Cobra 2008 ECX50 Service Manual
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 Street
Hillsdale, Michigan 49242
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 ECX50 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 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 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.
MCE52007.2
Table Of Contents
General Information..............................................................................................5
Specifications - General....................................................................................5
Specifications - Torque Values..........................................................................6
Optional Suspension Components....................................................................7
Break-In Procedure...........................................................................................8
Starting Procedure ............................................................................................9
Maintenance .......................................................................................................10
Tips .................................................................................................................10
Schedule .........................................................................................................10
Replacing Transmission / Clutch Lubricant .....................................................12
Chain adjustment ............................................................................................13
Air Filter Cleaning............................................................................................14
Frictional Drive (CFD)......................................................................................15
Front end.........................................................................................................16
Parts ...................................................................................................................17
Parts – Air Inlet System...................................................................................17
Parts – Bars and Steering ...............................................................................18
Parts – Bumper, Nerf & Grab Bars..................................................................19
Parts - Carburetor............................................................................................20
Parts – Coolant System...................................................................................21
Parts – Electrical System ................................................................................22
Parts – Engine – Bottom End and Transmission.............................................23
Parts – Engine Clutch and Kicker................................................................24
Parts – Engine – Water Pump .....................................................................25
Parts – Engine – Top End............................................................................26
Parts – Exhaust System..................................................................................27
Parts - Front A-Arms & Steering Upright .........................................................28
Parts – Front Brakes .......................................................................................29
Parts – Front Shock.........................................................................................30
Parts – Miscellaneous.....................................................................................31
Parts – Plastic Bodywork & Seat.....................................................................32
Parts – Rear Brake..........................................................................................33
Parts – Rear Drive...........................................................................................34
3
Parts – Rear Shock (Öhlins)............................................................................35
Parts – Rear Shock (Fox)................................................................................36
Parts – Swingarm Assembly............................................................................37
Parts – Tie Rod Assembly...............................................................................38
Service................................................................................................................39
Engine Service................................................................................................39
Base Gasket Selection ................................................................................40
Engine Removal ..........................................................................................42
Complete Engine Disassembly Procedure ..................................................43
Top End Disassembly Procedure ................................................................44
Splitting the Cases.......................................................................................45
Engine assembly .........................................................................................45
Clutch..............................................................................................................47
Ignition.............................................................................................................52
Cooling System...............................................................................................54
Fuel & Air System............................................................................................58
Exhaust ...........................................................................................................61
Tuning.................................................................................................................62
Gearing ...........................................................................................................62
Carburetion .....................................................................................................63
4
General Information
Specifications - General
Items ECX50
Dimensions
Wheelbase 42” (1067mm)
Width Front / Rear 43” / 46” (1092mm / 1168mm)
Weight 198lb
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) BTDC
Fuel type High octane pump gasoline
Oil type
Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In)
RACE FUELS ARE NOT RECOMMENDED
Cobra Venom 2-cycle Race Oil
Carburetion 21 mm Dell’Orto PHBG,
Jet Main / Slow (Pilot) 98 / 55
Slide / Needle #30 / W-4
Float Height 16mm + 0.5mm (0.63” + 0.020”)
Transmission
Speed / ratio Single / 14/38 T
Chain 104 links 420
Transmission / clutch oil type
Cobra Venom 3 Shoe Clutch Milk
Quantity 235 – 350 ml (8 – 12oz)
5
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
Torque Value
ENGINE Fastener
ft-lb in-lb Nm
Cylinder head nuts 8.8 105 12 M6 x 1.0
Crankcase bolts 8.8 105 12 M6 x 1.0
Spark plug (SP) (SP) (SP) M14 x 1.25
Stator bolts 2.1 25 2.8 M5 X 0.8
Stator cover bolts 1.7 20 2.3 M4 X 0.75
Clutch cover bolts 5.8 70 7.9 M6 X 1.0
Clutch nut 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
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.
Size &
Remarks
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 75 900 102 14 x 2.0
Units of mm unless otherwise specified
(R or G) 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
SCEX1080 (RED,
Greater than 100
SCEX1095 (YELLOW,
Rear shock springs
Weight of Rider (lb) Main
Less than 50 White 460 lb/in
50 to 75 Gold 500 lb/in
Greater than 75 Green 530 lb/in
80 LB/IN)
95 LB/IN)
(SCEX1460)
(SCEX1500)
SCEXA145 (RED, 145 LB/IN)
SCEXA155 (YELLOW, 155
LB/IN)
SCEXA165 (BLACK, 165 LB/IN)
(SCEX1530)
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 ECX50
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 MO2
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 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 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!
, with Cobra’s specially formulated Cobra
X
8
Starting Procedure
Before starting the machine inspect the following:
• Check for proper tire pressure in both tires.
• Observe the chain tension and adjust if necessary.
• Observe the coolant level and fill if necessary.
Verify that the chain rollers and sliders do not have improper wear.
• Verify that the handlebars are tight.
• Check the throttle for smooth operation and sound closing.
• Check for loose bolts and nuts, and re-torque as necessary.
• Verify that the air filter is clean and properly saturated with oil.
• Insure that the fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required. (High octane pump gas with Cobra’s
specially formulated Cobra Venom 2-cycle Race Oil)
• Turn the fuel on by rotating the fuel petcock knob to the vertically downward
position (reserve position is horizontally forward)
CAUTION:
For best results from your Cobra Motorcycle use only the recommended fuels.
Testing has shown that most ‘race’ fuels actually degrade performance.
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. Pull up the choke knob and turn it to lock it.
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. 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.
9
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.
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 ECX5.
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).
10
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.
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.
11
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:
• Minimum of 235 ml (8 oz) Cobra Venom 3 Shoe Clutch Milk (Part #
MCMUGF01).
NOTE:
Up to 350ml (12 oz) can be applied without hurting performance.
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).
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.
12
NOTE:
Putting additional oil, up to 350 ml (12 oz), can help clutch life. More than 350 ml
(12 oz) 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
# MCMUGF01) was formulated to provide superior lubrication and cooling
capability over extended periods of time and is the recommended lubricant for
your Cobra motorcycle.
(Part
Chain adjustment
Tools needed:
• 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 achieved (see fig. 2).
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.
Figure 1
13
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.
Air Filter Cleaning
This Cobra Motorcycle comes with a unique air filter / air boot unit designed to
facilitate motorcycle service.
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.
14
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.
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 55 75
Maximum 92 125
To properly measure the torque at which the CFD (Cobra Frictional Drive) slips,
one first access the slip clutch by draining the oil and removing the cover
exposing the CFD. Next, brace the CFD gear from turning with a suitable device
(Cobra tool EAMU0004 or similar).
Ft-lb N-m
Using a beam style torque wrench, turn the torque wrench counter clockwise and
observe the torque measurement when the shaft slips relative to the gear. Using
a preset value torque wrench, adjust the setting 55 ft-lb (75 Nm) and observe
whether the wrench clicks first or the shaft slips. If the shaft slips first, the slip
torque is below 55 ft-lb and the CFD needs servicing. If the wrench clicks first,
the CFD is of acceptable value.
15
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.
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.
16
Parts
Parts – Air Inlet System
Figure 4
Coolant System
REF # PART # DESCRIPTION
1 RCMU0403
2 MCKGHO01 HOSE CLAMP – BOOT TO CARB
3
4 RAEX0021 CARBURETOR, 21MM DELL’ORTO PHBG
RCMU0022 VENT HOSE
5 MCKGHO04 HOSE CLAMP – CARB TO MANIFOLD
6 HCBC0625 M6X25 SOCKET HEAD CAP SCREW
7 HCWF0601 6MM FLAT WASHER
8 ECKG0203 INLET MANIFOLD
9 ECKG0202 REED CAGE ASSEMBLY WITH REEDS
NOT SHOWN
10 ZCMU0132 GASKET – REEDS TO ENGINE
11 FCEX0016 THROTTLE, QUAD THUMB STYLE
12 FCPW0004 THROTTLE CABLE END GROMMET
13 RCEX0001 CABLE – THROTTLE, ECX50
14 RCE50001 FUEL LINE 5 INCH
15 FCDC0093 FILTER, FUEL
16 RCEX0019 COVER, AIR FILTER
RCCM1301 VELOCITY STACK
ECKG0205 REED REPLACEMENT KIT
FILTER ASSEMBLY
17
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 MCEXBR07 STEERING STEM BUSHING – SPLIT
NOT SHOWN
NOT SHOWN
5 TCMU0404 BAR MOUNT KIT, SHORT – REPLACEMENT (2 REQ’D)
NOT SHOWN
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)
ZCEX0002 O’RING – STEERING STEM SEAL (2 REQ’D)
HCBB0403 4MM X 8 BUTTON HEAD SCREW (2 REQ’D)
TCMU0403 BAR MOUNT KIT, TALL – OPTIONAL (2 REQ’D)
18
Parts – Bumper, Nerf & Grab Bars
Figure 6
BODY PROTECTION
REF #
1 FCEX0024 NERF BARS (LEFT & RIGHT)
FCEX0067B NERF NET SET (BLACK)
FCEX0067R NERF NET SET (RED)
FCEX0067Y NERF NET SET (YELLOW)
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
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)
PART # DESCRIPTION
HCBH0808 8MM X 30 HEX HEAD BOLT (FRONT MOUNT, 2 PLACES)
HCBH0809 8MM X 50 HEX HEAD BOLT (REAR MOUNT, 2 PLACES)
HCWF0801 8MM FLAT WASHER (2 REQ’D)
HCNL0801 8MM LOCKNUT (2 REQ’D)
19
Parts - Carburetor
Figure 7
Carburetor
REF. # PART # DESCRIPTION
1 RCMU0031 CARB SLIDE (30 slide)
2 RCMU0026 NEEDLE (W-4)
3 RCMU0023 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 RCE50001 FUEL LINE
Not Shown MCMUCL04 HOSE CLAMPS – FUEL LINE
RCCM1301 VELOCITY STACK -05
MCKGHO01 CLAMP – CARBURETOR TO FILTER
RCMU0022 VENT HOSE
20
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