HYOSUNG RT125D - PARTS CATALOGUE, Owner'S Manual

Page 1: ...his owner s manual contains important safety information ease read it carefully WARNING ...

Page 2: ...rt 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 information and instructions which should be read carefully before operating the motorcycle ...

Page 3: ...cycle We at Hyosung have designed tested and produced this motorcycle using the most modern technology available to provide you with much 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 presented in this Owner s Manual before riding the motorcycle The proper care and maintena...

Page 4: ... 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 specific break in recommendations WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAUTION and NOTE have special meanings Information following these signal word...

Page 5: ...ts 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 MAINTENANCE The exhaust system of this motorcycle requires no periodic maintenance The engine should be adjusted to the manufacture s specifications and the spark plug should be kept in good condition Runn...

Page 6: ... are listed in the INSPECTION BEFORE RIDING section on page 38 of this owner s manual Make sure the rider wears a helmet eye protection and protective clothing gloves leather or heavy cloth pants long sleeved shirt or jacket boots Permit use only by a two rider This motorcycle is designed for use only by a two rider Do not permit anyone to operate the under the influence of alcohol or other drugs ...

Page 7: ...uces the rider s ability to control the motorcycle and could lead to an accident WARNING Keep both hands on the handgrips at all times when riding Removing your hands from the handgrips reduces your ability to control the motorcycle and could result in an accident WARNING Always open the throttle gradually to prevent front wheel lifting Failure to observe this precaution may result in loss of cont...

Page 8: ...rm an entire safety inspection to ensure the safety of the rider and its passenger WARNING Your riding skill and mechanical knowledge form the foundation for safe riding practices We suggest you to practice riding your motorcycle in a non traffic situation until you are thoroughly familiar with your machine and its controls Remember practice makes perfect WARNING Ride within the boundaries of your...

Page 9: ...f the motorcycle When carrying a load on the motorcycle mount it as low as possible and as close as possible to the machine An improperly ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS There are a great variety of accessories available to Hyosung owners Hyosung can not have direct control over the quality or suitability of accessories you may wish to purchase except genuine parts The addition o...

Page 10: ...gal WARNING mounted load can create a high center of gravity which is very dangerous and makes the motorcycle difficult to handle The size of the load can also affect the aerodynamics and handling of the motorcycle Balance the load between the left and right side of the motorcycle and fasten it securely ...

Page 11: ...EY INSTRUMENT PANEL LEFT HANDLE SWITCHES RIGHT HANDLE SWITCHES CARBURETOR CHOKE LEVER FUEL COCK REAR BRAKE PEDAL GEARSHIFT LEVER STAND SEAT LOCK REAR SUSPENSION 5 SUPPLY OF GASOLINE AND ENGINE OIL 28 GASOLINE ENGINE OIL 6 RIDING TIPS 32 STARTING THE ENGINE STARTING OFF USING THE TRANSMISSION RIDING ON HILLS STOPPING AND PARKING TABLE OF CONTENTS ...

Page 12: ... GASOLINE FUEL HOSE RUBBER CAP OF CABLES EXHAUST PIPE AND MUFFLER FRONT FORK REAR SHOCK ABSORBER BATTERY AIR CLEANER SPARK PLUG CARBURETOR CLUTCH ADJUSTMENT DRIVE CHAIN BRAKES TIRE REPLACEMENT OF THE LAMP WHEN THE ENGINE REFUSES TO START WHEN KEEPING FOR LONG PERIOD CLEANING PROCEDURE 11 LABEL 66 12 SPECIFICATIONS 68 ...

Page 13: ... the upside of the crankcase assembly Please write down the numbers in the box provided below for your future reference The frame and or engine serial numbers are used to register the motorcycle They are also to assist your dealer in terms of ordering parts or referring to special service information SERIAL NUMBER LOCATION ...

Page 14: ...ces Do not overfill the fuel tank Do not fill the fuel tank above the entrance lower end WARNING Spilling gasoline can damage the pointed surfaces Be careful not to spill any fuel when filling the fuel tank Wipe spilled gasoline up immediately CAUTION Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside Wipe the spilled oil up im...

Page 15: ...14 NAMES OF EACH PARTS Clutch lever Left handle switches Choke lever Instrument panel Ignition switch Front brake fluid reservoir Right handle switches Front brake lever Throttle grip Fuel tank cap OFF ...

Page 16: ...15 Spark plug Fuel cock Seat Rear carrier Muffler Passenger footrests Side stand Footrests Gearshift lever N O T E means the invisable parts ...

Page 17: ...rottle stop screw Engine oil filter cap Engine oil filler cap Engine oil drain plug Engine oil level lens Footrests Rear brake pedal Passenger footrests Air cleaner Battery N O T E means the invisable parts ...

Page 18: ...ngine will not start The key can be removed ON POSITION The ignition circuit is completed and the engine can now start The key cannot be removed from the ignition switch in this position LOCK POSITION CONTROLS IGNITION SWITCH IGNITION KEY To lock the steering turn the handlebar all the way to the left Push down the key to the OFF position and turn it to the LOCK position after come up again and re...

Page 19: ...eam indicator lamp will come on when the head lamp high beam is turned on NEUTRAL INDICATOR LAMP The neutral 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 ODOMETER TRIP METER CLOCK The display in it has three functions odometer trip meter and clock The display changes clock trip meter or odometer as indicated be...

Page 20: ...tes display by pushing the switch in the minutes reset mode for 0 6 1 seconds 5 Push the switch in the minutes reset mode 0 6 1 seconds to resume in the clock mode To reset the trip meter to zero push the switch in the trip meter mode for 0 6 1 seconds Operating the display while riding can be hazardous Removing a hand from the handlebar can reduce your ability to control the motorcycle Always kee...

Page 21: ...ent Clock mode Trip meter mode Odometer mode Clock mode In the hour reset mode Push it for 0 6 1 seconds Adjustment Increase the hour of clock SELECT SWITCH Use this switch to adjust the following In the clock mode Push it for Adjustment 0 6 1 seconds Clock mode Hour reset mode In the hour reset mode Push it for 0 6 1 seconds Adjustment Hour reset mode Minutes reset mode In the minutes reset mode ...

Page 22: ...ezing the lever disengages the clutch PASS SWITCH Press the PASS switch to operate the head lamp high beam for using when pass DIMMER SWITCH Change direction of head lamp light The head lamp high beam come on The high beam indicator lamp also comes on The head lamp low beam come on LEFT HANDLE SWITCHES Not operate when the dimmer switch position CAUTION Set the dimmer switch when other vehicle is ...

Page 23: ...alling down during drive and others or engine stop suddenly The ignition circuit is off The engine cannot start or run Position Using when need operation of engine as drive and others The ignition circuit is on and the engine can run 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...

Page 24: ...e the engine speed Avoid turning the throttle grip during brakes WARNING The carburetor is equipped with a choke system to provide easy starting when the engine is cold When starting the cold engine turn the choke lever all the way toward you The choke works best when the throttle is in the closed position When the engine warm you do not need to use the choke system for starting CARBURETOR CHOKE L...

Page 25: ... the closest gas station After refueling be sure to move the fuel cock to the ON position CAUTION Confirm the each mark by mark at the fuel cock lever is equipped with a manually operated fuel cock There are three position ON OFF and RES ON Position The normal operating position for the fuel cock lever is in the ON position OFF Position Turn the lever to the OFF position whenever stopping the engi...

Page 26: ...at the same time you operate the gearshift lever Each time that 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 and depress the lever to downshift Neutral is located between first and 2nd gear When neutral is desired depress or lift the lever halfway between first and 2nd gear It is not possible to upshift ...

Page 27: ... When down shifting the engine speed should be increased before the clutch is engaged This will prevent unnecessary wear on the drive train components and the rear tire When the transmission is in neutral the green indicator lamp on the instrument panel will be lit However even though the light is illuminated cautiously release the clutch lever slowly to determine whether the transmission is posit...

Page 28: ...s of rider control Make sure to properly position and securely attach the seat when you install it WARNING Hot muffler can be hazardous The hot muffler can be hot enough to burn you when loosening seat mounting bolts WARNING To adjust the spring pre load turn the adjuster clockwise or counter clockwise to the desired position with the clamp wrench Position 1 provides the softest spring pre load an...

Page 29: ...ne vapors Keep children and pets away during refueling WARNING To open the fuel tank cap remove the end of vent tube from the vehicle body and turn fuel tank cap counter clockwise To close the fuel tank cap turn it clockwise and tighten it securely Be sure that the end of the vent tube is reinstalled in the hole of the fuel tank cap GASOLINE Do not overfill the fuel tank Stop adding fuel when the ...

Page 30: ...l filter replace 950 ENGINE OIL CAPACITY ENGINE OIL AND FILTER CHANGE Change the engine oil and filter after first running 1 000km and every running 4 000km The oil should always be changed when the engine is hot so that the oil will drain thoroughly from the engine The procedure is as follows Never operate the motorcycle if the engine oil level is below the Lower line mark L in the engine oil lev...

Page 31: ...n motorcycles that are used under severe conditions inspect Amount 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 confirm and clean the oil strainer when replace the Engine oil specially when first replacement CAUTION Ａ 5 Remove the three nuts holding the filter cap in place ...

Page 32: ...ly Use new O ring each time the engine oil filter element is replaced 8 Replace the oil filter cap and tighten the nuts securely but do not over tighten them 9 Replace the drain plug and tighten it securely This time insert the gasket necessarily Pour fresh oil through the filler hole Approximately 950 of oil will be required New and used oil and solvent can be hazardous Children and pets may be h...

Page 33: ... 1 8 1 4 2 Push the starter switch RIDING TIPS STARTING THE ENGINE Before attempting to start the engine make sure Operation of the carburetor choke system is not necessary when the engine is warm CAUTION 10 Install the engine oil filler cap 11 Operate the engine a few seconds by idling speed Inspect to leak oil at the oil filter cap 12 Confirm the oil level with the oil level lens after waiting a...

Page 34: ...er several attempts check the fuel supply and igintion system Refer for Page 62 CAUTION STARTING OFF Riding this motorcycle at excessive speed increases your chances of losing control of the motorcycle This may result in an accident Always ride within the limits of your skills your motorcycle and the riding conditions WARNING Removing your hands from the handlebars or feet from the footrests durin...

Page 35: ...ing the gearshift lever downward Turn the throttle grip toward you and at the same time release the clutch lever gently and smoothly As the clutch engages the motorcycle will start moving forward To shift to the next higher gear accelerate gently then close the throttle and pull the clutch lever in simultaneously Lift the gearshift lever upward to select the next gear and release the clutch lever ...

Page 36: ... 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 be confirmed by observing the neutral indicator lamp Inexperienced riders tend to underutilize the front brake This can cause excessive stopping distance and lead to a collision Using only the front or...

Page 37: ...s during break in to ensure this mating process Do not though apply excessive load on the engine MAXIMUM THROTTLE OPENING RECOMMENDATIONS The table below shows the maximum throttle opening recommendation during the break in period BREAK IN 5 Park the motorcycle on a firm flat surface where it will not fall over Following another vehicle too closely can lead to a collision As vehicle speeds increas...

Page 38: ...ire Perform proper break in of the tire as described in this section and avoid hard acceleration hard cornering and hard braking for the first 160km 100miles WARNING BREAKING IN THE NEW TIRES New tires need proper break in to assure maximum performance just as the engine does Wear in the tread surface by gradually increasing your cornering lean angles over the first 160km 100miles before attemptin...

Page 39: ...r play No sponginess Brake pads and shoes not to be worn down to the limit line Smoothness No restriction of movement No play or looseness No dust or damage Correct fuction Smooth movement Spokenipple No loosening Enginestop switch Correct function Proper tension Adequate lubrication No excessive wear or damage No damage lever Smooth operation Correct lever play Smooth and progressive action Prope...

Page 40: ...ons and require very special and careful servicing For maximum safety we suggest that you have these items inspected and serviced by your authorized Hyosung dealer or a qualified service mechanic LUBRICATION POINTS Proper lubrication is important for smooth and long life of each working part of your motorcycle and also for safe riding It is a good practice to lubricate the motorcycle after a long ...

Page 41: ...40 Clutch lever holder Passenger footrests pivot Drive chain Side stand pivot and spring hook Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot O Motor oil G Grease ...

Page 42: ...head Cylinder Spark plug Fuel hose Engine oil filter Engine oil Throttle cable Idle speed Clutch First 1 000 km Every 4 000 km Every 8 000 km Interval Item Clean and lubricate every 1 000 km Inspect Inspect Inspect Inspect Replace every 4 years Inspect Inspect Replace every 2 years Inspect Inspect Inspect Inspect Inspect Inspect Tighten Tighten CHASSIS Drive chain Brake Tire Steering Front forks R...

Page 43: ... you are not sure how to do any of the jobs ask your Hyosung dealer or a qualified mechanic to do the maintenance WARNING If you use your motorcycle under severe conditions it will need maintenance more often than shown in the chart Operating your motorcycle under severe conditions causes more wear on your motorcycle Severe conditions include operating under frequent full throttle or in dusty wet ...

Page 44: ...ance of periodic maintenance a tool kit is supplied and is located under the seat The tool kit consists of the following items INSPECTION AND REPAIR TOOL ENGINE OIL GASOLINE Mop them up with a patch when washing RUBBER CAP OF CABLES Inspect the fuel hose for damage and fuel leakage If any defect are found the fuel hose must be replaced Replace the fuel hose every 4 years FUEL HOSE Inspect the exha...

Page 45: ... of battery periodically Check if there is any noise by bend of front fork while moving the handle upward and downward Inspect whether the steering stem is well assembled while moving front fork upward downward and or forward backward FRONT FORK REAR SHOCK ABSORBER BATTERY Do not remove absolutely airtight cover as airtight type battery Keep after separate at the motorcycle for the minimum of self...

Page 46: ...lode if exposed to flames or sparks Keep the battery away from fires or sparks Never smoke when working near the battery When disconnecting the battery wire be sure to remove the negative battery wire first with the ignition switch OFF position then remove the positive battery wire When reinstalling the battery be sure to connect the positive battery wire first then connect the negative battery wi...

Page 47: ...e element in the cleaning solvent and wash it clean If the air cleaner element has become clogged with dust intake resistance will increase with a resultant decrease in power output and an increase in fuel consumption If riding under severe conditions must be cleaned or replaced more frequently than maintenance schedule Check and clean the air cleaner element periodically according to the followin...

Page 48: ...r cleaner element CAUTION When the assembly of air cleaner element is not completely done dusts 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 performed on motorcycles that are used under severe conditions also clean the air cleaner element when replacing the oil to prevent damage of the engine CAUT...

Page 49: ... Do not over torque or cross thread the spark plug or the aluminum threads of the cylinder head will be damaged Do not allow contaminants to enter the engine through the spark plug holes when the plug is removed The standard spark plug for this motorcycle has been carefully selected to meet the vast majority of all operational ranges If the spark plug color indicates that other than a standard spa...

Page 50: ...uddenly when you turn the throttle grip This can lead to loss of rider control Adjust the throttle cable play so that engine idle speed does not rise due to throttle grip movement WARNING At each maintenance interval adjust the clutch cable play by means of clutch cable adjuster The cable play should be 4 mm 0 16 in as measured at the clutch lever holder before the clutch begins to disengage CLUTC...

Page 51: ... for the following Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear Damaged O rings Improper chain adjustment If you find something wrong with the drive chain condition or adjustment correct the problem if you know how If necessary consult your authorized Hyosung dealer Damage to the drive chain means that the sprockets may also be damaged Inspect the sprockets...

Page 52: ...e rear sprocket and the front sprocket there are reference mark on the same position right and left After aligning and adjusting the slack in the drive chain to 20 30 mm 0 79 1 18 in retighten the axle nut securely and perform a final inspection The drive chain for this motorcycle is made of the special material The chain should be replaced with a 428SO Use of another chain may lead to premature c...

Page 53: ...hysician immediately WARNING Cleaning the chain with gasoline or other commercial cleaning solvents can damage your motorcycle These fluids can damage the O rings and ruin the chain Use only kerosene to clean the drive chain CAUTION 2 After thoroughly washing the chain and allowing it to dry then lubricate the links with Hyosung chain lube or an equivalent Some drive chain lubricants contain solve...

Page 54: ...ke pads Replenishing the master cylinder to considered normal periodic maintenance LOWER BRAKES Brake fluid may be harmful if swallowed or if it comes in contact with skin or eyes Contact your doctor immediately if brake fluid is swallowed and induce vomiting If brake fluid gets into the eyes or in contact with the skin flush thoroughly with plenty of water WARNING This motorcycle uses glycol base...

Page 55: ... the front brake system should be replaced according to periodic inspection chart by your authorized Hyosung dealer for safety operating at high pressure CAUTION Riding with 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 brake pads if any pad is worn to ...

Page 56: ...ke shoes to rub against the drum at all times causing damage to the shoes and the drum Follow the steps in this section to adjust the rear brake pedal properly WARNING FRONT BRAKE FLUID SUPPLY 1 Place the motorcycle on a level surface and keep the handlebars straight 2 Clean the brake fluid reservior around not to allow dust to get inside of it 3 Loosen the screw and open the cap 4 Replenish with ...

Page 57: ... limit indicators on the rear brakes To check wear of the brake shoe perform the following REAR BRAKE LAMP SWITCH The rear brake lamp switch is located at 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 Riding with worn brake shoe will reduce braking performance and will increase you...

Page 58: ... specified limit or if you find damage such as cuts or cracks Always use the size and type of tires specified in this owner s manual WARNING TIRE PRESSURE Insufficient air pressure in the tires not only hasten tire wear but also seriously affects the stability of the motorcycle Under inflated tires make smooth cornering difficult and over inflated tires decrease the amount of tire in contact with ...

Page 59: ...lace the front and rear tires at once when appear the tire wear indicator REAR AXLE NUT Inspect the rear axle shaft and jointing nut for loosening TIRE TREAD CONDITION Tire wear indicator Tire wear indicator mark The standard tire on is 130 80 18M C 66P for front and 180 80 14M C 78P for rear The use of a tire other than standard may cause trouble It is highly recommended to use the standard tire ...

Page 60: ...LO Position Brake Tail lamp Turn signal lamp License plate lamp Head lamp 12V 35W 1 12V 35W 1 12V 5W 1 12V 21 5W 1 12V 10W 4 12V 5W 1 NAMES CAPACITY Requirement electric power of the lamp shown in the following chart When replace the damaged lamp always use the equal capacity The use of a lamp other than rules may cause excessive voltage at the electric system or damage the lamp REPLACEMENT OF THE...

Page 61: ...ens by removing the screw 2 Push the bulb turn it to the counter clockwise and pull it out 3 After stick in the new lamp assemble the lens 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 Overtightening the screws may cause the lens to crack CAUTION HEAD LAMP 1 Remove the two screw right and left...

Page 62: ... and turn it to the clockwise while pushing FUSE The fuse box is located behind the seat If the engine suddenly stops while running or any electrical system fails to operate then the fuse must be checked In case a fuse blows there is a 15A spare fuse Never use other than specified 15A fuse Installing a fuse of incorrect rating may seriously damage the electrical system You should consult your Hyos...

Page 63: ... in neutral and the clutch disengaged If the ignition system is operating properly a blue spark should jump a cross the spark plug gap If there is no spark clean the spark plug Replace it if necessary Retry the above procedure with the cleaned spark plug or new one If there is still no spark consult your Hyosung dealer for repairs WHEN THE ENGINE REFUSES TO START Do not allow the fuel to spill Cat...

Page 64: ...in the OFF position 3 Do drain wholly the fuel in the carburetor 4 Remove the battery from the motorcycle Do not hold the spark plug close to the open spark plug hole in the cylinder head as gasoline vapor inside the cylinder should be ignited creating a fire hazard WARNING When occur any trouble the best way is to consult your Hyosung dealer for repairs CAUTION WHENKEEPINGFORLONGPERIOD ...

Page 65: ...horough cleaning of your motorcycle is a necessary part of maintenance and will help keep your motorcycle looking and performing its best Proper cleaning can also extend the life of your motorcycle It is important to clean and inspect your motorcycle after every ride 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 eng...

Page 66: ...ORE RIDING section to check your motorcycle for any problems that may have arisen during your last ride Operating motorcycle with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing motorcycle while riding at slow speed If necessary apply brakes several times to let friction dry out the shoes and ...

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Page 69: ...lbs Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Four stroke DOHC Air oil cooled 1 cylinder 57 mm 2 24 in 48 8 mm 1 92 in 124 5 7 6 in3 Piston valve ELECTRIC STARTER Clutch Final reduction Drive chain Transmission Wet multi plate type 3 357 428SO 130 links 1st 2 750 2nd 1 785 3rd 1 368 4th 1 045 5th 0 913 DIMENSIONS AND DRY MASS ENGINE TRANSMISSION ...

Page 70: ...47 right left 130 80 18M C 66P 180 80 14M C 78P Disk Drum Fuel tank Engine oil 9 0 ℓ 850 Replace 950 Oil filter replace 1 200 Overhaul ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Head lamp License plate lamp Turn signal lamp Brake Tail lamp CDI type 6 B T D C at 1 900rpm CR8E 12V 6Ah MF 15A HI 12V 35W 1 LO 12V 35W 1 POSITION 12V 5W 1 12V 5W 1 12V 10W 4 12V 21 5W 1 ...

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Page 73: ...Prepared by 1st Ed APR 2007 Printed in KOREA ...