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Hyosung GV250 GT250 EFI Service Repair Manual

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The GV250, also known as the Aquila, and its GT250 EFI variant, represent a classic cruiser motorcycle designed for comfortable riding and accessible customization. Featuring a 4-stroke, liquid-cooled, 45-degree V-twin...
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Hyosung GV250 GT250 EFI Service Repair Manual
The GV250, also known as the Aquila, and its GT250 EFI variant, represent a classic cruiser motorcycle designed for comfortable riding and accessible customization. Featuring a 4-stroke, liquid-cooled, 45-degree V-twin engine with a displacement of 249 cc, this model offers a blend of traditional cruiser styling with modern Electronic Fuel Injection (EFI) for improved performance and efficiency. The EFI system enhances throttle response and cold starts, making it a practical choice for commuting and recreational riding. With its robust engineering and focus on value, the GV250/GT250 EFI provides a reliable platform that has been a popular option in the entry-level to mid-range cruiser segment for many years. This comprehensive service repair manual is designed to provide detailed information for the maintenance and repair of the GV250 (Aquila) GT250 EFI. It covers a wide range of essential areas, including complete engine overhauls, fuel system diagnostics, transmission maintenance, chassis and suspension adjustments, and braking system procedures. Additionally, the manual offers guidance on electrical systems, cooling systems, and exhaust systems, along with scheduled maintenance tasks, troubleshooting guides for common issues, and specific repair procedures. With over 400 pages of content, this English-language digital manual serves as an indispensable resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Hyosung
Model:
GV250 (Aquila)
Model Variant:
GT250 EFI
Vehicle Type:
Cruiser Motorcycle
Codes
Engine Code:
GD250
👋 Introduction
Market Position
Market Segment:
Entry-level to mid-range cruiser motorcycle, popular for customization and commuting
Competitive Analysis
Key Competitors:
Honda Shadow 750, Kawasaki Vulcan 500, Suzuki Boulevard S40, Yamaha V-Star 650 (in terms of styling and intended use)
Key Features
Design Philosophy:
Classic cruiser styling with a V-twin engine, designed for comfortable riding and accessibility
Efi Advantage:
Electronic Fuel Injection offers improved fuel efficiency, throttle response, and easier cold starts compared to carbureted models
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count
Approximate Pages:
400+
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, piston, rings, cylinder, crankshaft, camshaft, valve train, timing
Engine Electrical:
Ignition system, CDI unit, spark plugs, charging system, stator, regulator/rectifier, starting system
Fuel System:
Electronic Fuel Injection (EFI) system, throttle body, fuel pump, injectors, sensors (MAP, TPS, IAT), ECU diagnostics
Transmission:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, gear ratios
Chassis:
Frame, swingarm, suspension (front fork, rear shock absorber) disassembly and adjustment
Braking System:
Front and rear brake calipers, master cylinders, brake lines, bleeding procedures, pad replacement
Electrical System:
Wiring diagrams, lighting system, instrumentation, horn, battery, fuses, relays
Cooling System:
Radiator, fan, coolant, hoses, thermostat
Exhaust System:
Exhaust pipes, mufflers, catalytic converter (if applicable)
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, valve clearance checks
Troubleshooting:
Diagnostic flowcharts for common issues, error code interpretation for EFI system
Repair Procedures:
Step-by-step instructions for major component overhauls and replacements
Assembly Disassembly:
Detailed guides for taking apart and reassembling all major motorcycle systems
Adjustment Procedures:
Carburetor synchronization (for non-EFI models, though this is EFI), clutch adjustment, throttle cable adjustment, suspension settings
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine rebuild)
Diagnostic Capability:
Includes EFI system diagnostic codes and procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations
Binding Type
Binding Type Digital:
N/A (Digital Format)
Paper Type
Paper Type Digital:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, liquid-cooled, 45-degree V-twin
Displacement:
249 cc (249 cm³)
Bore X Stroke:
57 mm x 49 mm
Compression Ratio:
11.0:1
Valvetrain:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approximately 30-33 HP (varies by market and specific tuning)
Torque:
Approximately 23-25 Nm (varies by market and specific tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Keihin (or similar) components
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
15 Liters (approx.)
🔧 Transmission
Standard
Transmission Type:
5-speed manual
Clutch Type:
Wet multi-plate
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2300 mm
Width:
Approx. 830 mm
Height:
Approx. 1120 mm
Wheelbase:
Approx. 1600 mm
Weights
Dry Weight:
Approx. 170-175 kg
Gross Vehicle Weight Rating:
Typically around 350 kg
🛡️ Safety Features
Ratings
Safety Standards:
Meets relevant motorcycle safety standards for its era and market
Active Features
Braking System Type:
Disc brakes front and rear (dual piston front, single piston rear common)
Passive Features
Lighting:
Halogen headlamp, LED taillight/indicators (model dependent)
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, fuel gauge, gear indicator, clock, and warning lights.
Driver Assistance
ABS:
ABS was an optional feature on some later EFI models.
Connectivity
Diagnostic Port:
OBD-II or proprietary diagnostic connector for EFI system access
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 - 6,000 km or 6 months, whichever comes first (refer to manual for exact spec)
Air Filter Inspection:
Every 6,000 km
Spark Plug Replacement:
Every 12,000 - 16,000 km
Valve Clearance Check:
Every 12,000 - 18,000 km
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA
Engine Oil Capacity:
Approx. 1.8 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze (50% solution) with corrosion inhibitors
Brake Fluid Type:
DOT 4
Chain Lubricant:
Motorcycle chain lubricant (e.g., SAE 80W-90 gear oil for dry conditions, specialized chain lube)
Known Issues
Common Complaints:
Some owners report occasional starting issues in very cold weather (addressed by EFI), potential for electrical connector corrosion in humid climates, and the need for regular chain maintenance.
Efi Considerations:
EFI system requires clean fuel and proper maintenance of sensors; diagnostic tools may be needed for advanced troubleshooting.
📚 Vehicle History
Brand Heritage
Manufacturer:
Hyosung (part of S&T Motors, now KR Motors)
Model Evolution
Gv250 Introduction:
The GV250 model, also known as the Aquila, was introduced to offer a stylish cruiser option in the smaller displacement segment. The GT250 EFI is an evolution featuring modern fuel injection.
Production
Production Period:
The GV250/GT250 platform has been in production for many years, with EFI versions becoming more prevalent from the late 2000s onwards.
🏆 Awards & Recognition
Recognitions
Awards Received:
N/A - Hyosung motorcycles generally position themselves as value-oriented options rather than award-winning performance machines.
Ratings
Reliability Perception:
Perceived as a reliable option within its price segment, with good support from the manual for maintenance.
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