Aeon Overland 125 180 Factory Service Repair Manual

AEON MOTOR CO.,LTD    

1 CONTENTS 1. INFORMATION………………………………………... 2 2. MAINTENANCE…………………….………………… 6 3. ENGINE REMOVAL AND INSTALLATION………… 16 4. ENGINE LUBRICATION AND COOLING SYSTEM.. 17 5. CYLINDER HEAD & VALVES……………………….. 26 6. CYLINDER & PISTON………………………………... 37 7. TRANSMISSION SYSTEM…………………………… 46 8. FRONT WHEEL, SUSPENSION AND STEERING….. 57 9. REAR WHEEL SYSTEM……………………………… 68 10. FENDERS AND EXHAUST PIPE…………………….. 79 11. ELECTRICAL SYSTEM………………………………. 81 12. TROUBLE SHOOTING……………………………….. 88

2 1. INFORMATION 1.1 Safety 1.2 Notes 1.3 Specifications 1.4 Serial number  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 180 Type Displacement Bore and Stroke Compression Maximum Power Carburetor Ignition Starting Lubrication Air Cleaner Transmission CHASSIS Overall Length Overall Width Overall Height Wheel Base Dry Weight Fuel Tank Capacity SUSPENSION Front Rear BRAKES Front Rear TIRES Front Rear Specifications subject to change without notice. Air-Cooled 4-syroke with Oil Cooler 169 cc 61×57.8mm 9.1:1 6.2 Nm@6300 min -1 MIKUNI 180 C.D.I Electronic Electrical & Kick-Start Wet crankcase with lobes pump AE-9 Automatic(C.V.T. system) 1790mm 970mm 1200mm 1050mm 156kg 8.0 liter Double wishbone Swing Arm Drum Disc 21” × 7” - 10” 22” × 10” - 8”

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 VALUES 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 King pin 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 Swingarm 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) 28 N.m (20.7 lbs.ft) 12 N.m (8.9 lbs.ft) 20 N.m (14.8 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 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 Fuel tube 2.4 Throttle operation 2.5 Throttle cable adjustment 2.6 Air cleaner 2.7 Spark plug 2.8 Idle speed 2.9 Drive chain 2.10 Brake system 2.11 Wheels and tires 2.12 Steering system 2.13 Toe-in 2.14 Gear oil 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG 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 VALUES SPARK PLUG TIE-ROD LOCK NUT ENGINE OIL Viscosity: GEAR LUBRICATION OIL Viscosity: 0.6-0.7mm NGK C7HSA or CR7HSA 5-10mm 1800rpm 10~20mm 15-25mm 21×7-10 / 22×10-8 3±0.3psi (0.15 kgf/cm 2 ) 5±10mm 12-19 N.m 35-43 N.m SAE 15W-40 SAE 85W-140

7 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. Service Item Initial Service (First 30 hours) Every 100 hours Every 200 hours Every 300 hours ENGINE OIL R R GEAR OIL R R FUEL FILTER R AIR VLEAN FILTER R ENGINE OIL FILTER C CARBURETOR I SPARK PLUG C VALVE GAP A IGNITION TIMING A CHAIN A BATTERY I DRIVE BATTERY I CLUTCH I THROTTLE OPERATE I TIRE PRESSURE Check before riding each time BRAKE SYSTEM Check before riding each time NUTS/BOLTS T A: Adjust C: Clean I: Inspection R: Replace T: Tighten

8 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. 2.4 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.

9 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 2.6 AIR CLEANER MAINTENANCE (1) Loosen the screw and remove the air cleaner from carburetor. (2) Disassemble the air cleaner cover and body. (3) Remove the air cleaner element and screen.. (4) Install the new one. (5) Assemble the air cleaner body and cover and re-attach to the carburetor with screw.

Aeon Overland 125 180 Factory Service Repair Manual

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