Cobra 2005 cm50 Service Manual
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
1
MCCM2005.6
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 CM50 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 OPER ATOR, 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 OPER ATED 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
Specifications - Torque Values .......................................................................... 6
Optional Components ........................................................................................ 7
Break-In Procedure ........................................................................................... 8
Starting Procedure ............................................................................................ 9
General Tips .................................................................................................... 10
Maintenance ....................................................................................................... 11
Schedule & Tips .............................................................................................. 11
Replacing Transmission / Clutch Lubricant ..................................................... 12
Chain adjustment ............................................................................................ 13
Front brake adjustment ................................................................................... 14
Rear brake adjustment .................................................................................... 15
Air Filter Cleaning ............................................................................................ 15
Fork Oil Replacement ...................................................................................... 16
Parts ................................................................................................................... 18
Parts – Airbox and Inlet System ...................................................................... 18
Parts – Bars and Controls ............................................................................... 19
Parts - Carburetor ............................................................................................ 20
Parts – Coolant System ................................................................................... 21
Parts – Electrical System ................................................................................ 22
Parts – Engine – Bottom End and Transmission ............................................. 23
Parts – Engine – Clutch and Kick Starter ..................................................... 24
Parts – Engine – Ignition and Water Pump .................................................. 25
Parts – Engine – Top End ............................................................................ 26
Parts – Exhaust System .................................................................................. 27
Parts – Forks & Triple Clamps ......................................................................... 28
Parts – Forks – Leg Assembly ..................................................................... 29
Parts – Frame – Mounting Hardware I ............................................................ 30
Parts – Frame – Mounting Hardware II ........................................................ 31
Parts - Frame – Mounting Hardware III ........................................................ 32
3
Parts – Front Brakes ....................................................................................... 33
Parts – Front Wheel ........................................................................................ 34
Parts – Plastic Bodywork & Seat ..................................................................... 35
Parts – Rear Brake .......................................................................................... 36
Parts – Rear Wheel ......................................................................................... 37
Parts – Shock .................................................................................................. 38
Parts – Swingarm Assembly............................................................................ 39
Service ................................................................................................................ 40
Engine Service ................................................................................................ 40
Engine Removal .......................................................................................... 41
Complete Engine Disassembly Procedure .................................................. 42
Top End Disassembly Procedure ................................................................ 42
Splitting the Cases ....................................................................................... 43
Engine assembly ......................................................................................... 44
Clutch .............................................................................................................. 49
Ignition ............................................................................................................. 54
Cooling System ............................................................................................... 57
Fuel & Air System ............................................................................................ 60
Exhaust ........................................................................................................... 63
Wheels & Tires ................................................................................................ 64
Tuning ................................................................................................................. 65
Suspension ..................................................................................................... 65
Rear shock ................................................................................................... 67
Front Forks .................................................................................................. 67
Gearing ........................................................................................................... 68
Carburetion ..................................................................................................... 70
Troubleshooting .................................................................................................. 72
Index ................................................................................................................... 74
4
General Information
Items
CM 50
Dimensions
Wheelbase
35.75” (908mm)
Wheel size
10” (254mm)
Seat height
23.9” (607 mm)
Engine
Type
2-stroke, single cylinder, reed valve
Cooling system
Liquid-cooled
Coolant
Liquid Performance Mini Coolant / Antifreeze
Displacement
49.8 cc
Bore and stroke
39 mm x 41.7 mm
Ignition system
Electronic, analogic 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)
Carburetion
14 mm Dell’Orto
Main Jet
92
Slow (Pilot) jet
55
Float Height
16mm + 0.5mm (0.63” + 0.020”)
Transmission
Speed / Clutch
Single / Cobra 3 shoe
Final drive ratio
13/38T or 14/38 T
Chain
420
Transmission / clutch oil type
Cobra Venom 3 Shoe Clutch Milk
Quantity
235 ml (8.0oz)
Specifications - General
RACE FUELS ARE NOT RECOMMENDED
5
Chassis
Front tire
2.50 – 10
Pressure
15 psi minimum
Rear tire
2.75 – 10
Pressure
15 psi min. (20 psi for hard pack or rocky conditions)
Front fork
Marzocchi 32mm
Fork oil type
SAE 20 weight
Fork oil amount
200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild
Collapsed fork oil height
70 mm (2.75”) spring in, no spacer
Torque Value
Size &
ft-lb
in-lb
Nm
Cylinder head nuts
M6 X 1.0
Crankcase bolts
M6 x 1.0
Spark plug
(SP)
(SP)
(SP)
M14 x 1.25
Stator bolts
2.1
25
2.8
M5 X 0.8
Stator cover bolts
1.7
20
2.3
M4 X 0.75
Clutch cover bolts
5.8
70
7.9
M6 X 1.0
Clutch nut
40
480
54
10 x 1.25*
Clutch bolts
14
170
19
M6 x 1.0
Engine mount bolts
22
265
30
M8 X 1.25
Swingarm Pivot
21
250
28
M14 X 2.0
Intake manifold bolts
4.6
55
6.2
M6 X 1.0
Ignition rotor nut
40
480
54
M10 x 1.25*
Rear Sprocket Bolts
18
216
24
M7 X 1.0
Rear shock mounts
40
480
54
M10 x 1.5
Axle nuts
25
300
34
M12 X 1.25
Specifications - Torque Values
Fastener
8.8 105 12
8.8 105 12
* Apply high strength thread locking agent when installing
(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.
Remarks
6
Optional Components
Weight of Rider (lb)
Fork Spring
Shock Spring
Less than 38 (light)
KCMZ0012A
SCMUOH04
38 – 45 (std)
KCMZ0012
SCMUOH05
46 to 55 (stiff)
KCMZ0012B
SCMU0H06
Damping Rate
Fork Valving
(right)
Fork Valving
(left)
Shock Valving
Soft (fast)
KCMZ0033A
KCMZ0032A
SCMUOH07
Standard
KCMZ0033
KCMZ0032
SCMUOH08
Hard (slow)
KCMZ0033B
KCMZ0032B
SCMUOH09
Call your dealer, or the factory, for details
• Carburetor jets
• Pre-filter for the airbox
• Sprockets
o Front
o Rear
• Suspension Springs
• Suspension valving
Compression
• Tires
• Tubes or ‘Tire Balls’
(12 lb/in, 2.10 N/mm))
(14 lb/in, 2.45 N/mm))
(16 lb/in, 2.80 N/mm)
Rebound
(275 lb/in) red
(285 lb/in) yellow
(295 lb/in) white
(kit)
7
Break-In Procedure
Your Cobra CM50 is a close-tolerance high performance machine an d break-in
time is very important for maximum life and performance. The CM50 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 th e 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 sur e 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.
• Start bike on stand
• First 5 minute period, operate the bike on the stand with a combination of idle
and high RPM operation. (avoid prolonged high RPM but spin the rear
wheel good at least once or twice per minute)
• Allow bike to cool
• Ride for 15 minutes maximum (avoid prolonged high RPM operation and
avoid abusing the clutch with throttle blipping.
• Cool and inspect bike for loose fasteners.
• Next ½ hour of operation, 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 c oolant 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.
8
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 otherwis e
engine damage could occur.
Starting Procedure
Before starting the machine inspect the following:
• Make sure vehicle is properly maintained (see Schedule & Tips in the
Maintenance section)
• Check the throttle for smooth operation and sound closing.
• 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 complete 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. 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. Make sure your
engine is properly warmed up before racing.
This is a high performance race motorcycle. Too much application of throttle will
likely land your little racer on his or her arse. Fenders can be replaced but
bruised egos and other body parts take longer.
9
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.
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. Cobra offers a carburetor inlet cover RCMU0109 to keep water and dirt
from getting into the carburetor when the bike is being washed.
7. New chains will stretch on first use. Never install a new chain prior to a
race. Always ‘break’ them in during practice.
8. 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, CMxxxx5xxx is a 2005 Model Year CM50.
10
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 str ands of t he 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 ot her light oil.
o Check drive chain for
Proper tension and adjust if necessary.
Adequate lubrication and lubricate if necessary.
o Insure that the ignition s tator 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 spr ocket dam per plate for bending or warping.
Straighten or replace if more than 1/16” (1.6 mm) from flat.
• 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.
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.
11
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 Lubr i cant
Tools needed:
• 225 ml (7.6 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01).
• 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 is ‘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.
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).
NOTE: You may need to adjust the brake pedal (up or down) to gain access to
the drain bolt.
4. After it has drained, reinstall the bolt being sure that the copper gasket is in
place. Torque to 15 Nm (11 ft-lb).
12
Figure 1
5. Reapply oil from oil fill plug 235 cc Cobra Venom 3 Shoe Clutch Milk thru the
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 bolt, hand tight, being sure the fiber gasket is in place.
CAUTION:
Cobra has spent considerable time and money developing the proper lubr ication
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.
Chain adjustment
Tools required for chain adjustment
• 19 mm wrench or socket
• 13 mm wrench or socket
1. Make sure that the rear wheel is
aligned properly.
2. For proper adjust ment, the chain
should have 35 mm (1 3/8”) free
movement just behind the chain
block with no load on the bike
(figure 2)
Figure 2
CAUTION:
Sit on the bike and verify that the chain has a minimum of 12mm (1/2”) free
movement when the chain is at it’s tightest point.
13
Figure 3, from the brake lever
Figure 4, from the brake hub
3. If the chain requires adjusting, loosen the
axle with a 19 mm wrench and tighten the
chain by rotating the adjustor bolts
clockwise (CW) or loosen the chain by
rotating the adjustor bolts (CCW).
4. Retighten the axel bolt to 25 ft-lb (34 Nm).
5. Retighten the adjustor bolt
Figure 3
CAUTION:
Always check rear brake adjustment and free-play after adjusting the chain.
Front brake adjustment
Tools recommended for front brake maintenance:
• 10mm open end wrench
From the brake lever:
1. Slide the cover out of the way
2. Loosen the locking nut on the brake lever.
3. Adjust the bolt to desirable position.
4. Tighten the locking nut.
5. Slide the protective cover back over the lever pivot and adjustor
From the brake hub:
1. Loosen the 10mm nut on the hub.
2. Adjust the brake cable to desirable position
3. Tighten the 10mm nut.
CAUTION:
If you tighten the front brake up too much, the brakes may hang up causing the
brake pads to wear incorrectly and prematurely.
14
Rear brake adjustment
Figure 5, adjust brake lever free hei ght
Figure 6, adjust brake lever ‘free pl ay’
Tools recommended for rear brake maintenance:
• 10mm open end wrench
There are 2 adjustments on the brake.
From the brake lever:
6. Loosen the 10mm nut on the back of the brake pedal.
7. Adjust the bolt to desirable position
8. Tighten the 10mm nut.
From the brake hub:
1. Adjust the wing nut to the desirable position.
CAUTION:
If you tighten the wing nut too much, the brakes may hang up. If so, the brake
pads will burn up, and need to be replaced.
Air Filter Cleaning
Tools recommended for air filter maintenance:
• #2 Phillips head screwdriver
• 4 mm hex key (Allen)
• Foam filter oil
Procedure
1. Removed the seat with the 4 mm hex key
2. Remove the filter/air inlet boot from the back of the carburetor with a flat
screwdriver
3. Pull the filter / boot assembly back, up, and out the top of the airbox.
4. Clean the filter in a nonflammable solvent to remove the filter oil.
Do not clean the air filter with gasoline or other highly volatile petr oleum product.
15
Diesel fuel or kerosene would be preferred but caution should still be taken. Ho t
soapy water works well.
5. Clean the filter in hot soapy water to remove all dirt particles.
6. Allow it to dry thoroughly.
7. Saturate with filter oil and remove excess.
NOTE:
The Cobra is equipped with a special designed Air box. It is very important to
keep the air filter clean and properly oiled with high quality water-resist ant foam
filter oil. It’s very important to oil your filter consistently each time because varied
amounts of oil will change your carburetor jetting.
8. Reinstall the filter / boot assembly by pushing it down and forward into the
airbox making sure the letters “CM” are visible between the carburetor and
airbox (figure 8).
Figure 8
NOTE:
Make sure you change or clean your filter after each moto. We recommend
carrying multiple filters in your toolbox, one for each practice session and moto.
Fork Oil Replacement
Tools required
• 5 & 6 mm Allen wrench
• 19 mm wrench or socket (two required)
• Spring clip remover
Disassembly
16
1. Remove the front wheel.
2. Remove the fork legs from the triple clamps.
3. Perform the following on one leg at a time.
4. Using your hands, remove the black rubber plug from the top of the fork leg
exposing the white plastic cap.
5. Secure the fork leg assembly in a vice by gripping the leg across the flats
through which the axle bolt goes through.
6. Depress the white plastic cap inwards (down) and remove the wire spring clip
from its groove.
7. Remove the white cap, the fork spring preload sleeve, and the fork spring.
NOTE: Depressing the fork leg will facilitate removing the white cap.
8. The fork can now be turned upside down and drained.
Assembly
1. Fill the leg with 200 cc (6.8 oz) 20 wt fork oil.
2. Standard fork oil level is 70 mm (2.75”) from the top edge with the fork
collapsed.
NOTE: Remove the preload sleeve but leave the spring in for the measurement.
3. Install the preload sleeve.
4. Install and depress the white cap while installing the spring clip.
5. Fork may be reinstalled.
17
Parts
Airbox and Inlet System
REF #
PART #
DESCRIPTION
1
ZCMU0032
GASKET – REED TO CYLINDER
2
ECKG0205
REED VALVE
3
ZCMU0031
GASKET – MANIFOLD TO REED
4
ECKG0203
INLET MANIFOLD
5
HCWF0601
6MM FLAT WASHER
6
HCBC0625
M6X25 SOCKET HEAD CAP SCREW
7
MCKGHO04
HOSE CLAMP – CARBURETOR TO MANIFOLD
8
RACM0002
CARBURETOR 14MM
Not Shown
FCMU0026
FUEL LINE
Not Shown
MCMUCL04
HOSE CLAMPS – FUEL LINE
9
FCMU0067
THROTTLE CABLE
10
RCCM1301
VELOCITY STACK
11
MCKGHO01
HOSE CLAMP – AIR BOOT TO CARBURETOR
12
RCMU0403
AIR FILTER WITH BOOT
13
RCMU0405
AIR BOX – CM
14
HCBB0612
M6X12 BUTTON HEAD BOLT (2 REQ’D)
15
RCMU1407
BRACKET – MUD FLAP
16
RCMU0406
MUD FLAP – CM
Parts – Airbox and Inlet System
Figure 7
18
Parts – Bars and Controls
Bars and Controls
REF #
PART #
DESCRIPTION
1
FCMU0066
THROTTLE ASSEMBLY
2
FCMU0068
THROTTLE COVER
3
TCMU0008
GRIPS (SET OF TWO)
4
FCMU0067
THROTTLE CABLE
5
FCMU0033
KILL SWITCH ASSEMBLY
6
KCMZ0001
M8X50 SOCKET HEAD CAP SCREW (4 REQ’D)
7
KCMZ0003
LOWER HANDLE BAR CLAMP (2 REQ’D)
8
KCMZ0002
TOP HANDLE BAR CLAMP (2 REQ’D)
9
TCMU0019
HANDLEBAR - ALUMINUM
11
BCMU0100
BRAKE LEVER / PERCH ASSEMBLY WITH ADJUSTOR
13
BCMU0108
FRONT BRAKE CABLE
Figure 8
19
REF. #
PART #
DESCRIPTION
RCCM0001
COMPLETE CARBURETOR 14MM
1
RCMU0305
CARB SLIDE
2
RCMU0601
NEEDLE
3
RCMU0002
ATOMIZER
4
RCMU0092
MAIN JET
6
CHOKE JET
7
RCMU0301
FLOAT
8
RCMU0102
RUBBER CABLE CAP SEAL
9
RCMU0003
CABLE ADJUSTOR
11
RCMU0006
TOP CARB SCREW
12
RCMU0106
CARB TOP
27
RCMU0012
DIFFUSER
33
RCCM1301
VELOCITY STACK – 05 style
RCCM0314
14MM CARB RESTRICTOR
Not Shown
FCMU0026
FUEL LINE
Not Shown
MCMUCL04
HOSE CLAMPS – FUEL LINE
Parts Carburetor
Figure 9
20
5 RCMU0055 PILOT JET
13 ZCMU0007 TOP CARB GASKET
14 RCMU0004 SLIDE SPRING
15 RCMU0205 NEEDLE RETA INER PLATE
16 RCMU0007 NEEDLE CLIP
17 RCMU0204 CHOKE ASS’Y. 2001 CM
20 RCMU0009 FUEL MIX TURE SC REW
21 RCMU0011 IDLE ADJUSTMENT SCREW
25 RCMU0103 FLOAT BOWL GASKET
26 RCMU0107 FLOAT NEEDLE
28 RCMU0016 FLOAT RETAINER PIN
29 RCMU0106 FLOAT BOWL
30
RCMU0201 BOTTOM FLOAT SCREW
31
Carburetor
Parts – Coolant System
Coolant System
REF #
PART #
DESCRIPTION
1
ECMU0061
RADIATOR WITH CAP
2
MCMUHO02
RADIATOR HOSE LEFT
3
MCMUCL02
HOSE CLAMP
4
ECHA0003
MOUNTING BRACKET – RADIATOR BOTTOM
5
HCBC0607
M6X50 SOCKET HEAD CAP SCREW
6
HCNL0601
6MM LOCK NUT
7
MCKGGR00
GROMMET – RADIATOR MOUNTING
8
MCMUHO03
RADIATOR HOSE RIGHT
10
ECHA0002
VENT HOSE
11
ECHA0109
MOUNTING BRACKET – RADIATOR TOP
12
HCBC0660
M6X60 SOCKET HEAD CAP SCREW
Figure 10
21
Parts – Electrical System
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
IAMU0003
GROUND WIRE
31
HCWF0504
WASHER FOR STATOR (3 PER)
32
HCBC0525
5mm x 25 SOCKET HEAD CAP SCREW
33
HCBC0535
5mm x 35 SOCKET HEAD CAP SCREW (2 req’d)
34
HCNS1001
NUT 10MM
35
ECKG0042
PULLEY, WATERPUMP CRANK
59
ICMU0006
ROTOR
NOT SHOWN
ICMU0012
WOODRUFF KEY
60
ICMU0007
STATOR
NOT SHOWN
MCKGGR01
GROMMET - STATOR LEAD
Figure 6
22
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