HYOSUNG GT250 REi User manual

Part No. 99011HM8110EI
MAR. 2009.
Printed in KOREA
1st Ed.
This owner’s manual contains important safety information.
Please read it carefully.
WARNING

1
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
information and instructions which should be read carefully before
operating the motorcycle.

2
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 battery to the motorcycle.
󳛪STANDARD CHARGING TIME
: 1.0 A for 10 hours
: 0.8 A for 10 hours 󳛫
BATTERY INITIAL CHARGING
Do not use the battery without the battery initial charging.
Otherwise, the battery may be shortened service life.
CAUTION
The

&

are started as the battery ignition system.
Do not permit to start or operate the throttle grip after started without the battery caused
by damage to the electrical system.
Always start or ride these motorcycles with the battery.
WARNING

3
&
&
FUEL SYSTEM

: EI
󳛪󳛪
Electric fuel Injection
󳛫󳛫
System

: Carburetor
N O T E

4
All information, illustrations photographs
and specifications contained in this manual
are based on the latest product information
available at the time of publication. Due to
improvements or other changes, there may
be some discrepancies in this manual.
Hyosung reserves the right to make
changes at any time.
Please note that this manual applies to all
specifications for all respective destinations
and explains all equipments. Therefore,
your model may have different standard
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
motorcycle 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 thoroughly familiar with
the information presented in this Owner's
Manual before riding the motorcycle.
The proper care and maintenance that
your motorcycle requires are outlined in this
manual.
By following these instructions explicitly
you will insure a long trouble-free operating
life for your motorcycle. Your Hyosung
dealer has experienced technicians that are
trained to provide your machine with the
best possible service with the right tools and
equipment.

5
IMPORTANT
BREAK-IN INFORMATION FOR
YOUR MOTORCYCLE
The first 1,600 km (1,000 miles) are the
most important in the life of your motorcycle.
Proper break-in operation during this time
will help ensure maximum life and
performance from your new motorcycle.
Hyosung parts are manufactured of high
quality materials, and manufactured parts
are finished to close tolerances. Proper
break-in operation allows the machined
surfaces to polish each other and mate
smoothly.
Motorcycle reliability and performance
depend on special care and restraint
exercise 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
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 words
should be carefully reviewed.
N O T E
This provides special information to
make maintenance easier or important
instructions clearer.
These instructions point out special
service procedures or precautions that
must be followed to avoid damaging the
machine.
CAUTION
The personal safety of the rider may be
involved. Disregarding this information
could result in injury to the rider.
WARNING

6
Noise Control System (muffler assembly)
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Owners are warned that the law may prohibit :
(a) The removal or rendering inoperative by any person other than for the
purpose of maintenance, repair or replacement, of any device or
element of design incorporated into any new vehicle for the purpose of
noise control prior 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 condition. Running the engine with
incorrectly operating spark plug or misadjusted carburetor may cause
permanent damage to the catalyst and to the noise control system.
WARNING

7
Motorcycle riding is great fun and an
exciting sport. Motorcycle riding also
requires that some extra precautions be
taken to ensure the safety of the rider and
passenger. These precautions are :
Before first use of the

&

read this owner
’ s manual carefully to
become familiar with these
motorcycles
’ s features, and safety
and maintenance requirements.
Review all instructions, requirements
and warnings. Keep the owner’s
manual in the owner’s manual
storage compartment located under
the rear seat.
Before the rider
’ s first use of the

&

,
make sure that he/she is familiar with
the location and operation of all
controls, and has been instructed in
the proper operation of the
motorcycle.
For first use of the

&

,
find a level, open area for the rider to
use to become familiar with the
operation of controls and the
operating and handling
characteristics
of these motorcycles.
WARNING
Before each use, perform daily
inspections with the rider. Specific
items to check are listed in the
INSPECTION BEFORE RIDING
section on page 58 of this owner
’
s
manual.
Make sure the rider wears a helmet,
eye protection, and protective
clothing (gloves, leather or heavy
cloth pants, long sleeved shirt or
jacket, boots).
Permit use only by two-passenger.
These motorcycles are designed for
use only by two-passenger.
Do not permit anyone to operate the

&

under the influence of alcohol or
other drugs caused by damage to the
motorcycle or altered handling
characteristics.
Observe periodic maintenance
requirements your authorized
Hyosung dealer is trained and
equipped to perform this service.
Drain gasoline from the fuel tank
prior to transporting the

.
Drain gasoline from the fuel tank and
carburetor prior to transporting the

.
Caution the rider and others near
the

&

not to get close to or touch any
moving parts or any heated areas
such as the engine and exhaust
system.

Do not make any modifications to
the

&

.
Modifications may make the
motorcycle unsafe or illegal in your
state.
WARNING
CONSUMER INFORMATION
SAFE RIDING RECOMMENDATION
FOR MOTORCYCLE RIDERS

88
The

&

are equipped with the side stand
ignition interlock system.
1. If the transmission is in neutral, you
can start the engine regardless of the
clutch lever and side stand.
2. If the transmission is not in neutral, you
can only start the engine with pulling in
the clutch lever and the side stand up.
Make sure that the side stand igintion
interlock system is working properly
before riding.
WARNING
Do not run the engine indoors or
where there is little or no ventilation.
Exhaust gases contain carbon
monoxide, a potentially lethal gas that
is colorless and odorless.
Never leave the motorcycle running
while unattended, even for a short
time.
WARNING
The 
&

always come on the head lamp,
meter lamp, tail lamp and license
plate lamp when the ignition switch
was turned to the “ON” position .
The 
’s lamps are come on
by operating the light switch turning
the ignition switch to the “ON”
position.
CAUTION
While operating the

&

, the rider should keep
both feet on 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
Keep both hands on the handgrips at all
times when riding. Removing your
hands from the handgrips reduces your
ability to control the motorcycle, and
could result in an accident.
WARNING
Always open the throttle gradually to
prevent front wheel lifting. Failure to
observe this precaution may result in
loss of control and an accident.
WARNING

9
WEAR A HELMET
RIDING APPAREL
INSPECTION BEFORE RIDING
Motorcycle safety equipment starts with
a quality safety helmet. One of the most
serious injuries that can happen is a
head injury. ALWAYS wear a properly
approved helmet. You should also wear
a suitable eye protection.
WARNING
Do not operate for the ignition switch is
in the “OFF” or “LOCK” position or the
engine stop switch is in the “ ”
position while driving at one

s pleasure.
WARNING
Loose fancy clothing can be
uncomfortable and unsafe in terms of
riding your motorcycle.
Choose good quality motorcycle riding
apparel in terms of riding your
motorcycle.
WARNING
Review thoroughly the instructions in
the “INSPECTION 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
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 rear seat could
cause serious accident.
Don’t allow water to get inside the
trunk or it could damage.
Don’t keep the valuables in the trunk
when leaving unattended.
Loading limit of trunk : 1 (2.21 lbs)
CAUTION
WHEN KEEPING FOR LONG PERIOD :
1. Supply enough the fuel in the fuel
tank.
2. Remove the battery from the
motorcycle.
3.
󳛪󳛪For 󳛫󳛫
Drain wholly the fuel in the
carburetor.
CAUTION

10
There are a great variety of accessories
available to Hyosung owners. Hyosung
can not have direct control over the quality
or suitability of accessories you may wish to
purchase except genuine parts.
The addition of unsuitable accessories
can lead to unsafe operating conditions. It
is not possible for Hyosung to test each
accessory on the market or combinations
of all available accessories, however, your
dealer can assist you in selecting quality
accessories and installing them correctly.
Use extreme caution when selecting and
installing the accessories for your
Hyosung. We have developed some
general guidelines which will aid you when
deciding whether, and how to equip your
motorcycle.
ACCESSORY INSTALLATION AND
PRECAUTION SAFETY TIPS
Improper accessories or modifications
can make your motorcycle unsafe and
can lead to an accident.
Never modify the motorcycle with
improper or poorly installed
accessories. Follow all instructions in
this owner’s manual regarding
accessories and modifications. Use
genuine Hyosung accessories or
equivalent designed and tested for
your motorcycle. Consult your
Hyosung dealer if you have any
questions.
WARNING
FAMILIARIZE YOURSELF WITH
THE MOTORCYCLE
KNOW YOUR LIMITS
BE EXTRA SAFETY CONSCIOUS
ON BAD WEATHER DAYS
Your riding skill and mechanical
knowledge form 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.
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 days, especially
wet ones, requires extra caution.
Braking distances double on a rainy
day. Stay off of the painted surface
marks, manhole covers and greasy
appearing areas as they can be
especially slippery.
Use extreme caution at railway
crossings and on metal gratings and
bridges. Whenever you have a doubt
about road condition, slow down!
WARNING

1. In case that additional weight or
aerodynamic affecting accessories are
installed, they should be mounted as
low as possible, as close to the
motorcycle and as near the center of
gravity as is feasible. The mounting
brackets and other attachment
hardware should be carefully checked
to ensure that it provides for a rigid,
nonmovable mount. Weak mounts can
allow the shifting of the weight and
create a dangerous, unstable condition.
2. Inspect for proper ground clearance
and bank angle. An improperly
mounted 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 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 minimum.
4. The motorcycle may be affected by a
lifting condition or by an instability in
cross winds or when being passed or
passing large vehicles. Improperly
mounted or poorly designed
accessories can result in an unsafe
riding condition, therefore caution
should be used when selecting and
installing all accessories.
11
5. Certain accessories displace the rider
from his or her normal riding position.
This limits the freedom of movement of
the rider and may limit his or her control
ability.
6. Additional electrical accessories may
damage the existing electrical system.
Severe overloads may damage 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 affect the
aerodynamics and handling of the
motorcycle.
Balance the load between the left and
right side of the motorcycle and fasten it
securely.
Modification of the motorcycle, or removal of
original equipment may render the vehicle
unsafe or illegal.
Obey all applicable equipment regulations in
your area.
MODIFICATION

12
1. SERIAL NUMBER LOCATION  14
2. FUEL AND OIL RECOMMENDATION  15
FUEL
ENGINE OIL
3-1. NAMES OF EACH PARTS [ ] 16
3-2. NAMES OF EACH PARTS [ ] 19
3-3. NAMES OF EACH PARTS [ ] 22
3-4. NAMES OF EACH PARTS [ ] 25
4. CONTROLS  28
IGNITION SWITCH
IGNITION KEY
INSTRUMENT PANEL
LEFT HANDLE SWITCHES
RIGHT HANDLE SWITCHES
FRONT BRAKE LEVER ADJUSTMENT
[ Only for  ]
CARBURETOR CHOKE LEVER [ For  ]
REAR BRAKE PEDAL
GEARSHIFT LEVER
FOOTRESTS
SIDE STAND
SEAT LOCK
TRUNK
REAR SHOCK ABSORBER
5. SUPPLY OF GASOLINE AND ENGINE OIL 44
GASOLINE
ENGINE OIL
6. RIDING TIPS 50
STARTING THE ENGINE
STARTING OFF
USING THE TRANSMISSION
RIDING ON HILLS
STOPPING AND PARKING
TABLE OF CONTENTS

13
7. BREAK-IN56
8. INSPECTION BEFORE RIDING 58
9. PERIODIC MAINTENANCE  60
10. INSPECTION AND MAINTENANCE 64
TOOL
ENGINE OIL
FUEL HOSE
GASOLINE
RUBBER CAP OF CABLES
EXHAUST PIPE AND MUFFLER
FRONT AND REAR SUSPENSIONS
REAR-VIEW MIRROR
REFLECTOR
BATTERY
AIR CLEANER
SPARK PLUG
IDLING SPEED ADJUSTMENT
THROTTLE CABLE PLAY ADJUSTMENT
CLUTCH CABLE
DRIVE CHAIN
BRAKES
TIRE
BULBS
11. TROUBLESHOOTING 88
12. TRANSPORT 90
13. CLEANING PROCEDURE 90
14. STORAGE PROCEDURE 92
15. LABEL94
16. SPECIFICATIONS 98

14
Frame number :
Engine number :
The frame number  is stamped on the
right side of the steering head tube.
The engine serial number
 is stamped
on the left upside 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 motorcycle. They
are also to assist your dealer in terms of
ordering parts or referring to special service
information.
SERIAL NUMBER LOCATION
󱆂
󱆃

15
ENGINE OIL
Classification
system
API
SAE
Grade
Over SL
10W/40
Remarks
ENGINE OIL SPECIFICATION
Using a premium quality four stroke motor
oil will increase the service life of your
motorcycle.
 If a SAE 10W/40 motor oil is not
available, select alternative according to
the following chart.
Don’t mix the unrecommended oil.
It could damage the engine.
When refilling the oil, don’t allow the
dust to get inside.
Wipe the spilled oil up immediately.
Don’t put the patch on the filler cap.
It could disturb the oil to be provided
and damage the engine.
WARNING
F U E L
Use unleaded gasoline with an octane
rating of 91 or higher.
Unleaded gasoline can extend spark plug
life and exhaust components life.
FUEL AND OIL
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 the fuel tank above the
entrance lower end.
WARNING
Spilling gasoline can damage the
painted surfaces.
Be careful not to spill any fuel when
filling the fuel tank.
Wipe spilled gasoline up immediately.
CAUTION
Use the chart to select a viscosity rating
based on temperature range in your area.
N O T E
In very cold weather [below
- 15

(5

F)], use SAE 5W/30 for good
starting and smooth operation.
ENGINE OIL
Temperature


-30
-22
-20
-4
-10
14
0
32
10
50
20
68
30
86
40
104
20W50
15W40 15W50
10W40 10W50
10W30
5W30

16
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

17
Spark plug (Front)
Front turn signal lamp
Head lamp
Ignition coil (Front)
Ignition coil (Rear)
Spark plug (Rear)
󱇸Rear seat lock
󱇹Fuses
󱇺Brake / Tail lamp
󱇻Rear turn signal lamp
󱇼License plate lamp
󱇽Passenger footrests
󱇾Footrests
󱇿Gearshift lever
󱈀Side stand
󱈁Engine oil drain plug
N O T E
“ ”

means the invisible parts.

18
󱈂Muffler
󱈃Rear carrier
󱈄Rear seat & Trunk & Tools
󱈅Front seat
󱈆ECU (Engine Control Unit)
Battery
Air cleaner
Front brake fluid reservoir
Front brake lamp switch
Engine oil filter
Engine oil filler cap
Engine oil level lens
Rear brake pedal
Rear brake lamp switch
Rear brake fluid reservoir
N O T E
“ ”

means the invisible parts.

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