HYOSUNG Aquil GV650 Bedienungsanleitung

ELECTRICAL SYSTEM

COOLING SYSTEM

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

ENGINE 3

FUEL SYSTEM 4

CHASSIS 7

SERVICING INFORMATION 8

This manual has been prepared on the basis of the

latest specification at the time of publication.

If modification has been made since then,

difference may exist between the content of this

manual and the actual vehicle.

Illustrations in this manual are used to show the

basic principles of operation and work procedures.

They may not represent the actual vehicle exactly

in detail.

COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2005.

HYOS NG MOTORS & MACHINERY INC.

FOREWORD

This manual contains an introductory description on

HYOSUNG and procedures for its

inspection/service and overhaul of its main components.

Other information considered as generally kno n is not

included.

Read GENERAL INFORMATION section to familiarize

yourself ith outline of the vehicle and MAINTENANCE

and other sections to use as a guide for proper inspec-

tion and service.

This manual ill help you kno the vehicle better so

that you can assure your customers of your optimum

and quick service.

WARNING

This manual is intended for those who have

enough knowledge and skills for servicing

HYOS NG vehicles. Without such knowledge and

skills, you should not attempt servicing by relying

on this manual only.

Instead, please contact your nearby authorized

HYOS NG motorcycle dealer.

HOW TO SE THIS MAN AL

TO LOCATE WHAT YO ARE

LOOKING FOR:

1. The text of this m nu l is divided into sections.

2. As the title of these sections is listed on the previous

p ge s GROUP INDEX, select the section where you re look-

ing for.

3. Holding the m nu l s shown t the right will llow you to find

the first p ge of the section e sily.

4. On the first p ge of e ch section, its contents re listed. Find

the item nd p ge you need.

COMPONENT PARTS

Ex mple : Front wheel

SYMBOL

Listed in the t ble below re the symbols indic ting instructions nd other inform tion necess ry for servicing nd

me ning ssoci ted with them respectively.

Apply THREAD LOCK 1324.

Apply or use br ke fluid.

Me sure in volt ge r nge.

Me sure in resist nce r nge.

Me sure in current r nge.

Use speci l tool.

Use engine cool nt.

Torque control required.

D t beside it indic tes specified torque.

Apply oil. Use engine oil unless otherwise

specified.

Apply SUPER GREASE

A

Apply SILICONE GREASE.

Apply MOLY PASTE.

Apply BOND 1215.

Use fork oil.

DEFINITIONSYMBOL DEFINITIONSYMBOL

Apply SUPER GREASE

C

NOTE

Di erence between photographs and actual motorcycles depends on the markets.

GENERAL INFORMATION

INFORMATION LABELS 1- 1

GENERAL PRECAUTIONS  1- 1

SERIAL NUMBER LOCATION 1- 3

FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS

 1- 4

BREAK-IN PROCEDURES 1- 6

CYLINDER CLASSIFICATION  1- 6

EXTERIOR ILLUSTRATION  1- 7

SPECIFICATIONS  1- 8

CONTENTS

1-1 GENERAL INFORMATION

Ple se note, however, th t the w rning nd c utions cont ined in this m nu l c nnot possibly cover ll potenti l

h z rds rel ting to the servicing, or l ck of servicing, of the motorcycle. In ddition to the WARNING nd CAUTION

st ted, you must use good judgement nd b sic mech nic l s fety principles. If you re unsure bout how to perform

p rticul r service oper tion, sk more experienced mech nic for dvice.

GENERAL PRECA TIONS

WARNING / CA TION / NOTE

Ple se re d this m nu l nd follow its instructions c refully. To emph size speci l inform tion, the symbol nd

the words WARNING, CAUTION nd NOTE h ve speci l me nings. P y speci l ttention to the mess ges

highlighted by these sign l words.

CA TION

Indicates a potential hazard that could result in vehicle damage.

WARNING

Indicates a potential hazard that could result in death or injury.

NOTE

Indicates special in ormation to make maintenance easier or instructions cleaner.

WARNING

Proper service and repair procedures are important for the safety of the service machanic and the safe-

ty and reliability of the vehicle.

When 2 or more persons work together, pay attention to the safety of each other.

When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.

When working with toxic or flammable materials, make sure that the area you work in is well-ventilat-

ed and that you follow all off the material manufacturers instructions.

Never use gasoline as a cleaning solvent.

To avoid getting burned, do not touch the engine, engine oil, exhaust system or radiator during or

for a while after engine operation.

After servicing fuel, oil, engine coolant, exhaust or brake systems, check all lines and fittings related

to the system for leaks.

GENERAL INFORMATION 1-2

WARNING

If parts replacement is necessary, replace the parts with HYOS NG Genuine Parts or their equivalent.

When removing parts that are to be reused, keep them arranged in an orderly manner so that they may

be reinstalled in the proper order and orientation.

Be sure to use special tools when instructed.

Make sure that all parts used in reassembly are clean, and also lubricated when specified.

When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.

When removing the battery, disconnect the negative cable first and then positive cable. When

reconnecting the battery, connect the positive cable first and then negative cable, and replace the terminal

cover on the positive terminal.

When performing service to electrical parts, if the service procedures do not require use of

battery power, diconnect the negative cable at the battery.

Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with small-

er diameter, from inside to outside diagonally, to the specified tightening torque.

Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips,

and certain other parts as specified, be sure to replace them with new ones. Also, before installing

these new parts, be sure to remove any material left over from the mating surfaces.

Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is com-

pletely seated in its groove and securely fitted.

Do not use self-locking nuts a few times over.

se a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or

oil if a thread is smeared with them.

After reassembly, check parts for tightness and operation.

WARNING

To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.

To protect Earths natural resouces, properly dispose of used vehicles and parts.

SERIAL N MBER LOCATION

The fr me seri l number or V.I.N. (Vehicle Identific tion Number) is st mped on the steering he d tube.

The engine seri l number is loc ted on the left downside of cr nkc se ssembly.

These numbers re required especi lly for registering the m chine nd ordering sp re p rts.

FRAME SERIAL N MBER

ENGINE SERIAL N MBER

1-3 GENERAL INFORMATION

FRONT FORK OIL

se fork oil : TELL S #32

BRAKE FL ID

Specification and classification (Front brake) : DOT3 or DOT4

(Rear brake) : DOT4

Gr de

Over SL

10W/40

Classification system

API

SAE

I an SAE 10W/40 motor oil is not available, select an

alternative according to the ollowing chart.

Use premium qu lity 4-stroke motor oil to ensure

longer service life of your motorcycle.

F EL, OIL AND ENGINE COOLANT RECOMMENDATIONS

F EL

G soline used should be gr ded 91 oct ne (Rese rch Method) or higher. An unle ded g soline type is

recommended.

ENGINE OIL

ENGINE OIL SPECIFICATION

WARNING

Dont mix the unrecommended oil. It could damage the engine.

When refilling the oil tank, dont allow the dust to get inside.

Mop the oil spilt.

Dont put the patch on the cap. It could disturb the oil to be provided and damage the engine.

WARNING

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not

use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the sys-

tem, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.

GENERAL INFORMATION 1-4

1-5 GENERAL INFORMATION

ENGINE COOLANT

Use n nti-freeze/engine cool nt comp tible with n luminum r di tor, mixed with distilled w ter only.

WATER FOR MIXING

Use distilled w ter only. W ter other th n distilled w ter c n corrode nd clog the luminum r di tor.

ANTI-FREEZE/ENGINE COOLANT

The engine cool nt perform s corrosion nd rust inhibitor s well s nti-freeze. Therefore, the engine cool nt

should be used t ll times even though the tmospheric temper ture in your re does not go down to freezing point.

Hyosung recommends the use of HYOSUNG COOLANT nti-freeze/engine cool nt. If this is not v il ble, use n

equiv lent which is comp tible with n luminum r di tor.

LIQ ID AMO NT OF WATER/ENGINE COOLANT

For engine cool nt mixture inform tion, refer to cooling system section, p ge 5-1

CA TION

Mixture of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its

efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance

is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature does not

go down to the freezing point.

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