GV250 - Hyosung
Contents
1. Side stand 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 Clutch Side stand Engine Start 1 AWARNING Riding with the side stand incompletely retracted can result in an accident when you turn left Check operation of the side stand igni tion interlock system before riding e Always retract the side stand complete ly before starting off 6 SEAT LOCK The seat lock is located left under of the seat To unlock the seat insert the ignition key into Possible the lock and turn it counter clockwise 2 To lock the seat push down firmly until the seat A Possible latch snaps into the lock position 3 A e Impossible ECAA e impossible REAR SUSPENSION Neutral Neutral switch Clutch Clutch lever On or UP A Off or Down CAUTION Before starting off check that the side stand is returned to fully upper position and is not hanging down 1 Rear shock absorber 2 Pin spanner To adjust the spring pre load turn the adjuster ENGINE OIL clockwise or counter clo2. The carburetor is equipped with a choke system to provide easy starting when the engine is cold When starting the cold engine turn the choke lever all the way toward you The choke works best when the throttle is in the closed position When the engine warm you do not need to use the choke system for starting CAUTION If keep running in condition that full choke lever cause in fuel excess exhaustion high speed not running damage of igni tion plug FUEL COCK 250 equipped with a manually operated fuel cock There are three position ON OFF and RES Position The normal operating position for the fuel cock lever is in the ON position OFF Position Turn the lever to the OFF position whenever stopping the engine for more than a few min utes RES RESERVE Position If the fuel level in the tank is too low turn the lever to the RES position to use the 2 0 2 of reserve fuel supply Confirm the each mark by A mark at the fuel cock lever CAUTION After switching the fuel cock lever to the RES position it is advisable that the tank be refilled at the closest gas station After refueling be sure to move the fuel cock to the ON position C REAR BRAKE PEDAL Depressing the rear brake pedal will apply the
3. 1 Place the motorcycle the center stand jack or block Necessarily confirm and clean the oil strain when replace the Engine oil specially when first replace ment CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions inspect 1 Quantity of Engine oil Pollution degree of Engine oil before rid ing the motorcycle and then supplement and replace at any time to prevent damage of the engine 2 Como Cou Como 407 D YA HYOSUNG a 2 Remove the engine filler cap 27 3 Drain the oil by removing the drain plug located on the bottom of the engine CAUTION Insert the filter so that surface of the filter hole turn toward the engine OIL FILTER INSTALLATION CAUTION When install the oil fiter necessarily HYOSUNG character and 16510H05240 part s NO install toward the outside other wise can damage the engine AWARNING 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 AWARNING New and used oil and solvent can be haz ardous Children and pets may be harmed by swallowing new or used engine oil or solvent Continuous contact with used
4. ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS SERIAL NUMBER LOCATION 2 NAMES OF EACHPART 6 3 CONTROLS sise ments 9 IGNITION SWITCH IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH SUPPLY OF GASOLINE CARBURETOR CHOKE LEVER FUEL COCK REAR BRAKE PEDAL GEARSHIFT LEVER STAND SEAT LOCK REAR SUSPENSION 4 FUEL AND OIL RECOMMENDATION 15 6 INSPECTION BEFORE RIDING 17 PERIODIC MAINTENANCE TRIDING TIPS rererere noei 20 STARTING THE ENGINE STARTING OFF USING THE TRANSMISSION RIDING ON HILLS STOPPING AND PARKING 8 INSPECTION AND REPAIR 22 TOOL BATTERY AIRCLEANER FUEL HOSE SPARK PLUG ENGINE OIL CARBURETOR CLUTCH ADJUSTMENT DRIVE CHAIN BRAKES TIRES REPLACE OF THE LAMP WHEN THE ENGINE REFUSE TO START WHEN KEEPING FOR LONG PERIOD 9 SPECIFICATIONS sawn eames 41 CONSUMER INFORMATION 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 the available accessories how ever your dealer can assist you in selecting quality accessories and installing the
5. 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 0 4 at E Empty the capacity is 14 0 2 Fill the fuel tank before E Empty CAUTION The fuel gauge indicates the remaining amount whenever the ignition switch is or OFF For checking the rema ining amount of fuel hold the motorcycle vertically and set the ignition switch 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 headlamp high beam is turned on LEFT HANDLE SWITCH CLUTCH LEVER Using to cut off dilivering power at rear wheel when starting engine or shifting gear DIMMER SWITCH Change direction of headlamp light p The headlamp high beam and tail lamp come on The high beam indicator lamp also comes on ZD The headlamp low beam and tail lamp come on Set the dimmer
6. 1mm under the Upper line mark F of the engine oil lens In case of the engine oil pouring in excessively the engine output being made insufficient Be careful not to pouring in the engine oil excessively 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 minute 3 Hold the motorcycle vertically and inspect the engine oil level through the engine oil level inspection window on the right side of the engine 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 26 A CAUTION Fuel and Engine oil use certainly to rec ommend at the front part ENGINE OIL AND FILTER CHANGE Change the engine oil and filter after first run ning 1 000km and every running 4 000km 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 Replace 1 450 ml Oil filter replace 1 500 ml Overhaul 1 800 CAUTION In case of the engine oil pouring in exces sively the engine output being made insuffi cient Be careful not to pouring in the engine oil excessively CAUTION
7. If the air cleaner element is polluted will occur to starting go out output insuffiency combustion effciency decline and sooty smoke black smoke This appearence is occurred at first to clean the air cleaner ele ment and confirm 6 OK 1 Remove the screws and remove the cover FUEL HOSE Inspect the fuel hose for damage and fuel leak age If any defect are found the fuel hose must be replaced Replace the fuel hose every 4 years 4 SPARK PLUG D 3 Remove the air cleaner element 4 Clean the air cleaner element for the following 1 When the air cleaner element clean with the air gun necessarily blow at the inside by compessed 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 dam age severely the engine Remove the carbon deposits periodically from 4 Be careful not to allow water to go inside the spark plug with a piece of hard wire or pi
8. 12 000 km Exhaust pipe bolts and muffler mounting bolts x Tighten Tighten Valve clearance adjust x Inspect Inspect Spark plug Clean Clean Replace Inspect Inspect Fuel hose Replace every 4 years Engine oil filter Replace Replace Engine oil Replace Replace Throttle cable Inspect Inspect Idle speed Inspect Inspect Clutch Inspect Inspect CHASSIS Interval First Every Every Item 1 000 km 4 000 km 8 000 km Drive chain Clean and lubricate every 1 000 km Brake Inspect Inspect Inspect Inspect Brake hose Replace every 4 years Inspect Inspect un Brake fluid Replace every 2 years Tire Inspect Inspect Steering Inspect Inspect Front forks Inspect Rear suspension Inspect Chassis nuts bolts Tighten Tighten CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions NOTE Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked 19 6 RIDING TIPS STARTING THE ENGINE D Before attempting to start the engine make sure 1 The transmission is in neutral 2 The fuel cock lever is in the ON position 3 The engine stop switch is in the 7 pos ition When the engine is cold 1 Turn the carburetor choke lever all the way toward you Close the throttle grip and push the starter switch Immediately after the engine starter return th
9. at Hyosung have designed tested and produced this motorcycle using the most modern tech nology available to provide you with many happy enjoyable safe riding Motorcycling is one of the most exhilarating sports and insure your riding enjoyment you should become throughly familiar with the information pre sented 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 experi enced 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 avail able at the time of publication Due to improve ments or other changes there may be some discrepancies in this manual Hyosung reserves the right to make changes at any time Please note that this manual applies to all speci fications for all respective destinations and explains all equipments Therefore your model may have different standard features than shown in this manual S gt HYOSUNG MOTORS amp MACHINERY INC Overseas Technical Department COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC TABLE OF CONTENTS 1 CONSUMER INFORMATION 4
10. 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 free dom of movement of the rider and may limit his or her control ability 6 Additional electrical accessories may over load 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 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS Motorcycle riding is great fun and an exciting sport Motorcycle riding also requires that some extra precautions be taken to ensure the safety of the rider and passenger These precautions are WEAR HELMET Motorcycle safety equipment starts with a quality safety helmet One of
11. 600miles service will ensure optimum service life and per formance from the engine A CAUTION Service should may be peformed before 1 000km 600miles on motorcycle that are used under severe conditions A CAUTION The 1 000km 600miles 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 that section INSPECTION BEFORE RIDING Before riding the motorcycle be sure to check the follwing item Inspect every day once them before riding the motorcycle Abnormal point of the previous day Extra braking power of the brake lever Fluid measure of the master cylinder Pressure crack cut strange wear foreign substance stone nail and others of Tire e Adequate tread depth of Tire Fluid measure of Engine oil Pollution degree inspect of Engine oil e Fluid measure of Fuel e On and off condition or damage of Lamp turn signal lamp and others e Condition of rear view mirror C D The chart indicates the intervals between peri odic service in kilometers At the end of each interval be sure to in spect check lubricate and service as instructed If your motorcycle is used under high stress con ditions such as continuous full throttle operation or is operated in a dusty climate certain ser vices should be performed more often to ensure reliability o
12. IMPORTANT BREAK IN INFORMATION FOR YOUR MOTORCYCLE The first 1 000km 600miles are the most impor tant 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 exercised 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 exces sive heat Please refer to the BREAK IN section for specific break in recommendations WARNING CAUTION NOTE Please read this manual and follow its instruc tions carefully To emphasize special informa tion the words WARNING CAUTION and NOTE carry special meanings and should be carefully reviewed AWARNING The personal safety of the rider may be involved Disregarding this information could result in injury to the rider CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damag ing the machine NOTE This provides special information to make maintenance easier or impor tant instructions clearer FOREWORD THANK YOU for choosing Hyosung We
13. OUBLE Starter System ELECTRIC STARTER TRANSMISSION et EESE Wet shoe Mechanical pressure plate type Reduction ratio 2 460 0 840 Drive chain 520 116 Links 3 05 Transmission 1st 2 460 2nd 1 560 3rd 1 190 Ath 0 960 5th 0 840 3 29 4 CHASSIS Front suspension Rear suspension Trail Steering angle Front tire size Rear tire size Front brake Rear brake ELECTRICAL Ignition type Ignition timing Spark plug Fuse Headlamp Position lamp License plate lamp High beam indicator lamp signal lamp ee ites Brake Tail lamp Speedometer lamp Turn signal indicator lamp right amp left CAPACITIES Fuel tank Engine oil Telescopic type Swing arm type 33 135mm 5 32in 40 right amp left 110 90 16 59S 150 80 15M C 70S Disc Drum CDI type 13 B T D C at 2 000 rpm 30 B T D C at 6 000 rpm CR8E 12V 6Ah MF 15A HI 35 LO 35 5W 5W 1 7W 1 7W 10W 21 5W 1 7WX3 1 7WX2 14 0 2 1 450 Replace 1 500m Oil filter replace 1 800m Overhaul e Prepared by HYOSUNG MOTORS amp MACHINERY INC 2nd Ed MAR 2003 Printed in KOREA 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 b
14. airtight type is used for this motorcycle It is not necessary to inspect or supplement bat tery fluid The battery is located behind the right frame cover However have your dealer check the charging condition of battery periodically To remove the battery loosen the screw 0 unhook the hook and remove the right frame cover After remove the frame cover can pull it out as to take off the starter relay and fuse and sepa rate the battery support 23 Do not remove absolutely airtight cover as airtight type battery Keep after separate at the motorcycle for the minimum of self electric dis charge and electric leakage when dont use for a long time Remove the negative terminal when keep intact at the motorcycle CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 2 Set the ignition switch OFF position Disassemble the battery cover disassemble the positive battery wire after the neg ative battery wire Remove the battery Clean the terminal If there is white dust clean it with warm water Assemble the battery wires and grease the terminal lightly BATTERY INSTALLATION 250 s battery installation order pay attention to following points Hot Lead wire Front Remove the seat right fra
15. an rules may cause to occur the vehicle fire and to damage at electric parts Surely use only the lamp of proper capaci ty TURN SIGNAL LAMP 1 Remove the two screw right and left and the headlamp assembly 2 Disconnect the socket from the headlamp 3 Remove the rubber cap 2 Push in the bulb turn it to the counter clock wise and pull it out 3 After stick in the new lamp assemble the lens 4 Umhook the bulb holder spring and remove the bulb 5 To install the headlamp reverse the above sequence 38 TAIL BRAKE LAMP al Pa 2 Remove the tail amp brake lamp cover 3 Push in the bulb turn it to the counter clockwise and pull it out 4 After stick in the new lamp assemble the lens CAUTION Overtightening the screws may cause the lens to crack a FUSE i LJ 2 Push in the bulb turn it to the counter clock wise and pull it out 3 To fit the replacement bulb push it in and turn it to the clockwise while pushing LICENSE PLATE LAMP 1 Remove the three nuts at the seat tail cover 39 The fuse box is located behind the right frame cover If the engine suddenly stops while run ning or any electrical system fails to operate then
16. ckwise to the desired position with the pin spanner Position 1 provides the softest spring pre load Classification and position 5 provides the stiffest system Grade Remarks 250 is delivered from the factory with its adjuster set on position 1 ENGINE OIL SPECIFICATION API SF or SG SAE 10 W 40 AWARNING X If a SAE 10 W 40 motor oil is not available Unequal suspension adjustment can select and alternative according to the follow cause poor handling and loss of stability ing chart Adjust the right and left shock absorber to the same settings TIRE 20W50 as a 15W40 15W50 VGE a EEE 10W40 10W50 ee 10W30 FUEL AND OIL RECOMMENDA Temperature TION 22 4 4 32 50 68 8 104 ENGINE OIL Using a premium quality four stroke motor oil will x FUEL increase the service life of your motorcycle Use unleaded gasoline with an octane rating or AWARNING higher Unleaded gasoline can extend spark plug life and exhaust components life Don t mix the unrecommended oil It could damage the engine A CAUTION When refilling the oil tank don t allow the dust to get inside Mop the oil spilt Don t put the patch the cap It could Spilling gasoline can damage pointed sur faces 4 I Be careful not to spill any fuel when fill
17. e choke lever halfway and warm up the engine Return the choke lever all the way to its dis engaged position When the engine is warm 1 Open the throttle grip 1 8 1 4 2 Push the starter switch CAUTION Operation of the carburetor choke system is not necessary when the engine is warm AWARNING 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 20 CAUTION Running the engine too long without riding may cause the engine to overheat Overheating can result in damage to inter nal engine components and discoloration of exhaust pipes Shut the engine off if you cannot begin your ride promptly STARTING OFF C AWARNING Riding this motorcycle 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 condi tions AWARNING Removing your hands from the handle bars or feet from the footrests during operation can be hazardous If you remove even one hand or foot the motor cycle you can reduce your ability to con trol the motorcycle Always keep both hands on th handlebars and both feet on the footrests of your motorcycle du
18. e 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 riding the motorcycle untill operating the brake fluid and becoming the brake distance 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 REAR BRAKE REAR BRAKE ADJUSTMENT AWARNING Too much clearance in the rear brake pedal can cause poor braking perfor mance and may lead to an accident Too little clearance may force brake shoes to rub against 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 BRAKE LINING WEAR LIMIT The motorcycle is equipped with the brake lining wear limit indicators on the rear brakes To check wear of the brake lining perform the following Adjust the free travel to 20 30 mm 0 79 1 18 in by screwing in or out the brake adjusting nut Check if the brake system is properly adjust ed While fully applying the brake check to see that the ext
19. e the brake adjuster nut and place a jack or block under the swing arm to lift the rear wheel slightly off the ground AWARNING A hot muffler can burn you The muffler will be hot enough to burn you for some time after stopping the engine Wait until the muffler cools to avoid burns 4 Loosen the drive chain adjuster 0 left and right and disengage the drive chain from the rear sprocket 5 Remove the rear break hub from the swing arm 6 Loosen the rear shock absorber lower bolt left and right draw out the rear axle with the rear wheel push to the bottom 7 Pull the rear wheel assembly rearward 8 To replace the wheel reverse the complete sequence listed CAUTION The standard tire 002200702 ABW is 110 90 16 59S for front and 150 80 15M C 70S for rear The use of a tire other than standard may cause trouble It is highly recommended to use the standard tire supplied by Hyosung REPLACE OF THE LAMP 3 Requirement electric power of the lamp is fol lowing the chart When replace the damaged lamp always use the equal capacity The use of a lamp other than rules may cause to excessive at the electric system or to damage the lamp NAMES CAPACITY HI 35 W Head lamp LO 35 W Position lamp 5W Brake Tail lamp 21 5 W Turn signal lamp 10 W License lamp 5 W HEAD LAMP A CAUTION The use of a lamp other th
20. 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 waterproof gloves Wash with soaf if oil or solvent contact your skin INSERTION DIRECTION LUSTER MATERIAL OUTSIDE 16510H05240 28 Remove the three nuts holding the filter cap in place Replace the engine oil filter with a new one Before replacing the engine oil filter cover be sure to check that the engine oil filter spring and the are installed correctly Use new each time the engine oil fil ter element is replaced Replace the oil filter cover and tighten the nuts securely but do not over tighten them CAUTION CAUTION Approximately 1 450m of oil must be required when changing oil only without replacing the oil filter 8 Replace the drain plug and tighten it securely Pour fresh oil through the filler hole Approximately 1 500m of oil will be required Never adjust CO adjust screw of the carburetor If adjust optionally exert a bad influence upon output of the engine as the two car buretor is disharmonious CAUTION In case of the engine oil pouring in exces sively the engine output being made insuffi cient Be careful not to pouring in the eng
21. ension line of the index mark is within the range on the brake panel If the extension line is beyond the range have the brake shoe assembly replaced by your Hyosung dealer to ensure safe opera tion AWARNING Riding with worn brake shoe will reduce braking performance and will increase your chance of having an accident Inspect brake shoe wear before each use Ask your Hyosung dealer or qualified mechanic to replace brake shoe if the shoes are worn to the limit 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 the brake lamp after the brake pedal begins to be depressed Inspect the tire pressure and the tire thread depth periodically Inspect frequently the tire pressure for the safety and the tire life TIRE PRESSURE Insufficient air pressure in the tires not only has ten tire wear but also seriously affects the stabil ity of the motorcycle Under inflated tires make smooth cornering dif ficult 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 lim its at all times Tire pressure should only be adjusted when the tire is cold Operating the motorcycle with excessively worn tire will decrease riding stabilit
22. f the machine as explained in the maintenance section Your Hyosung dealer can provide you with fur ther 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 PERIODIC MAINTENANCE 17 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 fol lows AWARNING Improper maintenance or failure to per form recommended maintenance increas es the chance of an accident or motorcy cle damage 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 Clutch lever holder Brake lever holder Drive chain Brake pedal pivot Side stand pivot and spring hook 81 Motor oil 9 Grease ENGINE Interval First Every Every Item 1 000 km 4 000 km 8 000 km Air cleaner element Clean every 3 000 Replace every
23. hain look for the follow ing Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear 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 autho rized Hyosung dealer Damage to the drive chain means that the sprockets may also be damaged Inspect the sprockets for the following Good Worn Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nuts If you find any of these problems with your sprocket consult your Hyosung dealer 31 A CAUTION The two sprockets should be inspected for wear when a new chain is installed and replace them if necessary DRIVE CHAIN ADJUSTMENT Chain adjust in the following way 20 30mm _ 1 Place the motorcycle on the jack or block 2 Loosen the axle nut 0 3 Adjust the slack in the drive chain by adjuster as the lock nut turning toward the left and right 4 For alignment of the rear sprocket and the front sprocket there are reference mark on the same position After aligning and adjusting the slack in the drive chain to 20 30mm 0 79 1 18 in retighten the axle nut securely and perform a final inspection CAUTION BRAKES C The drive chain for this motorcycle is made of the
24. he engine with the ignition switch in the ON switch 40 AWARNING 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 Starting Check the fuel supply in the fuel tank Check the ignition system for intermittent spark Check the engine idle speed CAUTION When occur any trouble the best way is to consult your Hyosung dealer for repairs WHEN KEEPING FOR LONG PERIOD D 1 Supply enough the fuel in the fuel tank 2 Do the fuel cock in the OFF position 3 Do drain wholly the fuel in the carburetor 4 Remove the battery from the motorcycle SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2 270mm 89 4in Overall width 800mm 31 5in Overall height 1 090mm 42 9in Wheelbase 1 500mm 59 1in Ground clearance 155mm 6 1in Mass En dr OS US 170kg 375lbs ENGINE Type nr ide Four stroke air cooled and oil cooled Number of cylinder ss V 2 cylinder BO tete 57 0mm 2 24in sde eme dreds detest 48 8mm 1 92in Piston displacement 249cm 15 2in Corrected compression ratio 2 2 10 2 1 720 BDS 26 TYPE D
25. ine oil excessively 9 Operate the engine a few second by idling speed Inspect to leak oil at the oil filter cap 10 Confirm the oil level through 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 CARBURETOR 250 eqipped one set of composed the two carburetors for efficiency increase of the two cylinder The carburetor is from the factory setting for the best carburetion Do not attempt to alter its set ting There are two items of adjustment howev er under your care idle speed and throttle cable play 1 Start the engine and let the engine until it warms up fully 2 After engine warms up turn the throttle stop screw D located on the carburetor in or out so that engine may run at 1 450 1 550 A CAUTION The engine idle speed should be adjusted with the engine fully warm THROTTLE CABLE ADJUSTMENT 1 Loosen the lock nut 2 Adjust the cable slack by cable adjuster 2 in or out to obtain the correct slack 0 5 1 0mm 0 02 0 04in 3 After adjusting the slack tighten the lock nut A CAUTION After completing throttle cable adjust ment check that handlebar movement does
26. ing disturb the oil to be provided and dam the fuel tank age the engine Wipe spilled gasoline up immediately AWARNING When refueling always shut the engine off and turn the ignition key to the OFF position Never refuel near the The opening explains how important proper flames sparks and heat sources break in is to achieve maximum life and perfor Do not overfill the fuel tank Do not fill the mance from your new Hyosung The following fuel tank above the entrance lower end guidelines explain proper break in procedures 15 MAXIMUM THROTTLE OPENING REC OMMENDATIONS The table below shows the maximum throttle opening recommendation during the break in period Initial 800km 500miles Less than 1 2 throttle Up to 1 600km 1 000miles Less than 3 4 throttle AWARNING 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 in of the tire as described in this section and avoid hard acceleration hard cornering and hard braking for the first 160km 100miles 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 gear without exceeding the recommended max imum limits Do not however use full throttle for first 1 600km 1 000mile
27. lamp and taillamp come on If not start engine do not come on lt position The position lamp meter lamp and taillamp come on position The headlamp meter lamp and taillamp go off 5 G STARTER SWITCH Use this switch to operate the starter motor 11 With the ignition switch in the ON position the engine stop switch in the position and the transmission is in neutral pull in the clutch lever and push the starter switch to start the engine A CAUTION Do not engage the starter motor for more than five seconds at a time as it may over heat the wiring harness and starter motor If the engine does not start after several attempts check the fuel supply and igni tion system Refer to Page 40 6 SUPPLY OF GASOLINE To open the fuel tank cap insert the ignition key into the lock and turn it clockwise With the key inserted lift the cap up with the key To close the fuel tank cap push the cap down firmly with the key in the cap lock AWARNING Fuel and fuel vapor are highly flammable and toxic You can be burned or poisoned when refueling Stop the engine and keep flames sparks and heat sources away Refuel only outdoors or in a well venti lated area Do not smoke Wipe up spills immediately Avoid breathing fuel vapor Keep children and pets away CARBURETOR LEVER D
28. m 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 1 In case that additional weight or aerody namic affecting accessories are installed they should be mounted as low as possible as close to the motorcycle and as near the center of gravity as is feasible The mounting brack ets and other attachment hardware should be carefully checked to ensure that it pro vides 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 criti cally 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 con dition or by an instability in cross winds or when being passed or passing large vehicles Improperly mounted or
29. me cover and bat tery support Lay down positive terminal of the battery at leftside of the battery case on the motor cycle Install positive lead wire at the battery terminal Put on the rubber cap at the positive ter minal of the battery Install negative lead wire at the battery terminal Install the battery support and right frame cover CAUTION If install first the lead wire at the battery then lay down at the battery case will be installed the opposite direction posi tive terminal face on the rightside of the motorcycle as that length of the lead 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 24 CAUTION Keep the battery away from fires When disassemble the battery wire take off terminal first with the ignition switch OFF position When assemble terminal first Fasten certainly the battery wires C 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 ele ment must be cleaned or replaced more fre quently than maintenance schedule Check and clean the air cleaner element periodically according to the following procedure AIR CLEANER A CAUTION
30. mes in con tact with skin or eyes Contact your physi cian immediately If swallowed induce vomiting If brake fluid gets into the eye or in contact with the skin it should be flushed thoroughly with plenty of water CAUTION This motorcycle uses glycol based brake fluid Do not use or mix different types of brake fluid such as silicone based or petroleum based 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 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 ser vice machanic Limit line 2 SSI 5 7 33 Inspect every day the following point at the brake system Brake fluid leak of the front brake system Leak or damage of the brake hose Operating of the brake lever Wear of the front brake pads A CAUTION The front brake system be replaced the brake hose or the brake fluid according to periodic inspection chart by your autho rized Hyosung dealer for safety as in times of operating at high pressure AWARNING Riding with worn brake pads will reduce braking performanc
31. n the air cleaner element CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions also clean the air cleaner ele ment when replacing the oil to prevent damgae of the engine 0 7 0 8mm 25 Readjust the spark plug gap to 0 7 0 8 mm 0 028 0 031 inch by using a spark plug gap thickness gauge PLUG REPLACEMENT GUIDE Hotter type CR7E Standard type CR8E Colder type CR9E CAUTION 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 this motor cycle 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 z ENGINE OIL 4 R Way HYOSUNG K Q o lt lt C A CAUTION Never operate the motorcycle if the engine oil level is below the Lower line mark L in the engine oil level gauge Never fill the engine oil above the Upper line mark F Engine oil level being most suitable about
32. not raise the engine idle speed and that the throttle grip return smoothly and automatically C CLUTCH ADJUSTMENT 2 At each maintenance interval adjust the clutch cable play by means of clutch cable adjuster The cable play should be 4mm 0 16in as mea sured at the clutch lever holder before the clutch begins to disengage 30 The clutch lever play The lock nut The clutch lever adjuster The rubber boot The cable adjuster The clutch cable adjuster lock nut If you find the play of the clutch incorrect adjust it in the following way CLUTCH CABLE 1 Loosen the lock nut and the clutch lever adjuster turn all the way toward clockwise 2 Loosen the clutch cable adjuster lock nut Turn the cable adjuster that the clutch lever play should be 4mm 0 16in 3 A little adjustment be allowed by the clutch lever adjuster 4 After end of adjustment tighten the lock nut and cover the rubber boot DRIVE CHAIN The chain may require more frequent adjust ment that it is with periodic maintenance depending upon your riding conditions Check the chain every 1 000km AWARNING Riding with the chain in poor condition or improperly adjusted can lead to an accident Inspect adjust and maintain the chain properly before each ride according to this section Insepcting the Drive Chain When inspecting the c
33. ns OFF POSITION All electrical circuits are cut off The engine will not start The key can be removed 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 To lock the steering turn the handlebar all the way to the left Push down the key to the OFF position and turn it to the LOCK position after come up again and remove the key All electrical circuits are disconnected IGNITION KEY 254 comes equipped with pair of identical ignition keys Keep the spare key in a safe place 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 VN INSTRUMENT PANEL D 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 Pressing control button will return the meter to zero ODOMETER The odometer registers the total distance that the motorcycle has been ridden 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
34. ow down SERIAL NUMBER LOCATION The frame and or engine serial numbers are used to register the motorcycle They are also to assist your dealer interms ofordering parts or referring to special service infor mation The frame number is stamped on the steering head tube The engine serial number is stamped on the left upside of the crankcase assembly Please write down the numbers in the box provided below for your future reference Frame number Engine number NAMES OF EACH PARTS Clutch lever Front brake fluid reservoir Left handle switches Throttle grip Choke lever Front brake lever Speedometer Right handle switches Fuel gauge Fuel tank cap Tachometer Ignition switches Ignition coil Front Throttle stop screw Ignition coil Rear Fuel cock 47 Spark plug Rear Fuel pump Seat lock Passenger footrests Side stand Footrests Gearshift lever Spark plug Front UT ER TAS lt yor BE TE a KES Z v Tools Battery and fuse Air cleaner Rear brake pedal Rear brake lamp switch Engine oil filter Engine oil drain plug Engine oil filler cap 93 Engine oil level lens CONTROLS 6 IGNITION SWITCH ignition switch has three positio
35. rear brake The brake lamp will be illuminated when the rear brake is operated AWARNING When brake rear brake haste braking pay attention surely to occure accident of vehicle falling down C gt GEARSHIFT LEVER P 250 has a 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 Each time that a gear is select ed 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 Neutual is located between first and 2nd gear When neutral is desired depress or lift the lever halfway between first and 2nd gear It is not possible to upshift or downshift more than one gear at a time When shifting from first to 2nd gear or 2nd gear to low neutral will be automatically skipped Reduce the motorcycle speed before down shift ing 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 13 CAUTION When the transmission is in neutral the green indicator lamp on the instrument panel will be lit However even though the light is illumi nated cautiously release the clutch lever slowly to determine whether the transmis sion is positively in neutral
36. ring operation AWARNING 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 After moving the side stand to the fully upper position 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 simultaneous ly 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 RIDING ON HILLS C When climbing steep hills the motorcycle may begin to slow down and show lack of power At this point you should shift to a lower gear so that the engine will again be operat ing in its normal power range Shift rapidly to prevent the motorcycle from losing momen tum When riding down a 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 USING THE TRANSMISSION C JL STOPPING AND PARKING D The transmission is provided to keep the engine operating smoothl
37. s 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 pres sure 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 maxi mum performance just as the engine does Wear in the tread surface by gradually increas ing your cornering lean angles over the first 160km 100miles before attempting maximum performance Avoid hard acceleration hard cor nering and hard braking for the first 160km 100miles ALLOW THE ENGINE OIL CIRCU LATE BEFORE RIDING Allow sufficient idling time after warm or cold engine start up before applying load or reviving the engine This allows time for the lubricating oil to reach all critical engine components OBSERVE YOUR FIRST AND MOST 1 000km SERVICE The 1 000km 600miles 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 000km
38. s of control TOOL D Brake before you begin to turn To assist you in the performance of periodic AWARNING maintenance a tool kit is supplied and is located under the seat The tool kit consists of the fol Hard braking on wet loose rough or lowing items other slippery surfaces can cause wheel skid and loss of control NO NAME Brake lightly and with care on slippery or irregular surfaces AWARNING Following another vehicle too closely can lead to a collision As vehicle speeds increase stopping distance increases progressively Tool bag 10 X 12 mm open end wrench Spark plug wrench Combination screw driver aR N gt Screw driver handle Be sure you have a safe stopping distance between you and the vehicle in front of you 5 Park the motorcycle a firm flat surface where it will not fall over 5 AWARNING A hot muffler can burn you The muffler will be hot enough to burn you for some time after stopping the engine Park the motorcycle where pedestrians or O children are not likely to touch the muffler 6 Turn the ignition key to the OFF position or Q turn the handlebars all the way to the left and turn the LOCK position as push the ignition key 7 Remove the ignition key 22 CAUTION INSPECTION OF BATTERY SOLUTION LEVEL MF Maintenance Free battery of
39. special material The chain should be replaced with a 52005 Use of another chain may lead to ture 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 AWARNING Be careful not to touch the muffler when it is hot a hot muffler can burn you DRIVE CHAIN CLEANING AND OILING If the drive chain become dirty the drive chain and the sprocket is wore easily This times clean the drive chain with solvent and oil every 1 000km with lubricating oil or motor oil 32 Properly operating the brake systems are vital to safe riding Be sure to perform the brake inspec tion 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 mas ter cylinder If the level was found to be lower than the lower mark while holding the motorcycle upright replenish with the proper brake fluid that meets Hyosung 5 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 AWARNING Brake fluid may be harmful or fated if swallowed and harmful if it co
40. switch 20 when other 2 vehicle is running in front or against HORN SWITCH Press the switch to operate the horn TURN SIGNAL SWITCH Using when left right turn or change direction Position Flash the left turn signal lamp Position Flash the right turn signal lamp A 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 com pleting the turn or lane change RIGHT HANDLE SWITCH gt 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 sys tem The brake lamp will come on when the lever is squeezed 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 ENGINE STOP SWITCH 54 Position Using when dangerous con dition of falling down during drive and others or engine stop suddenly The ignition circuit is off The engine cannot start or run O Position Using when need operation of engine as drive and oth ers The ignition circuit is on and the engine can run LIGHT SWITCH position The headlamp position lamp meter
41. the fuse must be checked In case a fuse blows there is a 15A spare fuse CAUTION If the ignition system is operating properly a blue spark should jump across the spark plug gap If there is no spark consult your Hyosung dealer for repairs Never use other than specified 15A fuse Installing a fuse of incorrect rating may seri ously damage the electrical system You should consult your Hyosung dealer or a qualified service mechanic immediately WHEN THE ENGINE REFUSES TO START TROUBLE SHOOTING If the engine refuses to start perform the follow ing inspections to determine the cause Fuel Supply Check Is there enough fuel in the fuel tank 5 the fuel reaching the carburetor from the fuel cock Disconnect the fuel line from the carburetor turn the fuel cock to the ON position and see if gasoline flows from the hole If it has been determined that fuel is reaching the carburetor the ignition system should be checked next CAUTION Do not allow the fuel to spill Catch the fuel in container Do not allow any fuel to come in contact with the hot engine or exhaust system Extinguish any smoking materials before performing this check and stay away from any other fire or heat source Ignition System Check Remove a spark plug and reattach to the spark lead While holding the spark plug firmly against the engine crank t
42. 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 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 Review throughly 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 FAMILIARIZE YOURSELF WITH THE MOTORCYCLE 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 KNOW YOUR LIMITS Ride within the boundaries of your own skill at all times Knowing these limits and staying within them will help you to avoid accidents BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS 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 slip pery Use extreme caution at railway crossings and on metal gratings and bridges Whenever you have a doubt about road condition sl
43. y and can lead to loss of control Inspect stortage of tire thread s depth by the tire wear indicators Replace the front and rear tires at once when appear the tire wear indicators TIRE REPLACEMENT FRONT REPLACEMENT 1 Place the motorcycle on the center stand TIRE PRESSURE NORMAL RIDING COLD INFLA TION SOLO RIDING DUAL RIDING 2 Remove the caliper from the front fork by 1 75 1 75 removing the mounting bolts FRONT 172 kpa 172 kpa 25 psi 25 psi CAUTION 2 00 2 25 Never squeeze the front brake lever with REAR 196 kpa 221 kpa the caliper removed It is very difficult to 29 psi 32 psi force the pads back into the caliper assembly and brake fluid leakage may result TIRE TREAD CONDITION Tire wear Tire wear indicator mark WY sf 35 3 Loosen the front axle pinch bolt 4 Loosen the front axle 5 Carefully position a jack or block under engine and raise until the front wheel is slight ly off the ground A CAUTION Improper jaking may cause damage to the oil filter Do not apply the jack head to the oil filter when jacking up the motorcycle REAR TIRE REPLACEMENT 1 Place the motorcycle on the center stand 7 Slide the front wheel forward 8 To reinstall the wheel assembly reverse the sequence as described 3 Remov
44. y any person other than for purpose of mainte nance 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 of delivery to the ulti mate 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 ren dered inoperative by any person MAINTENANCE The exhaust system of this motorcycle requires no periodic maintenance The engine should be adjusted to the manufacturer 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
45. y in its normal operating speed range The gear ratios have been careful ly chosen to meet the characteristics of the engine The rider should always select the most suitable gear for the prevailing conditions AWARNING Downshifting when engine speed is too high can cause the rear wheel to skid and lose traction due to increased engine brak ing resulting in an accident or force the engine to overrev in the lower gear resulting in engine damage Reduce speed before downshifting AWARNING 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 21 1 Turn the throttle grip away from you to close the throttle completely Apply the front and rear brakes evenly and at the same time Downshift through the gears as road speed decreases Select neutral with the clutch lever squeezed towards the grip disengaged position just before the motorcycle stops Neutral position can be confirmed by observing the neutral indicator lamp AWARNING Inexperienced riders tend to underutilize the front brake This can cause excessive stopping distance and lead to a collision Using only the front or rear brake can cause skidding and loss of control Apply both brakes evenly and at the same time AWARNING INSPECTION AND REPAIR Hard braking while turning may cause wheel skid and los
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