TE450 SM service manual.pdf - Hyosung

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1-3 GENERAL INFORMATIONSERIAL NUMBER LOCATIONThe frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the frame pipe.The engine serial number is stamped on the left downside of the crankcase assembly.These numbers are required especially for registering the machine and ordering spare parts.◉ FRAME SERIAL NUMBER◉ ENGINE SERIAL NUMBER
GENERAL INFORMATION 1-4FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS◉ FUELGasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is recommended.◉ ENGINE OIL▣ ENGINE OIL SPECIFICATIONClassification systemGrade20W50APISAEOver SL10W/40※ If an SAE 10W/40 motor oil is not available, select analternative according to the following chart.ENGINE OILTemperature ℃ ℉-30-22-20-4-101415W40 15W5010W40 10W5010W305W300 1032 5020 3068 8640104Use a premium quality 4-stroke motor oil to ensurelonger <strong>service</strong> life of your vehicle.WARNING Don’t mix the unrecommended oil. It could damage the engine. When refilling the oil tank, don’t allow the dust to get inside. Wipe the spilled oil up immediately. Don’t put the patch on the cap. It could disturb the oil to be provided and damage the engine.◉ BRAKE FLUID▣ Specification and classification (Front brake) : DOT4(Rear brake) : DOT4WARNINGSince the brake system of this vehicle is filled with a glycol-based brake fluid by the manufacturer, do not useor mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system,otherwise serious damage will result.Do not use any brake fluid taken from old or used or unsealed containers.Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
Page 2: HOW TO USE THIS MANUALTO LOCATE WHA
Page 5 and 6: GENERAL INFORMATIONCONTENTS1INFORMA
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 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 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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