E-TON Viper 40E (RXL-40E) Service Manual

ETON America 40cc Service Manual Covering: Rascal IXL-40 Viper Jr. RXL-40 Viper 40E RXL-40E www.Get2itParts.comwww.Get2itParts.comwww.Get2itP

MAINTENANCE 2.2 MAINTENANCE SCHEDULE The maintenance intervals in the follow table are based upon average riding conditions. Riding in unusually dust

MAINTENANCE 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle housing, loosen the lock nut, and adjust the free pla

2.7 SPARK PLUG (1) Disconnect the spark plug cap and remove the spark plug. (2) Visually inspect the spark plug electrodes for wear. (3) The center el

Remove the chain protection cover. Adjust the chain slack. Loosen the lock bolts (4), and then adjust the drive chain slack by turning the adjustin

MAINTENANCE Adjust the free play of the rear brake lever by turning the adjuster on the rear axle. 2.11 WHEELS AND TIRES Inspect the tire surfaces f

MAINTENANCE Carefully moving the vehicle back, let the wheels turn 180° so the marks on the tires are aligned with the axle center height. Measure the

3. ENGINE REMOVAL AND INSTALLATION 3.1 ENGINE REMOVAL Remove the seat and the Body Cover. (chapter 10) Remove the spark plug cap from the spark plug

4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING • No fuel in tank • No fuel to cylinder • Too much fuel into cylinder • No spark at plug • Air cleaner

4.2 FUEL TANK REMOVAL Remove the fuel tank cap. Remove the seat and Body Cover. Disconnect the fuel line from the carburetor. Unscrew the fuel tank m

4.5 CARBURETOR REMOVAL Loosen the drain screw and drain the gasoline. Remove the float chamber by removing the two retaining screws. Remove the flo

www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

4.7 THROTTLE VALVE ASSEMBLY Install the needle clip on the needle jet. STANDARD SETTING: 2nd groove from the top. Install the jet needle into the thr

5. ENGINE COMBUSTION SYSTEM 5.1 CYLINDER REMOVAL Remove the air cleaner and carburetor. Remove the Ignition Coil assembly. Remove the cylinder shroud

Remove the cylinder. 5.2 INSPECTION Inspect the cylinder bore for wear or damage. Measure he cylinder inner diameter at three levels in an X and Y axi

Spread each piston ring and remove it by lifting up at a point opposite gap. Insert each piston ring into the cylinder and measure the end gap. SERVI

COMBUSTION SYSTEM 5.4 PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings. NOTE: Avoid piston and piston

5.6 CYLINDER INSTALLATION Clean off any gasket material from the crankcase surface. NOTE: Be careful not to damage the crankcase surface. Install a

6. STARTER SYSTEM 6.1 STARTER REMOVAL - RXL-40, IXL-40 Remove the left crankcase cover. Remove the collar and return pull spring. Do not remove the r

Remove the holder and ignition coil assembly. Remove the A.C. generator assembly. Disassemble the right crankcase and left crankcase. Remove the crank

6.3 INSPECTION Assemble the crankshaft composition and right crankcase. Clean off the gasket material and install the dowel pins and a new gasket.

Install the dowel pins and ignition coil assembly. Assemble the right crankcase and right crankcase cover. 6.5 LEFT CRANKCASE ASSEMBLY I

TABLE OF CONTENTS 1. ATV Unit Information 2. General Maintenance Schedule 3. Engine Removal 4. Fuel System 5. Engine Combustion system 6. Pull/Electr

6.6 CLUTCH OUTER REMOVAL Remove the gearbox from the right crankcase cover. NOTE: The four bolts shown are green; the others are gold. Remove the fl

STARTER SYSTEM 6.9 WEIGHT INSTALLATION Install the washer, bolts, and clutch weight set on the A.C. generator assembly. 6.10 CLUTCH OUTER INSTALLATION

7. TRANSMISSION SYSTEM 7.1 GEAR BOX SEPARATION Remove the sprocket and fixing plate from the final shaft. Check the sprocket for damage and replace i

7.2 INSPECTION Check the gears for abnormal wear or lack of lubrication. Replace the gears if necessary. Turn the inner race of the bearing with yo

Assemble the gear box and gear box cover. Install one clamp pulser cord and tighten all the box bolts. Install the sprocket and fixing plate on the f

www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

FRONT WHEEL/STEERING 8.2 TROUBLESHOOTING Faulty tire Insufficient tire pressure Steering shaft nut too tight Damaged steering shaft bearing Faulty

FRONT WHEEL/STEERING 8.3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar. Remove engine switch housing on the left handle

FRONT WHEEL/STEERING Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely. Align the split line of the th

Take off the rubber cap on the kingpin. Unscrew the nut and remove the kingpin. TIE-ROD INSPECTION Inspect the tie-rod for damage or bending. Inspect

www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

STEERING SHAFT REMOVAL Remove the handle bar and handle bar cover. (See chapter 8-3) Remove the front fender. (See chapter 10-3) Unscrew the steering

STEERING SHAFT BEARING INSPECTION Turn the shaft bearing with finger. The bearing is on the front part of frame. The bearing should turn smoothly and

9. REAR WHEEL SYSTEM 9.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 9-1 www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

REAR WHEEL SYSTEM 9.2 TROUBLESHOOTING • Sticking brake cam • Sticking brake cable • Incorrect brake adjustment • Worn brake cam • Worn brake dr

9.3 REMOVE REAR WHEEL AND REAR BRAKE Lift the rear wheels off the ground. Release the cotter pin, axle nut and washer. Release the wheel and wheel hu

9.4 DRIVE MECHANISM REMOVAL AND INSPECTION Remove the rear wheel and the rear brake. Remove the drive chain under cover. Disassemble the chain retai

Check the turning of bearing with fingers. The bearings should turn smoothly and quietly. Replace if necessary. INSTALLATION Add grease to the dust s

REAR WHEEL SYSTEM Assemble the brake arm aligning the punch marks on the cam and the arm. Tighten the brake arm bolt and nut with 7-12 N/m torque. (5

BODY COVER & EXHAUST MUFFLER 10. FENDERS AND EXHAUST PIPE 10.1 FENDERS DRAWING 9 bolts www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

BODY COVER & EXHAUST MUFFLER Remove the four bolts which connect the body cover and right & left fender side cover. (See picture) Remove the f

1. INFORMATION 1.1 SAFETY • Gasoline is extremely flammable and is explosive under certain conditions. • Do not smoke or allow sparks or flames in

10.5 EXHAUST PIPE REMOVAL The exhaust system becomes extremely hot after running the unit. Ensure that the exhaust system has completely cooled before

11. ELECTRICAL SYSTEM 11.1 TROUBLESHOOTING ENGINE STARTS BUT STOPS NO SPARK AT PLUG ENGINE STARTS BUT RUNS POORLY ENGINE INTERMITTENT POWER ENGINE

11.2 IGNITION COIL - RXL-40 Remove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire. Measure the primary coil resis

11.5 WIRING DIAGRAMS FOR RXL40 FOR IXL40 11-3 www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

FOR RXL 40E 11-4 www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

Possible Problem Areas ♦ No Fuel in Fuel Tank ♦ Clogged Float Valve ♦ Clogged Fuel Tank Cap Breather Hose ♦ Clogged Fuel Line ♦ Faulty Spark

TROUBLE SHOOTINGPossible Problem Areas ♦ Faulty C. D. I. Unit ♦ Faulty Pulse Generator ♦ Improper Air Screw Adjustment ♦ Fuel / Air mixture

TROUBLE SHOOTING Possible Problem Areas ♦ Faulty C. D. I. Unit ♦ Faulty Pulse Generator ♦ No Fuel in Fuel Tank ♦ Clogged Fuel Line ♦ Clogg

TROUBLE SHOOTING Possible Problem Areas ♦ Brake Dragging (Adjust brake Cable) ♦ Drive Chain too tight ♦ Worn or Damaged wheel Bearings ♦ Wheel be

TROUBLE SHOOTING Vehicle pulls to one side Possible Problem Areas ♦ Damaged Steering Shaft Bearing ♦ Damaged Steering Shaft Bushing ♦ Bent Steeri

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

12.7 Engine Will Not Start (Start motor turns)Engine Does NotStartIs Ignitionswitch on?Legend:Flow"Yes""No"Turn on ignition

12.7.2 Engine Will Not Start, continuedEngine Does NotStartTether switchactive?Repair/replacetether switchEnginestarts?Fuel in tank?Fill tank (50:1fue

12.7.3 Engine Will Not Start, continuedLegend:Flow"Yes""No"Engine Does NotStartCarburetor mainjet stuck/clogged?Clean carburetorEn

12.7.4 Engine Will Not Start, continuedLegend:Flow"Yes""No"Engine Does NotStartTurn the ignitionswitch to the OFFposition to betes

12.7.5 Engine Will Not Start, continuedLegend:Flow"Yes""No"Engine Does NotStartCheck the keyway onthe flywheel.Key issheared?Repla

12.7.6 Engine Will Not Start, continuedLegend:Flow"Yes""No"Engine Does NotStartEnginecompressionbelow95PSI?Rebuild top endEnginest

13.1 VIPER 40E ELECTRIC STARTER The Viper 40E is equipped with an electric starter as well as a backup pull starter. To gain access to the reduction

To gain access to the AC Generator, remove the two bolts from the clutch shoes, then remove the center nut from the engine cooling fan to gain acces

ETON America, LLC Bulletin No: Date: 0008 08/25/2000 Technical Tips Service Bulletin 1. PAPER FUEL FILTERS -CAUSE: RESTRICTIVE FUEL FLOW THEY CLOG

ETON America, LLC Bulletin No: Date: 0014 03/07/2001 Rascal (IXL 40): CDI Speed Limiter Adjustment Procedure. Service Bulletin Rascal IXL 40 CDI Spee

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 stamp

ETON America, LLC Bulletin No: Date: 0017 03/07/2001 Rascal (IXL 40): Fuel/oil Mixture Ratio Update Service Bulletin Rascal IXL 40 Oil Mixture Update

ETON America, LLC Bulletin No: Date: 0018 05/15/2001 Rascal No Spark Preliminary Check Service Bulletin ETON Technical department has recently receiv

ETON America, LLC Bulletin No: Date: 0021 09/10/03 ATV Break-In Procedure Service Bulletin Your ATV requires a break-In period just as with all oth

ETON America, LLC Rascal (IXL-40) & Viper Jr. (RXL-40)Carburetor Kits Service Bulletin There are two different carburetors for the Rascal (IX

ETON America, LLC Safety Tether Switch Installation Service Bulletin Install the tether switch on the LH side of the handlebars and shown in the pict

ETON America, LLC 2005 Viper Models No Power Service Bulletin Viper models with no power or bad throttle response. Remove the 4mm spark arrestor reta

ETON America, LLC Oil Pump Flow Adjustment all Oil Injected two cycle Engines Service Bulletin To adjust the oil pump flow on a two cycle oil inject

ETON America, LLC C.D.I. Module Specifications Viper 40E (2 Cyle) Service Bulletin Specifications highlighted in yellow are the suggested critical te

www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

INFORMATION 1.5 TORQUE VALUES ENGINE Item Qty Thread dia.(mm) Torque : N–m / (ft-lbs) Spark plug 1 14 mm12-19 / (9-14)Intake pipe mounting bolt 2 5

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