Cobra 2004 King Owner's Manual
2004 KING
Owners / Service / Parts
“CHAMPIONS START HERE”
For parts orders contact your local dealer
To locate your closest Cobra dealer
log on to
www.cobramotorcycle.com
or call
(330) 549-9600
If you need technical assistance
contact your local dealer or call
the Cobra Technical Support Hotline at
(330) 549-9603
Cobra Motorcycle MFG., Inc.
11511 Springfield Road
North Lima, Ohio 44452
MCKG2004.7
1
DISCLAIMER OF WARRANTY
This motorcycle is sold “as is” with all faults, obvious or not. There are no warranties
expressed or implied, including any warranty of merchantability and warranty of fitness
for any particular purpose.
“WARNING”
THE COBRA KING IS A COMPETITION MODEL ONLY AND IS NOT
MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS
OR HIGHWAYS.
THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN
SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE BY A
SUFFICIENTLY SKILLED RIDER AND SHOULD NOT BE USED FOR GENERAL
OFF-ROAD RECREATIONAL RIDING.
IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH.
THIS BIKE IS INTENDED FOR EXPERIENCED RACERS ONLY AND NOT FOR
BEGINNERS.
IT IS YOUR RESPONSIBILITY AS THE OWNER OF THIS COBRA MOTORCYCLE
OR AS THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS
COBRA MOTORCYCLE IN PROPER OPERATING CONDITION.
THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 80 LBS WITH
FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH
MORE THAT.
BE SURE THAT THE RIDER ALWAYS WEARS ADEQUATE SAFETY GEAR
EVERYTIME HE OR SHE RIDES THEIR COBRA MOTORCYCLE.
IMPORTANT SAFETY NOTICE
Failure to follow WARNING instructions could result in severe injury or death to
the machine operator, a bystander, or a person inspecting or repairing the
machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the machine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
2
Table Of Contents
GENERAL INFORMATION............................................................................................5
SPECIFICATIONS - GENERAL...........................................................................................5
OPTIONAL COMPONENTS................................................................................................6
SPECIFICATIONS - TORQUE VALUES ..............................................................................7
BREAK-I N PROCEDURE...................................................................................................8
STARTING PROCEDURE ..................................................................................................9
GENERAL TIPS................................................................................................................9
MAINTENANCE .............................................................................................................10
SCHEDULE & TIPS.........................................................................................................10
REPLACING TRANSMISSION / CLUTCH LUBRICANT ......................................................11
CHAIN ADJUSTMENT......................................................................................................13
REAR BRAKE MAINTENANCE ........................................................................................13
AIR FILTER CLEANING...................................................................................................14
FORK OIL REPLACEMENT.............................................................................................15
PARTS .............................................................................................................................17
PARTS – BARS AND CONTROLS ...................................................................................17
PARTS - CARBURETOR .................................................................................................18
PARTS – COOLANT SYSTEM.........................................................................................19
PARTS – ELECTRICAL SYSTEM.....................................................................................20
PARTS – ENGINE – BOTTOM END AND TRANSMISSION...............................................21
Parts – Engine – Clutch and Kick Starter...........................................................22
Parts – Engine – Ignition and Water Pump........................................................23
Parts – Engine – Top End.....................................................................................24
PARTS – EXHAUST SYSTEM .........................................................................................25
PARTS – FORKS & TRIPLE CLAMPS.............................................................................26
Parts – Forks – Leg Assembly.............................................................................27
Parts – Forks – Damper Assembly......................................................................28
Parts – Forks – Damper – Base Valve Assembly.............................................29
Parts – Forks – Damper – Mid Valve Assembly................................................30
PARTS – FRAME – BRAKE MOUNTS, PLASTIC SHIELD & FOOTPEGS.........................31
3
Parts – Frame - Exhaust, Radiator, & Engine Mounts.....................................32
Parts - Frame – Subframe, Shock, & Bodywork Mounts.................................33
PARTS – FRONT BRAKES..............................................................................................34
PARTS – FRONT WHEEL...............................................................................................35
PARTS – PLASTIC BODYWORK & SEAT........................................................................36
PARTS – REAR BRAKE..................................................................................................37
PARTS – REAR WHEEL.................................................................................................38
PARTS – SHOCK ...........................................................................................................39
PARTS – SWINGARM ASSEMBLY ..................................................................................40
SERVICE.........................................................................................................................41
ENGINE SERVICE...........................................................................................................41
Engine Removal.....................................................................................................42
Complete Engine Disassembly Procedure.........................................................43
Top End Disassembly Procedure........................................................................43
Splitting the Cases.................................................................................................44
Engine assembly....................................................................................................45
CLUTCH .........................................................................................................................50
I GNITION ........................................................................................................................54
COOLING SYSTEM.........................................................................................................56
FUEL & AIR SYSTEM.....................................................................................................60
EXHAUST.......................................................................................................................63
WHEELS & TIRES..........................................................................................................64
BRAKES.........................................................................................................................65
SUSPENSION.................................................................................................................69
Rear Shock..............................................................................................................71
Front Forks..............................................................................................................72
TROUBLESHOOTING ..................................................................................................73
INDEX..............................................................................................................................75
4
General Information
Specifications - General
Items KING
Dimensions
Wheelbase 39” (991mm)
Wheel size 10” (254mm) rear, 12” (305mm) front
Seat height 26” (660mm)
Engine
Type 2-stroke, single cylinder, reed valve
Cooling system Liquid-cooled
Displacement 49.8 cc
Bore and stroke 39 mm x 41.7 mm
Ignition system Electronic, analog advance
Spark plug Champion 8339-1, 8332-1 hotter, 8904-1 colder
Gap 0.023” – 0.025” (0.58 – 0.64 mm)
Ignition timing 0.045” (1.14 mm) Before To Dead Center (BTDC)
Fuel type High octane pump gasoline
Oil type Cobra Venom 2-cycle Race Oil
Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In is
Carburetion 19 mm Dell’Orto
RACE FUELS ARE NOT RECOMMENDED
complete)
Slow (Pilot) jet 65
Float Height 16mm + 0.5mm (0.63” + 0.020”)
Coolant Liquid Performance Mini Coolant / Antifreeze
Transmission
Speed Single
Final drive ratio 14/39 T
Chain 100 links 420
Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III
5
Main Jet 95
Quantity 235 ml (8.0oz)
Chassis
Front tir e 2.50 - 12
Pressure 16 psi minimum
Rear tire 2.75 - 10
Pressure 16 psi min. (20 psi for hard pack or rocky conditions)
Front fork Cobra 30mm USD
Fork oil type SAE 10 weight
Fork oil amount 105 ml (3.5oz)
Optional Components
• Carburetor jets
• Sprockets
o Front
o Rear
• Suspension Springs
Weight of Rider (lb) Fork Spring Shock Spring
Less than 51 9 lb/in,
KCKG0109
51 - 60 12 lb/in,
KCKG1201
Greater than 60 15 lb/in,
KCKG0015
• Suspension Valving
Damping Rate Fork Valving
Compression
(base valve)
Soft (fast) KAKG0013 KAKG0016 SCKGOH24A
Standard KAKG0014 KAKG0017 SCKGOH24
Hard (slow) KAKG0015 KAKG0018 SCKGOH24B
SCKGOH85 (gray, 185 lb/in)
SCKG0H95, (yellow, 195 lb/in)
SCKG0205, (gold, 205 lb/in)
Fork Valving
Rebound
(mid valve)
Shock Valving
(kit)
6
Specifications - Torque Values
Fastener
Cylinder head
nuts
Crankcase
bolts
Spark plug (SP) (SP) (SP) 14 x 1.25
Stator bolts 2.1 25 2.8 #8
Stator cover
bolts
Clutch cover
bolts
Clutch 40 480 54 10 x 1.25***
Front axle nut 25 300 34 12 x 1.25
Engine mount
bolts
Swingarm
Pivot
Intake manifold
bolts
Torque Value
ft-lb in-lb Nm
9.2 110 12 ¼”-20
6.6 80 9 6 x 1.0
1.7 20 2.3 #8
5.8 70 7.9 6 mm
22 265 30 8 mm
21 250 28 14 mm
4.6 55 6.2 6 mm
Size &
Remarks
Rear Axle Bolt 25 300 34 12 mm
Rear Sprocket
Bolts
Fork cartridge
rod
Triple clamp
bolts
Fork cap 5 60 6.7 1.25” x 18
Ignition rotor
nut
** Use green (wicking / bearing retainer) thread locker, with primer, on the
flywheel / crankshaft taper but none on the threads.
*** Use green (wicking / bearing retainer) thread locker, with primer, on the
crankshaft / clutch taper but use red (high strength) thread locker, with primer, on
the nut.
(SP) To apply the proper torque to the spark plug when inserting, one must first
screw the spark plug in until the metal gasket ring causes resistance and then
turn another 1/8 to ¼ turn.
18 216 24 7 mm
12 144 16
6 72 8 6 x 1.0
40 480 54 10 x 1.25**
7
Break-In Procedure
Your Cobra KING is a close-tolerance high performance machine and break-in
time is very important for maximum life and performance. The KING can be
ridden hard after the first ½ hour break-in time but it is recommended that no
adjustments are made to the carburetion or suspension until the full 8 hours of
bike break-in has elapsed. Also, after the engine, transmission, and drive train
have been broken -in for the full 8 hours, the bike will be faster!
Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use
high octane pump gas, with Cobra’s specially formulated Cobra Venom 2-cycle
Race Oil. (Part # MCMUOL02)
CAUTION:
Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine
wear or damage to the machine.
Adhering to the following break-in schedule will result in long lasting high
performance machine.
• First ½ hour of operation
o Follow the starting procedure listed in this manual.
o Avoid prolonged operation at Wide Open Throttle.
• After 1 hour of operation
o Check for loose bolts and nuts on the bike and retighten as
necessary (proper toque values are listed under Specifications).
o Clean the carburetor bowl.
o Change the transmission / clutch lubricant.
• After 8 hours of operation
o Change the fork oil.
o Have a Certified Cobra Mechanic change the shock oil.
• Your bike is now ready for the highest level of competition!
NOTE:
During break-in the bike will likely lose some engine coolant through the radiator
overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level
will cover the top of the radiator cores. Removing the radiator cap and looking
inside is the only way to check the coolant level.
Never open the radiator cap of a machine that has a hot or warm engine or one
that has recently been ridden. Burning and scalding could occur.
CAUTION:
It is important that the radiator cap is installed correctly and completely otherwise
engine damage could occur.
8
Starting Procedure
Before starting the machine inspect the following:
• Check for proper tire pressure in both tires.
• Observe the chain tension and adjust if necessary.
• Observe the coolant level and fill if necessary.
• Verify that the chain rollers and sliders do not have improper wear.
• Verify that the handlebars are tight.
• Check the throttle for smooth operation and sound closing.
• Check for loose bolts and nuts, and re-torque as necessary.
• Verify that the air filter is clean and properly saturated with oil.
• Insure that the fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required. (High octane pump gas with Cobra’s
specially formulated Cobra Venom 2-cycle Race Oil)
• Turn the fuel on by rotating the fuel petcock knob to the vertically downward
position (reserve position is horizontally forward)
CAUTION:
For best results from your Cobra Motorcycle use only the recommended fuels.
Testing has shown that most ‘race’ fuels actually degrade performance.
When your pre-ride inspection is compl ete the bike may be started. For a cold
engine follow this procedure.
1. Place the motorcycle on a stand of sufficient strength that positions the
motorcycle in a level upright position with the rear wheel off the ground.
2. Pull up the choke knob and turn it to lock it.
3. Kick start the engine.
4. Rev the engine in short spurts, turning the throttle no more than 1/4 open
until the engine will run without the choke.
5. Verify a functional engine shut-off switch by shutting off the engine.
6. Restart the engine and proceed with riding when the engine is sufficiently
warm (i.e. the side of the cylinder is warm to touch).
CAUTION:
Never rev an engine full throttle when it's cold or slightly warmed up. Also, for
best clutch performance, warm up the bike before taking off.
General Tips
1. Always wear a helmet and other protective riding gear.
2. Cobra recommends that you tell your child to take it easy the first couple of
minutes in practice until the engine comes up to full operating temperature.
3. Make sure your riders’ foot is not resting on the foot brake while they are
riding.
9
4. Evaluate the bikes jetting only after it has been warmed up to race
temperatures.
5. A properly maintained machine is safer, faster, and more fun to ride.
6. Filling your transmission with more than 8.0 oz (235ml) of lubricant may
help to transfer heat from the clutch, but be aware that this extra oil will
increase the frictional drag on the engine, thus reducing power, and will
often get purged out the cran kcase vent during riding.
7. Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number).
The first two digits indicate the model and the seventh indicates the model
year (MY).
a. Example, ACxxxx4xxx is a 2004 MY King.
Maintenance
Schedule & Tips
It is important that you adhere to this maintenance schedule so as to promote the
longevity of your Cobra Motorcycle.
• Between each ride
o Check the air filter (clean and re-oil as necessary).
o Insure the smooth operation of the throttle cable (throttle soundly
‘clacks’ shut).
o Check for frayed strands of the throttle cable inside the throttle housing
and replace if necessary.
o Check for adequate tire pressures and adjust if necessary.
o Check all nuts and bolts for proper torque and re-torque if necessary.
o Spray all moving parts with WD40 or other light oil.
o Check drive chain for
§ Proper tension and adjust if necessary.
§ Adequate lubrication and lubricate if necessary.
o Insure that the ignition stator and rotor are clean and dry.
o Check the frame for cracks in the metal or cracks in the paint that
might indicate that the metal has been stressed beyond it’s safe limits.
Replace or get properly rewelded as necessary.
o Inspect the rear sprocket damper plate for bendin g or warping.
Straighten or replace if more than 1/16” (1.6 mm) from flat.
o Check the rims for signs of stress, like cracks around the rim, spokes
and hub.
• Every 2 hours of operation
o Replace the transmission oil.
• Every 10 hours of operation
o Replace the fork oil.
o Have the shock oil replaced by a Certified Cobra Mechanic.
10
CAUTION:
1. Because of the amount of heat generated by the clutch and engine during
extended periods of riding, it is advisable to remove the ignition cover
afterward to allow the ignition to cool off. The heat transfers through the
cases and can damage the stator as it cools off because of lack of airflow
around the stator.
2. If you ever need to weld anything on the bike, disconnect the spark plug
cap, unplug the ignition, disconnect the kill switch, scrape the paint bare
near the area to be welded and put the ground clamp as close to the area
to be welded as possible.
Be sure the fuel tank and carburetor have been removed and safely located
away from the welding process.
3. The frame is 4130 Chrome Moly and it is important to weld it with the proper
rod and heat settings set as light as possible. Cobra recommends replacing
the frame with a new one if the old one becomes damaged.
4. If your kick-starter lever does not return to the rubber bumper, use WD-40
or light penetrating oil under the plastic cover behind the spring on the
shaft. The shaft is a very close fit to the case and also has an O ring in it
and is difficult to get lubrication to which may cause binding. If it does not
loosen up, remove the kick-starter cover and kicking assembly. Grease the
shaft.
Replacing Transmission / Clutch Lubricant
Tools needed:
• 235 ml (8.0 oz) Cobra Venom 3 Shoe Clutch Milk (P art # MCMUGF01), or
Dexron III Automatic Transmission Fluid.
• 13 mm combination wrench
Procedure:
1. Begin this procedure with a bike that has been ridden more than 5 minutes
but less than 10 minutes. It is desired to have the engine warm enough so
that the oil ‘runny’ but not so hot that there is risk of being burned by the
engine or the oil.
Hot oil and hot components on the motorcycle may cause burns.
2. Lean bike against something or set on stand with oil drain hole.
11
3. Using a 13 mm wrench, remove the oil drain bolt located on the right side of
the engine, on the clutch cover, near the brake lever (Item 2, figure 1).
Figure 1
4. After it has drained, reinstall the bolt being sure that the copper gasket is in
place. Torque to 15 Nm (11 ft-lb).
5. Reapply oil from oil fill plug 235 cc (8.0 oz) Cobra Venom 3 Shoe Clutch Milk,
or Dexron III Automatic Transmission Fluid, thru the oil fill plug.
NOTE:
Lean bike over onto it’s left hand side so that the clutch cover is up unless you
have a squeeze bottle.
6. Reapply the oil fill plug, hand tight, being sure the fiber gasket is in place.
CAUTION:
Cobra has spent considerable time and money developing the proper lubrication
to handle the harsh environment of the automatic clutch and transmission of this
motorcycle. Cobra’s specially developed Cobra Venom 3 Shoe Clutch Milk (Part
# MCMUGF01) was formulated to provide superior lubrication and cooling
capability over extended periods of time and is the recommended lubricant for
your Cobra motorcycle.
12
Chain adjustment
1. Make sure that the rear
wheel is aligned properly.
2. Push down on the seat,
compressing the suspension down to where the
chain is tightest. At this
point, there should be a
minimum of 1” of slack.
3. With the rear wheel
Figure 2
elevated, there should be
a minimum of 2.5” of
slack between the swing
arm and the chain.
Rear Brake Maintenance
Brake pedal height can be adjusted with the bolt and nut located under the rear
of the brake pedal. The free-play is adjusted with the adjustable plunger on the
end of the brake pedal.
CAUTION:
Use only DOT 4 brake fluid
CAUTION:
Too little brake pedal free-play will allow the brake pads to drag causing the pads
to wear prematurely. Too much free-play will not all the rider to apply the brakes
quickly.
1. Set pedal position first, then
2. Set pedal free play.
Setting rear brake pedal position (see figure 2b):
1. Loosen the lock nut (10mm wrench).
2. Adjust the brake lever stop (10mm wrench) so that the lever is comfortably
reachable in both:
a. Standing riding position, and
b. Sitting riding position.
3. Tighten the lock nut (10 mm wrench).
13
Figure 2b
Setting rear brake pedal free play
CAUTION:
Adequate pedal free play is required so that the brake pads do not wear
prematurely.
Make sure that the free play locking clip is installed such that one must push
forward, toward the front of the bike, to remove. Otherwise the clip is apt to come
undone while riding.
To adjust (see figure 2b):
1. Loosen the lock nut (10mm).
2. Undo the free pl ay locking clip from around the brake adjuster (plunger),
with your hand by pushing it forward.
3. Slide the pin of the locking free play locking clip from the brake lever
4. Adjust as needed by rotating the clevis on the end of the adjuster
(plunger).
NOTE:
Turning the clevis Clockwise will lengthen the adjuster (plunger), removing free
play from the system, and turning the clevis Counter-Clockwise will shorten the
adjuster (plunger) adding free play to the system.
Air Filter Cleaning
Tools recommended for air filter maintenance:
• Flat head screwdriver
• Air filter oil
• 5mm hex key
• Foam filter oil
Your Cobra comes with a pre-filter, or filter skin, to prevent the passing of water
14
to the standard air filter. Remove this pre-filter before cleaning and oiling the
standard air filter. The filter skin should be cleaned, with detergent in warm water,
but does not require the application of any oil.
CAUTION:
It is very important to keep it clean and properly oiled with high quality waterresistant foam filter oil. It is also very important to oil your filter consistently each
time because varied amounts of oil will change your carburetor jetting.
Make sure you change your filter after each moto. We recommend carrying
three or more filters in your toolbox.
1 for practice
1 for the each moto
In our testing when filters are properly oiled, no water, dirt or mud can penetrate
through the yellow or red foam to the carburetor inlet. It is important that the filter
does not touch any of the frame components in a rainy, muddy situation. We
offer two different filters. One filter, red in color, is for use in sand and extremely
dusty conditions (part # RCMU0101), and the regular filter, yellow in color, is for
more non extreme conditions (part # RCMU0206).
When washing your bike cover the carburetor/filter with a suitable shield capable
of keeping water from entering the engine. Cobra has a rubber clamp-on plug for
the carburetor (part # RCMU0104).
Fork Oil Replacement
Tools required
• Two 19 mm wrenches or sockets
• 4 & 5 mm hex key (Allen wrench)
• 1” wrench or socket
• 10 wt fork oil
Disassembly procedure
1. Remove the front wheel (19 mm wrench).
2. Remove the brake caliber from the fork leg (4 mm hex key).
3. Loosen the fork caps (1” socket).
4. Remove the fork legs from the triple clamps (5 mm hex key).
5. One leg at a time
a. Remove the fork cap from the leg.
b. Separate the fork cap from the damper rod.
c. Pull out the fork spring.
d. Place upside down over a suitable pan, tray, or container.
e. Work the damper rod up and down several times.
f. Allow to drain completely.
15
Assembly procedure
1. Fill the fork leg with 3.5 oz (105 ml) 10 wt fork oil.
2. Measure the fork oil level to the top of the fork tube with the leg collapsed,
and record for tuning purposes.
3. Install the fork spring.
4. Reconnect the damper rod to the fork cap (12 ft-lb, 16 Nm).
CAUTION:
The damper rod is hollow and will break if the nut is over tightened.
5. Reinstall the for cap into the fork leg (5 ft-lb, 6.7 Nm)
6. Reinstall the fork legs into the clamps (6 ft-lb, 8 Nm).
7. Reinstall the brake caliper.
8. Reinstall the front wheel (25 ft-lb, 34 Nm).
16
Parts
Parts – Bars and Controls
Figure 3
Bars and Controls
REF # PART # DESCRIPTION
1 TCMU 0009 HANDLEBAR - STEEL
2 MCMU0001 OPTIONAL CROSS BAR PAD
3 TCMU0008 GRIPS (SET OF TWO)
4 FCMU0066 THROTTLE ASSEMBLY
NOT SHOWN THROTTLE COVER
5 BCMU0209 ALLOY BRAKE LEVER W/BALL
6 BAMU2002 BRAKE PERCH ASSY W/LEVER & BALL
NOT SHOWN BAKG0004 SHIELDED BRAKE HOSE ASSEMBLY
7 FCMU0067 THROTTLE CABLE
8 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 (4 PER)
9S TKMU0404 BAR MOUNT KIT, SHORT (2 PER)
9T TKMU0403 BAR MOUNT KIT, TALL (2 PER)
10 HCBC3812 SOCKET HEAD CS 3/8-16 X 1-1/2 (2 PER)
12 HCNL3816 LOCK NUT 3/8 - 16 (2 PER)
13 FCMU0033 KILL SWITCH ASSEMBLY
17
Parts Carburetor
Figure 4
Carburetor
REF. # PART # DESCRIPTION
1 RCMU0305 CARB SLIDE
2 RCMU0601 NEEDLE
3 RCMU0002 ATOMIZER
4 RCMU0095 MAIN JET
5 RCMU0065 PILOT JET
6 CHOKE JET
7 RCMU0301 FLOAT
8 RCMU0102 RUBBER CABLE CAP SEAL
9 RCMU0003 CABLE ADJUSTER
11 RCMU0006 TOP CARB SCREW
12 RCMU0106 CARB TOP
13 ZCMU0007 TOP CARB GASKET
14 RCMU0004 SLIDE SPRING
15 RCMU0205 NEEDLE RETAINER PLATE
16 RCMU0007 NEEDLE CLIP
17 RCMU0204 CHOKE ASS’Y. 2001 CM
20 RCMU0009 FUEL MIXTURE SCREW
21 RCMU0011 IDLE ADJUSTMENT SCREW
25 RCMU0103 FLOAT BOWL GASKET
26 RCMU0107 FLOAT NEEDLE
27 RCMU0012 DIFFUSER
28 RCMU0016 FLOAT RETAINER PIN
29 RCMU0106 FLOAT BOWL
30
RCMU0201 BOTTOM FLOAT SCREW
31
33 RCMU0269 VELOCITY STACK
18
Parts – Coolant System
Figure 5
Coolant System
REF # PART # DESCRIPTION
1 FCMU0045 RADIATOR
2 FCMU0047 RADIATOR CAP
3 ECMU0024 RADIATOR HOSE LARGE, TOP, LEFT
4 MCMUHO01 RADIATOR HOSE, SMALL, BOTTOM, RIGHT
5 MCMUGR03 MOUNTING GROMMET (3 PER)
6 FCMU0006 RADIATOR MOUNTING BRACKET (TEARDROP)
7 HCBF0616 FLANGE HEAD BOLT M6X16
8 MCMUCL02 HOSE CLAMP (4 PER)
19
Parts – Electrical System
Figure 6
Electrical System
REF # PART # DESCRIPTION
1 IAMU0001 COIL W/SPARK PLUG CAP
2 ECMU0065 SPARK PLUG, CHAMPION (8339-1)
2H ECMU0067 OPTIONAL HOTTER PLUG (8332-1)
2C ECMU0066 OPTIONAL COLDER PLUG (8904-1)
3 FCMU0033 KILL SWITCH ASSEMBLY
4 HCBC0516 SCREW, M5 X 16 (2 PER)
5 HCCN0000 5MM CLIP NUT (2 PER)
6 IAMU0002 GROUND WIRE
31 HCWP0001 WASHER FOR STATOR (3 PER)
32 HCBC8312 SOCKET HEAD CS, 8-32X1
33 HCBC0801 SOCKET HEAD CS, 8-32X 1-1/2 (2 PER)
34 HCNS1001 NUT 10MM
35 ECKG0042 PULLEY, WATERPUMP CRANK
59 ICMU0006 ROTOR
60 ICMU0007 STATOR
NOT SHOWN MCKGGR00 GROMMET - STATOR LE AD
NOT SHOWN ICMU0012 ROTOR SHAFT KEY
20
Parts – Engine – Bottom End and
Transmission
Figure 7A
Engine Bottom End and Transmission
REF # PART # DESCRIPTION
1 ECKG0017 CRANKCASE, IGNITION SIDE
2 ECMU0020L BEARING, TRANSMISSION PRECISION
3 ECKG0004 SNAP RING, WATER PUMP
4 ZCKG2001 GASKET, CRANKCASE
5 ECMU0106 SECONDARY SHAFT, TRANSMISSION WITH GEAR
6 ECMU0017 SEAL, CRANKSHAFT
7 ECMU0016 BEARING, CRANKSHAFT
8 ECMU0001 BEARING, TRANMISSION SECONDAY SHAFT
9 ECMU0038 CRANKSHAFT
10 ECKGBR01 BEARING, TRANSMISSION OUTPUT SHAFT
13 HCDP1401 DOWEL, ENGINE CASE ALIGNEMENT
14 HCBH0805 M8X12 SCREW
15 HCWC0000 COPPER GASKET
16 ECMU0107 OUTPUT SHAFT, TRANSMISSION WITH GEAR
17 ECMU0020 BEARING, TRANSMISSION PRECISION
19 ECKG0018 CRANKCASE, CLUTCH SIDE
20 ZCMU0032 GASKET, REED TO CASE
21 ECKG0202 REED ASSEMBLY
NOT SHOWN ECKG0205 REED KIT
22 ZCMU0031 GASKET, INTAKE TO REED
23 ECKG0203 INTAKE MANIFOLD
24 HCBC0602 SCREW M6X20
25 HCBB0612 M6X12 BUTTON HEAD SCREW - BEARING RETAINER
26 HCWF0601 6MM FLAT WASHER
21
Parts –
Engine –
Clutch
and Kick
Starter
Figure 7B
Engine – Clutch and Kick Starter
REF # PART # DESCRIPTION
1 ECMU0128 CLUTCH COVER WITH KICK SHAFT AND GEAR (NO LEVER)
2 ZCMU0030 CLUTCH COVER GASKET
3 ECMU0207 KICKSTART GEAR SMALL
4 HCBC0608 M6X55 SHCS CLUTCH CVR SCREW LNG (2 REQD) CENTER
5 HCBC606 M6X45 SHCS CLUTCH COVER SCREW SHORT (4 REQD)
6 ECMU0068 KICKSTART STOP BOLT
7 ECMUOO37 OIL FILL PLUG
8 ZCMU0001 OIL FILL PLUG GASKET
9 HCBH0805 M8X12 OIL DRAIN SCREW
10 HCWC0000 COPPER GASKET
11 ECDC0046 KICK START LEVER
12 ECMU0164 KICK LEVER STOP BRACKET
13 HCBF0625 M6X25 FLANGE HEAD BOLT
14 ECMU0204 KICK STARTER DUST COVER
15 ECMU0063 KICK RETURN SPRING
16 CCMU0031 CLUTCH ARBOR
17 CAKG0005 CLUTCH SHOE (SET OF 3)
NOT SHOWN CAKG0004 SET OF 3 CLUTCH SHOES WITH SPRINGS, WASHER & BOLT
NOT SHOWN CAKG0002 CLUTCH ASSY W/ ARBOR, SHOES, SPRINGS, WSHR & BOLT
18 CCMU0129 SPRING, CLUTCH (SINGLE PIECE)
19 See Clutch WASHERS, CLUTCH FLAT
NOT SHOWN CAMU0008 SPRINGS, WASHER, & BOLT (COMPLETE SET FOR 3 SHOES)
20 HCBS5603 BOLT, CLUTCH CENTER (SINGLE PIECE)
21 ECMU0018 NUT, CLUTCH SPECIAL
22 ECMU0133 CLUTCH BASKET, WELDED WITH BUSHING
23 ECMU0003 BUSHING, CLUTCH BASKET
24 ECMU0040 SPACER, CLUTCH BASKET (1 - 3 REQD)
25 ECMU0131 WATER ELBOW
26 ECMU0108 GEAR, PRIMARY TRANSMISSION
27 HCNS1202 NUT, 1/2-20 LEFT HAND THREAD
28 ECDC0105 ELBOW, CASE VENT
29 ECMUSP01 KICK START DOG SPRING (PAPER CLIP)
31 HCWB0042 SPRING WASHER
22
Parts – Engine – Ignition and Water Pump
Figure 7C
Engine – Ignition and Water Pump
REF # PART # DESCRIPTION
1 ECKG0001 IGNITION COVER
2 ZCKG0101 IGNITION COVER GASKET
3 HCBC0802 COVER SCREW, SHCS 802X1 -3/4
4 ECKG0070 WATER PUMP BELT
5 ECKG0075 WATER PUMP PULLEY, FAN TYPE - DRIVEN
6 ECMU0080 BELT RETAINER
7 HCBC1033 PULLEY SCREW, SHCS 10-32X3/4
8 HCWF0501 FLAT WASHER
9 ECKG0072 BEARING, WATER PUMP
10 ECKG0141 SHAFT, WATER PUMP
11 ECKG0074 SEAL, WATER PUMP SHAFT
12 ECKG0073 IMPELLER, WATER PUMP
13 HCBB0001 IMPELLER SCREW, SHCS 10-32X1/2
14 HCSS8201 RETAINING SCREW, SHCS 8-32X3/8
15 HCBC0603 CASE SCREW, SHCS M6X30
16 HCBC0606 CASE SCREW, SHCS M6X45 (3 REQD)
17 HCBC0604 CASE SCREW, SHCS M6X35 (5 REQD)
18 HCWP0001 WASHER, STATOR (3 REQD)
19 ICMU0007 STATOR
20 HCBC0801 STATOR SCREW, SHCS 8-32X1-1/2 (2 REQD)
21 HCBC8312 STATOR SCREW, SHCS 8-32X1
22 ICMU0006 ROTOR
23 ECKG0042 WATER PUMP PULLEY, CRANK
24 HCNS1001 NUT 10MM
25 MCKGGR00 GROMMET
26 PCKG0014 SPROCKET, 14T COUNTERSHAFT
27 ECKGSR03 SNAP RING, COUNTERSHAFT SPROCKET
28 ECMU0073 SPACER, SPROCKET
29 ECMU0072 SEAL, COUNTERSHAFT
30 ZCDCOR01 O’RING, COUNTERSHAFT SPACER
31 ECKG004 RETAINER, WATER PUMP ASSEMBLY
23
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