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Air Filter

Air Filter Maintenance

To maintain the highest performance from your
engine and to reduce excessive wear that could
cause engine failure the engine requires a
continuous flow of clean air. Air is taken into the
engine through an air filter to clean the air prior
to mixing it with fuel and oil in the carburetor.

During normal operation the filter accumulates
dirt from the air and will need to be cleaned to 
maintain the proper air flow.
The filter should be cleaned every  30 days, more 
often if you ride in a dusty or dirty environment 
and the element should be replaced every year. 

The air filter box is located on the left side of the
engine under the front fender. It is a black box
about 6" square and is attached  to the crankcase 
with two bolts and the carburetor by a tube.

To clean the filter

Remove the air filter box cover.
Remove the filter element from the air box.
Wash the element in a non-flammable solvent
such as Air-Filter cleaner from your local auto
parts dealer.

1.    Dry the element completely before  continuing.
2.   Soak the element in clean engine oil until 
      completely saturated.
3.   Squeeze out  the excess oil until the element 
      does not drip any oil.
4.   Allow the element to dry then reinstall the
      element and cover.

C.V.T. Filter

This unit is equipped with an air filter for the
C.V.T. transmission. It is located on the left-
hand side of the engine, just ahead of the kick
starter spindle. The filter will accumulate dust

and must be cleaned periodically to maintain
normal vehicle operations. Inspect and clean
the filter every 30 operating  days, more frequently

if operated in a dusty environment.

To clean the filter, remove the two cover bolts
and remove the filter. Clean the filter element
in a non-flammable solvent and  let dry completely
before reinstalling. Replace the filter element
and the cover.

Spark Plug

Replace spark plug at the beginning of each
season with a replacement plug NGK- BPR7HS.

Disconnect spark plug wire.
Clean dirt from around spark plug base with
brush or air.
Remove spark plug with spark plug wrench.
Set the spark plug gap on the  new plug to 0.023"
Install the new plug screwing it in finger tight and
then use the plug wrench to screw the plug in
another 

1/2

 turn.

Inspect the spark plug wire for cuts, nicks or
other damage. Replace as needed.

Page 16

Summary of Contents for EXL-50 - SERVICE

Page 1: ...VER THROTTLE LEVER FUEL SYSTEM FUEL SYSTEM SPEEDOMETER ODOMETER SPEEDOMETER ODOMETER FUEL INDICATOR METER FUEL INDICATOR METER BRAKE CONTROLS BRAKE CONTROLS TIRES AND WHEELS TIRES AND WHEELS Fuel Tank...

Page 2: ...24 24 24 25 25 23 BRAKING SYSTEMS BRAKING SYSTEMS THROTTLELEVER THROTTLELEVER DRIVE CHAIN DRIVE CHAIN ELECTRICAL BATTERY ELECTRICAL BATTERY Front Brake System Inspection Front Brake Adjustment Rear B...

Page 3: ...the E TON manufacturer s warranty Riders must thoroughly read this manual and must fully understand its contents b efore r iding All riders should enroll in an ATV Rider Safety Course Your E TON deale...

Page 4: ...tification Number VIN is located at the front of the unit under the front fender on a plate mounted between the main frame rails Engine serial number is located on the left hand side of the engine on...

Page 5: ...eadlight Rear position lamp switch 12 Horn button 13 Start button 14 Direction indicator switch Parking indicator switch Controls Switches Feature Locations for ViperST Locations of controls and featu...

Page 6: ...4 Direction indicator switch 15 Fuel indicator meter Transmission gear selector Parking indicator switch Controls Switches Feature Locations for YukonST Locations of controls and features 1 Fuel tank...

Page 7: ...reduce your pressure on the lever and the spring tension will automatically reduce your speed To increase the throttle s travel thus increasing the maximum speed turn the throttle stop bolt counter cl...

Page 8: ...caution not to apply too much pressure to your front brakes so that the wheels lock up stop turning and causing a loss of steering control If the front wheels lock up and stop turning lightly reduce t...

Page 9: ...ine with an octane level of 91 orhigher YourATV is equipped with a fuel gage located in the instrument cluster between the handlebars NEVER REFUEL YOUR ATV when the engine is HOT Wait 30 minutes after...

Page 10: ...your tires and wheels for damage and wear before each riding session Inspect each tire for cuts tears and punctures Inspect the wheel rim for dents and separation of the wheel from the tire bead Repla...

Page 11: ...power on and off 2 Fuel indicator to F when the tank is full and to E when empty The theoil gauge flashes when 3 4 stages left 3 The direction indicator switch is on the left handlebar push to right o...

Page 12: ...elector switch Always pause in the N neutral positon for a few seconds when shifting from forward to revers or from revers to forward this allows thetransmissiontime todisengageand resycronize Transmi...

Page 13: ...le air cooled 49 3cc 50 0 42 0mm 7ps 7500rpm Automatic C V T V Belt 1670mm 65 8 940mm 37 0 1040mm 41 0 1110mm 43 7 152kg 3351b SingleA arm AdjustableShocks SwingArm AdjustableShock Dual Mechanical dru...

Page 14: ...octane 4 5 liters 1 2 gal 1 0 liters 1gt SAE 80 90 weight 300cc 10 2oz BPR7HS W22FRP U QL82YC 0 6 0 7mm 0 023 High grade synthetic 2 cycle injector oil JASO FC Grade 12V 4AH 5AH GTX5L 19 teeth 34 tee...

Page 15: ...ng Transmission Oil 1 Place an oil catch pan under the unit directly below the transmission box 2 Remove the transmission box drain plug located on the bottom of the transmission box on the underside...

Page 16: ...element in clean engine oil until completely saturated 3 Squeeze out the excess oil until the element does not drip any oil 4 Allow the element to dry then reinstall the element and cover C V T Filte...

Page 17: ...taining the correct adjustment insure that the locking nut is tightened securely against the adjusting wheel to prevent the adjustment wheel from turning due to vibration Keep your brake cables lubric...

Page 18: ...rakes are applied check your fluid level and brake pads If the brake lever feels spongy or does not stop when squeezed you may have air in the lines All air must be purged from the brake lines for the...

Page 19: ...electrical power to the unit The battery is a 12 volt jell acid type that contains no liquid electrolyte The battery should be removed from the vehicle when stored for extended periods and charged be...

Page 20: ...the throttle will return to the idle position automatically ThrottleLever Adjusting the throttle cable The cable should be adjusted to allow for free travel before the throttle engages the carburetor...

Page 21: ...nut to take up the excess slack inthechain Oncethechainhas beenadjustedto the proper tension retightenthe axle position locking bolt Inspect the drive and axlesprockets for worn damaged or broken tee...

Page 22: ...e I L I R Inspect as part of pre ride inspection Inspect as part of pre ride inspection of pre ride inspection Inspect as part Replace every 2 years Inspect as part of pre ride inspection Inspect as p...

Page 23: ...go gently Do not run at high speeds Do not approach the maximum RPMs during the break in period Failing to adequately break in your E TON ATV will decrease the long term power and life of the engine...

Page 24: ...ing may cause the front wheels to slide straight ahead If this happens back off the throttle and Stop To keep from skidding on slippery terrain avoid braking or accelerating until you have regained di...

Page 25: ...pendable maintenance items made in connection with required maintenance services including but not limited to coolant spark plugs gaskets belts filters lubricants and hoses In addition this warranty d...

Page 26: ...WIRING DIAGRAM Page 26 VIPER Wiring Diagram...

Page 27: ...WIRING DIAGRAM YUKON Wiring Diagram...

Page 28: ...conditions that are specifically excluded from this warranty program are 1 Damage caused by accidents misuse negligence improper vehicle operation 2 Any modification or alteration to any standard spec...

Page 29: ...in proper operatingcondition The dealer is responsiblefor checking and performing all items on the set up and pre delivery checklist prior to delivery to the customer This warranty isvalid at anyautho...

Page 30: ...Owner s Notes Page 30...

Page 31: ...Page 31...

Page 32: ...Page 32 Page 31...

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