Pages: [1] 2

07 Dec 2009 - GV650 WOLO Air Horn Mod

<br /> <div style="text-align: center;"><br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\02\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--> </div> <p style="text-align: center;" class="MsoNormal"><strong style=""><span style="font-size: 20pt;">Replacing the Stock Hyosung GV650 horn<o:p></o:p></span></strong></p> <div style="text-align: center;"> <strong style=""><span roman="" new="" times="" style="font-size: 20pt;">With a Chrome WOLO Bad Boy Air-Horn</span></strong><br /> <strong style=""></strong></div> <strong style=""><strong style=""><span roman="" new="" times="" style="font-size: 20pt;"><br /> <img height="301" width="400" alt="" src="/images3/clintrm/image001.jpg" /><br /> <br /> </span></strong> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\01\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">The Stock horn is both ugly and anemic &ndash; it sounds like a Duck.</span></strong><br /> <br /> <img height="299" width="400" alt="" src="/images3/clintrm/image004.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\03\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--> </strong> <p class="MsoNormal"><strong style=""><strong style=""><span style="font-size: 14pt;">The WOLO Bad-Boy Chrome air-horn is an easy replacement, looks better than stock, like it was designed to fit, and adds a safety margin &ndash; people will hear it! You can bid for one on EBay&ndash; or get it cheaper from a supplier on Amazon.<o:p></o:p></span></strong></strong></p> <strong style=""><br /> <img width="400" alt="" src="/images3/clintrm/image003.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\04\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--> </strong> <p class="MsoNormal"><strong style=""><strong style=""><span style="font-size: 14pt;">A single bolt holds the factory horn on, remove it and save, remove the seat and prop up the gas tank (best done when it&rsquo;s near empty to reduce the stress on those Hyosung welds) and fish the factory horn wires up to a location near the rear cylinder coil.<o:p></o:p></span></strong></strong></p> <strong style=""><br /> <img height="277" width="400" alt="" src="/images3/clintrm/image010.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\05\clip_filelist.xml" /><o:smarttagtype namespaceuri="urn:schemas-microsoft-com:office:smarttags" name="City"></o:smarttagtype><o:smarttagtype namespaceuri="urn:schemas-microsoft-com:office:smarttags" name="place"></o:smarttagtype><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><!--[if !mso]><object classid="clsid:38481807-CA0E-42D2-BF39-B33AF135CC4D" id=ieooui></object> <style> st1\:*{behavior:url(#ieooui) } </style> <![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">Bracket Material was obtained from Ace Hardware.<span style="">&nbsp; </span>A 7/8&ldquo; x<span style="">&nbsp; </span>8&rdquo; </span></strong><st1:city><st1:place><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">Stanley</span></strong></st1:place></st1:city><strong style=""><span roman="" new="" times="" style="font-size: 14pt;"> Mending Bracket for mounting the horn and a 2&rdquo; U bolt for mounting the relay (only cross the plate was used).<span style="">&nbsp; </span>You may have adequate material lying around but these work great.<span style="">&nbsp; </span>The lines on the mending bracket show approximately where the cuts were made per the following diagram.</span></strong><br /> <br /> <img width="400" alt="" src="/images3/clintrm/image013.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\06\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">The Mending Bracket was bent (align in a vise to finish to the dimensions as shown and whack away with a hammer, I put a torch on the metal but I&rsquo;m not sure its necessary, probably makes a tighter bend) and then cut to the proper dimensions,<span style="">&nbsp; </span>drill out the existing holes for the mounting bolts as shown.</span></strong><br /> <br /> <img width="400" alt="" src="/images3/clintrm/image015.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\07\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--> </strong> <p class="MsoNormal"><strong style=""><strong style=""><span style="font-size: 14pt;">The bracket mounts on the existing horn bolt and the bent end rest on the cylinder head to eliminate any torque on the mounting bolt caused by the weight of the Air-Horn.<span style="">&nbsp; </span>The black line on the bracket indicated the vertical plumb to mount the horn which is installed with the supplied bolt from the rear of the bracket prior to mounting the bracket.</span></strong></strong></p> <p class="MsoNormal"><strong style="">&nbsp;</strong></p> <p class="MsoNormal"><strong style=""><img width="400" alt="" src="/images3/clintrm/image016.jpg" /></strong></p> <p class="MsoNormal"><strong style="">&nbsp;</strong></p> <p class="MsoNormal"> <strong style=""> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\08\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--> </strong></p> <p class="MsoNormal"><strong style=""><strong style=""><span style="font-size: 14pt;">I added a hard rubber cover to the bent area of the bracket (made from a mower battery terminal cover) to reduce any marring on the cylinder head, but it probably isn&rsquo;t necessary.<o:p></o:p></span></strong></strong></p> <p>&nbsp;</p> <p class="MsoNormal"><strong style="">&nbsp;<img height="294" width="400" alt="" src="/images3/clintrm/image020.jpg" /></strong></p> <p class="MsoNormal"><strong style="">&nbsp;</strong></p> <p class="MsoNormal"> <strong style=""> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\09\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">The finished installation couldn&rsquo;t look more like a factory fit.</span></strong><strong style=""><span style="font-size: 14pt;"><o:p></o:p></span></strong></strong></p> <strong style=""><br /> <img height="262" width="400" alt="" src="/images3/clintrm/image024.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\10\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">The U- Bolt cross piece was used to mount the horn relay on the front bolt that secures the rear cylinder ignition coil to the frame under the gas tank. The bracket was given a slight twist down to assure the relay cleared the Air-box.<span style="">&nbsp; </span>The factory horn switch leads were connected to the relay coil connections #86 and #85 on the relay. A 16 gauge ground wire was run from the horn (make sure you observe the polarity on the horn the hot wire goes on the compressor side, ground on the horn trumpet) to the coil mounting bolt &ndash; already home for another ground.<span style="">&nbsp; </span><span style="">&nbsp;</span>12V power from the battery was run to the #30 terminal on the relay and the horn hot lead connects to the relay <span style="">&nbsp;</span># 87 terminal.</span></strong><br /> <br /> <img height="295" width="400" alt="" src="/images3/clintrm/image027.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\11\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:1.0in 1.25in 1.0in 1.25in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--><strong style=""><span roman="" new="" times="" style="font-size: 14pt;">A 20 amp in-line fuse was installed in the line from the battery to the relay.<span style="">&nbsp;&nbsp; </span>This is also an excellent opportunity to install a power plug for connecting a battery maintainer/charger (or for power take off) as per the brown and yellow wires attached to the battery terminals.</span></strong><br /> <br /> <img height="270" width="400" alt="" src="/images3/clintrm/image030.jpg" /><br /> <br /> <link rel="File-List" href="file:///C:\Users\Bill\AppData\Local\Temp\msohtml1\12\clip_filelist.xml" /><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:Compatibility> <w:BreakWrappedTables /> <w:SnapToGridInCell /> <w:WrapTextWithPunct /> <w:UseAsianBreakRules /> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><style type="text/css"> <!-- /* Style Definitions */ p.MsoNormal, li.MsoNormal, div.MsoNormal {mso-style-parent:""; margin:0in; margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:12.0pt; font-family:"Times New Roman"; mso-fareast-font-family:"Times New Roman";} @page Section1 {size:8.5in 11.0in; margin:.8in 1.0in .8in 1.0in; mso-header-margin:.5in; mso-footer-margin:.5in; mso-paper-source:0;} div.Section1 {page:Section1;} --> </style><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman";} </style> <![endif]--> </strong> <p class="MsoNormal"><strong style=""><strong style=""><span style="font-size: 14pt;">A polarized plug set that matches most trickle chargers (make sure you use the right end and get the polarity straight) is available from Radio Shack. It neatly tucks into a wire clamp under the frame in this location (shown pulled out). <o:p></o:p></span></strong></strong></p>

13 Jun 2009 - Sandgroper's Mods

<font size="5"><span style="font-weight: bold;">Sandgroper's Mods</span></font><br /> <br /> I have gained so much from Alternative Cruisers right from the first bike I purchased three years ago, a GV250.<br /> <br /> I think I bled this web site dry of information on my Piglet and fitted plenty of mods including Larry Cook&rsquo;s performance kit. I loved that motorcycle and when I felt the need for a bit more speed I naturally upgraded to a Hyosung GV650. I have also just purchased a Regal Raptor for my wife to learn to ride on so Alternative Cruisers is our home site!<br /> <br /> I have had a good run with the GV650 and had no major problems with it apart from the clutch making a noise like I have a cat stuck in there if I take off a bit fast. I have not got around to fitting a new one yet. <br /> <br /> I have fitted plenty of mods and most of them have come from friends of this web site.<br /> Larry Cook&rsquo;s performance kit has been installed (not the exhaust pipe) and she looks &amp; sounds great.<br /> <br /> <a href="http://www.alternativecruisers.com/images3/sandgroper/side.jpg"><img height="450" width="600" src="/images3/sandgroper/side_sm.jpg" alt="" /></a><br /> <span style="font-style: italic;">To see a larger image, click the pic!</span><br /> <br /> This is a&nbsp; side view.<br /> Side bags from ebay US supplier.<br /> Slasher pipe from local supplier in Australia. Sounds great, improves performance but the chrome has burned blue!<br /> Flame decals ebay China supplier.<br /> Under tank chrome trim local auto shop.<br /> <br /> <a href="http://www.alternativecruisers.com/images3/sandgroper/chrome_trim.jpg"><img height="450" width="600" src="/images3/sandgroper/chrome_trim_sm.jpg" alt="" /></a><br /> <span style="font-style: italic;">To see a larger image, click the pic!</span><br /> <br /> Side view<br /> Custom brake reservoir from a Kawasaki VN800 ebay US, <a href="javascript:void(0);/*1244901841878*/">pm me</a> for full details.<br /> Brake line braid ebay US<br /> Blue reflector Richard Hyosung<br /> <br /> <a href="http://www.alternativecruisers.com/images3/sandgroper/tool_bag.jpg"><img height="450" width="600" src="/images3/sandgroper/tool_bag_sm.jpg" alt="" /></a><br /> <span style="font-style: italic;">To see a larger image, click the pic!</span><br /> <br /> Front view.<br /> Mirrors from a GV250.<br /> Screen universal fitting screen from local supplier. I did want a Memphis Big Shot but it was way too expensive to ship to Australia!<br /> Braided lines from ebay US.<br /> Tool bag from local Triumph mc shop.<br /> <br /> <a href="http://www.alternativecruisers.com/images3/sandgroper/rear.jpg"><img height="627" width="600" src="/images3/sandgroper/rear_sm.jpg" alt="" /></a><br /> <span style="font-style: italic;">To see a larger image, click the pic!</span><br /> <br /> Rear view<br /> Sissy bar from Larry Cook.<br /> Tax disk holder ebay UK site.<br /> Custom cut indicators.<br /> Tail chop, I just followed the instructions on this site.<br /> <br /> <a href="http://www.alternativecruisers.com/images3/sandgroper/helmet_lock.jpg"><img height="450" width="600" src="/images3/sandgroper/helmet_lock_sm.jpg" alt="" /></a><br /> <span style="font-style: italic;">To see a larger image, click the pic!</span><br /> <br /> Left side.<br /> A great place to mount a helmet lock, ebay US.<br /> <br /> The next mod I am planning is to fit air horns, the standard horn is a bit lame and I saw a Harley with a great set of mini air horns. If anyone knows where they are available from, I would appreciate the details.<br /> <br /> Sandgroper
<!--[if !mso]> <style> v\:* {behavior:url(#default#VML);} o\:* {behavior:url(#default#VML);} w\:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);} </style> <![endif]--> <o:smarttagtype name="State" namespaceuri="urn:schemas-microsoft-com:office:smarttags"></o:smarttagtype><o:smarttagtype name="City" namespaceuri="urn:schemas-microsoft-com:office:smarttags"></o:smarttagtype><o:smarttagtype name="country-region" namespaceuri="urn:schemas-microsoft-com:office:smarttags"></o:smarttagtype> <o:smarttagtype name="place" namespaceuri="urn:schemas-microsoft-com:office:smarttags"></o:smarttagtype><!--[if gte mso 9]><xml> <o:DocumentProperties> <o:Author>Tod J Raab</o:Author> <o:LastAuthor>William R. Ramby</o:LastAuthor> <o:Revision>2</o:Revision> <o:TotalTime>174</o:TotalTime> <o:LastPrinted>2008-06-14T02:30:00Z</o:LastPrinted> <o:Created>2008-06-14T03:28:00Z</o:Created> <o:LastSaved>2008-06-14T03:28:00Z</o:LastSaved> <o:Pages>1</o:Pages> <o:Words>899</o:Words> <o:Characters>5126</o:Characters> <o:Company>Raab Enterprises</o:Company> <o:Lines>42</o:Lines> <o:Paragraphs>12</o:Paragraphs> <o:CharactersWithSpaces>6013</o:CharactersWithSpaces> <o:Version>10.6839</o:Version> </o:DocumentProperties> </xml><![endif]--><!--[if gte mso 9]><xml> <w:WordDocument> <w:SpellingState>Clean</w:SpellingState> <w:GrammarState>Clean</w:GrammarState> <w:PunctuationKerning/> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><!--[if !mso]><object classid="clsid:38481807-CA0E-42D2-BF39-B33AF135CC4D" id=ieooui></object> <style> st1\:*{behavior:url(#ieooui) } </style> <![endif]--><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"Table Normal"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0in 5.4pt 0in 5.4pt; mso-para-margin:0in; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:Calibri;} </style> <![endif]--><!--[if gte mso 9]><xml> <o:shapedefaults v:ext="edit" spidmax="2050"/> </xml><![endif]--><!--[if gte mso 9]><xml> <o:shapelayout v:ext="edit"> <o:idmap v:ext="edit" data="1"/> </o:shapelayout></xml><![endif]--> <div class="Section1"> <p align="center" style="text-align: center;" class="MsoNormal"><span class="GramE"><strong style="">Hyosung<span style=""> </span>GV650</strong></span><strong style="">-GT650 Fuel Tank Venting Modification<o:p></o:p></strong></p> <p class="MsoNormal"><o:p> </o:p></p> <p class="MsoNormal">To comment on this mod, <a href="http://www.alternativecruisers.com/index.php?topic=6272.0">please click here</a>.<br /> </p> <p class="MsoNormal">This modification is the Hyosung factory approved action at remedying both excessive pressure and negative pressure (referred to as &ldquo;Vapor Lock&rdquo;) issues in the Hyosung GV/GT 650 models. The modification encompasses removing a section of gasket material from within the fuel cap assembly to allow ambient air to enter the fuel tank during incidents of excessive fuel tank pressure and/or vacuum. Hyosung released this information, second quarter 2007. The actual facsimile from Hyosung is viewable at:</p> <p style="margin-bottom: 0.0001pt; line-height: normal;" class="MsoNormal"><span roman="" new="" times="" style="font-size: 12pt;"><a target="_blank" href="http://www.alternativecruisers.com/images/toad/toad_letter_1.jpg">http://www.alternativecruisers.com/images/toad/toad_letter_1.jpg</a><br /> <br /> <a target="_blank" href="http://www.alternativecruisers.com/images/toad/toad_letter_2.jpg">http://www.alternativecruisers.com/images/toad/toad_letter_2.jpg</a><o:p></o:p></span></p> <p style="margin-bottom: 0.0001pt; line-height: normal;" class="MsoNormal"><span roman="" new="" times="" style="font-size: 12pt;"><o:p> </o:p></span></p> <p class="MsoNormal"><strong style=""><o:p> </o:p></strong></p> <p class="MsoNormal"><strong style="">Step 1:</strong> Download and print the facsimile in the above hyperlinks. Detailed instructions are included in the facsimile, and a template is provided depicting which gasket to modify and where to modify this gasket. </p> <p class="MsoNormal"><strong style="">Step 2:</strong> Grab some tools. For this modification, the tools needed are as follows; Phillip&rsquo;s #2 screw driver, 4mm Allen wrench, scissors or diagonal cutters (dykes), petroleum jelly (optional), and <span class="SpellE">Loctite</span> or other suitable thread locking agent.</p> <p class="MsoNormal"><span style=""><!--[if gte vml 1]><v:shapetype id="_x0000_t75" coordsize="21600,21600" o:spt="75" o:preferrelative="t" path="m@4@5l@4@11@9@11@9@5xe" filled="f" stroked="f"> <v:stroke joinstyle="miter"/> <v:formulas> <v:f eqn="if lineDrawn pixelLineWidth 0"/> <v:f eqn="sum @0 1 0"/> <v:f eqn="sum 0 0 @1"/> <v:f eqn="prod @2 1 2"/> <v:f eqn="prod @3 21600 pixelWidth"/> <v:f eqn="prod @3 21600 pixelHeight"/> <v:f eqn="sum @0 0 1"/> <v:f eqn="prod @6 1 2"/> <v:f eqn="prod @7 21600 pixelWidth"/> <v:f eqn="sum @8 21600 0"/> <v:f eqn="prod @7 21600 pixelHeight"/> <v:f eqn="sum @10 21600 0"/> </v:formulas> <v:path o:extrusionok="f" gradientshapeok="t" o:connecttype="rect"/> <o:lock v:ext="edit" aspectratio="t"/> </v:shapetype><v:shape id="Picture_x0020_4" o:spid="_x0000_i1025" type="#_x0000_t75" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0077.jpg" style='width:394.5pt;height:295.5pt;visibility:visible'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image001.jpg" o:title="IMG_0077"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="Picture_x0020_4" alt="" src="http://www.alternativecruisers.com/images2/Toad/capmod/image002.jpg" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></span></p> <p class="MsoNormal"><em style="">Phillip&rsquo;s #2 screwdriver and 4mm Allen wrench are included in the motorcycle&rsquo;s tool kit.<o:p></o:p></em></p> <p class="MsoNormal"><strong style="">Step 3:</strong> Remove fuel cap from gas tank. To do this, remove (4) denoted screws from fuel cap trim ring. Unlock fuel cap and remove assembly from fuel tank. <em style="">(Use some caution here&hellip;do not smoke while you are doing this. Do not drop screws or tools into the fuel tank.)<o:p></o:p></em></p> <p class="MsoNormal"><span style=""><!--[if gte vml 1]><v:shape id="Picture_x0020_1" o:spid="_x0000_i1026" type="#_x0000_t75" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0076.jpg" style='width:394.5pt;height:295.5pt;visibility:visible'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image003.jpg" o:title="IMG_0076"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="Picture_x0020_1" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0076.jpg" src="http://www.alternativecruisers.com/images2/Toad/capmod/image004.jpg" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></span><o:p></o:p></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 4:</strong> Detach locking assembly. To do this, remove the (2) denoted screws with Phillip&rsquo;s #2 screw driver.</p> <p class="MsoNormal"><span style=""><!--[if gte vml 1]><v:shape id="Picture_x0020_7" o:spid="_x0000_i1036" type="#_x0000_t75" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0082.jpg" style='width:394.5pt;height:295.5pt;visibility:visible'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image005.jpg" o:title="IMG_0082"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="Picture_x0020_7" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0082.jpg" src="http://www.alternativecruisers.com/images2/Toad/capmod/image006.jpg" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></span></p> <p class="MsoNormal"><em style="">Note: Place fuel cap up-side-down on a table for this step and following steps. There will be small springs that will want to pop out as this component is removed. Leaving the fuel cap on a table will reduce the chances of you losing some of these springs. There are (6) springs total. Do not lose any! <o:p></o:p></em></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 5: </strong>Lift off inner locking assembly. Pick it up; no pieces-parts are going to fall out of this one.</p> <p class="MsoNormal"><span style=""><!--[if gte vml 1]><v:shape id="Picture_x0020_10" o:spid="_x0000_i1035" type="#_x0000_t75" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0084.jpg" style='width:394.5pt;height:295.5pt;visibility:visible'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image007.jpg" o:title="IMG_0084"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="Picture_x0020_10" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0084.jpg" src="http://www.alternativecruisers.com/images2/Toad/capmod/image008.jpg" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></span></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 6:</strong> Remove the plate <span class="SpellE">doo-hicky</span> thing. I don&rsquo;t know what it&rsquo;s called. It lays there, just pick it up. </p> <p class="MsoNormal"><span style=""><!--[if gte vml 1]><v:shape id="Picture_x0020_13" o:spid="_x0000_i1034" type="#_x0000_t75" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0085.jpg" style='width:394.5pt;height:295.5pt;visibility:visible'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image009.jpg" o:title="IMG_0085"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="Picture_x0020_13" alt="C:\Documents and Settings\tod\Local Settings\Temporary Internet Files\Content.Word\IMG_0085.jpg" src="http://www.alternativecruisers.com/images2/Toad/capmod/image010.jpg" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></span></p> <p class="MsoNormal"><em style="">Note: Pay attention to the direction the plate <span class="SpellE">doo-hicky</span> thing is placed. Upon reinstallation, the plate <span class="SpellE">doo-hicky</span> thing will only install in one direction.<o:p></o:p></em></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 7:</strong> Remove key lock assembly. The component lifts up. Do not lose the springs!</p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1028" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image011.jpg" o:title="IMG_0086"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1028" src="http://www.alternativecruisers.com/images2/Toad/capmod/image012.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1027" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image013.jpg" o:title="IMG_0089"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1027" src="http://www.alternativecruisers.com/images2/Toad/capmod/image014.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></p> <p class="MsoNormal"><strong style=""><em style="">Important</em></strong><em style=""> Note: When the key lock assembly is removed, a small ball bearing and a small spring will fall out the back side. This is the detent assembly that holds the fuel cap key flap up/down. Pay attention to its original location as depicted in the above picture.<o:p></o:p></em></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 8:</strong> Remove upper gasket. This is the gasket that is to be modified. It lifts straight up. Do not tear it!</p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1033" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image015.jpg" o:title="IMG_0087"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1033" src="http://www.alternativecruisers.com/images2/Toad/capmod/image016.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 9: </strong>Modify gasket. Flip the gasket over and hold it up to the template on the provided facsimile. Use scissors or dykes to modify the gasket. The depth of the cut is the critical measurement, not necessarily the shape.</p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1032" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image017.jpg" o:title="IMG_0088"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1032" src="http://www.alternativecruisers.com/images2/Toad/capmod/image018.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></p> <p class="MsoNormal"><em style="">Note: Upon reassembly; in case you get mixed up as to which side of the gasket the cut is on, holding the gasket against the template, you can only cut it one way. In case you get mixed up as to which side of the gasket lays down upon reassembly, there are &ldquo;rubber blocks&rdquo; molded into the sides of the gasket that lay into the back of the fuel cap door. If the blocks lay into the slots molded in the back of the fuel cap door, you have reinstalled the gasket correctly.<o:p></o:p></em></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 10:</strong> Reassembly is opposite of disassembly. Use <span class="SpellE">Loctite</span> on all threads.</p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1031" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image019.jpg" o:title="IMG_0090"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1031" src="http://www.alternativecruisers.com/images2/Toad/capmod/image020.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></p> <p class="MsoNormal"><em style="">Here is a trick that will aid in reassembly, add a glob of petroleum jelly to all the spring seats on the back of the fuel cap door. This will hold the springs upright and make reassembly easier. <o:p></o:p></em></p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1030" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image013.jpg" o:title="IMG_0089"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1030" src="http://www.alternativecruisers.com/images2/Toad/capmod/image014.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--><em style=""><o:p></o:p></em></p> <p class="MsoNormal"><em style="">Also, pack the hole for the key flap detent spring with petroleum jelly; this will hold the detent spring and ball bearing in the key lock assembly when you flip it over to reassemble.<o:p></o:p></em></p> <strong style=""><span style="font-size: 11pt; line-height: 115%; font-family: Calibri;"><br clear="all" style="page-break-before: always;" /> </span></strong> <p class="MsoNormal"><strong style="">Step 11:</strong> Check your work. Are all the springs lined up? Does the key flap stay up/down? If so, you are ready to put the fuel cap assembly back on the bike and get back to riding&hellip;No more venting issues!</p> <p class="MsoNormal"><!--[if gte vml 1]><v:shape id="_x0000_i1029" type="#_x0000_t75" style='width:394.5pt;height:295.5pt'> <v:imagedata src="Hyosung_GV650-GT650_Fuel_Tank_Venting_Modification_files/image021.jpg" o:title="IMG_0091"/> </v:shape><![endif]--><!--[if !vml]--><img v:shapes="_x0000_i1029" src="http://www.alternativecruisers.com/images2/Toad/capmod/image022.jpg" alt="" style="border: 0px solid ; width: 526px; height: 394px;" /><!--[endif]--></p> <p class="MsoNormal"><strong style="">**DEALERS**: </strong>Denote service by placing a red dot of paint under the key flap. Labor claim is (.4) hours under basic code (DH9999).</p> <p class="MsoNormal">Discussion of &ldquo;for off road use only&rdquo;. This repair was originally a Technical Service Bulletin (TSB) released by Hyosung. The repair depicted in this TSB made the motorcycle illegal for highway use in the <st1:country-region><st1:place>USA</st1:place></st1:country-region> under Environmental Protection Agency (EPA) guidelines. This was alluded to as Hyosung stated that this modification is intended &ldquo;for off road use only&rdquo;. In February 2008 the National Highway Traffic Safety Administration (NHTSA) released a recall regarding fuel tank venting issues on the Hyosung GV 650 models under certain VIN codes. The repair depicted in this TSB became the recall repair. Under NHSTA guidelines, Hyosung is responsible and mandated to exercise this repair to all the modes affected in the recall.<span style=""> </span>In the <st1:country-region><st1:place>USA</st1:place></st1:country-region>, NHTSA legislation supersedes EPA legislation. At the point that this TSB became the recall repair, EPA legislation was superseded by the NHTSA. On the recall affected models, this repair is legal for highway use in the <st1:country-region><st1:place>USA</st1:place></st1:country-region>. <em style="">Note: I am not a lawyer, and I claim no legal responsibility for any modifications you or any other party makes to your motorcycle.<o:p></o:p></em></p> <p class="MsoNormal">This posting is a courtesy of Toad (Toad442) and Terry <span class="SpellE">Verble</span> of AC Motors, <st1:place><st1:city>North Canton</st1:city> <st1:state>Ohio</st1:state></st1:place>. Hyosung Authorized Dealer.</p> <p class="MsoNormal"><em style=""><span style="font-size: 8pt; line-height: 115%;">This posting remains as intellectual property of Toad (Toad442), Alternative Cruisers Discussion (<a href="http://www.alternativecruisers.com">www.alternativecruisers.com</a>), et al. Reprint of this posting is only by consent of Toad (Toad442), and Alternative Cruisers Discussion (<a href="http://www.alternativecruisers.com">www.alternativecruisers.com</a>).<o:p></o:p></span></em></p> </div>

18 Mar 2007 - GV650 Rider Mods

<table cellspacing="2" cellpadding="5" border="1" style="text-align: left; width: auto; height: auto;"> <tbody> <tr> <td> <center style="text-decoration: underline;"><big><big><big><strong>GV650: Rider Mods</strong></big></big></big></center> <p>By: William R. Ramby<br clear="all" /> <a href="http://www.alternativecruisers.com/index.php?topic=1776.msg20871#msg20871"><br /> </a></p> I decided to put together a page of mods I and others have done for the GV250. If you have a mod, and would like it added, <a href="http://www.alternativecruisers.com/index.php?action=pm;sa=send;u=1">please contact me here</a>.<br /> <br /> <h2 style="font-weight: normal; color: rgb(255, 0, 0);">Warning: Some of these mods may void your warranty! Use them at your own risk! AlternativeCruisers.com take no responsibility for damages if you try these mods!</h2> <br /> <table cellspacing="2" cellpadding="2" border="0" style="text-align: left; width: 70%;"> <tbody> <tr> <td rowspan="1" colspan="2"> <hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img src="http://www.alternativecruisers.com/images/lic_mod/lic_mod_pic02.jpg" alt="GV650 Mod: Not available" style="width: 175px; height: 131px;" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/license_plate_mod.pdf" target="_blank">GV650 Mod: License Plate Cleanup</a><br /> PDF File Coutesy of FithGear Customs.<br /> </td> </tr> <tr> <td rowspan="1" colspan="2"> <hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img src="http://www.alternativecruisers.com/attachments/pullout.JPG" alt="GV650 Mod: Spiderweb Exhaust Mod" style="width: 175px; height: 131px;" /></td> <td><a href="http://www.alternativecruisers.com/index.php?page=18">GV650 Mod: Exhaust Chamber Mod</a><br /> </td> </tr> <tr> <td rowspan="1" colspan="2"> <hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img src="http://www.alternativecruisers.com/images/cc_mod/cc_mod_pic04.jpg" alt="GV650 Mod: Install A Lube Fitting With Bruno" style="width: 175px; height: 131px;" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/carbon_canister_bypass.pdf" target="_blank">GV650 Mod: Pollution Cannister Removal</a><br /> PDF File Coutesy of FithGear Customs - <br /> Updated 29-Feb-2008.<br /> </td> </tr> <tr> <td rowspan="1" colspan="2"> <hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="175" height="131" src="http://www.alternativecruisers.com/images2/amish/AIS_Bypass.jpg" alt="GV650 Mod: Not available" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/GV650_AIS_Bypass.pdf">AmishCrackDealers AIS Bypass Mod</a><br /> PDF File Coutesy of FithGear Customs.<br /> </td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="175" height="131" src="http://www.alternativecruisers.com/images2/amish/amishgaugeclstr.jpg" alt="GV650 Mod: Not available" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/gauge_cluster_how_to.pdf">AmishCrackDealers GV650 Gauge Cluster Mod</a><br /> PDF File Coutesy of FithGear Customs.</td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="175" height="131" src="http://www.alternativecruisers.com/images2/amish/gv650_fender_mod.jpg" alt="GV650 Fender Mod" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/gv650_front_fender_how_to.pdf">AmishCrackDealers GV650 Front Fender Mod</a><br /> PDF File Coutesy of FithGear Customs.</td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img alt="" style="width: 176px; height: 131px;" src="http://www.alternativecruisers.com/images2/Toad/capmod/image004.jpg" /></td> <td><a href="http://www.alternativecruisers.com/index.php?page=29">Toads GV650-GT650 Fuel Tank Venting Modification</a><br /> </td> </tr> </tbody> </table> <table cellspacing="2" cellpadding="2" border="0" style="text-align: left; width: 70%;"> <tbody> <tr> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="176" height="131" alt="" src="http://www.alternativecruisers.com/pdfs/gv650exhaustmod.jpg" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/gv650exhaustmod.pdf">AmishCrackDealers GV650 Exhaust Mod </a><br /> </td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img src="/images2/amish/chain_drv.jpg" alt="Chain Drive" /></td> <td><a href="http://www.alternativecruisers.com/pdfs/gv650_chain_drive.pdf">AmishCrackDealers GV650 Chain Mod </a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="200" height="134" alt="" src="/images3/sandgroper/thumbnail.jpg" /></td> <td><a href="http://www.alternativecruisers.com/index.php?page=37">Sandgroper's Mod's</a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="200" height="134" alt="" src="/images3/clintrm/image004.jpg" /></td> <td><a href="http://www.alternativecruisers.com/index.php?page=41">clintrm WOLO Air Horn Mod</a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img alt="Battery Replacement Guide" src="http://www.alternativecruisers.com//images3/tom740509/batt_guide.jpg" /><br /> </td> <td><a href="http://www.alternativecruisers.com/pdfs/Replace_The_Clock_Battery.pdf" target="_self">tom740509's Battery Replacement Mod</a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img alt="GV650 Shock Repair Guide" src="../..//images3/tom740509/GV650_Shock.jpg" /></td> <td><a href="../../pdfs/GV650_Shock_Repair_Guide.pdf" target="_self">tom740509's GV650 Shock Repair Guide<br /> </a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img src="/images3/tom740509/AIS_Rem.jpg" alt="AIS Block Plate" /></td> <td><a target="_blank" href="http://www.alternativecruisers.com/pdfs/Manual_removal_of_AIS_for_GV650_FI_and_GT650_FI.pdf">tom740509's AIS Removal For GV650FI and GT650FI</a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img src="/images3/tom740509/tom_fan.jpg" alt="tom740509's Fan Mos" /></td> <td><a target="_blank" href="http://www.alternativecruisers.com/pdfs/FACTORY_ REPLACEMENT_RADIATOR_FAN_GV650_mod.pdf">tom740509's GV650/Kawasaki fan replacement guide<br /> </a></td> </tr> <tr> <td colspan="2"><hr style="width: 100%; height: 2px;" /> </td> </tr> <tr> <td><img width="175" height="175" src="/images3/tom740509/TOS_Sensor.jpg" alt="" /></td> <td><a target="_blank" href="http://www.alternativecruisers.com/pdfs/Modification_of_the_TOS_sensor_GV-GT_650.pdf">tom740509's GV650 TOS Sensor Mod<br /> </a></td> </tr> </tbody> </table> <a href="http://www.alternativecruisers.com/pdfs/gauge_cluster_how_to.pdf"> </a> <p>&nbsp;</p> </td> </tr> </tbody> </table>

18 Mar 2007 - GV650 Exhaust Mod

<div style="overflow: auto; width: 100%;"> <table cellspacing="2" cellpadding="2" border="1" style="text-align: left; width: 703px; height: 3225px;"> <tbody> <tr> <td> <h2 style="font-weight: bold; color: rgb(255, 0, 0);">Warning: This mod may void your warranty. Implement this mod at your own risk. AlternativeCruisers.com takes no responsibility at all if you try this mod.</h2> <br /> Hello everyone,<br /> Last weekend my wife and I rode to the country with other bikes, HD&rsquo;s, VTX1300 and 1800, Moto Guzzi California cruiser. After riding all days with big bikes and heard all the sweet sounds around me. I just can&rsquo;t stand it any more of the gv650 sound so that evening I decide to mod the exhaust.<br /> The mod took about 15 minutes without removing the stock exhaust from the bike, this is what I did.<br /> <br /> First, removing the end cap then I use a rotary cutter with metal blade, cutting around the end. The new blade is bigger than the hole of the exhaust, get it worn down until it would fit into the hole then replace it with the new one, save this blade for the inside hole cut. <br /> <br /> When you&rsquo;re done with the outside wall, now use the blade that you saved earlier to cut the inside pipe hole, just stick the rotary cutter into the hole and cut around the wall.<br /> <br /> Remove the whole thing that you cut and put back the end cap and you&rsquo;re done.<br /> <br /> The sounds are much deeper (not loud) and this is what I&rsquo;m looking for especially on the freeway and tunnel, I can&rsquo;t tell if I&rsquo;m riding a HD or Hyosung. I drove it 400 miles now and I&rsquo;m a happy man. <img border="0" src="http://www.alternativecruisers.com/Smileys/default/grin.gif" alt="Grin" /><br /> <br /> Note, since my exhaust did have some back fire before the mod but its not noticeable then, now the new sounds are little deeper and louder so it would be more noticeable, but I like the backfire sounds (its more like Blumm blum blum). I have been checking the spark plug every 100 miles to see any color changes, so far not.<br /> <span style="color: Red;">Video Link Below</span><br /> <span style="color: LimeGreen;"><a href="javascript:void(window.open('http://www.alternativecruisers.com/video/spyderweb_newsounds.MPG','ACD_Video','resizable=no,location=no,menubar=no,scrollbars=no,status=no,toolbar=no,fullscreen=no,dependent=no'))">Video Download</a></span><br /> <br /> <img width="640" height="480" border="0" src="http://www.alternativecruisers.com/attachments/metalcut.JPG" alt="" /><br /> <br /> <br /> <img width="640" height="480" border="0" src="http://www.alternativecruisers.com/attachments/metalcut.JPG" alt="" /><br /> <br /> <br /> <img width="640" height="480" border="0" src="http://www.alternativecruisers.com/attachments/outsidecut.JPG" alt="" /><br /> <br /> <br /> <img width="640" height="480" border="0" src="http://www.alternativecruisers.com/attachments/insidecut.JPG" alt="" /><br /> <br /> <img width="640" height="480" border="0" src="http://www.alternativecruisers.com/attachments/pullout.JPG" alt="" /><br /> <br /> Cheers<br /> Mike<br /> </td> </tr> </tbody> </table> <br /> </div>
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