TE450 SM service manual.pdf - Hyosung

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7-11 CHASSIS● Install the front disk to the front wheel hub.(Refer to page 7-18)● Apply SUPER GREASE “A” to the front axle.SUPER GREASE “A”● Install the wheel hub.● Install the front brake caliper. (Refer to page 7-17)● Tighten the front wheel hub nut to the specifiedtorque.Front wheel hub nut: 55 N∙m (5.5 kgf∙m)1● Install the hub plate 1 .● Install the cotter pin into the front axle.● Install the front wheel.CAUTIONReplace the removed cotter pin with a new one.▣ REAR WHEEL HUB● Apply small amount of SUPER GREASE “A” tothe wheel hub’s spline.SUPER GREASE “A”● Install the rear wheel hub 2 , washer and nut.● Tighten the rear wheel hub nut to the specifiedtorque.Rear wheel hub nut: 100 N∙m (10.0 kgf∙m)● Install the cotter pin into the rear axle.● Install the rear wheel.CAUTIONReplace the removed cotter pin with a new one.2
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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
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3-33 ENGINECRANK BALANCER AND BALAN
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3-35 ENGINECLUTCH▣ CLUTCH DRIVE P
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3-37 ENGINETRANSMISSION▣ DISASSEM
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3-39 ENGINE▣ REASSEMBLYReassemble
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3-41 ENGINE● Remove the oil strai
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3-43 ENGINE▣ CLUTCH RELEASE CAMSH
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3-45 ENGINE◉ GEARSHIFT CAM, FORK
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13-47 ENGINE◉ GEAR POSITION SWITC
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3-49 ENGINE● Install the gearshif
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23-51 ENGINE● Bend the tongue of
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3-53 ENGINE◉ PISTON RING● Insta
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3-55 ENGINE● Install the cam chai
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3-57 ENGINE21st pin15th pin31
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3-59 ENGINE◉ CAM CHAIN TENSION AD
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FUEL SYSTEMCONTENTSFUEL TANK……
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FUEL SYSTEM 4-2◉ REMOUNTINGRemoun
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FUEL SYSTEM 4-4◉ LOCATION OF CARB
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7FUEL SYSTEM 4-6● Remove the spri
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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 and 124: COOLING SYSTEM 5-10● Keep on heat
Page 125 and 126: COOLING SYSTEM 5-12● Remove the c
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 165 and 166: 7-13 CHASSISFRONT BRAKE◉ CONSTRUC
Page 167 and 168: 7-15 CHASSIS◉ BRAKE FLUID REPLACE
Page 169 and 170: 7-17 CHASSIS◉ BRAKE CALIPER REASS
Page 171 and 172: 7-19 CHASSIS◉ MASTER CYLINDER DIS
Page 173 and 174: 7-21 CHASSISFRONT SUSPENSION◉ CON
Page 175 and 176: 7-23 CHASSIS● Remove the shock ab
Page 177 and 178: 7-25 CHASSIS▣ SUSPENSION ARM PIVO
Page 179 and 180: 7-27 CHASSIS● Tighten the suspens
Page 181 and 182: 7-29 CHASSIS▣ DAMPING FORCE ADJUS
Page 183 and 184: 7-31 CHASSIS◉ REMOVAL▣ HANDLEBA
Page 185 and 186: 7-33 CHASSIS● Remove the cotter p
Page 187 and 188: 7-35 CHASSISwith a narrow width hav
Page 189 and 190: 7-37 CHASSIS● Tighten the steerin
Page 191 and 192: 7-39 CHASSIS● Install the speedom
Page 193 and 194: 7-41 CHASSISREAR BRAKE◉ CONSTRUCT
Page 195 and 196: 7-43 CHASSIS● Tighten the caliper
Page 197 and 198: 457-45 CHASSIS● Loosen the calipe
Page 199 and 200: 7-47 CHASSIS● Tighten the caliper
Page 201 and 202: 7-49 CHASSIS◉ MASTER CYLINDER REM
Page 203 and 204: 7-51 CHASSIS◉ REVERSE CABLE▣ RE
Page 205 and 206: 7-53 CHASSISNOTE When installing th
Page 207 and 208: 7-55 CHASSIS● Remove the cushion
Page 209 and 210: 7-57 CHASSIS◉ REAR SUSPENSION SET
Page 211 and 212: 7-59 CHASSISREAR SUSPENSION◉ CONS
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7-61 CHASSIS● Remove the brake ho
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7-63 CHASSIS▣ SWINGARM BEARING AN
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7-65 CHASSIS◉ REMOUNTINGRemount t
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7-67 CHASSIS◉ REMOVAL● Place th
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7-69 CHASSIS▣ REAR AXLE SHAFTMeas
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7-71 CHASSIS● Install the axle ho
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7-73 CHASSIS● Install the rear wh
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8-1 SERVICING INFORMATIONTROUBLESHO
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8-3 SERVICING INFORMATIONComplaintD
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8-5 SERVICING INFORMATION◉ ELECTR
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8-7 SERVICING INFORMATION◉ CHASSI
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8-9 SERVICING INFORMATIONSPECIAL TO
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8-11 SERVICING INFORMATIONSpecial t
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8-13 SERVICING INFORMATION◉ CHASS
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8-15 SERVICING INFORMATION◉ CYLIN
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8-17 SERVICING INFORMATION◉ CAMSH
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8-19 SERVICING INFORMATION◉ CARBU
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8-21 SERVICING INFORMATION◉ ELECT
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8-23 SERVICING INFORMATION◉ SUSPE
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8-25 SERVICING INFORMATION◉ TIRE
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8-27 SERVICING INFORMATION
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MEASURINGTAPPETCLEARANCE (mm)0.00 ~
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Prepared by1st Ed. MAR. 2007.Manual
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TE450 SM service manual.pdf - Hyosung

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