E-TON ATV3U 150 Manuals

Manuals and User Guides for E-TON ATV3U 150. We have 1 E-TON ATV3U 150 manual available for free PDF download: Service Manual

E-TON ATV3U 150 Service Manual

E-TON ATV3U 150 Service Manual (225 pages)

Brand: E-TON | Category: Offroad Vehicle | Size: 52 MB

Table of Contents

How to Use this Manual
4
Table of Contents
6
General Information
7
Specifications
8
Periodic Checks and Adjustments
9
Engine
10
Chapter 1

17
- Engine Serial Number
  17
- Machine Identification
  17
- Vehicle Identification Number
  17
- Important Information
  18
  - Preparation for Removal and Disassembly
    18
  - Replacement Parts
    18
  - Gaskets, Oil Seals and O-Rings
    18
  - Lock Washers/Plates and Cotter Pins
    19
  - Bearings and Oil Seals
    19
  - Circlips
    19
  - Checking the Connections
    20
Chapter 2

21
- General Specifications
  21
- Engine Specifications
  24
- Chassis Specifications
  31
- Electrical Specifications
  33
- Tightening Torques
  35
  - Engine Tightening Torques
    35
  - Chassis Tightening Torques
    36
- General Tightening Torque Specifications
  37
- How to Use the Conversion Table
  37
- Lubrication Points and Lubricant Types
  38
  - Engine
    38
- Oil Flow Diagrams
  40
- Cable Routing
  41
Chapter 3

48
Chapter 4

87
- Exhaust Pipe/Muffler, Cables and Leads
  87
- Engine Mounting Bolts
  88
- Removing the Engine
  89
- Installing the Engine
  89
- Engine
  87
- Cylinder Head
  90
- Camshaft, Rocker Arms and Valves
  97
- Cylinder and Piston
  106
  - Removing the Piston
    107
  - Checking the Cylinder and Piston
    107
  - Checking the Piston Rings
    109
  - Checking the Piston Pin
    110
  - Installing the Piston
    110
  - Installing the Cylinder
    111
- C.D.I. Magneto
  112
- Belt Drive
  114
  - Crankcase Cover
    114
  - Kickstarter
    115
  - Installing the Kickstarter
    116
  - V-Belt, Clutch, Drive and Driven Pulley
    117
  - Disassembling the Secondary Sheave
    118
  - Removing the Secondary Sheave and V-Belt
    119
  - Disassembling the Secondary Sheave
    120
  - Checking the Clutch Shoe
    120
  - Checking the V-Belt
    120
  - Checking the Drive Pulley
    121
  - Checking the Primary Roller Weights
    121
  - Checking the Piece Slider
    121
  - Checking the Driven Pulley
    121
  - Assembling the Primary Sheave
    122
  - Assembling the Secondary Sheave
    123
  - Installing the Belt Drive
    124
- Starter Clutch and Starter Motor
  125
  - Checking the Starter Wheel Gear
    126
- Oil Pump
  127
  - Removing the Oil Pump
    128
  - Checking the Oil Pump
    129
  - Installing the Oil Pump
    130
- Crankcase and Crankshaft
  131
- Transmission
  135
  - Shift Shaft
    136
  - Checking the Shift Fork
    137
  - Checking the Drum Comp Gear Shift
    137
  - Checking the Transmission
    137
  - Removing the Gear Set
    138
  - Checking the Gear Set
    139
  - Installing the Gear Set
    140
Chapter 6

148
- Chassis
  148
- Front and Rear Wheels
  148
- Front Wheels
  148
- Rear Wheels
  149
- Checking the Wheels
  150
- Checking the Front Wheel Hubs
  150
- Checking the Rear Wheel Hubs
  151
- Installing the Wheel Hubs
  151
- Installing the Front Wheels
  152
- Installing the Rear Wheels
  152
- Front Brakes
  153
- Removing the Front Brakes
  154
- Checking the Front Brake Shoe Plates
  154
- Checking the Front Brake Shoes
  154
- Checking the Front Brake Drums
  155
- Installing the Front Brakes
  155
- Rear Axle and Rear Axle Hub
  157
- Removing the Rear Axle
  159
- Checking the Rear Axle
  159
- Checking the Driven Sprocket
  159
- Checking the Brake Disc
  160
- Installing the Driven Sprocket
  160
- Installing the Rear Axle
  160
- Rear Brake
  161
- Rear Brake Caliper
  161
- Checking the Rear Brake Caliper
  162
- Installing the Rear Brake Caliper
  162
- Replacing the Rear Brake Pads
  164
- Rear Brake Master Cylinder
  166
- Checking the Master Cylinder
  167
- Assembling the Rear Brake Master Cylinder
  167
- Installing the Rear Brake Master Cylinder
  167
- Steering System
  170
- Removing the Handlebar Grips
  172
- Removing the Rear Brake Switch
  172
- Checking the Handlebar
  172
- Installing the Handlebar
  173
- Installing the Handlebar Grips
  173
- Installing the Rear Brake Master Cylinder
  174
- Installing the Front Brake Lever Assembly
  174
- Steering Stem
  175
- Removing the Steering Stem
  176
- Installing the Lower Handlebar Holder
  176
- Installing the Steering Stem
  177
- Installing the Lock Washer
  177
- Tie-Rods and Steering Knuckles
  178
- Removing the Tie-Rods
  179
- Removing the Steering Knuckles
  179
- Checking the Steering Knuckles
  179
- Installing the Tie-Rods
  180
- Front Arms and Front Shock Absorber Assemblies
  181
- Front Arms and Front Shock Absorber
  181
- Assemblies
  181
- Removing the Front Arms
  182
- Checking the Front Arms
  182
- Checking the Front Shock Absorbers
  182
- Checking the Ball Joints
  183
- Installing the Front Arms
  183
- Rear Shock Absorber, Swingarm and Drive Chain
  184
  - Drive Chain
    185
  - Checking the Rear Shock Absorber
    186
  - Removing the Rear Shock Absorber
    186
  - Removing the Swingarm
    186
  - Checking the Drive Chain
    187
  - Checking the Swingarm
    187
  - Installing the Drive Chain
    188
  - Installing the Drive Sprocket
    188
Chapter 7

189
- Electricalcomponents
  189
- Wiring Diagram
  190
- Checking Switch Continuity
  191
- Checking the Switches
  192
- Checking the Bulbs and Bulb Sockets
  193
- Checking the Condition of the Bulbs
  193
- Checking the Condition of the Bulbs Sockets
  194
- Ignition System
  195
- Circuit Diagram
  195
- Troubleshooting
  196
- Electric Starting System
  199
- Circuit Diagram
  199
- Starting Circuit Out-Off System Operation
  200
- Troubleshooting
  201
- Starter Motor
  203
- Removing the Starter Motor
  204
- Checking the Starter Motor
  204
- Assembling the Starter Motor
  205
- Charging System
  206
- Circuit Diagram
  206
- Troubleshooting
  207
- Lighting System
  209
- Circuit Diagram
  209
- Troubleshooting
  210
- Checking the Lighting System
  211
- Signaling System
  213
- Circuit Diagram
  213
- Troubleshooting
  214
- Checking the Signaling System
  215
- Auto Choke System
  220
- Circuit Diagram
  220
Chapter 8

222
- Fuel System
  222
- Electrical System
  222
- Compression System
  223
- Poor Idle Speed Performance
  223
- Poor Medium and High-Speed Performance
  223
- Faulty Clutch
  224
- Engine Operates but Vehicle will Not Move
  224
- Clutch Slipping
  224
- Poor Starting Performance
  224
- Poor Speed Performance
  224
- Overheating
  224
- Faulty Brake
  225
- Poor Braking Effect
  225
- Shock Absorber Malfunction
  225
- Malfunction
  225
- Unstable Handling
  225
- Troubleshooting
  222
  - Starting Failure/Hard Starting
    222

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