2003 DCx65
Owners / Service
Manua
l
“CHAMPIONS START HERE”
Страница 1: ...2003 DCx65 Owners Service Manual CHAMPIONS START HERE...
Страница 2: ...Cobra dealer log on to www cobramotorcycle com or call 330 549 9600 If you need technical assistance contact your local dealer or call the Cobra Technical Support Hotline at 330 549 9603 Cobra Motorcy...
Страница 3: ...NTENDED 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 MOTORCYC...
Страница 4: ...Maintenance 13 Schedule Tips 13 M1 Replacing Transmission Lubricant 14 M2 Chain adjustment 15 M3 Front brake adjustment 16 M4 Clutch lever adjustment 16 M5 Rear brake adjustment 17 M6 Air Filter Clean...
Страница 5: ...nges 30 Tuning 2 Suspension 34 1 Suspension Guidelines 35 2 Proper Suspension Adjustments for Your Rider 36 3 Symptoms of Incorrect Suspension Adjustment 40 4 Proactive Suspension Adjustments 41 5 How...
Страница 6: ...ark plug Splitfire SF406B Gap 0 023 0 025 0 58 0 64 mm Fuel type Sunoco MO2X or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2 cycle Race Oil Fuel oil mix ratios 3...
Страница 7: ...2 24 2 7 14 x 1 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 m...
Страница 8: ...10 120 13 6 8 x 1 25 Subframe fasteners 22 265 30 8 x 1 25 Upper shock mount 40 480 54 10 x 1 5 Lower shock mount 40 480 54 10 x 1 5 Swingarm pivot 21 250 28 14 x 2 0 Rear axle nut 25 300 34 12 x 1 2...
Страница 9: ...actory setting Track 1 Track 2 Track 3 Track 4 Fork Oil Viscosity 5 wt Oil Height amount 4 oz 118 ml Fork Spring STD Shock Spring STD Preload height Rebound Damping clicks from full damp Compression D...
Страница 10: ...SCDC0300 300 lb in Greater than 60 KCDCSP02 red lb in SCDC0325 325 lb in SCDC0350 350 lb in Suspension Valving Damping Rate Fork Valving Compression base valve Fork Valving Rebound mid valve Shock Val...
Страница 11: ...specially formulated Cobra Venom 2 cycle Race Oil Part MCMUOL02 CAUTION Failure to use proper fuel or oil may result in premature engine wear or damage to the machine Adhering to the following break i...
Страница 12: ...b to the vertically downward position reserve position is horizontally forward CAUTION For best results from your Cobra Motorcycle use only the recommended fuels Testing has shown that most race fuels...
Страница 13: ...is apt to enter the airbox 7 Some people have found cable ties zip ties more favorable for securing the rear brake line to the swingarm 8 Also some people are moving the rear brake line hose between...
Страница 14: ...tion stator and rotor are clean and dry o Check 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 pro...
Страница 15: ...ed 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 oil drain...
Страница 16: ...r measurement location NOTE This measurement is to be made with the motorcycle setting on a stand and the rear wheel suspended in the air while lifting on the chain Figure 2 3 From the back sight down...
Страница 17: ...mm hex key CAUTION Adequate lever free play is required so that the brake pads do not wear prematurely 1 Loosen the lock nut 10mm wrench 2 Screw the adjuster in Clockwise to remove free play or out Co...
Страница 18: ...lay CAUTION Adequate pedal free play is required so that the brake pads do not wear prematurely To adjust see figure 4 1 Loosen the lock nut 10mm 2 Undo the free play locking clip from around the brak...
Страница 19: ...buretor a 5 Clean the filter with cleaning solvent and then again with hot soapy water 6 Allow it to dry thoroughly 7 Saturate with foam filter oil and remove excess Do not clean the air filter with g...
Страница 20: ...front brake lever perch from the handlebars 4 mm hex 3 Remove the fork legs from the triple clamps 5mm hex key 4 Perform the following on one leg at a time Assembly 1 Remove the fork cap 1 wrench 2 Tu...
Страница 21: ...rts list coming soon ES2 Bottom end transmission Parts list coming soon CAUTION Take caution when handling the crankshaft It is the main power transfer to the rest of the engine If it is out of alignm...
Страница 22: ...21 ES3 Clutch and Shifter components Figure 5...
Страница 23: ...SCREW 22 ECDC0072 1 12X30CS M10 23 ECDC0019 CLUTCH BEARING SEAT 24 ECDC0018 BEARING CLUTCH THROW OUT DC65 25 ECDC0020 CLUTCH PUSH ROD 26 ECDC0111 SPACER KICKSTARTER DC65 27 ECDC0040 SPRING KICKSTARTER...
Страница 24: ...SCREW M6X25 HEX HEAD 8 ECDC0078 SEAL KICKSTARTER DC65 9 ZCMU0001 GASKET OIL FILL PLUG ALL 50 S 10 ECMU0037 OIL FILL PLUG 11 ZCDCOR03 ORING CLUTCH CAP DC65 12 HCNL0602 M6 CONICAL TOP LOCKNUT 13 ECDC007...
Страница 25: ...5X35 SOCKET HEAD CAP SCREW 6 HCWF0501 WASHER FLAT 5MM 7 HCNS1001 NUT M10 8 HCWF0038 3 8 FLAT WASHER 9 ICMU0006 ROTOR 10 ICMU0007 STATOR 11 ECDC0024 SEAL CRANKSHAFT DC65 12 ECDC0087 SHIFTER LEVER DC65...
Страница 26: ...ace 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 through the cage If you see light between the reed pedals...
Страница 27: ...mmerse 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 As...
Страница 28: ...l ratio o Poor acceleration o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o Excessive black oil dripping from exhaust system Symptoms of too rich a fuel mixture o Poor accelera...
Страница 29: ...The carburetor is clean no plugged jets o The air filter is properly clean and oiled o The float height is within proper specification proper measuring technique is described later in this section NO...
Страница 30: ...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...
Страница 31: ...retor from the inlet and airbox 4 Detach the fuel line from the top of the carburetor 5 Detach the carburetor from the cable and slide by unscrewing the cap off the top of the carburetor CAUTION The j...
Страница 32: ...of the carburetor screwdriver 3 Rotate the carburetor so that the float bowl is exposed may need to dislocate from the air boots 4 Remove the jet access plug from the bottom of the float bowl 17 mm w...
Страница 33: ...e jet access plug in the bottom of the float bowl 17 mm wrench 6 Reinstall the carburetor properly in the inlet and air boot CAUTION Make certain that the carburetor completely inserted into the inlet...
Страница 34: ...cable lightly push on the pointed end of the jet needle to remove it from the slide 10 Make note of what groove the clip is in on the end of the needle groove one is at the top and groove 5 is furthe...
Страница 35: ...uspension Adjustment 4 Proactive Suspension Adjustments 5 How to Adjust the Suspension 6 Suspension Reference Factory setting Track 1 Track 2 Track 3 Track 4 Fork Oil Viscosity 5 wt Oil Height amount...
Страница 36: ...t forks are designed to operate without any gas pressure Continually bleed off any pressure that builds up during riding or this will effect the feel of the front forks A properly adjusted machine is...
Страница 37: ...more than 85 lb 39 kg then the optional stiffer spring is recommended If you child weights less than 60 lb 27 kg then the optional softer spring is recommended STEP 2 Proper Ride Height Taller riders...
Страница 38: ...until the rear frame spars are vertical see figure13 and notes below 2 3 Tighten the front fork clamps 6 ft lb 8 Nm NOTE Measuring how vertical the frame spar is can be most accurately done by placing...
Страница 39: ...etween the centers of the rear fender bolt and the rear axel bolt see figure 14 3 Write this number in table 1 as the Free Length 4 Remove the bike from the stand and with your rider sitting aboard th...
Страница 40: ...2 1 Loosen the shock preload lock nut 7 2 2 Turn the preload adjuster back from the spring by one turn NOTE If you unload the spring while performing this task you must purchase a softer spring 7 2 3...
Страница 41: ...Load Sag is acceptable then verify the following 6 1 Ride height is still acceptable if not readjust 6 2 Front to back balance is still acceptable Step 1 vertical frame spar if not readjust Other par...
Страница 42: ...ping Rear end kicks over square edge bumps 1 Harder rebound 2 Softer Compression S4 Proactive Suspension Adjustments Once you have the suspension adjusted for decent overall feel you can make proactiv...
Страница 43: ...preload Figure 15 Shock Damping Figure 16 Shock Length The shock on your Cobra Motorcycle has an adjustable eye to eye length It is not to be extended any longer than when one groove is visible below...
Страница 44: ...stability 2 Rear shock 2 1 Shock length eye to eye 2 1 1 Shorter shock length lower ride height for shorter riders 2 1 2 Longer shock length higher ride height for taller riders 2 2 Preload adjustment...
Страница 45: ...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...
Страница 46: ...24 Jetting Stock 5 Troubleshooting 27 Lubrication Recommended 5 Maintenance Schedule 13 Tips 13 Oil Recommended 5 Optional Components 9 Parts Bottom end 20 Clutch 21 Ignition 24 Inlet 25 Reeds 25 Top...
