Cobra 2009 ECX80 AC Owner'S Manual Download

Page: 24 / 53

Parts – Electrical System

Figure 10

Electrical System

REF #

PART #

DESCRIPTION

ICMU0013

COIL (3 WIRE DIGITAL)

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 W/ GROMMET

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

ICMUGR01

GROMMET - STATOR LEAD

12 HCNS1001

NUT

10MM

HCWF0038

WASHER - FLYWHEEL

ICMU0016

SPARK PLUG CAP RESISTIVE

NOT SHOWN

ICMU0012 WOODRUFF

KEY

NOT SHOWN

ECDC0085 IGNITION

COVER

NOT SHOWN

ZCDC0004 GASKET,

IGNITION

COVER

Summary of Contents for 2009 ECX80 AC

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: ...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 PRODUCT IN...

Page 4: ...Tips 10 M1 Replacing Transmission Lubricant 11 M2 Chain adjustment 12 M3 Air Filter Cleaning 13 M4 Front end 14 Toe in adjustment 14 Steering 14 Parts 15 Parts Air Inlet System 15 Parts Bars and Steer...

Page 5: ...30 Parts Front Brakes 31 Parts Front Shock 32 Parts Miscellaneous 33 Parts Plastic Bodywork Seat 34 Parts Rear Brake 35 Parts Rear Drive 36 Parts Rear Shock 37 Parts Swingarm Assembly 38 Parts Tie Ro...

Page 6: ...Electronic Spark plug Champion 8339 Gap 0 023 0 025 0 58 0 64 mm Fuel type 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2 cycle Race Oil Fuel oil mix ratios 32 1...

Page 7: ...0 Spark Plug SP SP SP 14 x 1 25 Crank case half 5 60 6 8 6 x 1 0 Crank case cover 5 60 6 8 6 x 1 0 Flywheel rotor nut 40 480 54 10 x 1 25 G Clutch hub 40 480 54 10 x 1 25 G Units of mm unless otherwi...

Page 8: ...of high strength red or green 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 threads Option...

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: ...ine 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 neutral with a combination...

Page 11: ...operly saturated with oil Turn the fuel on by rotating the fuel petcock knob to the vertically downward position reserve position is horizontally inward CAUTION For best results from your Cobra ATV us...

Page 12: ...Evaluate the bikes jetting only after it has been warmed up to race temperatures 5 A properly maintained machine is safer faster and more fun to ride 6 When washing the bike be careful to not directly...

Page 13: ...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 necessary Every 2 hours of op...

Page 14: ...eing burned by the engine or the oil Hot oil and hot components on the motorcycle may cause burns 2 Lean bike against something or set on stand with oil drain hole 3 Using the 13 mm wrench remove the...

Page 15: ...location of the pin hole is the fattest part of the eccentric Restated if the pin hole is all the way forward the chain is as tight as possible and if the pin hole is all the way back the chain is as...

Page 16: ...roduct Cleaning solvent diesel fuel or kerosene would be preferred but caution should still be taken NOTE The biodegradable air filter oils greases and cleansers work acceptably with this Cobra Motorc...

Page 17: ...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 18: ...BOOT TO REED MANIFOLD NARROW 7 ECDC0094 INLET MANIFOLD WITH REED ASSEMBLY REEDS REMPLACMENT STOCK ECDCRD15 REEDS SOFT 8 HCBC0602 M6 X 20 SOCKET HEAD CAP SCREW 4 REQ D 9 ECDC0093 GASKET INLET 2 PLACES...

Page 19: ...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 20: ...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 21: ...E CABLE ADJUSTER 5 RCEX0007 GASKET CARBURETOR BOWL 6 RCEX0008 PLUG WASHER MAIN JET 7 RCEX0009 SPRING THROTTLE VALVE 8 RCEX0010 E CLIP NEEDLE 9 RCEX0011 NEEDLE VALVE SEAT ASSEMBLY 10 RCEX0012 SCREW FLO...

Page 22: ...CYLINDER 2 CCDC0001 CLUTCH LEVER 3 FCEX0020 CLUTCH LINE 4 CCDC0002 CLUTCH SLAVE CYLINDER 5 ECDC0074 CLUTCH CAP 6 M6 x 16 Bolt 7 ECDC0082 SNAP RING CLUTCH CAP 8 ECDC0020 CLUTCH PUSH ROD 9 ECDC0018 CLU...

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: ...C0516 SCREW M5 X 16 2 PER 5 HCCN0000 5MM CLIP NUT 2 PER 6 ICMU0018 STATOR 3 WIRE W GROMMET 7 HCBC0535 5mm x 35 SOCKET HEAD CAP SCREW 2 REQ D 8 HCBC0525 5mm x 25 SOCKET HEAD CAP SCREW 9 HCWF0504 WASHER...

Page 25: ...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 ECDC0224 PLATE CLUTCH SPRING 10 HCBC0525 5X...

Page 26: ...AL KICKSTARTER 9 ZCMU0005 GASKET OIL FILL PLUG 10 ECMU0037 OIL FILL DRAIN BOLT W GASKET 11 ZCDCOR05 ORING CLUTCH CAP 13 ECDC0074 CLUTCH CAP 14 ZCDCOR04 ORING CLUTCH SLAVE CYLINDER NOT SHOWN CCEX0009 B...

Page 27: ...1 WASHER FLAT 5MM 7 HCNS1001 NUT M10 8 HCWF0038 3 8 FLAT WASHER 9 ICMU0006 ROTOR 10 ICMU0018 STATOR 3 WIRE 11 ECDC0024 SEAL CRANKSHAFT 12 ECDC0087 SHIFTER LEVER 13 HCBH0620 M6 X 20 HEX HEAD BOLT 14 EC...

Page 28: ...MM 5 ECDC0043 WASHER 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 ECDC0...

Page 29: ...0 ECMU0548 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 PHI...

Page 30: ...00 SNAP RING FOR PISTON 2 REQ D 7 ECDC0090 WRIST PIN 8 ECDC0061 BEARING WRIST PIN 9 ZCMUOR07 O RING EXHAUST FLANGE 10 ECMU0074 EXHAUST FLANGE NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0...

Page 31: ...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 ECDC0...

Page 32: ...LE IN MCMUGR02 GROMMET KIT 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D 8 HCBF0635 M6X35 FLANGE HEAD BOLT MCMUGR02 GROMMET KIT NOT SHOWN HCNL0601 6MM LOCK NUT FOR FRONT PIPE MOUNT 9 XCMU0032 SILENCER NOT SH...

Page 33: ...T 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 34: ...0504 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 WCE...

Page 35: ...5 SHOCK SPRING STANDARD RED 145 LB IN See Optional Components section of this manual for other springs 4 SCSP0001 TRAVEL LIMITER 1 50 SCSP0002 TRAVEL LIMITER 1 25 SCSP0003 TRAVEL LIMITER 1 00 5 TOP SP...

Page 36: ...L 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 WASHER 2 REQ D HCNL1001 10MM LOCK NUT...

Page 37: ...O 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 TAEX0011 SEAT NOT SHOWN...

Page 38: ...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 39: ...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 HUB SPACER 2 REQ D 12 GCEX0011 REAR WHEEL...

Page 40: ...RING 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 WASHER 8 HCNL1001 10MM LOCKNUT...

Page 41: ...ER WITHOUT GROOVE 4 HCBH1421 SWINGARM PIVOT BOLT M14 X 1 HEX HEAD 5 HCNL1402 SWINGARM LOCK NUT M14 X1 6 GCEX0050 TOP SWINGARM GUARD ECX70 7 HCPP0834 SELF TAPPING SCREW 8 HCBF1040 BOLT SHOCK 9 HCCC0000...

Page 42: ...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 43: ...kicks 20 before you establish 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 simil...

Page 44: ...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...

Page 45: ...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 46: ...the reed cage If the reed is damaged in any way replace it This means cracks chips and ruptures Anything abnormal replace the reeds Take the reed cage out and hold it up to the light and look in thro...

Page 47: ...merse all the metal parts in a carburetor cleaning solution 6 Rinse the parts in water 7 After the parts are cleaned dry them with compressed air 8 Blow out the fuel passages with compressed air 9 Ass...

Page 48: ...dripping from exhaust system Symptoms of too rich a fuel mixture o Poor acceleration o Engine will not rev out blubbers on top o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o...

Page 49: ...ing changes on a motorcycle that has been warmed up to proper operating temperature The carburetor on your Cobra motorcycle is quite adjustable Figure 8 shows its range of adjustment and in particular...

Page 50: ...cceleration of your Cobra Motorcycle on the longest straight at the track Observe any of the lean or rich symptoms spark plug appearance and bike performance listed above and change your jetting accor...

Page 51: ...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 52: ...st 42 Cylinder 28 Eccentric 37 Electrical Parts 22 Engine Parts List 41 Specifications 3 Torque 5 Engine Mount Front 34 Exhaust 45 Parts 30 Fenders 35 Frame Parts 34 Front Brake 32 Fuel Petcock 9 Fuel...

Page 53: ...g Recommended 3 Specifications 3 Torque Values 5 Spherical Steering Bearing 15 Starting 9 Steering Stem 17 Steering Upright 31 Swingarm Parts 39 Throttle 16 Tie Rod 40 Tips 10 Toe In Adjustment 15 Top...

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