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Hyosung Comet 650 S R All Service Repair Manual

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🏷️ Basic Information Identification Make: Hyosung Model: Comet 650 S R Product Type: Service and Repair Manual 👋 Introduction Market Position Motorcycle Segment: Sportbike / Naked Sportbike Competitive Analysis Competitors: Directly competes with other mid-sized naked and faired sportbikes from manufacturers like Kawasaki (Ninja 650/ER-6n), Suzuki (SV650), Yamaha (FZ6/MT-07), and Honda (CB500F/CBR500R). Key Features Design Philosophy: Offers a performance-oriented V-twin engine in a sporty chassis, providing a balance of power, handling, and aggressive styling at a competitive price point. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service, repair, diagnostics, and maintenance for Hyosung Comet 650 S and R models. Page Count Estimated Page Count: 400-600 pages (typical for this class of motorcycle manual) Manual Type Manual Type: Factory-level Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed breakdown of the 650cc V-twin engine, including cylinder head, valve train, crankshaft, piston, connecting rods, lubrication system, cooling system, and fuel injection. Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, sensors (TPS, MAP, IAT, ECT), and emissions control. Transmission: Clutch operation, gear shifting mechanism, gearbox internals, lubrication, and troubleshooting. Electrical System: Battery, charging system (stator, regulator/rectifier), ignition system (ECU, coils, spark plugs), lighting, starter motor, and wiring diagrams for all circuits. Chassis And Suspension: Frame inspection, front fork service (oil change, seal replacement), rear shock absorber adjustment and overhaul, steering head bearing service. Brakes: Front and rear brake caliper overhaul, master cylinder service, brake line replacement, bleeding procedures, pad and disc inspection and replacement. Cooling System: Radiator, coolant hoses, thermostat, water pump, and coolant flush and refill procedures. Exhaust System: Exhaust pipe inspection, muffler, and lambda sensor (if applicable). Bodywork And Trim: Fairing removal and installation, seat, fuel tank, fenders, and other cosmetic components. Wheels And Tires: Wheel bearing inspection and replacement, tire pressure, and mounting/balancing procedures. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid checks, coolant level checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), and problem isolation techniques. Engine Rebuild: Detailed instructions for engine disassembly, inspection of internal components, reassembly, and break-in procedures. Suspension And Steering Overhaul: Fork seal replacement, shock absorber rebuild, steering stem bearing replacement. Brake System Overhaul: Caliper rebuild, master cylinder replacement, line bleeding. Electrical Diagnostics And Repair: Wiring diagram interpretation, component testing, fault finding for lighting, ignition, charging, and starter systems. Fuel System Cleaning And Adjustment: Injector cleaning, throttle body synchronization, sensor testing. Technical Depth Depth Of Information: Provides detailed specifications, torque values, clearance measurements, diagnostic procedures, and step-by-step repair instructions suitable for both DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format File Type: PDF Print Quality Print Readability: High-resolution, fully searchable text and clear, legible diagrams for easy printing and on-screen viewing. Binding Type Binding: Not Applicable (Digital PDF Download) Paper Type Paper Quality: Not Applicable (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, 8-valve, DOHC, 90-degree V-twin Displacement: 647cc Bore X Stroke: 81.5 mm x 62 mm Compression Ratio: 11.3:1 Max Power: Approximately 80 HP (59.6 kW) @ 9000 rpm (Varies slightly by model year and specific variant) Max Torque: Approximately 63 Nm (46.5 lb-ft) @ 7000 rpm (Varies slightly by model year and specific variant) Performance Top Speed: Estimated 210+ km/h (130+ mph) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual throttle bodies Fuel Type: Unleaded gasoline, minimum 91 octane Fuel Tank Capacity: Approximately 17 Liters (4.5 US gal) 🔧 Transmission Standard Transmission Type: Constant-mesh, 6-speed Clutch Type: Wet, multi-plate Features Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approximately 2100 mm (82.7 in) Width: Approximately 750 mm (29.5 in) Height: Approximately 1100 mm (43.3 in) Wheelbase: Approximately 1445 mm (56.9 in) Weights Dry Weight: Approximately 170-180 kg (375-397 lbs) (Varies by specific model and equipment) Wet Weight: Approximately 190-200 kg (419-441 lbs) (Varies by specific model and equipment) 🛡️ Safety Features Ratings Braking System: Dual hydraulic discs front, single hydraulic disc rear. ABS may be optional on certain model years/trims. Active Features Lighting: Halogen headlight, LED taillight, standard turn signals. Passive Features Frame Construction: Steel trellis frame providing rigidity and handling characteristics. 💡 Technology Features Infotainment Instrument Cluster: Digital/Analog combination instrument cluster featuring speedometer, tachometer, odometer, trip meters, fuel gauge, and indicator lights. Specific features may vary by model year. Driver Assistance ABS: Anti-lock Braking System (ABS) available as an optional feature on some Comet 650 S R models. Connectivity ECU Control: Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. Diagnostic capabilities are covered in the manual. 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km (3,700 miles) or 12 months, whichever comes first. Oil Filter Replacement: At each engine oil change. Air Filter Cleaning Or...
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Hyosung Comet 650 S R All Service Repair ManualHyosung Comet 650 S R All Service Repair ManualHyosung Comet 650 S R All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Hyosung
Model:
Comet 650 S R
Product Type:
Service and Repair Manual
👋 Introduction
Market Position
Motorcycle Segment:
Sportbike / Naked Sportbike
Competitive Analysis
Competitors:
Directly competes with other mid-sized naked and faired sportbikes from manufacturers like Kawasaki (Ninja 650/ER-6n), Suzuki (SV650), Yamaha (FZ6/MT-07), and Honda (CB500F/CBR500R).
Key Features
Design Philosophy:
Offers a performance-oriented V-twin engine in a sporty chassis, providing a balance of power, handling, and aggressive styling at a competitive price point.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service, repair, diagnostics, and maintenance for Hyosung Comet 650 S and R models.
Page Count
Estimated Page Count:
400-600 pages (typical for this class of motorcycle manual)
Manual Type
Manual Type:
Factory-level Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed breakdown of the 650cc V-twin engine, including cylinder head, valve train, crankshaft, piston, connecting rods, lubrication system, cooling system, and fuel injection.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, sensors (TPS, MAP, IAT, ECT), and emissions control.
Transmission:
Clutch operation, gear shifting mechanism, gearbox internals, lubrication, and troubleshooting.
Electrical System:
Battery, charging system (stator, regulator/rectifier), ignition system (ECU, coils, spark plugs), lighting, starter motor, and wiring diagrams for all circuits.
Chassis And Suspension:
Frame inspection, front fork service (oil change, seal replacement), rear shock absorber adjustment and overhaul, steering head bearing service.
Brakes:
Front and rear brake caliper overhaul, master cylinder service, brake line replacement, bleeding procedures, pad and disc inspection and replacement.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, and coolant flush and refill procedures.
Exhaust System:
Exhaust pipe inspection, muffler, and lambda sensor (if applicable).
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders, and other cosmetic components.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure, and mounting/balancing procedures.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid checks, coolant level checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), and problem isolation techniques.
Engine Rebuild:
Detailed instructions for engine disassembly, inspection of internal components, reassembly, and break-in procedures.
Suspension And Steering Overhaul:
Fork seal replacement, shock absorber rebuild, steering stem bearing replacement.
Brake System Overhaul:
Caliper rebuild, master cylinder replacement, line bleeding.
Electrical Diagnostics And Repair:
Wiring diagram interpretation, component testing, fault finding for lighting, ignition, charging, and starter systems.
Fuel System Cleaning And Adjustment:
Injector cleaning, throttle body synchronization, sensor testing.
Technical Depth
Depth Of Information:
Provides detailed specifications, torque values, clearance measurements, diagnostic procedures, and step-by-step repair instructions suitable for both DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Print Readability:
High-resolution, fully searchable text and clear, legible diagrams for easy printing and on-screen viewing.
Binding Type
Binding:
Not Applicable (Digital PDF Download)
Paper Type
Paper Quality:
Not Applicable (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, 8-valve, DOHC, 90-degree V-twin
Displacement:
647cc
Bore X Stroke:
81.5 mm x 62 mm
Compression Ratio:
11.3:1
Max Power:
Approximately 80 HP (59.6 kW) @ 9000 rpm (Varies slightly by model year and specific variant)
Max Torque:
Approximately 63 Nm (46.5 lb-ft) @ 7000 rpm (Varies slightly by model year and specific variant)
Performance
Top Speed:
Estimated 210+ km/h (130+ mph)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline, minimum 91 octane
Fuel Tank Capacity:
Approximately 17 Liters (4.5 US gal)
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 6-speed
Clutch Type:
Wet, multi-plate
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approximately 2100 mm (82.7 in)
Width:
Approximately 750 mm (29.5 in)
Height:
Approximately 1100 mm (43.3 in)
Wheelbase:
Approximately 1445 mm (56.9 in)
Weights
Dry Weight:
Approximately 170-180 kg (375-397 lbs) (Varies by specific model and equipment)
Wet Weight:
Approximately 190-200 kg (419-441 lbs) (Varies by specific model and equipment)
🛡️ Safety Features
Ratings
Braking System:
Dual hydraulic discs front, single hydraulic disc rear. ABS may be optional on certain model years/trims.
Active Features
Lighting:
Halogen headlight, LED taillight, standard turn signals.
Passive Features
Frame Construction:
Steel trellis frame providing rigidity and handling characteristics.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/Analog combination instrument cluster featuring speedometer, tachometer, odometer, trip meters, fuel gauge, and indicator lights. Specific features may vary by model year.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) available as an optional feature on some Comet 650 S R models.
Connectivity
ECU Control:
Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters. Diagnostic capabilities are covered in the manual.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first.
Oil Filter Replacement:
At each engine oil change.
Air Filter Cleaning Or Replacement:
Every 6,000 km (3,700 miles) or as needed based on operating conditions. Replacement recommended every 12,000 km (7,500 miles).
Spark Plug Inspection And Replacement:
Inspect every 6,000 km (3,700 miles), replace every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Coolant Flush And Replacement:
Every 24,000 km (15,000 miles) or 24 months.
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
Approximately 3.0 Liters (3.2 US qt) with filter change.
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water. Color may vary by manufacturer, but often green or orange.
Brake Fluid Type:
DOT 4
Fork Oil Type:
SAE 10W (Specific type and amount detailed in the manual)
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, fork seals, and clutch plates are typical wear items that may require replacement over time.
Electrical Components:
Some earlier models reported potential issues with the regulator/rectifier. Regular checks of the charging system are advisable.
Engine Performance Quirks:
Ensure proper synchronization of throttle bodies and clean injectors for optimal performance, especially at higher mileage.
📚 Vehicle History
Brand Heritage
Manufacturer:
Hyosung Motors & Marine Machinery (now S&T Motors, later rebranded to KR Mobility).
Model Evolution
Introduction Year:
The Comet 650 platform, including the GT650 naked and GT650R faired variants, was introduced in the early 2000s, with the Comet 650 S R representing specific styling and configuration updates over the years.
Production
Manufacturing Origin:
South Korea
🏆 Awards & Recognition
Recognitions
Market Reputation:
The Hyosung Comet 650 platform is generally recognized for offering strong value for money within its performance segment, providing a capable and engaging riding experience.
Ratings
Performance Segment Analysis:
Considered a strong contender for riders seeking a sportbike experience without the premium price tag of some Japanese or European competitors. Known for its robust V-twin motor.
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