HYOSUNG GT650 - PARTS CATALOGUE User manual

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 informa-
tion and instructions which should be read carefully before operating the
motorcycle.

22


33


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.
lease 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.
HYOSUNG MOTORS & MACHINERY INC.
CO YRIGHT HYOSUNG MOTORS & MACHINERY INC.
FOREWORD
THANK YOU for 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. Motorcycling
is one of the most exhilarating sports and
insure you to enjoy riding and you should
become thoroughly familiar with the infor-
mation 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
MPORTANT
BREAK- N NFORMAT ON FOR
YOUR MOTORCYCLE
The first 1,600km(1,000miles) are the
most important in the life of your motorcycle.
roper break-in operation during this time
will help ensure maximum life and perfor-
mance from your new motorcycle.
Hyosung parts are manufactured of high
quality materials, and manufactured parts
are finished to close tolerances. roper
break-in operation allows the machined sur-
faces to polish each other and mate
smoothly.
Motorcycle reliability and performance
depend on special care and restraint exer-
cise during the 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.
lease refer to the BREAK-IN section for
specific break-in recommendations.
WARN NG/CAUT ON/NOTE
lease read this manual and follow its
instructions carefully. To emphasize special
information the words WARNING,
CAUTION and NOTE 
N O T E
This provides special information to
make maintenance easier or important
instructions clearer.
These instructions point out special ser-
vice procedures or precautions that
must be followed to avoid damaging the
machine.
CAUT ON
The personal safety of the rider may be
involved. Disregarding this information
could result in injury to the rider.
WARN NG

6
Noise Control System(muffler assembly)
TAMPER NG W TH NO SE CONTROL SYSTEM PROH B TED
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 ele-
ment 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.
MA NTENANCE:
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 per-
manent damage to the catalyst and to the noise control system.
WARN NG

7
Motorcycle riding is great fun and an excit-
ing sport. Motorcycle riding also requires
he/she to take some extra precautions to
ensure the safety of the rider and passen-
ger. These precautions are:
Before first use of the
read this owner
 s manual carefully to
become familiar with the
 s features, and safe-
ty and maintenance requirements.
Review all instructions, requirements
and warnings with the riders. Keep
the owner
 s manual in the owner  s
manual storage compartment located
under the 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 opera-
tion of the motorcycle.
For first use of the ,
find a level, open area for the rider to
use to become familiar with the oper-
ation of controls and the operating
and handling characteristics of the
.
WARN NG
Before each use, perform daily
inspections with the rider. Specific
items to check are listed in the
NSPECT ON BEFORE R D NG sec-
tion on page 56 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. These
motorcycles is designed for use only
by dual rider.
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 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 heat-
ed areas such as the engine and
exhaust system.
Do not make any modifications to
the .
Modifications may make the motor-
cycle unsafe or illegal in your state.
WARN NG
CONSUMER NFORMAT ON
SAFE R D NG RECOMMENDAT ON
FOR MOTORCYCLE R DERS

8
The is equipped with the
side stand ignition interlock system.
f the transmission is in neutral or side
stand up, you can only start the engine
pulling the clutch lever.
This side stand ignition interlock system
prevents the motorcycle from being
started with side stand down.
Make sure that the side stand igintion
interlock system is working properly
before riding.
WARN NG
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.
WARN NG
These motorcycles always come on the
head lamp, meter lamp and tail lamp
when starting engine.
CAUT ON
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.
WARN NG
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.
WARN NG
Always open the throttle gradually to
prevent front wheel lifting. Failure to
observe this precaution may result in
loss of control and an accident.
WARN NG
WHEN KEEP NG FOR LONG PER OD :
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.
CAUT ON
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)
CAUT ON

9
WEAR A HELMET
R D NG APPAREL
NSPECT ON BEFORE R D NG
FAM L AR ZE YOURSELF W TH
THE MOTORCYCLE
KNOW YOUR L M TS
BE EXTRA SAFETY CONSC OUS
ON BAD WEATHER DAYS
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.
WARN NG
Do not operate the ignition switch in the
OFFor
LOCKposition or the
engine stop switch in the

position
while driving at ones pleasure.
WARN NG
Loose fancy clothing can be uncomfort-
able and unsafe in terms of riding your
motorcycle.
Choose good quality motorcycle riding
apparel in terms of riding your motorcy-
cle.
WARN NG
Review thoroughly the instructions in
the
NSPECT ON BEFORE R D NG
section of this manual. Do not forget to
perform an entire safety inspection to
ensure the safety of the rider and its
passenger.
WARN NG
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.
WARN NG
Ride within the boundaries of your own
skill at all times. Knowing these limits
and staying within them will help you to
avoid accidents.
WARN NG
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 espe-
cially slippery.
Use extreme caution at railway cross-
ings and on metal gratings and bridges.
Whenever you have a doubt about road
condition, slow down!
WARN NG

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 Hyosungto test each
accessory on the market or combinations
of all the available accessories, however,
your dealer can assist you in selecting qual-
ity accessories and installing them correct-
ly.
Use extreme caution when selecting and
installing the accessories for your
Hyosung. We have developed some gen-
eral guidelines which will aid you when
deciding what kind of accessories you will
select and how to equip them into motorcy-
cle.
1. In case that additional weight or aero-
dynamic affecting accessories are
installed, they should be mounted as
low as possible, as close to the motor-
cycle 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 dan-
gerous, unstable condition.
2. Inspect for proper ground clearance
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 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 acces-
sories can result in an unsafe riding
condition, therefore caution should be
used when selecting and installing all
accessories.
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 aerody-
namics and handling of the motorcycle.
ACCESSORY NSTALLAT ON AND
PRECAUT ON SAFETY T PS

11
Modification of the motorcycle, or
removal of original equipment may ren-
der the vehicle unsafe or illegal.
WARN NG
Balance the load between the left and
right side of the motorcycle and fasten it
securely.

12
1. SER AL NUMBER LOCAT ON  14
2. FUEL , ENG NE O L AND COOLANT RECOMMENDAT ON  14
FUEL
ENGINE OIL
COOLANT
3. NAMES OF EACH PARTS []  17
4. NAMES OF EACH PARTS [

] 20
5. NAMES OF EACH PARTS [

] 23
6. NAMES OF EACH PARTS []
 26
7. CONTROLS  29
IGNITION SWITCH
IGNITION KEY
INSTRUMENT ANEL(
)
INSTRUMENT ANEL( )
LEFT HANDLE SWITCH
RIGHT HANDLE SWITCH
CARBURETOR CHOKE LEVER
REAR BRAKE EDAL
GEARSHIFT LEVER
FOOTRESTS
SIDE STAND
SEAT LOCK
TRUNK
REAR SHOCK ABSORBER
FRONT FORK
8. SUPPLY OF GASOL NE , ENG NE O L AND COOLANT  44
GASOLINE
ENGINE OIL
COOLANT
9. R D NG T PS 50
STARTING THE ENGINE
STARTING OFF
TABLE OF CONTENTS

13
USING THE TRANSMISSION
RIDING ON HILLS
STO ING AND ARKING
10. BREAK- N  54
11. NSPECT ON BEFORE R D NG 56
12. PER OD C MA NTENANCE  57
13. NSPECT ON AND MA NTENANCE 60
TOOL
FUEL HOSE
ENGINE OIL
GASOLINE
COOLANT
RADIATOR
RADIATOR HOSE
RUBBER CA OF CABLES
EXHAUST I E AND MUFFLER
FRONT FORK
REAR SHOCK ABSORBER
BATTERY
AIR CLEANER
S ARK LUG
CARBURETOR
CLUTCH ADJUSTMENT
DRIVE CHAIN
BRAKES
TIRE
RE LACEMENT OF THE LAM
WHEN THE ENGINE REFUSES TO START
WHEN KEE ING FOR LONG ERIOD
CLEANING ROCEDURE
14. LABEL 81
15. SPEC F CAT ONS 83

14
F U E L
Frame number :
Engine number :
The frame number  is stamped on the
steering head tube.
The engine serial number
 is stamped
on the left downside of the crankcase
assembly.
lease 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 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.
SER AL NUMBER LOCAT ON
FUEL, ENG NE O L AND
COOLANT RECOMMENDAT ON
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.
WARN NG
Spilling gasoline can damage the paint-
ed surfaces.
Be careful not to spill any fuel when fill-
ing the fuel tank.
Wipe spilled gasoline up immediately.
CAUT ON



15
ENG NE O L COOLANT
Classification
system
A I
SAE
Grade
Over SG
10W/40
Remarks
ENG NE O L SPEC F CAT ON
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
Using a premium quality four stroke motor
oil will increase the service life of your
motorcycle.
Use an anti-freeze compatible with alu-
minium radiator mixed with distilled water
only at the ratio of 50:50
If a SAE 10W/40 motor oil is not avail-
able, select alternative according to the
following chart.
Don
t mix the unrecommended oil. t
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.
t could disturb the oil to be provided
and damage the engine.
WARN NG
Engine coolant is harmful or fatal if
swallowed or inhaled.
Do not drink anti-freeze or coolant solu-
tion. f swallowed, do induce vomiting.
mmediately contact a poison control
center or a physician. Avoid inhaling
mist or hot vapors ; if inhaled, remove to
fresh air. f coolant gets in eyes, flush
eyes with water and seek medical atten-
tion. Wash thoroughly after handling.
Solution can be poisonous to animals.
Keep out of the reach of children and
animals.
WARN NG
Spilled engine coolant can damage
painted surfaces.
Do not spill any fluid when filling the
radiator. Wipe spilled engine coolant
up immediately.
CAUT ON
WATER FOR M X NG
Use distilled water only. Water other than
distilled water can corrode and clog the alu-
minium radiator.

16
N O T E
This 50mixture will protect the cooling
system from freezing at temperatures
above -31

. f the motorcycle is to be
exposed to temperature below -31


this mixing ratio should be increased up
to 55(-40

) or 60(-55

). The mix-
ing ratio should not exceed 60.
ANT -FREEZE
The coolant performs as rust inhibitor and
water pump lubricant as well as anti-freeze.
Therefore the coolant should be used at all
times even though the atmospheric temper-
ature in your area does not go down to
freezing point.
50%
Water
Coolant
0.8

0.8

Required amount of water/coolant
Solution capacity(total) 1.6

COOLANT RESERVO R TANK
Refer to 48 page.

17
NAMES OF EACH PARTS [ ]
Clutch lever
Left handle switches
Choke lever
Speedometer
Coolant temperature meter
Tachometer
Front brake fluid reservoir
Right handle switches
Front brake lever
Throttle grip
Ignition switches
Fuel tank cap

18
Spark pulg (Front)
Head lamp
Front turn signal lamp
Ignition coil (Front)
Ignition coil (Rear)
Spark pulg (Rear)
Fuses
Seat lock
Rear turn signal lamp
Tail/Brake lamp
License plate lamp
assenger footrests
Footrests
Gearshift lever
Side stand
Engine oil drain plug
N O T E
means the invisable parts.













19
Muffler
Rear seat & Trunk
Front seat
Tools
Battery
Fuel pump
Throttle stop screw
Air cleaner
Front brake fluid reservoir
Front brake lamp switch
Radiator
Cooling fan and motor
Engine oil filter
Engine oil filler cap
Water pump
Engine oil level lens
Rear brake pedal
Rear brake lamp switch
Coolant reserve tank
Rear brake fluid reservoir
N O T E
means the invisable parts.



20
NAMES OF EACH PARTS [  ]
Clutch lever
Left handle switches
Choke lever
Tachometer
Speedometer
Front brake fluid reservoir
Right handle switches
Front brake lever
Throttle grip
Ignition switches
Fuel tank cap






