TE450 SM service manual.pdf - Hyosung

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CHASSIS 7-52● Remove the reverse lever 1 .● Disconnect the cable by removing the spool 2 .21● Remove the engine sprocket cover.(Refer to page 3-3)● Disconnect the reverse cable by removing thecable mounting screw.▣ REMOUNTINGRemount the reverse cable in the reverse orderremoval.Pay attention to the following points :3● Install the spring with the spring end 3the groove 4 on the housing.matched4● Apply SUPER GREASE “A” to the O-ring 5 .SUPER GREASE “A”● Install the O-ring 5 to the reverse cable 6 .● Connect the cable to the spool 7 through the holeof the housing.6537
7-53 CHASSISNOTE When installing the spool, hook the spring end1 on the concave portion 2 of the spool. Make sure that the reverse cable is routed correctly.12▣ CABLE PLAY ADJUSTMENTAfter installing the reverse cable, adjust the cableplay.The cable adjuster is located at left downside of thecrankcase assembly.● Loosen the lock nut 3 .● Turn the adjuster 4 in or out until the cable play should be 1 ~ 2 mm (0.04 ~ 0.08 in) at thereverse lever.● Tighten the lock nut 3 securely.43● After adjustment, be sure to check for reversefunction.
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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
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FUEL SYSTEM 4-10● Align the hole
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5-1 COOLING SYSTEMENGINE COOLANTAt
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5-3 COOLING SYSTEM● Disconnect re
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5-5 COOLING SYSTEMCOOLING FAN◉ IN
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5-7 COOLING SYSTEM◉ INSTALLATIONI
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COOLING SYSTEM 5-10● Keep on heat
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COOLING SYSTEM 5-12● Remove the c
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COOLING SYSTEM 5-14▣ BEARING CASE
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COOLING SYSTEM 5-16OIL TANK AND HOS
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5-19 COOLING SYSTEM● Install the
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ELECTRICAL SYSTEM 6-21314121512 Bat
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6-5 ELECTRICAL SYSTEM▣ IGNITION C
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6-7 ELECTRICAL SYSTEMCHARGING SYSTE
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6-9 ELECTRICAL SYSTEMSTARTER SYSTEM
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6-11 ELECTRICAL SYSTEM◉ STARTER M
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6-13 ELECTRICAL SYSTEMLAMPS◉ HEAD
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6-15 ELECTRICAL SYSTEM◉ COMBINATI
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6-17 ELECTRICAL SYSTEMCapSeal3 Pour
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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
Page 174 and 175: CHASSIS 7-22◉ REMOVAL● Remove t
Page 176 and 177: CHASSIS 7-24◉ INSPECTION AND DISA
Page 178 and 179: CHASSIS 7-26◉ REASSEMBLY AND REMO
Page 180 and 181: CHASSIS 7-28NOTEWhen installing the
Page 182 and 183: CHASSIS 7-30STEERING◉ CONSTRUCTIO
Page 184 and 185: CHASSIS 7-32▣ STEERING SHAFT AND
Page 186 and 187: CHASSIS 7-34● Remove the steering
Page 188 and 189: CHASSIS 7-36◉ REASSEMBLY AND REMO
Page 190 and 191: CHASSIS 7-38with a narrow width hav
Page 192 and 193: CHASSIS 7-40◉ TOE-IN ADJUSTMENTAd
Page 194 and 195: CHASSIS 7-42◉ BRAKE PAD REPLACEME
Page 196 and 197: CHASSIS 7-44◉ BRAKE CALIPER REMOV
Page 198 and 199: 21CHASSIS 7-46◉ BRAKE CALIPER REA
Page 200 and 201: CHASSIS 7-48● Connect the parking
Page 202 and 203: CHASSIS 7-50◉ MASTER CYLINDER REA
Page 206 and 207: CHASSIS 7-54REAR SHOCK ABSORBER◉
Page 208 and 209: CHASSIS 7-56◉ REAR SHOCK ABSORBER
Page 210 and 211: CHASSIS 7-58▣ DAMPING FORCE ADJUS
Page 212 and 213: CHASSIS 7-60◉ REMOVAL▣ CUSHION
Page 214 and 215: CHASSIS 7-62◉ INSPECTION AND DISA
Page 216 and 217: CHASSIS 7-64▣ CUSHION LEVER AND R
Page 218 and 219: CHASSIS 7-66REAR AXLE◉ CONSTRUCTI
Page 220 and 221: CHASSIS 7-68● Remove the brake di
Page 222 and 223: CHASSIS 7-70▣ REASSEMBLY AND REMO
Page 224 and 225: CHASSIS 7-72● Apply SUPER GREASE
Page 226 and 227: SERVICING INFORMATIONCONTENTSTROUBL
Page 228 and 229: SERVICING INFORMATION 8-2ComplaintN
Page 230 and 231: SERVICING INFORMATION 8-4◉ CARBUR
Page 232 and 233: SERVICING INFORMATION 8-6◉ BATTER
Page 234 and 235: SERVICING INFORMATION 8-8◉ BRAKES
Page 236 and 237: SERVICING INFORMATION 8-10Special t
Page 238 and 239: SERVICING INFORMATION 8-12TIGHTENIN
Page 240 and 241: SERVICING INFORMATION 8-14SERVICE D
Page 242 and 243: SERVICING INFORMATION 8-16◉ OIL P
Page 244 and 245: SERVICING INFORMATION 8-18◉ TRANS
Page 246 and 247: SERVICING INFORMATION 8-20◉ THERM
Page 248 and 249: SERVICING INFORMATION 8-22◉ WATTA
Page 250 and 251: SERVICING INFORMATION 8-24◉ BRAKE
Page 252 and 253: 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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TE450 SM service manual.pdf - Hyosung

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