Eton America Matrix R4-150 Service Manual
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Eton America Matrix R4-150 Service Manual

E-ton matrix r4-150 (pn2i) scooter service manual
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ETON America
MATRIX R4-150
Service Manual
Covers:
MATRIX R4-150 (PN2I) SCOOTER

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  • Page 1 ETON America MATRIX R4-150 Service Manual Covers: MATRIX R4-150 (PN2I) SCOOTER...

  • Page 2: Table Of Contents

    CONTENTS 1. INFORMATION ......................4 1.1 SAFETY ........................4 1.2 NOTES .......................... 4 1.3 SERIAL NUMBER ......................5 1.4 TORQUE VALUES ....................... 6 2. MAINTENANCE ......................8 2.1 MAINTENANCE DATA SPECIFICATIONS ..............8 2.2 MAINTENANCE SCHEDULE ..................8 2.3 FUEL TUBE ........................9 2.4 THROTTLE OPERATION ....................
  • Page 3 9.6 REAR SHOCK ABSORBER DRAWING ..............64 10. PLASTIC PARTS ..................... 65 10.1 FRONT FENDER ...................... 65 10.2 BODY COVER ......................65 10.3 CANISTER COMP REMOVAL AND INSTALLATION ..........69 11. ELECTRICAL SYSTEM ..................70 11.1 TROUBLESHOOTING ..................... 70 11.2 IGNITION COIL ......................71 11.3 BATTERY INSPECTION ...................

  • Page 4: Information

    All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing. E-TON POWER TECH CO., LTD. reserves the right to make changes at any time without notice and without incurring any obligation whatever.

  • Page 5: Serial Number

    1.3 SERIAL NUMBER The frame serial number is stamped on the front of the frame, just at the front of footrest plate. The engine serial number is stamped on the left side of the engine crankcase. Frame serial number Engine serial number...

  • Page 6: Torque Values

    1.4 TORQUE VALUES FRAME Tightening torque Thread Part to tightened Remarks size kg-m ft.lb Handlebar upper holder bolt 30-40 3.0-4.0 22.1-29.5 Front fork nut upper 55-65 5.5-6.5 40.6-47.9 below 10.3 Front axle nut 30-40 3.0-4.0 22.1-29.5 Rear axle nut 110-130 11.0-13.0 81.1-95.9 Engine hanger bolt...
  • Page 7 ENGINE Part to tightened Tightening torque Thread Remarks size kg-m ft.lb Spark plug 10-12 1.0-1.2 7.4-8.9 Cylinder head bolts 10-14 1.0-1.4 7.4-10.3 Tappet adjusting nut 7-11 0.7-1.1 5.2-8.1 Oil drain bolt 20-30 2.0-3.0 14.8-22.1 Clutch outer nut 40.6 Loctite 638 Drive face nut 40.6 Catalyst 7649...

  • Page 8: Maintenance Data Specifications

    2. MAINTENANCE 2.1 MAINTENANCE DATA SPECIFICATIONS SPARK PLUG GAP 0.6-0.7 mm RECOMMENDED SPARK PLUGS NGK CR7HSA THROTTLE LEVER FREE PLAY 5-10 mm IDLE SPEED 1700-1 900 rpm BRAKE LEVER FREE PLAY 15-25 mm ENGINE OIL SAE 15W-40 GEAR LUBRICATION OIL SAE 80W-90 gear Oil 2.2 MAINTENANCE SCHEDULE The maintenance internals in the follow table is based upon average riding, conditions.

  • Page 9: Maintenance

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

  • Page 10: Fuel Tube

    2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage, or leaking, and replace if necessary. 2.4 THROTTLE OPERATION Inspect the hand grip for smooth full opening and automatic full closing in all steering positions. Inspect for deterioration, damage, or kinking in the throttle cable, and replace it if necessary.

  • Page 11: Air Cleaner

    2.6 AIR CLEANER Unscrew the air cleaner cover screws. Pull out the air filter from the air cleaner case. Wash the component in non-flammable solvent and squeeze out the solvent thoroughly. Let it dry completely. Soak the filter in gear oil and then squeeze out the excess oil.

  • Page 12: Wheels And Tires

    Inspect the rear and brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard free play in those two-brake levels are 15-25 mm.

  • Page 13: Engine Stop Switch

    2.12 ENGINE STOP SWITCH The engine stop switch is located on left handle bar. When the engine must be stopped quickly, push the switch with your left hand thumb and the engine will stop running immediately. 2.13 UPPER – LOWER BEAM CONTROLLER This controller is located beside right handle bar.

  • Page 14: Engine Removal And Installation

    3. ENGINE REMOVAL AND INSTALLATION 3.1 ENGINE REMOVAL Remove the seat, helmet box, and body cover. Disconnect the oil tube, fuel tube, and vacuum tube. Disconnect the AC generator and starter motor.
  • Page 15 Disconnect the carburetor and throttle cable wires. Remove the spark plug cap. Remove the muffler by removing the retaining bolts.
  • Page 16 Remove the air cleaner by removing the retaining bolts as shown. Remove the bolt at the bottom of the rear shock absorber. Remove the rear disc brake caliper bolts. Remove the rear brake tube bolt.

  • Page 17: Engine Installation

    Remove engine hanger nut. Remove the engine from the frame. 3.2 ENGINE INSTALLATION Install engine in reverse order of disassembly. Torque value: M8 nut: 20-30 N-m M10 nut: 30-40 N-m M12 nut: 50-60 N-m After the engine is installed, check these parts: Wires and connections Carburetor and throttle cable Rear brake cable...

  • Page 18: Cylinder Head And Valves

    4. CYLINDER HEAD AND VALVES 4.1 SERVICE INFORMATION GENERAL This section describes maintenance for the cylinder head, valves, camshaft, and related parts. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case.

  • Page 19: Trouble Shooting

    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. Valve  Incorrect valve adjustment  Worn or damaged valve seats ...
  • Page 20 Remove the air cleaner and carburetor. Remove the inlet pipe assembly. Remove the shroud compositions. Loosen the cam chain adjuster screw. Remove the screw and O-ring and tighten the cam chain adjusting bolt in the clockwise direction. Remove the nuts and washers. Remove the camshaft holder and dowel pins.
  • Page 21 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 and replace them if necessary. BEARINGS Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms.

  • Page 22: Cylinder Head Removal

    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. Remove the cylinder head gasket and dowel pins. Remove the cam chain guide.

  • Page 23: Cylinder Head Disassembly

    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 waring with a straight edge and feeler gauge.
  • Page 24 Inspect each valve for turning, burning, scratches or abnormal stem wear. Check the valve movement in the guide. Measure and record each valve stem O.D. 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 25 INSTALLATION Install the new gasket and dowel pins. Install the cam chain guide. Install the cylinder head. CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder.
  • Page 26 Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter- clockwise. Position the camshaft gear with cam chain so that its“I” mark aligns with the cylinder head surface and the circle hole forwards front.
  • Page 27 Loosen the cam chain-adjusting bolt with counter clockwise direction and install the o-ring and screw. Install the cylinder head cover.

  • Page 28: Lubrication

    5. LUBRICATION 5.1 SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump. Fill the oil pump with clean oil when reassembling the pump. SPECIFICATION ENGINE OIL CAPACITY 1.0 liter at disassembly (0.9 liter at draining) API service classification: SE or SF ENGINE OIL RECOMMENDATION...

  • Page 29: Troubleshooting

    5.2 TROUBLESHOOTING Oil level too low  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 30: Oil Pump Removal

    Remove the oil filter cap, spring and oil filter screen. OIL FILTER SCREEN OIL FILTER CAP Check the O-ring for damage or fatigue. Install a new oil filter screen and spring then install the cap. SPRING O-RING Install the oil drain bolt with sealing washer. TORQUE: 20-30 N-m Fill the crankcase with recommended oil.
  • Page 31 Remove the cooling fan assembly. Remove the AC generator assembly. Remove the right crankcase cover. Remove the starting clutch outer and gear assy.
  • Page 32 Remove the flange bolts and oil separator. Remove the oil pump chain and oil pump driven sprocket. Remove the oil pump assy. Disassemble the oil pump.
  • Page 33 INSPECTION Measure the oil pump rotor-to-body clearance. SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump rotor tip clearance. SERVICE LIMIT: 0.12 mm. Remove the oil pump shaft and measure the pump end clearance. SERVICE LIMIT: 0.2 mm. OIL PUMP ASSEMBLY / INSTALLATION Install the outer rotor, inner rotor and oil pump shaft onto the body.
  • Page 34 Install the oil pump assembly. Install the oil pump driven sprocket and oil pump chain. OIL PUMP DRIVEN SPROCKET PS: The tighten torque of driven sprocket nut is 8-12 N-m Install the oil separator. OIL SEPARATOR Install the starting clutch outer and gear assembly.
  • Page 35 Install the new gasket, dowel pins, and right crankcase cover. Install the AC generator assembly and cooling fan composition.

  • Page 36: Cylinder / Piston

    6. CYLINDER / PISTON 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 37: Cylinder Removal

    6.3 CYLINDER REMOVAL Remove the cylinder head. CYLINDER HEA 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 38: Piston Removal

    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 a...
  • Page 39 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 40 Inspect the piston for wear or damage. 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.

  • Page 41: Piston Installtion Piston Ring Installation

    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 42: Cylinder Installation

    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 43 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.

  • Page 44: Transmission / Kick Starter

    7. TRANSMISSION / KICK STARTER 7.1 SERVICE INFORMATION If the drain tube assembly fills with water, the tube should be drained. SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Driven belt width 19.8 - 20.2 19.0 Weight roller O.D. 17.9 - 18.1 17.40 Movable drive face I.D.
  • Page 45 7.3 C.V.T DISASSEMBLY L CRANK CASE COVER REMOVAL Loosen the band screw and remove the C.V.T inlet duct. Disassemble the ground wire as shown. Remove the bolts and L cranks case cover.
  • Page 46 Remove the gasket and dowel pins. Clean off any gasket material from L crank case surface. CVT REMOVAL Loosen the flange nut and remove kick-starter ratchet. Remove the drive face. Loosen the flange nut. Remove the drive pulley assy. and driven belt. Remove the drive face boss and movable driven face assembly.
  • Page 47 Remove the ramp plate and weight roller set. Loosen the special nut and remove the driven plate composition and driven face spring. INSPECTION Inspect the driven belt for wear, tears or damage. Measure the width of driven belt. SERVICE LIMIT: 19.0 mm DRIVEN BELT Inspect the weight roller for wear or damage and replace them if necessary.
  • Page 48 Measure the I.D. of movable driven 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. Measure the O.D. of drive face boss. SERVICE LIMIT: 23.92 mm Inspect the clutch outer for wear or damage.

  • Page 49: Kick Starter Disassembly

    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 Remove the kick-starter. L CRANK CASE COVER Remove the ex.
  • Page 50 Rotate the kick-starter spindle composition to remove the kick driven gear and spring. Remove the kick-starter spindle composition and return spring. Remove the kick spindle bush. INSPECTION Inspect the kick starter spindle composition for wear or damage. Inspect the kick return spring for fatigue or damage. Inspect the kick spindle bush for wear or damage.

  • Page 51: Kick Starter Assembly

    Inspect the machining surface for wear or damage. MACHINING SURFACE 7.5 KICK STARTER ASSEMBLY Install the kick spindle bush, return spring and spindle assembly. Install the kick driven gear and spring. Install the kick-starter. 7.6 C.V.T ASSEMBLY Assemble the driven face assembly, spring, and driven plate composition.
  • Page 52 Assemble the movable driven face composition, weight roller set, and drive face. Install the movable drive face assembly 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 assembly. DRIVEN BELT DRIVEN PULLEY ASSY.
  • Page 53 Install the dowel pins and gasket. Install the L crank case cover. Install the gas waste recovery and C.V.T ducts.

  • Page 54: Electric Self-Starter Mechanism

    7.7 ELECTRIC SELF-STARTER MECHANISM Starter Motor is installed on the upper side of engine. The starter motor can engage only when the left hand brake is applied. REDUCTION GEAR STARTER MOTOR 7.8 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-starter arm is kicked, the starting gear shaft will drive the kick-starter to rotate the crankshaft to start the engine.

  • Page 55: Removal Of Cvt System

    7.9 REMOVAL OF CVT 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. 7.10 DISASSEMBLY AND INSPECTION OF THE CVT SYSTEM Remove the screws on the clutch cover at the left side of engine.

  • Page 56: Front Wheel, Brakes, And Steering System

    8. FRONT WHEEL, BRAKES, AND STEERING SYSTEM 8.1 TROUBLESHOOTING  STEERING IS HEAVY DAMAGED STEERING BEARINGS  DAMAGED STEERING BEARING RACES  STEERING SHAFT HOLDER TOO TIGHT  DAMAGED TIRE  INSUFFICIENT TIRE PRESSURE  HANDLEBAR POSITIONED IMPROPERLY BENT FRONT FORK ...

  • Page 57: Replace Speedometer Cable

    8.3 REPLACE SPEEDOMETER CABLE Disassemble the handlebar cover. Unscrew the speedometer cable nut. Unscrew the speedometer cable fixing bolt on the front wheel. Remove the worn speedometer cable. Install the replacement speedometer cable in reverse order of removal. NOTE: Before installing the new speedometer cable, apply grease to the inner line of this cable.
  • Page 58 Loosen the handlebar fixing nut and bolt on the front fork. Remove the handlebar. Install a new handlebar in reverse order of removal. Locking nut torque: M10 nut: 30-40 N-m 8.5 FRONT WHEEL Release the anti-lock nut at the right side of front wheel. Remove the front wheel axle.
  • Page 59 FRONT WHEEL AXLE BEARING INSPECTION Spin the wheel freely off the ground. If there is any noise or shaking, replace the bearing. INSPECT THE FRONT RIM Check the rim for warping or bending. Limit: Replace therim if warping is over 2.0 mm 8.6 FRONT BRAKE REPLACING THE FRONT DISK BRAKE CALIPER ASSEMBLY...
  • Page 60 DISASSEMBLING FRONT BRAKE DISK Disassemble the front wheel. Unscrew the three brake disk fixing bolts. Release the brake disk. Torque of these M8 nuts: 30-40 N-m INSPECTING THE BRAKE DISK Measure the thickness of the brake disk. Standard thickness: 3.5 mm Minimum limit: 3.1 mm INSPECT BRAKE SHOES (LINING) Measure the thickness of the brake shoe lining.

  • Page 61: Rear Wheel And Brake System

    9. REAR WHEEL AND 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 ...

  • Page 62: Rear Wheel Removal

    9.3 REAR WHEEL REMOVAL Remove the bolt at the bottom of the rear shock absorber. Unscrew the rear bracket bolt. Unscrew the rear wheel axle nut. Disassemble the rear wheel. Torque value: M16 nut: 60-80 N-m...

  • Page 63: Inspecting The Rear Wheel

    9.4 INSPECTING THE REAR WHEEL Measure the warping or distortion of the rear wheel rim. Replace with a new rim if the distortion is over 2.0 mm. 9.5 REAR BRAKE REPLACE THE REAR DISC BRAKE CALIPER ASSEMBLY Unscrew the two fixing bolts on rear disc brake caliper assembly at the rear bracket.
  • Page 64 Remove the rear disc brake caliper. When reinstalling the caliper: Torque value: M8 nut 24-30 N-m BRAKE DISC INSPECTION Measure the thickness of the brake disc. Standard thickness: 3.5 mm Using limit: 3.1 mm BRAKE SHOES (LINING) INSPECTION Measure the thickness of brake lining. Standard thickness: 4.0 mm Using limit: 3.0 mm NOTE: Do not allow any grease to touch the surface...

  • Page 65: Rear Shock Absorber Drawing

    9.6 REAR SHOCK ABSORBER DRAWING...

  • Page 66: Plastic Parts

    10. PLASTIC PARTS 10.1 FRONT FENDER Unscrew the 7 fixing screws between the front fender and leg shield. Remove the front fender. 10.2 BODY COVER Unscrew the 4 fixing bolts on the rear carrier. Remove the rear carrier.
  • Page 67 Open the seat. Unscrew the 4 fixing bolts on the helmet box. Remove the helmet box. Unscrew the upper body cover fixing bolts. Unscrew the fixing bolts between the body cover and middle cover. Remove the middle cover. Unscrew the body cover fixing bolts under the middle cover.
  • Page 68 Open and remove the fuel tank cap. Unscrew the 2 rear cover fixing bolts near the fuel tank. Unscrew the 2 tail light fixing bolts near the fuel tank. Disconnect the negative pole of battery, then disconnect the positive pole. Remove the battery. Unscrew the two side protection cover fixing bolts.
  • Page 69 Remove the right and left side protecting covers. Unscrew the 5 leg shield fixing bolts. Unscrew the 6 fixing bolts on the footrest board. Remove the leg shield and footrest board. Reinstalling torque values: M6: 7-11 N-m M5: 3.5-5 N-m...

  • Page 70: Canister Comp Removal And Installation

    10.3 CANISTER COMP REMOVAL AND INSTALLATION Suggested: Change the canister composition every 2 years or 9000 miles (15000km). 3. CARBURETOR ASSY. 5. FUEL TANK ASSY. 4. FUEL PETCOCK 1. AIR CLEANER ASSY. 6. VAPOR CONTROL 2. CANISTER COMP...

  • Page 71: 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 72: Ignition Coil

    11.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0.1-0.30(20 11.3 BATTERY INSPECTION The battery is located under the seat. Measure the battery voltage using a voltmeter. VOLTAGE: Fully charged: 13.1 V Undercharged: Below 12.0 V...

  • Page 73: Charging

    11.4 CHARGING Connect the charger’s positive cable to the battery position terminal. Connect the charger’s negative cable to the battery negative terminal. Using a trickle charger, apply 0.9A-charging current for about 5 hours. (Normal charging - Recommended) Or using 4A-charging current, charge for about 1 hour. (Quick charging) Keep flames and sparks away from a battery being charged.

  • Page 74: Wiring Diagram

    11.6 WIRING DIAGRAM MATRIX R4-150...

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