Eton America Rascal IXL-40 Manual de usuario

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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