om rts .c om tP ar ts .c 2i tP a .G et ar ts .c .G et w 2i w ETON America 2i tP .G et Covers: VXL-250 w w w w w w VECTOR Service Manual Copyright ©2008-2009 ETON America, llc., all rights reserved.
om CONTENTS tP a .G et 2i tP 2i .G et w w w w w w Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i .G et w w rts .c om tP ar ts .c 1. Information ........................................................................................................................ 5 1.1 Safety ........................................................................................................................... 5 1.2 Notes ..................................................
om tP a .G et 2i tP 2i .G et w w w w w w Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i .G et w w rts .c om tP ar ts .c 6.3 Troubleshooting ......................................................................................................... 40 6.4 Cylinder Head Removal............................................................................................. 41 6.5 Cylinder Head Inspection .................................................................
om tP a .G et 2i tP 2i .G et w w w w w w Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i .G et w w rts .c om tP ar ts .c 11.5 Crankshaft Inspection ............................................................................................ 100 11.6 Crankcase Assembly.............................................................................................. 101 12. Cooling System.................................................................................
tP ar ts .c 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. rts .c om • BATTERY ELECTROLYTE The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing.
om 1.3 Important Symbols and Specifications tP ar ts .c Symbols will appear throughout the manual to indicate important information or tasks. CAUTION – Safety notification. Proceed carefully. rts .c om ADJUSTMENTS – Requires inspection, adjustment, or torque. 2i FLUIDS – Lubrication or check and replace fluids. .G et MULTIMETER – Diagnostics and electrical testing. tP a MEASUREMENT – Gap and size measurements. ar ts .c w SPECIAL TOOL – Uncommon tools may be required. w w w w 2i tP .
Engine (Model No. VXL-250) Four cycle , Single Cylinder, Liquid cooled 249cc φ71mm * 63mm 10.6 : 1 22.3Nm @ 5500rpm / 16.4bhp Meets or exceeds EPA clean air requirements/CA Green Sticker Electrical with Kick starter back up Transmission Type Automatic (C.V.T. V-Belt) Manual Shift (Fwr/Rev) Chassis Suspension Dual A-arm Adjustable Shocks @ 2.95" travel Swing Arm Adjustable Shock @ 4.72" travel 2i Brakes Front Min Max Rear Min Max w Tire Pressure 21/7-10 22/11-9 3.2psi / 0.23kg/cm2 4.0psi / 0.
#520*90 O-Ring Battery Jell Acid (Maintenance Free) 12V-9AH - GTX12-BS Spark Plug NGK 2i NGK-CR8E Electrode Gap 0.6-0.7mm / 0.023" Available Colors 136kg / 301lb (Optional) 330kg / 727lb (Optional) 50kg / 110lbs 150kg / 330lbs 16 years Red Blue w w w w .G et w w .G et * Subject to availability N/A 2i Front Rear Trailer Wgh Towing Capacity Tongue Wgh Maximum Rider Weight Minimum Rider Age Rack Capacity tP a .G et Carrying Capacity Copyright ©2008-2009 ETON America, llc.
om .G et 2i rts .c om tP ar ts .c 1.4 Serial Number w ar ts .c 2i tP .G et w w .G et w 2i w tP a The frame number is stamped on the front of the frame behind the front bumper. w w w The engine number is stamped on the left hand side of the crankcase. Copyright ©2008-2009 ETON America, llc., all rights reserved.
5 N-m (3.5 lbf-ft) 10 N-m (7.2 lbf-ft) 22 N-m (16 lbf-ft) 35 N-m (25 lbf-ft) 55 N-m (40 lbf-ft) tP ar ts .
tP ar ts .c 2.1 MAINTENANCE DATA om 2. MAINTENANCE SPECIFICATION SPARK PLUG w w w w .G et 2i tP 2i w w .G et w Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 12-19 N-m / 8.9-14 lbf-ft 35-43 N-m / 25.8-31.7 lbf-ft 1.4 Liter (1.2Liter for change) 750cc / 25.4oz (650cc for change) tP a 2i w .G et GAP 0.6-0.7 mm / 0.023” NGK CR8E 5-10 mm / 0.20 - 0.39” 1700±100 rpm 15-25 mm / 0.59 – 0.98” 10-25 mm / 0.39 – 0.98” 5±10 mm / 0.20 ± 0.39” rts .
om Maintenance Schedule Four Stroke Vehicles tP ar ts .c WP-0027 Oil filter (Screen) Engine oil 5 Tire, pressure 6 Battery 7 Spark plug 8 Carburetor (idle speed) 9 10 Steering bearing and handles Check transmission for leak‐ age 11 12 Check crankcase for leakage Transmission oil 13 Drive belt/roller .
om 2.2 MAINTENANCE SCHEDULE tP ar ts .c The internal maintenance in the following table is based on average riding in normal temperate conditions. Riding in dusty areas requires more frequent servicing. E-TON recommends that all maintenance and inspections be performed ONLY by a qualified and fully trained technician. I C I I I, L I I I I I I I .G et 2i tP a I I, L I I I I (Every 30 operating days) I 2.3 FUEL TUBE w .G et Inspect the fuel lines for deterioration, damage, or leaking.
• 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. 2i • • • tP a w • .G et • Remove the four clips. Remove the two screws inside the air cleaner case. Remove the air filter element from the air cleaner case. Soak the element in nonflammable solvent. Squeeze out the solvent thoroughly.
• With the sealing washer attached, thread the spark plug in by hand to prevent cross threading. Tighten the spark plug to 12-19 N-m. 2i • .G et • 2.8 IDLE SPEED tP a 2i • .G et • Connect an engine tachometer. Allow the engine to idle for at least 10 minutes to warm it up. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. “Turn in” (clockwise) to increase speed. “Turn out” (counter clockwise) to lower speed. IDLE SPEED: 1700±100 rpm 2.
om TORQUE: 90N-m (65 lb-ft) When the drive chain becomes very dirty, it should be removed, cleaned, and lubricated. Use specialized chain oil to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for any possible wear or damage. Replace the chain if it is worn excessively or damaged. • 2i .G et Inspect the sprocket teeth. If there is excessive wear or damage, replace it.
om Parking brake OFF The standard is 15-25 mm. w w NOTE: The rear brake master cylinder and reservoir is located under the left hand rear fender. This master cylinder is preset from the factory and no adjustment is necessary. Ensure the fluid is at the maximum level in the reservoir at all times. w w w w .G et Brake Fluid Dot-3 SAE-J1703 grade 2i tP .G et w 2i w tP a .G et • Parking brake ON Page 16 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .
om 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails, or other sharp objects. • Check each tire surface at cold tire condition. • The standard tire pressure is 3.2-4.0 psi (maximum). 2i 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels turned straight ahead. • If there is excessive play, inspect the tie-rod, kingpin bushing, and ball joint. .G et w 2i w tP a .G et • w • .G et w • Remove the front fender.
2i • Carefully move the vehicle backward, letting the wheels turn 180 degrees, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference between the front and rear measurements. Toe-in: 5±10mm • • If the toe-in is out of the specification, 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 w .G et 2i tP a • .
3.1 General Information tP ar ts .c ENGINE SHOULD BE REMOVED ONLY WHEN NECESSARY TO REPAIR OR ADJUST THE TRANSMISSION OR COMBUSTION SYSTEMS. rts .c om 3.2 ENGINE REMOVAL 2i Before removing engine, remove all of components such as seat, front and rear body cover, fuel tube, exhaust pipe, carburetor cable and drive chain. The engine is attached with three hanger bolts which will be visible after removing the components. .G et Loosen these three hanger bolts.
om Top rear hanger bolt. • Lower rear hanger bolt. tP a .G et 2i rts .c om tP ar ts .c • 3.3 ENGINE INSTALLATION .G et w w w w • 2i tP w Torque the engine hanger bolts to 30 N-m (22.1 lbf-ft). Reroute the throttle cable. Connect the carburetor cable and all fuel lines. Reinstall the drive chain. Install the exhaust pipe. Ensure all electrical connections are properly connected (A/C generator, starter motor, etc.) Reinstall the front and rear body covers.
om 4. LUBRICATION SYSTEM w w w w Page 21 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
om 4-2 Maintenance Guidelines General Information: tP ar ts .c This chapter contains maintenance information for the engine oil pump and gear oil replacement information. Inner rotor clearance Clearance between outer rotor and body tP a Oil pump Items Torque value Limit (mm) 0.15 0.20 0.15~0.20 0.25 0.04~0.09 0.12 14.7 N-m / 10.8 lbf-ft – 29 N-m / 22 lbf-ft 19 N-m / 14 lbf-ft – 25 N-m / 18 lbf-ft 10 N-m / 7 lbf-ft – 15 N-m / 10.7 lbf-ft 8 N-m / 5.8 lbf-ft – 12 N-m / 8.7 lbf-ft .
Drain oil when the engine is warm so it drains completely. Place an oil pan under the ATV. Remove the oil drain bolt. Drain the oil. Remove the oil strainer and spring. Clean the oil strainer. Check the O-ring, and replace if necessary. Install oil drain bolt, spring, and strainer. Torque value: 19 N-m / 14 lbf-ft – 25 N-m / 18 lbf-ft Add recommended oil (SAE 10W30) – 1.2L / 1.2 qt. Start the engine and allow to run for several minutes.
om 4-6 Oil Pump Oil Pump Removal • Remove generator and starting gear. rts .c om Remove cir clip and take out the oil pump driving chain and sprocket. Make sure that pump shaft can be rotated freely. Remove the 2 screws on the oil pump. Remove the oil pump. Remove the screws on oil pump cover and remove the cover. Remove oil pump shaft roller and shaft. w • • w Oil Pump Disassembly 2i tP .G et Retaining Bolts ar ts .c tP a Circle Clip 2i • • • w w .G et 2i • tP ar ts .
om Check the clearance between the rotor side face and pump body. Limit: 0.12 mm rts .c om tP ar ts .c • • tP a Tighten the oil pump screw. 2i • w w .G et w w .G et 2i • • Pins Install the inner and outer rotors into the pump body. Align the indention on the driving shaft with the mark on the inner rotor. Install the oil pump shaft and roller. Install the oil pump cover and fixing pins properly. w .G et Oil Pump Installation Screw Install the oil pump and tighten screws.
om Install the oil pump drive chain and sprocket. Install the cir clip onto the oil pump shaft. Install the starting gear and generator. (Refer to chapter 10) w w w w Page 26 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
om 5. FUEL SYSTEM tP a .G et 2i rts .c om tP ar ts .c 5-1 Drawing of the Fuel System w w w w .G et w Manifold Page 27 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP w .
General Information Warning tP ar ts .c Gasoline is flammable and explosive, so always work in a well-ventilated place and strictly prohibit smoking or flames when working with gasoline. Caution rts .c om • Do not bend the throttle cable. • When removing fuel system components, remember where O-rings were positioned, and replace them when reassembling the components. • Drain gasoline using the drain screw on the float chamber before removing it.
Engine Will Not Start Mixture too rich Rough idle Intermittent Misfires When Accelerating • Malfunctioning ignition system 2i • Malfunctioning ignition system • Incorrect idle speed • Malfunctioning carburetor • Fuel dirty • Clogged air jet • Malfunction of float valve • Fuel level too high in float chamber • Malfunction of carburetor choke • Dirty air cleaner tP a .
om 5-4 Carburetor Removal / Installation Removal 2i tP Clamp Ensure the drain screw is tightened. Install carburetor into intake and tighten the two nuts. Reconnect all vacuum and fuel lines. Reconnect the air boot from the air box. Turn the fuel petcock on and check for leaks. w w • Fuel Line .G et Installation w w • • Vacuum Line Choke Cable ar ts .c 2i w Remove the top of the carburetor from the carburetor. Remove the 2 intake nuts. Remove the carburetor.
Disassembly Remove the two screws to gain access to the air cut-off valve. • Remove the air cut-off valve cover, spring, and valve. • w w • Check the valve for damage or wear. If the valve is undamaged, it will restrict air flow. If air flow is not being restricted, install a new carburetor kit. Ensure the vacuum pipe O-ring is undamaged and can be reused. Install in reverse order of removal. w w w w • .G et Assembly 2i tP 2i • • .
tP ar ts .c 5-6 Throttle Valve Disassembly Disconnect the throttle cable from the throttle slide and remove the valve spring. Remove the fuel needle clip and fuel needle. Assembly • • Carburetor Cap 2i • Place the fuel needle onto the throttle slide and clip it with the needle clip. Install the sealed cap, carburetor cap, and throttle valve spring. Connect the throttle valve cable to the throttle slide. Install the throttle slide into the carburetor body. .G et • Clip w .
tP a Float Float Pin 2i tP w • Check the float valve and valve seat for damage or blockages. Check the float valve for wearing, and check the valve seat face for wear or dirt. .G et • 2i Inspection ar ts .c Remove the float pin, float, and float valve. .G et • rts .c om 2i tP ar ts .c Disassembly • Remove the three mounting screws. • Remove the carburetor bowl. w w Float Valve .
om Remove main jet, needle jet holder, needle jet, slow jet, and air adjustment screw. tP ar ts .c • .G et Assembly tP a Install main jet, needle jet holder, needle jet, slow jet, and air adjustment screw. Install the float valve, float, and float pin. .G et • 2i Caution Set the air adjustment screw according to number of turns noted before it was removed Caution • .G et w • Check to ensure the float valve and float are properly installed.
• Use a tachometer when adjusting engine RPM. Screw in the air adjustment screw gently, then back out to reach the standard. Standard turns: 1 ½ turns out • Warm up the engine. .G et 2i • • • Accelerate in small increments. Ensure the RPM and CO values remain standard after the engine returns to idle. If the RPM or CO values fluctuated, repeat the procedures described above for adjusting to standard value. Idle Adjustment Screw w .
om 5-9 Fuel Tank Fuel Tank Removal Remove the seat Remove the front cover and fuel tank. Remove the side covers and lower side covers. Remove the front fender (see chapter 13). Remove the 4 bolts Remove the fuel sending unit rts .c om tP ar ts .c Caution • Fuel Unit Installation w • tP a .G et 2i • When removing the sending unit, be careful to not bend the arm on the fuel sending unit.
om tP ar ts .c 5-10 Air Cleaner 2i Installation Cleaning air cleaner element • • 2i Remove the air cleaner cover (4 latches). Remove the element mounting screw. Loosen the air cleaner element clamp strip, and then remove the air cleaner element. Clean the element with non-flammable or high-flash point solvent and then squeeze out the excess fluid. Let it dry. .G et • • • tP a Install the tank in the reverse order of removal. .
om 6. CYLINDER HEAD/VALVE w w w w Page 38 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
om 6-2 Operation Precautions General Information tP ar ts .c This section contains maintenance and service information for the cylinder head, valve, and camshaft, as well as the rocker arm. Cylinder head service can be carried out when the engine is in the frame. CYLINDER HEAD Specifications Compression pressure Intake Exhaust ID of valve rocker arm Rocker arm ID of valve guide Clearance between valve stem and guide Exhaust 140psi 5.90mm 5.85mm 5.70mm 5.65mm 11.982~12.000mm 12.080mm 11.
Valve reamer: 5.0mm Valve guide driver: 5.0mm Valve spring compressor tP ar ts .c • • • 6-3 Troubleshooting rts .c om Engine performance can be affected by problems in the top end. The trouble usually can be determined or by performing cylinder compression test and judging the abnormal noise generated. Low compression pressure 1. Valve Improper valve adjustment Burnt or bent valve Improper valve timing Valve spring damage Valve carbon deposit .G et 2i • • tP a 2.
om 6-4 Cylinder Head Removal .G et w w w w Page 41 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. Spark plug 2i tP .G et w Remove the side cover mounting bolts of cylinder head, and then take out the side cover. w • Tensioner bolts ar ts .c tP a • Remove Air Injection system (AI) pipe mounting bolts. Remove the spark plug. 2i • w w .G et • Thermostat Bolts Remove the 2 thermostat bolts and then remove the thermostat.
om • Remove the cam shaft setting plate (1 bolt). rts .c om w Remove the cam shafts. Special Service Tool Needed: Rocker arm and cam shaft puller ar ts .c Rocker Arm Shafts .G et w • • Setting Plate tP a 2i Remove rocker arm shafts and rocker arms. Special Service Tool Needed: Rocker arm and cam shaft puller .G et • • w w w w w w .G et 2i tP ar ts .
om Remove the cylinder head gasket and dowel pins. Remove the chain guide. Clean any gasket material from the surfaces of the cylinder and cylinder head. Do not scratch the surfaces or allow any material to fall into the crankcase. tP a 2i .G et w w • Use a valve cotter removal & assembly tool to depress the valve spring. Do not compress the spring too much to preserve its elasticity. Remove the valves. .G et • w w w w w w .
• Clean any carbon deposits in the combustion chamber. Clean residue and foreign materials from the cylinder head matching surface. Do not damage the surface of the cylinder head. • Check if the spark plug or valve holes are cracked. Replace if necessary. Measure cylinder head warping with a straightedge and thickness gauge. .G et • 2i 6-5 Cylinder Head Inspection w Camshaft w Inspect the cam lobe height for damage. Service Limit: w .G et IN: Replace if less than 34.45mm.
• • om Rocker Arm Check the rocker arm for wear or damage. Measure the rocker arm cam inner diameter. Rocker Arm Shaft • Measure the active O.D. of the rocker arm cam shaft and cam rocker arm. Service Limit: Replace when less than 11.91 mm. Find the clearance between the rocker arm shaft and the rocker arm. 2i Valve spring free length Valve stem w • Check if valve stems are bent, cracked, or burned. Check the operation condition of valve stem in the valve guide.
• om Valve guide tP ar ts .c Before measuring the valve guide, clean any carbon deposits with a reamer. Service limit: 5.03 mm The inner diameter of the valve guide minus the outer diameter of the valve stem is the clearance between the valve stem and valve guide. 2i • .G et Service Limit: IN→0.08 mm If clearance between the valve stem and valve guide exceeds the service limit, check whether replacing the valve guide will bring it into service limit. If so, replace just the valve guide.
Heat up cylinder head to 100-150C (212- 300F) with a hot plate or other device. Caution tP ar ts .c Do not heat the cylinder head directly. Otherwise, the cylinder head may be deformed. Wear a pair of gloves to protect your hands when operating. • Hold the cylinder head and press out the old valve guide from the combustion chamber side. rts .c om • Tool: Valve guide driver: 5.0 mm • w w w w .G et w w • Use cutting oil when correcting the valve guide with a reamer.
Remove the valve and check its contact face. Replace the valve if the valve seal is rough, worn out, or does not come into contact with the valve seat. If the valve seat is too wide, narrow, or rough, adjust or replace it. 2i • • Valve seat width Service limit: 1.6mm • Check the condition of the valve seat surface. 2i Valve seat grinding The worn valve seat has to be ground with a valve seat chamfer cutter. Refer to operation manual for the valve seat chamfer cutter.
Use a 60° cutter to cut the quarter lower parts out. Remove the cutter and check the new valve seat. • Use a 45° cutter to grind the valve seat to the specified standard width. Make sure that all roughness and uneven faces have been ground. Grind the valve seat again if necessary. • If the contact surface is too high, grind the valve seat with a 32° cutter. Then, grind the valve seat to the specified width. If the contact surface is too low, grind the valve seat with a 60° cutter.
om • After the valve seat is ground, coat valve seat surface with emery and then carefully press the ground surface. Clean up all emery coated onto cylinder and valve after grinding. tP ar ts .c • • NOTE: The valve spring closed coils should face down toward the combustion chamber. .G et • In order to avoid damaging the valve stem and the cylinder head, place a rag in the combustion chamber inside by the valve spring remover/installer while compressing the valve spring.
Install the 4 washers and tighten the 4 nuts on the top of the cylinder head, and then tighten the 2 cylinder head mounting bolts on the right side of the cylinder. 2i • tP a Install the camshaft into the cylinder head. Install the rocker arm and rocker arm shaft. 2i • • w • w .G et w w .G et Torque values: Nut: 26-29 lbf-ft Bolt: 7-10 lbf-ft w w w w .G et Install the rocker arm pin mounting plate. Page 51 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .
• • Install the cylinder head side cover (3 bolts). Install the thermostat (2 bolts). tP a .G et w Install cylinder cover (4 bolts). w w w w .G et w • 2i tP 2i • Thermostat bolts Loosen the auto tensioner adjustment bolt and remove the bolt and spring. Install the tensioner and install the spring and adjustment bolt. w w • rts .c om tP ar ts .c .G et 2i • om • Install the cam chain onto the sprocket and align the timing mark on the sprocket with that of cylinder head.
Install the Air Injection system pipe. (4 bolts) Install the inlet pipe onto the cylinder Install and tighten the spark plug tP ar ts .c • • • om Spark plug Torque value: 7-14 lbf-ft 6-10 Valve Clearance Adjustment Loosen the two Air Injection system pipe upper side bolts. Remove the cylinder head cover. Remove the cylinder head side cover. Remove the left crankcase cover.
om 7. CYLINDER/PISTON w w w w Page 54 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
om 7-2 Operating Details General Information tP ar ts .c Remove the engine from the frame before servicing the piston or cylinder. Cylinder Specifications 70.995-71.015 71.100 - 0.050 Top ring 2nd ring 0.015-0.050 0.090 0.015-0.050 0.090 Top ring 2nd ring 0.150-0.300 0.500 0.300-0.450 0.650 Oil ring side rail 0.200-0.700 - 70.430-70.480 70.380 0.010-0.040 0.100 17.002-17.008 16.970 16.994-17.000 16.960 0.002-0.014 0.020 17.016-17.034 17.
tP ar ts .c Check if the inner diameter of cylinder is worn out or damaged. In the top, center, and bottom, of the cylinder, measure the X and Y values in respect to the cylinder. w w .G et Inspection w w Service limit: 71.016 mm w • 2i tP • Page 56 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c tP a 2i Remove the cylinder gasket and dowel pin. Clean up all gasket residue or foreign materials from the surfaces of the cylinder and crankcase.
om Inspect the cylinder for warping. Be careful when handling piston rings, as they are very fragile. Check if the piston rings are damaged or if the grooves are worn. • Place the piston rings into the cylinder 20 mm under the cylinder top. In order to keep the piston rings in even horizontal levels, push the rings in with the piston. .G et w w • w .G et 2i • w w Removing Piston Rings tP a .G et 2i Service Limit: Top ring: 0.09 mm 2nd ring: 0.09 mm w w w Service Limit: Top ring: 0.
om Measure the outer diameter of the piston pin. .G et w w w w • • Measure the piston outer diameter. The measurement position is 10 mm from the piston bottom side, at a 90° angle to the piston pin. Service limit: 71.00 mm Compare measured value with service limit to calculate the clearance between piston and cylinder. w • • w .G et w • Measure the inner diameter of the piston pin hole. Service Limit: 17.02 mm Calculate the clearance between the piston pin and its hole. Service Limit: 0.
om 7-5 Piston Ring Installation tP a .G et .G et w .G et w 2i tP 2i w w w w w w Page 59 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .c om tP ar ts .c Clean the piston top, ring groove, and piston surface. Install the piston ring onto the piston carefully. Place the piston ring openings as shown in the diagram. Do not damage piston or piston rings. All marks on the piston rings must be on the top side facing forward.
Clean up all residue and foreign materials on the surface of the crankcase. Do not let residue or foreign materials fall into the crankcase. • Remove the residue with solvent to aid in cleaning. • • .G et w 2i w tP a .G et • Install the piston and piston pin, placing the IN marks on the piston top side facing the inlet valve. Install a new piston pin clip. Do not let the opening of the piston pin clip align with the piston cutout.
Do not push the piston into the cylinder forcefully or the piston and piston rings will be damaged. • • Install the coolant hose onto cylinder. Install the cylinder head (refer to Chapter 6). .G et 2i tP ar ts .c • rts .c om w w w w .G et w w Page 61 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c .G et w 2i w tP a Coolant hose 2i tP • • Apply engine oil to the inside of the cylinder, piston, and piston rings.
om 8. V-BELT TRANSMISSION SYSTEM w w w w Page 62 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
• • tP ar ts .c Operating Procedures General Information Drive face, clutch outer, and driven pulley can be serviced while still installed. Drive belt and drive pulley must be free of grease. Standard value (mm) Limit (mm) 24.000 22.500 OD of movable drive face boss 29.946~29.980 29.926 2i ID of movable drive face 30.000~30.040 30.060 OD of weight roller 19.500~20.000 19.000 144.850~145.150 145.450 6.000 3.
Left crankcase cover removal Release the 2 clamps on the left hand crankcase cover ducts, and then remove the ducts. • Remove the left crankcase cover. (9 bolts) • Remove the 2 dowel pins and the gasket. tP a Reinstall left crankcase cover in the reverse order of removal. 2i .G et Removal w Remove the left hand crankcase cover. Hold the drive face with a universal holder Remove nut and drive face. Special Tool: Universal holder w .
om • • 2i Inspection tP a w .G et w • Pull out the driven face to keep it from closing. Be careful not to press the friction plate too hard to avoid warping or damage. Install the drive belt onto driven pulley. w • • • Install the driven pulley with the belt already installed onto drive shaft. On the other end of the drive belt, install the movable drive face. w w w • 2i tP 2i Installation .G et w w .G et • Check the drive belt for crack or wear. Replace it if necessary.
om Install the clutch outer and bearing stay collar. Hold the clutch outer with a universal holder. Tighten the nut to specified torque value. Torque value: 5.0-6.0kgf-m / 36-43 lbf-ft • • • • Install the drive face, washer, and drive face nut. Hold the drive face with a universal holder. Tighten the nut to specified torque value. Torque value: 8.5-10.5kgf-m / 61-76 lbf-ft .G et 8-6 Drive Face tP a Remove the left crankcase cover. Hold the drive face with a universal holder.
Remove the ramp plate. • Remove weight rollers from movable drive face. • tP a w • w • Check if drive face boss is worn or damaged and replace it if necessary. Measure the outer diameter of movable drive face boss, and replace it if it exceeds service limit. Service limit: mm .G et • • w w • Measure the inner diameter of movable drive face, and replace it if it exceeds service limit. Service limit: mm w • 2i tP • .
Install the weight rollers. • The weight roller end surfaces are not necessarily the same. In order to lengthen the rollers’ lifetime and prevent premature wear, install the weights in a counterclockwise order onto the movable drive face. • Install the ramp plate. tP a • w w w w .G et w Install the movable drive face assembly onto the crankshaft. 2i tP The movable drive face surface must be free of grease. Clean it with cleaning solvent. .
Press the drive belt into the pulley groove, and then pull the belt onto the drive shaft. • • Install drive face, washer, and nut. Ensure the two sides of the pulley surfaces are free of grease. Clean with cleaning solvent if necessary. Hold the drive face with a universal holder. Tighten nut to specified torque. Torque value: 8.5-10.5kgf-m / 61-76 lbf-ft • Install the left crankcase cover. 2i tP a • .G et 8-7 Clutch Outer/Driven Pulley • Do not overexert the compressor. w .
om 2i Clutch Outer • 2i .G et Clutch Lining w Driven Pulley Spring Measure the length of the driven pulley spring. Replace it if it exceeds service limit. Service limit: 83.2 mm .G et • • • 2i tP Measure each clutch weight thickness. Replace it if it exceeds service limit. Service limit: 2.0 mm w • • • w w w w w w • tP a .G et • Measure the inner diameter of the clutch outer. Replace the clutch outer if it exceeds the service limit. Service limit: 145.
om Driven Pulley Replace damaged or worn components. Measure the outer diameter of the driven face and the inner diameter of the movable driven face. Replace if either exceeds service limit. 2i rts .c om Service limit: • Outer diameter 33.94 mm • Inner diameter 34.06 mm .G et Driven Pulley Bearing Inspection • 2i • .G et w w • Check if the inner bearing oil seal is damaged. Replace it if necessary. Check if needle bearing is damaged or has too much clearance. Replace it if necessary.
om • Install the spring into the groove with pliers. tP a .G et Install the snap ring and mounting plate onto setting pin. • Remove the inner bearing. • If the inner bearing equipped with an oil seal on its side in the driven pulley, then remove the oil seal first. If the pulley equipped with a ball bearing, remove the snap ring and then the bearing. .G et w w • .G et Remove the snap ring and then push the bearing forward to the other side of the inner bearing.
• The sealing end should be facing outside after installation. Install the needle bearing with a hydraulic presser. Install the ball bearing with a hydraulic presser. Install the snap ring into the groove on the drive face. Align oil seal lip with bearing, and then install a new oil seal (if necessary). 2i • tP a .G et • 2i w .G et w w • Install a new oil seal and O-ring onto the movable driven face. Apply grease to lubricate the inside of the movable driven face.
om Install the collar. • Install the friction plate, spring, and clutch weight onto a clutch spring compressor, and press down the assembly by turning the manual lever until the mounting nut can be installed. Hold the compressor with a bench vise and tighten the mounting nut to specified torque with clutch nut wrench. Remove the clutch spring compressor. Torque value: 5.0-6.0kgf-m / 36-43 lbf-ft Install clutch outer/driven pulley and drive belt onto drive shaft.
om 9. FINAL DRIVE SYSTEM w w w w Page 75 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
Specification • Application oil: scooter gear oil Recommended oil: KING MATE serial gear oil Oil quantity: 750cc (650cc when replacing) tP ar ts .c • • Gear box cover 2.6-3.0kgf-m / 19-22 lbf-ft Gear oil drain bolt 0.8-1.2kgf-m / 6-9 lbf-ft Gear oil fill bolt 3.5-4.
om 9-4 Disassembly of Transmission Remove gear change lever (1 bolt). • • Remove the 3 bolts. Remove the drive chain protector. .G et w w w w • • 2i tP .G et w Remove gear oil fill bolt. Place an oil pan under the ATV. Remove the gear oil drain bolt. After draining, check whether washer can be re-used. Replace if not. Install the oil drain bolt. Torque values: Gear oil fill bolt 3.5-4.5 kgf-m Gear oil drain bolt 0.8-1.2 kgf-m w • • • • Page 77 of 151 Copyright ©2008-2009 ETON America, llc.
om Remove the gear box cover bolts (9 bolts). Remove the cover. • Remove the shift drum catch ball, spring, and bolt. .G et 2i tP .G et w w Remove the final shaft, counter shaft, and reverse shaft. w w w w • Page 78 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .c om tP a Remove the shift spindle, shift fork shaft, shift fork, and shift drum. 2i • w w .G et 2i tP ar ts .
Remove the drive shaft bearing setting plate (one bolt). • • • Remove the drive shaft. Special tool: Shaft protector Remove the gasket and dowel pin. w w w w .G et 2i tP 2i w w .G et w w • Unless it is necessary, do not remove the drive shaft from the case upper side. If the drive shaft is removed from the gear box, the bearing and oil seal must be replaced. Page 79 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c • tP a .G et 2i rts .c om tP ar ts .
om 9-5 Transmission Mechanism Inspection Check the shift spindle for wear or damage. • Check the shift drum for wear or damage. Check the shift fork and shaft for wear or damage. • Check the counter shaft for wear or damage. .G et 2i tP 2i w w .G et w w w w w Page 80 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c • w rts .c om tP a .G et 2i tP ar ts .
Check the reverse shaft for wear or damage. • Check the final shaft and gear for burning, wear, or damage. tP a If the drive shaft is removed from the crankcase upper side, the bearing has to be replaced. w w w w .G et w w • 2i tP • 2i • .G et • • • Check the bearings on the gear box and gear box cover. Rotate each bearing’s inner ring with fingers. The bearing should turn smoothly and quietly. Check if the bearing outer ring is mounted on the gear securely.
Never install used bearings. Once a bearing is removed, it must be replaced with new one. tP ar ts .c • om 9-6 Bearing Replacement Crankcase side • Special tool: Inner bearing puller Install new final shaft, counter shaft, and reverse shaft bearings into the left crankcase. 2i • Install new drive shaft bearings with a bearing driver into the left crankcase. • .G et w • Install the universal bearing puller with the bearing driver.
Install the drive shaft. 2i Special tool: Drive shaft and oil seal install bush Install the drive shaft bearing setting plate (1 bolt). tP a .G et • Gear box side Use inner bearing puller to remove the final shaft needle bearing, gear shift shaft bearing, and counter shaft bearing from the cover inner side. Special tool: .G et 2i • .G et Remove the final shaft cir clip from the outer bearing.
Remove the final shaft outer bearing. om Special tool: Inner bearing puller Remove the oil seal from the gear box cover and discard the seal. • Install a new bearing with the bearing driver into the outer gear box cover. Install the universal bearing puller with the bearing driver. • .G et w • Install new oil seal and bearing driver into gear box cover inner side. Install the universal bearing puller and bearing driver. Turn the universal bearing puller to install drive shaft oil seal.
om 9-7 Final Drive Reassembly Apply grease onto the oil seal lip of the final driving shaft. • Install the counter shaft, reverse shaft and final shaft onto the gear box. Install shift drum, shift fork, and fork shaft onto gear box. • Install shift drum fixed catch ball, spring, and bolt onto gear box. w w w w 2i tP .G et w w .G et w 2i w • Page 85 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .c om tP a .G et 2i tP ar ts .
• Install dowel pins and a new gasket. Install the gear box cover and bolts. Torque value: 1.0-1.4kgf-m / 7-10 lbf-ft • Install the shift spindle bracket, drive chain protector, and gear change lever. Add gear oil. Gear oil quantity: 750cc of 85/140 weight gear oil w w w w .G et 2i tP w w • • .G et w 2i w tP a • • Page 86 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c .G et 2i tP ar ts .
om 10. A/C GENERATOR & STARTING CLUTCH w w w w Page 87 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
om 10-2 Maintenance Notes General information Refer to chapter 17: The troubleshooting and inspection of alternator Refer to chapter 17: The service procedures and precaution items of starter motor tP ar ts .c • • Specifications Standard value (mm) Limit (mm) rts .c om Item ID of starting clutch gear 25.026~25.045 25.100 OD of starting clutch gear 42.175~42.200 42.100 2i Torque value Flywheel puller: SYM-3110A00 Universal holder: SYM-2210100 w w w w 2i tP .G et w w .
Remove the left footrest. Drain out the engine oil and coolant. Remove the coolant hoses. Remove the water pump cover (4 bolts). Remove 11 bolts from the right crankcase cover. Remove the right crankcase cover. Remove dowel pin and gasket. 10-5 Right Cover Bearing 2i Remove the cir clip. Remove the bearing. w • • .G et • Rotate the bearing with your finger. Make sure the bearing turns smoothly and quietly. Check if the bearing outer parts are closed and fixed. Replace if necessary. w • .
Check the oil seal for wear or damage. Replace if necessary. • Install a new bearing (6201LU) with a bearing driver. Remove the right crankcase cover. • • Remove the left crankcase cover. Hold the flywheel by the drive face with a universal holder. Remove the flywheel nut. w w w w .G et Special tool: Universal Holder 2i tP w w • .G et w 2i w • Page 90 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 10-6 Flywheel Removal tP a .
Remove the starter reduction gear and shaft. Pull out the flywheel with a flywheel puller tool. Remove the flywheel and starting driven gear. 10-7 Starting Clutch Starting Clutch Inspection Remove the starting clutch driven gear. Inspect the gear for wear or damage. Measure the ID and OD of the starting clutch driven gear. 2i • • • tP a .G et Service Limit: ID: 25.1 mm OD: 42.10 mm Inspect the starting reduction gear and shaft for wear or damage. • Check each roller for wear or damage.
• om • Install the starting clutch driven gear onto the one way clutch. Hold the flywheel and rotate the starting clutch gear. The starting clutch gear should be rotated counterclockwise freely, but not clockwise. tP ar ts .c • w w w w 2i tP .G et w w .G et w 2i tP a .G et Remove the 3 socket bolts. Remove the one way clutch. w • • Page 92 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c Remove the starting driven gear. 2i • rts .
• Install the starting driven gear. 2i • Align the key on the crankshaft with the flywheel groove. Install the flywheel. • • Hold the flywheel by drive face with a universal holder. Tighten the flywheel nut. Torque value: 5.0~6.0kgf-m w • .G et w w • w w w w .G et w Special tool: Universal Holder Page 93 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 10-8 Flywheel Installation tP a .G et 2i rts .c om tP ar ts .
om Install the reduction gear shaft and the reduction gear. tP ar ts .c • • Install the A/C generator coil set onto the right crankcase cover (3 screws). Install the A/C generator (2 screws). Attach the wire harness securely onto the indention of the crankcase. Ensure that the wire harness is placed under the A/C generator. 2i • • rts .c om 10-9 ACG Set Installation tP a .G et • • • Remove the water pump cover. Install the right crankcase cover onto the crankcase.
om Install the right crankcase cover (11 screws). Install the dowel pin, a new gasket, and the water pump cover onto the crankcase cover • Connect the water hoses to the right crankcase cover and water pump cover. w w w w Page 95 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
om 11. CRANKCASE / CRANK w w w w Page 96 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
Maintenance Notes rts .c om 2i Specifications - Crankshaft Item tP a .G et Connecting rod side clearance of the larger end Vertical clearance of the larger end of the connecting rod Run-out Torque value 2i Bolts for crankcase: 0.8~1.2kgf-m / 6-9 lbf-ft Engine oil drain bolt: 3.5~4.5kgf-m / 25-33 lbf-ft Cylinder stud bolt: 1.0~1.4kgf-m / 7-10 lbf-ft .G et • • • Standard (mm) 0.100~0.400 0~0.008 0.030 Special tools L.
om 11-4 Crankcase Disassembly Remove the cam chain setting plate. Remove cam chain. Loosen the pivot bolt and remove the tensioner. • Loosen the 2 bolts on the right crankcase. Loosen the 11 bolts on the left crankcase. • Place the right crankcase facing downward and the left crankcase facing upward. Gently tap the left crankcase with a plastic hammer to remove it. Care should be taken not to damage the contact surfaces. w w w w 2i tP .G et w • w • .
Remove the balance shaft from the right crankcase. • Remove the crankshaft from the right crankcase. tP a Remove the gasket and dowel pins. Gently scrape gasket residue off the crankcase contact surface. • • Do not damage contact surface of the gasket. It is recommended to moisten the gasket residue for easier removal. • Remove the left crankcase oil seal. w w w w 2i tP .G et w w .G et 2i • • Page 99 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i .
.G et 2i • Measure the clearance of the larger end in the vertical direction. Service limit: 0.05 mm Place the crankshaft on a V-block. Measure the run-out of the crankshaft. Service limit: 0.10 mm tP a • • • 2i .G et w • Special tool: Outer bearing puller w w w w • .G et • Use your hand to turn the bearing. It should turn smoothly and quietly. Check the inner ring to ensure it links firmly on the bearing. If any roughness, noise, or loose linkage is detected, replace the bearing.
• • Special tool: Inner bearing puller Special tool: Bearing driver 2i 11-6 Crankcase Assembly Install the wave washer into the right crank bearing seat. • w tP a Install the crank shaft on the right crankcase. .G et w w w w .G et w Align the position mark on the balance shaft drive gear with that of balance shaft driven gear, and then install the balance shaft onto right crankcase. 2i tP 2i • w w .G et • Page 101 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved.
Install the 2 dowel pins and a new gasket. • Install the left crankcase onto the right crankcase. Tighten the 11 bolts on the left crankcase. Torque value: 0.8~1.2kgf-m / 6-9 lbf-ft • • Tighten the 2 bolts on the right crankcase. Torque value: 0.8~1.2kgf-m / 6-9 lbf-ft w w w w 2i tP .G et w w .G et w 2i w • • Page 102 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .c om tP a .G et 2i tP ar ts .
Clean the crankshaft. Apply a layer of grease on the lip of oil seal. Install the left crankshaft. Install the oil seal in the left crankcase. Be careful not to damage the lip of the oil seal. • Use an oil seal driver (27×42×7) to install and secure the oil seal. .G et 2i tP .G et w w w w w w Page 103 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .c om tP a Install the tensioner and tighten the pivot bolt. Torque value: 0.8 ~1.
om 12. COOLING SYSTEM w w w w Page 104 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
Refill the radiator only with distilled water and anti-freeze solution. Add coolant to the reservoir only. The cooling system can be serviced while installed on the ATV. Never spill the coolant onto painted surfaces. Test the cooling system for any leaking after the repair. Refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the water thermometer. rts .c om 2i Technical Specifications Specification 0.9±0.15 kgf/cm2 850c.c. 420c.c. tP a .
Engine temperature too high Water thermometer or temperature sensor malfunctioning. Thermostat stays closed. Insufficient coolant. Water hose or jacket clogged. Fan motor malfunctioning. Radiator filler cap malfunctioning. tP ar ts .c • • • • • • • • Water thermometer or temperature sensor malfunctioning. Thermostat stays open. Coolant leaking Water pump mechanical seal loose or malfunctioning. O-ring worn or damaged. Water hose broken or worn. 2i • • • rts .c om Engine temperature too low .
Pressure which is too high may damage the radiator. Never use pressure which exceeds 1.05 kg/cm2. 2i • If the system fails to maintain the specified pressure for at least 6 seconds, repair or replace. .G et • • • • 2i w • • Coolant recommended: SYM Bramax radiator agent. Concentration: 50% w w w • Coolant reservoir Water pump .G et w • • Remove the front center cover. Remove filler cap. Place a water pan under the water pump. Loosen the drain bolt to drain out the coolant.
om Reserve Tank Inspection Inspection • Remove the front center cover, side covers, and front fender. Check for any leaking from the welded seam. Blow the radiator clean using compressed air. If the radiator is blocked by dirt or foreign material, use a low pressure water jet to clean it. Be careful when straightening the sink fan. • tP a .G et 2i • • Removal Place a water pan under the water pump. Loosen the drain bolt to drain out the coolant. • Remove the coolant filler pipe. .
om Loosen the radiator 4 bolts. Remove the coolant upper side pipes. • • Remove coolant outlet pipe. Disconnect the couplers for the thermo switch and fan motor. Remove the radiator and cooling fan. Liquid packing must be applied to the thermo switch before installation to avoid damaging the radiator. Installation w Install the removed parts in the reverse order of removal. Install the radiator in the reverse order of removal. w • • w w • .
Water pump Upon installation, inspect for any leaks. om 12-7 Water Pump 2i • Place a water pan underneath the unit. Remove the coolant drain bolt. Ensure all the coolant is drained from the cooling system. Inspect the drained coolant for any unusual material or dirt. If there is, the inner water pump seals or cooling system may be damaged. The cylinder or cylinder head gasket may also be damaged; take apart the crankcase and inspect these before dismantling the cooling system.
om rts .c om Mechanical Seal Replacement • • 2i • Remove the inside bearing by inner bearing puller. Drive the mechanical seal and inner seal out of the right crankcase. Special tools: o Inner bearing puller o Water pump bearing driver Replace the mechanical seal and inside seal after removing it. tP a Apply a coat of sealant to the adjoining surfaces of the right crankcase before installing the new mechanical seal. • Install the mechanical seal onto the right crankcase.
.G et w Install the cir clip onto the inner bearing to secure it. w w w w .G et w • Page 112 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c tP a Mount the water pump shaft and the inner bearing to the right crankcase cover. 2i • w w .G et 2i • 2i tP • Install a new outside bearing to the right crankcase cover. Special tool: Water pump bearing driver (6901) Note: Do not reuse old bearing. It must be replaced with a new one once it has been removed. rts .
Install the seal washer into the rotor. Note: The washer must be replaced together with the mechanical seal. • Install the rotor onto the water pump shaft and tighten. Torque Value: 1.0-1.4kgf-m The rotor is left hand threaded. • • Install the dowel pin and new gasket. Install the water pump cover (4 bolts). .G et w w w w w .G et w 2i tP 2i tP a • Install the dowel pin and right cover gasket.
Please refer to chapter 17 for inspection of the temperature sensor. tP ar ts .c • om 12-8 Thermostat Removal Drain the coolant. Remove the thermostat set. (2 bolts) Visually inspect the thermostat for any damage. .G et 2i • • Place the thermostat into heated water to check its operation. Do not let the thermostat or thermometer touch the side of the water container to ensure an accurate reading.
om 13. STEERING AND SUSPENSION w w w w .G et w w STEERING Page 115 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w 2i w tP a .G et 2i rts .c om tP ar ts .c 13.
om rts .c om tP ar ts .c 2i tP a .G et w w w w Page 116 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .
Steering Too Hard o Faulty tire o Steering shaft holder too tight o Insufficient tire pressure o Faulty or damaged steering shaft bushing • Front Wheel Wobbles o Faulty tire o Worn front brake drum bearing o Bent rim o Axle nut not tightened properly • Steering Pulls To One Side o Bent tie rods o Wheel installed incorrectly o Unequal tire pressure o Bent frame o Worn swing arm pivot bushings o Incorrect wheel alignment Nose in the Front Suspension o Loose front suspension fasteners o Suspension link bo
w w w w Page 118 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et • Remove the bolts attaching the handlebar upper holder. Remove the handlebar. 2i • tP a .G et w w rts .c om Remove the handle cover and instrument panel by the four screws at the right and left sides shown in the picture. 2i • om • Remove the handle bar switch on the left handle bar. Remove rear brake lever bracket assembly. tP ar ts .
om INSTALLATION • tP a .G et w w .G et • Install the rear brake lever bracket, aligning the small dot of the handlebar. Tighten the screw securely. 2i • w w w w w w .G et 2i • Install the switch housing, aligning the small dot of the handlebar. Tighten the upper screw first, and then tighten the lower one. Page 119 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c • 2i tP • rts .c om • Put the handlebar on the lower holders.
om 13.4 THROTTLE HOUSING Loosen 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. rts .c om 13.5 STEERING SYSTEM 2i Removal of Kingpin and Tie-rod Remove the front wheels and hub assembly. Remove the four self-lock nuts from the tie-rod ball joints and take off the two tie-rods. Nut Inspect the tie-rod for damage or bending.
om Steering Shaft Removal 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: 39.5 mm 2i • • • Steering Shaft Inspection • Inspect the steering shaft for damage or cracks. 2i w w w • • 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.
tP ar ts .c 14.1 PARTS DRAWING w w w w .G et 2i tP 2i w w .G et Front Brake Page 122 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c tP a .G et 2i rts .c om Front Wheel w w om 14.
om 14.2 TROUBLESHOOTING Hard Steering o Faulty tire o Insufficient tire pressure • Front Wheel Wobbling o Faulty tire o Worn front brake drum bearing o Bent rim o Axle nut not tightened properly • Brake Drag o Incorrect brake adjustment o Sticking brake cable • Steering Pulls to One Side o Bent tie rods o Wheel installed incorrectly o Unequal tire pressure o Incorrect wheel alignment .G et 2i tP 2i w w .G et w w w w w Page 123 of 151 Copyright ©2008-2009 ETON America, llc.
REMOVAL Install and tighten the four-wheel nuts Torque: 24 N.m (17.7 lbf.ft) Remember to put a cotter pin in the castle nut. 2i 14.4 HYDRAULIC BRAKE This applies to the two front brakes of the unit. 2i tP a .G et • REMOVAL w w w w .G et w w • Raise the front wheels off the ground by placing a jack or other support under the frame. Remove the front wheel nuts, washer, and front wheels. .G et • Page 124 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .
om Remove the two bolts on the caliper to remove it. • After disassembling the wheel, inspect the disk plate. If the disk plate needs to be changed, loosen the castle nut to take the wheel hub apart. Before loosening the castle nut, remove the cotter pin. w Note: Pull the master cylinder back when changing the brake shoe. w • .G et w • w w w Reinstall the front brake assembly in reverse order of removal. Page 125 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .
om BRAKE OIL REPLACEMENT 14.5 SUSPENSION SYSTEM Suspension in this type of ATV can be adjusted. There are two ways to adjust suspension: o 1. You can raise the all ATV body up by using a repair platform. The four wheels are in the free position, and the suspension can be adjusted easily. o 2. If a repair platform is not available, use a specialized tool to adjust it. This will require more effort. .G et w 2i w tP a .G et 2i • • w w w w 2i tP .
om 15. REAR WHEEL AND BRAKE SYSTEM tP a .G et 2i rts .c om tP ar ts .c 15.1 PARTS DRAWING w w Page 127 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et Rear Wheel Axle w w w w .
om rts .c om tP ar ts .c 2i tP a .G et w w w w Page 128 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .
om 15.
om Loosen the two bolts to remove the rear brake caliper. .G et Loosen the bolt shown in the picture. w w w • 2i tP w w Brake Shoe Replacement Page 130 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c tP a 2i Loosen the bolts and remove the brake disc Check the thickness of the disc. Replace if the thickness less than 3mm. .G et • • w w w .G et 2i rts .c om tP ar ts .
om Push the plate back to take the shoe out as shown in the picture. tP a .G et w w w w .G et w w The two types of brake linings are shown in this picture. 2i tP 2i w w • Page 131 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c Remove the brake shoe from the hub. .G et • rts .c om 2i tP ar ts .
om 2i • 2i .G et w w • Pull the left brake lever gently to extract air from brake system. Fill the brake oil to the level shown on the cup when no more air comes out. Assemble the cover .G et • w w w w w w • tP a • • Page 132 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c Add the brake oil (DOT 3 or DOT 4). Keep oil level at least halfway up the cup to prevent air from getting into the brake system. Loosen the bolt to vent the air from brake system.
om 2i tP a .G et 2i Swing arm .G et Tighten the hanger bolt on the right side as shown in picture. w w w w • 2i tP w w • Put the swing arm at the proper position as shown in picture. Two hanger bolts are used to hold the swing arm at its right and left side. .G et • ar ts .c This section introduces how to repair and install the swing arm. w w rts .c om tP ar ts .c 15.4 SWINGARM & REAR AXLE HOLDER Page 133 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved.
om .G et 2i tP 2i w w .G et w w w w w Page 134 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .c om Tighten the nut shown. w • tP a .G et 2i • Screw another hanger bolt on the left side as shown in the picture, but do not tighten it. Make sure the cross-section of bolt and crosssection of the hole are in the same plane. tP ar ts .
om Suspension Adjustment Suspension in this type of ATV can be adjusted. There are two ways to adjust suspension: o 1. You can raise the all ATV body up by using a repair platform. The four wheels are in the free position, and the suspension can be adjusted easily. o 2. If a repair platform is not available, use a specialized tool to adjust it. This will require more effort. w w w w Page 135 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .
2i .G et w w w w 2i tP .G et w w EXHAUST PIPE Page 136 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c tP a .G et 2i rts .c om tP ar ts .c 16.1 FENDERS DRAWING w w om 16.
Remove the rear rack. Loosen the four bolts which connect the front fender and rear fender. Loosen the two screws which connect the rear fender and frame. These two bolts are just below the seat. Remove the two screws on the top of the seat compartment. .G et • w w w Page 137 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c tP a w w .G et • Loosen the three screws which connect the footrest plate. Pull the rear fender backward. 2i • Screws w w w .
Remove the screws on the sides of the rear of the ATV as shown. • Remove the bolts that hold on the footrests. w w w w .G et 2i tP .G et w Remove the mounting bolts from the front fender. Page 138 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c • w tP a Remove the two screws shown in the picture. 2i • w w 16.3 FRONT FENDER REMOVAL rts .c om .G et 2i tP ar ts .
• 2i tP a .G et Remove the exhaust pipe bolts mounting on the frame below the seat. Remove the exhaust pipe carefully. w w w w • .G et w • 2i tP • 2i • .G et • Wait at least 15 minutes after stopping the engine before servicing the exhaust system. Remove the seat, rear fender and footrest plate before you take off the exhaust pipe. Loosen the two exhaust pipe bolts fixed on the engine. Warning: DO NOT service the exhaust pipe while hot.
Installation is the reverse order of removal. Torque: Exhaust muffler bolts 30 N-m (22 lbf-ft) After installing, make sure that there are no exhaust leaks. w w w w Page 140 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c 2i tP .G et w w .G et w 2i w tP a .G et 2i rts .c om tP ar ts .
17.1 TROUBLESHOOTING .G et w • w w w • 2i tP 2i w • .G et • w • tP a .G et • Page 141 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved. ar ts .c rts .
17.3 IGNITION TIMING The ignition advance is 15°± 3°/4000rpm. The Capacitive Discharge Ignition (CDI) system is factory pre-set and does not require adjustment. 2i .G et 17.4 BATTERY INFORMATION The battery can emit explosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging or service the battery in an open area. The battery contains sulfuric acid (an electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
om CHARGING • • 2i 17.5 ELECTRIC STARTER .G et Information TROUBLESHOOTING 2i w • Starter Motor Turns Slowly o Weak battery. o Poorly connected starter motor cable. o Malfunctioning starter motor. o Poorly connected battery ground cable. Starter Motor Inoperable o Engine stop switch at “off” position. o Gearshift bar is not at neutral position. o Blown fuse near the battery. o Battery is undercharged or in poor condition. .G et • w w 17.
• om • After loosening these three screws, find the wire connector. Detach the connector to replace the electrical bulb conveniently and safely. Installation is in the reverse order of removal. tP ar ts .c • • The cap is visible on the back of the brake light. Loosen the two screws on the cap to remove it. Turn the light bulb inside to remove it. .G et w w w w w .G et w 2i tP 2i • • • w w Rear Brake Light Removal tP a .
rts .c om Instrument Panel Removal • .G et w w w w w .G et w 2i tP 2i The sensor is installed at the brake disk and a cable is tightened on the left side of knuckle component as shown in the pictures. w w • tP a .G et 2i • There is a cable and connector on the back of the instrument panel. After removing the instrument panel, locate the electrical connector which is connected to the driving sensor at the back of the instrument panel.
o .c ar ts tP 2i et om ar t tP .c 2i et ar ts tP w .G 2i et .
tP ar ts .c 18.1 ENGINE DOES NOT RUN om 18.
om 18.
Raise the wheels off the ground and spin by hand – wheels spin poorly o Brake dragging o Drive chain too tight o Damaged wheel bearing o Wheel bearing needs lubrication • Low tire pressure o Tire punctured o Faulty valve stem • Engine speed does not increase when accelerating o Fuel / air mixture ratio too rich or lean o Clogged air cleaner o Clogged muffler o Restricted fuel flow o Clogged fuel tank cap breather hole Low cylinder compression o Leaking head gasket o Worn cylinder and piston rings • C
om 18.5 POOR HANDLING Steering is heavy o Damaged steering bearing o Damaged steering shaft bushing • Wheel wobbling o Bent rim o Improperly installed wheel hub o Excessive wheel bearing play o Bent swing arm o Bent frame o Swing arm pivot bushing excessively worn • Vehicle pulls to one side o Bent tie-rod o Incorrect tie-rod adjustment o Rear tie air pressure incorrect o Improper wheel alignment o Bent frame w Page 150 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved.
om ETON America, LLC tP ar ts .c Service Bulletin C.D.I. Module Specifications Vector 250 Bulletin No.: SB-0037 ar ts .c .G et w 2i w tP a .G et 2i rts .c om Date: 05/01/2006 VXL-250 -- C0410-LRA0-0000 Electric resistance(Ω) specification w ∞ ∞ ∞ ∞ ∞ 30-40K BACK GND 20-30K 4.8-5.2K 80-100K 30-50K 7-8K 0 13-15K 1-3K ∞ 2i tP w w ACC PC+ PCIGN BACK GND PC+ PCIGN 50-70K 1-2K ∞ 30-50K ∞ 30-50K ∞ 50-60K 1-3K ∞ ∞ ∞ .
om ETON America, LLC tP ar ts .c Service Bulletin 0051 03/01/2007 E-TON ATV, Scooter and Utility Kart Headlight Wattages rts .c om Bulletin No: Date: Head Light Wattages .G et Viper 70‐4 10w 12w 10w Viper 150 20w 50w 35w 90w .G et 18w 24w 24w Beamer Matrix 18w 24w Beamer R2 18w 24w Beamer R4 18w Rover N/A Rover GT N/A 2i tP 18w w Beamer III 50w 12w 24w .
om tP a .G et 2i tP 2i .G et w w w w w ar ts .c rts .c om tP ar ts .c 2i .G et w w w Page 151 of 151 Copyright ©2008-2009 ETON America, llc., all rights reserved.
