TE450 SM service manual.pdf - Hyosung

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3-33 ENGINECRANK BALANCER AND BALANCER DRIVE GEAR▣ DISASSEMBLY● Disassemble the crank balancer and balancer drive gear as shown in the illustration.▣ REASSEMBLYReassemble the crank balancer and balancer drivegear in the reverse order of disassembly.
ENGINE 3-34◉ STARTER CLUTCHInstall the starter driven gear onto the starter clutchand turn the starter driven gear by hand(the gearturns in only one direction). The starter driven gearshould turn smoothly. If excessive resistance is feltwhile turning the starter driven gear, inspect thestarter clutch. Also, inspect the surface of the starterdriven gear which contacts the starter clutch, forwear or damage. If any wear or damage is found,replace the defective parts.▣ DISASSEMBLY● With the magneto rotor held immovable, removethe starter clutch bolts.▣ REASSEMBLY● Apply a small quantity of THREAD LOCK “1324”to the starter clutch bolts and tighten them to thespecified torque with the magneto rotor heldimmovable.THREAD LOCK “1324”Starter clutch bolt: 23~28 N∙m (2.3~2.8 kgf∙m)
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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
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 54 and 55: 3-13 ENGINE● Place a clean rag ov
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 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
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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
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CHASSIS 7-32▣ STEERING SHAFT AND
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CHASSIS 7-34● Remove the steering
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CHASSIS 7-36◉ REASSEMBLY AND REMO
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CHASSIS 7-38with a narrow width hav
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CHASSIS 7-40◉ TOE-IN ADJUSTMENTAd
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CHASSIS 7-42◉ BRAKE PAD REPLACEME
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CHASSIS 7-44◉ BRAKE CALIPER REMOV
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21CHASSIS 7-46◉ BRAKE CALIPER REA
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CHASSIS 7-48● Connect the parking
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CHASSIS 7-50◉ MASTER CYLINDER REA
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CHASSIS 7-52● Remove the reverse
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CHASSIS 7-54REAR SHOCK ABSORBER◉
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CHASSIS 7-56◉ REAR SHOCK ABSORBER
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CHASSIS 7-58▣ DAMPING FORCE ADJUS
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CHASSIS 7-60◉ REMOVAL▣ CUSHION
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CHASSIS 7-62◉ INSPECTION AND DISA
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CHASSIS 7-64▣ CUSHION LEVER AND R
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CHASSIS 7-66REAR AXLE◉ CONSTRUCTI
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CHASSIS 7-68● Remove the brake di
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CHASSIS 7-70▣ REASSEMBLY AND REMO
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CHASSIS 7-72● Apply SUPER GREASE
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SERVICING INFORMATIONCONTENTSTROUBL
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SERVICING INFORMATION 8-2ComplaintN
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SERVICING INFORMATION 8-4◉ CARBUR
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SERVICING INFORMATION 8-6◉ BATTER
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SERVICING INFORMATION 8-8◉ BRAKES
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SERVICING INFORMATION 8-10Special t
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SERVICING INFORMATION 8-12TIGHTENIN
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SERVICING INFORMATION 8-14SERVICE D
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SERVICING INFORMATION 8-16◉ OIL P
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SERVICING INFORMATION 8-18◉ TRANS
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SERVICING INFORMATION 8-20◉ THERM
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SERVICING INFORMATION 8-22◉ WATTA
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SERVICING INFORMATION 8-24◉ BRAKE
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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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