Hyosung TE90 - 100owner's Manual

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.
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F O R E WO R D I M P O RTA N T
This manual is an essential part of your WARNING/CAUTION/NOTE
vehicle. Please read it carefully. It contains
important information on safety, operation Please read this manual and follow its
and maintenance. It is especially important instructions carefully. To emphasize special
that this manual remain with the vehicle at information the words 『 WARNING』』,
the time of resale. The next owner will need 『CAUTION』』and『NOTE』』have special
this information also. meanings. Information following these
signal words should be carefully reviewed.
Your H Y O S U N G 『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- WARNING
mmends, therefore, that you review this
The personal safety of the rider or
entire manual with your child and carefully
bystanders may be involved.
explain the instructions, requirements, and
Disregarding this information could
warnings it contains so that your child can
result in personal injury.
understand them.
CAUTION
These instructions point out special
service procedures or precautions that
must be followed to avoid damaging the
machine.
N O T E
This provides special information to
make maintenance easier or important
instructions clearer.
HYOSUNG MOTORS & MACHINERY INC.
� COPYRIGHT HYOSUNG MOTORS & MACHINERY INC.

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.

I M P O RTA N T N OTICE Read this owner’ s manual carefully and
TO PA R E N T S review its contents fully with your child. It is
YOUR RESPONSIBILITY to make sure
that your『TE100 / 90 』is properly and
WARNING safely ridden and maintained.
● Even though the『TE100 /9 0』』has

four wheels, it can tip over in any
direction. Improper turning techni-
ques, traversing hills, accelerating on
WARNING
hills, and turning on hills can all lead You must take special precautions to
to vehicle tip over. reduce the chance of accidents and
Learn proper riding techniques and injuries resulting from operation of this
avoid riding situations which can lead vehicle. Some of the important safety
to tip over accidents. precautions you should take are :
● The『T E 1 0 0 /9 0』』and other all- ● Supervise operation of the『TE100
terrain vehicles (ATVs) have unique /90』』AT ALL TIMES.
handling characteristics. ATVs Constant supervision is necessary
handle differently than motercycles. so you can observe that the operator
Although ATVs have four(or three) is riding safely.
wheels, they handle differently than ● Never permit children under age 12 to
automobiles, too. operate the『T E 1 0 0 /9 0』』. These
ATVs require special riding techni- children, as well as some children
ques suited to their handling age 12 and older, may not be able to
characteristics, so be sure that all operate this vehicle safely due
riders of the『TE100 /9 0』』practice to physical or mental limitations.
and master the riding techniques Parents should carefully observe
described in this owner’ s manual their child’ s first use of the vehicle.
(Starting on page 24). Further use should be permitted only
if the parent can determine that the
child has the physical and mental
capabilities necessary to operate the
WARNING vehicle safely.
Proper parental supervision and ● Before first use of the『 T E 1 0 0
instruction are necessary for safe and /9 0』』, read this owner’s manual
proper operation of this『TE100 /9 0』』 carefully to become familiar with the
by young riders. 『TE100 /90』』’ s features, and safety
and maintenance requirements.
Review all instructions, requirements
and warnings with the riders. Keep
It is important that both you and your
the owner’ s manual in the storage
child understand and observe the restric-
compartment located under the seat.
tions listed on the fender label of the
『TE100 / 90』』.

● Before the rider’ s first use of the by a single rider. Extra seat space is
『T E 1 0 0 / 9 0』』, make sure that provided so the rider can change
he/she is familiar with the location his/her body position to maneuver
and operation of all controls, and has the vehicle. This space should never
been instructed in the proper be used to carry a passenger.
operation of the vehicle. ● Do not permit anyone to operate the
● For first use of the『TE100 /9 0』』, 『T E 1 0 0 / 9 0』』while under the
find a level, open area for the rider influence of alcohol or other drugs.
to use to become familiar with the ● Make sure the combined weight of
operation of controls and the the rider, protective gear and any
operating and handling characteri- accessories or cargo does not
stics of the『TE100 /90』』. exceed the 68kg(150lbs) weight
● Before each use, perform daily limit. Exceeding this weight limit
inspections with the rider. Specific may result in injury caused by
items to check are listed in the damage to the vehicle or altered
INSPECTION BEFORE RIDING handling characteristics.
section on page 24 of this owner’ s ● Observe periodic maintenance
manual. requirements your authorized
● Make sure the rider wears a helmet, HYOSUNG dealer is trained and
eye protection, and protective equipped to perform this service.
clothing (gloves, leather or heavy ● Never permit vehicle refueling by
cloth pants, long sleeved shirt or anyone other than an adult.
jacket, boots). ● Drain gasoline from the fuel tank and
● Beware of hazardous situations. carburetor prior to transporting the
Instruct the rider to do Iikewise. 『TE100 /90』』.
● Do not permit the『TE100 /9 0』』to ● Caution the rider and others near the
be used on public roads AT ANY 『TE100 /90』』not to get close to or
TIME. touch any moving parts or any
This vehicle is designed and heated areas such as the engine and
manufactured for use ONLY off exhaust system.
public roads. It is not subject to ● Do not make any modifications to
Federal Motor Vehicle Safety the『T E 1 0 0 /9 0』』. Modifications
Standards as it is not equipped or may make the vehicle unsafe or
approved for operation on public illegal unsafe or illegal in your state.
streets, roads, or highways at any ● Do not allow the『TE 90』』to be
time. ridden at night. This vehicle is not
● Do not permit the『TE100 /9 0』』to equipped with a head lamp. Unseen
be operated on any paved surfaces. obstacles could cause an accident
The vehicle can be more difficult to resulting in injury to the rider.
control when it is operated on ●『TE100』』always come on the head
pavement. lamp and tail lamp when starting
● Permit use only by a single rider. engine.
This vehicle is designed for use only

TABLE OF CONTENTS
1. SERIAL NUMBER LOCATION∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 8
2. FUEL AND OIL RECOMMENDATION ∙∙∙∙∙∙∙∙∙∙∙∙∙ 8

FUEL
ENGINE OIL
TRANSMISSION OIL
3. LOCATION OF PARTS TE100 ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙9
4. LOCATION OF PARTS TE90 ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙13
5. CONTROLS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 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
TOOLS

AIR CLEANER
SPARK PLUG
IDLE SPEED ADJUSTMENT
THROTTLE CABLE ADJUSTMENT
FUEL HOSE
TRANSMISSION OIL
ENGINE OIL LEVEL
BRAKE
TIRES
DRIVE CHAIN
FRONT AND REAR WHEEL REMOVAL
REPLACEMENT OF THE LAMP (FOR TE100 )
GENERAL LUBRICATION ( TE100 )
12. TROUBLESHOOTING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 50
13. TRANSPORTING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙51
14. CLEANING PROCEDURE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 53
15. STORAGE PROCEDURE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙54
16. LOCATION OF LABELS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙56
17. SPECIFICATIONS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙58

SERIAL NUMBER LO C ATION Frame No. :
The frame and/or engine serial numbers Engine No. :

are used to title the vehicle. They are also
used to assist your dealer when ordering
parts or referring to special service
information.
FUEL AND OIL

R E C O M M E N DAT I O N
�
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
The frame number ① is stamped on the there are differences between brands.
front frame member as shown in the
illustration.
ENGINE OIL
Use HYOSUNG HYPOL OIL HS.

� If they are not available, use a good quality
TWO-STROKE engine oil.
TRANSMISSION OIL
Use a good quality SAE 10W/30 or 10W/40

multi-grade motor oil.
The engine serial number ② is stamped on

the right side of the crankcase assembly.
Please write down the serial numbers here

for your future reference.

LO C ATION OF PA RT S『TE100』
① Rear brake lever (Parking brake lever)

② Parking brake knob
③ Front brake lever
④ Throttle lever
⑤ Fuel tank cap
⑥ Starter switch
⑦ Engine stop switch

⑧
⑧ Remote engine stop switch
10

⑨ Fuel cock
⑩ Head lamp
⑪ Battery & fuse
⑫ Muffler
⑬ Drive chain
N O T E
“ ”: means the invisable parts.
11

⑭ Tail lamp
⑮ Tools
� Engine oil tank
� Air cleaner
N O T E
12

LO C ATION OF PA RT S『TE90』
① Rear brake lever (Parking brake Iever)

② Parking brake knob
③ Front brake lever
④ Throttle lever
⑤ Fuel tank cap
⑥ Starter switch
⑦ Engine stop switch
13

⑧
⑧ Remote engine stop switch
14

⑩ ⑪
⑨
⑨ Fuel cock
⑩ Battery & fuse
⑪ Muffler
⑫ Drive chain
N O T E
15

⑬ ⑭ ⑮
⑬ Tools
⑭ Engine oil tank
⑮ Air cleaner
N O T E
16

C O N T RO L S LEFT HANDLEBAR
IGNITION SWITCH
ON KEY
① Rear Brake Lever

Apply the rear brake by squeezing the rear
brake lever towards the grip.
The ignition switch has two position :
② Parking Brake Knob
◉ (ON) POSITION This knob is used to set the parking brake,
The ignition circuit is completed and the which is used to prevent the『A T V』from
engine can now be started. The key cannot moving when it is parked, being started, or
be removed from the ignition switch in this at idle. Set the parking brake by squeezing
position. the rear brake lever and pushing this knob
to lock the lever in the squeezed position.
◉“OFF”POSITION
All electrical circuits are cut off. ③ Starter Switch
The engine will not start. The key can be Push in the electric starter switch to rotate
removed. the starting motor.
IGNITION KEY
CAUTION
T E 1 0 0 always come on the head
『TE100 / 90』』comes equipped with a pair lamp and tail lamp when starting engine.
of identical ignition key.
Keep the spare key in a safe place.
N O T E
If the front or rear brake lever is not
squeezed, the starter motor will not
rotate.
17

③ Throttle Limiter
CAUTION
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.
④ Engine Stop Switch

◉“ ”Position : The ignition circuit is
off.
The engine cannot start
or run.
『TE100 / 90』is equipped with the throttle
◉“ ”Position : The ignition circuit is on
limiter to restrict maximum engine power by
and the engine can
limiting throttle lever travel. The supervising
run.
adult should adjust this limiter to limit
maximum vehicle speed according to the
rider’ s skill and experience.
RIGHT HANDLEBAR To adjust the throttle limiter :
1. Loosen the lock nut �.
2. Turn the throttle limiter screw �
clockwise to restrict maximum engine
power or counterclockwise to increase
maximum engine power.
3. Tighten the lock nut �.
① 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

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
『TE100 / 90』is equipped with a manually ℓ of reserve fuel supply.
operated fuel cock.
There are three position :“ON”,“OFF”
and“RES” .
◉“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“ON”position.
◉“OFF”
”Position
Turn the lever to the“OFF”position
whenever stopping the engine for more
than a few minutes.
19

E QUIPMENT AND WARNING
ADJUSTMENTS Do not overfill the fuel tank. Stop adding
fuel when the fuel level reaches the
FUEL TANK CAP 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.
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.
To open the fuel tank cap, remove the end ● Make sure the engine is off and avoid
of the vent tube from the hole in the vehicle spilling fuel on a hot engine.
body and turn the fuel tank cap ● Do not smoke, and make sure there
counterclockwise. To close the fuel tank are no open flames or sparks in the
cap, turn it clockwise and tighten it area.
securely. Be sure that the end of the vent ● Avoid prolonged contact with skin
tube is reinstalled in the hole in the vehicle and breathing of gasoline vapors.
body and routed properly as shown. ● Keep children and pets away during
refueling.
REMOTE ENGINE STOP SWITCH
The『TE100 / 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.
20

3. With the lanyard fastened to the vehicle
① and to your hand, follow after the moving
vehicle. If you notice any driving hazard
or unsafe situation, pull the lanyard
③ ② forcefully so that the rubber cap comes
off.
This will activated the remote engine
stop switch, stopping the vehicle ’ s
engine.
① Switch body WARNING

② Rubber cap
③ Remote engine stop switch lanyard When the remote engine stop switch
cap is pulled off, the engine will stop
The switch consists of a rubber cap fitted running.
over a plastic body. When the rubber cap is The vehicle will continue to roll for some
in place, the engine can operate. When the distance, however. Remember this
rubber cap is removed from the switch when judging when to operate the
body, the engine cannot be started. If the remote engine stop switch.
engine is running and the rubber cap is
removed by pulling the lanyard attached to
the cap, the engine will stop running. WARNING
To use the remote engine stop switch : If you do not put your fingers through
1. Fit the rubber cap on the engine of the the loop in the lanyard, it may slip from
lanyard over the remote engine stop your grasp unexpectedly. This could
switch body located on the rear end of make it impossible for you to stop the
the vehicle as shown. engine in an unsafe situation.
2. Put your fingers through the loop at the
other end of the lanyard.
21

1. Place the lanyard in the vinyl bag
WARNING provided with the vehicle, with the rubber
The throttle limiter should always be set cap visible at the bag opening.
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 /9 0』』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 the
throttle limiter set to the maximum
power position may run into the rider if 2. Hook the bag on the frame as shown
he stops, or may trip and fall down and fit the rubber cap snugly over the
trying to keep up with the vehicle. remote engine stop switch body.
Instruction For Remote engine N O T E

stop switch Lanyard Storage With the rubber cap off the switch, the
The lanyard may be stowed on the engine can not be started because the
『TE100 / 90』』when, in the judgement of the ignition circuit is not completed.
parents, the rider has developed sufficient
skills to be able to safely operate the
vehicle without parental use of the lanyard.
WARNING
For storage of the lanyard, follow the Avoid leaving any part of the lanyard
instructions below : visible outside the bag as it can be
caught and damaged by moving parts.
WARNING
To prevent unauthorized starting or
unsupervised operation of the『TE100
/9 0』』, 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

as part of the initial servie includes
BREAK-IN (RUNNING-IN) correction of all adjustments, tightening of
all fasteners and replacement of dirty oil.
The first month is the most important in the Timely performance of this service will
life of your vehicle. Proper operation during ensure optimum service life and perfor-
this break-in period will help ensure mance from the engine.
maximum life and performance from your
new vehicle. WARNING
The following guidelines explain proper
break-in procedures. The initial service (after 1 month of
vehicle operation) should be performed
as outlined in the INSPECTION AND
★ MAXIMUM THROTTLE OPEN- MAINTENANCE section of this Owner’ s
ING RECOMMENDATION Manual. Pay particular attention to the
During the first 10 hours of vehicle information contained in the CAUTION
operation, the maximum thottle opening and WARNING section when perform-
you should use is 1/2 throttle. ing this maintenance.
★ 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 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. Maintenance required
23

INSPECTION BEFORE WARNING
RIDING Failure to perform an inspection before
riding may result in an accident or
WHAT TO CHECK FOR : serious damage to the vehicle. Check
CHECK these items riding. Be sure your
Steering No rattle or looseness 『TE100 /9 0』』is in good condition for
Brakes ●Proper lever play the personal safety of the rider and
●Parking brake effectiveness protection of the vehicle.
Tires ●Proper pressure
●Enough tread depth
●No cracks, rips, or WARNING
other damage
All of the items above should be
Fuel ●Enough fuel for the
checked with the engine off, except the
intended run
functional check of the remote engine
●Fuel hose connected
『TE100』
stop switch.( 』be included the
securely
head lamp and tail lamp.) Make sure
●No damage to fuel tank
your child doesn’ t get too close when
or cap you check the fuel level and drive chain,
●Tank cap closed securely or he/she might be injured.
Engine stop Proper operation
switch
Head lamp
Tail lamp Proper operation
(For TE100
Engine oil Proper level RIDING TIPS
Transmission oil Proper level
Throttle ●Proper cable play ★ DO NOT START THE『TE100
●Smooth response 』 OR ALLOW YOUR
/ 9 0』
●Quick return to idle
position
CHILD TO RIDE YET
Adequate lubrication Finish reading the“Riding Tips”section
Drive chain
and then the“instructing the Young Rider”
General ●Bolts and nuts are tight
condition section before starting the『TE100 / 90』or
●No rattle from any part
beginning riding instructions. The“Riding
of the machine with the
Tips”section contains important operating
engine running
information you will need to know before
●No visible evidence of
you go to the“Instructing the Young Rider”
damage
section. The“Instructing the Young Rider”
Remote ●Proper operation section will guide you in teaching young
engine stop
●No damage to rubber cap riders how to operate and ride the
switch
●Secure attachment of 『TE100 / 90』, using the information you
(if used)
lanyard to cap learn in this owner’s manual.
24

★ STARTING THE ENGINE
Before attempting to start the engine, make
WARNING
sure: While operating the『TE100 /90』』, the
1. The parking brake is engaged. rider should keep both feet on the
2. The engine stop switch is in the“ ” footrests at all times, or injuries resulting
position. from accidents such as the rear wheels
3. Verify that the remote engine stop switch running over the rider’s feet could
cap is in place. occur. There is no need for the rider to
4. The fuel cock is in the“ON”position. move his/her feet from the footrests
during operation or maneuvering of the
vehicle. Moving the rider’ s feet from the
WARNING footrests reduces the rider’ s ability to
control the vehicle, and could lead to an
Do not run the engine indoors or
accident.
where there is little or no ventilation.
Exhaust gases contain carbon
monoxide, a potentially lethal gas
that is colorless and odorless. WARNING
Never leave the vehicle running while Keep both hands on the handgrips at all
unattended, even for a short time. times when riding. Removing your
hands from the handgrips reduces your
★ STARTING OFF ability to control the vehicle, and could
After the engine has warmed up, result in an accident.
disengage the parking brake. To release
the parking brake, simply squeeze the rear
brake lever until the lock knob release. WARNING
Always open the throttle gradually to
WARNING prevent front wheel lifting. Failure to
Before releasing the parking brake, observe this precaution may result in
make sure: loss of control and an accident.
The throttle is fully closed.
The rider is completely ready to ride.
If you do not observe these precautions, ★ BRAKING
the vehicle can move forward unexpect- To stop the『TE100 / 90』, release the
edly when the parking brake is released. throttle lever and apply the brake.
This may result in an accident and
injury.
Open the throttle gradually to move

forward.
25

To turn the『TE100 / 90』 , the rider should
WARNING use the following technique :
Avoid braking during turns. Use of Turn the handlebars in the direction of
the brake when turning could cause the turn.
the『T E 1 0 0 /9 0』』to slide or roll Shift body weight slightly forward and
over. Use the brake to slow down support your weight on the outer
before entering turns. footrest. This will reduce the load on the
Apply the brake lightly and with great inside rear wheel, reducing its traction.
care on slippery surfaces to avoid Lean upper body into the turn.
skidding.
■ At higher speeds :
WARNING Use the same technique that you use for
turning at low speeds, but lean farther into
Never operate the parking brake lock the turn. Since natural turning forces(which
when the『TE100 /90』』is moving. The tend to push the vehicle to the outside of
rear wheels will lock, and an accident the turn) increase as speed increases, you
could result. 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
★ TURNING supported on the outer footrest.
To turn the『TE100 / 90』the rider must
learn a special technique. Because this
vehicle has a solid rear axle, both rear
WARNING
wheels always turn at the same speed. If the rider does not use the proper
This means that if the rear wheels are technique to turn the『TE100 /9 0』』, it
getting equal traction, the vehicle will move may plow straight ahead even though
straight ahead, because the rear wheels the front wheels are turned. The rider
will travel the same distance. should practice the above technique at
For the vehicle to turn, the outside rear low speeds in a wide open area until
wheel must travel a greater distance than he/she has mastered it.
the inside rear wheel. To make this
happen, the rider must learn how to create
less traction for the inside wheel, so that it ★ SKIDDING OR SLIDING
can travel a shorter distance than the If the rider experiences inadvertent skidding
outside wheel, even though both wheels or sliding when not braking, he/she may be
are still turning at the same speed. able to overcome it by using the appropri-
ate technique listed below.
26

■ Front wheel: ■ Climbing a Hill
If front wheel skidding occurs, try to gain To climb a small hill with the『TE100 / 90』 ,
front wheel traction by reducing the throttle the rider should:
opening and leaning your body weight Speed up and maintain a steady speed
slightly forward. before reaching the bottom of the hill.
Shift body weight forward by sliding
■ Rear wheel forward on the seat. Lean slightly
If rear wheel skidding occurs, steer in the forward.
direction of the skid (if space permits), shift Maintain a steady speed while climbing
body weight away from the skid slightly, the hill.
and avoid using the throttle or brakes until Slow down when reaching the top of the
you regain directional control of the vehicle. hill.
WARNING WARNING
Skidding or sliding can result in Only permit your child to climb small
accidents caused by loss of rider hills. Do not let him/her attempt to climb
control. To avoid inadvertent skidding or a hill unless you are sure that he/she
sliding, the rider should slow down and can easily ride to the top of the hill
be very cautious when riding on without stopping. It can be dangerous to
slippery or loose surfaces. stop the『TE100 /90』』while climbing a
hill, because the vehicle may begin to
roll backwards and then roll over.
★ OPERATION ON HILLS
Riders who have become experienced at
operating the『TE100 / 90』on level
surfaces may wish to try riding on a wider
WARNING
variety of terrains. The『TE100 / 90』may The rider should never open the throttle
be operated on small hills with even suddenly when climbing a hill. The
surfaces, but extreme care should be vehicle could flip over backwards.
taken.
WARNING
WARNING The rider should never go over the top
When the『TE100 /90』』is operated on of the hill at high speed. Once over the
hills, it can roll over more easily than top of the hill, he/she could lose control
when it is operated on level ground, and crash or could collide with an
under certain conditions. Only children unseen object.
who are capable of safe operation of the
『TE100 /9 0』』on level ground should
be permitted to operate the vehicle on
hills.
27

If your child is climbing a hill and loses
forward momentum, he/she should : WARNING
Lean farther forward, uphill. The rider should never allow the
Apply the front and rear brake and stop 『TE100 /9 0』』to roll backwards on a
the vehicle before it starts to roll hill. If the vehicle does begin to roll
backwards. backwards, the rider should move
Set the parking brake and dismount to his/her body weight forward and try to
the right while still leaning uphill. slow the vehicle to a stop using the
Use one of the following procedures to FRONT BRAKE ONLY. If the front brake
turn the vehicle around : does not slow the vehicle, the rider
should dismount to the side immedia-
1. Ask the adult who is supervising to help tely. The rear brake should never be
drag the rear end of the『TE100 / 90』 used when rolling backwards on a hill.
around until the vehicle is angled Use of the rear brake can cause the
downhill. Stay on the uphill side of the vehicle to flip over.
vehicle while dragging it around.
2. Turn the handlebars fully to the right.
While standing on the uphill side of the ■ Descending a Hill
vehicle, release the parking brake and To ride down a small hill with the『TE100
pump the hand brake to let the / 90』, the rider should :
『TE100 / 90』roll slowly backwards. This Point the『TE100 / 90』straight down-
will turn the vehicle sideways to the hill. hill.
Reset the parking brake. Turn the Transfer body weight to the rear by slid-
handlebars to the left. Staying on the ing back on the seat.
uphill side, release the parking brake and Ride down the hill with the throttle
pump the hand brake to let the ATV roll closed.
until it is angled downhill. Reset the Apply the brake to control downhill
parking brake. speed.
� Remount the vehicle, release the

parking brake and ride down the hill as
instructed in the DESCENDING A HILL ■ Traversing a Slope
section.
WARNING
Traversing a slope is very tricky and
should be avoided when possible.
Improper riding techniques while
traversing a slope could cause the
『TE100 /90』』to tip over. Do not permit
your child to traverse a slope unless you
are sure he/she can perform this
maneuver safely.
28

To traverse a slope, the rider should:
Lean his/her body uphill. CAUTION
Steer slightly uphill, if necessary, to After extended operation of the
maintain a straight course.
『TE100 /90』』in water, bring it to your
authorized HYOSUNG dealer to have the
★ RIDING THROUGH WATER brakes inspected and cleaned, if
The『TE100 / 90』may be ridden through necessary. Failure to take this precau-
water, provided that it is not more than tion can result in excessive brake wear.
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 ★ STOPPING THE ENGINE
sides and the bottom of the stream is hard. Release the throttle lever. Turn the engine
If you are unfamiliar with the area you wish stop switch to the“ ”position.
to cross, park the『TE100 / 90』and inspect
the stream first, to find a suitable spot for
crossing. When crossing, operate the ★ PARKING THE VEHICLE
vehicle at a slow, steady speed. Set the parking brake securely as explained
in the“STARTING THE ENGINE”section.
WARNING WARNING
Do not attempt to cross a stream with
deep or fast flowing water. It takes some time for the engine and
The tires may lose their traction, and muffler to cool off after a long ride. Do
you may be unable to control the not touch these parts until they have
vehicle. This could result in personal had time to cool off, or you may burn
injury. yourself.
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.
29

I N S T RUCTING THE ■ STEP 1 - PROPER CLOTHING
YOUNG RIDER AND PROTECTIVE
GEAR
★ IMPORTANT ADVICE TO THE The first step to safe riding is proper
PARENT : protection of the rider. Your child should
Your child’s safety depends on your always wear a helmet, eye protection,
commitment to take the time necessary to gloves, long pants, a long sleeved shirt or
fully educate him/her on the proper jacket, and boots.
operation of the『TE100 / 90』. Remember Make sure that your child is not wearing
that proper instruction before your child any loose fitting clothes. Loose belts,
begins to ride is just as important as proper scarves, etc. can get caught in moving
instruction and supervision during riding. parts and cause personal injury. Even in
hot weather, make sure your child wears
Please go through this manual with your long pants and a long sleeved shirt. These
child, page by page, and fully explain all of not only protect against abrasive injuries,
the instructions, requirements and warnings but also help to reduce fatigue which
it contains. Be sure to put as much empha- comes from loss of body heat due to the
sis on safety precautions as on proper wind.
operational techniques. Question your child
as you go through the manual to make sure
he/she understands what you are saying. WARNING
Following is a step by step guide to help Failure to wear proper clothing and
make your child’s first use of the protective gear, as described above,
『 TE100 / 90』 a safe and enjoyable may result in severe personal injury.
experience. Before you begin to use this
guide, however, be sure you have revie-
wed the vehicle features and riding ■ STEP 2 - FAMILIARIZATION
techniques described in earlier parts of this WITH THE VEHICLE
owner’s manual, HYOSUNG strongly
urges that you use this guide to teach each Your child should become completely
child that you let ride the『TE100 / 90』
. familiar with the names and functions of all
controls. Let the young rider sit on the
Be sure to take breaks as the child being 『TE100 / 90』 , with the engine off, and ask
instructed gets tired or his/her attention him/her to operate specific controls.
begins to wander. Full attention at all times Demonstrate operation of the controls if
is needed to safely operate any motorized necessary. Ask the child to do such things
vehicle, including the『TE100 / 90』 . as“apply the brakes, turn 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.
30

Go over the INSPECTION BEFORE 4. As you approach the end of the practice
RIDING with your child until he/she knows area, tell the rider to stop the vehicle,
all of the items that should be checked and apply the parking brake, and get off. You
how they should be checked. Give specific should then drag the rear end of the
examples of things to look for. 『TE100 / 90』around so you can push it
straight ahead in the opposite direction.
Practice with the engine off until your
■ STEP 3 - STARTING OFF AND child gets the feel of using the brakes
STOPPING and can stop the vehicle and turn off the
engine stop switch without looking at the
controls, and without hesitation.
WARNING WARNING
For practice, choose a large, level area
Before permitting your child to operate
away from other riders and free of
the『TE100 /90』』under power, be sure
obstructions. Inspect the area before
to adjust the throttle limiter to provide
riding and remove any rocks, sticks or
a low maximum speed capability.
other potential hazards. Stay away from
Turning the limiter clockwise reduces
ditches and bumps.
the『TE100 /90』』’ s maximum speed
capability.
To help your child develop confidence,

he/she should PRACTICE FIRST WITH Next, start the『TE100 / 90』 ’ s engine and
THE ENGINE OFF, as follows : have your child practice starting off, riding
in a straight line, and stopping, with the
1. Have your child sit on the『TE100 / 90』 vehicle under power.
and tell him/her to release the parking Walk along the side of the『TE100 / 90』if
brake. you can, or have the young-ster ride back
2. Instruct your child to keep his/her eyes and forth between you and another
straight ahead and slowly push the supervisor.
vehicle from behind, if you are physically Watch closely to make sure the rider :
able to do so. This will allow your child to 1. Opens the throttle gently when starting
get the feel of riding a moving vehicle. off.
3. As you push the『TE100 / 90』, instruct 2. Releases the throttle and applies the
your child to steer straight ahead and brake in sequence when stopping.
perform operations such as stopping the 3. Becomes aware of the distance it takes
vehicle and turning off the engine stop the vehicle to stop when the engine stop
switch while moving. Watch your child switch is turned off while the vehicle is
closely to make sure he/she is operating moving.
the controls correctly and without looking
at the controls.
31

As you approach the end of the practice ■ STEP 5 - PUTTING IT ALL
area, you should again tell the rider to stop TOGETHER
the vehicle, apply the parking brake, and
get off so you can turn it around for him/her. When your child has mastered the basic
Practice this exercise until your child can riding maneuvers in the previous steps,
start off, accelerate, cruise and stop he/she should practice putting them all
correctly and with confidence. together. Instruct the rider to perform
various maneuvers such as turning right,
■ STEP 4 - TURNING turning left, stopping, parking, etc. Mix up
the order of these maneuvers so the child
After your child has learned to ride the will not know what he/she will be asked to
『TE100 / 90』in a straight line and can stop do next. Practice this exercise until you are
it when he/she wants to, you should teach confident that the rider has mastered all the
the child how to turn the vehicle. basic maneuvers.
Explain the proper body movements for
turning, and let your child PRACTICE
FIRST WITH THE ENGINE OFF, as you The above steps will help the first time rider
push the vehicle from behind. learn the most basic riding techniques. To
When turning, watch to make sure your become a skilled rider, your child will need
child: a great deal of practice and instruction after
1. Shifts his/her weight slightly forward and these steps have been completed. Be
supports his/her weight on the outer patient with your child; take extra time when
footrest. teaching him/her additional techniques
2. Leans his/her upper body into the turn such as the recommended techniques for
and turns the handlebars in the direction climbing and descending hills.
of the turn.
After your child has mastered all of the

When the rider is able to properly turn the basic riding techniques at slow speeds, you
『TE100 / 90』in both directions with the can adjust the throttle limiter to provide
engine off, he/she should practice with the higher speed capabilities, according to the
vehicle under power. Again, make sure that s skill and experience.
rider’
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

INSPECTION AND WARNING
M A I N T E NA N C E
The safety of the rider depends on how
well this machine is maintained. Follow
all inspection and maintenance
MAINTENACE SCHEDULE instructions carefully.
It is very important to inspect and maintain

your『TE100 / 90』regularly. Follow the WARNING
chart below. If indicates the intervals
between periodic services in months. At the Don’ t let your children tinker with this
end of each interval, be sure to inspect, machine. They may get hurt.
adjust, lubricate, replace and service as Maintenance should only be performed
indicated. by qualified adults. Make sure that the
engine stop switch is in the“ ”
position unless the engine must be
WARNING running to perform the required
H Y O S U N G recommends that mainten- maintenance.
ance on those items in the chart below
which are marked with an asterisk(*)
be performed by your authorized
H Y O S U N G dealer or a qualified service
CAUTION
mechanic. If you are qualified, you may The maintenance intervals shown in the
perform maintenance on the unmarked chart below are based on average riding
items by referring to the instructions in conditions. If the『T E 1 0 0 / 9 0』』is
this section. If you are not sure whether ridden in a dusty area, the air cleaner
you can successfully complete any of and drive chain should be serviced
the unmarked maintenance jobs, ask more frequently than shown in the chart.
your authorized HYOSUNG dealer to do All items should be serviced more
the maintenance for you. frequently if the vehicle is operated
under extreme conditions. If you have
any questions regarding appropriate
maintenance intervals, consult your
authorized H Y O S U N G dealer.
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

PERIODIC MAINTENANCE CHART
◉ ENGINE
Interval Initial Every Every
Item 1 month 3 months 6 months
Air cleaner element Clean at least every month
Cylinder head nut * Tighten Tighten ─
Cylinder head and cylinder * ─ ─ Remove carbon
Carburetor Inspect ─ Inspect
Spark plug Clean Clean Replace
Inspect Inspect ─
Fuel line
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 ─
Tires Inspect every month Check pressure each time ride
Chassis nuts and bolts * Tighten Tighten ─
General lubrication * ─ Lucbricate ─
CAUTION
More frequent servicing may be performed on motercycles that are used under sever
conditions.
N O T E
* = Ask your Hyosung dealer or qualified mechanic to do the maintenance items marked.
34

SEAT REMOVAL AIR CLEANER
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.
To remove the seat, pull the metal bar If you usually ride in dusty areas or
under the rear end of the seat and lift it up. 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, immediately
TOOLS clean the element and the inside of
the air cleaner case.
A tool kit is provided under the seat.
35

◉ Removing The Element ◉ Washing the Element
Wash the element as follows :
1. 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.
2. Squeeze the element by pressing it

between the palms of both hands to
remove excess solvent. Do not twist or
1. Remove the four bolts ①. wring the element or it will develop
2. Remove the clamp screw ②. cracks.
3. Take out the air cleaner cap ③ and air
cleaner element ④. 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).
WARNING
Before, during, and after the cleaning
operation, carefully examine the element
for any tears in the material. A torn
element could permit dirt and dust to
pass into the engine. If the air cleaner
element is torn, it must be replaced with
a new one.
36

4. Reinstall the cleaned element in reverse
SPARK PLUG
order of removal. Be sure that the
element is securely in position and is
sealing properly. Your『TE100 / 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
WARNING the color of the plug’ s porcelain center
electrode insulator after vehicle operation. If
Keep cleaning solvent and oil away from the plug has the correct heat range, it
children and pets. Dispose of used should be very light brown in color. If the
solvent and oil properly. 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
Be sure to position the air cleaner
element correctly. Make sure it fits CAUTION
properly so that no incoming air will
An improper spark plug may have an
bypass it. Remember, rapid wear of
incorrect fit or heat range for your
piston rings and cylinder walls is often
engine. This may cause severe engine
caused by an improperly positioned air
damage which may not be covered
cleaner element.
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.
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 IDLE SPEED ADUSTMENT
To install a spark plug, turn it in as far To adjust the idle speed properly, you need
as possible with your fingers, then a engine tachometer. If you do not have
tighten it with a wrench. Do not one, ask your HYOSUNG dealer to perform
overtighten or cross thread the spark this adjustment.
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.
To adjust the idle speed :

1. Start the engine and warm it up.
2. After engine warms up, turn the throttle
stop screw ① in or out so that the engine
idles at lowest steady speed.
CAUTION
Make sure that the engine is fully
warmed up before adjusting the engine
idle speed. Improper adjustment can
result in increased engine wear.
0.6~0.7mm
(0.024~0.028 in)
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

THROTTLE CABLE ADUSTMENT FUEL HOSE
2.5~6mm
(0.098~0.236 in)
Replace the fuel hose every 4 years, even

Measure the throttle cable play by pressing if it appears to be in good condition.
the throttle lever. The throttle lever should Damage from aging may not always be
have 2.5~6mm (0.098~0.236 in) play. visible.
TRANSMISSION OIL
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.
To adjust the throttle cable play : �

1. Remove the adjuster cover.
2. Loosen the lock nut ①.
3. Turn the adjuster ② in or out to obtain
the correct play.
4. Tighten the lock nut ①.
5. Recheck the throttle cable play. Readjust
it if it is not within the correct limits.
39

� 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.
ENGINE OIL LEVEL

�
To change the oil :

1. place the vehicle on level ground.
2. Remove the oil filler cap ①.
3. Remove the oil drain plug ③ from the
bottom of the engine and drain the oil
completely. The engine oil tank is located under the
4. Reinstall the drain plug ③. seat. Check the oil level each time before
5. Remove the clutch cover. starting the engine. If the oil level is low, fill
up the tank with the specified oil. The oil
6. Remove the level screw ② and pour
fresh oil of the specified type through the tank holds 1.0ℓ
filler hole until the oil flows out from the
oil level hole.
WARNING
TRANSMISSION OIL CAPACITY Never operate the『 T E 1 0 0 / 9 0』』
without an adequate amount of oil, if the
Replace 80 ㎖ engine runs out of oil, it can stop
suddenly, causing injury and/or severe
Overhaul 90 ㎖ mechanical damage.
7. Refit the oil filler cap ① and oil level

screw ②.
40

BRAKE ◉ Front Brake
The『TE100 / 90』has front drum brake ● Brake adjustment

and rear disk brake.
WARNING
WARNING Too much play in the front brake lever
can cause poor braking performance
Failure to properly inspect and maintain and may lead to an accident.
your ATV’s brake systems can be
hazardous. Too little play may force brake shoes to
rub against the drum at all times,
Improper maintenance of the brakes causing damage to the shoes and the
increases your chances of having an drum.
accident.
Follow the steps in this section to adjust
Be sure to inspect the brakes before the front brake lever properly.
each use of the vehicle according to
the INSPECTION BEFORE RIDING
section. Always maintain your brakes
5~15 mm (0.197~0.591 in)
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.
Adjust the free play ① to 5~15 mm
(0.197~0.591 in) by screwing in or out the
front brake adjusting nut ②.
41

● Brake shoe wear limit ◉ Rear Brake
This vehicle is equipped with the brake ● Brake adjustment
shoe wear limit indicators on the front
brakes. �
To check wear of the brake shoe, perform
the following :
�
5~15 mm
(0.197~0.591 in)
① Check if the brake system is properly

adjusted. �
② While fully applying the brake, check to
see that the extension line of the index
mark is within the range on the brake
panel.
③ If the extension line is beyond the range, 1. Set the parking brake by squeezing the
have the brake shoe assembly replaced rear brake lever and pressing the lock
by your Hyosung dealer to ensure safe knob ①.
operation. 2. Try to move the vehicle 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
WARNING wheels securely by releasing the parking
Riding with worn brake shoe will reduce brake and turning the adjuster ② in.
braking performance and will increase Repeat this procedure until the parking
your chance of having an accident. brake is properly adjusted.
Inspect brake shoe wear before each 3. Measure the amount of free play needed
use. Ask your H y o s u n g dealer or to lock the rear brake lever, as shown in
qualified mechanic to replace brake the above illustration. Adjust the rear
shoe if the shoes are worn to the limit. brake, if necessary, so that amount of
free play ③ 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.
42

● Brake pads
Inspect the rear brake pads by nothing
TIRES
whether or not the friction pads are worn
down to the grooved limit line. If a pad is The『TE100 / 90』is equipped with low
worn to the grooved limit line it must be pressure tubeless tires of the size listed
replaced with a new one by your authorized below :
Hyosung dealer or qualified service
machanic. Front Rear
Size 18×7.00 - 7 18×7.00 - 7
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-
Limit line teristics can result from differences in
carcass construction, sidewall strength,
tread pattern, etc.
WARNING
For the rider’ s safety, check your
vehicle’ s tires before each use of the
vehicle, to make sure they have proper
Inspect every day in the following point at pressure, enough tread depth, and no
the brake system. damage.
① Operating of the brake lever.
② Wear of the rear brake pads.
WARNING
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 H y o s u n g dealer or qualified
mechanic to replace brake pads if any
pad is worn to the limit.
43

◉ Tire Tread Condition ◉ 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.
WARNING
COLD TIRE PRESSURE
Operating the vehicle with excessively
worn tires can cause skidding due to 25 KPa
decreased traction. It is recommended FRONT 0.25 ㎏/㎠
that the front and rear tires be replaced 3.6 psi
when the depth of the tire tread is 3 mm
(0.118 in) or less. 25 KPa
REAR 0.25 ㎏/㎠
3.6 psi
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.
44

DRIVE CHAIN ◉ Drive Chain Cleaning and Oiling
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 Clean and oil the chain as follows :
chain for the following : 1. Wash the chain with kerosene.
Kerosene is a petroleum product and
● Loose pins will provide some lubrication as well as
● Damaged rollers cleaning action.
● Dry or rusted links
● Kinked or binding links WARNING
● Excessive wear
Keep kerosene away from children and
pets. Dispose of used kerosene pro-
Good Worn perly.
CAUTION
Do not use gasoline or other commer-
cial cleaning solvents to clean the drive
chain.
2. After thoroughly washing the chain and

allowing it do dry, oil the links with a drive
If you find anything wrong with the drive
chain lubricating oil or heavy weight
chain condition or adjustment, there is a
motor oil.
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

◉ Inspect Drive Chain Slack FRONT AND REAR WHEEL
REMOVAL
5~15mm
(0.197~0.591 in)
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 1. Place the vehicle on level groud and set
new one. the parking brake.
2. Loosen the three wheel nuts ① on the
wheel to be removed.
WARNING 3. Lift up the front or rear end of the vehicle
by placing a jack or block under the axle
Failure to inspect the drive chain slack or frame.
before each use of the vehicle could be 4. Remove the three wheel nuts.
hazardous. Too much chain slack could 5. Remove the wheel. To reinstall the
cause the chain to come off the wheel, reverse these steps.
sprockets, resulting in an accident or
serious damage to the vehicle.
Inspect the drive chain slack before WARNING

each use. 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
Front and Rear 25 N∙m
wheel nut (2.5㎏∙m)
46

REPLACEMENT OF THE LAMP ◉ TAIL LAMP
(FOR TE100
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 1. Remove the lens at the tail lamp rubber

Head lamp 12V 35W housing.
2. After removing the bulb at the socket,
Tail lamp 12V 5W replace the new bulb.
3. To install the tail lamp, reverse the above
sequence.
CAUTION
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 (right, left).

2. After removing the bulb at the socket,
replace the new bulb.
3. To install the head lamp, reverse the
above sequence.
47

① King pin ⑥ Rear axle housing

② Front wheel bearing ⑦ Front brake cable
③ Steering shaft holder ⑧ Throttle cable
④ Rear brake cable ⑨ Throttle lever
⑤ Drive chain ⑩ Front brake camshaft
O Motor oil
※“ ”: means the invisable parts.
G Grease
48

① King pin ⑥ Rear axle housing

② Front wheel bearing ⑦ Front brake cable
③ Steering shaft holder ⑧ Throttle cable
④ Rear brake cable ⑨ Throttle lever
⑤ Drive chain ⑩ Front brake camshaft
O Motor oil
※“ ”: means the invisable parts. G Grease
49

Proper lubrication is important for safe, ■ FUEL SYSTEM CHECK
smooth operation and long life of each 1. Make sure there is adequate fuel in the
working part of your vehicle. Pay attention fuel tank.
to the need for lubrication when you 2. Check that the engine stop switch is in
perform periodic maintenance on the the“ ”position.
vehicle. Be sure to have your authorized 3. Check that the remote engine stop
HYOSUNG dealer perform a general switch cap is installed on the remote
lubrication as shown in the maintenance engine stop switch.
chart on page 34. 4. Make sure there is enough fuel reaching
Your authorized HYOSUNG dealer will the carburetor from the fuel tank.
lubricate such items as wheel bearings, a. Loosen the drain screw which is
rear axle housings, steering shaft holder, located under the carburetor and
etc. drain the fuel from the carburetor.
T RO U B L E S H O OT I N G WARNING
Do not allow the fuel to spill; catch the
fuel in a container. Do not allow any fuel
CAUTION to come in contact with the hot engine
or exhaust system. Extinguish any
It is best to consult your H Y O S U N G smoking materials before performing
dealer before attempting to troubleshoot this check, and stay away from any
any problem. Damage may result from open flames or heat sources.
inappropriate repairs or adjustments.
Such damage may not be covered b. Tighten the drain screw.
under warranty. c. Remove the spark plug.
d. Loosen the drain screw and check
that the carburetor is filled back up
This troubleshooting guide is provided to
with fuel.
help you identify the cause of some
e. If it has been determined that fuel is
common complaints.
reaching the carburetor, the ignition
system should be checked next.
★ COMPLAINT : Engine is
hard to start or does not
start at all.
Something is probably wrong with the fuel
system or ignition system.
50

■ IGNITION SYSTEM CHECK
T R A N S P O RT I N G
1. Remove the spark plug and reattach it to
The『TE100 / 90』should be transported in
the spark plug lead.
the normal position.
2. 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]
WARNING
Do not check for a spark unless you are CAUTION
certain that you know how to do it ; you If the『TE100 /9 0』』be transported or
could get a high voltage electrical deposited in the standing position, it
shock. When testing for a spark, do not may air income in the oil pump.
point the spark plug near the spark plug 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,
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 [STANDING POSITION]
not clogged.
51

CAUTION WARNING
The『TE100 /9 0』』should be transpo- When draining the carburetor, always
rted or deposited in the normal position. shut the engine off. Do not smoke, and
If the『TE100 /9 0』』be transported or never drain or refuel in an area where
deposited in the standing position, there are open flames or sparks.
bleed air of oil pump.
Air bleeding of oil pump
① Loosen the air bleeding screw at the WARNING
engine idles. Be sure to use a suitable container to
② Wait until the air bleeds out from the catch the fuel you drain from the
air bleeding screw completely. carburetor. Do not allow the fuel to spill
③ Tighten the screw after air bleeding or you may create a fire hazard. Keep
of oil pump. fuel out of the reach of children and pets
or they may be injured, and dispose of
unwanted fuel properly.
Before transporting the『TE100 / 90』』 , drain
the fuel from the carburetor as follows :
1. Turn the fuel cock lever to the“OFF” WARNING

position.
2. Drain fuel from the carburetor into a When transporting the『TE100 /9 0』』,
suitable container by loosening the lock the parking brake and tie down the
carburetor drain bolt. vehicle securely with rope or some
3. When the fuel has drained completely, other suitable means. Use extra tie
retighten the drain bolt. 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.
★ STARTING THE 『 TE100

』AFTER TRANSPORT
/ 90』
To feed fuel into the carburetor, turn the
fuel cock to the“ON”position.
52

CLEANING PRO C E D U R E ★ WASHING YOUR ATV
With some care, your ATV can be washed
A thorough cleaning of your ATV is a in a similar manner to washing an auto-
necessary part of maintenance and will mobile.
help keep your ATV looking and performing
its best. Proper cleaning can also extend N O T E
the life of your ATV. Avoid spraying or allowing water to flow
over the following places :
It is important to clean and inspect your
ATV after every ride if it is used in mud,
● Spark plug
brush, grass, water, salt water, or very
● Fuel tank cap
dusty conditions.
● Carburetor
The build-up of mud, brush, grass, etc,
especially on the engine and exhaust After the battery removed, use a garden
system, can reduce engine cooling, hose at low pressure to remove the
conceal damage, or increase wear of majority of dirt or other debris. Hand wash
certain parts. It is important to remove all your ATV with a mild soap or detergent and
debris during cleaning. water. Try to thoroughly remove all dirt and
debris without excessive water pressure.
Cloth rags, washing mitts or cleaning
★ PREPARATION FOR brushes can be used, be careful with
CLEANING brushes as they may scratch plastic or
Wash the ATV before any mud dries on the painted surfaces. Rinse the ATV thoroughly
ATV. with clean water. Dry all areas using a
chamois or soft absorbent cloth.
Block or seal the end of the exhaust pipe
(muffler) using a piece of plastic wrap, cloth
rag or another method to prevent water ★ INSPECTION AFTER
from entering the engine.
CLEANING
CAUTION Remove the rags or wrapping from the
exhaust pipe. For extended life of your
High pressure washers can damage ATV, lubricate according to“GENERAL
your ATV. LUBRICATION”section.
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.
53

WARNING S TO R AGE PRO C E D U R E
Operating ATV with wet brakes can be
hazardous. If your『TE100 / 90』is to be left unused for
an extended period of time, it needs special
Wet brakes may not provide as much servicing requiring appropriate materials,
stopping power as dry brakes. This equipment and skill. For this reason,
could lead to an accident. HYOSUNG recommends that you trust this
maintenance work to your HYOSUNG
Test your brakes after washing ATV, dealer. If you wish to service the machine
while riding at slow speed. If necessary, for storage yourself, follow the general
apply brakes several times to let friction guidelines below :
dry out the linnings and pads.
★ VEHICLE
Place the vehicle on level ground and
thoroughly clean the entire vehicle.
Follow the procedures in the“INSPEC-
Remove the battery from the ATV.
TION BEFORE RIDING”section to check
your ATV for any problems that may have
arisen during your last ride. ★ 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.
WARNING
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
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.
54

★ 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.
● Reinstall the battery.
CAUTION
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.
● Make sure that the vehicle is properly
lubricated.
● Perform the“INSPECTION BEFORE
RIDING”as listed in this manual.
55

LO C ATION OF LABELS
⑥
⑤ ④
① ⑦③
33
56

66
44
55
57

SPECIFICAT I O N S
DIMENSIONS AND MASS
TE 100 TE 90
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 97.5kg (215 lbs) 96kg (212 lbs)
ENGINE
TE 100 TE 90
Type Two-stroke, forced air-cooled
Intake system Reed valve
Number of cylinder 1
Bore x Stroke 52.5 46.0mm (2.07 1.81 in) 52.5 41.4mm (2.07 1.63 in)
Piston displacement 99 (6.04 in3) 89 (5.43 in3)
Corrected compression ratio 6.7 : 1 6.6 : 1
Carburetor PB11M
58

TRANSMISSION
TE 100 TE 90
Transmission 2.257~0.782 2.842~1.042
Drive chain 428H 56 links
CHASSIS
TE 100 TE 90
Front brake Drum brake
Rear brake Disk brake
Front tire size 18 7.00 - 7
Rear tire size 18 7.00 - 7
ELECTRICAL
TE 100 TE 90
Ignition type “CDI”Type
Spark plug BPR7HS
CAPACITIES
TE 100 TE 90
Fuel tank 4.0ℓ
Engine oil tank 1.0ℓ
80㎖ (Replace)
Transmission oil
90㎖ (Overhaul)
59

Prepared by
H YO S U N G M OTORS & MACHINE RY INC.
2nd Ed. MAR. 2003.
Printed in KOREA

Hyosung TE90 - 100owner's Manual

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should remain with the vehicle when resold or otherwise transferred to a

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HYOSUNG MOTORS & MACHINERY INC.

� COPYRIGHT HYOSUNG MOTORS & MACHINERY INC.

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TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Owners are warned that the law may prohibit :

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● Even though the『TE100 /9 0』 』has

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1. SERIAL NUMBER LOCATION∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 8

2. FUEL AND OIL RECOMMENDATION ∙∙∙∙∙∙∙∙∙∙∙∙∙ 8

3. LOCATION OF PARTS TE100 ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙9

4. LOCATION OF PARTS TE90 ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙13

6. EQUIPMENT AND ADJUSTMENTS ∙∙∙∙∙∙∙∙∙∙∙∙∙ 20

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

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12. TROUBLESHOOTING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 50

13. TRANSPORTING ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙51

14. CLEANING PROCEDURE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙ 53

15. STORAGE PROCEDURE ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙54

16. LOCATION OF LABELS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙56

17. SPECIFICATIONS ∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙∙58

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The frame and/or engine serial numbers Engine No. :

FUEL AND OIL

Gasoline used should be graded 85 ~ 95

Use HYOSUNG HYPOL OIL HS.

Use a good quality SAE 10W/30 or 10W/40

The engine serial number ② is stamped on

Please write down the serial numbers here

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① Rear brake lever (Parking brake lever)

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⑧ Remote engine stop switch

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① Rear brake lever (Parking brake Iever)

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⑧ Remote engine stop switch

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① Rear Brake Lever

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④ Engine Stop Switch

① Front Brake Lever

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REMOTE ENGINE STOP SWITCH

The『TE100 / 90』 』comes equipped with a

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● Even though the『TE100 /9 0』』has

The『TE100 / 90』』comes equipped with a