HYOSUNG ST7 Owner'S Manual Download

Page: 56 / 90

Every

6,000 km

Every

12,000 km

Interval

Item

Clean every 3,000 km

Replace every 12,000 km

Tighten

─

Inspect

─

Tighten

─

Clean

Replace

Inspect

─

Replace every 4 years

Replace

─

Replace

─

Inspect

─

Inspect

─

Inspect

─

Replace every 2 years

─

Inspect

─

Replace every 4 years

⊙

ENGINE

Air cleaner element

Exhaust pipe bolts and muffler mounting bolts

★

Valve clearance adjust

★

Cylinder head bolt

★

Spark plug

Fuel hose

Engine oil

Engine oil filter

Throttle cable

Idle speed

★

Clutch

★

Engine coolant

★

Radiator hose

★

First

1,000 km

Every

6,000 km

Interval

Item

Inspect every 1,000 km

Inspect

─

Inspect

─

Replace every 4 years

Inspect

─

Replace every 2 years

Inspect

─

Inspect

─

Inspect

─

Inspect

─

Tighten

─

Lubricate

─

⊙

CHASSIS

Drive belt

★

Brake

★

Tire

Steering

★

Front forks

★

Rear shock absorber

★

Chassis nuts and bolts

★

General lubrication

First

1,000 km

Every

12,000 km

Brake hose

★

Brake fluid

★

N O T E

“

★

”

: Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.

Summary of Contents for ST7

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

Page 2: ...t 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 ...

Page 3: ... battery without the battery initial charging Otherwise the battery may be shortened service life 1 BATTERY INITIAL CHARGING Initial charging of the battery is first charging after filling electrolyte for improvement of the battery durability 2 BATTERY INSTALLATION Fill the electrolyte to the battery Leave the battery for 30 minutes Charge the battery by standard charging necessarily Install the b...

Page 4: ...d features than shown in this manual COPYRIGHT S T Motors Co Ltd FOREWORD THANK 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...

Page 5: ...ly 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 have special meanings Information following these signal wo...

Page 6: ...ior to its 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 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 condit...

Page 7: ...this motor cycle Before each use perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING sec tion on page 50 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 two passenger This motorcycle is designed for use ...

Page 8: ...p meter lamp tail lamp and license plate lamp when the ignition switch was turned to the ON position While operating the rider 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 lead to an accident Keep both hands on the handgrips at all times when ridin...

Page 9: ...s manual Do not forget to perform an entire safety inspection to ensure the safety of the rider and its passenger 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 practice makes perfect Ride within the ...

Page 10: ...erly 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 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...

Page 11: ...age the wiring harness or create a dangerous situation due to the loss of electrical power during the operation of the motorcycle When carrying a load on the motorcycle mount it as low as possible and as close as possible to the machine An improperly mounted load can create a high center of gravity which is very dangerous and makes the motorcycle difficult to handle The size of the load can also a...

Page 12: ...11 ...

Page 13: ...ENT PANEL LEFT HANDLE SWITCHES RIGHT HANDLE SWITCHES FRONT BRAKE LEVER ADJUSTMENT REAR BRAKE PEDAL GEARSHIFT LEVER FOOTRESTS SIDE STAND SEAT LOCK REAR SHOCK ABSORBER HELMET HOLDER 5 SUPPLY OF GASOLINE ENGINE OIL AND ENGINE COOLANT 36 GASOLINE ENGINE OIL ENGINE COOLANT 6 RIDING TIPS 44 STARTING THE ENGINE STARTING OFF USING THE TRANSMISSION RIDING ON HILLS STOPPING AND PARKING 7 BREAK IN 48 TABLE O...

Page 14: ...UBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT AND REAR SUSPENSIONS REAR VIEW MIRRORS REFLECTOR BATTERY AIR CLEANER SPARK PLUG IDLING ADJUSTMENT THROTTLE CABLE PLAY ADJUSTMENT CLUTCH CABLE ADJUSTMENT DRIVE BELT BRAKES TIRES BULBS 11 TROUBLESHOOTING 79 12 TRANSPORT 81 13 CLEANING PROCEDURE 81 14 STORAGE PROCEDURE 83 15 LABEL 84 16 SPECIFICATIONS 86 ...

Page 15: ...stamped on the right side of the steering head tube The engine serial number is stamped on the left downside of the crankcase assembly The frame and or engine serial numbers are used to register the motorcycle They are also to assist your dealer in terms of ordering parts or referring to special ser vice information SERIAL NUMBER LOCATION ...

Page 16: ...rding to the following chart FUEL ENGINE OIL AND ENGINE COOLANT RECOMMENDATION 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 fill gasoline above the fuel tank entrance lower end Spilling gasoline can damage the paint ed surfaces Be careful not to spill any fuel when f...

Page 17: ... if inhaled remove to fresh air If coolant gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Solution can be poisonous to animals Keep out of the reach of children and animals Spilled engine coolant can damage painted surfaces Do not spill any fluid when filling the radiator Wipe spilled engine coolant up immediately WATER FOR MIXING Use distilled water o...

Page 18: ...ing ratio should not exceed 60 ENGINE COOLANT The engine coolant performs as rust inhibitor and water pump lubricant as well as anti freeze Therefore the engine coolant should be used at all times even though the atmos pheric temperature in your area does not go down to freezing point 50 Water Engine coolant 0 8 ℓ 0 8 ℓ Required amount of water coolant Solution capacity total 1 6 ℓ COOLANT RESERVO...

Page 19: ...18 NAMES OF EACH PARTS Clutch lever Left handle switches Instrument panel Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Fuel tank cap ...

Page 20: ...nt seat lock Battery Fuses Passenger footrests Rear seat mounting bolt Rear turn signal lamp License plate lamp Brake Tail lamp 21 Helmet holder 22 Belt case inspecting hole 23 Side stand 24 Coolant reserve tank 25 Engine oil drain plug 26 Footrests 27 Gearshift lever means the invisable parts 21 22 23 24 25 26 27 ...

Page 21: ...p switch Ignition coil Front Radiator cap Rear brake fluid reservoir Radiator Cooling fan and motor Rear brake pedal Rear brake lamp switch Engine oil filter Water pump Engine oil level lens Air cleaner Engine oil filler plug means the invisable parts N O T E 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 ...

Page 22: ...be removed ON POSITION The ignition circuit is completed and the engine can now be started The key cannot be removed from the igni tion switch in this position CONTROLS IGNITION SWITCH Turning the ignition switch to the OFF position while the motorcycle is moving can be hazardous Start the engine after turning the key to the ON position or the battery will lose power due to consumption by the lamp...

Page 23: ...he steering Never attempt to move the motorcycle when the steering is locked has the steering lock below the steering head tube To lock the steering Turn the handlebar all the way to the left Insert the ignition key into the steering lock and turn it clockwise from the position Remove the ignition key To release the steering Insert the ignition key into the steering lock and turn it counter clockw...

Page 24: ...tion the display of speedome ter will come on Operating the display of the instrument panel while riding can be hazardous Removing a hand from the handlebars can reduce your ability to control the motorcycle Always keep both hands on the handle bars while riding Operating the motorcycle while the coolant temperature warning lamp is lit can damage your motorcycle Continued operation of the motorcyc...

Page 25: ...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 switch in the normal mode for 0 6 1 sec onds while the display indicates the odometer trip meter or trip meter you want to change A B A B s fuel meter is LCD Liquid Crystal Display type it indicates the remaining fuel amount in the fuel tank The fuel meter...

Page 26: ...or 2 sec onds while the display indicates trip meter B or B you want to reset A B Normal Clock reset mode Mode Select Reset Select Select 2 4 seconds 0 6 1 seconds 0 6 1 seconds 2 seconds Normal mode Clock reset mode Increase the hour of clock Increase the minutes of clock Clock reset mode Normal mode Switch Push it for Adjustment CLOCK ADJUSTMENT N O T E If push the switch in the normal mode for ...

Page 27: ...ent Adjustment Increase the minutes 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 Reset the trip meter to zero while the display indicates trip meter or 0 6 1 seconds Odometer Trip meter Trip meter Odometer In the clock reset mode Push it for 0 6 1 seconds Adjustment Increase the hour of cloc...

Page 28: ...be worn quickly HORN SWITCH Press the switch to operate the horn TURN SIGNAL SWITCH Using when left right turn or change direction Position Flash the left turn sig nal lamp Position Flash the left turn sig nal lamp OFF Pushing the position will stop the turn signal lamptooperate DIMMER SWITCH Change the direction of head lamp light The head lamp high beam come on The high beam indicator lamp also ...

Page 29: ...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 avoid skid ding Avoid turning the throttle grip during brakes FRONT BRAKE LEVER The front brake is applied by squeezing the brake lever gently toward the throttlegrip The front brake be anxious about motorcycle falling down when braking suddenly...

Page 30: ...the ON posi tion the engine stop switch in the position and the transmission is in neutral squeeze the clutch lever and the side stand up and push the starter switch to start the engine When the ignition switch is set to ON position with the engine stopped the meter lamp will come on and the needle of the speedometer will turn once to the end as a test of electric system operation Push the starter...

Page 31: ...push the brake lever forward and turn the adjuster to the desired position mark of the front brake lever holder When changing the brake lever position always be sure the adjuster stops in the proper position a projection of the brake lever holder should fit into the depression of the adjuster The is delivered from the fa ctory with its adjuster set on position 6 Position 1 provides the widest dist...

Page 32: ...ween first 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 GEARSHIFT LEVER 2nd gear to low neutral will be automatical ly skipped Reduce the motorcycle speed before down shifting When down shifting the engine speed should be increased before the clutch is engaged This will prevent unnecessary wear on the drive train compo...

Page 33: ...me off unexpectedly is delivered from the factory on position Footrest mounting bolt 4 0 6 0 kgf m 40 60 N m FOOTREST POSITION ADJUSTMENT has 2 type of the footrest position right and left To change the position remove the footrest mounting bolt footrest boss cap and bolt Install the bolt to the desired position and footrest boss cap bolt to the position FOOTRESTS POSITION ...

Page 34: ...tart is equipped with the side st and ignition interlock system If the transmission is in neutral or side stand up you can only start the engine with squeezing the clutch lever This side stand ignition interlock system prevents the motorcycle from being started with side stand down SIDE STAND 1 2 3 4 5 Possible Possible Impossible Impossible Impossible Off or Down On or Up Make sure that the side ...

Page 35: ...t and left shock absorber to the same settings Rear shock absorber Pin spanner Before leaving make sure that the front and rear seat are properly locked The front seat lock is located the left side cover under the front seat To unlock the front seat insert the ignition key into the front seat lock and turn it clock wise To lock the front seat push down firmly until the seat latch snaps into the lo...

Page 36: ...ter clockwise from the position 2 Hang a helmet s chin strap or bag s han dle into the bar of the helmet holder after the helmet holder s bar come out for the backside 3 Push the backside of the helmet holder s bar to lock it Never ride to hang the helmet or bag into the helmet holder This may result in injury caused by dam age to the vehicle or altered handling characteristics HELMET HOLDER Loadi...

Page 37: ...no open flames or sparks in the area Avoid prolonged contact with skin and breathing of gasoline vapors Keep children and pets away during refueling To open the fuel tank cap 1 Turn the fuel tank cap cover 2 Insert the ignition key into the cap lock and turn it clockwise 3 With the key inserted pull out the fuel tank cap To close the fuel tank cap 1 Align the fuel tank cap s mark with the fuel tan...

Page 38: ...nts of the exhaust system become very hot and remain hot for some time after the engine has been stopped Before han dling these components wear insulat ing gloves or wait until the engine and the exhaust system have cooled down 3 Hold the motorcycle vertically Position the motorcycle on firm and flat ground 4 Inspect the engine oil level through the engine oil level lens on the right side on the e...

Page 39: ...GINE OIL AND FILTER CHANGE Change the engine oil and filter after first running 1 000 km and every running 6 000 km The engine oil should always be changed when the engine is hot so that the engine oil will be drained thoroughly from the engine The procedure is as follows Oil change Engine overhaul Oil and filter change 3 000 3 400 3 200 ENGINE OIL CAPACITY In case of the engine oil pouring exces ...

Page 40: ...e hot muffler can burn you New and used oil can be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals Brief contact with used oil may irritate skin Keep new and used oil and used oil fil ters away from children and pets To minimize your exposure to used oil wear a long sleeve shir...

Page 41: ...e O ring are installed correctly Use new O ring each time the engine oil filter 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 exhaust pipes are cool enough to touch with bare hands before draining oil New and used oil can be hazardous Children and pets ...

Page 42: ... oil can damage your motorcycle Engine damage may occur if you use the engine oil that does not meet Hyosung s specifications Be sure to use the engine oil specified in the FUEL ENGINE OIL AND ENGINE COOLANTRECOMMENDATIONsection 13 Check the oil level according to Engine Oil Level Check procedure 12 Start the engine and allow it idle for a few minutes Check to see that no the engine oil is leaking...

Page 43: ...e FUEL ENGINE OIL AND ENGINE COOLANT RECOMMENDATION section 15 page Wait for the engine to cool down before checking or topping up coolant level If coolant level drops too quickly or the reservoir tank is empty check the cooling circuit for leaks Have the repair carried out at an authorized Hyosung dealer Engine coolant is harmful or fatal if swallowed or inhaled Do not drink anti freeze or coolan...

Page 44: ...e cap by turning it a quarter to allow pressure to escape and then turn the cap all the way off CHANGING THE COOLANT Change the coolant every two years OPEN THE RADIATOR CAP Remove the right frame head cover to operate the radiator cap To disassemble the right frame head cover remove the two mounting bolts About 1 6 ℓ ℓ of coolant will be required when filling the radiator and reservoir tank ...

Page 45: ...upper position 6 Squeeze the clutch lever RIDING TIPS STARTING THE ENGINE Necessary attempt before start the engine is equipped with the side stand ignition interlock system 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 prevents the motorcycle from being started with side stand down Make sure...

Page 46: ...xits or in hilly areas can upset your control Reduce your speed and be alert to side winds Riding the motorcycle with the FI check lamp lit can damage the engine and transmission Whenever the FI check lamp is lit haveyourauthorizedHyosungdealerora qualified mechanic inspect the electric fuelinjectionsystemassoonaspossible If the FI check lamp does not come on when the ignition switch is set to ON ...

Page 47: ...F position the steering lock to lock or the engine stop switch of its position while driving at one s pleasure The 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 always select the most suitable gear for the prevailing conditions USING THE TRANSMI...

Page 48: ...ars 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 by observing the neutral indicator lamp Inexperienced riders tend to underutilize the front brake This can cause exces sive stopping distance and lead to a col lision Using only the front or rear brake can cause skidding...

Page 49: ...ife and performance from your new Hyosung 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 RECOMMENDATIONS The table below shows the maximum throttle opening recommendation during the break in period AVOID CONSTANT LOW SPEED Operating the engine at constant low speed li...

Page 50: ... and hard braking for the first 160 km 100 miles ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING Allow sufficient idling time after warm or cold engine start up before applying load or revving the engine This allows time for the lubricating oil to reach all critical engine components OBSERVE YOUR FIRST AND MOST 1 000 km SERVICE The 1 000 km 600 miles service is the most important service your moto...

Page 51: ...manual Always maintain proper tire pressure as described in the INSPECTION AND MAINTENANCE section Operating this motorcycle with improper modifications can be hazardous Improper installation of accessories or modification of this motorcycle may cause changes in handling In some situ ations this could lead to an accident Never modify this motorcycle through improper installation or use of acces so...

Page 52: ... looseness Correct 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 reservoir to be above LOWER line Correct lever and pedal play No sponginess No fluid leakage Brake pads not to be worn down to the limit line Smooth movement Enough fuel for the planned d...

Page 53: ...nspection and main tenance recommendations 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 referring to the instruc tions in this section if you have mechanical experience If you are not sure how to do any of the jobs have your Hyosung dealer or a qualified m...

Page 54: ...of your motor 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 indicated as follows Lubricating switches can damage the switches Do not apply grease and oil to the switches ...

Page 55: ...Clutch lever holder and clutch cable Passenger footrests pivot Side stand pivot and spring hook Footrests pivot Speedo sensor Front brake lever holder Throttle cable Rear brake pedal pivot Motor oil Grease ...

Page 56: ...t Cylinder head bolt Spark plug Fuel hose Engine oil Engine oil filter Throttle cable Idle speed Clutch Engine coolant Radiator hose First 1 000 km Every 6 000 km Interval Item Inspect every 1 000 km Inspect Inspect Inspect Inspect Replace every 4 years Inspect Inspect Replace every 2 years Inspect Inspect Inspect Inspect Inspect Inspect Tighten Tighten Lubricate Lubricate CHASSIS Drive belt Brake...

Page 57: ...Check if there is leakage from fuel tank fuel pump hose fuel injection system 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 following items INSPECTION AND MAINTENANCE TOOL ENGINE OIL GASOLINE Inspect the fuel hose for damage and fuel leakage If any defect are found the fuel hose must be replaced Rep...

Page 58: ...ress in a smooth movement and must show no traces of oil on the legs Inspect the rear shock absorber for oil leakage and spring condition Ensure that all components are properly tightened and check the front and rear suspension articulated joints for correct operation Inspect whether the steering stem is well assembled while moving front fork up downwards and or foreward back ward In the event of ...

Page 59: ...ery of airtight type is used for this motorcycle It is not necessary to inspect or supple ment battery fluid However have your dealer check the charging condition of battery periodically BATTERY CHECK AND CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Set the ignition switch OFF position 2 Remove the front seat 3 Check that battery lead wire and termi nal 4 If ne...

Page 60: ...fier The air cleaner is located inside the air cleaner cover on the right side of the motor cycle If the air cleaner element has become clogged with dust intake resistance will increase with a resultant decrease in power output and an increase in fuel consumption If riding under severe conditions must be cleaned or replaced more frequently than maintenance schedule Check and clean the air cleaner ...

Page 61: ...eplaced Be sure to put the element snugly and correctly so that no incoming air will bypass it Remember rapid wear of the piston rings and cylinder bore is often caused by a defective or poorly fitted the ele ment 3 Remove the four screws of the air cleaner element 4 Remove the air cleaner element When the assembly of the air cleaner element is not completely done dusts can go inside and damage se...

Page 62: ...t and extract it from its seat taking care that neither dust nor other substances enter the cylinder 3 Make sure that there are neither carbon deposits nor corrosion marks on the electrode and on the central part if necessary clean them with the special cleaners for spark plugs with an iron wire and or a metal brush 4 Energetically blow some air in order to prevent the removed residues from Inspec...

Page 63: ...he thread 7 Tighten using the spanner supplied with the tool kit Screw in each spark plug by one half turn to compress the washer 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 overheat and severe damage may occur Use recommended spark plugs only A spark plug ...

Page 64: ... play is between 0 5 1 0 mm 0 02 0 04 in 7 Tighten the lock nut while holding the adjuster 8 While holding the throttle grip at the fully closed position slowly turn out the adjuster to feel resistance 9 Tighten the lock nut while holding the adjuster 10 Check free play again 11 Cover the protection We suggest that you have s idling speed adjusted by your authorized Hyosung dealer IDLING ADJUSTMEN...

Page 65: ...m 0 08 in as measured at the clutch lever holder before the clutch begins to disengage CLUTCH CABLE ADJUSTMENT 64 Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the throttle grip This can lead to loss of rider control Adjust the throttle cable play so that engine idle speed does not rise due to throttle grip movement When finished turn the handlebars to make s...

Page 66: ...ting the belt look for the fol lowing Edges of the belt for cuts or unusual wear patterns Outside ribbed surface of the belt for sign of stone puncture Roots of the belt teeth Sign of cracking at the base of the belt teeth Common types of belt wear and damage Improper belt adjustment If you find something wrong with the drive belt condition or adjustment correct the problem if you know how If nece...

Page 67: ...securely and per form a final inspection 4 5 5 5 mm 0 18 0 22 in When the rear tire be touched the ground 5 0 6 0 mm 0 20 0 24 in When the rear tire be not touched the ground DRIVE BELT SLACK 4 5kgf of Force DRIVE BELT SLACK ADJUSTMENT Adjust the drive belt slack to the proper specification The belt may require more fre quent adjustments than periodic mainte nance schedule depending upon your ridi...

Page 68: ...lt in accident or serious engine damage Be careful not to touch the muffler when it is hot a hot muffler can burn you CAUTIONOFDRIVEBELT When the drive belt was bent excessively the belt inner cord is broken Never bend the drive belt under the speci fication of inner or back bend capacity Never bend or twist when the drive belt is kept or installed If the drive belt was installed with dri ver forc...

Page 69: ...tions the brakes must be inspected more often than recommend ed in the MAINTENANCE SCHEDULE utilizes front and rear disk bra kes Properly operating the brake systems is vital to safe riding Be sure to perform the brake inspection requirements as sched ules The brakes should be inspected at period ic inspection by your authorized Hyosung dealer BRAKES Failure to properly inspect and maintain your m...

Page 70: ...wise serious damage will result in the brake system Use Only DOT4 brake fluid Do not spill any brake fluid on painted or plastic surfaces as it will damage the surface severely Never use any brake fluid 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 BRAKE PADS Inspect the ...

Page 71: ...squeeze depress and release sev eral times the brake lever pedal so that it is setting at the original place Then do not ride the motorcycle untill operating the brake fluid and becoming the brake distance Replacing only one of the two brake pads can be hazardous Replacing only one brake pads can result in uneven braking action Replace both pads together Rear Brake The front and rear brake system ...

Page 72: ...mage severely the plastics or rubbers When it is spilt on the parts wipe them up immediately REAR BRAKE FLUID SUPPLY 1 Place the motorcycle on a level surface and keep the handlebars straight 2 Clean 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 The recommended brake fluid DOT4 5 Fasten ...

Page 73: ... tires make smooth corner ing difficult and over inflated tires decrease the amount of tire in contact with the ground which can lead to skids and loss of control Be sure that the tire pressure is within the specified limits at all times Tire pressure should only be adjusted when the tire is cold If you see the problem with the tire adjust the pressure with the pressure gauge Failure to follow the...

Page 74: ...E TREAD CONDITION CRACKS AND CUTS Check if 1 there are visible cracks and cuts 2 there are abnormal wears ABNORMAL WEARS Tire wear indicator Tire wear indica tor mark REAR AXLE NUT Inspect the rear axle shaft and jointing nut for loosening The standard tire on is 120 80 16 60H for front and 170 80 15 77H for rear The use of a tire other than standard may cause trouble It is highly recommended to u...

Page 75: ...the ground 5 Draw out the front axle 6 Slide the front wheel forward 7 To reinstall the front wheel assembly reverse the sequence as described Improper jacking may cause damage to the frame or engine Improper jacking may cause damage to the frame or engine REAR TIRE REPLACEMENT 1 Place the motorcycle on the jack or block vertically 2 Remove the mounting bolts engine pulley cover and drive belt cas...

Page 76: ...ce listed BULBS Keep fuel and other flammable sub stances away from electric components Before changing a bulb set the ignition switch to position OFF and allow a few minutes for the bulb to cool down Wear clean gloves or use a clean dry cloth to handle the new bulb Do not put your fingerprints on the bulb as this may lead to overheating and fail ure If you have handled the bulb with bare hands cl...

Page 77: ...n lamp meter lamp tail lamp and license plate lamp when the ignition switch was turned to the ON position Brake Tail lamp Turn signal lamp License plate lamp Position lamp 12V H4 60 55W 1 12V W5W 1 LED type 12V RY10W 4 12V W5W 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 of a lamp other than...

Page 78: ...mp reverse the above sequence TURN SIGNAL LAMP S BULB REPLACEMENT 1 Remove the lens by removing the screw 2 Push the bulb turn it to the counter clockwise and pull it out 3 After stick in the new lamp assemble the lens Overtightening the screws may cause the lens to crack HEADLAMP SBULBREPLACEMENT 1 Remove the three screws right left and upside and the head lamp assem bly ...

Page 79: ...brake tail lamp cover 3 Turn the socket for 45 degree angle and pull the bulb out 4 Stick in the new bulb 5 Reinstall in the reverse the above sequence 78 BRAKE TAIL LAMP S BULB REPLACEMENT s the brake tail lamp is LED Light Emitting Diode type If any abnormal condition are found replace the brake tail lamp assembly ...

Page 80: ... should consult your Hyosung deal er or a qualified service mechanic imme diately WHEN THE ENGINE REFUSES TO START If the engine refuses to start perform the following inspections to determine the cause IGNITION SYSTEM CHECK 1 Remove a spark plug and reattach to the spark lead This troubleshooting guide is provided to help you find the cause of some common complaints Failure to troubleshoot a prob...

Page 81: ...s set to ON position with the engine stopped the meter lamp will come on and the needle of the speedometer will turn once to the end as a test of electric system operation Push the starter switch after the needle of the speedometer turn back 3 If there is no spark clean the spark plug Replace it if necessary Retry the above procedure with the cleaned spark plug or new one 4 If there is still no sp...

Page 82: ... system Do not damage the fuel pump assembly fuel level gauge accommodated inside the tank Refit the fuel tank cap after draining all fuel TRANSPORT A thorough cleaning of your motorcycle is a necessary part of maintenance and will help keep your motorcycle looking and per forming its best Proper cleaning can also extend the life of your motorcycle It is important to clean and inspect your motorcy...

Page 83: ...and polishes of good quality When using waxes and polishes observe the precautions specified by the manufacturers WASHING YOUR motorcycle With some care your motorcycle can be washed in a similar manner to washing an automobile Use a garden hose at low pressure to remove the majority of dirt or other debris Wash your motorcycle by hand with a mild soap or detergent and water Try to thor oughly rem...

Page 84: ... and remove 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 parts with rub ber protectant Spray the unpainted surfaces with rust preventative Coat the painted surfaces with car wax MAINTENANCE DURING STORAGE Once a month recharge the battery The s batter...

Page 85: ...84 L A B E L ...

Page 86: ...85 ...

Page 87: ...44 7 in 1 675 mm 66 0 in 155 mm 6 1 in 244 kg 538 lbs Type Number of cylinder Bore Stroke Piston displacement Fuel system Starter system Four stroke DOHC Liquid cooled V 2 cylinder 81 5 mm 3 21 in 65 0 mm 2 56 in 678 2 41 4 in3 Electric fuel injection ELECTRIC STARTER Clutch Final reduction ratio Drive belt Transmission Wet multi plate type 2 69 Poly chain belt 1st 2 46 2nd 1 78 3rd 1 38 4th 1 13 ...

Page 88: ...ht left 120 80 16 60H 170 80 15 77H Disk Disk Ignition type Ignition timing Spark plug Battery Fuse Head lamp Position lamp License plate lamp Turn signal lamp Brake Tail lamp ECU BTDC 5 1 600rpm and BTDC 35 7 000rpm CR8E 12V 12Ah MF Main 30A ECU 15A 12V H4 60 55W 1 12V W5W 1 12V RY10W 4 LED type 12V W5W 1 Fuel tank Engine oil 17 0 ℓ 3 000 Oil change 3 200 Oil and filter change 3 400 Engine overha...

Page 89: ...Prepared by 1st Ed JAN 2010 Printed in KOREA ...

Page 90: ...Part No 99011H99D10 JAN 2010 Printed in KOREA 1st Ed ...

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