use new “O” ring each time the engine oil filter element is replaced. When install the oil filter, necessarily, “HYOSUNG” character and “16510HN910” 8. Replace the oil filter cap ⑥ and tighten the part’s NO. install toward the outside, nuts securely but do not over tighten them.
- Page 39 9. Replace the drain plug and tighten it ENGINE COOLANT securely. This time, insert the gasket nec- essarily. Pour fresh oil through the filler hole. Approximately 3,200 ㎖ ◉ ◉ COOLANT LEVEL of oil will be required. CAUTION Approximately 3,000 ㎖ ㎖ of oil must be required when changing oil only without replacing the oil filter.
- Page 40 ◉ ◉ OPEN THE RADIATOR CAP WARNING Remove the right front side cover ① operate the radiator cap ③ . Engine coolant is harmful or fatal if To disassemble the right front side cover swallowed or inhaled. ① , remove the two mounting bolts ② . Do not drink anti-freeze or coolant WARNING solution.
- Page 41 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 can cause death or severe injury. Necessary attempt Only run the engine outdoors where before start the engine : there is a fresh air.
- Page 42 ② the LCD display panel indicates “FI” Removing your hands from the handle- letters, contact an authorized Hyosung bars or feet from the footrests during dealer. operation can be hazardous. If you remove even one hand or foot from the motorcycle, you can reduce your ability to control the motorcycle.
- Page 43 Pull the clutch lever and pause momen- USING THE TRANSMISSION tarily. Engage first gear by 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 gen- engine operating smoothly in its normal tly and smoothly.
- Page 44 RIDING ON HILLS STOPPING AND PARKING Climbing steep hills, the motorcycle may 1. Turn the throttle grip away from you to begin to slow down and show lack of close the throttle completely. power. At this point you should shift to a 2.
- Page 45 WARNING Following another vehicle too closely can lead to a collision. As vehicle speeds increase, stopping distance increases progressively. Be sure you have a safe stopping dis- tance between you and the vehicle in front of you. 5. Park the motorcycle on a firm, flat sur- face where it will not fall over.
- Page 46 Wear in the tread surface by gradually er break-in is to achieve maximum life and increasing your cornering lean angles performance from your new Hyosung. The over the first 160 km (100 miles) before following guidelines explain proper break-in attempting maximum performance. Avoid procedures.
- Page 47 Timely performance of the 1,000 km WHAT TO CHECK FOR : CHECK (600 miles) service will ensure optimum Smoothness ● ● service life and performance from the Steering No restriction of movement ● ● engine. No play or looseness ● ● Correct play in the throt- ●...
- Page 48 For maximum safety we suggest that you Using poor quality replacement parts have these items inspected and serviced by can cause your motorcycle to wear your authorized Hyosung dealer or a quali- more quickly and may shorten its useful fied service mechanic. life.
- Page 49 ① ⑤ Clutch lever holder and clutch cable Speedometer gear box ② ⑥ Passenger footrests pivot Front brake lever holder ③ ⑦ Side stand pivot and spring hook Throttle cable ④ ⑧ Footrests pivot Rear brake pedal pivot - Motor oil - Grease...
- Page 50 Front forks ★ ─ ─ Inspect Rear shock absorber ★ ─ Tighten Tighten Chassis nuts and bolts ★ ─ Lubricate Lubricate General lubrication N O T E ★ = Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.
- Page 51 INSPECTION AND � MAINTENANCE TOOL � To assist you in the performance of peri- odic maintenance, a tool kit is supplied and � is located under the seat. The tool kit con- sists of the following items. � NAME � Tool bag �...
- Page 52 ENGINE COOLANT BATTERY Check if there is leakage from the radiator, ◉ INSPECTION OF BATTERY SOLUTION coolant hose. LEVEL MF(Maintenance Free) battery of airtight type is used for this motorcycle. RADIATOR It is not necessary to inspect or supple- ment battery fluid. Check if there is damage from the radia- The battery is located under the seat.
- Page 53 ◉ ◉ CLEAN OF BATTERY TERMINAL AIR CLEANER Clean the battery terminal when it is dusty or rusted. 1. Set the ignition switch “OFF” position. If the air cleaner element has become 2. Disassemble the seat, disassemble the clogged with dust, intake resistance will ) positive battery wire after the ( increase with a resultant decrease in power negative battery wire.
- Page 54 CAUTION Before and during the cleaning opera- � tion, inspect the element for tears. A torn element must be replaced. Be sure to put the element snugly and correctly, so that no incoming air will bypass it. � Remember, rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element.
- Page 55 Remove the carbon deposits periodically dard spark plug be used, it is best to from the spark plug with a piece of hard wire consult your Hyosung dealer before or pin. selecting an alternate plug or heat range. The selection of an improper spark plug can lead to severe engine damage.
- Page 56 We suggest that you have Inadequate throttle cable play can cause ’s idling speed adjusted by your autho- engine speed to rise suddenly when you rized Hyosung dealer. turn the throttle grip. This can lead to loss of rider control. CAUTION...
- Page 57 ◉ CLUTCH CABLE ADJUSTMENT CLUTCH CABLE ADJUSTMENT ● A basis adjustment be allowed by the clutch lever adjuster ③ . At each maintenance interval, adjust the ● Loosen the clutch lever adjuster ③ . clutch cable play by means of clutch cable ●...
- Page 58 ● Loose pulleys mounting nuts If you find any of these problems with The belt may require more frequent your pulley, consult your Hyosung dealer. adjustment that it is with periodic mainte- nance depending upon your riding condi- CAUTION tions.
- Page 59 1. Place the motorcycle on the jack or block. ◉ CAUTION OF DRIVE BELT ① 2. Loosen the axle bolt When the drive belt was bent excessively, ② 3. Loosen the lock nut the belt inner cord is broken. 4. Adjust the slack in the drive belt by Never bend the drive belt under the speci- ③...
- Page 60 The proper operation the brake systems is vital to safe riding. Be sure to perform the brake inspection requirements as sched- ules. The brakes should be inspected at period- ic inspection by your authorized Hyosung [Rear Brake] dealer. WARNING ◉ BRAKE FLUID...
- Page 61 CAUTION The front and rear brake system be replaced the brake hose or the brake fluid according to periodic inspection chart by your authorized Hyosung deal- er for safety as in times of operating at high pressure. [Front Brake] WARNING...
- Page 62 ◉ BRAKE DISK INSPECTION ◉ FRONT BRAKE LAMP SWITCH Check the brake disk for damage or cracks. The front brake lamp switch is located beneath the front brake lever. Loosen the switch fitting screws and adjust the timing by ◉ FRONT BRAKE FLUID SUPPLY moving the switch body forward or back- 1.
- Page 63 NORMAL RIDING TIRE TIRE PRESSURE (COLD INFLATION) SOLO RIDING DUAL RIDING 2.25 kg/ ㎠ 2.25 kg/ ㎠ Inspect the tire pressure and the tire FRONT 221 kpa 221 kpa thread depth periodically. Inspect frequently the tire pressure for the 33.0 psi 33.0 psi safety and the tire life.
- Page 64 Do not apply the jack head to the oil filter may cause trouble. jacking up the motorcycle. It is highly recommended to use the standard tire supplied by Hyosung. 5. Draw out the axle shaft. 6. Slide the front wheel forward. ◉ REAR AXLE NUT 7.
- Page 65 REAR TIRE REPLACEMENT ● REPLACEMENT OF THE LAMP 1. Place the motorcycle on the jack or block. 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 specification may cause the electric system or the lamp to damage.
- Page 66 ◉ HEAD LAMP ◉ TURN SIGNAL LAMP � � ① 1. Remove the three screws (right, left 1. Remove the lens by removing the and upside) and the head lamp assem- screw. bly. 2. Push the bulb, turn it to the counter- clockwise, and pull it out.
- Page 67 CAUTION Never use other than specified 30A or 15A fuse. Installing a fuse of incorrect rating may seriously damage the electrical system. You should consult your Hyosung deal- er or a qualified service mechanic imme- diately.
- Page 68 When any trouble occurs, the best way ③ If there is no spark, clean the spark plug. is to consult your Hyosung dealer for Replace it if necessary. Retry the above repairs. procedure with the cleaned spark plug or new one.
- Page 69 ◉ ◉ WASHING YOUR motorcycle CLEANING PROCEDURE With some care, your motorcycle can be washed in a similar manner to washing an A thorough cleaning of your motorcycle is automobile. a necessary part of maintenance and will help keep your motorcycle looking and per- N O T E forming its best.
- Page 70 ◉ ◉ INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe. For extended life of your motorcycle, lubricate according to “GENERAL LUBRICATION” section. WARNING Operating motorcycle with wet brakes can be hazardous. Wet brakes may not provide as much stopping power as dry brakes.
- Page 71 L A B E L � � �...
- Page 72 � � �...
- Page 73 SPECIFICATIONS DIMENSIONS AND DRY MASS 2,430 mm ( 95.7 in ) Overall length 840 mm ( 33.1 in ) Overall width 1,155 mm ( 45.5 in ) Overall height 1,665 mm ( 65.6 in ) Wheelbase 160 mm ( 6.3 in ) Ground clearance 220 kg ( 485 lbs ) Mass...
- Page 74 CHASSIS Front suspension Telescopic type Rear suspension Swingarm type Caster 35。 160 mm ( 6.3 in ) Trail 35。 ( right & left ) Steering angle Front tire size 120/70 - ZR 18 59W Rear tire size 180/55 - ZR 17 73W Front brake Double disk Rear brake...
- Page 75 MEMO...
- Page 76 MEMO 75 75...
- Page 77 Prepared by 1st Ed. JUL. 2008. Printed in KOREA...
- Page 78 Part No. 99011HP9510FI JUL. 2008. 1st Ed. Printed in KOREA...
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