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DISCLAIMER OF WARRANTY 

 

This motorcycle is sold “as is” with all faults, obvious or not.  There are no warranties 
expressed or implied, including any warranty of merchantability and warranty of fitness for 
any particular purpose.

 

 
 

“WARNING” 

 

THE COBRA CX65 IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED 
FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS.  
 
THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED 
COMPETITION EVENTS UPON A CLOSED COURSE BY A SUFFICIENTLY SKILLED 
RIDER AND SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL 
RIDING.   
 
IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH. 
 
THIS BIKE IS INTENDED FOR 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 PROPER OPERATING CONDITION. 
 
THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 110 LBS WITH 
FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH 
MORE THAN THAT. 
 
BE SURE THAT THE RIDER ALWAYS WEARS ADEQUATE SAFETY GEAR 
EVERYTIME HE OR SHE RIDES THEIR COBRA MOTORCYCLE. 
 

 

IMPORTANT SAFETY NOTICE 

 

Failure to follow WARNING instructions could result in severe injury or death to the 
machine operator, a bystander, or a person inspecting or repairing the machine. 
 
CAUTION: 
A CAUTION indicates special precautions that must be taken to avoid damage to 
the machine. 
 

NOTE: 

A NOTE provides key information to make procedures easier or clearer. 

MCC62011.2

Summary of Contents for CX65 2022

Page 1: ...FOR 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 PROPER OPERATING CONDITION THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 110 LBS WITH FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE THAN THAT BE SURE THAT THE RIDER ALWA...

Page 2: ...OR 15 PARTS COOLANT SYSTEM 16 PARTS ELECTRICAL SYSTEM 17 PARTS ENGINE CLUTCH 18 PARTS ENGINE CLUTCH KICK COVER 19 PARTS ENGINE IGNITION SIDE 20 PARTS ENGINE KICK MECHANISM 21 PARTS ENGINE SHIFT MECHANISM 22 PARTS ENGINE TOP END 23 PARTS ENGINE TRANSMISSION 24 PARTS EXHAUST SYSTEM 25 PARTS FORKS LEG ASSEMBLY 26 PARTS FRAME TRIPLE CLAMPS 27 PARTS FRONT WHEEL 28 PARTS FRONT BRAKE 29 PARTS BODYWORK 30...

Page 3: ...2 GEARING 42 SUSPENSION 43 CARBURETION 44 TROUBLESHOOTING 47 INDEX 49 ...

Page 4: ...e pump gasoline Premix Oil type Motul 800 2T Premix oil ratio after break in Motul 800 2T Off Road 50 1 to 63 1 All other premix oil at 32 1 to 40 1 Carburetion 26 mm VM Mikuni 60Main Jet Slow Pilot Jet 240 42 5 Needle 5I 14 4 Float Height 21 1 1 0 Transmission 6 speed Final drive ratio 14 45 Chain 116 links 420 Transmission clutch oil type Quality gear lubricant or Cobra clutch milk Do Not Run Au...

Page 5: ...0 Spark plug SP SP SP M14 x 1 25 Stator bolts 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 Front axle bolt 10 120 13 5 M14 x 2 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 M...

Page 6: ... cool Ride for 15 minutes maximum avoid prolonged high RPM operation and avoid abusing the clutch Cool and inspect bike for loose fasteners Check retighten wheel spokes Next hour of operation avoid prolonged operation at Wide Open Throttle After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary proper toque values are listed under Specifications o Clean th...

Page 7: ... Cobra Motorcycle use only the recommended fuels Race fuels can be used however they are not required with the stock engine and the engine will require addition attention to maintain proper jetting as weather condition change throughout the day Always wear a helmet and other protective riding gear When your pre ride inspection is complete the bike may be started For a cold engine follow this proce...

Page 8: ... premature seal failure 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 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 New chains will stretch on first use Never inst...

Page 9: ...crape the paint bare near the area to be welded and put the ground clamp as close to the area to be welded as possible Be sure the fuel tank and carburetor have been removed and safely located away from the welding process The frame is a combination of HSLA steel and 4130 Chrome Moly and it is important to weld it with the proper rod and heat settings set as light as possible Cobra recommends repl...

Page 10: ...g making sure the rubber gasket is in place NOTE Filling after an engine rebuild required additional transmission fluid If the engine is completely flushed of oil refill with 18 oz 530ml Always capture and dispose of used oil properly all auto parts stores accept used oil Dumping oil on the ground is illegal inconsiderate and can get you disqualified from a race weekend quicker than cutting the tr...

Page 11: ... Procedure 1 Removed seat with the 5mm hex key 2 Unhook the air filter wire from its perch 3 Carefully remove the air filter and frame out the top of the airbox making sure not to dislodge any dirt into the intake tract 4 Clean the filter in a nonflammable solvent to remove the filter oil Do not clean the air filter with gasoline or other highly volatile petroleum product Diesel fuel mineral spiri...

Page 12: ...per rod lock nut Secure this nut using a 19mm wrench d With a 19mm wrench on the damper rod nut use a 27mm wrench to free the fork cap from the damper rod e Remove the 19mm wrench and allow the damper rod to fall into the damper tube f Remove the fork spring and spacer g Invert the fork to allow the oil to drain Pump the damper rod assembly several times to help the oil drain Assembly 1 Completely...

Page 13: ...d the front wheel are properly aligned with each other 11 Tighten the axle pinch bolts to 10N m 7 4 ft lb Ignition Timing The ignition timing value for the CX65 is 0 retarded from the standard base reference 0 This can be verified by removing the ignition cover and looking as shown in the figure below The center mark on the cases is the standard base reference timing mark 0 and the other two large...

Page 14: ...TER 6 RCC60003 AIR FILTER CAGE 7 RCC60004 AIR FILTER WIRE 8 RCC60014 AIR BOOT CARB TO AIRBOX 9 RCC60006 AIR FILTER CAP 10 ECC60006 REED ASSEMBLY 11 ECC60007 INLET MANIFOLD 12 HCBC0602 M6X20mm SOCKET HEAD CAP SCREW 13 MCC60003 CLAMP MANIFOLD TO CARB 14 ZCC60021 GASKET REED 15 RCR60026 CARBURETOR 26mm MIKUNI 16 MCMUCL04 HOSE CLAMP 8mm 17 FCMU0026 FUEL LINE 18 ECC60014 REED PETALS REPLACEMENT ...

Page 15: ...MOUNT KIT TALL 10 HCBC1002 M10X50mm SOCKET HEAD CAP SCREW 2 REQ D 11 HCNL1001 M10 LOCK NUT 12 HCBC0806 M8X30mm SCOCKET HEAD CAP SCREW 4 REQ D 13 BCC60009 MASTER CYLINDER ASSY W LEVER BRAKE OBSOLETE REPLACED BY BAC60010 14 BCC60008 BRAKE LEVER OBSOLETE MUST PURCHASE BAC60010 15 FCMU0033 KILL SWITCH ASSEMBLY ACCESSORY CCMU0135 REBUILD KIT MASTER CYLINDER CLUTCH ACCESSORY BCC60022 BUSHING BRAKE CLUTC...

Page 16: ... Carburetor REF PART DESCRIPTION 1 RCR60026 CARBURETOR 26MM MIKUNI 2 RCC60017 FLOAT BOWL CHAMBER 3 4 RCMU0271 NEEDLE VALVE SEAT ASSY 5 6 SEE BELOW MAIN JET 7 9 RCEX0026 NEEDLE JET STOCK 5L14 10 SEE BELOW PILOT JET 11 RCC60013 GASKET FLOAT BOWL 12 13 15 RCEX0016 SPRING IDLE ADJUST SCREW 16 RCEX0015 IDLE ADJUST SCREW 17 ZCDCOR01 O RING BOWL PLUG 18 RCEX0012 FLOAT BOWL SCREW 20 21 RCC60016 SLIDE MASS...

Page 17: ...SH PIN PLASTIC 7 HCCN0000 5mm EXTRUDED U NUT 8 ECC60063 HOSE RADIATOR UPPER 9 ECC60012 HOSE RADIATOR BOTTOM 10 ECC60013 HOSE TRANSFER CASES TO CYLINDER 11 MCMUCL07 HOSE CLAMP RADIATOR MEDIUM 4 REQ D 12 MCKGHO04 HOSE CLAMP RADIATOR LARGE 1 REQ D 13 MCC6GR01 GROMMET RADIATOR 2 REQ D 14 HCWF1478 6mm WASHER 22mm OD BLK ZINC 2 REQ D 15 HCBF0616 M6X16mm FLANGED HEX 8mm HEAD 2 REQ D 16 MCMUCL09 HOSE CLAM...

Page 18: ...CMU0035 MOUNT CDI 9 ICC60005 COIL DIGITAL 65 10 HCBC0516 M5X16mm SHCS COIL MOUNTING 2REQ D 11 HCSP0002 5mm WASHER COIL MOUNTING 2 REQ D 12 HCCN0000 5mm EXTRUDED U NUT COIL MOUNTING 2 REQ D 13 ECMU0033 SPARK PLUG 14 FCMU0033 KILL SWITCH ASSEMBLY 15 ECDC0085 COVER IGNITION 16 ZCDC0004 GASKET IGNITION COVER 17 HCBC0402 M4X35mm SHCS COVER MOUNTING 3 REQ D 18 ICMU0012 WOODRUFF KEY NOT SHOWN ACCESSORY I...

Page 19: ...DC0067 CLUTCH DISC STEEL 4 REQ D 7 ECDC0069 CLUTCH HUB 8 ECDC0070 SPRING CLUTCH 6 REQ D 9 ECDC0071 PLATE CLUTCH SPRING 10 HCBC0525 M5X25mm SOCKET HEAD CAP SCREW 6 REQ D 11 ECDC0030 SPRING WASHER CLUTCH 12 HCBF1035 M10X35mm FLANGE HEAD BOLT 13 ECDC0019 CLUTCH BEARING SEAT 14 ECDC0018 BEARING CLUTCH THROW OUT 15 ECC60050 CLUTCH PUSH ROD 16 CKMU0001 CLUTCH KIT INCLUDING SPRINGS STEELS AND FIBERS 17 E...

Page 20: ...G CLUTCH CAP 11 ECC60053 CLUTCH CAP W SLAVE CYLINDER 12 CCC60005 PISTON CLUTCH SLAVE CYLINDER 13 CCC60006 SPRING SLAVE RETURN 14 ZCMUOR35 O RING SLAVE PISTON 15 CCEX0009 BALL CLUTCH ACTUATOR 16 ECDC0082 SNAP RING CLUTCH CAP 17 BCMU0018 FITTING BLEED CLUTCH LINE 18 ECAX0150 IMPELLER COVER 19 HCBC0601 M6X16mm SOCKET HEAD CAP SCREW 21 ECDC0075 IMPELLER WATERPUMP 20 HCBC1512 M5X12mm SOCKET HEAD CAP SC...

Page 21: ...TOR PVL DIGITAL CX65 8 HCBB0516 M5X16mm BUTTON HEAD 3 REQUIRED 9 HCWF0501 5mm WASHER FLAT 3 REQUIRED 10 ECDC0024 SEAL CRANKSHAFT 11 ICMUGR01 GROMMET IGNITION 12 EKC62010 ENGINE CASE SET W B S CX65 13 ECDC0086 SHIFTER LEVER CX65 14 HCFH0620 M6X20mm HEX HEAD BOLT 15 ECDC0026 SEAL SHIFTER 16 ECEX0008 BUSHING SHIFTER SHAFT 17 ECKGSR03 SNAP RING OUTPUT 18 PCKG00xx xx DENOTES TEETH RANGE OF TEETH 13 16 ...

Page 22: ... KICKSTART BACKUP 5 ECDC0042 SPRING KICKSTART RAMP 6 ECMU0171 SHAFT KICK STARTER THREADED 7 ECDC0038 RAMP GEAR KICKSTART 8 ECDC0033 GEAR KICKSTART 9 ECDC0035 SNAP RING EXTERNAL 12mm 10 ECDC0037 SNAP RING EXTERNAL 15mm 11 ECDC0032 GEAR KICK START IDLE 12 ECDC0039 RAMP KICK START 13 ECDC0060 M6X16mm PHILLIPS FLAT HEAD SCREW 14 ECMU0170 SPRING HOLDER 15 ECMU0233 FITTING VENT HOSE 16 ECMU0534 VENT HOS...

Page 23: ...Q D 8A ECDC0053 DOWEL SHIFT DRUM INDEX 1 REQ D 9 ECDC0022 BEARING SHIFT DRUM 10 ECDC0035 CLIP ARM RETAINER 11 ECMU0545 ARM ASSY SHIFT FOLLOWER 12 ECMU0546 SPRING SHIFT FOLLOWER ARM 13 ECMU0548 PIVOT SHIFT ARM 14 HCBB1612 M6X12mm BUTTON HEAD BLACK OXIDE 15 ECMU0216 BEARING PRIMARY SHAFT CLUTCH SIDE 16 ECDC0036 SNAP RING EXT 16mm 17 ECDC0073 CRANK DRIVE GEAR 18 ECDC0112 SPACER CRANK DRIVE GEAR 19 EC...

Page 24: ... RINGS 43mm 2 PER SET 6 ECDC0061 BEARING WRIST PIN 7 ECMU0147 STUD CYLINDER 7mm 8 ZCMUOR10 O RING CYLINDER STUD 4 REQ D 9 ZCMUOR05 O RING CYLINDER HEAD MEDIUM YELLOW 10 ECC60073 CYLINDER HEAD INSERT 10 65 11 ZCMUV024 O RING CYLINDER HEAD SMALL 12 ZCMUOR02 O RING CYLINDER HEAD LARGE 13 ECC60010 CYLINDER HEAD OUTER 14 HCWS1401 FLAT WASHER HARDENED 15 HCNS0703 M7 NUT TALL 16 ZCMUOR07 O RING EXHAUST F...

Page 25: ...ARY 18 21T 13 ECDC0002 GEAR 6TH PRIMARY 24T 14 ECDC0001 SHAFT TRANSMISSION PRIMARY 1ST GEAR 13T 15 ECMU0016 BEARING PRIMARY SHAFT CLUTCH SIDE 16 ECDC0050 SHIFT ROD 2 REQ D 18 ECDC0048 SHIFT FORK INPUT 19 ECDC0049 SHIFT FORK OUTPUT 2 REQ D NOT SHOWN ECC60055 ROLLER SHIFT FORK PIN 3 REQ D 20 ECC60084 BEARING SHIFT DRUM IGN SIDE 21 EAC60010 SHIFT DRUM 2 PIECE ASSEMBLY 22 ECDC0053 CHANGE DRUM DOWEL 23...

Page 26: ...EQ D FOR SILENCER 4 HCBF0616 M6X16mm FLANGE HEAD BOLT 2 REQ D 5 ZCMOTE11 O RING EXHAUST 2 REQ D 6 XCMU0005 SPRING PIPE SHORT 2REQ D 7 XCKG0009 GROMMET SILENCER TO PIPE 8 XCMU0032 SILENCER 10 ROUND 9 MCMUGR03 GROMMET 2 REQ D 10 TCKG0001 SPACER GENERAL DIA 13 2 LG 2 REQ D 11 TCC60016 SPACER TOP HAT 2 REQ D 12 HCBF0630 M6X30mm FLANGE HEX 8mm HEAD ACCESSORY XCMU0026 SILENCER PACKING KIT ...

Page 27: ...06 SEAL PISTON 9 KCC60009 BASE VALVE BODY 10 KCC60008 WASHER FORK BOTTOM 11 KCC60007 CAP COMPRESSION SIDE 12 KCC60026 FORK SPRING 26 KG MM STANDARD 12 KCC60024 FORK SPRING 24 KG MM 12 KCC60028 FORK SPRING 28 KG MM HEAVY 13 KCC60014 FORK GUARDS PAIR 3 BOLT STYLE 14 HCBC0601 M6 X 16mm SHCS 6 REQ D 15 TCC60019 SPACER FORK GUARD MOUNTING 6 REQ D 16 BCC60015 CLAMP BRAKE LINE 17 HCNS0601 M6 NUT 2 REQ D ...

Page 28: ...D 10 HCWF0803 8mm FLAT WASHER 11 HCNL0802 M8 LOCKNUT FOOTPEG 2 REQ D 12 WCKG0011 SWINGARM PIVOT BOLT 13 HCWF1202 12mm FLAT WASHER 14 HCNL1201 M12 LOCKNUT 15 HCBH0865 M8X65mm HEX HEAD FRONT ENGINE MOUNTS 2 REQ D 16 HCWF0801 8mm FLAT WASHER FRONT ENGINE MOUNTS 4 REQ D 17 HCNL0801 M8 LOCKNUT FRONT ENGINE MOUNTS 2 REQ D 18 HCBH0807 M8X20mm HEX HEAD STEERING STOP 2 REQ D 19 HCNS0801 M8 NUT STEERING STO...

Page 29: ...CDC0011 NIPPLE SPOKE 9GA STAINLESS 6 WCC60008 AXLE FRONT CX65 7 WCMU0120 BEARING WHEEL SEALED 8 WCC60006 SPACER WHEEL BEARING FRONT 9 BCC60040 BRAKE ROTOR FRONT FLOATER 206mm 10 ECC60055 SPACER FLOATING ROTOR 4 REQ D 11 HCBF1612 M6X12mm FLANGE HEAD LOW PROFILE 4 REQ D 12 WCC60002 WHEEL SPACER CX65 FRONT LEFT 13 HCNL1402 NUT FRONT AXLE 14 WCDCTU14 TUBE 60 100 14 FRONT 15 WCC6F014D TIRE DUNLOP 60 10...

Page 30: ...8mm ID ACCESSORY BCC60010 CALIPER PISTON REBUILD KIT FRONT ACCESSORY BCC60022 BUSHING BRAKE LEVER PIVOT Note The company that supplied this brake system to Cobra AJP is no longer in business therefore some parts are not available any longer We still stock standard items such as brake pads and there are aftermarket options for levers however internal components are not available Cobra took great ca...

Page 31: ...CAP SCREW FRONT TANK MOUNTING 5B TCC60027 SPACER FRONT TANK MOUNTING 5C TCC60029 SPACER SEAT MOUNT 5D HCFH0620 M6X20mm FLAT HEAD BOLT FRONT SEAT MOUNT 5E TCMU0151 PETCOCK 6 TCHA0002 CAP FUEL TANK 6A TCHA0003 HOSE FUEL CAP 6B FCMU0151 CAP STEERING STEM 7 TAC60002 SEAT CX65 7A HCBC0625 M6X25mm SOCKET HEAD CAP SCREW SEAT HOLDING 7B TCC60018 SPECIAL WASHER SEAT HOLDING 8 TCC60005 SIDE NUMBER PLATE PAI...

Page 32: ...9 BRAKE PEDAL PIVOT BOLT 12 FCEX0018 BRAKE ADJUST ECCENTRIC 13 HCBC0612 M6X12mm SOCKET HEAD CAP SCREW 15 BCC60004 BRAKE ROTOR REAR 16 HCBB0616 M6X16mm BUTTON WITH THREAD LOCK rotor bolts 4 REQUIRED ACCESSORY BCKG0031 BLEED KIT MULTIPLE SYRINGES FITTINGS HOSE ACCESSORY BCC60030 BRAKE PAD SET CX65 SEMI METALLIC ACCESSORY BCC60031 BRAKE BELLOWS KIT CX65 ACCESSORY BCC60032 BRAKE CALIPER PISTON KIT CX6...

Page 33: ...HCWF0801 8mm FLAT WASHER 11 HCNS0801 M8 NUT 12 PCDC00xx SPROCKET xx denotes number of teeth 37 53 13 HCBH0825 M8X25mm HEX HEAD 4 REQ D 14 BCC60004 BRAKE ROTOR REAR 15 HCBC1616 M6X16mm SHCS WITH THREAD LOCK 4 REQ D 16 PCMU0116 CHAIN 420H 116 LINK CX65 14 48 17 WCC60004 AXLE REAR CX65 18 BAC60006 BRAKE BRACKET ZL 19 WCC60003 WHEEL SPACER CX65 REAR RIGHT 20 WCMU0120 BEARING WHEEL 21 WCC60007 SPACER W...

Page 34: ... 1 0 CARD 6 SCMU0056 SHOCK SLEEVE BLACK CARD 7 SCMU0100 BUMPER TAPPERED SHOCK 8 SCMU0040 SHOCK SPRING PAD CARD 9 SCMU0054 SHOCK SPRING PERCH CARD 10 SCC60240P SPRING EXTRA LIGHT 240 LB IN 42N mm WHITE 10 SCC60260P SPRING STANDARD 260 LB IN 45 N mm YELLOW 10 SCC60280P SPRING HEAVY 280 LB IN 49 N mm GOLD 10 SCEX1300 SPRING HEAVY 300 LB IN 53 N mm RED 11 HCBF1040 M10X40mm HEX HEAD BOLT 12 HCNL1001 M1...

Page 35: ... O RING SHOCK BASE 8 SCMU0050 RESERVOIR CAP RETAINER RING 9 SCMU0035 O RING CHARGE CAP 10 HCBB0506 M5X6mm LONG BUTTON HEAD STAINLESS STEEL 11 SCMU0044 SHOCK SEAL HEAD BUMPER 12 SCMU0048 SHAFT BUSHING 13 SCMU0046 SHOCK X RING SEAL 14 SCMU0034 O RING SEAL HEAD 15 SCMU0047 SPACER X RING 16 SCMU0045 SHOCK DUST SEAL 17 SCC60014 PISTON BAND 18 SCMU0059 O RING REBOUND PIN 19 SCC60013 CHECK VALVE NUT 20 S...

Page 36: ...WINGARM PIVOT TUBE SPACER 65 2 REQ D 7 TCC60004 CHAIN SLIDER TOP FOR SWINGARM 8 HCPP0832 8 X 1 2 SELF TAPING SCREW 2 REQ D FOR CHAIN SLIDER 9 HCBC0501 M5X12mm SHCS CHAIN SLIDER MOUNT 10 PCC60004 CHAIN GUIDE BOTTOM CX65 11 HCBF0645 M6X45mm FLANGE HEAD BOLT 2 REQ D 12 HCNL0601 M6 LOCK NUT 2 REQ D 13 HCNS0701 M7 NUT 2 REQ D 14 HCBH0701 M7X35mm HEX HEAD FULL THREAD 2 REQ D 15 HCCC0005 BRAKE HOSE GUIDE...

Page 37: ...er will affect the reading The shorter the hose length the more accurate your reading will be Because of these difficulties in measuring an absolute compression value a useful relative value can be achieved by testing your bike s compression with your own particular gauge after a new top end or when the bike is new so that you know what your particular gauge reads on a fresh engine When it has dro...

Page 38: ... the squish clearance of your engine to factory specifications For base gasket replacement use the code see figure 21 for location along with the table on the following page reorder the correct thickness gasket Figure 21 Code Supplied Base Gasket Thickness Cobra mm inch 0 15 0 006 ZCC60116 3 0 25 0 010 ZCC60110 4 0 4 0 015 ZCC60115 5 0 5 0 020 ZCC60015 8 0 8 0 031 ZCC60130 NOTE Tolerances will aff...

Page 39: ...t or back as the piston will rock more and give incorrect measurement Hold the wire at this position and rotate the crankshaft by the flywheel nut or kick lever three revolutions to smush the solder wire CAUTION If you rotate the flywheel nut in a counterclockwise direction there is a risk of loosening the nut Pull out the wire and measure the solder thickness at the thinnest location near its tip...

Page 40: ...ch fuel for the air are Engine not revving out or blubbering at high RPMs Engine will not clean out Wet or black spark plug NOTE Before changing jetting be sure that the air filter is properly cleaned and has the usual amount of air filter oil An overly dirty air filter can cause the engine to run rich If the engine is running rich on the top end it should be leaned out Leaning it out can be done ...

Page 41: ...ew out leans it STOCK CARBURETOR SETTINGS The 2009 CX65 stock carburetor settings from the factory are 40 pilot jet 210 main jet Cleaning the carburetor Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low...

Page 42: ...41 Shock preload Shock Damping ...

Page 43: ... 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 3 17 15 48 3 20 14 45 3 21 13 42 3 23 12 39 3 25 15 49 3 27 14 46 3 29 13 43 3 31 12 40 3 33 15 50 3 33 14 47 3 36 13 44 3 38 15 51 3 40 ...

Page 44: ...avel 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 suspension motion when the suspension is compressing 2 3 2 Softer less damping quicker reduces resistance to the suspension motion when the suspension is compressing 2 4 Rebound damping 2 4 1 Harder more damping slower adds resistance to the suspension motio...

Page 45: ...onditions Situation Actions Sand track Lower the rear end increase race sag Sand track Stiffer compression and rebound damping Long fast track Lower the forks in the clamps by 3 mm Tight slow track Raise the forks in the clamps by 3 mm Mud track Lower the bike if the rider has difficulties touching the ground Carburetion Although your Cobra is sent from the factory with the carburetor jetted for o...

Page 46: ...air Richer Leaner Low altitude Standard None High altitude Richer Leaner Low barometric pressure Richer Leaner High barometric pressure Leaner Richer NOTE Before making any carburetor jetting changes verify that o You are using the proper fuel and oil o The fuel is fresh and uncontaminated o The oil and fuel have been mixed in the proper ratio o The carburetor is clean no plugged jets o The air fi...

Page 47: ...rements and rev the engine after each adjustment To lower the idle turn the screw counter clockwise TOP END JETTING Adjust for clean full throttle acceleration Jet your top end main jet based on the acceleration 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 48: ...k 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 Rings e Reeds are damaged f Ignition timing is incorrect g Stator needs replaced 3 Engine is excessively loud a Silencer needs repacking 4 Engine blubbers at high RPMs a Jetting too rich b Stator needs replaced ...

Page 49: ...nd 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 shoe dragging on basket drum 6 Engine won t idle a Idle knob needs adjusted b Carburetor jets are dirty c Choke is stuck on d Air leak ...

Page 50: ...r 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 Service 40 Hardware Frame 30 Plastic 32 Jetting How To 40 Stock 3 Troubleshooting 45 Kick Mechanism 24 Lubrication Recommended 3 Maintenance Schedule 8 Tips 8 Oil Recommended 3 Optional components 4 Parts Bars and Controls 16...

Page 51: ...rts 34 Reeds 42 Rings 26 Shift Srum 27 Shift Forks 27 Shift Mechanism 25 Shock Parts 35 Service 47 Spark Plug Recommended 3 Specifications 3 Starting 7 Stator torque 5 Suspension 47 Swingarm Parts 36 Top End Parts 26 Service 37 Torque Values 5 Transmission 27 Transmission Lubricant Replacing 10 Troubleshooting 48 Jetting 45 VIN reading 8 WARNING 0 Water Pump Cover 22 ...

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