Vehicle Segment:
Entry-level to mid-range sport motorcycle
Hyosung Positioning:
Hyosung aimed to offer performance and styling comparable to Japanese rivals at a more accessible price point.
Key Competitors:
Kawasaki Ninja 250, Honda CBR250R, Yamaha YZF-R25 (though R25 came later, conceptually similar competition).
Design Philosophy:
Sportbike styling with a focus on accessible performance and a V-twin engine configuration.
Manual Value Proposition:
Empowers owners and technicians with factory-level knowledge for efficient and accurate maintenance and repair.
Primary Coverage:
Repair and Maintenance
Target Audience:
Professional Technicians and DIY Mechanics with Basic Knowledge
Page Count Estimate:
Not explicitly stated, but implied to be comprehensive, comparable to factory service manuals.
Manual Type:
Service and Repair Manual
Secondary Coverage Types:
Includes topics typically found in Owner's Manuals.
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
Engine Mechanical:
Detailed procedures for disassembly, assembly, inspection, and repair of all internal engine components.
Engine Electrical:
Ignition system, starting system, charging system, fuel injection system diagnostics and repair.
Fuel System:
Fuel pump, injectors, carburetor (if applicable), fuel lines, and tank servicing.
Transmission:
Clutch operation, gear shifting mechanisms, transmission case, and related components.
Brakes:
Brake fluid, master cylinder, brake lines, calipers, pads, discs/rotors, and bleeding procedures.
Suspension:
Front forks, rear shock absorber, linkages, and steering components.
Electrical System:
Wiring diagrams, lighting, horn, instrumentation, battery maintenance, and fault diagnosis.
Cooling System:
Radiator, coolant, hoses, thermostat, and fan operation.
Exhaust System:
Muffler, pipes, and catalytic converter inspection and replacement.
Frame And Body:
Frame inspection, fairings, seat, handlebars, and minor bodywork repair.
Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, and general upkeep.
Troubleshooting:
Diagnostic flowcharts and symptom-based problem solving.
Disassembly Assembly:
Step-by-step instructions for component removal and installation.
Cleaning Reinstallation:
Guidance on cleaning parts before reassembly for optimal performance and longevity.
Repair Procedures:
Comprehensive guides for repairing specific components and systems.
Specifications:
Critical torque values, clearances, and dimensional data for adjustments and assembly.
Illustrations Pictures:
Visual aids to clarify procedures and component identification.
Depth Of Information:
Comprehensive, covering routine maintenance to major overhauls.
Diagnostic Level:
Includes diagnostic procedures for common electrical and mechanical faults.
Engine Type:
V-twin, Four-stroke
Bore X Stroke:
57.0 mm x 48.0 mm (typical for this engine family, specific confirmation within manual)
Valvetrain:
DOHC, 4 valves per cylinder (typical for GT250 models)
Horsepower Approximate:
Around 28-30 hp at ~10,000 RPM (typical for the 2004 GT250)
Torque Approximate:
Around 22 Nm at ~7,000 RPM (typical for the 2004 GT250)
Fuel Delivery:
Carbureted (likely Mikuni BDST30 dual carburetors, specific confirmation in manual)
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Cooling Method:
Liquid-cooled
Overall Length:
Approx. 2050 mm (typical for GT250 models)
Overall Width:
Approx. 750 mm (typical for GT250 models)
Overall Height:
Approx. 1070 mm (typical for GT250 models)
Dry Weight:
Approx. 163 kg (typical for GT250 models)
Wet Weight:
Approx. 179 kg (typical for GT250 models, with fluids)
Fuel Capacity:
Approx. 17 Liters (typical for GT250 models)
Safety Ratings Note:
Specific crash test ratings or safety certifications are not typically provided for motorcycles of this era and segment in service manuals.
Braking System Front:
Disc brake (typically dual piston caliper)
Braking System Rear:
Disc brake (typically single piston caliper)
Lighting:
Headlight, tail light, brake light, turn signals.
Infotainment System:
Basic instrumentation (speedometer, tachometer, odometer, fuel gauge, indicator lights). No advanced infotainment features.
Driver Assistance Features:
N/A (Standard motorcycle design).
Connectivity Features:
N/A (Standard motorcycle design).
Oil Change Interval:
Typically every 3,000-5,000 km or 6 months, but specific interval and oil type detailed in manual.
Spark Plug Replacement:
Recommended at intervals specified in manual, usually around 10,000-15,000 km.
Air Filter Cleaning Replacement:
Dependent on riding conditions, typically inspected every 5,000 km and cleaned or replaced as needed.
Engine Oil Type:
API SG or higher, SAE 10W-40 recommended (refer to manual for exact specification).
Engine Oil Capacity:
Approx. 1.6 Liters (without filter change), 1.8 Liters (with filter change) - confirm in manual.
Coolant Type:
Ethylene Glycol based antifreeze (50% mixture with distilled water), specific type in manual.
Brake Fluid Type:
DOT 3 or DOT 4 (confirm in manual).
Fork Oil Type Viscosity:
Specific fork oil grade (e.g., 10W) and quantity detailed in manual.
Common Complaints Early Models:
Some early Hyosung models experienced minor electrical gremlins, starter issues, or carburetor synchronization problems. Build quality perception varied. These are areas the manual would help address.
Carburetor Maintenance:
Proper synchronization and cleaning of the dual carburetors is crucial for smooth operation. The manual will provide precise procedures.
Electrical Diagnostics:
The manual's detailed wiring diagrams are essential for troubleshooting electrical faults.
Hyosung History:
Hyosung Motors & Heavy Industries is a South Korean manufacturer with a history in various industrial sectors, including motorcycles, which it began producing in the late 1970s, often under license initially.
Gt250 Lineage:
The GT250 line evolved from earlier Hyosung models, focusing on the V-twin platform to differentiate itself in the 250cc sportbike class. The 2004 model represents an early iteration of this platform.
Production Location:
South Korea
