Aeon COBRA 400 2012 Service Manual
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Aeon COBRA 400 2012 Service Manual

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2012 COBRA 400
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Aeon Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with
service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper
tools as specified.

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  • Page 1 FOREWORD This service manual is designed primarily for use by certified Aeon Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
  • Page 2 UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
  • Page 3 GENERAL INFORMATION MAINTENANCE CVT SYSTEM ENGINE TRANSMISSION FUEL AND CARBURETOR BODY / SUSPENSION / STEERING BRAKE ELECTRICAL...
  • Page 4 GENERAL INFORMATION CHAPTER 1 MODEL INFORMATION ............. 1-2 .
  • Page 5 GENERAL INFORMATION MODEL INFORMATION VIN IDENTIFICATION ENGINE SERIAL NUMBER LOCATION The frame can be found under front cab on the right side of Engine serial number local under rear seat stamped on the rear of frame. crankcase beneath exhaust pipe. The vehicle identification number (VIN) and engine serial number are important for identification purposes.
  • Page 6 GENERAL INFORMATION COBRA 400 Model---AT56-69E Model Number---RF3RA56XXCTXXXXXX Engine Model---V69C...

  • Page 7: Conversion Table

    GENERAL INFORMATION SPECIFICATIONS MODEL: COBRA 400 ENGINE DRIVE SYSTEM Type 4 Stroke, Single horizontal camshaft Oil capacity/ type 900 CC/ 80w90 Displacement 346.4 CC Transmission selection Forward, Neutral, Reverse Cooling Liquid cooled Clutch type Centrifugal clutch Bore and stroke 82 mm *65.6 mm Final drive Chain Compression ratio...

  • Page 8: Glossary Of Terms

    GENERAL INFORMATION Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm = kg-m in. lbs x .0115 x .7376 = ft. lbs. kg-m x 7.233 = ft.
  • Page 9 GENERAL INFORMATION ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No.

  • Page 10: General Information

    GENERAL INFORMATION oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system.

  • Page 11: Table Of Contents

    MAINTENANCE CHAPTER 2 PERIODIC MAINTENANCE CHART ........... .2-3 PERIODIC MAINTENANCE OVERVIEW .
  • Page 12 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ..........2.20 BATTERY MAINTENANCE .

  • Page 13: Periodic Maintenance Chart

    AEON dealer. ◆ = SEVERE USE ITEM -- See Above NOTE: Inspection may reveal the need for replacement parts. Always use genuine Aeon parts. Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or death.

  • Page 14: Pre-Ride - 25 Hour Maintenance Interval

    Perform a break-in oil change at 25 hours, Clean filter at every oil change; ◆ Oil pre-filter screen 1000 ■ Perform these procedures more often for vehicles subjected to severe use. ◆ Have an authorized AEON dealer perform these services.

  • Page 15: 50 - 300 Hour Maintenance Interval

    ◆ Brake fluid 100H 1500 Inspect periodically; adjust when ■ Toe adjustment parts are replaced. Headlight Aim Adjust as needed ■ Perform these procedures more often for vehicles subjected to severe use. ◆ Have an authorized Aeon dealer perform these services.

  • Page 16: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE PRE-RIDE / DAILY INSPECTION • Throttle - check for free operation Perform the following pre-ride inspection daily, and when • Headlight / Taillight / Brake light - check operation of all servicing the vehicle at each scheduled maintenance indicator lights and switches •...

  • Page 17: Maintenance Quick Reference

    MAINTENANCE MAINTENANCE QUICK REFERENCE Item Comment Method Frequency Engine Oil OW-50 Synthetic Check level or Check during pre-ride inspection change 20W-40 Semi-Synthetic change oil oil every 30 hours or 6 months. Transmission SAE80W-90 Gear Check level or Inspect periodically and change Lubricant change lube.

  • Page 18: Recoil Starter And Operation

    MAINTENANCE RE-COIL OIL STARTER AND OPERATION Throttle Free Play Adjustment If the battery becomes too weak to start the engine, use the Inspection re-coil starter to start the engine until the battery is serviced. 1. Place the transmission in the N position. 2.

  • Page 19: Idle Speed Adjustment

    MAINTENANCE FUEL SYSTEM AND AIR INTAKE Vent Lines 1. Check fuel tank, front gear case, and rear gear case and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. 2. Be sure vent lines are routed properly and secured with cable ties.

  • Page 20: Fuel Filter

    MAINTENANCE FUEL FILTER 3. Inspect the drained fuel for water or sediment. The fuel filter should be replaced in accordance with the 4. Tighten drain screw. “Periodic Maintenance Chart” or whenever sediment is 5. Check for fuel leaks. visible in the filter. 6.

  • Page 21: Air Box Sediment Tube

    MAINTENANCE AIR BOX SEDIMENT TUBE Periodically check the air box sediment tube located toward the rear of the machine. Drain whenever deposits are visible in the clear tube. 4. Apply commercially available foam filter oil to the foam filter. 5. Inspect the filter support screen and clean away any oil or sediments in the air box.

  • Page 22: Engine And Transmission Oil Location

    MAINTENANCE ENGNIE ENGINE AND TRANSMISSION OIL LOCATION 4. Check to see that the oil level is in the ’normal’ range. The OIL LEVEL level should be, at minimum, halfway between to the top of the To Check The Oil Level viewing area.

  • Page 23: Engine Oil And Filter Service

    MAINTENANCE NOTE: The sealing surfaces on the drain plug and Recommended Engine oil: crankcase should be clean and free of burrs, nicks Synthetic, 0W-40 Above 0°C (32°F) or scratches. Semi-Synthetic 20W-40 Below 0°C (32°F) ENGINE OIL AND FILTER SERVICE 9. Reassemble the pre-filter screen and spring to the pre-filter The single cylinder engine is a wet-sump engine, meaning the plug.

  • Page 24: Engine Mounts Location

    MAINTENANCE 5. When clearance is correct, hold adjuster screw and tighten 2. Remove spark plug and rotate engine to TDC on the locknut securely. compression stroke. There are 2 places align TDC, One locates 6. Re-check the valve clearance. in engine oil filling cap of upper right crankcase, another locate 7.

  • Page 25: Transmission

    MAINTENANCE TRANSMISSION TRANSMISSION LUBRICATION The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. Remember to: • Verify the vehicle is level before proceeding. • Verify the vent hose is routed properly and is not obstructed.
  • Page 26 MAINTENANCE 2. The chain should have 6-12 mm (1/4”-1/2”) deflection. If the chain needs adjustment, use the following procedure. 3. Turn the chain adjuster clockwise until chain tension is setting specification. Sprocket Inspection Inspect the front and rear sprockets for worn, broken or bent teeth.

  • Page 27: Cooling System

    MAINTENANCE COOLING SYSTEM CVT DRYING COOLING SYSTEM OVERVIEW NOTE: If operating the vehicle through water, be sure The engine coolant level is controlled, or maintained, by the to check the CVT and other components for water recovery system. The recovery system components are the ingestion.

  • Page 28: Coolant Strength / Type

    MAINTENANCE With the engine at operating temperature, the coolant level • Do not use tap water, straight antifreeze, or straight water in the should be between the upper and lower marks on the coolant system. Tap water contains minerals and impurities, which build recovery bottle.

  • Page 29: Electrical And Ignition System

    MAINTENANCE ELECTRICAL AND IGNITION SYSTEM BATTERY MAINTENANCE Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one-tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels.

  • Page 30: Battery Cleaning

    MAINTENANCE Battery Cleaning CAUTION Keep the battery terminals and connections free of corrosion. Always wear safety glasses, rubber protective If cleaning is necessary, remove the corrosion with a stiff wire gloves and appropriate clothing when working with brush. Wash with a solution of one-tablespoon baking soda batteries.

  • Page 31: Battery Charging (Sealed Battery)

    MAINTENANCE BATTERY CHARGING (SEALED BATTERY) BATTERY INSPECTION The sealed battery is already filled with electrolyte and has When installing a new battery, make sure it's fully charged been sealed at the factory. Never pry the sealing strip off or prior to its initial use. Using a new battery that has not been add any type of fluid to this battery.

  • Page 32: Fuses / Fuse Holder Location

    MAINTENANCE FUSES / FUSE HOLDER LOCATION A 15 Amp fuse protects the main electrical system, a 30 Amp fuse protects ignition system and a 10 Amp fuse protects the headlight and taillight. See illustrations for fuse locations. 1. It locates under the seat and in storage box. 2.

  • Page 33: Engine/ Frame Ground

    Replace the tie-rod end, if tie rod end has any vertical sure the steering mechanism is not restricted or limited. play. Due to the critical nature of the procedures outlined in this chapter, an authorized Aeon Dealer should perform steering component repair adjustment.

  • Page 34: Toe Alignment Inspection

    MAINTENANCE 1. Elevate front end of ATV so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.
  • Page 35 MAINTENANCE 2-25...

  • Page 36: Toe Adjustment

    MAINTENANCE TOE ADJUSTMENT • Hold tie rod end to keep it from rotating. • Loosen jam nuts at both ends of the tie rod. Tie Rod Jam Nut Torque: • Shorten or lengthen the tie rod until alignment is as required to 16-19 Nm (12-14 ft.

  • Page 37: Rear Suspension Spring Preload Adjustment

    MAINTENANCE REAR SUSPENSION SPRING PRELOAD NOTE: ADJUSTMENT The spring preload of the rear shock absorber can be adjusted to suit the rider’s preference, weight, and The rear spring preload can be adjusted. To make preload the riding conditions. adjustments, rotate the adjustment cam clockwise to decrease spring tension or counter-clockwise to increase spring tension.

  • Page 38: Brake System

    MAINTENANCE BRAKE SYSTEM BRAKE FLUID INSPECTION Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only. Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.
  • Page 39 MAINTENANCE Foot Brake Adjustment 1. Repeat step 1~5 for parking caliper cable adjusting. 1. Position the vehicle on a level surface. 2. Shift the transmission into neutral (if applicable). 3. Elevate the vehicle by placing a suitable stand under the frame. The 4 tires should be slightly off the ground.

  • Page 40: Brake Pad/ Disc Inspection

    MAINTENANCE WHEELS AND TIRES Brake Pad / Disc Inspection WHEELS 1. Check the brake pads for wear, damage, or looseness. Inspect all wheels for run out or damage. Check wheel bolts 2. Inspect the brake pad wear surface for excessive wear. and ensure they are tight.

  • Page 41: Wheel Installation - Front / Rear

    MAINTENANCE Wheel Installation - Front / Rear Tire Pressure Inspection (PSI - Cold) 1. With the transmission in gear and the parking brake locked, Front Rear place the wheel in the correct position on the wheel hub. Be 5 psi (35 kPa) 5 psi (35 kPa) sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
  • Page 42 CVT SYSTEM CHAPTER 3 CVT SYSTEM OVERVIEW ............. .3-2 CVT MAINTENANCE / INSPECTION .

  • Page 43: Cvt System Overview

    (initial vehicle movement), clutch up shift reacting to the torque at the transmission input shaft. If the and backshift. During the development of an Aeon ATV, the torque resistance at the transmission input shaft is greater than CVT system is matched first to the engine power curve; then to the load from the drive belt, the drive belt is kept at the outer average riding conditions and the vehicle’s intended usage.

  • Page 44: Clutch Cover/ Re-Coil Starter Exploded View

    CVT SYSTEM CVT SYSTEM DRYING NOTE: If operating the ATV through water, be sure to check the CVT cover and other ATV components for water ingestion. The ATV should be checked immediately. Refer to Owner’s Manual for Safe Riding Tips. 1.

  • Page 45: Cvt Exploded View

    CVT SYSTEM CVT EXPLODED VIEW...

  • Page 46: Cvt Overheating/Diagnosis

    Repeat several times as required. During this procedure, the throttle should not be held at the full position. CVT seals should be inspected for damage if repeated leaking occurs. Clutch malfunction. A certified AEON technician should perform Inspection/repair of clutch components.

  • Page 47: Drive Clutch Removal

    CVT SYSTEM DRIVE CLUTCH REMOVAL Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Position the vehicle on a level surface. Use the parking brake. 2. Remove seat, storage box and LH plastic panel to gain access to the outer clutch cover.
  • Page 48 CVT SYSTEM 8. Remove outer sheave from crankshaft. 7. Remove belt. 8. Use two hands to hold the cam plate and the primary sliding sheave together when removing the primary sliding sheave and the cam plate assembly. This prevents the roller weights from falling out of the assembly.

  • Page 49: Driven Clutch Removal

    CVT SYSTEM DRIVEN CLUTCH DRIVEN CLUTCH REMOVAL 2. Remove the nut by pincer and air wrench. NOTE: This assembly utilizes a torque limiting system to prevent transmission damage. Use care removing the clutch assembly, as the torque limiting components become free and could fall apart. Mark or note parts during disassembly.

  • Page 50: Driven Clutch Service

    CVT SYSTEM DRIVEN CLUTCH SERVICE DRIVEN CLUTCH DISASSEMBLY AND INSPECTION Driven Clutch Friction Pad Service Limit: 2 mm (0.078”) 1. Inspect the condition of the clutch drum. Measure the inside Driven Clutch Hub I. D.: diameter of the cover at 90 degree intervals using a caliper. Service Limit: 153 ﹢0.2 mm Inspect the condition and diameter of the drum lining.

  • Page 51: Driven Clutch Assembly

    CVT SYSTEM 2. Have an assistant available for final assembly. Install the compression spring. Place the friction pad assembly over the spring and compress the driven assembly together with both hands. With the assembly compressed and the threads exposed, have an assistant thread a new retaining nut onto the shaft.

  • Page 52: Cvt Belt Inspection

    CVT SYSTEM CVT BELT INSPECTION Inspect the surface of the drive belt for uneven wear or grease deposits. Using a caliper, measure the width of the belt. The service limit of the belt is 24 mm. If the width of the belt is less Do not allow grease to contact the V-belt and the than the service limit, or if the belt is worn, glazed or secondary sheave assembly.

  • Page 53: Drive Clutch Service

    CVT SYSTEM DRIVE CLUTCH SERVICE DRIVE CLUTCH DISASSEMBLY AND 5. Inspect belt-contacting surface of both sheave for wear or INSPECTION damage. 1. Remove outer drive clutch sheave and drive belt. Note parts assembly order. 2. Slide sheave and cam plate off crankshaft as an assembly. NOTE: When removing primary sliding sheave and cam plate assembly, hold cam plate and sliding sheave together.
  • Page 54 ENGINE CHAPTER 4 ENGINE ILLUSTRATION ............. . .4-3 ENGINE EXPLODED VIEWS .
  • Page 55 ENGINE PISTON RING INSTALLED GAP ..............4-28 ALTERATOR/ STSTER/ OIL PUMP EXPLODED VIEW .

  • Page 56: Engine Illustration

    ENGINE ENGINE ILLUSTRATION ENGINE EXPLODED VIEW...
  • Page 57 ENGINE...

  • Page 58: Cooling System Exploded View

    ENGINE COOLING SYSTEM EXPLODED VIEW...

  • Page 59: Oil Folw Diagram

    ENGINE OIL FLOW DIAGRAM...

  • Page 60: Cooling System

    ENGINE COOLING SYSTEM SPECIFICATIONS CONDITION SPECIFICATION Thermostat Open 65° C Thermostat Full Open 80° C System Capacity 1200CC Fan Switch “On” 75° C/ 85° C (Two type) Pressure Cap Relief 0.9 Bar COOLANT CIRCULATION Recommended Coolant A) From radiator to coolant pump. Use only high quality antifreeze/coolant mixed with distilled B).

  • Page 61: Radiator

    ENGINE RADIATOR 1. Suspend the thermostat in a container filled with water. 1. Apply compressed air to the rear of the radiator. 2. Slowly heat the water. 2. Straighten any flattened fins with a thin, flathead screwdriver. 3. Place a thermometer in the water. 4.

  • Page 62: Fan Switch

    ENGINE FAN SWITCH WATER PUMP Removal 1. The fan switch is located at right of radiator. 1. Remove water pump tube. 2. Take off water pump bolts. 3. Tap water pump lightly with a plastic hammer in reinforced areas only until loose. FAN STARTING TEMPERATURE PRINT LOCATION.

  • Page 63: Air Drain Procedure

    ENGINE AIR DRAIN PROCEDURE 3. Remove recovery bottle cap and fill bottle to the full line. 4. Slightly loosen the bleed hose (bypass hose) to let air drain. 5. Push back and tight the bleed hose. Always wear safety glasses and proper shop clothing when performing the procedures in this manual.

  • Page 64: Overheat Trouble Shooting

    ENGINE OVERHEAT TROUBLE SHOOTING • Low coolant level • Air in cooling system • Wrong type/mix of coolant • Faulty pressure cap or system leaks • Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage) •...

  • Page 65: Piston

    ENGINE PISTON The following components require engine removal ASSEMBLY IDENTIFICATION for service: The piston has an identification mark for piston settle 1. Cam Chain and Sprockets placement. 2. Cylinder Head Note the directional and identification marks when viewing the 3. Cylinder pistons from the top.

  • Page 66: Engine Installation

    ENGINE Front engine mount Transmission ◎ Inspect transmission operation and adjust linkage if necessary. Exhaust ◎ Replace exhaust gaskets. Seal connections if desired with high temp sealant. ◎ After running the engine, verify all bolted exhaust connections are tight and in good condition. Engine Mount Torque ◎...

  • Page 67: Top-End Disassembly

    ENGINE TOP END DISASSEMBLY Oil Flow Test 4. Align single (TDC) mark on flywheel with in the inspection hole, and the cam sprocket holes (horizontal) aligned with the gasket surface line. Oil temperature can cause serious injury and damage. Wear the proper safety gear when performing these procedures.

  • Page 68: Cam Chain Tensioner Inspection

    ENGINE CAMSHAFT/SPROCKET REMOVAL AND INSPECTION 7. Using a cross screwdriver, turn the tensioner clockwise to retract the plunger. The plunger should move smoothly in and NOTE: Orientation of the components is important for reassembly. Mark all components before out of the tensioner body. 8.

  • Page 69: Rocker Arm/Shaft Disassembly And Inspection

    ENGINE ROCKER ARM/SHAFT DISASSEMBLY AND 3. Check de-compressor movement smooth on camshaft. INSPECTION 4. Inspect cam lobes surface, Replace it if has pitting, scratches or blue discoloration. 1. Remove rocker arm shaft and rocker arm from cylinder 5. Measure both intake and exhaust cam lobes length. Replace head.

  • Page 70: Cylinder Head Removal

    ENGINE CYLINDER HEAD REMOVAL 4. Check the two contact areas on the rocker arms. Replace them if has signs of abnormal wear. NOTE: Cam chain and tensioner must be removed. 5. Inspect the surface of the rocker arm shafts. Replace it if has If no crankshaft service is being performed, secure blue discoloration, pitting or scratches.

  • Page 71: Cylinder Head Inspection

    ENGINE CAUTION CYLINDER HEAD INSPECTION 1. Thoroughly clean cylinder head surface to remove all traces Tap only in reinforced areas or on thick parts of of gasket material and carbon. cylinder head casting to avoid damaging casting. 10. Remove cylinder head gasket and 2-dowel pins. Use care not to damage sealing surface.

  • Page 72: Combustion Chamber Inspection

    ENGINE COMBUSTION CHAMBER INSPECTION Clean all accumulated carbon deposits from combustion chamber and valve seat area with a soft wire brush. Inspect the combustion chamber for cracks and/or damage from foreign debris. CYLINDER HEAD DISASSEMBLY Wear eye protection or a face shield during cylinder 4.

  • Page 73: Valve Inspection

    ENGINE 5. Measure diameter of valve stem with a micrometer in three places and in two different directions (six measurements total). VALVE SPRING VERTICALITY Replace if excessive wear is evident. Service Limit: 1.6mm NOTE: Replace seals whenever the cylinder head is disassembled.

  • Page 74: Valve Seat Reconditioning

    ENGINE NOTE: Be sure to measure each guide and valve Follow the manufacturers instructions provided with the valve combination individually. seat cutters in the Valve Seat Reconditioning Kit. Abrasive 8. Replace valve and/or guide if clearance is excessive. stone seat reconditioning equipment can also be used. Keep NOTE: If valve guides are replaced, valve seats must valves in order with their respective seat.
  • Page 75 ENGINE ◎ If the indicated seat contact is at the top edge of the valve If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be face and contacts the margin area(B) it is too high on the valve face.

  • Page 76: Cylinder Head Assembly

    ENGINE CYLINDER HEAD ASSEMBLY 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. Lapping is not required with an interference angle. Wear eye protection during assembly. NOTE: Assemble the valves one at a time to maintain proper order.

  • Page 77: Valve Sealing Test

    ENGINE BOTTOM END AISASSEMBLY 6. Place retainer on spring and install valve spring compressor. 2. Pour a small amount of cleaning solvent into each port and Compress spring only enough to allow split keeper installation check for leakage around each valve. to prevent loss of spring tension.

  • Page 78: Cam Chain Follower/ Tensioner Blades

    ENGINE CAM CHAIN FOLLOWER /TENSIONER BLADES 1. Remove bolt securing tensioner blade to crankcase A *Using a piston ring plier: Carefully expand ring and lift it off the piston. 2. Remove blades and inspect for cracks, wear, or damage. PISTON REMOVAL Do not expand the ring more than the amount 1.

  • Page 79: Cylinder Hone Selection/Honing Procedure

    ENGINE CYLINDER TAPER Limit: 0.05mm Max. CYLINDER OUT OF ROUND Limit: 0.05mm Max. CYLINDER HONE SELECTION/HONING PROCEDURE A hone, which will straighten as well as remove material from the cylinder, is very important. Using a CYLINDER WARP: common spring loaded glaze breaker for honing is 0.05 mm MAX not advised.

  • Page 80: Piston Inspection

    ENGINE ◎ After honing has been completed, inspect cylinder for 2. Subtract this measurement from the maximum cylinder thinning or peeling. measurement obtained earlier. IMPORTANT: Clean the Cylinder After Honing PISTON TO CYLINDER CLEARANCE It is very important that the cylinder be thoroughly cleaned Std: 0.02-0.05 mm after honing to remove all grit material.

  • Page 81: Piston Ring Installed Gap

    ENGINE PISTON RING INSTALLED GAP 5. Measure connecting rod small end ID. Replace crankshaft if out of round. 1. Place each piston ring inside cylinder using piston to push ring squarely into place as shown. 6. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge.

  • Page 82: Alterator/ Stster/ Oil Pump Exploded View

    ENGINE ALTERATOR/ STATER/ OIL PUMP EXPLODED VIEW NOTE: The CVT system, starter motor, starter drive, flywheel, stator, oil pump and transmission can be serviced with the engine in the frame. 4-29...

  • Page 83: Sterterdrive Gear Removal/ Inspection

    ENGINE STARTER DRIVE GEAR REMOVAL/ INSPECTION 1. Remove water pump tube. 2. Take off water pump bolts. 3. Tap water pump lightly with a plastic hammer in reinforced areas only until loose. 8. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken.

  • Page 84: Flwheel/ One-Way Clutch Removal/ Inspection

    ENGINE 3. Remove flywheel. 3. Inspect the bearing surfaces and drive teeth for signs of CAUTION wear or gouging. Replace the one-way clutch as an assembly if it is not working properly. Do not hammer or strike the tool while attached to 4.

  • Page 85: Oil Pump Drive Sprocket Removal/ Inspection

    ENGINE 7. Inspect idle gear and starter wheel teeth. Replace it if has any burrs, clips, roughness or worn. 8. Inspect the starter wheel contact surface. Replace it if has too much worn, pitting or damaged. 3. Remove pump chain drive sprocket circlip and chain from pump drive shaft and crankshaft.

  • Page 86: Oil Pump Removal

    ENGINE OIL PUMP REMOVAL CRANKCASE SEPARATION AND CAM CHAIN REMOVAL NOTE: Oil pump is not a serviceable assembly. NOTE: Stator housing, flywheel and gears have are previously removed for this procedure. Use care during the removal process to avoid damage to the cam chain.

  • Page 87: Crankshaft Removal

    ENGINE CRANKSHAFT / CAM & OIL CHAIN / 3. Watch the gap along the crankcase mating surface and SPROCKET INSPECTION separate the crankcase evenly. 4. Once the crankshaft bearing is free from the case, the 1. Inspect the crankshaft main bearings and cam and oil pump crankshaft and cam chain can be removed by hand for service.

  • Page 88: Crankcase/ Bearing Inspection

    ENGINE CRANKCASE / BEARING INSPECTION NOTE: Removal and installation of new seals is recommended anytime the crankcase is disassembled. 1. Inspect the bearings in the crankcase. NOTE: Due to extremely close tolerances and minimal side wear, the bearing must be inspected visually and by feel.

  • Page 89: Engine Reassembly

    ENGINE ENGINE REASSEMBLY CRANKSHAFT AND CAM/ OIL CHAIN NOTE: Use care not to damage the crankshaft end. INSTALLATION Lubricate all bearings with clean engine oil before assembly. 1. Support the crankcase on blocks. The balance shaft flat must square with crankshaft 2.

  • Page 90: Oil Pump And Chain Installation

    ENGINE 5. Install 4 flange bolts (circled) from the right side crankcase. 3. Beware the oil pump cover arrow must align with point. NOTE: Use care not to damage the crankshaft end. OIL PUMP COVER SCREW TORQUE: CRANKCASE BOLT TORQUE: 8 Nm 20 Nm (15ft.

  • Page 91: Piston Ring Installation

    ENGINE PISTON RING INSTALLATION 5. Install chain on oil pump and crankshaft sprocket then place oil pump sprocket into oil pump shaft. NOTE: Apply clean engine oil to all ring surfaces and ring lands. Always check piston ring installed gap before rings are installed on piston.

  • Page 92: Piston Installation

    ENGINE PISTON INSTALLATION 4. Install the other circlip with the gap facing up or down. (See CAUTION: Do not re-use circlips. Circlips become Caution with Step 3 above). Push the piston pin in both deformed during the removal process. Do not directions to make sure the clips are properly seated in the compress the new clip more than necessary to groove.

  • Page 93: Cylinder Head And Camshaft Installation

    ENGINE 3. Install the cam chain guide and dowel pins into the cylinder. CYLINDER HEAD AND CAMSHAFT Verify the bottom end is seated properly in the crankcase. INSTALLATION 4. Pull the cam chain through the cylinder chain room and secure with mechanic’s wire. NOTE: Clean the gasket surfaces on the cylinder head and cylinder.
  • Page 94 ENGINE 4. Install cylinder head bottom mount nut. 6. Insert cam into cylinder head. 7. Install exhaust side rocker shaft and rocker arm. 5. Install cylinder head nuts and torque to specification. CYLINDER HEAD NUT TORQUE: 22~25Nm (16~18ft-lb) 4-41...
  • Page 95 ENGINE 8. Install intake side rocker shaft and rocker arm. 9. Install 2 dowel pins onto cylinder head. 15. Install decompressor into camshaft. 10. Ensure the piston locate At TDC (top die center). 11. Pull cam chain fully up then install cam sprocket into camshaft.

  • Page 96: Cam Chain Tensioner Installation

    ENGINE 18. Install rocker and cam sprocket cover then torque bolts to specification. TENSIONER BOLT TORQUE: 19. Connect coolant hose with cylinder and coolant pump. 10 Nm (7.4 ft. lbs.) 3. Install the tensioner cap. Torque cap to specification. TENSIONER CAP TORQUE: 10 Nm (7.4 ft.
  • Page 97 ENGINE CAMSHAFT TIMING - METHOD 1 Method 1 - Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) 4-44...
  • Page 98 ENGINE CAMSHAFT TIMING - METHOD 2 Method 2 - Camshaft Timing Using Flywheel TDC Mark Sprocket marks aligned with gasket surface at TDC on compression stroke (cam lobes facing downward) Cam Timing (View through timing inspection hole) Position crankshaft at TDC 4-45...

  • Page 99: Intake Valve Clearance Adjustment

    ENGINE INTAKE VALVE CLEARANCE ADJUSTMENT FLYWHEEL INSTALLATION 1. Verify cam lobes are pointed down. 1. Install flywheel key, flywheel washer, and nut. 2. Insert a 0.1mm feeler gauge between end of intake valve Torque flywheel nut to specification. stem and adjuster screw. 3.

  • Page 100: Stator Housing Installtion

    ENGINE TROUBLESHOOTING STATOR HOUSING INSTALLATION SPARK PLUG FOULING ◎ Spark plug cap loose or faulty ◎ Choke cable adjustment or plunger/cable sticking NOTE: The stator, flywheel, starter drive, and stator ◎ Foreign material on choke plunger seat or plunger can be serviced with the engine in the frame. ◎...

  • Page 101: Engine Does Not Turn Over

    ENGINE ENGINE TURNS OVER BUT FAILS TO PISTON FAILURE - SCORING START ◎ Lack of lubrication ◎ No fuel ◎ Dirt entering engine through cracks in air filter or ducts ◎ Dirt in fuel line or filter ◎ Engine oil dirty or contaminated ◎...
  • Page 102 TRANSMISSION CHAPTER 5 TRANSMISSION ................5-1 TRANSMISSION ASSEMBLY .

  • Page 103: Transmission

    TRANSMISSION TRANSMISSION TRANSMISSION ASSEMBLY TRANSMISSION DISASSEMBLY AND SHIFT SYSTEM REMOVAL INSPECTION 1. Remove right footwall. NOTE: Engine removal is not required to service 2. Remove sprocket cover and drive sprocket. transmission components. Process shown below is with 3. Remove shift cables from the bracket. engine removed for clarity.

  • Page 104: Transmission Disassembly

    TRANSMISSION 4. Remove shift cover and cables bracket screws. 8. Remove the shift shaft by pulling straight outward. 9. Remove detent ball, spring and socket bolt. 10. Remove shift detent. 5. Remove shift cover and the bracket. 6. Remove gasket and discard. 7.

  • Page 105: Transmission Inspection

    TRANSMISSION TRANSMISSION INSPECTION 4. Remove output shaft 7. If input shaft or gear requires service, remove driven clutch as 5. Remove main shaft and shift fork as an assembly. outlined in CVT Chapter. 6. Remove the counter shaft. 8. Remove above two bolts. 9.

  • Page 106: Shift Fork Inspection

    TRANSMISSION 3. The sealed drive shaft bearing has a snap ring that must be 2. Substantial axial movement in the forward drive gear is due to removed then drive shaft bearing can be removed. liberal oil clearance for the bushing, and is a normal condition. 4.

  • Page 107: Count Shaft Inspection

    TRANSMISSION 5. Remove forward gear and dog components until next snap ring. Snap ring pressure can cause rings and pliers to eject suddenly. Use care during removal. 7. Inspect the shaft and gears visually without excessive wear or crack. Replace any damaged components. 8.

  • Page 108: Shift Drum Removal And Inspection

    TRANSMISSION TRANSMISSION REASSEMBLY 2. Remove the gear ring from output shaft. 1. Place the counter shaft into case. 3. Inspect the shaft and shaft excessive wear or crack. 4. Assemble the output gear and a new snap ring on the shaft. 2.
  • Page 109 TRANSMISSION 4. Install the drum shaft. Ensure the shift sensor toward inside. 10. Install the drum detent and shift teeth. Ensure all dots must on 5. Use caution when installing the gear position indicator spring center position. and pin located in the end of the drum shaft. 11.

  • Page 110: Trouble Shooting

    TRANSMISSION TRANSMISSION TROUBLE SHOOTING TRANSMISSION TROUBLE SHOOTING 13. Install detent ball, spring, o-ring and bolt. Gear Will Not Engage • Shift arm indexed incorrectly • Shift cables loosened • Shift cables broken • CVT Belt broken • Internal trans gear damage •...

  • Page 111: Fuel And Carburetor

    FUEL AND CARBURETOR CHAPTER 6 CARBURETION SYSTEM ..............6-2 CARBURETOR FUNCTION .

  • Page 112: Carburetor Function

    FUEL AND CARBURETOR CARBURETOR SYSTEM CARBURETOR FUNCTION Carburetor Component Function System Main Main Main Gasoline is extremely flammable and explosive Components Function Affect under certain conditions. Float System Inlet Pipe, Needle Maintains All systems; all Always stop the engine and refuel outdoors or in a Level Control) and Seat, Float specified fuel...

  • Page 113: Carburetion Specifications

    FUEL AND CARBURETOR CARBURETION SPECIFICATIONS OPERATION OVERVIEW The engine of a vehicle is operated under a wide range of COBRA 400 KEIHIN conditions, from idling with the throttle valve remaining almost closed, to full load or maximum output with the throttle CVK AK4 BWGH Type valve fully opened.

  • Page 114: Carburetor Operation

    FUEL AND CARBURETOR CARBURETOR OPERATION HIGH ALTITUDE OPERATION NOTE: It is strongly recommended that Carbon Clean be added regularly as directed to the fuel systems. The COBRA 400 has been tested to 4,000 M above sea level to Carbon Clean stabilizes the fuel, preventing clogging assure satisfactory performance.
  • Page 115 FUEL AND CARBURETOR The CV carburetor has two throttles, the cable operated butterfly (1) and the vacuum operated plugs (2). The butterfly controls the idle mixture strength from the passage (13) that can be adjusted by screw (12). Idle mixture composition is determined by the idle jet (11) and the air jet (16).

  • Page 116: Float System

    FUEL AND CARBURETOR FLOAT SYSTEM The float system is designed to maintain a constant height of gasoline during operation. When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level, the floats rise. When the buoyancy of the float and the fuel pressure of the fuel pump balance, the needle valve seals the orifice in the needle seat, preventing further fuel delivery, and the level of fuel in the bowl remains...

  • Page 117: Fuel Level Test

    FUEL AND CARBURETOR FUEL LEVEL TEST FLOAT HEIGHT ADJUSTMENT A fuel level test can be performed if the drain hose fitting is 1. Hold the carburetor in an upside down position. accessible. Be sure to re-attach the bowl drain hose after 2.

  • Page 118: Carburetor Jetting

    FUEL AND CARBURETOR CARBURETOR JETTING Pilot Jet IMPORTANT: The following guidelines must be From idling to low speeds, the fuel supply is metered by the followed when establishing a main jet setting: pilot jet. There are several air bleed openings in the sides of the 1.

  • Page 119: Air / Fuel Mixtrue Ratio

    FUEL AND CARBURETOR Fuel flows through the space between the needle jet and jet needle. This space does not vary until the throttle reaches the 1/4 open point. At that time the tapered portion of the needle begins to move out of the jet, affecting fuel flow as the opening enlarges.

  • Page 120: Throttle Opening Vs Fuel Flow

    FUEL AND CARBURETOR THROTTLE OPENING VS FUEL FLOW Throttle valves are numbered 1.0, 1.5, 2.0, etc., according to In a full throttle condition the cross-sectioned area between the the size of the cutaway. The higher the number, the leaner the jet needle and the needle jet is larger than the cross-sectioned gasoline/air mixture.

  • Page 121: Idle And Low Speed Circuit

    FUEL AND CARBURETOR IDLE AND LOW SPEED CIRCUIT MIDRANGE SLIDE POSITION AND FUEL DISCHARGE At idle with the throttle plate closed and the air stream cut off, idle speed is maintained by fuel metered through the slow jet. As the throttle plate is opening, airflow increases through the Air from the slow air jet mixes with the fuel and is delivered to carburetor and the pressure drop in the venture near the needle the port at the vacuum side of the throttle plate.

  • Page 122: High Speed Circuit Slide Position And Fuel Discharge

    FUEL AND CARBURETOR HIGH SPEED CIRCUIT SLIDE POSITION AND ACCELERATIVE PUMP SYSTEM FUEL DISCHARGE The accelerator pump used sudden throttle openings (rapid As the throttle plate is opening, the pressure difference accelerations) to quickly inject fuel into carburetor venturi to between the chambers above and below the diaphragm provide extra fuel for smooth acceleration.

  • Page 123: Fuel Delivery

    FUEL AND CARBURETOR FUEL DELIVERY VENT SYSTEM The throttle opening chart below demonstrates component The fuel tank vent supplies atmospheric pressure to the fuel in relationship to fuel flow versus throttle valve opening. the tank. The vent must be free of debris and restrictions to The pilot system’s main function is that of a low speed jet.

  • Page 124: Carburetor Cleaning

    FUEL AND CARBURETOR CARBURETOR CLEANING Carburetor cleaners can be extremely caustic. Extended periods of soaking can loosen the adhesive sealer on the passage drill-way plugs. Do not soak rubber or plastic components (such as the vacuum slide diaphragm, needle seat screen, or O-Rings in caustic cleaning solutions.

  • Page 125: Fuel Tank System

    FUEL AND CARBURETOR FUEL TANK SYSTEM 6-15...

  • Page 126: Fuel Tank Removal

    FUEL AND CARBURETOR FUEL TANK REMOVAL 1. Refer chapter 7 to remove front of cab and plastic plate. 2. Place a shop rag or towel underneath the tank and remove fuel line, fuel valve and filter from the tank. 3. Completely drain fuel from fuel tank. 4.

  • Page 127: Air Cleaner System

    FUEL AND CARBURETOR AIR CLEANER SYSTEM DUAL INTAKE REMOVAL 2. Disconnect manifold vacuum hose “B” and remove dual 1.Remove and disconnect intake pipe from cylinder and dual intake filter box fastener bolt “A”. . intake. 3. Remove complete dual intake assembly. 4.

  • Page 128: Air Cleaner Removal

    FUEL AND CARBURETOR AIR CLEANER REMOVAL 5. Apply commercially available foam filter oil to the foam 1.Remove strap from carburetor snorkel and oil separator filter. hoses from head cover. 6. Reinstall the foam filter, foam and air box cover. Secure the clips.

  • Page 129: Troubleshooting

    FUEL AND CARBURETOR TROUBLE SHOOTING FUEL STARVATION / LEAN MIXTURE POOR ILDE Symptoms: Hard start or no start, bog, backfire, popping Idle Too High through intake / exhaust, hesitation, detonation, low power, • Idle adjusted improperly / air mixture screw damaged spark plug erosion, engine runs hot, surging, high idle, idle •...

  • Page 130: Body / Suspension / Steering

    BODY / SUSPENSION / STEERING CHAPTER 7 GENERAL INFORMATION / BODY REMOVAL ..........7-2 TORQUE SPECIFICATIONS .

  • Page 131: General Information/ Body Removal

    BODY / SUSPENSION / STEERING GENERAL INFORMATION/ BODY REMOVAL TORQUE SPECIFICATION FRONT CAB REMOVAL 1. Pull out the seat latch on tail and remove the seat. 2. Remove the 4 screws and the fuel tank cover. Fastener Torque Suspension Fasteners A–Arm Attaching Bolt 42 Nm (31 ft.
  • Page 132 BODY / SUSPENSION / STEERING 5. Remove the 2 bolts attaching the body to the footwalls on 9. Disconnect the main switch (ignition) harness. each side. 6. Remove radiator windshield bolts on each side. 10. Disconnect power supplier wires. 7. Remove the 8 screws attaching front and rear cabs to the footwalls on each side.

  • Page 133: Rear Cab Removal

    BODY / SUSPENSION / STEERING 2. Remove the 4 bolts of rear cab. 12. Disconnect the headlight harness. 3. Disconnect the taillight harness. 13. Remove shift lever grip. 14. Completely remove the front cab from body. 4. Remove the 2 bolts attaching the rear cabs then take off REAR CAB REMOVAL taillight.

  • Page 134: Headlight Housing Removal

    BODY / SUSPENSION / STEERING FRONT BUMPER REMOVAL/ INSTALLATION 5. Cut off the straps of rear indicators then disconnects indicator plugs with main harness. 1. Remove the (4) mounting bolts retaining the front bumper and remove the bumper from the ATV. 6.Remove Rear cab from cab.
  • Page 135 BODY / SUSPENSION / STEERING SUSPENSION...

  • Page 136: Rear Shock Removal

    BODY / SUSPENSION / STEERING FRONT SHOCK REMOVAL 2. Remove the upper shock-mounting bolt from the frame and the 1. Elevate front end of the ATV off the ground to remove lower shock-mounting bolt from the swing arm. shock spring tension. Severe injury could occur if machine tips or falls.

  • Page 137: Front A-Arm

    BODY / SUSPENSION / STEERING FRONT A-ARM A-ARM REPLACEMENT 3. Remove brake caliper bolts and caliper. 1. Elevate front end of ATV off the ground far enough to remove the wheel. Severe injury could occur if machine tips or falls. 4.
  • Page 138 BODY / SUSPENSION / STEERING 5. Remove the upper and lower ball joint cotter pins (K) from 9. Examine the A-arm shafts (E). Replace if worn. the ball joint studs (I & L) at wheel end of Discard hardware. A-arm. Remove the ball joint nuts until the nuts are flush with 10.

  • Page 139: Swing Arm

    BODY / SUSPENSION / STEERING SWING ARM SWING ARM REMOVAL 1. Elevate rear end of ATV off the ground far enough to remove the rear wheels. Severe injury could occur if machine tips or falls. 2. Remove the dust cap and cotter pin from 2 rear wheels 3.
  • Page 140 BODY / SUSPENSION / STEERING 4. Remove rear brake caliper bolts then brake caliper. 7. Loosen 2 nuts from rear axle. Ensure do not lose those washers. 5. Remove chain protector bolts then chain protector. 8. Bend the lock bracket back the remove bolts and sprocket. 6.
  • Page 141 BODY / SUSPENSION / STEERING 13. Inspect adjusting tooth and cam surface for wear, replace 10. Remove external cir-clip and brake caliper mount. the hub if the component fail inspection. 14. Inspect the axle hub main bearings for worn or damaged. The bearing must be inspected visually and by turning feel.

  • Page 142: Steering

    BODY / SUSPENSION / STEERING STEERING 7-13...

  • Page 143: Steering Post Assembly

    BODY / SUSPENSION / STEERING STEERING POST ASSEMBLY 1. Torque the steering axle nut (A) to 60Nm. 4. Check the steering. The handlebars must move freely and 2. Align the cotter pin hole. easily from full left to full right without binding. Check all 3.

  • Page 144: Handlebar

    BODY / SUSPENSION / STEERING HANDLEBAR HANDLEBAR BLOCK INSTALLATION PROCEDURE 1. Position the two steering post blocks (D) properly onto the 4. Install the four handlebar bolts and pod bracket (C) loosely handlebars. into the blocks. 2. Install the front block bolts (A) first and evenly tightens the 5.

  • Page 145: Decal Replacement

    BODY / SUSPENSION / STEERING DECAL REPLACEMENT The following procedure involves the use of an open flame. Perform this procedure in a well-ventilated area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free of gasoline or flammable residue.
  • Page 146 BRAKES CHAPTER 8 SPECIFICATIONS ................8-2 GENERAL SPECIFICATIONS .

  • Page 147: Specifications

    BRAKES SPECIFICATIONS GENERAL SPECIFICATIONS Front Brake Disc Item Standard Service Limit Brake Pad Thickness 7.6 mm (0.298”) 4.3 mm (0.17”) Brake Disc Thickness 4mm (0.16”) 3.5mm (0.14”) Brake Disc Thickness Variance 0.05mm (0.002”) Between Measurements Brake Disc Run out 0.25mm (0.01”) Rear Brake Disc Item Standard...

  • Page 148: Brake System Service Notes

    BRAKES BRAKE SYSTEM SERVICE NOTES ◎ Inspect caliper piston seals for foreign material that could Disc brake systems are lightweight, low maintenance, and prevent caliper pistons from returning freely. ◎ Perform a brake burnishing procedure after installing new perform well in the conditions ATVs routinely encounter. There are a few things to remember when replacing disc brake pads to maximize service life.

  • Page 149: Brake System Operation

    BRAKES BRAKE SYSTEM OPERATION The front brake system is hydraulically actuated. The foot brake system is hydraulically actuated. When the right front brake lever (master When the right foot brake lever (master cylinder) cylinder) is applied, the two front brake calipers is applied, the two front brake calipers and a rear are active and under pressure.

  • Page 150: Front Brakes

    BRAKES FRONT BRAKES The front brake system consists of the following components or assemblies: brake lever; master cylinder; hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line. When the hand activated brake lever (A) is applied it contacts a piston (B) within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brake system.

  • Page 151: Front Brake Exploded View

    BRAKES FRONT BRAKE EXPLODED VIEW MASTER CYLINDER...

  • Page 152: Front Brake Replacement/ Bleeding Procedure

    BRAKES FRONT BRAKE REPLACEMENT / BLEEDING 4. Remove the cotter pin, nut and washer. PROCEDURE NOTE: When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder. Always wear safety glasses during these procedures.

  • Page 153: Shunt Removal

    BRAKES 9. Remove the disc blots then disc. 4. The shunt system is hydraulically actuated. 10. Remove the speedometer sensor. ◎ When the right foot brake lever (master cylinder) is applied, the two front brake calipers and a rear caliper are active and under pressure.
  • Page 154 BRAKES 1. Clean reservoirs cover thoroughly. 8. While maintaining lever pressure, open bleeder screw. Close 2. Remove screws, cover, and diaphragm from reservoir. bleeder screw and release brake lever. 3. Inspect vent slots in cover and remove any debris or blockage.

  • Page 155: Master Cylinder Removal

    BRAKES MASTER CYLINDER REMOVAL 12. Add brake fluid to the proper level. Master Cylinder Fluid Level: 1. Clean master cylinder and reservoir assembly. Make sure MAX level inside reservoir sight glass must look you have a clean work area to disassemble brake components. 2.

  • Page 156: Master Cylinder Installation

    BRAKES MASTER CYLINDER INSTALLATION 3. Fill reservoir with DOT4 Brake Fluid. 1. Install master cylinder on handlebars. Torque mounting bolts to 3 Nm (25 in. lbs.). Torque the top bolt first. NOTE: To speed up the brake bleeding procedure the master cylinder can be purged of air before brake line is attached.

  • Page 157: Front Pad Assembly

    BRAKES 3. Remove the brake pads out of the caliper assembly. 4. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. 2. Install caliper on the steering knuckle, and torque mounting bolts. (If previously removed.) Front Brake Pad Thickness New 7.6mm( 0.298〃...

  • Page 158: Front Disc Inspection

    BRAKES FRONT DISC INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or Brake Disc Run out damage. Service Limit. 0.25 mm (0.01”) 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1〃 micrometer. FRONT BRAKE DISC REMOVAL / Replace disc if worn beyond service limit.

  • Page 159: Rear/Foot/ Parking Brake

    BRAKES REAR / FOOT / PARKING BRAKES REAR BRAKE REMOVAL AND INSPECTION NOTE: Follow the “Swing Arm Removal” procedure outlined in Chapter 6 to access the rear brake components. 1. Follow the “Swing Arm Removal” procedure to the point where the rear brake disc housing can be accessed on “Chapter 7”.

  • Page 160: Rear Caliper Fluid Replacement And Air Bleeding

    BRAKES Rear Brake Pad Thickness: Service Limit: (2 mm) 4. Pump the brake lever until no more fluid flow out of the bleed screw. REAR CALIPER FLUID REPLACEMENT AND REAR CALIPER FLUID FILLING / BLEEDING AIR BLEEDING Follow the “Front Brake-Bleeding Procedure” on BRAKE FLUID DRAINING page 8.8 to 8.10.

  • Page 161: Foot Brake Removal

    BRAKES FOOT BRAKE REMOVAL 2. Remove the cotter pin from foot brake lever and foot brake Note: The foot brake system is hydraulically actuated. Where is master cylinder. under right hand rear cab. When the right foot brake lever (master cylinder) is applied, the brake oil output to shunt.

  • Page 162: Foot Brake Fluid Filling/ Bleeding

    BRAKES 5. Remove 2 master cylinder bolts, banjo bolt and oil tank bolt. 2. Add brake fluid to the upper level mark on reservoir. Remove master cylinder and oil tank as an assembly. NOTE: Do not move foot brake lever when reservoir fluid level is low.

  • Page 163: Parking Brake Removal

    BRAKES 7. Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir. When removing and installing the parking braking NOTE: If brake pressure is hard to built, repeat breeding procedure with shunt breeding screw system.

  • Page 164: Inspection And Adjustment

    BRAKES 3. Install the both spring and swing to caliper. 3. Loosen rear caliper fastener nut, adjusting bolt then remove 4. Ensure the upper return spring 50~60mm with cable adapter. swing arm. 4. Remove the return spring and cable from swing arm. 5.

  • Page 165: Brake Troubleshooting

    BRAKES BRAKE TROUBLESHOOTING BRAKE SQUEAL 8. Position the left hand master cylinder aligned with dot mark ◎ Dirty/contaminated friction pads on handle bar. ◎ Improper alignment 9. Install parking lever on handlebars. Torque mounting bolts ◎ Worn disc to 5Nm. Torque the top bolt first. ◎...
  • Page 166 ELECTRICAL CHAPTER 9 GENERAL INFORMATION ............. 9-3 ELECTRICAL SYSTEM SERVICE NOTES .
  • Page 167 ELECTRICAL CHARGING SYSTEM ..............9-16 MAIN FUSE ASSEMBLY .

  • Page 168: General Information

    ELECTRICAL GENERAL INFORMATION ELECTRICAL SYSTEM SERVICE NOTES TRANSMISSION SWITCH SERVICE Reference the following notes when diagnosing electrical Switch Removal/Test problems. 1. Remove the CVT cover. The indicator switch will be visible • Refer to wiring diagram for stator and electrical between the drive and driven clutch.

  • Page 169: Switch Service

    ELECTRICAL SWITCH SERVICE Switch Installation 1. Once repairs are completed, reinstall the shift pin and spring into the shift drum (arrow). NOTE: assembly lube can be used to “stick” parts together for ease of assembly. 2. Install the indicator switch and o--ring (arrow), routing the wires in the same manner as during disassembly.

  • Page 170: Left Hand Switch Assembly

    ELECTRICAL LEFT HAND SWITCH ASSEMBLY The following illustration shows the internal operation of the LH switch assembly. If any part of the switch is faulty, the entire LH switch assembly must be replaced. KEY SWITCH continuity between any of the wires. The key switch can be tested with an ohmmeter.

  • Page 171: Lights

    ELECTRICAL LIGHTS 2. Remove the socket rubber seal. HEADLIGHT The headlights are powered by an AC current from the Generator / Stator. When headlight switch on but not working, perform the following: 1. Disconnect the harness from the faulty light. 2.

  • Page 172: Taillight

    ELECTRICAL TAILLIGHT 1. Place the vehicle on a level surface with the headlight TAILLIGHT LAMP REPLACEMENT approximately 7.6 m (25’) from a wall. If the tail light lamp does not work, the lamp may need to be replaced. 1. Remove the two screws securing the lens cover. Remove the lens cover.

  • Page 173: Front Signal Replacement

    ELECTRICAL SIGNAL 5. Remove and replace lamp. FRONT SIGNAL REPLACEMENT If the headlights do not operate, lamp replacement may be required. Install only the recommended replacement lamps 1. Take off the front signal wire plug from harness. 2. Remove front signal and bracket from cab as picture. 6.

  • Page 174: Speedometer And Indicator

    ELECTRICAL SPEEDOMETER AND INDICATOR SPEEDOMETER SIGNAL DESCRIPTION SPEEDOMETER REPLACEMENT 1. Remove the handlebar pod to access the speedometer. 2. Disconnect the speedometer wire connections from the harness.

  • Page 175: Speed/Hour

    ELECTRICAL SPEEDOMETER DIGITAL DISPLAY FUNCTIONAL SPEED/HOUR: 2. In “TRIP A” to press “zero” button after two seconds to clear There are metric and English. Turn the key switch “off”. Press mode and zero buttons both then turn the mileage. the key switch “on” as show. The KM/H and MILE/H symbol will twinkle.

  • Page 176: Radiator Temperature Scale

    ELECTRICAL RADIATOR TEMPERATURE SCALE: There are The Bimetal valve locates at right hand of cylinder. 10 scales; the fan will start at 7 scale (80 ). The temperature If the valve is faulty, replace the entire assembly. table list as following. Scale Range Scale...

  • Page 177: Ignition System

    ELECTRICAL IGNITION SYSTEM IGNITION COIL TEST 3. Press right button to setting tire diameter. If you pass the desire number continue pressing right button it will repeat again. The setting code from d 15-0 to d 28-7. The setting code show as following table Tire Spec.

  • Page 178: Cdi Output Test Using Peak Reading Adaptor Or A Volt Meter

    ELECTRICAL TEST 3: Measure AC Voltage Output of Each Stator coupler at Charging RPM with a voltmeter set to Volts AC. 1. Place the red lead on the tester in the 10A jack. 2. Turn the selector dial to the Volts AC position. 3.

  • Page 179: Cdi Cranking Output Test

    ELECTRICAL CDI CRANKING OUTPUT TEST CDI WIRE The following peak voltage tests will measure the amount of PLUG COLOR DECCRIPTION output directly from each component. A peak reading DC VOLTAGE INPUT. 2-WIRE voltmeter can be used to perform the tests. A variety of peak BRAKE LIGHT SIGNAL reading adaptors are commercially available for use with the 4-WIRE B/Y...

  • Page 180: Ignition System Test

    ELECTRICAL IGNITION SYSTEM TEST Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance values are also given on the specification pages.

  • Page 181: No Spark, Weak Or Intermittent Spark

    ELECTRICAL CHARGING SYSTEM NO SPARK, WEAK OR INTERMITTENT NOTE: Use only the recommended fuse capacity, as SPARK use of a higher amperage fuse to correct blown—fuse ◎ No12 volt power or ground to CDI situations could lead to electrical component ◎...

  • Page 182: Charging System Testing

    ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system checks: Using a multi-tester set on D.C. volts, measure the battery open circuit voltage (see Remove the battery and properly service. procedure later in chapter). It should be 12.4 Reinstall the fully charged battery or a fully volts or more.
  • Page 183 ELECTRICAL ◎ Connect a tachometer according to manufacturer’s CURRENT DRAW - KEY OFF instructions. ◎ With engine off and the key and kill switch in the ON position, the ammeter should read negative amps (battery discharge). Reverse meter leads if a positive reading is indicated.

  • Page 184: Battery

    ELECTRICAL BATTERY BATTERY IDENTIFICATION SEALED LOW MAINTENANCE BATTERY NOTICE: It is important to identify what type of NOTE: All Low Maintenance batteries are fully charged battery you have installed in your ATV. Different and tested at the factory before installation. Expected types of batteries require different service shelf life varies upon storage conditions.

  • Page 185: Sealed Low Maintenance Battery Inspection/ Removal

    ELECTRICAL NEVER attempt to add electrolyte or water to a Low SEALED LOW MAINTENANCE BATTERY Maintenance battery. Doing so will damage the case INSPECTION/ REMOVAL and shorten the life of the battery. Refer to the The battery is located under the seat. Battery Activation and Maintenance Video (PN 9917987) For proper instruction on servicing Low Maintenance batteries.

  • Page 186: Sealed Low Maintenance Battery Testing

    ELECTRICAL SEALED LOW MAINTENANCE BATTERY NOTE: This test can only be performed on machines TESTING with electric starters. It cannot be performed on Whenever a service complaint is related to either the starting engine or starting system is not working properly. or charging systems, the battery should be checked first.

  • Page 187: Sealed Low Maintenance Battery Charging Procedure

    ELECTRICAL NOTE: Stored batteries lose their charge at the rate of up to 1% per day. Recharge to full capacity every 30 to 60 days during a non-use period. If the battery is Battery electrolyte is poisonous. It contains sulfuric stored during the winter months, electrolyte will acid.

  • Page 188: Battery Terminals/Terminal Bolts

    ELECTRICAL 6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher. BATTERY TERMINALS/TERMINAL BOLTS Refill using only distilled water. Tap water contains Use corrosion resistant grease on battery bolts. See Battery minerals that are harmful to a battery.

  • Page 189: Conventional Battery Ocv-Open Circuit Voltage Test

    ELECTRICAL OPEN CIRCUIT VOLTAGE CONVENTIONAL BATTERY OCV - OPEN State of charge Conventional Low Maintenance CIRCUIT VOLTAGE TEST Lead-acid Type Battery voltage should be checked with a digital Multi-tester. 100% 12.60V 12.70V Readings of 12.6 volts or less require further battery testing and 75% Charged 12.40V 12.50V...

  • Page 190: Conventional Battery Off-Season Storage

    ELECTRICAL CONVENTIONAL BATTERY OFF SEASON STORAGE To prevent battery damage during extended periods of non-use, the following basic battery maintenance items must To avoid the possibility of explosion, connect be performed: positive (red) cable first and negative (black) cable ◎ Remove the battery from the machine and wash the case last.

  • Page 191: Starter System

    ELECTRICAL STARTER SYSTEM Use the illustration below when troubleshooting a “No Start” STARTER RELAY condition. Take off the right side panel. The starter relay locates under right hand rear cab. The starter relay consists of a simple 2-way circuit. Power is STARTER MOTOR SERVICE present at the (R/B) wire from the battery.

  • Page 192: Starter Brush Inspection / Replacement

    ELECTRICAL STARTER BRUSH INSPECTION / 1. Disconnect the negative battery cable and starter motor REPLACEMENT harness. Remove the (2) bolts from the starter and pull it from the engine. 1. Release the brush coil spring away. 2. Push the armature out of case. 2.

  • Page 193: Armature Test

    ELECTRICAL 5. Inspect the surface of the commutator for wear or discoloration. See Armature Test. 4. Check commutator bars for discoloration. Bars discolored in pairs indicate shorted coils, requiring replacement of the 4. Be sure that the terminal bolt insulation washer is properly seated in the housing and the tab on the brush plate engages the starter motor.

  • Page 194: Starter System Testing

    ELECTRICAL STARTER SYSTEM TESTING Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multi-tester must be used for this test. With the tester on the VDC position, place the tester’s black lead on the battery negative and the red lead on Remove battery and properly service.

  • Page 195: Starter System Troubleshooting

    ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn ◎ Battery discharged - low specific gravity ◎ Loose or faulty battery cables or corroded connections (see Voltage Drop Tests) ◎ Related wiring loose, disconnected, or corroded ◎ Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests)1 ◎...
  • Page 196 ELECTRICAL WIRE DIAGRAM 9-31...

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