ETON VIPER ST 50 EXL 50 QUAD Bike ATV Service Repair Manual

SERVICE MANUAL Downloaded from www.Manualslib.com manuals search engine

CONTENTS 1. INFORMATION 2. MAINTENANCE 3. ENGINE REMOVAL AND INSTALLATION 4. ENGINE FUEL SYSTEM 5. ENGINE LUBRICATION AND COOLING SYSTEM 6. ENGINE COMBUSTION SYSTEM 7. TRANSMISSION SYSTEM 8. STEERING SYSTEM 9. FRONT WHEEL SYSTEM 10. REAR WHEEL SYSTEM 11. FENDERS AND EXHAUST PIPE 12. ELECTRICAL SYSTEM 13. TROUBLE SHOOTING Downloaded from www.Manualslib.com manuals search engine

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. 2 Downloaded from www.Manualslib.com manuals search engine

1.3 SPECIFICATION ENGINE (for Viper ST & Yukon ST in this service manual) COLORING Specifications subject to change without notice. 3 Viper ST EXL-50 Yukon ST EXL-50 SUSPENSION Front Single A-arm / Adjustable Shocks Rear Swing Arm / Adjustable Shock BRAKES Front Dual Mechanical drum Rear Hydraulic Disc TIRES Front 20/6-10 Rear 20/10-9 PRESSURE 【psi (0.23 kgf/cm 2 )】 Front 12(0.8) 12(0.8) Rear 12(0.8) 12(0.8) Viper ST EXL-50 Yukon ST EXL-50 CHASSIS Overall Length 1670 mm 1750 mm Overall Width 940 mm 1010 mm Overall Height 1040 mm 1065 mm Seat Height 760 mm 760 mm Wheel base 1110 mm 1115 mm Ground Clearance 120 mm 120 mm Dry Weight 152 kg 152 kg Fuel Tank Capacity 4.5 Liters 4.5 Liters Type Two cycle air cooled Displacement 49.3 c.c. Bore and Stroke 40.0X39.2mm Compression ratio 6.8:1 Maximum Torque (Nm/rpm) 4.5 Nm/6000rpm Carburetor Piston type Ignition Capacitor Discharge Starting Electric and kick starter Lubrication Forced pressure and wet sump Transmission Automatic (C.V.T. V-belt) Fr Neut .Rev Maximum Power (ps/rpm) 3.8 ps/6000rpm Downloaded from www.Manualslib.com manuals search engine

1.4 SERIAL NUMBER (For Viper ST EXL-50 / Yukon ST EXL-50 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 Engine serial number 4 Downloaded from www.Manualslib.com manuals search engine

.5 TORQUE VALUES (For EXL 50 in this service manual) 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) 5 Downloaded from www.Manualslib.com manuals search engine

2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN 2.3 FUEL TUBE 2.10 BRAKE SYSTEM 2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES 2.5 THROTTLE CABLE ADJUSTMENT 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 GAP: 0.6-0.7 mm RECOMMENDED SPARK PLUGS: NGK BPR7HS THROTTLE LEVER FREE PLAY: 5-10 mm IDLE SPEED: 1800±100 rpm BRAKE LEVER FREE PLAY: 15-25 mm DRIVE CHAIN SLACK 10-25 mm FRONT/REAR TIRE PRESSURE MIN 2 psi (12.5kpa) TOE-IN 5±10 mm TORQUE VALUES SPARK PLUG 25-30 N.m TIE-ROD LOCK NUT 35-43 N.m ENGINE OIL JASO FC Grade or same degree oil GEAR LUBRICATION OIL SAE 90 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. (For ATV all serial in this service manual) INITIAL SERVICE (First week) REGULAR SERVICE (Every 30 operating days) EVERY YEAR FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG CARBURETOR IDLE SPEED DRIVE CHAIN BRAKE SHOE WEAR BRAKE SYSTEM NUT, BOLT, FASTENER WHEEL STEERING SYSTEM SUSPENSION SYSTEM C.V.T. AIR FILTER GEAR OIL REVERSE GEAR OIL-RXL90R I I I, L I I I I C I I I, L I I I C I I I I R R Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace Downloaded from www.Manualslib.com manuals search engine

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 kinking 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. 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. Downloaded from www.Manualslib.com manuals search engine

2.6 AIR CLEANER Unscrew the air cleaner cover screws. 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 carefully. 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 wearness. 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 cross threading. Tighten the spark plug with 25-30 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: 1800±100 rpm 2.9 DRIVE CHAIN Inspect the chain slack. The standard is 10-25mm. Downloaded from www.Manualslib.com manuals search engine

Adjust the chain slack. Loose the lock bolts (4 pcs) then adjust the drive chain slack by turn the adjusting nut. Tighten the four lock bolts. 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. Inspect the chain-tensioned roller. Replace it, if necessary. 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. Downloaded from www.Manualslib.com manuals search engine

ETON VIPER ST 50 EXL 50 QUAD Bike ATV Service Repair Manual

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