2005 Hyosung Comet 650 Service Manual (P/N 99000-94910)

Built for workshop use and experienced hands-on owners, this four-document factory set covers the standard Hyosung Comet 650 with its 2003 base service publication and adds the 2005 Comet 650S/650R model differences. It combines factory repair procedures with two OEM parts catalogs, allowing service operations, inspection data, exploded assemblies, and part-number tables to be checked together.

• 497-page PDF set: 210-page Comet 650 Service Manual P/N 99000-94810; 49-page Comet 650S/650R Service Manual Supplement P/N 99000-94910; 114-page GT650 parts catalog; and 124-page GT650S/R parts catalog.
• Engine and driveline repair: engine removal and reinstallation, full disassembly and reassembly of the liquid-cooled DOHC V-twin, cylinder heads, camshafts and valve train, pistons, crankshaft and crankcase, starter clutch, oil pump, clutch, six-speed transmission, and gearshift mechanism.
• Fuel, cooling, and brake work: BDSR39 carburetor removal, cleaning, inspection, float adjustment, and idle setup; radiator, cooling fan, thermostat, temperature sensor, and water pump testing; coolant and brake-circuit bleeding.
• S/R-specific chassis coverage: rear carrier removal and installation, under-cowling and body-cowling access, handlebar and control removal, footrest/link-rod adjustment, steering-stem service, headlamp replacement, and combination-meter testing.
• Electrical diagnosis: ignition, charging, starter, and side-stand interlock systems, igniter resistance tables, switch and vacuum fluorescent display (VFD) combination-meter continuity checks, cable-routing views, and complete wiring diagrams.
• OEM parts identification: 117 illustrated parts plates - 56 for the standard GT650 and 61 for the GT650S/R - with factory numbers, quantities, market-code columns, color-suffix guidance, model-specific bodywork, and VIN-based part breaks.

Base Manual vs. 2005 S/R Supplement

P/N 99000-94810 is the main workshop manual. It handles the shared engine, fuel, cooling, electrical, brake, suspension, steering, and chassis repair procedures. P/N 99000-94910 is a model supplement, not a stand-alone repair manual; it documents the 2005 Comet 650S/650R differences and directs the technician back to the base publication for unchanged work. With both manuals present, the original factory cross-reference structure remains intact.

The supplement adds standard- and sports-type specifications, revised carburetor idle checks, clutch and gearshift setup, three-position footrest information, optional gearshift-link-rod application, variant-specific cowling and handlebar procedures, steering work, VFD combination-meter checks, revised harness routing, and the S/R wiring diagram.

Engine, Electrical, and Chassis Repair Depth

The base engine chapter covers full internal repair rather than scheduled maintenance alone. It documents engine teardown and reassembly, with inspection coverage for the cylinder heads, valves and guides, camshafts, tappets and shims, cylinders, pistons and rings, connecting rods, crankshaft, starter clutch, clutch pack, transmission gears, shift forks, bearings, and crankcases. Troubleshooting tables address hard starting, low compression, abnormal engine or transmission noise, clutch slip or drag, poor shifting, overheating, carburetor faults, charging and starter problems, steering instability, suspension complaints, and brake performance.

Reference material includes component-specific torque tables, service limits, clearances, fluid data, and electrical test specifications. Key visual references include the cooling circuit, charging-system schematic, starter/side-stand interlock diagram, S/R VFD combination-meter terminal view, wire-and-cable routing layouts, and intake/exhaust tappet-shim selection charts. The special-tool section identifies the crankcase separator 09920-13120, crankshaft installer 09910-32812 with adapter 09910-32813, clutch sleeve hub holder 09920-53710, and front fork oil seal installer 09940-50113.

The manual also flags repair traps that matter on the bench: separating the crankcase from the wrong side can damage the gearshift-cam stopper, while driving the crankshaft into the case instead of using the installer can affect alignment. Oil-filter orientation is specifically marked because reverse installation can damage the engine. The rear shock absorber is treated as a non-serviceable assembly rather than an internal rebuild.

OEM Parts Identification and VIN Breaks

The two parts catalogs map the motorcycle from the front and rear cylinder heads through the radiator, crankcase, camshaft/valve system, carburetors, clutch, transmission, wiring harness, speedometer/combination meter, frame, brakes, suspension, wheels, fuel tank, seat, and body panels. The S/R catalog separately identifies S/R body cowling, R-only cowling, and high- and low-handlebar/steering-head configurations.

Market columns and VIN breaks help distinguish hardware before ordering. A recurring break between KM4MP51A341100140 and KM4MP51A341100141 appears across fork, handlebar/control, and rear-shock listings, while the front master-cylinder table identifies a change beginning at KM4MP51A351103171. Representative callouts retained in the catalogs include front cylinder-head assembly 11110SN9100HPA, CR8E spark plugs, brake-pedal assembly 43110HM810003P, and radiator-fan motor 17810HN9100.

Fuel-system, brake-hydraulic, steering, and internal-engine repair requires proper shop safety and the specified tools; the factory manual is written for users with motorcycle-service knowledge.