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Eton CXL-150 Service Manual

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CONTENTS
1.INFORMATION............................................................2
2.MAINTENANCE...........................................................6
3.ENGINE REMOVAL AND INSTALLATION.......................14
4. CYLINDER HEAD / VALVES........................................16
5. LUBRICATION..........................................................26
6. CYLINDER / PISTON..................................................34
7. TRANSMISSION / KICK STARTER...............................42
8. STEERING AND SUSPENSION....................................52
9. FRONT WHEEL AND BRAKE SYSTEM.........................59
10. REAR WHEEL AND BRAKE SYSTEM.........................68
11. FENDERS AND EXHAUST PIPE.................................83
12. ELECTRICAL SYSTEM.............................................89
13. TROUBLE SHOOTING............................................108
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Summary of Contents for Eton CXL-150

  • Page 1 CONTENTS 1.INFORMATION……………………………………………………2 2.MAINTENANCE…………………………………………………..6 3.ENGINE REMOVAL AND INSTALLATION…………………..14 4. CYLINDER HEAD / VALVES………………………………….16 5. LUBRICATION………………………………………………….26 6. CYLINDER / PISTON…………………………………………..34 7. TRANSMISSION / KICK STARTER………………………….42 8. STEERING AND SUSPENSION……………………………...52 9. FRONT WHEEL AND BRAKE SYSTEM…………………….59 10. REAR WHEEL AND BRAKE SYSTEM…………………….68 11. FENDERS AND EXHAUST PIPE…………………………...83 12.

  • Page 2: Information

    1. INFORMATION SAFTY SERIAL NUMBER NOTES TORQUE VALUE SPECIFICATION 1.1 SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

  • Page 3: Specification Engine

    1.3 SPECIFICATION ENGINE This service manual have six models, it is YXL-150, CXL-150, EXL-150 / 150 (2004 two-passengers) RXL-150 and EXL-150 (VIPER) in this service manual. Type Air-Cooling 4-Stroke with oil cooler Displacement 149.5 c.c. Bore and Stroke 57.4X57.8mm Compression 9.7:1 11.7 / 5000 ±...
  • Page 4 1.4 SERIAL NUMBER (For YXL 150, EXL 150 / EXL 150(2004 ) and CXL 150 in this service manual) two-passengers The frame serial number is stamped on the front of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number Side frame serial number --only in EXL 150 / 150 (2004...
  • Page 5 1.5 TORQUE VALUES STANDARD 5 mm bolt and nut 5 N.m (3.5 lbf.ft) 10 N.m (7.2 lbf.ft) 6 mm bolt and nut 8 mm bolt and nut 22 N.m (16 lbf.ft) 35 N.m (25 lbf.ft) 10 mm bolt and nut 12 mm bolt and nut 55 N.m (40 lbf.ft) ENGINE...

  • Page 6: Maintenance

    2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN 2.3 FUEL TUBLE 2.10 BRAKE SYSTEM 2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES 2.5 THROTTLE CABLE AJUSTMENT 2.12 STEERING SYSTEM 2.6 AIR CLEANER 2.13 TOE-IN 2.7 SPARK PLUG 2.14 GEAR OIL 2.1 MAINTENANCE DATA SPECIFICATION...
  • Page 7 2.2 MAINTENANCE SCHEDULE The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, require more frequent servicing. INITIAL SERVICE REGULAR SERVICE EVERY YEAR (First week) (Every 30 operating days) FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG CARBURETOR IDLE...
  • Page 8 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever.
  • Page 9 2.9 DRIVE CHAIN Stop the ATV and shift the transmission into neutral. Measure the drive chain slack midway between the sprockets. Chain slack =15~25mm (5/8~1 inch) Adjust the chain slack. Loosen the lock nuts and turn drive chain adjusting nuts until get the correct slack.
  • Page 10 (The right side picture is for CXL / RXL / EXL-150 they have a parking brake on the top of hand brake.) Only for EXL 150 (2004 two-passengers) / EXL-150 (VIPER) Inspect the rear brake lever and cable for excessive play or other damage.
  • Page 11 Adjust the free play of the rear brake lever by turning the adjuster on the rear axle. (Only for YXL 150 / EXL 150 (2004 two-passengers), / EXL-150 (VIPER)) Because of the CXL / EXL / RXL-150 are both disc brake system, so they don’t need to adjust the free play.
  • Page 12 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the tire surfaces at cold tire condition. *The standard of tire pressure is on chap 1. 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead.
  • Page 13 Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod...
  • Page 14 3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 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, front fender and rear fender (see chapter 11). Remove the footrest. Remove the spark plug cap from the spark plug.
  • Page 15 3.3 ENGINE INSTALLATION The torque of engine hanger bolt is 30 N.m Engine installation is essentially the reverse order of removal. Route the wires and cable in reverse order properly.

  • Page 16: Cylinder Head / Valves

    4.CYLINDER HEAD / VALVES 4.1 SERVICE INFORMATION 4.4 CYLINDER HEAD REMOVAL 4.2 TROUBLESHOOTING 4.5 CYLINDER HEAD INSTALLATION 4.3 CAMSHAFT COMPOSITION REMOVAL 4.1 SERVICE INFORMATION GENERAL This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head.
  • Page 17 4.2 TROUBLE SHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope. LOW COMPRESSION Valve Incorrect valve adjustment Worn or damaged valve seats Burned or bent valve Incorrect valve timing...
  • Page 18 Remove the air cleaner and carburetor. CARBURATOR Remove the inlet pipe assy. Remove the shroud compositions. SHROUD COMPOSITIONS INLET PIPE ASSY Relax the cam chain adjuster screw. Remove the screw and O-ring and tighten the cam CAM CHAIN ADJUSTING BOLT chain adjusting bolt with clockwise direction.
  • Page 19 INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage. SERVICE LIMIT: IN 29.395 mm EX 29.160 mm LOBES Inspect the camshaft and bearings for wear or damage BEARINGS and replace them if necessary. Screw a 5mm bolt into the rocker arm shaft threaded end.
  • Page 20 Measure the I.D. of each rocker arm. SERVICE LIMIT: 10.10 mm Measure the O.D. of each rocker arm shaft. SERVICE LIMIT: 9.91 mm 4.4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head. FLANGE BOLTS CYLINDER HEAD Remove the cylinder head gasket and dowel pins. DOWEL PINS CYLINDER HEAD GASKET Remove the cam chain guide.
  • Page 21 CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor. INSPECTION Clean off all carbon deposits from the combustion chamber. Check the spark plug hole and valve area for cracks. Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge.
  • Page 22 Inspect each valve for turning, burning, scratches INLET VALVE or abnormal stems wear. EXHAUST VALVE Check the valve movement in the guide. Measure and record each valve stem O.D. SERVICE LIMITS: 4.90 mm Measure and record the valve guide I.D. SERVICE LIMITS: IN / EX 5.30 mm Calculate the stem-to-guide clearance.
  • Page 23 INSTALLATION DOWEL PINS Install the new gasket and dowel pins. Install the cam chain guide. CAM CHAIN GUIDE Install the cylinder head. CYLINDER HEAD CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder.
  • Page 24 Align the “T” mark on the flywheel with the index mark “T” MARK on the alternator cover by turning the flywheel counter - clockwise. Position the camshaft gear with cam chain so that its “I” MARK “I” mark aligns with the cylinder head surface and the circle hole forwards front.
  • Page 25 Relax the cam chain-adjusting bolt with counterclockwise direction and install the o-ring and screw. Install the cylinder head cover. CYLINDER HEAD COVER...

  • Page 26: Lubrication

    5. LUBRICATION 5.1 SERVICE INFORMATION 5.4 ENGINE OIL & FILTER CHANGE 5.2 TROUBLESHOOTING 5.5 OIL PUMP 5.3 ENGINE OIL LEVEL 5.1 SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump.
  • Page 27 5.2 TROUBLESHOOTING Oil lever too low-high oil consumption Normal oil consumption. External oil leaks. Oil not changed often enough. Worn piston rings. Faulty heat gasket. Oil contamination Worn piston rings. Faulty heat gasket. Oil or filter not changed often enough. 5.3 ENGINE OIL LEVEL Place the engine on the level plane.
  • Page 28 Remove the oil filter cap, spring and oil filter screen. OIL FILTER OIL FILTER SCREEN Check the O-ring for damage or fatigue. Install a new oil filter screen and spring then install the cap. SPRING O-RINING Install the oil drain bolt with sealing washer. TORQUE: 20~30 n-m (2.0 ~ 3.0 kg-m) Fill the crankcase with recommended oil.
  • Page 29 Remove the cooling fan composition. COOLING FAN COMPOSITION Remove the A.C.G generator assy. A.C.G GENERATOR ASSY Remove the right crankcase cover. CRANKCASE COVER Remove the starting clutch outer and gear assy. STARTING CLUTCH OUTER STARTING CLUTCH GEAR...
  • Page 30 Remove the flange bolts and oil separator. OIL SEPARATOR FLANGE BOLTS Remove the oil pump chain and oil pump driven OIL PUMP CHAIN sprocket. OIL PUMP DRIVEN SPROCKET Remove the oil pump assy. OIL PUMP ASSY. Disassemble the oil pump. OIL PUMP ASSY.
  • Page 31 INSPECTION Measure the oil pump rotor-to-body clearance. OIL PUMP BODY SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump rotor tip clearance. SERVICE LIMIT: 0.12 mm OIL PUMP SHAFT Remove the oil pump shaft and measure the pump OIL PUMP OUTER ROTER end clearance.
  • Page 32 Install the oil pump assy. Install the oil pump driven sprocket and oil pump chain. OIL PUMP DRIVEN SPROCKET PS: The tighten torque of driven sprocket nut is 80~120 kgf-cm. Install the oil separator. OIL SEPARATOR Install the starting clutch outer and gear assy.
  • Page 33 Install the new gasket, dowel pins and right crankcase cover. Install the A.C.G generator assy. and cooling fan composition.

  • Page 34: Cylinder / Piston

    6.CYLINDER / PISTON 6.1 SERVICE INFORMATION 6.4 PISTON REMOVAL 6.2 TROUBLESHOOTING 6.5 PISTON INSTALLATION 6.3 CYLINDER REMOVAL 6.6 CYLINDER INSTALLATION 6.1 SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case. Before installing the cylinder head make sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place.
  • Page 35 6.3 CYLINDER REMOVAL Remove the cylinder head. CYLINDER HEAD Remove the cylinder. CYLINDER Remove the cylinder gasket and dowel pins. GASKET DOWEL CYLINDER SURFACE Clean off any gasket materials from the cylinder surface. NOTE: Be careful not to damage the gasket surface.
  • Page 36 6.4 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase. PISTON PIN CLIP Remove the piston pin from the piston. Remove the piston. PISTON PISTON PIN Spread each piston ring and remove it by lifting up at...
  • Page 37 Measure and record the cylinder I.D. at three levels in both an X and Y-axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 57.50 mm Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.10 mm Calculate cylinder taper at three levels in an X and Y-axis.
  • Page 38 Inspect the piston for wear or damage. PISTON 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 0.5 mm SECOND 0.5 mm...
  • Page 39 Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.02 mm Measure the connecting rod small end I.D. CONNECTING ROD SERVICE LIMIT: 15.06 mm 6.5 PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up. NOTE: Don’t interchange the top and second rings.
  • Page 40 PISTON INSTALLATION Install the piston with it’s “IN“ mark on the intake valve side. “IN”MARK 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.
  • Page 41 Coat the cylinder bore and piston rings with engine oil and install the cylinder. NOTE: Avoid piston rings damage cylinder bore during installation. Do not allow the cam chain fall into the crankcase. Install the cylinder head. CYLINDER...

  • Page 42: Transmission / Kick Starter

    7. TRANSMISSION / KICK STARTER 7.1 SERVICE INFORMATION 7.4 KICK STARTER DISASSEMBLY 7.2 TROUBLE SHOOTING 7.5 KICK STARTER ASSEMBLY 7.3 C.V.T DISASSEMBLY 7.6 C.V.T ASSEMBLY 7.1 SERVICE INFORMATION If the drain tube assy. fills with water, the tube should be drained. SPECIFICATIONS (mm) ITEM...
  • Page 43 7.3 C.V.T DISASSEMBLY L CRANK CASE COVER REMOVAL C.V.T INLET DUCT Relax the band screw and remove the C.V.T inlet duct. Relax the band screw and remove the C.V.T outlet duct. C.V.T OUTLET DUCT Remove the gas waste recovery. GAS WASTE RECOVERY Remove the bolts and L cranks case cover.
  • Page 44 Remove the gasket and dowel pins. Clean off any gasket material from L crank case surface. L CRANK CASE SURFACE DOWEL PINS GASKET C.V.T REMOVAL Relax the flange nut and remove kick-starter ratchet. DRIVE FACE FLANGE NUT Remove the drive face. KICK STARTER RATCHET Relax the flange nut.
  • Page 45 Remove the ramp plate and weight roller set. WEIGHT ROLLER SET RAMP PLATE Relax the special nut and remove the driven plate SPECIAL NUT composition and driven face spring. DRIVEN PLATE COMPOSITION INSPECTION Inspect the driven belt for wear, tears or damage. Measure the width of driven belt.
  • Page 46 Measure the I.D. of movable driven face. MOVABLE DRIVE FACE SERVICE LIMIT: 28.03mm Inspect the drive face collar for wear or damage. Measure the I.D. of drive face collar. SERVICE LIMIT: 24.098 mm Inspect the drive face boss for wear or damage. DRIVE FACE BOSS Measure the O.D.
  • Page 47 Measure the length of driven face spring. DRIVEN FACE SPRING SERVICE LIMIT: 164.0 mm Inspect the driven face assy. and replace them if necessary. 7.4 KICK STARTER DISASSEMBLY Remove the L crank case cover. KICK STARTER L CRANK CASE COVER Remove the kick-starter.
  • Page 48 Rotate the kick-starter spindle composition to remove KICK RETURN SPRING KICK DRINEN GEAR the kick driven gear and spring. Remove the kick-starter spindle composition and return spring. Remove the kick spindle bush. KICK STARTER SPINDLE COMPOSITION INSPECTION Inspect the kick starter spindle composition for wear or damage.
  • Page 49 Inspect the machining surface for wear or damage. MACHINING SURFACE 7.5 KICK STARTER ASSEMBLY Install the kick spindle bush, return spring and spindle assy. Install the kick driven gear and spring. Install the kick-starter. KICK STARTER 7.6 C.V.T ASSEMBLY Compose the driven face assy., spring and driven plate composition.
  • Page 50 Compose the movable driven face composition, weight roller set and drives face. Install the movable drive face assy. and boss. MOVABLE DRIVE FACE Install the drive face and kick-starter ratchet. DRIVE FACE KICK STARTER RATCHET Install the driven belt and driven pulley assy. DRIVEN PULLEY ASSY.
  • Page 51 Install the dowel pins and gasket. DOWEL PINS GASKET Install the L crank case cover. L CRANK CASE COVER Install the gas waste recovery and C.V.T ducts. C.V.T DUCTS GAS WASTE RECOVERY...

  • Page 52: Steering And Suspension

    8. STEERING AND SUSPENSION 8.1 PARTS DRAWING 8.4 THROTTLE HOUSING 8.2 TROUBLESHOOTING 8.5 STEERING SYSTEM 8.3 HANDLENAR 8.1 PARTS DRAWING STEERING STEERING (For ATV YXL / CXL-150) (For ATV EXL-150 / EXL 150 (2004 two-passengers) / RXL-150 / EXL-150 (VIPER)
  • Page 53 8.2 TROUBLESHOOTING HARD STEERING Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing FRONT WHEEL WOBBLING Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly STEERS TO ONE SIDE Bent tie rods Wheel installed incorrectly Unequal tire pressure...
  • Page 54 Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. Remove the bolts attaching the handlebar upper holder. Remove the handlebar. INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark match with the top end of the handlebar lower holders.
  • Page 55 Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely. Aligning the split line of the throttle housing and holder with the punch mark. Tighten the screw securely 8.4 THROTTLE HOUSING DISASSEMBLY Unscrew the screws on the throttle housing cover. Remove throttle housing cover and gasket.
  • Page 56 Remove the cotter pin on the kingpin. Unscrew the bolt 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. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly.
  • Page 57 Steering Shaft Removal Remove the handle bar cover and handle bar. (See paragraph 8-3) Remove the front fender. (See paragraph 10-1) Remove handlebar lower holder. Unscrew steering shaft holder bolt, remove steering shaft holder. Take off the cotter pin below steering shaft. Unscrew the steering shaft fixed out below shaft.
  • Page 58 Installation of Tie-rod Install the ball joint with “ L” mark on the steering shaft side. Install the tie-rod with the mark on the wheel side. Installation is in the reverse order of removal.

  • Page 59: Front Wheel And Brake System

    9. FRONT WHEEL AND BRAKE SYSTEM 9.1 PARTS DRAWING 9.4 FRONT BRAKES 9.2 TROUBLESHOOTING 9.5 BRAKE CABLE REMOVAL 9.3 FRONT WHEEL 9.6 HYDRAULIC BRAKE 9.1 PARTS DRAWING The picture below is for YXL / CXL / RXL-150 EXL 150 (2004 two-passengers) FRONT WHEEL FRONT WHEEL The picture below is for YXL / CXL / RXL-150...
  • Page 60 9.2 TROUBLESHOOTING HARD STEERING Faulty tire Insufficient tire pressure 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 STEERS TO ONE SIDE Bent tie rods Wheel installed incorrectly Unequal tire pressure Incorrect wheel alignment...
  • Page 61 Measure the brake lining thickness. The minimum limit: 1.5 mm If they are thinner than the minimum limit, replace the brake linings. 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.
  • Page 62 Remove brake arm and cam. Remove return spring. Remove indicator plate and felt seal. INSTALL BRAKE PANEL 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.
  • Page 63 9.5 BRAKE CABLE REMOVAL NOTE Because of ATV YXL and CXL don’t have the front brake distributor, so their brake parts chart and cable removal only follow the two steps below. Disconnect the front brake primary cable. Primary cable Secondary cable Disconnect the front brake secondary cable from the brake arm.
  • Page 64 Remove the adjusters and the front brake cables. Brake plate Front cable Remove the two bolts and the brake plate. (The mechanism of right side picture is only for ATV EXL-150) Bolt Adjuster INSTALLATION Install the brake plate and tighten the bolts. (The mechanism of right side picture is only for ATV EXL-150) Connect the front brake secondary cable to the brake arm.
  • Page 65 9.6 HYDRAULIC BRAKE This brake type is only applying in front wheel of EXL 150 (2004e-mark) / EXL 150 (VIPER). REMOVAL Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. Please follow the next three steps of right pictures.
  • Page 66 After disassembling the wheel, take the wheel hub apart the spindle shaft. Then using the power tool to drive the screw out from brake stopping plate. You can take the brake disc off. When change brake shoe wear, you must push the master piston to rearward.
  • Page 67 THE BRAKE FLOW CHART When actuate the brake lever, brake force will through oil tube to drive the wheel brake. Or force to the brake pedal, through mechanism to drive the wheel brake.

  • Page 68: Rear Wheel And Brake System

    10. REAR WHEEL AND BRAKE SYSTEM 10.1 PARTS DRAWING 10.5 REAR BRAKE AND WHEEL INSTALLATION 10.2 TROUBLESHOOTING 10.6 SHOCK ABSORBER 10.3 REMOVE REAR WHEEL AND REAR BRAKE 10.7 SWINGARM 10.4 DRIVE MECHANISM 10.8 SUBPART-HYDRAULIC BRAKE SYSTEM 10.1 PARTS DRAWING The picture below is for YXL / CXL-150 The picture below is for EXL/EXL-150 (2004 two-passengers) REAR WHEEL REAR WHEEL...
  • Page 69 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 Vibration or Wobble Axle is not tightened well Bent rim Axle bearings are worn Faulty tires Rear axle bearing holder is faulty Incorrect brake adjustment...
  • Page 70 Remove the axle collar and brake drum. Check the brake lining thickness. The minimum limit is 2.0 mm. CAUTION: DO not get grease or oil the brake lining surface and brake drum. Otherwise stopping power will be reduced. Check the brake drum for damage. Replace if necessary.
  • Page 71 Disassemblies the chain retaining clip and master link. Remove the chain. Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. Replace if necessary. 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 inner race of bearing with fingers.
  • Page 72 INSTALLATION Add grease to the dust seal lips and install dust seals. Assembly the rear axle and the driven sprocket. Assembly the drive chains on the driven sprocket. Assembly the master link and retaining clip. Note the retaining clip direction. Install the drive chain cover.
  • Page 73 The chain should be kept well lubricated to prevent excess wear and premature failure. We recommend that you lubricate the chain every 15 hours of operation, or more frequently if needed, with a high quality chain lubricant. 10.5 REAR BRAKE AND WHEEL INSTALLATION nstall the wear indicator plate aligning the tab on the axle holder with the slit on the cam.
  • Page 74 Install the brake drum and brake drum cover. 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 drive chain slack. 10.8 SUBPART –HYFRAULIC DISC BRAKE SYSTEM PARTS DRAWING NOTE This section is about ATV CXL / EXL / RXL-150 rear brake system.
  • Page 75 (The picture shows only for ATV EXL-150 system) Brake Lever Brake Cylinder (The picture shows only for ATV EXL-150 system) Brake Switch (The picture shows only for ATV EXL-150 system) Brake pedal Brake hose Disc plate Brake cable Rubber tube...
  • Page 76 There is a label showing how to adjust the disc brake (ATV CXL / EXL / RXL-150 have the same steps under) To replace brake disc Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper...
  • Page 77 Unscrew the rear wheel axle nut and then remove the mounting seat of the disc 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 and remove caliper...
  • Page 78 Unscrew these two plugs Unscrew & Remove the brake shoe pin as shown Remove the brake shoes as shown Check the thickness of brake shoe and replace thickness less than 1mm. a new one if the...
  • Page 79 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 (The oil reservoir of ATV CXL-150 just like right side picture. It is located on the handle bar but ATV EXL-150 is not on the same position.
  • Page 80 Unscrew the bolt to vent air from brake system. Fasten the bolt if there isn’t any air in the brake system Tighten torque 40~70kgf-cm Pull left brake lever slightly to extract air from brake system Fill the brake oil to the level shown on the cup when no air comes out Assemble the cover BRAKE CABLE REMOVAL --The mechanism of right side pictures is only for ATV EXL-150...
  • Page 81 Disconnect the foot brake spring and the foot brake cable. Brake pedal Remove the brake pedal. Foot brake spring Foot brake cable INSTALLATION Install the brake pedal. Connect the foot brake cables and the foot brake spring. Connect the rear brake cables and the adjusters.
  • Page 82 The brake flow chart --EXL 150 (2004 two-passengers) / EXL-150 (VIPER) There are two ways to operate rear brake system and you can use left lever or brake pedal.

  • Page 83: Fenders And Exhaust Pipe

    11. FENDERS AND EXHAUST PIPE 11.1 FENDRES DRAWING 11.4 CENTRAL-REAR-TRIM REMOVAL 11.2 REAR FENDERS REMOVAL 11.5 FRONT FENDER REMOVAL 11.3 FRONT-TRIM REMOVAL 11.6 EXHAUST PIPE REMOVAL 11.1 FENDERS DRAWING For YXL / CXL / EXL/EXL-150 (2004 two-passengers) For RXL / EXL-150 (VIPER) EXHAUST PIPE (For all serials)
  • Page 84 11.2 REAR FENDERS REMOVAL Pull the “Seat Release Bar” to take off the seat. This seat release bar is under the right side of the rear fender. Procedures of remove the rear fender: Remove the rear rack. Unscrew the two bolts which connect the front fender and rear fender.
  • Page 85 There are two screws on the top of seat compartment. Please remove them. Then there are two screws on side of the tail. Finally, you must remove the screws on the footrest. 11.3 FRONT-TRIM REMOVAL Unscrew the two screws just below the headlight of central-front-trim.
  • Page 86 EXL 150 (2004 two-passengers) RXL / EXL 150 (Viper. St) 11.4 CENTRAL-REAR-TRIM REMOVAL Remove the fuel tank cap. Remove the central-rear-trim two mounting bolts from the fuel tank. Pull the central-rear-trim up ward. 11.5 FRONT FENDER REMOVAL After remove the rear fender, central-front-trim and central-rear-trim, remove the two front fender mounting bolts from front frame.
  • Page 87 Remove the mounting bolts and nuts from the front fender and footrest plate. RXL / EXL 150 (Viper. St) Please remove the two screws on the top of the headlight. Then you can see there is a screw on the tip of the vehicle. Please remove it.
  • Page 88 11.6EXHAUST PIPE REMOVAL You must wait at least 15 minutes after turn off the engine. You need remove the seat, rear fender and footrest plate, before you take off the exhaust pipe. Unscrew the two exhaust pipe bolts that fixed with engine. NOTE Do not service the exhaust pipe while they are hot.

  • Page 89: Electrical System

    12. ELECTRICAL SYSTEM 12.1 TROUBLESHOOTING 12.6 ELECTRIC STARTER 12.2 IGNITION COIL 12.7 LIGHT BULBS REPLACEMENT 12.3 IGNITION TIMING 12.8 SPEEDOMETER AND FUEL METER 12.4 ALTERNATOR EXCITER COIL 12.9 WIRING DIAGRAM 12.5 BATTERY INFORMATION 12.1 TROUBLESHOOTING (The ATV serials in this manual have the same equipment) ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG...
  • Page 90 12.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1 - 0.3 (20 ) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7.4 –...
  • Page 91 BATTERY REMOVAL Remove the seat, and then you can see the battery. Disconnect the negative cable and then the position cable and remove the battery. BATTERY INSTALLATION Install the battery in the reverse order of removal. After installing the battery, coat the terminals with clean grease. CHARGING Connect the charge positive cable to the battery Position terminal.
  • Page 92 TROUBLESHOOTING Starter Motor Turns Slowly Weak battery. Poorly connected starter motor cable. Failed starter motor. Poorly connected battery ground cable. Starter Motor Not Turn Engine stop switch at “off “position. Gearshift bar is not at neutral position. Check for a blown fuse near battery. Make sure that the battery is fully charged and in good condition.
  • Page 93 When you will remove the headlight, there are three screws on the side of light independently. Only remove those screws first, the headlight just can be pull down. Than if you want to replace the bulb, you can use the driver to remove the screw on the front side of light first.
  • Page 94 TAILLIGHT Install the remove parts in the reverse order of removal EXL150 (2004 two-passengers) (For RXL-150) 12.8 SPEED METER AND FUEL METER PARTS DRAWING Headlight It is for EXL150 Fuel meter Speedometer...
  • Page 95 Picture of right side is for EXL150(2004 two-passengers) For EXL150(Viper. St)
  • Page 96 Picture of right side is for CXL150 For RXL150 REMOVAL Remove the headlight. Headlight Remove the brake pedal and the exhaust pipe. Exhaust pipe Brake pedal...
  • Page 97 Remove the speed gear and the plate. Speed gear Plate Disconnect the speed cable. Fuel meter Remove the speedometer and the fuel meter. Speedometer Speed cable INSTALLATION nstall the fuel meter and the speedometer. Connect the speed cable. Install the speed gear and the plate.
  • Page 98 Install the exhaust pipe. Install the brake pedal. Install the headlight. THE HEADLIGHT PHOTOGRAPH--EXL 150 (2004 two-passengers) EXL 150(Viper. St) have another shape but its cables position are the same as EXL 150(2004 two-passenger) FUEL METER ELECTRICAL SPEEDMETER...
  • Page 99 METER CABLE METER CABLE...
  • Page 100 METER METER CABLE SENSOR...
  • Page 101 12.9 WIRING DIAGRAM This diagram is for ATV YXL 150 流 喇 車...
  • Page 102 This diagram is for ATV CXL 150...
  • Page 103 This diagram is for ATV EXL 150...
  • Page 104 This diagram is for ATV EXL 150(2004 two-passengers)
  • Page 105 This diagram is for ATV EXL 150...
  • Page 106 This diagram is for ATV EXL 150(VIPER ST)
  • Page 107 This diagram is for ATV RXL 150...

  • Page 108: 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 Clogged float valve O.K.
  • Page 109 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 Loose carburetor O.K.
  • Page 110 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 Punctured tire Faulty tire valve PRESSURE NORMAL ACCELERATE LIGHTY...
  • Page 111 13.5 POOR HANDLING POSSIBLE REASON 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 swingarm Bent frame Swing arm pivot bushing excessively Worn VEHICLE PULLS TO ONE SIDE Bent tie-rod Incorrect tie-rod adjustment Rear tie air pressure incorrect...

This manual is also suitable for:

Exl-150 viperRxl-150Yxl-150Exl 150 2004

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