E-TON Viper 90R Owner's Manual
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E-TON Viper 90R Owner's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
This VIPER 90R should not be ridden by anyone under 12 years of age.
WARNING
This VIPER 90 should not be ridden by anyone under 12 years of age.
This VIPER 70 should not be ridden by anyone under 6 years of age.

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Summary of Contents for E-TON Viper 90R

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. This VIPER 90R should not be ridden by anyone under 12 years of age. WARNING This VIPER 90 should not be ridden by anyone under 12 years of age. This VIPER 70 should not be ridden by anyone under 6 years of age.
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 THE VIPER 70, AND ANY OTHER ATV OVER 50 cc, SHOULD NOT BE OPERATED BY A CHILD UNDER 6 YEARS OF AGE. THE VIPER 90 & VIPER 90R, AND ANY OTHER ATV OVER 70 cc, SHOULD NOT BE OPERATED BY A CHILD UNDER 12 YEARS OF AGE.
  • Page 4 ATV safely. Your ATV was delivered with an adjustable speed limiter. E-TON recommends that all beginners start off to limit the amount of speed available while they learn. As the beginner becomes more familiar with operating the ATV.
  • Page 5 IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS IN- JURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
  • Page 6 IMPORTANT NOTICE Welcome to the E-TON world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture.

  • Page 8: Table Of Contents

    Rear brake lever ........4-8 Parking brake ..........4-9 which, if not avoided, could result in death Transmission gear selector or serious injury. (for VIPER 90R)........4-10 TABLE OF CONTENTS Fuel tank cap .......... 4-10 Fuel ............4-10 SAFETY INFORMATION......1-1 Fuel cock ..........
  • Page 9 OPERATION..........6-1 General maintenance and lubrication chart ............8-5 Starting a cold engine ....... 6-1 Checking the spark plug ......8-9 Starting a warm engine ......6-3 Inline fuel filter .......... 8-11 Engine break-in ......... 6-4 Engine oil ..........8-11 Parking ............6-4 Final transmission oil ........
  • Page 10 Troubleshooting chart ......8-35 CLEANING AND STORAGE......9-1 Cleaning ............ 9-1 Storage ............. 9-2 SPECIFICATIONS ........10-1 CONSUMER INFORMATION .....11-1 Identification numbers ......11-1 Noise regulation ........11-3 Maintenance record ....... 11-4 E-TON POWER TECH., LTD. ATV LIMITED WARRANTY ....11-5...

  • Page 11: Safety Information

    SAFETY INFORMATION AN ATV IS NOT A TOY AND CAN BE HAZARD- OUS TO OPERATE. – A child under 16 years old should never oper- ate an ATV with engine size greater than 90 cc. An ATV handles differently from other vehicles, in- Never allow a child under age 16 to operate an cluding motorcycles and cars.
  • Page 12 operating this ATV. speeds and never turn at excessive speeds. Never operate at speeds too fast for your skills Never operate the ATV on hills too steep for the or the riding conditions. Always go at a speed ATV or for your abilities. Practice on smaller hills that is proper for the terrain, visibility, operating before attempting larger hills.
  • Page 13 Avoid crossing the side of a steep hill if possible. reduced stopping ability. Test your brakes after Always use proper procedures if you stall or roll leaving water. If necessary, apply them several backwards when climbing a hill. To avoid stall- times to let friction dry out the linings.
  • Page 14 TEACHING YOUR CHILD TO OPERATE THE how to operate an ATV safely. A child who is too ATV (FOR VIPER 70) tired or distracted should not be allowed to operate the ATV. WARNING Be sure your child is properly trained Never let your child ride an ATV without close Your child should take a certified training course.
  • Page 15 Supervise every use of the ATV 4. If there is a potential hazard ahead or if your Because an adult must supervise every ATV oper- child is not riding correctly, pull firmly on the ator under age 16, you should closely watch your cord to stop the engine.
  • Page 16 carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT.
  • Page 17 Down load your free copy of E-TON’s ATV Rider Safety Handbook From www.etonamerica.com...

  • Page 18: Location Of The Warning And Specification Labels

    Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your E-TON dealer.
  • Page 19 (FOR 70CC) (FOR 90CC)
  • Page 20 40 kg, (88 lbs). Includes weight of operator, cargo and accessories. H7103-5EA0-0001 (FOR 70CC) BY E-TON POWER TECH CO LTD. Improper tire pressure or overloading can cause loss of control. H7102-5EA1-9000 Loss of control can result in severe injury or death.
  • Page 21 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your E-TON dealer.
  • Page 22 (FOR 70CC) (FOR 90CC)
  • Page 23 Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. OPERATING TIRE PRESSURE Set with tires cold Recommended Front 27.6 kPa, 0.28 kgf/cm , 4 psi Rear 27.6 kPa, 0.28 kgf/cm , 4 psi Minimum Front...
  • Page 24 Les enfants de moins de 6 ans qui conduisent ce QUAD encourent des accidents graves ou mortels. La surveillance d'un adulte est requise pour les enfants de moins de 16 ans. NE JAMAIS laisser un enfant de moins de 6 ans conduire ce QUAD. (FOR 70CC) Les enfants de moins de 12 ans qui conduisent ce QUAD encourent des...
  • Page 25 Une pression de gonflage de pneu incorrecte ou une surcharge peuvent entra ner la perte de controle. La perte de controle peut entra ner de serieuses blessures ou la mort. PRESSION DE SERVICE DES PNEUS Regler avec des pneus froids Recommandee Avant 27.6 kPa, 0.28 kgf/cm , 4 psi...
  • Page 26 Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replace- ment label from your E-TON dealer.
  • Page 27 Les enfants de moins de 6 ans qui conduisent ce QUAD encourent des accidents graves ou mortels. La surveillance d'un adulte est requise pour les enfants de moins de 16 ans. NE JAMAIS laisser un enfant de moins de 6 ans conduire ce QUAD. (FOR 70CC) Les enfants de moins de 12 ans qui conduisent ce QUAD encourent des...
  • Page 28 Comprend poids de loperateur, chargement et accessoires. H7103-5EAF-0001( ) (FOR 70CC) Une pression de gonflage de pneu incorrecte ou BY E-TON POWER TECH CO LTD. une surcharge peuvent entra ner la perte de controle. H7102-5EA1-9000 La perte de controle peut entra ner de serieuses blessures ou la mort.

  • Page 29: Description

    DESCRIPTION Left view Right view 1. Fuel cock 1. Spark arrester 2. Rear wheel 2. Seat 3. Footrest 3. Footrest 4. Front wheel...

  • Page 30: Controls And Instruments

    Controls and instruments For VIPER 90 and VIPER 70 For VIPER 90R 1. Rear brake lever 6. Fuel tank cap 1. Rear brake lever 2. Parking brake 7. Engine stop switch with cord (lanyard) 2. Transmission gear indicator light (only for VIPER 70) 3.

  • Page 31: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started.

  • Page 32: Transmission Gear Indicator Light (For Viper 90R)

    Handlebar switches Transmission gear indicator light (for VIPER 90R) R N F 1. Engine stop switch “ENG. STOP” 1. Forward indicator light “F” 2. Start switch “START” 2. Neutral indicator light “N” Engine stop switch “ENG. STOP” 3. Reverse indicator light “R”...

  • Page 33: Engine Stop Switch With Lanyard (For Viper 70)

    Engine stop switch with lanyard (for VIPER 70) The rubber cap must be attached to the engine stop switch for the engine to run. 1. Lanyard Should the ATV be separated from the parent by a distance longer than the lanyard length after str- etching, the lanyard will pull out the rubber cap 1.
  • Page 34 The engine cannot be started with the safety tether cap removed. When your child has developed sufficient skill to no longer need you to follow with the lanyard, the lanyard can be stowed on the handlebars of the ATV. However, you must still closely supervise your child at all times during ATV operation.

  • Page 35: Throttle Lever

    Throttle lever Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns Once the engine is running, movement of the throt- to the idle position as soon as the lever is released. tle lever will increase the engine speed.

  • Page 36: Speed Limiting Throttle Adjustment

    Speed limiting throttle adjustment Your ATV is equipped with a throttle travel limiting bolt which is used to control the maximum speed of the ATV. The throttle limit bolt is set at the factory to comply with the speed limit standards set by government regulations.

  • Page 37: Vehicle Speed Limiter

    Vehicle speed limiter 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To decrease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b).

  • Page 38: Front Brake Lever

    Front brake lever Rear brake lever The front brake lever is located on the right handle- The rear brake lever is located on the left handle- bar. To apply the front brake, pull the brake lever bar. To apply the rear brake, pull the brake lever to- toward the handlebar grip.

  • Page 39: Parking Brake

    Parking brake WARNING The parking brake should be fully engaged before Always set the parking brake before starting starting the engine, or when the ATV is parked and the engine. The ATV could start moving not in use, especially when parking on any type of unexpectedly if the parking brake is not applied.

  • Page 40: Transmission Gear Selector (For Viper 90R)

    (for VIPER 90R) Always pause in the "N" neutral position for a few The Viper 90R model is equipped with a transmission seconds when shifting from forward to reverse or gear selector switch mounted on the right hand side from reverse to forward, this allows the transmission of the handlebars.
  • Page 41 Fuel tank capacity: containing methanol and ethanol are not recom- Plastic: 4.5 L (1.19 US gal) (0.99 Imp.gal) mended by E-TON because it can cause damage Iron: 3.6 L (0.95 US gal) (0.79 Imp.gal) to the fuel system or ATV performance problems.

  • Page 42: Fuel Cock

    With the fuel cock lever in this position, fuel flows Fuel cock to the carburetor. Turn the fuel cock lever to this The fuel cock supplies fuel from the tank to the car- position when starting the engine and riding. buretor while also filtering it.

  • Page 43: Choke

    Choke Seat The choke is used to start a cold engine. To remove the seat Move the choke in direction (a) to turn on the Pull the seat lock lever upward and pull up the seat choke. at the rear. Move the choke in direction (b) to turn off the choke.

  • Page 44: Kickstarter

    2. Move the kickstarter lever down lightly with your To install the seat foot until the gears engage, and then push it Insert the projection on the front of the seat into the down smoothly but forcefully. seat holder and push down on the seat at the rear. Make sure that the seat is securely fitted and the latch is fully engaged.

  • Page 45: Pre-Operation Checks

    Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by an E-TON dealer.
  • Page 46 Front brake Lubricate cable if necessary. 5-3, 8-22, 8-23 Check lever free play, and adjust if necessary. Check operation. If soft or spongy, have E-TON dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake...

  • Page 47: Fuel

    Apply the disc brake fully for one minute. If the specified level. Add oil as necessary. brake lever starts to fade or fluids is seen leaking (See page 8-14.) from the reservoir or brake line joints, have the vehicle brake system serviced by your E-TON dealership.

  • Page 48: Throttle Lever

    Use the tire pressure gauge to check and adjust tire open smoothly and spring back to the idle position pressures when the tires are cold. Tire pressures when released. Have an E-TON dealer correct if must be equal on both sides. necessary.
  • Page 49 Set tire pressures to the following specifications: Recommended pressure: Front 28 kPa (4.0 psi) (0.28 kgf/cm Rear 28 kPa (4.0 psi) (0.28 kgf/cm Minimum: Front 22 kPa (3.2 psi) (0.22 kgf/cm Rear 22 kPa (3.2 psi) (0.22 kgf/cm 1. Low-pressure tire gauge The tire pressure gauge is included as standard equipment.

  • Page 50: Tire Wear Limit

    Tire wear limit After extensive tests, only the tires listed below When the tire groove decreases to 3 mm (0.12 in) have been approved for this model by E-TON POWER TECH CO., LTD. due to wear, replace the tire. Front:...

  • Page 51: Chassis Fasteners

    Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. Instruments and switches Check that all instruments and switches are working properly. Correct if necessary.

  • Page 52: Operation

    If the indicator accident or injury. light does not come on, have an E-TON dealer check the electrical circuit.(for VIPER 90R) Starting a cold engine This model is equipped with an ignition circuit cut- off system.
  • Page 53 Position (1): Cold engine start with ambient temperature be- This model is equipped with an ignition circuit cut- low 30 °C (90 °F). off system. The engine can be started only when the rear brake lever is applied. Position (2): Warming up position.

  • Page 54: Starting A Warm Engine

    (2) to warm up the engine. If the engine is started with the choke in position (2), keep the To start out and accelerate(for VIPER 90R) choke in this position to warm up the engine. 1. Release the throttle lever and allow the engine NOTICE to return to idle speed.

  • Page 55: Engine Break-In

    If any engine trouble should immediately have There is never a more important period in the life of an E-TON dealer check the ATV. your engine than the first 320 km (200 mi) or 20 hours of riding. For this reason, you should read the following material carefully.

  • Page 56: Parking On A Slope

    Parking on a slope WARNING Avoid parking on hills or other inclines. Park- ing on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ATV transversely across the incline, stop the engine, apply the parking brake, and then block the front and rear wheels...

  • Page 57: Accessories And Loading

    E-TON vehicles. fere with your ability to control the ATV. Exam- E-TON is not in a position to test the products that ples include (but are not limited to) a heavy or these aftermarket companies produce. Therefore,...
  • Page 58 VIPER 70 : cessories. The ATV may handle differently than 40 kg (88 lb) it does without accessories. VIPER 90 & VIPER 90R : Loading 70 kg (154 lb) WARNING If you are carrying cargo and towing a trailer, in-...

  • Page 59: Riding Your Atv

    RIDING YOUR ATV...

  • Page 60: Getting To Know Your Atv

    GETTING TO KNOW YOUR ATV RIDE WITH CARE AND GOOD JUDGEMENT This ATV is for recreation use. This section, Riding Get training if you are inexperienced. your ATV, provides general ATV riding instructions WARNING for recreational riding. The skills and techniques described in this section, however, are appropriate Do not operate this ATV or allow anyone else for all types of riding.
  • Page 61 ATV at slow speeds first, even if you are an exper- Not recommended for children under 12 years ienced operator. of age.(For VIPER 90 and VIPER 90R) WARNING A child under 12 should never operate an ATV with engine size greater than 70 cc. Use by chil-...
  • Page 62 This ATV is designed to carry operator only – passengers prohibited. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. WARNING Never carry a passenger. Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV.
  • Page 63 Apparel WARNING Always wear the following to reduce risk of injury Operating without eye protection can result in in an accident: an accident and increases your chances of a Approved motorcycle helmet that fits properly severe injury in the event of an accident. Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt...
  • Page 64 Do not operate after consuming alcohol or Pre-operation checks drugs. Always inspect your ATV each time you use it to The operator’s performance capability is reduced make sure the ATV is in safe operating condition. by the influence of alcohol or drugs. Consuming Perform the pre-operation checks listed on page alcohol or drugs could seriously affect your judg- 5-1.
  • Page 65 Turning in the adjusting screw decreases top speed, and turning it out increases top speed. (See pages 4-6 and 4-7.) E-TON recommends that all beginning riders start off with the vehicle speed limiter turned in to limit the amount of speed available while they learn. The...
  • Page 66 VIPER 70 : WARNING 40 kg (88 lb) Improper loading or towing can increase the VIPER 90 & VIPER 90R : risk of loss of control, an overturn, or other 70 kg (154 lb) accident. To reduce the risk of an accident:...
  • Page 67 During operation Avoid wheelies and jumping. Always keep your feet on the footboards during WARNING operation; otherwise, they may contact the rear Attempting wheelies, jumps, and other stunts wheels. increases the chance of an accident, including WARNING an overturn. Never attempt stunts, such as Removing even one hand or foot can reduce wheelies or jumps.
  • Page 68 ATV should be gen- let brush, grass and other materials collect under uine E-TON or equivalent components designed the vehicle, near the muffler or exhaust pipe, or for use on this ATV and should be installed and used next to other hot parts.

  • Page 69: Be Careful Where You Ride

    BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. WARNING Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control. Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
  • Page 70 WARNING Never operate this ATV on any public street, road or highway, even a dirt or gravel one. You could collide with another vehicle. Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.
  • Page 71 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks, bumps, or holes.
  • Page 72 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WARNING You could collide with another vehicle if oper- ating in off-road areas where you cannot easily be seen.

  • Page 73: Turning Your Atv

    Do not ride in areas posted “no trespassing”. hot when riding and afterwards; do not allow skin Do not ride on private property without getting per- or clothing to come in contact with these compo- mission. nents. With the engine idling, the drive position and then release the parking brake.
  • Page 74 To achieve maximum traction while riding off-road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily.

  • Page 75: Climbing Uphill

    curves. Shift your weight forward. Improper riding procedures such as abrupt throttle Never open the throttle suddenly. The ATV changes, excessive braking, incorrect body move- could flip over backwards. ments, or too much speed for the sharpness of the Never go over the top of any hill at high speed. turn may cause the ATV to tip.
  • Page 76 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning for-ward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. Whenever possible, ride straight up hills.
  • Page 77 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to con- tinue up the hill, dismount the ATV on the uphill side.

  • Page 78: Riding Downhill

    Shift your weight backward and to the up side of the hill. Never go down a hill at high speed. Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where po- ssible.

  • Page 79: Crossing A Slope

    Whenever possible, ride your ATV straight downhill. CROSSING A SLOPE Avoid sharp angles which could allow the ATV to tip WARNING or roll over. Carefully choose your path and ride no Improperly crossing hills or turning on hills could faster than you will be able to react to obstacles cause loss of control or cause the ATV to over- which may appear.

  • Page 80: Crossing Through Shallow Water

    body in the uphill direction. It may be necessary to CROSSING THROUGH SHALLOW WATER correct the steering when riding on loose surfaces WARNING by pointing the front wheels slightly uphill. When Operating this vehicle through deep or fast- riding on slopes, be sure not to make sharp turns flowing water can lead to loss of control or over- either up or down hill.
  • Page 81 After riding your ATV in water, be sure to drain the Test your brakes after leaving the water. If necess- trapped water by removing the check hose at the ary, apply them several times to let friction dry out bottom of the air filter case. NOTICE: Undrained the linings.

  • Page 82: Riding Over Rough Terrain

    RIDING OVER ROUGH TERRAIN WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never att- empt to ride over large obstacles, such as large rocks or fallen trees. When you go over ob- stacles, always follow proper procedures as described in the Owner’s Manual.

  • Page 83: Sliding And Skidding

    SLIDING AND SKIDDING WARNING Skidding or sliding improperly may cause you to lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain.

  • Page 84: What To Do If

    WHAT TO DO IF... This section is designed to be a reference guide only. Be sure to read each section on riding tech- niques completely. WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again.
  • Page 85 If your ATV can’t make it up a hill you are trying If your ATV encounters shallow water: to climb: Ride slowly and carefully through slow moving Turn the ATV around if you still have forward water, watching for obstacles. Be sure to let wa- speed.

  • Page 86: Periodic Maintenance And Minor Repair

    If you are not familiar with vehicle service, have an E-TON The intervals given in the periodic maintenance and dealer perform service. lubrication chart should be considered as a general guide under normal riding conditions.

  • Page 87: Owner's Manual And Tool Kit

    1.owner’s manual If you do not have the tools or experience required for a particular job, have an E-TON dealer perform it for you.

  • Page 88: Periodic Maintenance Chart For The Emission Control System

    However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed. Items marked with an asterisk should be performed by an E-TON dealer as they require special tools, data and technical skills.
  • Page 89 INITIAL EVERY month Whichev- ITEM INSPECT OR MAINTAIN er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for leakage and replace gasket(s) if neces- sary. √ √ √ Exhaust system Check for looseness and tighten all screw clamps and joints if necessary.

  • Page 90: General Maintenance And Lubrication Chart

    General maintenance and lubrication chart INITIAL EVERY month Whichev- er comes ITEM INSPECT OR MAINTAIN 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element Clean and replace if necessary. dusty areas) √...
  • Page 91 INITIAL EVERY month Whichev- er comes ITEM INSPECT OR MAINTAIN 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Check for looseness or damage, and replace if √ √ √ √ Wheel hub bearings necessary. Make sure that all nuts, bolts, and screws are √...
  • Page 92 INITIAL EVERY month Whichev- ITEM INSPECT OR MAINTAIN er comes 1300 2500 2500 5000 first (mi) (200) (800) (1600) (1600) (3200) hours Drive select lever • Check operation and adjust or replace if neces- √ √ √ safety system cable sary.
  • Page 93 Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or muddy areas, or at full-throttle. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the brake master cylinder and caliper, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

  • Page 94: Checking The Spark Plug

    To remove the spark plug WARNING 1. Remove the spark plug cap. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Checking the spark plug The spark plug is an important engine component, which is easy to check.
  • Page 95 2. Clean the surface of the spark plug gasket attempt to diagnose such problems yourself. In- and its mating surface, and then wipe off any stead, have an E-TON dealer check the ATV. grime from the spark plug threads. 2. Check the spark plug for electrode erosion 3.

  • Page 96: Inline Fuel Filter

    Inline fuel filter "OFF" position. Then carefully compress the wire clamp rings until the clamp is free of the fuel line. Your ATV is equipped with an inline fuel filter to Slide each clamp away from the filter about 3/4". prevent dirt and debris from entering the carburetor and engine.
  • Page 97 If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil set- tles for an accurate reading. 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag.
  • Page 98 4. Remove the engine oil filler cap, and then 7. Add the specified amount of the recommend- remove the engine oil drain bolt to drain the ed engine oil, and then install and tighten the oil from the crankcase. engine oil filler cap. Recommended oil: See page 10-2.

  • Page 99: Final Transmission Oil

    The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have E-TON dealer check and repair the ATV. In addition, the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart.

  • Page 100: Cleaning The Air Filter Element

    4. Install the drain bolt, and then tighten it to the Cleaning the air filter elements specified torque. The air filter elements should be cleaned at the in- tervals specified in the periodic maintenance and Tightening torque: lubrication chart. Clean the air filter elements more Final transmission oil drain bolt: frequently if you are riding in unusually wet or dusty 15 Nm (1.5 m·kgf, 10.8 ft·lbf)
  • Page 101 2. Remove the air filter elements by removing the 1. Remove the air filter case covers by remov- screw, and then pull off the sponge materials ing the bolts. from the air filter element holders. 1.Two air filter case covers (opposite) 1.
  • Page 102 5. Check the sponge materials and replace it if damaged. NOTICE: Do not twist 6. Apply E-TON foam air filter oil or other quality the sponge materials when squeezing it. foam air filter oil to the sponge materials. The sponge materials should be wet but not drip- ping.
  • Page 103 7. Install the sponge materials onto the air filter This model is equipped with two air filter element holder. elements: one located on the left side and one 8. Place the air filter elements in the original position, located on the right side of the air box. and then install the screw.

  • Page 104: Cleaning The Spark Arrester

    Cleaning the spark arrester 2. Remove the spark arrester by pulling it out of the muffler. Be sure the exhaust pipe and muffler are cool be- 3. Tap the spark arrester lightly, and then use fore cleaning the spark arrester. a wire brush to remove any carbon deposits.

  • Page 105: Adjusting The Carburetor

    Always let the exhaust system cool prior to E-TON dealer, who has the necessary profes- touching exhaust components. sional knowledge and experience. The adjustment Always wear eye protection, and make sure described in the following section, however, may no one is behind the ATV.

  • Page 106: Checking The Throttle Cable Free Play

    (a), and to decrease If the specified idling speed cannot be obtained as it, turn the screw in direction (b). described above, have an E-TON dealer make the adjustment. Checking the throttle cable free play...

  • Page 107: Valve Clearance

    To essary, have an E-TON dealer adjust it. prevent this from occurring, the valve clearance must be adjusted by an E-TON dealer at the inter- vals specified in the periodic maintenance and lu- brication chart.

  • Page 108: Adjusting The Front Brake Lever Free Play

    The brake lever free play should measure 4.0– 12mm (0.47in), the brake shoes should be replaced 7.0 mm (0.16–0.28 in) as shown. If the free play as a set by E-TON dealer. is incorrect, adjust it as follows. 1. Upper adjusting bolt 2.
  • Page 109 1. Cable joint 1. Upper locknut 2. Upper adjusting bolt 3. Lower locknut 6. Tighten the upper locknut. 4. Lower adjusting bolt 4. Tighten the lower locknut. 5. While applying the front brake, turn out the up- per adjusting bolt until the upper and lower ca- ble lengths are equal.

  • Page 110: Checking The Rear Brake Pads

    If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have an E-TON dealer replace the brake pads as a set. 1. Wear indicator groove...

  • Page 111: Changing The Rear Brake Fluid

    The brake lever free play should measure 0 –1.5 mm (0 –0.06 in) as shown. If the free play is incorrect, have an E-TON dealer check the brake system. 1. Minimum level mark...

  • Page 112: Checking And Lubricating The Cables

    If a cable is damaged or does not move pivots should be lubricated if necessary. smoothly, have an E-TON dealer check or replace Recommended lubricants: Front brake lever: Lithium-soap-based grease...

  • Page 113: Checking The Wheel Hub Bearings

    However, the wheel and hub or if a wheel does not turn smoothly, battery lead connections need to be checked and, have an E-TON dealer check the wheel hub if necessary, tightened. bearings. NOTICE Never attempt to remove the battery cell seals, as this would permanently damage the battery.
  • Page 114 Make sure to properly connect the battery To charge the battery leads to the battery terminals. Have an E-TON dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the ATV is equipped with optional electrical accessories.

  • Page 115: Replacing The Fuse

    If you 2. Remove the blown fuse, and then install a do not have access to a constant-voltage new fuse of the specified amperage. battery charger, have an E-TON dealer charge your battery. Specified fuse: 7.0 A Replacing the fuse 3.

  • Page 116: Drive Chain Slack

    Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 To check the drive chain slack 1.

  • Page 117: Lubricating The Drive Chain

    The chain should be cleaned and lubricated after every use of the vehicle. Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.

  • Page 118: Removing A Wheel

    Removing a wheel When installing the wheel, make sure its arrow 1. Loosen the wheel nuts. mark points toward the rotating direction of the wheel. 1. Wheel nuts 1. Arrow mark 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified 2.

  • Page 119: Troubleshooting

    However, should your ATV re- quire any repair, take it to an E-TON dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the ATV properly.

  • Page 120: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have an E-TON dealer check the ATV. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 121: Cleaning And Storage

    CLEANING AND STORAGE applications such as those available in coin- Cleaning operated car washers. Frequent, thorough cleaning of your ATV will not 4. Once most of the dirt has been hosed off, only enhance its appearance but will improve its wash all surfaces with warm water and mild, general performance and extend the useful life of detergent-type soap.

  • Page 122: Storage

    Storage Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” Short-term section of this chapter. Always store your ATV in a cool, dry place and, if 2. Turn the fuel cock lever to “OFF”. necessary, protect it against dust with a porous 3.
  • Page 123 plug, and then place the spark plug on the cylinder head so that the electrodes are Make any necessary repairs before storing the grounded. (This will limit sparking during ATV. the next step.) d. Turn the engine over several times with the starter.

  • Page 124: Specifications

    The Specifications VIPER 70 VIPER 90 VIPER 90R Engine Type 4 Stroke 4 Stroke 4 Stroke Displacement 69.3cc 88.4cc 88.4cc Bore / Stroke 47.0 * 40.0mm 47.0 * 51.0mm 47.0 * 51.0mm Compression 8.5:1 10.6:1 10.6:1 Transmission Type Automatic (C.V.T. V-Belt) Automatic (C.V.T.

  • Page 125: Spark Plug

    VIPER 70 VIPER 90 VIPER 90R Wheel Bolt Pattern 4x 110mm 4x 110mm 4x 110mm Carburetor Make/Size SVR 22mm (Manual Choke) SVR 22mm (Manual Choke) SVR 22mm (Manual Choke) Main Jet Pilot Jet Back out 1 tums Back out 1...

  • Page 126: Consumer Information

    E-TON dealer or for ref- erence in case the ATV is stolen. KEY IDENTIFICATION NUMBER: VEHICLE IDENTIFICATION NUMBER: 1.
  • Page 127 1. Vehicle identification number 1. Engine serial number The vehicle identification number is used to identi- fy your ATV. Engine serial number The engine serial number is stamped into the engine. 11-2...

  • Page 128: Noise Regulation

    Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of de- sign incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 129: Maintenance Record

    Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document main- tenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required.
  • Page 130 Canada one should contact with your local E-TON dealer. The “limited vehicle warranty” is applicable to all the E-TON ATV consumers : However for the regions outside USA & Canada one should contact with your local E-TON dealer. 11-5...

  • Page 131: Atv Limited Warranty

    OR CONSEQUENTAL DAMAGES, SO THE ABOVE LIMITA TION OR EXCLUSION MAY NOT APPLY TO YOU. The “limited vehicle warranty” is applicable to all the E-TON ATV consumers : However for the regions outside USA & Canada one should contact with your local E-TON dealer.
  • Page 132 INDEX Accessories and loading ..........6-6 Engine break-in .............. 6-4 Air filter element, cleaning..........8-15 Engine, cold start............6-1 Engine idling speed............8-20 Engine oil............5-3, 8-11 Battery................8-28 Engine, starting a warm..........6-3 Brake lever, front.............4-8 Engine stop switch............4-2 Brake lever, rear.............4-8 Engine stop switch with lanyard ........4-2 Brake lever free play, checking the rear......8-26 Brake lever free play, adjusting the front......8-23 Brake levers, checking and lubricating ......8-27...
  • Page 133 Tire pressure, measuring ..........5-4 Main switch ..............4-1 Tires ................5-4 Maintenance and lubrication chart........8-5 Tire wear limit..............5-6 Maintenance chart, emission control system....8-3 Troubleshooting............8-34 Model label..............11-2 Troubleshooting chart..........8-35 Owner’s manual and tool kit........... 8-2 Valve clearance............8-22 Vehicle identification number ........11-1 Parking ................
  • Page 134 WARNING Improper ATV use can result in SEVERE INJURY or DEATH. ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate: ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough...

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Viper 70Viper 90

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