Aeon COBRA 400 2012 Manuals

Aeon COBRA 400 2012 Manuals

Manuals and User Guides for Aeon COBRA 400 2012. We have 1 Aeon COBRA 400 2012 manual available for free PDF download: Service Manual

Aeon COBRA 400 2012 Service Manual

Aeon COBRA 400 2012 Service Manual (196 pages)

Brand: Aeon | Category: Offroad Vehicle | Size: 8.45 MB

Table of Contents

Table of Contents

3
- Conversion Table
  7
- Glossary of Terms
  8
- General Information
  10
Maintenance Chapter 2

11
- Maintenance
  11
  - Periodic Maintenance Chart
    13
  - Table of Contents
    11
  - Chapter 2
    13
  - Maintenance Chart Key
    13
- Periodic Maintenance Overview
  13
- Severe Use Definition
  13
- Pre-Ride - 25 Hour Maintenance Interval
  14
- Transmission
  14
- 50 - 300 Hour Maintenance Interval
  15
- General Vehicle Inspection and Maintenance
  16
- Fuel System and Air Intake
  19
  - Fuel System Safety
    19
  - Fuel Line
    19
  - Fuel Filter
    20
  - Carburetor Draining
    20
  - Air Cleaner Service
    20
  - Air Box Sediment Tube
    21
  - Engine and Transmission Oil Location
    22
  - Oil Level
    22
  - Engine Oil and Filter Service
    23
  - Valve Clearance Adjustment
    23
  - Engine Mounts Location
    24
- Transmission
  25
  - Transmission Lubrication
    25
- Cooling System
  27
  - Cooling System Overview
    27
  - Coolant Level Inspection
    27
- Cvt System
  27
  - Coolant Strength / Type
    28
    
    Coolant Drain/ Radiator Removal
    28
    
    Cooling System Hoses
    28
  - Electrical and Ignition System
    29
    
    Battery Maintenance
    29
    
    Battery Removal
    29
    
    Radiator Removal
    29
    
    Battery Cleaning
    30
    
    Battery Installation
    30
    
    Battery off Seasonstorage
    30
    
    Battery Charging (Sealed Battery)
    31
    
    Battery Inspection
    31
    
    Fuses / Fuse Holder Location
    32
    
    Spark Plug Inspection
    32
    
    Engine/ Frame Ground
    33
  - Steering and Suspension
    33
    
    Steering
    33
    
    Tie Rod
    33
    
    Toe Alignment Inspection
    34
    
    Front Suspension Spring Preload Adjustment
    36
    
    Toe Adjustment
    36
    
    Front Suspension Inspection
    37
    
    Rear Suspension Spring Preload Adjustment
    37
  - Brake System
    38
    
    Brake Fluid Inspection
    38
    
    Parking Brake Adjustment
    38
    
    Brake Pad/ Disc Inspection
    40
  - Wheels and Tires
    40
    
    Wheel Inspection
    40
    
    Wheel Removal - Front / Rear
    40
    
    Wheels
    40
    
    Tire Notice
    41
    
    Tire Pressure
    41
    
    Wheel Installation - Front / Rear
    41
Cvt System Chapter 3

42
- Chapter 3
  43
- Cvt Maintenance / Inspection
  43
- Cvt System Overview
  43
- Drive Clutch Operation
  43
- Driven Clutch Operation
  43
- Clutch Cover/ Re-Coil Starter Exploded View
  44
- Cvt Exploded View
  45
- Cvt Overheating/Diagnosis
  46
  - Drive Clutch Removal
    47
  - Driven Clutch Removal
    49
- Driven Clutch Service
  50
- Drive Clutch Service
  53
  - Drive Clutch Disassembly and Inspection
    53
  - Drive Clutch Assembly
    53
Table of Contents

54
- Chapter 4
  56
- Engine Exploded Views
  56
- Engine Illustration
  56
- Cooling System Exploded View
  58
- Oil Folw Diagram
  59
- Cooling System
  60
  - Specifications
    60
  - Pressure Test
    60
  - Coolant Circulation
    60
  - Radiator
    61
  - Thermostat
    61
  - Fan Switch
    62
  - Water Pump
    62
  - Air Drain Procedure
    63
  - Overheat Trouble Shooting
    64
- Piston
  65
  - Assembly Identification
    65
  - Accessible Components
    65
  - Engine Removal
    65
  - Engine Installation
    66
  - Engine Lubrication
    66
- Top-End Disassembly
  67
  - Cam Chain Tensioner Remove
    67
  - Cam Chain Tensioner Inspection
    68
  - Camshaft/Sprocket Removal and Inspection
    68
  - Rocker Arm/Shaft Disassembly and Inspection
    69
  - Cylinder Head Removal
    70
  - Cylinder Head Inspection
    71
  - Cylinder Head Warp Inspection
    71
  - Combustion Chamber Inspection
    72
  - Cylinder Head Disassembly
    72
  - Valve Inspection
    73
  - Valve Seat Reconditioning
    74
  - Cylinder Head Assembly
    76
  - Valve Sealing Test
    77
- Bottom-End Disassembly
  77
- Engine Reassembly
  89
- Troubleshooting
  100
  - Spark Plug Fouling
    100
  - Engine Does Not Turn over
    101
  - Engine Has Low Power
    101
  - Piston Failure- Scoring
    101
  - Excessive Smoke and Carbon Buildup
    101
  - Low Compression
    101
  - Backfiring
    101
Transmission Chapter 5

102
- Chapter 5
  103
- Shift System Removal
  103
- Transmission
  103
- Transmission Assembly
  103
- Transmission Disassembly and Inspection
  103
- Transmission Disassembly
  104
- Transmission Inspection
  105
  - Drive Shaft Removal and Inspection
    105
  - Shift Fork Inspection
    106
  - Mian Shaft Removal and Inspection
    106
  - Count Shaft Inspection
    107
  - Output Shaft Removal and Inspection
    107
  - Shift Drum Removal and Inspection
    108
- Transmission Reassembly
  108
- Trouble Shooting
  110
Fuel and Carburetor Chapter 6

111
- Fuel and Carburetor
  111
- Carburetor Function
  112
  - Carburetion Specifications
    113
  - Operation Overview
    113
- Chapter 6
  112
- Carburetor Operation
  114
  - High Altitude Operation
    114
  - Float System
    116
  - Float Inspection
    116
  - Fuel Level Test
    117
  - Float Height Adjustment
    117
  - Carburetor Jetting
    118
  - Air / Fuel Mixtrue Ratio
    119
  - Jet Needle
    119
  - Needle Jet
    119
  - Throttle Opening Vs Fuel Flow
    120
  - Throttle Slide
    120
  - Main Jet
    120
  - Idle and Low Speed Circuit
    121
  - Midrange Slide Position and Fuel Discharge
    121
  - High Speed Circuit Slide Position and Fuel Discharge
    122
  - Accelerative Pump System
    122
  - Fuel Delivery
    123
  - Vent System
    123
  - Carburetor Cleaning
    124
- Fuel Tank System
  125
  - Fuel Tank Removal
    126
  - Fuel Flow Direction
    126
- Air Cleaner System
  127
  - Dual Intake Removal
    127
  - Air Cleaner Removal
    128
- Troubleshooting
  129
  - Fuel Starvation / Lean Mixture
    129
  - Rich Mixture
    129
Body / Suspension / Steering Chapter 7

130
- Body / Suspension / Steering
  130
  - General Information/ Body Removal
    131
- Chapter 7
  131
- Front Cab Removal
  131
- Rear Cab Removal
  133
- Front Bumper Removal/ Installation
  134
- Front Shock Removal
  134
- Headlight Housing Removal
  134
- Rear Shock Removal
  136
- Front A-Arm
  137
  - A-Arm Replacement
    137
- Swing Arm
  139
  - Swing Arm Removal
    139
- Steering
  142
  - Steering Post Assembly
    143
- Handlebar
  144
  - Handlebar Block Installation Procedure
    144
  - Exploded View
    144
- Decal Replacement
  145
Brakes Chapter 8

146
- Chapter 8
  147
- General Specifications
  147
- Specifications
  147
- Torque Specifications
  147
- Brake System Service Notes
  148
- Disc Brake Noise Troubleshooting
  148
- Brake System Operation
  149
- Front Brakes
  150
  - Front Brake Exploded View
    151
  - Front Brake Replacement/ Bleeding Procedure
    152
  - Shunt Removal
    153
  - Front Brake- Bleeding/ Fluid Change
    153
  - Master Cylinder Removal
    155
  - Master Cylinder Installation
    156
  - Front Pads Removal
    156
  - Front Pad Assembly
    157
  - Front Disc Inspection
    158
  - Front Brake Disc Removal/ Replacement
    158
- Rear/Foot/ Parking Brake
  159
  - Rear Brake Removal and Inspection
    159
  - Rear Caliper Fluid Replacement and Air Bleeding
    160
  - Brake Fluid Draining
    160
  - Rear Caliper Fluid Filling/ Bleeding
    160
  - Foot Brake Removal
    161
  - Foot Brake Fluid Filling/ Bleeding
    162
  - Parking Brake Removal
    163
  - Inspection and Adjustment
    164
- Brake Troubleshooting
  165
  - Brake Squeal
    165
  - Lever Vibration
    165
  - Brakes Lock
    165
Electrical Chapter 9

166
- Chapter 9
  168
- Electrical System Service Notes
  168
- General Information
  168
- Wire Color Letter List
  168
- Switch Service
  169
  - Brake Lever Switch
    169
  - Left Hand Switch Assembly
    170
  - Key Switch
    170
- Lights
  171
  - Headlight
    171
  - Headlight Lamp Replacement
    171
  - Headlight Adjustment
    171
  - Taillight
    172
  - Taillight Lamp Replacement
    172
  - Front Signal Replacement
    173
  - Rear Signal Replacement
    173
- Speedometer and Indicator
  174
  - Speedometeer Replacement
    174
  - Speed/Hour
    175
  - Odometer
    175
  - Radiator Temperature Scale
    176
  - Tire/Wheel Diameter Setting
    176
- Ignition System
  177
  - Rpm Limiter Specification
    177
  - Ignition Coil Test
    177
  - Alternator Output Test (Ac Amp)
    177
  - CDI Output Test Using Peak Reading Adaptor or a Volt Meter
    178
  - CDI Output Test Using Peak Reading Adaptor
    178
  - CDI Cranking Output Test
    179
  - CDI Wire
    179
  - Ignition System Test
    180
  - No Spark, Weak or Intermittent Spark
    181
- Charging System
  181
  - Main Fuse Assembly
    181
  - Voltage Regulator / Rectifier
    181
  - Charging System Testing
    182
- Battery
  184
- Starter System
  191
  - Starter Relay
    191
  - Voltage Drop Test
    191
  - Starter Motor Service
    191
  - Starter Motor Disassembly
    191
  - Starter Brush Inspection / Replacement
    192
  - Armature Test
    193
  - Starter Reassembly
    193
  - Starter System Testing
    194
  - Starter System Troubleshooting
    195

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