Hyosung Rapier 450 Service Manual (262 P.)

Technical Scope of the 2007 Hyosung Rapier 450 Service Manual

• Covers the 2007 Hyosung Rapier 450 ATV, identifying specific engine and chassis maintenance requirements for the 99000HP8910 model variant.
• Official Hyosung publication P/N 99000HP8910, dated 2007.
• Contains 8 major system groups, including detailed engine assembly, transmission gear ratios, valve clearance specifications, and electrical schematics.
• Your order stays downloadable from your account for life.
• Indexed PDF search covers every chapter and appendix.
• This 2007 edition remains the primary reference document for the Rapier 450 chassis and liquid-cooled engine build.

Engine and Chassis Walkthrough

This 2007 Hyosung Rapier 450 service manual provides technical data and procedural descriptions for the inspection and overhaul of major vehicle components. The document is structured into eight distinct segments, beginning with general vehicle information, fuel, oil, and coolant recommendations, and break-in protocols. Following the initial information, it details periodic maintenance requirements, including air cleaner service, throttle cable adjustment, and engine idle settings. The core of the document focuses on the 448.8 cc liquid-cooled powerplant, documenting engine removal, disassembly, and reassembly alongside component inspection limits for the cylinder head, pistons, and transmission internals.

Specification Highlights

Engine cooling system capacity for the 2007 Hyosung Rapier 450 is documented at 1.4 liters. Cylinder head bolt torque is specified at 47 Nm in the engine assembly data section. The transmission gear ratio for 1st gear is listed at 2.538 in the specification tables. Electrical data includes a 15A fuse rating and 12V 8Ah battery configuration. Torque specifications are provided for essential fasteners, such as the 140 Nm primary drive gear nut and 23 Nm exhaust pipe nuts. The understanding parts documentation for vintage Hyosung vehicles is facilitated by the included component illustrations and assembly diagrams.

An official 262-page Hyosung OEM workshop manual covering the 2007 Rapier 450, documenting engine, chassis, electrical, and fuel-system specifications for the 99000HP8910 production series.