HYOSUNG 2007 Rapier 450 Manuals

Manuals and User Guides for HYOSUNG 2007 Rapier 450. We have 1 HYOSUNG 2007 Rapier 450 manual available for free PDF download: Service Manual

HYOSUNG 2007 Rapier 450 Service Manual

HYOSUNG 2007 Rapier 450 Service Manual (262 pages)

Brand: HYOSUNG | Category: Offroad Vehicle | Size: 8 MB

Table of Contents

Group Index Foreword 1

2
- Table of Contents
  2
- How to Use this Manual
  3
General Information 1

6
- General Information
  7
  - General Precautions
    8
  - Serial Number Location
    9
    
    Frame Serial Number
    9
    
    Engine Serial Number
    9
  - Fuel, Oil and Engine Coolant Recommendations
    10
  - Engine Coolant
    11
  - Break-In Procedures
    12
  - Exterior Illustration
    13
  - Specifications
    14
Periodic Maintenance

16
- Periodic Maintenance Schedule
  17
  - Periodic Maintenance Chart
    17
  - Lubrication Points
    18
- Maintenance Procedures
  19
  - Air Cleaner
    19
  - Exhaust Pipe Nuts and Muffler Bolts
    20
  - Valve Clearance
    21
  - Spark Plug
    24
  - Fuel Hose
    25
  - Throttle Cable Play
    25
  - Engine Idle Speed
    25
  - Engine Oil and Oil Filter
    26
  - Engine Oil Hoses
    27
  - Engine Coolant
    28
  - Radiator Hoses
    29
  - Spark Arrester
    29
  - Clutch
    29
  - Brakes
    30
  - Brake Fluid
    32
  - Brake Hoses
    34
  - Tires
    34
  - Steering
    35
  - Drive Chain
    36
  - Suspensions
    39
  - Chassis Bolts and Nuts
    39
  - Compression Pressure
    40
  - Oil Pressure
    41
Engine

42
- Engine Removal and Remounting
  
  43
  - Engine Removal
    43
  - Engine Remounting
    48
- Engine Disassembly
  
  51
- Engine Component Inspection and Service
  
  63
  - Cylinder Head
    63
  - Cylinder
    70
  - Cam Chain Tension Adjuster and Tensioner
    70
  - Piston and Piston Ring
    71
  - Conrod
    73
  - Crankshaft
    74
  - Crank Balancer and Balancer Drive Gear
    75
  - Starter Clutch
    76
  - Clutch
    77
  - Oil Pump
    78
  - Transmission
    79
  - Crankcase
    82
  - Clutch Cover
    85
- Engine Reassembly
  
  86
  - Gear Position Switch
    89
  - Oil Pipe
    91
  - Camshaft Assembly
    97
  - Cylinder Head Cover
    100
Fuel System

103
- Fuel Cock
  104
- Fuel Tank
  104
- Fuel Pump
  105
- Carburetor
  106
- Float Height Adjustment
  112
Cooling System

114
- Engine Coolant
  115
- Cooling Circuit
  116
- Radiator
  116
- Radiator Reservoir Tank
  118
- Cooling Fan
  119
- Cooling Fan Thermo-Switch
  120
- Water Temperature Switch
  122
- Thermostat
  123
- Water Pump
  125
- Oil Tank and Hoses
  130
Electrical System

134
- Location of Electrical Components
  135
- Ignition System
  137
- Charging System
  141
- Starter System
  143
  - Starter Motor Removal
    144
  - Starter Motor Reassembly
    145
- Switches
  146
- Lamps
  147
  - Turn Signal Lamp
    148
  - Combination Meter
    149
- Battery
  150
- Chassis
  150
  - Recharging Operation
    152
Chassis

153
- Exterior Parts
  154
- Front and Rear Wheels
  160
- Front Brake
  166
  - Brake Pad Replacement
    167
  - Brake Fluid Replacement
    168
  - Brake Caliper Inspection
    169
  - Master Cylinder Inspection
    173
- Front Suspension
  174
- Steering
  183
- Rear Brake
  194
  - Master Cylinder Removal
    202
- Rear Shock Absorber
  207
- Rear Suspension
  212
- Rear Axle
  219
Servicing Information

227
- Troubleshooting
  228
- Special Tools
  236
- Tightening Torque
  239
- Service Data
  241
  - Tire Pressure
    252
- Wire and Cable Routing
  253
- Wiring Diagram
  259

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