Related Manuals for Eton America Beamer PN2
Summary of Contents for Eton America Beamer PN2
- Page 1 ETON America Beamer Service Manual Covers: Beamer PN2 Beamer II PN2B Beamer Matrix PN2C...
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Page 2: Table Of Contents
Table of Contents 1. INFORMATION............................. 4 1.1 SAFETY ............................4 1.2 NOTES.............................. 4 1.3 Specifications............................ 5 1.4 SERIAL NUMBER .......................... 6 1.5 Standard Torque Values........................7 2. MAINTENANCE ........................... 8 2.1 MAINTENANCE DATA ......................... 8 2.2 MAINTENANCE SCHEDULE ....................... 9 2.3 FUEL TUBE ............................. - Page 3 7.6 TRANSMISSION BOX ......................... 32 7.7 ELECTRIC STARTER MOTOR ....................33 7.8 KICK STARTER ..........................33 8. FRONT WHEEL, BRAKE AND STEERING SYSTEM ..............35 8.1 TROUBLESHOOTING........................35 8.2 MAINTANENCE DATA ....................... 35 8.3 SPEEDOMETER CABLE REMOVAL ..................36 8.4 HANDLEBAR REPLACEMENT....................36 8.5 FRONT WHEEL ..........................
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Page 4: Information
1. INFORMATION 1.1 SAFETY Gasoline is extremely flammable and is explosive under certain conditions. 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 5: Specifications
1.3 Specifications Engine Type Two cycle air cooled oil injected Displacement 49.3cc φ40.0 * 39.2mm Bore / Stroke Compression - Ratio / Pressure 6.8 : 1 / 90-120psi Torque / BHP 5.2N m @ 7000rpm / 1.5BHP Estimated MPG 65mpg/795mpg Starting Electrical with Kick starter back up Transmission... -
Page 6: Serial Number
Spark Plug NGK (recommended) BPR7HS Nipendenso W22FRP-U Champion QL82YC Electrode Gap 0.6-0.7mm / 0.023" GVWR 240kg. / 530lbs. GAWR (Front) 76kg. / 167lbs. GAWR (Rear) 165kg. / 164lbs. Available Colors Blue *Subject to availability Yellow Black 1.4 SERIAL NUMBER The frame serial number is stamped on the front of the frame, at the front of the footrest plate. The engine serial number is stamped on the left side of the engine crankcase. -
Page 7: Standard Torque Values
1.5 Standard Torque Values ENGINE Cylinder head nut 28-30 N-m (20.7-22.1 lb./ft) Spark plug 12-19 N-m (8.9-14.0 lb./ft) Cylinder head bolt 20-30 N-m (14.8-22.1 lb./ft) Alternator bolt 8-12 N-m (5.9- 8.9 lb./ft) FRAME Handlebar upper holder bolt 24-30 N-m (17.7-22.1 lb./ft) Steering shaft nut 50-60 N-m (36.9-44.3 lb./ft) Steering shaft bushing holder nut... -
Page 8: Maintenance
2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE ADJUSTMENT 2.6 AIR CLEANER 2.7 SPARK PLUG 2.8 IDLE SPEED 2.9 BRAKE SYSTEM 2.10 WHEELS AND TIRES 2.11 STEERING SYSTEM 2.12 GEAR OIL 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG:... -
Page 9: Maintenance Schedule
2.2 MAINTENANCE SCHEDULE The maintenance intervals in the follow table are based upon average riding conditions. Riding in unusually dusty areas may require more frequent servicing. E-TON recommends that all maintenance and inspections be performed ONLY by a qualified and fully trained technician. INITIAL REGULAR SERVICE SERVICE... -
Page 10: Throttle Cable Adjustment
2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber adjuster cap off the throttle housing, loosen the locking 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. This free play should be 5-10mm. -
Page 11: Idle Speed
2.8 IDLE SPEED Air Mixture Adjustment Screw Connect a tachometer. Warm up the engine for at least 10 minutes. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. "Turn in" (clockwise) to get higher speed. "Turn out" (counter clockwise) to get lower speed. -
Page 12: Wheels And Tires
2.10 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails, or other sharp objects. Check the tire pressure at cold tire condition. The standard tire pressure is 2.5±0.3 kgf/cm2 2.11 GEAR OIL Fill Plug Transmission gear oil needs to be changed every year or after every 3000 miles of service. -
Page 13: High-Low Beam Controller
2.13 HIGH-LOW BEAM CONTROLLER This controller is located beside right handle bar and controls the headlight intensity setting. When the switch is placed in the full right position, the headlights are set to illuminate at 100% intensity. In the center position the headlight will illuminate at 60% intensity. -
Page 14: Engine Removal And Installation
3. ENGINE REMOVAL AND INSTALLATION 3.1 ENGINE REMOVAL Remove the seat, helmet box, and body cover. (See chapter 10 for complete instructions) Disconnect oil tube, fuel tube, and vacuum line tube. Disconnect the wires of the A/C generator and the starter motor. - Page 15 Disconnect the wires of the carburetor and the throttle cable. Remove the cap from the spark plug. Remove the bolt at the low end of the rear shock. Beamer Rev-2.0.2 Page 15 of 55 11/21/2005...
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Page 16: Engine Installation
Remove the engine hanger nut. Remove the rear brake cable adjusting nut. Pull the engine out from the frame. 3.2 ENGINE INSTALLATION Install engine in reverse order of disassembly. Torque value: M8 nut 15 - 22 lbf-ft M10 nut 22 - 29 lbf-ft M12 nut 36 –... -
Page 17: Engine Fuel System
4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING NGINE WILL NOT START O FUEL IN TANK O FUEL IN CYLINDER OO MUCH FUEL INTO CYLINDER O SPARK AT PLUG IR CLEANER CLOGGED NGINE IDLES UNSTEADILY STALLS MPROPER ADJUSTMENT F THE OR RUNS POORLY DLE SPEED SCREW AT CARBURETOR GNITION MALFUNCTION AIR MIXTURE RATIO TOO LEAN OR... -
Page 18: Carburetor
4.2 CARBURETOR Carburetor REMOVAL Remove the air cleaner. Disconnect the fuel line and auto-choke electric wire. Unscrew the intake pipe mounting bolts at the carburetor, and then remove the carburetor. Note: Before removing carburetor, you must shut the fuel flow off. Air Cleaner Remove the carburetor cap. - Page 19 DISASSEMBLY Unscrew the float chamber screws and remove the float chamber. Disassemble the float arm pin, float and float needle valve. Inspect the seat of the float needle valve for wear or damage. Disassemble the idle jet, main jet, idle speed adjustment screw, and idle mixture adjustment screw.
- Page 20 THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle. Install the jet needle into the throttle valve. Assemble the throttle cable, spring, and throttle valve. Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap to the carburetor.
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Page 21: Engine Lubrication And Cooling System
5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 TROUBLESHOOTING NOT ENOUGH OIL GIVEN TO ENGINE THE OIL LEVEL IN THE OIL TANK IS TOO LOW. OIL TUBES NOT FIXED PROPERLY. OIL LEAKING FROM TUBE ENDS. OIL TUBES BROKEN. OIL TUBES CLOGGED. OIL PUMP BROKEN. -
Page 22: Oil Pump
5.4 OIL PUMP The quantity of oil that is delivered from oil pump increases with the engine speed and carburetor throttle width opening. The oil pump is located under the right side of the engine and connected by a control cable from the throttle. The throttle cable assembly splits into two cables with one end controlling the carburetor throttle cylinder and the other end controlling the quantity of oil delivered... -
Page 23: Cooling System
5.5 COOLING SYSTEM The engine-cooling fan forces the air over the engine. The cooling fan is on the right side of engine. The air is forced to flow through cylinder fin and cylinder head. This prevents the cylinder and piston from overheating. Disassemble the engine fan cover and cylinder plastic cover. -
Page 24: Engine Combustion System
6. ENGINE COMBUSTION SYSTEM 6.1 TROUBLESHOOTING LOW COMPRESSION HEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD CYLINDER OR PISTON RINGS WORN OUT HIGH COMPRESSION EXCESSIVE CARBON BUILD UP ON PISTON HEAD OR IN COMBUSTION CHAMBER EXCESSIVE NOISE PISTON AND CYLINDER WORN EXCESSIVE CARBON BUILD EXCESSIVE SMOKE CYLINDER OR PISTON RINGS WORN OUT... -
Page 25: Cylinder And Piston Removal
6.2 CYLINDER AND PISTON REMOVAL Remove the engine. (See chapter 3) Disassemble the air cleaner and carburetor. Remove the intake pipe mounting bolts. Remove the cylinder bolt nuts. Remove the cylinder head. Remove the cylinder carefully, so the whole piston is visible. Remove one piston pin clip. - Page 26 Insert each piston ring into the cylinder, and measure the end gap. Service limit: 0.5 mm Measure the clearance between the ring and groove. Service limit: 0.09 mm Measure the pistons outer diameter at 10 mm above the bottom. Service limit: 39.9 mm Beamer Rev-2.0.2 Page 26 of 55 11/21/2005...
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Page 27: Installation
Measure the piston pin bore, and the piston pin outer diameter. Pin outer diameter Service limit: 10.04 mm Pin bore Service limit: 9.96 mm Measure the connecting rod small end inner diameter with a small hole-gauge. Service limit: 14.06 mm 6.4 INSTALLATION Install the piston rings with the marks facing up. - Page 28 Do not align the piston pin clip end gap with the piston cut-out. Install a new cylinder gasket. Apply a thin coat of engine oil to the piston rings and cylinder wall. Install the cylinder, compressing the piston rings. Replace the cylinder head gasket. Install the cylinder head.
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Page 29: Transmission System
7. TRANSMISSION SYSTEM 7.1 TROUBLESHOOTING BELT WORN Vehicle will not move after engine is started FRONT PULLEY WORN OR BROKEN CLUTCH LINING WORN BELT WORN Vehicle will not attain high speed ROLLERS WORN SPRING OF REAR PULLEY IS DISTORTED ELECTRONIC SPEED LIMITER EXCEDED 7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM Beamer Rev-2.0.2... -
Page 30: Transmission Power Path
7.3 TRANSMISSION POWER PATH The crankshaft torque drives the front pulley. The torque (drive) pulley turns the belt. The belt drives the rear (driven) pulley. The force is transmitted through the clutch shoe, clutch housing, and drive shaft. The drive shaft turns the idle gear in gearbox. Turning speed is reduced by the final-gear and transmitted to the rear-axle shaft to move rear wheel. -
Page 31: Automatic Continuous Variable Transmission
7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION The transmission is a combination of an automatic centrifugal clutch and a V-belt continuous variable transmission, which can change the transmission ratio automatically. When the engine speed increases, the drive pulley will push the belt by centrifugal force from the six rollers. -
Page 32: Transmission Box
There is a Torque Cam on the Movable Drive Face. The torque Cam is loaded from the outside. When the outside load is higher than the engine's output, the pulley of the fixed shaft and belt slip to make the Movable Drive Face move along the inner side of the cam and compensate to increase to high torque (toward low speed) and make the engine maintain smooth running with original revolution. -
Page 33: Electric Starter Motor
7.7 ELECTRIC STARTER MOTOR The Starter Motor is installed on the upper side of engine. The starter motor can only be activated when the left hand brake is applied and the engine stop switch is in the run position. 7.8 KICK STARTER The kick-starter arm is on the left side of engine. - Page 34 7.9 DISASSEMBLY AND INSPECTION OF THE C.V.T. SYSTEM Remove the engine clutch cover by unscrewing the fixed bolts. Check the belt for wear. If necessary, replace the belt. Disassemble the front drive pulley and check the six rollers for wear. If necessary, replace the rollers.
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Page 35: Front Wheel, Brake And Steering System
8. FRONT WHEEL, BRAKE AND STEERING SYSTEM 8.1 TROUBLESHOOTING STEERING IS HEAVY DAMAGED STEERING BEARINGS DAMAGED STEERING BEARING RACES STEERING SHAFT HOLDER TOO TIGHT DAMAGED TIRE LOW INSUFFICIENT TIRE PRESSURE HANDLEBAR POSITIONED IMPROPERLY BENT FRONT FORK BENT FRONT AXLE DAMAGED FRONT WHEEL DAMAGED FRONT FORK SHOCK ABSORBERS UNBALANCED FRONT SHOCK ABSORBERS FRONT WHEEL IS WOBBLING... -
Page 36: Speedometer Cable Removal
8.3 SPEEDOMETER CABLE REMOVAL Remove the handlebar cover. Unscrew speedometer cable nut. Unscrew the speedometer cable fixing bolt at the front wheel. Pull out the worn speedometer cable. Install a new speedometer cable. NOTE: Before assembling the new speedometer cable, apply grease on the inner line of this cable. -
Page 37: Front Wheel
Remove the fixing nut and handlebar bolt on the front fork. Remove the handlebar. Torque when installing a handlebar: M6 nut: 7 - 9 lbf-ft M10 nut: 22 - 29 lbf-ft 8.5 FRONT WHEEL Remove the locking nut at the right side of the front wheel. -
Page 38: Front Brake
FRONT WHEEL AXLE BEARING INSPECTION Spin the wheel. Replace with a new bearing if needed. INSPECT THE FRONT RIM Check the rim swing limit. Limit: Replace if the swing is over 2.0mm 8.6 FRONT BRAKE REPLACING THE FRONT DISK BRAKE CALIPER ASSEMBLY Unscrew the two front disk brake caliper fixing bolts. - Page 39 Bleeder Valve Engage the front brake a few times by pulling the brake lever gently. Then, hold the front brake level all the way in; while holding in, release the bleeder valve on the front caliper to force the air out. Then, lock the valve.
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Page 40: Front Fork
8.7 FRONT FORK FRONT FORK INSPECTION Replace if there is any bending or distortion. FRONT SHOCK ABSORBER INSPECTION Look for leaks, torn seals, scratched shafts, and loose connections. Beamer Rev-2.0.2 Page 40 of 55 11/21/2005... -
Page 41: Rear Wheeland Brake System
9. REAR WHEELAND BRAKE SYSTEM 9.1 TROUBLESHOOTING BAD BRAKE PERFORMANCE WORN BRAKE SHOES BRAKE ADJUSTED IMPROPERLY BRAKE LININGS OILY GREASY OR DIRTY WORN BRAKE DRUM BRAKE ARM SETTING IMPROPERLY ENGAGED VIBRATION OR WOBBLE BENT RIM DAMAGED TIRED WHEEL AXLE IMPROPERLY TIGHTENED 9.2 MAINTENANCE DATA Brake drum inner diameter Standard: 110 mm... -
Page 42: Rear Wheel Inspection
9.4 REAR WHEEL INSPECTION Measure the rear wheel rim for distortion. Replace rim if the distortion is over 2.0 mm in difference. 9.5 REAR BRAKE REAR BRAKE DRUM INSPECTION Measure the rear brake drum inner diameter. Replace if the diameter is over 110.5mm. BRAKE LINING INSPECTION Measure the brake lining thickness. -
Page 43: Rear Shock Absorber Parts Drawing
9.6 REAR SHOCK ABSORBER PARTS DRAWING Beamer Rev-2.0.2 Page 43 of 55 11/21/2005... -
Page 44: Plastic Body Parts
10. PLASTIC BODY PARTS 10.1 FRONT FENDER Unscrew the five fixing screws between the front fender and leg shield. Remove the front fender. 10.2 BODY COVER Unscrew the four fixing bolts on the rear handle bar. Remove the rear handle bar. Unscrew the two fixing screws of each side of the protective covers. - Page 45 Open the seat. Unscrew four fixing bolts of the helmet box. Remove the helmet box. Unscrew the fixing screws between the body cover and middle cover. Remove the middle cover. Unscrew the two fixing screws of the body cover under the middle cover.
- Page 46 Unscrew two taper screws of the body cover near the footrest board. Remove the body cover. Unscrew three fixing screws of the battery cover at footrest board. Remove the battery cover. Disconnect the negative terminal of the battery, then disconnect the positive terminal. Remove battery. Unscrew the fixing screws of the lower cover.
- Page 47 Unscrew four fixing screws near the rear lamp cover. Remove rear lamp cover. Unscrew two fixing bolts of the footrest board. Remove footrest board. Torque value: M6: 5 – 8 lbf-ft M5: 3 – 4 lbf-ft Beamer Rev-2.0.2 Page 47 of 55 11/21/2005...
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Page 48: Electrical System
11. ELECTRICAL SYSTEM 11.1 TROUBLESHOOTING ENGINE STARTS BUT STOPS • IMPROPER IGNITION TIMING • FAULTY SPARK PLUG NO SPARK AT PLUG • ENGINE STOP SWITCH AT “ OFF “ • FAULTY IGNITION COIL • FAULTY GENERATOR • FAULTY CDI UNIT •... -
Page 49: Ignition Coil
11.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Testing the ignition coil: • Remove the coil wire cap from the spark plug • Unplug the ignition coil primary leads • Test the primary coil as shown in the picture. -
Page 50: Battery Inspection And Maintenance
11.4 BATTERY INSPECTION AND MAINTENANCE CAUTION: The battery emits flammable and explosive fumes during normal operation. Keep away from sparks, open flame, and other possible sources of ignition. Always provide adequate ventilation during charging and maintenance of the battery. The battery contains sulfuric acid (an electrolyte). Contact with skin or eyes may cause severe burns or blindness. - Page 51 • If after charging the battery is still indication a low voltage or the battery will not hold the charge for more than a day or two the battery should be replaced. ETON recommends replacing the battery every two years for optimal performance. Beamer Rev-2.0.2 Page 51 of 55 11/21/2005...
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Page 52: Starter Motor
Battery Storage: If the vehicle will not be in use for an extended period of time, the battery should be removed and stored in a location that will ensure that battery will not freeze. DO NOT store the battery on a concrete surface as it can draw the charge from the battery and damage the battery plates. -
Page 53: Wiring Diagrams
11.6 WIRING DIAGRAMS Beamer PN2 Beamer Rev-2.0.2 Page 53 of 55 11/21/2005... - Page 54 Beamer II PN2B & Beamer Matrix PN2C Beamer Rev-2.0.2 Page 54 of 55 11/21/2005...
- Page 55 ETON America, LLC Service Bulletin Bulletin No: 0007 Beamer Brake Lights Stay on Date: 08/22/2000 BEAMER Units Affected : Beamer Scooters Reason for bulletin: Brake lights stay on after brake released. Cause: Light on will also draw on battery. Repair: Lube rear brake cam-it will bind in housing and cause brake lights to stay on.
- Page 56 REPAIR: CLEAN AFTER EVERY 3-5 RIDES, MORE FREQUENTLY IN DUSTY CONDI- TIONS. USE A GOOD QUALITY FOAM FILTER SPRAY.(BEL-RAY FOAM FILTER SPRAY) 4. BATTERIES----THE BATTERIES FOR ALL ETON VEHICLES ARE MAINTANCE-FREE . PROPER SERVICE PROCEDURES ARE AS FOLLOWS: 1. FILL BATTERY WITH BATTERY PACK SUPPLIED.
- Page 57 ETON America, LLC Service Bulletin Oil Pump Flow Adjustment Bulletin No: 0033 Date: 04/01/2004 all Oil Injected two cycle Engines To adjust the oil pump flow on a two cycle oil injected engine you must adjust the oil pump cable length. . The...
- Page 58 ETON America, LLC Service Bulletin C.D.I. Module Specifications Bulletin No.: SB-0040 Beamer II (PN2B) & Beamer Matrix (PN2C) Date: 05/01/2006 PN2B & PN2C -- C0410-B00-9001 Electric resistance(Ω) specification Pcin 10-12K 60-80K ∞ 7-8K 28-32K ∞ 28-32K 10-12K ∞ Pcin 11-14K...
- Page 59 ETON America, LLC Service Bulletin Beamer Luggage box installation Bulletin No.: SB-0046 Date: 07/26/06 1st check the contents of package FIG #1 1-Luggage box 1-Set of keys 1-Mounting plate 1-Luggage box pad 4-Mounting brackets 4-Bolts 4-Washers 4-Nuts FIG #3 FIG #2...
- Page 60 ETON America, LLC Service Bulletin Beamer Luggage box installation Bulletin No.: SB-0046 Date: 07/26/06 FIG #5 Once the luggage box is installed push the rear brake light LED wires through the hole in the box as shown in Fig #5 and install the luggage box pad.
- Page 61 ETON America, LLC Service Bulletin Beamer III & Matrix II Bulletin No: 0049 Date: 02/15/2007 Speed Limiter CDI Version 3.5.0.0 The Beamer III and Matrix II CDI Version 3.5.0.0 has two speed limiter wires located on the back side. The following chart denotes the speed control of these wires: Beamer CDI Version 3.5.0.0...
- Page 62 ETON America, LLC Service Bulletin Bulletin No: 0050 Beamer rear wheel inspection and removal. Date: 03/01/2007 Put the bike on the center stand and let the exhaust cool down before installation . Then remove the (2) 10mm bolts from the exhaust pipe flange on the bottom of the cylinder. The remove the (2) 12mm bolts from the exhaust RH side.
- Page 63 ETON America, LLC Service Bulletin Bulletin No: 0051 E-TON ATV, Scooter and Utility Kart Date: 03/01/2007 Headlight Wattages Head Light Wattages Model Factory Maximum Viper 70‐4 10w Viper 90‐4 10w Viper 150 20w Yukon 150 20w Vector 250 35w Beamer II 18w Beamer III 18w Beamer Matrix 18w Beamer R2 18w ...
- Page 64 ETON America, LLC Service Bulletin Bulletin No: 0052 E-TON 50 & 90cc 2 cycle engine Date: 06/12/2007 Oil pump testing The following steps are used to determine if the 2 cycle oil injector pump is functioning properly on E-TON 50cc and 90cc 2 cycle engines.
- Page 65 Beamer Rev-2.0.2 Page 55 of 55 11/21/2005...