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HYOSUNG
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GT 650
HYOSUNG GT 650 Service Manual
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GT 650
Fra 2004 og fr
em.
Servicemanual
Holtvej 8-10, Høruphav
6470 Sydals
T
elefon: +45 73 15 11 00
Fax: +45 73 15 11 01
E-mail: info@scanmi.dk
www
.scanmi.dk
CVR: 27 73 31 07
2
Table of Contents
General Information 1
6
How to Use this Manual
3
Table of Contents
6
General Precautions
7
Serial Number Location
9
Fuel, Oil and Engine Coolant Recommendations
10
Engine Coolant
11
Break-In Procedures
12
Cylinder Classification
12
Exterior Illustration
13
Specifications
14
Periodic Maintenance 2
16
2-1 Periodic Maintenance
17
Periodic Maintenance Schedule
17
Periodic Maintenance Chart
17
Lubrication Points
18
Maintenance Procedures
19
Valve Clearance
19
Engine
20
Spark Plug
21
Exhaust Pipe Nuts and Muffler Mounting Bolts
22
Air Cleaner
23
Carburetor
23
Fuel Hose
24
Clutch
25
Engine Oil
25
Engine Oil Filter
27
Drive Chain
28
Brake System
30
Steering
34
Front Fork
34
Rear Suspension
34
Tire
35
Chassis Bolts and Nuts
35
Engine Coolant
36
Radiator Hose
38
Compression Pressure
39
Oil Pressure
40
Engine
41
Engine Removal and Reinstallation
42
Engine Removal
42
Clutch Cable
44
Engine Reinstallation
48
Engine Disassembly
50
Starter Motor
50
Thermostat
50
2Nd Air Valve
51
Cylinder Head Cover
51
Piston
55
Magneto Cover
55
Magneto Rotor
56
Clutch Cover
57
Clutch
58
Primary Drive Gear
59
Oil Pump
59
Gearshift Shaft
60
Engine Component Inspection and Service
62
Valve Spring
65
Cam Chain Tension Adjuster
66
Piston Ring End Gap Inspection
68
Oil Jet
72
Engine Reassembly
80
Piston Ring
90
Cylinder Head
91
Fuel System
99
Fuel Pump
101
Float Height Adjustment
106
Cooling System
108
Engine Coolant
109
Cooling Circuit
110
Radiator
110
Inspection and Cleaning
111
Cooling Fan
113
Cooling Fan Thermo-Switch
114
Engine Coolant Temperature Sensor
115
Thermostat
116
Water Pump
118
Reassembly and Installation
120
Electrical System
122
Location of Electrical Components
123
Ignition System
125
Charging System
129
6-11 Electrical System
133
Starter System Description
133
Starter Motor Inspection
135
Combination Meter
139
Chassis
140
Recharging Operation
142
Battery
133
Starter System and Side Stand Ignition Interlock System
133
Chassis
143
Exterior Parts
144
Front Fender
144
Rear Seat
144
Front Seat
144
Front Wheel
145
Front Brake
149
Brake Fluid Replacement
150
Brake Pad Replacement
150
Caliper Disassembly
150
Caliper Inspection
151
Caliper Reassembly
152
Master Cylinder Disassembly
153
Master Cylinder Inspection
154
Handlebars
156
Front Fork
158
Front Fork Setting
165
Steering
166
Rear Wheel
169
Rear Brake
173
Rear Shock Absorber
175
Swingarm
176
Servicing Information
179
Troubleshooting
180
Special Tools
188
Tightening Torque
191
Service Data
193
Tire Pressure
202
Wire and Cable Routing
203
Wiring Diagram
207
4
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HYOSUNG GT 650 Specifications
General
Fuel System
Electronic Fuel Injection
Transmission
6-speed
Front Brakes
Dual disc
Rear Brakes
Single disc
Rear Tire
160/60 ZR17
Fuel Capacity
17 liters
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