Cobra 2009 ECX50 Owner'S Manual Download

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Parts – Electrical System

Figure 10

Electrical System

REF #

PART #

DESCRIPTION

IAMU0005

COIL W/SPARK PLUG CAP (3 WIRE)

ECMU0065

SPARK PLUG, CHAMPION (8339-1)

ECMU0067

OPTIONAL HOTTER PLUG (8332-1)

ECMU0066

OPTIONAL COLDER PLUG (8904-1)

IKEX0001

IGNITION KILL TETHER

HCBC0516

SCREW, M5 X 16 (2 PER)

HCCN0000

5MM CLIP NUT (2 PER)

ICMU0018

STATOR 3 WIRE ANALOG

HCBC0535

5mm x 35 SOCKET HEAD CAP SCREW (2 REQ’D)

HCBC0525

5mm x 25 SOCKET HEAD CAP SCREW

HCWF0504

WASHER FOR STATOR (3 REQ’D)

10 ICMU0006

ROTOR

MCKGGR01 GROMMET - STATOR LEAD

12 HCNS1001

NUT

10MM

NOT SHOWN

ICMU0012 WOODRUFF

KEY

NOT SHOWN

ECKG0001 IGNITION

COVER

NOT SHOWN

ZCKG0101 GASKET,

IGNITION

COVER

Summary of Contents for 2009 ECX50

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: ...NTENDED 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 PRODUCT IN...

Page 4: ...aning 15 Frictional Drive CFD 16 Front end 17 Parts 18 Parts Air Inlet System 18 Parts Bars and Steering 19 Parts Bumper Nerf Grab Bars 20 Parts Carburetor 21 Parts Coolant System 22 Parts Electrical...

Page 5: ...Assembly 39 Service 40 Engine Service 40 Base Gasket Selection 41 Engine Removal 43 Complete Engine Disassembly Procedure 44 Top End Disassembly Procedure 44 Splitting the Cases 45 Engine assembly 46...

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 0 040 1 02 mm BTDC Fuel type High octane pump gasoline RACE FUELS ARE NOT RECOMMENDED Oil t...

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 40 480 54 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: ...n 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 locking agent applied to the threa...

Page 9: ...nge SCEX1105 115 Green SCEX1115 125 White SCEX2125 135 Blue SCEX1135 145 Red SCEX1145 155 Yellow SCEX1155 165 Black SCEX1165 Fox 7 long main spring rear 300 Red SCEX1300 315 Yellow SCEX1315 330 White...

Page 10: ...remature 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 on the stand with...

Page 11: ...t results from your Cobra Motorcycle use only the recommended fuels Testing has shown that most race fuels actually degrade performance Always wear a helmet and other protective riding gear When your...

Page 12: ...re than 8 0 oz 235 cc of lubricant may help to transfer heat from the clutch Filling with more than 12 oz 295 cc will degrade performance 3 The cylinder base gasket has been fitted for your engine The...

Page 13: ...ended periods of riding it is advisable to remove the ignition cover afterward to allow the ignition to cool off The heat transfers through the cases and can damage the stator as it cools off because...

Page 14: ...ng performance 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...

Page 15: ...ated to provide superior lubrication and cooling capability over extended periods of time and is the recommended lubricant for your Cobra motorcycle Chain adjustment Tools needed 13 mm wrench or socke...

Page 16: ...ewdriver Foam filter oil Procedure 1 Removed the filter from the carburetor 2 Clean the filter with cleaning solvent and then again with hot soapy water 3 Allow it to dry thoroughly 4 Saturate with fo...

Page 17: ...value and a maximum torque value The slip torque of the CFD should be checked every 5 hours of operation Slip Torque Ft lb N m Minimum 55 75 Maximum 92 125 To properly measure the torque at which the...

Page 18: ...oe in adjustment between 12mm out to 12mm in This is set by adjusting the length of the tie rod assemblies See figure 3 for direction of turn Adjust both wheels so that they have the same amount of to...

Page 19: ...HO04 HOSE 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 REPLACEMEN...

Page 20: ...0404 BAR MOUNT KIT SHORT REPLACEMENT 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 H...

Page 21: ...0067Y NERF NET SET YELLOW NOT SHOWN HCBH0808 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 SH...

Page 22: ...007 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0028 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLIP 17 RCMU0204 CHOKE ASS Y 2001 CM 20 RCMU0009 FUEL MIXTURE SCREW 21 RCMU0011 IDLE ADJUSTMENT SCREW...

Page 23: ...20 RADIATOR CAP 3 ECEX0010 RADIATOR HOSE 4 MCEXGR01 GROMMET RAD MOUNT 4 REQ D 5 MCMUGR04 GROMMET TOP RAD MOUNT 2 REQ D 6 HCBF0620 FLANGE HEAD BOLT M6X20 2 REQ D 7 HCWF1478 WASHER RADIATOR MOUNTING 8 M...

Page 24: ...3 IKEX0001 IGNITION KILL TETHER 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 SOCK...

Page 25: ...099 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 15 HCBH0612 M6X12...

Page 26: ...ESSURE PLATE WITH FRICTION MATL 08 STYLE 13 ECMU0138 FRICTION PAPER CFD 14 ECMU0161 GEAR CFD 08 STYLE 15 ECMU0159 SPRING WASHER CFD 60MM OD 16 ECMU0160 CENTERING WASHER CFD 17 HCNS1202 NUT CFD 20 LEFT...

Page 27: ...AL WATER PUMP SHAFT 5 ECKG0073 IMPELLER WATER PUMP ALUMINUM 6 ECKG0004 RETAINER WATER PUMP ASSEMBLY 7 HCBC1512 5X12MM SHCS STAINLESS 9 ECKG0175 WATER PUMP PULLEY FAN TYPE DRIVEN 10 ECMU0180 BELT RETAI...

Page 28: ...PISTON 2 REQ D 7 ECKG0012 WRIST PIN 8 ECMU0077 BEARING WRIST PIN 9 ZCMUOR07 O RING EXHAUST FLANGE 10 ECMU0086 EXHAUST FLANGE NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0612 M6X12 EXHAUS...

Page 29: ...GR10 PIPE GROMMET FEMALE 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D NOT SHOWN MCMUGR02 GROMMET KIT 8 FCEX5003 BRACKET PIPE MOUNT 9 HCBF0620 M6 X 20 FLANGE HEAD BOLT 10 XCKG0009 PIPE SILENCER SEAL 11 TCKG0...

Page 30: ...M LEFT 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...

Page 31: ...REW 2 PER SIDE 13 HCBC0601 6MM X 16 SOCKET HEAD CAP SCREW 3 PER SIDE 14 WCEX0001 FRONT HUB WITH WHEEL STUDS 16 GCEX0008 WHEEL SPINDLE SAME L R 17 HCNS1400 M14 CASTLE NUT SAME L R 18 HCCP0002 COTTER PI...

Page 32: ...4 BRAKE ROTOR SPACER 4 REQ D PER ROTOR 9 HCBB0516 ROTOR BOLT 10 HCBC0602 M6 X 20 SHCS 11 HCBF0640 M6 X 40 FLANGE HEAD BOLT 12 HCBF0635 M6 X 35 FLANGE HEAD BOLT 13 BCEX0022 BRAKE MOUNT SPACER 14 WCEX00...

Page 33: ...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 34: ...TIRE 6X8 WCEX0004L LEFT FRONT WHEEL WITH TIRE WCEX0004R RIGHT FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING HCBC1120 M10 X 120 FRONT ENGINE MOUNT BOLT HCWF0010 10MM FLAT WAS...

Page 35: ...AR 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 TAEX0011 SEAT NOT SHOWN HCBB063...

Page 36: ...32 SPACER CALIPER MOUNT 15 BCEX0014 CALIPER SPACER 2 REQ D 16 BCDC0002 CALIPER REAR BRAKE 17 BCDC0007 BRAKE PAD KIT ORGANIC 17 BCEX0013 BRAKE PAD KIT SINTERED METAL 18 BAEX0006 REAR BRAKE CARRIER FULL...

Page 37: ...EQ 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 HUB SPACER 2 REQ D 12 GCEX0011 REAR WHEEL HUB...

Page 38: ...GHT 325 LB IN SCEX2400 SHOCK SPRING HEAVY 400 LB IN 3 SCKGFX04 PRELOAD RING BOTTOM 4 SCKGFX05 PRELOAD RING TOP LOCK RING 5 HCBC1050 10MM X 50 SHCS 6 HCBF1040 10MM X 44 SHOCK BOLT 7 HCWF0010 10MM FLAT...

Page 39: ...E TUBE 4 HCBH1421 SWINGARM PIVOT BOLT M14 X 1 HEX HEAD 5 HCNL1402 SWINGARM LOCK NUT M14 X1 6 GCEX0050 TOP SWINGARM GUARD ECX50 7 HCPP0834 SELF TAPPING SCREW 8 HCBF1040 BOLT SHOCK 9 HCCC0000 BRAKE HOSE...

Page 40: ...ssembly REF PART DESCRIPTION 1 FAEX0002 TIE ROD 2 MCEXBR02R RH TIE ROD END 3 MCEXBR02L LH TIE ROD END 4 HCNJ120L LH JAM NUT 5 HCNJ120R RH JAM NUT 6 GCEX0002 SPACER BALL JOINT 7 HCNC0010 10MM CASTLE NU...

Page 41: ...ablish 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 in...

Page 42: ...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...

Page 43: ...ommended 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 igni...

Page 44: ...emoval tool Call local dealer for details Procedure 1 Remove the seat 2 Turn of the fuel at the petcock and disconnect the fuel line 3 Remove the tank 8 mm socket 4 Remove the carburetor from the inle...

Page 45: ...mp belt 3 Using a flywheel 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...

Page 46: ...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 47: ...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 48: ...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 49: ...r 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 Clutch puller installatio...

Page 50: ...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 51: ...e engine speed for clutch engagement thus decreasing the abruptness of clutch engagement softer hit Part Thickness mm inch HKCSM015 1 5 0 060 HKCSM012 1 2 0 047 HKCSM008 0 8 0 031 HKCSM006 0 6 0 025 H...

Page 52: ...a throttle 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 slud...

Page 53: ...tch or the 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...

Page 54: ...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 55: ...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 56: ...ition cover back on 7 Put the spark plug back in and firmly stick the spark plug cap onto the spark plug Cooling System Radiator fluid removal Remove the coolant drain plug 13mm bolt on the front of t...

Page 57: ...bearing retainer screw using a 3mm hex key 6 Thread a slide hammer onto the end of the water pump shaft and remove the assembly NOTE It is quite common for the older plastic impellers to fall off the...

Page 58: ...ad is oriented toward the stator 10 Hold the installation tool firmly against the engine case and tap on the end of the water pump shaft with a dead blow hammer until the insertion punch is needed 11...

Page 59: ...altitude Proper jetting is very important for engine performance and engine life Serious damage to the engine can occur if not properly adjusted IDLE ADJUSTMENT On the left side of the carburetor ther...

Page 60: ...l 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 su...

Page 61: ...TION 1 The motorcycle will only operate properly if the carburetor top is installed properly with the mounting screws cable and choke knob oriented as shown in figure 43 Figure 43 Proper carburetor to...

Page 62: ...s the jetting proper for the conditions See figure 44 Figure 44 The presence of light may indicate that the reeds should be replaced or turned over Exhaust The pipe is a crucial element to a motorcycl...

Page 63: ...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 64: ...0 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 carburetor jetted for o...

Page 65: ...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 66: ...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 adjustment T...

Page 67: ...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 68: ...lutch Lubricant Replacing 13 Compression test 40 Cooling System 55 Cylinder head torque 6 Eccentric 36 Electrical Parts 23 Engine Specifications 5 Engine Mount Front 33 Exhaust 61 Parts 28 Fenders 34...

Page 69: ...ervice 65 Shock 32 Slip Clutch 16 Spark Plug Recommended 5 Specifications 5 Torque Values 6 Spherical Steering Bearing 17 Starting 10 Stator torque 6 Steering Stem 19 Steering Upright 29 Suspension 65...

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