User manual ETON ATV BXL 90 SERVICE MANUAL

[. . . ] INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. ENGINE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 12 4. ENGINE FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 5. [. . . ] 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 enlarge its turning radius. The aluminum fan is installed on the exterior of fixed drive face. It can reduce the belt temperature. 26 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. 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 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 (for 50cc engine), 47/15 (for 100cc engine). The second gear ratio is 48/12 (for 50cc engine), 31/11 (for 100cc engine). DISASSEMBLE TRANSMISSION BOX Unscrew fixing nut of rear wheel axle. Unscrew oil-leaking bolt at the bottom of crankcase. Torque value: M6: 1. 0 ­ 1. 2 kgf-m M10: 3. 5 ­ 4. 0 kgf-m 27 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. 7. 8 DISASSEMBLY AND CHECK OF C. V. T. SYSTEM Remove the engine clutch cover, by unscrew the fixed bolts. Disassembly the front drive pulley, check the six rollers for wear. If necessary, replace the rollers. 28 8. FRONT WHEEL AND STEERING SYSTEM 8. 1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM 8. 2 TROUBLESHOOTING 8. 3 HANDLEBAR 8. 4 FRONT WHEEL 8. 5 FRONT BRAKES 8. 6 SPEEDOMETER 8. 7 STEERING SYSTEM 8. 1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM FRONT WHEEL FRONT BRAKE STEERING SYSTEM HANDLEBAR 29 8. 2 TROUBLESHOOTING HARD STEERING FAULTY TIRE STEERING SHAFT HOLDER TOO TIGHT INSUFFICIENT TIRE PRESSURE FAULTY STEERING SHAFT BEARINGS DAMAGED STEERING SHAFT BEARING 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 BENT FRAME WORN SWING ARM PIVOT BUSHINGS BRAKE SHOES WORN WORN BRAKE DRUM IMPROPER BRAKE ADJUSTMENT FRONT WHEEL WOBBLING BRAKE DRAG STEERS TO ONE SIDE POOR BRAKE PERFORMANCE FRONT SUSPENSION NOISE HARD SUSPENSION 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 SOFT SUSPENSION 30 PS: ADJUST THE SUSPENSION Both the suspension is soft or too hard. One must adjust the suspension to an appropriate elasticity position. See the top right of the picture for adjustment tool. 8. 3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar. Remove the couple of brake switch assy. Remove engine switch housing on the left handle bar. Remove rear brake cable. Remove the bolts attaching the upper holder cover. [. . . ] Be careful it will be filled with the brake oil in reservoir beforehand, and then the wheel cylinder should drained the air. 52 12. ELECTRICAL SYSTEM 12. 1 TROUBLESHOOTING 12. 2 IGNITION COIL 12. 3 IGNITION TIMING 12. 4 ALTERNATOR EXCITER COIL 12. 5 BATTERY CAUTION 12. 6 BATTERY INSPECTION 12. 7 WIRING DIAGRAMS 12. 1 TROUBLESHOOTING ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG ENGINE STOP SWITCH AT " OFF " FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POOLY CONNECTED: 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 NO SPARK AT PLUG 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 LOOSE, BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH LOOSE BATTERY CONNECTION LOOSE CHARGING SYSTEM CONNECTION DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE FAULTY IGNITION SYSTEM ENGINE PROBLEMS FAULTY ENGINE STOP SWITCH THE SWITCH DO NOT PUSH TO THE "ON" POSITON THE LIGHT BULB IS BURN OUT, NEED BE REPLACED CHARGING SYSTEM FAILURE ENGINE INTERMITTENT POWER STARTER MOTOR WILL NOT TURN STARTER MOTOR AND ENGINE TURN, BUT ENGINE DOES NOT START HEAD LIGHT CAN NOT WORK 53 12. 2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0. 1 - 0. 3(20) Measure the secondary coil resistance with the spark plug cap in place. [. . . ]