Cobra 2007 CX65 User Manual Download

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2007

2007 CX65

CX65

Owners

Parts

Service

Tuning

Summary of Contents for 2007 CX65

Page 1: ...2007 2007 2007 2007 CX65 CX65 CX65 CX65 Owners Owners Owners Owners Parts Parts Parts Parts Service Service Service Service Tuning Tuning Tuning Tuning...

Page 2: ...OR 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 PRO...

Page 3: ...RETOR 16 PILOT JET 16 MAIN JET 16 PARTS COOLANT SYSTEM 17 PARTS ELECTRICAL SYSTEM 18 PARTS ENGINE CLUTCH 19 Parts Engine Clutch Kick Cover 20 Parts Engine Ignition Side 21 Parts Engine Kick Mechanism...

Page 4: ...2 GEARING 42 SUSPENSION 43 CARBURETION 44 TROUBLESHOOTING 47 INDEX 48...

Page 5: ...m Ignition system Electronic digital advance Spark plug Champion 8339 1 8332 1 hotter 8904 1 colder Gap 0 023 0 025 0 58 0 64 mm Ignition timing Digital advance set at TDC Fuel type High octane pump g...

Page 6: ...table Spring rate 280 lb in 49 N mm Optional Components Call your dealer or the factory for details Carburetor jets Pre filter for the airbox Tires tubes or Tire Balls Sprockets o Front o Rear Suspens...

Page 7: ...pinch bolt 7 4 88 5 10 M6 X 1 0 Engine mount bolts 22 265 30 M8 X 1 25 Swingarm Pivot 21 250 28 M12 X 1 5 Intake manifold bolts 4 6 55 6 2 M6 X 1 0 Rear Axle Bolt 25 300 34 M14 X 1 5 Rear Sprocket Bol...

Page 8: ...st 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...

Page 9: ...ted 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 fu...

Page 10: ...lure 3 The cylinder base gasket has been fitted for your engine See the service section of this manual for instructions how to properly size a base gasket during an engine rebuild 4 Evaluate the bikes...

Page 11: ...f operation o Replace the transmission oil 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 t...

Page 12: ...lutch 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 plas...

Page 13: ...ain is at its tightest point 3 If the chain requires adjusting loosen the axle with a 22mm wrench and loosen the jam nut with an 11mm wrench Tighten the chain by rotating the adjustor bolts clockwise...

Page 14: ...filter in hot soapy water to remove all dirt particles 6 Allow it to dry thoroughly 7 Saturate with filter oil and remove excess 8 Apply a thin coating of grease around the sealing lip of the filter N...

Page 15: ...he 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 retrievin...

Page 16: ...FILTER 07 65 6 RCC60003 AIR FILTER CAGE 7 RCC60004 AIR FILTER WIRE 07 65 8 RCC60005 AIR BOOT CARB TO AIRBOX 65 9 RCC60006 AIR FILTER CAP 07 65 10 ECC60006 REED ASSEMBLY 07 65 11 ECC60007 INLET MANIFO...

Page 17: ...THROTTLE COVER 6 BCC60008 ALLOY BRAKE LEVER 6 BCC60009 MASTER CYLINDER ASSY W LEVER 7 RAC60001 THROTTLE CABLE 8 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 4 PER 9S TKMU0404M BAR MOUNT KIT SHORT 2 PER 9T...

Page 18: ...RCMU0245 250 RCMU1250 Carburetor REF PART DESCRIPTION 1 RCC60001 CARBURETOR 24MM MIKUNI 2 FLOAT BOWL 3 FLOAT ARM PIN 4 NEEDLE VALVE SEAT ASSY 5 WASHER NEEDLE VALVE 6 SEE BELOW MAIN JET 8 NEEDLE JET 9...

Page 19: ...DC0009 RADIATOR LOUVER CX65 5 HCCN0000 5MM EXTRUDED U NUT 6 ECC60011 HOSE RADIATOR UPPER 7 ECC60012 HOSE RADIATOR BOTTOM 8 ECC60013 HOSE TRANFTER CASES TO CYLINDER 9 MCMUCL07 HOSE CLAMP RADIATOR SMALL...

Page 20: ...0002 CDI UNIT 07 65 8 HCNL0601 6MM LOCKNUT CDI MOUNTING 2 REQ D 9 ICC60001 COIL DIGITAL 07 65 10 HCBC0516 5X16MM SHCS COIL MOUNTING 2REQ D 11 HCSP0002 5MM WASHER COIL MOUNTING 2 REQ D 12 HCCN0000 5MM...

Page 21: ...S 4 ECDC0066 CLUTCH PRESSURE PLATE 5 ECDC0068 CLUTCH DISC FRICTION 5 REQ D 6 ECDC0067 CLUTCH DISC STEEL 4 REQ D 7 ECDC0069 CLUTCH HUB 8 ECDC0070 SPRING CLUTCH 6 REQ D 9 ECDC0071 PLATE CLUTCH SPRING 10...

Page 22: ...ECDC0078 SEAL KICKSTARTER 9 ZCMU0005 GASKET OIL FILL PLUG 10 ECMU0037 OIL FILL PLUG W GASKET 11 ZCDCOR05 ORING CLUTCH CAP 13 ECDC0074 CLUTCH CAP 14 ZCDCOR04 ORING CLUTCH SLAVE CYLINDER NOT SHOWN CCEX...

Page 23: ...LAT WASHER 9 ICC60003 ROTOR PVL OUTER STYLE 10 ICC60004 STATOR PVL DIGITAL 07 65 11 ECDC0024 SEAL CRANKSHAFT 12 ECDC0086 SHIFTER LEVER CX65 13 HCBH0620 M6 X 20 HEX HEAD BOLT 14 ECKGSR03 SNAP RING OUTP...

Page 24: ...HER KICKSTART BACKUP 6 ECDC0042 SPRING KICKSTART RAMP 7 ECMU0135 SHAFT KICK START 8 ECDC0038 RAMP GEAR KICKSTART 9 ECDC0033 GEAR KICKSTART 10 ECDC0035 SNAP RING EXTERNAL 12MM 11 ECDC0037 SNAP RING EXT...

Page 25: ...LAR 10 ECDC0057 LEVER NEUTRAL POSITIONING 11 ECDC0058 LEVER DRIVE GEAR POSITIONING 12 ECDC0098 SPRING CHANGE LEVER 13 ECDC0059 BOLT SHOULDER 14 ECDC0056 BEARING RETAINER PLATE 15 ECDC0060 6MM X 16 FLA...

Page 26: ...CMUOR07 O RING EXHAUST FLANGE 10 ECC60002 EXHAUST FLANGE 30MM NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0601 M6X16 SHCS EXHAUST FLANGE SCREW 2 REQ D 12 HCNS0701 7MM Nut 13 HCWS1401 FLAT...

Page 27: ...4 TH PRIMARY 18 21T 11 ECDC0005 GEAR 5 TH PRIMARY 23T 12 ECDC0006 GEAR 2 ND PRIMARY 16T 13 ECKGBR01 BEARING OUTPUT IGNITION SIDE 14 ECDC0007 SHAFT TRANSMISSION OUTPUT 15 ECDC0010 GEAR 2 ND OUTPUT 34T...

Page 28: ...HCBF0612 6X12MM FLANGE HEAD BOLT 2 REQ D 6 HCCN0000 5MM EXTRUDED U NUT 7 HCBC0516 5X16MM SHCS FOR RIGHT SHROUD MOUNT 8 ZCMOTE11 O RING EXHAUST 2 REQ D 9 XCMU0005 SPRING PIPE SHORT 10 XCKG0009 GROMMET...

Page 29: ...ING FORK CAP 10 KCC60005 BUSHING BOTTOM 11 FORK LEG INNER NON BRAKE SIDE 12 KCC60006 SEAL PISTON 13 KCC60009 BASE VALVE BODY 14 BOLT FORK BOTTOM 15 KCC60008 WASHER FORK BOTTOM 16 BOLT AXLE CLAMP 17 KC...

Page 30: ...8MM LOCKNUT FOOTPEG 2 REQ D 7 WCKG0011 SWINGARM PIVOT BOLT HCWF1202 12MM FLAT WASHER HCNL1201 12MM LOCKNUT 8 HCBH0865 8X65MM HEX HEAD FRONT ENGINE MOUNTS 2 REQ D HCWF0801 8MM FLAT WASHER FRONT ENGINE...

Page 31: ...FRONT 07 65 STEEL 3 WCMU0120 BEARING WHEEL SEALED 4 WCC60006 SPACER WHEEL BEARING FRONT 5 WCC60002 WHEEL SPACER 07 65 FRNT LEFT 6 BCC60003 BRAKE ROTOR FRONT 7 HCBC1616 6X16MM SHCS WITH THREAD LOCK 4 R...

Page 32: ...HOSE FUEL CAP NOT SHOWN TCHA0005 SPACER FRONT TANK MOUNT NOT SHOWN HCFH0620 M6X20 FLAT HEAD FRONT SEAT MOUNT 6 TCC60010 ISOLATION CAP TANK MOUNTING REAR NOT SHOWN TCMU0000 FUEL PETCOCK NOT SHOWN FCMU...

Page 33: ...015B BRAKE RETAINING SPRING PIN 12 BCMU0016 PLUNGER THREADED FOR CLEVIS 13 HCNS0601 6MM NUT FOR PLUNGER 14 BCMU0501 SEAL BRAKE PEDAL 15 BCMUSP02 SPRING REAR BRAKE PEDAL 16 FCEX0018 BRAKE ADJUST ECCENT...

Page 34: ...EL 32 REQ D WCDC0008 RIM LOCK SPACER DC65 HCNS0801 8MM NUT HCWF0801 8MM FLAT WASHER 3 PCDC00xx SPROCKET xx denotes number of teeth 4 HCBH0808 8X30MM HEX HEAD 4 REQ D 5 BCC60004 BRAKE ROTOR REAR 6 HCBC...

Page 35: ...5 SCKGOH03 BALL JOINT 6 SCKGOH11 O RING FOR BALL JOINT 7 SCKGOH02 SPACER FOR BALL JOINT 8 SCKGOH04 SPRING PLATFORM UPPER THREADED 9 SCKGOH05 LOCKNUT 10 SCKGOH22 KNOB FOR ADJUSTMENT 11 SCKGOH21 SCREW F...

Page 36: ...01 SWINGARM PIVOT TUBE SPACER 07 65 J 2 REQ D 7 TCC60004 CHAIN SLIDER TOP FOR SWINGARM 8 HCPP0832 8X1 2 SELF TAPING SCREW 2 REQ D FOR CHAIN SLIDER 9 HCBC0501 5X12MM SHCS CHAIN SLIDER MOUNT 10 PCC60004...

Page 37: ...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 accur...

Page 38: ...e 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...

Page 39: ...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 cylinder wall against o...

Page 40: ...030 ZCC60130 0 6 0 024 0 4 0 015 ZCC60115 0 75 0 030 0 25 0 010 ZCC60110 Engines may be properly assembled with gaskets thicker than 0 8mm 0 032 although a slightly different measuring technique will...

Page 41: ...increments and rev the engine after each adjustment To lower the idle turn the screw counter clockwise TOP END JETTING Indications that the engine is running too rich too much fuel for the air are En...

Page 42: ...ditions 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 carbureto...

Page 43: ...s 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 CX65shoc...

Page 44: ...33 15 50 3 33 14 47 3 36 13 44 3 38 15 51 3 40 12 41 3 42 14 48 3 43 13 45 3 46 15 52 3 47 12 42 3 50 14 49 3 50 15 53 3 53 13 46 3 54 14 50 3 57 12 43 3 58 15 54 3 60 13 47 3 62 14 51 3 64 12 44 3 67...

Page 45: ...k 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 sus...

Page 46: ...mpression 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 Action...

Page 47: ...lor Environmental and altitude related mixture adjustments Condition Mixture will be Required adjustment Cold air Leaner Richer Warm air Richer Leaner Dry air Leaner Richer Very humid air Richer Leane...

Page 48: ...ts knurled head for easy fingertip adjustment To raise the idle turn the screw in clockwise in 1 4 turn increments and rev the engine after each adjustment To lower the idle turn the screw counter clo...

Page 49: ...ls 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 R...

Page 50: ...Engine won t idle a Idle knob needs adjusted b Carburetor jets are dirty c Choke is stuck on d Air leak Index Air Filter Maintenance 12 Bars and Controls 15 Base Gasket Selection 36 Break In 6 Carbure...

Page 51: ...30 Rear Brake 31 Rear Wheel 32 Shock 33 Swingarm 34 Piston 24 Plastic Seat Parts 30 Rear Brake Parts 31 Rear Wheel Parts 32 Reeds 41 Rings 24 shift drum 25 shift forks 25 Shift Mechanism 23 Shock Part...

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Cobra 2007 CX65, Owner'S Manual

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