A-EON COBRA 400 2012 User manual

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.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander
or person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
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 disassembly, assembly and inspection of components.

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

GENERAL INFORMATION
1-1
CHAPTER 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

GENERAL INFORMATION
1-2
MODEL INFORMATION
VIN IDENTIFICATION
The frame can be found under front cab on the right 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.

GENERAL INFORMATION
1-3
COBRA 400
Model---AT56-69E
Model Number---RF3RA56XXCTXXXXXX
Engine Model---V69C

GENERAL INFORMATION
1-4
SPECIFICATIONS MODEL: COBRA 400
ENGINE DRIVE SYSTEM
Type 4 Stroke, Single horizontal camshaft Oil capacity/ type 900 CC/ 80w90
Displacement 346.4 CC Transmission selection Forward, Neutral, Reverse
Cooling Liquid cooled Clutch type Centrifugal clutch
Bore and stroke 82 mm *65.6 mm Final drive Chain
Compression ratio 10.6: 1 Forward gear ratio 17/45* 30/47
Number of valve 2 Rocker arm activated Reverse gear ratio 17/49* 21/37* 30/47
Inlet valve Ø Ø 29.00mm Rear Sprocket ratio 15/36
Inlet valve clearance 0.10mm CHASSIS
Exhaust valve Ø Ø 25.00mm Frame Steel
Exhaust valve clearance 0.12mm Front suspension Duel shock with double wishbone
Lubrication Wet sump and pump pressurized Rear suspension Single shock with swing Arm
Recommended oil 0W/ 40 Front brake Duel disc with single bore caliper
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 NJDB Overall width 1150 mm
Idle RPM 1500±100 rpm Overall height 1160 mm
Needle Jet 38 Seat height
790 mm
Air screw 1.5 Turn Wheelbase 1040 mm
ENG. ELECTRICAL Max. Permissible weight
173 Kg
Charging system Alternator and voltage regulator Number of passenger 2
Alternator output 176W@5000RPM Min. ground clearance 170 mm
Ignition type CDI Dry weight 207 Kg
Spark plug type NGK/ CR8E Front track 930 mm
Spark plug gap 0.8~0.9mm Rear track 1020 mm
RPM limiter setting 8500 rpm Fuel tank capacity 9.3 Liter
Battery type GTX12-BS Max. Speed 97 Km/hr
Fuse type Charge 30A/ Main 15A/
Light 10A/ Spare 15A
CONVERSION TABLE

GENERAL INFORMATION
1-5
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 = mm
Mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
Km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = 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 (US gal)
Pounds - force per square inch x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square x 98.1 = Kilopascals (kPa)
P (3.14) xR2x H (height) = Cylinder Volume
°C to °F:
9/5 (°C + 32) = °F
°F to °C: 5/9 (°F - 32) = °C
Glossary Of Terms
ABDC: After bottom dead center.

GENERAL INFORMATION
1-6
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and
grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V
blocks or resting in crankcase. Measure at various points especially at PTO.
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder-measuring instrument, 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 which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Weight unit in the metric system.
gal.: Gallon.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
kg/cm2: Kilograms per square centimeter.
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in2: Pounds per square inch.
Left or Right Side: Always referred to base on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical
energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Length unit in the metric system. 1 mm = approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.

GENERAL INFORMATION
1-7
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, it means friction or load. In the electrical sense, it means ohms, resulting in 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 center. Piston is most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide-open throttle.

MAINTENANCE
2-1
CHAPTER 2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
50 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
GENERAL VEHICLE INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
RE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
MAINTENANCE QUICK CHART (SIDE / FRONT / REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
RECOIL STARTER AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
DRIVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
COOLANT DRAIN/ RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

MAINTENANCE
2-2
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
BATTERY MAINTENANCE . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
BATTERY OFF SEASONSTORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
BATTERY CHARGING (SEALED BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
FUSES / FUSE HOLDER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
ENGINE/ FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
STEERING AND 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
WHEEL INSTALLATION - FRONT / REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
TIRE NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .2.31

MAINTENANCE
2-3
PERIODIC MAINTENANCE CHART
PERIODIC MAINTENANCE OVERVIEW
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and
lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use
genuine Polaris parts available from your dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average
vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequency.
Severe Use Definition
• Frequently immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants 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 more efficient performance and longer life for these components.
• Drive the vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform the regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key
The following symbols denote potential items to be aware of during maintenance:
■ = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by
authorized AEON dealer.
◆ = SEVERE USE ITEM -- See Above
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Aeon parts.
Improperly performing the procedures marked with a
■
could
result in component failure and lead to
serious injury or death.
Have an authorized AEON
dealer perform these services.

MAINTENANCE
2-4
PRE-RIDE - 25 HOURS MAINTENANCE INTERVAL
Periodic Maintenance Chart
Item
Maintenance Interval
(Whichever comes first) Remarks
Hours Calendar Km
◆Front- Suspension - Pre-Ride - Make adjustments as needed.
◆Rear- Suspension - Pre-Ride - Make adjustments as needed.
Tire - Pre-Ride - Make adjustments as needed.
Brake fluid lever Pre-Ride Make adjustments as needed.
■Brake Pedal Travel Pre-Ride Make adjustments as needed.
Brake system - Pre-Ride - Check Operation
Wheels/ Fasteners - Pre-Ride - Make adjustments as needed.
Frame fasteners - Pre-Ride - Make adjustments as needed.
◆Engine oil lever - Pre-Ride - Make adjustments as needed.
Air filter - Pre-Ride - Inspect; clean often, replace as
needed.
■Coolant lever - Pre-Ride - Inspect coolant lever.
◆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 operation.
■
◆
Engine oil change * Severe duty
**Normal Duty
25H
50H
Monthly
12M
500
1000
Inspect level; change yearly;
Perform a break-in oil change at
25 hours, change more frequently
during cold weather
■Radiator 25H
50H
Monthly
12M
500
1000
Inspect external surface; change
coolant
Perform a break-in oil change at
25 hours,
◆Oil pre-filter screen 50H 12M 1000 Clean filter at every oil change;
■Perform these procedures more often for vehicles subjected to severe use.
◆Have an authorized AEON dealer perform these services.

MAINTENANCE
2-5
50 - 300 HOUR MAINTENANCE INTERVAL
Periodic Maintenance Chart
Item
Maintenance Interval
(Whichever comes first) Remarks
Hours Calendar Km
◆General lubrication 50H 3M 800 Lubricate all grease fittings,
pivots, & cables.
■Carburetor float bowl 50H 6M 800 Drain bowl periodically and prior
to storage.
■Throttle cable 50H 6M 800 Inspect; adjust; lubricate; replace
if necessary.
■Choke cable 50H 6M 800 Inspect; adjust; lubricate; replace
if necessary.
◆Carburetor intake flange 50H 6M 800 Inspect for proper sealing / air
leaks.
■Brake pads wear 50H 6M 800 Inspect; replace as needed.
■Drive belt 50H 6M 800 Inspect; replace as needed.
Shift linkage & cable 50H 6M 800 Inspect; adjust; lubricate; replace
if necessary.
◆Front suspension 50H 6M 800 Inspect; lubricate; tighten
fasteners.
◆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,
security; apply dielectric grease
to connectors subjected to water,
mud, etc.
■Clutch (drive & driven) 100H 12M 1500 Inspect; clean; replace worn
parts.
■Front wheel bearings 100H 12M 1500 Inspect; replace as needed.
◆Valve clearance 100H 12M 1500 Inspect; adjust.
◆Ignition timing 100H 12M 1500 Inspect
◆Brake fluid 100H 12M 1500 Change every two years.
■Toe adjustment - - - Inspect periodically; adjust when
parts are replaced.
Headlight Aim Adjust as needed
■Perform these procedures more often for vehicles subjected to severe use.
◆Have an authorized Aeon dealer perform these services.

MAINTENANCE
2-6
GENERAL VEHICLE INSPECTION AND MAINTENANCE
PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when
servicing the vehicle at each scheduled maintenance
• Tires - check condition and tire pressure
• Fuel and oil - fill both to their proper level; do 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 vehicle for any damaged or
loose nuts, bolts or fasteners
MAINTENANCE QUICK CHART (SIDE)

MAINTENANCE
2-7
MAINTENANCE QUICK REFERENCE
Item Comment Method Frequency
1 Engine Oil OW-50 Synthetic
20W-40 Semi-Synthetic
Check level or
change oil Check during pre-ride inspection change oil every 30 hours or 6 months.
2 Transmission SAE80W-90 Gear
Lubricant Check level or change lube. Inspect periodically and change lubrication every 40 hours or annually.
More often in severe use.
3 Brake Fluid DOT-4 Brake Fluid Fill master cylinder
reservoir to indicated
lever inside reservoir.
As require. Change fluid every 2 years.
4 Radiator Coolant 50% Glycol with 50%
Water Fill Ext. tank to indicated lever. Check Exe. Tank lever pre-ride. Change coolant yearly.
5 Front Suspension
A-Arm and Spindle)
Premium All Season
Grease Inspect; tighten fasteners; grease
zerks
Every 3 months or 50 hours (also after
washing SxS or driving in water). 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, suspension, and
engine areas. Always consult the exploded views in each manual section when available for torque values of fasteners before
using standard torque.
Standard Fastener Torques
Thread Size Torque (ft. lbs. / in. lbs.) Torque (Nm)
5 mm bolts and nuts 39-52 in. lbs. 4.5-6 Nm
6 mm bolt and nuts 69-104 in. lbs. 8-12 Nm
8 mm bolts and nuts 13-18 ft. lbs. 18-25 Nm
10 mm bolts and nuts 22-29 ft. lbs. 30-40 Nm
12 mm bolts and nuts 36-43 ft. lbs. 50-60 Nm
4 mm screws 22-30 in. lbs. 2.5-3.4 Nm
5 mm screws 30-43 in. lbs. 3.5-5 Nm
6 mm Hex bolts 87-121 in. lbs. 10-14 Nm
8 mm Hex bolts 17-22 ft. lbs. 24-30 Nm
10 mm Hex bolts 25-32 ft. lbs. 35-45 Nm

MAINTENANCE
2-8
RE-COIL OIL STARTER AND OPERATION
If the battery becomes too weak to start the engine, use the
re-coil starter to start the engine until the battery is serviced.
1. Position the vehicle on a level surface.
2. Shift the transmission into neutral (if equipped).
3. Lock the parking brake.
4. Push the engine stop switch up to the RUN position.
5. Turn the key ON.
6. Pull the re-coil to crank the engine.
THROTTLE INSPECTION
If the throttle has excessive play due to cable stretch or cable
maladjustment, it will cause a delay in throttle speed. Also, the
throttle may not open fully. If the throttle lever has no play, the
throttle may be hard to control, and the idle speed may be erratic.
Check the throttle free play periodically in accordance with the
Periodic Maintenance Chart 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 cable adjuster.
2. Loosen the adjuster lock nut.
3. Rotate the boot to turn the adjuster until 1.5 - 3 mm (1/16" to
1/8") of free play is achieved at the throttle pedal.
NOTE: While adjusting, lightly flip the throttle pedal up
and down.
4. Tighten the lock nut.
5. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.
Adjusting The Speed Limiter
The speed limiter keeps the carburetor throttle from becoming
fully opened even when the throttle lever is applied to the
maximum position.
Screwing in the adjuster stops the engine speed from increasing.

MAINTENANCE
2-9
FUEL SYSTEM AND AIR INTAKE
IDLE SPEED ADJUSTMENT
1. Start engine and warm it up thoroughly.
2. Adjust idle speed by turning the slide adjustment screw in
(clockwise) to increase or out (counterclockwise) to decrease
RPM. (Refer to illustration).
Idle Speed
1500 ± 100 r.p.m.
NOTE: Adjusting the idle speed affects throttle cable
free play. Always check throttle cable free play after
adjusting idle speed and adjust if necessary.
Fuel Line
1. Check the quick-connect fuel line for signs of wear,
deterioration, damage or leakage. Replace if necessary.
2. Be sure fuel line is routed properly.
IMPORTANT: Make sure line is not kinked or pinched.
3. Replace fuel line every two years.
Vent Lines
1. Check fuel tank, front gear case, and rear gear case and
transmission vent lines for signs of wear, deterioration,
damage or leakage. Replace every two years.
2. Be sure vent lines are routed properly and secured with
cable ties.
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 or sparks in or
near the area where refueling is performed or where
gasoline is stored.
. Do not overfill the tank.
. Fill the tank to the bottom of the filler neck.
. This will allow for thermal expansion.
. If you get gasoline in your eyes or swallow
gasoline, see your doctor immediately.
. If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
. Never start the engine or run it in an enclosed area
Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness
and death in a short time.

MAINTENANCE
2-10
FUEL FILTER
The fuel filter should be replaced in accordance with the
“Periodic Maintenance Chart” or whenever sediment is
visible in the filter.
Fuel Filter Location - Located in-line between fuel
tank and fuel pump under seat.
Fuel Filter Service
1. Shut off fuel supply at fuel tank and fuel pump.
2.Remove line clamps at both ends of the filter.
3. Replace new filter and clamps onto fuel lines.
4. Release both side fuel lines.
5. Start engine and inspect for leaks.
CARBURETOR DRAINING
The carburetor float bowl should be drained periodically to
remove accumulated moisture or sediment from the bowl, or
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 inspection. In extremely dusty conditions, air filter
replacement will be required more often.
The filter should be inspected using the following procedure.
Remove
1. The air cleaner is located under the dump box.
2. Release the air box cover spring clips and remove the cover.
3. Remove the foam air filter. Wash the foam filter in warm
soapy water, then rinse and let it dry. If the filter is damaged,
install a new foam filter.