E-TON Sport 150 Service Manual
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E-TON Sport 150 Service Manual

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E-TON POWER
SF3A 150
SPORT 150

SERVICE MANUAL

Copyright ©2008-2009 ETON America, all rights reserved.

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Summary of Contents for E-TON Sport 150

  • Page 1: Service Manual

    E-TON POWER SF3A 150 SPORT 150 SERVICE MANUAL Copyright ©2008-2009 ETON America, all rights reserved.
  • Page 2 E-TON FORWARD This service manual contains the technical data of each component inspection and repair for the E-TON series motorcycle. The manual is shown with illustrations and focused on Service Procedures , Operation Key Points , and Inspection Adjustment so that provides technician with service guidelines.
  • Page 3 HOW TO USE THIS MANUAL E-TON This service manual describes basic information of different system parts and system inspection & service for E-TON series motorcycles. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment.
  • Page 4 MECHANISM ILLUSTRATIONS E-TON Engine stop switch/starter Fuse &C.D.I Battery Front turn signal light Fuel tank cap High& Low beam/ Turn signal/Horn switch Front light/ Seat lock Position light Air Cleaner Kick starter pedal Engine oil draining Engine number Side stand...

  • Page 5: Table Of Contents

    E-TON CONTENTS CONTENTS GENERAL INFORMATION/TROUBLE DIAGNOSIS ........1 MAINTENANCE INFORMATION ..............2 LUBRICATION SYSTEM................3 FUEL SYSTEM .....................4 REMOVAL OF ENGINE................5 CYLINDER HEAD/VALVE................6 CYLINDER/PISTON..................7 V-BELT DRIVING SYSTEM/KICK STARTER ARM........8 FINAL DRIVING MECHANISM..............9 A.C. GENERATOR/STARTING CLUTCH ............10 CRANKCASE/CRANKSHAFT ..............11 BODY COVER ....................12 BRAKE......................13 STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER ......14 REAR WHEEL/SUSPENSION..............15...

  • Page 6: Symbols And Marks

    E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SYMBOLS AND MARKS ....1-1 TORQUE VALUES (ENGINE) ....1-10 GENERAL SAFETY......1-2 TORQUE VALUES (FRAME) ....1-11 SERVICE PRECAUTIONS ....1-3 TROUBLES DIAGNOSIS ..... 1-12 SPECIFICATIONS......1-9 LUBRICATION POINTS ....... 1-16 SYMBOLS AND MARKS Symbols and marks are used in this manual to indicate what and where the special service are needed, in case supplemental information is procedures needed for these symbols and marks, explanations will be added to the text instead of using the symbols or marks.

  • Page 7: General Safety

    E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS GENERAL SAFETY Carbon monoxide Battery If you must run your engine, ensure the place is Caution well ventilated. Never run your engine in a closed area. Run your engine in an open area, if Battery emits explosive gases; flame is you have to run your engine in a closed area, be strictly prohibited.

  • Page 8: Service Precautions

    E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SERVICE PRECAUTIONS y Always use with SANYANG genuine parts y Never bend or twist a control cable to prevent and recommended oils. Using non-designed stiff control and premature worn out. parts for SANYANG motorcycle may damage the motorcycle.
  • Page 9 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS y The length of bolts and screws for y Remove residues of the old gasket or sealant assemblies, cover plates or boxes is different before reinstallation, grind with a grindstone if from one another, be sure they are correctly the contact surface has any damage.
  • Page 10 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS y Lubricate the rotation face with specified y Before battery removal operation, it has to lubricant on the lubrication points before remove the battery negative (-) cable firstly. assembling. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.
  • Page 11 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS y When separating a connector, it locker has to y Before terminal connection, check if the boot be unlocked firstly. Then, conduct the is crack or the terminal is loose. service operation. y Insert the terminal completely. Check if the terminal is covered by the boot.
  • Page 12 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS y Do not let the wire harness contact with y Protect wires or wire harnesses with electrical rotating, moving or vibrating components as tape or tube if they contact a sharp edge or routing the harness.
  • Page 13 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS y Do not let the wire harness been twisted as y With sand paper to clean rust on connector installation. pins/terminals if found. And then conduct connection operation later. Clean rust. y Wire harnesses routed along the handlebar...

  • Page 14: Specifications

    E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS MAKER SANYANG MODEL XS125T-13 Overall Length 1800 mm Front TELESCOPIC FORK Overall Width 695 mm Rear DOUBLE SWING ARM Overall Height 1125 mm Front 120/70-12 56J Wheel Base 1300 mm Rear 120/70-12 56J Front...
  • Page 15 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (ENGINE) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Cylinder head holder nuts 1.8~2.2 Cylinder head bolts 0.8~1.2 Cylinder/cylinder head 0.7~1.1 Tighten to crankcase two-ends bolts Cylinder head cover bolts 0.8~1.2 Valve adjustment fixing nuts 1.0~1.5...
  • Page 16 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (FRAME) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Mounting Hex socket bolt for 4.0~5.0 steering handlebar Mounting nut for steering rod 25.4 1.0~2.0 Cone seat for steering rod 25.4 0.2~0.3 Front wheel shaft nut 5.0~7.0...

  • Page 17: Troubles Diagnosis

    E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TROUBLES DIAGNOSIS A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes 1. No fuel in fuel tank Loosen carburetor drain 2. Check if the pipes, fuel tank to...
  • Page 18 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Fault condition Probable causes Try gradual acceleration and check engine speed 1. Air cleaner clogged 2. Poor fuel supply Engine speed can be Engine speed can not be 3.
  • Page 19 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Abnormal Normal 1. Incorrect ignition timing (malfunction of CDI or AC alternator)
  • Page 20 E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS E. CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved.

  • Page 21: Lubrication Points

    E-TON 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS LUBRICATION POINTS Seat lock Acceleration cable/ Front & rear brake lever pivot Steering shaft bearing Speedometer gear / Rear wheel bearing Side stand shaft Main stand shaft Front wheel bearing 1-16 Copyright ©2008-2009 ETON America, all rights reserved.
  • Page 22 E-TON 2. MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION ..2-1 IGNITION SYSTEM/SPARK PLUG .. 2-8 PERIODICAL MAINTENANCE CYLINDER COMPRESSION SCHEDULE ........2-2 PRESSURE........2-9 LUBRICATION SYSTEM ....2-3 DRIVING SYSTEM......2-9 FUEL SYSTEM........2-4 STEERING SYSTEM ......2-10 AIR CLEANER........2-5 SUSPENSION SYSTEM ....2-10 THROTTLE VALVE OPERATION ..2-5 FRONT DISK BRAKE SYSTEM ..

  • Page 23: Periodical Maintenance Schedule

    Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your E-TON Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.

  • Page 24: Lubrication System

    E-TON 2. MAINTENANCE INFORMATION LUBRICATION SYSTEM Engine Oil Capacity Caution The vehicle must be parked on a level ground when checking oil capacity. Run the engine for 2-3 minutes then stop, wait about 2-3 more minutes allowing engine oil to settle before checking the oil level.

  • Page 25: Fuel System

    2. MAINTENANCE INFORMATION E-TON Gear Oil Gear oil refilling bolt Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engine and remove the gear oil draining plug. Place a measurement cup under the draining hole.

  • Page 26: Air Cleaner

    E-TON 2. MAINTENANCE INFORMATION AIR CLEANER screws 7 Element Remove left side cover. Remove 7 screws from the air cleaner cover. Remove element of air cleaner (2 screws). Check the element if dirt or damaged. Replace it with new one if dirt or damaged.

  • Page 27: Crankcase Ventilation

    2. MAINTENANCE INFORMATION E-TON Adjustment nut Primary adjustment is conducted from button side. Loosen fixing nut, and adjust by turning the adjustment nut. Tighten the fixing nut, and check acceleration operation condition. Fixing nut CRANKCASE VENTILATION Crankcase blow-by system Pull out the plug from draining hose to clean...

  • Page 28: Adjustment

    E-TON 2. MAINTENANCE INFORMATION Check & adjust valve clearance with feeler gauge. Feeler gauge Valve clearance (IN/EX): 0.06±0.02 mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution It has to make sure that valve-rocker arm is be adjusted to standard level when adjusting it, and re-check the valve clearance after tightened the fixing nut.

  • Page 29: Ignition System/Spark Plug

    2. MAINTENANCE INFORMATION E-TON IGNITION SYSTEM F mark Ignition timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for Ignition light checking whether C.D.I. function is in normal or not.

  • Page 30: Cylinder Compression Pressure

    E-TON 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Open the seat. Remove the luggage box. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.

  • Page 31: Steering System

    2. MAINTENANCE INFORMATION E-TON STEERING SYSTEM Caution Check all wires and cables if they are interfered with the rotation of steering handle bar. Lift the front wheel out of ground. Turn handle from right to left and check if turning is smoothly.

  • Page 32: Front Disk Brake System

    E-TON 2. MAINTENANCE INFORMATION FRONT DISC BRAKE SYSTEM Brake hose BRAKE SYSTEM HOSE Make sure the brake hoses for corrosion or leaking oil, and also check brake system for leaking. BRAKE FLUID Check brake fluid level in the brake fluid reservoir.
  • Page 33 2. MAINTENANCE INFORMATION E-TON Brake fluid cap ADDED BRAKE FLUID Add brake fluid to UPPER limit lever. Recommended brake fluid: DOT3 or DOT4 Low limit WELL RUN brake fluid. Caution Never mix or use dirty brake fluid to prevent from damage brake system or reducing brake performance.

  • Page 34: Drum Brake System

    E-TON 2. MAINTENANCE INFORMATION DRUM BRAKE SYSTEM Front Brake Free Play: (Drum brake) Measure free play of rear brake level at the 10 20mm end of the lever. Free play: 10-20 mm Adjust the free play by turning the front brake adjustment nut if necessary.

  • Page 35: Wheel/Tire

    2. MAINTENANCE INFORMATION E-TON BRAKE LIGHT SWITCH Brake light switch The brake light switch is to lit up brake light as brake applied. Make sure that electrical starter can be operated only under brake applying. WHEEL/TIRE Check if both front and rear tire pressure are within specification.

  • Page 36: Battery

    E-TON 2. MAINTENANCE INFORMATION BATTERY Battery Removal Remove the 2 screws on the floor panel. Remove battery cap. (2 nuts) Battery cables removal: 1. At first, remove the negative “-” cable. 2. Then, remove the positive “+” cable. 3. Remove the battery.
  • Page 37 E-TON 3. LUBRICATION SYSTEM MECHANISM DIAGRAM ....3-1 CLEANING ENGINE OIL STRAINER... 3-3 OPERATIONAL PRECAUTIONS ..3-2 OIL PUMP ..........3-4 TROUBLE DIAGNOSIS......3-2 GEAR OIL ..........3-7 ENGINE OIL ........3-3 MECHANISM DIAGRAM Valve rocker Forcedly lubrication Camshaft Scoop lubrication Inner passage Connecting rod...

  • Page 38: Operational Precautions

    3. LUBRICATION SYSTEM E-TON OPERATIONAL PRECAUTIONS General Information This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil. Oil viscosity Specifications Engine oil quantity Disassembly 900 c.c. Replacement 850 c.c. Oil viscosity SAE 10W-30 or equivalent Gear Oil Capacity Disassembly 100 c.c.

  • Page 39: Engine Oil

    E-TON 3. LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the motorcycle in flat ground with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not rotate the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.

  • Page 40: Oil Pump

    3. LUBRICATION SYSTEM E-TON OIL PUMP bolts Oil Pump Removal Remove the alternator (refer to chapter10). Remove the engine right crankcase cover. Remove the one-way clutch and starting drive gear (1 nut). Make sure that the pump axle can be rotated freely.
  • Page 41 E-TON 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm Check clearance between rotor side face and pump body.
  • Page 42 3. LUBRICATION SYSTEM E-TON Oil Pump Installation Install the oil pump (2 bolts). 2 bolts Install oil pump driver chain and drive gear. oil pump driver chain drive gear Install oil pump outer cover (2 bolts). oil pump outer cover 2 bolts Install the starting gear and the alternator.

  • Page 43: Gear Oil

    E-TON 3. LUBRICATION SYSTEM GEAR OIL Filling bolt Draining bolt Oil Level Inspection Park the motorcycle on flat ground with main stand. Turn off engine and remove both engine oil filling bolt and oil draining bolt. Remove gear oil filling hole bolt and place a measurement cup under the draining plug.
  • Page 44 E-TON 4. FUEL SYSTEM MECHANISM ILLUSTRATION ..... 4-1 AUTO BY-STARTER ......4-7 PRECAUTIONS IN OPERATION ..4-2 FLOAT CHAMBER ......4-8 TROUBLE DIAGNOSIS......4-3 INSTALLATION OF CARBURETOR .. 4-9 CARBURETOR REMOVAL ....4-4 IDLE SPEED ADJUSTMENT ..... 4-9 VACUUM CHAMBER ......4-4 FUEL TANK ........

  • Page 45: Precautions In Operation

    4. FUEL SYSTEM E-TON PRECAUTIONS IN OPERATION General Information Warning Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and strictly prohibit flame when working with gasoline. Cautions z Do not bend or twist throttle valve cable. Damaged cable will make unstable drivability.

  • Page 46: Trouble Diagnosis

    E-TON 4. FUEL SYSTEM TROUBLE DIAGNOSIS Power insufficiency and fuel consuming Poor engine start z Fuel system clogged z No fuel in fuel tank Malfunction of ignition system z Clogged fuel tube z Too much fuel in cylinder z No spark from spark plug (malfunction of...

  • Page 47: Carburetor Removal

    4. FUEL SYSTEM E-TON throttle valve cable vacuum CARBURETOR REMOVAL hose Open the seat. Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose.

  • Page 48: Fuel System

    E-TON 4. FUEL SYSTEM Remove fuel needle seat, spring, and fuel needle injector needle. seat Check if the vacuum piston for wear out, fuel needle crack or other damage. spring Check if the diaphragm for damage or crack. injector Cautions needle Do not damage vacuum diaphragm.

  • Page 49: Air Cut-Off Valve

    4. FUEL SYSTEM E-TON AIR CUT-OFF VALVE Removal Remove the vacuum hose clamp and then the vacuum hose. Screws Remove the screws (screw x 2) of the air cut-off valve and its cover. screws vacuum diaphragm Remove the spring and vacuum diaphragm.

  • Page 50: Fuel System

    E-TON 4. FUEL SYSTEM AUTO BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter Resistance value: Max. 10 (Measured after engine stopped for more than 10...

  • Page 51: Float Chamber

    4. FUEL SYSTEM E-TON FLOAT CHAMBER float Disassembly float pin Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. screws× 4 Checking Check float needle valve and valve seat for float pin drop difference damage, wear out, dirty or clogged.

  • Page 52: Installation Of Carburetor

    E-TON 4. FUEL SYSTEM Installation Install main jet, slow jet and fuel amount adjustment screw. Cautions Set the adjustment screw in according to number of turns noted before it was removed. fuel amount adjustment screw Install the float valve, float, and float pin.

  • Page 53: Fuel Tank

    4. FUEL SYSTEM E-TON FUEL TANK Fuel unit removal Remove the seat. Remove the luggage box assembly (2 bolts and 3 nuts). Disconnect fuel unit connector. Remove fuel unit. Cautions Do not bend the float arm of fuel unit. Do not fill out too much gasoline to fuel tank.

  • Page 54: Air Cleaner

    E-TON 4. FUEL SYSTEM AIR CLEANER Removal Open the seat and remove the luggage box . Loosen the clamp strip of air cleaner. Remove evaporative return hose. Remove body cover. Remove the air cleaner body bolts (2 bolts). Remove the air cleaner.
  • Page 55 E-TON 5. REMOVAL OF ENGINE MECHANISM DIAGRAM ...... 5-1 ENGINE SUSPENSION FRAME..5-7 OPERATIONAL PRECAUTIONS ..5-2 INSTALLATION OF ENGINE ....5-8 ENGINE REMOVAL ......5-3 REMOVAL OF ENGINE SUSPENSION BUSHING ..........5-6 MECHANISM DIAGRAM 3.5~4.5kgf-m 4.5~5.5kgf-m 4.5~5.5kgf-m 2.4~3.0kgf-m 4.5~5.5 kgf-m...

  • Page 56: Operational Precautions

    5. REMOVAL OF ENGINE E-TON OPERATIONAL PRECAUTIONS General Information Engine must be supported by a bracket or adjustable tool in height. The following parts can be serviced with the engine installed on the frame. 1. Carburetor 2. Driving disk, driving belt, clutch, and transporting disk 3.

  • Page 57: Engine Removal

    E-TON 5. REMOVAL OF ENGINE ENGINE REMOVAL Generator connector Open the seat. Remove the luggage box assembly (2 bolts and 3nuts ). Remove the body cover (screw3x2). Remove the power connector of auto by- start. Remove the generator connector and pulse generator connector.
  • Page 58 5. REMOVAL OF ENGINE E-TON Remove the fuel pipe, vacuum hose, and throttle valve cable from the carburetor. Loose the strap screw of the air cleaner guide, and remove the air cleaner guide. Remove the exhaust muffler (Bolts × 2, Nuts × 2).
  • Page 59 E-TON 5. REMOVAL OF ENGINE Rear shock absorber bolt Remove the rear brake cable nut. Remove the rear brake cable. Remove the rear shock absorber lower bolt. Brake cable nut Loose the strap screw of engine left guide, and then remove the engine left guide.

  • Page 60: Removal Of Engine Suspension Bushing

    5. REMOVAL OF ENGINE E-TON REMOVAL OF ENGINE SUSPENSION BUSHING If engine suspension frame and the cushion rubber of rear shock absorber bushing damaged. Then, with the bushing remover / presser, 28mm & 20mm, to press the bushing out, and replace it with new one.

  • Page 61: Removal Of Engine

    E-TON 5. REMOVAL OF ENGINE ENGINE SUSPENSION FRAME Removal Remove the right side bolt of engine suspension frame. Bolt of engine suspension frame (right side) Remove the left side bolt of engine suspension frame. Bolt of engine suspension frame (left side) Check if the engine suspension frame bushing and cushion rubber for damage.

  • Page 62: Installation Of Engine

    5. REMOVAL OF ENGINE E-TON INSTALLATION OF ENGINE Engine suspension nut 1 Check if the bushings of engine suspension frame and shock absorber for damaged. If so, replace with new ones. Install the engine according to the reversing order of removal.

  • Page 63: Cylinder Head/Valve

    E-TON 6. CYLINDER HEAD/VALVE MECHANISM DIAGRAM ....6-1 VALVE SEAT INSPECTION AND PRECAUTIONS IN OPERATION ..6-2 SERVICE..........6-10 TROUBLE SHOOTING.......6-3 CYLINDER HEAD REASSEMBLY ..6-12 CAMSHAFT REMOVAL .....6-4 CYLINDER HEAD INSTALLATION ..6-13 CYLINDER HEAD REMOVAL ....6-6 CAMSHAFT INSTALLATION ....6-13 CYLINDER HEAD DISASSEMBLY ..6-7...
  • Page 64 6. CYLINDER HEAD/VALVE E-TON PRECAUTIONS IN OPERATION General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as valve rocker arm. Cylinder head service cannot be carried out when engine is in frame.
  • Page 65 E-TON 6. CYLINDER HEAD/VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure.

  • Page 66: Camshaft Removal

    6. CYLINDER HEAD/VALVE E-TON CAMSHAFT REMOVAL Blow-by hose Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head cover 4 bolts and then remove the cylinder head cover. A.I. 4 bolts...
  • Page 67 E-TON 6. CYLINDER HEAD/VALVE Remove the camshaft holder and rocker arm set. Remove the camshaft chain from the camshaft sprocket. Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Camshaft Service Limit bearing IN: Replacement when less than 25.29 mm EX: Replacement when less than 25.12 mm...

  • Page 68: Cylinder Head Removal

    6. CYLINDER HEAD/VALVE E-TON Measure the valve rocker arm I.D. Service Limit: Replace when it is above 10.100 mm Measure the active O.D. of the valve rocker arm shaft . Service Limit: Replace when it is above 9.910 mm Calculate the clearance between the rocker arm shaft and the rocker arm.

  • Page 69: Cylinder Head Disassembly

    E-TON 6. CYLINDER HEAD/VALVE dowel pins Remove the 2 cylinder head mounting bolts from cylinder head left side cover. Remove cylinder head gasket and 2 dowel pins. Remove chain plate. Clean up residues from the matching surfaces of cylinder and cylinder head.

  • Page 70: Cylinder Head Inspection

    6. CYLINDER HEAD/VALVE E-TON CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack. Measure cylinder head flat with a straightedge and flat feeler gauge. Service limit: 0.05mm Valve spring free length Measure the free length of intake and exhaust valve springs.
  • Page 71 E-TON 6. CYLINDER HEAD/VALVE Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement.

  • Page 72: Valve Seat Inspection And Service

    6. CYLINDER HEAD/VALVE E-TON VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution y Do not let emery enter into between valve stem and valve guide.
  • Page 73 E-TON 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. 1.0mm Caution Make sure that all roughness and uneven faces had been grinded.

  • Page 74: Cylinder Head Reassembly

    6. CYLINDER HEAD/VALVE E-TON After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up all emery coated onto cylinder and valve after grinded. Valve cotters Valve stem CYLINDER HEAD REASSEMBLY...

  • Page 75: Cylinder Head Installation

    E-TON 6. CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION Cylinder head gasket Lock pins Install the lock pins and new cylinder head gasket onto the cylinder head. Install the camshaft chain plate. Chain plate Install the cylinder head. CAMSHAFT INSTALLATION Assemble the camshaft holder.

  • Page 76: Valve Clearance Adjustment

    6. CYLINDER HEAD/VALVE E-TON Install the lock pins. Install the camshaft holder, gasket and nut onto the cylinder head. Tighten the cylinder head nuts. (4 nuts) At first, tighten the 4 nuts on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.

  • Page 77: Cylinder/Piston

    E-TON 7. CYLINDER/PISTON MECHANISM DIAGRAM ....7-1 PISTON REMOVAL......7-5 PRECAUTIONS IN OPERATION ..7-2 PISTON RING INSTALLATION..7-7 TROUBLE DIAGNOSIS......7-2 PISTON INSTALLATION....7-8 CYLINDER REMOVAL .......7-3 CYLINDER INSTALLATION....7-8 MECHANISM DIAGRAM 0.8~1.2kgf-m Copyright ©2008-2009 ETON America, all rights reserved.
  • Page 78 7. CYLINDER/PISTON E-TON PRECAUTIONS IN OPERATION General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. : t i 57.395~57.415 57.7 Bend/wrap age 0.050 Cylinder n i l Top ring 0.025~0.060 0.090 Clearance between...
  • Page 79 E-TON 7. CYLINDER/PISTON CYLINDER REMOVAL 2 bolts Cylinder Remove cylinder head. (refer to chapter 6) Remove 2 bolts and then take out the cam chain auto-adjuster. Cam chain Cam chain guide auto-adjuster Remove cam chain plate. Remove cylinder. Remove cylinder gasket and lock pins...
  • Page 80 7. CYLINDER/PISTON E-TON Cover the holes of crankcase and cam chain with a piece of cleaning cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soap the residues into solvent so that the residues can be removed more easily.

  • Page 81: Piston Removal

    E-TON 7. CYLINDER/PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 82 7. CYLINDER/PISTON E-TON Measure the outer diameter of piston pin. Service Limit: 14.96mm Measure the inner diameter of connecting rod small end. Service Limit: 15.06mm Measure the inner diameter of piston pin hole. Service Limit: 15.04mm Calculate clearance between piston pin and its hole.

  • Page 83: Piston Ring Installation

    E-TON 7. CYLINDER/PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston skirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution y Do not damage piston and piston rings as installation.

  • Page 84: Piston Installation

    7. CYLINDER/PISTON E-TON PISTON INSTALLATION Install piston and piston pin, and place the IN IN mark mark on the piston top side forward to intake valve. Install new piston pin snap ring. Piston pin Caution y Do not let the opening of piston pin snap ring align with the opening piston ring.

  • Page 85: V-Belt Driving System/Kick Starter Arm

    E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM MECHANISM DIAGRAM ....8-1 KICK STARTER ARM ......8-3 MAINTENANCE DESCRIPTION ..8-2 DRIVING BELT........8-4 TROUBLE DIAGNOSIS......8-2 SLIDING PULLEY ......8-6 LEFT CRANKCASE COVER ....8-3 CLUTCH/DRIVEN PULLEY ....8-9 MECHANISM DIAGRAM 5.0~6.0kgf-m 5.0~6.0kgf-m 5.0~6.0kgf-m 1.0~1.5kgf-m...
  • Page 86 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM E-TON MAINTENANCE DESCRIPTION Precautions in operation General information Driving pulley, clutch, and driven pulley can be serviced on the motorcycle. Driving belt and driving pulley surface must be free of grease. Specification Unit: mm...

  • Page 87: Kick Starter Arm

    E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM air cleaner lock bolts kick starter arm LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner. (2 bolts) Remove kick starter arm. (1 bolt) Loosen vent strap on the front-left side of cover, and then remove the vent.

  • Page 88: Driving Belt

    8. V-BELT DRIVING SYSTEM/KICK STARTER ARM E-TON DRIVING BELT Removal Remove left crankcase cover. Hold the driving pulley with a universal fixture, and then remove the nut and driving pulley. Universal fixer Hold driving pulley with universal fixture, and remove nut and clutch outer.
  • Page 89 E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation Pull out the driving pulley and then insert the driving belt into the driving pulley. Sliding driven Caution pulley Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily.

  • Page 90: Sliding Pulley

    8. V-BELT DRIVING SYSTEM/KICK STARTER ARM E-TON SLIDING PULLEY REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Universal fixture Remove the driving belt from the pulley. Sliding pulley Remove sliding pulley set and driving pulley hub from crankshaft.
  • Page 91 E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the title plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.
  • Page 92 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM E-TON Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Install siding pulley assembly onto crankshaft.

  • Page 93: Clutch/Driven Pulley

    E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM CLUTCH/DRIVEN PULLEY Special nut wrench Disassembly Remove driving belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much.
  • Page 94 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM E-TON Clutch lining Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit: 1.5mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit.
  • Page 95 E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch Block Replacement Driving plate Remove snap and washer, and the remove Spring clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Shock absorption rubber Check if shock absorption rubber is damage or deformation.
  • Page 96 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM E-TON Install snap ring and mounting plate onto setting pin. Snap ring Replacement of driven pulley bearing Remove inner bearing. Oil seal Outer bearing Caution y If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.
  • Page 97 E-TON 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation of clutch/driven pulley Oil seal Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Specified grease O-ring Install sliding pulley onto driven pulley.

  • Page 98: Final Driving Mechanism

    E-TON 9. FINAL DRIVING MECHANISM MECHANISM DIAGRAM ....9-1 INSPECTION OF FINAL DRIVING OPERATIONAL PRECAUTIONS ..9-2 MECHANISM ........9-3 TROUBLE DIAGNOSIS......9-2 BEARING REPLACEMENT ....9-4 DISASSEMBLY OF FINAL DRIVING RE-ASSEMBLY OF FINAL DRIVING MECHANISM........9-3 MECHANISM ........9-6 MECHANISM DIAGRAM final driving shaft...

  • Page 99: Operational Precautions

    9. FINAL DRIVING MECHANISM E-TON OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover 0.8~1.2 kgf-m Recommended gear oil:85W-140 Gear oil drain plug 0.8~1.2 kgf-m Oil quantity: 100 c.c. (90 c.c. when Gear oil filling bolt 0.8~1.2 kgf-m...

  • Page 100: Disassembly Of Final Driving Mechanism

    E-TON 9. FINAL DRIVING MECHANISM DISASSEMBLY OF FINAL DRIVING MECHANISM Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7bolts) and then remove the cover and the final driving shaft.

  • Page 101: Bearing Replacement

    9. FINAL DRIVING MECHANISM E-TON Check bearings on gear box and cover. final driving shaft Rotate each bearing’s inner ring with fingers. final driving gear Check if bearings can be turned in smooth countershaft gear and silent, and also check if bearing outer ring is mounted on gear box &...
  • Page 102 E-TON 9. FINAL DRIVING MECHANISM Press out the driving shaft from the gear box. Driving shaft Remove oil seal from the gear box. Remove the driving shaft bearing from the gear box cover with the inner type bearing puller. Caution Using the bearing protector as pressing out the driving shaft from the left crankcase.

  • Page 103: Re-Assembly Of Final Driving Mechanism

    9. FINAL DRIVING MECHANISM E-TON RE-ASSEMBLY OF FINAL DRIVING final driving shaft countershaft MECHANISM Install final driving shaft and final driving gear, countershaft, and countershaft gear. final shaft gear Install the setting pins(2 pins) and new gasket. dowel pins Apply with grease onto the oil seal lip of final driving shaft.

  • Page 104: A.c. Generator/Starting Clutch

    E-TON 10. A.C. GENERATOR/STARTING CLUTCH MECHANISM DIAGRAM ....10-1 RIGHT CRANKCASE COVER PRECAUTIONS IN OPERATION ..10-2 INSTALLATION ........10-8 A.C.GENERATOR REMOVAL ...10-3 MOUNTED COIL SET RIGHT CRANKCASE COVER INSTALLATION ........10-8 REMOVAL .......... 10-4 FLY WHEEL INSTALLATION..... 10-8 STARTING CLUTCH ......10-5 MECHANISM DIAGRAM 5.0~6.0kgf-m...

  • Page 105: Precautions In Operation

    10. A.C. GENERATOR/STARTING CLUTCH E-TON PRECAUTIONS IN OPERATION General information Refer to chapter 5: Engine removal and installation Refer to chapter 1: The troubleshooting and inspection of A.C. generator Refer to chapter 16: The service procedures and precaution items of starter motor...

  • Page 106: A.c.generator Removal

    E-TON 10. A.C. GENERATOR/STARTING CLUTCH A.C. GENERATOR REMOVAL Flywheel Pulse generator Cooling fan Cooling fan shroud Coil Cable guide Drain out the engine oil. Exhaust muffler Remove the rear center cover. (2 screws) Remove the right side cover. (3 screws) Remove the exhaust muffler.

  • Page 107: Right Crankcase Cover Removal

    10. A.C. GENERATOR/STARTING CLUTCH E-TON Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller.

  • Page 108: Starting Clutch

    E-TON 10. A.C. GENERATOR/STARTING CLUTCH STARTING CLUTCH Starting Clutch Removal Hold the starting driven gear with the universal fixture. Remove the 22mm anti-loosen lock nut and Lock nut gasket. Special service tools: Anti-loosen lock nut socket Universal fixture. Caution The mounting nut is left-turn thread.
  • Page 109 10. A.C. GENERATOR/STARTING CLUTCH E-TON Check the starting driven gear for wear or Starting driven gear damage. Measure the ID of the starting driven gear. Service Limit: ID: 32.06 mm or less Starting reduction Check the starting reduction gear and shaft gear for wear or damage.
  • Page 110 E-TON 10. A.C. GENERATOR/STARTING CLUTCH Installation Hex socket Install the components in the reverse bolt Plug Spring procedures of removal. Caution Add adhesive onto the thread of hex Roller socket bolt. Torque value: 1.0~1.4kgf-m Clutch body Clutch cover Starting clutch...

  • Page 111: Right Crankcase Cover Installation

    10. A.C. GENERATOR/STARTING CLUTCH E-TON RIGHT CRANKCASE COVER 6 bolts INSTALLATION Install setting pin and new gasket on the crankcase. Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip. Install right crankcase cover onto the right crankcase.
  • Page 112 E-TON 10. A.C. GENERATOR/STARTING CLUTCH Install the cooling fan. (4 bolts) Torque value: 0.8~1.2kgf-m Cooling fan Exhaust muffler Install the cooling fan shroud. (4 bolts) Install the exhaust muffler. (2 bolts, 2 nuts) Install the right side cover. (3 screws) Install the rear center cover.

  • Page 113: Crankcase/Crankshaft

    E-TON 11. CRANKCASE/CRANKSHAFT ....11-1 11-3 MECHANISM DIAGRAM DISASSEMBLY OF CRANKCASE ... 11-2 ..11-5 OPERATIONAL PRECAUTIONS CRANKSHAFT INSPECTION ....11-2 ..11-6 TROUBLE DIAGNOSIS ASSEMBLY OF CRANKCASE MECHANISM DIAGRAM 1.5~2.0 kgf-m 0.8~1.2 kgf-m 0.7~1.1 kgf-m 0.8~1.2 kgf-m 0.8~1.2 kgf-m 3.5~4.5 kgf-m...

  • Page 114: Operational Precautions

    11. CRANKCASE/CRANKSHAFT E-TON OPERATIONAL PRECAUTIONS General Information z This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced. z Complete following operations before disassembling crankcase. Engine Chapter 5 Cylinder head Chapter 6 Cylinder and piston...

  • Page 115: Disassembly Of Crankcase

    E-TON 11. CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 2 bolts Remove the 2 bolts from the right crankcase. Remove the cam chain tensioner (hex socket 1 hex socket bolt bolt) from the left side of crankcase. Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.
  • Page 116 11. CRANKCASE/CRANKSHAFT E-TON Remove the crankshaft from the right crankcase. Caution z The left and right bearings of crankshaft is to press-fit onto the crankshaft. Remove gasket and dowel pins (2). Scrape gasket residues off the crankcase contact surface. Caution z Do not damage contact surface of the crankcase.

  • Page 117: Crankshaft Inspection

    E-TON 11. CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Measure left and right clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm Measure the radical clearance of the big end at the vertical directions. Service limit : 0.05 mm...

  • Page 118: Assembly Of Crankcase

    11. CRANKCASE/CRANKSHAFT E-TON ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution z Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and...
  • Page 119 E-TON 11. CRANKCASE/CRANKSHAFT Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the oil seal to specified position with the oil seal installer (19.8 x30 x5). Special service tools: the oil seal installer (19.8 x30 x5)
  • Page 120 E-TON 12. BODY COVER FRONT CENTER COVER....12-6 MECHANISM DIAGRAM ....12-1 MAINTENANCE INFORMATION..12-2 LUGGAGE BOX ......... 12-6 HANDLE COVER .......12-3 FLOOR PANEL ........12-6 FRONT COVER........12-4 UNDER COVER ......... 12-7 FRONT INNER BOX......12-4 REAR FENDER........12-8 BODY COVER........12-5...
  • Page 121 12. BODY COVER E-TON MAINTENANCE INFORMATION Body covers disassemble sequence: Front Handle cover Front wheel Luggage box & Seat Rear handle cover Front cover Rear carrier Left/right side cover Front fender Under cover Front center cover Floor panel Rear fender...

  • Page 122: Handle Cover

    E-TON 12. BODY COVER HANDLE COVER Removal: Remove 4 lower mounting screw of the front handle cover. screw Remove the mounting screws (2 screws) between the front handle cover and the rear handle cover. screws the connector Remove the front handle cover.

  • Page 123: Front Cover

    12. BODY COVER E-TON FRONT COVER Removal Remove the 6 mounting screws of front cover from the front inner box side. screws 2 3 Screw Remove the 2 mounting screws of front cover emblem from the front cover. Remove the headlight wire connector.

  • Page 124: 12. Body Cover

    E-TON 12. BODY COVER BODY COVER Removal Remove the rear carrier. (4 bolts) 4 bolts Remove the 4 bolts of the luggage box. 4 bolts Remove the luggage box and the seat. Remove the mounting bolts of the body cover.

  • Page 125: Front Center Cover

    12. BODY COVER E-TON FRONT CENTER COVER screw 2 Removal Remove the front center little cover. Remove the screws of the front center cover. Remove the rear luggage box and the seat. Remove the front center cover mounting screws. Front center Remove the front center cover.

  • Page 126: Under Cover

    E-TON 12. BODY COVER Remove the 4 bolts on both left & right sides. Remove the floor panel. Installation Install the floor panel according to the reverse procedure of removal. 4 bolts on both left & right sides. 4 bolts on both left &...

  • Page 127: Rear Fender

    12. BODY COVER E-TON REAR FENDER Removal Remove 4 the rear carrier mounting bolts and remove the rear carrier. Remove the 4 bolts from the luggage box and remove the luggage box and the double seat. Remove the left & right body cover.

  • Page 128: Brake

    E-TON 13. BRAKE MECHANISM DIAGRAM-FRONT BRAKE FLUID REPLACEMENT/AIR-BLEED DISC BRAKE SYSTEM ...... 13-1 ............13-6 MECHANISM DIAGRAM-REAR BRAKE CALIPER ....... 13-7 DRUM BRAKE SYSTEM ....13-2 BRAKE DISC........13-8 MAINTENANCE INFORMATION..13-3 BRAKE MASTER CYLINDER .... 13-8 TROUBLE DIAGNOSIS...... 13-4 DRUM BRAKE-DRUM......

  • Page 129: Mechanism Diagram-Rear Drum Brake System

    13. BRAKE E-TON MECHANISM DIAGRAM Rear Drum Brake System 0.8~1.2 kgf-m 0.8~1.2 kgf-m 13-2 Copyright ©2008-2009 ETON America, all rights reserved.

  • Page 130: Maintenance Information

    E-TON 13. BRAKE MAINTENANCE INFORMATION Precautions in Operation Caution Installing lining dusts may cause disorders of respiration system or cancer, therefore, never use air hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.

  • Page 131: Trouble Diagnosis

    13. BRAKE E-TON TROUBLE DIOGNOSIS DISC BRAKE Soft brake lever Uneven brake z Air inside the hydraulic system z Dirty brake lining/disc z Hydraulic system leaking z Poor wheel alignment z Worn master piston z Clogged brake hose z Worn brake pad...

  • Page 132: Hydraulic Brake System Inspection

    E-TON 13. BRAKE HYDRAULIC BRAKE SYSTEM Hose connection INSPECTION Inspection Visual inspect for brake fluid leaking or damage. Check if brake hose connection loosened with wrench and turn the handlebar from right to left motion or press down the shock absorber to check if there is something is interfered with the brake system or brake components.

  • Page 133: Brake Fluid Replacement/Air-Bleed

    13. BRAKE E-TON Remove the master cylinder cap and Master diaphragm. cylinder Add good quality brake fluid and it has to add same brand brake fluid into the master cylinder. Diaphragm Clean dirty brake disc. CAUTION The dirty brake lining or disc will reduce the brake performance.

  • Page 134: Brake Caliper

    E-TON 13. BRAKE BRAKE CALIPER hose bolt Removal Place a container under the brake caliper, bolts x 2 and loosen the brake hose bolt and finally remove the brake hoses. CAUTION Do not spill brake fluid on painted surfaces. Remove two caliper bolts and the caliper.

  • Page 135: Brake Disc

    13. BRAKE E-TON BRAKE DISC Inspection Visually check the brake disc for wear or break. Measure the thickness of the disc at several places. Replace the disc if it has exceeded the service limit. brake disc Allowable limit: 2.0 mm micrometer Remove the brake disc from wheel.
  • Page 136 E-TON 13. BRAKE Inspection Check the master cylinder for damage or master cylinder scratch. Replace it if necessary. Measure the cylinder inner diameter at several points along both X and Y directions. Replace the cylinder if the measured values exceed allowable limit.
  • Page 137 13. BRAKE E-TON INSTALLATION master cylinder mounting seat Place the master cylinder onto handlebar, and install the split ring and bolts. The “UP” mark on the split ring should face bolts x 2 upward. Align the split ring on the master cylinder...

  • Page 138: Drum Brake-Drum

    E-TON 13. BRAKE DRUM BRAKE-DRUM Brake Drum Removal Use a vacuum cleaner and other suitable tools to clean the brake parts to minimize the hazard caused by the dust. Caution Inhaling dust may cause respiration system disorder even cancer. Never use an air hose or a dry brush as to clean the brake parts.

  • Page 139: Brake Panel

    13. BRAKE E-TON Removal Caution Brake linings must be replaced as a set. brake cam Remove brake shoes from the brake panel by pulling out the brake linings with two hands. anchor Installation Apply a thin coat of grease to the brake cam and the anchor pin.

  • Page 140: Steering/Front Wheel/Front Shock Absorber

    E-TON 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER MECHANISM DIAGRAM ....14-1 FRONT WHEEL ......... 14-4 PRECAUTIONS IN OPERATION ..14-2 FRONT SHOCK ABSORBER .... 14-7 TROUBLE DIAGNOSIS......14-2 FRONT FORK/STEERING COLUMN 14-8 STEERING HANDLE......14-3 MECHANISM DIAGRAM 14-1 Copyright ©2008-2009 ETON America, all rights reserved.

  • Page 141: Precautions In Operation

    14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER E-TON PRECAUTIONS IN OPERATION General Information Before remove front wheel, use a jack to lift the body until front wheel free of ground, and take care not to rotate body in reverse. Be careful not to allow oil or grease get on brake drum or linings.

  • Page 142: Steering Handle

    E-TON 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER STEERING HANDLE REMOVAL Master cylinder Remove handle front & rear covers and the Seat front cover (refer to chapter 12). Split ring Disc Brake Remove the 2 bolts of the brake master cylinder, and then take out the master Bolts x 2 cylinder and the split ring.

  • Page 143: Front Wheel

    14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER E-TON With a wrench to hold the handlebar bolt and then remove the nut. Bolt Take out the handlebar after removed the bolt. Installation Install the handlebar according to the reverse procedure of removal. Apply with some grease onto the handlebar...
  • Page 144 E-TON 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Inspection Wheel axle Set the axle in V-blocks and measure the run-out. Service limit: 0.2 mm. Wheel axle Wheel Rim Place the wheel onto a rotated bracket. Turn the wheel with hand and measure its wobble value with a dial gauge.
  • Page 145 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER E-TON Bearing Inspection Turn the inner race of bearing with fingers. The bearing should be turn smoothly. Also check if the outer collar is tightly connected to the wheel hub. If the bearing does not turn smoothly, or if they...

  • Page 146: Front Shock Absorber

    E-TON 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER Installation Align the flange part on the speedometer gear with the slot of wheel hub, and then install the brake disc (drum brake) or speedometer gear box. Place the front wheel between the front shock absorbers.

  • Page 147: Front Fork/Steering Column

    14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER E-TON Remove the top connection bolt of the right Bolts shock absorber. (bolt x 4) Remove the shock absorber from the front fork. Shock absorbers Installation Install the shock absorbers according to the reverse procedure of removal.
  • Page 148 E-TON 14. STEERING/FRONT WHEEL/FRONT SHOCK ABSORBER With a plastic hammer to tap the steering column slightly, and then remove the top ball bearing seat. Remove the lower-end cone bearing seat on the frame with a punch. Caution Do not damage the frame and the steering column.
  • Page 149 E-TON 15. REAR WHEEL/REAR SHOCK ABSORBER MECHANISM DIAGRAM....15-1 EXHAUST MUFFLER......15-3 PRECAUTIONS IN OPERATION..15-2 REAR WHEEL........15-3 TROUBLE DIAGNOSIS ..... 15-2 REAR SHOCK ABSORBER ....15-4 MECHANISM DIAGRAM 3.5~4.5kgf-m 2.4~3.0kgf-m 0.8~1.2kgf-m 1.0~1.4kgf-m 3.0~3.6kgf-m 11.0~13.0kgf-m 15-1 Copyright ©2008-2009 ETON America, all rights reserved.

  • Page 150: Precautions In Operation

    15. REAR WHEEL/REAR SHOCK ABSORBER E-TON PRECAUTIONS IN OPERATION General Information As for the wheel removal, service, and installation procedures, please refer to the service manual of high speed tire. Specification Unit: mm Items Standard Limit Radial Wheel wobbling Axial...

  • Page 151: Exhaust Muffler

    E-TON 15. REAR WHEEL/REAR SHOCK ABSORBER EXHAUST MUFFLER Exhaust muffler Removal Remove the front-end nut of the exhaust muffler. (nuts x 2) Remove the bolts. (bolts x 2) Remove the exhaust muffler. Installation Install the exhaust muffler according to the reverse procedure of removal.

  • Page 152: Rear Shock Absorber

    15. REAR WHEEL/REAR SHOCK ABSORBER E-TON REAR SHOCK ABSORBER Removal Remove the left & right covers. (screws x 8) Remove the luggage box. (bolts x 4, nuts x 2, screw x 1) Remove the rear carrier. (bolts x 3) Remove the body cover (bolts x2)

  • Page 153: Electrical Equipment

    E-TON 16. ELECTRICAL EQUIPMENT MECHANISM DIAGRAM ....16-1 STARTING SYSTEM ......16-14 PRECAUTIONS IN OPERATION ..16-2 METER ..........16-15 TROUBLE DIAGNOSIS......16-4 LIGHTS/BULBS ........16-17 CHARGING SYSTEM......16-5 SWITCH ..........16-20 IGNITION SYSTEM ......16-11 FUEL UNIT .........16-23 MECHANISM DIAGRAM REG.REC Horn Winker relay Front stop switch Rear stop switch...

  • Page 154: Precautions In Operation

    16. ELECTRICAL EQUIPMENT E-TON PRECAUTIONS IN OPERATION Charging System z When remove the battery, the disconnection sequence of cable terminals shall be strictly observed. (First disconnect the negative cable terminal, next, the positive cable terminal.) z MF (Maintenance Free) battery does not need to check, add electrolyte or distilled water.
  • Page 155 E-TON 16. ELECTRICAL EQUIPMENT Specification Charging System c i f Capacity/type 12V6Ah(closed type maintenance-free battery) STD:0.6A/5~10hrs, emergency charging: Charging rate 6A/0.5hrs Battery Full charged 13.1V(at 20 ) Voltage Under Below 12.3 V (at 20 ) charged Alternator Capacity 12V / 6.2 A...

  • Page 156: Trouble Diagnosis

    16. ELECTRICAL EQUIPMENT E-TON TROUBLE DIAGNOSIS Charging System System Ignition No spark produced by spark plug No power supply z The spark plug is out of work z Dead battery z The cable is poorly connected, open or z Disconnect battery cable...

  • Page 157: Charging System

    E-TON 16. ELECTRICAL EQUIPMENT CHARGING SYSTEM Charging wire diagram Current Leakage Inspection Turn the main switch to OFF position, and remove the negative cable terminal (-) from the battery. Battery(-) terminal Connect an ammeter between the negative cable terminal and the battery negative terminal (as shown on left diagram).
  • Page 158 16. ELECTRICAL EQUIPMENT E-TON Battery Removal Remove the battery cover. CAUTION Electrolyte (diluted sulfuric acid) is very toxic. Once it spreading on clothes, skin, or eyes, it will cause burned or blind. In case of being spread, flush with great quantity of water immediately, Battery cover and then send to hospital.
  • Page 159 E-TON 16. ELECTRICAL EQUIPMENT Voltage Check With a digital voltage meter or multi-meter to measure battery voltage. Voltage: Fully charged: 13.0 – 13.2V (at 20 ) Undercharged: Below 12.3 V (at 20 ) CHARGING Connect the Charger positive (+) to the battery positive (+) terminal.
  • Page 160 16. ELECTRICAL EQUIPMENT E-TON digital voltmeter Charging Voltage/Current ammeter Inspection Caution z Before conducting the inspection, be sure that the battery is fully charged. Use a fully charged battery having a voltage larger than 13.1 V. If undercharged, the current changes dramatically.
  • Page 161 To use the multi-meter recommended by E-TON. Otherwise, the measured resistance might be different. Headlight control unit Inspection Remove the front cover emblem and the front cover.
  • Page 162 16. ELECTRICAL EQUIPMENT E-TON Alternator charging coil Caution The check of alternator charging coil and illumination coil can be done when the alternator is mounted on engine. Check Remove the 3P connector of the alternator. Measure the resistance between the white wire on the alternator and frame ground with a multi-meter.

  • Page 163: Ignition System

    E-TON 16. ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition System Circuit green Yellow /blue green Black/ yellow Black CDI UNIT Removal Remove the right body cover, then the C.D.I. unit can be removed from the frame. CDI UNIT Check Disconnect the connector from the CDI unit.
  • Page 164 16. ELECTRICAL EQUIPMENT E-TON Ignition coil Ignition coil Removal Remove the luggage box, center cover. Remove spark plug cap. Remove the primary coil wire of ignition coil. Remove the fix bolts for the ignition coil, and remove the ignition coil.
  • Page 165 E-TON 16. ELECTRICAL EQUIPMENT Secondary coil Attached the spark plug cap, measure the resistance between plug cap side and green terminal. Standard value: 7-12 k (20 ) Remove the spark plug cap, measure the resistance between plug cap side and green terminal.

  • Page 166: Starting System

    16. ELECTRICAL EQUIPMENT E-TON STARTING SYSTEM Starting Circuit CDI unit Starter magnetic switch inspection Turn main switch to "on", and operate the brake lever. Then press starting button to check if there a click sound. It is normal if there is a click sound.

  • Page 167: Meter

    E-TON 16. ELECTRICAL EQUIPMENT Starting Motor Removal Bolts x2 Remove the right side cover. (screws x3) Firstly, remove the battery negative (-) terminal, and then remove the positive (+) terminal. Remove the luggage box. Remove the starting motor power wire.
  • Page 168 16. ELECTRICAL EQUIPMENT E-TON Odometer Speedometer Tachometer Fuel gauge Turn left Turn right signal light signal light High/low beam indicator Caution Do not wipe the meter or headlight with organic solvent such as gasoline to prevent from damage these components.
  • Page 169 E-TON 16. ELECTRICAL EQUIPMENT LIGHT/BULBS Headlight Bulb Replacement Rear the screw of the front cover. Rear the front cover. Disconnect the headlight wire connector, and then remove the rubber boot. Press down the bulb spring locker and then remove the locker with turning it left motion.
  • Page 170 16. ELECTRICAL EQUIPMENT E-TON Front Turn Signal Lamp Bulb Replacement Remove the front handle cover. ( screw x 4) Remove the wire connector of the turn signal light. Pull out the bulb and replace it with new one. (12V 10W) Installation Install the bulb in reverse order of removal.
  • Page 171 E-TON 16. ELECTRICAL EQUIPMENT Bulbs Replacement of tail light/brake bolts x2 light/rear turn signal light. Remove the rear carrier (bolts x4). bolts x2 Remove the rear luggage box (bolts x4). right body cover Remove the left/right body cover. left body cover...

  • Page 172: Switch

    16. ELECTRICAL EQUIPMENT E-TON Replace the bolts of the tail light. bolts Replace the bulbs of the tail light, brake light (12V 5W/21W and the turn signal light (12V/10W). Installation Install the bulb in reverse order of removal. SWITCH Main Switch...
  • Page 173 E-TON 16. ELECTRICAL EQUIPMENT Handle switch Engine stop switch Remove the right handle switch. Disconnect the connector of the handle switch. Check the continuity of follow pins listed below columns. Engine stop switch color Black Black /Red Location starting switch...
  • Page 174 16. ELECTRICAL EQUIPMENT E-TON urn signal light switch color Gray orange Location blue FROM R PUSH OFF FROM L Brake light switch The circuit of black wire and the green/yellow wire on the brake light switch should be in continuity when operating the brake lever.

  • Page 175: Fuel Unit

    E-TON 16. ELECTRICAL EQUIPMENT FUEL UNIT Open the seat. Remove the luggage box . (bolts x4). Disconnect the fuel unit wire connector. Caution Do not damage or bend the float arm as removing. The resistance values are listed below when the float arm in “F”...
  • Page 176 E-TON POWER TECH CO., LTD. 2009.01.14 Copyright ©2008-2009 ETON America, all rights reserved.

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