Eton CXL-150 - SERVICE Service Manual Download Page 40

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PISTON INSTALLATION

“IN”MARK

Install the piston with it’s “IN“ mark on the intake valve
side.

Install the piston pin with new pin clips.

PISTON PIN

Do not align the piston pin clip end gap with the piston
cutout.
NOTE: Do not allow the clip to fall into the

crankcase.

6.6 CYLINDER INSTALLATION

Clean any gasket material from the crankcase surface.
NOTE: Be careful not to damage the gasket surface.

Install the dowel pins and a new gasket.

GASKET

Summary of Contents for CXL-150 - SERVICE

Page 1: ...14 4 CYLINDER HEAD VALVES 16 5 LUBRICATION 26 6 CYLINDER PISTON 34 7 TRANSMISSION KICK STARTER 42 8 STEERING AND SUSPENSION 52 9 FRONT WHEEL AND BRAKE SYSTEM 59 10 REAR WHEEL AND BRAKE SYSTEM 68 11 FE...

Page 2: ...ctor if electrolyte gets in your eyes HOT PARTS Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run Wear insulated gloves before handling these parts USED ENGIN...

Page 3: ...m 1010 mm 1010 mm 1010 mm Overall Height 1070 mm 1065 mm 1070 mm 1070 mm Wheel base 1115 mm 1115 mm 1090 mm 1090 mm Ground Clearance 130 mm 130 mm 120 mm 120 mm Dry Weight 172 kg 176 kg 168 kg 170 kg...

Page 4: ...this service manual The frame serial number is stamped on the front of the frame The engine serial number is stamped on the left side of the crankcase Frame serial number Side frame serial number onl...

Page 5: ...t nut 50 N m 36 9 lbf ft Steering shaft holder bolt 33 N m 24 lbf ft Wheel rim bolt 18 N m 13 3 lbf ft Tie rod lock nut 35 N m 25 8 lbf ft King pin nut 40 N m 29 lbf ft Handlebar lower holder nut 40 N...

Page 6: ...ANER 2 13 TOE IN 2 7 SPARK PLUG 2 14 GEAR OIL 2 1 MAINTENANCE DATA SPECIFICATION SPARK PLUG SPARK PLUG CAP 0 6 0 7 mm RECOMMENDED SPARK PLUGS THROTTLE LEVER FREE PLAY 5 10 mm IDLE SPEED 1600 100rpm BR...

Page 7: ...M I GEAR OIL R ENGINE OIL R I R ENGINE OIL FILTER C C Note I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate R Replace 2 3 FUEL TUBE Inspect the fuel lines for deteriora...

Page 8: ...of removal 2 7 SPARK PLUG This spark plug located at the front of the engine Disconnect the spark plug cap and unscrew the spark plug Check the spark plug electrodes for wear Change a new spark plug...

Page 9: ...ioner When the drive chain becomes very dirty it should be removed cleaned and lubricated by specify lubricator Using commercial chain lubricant to lubricate the drive chain Clean the drive chain with...

Page 10: ...L 150 VIPER Inspect the rear brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the free play of the rear brake lever at the end of the lever The standard...

Page 11: ...d in chap10 BRAKE SHOE WEAR FRONT BRAKE The YXL CXL EXL RXL 150 have the same model of front brake Release the front wheel and inspect the brake lining thickness Service Limit 2 0mm 0 08 inch If eithe...

Page 12: ...and ball joint STEERING SHAFT HOLDER BUSHING Remove the front fender first Remove the steering shaft holder and check the steering shaft bushing for wears or damage If the bushing is worn or damaged c...

Page 13: ...0mm 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 G...

Page 14: ...Remove the footrest Remove the spark plug cap from the spark plug Remove the exhaust muffler Disconnect the carburetor cable by unscrew two screws on top of the carburetor Disconnect the wire connect...

Page 15: ...3 3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal The torque of engine hanger bolt is 30 N m Route the wires and cable in reverse order properly 15...

Page 16: ...e 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 IN 29 795 29 395 CAM LOBE HEIGHT EX 29 560 29 160 ROCKE...

Page 17: ...ng Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damag...

Page 18: ...e cam chain adjuster screw CAM CHAIN ADJUSTER SCREW CAM CHAIN ADJUSTING BOLT Remove the screw and O ring and tighten the cam chain adjusting bolt with clockwise direction Remove the nuts and washers N...

Page 19: ...Inspect the camshaft and bearings for wear or damage BEARINGS and replace them if necessary ROCKER ARMS Screw a 5mm bolt into the rocker arm shaft threaded end Pull on the bolt to remove the shafts a...

Page 20: ...O D of each rocker arm shaft SERVICE LIMIT 9 91 mm 4 4 CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head FLANGE BOLTS CYLINDER HEAD Remove the cylinder head gasket and dowel pins DOWEL P...

Page 21: ...ll carbon deposits from the combustion chamber Check the spark plug hole and valve area for cracks Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge SERVICE LIMIT...

Page 22: ...0 10 mm NOTE If the stem to guide clearance exceeds the service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary a...

Page 23: ...tall the new gasket and dowel pins Install the cam chain guide CAM CHAIN GUIDE Install the cylinder head CYLINDER HEAD CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts i...

Page 24: ...haft gear with cam chain so that its CIRCLE HOLE I MARK I mark aligns with the cylinder head surface and the circle hole forwards front Install the dowel pins and camshaft holder Tighten the washers a...

Page 25: ...Relax the cam chain adjusting bolt with counterclockwise direction and install the o ring and screw Install the cylinder head cover CYLINDER HEAD COVER 25...

Page 26: ...ENGINE OIL CAPACITY 0 8 1 0 liter API service classification SF or SG ENGINE OIL RECOMMENDATION VISCOSITY SAE 20w 40 When the average temperature in your riding area is within the indicated range you...

Page 27: ...gh 5 3 ENGINE OIL LEVEL OIL LEVEL GAUGE Place the engine on the level plane Check the oil level with the oil level gauge but do not screw it in when making this check Add the recommended oil up to the...

Page 28: ...ith sealing washer TORQUE 20 30 n m 2 0 3 0 kg m Fill the crankcase with recommended oil OIL FILTER CAP ENGINE OIL CAPACITY 0 8 liter at draining Install the oil filter cap Install the oil level gauge...

Page 29: ...osition COOLING FAN COMPOSITION A C G GENERATOR ASSY Remove the A C G generator assy Remove the right crankcase cover CRANKCASE COVER Remove the starting clutch outer and gear assy STARTING CLUTCH GEA...

Page 30: ...s and oil separator OIL SEPARATOR FLANGE BOLTS Remove the oil pump chain and oil pump driven OIL PUMP DRIVEN SPROCKET OIL PUMP CHAIN sprocket Remove the oil pump assy OIL PUMP ASSY Disassemble the oil...

Page 31: ...SHAFT rotor tip clearance SERVICE LIMIT 0 12 mm Remove the oil pump shaft and measure the pump OIL PUMP OUTER ROTER OIL PUMP INNER ROTER end clearance SERVICE LIMIT 0 2 mm OIL PUMP ASSEMBLY INSTALLAT...

Page 32: ...all the oil pump driven sprocket and oil pump chain OIL PUMP DRIVEN SPROCKET PS The tighten torque of driven sprocket nut is 80 120 kgf cm Install the oil separator OIL SEPARATOR Install the starting...

Page 33: ...Install the new gasket dowel pins and right crankcase cover Install the A C G generator assy and cooling fan composition 33...

Page 34: ...N BORE 15 002 15 008 15 04 PISTON PIN O D 14 994 15 000 14 960 PISTON TO PIN CLEARANCE 0 002 0 014 0 02 PISTON TO PIN CLEARANCE TOP 0 015 0 050 0 12 SECOND 0 015 0 050 0 12 PISTON RING TO RING GROOVE...

Page 35: ...inder head CYLINDER HEAD Remove the cylinder CYLINDER Remove the cylinder gasket and dowel pins DOWEL GASKET CYLINDER SURFACE Clean off any gasket materials from the cylinder surface NOTE Be careful n...

Page 36: ...with needle nose pliers NOTE Do not allow the clip fall into the crankcase Remove the piston pin from the piston PISTON PIN PISTON Remove the piston Spread each piston ring and remove it by lifting u...

Page 37: ...0 mm Calculate cylinder taper at three levels in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 10 mm Calculate the cylinder out of round at three levels in an X and Y...

Page 38: ...asure the ring end gap NOTE Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder SERVICE LIMITS TOP 0 5 mm SECOND 0 5 mm Measure the piston pin...

Page 39: ...SERVICE LIMIT 15 06 mm 6 5 PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up NOTE Don t interchange the top an...

Page 40: ...ew pin clips PISTON PIN Do not align the piston pin clip end gap with the piston cutout NOTE Do not allow the clip to fall into the crankcase 6 6 CYLINDER INSTALLATION Clean any gasket material from t...

Page 41: ...bore and piston rings with engine oil and install the cylinder NOTE Avoid piston rings damage cylinder bore during installation Do not allow the cam chain fall into the crankcase Install the cylinder...

Page 42: ...19 0 Weight roller O D 17 9 18 1 17 40 Movable drive face I D 27 98 28 0 28 03 Drive face collar I D 24 06 24 09 24 098 Drive face boss O D 23 96 23 98 23 92 Clutch outer I D 124 8 125 2 125 5 Clutch...

Page 43: ...T DUCT REMOVAL Relax the band screw and remove the C V T inlet duct Relax the band screw and remove the C V T outlet duct C V T OUTLET DUCT Remove the gas waste recovery GAS WASTE RECOVERY Remove the...

Page 44: ...REMOVAL DRIVE FACE KICK STARTER RATCHET FLANGE NUT Relax the flange nut and remove kick starter ratchet Remove the drive face DRIVE PULLEY ASSY FLANGE NUT DRIVEN BELT Relax the flange nut Remove the d...

Page 45: ...COMPOSITION SPECIAL NUT composition and driven face spring INSPECTION Inspect the driven belt for wear tears or damage DRIVEN BELT Measure the width of driven belt SERVICE LIMIT 19 0 mm Inspect the w...

Page 46: ...4 098 mm Inspect the drive face boss for wear or damage DRIVE FACE BOSS Measure the O D of drive face boss SERVICE LIMIT 23 92 mm Inspect the clutch outer for wear or damage CLUTCH OUTER Measure the I...

Page 47: ...164 0 mm Inspect the driven face assy and replace them if necessary 7 4 KICK STARTER DISASSEMBLY Remove the L crank case cover L CRANK CASE COVER KICK STARTER Remove the kick starter Remove the ex ci...

Page 48: ...the kick starter spindle composition and return spring Remove the kick spindle bush INSPECTION Inspect the kick starter spindle composition for wear or damage Inspect the kick return spring for fatig...

Page 49: ...SURFACE 7 5 KICK STARTER ASSEMBLY Install the kick spindle bush return spring and spindle assy Install the kick driven gear and spring Install the kick starter KICK STARTER 7 6 C V T ASSEMBLY Compose...

Page 50: ...roller set and drives face Install the movable drive face assy and boss MOVABLE DRIVE FACE Install the drive face and kick starter ratchet KICK STARTER RATCHET DRIVE FACE Install the driven belt and d...

Page 51: ...Install the dowel pins and gasket DOWEL PINS GASKET Install the L crank case cover L CRANK CASE COVER Install the gas waste recovery and C V T ducts C V T DUCTS GAS WASTE RECOVERY 51...

Page 52: ...ION 8 1 PARTS DRAWING 8 2 TROUBLESHOOTING 8 3 HANDLENAR 8 4 THROTTLE HOUSING 8 5 STEERING SYSTEM 8 1 PARTS DRAWING STEERING STEERING 52 For ATV YXL CXL 150 For ATV EXL 150 EXL 150 2004 two passengers...

Page 53: ...ngs Incorrect wheel alignment Loose front suspension fasteners Binding suspension link Faulty front swing arm bushings Improperly installed front swing arms Bent front shock absorber swing rod Weak fr...

Page 54: ...e lower holders Make sure the handlebar punch mark match with the top end of the handlebar lower holders Install the handlebar upper holders with the L or R marks facing forward Tighten the forward bo...

Page 55: ...DISASSEMBLY Unscrew the screws on the throttle housing cover Remove throttle housing cover and gasket Disconnect throttle cable from the throttle arm and remove from the throttle housing Assembly is...

Page 56: ...od for damage or bending Inspect the ball joint rubbers for damage wear or deterioration Turn the ball joints with fingers The ball joints should turn smoothly and quietly Kingpin Inspection Inspect t...

Page 57: ...efully 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 Maxim...

Page 58: ...Installation of Tie rod Install the ball joint with L mark on the steering shaft side Install the tie rod with the mark on the wheel side Installation is in the reverse order of removal 58...

Page 59: ...MOVAL 9 6 HYDRAULIC BRAKE 9 1 PARTS DRAWING The picture below is for YXL CXL RXL 150 EXL 150 2004 two passengers FRONT WHEEL FRONT WHEEL The picture below is for YXL CXL RXL 150 the picture below is f...

Page 60: ...wheel alignment Brake shoes worn Worn brake drum Brake linings oily greasy or dirty Improper brake adjustment 9 3 FRONT WHEELS REMOVAL The disassemble of front wheel system in this serials are the sam...

Page 61: ...the brake drum inner diameter The maximum limit 86 mm Turn the inner race of each bearing with fingers The bearings should turn smoothly and quietly If the race does not turn smoothly or quietly remo...

Page 62: ...nstall the brake arm on the cam by aligning the punch mark and the groove on the cam Tighten the brake arm bolt and nut Torque 4 7 N m Install the return spring Install the brake panel on the knuckle...

Page 63: ...t have the front brake distributor so their brake parts chart and cable removal only follow the two steps below Disconnect the front brake primary cable Primary cable Secondary cable Brake arm Discon...

Page 64: ...olts and the brake plate The mechanism of right side picture is only for ATV EXL 150 INSTALLATION Install the brake plate and tighten the bolts The mechanism of right side picture is only for ATV EXL...

Page 65: ...VIPER REMOVAL 1 Raise the front wheels off the ground by placing a jack or other support under the frame Remove the front wheel nuts washer and wheels Please follow the next three steps of right pict...

Page 66: ...te You can take the brake disc off When change brake shoe wear you must push the master piston to rearward After removal front brake assembly you must fabricate in reverse sequence ADD BRAKE OIL The b...

Page 67: ...THE BRAKE FLOW CHART When actuate the brake lever brake force will through oil tube to drive the wheel brake Or force to the brake pedal through mechanism to drive the wheel brake 67...

Page 68: ...INSTALLATION 10 6 SHOCK ABSORBER 10 7 SWINGARM 10 8 SUBPART HYDRAULIC BRAKE SYSTEM 10 1 PARTS DRAWING The picture below is for YXL CXL 150 The picture below is for EXL EXL 150 2004 two passengers REA...

Page 69: ...brake cable Hard Suspension Bent damper rod Faulty swing arm pivot bushings Soft Suspension Weak shock absorber damper Weak shock absorber spring 10 3 REMOVE REAR WHEEL AND REAR BRAKE For ATV YXL EXL...

Page 70: ...lining surface and brake drum Otherwise stopping power will be reduced Check the brake drum for damage Replace if necessary Check the brake drum inner diameter The maximum limit is 131 mm 10 4 DRIVE M...

Page 71: ...ge or wear Replace if necessary Let the rear axle lie in V blocks and check the run out The run out limit is 0 5 mm Check the turning of inner race of bearing with fingers The bearings should turn smo...

Page 72: ...ining clip Note the retaining clip direction Install the drive chain cover Assembly the chain under cover Install the skid plate Install the drive chain cover Chain Slack Adjustment Loosen the axle po...

Page 73: ...STALLATION Install the wear indicator plate aligning the tab on the axle holder with the slit on the cam Install the brake arm spring and felt seal INSTALL THE BRAKE ARM Tighten the brake arm bolt and...

Page 74: ...l free play Adjust drive chain slack 10 8 SUBPART HYFRAULIC DISC BRAKE SYSTEM PARTS DRAWING NOTE This section is about ATV CXL EXL RXL 150 rear brake system But those two serial have something differe...

Page 75: ...nly for ATV EXL 150 system Brake Cylinder Brake Lever The picture shows only for ATV EXL 150 system Brake Switch The picture shows only for ATV EXL 150 system Rubber tube Brake cable Brake pedal Disc...

Page 76: ...is a label showing how to adjust the disc brake ATV CXL EXL RXL 150 have the same steps under To replace brake disc Remove the rear left tire Unscrew the two bolts shown on the photo and remove calip...

Page 77: ...e mounting seat of the disc Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE Remove the rear left tire...

Page 78: ...Unscrew these two plugs Unscrew Remove the brake shoe pin as shown Remove the brake shoes as shown Check the thickness of brake shoe and replace a new one if the thickness less than 1mm 78...

Page 79: ...CXL 150 just like right side picture It is located on the handle bar but ATV EXL 150 is not on the same position Unscrew the bolt and drain out the used oil drain Fasten the bolt after the used oil b...

Page 80: ...0 70kgf cm Pull left brake lever slightly to extract air from brake system Fill the brake oil to the level shown on the cup when no air comes out Assemble the cover BRAKE CABLE REMOVAL The mechanism o...

Page 81: ...the foot brake cable 81 Remove the brake pedal Foot brake spring Brake pedal Foot brake cable INSTALLATION Install the brake pedal Connect the foot brake cables and the foot brake spring Connect the...

Page 82: ...The brake flow chart EXL 150 2004 two passengers EXL 150 VIPER There are two ways to operate rear brake system and you can use left lever or brake pedal 82...

Page 83: ...1 4 CENTRAL REAR TRIM REMOVAL 11 2 REAR FENDERS REMOVAL 11 5 FRONT FENDER REMOVAL 11 3 FRONT TRIM REMOVAL 11 6 EXHAUST PIPE REMOVAL 11 1 FENDERS DRAWING For YXL CXL EXL EXL 150 2004 two passengers For...

Page 84: ...fender Remove the rear rack Unscrew the two bolts which connect the front fender and rear fender Unscrew the two bolts which connect the rear tender and frame these two bolts just below the seat Unsc...

Page 85: ...screws on side of the tail Finally you must remove the screws on the footrest 11 3 FRONT TRIM REMOVAL Unscrew the two screws just below the headlight of central front trim Unscrew the two screw which...

Page 86: ...ove the fuel tank cap Remove the central rear trim two mounting bolts from the fuel tank Pull the central rear trim up ward 11 5 FRONT FENDER REMOVAL After remove the rear fender central front trim an...

Page 87: ...p of the headlight Then you can see there is a screw on the tip of the vehicle Please remove it And there are the screws on the both side of the vehicle You can see it inside of the front fender After...

Page 88: ...he two exhaust pipe bolts that fixed with engine NOTE Do not service the exhaust pipe while they are hot Remove the exhaust pipe bolts mounting on the frame below the seat Remove the exhaust pipe care...

Page 89: ...nition coil and spark plug Between generator and CDI unit ENGINE STARTS BUT RUNS POORLY IGNITION PRIMARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted termin...

Page 90: ...oil wire Measure the resistance between the yellow red wire and ground STANDARD 460 700 AT 20 68 12 5 BATTERY INFORMATION The battery gives off explosive gases keep sparks flames and cigarettes away P...

Page 91: ...y Position terminal Connect the charge negative cable to the battery negative terminal Using 0 9A charging current about 5 hours Normal charging Or using 4A charging current about 1 hour Quick chargin...

Page 92: ...sition Check for a blown fuse near battery Make sure that the battery is fully charged and in good condition 12 7 LIGHT BULBS REPLACEMENT HEADLIGHT Remove the handle bar cover Remove the central front...

Page 93: ...the driver to remove the screw on the front side of light first For ERXL 150 Viper St After you remove the screws on the top of headlight it can be take off Be careful around the headlight there are m...

Page 94: ...ILLIGHT Install the remove parts in the reverse order of removal EXL150 2004 two passengers For RXL 150 12 8 SPEED METER AND FUEL METER Speedometer Fuel meter Headlight PARTS DRAWING It is for EXL150...

Page 95: ...Picture of right side is for EXL150 2004 two passengers For EXL150 Viper St 95...

Page 96: ...Picture of right side is for CXL150 For RXL150 REMOVAL Remove the headlight Headlight Remove the brake pedal and the exhaust pipe Brake pedal Exhaust pipe 96...

Page 97: ...ate Speed gear Disconnect the speed cable Speed cable Speedometer Fuel meter Remove the speedometer and the fuel meter INSTALLATION Install the fuel meter and the speedometer Connect the speed cable I...

Page 98: ...l the brake pedal Install the headlight THE HEADLIGHT PHOTOGRAPH EXL 150 2004 two passengers EXL 150 Viper St have another shape but its cables position FUEL METER ELECTRICAL SPEEDMETER are the same a...

Page 99: ...METER CABLE METER CABLE 99...

Page 100: ...METER CABLE METER SENSOR 100...

Page 101: ...12 9 WIRING DIAGRAM This diagram is for ATV YXL 150 101...

Page 102: ...This diagram is for ATV CXL 150 102...

Page 103: ...This diagram is for ATV EXL 150 103...

Page 104: ...This diagram is for ATV EXL 150 2004 two passengers 104...

Page 105: ...This diagram is for ATV EXL 150 105 1 Reserve for a electric choke carburetor Optional...

Page 106: ...This diagram is for ATV EXL 150 VIPER ST 106...

Page 107: ...This diagram is for ATV RXL 150 1 Reserve for a electric choke carburetor Optional 107...

Page 108: ...gnition coil Broken or shorted spark plug wire Faulty pulse generator Faulty ignition switch Worn cylinder and piston rings Damaged cylinder head gasket Auto choke off or damaged Auto choke power wire...

Page 109: ...rnator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted spark plug wire Faulty engine stop switch CHECK IGNITION TIMING 13 3 POOR PERFORMANCE AT HIG...

Page 110: ...ings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel worn pist...

Page 111: ...roperly installed wheel hub Excessive wheel bearing play Bent swingarm Bent frame Swing arm pivot bushing excessively Worn Bent tie rod Incorrect tie rod adjustment Rear tie air pressure incorrect Imp...

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