Eton ATV RXL 50 Service Manual
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Eton ATV RXL 50 Service Manual

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  • Page 2: Table Of Contents

    CONTENTS 1. INFORMATION…………………………………………………...2 2. MAINTENANCE………………………………………………….6 3. ENGINE REMOVAL AND INSTALLATION………………….12 4. ENGINE FUEL SYSTEM………………………………………14 5. ENGINE LUBRICATION AND COOLING SYSTEM….…….18 6. ENGINE COMBUSTION SYSTEM…………………………...20 7. TRANSMISSION SYSTEM……………………………………25 8. STEERING SYSTEM…………………………………………..31 9. FRONT WHEEL SYSTEM…………………………………….38 10. REAR WHEEL SYSTEM……..………………………………42 11. FENDERS AND EXHAUST PIPE..………………………….51 12.

  • Page 3: Information

    1. INFORMATION 1.1 SAFTY 1.4 SERIAL NUMBER 1.2 NOTES 1.5 TORQUE VALVE 1.3 SPECIFICATION 1.1 SAFETY ● Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. ● 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.
  • Page 4 1.3 SPECIFICATION RXL50 RXL70 RXL90 RXL90R RXL50M ENGINE TYPE AIR-COOLING TWO STROKE 49.3 ㏄ 68.0 ㏄ 82.5 ㏄ 82.5 ㏄ DISPLACEMENT 49.3 BORE & STROKE 40.0*39.2 mm 47.0*39.2 mm 50.0*42.0 mm 50.0*42.0 mm 40.0*39.2 mm 9.2：1 8.3：1 7.9：1 7.9：1 9.2：1 COMPRESSION MAXIMUN TORQUE 5.2 N-m @ 7000rpm...
  • Page 5 1.4 SERIAL NUMBER For this ATV serial; the number of frame and engine are the same position, just like the picture below; 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 Engine serial number...
  • Page 6 1.5 TORQUE VALUES For this ATV serial; the torque values of frame and engine are the same, just like the picture below; ENGINE ● Cylinder head nut 28-30 N.m (20.7-22.1 lbf.ft) 12-19 N.m (8.9-14.0 lbf.ft) ● Spark plug 20-30 N.m (14.8-22.1 lbf.ft) ●...

  • Page 7: Maintenance

    2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN 2.3 FUEL TUBE 2.10 BRAKE SYSTEM 2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES 2.5 THROTTLE CABLE ADJUSTMENT 2.12 STEERING SYSTEM 2.6 AIR CLEANER 2.13 TOE-IN 2.7 SPARK PLUG 2.14 GEAR OIL 2.1 MAINTENANCE DATA SPECIFICATION...
  • Page 8 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. (For RXL50 / 90) (For RXL70 / RXL90R / RXL50M) 2.4 THROTTLE OPERATION Inspect for smooth throttle lever full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kinking in the throttle cable, replace it if necessary.
  • Page 9 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, squeeze out the solvent thoroughly. Let it dry. Soak the filter element in gear oil and then squeeze out the excess oil.
  • Page 10 Adjust the chain slack. Loose the lock bolts (4 pcs) then adjust the drive chain slack by turn the adjusting nut. Tighten the four lock bolts. When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain.
  • Page 11 For RXL50M, because it have parking brake in rear tire. So, its controller is at the handler bar 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 standard is 15-25 mm.
  • Page 12 2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height.

  • Page 13: Engine Removal And Installation

    3. ENGINE REMOVAL AND INSTALLATION 3.1 SERVICE INFORMATION 3.3 ENGINE INSTALLATION 3.2 ENGINE REMOVAL 3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY 3.2 ENGINE REMOVAL Remove the seat and rear fender. (Chapter 11) Remove the spark plug cap from the spark plug.
  • Page 14 (The right side picture is for ATV RXL 90R) 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.

  • Page 15: Engine Fuel System

    4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING 4.3 CARBURETOR 4.2 FUEL TANK 4.1 TROUBLESHOOTING ★ N NGINE CAN NOT START O FUEL IN TANK ★ N O FUEL TO CYLINDER ★ T OO MUCH FUEL GO INTO CYLINDER ★ N O SPARK AT PLUG ★...
  • Page 16 4.2 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel tank cap and front fender. Unscrew the fuel tank fixed bolts. Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. 4.3 CARBURETOR REMOVAL Remove the air cleaner.
  • Page 17 DISASSEMBLY Unscrew the float chamber screws and remove the float chamber. Disassembly the float arm pin, float and float needle valve. Inspect the seat of the float needle valve for wear or damage. Disassembly the idle jet, main jet, idle speed adjust screw and idle mixture adjusts screw.
  • Page 18 ASSEMBLY Clean all parts in solvent and blow it dry with compressed air. Assembly is essentially the reverse order of disassembly. THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle. Install the jet needle into the throttle valve. Assembly the throttle cable, spring and the throttle valve.

  • Page 19: Engine Lubrication And Cooling System

    5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 ENGINE LUBRICATION SYSTEM 5.4 COOLING SYSTEM 5.2 CAUTION 5.5 TROUBLESHOOTING 5.3 OIL PUMP 5.1 ENGINE LUBRICATION SYSTEM The engine drives the pump gears of oil pump crankshaft. Pump gears rotate the plunger shaft in oil pump.
  • Page 20 5.5 TROUBLESHOOTING NO ENOUGH OIL SUPPLY TO ENGINE ★ THE OIL LEVEL IN OIL TANK IS TOO LOW. ★ OIL TUBES WERE NOT FIXED WELL. ★ OIL HAS LEAKAGED FROM TUBE ENDS. ★ OIL TUBES WERE BROKEN. ★ OIL TUBES WERE CLOGGED. ★...

  • Page 21: Engine Combustion System

    6. ENGINE COMBUSTION SYSTEM 11.1 TROUBLESHOOTING 11.3 CYLINDER AND PISTON INSPECTION 11.2 CYLINDER AND PISTON REMOVAL 11.4 INSTALLATION 6.1 TROUBLESHOOTING LOW COMPRESSION ★ CYLINDER HEAD HEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD ★ CYLINDER OR PISTON RINGS WORN OUT HIGH COMPRESSION ★...
  • Page 22 6.2 CYLINDER AND PISTON REMOVAL Remove the seat and rear fender. Remove the exhaust pipe. Remove the spark plug cap. Disconnect the wire. Drag out the engine. Disassembly the air cleaner and carburetor. Remove the intake pipe mounting bolts. Remove the cylinder bolt nuts. Remove the cylinder head.
  • Page 23 Check the cylinder head mating surface for warp with a straight edge and feeler gauge. Service limit: 0.10 mm Insert each piston ring into the cylinder, and measure the end gap. Service limit: 0.5 mm Measure the clearance between ring and groove. Service limit: 0.09 mm Measure the piston outer diameter at 10 mm high from the skirt’s bottom.
  • Page 24 Measure the piston pin bore, and the piston pin outer diameter. Pin outer diameter service limit: 50 ㏄ 90R ㏄ 50M ㏄ 90 ㏄ 50 ㏄ 9.96 mm 9.96 mm 1.96 mm 1.96 mm 9.96 mm Pin bore service limit: 50 ㏄...
  • Page 25 Apply some oil to inside of the connecting rod small end. Install the piston, piston pin and clip. Install the piston with the arrow mark facing the exhaust pipe. Do not align the piston pin clip end gap with the piston cutout. Install a new cylinder gasket.

  • Page 26: Transmission System

    7. TRANSMISSION SYSTEM 7.1 TROUBLE SHOOTING 7.6 GEAR BOX 7.2 THE PARTS DRAWING OF TRANSMISSION 7.7 ELECTRIC SELF-STARTER MECHANISM SYSTEM 7.8 KICK STARTER 7.3 SHIFT MECHANISM (INCLUDE C.D.I) 7.9 DISASSEMBLY AND CHECK OF C.V.T. 7.4 AUTOMATIC CONTINUOUS VARIABLE SYSTEM TRANSMISSION 7.5 CONTINUOUS VARIABLE TRANSMISSION 7.1 TROUBLESHOOTING ABNORMALLY ACT IN SHIFTING AND CAN’T RESET...
  • Page 27 Shift Mechanism For RXL 90R Gear Box For RXL 90R...
  • Page 28 7.3 SHIFT MECHANISM (For RXL 90R) C.D.I We can find C.D.I below the seat. It include shift control system. Replace it if control system invalid. There is a Speed-Limited Adjuster speed-limited adjuster in the corner. Adjust speed-limited as follows: C.D.I Sensor Inspect wire for break or damage and check contact.
  • Page 29 Shift Motor Check shift motor whether it’s action is normal as follow data: Brush Disassembly mission side cover, parts of shift mechanism and mission cover. Get seal and bearing after disassembly shift motor of mission cover. Seal Bearing Check seal and for wear or fatigue. Replace it if necessary.
  • Page 30 Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at the Driven End to shorten the revolving radius. There is a Torque Cam on the Movable Drive Face. Torque Cam is loaded from outside.
  • Page 31 ELECTRIC SELF-STARTER MECHANISM KICK STARTER 7.8 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-starter arm is kicked, the gear of start shaft will drive the kick-starter to revolve the crankshaft to start the engine. After the engine is started, the kick-started will stop transfer the power to the kick-starter driven gear.

  • Page 32: Steering System

    8. STEERING SYSTEM 8.1 THE PARTS DRAWING OF STEERING SYSTEM 8.3 HANDLEBAR 8.2 TROUBLESHOOTING 8.4 STEERING SYSTEM 8.1 THE PARTS DRAWING OF STEERING SYSTEM 8.2 TROUBLESHOOTING HARD STEERING ★ FAULTY TIRE ★ STEERING SHAFT HOLDER TOO TIGHT ★ INSUFFICIENT TIRE PRESSURE ★...
  • Page 33 (The picture of right side is for ATV RXL 50M) Remove engine switch housing on the left handle bar. Remove rear brake level bracket. (For all type) Remove the bolts attaching the upper holder cover. Remove the handlebar holder and handlebar. INSTALLATION Put the handlebar on the lower holders.
  • Page 34 Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely. (The picture of right side is for ATV RXL 50/90 and RXL 90R) Aligning the split line of the throttle housing and holder with the punch mark. Tighten the screw securely (The picture of right side is for ATV RXL 50/90 and RXL 90R)
  • Page 35 Take off the rubber cap on the kingpin and remove the cotter pins on the kingpin. 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 36 STEERING SHAFT REMOVAL Remove the handle bar and handle bar cover. (see paragraph 8-1) Remove the front fender. (see paragraph 11-1) Unscrew the steering shaft fixed out below shaft. Pull steering shaft carefully. BUSHING INSPECTION Remove the steering shaft. Remove the bushing from the shaft. Inspect the bushing for damage or wear, replace if necessary.
  • Page 37 INSTALLATION OF STEERING SHAFT Install the steering shaft with the bushing. Apply grease to the bushing. Install the bushing holder and tighten the nuts. Torque: 24-30 N.m Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50-60 N.m INSTALLATION OF TIE-ROD Install the ball joint with “...
  • Page 38 INSTALLATION OF KINGPIN Use grease to the kingpin lower dust seal lips and install it. Pump grease to bushing and install the kingpin. Tighten the kingpin nut, the setting torque is 30-40 N.m. Fix the waterproof rubber cap. Temporarily, set the distance 147mm between the ball joints. Install the tie-rod and tighten the nuts.

  • Page 39: Front Wheel System

    9. FRONT WHEEL SYSTEM 9.1 THE PARTS DRAWING 9.3 FRONT WHEEL OF FRONT WHEELS SYSTEM 9.2 TROUBLESHOOTING 9.4 FRONT BRAKES 9.1 THE PARTS DRAWING OF FRONT WHEELS SYSTEM FOR RXL 50 FOR RXL 70 AND RXL 50M FOR RXL 90 AND RXL 90R...
  • Page 40 9.2 TROUBLESHOOTING FRONT WHEEL WOBBLING ★ FAULTY TIRE ★ WORN FRONT BRAKE DRUM BEARING ★ BENT RIM ★ AXLE NUT NOT TIGHTENED PROPERLY ★ INCORRECT BRAKE ADJUSTMENT BRAKE DRAG ★ STICKING BRAKE CABLE POOR BRAKE PERFORMANCE ★ BRAKE SHOES WORN ★...
  • Page 41 Measure the brake drum inner diameter. The maximum limit: 86 mm Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly. If the race does not turn smoothly or quietly, remove and discard the bearings BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm.
  • Page 42 INSTALL BRAKE PANAL Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and install the seal on the brake cam. Install the brake arm on the cam by aligning the punch mark and the groove on the cam.

  • Page 43: Rear Wheel System

    10. REAR WHEEL AND BRAKE SYSTEM 10.1 THE PARTS DRAWING OF REAR WHEEL DRIVE MECHANISM 10.3 SYSTEM 10.2 TROUBLESHOOTING HYFRAULIC DISC BRAKE SYSTEM 10.4 10.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM FOR ATV RXL50 FOR ATV RXL90 AND RXL90R FOR ATV RXL70 AND RXL50M FOR RXL 50/70/90/90R FOR RXL 50M...
  • Page 44 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 ENGAGE ★ AXLE IS NOT TIGHTENED WELL VIBRATION OR WOBBLE ★...
  • Page 45 Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. Let the rear axle lie in V-blocks and check the run out. The run out limit is 0.5 mm Check the turning of bearing with fingers. The bearings should turn smoothly and quietly.
  • Page 46 Assembly the wheel. Tighten the rear axle castle nut with 40-60 N.m. Install a new cotter pin. Adjust rear brake level free play. Adjust chain slack. 10.4 HYFRAULIC DISC BRAKE SYSTEM To replace brake disc To replace brake disc Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper Unscrew the rear wheel axle nut and then remove...
  • Page 47 Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper Press the plate to the end...
  • Page 48 Remove the brake shoe as shown Check the thickness of brake shoe and replace a new one if the thickness less than 1mm. Press the piston to the end prior to installation of brake shoe Piston TO REPLACE THE BRAKE HYDRAULIC OIL Unscrew the bolts and open the cover.
  • Page 49 Unscrew the bolt and drain out the used oil drain. Fasten the bolt after the used oil being drained out completely. (Dot 3 or Dot 4) Add the brake oil Keep oil level at least half of the cup to avoid air gets into brake system, such like caliper and tube Unscrew the bolt to vent air from brake system.
  • Page 50 Fill the brake oil to the level shown on the cup when no air comes out Assemble the cover PARKING BRAKE ASSEMBLY- RXL 50R In RXL 50R, it has a parking brake in the rear brake. It uses another clipper to make brake stopping, and the controller is on handle bar right side.
  • Page 51 There are two brake caliper fixing bolt on the back of the plate. Use wrench to remove those two bolts, you can take the whole caliper out. After removing the rear brake caliper, release the brake cable-fixing nut. Then you can take apart the parking brake caliper.

  • Page 52: Fenders And Exhaust Pipe

    11. FENDERS AND EXHAUST PIPE 11.1 FENDERS DRAWING 11.4 EXHAUST PIPE REMOVE 11.2 HOW TO REMOVE THE FENDERS 11.5 EXHAUST PIPE INSTALLATION 11.3 EXHAUST PIPE DRAWING 11.1 FENDERS DRAWING All type has the same model below 11.2 HOW TO REMOVE THE FENDERS Unscrew two plastic bolts, you can remove the front body covers as picture 1 &...
  • Page 53 You should remove the seat before removing the front and rear fender. Unscrew the bolts as pictures 3 & 4 then you can remove the rear R/L fender. Picture 3 Picture 4 As picture 5 you can remove the rear R/L fender. Picture 5 As picture 6 unscrew these four bolts then Picture 6...
  • Page 54 Before remove the front body cover Picture 7 you should remove the handle bar cover firstly. Secondly, you should disassembly the front and rear brake cable and throttle cable, then disassembly the handle bar. As picture 7 unscrew the bolt then you can remove the front body fender.
  • Page 55 11.4 EXHAUST PIPE REMOVE Do not service the exhaust pipe while they are hot. Unscrew the exhaust pipe nuts that fixed with engine. Remove the exhaust pipe mounting bolts that beside the muffler body. Remove the exhaust pipe carefully. 11.5 EXHAUST PIPE INSTALLATION (There are three screw bolts in the vehicle frame.

  • Page 56: Electrical System

    12. ELECTRICAL SYSTEM 12.1 TROUBLESHOOTING 12.5 CHARGING 12.2 IGNITION COIL 12.6 REMOTE CONTROLLER 12.3 BATTERY CAUTION 12.7 WIRING DIAGRAMS 12.4 BATTERY INSPECTION 12.1 TROUBLESHOOTING ENGINE STARTS BUT STOPS ★ IMPROPER IGNITION TIMING ★ FAULTY SPARK PLUG NO SPARK AT PLUG ★...
  • Page 57 12.2 IGNITION COIL (ATV RXL 50/90 and KXL 90 and MXL 50 all have the same model in this chapter) Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1 - 0.3Ω(20℃) Measure the secondary coil resistance with the spark plug cap in place.
  • Page 58 12.4 BATTERY INSPECTION Battery is under the seat, you can see this battery from the left side. Measure the battery voltage using a voltmeter. VOLTAGE: Fully charged: 13.1 V Undercharged: Below 12.0 V BATTERY REMOVAL Remove the battery holder bolt nuts. Disconnect the negative cable and then the position cable and remove the battery.
  • Page 59 First turn the switch off and take the front center cover apart. Find out the receiver pin on the right side of front vehicle. Use the wire clip to connect the receiver pin and vehicle frame ground. After connecting the wire link, you must finish controller adjust frequency in ten seconds.
  • Page 60 Take a new remote controller and press any button one time for one second to adjust the frequency of controller. Then waiting ten seconds later pull out end of wire clip from receiver pin or frame ground. Before testing the remote controller, make sure the engine stop switch on the left handle bar is on position.
  • Page 61 12.7 WIRING DIAGRAMS The wiring diagram above is for RXL 50 / 90 The wiring diagram above is for RXL 70 / 90 and RXL 50M...
  • Page 62 The wiring diagram above is for RXL 90R...

  • Page 63: Trouble Shooting

    13.TROUBLESHOOTING 13.1 ENGINE DOES NOT START 13.4 LOSS POWER 13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 13.5 POOR HANDLING 13.3 POOR PERFORMANCE AT HIGH SPEED 13.1 ENGINE DOES NOT START POSSSIBLE REASON N.G. CHECK FUEL FLOW TO CARBURETOR ★ No fuel In fuel tank ★...
  • Page 64 13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS POSSIBLE REASON N.G. CHECK IGNITION TIMING ★ Faulty CDI unit or pulse generator O.K. CHECK carburetor N.G. ★ Improperly adjusted air screw AIR SCREW ADJUSTMENT CHECK FOR LEAKING ★ Deteriorated insulator o-ring INTAKE PIPE ★...
  • Page 65 13.4 LOSS POWER POSSIBLE REASON RAISE WHEELS OFF GROUND DOES NOT SPIN FREELY ★ Brake dragging AND SPIN BY HAND ★ Drive chain too tight SPIN FREELY ★ Damaged wheel bearing ★ Wheel bearing needs lubrication PESSURE LOW CHECK TIRE CHECK TIRE PRESSURE ★...
  • Page 66 13.5 POOR HANDLING POSSIBLE REASON ★ Damaged steering bearing STEERING IS HEAVY ★ Damaged steering shaft bushing ONE WHEEL IS WOBBLING ★ Bent rim ★ Improperly installed wheel hub ★ Excessive wheel bearing play ★ Bent swingarm ★ Bent frame ★...

This manual is also suitable for:

Atv rxl 70Atv rxl 90Rxl 90Rxl 90rAtv rxl 50m

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