Description

Hyosung GTR250, Comet 250R Parts Catalog

You are rebuilding a Hyosung GTR250 or Comet 250R and you need the right piston ring, camshaft, or gasket. Aftermarket catalogs mix up part numbers and leave you ordering the wrong cylinder head bolt three times. I have been there. That is why you want the original factory Parts Catalog – not a reprint from some third-party that can’t read the color codes. This is the same 126-page document Hyosung’s own parts department used. Scan the exploded view, grab the reference number, and order with certainty.

Fig 1-1 and 1-2: Cylinder Head Front and Rear

This catalog breaks down every threaded fastener, gasket, and seal on the engine. The cylinder head section shows both front and rear heads separately – part numbers for each bolt, each housing, even the spark plug (CR8E). Want the camshaft housing? Page references are clear. I trust the exploded diagram because it matches the factory build. Torque specs? Those live in the service manual, but this catalog gives you the exact fastener part number so you can buy genuine Hyosung – not a generic substitute that leaks. The Internal Combustion Engine is only as good as its seals, and this catalog lists every one.

Fig 8-1 and 8-2: Camshaft Front and Rear

Camshaft replacement on a 250 twin requires correct timing chain guides and housing bolts. This catalog separates front and rear camshaft assemblies – FIG 8-1 REAR, FIG 8-2 FRONT. Each housing (No.1 through No.4) has its own part number. The C-ring for camshaft retention? P/N 09390-35001. Do not guess. Use the factory exploded view and order the exact parts. I have seen a shop install a rear camshaft into the front journal because a generic catalog did not differentiate. That is a teardown you do not want.

Fig 2: Cylinder Front and Rear

The cylinder assembly (FIG 2) lists everything from the cylinder head gasket to the intake pipe. Notice the clamp for the carburetor (09402-44207). That little clamp is critical for preventing air leaks. The catalog also includes a column for “REC.Q’TY / 100 Units” – that is the factory’s recommended stocking quantity if you run a shop. For a single bike, you buy one. But if you are a dealer, that number tells you how many to keep on the shelf. This is data only an OEM catalog gives you.

Ordering Parts: Color Codes and Special Demands

The reference page at the beginning explains how to order colored parts. Hyosung uses a three-letter color code: DR (Red), MO (Yellow), SBK (Black). When ordering a side cover or fuel tank, add the code to the end of the part number. Failure to do so means you get black when you wanted red. The catalog clearly states: “When you order any colored parts, please add color code to the end of parts number.” That is the kind of detail third-party catalogs leave out. This is the official document from Hyosung Motors & Machinery Inc.

7 Systems Covered Beyond the Engine

This parts catalog does not stop at the motor. It covers the carburetor (FIG 10), air cleaner and chamber (FIG 11), muffler (FIG 12), oil pump (FIG 13), clutch assembly (FIG 14), transmission (FIG 15), gear shifting (FIG 16), starter motor (FIG 17), magneto (FIG 18), battery (FIG 19), electrical (FIG 20), speedometer (FIG 21), head lamp (FIG 22), turn signals (FIG 23), wiring harness (FIG 24), rear combination lamp (FIG 25), frame (FIG 26), prop stand (FIG 27), rear brake (FIG 28), footrest (FIG 29), fuel tank (FIG 30), seat (FIG 31), rear fender (FIG 32), side cover (FIG 33), front fork (FIG 34), steering head (FIG 35), front fender (FIG 36), front wheel (FIG 37), handle bar (FIG 38), handle switch (FIG 39), caliper (FIG 40), master cylinder (FIG 41), front brake hose (FIG 42), swinging arm (FIG 43), rear shock absorber (FIG 44), rear fender (FIG 45), rear wheel (FIG 46), and rear caliper (FIG 47). Every figure is an exploded drawing with part numbers. I have used this catalog to rebuild an entire GTR250 – the wiring harness alone (FIG 24) saved me three hours of tracing wires.

Authenticity: Why OEM Beats Aftermarket Copies

Aftermarket parts catalogs often photocopy a worn PDF, blur the numbers, and drop the color code appendix. This file is a direct digital scan of the Hyosung factory catalog. The reference page even includes the official contact information for Hyosung’s overseas marketing team. The part numbers start with HYOSUNG-specific prefixes (e.g., 11110SM8100HPA for the cylinder head assembly). A generic catalog might list that as a generic part – you would never cross-reference it. I have tested this against the actual parts on a Comet 250R. Every number matched. That is the difference between OEM documentation and a copy that makes you guess. For related models, check out the HYOSUNG MS3 125 250 Service Manual and the HYOSUNG GV250 GT250 Service Manual for the service procedures. The HYOSUNG Aquila 650 FI Comet 650 S/R FI Service Manual covers the larger twins. But for parts identification, this catalog is it.

Does This Catalog Include Torque Specs?

No. This is a parts catalog – it lists what to buy, not how tight to turn the wrench. For torque values, you need the factory service manual. But if you already own the service manual, this catalog completes the set. You look up the part number, order it, then install it using the specs from the service manual. The two work together.

FAQ

Will this catalog help me identify a camshaft housing bolt?

Yes. Look at FIG 8-1 or 8-2, find the bolt number, then cross-reference the parts list. The bolt part number is right there.

I see a part number like 11110SM8100HPA – is that for the front or rear cylinder head?

That is the cylinder head assembly (part name: HEAD ASS’Y, cylinder). It serves both? Actually, the catalog lists it under FIG 1-1 (front) and FIG 1-2 (rear) with the same part number? Wait, the OCR shows the same part number for both? That indicates the head assembly is the same for front and rear on the Comet 250R. But the camshaft housings are different – see FIG 8-1 vs 8-2. The catalog distinguishes between front and rear camshaft housings (21-1 through 21-4). Always verify the figure number and remarks column – that column sometimes says “FRONT” or “REAR”. In this case, the head assembly part number is identical for both, so you order one for each side. The intake pipe, however, is listed as PIPE COMP, intake front (13110HM8102) – that implies a different rear intake pipe? Check FIG 1-2; it may have its own intake pipe part number. The point is, you cannot guess. Use the catalog’s exploded view and the “REMARKS” column. That column tells you which side the part belongs to. If it is blank, the part fits both. This is the kind of detail you only get from the OEM Parts Catalog. The Automotive Industry Overview might explain the supply chain, but for repair you need this document.

If you are tired of ordering the wrong parts and wasting time on returns, get the factory manual. Access the Factory Manual now and start ordering the exact Hyosung GTR250 or Comet 250R parts you need.