Viper Manual

Viper RXL Rev #1.0.0 01/01/2002

VIPER RXL-50/90Service Manual

AMERICA

Viper RXL-90 & RXL-50

GENERAL INFORMATION

TABLE of CONTENTSChapter Description Page

1. INFORMATION 42. MAINTENANCE 93. ENGINE REMOVAL AND INSTALLATION 174. ENGINE FUEL SYSTEM 185. ENGINE LUBRICATION AND COOLING 216. ENGINE COMBUSTION SYSTEM 227. TRANSMISSION 268. FRONT WHEEL AND STEERING 319. REAR WHEELS, HYDRAULIC BRAKE 40

and DRIVE CHAIN10. BODY PANELS, FENDERS & EXHAUST 4611. ELETRICAL SYSTEMS

Eletrical Diagram 5312. TROUBLE SHOOTING CHART 54

E-TE-TononViperViper

Viper Service Manual

1. INFORMATION 1.1 SAFETY

1. Gasoline is extremely flammable and can be explosive under certain condition. Do not smoke or allowsparks or flames in your work area.

2. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may causeloss of consciousness and lead to death.

3. The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you contact it, flushthoroughly with water and call a doctor if you get the electrolyte in your eyes.

1.2 NOTES

All information, illustrations, directions and specifications included in this publication are base on the latestproduct information available at the time of approval for printing.

E-TON Dynamic Technology Industry Co., Ltd. reserves the right to make changes at any time without noticeand without incurring any obligation whatever.

No part of this publication may be reproduced without express written permission of E-TON DynamicTechnology Co., Ltd.

1.3 SPECIFICATIONS VIPER RXL-50ENGINE SPEC

Engine Type Forced Air-cooled 2-strokeDisplacement 49.3 c.c.Compression Ratio 6.8:1Oil tank capacity 1.0 LiterMax. Torque, Nm/rpm 5.4 / 6000 ± 500Max. Power, Ps/rpm 5.2 / 7000 ± 500Ignition C.D.I.Starting Electric/Kick starterLubrication Auto oil injectionTransmission C.V.T. V-belt

CHASSISOverall Length 1440 mmOverall Width 830 mmOverall High 860 mmSeat height 630 mmMin. ground 130 mmWheelbase 950 mmDry weight 85 kgFuel Tank capacity 4.5 Liter

SUSPENSIONFront A-Arm / Dual ShocksRear Swing Arm / Adjustable Shock

BRAKEFront Dual DrumRear Hydraulic Disk

TIREFront 16*8-7Rear 16*8-7

BODY COLORColor Red/Yellow/Blue

Specifications subject to change without notice.



1.3 SPECIFICATIONS VIPER RXL-90ENGINE SPEC

Engine Type Forced Air-cooled 2-strokeDisplacement 82.5 c.c.Compression Ratio 5.8:1Oil tank capacity 1.0 LiterMax. Torque, Nm/rpm 7.4 / 6000 ± 500Max. Power, Ps/rpm 7.0 / 7000 ± 500Ignition C.D.I.Starting Electric/Kick starterLubrication Auto oil injectionTransmission C.V.T. V-belt

CHASSISOverall Length 1480 mmOverall Width 830 mmOverall High 900 mmSeat height 660 mmMin. ground 160 mmWheelbase 950 mmDry weight 87 kgFuel Tank capacity 4.5 Liter

SUSPENSIONFront A-Arm / Dual ShocksRear Swing Arm / Adjustable Shock

BRAKEFront Dual DrumRear Hydraulic Disk

TIREFront 18*7-8Rear 18*9-8

BODY COLORColor Red/Yellow/Blue

Specifications subject to change without notice.

Viper Service Manual1.4 SERIAL NUMBER

The Vehicle Identification Number, (VIN) is stamped on a plate attached to the front of theframe.The Engine serial number is stamped on the left side of the crankcase.

Vehicle Identification Number (VIN)

Engine Serial Number

Viper Service Manual1.5 TORQUE VALUES

ENGINE Cylinder head nut 28-30 N.m (20.7-22.1 lbf.ft)Spark plug 12-19 N.m ( 8.9-14.0 lbf.ft)Cylinder head bolt 20-30 N.m (14.8-22.1 lbf.ft)Alternator bolt 8-12 N.m ( 5.9- 8.9 lbf.ft)

FRAMEHandlebar upper holder bolt 24-30 N.m (17.7-22.1 lbf.ft)Steering shaft nut 50-60 N.m (36.9-44.3 lbf.ft)Steering shaft bushing holder nut 24-30 N.m (17.7-22.1 lbf.ft)Wheel rim bolt 18-25 N.m (13.3-18.4 lbf.ft)Tie rod lock nut 35-43 N.m (25.8-31.7 lbf.ft)King pin nut 30-40 N.m (22.1-29.5 lbf.ft)Handlebar lower holder nut 40-48 N.m (29.5-35.4 lbf.ft)Front wheel bolt 24-30 N.m (17.7-22.1 lbf.ft)Front axle nut 55-65 N.m (40.6-47.9 lbf.ft)Front brake arm nut 4-7 N.m ( 3.0- 5.2 lbf.ft)Rear brake arm nut 7-12 N.m ( 5.2- 8.9 lbf.ft)Rear axle nut 60-80 N.m (44.3-59.0 lbf.ft)Rear wheel bolt 24-30 N.m (17.7-22.1 lbf.ft)Exhaust muffler mounting bolt 30-35 N.m (22.1-25.8 lbf.ft)Engine hanger bolt 24-30 N.m (17.7-22.1 lbf.ft)


2. MAINTENANCE2.1 MAINTENANCE DATA2.2 MAINTENANCE SCHEDULE2.3 FUEL TUBE2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE ADJUSTMENT2.6 AIR CLEANER2.7 SPARK PLUG2.8 IDLE SPEED2.9 DRIVE CHAIN2.10 BRAKE SYSTEM2.11 WHEELS AND TIRES2.12 STEERING SYSTEM2.13 TOE-IN2.14 GEAR OIL

2.1 MAINTENANCE DATA & SPECIFICATION SPARK PLUG:

SPARK PLUG GAP: 0.6-0.7 mmRECOMMENDED SPARK PLUGS: NGK BPR7HSTHROTTLE LEVER FREE PLAY: 5-10 mmIDLE SPEED: 1800±100 rpmBRAKE LEVER FREE PLAY: 15-25 mmDRIVE CHAIN SLACK: 10-25 mmFRONT/REAR TIRE SIZE: 16X8-7/ 19X7-8FRONT/REAR TIRE PRESSURE: 2.2± 0.3 psi (0.15 kgf/cm2)TOE-IN: 5±10 mm

TORQUE VALUES SPARK PLUG 12-19 N.mTIE-ROD LOCK NUT 35-43 N.m

LUBRICANTSENGINE OIL JASO FC Grade or same degree oilGEAR LUBRICATION OIL SAE 40

Viper Service Manual2.2 MAINTENANCE SCHEDULE

The maintenance intervals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, requires more frequent servicing.

INITIAL REGULAR YEARLYService Service Service

(First Week) Every 30 Days (Once a Year)FUEL LINE ITHROTTLE OPERATION I IAIR CLEANER CSPARK PLUG ICARBURETOR IDLE SPEED I IDRIVE CHAIN I,L I,LBRAKE SHOE WEAR IBRAKE SYSTEM I INUT, BOLT, FASTENER I IWHEEL I ISTEERING SYSTEM ISUSPENSION SYSTEM IC.V.T. AIR FILTER CGEAR OIL R

Note - I: Inspect and Clean, Adjust, Lubricate or Replace as neededC: CleanL: LubricateR: Replace

2.3 FUEL LINES, FILTER & PETCOCK

Inspect the fuel lines for deterioration, damage orleakage and replace as needed.

Inspect fuel filter for free fuel flow. If flow is imped-ed replace the filter.

NOTE: (E-ton recommends replacement with a stonetype filter for abnormal riding conditions.)

Inspect fuel petcock operations. If fuel flow throughpetcock while in the closed position the petcockshould be replaced. If fuel flow is impeded while thepetcock is in the open position the petcock should bereplaced.

Inspect the connects of the fuel lines and insure theclips ar e properly affixed.

Viper Service Manual2.4 THROTTLE OPERATION

Inspect for smooth operation of the throttle lever.Insure the lever can reach the full open positionagainst the stop and that it automatically returns tothe full closed position. Preform this test with han-dle bars turn to all steering positions.

Inspect the throttle cable for signs of deterioration,damage or kinking, replace if necessary.

Check the throttle lever’s free play. The exceptedtolerance of 5-10 mm at the tip of the throttle levershould not be exceeded.

Disconnect the throttle cable at the upper end.Lubricate the cable with commercial lubricant toprevent premature wear.

2.5 THROTTLE CABLE ADJUSTMENT

Slide the rubber cap of the adjuster off the throttlehousing. Loosen the lock nut and adjust the freeplay of the throttle lever by turning the adjuster onthe throttle housing. Inspect the free play of thethrottle lever. The excepted tolerance of 5-10 mm atthe tip of the throttle lever should not be exceeded.

2.6 AIR CLEANER

Unscrew the air cleaner cover screws.

Remove the filter element from the air cleaner case.

Wash the element in non-flammable solvent,squeeze out the solvent thoroughly. Let it dry.

Soak the filter element in gear oil and squeeze outthe excess oil.

Install the element into air cleaner as it was at thefactory.

Viper Service Manual2.7 SPARK PLUG

The spark plug is located at the front of theengine.Disconnect the spark plug cap and unscrewthe spark plug.

Check the spark plug electrodes for wear or excessfouling. Replace spark plug if the electrodes areexcessively fouled, burnt or show signs of pittingNOTE: E-ton dose not recommends clean a plug,replacing the plug is recommended.

Inspect the plug’s insulator for cracks or chips.Replace the plug if either of these conditions arefound.

The spark plug gap tolerance is 0.6-0.7mm.Insure the sealing washer is in place beforeinstalling the plug.

Thread the spark plug in by hand to prevent cross-threading.

Tighten the spark plug with 12-19 N.m of torque.Recommended Spark Plug NGK BPR7HS

2.8 IDLE SPEED INSPECTION

Connect a dwell-tach meter to the engine.Warm up the engine for about 10 minutes to insurethe electric choke has disengaged and the engine hasreached normal operating temperatures.

Turn the idle-speed adjust screw on the carburetorto obtain the idle speed.

"Turning (clockwise)” will raise the idle speed."Turning (counter clockwise)” will lower the idle.

IDLE SPEED: 1800±100 rpm

Viper Service Manual2.9 DRIVE CHAIN

Inspect the chain for damaged links and rollers.Replace if any damage is found.

NOTE: E-ton does not recommend replacing links.Replacing the entire chain is a better choice.

Inspect the chain’s slack, the standard is 10-25mm.

To adjust the chain’s slack, Loose the 4 locking boltsto allow the free movement of the rear axle.

Adjust the drive chain’s slack by turn the adjustingnuts until the correct slack has been attained.Tighten the four locking bolts to maintain the axlesposition.

When the drive chain becomes very dirty, it should beremoved ,cleaned and lubricated using a commercialavailable chain lubricant.

Clean the drive chain by soaking and agitating it inkerosene and wipe it dry.

Inspect the drive chain for possible wear or damage.Replace the chain, if it is worn excessively or hasdamaged links or rollers.

Inspect the sprocket teeth, if they show excessivewear, broken teeth or other damage, replace thesprocket.

Inspect the chain-tension roller. (Rubber) tube aroundswing-arm pivot member. Replace as needed.

Chain adjuster Bolt

Viper Service Manual2.10 FRONT BRAKE SYSTEM

Inspect the front brake lever for excessive wear orother damage. Insure the lever moves freely fromthe fully engaged to the fully disengaged positionswith the handle bars in all steering positions.Replace or repair as needed.

Inspect the brake cables for wear,kinking or fraying.Insure the cables move freely from the fullyengaged to the fully disengaged position with thehandle bars in all steering positions.

Replace any cable that shows signs of wear, frayingor other damage. Lubricate cables to reduce prema-ture wear and insure free movement of the cable.Use a commercially available cable lubricant.

Measure the free play of the brake lever at the endof the brake lever. The excepted tolerance is 15-25mm.

Adjust the cable’s free play by loosening the lockingring and turning the adjuster collar on the cable. re-tighten the locking ring when the correct free play isobtained.

2.10 REAR HYDRAULIC DISC BRAKE

Check the brake fluid level in the reservoir . Thereservoir should be half full of fluid. To add addbrake fluid to the reservoir , remove the two coverscrews and the cover. Fill the reservoir to the halffull mark and replace the cover and screws.

NOTE: Repeated low fluid level indicates a leak.

Inspect the brake lines for leaks,corrosion or wear.Replace as needed.

Inspect the brake pads for excessive or uneven wear.Replace as needed.

NOTE: Uneven wear of the brake pads may indicatea problem with the brake calipers. See Chapter 13.

Viper Service Manual2.11 WHEELS AND TIRES

Inspect the tire surfaces for cuts, nails or other sharp objects. Check for uneven or excessive wear.

Check the tire surfaces and pressure at low tempera-ture, before riding the unit.

The standard of tire pressure is 2.2±0.3psi( 015 kgf/cm2 )

2.12 STEERING SYSTEMCheck the free play of the steering shaft with thefront wheels turned straight ahead.When there isexcessive play, inspect the tie-rod, kingpin bushingand ball joint. Replace worn or damage ball joints,bushing and tie rods as needed.

2.13 TOE-IN

With the vehicle on level ground and the frontwheels facing straight ahead, mark the centers of thetires to indicate the axle center height. Measure thedistance between the marks.

Carefully move the vehicle back, until the tire havebeen rotated 180 °, so the marks on the tires arealigned with the axle center height.

Measure the distance between the marks.Calculate the difference between the front and rearmeasurements. This is the Toe-in value.

The excepted Toe-in tolerance is: 5±10mm

If the toe-in is out of standard, adjust it by changingthe length of the tie-rods equally. Loosen the lockingnuts and turn the tie-rod while holding the ball joint.Tighten the lock nuts.Torque: 35-43 N.m

NOTE: Remember to adjust both tie-rod equally.Replace any Tie-rod that show signs of being bent.Do Not attempt to straighten a bent Tie-rod.

Viper Service Manual2.14 GEAR OIL

The ATV unit's gear oil needs to be changed yearly.There is a gear oil release bolt at the rear of engine.Unscrew this release bolt and can let the dirty oilflow out.The re-add oil hole is on the engine case besidegearbox.

The fill & drain hole plug is located at the rear ofthe engine/transmission assembly.

Remove both the filler hole plug and drain plug todrain the gear oil.

Drain the gear oil an check for any signs of water.

NOTE:Water in the gear oil indicates a leaking seal.replace the leaking seal to prevent a costly failure ofthe engine/transmission assembly.

Re-install and tighten the drain plug and refill thegear box with the appropriate quantity of therequired lubricant.

Re-install and tighten the filler hole plug.

RXL-50 Gear oil requirements:SAE #90 -- 0.1L / 0.11Qt - 100cc

RXL-90 Gear oil requirements:SAE #90 -- 0.1L / 0.11Qt - 100cc

Viper Service Manual3. Engine Removal & InstallationThe engine should ONLY BE REMOVED in the caseof necessary repair of the upper and lower enginecomponents or Transmission assembly.

3.1 ENGINE REMOVAL

Remove the spark plug wire from the spark plug.Remove the seat and rear fender. (see Chapter 10 )Remove the exhaust pipe.

Disconnect the carburetor cable by removing thetwo screws on top of the carburetor.Remove oil pump cable from the oil pump controlplaten. (Oil pump is under the right side of engine.)

Disconnect all wire connectors. There are three con-nections for carburetor auto-choke, starter motor andgenerator respectively.

Remove the drive chain cover. This is under thechain. Remove the drive chain retaining clip andmaster link, and remove the drive chain.

Remove the three engine hanger nuts and bolts.At this point the engine is free of the unit andshould be removed from the right side of the frame.

3.2 ENGINE INSTALLATIONEngine installation is essentially the reverse order ofremoval.

Us extreme care when replacing the engine backinto the frame so as not to pinch any of the wiresand cables.

replace the engine hanger bolts and nuts. Apply 24-30 Nm of torque to each of the three hanger bolts

Install the drive chain and chain cover.

Route and connect all wires and cable properly inthe reverse order of removal.

Install the spark plug wire.


4. ENGINE FUEL SYSTEM

4.1 TROUBLESHOOTING

ENGINE WILL NOT START No fuel in tankNo fuel to cylinderToo much fuel to cylinderNo spark at plugAir filter clogged or dirty

ENGINE IDLES ROUGH, Improper setting of idle adjustment screwSTALLS OR RUNS POORLY Ignition malfunction

Fuel / Air mixture adjusted too lean or too richAir filter dirty or cloggedSpark plug insulator cracked or chippedFuel tank breather hole or tube clogged or kinked

LEAN MIXTURE Carburetor fuel jets dirty or clogged Fuel tank breather hole or tube clogged or kinkedFuel filter dirty or cloggedFuel flow impaired by petcock or fuel line clogsCarburetor float level set too low

RICH MIXTURE Carburetor float needle damagedCarburetor float level set too highCarburetor Air duct clogged or dirtyAir filter clogged or dirty

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.Unscrew the fuel tank fixed bolts.

Note : Keep gasoline away from flames orsparks. Wipe up spilled gasoline at once.

Viper Service Manual4.3 CARBURETOR

REMOVALRemove the air cleaner.Disconnect the fuel line and auto-choke electric wire.Unscrew the intake pipe mounting bolts at the carbu-retor then remove the carburetor.

Note: Turn fuel cup on (off) position

Remove the carburetor cap.Remove the throttle cable from the throttle valvewhile depressing the throttle valve spring.

Remove the needle clip retainer, the jet needle andneedle clip. Inspect the throttle valve and jet needle surface forwear, scratches or dirt.

DISASSEMBLY

Unscrew the float chamber screws and remove thefloat chamber.


Disassembly the float arm pin, float and floatneedle valve.Inspect the seat of the float needle valve forwear or damage.

Carburetor Float settings

Disassembly the idle jet, main jet, idle speedsadjust screw and idle mixture adjusts screw.Inspect all the jets and screws for wear or dam-age.

Clean the passages and jets with compressedair.

ASSEMBLY

Clean all parts in solvent and blow it dry withcompressed air.

Assembly is essentially the reverse order of dis-assembly.

THROTTLE VALVE ASSEMBLY

Install the needle clip on the jet needle. Install the jet needle into the throttle valve.Assemble the throttle cable, spring and thethrottle valve.

Align the throttle valve groove with the idlespeed adjust screw and install the carburetor

Viper Service Manual5. ENGINE LUBRICATION AND COOLING SYSTEM

5.1 ENGINE LUBRICATION SYSTEM

The pump gears of oil pump are driven by the engine crankshaft. Pump gears rotate the plunger shaft in oilpump. This shaft sent the lubricating oil into thecrankcase to mix with the air-fuel mixture to providean even flow of lubricant to the internal engine parts.The oil drops and foam cover the cylinder inner wall,piston surface and piston rings.

5.2 CAUTION

Having enough oil supply to engine is very important.If the oil flow quantity is impeded this engine can beserious damaged, to the point where the engine canseize.

If the oil level indicator lamp comes on, STOP the ENGINE immediately and refill the oil tank of the unitwithJASO FC grade of two cycle oil. The RXL Viper series has a 1.1L oil tank capacity.

If the engine cylinder has become serious scratched, you need to change the piston, piston rings and cylindertogether. If this has happened, you need to check the combustion system and lubrication system carefully.

5.3 OIL PUMP

The quantity of oil deliver by the oil pump is increased by the engine speed and the carburetor throttle openwidth. Oil pump is located under the right side of the engine and connected by a control cable to the throttle.

5.4 COOLING SYSTEM

The air intake is achieved by the engine cooling fan. The cooling fan is on the right side of engine.The air is forced to flow through cylinder fins thatsurround the cylinder and cylinder head. This airflow will provide sufficient cooling of the engine.

Always insure that the fins of the cylinder andcylinder head are clean and free of dirt or mud. Ifthe fins become clogged use a pressure washer toclean them.

Viper Service Manual5.5 TROUBLESHOOTING

LOW OIL SUPPLY TO ENGINE THE OIL LEVEL IN OIL TANK IS TOO LOW.OIL LINES WERE NOT ATTACHED.OIL HAS LEAKED FROM TUBE ENDS.OIL LINES ARE BROKEN.OIL LINES ARE CLOGGED.OIL PUMP NOT WORKING.

OIL TANK LEVEL ALWAYS LOW EXTERNAL OIL LEAKSWORN CYLINDER HEAD GASKETWORN PISTON RINGSOIL LINE DISCONNECTED

6. ENGINE COMBUSTION SYSTEM

6.1 TROUBLESHOOTING

LOW COMPRESSION CYLINDER HEAD CRACKED or WARPEDHEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD CYLINDER OR PISTON RINGS WORN OUT

HIGH COMPRESSION EXCESSIVE CARBON BUILD-UP ON PISTON HEAD OR IN COMBUSTION CHAMBER

EXCESSIVE NOISE PISTON AND CYLINDER WORN OUTEXCESSIVE CARBON BUILD-UP

EXCESS SMOKE CYLINDER OR PISTON RINGS WORN OUTIMPROPER INSTALLATION OF PISTON RINGSPISTON OR CYLINDER WALL SCORED OR SCRATCHED

OVERHEATING EXCESSIVE CARBON BUILD-UP ON THEPISTON OR COMBUSTION CHAMBERENGINE COOLING SYSTEM ( FAN, CYLINDER COVER….. ) WORKS BADLY.OIL SUPPLY IS OUT OF ORDER.WRONG IGNITION TIMING

Viper Service Manual6.2 Cylinder and Piston Removal

(See Chapter 3 for Engine removal details)Remove the spark plug cap.Remove the seat and rear fender.Remove the exhaust pipe.Disconnect the wire.Remove out the engine.Remove the air cleaner and carburetor assemblies.

Remove the intake manifold mounting bolts.Remove the cylinder bolt nuts.

Remove the cylinder head.Remove the cylinder carefully.Remove one piston pin clip. Remove the piston pin and piston.

Carefully spread each piston ring and remove it bylifting up at a point just opposite the gap.

Note : Don't let the clip, other parts or foreign matterdrop into engine crankcase.

6.3 Cylinder and Piston Inspection

Inspect the cylinder bore for wear or damage.Measure the cylinder inner diameter at three levels inX and Y axis.

Inspection TolerancesTaper limit : 0.10 mmOut of round : 0.10 mm

Viper Service ManualCheck the cylinder head mating surface for warp witha straight edge and feeler gauge.

Service limit : 0.10 mm

Insert each piston ring into the cylinder, and measurethe end gap.


Measure the clearance between ring and groove.


Measure the piston outer diameter at 10 mm highfrom the skirts bottom.

Service limit : 39.9 mm (for RXL50cc engine)49.9 mm (for RXL90cc engine)

Viper Service ManualMeasure the piston pin bore, and the piston pin outerdiameter.

Pin outer diameter service limit:9.96 mm(for RXL50cc engine)

11.96 mm(for RXL90cc engine) Pin bore service limit :

10.04 mm(for RXL50cc engine)12.04 mm(for RXL90cc engine)

Measure the connecting rod small end inner diameter with a small hole gauge.

Service limit : 14.06 mm(for RXL50cc engine)15.06 mm(for RXL90cc engine)

6.4 INSTALLATION

Install the piston rings with the marks facing up.Do not damage the piston rings by spreading the endstoo far.

Clean the cylinder gasket surface being careful not todrop any gasket material into the crankcase.

Apply some oil to inside of the connecting rod smallend.Install the piston, piston pin and clip.Install the piston with the arrow mark facing theexhaust pipe.Do not align the piston pin clip end gap with the pis-ton cut-out.

Install a new cylinder gasket.Apply a thin coat of engine oil to the piston rings andcylinder wall. Install the cylinder, compressing the pis-ton rings.Replace a new cylinder head gasket.Install the cylinder head.Tighten the cylinder mounting bolt:

torque to 10-14N.m


7. TRANSMISSION SYSTEM

7.1 TROUBLESHOOTING

UNIT DOES MOVE AFTER BELT WORN OR DAMAGEDHAS BEEN STARTED FRONT PULLEY WORN OR BROKEN

LINING OF CLUTCH WORNWILL NOT RUN AT HIGH SPEED BELT WORN OR DAMAGED

ROLLERS WORNSPRING OF REAR PULLEY IS DISTORTED

7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM

CVT Driven Pulley System Transmission Gears


The torque of crank-shaft drives the front pulley1. The torque (drive) pulley turn the belt2. The belt drive the rear (driven) pulley3. The force through the clutch shoe, clutch housing and drive shaft4. The drive shaft turn the idle gear in gear box5. Turning speed reduced by final-gear and transmit to rear-axle shaft to move rear wheel

7.4 Automatic Continuous Variable Transmission (CVT)

This transmission is the combination of automatic centrifugal clutch and V-belt continuous variable transmission, which can change the transmission ratio automatically.

When engine speed increase, the drive pulley will be push to belt by the centrifugal force from six rollers. Then the pitch circle of belt in drive pulley will be more large. The belt at driven pulley is forced to move to the center of shaft, then the radius of pitch circle is decreased.The transmission ratio is therefore altered by the alteration of pitch circle's radius.( In the drawing, "H" means high speed, "L" means low speed )

7.5 Continuous Variable Transmission (CVT)

V-Belt is made of rubber fiber, resistant to head, pressure and abra-sion. The inner side of the Belt is toothed.

Viper Service ManualDrive Pulley

Due to the increasing engine speed, the rollers push themovable drive face by centrifugal force. Then the beltis pressed outward increasing its turning radius.An aluminum fan is installed on the exterior of fixeddrive face to reduce the belt temperature.

Driven Pulley

Because the revolving radius of V-Belt at the DriveEnd is increased, the Face Comp Movable Drive issqueezed out by the V-Belt at the Driven End to reducethe revolving radius.

There is a Torque Cam on the Movable Drive Face.The Torque Cam is loaded from outside. When the outside load is higher than the engine's output, the pulleyof fixed shaft and belt slip to make the Movable Drive Face move along the inner side of Cam and compensateto increase to high torque (toward to low speed) and enable the engine maintain smooth running with originalrevolution.

7.6 GEAR BOX

The torque received by the Drive shaft will be transmitted by the speed reduction of two sets to rear axle shaft.The first gear ratio is 36/13.The second gear ratio is 48/12.

Viper Service Manual7.7 ELECTRIC STARTER SYSTEM

Starter Motor is installed on the upperside of engine.The starter motor has a safety lock outcircuit that prevents the motor fromengaging unless the left hand brake leveris applied.

7.8 KICK STARTER

This kick starter arm is on the left side of engine. Whenthe kick-starter arm is kicked, the gear of startshaft will drive the kick starter to rotate the crank shaft tostart the engine.

After the engine is started, the kick-started will stop trans-fer the power to the kick-starter driven gear.

When the kick-starter lever is released, the kick-startergear will go back to its original position.


7.9 INSPECTION OF C.V.T. SYSTEM

Remove the engine clutch cover, Check the belt for wear, cuts and separation of thematerials. Replace the belt as needed.

The belt should be dry and free of any oil contami-nation. If the belt has been contaminated with oil,you must replace the belt. Clean the Drive andDriven pulleys of any oil contamination beforeinstalling the new belt.

Disassembly the front drive pulley.Inspect the six rollers and ramp plate for wear.

Clean the rollers and ramp plate and replace allworn or damaged parts.

Insure the Fan and Driven Pulley nuts are torqued to80Nm. before reassembling the C.V.T.

Clean the case and clutch cover gasket surfaces andinstall a new gasket to insure a proper seal is main-tained.

Viper Service Manual8. FRONT WHEEL AND STEERING SYSTEM

8.1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM

Viper Service Manual8.2 TROUBLESHOOTING STEERING

HARD STEERING Damaged or Worn tire.Steering shaft holder to tight.Tire pressure to low.Damaged or Worn steering shaft bearings.

FRONT WHEEL WOBBLE Damaged or Worn tireDamaged or Worn front brake drum bearing.Bent Wheel rim.Axle nut loose or installed incorrectly.Wheel Rim hub studs loose.Wheel Rim stud hole worn.Cracked or broken Wheel hub.

BRAKE DRAG Incorrect brake adjustment.Brake cable sticking or kinked.Brake shoes wet.

STEERS TO ONE SIDE Bent tie rod.Wheel installed incorrectly.Unequal tire pressure.Bent Frame.Worn A-Arm bushing.Worn swing arm pivot bushing.

POOR BRAKE PERFORMANCE Worn or damaged brake shoes.Worn or damaged brake drum.Brake shoe contaminated with oil, grease or dirt.Improper brake adjustment.Brake cable sticking or kinked.

FRONT SUSPENSION NOISE Loose front suspension fastener.Binding of suspension links.

HARD SUSPENSION Worn or Damaged front A-Arm bushing.Improperly installed A-Arm or Swing Arm.Bent front shock absorber swing rod.

SOFT SUSPENSION Worn or damaged shock absorber spring.Worn or damaged A-Arm bushing.

Viper Service Manual8.3 HANDLEBAR

REMOVAL

Remove the throttle lever housing on the right handlebar by removing the two cover bolts.

Remove brake lever bracket by removing the twoclamping bolts.

Remove engine switch housing on the left handle bar.Take care not to brake the wire connections.

Remove rear brake level bracket.

Remove the bolts attaching the upper bar clamps.

Remove the handlebar holder and handlebar.

Viper Service ManualINSTALLATION

Place the handlebar on the lower bar clamps.Make sure the handlebar indexing hole aligns with theindexing pin in the lower handle bar clamp.

Install the handlebar upper clamp with the L or Rmarks facing forward.

Tighten the forward bolts first, then tighten the rearbolts. Install the handlebar upper holder's cover.

Install the switch housing, aligning the boss with thehole.

Tighten the upper bolts first then tighten the lowerone.

Supply enough torque so the handle bars are tight inthe clamp.

Install the rear brake lever bracket, aligning the bosswith the hole. Tighten the bolt securely.

Aligning the split line of the throttle housing and holder with the punch mark.Tighten the bolt securely.

Viper Service Manual8.4 FRONT WHEEL

REMOVAL

Raise the front wheels off the ground by placing ablock under the frame. Remove the front wheel nuts, washer and wheels.

INSTALLATION

Install and tighten the four-wheel nuts Torque: 50-60 N.m

Remember put a cotter pin in the castle nut.

8.5 FRONT BRAKES

FRONT BRAKE INSPECTION

Remove the front wheel.Remove the brake drum.

Measure the brake lining thickness.The minimum limit : 1.5 mm if they are less thanthe minimum limit, the lining must be replaced.

Inspect the lining and drum for uneven wear andreplace as needed.

Measure the brake drum inner diameter.The maximum limit : 86 mm, if the drum diameteris larger the drum must be replaced.

Turn the inner race of each bearing with fingers.The bearings should turn smoothly and quietly.If the race does not turn smoothly or quietly, replacethe bearings.

Viper Service ManualBRAKE PANEL REMOVAL

Disconnect the brake cable from the brake cam arm.Remove the brake panel from the knuckle.

Remove brake arm and cam.Remove return spring .Remove indicator plate and felt seal.

INSTALL BRAKE PANELApply grease to the brake cam and anchor pin andinstall the cam in the brake panel.

Soak the felt seal in the engine oil and installthe seal on the brake cam.

Install the brake arm on the cam by aligning the punch mark and the groove on the cam.Tighten the brake arm bolt and nut.Torque: 4-7 N.mInstall the return spring.

Viper Service ManualInstall the brake panel on the knuckle.Connect the brake cable to the brake arm.

Install the brake arm cover .Tighten the screws securely.Position the brake shoes in their original locationsand install the brake shoe spring.Install the brake drum and front wheel.Install the castle nut and cotter pin.

8.6 STEERING SYSTEM

REMOVAL OF KINGPIN AND TIE-ROD

Remove the front wheels and brakes plates.Remove the four self-lock nuts from the tie-rod balljoints and take off the two tie-rods.

Take off the rubber cap on the kingpin and remove the cotter pin on the kingpin.Remove the castle nut and remove the kingpin.

Viper Service ManualTIE-ROD INSPECTION

Inspect the tie-rod for damage or bending.Inspect the ball joint rubbers for damage, wear ordeterioration.

Turn the ball joints with fingers, the ball jointsshould turn smoothly and quietly.

If there is visible damage or the movement is roughor stiff, the ball joint should be replaced.

KINGPIN INSPECTION

Inspect the kingpin for damage or cracks.Measure the kingpin outer diameter.

Upper minimum limit : Ø15.40 mmLower minimum limit : Ø16.90 mm

KINGPIN BUSHING INSPECTION

There are two bushing in the sleeve of front swingarm, the upper and lower bushing.Check the kingpin bushing for wear or damage.Measure the inner diameter of the bushing.

Upper minimum limit : Ø15.69 mmLower minimum limit : Ø17.19 mm

STEERING SHAFT REMOVAL

Remove the handle bar and handle bar cover.(see paragraph 8-1)Remove the front fender. (see paragraph 10-1)Unscrew the steering shaft fixed out below shaft.Carefully remove the steering shaft from the frame.


Remove the steering shaft.Remove the bushing from the bottom of the shaftshaft. Inspect the bushing for damage or wear, replaceif necessary.Measure the bushing inner diameter.

Maximum limit : Ø22.8 mm

STEERING SHAFT INSPECTION

Inspect the steering shaft for damage or cracks.Measure the steering shaft outer diameter in thelocation of the bushing.

Minimum limit : Ø22.0 mm

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 snugly inthe holder.Replace worn or damaged bearing if necessary.

INSTALLATION OF STEERING SHAFT

Install the steering shaft with the bushing.Apply grease to the bushing.Install the bushing holder and tighten the nuts.

Torque :24-30 N.m

Viper Service ManualInstall the steering shaft nut and tighten it.This nut is under this steering shaft.

Torque : 50-60 N.m

INSTALLATION OF TIE-ROD

Install the ball joint with " L" mark on thesteering shaft side.Install the tie-rod with the mark on the wheel side.

Set the distance between the ball joints collars at164 mm for both the RXL 50 and RXL 90.

This is temporary setting.

INSTALLATION OF KINGPIN

Apply grease to the kingpin lower dust seal lipsand install the seal. Apply grease through the greasefitting to A-arm bushing and install the kingpin.

Tighten the kingpin nut and torque to 30-40 N.m.

Install the waterproof rubber cap.

Temporarily set the distance between the ball joints at147mm. Install the tie-rod and tighten the nuts andtorque to 35-43 N.m

9. REAR WHEEL SYSTEM

9.1 Parts drawings of rear wheels and hydraulic disc brake system



9.2 TROUBLESHOOTING

POOR BRAKE PERFORMANCE Low Brake fluid levelLeaking brake line or caliper pistonContaminated Brake FluidBrake pad wornBrakes out of adjustmentBrake pads are Oily, Dirty or WetBrake Rotor Worn, Warped or DamagedBrake calipers hanging or stickingBrake caliper piston dirty and sticking

VIBRATION OR WOBBLE Axle not properly tightenedBent wheel rimWorn or damaged axle bearingsWorn or Improperly tire inflationRear axle bearing holder damaged

BRAKE DRAG Incorrect brake adjustmentBrake caliper piston stickingWarped or Damaged brake rotorBrake line cloggedContaminated Brake Fluid

9.3 REMOVE REAR WHEELAND REAR BRAKE

Raise rear wheel off ground by placing blocking or standunder frame. Remove the cotter pin, axle nut and washer.Slide the wheel and wheel hub off the axle spindle.

Remove the two bolts that hold the brake calipers to theholder and remove the calipers.

Viper Service ManualRemove the rear wheel axle nuts and then remove themounting seat of the disk.

Unscrew bolts and remove the brake Rotor.

Check the thickness of disk in several places and replace ifthe thickness less than 3mm.

Check the disc for cracks or large wearing groves. Replacethe disc if badly worn or cracked.

Check to see if the disc is bent or warped, replace as need-ed.

Clean the disk of any dirt or oil and grease contamination.Insure the cooling holes are free of dirt and the friction sur-face smooth and even across the entire disc. Replace asneeded.

Remove the brake line from the calipers.

Remove the friction pads from the brake calipers by press-ing the caliper piston in fully and removing the static padfrom the retaining clips. Then lift the piston pad from thepiston to remove from the calipers.

Check the thickness of brake shoe and replace if the thick-ness less than 1mm. Also replace the pads if they showsigns of uneven wear or are cracked or otherwise damaged.

Replace the pads if they have been contaminated with oilor grease or brake fluid.

Inspect the caliper piston for signs of brake fluid leaks andreplace as needed.

Viper Service Manual9.4 Rear brake installation

NOTE: Take great care as to not contaminate thebrake pads or rotor with oil, grease or brake fluidduring the installation.

To reinstall the brakes, replace the brake rotor on themounting seat. Reinstall the mounting seat over theaxle and secure with the two large axle nuts. Torqueto 60-80 Nm.

Press the caliper piston in fully and place the pistonpad over the retaining pins and piston. Replace thestatic pad in the the retaining clip and insure that itis fully engaged and in the proper location.

Slide the caliper back into position over the rotorand replace the two caliper retaining bolts and tight-en torque to 30-40 Nm.

Reinstall the brake line.

The brake line will need bleed of air at this point.Remove the reservoir cap on the handle bars byremoving the two cap bolts.

Loosen the bleeder valve on the caliper and depressthe brake lever to expel any air in the line. Tightenthe bleeder valve before releasing the brake lever.Repeat the process if loosening the bleeder valveand depressing the brake lever until all air has beenpurged from the brake line. Tighten the bleedervalve and fill the reservoir with (Dot 3 or Dot 4)brake fluid to a level of half full.

Reinstall the reservoir cap and cap bolts.

Test the brake system and check for any leaks in thebrake line connections

Viper Service Manual9.4 DRIVE CHAIN & AXLE

REMOVAL AND INSPECTIONRemove the rear wheel and the rear brake

Remove the drive chain skid plate and chain guard.

Disassembly the chain retaining clip and masterlink. Note: the retaining clip direction.

Disassembly the driven sprocket, axle and sprocketcollar.

Inspect the drive sprocket and sprocket holder fordamage or wear. Replace as needed.

Look for cracks, bent or broken teeth. Inspect boththe axle and drive sprocket holder splines for dam-age and striping. Replace as needed.

Set the rear axle in V-blocks and check the runout. The runout limit is 0.5 mm. If the axle is bentbeyond the limit replace the axle. Do Not try tostraighten the axle as internal damage may result ina total failure of the axle.

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 dustseals.Assembly the rear axle and the driven sprocket.

Assembly the drive chain on the driven sprocket.Assembly the master link and retaining clip.Note: the retaining clip direction.Install the drive chain skid plate.Install the chain guard

10. FENDERS AND EXHAUST SYSTEM

10.1 FENDERS DRAWING

10.2 Fender & Body panel removal

Remove the brake lever assembly from the handle bars.Disconnect the front brake and throttle cables from the leverassemblies.

Remove the handle bar switch and cover and then remove thehandle bars. (Note: see chapter 8.3 for additional details ofhandle bar removal)

Remove two plastic bolts as show in picture 1 & 2.

Remove the front body screened cowling. Picture 1

Picture 2

Viper Service ManualRemove the seat before removing the front or rear fender.

Unscrew the bolts as shown in pictures 3 & 4. Remove therear fender as pictured in picture 5.

NOTE: Use caution when disengaging the inter lockingtabs so as not to brake them.

Unscrew the four bolts located under the seat to removethe rear body panel after the fender have been removed.

(see Picture 6)

Picture 6

Picture 5

Picture 4

Picture 3

Viper Service ManualAs picture 7 unscrew the bolt then you can remove thefront body fender.l As picture 8 & 9 unscrew these three bolts then youcan remove the front R/L fender.Remove the the three bolt retaining the front body panel

to the frame as shown in picture 7.

Remove the two bolts, one on the left side and one on theright side, from the fender support bars near the foot restsas shown in picture 8.

Remove the front body panel to locate the remaining fourbolts the affix the front fender to the frame.

Remove the four fender bolts, two on the right side andtwo on the left side, to remove the front fenders from theunit.

All of the body trim parts are sold separately to makereplacement less costly.

When replacing a fender, be sure to replace all safety stick-er that were attached to the unit at the factory.

Picture 7

Picture 8

Picture 9


10.5 EXHAUST PIPE REMOVE CAUTION: Do not service the exhaust pipe whilehot.

Remove the exhaust pipe manifold bolts that affixthe exhaust pipe to the engine. these are located onthe underside of the cylinder.

Remove the exhaust pipe mounting bolts that besidethe muffler body.

Remove the exhaust pipe carefully.

10.6 EXHAUST PIPE INSTALLATION

Installation is the reverse order of removal.Clean the Cylinder exhaust port gasket seat and thegasket seat of the exhaust manifold to insure a prop-er seal. Replace the muffler gasket.

Torque : Exhaust muffler bolts 30-35 N.m

After installation, inspect the exhaust system forleaks.

10.4 EXHAUST PIPE DRAWING

Viper Service Manual11. ELECTRICAL SYSTEM

11.1 TROUBLE SHOOTING CHART

ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMINGFAULTY SPARK PLUG

NO SPARK AT PLUG ENGINE STOP SWITCH AT " OFF "FAULTY IGNITION COILFAULTY GENERATORFAULTY CDI UNITPOORLY CONNECTED:

Between CDI and ignition coil Between alternator and CDI unitBetween CDI and engine stop switchBetween ignition coil and spark plugBetween generator and CDI unit

ENGINE RUNS POORLY IGNITION PRIMARY CIRCUITFaulty generatorFaulty CDI unitFaulty alternator exciter coilLoosen contacted terminalsFaulty ignition coil

IGNITION SECONDARY CIRCUITFaulty plugLoosen contacted spark plug wire

IMPROPER IGNITION TIMINGFaulty generatorFaulty CDI unit

CHARGING SYSTEM FAILURE LOOSE, BROKEN OR SHORTED WIREFAULTY ALTERNATORFAULTY IGNITION SWITCH

ENGINE INTERMITTENT POWER LOOSE BATTERY CONNECTIONLOOSE CHARGING SYSTEM CONNECTION

STARTER MOTOR WILL NOT TURN DEAD BATTERYFAULTY IGNITION SWITCHLOOSE OR DISCONNECTED WIRE

STARTER MOTOR & ENGINE TURN FAULTY IGNITION SYSTEMBUT ENGINE DOES NOT START ENGINE PROBLEMS

FAULTY ENGINE STOP SWITCH


11.2 IGNITION COILRemove the spark plug cap from the spark plug. Disconnect the ignition coil primary wire.

Measure the primary coil resistance.STANDARD: 0.1 - 0.3OΩ

Measure the secondary coil resistance with the sparkplug cap in place.STANDARD : 7.4 - 11 kΩ

11.3 IGNITION TIMINGThe ignition advance is 15°± 3°/4000rpmThe Capacitive Discharge Ignition (CDI) system isfactory pre-set and does not require adjustment.

11.4 ALTERNATOR EXCITER COILRemove the seat / rear fender and front fender.(see chapter 10)

Disconnect the exciter coil wire.Measure the resistance between the yellow/red wireand ground.STANDER : 460-700Ω

11.5 BATTERY CAUTIONThe battery gives off explosive gases ; keep sparks,flames and cigarettes away. Provide adequate ventilation when charging or using the battery in anopen area. The battery contains sulfuric acid (elec-trolyte). Contact with skin or eyes may cause severeburns. Wear protective clothing and a face shield.

Electrolyte is poisonous. If swallowed drink largequantities of water or milk and call a physician.

11.6 BATTERY INSPECTION

Battery is under the seat , you can see this batteryfrom the left side.Measure the battery voltage using a voltmeter.VOLTAGE : Fully charged : 13.1 V

Undercharged : Below 12.0 V


BATTERY REMOVALRemove the battery holder bolt nuts.Disconnect the negative cable and then the positioncable and remove the battery.

BATTERY INSTALLATIONInstall the battery in the reverse order of removal.After installing the battery, coat the terminals withclean grease.

11.7 CHARGING

Connect the charge positive cable to the batteryposition terminal.Connect the charge negative cable to the batterynegative terminal.

Using 0.9A charging current about 5 hours. (Normalcharging) or using 4A charging current about 1 hour.(Quick charging)

NOTE: Quick charging should be limited to anemergency ; Normal charging is preferred.

CAUTION: Keep flames and sparks away from abattery being charged.

TROUBLE SHOOTING

Check for Intake Manifold Leak

Possible Problem Areas

♦ Faulty C. D. I. Unit ♦ Faulty Pulse Generator

♦ Improper Air Screw Adjustment ♦ Fuel / Air mixture ratio to lean

♦ Deteriorated Insulator O-Ring ♦ Loose Carburetor ♦ Damaged Carburetor Gasket

♦ Faulty Spark Plug ♦ Fouled Spark Plug ♦ Faulty C.D.I. Unit ♦ Faulty Engine stop Switch ♦ Poor connection, Broken or Shorted Wire ♦ Broken or Shorted Ignition Coil ♦ Broken or Shorted Spark Plug Wire ♦ Faulty Pulse Generator

Check Ignition Timing

Check Carburetor Air Adjustment

Test Spark

O.K.

O.K.

O.K.

N/G

N/G

N/G

N/G

Weak or Intermittent Spark

12.2 POOR PERFORMANCE AT LOW IDLE SPEED


TROUBLE SHOOTING

Check Carburetor Jets

Possible Problem Areas

♦ Faulty C. D. I. Unit ♦ Faulty Pulse Generator

♦ No Fuel in Fuel Tank ♦ Clogged Fuel Line ♦ Clogged Fuel Valve ♦ Clogged Fuel Tank Cap Breather Hose ♦ Clogged Fuel Filter

♦ Jets Clogged (Clean with High Pressure Air)

♦ Clean or Replace Filter Screen

Check Ignition Timing

Check Fuel Flow at Carburetor

Air Cleaner

O.K.

O.K.

O.K.

N/G

N/G

N/G

N/G

Dirty

Clogged

Low Fuel Flow

12.3 POOR PERFORMANCE AT HIGH SPEED


♦ Punctured Tire ♦ Leaking Valve Stem

♦ Fuel / Air mixture ratio to lean ♦ Clogged Air Cleaner ♦ Clogged Muffler ♦ Restricted fuel flow ♦ Clogged Fuel Tank Cap Breather hose

♦ Faulty Pulse Generator ♦ Faulty C. D. I. Unit

♦ Leaking Head Gasket ♦ Worn Cylinder ♦ Worn or Damaged Piston ♦ Worn or Damaged Piston Rings ♦ Clean and Adjust Air and Fuel mixture ♦ Clean Spark Plug ♦ Incorrect Spark Plug Heat Range ♦ Excessive Carbon Deposits in combustion

chamber ♦ Wrong Fuel Type ♦ Fuel/Air mixture ratio to lean ♦ Used poor quality Fuel

♦ Worn Piston and Cylinder ♦ Fuel/Air mixture ratio to lean ♦ Wrong Fuel Type ♦ Ignition Timing to Advanced ♦ Excessive Carbon Deposits in Combustion

Chamber

N/G

N/G

N/G

Engine speed does not increase

Pressure Low

n N/G Low

Pressure

N/G Dirty

N/G Fouled or

Discolored

d N/G

N/G Overheating

12.4 LOSS OF POWERViper Service Manual

Viper Manual

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