Eton america Rascal ixl-40 User manual

ETON America

40cc Service Manual

Covering:

Rascal IXL-40

Viper Jr. RXL-40

Viper 40E RXL-40E

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TABLE OF CONTENTS

1. ATV Unit Information

2. General Maintenance Schedule

3. Engine Removal

4. Fuel System

5. Engine Combustion system

6. Pull/Electric Starter

7. Transmission

8. Front Wheels and Steering

9. Rear Wheels and Drive System

10. Body Cover & Exhaust System

11. Electrical System

12. Trouble Shooting Chart

13. RXL-40E Specific

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1. INFORMATION

1.1 SAFETY

•Gasoline is extremely flammable and is explosive under certain conditions.

•Do not smoke or allow sparks or flames in your work area.

•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.

•The battery electrolyte contains sulfuric acid. Protect your eyes, skin, and clothing. In case of contact,

flush thoroughly with water. Seek medical attention if electrolyte gets in the eyes.

1.2 NOTES

All information, illustrations, directions and specifications included in this publication are based on the

latest product information available at the time of approval for printing.

ETON America, LLC reserves the right to make changes at any time without notice and

without incurring any obligation whatever.

No part of this publication may be reproduced without written permission. Revised 11/04/2004.

1-1

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INFORMATION

1.3 SPECIFICATIONS

ENGINE

Type Air-Cooled 2-Stroke

Displacement 41.5 cc

Bore and Stroke 40.0*33mm

Compression 6.6:1

Maximum Torque 2.5 N-m@5000rpm

Maximum Horsepower 2.2 Ps @7000rpm

Carburetor Mikuni VM16

Ignition Capacitor Discharge

Starting Hand Pull (Recoil) starter

Lubrication Oil/Fuel Premix

Air cleaner Dry Type

Transmission Single-speed automatic clutch

CHASSIS

Overall Length 1160mm(45.7inch)

Overall Width 650mm(25.6inch)

Overall Height 727mm(28.6inch)

Seat Height 540mm(21.3inch)

Wheel base 728mm(28.7inch)

Ground Clearance 75mm(3.0inch)

Dry Weight 60kg

Fuel Tank Capacity 3.5liter

SUSPENSION

Front Two absorber and A-arm

Rear One absorber and Swing arm

BRAKES

Front None

Rear Drum

TIRESFront 145-70/6

Rear 145-70/6

COLOR

Color Red / Blue

*Specifications subject to change without notice.

1-2

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1.4 SERIAL NUMBER

The Vehicle Identification Number (VIN) is stamped on a plate attached to the front of the frame.

The Engine serial number is stamped on the left side of the crankcase.

1-3

Engine Number

Serial Number

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INFORMATION

1.5 TORQUE VALUES

ENGINE

Item Qty Thread dia.(mm) Torque : N–m / (ft-lbs)

ark

1 14 m

12-19 /

(

9-14

)

Intake pipe mounting bolt 2 5 mm 3.5-5 / (2.5 – 4)

Cylinder socket bolt 4 5 m

4.5-6 (3-4.5)

L Case bolt 4 5 m

4.5-6 (3-4.5)

AC generator assembly nut 1 8 mm 18-20 (13-15)

Clutch weight bolt 2 8 mm 18-20 (13-15)

Clutch flange nut 1 10 m

35-45 (26-33)

R. Case cover bolt 4 6 m

10-14 (7-10)

Mission case socket bolt 4 6 mm 10-14 (7-10)

Gearbox cover socket bolt 5 6 mm 10-14 (7-10)

Gearbox cover drain bolt 1 8 m

20-30 (15-22)

Oil drain bolt 1 8 mm 20-30 (15-22)

Cam sprocket bolt 2 6 m

10-14 (7-10)

L Case bolt 4 6 mm 10-14 (7-10)

FRAME Item Qty Thread dia.(mm) Torque: N – m / (ft-lbs)

Handlebar u

er holder bolt 4 6 m

10-14 /

(

7-10

)

Steering shaft nut 1 14 mm 50-60 / (37-44)

Steering shaft bushing holder nut 2 8 m

24-30 / (17-22)

Tie rod lock nut 4 10 m

35-43 (25-32)

King pin nut 2 10 mm 30-40 / (22-30)

Front axle nut 2 12 m

55-65 / (41-48)

Rear brake arm nut 1 6 mm 7-12 / (5-9)

Rear axle nut 2 14 m

60-80 / (44-59)

Exhaust muffler mounting bolt 1 8 mm 30-35 / (22-25)

Engine hanger bolt nut 3 8 mm 30-35 / (22-25)

STANDARD TORQUE VALUES

Item Torque N-m / (ft-lbs) Item Torque N-m / (ft-lbs)

5mm bolt nut 4.5-6 /

(

3-4.5

)

5mm screw 3.5-5 /

(

2.5-4

)

6mm bolt nut 8-12 / (6-9) 6mm screw, 6mm flange bolt 7-11 / (5-8)

8 mm bolt nut 18-25 / (13-18) with 8mm head

6mm flange bolt nut 10-14 / (7-10)

10 mm bolt nut 30-40 / (22-30) 8mm flange bolt nut 24-30 / (17-22)

12 mm bolt nut 50-60 / (37-44) 10mm flange bolt nut 35-45 / (25-33)

1-4

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MAINTENANCE

2. MAINTENANCE

2.1 MAINTENANCE DATA

2.2 MAINTENANCE SCHEDULE

2.3 FUEL TUBE

2.4 THROTTLE OPERATION

2.5 THROTTLE CABLE ADJUSTMENT

2.6 AIR CLEANER

2.7 SPARK PLUG

2.8 IDLE SPEED

2.9 DRIVE CHAIN

2.10 BRAKE SYSTEM

2.11 WHEELS AND TIRES

2.12 STEERING SYSTEM

2.13 TOE-IN

2.14 GEAR OIL

2.1 MAINTENANCE DATA

SPECIFICATIONS

SPARK PLUG GAP:

RECOMMENDED SPARK PLUGS:

THROTTLE LEVER FREE PLAY:

IDLE SPEED:

BRAKE LEVER FREE PLAY:

DRIVE CHAIN SLACK

FRONT/REAR TIRE PRESSURE

TOE-IN

0.6-0.7 mm

DR8ES-L (NGK)

5-10 mm

1700±100 rpm

15-25 mm

10-25 mm

2.2± 0.3 psi(0.15 kgf/cm2)

5±10 m

2-1

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MAINTENANCE

2.2 MAINTENANCE SCHEDULE

The maintenance intervals in the follow table are based upon average riding conditions. Riding in unusually

dusty areas requires more frequent servicing.

INITIAL SERVICE

(First week) REGULAR SERVICE

(Every 30 operating days) EVERY YEAR

FUEL LINE I

THROTTLE OPERATION

AIR CLEANER I I

SPARK PLUG I

CARBURETOR IDLE SPEED

DRIVE CHAIN

BRAKE SHOE WEAR

I,L I

I,L

BRAKE SYSTEM

UT, BOLT, FASTENER

WHEEL

STEERING SYSTEM

SUSPENSION SYSTEM I

GEAR OIL R

Note - I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary

C: Clean

L: Lubricate

R: Replace

2.3 FUEL LINES

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 for

deterioration, damage, or kinking in the throttle cable. If

any, replace it.

Check the throttle lever. Free play is 5-10 mm at the tip of

the throttle lever.

Disconnect the throttle cable at the upper end. Lubricate

the cable with commercially lubricant to prevent premature

wear.

2-2

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MAINTENANCE

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

(1) Loosen the screws and remove the air cleaner from

carburetor.

(2) Disassemble the air cleaner cover and body.

(3) Remove the air cleaner element and screen.

(4) Wash the element in non-flammable or high

flash point solvent, squeeze out the solvent

thoroughly, and allow to dry completely.

(5) Soak the element in gear oil (SAE 80-90) and

squeeze out the excess oil.

(6) Install the air cleaner element and screen in the

body.

(7) Assemble the air cleaner body and cover.

2-3

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2.7 SPARK PLUG

(1) Disconnect the spark plug cap and remove the spark

plug.

(2) Visually inspect the spark plug electrodes for wear.

(3) The center electrode should have square edges and

the side electrode should have a constant thickness.

(4) Discard the spark plug if there is apparent wear

or if the insulator is cracked or chipped.

(5) Measure the gap with a wire-type feeler gauge and

adjust if necessary by carefully bending the side electrode.

SPARK PLUG GAP: 0.2-0.6 mm

REQUIRED REPLACEMENT PLUG:

BPM7A (NGK) or

BPM6Y (NGK)

(6) Check the sealing washer and replace with a new

one if damaged.

2.8 IDLE SPEED

(1) Inspect and adjust the idle speed after all other engine

maintenance has been performed and is within

specifications. The engine must be warm for accurate idle

speed inspection and adjustment.

(2) Warm up the engine for about five minutes and

connect a tachometer.

(3) Turn the throttle stop screw as required to obtain the

specified idle speed.

IDLE SPEED: 1700 ± 100 rpm

2.9 DRIVE CHAIN

Inspect the chain slack. The standard is 10-25mm.

MAINTENANCE

2-4

With the sealing washer attached thread the spark

lug in by hand to prevent cross threading.

Tighten the spark plug.

TORQUE: 12-19 N-m

(7)

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Remove the chain protection cover.

Adjust the chain slack.

Loosen the lock bolts (4), and then adjust the drive

chain slack by turning the adjusting nut.

Tighten the four lock bolts.

When the drive chain becomes very dirty, it should be

removed, cleaned, and lubricated with a specified lubricator.

Use 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 shows signs of excessive wear

or damage, replace.

2.10 BRAKE SYSTEM

Inspect the rear brake lever and cable for excessive play

or damage.

Replace or repair if necessary.

Measure the free play of the rear brake lever at the end of

the lever. The standard is 15-25 mm.

MAINTENANCE

2-5

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MAINTENANCE

Adjust the free play of the rear brake lever by turning

the adjuster on the rear axle.

2.11 WHEELS AND TIRES

Inspect the tire surfaces for cuts, nails, or other sharp

objects. Check the tire surfaces at cold tire conditions. The

standard tire pressure is

2.2±0.4 psi. (0.15 kgf/cm2)

2.12 STEERING SYSTEM

Check the free play of the steering shaft with the front

wheels pointed straight ahead.

If there is excessive play, inspect the tie-rod, kingpin

bushing, and ball joint.

2.13 TOE-IN

Park the vehicle on level ground with the front wheels

facing straight ahead.

Mark the centers of the tires to indicate the axle center

height.

Measure the distance between the marks.

2-6

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MAINTENANCE

Carefully moving the vehicle back, let the wheels turn

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 measure-

ments.

Toe-in: 5±10mm

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 Drain Plug at the right side of engine.

Remove the Oil Drain Plug Bolt and to drain dirty oil

The oil filling hole is on the engine case beside gear box. Refill

the case with 70cc / 2.4 oz of SAE 80/90 weight gear oil.

2-7

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3. ENGINE REMOVAL AND INSTALLATION

3.1 ENGINE REMOVAL

Remove the seat and the Body Cover. (chapter 10)

Remove the spark plug cap from the spark plug.

Remove the exhaust pipe.

Remove the air cleaner and carburetor Remove the

throttle cable and fuel lines.

Disconnect the wire connectors and remove the wire

from the frame clamps.

Remove the chain protection cover.

Remove the drive chain retaining clip and master link, and

remove the drive chain.

Remove the lower engine hanger nuts and the lower

mission case hanger bolt at the right side.

Remove the engine from the left side.

3.2 ENGINE INSTALLATION

Engine installation is essentially the reverse order of

removal. The torque of engine hanger bolt is 24-30 Nm

Route the wires and cable in reverse order properly.

3-1

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4. ENGINE FUEL SYSTEM

4.1 TROUBLESHOOTING

•No fuel in tank

•No fuel to cylinder

•Too much fuel into cylinder

•No spark at plug

•Air cleaner clogged

•Improper adjustment of the idle speed

screw

•Ignition malfunction

•Fuel/air mixture ratio no good

•Air cleaner dirty

•Insulator leaks

•Fuel tank cap breathing hole clogged

•Carburetor fuel jet clogged

•Fuel tank cap breathing hole

clogged

•Fuel filter clogged

•Fuel flows restricted

•Float level in carburetor too low

•Float needle valve in carburetor

faulty

•Float level too high

•Air duct in carburetor is clogged

•Air cleaner dirty

4-1

Engine will not start

Engine idles roughly, stalls, or runs poorly

Lean mixture

Rich mixture

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4.2 FUEL TANK

REMOVAL

Remove the fuel tank cap.

Remove the seat and Body Cover. Disconnect

the fuel line from the carburetor. Unscrew the

fuel tank mounting bolts.

Note: Keep gasoline away from flames or sparks.

Wipe up spilled gasoline immediately.

4.3 THROTTLE VALVE DISASSEMBLY

Remove the throttle top from the carburetor.

4.4 CAUTION

The carburetor top is an integral part of the throttle cable

assembly. The carburetor top cannot be separated from the

assembly without causing damage to the cable.

Never kink or twist control cables. They will not operate

smoothly and may stick if they are kinked or twisted.

Remove the throttle cable from the throttle valve while

depressing the throttle valve spring.

Remove the needle clip retainer.

Remove the needle jet and needle clip.

Inspect the throttle valve and needle jet surface for dirt,

scratches, or wear, and replace if necessary.

4-2

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4.5 CARBURETOR REMOVAL

Loosen the drain screw and drain the gasoline. Remove

the float chamber by removing the two retaining

screws.

Remove the float arm pin.

Remove the float and float valve.

Inspect the float valve for wear or damage.

Remove the main jet and needle jet.

Blow open all jets and body openings with compressed

air.

Inspect the needle jet and main jet.

Check each part for wear or damage.

Clean the passages and jets with compressed air.

4.6 FLOATS, FLOAT VALVE, AND JETS

ASSEMBLY

NOTE:

Handle all jets and needles with care. They can be easily

scored or scratched.

Install the needle jet, main jet, and throttle stop screw.

Install the float valve, float, and float arm pin. Install the

float chamber.

4-3

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4.7 THROTTLE VALVE ASSEMBLY

Install the needle clip on the needle jet.

STANDARD SETTING: 2nd groove from the top. Install

the jet needle into the throttle valve and secure it with the

needle clip retainer.

Install the spring and throttle valve.

Align the throttle valve slit with the locating pin in the

carburetor body and install the carburetor top onto the

carburetor.

Adjust throttle lever free play.

4-4

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