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 CX65 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 110 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.
MCC62014.V1
1
2
Table of Contents
GENERAL INFORMATION .......................................................................................... 4
SPECIFICATIONS - GENERAL ............................................................................................. 4
OPTIONAL COMPONENTS ................................................................................................. 5
SPECIFICATIONS - TORQUE VALUES ................................................................................. 5
BREAK-IN PROCEDURE .................................................................................................... 6
STARTING PROCEDURE .................................................................................................... 6
MAINTENANCE ........................................................................................................... 7
TIPS ................................................................................................................................. 7
SCHEDULE........................................................................................................................ 8
REPLACING TRANSMISSION / CLUTCH LUBRICANT .......................................................... 9
CHAIN ADJUSTMENT ...................................................................................................... 10
AIR FILTER CLEANING ................................................................................................... 11
FORK MAINTENANCE ..................................................................................................... 11
Fork Air Bleeding ..................................................................................................... 12
Fork Oil Replacement ............................................................................................... 12
IGNITION TIMING ........................................................................................................... 14
CABLE TIES .................................................................................................................... 14
PARTS ........................................................................................................................ 16
PARTS – AIRBOX & INLET SYSTEM ................................................................................ 16
PARTS – BARS AND CONTROLS ...................................................................................... 17
PARTS - CARBURETOR ................................................................................................... 18
PARTS – CLUTCH – MASTER CYLINDER ......................................................................... 19
PARTS – COOLANT SYSTEM ........................................................................................... 20
PARTS – ELECTRICAL SYSTEM ....................................................................................... 21
PARTS – ENGINE CLUTCH .............................................................................................. 22
PARTS – ENGINE – CLUTCH / KICK COVER .................................................................... 23
PARTS – ENGINE – IGNITION SIDE .................................................................................. 24
PARTS – ENGINE – KICK MECHANISM............................................................................ 25
PARTS – ENGINE – SHIFT MECHANISM ........................................................................... 26
PARTS – ENGINE – TOP END .......................................................................................... 27
PARTS – ENGINE – POWER VALVE ................................................................................. 28
PARTS – ENGINE – TRANSMISSION ................................................................................. 29
PARTS – EXHAUST SYSTEM ............................................................................................ 30
PARTS – FORKS & TRIPLE CLAMPS ................................................................................ 31
PARTS – FORK – LEG ASSEMBLY – BRAKE SIDE ............................................................ 32
PARTS – FORK – LEG ASSEMBLY – NON-BRAKE SIDE ................................................... 33
3
PARTS – FRAME ............................................................................................................. 34
PARTS – FRONT WHEEL ................................................................................................. 35
PARTS – FRONT BRAKES – MASTER CYLINDER ............................................................. 36
PARTS – FRONT BRAKES – CALIPER ............................................................................... 37
PARTS – BODYWORK ..................................................................................................... 38
PARTS – REAR BRAKE.................................................................................................... 39
PARTS – REAR WHEEL ................................................................................................... 40
PARTS – SHOCK EXTERNAL ........................................................................................... 41
PARTS – SHOCK – INTERNAL .......................................................................................... 42
PARTS – SWINGARM ASSEMBLY .................................................................................... 43
SERVICE .................................................................................................................... 44
ENGINE SERVICE ............................................................................................................ 44
Base Gasket Selection ............................................................................................... 45
Power Valve .............................................................................................................. 47
EXHAUST ....................................................................................................................... 48
FUEL & AIR SYSTEM ...................................................................................................... 48
CARBURETOR: ................................................................................................................ 48
REAR SHOCK.................................................................................................................. 50
BRAKES ......................................................................................................................... 50
Rear Brakes ............................................................................................................... 50
Front Brakes ............................................................................................................. 51
FRONT WHEEL ............................................................................................................... 52
Assembly ................................................................................................................... 52
TUNING ...................................................................................................................... 53
GEARING ........................................................................................................................ 53
SUSPENSION ................................................................................................................... 54
Adjustment: ............................................................................................................... 54
Front Fork Operation ............................................................................................... 54
Fork Damping Adjustments ...................................................................................... 55
Rear Shock Adjustments. ........................................................................................... 56
CARBURETOR ................................................................................................................. 57
TROUBLESHOOTING ............................................................................................... 60
INDEX ......................................................................................................................... 62
4
General Information
Items
CX65
Dimensions
Wheelbase
40.9” (1040mm)
Wheel size
12” (305mm) rear, 14” (356mm) front
Seat height
29.9” (760mm)
Engine
Type
2-stroke, single cylinder, reed valve
Cooling system
Liquid-cooled
Coolant
50/50 antifreeze-coolant / distilled water
Displacement
64.9 cc
Bore and stroke
44.5 mm x 41.7 mm
Ignition system
Electronic, digital advance
Spark plug
Autolite 4063 or XS4063
Gap
0.024” – 0.026” (0.60 – 0.65 mm)
Ignition timing
Digital advance (set at “0” timing mark)
Fuel type
High octane pump gasoline
Premix Oil type
Bel-Ray H1-R
Premix oil ratio after break-in
40:1 – 50:1
Carburetion
26 mm VM Mikuni
Main Jet / Slow (Pilot) Jet
280 / 42.5
Needle
5I 14 - 4
Float Height
21.1 ± 1.0
Transmission
6 speed
Final drive ratio
14/45
Chain
116 links 420
Transmission / clutch oil type
Quality gear lubricant, or Cobra clutch milk
Do Not Run Automotive Motor Oil
Quantity
530 ml (18.0oz)
Chassis
Front tire
60/100 – 14
Rear tire
80/100 – 12
Front fork
CARD 37mm USD, Fully adjustable
Fork oil type
SAE 2.5 WT
Fork oil amount
250 ml (8.5oz)
Adjustments (turns out)
Compression 5/8, Rebound 2 1/2, Bottoming 2 3/4
Rear shock (clicks out)
Compression Low 9, High 8, Rebound 26
Race sag 87mm
Specifications - General
5
Optional Components
Weight of Rider (lb)
Fork Spring
Shock Spring
less than 70 lb
0.24 kg/mm
KCC63724
42 N/MM (240 lb/in)
SCC60240P (white)
75-85 lb
0.26 kg/mm
KCC63726
45 N/MM (260 lb/in)
SCC60260PY stock (yellow)
85-100 lb
0.28 kg/mm
KCC63728
49 N/MM (280 lb/in)
SCC60280PG (gold)
Greater than 100
53 N/MM (300 lb/in)
SCEX1300 (red)
Fastener
Torque Value
Size & Remarks
ft-lb
in-lb
Nm
Cylinder head nuts
9
110
12
M6 x 1.0
Cylinder nuts
22
265
30
M8 x 1.25**
Crankcase bolts
9
110
12
M6 x 1.0
PV Jam Nut
6
72 8 M6 x 1.0**
PV Cap Screws
3
35 4 M5 x 0.8
Exhaust Flange
5
60 6 M6 x 1.0
Spark plug
(SP)
(SP)
(SP)
M14 x 1.25
Stator bolts
2.1
25
2.8
M5 X 0.8
Stator cover bolts
1.7
20
2.3
M4 X 0.75
Clutch cover bolts
5.8
70
7.9
M6 X 1.0
Clutch nut
40
480
54
M10 x 1.25
Front axle bolt
33
400
45
M20 x 1.0
Front axle pinch bolt
8.8
106
12
M6 X 1.0
Front brake rotor
7.4
88.5
10
M6 x 1.0
Engine mount bolts
22
265
30
M8 X 1.25
Swingarm pivot
21
250
28
M12 X 1.5
Intake manifold bolts
4.6
55
6.2
M6 X 1.0
Rear axle
25
300
34
M14 X 1. 5
Rear sprocket
20
240
27
M8 X 1.25
Rear brake rotor
7.4
88.5
10
M6 x 1.0
Triple clamp (top)
9
108
12
M6 x 1.0
Triple clamp (bottom)
6
72 8 M6 x 1.0
Fork cap
15
177
20 Fork Damper Nut
11
133
15 Ignition rotor nut
33
400
45
M10 x 1.25*
Specifications - Torque Values
* Apply high strength thread locking agent when installing
** Use a ‘crows foot’ attachment oriented 90° to the torque wrench
(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.
6
Break-In Procedure
Your Cobra CX65 is a close-tolerance high performance machine and break-in
time is very important for maximum life and performance. The CX65 can be
ridden hard after the first ½ hour break-in time.
Cobra recommends Bel-Ray H1-R premix oil with high octane pump gas mixed
at 40:1.
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).
Cool and inspect bike for loose fasteners.
Check & retighten wheel spokes
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!
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.
7
Insure that the fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required.
Turn the fuel on by rotating the fuel petcock lever to the vertically downward
position.
CAUTION:
For best results from your Cobra Motorcycle use only the recommended fuels.
‘Race’ fuels can be used, however, they are not required with the stock engine,
and the engine will require addition attention to maintain proper jetting as
weather condition change throughout the day.
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. Engage the choke by pulling out on the choke button until it stops.
3. Kick start the engine.
4. Rev the engine in short spurts, turning the throttle no more than 1/4 open
until the engine will run without the choke.
5. Verify a functional engine shut-off switch by shutting off the engine.
6. Restart the engine and proceed with riding when the engine is sufficiently
warm (i.e. the side of the cylinder is warm to touch).
CAUTION:
Never rev an engine full throttle when it's cold or slightly warmed up. This may
lead to premature wear of engine components or complete cold seizure of the
engine.
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.
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. Use only high quality transmission oil designed specifically for two-
stroke racing engines.
b. Bel-Ray H1-R oil is the recommended premix oil:
Maintenance
8
2. Fill your transmission only with the recommended amount of oil. Overfilling
may lead to premature seal failure.
3. The cylinder base gasket has been ‘fitted’ for your engine. See the service
section of this manual for instructions how to properly size a base gasket
during an engine rebuild.
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, CXxxxx7xxx is a 2007 MY CX65.
Schedule
Prior to 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 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 its safe limits.
Replace or get properly re-welded as necessary.
o Check the spokes for tightness and adjust if necessary.
o Check the rims and hubs for signs of stress, like cracks around the rim,
spokes and hub.
o Equalize the pressure in the forks with atmosphere.
o Check for adequate brake operation and pad thickness
Every 2 hours of operation
o Replace the transmission oil.
o Check spoke tension
Every 10 hours of operation
o Replace the fork oil.
o Have the shock oil replaced by a Certified Cobra Mechanic.
Every 15 hours
o Replace piston rings
Inspect piston for wear and cracks.
o Clean the power valve (no adjustment necessary)
o Inspect the power valve cable.
9
CAUTION:
Figure 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.
The frame is a combination of HSLA steel and 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.
Replacing Transmission / Clutch Lubricant
Tools needed:
18 oz, of high quality transmission oil, or Cobra clutch milk
8 mm Allen wrench
CAUTION:
General automotive motor oil has frictional modifiers which will cause premature
wear and failure of the clutch.
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 the bike against something or
set on stand with oil drain hole.
3. Using a 8mm Allen wrench, remove
the oil drain bolt located on the
right side of the engine, on the
clutch cover, near the brake lever
(See Figure 1).
NOTE: You may need to adjust the
brake pedal (up or down) to gain
access to the drain bolt.
10
4. After it has drained, reinstall the bolt being sure that the rubber gasket is in
Figure 2
Figure 3
place. Torque to 11 Nm (8 ft-lb).
5. Remove oil fill plug with an 8mm Allen wrench.
6. Carefully pour 16 oz (470 ml) of transmission oil into the oil fill opening.
7. Reinstall the oil fill plug making sure the rubber gasket is in place.
NOTE: Filling after an engine rebuild required additional transmission fluid. If the
engine is completely flushed of oil, refill with 18 oz (530ml).
Always capture and dispose of used oil properly (all auto parts stores accept
used oil). Dumping oil on the ground is illegal, inconsiderate, and can get you
disqualified from a race weekend quicker than cutting the track.
Chain adjustment
Tools required for chain adjustment
22 mm wrench or socket
2 - 11 mm open-end wrenches
1. Make sure that the rear wheel is aligned
properly.
2. For proper adjustment, the chain should
have 35 mm free movement just behind
the chain block with no load on the bike
(Figure 2)
CAUTION:
Sit on the bike and verify that the chain has a minimum of 12mm (1/2”) free
movement when the chain is at its tightest point.
3. If the chain requires adjusting, loosen the axle
with a 22mm wrench, and loosen the jam nut with
an 11mm wrench. Tighten the chain by rotating
the adjustor bolts clockwise (CW) or loosen the
chain by rotating the adjustor bolts (CCW).
4. Put a rag between the sprocket and chain, and
roll the wheel backward to pull the chain adjustor
blocks tightly against the adjustor bolts (Figure
3).
5. Retighten the axle bolt to 25 ft-lb (34 Nm).
6. Retighten the adjustor jam nuts.
CAUTION:
Always check rear brake adjustment and free-play after adjusting the chain.
11
Air Filter Cleaning
Figure 5
Figure 4
Tools recommended for air filter maintenance:
5 mm hex key (Allen)
Foam filter oil
1. Removed seat with the 5mm hex key.
2. Unhook the air filter wire from its perch
3. Carefully remove the air filter and frame out the top
of the airbox making sure not to dislodge any dirt
into the intake tract.
4. Clean the filter in a nonflammable solvent to
remove the filter oil.
Do not clean the air filter with gasoline or other highly
volatile petroleum product. Diesel fuel, mineral spirits,
or kerosene would be preferred but caution should still
be taken.
5. Clean the filter in hot soapy water to remove all dirt
particles.
6. Allow it to dry thoroughly.
7. Saturate with filter oil and remove excess.
NOTE: It is very important to keep the air filter clean
and properly oiled with high quality water-resistant
foam filter oil. Apply oil consistently because varied
amounts of oil will affect carburetor jetting.
8. Reinstall the filter assembly by pushing it down and forward into the airbox
making sure the lip of the filter cage is properly seated into its receptacle
(figure 5). Reinstall the air filter cap and holding wire.
CAUTION:
Double check to insure that the filter is pushed in tight at the bottom
NOTE: Make sure you change or clean your filter after each moto. We
recommend carrying multiple filters in your toolbox, one for each practice session
and moto.
Fork Maintenance
Cobra strongly recommends that a professional service technician conduct all
internal maintenance other than changing springs and oil. This will help to ensure
safe and consistent operation.
12
For routine maintenance, the chart below provides suggested service intervals
Each Ride
10 hours
20 hours
As Needed
Bleed excess air
X Change Oil
X
Change
Seal/Swiper
X
Change Bushings
X
for common procedures:
Fork Air Bleeding
Tools required
3mm hex key (Allen wrench)
During normal operation, both fork legs will build up air pressure. This pressure
acts as an additional spring so it must be bled on a regular basis to maintain
consistent suspension operation. Before each ride, loosen the socket head cap
screw located at the front of each fork cap far enough so that any excess
pressure in the leg is relieved. After excess air is bled off, retighten the screw to 5
in-lb. Be careful not to lose or damage the sealing ring that is located under the
head of each bleed screw.
Fork Oil Replacement
Tools required
37mm Fork Cap Tool (MCMUTL37)
22mm closed-end wrench or socket
14mm open-end wrench
Drift punch (12mm OD x 300mm long (1/2” x 12”))
5 & 6 mm hex key (Allen wrench)
Mallet
2.5 wt. Bel-Ray fork oil
Disassembly procedure
1. Remove the front wheel.
a. Loosen the brake-side axle pinch bolts (5mm hex key)
b. Carefully remove the brake side axle cap using a closed-end wrench to
protect the cap from damage. (22mm wrench)
c. Loosen the non-brake side axle pinch bolts (5mm hex key)
d. Using the drift punch (a long 3/8 socket extension will also work),
remove the axle from the fork lugs by placing the punch inside the
hollow axle and tapping lightly on the exposed end with the mallet.
13
e. Carefully slide with wheel downward out of the brake caliper.
2. Remove the brake caliper from the fork leg (6mm hex key).
3. Loosen the fork caps (Cobra 37mm Fork Cap Tool).
4. Remove the fork legs from the triple clamps (5mm hex key).
5. One leg at a time:
a. Remove the fork cap from the fork tube.
b. Lower the fork tube to expose the fork spring.
c. Pull the fork spring down from the fork cap to expose the damper rod
lock nut. Secure this nut using a 14mm wrench.
d. With the 14mm wrench on the damper rod nut, use the 37mm fork cap
wrench to free the fork cap from the damper rod.
e. Remove the 14mm wrench and allow the damper rod to fall into the
cartridge tube.
f. Remove the fork spring.
g. Invert the fork to allow the oil to drain. Pump the damper rod assembly
several times to help any excess oil trapped in the cartridge to drain.
Assembly procedure
1. Completely collapse the outer fork tube onto the stanchion tube. Add enough
2.5 wt. Bel-Ray fork oil to fill the cartridge tube. Pump the damper rod up and
down slowly to help the assembly fill with oil.
2. Once the cartridge assembly is bled, continue to fill the fork with oil until it is
120mm +/- 2.5mm from the top of the fork.
3. Install the fork spring.
4. Use a flexible retrieving tool to pull the damper rod up through the fork spring
and thread the damper rod into the fork cap.
CAUTION:
Ensure that the fork cap is completely threaded onto the damper rod before it
makes contact with the lock nut.
5. Pull the fork spring down from the cap and torque the damper rod lock nut to
15 N-m (11ft-lb) with a 14mm wrench.
CAUTION:
The damper rod is hollow and will break if the nut is over tightened.
6. Ensure that the fork cap o-ring is in good condition, Use the 37mm fork cap
wrench to secure the fork cap to the fork outer tube. Torque the fork cap to 20
Nm (15 ft-lb).
7. Pump the fork leg several times to verify that it operates smoothly.
8. Install each leg back into the triple clamp. Torque each pinch bolt to 11N-m (8
ft-lb) making sure both legs are set to the same height in the clamps.
9. Reinstall the brake caliper.
10. Reinstall the front wheel.
1. Install axle through non-brake side fork lug and wheel hub
14
2. Slide wheel spacer over axle taking care to ensure that the internal
o-ring is in place.
3. Continue sliding axle through brake-side lug and reinstall axle cap
(6 ft-lb, 8 Nm)
4. Lightly torque all four axle pinch bolts
5. Drop the bike onto the ground, engage the front brake, and push up
and down on the handlebars several times to ensure that the front
forks and the front wheel are properly aligned with each other.
6. Apply final torque to all four axle pinch bolts (7.4 ft-lb, 10 Nm)
Ignition Timing
The ignition timing value for the CX65 is 0° retarded from the standard base
reference (0°). This can be verified by removing the ignition cover and looking as
shown in the figure below.
The center mark on the cases is the standard base reference timing mark (0°),
and the other two large marks are 5° advanced and retarded. The small timing
marks between 0 & 5° is 2.5°.
To change the timing, one must remove the flywheel with Cobra 65 flywheel
puller # MCMUTL05. After the flywheel has been removed, the timing can be
adjusted by loosening the stator bolts and rotating the stator to the desired
position.
Cable Ties
There are two locations where we have used reusable frame mount cable ties
this year on the 2013 CX65.
15
To disconnect these cable ties, use a screw driver as shown and push down on
the short tab. The tab will be hidden from view by the cable tie strap.
16
Parts
Air Box & Inlet
REF #
PART #
DESCRIPTION
1
RCC60007
AIRBOX
2
TCC60008
MUD FLAP
3
HCSP0003
SCREW - PLASCREW
4
MCKGHO03
CLAMP, AIR BOOT TO AIR BOX
5
RCC60002
AIR FILTER
6
RCC60003
AIR FILTER CAGE
7
RCC60004
AIR FILTER WIRE
8
RCC60014
AIR BOOT, CARB TO AIRBOX
9
RCC60006
AIR FILTER CAP
10
ECC60006
REED ASSEMBLY
11
ECC60007
INLET MANIFOLD
12
HCBC0625
M6x25mm SOCKET HEAD CAP SCREW
13
MCC60003
CLAMP, MANIFOLD TO CARB
14
ZCC60021
GASKET REED
15
RCR60026
CARBURETOR 26mm MIKUNI
16
MCMUCL04
HOSE CLAMP 8mm
17
FCMU0026
FUEL LINE
18
ECC60014
REED PETALS - REPLACEMENT
Parts – Air Box & Inlet System
17
Parts – Bars and Controls
Bars and Controls
REF #
PART #
DESCRIPTION
1
FAMU0011
HANDLEBAR – ALUMINUM
2
TCMU0008
GRIPS (SET OF TWO)
3
FCMU0066
THROTTLE ASSEMBLY
4
FCPW0004
CABLE COVER
5
FCMU0021
THROTTLE COVER
6
RAC60001
THROTTLE CABLE
7
CAC60003
MASTER CYLINDER W/LEVER - CLUTCH
8
FCMU0033
KILL SWITCH ASSEMBLY
9
TKMU0404
BAR MOUNT KIT, SHORT (1 REQ’D) STANDARD
9A
TKMU0403
BAR MOUNT KIT, TALL (1 REQ’D)
10
HCBC1002
M10X50mm SOCKET HEAD CAP SCREW (2 REQ’D)
11
HCNL1001
M10 LOCK NUT
12
HCBH0820
M8 X 20 HEX HEAD BOLT (4 REQ’D)
13
BCC60057
BRAKE LEVER
14
BAC60008
BRAKE ASSY COMPLETE – FRONT CX65 ZL150
ACCESSORY
BKC60004
BRAKE - MASTER CYLINDER - REBUILD KIT - ZL150
ACCESSORY
CKC60001
CLUTCH - MASTER CYLINDER - REBUILD KIT
18
Parts - Carburetor
PILOT JET
MAIN JET
30
RCEX0030
190
RCMU0190
32.5
RCEX0032
195
RCMU0195
35
RCEX0035
200
RCMU0200
37.5
RCEX0037
205
RCMU0205
40
RCEX0040
210
RCMU0210
42.5
RCEX0042
215
RCMU0215
45
RCEX0045
220
RCMU0220
47.5
RCEX0047
225
RCMU0225
50
RCEX0050
230
RCMU0230
52.5
RCEX0052
235
RCMU0235
55
RCEX0055
240
RCMU0240
57.5
RCEX0057
250
RCMU1250
60
RCEX0060
260
RCMU1260
270
RCMU1270
280
RCMU1280
290
RCMU1290
300
RCMU1300
310
RCMU1310
Carburetor
REF. #
PART #
DESCRIPTION
1
RCR60026
CARBURETOR 26MM MIKUNI
2
RCC60017
FLOAT BOWL CHAMBER
4
RCMU0271
NEEDLE VALVE & SEAT ASSY
6
SEE BELOW
MAIN JET
9
RCEX0026
NEEDLE JET STOCK 5L14
10
SEE BELOW
PILOT JET
11
RCC60013
GASKET, FLOAT BOWL
15
RCEX0016
SPRING IDLE ADJUST SCREW
16
RCEX0015
IDLE ADJUST SCREW
17
ZCDCOR01
O’RING BOWL PLUG
18
RCEX0012
FLOAT BOWL SCREW
20
RCC60025
SLIDE
21
RCC60016
SLIDE STUFFER
22
RCMU0277
CLIP - NEEDLE
24
RCEX0005
ADJUSTER
25
RCEX0006
LOCK NUT
27
RCC60026
CHOKE ASSY
33
RCEX0013
AIR ADJUSTING SCREW
34
RCEX0014
SPRING – AIR ADJUST SCREW
NOT
SHOWN
RCMU0415
CABLE ADJUSTER CAP (RUBBER)
RCC60021
AIR SCREW O-RING
RCC60020
AIR SCREW WASHER
19
Parts – Clutch – Master Cylinder
Clutch – Master Cylinder
REF#
PART #
DESCRIPTION
1
CAC60003
ASSEMBLY - CLUTCH MASTER CYLINDER (M/C) CX65
2
BKC60008
CAP & BLADDER KIT ZL150
CAP
BLADDER
M3-0.5 X 6mm LONG PHILLIPS SCREW (2)
3
BCC60058
CLAMP ZL150
4
HCBC0601
M6-1.0 X 25mm LONG SOCKET HEAD CAP SCREW
5
BKC60007
PIVOT BOLT KIT ZL150
BOLT – PIVOT ZL150
CLIP – PIVOT BOLTZL150
6
BCC60055
BOOT MASTER CYLINDER
7
CKC60001
REBUILD KIT - MASTER CYLINDER
PISTON
SEAL FRONT
SEAL REAR
SPRING
CLIP
SPACER
8
BCC60057
LEVER ZL150
9
BKC60005
KIT – LEVER FREEPLAY ADJUSTMENT
SPRING - BALL DETENT
BALL - DETENT
DIAL - ADJUSTMENT
SCREW – SET
PLUNGER - BALL END - ADJUSTABLE
10
BKC60006
KIT - LEVER RETURN STOP POSITION - BOLT & SPRING KIT
11
BCMU0017
FERRULE – COMPRESSION FITTING
12
BCMU0020
FITTING – THREADED CLUTCH LINE END
13
CCC60010
LINE – CLUTCH - REPLACEMENT KIT CX65
FERRULE – COMPRESSION FITTING (2 INCLUDED)
CLUTCH - LINE
NOT SHOWN
BCC60017
BOOT – CLUTCH MASTER CYLINDER PISTON COVER
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