E-TON ROVER GT Service Manual

ETON America ROVER & ROVER GT SERVICE MANUAL ROVER (UK1-90R) ROVER GT

Maintenance Schedule Four Stroke Vehicles WP-0027 ScheduledMaintenance300KM Every1000KM Every3000KM Every6000KM Every12000KM200Miles

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UKI Rover will not shift into gear properly Service Bulletin Page 6 of 7 Step 19 Step 20 Inst

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UK1 Rover will not shift into gear properly Service Bulletin Page 7 of 7 Step 23 Step 24 Tight

ETON America, LLC Bulletin No: Date: 0051 03/01/2007 E-TON ATV, Scooter and Utility Kart Headlight Wattages Service Bulletin Page 1 HeadLightWat

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

92.3 Fuel Lines & Filter Inspect the fuel lines for deterioration, damage, or leakage, and replace if necessary. Check the fuel filter for ac

102.6 Air Cleaner • Unscrew the air cleaner cover screws. • Pull out the air filter element from the air cleaner case. Wash the element in non-f

11 2.8 Idle Speed Air/Fuel Ratio adjusting procedure: Step 1: Air adjusting screw. Turn adjusting screw all the way in then back off ¾ to 1¼ turn

12 When the drive chain becomes very dirty, it should be removed, cleaned, and lubricated. Use commercial chain lubricant to lubricate the drive cha

132.11 Wheels & Tires • Inspect the tire surfaces for cuts, nails, or other sharp objects. • Check the tire surfaces at cold tire condition.

142.14 Gear Oil Gear oil needs to be changed every year. 1. Place an oil catch pan under the unit directly below the transmission box. 2. Remove

153. ENGINE REMOVAL AND INSTALLATION 3.1 Service Information NOTE: The engine should only be removed when repair conditions warrant its removal. E

16Engine installation is basically removal in reverse. 1. Replace the engine in the frame from the right side. 2. Reinstall the engine hanger bolt

174. FUEL AND LUBRICATION SYSTEMS 4.1 Trouble Shooting • No fuel in tank • No fuel to cylinder • Too much fuel going i

1Table of Contents 1. INFORMATION...

184.2 Fuel Tank REMOVAL • Remove the fuel tank cap and rear bed assembly. • Disconnect the fuel line from the carburetor. • Unscrew the fuel ta

19 • Unscrew the float chamber screws and remove the float chamber. • Remove the float arm pin, float, and float needle valve. • Inspect the sea

20ASSEMBLY Clean all parts in solvent and blow it dry with compressed air. Assembly is essentially disassembly in reverse. E-TON recommends that t

21Draining the oil: Remove the oil filter cap and the oil drain bolt. NOTE: Drain the oil while the engine is warm to ensure complete draining.

224.5 Oil Pump removal / Installation Remove the fan cover assembly. Remove the cooling fan. Remove the flywheel and A/C G

23Remove the oil pump driven sprocket. Remove the oil pump assembly. Disassemble the oil pump.

24Inspection: Measure the oil pump body-to-rotor clearance with a feeler gauge. SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measu

25 Installation: Install the oil pump assembly. Install the oil pump driven sprocket. Install the A/C Generator, flywheel

265. ENGINE COMBUSTION SYSTEM 5.1 Service & General Information This section describes cylinder head, valves, camshaft and the other parts main

275.2 Trouble Shooting Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by traci

27.5 Electrical Starter Mechanisim ...46 7.7

285.3 Top End Removal Remove the rocker arm cover. • Remove the air cleaner and carburetor. • Remove the intake pipe assembly. •

29Loosen the camshaft gear from cam chain and remove the camshaft. Inspection Inspect the cam lobes’ surface and height of cam lobes for wear o

30Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage. Measure the I.D. of each rocker arm. SERVICE LIMIT:

31Remove the cam chain guide. Cylinder Head Disassembly Remove the valve cotters, spring retainers, and valve springs with a valve spring com

32 Measure the free length of the inner and outer valve springs. SERVICE LIMITS: Inner 27.0mm / 1.063” Outer 30.5mm / 1.201” Inspect each v

335.5 Cylinder Head Assembly • Lubricate each valve stem with oil. • Insert the valves into guides. • Install the valve springs, retainers and

34Camshaft and Rocker Arm Installation Install the cam shaft and cam chain. Install the rocker arms and rocker arm shafts into the camsha

35Using a feeler gauge, measure the clearance between the rocker arm and valve stem. Adjust if necessary. Standard value: IN: 0.07mm / 0.0028”

366. CYLINDER & PISTON 6.1 Service Information Camshaft lubrication oil is fed to the cylinder head through an oil hole in the cylinder head an

376.3 Cylinder & Piston Removal 1. Remove the seat, rear fender, and exhaust. 2. Remove the spark plug cap. 3. Disconnect the wiring. 4. Pul

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

38 • Remove the piston pin from the piston. • Remove the piston. Spread each piston ring and remove it by lifting up at a point opposite

39 Calculate cylinder taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.05 mm / 0.00196”

40Insert each piston ring into the cylinder and measure the ring end gap. NOTE: Push the rings into the cylinder with the top of the piston to be s

41Measure the connecting rod small end I.D. SERVICE LIMIT: 13.06 mm / 0.514” 6.4 Piston Installation Clean the piston ring grooves tho

42 • Install the piston pin with new pin clips. • Do not align the piston pin clip end gap with the piston cutout. NOTE: Do not allow the clip to

43 Install a new head gasket, then install the cylinder head. Head Gasket: Part # 811589 Torque the cylinder head nuts. Torque v

447. TRANSMISSION SYSTEM 7.1 Service Information Troubleshooting Abnormal shifting or will not reset Will not move after engine is started Does n

45 7.2 Shift Mechanism C.D.I. The C.D.I. is located underneath the front hood cover. It includes the shift control system. Replace it if the contro

46 Driven Pulley Because the revolving radius of the V-Belt at the Drive End is increased, the Face Comp Movable Drive is forced out by the V-Belt

477.6 C.V.T. Disassembly – (LH) Crankcase Removal Loosen the band screw and remove the CVT inlet duct. Remove the bolts and LH crankcas

41.3 Specifications Component Rover (UK1-90R)Rover GT (UK2) Engine Type Four cycle liquid cooled Four cycle liquid cooled Displacement 88

48 • Loosen the flange nut. • Remove the drive pulley assembly and driven belt. Remove the drive face boss and movable driven face

49  Inspect the weight roller for wear or damage and replace them if necessary.  Measure the O.D. of weight rollers. SERVICE LIMIT: 14.6 mm

50 Inspect the clutch weight set for wear or damage.  Measure the thickness of clutch weight lining. SERVICE LIMIT: 2.0mm / 0.0787”

51 Install the dowel pins and gasket. Install the driven belt and driven pulley assembly. Install the movable driv

528A. TRANSMISSION GEAR SET 8A.1 Service Information  For transmission repairs, the engine must be removed from the frame.  Drain oil from the

53 Remove the cir clip. Then, the final shaft can be removed from the transmission cover. Loosen the bolts and remove the transmis

548A.4 Gear Set and Bearing Inspection Turn the inner race of the bearing with your finger.  The bearing should turn smoothly and quietly, with

55COUNTER SHAFT SHIFT FORK GEAR SHIFT SHAFT  Install the counter shaft and reverse shaft in the LH crankcase.  Install the gear shift shaft and

568B. SHIFTING GEAR BOX 8B.1 Service Information  For transmission repairs, the engine must be removed from the frame.  Drain oil from the tran

578B.3 Transmission Assembly Drawing Shift Mechanism www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

5Component Rover (UK1-90R)Rover GT (UK2) Idle Speed Idle 1700 - 1900rpm Idle 1700 - 1900rpm Sprockets Front 520x12t 520x12t Rear 520x32t

588B.4 Shift Mechanism Gear box disassembly  Remove the transmission cover and gears  Remove and inspect the shift push, fixed shaft, and fork

598B.5 Gear Box Assembly  Remove the transmission cover and gears.  Inspect gears for wear, scoring, chipping, or b

608B.5 Gear Box Assembly • Remove the transmission cover and gears. • Inspect gears for wear, scoring, chipping, or b

619. STEERING SYSTEM 9.1 Steering System Drawing 9.2 Trouble Shooting Hard Steering • Faulty tire(s) • Ste

629.3 Steering Wheel Removal Remove the horn button to gain access to the four steering wheel bolts. Then, remove the steering wheel. INSTALL

63• Remove the rubber cap on the kingpin and remove the cotter pin. • Unscrew the castle nut and remove the kingpin. TIE-ROD INSPECTION • Inspect

64STEERING SHAFT REMOVAL • Remove the handle bar and handle bar cover (see paragraph 8-1). • Remove the front fender (see section 11-1). • Remov

65 INSTALLATION OF STEERING SHAFT • Apply grease to the steering shaft bushing. • Insert the steering shaft through the bushing. • Ensure the sha

66INSTALLATION OF KINGPIN • Apply grease on the kingpin lower dust seal lips and install. • Grease the bushing and install the kingpin. • Tighte

6710. WHEEL AND BRAKE SYSTEM 10.1 Wheel and Brake System Drawings Front wheel Rear wheel Hydraulic bra

61.4 VIN & Engine Number The unit’s serial numbers are available directly on the unit. See the pictures below. The frame VIN number is stamped

6810.2 Troubleshooting 10.3 Wheel Removal & Installation REMOVAL Raise the wheels off the ground by placing a block under the

69 10.4 Drive Mechanism & Rear Brake Removal Removal and inspection: • Remove the rear wheel • Raise the rear wheels off the ground. • Remove

70 Disassemble the driven sprocket, axle, and sprocket collar. Check the driven sprocket for damage or wear. Place the rear axle on V-blocks and c

71INSTALLATION Add grease to the dust seal lips and install dust seals. Assemble the rear axle and the driven sprocket. • Assemble t

72 • Assemble the wheel. • Tighten the rear axle nut with 30-35 N/m (22.1-25.8 lbf-ft). Install a new cotter pin. • Adjust the rear brake slac

73Unscrew the bolts and remove the brake disc. Check the thickness of disc and replace with a new one if the thickness less than 3mm (0.118 in”). RE

74• Remove the brake pad as shown. • Check the thickness of the brake pad and replace with a new one if the thickness less than 1mm (0.039”). Tak

75 • Unscrew the bolt and drain the used oil. • Fasten the bolt after the used oil has been drained out completely. • Loosen the bleeder valve o

76PARKING BRAKE PAD REMOVAL Remove the tire. There are two brake caliper fixing bolts on the back of the plate. Use a wrench to remove those two b

7711. BODY COVERS AND EXHAUST SYSTEM 11.1 Body Cover Drawings 11.2 Cage & Body Cover Removal The support cage must first be remov

71.5 Standard Torque Values NOTE: Maximum metric torque value is shown. Do not exceed maximum torque value. ENGINE Cylinder head nut 25 N/m (13.3

78 Remove the four bolts above the front fender panels to remove the front side fenders on the left and right hand sides (ref 11.2-B).

7911.3 Exhaust System Drawing This is the two-piece exhaust system (exhaust reed system and pipe). www.Get2itParts.comwww.Get2itParts.comwww.Get2

8011.4 Exhaust System Removal • Caution: Do not attempt to perform maintenance on a hot exhaust system. Hot exhaust pipe and muffler pose a seriou

81 After every 200 hours of operation, the Spark Arrestor has to be replaced by removing the retaining bolt using a 4mm allen wrench. Use pliers o

8212. ELECTRICAL SYSTEM 12.1 Trouble Shooting  Fuel petcock not in ON position  Dirty or clogged fuel filter  Improper ignition timing  Faul

83 Charging system failure • Loose connection of battery terminal • Corrosion of battery terminal leads • Loose or poor connection of frame gr

8412.2 Ignition Coil Testing the ignition coil: • Remove the coil wire cap from the spark plug • Unplug the ignition coil primary leads • Test t

85Battery removal: • Remove the battery retainer strap • Disconnect the negative (BLACK) battery lead first • Disconnect the positive (RED) batt

86Battery installation: • Place the battery in the battery compartment. • Clean the battery terminals and lead connectors of all dirt and corros

8712.5 Wiring Diagram www.Get2itParts.comwww.Get2itParts.comwww.Get2itParts.com

82. MAINTENANCE 2.1 Maintenance Schedule The maintenance internals in the follow table are based upon average riding conditions. Riding in unusually

8813. TROUBLESHOOTING 13.1 Engine Does Not Start No fuel flow to carburetor • No fuel In fuel tank • Clogged float valve • Clogged fuel tank c

8913.2 Poor Performance at Low Idle 13.3 Poor Performance at High Speed Bad ignition timing  Faulty CDI unit  Faulty pulse generator Rest

9013.4 Loss of Power Wheels do not spin freely • Brake dragging • Drive chain too tight • Damaged wheel bearing •Wheel bearing needs lubrication

9113.5 Poor Handling Steering is heavy • Damaged steering bearing • Damaged steering shaft bushing One wheel is wobbling • Bent rim • Improper

ETON America, LLC Speed limit keys for the UK1-90R FX-ROVER Service Bulletin Bulletin No.: SB-0047 Date: 11/21/06 The UK1-90R Rover is equipped with

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UK1 Rover not shifting into gear properly Service Bulletin There is an engineering change affect

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UK1 Rover not shifting into gear properly Service Bulletin Page 2 of 7 Step 3 Step 4 Step 5

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UKI Rover will not shift into gear properly Service Bulletin Step 7 Step 8 Page 3 of 7 Step 9

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UK1 Rover will not shift into gear properly Service Bulletin Page 4 of 7 Remove the 2 pins from

ETON America, LLC Bulletin No: Date: 0048 12/08/06 UK1 Rover will not shift into gear properly Service Bulletin Page 5 of 7 Step 16 Step 15 Now, r