GT 125 R GT 250 R
Contents
1. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque a w N ES Apply THREAD LOCK 1324 Apply oil Use engine oil unless otherwise Q specified Apply or use brake fluid AGH Apply SUPER GREASE A 1 KZ Measure in voltage range AOH Apply SUPER GREASE C jal Measure in resistance range AH Apply SILICONE GREASE ij EX Measure in current range AH Apply MOLY PASTE Use special tool Apply BOND 1215 LLC Use engine coolant OD AJI A Use fork oil GENERAL INFORMATION CONTENTS EXTERIOR ILLUSTRATION eee SPECIFICATIONS rr 1 6 GENERAL INFORMATION EXTERIOR ILLUSTRATION Ge 25052 Copper 125 zo Turn signal lamp Rear Rear reflector g 655 WIDTH Head lamp Turn signal lamp Front Passenger footrests OE 1 125 HEIGHT 1 435 WHEEL BASE 2 060 LENGTH SPECIFICATIONS DIMENSIONS AND DRY MASS GENERAL INFORMATION 1 8 ITEM CHEF 250 ZE Corner 125 Ze Overall length 2 060 mm 81 1 in lt Overall width 655 mm 25 8 in lt Overall height 1 125 mm 44 3 in lt Wheelbase 1 435 mm 56 5 in lt Ground clearance 130 mm 5 1 in lt Mass 185 kg 402. GT 125R GT 250 R Euro 2 karburatormodel ServiceManual Se ogs FI Service Manual for indspr jtnings delene og GT 250 Naked for vrige service information zn SCANDINAVIAN MACHINERY IMPORT ApS Holtvej 8 10 Horuphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 FOREWORD This manual contains an introductory description on HYOSUNG Coms 25022 amp Coma 125 and procedures for its inspection service and overhaul of its main components It covers the differences from Comma 250 125 and please refer to the service manual of Cormsr250 125 99000 94710 for others which are not covered in this manual This page numbers on the top are ones which are in the service manual of Cas 250 125 and ones on the bottom are the page numbers in this manual Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service This manual has been prepared on the basis of the latest specification at the time of publication If modification has been made since then difference may exist between the content of this manual and the actual vehicle
3. Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual vehicle exactly in detail AS WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION HYOSUNG MOTORS amp MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC 2006 Corne 250 amp Come 125 NOTE Difference between photographs and actual motorcycles depends on the markets 2 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections are listed on the previous page as GROUP INDEX select the section where you are look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively
4. 06 10 2 8 1 PERIODIC MAINTENANCE CLUTCH FOOTREST POSITION ADJUSTMENT CENE 25032 amp Comet 125 have 3 type of the footrest position right and left To change the position remove the 8mm wrench bolts and install the bolts to the desired position by using the hexagon wrench 6mm Const 25022 amp Comer I25 are delivered from the factory on position WARNING When adjusting the footrest position the 8mm wrench bolts be torqued to the proper specification If they are not the footrest can come off unexpectedly MW Footrest mounting bolt 122 35N m 2 2 3 5 kgf m POSITION 11 PERIODIC MAINTENANCE 2 8 2 GEARSHIFT LINK ROD FOR Comes OR amp Comet 12572 8 OPTIONAL PARTS DID DD When the footrests in position exchange the gearshift link rod for appropriate riding position Position Wor Install the gearshift link rod amp Cp NW Position Optional parts Install the gearshift link rod NOTE The gearshift link rod is optional parts 12 ELECTRICAL SYSTEM CONTENTS zA T VEEE eu A E E EE Notes 14 5 16 1 ELECTRICAL SYSTEM 5 16 1 LAMP HEAD LAMP m REPLACEMENT OF HEAD LAMP BULB amp Remove the under cowling Refer to page 6 1 2 3 Remove the body
5. 27 REMOVAL AND DISASSEMBLY amp Remove the under cowling and body cowling Refer to page 6 1 2 5 Take off the front wheel Refer to the service manual les 250 125 99000 94710 page 6 2 Remove the four bolts and front fender Take off the front fork Refer to the service manual C yras 250 125 99000 94710 page 6 14 29 6 28 CHASSIS Remove the handlebar clamp bolts Remove the steering stem head nut D and take off the steering stem upper bracket 2 Remove the steering stem nut and draw out the steering stem Clamp wrench 09940 10122 Take off the steering stem lower bracket CAUTION Hold the steering stem lower bracket by hand to prevent from falling Remove the upper and lower bearings Remove the outer race fitted on the steering stem This can be done with a chisel Draw out the two inner races fitted to the top and bottom ends of the head pipe 30 INSPECTION Inspect and check the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear Abnormality operation of bearing Worn or damaged races Distortion of steering stem REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal and also carry out the following steps Apply SUPER GREASE A to the upper bearing and low
6. 8 Ibs 180 kg 397 lbs ENGINE ITEM COTE 250 ZE CONE 125 FR Type Four stroke DOHC Air cooled and oil cooled lt Number of cylinder V 2 cylinder lt Bore 57 0 mm 2 24 in 44 0 mm 1 73 in Stroke 48 8 mm 1 92 in 41 0 mm 1 61 in Piston displacement 249 om 15 2 in 124 7 cm 7 6 in Carburetor BDSR26 TYPE DOUBLE lt Starter system Electric starter Lubrication system Wet sump lt TRANSMISSION ITEM Com 250 Ze Copper 125 Clutch Wet multi plate type lt Transmission 5 speed constant mesh lt Gearshift pattern 1 down 4 up lt Final reduction 3 290 3 690 Gear ratio 1st 2 460 2 750 2nd 1 560 1 790 3rd 1 190 1 350 4th 0 960 1 090 5th 0 840 0 910 Drive chain 520HO 112 links 428HO 136 links 1 9 GENERAL INFORMATION CHASSIS ITEM CHEF 250 ZE Corner 125 Front suspension Telescopic type lt Rear suspension Swingarm type lt Steering angle 27 right amp left lt Caster 25 5 lt Trail 90 mm 3 54 in lt Front brake Double disc brake Disc brake Rear brake Disc brake lt Front tire size 110 70 17 54H lt Rear tire size 150 70 17 69H lt Front fork stroke 120 mm 4 72 in lt ELECTRICAL ITEM COR 250 ZE CONNEC 125 FZ Ignition type CDI type lt Ignition timing 13 B T D C at 2 000 rpm an
7. Ay CAUTION Do not use except the specified bulb Wattage NOTE VFD Vacuum Fluorescent Display 34 VFD Level type SERVICING INFORMATION 7 31 35 WIRING DIAGRAM 1898 DEJE UPM MOIISA FA 1898 SWUM YIM ENIE MT RUM M eng 1 19921 POY YIM SUM YM 13921 pay YIM 9819 Ya nq 417 qS keg 19 1898 DEJE YIM SUM EM 1898 SHYAN YM MOJE ME peu y vad 9 19981 SJIUAA UM PSY MY 1998 UB91 YIM yORIG Dg eBuelO O UMOIg Jg 1898 198 g YIM pay gy MORA use yudi 67 yg g 40109 YIM UTHOLIMS 3 TONVH MIS NOLLINOI EE
8. E Lecce rer De er LU Le O13NOVN EE MS NUS 308 NSOH Los OO i ssa amwa WNOISNEAT or OO NO i san mi ka sen A nololo soon I HIVI __HOLOW HOLIMS 1 30010 0 20 mM Q FIT fora i ANIONS Rove valyvis IAS Svd pa 61 oog i A 2 na 18 y UAN KA RIE Z NTI a Yo sas ne L j 915 AGUA A Ask 19 8 i 8 il 39 19 eee MB 88 B o a4 ae FEN els Ta ABBA KOH SSNs Y SEE AAA 19 VY 88 8 O MA A KOS BG 08 AB m a S cus O M A M 45 amp 61 BB M UT NENL IS T ao 8 me CR I i dOLS 8 TIVL aM am Ma Ma sal dAVT 3SN39N I PRESA ENE is UTNYNL IS 8 ma S dINYT NOLLISOd BM 49 O 80 x U 3 Ma E M9 0809 anna C Ima TT3 a ME BA 2 4 Z Z sm o g g ptet INT OH M8 0 d 5 V V i is M YA 2 r RB 2098 momo RA RA M LIII amp 3 e EL hos TL 10991 130 230 230 EE ma ret FI 6 lave 6 lino letolno ofo xo ofojmj lofojHsna A pp HON dOLS 3NION3 TH NUNI 1i YOLVINO3Y NN ao au 619 Y Y SE ADS 4NHNLH DISNENL INV AV3H AA Lines je ee 2008 me Sanyo EN UN HOLIMS STON EGP Ss M S Siva IU AVIASIA SE Prepared by HYOSUNG MOTORS amp MACHINERY INC 1st Ed JUL 2006 Manual No 99000HR8310 Printed in Korea
9. OT m 14 O dNYTAV3H M lt F Ma i T 17 18 CHASSIS CONTENTS EXTERIOR PARTS nents 20 6 1 1 HANDLEBARS nnn nents 25 6 12 1 STEERING esse eee 29 6 27 6 1 1 CHASSIS EXTERIOR PARTS REAR CARRIER m REMOVAL Open the rear seat with the ignition key Remove the rear carrier mounting bolts and separate the rear carrier m INSTALLATION Reassemble the rear carrier in the reverse order of removal 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 20 CHASSIS 6 1 2 UNDER COWLING 00000000000000000000N fP000000000000000000000N Under center cowling Under center cowling grill Under cowling RH Under cowling LH 21 6 1 3 CHASSIS m REMOVAL Remove the under cowling screws at the rightside Remove the under cowling screws at the leftside 22 CHASSIS 6 1 4 BODY COWLING D Windscreen G Body side cowling inner RH Air duct cowling LH Meter panel Body side cowling lower RH Body center lower cowling Body side cowling RH Body side cowling lower LH Body side cowling LH Air duct cowling RH 23 6 1 5 CHASSIS m REMOVAL Remove the body cowling screw at the rightside Remove the body cowling s
10. cowling Refer to page 6 1 4 5 Remove the head lamp coupler Remove the dust cover 14 5 16 2 ELECTRICAL SYSTEM Remove the socket spring Remove the bulb and replace the new bulb Remove the head lamp HI bulb with the same manner of the head lamp LOW bulb removal Reinstall the head lamp bulb in the reverse order of head lamp bulb removal 15 COMBINATION METER Remove the combination meter Disassemble the combination meter as shown in the illustration m INSPECTION Using the pocket tester check the continuity between lead wires in the following illustration If the continuity measured incorrect replace the respective part Pocket tester 09900 25002 CAUTION When making this test it is not necessary to remove the combination meter 16 ELECTRICAL SYSTEM 5 17 1 5 17 2 ELECTRICAL SYSTEM B BW O TURN L HIGH u uy o 13N9 8A ion ol s a gt E o 9 S o e 0 OS Om E o HNHNL ET a NB rT HIT Om CE NUNS ee DE ELO O ANNOHD SNIDN3 ME LI lt Ey 301 CO IVNOIS 1 M o ETO O AHILIVE O e 2 Mm e 3 ELO Ss wn 1 le dr eae Zz Er 4 5 9 1 i O z 1 EH avag M
11. crew at the leftside Remove the two cowling brace bolts Remove the speedometer lead wire and head lamp lead wire m REMOUNTING Tighten the two cowling brace bolts 5 Cowling brace bolt 22 35N m 2 2 3 5 kg m 24 CHASSIS 6 12 1 HANDLEBARS D Handlebar composition RH 3 Rear view mirror assembly RH Handlebar switch assembly RH 2 Handlebar composition LH 4 Rear view mirror assembly LH Handlebar switch assembly LH m HANDLEBAR RIGHT SIDE PARTS REMOVAL Remove the right handlebar switches Disconnect the brake lamp switch lead wires and remove the master cylinder Refer to the service manual res 250 125 99000 94710 page 6 10 Remove the handlebar balancer and grip 25 6 12 2 CHASSIS m HANDLEBAR LEFT SIDE PARTS REMOVAL Remove the left handlebar switches Remove the handlebar balancer and grip Remove the clutch lever holder Loosen the handlebar clamp bolts right and left Loosen the front fork upper clamp bolt right and left Remove the steering stem upper bracket by removing the steering stem head nut NOTE Place the rags under the steering stem upper bracket to prevent scratching the body cowling 26 Remove the handlebar holder bolt right and left Draw out the handlebars to upward m REMOUNTING Remount the ha
12. d 13 B T D C at 2 000 rpm and 30 B T D C at 6 000 rom 30 B T D C at 5 000 rom Spark plug CR8E lt Battery 12V 12Ah MF lt Fuse 15A lt der HI 12V H1 55W x1 lt LO 12V H3 55W x1 Position lamp 12V 5W x 1 lt Turn signal lamp 12V 10W x 4 lt Brake Tail lamp 12V 21 5W x 1 lt Illumination lamp 12V 1 7W X 2 lt License plate lamp 12V 5W x 1 lt High beam indicator lamp VFD Turn signal indicator lamp right amp left VFD lt Neutral indicator lamp VFD lt Fuel indicator lamp VFD Level type lt CAPACITIES ITEM Corse 250 Corner 125 Fuel tank 17 0 1 Engine oil oil change 1 450 m with filter change 1 500 m lt overhaul 1 800 ml 1 650 m Front fork oil capacity One side 400 2 5 cc 400 2 5 cc NOTE The specifications are subject to change without notice 8 PERIODIC MAINTENANCE CONTENTS MAINTENANCE PROCEDURES CARBURETOR o a tale 10 2 7 CLUTCH rr 11 2 8 1 2 7 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES CARBURETOR Inspect Interval Inspect Initial 1 000 km and Every 4 000 km IDLE SPEED NOTE Make this inspection when the engine is hot Connect an engine tachometer to the high tension cord Start up the engine and set its speed at anywhere 1 400 and 1 500 rpm by turning throttle stop screw D Engine idle speed 1 400 1 500 rom Engine tachometer 09900 260
13. er bearing ACH SUPER GREASE A Tighten the steering stem nut with the special tool Clamp wrench 09940 10122 8 Steering stem nut 80 100 N m 8 0 10 0 kg m Turn the steering stem right and left lock to lock five or six times Tighten the steering stem head nut to the specified torque Q Steering stem head nut 80 100 N m 8 0 10 0 kg m A CAUTION After performing the adjustment and installing the steering stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering stem nut 31 CHASSIS 6 29 1 6 29 2 CHASSIS Tighten the handlebar clamp bolts right and left Q Handlebar clamp bolts 22 35N m 2 2 3 5 kg m 32 SERVICING INFORMATION CONTENTS SERVICE DATA cori rr 34 7 20 WIRING DIAGRAM esse 35 7 31 7 20 SERVICING INFORMATION SERVICE DATA WATTAGE SPECIFICATION Unit W Head lamp H1 55W Position lamp 5W License plate lamp 5W Brake Tail lamp 21 5W Turn signal lamp Front 10W x2 Rear 10W x2 Illumination lamp 1 7Wx2 Neutral indicator lamp VFD Turn signal indicator lamp Right amp left VFD High beam indicator lamp Fuel indicator lamp
14. ndlebar in the reverse order of removal Pay attention to the following point Install the handlebars temporary Install the steering stem upper bracket Tighten the steering stem head nut 5 Steering stem head nut 80 100 N m 8 0 10 0 kg m Tighten the front fork upper clamp bolt right and left 5 Front fork upper clamp bolts 22 35N m 2 2 3 5 kg m O Tighten the handlebar clamp bolts right and left Q Handlebar clamp bolt 22 35N m 2 2 3 5 kg m 27 CHASSIS 6 13 1 6 13 2 CHASSIS When remounting the clutch lever holder align the holder s mating surface A with punch mark on the handlebar When remounting the front brake master cylinder onto the handlebar align the master cylinder holder s mating surface with punch mark on the handlebar and tighten the upper clamp bolt first as shown A WARNING Bleed air from the brake fluid circuit after assembling master cylinder Refer to the service manual 2250 1225 99000 94710 page 2 16 Apply SUPER GREASE A to the throttle cables AGH SUPER GREASE A Install the throttle cable to the throttle grip Throttle cable 28 Upper Clutch lever holder Handlebar A Upper Handlebar TD Master cylinder holder Throttle grip Rotation Throttl Fu direction cable STEERING CHASSIS 6
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