1. Manuals
  2. Brands
  3. Eton America Manuals
  4. Utility Vehicle
  5. ROVER GT
  6. Service manual

Eton America ROVER GT Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
ETON America
ROVER GT
SERVICE MANUAL
ROVER GT
(UK2)
ROVER GT
7 / 2007

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ROVER GT and is the answer not in the manual?

Questions and answers

Summary of Contents for Eton America ROVER GT

  • Page 1 ETON America ROVER GT SERVICE MANUAL ROVER GT (UK2) ROVER GT 7 / 2007...

  • Page 2: Table Of Contents

    Table of Contents 1. INFORMATION............................3 1.1 Safety ..............................3 1.2 Notes ..............................3 1.3 Specifications .............................4 1.4 VIN & Engine Number ........................6 1.5 Standard Torque Values ........................7 2. MAINTENANCE ............................. 8 2.1 Maintenance Schedule ........................8 2.2 Maintenance Record ..........................8 2.3 Fuel Lines & Filter ..........................9 2.4 Throttle Operation ..........................9 2.5 Throttle Cable Adjustment .........................9 2.6 Air Cleaner ............................10...
  • Page 3 7.5 Electrical Starter Mechanisim ......................46 7.7 C.V.T. Reassembly ..........................50 8A. TRANSMISSION GEAR SET ......................52 8A.1 Service Information ........................52 8A.2 Trouble Shooting...........................53 8A.3 Gear Removal ..........................53 8A.4 Gear Set and Bearing Inspection ....................54 8A.5 Gear Set Installation ........................55 8B. SHIFTING GEAR BOX ........................56 8B.1 Service Information ........................56 8B.2 Trouble Shooting ...........................57 8B.3 Transmission Assembly Drawing ....................58...

  • Page 4: Information

    GENERAL MAINTENCE PART – These parts may need to be replaced often. Part numbers will be provided when applicable. ETON America, LLC 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...
  • Page 5 1.3 Specifications Rover GT Component (UK2) Engine Type Four cycle liquid cooled Displacement 88.4cc φ47.0 * 51mm Bore / Stroke Compression Ratio / Pressure 10.2 : 1 Torque / BHP 6.5hp @ 6500rpm / 48BHP Starting Electrical Transmission Type Automatic (C.V.T. V-Belt)

  • Page 6: Specifications

    Front 520x12t Rear 520x32t Chain #520 Battery Size Jell Acid (Maintenance Free) 12V-4AH/5AH - GTX5L Fluids Type Unleaded Gasoline 92 octane Fuel Volume 11 liters / 2.9gal Type SAE 20W - 40 Engine Oil Volume 0.9 liters / 0.23gal Type SAE 80/90 weight Transmission Volume...

  • Page 7: Vin & Engine Number

    1.4 VIN & Engine Number The unit’s serial numbers are available directly on the unit. See the pictures below. The frame VIN number is stamped on the right side of the frame near the front right wheel. The engine VIN number is stamped on the left side of the crankcase. Engine Number Frame Number...

  • Page 8: Standard Torque Values

    1.5 Standard Torque Values NOTE: Maximum metric torque value is shown. Do not exceed maximum torque value. ENGINE Cylinder head nut 25 N/m (13.3 – 18.4 lbf-ft) Spark plug 12 N/m (5.2 - 8.9 lbf-ft) Cylinder head bolt 30 N/m (14.8 - 22.1 lbf-ft) Alternator bolt 12 N/m (5.9 - 8.9 lbf-ft) FRAME...
  • Page 9 2. MAINTENANCE 2.1 Maintenance Schedule The maintenance internals in the follow table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent servicing. This table applies to units covered by this service manual. E-TON recommends that all maintenance and inspections be performed ONLY by a qualified and fully trained technician. INITIAL REGULAR SERVICE SERVICE...

  • Page 10: Maintenance

    Maintenance Schedule WP-0027 Four Stroke Vehicles 300KM   Every 1000KM   Every 3000KM   Every 6000KM   Every 12000KM   Scheduled   200 Miles  600 Miles  2000 Miles  3700 Miles  7500 Miles  Maintenance  NEW   1 Month  3 Months   6 Months   1 Year   I *  C *     R(paper)   R(sponge)   1  Air cleaner element   I               2  Air cleaner   C         C  ...

  • Page 11: Fuel Lines & Filter

    2.3 Fuel Lines & Filter Inspect the fuel lines for deterioration, damage, or leakage, and replace if necessary. Check the fuel filter for accumulated dirt and debris. Replace as needed. Filter replacement is also recommended at the beginning of each riding season. Filter assembly: Part # 812555 Filter element: Part # 800002 2.4 Throttle Operation...

  • Page 12: Air Cleaner

    2.6 Air Cleaner • Unscrew the air cleaner cover screws. • Pull out the air filter element from the air cleaner case. Wash the element in non-flammable solvent and squeeze out the solvent thoroughly. • Let it dry. • Soak the filter element in gear oil, and then squeeze out the excess oil.

  • Page 13: Idle Speed

    2.8 Idle Speed Air/Fuel Ratio adjusting procedure: Step 1: Air adjusting screw. Turn adjusting screw all the way in then back off ¾ to 1¼ turn on 70cc engine. 1 to 1½ turns on 90cc engine. Step 2: Adjust idle RPM. (Warm Engine) Connect an RPM gauge.

  • Page 14: Braking Systems

    When the drive chain becomes very dirty, it should be removed, cleaned, and lubricated. Use commercial chain lubricant to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for worn or damaged links and rivets. Replace the chain if it is worn excessively or damaged.

  • Page 15: Wheels & Tires

    2.11 Wheels & Tires • Inspect the tire surfaces for cuts, nails, or other sharp objects. • Check the tire surfaces at cold tire condition. standard tire pressure is 2.2±0.3 psi. (0.15 kg/cm 2.12 Steering System Check the slack of the steering shaft with the front wheels facing straight ahead.

  • Page 16: Gear Oil

    2.14 Gear Oil Front of engine Gear oil needs to be changed every year. Drain Bolt 1. Place an oil catch pan under the unit directly below the transmission box. 2. Remove the transmission box drain plug located on the bottom of the transmission box on the underside of the unit.

  • Page 17: Engine Removal And Installation

    3. ENGINE REMOVAL AND INSTALLATION 3.1 Service Information NOTE: The engine should only be removed when repair conditions warrant its removal. Engine removal is a complex task that should be performed only by a qualified technician or mechanic. 3.2 Engine Removal 1.
  • Page 18 Engine installation is basically removal in reverse. 1. Replace the engine in the frame from the right side. 2. Reinstall the engine hanger bolts and torque to 24- 30 N/m (1.64-2.06 lb/ft). 3. Reinstall the drive chain, and connect with the master link and retaining clip.

  • Page 19: Fuel And Lubrication Systems

    4. FUEL AND LUBRICATION SYSTEMS 4.1 Trouble Shooting Engine does not start. • No fuel in tank • No fuel to cylinder • Too much fuel going into cylinder • No spark at plug • Air cleaner clogged Engine idles roughly, stalls, or runs poorly. •...

  • Page 20: Fuel Tank

    4.2 Fuel Tank REMOVAL • Remove the fuel tank cap and rear bed assembly. • Disconnect the fuel line from the carburetor. • Unscrew the fuel tank mounting bolts. Warning: Gasoline is highly flammable Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once.
  • Page 21 • Unscrew the float chamber screws and remove the float chamber. • Remove the float arm pin, float, and float needle valve. • Inspect the seat of the float needle valve for wear or damage. • Inspect the float for signs of leakage (fluid inside of float) •...

  • Page 22: Engine Oil Level & Changing

    ASSEMBLY Clean all parts in solvent and blow it dry with compressed air. Assembly is essentially disassembly in reverse. E-TON recommends that the bowl gasket be replaced during reassembly. THROTTLE VALVE ASSEMBLY • Install the needle clip on the jet needle. •...
  • Page 23 Draining the oil: Remove the oil filter cap and the oil drain bolt. NOTE: Drain the oil while the engine is warm to ensure complete draining. Remove the oil filter cap, spring, and oil filter screen. Drain Bolt Check the O-ring for damage or fatigue. Install a new oil filter screen and spring.

  • Page 24: Oil Pump Removal / Installation

    4.5 Oil Pump removal / Installation Remove the fan cover assembly. Remove the cooling fan. Remove the flywheel and A/C Generator. Remove the right crankcase cover.
  • Page 25 Remove the oil pump driven sprocket. Remove the oil pump assembly. Oil Pump Assembly Disassemble the oil pump. Units in mm.
  • Page 26 Inspection: Measure the oil pump body-to-rotor clearance with a feeler gauge. SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump rotor tip clearance with a feeler gauge. SERVICE LIMIT: 0.12 mm. Remove the oil pump shaft and measure the pump end clearance with a feeler gauge.
  • Page 27 Installation: Oil Pump Assembly Install the oil pump assembly. Install the oil pump driven sprocket. Install the A/C Generator, flywheel, and cooling fan.

  • Page 28: Engine Combustion System

    5. ENGINE COMBUSTION SYSTEM 5.1 Service & General Information 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.

  • Page 29: Trouble Shooting

    5.2 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 • Cylinder head gasket leaking or damaged •...

  • Page 30: Top End Removal

    Rocker Arm Cover 5.3 Top End Removal Remove the rocker arm cover. Carburetor • Remove the air cleaner and carburetor. • Remove the intake pipe assembly. Engine Shroud Engine Shroud • Remove the engine shroud. Intake pipe Loosen the cam chain adjuster screw. •...
  • Page 31 Loosen the camshaft gear from cam chain and remove the camshaft. Inspection Inspect the cam lobes’ surface and height of cam lobes for wear or damage. SERVICE LIMIT: IN: 25.683mm / 1.008” EX: 25.241 mm / 0.994” Inspect the camshaft and bearings for wear or damage and replace them if necessary.

  • Page 32: Cylinder Head Removal

    Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage. Measure the I.D. of each rocker arm. SERVICE LIMIT: 10.10 mm / 0.398” Measure the O.D. of each rocker arm shaft. SERVICE LIMIT: 9.91 mm / 0.390” 5.4 Cylinder Head Removal Remove the flange bolts and cylinder head.
  • Page 33 Remove the cam chain guide. Cam Chain 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. Be sure not to damage the gasket surface.
  • Page 34 SPRING Measure the free length of the inner and outer valve springs. SERVICE LIMITS: Inner 27.0mm / 1.063” Outer 30.5mm / 1.201” SPRING Inspect each valve for turning, burning, scratches, or abnormal stem wear. Check the valve movement in the guide. Measure and record each valve stem O.D.

  • Page 35: Cylinder Head Assembly

    5.5 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. Installation Install the new gasket and dowel pins.
  • Page 36 Camshaft and Rocker Arm Installation Install the cam shaft and cam chain. Install the rocker arms and rocker arm shafts into the camshaft holder. TORQUE: 15 N-m (10 lbf-ft) Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter-clockwise.
  • Page 37 Using a feeler gauge, measure the clearance between the rocker arm and valve stem. Adjust if necessary. Standard value: IN: 0.07mm / 0.0028” EX: 0.07 mm / 0.0028” Loosen the cam chain adjusting bolt by turning it in a counterclockwise direction. Install the O-ring and screw. Install the cylinder head cover.

  • Page 38: Cylinder & Piston

    6. CYLINDER & PISTON 6.1 Service Information Camshaft lubrication oil is fed to the cylinder head through an oil hole in the cylinder head and engine case. Before installing the cylinder head make sure the hole is not clogged and the gasket, O-ring, and dowel pins are in place.

  • Page 39: Cylinder & Piston Removal

    6.3 Cylinder & Piston Removal 1. Remove the seat, rear fender, and exhaust. 2. Remove the spark plug cap. 3. Disconnect the wiring. 4. Pull out the engine. (see engine removal – section 3) 5. Remove the air cleaner and carburetor. 6.
  • Page 40 • Remove the piston pin from the piston. • Remove the piston. Spread each piston ring and remove it by lifting up at a point opposite the gap. Inspection Inspect the cylinder walls for scratches or wear. Measure and record the cylinder I.D. at three levels in both an X and Y axis.
  • Page 41 Calculate cylinder taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.05 mm / 0.00196” Calculate the cylinder out-of-round at three levels in an X and Y axis. Take the maximum reading to determine the out-of – round.
  • Page 42 Insert each piston ring into the cylinder and measure the ring end gap. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder. SERVICE LIMITS: TOP 0.45 mm / 0.0177” SECOND 0.45 mm / 0.0177”...

  • Page 43: Piston Installation

    Measure the connecting rod small end I.D. SERVICE LIMIT: 13.06 mm / 0.514” 6.4 Piston Installation Clean the piston ring grooves thoroughly and install the piston ring with the mark facing up. NOTE: Don’t interchange the top and second rings. Avoid piston and piston ring damage during installation.
  • Page 44 • Install the piston pin with new pin clips. • Do not align the piston pin clip end gap with the piston cutout. NOTE: Do not allow the clip to fall into the crankcase. 6.5 Cylinder Installation Clean any gasket material from the crank case surface. NOTE: Be careful not to damage the gasket surface.
  • Page 45 HEAD Install a new head gasket, then install the cylinder head. Head Gasket: Part # 811589 Torque the cylinder head nuts. Torque value: 25 N/m (13.3 – 18.4 lbf-ft) Install the cylinder head cover Torque value: 30 N/m (14.8 - 22.1 lbf-ft)

  • Page 46: Transmission System

    7. TRANSMISSION SYSTEM 7.1 Service Information Troubleshooting • Abnormal speed limited function Abnormal shifting or will not reset • Faulty C.D.I. • Faulty brake switch • Idle too high Will not move after engine is started • Faulty shift motor •...

  • Page 47: Shift Mechanism C.d.i

    7.2 Shift Mechanism C.D.I. The C.D.I. is located underneath the front hood cover. It includes the shift control system. Replace it if the control system is functioning improperly. There is also a speed-limit adjuster in the corner. Adjust speed-limited as follows: Position Refer to Service Bulletin 45 at the Speed Limit Adjuster...

  • Page 48: Belt

    Driven Pulley Because the revolving radius of the V-Belt at the Drive End is increased, the Face Comp Movable Drive is forced out by the V-Belt at the Driven End to shorten the revolving radius. There is a Torque Cam on the Movable Drive Face. The Torque Cam is loaded from outside.
  • Page 49 7.6 C.V.T. Disassembly – (LH) Crankcase Removal Loosen the band screw and remove the CVT inlet duct. Remove the bolts and LH crankcase cover. Remove the gasket and dowel pins. Clean off any gasket material from the LH crankcase surface. CVT Removal •...
  • Page 50 • Loosen the flange nut. • Remove the drive pulley assembly and driven belt. Remove the drive face boss and movable driven face assembly. Remove the ramp plate and weight roller set. Inspection • Inspect the driven belt for wear, tearing, or damage. •...
  • Page 51 • Inspect the weight roller for wear or damage and replace them if necessary. • Measure the O.D. of weight rollers. SERVICE LIMIT: 14.6 mm / 0.575” Clutch Rollers: Part # 811654 WEIGHT ROLLER • Measure the I.D. of movable driven face. SERVICE LIMIT: 21.24mm / 0.836”...

  • Page 52: Reassembly

    • Inspect the clutch weight set for wear or damage. • Measure the thickness of clutch weight lining. SERVICE LIMIT: 2.0mm / 0.0787” Measure the length of driven face spring in a relaxed position. SERVICE LIMIT: 82.6 mm / 3.25” Inspect the driven face assembly and replace if necessary.
  • Page 53 Install the dowel pins and gasket. Install the driven belt and driven pulley assembly. Install the movable drive face assembly and boss. • Install the drive face. • Apply red Lock-Tite and torque the locking flange nut.

  • Page 54: Transmission Gear Set

    Torque: 27 N-m (20 lbf-ft) • Install the LH crankcase cover. 8A. TRANSMISSION GEAR SET 8A.1 Service Information • For transmission repairs, the engine must be removed from the frame. • Drain oil from the transmission case before disassembly. Refill with recommended oil after reassembly. •...

  • Page 55: Trouble Shooting

    • Shifting while in motion can cause damage to the transmission gears. 8A.2 Trouble Shooting Difficulty shifting • Shift fork bent • Shift fork shaft bent • Speed too high Transmission jumps out of gear • Gear indicator worn • Shift fork bent or damaged Excessive noise from gears Worn transmission gear...

  • Page 56: Gear Set And Bearing Inspection

    Loosen the bolts and remove the transmission cover. COVER Remove the dowel pins and gasket. GEAR SHIFT SHAFT Disassemble the transmission. Inspect and clean. SHIFT FORK COUNTER SHAFT 8A.4 Gear Set and Bearing Inspection Turn the inner race of the bearing with your finger. •...

  • Page 57: Gear Set Installation

    • Replace the bearings if necessary. Check the sprocket and fixing plate for wear or damage. Replace if necessary. 8A.5 Gear Set Installation Install the transmission cover and final shaft. Secure in place with the cir clip. GEAR SHIFT • Install the counter shaft and reverse shaft in the LH SHAFT crankcase.

  • Page 58: Shifting Gear Box

    Assemble the transmission cover, sprocket, and fixing plate. Fill the transmission cover with the recommended oil. Capacity – 300cc / 10.2oz 8B. SHIFTING GEAR BOX 8B.1 Service Information • For transmission repairs, the engine must be removed from the frame. •...

  • Page 59: Trouble Shooting

    8B.2 Trouble Shooting Engine dies after shifting Idle set too high Faulty CDI Faulty shift motor Faulty F/N/R sensor Faulty shift spring or gear Faulty A/C generator Faulty brake switch No power when throttle applied • Belt worn • Front pulley worn or broken •...

  • Page 60: Transmission Assembly Drawing

    8B.3 Transmission Assembly Drawing Shift Mechanism...

  • Page 61: Shift Mechanism

    8B.4 Shift Mechanism Gear box disassembly • Remove the transmission cover and gears • Remove and inspect the shift push, fixed shaft, and fork for wear or damage. • Measure the fixed shift spring. SERVICE LIMIT: 24mm / 0.945” Check the knock block, bearing, and cam shift for wear or knock block cam shift damage.

  • Page 62: Gear Box Assembly

    8B.5 Gear Box Assembly COUNTER SHAFT GEAR SHIFT SHAFT • Remove the transmission cover and gears. • Inspect gears for wear, scoring, chipping, or breaking. Replace if necessary.

  • Page 63: Steering System

    9. STEERING SYSTEM 9.1 Steering System Drawing Steering System A-Arms 9.2 Trouble Shooting Hard Steering • Faulty tire(s) • Steering shaft holder too tight • Insufficient tire pressure • Faulty or damaged steering shaft bearings...

  • Page 64: Steering Wheel Removal

    9.3 Steering Wheel Removal Remove the horn button to gain access to the four steering wheel bolts. Then, remove the steering wheel. INSTALLATION • Mount the steering wheel into position. • Replace and tighten the four holding bolts. • Replace the horn button. 9.4 Steering System Removal •...
  • Page 65 • Remove the rubber cap on the kingpin and remove the cotter pin. • Unscrew the castle nut and remove the kingpin. TIE-ROD INSPECTION • Inspect the tie-rod for damage or bending. • Inspect the ball joint rubbers for damage, wear or deterioration.
  • Page 66 STEERING SHAFT REMOVAL • Remove the handle bar and handle bar cover (see paragraph 8-1). • Remove the front fender (see section 11-1). • Remove attaching nut from the bottom of the steering shaft. • Pull steering shaft carefully. STEERING SHAFT BUSHING INSPECTION •...
  • Page 67 INSTALLATION OF STEERING SHAFT • Apply grease to the steering shaft bushing. • Insert the steering shaft through the bushing. • Ensure the shaft is properly seated in the bearing at the bottom of the shaft. Torque: 24-30 N/m (17-22 lbf-ft) Install the steering shaft nut at the bottom of the steering shaft and tighten it.
  • Page 68 NSTALLATION OF KINGPIN • Apply grease on the kingpin lower dust seal lips and install. • Grease the bushing and install the kingpin. • Tighten the kingpin nut. • The torque setting is 30-40 N/m (2.06-2.74 lb/ft). • Fix the waterproof rubber cap. •...

  • Page 69: Wheel And Brake System

    10. WHEEL AND BRAKE SYSTEM 10.1 Wheel and Brake System Drawings Front wheel Rear wheel Hydraulic brake...

  • Page 70: Troubleshooting

    10.2 Troubleshooting Bad brake performance Brake shoes are worn Bad brake adjustment Brake linings are oily, greasy, or dirty Brake drums are worn Brake arm setting is improperly engaged Axle is not tightened well Vibration or wobble • Bent rim •...

  • Page 71: Drive Mechanism & Rear Brake Removal

    10.4 Drive Mechanism & Rear Brake Removal Removal and inspection: • Remove the rear wheel • Raise the rear wheels off the ground. • Remove the cotter pin, axle nut, and washer. Remove the wheel and wheel hub. Remove the drive chain. Disassemble the chain, retaining clip, and master link.
  • Page 72 Disassemble the driven sprocket, axle, and sprocket collar. Check the driven sprocket for damage or wear. Place the rear axle on V-blocks and check the run out. The run out limit is 0.5 mm (0.0197 in) Check the bearing by turning with your fingers. The bearings should turn smoothly and quietly.
  • Page 73 INSTALLATION Add grease to the dust seal lips and install dust seals. Assemble the rear axle and the driven sprocket. • Assemble the drive chain on the driven sprocket. Assemble the master link and retaining clip. Note the retaining clip’s direction. Install the drive chain cover. •...

  • Page 74: Front Hydraulic Disc Brake System

    • Assemble the wheel. • Tighten the rear axle nut with 30-35 N/m (22.1-25.8 lbf-ft). Install a new cotter pin. • Adjust the rear brake slack. Adjust chain slack. 10.5 Front Hydraulic Disc Brake System • To the replace brake disc, first remove the front tire by removing the four nuts as shown.
  • Page 75 Unscrew the bolts and remove the brake disc. Check the thickness of disc and replace with a new one if the thickness less than 3mm (0.118 in”). REPLACE THE BRAKE PADS: First, remove the tire. • Unscrew the two bolts shown on the photo and remove the caliper.
  • Page 76 • Remove the brake pad as shown. • Check the thickness of the brake pad and replace with a new one if the thickness less than 1mm (0.039”). Take great care as to not contaminate the brake pads or rotor with oil, grease, or brake fluid during the installation.
  • Page 77 • Unscrew the bolt and drain the used oil. • Fasten the bolt after the used oil has been drained out completely. • Loosen the bleeder valve on the caliper and depress the brake lever to expel any air in the line. Tighten the bleeder valve before releasing the brake lever.
  • Page 78 PARKING BRAKE PAD REMOVAL Remove the tire. There are two brake caliper fixing bolts on the back of the plate. Use a wrench to remove those two bolts; you can now take the whole caliper out. After removing the rear brake caliper, release the brake cable nut.

  • Page 79: Body Covers And Exhaust System

    11. BODY COVERS AND EXHAUST SYSTEM 11.1 Body Cover Drawings Ref. 11.2-C Ref. 11.2-A Ref. 11.2-B 11.2 Cage & Body Cover Removal The support cage must first be removed to be able to remove the front and rear fenders. First, remove the mounting bolts on the left and right-hand support arms that attach the cage to the front of the frame.
  • Page 80 Remove the four bolts above the front fender panels to remove the front side fenders on the left and right hand sides (ref 11.2- To remove the rear bed, remove the fuel tank cap and the four bolts from the rear carrier. Remove the bed from the frame. To remove the seat, first remove the two allen bolts on the right hand side beneath the rear body cover.

  • Page 81: Exhaust System Drawing

    11.3 Exhaust System Drawing This is the two-piece exhaust system (exhaust reed system and pipe).

  • Page 82: Exhaust System Removal

    11.4 Exhaust System Removal • Caution : Do not attempt to perform maintenance on a hot exhaust system. Hot exhaust pipe and muffler pose a serious risk of burn and/or fire hazard. • Remove the two mounting bolts that attach the exhaust pipe to the exhaust port on the under side of the engine cylinder.
  • Page 83 After every 200 hours of operation, the Spark Arrestor has to be replaced by removing the retaining bolt using a 4mm allen wrench. Removal Bar Use pliers on the removal bar to turn the sleeve of the Spark Arrestor counterclockwise while applying an outward pressure until the screen is removed.

  • Page 84: Electrical System

    12. ELECTRICAL SYSTEM 12.1 Trouble Shooting Fuel petcock not in ON position Engine starts but dies Dirty or clogged fuel filter Improper ignition timing Faulty spark plug No spark at plug Engine stop switch in OFF position Remote control switch in OFF position Ignition switch in OFF position Safety tether switch disengaged Faulty spark plug...
  • Page 85 Charging system failure • Loose connection of battery terminal • Corrosion of battery terminal leads • Loose or poor connection of frame ground wire • Loose connection of A/C generator wires • Abnormal high current draw on battery • Faulty A/C generator •...

  • Page 86: Ignition Coil

    12.2 Ignition Coil Testing the ignition coil: • Remove the coil wire cap from the spark plug • Unplug the ignition coil primary leads • Test the primary coil as shown in the picture. Primary coil resistance should range between 0.1-0.3 Ω. •...
  • Page 87 Battery removal: • Remove the battery retainer strap • Disconnect the negative (BLACK) battery lead first • Disconnect the positive (RED) battery lead next • Use caution when disconnecting lead so as not to cause a spark • Remove the battery from the battery compartment Testing the battery: •...
  • Page 88 Battery installation: • Place the battery in the battery compartment. • Clean the battery terminals and lead connectors of all dirt and corrosion. • Attach the positive (RED) lead to the positive terminal of the battery first. • Attack the negative (BLACK) lead to the negative terminal of the battery next.

  • Page 89: Wiring Diagram

    12.5 Wiring Diagram...

  • Page 90: Troubleshooting

    13. TROUBLESHOOTING 13.1 Engine Does Not Start • No fuel In fuel tank No fuel flow to carburetor • Clogged float valve • Clogged fuel tank cap breather hole • Clogged at fuel tube Weak or no spark • Faulty spark plug •...

  • Page 91: Poor Performance At Low Idle

    13.2 Poor Performance at Low Idle Bad ignition timing Faulty CDI unit or pulse generator Restricted fuel flow Improperly adjusted air screw Leaking intake pipe Deteriorated insulator o-ring Loose carburetor Weak or intermittent spark Loose or disconnected ignition system wires Faulty, wet, or fouled spark plug Faulty alternator Faulty CDI unit...

  • Page 92: Loss Of Power

    13.4 Loss of Power Wheels do not spin freely • Brake dragging • Drive chain too tight • Damaged wheel bearing • Wheel bearing needs lubrication • Punctured tire Low tire pressure • Faulty tire valve Engine speed does not increase when •...

  • Page 93: Poor Handling

    13.5 Poor Handling Steering is heavy • Damaged steering bearing • Damaged steering shaft bushing One wheel is wobbling • Bent rim • Improperly installed wheel hub • Excessive wheel bearing play • Bent swing arm • Bent frame • Swing arm pivot bushing excessively worn •...
  • Page 94 ETON America, LLC Service Bulletin Speed limit keys for the UK1-90R FX-ROVER Bulletin No.: SB-0047 Date: 11/21/06 The UK1-90R Rover is equipped with 2 different speed range keys. The blue (shorter) key is restricted to slower rpm’s, and with no adjustment on the CDI rev- limiter.
  • Page 95 ETON America, LLC Service Bulletin Bulletin No: 0051 E-TON ATV, Scooter and Utility Kart Date: 03/01/2007 Headlight Wattages Head Light Wattages  Model  Factory  Maximum  Viper 70‐4   10w  Viper 90‐4  10w  Viper 150  20w  Yukon 150  20w  Vector 250  35w  Beamer II   18w  Beamer III   18w  Beamer Matrix   18w  Beamer R2   18w ...

This manual is also suitable for:

Uk2

Table of Contents