TE450 SM service manual.pdf - Hyosung

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5-11 COOLING SYSTEMWATER PUMP◉ REMOVAL AND DISASSEMBLY● Drain engine coolant. (Refer to page 2-12)● Drain engine oil. (Refer to page 2-10)WARNING Do not open the radiator cap when the engineis hot, as you may be injured by escaping hotliquid or vapor. The engine must be harmful if swallowed or if itcomes in contact with the skin or eyes.If engine coolant gets into the eyes or contactsthe skin, flush the eyes or wash the skin thoroughly,with plenty of water. If engine coolantis swallowed, induce vomiting and call a physicianimmediately.● Disconnect the water hoses.● Disconnect the rear brake switch spring and rearbrake pedal spring as to lower side.● Remove the rear brake master cylinder mountingbolts.● Remove the clutch cover with pushing down therear brake pedal.NOTEBefore draining engine oil and engine coolant,inspect engine oil and coolant leakage betweenthe water pump and clutch cover.If engine oil is leaking, visually inspect the oil sealand O-ring. If engine coolant is leaking, visuallyinspect the O-ring.
COOLING SYSTEM 5-12● Remove the circlip and water pump driven gear1 .1● Remove the pin 2 and washer 3 .32● Remove the water pump case 4cover.from the clutch4● Remove the O-rings 5 .5
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HOW TO USE THIS MANUALTO LOCATE WHA
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GENERAL INFORMATIONCONTENTS1INFORMA
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1-3 GENERAL INFORMATIONSERIAL NUMBE
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1-5 GENERAL INFORMATION◉ ENGINE C
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1-7 GENERAL INFORMATIONEXTERIOR ILL
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2-1 PERIODIC MAINTENANCEPERIODIC MA
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2-3 PERIODIC MAINTENANCEMAINTENANCE
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2-5 PERIODIC MAINTENANCEVALVE CLEAR
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2-7 PERIODIC MAINTENANCE● If the
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2-9 PERIODIC MAINTENANCECAUTIONTo a
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2-11 PERIODIC MAINTENANCECAUTIONNec
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2-13 PERIODIC MAINTENANCE5. Install
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2-15 PERIODIC MAINTENANCE● Remove
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2-17 PERIODIC MAINTENANCE▣ AIR BL
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2-19 PERIODIC MAINTENANCESTEERINGIn
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2-21 PERIODIC MAINTENANCE● Count
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2-23 PERIODIC MAINTENANCESUSPENSION
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2-25 PERIODIC MAINTENANCEOIL PRESSU
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3-1 ENGINEENGINE REMOVAL ANDREMOUNT
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3-3 ENGINE● Remove the carburetor
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3-5 ENGINE● Loosen the muffler co
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3-7 ENGINE● Tighten the exhaust p
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3-9 ENGINEENGINE DISASSEMBLY● Rem
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3-11 ENGINE● Turn the magneto rot
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3-13 ENGINE● Place a clean rag ov
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3-15 ENGINE● Remove the clutch pu
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3-17 ENGINE● Remove the gearshift
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3-19 ENGINE● Remove the cam chain
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3-21 ENGINE● Remove the crankshaf
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3-23 ENGINE● Install the valve sp
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3-25 ENGINE▣ VALVE HEAD RADIAL RU
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3-27 ENGINE▣ CAMSHAFT JOURNAL WEA
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3-29 ENGINE▣ CAM CHAIN AND CAM CH
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3-31 ENGINE▣ PISTON RING-TO-GROOV
Page 74 and 75: 3-33 ENGINECRANK BALANCER AND BALAN
Page 76 and 77: 3-35 ENGINECLUTCH▣ CLUTCH DRIVE P
Page 78 and 79: 3-37 ENGINETRANSMISSION▣ DISASSEM
Page 80 and 81: 3-39 ENGINE▣ REASSEMBLYReassemble
Page 82 and 83: 3-41 ENGINE● Remove the oil strai
Page 84 and 85: 3-43 ENGINE▣ CLUTCH RELEASE CAMSH
Page 86 and 87: 3-45 ENGINE◉ GEARSHIFT CAM, FORK
Page 88 and 89: 13-47 ENGINE◉ GEAR POSITION SWITC
Page 90 and 91: 3-49 ENGINE● Install the gearshif
Page 92 and 93: 23-51 ENGINE● Bend the tongue of
Page 94 and 95: 3-53 ENGINE◉ PISTON RING● Insta
Page 96 and 97: 3-55 ENGINE● Install the cam chai
Page 98 and 99: 3-57 ENGINE21st pin15th pin31
Page 100 and 101: 3-59 ENGINE◉ CAM CHAIN TENSION AD
Page 102 and 103: FUEL SYSTEMCONTENTSFUEL TANK……
Page 104 and 105: FUEL SYSTEM 4-2◉ REMOUNTINGRemoun
Page 106 and 107: FUEL SYSTEM 4-4◉ LOCATION OF CARB
Page 108 and 109: 7FUEL SYSTEM 4-6● Remove the spri
Page 110 and 111: FUEL SYSTEM 4-8● Remove the main
Page 112 and 113: FUEL SYSTEM 4-10● Align the hole
Page 114 and 115: 5-1 COOLING SYSTEMENGINE COOLANTAt
Page 116 and 117: 5-3 COOLING SYSTEM● Disconnect re
Page 118 and 119: 5-5 COOLING SYSTEMCOOLING FAN◉ IN
Page 120: 5-7 COOLING SYSTEM◉ INSTALLATIONI
Page 123: COOLING SYSTEM 5-10● Keep on heat
Page 127 and 128: COOLING SYSTEM 5-14▣ BEARING CASE
Page 129: COOLING SYSTEM 5-16OIL TANK AND HOS
Page 132 and 133: 5-19 COOLING SYSTEM● Install the
Page 135 and 136: ELECTRICAL SYSTEM 6-21314121512 Bat
Page 138 and 139: 6-5 ELECTRICAL SYSTEM▣ IGNITION C
Page 140 and 141: 6-7 ELECTRICAL SYSTEMCHARGING SYSTE
Page 142 and 143: 6-9 ELECTRICAL SYSTEMSTARTER SYSTEM
Page 144 and 145: 6-11 ELECTRICAL SYSTEM◉ STARTER M
Page 146 and 147: 6-13 ELECTRICAL SYSTEMLAMPS◉ HEAD
Page 148 and 149: 6-15 ELECTRICAL SYSTEM◉ COMBINATI
Page 150 and 151: 6-17 ELECTRICAL SYSTEMCapSeal3 Pour
Page 152 and 153: CHASSISCONTENTSEXTERIOR PARTS …
Page 154 and 155: CHASSIS 7-2
Page 156 and 157: CHASSIS 7-4● Remove the four stee
Page 158 and 159: CHASSIS 7-6◉ REMOUNTINGRemount th
Page 161: 7-9 CHASSIS▣ REAR WHEEL HUB● Re
Page 164 and 165: CHASSIS 7-12▣ FRONT WHEEL● Inst
Page 166 and 167: CHASSIS 7-14◉ BRAKE PAD REPLACEME
Page 168 and 169: 32CHASSIS 7-16● Remove the brake
Page 170 and 171: CHASSIS 7-18◉ BRAKE DISK REMOVAL
Page 172 and 173: CHASSIS 7-20◉ MASTER CYLINDER INS
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CHASSIS 7-22◉ REMOVAL● Remove t
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CHASSIS 7-24◉ INSPECTION AND DISA
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CHASSIS 7-26◉ REASSEMBLY AND REMO
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CHASSIS 7-28NOTEWhen installing the
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CHASSIS 7-30STEERING◉ CONSTRUCTIO
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CHASSIS 7-32▣ STEERING SHAFT AND
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CHASSIS 7-34● Remove the steering
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CHASSIS 7-36◉ REASSEMBLY AND REMO
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CHASSIS 7-38with a narrow width hav
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CHASSIS 7-40◉ TOE-IN ADJUSTMENTAd
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CHASSIS 7-42◉ BRAKE PAD REPLACEME
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CHASSIS 7-44◉ BRAKE CALIPER REMOV
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21CHASSIS 7-46◉ BRAKE CALIPER REA
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CHASSIS 7-48● Connect the parking
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CHASSIS 7-50◉ MASTER CYLINDER REA
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CHASSIS 7-52● Remove the reverse
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CHASSIS 7-54REAR SHOCK ABSORBER◉
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CHASSIS 7-56◉ REAR SHOCK ABSORBER
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CHASSIS 7-58▣ DAMPING FORCE ADJUS
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CHASSIS 7-60◉ REMOVAL▣ CUSHION
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CHASSIS 7-62◉ INSPECTION AND DISA
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CHASSIS 7-64▣ CUSHION LEVER AND R
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CHASSIS 7-66REAR AXLE◉ CONSTRUCTI
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CHASSIS 7-68● Remove the brake di
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CHASSIS 7-70▣ REASSEMBLY AND REMO
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CHASSIS 7-72● Apply SUPER GREASE
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SERVICING INFORMATIONCONTENTSTROUBL
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SERVICING INFORMATION 8-2ComplaintN
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SERVICING INFORMATION 8-4◉ CARBUR
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SERVICING INFORMATION 8-6◉ BATTER
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SERVICING INFORMATION 8-8◉ BRAKES
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SERVICING INFORMATION 8-10Special t
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SERVICING INFORMATION 8-12TIGHTENIN
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SERVICING INFORMATION 8-14SERVICE D
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SERVICING INFORMATION 8-16◉ OIL P
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SERVICING INFORMATION 8-18◉ TRANS
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SERVICING INFORMATION 8-20◉ THERM
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SERVICING INFORMATION 8-22◉ WATTA
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SERVICING INFORMATION 8-24◉ BRAKE
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WIRE AND CABLE ROUTINGSERVICING INF
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SERVICING INFORMATION 8-28
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SERVICING INFORMATION 8-30
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SERVICING INFORMATION 8-32WIRING DI
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MEASURINGTAPPETCLEARANCE (mm)0.10 ~
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