Hyosung GV650 Aquila Motorcycle Workshop Service Manual (2005) – Full 560 Page Doc | OEM Specs
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Sample pages from the Hyosung GV650 Aquila Motorcycle Workshop Service Manual (2005) – Full 560 Page Doc | OEM Specs manual
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Models Covered & Key Technical Specifications
- Hyosung Aquila (Series: GV650 / Model ID: 99000-51210)
Machine Identification & Series
- Hyosung Aquila (Series: GV650) | Dry Mass: 220 kg (485 lbs) | Wheelbase: 1,665 mm (65.6 in)
- Overall Dimensions: 2,430 mm (L) | 840 mm (W) | 1,155 mm (H) | Ground Clearance: 160 mm (6.3 in)
Powerplant & Performance
- Engine: 4-Stroke, DOHC, Liquid-Cooled V-2 Cylinder | Displacement: 647 cm³ (39.5 in³)
- Bore & Stroke: 81.5 x 62.0 mm | Compression: 14 kg/cm² (Standard) | 12 kg/cm² (Service Limit)
- Carburetor: BDSR39 Type (Double) | Idle Speed: 1,300 – 1,500 RPM | Ignition: Igniter Type
Drivetrain & System Logic
- Transmission: 5-Speed Constant Mesh | Pattern: 1-down, 4-up | Clutch: Wet Multi-plate
- Final Reduction: 2.79 | Drive: Poly Chain Belt | Ratios: 1st 2.46, 2nd 1.78, 3rd 1.38, 4th 1.13, 5th 0.96
- Chassis: Telescopic Front Suspension | Swingarm Rear | Double Disk Front Brakes | Single Disk Rear
Service Benchmarks & Settings
- Valve Clearance (Cold): Intake 0.1 – 0.2 mm | Exhaust 0.28 – 0.32 mm
- Spark Plug: CR8E (Standard) | Gap: 0.7 – 0.8 mm (0.028 – 0.032 in) | Torque: 11 Nm
- Torque Specs: Engine Pulley Nut 130–160 Nm | Rear Axle Bolt 90–140 Nm | Oil Drain Plug 21 Nm
- Belt Slack (Rear on Ground): 4.5 – 5.5 mm (at 4.5 kg force) | Throttle Play: 0.5 – 1.0 mm
Fluids & Capacities
- Fuel Tank: 16.0 Liters | Octane: 91+ (Research Method)
- Engine Oil: SAE 10W/40 (API Over SL) | 3,000 ml (Change) | 3,200 ml (Filter Change) | 3,400 ml (Overhaul)
- Coolant: 1.6 Liters Total (Engine 940ml | Radiator 430ml | Reserve 230ml) | Ratio: 50:50 Distilled/Ethylene Glycol
- Brakes: DOT 3 or DOT 4 (Front) | DOT 4 (Rear) | Fork Oil: 420 cc (Tellus #32)
Professional Workshop Service Manual & Technical Specifications
Hyosung GV650 Aquila Workshop Service Manual
Maximize your machine's operational uptime and ensure structural integrity by utilizing the same technical protocols used by factory-certified technicians. This comprehensive documentation provides the precise mechanical tolerances and safety sequences required to maintain the high-performance standards of the Aquila powerplant. By following these OEM-validated procedures, you eliminate the risks associated with guesswork, protecting both the rider and the long-term resale value of the motorcycle.
Precision Model Coverage and Series Identification
This manual is engineered specifically for the Hyosung GV650 (Aquila) series. It covers the core 647cc V-Twin platform, including specific technical variations for the carburetor-based induction systems and the specialized belt-drive drivetrain. It is the primary resource for models identified under the 99000-51210 engineering code.
Strategic Maintenance for Maximum Reliability
- Eliminate Costly Diagnostic Errors: Identify root causes in the electrical or fuel systems using step-by-step troubleshooting flows before replacing expensive components.
- Preserve Component Longevity: Adhere to exact torque specifications and fluid requirements to prevent premature wear on the V-twin engine and final drive belt.
- Professional Grade Accuracy: Access factory-level clearance measurements (0.1mm–0.32mm) to maintain optimal valve timing and combustion efficiency.
Manual Technical Metadata
- Document Type: Full Factory Service Manual
- Total Page Count: 560 Pages
- File Format: Searchable Digital PDF
- Language: English
Advanced Diagnostics and System Troubleshooting
The manual features sophisticated diagnostic matrices designed to isolate performance bottlenecks within the DOHC engine and the transistorized ignition system. By cross-referencing error symptoms with the provided voltage and resistance benchmarks, technicians can quickly restore the machine to factory specifications, reducing labor hours and ensuring a first-time-fix rate.
High-Resolution Schematic Engineering
Every system is supported by high-fidelity technical illustrations and exploded-view diagrams that maintain clarity even at high zoom levels. These visuals provide a transparent look at complex assemblies, such as the 5-speed constant mesh transmission and the dual-disk front braking system, allowing for confident disassembly and error-free re-integration.
Detailed Technical Architecture
- General Information: Product identification, specifications, and professional service precautions.
- Periodic Maintenance: Lubrication schedules, drive belt tensioning, and compression testing.
- Engine Overhaul: Cylinder head servicing, piston ring alignment, and crankshaft tolerances.
- Fuel & Cooling Systems: Carburetor synchronization, cooling fan circuitry, and thermostat testing.
- Electrical Infrastructure: Wiring diagrams, charging system output, and ignition timing.
- Chassis & Suspension: Fork oil replacement, brake caliper rebuilding, and steering stem adjustment.
Critical Service Benchmarks and Performance Benefits
| Technical Specification | Value / Setting | Longevity Benefit |
|---|---|---|
| Valve Clearance (Cold) | IN: 0.1–0.2mm / EX: 0.28–0.32mm | Prevents valve burnt-out and maintains peak volumetric efficiency. |
| Engine Oil Capacity | 3.2 Liters (with Filter Change) | Ensures optimal thermal regulation and reduces internal friction wear. |
| Drive Belt Tension | 4.5–5.5mm Slack | Prevents premature bearing failure in the final drive and transmission. |
| Spark Plug Gap | 0.7–0.8 mm (CR8E) | Guarantees complete combustion to prevent carbon buildup and fouling. |
FAQ
Does this manual cover the specific fuel and induction systems for the GV650 series? Yes, this document provides comprehensive technical coverage for the Mikuni BDSR39 carburetor setup used on the Aquila powerplant. It includes precise synchronization procedures and float height settings to ensure the 90-degree V-twin maintains its target idle speed of 1,300 – 1,500 RPM, which is critical for preventing engine stalling and ensuring smooth throttle response during low-speed maneuvers.
What is the specific valve clearance required for the Aquila DOHC engine? The manual specifies a cold valve clearance of 0.1 – 0.2 mm for the intake valves and 0.28 – 0.32 mm for the exhaust valves. Adhering to these exact tolerances during periodic maintenance prevents premature valvetrain wear and ensures optimal volumetric efficiency, which protects the engine from power loss and potential cylinder head damage.
Can I resolve charging system failures using the electrical schematics in this guide? Absolutely. The manual details the transistorized ignition system and the charging circuit, providing specific output benchmarks such as the 14.0 – 15.0V regulated voltage at 5,000 RPM. By using these values to test the magneto and rectifier, owners can accurately diagnose battery drain issues and avoid the unnecessary expense of replacing functional electrical components.
What are the critical torque specifications for the final drive system? For the belt-drive assembly, the manual mandates a high-torque setting of 130 – 160 Nm for the engine pulley nut and 90 – 140 Nm for the rear axle bolt. Applying these specific force values ensures the structural integrity of the drivetrain and maintains the required 4.5 – 5.5 mm of belt slack, which prevents vibration and extends the service life of the Poly Chain belt.
How does the digital format assist with complex mechanical repairs? The high-resolution digital format allows for 400% zoom on intricate technical illustrations, such as the 5-speed constant mesh transmission exploded views and the liquid-cooling system routing. This level of visual detail ensures that technicians can identify the exact placement of small components like the 1.1 kg/cm² radiator cap seal or internal O-rings, facilitating a professional-grade reassembly that meets original factory standards.
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