WARNING - Hyosung Motos Schweiz
Contents
1. 34 10 8 INSPECTION BEFORE RIDING 36 9 PERIODIC MAINTENANCE 37 10 INSPECTION AND MAINTENANCE 40 TOOL ENGINE OIL FUEL HOSE GASOLINE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER SPARK PLUG IDLING ADJUSTMENT THROTTLE CABLE ADJUSTMENT CLUTCH CABLE DRIVE CHAIN BRAKES TIRE REPLACEMENT OF THE LAMP WHEN THE ENGINE REFUSES TO START WHEN KEEPING FOR LONG PERIOD CLEANING PROCEDURE TT LABEL eI a g Wore BES es S 65 12 SPECIFICATIONS 68 SERIAL NUMBER LOCATION 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 The frame number 1 is stamped on the steering head tube The engine serial number 2 is stamped on the left upside of the crankcase assembly 12 Please write down the numbers in the box provided below for your future reference Frame number Engine number FUEL AND OIL ENGINE OIL RECOMMENDATION 9 ENGINE OIL SPECIFICATION Classificatio C ne I Use unleaded gasoline with an octane ARI aire rating of 91 or higher Unleaded gasoline can extend spark plug SAE 10 life and exhaust components life CAUTION Spilling gasoline can damage the painted surfaces Be careful n2. hose To assist you in the performance of and is located under the front seat The tool C FUEL HOSE Inspect the fuel hose for damage and fuel leakage If any defect are found the fuel hose must be replaced Replace the fuel hose every 4 years C GASOLINE periodic maintenance a tool kit is supplied kit consists of the following items NO NAME 1 Tool bag 2 10 x 12 mm open end wrench 3 Spark plug wrench 4 Combination screw driver 5 Screw driver handle 9 e 2 o Check if there is leakage from fuel tank fuel pump hose fuel injection system C RUBBER CAP OF CABLES b Mop them up with a patch when washing EXHAUST PIPE AND MUFFLER Inspect the exhaust pipe and muffler joint for loosening 40 FRONT FORK BATTERY Check if there is any noise by bend of front fork while moving the handle upward and downward Inspect whether the steering stem is well assembled while moving front fork up downwards and foreward backward REAR SHOCK ABSORBER Inspect the rear shock absorber for oil leakage and spring condition INSPECTION OF BATTERY SOLUTION LEVEL MF Maintenance Free battery of airtight type is used for these motorcycles It is not necessary to inspect or supplement battery fluid The battery is located behind the right frame cover However have your dealer check the charging condition of
3. HYOSUNG OWNER S MANUAL 2 1250 A WARNING This own er s manual contains important safety information Please read it an carefully 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 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 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 c
4. right amp left Front tire size 110 90 16 59S Rear tire size 150 80 15 M C 705 Front brake Disk Rear brake Drum 9 ELECTRICAL Ignition type ECU Ignition timing 13 B T D C at 2 000 rpm 30 B T D C at 6 000 rpm Spark plug CR8bE Battery 12V 12Ah MF Fuse 30A amp 15A HI 12V H4 60Wx 1 Head lamp LO 12V H4 55Wx 1 Position 12V W5W x 1 License plate lamp 12V WW 1 Tum signal lamp 12V RY10W 4 Brake Tail lamp 12V P21 5W X 1 9 CAPACITIES Fuel tank 14 00 1 450m Oil change Engine oil 1 500 0 Oil and filter change 1 800 m Engine overhaul 69 MEMO 70 MEMO 71 M Prepared by HYOSUNG S amp T Motors Co Ltd 1st Ed JUL 2008 Printed in KOREA S amp T Motors Co Ltd Part No 99011HJ8210FI 1st Ed JUL 2008 Printed in KOREA
5. OIL FILTER INSTALLATION INSERTION DIRECTION LUSTER MATERIAL 4 Remove the three nuts holding the HYOSUNG OUTSIDE filter in place 46510H05240 CAUTION When install the oil filter necessarily HYOSUNG character and 16510 05240 part s NO install toward the outside otherwise can damage the engine A WARNING 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 27 WARNING New and used oil and solvent can be hazardous Children and pets may be harmed by swallowing new or used engine oil or solvent Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals Brief contact with used oil or Solvent 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 soaf if oil or solvent contact your skin 6 Before replacing the engine oil filter cover be sure to check that the engine oil filter spring and the ring are installed correctly Use new ring each time the engine oil filter element is replaced T Replace the oil filter cover and tighten the nuts securely but do not over tighten them 8 Replace the drain plug and tighten i
6. and maintain the chain properly before each ride according to this section 9 INSPECTING THE DRIVE CHAIN When inspecting the chain look for the following Loose pins Damaged rollers Dry or rusted links Missing O ring seals Kinked or binding links Excessive wear e Improper chain adjustment If you find something wrong with the drive chain condition or adjustment correct the problem if you know how If necessary consult your authorized Hyosung dealer Damage to the drive chain means that the sprockets may also be damaged Inspect the sprockets for the following Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nuts 48 Worn If you find any of these problems with your sprocket consult your Hyosung dealer CAUTION The two sprockets should be inspected for wear when a new chain is installed and replace them if necessary 9 DRIVE CHAIN ADJUSTMENT Adjust the drive chain slack to the proper specification The chain may require more frequent adjustments than periodic maintenance schedule depending upon your riding conditions Chain adjust in the following way 1 Place the motorcycle on the jack or block 2 Loosen the axle 3 Adjust the slack in the drive chain by adjuster as the lock nut 2 turning toward the left and right 4 For alignment of t
7. e Impossible e OnorUp Offor Down NS A WARNING Make sure that the side stand ignition interlock system is working properly before riding 23 REAR SHOCK ABSORBER SUPPLY OF GASOLINE AND ENGINE OIL GASOLINE D Y D Rear shock absorber Pin spanner To adjust the spring pre load turn the To open the fuel tank cap insert the adjuster clockwise or counter clockwise to ignition key into the lock and turn it the desired position with the pin spanner clockwise With the key inserted lift the cap Position 1 provides the softest spring pre up with the key load and position 5 provides the stiffest To close the fuel tank cap push the cap 250 FI is delivered from the factory down firmly with the key in the cap lock with its adjuster set on position 1 A WARNING Do not overfill the fuel tank Stop adding WARNING Unequal suspension adjustment fuel when the fuel level reaches the can cause poor handling and loss bottom of the filler neck If you fill the of stability tank beyond this level fuel may Adjust the right and left shock overflow when it expands due to engine absorber to the same settings heat or heating by the sun 24 WARNING ENGINEOL Gasoline is extremely flammable and toxic Always observe the following precautions when refueling your 250 Never permit motorc
8. Cleaning the chain with gasoline or commercial cleaning solvents can damage O rings and ruin the chain Clean the drive chain with kerosene only 2 After thoroughly washing the chain and allowing it to dry oil the links with a Hyosung chain lube or an equivalent CAUTION Some drive chain lubricants contain solvents and additives which could damage the O rings in your chain Use Hyosung chain lube or an equivalent that is specifically intended for use with O rings chains 50 BRAKES 250 FI utilizes disk brake for front and drum brake for rear Properly operating the brake systems are vital to safe riding Be sure to perform the brake inspection requirements as schedules The brakes should be inspected at periodic inspection by your authorized Hyosung dealer FRONT BRAKE Brake fluid Be sure to check the brake fluid level in the master cylinder If the level was found to be lower than the lower mark while holding the motorcycle upright inspect the brake pad s wear condition If the brake pad s wear condition is good replenish with the proper brake fluid that meets Hyosung s requirements As the brake pads wear the fluid level will drop to compensate for the new position of barke pads Replenishing the master cylinder to considered normal periodic maintenance A WARNING Brake fluid may be harmful if swallowed or if it
9. battery periodically To remove the battery loosen the screw D unhook the hook and remove the right frame cover After remove the frame cover can pull it out as to take off the relays and fuses and separate the battery support CAUTION CAUTION Do not remove absolutely airtight Cover as airtight type battery Keep after separate at the motorcycle for the minimum of self electric discharge and electric leakage when don t use for a long time Remove the negative terminal when keep intact at the motorcycle 9 CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Setthe ignition switch OFF position 2 Remove the right frame cover 3 Check that battery lead wire and terminal 4 If necessary disconnect the negative battery wire first then disconnect the positive battery wire Remove the battery 5 Clean the terminal If there is white dust clean it with warm water 6 Connect the battery wires and grease the terminal lightly When reinstalling the battery be sure to connect the positive battery wire first then connect the negative battery wire Keep the battery away from fires When disconnecting the battery wire be sure to remove the negative battery wire first with the ignition switch OFF position then remove the positive
10. front of you squeezed towards the grip disengaged position just before the motorcycle Stops Neutral position can be confirmed by observing the neutral indicator lamp A WARNING A WARNING 5 Park the motorcycle on a firm flat surface where it will not fall over Inexperienced riders tend to underutilize A hot muffler can burn you The muffler the front brake This can cause Will be hot enough to burn you for some excessive stopping distance and lead to time after stopping the engine a collision Using only the front or rear brake can cause skidding and loss of Park the motorcycle where pedestrians control or children are not likely to touch the Apply both brakes evenly and at the muffler same time J 7 M 6 Push down the key to the OFF position WARNING and turn it to the LOCK position after come up again Hard braking while turning may cause 7 Remove the ignition key wheel skid and loss of control Brake before you begin to turn A WARNING Hard braking on wet loose rough or other slippery surfaces can cause wheel skid and loss of control Brake lightly and with care on slippery or irregular surfaces 33 BREAK IN The opening explains how important proper break in is to achieve maximum life and performance from your new Hyosung The following guidelines explain proper break in procedures MAXIMUM THROTTLE OPENING RECOMMENDATIONS T
11. in of the tire as described in this section and avoid hard acceleration hard cornering 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 motorcycle will receive During break in procedures all of the engine components will have worn in and all of the other parts will have seated in All adjustments will be restored all fasteners will be tightened and the dirty engine oil and engine oil filter will be replaced Timely performance of the 1 000 km 600 miles service will ensure optimum service life and performance from the engine CAUTION Service should may be peformed before 1 000 km 600 miles on motorcycle that are used under severe conditions CAUTION The 1 000 km 600 miles service should be performed as outlined in the INSPECTION AND MAINTENANCE section of this Owner s Manual Pay particular attention to the CAUTION and WARNING in that section 35 RIDING Correct pressure Tires Adequate tread depth Nocracks or cuts ue be sure to Correc
12. motorcycles has been carefully selected to meet the vast majority of all operational ranges If the spark plug color indicates that other than a standard 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 IDLING ADJUSTMENT THROTTLE CABLE ADJUSTMENT We suggest that have TZ 57 Je ill 250 Fly s idling speed adjusted by io E your authorized Hyosung dealer CAUTION not adjust the idle speed to variations of the cabruretion setting 46 pis 1 0 mm Q Q 0 02 0 04 in To adjust the throttle cable play 1 Loosen the lock nut 1 2 Adjust the cable slack by cable adjuster in or out to obtain the correct slack 0 5 1 0 mm 0 02 0 04 in 3 After adjusting the slack tighten the lock nuta A WARNING 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 CAUTION After completing throttle cable adjustment check that handlebar movement does not raise the engine idle speed and that the throttle grip return smoothly and automatically CLUTCH CABLE At each m
13. replacement bulb push it in and lens turn it to the clockwise while pushing 60 LICENSE PLATE LAMP FUSE 1 Remove the three nuts at the seat tail The fuse box is located behind the front cover seat If the engine suddenly stops while running or any electrical system fails to operate then the fuse must be checked In case a fuse blows there is 30A and 15A for main spare fuse 2 CAUTION Never use other than specified 30A or 15A fuse Installing a fuse of incorrect rating may 2 Remove the tail amp brake lamp cover seriously damage the electrical system 3 Push in the bulb turn it to the counter You should consult your Hyosung clockwise and pull it out dealer or a qualified service mechanic 4 After stick in the new lamp assemble the immediately lens A CAUTION the screws may cause the lens to crack 61 WHEN THE ENGINE REFUSES TO START 9 TROUBLE SHOOTING If the engine refuses to start perform the following inspections to determine the cause Ignition System Check Remove a spark plug and reattach to the spark lead While holding the spark plug firmly against the crankcase of the engine push the starter switch with the ignition switch in the ON position the engine stop switch in the position the transmission in neutral the side stand up and the clutch disengaged If the ignition syst
14. NING Position Using when Avoid turning the throttle grip during dangerous condition of falling brakes down during drive and others or engine stop suddenly The ignition circuit is off The engine LIGHT SWITCH cannot start or run 15 position The head lamp comes on Cy Position Using when need operation of engine as drive and 9 e position others The ignition circuit is on The head lamp goes off and the engine can run A CAUTION Do not operate for the engine stop The 474772220 Fly always comes on switch is the 55 position while the position lamp meter lamp tail lamp driving at one s pleasure and license plate lamp when the ignition Switch is turned to the position WARNING FRONT BRAKE LEVER The front brake is applied by squeezing the brake lever gently toward the throttle grip Front brake be anxious about motorcycle falling down when braking suddenly as disk brake system The brake lamp will come on when the lever is squeezed 20 STARTER SWITCH Use this switch to operate the starting motor With the ignition switch in the position the engine stop switch in the position and the transmission is in neutral pull in the clutch lever and side stand up and push the starter switch to start the engine CAUTION Do not engage the starting motor for more than five seconds at a t
15. NUINE OIL M p 68319H05350 PL WARNING AN IMPROPER TIRE PRESSURE CAN CAUSE DIFFICULTIES IN HANDLING SERIOUS INJURIES OR DEATH e BEFORE RIDING INSPECT THE TIRE PRESSURE DAMAGE ABNORMAL WEAR AND ETC ACCORDING TO THE INSPECTION BEFORE RIDING ALWAYS MAINTAIN A PROPER TIRE PRESSURE AS SHOWN IN THE BELOW peers FRONT REAR SOLO RIDING 8320HM8 190 PL 66 HYOSUNG MOTORS amp MACHINERY INC 9 2002 24 0005 KM4MJ53A 88 dB A 5000 67 SPECIFICATIONS 9 DIMENSIONS AND DRY MASS Overall length 2 270 mm 89 4 in Overall width 800 mm 31 5 in Overall height 1 090 mm 42 9 in Wheelbase 1 500 mm 59 1 in Ground clearance 155 mm 6 1 in Mass 170 kg 375 1 5 9 ENGINE Type Four stroke air cooled and oil cooled Number of cylinder V 2 cylinder Bore 57 0 mm 2 24 in Stroke 48 8 mm 1 92 in Piston displacement 249 15 2 in Compression ratio 10 2 1 Fuel system Fuel injection Starter system ELECTRIC STARTER TRANSMISSION Clutch Wet multi plate type Reduction ratio 3 290 Drive chain 520 116 Links Transmission 1st 2 460 2nd 1 560 3rd 1 190 4th 0 960 5th 0 840 68 9 CHASSIS Front suspension Telescopic type Rear suspension Swing arm type Caster 33 Trail 135 mm 5 32 in Steering angle 40
16. V H4 60Wx 1 swing arm 5 Loosen the rear shock absorber lower Headlamp LO 12V H4 55Wx 1 bolts left and right draw out the rear Position 12V W5W x 1 with the rear wheel push to Brake Taillamp 12V P21 5Wx 1 6 Pull the rear wheel assembly rearward Turn signal lamp 12V RY10W x 4 License plate lamp 12V W5Wx 1 7 replace the wheel reverse the complete sequence listed 58 9 HEAD LAMP 6 To install the head lamp reverse the above sequence CAUTION The use of a lamp other than rules may cause to occur the vehicle fire and to damage electric parts Surely use only the lamp of proper capacity M J 1 Remove the two screw D right and left and the head lamp assembly 2 Disconnect the socket from the head lamp 3 Remove the rubber cap 4 Umhook the bulb holder spring and remove the bulb 5 5 To install the head lamp reverse the above sequence 59 TURN SIGNAL LAMP BRAKE TAIL LAMP je del sb 6 2 Push in the bulb turn it to the counter 2 Push in the bulb turn it to the counter clockwise and pull it out clockwise and pull it out 3 After stick in the new lamp assemble the 3 To fit the
17. acks and cuts FRONT 170 kpa 170 kpa 2 there are abnormal wears 25 0 psi 25 0 psi 2 00 2 25 kg LM REAR 200 kpa 225 kpa SCREW 29 0psi 32 0 psi EGEEIGN MATERIAL x x gt OVER NORMAL SHORT WORN CRACK If there are some problem with the tirepressure or cracks and cuts it will decrease the riding stability and lead to flat tire M ABNORMAL WEARS 55 TIRE TREAD CONDITION Tire wear indicator mark indicator 4 j k 1 WU SZ L Tire wear Operating the motorcycle with excessively worn tire will decrease riding stability and can lead to loss of control Inspect storage of tire thread s depth by the tire wear indicator Replace the front and rear tires at once when appear the tire wear indicator CAUTION The standard tire on 12774771250 is 110 90 16 59S for front and 150 80 15M C 705 for rear The use of a tire other than standard may cause trouble It is highly recommended to use the TIRE REPLACEMENT Front tire replacement 1 Remove the caliper from the front fork by removing the mounting bolts CAUTION Never squeeze the front brake lever with the caliper removed It is very difficult to force the pads back into the caliper assembly and brake fluid standard tire supplied by Hyosung 9 REAR AXLE NUT Inspect the rear ax
18. aintenance interval adjust the clutch cable play by means of clutch cable adjuster The cable play should be 4 mm 0 16 in as measured at the clutch lever holder before the clutch begins to disengage The clutch lever play 2 The lock nut 3 The clutch lever adjuster 4 The rubber boot 5 The cable adjuster The clutch cable adjuster lock nut If you find the play of the clutch incorrect adjust it in the following way 47 9 CLUTCH CABLE ADJUSTMENT A basis adjustment be allowed by the clutch lever adjuster Loosen the lock nut counter clockwise Turn the clutch lever adjuster in or out to acquire the specified play After end of adjustment tighten the lock nut 2 clockwise fully and cover the rubber boot 4 If not adjust by the adjuster loosen the clutch cable adjuster lock nut Turn the clutch cable adjuster in or out to acquire the specified play After end of adjustment tighten the lock The clutch cable should be lubricated with a light weight oil whenever it is adjusted Clutch cable 1 4 mm 0 16 in DRIVE CHAIN The chain may require more frequent adjustment that it is with periodic maintenance depending upon your riding conditions Check the chain every 1 000 km A WARNING Riding with the chain in poor condition or improperly adjusted can lead to an accident Inspect adjust
19. ansmission is not in neutral you can only start the engine with pulling in clutch lever and side stand up Make sure that the side stand igintion interlock system is working properly before riding CAUTION 250 always comes on the position lamp meter lamp tail lamp and license plate lamp when the ignition switch is tumed to the position M 29 A WARNING Running the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause death or severe injury Only run the engine outdoors where there is a fresh air CAUTION Running the engine too long without riding may cause the engine to overheat Overheating can result in damage to internal engine components and discoloration of exhaust pipes Shut the engine off if you cannot begin your ride promptly CAUTION 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 several attempts check the fuel supply and igintion system Refer for Page 62 CAUTION CAUTION The following happens the FI check lamp _ on the instrument panel should comes on This lamp should go out after t
20. ate lamp when the ignition switch is turned to the position 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 While operating the 47772222 250 FI 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 A 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 CAUTION M WHEN KEEPING FOR LONG PERIOD 1 Supply enough the fuel in the fuel tank 2 Remove the battery from the motorcycle A WARNING Do not operate for the ignition switch is in the LOCK position or the engine stop switch is in the e position while driving at one s pleasure WEAR HELMET A WARNING Motorcycle safety equipment starts with a quality safety
21. ays select the most suitable gear for the prevailing conditions WARNING Downshifting when engine speed is too high cause the rear wheel to skid and lose traction due to increased engine braking resulting in an accident or force the engine to overrev in the lower gear resulting in engine damage Reduce speed before downshifting CAUTION Revving the engine into the red zone can cause severe engine damage Never allow the engine to rev into the red zone in any gear 32 When climbing steep hills the motorcycle may begin to slow down and show lack of power At this point you should shift to lower gear so that the engine will again be operating in its normal power range Shift rapidly to prevent the motorcycle from losing momentum When riding down steep hill the engine may be used for braking by shifting to a lower gear Be careful however not to allow the engine to overrev STOPPING AND PARKING A WARNING Following another vehicle too closely 1 Turn the throttle grip away from you to can lead to a collision As vehicle close the throttle completely speeds increase stopping distance 2 Apply the front and rear brakes evenly increases progressively and at the same time 3 Downshift through the gears as road Be sure you have a safe stopping Speed decreases distance between you and the vehicle in 4 Select neutral with the clutch lever
22. battery wire When reinstalling the battery be sure to connect the positive battery wire first then connect the negative battery wire Fasten certainly the battery wires Incorrect installation of the battery will reverse the terminal position resulting in possible electrical system damage due to incorrect battery lead connection Never charge a battery while still in the machine as damage may result to the battery or regulator rectifier 9 BATTERY INSTALLATION 250 FT s battery installation order pay attention to following points lt lt V gt DE EX Remove the front seat right frame cover and battery support Lay down positive terminal of the battery at leftside of the battery case on the motorcycle Connect positive battery wire at the battery terminal Put on the rubber cap at the positive terminal of the battery 5 Install negative battery wire at the battery terminal 6 Install the battery support right frame cover and front seat CAUTION AIR CLEANER 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 element periodically accor
23. comes in contact with skin or eyes Contact your doctor immediately if brake fluid is swallowed and induce vomiting If brake fluid gets into the eyes or in contact with the skin flush thoroughly with plenty of water CAUTION This motorcycle uses glycol based brake fluid Do not use or mix different types of brake fluid otherwise serious damage will result in the brake system Use only DOT3 or DOT4 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 51 Brake pads Inspect the front brake pads by nothing whether or not the friction pads are worn down to the grooved limit line If a pad is worn to the grooved limit line it must be replaced with a new one by your authorized Hyosung dealer or qualified service mechanic Inspect every day in the following point at the brake system CD Brake fluid leakage of the front brake System Leak or damage of the brake hose 3 Operating of the brake lever 4 Wear of the front brake pads CAUTION The brake hoses or the brake fluid of the front brake system should be replaced according to periodic inspection chart by your authorized Hyosung dealer for safety as in times of o
24. ctrical 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 Modification of the motorcycle or removal of original equipment may render the vehicle unsafe or illegal Obey all applicable equipment regulations in your area TABLE OF CONTENTS 1 SERIAL NUMBER LOCATION 12 2 FUEL AND OIL RECOMMENDATION 13 FUEL ENGINE OIL 3 NAMES OF EACH PARTS 14 4 CONTROLS 6 2 sur Em Sh EE S 17 IGNITION SWITCH IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH REAR BRAKE PEDAL GEARSHIFT LEVER SIDE STAND SEAT LOCK REAR SHOCK ABSORBER 5 SUPPLY OF GASOLINE AND 24 GASOLINE ENGINE OIL 6 RIDING TIPS 22 55 45 29 STARTING THE ENGINE STARTING OFF USING THE TRANSMISSION RIDING ON HILLS STOPPING AND PARKING 7 BREAK IN
25. cycle during operation M A WARNING Sudden side winds which can occur when being passed by large vehicles at tunnel exits or in hilly areas can upset your control Reduce your speed and be alert to side winds Pull the clutch lever in and pause momentarily Engage first gear by depressing the gearshift lever downward Turn the throttle grip toward you and at the same time release the clutch lever gently and smoothly As the clutch engages the motorcycle will start moving forward To shift to the next higher gear accelerate gently then close the throttle and pull the clutch lever in simultaneously Lift the gearshift lever upward to select the next gear and release the clutch lever and open the throttle again Select the gears in this manner until fifth gear is reached A WARNING Downshifting while the motorcycle is leaned over in a corner may cause rear wheel skid and loss of control Reduce your speed and downshift before entering corner A 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 USING THE TRANSMISSION RIDING ON HILLS 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 alw
26. de insufficient Be careful not to pour the engine oil excessively 9 ENGINE OIL AND FILTER CHANGE Change the engine oil and filter after first running 1 000 km and every running 4 000 km The oil should always be changed when the engine is hot so that the oil will drain thoroughly from the engine The procedure is as follows ENGINE OIL CAPACITY Oil change 1 450 me Oil and filter change 1 500 m2 Engine overhaul 1 800 ml CAUTION In case of the engine oil pouring excessively the engine output being made insufficient Be careful not to pour the engine oil excessively P 1 Place the motorcycle on the jack or block 26 More frequent servicing may be performed on motorcycles that are used under severe conditions inspect D Quantity of Engine oil Pollution degree of Engine oil before riding the motorcycle and then supplement and replace at any time to prevent damage of the engine 2 Remove the engine oil filler 3 Drain the oil by removing the drain plug 2 located on the bottom of the engine CAUTION Necessarily confirm and clean the oil strainer amp when replace the Engine oil specially when first replacement 5 Replace the engine oil filter 7 with a new one CAUTION Insert the filter so that surface of the filter hole tum toward the engine
27. ding to the following procedure CAUTION If the air cleaner element is polluted will occur to starting go out output insuffiency combustion effiency decline and sooty smoke black smoke This appearence is occurred at first to clean the air cleaner element and confirm 1 Remove the screws 1 and remove the cover If connect first the battery wire at the battery then lay down at the battery case will be installed the opposite direction positive terminal face on the rightside of the motorcycle as that length of the battery wire has no something extra This time the battery could not lay down perfectly and to occur the short circuit etc if the battery install the opposite direction 43 2 Remove the screws and take off CAUTION Before and during the cleaning operation inspect the element for tears A torn element must be replaced Be sure position the element snugly and correctly so that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element CAUTION When the assembly of air cleaner element 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 4 Clean the air cleane
28. 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 GENERAL LUBRICATION section A WARNING Operating motorcycle with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing motorcycle while riding at slow speed If necessary apply brakes several times to let friction dry outthe pads Follow the procedures in the INSPECTION BEFORE RIDING section to check your motorcycle for any problems that may have arisen during your last ride LABEL 65 WARNING e BE FULLY AWARE OF THE OWNER S MANUAL BEFORE OPERATING AND RIDING MAKE SURE TO WEAR A HELMET OBSERVE THE RESTRICTED SPEED DO NOT BE TOUCHED ON MUFFLER BECAUSE IT 15 HOT DO NOT MAKE ILLEGAL MODIFICATION FOR THE SAFE RIDING TAKE THE INSPECTION AND THE MAINTENANCE ACCORDING TO THE REGULAR CHECKLIST OF THE OWNER S MANUAL e THE CHECKLIST BEFORE RIDING DASHBOARD HORN LAMP OIL BRAKE TIRE AIR PRESSURE DAMAGE ABNORMAL WEAR AND ETC e USE THE HYOSUNG GE
29. em is operating properly a blue spark should jump a cross the spark plug gap 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 If there is still no spark consult your Hyosung dealer for repairs A WARNING Performing the spark test improperly can cause a high voltage electrical shock or an explosion Avoid performing this check if you are not familiar with this procedure or if you have a heart condition or wear a pacemaker Keep the spark plug away from the spark plug hole during this test 62 A WARNING Do not hold the spark plug close to the open spark plug hole in the cylinder head as gasoline vapor inside the cylinder should be ignited creating a fire hazard Engine Stalling D Check the fuel supply in the fuel tank Check the ignition system for intermittent spark 3 Check the engine idle speed A CAUTION When occur any trouble the best way is to consult your Hyosung dealer for repairs WHEN KEEPING FOR LONG PERIOD 1 Supply enough the fuel in the fuel tank 2 Remove the battery from the motorcycle CLEANING PROCEDURE A thorough cleaning of your motorcycle is a necessary part of maintenance and will help keep your motorcycle looking and performing its best Proper cleaning can also extend the life of your mo
30. ence 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 250 Caution the rider and others near the Cuz 250 FI 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 Agria 250 Modifications may make the motorcycle unsafe or illegal in your state WARNING Avila 250 FI is 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 A WARNING The 70700200 FT is equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in clutch lever and side stand up Make sure that the side stand igintion interlock system is working properly before riding M M ACAUTION The Algpuillz 250 FI always comes on the position lamp meter lamp tail lamp and license pl
31. ery Use extreme caution at railway crossings and on metal gratings and bridges Whenever you have a doubt about road condition slow down ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS 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 A WARNING 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 1 In case that additional weight or aerodynamic affecting accessories are installed they should be mounted as low as poss
32. g the drive to the rear wheel when starting the engine or shifting the transmission gear Squeezing the lever disengages the clutch PASS SWITCH Press the 55 switch to operate the head lamp high beam for using when pass A CAUTION Do not operate when the dimmer switch D position 8 DIMMER SWITCH Change direction of head lamp light D The head lamp high beam come on The high beam indicator lamp also comes on 20 The head lamp low beam come on A WARNING Set the dimmer switch 2 when other vehicle is running in front or against 4 TURN SIGNAL SWITCH Using when left right turn or change direction Position Flash the left turn signal lamp D gt Position Flash the right turn signal lamp CAUTION 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 completing the turn or lane change HORN SWITCH Press the switch to operate the horn RIGHT HANDLE SWITCH A WARNING Apply the brake lightly and with great care on slippery surfaces to avoid skidding 8 THROTTLE GRIP Engine speed is controlled by position of the throttle grip Turn it toward you to increase engine speed Turn it away from you to decrease the engine speed D ENGINE STOP SWITCH WAR
33. hanges 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 HYOSUNG COPYRIGHT S amp T Motors Co Ltd 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 NOTE have special meanings Information following these signal words should be carefully reviewed A WARNING The
34. he brake lamp after the brake pedal begins to be depressed TIRE Inspect the tire pressure and the tire thread depth periodically Inspect frequently the tire pressure for the safety and the tire life A WARNING 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 tire when worn to the specified limit or if you find damage such as cuts or cracks Always use the size and type of tires specified in this owner s manual M 22 9 TIRE PRESSURE Insufficient air pressure in the tires not only hasten tire wear but also seriously affects the stability of the motorcycle Under inflated tires make smooth cornering 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 CRACKS AND CUT TIRE PRESSURE NORMAL RIDING VTS COLD INFLATION SOLO RIDING DUAL RIDING Check if 1 75 kge 1 75 1 there are visible cr
35. he rear sprocket and the front sprocket there are reference on the same position right and left After aligning and adjusting the slack in the drive chain to 20 30 mm 0 79 1 18 in retighten the axle nut securely and perform a final inspection CAUTION The drive chain for these motorcycles are made of the special material The chain should be replaced with a 520HO for 47 1 250 FT Use of another chain may lead to premature chain failure CAUTION The drive chain should be inspected every time before riding Excessive chain slack could cause the chain to come off the sprockets and result in accident or serious engine damage A WARNING Be careful not to touch the muffler when itis hot a hot muffler can burn you 9 DRIVE CHAIN CLEANING AND OILING This drive chain has special O rings Clean and oil the chain periodically as follows 1 Clean the chain with kerosene If the chain tends to rust the interval must be shortened Kerosene is a petroleum product and will provide some lubrication as well as cleaning action WARNING Kerosene can be hazardous Kerosene is flammable Children or pets may be harmed from contact with kerosene Keep flames and smoking materials away from kerosene Keep children and pets away from kerosene If swallowed do induce vomiting Call a physician immediately Dispose of used kerosene properly CAUTION
36. he table below shows the maximum throttle opening recommendation during the break in period Initial 800 km 500 miles Less than 1 2 throttle Up to 1 600 km 1 000 miles Less than 3 4 throttle AVOID CONSTANT LOW SPEED Operating the engine at constant low speed light load can cause parts to glaze and not seat in Allow the engine to accelerate freely through the gears without exceeding the recommended maximum limits Do not however use full throttle for the first 1 600 km 1 000 miles VARY THE ENGINE SPEED The engine speed should be varied and not held at a constant speed This allows the parts to be loaded with pressure and then unloaded allowing the parts to cool This aids the mating process of the parts It is essential that some stress be placed on the engine components during break in to ensure this mating process Do not though apply excessive load on the engine 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 160 km 100 miles before attempting maximum performance Avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles A WARNING Failure to perform break in of the tires could cause tire slip and loss of control Use extra care when riding on new tire Perform proper break
37. 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 RIDING APPAREL A 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 INSPECTION BEFORE RIDING A 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 9 FAMILIARIZE YOURSELF WITH THE MOTORCYCLE A WARNING 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 9 KNOW YOUR LIMITS 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 9 BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS A 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 slipp
38. hree seconds whenever the ignition switch is setto position If this lamp does not come on when the ignition switch is set to position or fails to go out after three seconds whenever the ignition switch is set to ON position contact an authorized Hyosung dealer After three seconds whenever the ignition switch is set to position FI check lamp lt gt must goes out If this lamp stays on or brinks during normal operation it means that the fuel injection system is not operating correctly Stop the engine immediately and contact an authorized Hyosung dealer Do not use the motorcycle with disabled fuel injection system in order to avoid damaging the engine components CAUTION Avoid pressing the starter switch when the engine is running or starting motor damage M STARTING OFF A WARNING Riding these motorcycles 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 C conditions A WARNING Removing your hands from the handlebars or feet from the footrests during operation can be hazardous If you remove even one hand or foot from the motorcycle you can reduce your ability to control the motorcycle Always keep both hands on the handlebars and both feet on the footrests of your motor
39. ible 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 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 ele
40. ime as it may overheat the wiring harness and starting motor If the engine does not start after several attempts check the fuel supply and igintion system Refer for Page 62 Ne P WARNING The 250 is equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in clutch lever and side stand up Make sure that the side stand igintion interlock system is working properly before riding M REAR BRAKE PEDAL Depressing the rear brake pedal will apply the rear brake The brake lamp will be illuminated when the rear brake is operated A WARNING Apply the brake lightly and with great care on slippery surfaces to avoid skidding M GEARSHIFT LEVER 250 FT has 5 speed transmission which operates as shown To shift properly pull the clutch lever and close the throttle at the same time you operate the gearshift lever Whenever a gear is selected the gearshift lever will return to its normal position ready to select the next gear Lift the gearshift lever to upshift and depress the lever to downshift Neutral is located between first and 2nd gear When neutral is desired depress or lift the lever halfway between first a
41. ing 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 WARNING Before first use of the 250 FI read this owner s manual carefully to become familiar with the riz 250 features and safety 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 250 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 e For first use of the 1900 FIL 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 the Agra 250 A WARNING Before each use perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING section on page 36 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 rider This motorcycle is designed for use only by two rider Do not permit anyone to operate the Ligula 250 FI under the influ
42. le shaft and jointing nut for loosening leakage may result M 2 Loosen the front axle pinch bolt 3 Loosen the front axle 3 4 Carefully position a jack or block under engine and raise until the front wheel is slightly off the ground CAUTION Improper jaking may cause damage to the oil filter Do not apply the jack head to the oil filler when jacking up the motorcycle 5 Draw out the axle shaft Rear tire replacement 1 Remove the two screws and chain case M P 2 Remove the brake adjuster nut Q and place a jack or block under the swing arm to lift the rear wheel slightly off the ground 7T To reinstall the wheel assembly reverse the sequence as described s WARNING REPLACEMENT OF THE LAMP A hot muffler can burn you The muffler will be hot enough to burn you for some time after stopping Requirement electric power of the lamp shown in the following chart When replace the damaged lamp always the engine th it Wait until the muffler cools to avoid USE Me burns The use of a lamp other than rules may cause to excessive at the electric system or to damage the lamp 3 Loosen the drive chain adjusters 3 left and right and disengage the drive chain from the rear sprocket NAMES CAPACITY 4 Remove the rear break hub from the HI 12
43. nd 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 2nd gear to low neutral will be automatically skipped 22 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 components and the rear tire CAUTION When the transmission is in neutral the green indicator lamp on the instrument panel will be lit However even though the lamp is illuminated cautiously release the clutch lever slowly to determine whether the transmission is positively in neutral M SIDE STAND SEAT LOCK LAG 250 FI is equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in clutch lever and side stand up No Neutral Clutch Side Engine Switch lever stand start The seat lock is located left downside of the seat To unlock the seat insert the ignition key into the lock and turn it clockwise To lock the seat push down firmly until the seat latch snaps into the lock position Possible 2 A e Possible 3 e A Impossible 4
44. ot to spill any fuel when filling the fuel tank Wipe spilled gasoline up immediately y A WARNING When refueling always shut the engine off and tum 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 X If a SAE 10W 40 motor oil is not available select alternative according to the following chart 15W40 15W50 MEET FEET IEEE HERES 10W40 10W50 ENGINE OIL 30 20 40 0 10 20 30 40 Temperature Ad RE E m mW m 2 4 4 32 50 68 86 104 Use the chart to select a viscosity rating based on temperature range in your area NOTE In very cold weather below 15 5 F use SAE 5W130 for good starting and smooth operation Using a premium quality four stroke motor oil will increase the service life of your motorcycle A WARNING 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 NAMES OF EACH PARTS Clutch lever Front brake lever 2 Left handle switches Throttle grip Speedometer Right handle switches Fuel gauge Fuel tank cap Tachometer Ignition swi
45. perating at high pressure P4 A WARNING Riding with worn brake pads will reduce braking performance and will increase your chance of having accident Inspect brake pad wear before each use Ask your Hyosung dealer or qualified mechanic to replace brake pads if any pad is worn to the limit CAUTION After replaced the front brake pads the brake lever pull and release several times 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 52 Brake disk inspection Check the brake disk for damage or cracks Front 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 Loosen the screw and open the cap 4 Replenish with brake fluid to the upper line CAUTION Do not spill any brake fluid on painted or plastic surfaces as it will damage the b surface severely NOTE The recommended brake fluid DOT3 or DOT4 V 5 Fasten the cap Front brake lamp switch The front brake lamp switch is located beneath the front brake lever Loosen the Switch fitting screws and adjust the timing by moving the switch body forward or backward 9 REAR BRAKE Brake shoes wear limit Rear brake adjustment This motorcycle is equipped wi
46. personal safety of the rider may be involved Disregarding this information could result in injury to the rider M CAUTION These instructions point out special Service procedures or precautions that must be followed to avoid damaging the C machine J a NOTE This provides special information to make maintenance easier or important instructions clearer M A WARNING 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 CONSUMER INFORMATION SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS Motorcycle rid
47. r element for the following 1 When the air cleaner element clean with the air gun necessarily blow at the inside by compressed air 2 Carefully examine the air cleaner element for tears during cleaning Replace it with a new one if it is torn 3 Assemble the element completely or damage severely the engine 4 Be careful not to allow water to go inside the air cleaner element ACAUTION Assemble the element completely or damage severely the engine Be careful not to allow water to go inside the air cleaner element CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions also clean the air cleaner element when replacing the oil to prevent damage of the engine SPARK PLUG CAUTION Remove carbon deposits periodically from the spark plug with a piece of hard wire or pin 0 7 0 8 mm 0 028 0 032 in gt Readjust the spark plug gap to 0 7 0 8 mm 0 028 0 032 in by using a spark plug gap thickness gauge PLUG REPLACEMENT GUIDE Hotter type CR7E Standard type CR8E Colder type CR9E 45 Do not over torque or cross thread the spark plug or the aluminum threads of the cylinder head will be damaged Do not allow contaminants to enter the engine through the spark plug holes when the plug is removed The standard spark plug for these
48. remaining amount whenever the ignition switch is or OFF For checking the remaining amount of fuel hold the motorcycle vertically C and set the ignition switch ON TACHOMETER The tachometer indicates the engine speed in revolutions per minute r min TURN SIGNAL INDICATOR LAMP When the turn signals are being operated either to the right or to the left the indicator will flash at the same time NEUTRAL INDICATOR LAMP The neutral indicator lamp will come on when the transmission is in neutral The lamp will go out when you shift into any gear other than neutral HIGH BEAM INDICATOR LAMP The high beam indicator lamp will come on when the head lamp high beam is turned on FI Fuel Injection CHECK LAMP It comes on for about three seconds whenever the ignition switch is set to ON position with the engine stopped as a test of injection system operation The check lamp must go off after three seconds CAUTION If the lamp blinks on during normal engine operation it means that the fuel injection system is not operating correctly When this is the case stop the engine immediately and contact a Hyosung authorised dealer The FI check lamp amp blinks differently according to each malfunction parts 18 LEFT HANDLE SWITCH D CLUTCH LEVER The clutch lever is used for disengagin
49. rests pivot 38 6 Speedometer gear box 7 Brake lever holder Throttle cable 9 Brake pedal pivot 8 Motor oil e Grease 9 ENGINE Interval First Every Every Item 1 000 km 4 000 km 8 000 km Air cleaner element Clean every 3 000 km Replace every 12 000 km Exhaust pipe bolts and muffler mounting bolts Tighten Tighten Valve clearance adjust Inspect Inspect Cylinder head nut Tighten Tighten Spark plug Clean Clean Replace Inspect Inspect NS jas Replace every 4 years Engine oil filter Replace Replace m Engine oil Replace Replace Throttle cable Inspect Inspect m Idle speed Inspect Inspect Clutch Inspect Inspect 9 CHASSIS Interval First Every Every Item 1 000 km 4 000 km 8 000 km Drive chain x Clean and lubricate every 1 000 km Brake Inspect Inspect m Biske hos k Inspect Inspect Replace every 4 years Brake fluid X Inspect Inspect Replace every 2 years Tire Inspect Inspect Steering Inspect Inspect Front forks Inspect Rear shock absorber Inspect Chassis nuts and bolts Tighten Tighten General lubrication Lubricate Lubricate NOTE Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked J 39 INSPECTION AND MAINTENANCE ENGINE OIL Check if there is leakage from crankcase C TOOL 2
50. rn it to the LOCK position after come up again and remove the key All electrical circuits are disconnected A WARNING Do not operate the ignition switch to be in the OFF or LOCK position while driving at one s pleasure C This motorcycle is equipped with a pair of identical ignition keys Keep the spare key in a safe place IGNITION KEY Your motorcycle ignition keys are stamped with an identifying number This number is used when making replacement keys Please write your key number in the box provided for your future reference Key number INSTRUMENT PANEL TRIP METER The trip meter is a resettable odometer located in the speedometer assembly It can be used to indicate the distance traveled on short trip or between fuel stops Turning control button amp will return the meter to zero ODOMETER The odometer registers the total distance that the motorcycle has been ridden 8 SPEEDOMETER The speedometer indicates the road speed in kilometers and miles per hour FUEL GAUGE It indicates the remaining fuel amount in the fuel tank The F Full mark indicates the fuel tank is full The E Empty mark indicates the fuel tank is empty or nearly so the remaining fuel is 2 02 at Empty to the fuel tank the capacity is 14 0 Fill the fuel tank before E Empty CAUTION The fuel gauge indicates the
51. t check lubricate and service as instructed If your motorcycle is used under high Stress conditions such as continuous full throttle operation or is operated in a dusty climate certain services should be performed more often to ensure reliability of the machine as explained in the maintenance section Your Hyosung dealer can provide you with further guide lines Steering components suspensions and require very special and careful servicing For maximum safety we suggest that you have these items inspected and serviced by your authorized Hyosung dealer or a qualified service mechanic 37 9 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 washing it Major lubrication points are indicated as follows A WARNING Improper maintenance or failure to perform recommended maintenance increases the chance of an accident or motorcycle damage M 2 CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life Use only genuine Hyosung replacement parts or their equivalent 9G OF D Clutch lever holder Passenger footrests pivot 3 Drive chain 4 Side stand pivot and spring hook 5 Foot
52. t securely Pour fresh oil through the filler hole Approximately 1 500 mQ of oil will be required ACAUTION Approximately 1 450 m of oil must be required when changing oil only without replacing the oil filter 28 CAUTION In case of the engine oil pouring excessively the engine output being made insufficient Be careful not to pour engine oil 9 Operate the engine a few minutes by idling speed Inspect to leak oil at the oil filter cap 10 Confirm the oil level with the oil level lens after waiting about a minute next to stopping the engine The oil level is located between the Lower line L and the Upper line F When below the Lower line L refill the oil between the Lower line L and the Upper line F RIDING TIPS 6 STARTING THE ENGINE Before attempting to start the engine make sure 1 Inspect every day once before riding the motorcycle 2 The transmission is in neutral 3 The ignition switch is in the position 4 The engine stop switch is in the position 5 Moving the side stand to the fully upper position 6 Push the starter switch without turning the throttle grip after go out the FI check lamp A WARNING The 250 FI is equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of clutch lever and side stand 2 If the tr
53. t level and pollution M i nen idi Engine degree of engine oil 7 2 ay once them before riding No engine oil leakage e motorcycle L Operation of all lamps and amp indicators WHAT TO CHECK FOR CHECK Horn Correct function Smoothness Rear view Steering No restriction of movement mirror No dust or damage No play or looseness Engine itch Correct function e Correct play in the switci throttle cable Side stand Smooth operation and Ignition P A roper operation Throttle positive return of the interlock throttle grip to the closed switch position Bolts and nuts are tight s Comsctlever pla No rattle from any parts of Clutch e Smooth and General motorcycle with the utc ithe condition engine running No visible evidence of Proper operation damage Fluid level in the reservoir to be above LOWER line Correct pedal and lever Brakes play No sponginess No fluid leakage Brake pads and shoes not to be worn down to the limit line Suspension Smooth movement Enough fuel for the planned Fuel distance of operation Gerashift No damage lever lever Smooth operation Correct tension or slack Drive Adequate lubrication chain No excessive wear or damage 36 PERIODIC MAINTENANCE The chart indicates the intervals between periodic service in kilometers At the end of each interval be sure to inspec
54. tch Front brake fluid reservoir 0 Spark pulg Front 3 Front turn signal lamp Head lamp Ignition coil Front Ignition coil Rear 7 Spark pulg Rear Fuel pump Seat lock Q Fuses Passenger footrests Rear turn signal lamp 03 License plate lamp Brake Tail lamp 5 Side stand 00 Footrests 0 Gearshift lever NOTE um means the invisable parts 15 e h 4 7 Muffler Rear seat Front seat Gp Tools ECU Engine Control Unit 93 Battery 82 Front brake fluid reservoir 95 Front brake lamp switch 96 Air cleaner 87 Rear brake pedal 98 Rear brake lamp switch 99 Engine oil filter 40 Engine oil drain plug Engine oil filler cap amp Engine oil level lens NOTE means the invisable parts 16 CONTROLS IGNITION SWITCH KEY The ignition switch has three positions 9 OFF POSITION electrical circuits are cut off The engine will not start The key can be removed 9 POSITION The ignition circuit is completed and the engine can now be started The key cannot be removed from the ignition switch in this position LOCK POSITION STEERING LOCK To lock the steering turn the handlebar all the way to the left Push down the key to the OFF position and tu
55. th the brake shoes wear limit indicators on the rear brakes WARNING To check wear of the brake shoes Too much clearance in the rear Perform the following brake pedal can cause poor braking performance and may lead to an accident Too little clearance may force brake shoes to rub against BRE AR E the drum at all times causing damage to the shoes and the drum Follow the steps in this section to adjust the rear brake pedal properly 1 Check if the brake system is properly adjusted 2 While fully applying the brake check to see that the extension line of the index mark is within the range on the brake panel 3 If the extension line is beyond the range have the brake shoes assembly replaced by your Hyosung dealer to ensure safe operation 4 A WARNING Riding with worn brake shoes will reduce braking performance and will increase your chance of having an accident 2 Inspect brake shoes wear before each use Ask your Hyosung dealer or qualified mechanic to replace Adjust the free travel to 20 30 mm brake Shoes If Wie Shoes gre wem to the limit 0 79 1 18 screwing in or out the 2 brake adjusting 53 Rear brake lamp switch The rear brake lamp switch is located at right side of the engine Move the switch up or down to adjust it until the switch operates and turns on t
56. torcycle It is important to clean and inspect your motorcycle after every ride if it is used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust System can reduce engine cooling conceal damage or increase wear of certain parts It is important to remove all debris during cleaning CAUTION High pressure washers can damage your motorcycle especially the oil cooler pin High pressure washers such as those found at coin operated car washes have enough pressure to damage the parts of your motorcycle It may cause rust corrosion and increase wear Do not use high pressure washers to clean your motorcycle M 63 9 WASHING YOUR motorcycle With some care your motorcycle can be washed in a similar manner to washing an automobile NOTE Avoid spraying or allowing water to flow over the following places Ignition switch Fuel injection system Brake master cylinders Oil cooler fins Snorkel air intake for air cleaner 4 gt Spark plug Fuel tank cap M P Do not use parts cleaner to throttle body and fuel injection sensors L 2 Use a garden hose at low pressure to remove the majority of dirt or other debris Hand wash your motorcycle with a mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressur
57. ycle refueling by anyone other than an adult Refuel in a well ventilated area Make sure the engine is off and avoid spilling fuel on a hot engine Do not smoke and make sure there are 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 LLL 25 Long engine life depends much on the selection of quality oil and the periodic changing of the oil Daily oil level checks and periodic changes are two of the most important maintenances to be performed 9 ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level 1 Start the engine and run it for a few minutes 2 Stop the engine and wait three minutes 3 Hold the motorcycle vertically and inspect the engine oil level through the engine oil level lens on the right side on the engine Do 7 HYOSUNG j E CAUTION Fuel and Engine oil use certainly to recommend at the front part M CAUTION CAUTION Never operate the motorcycle if the engine oil level is below the Lower line mark L in the engine oil level lens Never fill the engine oil above the Upper line mark F Engine oil level being most suitable about 1mm under the Upper line mark F of the engine oil level lens In case of the engine oil pouring excessively the engine output being ma
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