HYOSUNG TE450 - Manual Download

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Interval

Item

─

Clean

─

Tighten

─

Inspect

─

Inspect

─

Inspect

Replace every 18 months

─

Inspect

─

Replace every 4 years

Replace

─

Replace

Inspect

─

Clean

Inspect

─

Inspect

─

Inspect

─

Inspect

Replace every 2 years

─

Inspect

Replace every 4 years

▣

ENGINE

Air cleaner element
Exhaust pipe nuts and muffler bolts

★

Valve clearance

★

Spark plug

Fuel hose

★

Engine oil and oil filter
Engine oil hoses
Spark arrester
Throttle cable
Idle speed

★

Clutch

★

Engine coolant

★

Radiator hoses

★

Initial

1 month

Every

3 months

Every

6 months

Interval

Item

Inspect every time before riding

Inspect

─

Inspect

Replace every 4 years

─

Inspect

─

Replace every 2 years

─

Inspect

─

Inspect

─

Inspect

Tighten every time before riding

Tighten

─

Tighten

─

Lubricate

─

▣

CHASSIS

Drive chain

★

Brakes

★

Brake hose

★

Brake fluid

★

Tires
Steering

★

Suspensions

★

Front and Rear wheel set nuts
Rear axle nut and lock nut

★

Chassis nuts and bolts

★

General lubrication

Initial

1 month

Every

3 months

Every

6 months

★

= Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.

N O T E

INSPECTION AND MAINTENANCE

Perform maintenance according to time interval.

MAINTENANCE SCHEDULE

Summary of Contents for TE450 -

Page 1: ...t part of the vehicle and should remain with the vehicle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should be read carefully before operating the vehicle ...

Page 2: ... s natural resources To that end we encourage every vehicle owner to recycle trade in or properly dispose of as appropriate used motor oil coolant other fluids batteries and tires The proper care and maintenance that your ATV requires is outline in this manual By following these instructions explicitly you will ensure a long trouble free operating life for your ATV This ATV also conforms to the U ...

Page 3: ...ts any sale or delivery to the ultimate purchaser or while it is in use and b The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person MAINTENANCE The exhaust system of this motorcycle requires no periodic maintenance The engine should be adjusted to the manufacture s specifications and the spark plug should be kept in good condition Runn...

Page 4: ...all instructions requirements and warnings Keep the owner s manual in the storage compartment located under the seat Before the rider s first use of the ATV make sure that he she is familiar with the location and operation of all controls and has been instructed in the proper operation of the vehicle For first use of the ATV find a level open area for the rider to use to become familiar with the o...

Page 5: ...to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible rough surfaces Please check your local riding laws and regulations before operating ON ROAD type ATV Never operate an ATV without wearing an approved motorcycle helmet that fits properly You should also wear eye protection gog...

Page 6: ...t the pads Always use tires of the size and type specified in this manual Always maintain proper tire pressure as described in this manual Do not make any modifications to this ATV Modifications may make the ATV unsafe or illegal unsafe or illegal in your state Never exceed the stated load capacity for an ATV Cargo should be properly distributed and securely attached Reduce speed and follow instru...

Page 7: ...reverse After the ATV reverse completely stop it and wait 3 seconds Before the ATV started confirm that the reverse gear is released If you started the ATV that reverse gear is shifted into it could be hazardous and damage the ATV Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Confirm the safety certainly when ...

Page 8: ...OKE LEVER REAR BRAKE PEDAL GEARSHIFT LEVER REVERSE LEVER FLAG BRACKET 5 EQUIPMENT AND ADJUSTMENTS 28 FUEL TANK CAP SEAT REMOVAL FRONT REAR SUSPENSION 6 RIDING YOUR ATV 32 WHAT YOU SHOULD KNOW BEFORE RIDING INSPECTION BEFORE RIDING WHAT TO WEAR BREAK IN STARTING THE ENGINE STARTING OFF AND SHIFTING BRAKING PARKING TURNING SKIDDING OR SLIDING OPERATION ON HILLS RIDING OVER OBSTACLES RIDING THROUGH W...

Page 9: ...CLEANER DRAIN CAP CLUTCH ADJUSTMENT DRIVE CHAIN COOLANT TIRES BRAKES PARKING BRAKE ADJUSTMENT FRONT AND REAR WHEEL REMOVAL REAR AXLE NUT AND LOCK NUT SPARK ARRESTER LAMP BULB REPLACEMENT HEAD LAMP BRAKE LAMP TAIL LAMP TURN SIGNAL LAMP FUSE GENERAL LUBRICATION 9 TROUBLESHOOTING 87 10 PREPARATION FOR WINTER RIDING 89 11 TRANSPORTING 89 12 CLEANING PROCEDURE 90 13 LOCATION OF LABELS 94 14 SPECIFICATI...

Page 10: ...ped on the left downside of the crankcase assembly Please write down the numbers in the box provided below for your future reference The frame and or engine serial numbers are used to register the vehicle They are also to assist your dealer in terms of ordering parts or referring to special service information SERIAL NUMBER LOCATION ...

Page 11: ...ade Over SL 10W 40 Remarks ENGINE OIL SPECIFICATION ENGINEOIL Temperature 30 22 20 4 10 14 0 32 10 50 20 68 30 86 40 104 20W50 15W40 15W50 10W40 10W50 10W30 5W30 Using a premium quality four stroke motor oil will increase the service life of your ATV Use the chart to select a viscosity rating based on temperature range in your area If a SAE 10W 40 motor oil is not available select alternative acco...

Page 12: ...Solution capacity total 1 4 ℓ COOLANT RESERVOIR TANK Refer to 72 page Engine coolant is harmful or fatal if swallowed or inhaled Do not drink anti freeze or coolant solution If swallowed do induce vomiting Immediately contact a poison control center or a physician Avoid inhaling mist or hot vapors if inhaled remove to fresh air If coolant gets in eyes flush eyes with water and seek medical attenti...

Page 13: ... PARTS Clutch lever Emergency brake lever Left handle switches Parking brake lever knob Instrument panel Front brake fluid reservoir Front brake lever Throttle lever Ignition switch Reverse lever Fuel tank cap 1 2 1 1 ...

Page 14: ...gnition coil Spark pulg Carburetor choke lever Fuel pump Fuse Battery Tools Seat lock lever Footrests Gearshift lever Engine oil drain plug Crankcase Coolant reservoir tank N O T E means the invisable parts ...

Page 15: ...s Muffler Air cleaner Seat Throttle stop screw Front brake lamp switch Cooling fan and motor Radiator Engine oil tank Engine oil level gauge Water pump Engine oil filter Rear brake pedal Rear brake lamp switch Rear brake fluid reservoir ...

Page 16: ...nnot be removed from the ignition switch in this position CONTROLS IGNITION SWITCH Turning the ignition switch to the OFF position while the ATV is moving can be hazardous WARNING IGNITION KEY Key number This ATV comes equipped with two ignition keys Keep the spare key in a safe place Your ATV ignition keys are stamped with an identifying number This number is used when making replacement keys Ple...

Page 17: ...e upper right suspension arm assembly To lock the steering Turn the handlebar all the way to the right Insert the ignition key into the steering lock and take a turn it from the position Remove the ignition key STEERING LOCK COOLANT TEMPERATURE INDICATOR LAMP The coolant temperature indicator lamp will come on when the coolant gets too hot while operating When coolant temperature is higher than 12...

Page 18: ...lly and the ignition switch ON CAUTION The lack of fuel will go off suddenly Failure to observe this precaution may result in loss of control and an accident CAUTION N O T E High engine speed low vehicle speeds or heavy load can increase engine coolant temperature Decrease engine speed reduce load and select an appropriate transmission gear to lower the temperature Debris or mud in front of the en...

Page 19: ... pushing the switch in the hour reset mode for 0 6 1 seconds 3 Push the switch in the hour reset mode for 0 6 1 seconds until the minutes display blink It is the minutes reset mode 4 Adjust the minutes display by pushing the switch in the minutes reset mode for 0 6 1 seconds 5 Push the switch in the minutes reset mode 0 6 1 seconds to resume in the clock mode To reset the trip meter to zero push t...

Page 20: ...nt Odometer mode Trip meter mode Clock mode Odometer mode In the hour reset mode Push it for 0 6 1 seconds Adjustment Increase the hour of clock SELECT SWITCH Use this switch to adjust the following In the clock mode Push it for Adjustment 0 6 1 seconds Clock mode Hour reset mode In the hour reset mode Push it for 0 6 1 seconds Adjustment Hour reset mode Minutes reset mode In the minutes reset mod...

Page 21: ...Y BRAKE LEVER The emergency brake lever is used for applying to the rear brake during emergency situation PARKING BRAKE LEVER KNOB Use this knob to set and lock the parking brake Use the parking brake to help prevent this ATV from moving when it is parked being started or at idle To lock the parking brake push the pin squeeze the clutch lever and engage this knob To release the parking brake simpl...

Page 22: ... head lamp beam and put off the head lamp when ignition switch is in the ON position The head lamp high beam comes on The high beam indicator lamp also comes on The head lamp low beam comes on The head lamp go off Always use the turn signals when you intend to change lanes or make a turn Always be sure to turn the turn signal switch to the OFF position after completing the turn or lane change CAUT...

Page 23: ...ense plate lamp when starting the engine CAUTION RIGHT HANDLEBAR FRONT BRAKE LEVER The front brake is applied by squeezing the front brake lever gently toward the handle grip The brake lamp will come on when the lever is squeezed FRONT BRAKE LEVER ADJUSTMENT Apply the brake lightly and with great care on slippery surfaces to avoid skidding WARNING The distance between the handle grip and the front...

Page 24: ...rider s skill and experience To adjust the throttle limiter 1 Loosen the lock nut 2 Turn the throttle limiter screw clockwise to restrict maximum engine power or counter clockwise to increase maximum engine power 3 Tighten the lock nut THROTTLE LIMITER desired position When changing the brake lever position always be sure the adjuster stops in the proper position a projection of the brake lever ho...

Page 25: ...ngine is warm you do not need to use the choke system for starting CARBURETOR CHOKE LEVER If you keep running in condition of full choke lever it causes fuel excess exhaustion high speed not to run it may damage spark plug CAUTION Depressing the rear brake pedal will apply the rear brake The brake lamp will be illuminated when the rear brake is operated REAR BRAKE PEDAL Apply the brake lightly and...

Page 26: ... desired depress or lift the lever halfway between first and 2nd gear It is not possible to upshift or downshift more than one gear at a time GEARSHIFT LEVER When shifting from first to 2nd gear or 2nd gear to low neutral will be automatically skipped Reduce the ATV speed before downshifting When downshifting the engine speed should be increased before the clutch is engaged This will prevent unnec...

Page 27: ...erse or return to 1st gear Check that the reverse indicator lamp is lit after shifting into reverse Shifting into reverse gear when the ATV is moving can be hazardous If you shift the ATV into reverse gear when the ATV is moving it could stop suddenly throwing you from the ATV Always come to a complete stop and shift into neutral before shifting into reverse gear WARNING Always be sure there are n...

Page 28: ...ler neck as shown in the illustration If you fill the fuel tank beyond this level fuel may overflow when it expands due to engine heat or heating by the sun WARNING Gasoline is extremely flammable and toxic Always observe the following precautions when refueling your ATV Never permit ATV refueling by anyone other than an adult Refuel in a well ventilated area Make sure the engine is off and avoid ...

Page 29: ...r Hyosung recommends that this adjustment be done by your authorized Hyosung dealer SPRING PRE LOAD ADJUSTMENT FRONT REAR SUSPENSION Improperly installing the seat can be hazardous Failure to install the seat properly could allow the seat to move and cause loss of rider control Make sure to properly position and securely attach the seat when you install it WARNING Hot muffler can be hazardous The ...

Page 30: ... the number of turns from the fully turned in position Fully turned in H direction or clockwise provides stiffest damping force and turning S direction or counter clockwise the adjuster will soften damping force The compression and tension damping force is set on Standard Refer to page 31 position at the factory Unequal front suspension adjustment can cause poor handling and loss of stability Be s...

Page 31: ...r clockwise End of S direction counter clockwise Turn to H direction clockwise Compression Tension STANDARD REAR SUSPENSION DAMPING FORCE Softer Standard Stiffer Turn to S direction counter clockwise 1 turnfromendof S direction counter clockwise Turn to H direction clockwise Turn to S direction counter clockwise 1 turnfromendof S direction counter clockwise Turn to H direction clockwise Compressio...

Page 32: ...fore riding Learn to find these controls without looking for them You will not have time to look for them when you are riding Operation of this ATV by children under age 16 can be hazardous Use by children under age 16 can lead to their severe injury or death Children under age 16 may not have the size strength skills or judgment needed to operate this ATV safely Do not allow any child under age 1...

Page 33: ...INTENANCE section WARNING Operating this ATV with improper modifications can be hazardous Improper installation of accessories or modification of this ATV may cause changes in handling In some situations this could lead to an accident Never modify this ATV through improper installation or use of accessories Refer to the ACCESSORY USE AND VEHICLE LOADING section in this manual WARNING Overloading t...

Page 34: ...e LOWER line No fluid leakage or damage Proper pedal and lever play No sponginess Parking brake effectiveness Brake pads not to be worn down to the limit line Smoothness No restriction of movement No play or looseness No dust or damage Correct fuction Smooth movement Proper tension Adequate lubrication No excessive wear or damage No damage lever Smooth operation Correct lever play Smooth and progr...

Page 35: ...Wear a good pair of gloves strong boots that fit over the ankle long pants and a long sleeve shirt The first month is the most important in the life of your ATV Proper operation during this break in period will help assure maximum life and performance from your new ATV The following guidelines explain proper break in procedures MAXIMUM THROTTLE OPENING RECOMMENDATION During the first 10 hours of o...

Page 36: ...C 40 F 1 Pull the choke lever to the ENGAGE position 2 Apply the rear brake pedal and release the parking brake by squeezing the clutch lever 3 Squeeze the clutch lever and push the electric starter switch 4 Immediately after the engine starts return the choke lever halfway 5 When the engine is sufficiently warmed up move the choke lever to the OFF position If the ambient temperature is at or abov...

Page 37: ...parking brake by squeezing the clutch lever 2 Squeeze the clutch lever open the throttle slightly and push the electric starter switch N O T E Operation of the choke is not necessary to start the engine Operation of the choke can make the engine hard to start due to too rich fuel air mixture ON ROAD type ON ROAD type ATV is designed and manufactured for ON ROAD use only and handling maneuvers are ...

Page 38: ...operating the OFF ROAD type ATV on paved surfaces whenever possible If you must ride on a paved surface go slowly and do not make sudden turns or stops WARNING Operating OFF ROAD type ATV on public streets roads or highways can be hazardous You can collide with another vehicle if you ride on public roads Never operate OFF ROAD type ATV on any public street road or highway even a dirt or gravel one...

Page 39: ...ncluding an overturn Never attempt stunts such as wheelies or jumps Don t try to show off WARNING Removing your hands from the handlebars or feet from the footrests during operation can be hazardous If you remove even one hand or foot from the ATV you can reduce your ability to control the ATV This could cause you to lose your balance and fall off the ATV If you remove a foot from a footrest your ...

Page 40: ... terrain WARNING Failure to use extra care when operating this ATV on unfamiliar terrain can be hazardous You can come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of control Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV WARNING The ATV can sta...

Page 41: ...o engage second gear and release the clutch lever You can select third fourth and top gear in succession by repeating this shifting sequence Reduce ATV speed before shifting down To shift down release the throttle and push down on the gearshift lever to engage a lower gear Opening the throttle suddenly can be hazardous The front wheels can lift off the ground and cause loss of control of the ATV A...

Page 42: ...n slippery surfaces can be hazardous The ATV can skid and go out of control if you brake too hard Apply the brakes lightly and with care on slippery surfaces WARNING Operating the parking brake lever knob when the ATV is moving can be hazardous The rear wheels can lock causing a skid and an accident Use the parking brake only after you stop the ATV WARNING After stopping the ATV according to the B...

Page 43: ... slip somewhat This allows it to travel a shorter distance than the outside wheel This happens even though both wheels are still turning at the same speed To turn the ATV use the following technique Turn the handlebars in the direction of the turn Shift body weight slightly forward and support your weight on the outer footrest This will reduce the load on the inside rear wheel reducing its tractio...

Page 44: ... overcome it by using the techniques listed below If your front wheel skids Gain front wheel traction by reducing the throttle opening and leaning your body weight slightly forward If your rear wheel skids If space permits steer in the direction of the skid Shift your body weight away from the skid slightly Avoid using the throttle or brakes until you regain directional control of the ATV OPERATIO...

Page 45: ...mb a hill with the ATV follow the directions below 1 Speed up and maintain a steady speed before reaching the bottom of the hill Shift down to increase approach speed if necessary Remember that you must ride at a steady speed all the way to the top of the hill 2 Shift body weight forward by sliding forward on the seat Lean slightly forward For steep hills stand on the footrests and lean out over t...

Page 46: ...the front brake 4 Set the parking brake and dismount to the left side while still leaning uphill 5 Use one of the following procedures to turn the ATV around a If you are able to drag the rear end of the ATV around until the ATV points downhill Stay on the uphill side of the ATV while dragging it around b Turn the handlebars fully to the right Stand on the uphill side of the ATV Release the parkin...

Page 47: ...leased 5 Apply the rear brake to control downhill speed 6 Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side Go straight down the hill where possible TRAVERSING A SLOPE When traversing a slope you should 1 Lean your body uphill 2 Steer slightly uphill if necessary to maintain a straight course Crossing hills or turning on hills improperly can be hazardous Cros...

Page 48: ... overturn Follow the procedure in this section carefully when crossing over obstacles WARNING You can ride the ATV through shallow water Make sure it is not more than 30 cm 12 in deep and is not moving fast Choose a good place to cross before you ride through any water Look for a spot where the banks are gently sloped on both sides and the bottom of the stream is hard If you are unfamiliar with th...

Page 49: ... drive train may occur if you use engine power to free frozen wheels Before riding manually move the ATV forward and backward to make certain that all wheels roll freely CAUTION With the transmission in neutral move the ATV forward and backward to check that the wheels roll freely If you cannot move the ATV the tires may be frozen to the ground or the brakes may be frozen to the wheels If the tire...

Page 50: ...ding slowly Before your next ride be sure to do a Pre ride inspection as described earlier in this section Operating your ATV in cold weather without proper clothing can be hazardous Continued exposure to cold temperatures can lead to hypothermia Hypothermia is a condition where your body s inner temperature drops low enough to cause injury or death Always dress for the worst weather conditions yo...

Page 51: ...areful when riding on snow covered terrain Always be alert to changing terrain conditions when operating the ATV WARNING Riding on a frozen lake or river can be hazardous Serious injury or death can occur if the ice breaks and you fall into the cold water Check with local authorities to verify the thickness of the ice and areas to avoid WARNING Plan your winter rides with safety and comfort in min...

Page 52: ...yes than dirt or grass does Tinted eye protection will reduce the amount of light reaching your eyes Always use clear eye protection when riding at night On overcast days you may find it helpful to use yellow tinted eye protection Improperly riding this ATV in reverse can be hazardous You could hit an obstacle or person behind you resulting in serious injury When you select reverse gear make sure ...

Page 53: ...ution when choosing and installing accessories for your Hyosung Your Hyosung dealer may be able to help you choose accessories and install them correctly The guidelines below should help you decide how to equip your ATV and how to use it correctly when you use accessories or carry cargo Operating this ATV with improper modifications can be hazardous Improper installation of accessories or modifica...

Page 54: ...ht as possible The extra weight can cause the ATV to be harder to steer 4 Do not add accessories or cargo which interfere with controls or other equipment 5 Do not carry heavy or bulky cargo 6 Distribute cargo weight evenly between the front and rear of the ATV as well as both sides of the ATV Locate cargo weight as close to the center of the ATV as possible 7 Secure your load well Shifting weight...

Page 55: ...nitial 1 month Every 3 months Every 6 months Interval Item Inspect every time before riding Inspect Inspect Inspect Replace every 4 years Inspect Replace every 2 years Inspect Inspect Inspect Inspect Tighten every time before riding Tighten Tighten Tighten Tighten Lubricate Lubricate CHASSIS Drive chain Brakes Brake hose Brake fluid Tires Steering Suspensions Front and Rear wheel set nuts Rear axl...

Page 56: ...ot sure how to do any of the jobs ask your Hyosung dealer or a qualified mechanic to do the maintenance WARNING Using poor quality replacement parts can damage your ATV Poorly made replacement parts can cause your ATV to wear more quickly and may shorten its useful life When replacing parts on your ATV use only genuine Hyosung replacement parts or their equivalent CAUTION If you use your ATV under...

Page 57: ...ur dealer check the charging condition of battery periodically BATTERY CLEAN OF BATTERY TERMINAL Clean the battery terminal when it is dusty or rusted 1 Set the ignition switch OFF position 2 Remove the seat disconnect the negative battery wire first then disconnect the positive battery wire Remove the battery 3 Clean the terminal If there is white dust clean it with warm water 4 Connect the batte...

Page 58: ... go to the negative terminal Never charge a battery while still in the machine as damage may result to the battery or regulator rectifier CAUTION Your ATV comes equipped with a CR8E spark plug To determine if the standard spark plug is right for your usage check the color of the plug s porcelain center electrode insulator after ATV operation A light brown color indicates that the plug is correct A...

Page 59: ...Carefully turn the spark plug by hand into the treads If the spark plug is new tighten it with a wrench about 1 2 turn past finger tight If you are reusing the old spark plug tighten it with a wrench about 1 8 turn past finger tight CAUTION Dirt can damage your ATV if it enters an open spark plug hole Dirt can damage engine parts that move Cover the spark plug hole while the spark plug is out of t...

Page 60: ...e to the correct speed Make sure the engine is fully warm before adjusting the idle speed WARNING Measure the throttle cable play by pressing the throttle lever The throttle lever should have 3 0 5 0 mm 0 12 0 20 in play To adjust the throttle cable play 1 Loosen the lock nut 2 Turn the adjuster in or out to obtain the correct play 3 Tighten the lock nut 4 Recheck the throttle lever play Readjust ...

Page 61: ...art the engine and allow it to idle for three minutes N O T E When starting the engine follow the WARNING and CAUTION in ENGINE STARTING PROCEDURE section 3 Stop the engine and wait three minutes 4 Remove the oil level gauge 5 Wipe the oil from the oil level gauge using a clean rag 6 Reinsert the oil level gauge until the threads touch filler neck but do not screw the oil level gauge in N O T E En...

Page 62: ...re each use of the ATV Be sure the engine oil level is always above the Lower limit line and not higher than the Upper limit line CAUTION ENGINE OIL AND FILTER CHANGE The oil should always be changed when the engine is warm so that the oil will drain thoroughly from the engine The procedure is as follows 1 Place the ATV on the level ground 2 Remove the oil level gauge and engine oil outer cover of...

Page 63: ...Drain the engine oil from the crankcase by removing the crankcase drain plug New and used oil can be hazardous Children and pets may be harmed by swallowing new or used oil Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals Brief contact with used oil may irritate skin Keep new and used oil and used oil filters away from children and pets To minimize ...

Page 64: ...l be felt To tighten the oil filter properly it is important to accurately identify the position at which the oil filter gasket first contacts the mounting surface CAUTION 12 Pour fresh oil through the filler hole of the oil tank and the filler hole of outer cover Approximately 2 600 of oil will be required 13 Install the oil level gauge of the oil tank and the outer cover of crankcase N O T E App...

Page 65: ...e good engine power and gas mileage If you use your ATV under normal low stress conditions you should service the air cleaner at the intervals specified If you ride in dusty wet or muddy conditions you will need to inspect the air cleaner element much more frequently Use the following procedure to remove the element and inspect it AIR CLEANER Operating the engine without the air cleaner element in...

Page 66: ...sult Always check the air cleaner element after riding in severe conditions Clean or replace the element as necessary If water gets in the air cleaner case immediately clean the element and the inside of the case CAUTION 3 Remove the screw then remove the element assembly 4 Pull out the foam element from the element frame 2 Unhook the hooks and take off the air cleaner case cover REMOVING THE ELEM...

Page 67: ...arburetor Before and during the cleaning operation inspect the element for tears A torn element must be replaced Be sure position the element snugly and correctly so that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element CAUTION Don t use the cleaning solvent whose flash point is low when cleaning the elemen...

Page 68: ...swallowed Be sure to drain the fluid into a suitable container and immediately dispose of it properly WARNING At each maintenance interval adjust the clutch cable play by means of clutch cable adjuster The cable play should be 10 15 mm 0 4 0 6 in as measured at the clutch lever holder before the clutch begins to disengage CLUTCH ADJUSTMENT The clutch lever play The clutch lever adjuster lock nut T...

Page 69: ...ster lock nut The clutch cable should be lubricated with a light weight oil whenever it is adjusted 10 15 mm 0 4 0 6 in Clutch cable play The condition and adjustment of the drive chain should be checked before each use of the ATV Always follow the guidelines below for inspecting and servicing the chain We recommend that you take your ATV to an authorized Hyosung dealer if the drive chain needs re...

Page 70: ...should be inspected for wear when a new chain is installed and replace them if necessary DRIVE CHAIN CLEANING AND OILING Clean and oil the chain periodically as follows 1 Wash the chain with kerosene If the chain tends to rust the interval must be shortened Kerosene will provide some lubrication and clean the chain Kerosene can be hazardous Kerosene is flammable Children or pets may be harmed from...

Page 71: ...nt lubricant that is specifically intended for use on O rings chains CAUTION Adjust the drive chain slack in the following manner until it has 30 40 mm 1 2 1 6 in of slack at the mid point between the chain buffer and the rear sprocket To adjust the drive chain follow the procedure below Failure to inspect the drive chain slack before each use of the ATV could be hazardous Too much chain slack cou...

Page 72: ... of the proper procedure have your authorized Hyosung dealer or qualified mechanic do this WARNING REAR AXLE HOUSING NUT REAR AXLE HOUSING WRENCH BOLT 70 100 N m 7 0 10 0 kgf m 40 60 N m 4 0 6 0 kgf m TIGHTENING TORQUE The coolant should be kept between the F FULL and L LOW level lines in the reservoir tank at all times Inspect the level every time before riding while the ATV horizontally If the c...

Page 73: ... out of the reach of children and aminals WARNING N O T E Adding only water will dilute the engine coolant and reduce its effectiveness Add 50 50 mixture of engine coolant and water N O T E About 1 4 ℓℓ of coolant will be required when filling the radiator and reservoir tank CHANGING THE COOLANT Change the coolant every two years You can be injured by scalding fluid or steam if you open the radiat...

Page 74: ...proper or uneven tire pressure you may lose control of the ATV Always use the size tires specified Always maintain proper tire pressure as described in this section WARNING Front Size 21 7 10 20 11 9 Rear TIRE TREAD CONDITION The use of very worn tires can be hazardous The traction of the ATV will be decreased This increases your risk of having an accident Replace the front and rear tires when the...

Page 75: ...cified pressure is obtained WARNING TIRE REPLACEMENT Your ATV has low pressure tubeless tires Air is sealed by the contact surfaces of the inner wheel rim and the tire bead If either the inner wheel rim or tire bead is damaged air may leak Be extremely careful not to damage these sections when replacing tires It is very important to use the proper tools when repairing or replacing tires to prevent...

Page 76: ...roperly inspect and maintain your ATV s brake systems can be hazardous Improper maintenance of the brakes increases your chances of having an accident Be sure to inspect the brakes before each use of the ATV according to the INSPECTION BEFORE RIDING section Always maintain your brakes according to the MAINTENANCE SCHEDULE WARNING Operating the ATV in harsh conditions can be hazardous if you do not...

Page 77: ...dic maintenance Brake fluid is harmful or fatal if swallowed and farmful if it comes in contact with skin or eyes If swallowed do induce vomiting Immediately contact a poison control center or a physician If brake fluid gets in eyes flush eyes with water and seek medical attention Wash thoroughly after handling Solution can be poisonous to animals Keep out of the reach of children and animals WARN...

Page 78: ... spilled up immediately CAUTION BRAKE PADS Inspect the brake pads as follows 1 Inspect the brake pads to see if they are worn down to the grooved wear limit line 2 If you find that the pads are worn to the grooved wear limit line bring the ATV to your authorized Hyosung dealer to have the brake pads replaced N O T E Adjust parking brake after replacing the rear brake pads Failure to maintain the b...

Page 79: ...get enough braking performance and may result in an accident Pump the brake lever and pedal several times until brake pads are pressed against the brake disks and proper lever and pedal stroke and firm feel are restored WARNING Replacing only one of the two brake pads can be hazardous Replacing only one brake pads can result in uneven braking action Replace both pads together WARNING PARKING BRAKE...

Page 80: ...erse these steps Use the tightening torque chart to determine the tightness of the wheel set nuts Tighten the nuts in a cross wise pattern 1 Park the ATV on level ground and set the parking brake FRONTANDREARWHEELREMOVAL 1 Park the ATV on level ground Check the front wheels Lift the rear end of the ATV and place a block under the swing arm 2 Loosen the parking brake adjuster lock nut while holding...

Page 81: ...If the wheel nuts are not properly tightened the wheel can come off causing an accident Be sure to tighten the wheel nuts to the specified torque If you do not have a torque wrench or do not know how to use one ask your Hyosung dealer or a qualified mechanic to check the nuts WARNING Retighten the rear axle nut periodically REAR AXLE NUT AND LOCK NUT N O T E Ask your Hyosung dealer or qualified me...

Page 82: ...you You can be burned if you touch the hot muffler Wait until the muffler cools to avoid burns WARNING 1 Remove the five bolts and pull out the spark arrester 2 Use a brush to remove carbon deposits from the spark arrester screen Be careful not to damage the spark arrester screen Check that the screen has no holes or tears Replace the screen if necessary 3 Reinstall the spark arrester in the rever...

Page 83: ...tage rating can damage your ATV The electrical system can overload or the bulb may burn out sooner Use only the lamp bulbs shown in the chart as replacement bulbs CAUTION To replace the head lamp bulb use the following procedure 1 Remove the front fender bolts Move the front fender upward to get enough space to remove the head lamp bulb HEAD LAMP 2 Remove the dust cover and socket spring 3 After r...

Page 84: ... your fingerprints if you touch it When replacing the head lamp bulb be careful not to touch the glass Grasp the new bulb with a clean cloth CAUTION This ATV s brake tail lamp is LED Light Emitting Diode type If any abnormal condition are found replace the brake tail lamp assembly BRAKE LAMP TAIL LAMP ...

Page 85: ... there is any electrical system failure first check the fuse In case the fuse blows there is one spare fuse 15A FUSE Failure to install the correct fuse can damage your ATV Installing a fuse of incorrect rating or using aluminum foil or wire instead of a fuse may seriously damage the electrical system Always replace a blown fuse with a fuse of the same type and rating If the new fuse blows in a sh...

Page 86: ...al lubrication as shown in the MAINTENANCE CHART He she will lubricate things such as wheel bearings rear axle housing swing arm bearing steering shaft holder etc GENERAL LUBRICATION Clutch lever holder Steering shaft holder Throttle lever Front brake lever holder Rear brake pedal and rod link Drive shaft joint spline Lubricating switches can damage your ATV Lubricating switches can damage the swi...

Page 87: ... position 3 Make sure there is enough fuel reaching the carburetor from the fuel tank a Loosen the drain screw which is located under the carburetor Drain the fuel from the carburetor into a container Draining fuel from the carburetor can be hazardous Fuel can catch on fire if you do not handle it properly When draining the carburetor always shut the engine off Do not smoke and never drain or refu...

Page 88: ...Remove the plug and clean it Replace it if necessary 3 Check the idle speed If necessary adjust it using a engine tachometer The correct idle speed is 1 300 1 500 rpm 3 Put the ignition switch in the ON position While holding the spark plug base firmly against the engine squeeze in the clutch lever and push the electric starter switch If the ignition system is operating properly a blue spark shoul...

Page 89: ...er below freezing even if the oil that is in the engine is the right type for colder temperatures It is best to transport the ATV in the normal position It may also be transported on its back wheels but this is not as stable as the normal position Failure to properly secure the ATV can be hazardous Failure to properly secure the ATV may result in an accident or damage to the ATV When transporting ...

Page 90: ... maintenance and will help keep your ATV looking and performing its best Proper cleaning can also extend the life of your ATV It is important to clean and inspect your ATV after every ride if it is used in mud brush grass water salt water or very dusty conditions The build up of mud brush grass etc especially on the engine and exhaust system can reduce engine cooling conceal damage or increase wea...

Page 91: ...d wash your ATV with a mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure even at remote areas such as between engine cooling fins linkages or mounting brackets Cloth rags washing mitts or cleaning brushes can be used be careful with brushes as they may scratch plastic or painted surfaces Rinse the ATV thoroughly with clean water Dry all ...

Page 92: ...n during your last ride STORAGE PROCEDURE If you don t plan on using your ATV for a long time it will need special servicing requiring appropriate materials equipment and skill For this reason Hyosung recommends that you trust this maintenance work to your dealer If you wish to service the machine for storage yourself follow the general guidelines below VEHICLE Place the ATV on level ground and wa...

Page 93: ...th rubber protectant Spray unpainted surfaces with rust preventative Coat painted surfaces with car wax MAINTENANCE DURING STORAGE Once a month recharge the battery The standard charging rate is 0 8A 10 hours PROCEDURE FOR RETURNING TO SERVICE 1 Clean the entire ATV 2 Drain all the engine oil Install a new oil filter and fill the engine with fresh oil as outlined in this manual 3 Reinstall the bat...

Page 94: ...94 LOCATION OF LABELS ...

Page 95: ...95 ...

Page 96: ...96 ...

Page 97: ...97 ...

Page 98: ...pe Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Four stroke DOHC Liquid cooled 1 cylinder 96 mm 3 78 in 62 mm 2 44 in 448 8 27 4 in3 BDS42 TYPE ELECTRIC STARTER Clutch Final reduction Drive chain Transmission Wet multi plate type 3 143 RK 520EXW 102 Links 1st 2 538 2nd 1 684 3rd 1 261 4th 1 040 5th 0 885 Reverse 2 231 DIMENSIONS AND DRY MASS ENGINE TRANSMISSION ...

Page 99: ... 34 mm 1 34 in 37 right left 0 0 5 mm 0 0 2 in 21 7 10 20 11 9 Double disk Disk Fuel tank Engine oil 8 0 ℓ 2 500 Replace 2 600 Oil filter replace 2 700 Overhaul ELECTRICAL Ignition type Ignition timing Spark plug Battery Fuse Head lamp License plate lamp Turn signal lamp Brake Tail lamp Speedometer lamp Igniter type CR8E 12V 8Ah MF 15A 12V 5W 1 12V 10W 4 LED type LCD type 6 B T D C at 1 500rpm HI ...

Page 100: ...Prepared by 1st Ed FEB 2007 Printed in KOREA ...

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