User manual ETON VIPER 50 ST - SERVICE MANUAL

SERVICE MANUAL CONTENTS 1. INFORMATION 2. MAINTENANCE 3. ENGINE REMOVAL AND INSTALLATION 4. ENGINE FUEL SYSTEM 5. ENGINE LUBRICATION AND COOLING SYSTEM 6. ENGINE COMBUSTION SYSTEM 7. TRANSMISSION SYSTEM 8. STEERING SYSTEM 9. FRONT WHEEL SYSTEM 10. 11. 12. 13. REAR WHEEL SYSTEM FENDERS AND EXHAUST PIPE ELECTRICAL SYSTEM TROUBLE SHOOTING 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 (for ViperST & YukonST in this service manual) Type Displacement Bore and Stroke Compression ratio Maximum Torque (Nm/rpm) Maximum Power (ps/rpm) Carburetor Ignition Starting Lubrication Transmission Two cycle air cooled 49.3 c.c. 40.0X39.2mm 6.8:1 4.5 Nm/6000rpm 3.8 ps/6000rpm Piston type Capacitor Discharge Electric and kick starter Forced pressure and wet sump Automatic (C.V.T. V-belt) Fr Neut .Rev CHASSIS Overall Length Overall Width Overall Height Seat Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity ViperST EXL-50 YukonST EXL-50 1750 mm 1010 mm 1065 mm 760 mm 1115 mm 120 mm 152 kg 4.5 Liters 1670 mm 940 mm 1040 mm 760 mm 1110 mm 120 mm 152 kg 4.5 Liters ViperST SUSPENSION Front Rear BRAKES Front Rear TIRES Front Rear PRESSURE Front Rear EXL-50 YukonST EXL-50 Single A-arm / Adjustable Shocks Swing Arm / Adjustable Shock Dual Mechanical drum Hydraulic Disc 20/6-10 20/10-9 ¡i psi (0.23 kgf/cm2)¡j 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 ViperST EXL-50 / YukonST EXL-50 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 Engine serial number 4 .5 TORQUE VALUES (For EXL 50 in this service manual) STANDARD 5 mm bolt and nut 6 mm bolt and nut 8 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) 10 mm bolt and nut 12 mm bolt and nut 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 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 2 psi (12.5kpa) 5±10 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT 25-30 N.m 35-43 N.m ENGINE OIL GEAR LUBRICATION OIL JASO FC Grade or same degree oil SAE 90 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. (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 I, L DRIVE CHAIN 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 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 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. 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 25-30 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. 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. 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. BRAKE SHOE WEAR 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. 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 1.2±0.3 psi. (0.8 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. 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. Toe-in: 5±10mm 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. Torque: 35-43 N.m 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. 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. 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. 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. 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 4. ENGINE FUEL SYSTEM 4.1 FUEL TANK 4.2 CARBURETOR 4.1 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel tank cap and front fender. Unscrew the fuel tank fixed bolts. Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. 4.2 CARBURETOR REMOVAL Remove the air cleaner. Disconnect the fuel line and auto-choke electric wire. Unscrew the intake pipe mounting bolts at the carburetor then removes the carburetor. Note: Turn fuel cup on (off) position Remove the carburetor cap. Remove the throttle cable from the throttle valve while depressing the throttle valve spring. Remove the needle clip retainer, the jet needle and needle clip. Inspect the throttle valve and jet needle surface for wearness, scratches or dirt. DISASSEMBLY Unscrew the float chamber screws and remove the carburetor chamber. carburetor chamber Disassembly the float and float needle valve. Inspect the seat of the float needle valve for wear or damage. Disassembly the slow jet, main jet, throttle adjusting screw and air flow adjusts screw. Inspect all the jets and screws for wear or damage. Clean the passages and jets with compressed air. throttle adjusting screw air flow adjusts screw main jet slow jet ASSEMBLY Clean all parts in solvent and blow it dry with compressed air. Assembly is essentially the reverse order of disassembly. THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle. Install the jet needle into the throttle valve. Assembly the throttle cable, spring and the throttle valve. Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap to the carburetor. 5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 ENGINE LUBRICATION SYSTEM 5.2 CAUTION 5.3 OIL PUMP 5.4 COOLING SYSTEM 5.5 TROUBLESHOOTING 5.1 ENGINE LUBRICATION SYSTEM The engine drives the pump gears of oil pump crankshaft. Pump gears rotate the plunger shaft in oil pump. This shaft sent the lubricating oil into the crankcase to mix with the mixture of air-fuel flow evenly. The oil drops and foam cover the cylinder inner wall, piston surface and piston rings. 5.2 CAUTION Having enough oil supply to engine is very important. If the oil quantity is not enough, this engine will be serious scratched, and then this engine will stop, even cannot work again. When this engine is serious scratched, you need to change the piston, piston rings and cylinder together. Also you need to check the combustion system and lubrication system carefully. 5.3 OIL PUMP The quantity of oil that deliver out from oil pump increased by the engine speed and the carburetor throttle open width. Oil pump is under the right side of the engine and connected by a control cable of throttle. 5.4 COOLING SYSTEM The engine-cooling fan sucks the air. The cooling fan is on the right side of engine. The air is forced to flow through cylinder fin and cylinder head. So, the cylinder and piston will not over heat. 5.5 TROUBLESHOOTING NO ENOUGH OIL SUPPLY TO ENGINE THE OIL LEVEL IN OIL TANK IS TOO LOW. OIL TUBES WERE NOT FIXED WELL. OIL HAS LEAKAGED FROM TUBE ENDS. OIL TUBES WERE BROKEN. OIL TUBES WERE CLOGGED. OIL PUMP CANNOT WORK. ALWAYS INSUFFICIENT OIL LEVEL IN LUBRICATE OIL TANK EXTERNAL OIL LEAKS WORN CYLINDE HEAD GASKET WORN PISTON RINGS 6. ENGINE COMBUSTION SYSTEM 11.1 TROUBLESHOOTING 11.2 CYLINDER AND PISTON REMOVAL 11.3 CYLINDER AND PISTON INSPECTION 11.4 INSTALLATION 6.1 TROUBLESHOOTING LOW COMPRESSION CYLINDER HEAD HEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD HIGH COMPRESSION CYLINDER OR PISTON RINGS WORN OUT EXCESSSIVE CARBON BUILD-UP ON PISTON HEAD OR IN COMBUSTION CHAMBER EXCESSIVE NOISE EXCESS SMOKE PISTON AND CYLINDER WORN OUT EXCESSIVE CARBON BUILD-UP CYLINDER OR PISTON RINGS WORN OUT IMPROPER INSTALLATION OF PISTON RINGS OVERHEATING PISTON OR CYLINDER WALL SCORED OR SCRATCHED EXCESSIVE CARBON BUILD-UP ON THE PISTON OR COMBUSTION CHAMBER ENGINE COOLING SYSTEM (FAN, CYLINDER COVER...) WORKS BADLY. OIL SUPPLY IS OUT OF ORDER. WRONG IGNITION TIMING 6.2 CYLINDER AND PISTON REMOVAL Remove the seat and rear fender. Remove the exhaust pipe. Remove the spark plug cap. Disconnect the wire. Drag out the engine. Disassembly the air cleaner and carburetor. Remove the intake pipe mounting bolts. Remove the cylinder bolt nuts. Remove the cylinder head. Remove the cylinder carefully, then you can see the whole piston. Remove one piston pin clip. Remove the piston and piston pin. Spread each piston ring and remove it by lifting up at a point just opposite the gap. Note: Don't let the clip drop into engine crankcase. 6.3 CYLINDER AND PISTON INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder inner diameter at three levels in X and Y-axis. Taper limit: 0.10 mm Out of round: 0.10 mm Check the cylinder head mating surface for warp with a straight edge and feeler gauge. Service limit: 0.10 mm Insert each piston ring into the cylinder, and measure the end gap. Service limit: 0.5 mm Measure the clearance between ring and groove. Service limit: 0.09 mm Measure the piston outer diameter at 10 mm high from the skirt's bottom. Service limit: 39.9 mm Measure the piston pin bore, and the piston pin outer diameter. Pin outer diameter service limit: 9.96 mm Pin bore service limit: 10.04 mm Measure the connecting rod small end inner diameter with a small bore diameter gauge. Service limit: 14.06 mm 6.4 INSTALLATION Install the piston rings with the marks facing up. Do not damage the piston rings by spreading the ends too far. Clean the cylinder gasket surface being careful not to drop any gasket material into the crankcase. Apply some oil to inside of the connecting rod small end. Install the piston, piston pin and clip. Install the piston with the arrow mark facing the exhaust pipe. Do not align the piston pin clip end gap with the piston cutout. Install a new cylinder gasket. Apply a thin coat of engine oil to the piston rings and cylinder wall. Install the cylinder, compressing the piston rings. Replace a new cylinder head gasket. Install the cylinder head. Tighten the cylinder-mounting bolt. The torque is 10-14N.m 7. TRANSMISSION SYSTEM 7.1 TROUBLE SHOOTING 7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM 7.3 SHIFT MECHANISM (INCLUDE C.D.I) 7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION 7.5 CONTINUOUS VARIABLE TRANSMISSION 7.6 GEAR BOX 7.7 ELECTRIC SELF-STARTER MECHANISM 7.8 KICK STARTER 7.9 DISASSEMBLY AND CHECK OF C.V.T. SYSTEM 7.1 TROUBLESHOOTING ABNORMALLY ACT IN SHIFTING AND CAN'T RESET CAN NOT MOVE AFTER ENGINE START CAN NOT RUN AT HIGH SPEED ENGINE STOP AFTER SHIFT SUCCESSFULLY THE FUNCTION OF SPEED LIMITED IS ABNORMAL FAULTY C.D.I FAULTY SHIFT MOTOR FAULTY SENSOR (F, N1, R, N2) FAULTY SHIFT SPRING OR GEAR BELT WORN FRONT PULLEY WORN OR BROKEN LINING OF CLUTCH WORN FAULTY SHIFT SPRING BELT WORN ROLLERS WORN SPRING OF REAR PULLEY IS DISTORTED FAULTY C.D.I FAULTY C.D.I 7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM C.V.T Shift Mechanism Gear Box For 7.3 SHIFT MECHANISM Sensor Inspect wire for break or damage and check contact. Measure sensor dimension as fig-1 after unscrew sensor. fig-1 If length is below 30mm, it must be replaced. Smear with loctite 5699 and screw with torque 25 kgf-cm in assembly. SERVICE LIMITS: 30 mm TORQUE: 25 kgf-cm Sensor N2 Sensor Sensor Sensor Shift R N1 F Motor Shift Spring and Gear Remove mission side cover and other parts. Check shift gear for wear or damage. Measure open width of shift spring as fig-2. fig-2 If open width greater than 5mm, it must be replaced. SERVICE LIMITS: 5 mm Shift Spring Shift Gear Shift Motor Check shift motor whether it's action is normal as follow data: Disassembly mission side cover, parts of shift mechanism and mission cover. Get seal and bearing after disassembly shift motor of mission cover. Check seal and for wear or fatigue. Replace it if necessary. Brush Seal Bearing 7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION This transmission is the combination of automatic centrifugal clutch and V-belt continuous variable transmission, which can change the transmission ratio automatically. When engine speed increase, the drive pulley will be push to belt by the centrifugal force from six rollers. Then the pitch circle of belt in drive pulley will be larger. The belt at driven pulley is forced to move to the center of shaft, then the radius of pitch circle is decreased. The transmission ratio is therefore altered by the alteration of pitch circle's radius. (In the drawing, "H" means high speed, "L" means low speed) 7.5 CONTINUOUS VARIABLE TRANSMISSION V-Belt Made of rubber fiber, resistant to head, pressure and abrasion. The inner side of the Belt is toothed. Drive Pulley Due to the increasing engine speed, the rollers push the movable drive face by centrifugal force. Then the belt is pressed and enlarges its turning radius. The aluminum fan is installed on the exterior of fixed drive face. It can reduce the belt temperature. Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at the Driven End to shorten the revolving radius. There is a Torque Cam on the Movable Drive Face. Torque Cam is loaded from outside. When the outside load is higher than the engine's output, the pulley of fixed shaft and belt slip to make the Movable Drive Face move along the inner side of Cam and compensate to increase to high torque (toward to low speed) and make the engine maintain smooth running with original revolution. 7.6 GEAR BOX Reverse Shaft Comp Sensor Drive Shaft Comp Drum Gear Shift Fork Fork Counter Shaft Comp Shaft Remove mission side cover, parts of shift mechanism and mission cover. Inspect gears for wear, scoring, chipping or break. Replace it if necessary. The gear ratio of front gear composition is about 47 x 31 15 11 49 49 31 × × 15 16 11 The gear ratio of reverse gear composition is about 7.7 ELECTRIC SELF-STARTER MECHANISM Starter Motor is installed on the upper side of engine. The starter motor can act only when the left hand brake is applied. ELECTRIC SELF-STARTER MECHANISM KICK STARTER 7.8 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-starter arm is kicked, the gear of start shaft will drive the kick-starter to revolve the crankshaft to start the engine. After the engine is started, the kick-started will stop transfer the power to the kick-starter driven gear. When the kick-starter lever is released, the kick-starter gear will go back to its original position. 7.9 DISASSEMBLY AND CHECK OF C.V.T. SYSTEM Remove the engine clutch cover, by unscrew the fixed bolts. Check the belt for wear. If necessary, replace the belt. Disassembly the front drive pulley, check the six rollers for wear. If necessary, replace the rollers. 8. STEERING SYSTEM 8.1 THE PARTS DRAWING OF STEERING SYSTEM 8.2 TROUBLESHOOTING 8.3 HANDLEBAR 8.4 STEERING SYSTEM 8.1 THE PARTS DRAWING OF STEERING SYSTEM 8.2 TROUBLESHOOTING HARD STEERING Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment FRONT WHEEL WOBBLING STEERS TO ONE SIDE FRONT SUSPENSION NOISE ¡¹ ¡¹ HARD SUSPENSION ¡¹ ¡¹ ¡¹ SOFT SUSPENSION ¡¹ Loose front suspension fasteners Binding suspension link Faulty front swing arm bushings Improperly installed front swing arms Bent front shock absorber swing rod Weak front shock absorber springs Worn or damage front swing arm bushings ¡¹ 8.3 HANDLEBAR REMOVAL Remove the right side handlebar cover by unscrew two fix screws. Remove the throttle lever housing on the right side handle bar. Remove brake lever bracket assemb Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. Remove the bolts attaching the handlebar upper holder. Remove the handlebar. I INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark match with the top end of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts. Install the handlebar upper holder's cover. Install the switch housing, aligning the boss with the hole. Tighten the upper screw first then tighten the lower one. Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely. Aligning the split line of the throttle housing and holder with the punch mark. Tighten the screw securely 8.4 THROTTLE HOUSING DISASSEMBLY Unscrew the screws on the throttle housing cover. Remove throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing. Assembly is in the reverse order of disassembly. 8.5 STEERING SYSTEM Removal of Kingpin and Tie-rod Remove the front wheels and brakes plates. Remove the four self-lock nuts from the tie-rod ball joints and take off the two tie-rods. Remove the cotter pin on the kingpin. Unscrew the bolt and remove the kingpin. Tie-rod Inspection Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage, wear or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly. Kingpin Inspection Inspect the kingpin for damage or cracks. Steering Shaft Removal Remove the handle bar cover and handle bar. (See paragraph 8-3) Remove the front fender. (See paragraph 10-1) Remove handlebar lower holder. Unscrew steering shaft holder bolt, remove steering shaft holder. Take off the cotter pin below steering shaft. Unscrew the steering shaft fixed out below shaft. Pull steering shaft carefully. Steering Shaft Holder Inspection Remove the steering shaft. Remove the bushing from the shaft. Inspect the bushing for damage or wear, replace if necessary. Measure the bushing inner diameter. Maximum limit: Ø39.5 mm Steering Shaft Inspection Inspect the steering shaft for damage or cracks. Installation of Steering Shaft Apply grease to the holder. Install the holder and oil seal tighten with the nuts. Torque: 33 N.m (24 lbf-ft) Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50 N.m (37 lbf.ft) Installation of Tie-rod Install the ball joint with " L" mark on the steering shaft side. Install the tie-rod with the mark on the wheel side. Installation is in the reverse order of removal. 9. FRONT WHEEL SYSTEM 9.1 PARTS DRAWING 9.3 FRONT WHEEL 9.2 TROUBLESHOOTING 9.4 FRONT BRAKES 9.1 PARTS DRAWING FRONT WHEEL FRONT BRAKE 9.2 TROUBLESHOOTING HARD STEERING FRONT WHEEL WOBBLING Faulty tire Insufficient tire pressure Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly Incorrect brake adjustment Sticking brake cable Bent tie rods Wheel installed incorrectly Unequal tire pressure Incorrect wheel alignment Brake shoes worn Worn brake drum Brake linings oily, greasy or dirty Improper brake adjustment BRAKE DRAG STEERS TO ONE SIDE POOR BRAKE PERFORMANCE 9.3 FRONT WHEELS REMOVAL Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. INSTALLATION Install and tighten the four-wheel castle nuts Torque: 40-60 N.m (30-45 lbf.ft) Remember put a cotter pin in the castle nut. 9.4 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel. Remove the brake drum. Measure the brake lining thickness. The minimum limit: 1.5 mm If they are thinner than the minimum limit, replace the brake linings. Measure the brake drum inner diameter. The maximum limit: 86 mm Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly. If the race does not turn smoothly or quietly, remove and discard the bearings. BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm. Remove the brake panel from the knuckle. Remove brake arm and cam. Remove return spring. Remove indicator plate and felt seal. INSTALL BRAKE PANEL Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and install the seal on the brake cam. Install the brake arm on the cam by aligning the punch mark and the groove on the cam. Tighten the brake arm bolt and nut. Torque: 4-7 N.m Install the return spring. Install the brake panel on the knuckle. Connect the brake cable to the brake arm. Install the brake arm cover. Tighten the screws securely. Position the brake shoes in their original locations and install the brake shoe spring. Install the brake drum and front wheel. Install the castle nut and cotter pin. 10. REAR WHEEL AND BRAKE SYSTEM 10.1 PARTS DRAWING 10.2 TROUBLESHOOTING 10.3 DRIVE MECHANISM 10.4 HYFRAULIC DISC BRAKE SYSTEM 10.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM FOR ATV RXL70 AND RXL50M FOR RXL 50/70/90/90R 10.2 TROUBLESHOOTING BAD BRAKE PERFORMANCE BRAKE SHOES ARE WORN BAD BRAKE ADJUSTMENT BRAKE LININGS ARE OILY, GREASY OR DIRTY BRAKE DRUMS ARE WORN BRAKE ARM SETTING IS IMPROPERLY ENGAGE AXLE IS NOT TIGHTENED WELL BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER IS FAULTY INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CAM STICKING BRAKE CABLE VIBRATION OR WOBBLE BRAKE DRAG 10.3 DRIVE MECHANISM REMOVAL AND INSPECTION Remove the rear wheel Let the rear wheels off the ground. Release the cotter pin, axle nut and washer. Release the wheel and wheel hub. Remove the drive chain under cover. Disassemblies the chain retaining clip and master link. Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. The run out limit is 0.5 mm Let the rear axle lie in V-blocks and check the run out. Check the turning of bearing with fingers. The bearings should turn smoothly and quietly. Replace if necessary. INSTALLATION Add grease to the dust seal lips and install dust seals. Assembly the rear axle and the driven sprocket. Assembly the drive chain on the driven sprocket. Assembly the master link and retaining clip. Note the retaining clip direction. Install the drive chain cover. Assembly the chain under cover. Assembly the wheel. Tighten the rear axle nut with 60-80 N.m. Install a new cotter pin. Adjust rear brake level free play. Adjust chain slack. 10.4 HYFRAULIC DISC BRAKE SYSTEM To replace brake disc To replace brake disc Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper Unscrew the rear wheel axle nut and then remove the mounting seat of the disc Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper Press the plate to the end Remove the brake shoe as shown Check the thickness of brake shoe and replace a new one if the thickness less than 1mm. Press the piston to the end prior to installation of brake shoe Piston TO REPLACE THE BRAKE HYDRAULIC OIL Unscrew the bolts and open the cover. Unscrew the bolt and drain out the used oil drain. Fasten the bolt after the used oil being drained out completely. Add the brake oil (Dot 3 or Dot 4) Keep oil level at least half of the cup to avoid air gets into brake system, such like caliper and tube Unscrew the bolt to vent air from brake system. Fasten the bolt if there isn't any air in the brake system. Pull left brake lever slightly to extract air from brake system Fill the brake oil to the level shown on the cup when no air comes out Assemble the cover