User manual ETON YXL-150 SERVICE MANUAL

[. . . ] 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. [. . . ] of drive face collar. MOVABLE DRIVE FACE SERVICE LIMIT: 24. 098 mm Inspect the drive face boss for wear or damage. of drive face boss. DRIVE FACE BOSS SERVICE LIMIT: 23. 92 mm Inspect the clutch outer for wear or damage. of clutch outer. CLUTCH OUTER SERVICE LIMIT: 125. 5 mm Inspect the clutch weight set for wear or damage. Measure the thickness of clutch weight lining. CLUTCH WEIGHT LINING SERVICE LIMIT: 1. 5mm 46 Measure the length of driven face spring. SERVICE LIMIT: 164. 0 mm DRIVEN FACE SPRING Inspect the driven face assy. and replace them if necessary. 7. 4 KICK STARTER DISASSEMBLY Remove the L crank case cover. Remove the kick-starter. KICK STARTER L CRANK CASE COVER Remove the ex. circle-clip and washer from kick-starter spindle composition. EX. CIRCLIP 47 Rotate the kick-starter spindle composition to remove the kick driven gear and spring. Remove the kick-starter spindle composition and return spring. Remove the kick spindle bush. KICK RETURN SPRING KICK DRINEN GEAR KICK STARTER SPINDLE COMPOSITION INSPECTION Inspect the kick starter spindle composition for wear or damage. Inspect the kick return spring for fatigue or damage. Inspect the kick spindle bush for wear or damage. KICK SPINDLE BUSH Inspect the kick driven gear and spring for wear or damage. KICK DRIVEN SPRING 48 Inspect the machining surface for wear or damage. MACHINING SURFACE 7. 5 KICK STARTER ASSEMBLY Install the kick spindle bush, return spring and spindle assy. Install the kick driven gear and spring. Install the kick-starter. KICK STARTER 7. 6 C. V. T ASSEMBLY Compose the driven face assy. , spring and driven plate composition. 49 Compose the movable driven face composition, weight roller set and drives face. Install the movable drive face assy. and boss. MOVABLE DRIVE FACE Install the drive face and kick-starter ratchet. DRIVE FACE KICK STARTER RATCHET Install the driven belt and driven pulley assy. DRIVEN BELT DRIVEN PULLEY ASSY. 50 Install the dowel pins and gasket. DOWEL PINS GASKET Install the L crank case cover. L CRANK CASE COVER Install the gas waste recovery and C. V. T ducts. C. V. T DUCTS GAS WASTE RECOVERY 51 8. STEERING AND SUSPENSION 8. 1 PARTS DRAWING 8. 2 TROUBLESHOOTING 8. 3 HANDLENAR 8. 4 THROTTLE HOUSING 8. 5 STEERING SYSTEM 8. 1 PARTS DRAWING STEERING STEERING (For ATV YXL / CXL-150) (For ATV EXL-150 / EXL 150 (2004 two-passengers) / RXL-150 / EXL-150 (VIPER) 52 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 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 FRONT WHEEL WOBBLING STEERS TO ONE SIDE FRONT SUSPENSION NOISE HARD SUSPENSION SOFT SUSPENSION 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 assembly. 53 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. 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. 54 Install the rear brake lever bracket, aligning the boss with the hole. [. . . ] (Normal charging) Or 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. 12. 6 ELECTRIC STARTER Information A week battery may be unable to run the starter motor quickly enough. If the battery voltage is enough while the engine is not Cranking, the starter motor may be damaged. 91 TROUBLESHOOTING Starter Motor Turns Slowly Weak battery. [. . . ]