Sierra DXL-90 - Get 2 It Sales, LLC
Contents
1. Sierra DXL 90 Service Manual Spartanburg SC 29303 Rev 2 0 0 06 30 2000 TABLE OF CONTENTS Section Table of Contents Page 1 INFORMATION 5 2 MAINTENANCE 9 3 ENGINE REMOVAL AND INSTALLATION 16 4 ENGINE FUEL SYSTEM 17 5 ENGINE LUBRICATION AND COOLING SYSTEM 21 6 ENGINE COMBUSTION SYSTEM 23 T TRANSMISSION SYSTEM 28 8 FRONT WHEEL AND STEERING SYSTEM 33 9 REAR WHEEL SYSTEM 45 10 FENDERS AND EXHAUST PIPE 51 11 ELECTRICAL SYSTEM 54 12 TROUBLE SHOOTING 58 INFORMATION 1 INFORMATION 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 E TON 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 1 1 1 3 SPECIFICATION2. O K N G Check Carburetor Jets Clogged O K Air Cleaner Possible Problem Areas Faulty C D I Unit Faulty Pulse Generator No Fuel in Fuel Tank Clogged Fuel Line Clogged Fuel Valve Clogged Fuel Tank Cap Breather Hose Clogged Fuel Filter 9999 Jets Clogged Clean with High Pressure Air Clean or Replace Filter Screen 12 3 12 4 LOSS OF POWER Possible Problem Areas Raise Wheels off of Ground and turn by hand Brake Dragging Adjust brake Cable Drive Chain too tight Does not spin freely Worn or Damaged wheel Bearings O K Wheel bearings need Lubrication N G Punctured Tire Check Tire Pressure Pressure Low Leaking Valve Stem O K Accelerate Lightly Fuel Air mixture ratio to lean Engine speed does Clogged Air Cleaner not increase Clogged Muffler Restricted fuel flow Clogged Fuel Tank Cap Breather hose Check Ignition Timing Faulty Pulse Generator Faulty C D I Unit O K N G Leaking Head Gasket Test Cylinder Compression I 5 Low Worn Cylinder Pressure Worn or Damaged Piston O K Worn or Damaged Piston Rings N G Check Carburetor Clean and Adjust Air and Fuel mixture Check Spark Plug Clean Spark Plug Discoloted Incorrect Spark Plug Heat Range O K Excessive Carbon Deposits in combustion chamber Wrong
3. 10 6 EXHAUST PIPE INSTALLATION Installation is the reverse order of removal Torque Exhaust muffler bolts 30 35 N m After installation make sure that three are no exhaust leaks 10 3 11 ELECTRICAL SYSTEM 11 1 Trouble Shooting ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG NO SPARK AT PLUG ENGINE STOP SWITCH AT OFF FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POOR CONNECTION Between CDI and ignition coil Between alternator and CDI unit Between CDI and engine stop switch Between ignition coil and spark plug Between generator and CDI unit ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING Faulty generator Faulty CDI unit CHARGING SYSTEM FAILURE LOOSE BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH ENGINE INTERMITTENT POWER LOOSE BATTERY CONNECTION LOOSE CHARGING SYSTEM CONNECTION STARTER MOTOR WILL NOT TURN DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE STARTER MOTOR AND ENGINE TURN FAULTY IGNITION SYSTEM PROBLEMS BUT ENGINE DOES NOT START FAULTY ENGINE STOP SWITCH ELECTRICAL SYSTEM 11 2 IGNITION COIL Remove the spark plug cap from the spark pl
4. ENGINE Type Displacement Bore and Stroke Compression Maximum Torque Carburetor Ignition Starting Lubrication Cil Capacity Transmission CHASSIS Overall Overall Width Overall Height Seat Height Wheel base Ground Clearance 85kg 95kg Fuel Tank Capacity SUSPENSION Front Rear BRAKES Front Rear TIRES Front Rear COLORING Specifications subject to change without notice 1 2 INFORMATION Air Cooling 2 Stroke DXL 90 82 5cc 50 0 x 42 0mm 5 811 7 2 N m 6000rpm Mikuni VM16 Capacitor Discharge Electric Oil Pump Separate Supply 1 0 liter Automatic C V T V belt 1 510mm 59 4inch 860mm 39 3inch 950mm 37 4inch 630mm 24 8inch 1040mm 40 9inch 130mm 5 1inch 102kg 4 0liter Dual Arm Swing Arm Drum Drum 19 X 7 8 19 X E 2 8 Light Green Green White Red INFORMATION 1 4 SERIAL NUMBER 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 Engine serial number 1 3 INFORMATION 1 5 TORQUE VALUES ENGINE Cylinder head nut 28 30 N m 20 7 22 1 Ib ft Spark plug 12 19 N m 8 9 14 0 Ib ft Cylinder head bolt 20 30 N m 14 8 22 1 Ib ft Alternator bolt 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 Re
5. Fuel Type Fuel Air mixture ratio to lean Used poor quality Fuel Check for Engine Overheating Overheating O K Worn Piston and Cylinder Fuel Air mixture ratio to lean Wrong Fuel Type Ignition Timing to Advanced Excessive Carbon Deposits in Combustion Chamber Accelerate to High Speed 9999 12 4 ETON America LLC Service Bulletin Bulletin No 0008 Technical Tip 1 PAPER FUEL FILTERS CAUSE RESTRICTIVE FUEL FLOW THEY CLOG EASIER THEY WILL SHOW FUEL IN FILTER BUT THERE WILL BE NO FUEL IN CARBURATER BOWL REPAIR REPLACE WITH AN E Z FLO WITH FILTER OR A STONE TYPE FILTER 2 EXHAUST RESTRICTERS CAUSE LACK OF POWER LOSS OF POWER FOULED PLUGS REPAIR CLEAN RESTRICTER ONCE A MONTH OR REMOVE RESTRICTER AND USE THROTTLE STOP SCREW 3 AIR FILTERS CAUSE LACK LOSS OF POWER LEAN CONDITIONS POOR THROTTLE RESPONSE REPAIR CLEAN AFTER EVERY 3 5 RIDES MORE FREQUENTLY IN DUSTY CONDI TIONS USE A GOOD QUALITY FOAM FILTER SPRAY BEL RAY FOAM FILTER SPRAY 4 BATTERIES THE BATTERIES FOR ALL ETON VEHICLES ARE MAINTANCE FREE PROPER SERVICE PROCEDURES ARE AS FOLLOWS FILL BATTERY WITH BATTERY PACK SUPPLIED REMOVE FUNNEL AND LET BATTERY STAND WITH CAP OFF FOR AT LEAST 1 HR ALL FLUID IN BATTERY SHOULD ABSORBED BY BATTERY PLATES BEFORE CAP IS INSTALLED BATTERY IS READY TO BE CAPPED WHEN ALL ELECTROLYTE IS ABSORBED YOU SHOULD BE ABLE TO TURN BATTERY UPSIDE DOWN AND NO FLUID COME OUT MEASU
6. NOT FIXED WELL OIL HAS LEAK FROM TUBE ENDS OIL TUBES WERE BROKEN OIL TUBES WERE CLOGGED OIL PUMP NOT WORKING ALWAYS LOW OIL LEVEL EXTERNAL OIL LEAKS IN LUBRICATE OIL TANK WORN CYLINDER HEAD GASKET WORN PISTON RINGS 5 2 ENGINE COMBUSTION SYSTEM 6 ENGINE COMBUSTION SYSTEM 6 1 TROUBLESHOOTING LOW COMPRESSION CYLINDER HEAD HEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD CYLINDER OR PISTON RINGS WORN OUT HIGH COMPRESSION EXCESSIVE CARBON BUILD UP ON PISTON HEAD OR COMBUSTION CHAMBER EXCESSIVE NOISE PISTON AND CYLINDER WORN OUT EXCESSIVE CARBON BUILD UP CYLINDER OR PISTON RINGS WORN OUT IMPROPER INSTALLATION OF PISTON RINGS 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 1 ENGINE COMBUSTION SYSTEM 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 Disassemble 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 oppo
7. 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 Assemble the rear axle and the driven sprocket Assemble the drive chain on the driven sprocket Assemble the master link and retaining clip Note the retaining clip direction Install the drive chain cover Assemble the chain under cover 9 4 REAR WHEEL SYSTEM REAR WHEEL SYSTEM 9 5 REAR BRAKE AND WHEEL INSTALLATION Install the brake panel Add grease to the brake cam and anchor pin Install the brake arm spring and oil seal Assembly the brake arm aligning the punch marks on the cam and the arm Tighten the brake arm bolt and nut with 7 12 N m torque Install the adjusters Install the brake shoes and springs to their original positions Assembly the brake drum axle collar and brake drum cover Assemble 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 9 5 FENDERS AND EXHAUST PIPE 10 FENDERS AND EXHAUST PIPE 10 2 REAR FENDERS REMOVE Pull the Seat Release Bae to unlatch the seat for removal This seat release bar is located under the right hand side rear fender Procedure for removal of the rear fender Unscrew the four bolts which connect the front fender and rear fender Unscrew the two bolts which fix the rear fender on the
8. the mark on the wheel side LOCK NUT 8 9 REAR WHEEL SYSTEM 9 REAR WHEEL SYSTEM 9 1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 9 1 REAR WHEEL SYSTEM 9 2 TROUBLESHOOTING BAD BRAKE PERFORMANCE e BRAKE SHOES ARE WORN BAD BRAKE ADJUSTMENT BRAKE LINING ARE OILY GREASY OR DIRTY BRAKE DRUMS ARE WORN BRAKE ARM SETTING IS IMPROPERLY ENGAGE VIBRATION OR WOBBLE AXLE IS NOT TIGHTENED WELL BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER IS FAULTY BRAKE gt INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CAM STICKING BRAKE CABLE 9 3 REMOVE REAR WHEEL AND BRAKE Let the rear wheels off the ground Release the cotter pin axle nut and washer Release the wheel and wheel hub Remove the brake drum cover Remove the acle collar and brake drum 9 2 REAR WHEEL SYSTEM Check the brake lining thickness The minimum limit is 2 0 mm Check the brake drum for damage Replace if necessary Check the brake drum inner diameter The maximum limit is 131 mm 9 4 DRIVE MECHANISM REMOVAL AND INSPECTION Remove the rear wheel and the rear brake Remove the drive chain under cover Disassemble the chain retaining clips and master link 9 3 Disassemble the driven sprocket axle and sprocket collar Check the driven sprocket for damage or wear Let the rear axle lie in V blocks and check the run out The run out limit is 0 5 mm Check the turning
9. the reverse order of removal After installing the battery coat the terminals with clean grease 11 7 CHARGING Connect the charge positive cable to the battery position terminal Connect the charge negative cable to the battery negative terminal Using 0 9A charging current about 5 hours Normal charging Using 4A charging current about 1 hour Quick charging Keep flames and sparks away from a battery being charged Quick charging should be limited to an emergency Normal charging is preferred 11 3 ELECTRICAL SYSTEM 11 8 WIRING DIAGRAMS Broke Switch Main Switch Head Lamp 1 8 T 1 16 17 7 15 5 1164 15 13 Hondle Bor Switch LH m Hom Button Starter Button Heod Switch Stop Switch NT 9 1 4 OFO fon OFO I onl OFO Flywheel Magneto C D I Unit Lgnition Coil 12 TROUBLE SHOOTING 12 1 Engine does not start N G Check Fuel Flow to Carburetor O K Test Spark NS Weak or No Spark O K Test Cylinder Compression Low Compression O K Start Engine OM Wet Plug Engine does not start Remove and Inspect Spark Plug Possible Problem Areas 9 9 9 9 9 9 9 9 9 9 9 9 9999 No Fuel in Fuel Tank Clogged Float Valve Clogged Fuel Tank Cap Breather Hose Clogged Fuel Line Faulty Spark Plug Fouled S
10. EANER 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 wear Change a new spark plug if the electrodes and insu lator 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 cross threading Tighten the spark plug with 12 19 N m 2 8 IDLE SPEED Connect a 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 3 MAINTENANCE 2 9 DRIVE CHAIN Inspect the chain slack The standard is 5 15mm Adjust the chain slack Loose the lock bolts 4 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
11. RE BATTERY VOLTAGE ACROSS TERMINALS AND IT SHOULD BE ABOVE 12 8 VOLTS IF PLATES HAVE ABSORBED ALL ELECTROLYTE NEVER ADD WATER OR HYDRO SULFURIC ACID TO BATTERY HYDRO SULFURIC ACID WILL CAUSE A SERIOUS CHEMICAL REACTION AND COULD CAUSE HARM TO YOU AND WILL DAMAGE BATTERY ADDING WATER WILL ALSO DAMAGE BATTERY IF CHARGING IS REQUIRED SLOW CHARGE 5 AMPS FOR 5 HRSAND FAST CHARGE 5 AMPS FOR 30 MIN ETON America LLC Service Bulletin Bulletin No 0021 ATV Break In Procedure Your ATV requires a break In period just as with all other internal combustion en gines This period allows the engine parts to seat and wear properly without undue strain which can cause premature failure 1 Forthe first two weeks of operation do not run your ATV at full throttle for ex tended periods of time 2 Viper 50M 50 70 90 90R Your first tank of fuel should be a pre mixture of fuel and oil at a 50 1 ratio This will insure that the oil pump system has been primed and bled of air that may have oc curred in shipping Viper Jr All fuel should be a pre mixture of fuel and oil at a 50 1 ratio Do not operate the unit at more than 85 of maximum speed Do not over rev the engine Use light braking pressure to allow the brake pads to seat to the rotor and drums ETON America LLC Service Bulletin Bulletin No 0033 Oil Pump Flow Adjustment all Oil Injected two cycle Engines To adjust the oil pump flow on a two cycle oil injected en
12. UBLE SHOOTING HARD 5 TIRE STEERING SHAFT HOLDER TOO TIGHT INSUFFICIENT TIRE PRESSURE FAULTY STEERING SHAFT BEARINGS DAMAGED STEERING SHAFT BEARING FRONT WHEEL WOBBLING FAULTY TIRE WORN FRONT BRAKE DRUM BEARING BENT RIM AXLE NUT NOT TIGHTENED PROPERLY BRAKE DRAG BRAKE ADJUSTMENT STICKING BRAKE CABLE STEERS TO ONE SIDE gt BENT TIE RODS WHEEL INSTALLED INCORRECTLY UNEQUAL TIRE PRESSURE BENT FRAME WORN SWING ARM PIVOT BUSHINGS POOR BRAKE PERFORMANCE BRAKE SHOES WORN WORN BRAKE DRUM BRAKE LINING OILY GREASY OR DIRTY IMPROPER BRAKE ADJUSTMENT FRONT SUSPENSION NOISE LOOSE FRONT SUSPENSION FASTENER BINDING SUSPENSION LINK HARD SUSPENSION FAULTY FRONT SWING ARM BUSHINGS IMPROPERLY INSTALLED FRONT SWING ARMS BENT FRONT SHOCK ABSORBER SWING ROD SOFT SUSPENSION WEAK FRONT SHOCK ABSORBER SPRINGS WORN OR DAMAGE FRONT SWING ARM BUSHINGS 8 2 FRONT WHEEL AND STEERING SYSTEM 8 3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right han dle bar Remove brake lever bracket Remove engine switch housing on the left handle bar Remove rear brake level bracket Remove the bolts attaching the upper holder cover Remove the handlebar holder and handlebar INSTALLATION Put the handlebar on the lower holders Make sure the handlebar punch mark with the top of th
13. ar brake arm nut Rear axle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt 1 4 8 12 N m 5 9 8 9 Ib ft 24 30 N m 17 7 22 1 Ib ft 50 60 N m 36 9 44 3 Ib ft 24 30 N m 17 7 22 1 Ib ft 18 25 N m 13 3 18 4 Ib ft 35 43 N m 25 8 31 7 Ib ft 30 40 N m 22 1 29 5 Ib ft 40 48 N m 29 5 35 4 Ib ft 24 30 N m 17 7 22 1 Ib ft 55 65 N m 40 6 47 9 Ib ft 4 7 N m 3 0 5 2 Ib ft 7 12 N m 5 2 8 9 Ib ft 60 80 N m 44 3 59 0 Ib ft 24 30 N m 17 7 22 1 Ib ft 30 35 N m 22 1 25 8 Ib ft 24 30 N m 17 7 22 1 Ib ft 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 PARK PLUG GAP RECOMMENDED SPARK PLUGS THROTTLE LEVER FREE PLAY IDLE SPEED BRAKE LEVER FREE PLAY DRIVE CHAIN SLACK FRONT REAR TIRE SIZE FRONT REAR TIRE PRESSURE TOE IN TORQUE VALUES SPARK PLUG TIE ROD LOCK NUT ENGINE OIL GEAR LUBRICATION OIL 2 1 MAINTENANCE 0 6 0 7 mm NGK BPR7HS 5 10 mm 1800 100 rpm 15 25 mm 10 25 mm 19X7 8 19X7 8 2 2 0 3 psi 0 15 kgf cm2 5 10 mm 12 19 N m 35 43 N m JASO FC Grade or same degree oil SAE 40 MAINTENANCE 2 2 MAINTENANCE SCHEDULE The maintenance interva
14. cleaned and lubricated by specify lubri cator 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 dam aged Inspect the sprocket teeth If it is excessive wear or damage replace it 2 4 MAINTENANCE 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 rake 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 Adjust the free play of the rear brake lever by turn ing the adjuster on the rear axle 2 11 WHEELS AND TIRES Inspect the tire surfaces for cuts nails or other sharp objects Check the tire pressure at cold tire condition The standard of tire pressure is 2 2 0 3 psi 015 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 2 5 MAINTENANCE 2 13 TOE IN Let the vehicle on level ground and the front wheels facing straight ahead Mark the cente
15. e 4 1 ENGINE FUEL SYSTEM 4 3 CARBURETOR REMOVAL Remove the air cleaner j i Disconnect the fuel line and auto choke electric wire 4 Gam 7 j Unscrew the intake pipe mounting bolts at the car buretor then remove 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 wear scratches or dirt DISASSEMBLY Unscrew the float chamber screws and remove the float chamber 4 2 ENGINE FUEL SYSTEM Disassembly the float arm pin float and float needle valve Inspect the seat of the float needle valve for wear or FLOAT NEEDLE VALVE damage Disassembly the idle jet main jet idle speeds adjust screw and idle mixture adjusts screw Inspect all the jets and screws for wear or damage Clean the passages and jets with compressed air ASSEMBLY Clean all parts in solvent and blow it dry with com pressed air Assembly is essentially the reverse order of disas sembly THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle Install the jet needle into the throttle valve Assemble the throttle cable spring and the throttle valve Align the throttle valve groove with the idle speed adjust screw and install the carb
16. e 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 8 3 FRONT WHEEL AND STEERING SYSTEM 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 FRONT WHEEL REMOVAL Raise the front wheels off the ground by placing a block under the frame Remove the front wheel nuts washer and wheels INSTALLATION Install and tighten the four wheel nuts Torque 50 60 N m Remember put a cotter pin in the castle nut 8 5 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel Remove the brake drum 8 4 FRONT WHEEL AND STEERING SYSTEM Measure the brake lining thickness The minimum limit 1 5 mm If they are thinner than the minimum limit replace the brake lining 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 Re
17. fixed plate just under rear Fender See the up left picture Unscrew the six screws which connect with the foot rest plate Pull the rear fender toward the rear of the unit until the fender can be removed 10 1 FENDERS AND EXHAUST PIPE 10 3 FRONT FENDER REMOVE Pull the front fender upward Remove the handle bar assembly and handle bar cover Unscrew the two fixed screws under the front fend er just above front wheels See up left picture Unscrew the two fixed screws beside the oil tank See down left picture Unscrew the fuel tank cap Then the front fender can be removed Remove the seat by pulling the seat release bar under the rear fender Remove the handle bar assembly headlight and handlebar cover Take off the central front trim fender Unscrew the six screws which connect with footrest plate Unscrew the four screws which connect with the frame Two screws are just behind the fuel tank the other two screws are above the front absorbers 10 4 EXHAUST PIPE DRAWING 10 2 FENDERS AND EXHAUST PIPE 10 5 EXHAUST PIPE REMOVE Do not service the exhaust pipe while they are hot You must wait at least 15 minutes after turn off the engine You need remove the seat rear fender and footrest plate before you take off the exhaust pipe Unscrew the two exhaust pipe bolts that fixed with engine Remove the exhaust pipe mounting bolts that fixed on the engine Remove the exhaust pipe carefully
18. gine you must adjust the oil pump cable length The Oil pump cable is located on the right hand side of the engine just above the RH A arm To reduce the oil flow you must lengthen the cable by loosening the lock nut and turning the adjusting nut counter clockwise then retighten the locking nut To increase the oil flow you would shorten the cable by turning the adjusting nut clockwise Oil Pump Locking Nut ETON America LLC Service Bulletin E TON 50 amp 90cc 2 cycle engine Oil pump testing The following steps are used to determine if the 2 cycle oil injector pump is functioning properly on E TON 50cc and 90cc 2 cycle engines 1 Fill the fuel tank with a pre mix fuel 2 cycle oil mixture at a 50 1 ratio 2 Disconnect the oil pump line at the carburetor 3 Start the engine and count the drops per minute at the various RPM listed in the table below Oil Pump Line Note 32 Drop aporx lcc Page 1 H
19. ically When engine speed increase the drive pul ley will be push into 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 and 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 Pulley Assy Driven Pulley Assy Drive 7 2 TRANSMISSION SYSTEM 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 This then applies pressed to the belt and enlarges its turning radius The aluminum fan is installed on the exterior of fixed drive face It can reduce the belt temperature 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 l
20. ls in the follow table is based upon average riding conditions Riding in unusually dusty areas require more frequent servicing INITIAL SERVICE FUEL LINE AIR CLEANER SPARKPLUG w 2 5 CARBURETOR IDLE SPEED l Z J o I O DRIVE CHAIN 9 5 LL f BRAKESHOEWEAR amp wW7 3 BRAKE SYSTEM Et 2 FASTENER WHEEL STEERING SYSTEM SUSPENSIONSYSTEM 21101 CVT AIR FILTER lt lt SS R EAR OIL Note l 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 leak f age and replace if necessary 2 4 THROTTLE OPERATION Inspect for smooth throttle lever full opening and auto matic 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 pre vent premature wear 2 2 MAINTENANCE 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 CL
21. move the brake panel from the knuckle 8 5 FRONT WHEEL AND STEERING SYSTEM 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 8 6 FRONT WHEEL AND STEERING SYSTEM 8 6 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 Take off the rubber cap on the kingpin and remove the cotter pin on the kingpin Unscrew the castle nut and remove the kingpin 3 TIE ROD INSPECTION E TIE ROD pr Inspect the tie rod for damage or bending Inspect the ball joint rubbers for damage wear or deterioration S Turn the ball joints with fingers The ball joints BALL JOINT RUBBERS should turn sm
22. nd clip Install the piston with the arrow mark facing the exhaust pipe Do not align the piston pin clip end gap with the pis ton cutout Install a new cylinder gasket Apply a thin coat of engine oil to the piston rings and 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 CYLINDER GASKET 6 4 TRANSMISSION SYSTEM 7 TRANSMISSION SYSTEM 7 1 TROUBLESHOOTING SCOOTER DOES NOT MOVE BELT WORN AFTER ENGINE START FRONT PULLEY WORN OR BROKEN LINING OF CLUTCH WORN DOES NOT RUN AT HIGH SPEED BELT WORN ROLLERS WORN SPRING OF REAR PULLEY IS DISTORTED 7 2 THE PARTS DRAWING OF TRANSMISSION SYSTEM 7 1 7 3 PATH OF POWER TRANSMISSION TRANSMISSION SYSTEM Rear Axle The torque of crank shaft drive the front pulley The torque drive pulley turn the belt gt The belt drive the rear driven pulley gt The force through the clutch shoe clutch housing and drive shaft The drive shaft turn the idle gear in gearbox Turning speed reduced by final gear and transmits to rear axle shaft to move rear wheel 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 automat
23. oothly and quietly KINGPIN INSPECTION Inspect the kingpin for damage or cracks 8 7 FRONT WHEEL AND STEERING SYSTEM STEERING SHAFT REMOVAL Remove the handle bar and handle bar cover See paragraph 8 1 Remove the front fender See paragraph 10 1 Unscrew the steering shaft fixed out below shaft Pull steering shaft carefully STEERING SHAFT BUSHING 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 022 8 mm STEERING SHAFT INSPECTION Inspect the steering shaft for damage or cracks Measure the steering shaft outer diameter in the location of the bushing Minimum limit 022 0 mm STEERING SHAFT BEARING INSPECTION Turn the shaft bearing with finger The bearing is on the front part of frame The bearing should turn smoothly and quietly Also check that the bearing outer race fits in the holder Replace the bearing if necessary 8 8 FRONT WHEEL AND STEERING SYSTEM INSTALLATION OF STEERING SHAFT Install the steering shaft with the bushing Apply grease to the bushing Install the bushing holder and tighten the nuts Torque 24 30 N m Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 60 N m INSTALLATION OF TIE ROD Install the ball joint with L mark on the steering shaft side Install the tie rod with
24. ow speed and make the engine maintain smooth running with original revolution 7 6 GEAR BOX The torque received by the Drive shaft will be transmitted by the speed reduction of two sets to rear axle shaft The first gear ratio is 36 13 The second gear ratio is 48 12 Shaft Drive rr TRANSMISSION SYSTEM 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 Gear Started Motor Assy Starting 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 crank shaft to start the engine After the engine is started the kick started will stop transfer the power to the kick starter driven gear When he kick starter lever is released the kick starter gear will go back to its original position 7 4 TRANSMISSION SYSTEM 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 7 5 FRONT WHEEL AND STEERING SYSTEM 8 FRONT WHEEL AND STEERING SYSTEM 8 1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM Steering System FRONT WHEEL AND STEERING SYSTEM 8 2 TRO
25. park Plug Faulty C D I Unit Faulty Engine stop Switch Poor connection Broken or Shorted Wire Broken or Shorted Ignition Coil Broken or Shorted Spark Plug Wire Faulty Pulse Generator Worn Cylinder Worn Damaged piston Rings Damaged Piston Leaking Cylinder Head Gasket Auto Choke Off or Damaged Auto Choke Power Wire not connected Improperly Adjusted Air Screw Improper Ignition Timing Adjustment Fuel Air mixture ratio is too lean Carburetor Flooded Improperly Adjusted Air Screw Fuel Air mixture ration to rich Auto Choke stuck or damaged Air Cleaner Dirty 12 1 TROUBLE SHOOTING 12 2 POOR PERFORMANCE AT LOW IDLE SPEED Possible Problem Areas Faulty C D I Unit Faulty Pulse Generator Check Ignition Timing O K Check Carburetor Air Adjustment 4 Torop Aie Fuel Air mixture ratio to lean O K Check for Intake Manifold Leak Deteriorated Insulator O Ring Loose Carburetor Damaged Carburetor Gasket O K Test Spark Faulty Spark Plug Fouled Spark Plug Faulty C D I Unit Faulty Engine stop Switch Poor connection Broken or Shorted Wire Broken or Shorted Ignition Coil Broken or Shorted Spark Plug Wire Faulty Pulse Generator Weak or Intermittent Spark 9999 9 9 9 12 2 TROUBLE SHOOTING 12 3 POOR PERFORMANCE AT HIGH SPEED Check Ignition Timing O K Check Fuel Flow at Carburetor Low Fuel Flow
26. rs 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 meas urements 5 10 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 MAINTENANCE 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 gear box 2 7 3 ENGINE REMOVAL AND INSTALLATION ENGINE 3 1 ENGINE SHOULD NOT BE REMOVED UNLESS IT IS NECESSARY TO REPAIR OR MAKE ADJUSTMENTS TO THE TRANSMISSION AND OR COMBUSTION SYSTEM 3 2 ENGINE REMOVAL Remove the seat and rear fender See chapter 10 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 Remo
27. site 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 6 2 ENGINE COMBUSTION SYSTEM 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 meas ure 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 E from the skirts bottom Service limit 39 9 mm for 50cc engine 49 9 mm for 90cc engine 6 3 Measure the piston pin bore and the piston pin outer diameter Pin outer diameter service limit 9 96 mm for 50cc engine 11 96 mm for 90cc engine Pin bore service limit 10 04 mm for 50cc engine 12 04 mm for 90cc engine Measure the connecting rod small end inner diame ter with a small hole gauge Service limit 14 06 mm for 50cc engine 15 06 mm for 90cc engine 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 a
28. ug Disconnect the ignition coil primary wire Measure the primary coil resistance STANDARD 0 1 0 30 20 Measure the secondary coil resistance with the spark plug cap in place Standard 7 4 11 kO 20 11 3 IGNITION TIMING The ignition advance is 15 3 4000 The Capacitive Discharge Ignition CDI system is factory pre set and does not require adjustment 11 4 ALTERNATOR EXCITER COIL Remove the seat rear fender and front fender see chapter 10 Disconnect the exciter coil wire Measure the resistance between the yellow red wire and ground Standard 460 7000 20n 68n ELECTRICAL SYSTEM 11 5 BATTERY CAUTION The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate venti lation when charging or using the battery in an open area The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield Electrolyte is poisonous If swallowed drink large quantities of water or milk and call a physician 11 6 BATTERY INSPECTION Battery is under the seat you can see this battery from the left side Measure the battery voltage using a voltmeter VOLTAGE Fully charged 13 1 V Undercharged Below 12 0 V BATTERY REMOVAL Remove the battery holder bolt nuts Disconnect the negative cable and then the position cable and remove the battery BATTERY INSTALLATION Install the battery in
29. uretor cap to the carburetor 4 3 5 ENGINE LUBRICATION AND COOLING SYSTEM 5 1 ENGINE LUBRICATION SYSTEM The engine crankshaft drives the pump gears of oil pump The gears rotate the plunger shaft in oil pump This shaft sent the lubricating oil into the crankcase to mix with the air fuel mixture and 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 impor tant 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 togeth er Also you need to check the combustion system and lubrication system carefully 5 3 OIL PUMP The quantity of oil that is delivered from oil pump increases with 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 circulates the air The cooling fan is on the right hand side of engine The air is forced to flow through cylinder fin and cylinder head So the cylinder and piston will not overheat Fan Cooling 5 1 ENGINE LUBRICATION AND COOLING SYSTEM 5 5 TROUBLESHOOTING NO ENOUGH OIL SUPPLY TO ENGINE THE OIL LEVEL IN OIL TANK IS TOO LOW OIL TUBES WERE
30. ve the drive chain cover This is under the chain Remove the drive chain retaining clip and master Z link and remove the drive chain Remove the three engine hanger nuts and bolts Remove the engine from the right side of frame MS NY ETAINING CLIP fS 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 3 1 4 ENGINE FUEL SYSTEM ENGINE FUEL SYSTEM 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 ROUGH IMPROPER ADJUSTMENT TO IDLE SPEED SCREW STALLS OR RUNS POORLY 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 ROUGHLY FLOAT LEVEL IN CARBURETOR TOO LOW FLOAT NEEDLE VALVE IN CARBURETOR FAULTY FLOAT LEVEL TOO HIGH AIR DUCT IN CARBURETOR IS CLOGGED AIR CLEANER DIRTY 4 2 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 onc
Download Pdf Manuals
Related Search