E TON EXL 150 ATV Service Repair Manual 2004-2009
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CONTENTS
1.INFORMATION……………………………………………………2
2.MAINTENANCE…………………………………………………..6
3.ENGINE REMOVAL AND INSTALLATION…………………..14
4. CYLINDER HEAD / VALVES………………………………….16
5. LUBRICATION………………………………………………….26
6. CYLINDER / PISTON…………………………………………..34
7. TRANSMISSION / KICK STARTER………………………….42
8. STEERING AND SUSPENSION……………………………...52
9. FRONT WHEEL AND BRAKE SYSTEM…………………….59
10. REAR WHEEL AND BRAKE SYSTEM…………………….68
11. FENDERS AND EXHAUST PIPE…………………………...83
12. ELECTRICAL SYSTEM………………………………………89
13. TROUBLE SHOOTING……………………………………..108
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1. INFORMATION
1.1 SAFTY
1.2 NOTES
1.3 SPECIFICATION
1.4 SERIAL NUMBER
1.5 TORQUE VALUE
1.1 SAFETY
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition.
Do not smoke or allow sparks or flames in your work area.
● CARBON MONOXIDE
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.
● BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and
clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte
gets in your eyes.
● HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the
engine is run. Wear insulated gloves before handling these parts.
● USED ENGINE/GEAR OIL
Used engine oil and gear oil may cause skin disease if repeatedly contact with
the skin for long periods.
Keep out of reach of children.
1.2 NOTES
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.
JI-EE Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without notice
and without incurring any obligation whatever.
No part of this publication may be reproduced without written permission.
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1.3 SPECIFICATION ENGINE
※ This service manual have six models, it is YXL-150, CXL-150, EXL-150 / 150 (2004
two-passengers) RXL-150 and EXL-150 (VIPER) in this service manual.
Type Air-Cooling 4-Stroke with oil cooler
Displacement 149.5 c.c.
Bore and Stroke φ57.4X57.8mm
Compression 9.7:1
Maximum Torque (Nm/rpm) 11.7 / 5000 ± 500
Carburetor
Ignition Capacitor Discharge
Starting Electric and kick starter
Lubrication Auto oil injection
Transmission Automatic (C.V.T. V-belt)
YXL-150 CXL-150 EXL-150 EXL 150 (2004) RXL-150 EXL-150 (VIPER)
CHASSIS
Overall Length 1730 mm 1750 mm 1665 mm 1670 mm
Overall Width 980 mm 1010 mm 1010 mm 1010 mm
Overall Height 1070 mm 1065 mm 1070 mm 1070 mm
Wheel base 1115 mm 1115 mm 1090 mm 1090 mm
Ground Clearance 130 mm 130 mm 120 mm 120 mm
Dry Weight 172 kg 176 kg 168 kg 170 kg
Fuel Tank Capacity 6.5 Liters 6.5 Liters 8.0 Liters
YXL-150 EXL-150 CXL-150 EXL 150 (2004) RXL-150 EXL-150 (VIPER)
SUSPENSION
Front Dual Arm
Rear Swing arm
BRAKES
Front Drum Disc Drum Disc
Rear Drum Disc Drum Disc Drum
TIRES
Front 20”*7”-8” 21”*7”-10” 21”*7”-10” 21”*7”-10”
21”*7”-10” 21”*7”-10”
Rear 22”*10”-8” 22”*10”-10” 22”*10”-10” 22”*10”-10” 20”*11”-9” 20”*11”-9”
PRESSURE 【 psi ( kgf/cm
2
)】
Front MAX 4.0 (0.28) 4.0 (0.28) 4.0 (0.28)
MIN 3.2 (0.23)
12(0.8)
3.2 (0.23)
12(0.8)
3.2 (0.23)
12(0.8)
Rear MAX 4.0 (0.28) 4.0 (0.28) 4.0 (0.28)
MIN 3.2 (0.23)
12(0.8)
3.2 (0.23)
12(0.8)
3.2 (0.23)
12(0.8)
COLORING
Specifications subject to change without notice.
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1.4 SERIAL NUMBER
(For YXL 150, EXL 150 / EXL 150(2004 two-passengers) and CXL 150 in this service manual)
The frame serial number is stamped on the front of the frame.
The engine serial number is stamped on the left side of the crankcase.
Frame serial number Side frame serial number --only in
EXL 150 / 150 (2004 two-passengers)
Engine serial number RXL / EXL150 (Viper. St)
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1.5 TORQUE VALUES
STANDARD
● 5 mm bolt and nut 5 N.m (3.5 lbf.ft)
● 6 mm bolt and nut 10 N.m (7.2 lbf.ft)
● 8 mm bolt and nut 22 N.m (16 lbf.ft)
●10 mm bolt and nut 35 N.m (25 lbf.ft)
●12 mm bolt and nut 55 N.m (40 lbf.ft)
ENGINE
● Cylinder head nut 28 N.m (20.7 lbf.ft)
● Spark plug 12 N.m (8.9 lbf.ft)
● Cylinder head bolt 20 N.m (14.8 lbf.ft)
● Alternator bolt 8 N.m (5.9 lbf.ft)
FRAME
● Handlebar upper holder bolt 24 N.m (17.7 lbf.ft)
● Throttle housing cover screw 4 N.m (2.9 lbf.ft)
● Steering shaft nut 50 N.m (36.9 lbf.ft)
● Steering shaft holder bolt 33 N.m (24 lbf.ft)
● Wheel rim bolt 18 N.m (13.3 lbf.ft)
● Tie rod lock nut 35 N.m (25.8 lbf.ft)
● King pin nut 40 N.m (29 lbf.ft)
● Handlebar lower holder nut 40 N.m (29.5 lbf.ft)
● Front wheel bolt 24 N.m (17.7 lbf.ft)
● Front axle castle nut 40-60 N.m (30-45 lbf.ft)
● Front brake arm nut 4 N.m (3.0 lbf.ft)
● Rear brake arm nut 7 N.m (5.2 lbf.ft)
● Rear axle castle nut 40-60 N.m (30-45 lbf.ft)
● Rear wheel bolt 24 N.m (17.7 lbf.ft)
● Exhaust muffler mounting bolt 30 N.m (22.1 lbf.ft)
● Engine hanger bolt 30 N.m ( 22 lbf.ft)
● Rear axle holder bolt 90 N.m (65 lbf.ft)
● Swing arm pivot nut 90 N.m (65 lbf.ft)
● Rear shock absorber mounting nut 45 N.m (33 lbf.ft)
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2. MAINTENANCE
2.1 MAINTENANCE DATA 2.8 IDLE SPEED
2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN
2.3 FUEL TUBLE 2.10 BRAKE SYSTEM
2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES
2.5 THROTTLE CABLE AJUSTMENT 2.12 STEERING SYSTEM
2.6 AIR CLEANER 2.13 TOE-IN
2.7 SPARK PLUG 2.14 GEAR OIL
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG
SPARK PLUG CAP 0.6-0.7 mm
RECOMMENDED SPARK PLUGS
THROTTLE LEVER FREE PLAY 5-10 mm
IDLE SPEED 1600±100rpm
BRAKE LEVER FREE PLAY 15-25 mm
DRIVE CHAIN SLACK 10-25 mm
TOE-IN
5±10 mm
TORQUE VALUES
SPARK PLUG 12-19 N.m
TIE-ROD LOCK NUT 35-43 N.m
ENGINE OIL
Viscosity: SAE 10W-40
API service classification SF or SG
GEAR LUBRICATION OIL SAE 90
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2.2 MAINTENANCE SCHEDULE
The maintenance internals in the follow table is based upon average riding, conditions. Riding in
unusually
dusty areas, require more frequent servicing.
INITIAL SERVICE
(First week)
REGULAR SERVICE
(Every 30 operating days)
EVERY YEAR
FUEL LINE I I
THROTTLE OPERATION I I
AIR CLEANER C
SPARK PLUG I
CARBURETOR IDLE
SPEED
I I
DRIVE CHAIN I, L I, L
BRAKE SHOE WEAR I
BRAKE SYSTEM I I
NUT, BOLT, FASTENER I I
WHEEL/TIRES I I
STEERING SYSTEM I
SUSPENSION SYSTEM I
GEAR OIL R
ENGINE OIL R I R
ENGINE OIL FILTER C C
Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary
C: Clean L: Lubricate R: Replace
2.3 FUEL TUBE
Inspect the fuel lines for deterioration, damage or
leakage and replace if necessary.
2.4 THROTTLE OPERATION
Inspect for smooth throttle lever full opening and
automatic full closing in all steering positions.
Inspect if there is no deterioration, damage or kink
in the throttle cable, replace it if necessary.
Check the throttle lever, free play is 5-10 mm at
the tip of the throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to
prevent premature wear.
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2.5 THROTTLE CABLE ADJUSTMENT
Slide the rubber cap of the adjuster off the throttle
Housing, loosen the lock 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.
2.6 AIR CLEANER
Unscrew the air cleaner cover screws.
Remove the air cleaner case cover.
Pull out the air filter element from the air cleaner case.
Wash the element in non-flammable solvent, squeeze
out the solvent thoroughly.
Let it dry.
Soak the filter element in gear oil and then squeeze
out the excess oil.
Install the element into air cleaner in the reverse order
of removal.
2.7 SPARK PLUG
This spark plug located at the front of the engine.
Disconnect the spark plug cap and unscrew
the spark plug.
Check the spark plug electrodes for wear.
Change a new spark plug if the electrodes and
insulator tip appear unusually fouled or burned.
Discard the spark plug if there is apparent wear or
if the insulator is cracked or chipped.
The spark plug gap shall keep in 0.6-0.7mm.
With the sealing washer attached, thread the
spark plug in by hand to prevent crosses threading.
Tighten the spark plug with 12-19 N.m
2.8 IDLE SPEED
Connect an engine speed meter.
Warm up the engine, 10 minutes are enough.
Turn the idle-speed adjust screw on the carburetor
to obtain the idle speed. “Turn in” (clockwise) will
get higher speed. “Turn out” (counter clockwise) will
get lower speed.
IDLE SPEED: 1700±100 rpm
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2.9 DRIVE CHAIN
Stop the ATV and shift the transmission into neutral.
Measure the drive chain slack midway between the
sprockets.
Chain slack =15~25mm (5/8~1 inch)
Adjust the chain slack.
Loosen the lock nuts and turn drive chain adjusting nuts
until get the correct slack.
Tighten the axle holder bolts.
Torque = 90N.m (65 lbf.ft)
If your ATV has the tensioner inside the drive
chain. You don't need to follow the procedure
of chain slack adjustment. The drive chain will
be adjusted by tensioner.
When the drive chain becomes very dirty, it should be
removed, cleaned and lubricated by specify lubricator.
Using commercial chain lubricant to lubricate the drive
chain.
Clean the drive chain with kerosene and wipe it dry.
Inspect the drive chain for possible wear or damage.
Replace the chain, if it is worn excessively or damaged.
Inspect the sprocket teeth, if it is excessive wear
or damage, replace it.
2.10 BRAKE SYSTEM
Inspect the front 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 of free play is 15-25 mm.
(The right side picture is for YXL 150)
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(The right side picture is for CXL / RXL / EXL-150
they have a parking brake on the top of hand brake.)
Only for EXL 150 (2004 two-passengers) / EXL-150 (VIPER)
Inspect the rear brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the free play of the rear brake lever at the
end of the lever. The standard is 10-20 mm.
(The right side picture is for YXL 150
/ EXL-150 (2004 two-passengers) / EXL-150 (VIPER))
(The right side picture is for CXL / RXL-150)
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Full Repair Coverage
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Our service repair workshop manual is a comprehensive guide designed for easy readability and covers all repairs from A-Z for all models. It is a valuable resource for both professional mechanics and DIY enthusiasts.
- Maintenance & Servicing
- Engine & Clutch
- Transmissions
- Cooling Systems
- Fuel & Exhaust
- Ignition & Electrical
- Brakes & Brake Assembly
- Wheels & Tires
- Steering & Suspension
- Frame & Bodywork
- Wiring Diagrams
- Fault Finding Troubleshooting
Our manual also includes high-quality pictures and diagrams, providing professional quality information for all major repair topics. It is compatible with all operating systems, including PC and MAC, ensuring accessibility for all users.
