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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.
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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...
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Proper break-in operation during this time will help ensure maximum life and perfor- WARNING mance 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.
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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 ;...
● ● 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 ●...
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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 pulling the clutch lever.
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◉ ◉ FAMILIARIZE YOURSELF WITH WARNING THE MOTORCYCLE Do not operate the ignition switch in the WARNING “ “ OFF ” ” or “ “ LOCK ” ” position or the engine stop switch in the “ “ ” ” position Your riding skill and mechanical knowl- while driving at one’...
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It 4. The motorcycle may be affected by a is not possible for Hyosung to test each lifting condition or by an instability in accessory on the market or combinations...
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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.
TABLE OF CONTENTS 1. SERIAL NUMBER LOCATION ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 2. FUEL , ENGINE OIL AND COOLANT RECOMMENDATION ∙∙ FUEL ENGINE OIL COOLANT 3. NAMES OF EACH PARTS [ ∙∙∙∙∙∙∙∙∙∙∙ 4. NAMES OF EACH PARTS [ ∙∙∙ (Standard type) 5. NAMES OF EACH PARTS [ ∙∙∙∙...
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USING THE TRANSMISSION RIDING ON HILLS STOPPING AND PARKING 10. BREAK-IN ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 11. INSPECTION BEFORE RIDING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 12. PERIODIC MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 13. INSPECTION AND MAINTENANCE ∙∙∙∙∙∙∙∙∙∙∙∙∙ TOOL FUEL HOSE ENGINE OIL GASOLINE COOLANT RADIATOR RADIATOR HOSE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER...
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. �...
ENGINE OIL COOLANT Use an anti-freeze compatible with alu- ◉ ◉ ENGINE OIL SPECIFICATION minium radiator mixed with distilled water only at the ratio of 50:50 Classification Grade Remarks system WARNING Over SG Engine coolant is harmful or fatal if swallowed or inhaled.
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◉ ◉ ANTI-FREEZE The coolant performs as rust inhibitor and water pump lubricant as well as anti-freeze. Therefore the coolant should be used at all times even though the atmospheric temper- ature in your area does not go down to freezing point.
NAMES OF EACH PARTS [ ① Clutch lever ⑦ Front brake fluid reservoir ② Left handle switches ⑧ Right handle switches ③ Choke lever ⑨ Front brake lever ④ Speedometer ⑩ Throttle grip ⑤ Coolant temperature meter ⑪ Ignition switches ⑥...
NAMES OF EACH PARTS [ (Standard type) (Standard type) � � � � � � � � � � � ① Clutch lever ⑦ Right handle switches ② Left handle switches ⑧ Front brake lever ③ Choke lever ⑨ Throttle grip ④...
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(Standard type) � Muffler Side cowling inner � Rear carrier Radiator � Rear seat & Trunk Cooling fan and motor Front seat Engine oil filter Tools Water pump Battery Engine oil level lens Fuel pump Engine oil filler cap Throttle stop screw Rear brake pedal Air cleaner Rear brake lamp switch...
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NAMES OF EACH PARTS [ (Sports type) (Sports type) � � � � � � � � � � � ① Clutch lever ⑦ Right handle switches ② Left handle switches ⑧ Front brake lever ③ Choke lever ⑨ Throttle grip ④...
NAMES OF EACH PARTS [ ① Clutch lever ⑦ Right handle switches ② Left handle switches ⑧ Front brake lever ③ Choke lever ⑨ Throttle grip ④ Tachometer ⑩ Ignition switches ⑤ Speedometer ⑪ Fuel tank cap ⑥ Front brake fluid reservoir...
◉ ◉ “ “ LOCK ” ” POSITION CONTROLS To lock the steering, turn the handlebar all the way to the left. Push down the key to the “ OFF ” position and turn it to the IGNITION SWITCH “ LOCK ” position after come up again and remove the key.
⑥ ⑥ TACHOMETER INSTRUMENT PANEL The tachometer indicates the engine speed in revolutions per minutes(rpm). � � ⑦ ⑦ � FUEL INDICATOR LAMP � When the fuel drop below approximately 8.5 ℓ , the indicator lamp lit. When the fuel drop below approximately �...
INSTRUMENT PANEL ③ ③ HIGH BEAM INDICATOR LAMP & The high beam indicator lamp will come on when the head lamp high beam is turned on. ④ ④ NEUTRAL INDICATOR LAMP 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.
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⑥ FUEL METER ⑦ ⑦ 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. 『 』 & 『 』...
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⑧ ⑧ CLOCK The clock indicates 12-hour mode. Follow the procedure below to adjust the clock. 1. Push the switch ⑨ (in the normal mode) for 2 seconds until the hour and To reset the trip meter to zero, push the minutes display blink.
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⑨ ⑨ ⑪ ⑪ 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 →...
WARNING LEFT HANDLE SWITCH Set the dimmer switch “ “ ” ” when other vehicle is running in front or against. � � � ④ ④ TURN SIGNAL SWITCH Using when left, right turn or change direction. ◉ “ � ” Position : Flash the left turn sig- nal lamp.
WARNING RIGHT HANDLE SWITCH Apply the brake lightly and with great care on slippery surfaces to avoid skid- � � ding. ③ ③ THROTTLE GRIP Engine speed is controlled by position of the throttle grip. Turn it toward you to �...
CAUTION CARBURETOR CHOKE LEVER Do not engage the starting motor for more than five seconds at a time as it may overheat the wiring harness and starting motor. If the engine does not start after several attempts, check the fuel supply and igin- tion system.
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.
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. (FOR 『 『 』 』 & 『 『 』 』 ) This will prevent unnecessary wear on the drive train components and the rear tire.
『 』&『 』are deliv- ered from the factory on position �. ③ WARNING When adjusting the footrest position, the 6mm hexagon bolts be torqued to ④ [Optional parts] the proper specification. If they are not, the footrest can come off unexpectedly.
Neutral Clutch Side Engine SEAT LOCK switch lever stand start ● ● △ Possible ● ● △ Possible ● △ △ Impossible △ ● △ Impossible △ ● △ Impossible N O T E The rear seat lock is located under the left ●...
TRUNK REAR SHOCK ABSORBER A small and light article such as mainte- nance manual or Owner’ s manual can be placed under the rear seat. To adjust the spring pre-load, turn the adjuster counter-clockwise to the desired position with the clamp wrench. Position 1 provides the softest spring pre- load and position 5 provides the stiffest.
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...
WARNING 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. ●...
CAUTION ENGINE OIL “ “ Fuel, Engine oil and Coolant ” ” use cer- Long engine life depends much on the tainly to recommend at the front part. selection of quality oil and the periodic changing of the oil. Daily oil level checks and periodic changes are two of the most important CAUTION maintenances to be performed.
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CAUTION CAUTION In case of the engine oil pouring exces- Necessarily, confirm and clean the oil sively, the engine output being made � � strainer when replace the Engine oil insufficient. (specially, when first replacement). Be careful not to pour the engine oil excessively.
Use new “ O ” ring each time the engine oil filter element is replaced. When install the oil filter, necessarily, “ “ HYOSUNG” ” character and 8. Replace the oil filter cap ⑥ and tighten the “ “ 16510HN910 ” ” part’ ’ s NO. install toward nuts securely but do not over tighten them.
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.
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◉ ◉ SIDE COWLING INNER WARNING (FOR 『 『 』 』 & 『 『 』 』 ) Engine coolant is harmful or fatal if swallowed or inhaled. 『 』&『 』have the “side cowling inner ①” at the rightside. Do not drink anti-freeze or coolant Use the “side cowling inner”...
◉ ◉ When the engine is cold : RIDING TIPS 1. Turn the carburetor choke lever all the way toward you. 2. Close the throttle grip and push the STARTING THE ENGINE starter switch. 3. Immediately after the engine starts, return the choke lever halfway and Before attempting to warm up the engine.
CAUTION STARTING OFF Do not engage the starting motor for more than five seconds at a time as it WARNING may overheat the wiring harness and starting motor. Riding these motorcycles at excessive If the engine does not start after several speed increases your chances of losing attempts, check the fuel supply and igin- control of the motorcycle.
Pull the clutch lever in and pause USING THE TRANSMISSION momentarily. Engage first gear by depress- ing 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.
RIDING ON HILLS STOPPING AND PARKING When climbing steep hills, the motorcycle 1. Turn the throttle grip away from you to may begin to slow down and show lack of close the throttle completely. power. At this point you should shift to a 2.
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The opening explains how important can lead to a collision. As vehicle proper break-in is to achieve maximum life speeds increase, stopping distance and performance from your new Hyosung. increases progressively. The following guidelines explain proper break-in procedures. Be sure you have a safe stopping dis- tance between you and the vehicle in front of you.
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Timely performance of the 1,000km ★ ★ BREAKING IN THE NEW TIRES (600miles) service will ensure optimum New tires need proper break-in to assure maximum p e r f o r m a n c e , just as the service life and performance from the engine does.
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WHAT TO INSPECTION BEFORE CHECK FOR : CHECK RIDING Smoothness ● ● Steering No restriction of movement ● ● Before riding the motorcycle, be sure to No play or looseness ● ● check the following item. Correct play in the throttle ●...
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.
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① ⑥ Clutch lever holder and clutch cable Speedometer gear box ② ⑦ Footrests pivot Front brake lever holder ③ ⑧ Passenger footrests pivot Throttle cable ④ ⑨ Drive chain Rear brake pedal pivot ⑤ Side stand pivot and spring hook - Motor oil - Grease...
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─ 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.
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INSPECTION AND ① MAINTENANCE TOOL ⑪ To assist you in the performance of peri- ⑩ odic maintenance, a tool kit is supplied and is located under the front seat. The tool kit ⑨ consists of the following items. ⑧ NAME ⑦...
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GASOLINE REAR SHOCK ABSORBER Check if there is leakage from fuel tank, Inspect the rear shock absorber for oil fuel pump, fule cock, hose, carburetor. leakage and spring condition. COOLANT BATTERY Check if there is leakage from the radiator, ◉ ◉ INSPECTION OF BATTERY SOLUTION coolant hose.
◉ ◉ 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 front seat, disassem- clogged with dust, intake resistance will ble the ( ) positive battery wire after the...
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CAUTION ① Before and during the cleaning opera- tion, inspect the element for tears. A torn element must be replaced. Be sure position the element snugly and ② 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.
Hyosung dealer before selecting an alternate plug or heat range. The selection of an improper spark plug can lead to...
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CAUTION CARBURETOR The engine idle speed should be adjust- equipped one set of ed with the engine fully warm. composed the two carburetors for efficiency increase of the two cylinder. The carburetor is factory setting for the best carburetion. Do not attempt to alter the carburetion set- tings.
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.
If you find something wrong with the drive chain condition or adjustment, correct the problem if you know how. If necessary, con- sult your authorized Hyosung dealer. Damage to the drive chain means that the sprockets may also be damaged. Inspect the sprockets for the following : ●...
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1. Place the motorcycle on the jack or block. If you find any of these problems with your ① 2. Loosen the axle nut sprocket, consult your Hyosung dealer. ② 3. Loosen the lock nut 4. Adjust the slack in the drive chain by ③...
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“ X-O rings ” in your chain. This drive chain has special “ X-O rings ” . Clean and oil the chain periodically, as fol- Use Hyosung chain lube or an equiva- lows: lent that is specifically intended for use 1.
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CAUTION These motorcycles uses glycol-based brake fluid. Do not use or mix different types of brake fluid, otherwise serious damage will result in the brake system. Use DOT4 brake fluid. Do not spill any brake fluid on painted [Front Brake] or plastic surfaces as it will damage the surface severely.
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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...
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◉ ◉ 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 ◉...
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. 33.0 psi 33.0 psi Inspect frequently the tire pressure for the safety and the tire life.
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7. To reinstall the wheel assembly, may cause trouble. reverse the sequence as described. It is highly recommended to use the standard tire supplied by Hyosung. REAR TIRE REPLACEMENT ● ● ◉ ◉ REAR AXLE NUT 1. Place the motorcycle on the jack or Inspect the rear axle shaft and jointing nut block.
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2. Loosen the rear axle ①. 3. Carefully position a jack or block under engine and raise until the rear wheel is slightly off the ground. WARNING A hot muffler can burn you. The muffler will be hot enough to burn yor for some time after stopping the engine.
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We suggest that you have 『 』 & 『 』 ’ s head lamp bulb replaced by your authorized Hyosung dealer or a qualified service machanic. ③ ② 2. Disconnect the headlamp coupler. ②...
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◉ ◉ TURN SIGNAL LAMP 2. Turn the socket to the counter-clockwise 1. Remove the lens by removing the and pull it out at the lamp housing. screw. 3. Push the bulb, turn it to the counter- 2. Push the bulb, turn it to the counter- clockwise, and pull it out.
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Avoid performing this check if you are seriously damage the electrical system. not familiar with this procedure, or if you You should consult your Hyosung deal- have a heart condition or wear a pace- er or a qualified service mechanic imme- maker.
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CAUTION CAUTION High pressure washers can damage When occur any trouble, the best way is your motorcycle. (especially the radiator to consult your Hyosung dealer for pin) repairs. High pressure washers such as those found at coin-operated car washes have enough pressure to damage the parts of your motorcycle.
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Use a garden hose at low pressure to remove the majority of dirt or other debris. Hand wash your motorcycle with a mild soap or detergent and water. Try to thor- oughly 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.
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L A B E L ① ② ③ NOTE : “ ” = means the invisable parts.
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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.
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Prepared by HYOSUNG MOTORS & MACHINERY INC. 3rd Ed. MAR. 2005. Printed in KOREA...
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If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Hyosung Motors & Machinery Inc. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.