Cobra 2005 King Owner's 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
MCKG2005.4
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 B E USED ON PUBLIC STREETS, ROAD S
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 OPE RATED 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 c ould 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-IN PROCEDURE......................................................................................... 8
STARTING PROCEDURE ........................................................................................ 9
GENERAL TIPS ................................................................................................... 10
MAINTENANCE .................................................................................................. 10
SCHEDULE & TIPS .............................................................................................. 10
REPLACING TRANSMISSION / CLUTCH LUBRICANT ................................................. 12
CHAIN ADJUSTMENT ........................................................................................... 13
REAR BRAKE MAINTENANCE ............................................................................... 13
AIR FILTER CLEANING ........................................................................................ 14
FORK OIL REPLACEMENT ................................................................................... 15
PARTS ................................................................................................................ 16
PARTS – AIRBOX & INLET SYSTEM ...................................................................... 16
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 Kicker ................................................................ 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
3
PARTS – FRAME I ............................................................................................... 31
Parts – Frame II ........................................................................................... 32
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 ............................................................................................................ 50
IGNITION ........................................................................................................... 55
COOLING SYSTEM .............................................................................................. 57
FUEL & AIR SYSTEM .......................................................................................... 61
EXHAUST .......................................................................................................... 64
WHEELS & TIRES ............................................................................................... 65
BRAKES ............................................................................................................ 66
FRONT FORKS ................................................................................................... 67
REAR SHOCK .................................................................................................... 69
TUNING .............................................................................................................. 70
GEARING ........................................................................................................... 70
SUSPENSION ..................................................................................................... 71
CARBURETION ................................................................................................... 72
TROUBLESHOOTING ........................................................................................ 75
INDEX ................................................................................................................. 76
4
General Information
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
0.040” (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
Main Jet
96
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
14/38 T
Chain
100 links 420
Transmission / clutch oil type
Cobra Venom 3 Shoe Clutch Milk
Quantity
235 ml (8.0oz)
Specifications - General
RACE FUELS ARE NOT RECOMMENDED
complete)
5
Chassis
Front tire
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)
Weight of Rider (lb)
Fork Spring
Shock Spring
Less than 51
9 lb/in,
KCKG0109
SCKGOH85 (gray, 185 lb/in)
51 - 60
12 lb/in,
KCKG1201
SCKGOH95, (yellow, 195 lb/in)
Greater than 60
15 lb/in,
KCKG0015
SCKGO205, (gold, 205 lb/in)
Damping Rate
Fork Valving
(base valve)
Fork Valving
(mid valve)
Shock Valving
Soft (fast)
KAKG0013
KAKG0016
SCKGOH24A
Standard
KAKG0014
KAKG0017
SCKGOH24
Hard (slow)
KAKG0015
KAKG0018
SCKGOH24B
Optional Components
Call your dealer, or the factory, for details
• Carburetor jets
• Flat clutch washers (see clutch service section)
• Pre filter for the airbox
• Sprockets
o Front
o Rear
• Suspension Springs
• Suspension Valving
Compression
• Tires
• Tubes or ‘Tire Balls’
6
Rebound
(kit)
Specifications - Torque Value s
Cylinder head
nuts
Crankcase
bolts
Stator cover
bolts
Clutch cover
bolts
Engine mount
bolts
Swingarm
Pivot
Intake manifold
bolts
Rear Sprocket
Bolts
Fork cartridge
rod
Triple clamp
bolts
Ignition rotor
nut
Fastener
Spark plug (SP) (SP) (SP) M14 x 1.25
Stator bolts 2.1 25 2.8 M5 X 0.8
Clutch nut 40 480 54 M10 x 1.25*
Clutch bolts 14 170 19 M6 x 1.0
Front axle nut 25 300 34 M12 x 1.25
ft-lb in-lb Nm
8.8 105 12 M6 x 1.0
8.8 105 12 M6 x 1.0
1.7 20 2.3 M4 X 0.75
5.8 70 7.9 M6 X 1.0
22 265 30 M8 X 1.25
Torque Value
Size &
Remarks
21 250 28 M14 X 2.0
4.6 55 6.2 M6 X 1.0
Rear Axle Bolt 25 300 34 M12 X 1.25
18 216 24 7 mm
12 144 16
6 72 8 M6 x 1.0
Fork cap 5 60 6.7 1.25” x 18
40 480 54 M10 x 1.25*
* 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.
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 m ixture 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 som e engine coolant through the radiator
overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper c oolant 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 complet ely otherwise
engine damage could occur.
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 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. Also, for
best clutch performance, warm up the bike before taking off.
9
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.
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. 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 crankcase vent during riding.
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, Acxxxx5xxx is a 2005 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 t he air f ilt er (clean and re-oil as necessary).
o Ins ur e the smooth operation of the throttle cable (throttle soundly
‘clacks’ shut).
o Check f or fr ayed s t rands of the throttle cable inside the throttle housing
and replace if necessary.
o Check f or adequate tire pressures and adjust if necessary.
o Check al l nut s and bolt s for proper torque and re-torque if necessary.
o Spray all m oving par ts with WD40 or other light oil.
o Check dr ive chain for
Proper tension and adjust if necessary.
Adequate lubrication and lubricate if necessary.
o Ins ur e that the ignition stator and rotor are clean and dry.
10
o Check t he f rame 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 Ins pect the rear sprocket damper plate for bending or warping.
Straighten or replace if more than 1/16” (1.6 mm) from flat.
o Check t he r im s f or 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.
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.
11
Replacing Transmission / Clut ch Lubricant
Tools needed:
• 235 ml (8.0 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).
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
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 t he proper lubrication
to handle the harsh environment of the automat ic 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
12
capability over extended periods of time and is the recommended lubricant for
1. Make sure that the rear
Push down on the seat,
sion down to where the
chain is tightest. At this
e should be a
With the rear wheel
a minimum of 2.5” of
slack between the swing
arm and the chain.
your Cobra motorcycle.
Chain adjustment
Figure 2
Rear Brake Maintenance
CAUTION:
Too little brake pedal free-play will allow the brake pads to drag causing the pads
to wear prematurely and possible engine component failures. Too much free-play
will not all the rider to apply the brakes quickly.
1. Set pedal height/position first, then
2. Set pedal free play.
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
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).
wheel is aligned properly.
2.
compressing the suspen-
point, ther
minimum of 1” of slack.
3.
elevated, there should be
13
Figure 2b
CAUTION:
Adequate pedal free play is required so that the brake pads do not drag on the
rotor. 1” MINIMUM.
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 play locking clip from around the brake adjustor (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 adjustor
(plunger).
NOTE:
Turning the clevis Clockwise will lengthen the adjustor (plunger), removing free
play from the system, and turning the clevis Counter-Clockwise will shorten the
adjustor (plunger) adding free play to the system.
Air Filter Cleaning
Tools recommended for air filter maintenance:
• Filter oil
• Grease
• Proudly nothing other than that!
CAUTION:
It is very important to keep it clean and properly oiled with high quality waterresistant foam filter oil. It is also very import ant to oil your filter consistently each
time because varied amounts of oil will change your carburetor jetting.
14
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
When washing your bike, it may be handy to remove the airboot and hose out the
airbox. When doing so, cover the carburetor inlet with a suitabl e shield capable of
keeping water from entering the engine. Cobra has a rubber cap for the
carburetor inlet (part # RCMU0109).
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 t he 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 it to drain completely.
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).
15
Parts
Coolant System
REF #
PART #
DESCRIPTION
1
RAKG0001
AIRBOX
2
HCBF0616
M6X16 FLANGE HEAD BOLT
3
RCKG0502
AIR FILTER
4
RCKG0503
FILTER RETAINER
5
TCKG0004
MUDFLAP – AIRBOX
6
TCKG0105
BRACKET – MUDFLAP
7
HCBB0612
M6X12 BUTTON HEAD BOLT
8
MCKGHO03
HOSE CLAMP – AIRBOX TO BOOT
9
RCKG0505
AIR BOOT
10
MCKGHO01
HOSE CLAMP – BOOT TO CARB
11
MCKGHO04
HOSE CLAMP – CARB TO MANIFOLD
12
ECKG0203
INLET MANIFOLD
13
ZCMU0031
GASKET – MANIFOLD TO REED
14
ECKG0202
REED CAGE ASSEMBLY WITH REEDS
NOT SHOWN
ECKG0205
REED REPLACEMENT KIT
15
ZCMU0032
GASKET – REEDS TO ENGINE
16
HCBC0625
M6X25 SOCKET HEAD CAP SCREW
17
HCWF0601
6MM FLAT WASHER
18
RCCM1301
VELOCITY STACK
Parts – Airbox & Inlet System
Figure 5
16
Parts – Bars and Controls
Bars and Controls
REF #
PART #
DESCRIPTION
1
TCMU0009
HANDLEBAR - STEEL
2
MCMU0001
OPTIONAL CROSS BAR PAD
3
TCMU0008
GRIPS (SET OF TWO)
4
FCMU0066
THROTTLE ASSEMBLY
NOT
SHOWN
FCMU0068
THROTTLE COVER
5
BCKG0023
ALLOY BRAKE LEVER W/BALL
6
BCKG0024
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
TKMU0404M
BAR MOUNT KIT, SHORT (2 PER)
9T
TKMU0403M
BAR MOUNT KIT, TALL (2 PER)
10
HCBC1001
M10X45 SOCKET HEAD CAP SCREW (2 REQ’D PER BIKE)
12
HCNL1001
M10 LOCK NUT
NOT
SHOWN
HCBH0816
M8 X 16 HEX HEAD BOLT
NOT
SHOWN
HCWF0801
8MM FLAT WASHER
13
FCMU0033
KILL SWITCH ASSEMBLY
Figure 3
17
REF. #
PART #
DESCRIPTION
1
RCMU0305
CARB SLIDE
2
RCMU0601
NEEDLE
3
RCMU0002
ATOMIZER
4
RCMU0096
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
NOT
SHOWN
NOT
SHOWN
Not Shown
FCMU0026
FUEL LINE
Not Shown
MCMUCL04
HOSE CLAMPS – FUEL LINE
Parts - Carburetor
Figure 4
Carburetor
5 RCMU0065 PILOT JET
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
RCCM1301 VELOCITY STACK -05
MCKGHO01 CLAMP – CARBURETOR TO FILTER
18
Parts – Coolant System
Coolant System
REF #
PART #
DESCRIPTION
1
FCKG0036
RADIATOR WITH CAP
2
FCMU0047
RADIATOR CAP (2 ears or ribbed)
3
MCMUHO05
RADIATOR HOSE, TOP, LEFT
4
MCKGHO06
RADIATOR HOSE, 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 REQ’D)
9
ECHA0002
RADIATOR VENT HOSE
Figure 5
19
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
IAMU0002
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
20
Parts – Engine – Bottom End and
Engine Bottom End and Transmission
REF #
PART #
DESCRIPTION
1
ECKG0017
CRANKCASE, IGNITION SIDE no bearings
2
ECMU0020L
BEARING, TRANSMISSION PRECISION
3
ECKG0004
SNAP RING, WATER PUMP
4
ZCMU0501
GASKET, CRANKCASE
5
ECMU0106
SECONDARY SHAFT, TRANSMISSION WITH GEAR
6
ECMU0017
SEAL, CRANKSHAFT
7
ECMU0016
BEARING, CRANKSHAFT
8
ECMU0001
BEARING, TRANMISSION SECONDARY SHAFT
9
ECMU0038
CRANKSHAFT
10
ECKGBR01
BEARING, TRANSMISSION OUTPUT SHAFT
13
ECDC0031
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, no berings
25
HCBH0612
M6X12 HEX HEAD SCREW - BEARING RETAINER
27
HCWL0601
6MM LOCK WASHER
Transmission
Figure 7A
21
Parts –
Engine – Clutch and Kick Starter
REF #
PART #
DESCRIPTION
1
ECMU0127
CLUTCH COVER WITH KICK SHAFT, GEAR, AND LEVER
2
ZCMU0030
CLUTCH COVER GASKET
3
ECMU0207
KICKSTART GEAR SMALL
4
HCBC0608
M6X55 SHCS CLUTCH CVR SCREW LNG (2 REQ’D) CENTER
5
HCBC0606
M6X45 SHCS CLUTCH COVER SCREW SHORT (4 REQ’D)
6
ECMU0068
KICKSTART STOP BOLT
7
ECMU0037
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
ECMU0089
CLUTCH BASKET, WELDED WITH BUSHING
23
ECMU0110
BUSHING, CLUTCH BASKET
24
ECMU0040
SPACER, CLUTCH BASKET (1 - 3 REQ’D)
25
ECMU0132
COOLANT FITTING
26
ECMU0109
GEAR, PRIMARY TRANSMISSION
27
HCNS1202
NUT, 1/2-20 LEFT HAND THREAD
28
ECMU0503
FITTING, CASE VENT
NOT SHOWN
ECMU0504
HOSE – CRANKCASE VENT
29
ECMUSP01
KICK START DOG SPRING (PAPER CLIP)
31
HCWB0042
SPRING WASHER
Engine
Clutch
and
Kicker
Figure 7B
22
Parts –
Engine – Ignition and Water Pump
REF #
PART #
DESCRIPTION
1
ECKG0001
IGNITION COVER
2
ZCKG0101
IGNITION COVER GASKET
3
HCBC0445
M4 x 45 SOCKET HEAD (4 REQ’D)
4
ECKG0170
WATER PUMP BELT
5
ECKG0175
WATER PUMP PULLEY, FAN TYPE - DRIVEN
6
ECMU0180
BELT RETAINER
7
HCBS0003
SHOULDER BOLT 6MM
8
HCWF0501
FLAT WASHER
9
ECKG0072
BEARING, WATER PUMP
10
ECKG0142
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 REQ’D)
17
HCBC0604
CASE SCREW, SHCS M6X35 (5 REQ’D)
18
HCWF0504
WASHER FOR STATOR (3 PER)
19
ICMU0007
STATOR
20
HCBC0535
5mm x 35 SOCKET HEAD CAP SCREW (2 REQ’D)
21
HCBC0525
5mm x 25 SOCKET HEAD CAP SCREW
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
ECKG0004
RETAINER, WATER PUMP ASSEMBLY
32
ICMU0012
WOODRUFF KEY – FLYWHEEL / CRANKSHAFT
Engine –
Ignition
and
Water
Pump
Figure 7C
23
Loading...