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Aeon COBRA 400 2012 User Manual

Aeon COBRA 400 2012
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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.

Table of Contents

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Aeon COBRA 400 2012 Specifications

General IconGeneral
BrandAeon
ModelCOBRA 400 2012
CategoryOffroad Vehicle
LanguageEnglish

Summary

Foreword

Understanding Manual Safety Labels and Directions

General Information

Model Information

Details on vehicle identification numbers (VIN) and engine serial number locations.

General Specifications

Technical specifications for the Cobra 400 model, including engine and chassis details.

Conversion Table

Table for converting various units of measure used in the service manual.

Glossary of Terms

Definitions of technical terms and abbreviations used throughout the service manual.

Maintenance

Periodic Maintenance Chart

Overview of inspection, adjustment, and lubrication intervals for regular upkeep.

Pre-Ride - 25 Hour Maintenance Interval

Scheduled maintenance tasks for pre-ride checks and 25-hour intervals.

50 - 300 Hour Maintenance Interval

Scheduled maintenance tasks for 50, 100, 150, 200, 250, and 300-hour intervals.

Standard Torque Specifications

General torque values for common fasteners, with exceptions noted.

Engine Oil and Filter Service

Procedure for changing engine oil and replacing the oil filter.

Brake System

Procedures for inspecting and adjusting brake fluid levels and parking brakes.

CVT System

CVT System Overview

Explanation of the Continuously Variable Transmission (CVT) and its main assemblies.

CVT Overheating/Diagnosis

Troubleshooting guide for CVT system overheating, including possible causes and solutions.

Driven Clutch Service

Procedures for disassembling, inspecting, and assembling the driven clutch.

Drive Clutch Service

Procedures for disassembling, inspecting, and assembling the drive clutch.

Engine

Engine Illustration

Exploded views of engine components, including cam/rock arm and crankcase.

Cooling System

Specifications, pressure testing, and coolant circulation details for the cooling system.

Piston

Information on piston assembly identification, accessible components, and engine removal.

Top-End Disassembly

Procedures for disassembling the engine's top end, including cam chain and camshafts.

Engine Reassembly

Procedures for reassembling engine components after servicing.

Troubleshooting

Common engine problems and their potential causes and solutions.

Transmission

Transmission Assembly

Exploded view and components of the transmission system.

Transmission Disassembly and Inspection

Steps for disassembling and inspecting transmission components.

Transmission Inspection

Inspection procedures for shaft bearings and gear components.

Transmission Reassembly

Step-by-step guide for reassembling the transmission components.

Transmission Trouble Shooting

Common transmission issues like gear engagement, noise, and pops out of gear.

Fuel and Carburetor

Carburetion System

Overview of carburetor function, components, and specifications.

Carburetor Operation

Explanation of how the carburetor operates under various conditions.

Float System

Details on the float system's function in maintaining fuel level.

Carburetor Jetting

Guidelines for selecting and adjusting main jet settings based on conditions.

Carburetor Cleaning

Procedure for cleaning carburetor jets and passages.

Fuel Tank System

Information on the fuel tank, its location, and removal.

Air Cleaner System

Procedures for removing and servicing the air cleaner and dual intake.

Troubleshooting

Common fuel and carburetor issues like lean mixture, rich mixture, and poor idle.

Body / Suspension / Steering

Front Cab Removal

Step-by-step instructions for removing the front cab assembly.

Suspension

Exploded views and removal procedures for front and rear shocks.

Front A-Arm

Procedure for replacing the front A-arm, including wheel and hub removal.

Swing Arm

Procedure for removing the swing arm and associated components.

Steering

Overview of steering components and exploded view.

Handlebar

Installation procedure for the handlebar blocks and related components.

Decal Replacement

Procedure for flame treating and applying decals to plastic body panels.

Brakes

Specifications

Service limits for brake pad thickness, disc thickness, and run out.

Front Brakes

Details on front brake system components and operation.

Front Brake Replacement / Bleeding Procedure

Steps for replacing front brake pads and bleeding the brake system.

Rear / Foot / Parking Brakes

Procedures for rear brake removal, inspection, and fluid replacement.

Brake Troubleshooting

Common brake issues like squeal, poor performance, lever vibration, and brake lock.

Electrical

General Information

Service notes for diagnosing electrical problems and using a multimeter.

Switch Service

Procedures for servicing brake lever switches and transmission switches.

Headlight

Troubleshooting and replacement procedures for headlight operation.

Speedometer and Indicator

Information on the digital speedometer display functions and replacement.

Ignition System Test

Diagnostic flowchart for troubleshooting no spark or intermittent spark conditions.

Charging System

Information on the charging system, including testing and component checks.

Battery

Identification, testing, and maintenance procedures for different battery types.

Starter System

Service and troubleshooting procedures for the starter motor system.

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