Table of Contents
Advertisement
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.
1
Advertisement
Table of Contents
Related Manuals for HYOSUNG Motorcycle
Summary of Contents for HYOSUNG Motorcycle
- Page 1 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...
- Page 2 Therefore, your model may have different standard The proper care and maintenance that features than shown in this manual. your motorcycle requires are outlined in this manual. By following these instructions explicitly HYOSUNG MOTORS & MACHINERY INC.
- Page 3 『 WARNING』 , 『 CAUTION 』 and 『 NOTE 』 . The first 1,600km(1,000miles) are the most important in the life of your motorcycle. Proper break-in operation during this time will help ensure maximum life and perfor- WARNING mance from your new motorcycle.
- Page 4 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 carburetor may cause per- manent damage to the catalyst and to the noise control system.
-
Page 5: Consumer Information
Specific FOR MOTORCYCLE RIDERS items to check are listed in the INSPECTION BEFORE RIDING sec- Motorcycle riding is great fun and an excit- tion on page 46 of this owner’ s man- ing sport. Motorcycle riding also requires ual. - Page 6 Exhaust gases contain carbon monoxide, a potentially lethal gas that is colorless and odorless. ● ● Never leave the motorcycle running while unattended, even for a short time. WARNING While operating the...
- Page 7 We suggest that you practice riding your motorcycle in a non-traffic situation ◉ ◉ WEAR A HELMET until you are thoroughly familiar with your machine and its controls.
- Page 8 The addition of unsuitable accessories and kept to a minimum. can lead to unsafe operating conditions. It 4. The motorcycle may be affected by a is not possible for Hyosung to test each lifting condition or by an instability in...
- Page 9 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 ren- der the vehicle unsafe or illegal.
-
Page 10: Table Of Contents
TABLE OF CONTENTS 1. SERIAL NUMBER LOCATION ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 2. FUEL , ENGINE OIL AND COOLANT RECOMMENDATION ∙∙ FUEL ENGINE OIL COOLANT 3. NAMES OF EACH PARTS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 4. CONTROLS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ IGNITION SWITCH STEERING LOCK IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH CARBURETOR CHOKE LEVER REAR BRAKE PEDAL... - Page 11 7. BREAK-IN ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 8. INSPECTION BEFORE RIDING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 9. PERIODIC MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 10. INSPECTION AND MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙ TOOL ENGINE OIL GASOLINE FUEL HOSE COOLANT RADIATOR RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER SPARK PLUG CARBURETOR CLUTCH ADJUSTMENT...
-
Page 12: 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 ser- vice information. -
Page 13: Engine Oil
℉ CAUTION Using a premium quality four stroke motor oil will increase the service life of your Spilled engine coolant can damage motorcycle. painted surfaces. WARNING Do not spill any fluid when filling the radiator. Wipe spilled engine coolant ● Don’ t mix the unrecommended oil. It up immediately. - Page 14 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 ℃ ℃...
-
Page 15: Names Of Each Parts
NAMES OF EACH PARTS ① Clutch lever ⑥ Right handle switches ② Left handle switches ⑦ Front brake lever ③ Choke lever ⑧ Throttle grip ④ Instrument panel ⑨ Fuel tank cap ⑤ Front brake fluid reservoir... - Page 16 ⑩ Spark pulg (Front) � Passenger footrests ⑪ Ignition coil (Front) � Side stand ⑫ Fuses � Coolant reserve tank ⑬ Ignition coil (Rear) � Engine oil drain plug ⑭ Spark pulg (Rear) � Footrests ⑮ Seat lock bolt � Gearshift lever N O T E “...
- Page 17 � Muffler Rear brake fluid reservoir � Seat Radiator � Battery Cooling fan and motor � Tools Rear brake pedal � Throttle stop screw Rear brake lamp switch � Fuel pump Engin oil filter � Front brake fluid reservoir Water pump �...
-
Page 18: Controls
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. -
Page 19: Steering Lock
You could lose your balance and fall, or you could drop the motorcycle. Stop the motorcycle and place it on the side stand if equipped before locking the steering. Never attempt to move the... -
Page 20: Instrument Panel
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 ④ COOLANT TEMPERATURE METER CAUTION When the ignition switch is turned to the ON position, the display of speedome- ter will come on. - Page 21 The F (Full) mark indicates the fuel tank is full. The odometer registers the total distance The E (Empty) mark indicates the fuel that the motorcycle has been ridden. tank is empty or nearly so. When the remaining fuel is approximately The two trip meters are resettable 3.0ℓ...
-
Page 22: Clock Adjustment
4. Push the switch ⑧ for 2 seconds to be hazardous. Removing a hand from resume in the normal mode. the handlebars can reduce your ability to control the motorcycle. Always keep both hands on the handle- bars while riding. CLOCK ADJUSTMENT... - Page 23 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 Clock reset mode...
-
Page 24: Left Handle Switch
WARNING LEFT 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- nal lamp. -
Page 25: Right Handle Switch
“ ” grip. position, and the transmission is in neutral, Front brake be anxious about motorcycle pull in the clutch lever and side stand up falling down when braking suddenly as disk and push the starter switch to start the brake system. -
Page 26: Carburetor Choke Lever
If you keep running in condition of full choke lever, it causes fuel excess CAUTION exhaustion, high speed not to run, it may damage ignition plug. This motorcycle always come on the head lamp and tail lamp when starting the engine. -
Page 27: Rear Brake Pedal
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 28: Footrests
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. - Page 29 ◉ ◉ 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 30: Side Stand
If the transmission is in neutral or side stand up, you can only start the engine with pulling in the clutch lever. This side stand ignition interlock system pre- vents the motorcycle from being started with side stand down. Neutral Clutch... -
Page 31: Seat Lock
SEAT LOCK REAR SHOCK ABSORBER ① ② 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 32: Front Fork
The compression selected to meet various riding conditions damping force adjuster ② is located at the such as low to high motorcycle speed and bottom of the front fork. light to heavy load on the motorcycle. -
Page 33: Fuel Tank Stay
Use the “fuel tank stay”to inspect the engine or the other parts easily. ◉ ◉ USE OF FUEL TANK STAY 1. Place the motorcycle on the side stand. � � 5. Lift the rear end of the fuel tank and prop it up as shown above. -
Page 34: Supply Of Gasoline 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. ● Make sure the engine is off and avoid spilling fuel on a hot engine. -
Page 35: Engine Oil
In case of the engine oil pouring exces- tainly to recommend at the front part. sively, the engine output being made insufficient. Be careful not to pour the engine oil excessively. 1. Place the motorcycle on the jack or block. - Page 36 ② Quantity of Engine oil, Pollution degree of Engine oil before riding the motorcycle and then supplement and replace at any time to prevent damage � of the engine. 2. Place a drain pan under the engine.
- Page 37 MATERIAL ● Wear a long-sleeve shirt and water- proof gloves. ● Wash with soap if oil or solvent con- tact your skin. HYOSUNG 6. Replace the engine oil filter ⑦ with a new OUTSIDE one. 16510HN910 7. Before replacing the engine oil filter cap ⑥, be sure to check that the engine oil filter spring ④...
-
Page 38: Coolant
9. Replace the drain plug and tighten it COOLANT securely. This time, insert the gasket nec- essarily. Pour fresh oil through the filler hole. Approximately 3,200 ㎖ of oil will be ◉ ◉ COOLANT LEVEL required. CAUTION Approximately 3,000 ㎖ ㎖ of oil must be required when changing oil only without replacing the oil filter. - Page 39 ◉ ◉ OPEN THE RADIATOR CAP WARNING Remove the right front side cover ① to 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 bolt ②. Do not drink anti-freeze or coolant WARNING solution.
-
Page 40: Riding Tips
Running the engine too long without rid- CAUTION ing may cause the engine to overheat. Overheating can result in damage to This motorcycle always come on the internal engine components and discol- head lamp and tail lamp when starting oration of exhaust pipes. -
Page 41: Starting Off
(Refer for Page 67) This may result in an accident. Always ride within the limits of your skills, your motorcycle, and the riding conditions. WARNING Removing your hands from the handle- bars or feet from the footrests during operation can be hazardous. -
Page 42: Using The Transmission
As the clutch engages, operating speed range. The gear ratios the motorcycle will start moving forward. have been carefully chosen to meet the To shift to the next higher gear, accelerate characteristics of the engine. -
Page 43: Riding On Hills
Shift 3. Downshift through the gears as road gear rapidly to prevent the motorcycle from speed decreases. losing momentum. 4. Select neutral with the clutch lever... - Page 44 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. WARNING A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine.
- Page 45 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 160km(100miles) before following guidelines explain proper break-in attempting maximum performance. Avoid procedures.
- Page 46 ● ● RIDING system No coolant leakge ● ● Operation of all lights and indi- Lighting Before riding the motorcycle, be sure to cators check the following item. Horn Correct function Engine Inspect every day once them before rid- Correct function stop switch ing motorcycle.
-
Page 47: Periodic Maintenance
PERIODIC MAINTENANCE Proper lubrication is important for smooth and long life of each working part of your motorcycle and also for safe riding. It is a The chart indicates the intervals between good practice to lubricate the motorcycle periodic service in kilometers. - Page 48 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 49 ─ ─ Inspect Front forks ★ ─ ─ Inspect Rear shock absorber ★ ─ Tighten Tighten Chassis nuts and bolts ★ N O T E ★ = Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.
- Page 50 INSPECTION AND ① MAINTENANCE TOOL ⑨ To assist you in the performance of peri- odic maintenance, a tool kit is supplied and ⑧ is located under the seat. The tool kit con- ⑦ sists of the following items. ⑥ NAME ⑤...
- Page 51 Mop them up with a patch when washing. ● Do not remove absolutely airtight cover as airtight type battery. ● Keep after separate at the motorcycle for the minimum of self electric dis- EXHAUST PIPE AND MUFFLER charge and electric leakage when don’...
-
Page 52: Air Cleaner
◉ ◉ 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... - Page 53 CAUTION ① 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 ② correctly, so that no incoming air will bypass it. Remember, rapid wear of piston rings ③...
-
Page 54: Spark Plug
● The standard spark plug for this motorcycle has been carefully select- ed to meet the vast majority of all operational ranges. If the spark plug color indicates that other than a stan-... - Page 55 � � There are two items of adjustment, how- � ever, under your care : engine idle speed � and throttle cable play. This motorcycle has a twin throttle cable � system. Cable is for throttle cable and � cable is for returing cable.
-
Page 56: Clutch Adjustment
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. Adjust the throttle cable play so that engine idle speed does not rise due to throttle grip movement. - Page 57 ● 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 58 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 59: Brake Fluid
Contact your doctor immediately the motorcycle upright, replenish with the if brake fluid is swallowed and induce proper brake fluid that meets Hyosung’ s vomiting. -
Page 60: Brake Pads
After replaced the front or rear brake pads, the brake lever and pedal pull and release several times so that it is setting at the original place. Then, do not ride the motorcycle untill operating the brake fluid and becoming the brake distance. - Page 61 ◉ FRONT BRAKE FLUID SUPPLY moving the switch body forward or back- 1. Place the motorcycle on a level surface ward. and keep the handlebars straight. 2. Clean the brake fluid reservior around not ◉...
- Page 62 36.0 psi 42.0 psi Failure to follow these warnings may result in an accident due to tire failure. The tires on your motorcycle form the crucial link between your motorcycle and the road. Follow these instructions ; ● Check tire condition and pressure, and adjust pressure before each ride.
- Page 63 It is highly recommended to use the standard tire supplied by Hyosung. REAR TIRE REPLACEMENT ● 1. Place the motorcycle on the jack or block. ◉ REAR AXLE NUT Inspect the rear axle shaft and jointing nut for loosening. ◉ TIRE REPLACEMENT ●...
- Page 64 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 specification � may cause the electric system or the lamp to damage.
- Page 65 ◉ HEAD LAMP ◉ TURN SIGNAL LAMP ① � ① 1. Remove the three screw (right, left 1. Remove the lens by removing the and upside) and the headlamp assembly. screw. 2. Push the bulb, turn it to the counter- clockwise, and pull it out.
- Page 66 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 67 1. Supply the enough fuel in the fuel tank. 2. Do drain wholly the fuel in the carburetor. WARNING 3. Remove the battery from the motorcycle. Performing the spark test improperly can cause a high voltage electrical shock or an explosion.
- Page 68 It is important to clean and inspect your scratch plastic or painted surfaces. Rinse motorcycle after every ride if it is used in the motorcycle thoroughly with clean water. mud, brush, grass, water, salt water, or very Dry all areas using a chamois or soft dusty conditions.
- Page 69 L A B E L ① ③ ②...
- Page 70 ① ② ③...
-
Page 71: Specifications
SPECIFICATIONS DIMENSIONS AND DRY MASS 2,430mm ( 95.7 in ) Overall length 840mm ( 33.1 in ) Overall width 1,155mm ( 45.5 in ) Overall height 1,665mm ( 65.6 in ) Wheelbase 160mm ( 6.3 in ) Ground clearance 220kg ( 485 lbs ) Mass ENGINE Type... - Page 72 CHASSIS Front suspension Telescopic type Rear suspension Swingarm type Caster 35。 160mm ( 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 73 However, NHTSA cannot become involved in any individual problems between you, your dealer, or Hyosung Motors & Machinery Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (366-0123 in Washington, D.C. area) or write to : NHTSA U.S.
- Page 74 MEMO...
- Page 75 MEMO...
- Page 76 Prepared by HYOSUNG MOTORS & MACHINERY INC. 2nd Ed. OCT. 2005. Printed in KOREA...