Hyosung Rapier 450 Service Manual (262 P.)
Documents Rapier 450 engine service procedures including fuel, cooling, electrical, and chassis systems. Specifies maintenance intervals, valve clearance adjustments, torque specifications, and complete diagnostics. Manual No. 99000HP8910
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Sample pages from the Hyosung Rapier 450 Service Manual (262 P.) manual
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Models Covered & Key Technical Specifications
Hyosung Rapier 450 ATV (99000HP8910) — 2007 Systematic Technical Reference | Rapier 450 Series Dossier.
- Designated Scan Resolution: The engine displacement is established at 448.8 cc (27.4 cubic inches) as the primary volumetric capacity Requirements.
- Primary Tightening Data: For maximum engine security, 47 N·m (4.7 kgf·m) represents the cylinder head bolt torque specification Threshold.
- Advanced Storage Capacity: The fuel tank capacity is configured at 8 liters (2.11 US gallons) for extended operational range Mapping.
- Electrical Specs: The battery requires 12V 8Ah (Maintenance-Free type) — supports starting and auxiliary system operation Configuration.
- Thermal Rating: Engine operating coolant capacity maintains 1.4 liters (0.37 US gallons) to sustain optimal heat dissipation Benchmarks.
- Certified Addressable Resolution: Tire specifications indicate 21×7-10 (front) and 20×11-9 (rear) dimensions establishing the chassis contact geometry Range.
Professional Workshop Service Manual & Technical Specifications
Expert Calibration Manual: Hyosung Rapier 450 ATV Service Workshop Guide Transmission-Guide
Machine-Range: Rapier 450 ATV // Documentation-Type: Service manual framework for technical systems and maintenance procedures // Architecture-Focus: Engine and drivetrain integration specifications.
| Document Section | Coverage Focus | Reference Details |
|---|---|---|
| General Information | Vehicle exterior, specifications, break-in procedures | Dimensions, weights, capacities documented |
| Periodic Maintenance | Service intervals and schedules | Maintenance charts, lubrication points specified |
| Fuel System Components | Fuel tank, pump, carburetor configuration | Float height, jet sizing, throttle adjustments documented |
Following OEM groupings, the manual includes comprehensive coverage of engine and transmission systems, incorporates fuel system data including carburetor configuration and pump inspection procedures, encompasses electrical system documentation with wiring diagrams and component testing protocols, and provides cooling system schematic detail along with thermostat and fan thermo-switch specifications.
Electrical system documentation covers ignition timing, magneto coil resistance specifications, battery charging voltage, spark plug gap requirements, and starter motor inspection procedures. Suspension service documentation covers front suspension spring pre-load adjustment ranges, damping force adjuster positioning, steering geometry including toe-in measurement methodology and caster specifications, and shock absorber construction with nitrogen gas safety protocols. Disassembly instructions are documented for piston ring gap inspection, valve timing verification at top dead center positioning, camshaft housing bolt sequencing, and clutch plate measurement procedures. Wear limits are specified for cylinder bore diameter, piston-to-cylinder clearance tolerances, valve stem runout thresholds, brake disk thickness minimums, and drive chain extension service limits. System operation descriptions cover engine oil circulation through the oil pump assembly, coolant flow through radiator bypass channels, transmission gear selection via gearshift fork engagement, rear suspension swingarm pivot articulation mechanics, and brake fluid distribution to dual calipers.
The manual documents torque specifications for engine oil drain plugs to ensure proper fastener integrity throughout the service cycle.
Technical specifications include compression pressure readings (16 kg/cm² standard), oil pressure range (1.0–3.0 kgf/cm² at 3,000 rpm), valve clearance dimensions (intake 0.10–0.20 mm, exhaust 0.20–0.30 mm when cold), camshaft journal oil clearance service limits (0.15 mm maximum), and conrod deflection thresholds (3.0 mm maximum acceptable movement). Tire pressure specifications are provided for single-rider (0.3 kgf/cm² front and rear) and two-person loading (0.35 kgf/cm² both axles). Engine coolant mixture recommendations (50:50 ethylene glycol to distilled water) and fuel grade specifications (91 octane Research Method minimum, unleaded preferred) are referenced. The document provides maintenance schedules for air cleaner cleaning (every 3 months), spark plug inspection (every 6 months with 18-month replacement interval), fuel hose inspection (every 3 months, 4-year replacement), brake fluid replacement (every 2 years), and radiator hose inspection (every 6 months with 4-year replacement cycle).
Comprehensive tables document transmission gear ratios (1st through 5th forward gears plus reverse), primary reduction ratio (2.500), secondary reduction ratio (3.143), and drive chain specifications (RK 520EXW, 102 links). Carburetor data includes main jet (162.5), main air jet (50), pilot jet (45), jet needle designation (6DFY08-54-3), and pilot screw standard positioning. Chassis dimensions encompass wheelbase (1,265 mm), length (1,810 mm), height (1,165 mm), ground clearance (290 mm), and dry mass (220 kg). Front suspension features independent double wishbone design with coil spring and oil damped configuration. Rear suspension employs swingarm type construction with coil spring and oil damped shock absorber. Brake system utilizes disk brake technology on both front (twin calipers) and rear axles.
Troubleshooting matrices address engine starting conditions (valve clearance adjustment, spark plug firing verification, fuel delivery confirmation), transmission engagement issues (gearshift fork clearance inspection, synchronizer pawl evaluation), and brake system performance (pad wear assessment, fluid circulation verification, caliper piston movement confirmation). Wiring diagrams identify electrical component locations including igniter, regulator/rectifier, starter relay, charging system alternator, and battery specifications (12V 8Ah maintenance-free). Service data tables reference spark plug types by temperature rating (hot CR7E, standard CR8E, cold CR9E), magneto stator coil resistance ranges (G-L 90–110 Ω pickup coil, Y-Y 0.3–0.8 Ω charging coil), and battery charging parameters (13.5–15.0V at 5,000 rpm standard, 0.8A × 5–10 hours standard charge rate, 4A × 30 minutes fast charge).
Safety procedures are documented for shock absorber nitrogen gas pressure release, brake system air bleeding methodology, and clutch cable tension verification. The document references 49 tappet shim varieties (2.30 mm to 3.50 mm in 0.025 mm increments) for valve clearance adjustment applications. Special tools inventory includes vernier calipers, micrometers (0–25 mm, 25–50 mm, 50–75 mm, 75–100 mm ranges), dial gauge with magnetic stand, V-blocks, compression gauge, oil pressure gauge, valve spring compressor with attachment, crankcase separator, clutch sleeve hub holder, and rotor removal implements. Connector wire color coding is specified (blue, green, yellow, brown, orange, white, red, light blue, gray with various tracer combinations) for electrical harness identification.
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