Download Cobra 0840 Specifications

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 SAN CTIONED
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.
MCC62011
Table of Contents
GENERAL INFORMATION ............................................................................................ 3
SPECIFICATIONS - GENERAL........................................................................................... 3
OPTIONAL COMPONENTS ................................................................................................ 4
SPECIFICATIONS - TORQUE VALUES............................................................................... 4
BREAK -IN PROCEDURE ................................................................................................... 5
STARTING PROCEDURE .................................................................................................. 6
MAINTENANCE ............................................................................................................... 7
TIPS ................................................................................................................................. 7
SCHEDULE ....................................................................................................................... 7
REPLACING TRANSMISSION / CLUTCH LUBRICANT......................................................... 8
CHAIN ADJUSTMENT........................................................................................................ 9
AIR FILTER CLEANING................................................................................................... 10
FORK OIL REPLACEMENT ............................................................................................. 11
IGNITION TIMING ............................................................................................................ 12
PARTS ............................................................................................................................. 13
PARTS – AIRBOX & INLET SYSTEM............................................................................... 13
PARTS – BARS AND CONTROLS .................................................................................... 14
PARTS - CARBURETOR.................................................................................................. 15
PARTS – COOLANT SYSTEM ......................................................................................... 16
PARTS – ELECTRICAL SYSTEM..................................................................................... 17
PARTS – ENGINE CLUTCH ............................................................................................ 18
Parts – Engine – Clutch / Kick Cover .................................................................. 19
Parts - Engine - Ignition Side................................................................................ 20
Parts - Engine – Kick Mechanism........................................................................ 21
Parts – Engine – Shift Mechanism ...................................................................... 22
Parts – Engine – Top End ..................................................................................... 23
Parts - Engine - Transmission .............................................................................. 24
PARTS – EXHAUST SYSTEM.......................................................................................... 25
PARTS – FORKS – LEG ASSEMBLY ............................................................................... 26
PARTS – FRAME & TRIPLE CLAMPS ............................................................................. 27
PARTS – FRONT WHEEL & BRAKES ............................................................................. 28
1
PARTS –BODYWORK ..................................................................................................... 29
PARTS – REAR BRAKE.................................................................................................. 30
PARTS – REAR WHEEL................................................................................................. 31
PARTS – SHOCK............................................................................................................ 32
PARTS – SWINGARM ASSEMBLY................................................................................... 33
SERVICE ......................................................................................................................... 34
ENGINE SERVICE........................................................................................................... 34
Base Gasket Selection .......................................................................................... 35
FUEL & AIR SYSTEM ..................................................................................................... 36
TUNING ........................................................................................................................... 40
GEARING ....................................................................................................................... 40
SUSPENSION ................................................................................................................. 41
CARBURETION ............................................................................................................... 42
TROUBLESHOOTING .................................................................................................. 45
INDEX .............................................................................................................................. 47
2
General Information
Specifications - General
Items
Dimensions
Wheelbase
Wheel size
Seat height
Engine
Type
Cooling system
Coolant
Displacement
Bore and stroke
Ignition system
Spark plug
Gap
Ignition timing
Fuel type
Premix Oil type
Premix oil ratio after break-in
Carburetion
60Main Jet / Slow (Pilot) Jet
Needle
Float Height
Transmission
Final drive ratio
Chain
Transmission / clutch oil type
Quantity
Chassis
Front tire
Rear tire
Front fork
Fork oil type
Fork oil amount
Spring Preload Length
Rear shock
CX65
40.9” (1040mm)
12” (305mm) rear, 14” (356mm) front
29.9” (760mm)
2-stroke, single cylinder, reed valve
Liquid-cooled
50/50 antifreeze-coolant / distilled water
64.9 cc
43.0 mm x 44.7 mm
Electronic, digital advance
Champion 8339-1, 8332-1 hotter, 8904-1 colder
0.023” – 0.025” (0.58 – 0.64 mm)
Digital advance (set at TDC)
High octane pump gasoline
Motul 800 2T
Motul 800 2T Off Road, 50:1 to 63:1
All other premix oil at 32:1 to 40:1
26 mm VM Mikuni
240 / 42.5
5I 14 - 4
21.1 ± 1.0
6 speed
14/45
116 links 420
Quality gear lubricant, or Cobra clutch milk
Do Not Run Automotive Motor Oil
530 ml (18.0oz)
60/100 – 14
80/100 – 12
Marzocchi 35mm USD, Compression adjustable
SAE 10 weight
210 ml (7.1oz)
178mm (49 N/mm
Compression Low 9 of 19 out, High 8 of 16 out
Rebound16 of 29 clicks out
3
Optional Components
Call your dealer, or the factory, for details
• Carburetor jets
• Pre filter for the airbox
• Tires, tubes or ‘Tire Balls’
• Sprockets
• Suspension Springs
Weight of Rider (lb)
less than 70 lb
75-85 lb
85-100 lb
Fork Spring
0.24 kg/mm
KCC60024
0.26 kg/mm
KCC60026
0.28 kg/mm
KCC60028
Greater than 100
Shock Spring
42 N/MM (240 lb/in)
SCC60240P (white)
45 N/MM (260 lb/in)
SCC60260PY stock (yellow)
49 N/MM (280 lb/in)
SCC60280PG (gold)
Ohlins
# lb/in)
53 N/MM
(300
SCEX1300 (red)
Specifications - Torque Values
Torque Value
Fastener
ft-lb
in-lb
Nm
Cylinder head nuts
12.5
150
17
Crankcase bolts
8.8
105
12
Exhaust Flange
5
60
6
Spark plug
(SP)
(SP)
(SP)
Stator bolts
2.1
25
2.8
Stator cover bolts
1.7
20
2.3
Clutch cover bolts
5.8
70
7.9
Clutch nut
35
420
47
Front axle bolt
10
120
13.5
Front axle pinch bolt 7.4
88.5
10
Engine mount bolts
22
265
30
Swingarm Pivot
21
250
28
Intake manifold bolts 4.6
55
6.2
Rear Axle Bolt
25
300
34
Rear Sprocket Bolts 20
240
27
Triple clamp bolts
6
72
8
Fork cap
15
177
20
Fork Damper Nut
11
133
15
Ignition rotor nut
33
400
45
* Apply high strength thread locking agent when installing
Size & Remarks
M7 x 1.0
M6 x 1.0
M6x1.0
M14 x 1.25
M5 X 0.8
M4 X 0.75
M6 X 1.0
M10 x 1.25*
M14 x 2.0
M6 X 1.0
M8 X 1.25
M12 X 1.5
M6 X 1.0
M14 X 1. 5
M8 X 1.25
M6 x 1.0
M10 x 1.25*
(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
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 Motul 800 T2 premix oil with high octane
pump gas mixed at 50:1 (50 ml oil to 1.3 gallon of gas, or 38ml oil to 1 gallon of gas).
Other brands of oil should be mixed at 32:1 for break-in.
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!
NOTE:
During break-in the bike will likely lose some engine coolant through the radiator
overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level will
cover the top of the radiator cores. Removing the radiator cap and looking inside is
the only way to check the coolant level.
Never open the radiator cap of a machine that has a hot or warm engine or one that
has recently been ridden. Burning and scalding could occur.
5
CAUTION:
It is important that the radiator cap is installed correctly and completely otherwise
engine damage could occur.
Starting Procedure
Before starting the machine inspect the following:
•
•
•
•
•
•
•
•
•
•
Check for proper tire pressure in both tires.
Observe the chain tension and adjust if necessary.
Observe the coolant level and fill if necessary.
Verify that the chain rollers and sliders do no t 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 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.
2.
3.
4.
5.
6.
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.
Engage the choke by pulling out on the choke button until it stops.
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. This may lead
to premature wear of engine components or complete cold seizure of the engine.
6
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.
Maintenance
It is important that you adhere to this maintenance schedule so as to promote the
longevity of your Cobra Motorcycle.
Tips
1.
2.
3.
4.
5.
6.
7.
Cobra lubricants:
a. Use only high quality transmission oil designed specifically for two stroke racing engines.
b. Motul 800 2T Off Road oil is the recommended premix oil because:
• Its Ester base leaves a film on all parts at all times. No metal to
metal startups or corrosion potential.
• Exception film strength over petroleum based oils or synthetic
blends.
• Easily atomizes and burns completely.
• Does not fall out of suspension from premix in cold weather.
• Produces virtually no coking deposits, leaving pistons, rings and
heads extremely clean with minimal pipe ‘spooge’.
Fill your transmission only with the recommended amount of oil. Overfilling may
lead to premature seal failure.
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.
Evaluate the bikes jetting only after it has been warmed up to race
temperatures.
A properly maintained machine is safer, faste r, and more fun to ride.
New chains will stretch on first use. Never install a new chain prior to a race.
Always ‘break’ them in during practice.
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
•
Between each ride
o
Check the air filter (clean and re-oil as necessary).
o
Insure the smooth operation of the throttle cable (throttle soundly ‘clacks’
shut).
o
Check for frayed strands of the throttle cable inside the throttle housing
and replace if necessary.
o
Check for adequate tire pressures and adjust if necessary.
o
Check all nuts and bolts for proper torque and re-torque if necessary.
o
Spray all moving parts with WD40 or other water displacing oil.
o
Check drive chain for
7
•
•
§ 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 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.
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.
CAUTION:
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.
8
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.
4. After it has drained, reinstall the
bolt being sure that the rubber
gasket is in 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
Figure 1
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
Figure 2
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).
9
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.
Figure 3
Air Filter Cleaning
Tools recommended for air filter maintenance:
• 5 mm hex key (Allen)
• Foam filter oil
Procedure
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.
Figure 4
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 waterresistant 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
10
Figure 5
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 Oil Replacement
Requirements
• 19mm and 27mm combination wrench
• 6mm and 10mm hex key (Allen)
• Flexible retrieving tool
• 10w fork oil (approximately 210cc per fork leg)
Disassembly
1. Remove the front wheel and front brake caliper.
2. Remove the fork legs from the triple clamps.
3. Perform the following on each fork leg:
a. Remove the fork cap from the fork tube using a 27mm wrench.
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 19mm wrench.
d. With a 19mm wrench on the damper rod nut, use a 27mm wrench to free the
fork cap from the damper rod.
e. Remove the 19mm wrench and allow the damper rod to fall into the damper
tube.
f. Remove the fork spring and spacer.
g. Invert the fork to allow the oil to drain. Pump the damper rod assembly
several times to help the oil drain.
Assembly
1. Completely collapse the outer fork tube onto the stanchion tube. Add enough oil
to the fork 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.
Pull the fork spring down from the damper rod to expose the damper rod lock nut.
Secure this nut using a 19mm wrench.
5. Install the spacer and fork cap to the damper rod. Ensure that the fork cap is
completely threaded onto the damper rod before it makes contact with the lock
nut. Torque the damper rod lock nut to 15N-m (11ft-lb).
6. Install the fork cap to the fork tube. Torque the fork cap to 20Nm (15ft-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 ftlb) making sure both legs are set to the same height in the clamps.
11
9. Install the front wheel, and torque the axle to 13.5N-m (10 ft-lb).
10. Drop the bike onto the ground, engage the front brake, and push up and down
on the handlebars several time to ensure that the front forks and the front wheel
are properly aligned with each other.
11. Tighten the axle pinch bolts to 10N-m (7.4 ft-lb).
Ignition Timing
The ignition timing value for the CX65 is 5° 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.
12
Parts
Parts – Airbox & Inlet System
REF #
1
2
3
4
5
6
7
8
9
10
NOT SHOWN
11
12
13
14
15
16
17
PART #
RCC60007
TCC60008
HCSP0003
MCKGHO03
RCC60002
RCC60003
RCC60004
RCC60014
RCC60006
ECC60006
ECC60014
ECC60007
HCBC0602
MCC60003
ZCC60021
RCR60026
MCMUCL04
FCMU0026
Coolant System
DESCRIPTION
AIRBOX 07 65
MUD FLAP 07 65
SCREW - PLASCREW
CLAMP, AIR BOOT TO AIR BOX
AIR FILTER 07 65
AIR FILTER CAGE
AIR FILTER WIRE 07 65
AIR BOOT, CARB TO AIRBOX 65
AIR FILTER CAP 07 65
REED ASSEMBLY 07 65
REED PETALS - REPLACEMENT
INLET MANIFOLD 07 65
6X20MM SOCKET HEAD CAP SCREW
CLAMP, MANIFOLD TO CARB
GASKET REED 07 65
CARBURETOR 26MM MIKUNI
HOSE CLAMP 8MM
FUEL LINE
13
Parts – Bars and Controls
Bars and Controls
REF #
1
2
3
4
6
7
8
9
10
11
12
13
14
PART #
FAMU0011
TCMU0008
FCMU0066
FCMU0021
CCMU0014
CCDC0001
CCMU0004
BCC60014
CCC60001
BCMU0020
BCMU0017
RAC60001
TKMU0404
TKMU0403
HCBC1002
HCNL1001
HCBC0806
BCC60009
BCC60008
DESCRIPTION
HANDLEBAR - ALUMINUM
GRIPS (SET OF TWO)
THROTTLE ASSEMBLY
THROTTLE COVER
MASTER CYLINDER W/LEVER - CLUTCH
CLUTCH LEVER
COVER – RESERVOIR (REPLACEMENT)
CLAMP – PERCH (REPLACEMENT)
LINE - CLUTCH (REPLACEMENT)
FITTING – THREADED CLUTCH LINE END
FERRULE – COMPRESSION FITTING
THROTTLE CABLE
BAR MOUNT KIT, SHORT (1 REQ’D)
BAR MOUNT KIT, TALL (1 REQ’D) STOCK
10X50 SOCKET HEAD CAP SCREW (2 REQ’D PER BIKE)
M10 LOCK NUT
SOCKET HEAD CAP SCREW M8 X 30 (4 PER)
MASTER CYLINDER ASSY W/LEVER
BRAKE LEVER
HCBH0820
FCMU0033
M8 X 20 HEX HEAD BOLT
KILL SWITCH ASSEMBLY
14
Parts - Carburetor
Carburetor
REF. #
1
2
3
4
5
6
8
9
10
11
12
13
15
16
17
18
20
21
22
23
24
PART #
DESCRIPTION
RCR60026
CARBURETOR 26MM MIKUNI
RCMU0271
NEEDLE VALVE & SEAT ASSY
SEE BELOW
MAIN JET
SEE BELOW
RCC60013
PILOT JET
GASKET , FLOAT BOWL
ZCDCOR01
O’RING BOWL PLUG
RCC60016
RCMU0277
SLIDE MASS
CLIP - NEEDLE
RCMU0415
CABLE ADJUSTER CAP
25
26
27
31
33
34
PILOT JET
22.5
25
27.5
30
32.5
35
37.5
40
42.5
45
47.5
50
52.5
55
57.5
60
65
70
MAIN JET
RCEX0022
RCEX0025
RCEX0027
RCEX0030
RCEX0032
RCEX0035
RCEX0037
RCEX0040
RCEX0042
RCEX0045
RCEX0047
RCEX0050
RCEX0052
RCEX0055
RCEX0057
RCEX0060
RCEX0065
RCEX0070
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
15
RCMU0165
RCMU0170
RCMU0175
RCMU0180
RCMU0185
RCMU0190
RCMU0195
RCMU0200
RCMU0205
RCMU0210
RCMU0215
RCMU0220
RCMU0230
RCMU0240
RCMU1250
Parts – Coolant System
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART #
FCC60046
FCMU0022
MCMUCL05
FCKG0214
FCDC0009
HCSP0002
HCCN0000
ECC60063
ECC60012
ECC60013
MCMUCL07
MCKGHO04
MCC6GR01
HCWF1478
HCBF0612
MCMUCL09
Coolant System
DESCRIPTION
RADIATOR W/CAP - CX65
CAP – 1.3 BAR
HOSE CLAMP 11-20 UNIVERSAL
HOSE - OVERFLOW
RADIATOR LOUVER-CX65
PUSH PIN - PLASTIC
5MM EXTRUDED "U" NUT
HOSE RADIATOR UPPER
HOSE RADIATOR BOTTOM
HOSE TRANFTER – CASES TO CYLINDER
HOSE CLAMP RADIATOR MEDIUM (4 REQ’D)
HOSE CLAMP RADIATOR LARGE (1 REQ’D)
GROMMET RADIATOR (2 REQ’D)
6MM WASHER 22MM OD BLK ZINC (2 REQ’D)
6X12 FLANGED HEX-8MM HEAD (2 REQ’D)
HOSE CLAMP RADIATOR SMALL (1 REQ’D)
16
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
HCWF0010
HCNS1001
ICC60006
ICMU0035
ICC60005
HCBC0516
HCSP0002
HCCN0000
ECMU0065
ECMU0067
ECMU0066
FCMU0033
ECDC0085
ZCDC0004
HCBC0402
DESCRIPTION
STATOR DIGITAL 07 65
5X12MM SHCS (3 REQ’D)
5MM FLAT WASHER (3 REQ’D)
ROTOR OUTER STYLE 07 65
WOODRUFF KEY
10 FLAT WASHER
10MM X 1.25 NUT
CDI UNIT 2010 65
MOUNT - CDI
COIL DIGITAL 2011 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)
KILL SWITCH ASSEMBLY
COVER - IGNITION
GASKET-IGNITION COVER
4X35MM SHCS – COVER MOUNTING (3 REQ’D)
17
Parts – Engine Clutch
Clutch components
REF. #
PART #
1
EAEX0003
2
ECDC0064
NOT
SHOWN ECDC0167
3
4
5
6
ECDC0063
ECDC0066
ECDC0068
ECDC0067
7
8
9
10
11
12
13
14
15
CKMU0001
ECDC0069
ECDC0070
ECDC0071
HCBC0525
ECDC0030
HCBF1035
ECDC0019
ECDC0018
ECC60050
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 KIT INCLUDING- SPRINGS, STEELS
AND FIBERS
CLUTCH HUB
SPRING, CLUTCH – (6 REQ’D)
PLATE, CLUTCH SPRING
5X25 SOCKET HEAD CAP SCREW (6 REQ’D)
SPRING WASHER – CLUTCH
10MM X 35 FLANGE HEAD BOLT
CLUTCH BEARING SEAT
BEARING,CLUTCH THROW OUT
CLUTCH PUSH ROD - 2010
18
Parts – Engine – Clutch / Kick Cover
REF. #
1
2
3A
3B
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
22
23
Clutch / kick cover components
PART #
DESCRIPTION
ECC60045
CLUTCH COVER (2010)
ZCC60007
GASKET-CLUTCHCOVER
HCBC0625
6X25 SOCKET HEAD CAP SCREW (6 REQ’D)
HCBC0630
6X30 SOCKET HEAD CAP SCREW (2 REQ’D)
HCFH0616
6X16 FLAT HEAD BOLT
ECMU0250
WASHER – KICK LEVER
ECMU0240
KICKSTARTER LEVER – ALUMINUM
EKMU0002
PIVOT SPRING, BALL AND SET SCREW KIT
ECDC0078
SEAL,KICKSTARTER
ZCMUB014
O’RING-OIL FILL PLUG
ECMU0168 (B, OIL FILL PLUG, ALUMINUM (SUFFIX INDICATES
BL, OR R)
COLOR, B – BLACK, BL – BLUE, R – RED)
ZCDCOR05
ORING-CLUTCH CAP
ECC60053
CLUTCH CAP W/SLAVE CYLINDER
CCC60005
PISTON – CLUTCH SLAVE CYLINDER
CCC60006
SPRING – SLAVE RETURN
ZCMUOR35
O’RING – SLAVE PISTON
CCEX0009
BALL, CLUTCH ACTUATOR
ECDC0082
SNAP RING-CLUTCH CAP
BCMU0018
FITTING – BLEED, CLUTCH LINE
ECAX0150
IMPELLER COVER
HCBC0601
6X16 SOCKET HEAD CAP SCREW
ECDC0075
IMPELLER, WATERPUMP
ECKG0074
SEAL, WATERPUMP
ECMU0218
RETAINING RING, WATER PUMP SEAL
MCMUTL12
TOOL – CLUTCH CAP REMOVAL
CCC60001
LINE – CLUTCH REPLACEMENT
BCMU0021
COVER – RUBBER CLUTCH LINE END
BCMU0020
FITTING – THREADED CLUTCH LINE END
BCMU0017
FERRULE – COMPRESSION FITTING
19
Parts – Engine – Ignition Side
REF. # PART #
1
ECDC0085
2
ZCDC0004
3
HCBC0402
4
HCBC0501
6
7
8
9
10
11
12
13
14
15
16
17
18
21
22
23
24
HCWF0501
HCNS1001
HCWF0010
ICC60003
ICC60004
ECDC0024
ECDC0086
HCFH0620
ECKGSR03
PCKG00xx
ECDC0009
ECDC0025
ECDC0026
ICMUGR01
EKC62010
ZCDCOR01
ECEX0008
Ignition side engine components
DESCRIPTION
IGNITION COVER
GASKET-IGNITION COVER
4X35 SOCKET HEAD CAP SCREW (3 REQ’D)
5X12MM SHCS
WASHER FLAT 5MM
NUT M10
10MM FLAT WASHER
ROTOR PVL OUTER STYLE
STATOR PVL DIGITAL 07 65
SEAL, CRANKSHAFT
SHIFTER LEVER – CX65
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
O-RING, SPROCKET SPACER
BUSHING, SHIFTER SHAFT
20
Parts – Engine – Kick Mechanism
REF. #
PART #
1
ECC60066
2
ECC60067
3
ECDC0036
4
ECDC0043
5
ECDC0042
6
ECMU0171
7
ECDC0038
8
ECDC0033
9
ECDC0035
10
ECDC0037
11
ECDC0032
12
ECDC0039
13
ECDC0060
14
ECMU0170
15
ECMU0233
Kick Mechanism
DESCRIPTION
SPACER – KICK SPRING CENTERING
SPRING KICK START CX65
SNAP RING,EXT.16MM-SPRING RET.
WASHER, KICKSTART BACKUP
SPRING, KICKSTART RAMP
SHAFT,KICK STARTER – THREADED
RAMP GEAR, KICKSTART
GEAR, KICKSTART
SNAP RING, EXTERNAL 12MM
SNAP RING, EXTERNAL 15MM
GEAR, KICK START IDLE
RAMP, KICK START
6MM X 16 PHILLIPS FLAT HEAD SCREW
SPRING HOLDER
FITTING, VENT HOSE
NOT
SHOWN ECMU0534
VENT HOSE
21
Parts – Engine – Shift Mechanism
Clutch components
REF. #
PART #
1
EADC0154
2
ECDC0055
4
ECDC0110
ECMU0172
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
26
27
28
ECC60003
ECDC0099
ECMU0550
ECDC0051
ECDC0053
HCBC1825
HCWL0802
ECMU0548
ECMU0546
ECMU0545
ECDC0035
ECDC0056
ECDC0060
ECDC0022
ECMU0216
HCBB1612
ECDC0024
ECDC0112
ECDC0073
ECDC0036
EKC62010
ECDC0031
HCBB1612
DESCRIPTION
SHIFTER SHAFT (2 COMPONENTS) W/SPRING
SPRING – SHIFTER SHAFT
SPACER, CENTERING SPRING
BUSHING
SPACER BUSHING (INCOMPATIBLE WITH
ECDC0010 & ECMU0172)
SPRING, CENTERING
SHIFT CASSETTE (W/O PINS)
DOWEL – SHIFT CASSETTE ( 6 REQ’D)
DOWEL – SHIFT DRUM INDEX ( 1 REQ’D)
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
ENGINE CASE SET W/B&S CX65
DOWEL, HOLLOW (2 PLACES)
6MM X 12 BUTTON HEAD
22
Parts –
Engine –
Top End
Engine – Top End
REF #
1
2
3
5
6
7
8
9
10
NOT
SHOWN
11
12
13
14
15
16
17
18
19
20
PART #
ECC60075
ZCC60115
ECC60389
ECMU0121
ECMUSR00
DESCRIPTION
CYLINDER KIT (INCLUDES PISTON KIT) 10 65
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…) 10 65
PISTON RINGS 43MM (2 PER SET)
SNAP RING FOR PISTON (2 REQ’D)
ECDC0061
ZCMUOR07
ECC60002
BEARING, WRIST PIN
O-RING, EXHAUST FLANGE
EXHAUST FLANGE 30MM
ZCMOTE11
HCBC0601
HCNS0703
HCWS1401
ECC60010
ECC60034
ZCMUOR02
ZCMUV024
ZCMUOR10
ECC60073
ZCMUOR05
ECMU0147
O-RINGS – PIPE TO FLANGE (2 REQ’D)
M6X16 SHCS, EXHAUST FLANGE SCREW (2 REQ’D)
7MM NUT TALL
FLAT WASHER – HARDENED
CYLINDER HEAD OUTER
BRASS COOLANT PLUG WITH SEAL
O-RING, CYLINDER HEAD LARGE
O-RING CYLINDER HEAD SMALL
O-RING CYLINDER STUD (4 REQ’D)
CYLINDER HEAD INSERT 10 65
O-RING CYLINDER HEAD MEDIUM - YELLOW
STUD, CYLINDER 7mm
23
Parts – Engine – Transmission
Transmission
REF #
1
2
PART #
DESCRIPTION
ECEX0015
CRANKSHAFT 2010 CX65
ECDC0023
BEARING, CRANKSHAFT
ACCESSORY
EKEX0001
ROD KIT
3
EKC62010
ENGINE CASE SET W/B&S CX65
4
EKC62010
ENGINE CASE SET W/B&S CX65
5
ZCC60006
GASKET CRANKCASE 2010 65
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
ST
7
ECDC0001
SHAFT, TRANSMISSION PRIMARY (1 GEAR), 13T
TH
8
ECDC0002
GEAR, 6 PRIMARY 24T
9
ECDC0003
SNAP RING, EXTERNAL 17 MM (2 REQ’D)
RD
TH
10
ECDC0004
GEAR, 3 / 4 PRIMARY, 18/21T
TH
11
ECDC0005
GEAR, 5 PRIMARY, 23T
ND
12
ECDC0006
GEAR, 2 PRIMARY, 16T
13
ECKGBR01
BEARING, OUTPUT IGNITION SIDE
14
ECDC0007
SHAFT, TRANSMISSION OUTPUT
ND
15
ECDC0014
GEAR, 2 OUTPUT, 31T
16
ECDC0017
SHAP RING, EXTERNAL 18MM (3 REQ’D)
TH
17
ECDC0013S
GEAR, 5 , OUTPUT, 30T
TH
18
ECDC0011S
GEAR, 4 OUTPUT, 28T
RD
19
ECDC0010S
GEAR, 3 OUTPUT, 34T
TH
20
ECDC0015S
GEAR, 6 OUTPUT, 26T
ST
21
ECDC0016
GEAR, 1 OUTPUT, 37T
22
ECC60051
SHIFT DRUM
NOT SHOWN
ECC60055
ROLLER – SHIFT FORK PIN (3 REQ’D)
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” (0.8mm) THICK
28B
ECMU0040T
SHIM TRANSMISSION 0.015” (0.4 mm) THIN
31
ECC60015
BUSHING ENGINE / SWINGARM PIVOT CX65
32
ECMU0549
BEARING, NEEDLE, SHIFT DRUM LEFT SIDE
33
ECDC0024
SEAL, CRANKSHAFT
24
Parts – Exhaust System
Exhaust System
REF #
1
2
PART #
XAC62010
XCMU0033
3
4
5
6
7
8
9
10
11
12
13
14
15
HCHA0003
HCBF0616
HCBF0612
HCCN0000
HCBC0516
ZCMOTE11
XCMU0005
XCKG0009
XCMU0032
MCMUGR03
TCKG0001
TCC60016
HCBF0630
XCMU0026
NOT SHOWN
DESCRIPTION
EXPANSION CHAMBER 2010
ISOLATION MOUNT (2 REQ’D)
6MM CLIP NUT-PLASTIC/PIPE MNT (2 REQ’D FOR PIPE & 2
REQ’D FOR SILENCER)
6X16MM FLANGE HEAD BOLT (2 REQ’D)
6X12MM FLANGE HEAD BOLT (2 REQ’D)
5MM EXTRUDED “U” NUT
5X16MM SHCS FOR RIGHT SHROUD MOUNT
O-RING – EXHAUST (2 REQ’D)
SPRING – PIPE – SHORT
GROMMET – SILENCER TO PIPE
SILENCER 10” ROUND 2007
GROMMET FOR RADIATOR (4 REQ’D)
SPACER GENERAL ½DIA 13.2 LG (2 REQ’D)
SPACER TOP HAT (2 REQ’D)
6X30 FLANGE HEX-8MM HEAD
SILENCER PACKING KIT
25
Parts – Forks – Leg Assembly
Fork Leg Assembly
REF #
PART #
KACX6527
1
NOT SHOWN
2
3
4
5
6
7
NOT SHOWN
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
KCC60023
KCC60004
KCC60002
KCC60011
KCC60003
KCC60012
ZCMUOR34
ZCMUOR16
KCC60005
KCC60006
KCC60009
KCC60008
KCC60007
KCC60024
KCC60026
KCC60028
KCC60014
HCBC0601
TCC60019
BCC60015
HCNS0601
HCBC0612
BCC60013
HCBC0820
HCBC0812
DESCRIPTION
FORK SET – 2008 CX65
FORK LEG OUTER
RING – FORK OUTER WEAR
BUSHING – TOP
WASHER
FORK SEAL
CLIP RING
DUST COVER (SWIPER)
BLEED SCREW WITH SEAL
SEAL – BLEED SCREW
O-RING – FORK CAP
BUSHING – BOTTOM
FORK LEG INNER – NON BRAKE SIDE
SEAL – PISTON
BASE VALVE BODY
BOLT – FORK BOTTOM
WASHER – FORK BOTTOM
BOLT – AXLE CLAMP
CAP - COMPRESSION SIDE
SPACER – PRELOAD
FORK SPRING .24 KG/MM
FORK SPRING .26 KG/MM STANDARD
FORK SPRING .28 KG/MM HEAVY
FORK LEG INNER – BRAKE SIDE
FORK GUARDS – PAIR (3 BOLT STYLE)
6MM X 16 SHCS
SPACER – FORK GUARD MOUNTING
CLAMP – BRAKE LINE
6MM NUT
6MM X 12 SHCS
BRAKE BRACKET
8X20MM SHCS
8X12MM SHCS LOW HEAD
26
Parts – Frame & Triple Clamps
Frame
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART #
FACX0020
FAC60016
HCBB0835
HCFH0825
FCC60020
BCDC0153
TCMU0039
TCC60012
HCBH0840
HCWF0803
HCNL0802
WCKG0011
HCWF1202
HCNL1201
HCBH0865
HCWF0801
HCNL0801
HCBH0807
HCNS0801
FAC60001
FCMU0001
HCBC0625
FCMU1103
FCMU0004
FCMU0011
HCNJ0102
FCC60053
HCBC0625
DESCRIPTION
FRAME WELDED ASSEMBLY 2010 CX65
SUBFRAME 2010 CX65
8X35MM BUTTON HEAD SCREW (2 REQ’D) – TOP MOUNT
8X25MM FLAT HEAD CAP SCREW – (2 REQ’D) – BOTTOM MOUNT
CHAIN ROLLER W BEAR & SEALS
WASHER
FOOTPEG SET ULTRA WIDE CX65
FOOTPEG SPRING ULTRA WIDE 07 (2 REQ’D)
8MM X 40 HEX HEAD 30MM NO THRD – FOOTPEG (2 REQ’D)
8MM FLAT WASHER
8MM LOCKNUT – FOOTPEG (2 REQ’D)
SWINGARM PIVOT BOLT
12MM FLAT WASHER
12MM LOCKNUT
8X65MM HEX HEAD – FRONT ENGINE MOUNTS (2 REQ’D)
8MM FLAT WASHER – FRONT ENGINE MOUNTS (4 REQ’D)
8MM LOCKNUT – FRONT ENGINE MOUNTS (2 REQ’D)
8X20MM HEX HEAD – STEERING STOP (2 REQ’D)
8MM NUT – STEERING STOP (2 REQ’D)
TRIPLE CLAMP BOTTOM W/STEM, BEARING & DUST COVER
STEERING STEM
6X25MM FOR BOTTOM CLAMP (6 REQ’D)
DUST COVER STEER STEM, RUBBER (2 REQ’D)
BEARING – STEERING TAPERED
RACE – STEERING BEARING
JAM NUT STEERING STEM (2 REQ’D)
TRIP LE CLAMP TOP - 2010
6X25MM SHCS FOR TOP CLAMP (4 REQ’D)
27
Parts – Front Wheel & Brakes
REF#
1
2
NOT SHOWN
3
4
5
6
NOT SHOWN
7
8
9
10
ACCESSORY
NOT SHOWN
NOT SHOWN
NOT SHOWN
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
PART #
WAC6FR01B
WCC6F014B
WCC6F014D
WCDCHB01
WCMU1400B
WCDCTU14
WCDC0009
WCDC0002
WCDC0011
WCC60008
HCNL1402
WCMU0120
WCC60006
WCC60002
BCC60040
ECC60055
HCBF1612
BAC60002
HCBC0850
HCBC0820
BCC60021
BCC60013
HCBC0820
HCBC0812
MCMUZT04
BCC60006
BCC60024
BCC60008
BCC60009
BCC60010
BCC60011
Front Brakes
DESCRIPTION
WHEEL 14” FRONT W BEARINGS (NO TIRE, OR TUBE,), BLACK
TIRE -BRDGESTNE-60/100-14M39
TIRE -DUNLOP-60/100-14 756
HUB FOR CX65 – FRONT
14” RIM, BLACK
TUBE – 60/100-14 FRONT
RIM LINER 14” WHEEL
SPOKE-FRONT WHEEL-65
NIPPLE-SPOKE 9GA. STAINLESS
AXLE FRONT 07 65 STEEL
NUT, FRONT AXLE
BEARING, WHEEL-SEALED
SPACER WHEEL BEARING FRONT
WHEEL SPACER 07 65 FRNT LEFT
BRAKE ROTOR FRONT – FLOATER
SPACER – FLOATING ROTOR (4 REQ’D)
6X12MM FLANGE HEAD – LOW PROFILE (4 REQ’D)
BRAKE ASSEMBLY FRONT AJP
8X50MM SHCS
8X20MM SHCS
CALIPER ADJUSTMENT SHIMS 8MM ID
BRAKE BRACKET
8X20MM SHCS
8X12MM SHCS LOW HEAD
TIE WRAP (2 REQ’D)
REPLACEMENT HOSE BRAKE PADS (NARROW)
BRAKE LEVER
MASTER CYLINDER
CALIPER PISTON REBUILD KIT FRONT
CALIPER
28
Parts – Bodywork
Plastic and Seat
REF #
1
2
3
4
5
6
7
8
9
10
PART #
TCC62010
TCC60020
HCBF0616
TCC60021
TCC60002
HCBF0612
TCC60024
HCBC0503
TCC60027
TCC60029
HCFH0620
TCMU0151
TCHA0002
TCHA0003
FCMU0151
TAC60002
HCBC0625
TCC60018
TCC60022
TCC60022xxx
HCSP0003
HCBC0516
HCCN0000
TCC60023
TCC60023xxx
HCSP0003
TCC60005
HCBC0516
HCBF0630
TCC60017
TCC60016
TCC60007
HCSP0003
HCBC0516
HCWP0002
HCHA0003
DESCRIPTION
GRAPHIC KIT – 2010 CX65
FRONT FENDER
FENDER BOLT, M6X16 FLANGE HEAD (4 REQ’D)
SPACER – FRONT FENDER BOLT (4 REQ’D)
NUMBER PLATE – FRONT
M6X12 FLANGE HEAD BOLT – FRONT NUMBER PLATE MOUNT
FUEL TANK (NO PETCOCK OR CAP)
M5X30 SHCS – FRONT TANK MOUNTING
SPACER – FRONT TANK MOUNTING
SPACER – SEAT MOUNT
M6X20 FLAT HEAD – FRONT SEAT MOUNT
PETCOCK
CAP – FUEL TANK
HOSE – FUEL CAP
CAP – STEERING STEM
SEAT – 2010 CX65
M6X25 SOCKET HEAD CAP SCREW – SEAT HOLDING
SPECIAL WASHER – SEAT HOLDING
SHROUD LEFT – YELLOW
xxx DENOTES COLOR, BLK – BLACK, BLU – BLUE, WHT - WHITE
PLASCREW (1 REQ’D) – MOUNT SHROUD TO TANK
M5X16 SHCS (1 REQ’D) – MOUNT SHROUD TO RADIATOR
5MM EXTRUDED “U” NUT
SHROUD RIGHT – YELLOW
xxx DENOTES COLOR, BLK – BLACK, BLU – BLUE, WHT - WHITE
PLASCREW (2 REQ’D) – MOUNT SHROUD TO TANK
SIDE NUMBER PLATE – PAIR
M5X16 SOCKET HEAD CAP SCREW (3 REQ’D)
M6X30 FLANGE HEAD BOLT – SILENCER (2 REQ’D)
BODY PANEL WASHER 5MM (3 REQ’D)
BODY PANEL WASHER 6MM (2 REQ’D)
FENDER – REAR
PLASCREW – FENDER TO AIRBOX (2 REQ’D)
M5x16 SOCKET HEAD CAP SCREW (2 REQ’D)
WASHER - BODY PANEL FLAT (2 REQ’D)
CLIP NUT – 6MM
29
Parts – Rear Brake
REF #
1
1A
1B
1C
2
3
4
5
6
7
8
9
10
11
12
13
15
16
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
ACCESSORY
PART #
BAC60005
BCC60028
BCC60027
BCC60029
BAC60006
HCBF0620
HCCC0005
HCPP0832
BAC60004
BCMU0022
BCMUSP02
BCMU0099
BCMU0501
BCDC0009
FCEX0018
HCBC0612
BCC60004
HCBB0616
BCKG0031
BCC60030
BCC60031
BCC60032
BCC60033
BCC60034
BCC60035
BCC60036
BCC60037
BCC60038
BCC60045
HCFH0501
Rear Brake System
DESCRIPTION
BRAKE ASSEMBLY REAR 2011
BRAKE MASTER CYLINDER CX65 8mm
BRAKE LINE 8mm BOTH ENDS CX65
BRAKE CALIPER 8mm CX65
BRAKE BRACKET
6X20 FLANGE HEX-8MM HEAD
BRAKE - HOSE GUIDE (2 REQUIRED)
#8X1/2 SELF TAPING SCREW (2 REQUIRED)
BRAKE PUSH ROD ASSEMBLY WITH CLEVIS - CX65
BRAKE - RUBBER CAP - BOTTOM OF MASTER CYLINDER
BRAKE SPRING RETURN
BRAKE PEDAL
SEAL-BRAKE PEDAL (2 REQUIRED)
BRAKE PEDAL PIVOT BOLT
BRAKE ADJUST ECCENTRIC
6X12 SHCS
BRAKE ROTOR REAR
6X16 BUTTON WITH THREAD LOCK rotor bolts (4 REQUIRED)
BLEED KIT (MULTIPLE SYRINGES, FITTINGS & HOSE)
BRAKE PAD SET CX65 SEMI-METALLIC
BRAKE BELLOWS KIT CX65
BRAKE PISTON KIT CX65
BRAKE BLEED SCREW KIT CX65
BRAKE CAP ONLY BLEED SCREW CX65
BRAKE MASTER CYLINDER CAP & SEAL KIT
BRAKE MASTER CYLINDER REBUILD KIT
BRAKE CLEVIS KIT
BRAKE BANJO BOLT AND WASHER KIT
SHARK FIN
5 X 12 FLAT HEAD
30
Parts – Rear Wheel
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART #
WAC6RR01B
WCC6R012D
WCDCHB02
WCMU1200B
WCDCTU12
WCDC0010
WCDC0003
WCDC0011
WCMU0109
WCDC0001
WCDC0008
HCNS0801
HCWF0801
PCDC00xx
HCBH0825
BCC60004
HCBC1616
PCMU0116
WCC60004
Rear Wheel
DESCRIPTION
WHEEL 12" REAR W BEARINGS (NO TIRE, TUBE, ROTOR OR SPROCKET),
BLACK
TIRE – DUNLOP- 80/100-12 756
HUB FOR CX65-REAR
12" RIM, BLACK
TUBE-275-80/100-12 REAR
RIM LINER 12" WHEEL
SPOKE-REAR WHEEL-65
NIPPLE-SPOKE 9GA. STAINLESS
WASHER-NIPPLE (NOT REQUIRED ON ALL MODELS)
RIM LOCK FOR REAR WHEEL (32 REQ’D)
RIM LOCK SPACER-DC65
8MM NUT
8MM FLAT WASHER
SPROCKET – xx denotes number of teeth
8X25MM HEX HEAD (4 REQ’D)
BRAKE ROTOR REAR
6X16 SHCS WITH THREAD LOCK (4 REQ’D)
CHAIN 420H 116 LINK CX65 14/48
AXLE REAR 07 65
BAC60006
BRAKE BRACKET (2011)
WCC60003
WCMU0120
WCC60007
WCC60005
GCC60010
HCWF1400
HCNL1402
WHEEL SPACER 07 65 REAR RIGHT
BEARING, WHEEL
SPACER WHEEL BEARING REAR
WHEEL SPACER 07 65 REAR LEFT
CHAIN ADJUST BLOCK OFFSET
14MM FLAT WASHER
14MM LOCKNUT
31
Parts – Shock
Shock
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
PART #
SAC62011
SCMU0043
SCMU0039
SCMU0042
SCMU0058
SCMU0056
SCMU0100
SCMU0040
SCMU0054
SCC60240P
SCC60260P
SCC60280P
SCEX1300
HCBF1040
HCNL1001
HCBC1055
DESCRIPTION
SHOCK ABSORBER – CX65
SHOCK - BEARING SPHERICAL SHOCK MOUNT–CARD (2 REQ’D)
O-RING - SHOCK - BUSHING – CARD (4 REQ’D)
SHOCK - MOUNT BUSHING – CARD (4 REQ’D)
SHOCK - WHITE NYLON TIP SETSCREW M6-1.0 - CARD
SHOCK - SLEEVE BLACK - CARD
BUMPER - TAPPERED - SHOCK
SHOCK - SPRING PAD - CARD
SHOCK - SPRING PERCH - CARD
SPRING EXTRA LIGHT 240 LB/IN (42N/mm) (WHITE)
SPRING STANDARD 260 LB/IN (45 N/mm) (YELLOW)
SPRING HEAVY 280 LB/IN (49 N/mm) (GOLD)
SPRING HEAVY 300 LB/IN (53 N/mm) (RED)
M10 X 40 HEX HEAD BOLT
10MM LOCKNUT-REGULAR
10 X 55 SOCKET HEAD CAP SCREW (8mm HEX)
32
Parts – Swingarm Assembly
Swingarm
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
PART #
GACX6511
GCC60015
HCWF1202
HCNL1201
GCC60002
GCC60001
TCC60004
HCPP0832
HCBC0501
PCC60004
HCBF0645
HCNL0601
HCNS0701
HCBH0701
HCCC0005
HCPP0834
DESCRIPTION
SWINGARM WELDED ASSY ALUMINUM 2011
BOLT - SWINGARM PIVOT
12MM WASHER – SWINGARM PIVOT
12MM LOCK NUT – SWINGARM PIVOT
SWINGARM BUSHING 07 65 (4 REQ’D)
SWINGARM PIVOT TUBE SPACER 07 65 J(2 REQ’D)
CHAIN SLIDER TOP FOR SWINGARM
#8X1/2 SELF TAPING SCREW (2 REQ’D FOR CHAIN SLIDER)
5X12MM SHCS – CHAIN SLIDER MOUNT
CHAIN GUIDE (BOTTOM) CX65
6X45 FLANGE HEAD BOLT (2 REQ’D)
6MM LOCK NUT (2 REQ’D)
7MM NUT (2 REQ’D)
7X35 HEX HEAD FULL THREAD (2 REQ’D)
BRAKE - HOSE GUIDE (2 REQ’D)
#8X3/4 SELF TAPING SCREW (2 REQ’D)
33
Service
This portion of the manual is still under development. If you have questions please
call the Cobra technical support line at 517 437 9100.
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
Engine is Fresh
Measured Value
Engine Down on Power
Measured Value * 0.9
Engine NEEDS Rebuilt
Measured Value * 0.8
110 psi
110 psi * 0.9 = 99 psi
110 psi * 0.8 = 88 psi
Your Values
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.
34
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
Code
#
34
5
8
Supplied Base
Gasket Thickness
mm
inch
0.15
0.006
0.25
0.010
0.4
0.015
0.5
0.020
0.8
0.031
Cobra #
ZCC60116
ZCC60110
ZCC60115
ZCC60015
ZCC60130
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:
35
•
•
•
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.
Upon completion, your final assembly squish clearance should agree with the chart
below
Fuel & Air System
Carburetor:
Tools recommended for carburetor service:
• Small flat head screwdriver
• WD-40
• 6mm socket
Your Cobra is equipped with an adjustable carburetor. Some fine-tuning may be
needed according to weather condition and altitude. Proper jetting is very important
36
for engine performance and engine life. Serious damage to the engine can occur if
not properly adjusted.
IDLE ADJUSTMENT:
On the each side of the
carburetor, there are two
adjustment screws. The right
side screw with the knurled
head is the idle adjustment
screw. 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 counterclockwise.
TOP END JETTING:
Indications that the engine is
running too rich (too much
fuel for the air) are:
• Engine not revving out or
blubbering at high RPMs.
• Engine will not ‘clean out’
• Wet or black spark plug
NOTE:
Before changing
jetting be sure that the air
filter is properly cleaned and
has the usual amount of air
filter oil. An overly dirty air
filter can cause the engine to
run rich.
If the engine is running rich on the top end it should be leaned out. Leaning it out
can be done by:
1. Changing the main jet to a smaller number.
2. Raising the needle clip (this lowers the jet needle) one notch at a time on the
slide.
Indications that the engine is running too lean are:
• Engine cutting out on top end.
• Engine overheating and ultimately seizure.
• White spark plug
CAUTION:
It is much safer to operate the engine slightly rich as opposed to slightly lean. This is
because an overly rich engine will just run poorly while an overly lean engine will
seize, potentially causing an expensive top end rebuild and a DNF.
37
To richen the carburetor:
1. Change the main jet one number at a time (larger).
2. Lower the needle clip (raising the jet needle) one notch at a time until the engine
starts to blubber on the top end, then move the clip back up one notch or until
you get the blubber out.
FUEL MIXTURE SCREW
The left side brass screw is a fuel mixture (air) screw. This screw will also richen
and lean your engine more on the bottom and mid-range. In warmer conditions, turn
the screw in. In colder conditions, turn the screw out.
Be sure to keep the
carburetor very clean and make sure you don't have water or dirt in the carburetor
bowl. Use automotive carburetor cleaner or WD-40 to clean the carburetor inside
and out. Turning the screw in richens the mixture at partial throttle openings. Turing
the screw out, leans it.
STOCK CARBURETOR SETTINGS
The 2009 CX65 stock carburetor settings from the factory are:
• 40 pilot jet
• 210 main jet
Cleaning the carburetor:
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 flashpoint solvent to clean the carburetor.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Make sure the fuel is shut off.
Remove the carburetor.
Drain the fuel from the carburetor.
Disassemble the carburetor.
Immerse all the metal parts in a carburetor cleaning solution.
After the parts are cleaned, dry them with compressed air.
Blow out the fuel passages with compressed air.
Assemble the carburetor
Install the carburetor onto the motorcycle.
Rear Shock
The rear shock is fully serviceable but it is recommended that only trained
professionals should service your shock. Contact Cobra or another qualified
specialist (PR2, MCR, etc..) for questions and service of your CX65shock.
38
Shock preload
Shock Damping
39
Tuning
Gearing
Rear
Sprocket
37
38
Gear
Ratio
2.47
2.53
39
37
40
2.60
2.64
2.67
38
41
39
2.71
2.73
2.79
15
42
37
40
2.80
2.85
2.86
15
43
38
41
2.87
2.92
2.93
15
44
39
42
2.93
3.00
3.00
15
15
45
46
43
3.00
3.07
3.07
40
37
47
3.08
3.08
3.13
44
41
38
3.14
3.15
3.17
48
45
42
3.20
3.21
3.23
39
49
46
3.25
3.27
3.29
15
43
40
50
3.31
3.33
3.33
15
47
44
51
3.36
3.38
3.40
Front Sprocket
15
15
15
14
15
14
15
14
13
14
13
14
13
14
14
13
12
15
14
13
12
15
14
13
12
15
14
13
12
14
13
40
Suspension
Adjustment:
1. Front forks
1.1. Fork oil
1.1.1. Oil type
1.1.1.1. Heavier weight oil – more damping – slower responding
1.1.1.2. Lighter weight oil – less damping – quicker responding
1.1.2. Oil quantity / level
1.1.2.1. Greater quantity / higher level – greater bottoming resistance,
stiffer near the end of the travel.
1.1.2.2. Smaller quantity / lower level – less bottoming resistance, less
stiff near the end of the travel.
1.2. Fork spring
1.2.1. Stiffer spring (higher spring rate) – stiffer throughout the travel.
1.2.2. Less stiff spring (lower spring rate) – less stiff througho ut the travel.
1.3. Gas pressure – always bleed off any pressure.
1.4. Fork height
1.4.1. Rise in clamps for quicker turning.
1.4.2. Lower in clamps for improved straight line stability.
2. Rear shock
2.1. Preload adjustment
2.1.1. More preload (greater distance) – less race sag.
2.1.2. Less preload (smaller distance) – more race sag.
2.2. Shock spring
2.2.1. Stiffer spring – stiffer throughout the travel.
2.2.2. Less stiff spring – less stiff throughout the travel.
2.3. Compression damping
2.3.1. Harder (more damping, slower) – adds resistance to the suspension
motion when the suspension is compressing.
2.3.2. Softer (less damping, quicker) – reduces resistance to the suspension
motion when the suspension is compressing.
2.4. Rebound damping
2.4.1. Harder (more damping, slower) – adds resistance to the suspension
motion when the suspension is returning to full length.
2.4.2. Softer (less damping, quicker) - reduces resistance to the suspension
motion when the suspension is returning to full length
Front Forks Bottoming Too Frequently
Fork oil level
If the front forks bottom harshly more than a couple of times per lap and the fork
springs are proper for the weight of rider (as detailed above), try raising the fork oil
level in increments of 10mm. Raising the fork oil level, reduces the air volume, and
increases the stiffness of the forks late in the travel, thus adding a progressive’ feel.
Front forks feel too stiff over small bumps.
Fork oil weight
If the forks feel too stiff over small bumps try decreasing the weight (increasing the
viscosity) of the fork oil.
41
Rear suspension troubleshooting.
Damping
Always start with standard settings and make damping changes in no more than two
click increments and only make one change at a time.
Symptom
Rear end feels stiff on small bumps
Rear end ‘sways’ on straights
Bike tends to jump ‘rear end high’
Bike tends to jump ‘rear end low’
Frequent rear end bottoming
Bottoms after end of continuous bumps
Rear end ‘kicks’ over square edge bumps
Action
Softer compression damping
Harder compression damping
Harder rebound damping
Softer rebound damping
Harder compression damping
Softer rebound damping
1) Harder rebound, 2) Softer
Compression
Proactive Suspension Adjustments
Once you have the suspension adjusted for decent overall feel, you can make
proactive adjustments when faced with different racing conditions.
Situation
Sand track
Sand track
Long fast track
Tight slow track
Mud track
Actions
Lower the rear end (increase race sag).
Stiffer compression and rebound damping.
Lower the forks in the clamps by 3 mm.
Raise the forks in the clamps by 3 mm.
Lower the bike if the rider has difficulties
touching the ground.
Carburetion
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
42
•
o Excessive smoke
o Spark plug fouling
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 49 shows its
range of adjustment and in particular what adjustable component affects what range
of operation (specifically throttle position).
43
FUEL SCREW ADJUSTMENT:
Adjust for throttle response
The air adjustment screw is located on the left side of the carburetor. It requires the
use of a small flat blade screw driver for adjustment. After adjusting for proper
throttle response, 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 fuel screw.
IDLE ADJUSTMENT:
Adjust for desired idle speed
The idle speed screw is located on the right side of the carburetor. It is hidden
behind the exhaust stinger pipe and is barely reachable with a screwdriver. 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.
44
Troubleshooting
1) Engine operates erratically
a) Carburetor top is installed backwards
b) The carburetor slide indexing pin is missing
c) A carburetor vent elbow is plugged or has fallen out
d) Faulty stator
e) An air leak
i) Base gasket
ii) Intake / reed gaskets
iii) Crank seals
iv) Crank case gasket
2) Engine is down on power
a) Jetting is incorrect
b) Silencer needs repacked
c) Exhaust pipe
i) Has excess carbon buildup
ii) Has large dent in it
d) Compression is low
i) Piston
ii) Rings
e) Reeds are damaged
f) Ignition timing is incorrect
g) Stator needs replaced
3) Engine is excessively loud
a) Silencer needs repacking
4) Engine ‘blubbers’ at high RPMs
a) Jetting too rich
b) Stator needs replaced
5) Engine won’t start
a) Fuel
i) None in tank
ii) Is sour or bad
b) Carburetor is dirty
45
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 with object of flooded fuel
e) Engine is flooded
f) Cracked, broken, or jammed reed pedal
g) Excessive piston or cylinder wear
h) Clutch bolt or shoe dragging on basket (drum).
6)
Engine won’t idle
a)
Idle knob needs adjusted
b) Carburetor jets a re dirty
c) Choke is stuck on
d) Air leak
46
Index
Front Brake
Air Filter Maintenance...................... 12
Parts ............................................... 31
Fuel System
Bars and Controls ............................. 16
Parts list ......................................... 40
Base Gasket Selection .................... 38
Service ........................................... 40
Break-In................................................ 6
Hardware
Carburetor
Frame ............................................. 30
Parts ............................................... 17
Plastic ............................................. 32
Service ........................................... 40
Specifications .................................. 3
Jetting
Chassis
How To ........................................... 40
Specification.................................... 3
Stock................................................. 3
Clutch ................................................. 21
Troubleshooting ............................ 45
Clutch Cover ..................................... 22
Clutch Lubricant
Kick Mechanism ............................... 24
Replacing ....................................... 10
Compression test ............................. 38
Lubrication
Cylinder .............................................. 26
Recommended ............................... 3
Cylinder head
torque ............................................... 5
Maintenance
Schedule .......................................... 8
Electrical
Tips ................................................... 8
Parts ............................................... 20
Engine
Oil
Specifications .................................. 3
Recommended ............................... 3
Exhaust
Optional components ......................... 4
Parts ............................................... 28
Parts
Fork Oil
Bars and Controls ......................... 16
Replacement ................................. 13
Carburetor ..................................... 17
Frame Parts....................................... 30
Coolant System ..................... 15, 19
47
Electrical ........................................ 20
Service ........................................... 47
Exhaust .......................................... 28
Spark Plug
Frame ............................................. 30
Recommended ............................... 3
Front Brake.................................... 31
Specifications ...................................... 3
Plastic & Seat................................ 32
Starting ................................................. 7
Rear Brake .................................... 33
Stator
Rear Wheel ................................... 34
torque ............................................... 5
Shock.............................................. 35
Suspension........................................ 47
Swingarm ....................................... 36
Swingarm Parts ................................ 36
Piston.................................................. 26
Plastic & Seat Parts ......................... 32
Top End
Parts ............................................... 26
Rear Brake
Service ........................................... 37
Parts ............................................... 33
Torque Values..................................... 5
Rear Wheel
Transmission ..................................... 27
Parts ............................................... 34
Transmission Lubricant
Reeds ................................................. 42
Replacing ....................................... 10
Rings .................................................. 26
Troubleshooting ................................ 48
Jetting ............................................. 45
shift drum ........................................... 27
shift forks............................................ 27
VIN reading ......................................... 8
Shift Mechanism ............................... 25
Shock
WARNING ........................................... 0
Parts ............................................... 35
Water Pump Cover........................... 22
48