ECX70 - King Cobra of Florida

Transcription

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
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 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.
MCE72009 1
Table Of Contents
General Information ..............................................................................................3
Specifications - General ....................................................................................3
Specifications - Torque Values..........................................................................4
Optional Suspension Components ....................................................................5
Starting Procedure ............................................................................................8
General Tips......................................................................................................9
Maintenance .......................................................................................................10
Schedule & Tips ..............................................................................................10
M1: Replacing Transmission Lubricant ...........................................................11
M2: Chain adjustment .....................................................................................12
M3: Air Filter Cleaning.....................................................................................13
M4: Front end ..................................................................................................14
Toe in adjustment ........................................................................................14
Steering .......................................................................................................14
Parts ...................................................................................................................15
Parts – Air Inlet System...................................................................................15
Parts – Bars and Steering ...............................................................................16
Parts – Bumper, Nerf & Grab Bars ..................................................................17
Parts – Carburetor...........................................................................................18
Parts – Clutch Actuation..................................................................................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 - Transmission......................................................................28
Parts – Exhaust System ..................................................................................29
Parts - Front A-Arms & Steering Upright .........................................................30
Parts – Front Brakes .......................................................................................31
Parts – Front Shock.........................................................................................32
Parts – Miscellaneous .....................................................................................33
1
Parts – Plastic Bodywork & Seat .....................................................................34
Parts – Rear Brake..........................................................................................35
Parts – Rear Drive...........................................................................................36
Parts – Rear Shock .........................................................................................37
Parts – Swingarm Assembly............................................................................38
Parts – Tie Rod Assembly...............................................................................39
Engine Parts / Service ........................................................................................40
Engine Service ................................................................................................40
Base Gasket Selection ................................................................................41
Fuel & Air System............................................................................................43
Reeds ..........................................................................................................43
Carburetor Cleaning ....................................................................................44
Exhaust ...........................................................................................................45
Tuning.................................................................................................................45
Carburetor .......................................................................................................45
Jetting Decisions..........................................................................................45
Troubleshooting ..................................................................................................48
2
General Information
Specifications - General
Items
Dimensions
ECX70
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
44.5 mm x 44.7 mm
Ignition system
Digital Electronic
Spark plug
Champion 8339
Gap
0.023” – 0.025” (0.58 – 0.64 mm)
Fuel type
93 octane pump gasoline
OTHER RACE FUELS ARE NOT RECOMMENDED
Oil type
Cobra Venom 2-cycle Race Oil
Fuel / oil mix ratios
32:1
Ignition timing
.050” (1.3mm) BTDC
Carburetion
26mm Mikuni VM
Main jet 190
Slow (Pilot) jet 50
Jet needle 5F21, 4th position from the top
Float height
Transmission
Speed
Six speed
Clutch
Manual hydraulic
Final drive ratio
13/48 T
Transmission / clutch oil type
Cobra Power Shift Transmission Lubricant
Quantity 530 ml (18 oz)
3
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
Size &
ENGINE Fastener
ft-lb
in-lb
Nm
Remarks
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)
14 x 1.25
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.
4
Torque Value
Size &
CHASSIS Fastener
ft-lb
in-lb
Nm
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 or
green) 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
SCEX0065P (SILVER,
65 LB/IN)
SCEX1080 (RED, 80
LB/IN)
SCEX1095 (YELLOW,
95 LB/IN)
SCEXA135 (BLUE, 135 LB/IN)
65 to 100
Greater than 100
SCEXA145 (RED, 145 LB/IN)
SCEXA155 (YELLOW, 165
Rear shock springs
Weight of Rider (lb)
Main
Less than 65
SCEX2350 (Yellow, 350 LB/IN)
65 to 100
SCEX2375 (Red, 375 LB/IN)
Greater than 100
SCEX2400 (Black, 400 LB/IN)
5
LB/IN)
Helper
Spring Rate
(lb/in)
65
80
95
110
125
150
175
200
250
300
350
Color
Part Number
Silver
Red
Yellow
White
Gold
Green
Black
Silver
Red
Yellow
White
SCEX0065P
SCEX1080
SCEX1095
SCEDX1110
SCEX1125
SCEX1150
SCEX0175P
SCEX0200P
SCEX0250P
SCEX0300P
SCEX0350P
105
115
125
135
145
155
165
Orange
Green
White
Blue
Red
Yellow
Black
SCEX1105
SCEX1115
SCEX2125
SCEX1135
SCEX1145
SCEX1155
SCEX1165
300
315
330
350
375
400
425
450
475
500
Red
Yellow
White
Red
White
Yellow
Blue
Green
Black
Purple
SCEX1300
SCEX1315
SCEX1330
SCEX1350
SCEX1375
SCEX1400
SCEX0425P
SCEX0450P
SCEX0475P
SCEX0500P
Fox 8” long main
spring (front)
Fox 7” long main
spring (rear)
Fox 10” long main
spring (rear)
325
White
350
Yellow
375
Red
400
Black
Spring rate chart for Cobra Fox quad shocks
6
SCEX2325
SCEX2350
SCEX2375
SCEX2400
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 with Cobra Power Shift
Transmission 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!
7
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.
Observe the level of lubricant in the transmission and add Cobra Power
Shift Transmission Lubricant 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.
2.
3.
4.
5.
Reaching down to the carburetor, on the left side of the bike, push down on
the black choke lever.
Kick start the engine.
Rev the engine in short spurts, turning the throttle no more than 1/4 open
until the engine will run without the choke.
Verify a functional engine shut-off switch by shutting off the engine.
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.
8
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.
Mare sure that there is adequate free play in both the front lever and rear
brake pedal.
8.
Your Cobra ATV has a 10 digit VIN (Vehicle Identification Number). The
first three digits indicate the model and the seventh indicates the model
year (MY).
a. Example, ECXxxx7xxx is a 2007 MY ECX70.
9
Maintenance
Schedule & Tips
It is important that you adhere to this maintenance schedule so as to promote the
longevity of your Cobra Motorcycle.
•
•
•
Between each ride
o
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 with Cobra Power Shift Transmission
Lubricant.
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 light as possible. Cobra recommends
replacing the frame with a new one if the old one becomes damaged.
10
M1: Replacing Transmission Lubricant
Tools needed:
•
530 ml (18 oz) Cobra Power Shift Transmission 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.
3.
Lean bike against something or set on stand with oil drain hole.
Using the 13 mm wrench, remove the oil drain bolt located on the right side
of the engine (figure 1).
4.
5.
After it has drained, reinstall the drain screw with gasket.
Remove the oil fill plug and pour in 530 ml (18 oz) 85W 90 gear lubricant.
Figure 1
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.
11
M2: 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).
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.
12
M3: 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.
2.
3.
4.
Removed the filter from the carburetor.
Clean the filter with cleaning solvent and then again with hot soapy water.
Allow it to dry thoroughly.
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.
13
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.
14
Parts
Parts – Air Inlet System
Figure 4
REF #
1
2
3
4
5
6
7
PART #
RCDC0001
MCKGHO03
RAEX0026
MCMUCL10
ECEX0012
MCMUCL03
ECDC0094
8
9
10
11
12
13
ECDCRD15
HCBC0602
ECDC0093
RCMU0001
FCEX0016
FCPW0004
RCEX0002
Coolant System
DESCRIPTION
AIR FILTER ASSEMBLY
HOSE CLAMP – FILTER TO CARB
CARBURETOR 26MM MIKUNI VM
HOSE CLAMP – CARB TO INLET BOOT (WIDE)
INLET BOOT
HOSE CLAMP – BOOT TO REED MANIFOLD (NARROW)
INLET MANIFOLD WITH REED ASSEMBLY
REEDS - REMPLACMENT STOCK
REEDS – SOFT
M6 X 20 SOCKET HEAD CAP SCREW (4 REQ’D)
GASKET – INLET (2 PLACES)
SPACER – REED
THROTTLE, QUAD THUMB STYLE
THROTTLE CABLE END GROMMET
CABLE - THROTTLE
RCE50001
FCDC0093
RCEX0019
RCMU0415
RCMU0022
FUEL LINE 5 INCH
FILTER, FUEL
COVER, AIR FILTER
CABLE ADJUSTER CAP
CARBURETOR VENT HOSE
14
15
16
17
15
Parts – Bars and Steering
Figure 5
Bars and Steering
REF #
1
2
3
4
NOT SHOWN
5
NOT SHOWN
6
7
8
9
10
11
12
13
14
15
16
17
PART #
FAEX0020
TCMU0009
FCEX0011
MCEXBR07
ZCEX0002
DESCRIPTION
STEERING STEM
HANDLEBAR - QUAD
STEERING STEM BLOCK (2 REQ’D)
STEERING STEM BUSHING – SPLIT
O’RING – STEERING STEM SEAL (2 REQ’D)
TCMU0404
TCMU0403
HCBC0806
HCBC1001
HCNL1001
HCWF0801
HCBH0810
HCNL1001
HCWF0010
MCEXBR04
MCMU0001
TCEX0013
HCBH0601
HCNS0601
BAR MOUNT KIT, SHORT – REPLACEMENT (2 REQ’D)
BAR MOUNT KIT, TALL – OPTIONAL (2 REQ’D)
SOCKET HEAD CAP SCREW M8 X 30 (4 REQ’D)
M10X45 SOCKET HEAD CAP SCREW (2 REQ’D)
M10 LOCK NUT (2 REQ’D)
8MM FLAT WASHER
8MM X 65 HEX HEAD BOLT (2 REQ’D)
10MM LOCK NUT
10MM FLAT WASHER
STEM PIVOT BUSHING - LOWER
CROSS BAR PAD
GRIPS SET OF TWO
6MM X 16 HEX HEAD BOLT (2 REQ’D)
6MM NUT (2 REQ’D)
16
Parts – Bumper, Nerf & Grab Bars
Figure 6
REF #
1
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
2
3
4
5
PART #
FCEX0024
FCEX0067B
FCEX0067R
FCEX0067Y
HCBH0808
HCBH0809
HCWF0801
HCNL0801
FAEX0099
HCBB0802
FCEX0003
HCBC0820
BODY PROTECTION
DESCRIPTION
NERF BARS (LEFT & RIGHT)
NERF NET SET (BLACK)
NERF NET SET (RED)
NERF NET SET (YELLOW)
8MM X 30 HEX HEAD BOLT (FRONT MOUNT, 2 PLACES)
8MM X 50 HEX HEAD BOLT (REAR MOUNT, 2 PLACES)
8MM FLAT WASHER (2 REQ’D)
8MM LOCKNUT (2 REQ’D)
FRONT BUMPER
M8 X 20 BUTTON HEAD BOLT (4 REQ’D)
GRAB BAR
M8 X 20 SOCKET HEAD CAP SCREW (4 REQ’D)
17
Parts –
Carburetor
Figure 7
Carburetor accessories
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART #
RAEX0026
RCEX0001
RCEX0017
RCEX0018
RCMU0415
RCEX0005
RCEX0006
RCEX0007
RCEX0008
RCEX0009
RCEX0010
RCEX0011
RCEX0012
RCEX0013
RCEX0014
RCEX0015
RCEX0016
RCMU0xxx
RCEX00xx
REMU0022
DESCRIPTION
CARBURETOR, 26MM MIKUNI VM
CABLE, THROTTLE
JET NEEDLE (5F21) STANDARD
JET NEEDLE (5F3)
CABLE ADJUSTER CAP
ADJUSTER, THROTTLE CABLE
LOCK NUT, THROTTLE CABLE ADJUSTER
GASKET, CARBURETOR BOWL
PLUG WASHER, MAIN JET
SPRING, THROTTLE VALVE
E-CLIP, NEEDLE
NEEDLE VALVE, SEAT ASSEMBLY
SCREW, FLOAT BOWL
SCREW, AIR ADJUSTING
SPRING, AIR ADJUSTING SCREW
SCREW, IDLE ADJUSTING
SPRING, IDLE ADJUSTING SCREW
MAIN JET, xxx DENOTES SIZE
(170, 175, 180, 185, 190, 195, 200, 205, 210)
PILOT JET, xx DENOTES SIZE
VENT HOSES
18
Parts – Clutch Actuation
Figure 8
Clutch Actuation
REF #
1
2
3
4
5
6
7
8
9
10
11
NOT SHOWN
NOT SHOWN
PART #
CADC0001
CCMU0004
CCDC0001
FCEX0020
CCDC0002
ECDC0074
ECDC0082
ECDC0020
ECDC0018
ECDC0019
HCCC0002
ZCDCOR05
ZCDCOR04
DESCRIPTION
CLUTCH ACUTATOR ASSEMBLY (Lever, Master Cyl., Line, Slave Cyl.)
MASTER CYLINDER
CLUTCH LEVER
CLUTCH LINE
CLUTCH SLAVE CYLINDER
CLUTCH CAP
M6 x 16 Bolt
SNAP RING – CLUTCH CAP
CLUTCH PUSH ROD
CLUTCH THROW-OUT BEARING
CLUTCH BEARING SEAT
CABLE CLAMP
CLUTCH CAP O-RING
SLAVE CYLINDER O-RING
19
Parts – Coolant System
Figure 9
REF #
1
2
3
4
5
6
7
8
9
Not Shown
PART #
FCEX0066
FCMU0020
ECEX0010
MCEXGR01
MCMUGR04
HCBF0620
HCWF1478
MCMUCL07
FCMU0049
MCMUCL05
Coolant System
DESCRIPTION
RADIATOR WITH CAP
RADIATOR CAP
RADIATOR HOSE
GROMMET, RAD MOUNT (4 REQ’D)
GROMMET, TOP RAD MOUNT (2 REQ’D)
FLANGE HEAD BOLT M6X20 (2 REQ’D)
WASHER RADIATOR MOUNTING
HOSE CLAMP (4 REQ’D)
RADIATOR OVERLFLOW HOSE
HOSE CLAMP, OVERFLOW HOSE
20
Parts – Electrical System
Electrical System
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PART #
ICC60004
HCBB0516
HCWF0501
ICC60003
ICMU0012
HCWF0038
HCNS1001
ICC60002
HCNL0601
ICC60001
HCBC0516
HCSP0002
HCCN0000
ECMU0065
ECMU0067
ECMU0066
IKEX0001
ECDC0085
ZCDC0004
HCBC0402
DESCRIPTION
STATOR DIGITAL 07 65
5X12MM SHCS (3 REQ’D)
ROTOR OUTER STYLE 07 65
WOODRUFF KEY
3/8 FLAT WASHER
10MM X 1.25 NUT
CDI UNIT 07 65
6MM LOCKNUT – CDI MOUNTING (2 REQ’D)
COIL DIGITAL 07 65
5X16MM SHCS – COIL MOUNTING (2REQ’D)
5MM WASHER – COIL MOUNTING (2 REQ’D)
5MM EXTRUDED "U" NUT – COIL MOUNTING (2 REQ’D)
SPARK PLUG, CHAMPION (8339-1)
OPTIONAL HOTTER PLUG (8332-1)
OPTIONAL COLDER PLUG (8904-1)
IGNITION KILL TETHER
COVER - IGNITION
GASKET-IGNITION COVER
4X35MM SHCS – COVER MOUNTING (3 REQ’D)
21
Parts – Engine Clutch
Figure 11
Clutch components
REF. #
PART #
1
EAEX0003
2
ECDC0064
NOT
SHOWN
3
4
5
6
7
8
9
10
11
12
13
14
15
ECDC0167
ECDC0063
ECDC0066
ECDC0068
ECDC0067
ECDC0069
ECDC0070
ECDC0224
HCBC0525
ECDC0030
HCBC1035
HCBF1035
ECDC0019
ECDC0018
ECDC0020
DESCRIPTION
CLUTCH BASKET ASSEMBLY
CLUTCH BUSHING – INNER / STEEL
CLUTCH BUSHING - OUTER / BRONZE
CLUTCH WASHER (2 PLACES)
CLUTCH PRESSURE PLATE
CLUTCH DISC-FRICTION – (5 REQ’D)
CLUTCH DISC-STEEL – (4 REQ’D)
CLUTCH HUB
SPRING, CLUTCH – (6 REQ’D)
PLATE, CLUTCH SPRING
5X25 SOCKET HEAD CAP SCREW (6 REQ’D)
SPRING WASHER – CLUTCH
10MM X 35 SHCS BLACK OXIDE
10MMX35 FLANGE HEAD BOLT
CLUTCH BEARING SEAT
BEARING,CLUTCH THROW OUT
CLUTCH PUSH ROD
22
Parts – Engine – Clutch / Kick Cover
Figure 12
Clutch / kick cover components
PART #
DESCRIPTION
ECMU0150 CLUTCH COVER (07 STYLE)
ZCMU0014 GASKET-CLUTCHCOVER
HCBF0625 6X25 SOCKET HEAD CAP SCREW (6 REQ’D)
HCBF0630 6X30 SOCKET HEAD CAP SCREW (2 REQ’D)
HCBF0612 6X12 FLANGE HEAD BOLT
HCWF0618 WASHER - KICK LEVER
ECDC0046 KICKSTARTER LEVER
HCBB0625 SCREW M6X25 BUTTON HEAD
ECDC0078 SEAL,KICKSTARTER
ZCMU0005 GASKET-OIL FILL PLUG
ECMU0037 OIL FILL/DRAIN BOLT W/GASKET
ZCDCOR05 ORING-CLUTCH CAP
ECDC0074 CLUTCH CAP
ZCDCOR04 ORING,CLUTCH SLAVE CYLINDER
NOT SHOWN CCEX0009 BALL, CLUTCH ACTUATOR
15
CADC0001 CLUTCH ASSEMBLY
16
HCBC0601 6X16 SOCKET HEAD CAP SCREW
17
ECDC0082 SNAP RING-CLUTCH CAP
18
ECAX0150 IMPELLER COVER
19
ZCC60004 GASKET-IMPELLER COVER (may not be used)
20
HCBC0601 6X16 SHCS
21
ECDC0075 IMPELLER, WATERPUMP
22
HCBC1512 M5 X 12 SHCS STAINLESS
23
HCWF0501 5MM FLAT WASHER
24
ECKG0074 SEAL, WATERPUMP
NOT SHOWN ECMU0218 RETAINING RING, WATER PUMP SEAL
REF. #
1
2
3A
3B
4
5
6
7
8
9
10
11
13
14
23
Parts - Engine - Ignition Side
Figure 13
REF. # PART #
1
ECDC0085
2
ZCDC0004
3
HCBC0402
4
HCBC0525
5
HCBC0535
6
HCWF0501
7
HCNS1001
8
HCWF0038
9
ICMU0006
10 ICMU0018
11 ECDC0024
12 ECDC0087
13 HCBH0620
14 ECKGSR03
15 PCKG00xx
16 ECDC0009
17 ECDC0025
18 ECDC0026
ICMUGR01
22 EKC62009
23 ZCDCOR01
24 ECEX0008
Ignition side engine components
DESCRIPTION
IGNITION COVER
GASKET-IGNITION COVER
5X25 SOCKET HEAD CAP SCREW
WASHER FLAT 5MM
NUT M10
3/8 FLAT WASHER
ROTOR
STATOR – 3 WIRE
SEAL, CRANKSHAFT
SHIFTER LEVER
M6 X 20 HEX HEAD BOLT
SNAP RING-OUTPUT-COBRA
SPROCKET xx denotes number of teeth
SPACER,SPROCKET
SEAL,OUTPUT
SEAL,SHIFTER
GROMMET-IGNITION
ENGINE CASE SET W/B&S CX65/70 09
O-RING, SPROCKET SPACER
BUSHING, SHIFTER SHAFT
24
Parts - Engine – Kick Mechanism
Figure 14
REF. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
NOT
SHOWN
PART #
EKC62009
ECDC0107
ECDC0111
ECDC0040
ECDC0036
ECDC0043
ECDC0042
ECMU0135
ECDC0038
ECDC0033
ECDC0035
ECDC0037
ECDC0032
ECDC0039
ECDC0060
HCBB1612
ECMU0533
Kick Mechanism
DESCRIPTION
SPLASH GUARD
SPACER, KICK START SHAFT
SPRING, KICKSTART RETURN
SNAP RING, EXTERNAL 16MM
WASHER, KICKSTART BACKUP
SPRING, KICKSTART RAMP
SHAFT, KICK START
RAMP GEAR, KICKSTART
GEAR, KICKSTART
GEAR, KICK START IDLE
RAMP, KICK START
6MM X 16 PHILLIPS FLAT HEAD SCREW
6MM X 12 MM BUTTON HEAD BLACK OXIDE
FITTING, VENT HOSE
ECMU0534 VENT HOSE
25
Parts – Engine – Shift Mechanism
Figure 15
Clutch components
REF. #
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
26
27
28
PART #
EADC0154
ECDC0055
ECDC0110
ECDC0099
ECMU0550
ECDC0051
HCBC1825
HCWL0802
ECMU0548
ECMU0546
ECMU0545
ECDC0035
ECDC0056
ECDC0060
ECDC0022
ECMU0216
HCBB1612
ECDC0024
ECDC0112
ECDC0073
ECDC0036
EKC62009
ECDC0031
HCBB1612
DESCRIPTION
SHIFTER SHAFT (2 COMPONENTS) W/SPRING
SPRING - SHIFTER SHAFT
SPACER, CENTERING SPRING
SPRING, CENTERING
SHIFT CASSETTE (W/O PINS)
DOWEL – SHIFT DRUM INDEX
8MM X 25 SHCS BLACK OXIDE
8MM LOCKWASHER, HI COLLAR
PIVOT, SHIFT ARM
SPRING, SHIFT FOLLOWER ARM
ARM ASSY, SHIFT FOLLOWER
CLIP, ARM RETAINER
BEARING RETAINER PLATE
6MM X 16 FLAT HEAD PHILLIPS SCREW
BEARING, SHIFT DRUM
BEARING, PRIMARY SHAFT CLUTCH SIDE
6MM X 12 BUTTON HEAD BLACK OXIDE
SEAL, CRANKSHAFT
SPACER, CRANK DRIVE GEAR
CRANK DRIVE GEAR
SNAP RING, EXT 16MM
DOWEL, HOLLOW (2 PLACES)
6MM X 12 BUTTON HEAD
26
Parts – Engine – Top End
Figure 16
Engine – Top End
REF #
1
2
3
ZCKG0501
ECMU0184xx
DESCRIPTION
CYLINDER KIT 09 ECX70 (INCLUDES PISTON KIT)
BASE GASKET 0.015” (0.4mm thick) For other Base Gaskets refer to
Base Gasket Selection section of this manual (PG 37) More than one
gasket may be required!
PISTON KIT (xx denotes piston size, A, or AB, etc…)
5
6
7
8
9
10
ECEX0005
ECMUSR00
ECDC0090
ECDC0061
ZCMUOR07
ECMU0074
PISTON RINGS (2 PER SET)
SNAP RING FOR PISTON (2 REQ'D)
WRIST PIN
BEARING, WRIST PIN
O-RING, EXHAUST FLANGE
EXHAUST FLANGE
ZCMOTE11
HCBC0612
HCNS0702
HCWS1401
ECEX0014
ZCMUOR02
ZCMUV024
ZCMUOR10
ECE70010
ZCMUV032
ECMU0147L
O-RINGS – PIPE TO FLANGE (2 REQ’D)
M6X12, EXHAUST FLANGE SCREW (2 REQ'D)
7MM NUT HIGH STRENGTH
FLAT WASHER - HARDENED
CYLINDER HEAD OUTER
O-RING, CYLINDER HEAD LARGE
O-RING CYLINDER HEAD SMALL
O-RING CYLINDER STUD (4 REQ'D)
CYLINDER HEAD, INSERT 09
O-RING CYLINDER HEAD MEDIUM
STUD, CYLINDER 7mm LONG
NOT
SHOWN
11
12
13
14
15
16
17
18
19
20
PART #
ECC60017
27
Parts - Engine Transmission
Figure 17
Transmission
REF #
1
PART #
ECEX0015
EKEX0001
ECDC0023
EKC62009
EKC62009
DESCRIPTION
CRANKSHAFT, ‘09
ROD KIT
ACCESSORY
2
BEARING, CRANKSHAFT
3
4
ZCC60003
5
GASKET, CRANKCASE CENTER, ‘09
Left Case Screws
HCBC0604
6X35MM SOCKET HEAD CAP SCREW (4 REQ’D)
Right Case Screws HCBC0603
6X30MM SHCS (7 REQ’D)
Right Case Screws HCBC0607
6X50 SHCS
6
ECDC0021
BEARING, OUTPUTSHAFT CLUTCH SIDE
7
ECDC0001
SHAFT, TRANSMISSION PRIMARY (1ST GEAR), 13T
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
ECDC0014
GEAR, 2ND OUTPUT, 31T
16
ECDC0017
SHAP RING, EXTERNAL 18MM (3 REQ’D)
17
ECDC0013
GEAR, 5TH, OUTPUT, 30T
18
ECDC0011
GEAR, 4TH OUTPUT, 28T
19
ECDC0010
GEAR, 3RD OUTPUT, 34T
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
HCDP1401
DOWEL, SOLID CENTERING (2 REQ’D)
27
ECKG0031
BEARING, PRIMARY SHAFT IGNITION SIDE
28A
ECMU0040
SHIM TRANSMISSION 0.030” (0.48mm) THICK
28B
ECMU0040T SHIM TRANSMISSION 0.015” (0.4 mm) THICK
ECMU0146
BUSHING, SWINGARM PIVOT ENGINE MOUNT (2 REQ’D)
NOT SHOWN
32
ECMU0549
BEARING, NEEDLE, SHIFT DRUM LEFT SIDE
28
Parts – Exhaust System
Figure 18
Exhaust System
REF #
1
2
3
NOT SHOWN
PART #
XAEX2005
ZCMOTE11
XCMU0005
XCMU0030
4*
5*
MCMUGR02
MCMUGR10
6*
7*
8*
MCMUGR02
HCWF1478
HCBF0635
MCMUGR02
HCNL0601
XCMU0032
XAEX0001
XCMU0026
HCBB0408
XCKG0009
MCMUGR03
TCKG0001
HCBF0630
ZCEX0001
NOT SHOWN
9
NOT SHOWN
NOT SHOWN
NOT SHOWN
10
11
12
13
14
DESCRIPTION
ECX70 EXHAUST PIPE
HEADER PIPE O-RINGS (2 REQ’D)
SPRING, EXHAUST – SHORT
COVER, EXHAUST SPRING
PIPE GROMMET MALE (ONLY AVAILABLE IN MCMUGR02
GROMMET KIT)
PIPE GROMMET FEMALE
PIPE GROMMET SPACER (ONLY AVAILABLE IN MCMUGR02
GROMMET KIT)
PIPE GROMMET WASHER (2 REQ’D)
M6X35 FLANGE HEAD BOLT
GROMMET KIT
6MM LOCK NUT – FOR FRONT PIPE MOUNT
SILENCER
SILENCER – ‘STAR’ REINFORCED
SILENCER PACKING
M4 X 8 SILENCER SCREW
PIPE / SILENCER SEAL
MOUNTING GROMMET (4 REQ’D TOTAL, 2 PER BOLT)
SPACER (2 REQ’D)
M6X30 FLANGE HEAD BOLT (2 REQ’D)
PIPE COUPLING O-RING (2 REQ’D)
*Parts are included in MCMUGR02 grommet kit.
29
Parts - Front A-Arms & Steering Upright
Figure 19
A-arms & steering upright
REF #
1
2
3
4
5
6
7
8
9
10
NOT
SHOWN
11
12
13
14
PART #
GAEX0001
GAEX0002
GAEX0007
GAEX0006
GAEX0009
GAEX0008
HCBC1065
MCEXBR05
GCEX0006
HCBF1070
HCNL1001
GAEX0003/4
DESCRIPTION
A-ARM FRONT TOP (SAME PIECE FROM LEFT TO RIGHT)
A-ARM BACK TOP (SAME PIECE FROM LEFT TO RIGHT)
A-ARM FRONT BOTTOM RIGHT
A-ARM FRONT BOTOTM LEFT
A-ARM BACK BOTTOM RIGHT
A-ARM BACK BOTTOM LEFT
10MM X 65 SOCKET HEAD CAP SCREW (BLACK OXIDE)
BUSHING, A-ARM
SPACER, A-ARM PIVOT TUBE
10MM X 70 FLANGE HEAD BOLT
10MM LOCKNUT
UPRIGHT WITH SPINDLE, 03 Right, 04 Left
GCEX0032
MCEXCL01
MCEXBR01
HCBC0806
GCEX0009
GREASE FITTING
SNAP RING, 1-3/8 INTERNAL
BEARING, SPHERICAL
8MM X 30 SOCKET HEAD CAP SCREW (2 REQ’D)
STEERING ARM
30
Parts – Front Brakes
Figure 20
Front Brakes
REF #
1
2
3
4
5
6
7
8
Not Shown
9
10
11
12
13
14
16
17
18
19
NOT SHOWN
20
21
22
23
24
PART #
BAEX0004
BCEX0024
BCEX0025
BCEX0029
BCDC0003
BCEX0026
BCEX0028
BCEX0027
BCEX0020
HCBC0825
BCEX0021
BCEX0019
HCWF0504
HCBB0516
HCBC0602
HCBF0640
HCBF0635
BCEX0022
WCEX0001
GCEX0008
HCNS1400
HCCP0002
GCEX0022
ECKGBR01
WCEX0301
WCEX0300
ECMU0001
WCEX0302
GCEX0023
DESCRIPTION
BRAKE SYSTEM COMPLETE
BANJO BOLT
BRAKE PADS
CRUSH WASHER
MASTER CYLINDER
REPLACEMENT LINE
CALIPER LEFT
CALIPER RIGHT
BRAKE ARM
M8 X 25 SHCS
BRAKE MOUNT
BRAKE ROTOR
BRAKE ROTOR SPACER (4 REQ’D PER ROTOR)
ROTOR BOLT
M6 X 20 SHCS
M6 X 40 FLANGE HEAD BOLT
M6 X 35 FLANGE HEAD BOLT
BRAKE MOUNT SPACER
FRONT HUB WITH WHEEL STUDS
WHEEL SPINDLE (SAME L&R)
M14 CASTLE NUT (SAME L&R)
COTTER PIN (SAME L&R)
INNER HUB SEAL (SAME L&R)
INNER HUB BEARING
INNER HUB BUSHING
CENTER HUB SPACER
OUTER HUB BEARING
OUTER HUB BUSHING
OUTER HUB SEAL
BRAKE FLUID
31
Parts – Front Shock
Figure 21
Front Shock
REF #
1
2
PART #
SAEX2005
SCEX1080
3
SCEX1145
4
SCSP0001
SCSP0002
SCSP0003
5
6
7
8
9
10
11
HCNL1001
HCWF0010
HCBF1040
HCBC1002
SCKGFX04
SCKGFX05
DESCRIPTION
SHOCK ECX70 – FRONT (2 REQ’D)
SPRING, HELPER, 80 LB/IN (STANDARD)
See Optional Components section of this manual for other springs
SHOCK SPRING, STANDARD (RED, 145 LB/IN)
See Optional Components section of this manual for other springs
TRAVEL LIMITER (1.50”)
TOP SPRING PERCH
10MM LOCK NUT (2 REQ’D)
10MM FLAT WASHER
10MM X 44 SHOCK BOLT
10MM X 50 SOCKET HEAD CAP SCREW
PRELOAD RING BOTTOM
PRELOAD RING TOP (LOCK RING)
32
Parts – Miscellaneous
If you couldn’t find it in one of the other pictures try the table below.
PART #
WCEX0005
WCEX0004L
WCEX0004R
FAEX2006
FCEX0002
HCBC1120
HCWF0010
HCNL1001
FCEX0038R
FAE70001
HCBC0816
DESCRIPTION
REAR WHEEL WITH TIRE
LEFT FRONT WHEEL WITH TIRE
RIGHT FRONT WHEEL WITH TIRE
FRAME
CHAIN SLIDER SPLIT BUSHING
M10 X 120 (FRONT ENGINE MOUNT BOLT)
10MM LOCK NUT
SPACER, FRONT ENGINE MOUNT RIGHT
ENGINE MOUNT – BOLT ON (2 REQ’D)
8X16MM SOCKET HEAD CAP SCREW (4 REQ’D)
33
Parts –
Plastic
Bodywork
& Seat
Figure 22
Plastic and Bodywork
REF #
1
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
2
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
3
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
4
5
6
7
8
9
10
11
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
NOT SHOWN
PART #
TCEX0001Y
HCBB0616
HCWF0601
HCBB0625
HCWF0601
MCMUGR10
HCWF1478
HCNL0601
TCEX0002Y
HCBB0625
HCWF0601
MCMUGR10
HCWF1478
HCNL0601
HCBB0616
HCWF0601
TAEX0011
HCBB0635
MCMUGR04
HCWF1478
HCNL0601
RCE50002
TCHA0002
TCEX0019
RCE50001
TCMU0000
HCBC0601
MCMUGR04
TCEX0110
TCHA0005
HCFH0620
HCBF0616
HCBF0620
TCKG0001
TCEX2009
DESCRIPTION
FRONT CLIP - YELLOW
M6 X 16 BUTTON HEAD (4 REQ’D AT BACK)
6 MM FLAT WASHER (4 REQ’D AT BACK)
M6 X 25 BUTTON HEAD (2 REQ’D AT FRONT)
6MM FLAT WASHER (2 REQ’D AT FRONT)
GROMMET, (2 REQ’D AT FRONT)
WASHER, FENDER (2 REQ’D AT FRONT)
6MM LOCK NUT (2 REQ’D AT FRONT)
REAR DECK - YELLOW
M6 X 25 BUTTON HEAD (2 REQ’D PLASTIC TO GRAB BAR)
6MM FLAT WASHER (2 REQ’D PLASTIC TO GRAB BAR)
GROMMET, (2 REQ’D PLASTIC TO GRAB BAR)
WASHER, FENDER (2 REQ’D PLASTIC TO GRAB BAR)
6MM LOCK NUT (2 REQ’D PLASTIC TO GRAB BAR)
6MM BUTTON HEAD (2 REQ’D AT FRONT)
6MM FLAT WASHER (2 REQ’D AT FRONT)
SEAT
M6 X 35 BUTTON HEAD (1 REQ’D SEAT TO PLASTIC)
GROMMET (1 REQ’D SEAT TO PLASTIC)
WASHER, FENDER (1 REQ’D SEAT TO PLASTIC)
6MM LOCK NUT (1 REQ’D SEAT TO PLASTIC)
FUEL VENT HOSE
FUEL CAP
FUEL TANK (NO PETCOCK, CAP, OR BRACKET)
FUEL LINE
FUEL PETCOCK (’06 LEVER)
M6 X 16 SOC. HEAD BOLT (2 REQ’D)
GROMMET (2 REQ’D)
FUEL TANK BRACKET
TANK MOUNT REAR
M6 X 20 FLAT HEAD
M6 X 16 FLANGE HEAD BOLTS (2 REQ’D)
M6 X 20 FLANGE HEAD BOLT (1REQ’D AT THE REAR)
SPACER, TANK MOUNT (1REQ’D AT THE REAR)
GRAPHICS
34
Parts –
Rear Brake
Figure 23
Rear Brake System
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
NOT SHOWN
15
16
17
17
18
NOT SHOWN
NOT SHOWN
19
20
NOT SHOWN
21
22
23
24
NOT SHOWN
NOT SHOWN
25
26
NOT SHOWN
NOT SHOWN
PART #
BADC0001
BCEX0007
BCDC0009
HCBC0601
FCEX0018
BCEX0012
BCMU0501
BCDC0004
HCBC0601
HCWF0601
HCPP0832
HCCC0000
BCDC0151
HCBC0850
HCBC0825
BCEX0032
BCEX0014
BCDC0002
BCDC0007
BCEX0013
BAEX0006
GCEX0016
WCEX0006
GCEX0014
BCEX0004
HCBC0625
HCBB0830
HCNL0801
BCDC0005
BCDC0012
HCBC0601
WCMU0006
BCDC0006
MCMUCL05
BCDC0152
BCDC0153
DESCRIPTION
BRAKE COMPLETE
BRAKE PEDAL
BRAKE PIVOT BOLT
M6X16 SOC. HEAD BOLT
BRAKE ADJUST ECCENTRIC
BRAKE RETURN SPRING
SEAL – BRAKE PEDAL (2 REQ’D)
PUSH ROD, REAR BRAKE
M6X16 SOC. HEAD BOLT (2 REQ’D)
BRAKE HOSE CLAMP FASTENER (2 REQ’D)
BRAKE HOSE CLAMP (2 REQ’D)
REAR BRAKE HOSE
M8X50 SOCKET HEAD CAP SCREW
M8X25 SOCKET HEAD CAP SCREW
SPACER – CALIPER MOUNT
CALIPER SPACER (2 REQ’D)
CALIPER – REAR BRAKE
BRAKE PAD KIT – ORGANIC
BRAKE PAD KIT – SINTERED METAL
REAR BRAKE CARRIER, FULL ADJUSTABLE
SPACER BRAKE HUB
SNAP RING, BRAKE CARRIER RETAINER
BRAKE/SPROCKET HUB
BRAKE ROTOR REAR QUAD
6MM X 25 SOCKET HEAD CAP SCREW (2 REQ’D)
8MM X 30 BUTTON HEAD (4 REQ’D)
8MM LOCKNUT (4 REQ’D)
MASTER CYLINDER - REAR
BRAKE LINE – RESERVOIR TO MASTER CYLINDER
M6X16 SOC. HEAD BOLT
SPACER – RESERVOIR MOUNT
BRAKE FLUID RESERVOIR
LINE CLAMP (2 REQ’D)
BANJO BOLT
CRUSH WASHER
35
Parts – Rear Drive
Figure 24
Rear Drive
REF #
1
2
3
NOT SHOWN
4
NOT SHOWN
5
6
7
9
10
11
12
13
NOT SHOWN
14
15
16
PART #
GAEX0033
WCEX0003
HCNS1001
HCWF0010
GCEX0014
HCBC0625
HCBH0808
HCNL0801
PCDC00XX
GCEX0016
HCKW0001
GCEX0024
GCEX0011
HCCP0002
PCMU0104
HCNC0020
MCEXBR03
GCEX0015
DESCRIPTION
REAR AXLE -SOLID
WHEEL LUG (8 REQ’D)
LUG NUT (8 REQ’D)
LUG WASHER (8 REQ’D)
BRAKE/SPROCKET HUB (2 REQ’D)
M6 X 25 HUB PINCH BOLT (2 PER HUB)
M8 X 30 HEX HEAD BOLTS (4 REQ’D)
M8 LOCK NUT (4 REQ’D)
SPROCKET (37T – 51T) – XX DENOTES # OF TEETH
BRAKE HUB SPACER
HUB KEY
REAR WHEEL HUB SPACER (2 REQ’D)*
REAR WHEEL HUB (2 REQ’S)
COTTER PIN (2 REQ’D)
420 CHAIN – 104 LINK
20 MM X 1.5 NUT CASTLE
BEARING, REAR AXLE (4 TOTAL, 2 PER SIDE)
ECCENTRIC
- UP TO TWO HUB SPACERS CAN BE USED PER SIDE TO ADJUST TRACK
WIDTH. USING THREE HUB SPACERS MAY CAUSE THE SPLINES TO
STRIP.
36
Parts – Rear Shock
Figure 25
Rear Shock
REF #
1
2
3
4
5
6
7
8
9
9
10
10
PART #
SAE72009
SCEX2375
SCEX2350
SCEX2400
SCKGFX04
SCKGFX05
HCBC1050
HCBF1040
HCWF0010
HCNL1001
SCKGFX01
ZCMU0114
SCEX0008
ZCMUB208
DESCRIPTION
SHOCK, REAR QUAD FOX
SHOCK SPRING, STANDARD (WHITE, 375 LB/IN)
SHOCK SPRING, LIGHT (350 LB/IN)
SHOCK SPRING, HEAVY (400 LB/IN)
PRELOAD RING BOTTOM
PRELOAD RING TOP (LOCK RING)
10MM X 50 SHCS
10MM X 44 SHOCK BOLT
10MM FLAT WASHER
10MM LOCKNUT
TOP WIDTH REDUCER FOR BEARING STYLE END
TOP O-RING FOR BEARING STYLE END
BOTTOM WIDTH REDUCER FOR BEARING STYLE END
BOTTOM O-RING FOR BEARING STYLE END
37
Parts – Swingarm Assembly
Figure 26
Swingarm
REF #
1
2
3R
3L
4
5
6
7
8
9
10
11
12
13
14
PART #
GAEX2009
GCMU0030
GCE70002
GCE70003
HCBH1421
HCNL1402
GCEX0050
HCPP0834
HCBF1040
HCCC0000
HCBH0810
HCNL0801
HCWF0801
PAEX0001
HCBF0620
DESCRIPTION
SWINGARM
BUSHING, SWINGARM (4 PER)
SPACER, SWINGARM PIVOT (RIGHT SIDE, TUBE)
SPACER, SWINGARM PIVOT (LEFT SIDE, STEPPED SPACER)
SWINGARM PIVOT BOLT (M14 X 1 HEX HEAD)
SWINGARM LOCK NUT (M14 X1)
TOP SWINGARM GUARD – ECX70
SELF TAPPING SCREW
BOLT, SHOCK
BRAKE HOSE CLAMP (2 REQ’D)
ECCENTRIC PINCH BOLT (2 REQ’D)
8MM LOCK NUT (2 REQ’D)
CHAIN GUIDE ASSEMBLY COMPLETE W/ ALUMINUM PLATE
6MM X 20 FLANGE HEAD BOLT (2 REQ’D)
38
Parts – Tie Rod Assembly
Figure 27
Tie Rod Assembly
REF #
1
2
3
4
5
6
7
8
PART #
FAEX0002
MCEXBR02R
MCEXBR02L
HCNJ120L
HCNJ120R
GCEX0002
HCNC0010
HCCP0003
DESCRIPTION
TIE ROD
RH TIE ROD END
LH TIE ROD END
LH JAM NUT
RH JAM NUT
SPACER, BALL JOINT
10MM CASTLE NUT (2 REQ’D)
COTTERPIN 3/32” X ¾” (2 REQ’D)
39
Engine Parts / Service
Trained technicians with precision gauging and proper assembly fixtures carefully
assemble all Cobra engines to specific tolerances. If you feel you have the skills,
and the appropriate tools, to perform the following service tasks please follow the
instructions closely. The part numbers are listed throughout to help you when
ordering parts from your local Cobra dealer.
If you don’t feel comfortable with the service work, log
www.cobramotorcycle.com to find a Cobra dealer or Call 517 437 9100.
on
to
Engine Service
One method for determining whether the top end of your engine needs rebuilt is
to perform a WOT (Wide Open Throttle) kicking compression test. Before
performing the procedure please read the caution notes below.
CAUTION:
• There appears to be a wide range of variability in reading compression
gauges across the country.
•
The head volume of this Cobra Motorcycle is very small and so requires many
kicks ~20 before you establish the most accurate reading possible.
•
Because of the geometry of the spark plug used in this Cobra Motorcycle, the
adapter used with your compression tester must have a similar volume
protruding into the combustion chamber to establish an accurate value.
•
Length of hose on the compression tester will affect the reading. The shorter
the hose length the more accurate your reading will be.
Because of these difficulties in measuring an absolute compression value, a
useful relative value can be achieved by testing your bike’s compression with
your own particular gauge after a new top end or when the bike is new so that
you know what your particular gauge reads on a ‘fresh’ engine. When it has
dropped to 90% of its original value the engine will be down on power and would
benefit from a rebuild. When it’s dropped to 80% it really needs rebuilt! Using the
table below will help you determine monitor the condition of your top end.
Example
Your Values
Engine is Fresh
Measured Value
110 psi
Engine Down on Power
Measured Value * 0.9
110 psi * 0.9 = 99 psi
40
Engine NEEDS Rebuilt
Measured Value * 0.8
110 psi * 0.8 = 88 psi
Procedure for Compression Testing
1. Shut off the fuel petcock.
2. Install the compression gauge into the spark plug hole.
3. Hold the throttle to wide open, and kick repeatedly (approximately 20
times) or until the gauge reading does not increase in value with each
kick.
Base Gasket Selection
Tools required
• 17mm wrench
• 1mm flexible solder material
• measurement calipers
When rebuilding the ‘top end’ of your Cobra motorcycle, care must be taken to
ensure the proper squish clearance. Squish clearance is defined as the minimum
distance between cylinder head and piston at TDC, and there are negative
effects of either having too much or too little clearance. Since parts like the crank,
connecting rod, cylinder head, piston, and crankcases all have varying
tolerances, Cobra offers several different base gasket thickness’ to ensure that
you can always set the squish clearance of your engine to factory specifications.
For base gasket replacement use the code (see figure 21 for location) along with
the table on the following page reorder the correct thickness gasket.
Figure 21
41
Code
#
2
3
4
5
6
7
8
9
1
Supplied Base
Gasket Thickness
mm
inch
0.2
0.008
0.25
0.010
0.3
0.012
0.4
0.015
0.5
0.020
0.6
0.024
0.7
0.028
0.8
0.031
0.9
0.035
1.0
0.039
Cobra #
Part #
ZCMU0702
ZCMU0011
ZCMU0703
ZCKG0501
ZCMU0705
ZCMU0706
ZCMU0707
ZCMU0708
ZCMU0015
ZCMU0016
NOTE
Tolerances will affect the actual gasket thicknesses.
If during the course of the maintenance more parts than the base gasket are
changed, the squish clearance should be measured, and possibly a different
base gasket will be required.
The easiest way to measure squish clearance is with 1mm to 1.5mm thick
flexible solder wire (available through most popular electronic stores). The
process is as follows:
•
•
•
Assemble the top end of the engine with either; 1) the crankcase stamp
recommended base gasket or, 2) if assembling with a new set of cases
assemble with a 0.4mm (0.015”) base gasket, and torque the head nuts to
the proper torque specifications leaving off the spark plug and ignition cover
(piston rings can be left off to ease assembly).
Carefully insert the solder wire though the spark plug hole, into the cylinder
far enough such that the tip of the wire touches the left or right side cylinder
wall (not the front or back as the piston will rock more and give incorrect
measurement).
Hold the wire at this position and rotate the crankshaft, by the flywheel nut (or
kick lever) three revolutions to ‘smush’ the solder wire.
CAUTION:
If you rotate the flywheel nut in a counterclockwise direction there is a risk of
loosening the nut.
•
•
Pull out the wire and measure the solder thickness at the thinnest location
near its tip accurately with the thin tips of calipers.
Adjust base gasket thickness as necessary to get the desired value.
42
Upon completion, your final assembly squish clearance should agree with the
chart below
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)
43
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.
2.
3.
4.
Make sure the fuel is shut off.
Remove the carburetor.
Drain the fuel in the carburetor.
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.
44
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
Carburetor
Jetting Decisions
Although your Cobra is sent from the factory with the carburetor jetted for optimal
performance, you may find it necessary to adjustment your particular jetting due
to current weather conditions, altitude, fuel variations, and/or engine
modifications.
CAUTION:
Proper jetting is very important for engine performance and engine life.
Symptoms of improper jetting are listed below.
•
•
Symptoms of incorrect oil or oil / fuel ratio
o Poor acceleration
o Misfire at low engine speeds
o Excessive smoke
o Spark plug fouling
o Excessive black oil dripping from exhaust system
Symptoms of too rich a fuel mixture
o Poor acceleration
o Engine will not ‘rev’ out, blubbers on top
o Misfire at low engine speeds
o Excessive smoke
o Spark plug fouling
45
•
o Wet, black, or overly dark spark plug (when removed for inspection)
Symptoms of too lean a fuel mixture
o Pinging or rattling
o Erratic acceleration
o Same actions as running out of fuel
o High engine temperature
o White spark plug (when removed for inspection)
NOTE:
When inspecting the spark plug to evaluate jetting, a properly jetted machine will
produce a spark plug that is dry and light tan in color.
Environmental and altitude related mixture adjustments
Condition
Mixture will be
Required adjustment
Cold air
Warm air
Dry air
Very humid air
Low altitude
High altitude
Low barometric pressure
High barometric pressure
Leaner
Richer
Leaner
Richer
Standard
Richer
Richer
Leaner
Richer
Leaner
Richer
Leaner
None
Leaner
Leaner
Richer
NOTE:
• Before making any carburetor jetting changes verify that:
o You are using the proper fuel and oil
o The fuel is fresh and uncontaminated
o The oil and fuel have been mixed in the proper ratio
o The carburetor is clean (no plugged jets)
o The air filter is properly clean and oiled
o The float height is within proper specification (proper measuring technique
is described later in this section)
NOTE:
Perform all jetting changes on a motorcycle that has been warmed up to proper
operating temperature.
The carburetor on your Cobra motorcycle is quite adjustable. Figure 8 shows its
range of adjustment and in particular what adjustable component affects what
range of operation (specifically throttle position).
46
Figure 29
AIR SCREW ADJUSTMENT:
Adjust for maximum idle speed
The air adjustment screw is located on the left side of the carburetor. It is the
smaller of the two adjustment screws and requires the use of a small flat blade
screw driver for adjustment. After adjusting for maximum idle speed, use the idle
screw to adjust the desired idle speed.
NOTE:
If the air screw requires more than 3 turns out, replace the pilot jet for one that is
one size leaner (smaller number) then readjust the air screw.
IDLE ADJUSTMENT:
Adjust for desired idle speed
The idle speed screw is located on the left side of the carburetor. It is the larger
of the two screws on the side of the carburetor and is unique with its knurled
head for easy fingertip adjustment. To raise the idle, turn the screw in, clockwise,
(in 1/4 turn increments) and rev the engine after each adjustment. To lower the
idle, turn the screw counter-clockwise.
TOP END JETTING:
Adjust for clean full throttle acceleration
Jet your top end (main jet) based on the acceleration of your Cobra Motorcycle
on the longest straight at the track. Observe any of the lean or rich symptoms
(spark plug appearance and bike performance) listed above and change your
jetting accordingly.
PART THROTTLE
Adjust for desired acceleration
Using an area of the track that allows the rider to operate and mid throttle and
transition (accelerate, or ‘roll on’) from closed, or mostly closed throttle, to a
larger throttle opening. Observe the rich and lean symptoms listed above.
Adjust the jet needle position by moving the clip from its current position (move
the clip higher on the needle to make the bike run leaner, or move the clip lower
on the needle to make the bike run richer) to one higher or lower.
47
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
48
Index
A-arms .......................................... 30
Parts ..........................................29
Air Filter ........................................ 15
Fenders .........................................34
Maintenance.............................. 13
Frame Parts ..................................33
Axle............................................... 36
Front Brake ...................................31
Bars and Controls ......................... 16
Fuel
Base Gasket Selection.................. 41
Petcock........................................8
Break-In .......................................... 7
Fuel System
Bumper ......................................... 17
Parts list.....................................43
Carburetion
Service.......................................43
Specifications .............................. 3
Gas Tank.......................................34
Carburetor..................................... 18
General Tips....................................9
Chain
Grab Bar........................................17
Adjustment ................................ 12
Hardware
Chassis
Frame ........................................33
Specification ................................ 3
Plastic ........................................34
Torque......................................... 5
Jetting
Clutch............................................ 22
Stock............................................3
Clutch Cover ................................. 23
Troubleshooting .........................45
Clutch Lubricant
Kick Mechanism ............................25
Replacing .................................. 11
Lubrication
Compression test .......................... 41
Recommended ............................3
Cylinder......................................... 27
Maintenance
Eccentric ....................................... 36
Schedule....................................10
Electrical
Tips............................................10
Parts.......................................... 21
Nerf Bars .......................................17
Engine
Oil
Parts List ................................... 40
Recommended ............................3
Specifications .............................. 3
Optional Components......................5
Torque......................................... 4
Parts
Engine Mount Front ...................... 33
Inlet............................................43
Exhaust......................................... 45
Reeds ........................................43
49
Petcock ........................................... 8
Steering Stem ...............................16
Piston............................................ 27
Steering Upright ............................30
Plastic ........................................... 34
Swingarm Parts .............................38
Radiator ........................................ 20
Throttle ..........................................15
Rear Brake
Tie Rod..........................................39
Parts.......................................... 35
Tips .................................................9
Rear Drive..................................... 36
Toe In Adjustment .........................14
Rear Shock
Top End
Parts.......................................... 37
Parts ..........................................27
Reeds ........................................... 43
Torque
Parts.......................................... 15
Chassis........................................5
Rings............................................. 27
Engine .........................................4
Seat .............................................. 34
Transmission.................................28
shift drum ...................................... 28
Specifications ..............................3
shift forks ...................................... 28
Transmission Lubricant
Shift Mechanism ........................... 26
Replacing...................................11
Shock............................................ 32
Troubleshooting
Spark Plug
General......................................48
Recommended ............................ 3
Jetting ........................................45
Specifications.................................. 3
VIN reading .....................................9
Torque Values ............................. 4
WARNING.......................................0
Spherical Steering Bearing ........... 14
Water Pump Cover........................23
Starting ........................................... 8
Wheels ..........................................33
50