HYOSUNG RT125 KARION Service Repair Manual 01-ON

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🏷️ Basic Information Identification Make: Hyosung Model: RT125 Karion Year Coverage: 2001 onwards Product Type: Service and Repair Manual Codes Chassis Code Identifier: RT125 👋 Introduction Market Position Category: Lightweight...

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Type: Motorcycle

Vendor:

Sku: 267232

Tags: 2001 Hyosung Karion Motorcycle Motorcycles RT125 KARION

Product variants

Description

🏷️ Basic Information

Identification

Make:

Hyosung

Model:

RT125 Karion

Year Coverage:

2001 onwards

Product Type:

Service and Repair Manual

Codes

Chassis Code Identifier:

RT125

👋 Introduction

Market Position

Category:

Lightweight Dual-Sport / Street Motorcycle

Target Audience:

Commuters, entry-level riders, recreational riders seeking an affordable and versatile machine.

Competitive Analysis

Competitors:

Honda XR/CRF series (125cc variants), Yamaha TW/XT series (125cc variants), Kawasaki KLX series (125cc variants), Suzuki DR-Z/TS series (125cc variants).

Key Features

Design Philosophy:

Combines on-road usability with light off-road capability, offering a rugged yet accessible package.

Engine Type:

Air-cooled, four-stroke, single-cylinder engine known for reliability and fuel efficiency.

Ergonomics:

Upright riding position, dual-purpose tires, and relatively long-travel suspension contribute to comfort and versatility.

Manual Value:

Essential for owners and technicians to maintain the RT125 Karion's longevity and performance, covering all aspects of repair and upkeep.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair, maintenance, rebuilding, refurbishment, and restoration of the Hyosung RT125 Karion.

Page Count

Estimated Pages:

Hundreds of pages

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English (Presumed, typical for such manuals)

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed disassembly, assembly, inspection, and repair of the 125cc engine, including cylinder head, piston, crankshaft, camshaft, valve train, and lubrication system.

Fuel System:

Carburetor tuning, cleaning, and overhaul; fuel tank and lines inspection and maintenance.

Ignition System:

Spark plug specifications, ignition timing, CDI unit inspection, and troubleshooting.

Transmission:

Clutch operation, maintenance, and adjustment; gearbox disassembly, inspection, and reassembly.

Cooling System:

Air cooling system maintenance, including fin cleaning and inspection.

Electrical System:

Wiring diagrams, battery maintenance, starter motor, alternator/generator, lighting systems (headlight, taillight, indicators), horn, and switches.

Brake System:

Front and rear brake inspection, adjustment, and component replacement (pads, shoes, calipers/drums, levers, cables).

Suspension System:

Front fork (telescopic) disassembly, service, and seal replacement; rear shock absorber inspection and mounting.

Steering System:

Handlebar inspection, steering bearing adjustment, and front fork mounting.

Wheel And Tires:

Tire pressure specifications, wheel bearing inspection, and spoke tensioning (if applicable).

Frame And Bodywork:

Frame inspection, fuel tank removal/installation, seat, fenders, and fairings.

Procedures Included

Basic Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic flowcharts and common problem identification for starting issues, running problems, electrical faults, etc.

Disassembly And Assembly:

Step-by-step instructions for removing, inspecting, servicing, and reinstalling all major vehicle components.

Engine Rebuild:

Detailed procedures for engine overhaul, including piston ring replacement, gasket replacement, and bearing checks.

Electrical Diagnostics:

Component testing, continuity checks, and voltage measurements using multimeters.

Brake Service:

Brake pad/shoe replacement, caliper/wheel cylinder service, and bleeding procedures.

Suspension Service:

Front fork oil change and seal replacement, shock absorber mounting.

Special Tools:

Identification of necessary special tools for specific repair procedures.

Technical Depth

Depth:

Comprehensive, covering all aspects from basic checks to complete engine and component rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Digital (PDF)

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Print Quality

Quality:

High-resolution scans or digital originals, ensuring clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, Air-cooled, Single Cylinder

Displacement:

124 cc (approximate, based on model designation)

Bore X Stroke:

Specifics to be found in manual (e.g., 54.0 mm x 54.5 mm typical for 125cc class)

Compression Ratio:

Specifics to be found in manual (e.g., 9.5:1 - 10.0:1 typical)

Performance

Horsepower:

Estimated 10-12 HP (actual figures vary by region and specific tuning)

Torque:

Estimated 7-9 lb-ft (actual figures vary)

Fuel System

Carburetor Type:

CV Carburetor (e.g., Mikuni VM series or similar) - Specific model to be confirmed in manual

Fuel Type:

Unleaded Gasoline

Fuel Capacity:

Typical 8-10 Liters (manual will provide exact capacity)

Lubrication

Oil Type:

API SG or higher, SAE 10W-40 Motorcycle Oil recommended (manual will specify exact grade and API classification)

Oil Capacity:

Approx. 1.0-1.2 Liters (manual will provide exact capacity including filter change)

🔧 Transmission

Standard

Type:

Constant Mesh, 5-speed

Optional

Optional Types:

N/A (Standard transmission is typical for this model)

Features

Clutch Type:

Wet, Multi-plate

Final Drive:

Chain Drive

Transmission Fluid:

API GL-1 or GL-4 Gear Oil (manual will specify exact type and viscosity, often a lighter weight for motorcycle gearboxes)

📐 Dimensions

Exterior

Length:

Refer to manual for exact dimensions

Width:

Refer to manual for exact dimensions

Height:

Refer to manual for exact dimensions

Wheelbase:

Refer to manual for exact dimensions (typically around 1300-1350 mm)

Weights

Dry Weight:

Refer to manual for exact weight (typically around 120-130 kg)

Gross Vehicle Weight Rating:

Refer to manual for GVWR

🛡️ Safety Features

Ratings

Crash Safety Ratings:

Motorcycles of this class are not typically subjected to standardized automotive crash testing. Safety relies on rider skill and vehicle design.

Active Features

Braking System:

Front Disc Brake, Rear Drum Brake (standard configuration). ABS is generally not featured on models of this displacement and era.

Passive Features

Lighting:

Headlight, taillight, brake light, and turn signals for visibility.

Frame Integrity:

Robust steel frame construction designed for stability.

💡 Technology Features

Infotainment

Features:

Basic instrumentation (speedometer, odometer, indicator lights). No advanced infotainment systems are present on this model.

Driver Assistance

Features:

N/A. Standard motorcycle safety features (lights, brakes) apply.

Connectivity

Features:

N/A. No Bluetooth, Wi-Fi, or mobile connectivity.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 km or 6 months (whichever comes first, refer to manual for exact interval)

Oil Filter Replacement:

Concurrent with oil changes (if equipped with a replaceable filter element, otherwise screen cleaning)

Air Filter Cleaning:

Every 3,000 km or 6 months (more frequently in dusty conditions)

Spark Plug Replacement:

Every 6,000 km (refer to manual for specific plug type and gap)

Valve Clearance Check:

Every 6,000 km or 12 months (critical for performance and engine longevity)

Chain Lubrication And Adjustment:

Every 1,000 km or more frequently as needed.

Fluid Specifications

Engine Oil Specification:

API SG or higher, SAE 10W-40 (refer to manual for definitive specification)

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for exact specification)

Fork Oil Type And Level:

Specific viscosity (e.g., 10W) and level to be detailed in manual.

Known Issues

Common Wear Items:

Brake pads/shoes, clutch plates, chain and sprockets, tires, fork seals, and carburetor jets are common wear items that require regular inspection and replacement.

Carburetor Issues:

Can be prone to clogging if fuel is left standing for extended periods or if contaminated. Regular cleaning and proper fuel storage are recommended.

Electrical Connections:

Corrosion or looseness in electrical connectors can lead to intermittent issues. The manual provides guidance on inspection and cleaning.

📚 Vehicle History

Brand Heritage

Manufacturer:

Hyosung Motors & Machinery Inc. (South Korea)

Brand Focus:

Known for producing a range of motorcycles, scooters, and ATVs, often with competitive pricing and a focus on value.

Model Evolution

Rt125 Lineage:

The RT125 Karion is part of Hyosung's effort to capture the entry-level and dual-sport market segments, building on their experience with smaller displacement engines.

Production

Production Period:

Production commenced around 2001 and continued for several years, with variations and updates likely occurring over its lifecycle.

Manufacturing Location:

South Korea

🏆 Awards & Recognition

Recognitions

Awards Received:

Specific awards for the Hyosung RT125 Karion are not widely documented. Its market success is typically based on its value proposition and affordability.

Ratings

Consumer Reviews:

Generally positive for its intended use as an affordable, reliable entry-level dual-sport motorcycle. Owners often praise its ease of use and low running costs.

Certifications

Emissions Standards:

Compliant with prevailing emissions standards for its production period and market (e.g., Euro standards in Europe).