2005 Hyosung GV650 Aquila Factory Service Manual PDF (P/N 99000-51210)

• 2005 Hyosung GV650 Aquila: BDSR39 dual carburetors and belt final drive.

• Engine repair: Removal and reinstallation, crankcase separation, wet-clutch repair, and transmission disassembly.

• Carburetor service: Teardown, float-height adjustment, and fuel-cock and fuel-pump inspection.

• Cooling system: Water-pump service, thermostat testing, radiator removal, and cooling-system bleeding.

• Chassis and brakes: Drive-belt adjustment, front-fork service, steering-stem work, and front and rear brake repair.

• Electrical troubleshooting: Ignition and charging tests, starter-motor overhaul, and starter/side-stand interlock circuit diagrams.

Hyosung's factory service manual, Manual No. 99000-51210, is the July 2005 first edition.

This 223-page PDF is intended for readers who already have the knowledge and skills to service Hyosung motorcycles.

Engine Repair and Maintenance

This factory manual covers maintenance and mechanical overhaul of the liquid-cooled 647cc DOHC V-twin.

Maintenance and diagnosis: The periodic maintenance chart lays out scheduled service. Compression and oil-pressure tests help assess engine condition.

Internal engine work: Coverage includes cylinder-head disassembly, valve-clearance checks, cam-chain tensioner inspection, and piston-to-cylinder clearance measurement.

Valve timing and shims: Front and rear cylinder timing procedures account for their different camshaft installation arrangements. Tappet-shim selection charts cover intake and exhaust valves.

Transmission: Exploded views of the five-speed transmission accompany gear, shaft, and shift-fork inspection.

Crankcase caution: Incorrect separator placement can damage the gearshift cam stopper. For heavy maintenance or engine removal, follow standard shop safety protocols and use properly rated lifting equipment.

Fuel and Carburetor Service

Front and rear carburetor specifications distinguish the main jets and jet needles, helping keep cylinder-specific parts correctly matched during repair.

The fuel chapter also covers diaphragm, float, and needle-valve inspection, along with idle-speed and throttle-cable adjustment.

Cooling System

The Cooling Circuit diagram maps coolant flow through both cylinders. Water-pump coverage extends to the impeller, shaft bearing, and sealing components.

Fan-motor current checks, thermo-switch testing, and coolant-temperature sensor resistance tests support overheating diagnosis.

Chassis, Suspension and Brakes

Brake service: Caliper disassembly and inspection, front master-cylinder overhaul, disc wear checks, and hydraulic bleeding.

Bearings and swingarm: Wheel-bearing replacement and swingarm removal are covered.

Front forks: Procedures cover oil seals, oil-level setting, and rebound/compression adjustment.

Scope limitation: Fork-cartridge and rear-shock internal rebuilding are outside the scope; these units are treated as replacement assemblies.

Drive-belt handling: Cautions explain how excessive bending can break the belt's internal cords.

Electrical Troubleshooting

Electrical repair coverage includes igniter resistance tables and regulator/rectifier checks.

The Wiring Diagram and routing drawings document circuit connections and wire-and-cable placement.

Symptom/cause/remedy tables address starting and running faults, charging problems, overheating, and chassis complaints.

Specifications and Special Tools

Reference tables detail tightening torques, fluid capacities, wear limits, and spark-plug settings. Electrical test values and suspension adjustment data are also included.

Special-tool references identify the engine-mounting socket wrench 09940H30010 and front-fork oil-level gauge 09943-74111.

File Format and Readability

• Text search: Image-only scan without searchable text.
• Navigation: 223 bookmarks labeled by page number, without chapter names.
• Wiring diagram: Small wire-color codes are readable when enlarged; rotating the main schematic also helps.
• Scan quality: Sharpness varies elsewhere in the manual.

The 223-page total includes the cover, four introductory pages, two tappet-shim charts, and closing publication page.