HYOSUNG Comet650, Owner'S Manual

Page 1: ...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 informa tion and instructions which should...

Page 2: ...2 2 Standard type...

Page 3: ...3 3 Sports type...

Page 4: ...WORD THANK YOU for choosing Hyosung motorcycle We at Hyosung have designed tested and produced these motorcycles using the most modern tech nology available to provide you with much happy enjoyable sa...

Page 5: ...e during the break in period It is espe cially 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...

Page 6: ...s 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 MAINTE...

Page 7: ...re each use perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING sec tion on page 56 of this owner s man ual Make sure the rider wears a helmet e...

Page 8: ...ries 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 WARNING Keep both hands on the handgrips at...

Page 9: ...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 WARNING Your riding skill and mechanical knowl...

Page 10: ...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 weigh...

Page 11: ...Modification of the motorcycle or removal of original equipment may ren der the vehicle unsafe or illegal WARNING Balance the load between the left and right side of the motorcycle and fasten it secur...

Page 12: ...NAMES OF EACH PARTS 26 7 CONTROLS 29 IGNITION SWITCH IGNITION KEY INSTRUMENT PANEL INSTRUMENT PANEL LEFT HANDLE SWITCH RIGHT HANDLE SWITCH CARBURETOR CHOKE LEVER REAR BRAKE PEDAL GEARSHIFT LEVER FOOTR...

Page 13: ...0 TOOL FUEL HOSE ENGINE OIL GASOLINE COOLANT RADIATOR RADIATOR HOSE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER SPARK PLUG CARBURETOR CLUTCH ADJUST...

Page 14: ...ecial ser vice information Use unleaded gasoline with an octane rating of 91 or higher Unleaded gasoline can extend spark plug life and exhaust components life SERIAL NUMBER LOCATION FUEL ENGINEOILAND...

Page 15: ...spilt Don t put the patch on the filler cap It could disturb the oil to be provided and damage the engine WARNING Engine coolant is harmful or fatal if swallowed or inhaled Do not drink anti freeze or...

Page 16: ...60 55 The mix ing ratio should not exceed 60 ANTI FREEZE The coolant performs as rust inhibitor and water pump lubricant as well as anti freeze Therefore the coolant should be used at all times even...

Page 17: ...PARTS Clutch lever Left handle switches Choke lever Speedometer Coolant temperature meter Tachometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switche...

Page 18: ...lamp Ignition coil Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oi...

Page 19: ...cleaner Front brake fluid reservoir Front brake lamp switch Radiator Cooling fan and motor Engine oil filter Engine oil filler cap Water pump Engine oil level lens Rear brake pedal Rear brake lamp swi...

Page 20: ...PARTS Standard type Clutch lever Left handle switches Choke lever Tachometer Speedometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank c...

Page 21: ...gnition coil Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oil drain...

Page 22: ...ont brake fluid reservoir Front brake lamp switch Side cowling inner Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil filler cap Rear brake pedal Rear brake...

Page 23: ...H PARTS Sports type Clutch lever Left handle switches Choke lever Tachometer Speedometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank c...

Page 24: ...Ignition coil Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oil drai...

Page 25: ...Throttle stop screw Air cleaner Front brake fluid reservoir Front brake lamp switch Side cowling inner Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil fil...

Page 26: ...NAMES OF EACH PARTS Clutch lever Left handle switches Choke lever Tachometer Speedometer Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Ignition switches Fuel tank c...

Page 27: ...lamp Ignition coil Front Ignition coil Rear Spark pulg Rear Fuses Seat lock Rear turn signal lamp Tail Brake lamp License plate lamp Passenger footrests Footrests Gearshift lever Side stand Engine oi...

Page 28: ...aner Front brake fluid reservoir Front brake lamp switch Side cowling inner Radiator Cooling fan and motor Engine oil filter Water pump Engine oil level lens Engine oil filler cap Rear brake pedal Rea...

Page 29: ...ey cannot be removed from the ignition switch in this position CONTROLS IGNITION SWITCH IGNITION KEY Turning the ignition switch to the OFF or LOCK position while the motorcy cle is moving can be haza...

Page 30: ...er minutes rpm FUEL INDICATOR LAMP When the fuel drop below approximately 8 5 the indicator lamp lit When the fuel drop below approximately 3 0 the indicator lamp lit Fill the fuel tank before the ind...

Page 31: ...e engine with high engine coolant temperature can cause serious engine damage If the engine coolant temperature meter comes on the red lamp of H mark stop the engine to let it cool CAUTION When the ig...

Page 32: ...They can register two kinds of distance at the same time For instance trip meter A can register the trip distance and trip meter can register the distance between fuel stops To change the display pus...

Page 33: ...in the normal mode To reset the trip meter to zero push the switch in the normal mode for 2 sec onds while the display indicates trip meter B or B you want to reset A B Operating the display while rid...

Page 34: ...ase the minutes of clock 2 seconds Clock reset mode Normal mode RESET SWITCH Use this switch to adjust the following In the normal mode Push it for 2 seconds Adjustment To reset the trip meter to zero...

Page 35: ...TCH Using when left right turn or change direction Position Flash the left turn sig nal lamp Position Flash the right turn signal lamp DIMMER SWITCH Change the direction of head lamp light The head la...

Page 36: ...ard you to increase engine speed Turn it away from you to decrease the engine speed Apply the brake lightly and with great care on slippery surfaces to avoid skid ding WARNING Avoid turning the thrott...

Page 37: ...supply and igin tion system Refer to Page 78 CAUTION CARBURETOR CHOKE LEVER If you keep running in condition of full choke lever causes fuel excess exhaus tion high speed not to run it may dam age ig...

Page 38: ...le 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...

Page 39: ...indicator lamp on the instrument panel will be lit However even though the light is illumi nated cautiously release the clutch lever slowly to determine whether the transmission is positively in neut...

Page 40: ...lock system If the transmission is in neutral or side stand up you can only start the engine with pulling the clutch lever This side stand ignition interlock system pre vents the motorcycle from being...

Page 41: ...hook retainer and push down firmly until the seat snaps into the locked position To remove the front seat pull the knob located under the rear seat SEAT LOCK Make sure that the side stand ignition in...

Page 42: ...and light article such as mainte nance manual or Owner s manual can be placed under the rear seat REAR SHOCK ABSORBER TRUNK N O T E Loading limit of trunk 1k kg g 2 21 lbs The trunk could be heated Do...

Page 43: ...r of clicks from the fully turned in position Fully turned in H direction provides stiffest damping force and turning S direction the adjuster will soften damping force The rebound and compression dam...

Page 44: ...d breathing of gasoline vapors Keep children and pets away during refueling WARNING To open the fuel tank cap insert the igni tion key into the lock and turn it clockwise With the key inserted lift th...

Page 45: ...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 CAUTION ENGINE OIL LEVEL CHECK Fo...

Page 46: ...conditions inspect Quantity of Engine oil Pollution degree of Engine oil before riding the motorcycle and then supplement and replace at any time to prevent damage of the engine CAUTION Necessarily c...

Page 47: ...filter element is replaced 8 Replace the oil filter cap and tighten the nuts securely but do not over tighten them Engine oil and exhaust pipes can be hot enough to burn you Wait until the oil drain...

Page 48: ...anging oil only without replacing the oil filter CAUTION In case of the engine oil pouring exces sively the engine output being made insufficient Be careful not to pour engine oil CAUTION COOLANT COOL...

Page 49: ...of the reach of chil dren and aminals WARNING CHANGING THE COOLANT Change the coolant every two years N O T E Adding only water will dilute the engine coolant and reduce its effectiveness Add 50 50 m...

Page 50: ...lamp when starting the engine CAUTION Running the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause death or severe...

Page 51: ...ays ride within the limits of your skills your motorcycle and the riding conditions WARNING Removing your hands from the handle bars or feet from the footrests during operation can be hazardous If you...

Page 52: ...d and downshift before entering corner WARNING Do not operate the ignition switch of its OFF or LOCK position or the engine stop switch of its position while driving at one s pleasure WARNING The tran...

Page 53: ...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 Neutral position can b...

Page 54: ...idelines explain proper break in procedures Less than 3 4 throttle Less than 1 2 throttle Upto1 600km 1 000miles Initial 800km 500miles MAXIMUM THROTTLE OPENING RECOMMENDATIONS The table below shows t...

Page 55: ...ll of the engine components will have worn in and all of the other parts will have seated in All adjustments will be restored all fas teners will be tightened and the dirty engine oil and engine oil f...

Page 56: ...return of the throttle grip to the closed position Correct lever play Smooth and progressive action Fluid level in the reservoir to be above LOWER line Correct pedal and lever play No sponginess No f...

Page 57: ...e Hyosung replacement parts or their equivalent CAUTION The chart indicates the intervals between periodic service in kilometers At the end of each interval be sure to inspect check lubricate and serv...

Page 58: ...r holder and clutch cable Footrests pivot Passenger footrests pivot Drive chain Side stand pivot and spring hook Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot Mot...

Page 59: ...Cylinder head Cylinder Spark plug Fuel hose Engine oil filter Engine oil Throttle cable Idle speed Clutch Engine coolant Radiator hose First 1 000 km Every 6 000 km Every 12 000 km Interval Item Clea...

Page 60: ...3 4 5 6 7 8 9 10 11 Check if there is leakage from crankcase To assist you in the performance of peri odic maintenance a tool kit is supplied and is located under the front seat The tool kit consists...

Page 61: ...OCK ABSORBER BATTERY Do not remove absolutely airtight cover as airtight type battery Keep after separate at the motorcycle for the minimum of self electric dis charge and electric leakage when don t...

Page 62: ...at first to clean the air cleaner element and con firm CAUTION CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Set the ignition switch OFF position 2 Disassemble the...

Page 63: ...osition 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 Wh...

Page 64: ...g for these motorcycles has been carefully selected to meet the vast majority of all operational ranges If the spark plug color indicates that other than a standard spark plug be used it is best to co...

Page 65: ...cles has a twin throttle cable system Cable is for throttle cable and cable is for returing cable To adjust the cable play 1 Loosen the lock nut 2 Turn in the adjuster fully 3 Loosen the lock nut 4 Tu...

Page 66: ...holder before the clutch begins to disengage CLUTCH ADJUSTMENT After completing throttle cable adjust ment check that throttle grip movement does not raise the engine idle speed and that the throttle...

Page 67: ...Loose pins Damaged rollers Dry or rusted links Missing X O ring seals Kinked or binding links Excessive wear Improper chain adjustment If you find something wrong with the drive chain condition or adj...

Page 68: ...th a RK525XSO for Use of another chain may lead to prema ture chain failure CAUTION The drive chain should be inspected every time before riding Excessive chain slack could cause the chain to come off...

Page 69: ...erosene only CAUTION utilizes front and rear disk brakes Properly operating the brake systems are vital to safe riding Be sure to perform the brake inspection requirements as sched ules The brakes sho...

Page 70: ...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 CAUTION Brake...

Page 71: ...ith 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 bra...

Page 72: ...ight 2 Clean the brake fluid reservior around not to allow dust to get inside of it 3 Turn the cap to the counter clockwise 4 Replenish with brake fluid to the upper line N O T E The recommended brake...

Page 73: ...arnings 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 pressur...

Page 74: ...four front axle pinch bolt right and left 3 Loosen the front axle 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...

Page 75: ...y cause to excessive at the electric system or to damage the lamp REPLACEMENT OF THE LAMP 2 Loosen the rear axle 3 Carefully position a jack or block under engine and raise until the rear wheel is sli...

Page 76: ...above sequence 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 capacity CAUTION HEAD LAMP 1 Remove the three scr...

Page 77: ...he lens to crack CAUTION LICENSE PLATE LAMP Overtightening the screws may cause the lens to crack CAUTION 1 Remove the socket under the rear fend er 2 Push the bulb turn it to the counter clockwise an...

Page 78: ...one If there is still no spark consult your Hyosung dealer for repairs WHEN THE ENGINE REFUSES TO START Performing the spark test improperly can cause a high voltage electrical shock or an explosion...

Page 79: ...e 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 sys tem can reduce engine cooling conceal damage o...

Page 80: ...or soft absorbent cloth INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe For extended life of your motorcycle lubricate according to GENERAL LUBRICATION section Follow the p...

Page 81: ...81 L A B E L NOTE means the invisable parts...

Page 82: ...82...

Page 83: ...30mm 5 1 in 219kg 483 lbs Standard type Sports type Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Four stroke DOHC Liquid cooled V 2 cylinder 81 5mm 3 21 in 62 0mm...

Page 84: ...t Standard type Sports type ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Head lamp License plate lamp Turn signal lamp Brake Tail lamp Igniter type 5 B T D C at 1 500rpm CR8E 12V 1...

Page 85: ...aints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual p...

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Page 88: ...Prepared by HYOSUNG MOTORS MACHINERY INC 3rd Ed MAR 2005 Printed in KOREA...

Page 89: ...aints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in any individual p...