Hyosung GV650 Aquila Carbureted Service Manual (2005)

Hyosung GV650 Aquila Carbureted Service Manual (2005)
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Original Hyosung Motors & Machinery Inc. factory Service Manual for the carbureted GV650 Aquila. The 223-page PDF covers general specifications, periodic maintenance, valve-clearance and compression checks, complete engine removal and overhaul, cylinder heads, pistons, crankshaft, clutch and five-speed transmission, drive-belt service, 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, cable routing, wiring diagram and tappet-shim charts.

About the Manual

Manual type
Factory Service Manual
Years covered*
2005
Pages
223
Language
English
Format
PDF
Main sections
49
Searchable PDF
Yes
Printable PDF
Yes
File size
7.6 MB
Delivery
Digital download

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

Hyosung Aquila GV650 GV650 Aquila - carbureted version Motorcycle Details

Manufacturer
Hyosung
Series
Aquila
Models Covered
GV650
Generation / variant
GV650 Aquila - 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
5-speed constant-mesh gearbox; 1-down, 4-up shift pattern
Final Drive
Poly chain belt; final reduction ratio 2.79
Overall dimensions
2,430 × 840 × 1,155 mm (L × W × H)
Wheelbase
1,665 mm
Ground clearance
160 mm
Mass
220 kg
Front suspension
Telescopic type; 130 mm fork stroke
Rear suspension
Swingarm type
Caster / trail
35° / 160 mm
Front brake
Twin hydraulic disc brakes
Rear brake
Hydraulic disc brake
Front tire
120/70-ZR18 59W
Rear tire
180/55-ZR17 73W
Battery
12 V 12 Ah maintenance-free
Ignition
Igniter type; 5° BTDC at 1,500 rpm
Spark plug
CR8E
Starter system
Electric starter
Gear ratios
1st 2.46 / 2nd 1.78 / 3rd 1.38 / 4th 1.13 / 5th 0.96

What’s Included in the Hyosung Aquila GV650 GV650 Aquila - carbureted version Service Manual?

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

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About the Hyosung GV650

Hyosung introduced the GV650 in 2005 as a middleweight cruiser that deliberately broke with the low-output, air-cooled formula common in the class. The bike used the company's 647 cm³ liquid-cooled DOHC 90-degree V-twin, closely related to the engine family used in Hyosung's GT650 road and sport models. Australian model records list the GV650 Aquila as a 2005 release, while contemporary launch coverage described the machine as a “sports cruiser” rather than a traditional heavyweight custom. RedBook's 2005 GV650 Aquila record documents that launch-year positioning and basic specification.

The Aquila name was used in many export markets for the same platform, while North America also saw the Avitar name. The 2005 chassis was long and low, with a 1,665 mm wheelbase, 35-degree caster, 160 mm trail and 220 kg mass, but its hardware was more performance-oriented than its cruiser silhouette suggested. The factory specification combined 120/70-ZR18 and 180/55-ZR17 radial tires, twin front discs, a rear disc and 130 mm of front-fork travel. Motoplanete's 2005 overview described the GV650 as Hyosung's expansion of its 650 twin into the custom segment and emphasized how unusual its performance focus was for the class. Motoplanete's 2005 GV650 Aquila history provides that period context.

The first production specification used twin BDSR39 carburetors feeding the 647 cm³ V-twin, with a five-speed constant-mesh gearbox, wet multi-plate clutch and belt final drive. The result was a sport-oriented middleweight cruiser with a higher-revving character than many similarly styled motorcycles. The belt final drive reduced routine chain maintenance, while the shared 650 engine architecture gave the GV650 a technical link to Hyosung's GT650 family rather than to the company's smaller cruisers.

The platform subsequently evolved, with electronic fuel injection becoming the key technical break from this original carbureted generation. Later factory EFI service documentation treats the injection system as a distinct specification and refers technicians back to the earlier carburetor manual only for systems that remained unchanged. That makes the carbureted 2005 machine a clearly identifiable first-generation service configuration rather than a manual that should automatically be stretched across later EFI years.

This listing is therefore tied to the original carbureted factory source. Hyosung Motors & Machinery Inc. Service Manual No. 99000-51210 is explicitly marked “1st Ed. JUL. 2005” and documents the twin-carburetor, five-speed, belt-drive GV650/Aquila specification. Because the source itself does not state 2006-2009 applicability, catalog coverage is conservatively limited to 2005. Related factory publications are grouped in the Hyosung GV650 manual catalog.

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