User manual ETON VIPER SERVICE MANUAL

[. . . ] CONTENTS 1. INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. ENGINE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . 14 4. LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6. CYLINDER / PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 7. TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 1 1. [. . . ] of weight rollers. WEIGHT ROLLER SERVICE LIMIT: 17. 40 mm 45 Measure the I. D. of movable driven face. SERVICE LIMIT: 28. 03mm Inspect the drive face collar for wear or damage. 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. CIRCLIP 47 Rotate the kick-starter spindle composition to remove the kick driven gear and 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. 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. Tighten the screw securely. Aligning the split line of the throttle housing and holder with the punch mark. [. . . ] Provide adequate ventilation when charging or using the battery in an open area. If swallowed drink large quantities of water or milk and call a physician. BATTERY VOLTAGE INSPECTION Battery is under the seat; you can see this battery after removing the seat. Measure the battery voltage using a voltmeter. VOLTAGE: Fully charged: 13. 1 V Undercharged: Below 12. 0 V 90 BATTERY REMOVAL Remove the seat, and then you can see the battery. Disconnect the negative cable and then the position cable and remove the battery. BATTERY INSTALLATION Install the battery in the reverse order of removal. [. . . ]