Eton Viper 70 Silver, Viper 90 Silver, Viper 90R Silver Service Manual
ETON America
2009 VIPER SILVER SERIES
SERVICE MANUAL
Covers:
Viper 70 Silver
Viper 90 Silver
Viper 90R Silver
CONTENTS
1. INFORMATION
2. MAINTENANCE
3. ENGINE REMOVAL AND INSTALLATION
4. LUBRICATION
5. CYLINDER HEAD / VALVES
6. CYLINDER / PISTON
7. TRANSMISSION / KICK STARTER
8A. TRANSMISSION GEAR SET
8B. SHIFTING / GEAR BOX (ONLY FOR VIPER 90R)
9. STEERING SYSTEM
10. FRONT WHEEL SYSTEM
11. REAR WHEEL AND BRAKE SYSTEM
12. FENDERS AND EXHAUST PIPE
13. ELECTRICAL SYSTEM
14.TROUBLESHOOTING
1. INFORMATION
1.1 GENERAL SAFETY 1.4 SERIAL NUMBER
1.2 NOTES
1.5 TORQUE VALUES
1.3 SPECIFICATION
1.1 GENERAL SAFETY
Gasoline
WARNING
Gasoline is extremely flammable and explosive under certain conditions. KEEP
OUT OF REACH OF CHILDREN
Carbon Monoxide
WARNING
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
WARNING
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
WARNING
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
WARNING
Used engine oil and gear oil may cause skin disease from repeated contact with
the skin for long periods of time. Keep out of reach of children.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are based on the
latest product information available at the time of approval for printing.
E-TON POWER TECH 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
GENERAL SPECIFICATIONS
Item Standard
Model code
VIPER 70 VIPER 90RVIPER 90
Dimensions
Overall length 1,510 mm (59.4 in)
Overall width 850mm (33.4 in)
Overall height 890 mm (35.0 in)
Seat height 670 mm (26.4 in)
Wheelbase 930 mm (36.6 in)
Minimum ground clearance 100 mm (3.9 in)
Minimum turning radius 2.9 m (114in)
1,500 mm (59.1 in)
850 mm (33.4 in)
900 mm (35.4 in)
680 mm (26.8 in)
930 mm (36.6 in)
120 mm (4.7 in)
2.9 m (114in)
Basic weight
With oil and full fuel tank
112 kg (247 lb)
Engine
Engine type Forced air cooled 4-stroke
Cylinder arrangement Single cylinder
Displacement 69.3 cm
(3.84 cu.in)
3
Bore ×stroke
Compression ratio 9.0 : 1
Standard compression pressure (at sea level)
(12.3 kg/cm ,
178.4 psi)
2
Electric starter & & kickstarterStarting system
Lubrication system
Wet sump
Oil type or grade
Engine oil
YAMALUBE 4, SAE5W-30 or SAE10W-40
or SAE20W-50
Final transmission oil SAE 80API “GL-4” Hypoid gear oil
Oil capacity
Engine oil
Periodic oil change 0.75 L (0.66 Imp qt, 0.80 US qt)
Total amount 0.80 L (0.70 Imp qt, 0.85 US qt)
Final transmission oil
Total amount 0.12 L (0.11 Imp qt,
0.13 US qt)
0.30 L (0.27 Imp qt,
0.32 US qt)
Air filter
Wet type element
0
10 30
50
70
90
110
130 F
YAMALUBE 4 (10W-40) or SAE 10W-40
SAE 5W-30
-20
-10 0
10
20
30 40 50 C
YAMALUBE 4 (20W-50) or SAE 20W-50
1,230 kPa
47.0 × 40.0 mm
(1.85 × 1.6 in)
88.4 cm
(4.90 cu.in)
3
10.6 : 1
(12.5 kg/cm ,
181.3 psi)
2
1,250 kPa
47.0 × 51.0 mm
(1.85 × 2.0 in)
113 kg (249 lb)
Item Standard
Model code
VIPER 70 VIPER 90RVIPER 90
Fuel
Type Unleaded gasoline only
Fuel tank capacity 4.5 L (0.99 lmp gal, 1.17 US gal)
Fuel reserve amount 1.2 L (0.26 Imp gal, 0.31 US gal)
1.0 L (0.22 Imp gal, 0.26 US gal)
Carburetor
Type/quantity SVR 22-1G x 1
Manufacturer TK
Spark plug
Type/manufacturer NGK/CR7HSA
Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Clutch type Dry, centrifugal automatic
Tire
Type
Tubeless
Size
front AT16 × 8-7
rear AT16 × 8-7
Manufacturer front MAXXIS
rear MAXXIS
Type
front M913
rear M913
Tubeless
AT18 × 7-8
AT18 × 9-8
MAXXIS
MAXXIS
M939
M940
Tubeless
AT18 × 7-8
AT18 × 9-8
MAXXIS
MAXXIS
M939
M940
Tire pressure (cold tire)
Maximum load* 62.8 kg (150 lb)
Brake
Front brake type Drum brake
operation Right hand operation
Rear brake type Single disc brake
operation Left hand operation
Suspension
Front suspension Single wishbone / Independent
Rear suspension Swingarm
Shock absorber
Front shock absorber Coil spring / oil damper
Rear shock absorber Coil spring/oil damper
Electrical
Ignition system DC-CDI
Generator system AC magneto
Battery type GTX5L-BS
Battery capacity 12 V 4.0 Ah
Off-road riding front 23 ~ 28 kPa (0.23 ~ 0.28 kgf/cm , 3.2 ~ 4.0 psi)
2
rear 23 ~ 28 kPa (0.23 ~ 0.28 kgf/cm , 3.2 ~ 4.0 psi)
2
*Load in total weight of rider and
accessories
3.6 L (0.79 lmp gal, 0.94 US gal)
Plastic
Iron
Plastic
Iron
ENGINE SPECIFICATIONS
Item Standard Limit
Cylinder head
Warp limit 0.05 mm
(0.002 in)
Cylinder
Bore size 47.000 ~ 47.010 mm
(1.8504 ~ 1.8508 in)
7.00 ~ 7.40 cm
3
(0.43 ~ 0.45 cu.in)
47.10 mm
(1.8543 in)
Taper limit ---- 0.05 mm
(0.002 in)
Maximum out-of-round ---- 0.01 mm
(0.0004 in)
Camshaft
Drive method Chain drive (Left) ---Cam dimensions
Intake “A” 25.683 ~ 25.843 mm
(1.0111 ~ 1.0174 in)
25.583 mm
(1.0072 in)
“B” 20.986 ~ 21.016 mm
(0.8262 ~ 0.8274 in)
20.886 mm
(0.8223 in)
Exhaust “A” 25.525 ~ 25.685 mm
(1.0049 ~ 1.0112 in)
25.425 mm
(1.0010 in)
“B” 20.986 ~ 21.016 mm
(0.8262 ~ 0.8274 in)
20.886 mm
(0.8223 in)
Timing chain
Timing chain type/No. of links KMC 92 RH 2005 / 82 ----
Timing chain type/No. of links KMC 92 RH 2005 / 86 ----
Timing chain adjustment method Automatic ----
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
A
B
VIPER 70
VIPER 90
VIPER 90R
Rocker arm/rocker arm shaft
Rocker arm inside diameter 10.000 ~ 10.015 mm
(0.3937 ~ 0.3943 in)
Rocker arm shaft outside diameter 9.972 ~ 9.987 mm
(0.3926 ~ 0.3932 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.034 mm
(0.0005 ~ 0.0017 in)
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.05 ~ 0.10 mm
(0.002 ~ 0.004 in)
----
EX 0.05 ~ 0.10 mm
(0.002 ~ 0.004 in)
----
Valve dimensions
“A” head diameter ----
----
“B” face width ----
----
“C” seat width
“D” margin thickness
Stem outside diameter
Guide inside diameter
Item Standard Limit
B
C
D
A
Head Diameter Face Width Seat Width Margin Thickness
IN 20.9 ~ 21.1 mm
(0.8228~ 0.8307 in)
EX 18.9 ~ 19.1 mm
(0.7441~ 0.7520 in)
IN 1.50 ~ 1.80 mm
(0.0591~ 0.0622 in)
EX 1.50 ~ 1.80 mm
(0.0591~ 0.0622 in)
IN 0.8 ~ 1.1 mm
(0.0315 ~ 0.0433 in)
1.6 mm
(0.0630 in)
EX 0.8 ~ 1.1 mm
(0.0315 ~ 0.0433 in)
1.6 mm
(0.0630 in)
IN 0.5 ~ 0.9 mm
(0.0197 ~ 0.0354 in)
1.6 mm
(0.0630 in)
EX 0.6 ~ 1.0 mm
(0.0236 ~ 0.0394 in)
1.6 mm
(0.0630 in)
IN 4.975 ~ 4.990 mm
(0.1959 ~ 0.1965 in)
4.900 mm
(0.1930 in)
EX 4.955 ~ 4.970 mm
(0.1951~ 0.1957 in)
4.900 mm
(0.1930 in)
IN 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)
5.030 mm
(0.1980 in)
EX 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)
5.030 mm
(0.1980 in)
10.100 mm
(0.3976 in)
9.910 mm
(0.3902 in)
0.19 mm
(0.0075 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
0.08 mm
(0.0031 in)
EX 0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
0.10 mm
(0.0039 in)
Stem runout limit ---- 0.02 mm
(0.0008 in)
Valve seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
1.6 mm
(0.0630 in)
Valve spring
Free length IN 30.00 mm (1.18 in) 27.00 mm
(1.06 in)
EX 30.00 mm (1.18 in) 27.00 mm
(1.06 in)
Compressed pressure
(installed) IN 39 ~ 48 N at 22.45 mm
(3.99 ~ 4.87 kg,
10.69 ~ 13.05 lb at 0.88 in)
----
EX 39 ~ 48 N at 22.45 mm
(3.99 ~ 4.87 kg,
10.69 ~ 13.05 lb at 0.88 in)
----
Tilt lim t IN
2.0
°/1.
1 mm
(2.0°/0
.04 in)
EX
2.0
°/1.1 mm
(2.0°/0.04 in)
Direction of winding
(top view) IN Counterclockwise ----
EX Counterclockwise ----
Item Standard Limit
IN 33.50 mm (1.32 in) 30.50 mm
(1.20 in)
EX 33.50 mm (1.32in) 30.50 mm
(1.20 in)
Inner spring
Free length
Outer spring
0.10 mm
(0.0039 in)(0.0004 ~ 0.0016 in)
46.970 ~ 46.990 mm
(1.8492 ~ 1.8500 in)
(0.5119 ~ 0.5121 in)
13.040 mm
(0.5134 in)
(0.5117 ~ 0.5118 in)
12.960 mm
(0.5102 in)
LimitStandardItem
Piston
Piston to cylinder clearance 0.010 ~ 0.040 mm
Piston size “D”
Measuring point “H”
----0.5 mm (0.02 in)
5.0 mm (0.20 in)
Piston off-set
----Intake sidePiston off-set direction
Piston pin bore inside diameter 13.002 ~ 13.008 mm
Piston pin outside diameter 12.996 ~ 13.000 mm
H
D
Compressed pressure
installed)
74 ~ 90 N at 25.45 mm
7.52 ~ 9.18 kg,
20.15 ~ 24.60 lb at 1.00 in)
74 ~ 90 N at 25.45 mm
7.52 ~ 9.18 kg,
20.15 ~ 24.60 lb at 1.00 in)
----
----
IN
Tilt limit
EX
IN
EX
Direction of winding
----Counterclockwise
Counterclockwise
IN(top view)
----EX
0.2
0.2
0.2
°/1.2 mm
°/0.05 in)
0.2 °/1.2 mm
°/0.05 in)
(
(
----
Barrel
1.0 × 2.1 mm
(0.0394 × 0.0827 in)
----
0.10 ~ 0.25 mm
(0.0039~0.0098in)
0.45 mm
(0.0177in)
0.015 ~0.055 mm
(0.0006~0.0022in)
0.09 mm
(0.0035in)
----Taper
1.0 × 2.0 mm
0.0394 × 0.0787 in)
----
0.25 ~ 0.40 mm
(0.0098~0.0157in)
0.55mm
(0.0217in)
0.015 ~ 0.055 mm
(0.0006~0.0022in)
0.09mm
(0.0035in)
2.0 × 1.9 mm
(0.0787 × 0.0748 in)
0.20 ~ 0.70 mm
(0.0079~0.0276in)
----
----
Crankshaft
Crankwidth 42.30~42.35mm
(1.6653~1.6673in)
----
44.10~44.15mm
(1.7362~1.7382in)
----
0.04 mm----Runout limit C1
(0.0016in)
0.04 mm----C2
(0.0016in)
Big endside clearanceD” 0.10~0.30mm
(0.0039~0.0118in)
0.50 mm
(0.0197in)
BigendradialclearanceE 0.007~
0.015mm
(0.0003
~0.0006in)
----
Small endfree play “F” 0.80~1.00mm
(0.0315~0.0394in)
1.50mm
(0.0591in)
F
A
D
C1
C2
E
A
“
”
“
“
LimitStandardItem
Piston rings
Top ring
Type
Dimensions (B × T)
End gap (installed)
Side clearance (installed)
2nd ring
Type
Dimensions (B × T)
End gap (installed)
Side clearance
T
B
B
T
Oil ring
Dimensions (B × ) T
End gap (installed)
B
T
VIPER 70
VIPER 90
VIPER 90R
Automatic centrifugalClutch type
3.5 ~ 4.0 mmClutch shoe thickness
Clutchshoe spring free length
Clutch housing inside diameter
Compression spring free length
87.9 mm (3.46 in)
Weight outside diameter
2110±140r/min
Clutch-in revolution
2350±150 r/min
Clutch-stall revolution
----
----
----
V-belt width
Clutch
V-belt
(0.1338 ~0.1575 in)
(4.21 ~4.22 in)
0 mm.2
(0.078 in)
0.08 mm
(0.0031in)
0.08 mm
(0.0031in)
17.0 mm
(0.669in)
107.5 mm
(4.23in)
3.5 ~ 4.0 mm
18.0 mm (0.709 in)
107.0 ~107.2 mm
(0.587 ~0.594 in)
14.9 ~ 15.1 mm
Transmission
V-belt automaticTransmission type
Primary reduction system Helicalgear
Primary reduction ratio
Secondary reduction system Spurgear
41/15 (2.733)
43/14 (3.071)
Secondary reduction ratio 40/13(3.077)
Max. main axle runout
Max. drive axle runout
LimitStandardItem
45/13(3.462)
VIPER 70
VIPER 90
VIPER 90R
VIPER 70
VIPER 90
VIPER 90R
Reverse reduction system Spurgear
Reverse reduction ratio 49/15 × 47/12 × 45/13
(44.288)
VIPER 90R
Carburetors
----A25 00
A26 00
A26 00
I. D. mark
----
#95
#100
(M.J)
(A.J)
Main jet
----
1.0Air jet
----#4T10 3/5
(J.N)Jet needle
2.090 H5.5(N.J)Needle jet
----
----
----
----
----
----
----
#32Pilot jet
----
----
1.6Valve seat size
5.0 ~ 6.0 mm (0.20 ~ 0.24 in)Fuel level
Below the float chamber mating
Surface ----
----1,600 ~ 1,800 r/minEngine idle speed
(V.S)
(F.L)
(P.J)
VIPER 70
VIPER 90
VIPER 90R
VIPER 70
VIPER 90
VIPER 90R
#4T10 3/5
#4T11 3/5
VIPER 70
VIPER 90
VIPER 90R
Oil pump
----TrochoidOil pump type
Inner-rotor-to-outer-rotor-tip clearance
(0.0016 ~ 0.0047 in)
0.15 mm
(0.006 in)
Outer-rotor-to-oil-pump-housing clearance
(0.0055 ~ 0.0083 in)
0.28 mm
(0.0110 in)
Oil-pump-housing-to-inner-rotor-and-outerrotor clearance
0.06 ~ 0.11 mm
0.14 ~ 0.21 mm
0.04 ~ 0.12mm
(0.0024 ~ 0.0043 in)
0.20 mm
(0.0079 in)
Lubrication chart
: Pressure feed
: Splashed scavenge
Crankshaft
pin
Camshaft
Rocker arm
Valve
Timing
chain area
Oil strainer
Oil pump
Piston
Piston pin
LimitStandardItem
CHASSIS SPECIFICATIONS
Item Standard Limit
Front suspension
Shock absorber travel 30 mm (1.18 in) ---Optional spring No ----
Rear suspension
Shock absorber travel 40 mm (1.57 in) ---Optional spring No ----
Front wheel
Type Panel wheel ---Rim size 7× 5 AT
8× 5.5 AT
----
Rim material Steel ---Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Rear wheel
Type Panel wheel ---Rim size 7× 5 AT
8× 7 AT
----
----
---Rim material Steel ---Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Front drum brake
Type Leading, trailing ---Brake drum inside diameter 95.0 mm (3.74 in) 96.0 mm
(3.38 in)
Lining thickness 3.0 mm (0.12 in) 1.5 mm
(0.06 in)
Shoe spring free length 60.0 mm (2.36 in) ----
Rear disc brake
Type
Disc outside diameter × thickness 3.0 mm
(0.12 in)
Brake disk maximum deflection 0.15 mm
(0.006 in)
Pad thickness inner 3.7 mm (0.15 in)
DOT 4
30.23 mm (1.19 in)
12.7 mm (0.50 in)
Single
190.0 × 3.5 mm (7.48 × 0.14 in)
1.0 mm
(0.04 in)
Pad thickness outer 3.7 mm (0.15 in) 1.0 mm
(0.04 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
----
----
----
----
VIPER 70
VIPER 90
VIPER 90R
VIPER 70
VIPER 90
VIPER 90R
Item Standard Limit
Brake lever and brake pedal
Brake lever free play (pivot) front 4.0 ~ 7.0 mm (0.16 ~ 0.28 in) ----
rear 0 ~ 1.5 mm (0 ~ 0.06 in) ----
Throttle lever free play 1.0 ~ 3.0 mm (0.04 ~ 0.12 in) ----
Item Standard Limit
Voltage
12 V ----
Ignition system
Ignition timing (B.T.D.C.) 13.0 °/1,700 r/min ---Advanced timing (B.T.D.C.) 29°/4,000 r/min ---Advancer type Electrical (analogue) ----
C.D.I.
Magneto model/manufacturer C1120-A26-6000/SHIHLIN ---Pickup coil resistance/color 94 ~ 140 at 20 °C (68 °F)/
White/Blue—Red
----
Source coil resistance/color 640 ~ 960 at 20 °C (68 °F)/
Ω
Ω
Ω
Ω
Ω
Black/Green—Red
----
C.D.I. unit model/manufacturer C0410-A26-6000/SHIHLIN ----
Ignition coil
Model/manufacturer C0510-A26-6000/SHIHLIN ---Minimum spark gap 6 mm (0.24 in) ----
----
----
Primary winding resistance 0.19 ~ 0.23 at 20 °C (68 °F)
Secondary winding resistance 2.79 ~ 3.41 k at 20 °C (68 °F)
Spark plug cap
Type Resin ---Resistance 5 ~ 12 k
Ω
----
Charging system
Type A.C. magneto ---Model/manufacturer C1120-A26-6000/SHIHLIN ---Nominal output 14 V 85 W at 5,000 r/min ---Charging coil resistance/color 0.60 ~ 0.90 at 20 °C (68 °F)/
White—White
----
Rectifier/regulator
Regulator type Semi conductor-short circuit ---No-load regulated voltage (DC) 14.0 ~ 15.0 V ----
----
Model/manufacturer C1600-9KB0-0000/EYE
----
Capacity (DC) 1 0A
----
Withstand voltage 500 V
ELECTRICAL SPECIFICATIONS
Electric starter system
----Constant meshType
Starter motor
----C1200-A26-6000/SYModel/manufacturer
----
----
0.35 kWOutput
Armature coil resistance 0.014 ~ 0.019 at 20 °C (68 °
----
F)
3.5 mm7.0 mm (0.24 in)
1.0 ~ 3.0 N
Brush overall length
(0.14 in)
Brush overall length
(102~ 306gf, 3.60 ~ 10.80 oz)
----
19.5 mm22.0 mm (0.87 in)Commutator diameter
(0.77in)
----.6 mm ( 0.06 in)1Mica undercut
Starter relay
----C5850-FBF0-0000/SYModel/manufacturer
----150 AModel/manufacturer
Coil winding resistance 2.98 ~ 4.03 at 20 °C (68 °F)
Circuit breakers
----
Fuse
Type
Amperage for individual circuit
Main fuse ----
1 0A × 1
Item Standard Limit
Ω
Ω
1.4 SERIAL NUMBER
Every E-TON’s ATV has a serial number which is stamped on each frame and engine. The position
of the serial number is shown in the pictures below. Make sure the serial number is the same as in your
owner’s 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
Engine serial number
1.5 TORQUE VALUES
FRAME
Tightening torque
Part to tightened
Thread
size
N.m kg-m ft.lb
Remarks
Handlebar upper holder bolt 12-15 8.9-11.11.2-1.5M 6
Throttle housing cover screw 3.5-5.0 2.6-3.70.35-0.5M 4
Steering shaft nut 50-60 36.9-44.3 5.0-6.0M14
Steering shaft holder bolt 20-30 2.0-3.0 14.8-22.1M 8
Tie rod lock nut 35-43 3.5-4.3 25.8-37.1M10
King pin nut 30-40 3.0-4.0 22.1-29.5M10
Front axle castle nut 70-90 7.0-9.0 30-45 M14
Front brake arm nut 8-12 5.2-8.9 0.8-1.2 M 6
Rear axle castle nut 70-90 7.0-9.0 30-45 M14
Swing arm pivot nut 70-90 7.0-9.0 30-45 M14
Rear brake calliper bolt 24-32 1.8-2.4 2.4-3.2 M 8
Loctite 271
Handlebar lower holder nut 30-40 3.0-4.0M10 22.1-29.5
Front wheel bolt 3.5-4.5 35-45M10 25.8-33.2
Rear wheel bolt 3.5-4.5 35-45M10 25.8-33.2
Exhaust muffler mounting bolt 20-30 2.0-3.0M 8 14.8-22.1
Engine hanger bolt 30-40 3.0-4.0 M10 22.1-29.5
Shock absorber mounting bolt 30-40 3.0-4.0M10 22.1-29.5
Rear axle holder bolt 160-180 16-18
Loctite 271
M33 11.8-13.3
Make sure every torque value is correct when you assemble the engine & frame. Please follow the
torque values list to assemble your ATV.
ENGINE
Tightening torque
Part to tightened
Thread
size
N.m kg-m ft.lb
Remarks
Spark plug M10 10-12 1.0-1.2 7.4-8.9
Cylinder head bolts M6 10-14 1.0-1.4 7.4-10.3
Tappet adjusting nut M5 7-11 0.7-1.1 5.2-8.1
Oil drain bolt M12 20-30 2.0-3.0 14.8-22.1
Clutch outer nut M10
Drive face nut M12
Loctite 638
Catalyst 7649
Camshaft holder nuts M8 14-16 1.4-1.6 10.3-11.8
Hole cap tap adjusting M30 7-9 0.7-0.9 5.2-6.6
Stud bolt M7 8-12 0.8-1.2 5.9-8.9
Starting clutch outer M28 50-60 5.0-6.0 36.9-44.3
GENERALITY
M5 3.5-5.0 0.3-0.5 2.2-3.7
M6 10.0~14.0 1.0-1.4 7.4-10.4
M8 20.0~30.0 2.0-3.0 14.8-22.1
M10 30.0~4.00 3.0-4.0 22.1-29.5
M12 50.0~60.0 5.0-6.0 36.9-44.2
General bolt nut
39-41 3.9-4.1 28.8-30.2
54-56 5.4-5.6 40.-41.4
Oil pump driven sprocket nut
10-14 1.0-1.4 7.4-10.3
M6
2. MAINTENANCE
2.1 MAINTENANCE SCHEDULE
2.2 FUEL TUBE
2.3 THROTTLE OPERATION
2.4 THROTTLE CABLE ADJUSTMENT
2.5 AIR CLEANER
2.6 SPARK PLUG
2.7
IDLE SPEED
2.8 DRIVE CHAIN
2.10 WHEELSAND TIRES
2.9 BRAKE SYSTEM
2.11 STEERINGSYSTEM
2.12 TOE-IN
2.13GEAR & ENGINE OIL
2.1 MAINTENANCE SCHEDULE
The maintenance times in this table are based upon average riding conditions. Riding
in unusually dusty areas requires more frequent servicing. (For any ATV in this service
manual.)
Periodic maintenance chart for the emission control system
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
intervals should be followed.
Items marked with an asterisk should be performed by a E-TON dealer as they require special tools,
data and technical skills.
NO. ITEM
CHECK OR MAINTENANCE
JOB
INITIAL EVERY
Whichever comes
first
month 1 3 6 6 12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours 20 80 160 160 320
1
*
Fuel line
Check fuel hoses for cracks or other damage, and
replace if necessary.
√ √ √
2 Spark plug
Check condition and clean, regap, or replace if
necessary.
√ √ √ √ √
3
*
Valves
Check valve clearance and adjust if necessary.
√ √ √ √
4
*
Carburetor
Check choke operation and correct if necessary.
Check engine idling speed and adjust if necessary.
√ √ √ √
5
*
Crankcase breather
system
Check breather hose for cracks or other damage,
and replace if necessary.
√ √ √
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
6
Exhaust system
Check for leakage and replace gasket(s) if necessary.
Check for looseness and tighten all screw clamps
and joints if necessary.
√ √ √
7 Spark arrester
Clean. √ √ √
General maintenance and lubrication chart
NO. ITEM
CHECK OR MAINTENANCE
JOB
INITIAL EVERY
Whichever comes
first
month 1 3 6 6 12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours 20 80 160 160 320
1
*
Timing chain
Check chain tension.
Adjust if necessary.
√ √ √ √
2 Air filter element
Clean and replace if necessary.
Every 20–40 hours (more often in wet or
dusty areas)
4
*
Front brake
Check operation and correct if necessary.
Check brake lever free play and adjust if necessary.
√ √ √ √ √
Replace brake shoes. Whenever worn to the limit
7
*
Wheels
Check runout and for damage, and replace if necessary.
√ √ √ √
8
*
Tires
Check tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.
√ √ √ √
5
*
Rear brake
Check operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.
√ √ √ √ √
Replace brake pads. Whenever worn to the limit
6
*
Brake hoses
Check for cracks or other damage, and replace if
necessary.
√ √ √ √
Replace. Every 4 years
3
*
Clutch
Check operation
√ √ √ √
11
*
Shock absorber
assemblies
Check operation and correct if necessary.
Check for oil leakage and replace if necessary.
√ √ √
12
*
Front knuckle pivots
Lubricate with lithium-soap-based grease. √ √ √
13
*
Steering shaft
Lubricate with lithium-soap-based grease.
√ √ √
14
*
Steering system
Check operation and repair or replace if damaged.
Check toe-in and adjust if necessary.
√ √ √ √ √
Engine oil
Change.
Check ATV for oil leakage, and correct if necessary.
√ √ √ √
Change.
17
Check ATV for oil leakage, and correct if necessary.
√√
18
*
Moving parts and
cables
Lubricate. √ √ √ √
9
*
Wheel hub bearings
Check for looseness or damage, and replace if
necessary.
√ √ √ √
10
*
Chassis fasteners
Make sure that all nuts, bolts, and screws are
properly tightened.
√ √ √ √ √
15
16
Engine oil strainer Clean.
√ √ √
Final transmission oil
2.2 FUEL TUBE
Inspect the fuel lines for deterioration, damage or
leakage and replace if necessary.
NO. ITEM
CHECK OR MAINTENANCE
JOB
INITIAL EVERY
Whichever comes
first
month 1 3 6 6 12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours 20 80 160 160 320
19
*
Moving parts and
cables
• Lubricate. √ √ √ √
20
*
Drive select lever
safety system cable
• Check operation and adjust or replace if necessary.
√ √ √
21
*
Throttle lever housing and cable
• Check operation and correct if necessary.
• Check throttle cable free play and adjust if necessary.
• Lubricate throttle lever housing and cable.
√ √ √ √ √
22
*
Front and rear brake
switches
• Check operation and correct if necessary. √ √ √ √ √
23
*
Lights and switches
• Check operation and correct if necessary.
• Adjust headlight beams.
√ √ √ √ √
√ √ √
25 *
Throttle lever housing and cable
Check operation and correct if necessary.
Check throttle cable free play and have a E -T ON
dealer adjust if necessary.
Lubricate throttle lever housing and cable.
√ √
24
*
Front and rear brake
switches
Check operation and correct if necessary. √ √
*
V-belt
Check operation
√
26
Check for wear, cracks or other damage, and replace
if necessary.
√ √ √
√ √ √
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service:
Regularly check and, if necessary, correct the brake fluid level.
Every two years, replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
2.3 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 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 lubricant to
prevent premature wear.
2.4 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.
2.5 AIR CLEANER
Lossen the air cleaner cover screws.
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 carefully.
2.6 SPARK PLUG
This spark plug is located at the front of the engine.
Disconnect the spark plug cap and unscrew the spark plug.
Check the spark plug electrodes for wear. Install
a n
ew 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 should be set to 0.6-0.7mm.
With the sealing washer attached, thread the spark plug in
by hand to prevent cross threading.
Tighten the spark plug with 10-12 N.m
2.7 IDLE SPEED
Connect an engine tachometer to the engine.
Warm up the engine by letting it run for at least 10 min.
Turn the idle-speed adjustable 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
2.8 DRIVE CHAIN
Inspect the chain slack. The standard range is 10-25mm.
Adjust the chain slack
Loosen the locked bolts (4 pcs) then adjust the drive chain
slack by turn the adjusting nut.
Tigh
ten the four locked bolts.
When the drive chain becomes very dirty, it needs be
removed, cleaned and lubricated.
Use a 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 there is excessive wear
or damage, replace it with new one.
Inspect the chain-tensioned roller.
Replace it, if necessary.
2.9 BRAKE SYSTEM
Inspect the front brake lever and cable for excessive
play or other damage.
Repl
ace or repair it 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.
There is a parking brake located at the rear tire.
Its controller is located at the handler bar on the right side.
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 range is 15-25 mm.
2.10 WHEELS AND TIRES
Inspect the tire surfaces for cuts, nails or other
puncturing objects.
Check the tire surfaces at cold tire condition.
The standard of tire pressure is 3.6±0.4 psi.
(0.25 kgf/cm
2
)
2.11 STEERING SYSTEM
Check the free play of the steering shaft with the front
wheels centered straight ahead.
When there is excessive play, inspect the tie-rod,
kingpin bushing, and ball joint.
2.12 TOE-IN
Set the vehicle on level ground and set the front wheels
facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.
Move the vehicle back carefully until 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 locking nuts.
Torque: 35-43 N.m
2.13 GEAR & ENGINE OIL
Gear oil needs to be changed every year.
There is a gear oil release bolt at the rear of engine.
Loosen this release bolt and let the dirty oil flow out.
The refilling oil hole is on the engine case beside gearbox.
Please refer to Chapter 4
3. ENGINE REMOVAL AND INSTALLATION
3.1 SERVICE INFORMATION 3.3 ENGINE INSTALLATION
3.2 ENGINE REMOVAL
3.1 SERVICE INFORMATION
ENGINE SH28/' BE REMOVED 21/<IN THE CONDITION OF NECESSARY REPAIR OR
ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM
3.2 ENGINE REMOVAL
Remove the seat and rear fender. (Chapter 11) Remove the
spark plug cap from the spark plug. Remove the exhaust
pipe.
Disconnect the carburetor cable by unscrewLQJ two screws
on top of the carburetor.
Take off oil pump cable from the oil pump control plate.
Oil pump is under the right side of engine.
Disconnect the wire connectors. There are three
connectors for carburetor auto-choke, starter motor
and generator respectively.
Remove the drive chain cover. This is under the chain.
Remove the drive chain retaining clip and master link,
and remove the drive chain.
Remove the tow engine hanger nuts and bolts.
Remove the engine from the right side of frame.
3.3 ENGINE INSTALLATION
Engine installation is essentially the reverse order of
removal.
The torque of engine hanger bolt is 24-30 Nm
Route the wires and cable in reverse order properly.
Loading...