Aeon AT56-69E Service Manual Download

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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.

Summary of Contents for AT56-69E

Page 1: ...de 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 spec...

Page 2: ...he 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 CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during di...

Page 3: ...GENERAL INFORMATION 1 MAINTENANCE 2 CVT SYSTEM 3 ENGINE 4 TRANSMISSION 5 FUEL AND CARBURETOR 6 BODY SUSPENSION STEERING 7 BRAKE 8 ELECTRICAL 9 ...

Page 4: ...ER 1 MODEL INFORMATION 1 2 VIN IDENTIFICATION 1 2 ENGINE SERIAL NUMBER LOCATION 1 2 VEHICLE IDENTIFICATION NUMBER LOCATION 1 2 GENERAL SPECIFICATIONS 1 3 SPECIFICATIONS MODEL COBRA 400 1 4 CONVERSION TABLE 1 5 GLOSSARY OF TERMS 1 6 ...

Page 5: ...ght side of frame The vehicle identification number VIN and engine serial number are important for identification purposes See the illustrations VEHICLE IDENTIFICATION NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION Engine serial number local under rear seat stamped on the rear of crankcase beneath exhaust pipe ...

Page 6: ...GENERAL INFORMATION 1 3 COBRA 400 Model AT56 69E Model Number RF3RA56XXCTXXXXXX Engine Model V69C ...

Page 7: ...liper Oil capacity 1800 CC Rear brake Single Disc with single bore caliper Starting system Electric start DC CDI Combined brake Foot pedal Max Power 22kw 8500rpm Parking device Cable controlled parking through rear caliper Max Torque 30Nm 6500rpm Front tire 21 7 10 CARBURATOR Rear tire 20 10 9 Type Keihin CVK36 Slide valve 36 Main jet 108 DIMENSIONS Pilot jet 90 Overall length 1820 mm Jet needle N...

Page 8: ...61 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 Liters l Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 Liters l Liters l x 0 264 US gallons...

Page 9: ...which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electrical Open Open circuit An electrical circuit which isn t complete Electrical Short Short circuit An electrical circuit which is completed before the current reaches the intended load i e a bare wire touching the chassis End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at whi...

Page 10: ... energy conversion to heat RPM Revolutions per minute Seized Piston Galling of the sides of a piston Usually there is a transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Stator Plate The plate mounted under the flywheel supporting the battery charging coils TDC Top dead ce...

Page 11: ... 2 9 THROTTLE INSPECTION 2 9 IDLE SPEED ADJUSTMENT 2 10 FUEL SYSTEM AND AIR INTAKE 2 10 FUEL SYSTEM SAFETY 2 10 FUEL LINE 2 10 CARBURETOR DRAINING 2 11 AIR CLEANER SERVICE 2 11 AIR BOX SEDIMENT TUBE 2 12 ENGINE 2 13 ENGINE AND TRANSMISSION OIL LOCATION 2 13 ENGINE OIL LEVEL 2 13 ENGINE OIL AND FILTER SERVICE 2 14 VALVE CLEARANCE ADJUSTMENT 2 15 ENGINE MOUNTS LOCATION 2 15 TRANSMISSION 2 16 TRANSMI...

Page 12: ...SUSPENSION 2 24 STEERING 2 24 CONSTANT VELOCITY JOINT DUST BOOT 2 24 TIE ROD 2 24 TOE ALIGNMENT INSPECTION 2 25 TOE ADJUSTMENT 2 26 FRONT SUSPENSION SPRING PRELOAD ADJUSTMENT 2 26 REAR SUSPENSION SPRING PRELOAD ADJUSTMENT 2 27 BRAKE SYSTEM 2 28 BRAKE FLUID INSPECTION 2 28 PARKING BRAKE ADJUSTMENT 2 28 BRAKE PAD DISC INSPECTION 2 30 WHEELS AND TIRES 2 30 WHEELS 2 30 WHEEL REMOVAL FRONT REAR 2 30 WH...

Page 13: ...ts collecting in oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues rise discontinue use and determine the cause or see your dealer Break in Period The break in period consists of the first 40 hours of operation or the time it takes to use 300 liters of fuel Careful treatment of a new engine and drive components will result in mor...

Page 14: ...ver Air filter Daily Drain deposits when visible Head lamp tail lamp Daily Check operation apply dielectric grease if replacing CVT housing Weekly Drain water as needed check often if operating in wet conditions Battery 25H Monthly 500 Check terminals clean test Transmission oil change 25H 40H Monthly 12M 500 1000 Inspect level change yearly perform break in oil change after the first 25 hours of ...

Page 15: ...asteners Rear suspension 50H 6M 800 Inspect lubricate tighten fasteners Fuel system 100H 12M 1500 Check for leaks at tank cap lines fuel valve filter carburetor replace lines every two years Fuel filter 100H 12M 1500 Replace yearly Engine mounts 100H 12M 1500 Inspect Exhaust muffler pipe 100H 12M 1500 Inspect Ignition timing 100H 12M 1500 Inspect Wring 100H 12M 1500 Inspect for wear routing securi...

Page 16: ...not overfill All brakes check operation Throttle check for free operation Headlight Taillight Brake light check operation of all indicator lights and switches Hazard switch check for proper function Wheels check for loose wheel nuts Air cleaner element check for dirt or water clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect ve...

Page 17: ... More often in severe use Frame Nuts Bolts and Fastener Inspection Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline There are exceptions in the steering ...

Page 18: ...rt and adjust the play if necessary Throttle Free Play Adjustment Inspection 1 Place the transmission in the N position 2 Start the engine and warm it up thoroughly 3 Measure the distance the throttle lever moves before the engine begins to pick up speed Free play should be 1 5 3 mm 1 16 1 8 Adjustment 1 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cab...

Page 19: ...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 IMPORTANT Ensure lines are not kinked or pinched FUEL SYSTEM SAFETY Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames o...

Page 20: ... before extended periods of storage 1 Place a container beneath the bowl drain hose 2 Loosen drain screw and allow fuel in the float bowl and fuel line to drain completely 3 Inspect the drained fuel for water or sediment 4 Tighten drain screw 5 Check for fuel leaks 6 Start engine and re check for leaks AIR CLEANER SERVICE It is recommended that the air filter be inspected as part of pre ride inspe...

Page 21: ...s 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 NOTE The sediment tube will require more frequent service if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Remove the hose clamp and remove the sediment tube 2 Drain and clean deposits from ...

Page 22: ...he oil level is in the normal range The level should be at minimum halfway between to the top of the viewing area Add oil as needed to reach the indicated level shown Do not overfill NOTE Do not fill the over the normal oil operating range Filling over the normal operating range could cause a mist of oil to enter the air box NOTE Rising oil level between checks in cool weather driving can indicate...

Page 23: ...ct the O ring on drain plug replace if needed Recommended Engine oil Synthetic 0W 40 Above 0 C 32 F Semi Synthetic 20W 40 Below 0 C 32 F NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug 10 Reinstall the pre filter drain plug Torque to 11 ft lbs 15Nm Crankcase Drain Plu...

Page 24: ...adjuster screw 4 If adjustment is required loosen the locknut and turn adjuster until the proper clearance is obtained 5 When clearance is correct hold adjuster screw and tighten locknut securely 6 Re check the valve clearance 7 Repeat steps 3 5 to adjust the exhaust valve clearance Valve Clearance In 0 1 mm Ex 0 12 mm ENGINE MOUNTS LOCATION Inspect engine mounts for cracks or damage Front Rear En...

Page 25: ...nd lever check bolt 3 View the lubricant level through the lever check hole 4 If the level is low add the recommended lubricant 5 Reinstall the fill plug and oil lever bolt Transmission Lubricant Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan beneath the axle gear case drain 4 Remove the drain bolt and allow the lubricant to drain completely 5 Clean and...

Page 26: ...lowing 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 To check for wear pull upward on the chain at the top of the rear sprocket Replace sprocket if chain movement exceeds 6mm 1 4 ...

Page 27: ...ted in salt water areas rinse it off frequently with fresh water COOLING SYSTEM OVERVIEW The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the...

Page 28: ...e recovery bottle cap 10 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overheating COOLANT STRENGTH TYPE Test the strength of the coolant using an antifreeze hydrometer A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight antifr...

Page 29: ... and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery NOTE Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery rate...

Page 30: ...on 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 Coat the terminals with dielectric grease or petroleum jelly Battery Installation IMPORTANT Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow t...

Page 31: ...DC or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for battery charging directions When using a constant current charger follow the guidelines in the following table STATE OF CHARGE VOLTAGE ACTION CHARGE TIME 100 12 8 13 VDC None check again in 3 months None Required 75 100 12 5 12 8 VDC May need slight charge check again in 3 months 3 6 hrs 50 75 1...

Page 32: ...sion of the electrodes A hot exhaust system and engine can cause serious burns Allow engine to cool or wear protective gloves when removing the spark plugs 4 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 5 Measure gap with a wire gauge Refer to specifications for proper spark plug type and gap Adjust gap if ...

Page 33: ... entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited Due to the critical nature of the procedures outlined in this chapter an authorized Aeon Dealer should perform the steering component repair and adjustment Only the qualified technician should replace worn or damaged steering parts Use only genuine Aeo...

Page 34: ... in this position 3 Place a chalk mark on the center line of the front tires approximately 25 4 cm 10 from the floor or as close to the hub axle center line as possible NOTE It is important that the height of both marks be equally positioned in order to get an accurate measurement 4 Measure the distance between the marks and record the measurement Call this measurement A 5 Rotate the tires 180 deg...

Page 35: ...MAINTENANCE 2 25 ...

Page 36: ... and premature wear Damage may not be immediately apparent if done incorrectly See illustration Tie Rod Jam Nut Torque 16 19 Nm 12 14 ft lbs Front Suspension Spring Preload Adjustment The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload Uneven adjustment may cause poor handling of the vehicle which could result in an accident and ...

Page 37: ...e upper and lower A arms Apply grease until it is visible on the ends of the pivot points REAR SUSPENSION SPRING PRELOAD ADJUSTMENT The rear spring preload can be adjusted To make preload adjustments rotate the adjustment cam clockwise to decrease spring tension or counter clockwise to increase spring tension Refer to Front Suspension Spring Adjustment for rear suspension service procedures Rear S...

Page 38: ...ir The level should be between the MAX and MIN level lines 5 If the fluid level is lower than the MIN level line add brake fluid until it reaches the MAX level line 6 Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings Brake fluid may erode painted surfaces or plastic parts A...

Page 39: ...nd Foot Brake Adjustment 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 4 While rotating the 4 wheels adjust the adjuster nut at the master cylinder piston rod of foot brake 5 When you begin to feel a slight drag in wheels rotation loosen th...

Page 40: ...l Hub and Spindle Torque Table Item Specification Front wheel bolts 30Nm 22ft lbs Rear wheel bolts 30Nm 22ft lbs Front spindle nut 65Nm 48ft lbs Rear hub retaining nut 65Nm 48ft lbs Wheel Inspection Inspect the front and rear wheel bolts for tightness Re torque the wheel bolts periodically and check before each ride WHEEL REMOVAL FRONT REAR 1 Position the vehicle on a level surface 2 Stop the engi...

Page 41: ...erability When replacing a tire always use original equipment size and type The use of non standard size or type tires may affect vehicle handling Tire Tread Depth Always replace tires when tread depth is worn to 3 mm 1 8 or less Tire Pressure Inspection PSI Cold Front Rear 5 psi 35 kPa 5 psi 35 kPa Tire Notice Operating an ATV with worn tires will increase the possibility of the vehicle skidding ...

Page 42: ...ODED VIEW 3 3 CVT EXPLODED VIEW 3 4 CVT OVERHEATING DIAGNOSIS 3 5 DRIVE CLUTCH REMOVAL 3 6 DRIVEN CLUTCH EXPLORED VIEW 3 8 DRIVEN CLUTCH REMOVAL 3 8 DRIVEN CLUTCH SERVICE 3 9 DRIVEN CLUTCH DISASSEMBLY AND INSPECTION 3 9 DRIVEN CLUTCH ASSEMBLY 3 10 CVT BELT INSPECTION 3 11 DRIVE CLUTCH SERVICE 3 12 DRIVE CLUTCH DISASSEMBLY AND INSPECTION 3 12 DRIVE CLUTCH ASSEMBLY 3 12 ...

Page 43: ... the rollers to push against the cam plate and force the moveable sheave toward the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch If belt speed is sufficient centrifugal friction shoes on the driven clutch overcome their return spring pressure and swing outward against the transmission drive hub and the ve...

Page 44: ... drain plug and O ring located on the bottom of the crankcase and let the water drain out The CVT drain plug is shown at right 2 To further expel water from the CVT area cover and to dry out the CVT system shift the transmission to neutral and rev the engine slightly to expel the moisture This will also air dry the belt and clutches 3 Allow engine RPM to settle to idle speed shift transmission to ...

Page 45: ...CVT SYSTEM 3 4 CVT EXPLODED VIEW ...

Page 46: ... 12 km Drive at higher speed for cooler CVT operating temperatures and longer component life Insufficient warm up of exposed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the...

Page 47: ...urface Use the parking brake 2 Remove seat storage box and LH plastic panel to gain access to the outer clutch cover 3 Remove the inlet dust screw and inlet duct 4 Remove all screws and cover with re coil start attached 5 Remove the entire re coil starter bolt 6 Remove the lock nut washer and the re coil start pawl from the crankshaft 7 Remove outer clutches cover screws and the clutch cover ...

Page 48: ...oving the primary sliding sheave and the cam plate assembly This prevents the roller weights from falling out of the assembly 5 Remove the roller weights from the primary sliding sheave Check the rollers for wear and scoring 6 Remove and inspect the slide bushings and cam plate Replace any components that found to be worn excessively or appear abnormal ...

Page 49: ...ts become free and could fall apart Mark or note parts during disassembly 1 Hold the driven clutch housing then releasing the nut from the shaft 2 Remove the nut by pincer and air wrench 3 Pull the entire clutch off as an assembly 4 Set the driven clutch assembly on a flat surface Remove the cover Inspect components for excessive wear or damage Replace components as required DRIVEN CLUTCH ...

Page 50: ...drum Measure the inside diameter of the cover at 90 degree intervals using a caliper Inspect the condition and diameter of the drum lining If either the measurements or the lining indicates excessive wear replace the clutch cover Driven Clutch Friction Pad Service Limit 2 mm 0 078 Driven Clutch Hub I D Service Limit 153 0 2 mm 3 Use a caliper to check the length of the compression spring At full e...

Page 51: ... rings and the outer roller pin cover Place the washer onto the threaded shaft and apply Loctite 272 to the threads 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 ...

Page 52: ...sembly into Crankshaft 4 Install the drive belt on driven clutch sheave side and move belt as far into the sheaves as possible 5 Install the V belt with the printed arrow mark on the V belt facing in the direction shown in the illustration Do not allow grease to contact the V belt and the secondary sheave assembly 6 Holding the clutch shoe assembly with the holding tool tighten the clutch shoe ass...

Page 53: ...r wear or damage The outside diameter is 23 2mm and the service limit is 22 7mm 5 Inspect surface of slide sheave slide bushing and cam plate for wear pitting or damage 5 Inspect belt contacting surface of both sheave for wear or damage DRIVE CLUTCH ASSEMBLY 1 Install the V belt onto the drive clutch assembly when the pulley is at its widest position 2 Install the drive clutch outer sheave when th...

Page 54: ...SASSEMBLY 4 14 CAM CHAIN TENSIONER REMOVE 4 14 CAM CHAIN TENSIONER INSPECTION 4 15 CAMSHAFT SPROCKET REMOVAL AND INSPECTION 4 15 ROCKER ARM SHAFT DISASSEMBLY AND INSPECTION 4 16 CYLINDER HEAD REMOVAL 4 17 CYLINDER HEAD INSPECTION 4 18 CYLINDER HEAD WARP INSPECTION 4 19 COMBUSTION CHAMBER INSPECTION 4 19 CYLINDER HEAD DISASSEMBLY 4 19 VALVE INSPECTION 4 20 VALVE SEAT RECONDITIONING 4 21 CYLINDER HE...

Page 55: ...NSTALLATION 4 36 OIL PUMP AND CHAIN INSTALLATION 4 37 PISTON RING INSTALLATION 4 38 PISTON INSTALLATION 4 39 CYLINDER INSTALLATION 4 39 CYLINDER HEAD AND CAMSHAFT INSTALLATION 4 40 CAM CHAIN TENSIONER INSTALLATION 4 43 CAMSHAFT INSTALLATION TIMING METHOD 1 4 44 CAMSHAFT INSTALLATION TIMING METHOD 2 4 45 INTAKE VALVE CLEARANCE ADJUSTMENT 4 46 EXHAUST VALVE CLEARANCE ADJUSTMENT 4 46 FLYWHEEL INSTALL...

Page 56: ...ENGINE 4 3 ENGINE ILLUSTRATION ENGINE EXPLODED VIEW ...

Page 57: ...ENGINE 4 4 ...

Page 58: ...ENGINE 4 5 COOLING SYSTEM EXPLODED VIEW ...

Page 59: ...ENGINE 4 6 OIL FLOW DIAGRAM ...

Page 60: ... pressure loss is evident within five minutes check the radiator hose lamps and water pump seals for leakage COOLANT CIRCULATION A From radiator to coolant pump B From coolant pump to cylinder C From Thermostat valve to radiator High capacity circulation when coolant temperature over 65 D Bypass from Thermostat bypass tube to radiator low capacity circulation when coolant temperature below 65 Pres...

Page 61: ...r hoses for cracks or damage THERMOSTAT 1 Suspend the thermostat in a container filled with water 2 Slowly heat the water 3 Place a thermometer in the water 4 While stirring the water observe the thermostat and thermometer s indicated temperature 5 If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling ...

Page 62: ...TER PUMP Removal 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 4 Remove impeller and mechanical seal from water pump housing 5 Ensure do not scratch impeller shaft surface 6 Inspect the impeller oil seal and o ring Replace parts if have too much worn or damaged Installation 1 Before installing the oil seal a...

Page 63: ...ntinuing 7 Until fan start the temperature will cool down and coolant be sucked into coolant system 8 Squeeze the coolant lines by hand to help purge the system of air NOTE If there is air in the system you will see air bubbles forming through the radiator filler neck 9 Add coolant to the radiator filler neck if the level goes down NOTE If the coolant level is LOW in the radiator or if there are l...

Page 64: ...tat stuck closed or not opening completely Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak Faulty pump shaft oil seal oil leak Be sure to install the pressure cap before shutting off the engine Coolant may spit out of the radiator 10 Repeat 8 to 9 step If no bubbles are seen at the filler neck the system should be purged of air ...

Page 65: ...nkshaft Main Bearings 8 Crankcase 9 Transmission 10 Valves NOTE Cam chain service requires crankshaft removal as the chain is located on the side of the engine NOTE Crankshaft components are not serviceable Replace crankshaft as an assembly ENGINE REMOVAL 1 Clean work area 2 Thoroughly clean the ATV engine and chassis 3 Disconnect battery cables 4 Drain engine oil 5 Drain radiator water 6 Disconne...

Page 66: ...f 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 Front Mount 80Nm Rear Mounts 80Nm Engine Break In Period 4 Cycle Engine Break In Period is defined as the first 10 hours of engine operation or 2 full tanks of fuel Use only All Season Synth...

Page 67: ...cation of good oil flow CAM CHAIN TENSIONER REMOVAL 1 Remove oil fill cap from the stator housing and valve cover To position crankshaft at Top Dead Center TDC on compression stroke 2 Rotate engine slowly in the direction of rotation watching intake valves open and start to close 3 Continue to rotate engine slowly while watching camshaft sprocket marks and the mark in the timing inspection hole 4 ...

Page 68: ...hain tensioner rod turn clockwise with a thin cross driver 1 until it stops 3 Removing the screwdriver and slowly release the chain tensioner rod 4 Make sure that the chain tensioner rod comes out of the chain tensioner housing smoothly If there is rough movement replace the timing chain tensioner 5 Inspect tensioner and plunger for wear or damage CAMSHAFT SPROCKET REMOVAL AND INSPECTION NOTE Orie...

Page 69: ...et and timing chain as a set if they are worn or damaged 2 Measure the space of cam chain and cam sprocket Replace the camshaft sprocket and timing chain as a set if the space out of 1 4 of width tooth ROCKER ARM SHAFT DISASSEMBLY AND INSPECTION 1 Remove rocker arm shaft and rocker arm from cylinder head 2 Measure the inside diameter of rocker arm hole and outside diameter of rocker arm shaft Repl...

Page 70: ...emoved If no crankshaft service is being performed secure cam chain with mechanics wire to avoid chain drop into the crankcase 1 Disconnect battery cables 2 Drain engine oil 3 Drain radiator water 4 Disconnect spark plug high tension lead 5 Disconnect all electrical wires from the engine 6 Disconnect radiator tubes 7 Loosen each of the four cylinder head bolts evenly 1 4 turn each time in a cross ...

Page 71: ...le cleaning CYLINDER HEAD INSPECTION 1 Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon Use care not to damage sealing surface If there is damage found on the cylinder head combustion chamber it is recommended the component be replaced CYLINDER HEAD WARP INSPECTION 1 Lay a straight edge across the surface of the head at several different points and measure ...

Page 72: ...or compress the valve springs and remove the split keeper NOTE To prevent loss of tension do not compress the valve spring more than necessary 2 Remove spring retainer and spring NOTE The valve springs should be positioned with the tightly wound coils against the cylinder head on progressively wound springs 3 Push valve out keeping it in order to reassembly in the same guide 4 Measure free length ...

Page 73: ... groove for wear or flaring of the keeper seat area B NOTE The valves cannot be re faced or end ground They must be replaced if worn bent or damaged 5 Measure diameter of valve stem with a micrometer in three places and in two different directions six measurements total Replace if excessive wear is evident VALVE STEM OUTER DIAMETER LIMITATION Intake Valve Limit 5 4mm Exhaust Valve Limit 5 4mm 6 Me...

Page 74: ...ctions provided with the valve seat cutters in the Valve Seat Reconditioning Kit Abrasive stone seat reconditioning equipment can also be used Keep valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper...

Page 75: ...k marker indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width A If the indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat If too low use the 60 or 75 cutter to raise the seat When contact are...

Page 76: ...times until the valve is fully seated and repeat process for the other valve 12 Clean cylinder head valves and camshaft oil supply passages thoroughly 13 Spray electrical contact cleaner into oil passages and dry using compressed air CYLINDER HEAD ASSEMBLY Wear eye protection during assembly NOTE Assemble the valves one at a time to maintain proper order 1 Install new valve seals on valve guides 2...

Page 77: ...keepers VALVE SEALING TEST 1 Clean and dry the combustion chamber area 2 Pour a small amount of cleaning solvent into each port and check for leakage around each valve The valve seats should hold fluid with no seepage CYLINDER REMOVAL Follow engine disassembly procedures to remove valve cover camshaft and rocker arms and cylinder head 1 Remove coolant tube from cylinder 2 Tap cylinder lightly with...

Page 78: ...ng Using a piston ring plier Carefully expand ring and lift it off the piston Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and pushes up on the opposite side Use care to not scratch the ring lands 4 Repeat procedure for second ring 5 The oil control ring is a three piece design con...

Page 79: ...d hone or arbor honing machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore HONING TO DEGLAZE A finished cylinder should have a crosshatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder ac...

Page 80: ...Cycle Lubricant to prevent the formation of surface rust If cylinder wearing or damage is excessive it will be necessary to replace the cylinder Hone only enough to deglaze the outer layer of the cylinder bore PISTON INSPECTION 1 Measure piston outside diameter at a point 7mm up from the bottom of the piston at a right angle to the direction of the piston pin 2 Subtract this measurement from the m...

Page 81: ...3 mm Limit 0 8 mm Second Ring Std 0 35 0 5 mm Limit 1 0 mm Oil Ring Std 0 2 0 7 mm Limit 1 5 mm 2 Measure the gap with a feeler gauge at both the top and bottom of the cylinder NOTE Measure at two points in the cylinder A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 If the installed gap measurement exceeds the limit replace t...

Page 82: ...ENGINE 4 29 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 ...

Page 83: ...ID of the bushing in the stator housing A and in the crankcase B in two directions 90º apart to determine if out of round Calculate clearance Replace components if clearance is excessive 8 Inspect gear teeth on starter drive Replace starter drive if gear teeth are cracked worn or broken FLYWHEEL REMOVAL INSPECTION The crankshaft end contains an oil passage plunge joint A as shown below The plunger...

Page 84: ... is not working properly 4 Install the starter wheel gear to the starter clutch and hold the starter clutch 5 When turning the starter wheel gear counter clockwise a the starter clutch and the wheel gear should be engaged If not the starter clutch is faulty Replace it 6 When turning the starter wheel gear clockwise b the starter wheel gear should turn freely If not the starter clutch is faulty Rep...

Page 85: ... if has too much worn pitting or damaged OIL PUMP DRIVE SPROCKET REMOVAL INSPECTION 1 Remove the oil pump shield 2 The outer chain is oil and water pump drive chain The inner chain is cam chain 3 Remove pump chain drive sprocket circlip and chain from pump drive shaft and crankshaft 4 Inspect sprocket teeth for wear or damage 5 Replace any worn or damaged parts ...

Page 86: ... with the engine in the frame CRANKCASE SEPARATION AND CAM CHAIN REMOVAL 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 NOTE Valve train and cylinder removal must be performed prior to this procedure NOTE Always replace the PTO crankshaft seal after performing this procedure 1 Remove 4 flang...

Page 87: ...ankshaft end CRANKSHAFT CAM OIL CHAIN SPROCKET INSPECTION 1 Inspect the crankshaft main bearings and cam and oil pump chain sprocket for wear or damage NOTE Due to extremely close tolerances and minimal wear the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should turn smoothly and quietly The inn...

Page 88: ...e used 3 Remove all traces of gasket sealer from the crankcase mating surfaces Inspect the surfaces closely for nicks burrs or damage CRANKCASE OIL STRAINER INSPECTION 1 Remove drain plug 2 Remove oil strainer and visually inspect for any rips tears or obstructions in screen 3 Replace oil strainer if it fails visual inspection BEARING SEAL INSTALLATION NOTE To ease crankcase bearing installation w...

Page 89: ...tall the balance shaft Turn the flat up 4 Install the PTO end of the crankshaft NOTE Use care not to damage the crankshaft end The balance shaft flat must square with crankshaft PTO end 3 Install 2 Pins onto crankcase Install a new gasket onto the right hand crankcase half Applying a thin amount of crankcase sealer to the gasket will help hold it in place 4 Place right of crankcase on crankshaft a...

Page 90: ...is not a service able assembly Do not disassemble pump Replace entire component 1 Inspect the oil pump sealing surface on the crankcase Apply a liberal amount of engine oil to the surfaces and pump 2 Install oil pump as shown Torque screws to specified torque 3 Beware the oil pump cover arrow must align with point OIL PUMP COVER SCREW TORQUE 8 Nm 4 Install the tensioner blade and tighten the mount...

Page 91: ...control ring holes 1 Place the oil control ring expander in oil ring groove with the end gap facing forward The expander has no up or down marking and can be installed either way The ends should butt squarely together and must not overlap 2 Install the oil ring top rail with the end gap at least 30 from the end of the expander 3 Install the bottom rail with the gap at least 30 from the end of the ...

Page 92: ...o make sure the clips are properly seated in the groove 5 Place the dowel pins in the crankcase and install a new cylinder base gasket 6 Lubricate the piston and rings with assembly lube and install a ring compressor on the piston assembly Verify that the ring gaps are 120 apart from each other before installation 7 Push the rings into the taper using a metallic blunt edge tool while holding the c...

Page 93: ...n crankshaft at Top Dead Center TDC on compression stroke 6 Install 2 dowel pin onto cylinder CYLINDER HEAD AND CAMSHAFT INSTALLATION NOTE Clean the gasket surfaces on the cylinder head and cylinder Remove all traces of old gasket material 1 Install the dowel pin s and a new cylinder head gasket 2 Pull the cam chain through the cylinder head chain room and secure with mechanic s wire 3 Place the c...

Page 94: ...tall cylinder head bottom mount nut 5 Install cylinder head nuts and torque to specification CYLINDER HEAD NUT TORQUE 22 25Nm 16 18ft lb 6 Insert cam into cylinder head 7 Install exhaust side rocker shaft and rocker arm ...

Page 95: ...ets 2 fasten holes which locate at horizontal 13 Ensure flywheel mark align with right crank cover mark line 14 Tight cam sprocket fastens bolt Serious engine damage may result if the camshaft is not properly timed to the crankshaft 15 Install decompressor into camshaft 16 Apply clean engine oil liberally to the valve springs cam chain rocker arms and camshaft 17 Adjust valves according to the VAL...

Page 96: ...e tensioner clockwise to retract the plunger B all the way into the tensioner body 2 With the plunger retracted install the tensioner assembly with a new gasket and tighten the bolts to specification TENSIONER BOLT TORQUE 10 Nm 7 4 ft lbs 3 Install the tensioner cap Torque cap to specification TENSIONER CAP TORQUE 10 Nm 7 4 ft lbs 4 Slowly rotate engine two to three revolutions and re check cam ti...

Page 97: ...ENGINE 4 44 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 ...

Page 98: ...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 ...

Page 99: ...djuster screw 3 Loosen locknut and turn adjuster screw until there is a slight drag on feeler gauge 4 When clearance is correct hold adjuster screw and tighten locknut securely 5 Re check the valve clearance 6 Repeat adjustment procedure if necessary until clearance is correct with locknut secured VALVE CLEARANCE 0 12 mm FLYWHEEL INSTALLATION 1 Install flywheel key flywheel washer and nut Torque f...

Page 100: ...roperly adjusted Excessive carburetor vibration loose or missing needle jet locating pins Loose jets in carburetor or calibration incorrect for altitude temperature Incorrect float level setting CVT system calibrated incorrectly or components worn or miss adjusted Fuel quality poor old or octane too high Low compression Restricted exhaust Weak ignition loose coil ground faulty coil or stator Restr...

Page 101: ...n ring or valve wear or damage check compression CVT not operating properly Restricted exhaust muffler Dirty carburetor Cam lobe worn PISTON FAILURE SCORING Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated EXCESSIVE SMOKE AND CARBON BUILDUP Worn rings piston or cylinder Excessive piston to cylinder clearance Worn valves guides or seals...

Page 102: ...EM REMOVAL 5 2 TRANSMISSION DISASSEMBLY 5 3 TRANSMISSION INSPECTION 5 4 DRIVE SHAFT REMOVAL AND INSPECTION 5 4 SHIFT FORK INSPECTION 5 5 MIAN SHAFT REMOVAL AND INSPECTION 5 5 COUNT SHAFT INSPECTION 5 6 OUTPUT SHAFT REMOVAL AND INSPECTION 5 6 SHIFT DRUM REMOVAL AND INSPECTION 5 7 TRANSMISSION REASSEMBLY 5 7 TROUBLE SHOOTING 5 9 ...

Page 103: ... is not required to service transmission components Process shown below is with engine removed for clarity 1 Drain the transmission oil from the gear case A and engine oil from crankcase B SHIFT SYSTEM REMOVAL 1 Remove right footwall 2 Remove sprocket cover and drive sprocket 3 Remove shift cables from the bracket ...

Page 104: ...ing The center tooth on shift shaft is positioned between the two dots on the drum teeth 8 Remove the shift shaft by pulling straight outward 9 Remove detent ball spring and socket bolt 10 Remove shift detent TRANSMISSION DISASSEMBLY 1 Remove the cover screws 2 Remove cover or with output shaft Push or tap on shift shaft to keep it in the case 3 Remove gasket and discard ...

Page 105: ...TION NOTE Always wear the appropriate protective gear and use caution when operating a press DRIVE SHAFT REMOVAL AND INSPECTION 1 With transmission components removed inspect all shaft bearings visually and by feel Bearings should roll smoothly without excessive movement or noise Replace any bearing that is removed as the removal process destroys the bearing 2 Bearings can be removed using a stand...

Page 106: ...sliding gear dogs E and dog slots in the mating gears F for wear or damage The edges of dogs and slots should be square and not rounded Replace both sliding gear and mating gears if any edges are rounded or chipped 2 Substantial axial movement in the forward drive gear is due to liberal oil clearance for the bushing and is a normal condition Gear replacement is not required due to axial movement i...

Page 107: ...damaged components 8 Assemble the reverse gear washer a new snap ring and the sliding gear on the shaft 9 Assemble the forward gear washer bush and a new snap ring on the shaft 6 Remove second snap ring from main shaft COUNTER SHAFT INSPECTION Inspect the shaft and gears visually without excessive wear or crack Replace any damaged components 6 Remove reverse gear components OUTPUT SHAFT REMOVAL AN...

Page 108: ...rd gear toward inside SHIFT DRUM REMOVAL AND INSPECTION Spring pressure can cause components to eject suddenly Use care during removal Always wear the appropriate protective gear Remove shift sensor from drum shaft NOTE Drum shaft components are not serviceable Replace Drum shaft as an assembly TRANSMISSION REASSEMBLY NOTE Lubricate all bearings with clean transmission oil before assembly Clean th...

Page 109: ... then install fork shaft 10 Install the drum detent and shift teeth Ensure all dots must on center position 11 Install detent bolt and fasten to 10Nm 7 Place flat washer on output shaft bearing 8 Install the output shaft 12 Check transmission operation before final assembly and after installing outer cover FORWARD NEUTRAL REVERSE 9 Install the transmission cover then fasten all bolts to 12Nm Trans...

Page 110: ...ncorrectly Shift cables loosened Detent spring or ball missing worn or broken Gear engagement dogs worn rounded or broken Shift fork bent Noise Incorrect transmission lubricant Lubricant level too low Lubricant level too high Bearings worn or damaged Gears worn or damaged CVT problem belt Final drive chain or sprockets worn or damaged 14 Install the shift cover then fasten bolts to 10Nm 15 Install...

Page 111: ...NG VS FUEL FLOW 6 10 THROTTLE SLIDE 6 10 MAIN JET 6 10 IDLE AND LOW SPEED CIRCUIT 6 11 MIDRANGE SLIDE POSITION AND FUEL DISCHARGE 6 11 HIGH SPEED CIRCUIT SLIDE POSITION AND FUEL DISCHARGE 6 12 ACCELERATIVE PUMP SYSTEM 6 12 FUEL DELIVERY 6 13 VENT SYSTEM 6 13 CARBURETOR CLEANING 6 14 FUEL TANK SYSTEM 6 15 FUEL TANK EXPLODED VIEW 6 15 FUEL TANK LOCATION 6 15 FUEL TANK REMOVAL 6 16 FUEL FLOW DIRECTIO...

Page 112: ...mediately wash with soap and water and change clothing CARBURETOR FUNCTION Carburetor Component Function System Main Components Main Function Main Affect Float System Level Control Inlet Pipe Needle and Seat Float and Float Pin Maintains specified fuel level in float chamber carburetor float bowl All systems all throttle ranges Venting Passages in carburetor and vent lines Supplies atmospheric pre...

Page 113: ... a low speed fuel system or pilot system and a main fuel system are provided in these types of carburetors The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor to mix the fuel with air in a proper ratio and to deliver the mixture to the engine A proper ratio means an ideal air fuel mixture that can burn without leaving ...

Page 114: ... constant performance reliability and easier starting HIGH ALTITUDE OPERATION The COBRA 400 has been tested to 4 000 M above sea level to assure satisfactory performance No jetting or clutching changes are required for high altitude operation NOTE If desired removing one CVT roller weight from each tower of the drive clutch and fine tuning the carburetor with optional jetting may provide a slight ...

Page 115: ...ure is also leaned out by air flowing in through the progression hole 14 When the butterfly opens the flow reverses in the progression holes 14 and richer mixture flows into the Venturi air stream When RPM increases a vacuum is developed in the manifold and this vacuum is transferred through a hole 6 in the slide onto the vacuum chamber 3 This vacuum lifts the slide 2 against the spring 4 and midr...

Page 116: ...emains relatively constant The fuel level in the bowl assists in controlling the amount of fuel in the fuel mixture Too high a level allows more fuel than necessary to leave the nozzle enriching the mixture Too low a level results in a leaner mixture since not enough fuel leaves the nozzle Therefore the predetermined fuel level should not be changed arbitrarily FLOAT INSPECTION 1 Inspect float and...

Page 117: ...15 1mm 4 If the float height is not within the specification inspect the valve seat and needle valve FUEL LEVEL TEST A fuel level test can be performed if the drain hose fitting is accessible Be sure to re attach the bowl drain hose after performing the test A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor The fuel level can be observ...

Page 118: ...dle and needle jet to prevent a rich condition TIP A worn needle jet is difficult to spot To check slide a slightly larger new jet needle into the needle jet and hold it to a light source Light will be visible between the needle and needle jet if it is worn Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot...

Page 119: ... lower end The top is fixed to the center of the throttle valve by the needle clip and the tapered end extends into the needle jet 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 If the nee...

Page 120: ...w control By controlling airflow the negative pressure over the needle jet is regulated in turn varying the fuel flow Throttle valves are numbered 1 0 1 5 2 0 etc according to the size of the cutaway The higher the number the leaner the gasoline air mixture MAIN JET When the throttle opening becomes greater and the main jet meters the area between the needle jet and jet needle increases fuel flow ...

Page 121: ...velocities provide great quantities of fuel necessary or good acceleration MIDRANGE SLIDE POSITION AND FUEL DISCHARGE As the throttle plate is opening airflow increases through the carburetor and the pressure drop in the venture near the needle jet increases The low pressure in the venture travels through the vacuum port in the vacuum piston to the chamber above the diaphragm The chamber beneath t...

Page 122: ...opening exposure to the air stream is at its maximum Air and fuel supplies are now available in quantities sufficient to meet all engine demands ACCELERATIVE PUMP SYSTEM The accelerator pump used sudden throttle openings rapid accelerations to quickly inject fuel into carburetor venturi to provide extra fuel for smooth acceleration This fuel also assists engine operation during cold engine warm up...

Page 123: ... range The jet needle and needle jet have an effective operating range from approximately 1 8 to 7 8 throttle opening The amount of fuel delivered during this range relies upon the jet needle clip position as well as the needle jet size and other specifications The main jet affects fuel delivery at 1 4 throttle and consistently increases to full throttle opening VENT SYSTEM The fuel tank vent supp...

Page 124: ...ean the carburetor body jets and all passages with carburetor cleaner or electrical contact cleaner 2 If the carburetor is extremely dirty or contaminated with fuel residue and varnish soak for short periods only in carburetor cleaner and rinse in hot water 3 Replace the jets if they have a buildup of fuel residue or bacterial growth that cannot be removed Even a small amount of residue will reduc...

Page 125: ...FUEL AND CARBURETOR 6 15 FUEL TANK SYSTEM ...

Page 126: ... 5 Disconnect fuel discharge hose from fuel tank 6 Disconnect fuel gauge wire from main harness 7 Remove both side of fasten bolts on frame as shows 8 Remove 2 of rear fastener bolts on frame 9 Carefully lift up on the fuel tank 7 Disconnect the fuel tube from tank 8 To reinstall the tank reverse the removal procedure Be sure to torque the tank mounting bolts Fuel Tank Mounting Bolt Torque 8 Nm 72...

Page 127: ...pe from cylinder and dual intake 2 Disconnect manifold vacuum hose B and remove dual intake filter box fastener bolt A 3 Remove complete dual intake assembly 4 Inspect the foam and diagraph Wash the foam filter in warm soapy water If the foam or diaphragm is damaged replace new foam and dual intake ...

Page 128: ...apy water then rinse and let it dry Use press air cleaner paper filter If the filter is damaged replace a new foam and filter 4 Remove cleaner box with bracket oil separator hose and boot from carburetor 5 Apply commercially available foam filter oil to the foam filter 6 Reinstall the foam filter foam and air box cover Secure the clips The air intake on cover must toward front of vehicle ...

Page 129: ...hoke cable binding or improperly routed Incorrect pilot air fuel screw adjustment Faulty inlet needle and seat Faulty inlet needle seat O Ring Float level too high Poor fuel quality old fuel Loose jets Worn jet needle needle jet or other carburetor parts Dirty carburetor air bleed passages or jets Weak or damaged choke plate return spring Fouled spark plug POOR ILDE Idle Too High Idle adjusted imp...

Page 130: ...XPLODED VIEW 7 6 SUSPENSION 7 6 SHOCKS EXPLODED VIEW 7 6 FRONT SHOCK REMOVAL 7 7 REAR SHOCK REMOVAL 7 7 FRONT A ARM 7 8 A ARM EXPLODED VIEW 7 8 A ARM REPLACEMENT 7 8 SWING ARM 7 10 SWING ARM EXPLODED VIEW 7 10 SWING ARM REMOVAL 7 10 STEERING 7 13 STEERING FRONT SUSPENSION EXPLODED VIEW 7 13 STEERING POST ASSEMBLY 7 14 HANDLEBAR 7 15 HANDLEBAR BLOCK INSTALLATION PROCEDURE 7 15 EXPLODED VIEW 7 15 DE...

Page 131: ...e Rod Bolts 19 Nm 14 ft lbs Steering Post Mount Nuts 22 Nm 16 ft lbs Steering Post Nut 55 Nm 40 ft lbs Final Drive Fasteners Front Wheel Spindle Nut 60 Nm 44 ft lbs Rear Wheel Hub Nut 80 Nm 58 ft lbs Front Rear Wheel Bolts 30 Nm 22 ft lbs Sprocket Bolts Front 9 8 Nm 87 in lbs Rear 22 Nm 16 ft lbs Chain Tensioner Bolt 10 Nm 84 in lbs Bearing Carrier Mounting Bolts 55 Nm 40 ft lbs Chain Guard Bolts ...

Page 132: ...adiator windshield bolts on each side 9 Disconnect the main switch ignition harness 10 Disconnect power supplier wires 11 Disconnect both front indicator plugs 7 Remove the 8 screws attaching front and rear cabs to the footwalls on each side 8 Remove the 2 bolts attaching the body to the front cab on each side ...

Page 133: ...ness 13 Remove shift lever grip 14 Completely remove the front cab from body REAR CAB REMOVAL 1 Remove 2 footwalls from body 2 Remove the 4 bolts of rear cab 3 Disconnect the taillight harness 4 Remove the 2 bolts attaching the rear cabs then take off taillight ...

Page 134: ...all the bumper 3 Torque mounting bolts to 87 in lbs 9 8 Nm Front Bumper Mount Bolt Torque 10 Nm 90 in lbs FRONT SHOCK REMOVAL 1 Elevate front end of the ATV off the ground to remove shock spring tension Severe injury could occur if machine tips or falls 2 Remove the upper shock mounting bolts from the frame and the lower shock mounting bolts from the front suspension arm A arm 3 Remove the 2 botto...

Page 135: ...BODY SUSPENSION STEERING 7 6 SUSPENSION ...

Page 136: ...above Exploded Figure 5 Torque shock mounting bolts to specification Front Shock Mounting Bolt Torque 44 Nm 32 ft lbs REAR SHOCK REMOVAL 1 Elevate rear end of the ATV off the ground to remove shock spring tension Severe injury could occur if machine tips or falls 2 Remove the upper shock mounting bolt from the frame and the lower shock mounting bolt from the swing arm 3 Replace the shock spring or...

Page 137: ...REPLACEMENT 1 Elevate front end of ATV off the ground far enough to remove the wheel Severe injury could occur if machine tips or falls 2 Remove wheel nuts and remove wheels 3 Remove brake caliper bolts and caliper 4 Remove wheel hub and brake disc ...

Page 138: ...eplace if worn Discard hardware 10 Insert A arm shaft E into the new A arm C H 11 Install new A arm assembly onto vehicle frame upper and lower Torque bolts to 42Nm 30 ft lbs 12 Attach upper A arm C and lower A arm H to steering knuckle J Tighten both ball joint nuts to 50 Nm 37 ft lbs If cotter pin holes are not aligned tighten nut slightly to align Install a new cotter pin with open ends toward ...

Page 139: ...VAL 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 Remove 2 rear wheels nut and remove wheel and hub as an assembly ...

Page 140: ...hose washers 5 Remove chain protector bolts then chain protector 8 Bend the lock bracket back the remove bolts and sprocket 6 Take off the master link from chain by pliers then remove chain from sprocket 9 Pull the axle with disc toward left way some time need to use soft hammer on right of rear axle Ensure do not damaged axle thread ...

Page 141: ...spection 14 Inspect the axle hub main bearings for worn or damaged The bearing must be inspected visually and by turning feel The bearing should turn smoothly and quietly 11 There is an o ring in caliper mount 12 Loosen 4 bolts then remove axle hub toward right hand away 15 Remove the rear shock upper blot 16 Remove brake tube clamp 17 Remove swing arm shaft then swing arm ...

Page 142: ...BODY SUSPENSION STEERING 7 13 STEERING ...

Page 143: ...n the cotter pin hole 3 Install the cotter pin B and bend both ends of the cotter pin around the nut in opposite directions 4 Check the steering The handlebars must move freely and easily from full left to full right without binding Check all cables and electrical wires for binding and route as needed ...

Page 144: ...tens the bolts down Evenly torque the 2 front bolts to 15 18 Nm 11 13 ft lb 3 Install the rear bolts B and tightens evenly Evenly torque the 2 rear bolts to 15 18 Nm 11 13 ft lb 4 Install the four handlebar bolts and pod bracket C loosely into the blocks 5 Install the handlebar pod E and screws F NOTE There will be a slight gap on the backside of the blocks after the procedure is performed EXPLODE...

Page 145: ...a decal to ensure good adhesion A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged To Flame Treat The Decal Area 1 Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy This should ...

Page 146: ...LATION 8 11 FRONT PADS REMOVAL 8 11 FRONT PADS ASSEMBLY 8 12 FRONT DISC INSPECTION 8 13 FRONT BRAKE DISC REMOVAL REPLACEMENT 8 13 REAR FOOT PARKING BRAKE 8 14 REAR FOOT PARKING BRAKE EXPLODED VIEW TORQUE 8 14 REAR BRAKE REMOVAL AND INSPECTION 8 14 REAR CALIPER FLUID REPLACEMENT AND AIR BLEEDING 8 15 BRAKE FLUID DRAINING 8 15 REAR CALIPER FLUID FILLING BLEEDING 8 15 FOOT BRAKE REMOVAL 8 16 FOOT BRA...

Page 147: ... 15 Brake Disc Thickness Variance Between Measurements 0 05mm 0 002 Brake Disc Run out 0 25mm 0 01 TORQUE SPECIFICATIONS Item Torque Nm Torque ft lbs except where noted Front Caliper Mounting Bolts 25 18 Rear Caliper Mounting Bolts 42 31 Master Cylinder Reservoir Cover Bolts 0 6 5 in lbs Brake Line Banjo Bolt 20 15 Brake Disc Mounting Bolts 29 21 4 Caliper Bleed Screws 3 27 in lbs Foot Brake Maste...

Page 148: ...OUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brake noise check the backing of each pad for worn spots allowing metal to metal contact See table below BRAKE NOISE TROUBLESHOORTING Possible Cause Remedy Dirt dust or imbedded material on pads or disc Spray disc and pads wi...

Page 149: ...ctuated When the right foot brake lever master cylinder is applied the two front brake calipers and a rear caliper are active and under pressure The rear brake system is hydraulically actuated When the right front brake lever master cylinder is applied the rear brake caliper is active and under pressure The parking brake system operates using mechanical brake cables The left front parking brake le...

Page 150: ...g due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or contraction cooled fluid During system service b...

Page 151: ...BRAKES 8 6 FRONT BRAKE EXPLODED VIEW MASTER CYLINDER ...

Page 152: ...injury could occur if machine tips or falls 1 Elevate front end of ATV off the ground far enough to remove the wheel 2 Remove the dust cap and cotter pin 3 Remove wheel nuts and remove wheel and rim as an assembly 4 Remove the cotter pin nut and washer 5 Remove the caliper two fastens bolts on knuckle and the banjo bolt on caliper and oil tube 6 Remove the wheel hub and caliper as an assembly 7 En...

Page 153: ...ght front brake lever master cylinder is applied the two front brake calipers are active and under pressure When the right front brake lever master cylinder is applied the rear brake caliper is active and under pressure 1 Remove two mounting bolts under frame 2 Remove all banjo bolts then shunt 3 Inspect two piston s o ring and rubber cups surface for wear or other damage Replace an assembly if ne...

Page 154: ... brake pressure is hard to built repeat breeding procedure with shunt breeding screw Maintain at least 2 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to 3 Nm 27 in lbs 11 Repeat procedure Steps 5 9 for the remaining caliper s 5 Add brake fluid to the upper level mark on reservoir R...

Page 155: ...til air bubbles do not appear in the plastic hose 3 If air is entering the bleeder from around the bleed valve threads seal the threads with Teflon tape 4 Close the bleed valve and operate brake lever If it still feels spongy bleed the system again 5 If a brake bleeder is not available use the following procedure Pump up the system pressure with the brake lever until lever resistance is felt MASTE...

Page 156: ... the master cylinder Torque the banjo bolt to 20 Nm 15 ft lb Master Cylinder Mounting Clamp Bolt Torque 3 Nm 25 in lbs Banjo Bolt Torque 20 Nm 15 ft lbs 3 Fill reservoir with DOT4 Brake Fluid 4 Follow bleeding procedure on Pages 8 8 Check all connections for leaks and repair if necessary FRONT PADS REMOVAL 1 Follow front caliper remove procedure on page 8 6 Severe injury could occur if machine tip...

Page 157: ...ng bolts If previously removed Front Caliper Mounting Bolts Torque 25 Nm 18 ft lbs 3 Slowly pump the brake lever until pressure has been built up Maintain at least 20 mm of brake fluid in the reservoir to prevent air from entering the brake system 4 Be sure fluid level in reservoir is between MIN and MAX lines and install reservoir cap 5 Install wheels and torque wheel nuts Front Wheel Nut Torque ...

Page 158: ...easure disc run out Slowly rotate the disc and read total run out on the dial indicator Replace the disc if run out exceeds specifications Brake Disc Run out Service Limit 0 25 mm 0 01 FRONT BRAKE DISC REMOVAL REPLACEMENT 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install dis...

Page 159: ...re to the point where the rear brake disc housing can be accessed on Chapter 7 NOTE You do not need to fully disassemble the rear axle swing arm to service the rear brakes 2 Inspect the brake pads contact disc surface and the axle housing seal surface for excessive wear pitting or damage Replace if necessary 3 Remove the brake pads from the rear caliper assembly Follow Front pads remove procedure ...

Page 160: ...Brake Bleeding Procedure on page 8 8 to 8 10 NOTE 1 Check the fluid lever often while bleeding the brake to prevent air from being pumped into the system 2 Repeat the above procedure until air bubbles do not appear in the plastic hose 3 If air is entering the bleeder from around the bleed screw threads seal the threads with Teflon tape 4 Close the bleed screw and operate brake lever If it still fe...

Page 161: ...ylinder is applied the brake oil output to shunt The two front brake calipers and a rear caliper are active and under pressure 1 Remove right hand foot well from body 2 Remove the cotter pin from foot brake lever and foot brake master cylinder 3 Loosen foot brake lever and brake sensor return spring with long nose pliers 4 Remove the brake lever fastener bolt ...

Page 162: ...e lever when reservoir fluid level is low 3 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a wrench on the top caliper bleeder screw 4 Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting 5 Slowly pump foot brake lever until pressure builds and holds 6 While maintaining lever pressure...

Page 163: ...ntil lever resistance is felt Ensure the vent slot ring must face with cover when install oil tank diaphragm vent slot ring and cover PARKING BRAKE REMOVAL The parking brake system operates using mechanical brake cables The left front parking brake lever operates the rear brake caliper swing arm to push caliper piston assembly When removing and installing the parking braking system The spring may ...

Page 164: ...then loosen about 5mm back 2 Replace rubber dust proof if worn or cracked 3 Install the both spring and swing to caliper 4 Ensure the upper return spring 50 60mm with cable adapter 5 Install the adjusting bolt and fastener nut an assembly 6 Fully turn the adjusting bolt to end then loosen it 3 4 circuit Fasten the nut present and security 7 Inspect the parking lever cable and rubber pad replace th...

Page 165: ...ged or lining ruptured Worn disc and or friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Improper clearance between lever and switch LEVER VIBRATION Disc damaged Disc worn run out or thickness variance exceeds service limit Caliper Overheats Brakes Drag Compensating port plugged Pad clearance set incorrectly Auxiliary brake ...

Page 166: ...NT 9 8 REAR SIGNAL REPLACEMENT 9 8 SPEEDOMETER AND INDICATOR 9 9 SPEEDOMETEER SIGNAL DESCRIPTION 9 9 SPEEDOMETEER REPLACEMENT 9 9 SPEEDOMETER DIGITAL DISPLAY FUCTIONAL 9 10 SPEED HOUR 9 10 ODOMETER 9 10 FUEL LEVER SCALE 9 10 RADIATOR TEMPERATURE SCALE 9 11 TIRE WHEEL DIAMETER SETTING 9 11 IGNITION SYSTEM 9 12 RPM LIMITER SPECIFICATION 9 12 IGNITION COIL TEST 9 12 ALTERNATOR OUTPUT TEST AC AMP 9 12...

Page 167: ...RY OFF SEASON STORAGE 9 21 SEALED LOW MAINTENANCE BATTERY CHARGING PROCEDURE 9 22 CONVENTIONAL BATTERY ACTIVATION SVC 9 22 BATTERY TERMINALS TERMINAL BOLTS 9 23 CONVENTIONAL BATTERY INSPECTION REMOVAL 9 23 CONVENTIONAL BATTERY INSTALLATION 9 23 CONVENTIONAL BATTERY TESTING 9 23 CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE TEST 9 24 CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST 9 24 CONVENTIONAL BATT...

Page 168: ...e component to be tested Disconnect it from the wiring harness or power supply WIRE COLOR LETTER LIST Letter Color Letter Color B Black L Y Blue Yellow B L Black Blue O Orange Br Brown O B Orange Black B R Black Red P Pink Br L Brown Blue Pu Purple Br W Brown White R Red B Y Black Yellow R B Red Black C Cyan R W Red White DB Deep Brown W White DG Deep Green WB Water Blue G Green W B White Black Gr...

Page 169: ...ing screws Torque to 5Nm 45 in lbs BRAKE LEVER SWITCH Each brake lever utilizes an electrical brake switch that sends voltage to activate the brake light 1 Locate the brake switches on each of the brake levers 2 Disconnect wire harness from brake switch and connect an ohmmeter across the two switch wires The reading should be infinite 3 To act the brake lever s and check for continuity between swi...

Page 170: ...d with an ohmmeter When the key switch is turned to the ON position there should be continuity between the red whore R W and brown white Br W wires When the key is turned to the OFF position there should no continuity between any of the wires When the key switch is turned to the position there should be continuity between the red whore R W and brown white Br W wires There should also be continuity...

Page 171: ...e running lights There should be continuity between the Y R wire at the light connector and the YE RD wire at the Generator Stator 3 If continuity is good Perform stator resistance tests by using the resistance chart located in the wiring diagram 4 Replace Generator Stator if resistance is not within specification HEADLIGHT LAMP REPLACEMENT If the headlights do not operate lamp replacement may be ...

Page 172: ...ld be aimed 5 1 cm 2 below the mark placed on the wall NOTE Rider weight must be included on the seat For machines with separate low beam lights the drop should be 20 3 cm 8 in 25 5 Adjust beam to desired position by moving headlight TAILLIGHT TAILLIGHT LAMP REPLACEMENT 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 ...

Page 173: ...arness 2 Remove front signal and bracket from cab as picture 3 Remove rubber waterproof cap 4 Remove socket fastener screw and lamp socket 5 Remove and replace lamp 6 Reinstall all front signal components REAR SIGNAL REPLACEMENT 1 Remove rear signal and bracket from cab as picture 2 Use small blade drive screw to remove lens 3 Remove all components and replace lamp 4 Reinstall all rear signal comp...

Page 174: ...RICAL 9 9 SPEEDOMETER AND INDICATOR SPEEDOMETER REPLACEMENT 1 Remove the handlebar pod to access the speedometer 2 Disconnect the speedometer wire connections from the harness SPEEDOMETER SIGNAL DESCRIPTION ...

Page 175: ...ton twice to finish selection ODOMETER It sum up total mileage that can t zero or delete anymore But will change following KM H and MILE H selection Odometer mode There are three modes ODO TRIP and TRIP B 1 As Odometer item in ODO you can t change anymore 2 In TRIP A to press zero button after two seconds to clear the mileage 3 In TRIP B press zero button after two seconds to clear the mileage FUE...

Page 176: ...mp The thermostatic sensor locates at right hand of the radiator If the sensor is faulty replace the entire assembly Don t open the radiator cap or remove sensor hose bimetal valve and water pump when engine is still hot The Bimetal valve locates at right hand of cylinder If the valve is faulty replace the entire assembly The water pump locates at right hand of crank cover The Remove and reinstall...

Page 177: ... 561 mm 1763 mm d 22 0 23x8 11 11 inch 588 mm 1842 mm d 23 0 RPM LIMITER SPECIFICATIONS NOTE The ATV is limited through the CDI box located on the bulkhead under the front cab In forward gear the CDI reads the RPM from the stator The CDI acts as a limiter when the peak RPM is met In Reverse Gear the CDI also limits RPM taking a signal from the shift drum switch that the vehicle is in reverse IGNIT...

Page 178: ...of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 Alternator Current Output Reading should be no less than 30 40V AC above 2000 RPM on each coupler NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced CDI OUTPUT TEST USING PEAK READING ADAPTOR OR A VOLT ...

Page 179: ...nectors from the CDI module Test output from the detection and pulse trigger coil and compare to the chart The following measurements were obtained when cranking the engine with the electric starter spark plug installed The starter system must be in good condition and the battery fully charged 210 Watt 4 Stroke CDI Ignition Voltage Test Connect Meter Wires To Reading With VOM Reading With Peak Rea...

Page 180: ...chematic for connections and specifications Compare results to the specifications on the exploded views Are all within specifications NO Inspect battery condition connectors wiring and grounds to the component in question Replace the component if a wiring problem cannot be found YES Check coil ground connection between engine and coil mount using an ohmmeter The coil mount should have good continu...

Page 181: ...H end Crankshaft bearings Sheared flywheel key Flywheel loose or damaged Excessive crankshaft run out on magneto RH end should not exceed 005 Faulty CDI module MAIN FUSE ASSEMBLY The main fuse assembly is located under the seat and has a 15 amp capacity NOTE Use only the recommended fuse capacity as use of a higher amperage fuse to correct blown fuse situations could lead to electrical component d...

Page 182: ...nually discharge if operated below the Break Even RPM Continued problems would call for battery inspection NO Disconnect the wires leading from the regulator rectifier Using a multi tester perform an Alternator Output AC amp test See test procedure on Page 9 18 for procedure Is output above 5 amps NO Inspect the wiring harness between the panel and the stator for damage If no damage is found remov...

Page 183: ...on into neutral and start the engine If using an ammeter in series start engine with kick start only Turn headlight on high beam and apply the brake light Increase engine RPM while observing ammeter and tachometer Note RPM at which the battery starts to charge ammeter indication is positive With lights and other electrical load off this should occur at approximately 1500 RPM or lower Turn the ligh...

Page 184: ...heck the battery condition and charge accordingly Battery Check 1 Check the date label on the side of the battery to calculate when to check voltage The battery should be checked every 3 months 2 Check the voltage with a voltmeter or multi meter A fully charged battery should be 12 8 V or higher 3 If the voltage is below 12 8 V the battery will need to be recharged New Batteries Batteries must be ...

Page 185: ...y condition before and 1 2 hours after the end of charging WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery Charging Reference Table State of Charge VOLTAGE ACTION CHARGE TIME 100 12 8 13 0V None FULL None Required 75 12 5 12 ...

Page 186: ...only be performed on machines with electric starters It cannot be performed on engine or starting system is not working properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever p...

Page 187: ...it has to check the battery type in the vehicle first Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt me...

Page 188: ...ful to a battery Do not allow cleaning solution or tap water inside the battery Battery life may be reduced CONVENTIONAL BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching p...

Page 189: ...50 Charged 25 Charged 0 Charged 12 60V 12 40V 12 10V 11 8V Less than 12 70V 12 50V 12 20V 12 0V Less than 11 9V SPECIFIC GRAVITY State of charge Conventional lead acid Low Maintenance Type 100 75 Charged 50 Charged 25 Charged 0 Charged 1 265 1 210 1 160 1 120 Less than 1 100 1 275 1 225 1 175 1 135 Less than 1 115 At 28 NOTE Subtract 01 from the specific gravity reading at 0 CONVENTIONAL BATTERY L...

Page 190: ...rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant dielectric grease 4 Connect battery cables To avoid the possibility of explosion connect positive red cable first and negative black cable last 5 After connecting the battery cables install the cover o...

Page 191: ...onnections should not exceed 0 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the chart on next page to perform voltage drop tests on the starter system Voltage Drop should not exceed 0 1 DC volts per connection Use the illustration below when troubleshooting a No Start condition STARTER MOTOR ...

Page 192: ...1 Release the brush coil spring away 2 Push the armature out of case 3 Using an Ohmmeter measure the resistance between the cable terminal and the insulated brush The reading should be 3 ohms or less Measure the resistance between the cable terminal and brush housing Make sure the brush is not touching the case The reading should be infinite no reading 4 Remove the brush plate and brushes Measure ...

Page 193: ... gauge lengthwise 3mm 1 8 above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted and must be replaced 6 Inspect the permanent magnets in starter housing Make sure they are not cracked or separated from housing CAUTION Use care when handling the starter housing Do not drop or strike the housing as magnet damage is possible If the ...

Page 194: ...r button and brake depressed Replace the defective component YES Test starter relay coil by connecting an ohmmeter between the coil leads Resistance should be 3 4 1 Check relay ground path by measuring resistance between the G Y harness wire and battery negative terminal Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the relay end of the battery to...

Page 195: ...stems function Faulty starter relay starter motor Engine problem seized or binding Can engine be rotated easily with recoil starter Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test below Engine problem seized or binding Can engine be rotated easily with recoil starter Faulty or worn brushes in starter motor ...

Page 196: ...ELECTRICAL 9 31 WIRE DIAGRAM ...

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Aeon AT56-69E, Service Manual

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