TE450 SM service manual.pdf - Hyosung

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SERVICING INFORMATION 8-8◉ BRAKESComplaintPoor braking(FRONT and REAR)Symptom and possible causes1. Not enough brake fluid in the reservoir.2. Air trapped in brake fluid circuit.3. Pads worn down.4. Too much play on brake lever or pedal.5. Oil adhesion on friction surface of pads.6. Worn disk.RemedyRefill to level mark.Bleed air out.Replace.Adjust.Clean disk and pads.Replace.Insufficient brakepower.1. Leakage of brake fluid from hydraulic system.2. Worn pads.3. Oil adhesion of engaging surface of pads.4. Worn disk.5. Air in hydraulic system.Repair or replace.Replace.Clean disk and pads.Replace.Bleed air.Brake squeaking.1. Carbon adhesion on pad surface.2. Tilted pad.3. Damaged wheel bearing.4. Loosen front-wheel axle or rear-wheel axle.5. Worn pads.6. Foreign material in brake fluid.7. Clogged return port of master cylinder.Repair surface withsandpaper.Modify pad fitting.Replace.Tighten to specified torque.Replace.Replace brake fluid.Disassemble and cleanmaster cylinder.Excessive brakelever stroke.Leakage of brakefluid.1. Air in hydraulic system.2. Insufficient brake fluid.3. Improper quality of brake fluid.1. Insufficient tightening of connection joints.2. Cracked hose.3. Worn piston and/or cup.Bleed air.Replenish fluid to specifiedlevel ; bleed air.Replace with correct fluid.Tighten to specifiedtorque.Replace.Replace piston and/or cup.
8-9 SERVICING INFORMATIONSPECIAL TOOLSSpecial tools Part Number∙Part Name∙Description09900-20101Vernier CalipersUsed to conveniently measure various dimensions.09900-20201Micrometer (0~25mm)Used for precise measurement (00~25mm measure ranges).09900-20202Micrometer (25~50mm)Used for precise measurement (25~50mm measure ranges).09900-20203Micrometer (50~75mm)Used for precise measurement (50~75mm measure ranges).09900-20204Micrometer (75~100mm)Used for precise measurement (75~100mm measure ranges).09900-20508Cylinder gauge setMeasure inside diameter of cylinder.09900-20605Dial calipersMeassure width of conrod big-end.09900-20606Dial gaugeMeassure oscillation of wheel with using magnetic stand.09900-20701Magnetic standWith using dial gauge.Special toolsPart Number∙Part Name∙Description09900-20806Thickness gaugeMeasure clearance of piston ring.09900-21109Torque wrenchMeasure torque of tightening.09900-21304V-blockWith using magnetic stand.09900-22401Small bore gaugeMeasure inside diameter of conrod small-end.09900-25002Pocket testerMeasure voltage, electric current, resistance.09900-25008Multi circuit tester setInspect thermo-switch or temperature switch.09900-26006Engine tachometerMeasure rotational frequency of engine.09910-20115Conrod holderUsed to lock the crankshaft.09910-32812Crankshaft installerUsed to install the crankshaft in the crankcase.
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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
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CHASSIS 7-18◉ BRAKE DISK REMOVAL
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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
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 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 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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