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.
Table of Contents GENERAL INFORMATION ............................................................................................ 3 SPECIFICATIONS - GENERAL........................................................................................... 3 OPTIONAL COMPONENTS ................................................................................................ 4 SPECIFICATIONS - TORQUE VALUES............................................................................... 4 BREAK -IN PROCEDURE ..........
PARTS –BODYWORK ..................................................................................................... 29 PARTS – REAR BRAKE.................................................................................................. 30 PARTS – REAR WHEEL................................................................................................. 31 PARTS – SHOCK............................................................................................................ 32 PARTS – SWINGARM ASSEMBLY..
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
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.
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: 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.
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.
• • § 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.
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.
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.
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.
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°).
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 - REPLACEM
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
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.
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.
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.
Parts – Engine Clutch Clutch components REF.
Parts – Engine – Clutch / Kick Cover REF.
Parts – Engine – Ignition Side REF.
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.
Parts – Engine – Shift Mechanism Clutch components REF.
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.
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
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 –
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 DU
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 CHAI
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
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
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 ASSEMB
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.
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.
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 CHAI
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.
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.
• • • 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).
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.
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.
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.
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.
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.
• 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.
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.
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 damag
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).
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 .....................
Electrical ........................................ 20 Service ........................................... 47 Exhaust .......................................... 28 Spark Plug Frame ............................................. 30 Recommended ............................... 3 Front Brake.................................... 31 Specifications ...................................... 3 Plastic & Seat................................ 32 Starting .................................................
