Aeon 180 Service Manual

Kolpin Powersports 180cc Service Manual

8 FIG-02. Vehicle Inspection FUEL TUBE Inspect the fuel lines for deterioration, (a-1) damage or leakage and replace if necessary. (Photo 1) THROT

9 FIG-02. Vehicle Inspection SPARK PLUG The spark plug is located at the front of the engine. 1. Disconnect the spark plug cap and remove the spark p

10 FIG-02. Vehicle Inspection DRIVE CHAIN ADJUSTMENT Stop ATV and shift transmission into neutral. Inspect the chain slack midway between the sprocke

11 FIG-02. Vehicle Inspection FRONT BRAKE ADJUSTMANT The front brake has two cables to control right and left side brake simultaneously. You could ad

12 FIG-02. Vehicle Inspection REAR BRAKE ADJUSTMENT Remove the rear brake locking nut set and the brake cylinder mounting bolts (a-1) (Photo 17) The

13 FIG-02. Vehicle Inspection REAR BRAKE FLUID REFILLING METHOD 1. Remove the oil tank cover (a-1). 2. Refill with the recommended DOT-3 brake fluid

14 FIG-02. Vehicle Inspection FRONT SUSPENSION 1. Check the R. and L. side suspension, the front suspension should be adjusted to the same preload (a-

15 FIG-02. Vehicle Inspection STEERING SYSTEM Check the free play of the steering shaft with the front wheels turned straight ahead. When there is exc

16 FIG-02. Vehicle Inspection GEAR OIL MAINTENANCE Gear oil needs to be changed every 200 hours. There is a gear oil drain hole bolt at the rear of th

17 0.6~0.7 mm

CONTENTS FIG.-01 INFORMATION.……………………….……………. ……………………………… 1 FIG.-02 VEHICLE INSPECTION…………………………... ……………………………… 6 FIG.-03 OVERVIEW…………………………………

18 FIG-03. Overview Parts Description 11. MAIN SWITCH ASS'Y 12. NEUTRAL INDICATOR 13. REVERSE INDICATOR 14. FUEL GAUGE AS

19 FIG-04. Fender BUMPER Loosen the bolts (a-1) and Remove the bumper (a-2) from the frame body (Photo 1) FRONT METAL RACK Loosen the bolts (a-1) a

20 FIG-04. Fender FRONT FENDER COVER Loosen the screws (a-1) Remove the front fender cover (a-2) (Photo 4) BUMPER COVER Loosen the screws (a-1) Loose

21 FIG-04. Fender FOOTREST Loosen the bolts (a-1) Remove the footrest ass’y (a-2) (Photo 10) Note: Refer to the preceding disassembly instructions fo

22 FIG-05. Fuel & Oil Tank FUEL TANK Loosen the bolts (a-1) Take off the main wire connect with the fuel gauge wire (a-2) Loosen the bolts (a-3)

23 FIG-06. Muffler MUFFLER Loosen the bolts (a-1) and make it connected to the cylinder (a-2). (Photo 13) CAUTION 1. The muffler is hot during operat

24 FIG-07. HANDLEBAR HANDLE BAR COVER Loosen the screws (a-1) Remove the head light cover (a-2) Take off the main wire connect with the head light wir

25 FIG-07. HANDLEBAR REAR BRAKE CABLE Remove the rear brake cable (a-1) (Photo 18) FRONT BRAKE CABLE Remove the R. and L. front brake cable (a-1) (

26 FIG-08. Engine Disassembly DRIVE CHAIN ASS'Y Take off the chain master link set (a-1) Remove the drive chain (a-2) (Photo 23) TRANSMISSION AS

27 FIG-09. Tire and Rim FRONT WHEEL ASS’Y Take off the rubber cap (a-1) and cotter pin (a-2) Loosen the insert lock nut (a-3) Remove the washer (a-4)

1 FIG-01 INFORMATION SAFETY GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames

28 FIG-10. Front Brake BRAKE SYSTEM Brake Parts & Location .

29 FIG-10. Front Brake FRONT BRAKE PLATE ASS'Y Remove the front brake cable (a-1) with the front brake arm put in the up side hole (a-2). Remove

30 FIG-11. Rear Brake MASTER CYLINDER SUB Brake fluid level must be below the maximum level Fill with fluid when the level is below the “min” line (

31 FIG-11. Rear Brake RIGHT FOOTWELL BOTTOM BOARD Loosen the bolts (a-1) Remove the right footwell bottom board (a-2) (Photo 41) REAR BRAKE CABLE FI

32 FIG-12. Suspension FRONT SUSPENSION The front suspension is mounted on the frame (a-1) and suspension arm (a-2). Loosen the bolts (a-3) and nut

33 FIG-13. Suspension Arm KNUCKLE Take off the cotter pin (a-1) Loosen the nut (a-2) Remove the steering tie-rod ass’y (a-3) (Photo 49) Take off the

34 FIG-14. Rear Axle Ass’y PROTECTIVE COVER Loosen the bolts (a-1) Remove the protective cover (a-2) (Photo 52) REAR AXLE Loosen the nuts (a-1) Remov

35 FIG-15. Steering Shaft STEERING SHAFT Turn on the spring washer (a-1) Loosen the bolts (a-2) Remove the spring washer (a-3) and cable fix seat (a

36 FIG-16. Frame Comp FRAME COMP Take off the o-ring (a-1) Remove the steering bearing seat (a-2) (Photo 58) Note: Refer to the preceding disassembly

37 FIG-17. Light HEAD LIGHT ASS’Y Loosen the screws (a-1) Remove the head light ass’y (a-2) (Photo 59) Turn off the light cover (a-1) Remove th

2 FIG-01 INFORMATION SPECIFICATIONS TYPE OVERLAND – 180CC ENGINE TYPE Air-Cooled 4-stroke, with Oil Cooler, Horizontal Stroke CYLINDER NUMBER 1 DISPL

38 0.6~0.7 mm

39 FIG-18. Engine Disassembly ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SY

40 FIG-18. Engine Disassembly LUBRICATION SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter

41 FIG-18. Engine Disassembly LUBRICATION ENGINE OIL LEVEL Place the engine on the level plane. Check the oil level with the oil level gauge, but do

42 FIG-18. Engine Disassembly LUBRICATION ENGINE OIL & FILTER CHANGE Remove the oil filter cap and the oil drain bolt. (a-1) (Photo 3) NOTE: drai

43 FIG-18. Engine Disassembly OIL PUMP REMOVAL FAN COVER ASS’Y Loosen the screw (a-1), Remove the fan cover ass’y (a-2), (Photo 6) FAN Loosen the scr

44 FIG-18. Engine Disassembly OIL PUMP REMOVAL OIL PUMP Loosen the bolts (a-1) Remove the oil separator. (a-2) (Photo 11) Remove the oil pump chain (

45 FIG-18. Engine Disassembly OIL PUMP REMOVAL DISASSEMBLE THE OIL PUMP INSPECTION Measure the oil pump rotor-to-body clearance. (Photo 14,15) SERVICE

46 FIG-18. Engine Disassembly CYLINDER HEAD / VALVES SERVICE INFORMATION GENERAL This section describes the maintenance of cylinder head, valves, cams

47 FIG-18. Engine Disassembly CYLINDER HEAD / VALVES TROUBLE SHOOTING Engine top-end problems usually affect engine performance. These problems can be

3 FIG-01 INFORMATION SERIAL NUMBER The frame serial number is stamped on the front frame. The engine number is stamped under the crankcase.

48 FIG-18. Engine Disassembly CYLINDER HEAD / VALVES CYLINDER HEAD ASS’Y REMOVAL SHROUD ASS’Y Loosen the bolts (a-1) Remove the carburetor overflow tu

49 FIG-18. Engine Disassembly CAMSHAFT COMP INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage. (a-1) (Photo 24) SER

50 FIG-18. Engine Disassembly CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head (Photo 29) Remove the cylinder head gasket and dowel

51 FIG-18. Engine Disassembly CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor.

52 FIG-18. Engine Disassembly CYLINDER HEAD ASS’Y Lubricate each valve stem with oil. Insert the valves into the guides. Install the valve springs,

53 FIG-18. Engine Disassembly CYLINDER HEAD ASS’Y CAMSHAFT ASS’Y INSTALLATION Position the camshaft gear with cam chain so that its “I” mark aligns w

54 FIG-18. Engine Disassembly CYLINDER AND PISTON SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil or

55 FIG-18. Engine Disassembly CYLINDER AND PISTON TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings. Overheating Excessive

56 FIG-18. Engine Disassembly CYLINDER AND PISTON CYLINDER REMOVAL Remove the cylinder head. (Photo 47) Remove the cylinder. (Photo 48) Remove the

57 FIG-18. Engine Disassembly CYLINDER AND PISTON PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose

4 FIG-01 INFORMATION TORQUE VALUES STANDARD 5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut ENGINE Cylinder he

58 FIG-18. Engine Disassembly CYLINDER AND PISTON INSPECTION Inspect the top of the cylinder for warp (Photo 57) SERVICE LIMITS: 0.10 mm PISTON / PI

59 FIG-18. Engine Disassembly CYLINDER AND PISTON PISTON / PISTON RING INSPECTION Calculate the piston-to-piston pin clearance. (Photo 63) SERVICE LI

60 FIG-18. Engine Disassembly CYLINDER AND PISTON CYLINDER INSTALLATION Clean any gasket material from the crankcase surface. (Photo 68) NOTE: Be car

61 FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER SERVICE INFORMATION If the drain tube ass’y fills with water, the tube should be drained

62 FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER DISASSEMBLE LH CRANKCASE COVER Relax the band screw (a-1) and remove the C.V.T inlet duc

63 FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER C.V.T REMOVAL Relax the flange nut (a-1), and remove the drive face. (a-2) (Photo 77) R

64 FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER INSPECTION Inspect the drive belt for wear, tears or damage. Measure the width of drive

65 FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER Measure the length of driven face spring (Photo 88) SERVICE LIMIT: 164.0 mm Inspect the

66 FIG-18. Engine Disassembly TRANSMISSION & KICK STARTER INSPECTION Inspect the kick-starter spindle composition for wear or damage. (Photo 93)

67

5

68 FIG-19. Electric System Troubleshooting ENGINE STARTS BUT STOPS

69 FIG-19. Electric System Troubleshooting IGNITION COIL Remove the spark plug cap from the spark plug. Disconnect the ignition coil pri

70 FIG-19. Electric System BATTERY CAUTION The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventil

71 FIG-19. Electric System ELECTRIC STARTER Information A weak battery may be unable run the starter motor quickly enough. If the battery voltage

72 0.6~0.7 mm

73 Loosen the carb fuel drain screw; check the carburetor for fuel flow FIG-20. Trouble shooting STARTING DIFFICULT

74 FIG-20. Trouble shooting STARTS BUT IMMEDIATELY STOPS ` Check 、Adjust Trouble Condition Tro

75 FIG-20. Trouble shooting STARTS BUT IMMEDIATELY STOPS Check 、Adjust Trouble Condition Trou

76 FIG-20. Trouble shooting SPEED TOO SLOW、NO POWER Check 、Adjust Trouble Condition Trouble Ca

77 FIG-20. Trouble shooting ENGINE RUNS ROUGH (ESPECIALLY AT LOW SPEED AND IDLING) Check 、Adjus

6 FIG-02. Vehicle Inspection MAINTENANCE DATA SPARK PLUG Spark plug cap Recommended spark plugs Throttle lever free play: Idle speed Brake lever free

78 FIG-20. Trouble shooting ENGINE RUNS ROUGH (ESPECIALLY AT HIGH SPEED) Check 、Adjust Trouble

79 FIG-20. Trouble shooting ABOUT THE CLUTCH AND DRIVE Trouble Condition Trouble Cause Engine w

80 FIG-20. Trouble shooting FRONT SUSPENSION AND REAR SUSPENSION NOT BALANCED BRAKE NO GOOD Troub

81 FIG-20. Trouble shooting OIL LEVEL LOW BUT LAMP NOT BRIGHT (WHEN MAIN SWITCH “ON”) ` Piston up=to put out light Piston do

82 FIG-20. Trouble shooting STARTING MOTOR DOES NOT SPIN Check 、Adjust Trouble Condition Tr

83 FIG-20. Trouble shooting STARTING MOTOR SPINS SLOWLY OR TURNS WITHOUT ENGAGING MOTOR STARTING MOTOR SPINS CONTINUO

84 0.6~0.7 mm

85 FIG-21. MAIN WIRING DIAGRAM

7 FIG-02. Vehicle Inspection MAINTENANCE SCHEDULE The maintenance intervals in the follow table are based upon average riding conditions. Riding in