Table of Contents
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IMPORTANT
BREAK-IN INFORMATION FOR
YOUR MOTORCYCLE
The first 1,000km(600miles) are the most impor-
tant in the life of your motorcycle .
Proper break-in operation during this time will
help ensure maximum life and performance from
your new motorcycle.
Hyosung parts are manufactured of high quality
materials, and manufactured parts are finished to
close tolerances. Proper break-in operation
allows the machined surfaces to polish each
other and mate smoothly.
Motorcycle reliability and performance depend
on special care and restraint exercised during
the break-in period. It is especially important that
you avoid operating the engine in a manner
which could expose the engine parts to exces-
sive heat.
Please refer to the BREAK-IN section for specific
break-in recommendations.
WARNING/CAUTION/NOTE
Please read this manual and follow its instruc-
tions carefully. To emphasize special informa-
tion the words 『 WARNING』 , 『 CAUTION』and
『 NOTE』carry special meanings and should
be carefully reviewed.
WARNING
The personal safety of the rider may be
involved. Disregarding this information
could result in injury to the rider.
CAUTION
These instructions point out special
s e r v i c e p r o c e d u r e s o r p r e c a u t i o n s
that must be followed to avoid damag-
i n g t h e m a c h i n e .
NOTE: This provides special information
to make maintenance easier or impor-
tant instructions clearer.
1
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Summary of Contents for HYOSUNG GV250
- Page 1 The personal safety of the rider may be Hyosung parts are manufactured of high quality involved. Disregarding this information materials, and manufactured parts are finished to could result in injury to the rider.
- Page 2 FOREWORD THANK YOU for choosing Hyosung. We at All information, illustrations photographs and Hyosung have designed, tested and produced specifications contained in this manual are this motorcycle using the most modern tech- based on the latest product information avail- nology available to provide you with many able at the time of publication.
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Page 3: Table Of Contents
TABLE OF CONTENTS 1. CONSUMER INFORMATION 6. INSPECTION BEFORE RIDING ACCESSORY INSTALLATION AND PERIODIC MAINTENANCE PRECAUTION SAFETY TIPS SAFE RIDING RECOMMENDATION 7. RIDING TIPS FOR MOTORCYCLE RIDERS STARTING THE ENGINE SERIAL NUMBER LOCATION STARTING OFF USING THE TRANSMISSION 2. NAMES OF EACH PART RIDING ON HILLS STOPPING AND PARKING 3. -
Page 4: Consumer Information
It is not possible for her normal riding position. This limits the free- Hyosung to test each accessory on the market or dom of movement of the rider and may limit his combinations of all the available accessories, how- or her control ability. -
Page 5: Serial Number Location
◉ WEAR A HELMET SERIAL NUMBER LOCATION Motorcycle safety equipment starts with a quality safety helmet. One of the most serious injuries The frame and/or engine serial numbers are that can happen is a head injury. ALWAYS wear used to register the motorcycle. They are a properly approved helmet. -
Page 6: Names Of Each Part
NAMES OF EACH PARTS ① Clutch lever ⑦ Front brake fluid reservoir ② Left handle switches ⑧ Throttle grip ③ Choke lever ⑨ Front brake lever ④ Speedometer ⑩ Right handle switches ⑤ Fuel gauge ⑪ Fuel tank cap ⑥ Tachometer ⑫... - Page 7 ⑬ Ignition coil (Front) � Seat lock ⑭ Throttle stop screw � Passenger footrests ⑮ Ignition coil (Rear) � Side stand � Fuel cock � Footrests � Spark plug (Rear) � Gearshift lever � Fuel pump � Spark plug (Front)
- Page 8 � Tools � Battery and fuse � Air cleaner � Rear brake pedal � Rear brake lamp switch � Engine oil filter Engine oil drain plug Engine oil filler cap Engine oil level lens...
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Page 9: Controls
INSTRUMENT PANEL CONTROLS IGNITION SWITCH ① TRIP METER The trip meter is a resettable odometer located in the speedometer assembly. It can be used to The ignition switch has three positions: indicate the distance traveled on short trip or between fuel stops. Pressing control button will ◉... -
Page 10: Left Handle Switch
⑤ TACHOMETER ◉“ ” : The headlamp low beam and tail- The tachometer indicates the engine speed in lamp come on. revolutions per minute(r/min). ⑥ TURN SIGNAL INDICATOR LAMP WARNING When the turn signals are being operated either Set the dimmer switch “ ”... -
Page 11: Ignition Key
① FRONT BRAKE LEVER With the ignition switch in the “ ON ” position, the engine stop switch in the “ ” position, and the The front brake is applied by squeezing the brake lever gently toward the throttle grip. transmission is in neutral, pull in the clutch lever Front brake be anxious about motorcycle falling and push the starter switch to start the engine. -
Page 12: Carburetor Choke Lever
CARBURETOR CHOKE LEVER ◉“ OFF ” Position Turn the lever to the “ OFF ” position whenever stopping the engine for more than a few min- The carburetor is equipped with a choke system utes. to provide easy starting when the engine is cold. When starting the cold engine, turn the choke lever all the way toward you. -
Page 13: Instrument Panel
CAUTION After switching the fuel cock lever to the “ RES ” position, it is advisable that the tank be refilled at the closest gas station. After refueling be sure to move the fuel cock to the “ ON ” position. REAR BRAKE PEDAL Depressing the rear brake pedal will apply the has a 5-speed transmission... -
Page 14: Stand
WARNING STAND Riding with the side stand incompletely retracted can result in an accident when you turn left. Check operation of the side stand/igni- tion interlock system before riding. Always retract the side stand complete- ly before starting off. SEAT LOCK ①... -
Page 15: Fuel And Oil Recommendation
Do not overfill the fuel tank. Do not fill the ● mance from your new Hyosung. The following fuel tank above the entrance lower end. guidelines explain proper break-in procedures. - Page 16 ★ MAXIMUM THROTTLE OPENING REC- WARNING OMMENDATIONS Failure to perform break-in of the tires The table below shows the maximum throttle could cause tire slip and loss of control. opening recommendation during the break-in Use extra care when riding on new tire. period.
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Page 17: Inspection Before Riding
Your Hyosung dealer can provide you with fur- ther guide lines. Steering components, suspensions and require very special and careful servicing. For maximum... - Page 18 ① Clutch lever holder ④ Brake lever holder ② Drive chain ⑤ Brake pedal pivot ③ Side stand pivot and spring hook - Motor oil - Grease...
- Page 19 Inspect Chassis nuts and bolts ★ ─ Tighten Tighten CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions. NOTE ★ = Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.
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Page 20: Riding Tips
CAUTION RIDING TIPS Running the engine too long without riding may cause the engine to overheat. STARTING THE ENGINE Overheating can result in damage to inter- nal engine components and discoloration of exhaust pipes. Before attempting to start Shut the engine off if you cannot begin the engine make sure: your ride promptly. -
Page 21: Using The Transmission
After moving the side stand to the fully upper RIDING ON HILLS position, pull the clutch lever in and pause momentarily. Engage first gear by depressing ● When climbing steep hills, the motorcycle the gearshift lever downward. may begin to slow down and show lack of Turn the throttle grip toward you and at the power. -
Page 22: Inspection And Repair
WARNING INSPECTION AND REPAIR Hard braking while turning may cause wheel skid and loss of control. TOOL Brake before you begin to turn. To assist you in the performance of periodic WARNING maintenance, a tool kit is supplied and is located under the seat. -
Page 23: Battery
CAUTION BATTERY Do not remove absolutely airtight cover ● as airtight type battery. ◉ INSPECTION OF BATTERY SOLUTION LEVEL ● Keep after separate at the motorcycle MF(Maintenance Free) battery of airtight type is for the minimum of self electric dis- used for this motorcycle. -
Page 24: Air Cleaner
◉ BATTERY INSTALLATION CAUTION ’ s battery installation order pay Keep the battery away from fires. ● attention to following points : ● When disassemble the battery wire, take off � terminal first with the ignition switch “OFF” position. When assemble, � terminal first. ●... -
Page 25: Fuel Hose
FUEL HOSE 2. Remove the screws ③ and take off ④ . Inspect the fuel hose for damage and fuel leak- age. If any defect are found the fuel hose must be replaced. Replace the fuel hose every 4 years. SPARK PLUG 3. -
Page 26: Engine Oil
If the spark plug color indicates that other than a standard spark plug be ◉ ENGINE OIL LEVEL CHECK used, it is best to consult your Hyosung Follow the procedure below to inspect the dealer before selecting an alternate engine oil level. - Page 27 ENGINE OIL CAPACITY 1,450 ㎖ Replace 1,500 ㎖ Oil filter replace 1,800 ㎖ Overhaul CAUTION In case of the engine oil pouring in exces- sively, the engine output being made insuffi- CAUTION cient. Be careful not to pouring in the engine oil Necessarily, confirm and clean the oil strain- excessively.
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Page 28: Oil Filter Installation
3. Drain the oil by removing the drain plug ② CAUTION located on the bottom of the engine. When install the oil fiter, necessarily, “HYOSUNG”character and “16510H05240” part’ s NO. install toward the outside, other- wise can damage the engine. WARNING ⑥... -
Page 29: Carburetor
CAUTION CAUTION Approximately 1,450 ㎖ of oil must be Never adjust “ CO adjust screw ”� of the required when changing oil only without carburetor. replacing the oil filter. If adjust optionally, exert a bad influence upon output of the engine as the two car- buretor is disharmonious. -
Page 30: Clutch Adjustment
◉ THROTTLE CABLE ADJUSTMENT ① The clutch lever play ② The lock nut 1. Loosen the lock nut ① . ③ The clutch lever adjuster 2. Adjust the cable slack by cable adjuster ② in ④ The rubber boot or out to obtain the correct slack 0.5~1.0mm ⑤... -
Page 31: Drive Chain
After aligning and adjusting the slack in the ● Loose sprocket mounting nuts drive chain to 20~30mm (0.79~1.18 in), retighten the axle nut securely and perform a If you find any of these problems with your final inspection. sprocket, consult your Hyosung dealer. -
Page 32: Brakes
The chain should be replaced with a tion requirements as schedules. 520DS. The brakes should be inspected at periodic Use of another chain may lead to prema- inspection by your authorized Hyosung dealer. ture chain failure. ◉ FRONT BRAKE BRAKE FLUID ●... - Page 33 BRAKE PADS ● rized Hyosung dealer for safety as in Inspect the front brake pads by nothing whether times of operating at high pressure. or not the friction pads are worn down to the grooved limit line.
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Page 34: Brakes
③ If the extension line is beyond the range, have the brake shoe assembly replaced by your Hyosung dealer to ensure safe opera- tion. WARNING Riding with worn brake shoe will reduce braking performance and will increase your chance of having an accident. -
Page 35: Tires
Operating the motorcycle with excessively worn TIRE tire will decrease riding stability and can lead to loss of control. Inspect the tire pressure and the tire thread Inspect stortage of tire thread’ s depth by the depth periodically. 『 tire wear indicator』 . Inspect frequently the tire pressure for the safety Replace the front and rear tires at once when and the tire life. - Page 36 3. Loosen the front axle pinch bolt ② . ◉ REAR TIRE REPLACEMENT 4. Loosen the front axle ③ . 1. Place the motorcycle on the center stand. 5. Carefully position a jack or block under engine and raise until the front wheel is slight- ly off the ground.
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Page 37: Replace Of The Lamp
It is highly recommended 5. Remove the rear break hub from the swing to use the standard tire supplied by Hyosung. arm. 6. Loosen the rear shock absorber lower bolt ④ , left and right, draw out the rear axle with the rear wheel push to the bottom. - Page 38 ◉ HEAD LAMP CAUTION The use of a lamp other than rules may cause to occur the vehicle fire and to damage at electric parts. Surely use only the lamp of proper capaci- ◉ TURN SIGNAL LAMP 1. Remove the two screw ① (right and left) and the headlamp assembly.
- Page 39 ◉ TAIL/BRAKE LAMP 1. Remove the screws ① and the lens. 2. Remove the tail & brake lamp cover. 3. Push in the bulb, turn it to the counter-clockwise, and pull it out. 4. After stick in the new lamp, assemble the lens. CAUTION Overtightening the screws may cause the lens to crack.
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Page 40: When The Engine Refuse To Start
If there is no spark, consult your Hyosung In case a fuse blows there is a 15A spare fuse. dealer for repairs. CAUTION Never use other than specified 15A fuse. -
Page 41: Specifications
SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2,270mm(89.4in) Overall width 800mm(31.5in) Overall height 1,090mm(42.9in) Wheelbase 1,500mm(59.1in) Ground clearance 155mm(6.1in) Mass 170kg(375lbs) ENGINE Type Four-stroke, air-cooled and oil-cooled Number of cylinder V-2 cylinder Bore 57.0mm(2.24in) Stroke 48.8mm(1.92in) Piston displacement 249cm (15.2in Corrected compression ratio 10.2 : 1 Carburetor... - Page 42 CHASSIS Front suspension Telescopic type Rear suspension Swing arm type 33 。 Caster Trail 135mm(5.32in) 40 。 (right & left) Steering angle Front tire size 110/90-16 59S Rear tire size 150/80-15M/C 70S Front brake Disc Rear brake Drum ELECTRICAL “ CDI ” type Ignition type 13 。...
- Page 43 Prepared by HYOSUNG MOTORS & MACHINERY INC. 2nd Ed. MAR. 2003. Printed in KOREA...
- Page 44 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 purpose of mainte- nance, 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 of delivery to the ulti- mate purchaser or while it is in use ;...
Need help?
Do you have a question about the GV250 and is the answer not in the manual?
Questions and answers
Where do the double hoses on the back of the carburetors on the left side of the bike connect
On the HYOSUNG GV250, the double hoses on the back of the carburetors are likely for vacuum and fuel routing:
1. One hose connects to the vacuum source, often from the intake manifold or a T-junction that joins both cylinder intakes.
2. The second hose may connect to the fuel pump’s vacuum input if the bike uses a vacuum-operated pump.
If you have a third hose on the carb, it could be a drain or overflow line that routes down and out the back of the bike.
This answer is automatically generated