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Cobra 2009 CX65, Service Manual

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Cobra 2009 CX65 Service Manual Download Page 2

 

1

For 

parts orders

 contact your local dealer 

 
 

To locate your closest Cobra dealer 

log on to 

www.cobramotorcycle.com 

or call 

(517) 437-9100 

 
 
 

If you need 

technical assistance

  

contact your local dealer or call  

the Cobra Technical Support Hotline at 

(517) 437-9100 

 
 
 
 
 
 
 

Cobra Motorcycle MFG., Inc. 

240 Uran Road 

Hillsdale, MI 49242 

 

Summary of Contents for 2009 CX65

Page 1: ......

Page 2: ...our closest Cobra dealer log on to www cobramotorcycle com or call 517 437 9100 If you need technical assistance contact your local dealer or call the Cobra Technical Support Hotline at 517 437 9100 C...

Page 3: ...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 4: ...EANING 12 FORK OIL REPLACEMENT 13 IGNITION TIMING 14 PARTS 15 PARTS AIRBOX INLET SYSTEM 15 PARTS BARS AND CONTROLS 16 PARTS CARBURETOR 17 PARTS CLUTCH ACTUATION 18 PARTS COOLANT SYSTEM 19 PARTS ELECTR...

Page 5: ...31 PARTS BODYWORK 32 PARTS REAR BRAKE 33 PARTS REAR WHEEL 34 PARTS SHOCK 35 PARTS SWINGARM ASSEMBLY 36 SERVICE 37 ENGINE SERVICE 37 Base Gasket Selection 38 FUEL AIR SYSTEM 40 TUNING 43 GEARING 43 SU...

Page 6: ...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 gasoline Oil type Cobra Venom 2 cycle...

Page 7: ...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 Suspension Springs Weight of Rider lb...

Page 8: ...0 Front axle 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 Rea...

Page 9: ...riod 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...

Page 10: ...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 11: ...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 12: ...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 an...

Page 13: ...he 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...

Page 14: ...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 15: ...ot 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 hig...

Page 16: ...p 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...

Page 17: ...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...

Page 18: ...03 AIR FILTER CAGE 7 RCC60004 AIR FILTER WIRE 07 65 8 RCC60014 AIR BOOT CARB TO AIRBOX 65 9 RCC60006 AIR FILTER CAP 07 65 10 ECC60006 REED ASSEMBLY 07 65 NOT SHOWN ECC60014 REED PEDALS REPLACEMENT 11...

Page 19: ...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 TKMU0403M BAR MO...

Page 20: ...5 RCMU0205 45 RCEX0045 210 RCMU0210 47 5 RCEX0047 215 RCMU0215 50 RCEX0050 220 RCMU0220 52 5 RCEX0052 225 55 RCEX0055 230 RCMU0230 57 5 RCEX0057 235 RCMU0235 60 RCEX0060 240 RCMU0240 65 RCEX0065 245 R...

Page 21: ...TCH ACUTATOR ASSEMBLY Lever Master Cyl Line Slave Cyl NOT SHOWN CCC60001 CLUTCH LINE ONLY 4 CCDC0002 CLUTCH SLAVE CYLINDER 5 ECDC0074 CLUTCH CAP 6 HCBC0601 6X16 SOCKET HEAD CAP SCREW 4 REQ D 7 ECDC008...

Page 22: ...0002 PUSH PIN PLASTIC 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 MEDIUM 4 RE...

Page 23: ...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 EXTRU...

Page 24: ...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 ECMU0224 PLATE CLUTCH SPRING 10...

Page 25: ...RTER 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 CCEX0009 BALL CLUTCH ACTUA...

Page 26: ...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 HCFH0620 M6 X 20 HEX HEAD BOLT 14 ECKGSR03 SNAP RING OUTP...

Page 27: ...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 28: ...U0548 PIVOT SHIFT ARM 11 ECMU0546 SPRING SHIFT FOLLOWER ARM 12 ECMU0545 ARM ASSY SHIFT FOLLOWER 13 ECDC0035 CLIP ARM RETAINER 14 ECDC0056 BEARING RETAINER PLATE 15 ECDC0060 6MM X 16 FLAT HEAD PHILLIPS...

Page 29: ...PIN 8 ECDC0061 BEARING WRIST PIN 9 ZCMUOR07 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...

Page 30: ...H PRIMARY 18 21T 11 ECDC0005 GEAR 5TH PRIMARY 23T 12 ECDC0006 GEAR 2ND PRIMARY 16T 13 ECKGBR01 BEARING OUTPUT IGNITION SIDE 14 ECDC0007 SHAFT TRANSMISSION OUTPUT 15 ECDC0014 GEAR 2ND OUTPUT 31T 16 ECD...

Page 31: ...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 32: ...L PISTON 13 KCC60009 BASE VALVE BODY 14 BOLT FORK BOTTOM 15 KCC60008 WASHER FORK BOTTOM 16 BOLT AXLE CLAMP 17 KCC60007 CAP COMPRESSION SIDE 18 SPACER PRELOAD 19 KCC60024 FORK SPRING 24 KG MM KCC60026...

Page 33: ...OTPEG 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 MOUNTS 4 REQ D...

Page 34: ...SHOWN HCNL1402 NUT FRONT AXLE 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 HCBC0612 6X12MM SHCS 4 REQ D...

Page 35: ...HA0003 HOSE FUEL CAP NOT SHOWN TCHA0005 SPACER SEAT MOUNT NOT SHOWN HCFH0620 M6X20 FLAT HEAD FRONT SEAT MOUNT NOT SHOWN TCHA0006 SPACER FRONT TANK MOUNT NOT SHOWN HCBF0630 6MM X 30 FLANGE HEAD BOLT NO...

Page 36: ...N 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 ECCENTRIC 17 HCBC0612 6X12 SHCS 18 B...

Page 37: ...DELS 2 WCDC0001 RIM LOCK FOR REAR WHEEL 32 REQ D WCDC0008 RIM LOCK SPACER DC65 HCNS0801 8MM NUT HCWF0801 8MM FLAT WASHER 3 PCDC00xx SPROCKET xx denotes number of teeth 4 HCBH0825 8X25MM HEX HEAD 4 REQ...

Page 38: ...LL JOINT 6 SCKGOH11 O RING FOR BALL JOINT 7 SCKGOH02 SPACER FOR BALL JOINT 8 SCKGOH04 SPRING PLATFORM UPPER THREADED 9 SCKGOH05 LOCKNUT 10 SCC60001 KNOB FOR ADJUSTMENT 11 SCKGOH21 SCREW FOR KNOB 12 SC...

Page 39: ...001 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 PCC6000...

Page 40: ...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 41: ...linder 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 va...

Page 42: ...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 sid...

Page 43: ...rn 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...

Page 44: ...n 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 partia...

Page 45: ...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 46: ...39 2 79 15 42 2 80 13 37 2 85 14 40 2 86 15 43 2 87 13 38 2 92 14 41 2 93 15 44 2 93 13 39 3 00 14 42 3 00 15 45 3 00 15 46 3 07 14 43 3 07 13 40 3 08 12 37 3 08 15 47 3 13 14 44 3 14 13 41 3 15 12 38...

Page 47: ...istance 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 slo...

Page 48: ...over square edge bumps 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 fac...

Page 49: ...ne 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 Leaner Richer Warm air Ric...

Page 50: ...d 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 clockwis...

Page 51: ...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 52: ...rical 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 sh...

Page 53: ...ression test 38 Cylinder 26 Cylinder head torque 5 Electrical Parts 20 Engine Specifications 3 Exhaust Parts 28 Fork Oil Replacement 13 Frame Parts 30 Front Brake Parts 31 Fuel System Parts list 40 Se...

Page 54: ...e Parts 33 Rear Wheel Parts 34 Reeds 42 Rings 26 shift drum 27 shift forks 27 Shift Mechanism 25 Shock Parts 35 Service 47 Spark Plug Recommended 3 Specifications 3 Starting 7 Stator torque 5 Suspensi...

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