A-EON Cobra 220 User manual

AEON MOTOR CO., LTD
SERVICE MANUAL

1
CONTENTS
1. INFORMATION………………………………………... 2
2. MAINTENANCE…………………….………………… 6
3. ENGINE REMOVALAND INSTALLATION………… 17
4. LUBRICATION…………………………………………19
5. CYLINDER HEAD / VALVES……………………….. 29
6. CYLINDER & PISTON………………………………... 40
7. TRANSMISSION & KICKSTARTER………………… 49
8. FRONT WHEEL, SUSPENSION AND STEERING….. 61
9. REAR WHEEL SYSTEM……………………………… 80
10. FENDERS AND EXHAUST PIPE…………………….. 91
11. ELECTRICAL SYSTEM………………………………. 94
12. TROUBLE SHOOTING……………………………….. 100

2
1. INFORMATION
1.1 Safety
1.2 Notes
1.3 Specifications
1.4 Serial number
1.5 Torque valve
1.1 SAFETY
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or
allow sparks or flames in your work area.
CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas
that may cause loss of consciousness and lead to death.
BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you come
into contact with the electrolyte, flush the area thoroughly with water. If you get the electrolyte
in your eyes, flush with water and contact a doctor immediately.
HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run.
Wear insulated gloves before handling these parts.
USED ENGINE /GEAR OIL
Used engine oil and gear oil may cause skin disease after repeated contact with the skin for
long periods. Keep out of reach of children.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are base
on the latest product information available at the time of approval for printing.
No part of this publication may be reproduced without written permission.

3
1.3 SPECIFICATION
ENGINE Type
Displacement
BoreandStroke
Compression
MaximumTorque
Carburetor
Ignition
Starting
Lubrication
Air Cleaner
Transmission
CHASSIS Overall Length
Overall Width
Overall Height
Seat Height
Wheel Base
Ground Clearance
Dry Weight
Fuel Tank Capacity
SUSPENSION Front
Rear
BRAKES Front
Rear
TIRES Front
Rear
*Specifications subject to change without notice.
Air-cooled 4-stroke , vertical
cylinder
195.8 cc
65×59mm
9.6:1
1.45 N-m @ 5000 rpm
Mikuni
C.D.I Electronic
Electrical & Kick-Start
Wet Sump
AE-9
Automatic(C.V.T sysetm with
reverse gear)
68.5 inches (1740mm)
41.3 inches (1050mm)
49.6 inches (1260mm)
31.1 inches (790mm)
44.9 inches (1140mm)
7.0 inches (178mm)
175kg (385.8lb)
8.5 liter
Double Wishbone
Swing Arm
Disc
Disc
21” × 7” - 10”
20” × 10” - 9”

4
1.4 SERIAL NUMBER
The frame serial number is stamped on the front frame.
And stick a bar code paper to cover it.
The engine number is stamped under the crankcase.

5
1.5 TORQUE VALVES
STANDARD
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
ENGINE
Cylinder head nut
Spark plug
Cylinder head bolt
Alternator bolt
FRAME
Handlebar upper holder bolt
Throttle housing cover screw
Steering shaft nut
Steering shaft holder bolt
Wheel rim bolt
Tie rod lock nut
Handlebar lower holder nut
Front wheel bolt
Front axle nut
Front brake arm nut
Rear brake arm nut
Rear axle nut
Rear wheel bolt
Exhaust muffler mounting bolt
Engine hanger bolt
Rear axle holder bolt
Swing arm pivot nut
Rear shock absorber mounting nut
5 N.m (3.5 lbs.ft)
10 N.m (7.2 lbs.ft)
22 N.m (16 lbs.ft)
35 N.m (25 lbs.ft)
55 N.m (40 lbs.ft)
18~22 N.m (13~16 lbs.ft)
12~14 N.m (9~11 lbs.ft)
7~9 N.m (5~7 lbs.ft)
8 N.m (5.9 lbs.ft)
24 N.m (17.7 lbs.ft)
4 N.m (2.9 lbs.ft)
50 N.m (36.9 lbs.ft)
33 N.m (24 lbs.ft)
18 N.m (13.3 lbs.ft)
35 N.m (25.8 lbs.ft)
40 N.m (29.5 lbs.ft)
24 N.m (17.7 lbs.ft)
60 N.m (44 lbs.ft)
4 N.m (3.0 lbs.ft)
7 N.m (5.2 lbs.ft)
60 N.m (44.3 lbs.ft)
24 N.m (17.7 lbs.ft)
30 N.m (22.1 lbs.ft)
30 N.m (22 lbs.ft)
90 N.m (65 lbs.ft)
90 N.m (65 lbs.ft)
45 N.m (33 lbs.ft)

6
2. Maintenance
2.1 Maintenance data
2.2 Maintenance schedule
2.3 Throttle operation
2.4 Air cleaner maintenance
2.5 Spark plug
2.6 Idle speed setting
2.7 Drive chain adjustment
2.8 Brake system adjustment
2.9 Wheels and tires
2.10 Steering system
2.11 Toe-alignment
2.12 Transmission lubrication
2.1 MAINTENANCE DATA
SPECIFICATION
SPARKPLUG
Spark plug cap
Recommended spark plugs
Throttle lever free play:
Idle speed
Brake lever free play:
Drive chain slack
Front/rear tire size
Front/rear tire pressure
Toe-in
TORQUE VALVES
SPARK PLUG
TIE-ROD LOCK NUT
ENGINE OIL
Viscosity:
GEAR LUBRICATION OIL
Viscosity:
0.6-0.7mm
N
GK CR7HSA
5-10mm
1500±100rpm
10~20mm
15-25mm
21×7-10 / 20×10-9
4±0.3psi (0.2 kgf/cm2)
5±10mm
12-14 N.m
35-43 N.m
SAE 15W-40
SAE 85W-140

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2.2 MAINTENANCE SCHEDULE
The maintenance intervals in the follow table is based upon average riding, condition. Riding
In usually dusty areas, require more frequent servicing.
Maintenance Interval
(whichever comes first)
Item
Hours Calender Miles(Km)
Remarks
◆
E Engine breather filter (if equipped) 25H 6 M 250 (400) Inspect; replace if necessary
Engine breather
hose 100H 3 M 1000 (1600) Inspect
◆General
lubrication 50H 6 M 500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 50H 6 M 500 (800) Inspect, lubricate, adjust
◆
■Steering 50H 6 M 500 (800) Inspect daily, Lubricate
◆Front suspension 50H 6 M 500 (800) Inspect, lubricate, Tighten
Fasteners
◆Rear suspension 50H 6 M 500 (800) Inspect, lubricate, Tighten
Fasteners
Carburetor float
bowel 50H 6 M 500 (800) Drain bowel periodically and prior to storage
■
E Throttle Cable/ETC
Switch
50H 6 M 500 (800) Inspect; adjust; lubricate; replace
if necessary
■
E Choke cable 50H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary
E Carburetor air
intake
ducts/flange
50H 6 M 500 (800) Inspect ducts for proper sealing/air
leaks
Drive belt 100H 12 M 1000
(1600) Inspect; adjust; replace as needed
Cooling system
(if applicable) 50H 6 M 500 (800) Inspect coolant strength seasonally; pressure test system
yearly
◆
E Engine oil change *Severe Duty
**Normal Duty
25H
50H
6 M
12 M
500 (800)
1000
(1600)
Perform a break-in oil change at
25 hours/one month, change more
frequently during cold weather
◆
E Engine oil change *Severe Duty
**Normal Duty
25H
50H
6 M
12 M
500 (800)
1000
(1600)
Replace at oil change
◆
E Oil filter change 100H 6 M 1000 (1600) Replace with oil change
◆
E Valve clearance 100H 12 M 1000 (1600) Inspect; adjust
◆Perform these procedures more often for vehicles
subjected to severe use.
EEmission Control System Service (California)
■ Have an authorized Polaris dealer perform these services.

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Maintenance Interval
(whichever comes first)
Item
Hours Calender Miles(Km)
Remarks
■
E Fuel system 100H 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter, pump,
carburetor; replace lines every two
years
■
E Fuel filter 100H 12 M 1000 (1600) Replace yearly
◆Radiator
(if applicable) 100H 12 M 1000 (1600) Inspect; clean external surfaces
◆Cooling hoses
(if applicable) 100H 12 M 1000 (1600) Inspect for leaks
◆Engine mounts 100H 12 M 1000
(1600) Inspect
Exhaust
muffler/pipe 100H 12 M 1000 (1600) Inspect
■
E Spark plug 100H 12 M 1000 (1600) Inspect; replace as needed
■
E Ignition Timing 100H 12 M 1000 (1600) Inspect
◆
Wiring 100H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to
connectors subjected to wear,
mud, etc.
■Clutches (drive and
driven) 100H 12 M 1000 (1600) Inspect; clean; replace worn parts
■Front wheel
bearings 100H 12 M 1000 (1600) Inspect; replace as needed
■Brake fluid 200H 24 M 2000
(3200) Change every two years
Spark arrestor 300H 36 M 3000
(4800) Clean out
E Idle speed Adjust as
needed
■Toe adjustment Inspect
periodically;
adjust when
parts are
replaced
◆
■Auxiliary brake Pre-Ride Inspect daily; adjust
as needed
Headlight aim Adjust as
needed
◆Perform these procedures more often for vehicles
subjected to severe use.
EEmission Control System Service (California)
■Have an authorized Polaris dealer perform these services.

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2.3 THROTTLE OPERATION
Inspect for smooth lever operation, full opening
and automatic full closing in steering positions.
Inspect for deterioration, damage, cuts and
nicks, or kink in the throttle cable, replace it if
necessary.
Check the throttle lever, free play should be
not more than 5-10 mm at the tip of the
throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially
lubricant to prevent premature wear.

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2.4 AIR CLEANER MAINTENANCE
(1) Lift up on the rear of the seat.
(2) Pull the seat back and free of the tabs.
NOTE: When reinstalling seat, make sure
the slots in the seat engage the tabs in the
fuel tank.
(3) Remove clips from air box cover (A) and
remove cover. Inspect the gasket. It should
adhere tightly to the cover and seal all the
way around.
(4) Install the new one.
(5) Reinstall filter on main filter mount. Place
filter clamp over the assembly and tighten.
NOTE: Apply a small amount of general
purpose grease to the sealing edges of the filter
before reinstalling.

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IDLE SPEED
2.5 SPARK PLUG
The spark plug is located at the front of the
engine.
(1) Disconnect the spark plug cap and remove
The spark plug
(2) Visually inspect the spark plug electrodes
For wear or cranks in insulator. Replace if
needed.
(3) The center electrodes should have square
edges and the side electrodes should have a
constant thickness.
(4) Discard the spark plug if there is apparent
wear or if the insulator is cracked or
chipped.
(5) Measure the gap with a wire-type feeler
gauge and adjust if necessary by carefully
bending the side electrode.
SPARK PLUG GAP: 0.6~0.7 mm
RECOMMENDED REPLACEMENT PLUG:
NGK CR7HSA
(6) Check the sealing washer and replace with a
new one if damaged.
(7) With the sealing washer attached thread the
spark plug in by hand to prevent cross
threading. Tighten the spark plug. TORQUE:
12-14 N-m
2.6 IDLE SPEED SETTING
(1) Inspect and adjust the idle speed after all
other engine maintenance items have been
performed and are within specifications.
The engine must be warm for accurate idle
speed inspection and adjustment.
(2) Warm up the engine for about ten minutes
and connect a tachometer.
(3) Turn the throttle stop screw as required to
obtain the specified idle speed.
IDLE SPEED: 1500 ± 100 rpm

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2.7 DRIVE CHAIN ADJUSTMENT
Stop ATV and shift transmission into neutral.
Inspect the chain slack midway between the
sprockets. The standard is 10-25 mm (5/8-1
inch).
If needed remove the chain protective cover
and adjust the chain slack.
Loosen the axle holder lock nut then adjust the
drive chain slack by turning the adjusting nut.
Tighten the axle holder lock nut.
Torque = 90N.m (65 Ft. lbs)
When the drive chain becomes very dirty, it
should be removed, cleaned and lubricated with
the specified lubricant.
Clean the drive chain with kerosene and wipe it
dry.
Inspect the drive chain for possible wear or
damage.
Replace the chain, if it is worn excessively or
damaged.
Inspect the sprocket teeth, if it has excessive
wear or damage, replace if needed.
Use a commercial chain lubricant to lubricate
the drive chain, replace and adjust the slack as
described above.

13
2.8 BRAKE SYSTEM ADJUSTMENT
Inspect the front brake lever and cable for
excessive play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the
end of the lever. The standard is 10~20 mm.
Adjust the free play of the front brake lever by
turning the adjuster on the brake lever
assembly.
Inspect the rear brake lever and cable for
excessive play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the
end of the lever. The standard is 10-20 mm.
Adjust the free play of the rear brake lever by
turning the adjuster on the rear axle.

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2.9 WHEELS AND TIRES
Inspect the tire surface for cuts, nails or other
sharp objects.
Check the tire pressure at cold tire conditions.
The standard tire pressure is 4psi.
(0.28kgf/cm2 )
2.10 STEERING SYSTEM
Check the free play of the steering shaft with
the front wheels, turned straight ahead. When
there is excessive play, inspect the tie-rod,
kingpin bushing and ball joint.
Steering shaft holder bushing
Remove the front fender.
Remove the steering shaft holder and check the
steering shaft bushing for wears or damage.
If the bushing is worn or damaged, change a
new one.
Grease the steering shaft bushing and install the
parts in the reverse order of removal.
Torque: steering shaft holder bolt: 33N.m (24
Ft. lbs)

15
2.11 TOE-ALIGNMENT
1. Place machine on a smooth level surface.
2. Set handlebars in a straight ahead position
and secure handlebars in this position.
NOTE: The steering arm can be used as an
indicator of whether the handlebars are
straight. The arm should always point
straight back from the steering post.
3. Place a chalk mark on the center line of the
front tires approximately10” (25.4cm) 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°by moving vehicle
forward or backward. Position chalk marks
facing rearward, even with the hub/axle
centerline.
6. Again measure the distance between the marks
and record. Call this measurement “B”.
Subtract measurement “B” from
measurement “A”. The difference between
measurements “A” and “B” is the
vehicle toe alignment. The recommended
vehicle toe tolerance is 1/8” to 1/4” (0.3 to
0.6 cm) toe out. This means the measurement
at the front of the tire (A) is 1/8” to 1/4”
(0.3 to 0.6 cm) wider than the measurement at
the rear (B).

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2.12 TRANSMISSION LUBRICATION
Transmission fluid needs to be changed every
400 km.
There is a gear oil drain hole bolt at the rear of
the engine.
(STEP1)
Place a drain pan beneath oil pan and remove
drain plug from the crankcase.Allow oil to
drain completely.
(STEP2)
Reinstall the drain plug. Tighten to
specification.
(STEP3)
Add the proper amount of lubricant to bring
level into operating range as shown. Do not
over fill.
(STEP4)
Verify fluid level is correct and no leaks are
present.

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3 ENGINE REMOVALS AND INSTALLATION
3.1 ENGINE REMOVAL
3.2 ENGINE REPLACEMENT
ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY
REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM
ONLY!
3.1 ENGINE REMOVAL
1. Clean work area.
2. Thoroughly clean the ATV engine and
chassis.
3. Disconnect battery cables.
4. Drain engine oil.
5. Disconnect spark plug high tension lead.
6. Disconnect all electrical wires from the
engine.
7. Remove the following parts as required.
 Seat
 Left and Right Side Covers
 Fuel Tank Cover / Front Cab
 Fuel Tank
8. Remove exhaust pipe.
9. Remove airbox.
10. Remove carburetor. Insert a clean shop towel
into the carburetor flange to prevent dirt
from entering the intake port.
11. Starter motor. Note ground cable location.
Mark positive (+) cable mounting angle and
remove cable.
12. Remove transmission link rod(s) from gear
selector and secure out of the way.
13. Remove engine to chassis ground cable.
14. Remove the swing arm and drive shaft
assemblies.
15. Remove all engine mount nuts and / or
engine mount plates.
16. Remove engine through left side of frame.

18
3.2 ENGINE REPLACEMENT
Engine installation is essentially the reverse
order of removal.
The torque of engine hanger bolt is 30 Nm
Route the wires and cable properly in reverse
order of removal.

19
4. LUBRICATION
4.1 Service Information
4.2 Trouble Shooting
4.3 Engine Oil Level
4.4 Engine Oil & Filter Change
4.5 Oil Pump Removal /Installation
4.1 SERVICE INFORMATION
GENERAL
This section describes inspection and replacement of the engine oil, oil filter screen and
assembly of the oil pump.
Fill the oil pump with clean oil when reassembling the pump.
SPECIFICATIONS
Engine Oil Capacity 0.8-1.0 Liters /
Engine Oil Recommendations Viscosity: (SAE 15W-40)
API Service classification: SF-SG
OILPUMP STANDARD SERVIC LIMIT
Cover-to-rotor clearance --------- 0.12
Rotor tip clearance -------- 0.12
End clearance 0.01-0.10 0.2
TORQUE VALUE
Oil Drain Bolt 14 ft. lbs. (19 Nm)