User manual ETON ATV RXL 70 SERVICE MANUAL

[. . . ] INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3. STEERING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 9. TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 1 1. [. . . ] Shift Spring fig-2 If open width greater than 5mm, it must be replaced. SERVICE LIMITS: 5 mm Shift Gear 27 Shift Motor Check shift motor whether it's action is normal as follow data: Disassembly mission side cover, parts of shift mechanism and mission cover. Replace it if necessary. Brush Seal Bearing 7. 4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION This transmission is the combination of automatic centrifugal clutch and V-belt continuous variable transmission, which can change the transmission ratio automatically. When engine speed increase, the drive pulley will be push to belt by the centrifugal force from six rollers. The belt at driven pulley is forced to move to the center of shaft, then the radius of pitch circle is decreased. The transmission ratio is therefore altered by the alteration of pitch circle's radius. (In the drawing, "H" means high speed, "L" means low speed) 7. 5 CONTINUOUS VARIABLE TRANSMISSION V-Belt Made of rubber fiber, resistant to head, pressure and abrasion. The inner side of the Belt is toothed. Drive Pulley Due to the increasing engine speed, the rollers push the movable drive face by centrifugal force. It can reduce the belt temperature. 28 Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at the Driven End to shorten the revolving radius. When the outside load is higher than the engine's output, the pulley of fixed shaft and belt slip to make the Movable Drive Face move along the inner side of Cam and compensate to increase to high torque (toward to low speed) and make the engine maintain smooth running with original revolution. 7. 6 GEAR BOX (For RXL 90R) Reverse Shaft Comp Sensor Drive Shaft Comp Drum Gear Shift Fork Fork Shaft Counter Shaft Comp Remove mission side cover, parts of shift mechanism and mission cover. The gear ratio of front gear composition is about 47 31 × 15 11 49 49 31 × × 15 16 11 The gear ratio of reverse gear composition is about 7. 7 ELECTRIC SELF-STARTER MECHANISM Starter Motor is installed on the upper side of engine. The starter motor can act only when the left hand brake is applied. 29 ELECTRIC SELF-STARTER MECHANISM KICK STARTER 7. 8 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-starter arm is kicked, the gear of start shaft will drive the kick-starter to revolve the crankshaft to start the engine. After the engine is started, the kick-started will stop transfer the power to the kick-starter driven gear. When the kick-starter lever is released, the kick-starter gear will go back to its original position. 7. 9 DISASSEMBLY AND CHECK OF C. V. T. STEERING SYSTEM 8. 1 THE PARTS DRAWING OF STEERING SYSTEM 8. 3 HANDLEBAR 8. 2 TROUBLESHOOTING 8. 4 STEERING SYSTEM 8. 1 THE PARTS DRAWING OF STEERING SYSTEM 8. 2 TROUBLESHOOTING HARD STEERING FAULTY TIRE STEERING SHAFT HOLDER TOO TIGHT INSUFFICIENT TIRE PRESSURE FAULTY STEERING SHAFT BEARINGS DAMAGED STEERING SHAFT BEARING 8. 3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar. (The picture of right side is for ATV RXL 50/90 and RXL 90R) 31 (The picture of right side is for ATV RXL 50M) Remove engine switch housing on the left handle bar. Remove the handlebar holder and handlebar. INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark with the tops of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the upper screw first then tighten the lower one. 32 Install the rear brake lever bracket, aligning the boss with the hole. (The picture of right side is for ATV RXL 50/90 and RXL 90R) Aligning the split line of the throttle housing and holder with the punch mark. [. . . ] Remove the exhaust pipe carefully. 11. 5 EXHAUST PIPE INSTALLATION (There are three screw bolts in the vehicle frame. One is on the engine exhaust pipe end, and the other Is on the side of the transmission, another is on the End of vehicle frame. ) Installation is the reverse order of removal. Torque: Exhaust muffler bolts 30-35 N. m After installation; make sure that there are no exhaust leaks. 54 12. ELECTRICAL SYSTEM 12. 1 TROUBLESHOOTING 12. 2 IGNITION COIL 12. 3 BATTERY CAUTION 12. 4 BATTERY INSPECTION 12. 5 CHARGING 12. 6 REMOTE CONTROLLER 12. 7 WIRING DIAGRAMS 12. 1 TROUBLESHOOTING ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG ENGINE STOP SWITCH AT " OFF " FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POOLY CONNECTED: Between CDI and ignition coil Between alternator and CDI unit Between CDI and engine stop switch Between ignition coil and spark plug Between generator and CDI unit NO SPARK AT PLUG ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMPROPER IGNITION TIMING Faulty generator Faulty CDI unit LOOSE, BROKEN OR SHORTED WIRE FAULTY ALTERNATOR FAULTY IGNITION SWITCH LOOSE BATTERY CONNECTION LOOSE CHARGING SYSTEM CONNECTION DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE FAULTY IGNITION SYSTEM ENGINE PROBLEMS FAULTY ENGINE STOP SWITCH FAULTY REMOTE CONTROLLER SCANTY CONTROLLER BATTERY ELECTRIC CHARGING SYSTEM FAILURE ENGINE INTERMITTENT POWER STARTER MOTOR WILL NOT TURN STARTER MOTOR AND ENGINE TURN, BUT ENGINE DOES NOT START REMOTE CONTROLLER INCAPABLE ACTION TO MAKE ENGINE UNABLE RUNNING 55 12. 2 IGNITION COIL (ATV RXL 50/90 and KXL 90 and MXL 50 all have the same model in this chapter) Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resistance. STANDARD: 0. 1 - 0. 3(20) Measure the secondary coil resistance with the spark plug cap in place. STANDARD : 7. 4 ­ 12 k(20) IGNITION TIMING The ignition advance is 15°± 3°/4000rpm The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not require adjustment. ALTERNATOR EXCITER COIL Remove the seat / rear fender and front fender. [. . . ]