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Eton America YXL-150 Service Manual

Eton america 150cc atv service manual
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ETON America
150cc Service Manual
Covers:
YXL-150, CXL-150, RXL-150R
200028

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Summary of Contents for Eton America YXL-150

  • Page 1 ETON America 150cc Service Manual Covers: YXL-150, CXL-150, RXL-150R 200028...

  • Page 3: Table Of Contents

    Table of Contents Information Maintenance Engine Removal And Installation Engine Lubrication And Cooling System Cylinder Head & Valves Cylinder & Piston Transmission System Front Wheel, Suspension And Steering Rear Wheel System Fenders And Exhaust Pipe Electrical System Trouble Shooting...

  • 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. ETON America, LLC reserves the right to make changes at any time without notice and without incurring any obligation whatever.
  • Page 5 (YXL only) Hydraulic Disc (CXL & RXL-150R only) TIRES 21” x 7” - 8” Front 22” x 10” Rear Red/Black & Silver/Black COLOR (YXL-150 only) Red, Blue, Green, Silver (CXL-150 only) Black/Yellow (RXL-150R only) * Specifications subject to change without notice.
  • Page 6 Information 1.4 SERIAL NUMBERS The frame serial number is stamped on the front frame just above the oil cooler. The engine number is stamped on the left side of the crankcase. Frame Number Engine Number...

  • Page 7: Torque Values

    Information 1.5 TORQUE VALUES STANDARD 5 mm bolt and nut 5 N-m (3.7 ft-lbs) 6 mm bolt and nut 10 N-m ( 7.4 ft-lbs) 8 mm bolt and nut 22 N-m ( 16 ft-lbs) 10 mm bolt and nut 35 N-m ( 26 ft-lbs) 12 mm bolt and nut 55 N-m ( 41 ft-lbs) ENGINE...

  • Page 8: Maintenance

    Maintenance 2. Maintenance Maintenance data Maintenance schedule Fuel tube Throttle operation Throttle cable adjustment Air cleaner Spark plug Idle speed Drive chain 2.10 Brake system 2.11 Wheels and tires 2.12 Steering system 2.13 Toe-in 2.14 Gear oil 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG: 0.6-0.7 mm / 0.024 –...

  • Page 9: Maintenance Schedule

    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 Maintenance 2.2 MAINTENANCE SCHEDULE The maintenance intervals in the follow table are based upon average riding conditions. Riding in unusually dusty areas requires more frequent servicing. E-TON recommends that all maintenance and inspections be performed ONLY by a qualified and fully trained technician. (First Week) _________ (30 Operating days) _____ (Once each Year) FUEL LINE...
  • Page 11 Maintenance 2.4 THROTTLE OPERATION Inspect for smooth lever operation, full opening, and automatic full closing in all steering positions. Inspect for deterioration, damage, cuts and nicks, or kink in the throttle cable, replace it if necessary. Check the throttle lever; free play should be no more than 5-10 mm / 0.2-0.4”...
  • Page 12 Maintenance 2.6 AIR CLEANER MAINTENANCE (1) Loosen the screws and remove the air cleaner from carburetor. (2) Disassemble the air cleaner cover and body. (3) Clean the air cleaner element and screen. (See Figure below) (4) Wash the element in non-flammable or high flash point solvent squeeze out the solvent thor- oughly and allow it to dry.

  • Page 13: Spark Plug

    Maintenance 2.7 SPARK PLUG The spark plug is located at the front of the engine. (1) Disconnect the spark plug cap and remove the spark plug. (2) Visually inspect the spark plug electrodes for wear or cracks in insulator. Replace if needed.

  • Page 14: Drive Chain Adjustment

    Maintenance 2.9 DRIVE CHAIN ADJUSTMENT Stop the ATV and shift transmission into neutral. Inspect the chain slack midway between the sprockets. The standard is 10-25mm (5/8 – 1”). If needed, remove the chain protective cover and adjust the chain slack. Loosen the axle holder lock nuts then adjust the drive chain slack by turning the adjusting nut.
  • Page 15 Maintenance 2.10 BRAKE SYSTEM ADJUSTMENT Inspect the front brake lever and cable for excessive play or damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the lever. The standard is 15-25 mm / 0.59-0.98”. Adjust the free play of the front brake lever by turning the adjuster on the brake lever assembly.

  • Page 16: Steering System

    Maintenance 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts or sharp objects. Check the tire pressure at cold tire conditions. The standard tire pressure is 2.2±0.3 psi (0.15 kgf/cm 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels turned straight ahead.
  • Page 17 Maintenance 2.13 TOE-IN Park the vehicle on level ground with the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully moving the vehicle backward, let the wheels turn 180°...
  • Page 18 2.14 GEAR OIL MAINTENANCE Maintenance Gear oil needs to be changed every year. There is a gear oil drain hole bolt at the rear of engine. Oil Fill Plug (STEP 1) Unscrew this drain hole bolt and let the dirty oil flow out;...

  • Page 19: Engine Removal And Installation

    ENGINE REMOVAL AND REPLACEMENT 3.1 ENGINE REMOVAL AND INSTALLATION ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM! 3.2 ENGINE REMOVAL Remove the seat, front and rear fender. (See Chapter 10 ) Remove the footrest.

  • Page 20: Service Information

    LUBRICATION 4. Lubrication 4.1 Service Information 4.2 Trouble Shooting 4.3 Engine Oil Level 4.4 Engine Oil & Filter Change 4.5 Oil Pump Removal / Installation 4.1 SERVICE INFORMATION GENERAL 1. This section describes cylinder head, valves, camshaft, and other parts maintenance. 2.

  • Page 21: Troubleshooting

    LUBRICATION 4.2 TROUBLE SHOOTING Engine top-end problems often 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.
  • Page 22 LUBRICATION 4.3 ENGINE OIL LEVEL (continued) Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge. 4.4 ENGINE OIL & FILTER CHANGE Remove the oil drain plug. LOWER LEVEL Drain the oil while the engine is warm to NOTE:...
  • Page 23 4.4 ENGINE OIL & FILTER CHANGE (continued) Install the oil drain bolt with sealing washer. TORQUE: 20-30 N-m (15-22 ft-lbs) Fill the crankcase with the SAE 10w40 oil. Oil drain plug OIL CAPACITY: 0.8 liter / 0.2 gal at draining. Install the oil drain plug.
  • Page 24 FLYWHEEL Remove the flywheel and the AC Generator assembly. Flywheel pullers are available from the ETON Parts Department. Remove the starting clutch outer and gear assembly. Remove the flange bolts and oil separator.
  • Page 25 Disassemble the oil pump. INSPECTION Measure the oil pump rotor-to-body clearance. SERVICE LIMIT: 0.12 mm / 0.005”...
  • Page 26 Install the oil pump shaft and measure the pump rotor tip clearance. SERVICE LIMIT: 0.12 mm / 0.005” OIL PUMP OUTER ROTOR Remove the oil pump shaft and measure the pump end clearance. SERVICE LIMIT: 0.2 mm / 0.008” OIL PUMP INNER ROTOR 4.5 OIL PUMP ASSEMBLY / INSTALLATION Install the outer rotor, inner rotor and oil pump shaft onto the body.
  • Page 27 LUBRICATION 4.5 OIL PUMP ASSEMBLY / INSTALLATION (continued) Install the oil pump driven sprocket and oil pump chain. Install the oil separator. Install the starting clutch outer and gear assembly. Install the new gasket, dowel pins, and right crankcase cover.
  • Page 28 LUBRICATION 4.5 OIL PUMP ASSEMBLY / INSTALLATION FLYWHEEL (continued) Install the AC Generator and then the outer flywheel. Install the cooling fan. Install fan housing cover.
  • Page 29 LUBRICATION 4.6 ENGINE OIL 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 0.8-1.0 liter / 0.2-0.3 gal API service classification: SF or SG Viscosity: SAE 20w-40 When the average temperature in your riding area is within the indicated range,...
  • Page 30 CYLINDER HEAD / VALVES 5. CYLINDER HEAD / VALVES 5.1 SERVICE INFORMATION 5.2 TROUBLESHOOTING 5.3 CAMSHAFT ASSEMBLY REMOVAL 5.4 CYLINDER HEAD REMOVAL 5.5 CYLINDER HEAD INSTALLATION 5.1 SERVICE INFORMATION GENERAL This section describes the maintenance of cylinder head, valves, camshaft, and the other parts. The engine must be removed from the frame to service the cylinder head.
  • Page 31 CYLINDER HEAD / VALVES 5.2 TROUBLE SHOOTING Engine top-end problems often 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.
  • Page 32 CYLINDER HEAD / VALVES 5.3 CAM SHAFT ASSEMBLY REMOVAL Remove the rubber gas waste recovery tube. Remove the cylinder head cover. Remove the air cleaner and carburetor. Remove the inlet pipe assembly. Remove the engine shroud. ENGINE SHROUD Loosen the cam chain adjuster screw.
  • Page 33 CYLINDER HEAD / VALVES 5.3 CAM SHAFT ASSEMBLY REMOVAL (continued) Remove the screw and O-ring and tighten the cam chain-adjusting bolt by turning in the clockwise direction. Remove the nuts and washers. Remove the camshaft holder and dowel pins. Loosen the camshaft gear from cam chain and remove the camshaft.
  • Page 34 CYLINDER HEAD / VALVES 5.3 CAM SHAFT ASSEMBLY REMOVAL (continued) Inspect the camshaft and bearings for wear or dam- age and replace them if necessary. Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms.
  • Page 35 CYLINDER HEAD / VALVES 5.4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head. Remove the cylinder head gasket and dowel pins. Remove the cam chain guide. CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers, and valve springs with a valve spring compressor.

  • Page 36: Cylinder Head Removal

    CYLINDER HEAD / VALVES 5.4 CYLINDER HEAD REMOVAL (continued) INSPECTION Clean off all carbon deposits from the com- bustion and check the spark plug hole and valve area for cracks. Measure the cylinder head diagonally for warping with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm / 0.002”...
  • Page 37 CYLINDER HEAD / VALVES Measure and record each valve stem O.D. SERVICE LIMITS: 4.90 mm / 0.19” Measure and record the valve guide I.D. SERVICE LIMITS: IN / EX 5.30 mm / 0.209” Calculate the stem-to-guide clearance. SERVICE LIMITS: IN 0.08 mm / 0.003” EX 0.10 mm / 0.004”...
  • Page 39 CYLINDER HEAD / VALVES Install the cam chain guide. Install the cylinder head. 5.6 CAMSHAFT ASSEMBLY INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder. Align the "T" mark (as shown in picture) on the flywheel with the index mark on the alternator cover by turning the flywheel counter-clockwise.
  • Page 40 CYLINDER HEAD / VALVES I MARK Position the camshaft gear with cam chain so that its "I" mark aligns with the cylinder head surface and the circle hole towards the front. Install the dowel pins and camshaft holder. Tighten the washers and nuts. TORQUE: 20 N-m (15 ft-lbs) Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge.
  • Page 41 CYLINDER HEAD / VALVES Install the cylinder head cover. 5-11...

  • Page 42: Cylinder And Piston

    CYLINDER & PISTON 6. CYLINDER AND PISTON 6.1 SERVICE INFORMATION 6.2 TROUBLESHOOTING 6.3 CYLINDER REMOVAL 6.4 PISTON REMOVAL 6.5 CYLINDER INSTALLATION 6.1 SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil hole in the cylinder head and engine case.
  • Page 43 CYLINDER & PISTON 6.2 TROUBLESHOOTING Low or unstable compression -Worn cylinder or piston rings. Overheating -Excessive carbon build-up on piston or combustion chamber wall. Knocking or abnormal noise -Worn piston and cylinder. -Excessive carbon build-up. Excessive smoke -Worn cylinder, piston, or piston rings. -Improper installation of piston rings.

  • Page 44: Cylinder Removal

    6.3 CYLINDER REMOVAL Remove the cylinder head. CYLINDER HEAD CYLINDER Remove the cylinder. Remove the cylinder gasket and dowel pins. BASE GASKET DOWEL PINS CRANKCASE SURFACE Clean off any gasket materials from the cylinder surface. NOTE: Be careful not to damage the gasket surface...

  • Page 45: 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. C-CLIPS 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 point...
  • Page 46 Measure and record the cylinder I.D. at three levels in both the X and Y axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 57.50 mm / 2.264” Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.10 mm / 0.004”...
  • Page 47 CYLINDER & PISTON 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.
  • Page 48 CYLINDER & PISTON Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.02 mm / 0.0008” Measure the connecting rod small end I.D. SERVICE LIMIT: 15.06 mm / 0.59” CONNECTING ROD 6.5 PISTON & PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston ring with the marks facing up.

  • Page 49: Cylinder Installation

    PISTON INSTALLATION Install the piston with its "IN" mark pointing up toward 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. PISTON PIN 6.6 CYLINDER INSTALLATION Clean any gasket material from the crankcase surface.
  • Page 50 CYLINDER & PISTON 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. CYLINDER Install the cylinder head.

  • Page 51: Specifications

    TRANSMISSION & KICK STARTER 7. TRANSMISSION & KICK STARTER 7.1 SERVICE INFORMATION 7.2 TROUBLE SHOOTING 7.3 CVT DISASSEMBLY 7.4 KICK STARTER DISASSEMBLY 7.5 KICK STARTER ASSEMBLY 7.6 CVT ASSEMBLY 7.7 TRANSMISSION SYSTEM 7.1 SERVICE INFORMATION If the drain tube assembly fills with water, the tube should be drained. If replacing transmission parts for YUKON/YUKON II, refer to the bulletin at the end of this manual first! Click here to see the service bulletin.
  • Page 52 7.2 TROUBLE SHOOTING Engine starts but won’t run -Worn driven belt. -Worn clutch lining. -Damaged driven face spring. Low engine power -Worn driven belt. -Worn weight roller. -Dirty drive face.
  • Page 53 7.3 CVT DISASSEMBLY LH CRANKCASE COVER REMOVAL Loosen the band screw and remove the CVT inlet duct. Loosen the band screw and remove the CVT outlet duct. Remove the gas waste recovery unit. Remove the 8 bolts and the LH crankcase cover.
  • Page 54 CVT REMOVAL Remove the flange nut and remove the kick-starter ratchet. Remove the drive face and primary clutch sheave. Remove the flange nut. Remove the drive pulley assembly and driven belt. Remove the driven face boss and movable driven face assembly.
  • Page 55 Remove the ramp plate and weight roller set. Loosen the special nut and remove the driven plate assembly and driven face spring. INSPECTION DRIVEN PLATE ASSEMBLY Inspect the drive belt for wear, tearing, or other damage. Measure the width of drive belt. SERVICE LIMIT: 19.0 mm / 0.75”...
  • Page 56 Measure the I.D. of movable driven face. SERVICE LIMIT: 28.03mm / 1.10” Inspect the drive face collar for wear or damage. Measure the I.D. of drive face collar. SERVICE LIMIT: 24.098 mm / 0.95” Inspect the drive face boss for wear or damage. Measure the O.D.
  • Page 57 Measure the length of the driven face spring in its natural state. SERVICE LIMIT: 164.0 mm / 6.46” Inspect the driven face assembly and replace if necessary. 7.4 KICK STARTER DISASSEMBLY Remove the LH crankcase cover. Remove the kick starter. Remove the external circle-clip and washer from the kick starter spindle.
  • Page 58 Rotate the kick-starter spindle assembly to remove KICK DRIVEN GEAR the kick driven gear and spring. Remove the kick-starter spindle assembly and return spring. Remove the kick spindle bush. INSPECTION ASSEMBLY Inspect the kick-starter spindle assembly for wear or damage. Inspect the kick-starter return spring for wear or damage.
  • Page 59 Inspect the machining surface for wear or damage. 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 CVT ASSEMBLY Install the dowel pins and gasket.
  • Page 60 Assemble the driven face assembly, spring, and driven plate. Assemble the movable driven face, weight roller set, and drive face. Install the movable drive face assembly and boss. Install the drive face and kick starter ratchet. Install the driven belt and driven pulley assembly 7-10...
  • Page 61 Install the LH crankcase cover. Install the gas waste recovery system and CVT ducts. 7-11...
  • Page 62 7.7 TRANSMISSION SYSTEM To remove the transmission, we recommend the motor be removed. The transmission can be serviced with the motor still in the frame, but this is not recommended. DRAIN BOLT Before servicing transmission, drain the gear oil from the transmission case.
  • Page 63 7.7 TRANSMISSION SYSTEM (cont’d) Installation Install the shift guide and shift drum. Insert the shift fork into the slot on the gear shift shaft. Install the gear shift shaft with the forward gear facing the CVT system. Install the countershaft and the ball bearing and spring under the shift drum.

  • Page 64: Front Wheel, Suspension And Steering

    FRONT WHEEL, SUSPENSION AND STEERING 8. FRONT WHEEL, SUSPENSION, AND STEERING 8.1 Parts drawing 8.2 Troubleshooting 8.3 Handlebar 8.4 Throttle housing 8.5 Front wheel 8.6 Front brakes 8.7 Steering system 8.8 Front suspension 8.1 PARTS DRAWING FRONT WHEELS STEERING...
  • Page 65 FRONT WHEEL, SUSPENSION AND STEERING 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 BRAKE DRAG: -Incorrect brake adjustment -Sticking brake cable...
  • Page 66 FRONT WHEEL, SUSPENSION AND STEERING 8.3 HANDLEBAR SYSTEM Removal Remove the handlebar cover by unscrewing the two fix screws. Remove the throttle lever housing on the right handle bar. Remove brake lever bracket assembly. Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly.
  • Page 67 FRONT WHEEL, SUSPENSION AND STEERING 8.4 HANDLEBAR SYSTEM Installation Put the handlebar on the lower holders. Make sure the handlebar punch marks match with the top end of the handlebar lower holders. Install the handlebar upper holders with the L / R marks facing forward.
  • Page 68 FRONT WHEEL, SUSPENSION AND STEERING 8.5 THROTTLE HOUSING Disassembly Unscrew the screws on the throttle housing cover. Remove the throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing. 8.6 FRONT WHEEL Removal Raise the front wheels off the ground by placing a jack or other support under the frame.

  • Page 69: Front Brakes

    FRONT WHEEL, SUSPENSION AND STEERING 8.7 FRONT BRAKES (continued) Measure the brake drum inner diameter. Inspect the brake drum surface for scoring or uneven surfaces. Maximum limit: 86 mm / 3.39” Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly.
  • Page 70 FRONT WHEEL, SUSPENSION AND STEERING 8.7 FRONT BRAKES (continued) 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 engine oil and install the seal on the brake cam.
  • Page 71 FRONT WHEEL, SUSPENSION AND STEERING 8.8 STEERING SYSTEM Kingpin and Tie-rod Removal Remove the front wheels and brakes plates. Remove the two self-lock nuts from the tie-rod ball joints and remove the two tie-rods. Remove the cotter pin on the kingpin. Unscrew the bolt and remove the kingpin.
  • Page 72 FRONT WHEEL, SUSPENSION AND STEERING 8.8 STEERING SYSTEM (continued) Steering Shaft Removal Remove the handle bar cover and handle bar. (See section 8-3) Remove the front fender. (See section 10-1) Remove handlebar lower holder. Unscrew the steering shaft holder bolt. Remove the steering shaft holder.
  • Page 73 FRONT WHEEL, SUSPENSION AND STEERING 8.8 STEERING SYSTEM (continued) Installation of Steering Shaft Apply Blue Lock-Tite and install the steering shaft nut (under the steering shaft) and tighten it. Also, install a new cotter pin. Torque: 50 N-m / 37 ft-lbs Installation of Tie-rod Install the ball joint with the “L”...
  • Page 74 R E A R W H E E L S Y S T E M 9 . R E A R W H E E L S Y S T E M 9.1 Parts drawing 9.2 Troubleshooting 9.3 Rear Wheel and Rear Brake Removal 9.4 Drive Mechanism 9.5 Rear Brake and Wheel Installation 9.6 Shock Absorber...

  • Page 75: Trouble Shooting

    REAR WHEEL SYSTEM 9.2 Trouble Shooting Bad Brake Performance: -Brake shoes are worn -Bad brake adjustment -Brake lining 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...
  • Page 76 REAR WHEEL SYSTEM 9.3 REAR WHEEL & REAR BRAKE REMOVAL (continued) Remove the axle collar and brake drum. Check the brake lining thickness. Minimum limit: 2.0 mm / 0.08” CAUTION: Do not get grease or oil the brake lining surface and brake drum.
  • Page 77 REAR WHEEL SYSTEM 9.4 DRIVE MECHANISM (continued) Disassemble the chain retaining clips and master link. Remove the chain. For chain tensioner installation and disassembly, see section 9.6 at the end of this chapter. Disassemble the driven sprocket, axle, and sprocket collar.
  • Page 78 REAR WHEEL SYSTEM 9.4 DRIVE MECHANISM (continued) Installation Add grease to the dust seal lips and install dust seals. Assemble the rear axle and the driven sprocket. Assembly the drive chains on the driven sprocket. Assemble the master link and retaining clip. Note the retaining clip direction.
  • Page 79 REAR WHEEL SYSTEM 9.5 REAR DRUM BRAKE & WHEEL INSTALLATION (continued) Install the brake arm. Tighten the brake arm bolt and nut with 10 N-m (7.4 ft-lbs) torque. Install the adjusters. Make sure the rear brake lever and pedal have NOTE: the proper amount of free play.
  • Page 80 REAR WHEEL SYSTEM 9.6 CHAIN TENSIONER (IF EQUIPPED) To remove the chain tensioner, relax the drive chain. Remove the chain tensioner bolt and retaining spring. Installation is the reverse order of removal.
  • Page 81 9.7 HYDRAULIC DISC BRAKE SYSTEM (CXL-150 & RXL-150R ONLY) Raise the rear wheel off the ground by placing a block or stand under the frame. Remove the cotter pin, axle nut, and washer. Slide the wheel and hub off the axle. To remove the rear caliper, remove the two bolts that hold the brake caliper to the holder as shown in picture.
  • Page 82 9.7 HYDRAULIC DISC BRAKE SYSTEM (cont’d) Remove the rear wheel axle nuts and then remove the mounting seat of the disc. Unscrew the bolts and remove the brake rotor. Check the thickness of the disc in several places and replace if less than 3mm / 0.12”. Check the disc for cracks or large worn grooves.
  • Page 83 9.7 HYDRAULIC DISC BRAKE SYSTEM (cont’d) Rear Brake Installation NOTE: Take great care as to not contaminate the brake pads or rotor with oil, grease, or brake fluid during installation To reinstall the brakes, first replace the brake rotor on PISTONS the mounting seat.

  • Page 84: Fenders And Exhaust Pipe

    FENDERS AND EXHAUST PIPE 10. FENDERS AND EXHAUST PIPE 0.1 Parts Drawings 10.2 REAR FENDER REMOVAL Pull the seat release latch to remove the seat. The seat release latch is under the center of the rear grab bar. Fender Removal: Remove the rear rack.
  • Page 85 FENDERS AND EXHAUST PIPE 10.2 REAR FENDER REMOVAL (continued) Unscrew the six screws which connect with the footrest plate. Pull the rear fender backward so the rear fender can be removed. 10.3 FRONT-TRIM REMOVAL Unscrew the two screws just below the headlights of the central-front-trim.
  • Page 86 FENDERS AND EXHAUST PIPE 10.5 FRONT FENDER REMOVAL After removing the rear fender, central-front-trim, and central-rear-trim, remove the two front fender mount- ing bolts from the front frame. Remove the mounting bolts and nuts from the front fender and footrest plate. 10.6 EXHAUST PIPE REMOVAL Do not service the exhaust pipe while hot.
  • Page 87 FENDERS AND EXHAUST PIPE 10.6 EXHAUST PIPE REMOVAL (continued) Remove the exhaust pipe bolts mounted on the frame below the seat. Remove the exhaust pipe carefully. 10.7 EXHAUST PIPE INSTALLATION Installation is the reverse order of removal. Be sure to install a new exhaust gasket as well. Exhaust muffler bolts torque: 30 N-m (22 ft-lbs) NOTE: After installation, check the entire system to make sure that there are no exhaust leaks.

  • Page 88: Electrical System

    ELECTRICAL SYSTEMS 11. ELECTRICAL SYSTEM 11.1 Troubleshooting 11.2 Ignition coil 11.3 Ignition timing 11.4 Alternator exciter coil 11.5 Battery Caution 11.6 Battery voltage 11.7 Charging 11.8 Electric starter 11.9 Light bulbs replacement 11.10 Wiring diagrams 11.1 Troubleshooting Engine starts but stops: -Improper ignition timing -Faulty spark plug No spark at plug:...
  • Page 89 ELECTRICAL SYSTEMS 11.1 Troubleshooting (continued) Intermittent engine power: -Loose battery connection -Loose charging system connection Starter motor will not turn: -Dead battery -Faulty ignition switch -Loose or disconnected wire Starter motor and engine turn, but engine does not start: -Faulty ignition system -Faulty engine stop switch Headlight malfunction: -Switch not in ON position...
  • Page 90 ELECTRICAL SYSTEMS 11.5 BATTERY CAUTION The battery gives off explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging or using the battery in an open area. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
  • Page 91 ELECTRICAL SYSTEMS 11.8 ELECTRIC STARTER A weak battery may be unable to run the starter motor correctly. If the battery voltage is sufficient but the engine is not cranking, the starter motor may be damaged. Troubleshooting Starter Motor Turns Slowly: -Weak battery.

  • Page 92: Light Bulb Replacement

    ELECTRICAL SYSTEMS 11.9 LIGHT BULB REPLACEMENT (continued) Remove the bulb socket by turning it counterclockwise. Replace the bulb with a new one. Install the bulb socket by turning clockwise until secured. INDICATOR Remove the handle bar cover. Remove the indicator lamp unit by turning it counter clockwise.
  • Page 93 ELECTRICAL SYSTEMS 11.10 WIRING DIAGRAMS YXL Wiring Diagram 11-6...
  • Page 94 CXL Wiring Diagram 11-7...
  • Page 95 RXL-150R Wiring Diagram 11-8...
  • Page 96 12. TROUBLESHOOTING 12.1 – Flowchart – Engine Will Not Start 12.2 – Flowchart – Engine Dies After Shifting (150cc)
  • Page 97 12.1 Engine Will Not Start (Start motor turns) Legend: Flow Engine Does Not "Yes" Start "No" Turn on ignition Is Ignition Engine switch on? switch starts? Turn on engine Engine stop Engine switch on? stop switch starts? Fully apply brake Engine Is brake lever...
  • Page 98 12.1.2 Engine Will Not Start, continued Legend: Flow "Yes" Engine Does Not "No" Start Repair/replace Engine Tether switch tether switch starts? active? Engine Fill tank (50:1 Fuel in tank? starts? fuel/oil mix for 40cc Turn fuel petcock Engine Fuel petcock to ON position starts? 'ON' position?
  • Page 99 12.1.3 Engine Will Not Start, continued Legend: Flow "Yes" Engine Does Not "No" Start Engine Carburetor main Clean carburetor starts? jet stuck/clogged? Clean or replace Spark plug Engine fouled? spark plug starts? Plug gap set Engine Set gap to 0.036' to 0.036'? starts? Test for spark at the spark...
  • Page 100 12.1.4 Engine Will Not Start, continued Legend: Flow Engine Does Not "Yes" Start "No" Turn the ignition Probe across the red switch to the OFF No current at and brown leads with ground? position to be a multi meter. tested. Turn the ignition switch to the ON position to be...
  • Page 101 12.1.5 Engine Will Not Start, continued Legend: Flow Engine Does Not "Yes" Start "No" Check the keyway on the flywheel. Key is Engine Replace the key sheared? starts? Replace CDI Box Problem Solved. Continue to 12.1.6...
  • Page 102 12.1.6 Engine Will Not Start, continued Legend: Flow Engine Does Not "Yes" Start "No" Engine Engine Rebuild top end compression starts? below 95PSI Contact ETON Technical Service at: Problem Solved. (864)-278-9585 EXT Problem unsolved.
  • Page 103 12.2-1 150cc Dies After Shifting Legend: Flow Dies After "Yes" Shifting "No" Turn on ignition switch. Set selector switch to 'N' position. Is vehicle Set stop switch to 'O' position. running? Apply LH brake lever and press the starter button. Apply brake lever Engine Problem Solved.
  • Page 104 12.2-2 150cc Dies After Shifting, continued Legend: Flow Dies After "Yes" Shifting "No" Test continuity on Replace the the safety neutral Continuity safety neutral switch with a exists? switch. multi-meter. Contact ETON Technical support at Return to CXL12.2-1 866-224-3619 EXT 114...
  • Page 105 ETON America, LLC Service Bulletin Bulletin No: 0008 Technical Tips Date: 08/25/2000 1. PAPER FUEL FILTERS -CAUSE: RESTRICTIVE FUEL FLOW THEY CLOG EASIER THEY WILL SHOW FUEL IN FILTER, BUT THERE WILL BE NO FUEL IN CARBURATER BOWL. REPAIR: REPLACE WITH AN E-Z FLO WITH FILTER OR A STONE TYPE FILTER.
  • Page 106 Yukon 150 BURNT IGNITION SWITCH (YXL-150) OR HARNESS TO SWITCH BLOWN MAIN FUSES UNITS AFFECTED; ALL YXL-150 UNITS BUILT BEFORE SEPT. 2000 VIN Prior to RFZFJA0Sx0A001501) REASON FOR BULLETIN - POOR GROUND AT ENGINE TO FRAME CONNECTION AND POSSIBLE PINCHEDWIRE HARNESS AT LEFT SIDE FUEL TANK AREA.
  • Page 107 0010 Ground bolt replacement for Yukon 150 Date: 09/11/2000 Yukon 150 (YXL-150) UNITS AFFECTED; ALL YXL-150 UNITS BUILT BEFORE SEPT. 2000 VIN Prior to RFZFJA0Sx0A001501) REASON FOR BULLETIN: POOR GROUND AT REGULATOR REPAIR: REPLACE GROUND BOLT AT REGULATOR, (ONLY for Models that have grounding wire on the Regulator) 1.
  • Page 108 10/06/03 Yukon (YXL-150) Flywheel Nut Coming Loose Units affected: All Yukon (YXL-150) with VIN’s ending in YA002964 or lower. Reason for bulletin: We have found in some cases that the flywheel nut is coming loose and causing severe internal damage, possibly damaging the crankshaft.
  • Page 109 ETON America, LLC Service Bulletin Bulletin No: 0021 ATV Break-In Procedure Date: 09/10/03 Your ATV requires a break-In period just as with all other internal combustion en- gines. This period allows the engine parts to seat and wear properly without undue strain which can cause premature failure.
  • Page 110 Yukon & Yukon II (YXL & Figure 1 CXL 150’s) ETON America has 2 different styles of gears for the transmission, the old style that comes on the older YXL 150’s which we have limited quantities of . And the new style which come on the CXL-150’s.
  • Page 111 As a result we have made two rebuild kits available to you to cover both carburetor models. For Yukon (YXL-150) with VIN numbers ending with numbers greater than 1A004519 and Yukon II (CXL-150) with VIN numbers ending in numbers greater than 3A001769 use Carburetor rebuild Kit Number 810420.
  • Page 112 ETON America, LLC Service Bulletin Bulletin No.: SB-0038 C.D.I. Module Specifications Date: 05/01/2006 Yukon II 150 CXL-150 -- C0410-V30-9001 Electric resistance(Ω) specification +12V BRAKE BACK SW Pcin 26-30K 20-24K ∞ 15-20K 5-6K +12V 30-50K 30-50K ∞ 30-50K 20-30K BRAKE BACK SW 30-40K 30-50K ∞...
  • Page 113 ETON America, LLC Service Bulletin C.D.I. Module Specifications Bulletin No.: SB-0039 Viper 150R Date: 05/01/2006 RXL-150R -- C0410-V30-9001 Electric resistance(Ω) specification +12V BRAKE BACK SW Pcin 26-30K 20-24K ∞ 15-20K 5-6K +12V 30-50K 30-50K ∞ 30-50K 20-30K BRAKE BACK SW 30-40K 30-50K ∞...
  • Page 114 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 ...

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