2007 Hyosung Rapier 450 ATV Service Manual (P/N 99000HP8910)

Hyosung's service manual for the 2007 Rapier 450 ATV, Manual No. 99000HP8910, covers factory inspection, maintenance, repair, and major-component overhaul across eight sections.

Text search and wiring detail: Body text and many tables are searchable, but some illustration labels, including those in the main wiring diagram, are not. There are no embedded PDF bookmarks. The main wiring diagram's small labels require enlargement.

• Engine repair: Engine removal and rebuilding, cylinder-head inspection, cam timing, crankshaft and balancer service, and compression and oil-pressure testing.

• Clutch and transmission: Wet multi-plate clutch inspection, gearbox disassembly and reassembly, shift-fork checks, and reverse-cable adjustment.

• Fuel system: BDS42 carburetor teardown, jet and diaphragm inspection, float-height adjustment, and fuel-pump delivery checks.

• Cooling system: Radiator service, cooling-fan and temperature-switch tests, thermostat checks, water-pump repair, and cooling-circuit bleeding.

• Electrical diagnosis: Ignition and charging tests, starter-motor inspection, switch-continuity tables, circuit diagrams, and the vehicle wiring diagram.

• Chassis and brakes: Caliper and master-cylinder repair, parking-brake adjustment, steering-shaft service, suspension settings, wheel bearings, and rear-axle removal.

This manual is written for readers who already have the knowledge and skills to service Hyosung vehicles; general mechanical fundamentals are not taught.

Engine Overhaul and Valve-Shim Selection

General information and maintenance coverage includes fluid recommendations, break-in guidance, periodic maintenance charts, throttle-cable adjustment, and engine idle settings.

The overhaul chapter follows engine removal through crankcase separation, cylinder-head and piston inspection, crankshaft installation, oil-pump service, and reassembly. Transmission coverage includes the reverse idler and shift mechanism, while the clutch section distinguishes the two drive-plate types and their assembly positions.

Valve adjustment: Separate intake and exhaust tappet-shim selection charts connect measured clearance and installed shim thickness to the replacement shim choice. These charts help avoid confusing the intake and exhaust requirements during valve-clearance work.

Special-tool references include crankcase separator 09920-13120 and crankshaft installer 09910-32812. The manual flags the primary-drive gear nut's left-hand thread because turning it the wrong way can damage the threaded connection.

BDS42 Carburetor and Fuel Supply

Fuel-system procedures cover the tank and fuel cock as well as pump flow and vacuum-hose connections. Carburetor inspection extends to the needle valve, valve seat, jets, diaphragms, and float setting.

A carburetor-specific caution explains how compressed air used during diaphragm removal can damage the diaphragm.

Cooling Circuit and Water Pump

The cooling chapter separates fan-motor checks, cooling-fan thermo-switch testing, water-temperature-switch testing, and thermostat opening and lift checks.

Water-pump procedures cover the impeller, shaft, bearing, and seals. Oil-tank and hose removal appear in the same section, alongside the cooling-circuit schematic and coolant density/freezing-point curves.

Ignition, Charging, and Starting Faults

Ignition-coil and igniter test tables accompany magneto no-load checks and regulator/rectifier tests. Starter-motor inspection covers the brushes, commutator, and armature, while switch-continuity tables include the gear-position switch.

The starter circuit shows the clutch-lever starting interlock. Electrical-component location views and wire-and-cable routing drawings support fault tracing. Symptom/cause/remedy charts address poor starting, weak spark, charging faults, clutch problems, and other engine complaints.

Steering, Suspension, and Brake Repair

Exploded assemblies and inspection procedures cover the double-wishbone front suspension, steering-shaft bushings, tie rods, swingarm linkage, and rear axle. Spring preload and compression/tension damping adjustments are documented for both front and rear suspension.

Brake procedures include disc inspection, fluid-circuit bleeding, and the rear parking-brake mechanism, alongside caliper and master-cylinder disassembly.

Shock-absorber scope: Front and rear units are covered for removal, inspection, adjustment, replacement, and disposal; the manual identifies them as non-serviceable internally. Follow its precautions for pressurized nitrogen shock absorbers and glycol-based brake fluid.

Workshop Specifications and Assembly References

The service-data section gathers engine and chassis torque tables, wear limits, fluid capacities, gear ratios, and electrical test specifications, including battery and fuse data. Exterior illustrations and exploded assembly views accompany the procedures.

English PDF and Included Pages

One printable English PDF totals 262 pages: 246 numbered technical pages, eight section contents pages, five cover and introductory pages, two unnumbered tappet-shim selection charts, and one publication page. All are included in the total.