HYOSUNG Rally Manual Download Page 2 | Manualshive

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This manual should be considered a permanent part 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 be read carefully before operating the
motorcycle.

*Rally(o/m)-E/060207

2006.2.7

6:43

PM

페이지1

001

PagePro

9100

300DPI

100LPI

COPYRIGHTED

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Summary of Contents for Rally

Page 1: ...SUNG MOTORS MACHINERY INC Part No 99011HN3210 NOV 2003 Printed in KOREA For U S A 6 0 2 0 7 2 0 0 6 2 7 6 4 2 P M 페이지1 001 PagePro 9100 300DPI 100LPI ...

Page 2: ...torcycle 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 carefully before operating the motorcycle C O P Y R I G H T E D ...

Page 3: ...NK YOU for choosing Hyosung motorcycle We at Hyosung have designed tested and produced this motor cycle using the most modern technology available to provide you with much happy enjoyable safe riding Motorcycling is one of the most exhilarating sports and insure your riding enjoyment you should become thor oughly familiar with the information present ed in this Owner s Manual before riding the mot...

Page 4: ...he 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 break in recommendations WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAUTION and NOTE N O T E This provides spe...

Page 5: ... 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 exhaust system of this motorcycle requires no periodic maintenance The engine should be adjusted to the manufacture s specifications and the spark plug should be kept in good condition Running the eng...

Page 6: ...aily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING sec tion on page 33 of this owner s man ual Make sure the rider wears a helmet eye protection and protective cloth ing gloves leather or heavy cloth pants long sleeved shirt or jacket boots Permit use only by dual rider This motorcycle is designed for use only by dual rider Do not permit anyone to op...

Page 7: ...ifting Failure to observe this precaution may result in loss of control and an accident WARNING WHEN KEEPING FOR LONG PERIOD 1 Supply the enough fuel in the fuel tank 2 Do drain wholly the fuel in the carbu retor 3 Remove the battery from the motorcy cle CAUTION The trunk could be heated Don t keep anything that doesn t endure heat Don t keep the fragile Check if it is locked The unlocking of trun...

Page 8: ... 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 the foundation for safe riding practices We suggest that you practice riding your motorcycle in a non traffic situation until you are thoroughly familiar with your machine and its controls Remember pr...

Page 9: ...nsion 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 to be less responsive to your steering control The weight may also cause oscillations in the front end and lead to instability problems Accessories added to the machine should be as light as possible and kept to a...

Page 10: ...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 R I G H T E D ...

Page 11: ...L OIL INDICATOR LAMP LEFT HANDLE SWITCH RIGHT HANDLE SWITCH 5 HOW TO USE 21 HOW TO USE THE HELMET HOLDER HOW TO OPEN THE SEAT HOW TO USE THE PERSONAL TRUNK 6 GASOLINE AND ENGINE OIL 23 HOW TO PROVIDE THE GASOLINE HOW TO SUPPLY THE ENGINE OIL 7 THE PROPER OPERATIONS 25 STARTING THE ENGINE STARTING OFF OPERATING THE BRAKE STOPPING AND PARKING TABLE OF CONTENTS C O P Y R I G H T E D ...

Page 12: ...DIC MAINTENANCE 40 EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BRAKES TIRES AIR CLEANER BATTERY TRANSMISSION OIL ENGINE OIL AND GASOLINE FUSES SPARK PLUG REAR VIEW MIRROR REFLECTOR RUBBER CAP OF CABLES TROUBLE SHOOTING WHEN KEEPING FOR LONG PERIOD CLEANING PROCEDURE 11 LABEL 53 12 SPECIFICATIONS 54 C O P Y R I G H T E D ...

Page 13: ...rring to special ser vice 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 FUELANDOILRECOMMENDATION When refueling always shut the engine off and turn the ignition key to the OFF position Never refuel near the flames sparks and heat sources Do not overfill the fuel tank Do not fil...

Page 14: ...il Use a good quality SAE 10W 30 or 10W 40 multi grade oil Don t mix the unrecommended oil It could damage the engine When refilling the oil don t allow the dust to get inside Mop the oil spilt Don t put the patch on the filler cap It could disturb the oil to be provided and damage the engine WARNING C O P Y R I G H T E D ...

Page 15: ...NAMES OF EACH PARTS Rear brake lever Left handle switches Speedometer Right handle switches Throttle grip Front brake lever 14 C O P Y R I G H T E D ...

Page 16: ...15 Fuel tank cover Oil tank Muffler Rear carrier N O T E means the invisable parts C O P Y R I G H T E D ...

Page 17: ...16 Oil indicator lamp Ignition switches Personal trunk Seat lock Battery Fuse Air cleaner Kick starter lever Center stand Side stand N O T E means the invisable parts C O P Y R I G H T E D ...

Page 18: ...ON KEY Turning the ignition switch to the OFF or LOCK position while the motorcycle is moving can be haz ardous Moving the motorcycle while the steering is locked can be hazardous You could lose your balance and fall or you could drop the motorcycle Stop the motorcycle and place it on the side stand if equipped before locking the steering Never attempt to move the motorcycle when the steering is l...

Page 19: ... indica tor will flash at the same time HIGH BEAM INDICATOR LAMP The high beam indicator lamp will come on when the head lamp high beam is turned on When the engine oil level in the tank becomes too low requiring HYPOL OIL refilling the red indicator will light When the oil indicator lamp turns on the remaining amount of oil has become approximately 0 23ℓ INSTRUMENT PANEL When the fuel indicator l...

Page 20: ...sh the PASS switch to oper ate the head lamp high beam LEFT HANDLE SWITCH Always use the turn signals when you intend to change lanes or make a turn Always be sure to turn the turn signal switch to the OFF position after com pleting the turn or lane change CAUTION Apply the brake lightly and with great care on slippery surfaces to avoid skidding WARNING Do not operate when the dimmer switch positi...

Page 21: ...rake lightly and with great care on slippery surfaces to avoid skid ding WARNING Avoid turning the throttle grip during brakes WARNING LIGHT SWITCH position The head lamp meter lamp and tail lamp come on position The head lamp meter lamp and tail lamp go off Do not operate for the engine stop switch is in the position while dri ving at one s pleasure WARNING N O T E If the front or rear brake leve...

Page 22: ...age the starting motor for more than five seconds at a time as it may overheat the wiring harness and starting motor If the engine does not start after several attempts check the fuel supply and igin tion system Refer for Page 51 CAUTION HOW TO USE HOW TO USE THE HELMET HOLDER When keep a helmet temporally use the helmet holder following the illustration below C O P Y R I G H T E D ...

Page 23: ...Use the vacuum cleaner Don t keep the valuables in the trunk when leaving unattended Exceed loading limit may result in injury caused by damage to the vehicle or altered handling charac teristics CAUTION HOWTOUSETHEPERSONALTRUNK Keep the owner s manual or maintenance manual in the personal trunk Put the helmet as shown in the picture 5kg HOW TO OPEN THE SEAT You can use the PERSONAL TRUNK after op...

Page 24: ...oard and turn it clockwise 2 Open the fuel tank cover 3 Turn the fuel tank cap counterclockwise 4 Fill the fuel tank and turn the cap colck wise tightly HOW TO PROVIDE THE GASOLINE Gasoline is extremely flammable and toxic Always observe the following pre cautions when refueling your Never permit motorcycle refueling by anyone other than an adult Refuel in a well ventilated area Make sure the engi...

Page 25: ...en and pets may be harmed by swallowing new or used engine oil or solvent Continuous con tact with used engine oil has been found to cause skin cancer in laboratory ani mals Brief contact with used oil or sol vent may irritate skin Keep new and used oil and solvent away from children and pets Wear a long sleeve shirt and water proof gloves Wash with soap if oil or solvent con tact your skin WARNIN...

Page 26: ...N I T I O N If the front or rear brake lever is not squeezed the starting motor will not rotate CAUTION Push the starter switch without turning the throttle grip Take off the starter switch right after started Do not engage the starting motor for more than five seconds at a time as it may overheat the wiring harness and starting motor If the engine does not start after sev eral attempts check the ...

Page 27: ...push the starter switch longer without turning the throttle grip When the engine is cold idle it for a while Start using by the kick starter lever You can start using by the kick starter lever when there is some problem in bat tery Put the motorcycle on the center stand Set the ignition switch ON Press forcefully the kick starter lever Running the engine indoors or in a garage can be hazardous Exh...

Page 28: ...en returning the center stand grip the rear carrier CAUTION Ride on Gripping the lever with both hands be seat ed on from leftside of the motorcycle Put the left foot on the earth and fasten the rear brake lever Don t let the engine run excessively before riding CAUTION Check the safety Turn on the left turn signal lamp and check the safety Grip up the rear brake lever Be careful of the vehicles i...

Page 29: ...tart off Take off the rear brake lever and turn the throttle grip slowly the motorcycle will start moving forward Riding this motorcycle at excessive speed increases your chances of losing control of the motorcycle This may result in an accident Always ride within the limits of your skills your motorcycle and the riding conditions WARNING Removing your hands from the handle bars or feet from the f...

Page 30: ...ke lever right after returning the throttle grip Make the speed lower by operating the brake slowly The quick brake can cause skid ding OPERATING THE BRAKE REAR BRAKE FRONT BRAKE Pay much more attention to dri ving when rains or snows When the brake doesn t work normal ly keep low speeds and apply the brake lightly until smoothly operated C O P Y R I G H T E D ...

Page 31: ...n the throttle grip When completely stopped turn off the turn signal lamp Set the key OFF position STOPPING AND PARKING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of control Brake lightly and carefully on slippery or irregular surfaces WARNING Hard braking while turning may cause wheel skid and loss of control Brake before you begin to turn WARNING Fol...

Page 32: ...ad on the engine BREAK IN BREAKING IN THE NEW TIRES New tires need proper break in to assure maximum performance just as the engine does Wear in the tread surface by gradually increasing your cornering lean angles over the first 160km 100miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160km 100miles ALLOW THE ENGINE OIL TO CIR CULAT...

Page 33: ...000km 600miles service should be performed as outlined in the PERIODIC MAINTENANCE section of this Owner s Manual Pay particular attention to the CAUTION and WARNING in that section CAUTION Timely performance of the 1 000km 600miles service will ensure optimum service life and performance from the engine C O P Y R I G H T E D ...

Page 34: ...lanned distance of operation Correct pressure Adequate tread depth No cracks or cuts Correct level and pollution degree of engine oil Operation of all lights and indi cators Correct function Correct function CHECK FOR utilizes disk brake for front and drum brake for rear Properly operating the brake systems are vital to safe riding Be sure to per form the brake inspection require ments as schedule...

Page 35: ... Operating the motorcycle in harsh condition can be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your motorcycle under these conditions the brakes must be inspected more often than recom mended in the MAINTENANCE SCHEDULE WARNING 5 20mm 15 25mm BRAKE FLUID Be s...

Page 36: ... it must be replaced with a new one by your authorized Hyosung dealer or qualified service mechanic The front brake system be replaced the brake hose or the brake fluid according to periodic inspection chart by your authorized Hyosung dealer for safety as in times of operating at high pressure CAUTION Riding with worn brake pads or shoes will reduce braking performance and will increase your chanc...

Page 37: ...e with 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 instructions Check tire condition and pressure and adjust pressure before each ride Avoid overloading your motorcycle Replace a tire when worn to the spec ified limit or if you find damage such ...

Page 38: ...d rear tires at once when appear the tire wear indicator TIRE TREAD CONDITION The standard tire on is 120 90 10 66J for front and 130 90 10 70J for rear The use of a tire other than standard may cause trouble It is highly recommended to use the standard tire supplied by Hyosung CAUTION Tire wear indicator Tire wear indicator mark CRACKS AND CUTS Check if 1 there are visible cracks and cuts 2 there...

Page 39: ...IL The lack of fuel will go off suddenly Failure to observe this precaution may result in loss of control and an accident CAUTION Check if the remaining gasoline is enough for running to the destination Replenish the GASOLINE when the Fuel indicator lamp on with the ignition switch in the ON INSPECTION OF FUEL FUEL INDICATOR LAMP OIL OIL INDICATOR LAMP C O P Y R I G H T E D ...

Page 40: ... 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 excessive at the electric system or to damage the lamp Check if the head lamp tail lamp and turn signal lamp work well with engine started Check if the head lamp are dusty or damaged INSPECTION OF LAMPS HEAD LAMP T...

Page 41: ...that you have these items inspected and serviced by your authorized Hyosung dealer or a quali fied service mechanic PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth and long 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 washin...

Page 42: ...tand pivot and spring hook Side stand pivot and spring hook Throttle cable Steering stem bearing Speedometer gear box Front brake lever holder Throttle grip Motor oil Grease G G G O G G G G means the invisable parts C O P Y R I G H T E D ...

Page 43: ...g Fuel hose Throttle cable Idle speed Oil pump Transmission oil First 1 000 km Every 4 000 km Every 8 000 km Interval Item Inspect Inspect Inspect Inspect Inspect Replace every 4 years Inspect Inspect Replace every 2 years Inspect Inspect Inspect Inspect Inspect Inspect Tighten Tighten CHASSIS Drive belt Brake Tire Steering Front forks Rear shock absorber Chassis nuts and bolts First 1 000 km Ever...

Page 44: ...r foreward backward Check the front rear brake while running in low speeds Check if there is leakage or damage on the brake fluid reservoir and the con nected parts are loose Check if the vibration damages the brake hose while moving the handle left right or running BRAKE FLUID Keep the motorcycle upright and place the handle straight Check the brake fluid level by observing the LOWER line When th...

Page 45: ...OT 4 UPPER LIMIT LINE Don t replenish with brake fluid over the limit line It will leak out of the brake fluid reservoir Be careful not to allow dusts or water to go inside when it is replenished Don t use the unrecommended brake fluid Brake fluid can damage severely the plastics or rubbers When it is spilt on the parts mop them up CAUTION LOWER WEAR LIMIT LINE BRAKE SHOE is equipped with the brak...

Page 46: ...justing nut of brake cam lever After adjustment check if it is within the required range when you squeeze the brake lever until feel the resistance PLAY OF REAR BRAKE LEVER Standard 15 25mm 0 59 0 98in PIN When it is beyond the index mark replace the brake shoe Fix part of nut to pin or serious accident can be cause by the brake failure CAUTION Check the tire pressure when it is cold TIRES TIRE PR...

Page 47: ...a proper size with nonflammable cleaning solvent Immerse the element in the cleaning sol vent and wash it clean 4 Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands do not twist or wring the element or it will develop tears 5 Immerse the element in HYOSUNG gen uine oil and squeeze the oil out of the element leaving it slightly wet with oil 6 Assem...

Page 48: ...he minimum of self electric dis charge and electric leakage when don t use for a long time Remove the negative terminal when keep intact at the motorcycle CAUTION When the assembly of air cleaner ele ment is not completely done dusts can go inside and damage severely engine Be careful not to allow water to go into the element while washing CAUTION More frequent servicing may be per formed on motor...

Page 49: ...If there is white dust clean it with warm water 4 Assemble 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 igni tion switch OFF position When assemble terminal first Fasten certainly the battery wires Incorrect installation of the battery will reverse the terminal position resulting in possible el...

Page 50: ...ere is a 10A spare fuse Check the fuse with the ignition switch OFF 1 Remove the battery cover under the pil lion seat 2 Take out the fuse holder 3 Open the fuse holder and take out the fuse FUSES FUSE HOLDER FUSE CONNECTOR FUSE Never use other than specified 10A fuse Installing a fuse of incorrect rating may seriously damage the electrical system You should consult your Hyosung deal er or a quali...

Page 51: ... standard spark plug for this motorcycle has been carefully select ed to meet the vast majority of all operational ranges If the spark plug color indicates that other than a stan dard spark plug be used it is best to consult your Hyosung dealer before selecting an alternate plug or heat range The selection of an improper spark plug can lead to severe engine damage CAUTION Remove the carbon deposit...

Page 52: ...ctions to determine the cause Fuel Supply Check Is there enough fuel in the fuel tank Is the fuel reaching the carburetor from the fuel pump If it has been determined that fuel is reaching the carburetor the ignition sys tem should be checked next Ignition System Check Remove a spark plug and reattach to the spark lead While holding the spark plug firmly against the engine crank the engine with th...

Page 53: ...e Cloth rags washing mitts or cleaning brushes can be used be careful with brushes as they may 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 the exhaust pipe For extended life of your motorcycle lubricate according to LUBRI CATION POINTS section Fo...

Page 54: ...53 L A B E L C O P Y R I G H T E D ...

Page 55: ... stroke forced air cooled Intake system Reed valve Number of cylinder 1 Bore 41 0mm 1 614in Stroke 37 4mm 1 472in Piston displacement 49 3 0in Corrected Compression ratio 7 4 1 Carburetor SIDEDRAFT VARIABLE VEN TURI PISTON Starter system KICK ELECTRIC STARTER TRANSMISSION Clutch Dry shoe automatic centrifugal type Reduction ratio 2 997 0 813 Drive system V belt drive SPECIFICATIONS C O P Y R I G H...

Page 56: ...tion type CDI type Ignition timing 23 B T D C at 1 000 rpm Spark plug BR8HSA Battery 12V 4Ah Generator Magneto Fuse 10A Head lamp HI 35W LO 35W Turn signal lamp 21W 2 10W 2 Brake Tail lamp 21 5W Speedometer lamp 3 4W Oil indicator lamp 1 7W Turn signal indicator lamp 1 7W Fuel indicator lamp 1 7W High beam indicator lamp 1 7W CAPACITIES Fuel tank 4 3ℓ Engine oil tank 1 0ℓ Transmission oil 110cc Re...

Page 57: ...ay 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 between you your dealer or Hyosung Motors Machinery Inc To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washington D C area or write to NHTSA U S DEP...

Page 58: ...57 MEMO C O P Y R I G H T E D ...

Page 59: ...58 Prepared by HYOSUNG MOTORS MACHINERY INC 1st Ed NOV 2003 Printed in KOREA C O P Y R I G H T E D ...

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