HYOSUNG Exceed 125 2002, Owner'S Manual

Page 1: ...Part No 99011HL7310 JUN 2002 Printed in KOREA HYOSUNG MOTORS MACHINERY INC 2nd Ed ProCarManuals com ...

Page 2: ...ce 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 t...

Page 3: ...MACHINERY INC FOREWORD THANK YOU for choosing Hyosung We at Hyosung have designed tested and produced this motorcycle using the most modern tech nology available to provide you with many 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 pre sented in this Owner s Manual before ...

Page 4: ...HEPERSONALTRUNK 5 GASOLINE 12 HOWTOPROVIDETHEGASOLINE 6 THEPROPEROPERATIONS 13 HOWTOSTARTTHEENGINE HOWTOSTARTOFF ADJUSTINGTHESPEEDS HOWTOOPERATETHEBRAKE HOWTOSTOPANDPARK 7 BRAKE IN 17 8 INSPECTIONBEFORERIDING 18 INSPECTIONBEFORERIDINGITEM BRAKES TIRES GASOLINE LAMPS REAR VIEWMIRROR REFLECTORANDNUMBERPLATE 9 PERIODICMAINTENANCE 20 FRONTFORK BRAKES TIRES AIRCLEANER BATTERY TRANSMISSIONOIL GASOLINE 1...

Page 5: ... 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 con dition or by an instability in cross winds or when being passed or passing large vehicles Improperly mounted or poorly designed acces sories can result in an unsafe r...

Page 6: ...ety of the rider and its passenger FAMILIARIZE YOURSELF WITH THE MOTORCYCLE 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 KNOW YOUR LIMITS Ride within the boundaries of your own...

Page 7: ...r Dimmer switch Instrument panel Light switch Front brake lever Throttle grip Starter switch Ignition switch Parking brake lever Emergency lamp switch Horn switch Turn signal switch NAMES OF EACH PARTS ProCarManuals com ...

Page 8: ...7 Battery 폈 Fuse Personal trunk Muffler Passenger footrests Center stand Side stand NOTE means the invisable parts ProCarManuals com ...

Page 9: ...8 Air cleaner Fuel tank cover Fuel tank Antitheft equipment Passenger footrests Kick start lever NOTE means the invisable parts ProCarManuals com ...

Page 10: ...h beam indicator lamp will come on when the headlamp high beam is turned on FUEL GAUGE It indicates the remaining fuel amount in the fuel tank F mark indicates the fuel tank is full E mark indicates the fuel tank is empty or nearly so the remaining fuel is 1 3ℓ at E the capacity is 7 0ℓ Fill the fuel tank before E The ignition switch has three positions ON POSITION The ignition circuit is complete...

Page 11: ... and light switch ON position operate the dim mer switch Change direction of headlamp light The headlamp high beam and tail lamp come on The high beam indicator lamp also comes on The headlamp low beam and tail lamp come on 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 com pleting the turn or lane ...

Page 12: ... tail lamp go off 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 sys tem The brake lamp will come on when the lever is squeezed toward the throttle grip THROTTLE GRIP Engine speed is controlled by position of the throttle grip Turn it toward you to inc...

Page 13: ... it take down lightly 3 Turn the fuel tank cap left 4 Fill the fuel tank and turn the cap right tightly HOW TO PROVIDE THE GASOLINE GASOLINE Check if it is locked The unlocking of trunk could cause serious accident Take care not to spill the gasoline or oil in the trunk Don t allow water to get inside the trunk or it could damage Don t keep the valuables in the trunk when leaving unattended The tr...

Page 14: ...he ignition switch 騏ON鑑얗 Squeeze the rear brake lever 슴혹텄텄크호좼템텍호호텄턱크텍심턱템탱호텀텍테 Push the starter switch without turning the throttle grip When it doesn t start after several trial turn the throttle grip to position Depress the start switch right after started When the start motor doesn t rotate within 5 seconds after pushing the starter switch try again after 10 sec onds for preventing the damage on...

Page 15: ...asily in the cases as follows 1鑑 It has been long since you started the motorcycle 2鑑 There was no gasoline left In this case騏1 2鑑 push the starter switch longer without turning the throttle grip When the engine is cold idle it for a while HOW TO START OFF Return the center stand For returning the center stand push the motorcycle forward gripping the rear brake lever with left hand and the rear ca...

Page 16: ...y the motorcycle will start moving forward Don t let the engine run excessively before riding CAUTION 템턱탱템크좍템탱텃턱 슴템텍테호크좍템탱텃턱 Apply the front and rear brakes at the same time HOW TO OPERATE THE BRAKE You can adjust the speeds with the throttle grip Turning Get faster Returning Get slower 템턱호혹템테텀테습 호혹템테텀테습 ADJUSTING THE SPEEDS When turned the throttle grip excessively i t w i l l m a k e q u i c k s...

Page 17: ... and apply the brake lightly until smoothly operated Using either front or rear brake is dangerous and can cause skidding and loss of control WARNING Turn on the turn signal lamp and return the throttle grip HOW TO STOP AND PARK P U S H I G N I T I O N When completely stopped turn off the turn signal lamp Set the key 騏OFF鑑 position Put the motorcycle on the center stand Don t park the motorcycle o...

Page 18: ... apply excessive load on the engine BREAKING IN THE NEW TIRES New tires need proper break in to assure maxi mum performance just as the engine does Wear in the tread surface by gradually increas ing your cornering lean angles over the first 160 km 100 miles before attempting maximum per formance Avoid hard acceleration hard corner ing and hard braking for the first 160 km 100 miles Failure to perf...

Page 19: ...s necessary The engine and muffler are too hot right after engine stopped please be caerful not to be burned Don t inspect the engine indoor where there is little or no ventilation available The exhaust gas is extremely poisonous CAUTION Pressure crack cut strange wear foreign substance stone nail and others of Tire Adequate tread depth of Tire Fluid measure of Engine oil Pollution degree inspect ...

Page 20: ...lead to loss of control Inspect stortage of tire thread s depth by the tire wear indicator Replace the front and rear tires at once when appear the tire wear indicator If there are some problem with the tire pressure or cracks and cuts it will decrease the riding stability and lead to flat tire CAUTION 호회캣홱크석홱칩캣크 회즉홰회쥑칩캥썼캣 호회캣홱크석홱칩캣크 회즉홰회쥑칩캥썼캣크툭칩캣밗 THE GASOLINE GASOLINE Check if the remaining gaso...

Page 21: ...ate is dusty or damaged 좼턱탱터크텄탱텅심 호혹템테크텝텀습테탱텄크텄탱텅심 호혹템테크텝텀습테탱텄크텄탱텅심 호탱텀텄크텄탱텅심 REAR VIEW MIRROR REFLECTOR AND NUMBER PLATE The belows show the schedule of periodic maintenance by mileages More frequent maintenance must be performed on motorcycles that are used under severe conditions LUBRICATION POINTS Proper lubrication is important for smooth and long life of each working part of your motorcycle ...

Page 22: ...lever holder Center stand pivot and spring hook Side stand pivot and spring hook Speedometer gear box Front brake lever holder Throttle cable Steering stem bearing O Motor oil G Grease 습 습 습 습 습 습 텍 ProCarManuals com ...

Page 23: ...ace Inspect Inspect Inspect Replace Replace Inspect Inspect Inspect CHASSIS Interval Item Every 8 000 km 4 800 miles Every 4 000 km 2 400 miles Initial 1 000 km 600 miles Brake Brake hose Brake fluid Tire Steering Front forks Rear suspension Chassis nuts and bolts Replace every 4 years Replace every 2 years Inspect Inspect Inspect Inspect Inspect Tighten Inspect Inspect Inspect Inspect Inspect Ins...

Page 24: ...rear brake while running in low speeds Check if there is leakage or damage on the brake fluid reservoir and the connected parts are loose Check if the vibration damages the brake hose while moving the handle left right or running BRAKE FLUID Keep the motorcycle upright and place the handle straight Check the brake fluid level by observing the middle line When the level is below the lower the middl...

Page 25: ...asten the cap 혹심심턱템크텄텀텅텀호크텄텀테턱 Check the tire pressure when it is cold TirePressure Soloriding Dualriding 1 25 쥠타 123 밗 18 회 1 75 쥠타 172 밗 25 회 2 00 쥠타 196 밗 29 회 2 25 쥠타 221 밗 33 회 Front Rear TIRES Don t replenish with brake fluid over the limit line It will leak out of the brake fluid reservoir Be careful not to allow dusts or water to go inside when it is replenished Don t use the unrecommended...

Page 26: ...can go inside and damage severely engine Be careful not to allow water to go into the element while washing CAUTION More frequent servicing may be per formed on motorcycles that are used under severe conditions also clean the air cleaner element when replacing the oil to prevent damage of the engine CAUTION Don t take off the sealed cap Take off the battery when the motorcycle is not used for a lo...

Page 27: ...e it means there are other problems Check the other parts Don t pour water on the fuse box when washing CAUTION BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Disassemble the cover of battery box 2 Set the ignition switch 騏OFF鑑 position 3 Clean the terminal If there is white dust clean it with warm water 4 Assemble the battery wires and grease the terminal lightly Keep th...

Page 28: ...OIL SPECIFICATION ENGINEOIL Temperature 30 22 20 4 10 14 0 32 10 50 20 68 30 86 40 104 20W50 15W40 15W50 10W40 10W50 10W30 Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside Mop the oil spilt Don t put the patch on the cap It could disturb the oil to be provided and dam age the engine WARNING Using a premium quality four stroke...

Page 29: ...e the drain plug at the lower part of engine and drain the engine oil Put in the drain plug again This time certainly put in with gasket Pouring in the purity oil or SAE 10W 30 or 10W 40 multi grade motor oil of purity as 850 as measur ing Confirm the oil level through the oil level lens Lock the oil filler cap ENGINE OIL CAPACITY Replace Oil filter replace Overhaul 850 900 1 100 SPARK PLUG Remove...

Page 30: ...e selection of an improper spark plug can lead to severe engine damage CAUTION SPARK PLUG REPLACEMENT GUIDE Hotter type Standard type Colder type DR7EA DR8EA DR9EA Readjust the spark plug gap to 0 6 0 7 mm 0 024 0 028 inch by using a spark plug gap thickness gauge PARKING BRAKE is equipped with the brake lining wear limit indicators on the parking brakes To check wear of the brake lining perform t...

Page 31: ...troke SOHC Number of cylinder 1 Bore 57 0mm 2 244in Bore 52 4mm 2 063in Stroke 57 8mm 2 276in Piston displacement 147 5cm3 9 0in3 Piston displacement 124 5cm3 7 6in3 Carburetor BDS 28 39 Starter system KICK ELECTRIC STARTER Lubrication system Wet sump TRANSMISSION Clutch Dry shoe automatic centifugal Reduction ratio 10 69 Transmission 0 905 2 517 Drive system V belt drive SPECIFICATIONS ProCarManu...

Page 32: ...and33 B T D C at 5 000rpm Spark plug DR8EA Battery 12V 6Ah MF Fuse 15A Head lamp HI 35 W LO 35 W Position lamp 5 W License plate lamp 5 W Parking brake indicator lamp 1 7 W High beam indicator lamp 1 7 W Turn signal lamp 10 W Brake Tail lamp 21 5 W Speedometer lamp 3 4 W 2 Turn signal indicator lamp right left 1 7 W CAPACITIES Fuel tank 7 0ℓ Engine oil 850 Replace 900 Oil filter replace 1 100 Over...

Page 33: ...Prepared by HYOSUNG MOTORS MACHINERY INC Overseas Technical Dept 2nd Ed JUN 2002 Printed in KOREA ProCarManuals com ...