HYOSUNG Karion Owner'S Manual Download Page 1

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HYOSUNG MOTORS & MACHINERY INC.

Part No. 99011HM5410

SEP. 2002.

Printed in KOREA

1st Ed.

Summary of Contents for Karion

Page 1: ...HYOSUNG MOTORS MACHINERY INC Part No 99011HM5410 SEP 2002 Printed in KOREA 1st Ed...

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 information and instructions which should...

Page 3: ...MACHINERYINC FOREWORD THANK YOU for choosing Hyosung motor cycle We at Hyosung have designed tested and produced this motorcycle using the most modern technology available to provide you with much hap...

Page 4: ...during the break in period It is especially 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 spe...

Page 5: ...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 6: ...se perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING section on page 36 of this owner s manual Make sure the rider wears a helmet eye protecti...

Page 7: ...the footrests at all times or injuries resulting 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 K...

Page 8: ...an entire safety inspection to ensure the safety of the rider and its passenger WARNING Your riding skill and mechanical knowledge form the foundation for safe riding practices We suggest that you pr...

Page 9: ...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 cause the motorcycle...

Page 10: ...cation of the motorcycle or removal of original equipment may render the vehicle unsafe or illegal WARNING motorcycle Balance the load between the left and right side of the motorcycle and fasten it s...

Page 11: ...MENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH CARBURETOR CHOKE LEVER FUEL COCK REAR BRAKE PEDAL KICK START LEVER GEARSHIFT LEVER STAND SEAT LOCK REAR SUSPENSION 5 SUPPLY OF GASOLINE AND ENGINE OIL...

Page 12: ...GASOLINE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER FUEL HOSE SPARK PLUG CARBURETOR CLUTCH ADJUSTMENT DRIVE CHAIN BRAKES TIRE REPLACEMENT OF THE L...

Page 13: ...to special service information Use unleaded gasoline with an octane rating 85 95 or higher Unleaded gasoline can extend spark plug life and exhaust components life SERIAL NUMBER LOCATION FUEL AND OIL...

Page 14: ...uality four stroke motor oil will increase the service life of your motorcycle If a SAE 10 W 30 or 10W 40 motor oil is not available select and alternative according to the following chart Don t mix t...

Page 15: ...utch lever Left handle switches Choke lever Speedometer Ignition switches Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Fuel tank cap OFF 0 10 20 30 40 50 60 70 80...

Page 16: ...Fuel cock Rear carrier Passenger footrests Side stand Footrests Gearshift lever...

Page 17: ...Kick starter lever Engine oil filter cap Engine oil filler cap level gauge Rear brake pedal Footrests Passenger footrests...

Page 18: ...ee positions OFF POSITION All electrical circuits are cut off The engine will not start The key can be removed ON POSITION The ignition circuit is completed and the engine can now be started The key c...

Page 19: ...road speed in kilometers and miles per hour TRIP METER The trip meter is a resettable odometer located in the speedometer assembly It can be used to indicate the distance traveled on short trip or be...

Page 20: ...n Position Using when need operation of engine as drive and others The ignition circuit is on and the engine can run Set the dimmer switch when other vehicle is running in front or against WARNING Alw...

Page 21: ...by position of the throttle grip Turn it toward you to 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 avoi...

Page 22: ...choke system for starting is equipped with a manually operated fuel cock There are three position ON OFF and RES ON Position The normal operating position for the fuel cock lever is in the ON position...

Page 23: ...kick start type After switching the fuel cock lever to the RES position it is advisable that the tank be refilled at the closest gas station After refueling be sure to move the fuel cock to the ON pos...

Page 24: ...t 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 automatically skipped Reduce the motorcyc...

Page 25: ...e frame below the seat When assemble the seat put up the seat at the frame and unite two bolts Side stand STAND SEAT LOCK The comes equipped with a side stand safe device This safe device is returned...

Page 26: ...desired position with the pin spanner Position 1 provides the softest spring pre load and position 5 provides the stiffest is delivered from the factory withits adjuster set on position 1 REAR SUSPENS...

Page 27: ...oil Daily oil level checks and periodic changes are two of the most important maintenances to be performed Gasoline is extremely flammable and toxic Always observe the following precautions when refu...

Page 28: ...ne oil level being most suitable about 1mm under the Upper line mark F of the engine oil level gauge In case of the engine oil pouring excessively the engine output being made insufficient Be careful...

Page 29: ...ON HYOSUNG 16510H05240 OUTSIDE LUSTER MATERIAL INSERTION DIRECTION Insert the filter so that surface of the filter hole turn toward the engine CAUTION When install the oil fiter necessarily HYOSUNG ch...

Page 30: ...in plug and tighten it securely Pour fresh oil through the filler hole Approximately 1 050 of oil will be required Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain p...

Page 31: ...starter switch RIDING TIPS STARTING THE ENGINE Before attempting to start the engine make sure Operation of the carburetor choke system is not necessary when the engine is warm CAUTION Running the eng...

Page 32: ...esult in an accident Always ride within the limits of your skills your motorcycle and the riding conditions WARNING Removing your hands from the handlebars or feet from the footrests during operation...

Page 33: ...lower gear so that the engine will again be operating in its normal power range Shift rapidly to prevent the motorcycle from losing momentum When riding down a steep hill the engine may be used for br...

Page 34: ...e rough or other slippery surfaces can cause wheel skid and loss of control Brake lightly and with care on slippery or irregular surfaces WARNING Following another vehicle too closely can lead to a co...

Page 35: ...rst 160km 100miles MAXIMUM THROTTLE OPENING RECOMMENDATIONS The table below shows the maximum throttle opening recommendation during the break in period ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING...

Page 36: ...motorcycle that are used under severe conditions CAUTION The 1 000km 600miles service should be performed as outlined in the INSPECTION AND MAINTENANCE section of this Owner s Manual Pay particular at...

Page 37: ...ong life of each working part of your motorcycle 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...

Page 38: ...Clutch lever holder Drive chain Side stand pivot and spring hook Speedometer gear box Brake lever holder Throttle cable Brake pedal pivot Motor oil Grease...

Page 39: ...ad Cylinder Spark plug Fuel hose Engine oil filter Engine oil Throttle cable Idle speed Clutch First 1 000 km Every 4 000 km Every 8 000 km Interval Item Clean and lubricate every 1 000 km Inspect Ins...

Page 40: ...here is leakage from fuel tank fule cock hose carburetor Mop them up with a patch when washing To assist you in the performance of periodic maintenance a tool kit is supplied and is located under the...

Page 41: ...of battery periodically Check if there is any noise by bend of front fork while moving the handle upward and downward Inspect whether the steering stem is well assembled while moving front fork up dow...

Page 42: ...the battery wires and grease the terminal lightly Keep the battery away from fires When disassemble the battery wire take off terminal first with the ignition switch OFF position When assemble termina...

Page 43: ...ions must be cleaned or replaced more frequently than maintenance schedule Check and clean the air cleaner element periodically according to the following procedure 1 Remove the seat and right side co...

Page 44: ...the element completely or damage severely the engine Be careful not to allow water to go inside the air cleaner element CAUTION FUEL HOSE SPARK PLUG When the assembly of air cleaner element is not com...

Page 45: ...the spark plug gap to 0 8 0 9 mm 0 028 0 031 inch by using a spark plug gap thickness gauge Do not over torque or cross thread the spark plug or the aluminum threads of the cylinder head will be damag...

Page 46: ...oes not raise the engine idle speed and that the throttle grip return smoothly and automatically CAUTION CLUTCH ADJUSTMENT The clutch lever play The lock nut The clutch lever adjuster The rubber boot...

Page 47: ...osung dealer Damage to the drive chain means that the sprockets may also be damaged Inspect the sprockets for the following Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nuts...

Page 48: ...this motorcycle is made of the special material The chain should be replaced with a 428HO Use of another chain may lead to premature chain failure CAUTION The drive chain should be inspected every tim...

Page 49: ...dic maintenance BRAKES Brake fluid may be harmful if swallowed or if it comes in contact with skin or eyes Contact your doctor immediately if brake fluid is swallowed and induce vomiting If brake flui...

Page 50: ...ating at high pressure CAUTION Riding with worn brake pads will reduce braking performance and will increase your chance of having accident Inspect brake pad wear before each use Ask your Hyosung deal...

Page 51: ...ll any brake fluid on painted or plastic surfaces as it will damage the surface severely CAUTION Too much clearance in the rear brake pedal can cause poor braking performance and may lead to an accide...

Page 52: ...L IMIT FRONT BRAKE LAMP SWITCH The front brake lamp switch is located beneath the front brake lever Loosen the switch fitting screws and adjust the timing by moving the switch body forward or backward...

Page 53: ...tires not only hasten tire wear but also seriously affects the stability of the motorcycle Under inflated tires make smooth cornering difficult and over inflated tires decrease the amount of tire in...

Page 54: ...ke nipple tightening torque 0 25 0 30 kgf m 2 5 3 0 N m If the spoke nipple loose it will increase damage of the spoke and rim and decrease the riding stability WARNING The standard tire on is 130 80...

Page 55: ...2V 35W 1 12V 35W 1 12V 21 5W 1 12V 10W 4 12V 5W 1 NAMES CAPACITY Requirement electric power of the lamp shown in the following chart When replace the damaged lamp always use the equal capacity The use...

Page 56: ...acement bulb push it in and turn it to the clockwise while pushing Overtightening the screws may cause the lens to crack CAUTION FUSE The fuse box is located behind the seat If the engine suddenly sto...

Page 57: ...Check the fuel supply in the fuel tank Check the ignition system for intermittent spark Check the engine idle speed 1 Drain the fuel in the fuel tank 2 Do the fuel cock in the OFF position 3 Do drain...

Page 58: ...y scratch plastic or painted surfaces Rinse the motorcycle thoroughly with clean water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remove the rags or wrapping from...

Page 59: ...L A B E L...

Page 60: ......

Page 61: ...98 lbs ENGINE Type Four stroke air cooled Bore 57 0mm 2 24 in Stroke 48 8mm 1 92 in Piston displacement 124 5 7 58 in3 Corrected Compression ratio 9 92 1 Carburetor Piston valve Starter system KICK SE...

Page 62: ...Front brake Disc Rear brake Drum ELECTRICAL Ignition type CDI type Ignition timing 15 B T D C at 2 250 rpm 31 B T D C at 4 000 rpm Spark plug C8EH 9 Battery 12V 6Ah MF Fuse 15A Headlamp HI 12V 35Wx1...

Page 63: ...Prepared by HYOSUNG MOTORS MACHINERY INC Overseas Technical Dept 1st Ed SEP 2002 Printed in KOREA...

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