HYOSUNG GT 650 Bedienungsanleitung

GT 650

Fra 2004 og frem.

Servicemanual

Holtvej 8-10, Høruphav

6470 Sydals

Telefon: +45 73 15 11 00

Fax: +45 73 15 11 01

E-mail: [email protected]

www.scanmi.dk

CVR: 27 73 31 07

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 proce-

dures.

They may not represent the actual vehicle exactly

in detail.

COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2003.

HYOSUNG 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 known is not

included.

Read GENERAL INFORMATION section to familiarize

yourself with outline of the vehicle and MAINTENANCE

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

tion and service.

This manual will help you know 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

HYOSUNG vehicles. Without such knowledge and

skills, you should not attempt servicing by relying

on this manual only.

Instead, please contact your nearby authorized

HYOSUNG motorcycle dealer.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE

LOOKING FOR:

1. The text of this manual is divided into sections.

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

page as GROUP INDEX, select the section where you are look-

ing for.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. On the first page of each section, its contents are listed. Find

the item and page you need.

COMPONENT PARTS

Example: Front wheel

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing and

meaning associated with them respectively.

Apply THREAD LOCK1324.

Apply or use brake fluid.

Measure in voltage range.

Measure in resistance range.

Measure in current range.

Use special tool.

Use engine coolant.

Torque control required.

Data beside it indicates 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

Difference 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

Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential

hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION

stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a

particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

WARNING / CAUTION / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and

the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages

highlighted by these signal words.

CAUTION

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 information 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 or exhaust system during or for a

while after engine operation.

After servicing fuel, oil, 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 HYOSUNG 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 left over material 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.

Use 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 NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine seri-

al number is located on the left down of crankcase assembly.

These numbers are required especially for registering the machine and ordering spare parts.

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

1-3 GENERAL INFORMATION

FRONT FORK OIL

Use fork oil : TELLUS #32

BRAKE FLUID

Specification and classification (Front brake) : DOT4

(Rear brake) : DOT4

Grade

Over SG

10W/40

Classification system

API

SAE

If an SAE 10W/40 motor oil is not available, select an

alternative according to the following chart.

Use a premium quality 4-stroke motor oil to ensure

longer service life of your motorcycle.

FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline 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

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