CONTENTS 1.INFORMATION............................................................2 2.MAINTENANCE...........................................................6 3.ENGINE REMOVAL AND INSTALLATION.......................14 4. CYLINDER HEAD / VALVES........................................16 5. LUBRICATION..........................................................26 6. CYLINDER / PISTON..................................................34 7. TRANSMISSION / KICK STARTER...............................42 8. STEERING AND SUSPENSION....................................52 9. FRONT WHEEL AND BRAKE SYSTEM.........................59 10. REAR WHEEL AND BRAKE SYSTEM.........................68 11. FENDERS AND EXHAUST PIPE.................................83 12. ELECTRICAL SYSTEM.............................................89 13. TROUBLE SHOOTING............................................108 1 1. INFORMATION 1.1 1.2 1.3 SAFTY NOTES SPECIFICATION 1.4 1.5 SERIAL NUMBER TORQUE VALUE 1.1 SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE 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. BATTERY ELECTROLYTE 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. HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run. Wear insulated gloves before handling these parts. USED ENGINE/GEAR OIL Used engine oil and gear oil may cause skin disease if repeatedly contact with the skin for long periods. Keep out of reach of children. 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 ENGINE This service manual have six models, it is YXL-150, CXL-150, EXL-150 / 150 (2004 two-passengers) RXL-150 and EXL-150 (VIPER) in this service manual. Type Displacement Bore and Stroke Compression Maximum Torque (Nm/rpm) Carburetor Ignition Starting Lubrication Transmission Air-Cooling 4-Stroke with oil cooler 149.5 c.c. 57.4X57.8mm 9.7:1 11.7 / 5000 ± 500 Capacitor Discharge Electric and kick starter Auto oil injection Automatic (C.V.T. V-belt) YXL-150 CHASSIS Overall Length Overall Width Overall Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity CXL-150 EXL-150 EXL 150 (2004) RXL-150 1665 mm 1010 mm 1070 mm 1090 mm 120 mm 168 kg EXL-150 (VIPER) 1670 mm 1010 mm 1070 mm 1090 mm 120 mm 170 kg 8.0 Liters 1730 mm 980 mm 1070 mm 1115 mm 130 mm 172 kg 6.5 Liters 1750 mm 1010 mm 1065 mm 1115 mm 130 mm 176 kg 6.5 Liters YXL-150 SUSPENSION Front Rear BRAKES Front Rear TIRES Front Rear PRESSURE Front Rear Drum EXL-150 CXL-150 EXL 150 (2004) RXL-150 EXL-150 (VIPER) Dual Arm Swing arm Drum Disc Disc Drum Drum Disc 21"*7"-10" 20"*11"-9" 4.0 (0.28) 3.2 (0.23) 4.0 (0.28) 3.2 (0.23) Disc Drum 21"*7"-10" 20"*11"-9" 20"*7"-8" 21"*7"-10" 22"*10"-8" 22"*10"-10" psi ( kgf/cm2) MAX 4.0 (0.28) 12(0.8) MIN 3.2 (0.23) MAX 4.0 (0.28) 12(0.8) MIN 3.2 (0.23) 21"*7"-10" 22"*10"-10" 4.0 (0.28) 3.2 (0.23) 4.0 (0.28) 3.2 (0.23) 21"*7"-10" 22"*10"-10" 12(0.8) 12(0.8) 12(0.8) 12(0.8) COLORING Specifications subject to change without notice. 3 1.4 SERIAL NUMBER (For YXL 150, EXL 150 / EXL 150(2004 two-passengers) and CXL 150 in this service manual) 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 Side frame serial number --only in EXL 150 / 150 (2004 two-passengers) Engine serial number RXL / EXL150 (Viper. St) 4 1.5 TORQUE VALUES STANDARD 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 5 N.m (3.5 lbf.ft) 10 N.m (7.2 lbf.ft) 22 N.m (16 lbf.ft) 35 N.m (25 lbf.ft) 55 N.m (40 lbf.ft) ENGINE Cylinder head nut Spark plug Cylinder head bolt Alternator bolt 28 N.m (20.7 lbf.ft) 12 N.m (8.9 lbf.ft) 20 N.m (14.8 lbf.ft) 8 N.m (5.9 lbf.ft) FRAME Handlebar upper holder bolt Throttle housing cover screw Steering shaft nut Steering shaft holder bolt Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle castle nut Front brake arm nut Rear brake arm nut Rear axle castle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt Rear axle holder bolt Swing arm pivot nut Rear shock absorber mounting nut 24 N.m (17.7 lbf.ft) 4 N.m (2.9 lbf.ft) 50 N.m (36.9 lbf.ft) 33 N.m (24 lbf.ft) 18 N.m (13.3 lbf.ft) 35 N.m (25.8 lbf.ft) 40 N.m (29 lbf.ft) 40 N.m (29.5 lbf.ft) 24 N.m (17.7 lbf.ft) 40-60 N.m (30-45 lbf.ft) 4 N.m (3.0 lbf.ft) 7 N.m (5.2 lbf.ft) 40-60 N.m (30-45 lbf.ft) 24 N.m (17.7 lbf.ft) 30 N.m (22.1 lbf.ft) 30 N.m ( 22 lbf.ft) 90 N.m (65 lbf.ft) 90 N.m (65 lbf.ft) 45 N.m (33 lbf.ft) 5 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBLE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE AJUSTMENT 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 CAP RECOMMENDED SPARK PLUGS THROTTLE LEVER FREE PLAY IDLE SPEED BRAKE LEVER FREE PLAY DRIVE CHAIN SLACK TOE-IN 5-10 mm 1600±100rpm 15-25 mm 10-25 mm 5±10 mm 0.6-0.7 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT ENGINE OIL GEAR LUBRICATION OIL 12-19 N.m 35-43 N.m Viscosity: SAE 10W-40 API service classification SF or SG SAE 90 6 2.2 MAINTENANCE SCHEDULE The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, require more frequent servicing. INITIAL SERVICE (First week) I I REGULAR SERVICE (Every 30 operating days) I C I I I, L I I I I I I I I I R R C EVERY YEAR I FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG CARBURETOR IDLE SPEED DRIVE CHAIN BRAKE SHOE WEAR BRAKE SYSTEM NUT, BOLT, FASTENER WHEEL/TIRES STEERING SYSTEM SUSPENSION SYSTEM GEAR OIL ENGINE OIL ENGINE OIL FILTER I I, L R C I Note ­ I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. 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 kink 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. 7 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. 2.6 AIR CLEANER Unscrew the air cleaner cover screws. Remove the air cleaner case cover. 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 in the reverse order of removal. 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 wear. 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. With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading. Tighten the spark plug with 12-19 N.m 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: 1700±100 rpm 8 2.9 DRIVE CHAIN Stop the ATV and shift the transmission into neutral. Measure the drive chain slack midway between the sprockets. Chain slack =15~25mm (5/8~1 inch) Adjust the chain slack. Loosen the lock nuts and turn drive chain adjusting nuts until get the correct slack. Tighten the axle holder bolts. Torque = 90N.m (65 lbf.ft) If your ATV has the tensioner inside the drive chain. You don't need to follow the procedure of chain slack adjustment. The drive chain will be adjusted by tensioner. 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. 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. (The right side picture is for YXL 150) 9 (The right side picture is for CXL / RXL / EXL-150 they have a parking brake on the top of hand brake.) Only for EXL 150 (2004 two-passengers) / EXL-150 (VIPER) 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 10-20 mm. (The right side picture is for YXL 150 / EXL-150 (2004 two-passengers) / EXL-150 (VIPER)) (The right side picture is for CXL / RXL-150) 10 Adjust the free play of the rear brake lever by turning the adjuster on the rear axle. (Only for YXL 150 / EXL 150 (2004 two-passengers), / EXL-150 (VIPER)) Because of the CXL / EXL / RXL-150 are both disc brake system, so they don't need to adjust the free play. They will be discussed in chap10. BRAKE SHOE WEAR FRONT BRAKE (The YXL / CXL / EXL / RXL 150 have the same model of front brake) Release the front wheel and inspect the brake lining thickness. Service Limit: 2.0mm(0.08 inch) If either lining is worn beyond the service limit, replace Both brakes shoes. REAR BRAKE This system is for YXL / EXL 150 (2004 two-passengers) / EXL-150 (VIPER). Replace the brake shoes if the indicator plate aligns with the brake index mark when the parking brake lever is applied. 11 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 on chap 1. 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. STEERING SHAFT HOLDER BUSHING Remove the front fender first. Remove the steering shaft holder and check the steering shaft bushing for wears or damage. If the bushing is worn or damaged, change a new one. Grease the steering shaft bushing and install the parts in the reverse order of removal. Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft) 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. 12 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. (STEP1) STEP1 The re-add oil hole is on the engine case beside gearbox. (STEP2) STEP2 13 3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 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 Remov ...