Eton CXL-150, RXL-150, YXL-150 SERVICE MANUAL

0 (0)

CONTENTS

1.INFORMATION……………………………………………………2

2.MAINTENANCE…………………………………………………..6

3.ENGINE REMOVAL AND INSTALLATION…………………..14

4.CYLINDER HEAD / VALVES………………………………….16

5.LUBRICATION………………………………………………….26

6.CYLINDER / PISTON…………………………………………..34

7.TRANSMISSION / KICK STARTER………………………….42

8.STEERING AND SUSPENSION……………………………...52

9.FRONT WHEEL AND BRAKE SYSTEM…………………….59

10.REAR WHEEL AND BRAKE SYSTEM…………………….68

11.FENDERS AND EXHAUST PIPE…………………………...83

12.ELECTRICAL SYSTEM………………………………………89

13.TROUBLE SHOOTING……………………………………..108

1. INFORMATION

1.1	SAFTY	1.4	SERIAL NUMBER
1.2	NOTES	1.5	TORQUE VALUE
1.3	SPECIFICATION

1.1 SAFETY

GASOLINE

Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area.

● 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.

● BATTERY ELECTROLYTE

The battery electrolyte contains sulfuric acid. Protect your eyes, skin and

clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte gets in your eyes.

● HOT PARTS

Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run. Wear insulated gloves before handling these parts.

● USED ENGINE/GEAR OIL

Used engine oil and gear oil may cause skin disease if repeatedly contact with the skin for long periods.

Keep out of reach of children.

1.2 NOTES

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.

JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever.

No part of this publication may be reproduced without written permission.

1.3 SPECIFICATION ENGINE

This service manual have six models, it is YXL-150, CXL-150, EXL-150 / 150 (2004 two-passengers) RXL-150 and EXL-150 (VIPER) in this service manual.

Type

Air-Cooling 4-Stroke with oil cooler

Displacement

149.5 c.c.

Bore and Stroke

φ57.4X57.8mm

Compression

9.7:1

Maximum Torque (Nm/rpm)

11.7 / 5000 ± 500

Carburetor

Ignition

Capacitor Discharge

Starting

Electric and kick starter

Lubrication

Auto oil injection

Transmission

Automatic (C.V.T. V-belt)

YXL-150

CXL-150

EXL-150

EXL 150 (2004)

RXL-150

EXL-150 (VIPER)

CHASSIS

1665 mm

Overall Length

1730 mm

1750 mm

1670 mm

Overall Width

980 mm

1010 mm

Overall Height

1070 mm

1065 mm

1070 mm

Wheel base

1115 mm

1090 mm

Ground Clearance

130 mm

120 mm

Dry Weight

172 kg

176 kg

168 kg

170 kg

Fuel Tank Capacity

6.5 Liters

8.0 Liters

YXL-150

EXL-150

CXL-150

EXL 150 (2004)

RXL-150

EXL-150 (VIPER)

SUSPENSION

Front

Dual Arm

Rear

Swing arm

BRAKES

Front

Drum

Disc

Drum

Disc

Rear

Drum

Disc

Drum

Disc

Drum

TIRES

21”*7”-10”

Front

20”*7”-8”

21”*7”-10”

20”*11”-9”

Rear

22”*10”-8”

22”*10”-10”

20”*11”-9”

PRESSURE psi (

kgf/cm2)

Front

MAX

4.0 (0.28)

12(0.8)

4.0 (0.28)

12(0.8)

4.0 (0.28)

12(0.8)

MIN

3.2 (0.23)

Rear

MAX

4.0 (0.28)

12(0.8)

4.0 (0.28)

12(0.8)

4.0 (0.28)

12(0.8)

MIN

3.2 (0.23)

COLORING

Specifications subject to change without notice.

1.4 SERIAL NUMBER

(For YXL 150, EXL 150 / EXL 150(2004 two-passengers) and CXL 150 in this service manual)

The frame serial number is stamped on the front of the frame.

The engine serial number is stamped on the left side of the crankcase.

Frame serial number	Side frame serial number --only in
	EXL 150 / 150 (2004 two-passengers)

Engine serial number

RXL / EXL150 (Viper. St)

1.5 TORQUE VALUES

STANDARD

● 5 mm bolt and nut	5	N.m (3.5 lbf.ft)
● 6 mm bolt and nut	10	N.m (7.2 lbf.ft)
● 8 mm bolt and nut	22 N.m (16 lbf.ft)
●10 mm bolt and nut	35 N.m (25 lbf.ft)
●12 mm bolt and nut	55 N.m (40 lbf.ft)

ENGINE

● Cylinder head nut	28 N.m (20.7 lbf.ft)
● Spark plug	12	N.m (8.9 lbf.ft)
● Cylinder head bolt	20 N.m (14.8 lbf.ft)
● Alternator bolt	8	N.m (5.9 lbf.ft)

FRAME

● Handlebar upper holder bolt	24 N.m (17.7 lbf.ft)
● Throttle housing cover screw	4	N.m (2.9 lbf.ft)
● Steering shaft nut	50 N.m (36.9 lbf.ft)
● Steering shaft holder bolt	33 N.m (24 lbf.ft)
● Wheel rim bolt	18 N.m (13.3 lbf.ft)
● Tie rod lock nut	35 N.m (25.8 lbf.ft)
● King pin nut	40 N.m (29 lbf.ft)
● Handlebar lower holder nut	40 N.m (29.5 lbf.ft)
● Front wheel bolt	24 N.m (17.7 lbf.ft)
● Front axle castle nut	40-60 N.m (30-45 lbf.ft)
● Front brake arm nut	4	N.m (3.0 lbf.ft)
● Rear brake arm nut	7	N.m (5.2 lbf.ft)
● Rear axle castle nut	40-60 N.m (30-45 lbf.ft)
● Rear wheel bolt	24 N.m (17.7 lbf.ft)
● Exhaust muffler mounting bolt	30 N.m (22.1 lbf.ft)
● Engine hanger bolt	30	N.m ( 22 lbf.ft)
● Rear axle holder bolt	90 N.m (65 lbf.ft)
● Swing arm pivot nut	90 N.m (65 lbf.ft)
● Rear shock absorber mounting nut	45 N.m (33 lbf.ft)

2. MAINTENANCE

2.1 MAINTENANCE DATA	2.8 IDLE SPEED
2.2 MAINTENANCE SCHEDULE	2.9 DRIVE CHAIN
2.3 FUEL TUBLE	2.10 BRAKE SYSTEM
2.4 THROTTLE OPERATION	2.11 WHEELS AND TIRES
2.5 THROTTLE CABLE AJUSTMENT	2.12 STEERING SYSTEM
2.6 AIR CLEANER	2.13 TOE-IN
2.7 SPARK PLUG	2.14 GEAR OIL

2.1 MAINTENANCE DATA

SPECIFICATION

SPARK PLUG

SPARK PLUG CAP	0.6-0.7 mm
RECOMMENDED SPARK PLUGS
THROTTLE LEVER FREE PLAY	5-10 mm
IDLE SPEED	1600±100rpm
BRAKE LEVER FREE PLAY	15-25 mm
DRIVE CHAIN SLACK	10-25 mm
TOE-IN	5±10 mm

	TORQUE VALUES
	SPARK PLUG	12-19 N.m
	TIE-ROD LOCK NUT	35-43 N.m
	ENGINE OIL	Viscosity: SAE 10W-40
	ENGINE OIL	API service classification SF or SG
		API service classification SF or SG
	GEAR LUBRICATION OIL	SAE 90

2.2 MAINTENANCE SCHEDULE

The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually

dusty areas, require more frequent servicing.

		INITIAL SERVICE	REGULAR SERVICE	EVERY YEAR
		(First week)	(Every 30 operating days)
	FUEL LINE	I		I
	THROTTLE OPERATION	I	I
	AIR CLEANER		C
	SPARK PLUG		I
	CARBURETOR IDLE	I	I
	SPEED
	DRIVE CHAIN	I, L	I, L
	BRAKE SHOE WEAR			I
	BRAKE SYSTEM	I	I
	NUT, BOLT, FASTENER	I	I
	WHEEL/TIRES	I	I
	STEERING SYSTEM			I
	SUSPENSION SYSTEM			I
	GEAR OIL			R
	ENGINE OIL	R	I	R
	ENGINE OIL FILTER	C		C
Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary
	C: Clean	L: Lubricate	R: Replace

2.3 FUEL TUBE

Inspect the fuel lines for deterioration, damage or leakage and replace if necessary.

2.4 THROTTLE OPERATION

Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kink 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 lubricant to prevent premature wear.

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.

2.6 AIR CLEANER

Unscrew the air cleaner cover screws. Remove the air cleaner case cover.

Pull out the air filter element from the air cleaner case. Wash the element in non-flammable solvent, squeeze out the solvent thoroughly.

Let it dry.

Soak the filter element in gear oil and then squeeze out the excess oil.

Install the element into air cleaner in the reverse order of removal.

2.7 SPARK PLUG

This spark plug located at the front of the engine. Disconnect the spark plug cap and unscrew

the spark plug.

Check the spark plug electrodes for wear. Change a new spark plug 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 shall keep in 0.6-0.7mm.

With the sealing washer attached, thread the

spark plug in by hand to prevent crosses threading.

Tighten the spark plug with 12-19 N.m

2.8 IDLE SPEED

Connect an engine speed meter.

Warm up the engine, 10 minutes are enough.

Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. “Turn in” (clockwise) will get higher speed. “Turn out” (counter clockwise) will get lower speed.

IDLE SPEED: 1700±100 rpm

2.9 DRIVE CHAIN

Stop the ATV and shift the transmission into neutral. Measure the drive chain slack midway between the sprockets.

Chain slack =15~25mm (5/8~1 inch)

Adjust the chain slack.

Loosen the lock nuts and turn drive chain adjusting nuts until get the correct slack.

Tighten the axle holder bolts.

Torque = 90N.m (65 lbf.ft)

If your ATV has the tensioner inside the drive chain. You don't need to follow the procedure of chain slack adjustment. The drive chain will be adjusted by tensioner.

When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain.

Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for possible wear or damage. Replace the chain, if it is worn excessively or damaged.

Inspect the sprocket teeth, if it is excessive wear or damage, replace it.

2.10 BRAKE SYSTEM

Inspect the front brake lever and cable 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. The standard of free play is 15-25 mm.

(The right side picture is for YXL 150)

(The right side picture is for CXL / RXL / EXL-150 they have a parking brake on the top of hand brake.)

Only for EXL 150 (2004 two-passengers) / EXL-150 (VIPER)

Inspect the rear brake lever and cable 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. The standard is 10-20 mm.

(The right side picture is for YXL 150

/ EXL-150 (2004 two-passengers) / EXL-150 (VIPER))

(The right side picture is for CXL / RXL-150)

Adjust the free play of the rear brake lever by turning the adjuster on the rear axle.

(Only for YXL 150 / EXL 150 (2004 two-passengers), / EXL-150 (VIPER))

Because of the CXL / EXL / RXL-150 are both disc brake system, so they don’t need to adjust the free play. They will be discussed in chap10.

BRAKE SHOE WEAR

FRONT BRAKE

(The YXL / CXL / EXL / RXL 150 have the same model of front brake)

Release the front wheel and inspect the brake lining thickness.

Service Limit: 2.0mm(0.08 inch)

If either lining is worn beyond the service limit, replace Both brakes shoes.

REAR BRAKE

This system is for YXL / EXL 150 (2004 two-passengers) / EXL-150 (VIPER). Replace the brake shoes

if the indicator plate aligns with the brake index mark when the parking brake lever is applied.

2.11 WHEELS AND TIRES

Inspect the tire surfaces for cuts, nails or other sharp objects.

Check the tire surfaces at cold tire condition.

*The standard of tire pressure is on chap 1.

2.12 STEERING SYSTEM

Check the free play of the steering shaft with the front wheels, turned straight ahead.

When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint.

STEERING SHAFT HOLDER BUSHING

Remove the front fender first.

Remove the steering shaft holder and check the steering shaft bushing for wears or damage.

If the bushing is worn or damaged, change a new one.

Grease the steering shaft bushing and install the parts in the reverse order of removal.

Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft)

2.13 TOE-IN

Let the vehicle on level ground and the front wheels facing straight ahead.

Mark the centers of the tires to indicate the axle center height.

Measure the distance between the marks.

Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height.

Measure the distance between the marks. Calculate the difference in the front and rear measurements.

Toe-in: 5±10mm

If the toe-in is out of standard, 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

2.14 GEAR OIL

Gear oil needs to be changed every year.

There is a gear oil release bolt at the rear of engine.

Unscrew this release bolt and can let the dirty oil flow out. (STEP1)

The re-add oil hole is on the engine case beside gearbox. (STEP2)

STEP1

STEP2

3. ENGINE REMOVE AND INSTALLATION

3.1 REPAIR CONDITION

3.3 ENGINE INSTALLATION

3.2ENGINE REMOVAL

3.1ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY

3.2ENGINE REMOVAL

Remove the seat, front fender and rear fender (see chapter 11). Remove the footrest. Remove the spark plug cap from the spark plug. Remove the exhaust muffler. Disconnect the carburetor cable by unscrew two screws on top of the carburetor.

Disconnect the wire connectors. There are three connectors for carburetor auto-choke, starter motor and generator respectively.

Remove the drive chain cover.

Remove the drive chain retaining clip and master link, and remove the drive chain.

Remove the engine hanger bolts under the engine.

Remove the three bolts and air cleaner together.

3.3 ENGINE INSTALLATION

Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 30 N.m Route the wires and cable in reverse order properly.

4.CYLINDER HEAD / VALVES

4.1 SERVICE INFORMATION	4.4 CYLINDER HEAD REMOVAL
4.2 TROUBLESHOOTING	4.5 CYLINDER HEAD INSTALLATION
4.3 CAMSHAFT COMPOSITION REMOVAL

4.1 SERVICE INFORMATION

GENERAL

This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case. Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place.

SPECIFICATIONS

ITEM		STANDARD	SERVICE LIMIT

CYLINDER COMPRESSION		12±0.5 kg/cm2	--------
CAM LOBE HEIGHT	IN	29.795	29.395

	EX	29.560	29.160
	EX	29.560	29.160

ROCKER ARM I.D.		10.000-10.018	10.10

ROCKER ARM SHAFT O.D.		9.972-9.987	9.91

CYLINDER HEAD WARPAGE		--------	0.05

VALVE SPRING FREE LENGTH	IN	32.3	31.2

	OUT	35.0	34.1
	OUT	35.0	34.1

VALVE STEM O.D.	IN	4.975-4.990	4.90

	EX	4.955-4.970	4.90
	EX	4.955-4.970	4.90

VALVE GUIDE I.D.	IN/EX	5.000-5.012	5.30

STEM-TO-GUIDE CLEARANCE	IN	0.010-0.037	0.08

	EX	0.030-0.057	0.10
	EX	0.030-0.057	0.10

VALVE SEAT WIDTH	IN	1.0	1.8

	EX	1.0	1.8
	EX	1.0	1.8

TORQUE VALUES

Cylinder head bolts	8	~ 12 n-m (0.8 ~ 1.2 kg-m)
Camshaft holder flange nuts	20 ~ 24 n-m (2.0 ~ 2.4 kg-m)
Tappet adjusting nut	9	~ 12 n-m (0.9 ~ 1.2 kg-m)

4.2 TROUBLE SHOOTING

Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope.

LOW COMPRESSION

Valve

Incorrect valve adjustment

Worn or damaged valve seats

Burned or bent valve

Incorrect valve timing

Weak valve spring

Cylinder head

Leaking or damaged head gasket

Warped or cracked cylinder head

Faulty cylinder or piston

Excessive noise

Incorrect valve adjustment

Sticking valve or broken valve spring

Worn or damaged rocker arm or camshaft

Worn or damaged cam chain

Worn or damaged cam chain tensioner

Worn cam sprocket teeth

Excessive smoke

Damaged valve stem seal

Faulty cylinder or piston rings

4.3 CAMSHAFT COMPOSITION REMOVAL

Remove the rubber tube of gas waste recovery.	RUBBER TUBE

GAS WASTE RECOVERY

Remove the cylinder head cover.

CYLINDER HEAD COVER

Eton CXL-150, RXL-150, YXL-150 SERVICE MANUAL

Remove the air cleaner and carburetor.

Remove the inlet pipe assy.

Remove the shroud compositions.

Relax the cam chain adjuster screw.

Remove the screw and O-ring and tighten the cam chain adjusting bolt with clockwise direction.

Remove the nuts and washers.

Remove the camshaft holder and dowel pins.

Relax the camshaft gear from cam chain and remove the camshaft.

CARBURATOR

SHROUD COMPOSITIONS		INLET PIPE ASSY

CAM CHAIN ADJUSTING BOLT

CAM CHAIN ADJUSTER SCREW

CAMSHAFT HOLDER

NUTS

CAMSHAFT

CAMSHAFT GEAR

INSPECTION

Inspect the cam lobes surface and height of cam lobes for wear or damage.

SERVICE LIMIT: IN 29.395 mm

EX 29.160 mm

Inspect the camshaft and bearings for wear or damage and replace them if necessary.

Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms.

Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage.

CAM		LOBES

BEARINGS

ROCKER ARMS

CAMSHAFT HOLDER		ROCKER ARM SHAFTS

Measure the I.D. of each rocker arm.

SERVICE LIMIT: 10.10 mm

Measure the O.D. of each rocker arm shaft.

SERVICE LIMIT: 9.91 mm

4.4 CYLINDER HEAD REMOVAL

Remove the flange bolts and cylinder head.	FLANGE BOLTS

CYLINDER HEAD

Remove the cylinder head gasket and dowel pins.

DOWEL PINS

CYLINDER HEAD GASKET

Remove the cam chain guide.

CAM CHAIN GUIDE

CYLINDER HEAD DISASSEMBLY

Remove the valve cotters, spring retainers and valve springs with a valve spring compressor.

INSPECTION

Clean off all carbon deposits from the combustion chamber.

Check the spark plug hole and valve area for cracks.

Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge.

SERVICE LIMIT: 0.05 mm

Measure the free length of the inner and outer valve springs.

SERVICE LIMITS: Inner 31.2 mm Outer 34.1 mm

INNER VALVE

OUTER VALVE

Inspect each valve for turning, burning, scratches or abnormal stems wear.

Check the valve movement in the guide. Measure and record each valve stem O.D.

SERVICE LIMITS: 4.90 mm

Measure and record the valve guide I.D.

SERVICE LIMITS: IN / EX 5.30 mm

Calculate the stem-to-guide clearance.

SERVICE LIMITS: IN	0.08 mm
EX	0.10 mm

NOTE: If the stem-to-guide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance.

If so, replace guides as necessary and ream to fit. If the valve guide is replaced, the valve guide is replaced; the valve seat must be refaced.

CYLINDER HEAD ASSEMBLY

Lubricate each valve stem with oil. Insert the valves into guides.

Install the valve springs, retainers and the cotters.

NOTE: To prevent loss of tension, don’t compress the valve springs more than necessary.

INLET VALVE

EXHAUST VALVE

INSTALLATION

Install the new gasket and dowel pins.

Install the cam chain guide.

Install the cylinder head.

CAMSHAFT COMPOSITION INSTALLATION

Install the rocker arms and rocker arm shafts into the camshaft holder.

DOWEL PINS

CAM CHAIN GUIDE

CYLINDER HEAD

Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter - clockwise.

Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole forwards front.

Install the dowel pins and camshaft holder. Tighten the washers and nuts.

TORQUE: 20 n-m (2.0 kg-m)

Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge.

STANDARD VALVE: 0.08 mm

“T” MARK

“I” MARK

CIRCLE HOLE

Relax the cam chain-adjusting bolt with counterclockwise direction and install the o-ring and screw.

Install the cylinder head cover.

CYLINDER HEAD COVER

5. LUBRICATION

5.1 SERVICE INFORMATION	5.4 ENGINE OIL & FILTER CHANGE
5.2 TROUBLESHOOTING	5.5 OIL PUMP
5.3 ENGINE OIL LEVEL

5.1 SERVICE INFORMATION

GENERAL

This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump.

Fill the oil pump with clean oil when reassembling the pump.

SPECIFICATION
ENGINE OIL CAPACITY	0.8-1.0 liter
API service classification: SF or SG	ENGINE OIL RECOMMENDATION
	VISCOSITY: SAE 20w-40

When the average temperature in your riding area is within the indicated range, you should use the other engine oil viscosities that are shown in the chart.

ENGINE OIL VISCOSITIES

SAE 20W-50

SAE 20W-40

SAE 10W-40

SAE 10W-30

		SAE 5W

	-20	-10	0	10	20	30	40 o C

	ITEM				STANDARD			SERVICE LIMIT
OIL PUMP	COVER-TO-ROTOR CLEARANCE				----------		0.12
	ROTOR TIP CLEARANCE				----------		0.12

	END CLEARANCE				0.05 – 0.10		0.2

TORQUE VALUE
OIL DRAIN BOLT		20-30 n-m	(2.0~3.0 kg-m)

5.2 TROUBLESHOOTING

Oil lever too low-high oil consumption

Normal oil consumption.

External oil leaks.

Oil not changed often enough.

Worn piston rings.

Faulty heat gasket.

Oil contamination

Worn piston rings.

Faulty heat gasket.

Oil or filter not changed often enough.

5.3 ENGINE OIL LEVEL

Place the engine on the level plane.

Check the oil level with the oil level gauge, but do not screw it in when making this check.

OIL LEVEL GAUGE

Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge.

LOWER

UPPER LEVEL

5.4 ENGINE OIL & FILTER CHANGE

Remove the oil filter cap and the oil drain bolt. NOTE: Drain the oil while the engine is warm to ensure complete draining.

27	OIL DRAIN

Remove the oil filter cap, spring and oil filter screen. Check the O-ring for damage or fatigue.

Install a new oil filter screen and spring then install the cap.

Install the oil drain bolt with sealing washer.

TORQUE: 20~30 n-m (2.0 ~ 3.0 kg-m)

Fill the crankcase with recommended oil.

ENGINE OIL CAPACITY: 0.8 liter at draining.

Install the oil filter cap. Install the oil level gauge.

Start the engine and let it idle speed for 2 or 3 minutes. Stop the engine and check that the oil level at the upper line on the gauge. Make sure there is no oil leaks.

5.5 OIL PUMP REMOVAL

Remove the fan cover assy.

OIL FILTER SCREEN

SPRING

OIL FILTER CAP

OIL FILTER

O-RINING

FAN COVER ASSY.

Remove the cooling fan composition.	COOLING FAN COMPOSITION

Remove the A.C.G generator assy.

A.C.G GENERATOR ASSY

Remove the right crankcase cover.

CRANKCASE COVER

Remove the starting clutch outer and gear assy.

STARTING CLUTCH OUTER

29	STARTING CLUTCH GEAR

Remove the flange bolts and oil separator.

Remove the oil pump chain and oil pump driven sprocket.

Remove the oil pump assy.

Disassemble the oil pump.

OIL SEPARATOR

FLANGE BOLTS

OIL PUMP CHAIN

OIL PUMP DRIVEN SPROCKET

OIL PUMP ASSY.

+ 81 hidden pages