Cobra 2007 King 50, 2008 CX50 SR Service Manual

Owners
Tuning
2007 King 50
Parts
Service
1
For parts orders contact your local dealer
To locate your closest Cobra dealer
log on to
www.cobramotorcycle.com
or call
(517) 437-9100
If you need technical assistance
contact your local dealer or call
the Cobra Technical Support Hotline at
(517) 437-9100
Cobra Motorcycle MFG., Inc.
240 Uran Road
Hillsdale, MI 49242
MCKG2007.3
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 CX50SR IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS.
THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE BY A SUFFICIENTLY SKILLED RIDER AND SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RIDING.
IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH. THIS BIKE IS INTENDED FOR EXPERIENCED RACERS ONLY AND NOT FOR
BEGINNERS. IT IS YOUR RESPONSIBILITY AS THE OWNER OF THIS COBRA MOTORCYCLE
OR AS THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS COBRA MOTORCYCLE IN PROPER OPERATING CONDITION.
THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 80 LBS WITH FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE THAN 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.
MCKG2007.6
2
Table Of Contents
GENERAL INFORMATION...................................................................................5
SPECIFICATIONS - GENERAL.................................................................................5
PTIONAL COMPONENTS......................................................................................6
O
PECIFICATIONS - TORQUE VALUES ......................................................................7
S
REAK-IN PROCEDURE.........................................................................................8
B
STARTING PROCEDURE........................................................................................9
MAINTENANCE ..................................................................................................10
IPS .................................................................................................................10
T
CHEDULE ........................................................................................................11
S
EPLACING TRANSMISSION / CLUTCH LUBRICANT.................................................12
R
ROPER CHAIN ADJUSTMENT .............................................................................14
P
EAR BRAKE MAINTENANCE...............................................................................14
R
IR FILTER CLEANING ........................................................................................16
A
ORK OIL REPLACEMENT ...................................................................................19
F
RICTIONAL DRIVE (CFD) ..................................................................................20
F
PARTS................................................................................................................21
ARTS – AIRBOX & INLET SYSTEM......................................................................21
P
ARTS – BARS AND CONTROLS ..........................................................................22
P
ARTS - CARBURETOR.......................................................................................23
P
ARTS – COOLANT SYSTEM ............................................................................... 24
P
ARTS – ELECTRICAL SYSTEM............................................................................25
P
ARTS – ENGINE – BOTTOM END AND TRANSMISSION ..........................................26
P
Parts – Engine Clutch and Kicker................................................................27
Parts – Engine – Ignition and Water Pump..................................................28
Parts – Engine – Top End............................................................................29
ARTS – EXHAUST SYSTEM................................................................................30
P
PARTS – FORKS & TRIPLE CLAMPS.....................................................................31
ARTS – FORKS – LEG ASSEMBLY...................................................................... 32
P P
ARTS – FRAME I ..............................................................................................33
Parts – Frame II...........................................................................................34
3
P
ARTS – FRONT BRAKES....................................................................................35
ARTS – FRONT WHEEL.....................................................................................36
P
ARTS – PLASTIC BODYWORK & SEAT ................................................................37
P
ARTS – REAR BRAKE .......................................................................................38
P
ARTS – REAR WHEEL.......................................................................................39
P
ARTS – SHOCK................................................................................................40
P
ARTS – SWINGARM ASSEMBLY..........................................................................41
P
SERVICE............................................................................................................42
NGINE SERVICE ...............................................................................................42
E
Base Gasket Selection ................................................................................43
Engine Removal ..........................................................................................45
Complete Engine Disassembly Procedure ..................................................46
Top End Disassembly Procedure ................................................................ 46
Splitting the Cases.......................................................................................47
Engine assembly .........................................................................................48
LUTCH ............................................................................................................50
C
GNITION ...........................................................................................................55
I
OOLING SYSTEM..............................................................................................57
C
FUEL & AIR SYSTEM ..........................................................................................61
XHAUST ..........................................................................................................64
E
HEELS & TIRES...............................................................................................65
W
RAKES ............................................................................................................65
B
RONT FORKS...................................................................................................66
F R
EAR SHOCK ....................................................................................................68
TUNING..............................................................................................................69
EARING...........................................................................................................69
G
USPENSION.....................................................................................................71
S C
ARBURETION ...................................................................................................72
TROUBLESHOOTING........................................................................................75
INDEX.................................................................................................................76
4
General Information
Specifications - General
Items CX50 SR
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 Coolant Liquid Performance Mini Coolant or Antifreeze Displacement 49.8 cc Bore and stroke 39 mm x 41.7 mm, “V” head 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” (1.02 mm) Before Top Dead Center (BTDC) Fuel type High octane pump gasoline
Oil type Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In) Carburetion 19 mm Dell’Orto
RACE FUELS ARE NOT RECOMMENDED
Cobra Venom 2-cycle Race Oil
Slow (Pilot) Jet 60
Float Height 16mm + 0.5mm (0.63” + 0.020”)
Transmission
Speed Single Final drive ratio 14/38 T Chain 100 links 420 Transmission / clutch oil type
Main Jet 95
Cobra Venom 3 Shoe Clutch Milk
Quantity 235 ml (8.0oz)
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 5 weight
Fork oil amount 107 ml (3.6oz)
Rear shock (std. settings) Compression 16 clicks out
Rebound 12 clicks out
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 Weight of Rider (lb) Fork Spring Shock Spring
Less than 51 0.23 kg/mm
KCKG1223
51 - 60 0.25 kg/mm
KCKG1206
Greater than 60 0.27 kg/mm
KCKG1227
Suspension Valving
Damping Rate Fork Valving
Compression
(base valve)
Soft (fast) KAKG0024 KAKG0027 SKKGFX02
Standard KAKG0022 KAKG0025 SKKGFX01
Hard (slow) KAKG0031 KAKG0032 SKKGFX03
Tires, tubes or ‘Tire Balls’
Fork Valving
Rebound
(mid valve)
gray, 3.5 kg/mm
SCKGFX35
yellow, 3.7 kg/mm
SCKGFX37
gold, 3.9 kg/mm
SCKGFX39
Shock Valving
(kit)
6
Specifications - Torque Values
Fastener Cylinder head
nuts Crankcase bolts
Spark plug (SP) (SP) (SP) M14 x 1.25 Stator bolts 2.1 25 2.8 M5 X 0.8
Stator cover bolts Clutch cover bolts
Clutch nut 35 420 47 M10 x 1.25* Clutch bolts 12 144 16 M6 x 1.0 CFD nut 55 664 75 ½” x 20 LHT Front axle nut 25 300 34 M12 x 1.25
Engine mount bolts Swingarm Pivot Intake manifold bolts
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 21 250 28 M14 X 2.0
4.6 55 6.2 M6 X 1.0
Torque Value
Size & Remarks
Rear Axle Bolt 25 300 34 M12 X 1.25 Rear Sprocket
Bolts Fork cartridge rod Triple clamp bolts (bottom) Triple clamp bolts (top)
Fork cap 5 60 6.7 1.25” x 18 Ignition rotor
nut
* 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.
18 216 24 7 mm 12 144 16 6 72 8 M6 x 1.0 9 108 12 M6 x 1.0
40 480 54 M10 x 1.25*
7
Break-In Procedure
Your Cobra CX50 SR is a close-tolerance high performance machine and break­in time is very important for maximum life and performance. The CX50 SR can be ridden hard after the first ½ hour break-in time but it is recommended that no adjustments are made to the carburetion or suspension until the full 8 hours of bike break-in has elapsed. Also, after the engine, transmission, and drive train have been broken-in for the full 8 hours, the bike will be faster!
Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use high-octane pump gas, with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil. (Part # MCMUOL02)
CAUTION: Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine wear or damage to the machine.
Adhering to the following break-in schedule will result in long lasting high performance machine.
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 coolant through the radiator overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level will cover the top of the radiator cores. Removing the radiator cap and looking inside is the only way to check the coolant level.
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 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 that it ‘clacks’ shut properly.
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.
Always wear a helmet and other protective riding gear. 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).
9
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.
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.
CAUTION: 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.
CAUTION: Make sure your riders’ foot is not resting on the foot brake while they are riding
.
Maintenance
It is important that you adhere to this maintenance schedule so as to promote the longevity of your Cobra Motorcycle.
Tips
1. Cobra lubricants:
a. Cobra Clutch Milk has been specifically formulated to meet the
stringent temperature, frictional, and load requirements unique to the high engine speeds and centrifugal clutch of the Cobra 50cc motorcycles.
b. Cobra Two Cycle Oil exceeds the JASO FD & ISO-L-EGD
specifications, which are the worlds most stringent requirements on lubrication, detergency, and smoke. Use only a 2-cycle oil that meets these specifications.
2. Filling your transmission with more than 8.0 oz (235 cc) of lubricant may
help to transfer heat from the clutch. Filling with more than 12 oz (295 cc) will degrade performance.
3. The cylinder base gasket has been ‘fitted’ for your engine. The code
number stamped into the engine cases will guide you to what thickness base gasket is required during a common top end service. See the service section of this manual to correspond a code number with a base gasket part number.
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. New chains will stretch on first use. Never install a new chain prior to a
race. Always ‘break’ them in during practice.
10
7. Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number).
The first two digits indicate the model and the seventh indicates the model year (MY).
a. Example, Acxxxx7xxx is a 2007 MY CX50 SR.
Schedule
Between each ride
o Check the air filter (clean and re-oil as necessary). o Insure the smooth operation of the throttle cable (throttle soundly
‘clacks’ shut).
o Check for frayed strands of the throttle cable inside the throttle housing
and replace if necessary.
o Check for adequate tire pressures and adjust if necessary. o Check all nuts and bolts for proper torque and re-torque if necessary. o Spray all moving parts with WD40 or other light oil. o Check drive chain for
Proper tension and adjust if necessary. Adequate lubrication and lubricate if necessary.
o Insure that the ignition stator and rotor are clean and dry. o Check the frame for cracks in the metal or cracks in the paint that
might indicate that the metal has been stressed beyond it’s safe limits. Replace or get properly rewelded as necessary.
o Check the rims for signs of stress, like cracks around the rim, spokes
and hub.
Every 2 hours of operation o Replace the transmission oil.
Every 10 hours of operation
o Replace the fork oil. o Have the shock oil replaced by a Certified Cobra Mechanic.
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.
11
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. Use ER70S6 filler if welding on the frame.
4. If your kick-starter lever does not return properly, first try loosening the six
kick/clutch cover screws ½ turn. Hold the kick lever ½ way down while retightening the six screws starting for the center and working out.
5. Inspect CFD slip torque every 10 hours of riding or replace the friction
papers and the load spring (Bellville spring) every 20 hours.
6. Check proper clutch engagement before and after each ride. If the clutch is
engaging properly DO NOT feel the need to take the clutch apart to; measure the spring stack, clean the stack, replace the springs, etc... Cobra has worked real hard to make a clutch that is low maintenance and so only take it apart if it NEEDS to be maintained.
Replacing Transmission / Clutch Lubricant
Tools needed:
235 ml (8.0 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01).
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. Remove the oil drain plug located on the right side of the engine, on the
clutch cover, near the brake lever (figure 1).
12
Figure 1
4. After it has drained, reinstall the plug, being sure that the gasket is in place.
5. Reapply oil from oil fill plug 235 cc (8.0 oz) Cobra Venom 3 Shoe Clutch Milk
thru the oil fill plug.
NOTE:
Putting additional oil, up to 12 oz (295 cc), can help clutch life. More than 12 oz (295 cc) will degrade engine performance.
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 gasket is in place.
CAUTION: Cobra has spent considerable time and money developing the proper lubrication to handle the harsh environment of the automatic clutch and transmission of this motorcycle. Cobra’s specially developed Cobra Venom 3 Shoe Clutch Milk
(Part
# MCMUGF01) was formulated to provide superior lubrication and cooling capability over extended periods of time and is the recommended lubricant for your Cobra motorcycle.
13
Proper Chain Adjustment
1. Make sure that the rear wheel is aligned properly.
Push down on the seat,
2.
compressing the suspen­sion down to where the chain is tightest. At this point, there should be a minimum of 1” of slack.
With the rear wheel
3.
Figure 2
elevated, there should be a minimum of 2.5” of slack between the swing arm and the chain.
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 allow 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).
14
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.
15
Air Filter Cleaning
Figure A1
Remove the seat (unscrew the knob under the seat & rear fender)
Squeeze the two tabs together as shown in figure A1 and pull the wire
retainer up and out of the air box
The filter may now be pulled from the airbox
Clean the airbox of dirt and clean the filter sealing surface of the old sealing
grease.
CAUTION: Pay particular attention to clean any particles from the airbox between the filter location and the carburetor.
NOTE:
Cobra has available a carburetor cover that allows easy cleaning of the airbox.
1. Remove the air boot
2. Install the cover (RCMU0109) over the carburetor inlet
3. Spray out the airbox.
Do not clean the air filter with gasoline or other highly volatile petroleum product. Diesel fuel or kerosene would be preferred but caution should still be taken. Hot soapy water works well.
1. Clean the filter in hot soapy water to remove all dirt particles.
2. Allow it to dry thoroughly.
3. Saturate with filter oil and remove excess.
16
NOTE:
It’s very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting.
4. Apply grease to the black sealing surface of the filter and reinstall as in figure A2.
Figure A2
5. Squeeze the two finger tabs together on the wire retainer and install into the airbox while aligning the bottom guiding tabs “legs” with the arrows on the filter (figures A3 & A4)
Figure A3 Figure A4
6. Push the wire retainer down until it bottoms
CAUTION: If the side arms do not align with the associated holes it is quite likely that the legs did not make it into the holes. Realign and try again.
17
7. Press each side arm into their respective holes one at a time with each finger tab.
Figure A5 Figure A6
8. When properly installed, the filter and retainer should look like figure A7, with the filter material extending beyond the perimeter of the wire retainer
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.
Figure A7
18
Fork Oil Replacement
Tools required
Two 19 mm wrenches or sockets
4 & 5 mm hex key (Allen wrench)
25mm wrench or socket
5 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 (25mm socket).
4. Remove the fork legs from the triple clamps (5 mm hex key).
5. One leg at a time
a. Remove the fork cap from the leg. b. Separate the fork cap from the damper rod. c. Pull out the fork spring. d. Place upside down over a suitable pan, tray, or container. e. Work the damper rod up and down several times. f. Allow it to drain completely.
Assembly procedure
1. Fill the fork leg with 4.4 oz (130 ml) 5 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).
19
Frictional Drive (CFD)
The Cobra Frictional Drive (CFD) is essentially a slip clutch that dissipates torque spikes transmitted from the rear wheel to the rest of the drive line and engine. Instead of these torque spikes potentially damaging internal components, the CFD allows the transmission to slip with respect to the engine. For this to occur, the CFD must function properly by ‘slipping’ between a minimum torque value, and a maximum torque value.
The slip torque of the CFD should be checked every 5 hours of operation.
Slip Torque
Minimum 50 67
Maximum 125 169
With the clutch cover off, you can check the slip torque by ‘blocking’ the primary gear with a suitably strong device, or Cobra tool EAMU0004, and then rotate the blue CFD nut counter clock-wise with a torque wrench observing the reading when the nut (and shaft) turn.
If you do not have the capability of checking for proper slip torque, you should replace the friction papers and the load spring (Bellville spring) every 10 hours to ensure proper operation.
NOTE
To loosen and tighten the blue CFD nut, use a strong wooden object (large hammer handle) through the spokes of the rear wheel as a brace against the swingarm to stop transmission shaft rotation.
CAUTION: The blue CFD nut has left hand threads which require clock-wise rotation to loosen.
Ft-lb N-m
20
Parts
Parts – Airbox & Inlet System
Figure 5
Coolant System
REF # PART # DESCRIPTION
1 RCKG0501 AIRBOX 2 HCBF0616 M6X16 FLANGE HEAD BOLT 3 RCKG0512 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 14 ECKG0202 REED CAGE ASSEMBLY WITH REEDS
NOT SHOWN
15 ZCMU0132 GASKET – REEDS TO ENGINE 16 HCBC0625 M6X25 SOCKET HEAD CAP SCREW 17 HCWF0601 6MM FLAT WASHER
NOT SHOWN
ECKG0205 REED REPLACEMENT KIT
RCCM1301 VELOCITY STACK
21
Parts – Bars and Controls
Figure 3
Bars and Controls
REF # PART # DESCRIPTION
1 TCMU0402 HANDLEBAR - ALUMINUM 2 MCMU0001 OPTIONAL CROSS BAR PAD 3 TCMU0008 GRIPS (SET OF TWO) 4 FCMU0066 THROTTLE ASSEMBLY
NOT
SHOWN
5 BCKG0023 ALLOY BRAKE LEVER W/BALL 6 BCKG0024 BRAKE PERCH ASSY W/LEVER & BALL
NOT
SHOWN
7 FCMU0019 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
NOT
SHOWN
13 FCMU0033 KILL SWITCH ASSEMBLY
FCMU0068 THROTTLE COVER
BAKG0004 SHIELDED BRAKE HOSE ASSEMBLY
HCBH0816 M8 X 16 HEX HEAD BOLT HCWF0801 8MM FLAT WASHER
22
Parts - Carburetor
Figure 4
Carburetor
REF. # PART # DESCRIPTION
1 RCMU0305 CARB SLIDE 2 RCMU0601 NEEDLE 3 RCMU00 ATOMIZER 2.62 AU
4 RCMU00xx MAIN JET, xx denotes size 5 RCMU00xx PILOT JET, xx denotes size 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
13 ZCMU0007 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0028 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 RCMU0108 FLOAT BOWL 30 HCWF0401 WASHER 4MM FLAT 31 RCMU0201 SCREW – FLOAT BOWL
NOT
SHOWN
NOT
SHOWN
Not Shown FCMU0026 FUEL LINE, 5” Not Shown MCMUCL04 HOSE CLAMPS – FUEL LINE
Not Shown RCMU0018 CARBURETOR COMPLETE 19 mm Not Shown RCMU0022 VENT HOSE 2” EACH
RCCM1301 VELOCITY STACK -05 MCKGHO01 CLAMP – CARBURETOR TO FILTER
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