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Adjust the chain slack.

Loose the lock bolts (4 pcs) then adjust the drive chain
slack by turn the adjusting nut.
Tighten the four lock bolts.

When the drive chain becomes very dirty, it should be
removed, cleaned and lubricated by specify lubricator.
Using commercial chain lubricant to lubricate the drive

chain.

Clean the drive chain with kerosene and wipe it dry.

Inspect the drive chain for possible wear or damage.

eplace the chain, if it is worn excessively or damaged.

Inspect the sprocket teeth, if it is excessive wear

r damage, replace it.

Inspect the chain-tensioned roller.
R

eplace it, if necessary.

2.10 BRAKE SYSTEM

Inspect the front brake lever and cable for excessive

play or other damage.

Replace or repair if necessary.

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

rake lever.

The standard of free play is 15-25 mm.

(For RXL50 / 90 / RXL90R, the ATV RXL50M doesn’t have
t

he front brake lever. )

Содержание ATV RXL 50

Страница 1: ......

Страница 2: ...12 4 ENGINE FUEL SYSTEM 14 5 ENGINE LUBRICATION AND COOLING SYSTEM 18 6 ENGINE COMBUSTION SYSTEM 20 7 TRANSMISSION SYSTEM 25 8 STEERING SYSTEM 31 9 FRONT WHEEL SYSTEM 38 10 REAR WHEEL SYSTEM 42 11 FE...

Страница 3: ...y electrolyte contains sulfuric acid Protect your eyes skin and clothing If you contact it flush thoroughly with water and call a doctor if electrolyte gets in your eyes 1 2 NOTES All information illu...

Страница 4: ...470mm 57 9 1500mm 59 0 1500mm 59 0 1430mm 56 3 OVERALL WIDTH 850mm 33 5 850mm 33 5 850mm 33 5 850mm 33 5 820mm 32 3 OVERALL HEIGHT 830mm 32 7 830mm 32 7 900mm 35 4 900mm 35 4 800mm 31 5 SEAT HEIGHT 65...

Страница 5: ...e same position just like the picture below 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 Engin...

Страница 6: ...Steering shaft bushing holder nut 24 30 N m 17 7 22 1 lbf ft Wheel rim bolt 18 25 N m 13 3 18 4 lbf ft Tie rod lock nut 35 43 N m 25 8 31 7 lbf ft King pin nut 30 40 N m 22 1 29 5 lbf ft Handlebar lo...

Страница 7: ...E VALUES SPARK PLUG 12 19 N m TIE ROD LOCK NUT 35 43 N m ENGINE OIL JASO FC Grade or same degree oil GEAR LUBRICATION OIL SAE 90 2 2 MAINTENANCE SCHEDULE The maintenance internals in the follow table...

Страница 8: ...inking in the throttle cable replace it if necessary Check the throttle lever free play is 5 10 mm at the tip of the throttle lever Disconnect the throttle cable at the upper end Lubricate the cable w...

Страница 9: ...a new spark plug if the electrodes and insulator tip appear unusually fouled or burned Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped The spark plug gap sh...

Страница 10: ...it dry Inspect the drive chain for possible wear or damage Replace the chain if it is worn excessively or damaged Inspect the sprocket teeth if it is excessive wear r damage replace it o Inspect the c...

Страница 11: ...end of the lever The standard is 15 25 mm For all type 2 11 WHEELS AND TIRES Inspect the tire surfaces for cuts nails or other sharp objects Check the tire surfaces at cold tire condition The standar...

Страница 12: ...the marks Calculate the difference in the front and rear measurements 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 whi...

Страница 13: ...arburetor cable by unscrew two screws on top of the carburetor Take off oil pump cable from the oil pump control plate Oil pump is under the right side of engine Disconnect the wire connectors There a...

Страница 14: ...picture is for ATV RXL 90R 3 3 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 or...

Страница 15: ...ROPER ADJUSTMENT TO THE IDLE SPEED SCREW IGNITION MALFUNCTION FUEL AIR MIXTURE RATIO NO GOOD AIR CLEANER DIRTY INSULATOR LEAKS FUEL TANK CAP BREATHING HOLE CLOGGED LEAN MIXTURE FUEL JET OF CARBURETOR...

Страница 16: ...EMOVAL Remove the air cleaner Disconnect the fuel line and auto choke electric wire Unscrew the intake pipe mounting bolts at the carburetor then removes the carburetor Note Turn fuel cup on off posit...

Страница 17: ...at arm pin float and float needle valve Inspect the seat of the float needle valve for wear or damage Disassembly the idle jet main jet idle speed adjust screw and idle mixture adjusts screw Inspect a...

Страница 18: ...order of disassembly THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle Install the jet needle into the throttle valve Assembly the throttle cable spring and the throttle valve Align th...

Страница 19: ...ntity is not enough this engine will be serious scratched and then this engine will stop even cannot work again When this engine is serious scratched you need to change the piston piston rings and cyl...

Страница 20: ...N OIL TANK IS TOO LOW OIL TUBES WERE NOT FIXED WELL OIL HAS LEAKAGED FROM TUBE ENDS OIL TUBES WERE BROKEN OIL TUBES WERE CLOGGED OIL PUMP CANNOT WORK ALWAYS INSUFFICIENT OIL LEVEL EXTERNAL OIL LEAKS I...

Страница 21: ...WORN OUT HIGH COMPRESSION EXCESSSIVE CARBON BUILD UP ON PISTON HEAD OR IN COMBUSTION CHAMBER EXCESSIVE NOISE PISTON AND CYLINDER WORN OUT EXCESSIVE CARBON BUILD UP EXCESS SMOKE CYLINDER OR PISTON RIN...

Страница 22: ...the cylinder head Remove the cylinder carefully then you can see the whole piston Remove one piston pin clip Remove the piston and piston pin Spread each piston ring and remove it by lifting up at a...

Страница 23: ...sert each piston ring into the cylinder and measure the end gap Service limit 0 5 mm Measure the clearance between ring and groove Service limit 0 09 mm Measure the piston outer diameter at 10 mm high...

Страница 24: ...m 12 04 mm 12 04 mm 10 04 mm Measure the connecting rod small end inner diameter with a small bore diameter gauge Service limit RXL RXL RXL 50 90R 50M 90 50 14 06 mm 14 06 mm 15 06 mm 15 06 mm 14 06 m...

Страница 25: ...xhaust pipe Do not align the piston pin clip end gap with the piston cutout Install a new cylinder gasket Apply a thin coat of engine oil to the piston rings and cylinder wall Install the cylinder com...

Страница 26: ...YSTEM 7 1 TROUBLESHOOTING ABNORMALLY ACT IN SHIFTING AND CAN T RESET FAULTY C D I FAULTY SHIFT MOTOR FAULTY SENSOR F N1 R N2 FAULTY SHIFT SPRING OR GEAR CAN NOT MOVE AFTER ENGINE START BELT WORN FRONT...

Страница 27: ...Shift Mechanism For RXL 90R Gear Box For RXL 90R 26...

Страница 28: ...easure sensor dimension as fig 1 after unscrew sensor Shift Motor Sensor N2 Sensor F Sensor N1 Sensor R fig 1 If length is below 30mm it must be replaced Smear with loctite 5699 and screw with torque...

Страница 29: ...elt by the centrifugal force from six rollers Then the pitch circle of belt in drive pulley will be larger The belt at driven pulley is forced to move to the center of shaft then the radius of pitch c...

Страница 30: ...to high torque toward to low speed and make the engine maintain smooth running with original revolution 7 6 GEAR BOX For RXL 90R Sensor Fork Fork Shaft Drum Gear Shift Reverse Shaft Comp Counter Shaf...

Страница 31: ...he engine is started the kick started will stop transfer the power to the kick starter driven gear When the kick starter lever is released the kick starter gear will go back to its original position 7...

Страница 32: ...G SYSTEM 8 2 TROUBLESHOOTING HARD STEERING FAULTY TIRE STEERING SHAFT HOLDER TOO TIGHT INSUFFICIENT TIRE PRESSURE FAULTY STEERING SHAFT BEARINGS DAMAGED STEERING SHAFT BEARING 8 3 HANDLEBAR REMOVAL Re...

Страница 33: ...r INSTALLATION Put the handlebar on the lower holders Make sure the handlebar punch mark with the tops of the handlebar lower holders Install the handlebar upper holders with the L or R marks facing f...

Страница 34: ...ng and holder with the punch mark Tighten the screw securely The picture of right side is for ATV RXL 50 90 and RXL 90R The picture of right side is for ATV RXL 50M 8 4 STEERING SYSTEM The ATV RXL and...

Страница 35: ...ith fingers The ball joints should turn smoothly and quietly KINGPIN INSPECTION Inspect the kingpin for damage or cracks Measure the kingpin outer diameter Upper minimum limit 15 40 mm Lower minimum l...

Страница 36: ...amage or wear replace if necessary Measure the bushing inner diameter Maximum limit 22 8 mm STEERING SHAFT INSPECTION Inspect the steering shaft for damage or cracks Measure the steering shaft outer d...

Страница 37: ...N m Install the steering shaft nut and tighten it This nut is under this steering shaft Torque 50 60 N m INSTALLATION OF TIE ROD Install the ball joint with L mark on the steering shaft side Install...

Страница 38: ...stall the kingpin Tighten the kingpin nut the setting torque is 30 40 N m Fix the waterproof rubber cap Temporarily set the distance 147mm between the ball joints Install the tie rod and tighten the n...

Страница 39: ...L SYSTEM 9 1 THE PARTS DRAWING OF FRONT WHEELS SYSTEM 9 3 FRONT WHEEL 9 2 TROUBLESHOOTING 9 4 FRONT BRAKES 9 1 THE PARTS DRAWING OF FRONT WHEELS SYSTEM FOR RXL 50 FOR RXL 70 AND RXL 50M FOR RXL 90 AND...

Страница 40: ...els off the ground by placing a block under the frame Remove the front wheel nuts washer and wheels INSTALLATION Install and tighten the four wheel castle nuts Torque 40 60 N m Remember put a cotter p...

Страница 41: ...e bearings should turn smoothly and quietly If the race does not turn smoothly or quietly remove and discard the bearings BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm Remove the b...

Страница 42: ...g the punch mark and the groove on the cam Tighten the brake arm bolt and nut Torque 4 7 N m Install the return spring Install the brake panel on the knuckle Connect the brake cable to the brake arm I...

Страница 43: ...RAWING OF REAR WHEEL SYSTEM 10 3 DRIVE MECHANISM 10 2 TROUBLESHOOTING 10 4 HYFRAULIC DISC BRAKE SYSTEM 10 1 THE PARTS DRAWING OF REAR WHEEL SYSTEM FOR ATV RXL50 FOR ATV RXL90 AND RXL90R FOR ATV RXL70...

Страница 44: ...L BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER IS FAULTY BRAKE DRAG INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CAM STICKING BRAKE CABLE 10 3 DRIVE MECHANISM REMOVAL AND INSPECT...

Страница 45: ...ing of bearing with fingers The bearings should turn smoothly and quietly Replace if necessary INSTALLATION Add grease to the dust seal lips and install dust seals Assembly the rear axle and the drive...

Страница 46: ...just rear brake level free play Adjust chain slack 10 4 HYFRAULIC DISC BRAKE SYSTEM To replace brake disc To replace brake disc Remove the rear left tire Unscrew the two bolts shown on the photo and r...

Страница 47: ...ake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown on the photo and remove calipe...

Страница 48: ...heck the thickness of brake shoe and replace a new one if the thickness less than 1mm Press the piston to the end prior to installation of Piston brake shoe TO REPLACE THE BRAKE HYDRAULIC OIL Unscrew...

Страница 49: ...ly Add the brake oil Dot 3 or Dot 4 Keep oil level at least half of the cup to avoid air gets into brake system such like caliper and tube Unscrew the bolt to vent air from brake system Fasten the bol...

Страница 50: ...r PARKING BRAKE ASSEMBLY RXL 50R In RXL 50R it has a parking brake in the rear brake It uses another clipper to make brake stopping and the controller is on handle bar right side The other types are d...

Страница 51: ...r removing the rear brake caliper release the brake cable fixing nut Then you can take apart the parking brake caliper When replace the brake shoes it must use hammer and punch to impact the pins out...

Страница 52: ...11 2 HOW TO REMOVE THE FENDERS 11 5 EXHAUST PIPE INSTALLATION 11 3 EXHAUST PIPE DRAWING 11 1 FENDERS DRAWING All type has the same model below 11 2 HOW TO REMOVE THE FENDERS Unscrew two plastic bolts...

Страница 53: ...front and rear fender Unscrew the bolts as pictures 3 4 then you can remove the rear R L fender Picture 4 As picture 5 you can remove the rear R L fender Picture 5 Picture 6 As picture 6 unscrew thes...

Страница 54: ...rear brake cable and throttle cable then disassembly the handle bar As picture 7 unscrew the bolt then you can remove the front body fender Picture 8 As picture 8 9 unscrew these three bolts then you...

Страница 55: ...body Remove the exhaust pipe carefully 11 5 EXHAUST PIPE INSTALLATION There are three screw bolts in the vehicle frame One is on the engine exhaust pipe end and the other Is on the side of the transmi...

Страница 56: ...MARY CIRCUIT Faulty generator Faulty CDI unit Faulty alternator exciter coil Loosen contacted terminals Faulty ignition coil IGNITION SECONDARY CIRCUIT Faulty plug Loosen contacted spark plug wire IMP...

Страница 57: ...does not require adjustment ALTERNATOR EXCITER COIL Remove the seat rear fender and front fender see chapter 10 Disconnect the exciter coil wire Measure the resistance between the yellow red wire and...

Страница 58: ...grease 12 5 CHARGING Connect the charge positive cable to the battery position terminal Connect the charge negative cable to the battery negative terminal Using 0 9A charging current about 5 hours Nor...

Страница 59: ...ver apart Find out the receiver pin on the right side of front vehicle Use the wire clip to connect the receiver pin and vehicle frame ground After connecting the wire link you must finish controller...

Страница 60: ...ds later pull out end of wire clip from receiver pin or frame ground Before testing the remote controller make sure the engine stop switch on the left handle bar is on position Then press both buttons...

Страница 61: ...12 7 WIRING DIAGRAMS The wiring diagram above is for RXL 50 90 The wiring diagram above is for RXL 70 90 and RXL 50M 60...

Страница 62: ...The wiring diagram above is for RXL 90R 61...

Страница 63: ...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...

Страница 64: ...ernator 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 HI...

Страница 65: ...rings Clean Clean the spark plug Spark plug is incorrect heat range Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel worn pis...

Страница 66: ...properly 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 Im...

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