Hyosung GT650 Comet Service Manual (2004)


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
- 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
What’s Included in the Hyosung Comet GT650 GT650 Comet - naked carbureted version Service Manual?
- General Information and General Precautions
- Serial Number Location and Fuel/Oil Recommendations
- Break-In Procedures and Exterior Illustration
- Specifications
- Periodic Maintenance Schedule
- Lubrication Points
- Valve Clearance and Spark Plug
- Exhaust, Air Cleaner and Carburetor Adjustment
- Fuel Hose and Clutch
- Engine Oil and Oil Filter
- Drive Chain
- Brake System
- Steering, Front Fork and Rear Suspension
- Tires and Chassis Fasteners
- Engine Coolant and Radiator Hoses
- Compression Pressure and Oil Pressure
- Engine Removal and Reinstallation
- Engine Disassembly
- Starter Motor, Thermostat and Secondary Air Valve
- Cylinder Heads, Pistons and Valve Train
- Clutch, Primary Drive and Oil Pump
- Gearshift Shaft, Crankshaft and Transmission
- Engine Component Inspection and Service
- Engine Reassembly
- Fuel Tank and Fuel Cock
- Fuel Pump
- Twin BDSR39 Carburetors
- Engine Coolant and Cooling Circuit
- Radiator and Cooling Fan
- Cooling Fan Thermo-Switch
- Coolant Temperature Sensor
- Thermostat and Water Pump
- Electrical Component Locations
- Ignition System
- Charging System
- Starter and Side-Stand Interlock Systems
- Switches and Lamps
- Battery
- Exterior Parts
- Front Wheel and Twin Front Brakes
- Handlebars
- Front Fork and Steering
- Rear Wheel and Rear Brake
- Rear Shock Absorber and Swingarm
- Troubleshooting
- Special Tools
- Tightening Torque
- Service Data
- Wire and Cable Routing
- 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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We do not offer printed manuals. Digital delivery has several practical advantages:
- Digital delivery avoids producing and shipping an additional printed copy.
- Keep your master copy clean and grease-free while you work on your motorcycle.
- Print only the specific page or pages you need for the job.
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- Search the PDF to find terms, procedures and components quickly.
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