HYOSUNG GT650 - PARTS CATALOGUE Owner'S Manual Download Page 66

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Tool bag

12 mm open end wrench

17 mm open end wrench

Spark plug wrench

Combination screw driver

Screw driver handle

Clamp wrench

Clamp wrench handle

Pliers

Hexagon spanner 4 mm

Hexagon spanner 6 mm

❶

❷

❸

❹

❺

❻

❼

❽

❾

❿

Check if there is leakage from crankcase.

To assist you in the performance of peri-

odic maintenance, a tool kit is supplied.

The tool kit is attached on the back of the

rear seat with a rubber band.

The tool kit consists of the following items.

INSPECTION AND

MAINTENANCE

TOOL

ENGINE OIL

Inspect the fuel hoses for damage and

fuel leakage. If any defect are found the fuel
hoses must be replaced.

Replace the fuel hoses every 4 years.

FUEL HOSE

NO.

N A M E

Summary of Contents for GT650 - PARTS CATALOGUE

Page 1: ...This owner s manual contains important safety information Please read it carefully WARNING...

Page 2: ...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...

Page 3: ...g necessarily Install the battery to the motorcycle STANDARD CHARGING TIME 1 2 A for 10 hours BATTERY INITIAL CHARGING Do not use the battery without the battery initial charging Otherwise the battery...

Page 4: ...3...

Page 5: ...4...

Page 6: ...r 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 Motorcy...

Page 7: ...y 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 break in recommendations WARNING CAU...

Page 8: ...s any sale 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 MAINTE...

Page 9: ...Before each use perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING sec tion on page 59 of this owner s manu al Make sure the rider wears a hel...

Page 10: ...should keep both feet on the footrests at all times or injuries resulting from acci dents Moving the rider s feet from the footrests reduces the rider s ability to control the motorcycle and could le...

Page 11: ...ion switch is in the OFF or LOCK position or the engine stop switch is in the posi tion while driving at one s pleasure WARNING Loose fancy clothing can be uncomfort able and unsafe in terms of riding...

Page 12: ...ber practice makes perfect WARNING Ride within the boundaries of your own skill at all times Knowing these limits and staying within them will help you to avoid accidents WARNING Riding on bad weather...

Page 13: ...learance and bank angle An improperly mount ed load could critically reduce these two safety factors Also determine that the load does not interfere with the operation of the suspension steering or ot...

Page 14: ...trical system Severe overloads may damage the wiring harness or create a dangerous sit uation due to the loss of electrical power during the operation of the motorcycle When carrying a load on the mot...

Page 15: ...H IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCHES RIGHT HANDLE SWITCHES FRONT BRAKE LEVER ADJUSTMENT REAR BRAKE PEDAL GEARSHIFT LEVER FOOTRESTS SIDE STAND SEAT LOCK TRUNK REAR SHOCK ABSORBER FRONT...

Page 16: ...OR HOSE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT AND REAR SUSPENSIONS REAR VIEW MIRROR REFLECTOR BATTERY AIR CLEANER SPARK PLUG IDLING ADJUSTMENT THROTTLE CABLE ADJUSTMENT CLUTCH CABLE ADJU...

Page 17: ...d on the left downside of the crankcase assembly Please write down the numbers in the box provided below for your future reference The frame and or engine serial numbers are used to register the motor...

Page 18: ...areful not to spill any fuel when fill ing the fuel tank Wipe spilled gasoline up immediately CAUTION Don t mix the unrecommended oil It could damage the engine When refilling the oil don t allow the...

Page 19: ...diator mixed with distilled water only at a 50 50 mixture ratio for engine coolant solution An engine coolant mixture other than 50 50 can affect cooling efficiency or rust inhibiting peformance Engin...

Page 20: ...19 NAMES OF EACH PARTS Clutch lever Left handle switches Instrument panel Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switch Fuel tank cap...

Page 21: ...tion coil Front Ignition coil Rear Spark plug Rear Rear seat lock Fuses Brake Tail lamp Rear turn signal lamp License plate lamp 21 Passenger footrests 22 Footrests 23 Gearshift lever 24 Side stand 25...

Page 22: ...attery Air cleaner Front brake fluid reservoir Front brake lamp switch Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil filler plug Rear brake pedal Rear br...

Page 23: ...22 Clutch lever Left handle switches Instrument panel Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switch Fuel tank cap NAMES OF EACH PARTS...

Page 24: ...tion coil Front Ignition coil Rear Spark plug Rear Rear seat lock Fuses Brake Tail lamp Rear turn signal lamp License plate lamp 21 Passenger footrests 22 Footrests 23 Gearshift lever 24 Side stand 25...

Page 25: ...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 plug Rear brake peda...

Page 26: ...25 Clutch lever Left handle switches Instrument panel Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switch Fuel tank cap NAMES OF EACH PARTS...

Page 27: ...tion coil Front Ignition coil Rear Spark plug Rear Rear seat lock Fuses Brake Tail lamp Rear turn signal lamp License plate lamp 21 Passenger footrests 22 Footrests 23 Gearshift lever 24 Side stand 25...

Page 28: ...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 plug Rear brake peda...

Page 29: ...ignition key from the OFF position come up again and turn it to the LOCK position Remove the ignition key STEERING LOCK STEERING LOCK KEY Turning the ignition switch to the OFF or LOCK position while...

Page 30: ...ar other than neutral INSTRUMENT PANEL When the ignition switch is turned to the ON position the display of speedome ter will come on CAUTION To adjust the light of speedometer dis play push the switc...

Page 31: ...fuel is approximately 3 4 the red lamp of E Empty mark comes on only Fill the fuel tank before the red lamp of E Empty mark came on only The fuel tank capacity is 17 0 30 Running the engine with high...

Page 32: ...dometer They can register 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 disp...

Page 33: ...itch in the normal mode for 2 seconds until the hour and minutes display blink 1 It is the clock reset mode 2 Adjust the hour display by pushing the switch in the clock reset mode for 0 6 1 seconds 3...

Page 34: ...ent Increase the hour of clock A B A B SPEEDOMETER The speedometer indicates the road speed in kilometers or miles per hour To change the speedometer display 1 Turn the ignition switch to the ON posi...

Page 35: ...ine stalls try restarting the engine after turning the ignition switch off and on When the LCD display panel indicates CHE make sure that the engine stop switch is in the position If the LCD display p...

Page 36: ...n LEFT HANDLE SWITCHES Do not operate when the dimmer switch position CAUTION Use the clutch correctly Otherwise the clutch may be worn quickly CAUTION TURN SIGNAL SWITCH Using when left right turn or...

Page 37: ...he engine stop switch is in the position while dri ving at one s pleasure ENGINE STOP SWITCH Position Using when danger ous condition of falling down during drive and others or engine stop suddenly Th...

Page 38: ...and igintion interlock system is working properly before riding WARNING These motorcycles always come on the head lamp position lamp meter lamp tail lamp and license plate lamp when the ignition switc...

Page 39: ...n push the brake lever forward and turn the adjuster to the desired position When changing the brake lever position always be sure the adjuster stops in the proper position a pro jection of the brake...

Page 40: ...and 2nd gear It is not possible to upshift or downshift more than one gear at a time When shifting from first to 2nd gear or 2nd gear to low neutral will be automatical ly skipped GEARSHIFT LEVER Redu...

Page 41: ...IFT LINK ROD FOR s OPTIONAL PARTS When the footrests in position exchange the gearshift link rod for appropri ate riding position Position or Install the gearshift link rod Position Install the gearsh...

Page 42: ...tion interlock system pre vents the motorcycle from being started with side stand down SIDE STAND The gearshift link rod is optional parts Optional parts Make sure that the side stand ignition interlo...

Page 43: ...To reinstall the rear seat slide the seat hook into the seat hook retainer and push down firmly until the seat snaps into the locked position To remove the front seat remove the two front seat mounti...

Page 44: ...manual or Owner s manual can be placed under the rear seat The tool kit is attached on the back side of the rear seat with a rubber band REAR SHOCK ABSORBER TRUNK N O T E Loading limit of trunk 1 k kg...

Page 45: ...of clicks from the fully turned in position Fully turned in H direction provides stiffest damping force and turning S direc tion the adjuster will soften damping force The rebound and compression dam...

Page 46: ...d breathing 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 th...

Page 47: ...periodic changes are two of the most important maintenances to be performed ENGINE OIL Fuel Engine oil and Coolant use cer tainly to recommend at the front part CAUTION The engine and the components o...

Page 48: ...r the engine oil excessively CAUTION Oil change Engine overhaul Oil and filter change 3 000 3 400 3 200 ENGINE OIL CAPACITY Operating the motorcycle with an incor rect amount of engine oil can damage...

Page 49: ...il or solvent con tact your skin WARNING 5 Remove the three nuts holding the filter cap in place 2 Place a drain pan under the engine 3 Remove the engine oil filler plug 4 Drain the engine oil by remo...

Page 50: ...ter spring and the O ring are installed correctly Use new O ring each time the engine oil filter element is replaced 8 Replace the oil filter cap and tighten the nuts securely but do not over tighten...

Page 51: ...ND COOLANT RECOMMENDATION section 17 page Failure to use the correct oil can damage your motorcycle Engine damage may occur if you use the engine oil that does not meet Hyosung s specifications Be sur...

Page 52: ...d do induce vomiting Immediately contact a poi son control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coolant gets in eyes flush eyes with water and seek...

Page 53: ...sassemble the side cowling inner remove the two bolts You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot After the engine cools wrap a thick cloth around...

Page 54: ...rcycles always come on the head lamp position lamp meter lamp tail lamp and license plate lamp when the ignition switch was turned to the ON position CAUTION Running the engine indoors or in a garage...

Page 55: ...exits or in hilly areas can upset your control Reduce your speed and be alert to side winds WARNING Take off the starter switch right after started Avoid pressing the starter switch when the engine i...

Page 56: ...transmission is provided to keep the engine operating smoothly in its normal operating speed range The gear ratios have been carefully chosen to meet the characteristics of the engine The rider should...

Page 57: ...neutral with the clutch lever squeezed towards the grip disengaged position just before the motorcycle stops Neutral position can be confirmed by observing the neutral indicator lamp Inexperienced ri...

Page 58: ...yosung The following guidelines explain proper break in procedures Less than 3 4 throttle Less than 1 2 throttle Upto1 600km 1 000miles Initial 800 km 500 miles MAXIMUM THROTTLE OPENING RECOMMENDATION...

Page 59: ...l of the engine 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 fi...

Page 60: ...tire pressure as described in the INSPECTION AND MAINTENANCE section WARNING Operating these motorcycles with improper modifications can be haz ardous Improper installation of accessories or modifica...

Page 61: ...orrect play in the throt tle cable Smooth operation and positive return of the throttle grip to the closed position Correct lever play Smooth and progressive action Proper operation Fluid level in the...

Page 62: ...endations and sched ules in this owner s manual Ask your Hyosung dealer or a qualified mechanic to do the maintenance items marked with a pentagram You may perform the unmarked mainte nance items by r...

Page 63: ...otor cycle and also for safe riding It is a good practice to lubricate the motorcycle after a long rough ride or after it gets wet in the rain or after washing it Major lubrication points are indicate...

Page 64: ...ch cable Footrests pivot Passenger footrests pivot Drive chain Side stand pivot and spring hook Speedo sensor Front brake lever holder Throttle cable Rear brake pedal pivot O Motor oil Grease G N O T...

Page 65: ...hose Engine oil Engine oil filter 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 lubricate every 1 000 km Inspect...

Page 66: ...there is leakage from crankcase To assist you in the performance of peri odic maintenance a tool kit is supplied The tool kit is attached on the back of the rear seat with a rubber band The tool kit...

Page 67: ...D MUFFLER Check if the mirror shows the rear and or side views REAR VIEW MIRROR Check if the reflector is dusty or damaged REFLECTOR Periodically check for the following Keep the front brake lever pul...

Page 68: ...cycle CAUTION 67 Never invert the battery cables Ensure that the ignition switch is in posi tion OFF before connecting or discon necting the battery otherwise some components might damage WARNING CHEC...

Page 69: ...res When disconnecting the battery wire be sure to remove the negative battery wire first with the ignition switch OFF position then remove the positive battery wire When reinstalling the battery be s...

Page 70: ...the 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...

Page 71: ...out the following opera tions let the engine and the muffler cool down to ambient temperature in order to avoid burns WARNING 1 Disconnect spark plug caps 2 Remove all the dirt from the base of the sp...

Page 72: ...28 0 032 in TIGHTENING TORQUE SPARK PLUG 11 N m 1 1 kgf m PLUG REPLACEMENT GUIDE Hotter type Standard type Colder type CR7E CR8E CR9E The spark plug must be tightened firmly otherwise the engine may o...

Page 73: ...hrottle cable system Cable is for throttle cable and cable is for returning 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 adjuster...

Page 74: ...ABLE ADJUSTMENT CLUTCH CABLE PLAY ADJUSTMENT A basis adjustment be allowed by the clutch lever adjuster Loosen the lock nut counter clockwise Turn the clutch lever adjuster in or out to acquire the sp...

Page 75: ...ing 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 correct the problem if you know how If nece...

Page 76: ...come off the sprockets and result in accident or serious engine damage CAUTION 20 30 mm 0 79 1 18 in DRIVECHAINCLEANINGANDOILING This drive chain has special X O rings Clean and oil the chain periodi...

Page 77: ...nt Some drive chain lubricants contain sol vents and additives which could dam age the X O rings in your chain Use Hyosung chain lube or an equiva lent that is specifically intended for use with X O r...

Page 78: ...cause accelerat ed brake wear This could lead to an accident If you operate your motorcycle under these conditions the brakes must be inspected more often than recommend ed in the MAINTENANCE SCHEDULE...

Page 79: ...style and road surface condition Front Brake Rear Brake These motorcycles use glycol based brake fluid Do not use or mix different types of brake fluid otherwise serious damage will result in the bra...

Page 80: ...is setting at the original place Then do not ride the motorcycle untill operating the brake fluid and becoming the brake distance CAUTION Inspect every day in the following point at the brake system B...

Page 81: ...clockwise 4 Replenish with brake fluid to the upper line N O T E The recommended brake fluid DOT4 BRAKE DISK INSPECTION Check the brake disk for damage or cracks FRONT BRAKE FLUID SUPPLY 1 Place the...

Page 82: ...h the pressure gauge Failure to follow these warnings may 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...

Page 83: ...E NUT Inspect the rear axle shaft and jointing nut for loosening The standard tire on are 120 60 ZR 17 55W for front and 160 60 ZR 17 69W for rear The use of a tire other than standard may cause troub...

Page 84: ...four front axle pinch bolts right and left 3 Loosen the front axle Improper jacking may cause damage to the frame or engine CAUTION 2 Loosen the rear axle Improper jacking may cause damage to the fra...

Page 85: ...alcohol to avoid any damage DO NOT PULL ON THE WIRES CAUTION N O T E Before changing a bulb check the fuses INSPECTION OF LAMPS Check if the head lamp position lamp meter lamp tail lamp and license pl...

Page 86: ...REPLACEMENT OF THE LAMP Requirement electric power of the lamp shown in the following chart When replace the damaged lamp always use the equal capacity The use of a lamp other than rules may cause to...

Page 87: ...After removing the bulb at the socket replace the new bulb HEAD LAMP S BULB REPLACEMENT 1 Remove the head lamp cowling 2 Remove the three screw right left and bottom and the head lamp assem bly HEAD L...

Page 88: ...rake tail lamp are LED Light Emitting Diode type If any abnormal condition are found replace the brake tail lamp assembly Overtightening the screws may cause the lens to crack CAUTION LICENSE PLATE LA...

Page 89: ...fied 30 A or 15 A fuse Installing a fuse of incorrect rating may seriously damage the electrical system You should consult your Hyosung deal er or a qualified service mechanic imme diately CAUTION Thi...

Page 90: ...ary Retry the above procedure with the cleaned spark plug or new one 4 If there is still no spark consult your Hyosung dealer for repairs ENGINE STALLING 1 Check the fuel supply in the fuel tank 2 Che...

Page 91: ...sure the area is well ventilated before proceeding Do not inhale fuel vapours Do not smoke nor use naked flames WARNING DRAINING THE FUEL TANK Place the motorcycle on firm and level ground Stop the en...

Page 92: ...cause rust cor rosion and increase wear Do not use high pressure washers to clean your motorcycle CAUTION 91 Use a garden hose at low pressure to remove the majority of dirt or other debris Wash your...

Page 93: ...ng motorcycle with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes washing motorcycle riding at slow speed I...

Page 94: ...e any corrosion from the terminals and wiring harness connec tions 3 Store the battery in a room above freez ing TIRES Inflate the tires to the normal pressure EXTERNAL Spray all vinyl and rubber part...

Page 95: ...94 L A B E L NOTE means the invisible parts 4 4 1 1 4 4 2 2 4 4 3 3...

Page 96: ...95...

Page 97: ...96 4 4 1 1...

Page 98: ...97 4 4 2 2 4 4 3 3...

Page 99: ...474 lbs Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system V 2 cylinder 81 5 mm 3 21 in 62 0 mm 2 44 in 647 39 5 in3 Electric fuel injection ELECTRIC STARTER Four strok...

Page 100: ...2 91 in 27 right left ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Head lamp License plate lamp Turn signal lamp Brake Tail lamp ECU 5 B T D C at 2 000 rpm CR8E 12V 12Ah MF Main 3...

Page 101: ...Prepared by 1st Ed APR 2009 Printed in KOREA...

Page 102: ...Part No 99011HN9110EI APR 2009 Printed in KOREA 1st Ed...

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