Eton America YXL-150 User manual

ETON America
150cc Service Manual
Covers:
YXL-150, CXL-150, RXL-150R
200028
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Table of Contents
1. Information
2. Maintenance
3. Engine Removal And Installation
4. Engine Lubrication And Cooling System
5. Cylinder Head & Valves
6. Cylinder & Piston
7. Transmission System
8. Front Wheel, Suspension And Steering
9. Rear Wheel System
10. Fenders And Exhaust Pipe
11. Electrical System
12. Trouble Shooting
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Information
1-2
1. INFORMATION
1.1 Safety
1.2 Notes
1.3 Specifications
1.4 Serial number
1.5 Torque valve
1.1 Safety
 GASOLINE
Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow
sparks or flames in your work area.
CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that
may cause loss of consciousness and lead to death.
BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin, and clothing. If you come into
contact with the electrolyte, flush the area thoroughly with water. If you get the electrolyte in your eyes,
flush with water and contact a doctor immediately.
HOT PARTS
The engine and exhaust pipe become very hot and remain hot for one hour after the engine is
run. Wear insulated gloves before handling these parts.
USED ENGINE / GEAR OIL
Used engine oil and gear oil may cause damage after prolonged exposure to the skin. Keep out of
reach of children.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are base on the
latest product information available at the time of approval for printing.
ETON America, LLC reserves the right to make changes at any time without notice and without
incurring any obligation whatever.
No part of this publication may be reproduced without written permission.
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Information
1-3
1.3 SPECIFICATION
SUSPENSION
Front
Rear
BRAKES
Front
Rear
TIRES
Front
Rear
COLOR
* Specifications subject to change without notice.
Dual A-arm
Swing Arm
Dual Mechanical Drum
Mechanical Drum
(YXL only)
Hydraulic Disc
(CXL & RXL-150R only)
21” x 7” - 8”
22” x 10”
Red/Black & Silver/Black
(YXL-150 only)
Red, Blue, Green, Silver
(CXL-150 only)
Black/Yellow
(RXL-150R only)
ENGINE Type Air-Cooled 4-Stroke
with Oil Cooler
Displacement 149.56 cc
Bore and Stroke 57.4x57.8mm
Compression 9.7:1
Maximum Torque 10.6 ps@7500rpm
Carburetor Kei-Hin / Electric choke
Air Cleaner Oil Bathed element type
Transmission Automatic (C.T.V. V-belt)
CHASSIS Overall Length 1730mm/68.1 inches
Overall Width 980mm/38.6 inches
Overall Height 1070mm/42.1 inches
Wheel base 1115mm/43.9 inches
Ground Clearance 140mm/5.5 inches
Dry Weight 172kg / 379lbs
Fuel Tank Capacity 6.5 liters/1.7 gal
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Information
1-4
1.4 SERIAL NUMBERS
The frame serial number is stamped on the front frame just above the oil cooler. The
engine number is stamped on the left side of the crankcase.
Frame Number
Engine Number
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Information
1-5
1.5 TORQUE VALUES
STANDARD
5 mm bolt and nut 5 N-m
(
3.7 ft-lbs
)
6 mm bolt and nut 10 N-m
(
7.4 f
t
-lbs
)
8 mm bolt and nut 22 N-m (16 ft-lbs)
10 mm bolt and nut 35 N-m (26 ft-lbs)
12 mm bolt and nut 55 N-m (41 ft-lbs)
ENGINE
C
y
linder head nut 28 N-m
(
20.7 f
t
-lbs
)
Spark plug 12 N-m (8.9 ft-lbs)
Cylinder head bolt 20 N-m (14.8 ft-lbs)
A
lternator bolt 8 N-m
(
5.9 ft-lbs
)
FRAME
Handlebar u
pp
er holder bolt 24 N-m
(
17.7 f
t
-lbs
)
Throttle housing cover screw 4 N-m ( 2.9 ft-lbs)
Steerin
g
shaft nut 50 N-m
(
36.9 f
t
-lbs
)
Steering shaft holder bolt 33 N-m (24 ft-lbs)
Wheel rim bolt 18 N-m (13.3 ft-lbs)
Tie rod lock nut 35 N-m (25.8 ft-lbs)
King pin nut 40 N-m (29 ft-lbs)
Handlebar lower holder nut 40 N-m (29.5 ft-lbs)
Front wheel bolt 24 N-m (17.7 ft-lbs)
Front axle nut 60 N-m (44 ft-lbs)
Front brake arm nut 4 N-m
(
3.0 ft-lbs
)
Rear brake arm nut 7 N-m ( 5.2 ft-lbs)
Rear axle nut 60 N-m
(
44.3 f
t
-lbs
)
Rear wheel bolt 24 N-m (17.7 ft-lbs)
Exhaust muffler mounting bolt 30 N-m (22.1 ft-lbs)
Engine hanger bolt 30 N-m (22 ft-lbs)
Rear axle holder bolt 90 N-m (65 ft-lbs)
Swingarm pivot nut 90 N-m (65 ft-lbs)
Rear shock absorber mounting nut 45 N-m (33 ft-lbs)
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2-1
Maintenance
2. Maintenance
2.1 Maintenance data
2.2 Maintenance schedule
2.3 Fuel tube
2.4 Throttle operation
2.5 Throttle cable adjustment
2.6 Air cleaner
2.7 Spark plug
2.8 Idle speed
2.9 Drive chain
2.10 Brake system
2.11 Wheels and tires
2.12 Steering system
2.13 Toe-in
2.14 Gear oil
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG:
Spark plug gap:
Recommended spark plugs:
Throttle lever free play:
Idle speed:
Brake lever free play:
Drive chain slack
Front/rear tire size
Front/rear tire pressure
Toe-in
TORQUE VALUES
SPARK PLUG
TIE-ROD LOCK NUT
ENGINE OIL
Viscosity :
API service classification
GEAR LUBRICATION OIL
Viscosity:
0.6-0.7 mm / 0.024 – 0.028”
NGK CR7HSA
5-10 mm / 0.2-0.4”
1600±100rpm
15-25 mm / 0.6-1.0”
10-25 mm / 0.4-1.0”
20*7-8 / 22*10-8
2.2± 0.3 psi (0.15 kgf/cm2)
5±10 mm / 0.2±0.4”
12-19 N-m / 9-14 ft-lbs
35-43 N-m / 26-32 ft-lbs
SAE 40 (10W-40)
SF or SG
SAE 90 (80/90 weight gear oil)
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Maintenance Schedule
Four Stroke Vehicles
WP-0027
Scheduled
Maintenance
300KM Every1000KM Every3000KM Every6000KM Every12000KM
200Miles600Miles2000Miles3700Miles7500Miles
NEW 1Month3Months 6Months 1Year
1Aircleanerelement I*C* R(paper) R(sponge)
2Aircleaner I    
3Oilfilter(Screen) C   C 
4Engineoil Change I Change  
5Tire,pressure I I   
6Battery I I   
7Sparkplug I  I  R
8Carburetor(idlespeed) I   I 
9Steeringbearingandhandles I  I  
10
Checktransmissionforleak‐
age I I   
11Checkcrankcaseforleakage I I   
12Transmissionoil Change   Change
13Drivebelt/roller    I R
14Fueltankswitchandlines I  I  
15
Throttlevalveoperationand
cable I I   
16Engineboltsandnuts I  I  
17
Cylinderhead,cylinder,and
piston    I 
18
Exhaustsystem/cleaning
carbon    I 
19CamChain/ignitiontime I  I  
20Valveclearance I I I I I
21Shockabsorbers I   I 
22Front/Rearsuspension I   I 
23Main/Sidestands I   I/L 
24Crankcase(PCV)Valve I  I  
25
Brakemechanism/brakelin‐
ing(pad) I I   
26
TightenallBolts/Nuts&Fas‐
teners
I I   
*=Cleanorreplacetheaircleanerelementmoreoftenwhenthevehicleisoperatedondusty
#=Maintenanceshouldbeperformedmoreoftenifthevehicleisfrequentlyoperatedathigh
speedforprolongedtimeandafterthevehiclehasaccumulated50,000miles.
roadsorinaheavilypollutedenvironment.
Code:
I=Inspection,clean,andadjust
R=Replace
C=Clean(replacedifnecessary)
L=Lubricate
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2-2
Maintenance
2.2 MAINTENANCE SCHEDULE
The maintenance intervals in the follow table are based upon average riding conditions. Riding in
unusually dusty areas requires more frequent servicing. E-TON recommends that all maintenance
and inspections be performed ONLY by a qualified and fully trained technician.
Initial Service Regular Service Yearly Service
Note - X: Inspect and Clean, Adjust, Lubricate or Replace, if necessary
C: Clean
L: Lubricate
R: Replace
2.3 FUEL TUBE
Inspect the fuel lines for deterioration,
damage, or leaks, and replace if
necessary.
ETON 150cc models are equipped with
a vacuum fuel valve. Fuel is
transferred into the carburetor when a
vacuum is created from the engine.
Fuel should not flow if engine is not
running or if vacuum is not applied.
(First Week)_________(30 Operating days) _____ (Once each Year)
FUEL LINE X X
THROTTLE OPERATION X X
AIR CLEANER C
SPARK PLUG X
CARBURETOR IDLE SPEED X X
DRIVE CHAIN X,L X,L
BRAKE SHOE WEAR X
BRAKE SYSTEM X X
NUT, BOLT, FASTENER X X
WH EEL/TIRES X X
STEERING SYSTEM X
SUSPENSION SYSTEM X
GEAR OIL R
ENGINE OIL R X R
ENGINE OIL FILTER C C
Vacuum
control line
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Maintenance
2-3
2.4 THROTTLE OPERATION
Inspect for smooth lever operation, full opening, and automatic
full closing in all steering positions.
Inspect for deterioration, damage, cuts and nicks, or kink in
the throttle cable, replace it if necessary.
Check the throttle lever; free play should be no more than
5-10 mm / 0.2-0.4” at the tip of the throttle lever.
Disconnect the throttle cable at the upper end. Lubricate the
cable with commercially lubricant to prevent premature wear.
2.5 THROTTLE CABLE ADJUSTMENT
Slide the rubber cap of the adjuster off the throttle
housing, loosen the lock nut, and adjust the free
play of the throttle lever by turning the adjuster on
the throttle housing. Inspect the free play of the
throttle lever.
Throttle cable adjuster
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Maintenance
2-4
2.6 AIR CLEANER MAINTENANCE
(1) Loosen the screws and remove the air cleaner from carburetor.
(2) Disassemble the air cleaner cover and body.
(3) Clean the air cleaner element and screen. (See Figure below)
(6) Install the air cleaner element and screen in
the body.
(7) Assemble the air cleaner body and cover and
attach to the carburetor with the screw.
(4) Wash the element in non-flammable or high
flash point solvent squeeze out the solvent thor-
ou
g
hl
y
and allow it to dr
y
.
(5) Soak the element in gear oil (SAE 80-90) and
s
q
ueeze out the excess.
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Maintenance
2-5
2.7 SPARK PLUG
The spark plug is located at the front of the engine.
(1) Disconnect the spark plug cap and remove the
spark plug.
(2) Visually inspect the spark plug electrodes for
wear or cracks in insulator. Replace if
needed.
(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 : 0.6-0.7 mm
Recommended replacement plug: NGK CR7HSA
(6) Check the sealing washer and replace with a new
one if damaged.
(7) With the sealing washer attached thread the spark
plug in by hand to prevent cross threading.
Tighten the spark plug.
TORQUE : 12-19 N-m / 9-14 ft-lbs
2.8 IDLE SPEED SETTING
(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 ten minutes and
connect a tachometer.
(3) Turn the throttle stop screw as required to obtain
the specified idle speed.
IDLE SPEED : 1700 ± 100 rpm
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Maintenance
2-6
2.9 DRIVE CHAIN ADJUSTMENT
Stop the ATV and shift transmission into
neutral. Inspect the chain slack midway
between the sprockets. The standard is
10-25mm (5/8 – 1”).
If needed, remove the chain protective
cover and adjust the chain slack.
Loosen the axle holder lock nuts then
adjust the drive chain slack by turning the
adjusting nut. Tighten the axle holder lock
nuts.
Torque = 90N-m (65 ft-lbs)
When the drive chain becomes very dirty, it
should be removed, cleaned, and lubricated with
commercially available lubricant.
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 there is
excessive wear or damage, replace.
Use a commercial chain lubricant to lubricate the
drive chain; replace and adjust the slack as
described above.
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Maintenance
2-7
2.10 BRAKE SYSTEM ADJUSTMENT
Inspect the front brake lever and cable for excessive play
or damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the end of the
lever. The standard is 15-25 mm / 0.59-0.98”.
Adjust the free play of the front brake lever by turning the
adjuster on the brake lever assembly.
Inspect the rear brake lever and cable for excessive play or
damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the end of the
lever.
The standard is 10-20 mm / 0.39-0.78”.
Adjust the free play of the rear brake lever by turning the
adjuster on the rear axle.
BRAKE SHOE WEAR
Front Brake
Loosen the front brake cable and inspect the brake lining
thickness.
Service Limit: 2.0mm (0.08”)
If either lining is worn beyond the service limit, replace both
brakes shoes.
Rear Brake
Replace the brake shoes if there is uneven wear or if the
lining is worn beyond the service limit.
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Maintenance
2-8
2.11 WHEELS AND TIRES
Inspect the tire surfaces for cuts or sharp
objects.
Check the tire pressure at cold tire conditions.
The standard tire pressure is 2.2±0.3 psi (0.15
kgf/cm2).
2.12 STEERING SYSTEM
Steering Shaft Holder Bushing
Remove the front fender.
Remove the steering shaft holder and check the
steering shaft bushing for wears or damage.
If the bushing is worn or damaged, replace.
Grease the steering shaft bushing and install the
parts in the reverse order of removal.
Torque steering shaft holder bolt: 33 N-m (24 ft-lbs)
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.
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Maintenance
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.
Carefully moving the vehicle backward, 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
measurements.
Toe-in: 5±10mm / 0.2±0.4”
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 / 26-32 ft-lbs
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Maintenance
2-10
2.14 GEAR OIL MAINTENANCE
Gear oil needs to be changed every year.
There is a gear oil drain hole bolt at the rear of
engine.
(STEP 1)
Unscrew this drain hole bolt and let the dirty oil
flow out; catch the oil in a proper container for
later disposal.
(STEP 2)
Reinsert the drain hole bolt and tighten.
(STEP 3)
Fill with 26oz of 80/90 weight gear oil through
the oil fill hole located on the engine case
beside the gear box.
NOTE: for best results, change the oil while the
engine is warm.
Oil Fill Plug
Drain bolt
Drain Bolt
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3-1
ENGINE REMOVAL AND REPLACEMENT
3.1 ENGINE REMOVAL AND INSTALLATION
ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRS OR
ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM!
3.2 ENGINE REMOVAL
Remove the seat, front and rear fender.
(See Chapter 10 )
Remove the footrest.
Remove the spark plug cap from the spark plug.
Remove the exhaust muffler.
Disconnect the carburetor cable by unscrewing
the two screws on top of the carburetor.
Disconnect the carburetor auto-choke (if
equipped), starter motor, generator, the neutral
safety switch, CDI box, and the ignition coil wire.
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 engine and air cleaner together
3.2 ENGINE REPLACEMENT
Engine installation is essentially the reverse order
of removal.
The torque of the engine hanger bolt is 30 N-m / 22
ft-lbs.
Route the wires and cable properly in reverse
order of removal.
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4-1
LUBRICATION
4. Lubrication
4.1 Service Information
4.2 Trouble Shooting
4.3 Engine Oil Level
4.4 Engine Oil & Filter Change
4.5 Oil Pump Removal / Installation
4.1 SERVICE INFORMATION
GENERAL
1. This section describes cylinder head, valves, camshaft, and other parts maintenance.
2. The engine must be removed from the frame to service the cylinder head.
3. Camshaft lubrication oil is fed to the cylinder head through an oil hole in the engine case.
4. Before installing the cylinder head, be sure the hole is not clogged and the gasket, O-ring,
and dowel pins are in place
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Cylinder compression 12±0.5 kg/cm2--------
Cam lobe height IN 29.795mm / 1.180” 29.395mm / 1.157”
EX 29.560mm / 1.16” 29.160mm / 1.148”
Rocker arm I.D. 10.000-10.018mm / 0.394” 10.10mm / 0.398”
Rocker arm shaft O.D. 9.972-9.987mm / 0.393 “ 9.91mm / 0.390”
Cylinder head warp -------- 0.05mm
Valve spring free length IN 32.3mm / 1.27” 31.2mm / 1.23”
EX 35.0mm / 1.38” 34.1mm / 1.34”
Valve stem O.D. IN 4.975-4.990mm / 0.196” 4.90mm / 0.193”
EX 4.955-4.970mm / 0.195” 4.90mm / 0.193”
Valve guide I.D. IN/EX5.000-5.012mm / 0.197” 5.30mm / 0.209”
Stem-to-guide clearance IN 0.010-0.037mm 0.08mm
EX 0.030-0.057mm 0.10mm
Valve seat width IN 1.0mm 1.80mm
EX 1.0mm 1.80mm
TORQUE VALUES
Cylinder head bolts
Camshaft holder flange nuts
Tappet adjusting nut
Oil Drain Bolt
8 - 12 N-m (6-9 ft-lbs)
20 - 24 N-m (15-18 ft-lbs)
9 - 12 N-m (7-9 ft-lbs)
20-30 N-m (15-22 ft-lbs)
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