E-TON Viper 90R Specifications

CONTENTS 1. INFORMATION 2. MAINTENANCE 3. ENGINE REMOVAL AND INSTALLATION 4. ENGINE FUEL SYSTEM 5. ENGINE LUBRICATION AND COOLING S

For RXL50M, because it have parking brake in rear tire. So, its controller is at the handler bar right side. Inspect the rear brake le

2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center h

3. ENGINE REMOVAL AND INSTALLATION 3.1 SERVICE INFORMATION 3.3 ENGINE INSTALLATION 3.2 ENGINE REMOVAL 3.1 ENGINE SHALL BE REMOVED IN THE CONDITIO

(The right side picture is for ATV RXL 90R) 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse orde

4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING 4.3 CARBURETOR 4.2 FUEL TANK 4.1 TROUBLESHOOTING ENGINE CAN NOT START ★NO FUEL IN TANK ★NO FUEL TO CY

4.2 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel tank cap and front fender. U

DISASSEMBLY Unscrew the float chamber screws and remove the float chamber. Disassembly the float arm pin, float and float needle valv

ASSEMBLY Clean all parts in solvent and blow it dry with compressed air. Assembly is essentially the reverse order of disassembly. THROTTLE VA

5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 ENGINE LUBRICATION SYSTEM 5.4 COOLING SYSTEM 5.2 CAUTION 5.3 OIL PUMP 5.5 TROUBLESHOOTING 5.1 ENGINE

5.5 TROUBLESHOOTING NO ENOUGH OIL SUPPLY TO ENGINE ★THE OIL LEVEL IN OIL TANK IS TOO LOW. ★OIL TUBES WERE NOT FIXED WELL. ★OIL HAS LEAKAGED FROM TU

1. INFORMATION 1.1 SAFTY 1.2 NOTES 1.3 SPECIFICATION 1.4 SERIAL NUMBER 1.5 TORQUE VALVE 1.1 SAFETY ● Gasoline is extremely flammable and is exp

6. ENGINE COMBUSTION SYSTEM 11.1 TROUBLESHOOTING 11.3 CYLINDER AND PISTON INSPECTION 11.2 CYLINDER AND PISTON REMOVAL 11.4 INSTALLATION 6.1 TROUB

6.2 CYLINDER AND PISTON REMOVAL Remove the seat and rear fender. Remove the exhaust pipe. Remove the spark plug cap. Disconnect the wire. Drag out th

Check the cylinder head mating surface for warp with a straight edge and feeler gauge. Service limit: 0.10 mm Insert each piston ring in

Measure the piston pin bore, and the piston pin outer diameter. Pin outer diameter service limit: Pin bore service limit: RXL RXL RXL 5

Apply some oil to inside of the connecting rod small end. Install the piston, piston pin and clip. Install the piston with the arrow mark facing the

7. TRANSMISSION SYSTEM 7.1 TROUBLE SHOOTING 7.6 GEAR BOX 7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM 7.7 ELECTRIC SELF-STARTER MECHANISM 7.3 SHIFT

Shift Mechanism For RXL 90R Gear Box For RXL 90R

7.3 SHIFT MECHANISM GENERAL For mission repair, the engine must separate from frame. Full stop the vehicle before shifting to forward or

3D DRAWING C.D.I We can find C.D.I under the seat. It include shift control system. Replace it if control system invalid. There

SHIFT MECH. Remove mission side cover and other parts. Check shift gear for wear or damage. Measure open width of shift spring as fig-2. If open wi

1.3 SPECIFICATION RXL50 RXL70 RXL90 RXL90R RXL50M ENGINE TYPE AIR-COOLING TWO STROKE DISPLACEMENT 49.3 ㏄ 68.0 ㏄ 82.5 ㏄ 82.5 ㏄ 49.3 BORE & STR

7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION This transmission is the combination of automatic centrifugal clutch and V-belt continuous variable tr

Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at th

ELECTRIC SELF-STARTER MECHANISM KICK STARTER 7.8 KICK STARTER This kick-starter arm is on the left side of engine. When the kick-sta

8. STEERING SYSTEM 8.1 THE PARTS DRAWING OF STEERING SYSTEM 8.3 HANDLEBAR 8.2 TROUBLESHOOTING 8.4 STEERING SYSTEM 8.1 THE PARTS DRAWING OF STEER

(The picture of right side is for ATV RXL 50M) Remove engine switch housing on the left handle bar. Remove rear brake level bracket. (F

Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely. (The picture of right side is for ATV RXL 50/90 a

Take off the rubber cap on the kingpin and remove the cotter pins on the kingpin. Unscrew the castle nut and remove the kingpin. TIE-ROD

STEERING SHAFT REMOVAL Remove the handle bar and handle bar cover. (see paragraph 8-1) Remove the front fender. (see paragraph 11-1) Unscrew the steer

INSTALLATION OF STEERING SHAFT Install the steering shaft with the bushing. Apply grease to the bushing. Install the bushing holder and tighten the nu

INSTALLATION OF KINGPIN Use grease to the kingpin lower dust seal lips and install it. Pump grease to bushing and install the kingpin. Tighten the kin

1.4 SERIAL NUMBER For this ATV serial; the number of frame and engine are the same position, just like the picture below; The frame serial number is

9. FRONT WHEEL 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 O

9.2 TROUBLESHOOTING FRONT WHEEL WOBBLING BRAKE DRAG POOR BRAKE PERFORMANCE ★ FAULTY TIRE ★ WORN FRONT BRAKE DRUM BEARING ★ BENT RIM

Measure the brake drum inner diameter. The maximum limit: 86 mm Turn the inner race of each bearing with fingers. The bearings should t

INSTALL BRAKE PANAL Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and in

10. REAR WHEEL AND BRAKE SYSTEM 10.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 10.3 DRIVE MECHANISM 10.2 TROUBLESHOOTING 10.4 HYFRAULIC DISC BRAKE SYSTE

10.2 TROUBLESHOOTING BAD BRAKE PERFORMANCE ★ BRAKE SHOES ARE WORN ★ BAD BRAKE ADJUSTMENT ★ BRAKE LININGS ARE OILY, GREASY OR DIRTY ★ BRAKE D

Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. Let the rear axle lie in V-block

Assembly the wheel. Tighten the rear axle nut with 60-80 N.m. Install a new cotter pin. Adjust rear brake level free play. Adjust chain slack.

Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm TO REPLACE TH

Remove the brake shoe as shown Check the thickness of brake shoe and replace a new one if the thickness less than 1mm.

1.5 TORQUE VALUES For this ATV serial; the torque values of frame and engine are the same, just like the picture below; ENGINE ● Cylinder head nut

Unscrew the bolt and drain out the used oil drain. Fasten the bolt after the used oil being drained out completely. Add the brake oil (D

Fill the brake oil to the level shown on the cup when no air comes out Assemble the cover PARKING BRAKE ASSEMBLY- RXL 50R In RXL 50R, i

There are two brake caliper fixing bolt on the back of the plate. Use wrench to remove those two bolts, you can take the whole caliper out.

11. FENDERS AND EXHAUST PIPE 11.1 FENDERS DRAWING 11.4 EXHAUST PIPE REMOVE 11.2 HOW TO REMOVE THE FENDERS 11.5 EXHAUST PIPE INSTALLATION 11.3 EXHAU

You should remove the seat before removing Picture 3the front and rear fender. Unscrew the bolts as pictures 3 & 4 then you can remove the rea

Before remove the front body cover Picture 7you should remove the handle bar cover firstly. Secondly, you should disassembly the front and rear br

11.4 EXHAUST PIPE REMOVE Do not service the exhaust pipe while they are hot. Unscrew the exh

12. ELECTRICAL SYSTEM 12.1 TROUBLESHOOTING 12.5 CHARGING 12.2 IGNITION COIL 12.6 REMOTE CONTROLLER 12.3 BATTERY CAUTION 12.4 BATTERY INSPECTION

12.2 IGNITION COIL (ATV RXL 50/90 and KXL 90 and MXL 50 all have the same model in this chapter) Remove the spark plug cap from the spark plug.

12.4 BATTERY INSPECTION Battery is under the seat, you can see this battery from the left side. Measure the battery voltage using a voltmeter. VOLT

2. MAINTENANCE 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN 2.3 FUEL TUBE 2.10 BRAKE SYSTEM 2.4 THROTTLE OPERATION

First turn the switch off and take the front center cover apart. Find out the receiver pin on the right side of front vehicle.

Take a new remote controller and press any button one time for one second to adjust the frequency of controller. Then waiting ten seconds later pu

12.7 WIRING DIAGRAMS The wiring diagram above is for RXL 50 / 90 The wiring diagram above is

VIPER 90R 2-Takter

13.TROUBLESHOOTING 13.1 ENGINE DOES NOT START 13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS13.3 POOR PERFORMANCE AT HIGH SPEED 13.4 LOSS POWER 13.5 PO

13.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS N.G. O.K. CHECK carburetor N.G. A

13.4 LOSS POWER RAISE WHEELS OFF GROUND DOES NOT SPIN FREELY AND SPIN BY HAND SPIN FREELY

13.5 POOR HANDLING POSSIBLE REASON

2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. (For RXL50 / 90)

2.6 AIR CLEANER Unscrew the air cleaner cover screws. Pull out the air filter element from the air cleaner case. Wash the element in non-flammable s

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. W