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Eton America Rascal IXL-40 Service Manual

Eton america kid's atv 40cc service manual
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ETON America
40cc Service Manual
Covering:
Rascal IXL-40
Viper Jr. RXL-40
Viper 40E RXL-40E

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Summary of Contents for Eton America Rascal IXL-40

  • Page 1 ETON America 40cc Service Manual Covering: Rascal IXL-40 Viper Jr. RXL-40 Viper 40E RXL-40E...
  • Page 3 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.
  • Page 5 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.

  • Page 6: Specifications

    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...

  • Page 7: Serial Number

    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 Serial Number Engine Number...

  • Page 8: Torque Values

    INFORMATION 1.5 TORQUE VALUES ENGINE Item Thread dia.(mm) Torque : N–m / (ft-lbs) Spark plug 14 mm 12-19 / (9-14) Intake pipe mounting bolt 5 mm 3.5-5 / (2.5 – 4) Cylinder socket bolt 5 mm 4.5-6 (3-4.5) L Case bolt 5 mm 4.5-6 (3-4.5) AC generator assembly nut...

  • Page 9: Table Of Contents

    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...

  • Page 10: Maintenance Schedule

    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 REGULAR SERVICE EVERY YEAR (First week) (Every 30 operating days) FUEL LINE THROTTLE OPERATION AIR CLEANER SPARK PLUG...

  • Page 11: Throttle Cable Adjustment

    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 play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 2.6 AIR CLEANER (1) Loosen the screws and remove the air cleaner from carburetor.

  • Page 12: Idle Speed

    MAINTENANCE 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 electrode should have square edges and the side electrode should have a constant thickness. (4) Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.

  • Page 13: Brake System

    MAINTENANCE Remove the chain protection cover. Adjust the chain slack. Loosen the lock bolts (4), and then adjust the drive chain slack by turning the adjusting nut. Tighten the four lock bolts. When the drive chain becomes very dirty, it should be removed, cleaned, and lubricated with a specified lubricator.

  • Page 14: Wheels And Tires

    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 for cuts, nails, or other sharp objects. Check the tire surfaces at cold tire conditions. The standard tire pressure is 2.2±0.4 psi.

  • Page 15: Gear Oil

    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 distance between the marks. Calculate the difference in the front and rear measure- ments. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while...

  • Page 16: Engine Removal And Installation

    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. Remove the exhaust pipe. Remove the air cleaner and carburetor Remove the throttle cable and fuel lines. Disconnect the wire connectors and remove the wire from the frame clamps.

  • Page 17: Engine Fuel System

    4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING • No fuel in tank Engine will not start • No fuel to cylinder • Too much fuel into cylinder • No spark at plug • Air cleaner clogged • Improper adjustment of the idle speed screw •...

  • Page 18: Fuel Tank

    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 mounting bolts. Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline immediately. 4.3 THROTTLE VALVE DISASSEMBLY Remove the throttle top from the carburetor.
  • Page 19 4.5 CARBURETOR REMOVAL Loosen the drain screw and drain the gasoline. Remove the float chamber by removing the two retaining screws. Remove the float arm pin. Remove the float and float valve. Inspect the float valve for wear or damage. Remove the main jet and needle jet.
  • Page 20 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 throttle valve and secure it with the needle clip retainer. Install the spring and throttle valve. Align the throttle valve slit with the locating pin in the carburetor body and install the carburetor top onto the carburetor.
  • Page 21 5. ENGINE COMBUSTION SYSTEM 5.1 CYLINDER REMOVAL Remove the air cleaner and carburetor. Remove the Ignition Coil assembly. Remove the cylinder shroud rubber cap and shroud. Remove the spark plug. Remove the inlet pipe insulator and gasket.
  • Page 22 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 axis. Calculate cylinder taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. TAPER LIMIT : 0.01mm Calculate the cylinder out-of-round at three levels in the X and Y-axis.
  • Page 23 Piston Spread each piston ring and remove it by lifting up at a point opposite gap. Spacer Rings Piston Rings Insert each piston ring into the cylinder and measure the end gap. SERVICE LIMIT: 0.5 mm Measure the clearance between the ring and groove. SERVICE LIMIT: 0.09 mm Measure the piston outer diameter at 10mm up from the...
  • Page 24 COMBUSTION SYSTEM 5.4 PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings. Avoid piston and piston ring damage during NOTE: installation. Align the piston rings slit with the lobe on the grooves. After installation, the rings should be free to rotate in the ring grooves.
  • Page 25 5.6 CYLINDER INSTALLATION Clean off any gasket material from the crankcase surface. Be careful not to damage the crankcase surface. NOTE: Install a new gasket. Coat the cylinder bore and piston rings with engine oil and install the cylinder. Avoid damaging piston rings during installation. NOTE: Install the spark plug and cylinder shroud.
  • Page 26 6. STARTER SYSTEM 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 reel unless the starter is damaged. NOTE: Be careful to remove the reel and prevent the spring from flicking away.
  • Page 27 Remove the holder and ignition coil assembly. Remove the A.C. generator assembly. Disassemble the right crankcase and left crankcase. Remove the crankshaft composition.
  • Page 28 6.3 INSPECTION Assemble the crankshaft composition and right crankcase. Clean off the gasket material and install the dowel pins and a new gasket. Assemble the right crankcase and left crankcase. 6.4 RIGHT CRANKCASE ASSEMBLY Install the A.C. generator assembly. Install the holder.
  • Page 29 Install the dowel pins and ignition coil assembly. Assemble the right crankcase and right crankcase cover. 6.5 LEFT CRANKCASE ASSEMBLY Install the L-crankcase plate and clutch one-way. Install the left crankcase cover.
  • Page 30 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 flange nut and clutch outer composition from gear box. CLUTCH DRUM Remove the bolts, washers, and clutch weight set from the A.C.
  • Page 31 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 Install the clutch outer composition on the gearbox. Assemble the gearbox and right crankcase cover.
  • Page 32 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 if necessary. Remove the five bolts and one clamp pulser cord. Remove the gearbox cover while tapping the cases at several locations with a rubber mallet or soft hammer.
  • Page 33 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 your finger. The bearing should turn smoothly and quietly. Also check that the outer races of the bearings fit tightly in the gear box.
  • Page 34 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 final gear shaft.
  • Page 36 FRONT WHEEL/STEERING 8.2 TROUBLESHOOTING Faulty tire Hard steering Insufficient tire pressure Steering shaft nut too tight Damaged steering shaft bearing Faulty steering shaft lower bearing Bent rim Front wheel wobbling Faulty tire Worn front wheel rim bearing Axle nut not tightened properly Steers to one side Bent frame Bent tie rods...
  • Page 37 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 bar. Remove rear brake level bracket. Remove the bolts attaching the upper holder cover. Remove the handlebar holder and handlebar. INSTALLATION Put the handlebar on the lower holders.
  • Page 38 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 throttle housing and holder with the punch mark. Tighten the screw securely. 8.4 FRONT WHEEL REMOVAL Raise the front wheels off the ground by placing a block under the frame.
  • Page 39 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 the ball joint rubbers for damage, wear, or dete- rioration. Turn the bolts of ball joints with fingers. The ball joints should turn smoothly and quietly.
  • Page 40 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 shaft fixed out below shaft. Pull the steering shaft carefully. BUSHING INSPECTION Remove the steering shaft. Remove the bushing from the shaft.
  • Page 41 FRONT WHEEL/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 quietly. Also check that the bearing outer race fits in the holder. Replace the bearing if necessary. INSTALLATION OF STEERING SHAFT Install the steering shaft with the bushing.
  • Page 42 9. REAR WHEEL SYSTEM 9.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM...
  • Page 43 REAR WHEEL SYSTEM 9.2 TROUBLESHOOTING • Sticking brake cam Brake drag • Sticking brake cable • Incorrect brake adjustment Poor brake performance • Worn brake cam • Worn brake drum • Worn brake shoes • Improper brake adjustment • Brake linings oily, greasy or dirty •...
  • Page 44 9.3 REMOVE REAR WHEEL AND REAR WHEEL SYSTEM REAR BRAKE Lift the rear wheels off the ground. Release the cotter pin, axle nut and washer. Release the wheel and wheel hub. Remove the brake drum cover. Remove the axle collar and brake drum. Check the brake lining thickness.
  • Page 45 9.4 DRIVE MECHANISM REMOVAL AND INSPECTION Remove the rear wheel and the rear brake. Remove the drive chain under cover. Disassemble the chain retaining clip and master link. Disassemble the driven sprocket, axle, and sprocket collar. Check the driven sprocket for damage or wear. Let the rear axle lie on V-blocks and check the run out.
  • Page 46 Check the turning of bearing with fingers. The bearings should turn smoothly and quietly. Replace if necessary. INSTALLATION Add grease to the dust seal lips and install dust seals. Assemble the rear axle and the driven sprocket. Assemble the drive chain on the driven sprocket. Assemble the master link and retaining clip.
  • Page 47 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. (5-9 ft-lbs.) Install the adjusters. Install the brake shoes and springs to their original positions. Assemble the brake drum, axle collar, and brake drum cover.
  • Page 48 BODY COVER & EXHAUST MUFFLER 10. FENDERS AND EXHAUST PIPE 10.1 FENDERS DRAWING 9 bolts...
  • Page 49 BODY COVER & EXHAUST MUFFLER Remove the four bolts which connect the body cover and right & left fender side cover. (See picture) Remove the four bolts which connect the body side cover and footrest. Remove the two bolts which attach the body cover on the REAR FRONT center frame.
  • Page 50 10.5 EXHAUST PIPE REMOVAL The exhaust system becomes extremely hot after running the unit. Ensure that the exhaust system has completely cooled before servicing. Remove the exhaust pipe nuts that attach the mani- fold to the engine. Remove the exhaust pipe mounting bolts that attach the exhaust pipe and muffler assembly to the frame.

  • Page 51: Electrical System

    11. ELECTRICAL SYSTEM ELECTRICAL SYSTEM 11.1 TROUBLESHOOTING Improper ignition timing ENGINE STARTS BUT STOPS Faulty spark plug No spark at plug NO SPARK AT PLUG Engine stop switch at "OFF" Safety Tether switch disconnected Poor connection: Between CDI and ignition coil Between CDI and engine stop switch Between CDI and body ground Between ignition coil and spark plug...
  • Page 52 ELECTRICAL SYSTEM 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 resistance. STANDARD: 0.1 - 0.3-(20) Measure the secondary coil resistance with the spark plug cap in place. STANDARD: 7.4 - 11 k(20) 11.3 IGNITION TIMING...
  • Page 53 11.5 WIRING DIAGRAMS FOR RXL40 FOR IXL40 11-3...
  • Page 54 FOR RXL 40E 11-4...

  • Page 55: Trouble Shooting

    12. TROUBLE SHOOTING TROUBLE SHOOTING 12.1 Engine does not start Possible Problem Areas ♦ No Fuel in Fuel Tank ♦ Clogged Float Valve Check Fuel Flow to Carburetor ♦ Clogged Fuel Tank Cap Breather Hose ♦ Clogged Fuel Line O.K. ♦...
  • Page 56 12.2 POOR PERFORMANCE AT TROUBLE SHOOTING LOW IDLE SPEED Possible Problem Areas ♦ Faulty C. D. I. Unit Check Ignition Timing ♦ Faulty Pulse Generator O.K. Check Carburetor Air Adjustment ♦ Improper Air Screw Adjustment ♦ Fuel / Air mixture ratio to lean O.K.
  • Page 57 12.3 POOR PERFORMANCE AT TROUBLE SHOOTING HIGH SPEED Possible Problem Areas ♦ Faulty C. D. I. Unit Check Ignition Timing ♦ Faulty Pulse Generator O.K. Check Fuel Flow at Carburetor ♦ No Fuel in Fuel Tank Low Fuel Flow ♦ Clogged Fuel Line ♦...
  • Page 58 TROUBLE SHOOTING 12.4 LOSS OF POWER Possible Problem Areas Raise Wheels off of Ground and ♦ Brake Dragging (Adjust brake Cable) turn by hand ♦ Drive Chain too tight Does not spin ♦ Worn or Damaged wheel Bearings freely ♦ Wheel bearings need Lubrication O.K.
  • Page 59 12.5 POOR HANDLING TROUBLE SHOOTING Possible Problem Areas ♦ Damaged Steering Shaft Bearing Steering Stiff or Heavy ♦ Damaged Steering Shaft Bushing ♦ Bent Steering Shaft O.K. One Wheel is Wobbling ♦ Bent Wheel Rim ♦ Improper Wheel Hub Installation ♦...
  • Page 60 12.7 Engine Will Not Start (Start motor turns) Legend: Flow Engine Does Not "Yes" Start "No" Turn on ignition Is Ignition Engine switch on? switch starts? Turn on engine Engine stop Engine switch on? stop switch starts? Fully apply brake Engine Is brake lever...
  • Page 61 12.7.2 Engine Will Not Start, continued Legend: Flow "Yes" Engine Does Not "No" Start Repair/replace Engine Tether switch tether switch starts? active? Engine Fill tank (50:1 Fuel in tank? starts? fuel/oil mix for 40cc Turn fuel petcock Engine Fuel petcock to ON position starts? 'ON' position?
  • Page 62 12.7.3 Engine Will Not Start, continued Legend: Flow "Yes" Engine Does Not "No" Start Engine Carburetor main Clean carburetor starts? jet stuck/clogged? Clean or replace Spark plug Engine fouled? spark plug starts? Plug gap set Engine Set gap to 0.036' to 0.036'? starts? Test for spark at the spark...
  • Page 63 Problem unsolved. Engine starts? Check all wire connections at CDI box and A/C generator assembly. If problem persists, contact ETON Technical Service at: Problem Solved. (864)-278-9585 EXT 114 12-9...
  • Page 64 12.7.5 Engine Will Not Start, continued Legend: Flow Engine Does Not "Yes" Start "No" Check the keyway on the flywheel. Key is Engine Replace the key sheared? starts? Replace CDI Box Problem Solved. Continue to 12.7.6 12-10...
  • Page 65 12.7.6 Engine Will Not Start, continued Legend: Flow Engine Does Not "Yes" Start "No" Engine Engine Rebuild top end compression starts? below 95PSI Contact ETON Technical Service at: Problem Solved. (864)-278-9585 EXT Problem unsolved. 12-11...
  • Page 66 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 gear and starter wheel, remove the six Phillips head screws (circled in the picture).
  • Page 67 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 access to the flywheel. Remove the flywheel. Clean and inspect. The AC generator also should be cleaned and inspected as well as the charging coils.
  • Page 68 REPAIR: CLEAN AFTER EVERY 3-5 RIDES, MORE FREQUENTLY IN DUSTY CONDI- TIONS. USE A GOOD QUALITY FOAM FILTER SPRAY.(BEL-RAY FOAM FILTER SPRAY) 4. BATTERIES----THE BATTERIES FOR ALL ETON VEHICLES ARE MAINTANCE-FREE . PROPER SERVICE PROCEDURES ARE AS FOLLOWS: 1. FILL BATTERY WITH BATTERY PACK SUPPLIED.
  • Page 69 ETON America, LLC Service Bulletin Bulletin No: 0014 Rascal (IXL 40): CDI Speed Limiter Adjustment Procedure. Date: 03/07/2001 Rascal IXL 40 CDI Speed Limiter Adjustment Procedure Units affected: All IXL-40 models (Rascal). Reason for bulletin: CDI speed limiter adjustments. Repair:...
  • Page 70 Road test and verify ease of starting Rascal IXL 40 Oil Mixture After an extensive amount of research into the proper fuel/oil mixture for the Rascal IXL-40 we have deter- mined the proper fuel/oil mixture ratio to be 50:1. Our research showed that with today's oil technologies a mixture of 50:1 is perfectly acceptable and this change will reduce plug fouling concerns and aid in easier starts.
  • Page 71 /or changing the plug type from Champion to NGK BPM7A. We are asking our dealer and field sales force to have these item checked before placing a service call to ETON America's Warranty / Tech Services line. Safety Tether...
  • Page 72 ETON America, LLC Service Bulletin Bulletin No: 0021 ATV Break-In Procedure Date: 09/10/03 Your ATV requires a break-In period just as with all other internal combustion en- gines. This period allows the engine parts to seat and wear properly without undue strain which can cause premature failure.
  • Page 73 ETON America, LLC Service Bulletin Rascal (IXL-40) & Viper Jr. (RXL-40) Bulletin No: 0024 Date: 04/01/2004 Carburetor Kits There are two different carburetors for the Rascal (IXL-40) and the Viper. Jr. (RXL-40). The different carburetors can be distinguished by the position and type of the fuel inlet tube. (see photo below) The only differences in the carburetor kits are the needle and seat assembly.
  • Page 74 ETON America, LLC Service Bulletin Safety Tether Switch Installation Bulletin No: 0031 Date: 07/20/04 Install the tether switch on the LH side of the handlebars and shown in the picture. Tighten to the handlebars with the 4 bolts supplied with the switch. Start the bike and lock the parking brake. Pull the rubber cap from the switch and the bike should stop.
  • Page 75 ETON America, LLC Service Bulletin 2005 Viper Models No Power Bulletin No: 0032 Date: 07/23/2004 Viper models with no power or bad throttle response. Remove the 4mm spark arrestor retainer bolt as shown in figure 2. Then remove the spark arrestor with a pair of needle nose pliers (figure 3).
  • Page 76 ETON America, LLC Service Bulletin Oil Pump Flow Adjustment Bulletin No: 0033 Date: 04/01/2004 all Oil Injected two cycle Engines To adjust the oil pump flow on a two cycle oil injected engine you must adjust the oil pump cable length. . The...
  • Page 77 ETON America, LLC Service Bulletin C.D.I. Module Specifications Bulletin No.: SB-0042 Viper 40E (2 Cyle) Date: 05/01/2006 BLA CK/W HITE PCi n RED/BL ACK E -TO N BL ACK WHI TE/ BLUE I G N RXL-40E -- C0410-UE8-0000 Electric resistance(Ω) specification Pcin 200-500K ∞...

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Viper jr. rxl-40Viper rxl-40eViper 40eViper 40e rxl-40e

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