VIPER 150 VIPER 150 WARNING READ THIS MANUAL CAREFULLY! It contains important safety information. The ATV should not be ridden by anyone under 16 years of age.
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
INTRODUCTION Congratulations on your purchase of the E-TON ATV. This ATV represents the result of many years of E-TON experience in the production of fine sporting, touring, and pacesetting racing machines. With the purchase of this E-TON, you can now appreciate the high degree of craftsmanship and reliability that have made E-TON a leader in these fields. This manual will provide you with a good basic understanding of the features and operation of this ATV.
IMPORTANT MANUAL INFORMATION FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
IMPORTANT NOTICE Welcome to the E-TON world of motor sports! This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV on any public street, road or highway. This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in effect at the time of manufacture. Please check your local riding laws and regulations before operating this ATV. VIPER 150 OWNER’S MANUAL ©2009 by E-TON POWER TECH., LTD.
WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. TABLE OF CONTENTS SAFETY INFORMATION..............................1-1 LOCATION OF THE WARNING AND SPECIFICATION LABELS............................2-1 DESCRIPTION ..............................................3-1 Left view.....................................................3-1 Right view...................................................3-1 Controls and instruments...........................
OPERATION................................................6-1 Starting a cold engine ............................... 6-1 Starting a warm engine ............................. 6-3 Engine break-in ......................................... 6-4 Parking ...................................................... 6-4 Parking on a slope ..................................... 6-5 Accessories and loading ............................ 6-6 RIDING YOUR ATV......................................7-1 GETTING TO KNOW YOUR ATV.......
Battery ..................................................... 8-26 Replacing the fuse ................................... 8-28 Drive chain slack....................................... 8-29 Removing a wheel ................................... 8-30 Installing a wheel .................................... 8-31 Troubleshooting ....................................... 8-32 Troubleshooting chart .............................. 8-33 CLEANING AND STORAGE........................9-1 Cleaning ............................
SAFETY INFORMATION Never allow a child under age 16 to operate an ATV without adult supervision, and never allow continued use of an ATV by a child if he or she does not have the abilities to operate it safely. Never carry a passenger on an ATV. Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets. Never operate an ATV on any public street, road or highway, even dirt or gravel one.
1 that is proper for the terrain, visibility, operating conditions, and your experience. Never attempt wheelies, jumps, or other stunts. Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. Always go slowly and be extra careful when operating on unfamiliar terrain.
ing, use the proper gear and maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees.
carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. 1 Do not run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels.
1 Down load your free copy of E-TON’s ATV Rider Safety Handbook From www.etonamerica.
LOCATION OF THE WARNING AND SPECIFICATION LABELS 2 1 5 (Only for Europe) 2 3 4 6 (Only for Europe) Read and understand all of the labels on your ATV. These labels contain important information for safe and proper operation. Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your E-TON dealer.
1 2 2 I I H7101-FID0-0000 2-2
3 4 2 6 5 2-3
DESCRIPTION 1 1 2 3 4 1. 2. 3. 4. 3 2 Left view 3 Fuel cock Rear wheel Footrest Front wheel 1. Spark arrester 2. Seat 3.
Controls and instruments 1 2 3 10 11 3 12 9 87 1. 2. 3. 4. 5. 6. 7. 8. 9. 6 5 4 10. Fuel Gauge 11. Transmission gear indicator light 12. Transmission gear Shift Shaft Rear brake lever Parking brake Front brake lever Throttle lever Main switch Fuel tank cap Auxiliary 12v DC Electrical Outlet Handlebar switches Choke TIP The ATV you have purchased may differ slightly from the figures shown in this manual.
INSTRUMENT AND CONTROL FUNCTIONS WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. 1 0 Main switch a F OF The positions of the main switch are as follows: IG ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. a. Main switch OFF All electrical systems are off. The key can be removed.
Handlebar switches Transmission gear indicator light 1 2 1 3 2 3 N F R 4 4 1. Forward indicator light “F” 2. Neutral indicator light “N” 3. Reverse indicator light “R” 1. 2. 3. 4. Neutral indicator light “F” This indicator light comes on when the transmission is in the forward position. Start switch “START” Light switch “LIGHTS” Engine stop switch “ENG. STOP” Horn switch “HORN” Engine stop switch “ENG. STOP” Set this switch to “ ” before starting the engine.
Horn switch “HORN” Start switch “START” Push this switch to crank the engine with the starter. See the starting instructions on page 6-1 prior to starting the engine. The horn button is a yellow push switch, located below the turning signal lamp switch on the left-hand handlebar. Pressing in on the button will sound the audible horn signal. Releasing the button will silence the horn. 4 Light switch “LIGHTS” Set this switch to “ ” to turn on the low beams and the taillight.
4 Throttle lever Speed limiting throttle adjustment Once the engine is running, movement of the throttle lever will increase the engine speed. Regulate the speed of the ATV by varying the throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will return to an idle any time the hand is removed from the throttle lever. Before starting the engine, check the throttle to be sure it is operating smoothly.
Vehicle speed limiter 1. Loosen the locknut. 2. To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (a). To decrease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction (b). Do not turn the adjusting screw out more than 11mm(0.4 in) or the throttle cable could be damaged. Always make sure the throttle lever free play is adjusted to 1.0-3.0 mm (0.04-0.12 in). (See page 8-19.
Front brake lever Rear brake lever The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever toward the handlebar grip. The rear brake lever is located on the left handlebar. To apply the rear brake, pull the brake lever toward the handlebar grip. 1 1 4 1. Rear brake lever 1.
Parking brake WARNING Use the parking brake before starting the engine or parking the ATV, especially on a slope. Apply the front bake lever and push down the lock button to apply the parking brake. Squeeze the front brake lever to release the parking brake. ȁAlways set the parking brake before starting the engine. The ATV could start moving unexpectedly if the parking brake is not applied. This could cause loss of control or a collision.
stop and the brake lever is fully engaged before moving the shifting shaft. Always pause in the "N" neutral position for a few seconds when shifting from forward to reverse or from reverse to forward, this allows the transmission time to disengage and resynchronize. Transmission gear selector The ATV is equipped with a fully automatic C.V.T. transmission and has forward and reverse gearing. A transmission shifting shaft is located on the right hand side of your engine.
Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing methanol and ethanol are not recommended by E-TON because it can cause damage to the fuel system or ATV performance problems. Recommended fuel: UNLEADED GASOLINE 92 OCTANE Fuel tank capacity: 8.5 L (2.25 US gal) (1.87 Imp.gal) 4 WARNING Do not overfill the fuel tank. Fuel expands when it heats up. If the fuel tank is overfilled, fuel could spill out due to heat from the engine or the sun.
With the fuel cock lever in this position, fuel flows to the carburetor. Turn the fuel cock lever to this position when starting the engine and riding. Fuel cock (for USA) The fuel cock supplies fuel from the tank to the carburetor while also filtering it. The fuel cock lever positions are explained as follows and shown in the illustrations. RE S OFF OFF OFF RE S NO OFF 1 RES 1 4 RES FUEL NO FUEL 1. Lever positioned over “RES” 1. Lever positioned over “OFF” This indicates reserve.
Choke Seat The choke is used to start a cold engine. Move the choke in direction (a) to turn on the choke. Move the choke in direction (b) to turn off the choke. See the “Starting a cold engine” section on page 6-1 for proper operation. To remove the seat Pull the seat lock lever upward and pull up the seat at the rear. 4 1 1. Seat lock lever (a) 1 2 3 (b) 1. 2. 3. 4.
To install the seat Insert the projection on the front of the seat into the seat holder and push down on the seat at the rear. 2. Move the kickstarter lever down lightly with your foot until the gears engage, and then push it down smoothly but forcefully. TIP Make sure that the seat is securely fitted. 4 1 1. Kickstarter 2 1 NOTICE Do not use the kickstarter if there is no battery installed or if the battery leads are disconnected. 1. Projection 2.
PRE-OPERATION CHECKS Pre-operation check list Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
ITE T M Fuel Engine oil Final transmission oil 5 Front brake Rear brake Throttle lever Control cables Wheels and tires Brake levers Chassis fasteners Instruments, lights and switches ROUTINEPAGE Check fuel level in fuel tank, and add recommended fuel if necessary. Check fuel line for leakage. Correct if necessary. Check oil level in engine, and add recommended oil to speciified level if necessary. Check A TV for oil leakage. Correct if necessary. Check ATV for oil leakage. Correct if necessary.
Fuel Front and rear brakes Make sure that there is sufficient fuel in the tank. (See page 4-8.) Brake levers Check for correct free play in the brake levers. If the free play is incorrect, adjust it. (See pages 8-21 and 8-24.) Check operation of the levers. They should move smoothly and there should be a firm feeling when the brakes are applied. If not, have the ATV checked by an E-TON dealer. Inline fuel filter Check the filter for dirt or damage before each ride and at each refueling.
5 Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. If the brakes do not provide proper braking performance, check the brakes for wear. (See pages 8-20 and 8-23.) Tires Throttle lever Tire pressure Check the operation of the throttle lever. It must open smoothly and spring back to the idle position when released. Have an E-TON dealer correct if necessary. Use the tire pressure gauge to check and adjust tire pressures when the tires are cold.
Set tire pressures to the following specifications: Recommended pressure: Front 28 kPa (4.0 psi) (0.28 kgf/cm2) Rear 28 kPa (4.0 psi) (0.28 kgf/cm2) Minimum: Front 22 kPa (3.2 psi) (0.22 kgf/cm2) Rear 22 kPa (3.2 psi) (0.22 kgf/cm2) 1 5 1. Low-pressure tire gauge The tire pressure gauge is included as standard equipment. Make two measurements of the tire pressure and use the second reading. Dust or dirt in the gauge could cause the first reading to be incorrect.
Tire wear limit After extensive tests, only the tires listed below have been approved for this model by E-TON POWER TECH CO., LTD. When the tire groove decreases to 3 mm (0.12 in) due to wear, replace the tire. Front: Manufacturer model Size Type 5 MAXXIS M931 AT21 x 7-10 Tubeless Rear: 1. Tire wear limit Manufacturer model Size Type Tire information This ATV is equipped with tubeless tires with valves.
Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. Instruments and switches Check that all instruments and switches are working properly. Correct if necessary.
OPERATION Starting a cold engine WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. 6 WARNING Inspect cables frequently and replace if damaged. Corrosion can result when the cable sheaths become damaged, and cables can also become frayed or kinked, which could restrict the operation of controls and lead to an accident or injury. Read the Owner’s Manual carefully before riding the ATV.
Ambient temp./choke position TIP This model is equipped with an ignition circuit cutoff system. The engine can be started under the following conditions. The transmission is in neutral. The clutch is disengaged with the transmission in gear. However, it is recommended to shift into neutral before starting the engine. 1 0° 10° 20° 30° °C 30° 50° 70° 90° °F 3 4 5. Use the choke in reference to the figure: 1 2 3 6 Position (1): Cold engine start with ambient temperature below 30 °C (90 °F).
crank the engine more than 10 seconds on each attempt. To start out and accelerate 1. Release the throttle lever. 7. If the engine is started with the choke in position (1), the choke should be returned to position (2) to warm up the engine. If the engine is started with the choke in position (2), keep the choke in this position to warm up the engine. NOTICE Always close the throttle before shifting gears, otherwise damage to the engine and drive train may result. NOTICE 6 2.
To decelerate When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose traction, reducing control and increasing the possibility of an accident. ances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. 0–160 km (0–100 mi) or 0–10 hours Avoid prolonged operation above 1/2 throttle. Vary the speed of the ATV regularly.
Parking on a slope 1 WARNING 6 Avoid parking on hills or other inclines. Parking on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ATV transversely across the incline, stop the engine, apply the parking brake, and then block the front and rear wheels with rocks or other objects. Do not park the ATV at all on hills that are so steep you could not walk up them easily. 1. Parking brake lock button 1.
Aftermarket parts, accessories, and modifications While you may find aftermarket products similar in design and quality to genuine E-TON Accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others. Installing aftermarket products or having other modifications performed to your ATV that change any of the vehicle’s design or operation characteristics can put you and others at greater risk of serious injury or death.
Use extra caution when riding an ATV with accessories. The ATV may handle differently than it does without accessories. MAXIMUM LOADING LIMIT ATV loading limit (total weight of rider, cargo, accessories, and tongue): 100.0 kg (220 lb) Loading If you are carrying cargo and towing a trailer, include the tongue weight in the maximum ATV load limit. Load cargo on the carriers as close to the center of the ATV as possible.
RIDING YOUR ATV 7 7-1
7 GETTING TO KNOW YOUR ATV This ATV is for recreation use. This section, Riding your ATV, provides general ATV riding instructions for recreational riding. The skills and techniques described in this section, however, are appropriate for all types of riding. Riding your ATV requires special skills acquired through practice over a period of time. Take the time to learn the basic techniques well before attempting more difficult maneuvers.
Not recommended for children under 16 years of age. WARNING A child under 16 should never operate an ATV with engine size greater than 90 cc. Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.
This ATV is designed to carry operator only – passengers prohibited. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. WARNING 7 Never carry a passenger. Carrying a passenger on this ATV greatly reduces your ability to balance and control this ATV. You could have an accident, resulting in severe injury or death to you and/or your passenger.
Apparel Always wear the following to reduce risk of injury in an accident: !Approved motorcycle helmet that fits properly Eye protection (goggles, helmet face shield, or protective eyewear) Over-the-ankle boots, gloves, long-sleeved shirt or jacket, and long pants WARNING Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident.
Do not operate after consuming alcohol or drugs. The operator’s performance capability is reduced by the influence of alcohol or drugs. Consuming alcohol or drugs could seriously affect your judgment, cause you to react more slowly, and affect your balance and perception. Pre-operation checks Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Perform the pre-operation checks listed on page 5-1.
Speed limiters For riders less experienced with this model, the throttle lever housing is equipped with a vehicle speed limiter. This speed limiter keeps the throttle from fully opening, even when the throttle lever is pushed to the maximum. Turning in the adjusting screw limits the maximum engine power available and decreases the maximum speed of the ATV. Turning in the adjusting screw decreases top speed, and turning it out increases top speed.
Loading and accessories As originally equipped, this ATV is not designed to carry cargo or tow a trailer. If you choose to add accessories to carry cargo, you must use common sense and good judgment. Reduce speed and allow more room to stop. A heavier vehicle takes longer to stop. Avoid hills and rough terrain. Choose terrain carefully. Use extreme caution when towing or carrying a load on inclines. Turn gradually and go slowly.
Avoid wheelies and jumping. During operation Always keep your feet on the footboards during operation; otherwise, they may contact the rear wheels. WARNING Attempting wheelies, jumps, and other stunts increases the chance of an accident, including an overturn. Never attempt stunts, such as wheelies or jumps. Don’t try to show off. WARNING Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off of the ATV.
material accumulated around the engine area could catch fire. Do not operate, idle, or park the ATV in dry grass or other dry ground cover. Keep the engine area free of dry grass, brush, or other combustible material. Someone touching the exhaust system during or after operation could be burned. Do not touch the hot exhaust system. Do not park the ATV in a place where others might be likely to touch it.
BE CAREFUL WHERE YOU RIDE This ATV is designed for off-road use only. WARNING Paved surfaces may seriously affect handling and control of the ATV, and may cause the ATV to go out of control. Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets.
WARNING Never operate this ATV on any public street, road or highway, even a dirt or gravel one. You could collide with another vehicle. 7 Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles. In many states it is illegal to operate ATVs on public streets, roads and highways.
Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks, bumps, or holes. Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
7 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV. DO NOT use the flag pole bracket as a trailer hitch. WARNING You could collide with another vehicle if operating in off-road areas where you cannot easily be seen. Mount a caution flag on the ATV to make you more visible. Watch carefully for other vehicles.
or clothing to come in contact with these components. With the engine idling, the drive position and then release the parking brake. Apply the throttle slowly and smoothly. You will start to accelerate. If the throttle is applied too abruptly, the front wheels may lift off the ground, resulting in a loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of your ATV. When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly.
To achieve maximum traction while riding off-road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. It is essential that this skill be learned first at low speed. 7 As you approach a curve, slow down and begin to turn the handlebars in the desired direction.
!Shift your weight forward. !Never open the throttle suddenly. The ATV could flip over backwards. !Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. !Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. Be very careful when turning on any hill. !Avoid crossing the side of a steep hill if possible.
It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning for-ward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars. Whenever possible, ride straight up hills. 7 Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side – there could be another person, an obstacle, or a sharp drop-off.
If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then descend the hill. If you start to roll backwards, DO NOT apply either brake abruptly. Apply only the front brake. When fully stopped, apply the rear brake as well, and then lock the parking brake.
ȁ Shift your weight backward and to the up side of the hill. !ȁNever go down a hill at high speed. !ȁAvoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where possible. !ȁImproper braking can cause the wheels on the uphill side to come off the ground or cause loss of traction. Gradually apply only the rear brake when going downhill.
Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV to tip or roll over. Carefully choose your path and ride no faster than you will be able to react to obstacles which may appear. CROSSING A SLOPE WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the ATV to overturn. ȁAlways follow proper procedures as described in the Owner’s Manual. ȁAvoid hills with excessively slippery or loose surfaces.
body in the uphill direction. It may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill. When riding on slopes, be sure not to make sharp turns either up or down hill. CROSSING THROUGH SHALLOW WATER WARNING Operating this vehicle through deep or fastflowing water can lead to loss of control or overturn. To reduce your risk of drowning or other injuries, use care when crossing through water.
Test your brakes after leaving the water. If necessary, apply them several times to let friction dry out the linings. Do not continue to ride your ATV without verifying that you have regained proper braking ability. WARNING Wet brakes may have reduced stopping ability which could cause loss of control.
RIDING OVER ROUGH TERRAIN WARNING Riding improperly over obstacles could cause loss of control or a collision. Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in the Owner’s Manual. Riding over rough terrain should be done with caution. Look out for obstacles which could cause damage to the ATV or could lead to an upset or accident.
SLIDING AND SKIDDING WARNING Skidding or sliding improperly may cause you to lose control of this ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. ȁ!Learn to safely control skidding or sliding ȁ!by practicing at low speeds and on level, ȁ!smooth terrain. ȁ!On extremely slippery surfaces, such as ice, ȁ!go slowly and be very cautious in order to ȁ!reduce the chance of skidding or sliding out of control.
WHAT TO DO IF... This section is designed to be a reference guide only. Be sure to read each section on riding techniques completely. 7 WHAT TO DO... If your ATV doesn’t turn when you want it to: Bring the ATV to a stop and practice the turning maneuvers again. Be sure you are putting your weight on the footboard to the outside of the turn. Position your weight over the front wheels for better control. (See page 7-15.) If your ATV begins to tip while turning: Lean more into the turn to regain balance.
If your ATV can’t make it up a hill you are trying to climb: Turn the ATV around if you still have forward speed. If not, stop, dismount on the uphill side of the ATV and physically turn the ATV around. If the ATV starts to slip backwards, DO NOT USE THE REAR BRAKE – the ATV may tip over on top of you.Dismount the ATV on the uphill side. (See page 7-17.) If your ATV encounters shallow water: Ride slowly and carefully through slow moving water, watching for obstacles.
PERIODIC MAINTENANCE AND MINOR REPAIR Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/ operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages. WARNING Turn off the engine when performing maintenance unless otherwise specified.
Owner’s manual and tool kit Be sure to put this owner’s manual in the plastic bag and to always carry it as well as the owner’s tool kit and the low-pressure tire gauge in their respective compartments under the seat. The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs.
Periodic maintenance chart for the emission control system TIP For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals. For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance intervals should be followed.
INITIAL NO. ITEM Whichev- month CHECK OR MAINTENANCE er comes km JOB first (mi) hours 6 7 * Exhaust system Spark arrester Check for leakage and replace gasket(s) if necessary. Check for looseness and tighten all screw clamps and joints if necessary. Clean.
General maintenance and lubrication chart INITIAL NO. ITEM Whichev- month CHECK OR MAINTENANCE er comes km JOB first (mi) hours 1 2 3 8 4 5 * * * * Air filter element Clean and replace if necessary. Clutch Check operation Front brake Rear brake Brake hoses 6 * Wheels 7 * Tires 1 3 6 6 12 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) 20 80 160 160 320 Every 20–40 hours (more often in wet or dusty areas) √ Check operation and correct if necessary.
INITIAL NO. ITEM 8 * Wheel hub bearings 9 * Chassis fasteners 10 * 11 * 12 * Shock absorber assemblies Front knuckle pivots Steering shaft 13 * Steering system 14 Engine oil 15 Engine oil strainer 16 17 * 1 3 6 6 12 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) 20 80 160 160 320 √ √ √ √ √ √ √ √ √ Lubricate with lithium-soap-based grease. √ √ √ Lubricate with lithium-soap-based grease. Check operation and repair or replace if damaged.
INITIAL NO. 8 ITEM CHECK OR MAINTENANCE JOB Whichever comes first month 1 3 km (mi) 320 (200) 1300 (800) hours 20 80 160 160 320 √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ 18 * Throttle lever housing and cable • Check operation and correct if necessary. • Check throttle cable free play and adjust if necessary. • Lubricate throttle lever housing and cable. 19 * Front and rear brake switches • Check operation and correct if necessary.
TIP The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service Regularly check and, if necessary, correct the brake fluid level. Every two years replace the components of the brake master cylinder and caliper, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.
2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the ATV is ridden normally). Checking the spark plug The spark plug is an important engine component, which is easy to check.
plug should be tightened to the specified torque as soon as possible. Spark plug gap: 0.6–0.7 mm (0.024–0.028 in) 4. Install the spark plug cap. Inline fuel filter Your ATV is equipped with an inline fuel filter to prevent dirt and debris from entering the carburetor and engine. Check the filter for dirt or damage before each ride and at each refueling. Replace the filter if dirty or damaged. The filter should be replaced every 600 hours of operation and at the start of each season. 1.
Start the engine and check for leaks. Inspect the fuel lines for cuts, abrasions and deterioration. Replace fuel lines as needed. DO NOT start or operate the engine if the fuel filter or lines are leaking. Leaking fuel can cause a fire. To replace the filter, first turn the fuel cock to the "OFF" position. Then carefully compress the wire clamp rings until the clamp is free of the fuel line. Slide each clamp away from the filter about 3/4".
TIP If the engine was started before checking the oil level, be sure to warm up the engine sufficiently, and then wait at least ten minutes until the oil settles for an accurate reading. 1 2 3. Remove the engine oil filler cap, and then wipe the dipstick off with a clean rag. 1 2 1. Maximum level mark 2. Minimum level mark TIP The engine oil should be between the minimum and maximum level marks. 1. Engine oil filler cap 2. Dipstick 4.
4. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil from the crankcase. 7. Add the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap. Recommended oil: See page 10-2. Oil quantity: 1.0 L (1.06 US qt) (0.88 Imp.qt) 4 NOTICE 3 8 1. 2. 3. 4. Engine oil drain bolt O-ring Spring Oil filter element Do not mix any chemical additives.
Final transmission oil The final transmission case must be checked for oil leakage before each ride. If any leakage is found, have E-TON dealer check and repair the ATV. In addition, the final transmission oil must be changed at the intervals specified in the periodic maintenance and lubrication chart. 1 To change the final transmission oil 1. Place the ATV on a level surface. 2. Place an oil pan under the final transmission. 3.
Cleaning the air filter element Tightening torque: Final transmission oil drain bolt: 25 Nm (2.5 m·kgf, 18.1 ft·lbf) The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 5. Add the specified amount of the recommended final transmission oil, and then check the oil level. 1. Remove the air filter case by removing the bolts.
2. Remove the air filter case cover by removing the bolts. 1 2 1. Air filter case cover 2. Air filter element 3. Clean the air filter element with compressed air. 8 4. Check the air filter element and replace it if damaged. 5. Install the air filter case cover by installing the bolts. 6. Place the air filter element in the original position, and then install the screw.
Cleaning the spark arrester Cleaning the spark arrester (for USA) Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screw and nut. Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. 1. Remove the screw. 2. Remove the spark arrester buy pulling it out of muffler. 3. Tap the spark arrester lightly, and then use a wire brush to remove any carbon deposits . 4. Insert the spark arrester into the muffler and align the screw holes. 5.
Adjusting the carburetor WARNING The carburetor should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The carburetor is an important part of the engine and requires very sophisticated adjustment. Therefore, most carburetor adjustments should be left to an E-TON dealer, who has the necessary professional knowledge and experience.
TIP A diagnostic tachometer is needed to make this adjustment. Engine idling speed: 1600–1800 r/min 1. Start the engine and warm it up. 8 TIP TIP The engine is warm when it quickly responds to the throttle. 2. Attach the tachometer to the spark plug lead. 3. Check the engine idling speed and, if necessary, adjust it to specification by turning the throttle stop screw at the carburetor.
Valve clearance The throttle cable free play should measure 1.0– 3.0 mm (0.04–0.12 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, have an E-TON dealer adjust it. The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by an E-TON dealer at the intervals specified in the periodic maintenance and lubrication chart.
the brake shoe wear without having to disassemble the brake. To check the brake shoe wear, check the position of the wear indicator while applying the brake. If a brake shoe has worn to the point that the wear indicator reaches the wear limit line or mark, have an E-TON dealer replace the brake shoes as a set. Adjusting the front brake lever free play Front brake Before adjusting the brake lever free play, check the front brake shoes for wear.
1. Turn the left brake cable adjusting nut in direction (a) to increase the free play, and in direction (b) to decrease it. 3 1 (b) (a) 1. Right brake cable 2. Left brake cable 3. Cable joint 2 1 8 1. Left brake cable adjusting nut 2. While applying the front brake, turn out the right brake cable adjusting nut in direction (a) to increase the free play, and in direction (b) to decrease it, until the right and left brake cable lengths are equal. The cable joint will become vertical.
Checking the rear brake pads 1 The rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with wear indicator grooves, which allows you to check the brake pad wear without having to disassemble the brake. If a brake pad has worn to the point that the wear indicator grooves have almost disappeared, have an E-TON dealer replace the brake pads as a set. 1.
Checking the rear brake lever free play MPXFS The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart. The brake lever free play should measure 0~3.0 mm (0~0.118 in) as shown. If the free play is incorrect, have an E-TON dealer check the brake system. 1 1.
Checking and lubricating the front and rear brake levers Checking and lubricating the cables The operation and the condition of all control cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have an E-TON dealer check or replace it. The operation of the front and rear brake levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
Checking the wheel hub bearings Battery The front and rear wheel hub bearings must be checked at the intervals specified in the periodic maintenance lubrication chart. If there is play in a wheel and hub or if a wheel does not turn smoothly, have an E-TON dealer check the wheel hub bearings. This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check the electrolyte or to add distilled water.
EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes or other sources of ignition away. Ventilate when charging or using in an enclosed space. KEEP OUT OF REACH OF CHILDREN. 8 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. To install the battery TIP Be sure the battery is fully charged. 1. Place the battery in its compartment.
If the fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off all electrical circuits. NOTICE Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. To charge a VRLA (Valve Regulated Lead Acid) battery, a special (constant-voltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a constant-voltage battery charger, have an E-TON dealer charge your battery.
Chain slack adjustment Drive chain slack The drive chain will stretch with use and will require periodic adjustments. To check the chain tension, remove the chain guard and measure the slack. 10-20 mm 1 2 1. The axle position lock bolts 2. The chain tension adjuster 8 Loosen the axle position lock bolts lightly and turn the chain adjuster nut to take up the excess slack in the chain. Once the chain has been adjusted to the proper tension retighten the axle position locking bolt.
Removing a wheel 2. Elevate the ATV and place a suitable stand under the frame. 3. Remove the nuts from the wheel. 4. Remove the wheel. 1. Loosen the wheel nuts. 1 8 1.
Installing a wheel 2. Lower the ATV to the ground. 3. Tighten the wheel nuts to the specified torques. 1. Install the wheel and the nuts. TIP When installing the wheel, make sure its arrow mark points toward the rotating direction of the wheel. Tightening torques: Front wheel nuts: 45 Nm (4.5 m·kgf, 33 ft·lbf) Rear wheel nuts: 45 Nm (4.5 m·kgf, 33 ft·lbf) Front 1 8 1.
Troubleshooting Although E-TON ATVs receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart represents a quick and easy procedure for checking these vital systems yourself.
Troubleshooting chart 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have an E-TON dealer check the ATV. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 3. Ignition 8 Wet Wipe off with a dry cloth and correct the spark plug gap, or replace the spark plug.
CLEANING AND STORAGE applications such as those available in coinoperated car washers. Cleaning Frequent, thorough cleaning of your ATV will not only enhance its appearance but will improve its general performance and extend the useful life of many components. 1. Before cleaning the ATV: a. Block off the end of the exhaust pipe to prevent water entry. A plastic bag and strong rubber band may be used. b. Make sure the spark plug and all filler caps are properly installed. 2.
Long-term Before storing your ATV for several months: 1. Follow all the instructions in the “Cleaning” section of this chapter. 2. Turn the fuel cock lever to “OFF”. 3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits from building up. Pour the drained fuel into the fuel tank. 4. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel from deteriorating.
6. 7. 8. 9. plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder wall with oil.) e. Remove the spark plug cap from the spark plug, and then install the spark plug and the spark plug cap. Lubricate all control cables and the pivoting points of all levers and pedals.
SPECIFICATIONS Engine Type Displacement Bore / Stroke Compression Four cycle Air / Oil cooled 149.6 cc 57.4 * 57.8mm 9.7:1 Transmission Type Automatic (C.V.T. V-Belt) Chassis Overall Length Overall Width Overall High Wheel Base Dry Weight 1665 mm / 65.6" 1010 mm / 39.8" 1070 mm / 42.1" 1090 mm / 42.9" 168 kg / 370 lbs Suspension Front Rear Single A-arm Swing Arm Adjustable Shocks @ 1.57" travel Adjustable Shock @ 2.
Carburetor Make/Size Main Jat Pilot Jet Air Mixture Adjustment Idle Speed Kei-Hin with Manual choke 1.08mm 0.35mm Back out 1 - 2 2/ 4 turns Idle 1600 - 1800rpm Sprockets Frnot Rear Chain 12 teeth 34 teeth #520 Battery Head Light Rear Light Fuses Fluids Fuel Engine Oil Transmission 12V-8AH-GTX9 35 W / 35 W 21 W / 5 W 10.0 A Type Volume Type Volume Type Volume Unleaded Gasoline 89 octane 8.5 L / 2.25 US gal / 1.87 Imp.gal SAE 15W-40 1.0 liters / 1 gt SAE80 / 90 weight gear Oil 750 cc / 25.
Noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been remove
Maintenance record Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance work.
ETON AMERICA, LLC. LIMITED VEHICLE WARRANTY ETON America warrants all new ETON vehicles sold by authorized ETON Dealers to be free from defects in materials and workmanship subject to the following exclusions and limitations. New vehicles sold by an authorized dealer to original retail consumers are covered by this policy for a period of six (6) months from the date of delivery. There is no mileage limitation. This warranty is given to the original retail purchaser and is non-transferable.
ETON AMERICA, LLC.
INDEX A E Engine break-in .............................................................. 6-4 Engine, cold start...........................................................6-1 Engine idling speed...................................................... 8-18 Engine oil............................................................5-3, 8-11 Engine, starting a warm.................................................6-3 Engine stop switch........................................................
M Main switch .................................................................... 4-1 Maintenance and lubrication chart..................................8-5 Maintenance chart, emission control system.................8-3 O Owner’s manual and tool kit........................................... 8-2 P Parking .......................................................................... 6-4 Parking brake ................................................................. 4-9 Parking on a slope ....................
WARNING Improper ATV use can result in SEVERE INJURY or DEATH. BEER BEER ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate: NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS: without proper training or instruction. use proper riding techniques to avoid at speeds too fast for your skills or the vehicle overturns on hills and rough conditions. terrain and in turns.
