Eton VECTOR 250 - SERVICE Service manual

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ETON America
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Covers: VXL-250
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VECTOR Service Manual
Copyright ©2008-2009 ETON America, llc., all rights reserved.
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CONTENTS
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
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1. Information ........................................................................................................................ 5
1.1 Safety ........................................................................................................................... 5
1.2 Notes ............................................................................................................................ 5
1.3 Important Symbols And Specifications ....................................................................... 6
1.4 Serial Number .............................................................................................................. 9
1.5 Torque Values.............................................................................................................. 9
1.5 Torque Values............................................................................................................ 10
2. Maintenance..................................................................................................................... 11
2.1 Maintenance Data ...................................................................................................... 11
2.2 Maintenance Schedule ............................................................................................... 12
2.3 Fuel Tube ................................................................................................................... 12
2.4 Throttle Operation...................................................................................................... 13
2.5 Throttle Cable Adjustment......................................................................................... 13
2.6 Air Filter..................................................................................................................... 13
2.7 Spark Plug.................................................................................................................. 14
2.8 Idle Speed................................................................................................................... 14
2.9 Drive Chain................................................................................................................ 14
2.10 Brake System ........................................................................................................... 15
2 . 1 1 W h e e l s A n d T i r e s .......................................................................................... 17
2 . 1 2 S t e e r i n g S y s t e m .............................................................................................. 17
2 . 1 3 T o e - I n .................................................................................................................. 18
3. Engine Remove And Installation ..................................................................................... 19
3 . 1 G e n e r a l I n f o r m a t i o n.......................................................................................... 19
3 . 2 E n g i n e R e mo v a l .................................................................................................. 19
3 . 3 E n g i n e I n s t a l l a t i o n ............................................................................................ 20
4. Lubrication System .......................................................................................................... 21
4 . 1 M e c h a n i s m D i a g r a m ......................................................................................... 21
4.2 Maintenance Guidelines............................................................................................. 22
4.3 Troubleshooting ......................................................................................................... 22
4.4 Engine Oil .................................................................................................................. 23
4.5 Transmission Oil Change........................................................................................... 23
4.6 Oil Pump .................................................................................................................... 24
5. Fuel System...................................................................................................................... 27
5.1 Drawing Of The Fuel System .................................................................................... 27
5.2 Maintenance Information........................................................................................... 28
5.3 Troubleshooting ......................................................................................................... 29
5.4 Carburetor Removal / Installation.............................................................................. 30
5.5 Air Cut-Off Valve ...................................................................................................... 31
5.6 Throttle Valve ............................................................................................................ 32
5.7 Float Chamber............................................................................................................ 33
5.8 Adjustment Of Idle Speed.......................................................................................... 35
5.9 Fuel Tank ................................................................................................................... 36
5.10 Air Cleaner............................................................................................................... 37
6. Cylinder Head/Valve ....................................................................................................... 38
6.1 Mechanism Diagram.................................................................................................. 38
6.2 Operation Precautions................................................................................................ 39
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
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6.3 Troubleshooting ......................................................................................................... 40
6.4 Cylinder Head Removal............................................................................................. 41
6.5 Cylinder Head Inspection .......................................................................................... 44
6.6 Valve Stem Replacement........................................................................................... 47
6.7 Valve Seat Inspection And Service............................................................................ 48
6.8 Cylinder Head Reassembly........................................................................................ 50
6.9 Cylinder Head Installation ......................................................................................... 51
6.10 Valve Clearance Adjustment ................................................................................... 53
7. Cylinder/Piston ................................................................................................................ 54
7.1 Mechanism Diagram.................................................................................................. 54
7.2 Operating Details ....................................................................................................... 55
7.3 Troubleshooting ......................................................................................................... 55
7.4 Cylinder And Piston Removal ................................................................................... 56
7.5 Piston Ring Installation.............................................................................................. 59
7.6 Piston Installation....................................................................................................... 60
7.7 Cylinder Installation................................................................................................... 60
8. V-Belt Transmission System ........................................................................................... 62
8.1 Mechanism Diagram.................................................................................................. 62
8.2 Maintenance Description ........................................................................................... 63
8.3 Troubleshooting ......................................................................................................... 63
8.4 Left Crankcase Cover ................................................................................................ 64
8.5 Drive Belt................................................................................................................... 64
8.6 Drive Face.................................................................................................................. 66
8.7 Clutch Outer/Driven Pulley ....................................................................................... 69
9. Final Drive System .......................................................................................................... 75
9.1 Mechanism Diagram - Transmission Cover .............................................................. 75
9.2 Maintenance Notes..................................................................................................... 76
9.3 Troubleshooting ......................................................................................................... 76
9.4 Disassembly Of Transmission ................................................................................... 77
9.5 Transmission Mechanism Inspection......................................................................... 80
9.6 Bearing Replacement ................................................................................................. 82
9.7 Final Drive Reassembly............................................................................................. 85
10. A/C Generator & Starting Clutch .................................................................................. 87
10.1 Mechanism Diagram................................................................................................ 87
10.2 Maintenance Notes................................................................................................... 88
10.3 Right Crankcase Cover Removal............................................................................. 89
10.4 A/C Generator Removal .......................................................................................... 89
10.5 Right Cover Bearing ................................................................................................ 89
10.6 Flywheel Removal ................................................................................................... 90
10.7 Starting Clutch ......................................................................................................... 91
10.8 Flywheel Installation................................................................................................ 93
10.9 Acg Set Installation.................................................................................................. 94
10.10 Right Crankcase Cover Installation ....................................................................... 94
11. Crankcase / Crank .......................................................................................................... 96
11.1 Mechanism Diagram................................................................................................ 96
11.2 General Information................................................................................................. 97
11.3 Troubleshooting ....................................................................................................... 97
11.4 Crankcase Disassembly ........................................................................................... 98
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
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11.5 Crankshaft Inspection ............................................................................................ 100
11.6 Crankcase Assembly.............................................................................................. 101
12. Cooling System............................................................................................................ 104
12.1 Mechanism Diagram.............................................................................................. 104
12.2 General Information............................................................................................... 105
12.3 Troubleshooting ..................................................................................................... 106
12.4 Troubleshooting Flowchart.................................................................................... 106
12.5 System Test............................................................................................................ 107
12.6 Radiator.................................................................................................................. 108
12.7 Water Pump ........................................................................................................... 110
12.8 Thermostat ............................................................................................................. 114
13. Steering And Suspension ............................................................................................. 115
13.1 Parts Drawing......................................................................................................... 115
13.2 Troubleshooting ..................................................................................................... 117
13.3 Handlebar............................................................................................................... 117
13.4 Throttle Housing .................................................................................................... 120
13.5 Steering System ..................................................................................................... 120
14. Front Wheel And Brake System .................................................................................. 122
14.1 Parts Drawing......................................................................................................... 122
14.2 Troubleshooting ..................................................................................................... 123
14.3 Front Wheels.......................................................................................................... 124
14.4 Hydraulic Brake ..................................................................................................... 124
14.5 Suspension System................................................................................................. 126
15. Rear Wheel And Brake System ................................................................................... 127
15.1 Parts Drawing......................................................................................................... 127
15.2 Troubleshooting ..................................................................................................... 129
15.3 Rear Wheel And Rear Brake Removal .................................................................. 129
15.4 Swingarm & Rear Axle Holder.............................................................................. 133
16. Fenders And Exhaust Pipe ........................................................................................... 136
16.1 Fenders Drawing.................................................................................................... 136
16.2 Rear Fenders Removal........................................................................................... 137
16.3 Front Fender Removal ........................................................................................... 138
16.4 Exhaust Pipe Removal ........................................................................................... 139
17. Electrical System ......................................................................................................... 141
17.1 Troubleshooting ..................................................................................................... 141
17.2 Ignition Coil ........................................................................................................... 142
17.3 Ignition Timing ...................................................................................................... 142
17.4 Battery Information................................................................................................ 142
17.5 Electric Starter ....................................................................................................... 143
17.6 Light Bulb Replacement ........................................................................................ 143
17.7 Instrument Panel .................................................................................................... 145
18. Troubleshooting ........................................................................................................... 147
18.1 Engine Does Not Run ............................................................................................ 147
18.2 Poor Performance At Low And Idle Speeds.......................................................... 148
18.3 Poor Performance At High Speed.......................................................................... 148
18.4 Loss Of Power........................................................................................................ 149
18.5 Poor Handling ........................................................................................................ 150
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1.1 SAFETY
GASOLINE
Gasoline is extremely flammable and is explosive under certain conditions.
Do not smoke or allow sparks or flames in your work area.
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CARBON MONOXIDE
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.
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•
BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If
it comes into contact with any part of your body, flush the area thoroughly with
water. Call a doctor if electrolyte gets in your eyes.
HOT PARTS
Engine and exhaust pipe become very hot and remain hot for up to one hour after
the engine is run. Wear insulated gloves before handling these parts.
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USED ENGINE/GEAR OIL
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Used engine oil and gear oil may cause skin damage if it repeatedly comes into
contact with the skin for long periods of time. Keep out of reach of children. Dispose
of used gear and engine oil properly.
1.2 NOTES
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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.
ETON America, LLC. reserves the right to make changes at any time without notice and
without incurring any obligation whatever.
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No part of this publication may be reproduced without written permission.
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1. INFORMATION
Copyright ©2008-2009 ETON America, llc., all rights reserved.
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1.3 Important Symbols and Specifications
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Symbols will appear throughout the manual to indicate important information or tasks.
CAUTION – Safety notification. Proceed carefully.
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ADJUSTMENTS – Requires inspection, adjustment, or torque.
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FLUIDS – Lubrication or check and replace fluids.
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MULTIMETER – Diagnostics and electrical testing.
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MEASUREMENT – Gap and size measurements.
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SPECIAL TOOL – Uncommon tools may be required.
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GENERAL MAINTENCE PART – These parts may need to be replaced often. Part
numbers will be provided when applicable.
Copyright ©2008-2009 ETON America, llc., all rights reserved.
Engine
(Model No. VXL-250)
Four cycle , Single Cylinder, Liquid cooled
249cc
φ71mm * 63mm
10.6 : 1
22.3Nm @ 5500rpm / 16.4bhp
Meets or exceeds EPA clean air requirements/CA Green Sticker
Electrical with Kick starter back up
Transmission
Type
Automatic (C.V.T. V-Belt) Manual Shift (Fwr/Rev)
Chassis
Suspension
Dual A-arm Adjustable Shocks @ 2.95" travel
Swing Arm Adjustable Shock @ 4.72" travel
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Brakes
Front
Min
Max
Rear
Min
Max
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Tire Pressure
21/7-10
22/11-9
3.2psi / 0.23kg/cm2
4.0psi / 0.28kg/cm2
3.2psi / 0.23kg/cm2
4.0psi / 0.28kg/cm2
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Wheels
Bolt Pattern
4 x 110mm (P.C.D.)
520x15t
520x38t
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Front
Rear
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Sprockets
Kei-Hin with Manual choke
1.1mm
0.35mm
Back out 1 - 2½turns
Idle 1600 - 1800rpm
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Make/Size
Main Jet
Pilot Jet
Air Mixture Adjustment
Idle Speed
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Carburetor
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Hydraulic Disc (2)
Hydraulic Disc
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Front
Rear
Copyright ©2008-2009 ETON America, llc., all rights reserved.
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Front
Rear
Front
Rear
1780mm / 70.1"
1030mm / 40.6"
1140mm / 44.9"
1190mm / 46.9"
890mm / 35.0"
150mm / 5.9"
200kg / 441lbs
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Overall Length
Overall Width
Overall High
Wheel Base
Seat Height
Ground Clearance
Dry Weight
Tires
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Type
Displacement
Bore / Stroke
Compression Ratio / Pressure
Torque / BHP
EPA Approved
Starting
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Vector 250 ATV Specifications
#520*90 O-Ring
Battery
Jell Acid (Maintenance Free)
12V-9AH - GTX12-BS
Spark Plug
NGK
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NGK-CR8E
Electrode Gap
0.6-0.7mm / 0.023"
Available Colors
136kg / 301lb (Optional)
330kg / 727lb (Optional)
50kg / 110lbs
150kg / 330lbs
16 years
Red
Blue
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* Subject to availability
N/A
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Front
Rear
Trailer Wgh
Towing Capacity
Tongue Wgh
Maximum Rider Weight
Minimum Rider Age
Rack Capacity
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Carrying Capacity
Copyright ©2008-2009 ETON America, llc., all rights reserved.
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Transmission
Unleaded Gasoline 89 octane
12liters / 3.17gal
SAE 10-30W
1.4 liters / 1.5 qt (1.2 liters / 1.3 qt for change)
SAE 85/140 weight gear Oil
750cc / 25.4oz (650cc / 22oz for change)
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Engine Oil
Type
Volume
Type
Volume
Type
Volume
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Fuel
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Fluids
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Chain
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1.4 Serial Number
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The frame number is stamped on the front of the frame behind the
front bumper.
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The engine number is stamped on the left hand side of the crankcase.
Copyright ©2008-2009 ETON America, llc., all rights reserved.
5 N-m (3.5 lbf-ft)
10 N-m (7.2 lbf-ft)
22 N-m (16 lbf-ft)
35 N-m (25 lbf-ft)
55 N-m (40 lbf-ft)
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STANDARD
5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut
ENGINE
Cylinder head nut
Spark plug
Cylinder head bolt
Alternator bolt
FRAME
Handlebar upper holder bolt
Throttle housing cover screw
Steering shaft nut
Steering shaft holder bolt
Wheel rim bolt
Tie rod lock nut
King pin nut
Handlebar lower holder nut
Front wheel bolt
Front axle castle nut
Front brake arm nut
Rear brake arm nut
Rear axle castle nut
Rear wheel bolt
Exhaust muffler mounting bolt
Engine hanger bolt
Rear axle holder bolt
Swing arm pivot nut
Rear shock absorber mounting nut
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24 N-m (17.7 lbf-ft)
4 N-m (2.9 lbf-ft)
50 N-m (36.9 lbf-ft)
33 N-m (24 lbf-ft)
18 N-m (13.3 lbf-ft)
35 N-m (25.8 lbf-ft)
40 N-m (29 lbf-ft)
40 N-m (29.5 lbf-ft)
24 N-m (17.7 lbf-ft)
40-60 N-m (30-45 lbf-ft)
4 N-m (3.0 lbf-ft)
7 N-m (5.2 lbf-ft)
40-60 N-m (30-45 lbf-ft)
24 N-m (17.7 lbf-ft)
30 N-m (22.1 lbf-ft)
30 N-m ( 22 lbf-ft)
90 N-m (65 lbf-ft)
90 N-m (65 lbf-ft)
45 N-m (33 lbf-ft)
Copyright ©2008-2009 ETON America, llc., all rights reserved.
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28 N-m (20.7 lbf-ft)
12 N-m (8.9 lbf-ft)
20 N-m (14.8 lbf-ft)
8 N-m (5.9 lbf-ft)
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1.5 Torque Values
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2.1 MAINTENANCE DATA
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2. MAINTENANCE
SPECIFICATION
SPARK PLUG
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
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12-19 N-m / 8.9-14 lbf-ft
35-43 N-m / 25.8-31.7 lbf-ft
1.4 Liter (1.2Liter for change)
750cc / 25.4oz (650cc for change)
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GAP 0.6-0.7 mm / 0.023”
NGK CR8E
5-10 mm / 0.20 - 0.39”
1700±100 rpm
15-25 mm / 0.59 – 0.98”
10-25 mm / 0.39 – 0.98”
5±10 mm / 0.20 ± 0.39”
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SPARK PLUG
RECOMMENDED SPARK PLUGS
THROTTLE LEVER FREE PLAY
IDLE SPEED
BRAKE LEVER FREE PLAY
DRIVE CHAIN SLACK
TOE-IN
TORQUE VALUES
SPARK PLUG
TIE-ROD LOCK NUT
ENGINE OIL
GEAR LUBRICATION OIL
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Maintenance Schedule
Four Stroke Vehicles
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WP-0027
300KM 2000 Miles 3700 Miles 7500 Miles NEW 1 Month 3 Months 6 Months 1 Year C * I I I Change I I R(paper) C I R(sponge) R I Change I R I I I I I I I I I I I I I I I I I I/L I 11 12 Check crankcase for leakage Transmission oil 13 Drive belt/roller 14 Fuel tank switch and lines Throttle valve operation and cable 19 Cam Chain/ignition time 20 Valve clearance 21 Shock absorbers 22 Front/Rear suspension 23 Main/Side stands 25 Crankcase (PCV) Valve Brake mechanism/brake lin‐
ing (pad) 26 Tighten all Bolts/Nuts & Fas‐
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18 Engine bolts and nuts Cylinder head, cylinder, and piston Exhaust system/cleaning carbon w
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Check transmission for leak‐
age 5 Air cleaner element 2i
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I I * = Clean or replace the air cleaner element more often when the vehicle is operated on dusty R = Replace C = Clean (replaced if necessary) L = Lubricate # = Maintenance should be performed more often if the vehicle is frequently operated at high w
Code: I = Inspection, clean, and adjust w
roads or in a heavily polluted environment. speed for prolonged time and after the vehicle has accumulated 50,000 miles. w
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600 Miles 9 2 Every 12000KM 200 Miles I * I Air cleaner C Oil filter (Screen) Engine oil Change I Tire, pressure I Battery I Spark plug I Carburetor (idle speed) I Steering bearing and handles 1 Every 1000KM Every 3000KM Every 6000KM rts
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Scheduled Maintenance Copyright ©2008-2009 ETON America, llc., all rights reserved.
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2.2 MAINTENANCE SCHEDULE
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The internal maintenance in the following table is based on average riding in normal
temperate conditions. Riding in dusty areas requires more frequent servicing. E-TON
recommends that all maintenance and inspections be performed ONLY by a qualified
and fully trained technician.
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(Every 30 operating
days)
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2.3 FUEL TUBE
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Inspect the fuel lines for deterioration, damage,
or leaking. Replace if necessary.
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Note –
I: Inspect and Clean, Adjust, Lubricate, or Replace (if necessary)
C: Clean
L: Lubricate
R: Replace
Copyright ©2008-2009 ETON America, llc., all rights reserved.
EVERY
YEAR
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Fuel Line
Throttle Operation
Air Filter system &
Element
Spark Plug
Carburetor Idle Speed
Drive Chain
Brake Shoe Wear
Brake System
Nut, Bolt, Fastener
Wheels & Wheel Nuts
Steering System
Suspension System
Waste Gas Recovery
Valve
Intake & Exhaust Valve
Adj.
Gear & Engine Oil
REGULAR SERVICE
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INITIAL
SERVICE
(First week)
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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.
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Remove the four clips.
Remove the two screws inside the air
cleaner case.
Remove the air filter element from the air
cleaner case. Soak the element in nonflammable solvent. Squeeze out the solvent
thoroughly.
Let it dry.
Soak the filter element in gear oil and
then squeeze out the excess oil.
Reinstall the components into air the cleaner.
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2.6 AIR FILTER
Element
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Note: for more detail, see chapter 5-10
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Throttle
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
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•
Inspect for smooth throttle lever full opening and
automatic full closing in all steering positions.
Ensure that 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 available
lubricant to prevent premature wear.
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2.4 THROTTLE OPERATION
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With the sealing washer
attached, thread the spark plug
in by hand to prevent cross
threading.
Tighten the spark plug to 12-19 N-m.
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2.8 IDLE SPEED
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Connect an engine tachometer.
Allow the engine to idle for at least 10
minutes to warm it up.
Turn the idle-speed adjust screw on
the carburetor to obtain the idle
speed. “Turn in” (clockwise) to
increase speed. “Turn out” (counter
clockwise) to lower speed.
IDLE SPEED: 1700±100 rpm
2.9 DRIVE CHAIN
CHAIN SLACK:15-25mm (5/8-1”)
Upper Locking Nuts
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Turn off the ATV and shift the transmission
into neutral (N). Measure the drive chain slack
midway between the sprockets.
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•
•
811799 Spark Plug (NGK – CR8E)
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
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•
This spark plug is located at the
front of the engine. Disconnect the
spark plug cap and unscrew the
spark plug.
Check the condition of spark plug
electrodes for wear.
Replace if the electrodes and insulator
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 distance is
0.6-0.7mm.
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2.7 SPARK PLUG
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TORQUE: 90N-m (65 lb-ft)
When the drive chain becomes very
dirty, it should be removed, cleaned,
and lubricated. Use specialized chain
oil to lubricate the drive chain.
Clean the drive chain with
kerosene and wipe it dry. Inspect
the drive chain for any possible
wear or damage.
Replace the chain if it is worn
excessively or damaged.
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Inspect the sprocket teeth. If there is
excessive wear or damage, replace it.
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Inspect the front brake lever and
lines 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.
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The standard free play is 15-25 mm.
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2.10 BRAKE SYSTEM
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Lower Locking Nuts
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•
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•
Adjust the chain slack.
Loosen the upper and lower locking
nuts and turn the drive chain adjusting
nuts until proper slack is achieved.
Tighten the axle holder bolts.
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•
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Parking brake OFF
The standard is 15-25 mm.
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NOTE:
The rear brake master cylinder and reservoir is
located under the left hand rear fender. This
master cylinder is preset from the factory and
no adjustment is necessary. Ensure the fluid
is at the maximum level in the reservoir at all
times.
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.G
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Brake Fluid Dot-3 SAE-J1703 grade
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Parking brake ON
Page 16 of 151
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•
•
Inspect the rear brake lever and line
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.
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•
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The parking brake is shown in the picture.
When turned to the left side, the parking brake
is OFF. Turn it to the right side to set it ON.
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2.11 WHEELS AND TIRES
Inspect the tire surfaces for cuts, nails,
or other sharp objects.
•
Check each tire surface at cold tire
condition.
•
The standard tire pressure is 3.2-4.0
psi (maximum).
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2.12 STEERING SYSTEM
Check the free play of the
steering shaft with the front
wheels turned straight ahead.
•
If there is excessive play, inspect the
tie-rod, kingpin bushing, and ball joint.
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•
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Remove the front fender.
Remove the steering shaft holder and
check the steering shaft bushing for
wear or damage.
If the bushing is worn or damaged,
replace it.
Grease the steering shaft bushing
and install the parts in the reverse
order of removal.
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Torque: steering shaft holder bolt: 33
N-m (24 lbf-ft)
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STEERING SHAFT HOLDER BUSHING
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•
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Carefully move the vehicle backward,
letting the wheels turn 180 degrees, so
the marks on the tires are aligned with
the axle center height.
Measure the distance between the
marks.
Calculate the difference between the
front and rear measurements.
Toe-in: 5±10mm
•
•
If the toe-in is out of the specification,
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
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Locking Nut
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Place the vehicle on level ground and
align the front wheels so they are
facing straight ahead.
Mark the centers of the tires to indicate
the axle center height.
Measure the distance between the
marks.
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2.13 TOE-IN
3.1 General Information
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ENGINE SHOULD BE REMOVED ONLY WHEN NECESSARY TO REPAIR
OR ADJUST THE TRANSMISSION OR COMBUSTION SYSTEMS.
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3.2 ENGINE REMOVAL
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Before removing engine, remove all of components such as seat, front and rear body cover,
fuel tube, exhaust pipe, carburetor cable and drive chain. The engine is attached with three
hanger bolts which will be visible after removing the components.
.G
et
Loosen these three hanger bolts. Two of these are in the rear of the engine, and one is in the
front. The engine can now be removed.
.G
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Front hanger bolt.
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•
Remove the drive chain cover.
Remove the drive chain retaining clip and
master link.
Remove the drive chain.
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Disconnect the wire connectors. There are three connectors: carburetor auto-choke,
starter motor, and generator.
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3. ENGINE REMOVE AND INSTALLATION
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Top rear hanger bolt.
•
Lower rear hanger bolt.
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3.3 ENGINE INSTALLATION
.G
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Torque the engine hanger bolts to 30 N-m (22.1 lbf-ft).
Reroute the throttle cable.
Connect the carburetor cable and all fuel lines.
Reinstall the drive chain.
Install the exhaust pipe.
Ensure all electrical connections are properly connected (A/C
generator, starter motor, etc.)
Reinstall the front and rear body covers.
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•
•
•
•
•
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Hanger bolt
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4. LUBRICATION SYSTEM
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4-1 Mechanism Diagram
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4-2 Maintenance Guidelines
General Information:
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This chapter contains maintenance information for
the engine oil pump and gear oil replacement
information.
Inner rotor clearance
Clearance between outer rotor and body
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Oil pump
Items
Torque value
Limit (mm)
0.15
0.20
0.15~0.20
0.25
0.04~0.09
0.12
14.7 N-m / 10.8 lbf-ft – 29 N-m / 22 lbf-ft
19 N-m / 14 lbf-ft – 25 N-m / 18 lbf-ft
10 N-m / 7 lbf-ft – 15 N-m / 10.7 lbf-ft
8 N-m / 5.8 lbf-ft – 12 N-m / 8.7 lbf-ft
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Torque value oil strainer cap
Engine oil drain bolt
Gear oil drain bolt
Oil pump connection bolt
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Clearance between rotor side and body
Standard (mm)
4-3 Troubleshooting
•
•
•
Oil leaking
Valve guide or seat worn out
Piston ring worn
Low engine oil level
Clog in oil strainer, circuits, or pipes
Oil pump damaged
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•
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Low oil pressure
Dirty oil
.G
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Change oil periodically
Cylinder head gasket damaged
Piston ring worn
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Low engine oil level
Page 22 of 151
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Engine oil quantity (initial): 1.4L / 1.5 qt
Engine oil quantity (replace): 1.2L / 1.2 qt
Oil viscosity: SAE 10W-30 (Recommended
King serial oils)
Gear oil quantity (initial): 750cc / 25oz
Gear oil quantity (replace): 650cc / 22 oz
Gear oil viscosity: 85/140 Gear Oil
(Recommended SYM Hypoid gear oils)
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Specifications
Drain oil when the engine is warm so it drains completely.
Place an oil pan under the ATV.
Remove the oil drain bolt.
Drain the oil.
Remove the oil strainer and spring.
Clean the oil strainer.
Check the O-ring, and replace if necessary.
Install oil drain bolt, spring, and strainer.
Torque value: 19 N-m / 14 lbf-ft – 25 N-m / 18 lbf-ft
Add recommended oil (SAE 10W30) – 1.2L / 1.2 qt.
Start the engine and allow to run for several minutes.
Stop the engine and check the engine oil level again,
Verify there are no engine oil leaks.
Strainer
.G
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O-Ring
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Drain Bolt
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Drain Bolt
Drain oil when the engine is warm so it drains completely.
Place an oil pan under the ATV.
Remove the oil drain bolt.
Drain the oil.
Verify the washer can be reused. Replace if not.
Install the drain bolt.
Torque the drain bolt: 10 N-m / 7 lbf-ft – 15 N-m / 10.7 lbf-ft
Add recommended gear oil
(85/140 W Gear oil) – 650cc / 22oz
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4-5 Transmission Oil Change
•
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Dipstick
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•
Turn off engine, and park the ATV on a flat surface.
Check the oil level with oil dipstick. Do not screw in
the dipstick when checking the level.
If the level is low, fill with the recommended oil to the
upper level.
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4-4 Engine Oil
Page 23 of 151
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Transmission Gear
Oil Drain Bolt
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4-6 Oil Pump
Oil Pump Removal
• Remove generator and starting gear.
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Remove cir clip and take out the oil pump driving chain
and sprocket.
Make sure that pump shaft can be rotated freely.
Remove the 2 screws on the oil pump.
Remove the oil pump.
Remove the screws on oil pump cover and remove the cover.
Remove oil pump shaft roller and shaft.
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Oil Pump Disassembly
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Retaining
Bolts
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Circle Clip
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(Refer to chapter 10)
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Retaining
Screw
Roller
Oil Pump Inspection
Check the clearance between oil pump body and outer rotor.
Limit: 0.25 mm
•
Check the clearance between the inner and outer rotors.
Limit: 0.20 mm
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Page 24 of 151
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Roller
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Check the clearance between the rotor side face and
pump body.
Limit: 0.12 mm
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Tighten the oil pump screw.
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•
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Pins
Install the inner and outer rotors into the pump body.
Align the indention on the driving shaft with
the mark on the inner rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins properly.
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Oil Pump Installation
Screw
Install the oil pump and tighten screws.
Torque value:
•
Ensure the oil pump shaft can be rotated freely.
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Oil Pump Assembly
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Install the oil pump drive chain and sprocket.
Install the cir clip onto the oil pump shaft.
Install the starting gear and generator. (Refer to chapter
10)
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5. FUEL SYSTEM
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5-1 Drawing of the Fuel System
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Manifold
Page 27 of 151
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Fuel
General Information
Warning
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Gasoline is flammable and explosive, so always work in a well-ventilated place and
strictly prohibit smoking or flames when working with gasoline.
Caution
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• Do not bend the throttle cable.
• When removing fuel system components, remember where O-rings were
positioned, and replace them when reassembling the components.
• Drain gasoline using the drain screw on the float chamber before removing it.
• Do not remove the choke valve unless absolutely necessary.
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Tools
Special service tools
.G
et
• Vacuum/air pressure pump
• Fuel level gauge
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Carburetor Specifications
Component
Specification
Carburetor diameter
I.D. number
PTG 050
Fuel level
Idle speed
# 110
# 35
1700 ± 100rpm
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Throttle lever clearance
Air screw
1-3 mm
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Idle injector
.G
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Main injector
14.8mm
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1 1/2 turns out
Page 28 of 151
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25mm
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5-2 Maintenance Information
Engine Will Not Start
Mixture too rich
Rough idle
Intermittent Misfires When Accelerating
• Malfunctioning ignition system
2i
• Malfunctioning ignition system
• Incorrect idle speed
• Malfunctioning carburetor
• Fuel dirty
• Clogged air jet
• Malfunction of float valve
• Fuel level too high in float chamber
• Malfunction of carburetor choke
• Dirty air cleaner
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Malfunctioning carburetor choke
Incorrect ignition timing
Malfunctioning carburetor
Dirty engine oil
Air remaining in intake system
• Idle speed too low
Late Ignition Timing
Clogged fuel jet
Vacuum piston stuck and closed
Malfunctioning float valve
Fuel level too low in float chamber
Clogged fuel tank cap vent
Clogged fuel filter
Obstructed fuel pipe
Clogged air vent hose
Air remaining in intake system
Loss of Power
• Fuel system clogged
• Malfunctioning ignition system
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• Malfunctioning ignition system
• Malfunctioning carburetor
Page 29 of 151
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•
•
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Engine Dies After Starting
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Mixture Too Lean
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No fuel in fuel tank
Clogged fuel tube
Too much fuel in cylinder
No spark from spark plug
(malfunctioning ignition system )
• Clogged air cleaner
• Malfunctioning carburetor choke
• Malfunctioning throttle
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5-3 Troubleshooting
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5-4 Carburetor Removal / Installation
Removal
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Clamp
Ensure the drain screw is tightened. Install carburetor into intake and tighten the two
nuts. Reconnect all vacuum and fuel lines. Reconnect the air boot from the air box.
Turn the fuel petcock on and check for leaks.
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Fuel Line
.G
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Installation
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•
Vacuum Line
Choke Cable
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Remove the top of the carburetor from the
carburetor.
Remove the 2 intake nuts.
Remove the carburetor.
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Screw
Disconnect the fuel hose.
Release the clamp strip on the air cleaner.
.G
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•
•
Drain Bolt
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Loosen the choke cable fixed screw
from the plate.
Remove the choke cable.
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Drain the fuel from the float chamber by loosening
the drain bolt.
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Disassembly
Remove the two screws to gain access to
the air cut-off valve.
•
Remove the air cut-off valve cover,
spring, and valve.
•
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Check the valve for damage or wear.
If the valve is undamaged, it will restrict air
flow.
If air flow is not being restricted, install a
new carburetor kit.
Ensure the vacuum pipe O-ring is
undamaged and can be reused.
Install in reverse order of removal.
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Assembly
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Inspection
Page 31 of 151
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5-5 Air Cut-Off Valve
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5-6 Throttle Valve
Disassembly
Disconnect the throttle cable from the
throttle slide and remove the valve spring.
Remove the fuel needle clip and fuel
needle.
Assembly
•
•
Carburetor
Cap
2i
•
Place the fuel needle onto the throttle slide
and clip it with the needle clip.
Install the sealed cap, carburetor cap, and
throttle valve spring.
Connect the throttle valve cable to the
throttle slide.
Install the throttle slide into the carburetor
body.
.G
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•
Clip
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Caution
Align the groove inside the throttle valve with the
throttle stopper screw of the carburetor body.
Reattach the carburetor cap.
Adjust the free play of throttle valve cable.
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Throttle
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•
Unscrew the carburetor cap to gain access to the
throttle cable, slide, and needle.
Remove the throttle slide and throttle cable.
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Carburetor Cap
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Float
Float Pin
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Check the float valve and valve seat for
damage or blockages.
Check the float valve for wearing, and check
the valve seat face for wear or dirt.
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Inspection
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Remove the float pin, float, and float valve.
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Disassembly
• Remove the three mounting screws.
• Remove the carburetor bowl.
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Float Valve
.G
et
Caution
In case of wear or dirt, the float valve and valve
seat will not tightly seal, causing the fuel level to
increase and as a result, fuel flooding. A worn out
or dirty float valve must be replaced with a new
one.
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5-7 Float Chamber
Page 33 of 151
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Remove main jet, needle jet holder, needle jet,
slow jet, and air adjustment screw.
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Assembly
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Install main jet, needle jet holder, needle jet,
slow jet, and air adjustment screw.
Install the float valve, float, and float pin.
.G
et
•
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Caution
Set the air adjustment screw according to number
of turns noted before it was removed
Caution
•
.G
et
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Check to ensure the float valve and float are
properly installed.
To ensure correct measurement, position the
float meter in such a way that float chamber face
is vertical to the main jet.
Fuel level: 14.8mm
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Carburetor Installation
•
Install the carburetor in the reverse order of
removal.
These adjustments must be made after
installation: throttle cable adjustment, and idle
adjustment.
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Checking fuel level
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Page 34 of 151
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Clean the jets with cleaning fluid.
Use compressed air to blow the dirt off.
Clean carburetor body passages with the
compressed air.
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•
•
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Caution
Do not damage the jets and adjust screw.
• Before removing adjustment screw, turn it all
the way down and note the number of turns.
• Do not turn adjust screw forcefully to avoid
damaging the valve seat face.
•
Use a tachometer when adjusting engine
RPM.
Screw in the air adjustment screw gently, then
back out to reach the standard.
Standard turns: 1 ½ turns out
•
Warm up the engine.
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•
•
•
Accelerate in small increments.
Ensure the RPM and CO values remain
standard after the engine returns to idle.
If the RPM or CO values fluctuated, repeat
the procedures described above for
adjusting to standard value.
Idle Adjustment Screw
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Connect an exhaust analyzer hose to the
exhaust front end. Press the test key on the
analyzer.
Adjust the pilot screw and read CO reading
on the analyzer.
CO standard value: 1.0-1.5%
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•
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•
Adjust the throttle stopper screw on the
throttle valve to reach standard RPM.
Idle speed rpm: 1700 ± 100 rpm
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Air Mixture Screw
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Caution
The air screw is factory set, so no adjustment is
needed. Note the number of turns it takes to
screw it all the way in.
Use the parking brake to park the ATV before
making adjustments.
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5-8 Adjustment of Idle Speed
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5-9 Fuel Tank
Fuel Tank Removal
Remove the seat
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender (see chapter 13).
Remove the 4 bolts
Remove the fuel sending unit
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Caution
•
Fuel Unit Installation
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When removing the sending unit, be careful to
not bend the arm on the fuel sending unit.
Some fuel needs to be drained from the tank to
ensure that no fuel will spill when the sending
unit is removed.
Install the gauge in the reverse order of removal.
.
Fuel Tank Removal
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Remove the seat
Remove the front cover and fuel tank.
Remove the side covers and lower side covers.
Remove the front fender. (See chapter 13)
Disconnect fuel unit coupler.
Remove fuel unit (4 bolts).
Remove the fuel tube.
Remove the vacuum tube.
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•
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Caution
Remember to install the fuel unit gasket. Do not
allow the gasket to be damaged.
Page 36 of 151
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5-10 Air Cleaner
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Installation
Cleaning air cleaner element
•
•
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Remove the air cleaner cover (4 latches).
Remove the element mounting screw.
Loosen the air cleaner element clamp strip,
and then remove the air cleaner element.
Clean the element with non-flammable or
high-flash point solvent and then squeeze
out the excess fluid.
Let it dry.
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et
•
•
•
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Install the tank in the reverse order of removal.
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•
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Soak the element in clean engine oil and
squeeze out the excess fluid.
Install the element onto the element seat.
Install the air cleaner cover.
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Element clamp
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Caution
Never use gasoline or acidic solvent to
clean the element.
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•
Loosen the air cleaner and carburetor clamp.
Remove the vapor hose.
Loosen the air cleaner clamp, and then
remove the air cleaner vapor hose.
Remove the air cleaner (4 clips)
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Removal
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Fuel tank bolts
Page 37 of 151
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Element mounting
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6. CYLINDER HEAD/VALVE
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Page 38 of 151
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6-1 Mechanism Diagram
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6-2 Operation Precautions
General Information
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This section contains maintenance and service information for the cylinder head, valve, and
camshaft, as well as the rocker arm.
Cylinder head service can be carried out when the engine is in the frame.
CYLINDER HEAD Specifications
Compression pressure
Intake
Exhaust
ID of valve rocker arm
Rocker arm
ID of valve guide
Clearance between
valve stem and guide
Exhaust
140psi
5.90mm
5.85mm
5.70mm
5.65mm
11.982~12.000mm
12.080mm
11.966~11.984mm
11.936mm
4.975~4.990mm
4.900mm
4.950~4.975mm
4.900mm
5.000~5.012mm
5.030mm
Intake
0.010~0.037mm
0.080mm
Exhaust
0.025~0.062mm
0.100mm
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Valve
Free length of valve
spring
Intake
38.700mm
Exhaust
40.400mm
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Intake
OD of valve stem
170±30psi
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OD of valve rocker arm shaft
Limit
Valve seat width
Exhaust
0.15±0.02mm or .006”
-
---
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7 -10 lbf-ft
17-22 lbf-ft
7 -10 lbf-ft
26-29 lbf-ft
6-9 lbf-ft
9-12 lbf-ft
7 -10 lbf-ft
7 -10 lbf-ft
5-8 lbf-ft
7-9 lbf-ft
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4.000mm
-
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36.900mm
0.10±0.02mm or .004”
Tilt angle of cylinder head
Torque Values
Bolt
Exhaust pipe stud bolt
Cylinder head bolt
Cylinder head Nut
Sealing bolt of cam chain auto-tensioner
Bolt of cam chain auto-tensioner
Cylinder side cover bolt
Cam sprocket bolt
Tappet adjustment screw nut
Spark plug
35.200mm
Intake
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Valve clearance
3.400mm
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Height of cam lobe
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Camshaft
Standard
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Item
Page 39 of 151
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0.050
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor
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6-3 Troubleshooting
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Engine performance can be affected by problems in the top end. The trouble usually can be
determined or by performing cylinder compression test and judging the abnormal noise
generated.
Low compression pressure
1. Valve
Improper valve adjustment
Burnt or bent valve
Improper valve timing
Valve spring damage
Valve carbon deposit
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2. Cylinder head
Cylinder head gasket leaking or damage
Tilted or cracked cylinder
•
Piston ring worn out
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3. Piston
High compression pressure
Too much carbon deposit on combustion chamber or piston head
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Improper valve clearance adjustment
Burnt valve or damaged valve spring
Camshaft worn out or damaged
Chain worn out or loose
Auto-tensioner worn out or damaged
Camshaft sprocket
Rocker arm or rocker arm shaft worn out
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Noise
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Special Service Tools
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6-4 Cylinder Head Removal
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Page 41 of 151
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Spark plug
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Remove the side cover mounting bolts of
cylinder head, and then take out the side cover.
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Tensioner bolts
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Remove Air Injection system (AI) pipe
mounting bolts.
Remove the spark plug.
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Thermostat Bolts
Remove the 2 thermostat bolts and then remove
the thermostat.
Remove the cam chain tensioner bolt and relax the
cam chain
Loosen the bolts, and then remove the tensioner
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Remove the engine. (Refer to chapter 5)
Remove the inlet pipe (2 nuts).
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Remove the cam shaft setting plate (1 bolt).
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Remove the cam shafts.
Special Service Tool Needed: Rocker
arm and cam shaft puller
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Rocker Arm
Shafts
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Setting Plate
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Remove rocker arm shafts and rocker arms.
Special Service Tool Needed: Rocker
arm and cam shaft puller
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Remove the LH clutch cover and turn the
drive face counterclockwise, aligning the timing
mark on the sprocket with that of cylinder head
so the piston is at the TDC position.
Remove cam sprocket bolts.
Remove the sprocket by prying the chain out.
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Timing Marks
Page 42 of 151
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Cam Shafts
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Remove the cylinder head gasket and dowel pins.
Remove the chain guide.
Clean any gasket material from the surfaces of the
cylinder and cylinder head. Do not scratch the
surfaces or allow any material to fall into the
crankcase.
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Use a valve cotter removal & assembly tool to
depress the valve spring. Do not compress
the spring too much to preserve its elasticity.
Remove the valves.
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Mounting Bolts
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Remove the 2 cylinder head mounting bolts from the
cylinder head right side.
Remove 4 nuts and washers from cylinder head
upper side.
Remove the cylinder head.
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Cylinder
Head
•
Clean any carbon deposits in the combustion
chamber.
Clean residue and foreign materials from the cylinder
head matching surface. Do not damage the surface
of the cylinder head.
•
Check if the spark plug or valve holes are cracked.
Replace if necessary.
Measure cylinder head warping with a straightedge
and thickness gauge.
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6-5 Cylinder Head Inspection
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Camshaft
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Inspect the cam lobe height for damage.
Service Limit:
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IN: Replace if less than 34.45mm.
EX: Replace if less than 34.30mm.
Inspect the camshaft bearing for looseness or
wear. If any damage, replace the camshaft and
bearing.
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Service limit: 0.5 mm
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Remove the valve stem seals.
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Rocker Arm
Check the rocker arm for wear or damage.
Measure the rocker arm cam inner diameter.
Rocker Arm Shaft
•
Measure the active O.D. of the rocker arm cam
shaft and cam rocker arm.
Service Limit: Replace when less than 11.91 mm.
Find the clearance between the rocker arm
shaft and the rocker arm.
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Valve spring free length
Valve stem
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Check if valve stems are bent, cracked, or burned.
Check the operation condition of valve stem in
the valve guide.
Measure & record the valve stem outer diameter.
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Service limit:
Inner spring 35.00 mm
Outer spring 39.00 mm
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Service Limit:
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IN: 4.90 mm
EX: 4.90 mm
Page 45 of 151
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Measure the relaxed length of the intake and exhaust
valve springs.
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Service Limit: Replace when less than 0.10mm.
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Service Limit: Replace when less than 12.10 mm.
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Valve guide
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Before measuring the valve guide, clean any
carbon deposits with a reamer.
Service limit: 5.03 mm
The inner diameter of the valve guide minus the
outer diameter of the valve stem is the clearance
between the valve stem and valve guide.
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Service Limit:
IN→0.08 mm
If clearance between the valve stem and valve guide
exceeds the service limit, check whether replacing
the valve guide will bring it into service limit.
If so, replace just the valve guide.
•
If clearance still exceeds the service limit after
replacing the valve guide, replace the valve stem as well.
•
Do not damage the valve seat when replacing the valve
guide.
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EX→0.10 mm
Page 46 of 151
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Measure and record each valve guide inner
diameter.
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Tool: 5.0 mm valve guide reamer
Heat up cylinder head to 100-150C (212- 300F) with a hot
plate or other device.
Caution
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Do not heat the cylinder head directly. Otherwise, the
cylinder head may be deformed.
Wear a pair of gloves to protect your hands
when operating.
•
Hold the cylinder head and press out the old
valve guide from the combustion chamber side.
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Tool: Valve guide driver: 5.0 mm
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Use cutting oil when correcting the valve guide with
a reamer.
Turn the reamer in same direction when it is inserted
or rotated.
Adjust the valve seat. Clean all metal residue from
the cylinder head.
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Check if the new valve guide has deformation after
being pressed it in.
When pressing in the new valve guide, ensure the
cylinder head is kept at the same temperature
(100-150C).
Adjust the valve guide driver until the valve guide
height is 13 mm.
Press in a new valve guide from rocker arm side.
Wait for the cylinder head to cool down to room
temperature, and then correct the new valve guide
with the reamer.
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6-6 Valve Stem Replacement
Remove the valve and check its contact face.
Replace the valve if the valve seal is rough, worn out,
or does not come into contact with the valve seat.
If the valve seat is too wide, narrow, or rough,
adjust or replace it.
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Valve seat width
Service limit: 1.6mm
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Check the condition of the valve seat surface.
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Valve seat grinding
The worn valve seat has to be ground with a valve
seat chamfer cutter. Refer to operation manual for
the valve seat chamfer cutter.
•
Use a 45° valve seat chamfer cutter to cut any rough
or uneven surfaces from the valve seat.
•
After valve guide had been replaced, it has to be
ground with a 45° valve seal chamfer cutter to
correct its seat face.
Use 32° cutter to cut the quarter upper parts out.
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•
Do not let emery enter between the valve stem
and valve guide.
Clean up the emery when finished, and apply
engine oil onto the contact faces of valve and
valve seat.
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Clean up any carbon deposits on the intake and
exhaust valves.
Apply emery carefully onto valve contact face.
Grind the valve seat with a rubber hose or other
manual grinding tool.
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6-7 Valve Seat Inspection and
Service
Use a 60° cutter to cut the quarter lower parts out.
Remove the cutter and check the new valve seat.
•
Use a 45° cutter to grind the valve seat to the
specified standard width.
Make sure that all roughness and uneven faces
have been ground.
Grind the valve seat again if necessary.
•
If the contact surface is too high, grind the valve
seat with a 32° cutter. Then, grind the valve seat to
the specified width.
If the contact surface is too low, grind the valve
seat with a 60° cutter. Then, grind the valve seat to
the specified width.
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The contact surfaces of the valve and valve seat
are very important to the valve sealing capacity.
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Coat the valve seat surface with red paint.
Install the valve through valve guide until the
valve touches the valve seat.
Slightly press down the valve but do not rotate
it so that a seal track will be created on the
contact surface.
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After the valve seat is ground, coat valve seat surface
with emery and then carefully press the ground
surface.
Clean up all emery coated onto cylinder and valve
after grinding.
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NOTE: The valve spring closed coils should
face down toward the combustion chamber.
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In order to avoid damaging the valve stem and the
cylinder head, place a rag in the combustion chamber
inside by the valve spring remover/installer while
compressing the valve spring.
•
Tap the valve stems gently with a plastic hammer
to make sure valve retainer and valve cotter are
secure.
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Place the cylinder head on a working table
to prevent damage to the valve.
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Use a valve cotter removal & assembly tool to press
the valve spring; then, remove the valves.
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Lubricate the valve stem with engine oil
Insert the valve into the valve guide.
Install a new valve stem oil seal.
Install the valve springs and retainers.
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6-8 Cylinder Head Reassembly
Install the 4 washers and tighten the 4 nuts on the
top of the cylinder head, and then tighten the 2
cylinder head mounting bolts on the right side of
the cylinder.
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Install the camshaft into the cylinder head.
Install the rocker arm and rocker arm shaft.
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Torque values:
Nut: 26-29 lbf-ft
Bolt: 7-10 lbf-ft
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Install the rocker arm pin mounting plate.
Page 51 of 151
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Do not damage the surfaces of the cylinder
and cylinder head.
Do not allow any gasket material to fall into
the crankcase.
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Clean off any residue and foreign materials on the
surfaces of the cylinder and cylinder head.
Install the chain guide, dowel pins and a new cylinder
head gasket onto the cylinder.
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6-9 Cylinder Head Installation
•
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Install the cylinder head side cover (3 bolts).
Install the thermostat (2 bolts).
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Install cylinder cover (4 bolts).
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Thermostat
bolts
Loosen the auto tensioner adjustment bolt and
remove the bolt and spring.
Install the tensioner and install the spring and
adjustment bolt.
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Install the cam chain onto the sprocket and align the
timing mark on the sprocket with that of cylinder
head.
Align the sprocket bolt hole with the camshaft bolt
hole.
Tighten the sprocket mounting bolts.
Page 52 of 151
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Tensioner
adjustment
bolt
Install the Air Injection system pipe. (4 bolts)
Install the inlet pipe onto the cylinder
Install and tighten the spark plug
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Spark plug
Torque value: 7-14 lbf-ft
6-10 Valve Clearance Adjustment
Loosen the two Air Injection system pipe upper side
bolts.
Remove the cylinder head cover.
Remove the cylinder head side cover.
Remove the left crankcase cover.
Turn the drive face, and align the timing mark on the
cam sprocket with that of the cylinder head with the
piston at the TDC position.
Loosen the valve clearance adjustment nuts and
bolts located on the valve rocker arm.
Measure and adjust valve clearance with a feeler
gauge.
After valve clearance had been adjusted to standard
value, hold the adjustment bolt and tighten the
adjustment nut.
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Install the cylinder head side cover.
Start the engine and make sure that engine oil flows
onto the cylinder head.
Stop the engine after confirming.
Install the cylinder head cover and AI pipe.
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Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
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If lubricant does not flow to the cylinder head, engine
components will be seriously damaged.
•
When checking lubricant flowing condition, run the
engine in idle speed. Do not accelerate the engine.
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Install the engine onto the frame (see chapter 5).
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This model is equipped with a special precision 4-valve
mechanism so its tightened torque can not exceed
the standard value in order to avoid causing cylinder
head deformation, engine noise, and leaking that affect
the vehicle’s performance.
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7. CYLINDER/PISTON
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7-1 Mechanism Diagram
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7-2 Operating Details
General Information
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Remove the engine from the frame before servicing the piston or cylinder.
Cylinder Specifications
70.995-71.015
71.100
-
0.050
Top ring
2nd ring
0.015-0.050
0.090
0.015-0.050
0.090
Top ring
2nd ring
0.150-0.300
0.500
0.300-0.450
0.650
Oil ring side rail
0.200-0.700
-
70.430-70.480
70.380
0.010-0.040
0.100
17.002-17.008
16.970
16.994-17.000
16.960
0.002-0.014
0.020
17.016-17.034
17.064
ID
Bend
Clearance between piston
rings
Ring-end gap
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Piston/ Piston
ring
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OD of piston (2nd)
ID of piston pin boss
OD of piston pin
Clearance between piston and piston pin
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7-3 Troubleshooting
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ID of connecting rod small-end
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Clearance between piston and cylinder
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Low or Unstable Compression Pressure
Cylinder or piston ring worn out
Knocking or Noise
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Cylinder or piston ring worn out
Carbon deposits on cylinder head top
Piston pin hole and piston pin worn out
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Smoke in Exhaust Pipe
Piston or piston ring worn out
Piston ring installed improperly
Cylinder or piston damaged
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Engine Overheats
Carbon deposits on cylinder head top
Cooling pipe clogged or not enough coolant in flow
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Limit
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Cylinder
Standard
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Item
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Check if the inner diameter of cylinder is worn out
or damaged.
In the top, center, and bottom, of the cylinder,
measure the X and Y values in respect
to the cylinder.
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Inspection
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Service limit: 71.016 mm
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Remove the cylinder gasket and dowel pin.
Clean up all gasket residue or foreign materials from
the surfaces of the cylinder and crankcase. Use a
solvent to remove the residue if necessary.
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Cover the openings in the crankcase and cam chain
with a rag or piece of cloth.
Remove the piston pin clip, and then remove piston
pin and piston.
Coolant hose
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Remove the cylinder head (refer to chapter 6).
Remove the coolant hose from cylinder.
Remove the cylinder.
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7-4 Cylinder and Piston Removal
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Inspect the cylinder for warping.
Be careful when handling piston rings,
as they are very fragile.
Check if the piston rings are damaged or if the
grooves are worn.
•
Place the piston rings into the cylinder 20 mm
under the cylinder top.
In order to keep the piston rings in even horizontal
levels, push the rings in with the piston.
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Removing Piston Rings
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Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm
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Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm
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Measure clearance between piston rings and
grooves.
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Service limit: 0.05 mm
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Measure the outer diameter of the piston pin.
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Measure the piston outer diameter.
The measurement position is 10 mm from the
piston bottom side, at a 90° angle to the piston pin.
Service limit: 71.00 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.
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Measure the inner diameter of the piston pin hole.
Service Limit: 17.02 mm
Calculate the clearance between the piston pin and
its hole.
Service Limit: 0.02 mm
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Service Limit: 17.02 mm
Page 58 of 151
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Measure the inner diameter of the smaller end
of the connecting rod.
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Service Limit: 17.00 mm
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7-5 Piston Ring Installation
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Clean the piston top, ring groove, and piston surface.
Install the piston ring onto the piston carefully.
Place the piston ring openings as shown in the diagram.
Do not damage piston or piston rings.
All marks on the piston rings must be on the top side facing forward.
Make sure that all piston rings can be rotated freely after being installed.
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•
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Clean up all residue and foreign materials on the
surface of the crankcase. Do not let residue
or foreign materials fall into the crankcase.
•
Remove the residue with solvent to aid in cleaning.
•
•
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Install the piston and piston pin, placing the IN
marks on the piston top side facing the inlet valve.
Install a new piston pin clip.
Do not let the opening of the piston pin clip align
with the piston cutout.
Place a rag or piece of cloth between the piston and
crankcase in order to prevent the ring or pieces of
foreign material from falling into crankcase.
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Install the dowel pins and a new gasket.
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7-7 Cylinder Installation
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7-6 Piston Installation
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Do not push the piston into the cylinder forcefully
or the piston and piston rings will be damaged.
•
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Install the coolant hose onto cylinder.
Install the cylinder head (refer to Chapter 6).
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Coolant hose
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•
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Apply engine oil to the inside of the cylinder, piston, and
piston rings.
Be careful when installing piston into cylinder.
Press the piston rings in one by one during installation.
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8. V-BELT TRANSMISSION SYSTEM
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8-1 Mechanism Diagram
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Operating Procedures
General Information
Drive face, clutch outer, and driven pulley can be serviced while
still installed.
Drive belt and drive pulley must be free of grease.
Standard value (mm)
Limit (mm)
24.000
22.500
OD of movable drive face boss
29.946~29.980
29.926
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ID of movable drive face
30.000~30.040
30.060
OD of weight roller
19.500~20.000
19.000
144.850~145.150
145.450
6.000
3.000
ID of clutch outer
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Thickness of clutch weight
Free length of driven pulley spring
OD of driven pulley boss
ID of driven face
97.400
40.950~40.990
40.930
41.000~41.050
41.070
17.700~18.300
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Weight of weight roller
102.400
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Torque values
Drive face nut: 8.5-10.5kgf-m / 61-76 lbf-ft
Clutch outer nut: 5.0-6.0kgf-m / 36-43 lbf-ft
Drive plate nut: 5.0-6.0kgf-m / 36-43 lbf-ft
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8-3 Troubleshooting
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Engine starts but ATV does not move
1. Worn drive belt
2. Worn drive face
3. Worn or damaged clutch weight
4. Broken driven pulley
Special Service Tools
17.200
Clutch spring compressor: SYM-2301000
Inner bearing puller: SYM-6204002
Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100
Insufficient horsepower or poor high
speed performance
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1. Worn drive belt
2. Insufficient spring force of driven pulley
3. Worn roller
4. Driven pulley malfunctioning
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Sputter or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
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Driving belt width
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V-BELT SYSTEM SPECIFICATIONS
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8-2 Maintenance Description
Page 63 of 151
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Left crankcase cover removal
Release the 2 clamps on the left hand
crankcase cover ducts, and then remove the
ducts.
•
Remove the left crankcase cover. (9 bolts)
•
Remove the 2 dowel pins and the gasket.
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Reinstall left crankcase cover in the reverse
order of removal.
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Removal
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Remove the left hand crankcase cover.
Hold the drive face with a universal holder
Remove nut and drive face.
Special Tool: Universal holder
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•
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Hold the clutch outer with the universal
holder, and remove the nut, bearing stay
collar, and clutch outer.
Using special service tools for tightening or
loosening the nut.
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8-5 Drive Belt
Page 64 of 151
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Left crankcase cover installation
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8-4 Left Crankcase Cover
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Inspection
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Pull out the driven face to keep it from closing.
Be careful not to press the friction plate too hard
to avoid warping or damage.
Install the drive belt onto driven pulley.
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Install the driven pulley with the belt already
installed onto drive shaft.
On the other end of the drive belt, install the
movable drive face.
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Installation
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• Check the drive belt for crack or wear.
Replace it
if necessary.
• Measure the width of drive belt as diagram
shown.
Service Limit: 22.5 mm
• Replace the belt if exceeds the service limit.
The surfaces of drive belt or pulley must be
free of grease. Clean up all grease or dirt
before installation.
Page 65 of 151
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Push the drive belt into the belt groove as
shown
in the diagram so that the belt can be
loosened.
Remove driven pulley. Do not remove drive
belt.
Remove the drive belt from the groove of
driven
pulley.
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Install the clutch outer and bearing stay collar.
Hold the clutch outer with a universal holder.
Tighten the nut to specified torque value.
Torque value: 5.0-6.0kgf-m / 36-43 lbf-ft
•
•
•
•
Install the drive face, washer, and drive face nut.
Hold the drive face with a universal holder.
Tighten the nut to specified torque value.
Torque value: 8.5-10.5kgf-m / 61-76 lbf-ft
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8-6 Drive Face
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Remove the left crankcase cover.
Hold the drive face with a universal holder.
Remove the drive face nut.
Remove the drive face and drive belt.
•
Remove the movable drive face and drive face
boss from the crankshaft.
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Removal
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•
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Remove the ramp plate.
•
Remove weight rollers from movable drive face.
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Check if drive face boss is worn or damaged and
replace it if necessary.
Measure the outer diameter of movable drive face
boss, and replace it if it exceeds service limit.
Service limit: mm
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Measure the inner diameter of movable drive face,
and replace it if it exceeds service limit.
Service limit: mm
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The weight rollers press the movable drive face
by centrifugal force.
If the weight rollers are worn out or damaged,
the force will be affected.
Check if rollers are worn or damaged. Replace
if necessary.
Measure each roller’s outer diameter. Replace it
if it exceeds the service limit.
Service limit: mm (Weight: 18.2g)
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Inspection
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Install the weight rollers.
•
The weight roller end surfaces are not
necessarily the same. In order to lengthen
the rollers’ lifetime and prevent premature wear,
install the weights in a counterclockwise
order onto the movable drive face.
•
Install the ramp plate.
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Install the movable drive face assembly onto the
crankshaft.
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The movable drive face surface must be free of
grease. Clean it with cleaning solvent.
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Apply grease to the movable drive face axle
hole.
Install drive face boss.
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Reassembly/Installation
Press the drive belt into the pulley groove, and
then pull the belt onto the drive shaft.
•
•
Install drive face, washer, and nut.
Ensure the two sides of the pulley surfaces
are free of grease. Clean with cleaning
solvent if necessary.
Hold the drive face with a universal holder.
Tighten nut to specified torque.
Torque value: 8.5-10.5kgf-m / 61-76 lbf-ft
•
Install the left crankcase cover.
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8-7 Clutch Outer/Driven Pulley
•
Do not overexert the compressor.
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Remove drive belt, Outer clutch, and driven
pulley.
Install clutch spring compressor onto the
pulley assembly, and press the compressor to
let the wrench be installed more easily.
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Hold the clutch spring compressor onto bench vise,
then remove mounting nut with a special service
tool.
Release the clutch spring compressor and remove
the friction plate, clutch weight, and spring from the
driven pulley.
Remove the seal collar from the driven pulley.
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Disassembly
Page 69 of 151
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Driven Pulley Installation
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Clutch Outer
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Clutch Lining
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Driven Pulley Spring
Measure the length of the driven pulley spring.
Replace it if it exceeds service limit.
Service limit: 83.2 mm
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Measure each clutch weight thickness.
Replace it if it exceeds service limit.
Service limit: 2.0 mm
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Measure the inner diameter of the clutch
outer.
Replace the clutch outer if it exceeds the
service limit.
Service limit: 145.450mm
Page 70 of 151
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Inspection
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Remove the guide pin, guide pin roller, and
movable driven face.
Remove the O-ring & oil seal seat from the
movable driven face.
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Driven Pulley
Replace damaged or worn components.
Measure the outer diameter of the driven face
and the inner diameter of the movable driven
face. Replace if either exceeds service limit.
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Service limit:
• Outer diameter 33.94 mm
• Inner diameter 34.06 mm
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Driven Pulley Bearing Inspection
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Check if the inner bearing oil seal is damaged.
Replace it if necessary.
Check if needle bearing is damaged or has too
much clearance. Replace it if necessary.
Rotate the inside of inner bearing with your
fingers. The bearing should turn smoothly and
quietly.
Check if the bearing outer parts are closed and
fixed. Replace if necessary.
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Remove the snap ring and washer.
Remove the clutch weight and spring from
driving plate.
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NOTE: Some of models are equipped with one
mounting plate instead of 3 snap rings.
Check if the spring is damaged or has
insufficient elasticity.
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Check if the shock absorption rubber is
damaged or deformed. Replace it if necessary.
Apply grease onto setting pins.
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Clutch Weight Replacement
Page 71 of 151
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Check for the following:
• If both surfaces are damaged or worn.
• If the guide pin groove is damaged or worn.
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Install the spring into the groove with pliers.
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Install the snap ring and mounting plate onto
setting pin.
•
Remove the inner bearing.
•
If the inner bearing equipped with an oil seal
on its side in the driven pulley, then remove the
oil seal first.
If the pulley equipped with a ball bearing,
remove the snap ring and then the bearing.
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Remove the snap ring and then push the bearing
forward to the other side of the inner bearing.
Place a new bearing onto the proper position
with its sealing end should facing outside.
Apply engine oil.
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The clutch block should not be greased. If it is,
replace it. Grease or lubricant will damage the
clutch weight and affect the block’s
connection capacity.
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Page 72 of 151
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•
Install a new clutch weight onto the setting
pin and then push into the specified location.
Apply grease onto all the setting pins.
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•
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The sealing end should be facing outside
after installation.
Install the needle bearing with a hydraulic
presser.
Install the ball bearing with a hydraulic presser.
Install the snap ring into the groove on the drive
face.
Align oil seal lip with bearing, and then install a
new oil seal (if necessary).
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Install a new oil seal and O-ring onto the
movable driven face.
Apply grease to lubricate the inside of the
movable driven face.
•
Install the movable driven face onto the
driven face.
Install the guide pin and guide pin roller.
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Clutch Outer/Driven Pulley Installation
Page 73 of 151
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Install a new inner bearing.
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Install the collar.
•
Install the friction plate, spring, and clutch
weight onto a clutch spring compressor,
and press down the assembly by turning
the manual lever until the mounting nut
can be installed.
Hold the compressor with a bench vise and
tighten the mounting nut to specified
torque with clutch nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0-6.0kgf-m / 36-43 lbf-ft
Install clutch outer/driven pulley and drive
belt onto drive shaft.
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9. FINAL DRIVE SYSTEM
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9-1 Mechanism Diagram - Transmission Cover
Specification
•
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oil
Oil quantity: 750cc (650cc when replacing)
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•
•
Gear box cover 2.6-3.0kgf-m / 19-22 lbf-ft
Gear oil drain bolt 0.8-1.2kgf-m / 6-9 lbf-ft
Gear oil fill bolt 3.5-4.5kgf-m / 25-33 lbf-ft
Special tools
Bearing driver (6204): SYM-9110400
Bearing driver (6205LLU): SYM-9100400-HMA
Bearing driver (6305): SYM-9100400-RB1
Needle bearing driver (HK2016): SYM-9100300-RB1
Drive shaft and oil seal driver: SYM-9120200-HMA
Drive shaft puller: SYM-2341100
Inner bearing puller: SYM-6204002
9-3 Troubleshooting
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Engine can be started but vehicle can not be moved
Damaged drive gear
Burnt out drive gear
Damaged gear shift system
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Excessive Noise
Worn or burnt gear
Worn gear
Excessive gear oil.
Worn or damage oil seal
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Gear Oil Leaking
Page 76 of 151
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Torque value
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9-2 Maintenance Notes
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9-4 Disassembly of Transmission
Remove gear change lever (1 bolt).
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•
Remove the 3 bolts.
Remove the drive chain protector.
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Remove gear oil fill bolt.
Place an oil pan under the ATV.
Remove the gear oil drain bolt.
After draining, check whether washer can
be re-used. Replace if not.
Install the oil drain bolt.
Torque values:
Gear oil fill bolt 3.5-4.5 kgf-m
Gear oil drain bolt 0.8-1.2 kgf-m
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•
•
•
•
Page 77 of 151
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Remove the 2 bolts shown in the picture.
Remove the drive sprocket fixing plate,
drive chain, and drive sprocket.
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Remove the gear box cover bolts (9 bolts).
Remove the cover.
•
Remove the shift drum catch ball, spring,
and bolt.
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Remove the final shaft, counter shaft, and
reverse shaft.
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Page 78 of 151
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Remove the shift spindle, shift fork shaft,
shift fork, and shift drum.
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•
•
Remove the drive shaft bearing setting plate (one
bolt).
•
•
•
Remove the drive shaft.
Special tool: Shaft protector
Remove the gasket and dowel pin.
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Unless it is necessary, do not remove the drive
shaft from the case upper side.
If the drive shaft is removed from the gear box,
the bearing and oil seal must be replaced.
Page 79 of 151
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9-5 Transmission Mechanism
Inspection
Check the shift spindle for wear or damage.
•
Check the shift drum for wear or damage.
Check the shift fork and shaft for wear or
damage.
•
Check the counter shaft for wear or damage.
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•
Check the reverse shaft for wear or damage.
•
Check the final shaft and gear for burning, wear,
or damage.
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If the drive shaft is removed from the
crankcase upper side, the bearing has to be
replaced.
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•
•
Check the bearings on the gear box and gear
box cover.
Rotate each bearing’s inner ring with fingers.
The bearing should turn smoothly and quietly.
Check if the bearing outer ring is mounted on
the gear securely.
If the bearing rotation is uneven, makes noise, or
mounted loosely, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.
Page 81 of 151
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Never install used bearings. Once a bearing
is removed, it must be replaced with new one.
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9-6 Bearing Replacement
Crankcase side
•
Special tool:
Inner bearing puller
Install new final shaft, counter shaft, and
reverse shaft bearings into the left crankcase.
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Install new drive shaft bearings with a
bearing driver into the left crankcase.
•
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Install the universal bearing puller with the
bearing driver.
Turn the universal bearing puller to install the
drive shaft bearing.
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Special tool:
Bearing driver (6204)
Needle bearing driver (HK2016)
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Special tool:
Bearing driver (6305)
Universal bearing puller
Page 82 of 151
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•
Remove the drive shaft bearing setting plate.
Remove the drive shaft bearing from left
crankcase.
Remove the reverse shaft bearing and counter
shaft bearing from the left crankcase.
Remove the drive shaft oil seal.
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•
•
Install the drive shaft.
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Special tool:
Drive shaft and oil seal install bush
Install the drive shaft bearing setting plate (1
bolt).
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Gear box side
Use inner bearing puller to remove the final
shaft needle bearing, gear shift shaft bearing,
and counter shaft bearing from the cover inner
side.
Special tool:
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Remove the final shaft cir clip from the outer
bearing.
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Inner bearing puller
Page 83 of 151
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Apply grease onto the new drive shaft oil seal
lip.
Install the oil seal.
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Special tool:
Drive shaft puller
Drive shaft and oil seal install bush
Clutch nut wrench
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Remove the final shaft outer bearing.
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Special tool:
Inner bearing puller
Remove the oil seal from the gear box cover
and discard the seal.
•
Install a new bearing with the bearing driver
into the outer gear box cover.
Install the universal bearing puller with the
bearing driver.
•
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Install new oil seal and bearing driver into gear
box cover inner side.
Install the universal bearing puller and bearing
driver.
Turn the universal bearing puller to install drive
shaft oil seal.
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Special tool:
Bearing driver (6205)
Universal bearing puller
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Special tool:
Bearing driver (6205)
Universal bearing puller
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Turn the universal bearing puller to install the
drive shaft bearing.
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9-7 Final Drive Reassembly
Apply grease onto the oil seal lip of the final
driving shaft.
•
Install the counter shaft, reverse shaft and
final shaft onto the gear box.
Install shift drum, shift fork, and fork shaft
onto gear box.
•
Install shift drum fixed catch ball, spring, and
bolt onto gear box.
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Install dowel pins and a new gasket.
Install the gear box cover and bolts.
Torque value: 1.0-1.4kgf-m / 7-10 lbf-ft
•
Install the shift spindle bracket, drive chain
protector, and gear change lever.
Add gear oil.
Gear oil quantity: 750cc of 85/140 weight
gear oil
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Align the position mark on the shift spindle
sprocket with the one on the shift drum.
Install the shift spindle.
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10. A/C GENERATOR & STARTING CLUTCH
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10-1 Mechanism Diagram
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10-2 Maintenance Notes
General information
Refer to chapter 17: The troubleshooting and inspection of alternator
Refer to chapter 17: The service procedures and precaution items of starter motor
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Specifications
Standard value (mm)
Limit (mm)
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Item
ID of starting clutch gear
25.026~25.045
25.100
OD of starting clutch gear
42.175~42.200
42.100
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Torque value
Flywheel puller: SYM-3110A00
Universal holder: SYM-2210100
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Special tools
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Flywheel nut: 5.0~6.0kgf-m / 36-43 lbf-ft
Starting clutch hexagon bolt: 1.0~1.4kgf-m / 7-10 lbf-ft with adhesive
8 mm bolts: 0.8~1.2kgf-m / 6-9 lbf-ft
12 mm bolts: 1.0~1.4kgf-m / 7-10 lbf-ft
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Remove the left footrest.
Drain out the engine oil and coolant.
Remove the coolant hoses.
Remove the water pump cover (4 bolts).
Remove 11 bolts from the right crankcase cover.
Remove the right crankcase cover.
Remove dowel pin and gasket.
10-5 Right Cover Bearing
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Remove the cir clip.
Remove the bearing.
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Rotate the bearing with your finger. Make sure
the bearing turns smoothly and quietly.
Check if the bearing outer parts are closed and
fixed. Replace if necessary.
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Special tool:
Inner bearing puller
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Inspection
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Remove the 2 mounted screws from the A/C
Generator.
Remove the A/C Generator.
Remove 3 screws from right crankcase cover.
Remove the generator coil set.
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10-4 A/C Generator Removal
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10-3 Right Crankcase Cover
Removal
Check the oil seal for wear or damage.
Replace if necessary.
•
Install a new bearing (6201LU) with a bearing
driver.
Remove the right crankcase cover.
•
•
Remove the left crankcase cover.
Hold the flywheel by the drive face with a
universal holder.
Remove the flywheel nut.
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Special tool:
Universal Holder
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10-6 Flywheel Removal
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Special tool:
Bearing driver
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Remove the starter reduction gear and shaft.
Pull out the flywheel with a flywheel puller tool.
Remove the flywheel and starting driven gear.
10-7 Starting Clutch
Starting Clutch Inspection
Remove the starting clutch driven gear.
Inspect the gear for wear or damage.
Measure the ID and OD of the starting clutch
driven gear.
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Service Limit: ID: 25.1 mm
OD: 42.10 mm
Inspect the starting reduction gear and shaft for
wear or damage.
•
Check each roller for wear or damage.
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Special tool:
Flywheel puller tool
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Install the starting clutch driven gear onto the one
way clutch.
Hold the flywheel and rotate the starting clutch
gear.
The starting clutch gear should be rotated
counterclockwise freely, but not clockwise.
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Remove the 3 socket bolts.
Remove the one way clutch.
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Remove the starting driven gear.
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One Way Clutch Removal
•
Install the starting driven gear.
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Align the key on the crankshaft with the flywheel
groove.
Install the flywheel.
•
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Hold the flywheel by drive face with a universal
holder.
Tighten the flywheel nut.
Torque value: 5.0~6.0kgf-m
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Special tool:
Universal Holder
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10-8 Flywheel Installation
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When reinstalling the components, use Teflon
tape on the thread of the hexagon bolt.
Torque value: 1.0-1.4kgf-m / 7-10 lbf-ft
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One way clutch Installation
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Install the reduction gear shaft and the reduction
gear.
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Install the A/C generator coil set onto the right
crankcase cover (3 screws).
Install the A/C generator (2 screws).
Attach the wire harness securely onto the
indention of the crankcase.
Ensure that the wire harness is placed under the
A/C generator.
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10-9 ACG Set Installation
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Remove the water pump cover.
Install the right crankcase cover onto the
crankcase.
Note: Align the water pump shaft indention with
the oil pump shaft.
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Install the dowel pin and new gasket.
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10-10 Right Crankcase Cover
Installation
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Install the right crankcase cover (11 screws).
Install the dowel pin, a new gasket, and the
water pump cover onto the crankcase cover
•
Connect the water hoses to the right crankcase
cover and water pump cover.
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11. CRANKCASE / CRANK
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11-1 Mechanism Diagram
Maintenance Notes
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Specifications - Crankshaft
Item
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Connecting rod side clearance of the larger end
Vertical clearance of the larger end of the connecting rod
Run-out
Torque value
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Bolts for crankcase: 0.8~1.2kgf-m / 6-9 lbf-ft
Engine oil drain bolt: 3.5~4.5kgf-m / 25-33 lbf-ft
Cylinder stud bolt: 1.0~1.4kgf-m / 7-10 lbf-ft
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Standard
(mm)
0.100~0.400
0~0.008
0.030
Special tools
L. crank shaft oil seal driver (27*42*7): SYM-1332100-HMA
11-3 Troubleshooting
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Loose crankshaft bearing
Loose crankshaft pin bearing
Worn out piston pin and pin hole
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Engine noise
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Copyright ©2008-2009 ETON America, llc., all rights reserved.
Limit
(mm)
0.600
0.050
0.100
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This Section concerns disassembly of the crankcase for repairs.
Remove following components before disassembling crankcase:
o Engine: Chapter 5
o Cylinder head: Chapter 6
o Cylinder and piston: Chapter 7
o Drive face and driven pulley: Chapter 8
o A/C generator & one way clutch: Chapter 10
If it becomes necessary to replace the crankshaft bearing, oil pump drive chain, or the
timing chain, it is recommended to replace the whole crankshaft assembly.
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11-2 General Information
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11-4 Crankcase Disassembly
Remove the cam chain setting plate.
Remove cam chain.
Loosen the pivot bolt and remove the tensioner.
•
Loosen the 2 bolts on the right crankcase.
Loosen the 11 bolts on the left crankcase.
•
Place the right crankcase facing downward and
the left crankcase facing upward.
Gently tap the left crankcase with a plastic
hammer to remove it.
Care should be taken not to damage the contact
surfaces.
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Remove the balance shaft from the right
crankcase.
•
Remove the crankshaft from the right crankcase.
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Remove the gasket and dowel pins.
Gently scrape gasket residue off the crankcase
contact surface.
•
•
Do not damage contact surface of the gasket.
It is recommended to moisten the gasket residue
for easier removal.
•
Remove the left crankcase oil seal.
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Measure the clearance of the larger end in the
vertical direction.
Service limit: 0.05 mm
Place the crankshaft on a V-block.
Measure the run-out of the crankshaft.
Service limit: 0.10 mm
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Special tool: Outer bearing puller
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Use your hand to turn the bearing.
It should turn smoothly and quietly.
Check the inner ring to ensure it links firmly on
the bearing.
If any roughness, noise, or loose linkage is
detected, replace the bearing.
Note: If bearing replacement is necessary,
replace both bearings.
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Crankshaft Bearing Inspection
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Use a thickness gauge to measure the left and
right clearance of the larger end of the
connecting rod.
Service limit: 0.6 mm
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11-5 Crankshaft Inspection
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Special tool: Inner bearing puller
Special tool: Bearing driver
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11-6 Crankcase Assembly
Install the wave washer into the right crank
bearing seat.
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Install the crank shaft on the right crankcase.
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Align the position mark on the balance shaft
drive gear with that of balance shaft driven gear,
and then install the balance shaft onto right
crankcase.
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Check the bearings on the right and left
crankcase.
Rotate each bearing inner ring with your fingers.
The bearings should turn smoothly and quietly.
Ensure the bearing outer ring is mounted on the
gear tightly.
If bearing rotation is uneven, makes noise, or is
loosely mounted, replace it.
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Balance Shaft Bearing Inspection
Install the 2 dowel pins and a new gasket.
•
Install the left crankcase onto the right
crankcase.
Tighten the 11 bolts on the left crankcase.
Torque value: 0.8~1.2kgf-m / 6-9 lbf-ft
•
•
Tighten the 2 bolts on the right crankcase.
Torque value: 0.8~1.2kgf-m / 6-9 lbf-ft
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Clean the crankshaft.
Apply a layer of grease on the lip of oil seal.
Install the left crankshaft.
Install the oil seal in the left crankcase. Be
careful not to damage the lip of the oil seal.
•
Use an oil seal driver (27×42×7) to install and
secure the oil seal.
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Install the tensioner and tighten the pivot bolt.
Torque value: 0.8 ~1.2kgf-m / 6-9 lbf-ft
Install the cam chain.
Install the cam chain setting plate.
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12. COOLING SYSTEM
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12-1 Mechanism Diagram
Refill the radiator only with distilled water and anti-freeze solution.
Add coolant to the reservoir only.
The cooling system can be serviced while installed on the ATV.
Never spill the coolant onto painted surfaces.
Test the cooling system for any leaking after the repair.
Refer to Section 17 for inspection of the temperature sensor switch for the fan motor
and the water thermometer.
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Technical Specifications
Specification
0.9±0.15 kgf/cm2
850c.c. 420c.c.
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Item
Pressure to open filler cap
Capacity of coolant: Engine + radiator
Reservoir upper
Begins to activate at 82~95℃
Stroke: 0.05~3mm
Thermostat
Thermos switch (fan)
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Begins to activate at 98±3℃
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Boiling point
Standard: 107.7℃
Pressurized: 125.6℃
Torque Value
•
Water pump rotor: 1.0~1.4kgf-m / 7-10 lbf-ft
Special tools
Anti-Freeze specification rating of H68
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Anti-freeze solution
percentage
20%
30%
40%
50%
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Operating
temperature
32° to -8° F
-9° to -15°F
-16° to -24°F
-36° to -45°F
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Water pump bearing driver (6901): SYM-9100100
Water pump oil seal driver (Inner): SYM-9120500-H9A
Water pump mechanical seal driver: SYM-1721700-H9A
Inner bearing puller: SYM-6204020
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Warning:
Never attempt to open the radiator filler cap while the engine is running. The pressurized hot
coolant may escape and cause serious scalding injuries. Do not perform maintenance unless
the engine is completely cooled down.
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12-2 General Information
Engine temperature too high
Water thermometer or temperature sensor malfunctioning.
Thermostat stays closed.
Insufficient coolant.
Water hose or jacket clogged.
Fan motor malfunctioning.
Radiator filler cap malfunctioning.
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Water thermometer or temperature sensor malfunctioning.
Thermostat stays open.
Coolant leaking
Water pump mechanical seal loose or malfunctioning.
O-ring worn or damaged.
Water hose broken or worn.
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Engine temperature too low
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12-4 Troubleshooting Flowchart
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Temperature indicated is too high:
• Stop the engine and let it cool completely. Open the radiator cap and check the
radiator coolant.
o Coolant level low: Refill radiator with coolant and check for leaks
• Turn the main switch on and make sure the water temperature indicator is at zero
o If not: Check for current going to the thermostat. It must be at least 6V.
ƒ If not: Replace the thermostat
ƒ If so: Check for shorts or grounding in the circuitry
• Open the radiator cap and very gently apply the throttle. Check if the coolant is
circulating.
o If it isn’t: Stop the engine and remove the water pump cover. Restart the
engine and inspect the pump rotation.
ƒ If it rotates, there is a clog in the water hose.
ƒ If it does not, repair or replace the water pump.
• Close the radiator cap. Test the thermostat current for variance as the temperature
rises.
o If it does not detect the temperature change, replace the thermostat.
• Allow the engine to run at 3-4000 RPM. Inspect the cooling fan.
o If the fan was not operating, check the thermal switch current for changes in
voltage (12 Æ 0V).
ƒ If the voltage does not change, replace the thermal switch.
ƒ If it does, test the fan directly by attaching a 12V battery to the
terminals on the fan. If the fan does not operate, replace it.
• Keep the engine running at 3-4000 RPM. Inspect the coolant flow in the reserve tank.
• Remove the thermostat from its holder and check its operation directly with water. If it
does not operate correctly, replace the thermostat.
• Refill the coolant reservoir and ensure there are no twists, bends, or air bubbles in the
coolant tube.
• To bleed air bubbles out, open the radiator cap while the engine is cool and start the
engine. Gently press on the hose to bleed. Apply throttle and check if the surface of
the coolant appears stable. Repeat bleeding if necessary.
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12-3 Troubleshooting
Pressure which is too high may damage the
radiator. Never use pressure which exceeds
1.05 kg/cm2.
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If the system fails to maintain the specified
pressure for at least 6 seconds, repair or
replace.
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Coolant recommended: SYM Bramax radiator
agent. Concentration: 50%
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Coolant reservoir
Water pump
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Remove the front center cover.
Remove filler cap.
Place a water pan under the water pump.
Loosen the drain bolt to drain out the coolant.
Reinstall the drain bolt.
Refill system with coolant and bleed the air
bubbles:
Run the engine, and remove the by-pass pipe.
Check by-pass hole for air bubbles to emit.
If no air (only coolant) flows out, reinstall the bypass pipe and shut off the engine.
Remove the radiator filler cap.
Start the engine, ensure there are no air
bubbles in the radiator coolant, and ensure the
coolant liquid level is stable.
Stop the engine. Add coolant to proper level if
necessary.
Screw in and tighten the radiator filler cap.
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Never attempt to carry out service work on the
cooling system unless the engine is completely
cooled down. Serious injury could result.
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Coolant Changing
Radiator filler cap
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Hermetically seal the filler cap.
Apply water and pressure to the filler cap.
Replace it with new one if it fails to maintain
the specified pressure within a given time
limit, or the opening pressure is too high or
too low.
The specified pressure should be maintained
at least for 6 seconds in the test.
Standard pressure for the filler cap: 0.9-0.15 kgf/cm2
Apply pressure to the radiator, engine and
water hose to check for any leakage
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Filler Cap Test
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12-5 System Test
Drain bolt
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Reserve Tank Inspection
Inspection
•
Remove the front center cover, side covers, and
front fender.
Check for any leaking from the welded seam.
Blow the radiator clean using compressed air. If
the radiator is blocked by dirt or foreign
material, use a low pressure water jet to clean it.
Be careful when straightening the sink fan.
•
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Removal
Place a water pan under the water pump.
Loosen the drain bolt to drain out the coolant.
•
Remove the coolant filler pipe.
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Lower
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12-6 Radiator
Upper
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•
Remove the front center cover.
Remove the reserve tank filler cap.
Check the liquid level in the reservoir under the
front right fender. Add coolant to the proper
level if too low.
Reinstall the reserve tank filler cap.
tP
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•
•
•
Filler coolant hose
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Loosen the radiator 4 bolts.
Remove the coolant upper side pipes.
•
•
Remove coolant outlet pipe.
Disconnect the couplers for the thermo switch
and fan motor.
Remove the radiator and cooling fan.
Liquid packing must be applied to the thermo
switch before installation to avoid damaging
the radiator.
Installation
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Install the removed parts in the reverse order of removal.
Install the radiator in the reverse order of removal.
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•
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Install the fan motor onto the fan duct and
insert the fan into the motor shaft.
Apply a coat of adhesive to the shaft thread of
the motor.
Install the washer and the lock nut.
Tighten the fan duct onto the radiator with 3
bolts.
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tP
Assembly
•
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Loosen the 3 bolts from the fan duct.
Remove the fan duct.
Loosen 3 screws from the fan motor.
Remove the fan motor.
Remove the nut to remove the fan from the
fan motor.
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Disassembly
Page 109 of 151
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•
Water pump
Upon installation, inspect for any leaks.
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12-7 Water Pump
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•
Place a water pan underneath the unit.
Remove the coolant drain bolt.
Ensure all the coolant is drained from the cooling
system.
Inspect the drained coolant for any unusual
material or dirt. If there is, the inner water pump
seals or cooling system may be damaged. The
cylinder or cylinder head gasket may also be
damaged; take apart the crankcase and inspect
these before dismantling the cooling system.
Water Pump Removal
•
•
•
•
•
•
•
Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen the 4 bolts and remove the pump cover.
Loosen the 9 bolts and remove the right cover.
Remove the gasket and dowel pins.
Turn the pump rotor clockwise and remove.
Note that the rotor uses a left hand threads.
•
Remove the cir clip from the right crankcase
cover.
Remove the water pump shaft and the inner
bearing.
Remove the outside bearing with an inner bearing
puller.
Rotate the inner ring of the bearing; the bearing
should turn smoothly and quietly.
If the bearing does not rotate smoothly or
produces a noise, replace it.
Special tool: Inner bearing puller
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Drain bolt
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Inspection
Page 110 of 151
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Mechanical Seal Replacement
•
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2i
•
Remove the inside bearing by inner bearing
puller.
Drive the mechanical seal and inner seal out of
the right crankcase.
Special tools:
o Inner bearing puller
o Water pump bearing driver
Replace the mechanical seal and inside seal
after removing it.
tP
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Apply a coat of sealant to the adjoining surfaces
of the right crankcase before installing the new
mechanical seal.
•
Install the mechanical seal onto the right
crankcase.
Special tool: Water pump mechanical seal
driver.
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Page 111 of 151
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•
Check for any wear and damage on the
mechanical seal and inside seal.
The mechanical seal and inside seal must be
replaced together if necessary.
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Install the cir clip onto the inner bearing to
secure it.
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Page 112 of 151
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tP
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Mount the water pump shaft and the inner
bearing to the right crankcase cover.
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tP
•
Install a new outside bearing to the right
crankcase cover.
Special tool: Water pump bearing driver
(6901)
Note: Do not reuse old bearing. It must be
replaced with a new one once it has been
removed.
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•
Install the new inner seal onto the right
crankcase.
Special tool: Water pump oil seal driver
(inner)
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•
Install the seal washer into the rotor.
Note: The washer must be replaced together
with the mechanical seal.
•
Install the rotor onto the water pump shaft and
tighten.
Torque Value: 1.0-1.4kgf-m
The rotor is left hand threaded.
•
•
Install the dowel pin and new gasket.
Install the water pump cover (4 bolts).
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Install the dowel pin and right cover gasket.
The water pump rotor rotating causes the water
pump drive shaft scoop channel, aligns the oil
pump drive shaft flange.
Install the right crank case. (9 bolts)
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•
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Please refer to chapter 17 for inspection of the
temperature sensor.
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12-8 Thermostat
Removal
Drain the coolant.
Remove the thermostat set. (2 bolts)
Visually inspect the thermostat for any damage.
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•
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Place the thermostat into heated water to check its
operation.
Do not let the thermostat or thermometer touch
the side of the water container to ensure an
accurate reading. If the valve of the thermostat
remains open at room temperature or the valve
operation is not corresponding to the temperature
change, then it must be replaced.
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•
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Valve begins to open
Valve stroke
Install the thermostat.
Install the thermostat cover. (2 bolts)
Refill the coolant and bleed out any air bubbles.
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Installation
82~95℃
0.05 ~ 3mm
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Technical Data
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Inspection
Page 114 of 151
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13. STEERING AND SUSPENSION
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STEERING
Page 115 of 151
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13.1 PARTS DRAWING
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HANDLEBAR
Steering Too Hard
o Faulty tire
o Steering shaft holder too tight
o Insufficient tire pressure
o Faulty or damaged steering shaft bushing
•
Front Wheel Wobbles
o Faulty tire
o Worn front brake drum bearing
o Bent rim
o Axle nut not tightened properly
•
Steering Pulls To One Side
o Bent tie rods
o Wheel installed incorrectly
o Unequal tire pressure
o Bent frame
o Worn swing arm pivot bushings
o Incorrect wheel alignment
Nose in the Front Suspension
o Loose front suspension fasteners
o Suspension link bound
•
Hard Suspension
o Faulty front swing arm bushings
o Improperly installed front swing arms
o Bent front shock absorber swing rod
•
Soft Suspension
o Weak front shock absorber springs
o Worn or damaged front swing arm bushings
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•
•
Remove the throttle housing by the two fixed
screws.
Remove the throttle lever housing on the right
side of the handle bar.
Remove the brake lever bracket assembly.
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REMOVAL
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13.3 HANDLEBAR
Page 117 of 151
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13.2 TROUBLESHOOTING
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•
Remove the bolts attaching the handlebar upper
holder.
Remove the handlebar.
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Remove the handle cover and instrument panel by
the four screws at the right and left sides shown in
the picture.
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•
Remove the handle bar switch on the left handle
bar.
Remove rear brake lever bracket assembly.
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INSTALLATION
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Install the rear brake lever bracket, aligning the
small dot of the handlebar.
Tighten the screw securely.
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Install the switch housing, aligning the small dot
of the handlebar.
Tighten the upper screw first, and then tighten
the lower one.
Page 119 of 151
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•
Put the handlebar on the lower holders.
Make sure the handlebar punch marks match
with the top end of the handlebar of 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.
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13.4 THROTTLE HOUSING
Loosen the screws on the throttle housing cover.
Remove throttle housing cover and gasket.
Disconnect throttle cable from the throttle arm and
remove from the throttle housing.
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13.5 STEERING SYSTEM
2i
Removal of Kingpin and Tie-rod
Remove the front wheels and hub assembly.
Remove the four self-lock nuts from the tie-rod ball joints and take off the two tie-rods.
Nut
Inspect the tie-rod for damage or bending.
Inspect the ball joint rubbers for damage, wear,
or deterioration.
Turn the ball joints with fingers. The ball joints
should turn smoothly and quietly.
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Tie-rod Inspection
Tie rod
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Nut
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DISASSEMBLY
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Steering Shaft Removal
Steering Shaft Holder 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: 39.5 mm
2i
•
•
•
Steering Shaft Inspection
•
Inspect the steering shaft for damage or cracks.
2i
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•
•
Apply grease to the holder.
Install the holder and oil seal tighten with the
nuts.
Torque: 33 N.m (24 lbf-ft)
Install the steering shaft nut and tighten it.
This nut is under this steering shaft.
Torque: 50 N.m (37 lbf.ft)
Install a new carter key
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Installation of Steering Shaft
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Page 121 of 151
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•
Remove the handle bar cover and handle bar.
(See section 8-3)
Remove the front fender. (See section 11-1)
Remove handlebar lower holder.
Loosen the steering shaft holder bolt and
remove steering shaft holder.
Take off the cotter pin below steering shaft.
Loosen the steering shaft fixed out below shaft.
Pull the steering shaft carefully.
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14.1 PARTS DRAWING
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Front Brake
Page 122 of 151
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Front Wheel
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14. FRONT WHEEL AND BRAKE SYSTEM
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14.2 TROUBLESHOOTING
Hard Steering
o Faulty tire
o Insufficient tire pressure
•
Front Wheel Wobbling
o Faulty tire
o Worn front brake drum bearing
o Bent rim
o Axle nut not tightened properly
•
Brake Drag
o Incorrect brake adjustment
o Sticking brake cable
•
Steering Pulls to One Side
o Bent tie rods
o Wheel installed incorrectly
o Unequal tire pressure
o Incorrect wheel alignment
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tP
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.G
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Poor Brake Performance
o Brake shoes worn
o Worn brake drum
o Brake linings oily, greasy, or dirty
o Improper brake adjustment
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REMOVAL
Install and tighten the four-wheel nuts
Torque: 24 N.m (17.7 lbf.ft)
Remember to put a cotter pin in the castle nut.
2i
14.4 HYDRAULIC BRAKE
This applies to the two front brakes of the unit.
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REMOVAL
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•
Raise the front wheels off the ground by placing
a jack or other support under the frame.
Remove the front wheel nuts, washer, and front
wheels.
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INSTALLATION
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•
Raise the front wheels off the ground by placing
a jack or other support under the frame.
Remove the front wheel nuts, washer, and
wheels.
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14.3 FRONT WHEELS
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Remove the two bolts on the caliper to remove
it.
•
After disassembling the wheel, inspect the disk
plate.
If the disk plate needs to be changed, loosen the
castle nut to take the wheel hub apart.
Before loosening the castle nut, remove the
cotter pin.
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Note: Pull the master cylinder back when
changing the brake shoe.
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Reinstall the front brake assembly in reverse
order of removal.
Page 125 of 151
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2i
Remove the bolt from the brake stopping plate.
Remove the brake disc.
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BRAKE OIL REPLACEMENT
14.5 SUSPENSION SYSTEM
Suspension in this type of ATV can be adjusted.
There are two ways to adjust suspension:
o 1. You can raise the all ATV body up by
using a repair platform. The four wheels
are in the free position, and the
suspension can be adjusted easily.
o 2. If a repair platform is not available, use a
specialized tool to adjust it. This will
require more effort.
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Special adjustment tool (See picture)
Page 126 of 151
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•
The brake fluid reservoir is located at the right hand
side of handle bar.
Check the brake fluid level position with the outside
window of the tank.
To open the brake oil tank cap, loosen the two
screws on top.
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15. REAR WHEEL AND BRAKE SYSTEM
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15.1 PARTS DRAWING
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Rear Wheel Axle
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Rear Wheel
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Rear Brake
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15.2 TROUBLESHOOTING
Poor Brake Performance
o Brake shoes are worn
o Improper brake adjustment
o Brake linings are oily, greasy, or dirty
o Brake drums are worn
o Brake arm setting is improperly engaged
•
Vibration or wobbling
o Axle is not tightened well
o Bent rim
o Axle bearings are worn
o Faulty tires
o Rear axle bearing holder is faulty
•
Brake Drag
o Incorrect brake adjustment
o Sticking brake cam
o Sticking brake cable
Soft Suspension
o Weak shock absorber damper
o Weak shock absorber spring
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.G
et
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Remove the four nuts and remove the rear
wheel.
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15.3 REAR WHEEL AND REAR BRAKE REMOVAL
Page 129 of 151
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Hard Suspension
o Bent damper rod
o Faulty swing arm pivot bushings
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Loosen the two bolts to remove the rear brake
caliper.
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Loosen the bolt shown in the picture.
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Brake Shoe Replacement
Page 130 of 151
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Loosen the bolts and remove the brake disc
Check the thickness of the disc. Replace if the
thickness less than 3mm.
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Push the plate back to take the shoe out as
shown in the picture.
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The two types of brake linings are shown in
this picture.
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Page 131 of 151
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Remove the brake shoe from the hub.
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Pull the left brake lever gently to extract air from
brake system.
Fill the brake oil to the level shown on the cup
when no more air comes out.
Assemble the cover
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Page 132 of 151
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Add the brake oil (DOT 3 or DOT 4).
Keep oil level at least halfway up the cup to
prevent air from getting into the brake system.
Loosen the bolt to vent the air from brake system.
Tighten the bolt if there isn’t any air in the brake
system.
Tightening torque: 40-70kgf-cm / 35-61 lbf-in
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Loosen the bolts and open the cover of the
reservoir.
Loosen the drain bolt and drain the used oil out.
Tighten the bolt after the used oil has been
drained out completely.
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REPLACING THE BRAKE HYDRAULIC OIL
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Swing arm
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Tighten the hanger bolt on the right side as
shown in picture.
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Put the swing arm at the proper position as
shown in picture.
Two hanger bolts are used to hold the swing arm
at its right and left side.
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This section introduces how to repair and install the swing arm.
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15.4 SWINGARM & REAR AXLE HOLDER
Page 133 of 151
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Hanger bolt
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Tighten the nut shown.
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Screw another hanger bolt on the left side as
shown in the picture, but do not tighten it.
Make sure the cross-section of bolt and crosssection of the hole are in the same plane.
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Suspension Adjustment
Suspension in this type of ATV can be adjusted.
There are two ways to adjust suspension:
o 1. You can raise the all ATV body up by
using a repair platform. The four wheels
are in the free position, and the
suspension can be adjusted easily.
o 2. If a repair platform is not available, use a
specialized tool to adjust it. This will
require more effort.
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Special adjustment tool (See picture)
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EXHAUST PIPE
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16.1 FENDERS DRAWING
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16. FENDERS AND EXHAUST PIPE
Remove the rear rack.
Loosen the four bolts which connect the front
fender and rear fender.
Loosen the two screws which connect the rear
fender and frame. These two bolts are just
below the seat.
Remove the two screws on the top of the seat
compartment.
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Loosen the three screws which connect the
footrest plate.
Pull the rear fender backward.
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Screws
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Bolts
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There are two seat release bars located at the
right and left hand side of the seat.
Use these to remove the seat first.
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16.2 REAR FENDERS REMOVAL
Remove the screws on the sides of the rear of
the ATV as shown.
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Remove the bolts that hold on the footrests.
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Remove the mounting bolts from the front
fender.
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Remove the two screws shown in the picture.
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16.3 FRONT FENDER REMOVAL
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Remove the exhaust pipe bolts mounting on
the frame below the seat.
Remove the exhaust pipe carefully.
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Wait at least 15 minutes after stopping the
engine before servicing the exhaust system.
Remove the seat, rear fender and footrest plate
before you take off the exhaust pipe.
Loosen the two exhaust pipe bolts fixed on the
engine.
Warning: DO NOT service the exhaust pipe
while hot.
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16.4 EXHAUST PIPE REMOVAL
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Remove the two screws on the top of the
headlight.
Remove the now visible single screw on the
front of the vehicle.
Remove the screw near the suspension as
shown in the picture.
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Installation is the reverse order of removal.
Torque: Exhaust muffler bolts 30 N-m (22 lbf-ft)
After installing, make sure that there are no
exhaust leaks.
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EXHAUST PIPE INSTALLATION
17.1 TROUBLESHOOTING
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Engine Starts But Dies
o Improper Ignition Timing
o Faulty Spark Plug
No Spark At Plug
o Engine Stop Switch At “Off” Position
o Gearshift Is Not At Neutral Position
o Faulty Ignition Coil
o Faulty Generator
o Faulty CDI Unit
o Poorly Connected:
ƒ Between CDI And Ignition Coil
ƒ Between CDI And Engine Stop Switch
ƒ Between Ignition Coil And Spark Plug
ƒ Between Generator And CDI Unit
Engine Starts But Runs Poorly
o Ignition Primary Circuit
ƒ Faulty Generator
ƒ Faulty CDI Unit
ƒ Faulty Alternator Exciter Coil
ƒ Loose Contact Terminals
ƒ Faulty Ignition Coil
o Ignition Secondary Circuit
ƒ Faulty Plug
ƒ Loose Contact Spark Plug Wire
ƒ Improper Ignition Timing
ƒ Faulty Generator
ƒ Faulty CDI Unit
Charging System Failure
o Faulty Generator
o Faulty CDI Unit
o Loose, Broken, Or Shorted Wire
o Faulty regulator
o Faulty Ignition Switch
Engine Intermittent Power
o Loose Battery Connection
o Loose Charging System Connection
Starter Motor Inoperable
o Battery Short
o Faulty Ignition Switch
o Loose Or Disconnected Wire
Engine Does Not Run
o Faulty Ignition System
o Engine Problems
o Faulty Engine Stop Switch
Headlight Inoperable
o Switch Not Set To “ON” Position
o Headlight Bulb Broken Or Needs Replacing
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17. ELECTRICAL SYSTEM
17.3 IGNITION TIMING
The ignition advance is 15°± 3°/4000rpm.
The Capacitive Discharge Ignition (CDI) system is
factory pre-set and does not require adjustment.
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17.4 BATTERY INFORMATION
The battery can emit explosive gases; keep sparks,
flames, and cigarettes away. Provide adequate
ventilation when charging or service the battery in an
open area. The battery contains sulfuric acid (an
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.
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Battery is under the seat. Measure the battery
voltage by using a multimeter.
VOLTAGE: Fully charged: 13.1 V
Undercharged: Below 12.0 V
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BATTERY REMOVAL
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Open the seat. The battery is underneath.
Disconnect the negative cable (Black - ) first and
then the positive cable (Red + ).
Remove the restraining bolt. Remove the battery.
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BATTERY INSTALLATION
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Install the battery in the reverse order of removal.
After installing the battery, coat the terminals with
clean grease.
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BATTERY VOLTAGE INSPECTION
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Remove the spark plug cap from the spark plug.
Disconnect the ignition coil primary wire.
Measure the primary coil resistance.
STANDARD: 0.1 - 0.3Ω(20)
Measure the secondary coil resistance with the spark
plug cap in place.
STANDARD : 7.4 – 12 kΩ(20)
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17.2 IGNITION COIL
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CHARGING
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17.5 ELECTRIC STARTER
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Information
TROUBLESHOOTING
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Starter Motor Turns Slowly
o Weak battery.
o Poorly connected starter motor cable.
o Malfunctioning starter motor.
o Poorly connected battery ground cable.
Starter Motor Inoperable
o Engine stop switch at “off” position.
o Gearshift bar is not at neutral position.
o Blown fuse near the battery.
o Battery is undercharged or in poor condition.
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17.6 LIGHT BULB REPLACEMENT
HEADLIGHT
To remove the headlight, loosen the three screws at
the back of the headlight.
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If a battery has not been used for a long period of time, the voltage may fade and may
not provide enough power to starter motor.
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Connect the charged positive cable to the battery
positive terminal.
Connect the charged negative cable to the battery
negative terminal.
Normal charging: Using 0.9A-charging current,
charge about 11 hours.
Quick charging: Using 4A-charging current, charge
about 3 hours.
Keep flames and sparks away from a battery that is
being charged.
Quick charging should be limited to an emergency.
Normal charging is preferred.
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After loosening these three screws, find the wire
connector.
Detach the connector to replace the electrical bulb
conveniently and safely.
Installation is in the reverse order of removal.
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The cap is visible on the back of the brake light.
Loosen the two screws on the cap to remove it.
Turn the light bulb inside to remove it.
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Rear Brake Light Removal
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The taillight combines a positional and a rear
brake light.
Normally, when users switch the key to “ON”
position, the front & rear positional lights are
always slightly illuminated.
When the brake lever on the handlebar is
depressed, the rear positional light becomes
brighter.
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TAILLIGHT
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Instrument Panel Removal
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The sensor is installed at the brake disk and a
cable is tightened on the left side of knuckle
component as shown in the pictures.
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There is a cable and connector on the back of the
instrument panel.
After removing the instrument panel, locate the
electrical connector which is connected to the
driving sensor at the back of the instrument panel.
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The instrument panel includes a fuel gauge,
speedometer, water temperature gauge, trip meter,
and indicator lamp.
A LCD is used on the Vector instrument panel to
display all driving information for the rider.
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17.7 Instrument Panel
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18.1 ENGINE DOES NOT RUN
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18. TROUBLESHOOTING
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Spark test – weak or no spark
o Faulty spark plug
o Fouled spark plug
o Faulty CDI unit
o Faulty alternator
o Faulty engine stop switch
o Poorly connected, broken, or shorted wires
o Broken or shorted ignition coil
o Broken or shorted spark plug wire
o Faulty pulse generator
o Faulty ignition switch
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Attempt to start engine – engine starts but dies
o Auto choke off or damaged
o Auto choke power wire disconnected
o Improperly adjusted air screw
o Improperly ignition timing
o Fuel / air mixture ratio is too lean
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Attempt to start engine – engine does not fire – inspect spark plug
o Carburetor flooded
o Improperly adjusted air screw
o Fuel / air mixture ratio too rich
o Auto choke stuck or damaged
o Air cleaner dirty
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Low cylinder compression
o Worn cylinder or piston rings
o Damaged cylinder head gasket
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Check fuel flow to carburetor
o No fuel in fuel tank
o Clogged float valve
o Clogged fuel tank cap breather hole
o Clogged at fuel tube
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18.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS
Check ignition timing
o Faulty CDI or A/C generator
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Check carburetor air screw adjustment
o Improperly adjusted air screw
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Check for leaking intake pipe
o Deteriorated insulator o-ring
o Loose carburetor
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Spark test – weak or intermittent spark
o Loose or disconnected ignition system wires
o Faulty, carbon fouled, or water fouled spark plug
o Faulty A/C generator
o Faulty CDI unit
o Faulty ignition switch
o Faulty ignition coil
o Faulty pulse generator
o Broken or shorted spark plug wire
o Faulty engine stop switch
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Carburetor fuel flow restricted in tube
o Lack of fuel in tank
o Clogged fuel line
o Clogged fuel valve
o Logged fuel tank breather hole
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Remove carburetor and check for clogged jets
o Clean with high pressure air gun
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Check air cleaner filter element
o Clean filter element if dirty
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Check ignition timing
o Faulty CDI unit
o Faulty A/C generator
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18.3 POOR PERFORMANCE AT HIGH SPEED
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Raise the wheels off the ground and spin by hand – wheels spin poorly
o Brake dragging
o Drive chain too tight
o Damaged wheel bearing
o Wheel bearing needs lubrication
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Low tire pressure
o Tire punctured
o Faulty valve stem
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Engine speed does not increase when accelerating
o Fuel / air mixture ratio too rich or lean
o Clogged air cleaner
o Clogged muffler
o Restricted fuel flow
o Clogged fuel tank cap breather hole
Low cylinder compression
o Leaking head gasket
o Worn cylinder and piston rings
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Clogged carburetor
o Clean carburetor jets with compressed air
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Fouled or discolored spark plug
o Clean the spark plug
o Improper spark plug heat range
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Check for engine overheating
o Excessive carbon deposited in combustion chamber
o Wrong type of fuel
o Fuel / air mixture ratio is lean
o Use of poor quality fuel
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Knocking when run at high speed
o Worn piston or cylinder
o Fuel / air mixture ratio is lean
o Wrong type of fuel
o Ignition timing too advanced
o Excessive carbon deposited in combustion chamber
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Check ignition timing – timing bad
o Faulty CDI unit
o Faulty A/C generator
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18.4 LOSS OF POWER
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18.5 POOR HANDLING
Steering is heavy
o Damaged steering bearing
o Damaged steering shaft bushing
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Wheel wobbling
o Bent rim
o Improperly installed wheel hub
o Excessive wheel bearing play
o Bent swing arm
o Bent frame
o Swing arm pivot bushing excessively worn
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Vehicle pulls to one side
o Bent tie-rod
o Incorrect tie-rod adjustment
o Rear tie air pressure incorrect
o Improper wheel alignment
o Bent frame
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ETON America, LLC
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Service Bulletin
C.D.I. Module Specifications
Vector 250
Bulletin No.: SB-0037
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Date: 05/01/2006
VXL-250 -- C0410-LRA0-0000
Electric resistance(Ω) specification
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∞
∞
∞
∞
∞
30-40K
BACK
GND
20-30K 4.8-5.2K
80-100K 30-50K
7-8K
0
13-15K
1-3K
∞
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ACC
PC+
PCIGN
BACK
GND
PC+
PCIGN
50-70K
1-2K
∞
30-50K
∞
30-50K
∞
50-60K
1-3K
∞
∞
∞
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ACC
0
∞
7-8K
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Specifications highlighted in yellow are the suggested critical testing points. Test points should be
tested first.
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We suggest using analogy type multi-meter to test the electric resistance. We have found using
digital type meter produces to many inaccurate readings.
Copyright ©2008-2009 ETON America, llc., all rights reserved.
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Service Bulletin
0051
03/01/2007
E-TON ATV, Scooter and Utility Kart
Headlight Wattages
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Bulletin No:
Date:
Head Light Wattages .G
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Viper 70‐4 10w 12w
10w Viper 150 20w 50w
35w 90w
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18w 24w
24w
Beamer Matrix 18w 24w
Beamer R2 18w 24w
Beamer R4 18w Rover N/A Rover GT N/A 2i
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Beamer III 50w
12w
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50w
20w 2i
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Maximum Viper 90‐4 Yukon 150 w
Factory 5/24/2007 w
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Per: JI‐EE Engineers Page 1
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