TE450 SM service manual.pdf - Hyosung

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CHASSIS 7-68● Remove the brake disk.CAUTIONDo not attempt to remove the brake disk flangefrom the rear axle shaft.The rear axle shaft is available only as an assembly.▣ REAR AXLE HOUSING● Remove the axle housing bolts, nuts and wrenchbolts.● Remove the chain adjuster 1 .● Remove the chain adjuster bolt 2 .● Remove the axle shaft 3 .2● Remove the axle housing from the swingarm’sright side.31◉ INSPECTION AND DISASSEMBLY▣ SPROCKETInspect the sprocket teeth for wear.If they are worn as shown, replace the enginesprocket, rear sprocket and drive chain as a set.Normal wearExcessive wear
7-69 CHASSIS▣ REAR AXLE SHAFTMeasure the rear axle shaft runout.If the runout exceeds the <strong>service</strong> limit, replace therear axle shaft with a new one.Rear axleshaft runoutService limit6 mm (0.24 in)Dial gauge : 09900-20606Magnetic stand : 09900-20701V-block : 09900-21304NOTEWhen measuring the runout, support the rear axleshaft at 34 mm (1.34 in) diameter of the rear axleshaft as shown in illustration.Measure the runout at 40 mm (1.57 in) diameter ofthe rear axle shaft as shown in illustration.▣ DUST SEALInspect the dust seals for wear or damage. If anydefect are founds, replace the dust seal with a newone.▣ AXLE BEARINGSInspect the play of the wheel bearings by finger whilethey are in the axle housing.Rotate the inner race by finger to inspect for abnormalnoise and smooth rotation.Replace the bearing with a new one, if there is anythingunusual.
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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 …
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CHASSIS 7-2
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CHASSIS 7-4● Remove the four stee
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CHASSIS 7-6◉ REMOUNTINGRemount th
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7-9 CHASSIS▣ REAR WHEEL HUB● Re
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CHASSIS 7-12▣ FRONT WHEEL● Inst
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CHASSIS 7-14◉ BRAKE PAD REPLACEME
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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 204 and 205: CHASSIS 7-52● Remove the reverse
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 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
Page 254 and 255: SERVICING INFORMATION 8-28
Page 256 and 257: SERVICING INFORMATION 8-30
Page 258 and 259: SERVICING INFORMATION 8-32WIRING DI
Page 260 and 261: MEASURINGTAPPETCLEARANCE (mm)0.10 ~
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TE450 SM service manual.pdf - Hyosung

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