HYOSUNG Comet 650R Service Manual Download Page 1

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SERVICE MANUAL

99000-94910

SERVICE MANUAL

HYOSUNG MOTORS & MACHINERY INC.

*Comet650S/R(SM)-COV

2005.4.28

5:11

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9100

300DPI

100LPI

Summary of Contents for Comet 650R

Page 1: ...SERVICE MANUAL 99000 94910 SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC C O V 2 0 0 5 4 2 8 5 1 1 P M 1 001 PagePro 9100 300DPI 100LPI...

Page 2: ...nts It covers the differences from and please refer to the service manual of 99000 94810 for others which are not covered in this manual This page numbers on the top are ones which are in the service...

Page 3: ...2 Standard type...

Page 4: ...3 NOTE Difference between photographs and actual motorcycles depends on the markets Sports type...

Page 5: ...em and page you need 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 L...

Page 6: ...5 GENERAL INFORMATION EXTERIOR ILLUSTRATION 6 1 7 1 SPECIFICATIONS 9 1 8 CONTENTS 1...

Page 7: ...RAL INFORMATION 6 EXTERIOR ILLUSTRATION Standard type Rear reflector Turn signal lamp Rear Tail Brake lamp License plate lamp Head lamp Turn signal lamp Front Passenger footrests HEIGHT WIDTH WHEEL BA...

Page 8: ...150 1 435 2 060 330 780 710 970 645 800 785 710 790 810 880 EXTERIOR ILLUSTRATION Sports type Rear reflector Turn signal lamp Rear Tail Brake lamp License plate lamp Head lamp Turn signal lamp Front P...

Page 9: ...3 GENERAL INFORMATION 8 EXTERIOR ILLUSTRATION Rear reflector Turn signal lamp Rear Tail Brake lamp License plate lamp Head lamp Turn signal lamp Front Passenger footrests HEIGHT WIDTH WHEEL BASE LENG...

Page 10: ...ke DOHC Liquid cooled V 2 cylinder 81 5 mm 3 21 in 62 0 mm 2 44 in 647 39 5 in3 BDSR39 TYPE DOUBLE Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter...

Page 11: ...8E 12V 12Ah MF 30 A 15 A 12V H1 55W 1 12V H3 55W 1 12V 10W 4 12V 21 5W 1 12V 1 7W 2 12V 5W 1 VFD VFD VFD VFD Level type VFD Level type Ignition type Ignition timing Spark plug Battery Fuse Head lamp T...

Page 12: ...11 MAINTENANCE PROCEDURES CARBURETOR 12 2 7 CLUTCH 13 2 9 1 ENGINE COOLANT 16 2 20 CONTENTS 2 2 PERIODIC MAINTENANCE...

Page 13: ...and set its speed at anywhere 1 300 and 1 500 rpm by turning throttle stop screw 1 300 1 500 rpm Engine idle speed Engine tachometer 09900 26006 MAINTENANCE PROCEDURES CARBURETOR IDLE SPEED Inspect I...

Page 14: ...ustment After finishing adjustment tighten the lock nut and cover the rubber boot If it is not adjusted by the adjuster loosen the clutch cable adjuster lock nut Turn the clutch cable adjuster in or o...

Page 15: ...8mm wrench bolts and install the bolts to the desired position by using the hexagon wrench 6mm are delivered from the factory on position WARNING When adjusting the footrest position the 8mm wrench bo...

Page 16: ...D FOR S OPTIONAL PARTS When the footrests in position exchange the gearshift link rod for appropriate riding position Position or Install the gearshift link rod Position Install the gearshift link rod...

Page 17: ......

Page 18: ...17 IGNITION SYSTEM 18 6 6 LAMP 19 6 16 1 ELECTRICAL SYSTEM 6 CONTENTS...

Page 19: ...F OFF OFF OFF 200 300 210 310 21 5 32 5 11 1 16 7 14 3 21 5 OFF 25 7 38 5 15 4 23 14 2 21 2 14 6 21 8 11 2 16 8 39 59 20 4 30 6 4 7 7 1 13 7 20 5 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OF...

Page 20: ...AL SYSTEM 6 16 1 19 REPLACEMENT OF HEAD LAMP BULB Remove the under cowling Refer to page 7 1 2 3 Remove the body cowling Refer to page 7 1 4 5 Remove the head lamp coupler Remove the dust cover LAMP H...

Page 21: ...Remove the socket spring Remove the bulb and replace the new bulb Remove the head lamp HI bulb with the same manner of the head lamp LOW bulb removal Reinstall the head lamp bulb in the reverse order...

Page 22: ...as shown in the illustration INSPECTION Using the pocket tester check the continuity between lead wires in the following illustration If the continuity measured incorrect replace the respective part...

Page 23: ...D LAMP 12V 1 7W T6 5 TACHO METER DISPLAY VFD TURN L B BW Lg BW BW W Y HIGH LOW TURN R ILLUM ILLUM SIGNAL YB FUEL Lg TURN R Br G B TURN L W L SIGNAL Gr ILLUM W HEAD LAMP LOW BEAM L Y 6 17 2 ELECTRICAL...

Page 24: ...23 CHASSIS EXTERIOR PARTS 24 7 1 1 HANDLEBARS 29 7 13 1 STEERING 33 7 23 CONTENTS 7...

Page 25: ...key Remove the rear carrier mounting bolts and separate the rear carrier INSTALLATION Reassemble the rear carrier in the reverse order of removal To reinstall the rear seat slide the seat hook into t...

Page 26: ...CHASSIS 7 1 2 25 UNDER COWLING Only Under cowling RH Under cowling LH Under center cowling Under center cowling grill...

Page 27: ...7 1 3 CHASSIS 26 REMOVAL Remove the under cowling screws at the rightside Remove the under cowling screws at the leftside...

Page 28: ...COWLING Windscreen Meter panel Body side cowling RH Body side cowling LH Body side cowling inner RH Body side cowling lower RH Body side cowling lower LH Air duct cowling RH Air duct cowling LH Body...

Page 29: ...screw at the rightside Remove the body cowling screw at the leftside Remove the two cowling brace bolts Remove the speedometer lead wire and head lamp lead wire REMOUNTING Tighten the two cowling brac...

Page 30: ...ight handlebar switches Disconnect the brake lamp switch lead wires and remove the master cylinder Refer to the service manual 99000 94810 page 7 10 Remove the handlebar balancer and grip Handlebar co...

Page 31: ...and grip Remove the clutch lever holder Loosen the handlebar clamp bolts right and left Remove the steering stem upper bracket by removing the steering stem head nut Loosen the front fork upper clamp...

Page 32: ...amp bolts right and left REMOUNTING Remount the handlebar in the reverse order of removal Pay attention to the following point Install the handlebars temporary Install the steering stem upper bracket...

Page 33: ...ounting the clutch lever holder align the holder s mating surface with punch mark on the handlebar When remounting the front brake master cylinder onto the handlebar align the master cylinder holder s...

Page 34: ...he body cowling Refer to page 7 1 4 5 Take off the front wheel Refer to the service manual 99000 94810 page 7 2 Remove the four bolts and front fender Take off the front fork Refer to the service manu...

Page 35: ...steering stem nut and draw out the steering stem Take off the steering stem lower bracket Remove the upper and lower bearings CAUTION Hold the steering stem lower bracket by hand to prevent from falli...

Page 36: ...to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering stem nut INSPECTION Inspect and check the removed parts for the followin...

Page 37: ...36 Tighten the handlebar clamp bolts right and left Handlebar clamp bolts 22 35 N m 2 2 3 5 kg m 7 25 2 CHASSIS...

Page 38: ...37 SERVICING INFORMATION SERVICE DATA 38 8 20 WIRE AND CABLE ROUTING 39 8 24 1 WIRING DIAGRAM 47 8 28 CONTENTS 8...

Page 39: ...lamp Right left High beam indicator lamp Fuel indicator lamp Coolant temperature indicator lamp 5W 21 5W Front 10W 2 Rear 10W 2 1 7W 2 VFD VFD VFD H1 55W H3 55W VFD VFD ITEM SPECIFICATION HI LO Level...

Page 40: ...R CABLE 09407 20406 09407 254A1 36618 30610 TUBE SPEEDOMETER LEAD WIRE 09408 00002 09407 20406 59460HN910 51511HN910 HOSE COMP FRONT BRAKE R JOINT FT BRAKE HOSE 59470HN910 HOSE COMP FRONT BRAKE L 094...

Page 41: ...PULSE CONTROL UNIT Install to the order TURN SIG RELAY 09407 14403 WIRING HARNESS Rr STOP S W WELDING CLAMP ENGINE EARTH WELDING CLAMP 09404 06404 GAUGE UNIT MOTOR LEAD WIRE Rr STOP S W 09407 14403 E...

Page 42: ...SERVICING INFORMATION 8 25 1 41 CARBURETOR ASS Y 58410HP920 CABLE COMP STARTER VIEW A...

Page 43: ...50 PROP STAND S W 09407 14403 09407 14403 WIRING HARNESS WIRING HARNESS FUSE 30A FUSE 15A IG N IT O R 09407 22402 WIRING HARNESS MAGNETO REGULATOR STARTING MOTOR RELAY 09407 14403 WIRING HARNESS FRAME...

Page 44: ...ICING INFORMATION 8 26 1 43 CYLINDER ASS Y R R MASTER 61610HM810 69480HM810 GUIDE RR BRAKE HOSE NO 2 61510HM810 GUIDE RR BRAKE HOSE NO 1 HOSE COMP REAR BRAKE Apply THREAD LOCK 1324 when install GUIDE...

Page 45: ...CABLE CARBURETOR BRACKET 09407 14403 THERMOSTAT 09407 20406 LEAD WIRE STARTER MOTOR 58200HN910 CABLE ASS Y CLUTCH PIPE COMP 2ND AIR FRONT ENGINE EARTH MOTOR LEAD WIRE Rr STOP S W Below 3mm Below 3m m...

Page 46: ...SERVICING INFORMATION 8 27 1 45 09404 06401 TO WATER TEMP GAUGE WIRING HARNESS FRONT CYLINDER REAR CYLINDER CAUTION FOR HIGHTENTION CORD INSTALLATION DIRECTION...

Page 47: ...8 27 2 SERVICING INFORMATION 46 09404 06429 MAGNETO GEAR SHIFT S W PROP STAND S W SPROCKET COVER...

Page 48: ...NITION S W OFF ON R O BW BR HAZARD E G STOP START CLUTCH LEVER S W Ft IG COIL FREE ON FRONT BRAKE THERMO S W FAN MOTOR RELAY SIDE STAND RELAY HEAD LAMP RELAY TURN RELAY DIODE 2 STOP LAMP S W IGNITOR L...

Page 49: ...Prepared by HYOSUNG MOTORS MACHINERY INC 1st Ed APR 2005 Manual No 99000 94910 Printed in Korea...

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