HYOSUNG TE 100, Manual

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: ... TE100 90 is built for use by children but this owner s manual is written for the adults who will be supervising the children H Y O S U N G strongly reco mmends therefore that you review this entire manual with your child and carefully explain the instructions requirements and warnings it contains so that your child can understand them N O T E This provides special information to make maintenance ...

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: ...ur TE100 90 is properly and safely ridden and maintained It is important that both you and your child understand and observe the restric tions listed on the fender label of the TE100 90 You must take special precautions to reduce the chance of accidents and injuries resulting from operation of this vehicle Some of the important safety precautions you should take are Supervise operation of the TE10...

Page 5: ... pavement Permit use only by a single rider This vehicle is designed for use only by a single rider Extra seat space is provided so the rider can change his her body position to maneuver the vehicle This space should never be used to carry a passenger Do not permit anyone to operate the T E 1 0 0 9 0 while under the influence of alcohol or other drugs Make sure the combined weight of the rider pro...

Page 6: ...S 17 IGNITION SWITCH LEFT HANDLEBAR RIGHT HANDLEBAR FUEL COCK 6 EQUIPMENT AND ADJUSTMENTS 20 FUEL TANK CAP REMOTE ENGINE STOP SWITCH 7 BREAK IN RUNNING IN 23 8 INSPECTION BEFORE RIDING 24 9 RIDING TIPS 24 10 INSTRUCTING THE YOUNG RIDER 29 11 INSTECTION AND MAINTENANCE 33 MAINTENANCE SCHEDULE PERIODIC MAINTENANCE CHART SEAT REMOVAL T O O L S TABLE OF CONTENTS ...

Page 7: ...OIL ENGINE OIL LEVEL B R A K E TIRES DRIVE CHAIN FRONT AND REAR WHEEL REMOVAL REPLACEMENT OF THE LAMP FOR TE100 GENERAL LUBRICATION TE100 GENERAL LUBRICATION TE90 12 TROUBLESHOOTING 50 13 TRANSPORTING 51 14 CLEANING PROCEDURE 53 15 STORAGE PROCEDURE 54 16 LOCATION OF LABELS 56 17 SPECIFICATIONS 58 ...

Page 8: ...d to title the vehicle They are also used to assist your dealer when ordering parts or referring to special service information Gasoline used should be graded 85 95 octane or higher An unleaded type gaso line is recommended If engine pinging is experienced substitute another brand as there are differences between brands Use HYOSUNG HYPOL OIL HS If they are not available use a good quality TWO STRO...

Page 9: ...9 LO C ATION OF PA RT S TE100 Rear brake lever Parking brake lever Parking brake knob Front brake lever Throttle lever Fuel tank cap Starter switch Engine stop switch ...

Page 10: ...10 Remote engine stop switch ...

Page 11: ...11 Fuel cock Head lamp Battery fuse Muffler Drive chain N O T E means the invisable parts ...

Page 12: ...12 Tail lamp Tools Engine oil tank Air cleaner N O T E means the invisable parts ...

Page 13: ...13 Rear brake lever Parking brake Iever Parking brake knob Front brake lever Throttle lever Fuel tank cap Starter switch Engine stop switch LO C ATION OF PA RT S TE90 ...

Page 14: ...14 Remote engine stop switch ...

Page 15: ...15 Fuel cock Battery fuse Muffler Drive chain N O T E means the invisable parts ...

Page 16: ...16 Tools Engine oil tank Air cleaner N O T E means the invisable parts ...

Page 17: ...h to rotate the starting motor TE100 always come on the head lamp and tail lamp when starting engine CAUTION N O T E If the front or rear brake lever is not squeezed the starter motor will not rotate C O N T RO L S IGNITION KEY The ignition switch has two position ON POSITION The ignition circuit is completed and the engine can now be started The key cannot be removed from the ignition switch in t...

Page 18: ...en the lock nut Throttle Limiter When the starter motor doesn t rotate within 5 seconds after pushing the switch try again after 10 seconds to prevent damage to the battery CAUTION Engine Stop Switch Position The ignition circuit is off The engine cannot start or run Position The ignition circuit is on and the engine can run RIGHT HANDLEBAR Front Brake Lever Apply the front brake by squeezing the ...

Page 19: ...he lever to the OFF position whenever stopping the engine for more than a few minutes RES RESERVE Position If the fuel level in the tank is too low turn the lever to the RES position to use the 1 ℓ of reserve fuel supply After switching the fuel cock lever to the RES position it is advisable that the tank be refilled at the closest gas station After refueling be sure to move the fuel cock to the O...

Page 20: ...heat or heating by the sun WARNING Gasoline is extremely flammable and toxic Always observe the following precautions when refueling your TE100 90 Never permit vehicle refueling by anyone other than an adult Refuel in a well ventilated area Make sure the engine is off and avoid spilling fuel on a hot engine Do not smoke and make sure there are no open flames or sparks in the area Avoid prolonged c...

Page 21: ...ut your fingers through the loop at the other end of the lanyard When the remote engine stop switch cap is pulled off the engine will stop running The vehicle will continue to roll for some distance however Remember this when judging when to operate the remote engine stop switch WARNING If you do not put your fingers through the loop in the lanyard it may slip from your grasp unexpectedly This cou...

Page 22: ...he throttle limiter should always be set to the low power position as described on page 18 when the remote engine stop lanyard is used Only children with enough skill for safe operation of the TE100 90 without parental use of the lanyard should be permitted to operate TE100 90 with the throttle limiter set to the maximum power position In addition an adult trying to follow a moving TE100 90 with t...

Page 23: ... cause parts to glaze and not seat properly Allow the engine to accelerate freely through the gears without exceeding the maximum recommnded throttle opening OBSERVE YOUR INITIAL AND MOST CRITICAL SERVICE The initial service break in maintenance is the most important service your vehicle will receive During break in operation all of the engine components will have mated together and seated Mainten...

Page 24: ... off except the functional check of the remote engine stop switch TE100 be included the head lamp and tail lamp Make sure your child doesn t get too close when you check the fuel level and drive chain or he she might be injured WARNING INSPECTION BEFORE RIDING WHAT TO CHECK CHECK FOR Steering Brakes Tires Fuel Engine stop switch Head lamp Tail lamp For TE100 Engine oil Transmissionoil Throttle Dri...

Page 25: ...keep both feet on the footrests at all times or injuries resulting from accidents such as the rear wheels running over the rider s feet could occur There is no need for the rider to move his her feet from the footrests during operation or maneuvering of the vehicle Moving the rider s feet from the footrests reduces the rider s ability to control the vehicle and could lead to an accident WARNING Ke...

Page 26: ...G SKIDDING OR SLIDING If the rider experiences inadvertent skidding or sliding when not braking he she may be able to overcome it by using the appropri ate technique listed below Avoid braking during turns Use of the brake when turning could cause the TE100 9 0 to slide or roll over Use the brake to slow down before entering turns Apply the brake lightly and with great care on slippery surfaces to...

Page 27: ...ot let him her attempt to climb a hill unless you are sure that he she can easily ride to the top of the hill without stopping It can be dangerous to stop the TE100 90 while climbing a hill because the vehicle may begin to roll backwards and then roll over WARNING The rider should never open the throttle suddenly when climbing a hill The vehicle could flip over backwards WARNING The rider should n...

Page 28: ...se a slope unless you are sure he she can perform this maneuver safely WARNING If your child is climbing a hill and loses forward momentum he she should Lean farther forward uphill Apply the front and rear brake and stop the vehicle before it starts to roll backwards Set the parking brake and dismount to the right while still leaning uphill Use one of the following procedures to turn the vehicle a...

Page 29: ...rake securely as explained in the STARTING THE ENGINE section Do not attempt to cross a stream with deep or fast flowing water The tires may lose their traction and you may be unable to control the vehicle This could result in personal injury After riding through water test the brakes to see if they have maintained their normal effectiveness If they are less effective than normal dry them by repea...

Page 30: ...operate all of the controls without hesitation and without looking at the controls INSTRUCTING THE YOUNG RIDER IMPORTANT ADVICE TO THE PARENT Your child s safety depends on your commitment to take the time necessary to fully educate him her on the proper operation of the TE100 90 Remember that proper instruction before your child begins to ride is just as important as proper instruction and superv...

Page 31: ...push the TE100 90 instruct your child to steer straight ahead and perform operations such as stopping the vehicle and turning off the engine stop switch while moving Watch your child closely to make sure he she is operating the controls correctly and without looking at the controls Next start the TE100 90 s engine and have your child practice starting off riding in a straight line and stopping wit...

Page 32: ...ience As you approach the end of the practice area you should again tell the rider to stop the vehicle apply the parking brake and get off so you can turn it around for him her Practice this exercise until your child can start off accelerate cruise and stop correctly and with confidence STEP 4 TURNING After your child has learned to ride the TE100 90 in a straight line and can stop it when he she ...

Page 33: ... WARNING Do not attempt to perform maintenance on this vehicle if you are not qualified You could be injured or may damage the machine WARNING The safety of the rider depends on how well this machine is maintained Follow all inspection and maintenance instructions carefully WARNING Don t let your children tinker with this machine They may get hurt Maintenance should only be performed by qualified ...

Page 34: ...nsmission oil Drive chain Sprockets Initial 1 month Every 3 months Every 6 months Interval Item Inspect Inspect Inspect Inspect Inspecteverymonth Checkpressureeachtimeride Tighten Tighten Lucbricate CHASSIS Brakes Steering Tires Chassis nuts and bolts General lubrication Initial 1 month Every 3 months Every 6 months AskyourHyosungdealerorqualifiedmechanictodothemaintenanceitemsmarked N O T E PERIO...

Page 35: ...he seat SEAT REMOVAL AIR CLEANER TOOLS DO NOT operate the engine without the air cleaner element in place or severe engine damage may result If you usually ride in dusty areas or regularly operate the vehicle in wet muddy conditions you must ins pect the air cleaner element more frequently than shown in the perio dic maintenance chart If at any time the air cleaner element is submerged in water im...

Page 36: ...g it between the palms of both hands to remove excess solvent Do not twist or wring the element or it will develop cracks 3 Immerse the element in a separate pan filled with 2 stroke engine oil Squeeze the element to remove excess oil Make sure that the element remains damp with oil but not soaked Before during and after the cleaning operation carefully examine the element for any tears in the mat...

Page 37: ...ve named plugs are not available consult your HYOSUNG dealer PLUG REPLACEMENT GUIDE Hotter type Standard type Colder type BPR6HS BPR7HS BPR8HS Keep cleaning solvent and oil away from children and pets Dispose of used solvent and oil properly WARNING Be sure to position the air cleaner element correctly Make sure it fits properly so that no incoming air will bypass it Remember rapid wear of piston ...

Page 38: ...r engine warms up turn the throttle stop screw in or out so that the engine idles at lowest steady speed 0 6 0 7mm 0 024 0 028 in To install a spark plug turn it in as far as possible with your fingers then tighten it with a wrench Do not overtighten or cross thread the spark plug or the aluminum threads of the cylinder head will be damaged Do not allow contaminants to enter the engine through the...

Page 39: ...ears to be in good condition Damage from aging may not always be visible Measure the throttle cable play by pressing the throttle lever The throttle lever should have 2 5 6mm 0 098 0 236 in play To adjust the throttle cable play 1 Remove the adjuster cover 2 Loosen the lock nut 3 Turn the adjuster in or out to obtain the correct play 4 Tighten the lock nut 5 Recheck the throttle cable play Readjus...

Page 40: ...ach time before starting the engine If the oil level is low fill up the tank with the specified oil The oil tank holds 1 0ℓ TRANSMISSION OIL CAPACITY Replace Overhaul 80 90 7 Refit the oil filler cap and oil level screw Frequent use in wet conditions will require more frequent oil changes If the vehicle becomes submerged in water immediately change the oil Failure to follow these instruction may r...

Page 41: ...rakes according to the MAINTENANCE SCHEDULE WARNING Operating the ATV in harsh condition can be hazardous if you do not inspect brake wear often Operating in mud water sand or other extreme conditions can cause accele rated brake wear This could lead to an accident If you operate your vehicle under these conditions the brakes must be inspected more often than reco mmended in the MAINTENANCE SCHEDU...

Page 42: ...rake check again to make sure the rear wheels can not turn when the parking brake lock knob is engaged Brake shoe wear limit This vehicle is equipped with the brake shoe wear limit indicators on the front brakes To check wear of the brake shoe perform the following Check if the brake system is properly adjusted While fully applying the brake check to see that the extension line of the index mark i...

Page 43: ...achanic Riding with worn brake pads will reduce braking performance and will increase your chance of having accident Inspect brake pad wear before each use Ask your Hyosung dealer or qualified mechanic to replace brake pads if any pad is worn to the limit WARNING TIRES Using tires of a different size than the tires originally equipped on your ATV can change the ATV s handling charac teristics Diff...

Page 44: ...ressure should only be measured or adjusted when the tires are cold or misleading measurements can result COLD TIRE PRESSURE FRONT 25 KPa 0 25 3 6 psi 25 KPa 0 25 3 6 psi REAR Operating the vehicle with excessively worn tires can cause skidding due to decreased traction It is recommended that the front and rear tires be replaced when the depth of the tire tread is 3 mm 0 118 in or less WARNING Usi...

Page 45: ...ive chain condition or adjustment there is a strong possibility that the sprockets will have some damage to them also Inspect the sprockets for the following Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nut s Clean and oil the chain as follows 1 Wash the chain with kerosene Kerosene is a petroleum product and will provide some lubrication as well as cleaning action Worn G...

Page 46: ...ace the drive chain with a new one Tighten Torque 25 N m 2 5 m Front and Rear wheel nut Failure to inspect the drive chain slack before each use of the vehicle could be hazardous Too much chain slack could cause the chain to come off the sprockets resulting in an accident or serious damage to the vehicle Inspect the drive chain slack before each use WARNING FRONT AND REAR WHEEL REMOVAL When replac...

Page 47: ...2 After removing the bulb at the socket replace the new bulb 3 To install the head lamp reverse the above sequence HEAD LAMP 1 Remove the lens at the tail lamp rubber housing 2 After removing the bulb at the socket replace the new bulb 3 To install the tail lamp reverse the above sequence TAIL LAMP NAME CAPACITY Head lamp Tail lamp 12V 35W 12V 5W The use of a lamp other than rules may cause to occ...

Page 48: ...eel bearing Steering shaft holder Rear brake cable Drive chain Rear axle housing Front brake cable Throttle cable Throttle lever Front brake camshaft O G Motor oil Grease GENERAL LUBRICATION TE100 means the invisable parts ...

Page 49: ...eel bearing Steering shaft holder Rear brake cable Drive chain Rear axle housing Front brake cable Throttle cable Throttle lever Front brake camshaft O G Motor oil Grease GENERAL LUBRICATION TE90 means the invisable parts ...

Page 50: ...c maintenance on the vehicle Be sure to have your authorized HYOSUNG dealer perform a general lubrication as shown in the maintenance chart on page 34 Your authorized HYOSUNG dealer will lubricate such items as wheel bearings rear axle housings steering shaft holder etc T ROUBLE SHOOTING b Tighten the drain screw c Remove the spark plug d Loosen the drain screw and check that the carburetor is fil...

Page 51: ...ng for a spark do not point the spark plug near the spark plug hole There may be some fuel inside the cylinder which could be ignited Due to the possibility of electrical shock anyone with a heart condition or pacemaker should avoid this check WARNING COMPLAINT Engine stalls 1 Make sure there is enough fuel in the fuel tank 2 Check to see that the spark plug is not fouled Remove the plug and decar...

Page 52: ... suitable means Use extra tie downs when you transport the vehicle in the standing position Failure to properly secure the vehicle may result in an accident or damage to the vehicle WARNING The TE100 90 should be transpo rted or deposited in the normal position If the TE100 90 be transported or deposited in the standing position bleed air of oil pump Air bleeding of oil pump Loosen the air bleedin...

Page 53: ... A thorough cleaning of your ATV is a necessary part of 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 c...

Page 54: ...lable hand pump or siphon Drain the fuel from the carburetor using the carburetor drain screw Do not allow the fuel to spill catch the fuel in a suitable container Do not allow any fuel to come in contact with the hot engine or exhaust system Extinguish smoking materials before draining any fuel and stay away from any other fire or heat source Keep pets and children away from fuel and dispose of u...

Page 55: ...urfaces with car wax PROCEDURE FOR RETURNING TO SERVICE Clean the entire vehicle Reinstall the battery Remove the spark plug Turn the engine a few times by pushing the starter switch Reinstall the spark plug Make sure that the vehicle is properly lubricated Perform the INSPECTION BEFORE RIDING as listed in this manual Make sure that the battery lead wire is routed properly CAUTION ...

Page 56: ...56 LO C ATION OF LABELS 3 1 2 1 3 2 ...

Page 57: ...57 4 6 5 7 4 5 6 ...

Page 58: ...1 in 885mm 34 8 in 950mm 37 4 in 120mm 4 7 in 658mm 25 9 in 658mm 25 9 in 97 5kg 215 lbs TE 90 96kg 212 lbs ENGINE Type Intake system Number of cylinder Bore x Stroke Piston displacement Corrected compression ratio Carburetor TE 100 Two stroke forced air cooled Reed valve 1 52 5 46 0mm 2 07 1 81in 99 6 04 in3 6 7 1 PB11M TE 90 52 5 41 4mm 2 07 1 63in 89 5 43 in3 6 6 1 ...

Page 59: ...1 042 CHASSIS Front brake Rear brake Front tire size Rear tire size TE 100 Drum brake Disk brake 18 7 00 7 18 7 00 7 TE 90 CAPACITIES Fuel tank Engine oil tank Transmission oil TE 100 4 0ℓ 1 0ℓ 80 Replace 90 Overhaul TE 90 ELECTRICAL Ignition type Spark plug TE 100 CDI Type BPR7HS TE 90 ...

Page 60: ...Prepared by H YOSUNG MOTORS MACHINERY INC 2nd Ed MAR 2003 Printed in KOREA ...