TE450 SM service manual.pdf - Hyosung

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3-13 ENGINE● Place a clean rag over the cylinder base to preventthe piston pin circlip from dropping into thecrankcase.● Remove the piston pin circlip.● Draw out the piston pin and remove the piston.● Remove the magneto cover 1 .1● Remove the dowel pins and gasket 2 .2● Remove the clutch cover 3 .3
ENGINE 3-14NOTEWhen remove or inspect the clutch drive and drivenplate, remove only the clutch pressure cover.● Remove the dowel pins 1 and gasket 2 .121● Loosen the clutch spring mounting bolts workingin diagonal stages.● Remove the bolts and springs.● Remove the clutch pressure disk 3 .3● Remove the clutch drive plates No. 1 and drivenplates.● Remove the spring washer and spring washerseat.● Remove the clutch drive plate No. 2.
Page 2:
HOW TO USE THIS MANUALTO LOCATE WHA
Page 5 and 6: GENERAL INFORMATIONCONTENTS1INFORMA
Page 8 and 9: 1-3 GENERAL INFORMATIONSERIAL NUMBE
Page 10 and 11: 1-5 GENERAL INFORMATION◉ ENGINE C
Page 12 and 13: 1-7 GENERAL INFORMATIONEXTERIOR ILL
Page 16 and 17: 2-1 PERIODIC MAINTENANCEPERIODIC MA
Page 18 and 19: 2-3 PERIODIC MAINTENANCEMAINTENANCE
Page 20 and 21: 2-5 PERIODIC MAINTENANCEVALVE CLEAR
Page 22 and 23: 2-7 PERIODIC MAINTENANCE● If the
Page 24 and 25: 2-9 PERIODIC MAINTENANCECAUTIONTo a
Page 26 and 27: 2-11 PERIODIC MAINTENANCECAUTIONNec
Page 28 and 29: 2-13 PERIODIC MAINTENANCE5. Install
Page 30 and 31: 2-15 PERIODIC MAINTENANCE● Remove
Page 32 and 33: 2-17 PERIODIC MAINTENANCE▣ AIR BL
Page 34 and 35: 2-19 PERIODIC MAINTENANCESTEERINGIn
Page 36 and 37: 2-21 PERIODIC MAINTENANCE● Count
Page 38 and 39: 2-23 PERIODIC MAINTENANCESUSPENSION
Page 40 and 41: 2-25 PERIODIC MAINTENANCEOIL PRESSU
Page 42 and 43: 3-1 ENGINEENGINE REMOVAL ANDREMOUNT
Page 44 and 45: 3-3 ENGINE● Remove the carburetor
Page 46 and 47: 3-5 ENGINE● Loosen the muffler co
Page 48 and 49: 3-7 ENGINE● Tighten the exhaust p
Page 50 and 51: 3-9 ENGINEENGINE DISASSEMBLY● Rem
Page 52 and 53: 3-11 ENGINE● Turn the magneto rot
Page 56 and 57: 3-15 ENGINE● Remove the clutch pu
Page 58 and 59: 3-17 ENGINE● Remove the gearshift
Page 60 and 61: 3-19 ENGINE● Remove the cam chain
Page 62 and 63: 3-21 ENGINE● Remove the crankshaf
Page 64 and 65: 3-23 ENGINE● Install the valve sp
Page 66 and 67: 3-25 ENGINE▣ VALVE HEAD RADIAL RU
Page 68 and 69: 3-27 ENGINE▣ CAMSHAFT JOURNAL WEA
Page 70 and 71: 3-29 ENGINE▣ CAM CHAIN AND CAM CH
Page 72 and 73: 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 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 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 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 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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