Cobra 2006 ECX50 Service Manual Download Page 1

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2006 ECX50

Owners

Parts

Service

Tuning

Summary of Contents for 2006 ECX50

Page 1: ...2006 ECX50 Owners Parts Service Tuning...

Page 2: ...Cobra dealer log on to www cobramotorcycle com or call 330 549 9600 If you need technical assistance contact your local dealer or call the Cobra Technical Support Hotline at 330 549 9603 Cobra Motorcy...

Page 3: ...E 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 PRODU...

Page 4: ...M1 Replacing Transmission Lubricant 12 M2 Chain adjustment 13 M3 Air Filter Cleaning 14 M4 Front end 15 Toe in adjustment 15 Steering 15 Parts 16 Parts Air Inlet System 16 Parts Bars and Steering 17 P...

Page 5: ...aust System 22 Parts Front A Arms Steering Upright 27 Parts Front Brakes 28 Parts Front Shock 29 Parts Miscellaneous 30 Parts Plastic Bodywork Seat 31 Parts Rear Brake 32 Parts Rear Drive 33 Parts Rea...

Page 6: ...nic analog advance Spark plug Champion 8339 1 8332 1 hotter 8904 1 colder Gap 0 023 0 025 0 58 0 64 mm Ignition timing 0 040 1 02 mm BTDC Fuel type High octane pump gasoline RACE FUELS ARE NOT RECOMME...

Page 7: ...ts 2 1 25 2 8 M5 X 0 8 Stator cover bolts 1 7 20 2 3 M4 X 0 75 Clutch cover bolts 5 8 70 7 9 M6 X 1 0 Clutch nut 35 420 47 M10 x 1 25 Clutch bolts 12 144 16 M6 x 1 0 CFD nut 55 664 75 x 20 LHT Units o...

Page 8: ...designates that the application requires the use of high strength red thread locking agent applied to the threads B designates that the application requires the use of medium strength blue thread loc...

Page 9: ...sult 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 neutra...

Page 10: ...e 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...

Page 11: ...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 Keep steering stops adjusted so that the wheels do not scrape on the A arm...

Page 12: ...te 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 necess...

Page 13: ...s on the motorcycle may cause burns 2 Lean bike against something or set on stand with oil drain hole 3 Remove the oil drain plug located on the right side of the engine on the clutch cover near the b...

Page 14: ...tric 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 directi...

Page 15: ...ot 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 ai...

Page 16: ...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 c...

Page 17: ...SE CLAMP CARB TO MANIFOLD 6 HCBC0625 M6X25 SOCKET HEAD CAP SCREW 7 HCWF0601 6MM FLAT WASHER 8 ECKG0203 INLET MANIFOLD 9 ECKG0202 REED CAGE ASSEMBLY WITH REEDS NOT SHOWN ECKG0205 REED REPLACEMENT KIT 1...

Page 18: ...PLACEMENT 2 REQ D NOT SHOWN TCMU0403 BAR MOUNT KIT TALL OPTIONAL 2 REQ D 6 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 4 REQ D 7 HCBC1001 M10X45 SOCKET HEAD CAP SCREW 2 REQ D 8 HCNL1001 M10 LOCK NUT 2 REQ...

Page 19: ...8 8MM X 30 HEX HEAD BOLT FRONT MOUNT 2 PLACES NOT SHOWN HCBH0809 8MM X 50 HEX HEAD BOLT REAR MOUNT 2 PLACES NOT SHOWN HCWF0801 8MM FLAT WASHER 2 REQ D NOT SHOWN HCNL0801 8MM LOCKNUT 2 REQ D 2 FAEX0099...

Page 20: ...7 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0205 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLIP 17 RCMU0204 CHOKE ASS Y 2001 CM 20 RCMU0009 FUEL MIXTURE SCREW 21 RCMU0011 IDLE ADJUSTMENT SCREW 25...

Page 21: ...ibbed 3 ECEX0010 RADIATOR HOSE TOP 4 ECEX0010 RADIATOR HOSE BOTTOM 5 MCEXGR01 GROMMET BOTTOM RAD MOUNT 2 REQ D NOT SHOWN FCEX0026 PAD RADIATOR 2 REQ D 6 HCBF0616 FLANGE HEAD BOLT M6X16 2 REQ D 7 ECHA0...

Page 22: ...ICEX0002 TETHER IGNITION SHUT OFF 4 HCBC0516 SCREW M5 X 16 2 PER 5 HCCN0000 5MM CLIP NUT 2 PER 6 ICMU0018 STATOR 3 WIRE ANALOG 7 HCBC0535 5mm x 35 SOCKET HEAD CAP SCREW 2 REQ D 8 HCBC0525 5mm x 25 SO...

Page 23: ...2 REQ D 11 ECMU0099 OUTPUT SHAFT TRANSMISSION WITH GEAR 12 ECMU0100 SECONDARY SHAFT TRANSMISSION WITH GEAR 13 ECMU0001 BEARING TRANMISSION SECONDARY SHAFT 14 ECKG0031 BEARING OUTPUT SHAFT RIGHT SIDE...

Page 24: ...0141 HUB CFD 12 ECMU0142 PLATE CFD 2 REQ D 13 ECMU0143 PAPER CFD 2 REQ D 14 ECMU0144 GEAR CFD 15 ECMU0145 SPRING WASHER CFD 16 HCWF0002 WASHER FLAT CFD 13MM 17 HCNS1202 NUT CFD 20 LEFT HAND THREAD BLU...

Page 25: ...TER PUMP SHAFT 5 ECKG0073 IMPELLER WATER PUMP 6 ECKG0004 RETAINER WATER PUMP ASSEMBLY 7 HCBB0003 5MM X 12 BUTTON HEAD STAINLESS 8 HCWF0501 FLAT WASHER 9 ECKG0175 WATER PUMP PULLEY FAN TYPE DRIVEN 10 E...

Page 26: ...9 ZCMUOR07 O RING EXHAUST FLANGE 10 ECMU0086 EXHAUST FLANGE NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0602 M6X20 EXHAUST FLANGE SCREW 2 REQ D 12 HCNS0601 6mm Nut 13 HCWF0601 6MM FLAT WA...

Page 27: ...MET MALE NOT SHOWN MCMUGR07 PIPE GROMMET FEMALE NOT SHOWN MCMUSP02 PIPE GROMMET SPACER NOT SHOWN HCBF0635 M6X35 FLANGE HEAD BOLT 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D NOT SHOWN BRACKET EXHAUST 9 XCDC...

Page 28: ...FT 4 GAEX0009 A ARM BACK BOTTOM RIGHT GAEX0008 A ARM BACK BOTTOM LEFT 5 HCBC1065 10MM X 65 SOCKET HEAD CAP SCREW BLACK OXIDE 6 MCEXBR05 BUSHING A ARM 7 GCEX0006 SPACER A ARM PIVOT TUBE 8 HCBF1070 10MM...

Page 29: ...13 HCBC0601 6MM X 16 SOCKET HEAD CAP SCREW 3 PER SIDE 14 WCEX0001 FRONT HUB WITH WHEEL STUDS 15 FRONT WHEEL STUD 4 REQ D WITH EACH HUB 16 GCEX0008 WHEEL SPINDLE SAME L R 17 HCNS1400 M14 CASTLE NUT SA...

Page 30: ...ELLOW 155 LB IN SCEXA145 SHOCK SPRING LIGHT RED 145 LB IN SCEXA165 SHOCK SPRING HEAVY BLACK 165 LB IN 4 SCSP0001 TRAVEL LIMITER 1 50 SCSP0002 TRAVEL LIMITER 1 25 SCSP0003 TRAVEL LIMITER 1 00 5 TOP SPR...

Page 31: ...the table below PART DESCRIPTION WCEX0007 REAR WHEEL WITH TIRE 6X8 WCEX0004 FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING HCBH0804 M8 X 120 FRONT ENGINE MOUNT BOLT HCWF0801...

Page 32: ...STIC TO GRAB BAR NOT SHOWN HCNL0601 6MM LOCK NUT 2 REQ D PLASTIC TO GRAB BAR NOT SHOWN HCBB0616 6MM BUTTON HEAD 2 REQ D AT FRONT NOT SHOWN HCWF0601 6MM FLAT WASHER 2 REQ D AT FRONT 3 TCEX0011 SEAT NOT...

Page 33: ...SCREW 14 HCBC0816 M8X16 SOCKET HEAD CAP SCREW 15 HCWF0801 M8 FLAT WASHER SPACER 4 REQ D 16 BCDC0002 CALIPER REAR BRAKE 17 BCDC0007 BRAKE PAD KIT ACCESSORY 18 BCEX0001 REAR BRAKE CARRIER NOT SHOWN WCEX...

Page 34: ...PER HUB 5 HCBH0808 M8 X 30 HEX HEAD BOLTS 4 REQ D 6 HCNL0801 M8 LOCK NUT 4 REQ D 7 PCDC00XX SPROCKET 37T 51T XX DENOTES OF TEETH 9 GCEX0016 BRAKE HUB SPACER 10 HCKW0001 HUB KEY 11 GCEX0024 REAR WHEEL...

Page 35: ...SPRING LIGHT WHITE 460 LB IN SCEX1530 SHOCK SPRING HEAVY GREEN 530 LB IN 4 SCKGOH04 SPRING PLATFORM 5 SCKGOH03 BALL JOIINT 6 SCKGOH02 SPACER 7 SCKGOH11 O RING FOR BALL JOINT 8 SCKGOH21 SCREW FOR KNOB...

Page 36: ...4 HCBH1421 SWINGARM PIVOT BOLT M14 X 1 HEX HEAD 5 HCNL1402 SWINGARM LOCK NUT M14 X1 6 GCEX0050 TOP SWINGARM GUARD ECX50 7 HCPP0832 SELF TAPPING SCREW 8 HCBF1040 BOLT SHOCK 9 HCCC0000 BRAKE HOSE CLAMP...

Page 37: ...ssembly REF PART DESCRIPTION 1 FCEX0015 TIE ROD 2 MCEXBR02R RH TIE ROD END 3 MCEXBR02L LH TIE ROD END 4 HCNJ120L RH JAM NUT 5 HCNJ120R LH JAM NUT 6 GCEX0002 SPACER BALL JOINT 7 HCNC0010 10MM CASTLE NU...

Page 38: ...please call 330 549 9603 for details 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 p...

Page 39: ...end and transmission the engine must be removed from the frame Tools required 10 11 13 22 mm wrench 8 10 14 17 19 mm sockets 3 4 5 mm hex key Allen wrench 7 mm nut driver flat or Phillip screwdriver...

Page 40: ...ywheel holding tool and 14 mm socket remove the nut that secures the flywheel 4 Using the Cobra flywheel clutch puller MCMUTL68 remove the flywheel from the crankshaft 5 Remove the stator 5mm hex key...

Page 41: ...ng etc are found replace the cylinder 2 If deposits are all are found a Clean with muratic acid b Once the deposits are removed inspect for abrasions and missing surface coating i If there are abrasio...

Page 42: ...ouple months of hard racing Engine assembly CAUTION For any seals that are to be installed apply a light amount of grease to the seals ID assembly lube on all bearings and a small amount of Loctite to...

Page 43: ...ins CAUTION Never force the cylinder If resistance is felt determine the problem and solve it Once installed slightly rotate the cylinder back and forth insuring that the rings are properly seated 15...

Page 44: ...belleville washers on your 2006 Cobra are similar looking but different in geometry from prior years Do not mix old and new parts as damage will occur Cobra clutch puller assembly Figure 30 Figure 31...

Page 45: ...acked Clean the washers and bolt if you intend to reuse The spring stacks in your 2006 Cobra clutch will contain 11 individual springs and a flat washer configured as a 5 stack See figure 32 This clut...

Page 46: ...tch engagement thus decreasing the abruptness of clutch engagement softer hit Part Thickness mm inch HCWS0801 1 4 0 056 HCWS0802 1 2 0 047 HCWS0803 0 79 0 031 HCWS0804 0 64 0 025 HCWS0805 0 51 0 020 H...

Page 47: ...tle blipper CAUTION Sludge build up between the spring washers also keeps the clutch shoe from engaging fully and this will cause the clutch to start to slip So you will need to clean the sludge out o...

Page 48: ...he clutch is likely to malfunction 4 Use fine emery paper on the center hole of the clutch and on the tapered section of the crankshaft 5 Apply a small amount of wicking bearing retainer green thread...

Page 49: ...use of the amount of heat generated by the clutch and engine during extended periods of riding it is advisable to remove the ignition cover afterward to allow the ignition to cool off The heat transfe...

Page 50: ...hole 3 Remove the four bolts from the ignition cover 4 Remove the water pump belt from the rotor and water pump shaft 5 Turn the crankshaft counterclockwise until it reaches top dead center 6 Set the...

Page 51: ...n the engine keeps the radiator fluid in circulation throughout the motor The air stream running through the radiator cools the radiator fluid Therefore dirty radiators additionally reduce the cooling...

Page 52: ...the system 4 Drain engine transmission oil by removing drain screw using a 13mm hex wrench item 2 in the figure below 5 Remove right side radiator hose and unscrew coolant fitting with a 8mm hex key...

Page 53: ...a of the seal If there is any sign of wear like a groove replace the shaft Figure 40 14 Reinstall new bearings seal open side toward impeller and impeller Clean all threads and use green wicking beari...

Page 54: ...ly U ltra black Hi Temp RTV silicon or Teflon pipe sealant to the tapered pipe threads of the coolant fitting before assembly NOTE Refill the coolant system with Liquid Performance Propylene Glycol ba...

Page 55: ...idle turn the screw in clockwise in 1 4 turn increments and rev the engine after each KING Carburetor Ref Drawing REF PART DESCRIPTION 1 RCMU0305 CARB SLIDE 2 RCMU0601 NEEDLE 3 ATOMIZER AU2 62 4 MAIN...

Page 56: ...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...

Page 57: ...om the carburetor 4 Disassemble the carburetor 5 Immerse all the metal parts in a carburetor cleaning solution 6 After the parts are cleaned dry them with compressed air 7 Blow out the fuel passages w...

Page 58: ...Figure 44 The presence of light indicates that the reeds should be replaced or possibly turned over Exhaust The pipe is a crucial element to a motorcycle Any kinks dents or damage done to the pipe wi...

Page 59: ...h improper gearing Poor performance Not enough top end speed No snap Over heat clutch Premature failure of engine seals bearings electronics High clutch wear Condition Gear Taller Gear Lower Mud Sand...

Page 60: ...42 2 80 13 37 2 85 14 40 2 86 13 38 2 92 14 41 2 93 13 39 3 00 14 42 3 00 13 40 3 08 13 41 3 15 13 42 3 23 Ratio Write Cobra R D 2004 Carburetion Although your Cobra is sent from the factory with the...

Page 61: ...te 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 C...

Page 62: ...ews 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 a...

Page 63: ...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 ric...

Page 64: ...Electrical Parts 23 Engine Parts List 42 Specifications 5 Torque 6 Engine Mount Front 35 Exhaust 44 Parts 31 Fenders 36 Frame Parts 35 Front Brake 33 Fuel Petcock 10 Fuel System Parts list 42 Service...

Page 65: ...ed 5 Specifications 5 Torque Values 6 Spherical Steering Bearing 16 Starting 10 Steering Stem 18 Steering Upright 32 Swingarm Parts 40 Throttle 17 Tie Rod 41 Tips 11 Toe In Adjustment 16 Top End Parts...

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