HYOSUNG TE 100 User manual

1
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.

2
IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its
instructions carefully. To emphasize special
information the words WARNING ,
CAUTION and NOTE have special
meanings. Information following these
signal words should be carefully reviewed.
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 TE100R 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.
N O T E
This provides special information to
make maintenance easier or impo-
rtant instructions clearer.
These instructions point out special
service procedures or precautions
that must be followed to avoid
damaging the machine.
CAUTION
The personal safety of the rider or
bystanders may be involved.
Disregarding this information could
result in personal injury.
WARNING
HYOSUNG MOTORS & MACHINERY INC.
COPYRIGHT HYOSUNG MOTORS & MACHINERY INC.

3
Even though the TE100R has
four wheels, it can tip over in any
direction. Improper turning techni-
ques, traversing hills, accelerating
on hills, 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 TE100R 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 TE100R practice
and master the riding techniques
described in this owner s manual
(Starting on page 21).
WARNING
Proper parental supervision and
instruction are necessary for safe and
proper operation of this TE100R
by young riders.
WARNING
WARNING
IMPORTANT NOTICE
TO PARENTS
Read this owner s manual carefully and
review its contents fully with your child. It is
YOUR RESPONSIBILITY to make sure
that your TE100R is properly and safely
ridden and maintained.
It is important that both you and your
child understand and observe the restric-
tions listed on the fender label of the
TE100R
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
TE100R AT ALL TIMES.
Constant supervision is necessary
so you can observe that the
operator is riding safely.
Never permit children under age 12
to operate the TE100R 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 TE100R
read this owner s manual carefully
to become familiar with the
TE100R s features, and safety
and maintenance requirements.
Review all instructions, require-
ments and warnings with the
riders. Keep the owner s manual in
the storage compartment located
under the seat.

4
Before the rider s first use of the
TE100R 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 TE100R
find a level, open area for the rider
to use to become familiar with the
operation of controls and the
operating and handling charact-
eristics of the TE100R
Before each use, perform daily
inspections with the rider. Specific
items to check are listed in the
INSPECTION BEFORE RIDING
section on page 21 of this owner s
manual.
Make sure the rider wears a
helmet, eye protection, and
protective clothing (gloves, leather
or heavy cloth pants, long sleeved
shirt or jacket, boots).
Beware of hazardous situations.
Instruct the rider to do Iikewise.
Do not permit the TE100R 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 TE100R 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 TE100R 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
transporting the TE100R
Caution the rider and others near
the TE100R 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 TE100R Modifications
may make the vehicle unsafe or
illegal unsafe or illegal in your
state.
TE100R always come on the
head lamp and tail lamp when
starting engine.
TE100R has a reverse gear
lever. The reverse gear indicator

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lamp will come on when the
transmission is in reverse gear.
To shift into reverse gear, comp-
letely stop the vehicle and wait 3
seconds.
Shifting into reverse gear when
the vehicle is moving can be
hazardous and damage the
vehicle.
If you shift the vehicle into reverse
gear when the vehicle is moving it
could stop suddenly, throwing you
from the vehicle.
Always come to a complete stop
before shifting into reverse gear.
Check the area behind the vehicle
if you are about to reverse.
After the vehicle reverse, comp-
letely stop it and wait 3 seconds.
Turn the reverse gear lever at the
original situation.
Before the vehicle started, confirm
that the reverse gear lever is
released.
If you started the vehicle that
reverse gear is shifted into, it
could be hazardous and damage
the vehicle.

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1. SERIAL NUMBER LOCATION 8
2. FUEL AND OIL RECOMMENDATION 8
FUEL
ENGINE OIL
TRANSMISSION OIL
3. LOCATION OF PARTS 9
4. CONTROLS 12
IGNITION SWITCH
IGNITION KEY
INDICATOR LAMP
LEFT HANDLEBAR
RIGHT HANDLEBAR
REVERSE GEAR LEVER
FUEL COCK
KICK START LEVER
5. EQUIPMENT AND ADJUSTMENTS 17
FUEL TANK CAP
REMOTE ENGINE STOP SWITCH
6. BREAK-IN (RUNNING-IN) 20
7. INSPECTION BEFORE RIDING 21
8. RIDING TIPS 21
9. INSTRUCTING THE YOUNG RIDER 28
10. INSTECTION AND MAINTENANCE 31
MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE CHART
TABLE OF CONTENTS

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SEAT REMOVAL
TOOLS
INSPECTION OF FUEL
INSPECTION OF ENGINE OIL
AIR CLEANER
SPARK PLUG
SHIFT PLAY
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
GENERAL LUBRICATION
11. TROUBLE SHOOTING 48
12. TRANSPORTING 49
13. CLEANING PROCEDURE 51
14. STORAGE PROCEDURE 52
15. LOCATION OF LABELS 54
16. SPECIFICATIONS 56

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F U E L
ENGINE OIL
TRANSMISSION OIL
Frame No. :
Engine No. :
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.
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.
Gasoline used should be graded 91 octane
or higher. An unleaded type gasoline is
recommended. If engine pinging is expe-
rienced, substitute another brand as there
are differences between brands.
Use HYOSUNG HYPOL OIL HS.
If they are not available, use a good quality
TWO-STROKE engine oil.
Use a good quality SAE 10W/30 or 10W/40
multi-grade motor oil.
SERIAL NUMBER LOCATION
FUEL AND OIL
RECOMMENDATION

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LOCATION OF PARTS
Rear brake lever (Parking brake lever)
Parking brake knob
Front brake lever
Throttle lever
Reverse gear lever
Fuel tank cap
lndicator lamp
Starter switch
Engine stop switch

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Fuel cock
Head lamp
Battery & fuse
Muffler
Drive chain
Gear shift shaft
N O T E
means the invisable parts.

11
Tail lamp
Remote engine stop switch
Tools
Engine oil tank
Air cleaner
Ignition switch
Kick start lever
N O T E
means the invisable parts.

12
CONTROLS
IGNITION KEY
The ignition switch has two position :
(ON) POSITION
The ignition circuit is completed and the
engine can now be started. The key 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.
TE100R comes equipped with a pair of
identical ignition key.
Keep the spare key in a safe place.
ON KEY
IGNITION SWITCH
OIL INDICATOR LAMP
when the engine oil level in the tank
becomes too low requiring HYPOL OIL
refilling, the indicator will light.
When the oil indicator lamp turns on, the
remaining amount of oil has become
approximately 0.2
The engine oil tank capacity is 0.6
INDICATOR LAMP
When the oil indicator lamp comes
on, you should add engine oil to the
engine oil tank at the first opportunity
to avoid running out of engine oil.
The lack of engine oil will damage
engine severely.
CAUTION
For checking the oil indicator lamp,
the ignition switch (ON).
CAUTION

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LEFT HANDLEBAR
Rear Brake Lever
Apply the rear brake by squeezing the rear
brake lever towards the grip.
Parking Brake Knob
This knob is used to set the parking brake,
which is used to prevent the ATV 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.
Starter Switch
Push in the electric starter switch to rotate
the starting motor.
TE100R always come on the
head lamp and tail lamp when starting
engine.
CAUTION
When the fuel indicator lamp comes
on, you should add fuel to the fuel
tank at first opportunity to avoid
running out of fuel.
The lack of fuel will go off suddenly.
Failure to observe this precaution
may result in loss of control and an
accident.
CAUTION
For checking the fuel indicator lamp,
the ignition switch (ON).
CAUTION
N O T E
If the front or rear brake lever is not
squeezed, the starter motor will not
rotate.
REVERSE GEAR INDICATOR LAMP
TE100R has a reverse gear lever.
The reverse gear indicator lamp will come
on when transmission is in reverse gear.
Shifting into reverse gear when the
vehicle is moving can be hazardous
and damage the vehicle.
If you shift the vehicle into reverse
gear when the vehicle is moving it
could stop suddenly, throwing you
from the vehicle.
Always come to a complete stop
before shifting into reverse gear.
Check the area behind the vehicle if
you are about to reverse.
WARNING
FUEL INDICATOR LAMP
When the fuel drop below approximately
0.8 , the indicator lamp lit.
Fill the fuel tank before the indicator lamp lit.
The fuel tank capacity is 4

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TE100R 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 .
2. Turn the throttle limiter screw
clockwise to restrict maximum engine
power or counterclockwise to increase
maximum engine power.
3. Tighten the lock nut .
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.
CAUTION
Engine Stop Switch
Position : The ignition circuit is
off.
The engine cannot start
or run.
Position : The ignition circuit is on
and the engine can
run.
RIGHT HANDLEBAR
Front Brake Lever
Apply the front brake by squeezing the front
brake lever towards the grip.
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.
REVERSE GEAR LEVER

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FUEL COCK
TE100R is equipped with a manually
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.
OFF Position
Turn the lever to the OFF position
whenever stopping the engine for more
than a few minutes.
Shifting into reverse gear when the
vehicle is moving can be hazardous
and damage the vehicle.
If you shift the vehicle into reverse
gear when the vehicle is moving it
could stop suddenly, throwing you
from the vehicle.
Always come to a complete stop
before shifting into reverse gear.
WARNING
When the reverse gear shift or release
the front or rear brake lever is
squeezed.
WARNING
TE100R has a reverse gear lever.
The reverse gear indicator lamp will come
on when the transmission is in reverse
gear.
To shift into reverse gear, completely stop
the vehicle and wait 3 seconds.
To shift into reverse gear, with the front or
rear brake lever is squeezed, pull the
reverse gear lever toward your body and
turn it for 90 direction to put in upper
groove.
After the vehicle reverse, completely stop it
and wait 3 seconds.
Turn the reverse gear lever at the original
situation.
To release from reverse gear, with the front
or rear brake lever is squeezed, pull the
reverse gear lever toward your body and
turn it for 90 direction to put in lower
groove.

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RES (RESERVE) Position
If the fuel level in the tank is too low, turn
the lever to the RES position to use the
0.68 of reserve fuel supply.
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.
CAUTION
When started the engine, check that
kick start lever return to normal
position.
CAUTION
When start by kick start lever, pay
attention to position of a foot.
If they are not pay attention, be will
injured.
WARNING
N O T E
Confirm the each mark by mark
at the fuel cock lever.
KICK START LEVER
The kick start lever exist at right side of the
engine.
You can start by using the kick start lever
when there is some problem in battery.
To use the kick start lever, set the parking
brake, turn the key to the (ON) position,
and set the engine stop switch to the
position.
Press forcefully the kick start lever.

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The TE100R 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.
REMOTE ENGINE STOP SWITCH
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.
WARNING
Gasoline is extremely flammable and
toxic. Always observe the following
precautions when refueling your
TE100R .
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.
WARNING
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.
EQUIPMENT AND
ADJUSTMENTS
FUEL TANK CAP

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Switch body
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.
When the 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.
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.
WARNING
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.

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2. Hook the bag on the frame as shown
and fit the rubber cap snugly over the
remote engine stop switch body.
1. Place the lanyard in the vinyl bag
provided with the vehicle, with the rubber
cap visible at the bag opening.
N O T E
With the rubber cap off the switch, the
engine can not be started because the
ignition circuit is not completed.
Avoid leaving any part of the lanyard
visible outside the bag as it can be
caught and damaged by moving parts.
WARNING
To prevent unauthorized starting or
unsupervised operation of the
TE100R 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.
WARNING
The throttle limiter should always be
set to the low power position(as
described on page 14) when the
remote engine stop lanyard is used.
Only children with enough skill for
safe operation of the TE100R
without parental use of the lanyard
should be permitted to operate
TE100R with the throttle limiter
set to the maximum power position.
In addition, an adult trying to follow a
moving TE100R 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.
WARNING
Instruction For Remote engine
stop switch Lanyard Storage
The lanyard may be stowed on the
TE100R 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 :

20
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.
BREAK-IN (RUNNING-IN)
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 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
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.
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 performing
this maintenance.
WARNING