1875 RX125 (Om-E)

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IMPORTANT WARNING/CAUTION/NOTE

Please read this manual and follow its


BREAK-IN INFORMATION FOR instructions carefully. To emphasize special
informa
YOUR MOTORCYCLE
The first 1,000km(600miles) are the most tion the words WARNING, CAUTION and
important in the life of your motorcycle . NOTE carry special meanings and should be
Proper break-in operation during this time will carefully reviewed.
help ensure maximum life and performance
from your new motorcycle. ▲WARNING
!
Hyosung parts are manufactured of high quality
materials, and manufactured parts are finished The personal safety of the rider may be
to close tolerances. Proper break-in operation involved. Disregarding this information could
allows the machined surfaces to polish each result in injury to the rider.
other and mate smoothly.

Motorcycle reliability and performance depend


▲CAUTION
!

on special care and restraint exercised during These instructions point out special service
the break-in period. It is especially important procedures or precautions that must be fol-
that you avoid operating the engine in a man- lowed to avoid damaging the machine.
ner which could expose the engine parts to
excessive heat.
NOTE: This provides special information to
Please refer to the BREAK-IN section for spe- make maintenance easier or important instruc-
cific break-in recommendations. tions clearer.

1
FOREWORD
THANK YOU for choosing Hyosung. We at All information, illustrations photographs and
Hyosung have designed, tested and produced specifications contained in this manual are
this motorcycle using the most modern tech- based on the latest product information avail-
nology available to provide you with many able at the time of publication. Due to
happy, enjoyable, safe riding. Motorcycling is improvements or other changes, there may be
one of the most exhilarating sports and insure some discrepancies in this manual. Hyosung
your riding enjoyment, you should become reserves the right to make changes at any time.
throughly familiar with the information present-
ed in this Owner's Manual before riding the Please note that this manual applies to all
motorcycle. specifications for all respective destinations
and explains all equipments. Therefore, your
The proper care and maintenance that your model may have different standard features
motorcycle requires is outlined in this manual. than shown in this manual.
By following these instructions explicitly you will
insure a long trouble-free operating life for
your motorcycle. Your Hyosung dealer has HYOSUNG MOTORS & MACHINERY INC.
experienced technicians that are trained to
provide your machine with the best possible
service with the right tools and equipment. COPYRIGHT HYOSUNG MOTORS & MACHINERY INC.

2
TABLE OF CONTENTS
1. CONSUMER INFORMATION 4 5. BREAK-IN 13
ACCESSORY INSTALLATION AND
PRECAUTION SAFETY TIPS
6. INSPECTION BEFORE RIDING 14
SAFE RIDING RECOMMENDATION
FOR MOTORCYCLE RIDERS
7. PERIODIC MAINTENANCE 14
SERIAL NUMBER LOCATION
LUBRICATION
ENGINE
2. NAMES OF EACH PARTS 6 CHASSIS

8. INSPECTION AND REPAIR 15


3. CONTROLS 7
TOOL
IGNITION SWITCH
INSPECTION OF BATTERY SOLUTION LEVEL
IGNITION KEY
CLEAN OF BATTERY TERMINAL
INSTRUMENT PANEL
CLEAN OF AIR CLEANER
LEFT HANDLEBAR SWITCH
FUEL HOSE
RIGHT HANDLEBAR SWITCH
SPARK PLUG
SUPPLY OF GASOLINE
ENGINE OIL
KICK START LEVER
CARBURETOR
CARBURETOR CHOKE LEVER
THROTTLE CABLE ADJUSTMENT
FUELCOCK
CLUTCH ADJUSTMENT
REAR BRAKE PEDAL
DRIVE CHAIN ADJUSTMENT
GEARSHIFT LEVER
DRIVE CHAIN CLEANING AND OILING
STAND
BRAKES
SEAT
TIRE
REAR SUSPENSION
REPLACE OF THE LAMP
WHEN THE ENGINE REFUSES TO START
4. FUEL AND OIL RECOMMENDATION 12 WHEN KEEPING FOR LONG PERIOD

3
1.CONSUMER INFORMATION cause oscillations in the front end and
lead to instability problems. Accessories
added to the machine should be as light
ACCESSORY INSTALLATION AND as possible and kept to a minimum.
PRECAUTION SAFETY TIPS (4) The motorcycle may be affected by a lift-
ing condition or by an instability in cross
There are a great variety of accessories avail- winds or when being passed or passing
able to Hyosung owners. Hyosung can not large vehicles. Improperly mounted or
have direct control over the quality or suitabil- poorly designed accessories can result in
ity of accessories you may wish to purchase an unsafe riding condition, therefore cau-
except genuine parts. The addition of unsuit- tion should be used when selecting and
able accessories can lead to unsafe operating installing all accessories.
conditions. It is not possible for Hyosung to (5) Certain accessories displace the rider
test each accessory on the market or combi- from his or her normal riding position. This
nations of all the available accessories, how- limits the freedom of movement of the
ever, your dealer can assist you in selecting rider and may limit his or her control abili-
quality accessories and installing them cor- ty.
rectly. (6) Additional electrical accessories may over
load the existing electrical system. Severe
Use extreme caution when selecting and overloads may damage the wiring harness
installing the accessories for your Hyosung. or create a dangerous situation due to the
We loss of electrical power during the opera-
have developed some general guidelines tion of the motorcycle.
which will aid you when deciding whether, and
how to equip your motorcycle. When carrying a load on the motorcycle,
mount it as low as possible and as close as
(1) Anytime that additional weight or aerody- possible to the machine. An improperly
namic affecting accessories are installed, mounted load can create a high center of
they should be mounted as low as possi- gravity which is very dangerous and makes the
ble, as close to the motorcycle and as motorcycle difficult to handle. The size of the
near the center of gravity as is feasible. “load”can also affect the aerody namics and
The mounting brackets and other attach- handling of the motorcycle.
ment hardware should be carefully Balance the load between the left and right
checked to ensure that it provides for a side of the motorcycle and fasten it securely.
rigid, nonmovable mount. Weak mounts
can allow the shifting of the weight and MODIFICATION
create a dangerous, unstable condition. Modification of the motorcycle, or removal of
(2) Inspect for proper ground clearance and original equipment may render the vehicle
bank angle. An improperly mounted load unsafe or illegal.
could critically reduce these two safety Motorcycle riding is great fun and an exciting
factors. Also determine that the“load” sport. Motorcycle riding also requires that some
does not interfere with the operation of the
suspension steering or other control oper- SAFE RIDING RECOMMENDATION
ations. FOR MOTORCYCLE RIDERS
(3) Accessories fitted to the handlebars or the
front fork area can create serious stability extra precautions be taken to ensure the safety of
problems. This extra weight will cause the the rider and passenger. These precautions are:
motorcycle to be less responsive to your
steering control. The weight may also

4
WEAR A HELMET
Motorcycle safety equipment starts with a SERIAL NUMBER LOCATION
quality safety helmet. One of the most
serious injuries that can happen is a head The frame and/or engine serial numbers are
injury. ALWAYS wear a properly approved hel- used to register the motorcycle. They are
met. You should also wear suitable eye pro- also to assist your dealer when ordering
tection. parts or referring to special service infor-
mation.
RIDING APPAREL
Loose fancy clothing can be uncomfortable
and unsafe when riding your motorcycle.
Choose good quality motorcycle riding apparel
when riding your motorcycle.

INSPECTION BEFORE RIDING


Review throughly the instructions in the ①
“INSPECTION BEFORE RIDING”section of this
manual. Do not forget to perform an entire
safety inspection to ensure the safety of the
rider and its passenger.

FAMILIARIZE YOURSELF WITH THE


MOTORCYCLE
Your riding skill and mechanical knowledge
form the foundation for safe riding practices. ②
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 per-
fect.

KNOW YOUR LIMITS


Ride within the boundaries of your own skill at
all times. Knowing these limits and staying The frame number ① is stamped on the right
within them will help you to avoid accidents. side of the steering head pipe.

BE EXTRA SAFETY CONSCIOUS ON BAD The engine serial number ② is stamped on the
WEATHER DAYS left upside of the crankcase assembly.
Riding on bad weather days, especially wet
ones, requires extra caution. Braking distances Please write down the numbers in the box pro-
double on a rainy day. Stay off of the painted vided below for your future reference.
surface marks, manhole covers and greasy
appearing areas as they can be especially
slippery. Use extreme caution at railway cross-
ings and on metal gratings and bridges. Frame number:
Whenever in doubt about road condition, slow
down! Engine number:

5
2.NAMES OF EACH PARTS
① Clutch lever
② Left handle switch
③ Instrument panel
④ Ignition switch
⑤ Right handle switch
⑥ Throttle grip
⑦ Front brake lever
⑧ Fuel cock
⑨ Gear shifting lever
⑩ Side stand
⑪ Rear brake pedal
⑫ Engine oil level gauge
⑬ Kick start lever

6
3.CONTROLS This motorcycle comes equipped with a pair of
identical ignition keys.
Keep the spare key in a safe place.

IGNITION SWITCH
INSTRUMENT PANEL

O FF ON

KEY
OFF ON
LOCK

LOCK

◉“OFF”POSITION ① TRIP METER


All electrical circuits are cut off. The trip meter is a resettable odometer
located in the speedometer assembly. It can
◉“ON”POSITION be used to indicate the distance traveled on
The ignition circuit is completed and the engine short trip or between fuel stops.
can now be started. The key cannot be removed Pressing control button will return the meter
from the ignition switch in this position. to zero.
◉“LOCK”POSITION ② ODOMETER
To lock the steering, turn the handlebar all The odmeter registers the total distance that
the way to the left. Push down the key to the the motorcycle has been ridden.
“ OFF ”position and turn it to the “ LOCK ” ③ SPEEDOMETER
position after come up again and remove The speedometer indicates the road speed in
the key. All electrical circuits are discon- kilometers per hour.
nected.
④ HIGH BEAM INDICATOR LAMP
The high beam indicator lamp will come on
IGNITION KEY when the headlamp high beam is turned on.
⑤ NEUTRAL INDICATOR LAMP
The meutral 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.
HYOSUNG HYOSUNG
⑥ 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.

7
LEFT HANDLEBAR SWITCH ▲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.

④ CLUTCH LEVER
Using to cut off dilivery power at rear wheel
when starting engine or shifting gear.

⑤ LIGHT SWITCH

◉“ ”position
① DIMMER SWITCH The headlamp, meter lamp and taillamp come
Change direction of headlamp light. on. If not start engine, do not come on.

◉“ ”: For headlamp high beam. ◉“ ”position


The headlamp, meter lamp and taillamp go
◉“ ”: For headlamp low beam. off.

▲WARNING
!

Set the dimmer switch“ ”when other


vehicle is running in front or against. RIGHT HANDLEBAR SWITCH

② HORN SWITCH
Press the switch to operate the horn.

③ TURN SIGNAL SWITH


Using when left, right turn or change direction.

◉“ � ”Position
Flash the left turn signal lamp.

◉“ � ”Position
Flash the right turn signal lamp.
① FRONT BRAKE LEVER
The front brake is applied by squeezing the
brake lever gently toward the throttle grip.
Front brake be anxious about motorcycle
falling down when braking suddenly as disk
brake system.

8
② STARTER BUTTON To open the fuel tank cap, remove the end
Push the electric starter button to rotate of vent tube from the vehicle body and turn
the starter motor.The transmission is in fuel tank cap counter clockwise. To close
neutral for safety during start and squeez- the fuel tank cap, turn it clockwise and
ing clutch. tighten it securely.

▲CAUTION
!
KICK START LEVER
Do not engage the starter motor for
more than five seconds at a time as it
may overheat the wiring harness and
starter motor. If the engine does not
start after several attempts, check the
fuel supply and ignition system. (Refer
to Page 26)

③ 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.

④ ENGINE KILL SWITCH The kick start lever be exist at right side of
the engine.
◉“ ” : Using when dangerous condi- This engine is possible starting any position
tion of falling down during drive and of gear after pull clutch lever as primary kick
others or engine stop suddenly. start type.

◉“ ” : Using when need operation of


engine as drive and others.
▲CAUTION
!

When started the engine, check that


kick start lever return to normal
SUPPLY OF GASOLINE position.

▲WARNING
!

When start by kick start lever, pay


attention to position of a foot.
It shoold contacted with footrest
lever, be will injured.

9
CARBURETOR CHOKE LEVER

◉“OFF”Position
Turn the lever to the“OFF”position whenever
stopping the engine for more than a few
After the engine starts next full com- minutes.
l e t e l y t h e choke lever toward left, was
returned the lever originally position as
halfway.
After operate engine with idling speed until
the engine sufficiently warms up, the choke
lever w a s r e t u r n e d c o m p l e t e l y t o w a r d
originally position.

▲CAUTION
!

If keep running in condition that full


choke lever, cause in fuel excess exhaus-
tion, high speed not running, damage of
ignition plug. ◉“RES”Position
If the fuel level in the tank is too low, turn the
lever to the“RES”position to use of reserve
fuel supply.

FUELCOCK

This motorcycle is equipped with a manually


operated fuelcock.
There are three position:“ON”,“OFF”and
“RES” .

◉“ON”Position
The normal operating position for the fuelcock
lever is in the“ON”position.

10
This motorcycle is equipped with a 5
▲CAUTION
!
speed constant mesh transmission switch
operates as shown in the figure.
After switching the fuelcock lever to the
“RES”position, it is advisable that the tank be The shift lever is attached to a ratchet
refilled at the closest gas station. After type mechanism in the transmission.
refueling be sure to move the fuelcock to Each time that a gear is selected, the
the“ON ” position. gear shift lever will return to its normal
position ready to select the next gear.
Neutral is located between low and 2nd
gear. Low gear is engaged by depressing
REAR BRAKE PEDAL the lever downward from the neutral posi-
tion. Shifting into the higher gears is
Depressing the rear lbrake pedal will accomplished by lifting up on the shift lever
apply the rear brake. once for each gear. It is not possible to
The brake light will be illuminated upshift or downshift more than one gear at
w h e n t h e rear brake is operated. a time due to the ratchet mechanism
being used.
When shifting from low to 2nd gear or
2nd gear to low, neutral will be auto-
matically skipped.

5
4
3
2
N 5
1 4
3
2
▲CAUTION
! N
1
When brake rear brake, haste braking
pay attention surely to occure accident of
vehicle falling down. When neutral is desired, depress or lift the lever
to a position halfway between low and 2nd
gear.

GEARSHIFT LEVER ▲CAUTION


!

When the transmission is in neutral


the green indicator lamp on the
instrument panel will be lit.
However, even though the light is illumi-
nat ed, cautiously release the clutch lever
slowly t o d e t e r m i n e w h e t h e r t h e
transmission is positively in neutral.

11
STAND REAR SUSPENSION

① Side stand. The rear shock absorber spring preload is


adjustable to compensate for rider, load,
riding style and road conditions.
▲CAUTION
!

Before starting off, check that the


side stand i s r e t u r n e d t o f u l l y u p
p o s i t i o n a n d i s n o t hanging down.

SEAT 4. FUEL AND OIL RECOM


MENDATION

� FUEL
Use both leaded gasoline, unleaded
gasoline.
However, use only one sort gasoline.

▲WARNING
!

∙W h e n r e f u e l i n g , a l w a y s s h u t t h e
engine o f f a n d t u r n t h e i g n i t i o n
k e y t o t h e “OFF” position. Never
To separate the seat, loose two bolts refuel near the flames, sparks and
heat sources.
that are united the rear fender and the
∙Do not overfill the fuel tank. Do
frame below the seat.
not fill the fuel tank above the
When assemble the seat, put up the
entrance lower end.
s e a t a t the frame and unit two bolts.

12
� ENGINE OIL � MAXIMUM ENGINE SPEED RECOM
MENDATIONS
This table shows the maximum recom-
mended engine RPM during the break-in period.

Initial 800km (500miles) Below 5,000 RPM

Up to 1,600km (1,000miles) Below 7,000 RPM

Over 1,600km (1,000miles) Below 10,000 RPM

Using a premium quality four stroke � AVOID CONSTANT LOW SPEED


motor oil w i l l i n c r e a s e t h e s e r v i c e Operating the engine at constant low
l i f e o f y o u r m o t o r c y cle. speed (light load) can cause parts to glaze
Use only oils which are rated SG or SJ and not seat in.
under the API classification system. Allow the engine to accelerate freely
through the gear, without exceeding the
recommended maximum limits.
20W50 Do not, however use full throttle for
15W40 15W50 first 1,600km (1,000miles).
ENGINE OIL
10W40 10W50
10W30 � VARY THE ENGINE SPEED
℃ -30 -20 -10 0 10 20 30 40 The engine speed should be varied and
Temperature not held at a constant speed.
℉ -22 -4 14 32 50 68 86 104
This allows the parts to be“loaded”with
pressure and then unloaded, allowing the
▲WARNING
! parts to cool.
This aids the mating process of the parts. It
∙Don’t mix the unrecommended oil. It is essential that some stress be placed
could damage the engine. o n t h e engine components during
∙When refilling the oil tank, don’t allow the break-in to ensure this mating process.
dust to get inside. Do not, though, apply excessive load
∙Mop the oil spilt. on the engine.
∙Don’t put the patch on the cap. It could
disturb the oil to be provided and damage � ALLOW THE ENGINE OIL TO CIRCULATE
the engine. BEFORE RIDING
Allow sufficient idling time after warm or cold
engine start up before applying load or
reviving the engine. This allows time for the
5. BREAK-IN lubricating oil to reach all critical engine
components.

The opening explains how important � OBSERVE YOUR FIRST, AND MOST
proper break-in is to achieving maxi- 1,000km SERVICE
mum life and performance from your The 1,000km (600miles) service is the
new Hyosung. The following guidelines most important service your motorcycle
explain proper break-in procedures. will receive.

13
During break-in procedures all of the � LUBRICATION
engine components will have seated in.
All adjustments will be restored, all fasten- First Every Every
ers will be tightened, and the dirty oil and 1,000km 4,000km 8,000km
oil filter will be replaced.
Timely performance of the Throttle cable Motor oil ← ←
1,000km
(600miles) service will ensure opti- Throttle grip Grease
mom service life and performance
Brake hose, cable Inspect Inspect Inspect
f r o m t h e engine.
Bearing of Grease every 2years or
▲CAUTION
! Steering stem every 20,000km

Brake lever Grease ← ←


The 1,000km (600miles) service should
be p e r f o r m e d a s o u t l i n e d i n t h e
INSPECTION A N D M A I N T E N A N C E
s e c t i o n o f t h i s Owner’s Manual.
� ENGINE
Pay particular attention to the CAU-
TION and WARNING in that section.
First Every Every
1,000km 4,000km 8,000km

Engine bolt/nut Tighten ← ←


6. INSPECTION BEFORE RIDING
Air cleaner Clean Clean every 3,000km
Before riding the motorcycle, be sure to check the
follwing item. Spark plug Clean Clean Exchange
Inspect every day once them before riding the
motorcycle. Carburetor Inspect ← ←
∙Abnormal point of the previous day.
∙Extra braking power of the brake lever. Inspect ← ←
Fuel hose
∙Fluid measure of the master cylinder.
∙Pressure, crack, cut, strange wear, foreign sub Replace every 2years
stance (stone, nail and others) of Tire.
∙Adequate tread depth of Tire.
∙Fluid measure of Engine oil.
� CHASSIS
∙Fluid measure of Fuel.
∙On and off condition or damage of Lamp,
turn signal lamp and others. First Every Every
1,000km 4,000km 8,000km
∙Condition of rear-view mirror.
Drive chain Replace every 2years

Brake Inspect ← ←
7. PERIODIC MAINTENANCE.
Tire Inspect ← ←
The below show the schedule of periodic
Bolt / Nut Inspect ← ←
maintenance by mileages.
More frequent maintenance must be per-
Steering Inspect ← ←
formed on motorcycles that are used under
severe conditions.

14
8. INSPECTION AND REPAIR INSPECTION OF BATTERY SOLUTION LEVEL

This motorcycle is used MF(Maintenance


Free) battery of airtight type.
TOOL
Inspection or supplement of battery do
unnecessary.
To assist you in the performance of periodic
maintenance, a tool kit is supplied and is
located under the seat. The tool kit consists of
the following items.
▲CAUTION
!

∙Do not remove absolutely airtight


cover as airtight type battery.
NO NAME ∙Keep after separate at the motor-
cycle for the minimum of self elec-
1 Tool bag
tric discharge and long time.
2 10 × 12 mm open end wrench ∙Remove the (-) negative terminal
3 Spark plug wrench when keep intact at the motorcycle.
4 Combination screw driver
5 Screw driver handle

CLEAN OF BATTERY TERMINAL

Clean the battery terminal when it is dusty or


① rusted.
1. Set the ignition switch“OFF”position.
2. Disassemble the battery cover, loose the
(+)position battery wire after the (-)nega
tive battery wire.
Remove the battery.
3. Clean the terminal.
If there is white dust, clean it with warm
⑤ water.
4. Assemble the battery wires and grease the
terminal lightly.

15
▲CAUTION
! FUEL HOSE
∙Keep the battery away from fires.
∙When disassemble the battery wire, take
off � termminal first with the ignition
switch“OFF”position.
When assemble, � terminal first.
∙Fasten certainly the battery wires.

CLEAN OF AIR CLEANER


Replace the fuel hose every 4 years.

1. Take off the air cleaner filter.


2. Wash it with cleaning solvent and dry.
3. Immerse it in motor oil squeeze the oil off to SPARK PLUG
make it slightly wet with oil.
4. Assemble the air cleaner filter.

Cleaning
solvent

Oil

Remove the carbon deposits periodically


from the spark plug with a piece of hard
▲CAUTION
! wire or pin.

∙Exchange it when tears.


∙Don’t use the cleaning solvent whose
flash point is low when cleaning the fil-
ter.
∙Assemble the filter completely or dam-
age severely the engine.
∙Be careful not to allow water to go
inside the air cleaner filter.

0.8~0.9 mm

16
Readjust the spark plug gap to 0.8~0.9 mm Superior engine life depends much on the
(0.031~0.035 inch) by using a spark plug gap selection of quality oil and the periodic
thickness gauge. changing of the oil.
Daily oil level checks and periodic changes are
two of the most important maintenances to be
PLUG REPLACEMENT GUIDE
performed.
Hotter type N.G.K. C7EH-9
▲CAUTION
!
Standard type N.G.K. C8EH-9
Never operate the motorcycle if the
Colder type N.G.K. C9EH-9 engine oil level is below the“Lower line
mark”in the engine oil level gauge. Never
fill the engine oil above the“Upper line
mark”
▲CAUTION
!

∙Do not over torque or cross thread the


spark plug or the aluminum threads of ▲CAUTION
!
the cylinder head will be damaged.
Do not allow contaminants to enter the “Fuel and Engine oil”use certainly to
engine through the spark plug holes recommend at the front part.
when the plug is removed.
∙The standard spark plug for this motor
cycle has been carefully selected to ◉ ENGINE OIL AND FILTER CHANGE
meet the vast majority of all operational Change the engine oil and filter, after first
ranges. If the spark plug color indicates running 1,000km and every running
that other than a standard spark plug 4,000km.
be used, it is best to consult your The oil should always be changed when the
Hyosung dealer before selecting an engine is hot so that the oil will drain
alternate plug or heat range. The throughly from the engine.
selection of an improper spark plug The procedure is as follows.
can lead to severe engine damage. Note : About 950 ml of oil will be required
when changing oil without replacing
the oil filter.
(1) Place the motorcycle on the jack or
block.
ENGINE OIL

1
1

17
(2) Remove the engine oil filter plug ①. (4) Remove the three nuts.
Remove the filter cap ⑥, pull out the
element and replace with a new oil filter
element.
(5) Before replacing the oil filter cap ⑥,
check to be sure that the filter spring ④
and cap“O”ring ⑤ are installed correctly.
Install a new“O”ring each time that the
2 filter element is replaced.
(6) Replace the oil filter cap and tighten the
bolts securely.
(7) R e p l a c e t h e d r a i n p l u g a n d p o u r
about 950 ml of oil through the plug
hole.
(8) Operate the engine a few second by
idling speed.
(3) Drain the oil by removing the drain plug
Inspect to leak oil at the oil filter
② located on the bottom of the engine.
cap.
(9) Confirm the oil level through the oil level
lenz after waiting about a minute next to
stoping the engine.
The oil level is located between the“Lower
line”and the“Upper line” .
When below the“Lower line”, refill the oil
between the“Lower line”and the“Upper
line” .

▲CAUTION
!

When remove the drain plug, pay attention


extremely to lose the spring and the shifting
3 cam stopper.
5
6 4
7

CARBURETOR

Undisturbed carburetion is the basis of


the performance you ought to expect of
your engine.
The carburetor is factory-set for the
▲CAUTION
!
best car buretion.
Do not attempt to alter its setting.
Insert the filter so that surface of the
There are two items of adjustment,
filter hole turn toward the engine.
however, under your care : engine idle
speed and throttle cable play.

18
Start up the engine and let the engine
run until it warms up fully.
▲CAUTION
!

After engine has warmed up, turn the After completing throttle cable
throttle valve stopper in or out so that adjustment, check that handlebar
the engine may run at 1,450~1,550 movement does not raise the engine
RPM. idle speed and that the throttle grip
return smoothly and automatically.

CLUTCH ADJUSTMENT

At each maintenance interval, adjust the


clutch cable play by means of clutch cable
adjuster.
▲CAUTION
! The cable play should be 4mm(0.16in) as
measured at the clutch lever holder before
The engine idle speed should be the clutch begins to disengage.
adjusted with the engine fully warm.

4 3

THROTTLE CABLE ADJUSTMENT

4mm
2
1

5
1 2 0.5~1.0mm

(1) Loosen the lock nut ①.


(2) Adjust the cable slack by cable adjuster ②
in or out to obtain the correct slack 6
0.5~1.0mm (0.02~0.04in).
(3) After adjusting the slack, tighten the lock
nut.

19
① The clutch lever play.
② The lock nut
③ The clutch lever adjuster
④ The rubber boot
⑤ The cable adjuster 50~60mm
⑥ The clutch cable adjuster lock nut.
If you find the play of the clutch incorrect,
adjust it in the following way :

� CLUTCH CABLE
(1) Loosen the lock nut ② and the clutch
lever adjuster ③ turn all the way toward
clockwise. (1)Place the motorcycle on the jack or
(2) Loosen the clutch cable adjuster lock nut block
⑥. (2) Loosen the axle nut ①.
Turn the cable adjuster ⑤ that the clutch (3) Adjust the slack in the drive chain by
lever adjuster ③ as the lock nut ② turning
play ① should be 4mm(0.16in) toward the left and right.
(3) A little adjustment be allowed by the (4) For alignment of the rear sprocket and the
clutch lever adjuster ③. front sprocket, there are reference mark ④
(4) After end of adjustment, tighten the lock on the same position.
nut ②, ⑥ and cover the rubber boot ④. After aligning and adjusting the slack in
the drive chain to 50~60mm (2.0~2.4in),
retighten the axle nut securely and perform
a final inspection.

DRIVE CHAIN ADJUSTMENT


▲CAUTION
!

The drive chain for this motorcycle is


The chain may require more frequent
made of the special material.
adjustment that it is with periodic mainte The chain should replaced with either a
nance depending upon your riding condi- 428H.
tions. Use of another chain may lead to prema-
Check the chain every 1,000km. ture chain failure.

▲CAUTION
!

The drive chain should be inspected


4 every time before riding.
Excessive chain slack could cause the
3 chain to come off the sprockets and
result in accident or serious engine dam-
2 age.
1

Chain adjust in the following way.

20
◉ BRAKE FLUID
▲WARNING
!
Be sure to check the brake fluid level in the
Be careful not to touch the muffler when it is master cylinder.
hot : a hot muffler can burn you. If the level was found to be lower than the
lower mark while holding the motorcycle
upright, replenish with the proper brake fluid
that meets Hyosung’s requirements.
As the brake pads wear, the fluid level will
DRIVE CHAIN CLEANING AND OILING drop to compensate for the new position of
barke pads.
Replenishing the master cylinder to consid-
ered normal periodic maintenance.

If the drive chain be made dirty, the drive


chain and the sprocket be wore easily.
This times, clean the drive chain with sol-
vent and oil every 1,000km with lubricating ▲WARNING
!
oil or motor oil.
Brake fluid may be harmful or fated if swal-
lowed and harmful if it comes in contact with
skin or eyes. Contact your physician immedi-
ately. If swallowed induce vomiting. If brake
fluid gets into the eye or in contact with the
skin, it should be flushed thoroughly with plenty
BRAKES of water.

Properly operating the brake systems ▲CAUTION


!
are vital to safe riding. Be sure to per-
form the brake inspection requirements This motorcycle uses glycol-based
as schedules. brake fluid. Do not use or mix differ-
The brakes should be inspected at ent types of brake fluid such as sili-
periodic inspection by your authorized cone-based or petroleum-based
Hyosung dealer. fluid, otherwise serious damage will
result to the brake system.
Use only SEA J1703, DOT3 or DOT4.
Do not spill any brake fluid on paint-
ed or plastic surfaces as it will dam-
age the surface severely.

21
◉ BRAKE PADS ◉ REAR BRAKE ADJUSTMENT
Inspect the front brake pads by nothing
whether or not the friction pads are worn down
to the grooved limit line. If a pad is worn to the
grooved limit line it must be replaced with a
new one by your authorized Hyosung dealer or
qualified service machanic.


10~20mm

BRAKE PAD BRAKE PAD

DISK

Inspect every day in the following point


at the brake system.
① Brake fluid leak of the front brake 2
system.
② Leak or damage of the brake hose.
③ Operating of the brake lever. Adjust the free travel ① to 10~20mm
④ Wear of the front brake pads. (0.4~0.8in)by screwing in or out the brake
adjusting nut ②.

▲CAUTION
! ◉ BRAKE LINING WEAR LIMIT
The motorcycle is equipped with the brake
The front brake system be replaced the lining wear limit indicators on the rear
brake hose or the brake fluid according brakes.
to periodic inspection chart by your To check wear of the brake lining, perform
authorized Hyosung dealer for safety as the following :
operating at high pressure.

▲CAUTION
!
G

After replaced the front brake pads, KE L


ININ
B RA R L IM
W EA
IT

the brake lever pull and release sev-


eral times so that it is setting at the
original place.
Then, do not riding the motorcycle
untill operating the brake fluid and
becoming the brake distance.

22
① Check if the brake system is properly
TIRE PRESSURE NORMAL RIDING
adjusted. (COLD INFLA-
② While fully applying the brake, check to TION) SOLO RIDING DUAL RIDING
see that the extension line of the index
mark is within the range on the brake 1.75 kg/㎠ 1.75 kg/㎠
panel. FRONT 172 kpa 172 kpa
③ If the extension line is beyond the range, 25 psi 25 psi
have the brake shoe assembly replaced by
your Hyosung dealer to ensure safe opera- 2.00 kg/㎠ 2.25 kg/㎠
tion. REAR 197 kpa 221 kpa
29 psi 32 psi
◉ FRONT BRAKE LIGHTING SWITCH
The front brake lighting switch is located
beneath the front brake lever. Loosen the ◉ TIRE TREAD CONDITION
switch fitting screws and adjust the timing
by moving the switch body forward or back
ward.
1.6mm
◉ REAR BRAKE LIGHTING SWITCH
The rear brake lighting switch is located at (0.06in)
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.

Operating the motorcycle with excessively


worn tire will decrease riding stability and
TIRE can lead to loss of control.
It is recommended that the front and rear
tires be replaced when the remaining depth
Inspect the tire pressure and the tire thread of tire thread becomes 1.6mm(0.06in) or
depth in periodically. less.
Inspect frequently the tire pressure for the
safety and the tire life.

◉ TIRE PRESSURE ▲CAUTION


!
Insufficient air pressure in the tires not only
hasten tire wear but also seriously affects The standard tire on your motorcycle is
the stability of the motorcycle. 2.75-21 45P for front, and 4.10-18 59P for
Under-inflated tires make smooth corner- rear.
ing difficult and over-inflated tires The use of a tire other than standard may
decrease the amount of tire in contact with cause trouble. It is highly recommended to
the ground which can lead to skids and loss use the standard tire supplied by Hyosung.
of control. Be sure that the tire pressure is
within the specified limits at all times.
Tire pressure should only be adjusted when
the tire is cold.

23
◉ TURN SIGNAL LAMP
REPLACE OF THE LAMP

Requirement electric power of the lamp is


following the chart.
When replace the damaged lamp, always
use the equal capacity.
The use of a lamp other than rules may
cause to excessive at the electric system or
to damage the lamp.

NAMES CAPACITY AND QUANTITY


① Loose one screw, and remove the lenz.
Head lamp 12V 35/35W×2 ② Pull out the lamp for front.
③ After stick in the new lamp, assemble the
Tail/Brake lamp 12V 21/5W×2 lenz.
Turn signal lamp 12V 1.7W×2
◉ TAIL BRAKE LAMP

◉ HEAD LAMP

① After turn counterclockwise the socket, pull


out it at the lamp housing.
① Remove the rubber boot.
② After push and turn counterclockwise the
socket, separate it at the lamp housing.
Then replace a new lamp of the equal
capacity.
③ Assemble the rubber boot at the original
position.

▲CAUTION
!

The use of a lamp other than rules may


cause to occur the vehicle fire and to ② After push and turn counterclockwise the
damage at electric parts. lamp, saperate it at the socket.
Surely use only the lamp of proper ③ Stick in the new lamp.
capacity. Then, be fixed to turn clockwise the socket.

24
◉ FUSE
WHEN THE ENGINE REFUSES TO START

TROUBLE SHOOTING
If the engine refuses to start, perform the
following inspections to determine the
cause.

Fuel Supply Check


① Is there enough fuel in the fuel tank?
② Is the fuel reaching the carburetor from
the fuelcock?
③ Disconnect the fuel line from the carbu-
retor, turn the fuelcock to the “ON”
position and see if gasoline flows from
the hole.
④ If it has been determined that fuel is
reach ing the carburetor, the ignition
system should be checked next.

▲CAUTION
!

Do not allow the fuel to spill.


Catch the fuel in container.
Do not allow any fuel to come in
The fuse box is located under the seat. If contact with the hot engine or
the engine suddenly stops while running or exhaust system.
any electrical system fails to operate then Extinguish any smoking materials
the fuse must be checked. before performing this check, and
In case a fuse blows there is a 15A spare stay away from any other fire or heat
fuse. source.

Ignition System Check


▲CAUTION
!
① Remove a spark plug and reattach to
the spark lead.
Never use other than specified 15A fuse. ② While holding the spark plug firmly
If the spare fuse installed blows out in a against the engine, crank the engine
short period of time it means that you with the ignition switch in the “ON”
could have a major electrical problem. switch.
You should consult your Hyosung dealer ③ If the ignition system is operating
or a qualified service mechanic immedi- properly, a blue spark should jump
ately. across the spark plug gap.
If there is no spark, consult your
Hyosung dealer for repairs.

25
SPECIFICATIONS

DIMENSIONS AND DRY MASS


Overall length 2,190mm
Overall width 800mm
Overall height 1,160mm
Ground clearance 295mm
Dry mass 125kg

ENGINE
Type Four-stroke,
air-cooled and
▲WARNING
! oil-cooled.
3
Piston displacement 124.5㎤(7.6in )
Do not hold the spark plug close to the Carburetor Piston valve
open spark plug hole in the cylinder head as Starter system kick/self starter
gasoline vapor inside the cylinder should be
ignited, creating a fire hazard. TRANSMISSION
Clutch Wet multi-plate type
Engine Stalling Transmission 5 speed
① Check the fuel supply in the fuel tank.
③ Check the ignition system for intermittent CHASIS
spark. Front tire size 2.75-21 45P
③ Check the engine idle speed. Rear tire size 4.10-18 59P
Front suspension Telescopic
Rear suspension Swing arm
▲CAUTION
!
Front brake Disc brake
When occur any trouble, the best way is Rear brake Internal expanding drum
to consult your Hyosung dealer for
repairs. TANK CAPACITIES
Fuel tank 8.0ℓ

WHEN KEEPING FOR LONG PERIOD

1. Supply enough the fuel in the fuel


tank.
2. Do the fuelcock in the “OFF”posi-
tion.
3. Do drain wholly the fuel in the car-
buretor.

26
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 purpose of mainte-
nance, repair or replacement, of any device or element of design incorporated into any
new vehicle for the purpose of noise control prior to its any sale of delivery to the ulti-
mate purchaser or while it is in use ; and
(b) The use of the vehicle after such device or element of design has been removed or ren-
dered inoperative by any person.
MAINTENANCE :
The exhaust system of this motorcycle requires no periodic maintenance. The engine
should be adjusted to the manufacturer s specifications and the spark plug should be kept
in good condition. Running the engine with incorrectly operating spark plug or misadjusted
carburetor may cause permanent damage to the catalyst and to the noise control system.
Prepared by

HYOSUNG MOTORS & MACHINERY INC.

Overseas Technical
1st Ed. JAN. 1999
Printed in KOREA

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