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Related Manuals for Cobra 2006 ECX70
Summary of Contents for Cobra 2006 ECX70
- Page 1 ECX70 Owners Parts Service Tuning...
- 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 THIS BIKE IS 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 PROPER OPERATING CONDITION.
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Page 4: Table Of Contents
Table Of Contents General Information ......................5 Specifications - General....................5 Specifications - Torque Values ..................6 Optional Suspension Components ................7 Break-In Procedure ......................8 Starting Procedure .......................9 General Tips........................10 Maintenance........................11 Schedule & Tips ......................11 M1: Replacing Transmission Lubricant..............11 M2: Chain adjustment....................12 M3: Air Filter Cleaning ....................13 M4: Front end ......................15 Toe in adjustment ....................15 Steering ........................15... - Page 5 Parts – Engine – Clutch / Kick Cover ..............24 Parts - Engine - Ignition Side................25 Parts - Engine – Kick Mechanism................26 Parts – Engine – Shift Mechanism ..............27 Parts – Engine – Top End ..................28 Parts - Engine - Transmission................29 Parts –...
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Page 6: General Information
Champion 8339 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 Ignition timing .050” (1.3mm) BTDC Carburetion... -
Page 7: Specifications - Torque Values
Chassis Tire Pressure front / rear (7 psi / 5 psi) Travel, front / rear 240mm / 247mm (9.4” / 9.7”) Race sag, front / rear 96mm / 99mm (3.8” / 3.9”) Free sag, front / rear 38mm / 40mm (1.5” / 1.6”) Specifications - Torque Values Torque Value Size &... -
Page 8: Optional Suspension Components
Torque Value Size & CHASSIS Fastener ft-lb in-lb Remarks Handle bar mounts 8 x 1.25 Handle bar clamps 8 x 1.25 Front engine mount 8 x 1.25 Rear brake lever pivot 13.6 8 x 1.25 Upper shock mount 10 x 1.5 Lower shock mount 10 x 1.5 Swingarm pivot... -
Page 9: Break-In Procedure
Clean the carburetor bowl. Change the transmission / clutch lubricant. Replace the fuel filter. • After 8 hours of operation have a Certified Cobra Mechanic change the shock oils. • Your bike is now ready for the highest level of competition! -
Page 10: 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 11: 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 12: Maintenance
The frame is a low carbon alloy tubing 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 13: M2: Chain Adjustment
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. It is desired to have the engine warm enough so that the oil ‘runny’... -
Page 14: M3: Air Filter Cleaning
After achieving the proper adjustment retighten the two eccentric pinch bolts. CAUTION: Be sure to remove the pin from the eccentric before riding. M3: Air Filter Cleaning This Cobra Motorcycle comes with a unique air filter / air boot unit designed to facilitate motorcycle service. - Page 15 NOTE: The biodegradable air filter oils, greases, and cleansers work acceptably with this Cobra Motorcycle. NOTE: It is very important to keep the air filter clean and properly oiled with high quality water-resistant foam filter oil. It’s very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting.
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Page 16: M4: Front End
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 call them) will fall out after the first ride. We have found that this causes no adverse effects and that the looseness does not get significantly worse as long as the bearings are sprayed with a spray lubricant (WD40 or similar) upon each ride. -
Page 17: Parts
Parts Parts – Air Inlet System Figure 4 Coolant System REF # PART # DESCRIPTION RCDC0001 AIR FILTER ASSEMBLY MCKGHO03 HOSE CLAMP – FILTER TO CARB RCEX0003 CARBURETOR 26MM MIKUNI VM MCMUCL10 HOSE CLAMP – CARB TO INLET BOOT (WIDE) ECEX0012 INLET BOOT MCMUCL03... -
Page 18: Parts - Bars And Steering
Parts – Bars and Steering Figure 5 Bars and Steering REF # PART # DESCRIPTION FAEX0020 STEERING STEM TCEX0009 HANDLEBAR - QUAD FCEX0011 STEERING STEM BLOCK (2 REQ’D) MCEXBR06 STEERING STEM BUSHING – SPLIT HCBB0403 4MM X 8 BUTTON HEAD SCREW (2 REQ’D) NOT SHOWN TCMU0404 BAR MOUNT KIT, SHORT –... -
Page 19: Parts - Bumper, Nerf & Grab Bars
Parts – Bumper, Nerf & Grab Bars Figure 6 BODY PROTECTION PART # DESCRIPTION REF # FCEX0024 NERF BARS (LEFT & RIGHT) HCBH0808 8MM X 30 HEX HEAD BOLT (FRONT MOUNT, 2 PLACES) NOT SHOWN NOT SHOWN HCBH0809 8MM X 50 HEX HEAD BOLT (REAR MOUNT, 2 PLACES) NOT SHOWN HCWF0801 8MM FLAT WASHER (2 REQ’D) -
Page 20: Parts - Carburetor
Parts – Carburetor Figure 7 Carburetor accessories REF # PART # DESCRIPTION RCEX0003 CARBURETOR, 26MM MIKUNI VM CABLE, THROTTLE RCEX0017 JET NEEDLE (5F21) STANDARD RCEX0018 JET NEEDLE (5F3) RCEX0004 RUBBER, THROTTLE CABLE ADJUSTER RCEX0005 ADJUSTER, THROTTLE CABLE RCEX0006 LOCK NUT, THROTTLE CABLE ADJUSTER RCEX0007 GASKET, CARBURETOR BOWL RCEX0008... -
Page 21: Parts - Clutch Actuation
Parts – Clutch Actuation Figure 8 Clutch Actuation REF # PART # DESCRIPTION CADC0001 CLUTCH ACUTATOR ASSEMBLY ( Lever, Master Cyl., Line, Slave Cyl. BCEX0005 MASTER CYLINDER CCDC0001 CLUTCH LEVER FCEX0020 CLUTCH LINE CCDC0002 CLUTCH SLAVE CYLINDER ECDC0074 CLUTCH CAP M6 x 16 Bolt ECDC0082 SNAP RING –... -
Page 22: Parts - Coolant System
Parts – Coolant System Figure 9 Coolant System REF # PART # DESCRIPTION FCEX0001 RADIATOR WITH CAP FCMU0047 RADIATOR CAP (2 ears or ribbed) ECEX0010 RADIATOR HOSE, TOP ECEX0011 RADIATOR HOSE, BOTTOM MCEXGR01 GROMMET, BOTTOM RAD MOUNT (2 REQ’D) FCEX0026 PAD, RADIATOR (2 REQ’D) SHOWN HCBF0616... -
Page 23: Parts - Electrical System
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) ICEX0002 TETHER, IGNITION SHUT OFF HCBC0516 SCREW, M5 X 16 (2 PER) HCCN0000... -
Page 24: Parts - Engine Clutch
Parts – Engine Clutch Figure 11 Clutch components REF. # PART # DESCRIPTION ECDC0165 CLUTCH BASKET BILLET ECDC0064 CLUTCH BUSHING DC65 – INNER / STEEL ECDC0063 CLUTCH WASHER-DC65 (2 PLACES) ECDC0066 CLUTCH PRESSURE PLATE ECDC0068 CLUTCH DISC-FRICTION – (5 REQ’D) ECDC0067 CLUTCH DISC-STEEL –... -
Page 25: Parts - Engine - Clutch / Kick Cover
Parts – Engine – Clutch / Kick Cover Figure 12 Clutch / kick 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... -
Page 26: Parts - Engine - Ignition Side
ROTOR ICMU0018 STATOR – 3 WIRE ECDC0024 SEAL, CRANKSHAFT DC65 ECDC0087 SHIFTER LEVER - DC65 HCBH0620 M6 X 20 HEX HEAD BOLT ECKGSR03 SNAP RING-OUTPUT-COBRA PCKG00xx SPROCKET xx denotes number of teeth ECDC0009 SPACER,SPROCKET ECDC0025 SEAL,OUTPUT DC65 ECDC0026 SEAL,SHIFTER DC65 HCBC0604 SCREW M6X35, SOCKET HEAD CAP (10 REQ’D) -
Page 27: Parts - Engine - Kick Mechanism
Parts - Engine – Kick Mechanism Figure 14 Kick Mechanism REF. # PART # DESCRIPTION ECDC0107 SPLASH GUARD ECDC0111 SPACER, KICK START SHAFT ECDC0040 SPRING, KICKSTART RETURN ECDC0036 SNAP RING, EXTERNAL 16MM ECDC0043 WASHER, KICKSTART BACKUP ECDC0042 SPRING, KICKSTART RAMP ECDC0034 SHAFT, KICK START ECDC0038... -
Page 28: Parts - Engine - Shift Mechanism
Parts – Engine – Shift Mechanism Figure 15 Clutch components REF. # PART # DESCRIPTION ECDC0054 SHIFTER SHAFT (2 COMPONENTS) EADC0055 SPRING, SHIFTER SHAFT EADC0110 SPACER, CENTERING SPRING EADC0099 SPRING, CENTERING EADC0152 SHIFT CASSETTE ASSEMBLY EADC0053 DOWEL – SHIFT DRUM INDEX HCBC1825 8MM X 25 SHCS BLACK OXIDE HCWL0802... -
Page 29: Parts - Engine - Top End
Parts – Engine – Top End Figure 16 Engine – Top End REF # PART # DESCRIPTION ECEX0001 CYLINDER ZCKG0501 BASE GASKET ECMU0084 PISTON KIT ECEX0005 PISTON RINGS (2 PER SET) ECMUSR00 SNAP RING FOR PISTON (2 REQ'D) ECDC0090 WRIST PIN ECDC0061 BEARING, WRIST PIN ZCMUOR07... -
Page 30: Parts - Engine - Transmission
Parts - Engine - Transmission Figure 17 Transmission REF # PART # DESCRIPTION ECDC0127 CRANKSHAFT ECDC0023 BEARING, CRANKSHAFT ECDC0128 CRANKCASE, LEFT SIDE ECDC0129 CRANKCASE, RIGHT SIDE ZCDC0001 GASKET, CRANKCASE CENTER ECDC0021 BEARING, OUTPUTSHAFT CLUTCH SIDE ECDC0001 SHAFT, TRANSMISSION PRIMARY (1 GEAR) ECDC0002 GEAR, 6... -
Page 31: Parts - Exhaust System
Parts – Exhaust System Figure 18 Exhaust System REF # PART # DESCRIPTION XAEX2005 ECX70 EXHAUST PIPE ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D) XCMU0005 SPRING, EXHAUST – SHORT XCMU0030 COVER, EXHAUST SPRING NOT SHOWN MCMUGR06 PIPE GROMMET MALE MCMUGR07 PIPE GROMMET FEMALE MCMUSP02 PIPE GROMMET SPACER HCWF1478... -
Page 32: Parts - Front A-Arms & Steering Upright
Parts - Front A-Arms & Steering Upright Figure 19 A-arms & steering upright REF # PART # DESCRIPTION GAEX0001 A-ARM FRONT TOP (SAME PIECE FROM LEFT TO RIGHT) GAEX0002 A-ARM BACK TOP (SAME PIECE FROM LEFT TO RIGHT) GAEX0007 A-ARM FRONT BOTTOM RIGHT GAEX0006 A-ARM FRONT BOTOTM LEFT GAEX0009... -
Page 33: Parts - Front Brakes
Parts – Front Brakes Figure 20 Front Brakes REF # PART # DESCRIPTION BAEX0001 FRONT BRAKE ASSEMBLY HOSE – TEE TO CALIPER BRAKE LEVER BCEX0005 BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER BCEX0003R CALIPER – FRONT RIGHT BCEX0003L CALIPER – FRONT LEFT BCMU0203 REPLACEMENT BRAKE PADS BCEX0002... -
Page 34: Parts - Front Shock
Parts – Front Shock Figure 21 Front Shock REF # PART # DESCRIPTION SAEX2005 SHOCK ECX70 – FRONT (2 REQ’D) SCEX1080 SPRING, HELPER, 80 LB/IN (STANDARD) SCEX1095 SPRING, HELPER, 95 LB/IN (HEAVY) SCEXA155 SHOCK SPRING, STANDARD (YELLOW, 155 LB/IN) SCEXA145 SHOCK SPRING, LIGHT (RED, 145 LB/IN) SCEXA165 SHOCK SPRING, HEAVY (BLACK, 165 LB/IN) -
Page 35: Parts - Miscellaneous
Parts – Miscellaneous If you couldn’t find it in one of the other pictures try the table below. PART # DESCRIPTION WCEX0005 REAR WHEEL WITH TIRE WCEX0004 FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING HCBH0804 M8 X 120 (FRONT ENGINE MOUNT BOLT) HCWF0801 8MM FLAT WASHER HCNL0801 8MM LOCK NUT FAEX0017R... -
Page 36: Parts - Plastic Bodywork & Seat
Parts – Plastic Bodywork & Seat igure 22 Plastic and Bodywork REF # PART # DESCRIPTION TCEX0001 FRONT CLIP NOT SHOWN HCBB0616 M6 X 16 BUTTON HEAD (4 REQ’D AT BACK) NOT SHOWN HCWF0601 6 MM FLAT WASHER (4 REQ’D AT BACK) NOT SHOWN HCBB0620 M6 X 20 BUTTON HEAD (2 REQ’D AT FRONT) -
Page 37: Parts - Rear Brake
Parts – Rear Brake Figure 23 Rear Brake System REF # PART # DESCRIPTION BADC0001 BRAKE COMPLETE BCKG0001 BRAKE PEDAL BCDC0009 BRAKE PIVOT BOLT HCBC0601 M6X16 SOC. HEAD BOLT FCEX0018 BRAKE ADJUST ECCENTRIC BCMUSP01 BRAKE RETURN SPRING BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D) BCDC0004 PUSH ROD, REAR BRAKE HCBC0601... -
Page 38: Parts - Rear Drive
Parts – Rear Drive Figure 24 Rear Drive REF # PART # DESCRIPTION GAEX0005 REAR AXLE WCEX0003 WHEEL LUG (8 REQ’D) HCNS1001 LUG NUT (8 REQ’D) NOT SHOWN HCWF0010 LUG WASHER (8 REQ’D) GCEX0014 BRAKE/SPROCKET HUB (2 REQ’D) NOT SHOWN HCBC0625 M6 X 25 HUB PINCH BOLT (2 PER HUB) HCBH0808... -
Page 39: Parts - Rear Shock
Parts – Rear Shock Figure 25 Rear Shock REF # PART # DESCRIPTION SAEX2006 SHOCK, REAR QUAD FOX SCEX0110 SPRING, HELPER 110LB/IN, STANDARD SCEX0125 SPRING, HELPER 125LB/IN, HEAVY SCEX0150 SPRING, HELPER, 150 LB/IN, X HEAVY SCEX1375 SHOCK SPRING, STANDARD (WHITE, 375 LB/IN) SCEX1350 SHOCK SPRING, LIGHT (RED, 350 LB/IN) SCEX0400... -
Page 40: Parts - Swingarm Assembly
Parts – Swingarm Assembly Figure 26 Swingarm REF # PART # DESCRIPTION GAEX0100 SWINGARM GCMU0001 BUSHING, SWINGARM (4 PER) GCEX0021 SPACER, SWINGARM PIVOT – (2 REQ’D) HCBH1421 SWINGARM PIVOT BOLT (M14 X 1 HEX HEAD) HCNL1402 SWINGARM LOCK NUT (M14 X1) GCEX0050 TOP SWINGARM GUARD –... -
Page 41: Parts - Tie Rod Assembly
Parts – Tie Rod Assembly Figure 27 Tie Rod Assembly REF # PART # DESCRIPTION FCEX0015 TIE ROD MCEXBR02R RH TIE ROD END MCEXBR02L LH TIE ROD END HCNJ120L RH JAM NUT HCNJ120R LH JAM NUT GCEX0002 SPACER, BALL JOINT HCNC0010 10MM CASTLE NUT (2 REQ’D) HCCP0003... -
Page 42: Engine Parts / Service
Engine Parts / Service At this time, the full service instructions for are not yet available your Cobra Motorcycle. If you don’t feel comfortable with the service work, simply take your engine out of the frame and sent it to: Cobra Motorcycle Mfg. -
Page 43: Carburetor Cleaning
Figure 28 The presence of light indicates that the reeds should be replaced, or possibly turned over. 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. -
Page 44: Es2: Exhaust
ES2: Exhaust The pipe is a crucial element to a two-stroke engine. Any kinks, dents, or damage done to the pipe will result in a performance loss. NOTE: Be sure to take the pipe off, and remove any carbon that may be built up. Carbon build up is created from exhaust. - Page 45 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 A-arms..........32 Frame Parts........35 Air Filter..........17 Front Brake........33 Maintenance........14 Fuel Axle .............38 Petcock ..........10 Bars and Controls ......18 Fuel System Break-In..........9 Parts list .........42 Bumper..........19 Service ...........42 Carburetion Gas Tank ...........36 Specifications ........5 General Tips........11 Carburetor .........20 Grab Bar ..........19 Chain Hardware Adjustment........13...
- Page 47 Radiator ..........22 Steering Upright........32 Rear Brake Swingarm Parts ........40 Parts ..........37 Throttle ..........17 Rear Drive..........38 Tie Rod..........41 Rear Shock Tips .............11 Parts ..........39 Toe In Adjustment ......16 Reeds ..........42 Top End Parts ..........17 Parts ..........29 Rings ..........29 Torque Seat ............36 Chassis ..........7 shift drum ...........30 Engine ..........6...
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