E TON YXL 150 ATV Service Repair Manual 2004-2009
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ETON America
150cc Service Manual
Covers:
YXL-150, CXL-150, RXL-150R
200028
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Table of Contents
1. Information
2. Maintenance
3. Engine Removal And Installation
4. Engine Lubrication And Cooling System
5. Cylinder Head & Valves
6. Cylinder & Piston
7. Transmission System
8. Front Wheel, Suspension And Steering
9. Rear Wheel System
10. Fenders And Exhaust Pipe
11. Electrical System
12. Trouble Shooting
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Information
1-2
1. INFORMATION
1.1 Safety
1.2 Notes
1.3 Specifications
1.4 Serial number
1.5 Torque valve
1.1 Safety
& GASOLINE
Gasoline is extremely flammable and is explosive under certain conditions. 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 come into
contact with the electrolyte, flush the area thoroughly with water. If you get the electrolyte in your eyes,
flush with water and contact a doctor immediately.
& HOT PARTS
The 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 damage after prolonged exposure to the skin. 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.
ETON America, LLC 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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Information
1-3
1.3 SPECIFICATION
SUSPENSION
Front
Rear
BRAKES
Front
Rear
TIRES
Front
Rear
COLOR
* Specifications subject to change without notice.
Dual A-arm
Swing Arm
Dual Mechanical Drum
Mechanical Drum
(YXL only)
Hydraulic Disc
(CXL & RXL-150R only)
21” x 7” - 8”
22” x 10”
Red/Black & Silver/Black
(YXL-150 only)
Red, Blue, Green, Silver
(CXL-150 only)
Black/Yellow
(RXL-150R only)
ENGINE Type Air-Cooled 4-Stroke
with Oil Cooler
Displacement 149.56 cc
Bore and Stroke 57.4x57.8mm
Compression 9.7:1
Maximum Torque 10.6 ps@7500rpm
Carburetor Kei-Hin / Electric choke
Air Cleaner Oil Bathed element type
Transmission Automatic (C.T.V. V-belt)
CHASSIS Overall Length 1730mm/68.1 inches
Overall Width 980mm/38.6 inches
Overall Height 1070mm/42.1 inches
Wheel base 1115mm/43.9 inches
Ground Clearance 140mm/5.5 inches
Dry Weight 172kg / 379lbs
Fuel Tank Capacity 6.5 liters/1.7 gal
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Information
1-4
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
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1-5
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
Cylinder head nut 28 N-m ( 20.7 ft-lbs)
Spark plug 12 N-m ( 8.9 ft-lbs)
Cylinder head bolt 20 N-m ( 14.8 ft-lbs)
Alternator bolt 8 N-m (5.9 ft-lbs)
FRAME
Handlebar upper holder bolt 24 N-m ( 17.7 ft-lbs)
Throttle housing cover screw 4 N-m ( 2.9 ft-lbs)
Steering shaft nut 50 N-m ( 36.9 ft-lbs)
Steering shaft holder bolt 33 N-m ( 24 ft-lbs)
Wheel rim bolt 18 N-m ( 13.3 ft-lbs)
Tie rod lock nut 35 N-m ( 25.8 ft-lbs)
King pin nut 40 N-m ( 29 ft-lbs)
Handlebar lower holder nut 40 N-m ( 29.5 ft-lbs)
Front wheel bolt 24 N-m ( 17.7 ft-lbs)
Front axle nut 60 N-m ( 44 ft-lbs)
Front brake arm nut 4 N-m ( 3.0 ft-lbs)
Rear brake arm nut 7 N-m ( 5.2 ft-lbs)
Rear axle nut 60 N-m ( 44.3 ft-lbs)
Rear wheel bolt 24 N-m ( 17.7 ft-lbs)
Exhaust muffler mounting bolt 30 N-m ( 22.1 ft-lbs)
Engine hanger bolt 30 N-m ( 22 ft-lbs)
Rear axle holder bolt 90 N-m ( 65 ft-lbs)
Swingarm pivot nut 90 N-m ( 65 ft-lbs)
Rear shock absorber mounting nut 45 N-m ( 33 ft-lbs)
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2-1
Maintenance
2. Maintenance
2.1 Maintenance data
2.2 Maintenance schedule
2.3 Fuel tube
2.4 Throttle operation
2.5 Throttle cable adjustment
2.6 Air cleaner
2.7 Spark plug
2.8 Idle speed
2.9 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:
Spark plug gap:
Recommended spark plugs:
Throttle lever free play:
Idle speed:
Brake lever free play:
Drive chain slack
Front/rear tire size
Front/rear tire pressure
Toe-in
TORQUE VALUES
SPARK PLUG
TIE-ROD LOCK NUT
ENGINE OIL
Viscosity :
API service classification
GEAR LUBRICATION OIL
Viscosity:
0.6-0.7 mm / 0.024 – 0.028”
NGK CR7HSA
5-10 mm / 0.2-0.4”
1600±100rpm
15-25 mm / 0.6-1.0”
10-25 mm / 0.4-1.0”
20*7-8 / 22*10-8
2.2± 0.3 psi (0.15 kgf/cm
2
)
5±10 mm / 0.2±0.4”
12-19 N-m / 9-14 ft-lbs
35-43 N-m / 26-32 ft-lbs
SAE 40 (10W-40)
SF or SG
SAE 90 (80/90 weight gear oil)
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Maintenance Schedule
Four Stroke Vehicles
WP-0027
Scheduled
Maintenance
300KM Every 1000KM Every 3000KM Every 6000KM Every 12000KM
200 Miles 600 Miles 2000 Miles 3700 Miles 7500 Miles
NEW 1 Month 3 Months 6 Months 1 Year
1 Air cleaner element I * C * R(paper) R(sponge)
2 Air cleaner I
3 Oil filter (Screen) C C
4 Engine oil Change I Change
5 Tire, pressure I I
6 Battery I I
7 Spark plug I I R
8 Carburetor (idle speed) I I
9 Steering bearing and handles I I
10
Check transmission for leak‐
age
I I
11 Check crankcase for leakage I I
12 Transmission oil Change Change
13 Drive belt/roller I R
14 Fuel tank switch and lines I I
15
Throttle valve operation and
cable
I I
16 Engine bolts and nuts I I
17
Cylinder head, cylinder, and
piston
I
18
Exhaust system/cleaning
carbon
I
19 Cam Chain/ignition time I I
20 Valve clearance I I I I I
21 Shock absorbers I I
22 Front/Rear suspension I I
23 Main/Side stands I I/L
24 Crankcase (PCV) Valve I I
25
Brake mechanism/brake lin‐
ing (pad)
I I
26
Tighten all Bolts/Nuts & Fas‐
teners
I I
* = Clean or replace the air cleaner element more often when the vehicle is operated on dusty
# = Maintenance should be performed more often if the vehicle is frequently operated at high
speed for prolonged time and after the vehicle has accumulated 50,000 miles.
roads or in a heavily polluted environment.
Code:
I = Inspection, clean, and adjust
R = Replace
C = Clean (replaced if necessary)
L = Lubricate
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2-2
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.
Initial Service Regular Service Yearly Service
Note - X: 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 leaks, and replace if
necessary.
ETON 150cc models are equipped with
a vacuum fuel valve. Fuel is
transferred into the carburetor when a
vacuum is created from the engine.
Fuel should not flow if engine is not
running or if vacuum is not applied.
(First Week) _________ (30 Operating days) _____ (Once each Year)
FUEL LINE X X
THROTTLE OPERATION X X
AIR CLEANER C
SPARK PLUG X
CARBURETOR IDLE SPEED X X
DRIVE CHAIN X,L X,L
BRAKE SHOE WEAR X
BRAKE SYSTEM X X
NUT, BOLT, FASTENER X X
WH EEL/TIRES X X
STEERING SYSTEM X
SUSPENSION SYSTEM X
GEAR OIL R
ENGINE OIL R X R
ENGINE OIL FILTER C C
Vacuum
control line
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Get your hands on a comprehensive service repair workshop manual that covers all repairs from A-Z and all models. This manual is designed for both professional mechanics and DIY enthusiasts, providing detailed coverage of major repair topics such as maintenance, engine, clutch, transmissions, cooling systems, fuel, exhaust, ignition, electrical, brakes, wheels, tires, steering, suspension, frame, bodywork, wiring diagrams, fault finding troubleshooting, and more. It also includes high-quality pictures and diagrams for easy understanding.
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