Hyosung Comet 650 Manual Set with 2005 650S/650R Supplement (P/N 99000-94810)

The supplement covers the S/R model differences and directs you to the included base manual for shared service and overhaul procedures. Use the catalogs alongside those procedures to match parts to the exploded assemblies and check the applicable market column before ordering.

Text Search, Bookmarks, and Wiring Detail

Finding parts and procedures: Both service manuals have searchable service text and chapter bookmarks. The supplement’s illustrated radiator-cap access page is outside text search. The GT650 catalog has searchable parts tables and image-only plates, while the S/R catalog also has searchable labels on many plates. Bookmarks are limited to the service manuals. Small connector and wire-color labels in both wiring diagrams are legible when enlarged.

The ZIP contains 497 pages across four printable PDFs. That total includes the service manuals’ two cover pages and two imprint pages, the base manual’s two tappet-shim charts, and four pages of catalog front matter.

Engine Overhaul, S/R Chassis Service, and Parts Lookup

These selected workshop topics sit alongside procedures for drive-chain inspection and steering-head bearing checks.

• Engine and driveline: Removal and reinstallation of the liquid-cooled DOHC V-twin, internal teardown and reassembly, and service of the starter clutch, oil pump, clutch, and six-speed transmission.
• Fuel system: Fuel-pump flow checks and BDSR39 carburetor removal, cleaning, inspection, float-height adjustment, and idle setup.
• Cooling system: Radiator and water-pump service, fan, thermostat, and temperature-sensor checks, plus coolant replacement and bleeding.
• Brakes and suspension: Front and rear brake service, including caliper and master-cylinder work, brake bleeding, and front fork disassembly and inspection.
• S/R chassis: Rear carrier removal and installation, cowling access, handlebar and steering-stem service, and footrest, clutch, and gearshift linkage adjustments.
• Electrical diagnosis: Ignition and charging tests, starter and side-stand interlock checks, switch continuity, harness routing, and model-specific wiring diagrams.
• OEM parts lookup: 117 illustrated plates, with 56 for the GT650 and 61 for the GT650S/GT650R, paired with part numbers, quantities, market columns, and VIN notes.

The service procedures are suited to technicians and experienced owners who already have motorcycle repair knowledge and the specified tools.

Engine Inspection and Bench Work

The base manual covers cylinder heads, valves and guides, camshafts, tappets and shims, cylinders, pistons and rings, connecting rods, the crankshaft, and crankcases. The gearbox inspection covers gears, shift forks, and bearings. Troubleshooting tables cover hard starting, low compression, abnormal engine or transmission noise, clutch slip or drag, poor shifting, overheating, carburetor faults, steering instability, suspension complaints, and brake performance.

The manual warns that splitting the crankcase from the wrong side can damage the gearshift-cam stopper, driving the crankshaft into the case can affect alignment, and reversing the oil filter can damage the engine. The special-tool references include crankcase separator 09920-13120, crankshaft installer 09910-32812 and adapter 09910-32813, clutch sleeve hub holder 09920-53710, and fork oil seal installer 09940-50113.

S/R Bodywork, Controls, and Electrical Checks

The supplement sends 650S Standard-type handlebar and steering work back to the base manual and gives separate procedures for the 650S Sports type and 650R. It covers the 650R under-cowling, S/R radiator-cap access, and the optional link rod used with the three-position footrests. The base manual treats the rear shock as a replacement assembly if inspection finds damage or leakage.

For electrical fault tracing, the manuals pair circuit diagrams with test specifications. The S/R supplement includes an igniter resistance table, headlamp bulb replacement, vacuum fluorescent display (VFD) combination-meter continuity checks, and a terminal view. The base manual includes a charging schematic and a starter/side-stand interlock diagram.

Fuel-system, brake-hydraulic, steering, and internal-engine work requires proper shop precautions and the specified tools.

Parts Identification by Market and VIN

The catalogs include front and rear cylinder heads, carburetors, radiator and fan, wiring harness, meters, frame, brakes, wheels, fuel tank, seat, and body panels. The S/R catalog separates shared cowling from R-only panels and shows high- and low-handlebar steering configurations.

Use the market columns and VIN remarks to distinguish fork, control, rear-shock, and front master-cylinder listings. The catalog front matter explains color suffixes for painted parts. Example callouts include front cylinder-head assembly 11110SN9100HPA, brake pedal 43110HM810003P, and radiator-fan motor 17810HN9100.

Valve and Fork Service Data

The base manual gives cold valve clearances of 0.10–0.20 mm for intake and 0.20–0.30 mm for exhaust, with separate tappet-shim selection charts.

Both service publications specify 380 cc of front fork oil per leg. The base manual also gives a 146 mm oil level measured from the end of the outer tube with the fork fully compressed and the spring removed.