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Cobra DCX65 2003 Owner's And Service Manual

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2003 DCx65
Owners / Service Manua
l
"CHAMPIONS START HERE"

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Summary of Contents for Cobra DCX65 2003

  • Page 1 2003 DCx65 Owners / Service Manua “CHAMPIONS START HERE”...
  • Page 2 For parts orders contact your local dealer To locate your closest 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 Motorcycle MFG., Inc.
  • Page 3 “WARNING” THE COBRA DC65 IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS.

  • Page 4: Table Of Contents

    Table Of Contents General Information ......................5 Specifications - General....................5 Specifications - Torque Values ..................6 Specifications – Suspension..................8 Optional Components ......................9 Break-In Procedure ....................10 Starting Procedure .....................11 General Tips........................12 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...
  • Page 5 ES7: Exhaust ......................26 Tuning ..........................27 Tuning 1: Carburetor....................27 Jetting Decisions ....................27 Jetting Changes......................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 to Adjust the Suspension................42 6 Suspension Reference ..................43 Troubleshooting ......................44...

  • Page 6: General Information

    Gap 0.023” – 0.025” (0.58 – 0.64 mm) Fuel type Sunoco MO2 or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios 32:1 to 40:1 Ignition timing 0.050” Carburetion...

  • Page 7: Specifications - Torque Values

    Pressure 10 - 15 psi. Rear tire 80/100 x 12 Pressure 10 - 15 psi. Front fork Cobra USD 35 mm Fork oil type SAE 5 weight Fork oil amount 4 oz (118 ml) Fork oil level Specifications - Torque Values Torque Value Size &...
  • Page 8 Torque Value Size & CHASSIS Fastener ft-lb in-lb Remarks Front axle nut 12 x 1.25 Front brake caliber 8 x 1.25 Front brake rotor 6 x 1.0 (B) Triple clamp bolts 6 x 1.0 Fork cap 1.25” x 18 Steering head 1.0”...

  • Page 9: Specifications - Suspension

    Specifications – Suspension Factory Track 1 Track 2 Track 3 Track 4 setting Fork Oil 5 wt Viscosity Oil Height 4 oz (amount) (118 ml) Fork Spring STD. Shock Spring STD. Preload height Rebound Damping (clicks from full damp) Compression Damping (clicks from full damp)

  • Page 10: Optional Components

    Optional Components • Carburetor jets • Sprockets o Front o Rear • Suspension Springs Weight of Rider (lb) Fork Spring Shock Spring Less than 51 SCDC0285 (285 lb/in) 51 - 60 KCDCSP01 SCDC0300 (300 lb/in) (blue, 14 lb/in) Greater than 60 KCDCSP02 SCDC0325 (325 lb/in) (red, lb/in)

  • Page 11: Break-In Procedure

    Break-In Procedure Your Cobra Motorcycle is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The DC65 can be ridden hard after the first ½ hour break-in time but it is recommended that no adjustments are made to the carburetion or suspension until the full 8 hours of bike break-in has elapsed.

  • Page 12: Starting Procedure

    (i.e. the side of the cylinder is warm to touch). CAUTION: Never rev an engine full throttle when it's cold or slightly warmed up. Cobra recommends that you tell your child to take it easy the first couple of minutes in practice until the engine comes up to full operating temperature.

  • Page 13: General Tips

    General Tips Always wear a helmet and other protective riding gear. Cobra recommends that you tell your child to take it easy the first couple of minutes in practice until the engine comes up to full operating temperature. Make sure your riders’ foot is not resting on the rear brake pedal while they...

  • Page 14: Maintenance

    The frame is 4130 Chrome Moly and it is important to weld it with the proper rod and heat settings set as light as possible. Cobra recommends replacing the frame with a new one if the old one becomes damaged.

  • Page 15: M1: Replacing Transmission Lubricant

    M1: Replacing Transmission Lubricant Tools needed: • 530 ml (18 oz) 85W 90 gear lubricant • large flat blade screwdriver • 13 mm wrench or socket Procedure: Begin this procedure with a bike that has been ridden more than 5 minutes but less than 10 minutes.

  • Page 16: M2: Chain Adjustment

    M2: Chain adjustment Tools needed: • Two 19 mm wrenches or sockets • 13 mm wrench or socket • Measuring device Procedure: Loosen the rear axel nut (two 19 mm wrenches). Adjust the chain adjusters in the end of the swingarm (clockwise for tighter chain) until proper chain tension, 37 –...

  • Page 17: M3: Front Brake Adjustment

    Figure 3 Tighten the rear axel nut to 25 ft-lb (34 Nm) (two 19 mm wrenches). Rotate the wheel forward and remove the shop rag. M3: Front brake adjustment Tools recommended for front brake maintenance: • 10mm open end wrench •...

  • Page 18: M5: Rear Brake Adjustment

    M5: Rear brake adjustment Tools required • 10 mm wrench Set pedal position first, then Set pedal free play. Setting rear brake pedal position (see figure 4): Loosen the lock nut (10mm wrench). Adjust the brake lever stop (10mm wrench) so that the lever is comfortably reachable in both: a.

  • Page 19: M6: Air Filter Cleaning

    M6: Air Filter Cleaning This Cobra Motorcycle comes with a unique air filter / air boot unit designed to facilitate motorcycle service. Tools recommended for air filter maintenance: • • Foam filter oil Procedure 1. Removed the front fastener from the left side number plate (?? Hex key).

  • Page 20: M7: Fork Oil Replacement

    • 1 for practice • 1 for each moto CAUTION: It is recommended to apply medium strength (blue) thread locking agent to the threads of the air box side fasteners as well as the number plate fastener. M7: Fork Oil Replacement Tools required •...

  • Page 21: Engine Parts / Service

    Do not try to true the crank yourself. Truing the crank should be done professionally. Cobra trues every crank before it leaves the factory, and also welds the pin to keep it true. If there are any problems send the engine in, or call tech support (330) 549-9603 to determine what the problem is.

  • Page 22: Es3: Clutch And Shifter Components

    ES3: Clutch and Shifter components Figure 5...
  • Page 23 REF. # PART # CLUTCH / SHIFTER COMP. DESCRIPTION ECDC0129 CASE,RIGHT,DC65-MACHINED ECDC0031 DOWEL,HOLLOW,CENTERING 6X13 HCBB0612 6X12 MET SOC BUT BOLT-ZINC YEL ECDC0022 BEARING,SHIFT DRUM 65CC ECMU0016 BEARING-50 CRANK ECDC0024 SEAL, CRANKSHAFT DC65 ECDC0073 CRANK DRIVE GEAR - DC65 ECDC0036 SNAP RING,EXT.16MM-SPRING RET. ECDC0075 IMPELLER,65CC WATERPUMP HCWF0501...
  • Page 24 Figure 6 Clutch cover components REF. # PART # DESCRIPTION ECDC0176 CLUTCH COVER-DC65-MACHINED ZCDC0002 GASKET-CLUTCHCOVER-DC65 HCBC0625 6X25 SOCKET HEAD CAP SCREW HCBH0805 M8X12 OIL DRAIN SCREW HCWC0000 GASKET 10MM COPPER WASHER ECDC0046 KICKSTARTER LEVER-DC65 HCBH0602 SCREW M6X25 HEX HEAD ECDC0078 SEAL,KICKSTARTER DC65 ZCMU0001 GASKET-OIL FILL PLUG-ALL 50'S ECMU0037 OIL FILL PLUG ZCDCOR03 ORING-CLUTCH CAP-DC65...

  • Page 25: Es4: Ignition

    ROTOR ICMU0007 STATOR ECDC0024 SEAL, CRANKSHAFT DC65 ECDC0087 SHIFTER LEVER - DC65 INCLUDED WITH SHIFTER LEVER CAUTION: ECKGSR03 SNAP RING-OUTPUT-COBRA • Make sure ground PCKG0013 SPROCKET 13T COBRA wires are secure. If ECDC0009 SPACER,SPROCKET the bike is not ECDC0025 SEAL,OUTPUT DC65...

  • Page 26: Es5: Cooling System

    ES5: Cooling System (Parts list coming soon.) ES6: Fuel & Air System (Parts list coming soon.) Reeds CAUTION: • The reeds must lay flat on the reed cage. • If the reed tips aren’t lying flat, replace them immediately. • The reeds must have a tight seal on the reed cage.

  • Page 27: Es7: Exhaust

    Carburetor Cleaning 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 flash-point solvent to clean the carburetor.

  • Page 28: Tuning

    Topics included are: 1. Jetting Decisions 2. Jetting Changes C1: Jetting Decisions Although your Cobra is sent from the factory with the carburetor jetted for optimal performance, you may find it necessary to adjustment your particular jetting due current weather...
  • Page 29 Perform all jetting 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 what adjustable component affects what range of operation (specifically throttle position).
  • Page 30 TOP END JETTING: Adjust for clean full throttle acceleration Jet your top end (main j e t) 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 accordingly.

  • Page 31: Jetting Changes

    C2: Jetting Changes STOCK CARBURETOR SETTINGS • 19 mm + 0.5mm (0.75” + 0.020”) float height • Air screw ½ turn out • 38 pilot jet • JJH – 3 (3 position from top) jet needle • 128 main jet To check and/or adjust float height: REQUIRED TOOLS •...
  • Page 32 Figure 10 NOTE: When measuring the float height, the float should be resting, but not depressing, the spring loaded float valve pin (his can be done by tilting the carburetor until the float tab just makes contact with the valve pin). If adjustment is needed, bend the metal tab on the float arm until correct height is obtained (19 mm + 0.5mm (0.75”...
  • Page 33 boot is pulled at least 8mm over the inlet of the carburetor body. To replace the pilot jet: REQUIRED TOOLS • Flat blade screwdriver • 17 mm wrench Removal 1. Insure that the fuel petcock is turned to off. 2. Loosen the hose clamps at the front and rear of the carburetor (screwdriver). 3.
  • Page 34 may drain. 6. To remove the slide from the cable, hold the slide in one hand and compress the spring into the cap with the other. 7. While compressing the spring, hold the slide upside down such that the retaining plate drops free. 8.

  • Page 35: Tuning 2: Suspension

    Tuning 2: Suspension Topics included are: 1. Suspension Guidelines 2. Proper Suspension Adjustments for Your Rider 3. Symptoms of Incorrect Suspension Adjustment 4. Proactive Suspension Adjustments 5. How to Adjust the Suspension 6. Suspension Reference Factory Track 1 Track 2 Track 3 Track 4 setting Fork Oil...

  • Page 36: Suspension Guidelines

    3. If you get confused, overwhelmed, or feel that you have just made things worse, take a step backward in adjustment to what DID work best. Perhaps even requiring you to return to stock settings. 4. If all else fails, call the Cobra Technical support hotline (330) 549- 9603.

  • Page 37: Proper Suspension Adjustments For Your Rider

    Figure 11 STEP 1: Fork Spring Selection The standard fork spring should be fine for the typical Cobra rider. Although, depending on your racers weight, and alternative spring may suit him/her better. If your child weights more than 85 lb (39 kg) then the optional stiffer spring is recommended.
  • Page 38 Adjustment Procedure 1. Adjust the height of the rear of the bike. 1.1. Remove the shock as covered in the service portion of this manual. 1.2. Using a vice and a thin 17 mm wrench, adjust the length of the shock. 1.3.
  • Page 39 STEP 3: Proper Race Sag Tools required Measuring tape Shock preload spanner Calculator or the ability to subtract without one NOTE: Always be consistent with measuring units. Stick with inches (“) or millimeters (mm). Adjustment Procedure 1. Place the bike on a suitable stand to suspend the rear wheel off the ground. 2.
  • Page 40 Free Race Race Sag No Load No Load Sag Length Length Target 75 mm (3.0”) Length Target 19 mm (3/4”) Calculate as Calculate as Measure Measure Free Length – Measure Free Length – Race Length No Load Length Table 1 Sag calculations 7.

  • Page 41: Symptoms Of Incorrect Suspension Adjustment

    2. Record the measurement in table 1 as the No Load Length. 3. Calculate the No Load Sag by subtracting the No Load Length from the Free Length and record it in the table. 4. The target 19 mm + 6mm (3/4” + ¼”). 5.

  • Page 42: Proactive Suspension Adjustments

    Symptom Action Rear end feels stiff on small bumps Softer compression damping Rear end ‘sways’ on straights Harder compression damping Bike tends to jump ‘rear end high’ Harder rebound damping Bike tends to jump ‘rear end low’ Softer rebound damping Frequent rear end bottoming Harder compression damping Bottoms after end of continuous bumps...

  • Page 43: How To Adjust The Suspension

    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 the locknut after tightening.

  • Page 44: Suspension Reference

    S6: Suspension Reference 1. Front forks 1.1. Fork oil 1.1.1. Oil type 1.1.1.1. Heavier weight oil – more damping – slower responding 1.1.1.2. Lighter weight oil – less damping – quicker responding 1.1.2. Oil quantity / level 1.1.2.1. Greater quantity / higher level – greater bottoming resistance, stiffer near the end of the travel.

  • Page 45: Troubleshooting

    Troubleshooting 1) Engine not behaving properly a) Carburetor top is installed backwards (happens a lot) b) The carburetor slide indexing pin is missing 2) Engine is down on power a) Clutch engagement is not set properly b) Jetting is incorrect c) Silencer needs repacked d) Exhaust pipe Has excess carbon buildup...

  • Page 46: Index

    Index Air Filter Maintenance........18 Recommended .......5 Bottom End Optional Components ......9 Service ...........20 Parts Break-In..........10 Bottom end ........20 Carburetion Clutch ..........21 Specifications ........5 Ignition..........24 Carburetor Inlet ..........25 Tuning ..........27 Reeds ..........25 Chain Top end ..........20 Adjustment........15 Water pump ........25 Chassis Petcock ..........11 Specification........5 Rear Brake...

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