TE 90-100R
Contents
1. OFF Position Turn the lever to the OFF position whenever stopping the engine for more than a few minutes 19 PMENT AND USTMENTS E QU DJ FUEL TANK CAP To open the fuel tank cap remove the end of the vent tube from the hole in the vehicle body and turn the fuel tank cap counterclockwise To close the fuel tank cap turn it clockwise and tighten it securely Be sure that the end of the vent tube is reinstalled in the hole in the vehicle body and routed properly as shown Filler neck Fuel level 20 AN WARNING Do not overfill the fuel tank Stop adding fuel when the fuel level reaches the bottom of the filler 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 D AN WARNING Gasoline is extremely flammable and toxic Always observe the following precautions when refueling your FTE100 9 04 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 contact with skin and breathing of gasoline vapors Keep children and pets away during refueling P REMOT2. 6 ENGINE OIL LEVEL The engine oil tank is located under the seat Check the oil level each time before starting the engine If the oil level is low fill up the tank with the specified oil The oil tank holds 1 0 4 AN WARNING Never operate the TE100 904 without an adequate amount of oil if the engine runs out of oil it can stop suddenly causing injury and or severe mechanical damage T Refit the oil filler cap D and oil level screw 2 C BRAKE The TE100 90 has front drum brake and rear disk brake AS WARNING NS Failure to properly 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 vehicle according to the INSPECTION BEFORE RIDING section Always maintain your brakes 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 SCHEDULE 41 9 Front Brake 6 Brake adjustment Too much play in the f
3. REPLACEMENT OF THE LAMP FOR 100 Requirement electric power of the lamp shown in the following chart When replace the damaged lamp always use the equal capacity The use of a lamp other than rules may cause to excesive at the electric system or damage the lamp NAME CAPACITY Head lamp 12V 35W 12V 5W CAUTION Tail lamp The use of a lamp other than rules may cause to occur the vehicle fire and to damage electric parts Surely use only the lamp of proper capacity HEAD LAMP 1 Remove the two screw a right left 2 After removing the bulb at the socket replace the new bulb 3 To install the head lamp reverse the above sequence M S TAIL LAMP NI 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 6 GENERAL LUBRICATION TE100 3 King pin 6 Rear axle housing 2 Front wheel bearing Front brake cable 3 Steering shaft holder 8 Throttle cable Rear brake cable Throttle lever Drive chain 49 Front brake camshaft inns Motor oil X J meanstheinvsablepats W Grease 48 e GENERAL LUBRICATION TE90 D TAREN Jas em
4. 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 spark plug hole when the plug is removed Y 0 6 0 7mm 4 0 024 0 028 To maintain a hot strong spark keep the plug free of carbon Remove carbon from the plug with a wire or pin and adjust the gap to 0 6 0 7mm 0 024 0 028 in for good ignition Use a thickness gauge to check the gap 38 To adjust the idle speed properly you need a engine tachometer If you do not have one ask your HYOSUNG dealer to perform this adjustment To adjust the idle speed 1 Start the engine and warm it up 2 After engine warms up turn the throttle stop screw in or out so that the engine idles at lowest steady speed PA CAUTION Make sure that the engine is fully warmed up before adjusting the engine idle speed Improper adjustment can result in increased engine wear THROTTLE CABLE ADUSTMENT 6 FUEL HOSE RU 5 6mm 0 098 0 236 in 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 n
5. Tighten Tighten Cylinder head and cylinder Remove carbon Carburetor Inspect Inspect Spark plug Clean Clean Replace Inspect Inspect Fue ime Replace every 4 years Transmission oil Inspect Inspect Drive chain Inspect and lubricate every month Sprockets Inspect Inspect CHASSIS Interval Initial Every Every Item 1 month 3 months 6 months Brakes Inspect Inspect Steering Inspect Inspect ai Tires Inspect every month Check pressure each time ride Chassis nuts and bolts Tighten Tighten General lubrication Lucbricate CAUTION More freguent servicing may be performed on motercycles that are used under sever conditions Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked NOTE 34 6 SEAT REMOVAL 6 AIR CLEANER D To remove the seat pull the metal bar under the rear end of the seat and lift it up TOOLS A tool kit is provided under the seat 35 If the air cleaner element is clogged with dust there will be greater intake resistance resulting in decreased power output and increased fuel consumption CAUTION DO NOT operate the engine without the air cleaner element in place or Severe engine damage may result e If you usually ride in dusty areas or regularly operate the vehicle in wet muddy conditions you must ins pect
6. or DEATH 68367 H 3100 A WARNING FAILURE TO TAKE THE FOLLOWING SAFETY PRECAUTIONS CAN RESULT IN SERIOUS PERSONAL INJURY READ OWNER S MANUAL CAREFULLY BEFORE OPERATION TO FAMILIARIZE YOURSELF WITH THIS VEHICLE S UNIQUE HANDLING CHARACTERISTICS PROPER RIDING TECHNIQUES AND DETAILED SAFETY PRECAUTIONS INSTRUCT ALL RIDERS ACCORDINGLY THE OWNER S MANUAL IS PROVIDED IN THE PACKING OF THIS VEHICLE MAKE SURE ALL RIDERS UNDERSTAND THAT EVEN THOUGH THIS VEHICLE HAS FOUR WHEELS IT CAN TIP OVER IN ANY DIRECTION IF IT IS IMPROPERLY USED NO RIDERS UNDERAGE 12 ADULT MUST SUPERVISE OPERATION AT ALL TIMES USE ONLY OFF ROAD NEVER USE ON PUBLIC ROADS OR PAVEMENT SINGLE RIDER ONLY NO PASSENGERS WEAR HELMET EYE PROTECTION AND PROTECTIVE CLOTHING ADULT MUST PERFORM DAILY INSPECTION BEFORE OPERATION TIRE INFLATION PRESSURE AND TIRE CHARACTERISTICS CAN AFFECT VEHICLE HANDLING SEE THE TIRE INFORMATION LABEL AND YOUR OWNER S MANUAL A TIRE PRESSURE GAUGE IS IN THE TOOL KIT UNDER THE SEAT ENGINE STARTING AND REFUELING MUST BE DONE BY ADULTS ONLY WHEN REFUELING DO NOT SMOKE AND AVOID SOURCES OF SPARK OR FLAME USE THE REMOTE ENGINE STOP SWITCH CAP AS AKEY TO PREVENT UNAUTHORIZED USE DO NOT ALLOW THIS VEHICLE TO BE RIDDEN AT NIGHT DO NOT EXCEED VEHICLE LOAD CAPACITY SHOWN ON THE TIRE INFORMATION LABEL WHEN USING ACCESSORIES OR CARRYING LOADS FOLLOW THE GUIDELINES IN THE OWNER S MANUAL RIDE SAFELY
7. WA CAUTION Using a high pressure air pump to fill the tires can be hazardous If too much air is put into a tire the tire may burst causing severe injury Use a manual type air pump to fill the tires DRIVE CHAIN 6 The chain may require more frequent adjustment that it is with periodic maintenance depending upon your riding conditions Inspect and lubricate every month If it becomes necessary to replace the drive chain we recommend that you take your vehicle to an authorized HYOSUNG dealer to have the work done You should periodically inspect the drive chain for the following Loose pins Damaged rollers Dry or rusted links 6 Kinked or binding links Excessive wear Good Worn If you find anything wrong with the drive 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 45 9 Drive Chain Cleaning and Oiling 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 AS WARNING Keep kerosene away from children and pets Dispose of used kerosene pro perly M r CAUTION Do not use gasoline or other commer cial cleaning solvents to
8. King 2 Front wheel bearing 3 Steering shaft holder Rear brake cable Drive chain 7 means the invisable parts Rear axle housing Front brake cable 8 Throttle cable 9 Throttle lever Front brake camshaft 2 dues Motor oil t Grease 49 Proper lubrication is important for safe smooth operation and long life of each working part of your vehicle Pay attention to the need for lubrication when you perform periodic 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 I ROUBLE SHOOTING CAUTION It is best to consult your HYOSUNG dealer before attempting to troubleshoot any problem Damage may result from inappropriate repairs or adjustments Such damage may not be covered under warranty This troubleshooting guide is provided to help you identify the cause of some common complaints COMPLAINT Engine is hard to start or does not start at all Something is probably wrong with the fuel System or ignition system 50 FUEL SYSTEM CHECK 1 Make sure there is adequate fuel in the fuel tank 2 Check that the engine stop switch is in the position 3 Check that the remote engine stop Switch
9. 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 Front wheel If front wheel skidding occurs try to gain front wheel traction by reducing the throttle opening and leaning your body weight slightly forward E Rear wheel If rear wheel skidding occurs steer in the direction of the skid if space permits shift body weight away from the skid slightly and avoid using the throttle or brakes until you regain directional control of the vehicle AS WARNING Skidding or sliding can result in accidents caused by loss of rider control To avoid inadvertent skidding or sliding the rider should slow down and be very cautious when riding on slippery or loose surfaces OPERATION ON HILLS Riders who have become experienced at operating the TE100 90 on level surfaces may wish to try riding on a wider variety of terrains The TE100 90 may be operated on small hills with even surfaces but extreme care should be taken AN WARNING When the 100 9 04 is operated on hills it can roll over more easily than when it is operated on level ground under certain conditions Only children who are capable of safe operation of the FTE100 904 on level ground should be permitted to operate the vehicle on hills 27 Climbing a Hill To climb a small hill with the TE100 90 the rider
10. and turning on hills can all lead to vehicle tip over Learn proper riding techniques and avoid riding situations which can lead to tip over accidents The 712100 904 and other all terrain vehicles ATVs have unique handling characteristics ATVs handle differently than motercycles Although ATVs have four or three wheels they handle differently than automobiles too ATVs require special riding techni ques suited to their handling characteristics so be sure that all riders of the 7E 100 9 04 practice and master the riding techniques described in this owner s manual Starting on page 24 AN WARNING Proper parental supervision and instruction are necessary for safe and proper operation of this 100 9 04 by young riders It is important that both you and your child understand and observe the restric tions listed on the fender label of the TTE100 904 Read this owner s manual carefully and review its contents fully with your child It is YOUR RESPONSIBILITY to make sure that your TE100 904 is properly and safely ridden and maintained A WARNING 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 100 904 AT ALL TIMES Constant supervision is necessary So you can observe that the operator is riding safely Ne
11. at the bag opening 2 Hook the bag on the frame as shown and fit the rubber cap snugly over the remote engine stop switch body With the rubber cap off the switch the engine can not be started because the ignition circuit is not completed AN WARNING Avoid leaving any part of the lanyard visible outside the bag as it can be caught and damaged by moving parts AN WARNING To prevent unauthorized starting or unsupervised operation of the TE 100 9 04 remove the remote engine stop Switch cap and lanyard after each use and store them in a safe place out of the reach of children 22 BR FAK N RUNN NG N The first month is the most important in the life of your vehicle Proper operation during this break in period will help ensure maximum life and performance from your new vehicle The following guidelines explain proper break in procedures MAXIMUM THROTTLE OPEN ING RECOMMENDATION During the first 10 hours of vehicle operation the maximum thottle opening you should use is 1 2 throttle VARY THE ENGINE SPEED The engine speed should be varied during the break in period Although it is essential that some stress be placed on the engine components during break in you must be careful not to excessively load the engine AVOID CONSTANT LOW SPEED Operating the engine at constant low speed light load can cau
12. cloth pants long sleeved shirt or jacket boots Beware of hazardous situations Instruct the rider to do likewise Do not permit the TE100 9 04 to be used on public roads AT ANY TIME This vehicle is designed and manufactured for use ONLY off public roads It is not subject to Federal Motor Vehicle Safety Standards as it is not equipped or approved for operation on public Streets roads or highways at any time Do not permit the TE100 9 04 to be operated on any paved surfaces The vehicle can be more difficult to control when it is operated on 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 100 901 while under the influence of alcohol or other drugs Make sure the combined weight of the rider protective gear and any accessories or cargo does not exceed the 68kg 150lbs weight limit Exceeding this weight limit may result in injury caused by damage to the vehicle or altered handling characteristics Observe periodic maintenance requirements your authorized HYOSUNG dealer is trained and equipped to perform this service Never permit vehicle refueling by anyone other than an adult Drain gasoline from the fuel tank and carburetor prior to tra
13. the air cleaner element more frequently than shown in the perio dic maintenance chart e If at any time the air cleaner element is submerged in water immediately clean the element and the inside of the air cleaner case M WA 9 Removing The Element 9 Washing the Element Wash the element as follows 1 Remove the four bolts 1 2 Remove the clamp screw 2 3 Take out the air cleaner cap and air cleaner element 4 36 for any tears in the material A torn Fill a washing pan large enough to hold the element with a non flammable cleaning solvent Immerse the element in the solvent and wash it Squeeze the element by pressing it between the palms of both hands to remove excess solvent Do not twist or wring the element or it will develop cracks 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 AN WARNING Before during and after the cleaning operation carefully examine the element element could permit dirt and dust to pass into the engine If the air cleaner element is torn it must be replaced with anew one 4 Reinstall the cleaned element in reverse order of removal Be sure that the element is securely in position and is sealing properly AN WARNING Keep cleaning solvent and oil away from children
14. you know how to do it you could get a high voltage electrical shock When testing for a spark do not point the spark plug near the spark plug If the TTE 100 9 04 be transported or deposited in the standing position it may air income in the oil pump This may cause severe cylinder and hole There may be some fuel inside the piston damage which may not be bleed cylinder which could be ignited Due to air of the oil pump the possibility of electrical shock L J anyone with a heart condition or pacemaker should avoid this check 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 decarbon or replace it if necessary 3 Make sure the fuel cock is clear Also check connected to the fuel tank cap is not clogged STANDING POSITION 51 CAUTION The 100 904 should be transpo rted or deposited in the normal position If the 12100 901 be transported or deposited in the standing position bleed air of oil pump 9 Air bleeding of oil pump DLoosen the air bleeding screw at the engine idles Wait until the air bleeds out from the air bleeding screw completely Tighten the screw after air bleeding of oil pump Before transporting the 100 901 drain the fuel from the carburetor as follows 1 Turn the fuel cock lever to the OFF posi
15. Before you begin to use this guide however be sure you have revie wed the vehicle features and riding techniques described in earlier parts of this owner s manual HYOSUNG strongly urges that you use this guide to teach each child that you let ride the TE100 90 Be sure to take breaks as the child being instructed gets tired or his her attention begins to wander Full attention at all times is needed to safely operate any motorized vehicle including the TE100 905 30 E STEP 1 PROPER CLOTHING AND PROTECTIVE GEAR The first step to safe riding is proper protection of the rider Your child should always wear a helmet eye protection gloves long pants a long sleeved shirt or jacket and boots Make sure that your child is not wearing any loose fitting clothes Loose belts Scarves etc can get caught in moving parts and cause personal injury Even in hot weather make sure your child wears long pants and a long sleeved shirt These not only protect against abrasive injuries but also help to reduce fatigue which comes from loss of body heat due to the wind AN WARNING Failure to wear proper clothing and protective gear as described above may result in severe personal injury STEP 2 FAMILIARIZATION WITH THE VEHICLE Your child should become completely familiar with the names and functions of all controls Let the young rider sit on the 100 903 with the engine off and ask him her to op
16. E ENGINE STOP SWITCH The 100 90 comes equipped with a remote engine stop switch which may be operated by pulling the leash like lanyard attached to the remote engine stop switch cap An adult supervising operation of the vehicle can use the lanyard to stop the engine from a short distance The adult who trains the young rider should always use this lanyard until the rider develops sufficient skills for safe operation of the vehicle Switch body 2 Rubber cap Remote engine stop switch lanyard The switch consists of a rubber cap fitted over a plastic body When the rubber cap is in place the engine can operate When the rubber cap is removed from the switch body the engine cannot be started If the engine is running and the rubber cap is removed by pulling the lanyard attached to the cap the engine will stop running To use the remote engine stop switch 1 Fit the rubber cap on the engine of the lanyard over the remote engine stop Switch body located on the rear end of the vehicle as shown 2 Put your fingers through the loop at the other end of the lanyard 21 3 With the lanyard fastened to the vehicle and to your hand follow after the moving vehicle If you notice any driving hazard or unsafe situation pull the lanyard forcefully so that the rubber cap comes off This will activated the remote engine stop switch stopping the vehicle s engine AN WARNING When th
17. NING Traversing a slope is very tricky and should be avoided when possible Improper riding technigues while traversing a slope could cause the FTE100 9 O4 to tip over Do not permit your child to traverse a slope unless you are sure he she can perform this maneuver safely To traverse a slope the rider should e Lean his her body uphill e Steer slightly uphill if necessary to maintain a straight course RIDING THROUGH WATER The TTE100 90 may be ridden through water provided that it is not more than 19cm 7 5 in deep and is not moving fast When crossing a stream choose a spot where the banks are gently sloped on both Sides and the bottom of the stream is hard If you are unfamiliar with the area you wish to cross park the TE100 90 and inspect the stream first to find a suitable spot for crossing When crossing operate the vehicle at a slow steady speed AN WARNING 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 e 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 repeatedly applying the front and rear while riding slowly until the brakes have regained their normal effectiveness CAUTION After extended operation of the FTE100 904 i
18. PRESERVE NATUR AND BE THOUGHTFUL OF OTHERS 68366 H L4150 57 SPECIF CAT DIMENSIONS AND MASS TE 100 ONS Overall length 1 376mm 54 2 in Overall width 840mm 33 1 in Overall height 885mm 34 8 in Wheelbase 950mm 37 4 in Ground clearane 120mm 4 7 in Front track 658mm 25 9 in Rear track 658mm 25 9 in Mass ENGINE 97 5kg 215 Ibs TE 100 Type Two stroke forced air cooled Intake system Reed valve Number of cylinder 1 Bore x Stroke 52 5 x 46 0mm 2 07 x 1 81 in 525 x41 4mm 2 07 x1 63 in Piston displacement 99 cri 6 04 in 89 ui 5 43 in Corrected compression ratio 6 7 1 6 6 1 Carburetor PB11M TRANSMISSION TE 100 TE 90 Transmission 2 257 0 782 2 842 1 042 Drive chain 428H 56 links CHASSIS TE 100 Front brake Drum brake Rear brake Disk brake Front tire size 18 x7 00 7 Rear tire size ELECTRICAL 18 7 00 7 TE 100 Ignition type CDI Type Spark plug CAPACITIES BPR7HS TE 100 Fuel tank 4 02 Engine oil tank 1 01 Transmission oil 80m Replace 90ml Overhaul 59 Prepared by HYOSUNG MOTORS amp MACHINERY INC 2nd Ed MAR 2003 Printed in KOREA
19. SMISSION OIL ENGINE OIL LEVEL BRAKE TIRES DRIVE CHAIN FRONT AND REAR WHEEL REMOVAL REPLACEMENT OF THE LAMP FOR TE100 G G ENERAL LUBRICATION TE100 ENERAL LUBRICATION TE90 12 5 50 13 TRANSPORTING 51 14 CLEANING PROCEDURE 5 95 86 6n ne 53 15 STORAGE PROCEDURE 54 16 LOCATION OF LABELS rne 56 17 SPECIFICATIONS 58 SERIAL NUMBER LOCATION The frame and or engine serial numbers are used to title the vehicle They are also used to assist your dealer when ordering parts or referring to special service information The frame number is stamped on the front frame member as shown in the illustration The engine serial number is stamped on the right side of the crankcase assembly Please write down the serial numbers here for your future reference Frame No Engine No FUEL AND OIL RECOMMENDATION 6 FUEL 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 e ENGINE OIL D Use HYOSUNG HYPOL OIL HS If they are not available use a good quality TWO STROKE engine oil C TRANSMISSION OIL D Use a good quality SAE 10
20. This manual should be considered a permanent 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 FOREWORD This manual is an essential part of your vehicle Please read it carefully It contains important information on safety operation and maintenance It is especially important that this manual remain with the vehicle at the time of resale The next owner will need this information also Your HYOSUNG 100 904 is built for use by children but this owner s manual is written for the adults who will be supervising the children HYOSUNG 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 IMPORTANT WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words FWARNING CAUTION and NOTE have special meanings Information following these signal words should be carefully reviewed AN WARNING The personal safety of the rider or bystanders may be involved Disregarding this information could result in personal injury CAUTION These instructions point out special service procedures or pre
21. W 30 or 10W 40 multi grade motor oil LOCATION OF PARTS TE100g CD Rear brake lever Parking brake lever Parking brake knob Front brake lever Throttle lever Fuel tank cap Starter switch Engine stop switch SWS ES gt Remote engine stop switch 10 9 Fuel cock amp 9 Head lamp Battery amp fuse 42 Muffler 13 Drive chain NOTE NER means the invisable parts 11 Tail lamp 49 Tools 6 Engine oil tank Air cleaner NOTE SER means the invisable parts 12 LOCATION 5 904 D Rear brake lever Parking brake lever 2 Parking brake knob Front brake lever Throttle lever Fuel tank cap Starter switch Engine stop switch 13 Fuel cock 0 Battery amp fuse Muffler 02 Drive chain 9 means the invisable parts 15 43 Tools Engine oil tank 05 Air cleaner NOTE SER means the invisable parts 16 CONTROLS IGNITION SWITCH C ON KEY W O The ignition switch has two position 9 e ON POSITION The ignition circuit is completed and the engine can now be started The ke
22. Young Rider section The Instructing the Young Rider section will guide you in teaching young riders how to operate and ride the 100 904 using the information you learn in this owner s manual STARTING THE ENGINE Before attempting to start the engine make Sure 1 The parking brake is engaged 2 The engine stop switch is in the 7 position 3 Verify that the remote engine stop switch cap is in place 4 The fuel cock is in the ON position A WARNING e Do not run the engine indoors where there is little or no ventilation Exhaust gases contain carbon monoxide a potentially lethal gas that is colorless and odorless Never leave the vehicle running while unattended even for a short time STARTING OFF After the engine has warmed up disengage the parking brake To release the parking brake simply squeeze the rear brake lever until the lock knob release AN WARNING Before releasing the parking brake make sure e The throttle is fully closed e The rider is completely ready to ride If you do not observe these precautions the vehicle can move forward unexpect edly when the parking brake is released This may result in an accident and injury Open the throttle gradually to move forward AS WARNING While operating the 7E 100 90 the rider should keep both feet on the footrests at all times or injuries resulting from accidents such
23. an water Dry all areas using a chamois or soft absorbent cloth INSPECTION AFTER CLEANING Remove the rags or wrapping from the exhaust pipe For extended life of your ATV lubricate according to GENERAL LUBRICATION section AN WARNING Operating ATV with wet brakes can be hazardous Wet brakes may not provide as much stopping power as dry brakes This could lead to an accident Test your brakes after washing ATV while riding at slow speed If necessary apply brakes several times to let friction dry out the linnings and pads Follow the procedures in the INSPEC TION BEFORE RIDING section to check your ATV for any problems that may have arisen during your last ride 54 PROCE S TO R AGE DURE Er If your 100 90 is to be left unused for an extended period of time it needs special servicing requiring appropriate materials equipment and skill For this reason HYOSUNG recommends that you trust this maintenance work to your HYOSUNG dealer If you wish to service the machine for storage yourself follow the general guidelines below VEHICLE e Place the vehicle on level ground and thoroughly clean the entire vehicle e Remove the battery from the ATV FUEL Drain the fuel from the fuel tank using a commercially available hand pump or siphon Drain the fuel from the carburetor using the carburetor drain screw AN WARNING Do not allow the fuel
24. and pets Dispose of used solvent and oil properly CAUTION 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 rings and cylinder walls is often caused by an improperly positioned air cleaner element 6 SPARK PLUG Your 100 90 comes equipped with an BPR7HS spark plug You can deter mine if the standard spark plug is suitable for your type of vehicle usage by observing the color of the plug s porcelain center electrode insulator after vehicle operation If the plug has the correct heat range it should be very light brown in color If the plug tends to run cold usually evidenced by blackening of the insulator or a wet electrode replace it with an alternate plug according to the following chart CAUTION An improper spark plug may have incorrect fit or heat range for your engine This may cause severe engine damage which may not be covered under warranty Use one of the spark plugs listed below or equivalents Consult your HYOSUNG dealer if you are not sure which spark plug is correct for your type of vehicle usage M 2 PLUG REPLACEMENT GUIDE Hotter type BPR6HS Standard type BPR7HS Colder type BPR8HS If the above named plugs are not available consult your HYOSUNG dealer 37 CAUTION C IDLE SPEED ADUSTMENT b
25. 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 AN WARNING Keep both hands on the handgrips at all times when riding Removing your hands from the handgrips reduces your ability to control the vehicle and could result in an accident AN WARNING Always open the throttle gradually to prevent front wheel lifting Failure to observe this precaution may result in loss of control and an accident BRAKING To stop the TE100 901 release the throttle lever and apply the brake AN WARNING e Avoid braking during turns Use of the brake when turning could cause the 100 904 to slide or roll over Use the brake to slow down before entering turns e Apply the brake lightly and with great care on slippery surfaces to avoid skidding AN WARNING Never operate the parking brake lock when the 100 904 is moving The rear wheels will lock and an accident could result TURNING To turn the TE100 90 the rider must learn a special technique Because this vehicle has a solid rear axle both rear wheels always turn at the same speed This means that if the rear wheels are getting equal traction the vehicle will move straig
26. cap is installed on the remote engine stop switch 4 Make sure there is enough fuel reaching the carburetor from the fuel tank a Loosen the drain screw which is located under the carburetor and drain the fuel from the carburetor AN WARNING Do not allow the fuel to spill catch the fuel in a container Do not allow any fuel to come in contact with the hot engine or exhaust system Extinguish any smoking materials before performing this check and stay away from any open flames or heat sources b Tighten the drain screw c Remove the spark plug d Loosen the drain screw and check that the carburetor is filled back up with fuel e If it has been determined that fuel is reaching the carburetor the ignition system should be checked next E IGNITION SYSTEM CHECK TRANSPORTING Remove the spark plug and reattach it to the spark plug lead The TE100 90 should be transported in the normal position N While holding the spark plug firmly against the engine push the starter switch with the engine stop switch in the position and the remote engine Stop switch cap is installed on the remote engine stop switch If the ignition system is operating properly a blue spark should jump across the spark plug gap If there is no spark take your machine to you authorized HYOSUNG dealer NORMAL POSITION AN WARNING dM CAUTION Do not check for a spark unless you are certain that
27. cautions that must be followed to avoid damaging the machine NOTE This provides special information to make maintenance easier or important instructions clearer 2 SP HYOSUNG MOTORS 8 MACHINERY INC COPYRIGHT HYOSUNG MOTORS amp MACHINERY INC A WARNING Noise Control System muffler assembly TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for the purpose of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its 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 Running the engine with incorrectly operating spark plug or misadjusted carburetor may cause permanent damage to the catalyst and to the noise control system IMPORTANT NOTICE TO PARENTS A WARNING Even though the TTE100 904 has four wheels it can tip over in any direction Improper turning techni ques traversing hills accelerating on hills
28. clean the drive chain V 2 After thoroughly washing the chain and allowing it do dry oil the links with a drive chain lubricating oil or heavy weight motor oil Pi Inspect Drive Chain Slack di FRONT AND REAR WHEEL REMOVAL The slack in the drive chain to 5 15mm 0 197 0 591 in If exceed 15mm 0 591 in of the drive chain slack replace the drive chain with a Place the vehicle on level groud and set new one AN WARNING 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 46 the parking brake Loosen the three wheel nuts on the wheel to be removed Lift up the front or rear end of the vehicle by placing a jack or block under the axle or frame Remove the three wheel nuts Remove the wheel To reinstall the wheel reverse these steps AN WARNING When replacing a wheel it is very impotant that the wheel nuts be torqued to the proper specifications If they are not the wheel can come off unexpec tedly We strongly recommend that you have these nuts checked and retorqued if necessary by your authorized HYOSUNG dealer Tighten Torque 25 2 5kg m Front and Rear wheel nut
29. e risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 12 to operate this 68931 H 1 4150 Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death ALWAYS maintain proper tire pressure as shown below WARNING N 7 Improper ATV use can result in SEVERE INJURY or DEATH DOG ALWAYS USE AN NEVER USE ON NEVER CARRY APPROVED HELMET PUBLIC ROADS PASSENGERS AND PROTECTIVE GEAR NEVER exceed the Vehicle Load Capacity of 150 Ibs 68kg COLD TIRE PRESSURE UP TO 150 Ibs FRONT 3 6 psi 0 25 kgf cm 68kg REAR 3 6 psi 0 25 kgf cm TIRE SIZE FRONT 18 700 7 REAR 18 700 7 68332 H LA150 NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS A WARN NG use proper riding techniques to avoid vehicle NEVER ride as overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously a passenger 5 affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Passengers can cause a loss of control resulting in SEVERE INJURY amp
30. e listed below Front Rear 18x7 00 7 18 7 00 7 Size AN WARNING Using tires of a different size than the tires originally equipped on your ATV can change the ATV s handling charac teristics Different handling charac teristics can result from differences in carcass construction sidewall strength tread pattern etc A WARNING For the rider s safety check your vehicle s tires before each use of the vehicle to make sure they have proper pressure enough tread depth and no damage M 9 Tire Tread Condition AN WARNING 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 44 Tire Pressure A low pressure gauge is provided in tool kit under the seat so you can measure the air pressure in your TE100 90 tires Check the air pressure in all tires before each use of the vehicle Improper air pressure can affect handling maneuverability traction tire life and rider comfort Be sure that the tires are inflated to the pressures shown below Tire pressure should only be measured or adjusted when the tires are cold or misleading measurements can result COLD TIRE PRESSURE 25 KPa 0 25 kg cnt 3 6 psi 25 KPa 0 25 kg cm 3 6 psi FRONT REAR
31. e 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 A WARNING If you do not put your fingers through the loop in the lanyard it may slip from your grasp unexpectedly This could make it impossible for you to stop the engine in an unsafe situation AN WARNING The 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 TTE100 9 04 without parental use of the lanyard should be permitted to operate TE 100 904 with the throttle limiter set to the maximum power position In addition an adult trying to follow a moving TTE100 904 with the throttle limiter set to the maximum power position may run into the rider if he stops or may trip and fall down trying to keep up with the vehicle Instruction For Remote engine stop switch Lanyard Storage The lanyard may be stowed on the TTE100 904 when in the judgement of the parents the rider has developed sufficient skills to be able to safely operate the vehicle without parental use of the lanyard For storage of the lanyard follow the instructions below 1 Place the lanyard in the vinyl bag provided with the vehicle with the rubber cap visible
32. er 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 wear of certain parts It is important to remove all debris during cleaning PREPARATION FOR CLEANING Wash the ATV before any mud dries on the ATV Block or seal the end of the exhaust pipe muffler using a piece of plastic wrap cloth rag or another method to prevent water from entering the engine CAUTION High pressure washers can damage your ATV High pressure washers such as those found at coinoperated car washers have enough pressure to damage the parts of your ATV It may cause rust corrosion and increase wear Do not use high pressure washers to clean your ATV KY 53 WASHING YOUR ATV With some care your ATV can be washed in a similar manner to washing an auto mobile NOTE Avoid spraying or allowing water to flow over the following places Spark plug Fuel tank cap Carburetor After the battery removed use a garden hose at low pressure to remove the majority of dirt or other debris Hand wash your ATV with a mild soap or detergent and water Try to thoroughly remove all dirt and debris without excessive water pressure 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 cle
33. erate specific controls Demonstrate operation of the controls if necessary Ask the child to do such things as apply the brakes tum off the engine lock the parking brake etc Practice this exercise until the child can operate all of the controls without hesitation and without looking at the controls Go over the INSPECTION BEFORE RIDING with your child until he she knows all of the items that should be checked and how they should be checked Give specific examples of things to look for STEP 3 STARTING OFF AND STOPPING AN WARNING For practice choose a large level area away from other riders and free of obstructions Inspect the area before riding and remove any rocks sticks or other potential hazards Stay away from ditches and bumps To help your child develop confidence he she should PRACTICE FIRST WITH THE ENGINE OFF as follows 1 Have your child sit on the TE100 905 and tell him her to release the parking brake 2 Instruct your child to keep his her eyes straight ahead and slowly push the vehicle from behind if you are physically able to do so This will allow your child to get the feel of riding a moving vehicle 3 As you 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 look
34. he uphill side of the vehicle while dragging it around 2 Turn the handlebars fully to the right While standing on the uphill side of the vehicle release the parking brake and pump the hand brake to let the 100 90 roll slowly backwards This will turn the vehicle sideways to the hill Reset the parking brake Turn the handlebars to the left Staying on the uphill side release the parking brake and pump the hand brake to let the ATV roll until it is angled downhill Reset the parking brake Remount the vehicle release the parking brake and ride down the hill as instructed in the DESCENDING A HILL section 28 AN WARNING The rider should never allow the TTE100 90y to roll backwards on a hill If the vehicle does begin to roll backwards the rider should move his her body weight forward and try to slow the vehicle to a stop using the FRONT BRAKE ONLY If the front brake does not slow the vehicle the rider should dismount to the side immedia tely The rear brake should never be used when rolling backwards on a hill Use of the rear brake can cause the vehicle to flip over Descending a Hill To ride down a small hill with the TE100 1901 the rider should e Point the TE100 90 straight down hill e Transfer body weight to the rear by slid ing back on the seat e Ride down the hill with the throttle closed e Apply the brake to control downhill speed lll Traversing a Slope AN WAR
35. hicle backward and forward to see if the rear wheels are securely locked If the rear wheels can turn adjust the rear brake to lock the wheels securely by releasing the parking brake and turning the adjuster in Repeat this procedure until the parking brake is properly adjusted 3 Measure the amount of free play needed to lock the rear brake lever as shown in the above illustration Adjust the rear brake if necessary so that amount of free play is about 5 15 mm 0 197 0 591 in 4 After any adjustment of the rear brake check again to make sure the rear wheels can not turn when the parking brake lock knob is engaged Brake pads Inspect the rear brake pads by nothing whether or not the friction pads are worn down to the grooved limit line If a pad is worn to the grooved limit line it must be replaced with a new one by your authorized Hyosung dealer or qualified service machanic T it line Inspect every day in the following point at the brake system Operating of the brake lever 2 Wear of the rear brake pads AN WARNING Riding with wom 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 43 TIRES C D The TE100 90 is equipped with low pressure tubeless tires of the siz
36. ht ahead because the rear wheels will travel the same distance For the vehicle to turn the outside rear wheel must travel a greater distance than the inside rear wheel To make this happen the rider must learn how to create less traction for the inside wheel so that it can travel a shorter distance than the outside wheel even though both wheels are still turning at the same speed 26 To turn the TE100 901 the rider should use the following technique e Turn the handlebars in the direction of the turn e 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 traction e Lean upper body into the turn Bi At higher speeds Use the same technique that you use for turning at low speeds but lean farther into the turn Since natural turning forces which tend to push the vehicle to the outside of the turn increase as speed increases you must lean your upper body farther into the turn as you go faster to prevent the vehicle from tipping over to the outside of the turn Remember though to keep your weight supported on the outer footrest AN WARNING If the rider does not use the proper technique to turn the TE100 90 it may plow straight ahead even though the front wheels are turned The rider should practice the above technique at low speeds in a wide open area until he she has mastered it SKIDDING OR
37. ing atthe controls 31 4 As you approach the end of the practice area tell the rider to stop the vehicle apply the parking brake and get off You should then drag the rear end of the 100 90 around so you can push it straight ahead in the opposite direction Practice with the engine off until your child gets the feel of using the brakes and can stop the vehicle and turn off the engine stop switch without looking at the controls and without hesitation A WARNING Before permitting your child to operate the rE100 9 04 under power be sure to adjust the throttle limiter to provide a low maximum speed capability Turning the limiter clockwise reduces the TE100 90 s maximum speed capability Next start the 100 90 s engine and have your child practice starting off riding in a straight line and stopping with the vehicle under power Walk along the side of the TE100 90 if you can or have the young ster ride back and forth between you and another supervisor Watch closely to make sure the rider 1 Opens the throttle gently when starting off 2 Releases the throttle and applies the brake in sequence when stopping 3 Becomes aware of the distance it takes the vehicle to stop when the engine stop Switch is turned off while the vehicle is moving 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
38. n water bring it to your authorized HYOSUNG dealer to have the brakes inspected and cleaned if necessary Failure to take this precau tion can result in excessive brake wear Ng STOPPING THE ENGINE Release the throttle lever Turn the engine stop switch to the 5 position PARKING THE VEHICLE Set the parking brake securely as explained in the STARTING THE ENGINE section AS WARNING It takes some time for the engine and muffler to cool off after a long ride Do not touch these parts until they have had time to cool off or you may burn yourself LH INSTRUCTING THI 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 905 Remember that proper instruction before your child begins to ride is just as important as proper instruction and supervision during riding Please go through this manual with your child page by page and fully explain all of the instructions requirements and warnings it contains Be sure to put as much empha sis on safety precautions as on proper operational techniques Question your child as you go through the manual to make sure he she understands what you are saying Following is a step by step guide to help make your child s first use of the 100 901 a safe and enjoyable experience
39. nsporting the FTE100 904 Caution the rider and others near the FTE100 9 O4 not to get close to or touch any moving parts or any heated areas such as the engine and exhaust system Do not make any modifications to the 100 904 Modifications may make the vehicle unsafe or illegal unsafe or illegal in your state Do not allow the TE 901 to be ridden at night This vehicle is not equipped with a head lamp Unseen obstacles could cause an accident resulting in injury to the rider 151004 always come on the head lamp and tail lamp when starting engine TABLE OF CONTENTS 1 SERIAL NUMBER LOCATION 588565 nx 2 FUEL AND OIL RECOMMENDATION FUEL ENGINE OIL TRANSMISSION OIL 3 LOCATION OF PARTS TE100 4 LOCATION OF PARTS TE9O 13 5 CONTROLS 17 GNITION SWITCH LEFT HANDLEBAR RIGHT HANDLEBAR FUEL COCK 6 EQUIPMENT AND ADJUSTMENTS 20 FUEL TANK CAP REMOTE ENGINE STOP SWITCH 7 BREAK IN RUNNING IN gt et tt ee es 23 8 INSPECTION BEFORE RIDING gt 24 9 RIDING TIPS ix ees REA RARE GS 24 10 INSTRUCTING THE YOUNG RIDER 29 11 INSTECTION AND MAINTENANCE 33 MAINTENANCE SCHEDULE PERIODIC MAINTENANCE CHART SEAT REMOVAL TOOLS AIR CLEANER SPARK PLUG DLE SPEED ADJUSTMENT THROTTLE CABLE ADJUSTMENT FUEL HOSE TRAN
40. 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 E STEP 4 TURNING After your child has learned to ride the 100 90 in a straight line and can stop it when he she wants to you should teach the child how to turn the vehicle Explain the proper body movements for turning and let your child PRACTICE FIRST WITH THE ENGINE OFF as you push the vehicle from behind When turning watch to make sure your child 1 Shifts his her weight slightly forward and supports his her weight on the outer footrest 2 Leans his her upper body into the turn and turns the handlebars in the direction ofthe turn When the rider is able to properly turn the 100 90 in both directions with the engine off he she should practice with the vehicle under power Again make sure that the throttle limiter is adjusted to provide a low maximum speed capability Watch closely to make sure the rider is using the proper turning technique The rider should practice turning until he she can do it correctly and with confidence 32 STEP 5 PUTTING IT ALL TOGETHER When your child has mastered the basic riding maneuvers in the previous steps he she should practice putting them all together Instruct the rider to perform various maneuvers such as turning right turning left stopping parking etc Mix up the order of these maneuve
41. operation ForrTE100 Engine oil Proper level Transmission oil Proper level Throttle G Proper cable play Q Smooth response G Quick return to idle position Drive chain Adequate lubrication General QG Bolts and nuts are tight condition No rattle from any part of the machine with the engine running No visible evidence of damage Remote QG Proper operation iei stop No damage to rubber if used Secure attachment of lanyard to cap 24 AN WARNING Failure to perform an inspection before riding may result in an accident or serious damage to the vehicle Check these items riding Be sure your FTE100 9 04 is in good condition for the personal safety of the rider and protection of the vehicle J AN WARNING All of the items above should be checked with the engine off except the functional check of the remote engine Stop switch TTE10 04 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 M RID NG T PS DO NOT START THE TE 100 901 OR ALLOW YOUR CHILD TO RIDE YET Finish reading the Riding Tips section and then the instructing the Young Rider section before starting the TE100 904 or beginning riding instructions The Riding Tips section contains important operating information you will need to know before you go to the Instructing the
42. ront brake lever can cause poor braking performance and may lead to an accident Too little play may force brake shoes to rub against the drum at all times causing damage to the shoes and the drum Follow the steps in this section to adjust the front brake lever properly AN WARNING M 5 15 mm 0 197 0 591 in Adjust the free play D to 5 15 mm 0 197 0 591 in by screwing in or out the front brake adjusting nut 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 is within the range on the brake panel If the extension line is beyond the range have the brake shoe assembly replaced by your Hyosung dealer to ensure safe operation AN WARNING Riding with worn brake shoe will reduce braking performance and will increase your chance of having an accident Inspect brake shoe wear before each use Ask your Hyosung dealer or qualified mechanic to replace brake shoe if the shoes are worn to the limit 42 9 Rear Brake Brake adjustment Set the parking brake by squeezing the rear brake lever and pressing the lock knob D 2 Try to move the ve
43. rs so the child will not know what he she will be asked to do next Practice this exercise until you are confident that the rider has mastered all the basic maneuvers The above steps will help the first time rider learn the most basic riding techniques To become a skilled rider your child will need a great deal of practice and instruction after these steps have been completed Be patient with your child take extra time when teaching him her additional techniques such as the recommended techniques for climbing and descending hills After your child has mastered all of the basic riding techniques at slow speeds you can adjust the throttle limiter to provide higher speed capabilities according to the rider s skill and experience NSP MA ECT NI ON ANI ENANCI LH MAINTENACE SCHEDULE It is very important to inspect and maintain your 100 90 regularly Follow the chart below If indicates the intervals between periodic services in months At the end of each interval be sure to inspect adjust lubricate replace and service as indicated AN WARNING HYOSUNG recommends that mainten ance on those items in the chart below which are marked with an asterisk be performed by your authorized HYOSUNG dealer or a qualified service mechanic If you are qualified you may perform maintenance on the unmarked items by referring to the instructions in this section If you are no
44. se 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 Maintenance required 23 as part of the initial servie includes correction of all adjustments tightening of all fasteners and replacement of dirty oil Timely performance of this service will ensure optimum service life and perfor mance from the engine A WARNING The initial service after 1 month of vehicle operation should be performed as outlined in the INSPECTION AND MAINTENANCE section of this Owner s Manual Pay particular attention to the information contained in the CAUTION and WARNING section when perform Ling this maintenance NSPECTION BEFORE DING WHAT TO CHECK CHECK FOR Steering No rattle or looseness Brakes Q Proper lever play Q Parking brake effectiveness Tires QG Proper pressure Enough tread depth No cracks rips or other damage Fuel G Enough fuel for the intended run Fuel hose connected securely No damage to fuel tank or cap Q Tank cap closed securely Engine stop Proper operation Head lamp Tail lamp Proper
45. should Speed up and maintain a steady speed before reaching the bottom of the hill e Shift body weight forward by sliding forward on the seat Lean slightly forward e Maintain a steady speed while climbing the hill e Slow down when reaching the top of the hill AN WARNING Only permit your child to climb small hills Do not 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 TE 100 9 0 4 while climbing a hill because the vehicle may begin to roll backwards and then roll over N AN WARNING The rider should never open the throttle suddenly when climbing a hill The vehicle could flip over backwards M A WARNING The rider should never go over the top of the hill at high speed Once over the top of the hill he she could lose control and crash or could collide with an unseen object M If your child is climbing a hill and loses forward momentum he she should e Lean farther forward uphill e Apply the front and rear brake and stop the vehicle before it starts to roll backwards e Set the parking brake and dismount to the right while still leaning uphill Use one of the following procedures to turn the vehicle around Ask the adult who is supervising to help drag the rear end of the TE100 90 around until the vehicle is angled downhill Stay on t
46. t sure whether you can successfully complete any of the unmarked maintenance jobs ask your authorized HYOSUNG dealer to do the maintenance for you AN WARNING Do not attempt to perform maintenance on this vehicle if you are not qualified You could be injured or may damage the machine 33 AS WARNING The safety of the rider depends on how well this machine is maintained Follow all inspection and maintenance instructions carefully AN WARNING Don t let your children tinker with this machine They may get hurt Maintenance should only be performed by qualified adults Make sure that the engine stop switch is in the 2 position unless the engine must be running to perform the required maintenance CAUTION The maintenance intervals shown in the chart below are based on average riding conditions If the 712100 904 is ridden in a dusty area the air cleaner and drive chain should be serviced more frequently than shown in the chart All items should be serviced more frequently if the vehicle is operated under extreme conditions If you have any questions regarding appropriate maintenance intervals consult your authorized Y O S UN G dealer N 6 PERIODIC MAINTENANCE CHART 9 ENGINE Interval Initial Every Every Item 1 month 3 months 6 months Air cleaner element Clean at least every month Cylinder head nut
47. tion 2 Drain fuel from the carburetor into a suitable container by loosening the carburetor drain bolt 3 When the fuel has drained completely retighten the drain bolt 52 AN WARNING When draining the carburetor always shut the engine off Do not smoke and never drain or refuel in an area where there are open flames or sparks J A WARNING Be sure to use a suitable container to catch the fuel you drain from the carburetor Do not allow the fuel to spill or you may create a fire hazard Keep fuel out of the reach of children and pets or they may be injured and dispose of unwanted fuel properly AN WARNING When transporting the 100 904 lock the parking brake and tie down the vehicle securely with rope or some other 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 J STARTING THE TE100 1904 AFTER TRANSPORT To feed fuel into the carburetor turn the fuel cock to the ON position CL EAN NG PROCE DURE 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 wat
48. 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 unwanted fuel properly ENGINE Pour one tablespoon of motor oil into the spark plug hole Reinstall the spark plug and crank the engine a few times TIRES Inflate tires to the normal specifications EXTERNAL Spray all vinyl and rubber parts with rubber preservative Spray unpainted surfaces with rust preventative Coat painted surfaces with car wax PROCEDURE FOR RETURNING TO SERVICE Clean the entire vehicle 6 Reinstall the battery ACAUTION Make sure that the battery lead wire is routed properly Remove the spark plug Turn the engine a few times by pushing the starter switch Reinstall the spark plug 6 Make sure that the vehicle is properly lubricated Perform the INSPECTION BEFORE RIDING as listed in this manual 55 LOCATION OF LA LS SET PARKING BRAKE BEFORE STARTING ENGINE 68343 K3100 A WARNING DO NOT TOUCH MUFFLER WHEN ENGINE IS IN OPERATION 68320 K3100 56 F A WARNING Operation of this ATV by children under the age of 12 increases th
49. ud MEN Front Brake Lever Apply the front brake by squeezing the front brake lever towards the grip 2 Throttle Lever Engine speed is controlled by the position of the throttle lever Push it forward to increase engine speed Release it to decrease engine speed This lever is operated by the rider s thumb 18 100 90 is equipped with the throttle limiter to restrict maximum engine power by limiting throttle lever travel The supervising adult should adjust this limiter to limit maximum vehicle speed according to the rider s skill and experience To adjust the throttle limiter 1 Loosen the lock nut A 2 Turn the throttle limiter screw clockwise to restrict maximum engine power or counterclockwise to increase maximum engine power 3 Tighten the lock nut A C FUEL COCK RES RESERVE Position If the fuel level in the tank is too low turn the lever to the RES position to use the 1 1 of reserve fuel supply 100 90 is equipped with a manually operated fuel cock There are three position ON OFF and RES 9 ON Position The normal operating position for the fuel cock lever is in the ON position CAUTION 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 position
50. ut D 3 Turn the adjuster in or out to obtain the correct play 4 Tighten the lock nut D 5 Recheck the throttle cable play Readjust it if itis not within the correct limits Replace the fuel hose every 4 years even if it appears to be in good condition Damage from aging may not always be visible 6 TRANSMISSION OIL D The transmission oil should always be changed when the engine is hot so that the oil s viscosity will be low and the oil will drain completely from the engine WIS a 8 a m K AN Dae 9 Any 3 2 522 PER 14 4 A 2 SAT To change the oil 1 place the vehicle on level ground 2 Remove the oil filler cap 3 Remove the oil drain plug from the bottom of the engine and drain the oil completely 4 Reinstall the drain plug amp 5 Remove the clutch cover 6 Remove the level screw 2 and pour fresh oil of the specified type through the filler hole until the oil flows out from the oil level hole TRANSMISSION OIL CAPACITY 80 ml 90 ml Replace Overhaul CAUTION 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 result in severe transmission damage
51. ver permit children under age 12 to operate the 100 904 These children as well as some children age 12 and older may not be able to operate this vehicle safely due to physical or mental limitations Parents should carefully observe their child s first use of the vehicle Further use should be permitted only if the parent can determine that the child has the physical and mental capabilities necessary to operate the vehicle safely Before first use of the TE100 9 04 read this owner s manual carefully to become familiar with the TTE100 90y s features and safety and maintenance requirements Review all instructions requirements and warnings with the riders Keep the owner s manual in the storage compartment located under the seat Before the rider s first use of the TTE100 90 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 FTE100 9 04 find a level open area for the rider to use to become familiar with the operation of controls and the operating and handling characteri stics ofthe Fr 100 904 Before each use perform daily inspections with the rider Specific items to check are listed in the INSPECTION BEFORE RIDING section on page 24 of this owner s manual Make sure the rider wears a helmet eye protection and protective clothing gloves leather or heavy
52. y cannot be removed from the ignition switch in this position OFF POSITION All electrical circuits are cut off The engine will not start The key can be removed TTE100 90 comes equipped with a pair of identical ignition key Keep the spare key in a safe place IGNITION KEY 17 LEFT HANDLEBAR C 3 Rear Brake Lever Apply the rear brake by squeezing the rear brake lever towards the grip 9 Parking Brake Knob This knob is used to set the parking brake which is used to prevent the T v4 from moving when it is parked being started or at idle Set the parking brake by squeezing the rear brake lever and pushing this knob to lock the lever in the squeezed position 3 Starter Switch Push in the electric starter switch to rotate the starting motor A CAUTION TE100 always come on the head lamp and tail lamp when starting engine N NOTE If the front or rear brake lever is not squeezed the starter motor will not rotate M CAUTION 8 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 Engine Stop Switch 54 Position The ignition circuit is off The engine cannot start or run O Position The ignition circuit is on and the engine can run RIGHT HANDLEBAR Ces me ebur pe q
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