2002 Hyosung Comet 250 / Comet 125 Factory Service Manual PDF (P/N 99000-94710)

The 2002 Hyosung Comet 250 and Comet 125 factory service manual, P/N 99000-94710, documents maintenance and repair for the carbureted V-twin models.

Text search and diagram detail: Service text is searchable, but model-name logos and some diagram lettering are not. There are no embedded PDF bookmarks. Small wiring labels require zooming.

• Engine and driveline: Engine removal, wet multi-plate clutch teardown, and five-speed transmission shaft removal; the internal engine inspection and reassembly sections are missing.

• Periodic maintenance: Valve-clearance inspection and shim selection, compression and oil-pressure testing, drive-chain adjustment, and fluid recommendations.

• Fuel system: Fuel tank and fuel-cock removal, dual-carburetor cleaning and float-height adjustment, plus model-specific fuel-pump checks.

• Electrical repair: Ignition and charging tests, starter-motor overhaul, switch continuity checks, and side-stand ignition-interlock circuits.

• Brakes and chassis: Disc-brake caliper and master-cylinder service, hydraulic bleeding, telescopic-fork rebuilds, steering-stem bearings, wheel bearings, and swingarm-pivot service.

• Workshop references: Model-specific wiring diagrams, wire and cable routing views, troubleshooting tables, tightening torques, and component wear limits.

Hyosung intended this manual for readers who already have the knowledge and skills to service its vehicles; general workshop fundamentals are not included.

Engine Teardown and Coverage Limits

Cylinder head cover, camshaft, piston, clutch, and oil-pump removal lead into crankcase separation. The engine chapter stops at printed page 3-18: “Engine Component Inspection and Service,” listed at 3-19, and “Engine Reassembly,” listed at 3-36, are absent. Engine, clutch, and transmission service-data tables remain included.

The crankcase instructions identify separator 09920-13120 and warn that separating the case from the wrong side can damage the gearshift cam stopper.

The maintenance section contains front- and rear-cylinder valve-clearance procedures and separate intake and exhaust Tappet Shim Selection Charts. Compression and oil-pressure tests provide different reference values for the two models.

Serial-number locations, exterior illustrations, and the Periodic Maintenance Chart support identification and routine servicing.

Fuel System Repair and Model Differences

Carburetor procedures cover diaphragm and piston-valve assemblies, jets, needle valves, and float chambers. Separate front- and rear-carburetor jetting tables help match specifications to the model and cylinder before carburetor repair.

The Comet 250 uses an electric fuel pump, with pump and relay tests in the electrical section. The Comet 125 fuel-pump section covers its vacuum connection and hose routing.

Charging, Ignition, and Starting Diagnosis

Charging-system and side-stand ignition-interlock circuit diagrams accompany regulator/rectifier, magneto, and ignition-coil checks. Switch tables and the interlock operating-condition chart help distinguish a starting-circuit fault from normal interlock operation.

Starter-motor coverage includes brush, commutator, and armature inspection, followed by reassembly.

Forks, Steering, and Brake Repair

Separate fork sections cover the different Comet 250 and Comet 125 assemblies, with exploded views, seal replacement, and oil-level procedures. Steering-stem and swingarm instructions address bearing work. Rear shock coverage is limited to removal, inspection, and replacement because the unit is nonserviceable.

Brake sections cover caliper bores, piston seals, master-cylinder inspection, and reassembly. The manual warns that incompatible brake fluids can damage the hydraulic system. Working with these components requires proper workshop safety gear and a solid mechanical foundation to prevent equipment damage or personal injury.

Cold Valve Clearances and Engine Mounting Torque

For both models, the valve-clearance section specifies 0.1-0.2 mm at the intake valves and 0.2-0.3 mm at the exhaust valves with the engine cold. These values accompany the inspection procedures and shim-selection charts.

Engine reinstallation specifies 40-60 N·m for the engine mounting bolts, also listed in the engine tightening-torque table.

Printable PDF and Included Pages

One printable, 163-page English PDF contains 150 technical/reference pages, seven section contents pages, five opening pages including the cover, and one publication-details page. All are included in the total.