The Eton EXL-150 Viper is a versatile Quad Bike / ATV designed for recreational trail riding and light utility tasks, catering to beginner and youth riders. Produced between 2004 and 2009, this model is recognized for its robust, user-friendly design and accessible performance, making it a popular choice in its market segment. Its engineering emphasizes reliability and ease of maintenance, featuring a 149.6 cc air-cooled, four-stroke engine paired with an automatic Continuously Variable Transmission (CVT) for smooth operation. With a focus on safety and durability, the EXL-150 Viper offers a stable riding experience with its steel tube frame and hydraulic disc brakes. This comprehensive Factory Service Repair Workshop Manual provides essential guidance for the maintenance and repair of the Eton EXL-150 Viper models from 2004 to 2009. It covers all critical systems, including detailed procedures for engine mechanicals, fuel, ignition, electrical, transmission, brakes, suspension, and chassis. The manual includes routine maintenance schedules, troubleshooting diagnostics with flowcharts, in-depth engine and component repair instructions, and electrical system analysis. Its purpose is to equip owners, mechanics, and technicians with the necessary technical specifications and step-by-step guidance to ensure the optimal performance, longevity, and safe operation of their ATV. 🏷️ Basic Information Identification Make: Eton Model: EXL-150 Viper Vehicle Type: Quad Bike / ATV Codes Product Code: ETON-EXL150-2004-2009-SRW 👋 Introduction Market Position Market Segment: Entry-level to mid-range recreational ATV for youth and smaller riders, suitable for trail riding and light utility work. Competitive Analysis Key Competitors: Other 150cc ATVs from brands like TaoTao, Kymco, Polaris (entry-level models), Yamaha (older models). Key Features Target Audience: Beginner riders, youth riders, recreational users seeking an affordable and user-friendly ATV. Vehicle Design Philosophy: Simple, robust, and easy-to-maintain design focused on reliability and accessibility. 📋 Manual Details Coverage Areas Model Years Covered: 2004, 2005, 2006, 2007, 2008, 2009 Page Count Estimated Page Count: Varies by specific manual, typically 300-500 pages for a complete factory service manual. Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, assembly, inspection, and repair of the 150cc engine (e.g., cylinder head, pistons, crankshaft, valve train). Fuel System: Carburetor overhaul, adjustment, fuel pump (if applicable), fuel lines, fuel tank inspection and repair. Ignition System: CDI unit, spark plug, ignition coil, wiring diagrams, timing. Electrical System: Starter motor, battery, charging system (stator, regulator/rectifier), lighting (headlights, taillights, brake lights), indicators, wiring diagrams, component testing. Transmission Drivetrain: Automatic transmission (CVT) overhaul, belt inspection and replacement, clutch assembly, final drive, chain adjustment and maintenance. Brake System: Front and rear brake caliper overhaul, brake pad replacement, brake fluid bleeding, hydraulic lines, parking brake mechanism. Suspension Steering: Front and rear suspension components (shocks, A-arms, bushings), steering linkage, tie rods, wheel alignment procedures. Chassis Frame: Frame inspection, welding repair (if applicable), body panel removal and installation, seat, handlebars. Cooling System: Radiator (if liquid-cooled), fan, coolant types and capacities, hoses, thermostat. Exhaust System: Muffler, exhaust pipe inspection and replacement. Procedures Included Routine Maintenance: Oil change, filter replacement, air filter cleaning/replacement, spark plug gap and replacement, chain lubrication and adjustment, brake adjustments. Troubleshooting: Diagnosis of common problems (e.g., hard starting, poor performance, electrical issues) with systematic diagnostic flowcharts. Engine Repair: Detailed step-by-step instructions for engine rebuilding, component replacement (e.g., piston rings, gaskets). Transmission Repair: CVT belt replacement, clutch adjustment, torque converter service (if applicable). Brake Service: Brake bleeding procedures, caliper rebuild, pad replacement. Electrical Diagnostics: Testing circuits, diagnosing battery issues, starter, charging system faults. Suspension And Steering Adjustment: Alignment procedures, shock absorber adjustment/replacement. Bodywork And Trim: Removal and installation of fenders, plastics, seat, handlebars. Technical Depth Depth Of Coverage: Comprehensive, covering all aspects from basic maintenance to complete engine and component overhauls. Includes detailed specifications and diagrams. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality Description: High-resolution, clear text and diagrams optimized for printing. Binding Type Binding Type: Not applicable (downloadable PDF) Paper Type Paper Type: Not applicable (downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, four-stroke, single-cylinder Engine Displacement: Approximately 149.6 cc (often marketed as 150cc) Bore X Stroke: Typically around 57.4 mm x 57.8 mm (exact figures may vary slightly) Compression Ratio: Likely around 9.0:1 to 10.0:1 Performance Horsepower Estimate: Estimated 8-10 HP (at peak RPM) Torque Estimate: Estimated 7-9 lb-ft (at peak RPM) Fuel System Fuel Delivery: Carburetor (likely a PZ26 or similar size) Fuel Type: Unleaded gasoline Fuel Tank Capacity: Typically around 3.5 - 4.5 liters (0.9 - 1.2 gallons) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with Forward, Neutral, Reverse (F-N-R) Optional Optional Transmissions: None (CVT is standard) Features Drive System: Chain drive to rear axle Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Length: Approximately 1700 mm (66.9 inches) Width: Approximately 960 mm (37.8 inches) Height: Approximately 1000 mm (39.4 inches) Wheelbase: Approximately...