Eton viper 90r service manual

The need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as to new machines that are being prepared for sale. Page 51 Every two years replace the brake master cylinder and caliper, and change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged. Since these items require special tools, data and technical skills, have an E-TON dealer perform the service. Fuel tank breather hose Handlebar cover When installing the handlebar cover, Seat Pull back the seat lock lever, than pull up on the rear of the seat. Measure the valve clearance using a thick- ness gauge Out of specification Adjust 3.

Loosen the locknut b. Insert a thickness gauge between the adjuster end and the valve end. Start the engine and let it warm up for sev- eral minutes. Throttle lever free play 1. Screwing in the adjuster stops the engine speed from increasing. Normal color is a medium-to-light tan color. Start the engine, warm it up for several min- utes, and then turn it off. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

Place the machine on a level surface. Oil level low Add oil to the proper level. Do not screw the dipstick in when checking the oil level. Place a container under the engine oil drain bolt. Squeeze the excess solvent out of the spo- nge materials and let it dry. Tap the tailpipe lightly with a soft-face ham- mer or suitable tool, then use a wire brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler.

Parking brake cable end length When checking the brake fluid level, make sure that the top of the brake master cylinder reser- voir or brake fluid reservoir is horizontal. Brake pad wear limit 1. Place a receptacle under the final transmission case. Excessive play Replace the steering shaft bushings and or bearings. Toe-in 10 mm 0. Mark both front tire tread centers. Mark both tie-rods ends.

This reference point will be needed during adjustment. Loosen the locknuts tie-rod end of both tie-rods. The same number of turns should be given to both the right and left tie-rods until the specified toe-in is obtained. Uneven adjustment can result in poor han- dling and loss of stability. Tire wear limit Front and rear: 3 mm 0. When tire wear is out of specification, replace the tire immediately. An unsafe condition may result so replace a damaged cable as soon as possi- ble.

Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage. Connect a charger and ammeter to the battery and start charging.

Clean with a wire brush. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. Turn the crankshaft clockwise with a wrench. Remove: cam shaft comp. Fasten a safety wire to the timing chain to prevent it from falling into crankcase. Install: cyl.

If the marks are aligned, temporarily tighten the camshaft sprocket bolt. If the marks are not aligned, change the meshing position of the camshaft sprocket and timing chain. Install: bolt, flg. Stem-to-guide clearance Intake 0. Margin thickness Intake 0. Valve seat width Intake 0. Apply molybdenum disulfide oil to the valve stem. Install the valve into the cylinder head. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound.

Spring tilt limit Inner 2. Be sure to align the round hole in camshaft sprocket away from the cylinder head. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston pin outside diameter Page C. Magneto C.

Page Removing The C. Magneto Rotor C. Remove: plate washer While holding the C. Do not allow the sheave holder to touch the projection on the C. Page Installing The C. Install: C. When installing the magneto rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. Arm comp kick starter Cover L side Dowel pin For installation, reverse the removal pro- cedure. Install: boss kick spindle spindle comp kick start spring kick starter 2.

Hook: spring kick starter Hook the spring end on the spindle comp kick start as shown, and hook the other end the projection 3. Remove: primary sheave nut plate washer oneway clutch primary fixed sheave - 1 primary fixed sheave - 2 collar primary sliding sheave While holding the primary fixed sheave with the rotor holding tool , loosen the primary fixed sheave nut. Remove: secondary sheave assembly V-belt Remove the V-belt and clutch assembly from the primary sheave side.

Remove: clutch carrier nut Install the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown. Measure: V-belt width Out of specification Replace.

V-belt width Clean: face driver face movable drive boss drive face roller weights Use thinner to clean up grease, dirt on the pri- mary sliding sheave cam side 2. Install: roller weights boss drive face 3. Install: face comp, movable driven Install the face comp, movable driven onto the face comp, driven with the oil seal guide 3.

Install: face comp, driven spring clutch comp Attach the clutch spring holder and clutch spring holder arm onto the secondary sheave as shown. Install: clutch nut hex 55 Nm 5. Install: outer clutch 40 Nm 4. Check: starter clutch operation a. Install the starter wheel gear onto the idle gear and hold the starter clutch.

When turning the starter wheel gear clock- wise , the starter clutch and the starter wheel gear should engage, otherwise the starter clutch Measure: inner-rotor-to-outer-rotor-tip clearance outer-rotor-to-oil-pump-housing clear- ance oil-pump-housing-to-inner-rotor-and- outer-rotor clearance Out of specification Replace the oil pump.

Inner rotor Outer rotor Oil pump housing Inner-rotor-to-outer-rotor-tip clear- ance 0. HEA Loss of control can result in severe injury or death. Page 21 Read and understand all of the labels on your ATV. Loss of control can result in severe injury or death.

Page 24 Les enfants de moins de 6 ans qui conduisent ce QUAD encourent des accidents graves ou mortels. La surveillance d'un adulte est requise pour les enfants de moins de 16 ans. Page 25 Une pression de gonflage de pneu incorrecte ou une surcharge peuvent entra ner la perte de controle.

La perte de controle peut entra ner de serieuses blessures ou la mort. Page 26 Read and understand all of the labels on your ATV.

Page 27 Les enfants de moins de 6 ans qui conduisent ce QUAD encourent des accidents graves ou mortels. Page 28 Comprend poids de loperateur, chargement et accessoires.

HEA La perte de controle peut entra ner de serieuses blessures ou la mort. Fuel cock 1. Spark arrester 2. Rear wheel 2. Seat 3. Footrest 3.

Footrest 4. Front wheel Rear brake lever 6. Fuel tank cap 1. Rear brake lever 2. Parking brake 7. Engine stop switch with cord lanyard 2. Main switch The positions of the main switch are as follows: All electrical systems are supplied with power, and the engine can be started. Lanyard Should the ATV be separated from the parent by a distance longer than the lanyard length after str- etching, the lanyard will pull out the rubber cap 1.

Page 34 The engine cannot be started with the safety tether cap removed. When your child has developed sufficient skill to no longer need you to follow with the lanyard, the lanyard can be stowed on the handlebars of the ATV. However, you must still closely supervise your child at all times during ATV operation.

Page Throttle Lever Throttle lever Before starting the engine, check the throttle to be sure it is operating smoothly. Make sure it returns Once the engine is running, movement of the throt- to the idle position as soon as the lever is released. The throttle limit bolt is set at the factory to comply with the speed limit standards set by government regulations. Page Vehicle Speed Limiter Vehicle speed limiter 1. Loosen the locknut.

To increase the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction a. To decrease the maximum engine power available and the maximum speed of the ATV, turn the adjusting screw in direction b. Page Front Brake Lever Front brake lever Rear brake lever The front brake lever is located on the right handle- The rear brake lever is located on the left handle- bar. To apply the front brake, pull the brake lever bar.

To apply the rear brake, pull the brake lever to- toward the handlebar grip. The ATV could start moving not in use, especially when parking on any type of unexpectedly if the parking brake is not applied. Page Transmission Gear Selector For Viper 90R for VIPER 90R Always pause in the "N" neutral position for a few The Viper 90R model is equipped with a transmission seconds when shifting from forward to reverse or gear selector switch mounted on the right hand side from reverse to forward, this allows the transmission of the handlebars.

Page 41 Fuel tank capacity: containing methanol and ethanol are not recom- Plastic: 4. Page Fuel Cock With the fuel cock lever in this position, fuel flows Fuel cock to the carburetor. Turn the fuel cock lever to this The fuel cock supplies fuel from the tank to the car- position when starting the engine and riding.

Page Choke Choke Seat The choke is used to start a cold engine. To remove the seat Move the choke in direction a to turn on the Pull the seat lock lever upward and pull up the seat choke. Move the choke in direction b to turn off the choke.

Page Kickstarter 2. Move the kickstarter lever down lightly with your To install the seat foot until the gears engage, and then push it Insert the projection on the front of the seat into the down smoothly but forcefully.

Make sure that the seat is securely fitted and the latch is fully engaged. Page Pre-Operation Checks Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.

If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by an E-TON dealer. Page 46 Front brake Lubricate cable if necessary. Check operation. If soft or spongy, have E-TON dealer bleed hydraulic system. Check brake pads for wear, and replace if necessary. Rear brake Page Fuel Apply the disc brake fully for one minute. If the specified level.

Add oil as necessary. Page Throttle Lever Use the tire pressure gauge to check and adjust tire open smoothly and spring back to the idle position pressures when the tires are cold. Tire pressures when released. Have an E-TON dealer correct if must be equal on both sides. Page 49 Set tire pressures to the following specifications: Recommended pressure: Front 28 kPa 4.

Low-pressure tire gauge The tire pressure gauge is included as standard equipment. Page Tire Wear Limit Tire wear limit After extensive tests, only the tires listed below When the tire groove decreases to 3 mm 0. Page Chassis Fasteners Chassis fasteners Make sure that all nuts, bolts and screws are prop- erly tightened. Instruments and switches Check that all instruments and switches are working properly. Correct if necessary. Page Operation If the indicator accident or injury. The engine can be started only when the rear brake lever is applied.

Position 2 : Warming up position. Page Starting A Warm Engine 2 to warm up the engine. If the engine is started with the choke in position 2 , keep the To start out and accelerate for VIPER 90R choke in this position to warm up the engine.

For this reason, you should read the following material carefully. Park- ing on a hill or other incline could cause the ATV to roll out of control, increasing the chance of an accident. If you must park on an incline, place the ATV transversely across the incline, stop the engine, apply the parking brake, and then block the front and rear wheels Exam- E-TON is not in a position to test the products that ples include but are not limited to a heavy or these aftermarket companies produce.

The ATV may handle differently than 40 kg 88 lb it does without accessories. This section, Riding Get training if you are inexperienced. The skills and techniques described in this section, however, are appropriate Do not operate this ATV or allow anyone else for all types of riding.

Page 61 ATV at slow speeds first, even if you are an exper- Not recommended for children under 12 years ienced operator. Use by chil Page 62 This ATV is designed to carry operator only — passengers prohibited. The long seat is to allow the operator to shift position as needed during operation. It is not for carrying passengers. Page 63 Apparel WARNING Always wear the following to reduce risk of injury Operating without eye protection can result in in an accident: an accident and increases your chances of a Approved motorcycle helmet that fits properly severe injury in the event of an accident.

Eye protection goggles, helmet face shield, or protective eyewear Over-the-ankle boots, gloves, long-sleeved shirt Page 64 Do not operate after consuming alcohol or Pre-operation checks drugs. Consuming Perform the pre-operation checks listed on page alcohol or drugs could seriously affect your judg- Page 65 Turning in the adjusting screw decreases top speed, and turning it out increases top speed.

See pages and E-TON recommends that all beginning riders start off with the vehicle speed limiter turned in to limit the amount of speed available while they learn. To reduce the risk of an accident Page 67 During operation Avoid wheelies and jumping. Always keep your feet on the footboards during WARNING operation; otherwise, they may contact the rear Attempting wheelies, jumps, and other stunts wheels.

Never attempt stunts, such as Removing even one hand or foot can reduce wheelies or jumps. Page 68 ATV should be gen- let brush, grass and other materials collect under uine E-TON or equivalent components designed the vehicle, near the muffler or exhaust pipe, or for use on this ATV and should be installed and used next to other hot parts.

Always avoid paved surfaces, including sidewalks, driveways, parking lots and streets. You could collide with another vehicle. Do not ride on any public road, street, or highway. Riding on public roads can result in collisions with other vehicles.

Page 71 Know the terrain where you ride. Ride cautiously in unfamiliar areas. Stay alert for holes, rocks, or roots in the terrain, and other hidden hazards which may cause the ATV to upset. Page 72 When riding in an area where you might not easily be seen, such as desert terrain, mount a caution flag on the ATV.

DO NOT use the flag pole bracket as a trailer hitch. With the engine idling, the drive position and then release the parking brake.

Page 74 To achieve maximum traction while riding off-road, the two rear wheels turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will resist turning. A special turning technique must be used to allow the ATV to make turns quickly and easily. Page Climbing Uphill curves.

Shift your weight forward. Improper riding procedures such as abrupt throttle Never open the throttle suddenly. The ATV changes, excessive braking, incorrect body move- could flip over backwards. Page 76 It is important when climbing a hill to make sure that your weight is transferred forward on the ATV. This can be accomplished by leaning for-ward and, on steeper inclines, standing on the footboards and leaning forward over the handlebars.

Whenever possible, ride straight up hills. Page 77 If your ATV has stalled or stopped and you believe you can continue up the hill, restart carefully to make sure you do not lift the front wheels which could cause you to lose control. If you are unable to con- tinue up the hill, dismount the ATV on the uphill side. Page Riding Downhill Shift your weight backward and to the up side of the hill. Never go down a hill at high speed.

Avoid going down a hill at an angle that would cause the ATV to lean sharply to one side. Go straight down the hill where po- ssible. Carefully choose your path and ride no Improperly crossing hills or turning on hills could faster than you will be able to react to obstacles cause loss of control or cause the ATV to over- which may appear. Page Crossing Through Shallow Water body in the uphill direction.

When Operating this vehicle through deep or fast- riding on slopes, be sure not to make sharp turns flowing water can lead to loss of control or over- either up or down hill. Page 81 After riding your ATV in water, be sure to drain the Test your brakes after leaving the water. If necess- trapped water by removing the check hose at the ary, apply them several times to let friction dry out bottom of the air filter case.

Before operating in a new area, check for obstacles. Never att- empt to ride over large obstacles, such as large rocks or fallen trees. You may also regain traction unexpectedly, which may cause the ATV to overturn. Learn to safely control skidding or sliding by practicing at low speeds and on level, smooth terrain. This section is designed to be a reference guide only. Be sure to read each section on riding tech- niques completely.