HYOSUNG Comet 650S, Comet 650R Service Manual
SERVICE MANUAL
99000-94910
SERVICE MANUAL
HYOSUNG MOTORS & MACHINERY INC.
SERVICING INFORMATION
GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ELECTRICAL SYSTEM
6
CHASSIS
7
8
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.
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.
COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2005.
HYOSUNG MOTORS & MACHINERY INC.
FOREWORD
This manual contains an introductory description on
HYOSUNG & and
procedures for its inspection/service and overhaul of its
main components.
It covers the differences from and please
refer to the service manual of
(99000-94810)
for others which are not covered in this manual.
This page numbers on the top are ones which are in the
service manual of 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 an
quick service.
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.
2
(Standard type)
3
NOTE
Difference between photographs and actual motorcycles depends on the markets.
(Sports type)
4
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 looking 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.
Apply THREAD LOCK 1324
Apply or use brake fluid.
Measure in voltage range.
Measure in resistance range.
Measure in current range.
Use special tool.
Use engine coolant.
Torque control required.
Data beside it indicates specified torque.
Apply oil. Use engine oil unless otherwise
specified.
Apply SUPER GREASE
A
Apply SILICONE GREASE.
Apply MOLY PASTE.
Apply BOND
1215 .
Use fork oil.
DEFINITION
SYMBOL
DEFINITIONSYMBOL
Apply SUPER GREASE C .
5
GENERAL INFORMATION
EXTERIOR ILLUSTRATION 6 (1-7-1)
SPECIFICATIONS 9 (1-8)
CONTENTS
1
1-7-1 GENERAL INFORMATION
6
EXTERIOR ILLUSTRATION [ (Standard type)]
Rear
reflector
Turn signal lamp (Rear)
Tail / Brake lamp
License plate lamp
Head lamp
Turn signal lamp (Front)
Passenger footrests
(HEIGHT)
(WIDTH)
(WHEEL BASE)
(LENGTH)
GENERAL INFORMATION 1-7-2
7
510
315
655
1,125
825
150
1,435
2,060
330
780
710
970
645
800
785
710
790
810
880
EXTERIOR ILLUSTRATION [ (Sports type)]
Rear
reflector
Turn signal lamp (Rear)
Tail / Brake lamp
License plate lamp
Head lamp
Turn signal lamp (Front)
Passenger footrests
(HEIGHT)
(WIDTH)
(WHEEL BASE)
(LENGTH)
1-7-3 GENERAL INFORMATION
8
EXTERIOR ILLUSTRATION [ ]
Rear
reflector
Turn signal lamp (Rear)
Tail / Brake lamp
License plate lamp
Head lamp
Turn signal lamp (Front)
Passenger footrests
(HEIGHT)
(WIDTH)
(WHEEL BASE)
(LENGTH)
GENERAL INFORMATION 1-8
9
2,060 mm (81.1 in)
740 mm (29.1 in)
1,125 mm (44.3 in)
1,435 mm (56.5 in)
150 mm (5.9 in)
215 kg (474 lbs)
655 mm (25.8 in)
130 mm (5.1 in)
220 kg (485 lbs)
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Mass
ITEM
SPECIFICATIONS
DIMENSIONS AND DRY MASS
(Standard type)
(Sport type)
Four-stroke, DOHC, Liquid-cooled
V-2 cylinder
81.5 mm (3.21 in)
62.0 mm (2.44 in)
647
(39.5 in3)
BDSR39 TYPE (DOUBLE)
Electric starter
Wet sump
Type
Number of cylinder
Bore
Stroke
Piston displacement
Carburetor
Starter system
Lubrication system
ITEM
ENGINE
(Standard type)
(Sport type)
Wet multi-plate type
6-speed constant mesh
1-down, 5-up
2.93
2.46
1.60
1.32
1.13
0.96
0.85
RK525XSO 108 links
Clutch
Transmission
Gearshift pattern
Final reduction
Gear ratio, 1st
2nd
3rd
4th
5th
6th
Drive chain
ITEM
TRANSMISSION
(Standard type)
(Sport type)
1-9 GENERAL INFORMATION
10
NOTE
The specifications are subject to change without notice.
Telescopic type
Swingarm type
27
(right & left)
25.5
74 mm (2.91 in)
Double disk brake
Disk brake
120/60 - ZR 17 55W
160/60 - ZR 17 69W
120 mm (4.72 in)
Front suspension
Rear suspension
Steering angle
Caster
Trail
Front brake
Rear brake
Front tire size
Rear tire size
Front fork stroke
ITEM
CHASSIS
(Standard type)
(Sport type)
Igniter type
5
B.T.D.C.at 1,500 rpm
CR8E
12V 12Ah (MF)
30 A
15 A
12V - H1 : 55W
1
12V - H3 : 55W
1
12V - 10W 4
12V - 21/5W
1
12V - 1.7W
2
12V - 5W
1
VFD
VFD
VFD
VFD (Level type)
VFD (Level type)
Ignition type
Ignition timing
Spark plug
Battery
Fuse
Head lamp
Turn signal lamp
Brake / Tail lamp
Illumination lamp
License plate lamp
High beam indicator lamp
Turn signal indicator lamp(right & left)
Neutral indicator lamp
Fuel indicator lamp
Coolant temperature indicator lamp
ITEM
ELECTRICAL
(Standard type)
(Sport type)
Main
Head lamp
HI
LO
17.0
3,000
3,200
3,400
380 cc
Fuel tank
Engine oil, oil change
with filter change
overhaul
Front fork oil capacity(One side)
ITEM
CAPACITIES
(Standard type)
(Sport type)
11
MAINTENANCE PROCEDURES
CARBURETOR 12 (2-7)
CLUTCH 13 (2-9-1)
ENGINE COOLANT 16 (2-20)
CONTENTS
2
2
PERIODIC MAINTENANCE
2-7 PERIODIC MAINTENANCE
12
Connect an engine tachometer to the high tension
cord.
Start up the engine and set its speed at anywhere
1,300 and 1,500 rpm by turning throttle stop screw
.
1,300 1,500 rpm
Engine idle speed
Engine tachometer : 09900-26006
MAINTENANCE PROCEDURES
CARBURETOR
¢`
IDLE SPEED
Inspect Interval
Inspect Initial 1,000 km and Every 6,000 km.
NOTE
Make this inspection when the engine is hot.
PERIODIC MAINTENANCE 2-9-1
13
(Standard type)
(Sports type)
CLUTCH
Clutch play should be 2 mm(0.08 in) as measured at the
clutch lever holder before the clutch begins to
disengage. If the play in the clutch is incorrect, adjust it in
the following way :
A basis adjustment can be done by the clutch lever
adjuster .
Loosen the clutch lever adjuster .
Screw the lock nut clockwise fully, after finishing
adjustment.
After finishing adjustment, tighten the lock nut and
cover the rubber boot .
If it is not adjusted by the adjuster , loosen the
clutch cable adjuster lock nut .
Turn the clutch cable adjuster in or out to acquire
the specified play.
After finishing adjustment, tighten the lock nut .
The clutch cable should be lubricated with a light
weight oil whenever it is adjusted.
¢`
GEARSHIFT LEVER HEIGHT
ADJUSTMENT
Loosen the lock nut .
With the link rod turned, adjust the gearshift lever
height.
Tighten the lock nut .
2 mm (0.08 in)
Clutch cable play
£
Inspect Interval
Inspect Initial 1,000 km and Every 6,000 km.
14
2-9-2 PERIODIC MAINTENANCE
¢`
FOOTREST POSITION ADJUSTMENT
& 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.
& 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.
Footrest mounting bolt
: 22 ~ 35 N¡⁄m (2.2 ~ 3.5 kgf¡⁄m)
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