HYOSUNG Comet 650 Manual Download Page 1

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HYOSUNG MOTORS & MACHINERY INC.

Part No. 99011HN9110
MAR. 2005.
Printed in KOREA

3rd Ed.

For U.S.A

Summary of Contents for Comet 650

Page 1: ...UNG MOTORS MACHINERY INC Part No 99011HN9110 MAR 2005 Printed in KOREA For U S A...

Page 2: ...orcycle 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 ca...

Page 3: ...2 2 Standard type C O P Y R I G H T E D...

Page 4: ...3 3 Sports type C O P Y R I G H T E D...

Page 5: ...YOU for choosing Hyosung motorcycle We at Hyosung have designed tested and produced these motorcycles using the most modern tech nology available to provide you with much happy enjoyable safe riding M...

Page 6: ...e break in period It is espe cially important that you avoid operating the engine in a manner which could expose the engine parts to excessive heat Please refer to the BREAK IN section for specific br...

Page 7: ...or delivery to the ultimate purchaser or while it is in use and b The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person MAINTENANCE The e...

Page 8: ...perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING sec tion on page 56 of this owner s man ual Make sure the rider wears a helmet eye protecti...

Page 9: ...ing from accidents Moving the rider s feet from the footrests reduces the rider s ability to control the motorcycle and could lead to an accident WARNING Keep both hands on the handgrips at all times...

Page 10: ...BEFORE RIDING section of this manual Do not forget to perform an entire safety inspection to ensure the safety of the rider and its passenger WARNING Your riding skill and mechanical knowl edge from t...

Page 11: ...ith the operation of the suspension steering or other control operations 3 Accessories fitted to the handlebars or the front fork area can create serious stability problems This extra weight will caus...

Page 12: ...n of the motorcycle or removal of original equipment may ren der the vehicle unsafe or illegal WARNING Balance the load between the left and right side of the motorcycle and fasten it securely C O P Y...

Page 13: ...CH PARTS 26 7 CONTROLS 29 IGNITION SWITCH IGNITION KEY INSTRUMENT PANEL INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH CARBURETOR CHOKE LEVER REAR BRAKE PEDAL GEARSHIFT LEVER FOOTRESTS SIDE S...

Page 14: ...HOSE ENGINE OIL GASOLINE COOLANT RADIATOR RADIATOR HOSE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER SPARK PLUG CARBURETOR CLUTCH ADJUSTMENT DRIVE...

Page 15: ...ice information Use unleaded gasoline with an octane rating of 91 or higher Unleaded gasoline can extend spark plug life and exhaust components life SERIAL NUMBER LOCATION FUEL ENGINEOILAND COOLANTREC...

Page 16: ...put the patch on the filler cap It could disturb the oil to be provided and damage the engine WARNING Engine coolant is harmful or fatal if swallowed or inhaled Do not drink anti freeze or coolant so...

Page 17: ...mix ing ratio should not exceed 60 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...

Page 18: ...ch lever Left handle switches Choke lever Speedometer Coolant temperature meter Tachometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank...

Page 19: ...ion coil Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oil drain plu...

Page 20: ...nt brake fluid reservoir Front brake lamp switch Radiator Cooling fan and motor Engine oil filter Engine oil filler cap Water pump Engine oil level lens Rear brake pedal Rear brake lamp switch Coolant...

Page 21: ...ard type Clutch lever Left handle switches Choke lever Tachometer Speedometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank cap Standard...

Page 22: ...l Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oil drain plug N O T...

Page 23: ...luid reservoir Front brake lamp switch Side cowling inner Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil filler cap Rear brake pedal Rear brake lamp switc...

Page 24: ...rts type Clutch lever Left handle switches Choke lever Tachometer Speedometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank cap Sports t...

Page 25: ...il Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oil drain plug N O...

Page 26: ...top screw Air cleaner Front brake fluid reservoir Front brake lamp switch Side cowling inner Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil filler cap Rea...

Page 27: ...CH PARTS Clutch lever Left handle switches Choke lever Tachometer Speedometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank cap C O P Y...

Page 28: ...ion coil Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oil drain plu...

Page 29: ...brake fluid reservoir Front brake lamp switch Side cowling inner Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil filler cap Rear brake pedal Rear brake lam...

Page 30: ...e removed from the ignition switch in this position CONTROLS IGNITION SWITCH IGNITION KEY Turning the ignition switch to the OFF or LOCK position while the motorcy cle is moving can be hazardous Movin...

Page 31: ...rpm FUEL INDICATOR LAMP When the fuel drop below approximately 8 5 the indicator lamp lit When the fuel drop below approximately 3 0 the indicator lamp lit Fill the fuel tank before the indicator lamp...

Page 32: ...th high engine coolant temperature can cause serious engine damage If the engine coolant temperature meter comes on the red lamp of H mark stop the engine to let it cool CAUTION When the ignition swit...

Page 33: ...egister two kinds of distance at the same time For instance trip meter A can register the trip distance and trip meter can register the distance between fuel stops To change the display push the switc...

Page 34: ...al mode To reset the trip meter to zero push the switch in the normal mode for 2 sec onds while the display indicates trip meter B or B you want to reset A B Operating the display while riding can be...

Page 35: ...utes of clock 2 seconds Clock reset mode Normal mode RESET SWITCH Use this switch to adjust the following In the normal mode Push it for 2 seconds Adjustment To reset the trip meter to zero while the...

Page 36: ...hen left right turn or change direction Position Flash the left turn sig nal lamp Position Flash the right turn signal lamp DIMMER SWITCH Change the direction of head lamp light The head lamp high bea...

Page 37: ...increase engine speed Turn it away from you to decrease the engine speed Apply the brake lightly and with great care on slippery surfaces to avoid skid ding WARNING Avoid turning the throttle grip dur...

Page 38: ...igin tion system Refer to Page 78 CAUTION CARBURETOR CHOKE LEVER If you keep running in condition of full choke lever causes fuel excess exhaus tion high speed not to run it may dam age ignition plug...

Page 39: ...ame time you operate the gearshift lever Whenever a gear is selected the gearshift lever will return to its normal position ready to select the next gear Lift the gearshift lever to upshift and depres...

Page 40: ...lamp on the instrument panel will be lit However even though the light is illumi nated cautiously release the clutch lever slowly to determine whether the transmission is positively in neutral CAUTION...

Page 41: ...If the transmission is in neutral or side stand up you can only start the engine with pulling the clutch lever This side stand ignition interlock system pre vents the motorcycle from being started wi...

Page 42: ...ner and push down firmly until the seat snaps into the locked position To remove the front seat pull the knob located under the rear seat SEAT LOCK Make sure that the side stand ignition interlock sys...

Page 43: ...rticle such as mainte nance manual or Owner s manual can be placed under the rear seat REAR SHOCK ABSORBER TRUNK N O T E Loading limit of trunk 1k kg g 2 21 lbs The trunk could be heated Don t keep an...

Page 44: ...from the fully turned in position Fully turned in H direction provides stiffest damping force and turning S direction the adjuster will soften damping force The rebound and compression damping force...

Page 45: ...of gasoline vapors Keep children and pets away during refueling WARNING To open the fuel tank cap insert the igni tion key into the lock and turn it clockwise With the key inserted lift the cap up wi...

Page 46: ...ne oil level lens In case of the engine oil pouring excessively the engine output being made insufficient Be careful not to pour the engine oil excessively CAUTION ENGINE OIL LEVEL CHECK Follow the pr...

Page 47: ...inspect 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 CAUTION Necessarily confirm and...

Page 48: ...ment is replaced 8 Replace the oil filter cap and tighten the nuts securely but do not over tighten them Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain plug and ex...

Page 49: ...only without replacing the oil filter CAUTION In case of the engine oil pouring exces sively the engine output being made insufficient Be careful not to pour engine oil CAUTION COOLANT COOLANT LEVEL T...

Page 50: ...ch of chil dren and aminals WARNING CHANGING THE COOLANT Change the coolant every two years N O T E Adding only water will dilute the engine coolant and reduce its effectiveness Add 50 50 mixture of e...

Page 51: ...tarting the engine CAUTION Running the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause death or severe injury Onl...

Page 52: ...thin 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 If you remove eve...

Page 53: ...hift before entering corner WARNING Do not operate the ignition switch of its OFF or LOCK position or the engine stop switch of its position while driving at one s pleasure WARNING The transmission is...

Page 54: ...nshift through the gears as road speed decreases 4 Select neutral with the clutch lever squeezed towards the grip disengaged position just before the motorcycle stops Neutral position can be confirmed...

Page 55: ...plain proper break in procedures Less than 3 4 throttle Less than 1 2 throttle Upto1 600km 1 000miles Initial 800km 500miles MAXIMUM THROTTLE OPENING RECOMMENDATIONS The table below shows the maximum...

Page 56: ...ngine components will have worn in and all of the other parts will have seated in All adjustments will be restored all fas teners will be tightened and the dirty engine oil and engine oil filter will...

Page 57: ...the throttle grip to the closed position Correct lever play Smooth and progressive action Fluid level in the reservoir to be above LOWER line Correct pedal and lever play No sponginess No fluid leakag...

Page 58: ...eplacement parts or their equivalent CAUTION The chart indicates the intervals between periodic service in kilometers At the end of each interval be sure to inspect check lubricate and service as inst...

Page 59: ...d clutch cable Footrests pivot Passenger footrests pivot Drive chain Side stand pivot and spring hook Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot Motor oil Grea...

Page 60: ...ead Cylinder Spark plug Fuel hose Engine oil filter Engine oil Throttle cable Idle speed Clutch Engine coolant Radiator hose First 1 000 km Every 6 000 km Every 12 000 km Interval Item Clean and lubri...

Page 61: ...9 10 11 Check if there is leakage from crankcase To assist you in the performance of peri odic maintenance a tool kit is supplied and is located under the front seat The tool kit consists of the foll...

Page 62: ...R BATTERY Do not remove absolutely airtight cover as airtight type battery Keep after separate at the motorcycle for the minimum of self electric dis charge and electric leakage when don t use for a l...

Page 63: ...clean the air cleaner element and con firm CAUTION CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Set the ignition switch OFF position 2 Disassemble the front seat...

Page 64: ...element snugly and 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 CAUTION When the asse...

Page 65: ...motorcycles has been carefully selected to meet the vast majority of all operational ranges If the spark plug color indicates that other than a standard spark plug be used it is best to consult your...

Page 66: ...twin throttle cable system Cable is for throttle cable and cable is for returing cable To adjust the cable play 1 Loosen the lock nut 2 Turn in the adjuster fully 3 Loosen the lock nut 4 Turn the adju...

Page 67: ...ore the clutch begins to disengage CLUTCH ADJUSTMENT After completing throttle cable adjust ment check that throttle grip movement does not raise the engine idle speed and that the throttle grip retur...

Page 68: ...Damaged rollers Dry or rusted links Missing X O ring seals Kinked or binding links Excessive wear Improper chain adjustment If you find something wrong with the drive chain condition or adjustment cor...

Page 69: ...SO for Use of another chain may lead to prema ture chain failure CAUTION The drive chain should be inspected every time before riding Excessive chain slack could cause the chain to come off the sprock...

Page 70: ...y CAUTION utilizes front and rear disk brakes Properly operating the brake systems are vital to safe riding Be sure to perform the brake inspection requirements as sched ules The brakes should be insp...

Page 71: ...d that has been stored in a used or unsealed container Never reuse brake fluid left over from the last servicing and stored for long period as it absorbs moisture from the air CAUTION Brake fluid may...

Page 72: ...ake pads will reduce braking performance and will increase your chance of having accident Inspect brake pad wear before each use Ask your Hyosung dealer or qualified mechanic to replace brake pads if...

Page 73: ...n the brake fluid reservior around not to allow dust to get inside of it 3 Turn the cap to the counter clockwise 4 Replenish with brake fluid to the upper line N O T E The recommended brake fluid DOT4...

Page 74: ...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 adjus...

Page 75: ...axle pinch bolt right and left 3 Loosen the front axle 4 Carefully position a jack or block under engine and raise until the front wheel is slightly off the ground 5 Draw out the axle shaft 6 Slide th...

Page 76: ...excessive at the electric system or to damage the lamp REPLACEMENT OF THE LAMP 2 Loosen the rear axle 3 Carefully position a jack or block under engine and raise until the rear wheel is slightly off t...

Page 77: ...ence The use of a lamp other than rules may cause to occur the vehicle fire and to damage electric parts Surely use only the lamp of proper capacity CAUTION HEAD LAMP 1 Remove the three screw right le...

Page 78: ...crack CAUTION LICENSE PLATE LAMP Overtightening the screws may cause the lens to crack CAUTION 1 Remove the socket under the rear fend er 2 Push the bulb turn it to the counter clockwise and pull it o...

Page 79: ...re is still no spark consult your Hyosung dealer for repairs WHEN THE ENGINE REFUSES TO START Performing the spark test improperly can cause a high voltage electrical shock or an explosion Avoid perfo...

Page 80: ...used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust sys tem can reduce engine cooling conceal damage or increase...

Page 81: ...orbent cloth INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe For extended life of your motorcycle lubricate according to GENERAL LUBRICATION section Follow the procedures i...

Page 82: ...81 L A B E L NOTE means the invisable parts C O P Y R I G H T E D...

Page 83: ...82 C O P Y R I G H T E D...

Page 84: ...219kg 483 lbs Standard type Sports type Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Four stroke DOHC Liquid cooled V 2 cylinder 81 5mm 3 21 in 62 0mm 2 44 in 647...

Page 85: ...type Sports type ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Head lamp License plate lamp Turn signal lamp Brake Tail lamp Igniter type 5 B T D C at 1 500rpm CR8E 12V 12Ah MF Main...

Page 86: ...y 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 However NHTSA cannot become involved in any individual problems bet...

Page 87: ...MEMO 86 C O P Y R I G H T E D...

Page 88: ...MEMO 87 C O P Y R I G H T E D...

Page 89: ...Prepared by HYOSUNG MOTORS MACHINERY INC 3rd Ed MAR 2005 Printed in KOREA C O P Y R I G H T E D...

Page 90: ...y 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 However NHTSA cannot become involved in any individual problems bet...

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