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Hyosung Comet 250 Gt250 2002-2010 Workshop Service Repair Manual

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The Comet 250, also known as the GT250, is a motorcycle produced between 2002 and 2010. This model is recognized for its sporty styling and accessible performance, making it a...
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Taper: Motorcycle
Distributeur:
Hyosung
UGS: 148506
Mots clés: 2002 2003 2004 2005 2006 2007 2008 2009 2010 Comet 250 GT250 Hyosung Motorcycle Motorcycles
Hyosung Comet 250 Gt250 2002-2010 Workshop Service Repair Manual
The Comet 250, also known as the GT250, is a motorcycle produced between 2002 and 2010. This model is recognized for its sporty styling and accessible performance, making it a popular choice in the entry-level to mid-range sportbike and naked bike segments. It features a liquid-cooled, 249 cc V-twin engine, a 6-speed transmission, and a steel diamond frame, offering a unique riding experience for its class. The Comet 250 was designed to provide value, often competing with other lightweight sportbikes by offering a distinctive aesthetic and manageable power delivery suitable for both new and experienced riders. This workshop service repair manual provides comprehensive guidance for the Comet 250 and GT250R models from 2002 through 2010. It covers all essential aspects of maintenance, repair, and technical specifications, including detailed procedures for engine systems, drivetrain, chassis components, and electrical systems. The manual is designed to assist owners and technicians in performing routine maintenance, troubleshooting common issues, and executing complex repair and rebuild tasks. With factory-level detail, it includes specific torque values, fluid capacities, and diagnostic information necessary for keeping the vehicle in optimal condition.
🏷️ Basic Information
Identification
Make:
Hyosung
Model:
Comet 250 (GT250)
Product Name:
Hyosung Comet 250 GT250 2002-2010 Workshop Service Repair Manual
👋 Introduction
Market Position
Market Segment:
Entry-level to mid-range sportbike/naked bike segment, popular for its accessible performance and styling.
Competitive Analysis
Competitors:
Kawasaki Ninja 250, Honda CBR250R, Suzuki GS500 (though 500cc, it competed for rider attention in the beginner sportbike class).
Key Features
Vehicle Appeal:
Sporty styling, manageable power delivery for new riders, relatively affordable ownership costs.
Manual Value
Diy Support:
Empowers owners to perform routine maintenance and complex repairs, reducing reliance on expensive dealership services.
📋 Manual Details
Coverage Areas
Covered Model Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Specific Models Covered:
GT250, GT250R (likely, as they share core components)
Page Count
Estimated Page Count:
Likely 300-500+ pages based on typical factory service manuals for this complexity
Manual Type
Manual Type:
Factory Service Repair Manual / Workshop Manual
Language
Language:
English (presumed, typical for official service documentation)
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, cylinder head, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system, fuel system (carburetor or early EFI depending on exact variant), ignition system.
Drivetrain Systems:
Clutch operation and service, transmission disassembly and reassembly, gear inspection, final drive (chain and sprockets).
Chassis Systems:
Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings, brake system (front and rear disc brakes, master cylinders, calipers, hydraulic lines).
Electrical Systems:
Wiring diagrams, lighting system, ignition system, starting system, charging system (stator, regulator/rectifier, battery), instrument cluster, switches.
Bodywork And Fittings:
Fairing removal and installation, seat, fuel tank, fenders, handlebars, controls, exhaust system.
Procedures Included
Routine Maintenance:
Oil change intervals and specifications, filter replacement, chain adjustment and lubrication, brake fluid checks, coolant checks, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, starting problems, braking issues.
Repair And Rebuild:
Complete step-by-step instructions for engine disassembly, component inspection, and reassembly; transmission rebuild; suspension overhaul; brake caliper servicing.
Technical Specifications:
Torque specifications for all fasteners, engine timing procedures, valve clearances, fluid capacities, electrical resistance values.
Technical Depth
Depth Of Coverage:
Comprehensive factory-level detail, suitable for complete motorcycle rebuilds and advanced diagnostics. Includes specific measurements for worn parts.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High resolution, clear text and illustrations. Printable pages.
Binding Type
Binding Type:
Digital (N/A for physical binding)
Paper Type
Paper Type:
Digital (N/A for physical paper type)
Usability
Searchability:
Likely searchable text content within the PDF for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, V-twin (90-degree)
Engine Displacement:
249 cc (approximately)
Bore X Stroke:
Specification available in manual (typical around 57mm x 49mm)
Cooling System:
Liquid-cooled
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Output:
Approx. 30-33 HP (at ~10,000 RPM, specific to year/tuning)
Torque Output:
Approx. 22-24 Nm (at ~8,000 RPM, specific to year/tuning)
Fuel System
Fuel Delivery:
Carbureted (typically dual Mikuni BS30 or similar) for most models in this range. Early or specific market versions might have had EFI.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Engine Oil
Recommended Oil Viscosity:
Typically 10W-40 or 20W-50 (refer to manual for exact specification and API service classification)
Oil Capacity:
Approx. 1.8 - 2.0 Liters with filter change (refer to manual for exact specification)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed sequential
Features
Clutch Type:
Wet multi-plate
Final Drive:
Chain driven (DID 520 O-ring chain or equivalent, with specific pitch and roller type detailed in manual)
Transmission Oil
Transmission Oil Specification:
Gear oil (GL-4 or GL-5, specific viscosity like 75W-90, manual will specify)
📐 Dimensions
Exterior
Length:
Approx. 2070 mm (refer to manual for exact specification)
Width:
Approx. 740 mm (refer to manual for exact specification)
Height:
Approx. 1100 mm (refer to manual for exact specification)
Weights
Dry Weight:
Approx. 160-165 kg (refer to manual for exact specification)
Fuel Tank Capacity:
Approx. 17 Liters (refer to manual for exact specification)
Wheels And Tires
Front Tire Size:
110/70-17 (Tubeless)
Rear Tire Size:
150/70-17 (Tubeless)
Wheel Bolt Pattern:
Not applicable (spoked wheels with axle nuts, not bolt-on wheels)
🛡️ Safety Features
Passive Features
Frame Construction:
Steel diamond frame (provides structural integrity)
Active Features
Braking System Front:
Dual piston caliper acting on a single disc (Hydraulic actuation). Disc diameter specified in manual.
Braking System Rear:
Single piston caliper acting on a single disc (Hydraulic actuation). Disc diameter specified in manual.
Lighting:
Halogen headlamp, LED taillight (model dependent), turn signals. Bulb types and wattages specified in manual.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, fuel gauge, indicator lights. Specific layout detailed in manual.
Driver Assistance
ABS Availability:
Generally not available on models within this specific year range (ABS became more common later).
Connectivity
Charging System:
AC generator (stator) with external regulator/rectifier.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km or 6 months, whichever comes first (refer to manual for precise interval).
Valve Clearance Check Interval:
Often around 10,000-15,000 km, but crucial to follow manual's recommendation.
Chain Maintenance Interval:
Check and lubricate every 500-1000 km, adjust slack as needed (specific slack measurement in manual).
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze coolant, typically 50/50 mix with distilled water. Manual specifies type and capacity.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (refer to manual for specific recommendation).
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets, spark plugs.
Potential Electrical Issues:
Regulator/rectifier failures, stator coil degradation (common in many liquid-cooled bikes of this era if not maintained).
Engine Tuning:
Carburetor synchronization and jetting can be sensitive; manual provides specifications for tuning.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
South Korea
Model Evolution
Platform Basis:
The Comet 250 platform was a key model for Hyosung, showcasing their V-twin engine technology. It evolved from earlier Hyosung designs and served as a basis for subsequent models.
Production
Manufacturing Period:
2002-2010 (for this specific manual coverage). Hyosung motorcycles continued production beyond these years with updated models.
🏆 Awards & Recognition
Recognitions
Industry Standing:
Hyosung models from this era were positioned as value-oriented alternatives, offering sporty looks and a unique V-twin experience at a competitive price point.
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