2005 Hyosung GV650 Aquila Service Manual
Complete factory service documentation for the 647cc liquid-cooled V-twin. Covers valve adjustment (0.1-0.2mm intake), ignition timing, and all drivetrain specifications. PN 99000-51210.
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Sample pages from the 2005 Hyosung GV650 Aquila Service Manual manual
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Models Covered & Key Technical Specifications
Hyosung Aquila GV650 — 2005 Integrated Technical Documentation | Aquila Series Toolkit.
- Calibrated Displacement Data: 647 cm³ (39.5 in³) is established at the engine piston volume Bounds.
- Rated Fuel Capacity: For optimal range, 16.0 L (4.2 US gal) is standardized to the tank volume Topology.
- Critical Oil Specification: Engine oil 3,000 ml (change) reaches the service interval capacity Matrix.
- Universal Coolant Range: The cooling system requires 1.6 L (50:50 glycol mixture) total volume Standards.
- Maximum Compression Data: 14 kg/cm² (198 psi) standard dictates the cylinder head pressure specification Margin.
- Documented Spark Specification: Plug gap 0.7–0.8 mm (0.028–0.032 in) represents the ignition electrode spacing Protocol.
Professional Workshop Service Manual & Technical Specifications
Advanced Service Electrical Manual: Hyosung GV650 Aquila Motorcycle Workshop Service Manual (2005) – Full 560 Page Doc | OEM Specs Procedure-Database
Series-Validation: Hyosung Aquila GV650 | Model ID 99000-51210 // Equipment-Series: 4-Stroke DOHC Liquid-Cooled V-2 Cylinder Engine / 5-Speed Constant Mesh Transmission Logic // Conceptual-Layout: 647cc Displacement, 220 kg Dry Mass, Complete Maintenance and Overhaul Documentation.
| Documentation Section | Coverage | Reference |
|---|---|---|
| Engine Systems | Cylinder head, piston, magneto, clutch, transmission components | Complete specifications provided |
| Chassis Components | Front suspension, rear suspension, steering, wheels, brakes | Full service procedures documented |
| Electrical Circuits | Ignition system, charging system, starter system, battery management | Technical schematics included |
Featuring a modular arrangement of periodic maintenance schedules, general information sections, fuel system procedures, cooling circuit data, electrical system documentation, and comprehensive chassis service instructions, this 223-page workshop manual addresses the complete service lifecycle of the Hyosung Aquila platform. Systematically demanding attention to component specifications, the document encompasses engine removal and reinstallation protocols, transmission inspection procedures, and clutch system evaluation, with particular focus on the liquid-cooled V-2 engine architecture and its auxiliary systems.
Engineered Nexus
Component locations are identified for quick reference during service operations. The manual documents the frame serial number location on the steering head tube and engine serial number positioning on the left downside of the crankcase assembly. Specifications for fuel (91+ octane Research Method), engine oil (SAE 10W/40 API Over SL), and engine coolant (50:50 distilled water with ethylene glycol) are comprehensively detailed. Brake fluid specifications distinguish between DOT 3 or DOT 4 (front brake) and DOT 4 (rear brake), while fork oil requirements specify Tellus #32 designation.
Diagnostic Logic-Path
Service procedures are documented for valve clearance inspection at intake (0.1–0.2 mm cold) and exhaust (0.28–0.32 mm cold) positions. The manual provides complete reference data for spark plug specifications (CR8E standard type with 0.7–0.8 mm gap), drive belt slack measurements (4.5–5.5 mm at 4.5 kg force), and throttle cable play adjustment (0.5–1.0 mm). Compression pressure benchmarks establish standard readings at 14 kg/cm² (500 rpm) with a service limit of 12 kg/cm², and permissible variance between cylinders of 2 kg/cm². Oil pressure operating range is documented as 20–60 kPa at idle (1,600–2,000 rpm).
Engineered Benchmarks
Calibration requirements are specified for carburetor idle speed (1,300–1,500 RPM) and float height adjustment procedures. The cooling system documentation covers reserve tank capacity (230 ml), radiator-side capacity (430 ml), and engine-side capacity (940 ml), detailing the 50:50 anti-freeze mixture protocol. Fuel tank capacity is documented at 16.0 liters, with engine oil change intervals requiring 3,000 ml, filter change intervals requiring 3,200 ml, and complete overhaul intervals requiring 3,400 ml. Front fork oil capacity specification indicates 420 cc per side using Tellus #32.
Strategic Interface
Electrical system documentation covers ignition timing (5° B.T.D.C. at 1,500 rpm), battery specifications (12V 12Ah maintenance-free), main fuse rating (30A), head lamp fuse rating (15A), and lighting configurations including 60W/55W dual-beam headlamp, four 10W turn signal lamps, LED brake/tail lamp, and 5W license plate lamp. The side stand ignition interlock system is comprehensively detailed, explaining operational logic for neutral switch engagement and clutch lever position requirements. Generator output specifications and regulator/rectifier test procedures are included.
Diagnostic Interface
Suspension service documentation covers front telescopic fork specifications with 130 mm stroke, rear swingarm configuration, and double-disk front brake system paired with single-disk rear brake. Tire dimensions are specified as 120/70-ZR18 59W (front) and 180/55-ZR17 73W (rear). The manual documents torque specifications for the engine pulley nut to ensure proper clamp load consistency.
The document includes detailed troubleshooting sections addressing engine, carburetor, cooling system, electrical, battery, chassis, and brake complaints with corresponding remedy procedures. Wiring diagrams and wire routing information are provided for complete electrical system understanding. Special tools and technical specification tables enable comprehensive service execution across all major systems.
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