User manual ETON ATV BXL 100 SERVICE MANUAL

[. . . ] INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 13. TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 1 1. INFORMATION 1. 1 SAFETY 1. 2 NOTES 1. 3 SERIAL NUMBER 1. 4 SPECIFICATION 1. 5 TORQUE VALUES 1. 1 SAFETY Gasoline is extremely flammable and is explosive under certain condition. [. . . ] (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. 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. 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. 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. 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. 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. There are two bolts on top and another two bolts on the both sides. 31 When take the three up toward screws, it can remove the handlebar holder and handlebar. INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark with the tops of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward. 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 32 8. 4 FRONT WHEELS 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 castle nuts Torque: 40-60 N. m Remember put a cotter pin in the castle nut. 8. 5 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel. 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 86mm 33 Turn the inner race of each bearing with fingers. [. . . ] Torque: Exhaust muffler bolts 30-35 N. m After installation, make sure that there are no exhaust leaks. 47 11. HYDRAULIC DISC BRAKE SYSTEM 11. 1 TROUBLESHOOTING 11. 2 REPLACE BRAKE DISC 11. 3 REPLACE THE BRAKE SHOE 11. 4 REPLACE THE BRAKE HYDRAULIC OIL 11. 5 REAR BRAKE ADJUSTMENT 11. 1 TROUBLESHOOTING POOR BRAKE PERFORMANCE Improper brake adjustment Worn brake shoes Brake linings oily, greasy or dirty Worn brake cam Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area 11. 2 REPLACE BRAKE DISC Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper. 48 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. 11. 3 REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown and remove caliper. 49 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 50 11. 4 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 get 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. 51 Fill the brake oil to the level shown on the cup when no air comes out. [. . . ]