Hyosung GT650 Comet Service Manual (2004)

Hyosung GT650 Comet Service Manual (2004)
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Original Hyosung Motors & Machinery Inc. factory Service Manual for the naked GT650 Comet. The 210-page PDF covers general specifications, periodic maintenance, valve-clearance and compression checks, complete engine removal and overhaul, cylinder heads, pistons, crankshaft, clutch and six-speed transmission, twin BDSR39 carburetors and fuel system, liquid-cooling system, ignition, charging and starter systems, electrical switches and battery, exterior parts, wheels, twin front and rear disc brakes, handlebars, front fork, steering, rear suspension and swingarm, troubleshooting, special tools, torque data, service limits, wire routing and the complete wiring diagram.

About the Manual

Manual type
Factory Service Manual
Years covered*
2004
Pages
210
Language
English
Format
PDF
Main sections
50
Searchable PDF
Yes
Printable PDF
Yes
File size
6.0 MB
Delivery
Digital download

* Indicative only. Please do your own research and confirm compatibility with your exact motorcycle and model year before purchasing.

Hyosung Comet GT650 GT650 Comet - naked carbureted version Motorcycle Details

Manufacturer
Hyosung
Series
Comet
Models Covered
GT650
Generation / variant
GT650 Comet - naked carbureted version
Engine
90-degree V-twin, 4-stroke, DOHC, liquid-cooled
Displacement
647 cm³
Bore × Stroke
81.5 × 62.0 mm
Cooling System
Liquid-cooled with radiator, electric cooling fan and thermostat
Fuel System
Twin BDSR39 carburetors
Clutch
Wet multi-plate clutch
Transmission
6-speed constant-mesh gearbox; 1-down, 5-up shift pattern
Final Drive
RK525XSO chain, 108 links; final reduction ratio 2.93
Overall dimensions
2,060 × 740 × 1,090 mm (L × W × H)
Wheelbase
1,435 mm
Ground clearance
150 mm
Unladen mass
185 kg
Front suspension
Telescopic type; 120 mm fork stroke
Rear suspension
Swingarm type
Caster / trail
25.5° / 85 mm
Steering angle
30° right and left
Front brake
Twin disc brakes
Rear brake
Disc brake
Front tire
120/60-ZR17 55W
Rear tire
160/60-ZR17 69W
Starter system
Electric starter
Ignition
Igniter type; 5° BTDC at 1,500 rpm
Spark plug
CR8E
Battery
12 V 12 Ah
Gear ratios
1st 2.46 / 2nd 1.60 / 3rd 1.32 / 4th 1.13 / 5th 0.96 / 6th 0.85

What’s Included in the Hyosung Comet GT650 GT650 Comet - naked carbureted version Service Manual?

  1. General Information and General Precautions
  2. Serial Number Location and Fuel/Oil Recommendations
  3. Break-In Procedures and Exterior Illustration
  4. Specifications
  5. Periodic Maintenance Schedule
  6. Lubrication Points
  7. Valve Clearance and Spark Plug
  8. Exhaust, Air Cleaner and Carburetor Adjustment
  9. Fuel Hose and Clutch
  10. Engine Oil and Oil Filter
  11. Drive Chain
  12. Brake System
  13. Steering, Front Fork and Rear Suspension
  14. Tires and Chassis Fasteners
  15. Engine Coolant and Radiator Hoses
  16. Compression Pressure and Oil Pressure
  17. Engine Removal and Reinstallation
  18. Engine Disassembly
  19. Starter Motor, Thermostat and Secondary Air Valve
  20. Cylinder Heads, Pistons and Valve Train
  21. Clutch, Primary Drive and Oil Pump
  22. Gearshift Shaft, Crankshaft and Transmission
  23. Engine Component Inspection and Service
  24. Engine Reassembly
  25. Fuel Tank and Fuel Cock
  26. Fuel Pump
  27. Twin BDSR39 Carburetors
  28. Engine Coolant and Cooling Circuit
  29. Radiator and Cooling Fan
  30. Cooling Fan Thermo-Switch
  31. Coolant Temperature Sensor
  32. Thermostat and Water Pump
  33. Electrical Component Locations
  34. Ignition System
  35. Charging System
  36. Starter and Side-Stand Interlock Systems
  37. Switches and Lamps
  38. Battery
  39. Exterior Parts
  40. Front Wheel and Twin Front Brakes
  41. Handlebars
  42. Front Fork and Steering
  43. Rear Wheel and Rear Brake
  44. Rear Shock Absorber and Swingarm
  45. Troubleshooting
  46. Special Tools
  47. Tightening Torque
  48. Service Data
  49. Wire and Cable Routing
  50. Wiring Diagram

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About the Hyosung GT650

Hyosung developed the GT650 as the largest member of its road-going GT family and brought the naked 650 into production for the 2004 model year. The motorcycle represented an important step beyond Hyosung's smaller commuter and 250-class machines: it used a 647 cm³ liquid-cooled 90-degree DOHC V-twin in a steel twin-spar-style chassis, giving the company a direct entry into the middleweight roadster market. Period specifications list the 2004 GT650 with the same 1,435 mm wheelbase, 17-litre fuel tank and 17-inch radial tires documented in the factory workshop source.

The Comet name was used for the GT road-bike family in a number of export markets. In its original naked form, the 650 combined upright handlebars with dual front discs, a 120/60-ZR17 front tire and 160/60-ZR17 rear tire, giving it a more sporting roadster layout than Hyosung's Aquila cruisers. The early engine used twin BDSR39 carburetors, a six-speed gearbox and chain final drive. That configuration made the bike a carbureted 650 cc V-twin roadster aimed at riders who wanted middleweight performance with a relatively simple mechanical package.

The GT family broadened soon after launch. By 2005 Hyosung had added the half-faired GT650S and fully faired GT650R around the same 647 cm³ V-twin platform. Rider Magazine's GT650S road test documents that shared engine architecture and describes the carbureted V-twin as the common powerplant for the GT650S, GT650R and GV650. Those derivatives changed riding position, bodywork and some chassis details, while the naked GT650 remained the simplest expression of the platform.

The family continued to evolve through the late 2000s and early 2010s. Electronic fuel injection eventually replaced the twin-carburetor setup, and Hyosung later revised styling, electronics and suspension. Cycle World's 2013 Hyosung buyer's guide records a later generation using Delphi fuel injection and upgraded suspension, providing a clear technical separation from the carbureted first-generation motorcycle documented here.

This listing is tied specifically to the original naked GT650 factory publication. Hyosung Motors & Machinery Inc. Service Manual No. 99000-94810 carries a 2003 copyright and is marked “2nd Ed. JUN. 2004.” Its specifications cover the naked 647 cm³, twin-carburetor, six-speed, chain-drive machine; later S/R variants used additional factory supplements. Because this source does not explicitly state 2002-2005 applicability, catalog coverage is conservatively limited to 2004. Related publications are grouped in the Hyosung GT650 manual catalog.

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