Eton America ROVER GT, Service Manual

Page 1: ...ETON America ROVER GT SERVICE MANUAL ROVER GT UK2 ROVER GT 7 2007 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 2: ...ine Installation 15 4 FUEL AND LUBRICATION SYSTEMS 17 4 1 Trouble Shooting 17 4 2 Fuel Tank 18 4 3 Carburetor 18 4 4 Engine Oil Level Changing 20 4 5 Oil Pump removal Installation 22 5 ENGINE COMBUSTION SYSTEM 26 5 1 Service General Information 26 5 2 Trouble Shooting 26 5 2 Trouble Shooting 27 5 3 Top End Removal 28 5 4 Cylinder Head Removal 30 5 5 Cylinder Head Assembly 33 6 CYLINDER PISTON 36 6...

Page 3: ...ystem Drawings 67 10 2 Troubleshooting 68 10 3 Wheel Removal Installation 68 10 4 Drive Mechanism Rear Brake Removal 69 10 5 Front Hydraulic Disc Brake System 72 11 BODY COVERS AND EXHAUST SYSTEM 77 11 1 Body Cover Drawings 77 11 2 Cage Body Cover Removal 77 11 3 Exhaust System Drawing 79 11 4 Exhaust System Removal 80 11 5 Servicing the Spark Arrestor 80 12 ELECTRICAL SYSTEM 82 12 1 Trouble Shoot...

Page 4: ...il properly at a proper facility 1 2 Notes All information illustrations directions and specifications included in this publication are base on the latest product information available at the time of approval for printing These symbols will appear throughout the manual to indicate important information or tasks CAUTION Safety notification Proceed carefully ADJUSTMENTS Requires inspection adjustmen...

Page 5: ... arm Dual Adjustable Shocks Rear Swing Arm Adjustable Shock Brakes Front Dual Hydraulic Disc Rear Hydraulic Disc Tires Front 18 7 10 Rear 18 8 10 Tire Pressure Front Min 3 2psi 0 23kg cm2 Max 4 0psi 0 28kg cm2 Rear Min 3 2psi 0 23kg cm2 Max 4 0psi 0 28kg cm2 Wheels Bolt Pattern 4 x 110mm P C D Carburetor Make Size TK SVR 22mm Manual Choke Main Jet 0 95mm Pilot Jet 0 32mm Air Mixture Adjustment Bac...

Page 6: ...liters 2 9gal Engine Oil Type SAE 20W 40 Volume 0 9 liters 0 23gal Transmission Type SAE 80 90 weight Volume 300cc 10 2oz Spark Plug NGK CR7HSA NGK Champion Z9Y Not recommended Electrode Gap 0 6 0 7mm 0 023 Specifications are subject to change without notice w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 7: ...pictures below The frame VIN number is stamped on the right side of the frame near the front right wheel The engine VIN number is stamped on the left side of the crankcase Frame Number Engine Number w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 8: ...t 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 30 35 N m 22 1 25 8 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 ...

Page 9: ...perating days Fuel Line I Throttle Operation I I I Air Filter system Element I C R Spark Plug I R Carburetor Idle Speed I I I Drive Chain I L I L I Brake Shoe Wear I I I Brake System I I I Nut Bolt Fastener I I I Wheels Wheel Nuts I I I Steering System I I Suspension System I I C V T Air Filter C R Waste Gas Recovery Valve I R Intake Exhaust Valve Adj I Gear Engine Oil I R Note I Inspect and Clean...

Page 10: ...and cable I I 16 Engine bolts and nuts I I 17 Cylinder head cylinder and piston I 18 Exhaust system cleaning carbon I 19 Cam Chain ignition time I I 20 Valve clearance I I I I I 21 Shock absorbers I I 22 Front Rear suspension I I 23 Main Side stands I I L 24 Crankcase PCV Valve I I 25 Brake mechanism brake lin ing pad I I 26 Tighten all Bolts Nuts Fas teners I I Clean or replace the air cleaner el...

Page 11: ... necessary To lubricate cable disconnect the throttle cable at the upper end Lubricate the cablewith commercially available lubricant to prevent premature wear and binding of the cable in the case To replace a damaged or worn cable order part 812469 2 5 Throttle Cable Adjustment The cable should be adjusted to allow for 1 8 free travel before the throttle engages the carburetor throttle slide To a...

Page 12: ...he supplied plugwrench and screwdriver by turning the plug counter clockwise 5 Set the electrode gap on the new plug to 0 6m 0 7mm 0 023 using a feeler gauge 6 Insert the new plug by hand and tighten finger tight by turning the plug in a clockwise direction Use caution not to cross thread the plug in the head 7 Use the plugwrench to tighten the plug another to turn Caution over tightening the plug...

Page 13: ... guard and measure the slack The amount of slack in the chain should not exceed 10 25mm 0 394 0 984 in Inspect the drive and axle sprockets for damaged or broken teeth Replace as needed Inspect the chain links for damaged worn or loose rivets Repair or replace as needed Chain Slack Adjustment Loosen the axle position lock bolts slightly and turn the chain adjuster nut to take up the excess slack i...

Page 14: ... the sprocket teeth If there is excessive wear or damage replace the sprocket Engine Sprocket Part 812478 Drive Axle Sprocket Part 812597 520x32t 2 10 Braking Systems Inspect the front parking brake lever the right hand lever and cable for excessive wear or other damage Replace or repair if necessary Measure the slack of the brake lever at the end of the brake lever The standard of slack is 15 25 ...

Page 15: ...facing straight ahead Mark the centers of the tires to indicate the axle center height Measure the distance between the marks Carefully move the vehicle back and rotate thewheels 180 so the marks on the tires are aligned with the axle center height on the other side Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 5 10mm 0 197 0 394 in If th...

Page 16: ...the oil tank bracket on the left hand side of the unit 4 Allow the oil to drain completely 15 30 min 5 Reinstall the drain plug and tighten Torque to 7 10lbf ft 6 Fill the transmission box with of SAE 80 90 gear oil Capacity 300cc 10 2oz 7 Reinstall the fill hole plug and finger tighten 8 Dispose of used oil at a proper recycling station as required by law Bottom of engine Drain Bolt Front of engi...

Page 17: ...Disconnect the wire connections a Carburetor auto choke If installed b Carburetor manual choke cable If installed c Starter motor d A C generator e C D I Leads Label before disconnecting f Disconnect the shifting motor g Label disconnect the shift sensor leads h Disconnect the engine ground wire on the LH side of the engine 6 Disconnect the fuel line from the carburetor 7 Remove the drive chain co...

Page 18: ...enerator 5 Reconnect C D I leads 6 Reconnect the engine ground wire on the LH side of the engine 7 Reconnect the shift motor 8 Reconnect the shift sensor leads Note Use care when rerouting the cables and wires so as not to pinch or bend them 6 Reconnect the throttle cable 7 Reinstall the exhaust muffler assembly Note Replacement of the exhaust gasket with a new gasket is recommended 8 Reconnect th...

Page 19: ...e ratio Air filter dirty Intake leaks Fuel tank cap breather clogged Main jet or pilot jet clogged Fuel filter clogged Fuel flows restricted Float level in carburetor set too low Lean mixture rich mixture Faulty float needle valve Float level set too high Carburetor air duct is clogged Engine does not start Engine idles roughly stalls or runs poorly w w G e t 2 i t P a r t s c o m w w w G e t 2 i ...

Page 20: ...n Remove the air filter assembly Disconnect the fuel line and choke cable or leadwire Unscrew the intake pipe mounting bolts at the carburetor Remove the carburetor DISASSEMBLY Remove the carburetor cap Remove the throttle cable from the throttle valve while depressing the throttle valve spring Remove the needle clip retainer the jet needle and needle clip Inspect the throttle valve and jet needle...

Page 21: ...f leakage fluid inside of float Replace all worn or damaged parts Disassemble the idle jet main jet idle speed adjustment and idle mixture adjustment screws Inspect all the jets and screws for wear or damage Replace as needed Clean the passages and jets with compressed air Air Fuel mixture screw Pilot jet Main jet w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t ...

Page 22: ...d throttle valve Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap on the carburetor Carburetor rebuild kit Part 812455 4 4 Engine Oil Level Changing Checking the level Place the unit on a level plane Check the oil level with the oil level gauge Do not screw it in when making this check Add the recommended oil up to the upper level if the oil level is ...

Page 23: ...ecommended oil ENGINE OIL CAPACITY 0 8 liter at draining Install the oil filter cap Install the oil level gauge Start the engine and let it idle for 2 to 3 minutes Stop the engine and check that the oil level is at the upper line on the gauge Ensure there are no oil leaks Oil Filter Screen Part 800182 Oil Filter Spring Part 800183 Drain Bolt O Ring Part 811479 Drain Bolt O Ring Oil Filter Screen O...

Page 24: ...tallation Remove the fan cover assembly Remove the cooling fan Remove the flywheel and A C Generator Remove the right crankcase cover w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 25: ...e the oil pump driven sprocket Remove the oil pump assembly Disassemble the oil pump Oil Pump Assembly Units in mm w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 26: ...stall the oil pump shaft and measure the pump rotor tip clearance with a feeler gauge SERVICE LIMIT 0 12 mm Remove the oil pump shaft and measure the pump end clearance with a feeler gauge SERVICE LIMIT 0 2 mm w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 27: ... the oil pump assembly Install the oil pump driven sprocket Install the A C Generator flywheel and cooling fan Oil Pump Assembly w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 28: ...emoved from the frame to service cylinder head Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case Before installing the cylinder head make sure the orifice is not clogged and the gasket O ring and dowel pins are in place 170 PSI w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 29: ... carbon build up on piston head or in combustion chamber Excessive wear of piston or cylinder Excessive carbon build up in cylinder Excessive wear of piston rings Improper installation of piston rings Piston or cylinder wall scored or scratched Excessive carbon build up on the piston or in the combustion chamber Engine cooling system fan damaged Engine cooling air intake blocked Cylinder fins dirt...

Page 30: ...pipe assembly Remove the engine shroud Loosen the cam chain adjuster screw Remove the nuts and washers Remove the camshaft holder and dowel pins Rocker Arm Cover Carburetor Engine Shroud Intake pipe Engine Shroud w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 31: ...amage SERVICE LIMIT IN 25 683mm 1 008 EX 25 241 mm 0 994 Inspect the camshaft and bearings for wear or damage and replace them if necessary Unscrew the 5mm bolt threaded in the rocker arm shaft end Pull on the bolt to remove the shafts and rocker arms w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 32: ...r arm SERVICE LIMIT 10 10 mm 0 398 Measure the O D of each rocker arm shaft SERVICE LIMIT 9 91 mm 0 390 5 4 Cylinder Head Removal Remove the flange bolts and cylinder head Remove the cylinder head gasket and dowel pins w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 33: ...pection Clean off all carbon deposits from the combustion chamber Be sure not to damage the gasket surface Check the spark plug hole and valve area for cracks Measure the cylinder head diagonally for warping with a straight edge and feeler gauge Cam Chain w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 34: ... valve guide I D SERVICE LIMIT IN EX 5 30 mm 0 209 Calculate the stem to guide clearance SERVICE LIMIT IN 0 08 mm 0 003 EX 0 10 mm 0 00394 NOTE If the stem to guide clearance exceeds the service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary and ream to fit If the valve guide is replaced the valve seat must be r...

Page 35: ... retainers and the cotters NOTE To prevent loss of tension don t compress the valve springs more than necessary Installation Install the new gasket and dowel pins Install the cam chain guide Install the cylinder head Cam Chain w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 36: ...the index mark on the alternator cover by turning the flywheel counter clockwise This will indicate that the engine is at top dead center Position the camshaft gear with cam chain so that its I mark aligns vertically with the cylinder head surface and the circle points away form the cylinder head Circle Indicator w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P...

Page 37: ...7mm 0 0028 EX 0 07 mm 0 0028 Loosen the cam chain adjusting bolt by turning it in a counterclockwise direction Install the O ring and screw Install the cylinder head cover Screw on and install the carburetor cap onto the carburetor w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 38: ... Shooting Low or unstable compression Worn cylinder or piston rings Overheating Excessive carbon build up on piston or combustion chamber wall Knocking or abnormal noise Worn piston and cylinder Excessive carbon build up Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Damaged valve stem seal Units in mm w w G e ...

Page 39: ...he piston pin and piston 12 Spreadeachpistonringand remove itbyliftingupat a point just opposite the gap Caution Don t let the clip or other foreign objects drop into engine crankcase 13 Remove the base gasket and dowel pins 14 Clean off any gasket materials from the gasket surface Be careful not to damage the gasket surface Piston Removal Detailed Stuff a shop towel into the crankcase Remove the ...

Page 40: ...site the gap Inspection Inspect the cylinder walls for scratches or wear Measure and record the cylinder I D at three levels in both an X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 47 1 mm 1 854 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 41: ...o determine the out of round SERVICE LIMIT 0 05 mm 0 00196 Inspect the top of the cylinder for warping SERVICE LIMIT 0 05 mm 0 00196 Use a feeler gauge to determine the flatness Measure the piston ring to groove clearance with a feeler gauge SERVICE LIMITS TOP 0 09 mm 0 00354 SECOND 0 09 mm 0 00354 Inspect the piston for wear or damage PISTON w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r...

Page 42: ...rely set in the cylinder SERVICE LIMITS TOP 0 45 mm 0 0177 SECOND 0 45 mm 0 0177 Measure the piston pin O D SERVICE LIMIT 12 98 mm 0 511 Measure the piston pin bore SERVICE LIMIT 13 04 mm 0 513 Calculate the piston to piston pin clearance SERVICE LIMIT 0 02 mm 0 00079 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 43: ... the piston ring with the mark facing up NOTE Don t interchange the top and second rings Avoid piston and piston ring damage during installation Space the piston ring end gaps 120 degrees apart Install the piston with its IN mark on the intake valve side w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 44: ... damage the gasket surface Install the dowel pins and a new gasket Base Gasket Part 811586 Coat the cylinder bore and piston rings with engine oil and install the cylinder NOTE Be careful to not damage the cylinder wall surface when installing the piston rings Use a screwdriver to hold the cam chain tightly Do not allow the cam chain to fall into the crankcase CYLINDER w w G e t 2 i t P a r t s c ...

Page 45: ... Head Gasket Part 811589 Torque the cylinder head nuts Torque value 25 N m 13 3 18 4 lbf ft Install the cylinder head cover Torque value 30 N m 14 8 22 1 lbf ft HEAD w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 46: ...l speed limited function Faulty C D I Faulty brake switch Idle too high Faulty shift motor Faulty shift spring or gear Faultysensor F N1 Belt worn Front pulley worn or broken Clutch lining worn Faulty shift spring Rollers worn Rear pulley spring distorted Faultysensor F N1 Faulty C D I Specifications Units in mm w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P ...

Page 47: ...centrifugal clutch and V belt continuous variable transmission which changes the transmission ratio automatically When engine speed increases the drive pulleywill push the belt by centrifugal force from six rollers Thiscausesthepitchcircleofthe beltinthedrivepulleytoincrease The belt at the driven pulley is forced to move to the center of the shaft causing the radius of the pitch circle to decreas...

Page 48: ...sure and abrasion The inner side of the belt is toothed to provide flexibility for radial diameter changes Drive Pulley When the engine speed increases the rollers push the movable drive face by centrifugal force This applies pressure to the belt which increases its turning radius The aluminum fan is installed on the exterior of fixed drive face This creates an air flow through the C V T case to r...

Page 49: ... bolts and LH crankcase cover Remove the gasket and dowel pins Clean off any gasket material from the LH crankcase surface CVT Removal Loosen the flange nut and remove the kick starter ratchet Remove the drive face w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 50: ...iven face assembly Remove the ramp plate and weight roller set Inspection Inspect the driven belt for wear tearing or damage Measure the width of the driven belt SERVICE LIMIT 17 0 mm 0 669 Driven Belt Part 811657 V BELT w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 51: ...ICE LIMIT 21 24mm 0 836 Inspect the drive face collar for wear or damage Inspect the drive face boss for wear or damage Measure the O D of drive face boss SERVICE LIMIT 20 94mm 0 824 Inspect the clutch outer for wear or damage Measure the I D of clutch outer SERVICE LIMIT 107 5 mm 4 232 WEIGHT ROLLER Clutch Weight w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t ...

Page 52: ...ing in a relaxed position SERVICE LIMIT 82 6 mm 3 25 Inspect the driven face assembly and replace if necessary 7 7 C V T Reassembly Assemble the driven face assembly spring and driven plate Assemble the movable driven face composition weight roller set and drive face w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 53: ...n belt and driven pulley assembly Install the movable drive face assembly and boss Install the drive face Apply red Lock Tite and torque the locking flange nut w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 54: ...repairs the engine must be removed from the frame Drain oil from the transmission case before disassembly Refill with recommended oil after reassembly Always bring the vehicle to a full stop before shifting into forward or reverse w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 55: ... Shift fork bent or damaged Excessive noise from gears Worn transmission gear 8A 3 Gear Removal Remove the drain bolt to drain the oil from the transmission case Remove the fixing plate bolts fixing plate and sprocket from the final shaft Remove the cir clip Then the final shaft can be removed from the transmission cover w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t...

Page 56: ...Bearing Inspection Turn the inner race of the bearing with your finger The bearing should turn smoothly and quietly with no restrictions Ensure that the outer races of the bearings fit tightly in the crankcase COVER GEAR SHIFT SHAFT COUNTER SHAFT SHIFT FORK w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 57: ...sary 8A 5 Gear Set Installation Install the transmission cover and final shaft Secure in place with the cir clip Install the counter shaft and reverse shaft in the LH crankcase Install the gear shift shaft and shift fork Install a new gasket and dowel pins w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 58: ...on repairs the engine must be removed from the frame Drain oil from the transmission case before disassembly Refill with recommended oil after reassembly Always bring the vehicle to a full stop before shifting into forward or reverse Shifting while in motion can cause damage to the transmission gears w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 59: ... generator Faulty brake switch No power when throttle applied Belt worn Front pulley worn or broken Lining of clutch worn Faulty shift spring Unit runs poorly at high speed Belt worn Rollers worn Rear pulley spring damaged Rev limiter is malfunctioning Faulty CDI w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 60: ...58 8B 3 Transmission Assembly Drawing Shift Mechanism w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 61: ...wear or damage Measure the fixed shift spring SERVICE LIMIT 24mm 0 945 Check the knock block bearing and cam shift for wear or damage Replace if necessary Check the shift motor for proper functionality by referring to this table knock block cam shift w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 62: ... the transmission cover and gears Inspect gears for wear scoring chipping or breaking Replace if necessary COUNTER SHAFT GEAR SHIFT SHAFT w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 63: ...le Shooting Hard Steering Faulty tire s Steering shaft holder too tight Insufficient tire pressure Faulty or damaged steering shaft bearings Steering System A Arms w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 64: ...ring wheel into position Replace and tighten the four holding bolts Replace the horn button 9 4 Steering System Removal Remove the front wheels and brake plates Remove the carter key and the two self locking nuts from the tie rod ball joint ends Remove the tie rod w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 65: ...INGPIN INSPECTION Inspect the kingpin for damage or cracks Measure the kingpin outer diameter Upper minimum limit 15 40 mm 0 606 in Lower minimum limit 16 90 mm 0 665 in KINGPIN BUSHING INSPECTION There are two bushing in the sleeve of front swing arm the upper and lower bushing Check the kingpin bushings for wear or damage Measure the inner diameter of the bushings Upper minimum limit 15 69 mm 0 ...

Page 66: ...ng inner diameter Maximum limit 22 8 mm 0 898 in STEERING SHAFT INSPECTION Inspect the steering shaft for damage or cracks Measure the steering shaft outer diameter at the bushing seat Minimum limit 22 0 mm 0 866 in STEERING SHAFT BEARING INSPECTION Turn the shaft bearing with your finger The bearing is on the front part of frame It should turn smoothly and quietly Inspect the bearing races for we...

Page 67: ... shaft nut at the bottom of the steering shaft and tighten it Then install a new carter key Torque 50 60 N m 37 44 lbf ft INSTALLATION OF TIE ROD Install the ball joint with the L mark on the steering shaft side Install the tie rod with the mark on the wheel side Set the distance between the ball joints to 164 mm 6 46 in This is a temporary setting L Mark w w G e t 2 i t P a r t s c o m w w w G e ...

Page 68: ... 30 40 N m 2 06 2 74 lb ft Fix the waterproof rubber cap Temporarily set the distance to 147mm 5 79 in between the ball joints Install the tie rod and tighten the nuts The torque setting is 35 43 N m 2 40 2 95 lb ft Install the front brake Install the front wheel Adjust the toe in w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 69: ...67 10 WHEEL AND BRAKE SYSTEM 10 1 Wheel and Brake System Drawings Front wheel Rear wheel Hydraulic brake w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 70: ...Torque 30 35 N m 22 1 25 8 lbf ft Cotter Pin New Cotter Pin recommended Rubber Dust Cover Bad brake performance Brake shoes are worn Bad brake adjustment Brake linings are oily greasy or dirty Brake drums are worn Brake arm setting is improperly engaged Axle is not tightened well Vibration or wobble Bent rim Axle bearings are worn Faulty tires Rearaxlebearingholderisfaulty Brake drag Incorrect bra...

Page 71: ...eel Raise the rear wheels off the ground Remove the cotter pin axle nut and washer Remove the wheel and wheel hub Remove the drive chain Disassemble the chain retaining clip and master link w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 72: ...eck the bearing by turning with your fingers The bearings should turn smoothly and quietly Replace if necessary REAR BRAKE CALIPER REMOVAL Remove the left hand side rear wheel Remove the two bolts from the caliper Remove the caliper from the rotor Inspect the brake pads To reinstall refer to section 10 5 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s ...

Page 73: ... the driven sprocket Assemble the drive chain on the driven sprocket Assemble the master link and retaining clip Note the retaining clip s direction Install the drive chain cover Assemble the chain cover w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 74: ...r brake slack Adjust chain slack 10 5 Front Hydraulic Disc Brake System To the replace brake disc first remove the front tire by removing the four nuts as shown Unscrew the two bolts shown on the photo and remove the caliper w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 75: ... with a new one if the thickness less than 3mm 0 118 in REPLACE THE BRAKE PADS First remove the tire Unscrew the two bolts shown on the photo and remove the caliper Press the plate to the end w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 76: ...44 3 59 0 lbf ft Brake Pads Part 610143 Press the caliper piston in fully and place the piston pad over the retaining pins and piston Replace the static pad in the retaining clip and ensure that it is fully engaged and in the proper location Slide the caliper back into position over the rotor and replace the two caliper retaining bolts and tighten the torque to 30 40 N m 22 30 lbf ft REPLACING BRA...

Page 77: ...er valve before releasing the brake lever Repeat the process until all air has been purged from the brake line Tighten the bleeder valve and fill the reservoir with Dot 3 or Dot 4 brake fluid to a half full level Reinstall the reservoir cap and cap bolts Test the brake system and check for any leaks in the brake line connections w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w...

Page 78: ... removing the rear brake caliper release the brake cable nut Then you can take apart the parking brake caliper When replacing the brake pads you must use a hammer and punch to push the pins out This will release the pad for replacement Reassemble the brake caliper using the reverse order of removal w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 79: ...me Next remove the four mounting bolts near the four corners of the seat assembly that attach the cage to the rear of the frame The front hood must be removed prior to removing the front body cover in order to gain access to the four body cover bolts Additionally remove the three bolts on the left and right hand sides as shown in the parts diagram above ref 11 2 A Ref 11 2 A Ref 11 2 B Ref 11 2 C ...

Page 80: ...rst remove the two allen bolts on the right hand side beneath the rear body cover Next loosen but do not remove the two allen bolts on the left hand side Slide the seat backward until the bolts line up with the openings on the seat mount then lift the seat to remove it Removal of the seat gives access to the four rear body cover panels as well as the starter relay ref 11 2 C w w G e t 2 i t P a r ...

Page 81: ...79 11 3 Exhaust System Drawing This is the two piece exhaust system exhaust reed system and pipe w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 82: ...e brush and scraper DO NOT scratch the gasket seat When reinstalling the exhaust system always use a new muffler gasket to ensure there are no exhaust leaks between the cylinder and muffler Muffler gasket Part 811634 11 5 Servicing the Spark Arrestor Afterevery100hoursofoperation themufflershouldbecleaned Removethecleanoutboltusinga12mmwrench Afterevery20hoursofoperation thesparkarrestor hastobecl...

Page 83: ...utwardpressureuntilthe screenisremoved ReplacewithanewSparkArrestorScreenandsecureitbytightening theretainingbolt SparkArrestorScreen Part 811462 NOTE Failuretomaintainacleanexhaustsystemwillcauselossof powerandcaneventuallyleadtoenginedamageand orfailure Removal Bar Spark Arrestor Screen Retaining Bolt Nut w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t...

Page 84: ...CDI unit Exhaust system clogged Fuel petcock not fully opened Fuel filter clogged or dirty Air filter clogged or dirty Carburetor vacuum leak Carburetor main jet pilot jet or needle valve dirty Ignition primary circuit Poor connection of primary contact Improper gap adjustment of pickup coil Faulty ignition coil Faulty A C generator Faulty CDI module Ignition secondary circuit Poor connection of i...

Page 85: ...y charge Faulty starter relay Starter switch wires disconnected Faulty starter switch Starter motor wires disconnected Faulty starter motor Starter motor turns but engine does not start Fuel tank empty Fuel petcock in OFF position Fuel filter dirty or clogged Dirty air filter Spark plug wire disconnected No spark at plug see No Spark above Dirty main jet pilot jet or needle valve in carburetor Loo...

Page 86: ... Chip Program The timing cannot be manually adjusted 12 4 Battery Inspection and Maintenance CAUTION The battery emits flammable and explosive fumes during normal operation Keep away from sparks open flame and other possible sources of ignition Always provide adequate ventilation during charging and maintenance of the battery The battery contains sulfuric acid an electrolyte Contact with skin or e...

Page 87: ...arging unit off before disconnecting the charging leads from the battery Retest the battery voltage If the battery voltage shows an under charge condition after charging replace the battery Part 750173 New battery preparation The new battery is shipped dry with the electrolyte in a separate container Remove the battery cell caps and install the electrolyte in the battery cells CAUTION Electrolyte ...

Page 88: ...itive terminal of the battery Connect the negative lead of the charger to the negative terminal of the battery Turn on the charger and allow the battery to charge from 4 to 6 hours Test the battery voltage after charging it should give a reading of between 12 and 13 volts If after charging the battery is still indication a low voltage or the battery will not hold the charge for more than a day or ...

Page 89: ...87 12 5 Wiring Diagram w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 90: ...or shorted spark plug wire Faulty pulse generator Faulty ignition switch Low compression Worn cylinder and piston rings Damaged cylinder head gasket Engine does not fire Auto choke off or damaged Auto choke power wire disconnected Improperly adjusted air screw Improperly ignition timing Fuel air mixture ratio is too lean Engine starts but dies Carburetor flooded Improperly adjusted air screw Fuel ...

Page 91: ...tor Bad ignition timing Faulty CDI unit or pulse generator Restricted fuel flow Improperly adjusted air screw Leaking intake pipe Deteriorated insulator o ring Loose carburetor Weak or intermittent spark Loose or disconnected ignition system wires Faulty wet or fouled spark plug Faulty alternator Faulty CDI unit Faulty ignition switch Faulty ignition coil Faulty pulse generator Broken or shorted s...

Page 92: ...or Faulty CDI unit Cylinder compression too low Leaking head gasket Worn cylinder and piston rings Clogged carburetor Clean and Adjust Fouled or discolored spark plug Clean the spark plug Spark plug is incorrect heat range Engine overheating Excessive carbon deposited in Combustion chamber Wrong type of fuel Fuel air mixture ratio is lean Use of poor quality fuel Engine knocking at high speed Worn...

Page 93: ...stalled wheel hub Excessive wheel bearing play Bent swing arm Bent frame Swing arm pivot bushing excessively worn Vehicle pulls to one side Bent tie rod Incorrect tie rod adjustment Rear tire pressure incorrect Improper wheel alignment Bent frame w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 94: ...with no adjustment on the CDI rev limiter The red longer key is unrestricted and the speed can be increased or de creased with the 1 4 adjustments on the CDI box Check the chart below for the speed ratings E TON FX Rover Speed Chart CDI Pod setting Blue Key MPH Red Key Mph 0 6 9 8 8 1 6 9 12 9 Factory 2 6 9 15 6 3 6 9 18 8 4 6 9 18 8 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o ...

Page 95: ...ctory Maximum Viper 70 4 10w 12w Viper 90 4 10w 12w Viper 150 20w 50w Yukon 150 20w 50w Vector 250 35w 90w Beamer II 18w 24w Beamer III 18w 24w Beamer Matrix 18w 24w Beamer R2 18w 24w Beamer R4 18w 50w Rover N A 12w Rover GT N A 24w Per JI EE Engineers 5 24 2007 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...

Page 96: ...92 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c ...