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GT250R ³»Áö - Hyosung Motos Schweiz

1. FUEL SYSTEM c amp 725o ze s El Electric fuel Injection System CTi25 z7 amp Carburetor 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 changes there may be some discrepancies in this manual Hyosung reserves the right to make changes at any time Please note that this manual applies to all specifications for all respective destinations and explains all equipments Therefore your model may have different standard features than shown in this manual
2. 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 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 s 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 N CAUTION 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 75 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 Hy
3. When the engine is warm 1 Apply the rear brake pedal 2 Squeeze the clutch lever open the throttle slightly and push the electric starter switch NOTE Operation of the choke is not necessary to start the engine Operation of the choke can make the engine hard to start due to too rich fuel air mixture 53 C 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 STARTING OFF 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 motorcycle during operation A 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 Sgueeze the clutch lever 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 movin
4. 15 A head lamp fuse protects the head lamp and high beam indicator lamp CAUTION Never use other than specified 30 A or 15 A fuse Installing a fuse of incorrect rating may seriously damage the electrical system You should consult your Hyosung dealer or a qualified service mechanic immediately 87 The fuse box is located under the rear seat If the engine suddenly stops running or any electrical system fails to operate then the fuse must be checked In case a fuse blows there is a 15 A spare fuse CAUTION Never use other than specified 15 A fuse Installing a fuse of incorrect rating may seriously damage the electrical system You should consult your Hyosung dealer or a qualified service mechanic immediately TROUBLESHOOTING This troubleshooting guide is provided to help you find the cause of some common complaints CAUTION Failure to troubleshoot a problem correctly can damage your motorcycle Improper repairs or adjustments may damage the motorcycle instead of fixing it Such damage may not be covered under warranty If you are not sure about the proper action consult your Hyosung dealer about the problem M 2 WHEN THE ENGINE REFUSES TO START 9 FUEL SUPPLY CHECK For 7125 If the engine refuses to start perform the following inspections to determine the cause Is there enough fuel in the fuel tank Is the
5. Check if it is locked The unlocking of rear seat could cause serious accident Don t allow water to get inside the trunk or it could damage 6 Don t keep the valuables in the trunk when leaving unattended Loading limit of trunk 1 kg 2 21 Ibs gt AN WARNING Do not operate for the ignition switch is in the OFF or LOCK position or the engine stop switch is in the 52 position while driving at one s pleasure 9 RIDING APPAREL AN 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 9 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 FAMILIARIZE YOURSELF WITH THE MOTORCYCLE AN 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 M KNOW YOUR LIMITS A WARNING Ride within the boundaries of your own skill at all times Knowing these limits and staying within them will help you t
6. 6 Position Install the gearshift link rod Tighten Torque Footrest mounting 2 2 3 5 kgf m bolt 22 35 N m Optional parts The gearshift link rod is optional parts 41 SIDE STAND SEAT LOCK l GT250 R EI amp GT125 R are equipped with the side stand ignition interlock System 1 If the transmission is in neutral you can start the engine regardless of the clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in the clutch lever and the side stand up Neutral Clutch Side Engine switch lever stand start 1 e A A Possible 2 A e e Possible 3 A e A Impossible 4 A A Impossible NOTE e OnorUp A Ofor Down M D AN WARNING Make sure that the side stand ignition interlock system is working properly before riding 42 The rear seat lock is located the frame cover under the front side of the rear seat To remove the rear seat insert the ignition key into the rear seat lock and turn it clockwise To reinstall the rear seat slide the seat hook into the seat hook retainer and push down firmly until the seat snaps into the locked position To remove the front seat remove the two front seat mounting bolts located the rear side of the front seat
7. 22 3 4 NAMES OF EACHPARTS c7z39 se 25 4 CONTROLS 28 IGNITION SWITCH IGNITION KEY INSTRUMENT PANEL LEFT HANDLE SWITCHES RIGHT HANDLE SWITCHES FRONT BRAKE LEVER ADJUSTMENT Only for erzesem rz CARBURETOR CHOKE LEVER For 5 7 125 REAR BRAKE PEDAL GEARSHIFT LEVER FOOTRESTS SIDE STAND SEAT LOCK TRUNK REAR SHOCK ABSORBER 5 SUPPLY OF GASOLINE AND ENGINE OIL 44 GASOLINE ENGINE OIL 6 RIDING TIPS_ 50 STARTING THE ENGINE STARTING OFF USING THE TRANSMISSION RIDING ON HILLS STOPPING AND PARKING 12 7 BREAKIN x43 94a REX AR a a ER 56 8 INSPECTION BEFORE RIDING 58 9 PERIODIC MAINTENANCE 60 10 INSPECTION AND MAINTENANCE 64 TOOL ENGINE OIL FUEL HOSE GASOLINE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT AND REAR SUSPENSIONS REAR VIEW MIRROR REFLECTOR BATTERY AIR CLEANER SPARK PLUG IDLING SPEED ADJUSTMENT THROTTLE CABLE PLAY ADJUSTMENT CLUTCH CABLE DRIVE CHAIN BRAKES TIRE BULBS 11 TROUBLESHOOTING 88 12 TRANSPORT 4 653 9 od IO Pepe ipe d e t 90 13 CLEANING PROCEDURE 90 14 STORAGE PROCEDURE 92 1S LABEL L nine dees A tok 94 16 SPECIFICATIONS 98 13 SERIAL NUMBER LOCATION The frame and or engine serial numbers are used to register the mot
8. FRONT TIRE REPLACEMENT 1 Place the motorcycle on the jack or block vertically CAUTION Improper jacking may cause damage to the frame or engine 2 Loosen the four front axle pinch bolts right and left 3 Loosen the front axle 2 4 Carefully position a jack or block under engine and raise until the front wheel is slightly off the ground 5 Draw out the axle shaft 6 Slide the front wheel forward 7 To reinstall the front wheel assembly reverse the sequence as described REAR REPLACEMENT 1 Place the motorcycle on the jack or block vertically NG Improper jacking may cause damage to the frame or engine CAUTION 2 Loosen the rear axle 1 engine and raise until the rear wheel is slightly off the ground A WARNING 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 Draw out the rear axle shaft 5 Pull the rear wheel assembly rear ward 6 To replace the rear wheel reverse the complete sequence listed 82 Keep fuel and other flammable substances away from electric components BULBS CAUTION Before changing a bulb set the ignition switch to position OFF and allow a few minutes for the bulb to cool down Wear clean gloves or use a clean dry cloth to
9. G HYOSUNG OWNER S MANUAL C 7 250 2 Ef Cr 7 125 roe A WARNING This owner s manual contains important safety information Please read it 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 BATTERY INITIAL CHARGING 1 BATTERY INITIAL CHARGING Initial charging of the battery is first charging after filling electrolyte for improvement of the battery durability 2 BATTERY INSTALLATION Fill the electrolyte to the battery Leave the battery for 30 minutes Charge the battery by standard charging necessarily Install the battery to the motorcycle STANDARD CHARGING TIME GT250 s 1 0 for 10 hours lt 77125 0 8 A for 10 hours CAUTION Do not use the battery without the battery initial charging Otherwise the battery may be shortened service life A WARNING GT250 R amp s amp 125 gt lt are started as the battery ignition system Do not permit to start or operate the throttle grip after started without the battery caused by damage to the electrical system Always start or ride these motorcycles with the battery lt 2 j JP GD 250 amp GY 4265
10. Muffler Rear carrier 09 Rear seat amp Trunk amp Tools Front seat ECU Engine Control Unit 3 Battery 82 Air cleaner 83 Front brake fluid reservoir 64 Front brake lamp switch 85 Engine oil filter 86 Engine oil filler cap 67 Engine oil level lens 88 Rear brake pedal 99 Rear brake lamp switch 4 Rear brake fluid reservoir NOTE means the invisible parts 18 NAMES OF EACH PARTS G77 250 27 exem Clutch lever Front brake lever Left handle switches Throttle grip Instrument panel Ignition switch Front brake fluid reservoir 9 Fuel tank cap Right handle switches Spark plug Front Head lamp Front turn signal lamp Ignition coil Front Ignition coil Rear Spark plug Rear Rear seat lock Fuses Brake Tail lamp Rear turn signal lamp License plate lamp Passenger footrests 02 Footrests 03 Gearshift lever Side stand Engine oil drain plug NOTE 5 means the invisible parts 20 G72se n Q9 Muffler 84 Front brake lamp switch Rear carrier 85 Engine oil filter Q8 Rear seat amp Trunk amp Tools 86 Engine oil filler cap Front seat amp Engine oil level lens ECU Engine Control Unit 99 Rear brake pedal Gp Battery 89 Rear brake lamp switch 82 Air cleaner Rear brake fluid reservoir 83 Front brake fluid reservoir NOTE 2
11. 0 SPEEDOMETER age D UN The speedometer indicates the road Speed in kilometers or miles per hour To change the speedometer display 1 Turn the ignition switch to the ON position 2 Pushing the switch in the normal mode turn the igniton switch to the OFF position and turn to the ON position again 3 Push the switch in the normal mode for 5 seconds continually until the speedometer display change A WARNING Obey the speed limit and traffic regulation at all times FI Fuel Injection CHECK LAMP It comes on for about three seconds whenever the ignition switch is set to position with the engine stopped as a test of injection system operation The check lamp must go off after three seconds If the electric fuel injection system fails the FI check lamp D comes and the LCD Liquid Crystal Display display panel indicates FI letters in following two modes The LCD display panel indicates FI letters and speedometer alternately and the FI check lamp comes on and remains lit The LCD display panel 40 indicates FI letters continuously and the FI check lamp 1 comes on and blinks The engine may continue to run in mode but the engine may not run in mode CAUTION Riding the motorcycle with the LCD display panel indicating a problem with electric fuel injection system and with FI check lamp lit
12. If this is not the case proceed as follows 2227 0 5 1 0 mm 0 02 0 04 6 Withdraw the protection Loosen the lock nut D 6 Rotate the adjuster 2 until achieving the specified free play When finished tighten the lock nut and check free play again 6 Refit the protection 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 A WARNING When finished turn the handlebars to make sure its movement does not affect the engine idle rpm and check that the throttle grip when opened and then released returns smoothly to the closed position d CLUTCH CABLE b At each maintenance 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 Q The clutch lever adjuster lock nut The clutch lever adjuster The rubber boot The clutch cable adjuster The clutch cable adjuster lock nut If you find the play of the clutch lever incorrect adjust it in the following way 9 CLUTCH CABLE PLAY ADJUSTMENT A basis adjustment be allowed by the clutch
13. WARNING in that section NS INSPECTION BEFORE RIDING A WARNING Failure to inspect the motorcycle before operating it can be hazardous Failure to perform proper maintenance can also be hazardous Failure to inspect and maintain your motorcycle increases the chances of an accident or equipment damage Always inspect your motorcycle each time you use it to make sure it is in safe operating condition Refer to the INSPECTION AND MAINTENANCE section in this owner s manual 27 A WARNING Operating these motorcycles with improper tires or with improper or uneven tire pressure can be hazardous If you use improper tires or improper or uneven tire pressure you may lose control of the motorcycle This will increase your risk of an accident Always use the size and type tires specified in this owner s manual Always maintain proper tire pressure as described in the INSPECTION AND MAINTENANCE section J WARNING Operating these motorcycles with improper modifications can be hazardous Improper installation of accessories or modification of these motorcycles may cause changes in handling In some situations this could lead to an accident Never modify these motorcycles through improper installation or use of accessories NG WA A WARNING Overloading these motorcycles or carrying or towing cargo improperly can be hazardous Overloading or improper to
14. replenish with the proper brake fluid that meets Hyosung s requirements Front Brake Rear Brake 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 AN WARNING Brake fluid may be harmful if swallowed or if it 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 A CAUTION N These motorcycles use 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 DOTA 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 9 BRAKE PADS Inspect the front and rear 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 The rate at which brake pads will wear depends on mo
15. A HELMET OBSERVE THE RESTRICTED SPEED DO NOT BE TOUCHED ON MUFFLER BECAUSE IT IS 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 GENUINE OIL 68319H05350 PL CAUTION DO NOT LOAD OVER MAXIMUM 1kg IN THE TRUNK DO PUT SOMETHING AFFECTED EASILY BY THE HEAT BECAUSE THE INSIDE OF TRUNK MAY BE HEATED DO NOT PUT VALUABLES OR FRAGILES IN THE TRUNK MAKE SURE THE SEAT WERE LOCKED IN CASE OF RIDING WITH UN LOCKED IT CAN CAUSE AN ABNORMAL RIDING OR DANGEROUS IN AN EMERGENCY WATER CAN COME INTO THE TRUNK ON WASHING AND ALSO BE CAREFUL WHEN SOMETHING IMPORTANT 5 PUT IN THE TRUNK DO NOT LAY CLOTH PIECE IN THE TRUNK UNDER THE SEAT IT CAN BE A CAUSE OF UNEXPECTED ACCIDENT e AN IMPROPER TIRE PRESSURE CAN CAUSE DIFFICULTIES IN HANDLING SERIQUS INJURIES OR DEATH BEFORE RIDING INSPECT THE TIRE PRESSURE DAMAGE ABNORMAL WEAR AND ETC ACCORDING TO THE INSPECTION BEFORE RIDING e ALWAYS MAINTAIN A PROPER TIRE PRESSURE AS SHOWN IN THE BELOW REAR 5 SOLO RIDING _29psi 2 00kG ar 32 51 2 25 1 DUAL RIDING 36 si 2 50kg or TIRE SIZE 110 70 17 54H 150 70 17 69H 68320HM8150 PL 95 S amp T MOTORS CO
16. The tachometer indicates the engine speed in revolutions per minutes rpm CAUTION Revving the engine into the red zone of the tachometer can cause severe engine damage Never allow the engine to rev into the red zone of the tachometer in any gear N 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 8 HIGH BEAM INDICATOR LAMP The high beam indicator lamp will come on when the head lamp high beam is turned on 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 5 FUEL METER 00000000109 E TGT250 R Es amp TGT125 2 5 the speedometer are LCD Liquid Crystal Display type it indicates the remaining fuel amount in the fuel tank The F Full mark indicates the fuel tank is full The mark indicates the fuel tank is empty or nearly so When the remaining fuel is approximately 3 4 Q the red lamp of E Empty mark comes on only Fill the fuel tank before the red lamp of E Empty mark came on only The fuel tank capacity is 17 0 0 CAUTION 6 ODOMETER TRIP METER The display in it has three functions odometer and two trip meters The display changes odometer or trip meter as indicated before turning t
17. are found the fuel hose must be replaced Replace the fuel hose every 4 years C GASOLINE Check if there is leakage from the fuel tank fuel pump hoses and electric fuel injection system 7 25 Ei Check if there is leakage from the fuel tank fuel pump fuel cock hoses and carburetor lt 77 125 RUBBER OF CABLES Wipe them up with a patch when washing EXHAUST PIPE AND MUFFLER Inspect the exhaust pipe and muffler joint for loosening FRONT AND REAR e SUSPENSIONS Periodically check for the following Keep the front brake lever pulled in and push down on the handlebars repeatedly to compress the front fork 6 The fork should compress in a smooth movement and must show no traces of oil on the legs Ensure that all components are properly tightened and check the front and rear suspension articulated joints for correct operation Inspect whether the steering stem is well assembled while moving front fork up downwards and or foreward backward CAUTION In the event of malfunction or if the suspension needs expert servicing contact an authorised Hyosung dealer C Check if the mirror shows the rear and or side views REAR VIEW MIRROR J Check if the reflector is dusty or damaged REFLECTOR 65 BATTERY INSPECTION OF BATTERY SOLUTION LEVEL The batter
18. can damage the engine and transmission Whenever the check lamp is lit and the display panel indicates have your authorized Hyosung dealer or a qualified mechanic inspect the electric fuel injection system as soon as possible M 33 NOTE If the LCD display panel indicates FI letters and speedometer alternately and the FI check lamp comes on and remains lit keep the engine running and bring your motorcycle to an authorized Hyosung dealer If the engine stalls try restarting the engine after turning the ignition switch off and on When the LCD display panel indicates CHE make sure that the engine stop switch is in the 9 position If the LCD display panel still indicates CHE after above procedure inspect the ignition fuse and connection of lead wire couplers 4 LEFT HANDLE SWITCHES GT7 250 Es D CLUTCH LEVER The clutch lever is used for disengaging the drive to the rear wheel when starting the engine or shifting the transmission gear Squeezing the lever disengages the clutch ACAUTION Use the clutch correctly Otherwise the clutch may be worn quickly PASS SWITCH Press the PASS switch to operate the head lamp high beam for using when pass ACAUTION Do not operate when the dimmer switch D position 8 DIMMER SWITCH Change the directio
19. contact an authorized Hyosung dealer CAUTION If the LCD display panel indicates FI letters and the FI check lamp comes on and remains lit it means that the electric fuel injection system is not operating correctly Stop the engine immediately and contact an authorized Hyosung dealer Do not use the motorcycle with disabled electric fuel injection system in order to avoid damaging the engine components 52 WHEN THE c7z257ze STARTING m When the engine is cold If the ambient temperature is below 5 40 F 1 Pull the choke lever to the ENGAGE position 2 Apply the rear brake pedal 3 Squeeze the clutch lever and push the electric starter switch 4 Immediately after the engine starts return the choke lever halfway 5 When the engine is sufficiently warmed up move the choke lever to the OFF position If the ambient temperature is at or above 40 F 1 Pull the choke lever to the ENGAGE position halfway 2 Apply the rear brake pedal 3 Squeeze the clutch lever and push the electric starter switch 4 When the engine is sufficiently warmed up move the choke lever to the OFF position f B NOTE If the ambient temperature is above 20 C 68 operation of the choke is not necessary to start the engine Operation of the choke can make the engine hard to start due to too rich fuel air mixture
20. every running 4 000 km The engine oil should always be changed when the engine is hot so that the engine oil will be drained thoroughly from the engine The procedure is as follows ENGINE OIL CAPACITY GT250 R ES GT125 Oil change 1 450 ml and filter change 1 500 ml Engine overhaul 1 800 md 1 650 m ACAUTION In case of the engine oil pouring excessively the engine output being made insufficient Be careful not to pour the engine oil excessively 1 Hold the motorcycle vertically CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions inspect 1 Quantity of Engine oil 2 Pollution degree of Engine oil before riding the motorcycle and then supplement and replace at any time to prevent damage of the engine 2 RNAOXSXUINKO 3 Place a drain pan under the egine 4 Drain the engine oil by removing the drain plug located on the bottom of the engine New and used oil can be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals Brief contact with used oil may irritate skin Keep new and used oil and used oil filters away from children and pets To minimize your exposure to used oil wear a long sleeve
21. exhaust system have cooled down 3 Hold the motorcycle vertically NOTE EN Position the motorcycle on firm and flat ground 2 45 4 Inspect the engine oil level through the engine oil level lens on the right side on the engine RNAOXSUUINKO NOTE Engine oil expands and oil level increases when the engine oil is hot Check and adjust engine oil level when the engine oil is not hot CAUTION J Fuel and Engine oil use certainly to recommend at the front part N CAUTION Operating the motorcycle with an incorrect amount of engine oil can damage your motorcycle Too little or too much engine oil can damage your engine Place the motorcycle on level ground Check the engine oil level with the engine oil level lens before each use of the motorcycle 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 1 mm under the Upper line mark F of the engine oil level lens In case of the engine oil pouring excessively the engine output being made insufficient Be careful not to pour the engine oil excessively 46 9 ENGINE OIL AND FILTER CHANGE Change the engine oil and filter after first running 1 000 km and
22. fuel reaching the carburetor from the fuel pump Disconnect the fuel hose from the carburetor and see if gasoline flows from the fuel hose If it has been determined that fuel is reaching the carburetor the ignition System should be checked next A 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 NG 9 IGNITION SYSTEM CHECK G7 250 R E 8 GTR 1 Remove the spark plug and reattach it to the spark plug lead 2 Put the engine stop switch in the O position and the ignition switch in the ON position Holding the spark plug base firmly against the engine the transmission in neutral the side stand up the clutch disengaged and push the electric starter switch If the ignition system is operating properly a blue spark should jump across the spark plug gap 3 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 4 If there is still no spark consult your Hyosung dealer for repairs 89 AS WARNING Performing the spark test improperly can be hazardous You could get a high voltage electrical shock or an explosion if you are not familiar with this proce
23. if necessary clean them with the special cleaners for spark plugs with an iron wire and or a metal brush 4 Energetically blow some air in order to prevent the removed residues from getting into the engine Change the spark plugs if it shows cracks on the insulating material corroded electrodes or excessive deposits 107 08 mm 0 028 0 022 in 5 Check the electrode gap with a thickness gauge The gap must be 0 7 0 8 mm 0 028 0 032 in if necessary adjust it 6 Make sure that the washer is in good condition Fit the washer and screw the spark plug finger tight to avoid damaging the thread 7 Tighten using the spanner supplied with the tool kit Screw in each spark plug by one half turn to compress the washer TIGHTENING TORQUE 20 25N m SPARK PLUG jo 25 kgf m PLUG REPLACEMENT GUIDE Hotter type CR7E Standard type CR8E Colder type CR9E A CAUTION The spark plug must be tightened firmly otherwise the engine may overheat and severe damage may occur Use recommended spark plugs only A spark plug of the wrong rating may shorten engine life and cause loss of performance M 2 8 Fit the spark plugs cap properly to prevent it coming off due to engine vibration IDLING SPEED ADJUSTMENT GT250 R Ei We suggest that you have G7 250 7 Es 5 idling speed adjusted by your authorized Hyosung dealer ACAUTION
24. ignition key to the OFF position Push down the ignition key from the OFF position come up again and turn it to the LOCK position Remove the ignition key AS WARNING Turning the ignition switch to the OFF or LOCK position while the motorcycle is moving can be hazardous Moving the motorcycle while the steering is locked can be hazardous You could lose your balance and fall or you could drop the motorcycle Stop the motorcycle and place it on the side stand if equipped before locking the steering Never attempt to move the motorcycle when the steering is locked M at 4 These motorcycles come equipped with two ignition keys Keep the spare key in a safe place IGNITION KEY INSTRUMENTPANEL CAUTION To adjust the light of speedometer G7250 Er display push the switch in the AN WARNING Operating the display while riding can be hazardous Removing a hand from the handlebars can reduce your ability to control the motorcycle Always keep both hands on the handlebars while riding P4 CAUTION When the ignition switch is tumed to the ON position the display of speedometer will come on 29 normal mode for 0 6 1 seconds while you want to change Light of speedometer display 100 75 50 25 CD TACHOMETER
25. lever adjuster 3 Loosen the lock nut counter clockwise Turn the clutch lever adjuster 3 in or out to acquire the specified play After end of adjustment tighten the lock nut clockwise fully and cover the rubber boot 4 If not adjust by the clutch lever adjuster adjust by the clutch cable 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 nut The clutch cable should be lubricated with a light weight oil whenever it is adjusted le JEMONE 4 mm 0 16 in 73 C 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 AN WARNING Riding with the chain in poor condition or improperly adjusted can lead to an accident DRIVE CHAIN Inspect adjust and maintain the chain properly before each ride according to this section J 9 INSPECTING THE DRIVE CHAIN When inspecting the chain look for the following 6 Loose pins Damaged rollers Dry or rusted links 6 Missing O ring seals Kinked or binding links 6 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 authorized Hyosun
26. the brake fluid and becoming the brake distance M A WARNING Replacing only one of the two brake pads can be hazardous Replacing only one brake pads result in uneven braking action Replace both pads together BRAKE DISK INSPECTION Check the brake disk for damage or cracks 9 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 NOTE The recommended brake fluid DOT3 or DOT4 CAUTION C TIRE Don t replenish with brake fluid over the limit line It will leak out of the brake fluid reservoir 6 Be careful not to allow dusts or water to go inside when it is replenished Don t use the unrecommended brake fluid 6 Brake fluid can damage severely the plastics or rubbers When it is spilt on the parts wipe them up immediately M 5 Fasten the cap 9 REAR 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 Tum the cap to the counter clockwise 4 Replenish with brake fluid to the upper line NOTE The recommended brake fluid DOT3 or DOT4 5 Fasten
27. 10 0 10 20 30 40 14 32 50 68 8 104 Temperature c F Use the chart to select a viscosity rating based on temperature range in your area NOTE In very cold weather below 15 5 use SAE 5W 30 for good starting and smooth operation Using a premium quality four stroke motor oil will increase the service life of your motorcycle AN WARNING Don t mix the unrecommended oil It could damage the engine When refilling the oil don t allow the dust to get inside Wipe the spilled oil up immediately Don t put the patch on the filler cap It could disturb the oil to be provided and damage the engine P NAMES OF EACH PARTS 72507 1 Clutch lever 6 Front brake lever Left handle switches Throttle grip Instrument panel Ignition switch 4 Front brake fluid reservoir Fuel tank cap Right handle switches GT 25052 059 o 1 1 3 T oR MAN OS L6 6 ON AS Spark plug Front Brake Tail lamp Front turn signal lamp Rear turn signal lamp Head lamp License plate lamp Ignition coil Front Passenger footrests Ignition coil Rear Q2 Footrests Spark plug Rear Q3 Gearshift lever Rear seat lock Side stand Fuses Q5 Engine oil drain plug NOTE dee means the invisible parts 17 ETOR
28. 255 means the invisible parts 21 NAMES OF EACH PARTS zz 2425 Clutch lever Right handle switches Left handle switches Front brake lever Carburetor choke lever Throttle grip 4 Instrument panel 9 Ignition switch 5 Front brake fluid reservoir Fuel tank cap 22 gt i YA NANG NG rus wd 553047 S ae Spark plug Front Rear turn signal lamp Front turn signal lamp License plate lamp Head lamp Passenger footrests Ignition coil Front Ignition coil Rear Spark plug Rear Rear seat lock Fuse Brake Tail lamp 03 Footrests Gearshift lever 5 Side stand Engine oil drain plug Throttle stop screw NOTE sce means the invisible parts 23 09 Muffler Q9 Rear carrier Rear seat amp Trunk amp Tools 8 Front seat Battery 93 Fuel pump 4 Air cleaner 85 Front brake fluid reservoir 46 Front brake lamp switch 87 Engine oil filter 88 Engine oil filler cap 99 Engine oil level lens 4 Rear brake pedal 4 Rear brake lamp switch 42 Rear brake fluid reservoir NOTE means the invisible parts NAMES OF EACH PARTS 7 225 GY 125 Clutch lever Right handle switches Left handle switches Front brake lever Carburetor choke lever Throttle grip 4 Instrument panel I
29. Carburetor lt Starter system ELECTRIC STARTER TRANSMISSION GY ABS xu GY ua Clutch Wet multi plate type lt Reduction ratio 3 690 Drive chain 428S0 136 Links 1st 2 750 lt 2nd 1 790 lt Transmission 3rd 1 350 lt 4th 1 090 lt 5th 0 910 lt CHASSIS LO 12V H3 55Wx1 GY 225 GY 125 Front suspension Telescopic type Rear suspension Swing arm type lt Caster 25 5 90 3 54 lt Steering angle 27 right amp left lt Front tire size 110 70 17 54H 4 Rear tire size 150 70 17 69H Front brake Disk lt Rear brake Disk 4 ELECTRICAL GY ABS GY um Ignition type CDI Ignition timing 13 B T D C at 2 000rpm LE 30 B T D C at 5 000rpm Spark plug CR8E lt Battery 12V 8Ah MF lt Fuse 15A Head lamp HI 12V H1 55W 1 HI 12V 60WX 1 LO 12V H4 55Wx 1 License plate lamp 12V W5W x1 Tum signal lamp 12V RY10W x4 Brake lamp LED type CAPACITIES GL 12S gt GY um Fuel tank 17 00 1 450 ml Oil change lt Engine oil 1 500 mQ Oil and filter change 1 650 m Engine overhaul lt 101 MEMO 102 MEMO 103 a Prepared by EF HYOSUNG S amp T Motors Co Ltd 1st Ed MAR 2009 Printed in KOREA y 1st
30. Do not adjust the idle speed to avoid variations of the cabruretion setting GT 125 re G7 125 7 are equipped one set of composed the two carburetors for efficiency increase of the two cylinder The carburetor is factory setting for the best carburetion Do not attempt to alter its setting There are two items of adjustment however under your care engine idle speed and throttle cable play CAUTION Never adjust adjust screw of the carburetor If adjust optionally exert a bad influence upon output of the engine as the two carburetor is disharmonious J To adjust the engine idle speed 1 Start up the engine and let the engine run until it warms up fully 2 After engine has warmed up turn the throttle stop screw 1 in or out so that the engine may run at 1 400 1 500 RPM 71 s WARNING Improper adjustment of the idle speed can be hazardous An idle that is too high can cause the motorcycle to lurch forward when you shift to first gear This may cause an accident Excessive engine wear may also result if idle speed is adjusted improperly or when the engine is not fully warmed up Adjust the idle to the correct speed Make sure the engine is fully warm before adjusting the idle speed M THROTTLE CABLE PLAY ADJUSTMENT There should be 0 5 1 0 mm 0 02 0 04 in free play in the throttle cable
31. ENANCE CHART specifies the minimun requirements for maintenance If you use your motorcycle under severe conditions perform maintenance more often than shown in the chart If you have any questions regarding maintenance intervals consult your Hyosung dealer or a qualified mechanic 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 CAUTION Lubricating switches can damage the switches Do not apply grease and oil to the switches 61 D Clutch lever holder amp Clutch cable 6 Speedo sensor 2 Passenger footrests pivot Brake lever holder 3 Drive chain Throttle cable Footrests pivot 9 Brake pedal pivot Side stand pivot and spring hook 9 Motor oil Grease X means the invisible parts 62 9 ENGINE EE Air cleaner element First 1 000 km Every 4 000 km Every 8 000 km Clean every 3 000 km Replace every 12 000 km Exhaust pipe nuts and muffler mounting bolts Tighten Tighten m Valve clearance adjust Inspect Inspect Cylinder head nut Tighten Tighte
32. Ed S amp T Motors Co Ltd Part No 99011 8110 MAR 2009 Printed in KOREA
33. 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 and NOTE have special meanings Information following these signal words should be carefully reviewed A WARNING The personal safety of the rider may be involved Disregarding this information could result in injury to the rider S 2 N CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine NOTE This provides special inform
34. LTD e9 92 61 0114 KM4MJ55B 87 dB A 5000 S amp T MOTORS CO LTD e9 92 61 0114 KM4MJ55A 87 dB A 5000 min 96 S amp T MOTORS CO LTD eg 92 61 0114 55 84 5250 min S amp T MOTORS CO LTD e9 92 61 0114 KMAMF55B 84 dB A 5250 97 SPECIFICATIONS DIMENSIONS AND DRY MASS GY 250 EX fT GY ZO ex ff Overall length 2 095 mm 82 5 in lt Overall width 720 mm 28 4 in 780 mm 30 7 in Overall height 1 135 mm 44 7 in 1 125 mm 44 3 in Wheelbase 1 430 mm 56 3 in Ground clearance 155 mm 6 1 in 175 mm 6 9 in Mass 185 kg 408 Ibs 175 kg 386 lbs ENGINE GT2SOR EU GT2SC ES air ud kana Number of cylinder V 2 oylinder Bore 57 0 mm 2 24 in lt Stroke 48 8 mm 1 92 in Piston displacement 249 15 2 in Compression ratio 10 2 1 lt Fuel system Electric fuel injection Starter system ELECTRIC STARTER lt _ lt TRANSMISSION GIRO EN GT2SOEN Clutch Wet multi plate type Reduction ratio 3 290 Drive chain 520HO 112 Links lt 1st 2 460 2nd 1 560 HL Transmission 3rd 1 190 lt 4th 0 960 lt 5th 0 840 lt 98 CHASSIS GY 250 BE GY ISO Front suspension Telescopic type lt Rear suspension Swing arm type lt Caster 25 5
35. To reinstall the front seat slide the seat hook into the seat hook retainer and install the two front seat mounting bolts C TRUNK REAR SHOCK ABSORBER 2 A small and light article such as maintenance manual or Owner s manual can be placed under the rear seat The tool kit is attached on the back side of the rear seat with a rubber band GI 250 Ei amp GT 125 are delivered from the factory with its adjuster set on position 2 Adjustment of the rear suspension is practicable position 2 to position 1 A WARNING N Don t adjust or rid the rear shock Loading limit of trunk 1 kg 2 21 Ibs absorber over position 3 WA 4 CAUTION 6 The trunk could be heated Don t keep anything that doesn t endure heat Don t keep the fragile Check if it is locked The unlocking of rear seat could cause serious accident 6 Don t allow water to get inside the trunk or it could damage Don t keep the valuables in the trunk when leaving unattended Ns 43 SUPPLY OF GASOLINE AND ENGINE OIL 4 GASOLINE 3 125 2 SESS TN RSR T 2 x To open the fuel tank insert the ignition key into the lock and turn it clockwise With the key inserted lift the cap up To close the fuel tank cap push the cap down firmly with the key in the cap l
36. Trail 90 mm 3 54 in Steering angle 27 right amp left Front tire size 110 70 17 54H lt Rear tire size 150 70 17 69H Front brake Double disk Disk Rear brake Disk Sa ELECTRICAL GY 250 RE GY 250 EJ Ignition type ECU Ignition timing 19 De 4 30 B T D C at 6 000rpm Spark plug CR8E lt Battery 12V 10Ah MF Fuse 30A amp 15A lt Head lamp HI 12V H1 55Wx 1 HI 12V 60WX 1 LO 12V 55Wx1 LO 12V H4 55Wx1 License plate lamp 12V W5W x 1 Tum signal lamp 12V RYTOW x4 Brake Tail lamp LED type CAPACITIES GGT 250 ER GG 250 ES Fuel tank 17 0 Q 1 450 ml Oil change Engine oil 1 500 mQ Oil and filter change 1 800 m Engine overhaul lt 99 DIMENSIONS AND DRY MASS GY LRO GY 125 Overall length 2 095 mm 82 5 in lt Overall width 720 mm 28 4 in 780 mm 30 7 in Overall height 1 135 mm 44 7 in 1 125 mm 44 3 in Wheelbase 1 430 mm 56 3 in lt Ground clearance 155 mm 6 1 in 175 mm 6 9 in 100 Mass 180 kg 397 Ibs 170 kg 375 lbs ENGINE GL 426 GY ua air 5 Number of cylinder V 2 cylinder lt _ Bore 44 0 mm 1 73 in 41 0 mm 1 61 in Piston displacement 124 7 7 6 in Compression ratio 113 1 lt Fuel system
37. anual 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 possible as close to the motorcycle and as near the center of gravity as is feasible The mounting brackets and other attachment hardware should be carefully checked to ensure that it provides for a rigid nonmovable mount Weak mounts can allow the shifting of the weight and create a dangerous unstable condition 2 Inspect for proper ground clearance and bank angle An improperly mounted load could critically reduce these two safety factors Also determine that the load does not interfere with the operation of the suspension steering or other control operations 3 Accessories fitted to the handlebars or the front fork area can create serious stability problems This extra weight will cause the motorcycle to be less responsive to your steering control The weight may also cause oscillations in the front end and lead to instability problems Accessories added to the machine should be as light as possible and kept to a minimum 4 The motorcycle may be affected by a lifting condition or by an instability in cross winds or when being passed or passing large vehicles Improperly mounted or poorly designed a
38. ar resulting in engine damage M A A WARNING Shifting incorrectly can be hazardous Engine and drive chain damage can occur if you do not shift correctly Slow down before downshifting and always release the throttle every time you shift gears CAUTION Rewing the engine into the red zone of the tachometer can cause severe engine damage Va M Never allow the engine to rev into the red zone of the tachometer in any gear N J 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 operating in its normal power range Shift rapidly to prevent the motorcycle from losing momentum 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 RIDING ON HILLS A WARNING Operating these motorcycles on steep hills can be hazardous Never operate these motorcycles on steep hills for these motorcycles 55 C STOPPING AND PARKING 1 Turn the throttle grip away from you to close the throttle completely 2 Apply the front and rear brakes evenly and at the same time 3 Downshift through the gears as road Speed decreases 4 Select neutral with the clutch lever squeezed towards the grip disengaged position just before the motorcycle Stops Neu
39. asoline from the fuel tank prior to transporting the 7 259 R Drain gasoline from the fuel tank and carburetor prior to transporting the 7125 1 6 Caution the rider and others near the GT250 R Ef amp GT125 R 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 gt 5 lt Ez amp e 225722 Modifications may make the motorcycle unsafe or illegal in your state A WARNING A WARNING lt 27 25 R amp s amp 77 125 2 1 are equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of the clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in the clutch lever and the side stand up Make sure that the side stand igintion interlock system is working properly before riding M P CAUTION The c7725o ze Ei amp always come on the head lamp meter lamp tail lamp and license plate lamp when the ignition switch was turned to the position The 77225 s lamps are come on by operating the light switch turning the ignition switch to the ON position Nc S Do not run the engine indoors or where there is little or no ventilation Exhaust gases contain car
40. ation to make maintenance easier or important instructions clearer WA 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 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 AN WARNING Before first use of the GT250 R Ei amp lt 77 125 2 1 read this owner s manual carefully to become familiar with these
41. bly 3 Disconnect the head lamp coupler 4 Remove the dust cover 3 and socket spring 5 After removing the bulb at the socket replace the new bulb 6 To install the head lamp reverse the above sequence TURN SIGNAL LAMP S BULB REPLACEMENT 1 Remove the lens by removing the screw 2 Pushing in the bulb turn it to the counter clockwise and pull it out 3 After stick in the new bulb assemble the lens A CAUTION Overtightening the screw may cause the lens to crack BRAKE TAIL LAMP S BULB REPLACEMENT 9 LICENSE PLATE LAMP S BULB REPLACEMENT ez 7250 z amp Es amp exT 125 24 5 brake tail lamp are LED Light Emitting Diode type If any abnormal condition are found replace the brake tail lamp assembly 86 1 Remove the lamp housing by unscrewing the screw 2 Pull out the socket 2 from the lamp housing 3 Pull out the bulb at the socket 4 Replace the new bulb 5 To install the license plate lamp reverse the above sequence 9 FUSE 1G7250 EF i GT125 R The fuse boxes are located under the rear seat If the engine suddenly stops running or any electrical system fails to operate then the fuses must be checked In case a fuses blow there is a 30 A for main and 15 A for head lamp spare fuse 30 A main fuse protects all electrical circuits
42. bly fuel level gauge accommodated inside the tank AS WARNING Refit the fuel tank cap after draining all fuel 90 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 motorcycle 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 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 J 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 0 Ignition switch Spark plugs Fuel tank cap Electric fuel injection system For a7 250 7e_ Ei Carburetor For a7 225 z Brake master c
43. bon monoxide a potentially lethal gas that is colorless and odorless Never leave the motorcycle running while unattended even for a short time AS WARNING While operating the 77 25e z Ef amp l 7125 1 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 A 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 WHEN KEEPING FOR LONG PERIOD 1 Supply enough the fuel in the fuel tank 2 Remove the battery from the motorcycle 3 For 772257z Drain wholly the fuel carburetor in the 2 WEAR A HELMET AN WARNING Motorcycle safety equipment starts with a quality safety helmet One of the most serious injuries that can happen is a head injury ALWAYS wear a properly approved helmet You should also wear a suitable eye protection CAUTION M 6 The trunk could be heated Don t keep anything that doesn t endure heat Don t keep the fragile
44. ccessories can result in an unsafe riding condition therefore caution should be used when selecting and installing all accessories 11 5 Certain accessories displace the rider from his or her normal riding position This limits the freedom of movement of the rider and may limit his or her control ability 6 Additional electrical accessories may damage the existing electrical system Severe overloads may damage the wiring harness or create a dangerous situation due to the loss of electrical power during the operation of the motorcycle When carrying a load on the motorcycle mount it as low as possible and as close as possible to the machine An improperly mounted load can create a high center of gravity which is very dangerous and makes the motorcycle difficult to handle The size of the load can also affect the aerodynamics and handling of the motorcycle Balance the load between the left and right side of the motorcycle and fasten it securely MODIFICATION 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 14 2 FUEL AND OIL RECOMMENDATION 55e 15 FUEL ENGINE OIL 3 1 NAMES OF 16 3 2 NAMES OF EACH PARTS creses 19 3 3 NAMES OF EACHPARTS amp 72
45. dure Do not perform this check if you are not familiar with the procedure Keep the spark plug away from the spark plug hole during this test Do not this test if you have a heart condition or wear a pacemaker 2 ENGINE STALLING 1 Check the fuel supply in the fuel tank 2 Check the ignition system for intermittent spark 3 Check the idle speed A CAUTION When occur any trouble the best way is to consult your Hyosung dealer for repairs TRANSPORT A WARNING Before transporting the motorcycle it is necessary to empty the fuel tank completely making sure that it is completely dry During transport the motorcycle must be firmly secured in an upright position to avoid fuel and oil leaks M DRAINING THE FUEL TANK WARNING Keep the fuel tank away from fires Allow some time for the engine and muffler to cool down completely Fuel vapours are harmful to human health Ensure the area is well ventilated before proceeding Do not inhale fuel vapours Do not smoke nor use naked flames Place the motorcycle on firm and level ground Stop the engine and wait until it has cooled down Prepare a container large enough to hold the fuel in the tank and place it on the floor on the left side of the motorcycle Remove the fuel tank cap Drain fuel using a manual pump or similar system Do not damage the fuel pump assem
46. e ON position The 7235 s lamps are come by operating the light switch turning the ignition switch to the ON capacity M position LLLA REPLACEMENT OF THE LAMP Requirement electric power of the lamp shown in the following 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 77 250 7 ADS 12V H1 55Wx 1 12V 55Wx 1 LED type 12V RY10Wx 4 Head lamp Brake Tail lamp Turn signal lamp 12V WW x 1 License plate lamp GT250 25 amp caua CAPACITY 12V 60Wx 1 12V H4 55Wx 1 H Head lamp LO 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 9 HEAD LAMP S BULB REPLACEMENT gt amp GTISE Brake Tail lamp LED type Turn signal lamp 12V RY10Wx 4 License plate lamp 12V WEWX 1 LED Light Emitting Diode We suggest that you have GOTOR 1 amp eras s head lamp bulb replaced by your authorized Hyosung dealer or a qualified service machanic r HEAD LAMP S BULB REPLACEMENT ems amp Eraz 1 Remove the head lamp cowling D 2 Remove the three screws 2 right left and bottom and the head lamp assem
47. e 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 D 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 The red lead wire must go to the positive D terminal and the black or black with white tracer lead wire must go to the negative O terminal Never charge a battery while still in the machine as damage may result to the battery or regulator rectifier C AIR CLEANER The air cleaner is located under the fuel tank 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 according to the following procedure CAUTION Never operate the engine without the element in position Operating the engine without the air cleaner element will increase engine wear Always be sure that the air cleaner element is in excellent op
48. e 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 Avoid pressing the starter switch when the engine is running or the starting motor damage 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 88 51 WHEN THE c75e ze Ei STARTING G7 250 ze is S Fl check lamp come on for about three seconds whenever the ignition switch is set to ON position and go off after three seconds Push the starter switch to start the engine after go off the FI check lamp CAUTION 6 If push the starter switch when FI check lamp D comes on the engine will be started badly and the spark plugs get wetted 6 If FI check lamp D does not come on when the ignition switch is set to ON position or fails to go out after three seconds whenever the ignition switch is set to ON position
49. en shifting from first to 2nd gear or 2nd gear to low neutral will be automatically skipped 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 A CAUTION When the transmission is in neutral the green indicator lamp on the instrument panel will be lit However even though the light is illuminated cautiously release the clutch lever slowly to determine whether the transmission is positively in neutral M J FOOTRESTS 9 FOOTREST POSITION ADJUSTMENT FOR ar2scx a amp cr amp Gras have 3 type of the footrest position right and left To change the position remove the M8 mounting bolts D and install the bolts to the desired position by using the hexagon spanner 6 mm GTO RES amp 7 are 9 GEARSHIFT LINK ROD delivered from the factory on position FOR erzo ar amp leors 6 OPTIONAL A WARNING M When adjusting the footrest position en Pe the M8 mounting bolts be torqued to the Snc iege proper specification appropriate riding position If they are not the footrest can come off Position unexpectedly Install the gearshift link rod 3
50. ening 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 The table below shows the maximum throttle opening recommendation during the break in period IA Less than 1 2 throttle Less than 3 4 throttle Up to 1 600 km 1 000 miles 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
51. erational condition The life of the engine depends largely on this single component 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 To remove the air cleaner 1 Remove the fuel tank 2 Remove the four screws 1 3 Pull up the air cleaner element 2 67 GT7 250 R Es 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 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 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 engi
52. erly installed have the motorcycle inspected by your Hyosung dealer or qualified mechanic 2 RIDING TIPS C STARTING THE ENGINE P 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 ON position 4 The engine stop switch is in the position 5 Moving the side stand to the fully upper position 6 Squeeze the clutch lever WARNING The a7 250 Ei amp GT125 R are equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of the clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in the clutch lever and the side stand up Make sure that the side stand igintion interlock system is working properly f before riding CAUTION The 725 En amp 7725 always come on the head lamp meter lamp tail lamp and license plate lamp when the ignition switch was turned to the ON position The 77235 5 lamps are come on by operating the light switch turning the ignition switch to the ON position 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 sever
53. first 160 km 100 miles AN 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 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 57 Timely performance of the 1 000 km 600 miles service will ensure optimum service life and performance from the engine N 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
54. g forward To shift to the next higher gear accelerate gently then close the throttle and squeeze the clutch lever 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 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 AN WARNING Do not operate for the ignition switch is in the OFF or LOCK position or the engine stop switch is in the 62 position while driving at one s pleasure A WARNING Opening the throttle suddenly can be hazardous The front wheel can lift off the ground and cause loss of control of the motorcycle Always open the throttle gradually when you accelerate M C USING THE TRANSMISSION 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 always select the most suitable gear for the prevailing conditions A WARNING Downshifting when engine speed is too high can 6 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 ge
55. g 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 Good 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 74 1 Hold the motorcycle vertically 2 Loosen the axle nut D 3 Adjust the slack in the drive chain by adjuster 3 as the chain adjust nut 2 turning toward the left and right 4 For alignment of the engine sprocket and the rear sprocket there are reference mark 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 a7 250 7 Ef 428SO for 72257 Use of another chain may lead to L premature chain failure
56. gnition switch 5 Front brake fluid reservoir Fuel tank cap 25 Spark plug Front Head lamp Front turn signal lamp Ignition coil Front Throttle stop screw Ignition coil Rear Spark plug Rear Rear seat lock Fuse Brake Tail lamp Rear turn signal lamp License plate lamp Passenger footrests Footrests Q5 Gearshift lever Side stand Engine oil drain plug NOTE means the invisible parts 26 GY 125 Q8 Muffler Rear carrier Rear seat amp Trunk amp Tools Gp Front seat Battery 83 Fuel pump 64 Air cleaner 85 Front brake fluid reservoir 66 Front brake lamp switch 67 Engine oil filter 88 Engine oil filler cap 99 Engine oil level lens 4 Rear brake pedal 4 Rear brake lamp switch Rear brake fluid reservoir NOTE means the invisible parts CONTROLS IGNITION SWITCH C 2 STEERING LOCK The ignition switch has three positions 9 ON POSITION The ignition circuit is completed and the engine can now start The key cannot be removed from the ignition switch in this position 9 OFF POSITION All electrical circuits are cut off The engine will not start The key can be removed 9 LOCK POSITION STEERING LOCK KEY 28 To lock the steering Turn the handlebars all the way to the left Turn the
57. h time the engine oil filter element is replaced Replace the oil filter cap 6 and tighten the nuts securely but do not over tighten them Replace the drain plug and tighten it securely At this time insert the gasket necessarily 10 Pour fresh engine oil through the engine oil filler hole Approximately 1 500 m of the engine oil will be required CAUTION Approximately 1 450 m of engine oil must be required when changing engine oil only without replacing the oil filter CAUTION In case of the engine oil pouring excessively the engine output being made insufficient M Be careful not to pour engine oil 11 Install the engine oil filler plug CAUTION Failure to use the correct oil can damage your motorcycle Engine damage may occur if you use the engine oil that does not meet Hyosung s specifications Be sure to use the engine oil specified in the FUEL AND OIL RECOMMENDATION section 49 12 Start the engine and allow it idle for a few minutes Check to see that no the engine oil is leaking from the oil filter cap and drain plug 13 Check the oil level according to Engine Oil Level Check procedure CAUTION BT Engine oil leaks from around the oil filter cap or drain plug indicate incorrect installation or the ring gasket damage If you find any leaks or are not sure that the oil filter cap drain plug has been prop
58. handle the new bulb Do not put your fingerprints on the bulb as this may lead to overheating and failure If you have handled the bulb with bare hands clean it with alcohol to avoid any damage DO NOT PULL ON THE WIRES NOTE Before changing a bulb check the fuses 9 INSPECTION OF LAMPS Check if the head lamp meter lamp tail lamp and license plate lamp work well when the ignition switch was turned to the ON position GT250 R es amp OTIS Check if the head lamp meter lamp tail lamp and license plate lamp work well by operating the light switch when the ignition switch was turned to the ON position zz zzs Check if the brake lamp work well when the front brak lever or rear brake pedal was operated Check if the turn signal lamp work well when the turn signal switch was operated Check if the head lamp tail lamp turn signal lamp and brake lamp are dusty or damaged EG7 250 7 amp Gigs Brake Tail lamp License Folate lamp e S signal lamp M Jl GT250 25 amp OTIL Turn signal lamp BE 1 License LZ DES Turn signal lamp 3 CAUTION CAUTION The 725 Een amp 25 always come on the head lamp meter lamp tail lamp and license plate lamp when the ignition switch was turned to th
59. he ignition switch off ODO TRIP 2588888 When the red lamp of mark comes on only you should add fuel to the fuel tank at the first opportunity to avoid L running out of fuel A CAUTION J For checking the fuel meter hold the motorcycle vertically and the ignition switch ON M J The odometer registers the total distance that the motorcycle has been ridden The two trip meters are resettable odometer They can register two kinds of distance at the same time For instance trip meter A can register the trip distance and trip meter B can register the distance between fuel stops To change the display push the switch in the normal mode for 0 6 1 seconds while the display indicates the odometer trip meter A or trip meter B you want to change CLOCK I indicates 12 hour mode TRIP m DD g 88 Follow the procedure below to adjust the clock Trip meter B 1 Push the switch in the normal mode for 2 seconds until the hour and To reset the trip meter to zero push the minutes display blink switch in the normal mode for 2 It is the clock reset mode seconds while the display indicates trip 2 Adjust the hour display by pushing the meter A or B you want to rese
60. itive terminal 2 Clean the outside of the battery with mild detergent and remove any corrosion from the terminals and wiring harness connections 3 Store the battery in a room above freezing TIRES Inflate the tires to the normal pressure EXTERNAL Spray all vinyl and rubber parts with rubber protectant Spray the unpainted surfaces with rust preventative Coat the painted surfaces with car wax MAINTENANCE DURING STORAGE Once a month recharge the battery The 7 250 amp z s battery standard charging time is 1 0 A X 10 hours The a7 225 ze s battery standard charging time is 0 8 A X 10 hours PROCEDURE FOR RETURNING TO SERVICE 1 Clean the entire motorcycle 2 Drain the engine oil and replace the engine oil filter amp engine oil with a new one 3 Reinstall the battery NOTE Be sure connect the positive terminal first then connect the negative terminal 4 Adjust the pressure of tires as described in the TIRE section 5 Remove the spark plugs and push several times the electric starter switch to start the engine Reinstall the spark plugs 6 Lubricate all places as instructed in this manual T Perform the INSPECTION BEFORE RIDING as listed in this manual 93 LABEL NOTE means the invisible parts A WARNING e BE FULLY AWARE OF THE OWNER S MANUAL BEFORE OPERATING AND RIDING MAKE SURE TO WEAR
61. l tank or cap Tank cap closed securely 59 WHAT TO CHECK CHECK FOR Gerashift damage lever lever Smooth operation Correct tension or slack Drive Adequate lubrication chain No excessive wear or damage Correct pressure Tires Adequate tread depth Nocracks or cuts Correct level and pollution Engine oil degree of engine oil Noengine oil leakage Lamp Operation of all lamps and indicators Horn Correct function Rear view mirror amp No dust or damage Reflector Engine Correct function stop switch Side stand Ignition interlock Proper operation switch Bolts and nuts are tight No rattle from any parts of General motorcycle with the condition engine running No visible evidence of damage ACAUTION 6 The engine and muffler are too hot right after engine stopped please be careful not to be burned Don t inspect the engine indoor where there is little or no ventilation available The exhaust gas is extremely poisonous PERIODIC MAINTENANCE The chart indicates the intervals between periodic service in kilometers At the end of each interval be sure to inspect 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
62. motorcycles s features and safety and maintenance requirements Review all instructions requirements and warnings Keep the owner s manual in the owner s manual storage compartment located under the rear seat Before the rider s first use of the GT250 R Ei 1 lt 7125 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 l GT250 R Ei 8 lt 27125 find a level open area for the rider to use to become familiar with the operation of controls and the operating and handling characteristics ofthese motorcycles 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 58 of this owner s manual Make sure the rider wears a helmet eye protection and protective clothing gloves leather or heavy cloth pants long sleeved shirt or jacket boots Permit use only by two passenger These motorcycles are designed for use only by two passenger Do not permit anyone to operate the GT250 R Ei amp 7125 amp under the influence of alcohol 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 6 Drain g
63. n Spark plug Clean Clean Replace Inspect Inspect Fuel hose Replace every 4 years Engine oil Replace Replace Engine oil filter Replace Replace Idle speed Inspect Inspect Throttle cable Inspect Inspect Clutch x Inspect Inspect 9 CHASSIS First Every Every a Se eM 1000km 4 000km 8 000km Drive chain Clean and lubricate every 1 000 km Brake Inspect Inspect a Brake hose d Inspect Inspect Replace every 4 years Brake fluid Inspect Inspect Replace every 2 years Tire Inspect Inspect Steering x 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 M 63 INSPECTION AND MAINTENANCE 4 TOOL To assist you in the performance of periodic maintenance a tool kit is supplied The tool kit is attached on the back side of the rear seat with a rubber band The tool kit consists of the following items NO NAME 1 Tool bag 2 10 x 12 mm open end spanner 3 Spark plug wrench 4 Combination screw driver 5 Screw driver handle 9 ENGINE OIL Check if there is leakage from the crankcase oil hoses and oil cooler FUEL HOSE Inspect the fuel hose for damage and fuel leakage If any defect
64. n of the head lamp light ED The head lamp high beam comes on The high beam indicator lamp also comes on 20 The head lamp low beam comes on A WARNING Set the dimmer switch when other vehicle is running in front or against TURN SIGNAL SWITCH Using when left right turn or change direction 41 Position Flash the left turn signal lamp 2 C Position Flash the right turn signal lamp A OFF Pushing the A position will stop the turn signal lamp to operate 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 M gt HORN SWITCH Press the switch to operate the horn A CAUTION Use the horn switch only in case of need Va N GT250 R Ei amp GTIS ER RIGHT HANDLE SWITCHES D ENGINE STOP SWITCH ij Position Using when dangerous condition 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 others The ignition circuit is on and the engine can run WARNING Do not operate for the engine stop switch is in the amp j position while driving at o
65. ne 6 Be careful not to allow water to go into the element while washing 68 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 L A WARNING Operating the engine without the air cleaner element in place can be hazardous Never run the engine without the air cleaner element in place 9 AIR CLEANER OIL DRAIN PLUG GT 250 r Ei Inspect the plug and drain water and oil at the periodic maintenance interval The air cleaner oil drain plug 1 is located beneath the air cleaner case 4 SPARK PLUG Check the spark plugs every time a scheduled maintenance service is performed At regular intervals remove the spark plugs and clean off any carbon deposits or replace as required To remove and clean the spark plugs AN WARNING Before carrying out the following operations let the engine and the muffler cool down to ambient temperature in order to avoid burns 1 Disconnect spark plug caps 2 Remove all the dirt from the base of the spark plugs then unscrew it and extract it from its seat taking care that neither dust nor other substances enter the cylinder 3 Make sure that there are neither carbon deposits nor corrosion marks on the electrode and on the central part
66. ne s pleasure FRONT BRAKE LEVER The front brake is applied by sgueezing 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 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 A WARNING Avoid turning the throttle grip during brakes HAZARD WARNING SWITCH For GT250 R s amp Leors A 1 All four turn signal lamps and indicator lamp will flash simultaneously when the switch is turned on with the ignition switch in ON position e The turn signal lamps and indicator lamp go off Use the hazard warning switch to warn other traffic during emergency parking or when your motorcycle could otherwise become a traffic hazard CAUTION Put out the hazard warning switch directly after used If the motorcycle ride with the hazard warning switch turned on condition other driver confuse and the battery s service life is shortened as electrical consumption CAUTION GT250 R 4 8 GTA always come on the head lamp meter lamp tail lamp and license plate lamp when the igniti
67. o avoid accidents 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 slippery Use extreme caution at railway crossings and on metal gratings and bridges Whenever you have a doubt about road condition slow down 10 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 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 m
68. ock A WARNING Do not overfill the fuel tank Stop adding fuel when the fuel level reaches the bottom of the filler neck If you fill the tank beyond this level fuel may overflow when it expands due to engine heat or heating by the sun AN WARNING Gasoline is extremely flammable and toxic Always observe the following precautions when refueling your 250 R Ei amp eT 125 Never permit motorcycle 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 M 2 C 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 ENGINE OIL 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 A WARNING The engine and the components of the exhaust system become very hot and remain hot for some time after the engine has been stopped Before handling these components wear insulating gloves or wait until the engine and the
69. on switch was turned to the ON position L 4 2 LIGHT SWITCH Only for 77225 2 position The head lamp comes on 2 DOS position The meter lamp tail lamp and license plate lamp come on But the head lamp not come on position All lamps go off NOTE The s lamps are come by operating the light switch turning the ignition switch to the ON position amp STARTER SWITCH Use this switch to operate the starting motor With the ignition switch in the ON position the engine stop switch in the CY position and the transmission is in neutral squeeze the clutch lever and the side stand up and push the starter switch to start the engine l GT250 R js Fl check lamp comes on for about three seconds whenever the ignition switch is set to ON position and go off after three seconds In case of GT250 R push necessarily the starter switch to start the engine after go off the FI check lamp N A CAUTION In case of c7 25e ze if push the starter switch when FI check lamp comes on the engine will be started badly and the spark plugs get wetted 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 hamess and starting motor If the engine does no
70. orcycle 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 right side of the steering head tube The engine serial number 2 is stamped on the left upside of the crankcase assembly 14 Please write down the numbers in the box provided below for your future reference Frame number Engine number FUEL AND OIL RECOMMENDATION C FUEL Use unleaded gasoline with an octane rating of 91 or higher Unleaded gasoline can extend spark plug life and exhaust components life CAUTION Spilling gasoline can damage the painted surfaces Be careful not to spill any fuel when filling the fuel tank Wipe spilled gasoline immediately WARNING When refueling always shut the engine off and turn the ignition key to the OFF position Never refuel near the flames sparks and heat sources Do not overfill the fuel tank Do not fill the fuel tank above the entrance lower end 15 C E ENGINE OIL SPECIFICATION ENGINE OIL Classification system API Over SL SAE 10W 40 X If a SAE 10W 40 motor oil is not available select alternative according to the following chart DT il 20W50 EXE DEI SEDI 15W40 15W50 AGA LA I RN 10W40 ENGINE OIL 10W50 30 20
71. osung chain lube or an equivalent that is specifically intended for use with O rings chains C l GT250 R amp 7125 2 utilize front and rear disk brakes 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 A WARNING Failure to properly inspect and maintain your motorcycle brake systems can be hazardous BRAKES Improper maintenance of the brakes increases your chances of having an accident Be sure to inspect the brakes before each use of the motorcycle according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE 76 MERE Operating the motorcycle in harsh condition can be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accelerated brake wear This could lead to an accident If you operate your motorcycle under these conditions the brakes must be inspected more often than recommended in the MAINTENANCE SCHEDULE 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 holding the motorcycle upright inspect the brake pad s wear condition If the brake pad s wear condition is good
72. p T125 R s 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 is warm you do not need to use the choke system for starting ACAUTION If you keep running in condition of the full choke lever causes fuel excess exhaustion high speed not to run it may damage the spark plugs REAR BRAKE PEDAL C GEARSHIFT LEVER Depressing the rear brake pedal will apply the rear brake The brake lamp will be illuminated when the rear brake is operated AN WARNING Apply the brake lightly and with great care on slippery surfaces to avoid skidding 39 NGT 250 RE amp exr125 z have a 5 speed transmission which operates as shown To shift properly squeeze 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 and 2nd gear It is not possible to upshift or downshift more than one gear at a time Wh
73. precautions specified by the manufacturers INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe For extended life of your motorcycle lubricate according to LUBRICATION POINTS 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 washing motorcycle riding at slow speed If necessary apply brakes several times to let friction dry out the pads 2 Follow the procedures in the INSPECTION BEFORE RIDING section to check your motorcycle for any problems that may have arisen during your last ride 92 STORAGE PROCEDURE If you don t plan on using your motorcycle for a long time it will need special servicing requiring appropriate materials equipment and skill For this reason Hyosung recommends that you trust this maintenance work to your dealer If you wish to service the machine for storage yourself follow the general guidelines below MOTORCYCLE Clean the entire motorcycle Place the motorcycle on a firm flat surface where it will not fall over Turn the handlebars all the way to the left and lock the steering and remove the ignition key FUEL Fill the fuel tank to the top with fuel BATTERY 1 Remove the battery from the motorcycle NOTE E sure to remove the negative sid first then remove the pos
74. shirt and moisture proof gloves such as dishwashing gloves when changing oil If oil contacts your skin wash thoroughly with soap and water Launder any clothing or rags if wet with oil Recycle or properly dispose of used oil and filters 2 WARNING The engine oil temperature may be high enough to burn you when the drain plug is loosened Wait until the drain plug is cool enough to touch with bare hands before draining oil Do not touch the hot muffler or the hot muffler can burn you J CAUTION Necessarily confirm and clean the oil strainer when replace the Engine oil specially when first replacement 5 Remove the three nuts 3 holding the filter cap 6 in place 48 6 Replace the engine oil filter 7 with a new one CAUTION Insert the oil filter so that surface of the ENGINE OIL FILTER oil filter hole turn toward the engine INSTALLATION INSERTED DIRECTION LUSTER ANG MATERIAL HYOSUNG 16510H05240 CAUTION M When install the engine oil filter necessarily HYOSUNG character and 16510H05240 part s NO be installed toward the outside otherwise can damage the engine Before replacing the engine oil filter cap be sure to check that the engine oil filter spring and the ring 5 are installed correctly Use new O ring eac
75. sure 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 CRACKS AND CUTS 2 00 2 00 kg cr 1 there are visible cracks and cuts FRONT 200 kpa 200 kpa 2 there are abnormal wears 29 0 psi 29 0 psi 2 25 2 50kg ar a REAR 225 kpa 250 kpa SCREW 320psi 36 0 psi FOREIGN MATERIAL OVER NORMAL SHORT WORN If there are some problem with the tirepressure or cracks and cuts it will m decrease the riding stability and lead to flat tire M ABNORMAL WEARS j iN 80 TIRE TREAD CONDITION Tirewear Tire wear indicator 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 GT250 Ei amp c7 125 are 110 70 17 54H for front and 150 70 17 69H 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 9 REAR AXLE NUT Inspect the rear axle shaft and jointing nut for loosening 81 9 TIRE REPLACEMENT
76. t switch 9 in the clock reset mode for 0 6 1 seconds 3 Adjust the minutes display by pushing the switch in the clock reset mode for 0 6 1 seconds 4 Push the switch in the clock reset mode for 2 seconds to resume in the normal mode CLOCK ADJUSTMENT Switch Push it for Adjustment Normal Select 2 seconds Normal mode Clock reset mode Reset 0 6 1 seconds Increase the hour of clock Select 0 6 1 seconds Increase the minutes of clock Select 2 seconds Clock reset mode Normal mode 31 SELECT SWITCH Use this switch to adjust the following e In the normal mode Push it for Adjustment 06 1 To adjust the light of SECON ds speedometer display 100 75 50 25 100 2 seconds Normal mode Clock reset mode e In the clock reset mode Push it for Adjustment 4274 Increase the minutes of clock seconds Clock reset mode 2 seconds Normal mode 9 RESET SWITCH Use this switch to adjust the following e In the normal mode Push it for Adjustment 0 6 1 Odometer Trip meter A seconds Trip meter B Odometer Reset the trip meter to zero 2 seconds while the display indicates trip meter A or B e In the clock reset mode Push it for Adjustment 0 6 1 Increase the hour of clock seconds
77. t start after several attempts check the fuel supply and igintion system Refer for Page 88 37 AN WARNING M GT250 R amp s amp G7 125 7 are equipped with the side stand ignition interlock system 1 If the transmission is in neutral you can start the engine regardless of the clutch lever and side stand 2 If the transmission is not in neutral you can only start the engine with pulling in the clutch lever and the side stand up Make sure that the side stand igintion interlock system is working properly before riding FRONTBRAKELEVER 7 ADJUSTMENT NG Only for Fes cm J The distance between the throttle grip and the front brake lever is adjustable among six positions To change the position push the brake lever forward and turn the adjuster to the desired position When changing the brake lever position always be sure the adjuster stops in the proper position a projection of the brake lever holder should fit into the depression of the adjuster The f ez sezzerms is delivered from the factory with its adjuster set on position 6 Position 1 provides the widest distance and position 6 provides narrowest distance A WARNING Naver attempt to change the front brake lever position while riding or you may lose control CARBURETOR CHOKE LEVER For lt 27 125 7 125 The am
78. the cap 9 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 REAL 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 79 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 a 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 ee 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 pres
79. 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 A WARNING Improper maintenance or failure to perform recommended maintenance increases the chance of an accident or motorcycle damage Always follow the inspection and maintenance recommendations and schedules in this owner s manual Ask your Hyosung dealer or a qualified mechanic to do the maintenance items marked with a pentagram You may perform the unmarked maintenance items by referring to the instructions in this section if you have mechanical experience If you are not sure how to do any of the jobs have your Hyosung dealer or a 5 qualified mechanic do them A WARNING Running the engine indoors orina 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 fresh air Va A 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 NOTE The MAINT
80. torcycle usage riding style and road surface condition J Limit line 2 KI SSSR ESS 2 77 Inspect every day in the following point at the brake system Brake fluid leakage of the front and rear brake system Leak or damage of the brake hose 3 Operating of the brake lever and pedal Wear of the front and rear brake pads A CAUTION The front and rear brake system be replaced the brake hose or the brake fluid according to periodic inspection chart by your authorized Hyosung dealer for safety as in times of operating at high pressure M 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 A WARNING If brake pads were allowed to wear down until uncovering the metal substrate metal to metal contact with the brake disk would lead to rattle and the brake caliper sparking this would result in loss of braking and brake disk damage cousing a dangerous riding conditions 7 78 CAUTION After replaced the front and rear brake pads squeeze depress and release several times the brake lever pedal so that itis setting at the original place Then do not ride the motorcycle untill operating
81. tral position can be confirmed by observing the neutral indicator lamp A WARNING 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 AN WARNING Hard braking while turning may cause wheel skid and loss of control Brake before you begin to turn 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 AN WARNING Following another vehicle too closely can lead to a collision As vehicle speeds increase stopping distance increases progressively Be sure you have a safe stopping distance between you and the vehicle in front of you 5 Park the motorcycle on a firm flat surface where it will not fall over AN WARNING 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 children are not likely to touch the muffler M 6 Turn the ignition key to the OFF position 7 Push down the ignition key from the OFF position come up again and turn it to the LOCK position 8 Remove the ignition key 56 BREAK IN The op
82. wing could cause changes in motorcycle handling which could lead to an accident Never exceed the stated load capacity for these motorcycles M gt Check the condition of the motorcycle to help make sure that you do not have mechanical problems or you might get stranded somewhere when you ride Before riding the motorcycle be sure to check the following items Be sure your motorcycle is in good condition for the personal safety of the rider and protection of the motorcycle 58 AS WARNING Checking maintenance items when the engine is running can be hazardous You could be severely injured if your hands or clothing gets caught in moving engine parts Shut the engine off when performing maintenance checks except when checking the lamp engine stop switch and throttle Smoothness Steering No restriction of movement No play or looseness Correct play in the throttle cable Smooth operation and positive return of the throttle grip to the closed position Throttle Correct lever play Clutch Smooth and progressive action Proper operation Fluid level in the reservoir to be above LOWER line Correct pedal and lever Brakes play No sponginess No fluid leakage Brake pads not to be worn down to the limit line Suspension Smooth movement Enough fuel for the planned distance of operation Fuel Fuel hoses connected securely No damage to fue
83. y is located under the front seat MF Maintenance Free battery of airtight type is used for these motorcycles It is not necessary to inspect or supplement the battery fluid However have your dealer check the charging condition of the battery periodically CAUTION 6 Do not remove absolutely the airtight Cover as the 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 WARNING Never invert the battery cables Ensure that the ignition switch is in position OFF before connecting or disconnecting the battery otherwise some components might damage 9 CHECK AND CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Set the ignition switch OFF position 2 Remove the front seat 3 Check that battery lead wire and terminal 4 If necessary disconnect the negative O battery wire first then disconnect the positive CD 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 D battery wire first then connect the negative battery wire 66 CAUTION Keep th
84. ylinders Oil cooler fins Snorkel air intake for air cleaner S CAUTION Do not use parts cleaner to throttle body and electric fuel injection sensors Use a garden hose at low pressure to remove the majority of dirt or other debris Wash your motorcycle by hand with a mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure 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 91 WINDSHIELD CLEANING Clean the windshield with a soft cloth and warm water with a mild detergent If scratched polish with commercially available plastic polish Replace the windshield if it becomes scratched or discolored so as to obstruct view When replacing the windshield use a Hyosung replacement windshield CAUTION Cleaning with any alkaline or strong acid cleaner gasoline brake fluid or any other solvent will damage the windshield N Clean only with a soft cloth and warm water with a mild detergent 2 WAXING THE MOTORCYCLE After washing the motorcycle waxing and polishing are recommended to further protect and beautify the paint Only use waxes and polishes of good quality When using waxes and polishes observe the

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GT250R ³»Áö - Hyosung Motos Schweiz