CONTENTS 1. INFORMATION............................................................2 2. MAINTENANCE..........................................................6 3. ENGINE REMOVAL AND INSTALLATION......................12 4. ENGINE FUEL SYSTEM.............................................14 5. ENGINE LUBRICATION AND COOLING SYSTEM...........18 6. ENGINE COMBUSTION SYSTEM.................................20 7. TRANSMISSION SYSTEM..........................................25 8. STEERING SYSTEM..................................................31 9. FRONT WHEEL SYSTEM...........................................38 10. REAR WHEEL SYSTEM............................................42 11. FENDERS AND EXHAUST PIPE.................................51 12. ELECTRICAL SYSTEM.............................................55 13. TROUBLE SHOOTING..............................................62 1 1. INFORMATION 1.1 SAFTY 1.2 NOTES 1.3 SPECIFICATION 1.4 SERIAL NUMBER 1.5 TORQUE VALVE 1.1 SAFETY Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte gets in your eyes. 1.2 NOTES All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing. JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission. 2 1.3 SPECIFICATION RXL50 ENGINE TYPE DISPLACEMENT BORE & STROKE COMPRESSION MAXIMUN TORQUE CARBURETOR IGNITION STARTING LUBRICATION OIL CAPACITY TRANSMISSION CHASSIS OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT SEAT HEIGHT WHEEL BASE GROUND CLEARANCE DRY WEIGHT FUEL TANK CAPACITY SUSPENSION FRONT REAR BRAKES FRONT REAR TIRES FRONT REAR COLORING Specifications subject to change without notice. 16" *8"-7 16" *8"-7 16" *8"-7 16" *8"-7 18" *7"-8 18" *9"-8 Red /Blue /Yellow /Black 18" *7"-8 18" *9"-8 145/70-6 145/70-6 DUAL MECHANICAL DRUM HYDRAULIC DISC N/A DUAL A-ARM SWING ARM 1470mm (57.9") 850mm (33.5") 830mm (32.7") 650mm (25.5") 930mm (36.1") 110mm (4.3") 108kg 1470mm (57.9") 850mm (33.5") 830mm (32.7") 650mm (25.5") 930mm (36.1") 95mm (3.7") 108 kg 1500mm (59.0") 850mm (33.5") 900mm (35.4") 670mm (26.3") 930mm (36.1") 120mm (4.7") 113 kg 4.5 LITERS 1500mm (59.0") 850mm (33.5") 900mm (35.4") 670mm (26.3") 930mm (36.1") 130mm (5.1") 113 kg 1430mm (56.3") 820mm (32.3") 800mm (31.5") 650mm (25.5") 930mm (36.1") 110mm (4.3") 108kg 49.3 40.0*39.2 mm 9.21 5.2 N-m @ 7000rpm RXL70 RXL90 RXL90R RXL50M AIR-COOLING TWO STROKE 68.0 82.5 82.5 47.0*39.2 mm 8.31 6.3 N-m @ 6000rpm 49.3 40.0*39.2 mm 9.21 50.0*42.0 mm 7.91 50.0*42.0 mm 7.91 7.0 N-m @ 7500rpm 7.0 N-m @ 7500rpm 5.2 N-m @ 7000rpm MIKUNI VM16 (for other country) / SW 18 mm-Manual Choke (for America) CAPACITOR DISCHARGE ELECTRIC/KICK START AUTO OIL INJECTION 1.0 LITER AUTOMATIC (C.V.T. V-Belt) 3 1.4 SERIAL NUMBER For this ATV serial; the number of frame and engine are the same position, just like the picture below; The frame serial number is stamped on the front of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number Engine serial number For RXL 50/70/90/RXL50M Engine serial number For RXL 90R 4 1.5 TORQUE VALUES For this ATV serial; the torque values of frame and engine are the same, just like the picture below; ENGINE Cylinder head nut Spark plug Cylinder head bolt Alternator bolt 28-30 N.m (20.7-22.1 lbf.ft) 12-19 N.m (8.9-14.0 lbf.ft) 20-30 N.m (14.8-22.1 lbf.ft) 8-12 N.m (5.9- 8.9 lbf.ft) FRAME Handlebar upper holder bolt Steering shaft nut Steering shaft bushing holder nut Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle nut Front brake arm nut Rear brake arm nut Rear axle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt 24-30 N.m (17.7-22.1 lbf.ft) 50-60 N.m (36.9-44.3 lbf.ft) 24-30 N.m (17.7-22.1 lbf.ft) 18-25 N.m (13.3-18.4 lbf.ft) 35-43 N.m (25.8-31.7 lbf.ft) 30-40 N.m (22.1-29.5 lbf.ft) 40-48 N.m (29.5-35.4 lbf.ft) 24-30 N.m (17.7-22.1 lbf.ft) 55-65 N.m (40.6-47.9 lbf.ft) 4-7 N.m (3.0- 5.2 lbf.ft) 7-12 N.m (5.2- 8.9 lbf.ft) 40-60 N.m (30-45 lbf.ft) 24-30 N.m (17.7-22.1 lbf.ft) 30-35 N.m (22.1-25.8 lbf.ft) 24-30 N.m (17.7-22.1 lbf.ft) 5 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE ADJUSTMENT 2.6 AIR CLEANER 2.7 SPARK PLUG 2.8 IDLE SPEED 2.9 DRIVE CHAIN 2.10 BRAKE SYSTEM 2.11 WHEELS AND TIRES 2.12 STEERING SYSTEM 2.13 TOE-IN 2.14 GEAR OIL 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG: SPARK PLUG GAP: RECOMMENDED SPARK PLUGS: THROTTLE LEVER FREE PLAY: IDLE SPEED: BRAKE LEVER FREE PLAY: DRIVE CHAIN SLACK FRONT/REAR TIRE PRESSURE TOE-IN 0.6-0.7 mm NGK BPR7HS 5-10 mm 1800±100 rpm 15-25 mm 10-25 mm MIN 3.2 psi (0.23 kg/cm2) MAX 4.0 psi (0.28 kg/cm2) 5±10 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT 12-19 N.m 35-43 N.m ENGINE OIL GEAR LUBRICATION OIL 2.2 MAINTENANCE SCHEDULE JASO FC Grade or same degree oil SAE 90 The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, require more frequent servicing. (For ATV all serial in this service manual) INITIAL SERVICE (First week) REGULAR SERVICE (Every 30 operating days) EVERY YEAR I FUEL LINE THROTTLE OPERATION I I AIR CLEANER C SPARK PLUG I CARBURETOR IDLE SPEED I I DRIVE CHAIN I, L I, L BRAKE SHOE WEAR BRAKE SYSTEM I I NUT, BOLT, FASTENER I I WHEEL I I STEERING SYSTEM SUSPENSION SYSTEM C.V.T. AIR FILTER C GEAR OIL REVERSE GEAR OIL-RXL90R Note ­ I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace I I I R R 6 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. (For RXL50 / 90) (For RXL70 / RXL90R / RXL50M) 2.4 THROTTLE OPERATION Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kinking in the throttle cable, replace it if necessary. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever. Disconnect the throttle cable at the upper end. Lubricate the cable with commercially lubricant to prevent premature wear. 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 7 2.6 AIR CLEANER Unscrew the air cleaner cover screws. Pull out the air filter element from the air cleaner case. Wash the element in non-flammable solvent, squeeze out the solvent thoroughly. Let it dry. Soak the filter element in gear oil and then squeeze out the excess oil. Install the element into air cleaner carefully. 2.7 SPARK PLUG This spark plug located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Check the spark plug electrodes for wearness. Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.6-0.7mm. Tighten the spark plug with 12-19 N.m With the sealing washer attached, thread the spark plug in by hand to prevent cross threading. 2.8 IDLE SPEED Connect an engine speed meter. Warm up the engine, 10 minutes are enough. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. "Turn in" (clockwise) will get higher speed. "Turn out" (counter clockwise) will get lower speed. IDLE SPEED: 1800±100 rpm 2.9 DRIVE CHAIN Inspect the chain slack. The standard is 10-25mm. 8 Adjust the chain slack. Loose the lock bolts (4 pcs) then adjust the drive chain slack by turn the adjusting nut. Tighten the four lock bolts. When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for possible wear or damage. Replace the chain, if it is worn excessively or damaged. Inspect the sprocket teeth, if it is excessive wear or damage, replace it. Inspect the chain-tensioned roller. Replace it, if necessary. 2.10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard of free play is 15-25 mm. (For RXL50 / 90 / RXL90R, the ATV RXL50M doesn't have the front brake lever. ) 9 For RXL50M, because it have parking brake in rear tire. So, its controller is at the handler bar right side. Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 15-25 mm. (For all type) 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the tire surfaces at cold tire condition. The standard of tire pressure is MIN 3.2 psi. (0.23 kgf/cm2) MAX 4.0 psi. (0.28 kgf/cm2) 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. 10 2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m 2.14 GEAR OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine. Unscrew this release bolt and can let the dirty oil flow out. The re-add oil hole is on the engine case beside gearbox. (CAUTION: Only the ATV RXL 90R must add the reverse oil) 11 3. ENGINE REMOVAL AND INSTALLATION 3.1 SERVICE INFORMATION 3.2 ENGINE REMOVAL 3.3 ENGINE INSTALLATION 3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3.2 ENGINE REMOVAL Remove the seat and rear fender. (Chapter 11) Remove the spark plug cap from the spark plug. Remove the exhaust pipe. Disconnect the carburetor cable by unscrew two screws on top of the carburetor. Take off oil pump cable from the oil pump control plate. Oil pump is under the right side of engine. Disconnect the wire connectors. There are three connectors for carburetor auto-choke, starter motor and generator respectively. Remove the drive chain cover. This is under the chain. Remove the drive chain retaining clip and master link, and remove the drive chain. Remove the three engine hanger nuts and bolts. Remove the engine from the right side of frame. (The pictures of right side are for ATV RXL 50 / 70 / 90 and RXL 50M) 12 (The right side picture is for ATV RXL 90R) 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 24-30 Nm Route the wires and cable in reverse order properly. 13 4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING 4.2 FUEL TANK 4.3 CARBURETOR 4.1 TROUBLESHOOTING ENGINE CAN NOT START NO FUEL IN TANK NO FUEL TO CYLINDER TOO MUCH FUEL GO INTO CYLINDER NO SPARK AT PLUG AIR CLEANER CLOGGED ENGINE IDLES UNSTEADY, STALLS OR RUNS POORLY UNPROPER ADJUSTMENT TO THE IDLE SPEED SCREW IGNITION MALFUNCTION FUEL/AIR MIXTURE RATIO NO GOOD AIR CLEANER DIRTY INSULATOR LEAKS FUEL TANK CAP BREATHING HOLE CLOGGED LEAN MIXTURE FUEL JET OF CARBURETOR CLOGGED FUEL TANK CAP BREATHING HOLE CLOGGED FUEL FILTER CLOGGED FUEL FLOWS IN THE TUBE UNSMOOTHLY FLOAT LEVEL IN CARBURETOR TOO LOW RICH MIXTURE FLOAT NEEDLE VALVE IN CARBURETOR FAULTY FLOAT LEVEL TOO HIGH AIR DUCT IN CARBURETOR IS CLOGGED AIR CLEANER DIRTY 14 4.2 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel t ...