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 1.2 1.3
SAFTY NOTES SPECIFICATION
1.4 1.5
SERIAL NUMBER 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 Displacement Bore and Stroke Compression Maximum Torque (Nm/rpm) Carburetor Ignition Starting Lubrication Transmission
Air-Cooling 4-Stroke with oil cooler 149.5 c.c. φ57.4X57.8mm 9.7:1 11.7 / 5000 ± 500 Capacitor Discharge Electric and kick starter Auto oil injection Automatic (C.V.T. V-belt)
YXL-150 CHASSIS Overall Length Overall Width Overall Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity
CXL-150
EXL-150
1730 mm 980 mm 1070 mm 1115 mm 130 mm 172 kg 6.5 Liters
YXL-150
EXL 150 (2004)
1750 mm 1010 mm 1065 mm 1115 mm 130 mm 176 kg 6.5 Liters
EXL-150
CXL-150
RXL-150 1665 mm 1010 mm 1070 mm 1090 mm 120 mm 168 kg
EXL 150 (2004)
EXL-150 (VIPER) 1670 mm 1010 mm 1070 mm 1090 mm 120 mm 170 kg 8.0 Liters
RXL-150
EXL-150 (VIPER)
Disc
Drum
Disc
Drum
Disc
Drum
21”*7”-10” 22”*10”-10”
21”*7”-10”
21”*7”-10”
20”*11”-9”
20”*11”-9”
SUSPENSION Front
Dual Arm
Rear
Swing arm
BRAKES Front Rear
Drum Drum
Disc
TIRES Front 20”*7”-8” 21”*7”-10” Rear 22”*10”-8” 22”*10”-10” PRESSURE 【 psi ( kgf/cm2)】 Front MAX 4.0 (0.28) 12(0.8) MIN 3.2 (0.23) Rear MAX 4.0 (0.28) 12(0.8) MIN 3.2 (0.23)
21”*7”-10” 22”*10”-10” 4.0 (0.28) 3.2 (0.23) 4.0 (0.28) 3.2 (0.23)
COLORING Specifications subject to change without notice.
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12(0.8) 12(0.8)
4.0 (0.28) 3.2 (0.23) 4.0 (0.28) 3.2 (0.23)
12(0.8) 12(0.8)
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 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBLE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE AJUSTMENT 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 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 5±10 mm
TOE-IN
TORQUE VALUES SPARK PLUG
12-19 N.m
TIE-ROD LOCK NUT
35-43 N.m Viscosity: SAE 10W-40
ENGINE OIL
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.
FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG CARBURETOR IDLE SPEED DRIVE CHAIN BRAKE SHOE WEAR BRAKE SYSTEM NUT, BOLT, FASTENER WHEEL/TIRES STEERING SYSTEM SUSPENSION SYSTEM GEAR OIL ENGINE OIL ENGINE OIL FILTER
INITIAL SERVICE (First week) I I
REGULAR SERVICE (Every 30 operating days)
I
I
I C I I
I, L
I, L
I I I
I I I
I
R C
I
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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EVERY YEAR
I I R R C
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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Adjust the free play of the rear brake lever by turning the adjuster on the rear axle. (Only for YXL 150 / EXL 150 (2004 two-passengers), / EXL-150 (VIPER))
Because of the CXL / EXL / RXL-150 are both disc brake system, so they don’t need to adjust the free play. They will be discussed in chap10.
BRAKE SHOE WEAR FRONT BRAKE (The YXL / CXL / EXL / RXL 150 have the same model of front brake) Release the front wheel and inspect the brake lining thickness.
Service Limit: 2.0mm(0.08 inch) If either lining is worn beyond the service limit, replace Both brakes shoes.
REAR BRAKE This system is for YXL / EXL 150 (2004 two-passengers) / EXL-150 (VIPER). Replace the brake shoes if the indicator plate aligns with the brake index mark when the parking brake lever is applied.
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2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the tire surfaces at cold tire condition.
*The standard of tire pressure is on chap 1.
2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint.
STEERING SHAFT HOLDER BUSHING Remove the front fender first. Remove the steering shaft holder and check the steering shaft bushing for wears or damage. If the bushing is worn or damaged, change a new one. Grease the steering shaft bushing and install the parts in the reverse order of removal.
Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft)
2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks.
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Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements.
Toe-in: 5Âą10mm
If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts.
Torque: 35-43 N.m
2.14 GEAR OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine.
STEP1
Unscrew this release bolt and can let the dirty oil flow out. (STEP1)
The re-add oil hole is on the engine case beside gearbox. (STEP2)
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STEP2
3. ENGINE REMOVE AND INSTALLATION 3.1 REPAIR CONDITION 3.2 ENGINE REMOVAL
3.3 ENGINE INSTALLATION
3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY
3.2 ENGINE REMOVAL Remove the seat, front fender and rear fender (see chapter 11). Remove the footrest. Remove the spark plug cap from the spark plug. Remove the exhaust muffler. Disconnect the carburetor cable by unscrew two screws on top of the carburetor.
Disconnect the wire connectors. There are three connectors for carburetor auto-choke, starter motor and generator respectively. Remove the drive chain cover. Remove the drive chain retaining clip and master link, and remove the drive chain.
Remove the engine hanger bolts under the engine. Remove the three bolts and air cleaner together.
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3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 30 N.m Route the wires and cable in reverse order properly.
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4.CYLINDER HEAD / VALVES 4.1 SERVICE INFORMATION 4.2 TROUBLESHOOTING
4.4 CYLINDER HEAD REMOVAL 4.5 CYLINDER HEAD INSTALLATION
4.3 CAMSHAFT COMPOSITION REMOVAL
4.1 SERVICE INFORMATION GENERAL This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case. Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place.
SPECIFICATIONS ITEM
STANDARD
SERVICE LIMIT
12±0.5 kg/cm2
--------
IN
29.795
29.395
EX
29.560
29.160
10.000-10.018
10.10
9.972-9.987
9.91
--------
0.05
IN
32.3
31.2
OUT
35.0
34.1
IN
4.975-4.990
4.90
EX
4.955-4.970
4.90
IN/EX
5.000-5.012
5.30
IN
0.010-0.037
0.08
EX
0.030-0.057
0.10
IN
1.0
1.8
EX
1.0
1.8
CYLINDER COMPRESSION CAM LOBE HEIGHT ROCKER ARM I.D. ROCKER ARM SHAFT O.D. CYLINDER HEAD WARPAGE VALVE SPRING FREE LENGTH
VALVE STEM O.D. VALVE GUIDE I.D. STEM-TO-GUIDE CLEARANCE
VALVE SEAT WIDTH
TORQUE VALUES Cylinder head bolts
8 ~ 12 n-m (0.8 ~ 1.2 kg-m)
Camshaft holder flange nuts
20 ~ 24 n-m (2.0 ~ 2.4 kg-m)
Tappet adjusting nut
9 ~ 12 n-m (0.9 ~ 1.2 kg-m) 16
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4.2 TROUBLE SHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope.
LOW COMPRESSION Valve Incorrect valve adjustment Worn or damaged valve seats Burned or bent valve Incorrect valve timing Weak valve spring
Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston
Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged rocker arm or camshaft Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth
Excessive smoke Damaged valve stem seal Faulty cylinder or piston rings
4.3 CAMSHAFT COMPOSITION REMOVAL RUBBER TUBE
Remove the rubber tube of gas waste recovery.
GAS WASTE RECOVERY
Remove the cylinder head cover.
CYLINDER HEAD COVER
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Remove the air cleaner and carburetor. Remove the inlet pipe assy. Remove the shroud compositions.
CARBURATOR
SHROUD COMPOSITIONS
Relax the cam chain adjuster screw. Remove the screw and O-ring and tighten the cam chain adjusting bolt with clockwise direction.
INLET PIPE ASSY
CAM CHAIN ADJUSTING BOLT
CAM CHAIN ADJUSTER SCREW
Remove the nuts and washers. Remove the camshaft holder and dowel pins.
CAMSHAFT HOLDER
NUTS
Relax the camshaft gear from cam chain and remove the camshaft.
CAMSHAFT
CAMSHAFT GEAR
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INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage.
SERVICE LIMIT:
IN 29.395 mm EX 29.160 mm
CAM
Inspect the camshaft and bearings for wear or damage and replace them if necessary.
LOBES
BEARINGS
Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms.
ROCKER ARMS
Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage.
CAMSHAFT HOLDER
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ROCKER ARM SHAFTS
Measure the I.D. of each rocker arm.
SERVICE LIMIT: 10.10 mm Measure the O.D. of each rocker arm shaft.
SERVICE LIMIT: 9.91 mm
4.4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head.
FLANGE BOLTS
CYLINDER HEAD
Remove the cylinder head gasket and dowel pins. DOWEL PINS
CYLINDER HEAD GASKET
Remove the cam chain guide. CAM CHAIN GUIDE
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CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor.
INSPECTION Clean off all carbon deposits from the combustion chamber. Check the spark plug hole and valve area for cracks.
Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge.
SERVICE LIMIT: 0.05 mm
Measure the free length of the inner and outer valve springs.
OUTER VALVE
SERVICE LIMITS: Inner 31.2 mm Outer 34.1 mm
INNER VALVE
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Inspect each valve for turning, burning, scratches or abnormal stems wear.
INLET VALVE
EXHAUST VALVE
Check the valve movement in the guide. Measure and record each valve stem O.D.
SERVICE LIMITS: 4.90 mm
Measure and record the valve guide I.D.
SERVICE LIMITS: IN / EX
5.30 mm
Calculate the stem-to-guide clearance.
SERVICE LIMITS: IN 0.08 mm EX 0.10 mm NOTE: If the stem-to-guide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace guides as necessary and ream to fit. If the valve guide is replaced, the valve guide is replaced; the valve seat must be refaced.
CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil. Insert the valves into guides. Install the valve springs, retainers and the cotters. NOTE: To prevent loss of tension, don’t compress the valve springs more than necessary.
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INSTALLATION
DOWEL PINS
Install the new gasket and dowel pins.
Install the cam chain guide.
CAM CHAIN GUIDE
Install the cylinder head. CYLINDER HEAD
CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder.
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Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter clockwise.
“T” MARK
Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole forwards front.
“I” MARK
CIRCLE HOLE
Install the dowel pins and camshaft holder. Tighten the washers and nuts. TORQUE: 20 n-m (2.0 kg-m)
Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge.
STANDARD VALVE: 0.08 mm
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Relax the cam chain-adjusting bolt with counterclockwise direction and install the o-ring and screw.
Install the cylinder head cover.
CYLINDER HEAD COVER
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5. LUBRICATION 5.1 SERVICE INFORMATION
5.4 ENGINE OIL & FILTER CHANGE
5.2 TROUBLESHOOTING
5.5 OIL PUMP
5.3 ENGINE OIL LEVEL
5.1 SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump. Fill the oil pump with clean oil when reassembling the pump.
SPECIFICATION ENGINE OIL CAPACITY API service classification: SF or SG
0.8-1.0 liter ENGINE OIL RECOMMENDATION VISCOSITY: SAE 20w-40
When the average temperature in your riding area is within the indicated range, you should use the other engine oil viscosities that are shown in the chart. ENGINE OIL VISCOSITIES
SAE 20W-50 SAE 20W-40 SAE 10W-40 SAE 10W-30 SAE 5W
-20
-10
0
10
ITEM OIL PUMP
20
30
40 o C
STANDARD
SERVICE LIMIT
COVER-TO-ROTOR CLEARANCE
----------
0.12
ROTOR TIP CLEARANCE
----------
0.12
0.05 – 0.10
0.2
END CLEARANCE
TORQUE VALUE OIL DRAIN BOLT
20-30 n-m (2.0~3.0 kg-m) 26
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5.2 TROUBLESHOOTING Oil lever too low-high oil consumption Normal oil consumption. External oil leaks. Oil not changed often enough. Worn piston rings. Faulty heat gasket.
Oil contamination Worn piston rings. Faulty heat gasket. Oil or filter not changed often enough.
5.3 ENGINE OIL LEVEL Place the engine on the level plane. Check the oil level with the oil level gauge, but do not screw it in when making this check.
OIL LEVEL GAUGE
Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge.
LOWER
UPPER LEVEL
5.4 ENGINE OIL & FILTER CHANGE Remove the oil filter cap and the oil drain bolt. NOTE: Drain the oil while the engine is warm to ensure complete draining.
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OIL DRAIN
Remove the oil filter cap, spring and oil filter screen. Check the O-ring for damage or fatigue. Install a new oil filter screen and spring then install the cap.
OIL FILTER SCREEN
SPRING
OIL FILTER
O-RINING
Install the oil drain bolt with sealing washer.
TORQUE: 20~30 n-m
(2.0 ~ 3.0 kg-m)
Fill the crankcase with recommended oil.
ENGINE OIL CAPACITY: 0.8 liter at draining. Install the oil filter cap. Install the oil level gauge. Start the engine and let it idle speed for 2 or 3 minutes. Stop the engine and check that the oil level at the upper line on the gauge. Make sure there is no oil leaks.
OIL FILTER CAP
5.5 OIL PUMP REMOVAL Remove the fan cover assy.
FAN COVER ASSY.
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Remove the cooling fan composition.
COOLING FAN COMPOSITION
Remove the A.C.G generator assy.
A.C.G GENERATOR ASSY
Remove the right crankcase cover.
CRANKCASE COVER
Remove the starting clutch outer and gear assy.
STARTING CLUTCH OUTER
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STARTING CLUTCH GEAR
Remove the flange bolts and oil separator. OIL SEPARATOR
FLANGE BOLTS
Remove the oil pump chain and oil pump driven sprocket.
OIL PUMP CHAIN
OIL PUMP DRIVEN SPROCKET
Remove the oil pump assy.
OIL PUMP ASSY.
Disassemble the oil pump. OIL PUMP ASSY.
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INSPECTION Measure the oil pump rotor-to-body clearance.
OIL PUMP BODY
SERVICE LIMIT: 0.12 mm
Install the oil pump shaft and measure the pump rotor tip clearance. SERVICE LIMIT: 0.12 mm.
OIL PUMP SHAFT
Remove the oil pump shaft and measure the pump end clearance.
OIL PUMP OUTER ROTER
SERVICE LIMIT: 0.2 mm.
OIL PUMP INNER ROTER
OIL PUMP ASSEMBLY / INSTALLATION Install the outer rotor, inner rotor and oil pump shaft onto the body. NOTE: Pour a drop of clean engine oil inside the oil pump.
OIL PUMP SHAFT
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Install the oil pump assy.
Install the oil pump driven sprocket and oil pump chain.
OIL PUMP DRIVEN SPROCKET
PS: The tighten torque of driven sprocket nut is 80~120 kgf-cm.
Install the oil separator.
OIL SEPARATOR
Install the starting clutch outer and gear assy.
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Install the new gasket, dowel pins and right crankcase cover.
Install the A.C.G generator assy. and cooling fan composition.
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6.CYLINDER / PISTON 6.1 SERVICE INFORMATION 6.2 TROUBLESHOOTING 6.3 CYLINDER REMOVAL
6.4 PISTON REMOVAL 6.5 PISTON INSTALLATION 6.6 CYLINDER INSTALLATION
6.1 SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case. Before installing the cylinder head make sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place.
ITEM I.D. TAPER OUT OF ROUND WARPAGE ACROSS TOP Piston PISTON O.D. Piston pin PISTON PIN BORE Piston rings PISTON PIN O.D. PISTON-TO-PIN CLEARANCE PISTON-TO-PIN CLEARANCE PISTON RING-TO-RING GROOVE CLEARANCE PISTON RING END GAP CYLINDER-TO-PISTON CLEARANCE CONNECTING ROD SMALL END I.D. Cylinder
TOP SECOND TOP/SEC OIL
6.2 TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings.
Overheating Excessive carbon build-up on piston or combustion chamber wall.
Knocking or abnormal noise Worn piston and cylinder. Excessive carbon build-up.
Excessive smoke Worn cylinder, piston, or piston rings. Improper installation of piston rings. Scored or scratched piston or cylinder wall. Damaged valve stem seal.
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STANDARD 57.400 - 57.410 ---------------------------------57.3075 - 57.3095 15.002 - 15.008 14.994 – 15.000 0.002 – 0.014 0.015 – 0.050 0.015 – 0.050 0.10 – 0.25 0.2 –0.7 0.0005 – 0.1025 15.010 – 15.028
SERVICE LIMIT 57.50 0.10 0.10 0.10 56.500 15.04 14.960 0.02 0.12 0.12 0.5 -----------0.1 15.06
6.3 CYLINDER REMOVAL Remove the cylinder head.
CYLINDER HEAD Remove the cylinder.
CYLINDER
Remove the cylinder gasket and dowel pins.
GASKET
Clean off any gasket materials from the cylinder surface. NOTE: Be careful not to damage the gasket surface.
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CYLINDER SURFACE
DOWEL
6.4 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase.
PISTON PIN CLIP Remove the piston pin from the piston. Remove the piston.
PISTON Spread each piston ring and remove it by lifting up at a point opposite the gap.
PISTON
INSPECTION Inspect the cylinder walls for scratches or wear.
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PISTON PIN
Measure and record the cylinder I.D. at three levels in both an X and Y-axis. Take the maximum reading to determine the cylinder wear.
SERVICE LIMIT: 57.50 mm Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance.
SERVICE LIMIT: 0.10 mm
Calculate cylinder taper at three levels in an X and Y-axis. Take the maximum reading to determine the taper.
SERVICE LIMIT: 0.10 mm Calculate the cylinder out-of-round at three levels in an X and Y-axis. Take the maximum reading to determine the out-of –round.
SERVICE LIMIT: 0.10 mm
Inspect the top of the cylinder for warpage.
SERVICE LIMIT: 0.10 mm
PISTON / PISTON RING INSPECTION Measure the piston ring-to-groove clearance.
SERVICE LIMITS: TOP 0.12 mm SECOND 0.12 mm
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Inspect the piston for wear or damage.
PISTON
Insert each piston ring into the cylinder and measure the ring end gap. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder.
SERVICE LIMITS: TOP 0.5 mm SECOND 0.5 mm
Measure the piston pin O.D.
PISTON PIN
SERVICE LIMIT: 14.960 mm
Measure the piston pin bore.
SERVICE LIMIT: 15.04 mm
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Calculate the piston-to-piston pin clearance.
SERVICE LIMIT: 0.02 mm
Measure the connecting rod small end I.D.
CONNECTING ROD
SERVICE LIMIT: 15.06 mm
6.5 PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up. NOTE: Don’t interchange the top and second rings. Avoid piston and piston ring damage during installation.
Space the piston ring end gaps 120 degrees apart.
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PISTON INSTALLATION Install the piston with it’s “IN“ mark on the intake valve side.
“IN”MARK Install the piston pin with new pin clips. Do not align the piston pin clip end gap with the piston cutout. NOTE: Do not allow the clip to fall into the crankcase.
PISTON PIN 6.6 CYLINDER INSTALLATION Clean any gasket material from the crankcase surface. NOTE: Be careful not to damage the gasket surface.
Install the dowel pins and a new gasket.
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GASKET
Coat the cylinder bore and piston rings with engine oil and install the cylinder. NOTE: Avoid piston rings damage cylinder bore during installation. Do not allow the cam chain fall into the crankcase.
Install the cylinder head.
CYLINDER
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7. TRANSMISSION / KICK STARTER 7.1 SERVICE INFORMATION
7.4 KICK STARTER DISASSEMBLY
7.2 TROUBLE SHOOTING
7.5 KICK STARTER ASSEMBLY
7.3 C.V.T DISASSEMBLY
7.6 C.V.T ASSEMBLY
7.1 SERVICE INFORMATION If the drain tube assy. fills with water, the tube should be drained.
SPECIFICATIONS (mm) ITEM
STANDARD
SERVICE LIMIT
Driven belt width
19.8 - 20.2
19.0
Weight roller O.D.
17.9 - 18.1
17.40
Movable drive face I.D.
27.98 – 28.0
28.03
Drive face collar I.D.
24.06 – 24.09
24.098
Drive face boss O.D.
23.96 – 23.98
23.92
Clutch outer I.D
124.8 – 125.2
125.5
Clutch weight lining thickness
------------------
1.5
Driven face spring length
168.4 – 169.4
164.0
TORQUE VALUES Clutch outer nut
55 N-m (5.5 kg-m)
Drive face nut
55 N-m (5.5 kg-m)
7.2 TROUBLE SHOOTING Engine starts but can’t travel Worn driven belt. Worn clutch lining. Damaged driven face spring.
Low engine power Worn driven belt. Worn weight roller. Dirty drive face.
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7.3 C.V.T DISASSEMBLY L CRANK CASE COVER REMOVAL
C.V.T INLET DUCT
Relax the band screw and remove the C.V.T inlet duct.
Relax the band screw and remove the C.V.T outlet duct.
C.V.T OUTLET DUCT
Remove the gas waste recovery.
GAS WASTE RECOVERY
Remove the bolts and L cranks case cover.
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L CRANK CASE COVER
Remove the gasket and dowel pins. Clean off any gasket material from L crank case surface. L CRANK CASE SURFACE
DOWEL PINS
GASKET
C.V.T REMOVAL Relax the flange nut and remove kick-starter ratchet. Remove the drive face.
DRIVE FACE
FLANGE NUT
KICK STARTER RATCHET
Relax the flange nut. Remove the drive pulley assy. and driven belt.
DRIVEN BELT
DRIVE PULLEY ASSY.
FLANGE NUT
Remove the drive face boss and movable driven face assy.
DRIVEN FACE BOSS
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MOVABLE DRIVEN FACE ASSY.
Remove the ramp plate and weight roller set.
WEIGHT ROLLER SET
RAMP PLATE
Relax the special nut and remove the driven plate composition and driven face spring.
SPECIAL NUT
DRIVEN PLATE COMPOSITION
INSPECTION Inspect the driven belt for wear, tears or damage. Measure the width of driven belt.
SERVICE LIMIT: 19.0 mm
DRIVEN BELT
Inspect the weight roller for wear or damage and replace them if necessary. Measure the O.D. of weight rollers.
WEIGHT ROLLER
SERVICE LIMIT: 17.40 mm
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Measure the I.D. of movable driven face.
MOVABLE DRIVE FACE
SERVICE LIMIT: 28.03mm Inspect the drive face collar for wear or damage. Measure the I.D. of drive face collar.
SERVICE LIMIT: 24.098 mm
Inspect the drive face boss for wear or damage. Measure the O.D. of drive face boss.
DRIVE FACE BOSS
SERVICE LIMIT: 23.92 mm
Inspect the clutch outer for wear or damage. Measure the I.D. of clutch outer.
CLUTCH OUTER
SERVICE LIMIT: 125.5 mm
Inspect the clutch weight set for wear or damage. Measure the thickness of clutch weight lining.
CLUTCH WEIGHT LINING
SERVICE LIMIT: 1.5mm
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Measure the length of driven face spring.
DRIVEN FACE SPRING
SERVICE LIMIT: 164.0 mm
Inspect the driven face assy. and replace them if necessary.
7.4 KICK STARTER DISASSEMBLY Remove the L crank case cover. Remove the kick-starter.
KICK STARTER
Remove the ex. circle-clip and washer from kick-starter spindle composition.
EX. CIRCLIP
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L CRANK CASE COVER
Rotate the kick-starter spindle composition to remove the kick driven gear and spring. Remove the kick-starter spindle composition and return spring. Remove the kick spindle bush.
KICK RETURN SPRING
KICK DRINEN GEAR
KICK STARTER SPINDLE COMPOSITION
INSPECTION Inspect the kick starter spindle composition for wear or damage.
Inspect the kick return spring for fatigue or damage. Inspect the kick spindle bush for wear or damage.
KICK SPINDLE BUSH
Inspect the kick driven gear and spring for wear or damage.
KICK DRIVEN SPRING
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Inspect the machining surface for wear or damage.
MACHINING SURFACE
7.5 KICK STARTER ASSEMBLY Install the kick spindle bush, return spring and spindle assy. Install the kick driven gear and spring.
Install the kick-starter.
KICK STARTER
7.6 C.V.T ASSEMBLY Compose the driven face assy., spring and driven plate composition.
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Compose the movable driven face composition, weight roller set and drives face.
Install the movable drive face assy. and boss.
MOVABLE DRIVE FACE
Install the drive face and kick-starter ratchet.
DRIVE FACE
KICK STARTER RATCHET
Install the driven belt and driven pulley assy.
DRIVEN BELT
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DRIVEN PULLEY ASSY.
Install the dowel pins and gasket.
DOWEL PINS
GASKET
Install the L crank case cover.
L CRANK CASE COVER
Install the gas waste recovery and C.V.T ducts. C.V.T DUCTS
GAS WASTE RECOVERY
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8. STEERING AND SUSPENSION 8.1 PARTS DRAWING 8.2 TROUBLESHOOTING 8.3 HANDLENAR
8.4 THROTTLE HOUSING 8.5 STEERING SYSTEM
8.1 PARTS DRAWING STEERING
STEERING
(For ATV YXL / CXL-150)
(For ATV EXL-150 / EXL 150 (2004 two-passengers) / RXL-150 / EXL-150 (VIPER)
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8.2 TROUBLESHOOTING HARD STEERING
★ ★ ★ ★ ★
Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing
FRONT WHEEL WOBBLING
★ ★ ★ ★
Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly
STEERS TO ONE SIDE
★ ★ ★ ★ ★ ★
Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushings Incorrect wheel alignment
FRONT SUSPENSION NOISE
★ ★
Loose front suspension fasteners Binding suspension link
HARD SUSPENSION
★ ★ ★
Faulty front swing arm bushings Improperly installed front swing arms Bent front shock absorber swing rod
SOFT SUSPENSION
★ ★
Weak front shock absorber springs Worn or damage front swing arm bushings
8.3 HANDLEBAR REMOVAL Remove the right side handlebar cover by unscrew two fix screws.
Remove the throttle lever housing on the right side handle bar. Remove brake lever bracket assembly.
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Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly.
Remove the bolts attaching the handlebar upper holder. Remove the handlebar.
INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark match with the top end of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts. Install the handlebar upper holder’s cover.
Install the switch housing, aligning the boss with the hole. Tighten the upper screw first then tighten the lower one.
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Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely.
Aligning the split line of the throttle housing and holder with the punch mark. Tighten the screw securely
8.4 THROTTLE HOUSING DISASSEMBLY Unscrew the screws on the throttle housing cover. Remove throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing.
Assembly is in the reverse order of disassembly.
8.5 STEERING SYSTEM Removal of Kingpin and Tie-rod Remove the front wheels and brakes plates. Remove the four self-lock nuts from the tie-rod ball joints and take off the two tie-rods.
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Remove the cotter pin on the kingpin. Unscrew the bolt and remove the kingpin.
Tie-rod Inspection Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage, wear or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly.
Kingpin Inspection Inspect the kingpin for damage or cracks. (For YXL-150)
For CXL / EXL / RXL-150 and EXL 150 (2004 two-passengers) / EXL 150 (VIPER)
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Steering Shaft Removal Remove the handle bar cover and handle bar. (See paragraph 8-3) Remove the front fender. (See paragraph 10-1) Remove handlebar lower holder. Unscrew steering shaft holder bolt, remove steering shaft holder. Take off the cotter pin below steering shaft. Unscrew the steering shaft fixed out below shaft. Pull steering shaft carefully.
Steering Shaft Holder Inspection Remove the steering shaft. Remove the bushing from the shaft. Inspect the bushing for damage or wear, replace if necessary. Measure the bushing inner diameter.
Maximum limit: Ă˜39.5 mm
Steering Shaft Inspection Inspect the steering shaft for damage or cracks.
Installation of Steering Shaft Apply grease to the holder. Install the holder and oil seal tighten with the nuts.
Torque: 33 N.m (24 lbf-ft)
Install the steering shaft nut and tighten it. This nut is under this steering shaft.
Torque: 50 N.m (37 lbf.ft)
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Installation of Tie-rod Install the ball joint with “ L� mark on the steering shaft side. Install the tie-rod with the mark on the wheel side. Installation is in the reverse order of removal.
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9. FRONT WHEEL AND BRAKE SYSTEM 9.1 PARTS DRAWING 9.2 TROUBLESHOOTING 9.3 FRONT WHEEL
9.4 FRONT BRAKES 9.5 BRAKE CABLE REMOVAL 9.6 HYDRAULIC BRAKE
9.1 PARTS DRAWING The picture below is for YXL / CXL / RXL-150 FRONT WHEEL
EXL 150 (2004 two-passengers) FRONT WHEEL
The picture below is for YXL / CXL / RXL-150 FRONT BRAKE
the picture below is for EXL150 FRONT BEAKE
PS. ATV EXL 150(2004 two-passengers) / EXL 150 (VIPER) will discuss in chapter 9.6 later.
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9.2 TROUBLESHOOTING HARD STEERING
★ ★
Faulty tire Insufficient tire pressure
FRONT WHEEL WOBBLING
★ ★ ★ ★
Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly
BRAKE DRAG
★ ★
Incorrect brake adjustment Sticking brake cable
STEERS TO ONE SIDE
★ ★ ★ ★
Bent tie rods Wheel installed incorrectly Unequal tire pressure Incorrect wheel alignment
POOR BRAKE PERFORMANCE
★ ★ ★ ★
Brake shoes worn Worn brake drum Brake linings oily, greasy or dirty Improper brake adjustment
9.3 FRONT WHEELS REMOVAL (The disassemble of front wheel system in this serials are the same) Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels.
INSTALLATION Install and tighten the four-wheel castle nuts
Torque: 40-60 N.m (30-45 lbf.ft) Remember put a cotter pin in the castle nut.
9.4 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel. Remove the brake drum.
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Measure the brake lining thickness.
The minimum limit: 1.5 mm If they are thinner than the minimum limit, replace the brake linings.
Measure the brake drum inner diameter.
The maximum limit: 86 mm
Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly. If the race does not turn smoothly or quietly, remove and discard the bearings .
BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm. Remove the brake panel from the knuckle.
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Remove brake arm and cam. Remove return spring. Remove indicator plate and felt seal.
INSTALL BRAKE PANEL Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and install the seal on the brake cam.
Install the brake arm on the cam by aligning the punch mark and the groove on the cam. Tighten the brake arm bolt and nut.
Torque: 4-7 N.m Install the return spring.
Install the brake panel on the knuckle. Connect the brake cable to the brake arm.
Install the brake arm cover. Tighten the screws securely. Position the brake shoes in their original locations and install the brake shoe spring. Install the brake drum and front wheel. Install the castle nut and cotter pin. 62
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9.5 BRAKE CABLE REMOVAL NOTEBecause of ATV YXL and CXL don’t have the front brake distributor, so their brake parts chart and cable removal only follow the two steps below.
Disconnect the front brake primary cable.
Primary cable
Secondary cable
Disconnect the front brake secondary cable from the brake arm.
Brake arm 63
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Remove the adjusters and the front brake cables. Remove the two bolts and the brake plate. (The mechanism of right side picture is only for ATV EXL-150)
Brake plate
Bolt
Adjuster INSTALLATION Install the brake plate and tighten the bolts. (The mechanism of right side picture is only for ATV EXL-150)
Connect the front brake secondary cable to the brake arm.
Connect the front brake primary cable.
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Front cable
9.6 HYDRAULIC BRAKE This brake type is only applying in front wheel of EXL 150 (2004e-mark) / EXL 150 (VIPER).
REMOVAL Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer and wheels. Please follow the next three steps of right pictures.
1
Remove the castle nut.
2
Remove the brake-locking nut. Then you can take the wheel apart.
3
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After disassembling the wheel, take the wheel hub apart the spindle shaft.
Then using the power tool to drive the screw out from brake stopping plate. You can take the brake disc off.
When change brake shoe wear, you must push the master piston to rearward.
After removal front brake assembly, you must fabricate in reverse sequence.
ADD BRAKE OIL The brake oil reservoir is locating below driver seat. After taking driver seat, you must follow the sequence on the reservoir add oil to right level.
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THE BRAKE FLOW CHART When actuate the brake lever, brake force will through oil tube to drive the wheel brake. Or force to the brake pedal, through mechanism to drive the wheel brake.
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10. REAR WHEEL AND BRAKE SYSTEM 10.1 PARTS DRAWING 10.2 TROUBLESHOOTING 10.3 REMOVE REAR WHEEL AND REAR BRAKE 10.4 DRIVE MECHANISM
10.5 REAR BRAKE AND WHEEL INSTALLATION 10.6 SHOCK ABSORBER 10.7 SWINGARM 10.8 SUBPART-HYDRAULIC BRAKE SYSTEM
10.1 PARTS DRAWING The picture below is for YXL / CXL-150
The picture below is for EXL/EXL-150 (2004 two-passengers)
REAR WHEEL
REAR WHEEL
The picture below is for YXL / EXL-150 (VIPER) / EXL-150 (2004 two-passengers)
The picture below is for EXL / CXL / RXL-150
REAR BRAKE
REAR BRAKE
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10.2 TROUBLESHOOTING Bad Brake Performance
Vibration or Wobble
Brake Drag
Hard Suspension Soft Suspension
★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Brake shoes are worn Bad brake adjustment Brake linings are oily, greasy or dirty Brake drums are worn Brake arm setting is improperly engage Axle is not tightened well Bent rim Axle bearings are worn Faulty tires Rear axle bearing holder is faulty Incorrect brake adjustment Sticking brake cam Sticking brake cable Bent damper rod Faulty swing arm pivot bushings Weak shock absorber damper Weak shock absorber spring
10.3 REMOVE REAR WHEEL AND REAR BRAKE (For ATV YXL/ EXL 150 (2004 two-passengers) drum brake) This section is about ATV YXL / EXL 150 (2004 two-passengers) / EXL-150 (VIPER) rear wheel and brake system. The ATV EXL / CXL / RXL-150 system will be discussed in subpart of this chapter. Loosen the cotter pin, wheel nuts, and raise the rear wheel off the ground by placing a support under the frame. Release the wheel and wheel hub.
Remove the brake drum cover.
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Remove the axle collar and brake drum.
Check the brake lining thickness.
The minimum limit is 2.0 mm.
CAUTION: DO not get grease or oil the brake lining surface and brake drum. Otherwise stopping power will be reduced.
Check the brake drum for damage. Replace if necessary. Check the brake drum inner diameter.
The maximum limit is 131 mm.
10.4 DRIVE MECHANISM Removal and Inspection Remove the rear wheel and the rear brake Remove the skid plate under swing arm. Remove the drive chain cover.
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Disassemblies the chain retaining clip and master link. Remove the chain.
Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. Replace if necessary.
Let the rear axle lie in V-blocks and check the run out.
The run out limit is 0.5 mm
Check the turning of inner race of bearing with fingers. The bearings should turn smoothly and quietly. Replace if necessary. Also check the bearing outer race fits tightly in the axle holder. Replace if necessary. Note: Replace the bearings in pairs.
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INSTALLATION Add grease to the dust seal lips and install dust seals. Assembly the rear axle and the driven sprocket.
Assembly the drive chains on the driven sprocket. Assembly the master link and retaining clip. Note the retaining clip direction. Install the drive chain cover. Assembly the chain under cover.
Install the skid plate. Install the drive chain cover.
Chain Slack Adjustment Loosen the axle position lock bolt slightly and turn the chain adjuster nut to take up the excess slack in the chain. Once the chain has been adjusted to the proper tension retighten the axle position locking bolt.
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The chain should be kept well lubricated to prevent excess wear and premature failure. We recommend that you lubricate the chain every 15 hours of operation, or more frequently if needed, with a high quality chain lubricant.
10.5 REAR BRAKE AND WHEEL INSTALLATION Install the wear indicator plate aligning the tab on the axle holder with the slit on the cam. Install the brake arm spring and felt seal.
INSTALL THE BRAKE ARM Tighten the brake arm bolt and nut with 10 N.m torque. (7.2 lbf.ft) Install the adjusters. NOTE: Make sure the rear brake lever and pedal have the proper amount of free plays.
Add grease to the brake cam and anchor pin. Install the brake shoes and springs to their original positions.
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Install the brake drum and brake drum cover.
Assembly the wheel. Tighten the rear axle castle nut with 40-60 N.m. Install a new cotter pin. Adjust rear brake level free play. Adjust drive chain slack.
10.8 SUBPART –HYFRAULIC DISC BRAKE SYSTEM PARTS DRAWING NOTE：This section is about ATV CXL / EXL / RXL-150 rear brake system. But those two serial have something different. 1. brake distributor and 2. foot brake and 3. the positions of oil reservoir, In EXL-150 it have but CXL / RXL-150 haven’t such system. Brake plate
Brake cable
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(The picture shows only for ATV EXL-150 system)
Brake Lever
Brake Cylinder
(The picture shows only for ATV EXL-150 system)
Brake Switch
(The picture shows only for ATV EXL-150 system)
Brake pedal Brake hose Disc plate
Brake cable
Rubber tube
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There is a label showing how to adjust the disc brake
(ATV CXL / EXL / RXL-150 have the same steps under) To replace brake disc Remove the rear left tire
Unscrew the two bolts shown on the photo and remove caliper
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Unscrew the rear wheel axle nut and then remove the mounting seat of the disc
Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm
TO REPLACE THE BRAKE SHOE Remove the rear left tire
Unscrew the two bolts shown and remove caliper
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Unscrew these two plugs
Unscrew & Remove the brake shoe pin as shown
Remove the brake shoes as shown
Check the thickness of brake shoe and replace a new one if the thickness less than 1mm.
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Press the piston to the end prior to installation of brake shoe
Piston TO REPLACE THE BRAKE HYDRAULIC OIL Unscrew the bolts and open the cover (The oil reservoir of ATV CXL-150 just like right side picture. It is located on the handle bar but ATV EXL-150 is not on the same position. )
Unscrew the bolt and drain out the used oil drain. Fasten the bolt after the used oil being drained out completely
Add the brake oil (Dot 3 or Dot 4) Keep oil level at least half of the cup to avoid air gets into brake system, such like caliper and tube
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Unscrew the bolt to vent air from brake system. Fasten the bolt if there isn’t any air in the brake system
Tighten torque 40~70kgf-cm
Pull left brake lever slightly to extract air from brake system
Fill the brake oil to the level shown on the cup when no air comes out Assemble the cover
BRAKE CABLE REMOVAL --The mechanism of right side pictures is only for ATV EXL-150 Remove the adjusters and the rear brake cables.
Adjuster
Rear brake cable
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Disconnect the foot brake spring and the foot brake cable. Remove the brake pedal.
Brake pedal
Foot brake spring
Foot brake cable INSTALLATION Install the brake pedal. Connect the foot brake cables and the foot brake spring.
Connect the rear brake cables and the adjusters.
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The brake flow chart --EXL 150 (2004 two-passengers) / EXL-150 (VIPER) There are two ways to operate rear brake system and you can use left lever or brake pedal.
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11. FENDERS AND EXHAUST PIPE 11.1 FENDRES DRAWING 11.2 REAR FENDERS REMOVAL 11.3 FRONT-TRIM REMOVAL
11.4 CENTRAL-REAR-TRIM REMOVAL 11.5 FRONT FENDER REMOVAL 11.6 EXHAUST PIPE REMOVAL
11.1 FENDERS DRAWING For YXL / CXL / EXL/EXL-150 (2004 two-passengers)
For RXL / EXL-150 (VIPER)
EXHAUST PIPE (For all serials)
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11.2 REAR FENDERS REMOVAL Pull the “Seat Release Bar� to take off the seat. This seat release bar is under the right side of the rear fender.
Procedures of remove the rear fender: Remove the rear rack. Unscrew the two bolts which connect the front fender and rear fender. Unscrew the two bolts, which connect the rear tender and frame, these two bolts just below the seat.
Unscrew the six screws, which connect with footrest plate. Pull the rear fender backward. So the rear fender can be removed.
RXL / EXL 150 (Viper. St) Pull the seat handle first.
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There are two screws on the top of seat compartment. Please remove them.
Then there are two screws on side of the tail.
Finally, you must remove the screws on the footrest.
11.3 FRONT-TRIM REMOVAL Unscrew the two screws just below the headlight of central-front-trim. Unscrew the two screw which between centralfront-trim and central-rear-trim. Then remove the and headlight together.
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EXL 150 (2004 two-passengers)
RXL / EXL 150 (Viper. St)
11.4 CENTRAL-REAR-TRIM REMOVAL Remove the fuel tank cap. Remove the central-rear-trim two mounting bolts from the fuel tank. Pull the central-rear-trim up ward.
11.5 FRONT FENDER REMOVAL After remove the rear fender, central-front-trim and central-rear-trim, remove the two front fender mounting bolts from front frame.
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Remove the mounting bolts and nuts from the front fender and footrest plate.
RXL / EXL 150 (Viper. St) Please remove the two screws on the top of the headlight.
Then you can see there is a screw on the tip of the vehicle. Please remove it.
And there are the screws on the both side of the vehicle. You can see it inside of the front fender. After you remove those screws above, you still must follow the procedure of 11.2 and 11.3. That’s the entire front fender could be removed.
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11.6EXHAUST PIPE REMOVAL You must wait at least 15 minutes after turn off the engine. You need remove the seat, rear fender and footrest plate, before you take off the exhaust pipe. Unscrew the two exhaust pipe bolts that fixed with engine. NOTEďźšDo not service the exhaust pipe while they are hot.
Remove the exhaust pipe bolts mounting on the frame below the seat. Remove the exhaust pipe carefully.
EXHAUST PIPE INSTALLATION Installation is the reverse order of removal.
Torque: Exhaust muffler bolts 30 N.m (22 lbf.ft) After installation, make sure that there are no exhaust leaks.
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12. ELECTRICAL SYSTEM 12.1 TROUBLESHOOTING 12.2 IGNITION COIL 12.3 IGNITION TIMING 12.4 ALTERNATOR EXCITER COIL 12.5 BATTERY INFORMATION
12.6 ELECTRIC STARTER 12.7 LIGHT BULBS REPLACEMENT 12.8 SPEEDOMETER AND FUEL METER 12.9 WIRING DIAGRAM
12.1 TROUBLESHOOTING (The ATV serials in this manual have the same equipment) ENGINE STARTS BUT STOPS NO SPARK AT PLUG
ENGINE STARTS BUT RUNS POORLY
★ ★ ★ ★ ★ ★ ★ ★
★
★
★
IMPROPER IGNITION TIMING FAULTY SPARK PLUG ENGINE STOP SWITCH AT “ OFF “ POSTION GEARSHIFT BAR IS NOT AT NORMAL POSITION 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 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
CHARGING SYSTEM FAILURE
★ ★ ★
ENGINE INTERMITTENT POWER
★ LOOSE BATTERY CONNECTION ★ LOOSE CHARGING SYSTEM CONNECTION
STARTER MOTOR WILL NOT TURN
★ ★ ★ ★ ★ ★ ★
STARTER MOTOR AND ENGINE TURN, BUT ENGINE DOES NOT START HEAD LIGHT CAN NOT WORK
DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE FAULTY IGNITION SYSTEM ENGINE PROBLEMS FAULTY ENGINE STOP SWITCH THE SWITCH DO NOT PUSH TO THE “ON” POSITON ★ THE LIGHT BULB IS BURN OUT, NEED BE REPLACED 89
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12.2 IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire.
Measure the primary coil resistance.
STANDARD: 0.1 - 0.3Ω(20℃) Measure the secondary coil resistance with the spark plug cap in place.
STANDARD : 7.4 – 12 kΩ(20℃)
12.3 IGNITION TIMING The ignition advance is 15°± 3°/4000rpm The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not require adjustment.
12.4 ALTERNATOR EXCITER COIL Remove the seat / rear fender and front fender. (See chapter 10) Disconnect the exciter coil wire. Measure the resistance between the yellow / red wire and ground.
STANDARD : 460-700Ω (AT 20℃, 68℉)
12.5 BATTERY INFORMATION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging or using the battery in an open area. The battery contains sulfuric acid (Electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. Electrolyte is poisonous. If swallowed drink large quantities of water or milk and call a physician.
BATTERY VOLTAGE INSPECTION Battery is under the seat; you can see this battery after removing the seat. Measure the battery voltage using a voltmeter.
VOLTAGE: Fully charged: 13.1 V Undercharged: Below 12.0 V
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BATTERY REMOVAL Remove the seat, and then you can see the battery. Disconnect the negative cable and then the position cable and remove the battery.
BATTERY INSTALLATION Install the battery in the reverse order of removal. After installing the battery, coat the terminals with clean grease.
CHARGING Connect the charge positive cable to the battery Position terminal. Connect the charge negative cable to the battery negative terminal. Using 0.9A-charging current about 5 hours. (Normal charging) Or using 4A-charging current about 1 hour. (Quick charging) Keep flames and sparks away from a battery being charged. Quick charging should be limited to an emergency; Normal charging is preferred.
12.6 ELECTRIC STARTER Information A week battery may be unable to run the starter motor quickly enough. If the battery voltage is enough while the engine is not Cranking, the starter motor may be damaged.
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TROUBLESHOOTING Starter Motor Turns Slowly Weak battery. Poorly connected starter motor cable. Failed starter motor. Poorly connected battery ground cable.
Starter Motor Not Turn Engine stop switch at “off “position. Gearshift bar is not at neutral position. Check for a blown fuse near battery. Make sure that the battery is fully charged and in good condition.
12.7 LIGHT BULBS REPLACEMENT HEADLIGHT Remove the handle bar cover. Remove the central–front cover with headlight together. (For YXL-150)
(The right side picture is for YXL / CXL-150) Remove the bulb socket by turning it counterclockwise Replace the bulb with a new one Install the removed parts in the reverse order of removed
(For RXL-150)
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When you will remove the headlight, there are three screws on the side of light independently. Only remove those screws first, the headlight just can be pull down. Than if you want to replace the bulb, you can use the driver to remove the screw on the front side of light first.
For ERXL-150 (Viper.St) After you remove the screws on the top of headlight, it can be take off. Be careful around the headlight, there are many pins mold on the plastic.
INDICATOR Remove the handle bar cover Remove the indicator lamp unit by turning it counterclockwise. Replace a new one
(For RXL-150) There are two screws on the side of indicator.
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TAILLIGHT Install the remove parts in the reverse order of removal
EXL150 (2004 two-passengers)
(For RXL-150)
12.8 SPEED METER AND FUEL METER PARTS DRAWING
Headlight
It is for EXL150
Fuel meter
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Speedometer
Picture of right side is for EXL150(2004 two-passengers)
For EXL150(Viper. St)
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Picture of right side is for CXL150
For RXL150
REMOVAL Remove the headlight.
Headlight
Remove the brake pedal and the exhaust pipe.
Exhaust pipe
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Brake pedal
Remove the speed gear and the plate.
Speed gear
Plate
Disconnect the speed cable. Remove the speedometer and the fuel meter.
Fuel meter
Speedometer
Speed cable INSTALLATION Install the fuel meter and the speedometer. Connect the speed cable.
Install the speed gear and the plate.
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Install the exhaust pipe.
Install the brake pedal.
Install the headlight.
THE HEADLIGHT PHOTOGRAPH--EXL 150 (2004 two-passengers) EXL 150(Viper. St) have another shape but its cables position are the same as EXL 150(2004 two-passenger)
FUEL METER
ELECTRICAL 98
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SPEEDMETER
METER CABLE
METER CABLE
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METER CABLE
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METER SENSOR
12.9 WIRING DIAGRAM This diagram is for ATV YXL 150
鎖頭
控制器
點火線圈
整流器
自動阻風
起動馬達
電瓶
汽油錶
檔位指示燈
空檔
頭燈 尾燈 喇叭
ＣＤＩ組
熄火開關
剎車開關
油計面
磁電機
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ＣＤＩ組
繼電器
This diagram is for ATV CXL 150
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This diagram is for ATV EXL 150
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This diagram is for ATV EXL 150(2004 two-passengers)
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This diagram is for ATV EXL 150
(Optional)
1^ Reserve for a electric choke carburetor
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This diagram is for ATV EXL 150(VIPER ST)
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This diagram is for ATV RXL 150
(Optional)
1^ Reserve for a electric choke carburetor
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13.TROUBLESHOOTING 13.1 ENGINE DOES NOT START 13.4 LOSS POWER 13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 13.5 POOR HANDLING 13.3 POOR PERFORMANCE AT HIGH SPEED
13.1 ENGINE DOES NOT START POSSSIBLE REASON N.G. CHECK FUEL FLOW TO CARBURETOR O.K. N.G. SPARK TEST
WEEK OR NO SPARK
O.K.
N.G. TEST CYLINDER COMPRESSION
LOW COMPRESSION
★ ★ ★ ★
No fuel In fuel tank Clogged float valve Clogged fuel tank cap breather hole Clogged at fuel tube
★ ★ ★ ★ ★ ★ ★ ★ ★ ★
Faulty spark plug Fouled spark plug Faulty CDI unit Faulty alternator Faulty engine stop switch Poorly connected ,broken or shorted wires Broken or shorted ignition coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch
★ ★
Worn cylinder and piston rings Damaged cylinder head gasket
★ ★ ★ ★ ★
Auto choke off or damaged Auto choke power wire disconnected Improperly adjusted air screw Improperly ignition timing Fuel / air mixture ratio is too lean
★ ★ ★ ★ ★
Carburetor flooded Improperly adjusted air screw Fuel / air mixture ratio too rich Auto choke stuck or damaged Air cleaner dirty
O.K. ENGINE START BUT STOPS START THE ENGING
ENGINE DOES NOT FIRE
REMOVE AND INSPECT SPARK PLUG
WET PLUG
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13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS POSSIBLE REASON N.G.
CHECK IGNITION TIMING
★
Faulty CDI unit or pulse generator
★
Improperly adjusted air screw
★ ★
Deteriorated insulator o-ring Loose carburetor
★ ★ ★ ★ ★ ★ ★ ★ ★
Loose or disconnected ignition system wires Faulty ,carbon or wet fouled spark plug Faulty alternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch
O.K. CHECK carburetor AIR SCREW ADJUSTMENT
N.G.
O.K CHECK FOR LEAKING INTAKE PIPE
N.G
O.K.
PERFORM SPARK TEST WEEK OR INTERMITTENT SPARK
13.3 POOR PERFORMANCE AT HIGH SPEED POSSIBLE REASON N.G. ★
CHECK IGNITION TIMING
★
Faulty CDI unit Faulty pulse generator
★ ★ ★ ★
Lack of fuel in tank Clogged fuel line Clogged fuel valve Logged fuel tank breather hole
★
Clean with high pressure air gun
★
Clean the filter
O.K. CHECK FUEL TUBE AT CARBURETOR
FUEL FLOW RESTRICTED
FUEL FLOWS FREELY
REMOVE CARBURETOR CHECK FOR CLOGGED JETS
CLOGGED
NOT CLOGGED CHECK AIR CLEANER FILTER ELEMENT
DIRTY
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13.4 LOSS POWER POSSIBLE REASON RAISE WHEELS OFF GROUND AND SPIN BY HAND
DOES NOT SPIN FREELY
SPIN FREELY
CHECK TIRE PRESSURE
PESSURE LOW CHECK TIRE
★ ★ ★ ★
Brake dragging Drive chain too tight Damaged wheel bearing Wheel bearing needs lubrication
★ ★
Punctured tire Faulty tire valve
★ ★ ★ ★ ★
Fuel / air mixture ratio too rich or lean Clogged in air cleaner Clogged in muffler Restricted fuel flow Clogged fuel tank cap breather hole
★ ★
Faulty pulse generator Faulty CDI unit
★ ★
Leaking head gasket Worn cylinder and piston rings
★
Clean
★ ★
Clean the spark plug Spark plug is incorrect heat range
★
Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel / air mixture ratio is lean Use of poor quality fuel
PRESSURE NORMAL ACCELERATE LIGHTY ENGINE SPEED DOES NOT INCREASE ENGINE SPEED INCREASE N.G. CHECK IGNITION TIMING O.K. TOO LOW TEST CYLINDER COMPRESSION O.K.
CLOGGED CHECK CARBURETOR O.K. FOULED OR DISCOLOED CHECK SPARK PLUG O.K. CHECK FOR ENGINE OVERHEATING
OVERHEATING
★ ★ ★
O.K.
ACCELERATE OR RUN AT HIGH SPEED
KNOCKS
★ ★ ★ ★ ★
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worn piston and cylinder Fuel / air mixture ratio is lean Wrong type of fuel Ignition timing too advanced Excessive carbon deposited in Combustion chamber
13.5 POOR HANDLING POSSIBLE REASON STEERING IS HEAVY
★ ★
ONE WHEEL IS WOBBLING
★ Bent rim ★ Improperly installed wheel hub ★ Excessive wheel bearing play ★ Bent swingarm ★ Bent frame ★ Swing arm pivot bushing excessively ★ Worn
VEHICLE PULLS TO ONE SIDE
★ ★ ★ ★ ★
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Damaged steering bearing Damaged steering shaft bushing
Bent tie-rod Incorrect tie-rod adjustment Rear tie air pressure incorrect Improper wheel alignment Bent frame