Cobra 2006 ECX70 Service Manual

Owners

ECX70

Parts

Service

Tuning

For parts orders contact your local dealer

To locate your closest Cobra dealer

log on to

www.cobramotorcycle.com

or call

[phone]

If you need technical assistance

contact your local dealer or call

the Cobra Technical Support Hotline at

[phone]

Cobra Motorcycle MFG., Inc.

11511 Springfield Road
North Lima, Ohio 44452

MCEX2006.3

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 ECX70 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 ATV SHOULD BE LIMITED TO PARTICIPATION IN SA NCTIONED
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 PRODUCT OR AS

THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS COBRA
PRODUCT IN PROPER OPERATING CONDITION.

THIS ATV WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 110 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 ATV.

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 Suspension Components............................................................................7

Break-In Procedure......................................................................................................8

Starting Procedure.......................................................................................................9

General Tips ................................................................................................................10

Maintenance....................................................................................................................11

Schedule & Tips .........................................................................................................11

M1: Replacing Transmission Lubricant...................................................................11

M2: Chain adjustment................................................................................................12

M3: Air Filter Cleaning ...............................................................................................13

M4: Front end..............................................................................................................15

Toe in adjustment...................................................................................................15

Steering....................................................................................................................15

Parts.................................................................................................................................16

Parts – Air Inlet System.............................................................................................16

Parts – Bars and Steering.........................................................................................17

Parts – Bumper, Nerf & Grab Bars..........................................................................18

Parts – Carburetor......................................................................................................19

Parts – Clutch Actuation ............................................................................................20

Parts – Coolant System.............................................................................................21

Parts – Electrical System..........................................................................................22

Parts – Engine Clutch................................................................................................23

3

Parts – Engine – Clutch / Kick Cover..................................................................24

Parts - Engine - Ignition Side................................................................................25

Parts - Engine – Kick Mechanism........................................................................26

Parts – Engine – Shift Mechanism ......................................................................27

Parts – Engine – Top End.....................................................................................28

Parts - Engine - Transmission..............................................................................29

Parts – Exhaust System............................................................................................30

Parts - Front A-Arms & Steering Upright................................................................31

Parts – Front Brakes..................................................................................................32

Parts – Front Shock...................................................................................................33

Parts – Miscellaneous ...............................................................................................34

Parts – Plastic Bodywork & Seat.............................................................................35

Parts – Rear Brake.....................................................................................................36

Parts – Rear Drive......................................................................................................37

Parts – Rear Shock....................................................................................................38

Parts – Swingarm Assembly.....................................................................................39

Parts – Tie Rod Assembly........................................................................................40

Engine Parts / Service...................................................................................................41

ES1: Fuel & Air System.............................................................................................41

Reeds.......................................................................................................................41

Carburetor Cleaning...............................................................................................42

ES2: Exhaust ..............................................................................................................43

Tuning ..............................................................................................................................43

4

General Information

Specifications - General

Items ECX70

Dimensions

Wheelbase 42” (1067mm)
Width Front / Rear 43” / 46” (1092mm / 1168mm)
Weight 210 lb

Engine

Type 2-stroke, single cylinder, reed valve
Cooling system Liquid-cooled
Displacement 64.8 cc (3.95 Cubic inches)
Bore and stroke 43 mm x 44.6 mm
Ignition system Electronic
Spark plug Champion 8339
Gap 0.023” – 0.025” (0.58 – 0.64 mm)
Fuel type 93 octane pump gasoline

Oil type Cobra Venom 2-cycle Race Oil
Fuel / oil mix ratios 32:1
Ignition timing .050” (1.3mm) BTDC
Carburetion 26mm Mikuni VM

OTHER RACE FUELS A RE NOT RECOMMENDED

Slow (Pilot) jet 50

Float height

Transmission

Speed Six speed
Clutch Manual hydraulic
Final drive ratio 13/48 T
Transmission / clutch oil type 85W 90 Gear Lubricant

5

Main jet 190

Jet needle 5F21, 4th position from the top

Quantity 530 ml (18 oz)

Chassis

Tire Pressure front / rear (7 psi / 5 psi)
Travel, front / rear 240mm / 247mm (9.4” / 9.7”)
Race sag, front / rear 96mm / 99mm (3.8” / 3.9”)
Free sag, front / rear 38mm / 40mm (1.5” / 1.6”)

Specifications - Torque Values

ENGINE Fastener

Torque Value

ft-lb in-lb Nm

Remarks

Size &

Cylinder head nuts 14 170 19 7mm

Engine oil drain 3 36 4 8 x 1.25

Engine oil fill 2 24 2.7 14 x 1.0

Spark Plug (SP) (SP) (SP)

Crank case half 5 60 6.8 6 x 1.0

Crank case cover 5 60 6.8 6 x 1.0

Flywheel rotor nut 40 480 54 10 x 1.25 (G)

Clutch hub 40 480 54 10 x 1.25 (G)

Units of mm unless otherwise specified

(G) denotes the use of wicking / bearing retainer (green) thread locking agent to

applied to the mating surfaces of the two components but not the threads.
(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.

14 x 1.25

6

CHASSIS Fastener

Torque Value

ft-lb in-lb Nm

Size &

Remarks

Handle bar mounts 15 177 20 8 x 1.25
Handle bar clamps 15 177 20 8 x 1.25

Front engine mount 22 265 30 8 x 1.25

Rear brake lever pivot 10 120 13.6

8 x 1.25

Upper shock mount 40 480 54 10 x 1.5
Lower shock mount 40 480 54 10 x 1.5

Swingarm pivot 21 250 28 14 x 2.0

Units of mm unless otherwise specified

(R) designates that the application requires the use of high strength (red) thread

locking agent applied to the threads.
(B) designates that the application requires the use of medium strength (blue)

thread locking agent applied to the threads.

Optional Suspension Components

Front shock springs

Weight of Rider (lb) Helper Main

Less than 65

65 to 100

Greater than 100

SCEX1080 (RED,

SCEX1095 (YELLOW,

80 LB/IN)

95 LB/IN)

Rear shock springs

Weight of Rider (lb) Helper Main

Less than 65

65 to 100

Greater than 100

SCEX0110 (WHITE,

110 LB/IN)

SCEX0125 (GOLD,

125 LB/IN)

SCEX0150 (150 LB/IN) SCEX0400 (YELLOW, 400 LB/IN)

SCEXA145 (RED, 145 LB/IN)

SCEXA155 (YELLOW, 155

LB/IN)

SCEXA165 (BLACK, 165 LB/IN)

SCEX1350 (RED, 350 LB/IN)

SCEX1375 (WHITE, 375 LB/IN)

7

Break-In Procedure

Your Cobra Motorcycle is a close-tolerance high performance machine and
break-in time is very important for maximum life and performance. The ECX70
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
93 octane pump gas, or Sunoco MO2X , with Cobra’s specially formulated Cobra
Venom 2-cycle Race Oil. (Part # MCMUOL02)

CAUTION:
Failure to use proper fuel or oil 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 5 minute period, operate the bike in neutral with a combination of idle
and high RPM operation. (avoid prolonged high RPM rev it good at least
once or twice per minute)

• Allow the engine to cool

• Ride for 15 minutes maximum, avoiding prolonged high RPM operation.

• 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.
o Replace the fuel filter.

• After 8 hours of operation have a Certified Cobra Mechanic change the

shock oils.

• Your bike is now ready for the highest level of competition!

8

Starting Procedure

Before starting the machine inspect the following:

• Insure that the fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required. (93 octane pump gas with Cobra’s specially
formulated Cobra Venom 2-cycle Race Oil)

• 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 do not have improper wear.

• Inspect the frame, for;

o Cracks in the metal.
o Cracking paint which might indicate overly stressed material.

• Verify that the handlebars are tight.

• Check the throttle for;

o Smooth operation and sound closing.
o Frayed strands of the cable inside the throttle housing.

• Check for loose bolts and nuts, and re-torque as necessary.

• Verify that the air filter is clean and properly saturated with oil.

• Turn the fuel on by rotating the fuel petcock knob to the vertically downward

position (reserve position is horizontally inward).

CAUTION:
For best results from your Cobra ATV 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. Reaching down to the carburetor, on the left side of the bike, push down on
the black choke lever.

2. Kick start the engine.

3. Rev the engine in short spurts, turning the throttle no more than 1/4 open
until the engine will run without the choke.

4. Verify a functional engine shut-off switch by shutting off the engine.

5. 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.

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 rear brake pedal 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. When washing the bike, be careful to not directly aim the hose at the air

filter area.

7. Keep steering stops adjusted so that the wheels do not scrape on the A-

arms

8. Mare sure that there is adequate free play in both the front lever and rear

brake pedal .

9. The appearance of black ‘stuff’ in the coolant is likely due to a head seal

being compromised. Replace the head seals and keep an eye on the
coolant.

10. Your Cobra ATV has a 10 digit VIN (Vehicle I dentification Number). The

first three digits indicate the model and the seventh indicates the model
year (MY).

a. Example, ECXxxx5xxx is a 2005 MY ECX70.

10

Maintenance

Schedule & Tips

I t is important that you adhere to this maintenance schedule so as to promote the
longevity of your Cobra Motorcycle.

• Between each ride

o Inspect the fuel filter for contaminates.
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 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.

• Every 2 hours of operation
o Replace the transmission oil.

• Every 10 hours of operation
o Have the shock oil replaced by a Certified Cobra Mechanic.

CAUTION:

1. 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.

2. The frame is a low carbon alloy tubing and it is important to weld it with the

proper rod and heat settings set as ligh t as possible. Cobra recommends
replacing the frame with a new one if the old one becomes damaged.

M1: Replacing Transmission Lubricant

11

Tools needed:

• 530 ml (18 oz) 85W 90 gear lubricant

• large flat blade screwdriver

• 13 mm wrench or socket

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.

3. Using the 13 mm wrench, remove the oil drain bolt located on the right side
of the engine (figure 1).

4. After it has drained, reinstall the drain screw with gasket.

5. Remove the oil fill plug and pour in 530 ml (18 oz) 85W 90 gear lubricant.

NOTE: Leaning the bike over onto it’s left hand side will facilitate the oil filling
procedure.

6. Reapply the oil fill screw, securely, being sure the gasket is in place.

M2: Chain adjustment

Tools needed:

12

Figure 1

• 13 mm wrench or socket

• 5mm pin (Screw driver or hex key will do)

Procedure:

1. Loosen the eccentric housing on the swingarm with two 13mm tools.

2. Stick the 5mm pin through the sprocket into the eccentric hole.

3. Push the quad forward or backward, turning the wheels (i.e. the sprocket) in
the direction shown until the desired chain tension is achiev ed (see fig. 2).

Figure 1

NOTE:

The location of the pin hole is the ‘fattest’ part of the eccentric. Restated, if the
pin hole is all the way forward, the chain is as tight as possible, and if the pin hole
is all the way back, the chain is as loose as possible.

CAUTION:
Proper chain tension allows no less than ½” (12mm) free play through out the
range of rear suspension travel.

NOTE:

It may be handy to set backwards on the seat and feel the chain as you weight,
and unweight, seat to feel for chain free play.

4. After achieving the proper adjustment retighten the two eccentric pinch
bolts.

CAUTION:
Be sure to remove the pin from the eccentric before riding.

M3: Air Filter Cleaning

This Cobra Motorcycle comes with a unique air filter / air boot unit designed to
facilitate motorcycle service.

13

Tools recommended for air filter maintenance:

• Srewdriver

• Foam filter oil

Procedure

1. Removed the filter from the carburetor.

2. Clean the filter with cleaning solvent and then again with hot soapy water.

3. Allow it to dry thoroughly.

4. Saturate with foam filter oil and remove excess.

Do not clean the air filter with gasoline or other highly volatile petroleum product.
Cleaning solvent, diesel fuel, or kerosene would be preferred but caution should
still be taken.

NOTE:

The biodegradable air filter oils, greases, and cleansers work acceptably with this
Cobra Motorcycle.

NOTE:

It is very important to keep the air filter clean and properly oiled with high quality
water-resistant foam filter oil. It’s very important to oil your filter consistently each
time because varied amounts of oil will change your carburetor jetting.

NOTE:

Make sure you change or clean your filter after each moto or significant ride. We
recommend carrying three or more filters in your toolbox.

• 1 for practice

• 1 for each moto

CAUTION:
Dusty conditions will require more frequent cleaning.

14

M4: Front end

Toe in adjustment

Riders and parents have provided feedback that they prefer the toe in adjustment
between ½” (12mm) out to ½” (12mm) in. This is set by adjusting the length of
the tie rod assemblies. See figure 3 for direction of turn.

Adjust both wheels so that they have the same amount of toe in.

Figure 3

Steering

The unique Cobra front end will exhibit some free play from the factory and that
the seals (it that’s what you want to call them) will fall out after the first ride. We
have found that this causes no adverse effects and that the looseness does not
get significantly worse as long as the bearings are sprayed with a spray lubricant
(WD40 or similar) upon each ride.

15

Parts

Parts – Air Inlet System

Figure 4

REF # PART # DESCRIPTION

1 RCDC0001 AIR FILTER ASSEMBLY
2 MCKGHO03 HOSE CLAMP – FILTER TO CARB
3 RCEX0003 CARBURETOR 26MM MIKUNI VM
4 MCMUCL10 HOSE CLAMP – CARB TO INLET BOOT (WIDE)
5 ECEX0012 INLET BOOT
6 MCMUCL03 HOSE CLAMP – BOOT TO REED MANIFOLD (NARROW)
7 ECDC0094 INLET MANIFOLD WITH REED ASSEMBLY

REEDS - REMPLACMENT STOCK

ECDCRD15 REEDS – SOFT
8 HCBC0602 M6 X 20 SOCKET HEAD CAP SCREW (4 REQ’D)
9 ECDC0093 GASKET – INLET (2 PLACES)

10 RCMU0001 SPACER – REED
11 FCEX0016 THROTTLE, QUAD THUMB STYLE
12 FCPW0004 THROTTLE CABLE END GROMMET
13 RCEX0001 CABLE - THROTTLE
14 FCMU0027 FUEL LINE 5 INCH
15 FCDC0093 FILTER, FUEL
16 RCEX0019 COVER, AIR FILTER

Coolant System

16

Parts – Bars and Steering

Figure 5

Bars and Steering

REF # PART # DESCRIPTION

1 FAEX0020 STEERING STEM
2 TCEX0009 HANDLEBAR - QUAD
3 FCEX0011 STEERING STEM BLOCK (2 REQ’D)
4 MCEXBR06 STEERING STEM BUSHING – SPLIT

NOT SHOWN HCBB0403 4MM X 8 BUTTON HEAD SCREW (2 REQ’D)

5 TCMU0404 BAR MOUNT KIT, SHORT – REPLACEMENT (2 REQ’D)

NOT SHOWN TCMU0403 BAR MOUNT KIT, TALL – OPTIONAL (2 REQ’D)

6 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 (4 REQ’D)
7 HCBC1001 M10X45 SOCKET HEAD CAP SCREW (2 REQ’D)
8 HCNL1001 M10 LOCK NUT (2 REQ’D)

9 HCWF0801 8MM FLAT WASHER
10 HCBH0810 8MM X 65 HEX HEAD BOLT (2 REQ’D)
11 HCNL1001 10MM LOCK NUT
12 HCWF0010 10MM FLAT WASHER
13 MCEXBR04 STEM PIVOT BUSHING - LOWER
14 MCMU0001 CROSS BAR PAD
15 TCEX0013 GRIPS SET OF TWO
16 HCBH0601 6MM X 16 HEX HEAD BOLT (2 REQ’D)
17 HCNS0601 6MM NUT (2 REQ’D)

17

Parts – Bumper, Nerf & Grab Bars

Figure 6

BODY PROTECTION

REF # PART # DESCRIPTION

1 FCEX0024 NERF BARS (LEFT & RIGHT)

NOT SHOWN HCBH0808 8MM X 30 HEX HEAD BOLT (FRONT MOUNT, 2 PLACES)
NOT SHOWN

NOT SHOWN
NOT SHOWN HCNL0801 8MM LOCKNUT (2 REQ’D)

2 FAEX0099 FRONT BUMPER

3 HCBB0802 M8 X 20 BUTTON HEAD BOLT (4 REQ’D)

4 FCEX0003 GRAB BAR

5 HCBC0820 M8 X 20 SOCKET HEAD CAP SCREW (4 REQ’D)

HCBH0809 8MM X 50 HEX HEAD BOLT (REAR MOUNT, 2 PLACES)
HCWF0801 8MM FLAT WASHER (2 REQ’D)

18

Parts –
Carburetor

Figure 7

Carburetor accessories

REF # PART # DESCRIPTION

RCEX0003 CARBURETOR, 26MM MIKUNI VM
CABLE, THROTTLE

1 RCEX0017 JET NEEDLE (5F21) STANDARD

RCEX0018 JET NEEDLE (5F3)

2 RCEX0004 RUBBER, THROTTLE CABLE ADJUSTER

3 RCEX0005 ADJUSTER, THROTTLE CABLE

4 RCEX0006 LOCK NUT, THROTTLE CABLE ADJUSTER
5 RCEX0007 GASKET, CARBURETOR BOWL
6 RCEX0008 PLUG WASHER, MAIN JET
7 RCEX0009 SPRING, THROTTLE VALVE
8 RCEX0010 E-CLIP, NEEDLE

9 RCEX0011 NEEDLE VALVE, SEAT ASSEMBLY
10 RCEX0012 SCREW, FLOAT BOWL
11 RCEX0013 SCREW, AIR ADJUSTING
12 RCEX0014 SPRING, AIR ADJUSTING SCREW

13 RCEX0015 SCREW, IDLE ADJUSTING
14 RCEX0016 SPRING, IDLE ADJUSTING SCREW

MAIN JET, xxx DENOTES SIZE

15 RCMU0xxx
16 RCEX00xx PILOT JET, xx DENOTES SIZE

(170, 175, 180, 185, 190, 195, 200, 205, 210)

19

Parts – Clutch Actuation

Figure 8

Clutch Actuation

REF # PART # DESCRIPTION

CADC0001 CLUTCH ACUTATOR ASSEMBLY (Lever, Master Cyl., Line, Slave Cyl.)
1 BCEX0005 MASTER CYLINDER
2 CCDC0001 CLUTCH LEVER
3 FCEX0020 CLUTCH LINE
4 CCDC0002 CLUTCH SLAVE CYLINDER
5 ECDC0074 CLUTCH CAP
6 M6 x 16 Bolt
7 ECDC0082 SNAP RING – CLUTCH CAP
8 ECDC0020 CLUTCH PUSH ROD
9 ECDC0018 CLUTCH THROW -OUT BEARING

10 ECDC0019 CLUTCH BEARING SEAT
11 HCCC0002 CABLE CLAMP

NOT SHOWN ZCDCOR05 CLUTCH CAP O-RING
NOT SHOWN ZCDCOR04 SLAVE CYLINDER O-RING

20

Parts – Coolant System

Figure 9

Coolant System

REF # PART # DESCRIPTION

1 FCEX0001 RADIATOR WITH CAP
2 FCMU0047 RADIATOR CAP (2 ears or ribbed)
3 ECEX0010 RADIATOR HOSE, TOP
4 ECEX0011 RADIATOR HOSE, BOTTOM
5 MCEXGR01 GROMMET, BOTTOM RAD MOUNT (2 REQ’D)

NOT

SHOWN FCEX0026 PAD, RADIATOR (2 REQ’D)

6 HCBF0616 FLANGE HEAD BOLT M6X16 (2 REQ’D)
7 ECHA0002 RADIATOR VENT HOSE

NOT

SHOWN MCMUCL05 HOSE CLAMP, VENT HOSE

8 MCMUCL07 HOSE CLAMP (4 REQ’D)
9 FCEXGR01 GROMMET, TOP RAD MOUNT (2 REQ’D)

21

Parts – Electrical System

Figure 10

Electrical System

REF # PART # DESCRIPTION

1 IAMU0005 COIL W/SPARK PLUG CAP (3 WIRE)

2 ECMU0065 SPARK PLUG, CHAMPION (8339-1)
2H ECMU0067 OPTIONAL HOTTER PLUG (8332-1)
2C ECMU0066 OPTIONAL COLDER PLUG (8904-1)

3 ICEX0002 TETHER, IGNITION SHUT OFF

4 HCBC0516 SCREW, M5 X 16 (2 PER)

5 HCCN0000 5MM CLIP NUT (2 PER)

6 ICMU0018 STATOR 3 WIRE ANALOG

7 HCBC0535 5mm x 35 SOCKET HEAD CAP SCREW (2 REQ’D)

8 HCBC0525 5mm x 25 SOCKET HEAD CAP SCREW

9 HCWF0504 WASHER FOR STATOR (3 REQ’D)

10 ICMU0006 ROTOR
11 MCKGGR01 GROMMET - STATOR LEAD
12 HCNS1001 NUT 10MM

NOT SHOWN ICMU0012 WOODRUFF KEY
NOT SHOWN ECDC0085 IGNITION COVER
NOT SHOWN ZCDC0004 GASKET, IGNITION COVER

22

Parts – Engine Clutch

Figure 11

Clutch components

REF. #

1 ECDC0165 CLUTCH BASKET BILLET
2 ECDC0064 CLUTCH BUSHING DC65 – INNER / STEEL
3 ECDC0063 CLUTCH WASHER-DC65 (2 PLACES)
4 ECDC0066 CLUTCH PRESSURE PLATE
5 ECDC0068 CLUTCH DISC-FRICTION – (5 REQ’D)
6 ECDC0067 CLUTCH DISC-STEEL – (4 REQ’D)
7 ECDC0069 CLUTCH HUB
8 ECDC0070 SPRING, CLUTCH – (6 REQ’D)

9 ECDC0071 PLATE, CLUTCH SPRING
10 HCBC0525 5X25 SOCKET HEAD CAP SCREW (6 REQ’D)
11 ECDC0300 SPRING WASHER – CLUTCH
12 HCBC1030 10MM X 30 SHCS BLACK OXIDE
13 ECDC0019 CLUTCH BEARING SEAT
14 ECDC0018 BEARING,CLUTCH THROW OUT
15 ECDC0020 CLUTCH PUSH ROD

PART # DESCRIPTION

23

Parts – Engine – Clutch / Kick Cover

Figure 12

Clutch / kick cover components

REF. # PART # DESCRIPTION

1 ECDC0176 CLUTCH COVER-DC65-MACHINED
2 ZCDC0002 GASKET-CLUTCHCOVER-DC65
3 HCBC0625 6X25 SOCKET HEAD CAP SCREW
4 HCBH0805 M8X12 OIL DRAIN SCREW
5 HCWC0000 GASKET 10MM COPPER WASHER
6 ECDC0046 KICKSTARTER LEVER-DC65
7 HCBH0602 SCREW M6X25 HEX HEAD
8 ECDC0078 SEAL,KICKSTARTER DC65

9 ZCMU0001 GASKET-OIL FILL PLUG
10 ECMU0037 OIL FILL PLUG
11 ZCDCOR05 ORING-CLUTCH CAP-DC65
13 ECDC0074 CLUTCH CAP, DC65, FINISHED
14 ZCDCOR04 ORING,CLUTCH SLAVE CYLINDER
15 CCDC0002 SLAVE CYLINDER-DC65
16 HCBC0601 6X16 SOCKET HEAD CAP SCREW
17 ECDC0082 SNAP RING-CLUTCH CAP
18 ECDC0180 IMPELLER COVER-DRILLED-DC65
19 ZCDC0003 GASKET-IMPELLER COVER
20 HCBC0516 5x16CS-IMPELLER COVER-DC65
21 ECDC0075 IMPELLER, WATERPUMP
22 HCBB0001 10-32X1/2 STAINLESS BUTTON HEAD
23 HCWF0501 5MM FLAT WASHER
24 ECKG0074 SEAL, WATERPUMP

24

Parts - Engine - Ignition Side

Figure 13

Ignition side engine components

REF. # PART # DESCRIPTION

1 ECDC0085 IGNITION COVER-DC65
2 ZCDC0004 GASKET-IGNITION COVER
3 HCBC0402 4X35 SOCKET HEAD CAP SCREW (3 REQ’D)
4 HCBC0525 5X25 SOCKET HEAD CAP SCREW
5 HCBC0535 5X35 SOCKET HEAD CAP SCREW (2 REQ’D)
6 HCWF0501 WASHER FLAT 5MM
7 HCNS1001 NUT M10
8 HCWF0038 3/8 FLAT WASHER

9 ICMU0006 ROTOR
10 ICMU0018 STATOR – 3 WIRE
11 ECDC0024 SEAL, CRANKSHAFT DC65
12 ECDC0087 SHIFTER LEVER - DC65
13 HCBH0620 M6 X 20 HEX HEAD BOLT
14 ECKGSR03 SNAP RING-OUTPUT -COBRA
15 PCKG00xx SPROCKET xx denotes number of teeth
16 ECDC0009 SPACER,SPROCKET
17 ECDC0025 SEAL,OUTPUT DC65
18 ECDC0026 SEAL,SHIFTER DC65
19 HCBC0604 SCREW M6X35, SOCKET HEAD CAP (10 REQ’D)
20 HCBC0606 SCREW M6X45, SOCKET HEAD CAP
21 MCKGGR00 GROMMET-ENGINE CASE-COBRA-STAT
22 ECDC0128 CASE,LEFT,DC65-MACHINED
23 ZCKGB017 O-RING, SPROCKET SPACER
24 ECEX0008 BUSHING, SHIFTER SHAFT

25

Parts - Engine – Kick Mechanism

VENT

Figure 14

Kick Mechanism

REF. # PART # DESCRIPTION

1 ECDC0107 SPLASH GUARD

2 ECDC0111 SPACER, KICK START SHAFT

3 ECDC0040 SPRING, KICKSTART RETURN

4 ECDC0036 SNAP RING, EXTERNAL 16MM

5 ECDC0043 WASHER, KICKSTART BACKUP

6 ECDC0042 SPRING, KICKSTART RAMP

7 ECDC0034 SHAFT, KICK START

8 ECDC0038 RAMP GEAR, KICKSTART

9 ECDC0033 GEAR, KICKSTART
10 ECDC0035 SNAP RING, EXTERNAL 12MM
11 ECDC0037 SNAP RING, EXTERNAL 15MM
12 ECDC0032 GEAR, KICK START IDLE
13 ECDC0039 RAMP, KICSTART
14 ECDC0060 6MM X 16 PHILLIPS FLAT HEAD SCREW
15 HCBB1612 6MM X 12 MM BUTTON HEAD BLACK OXIDE
16 ECDC0105 ELBOW, VENT HOSE

NOT

SHOWN

ECDC0106

HOSE

26

Parts –
Engine – Shift
Mechanism

Figure 15

Clutch components

REF. #

1 ECDC0054 SHIFTER SHAFT (2 COMPONENTS)
2 EADC0055 SPRING, SHIFTER SHAFT
4 EADC0110 SPACER, CENTERING SPRING
5 EADC0099 SPRING, CENTERING
6 EADC0152 SHIFT CASSETTE ASSEMBLY
7 EADC0053 DOWEL – SHIFT DRUM INDEX
8 HCBC1825 8MM X 25 SHCS BLACK OXIDE
9 HCWL0802 8MM LOCKWASHER, HI COLLAR

10 ECDC0057 LEVER NEUTRAL POSITIONING
11 ECDC0058 LEVER, DRIVE GEAR POSITIONING
12 ECDC0098 SPRING, CHANGE LEVER
13 ECDC0059 BOLT SHOULDER
14 ECDC0056 BEARING RETAINER PLATE
15 ECDC0060 6MM X 16 FLAT HEAD PHILLIPS SCREW
16 ECDC0022 BEARING, SHIFT DRUM
17 ECMU0016 BEARING, PRIMARY SHAFT CLUTCH SIDE
18 HCBB1612 6MM X 12 BUTTON HEAD BLACK OXIDE
19 ECDC0024 SEAL, CRANKSHAFT
20 ECDC0112 SPACER, CRANK DRIVE GEAR

21 ECDC0073 CRANK DRIVE GEAR
22 ECDC0036 SNAP RING, EXT 16MM
26 ECDC0129 ENGINE CASE, RIGHT MACHINED
27 ECDC0031 DOWEL, HOLLOW (2 PLACES)

PART # DESCRIPTION

27

Parts – Engine –
Top End

Figure 16

REF # PART # DESCRIPTION

1 ECEX0001 CYLINDER
2 ZCKG0501 BASE GASKET
3 ECMU0084 PISTON KIT
5 ECEX0005 PISTON RINGS (2 PER SET)
6 ECMUSR00 SNAP RING FOR PISTON (2 REQ'D)
7 ECDC0090 WRIST PIN
8 ECDC0061 BEARING, WRIST PIN
9 ZCMUOR07 O-RING, EXHAUST FLANGE

10 ECMU0074 EXHAUST FLANGE

NOT

SHOWN ZCMOTE11 O-RINGS – PIPE TO FLANGE (2 REQ’D)

11 HCBC0602 M6X20, EXHAUST FLANGE SCREW (2 REQ'D)
12 HCNS0701 7MM Nut
13 HCWS1401 FLAT WASHER - HARDENED
14 ECMU0530 CYLINDER HEAD OUTER
15 ZCMUOR02 O-RING, CYLINDER HEAD LARGE
16 ZCMUV024 O-RING CYLINDER HEAD SMALL
17 ZCMUOR10 O-RING CYLINDER STUD (4 REQ'D)
18 ECEX0004 CYLINDER HEAD, INSERT
19 ZCMUV032 O-RING CYLINDER HEAD MEDIUM
20 ECMU0047B STUD, CYLINDER 7mm / 6mm

Engine – Top End

28

Parts - Engine ­Transmission

Figure 17

Transmission

REF # PART # DESCRIPTION

1 ECDC0127 CRANKSHAFT
2 ECDC0023 BEARING, CRANKSHAFT
3 ECDC0128 CRANKCASE, LEFT SIDE
4 ECDC0129 CRANKCASE, RIGHT SIDE
5 ZCDC0001 GASKET, CRANKCASE CENTER
6 ECDC0021 BEARING, OUTPUTSHAFT CLUTCH SIDE
7 ECDC0001 SHAFT, TRANSMISSION PRIMARY (1ST GEAR)
8 ECDC0002 GEAR, 6TH PRIMARY 24T

9 ECDC0003 SNAP RING, EXTERNAL 17 MM (2 REQ’D)
10 ECDC0004 GEAR, 3RD/ 4TH PRIMARY, 18/21T
11 ECDC0005 GEAR, 5TH PRIMARY, 23T
12 ECDC0006 GEAR, 2ND PRIMARY, 16T
13 ECKGBR01 BEARING, OUTPUT IGNITION SIDE
14 ECDC0007 SHAFT, TRANSMISSION OUTPUT
15 ECDC0010 GEAR, 2ND OUTPUT, 34T
16 ECDC0017 SHAP RING, EXTERNAL 18MM (3 REQ’D)
17 ECDC0011 GEAR, 5TH, OUTPUT, 28T
18 ECDC0013 GEAR, 4TH OUTPUT, 30T
19 ECDC0014 GEAR, 3RD OUTPUT, 31T
20 ECDC0015 GEAR, 6TH OUTPUT, 26T
21 ECDC0016 GEAR, 1ST OUTPUT, 37T
22 ECDC0047 SHIFT DRUM
23 ECDC0050 SHIFT ROD (2 REQ’D)
24 ECDC0048 SHIFT FORK, INPUT
25 ECDC0049 SHIFT FORK, OUTPUT (2 REQ’D)
26 ECDC0031 DOWEL, HOLLOW CENTERING (2 REQ’D)
27 ECKG0031 BEARING, PRIMARY SHAFT IGNITION SIDE

NOT SHOWN ECMU0146 BUSHING, SWINGARM PIVOT ENGINE MOUNT (2 REQ’D)

29

Parts – Exhaust System

Figure 18

Exhaust System

REF # PART # DESCRIPTION

1 XAEX2005 ECX70 EXHAUST PIPE

2 ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D)

3 XCMU0005 SPRING, EXHAUST – SHORT

NOT SHOWN XCMU0030 COVER, EXHAUST SPRING

4 MCMUGR06 PIPE GROMMET MALE

5 MCMUGR07 PIPE GROMMET FEMALE

6 MCMUSP02 PIPE GROMMET SPACER

7 HCWF1478 PIPE GROMMET WASHER (2 REQ’D)

8 HCBF0635 M6X35 FLANGE HEAD BOLT

NOT SHOWN HCNL0601 6MM LOCK NUT – FOR FRONT PIPE MOUNT

9 XCDC0003 SILENCER

NOT SHOWN XCMU0018 SILENCER PACKING

10 XCKG0009 PIPE / SILENCER SEAL
11 MCMUGR03 MOUNTING GROMMET (4 REQ’D TOTAL, 2 PER BOLT)
12 TCKG0001 SPACER (2 REQ’D)
13 HCBF0630 M6X30 FLANGE HEAD BOLT (2 REQ’D)
14 ZCEX0001 PIPE COUPLING O-RING (2 REQ’D)

30

Parts - Front A-Arms & Steering Upright

Figure 19

A-arms & steering upright

REF # PART # DESCRIPTION

1 GAEX0001 A-ARM FRONT TOP (SAME PIECE FROM LEFT TO RIGHT)
2 GAEX0002 A-ARM BACK TOP (SAME PIECE FROM LEFT TO RIGHT)
3 GAEX0007 A-ARM FRONT BOTTOM RIGHT

GAEX0006 A-ARM FRONT BOTOTM LEFT

4 GAEX0009 A-ARM BACK BOTTOM RIGHT

GAEX0008 A-ARM BACK BOTTOM LEFT
5 HCBC1065 10MM X 65 SOCKET HEAD CAP SCREW (BLACK OXIDE)
6 MCEXBR05 BUSHING, A-ARM
7 GCEX0006 SPACER, A-ARM PIVOT TUBE
8 HCBF1070 10MM X 70 FLANGE HEAD BOLT
9 HCNL1001 10MM LOCKNUT

10 GAEX0003 UPRIGHT WITH SPINDLE, RIGHT SIDE

GAEX0004 UPRIGHT WITH SPINDLE, LEFT SIDE

11 MCEXCL01 SNAP RING, 1-3/8 INTERNAL
12 MCEXBR01 BEARING, SPHERICAL
13 HCBC0806 8MM X 30 SOCKET HEAD CAP SCREW (2 REQ’D)
14 GCEX0009 STEERING ARM

31

Parts – Front Brakes

Figure 20

Front Brakes

REF # PART # DESCRIPTION

1 BAEX0001 FRONT BRAKE ASSEMBLY
2 HOSE – TEE TO CALIPER
3 BRAKE LEVER
4 BCEX0005 BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER
5 BCEX0003R CALIPER – FRONT RIGHT
6 BCEX0003L CALIPER – FRONT LEFT
7 BCMU0203 REPLACEMENT BRAKE PADS
8 BCEX0002 BRAKE ROTOR - FRONT (SAME L&R)

9 HCBB0516 M5X16 BUTTON HEAD BOLTS WITH THREAD LOC (4 REQ’D)
10 BCEX0003R BRAKE CALIPER BRACKET - RIGHT
11 BCEX0003L BRAKE CALIPER BRACKET - LEFT
12 HCBC0612 6MM X 12 SOCKET HEAD CAP SCREW (2 PER SIDE)
13 HCBC0601 6MM X 16 SOCKET HEAD CAP SCREW (3 PER SIDE)
14 WCEX0001 FRONT HUB WITH WHEEL STUDS
15 FRONT WHEEL STUD (4 REQ’D WITH EACH HUB)
16 GCEX0008 WHEEL SPINDLE (SAME L&R)
17 HCNS1400 M14 CASTLE NUT (SAME L&R)
18 HCCP0002 COTTER PIN (SAME L&R)
19 GCEX0022 INNER HUB SEAL (SAME L&R)

NOT SHOWN ECKGBR01 INNER HUB BEARING

20 WCEX0301 INNER HUB BUSHING
21 WCEX0300 CENTER HUB SPACER
22 ECMU0001 OUTER HUB BEARING
23 WCEX0302 OUTER HUB BUSHING
24 GCEX0023 OUTER HUB SEAL

NOT SHOWN BCMU0205 BRAKE OIL, 2 OZ BOTTLE
NOT SHOWN BCMU0211 BRAKE OIL, 500 CC BOTTLE
NOT SHOWN BCMU0210 SYSTEM BLEED SYRINGE
NOT SHOWN BKMU0200 BRAKE BLEEDING KIT (2OZ OIL, SYRINGE, FITTINGS, ETC…)
NOT SHOWN BCMU0216 MASTER CYLINDER REMOVAL TOOL, TORX WRENCH T08

32

Parts – Front Shock

Figure 21

Front Shock

REF # PART # DESCRIPTION

1 SAEX2005 SHOCK ECX70 – FRONT (2 REQ’D)
2 SCEX1080 SPRING, HELPER, 80 LB/IN (STANDARD)

SCEX1095 SPRING, HELPER, 95 LB/IN (HEAVY)

3 SCEXA155 SHOCK SPRING, STANDARD (YELLOW, 155 LB/IN)

SCEXA145 SHOCK SPRING, LIGHT (RED, 145 LB/IN)
SCEXA165 SHOCK SPRING, HEAVY (BLACK, 165 LB/IN)

4 SCSP0001 TRAVEL LIMITER (1.50”)

SCSP0002 TRAVEL LIMITER (1.25”)

SCSP0003 TRAVEL LIMITER (1.00”)
5 TOP SPRING PERCH
6 HCNL1001 10MM LOCK NUT (2 REQ’D)
7 HCWF0010 10MM FLAT WASHER
8 HCBF1040 10MM X 44 SHOCK BOLT
9 HCBC1002 10MM X 50 SOCKET HEAD CAP SCREW

10 SCKGFX04 PRELOAD RING BOTTOM
11 SCKGFX05 PRELOAD RING TOP (LOCK RING)

33

Parts – Miscellaneous

If you couldn’t find it in one of the other pictures try the table below.

PART # DESCRIPTION
WCEX0005 REAR WHEEL WITH TIRE
WCEX0004 FRONT WHEEL WITH TIRE
FAEX2006 FRAME
FCEX0002 CHAIN SLIDER SPLIT BUSHING
HCBH0804 M8 X 120 (FRONT ENGINE MOUNT BOLT)

HCWF0801 8MM FLAT WASHER

HCNL0801 8MM LOCK NUT

FAEX0017R SPACER, FRONT ENGINE MOUNT RIGHT

FAEX0017L SPACER, FRONT ENGINE MOUNT LEFT

34

Parts –
Plastic
Bodywork
& Seat

Figure 22

Plastic and Bodywork

REF # PART # DESCRIPTION

1 TCEX0001 FRONT CLIP

NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN

2 TCEX0002 REAR DECK

NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN

NOT SHOWN HCBB0616 6MM BUTTON HEAD (2 REQ’D AT FRONT)
NOT SHOWN HCWF0601 6MM FLAT WASHER (2 REQ’D AT FRONT)

3 TCEX0011 SEAT

NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN

4 ECDC0106 FUEL VENT HOSE
5 TCHA0002 FUEL CAP
6 FAEX0010 FUEL TANK (NO PETCOCK, CAP, OR BRACKET)
7 FCMU0027 FUEL LINE
8 TCMU0000 FUEL PETCOCK (’06 LEVER)

9 HCBC0601 M6 X 16 SOC. HEAD BOLT (2 REQ’D)
10 MCMUGR04 GROMMET (2 REQ’D)
11 TCEX0010 FUEL TANK BRACKET

NOT SHOWN TCHA0005 TANK MOUNT REAR
NOT SHOWN HCFH0620 M6 X 20 FLAT HEAD
NOT SHOWN HCBF0616 M6 X 16 FLANGE HEAD BOLTS (2 REQ’D)
NOT SHOWN HCBF0620 M6 X 20 FLANGE HEAD BOLT (1REQ’D AT THE REAR)
NOT SHOWN WCMU0006 SPACER, TANK MOUNT (1REQ’D AT THE REAR)

HCBB0616 M6 X 16 BUTTON HEAD (4 REQ’D AT BACK)
HCWF0601 6 MM FLAT WASHER (4 REQ’D AT BACK)
HCBB0620 M6 X 20 BUTTON HEAD (2 REQ’D AT FRONT)
HCWF0601 6MM FLAT WASHER (2 REQ’D AT FRONT)
MCMUGR07 GROMMET, (2 REQ’D AT FRONT)
HCWF1478 WASHER, FENDER (2 REQ’D AT FRONT)
HCNL0601 6MM LOCK NUT (2 REQ’D AT FRONT)

HCBB0620 M6 X 20 BUTTON HEAD (2 REQ’D PLASTIC TO GRAB BAR)
HCWF0601 6MM FLAT WASHER (2 REQ’D PLASTIC TO GRAB BAR)
MCMUGR07 GROMMET, (2 REQ’D PLASTIC TO GRAB BAR)
HCWF1478 WASHER, FENDER (2 REQ’D PLASTIC TO GRAB BAR)
HCNL0601 6MM LOCK NUT (2 REQ’D PLASTIC TO GRAB BAR)

HCBB0635 M6 X 35 BUTTON HEAD (1 REQ’D SEAT TO PLASTIC)
MCMUGR04 GROMMET (1 REQ’D SEAT TO PLASTIC)
HCWF1478 WASHER, FENDER (1 REQ’D SEAT TO PLASTIC)
HCNL0601 6MM LOCK NUT (1 REQ’D SEAT TO PLASTIC)

35

Parts –
Rear
Brake

Figure 23

Rear Brake System

REF # PART # DESCRIPTION

BADC0001 BRAKE COMPLETE
1 BCKG0001 BRAKE PEDAL
2 BCDC0009 BRAKE PIVOT BOLT
3 HCBC0601 M6X16 SOC. HEAD BOLT
4 FCEX0018 BRAKE ADJUST ECCENTRIC
5 BCMUSP01 BRAKE RETURN SPRING
6 BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D)
7 BCDC0004 PUSH ROD, REAR BRAKE
8 HCBC0601 M6X16 SOC. HEAD BOLT (2 REQ’D)
9 HCWF0601 6MM FLAT WASHER (2 REQ’D)

10 HCPP0832 BRAKE HOSE CLAMP FASTENER (2 REQ’D)
11 HCCC0000 BRAKE HOSE CLAMP (2 REQ’D)
12 BCDC0151 REAR BRAKE HOSE
13 HCBC0840 M8X40 SOCKET HEAD CAP SCREW
14 HCBC0816 M8X16 SOCKET HEAD CAP SCREW
15 HCWF0801 M8 FLAT WASHER SPACER (4 REQ’D)
16 BCDC0002 CALIPER – REAR BRAKE
17 BCDC0007 BRAKE PAD KIT - ACCESSORY
18 BCEX0001 REAR BRAKE CARRIER

NOT SHOWN

19 BCEX0014 BRAKE/SPROCKET HUB
20 BCEX0004 BRAKE ROTOR REAR QUAD

NOT SHOWN

21 HCBB0830 8MM X 30 BUTTON HEAD (4 REQ’D)
22 HCNL0801 8MM LOCKNUT (4 REQ’D)
23 BCDC0005 MASTER CYLINDER - REAR
24 BCDC0012 BRAKE LINE – RESERVOIR TO MASTER CYLINDER

NOT SHOWN
NOT SHOWN

25 BCDC0006 BRAKE FLUID RESERVOIR
26 MCMUCL05 LINE CLAMP (2 REQ’D)

NOT SHOWN
NOT SHOWN

WCEX0006 SNAP RING, BRAKE CARRIER RETAINER

HCBC0625 6MM X 25 SOCKET HEAD CAP SCREW (2 REQ’D)

HCBC0601 M6X16 SOC. HEAD BOLT
WCMU0006 SPACER – RESERVOIR MOUNT

BCDC0152 BANJO BOLT
BCDC0153 CRUSH WASHER

36

Parts – Rear Drive

Figure 24

Rear Drive

REF # PART # DESCRIPTION

1 GAEX0005 REAR AXLE
2 WCEX0003 WHEEL LUG (8 REQ’D)
3 HCNS1001 LUG NUT (8 REQ’D)

NOT SHOWN

4 GCEX0014 BRAKE/SPROCKET HUB (2 REQ’D)

NOT SHOWN

5 HCBH0808 M8 X 30 HEX HEAD BOLTS (4 REQ’D)
6 HCNL0801 M8 LOCK NUT (4 REQ’D)
7 PCDC00XX SPROCKET (37T – 51T) – XX DENOTES # OF TEETH
9 GCEX0016 BRAKE HUB SPACER

10 HCKW0001 HUB KEY
11 GCEX0024 REAR WHEEL HUB SPACER (2 REQ’D)*
12 GCEX0011 REAR WHEEL HUB (2 REQ’S)
13 HCCP0002 COTTER PIN (2 REQ’D)

NOT SHOWN

14 HCNC0020
15 MCEXBR03 BEARING, REAR AXLE
16 GCEX0015 ECCENTRIC

HCWF0010 LUG WASHER (8 REQ’D)
HCBC0625 M6 X 25 HUB PINCH BOLT (2 PER HUB)

PCMU0104 428 CHAIN – 104 LINK

- UP TO THREE EXTRA HUB SPACER S CAN BE USED PER SIDE TO
ADJUST TRACK WIDTH.

37

Parts – Rear Shock

Figure 25

Rear Shock

REF # PART # DESCRIPTION

1 SAEX2006 SHOCK, REAR QUAD FOX
2 SCEX0110 SPRING, HELPER 110LB/IN, STANDARD

SCEX0125 SPRING, HELPER 125LB/IN, HEAVY
SCEX0150 SPRING, HELPER, 150 LB/IN, X HEAVY

3 SCEX1375 SHOCK SPRING, STANDARD (WHITE, 375 LB/IN)

SCEX1350 SHOCK SPRING, LIGHT (RED, 350 LB/IN)
SCEX0400 SHOCK SPRING, HEAVY (YELLOW, 400 LB/IN)

4 SCSP0003 TRAVEL LIMITER (1.00”)

SCSP0001 TRAVEL LIMITER (1.50”)

SCSP0002 TRAVEL LIMITER (1.25”)
5 SPRING SEPARATOR
6 HCNL1001 10MM LOCKNUT
7 HCWF0010 10MM FLAT WASHER
8 HCBF1040 10MM X 44 SHOCK BOLT
9 SCKGFX04 PRELOAD RING BOTTOM

10 SCKGFX05 PRELOAD RING TOP (LOCK RING)

38

Parts – Swingarm Assembly

Figure 26

Swingarm

REF # PART # DESCRIPTION

1 GAEX0100 SWINGARM
2 GCMU0001 BUSHING, SWINGARM (4 PER)
3 GCEX0021 SPACER, SWINGARM PIVOT – (2 REQ’D)
4 HCBH1421 SWINGARM PIVOT BOLT (M14 X 1 HEX HEAD)
5 HCNL1402 SWINGARM LOCK NUT (M14 X1)
6 GCEX0050 TOP SWINGARM GUARD – ECX70
7 HCPP0832 SELF TAPPING SCREW
8 HCBF1040 BOLT, SHOCK

9 HCCC0000 BRAKE HOSE CLAMP (2 REQ’D)
10 HCBH0810 ECCENTRIC PINCH BOLT (2 REQ’D)
11 HCNL0801 8MM LOCK NUT (2 REQ’D)
12 HCWF0801 8MM FLAT WASHER (4 REQ’D)
13 PAKG0002 CHAIN GUIDE ASSEMBLY COMPLETE
14 HCBF0620 6MM X 20 FLANGE HEAD BOLT (2 REQ’D)

39

Parts – Tie Rod Assembly

Figure 27

Tie Rod Assembly

REF # PART # DESCRIPTION

1 FCEX0015 TIE ROD
2 MCEXBR02R RH TIE ROD END
3 MCEXBR02L LH TIE ROD END
4 HCNJ120L RH JAM NUT
5 HCNJ120R LH JAM NUT
6 GCEX0002 SPACER, BALL JOINT
7 HCNC0010 10MM CASTLE NUT (2 REQ’D)
8 HCCP0003 COTTERPIN 3/32” X ¾” (2 REQ’D)

40

Engine Parts / Service

At this time, the full service instructions for are not yet available your Cobra
Motorcycle.

If you don’t feel comfortable with the service work, simply take your engine out of
the frame and sent it to:

Cobra Motorcycle Mfg.
11511 Springfield Road
North Lima, Ohio 44452

Cobra’s technicians will go through the entire engine, replacing gaskets, bolts,
any old part that is worn. The engine will be rebuilt using the same precision
gauging and assembly fixtures as when it was assembled new. Before being
returned, the engines performance will be measured on a dynamometer to
ensure that your engine is operating at its highest potential. All this for one low
nominal fee, plus cost of parts. Call [phone] for details.

ES1: Fuel & Air System

Reeds

CAUTION:

• The reeds must lay flat on the reed cage.

• If the reed tips aren’t lying flat, replace them immediately.

• The reeds must have a tight seal on the reed cage.

• If the reed is damaged in any way, replace it. This means cracks, chips,

and ruptures. Anything abnormal, replace the reeds.

Take the reed cage out and hold it up to the light and look in through the cage. If
you see light between the reed pedals and the frame, then replace the reeds. If
you do not see light, then the reeds should be ok. (See figure 28)

The presence of light indicates that the reeds should be replaced, or possibly

turned over.

41

Figure 28

The presence of light indicates that the reeds should be replaced, or possibly
turned over.

Carburetor Cleaning

Clean the carburetor in a well-ventilated area, and take care that there is no
spark or flame anywhere near the working area; this includes any appliance with
a pilot light. Because of the danger of highly flammable liquids, do not use
gasoline or low flash -point solvent to clean the carburetor.

1. Make sure the fuel is shut off.

2. Remove the carburetor.

3. Drain the fuel in the carburetor.

4. Disassemble the carburetor.
CAUTION:

Do not use compressed air on an assembled carburetor. Or the pressure may
deform the float. Do not use a strong carburetor cleaning solution, which could
attack the parts of the carburetor; instead, use a mild high cleaning solution safe
for plastic parts.

5. Immerse all the metal parts in a carburetor cleaning solution.

6. Rinse the parts in water.

7. After the parts are cleaned, dry them with compressed air.

8. Blow out the fuel passages with compressed air.

9. Assemble the carburetor

10. Install the carburetor onto the motorcycle.

42

ES2: Exhaust

The pipe is a crucial element to a two-stroke engine. Any kinks, dents, or
damage done to the pipe will result in a performance loss.

NOTE:
Be sure to take the pipe off, and remove any carbon that may be built up.

Carbon build up is created from exhaust. Exhaust has oils in it, and the oils cling
to the walls of the inside of the pipe. Over a long period of time, the diameter of
the pipe will decrease, due to carbon build up. So it is essential to clear the
residue.

CAUTION:
For optimum performance it is important to repack the silencer. Signs of your
silencer needing to be repacked are:

• The bike is louder than normal.

• A loss of power.

Tuning

This section is incompl ete at this time.

43

Troubleshooting

1) Engine not behaving properly

a) Carburetor top is installed backwards (happens a lot)
b) The carburetor slide indexing pin is missing

2) Engine is down on power

a) Clutch engagement is not set properly
b) Jetting is incorrect
c) Silencer needs repacked
d) Exhaust pipe

i) Has excess carbon buildup
ii) Has large dent in it

e) Compression is low

i) Piston

ii) Rings
f) Reeds are damaged
g) Ignition timing is incorrect

3) Engine is excessively loud

a) Silencer needs repacking

4) Engine ‘blubbers’ at high RPMs

a) Jetting too rich

5) Engine won’t start

a) Fuel

i) None in tank

ii) Is sour or bad
b) Carburetor is dirty
c) Ignition

i) Spark plug fouled

ii) Spark plug cap off

iii) Engine Shut-off ‘kill’ switch is shorted

iv) Bad electrical ground

v) Stator winding damaged
d) Exhaust is plugged

6) Engine won’t idle

a) Idle knob needs adjusted

b) Carburetor jets are dirty

44

Index

A-arms................................................32

Air Filter..............................................17

Maintenance..................................14

Axle.....................................................38

Bars and Controls.............................18

Break-In................................................9

Bumper...............................................19

Carburetion

Specifications..................................5

Carburetor.........................................20

Chain

Adjustment.....................................13

Chassis

Specification....................................5

Frame Parts.......................................35

Front Brake........................................33

Fuel

Petcock..........................................10

Fuel System

Parts list .........................................42

Service...........................................42

Gas Tank ...........................................36

General Tips ......................................11

Grab Bar ............................................19

Hardware

Frame.............................................35

Plastic.............................................36

Jetting

Torque..............................................7

Clutch.................................................24

Clutch Cover.....................................25

Clutch Lubricant

Replacing.......................................12

Cylinder..............................................29

Eccentric............................................38

Electrical

Parts...............................................23

Engine

Parts List........................................42

Specifications..................................5

Torque..............................................6

Engine Mount Front.........................35

Exhaust..............................................44

Stock.................................................5

Kick Mechanism ...............................27

Lubrication

Recommended ...............................5

Maintenance

Schedule........................................12

Tips.................................................12

Nerf Bars............................................19

Oil

Recommended ...............................5

Optional Components........................8

Parts

Inlet.................................................42

Reeds.............................................42

Petcock..............................................10

Parts...............................................31

Fenders..............................................36

45

Piston..................................................29

Plastic.................................................36

Radiator .............................................22

Steering Upright................................32

Rear Brake

Parts...............................................37

Rear Drive..........................................38

Rear Shock

Parts...............................................39

Reeds.................................................42

Parts...............................................17

Rings ..................................................29

Seat....................................................36

shift drum ...........................................30

shift forks............................................30

Shift Mechanism...............................28

Shock..................................................34

Spark Plug

Recommended ...............................5

Swingarm Parts ................................40

Throttle ...............................................17

Tie Rod...............................................41

Tips.....................................................11

Toe In Adjustment............................16

Top End

Parts...............................................29

Torque

Chassis............................................7

Engine ..............................................6

Transmission.....................................30

Specifications..................................5

Transmission Lubricant

Replacing.......................................12

Troubleshooting

Specifications......................................5

Torque Values.................................6

Spherical Steering Bearing.............16

Starting...............................................10

Steering Stem ...................................18

General..........................................45

VIN reading .......................................11

WARNING ...........................................2

Water Pump Cover...........................25

Wheels ...............................................35

1