Cobra 2009 CX65 Service Manual
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Cobra 2009 CX65 Service Manual

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Summary of Contents for Cobra 2009 CX65

  • Page 2 For parts orders contact your local dealer To locate your 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 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 MOTORCYCLE OR AS THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS COBRA MOTORCYCLE IN PROPER OPERATING CONDITION.

  • Page 4: Table Of Contents

    Table Of Contents GENERAL INFORMATION...................3 .................3 PECIFICATIONS ENERAL ..................4 PTIONAL OMPONENTS ..............5 PECIFICATIONS ORQUE ALUES ..................6 REAK ROCEDURE ..................7 TARTING ROCEDURE MAINTENANCE....................8 ........................8 ......................8 CHEDULE ..........10 EPLACING RANSMISSION LUTCH UBRICANT ...................11 HAIN ADJUSTMENT ..................12 ILTER LEANING ...................13 EPLACEMENT ....................14 GNITION IMING PARTS........................15 –...
  • Page 5 – F & T ..............30 ARTS RAME RIPLE LAMPS – F & B ..............31 ARTS RONT HEEL RAKES –B ..................32 ARTS ODYWORK – R ..................33 ARTS RAKE – R ..................34 ARTS HEEL – S ....................35 ARTS HOCK – S ................36 ARTS WINGARM SSEMBLY...

  • Page 6: General Information

    Needle 5I 14 - 4 Float Height 21.1 ± 1.0 Transmission Speed 6 speed Final drive ratio 15/48 Chain 116 links 420 Transmission / clutch oil type Quality gear lubricant, or Cobra clutch milk Do Not Run Automotive Motor Oil Quantity 530 ml (18.0oz)

  • Page 7: Optional Components

    Chassis Front tire 60/100 – 14 Rear tire 80/100 – 12 Front fork Marzocchi 35mm USD, Compression adjustable Fork oil type SAE 10 weight Fork oil amount 210 ml (7.1oz) Spring Preload Length 178mm (49 N/mm Rear shock Öhlins: Compression & Rebound Adjustable Spring rate 280 lb/in (49 N/mm) Optional Components Call your dealer, or the factory, for details...

  • Page 8: Specifications - Torque Values

    Specifications - Torque Values Torque Value Size & Fastener Remarks ft-lb in-lb Cylinder head 12.5 M7 x 1.0 nuts Crankcase M6 x 1.0 bolts Exhaust M6x1.0 Flange Spark plug (SP) (SP) (SP) M14 x 1.25 Stator bolts M5 X 0.8 Stator cover M4 X 0.75 bolts...

  • Page 9: Break-In Procedure

    Break-In Procedure Your Cobra CX65 is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The CX65 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 10: Starting Procedure

    CAUTION: For best results from your 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.

  • Page 11: Maintenance

    CAUTION: 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. Maintenance It is important that you adhere to this maintenance schedule so as to promote the longevity of your Cobra Motorcycle.
  • Page 12 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 replacing the frame with a new one if the old one becomes damaged. Use ER70S6 filler if welding on the frame.

  • Page 13: Replacing Transmission / Clutch Lubricant

    Replacing Transmission / Clutch Lubricant Tools needed: • 18 oz, of high quality transmission oil, or Cobra clutch milk • 8 mm Allen wrench CAUTION: General automotive motor oil has frictional modifiers which will cause premature wear and failure of the clutch.

  • Page 14: Chain Adjustment

    Chain adjustment Tools required for chain adjustment • 22 mm wrench or socket • 2 - 11 mm open-end wrenches 1. Make sure that the rear wheel is aligned properly. proper adjustment, the chain should have 35 mm free movement just behind chain block with no load on...

  • Page 15: Air Filter Cleaning

    Air Filter Cleaning Tools recommended for air filter maintenance: • 5 mm hex key (Allen) • Foam filter oil 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.

  • Page 16: Fork Oil Replacement

    Fork Oil Replacement Requirements • 19mm and 27mm combination wrench • 6mm and 10mm hex key (Allen) • Flexible retrieving tool • 10w fork oil (approximately 210cc per fork leg) Disassembly 1. Remove the front wheel and front brake caliper. 2.

  • Page 17: Ignition Timing

    Ignition Timing The ignition timing value for the 2009 CX65 is 5° 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 marks are 5°...

  • Page 18: Parts

    Parts Parts – Airbox & Inlet System Coolant System REF # PART # DESCRIPTION RCC60007 AIRBOX 07 65 TCC60008 MUD FLAP 07 65 HCSP0003 SCREW - PLASCREW MCKGHO03 CLAMP, AIR BOOT TO AIR BOX RCC60002 AIR FILTER 07 65 RCC60003 AIR FILTER CAGE RCC60004 AIR FILTER WIRE 07 65...

  • Page 19: Parts - Bars And Controls

    Parts – Bars and Controls Bars and Controls REF # PART # DESCRIPTION FAMU0011 HANDLEBAR - ALUMINUM TCMU0008 GRIPS (SET OF TWO) FCMU0066 THROTTLE ASSEMBLY FCMU0021 THROTTLE COVER BCC60008 ALLOY BRAKE LEVER BCC60009 MASTER CYLINDER ASSY W/LEVER RAC60001 THROTTLE CABLE HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 (4 PER) TKMU0404M...

  • Page 20: Parts - Carburetor

    Parts - Carburetor Carburetor REF. # PART # DESCRIPTION RCC60001 CARBURETOR 24MM MIKUNI SEE BELOW MAIN JET SEE BELOW PILOT JET RCC60013 GASKET , FLOAT BOWL RCMU0415 CABLE ADJUSTER CAP PILOT JET MAIN JET 22.5 RCEX0022 RCMU0165 RCEX0025 RCMU0170 27.5 RCEX0027 RCMU0175 RCEX0030...

  • Page 21: Parts - Clutch Actuation

    Parts – Clutch Actuation Clutch Actuation REF # PART # DESCRIPTION CCMU0004 MASTER CYLINDER CCDC0001 CLUTCH LEVER CCMU0035 COVER – RESERVOIR (REPLACEMENT) NOT SHOWN CCMU0036 CLAMP – PERCH (REPLACEMENT) NOT SHOWN CAC60001 CLUTCH ACUTATOR ASSEMBLY ( Lever, Master Cyl., Line, Slave Cyl. CCC60001 CLUTCH LINE ONLY NOT SHOWN...

  • Page 22: Parts - Coolant System

    Parts – Coolant System Coolant System REF # PART # DESCRIPTION FCDC0000 RADIATOR W/CAP - CX65 FCMU0047 CAP - RADIATOR FCKG0214 HOSE - OVERFLOW MCMUCL05 HOSE CLAMP 11-20 UNIVERSAL FCDC0009 RADIATOR LOUVER-CX65 HCSP0002 PUSH PIN - PLASTIC NOT SHOWN HCCN0000 5MM EXTRUDED "U"...

  • Page 23: Parts - Electrical System

    Parts – Electrical System Electrical System REF # PART # DESCRIPTION ICC60004 STATOR DIGITAL 07 65 HCBB0516 5X12MM SHCS (3 REQ’D) HCWF0501 5MM FLAT WASHER (3 REQ’D) ICC60003 ROTOR OUTER STYLE 07 65 ICMU0012 WOODRUFF KEY HCWF0038 3/8 FLAT WASHER HCNS1001 10MM X 1.25 NUT ICC60002...

  • Page 24: Parts - Engine Clutch

    Parts – Engine Clutch Clutch components REF. # PART # DESCRIPTION EAEX0003 CLUTCH BASKET ASSEMBLY ECDC0064 CLUTCH BUSHING – INNER / STEEL ECDC0167 CLUTCH BUSHING - OUTER / BRONZE SHOWN ECDC0063 CLUTCH WASHER (2 PLACES) ECDC0066 CLUTCH PRESSURE PLATE ECDC0068 CLUTCH DISC-FRICTION –...

  • Page 25: Parts - Engine - Clutch / Kick Cover

    Parts – Engine – Clutch / Kick Cover Clutch / kick cover components REF. # PART # DESCRIPTION ECMU0150 CLUTCH COVER (07 STYLE) ZCMU0014 GASKET-CLUTCHCOVER HCBF0625 6X25 SOCKET HEAD CAP SCREW (6 REQ’D) HCBF0630 6X30 SOCKET HEAD CAP SCREW (2 REQ’D) HCBF0612 6X12 FLANGE HEAD BOLT HCWF0618 WASHER - KICK LEVER ECMU0130 KICKSTARTER LEVER...

  • Page 26: Parts - Engine - Ignition Side

    ROTOR PVL OUTER STYLE ICC60004 STATOR PVL DIGITAL 07 65 ECDC0024 SEAL, CRANKSHAFT ECDC0086 SHIFTER LEVER – CX65 HCFH0620 M6 X 20 HEX HEAD BOLT ECKGSR03 SNAP RING-OUTPUT-COBRA PCKG00xx SPROCKET xx denotes number of teeth ECDC0009 SPACER,SPROCKET ECDC0025 SEAL,OUTPUT ECDC0026 SEAL,SHIFTER ICMUGR01 GROMMET-IGNITION EKC62009 ENGINE CASE SET W/B&S CX65 09...

  • Page 27: Parts - Engine - Kick Mechanism

    Parts - Engine – Kick Mechanism Kick Mechanism REF. # PART # DESCRIPTION EKC62009 ENGINE CASE SET W/B&S CX65 09 ECDC0111 SPACER, KICK START SHAFT ECDC0040 SPRING, KICKSTART RETURN ECDC0036 SNAP RING, EXTERNAL 16MM ECDC0043 WASHER, KICKSTART BACKUP ECDC0042 SPRING, KICKSTART RAMP ECMU0135 SHAFT, KICK START ECDC0038 RAMP GEAR, KICKSTART ECDC0033 GEAR, KICKSTART...

  • Page 28: Parts - Engine - Shift Mechanism

    Parts – Engine – Shift Mechanism Clutch components REF. # PART # DESCRIPTION EADC0154 SHIFTER SHAFT (2 COMPONENTS) W/SPRING ECDC0055 SPRING - SHIFTER SHAFT ECDC0110 SPACER, CENTERING SPRING ECDC0099 SPRING, CENTERING ECMU0550 SHIFT CASSETTE (W/O PINS) ECDC0051 DOWEL – SHIFT DRUM INDEX HCBC1825 8MM X 25 SHCS BLACK OXIDE HCWL0802...

  • Page 29: Parts - Engine - Top End

    Parts – Engine – Top End Engine – Top End REF # PART # DESCRIPTION ECC60017 CYLINDER KIT (INCLUDES PISTON KIT) BASE GASKET 0.015” (0.4mm thick) For other Base Gaskets refer to Base Gasket Selection section of this manual (PG 37) More than one gasket may be required! ZCC60115 ECMU0184xx...

  • Page 30: Parts - Engine - Transmission

    Parts - Engine - Transmission Transmission REF # PART # DESCRIPTION ECC60027 CRANKSHAFT 09 65 ECDC0023 BEARING, CRANKSHAFT EKEX0001 ROD KIT ACCESSORY EKC62009 ENGINE CASE SET W/B&S CX65 09 EKC62009 ENGINE CASE SET W/B&S CX65 09 ZCC60003 GASKET CRANKCASE 09 65 Left Case Screws HCBC0604 6X35MM SOCKET HEAD CAP SCREW (4 REQ’D)

  • Page 31: Parts - Exhaust System

    Parts – Exhaust System Exhaust System REF # PART # DESCRIPTION XAC62008 EXPANSION CHAMBER 08 XCMU0033 ISOLATION MOUNT (2 REQ’D) 6MM CLIP NUT-PLASTIC/PIPE MNT (2 REQ’D FOR PIPE & 2 HCHA0003 REQ’D FOR SILENCER) HCBF0616 6X16MM FLANGE HEAD BOLT (2 REQ’D) HCBF0612 6X12MM FLANGE HEAD BOLT (2 REQ’D) HCCN0000...

  • Page 32: Parts - Forks - Leg Assembly

    Parts – Forks – Leg Assembly Fork Leg Assembly REF # PART # DESCRIPTION KACX6527 FORK SET – 2008 CX64 FORK LEG OUTER KCC60004 BUSHING – TOP WASHER KCC60002 FORK SEAL KCC60011 CLIP RING KCC60003 DUST COVER (SWIPER) KCC60012 BLEED SCREW WITH SEAL CAP –...

  • Page 33: Parts - Frame & Triple Clamps

    Parts – Frame & Triple Clamps Frame REF # PART # DESCRIPTION FACX6507 FRAME WELDED ASSEMBLY 07 65 FAC60002 SUBFRAME CX65 W/ BEARING RACES HCBB0835 8X35MM BUTTON HEAD SCREW (2 REQ’D) – TOP MOUNT HCFH0825 8X25MM FLAT HEAD CAP SCREW – (2 REQ’D) – BOTTOM MOUNT FCC60020 CHAIN ROLLER W BEAR &...

  • Page 34: Parts - Front Wheel & Brakes

    Parts – Front Wheel & Brakes Front Brakes REF# PART # DESCRIPTION WAC6FR01B WHEEL 14” FRONT W BEARINGS (NO TIRE, OR TUBE,), BLACK WCC6F014B TIRE-BRDGESTNE-60/100-14M39 WCC6F014D TIRE-DUNLOP-60/100-14 756 WCDCHB01 HUB FOR CX65 – FRONT WCMU1400B 14” RIM, BLACK WCDCTU14 TUBE – 60/100-14 FRONT WCDC0009 RIM LINER 14”...

  • Page 35: Parts -Bodywork

    Parts –Bodywork Plastic and Seat REF # PART # DESCRIPTION TCC62009 GRAPHIC KIT NOT SHOWN TCC60001 FRONT FENDER HCBF0616 FENDER BOLT, M6X16 FLANGE HEAD (4 REQ’D) NOT SHOWN TCC60021 SPACER – FRONT FENDER BOLT NOT SHOWN TCC60002 NUMBER PLATE – FRONT HCBF0612 M6X12 FLANGE HEAD BOLT –...

  • Page 36: Parts - Rear Brake

    Parts – Rear Brake Rear Brake System REF # PART # DESCRIPTION BAC60003 BRAKE ASSEMBLY REAR 2009 BCEX0028 CALIPER – REAR BRAKE BCMU0218 MASTER CYLINDER - REAR BCMU0217 HOSE - REPLACEMENT BCC60018 CALIPER BRACKET REAR HCBC0601 6X16CS (2 REQ’D) HCBF0620 6X20 FLANGE HEX-8MM HEAD HCCC0005 BRAKE - HOSE GUIDE...

  • Page 37: Parts - Rear Wheel

    Parts – Rear Wheel Rear Wheel REF # PART # DESCRIPTION WHEEL 12" REAR W BEARINGS (NO TIRE, TUBE, ROTOR OR SPROCKET), WAC6RR01B BLACK WCC6R012B TIRE-BRDGESTNE-80/100-12M40 WCC6R012D TIRE – DUNLOP- 80/100-12 756 WCDCHB02 HUB FOR CX65-REAR WCMU1200B 12" RIM, BLACK WCDCTU12 TUBE-275-80/100-12 REAR WCDC0010...

  • Page 38: Parts - Shock

    Parts – Shock Shock REF # PART # DESCRIPTION SAAX2007 SHOCK ABSORBER - CX65 HCBF1040 10X44 ENG FAST FLANGE HEAD HCBH1055 10X55 HEX HEAD BOLT HCNL1001 10MM LOCKNUT-REGULAR SCKGOH03 BALL JOINT SCKGOH11 O-RING FOR BALL JOINT SCKGOH02 SPACER FOR BALL JOINT SCKGOH04 SPRING PLATFORM (UPPER THREADED) SCKGOH05...

  • Page 39: Parts - Swingarm Assembly

    Parts – Swingarm Assembly Swingarm REF # PART # DESCRIPTION GACX6507 SWINGARM WELDED ASSY ALUMINUM GCC60015 BOLT - SWINGARM PIVOT HCWF1202 12MM WASHER – SWINGARM PIVOT HCNL1201 12MM LOCK NUT – SWINGARM PIVOT GCC60002 SWINGARM BUSHING 07 65 (4 REQ’D) GCC60001 SWINGARM PIVOT TUBE SPACER 07 65 J(2 REQ’D) TCC60004...

  • Page 40: Service

    • There appears to be a wide range of variability in reading compression gauges across the country. • The head volume of this Cobra Motorcycle is very small and so requires many kicks ~20 before you establish the most accurate reading possible.

  • Page 41: Base Gasket Selection

    • 1mm flexible solder material • measurement calipers When rebuilding the ‘top end’ of your Cobra motorcycle, care must be 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 little clearance.
  • Page 42 If during the course of the maintenance more parts than the base gasket are changed, the squish clearance should be measured, and possibly a different base gasket will be required. The easiest way to measure squish clearance is with 1mm to 1.5mm thick flexible solder wire (available through most popular electronic stores).

  • Page 43: Fuel & Air System

    Tools recommended for carburetor service: • Small flat head screwdriver • WD-40 • 6mm socket Your Cobra is equipped with an adjustable carburetor. Some fine- tuning may be needed according to weather condition and altitude. Proper jetting is very important for engine performance and engine life.
  • Page 44 Turning the screw in richens the mixture at partial throttle openings. Turing the screw out, leans it. STOCK CARBURETOR SETTINGS The 2009 CX65 stock carburetor settings from the factory are: • 40 pilot jet • 210 main jet...

  • Page 45: Rear Shock

    Rear Shock The rear shock is fully serviceable but it is recommended that only trained professionals should service your shock. Contact Cobra or another qualified specialist (PR2, MCR, etc..) for questions and service of your CX65shock. Shock preload Shock Damping...

  • Page 46: Tuning

    Tuning Gearing Rear Gear Front Sprocket Sprocket Ratio 2.47 2.53 2.60 2.64 2.67 2.71 2.73 2.79 2.80 2.85 2.86 2.87 2.92 2.93 2.93 3.00 3.00 3.00 3.07 3.07 3.08 3.08 3.13 3.14 3.15 3.17 3.20 3.21 3.23 3.25 3.27 3.29 3.31 3.33 3.33...

  • Page 47: Suspension

    Suspension Adjustment: 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 48: Carburetion

    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 optimal performance, you may find it necessary to adjustment your particular jetting due to current weather conditions, altitude, fuel variations, and/or engine modifications.
  • Page 49 • Symptoms of incorrect oil or oil / fuel 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 acceleration o Engine will not ‘rev’...
  • Page 50 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 accordingly.

  • Page 51: Troubleshooting

    Troubleshooting 1) Engine operates erratically a) Carburetor top is installed backwards b) The carburetor slide indexing pin is missing c) A carburetor vent elbow is plugged or has fallen out d) Faulty stator e) An air leak i) Base gasket ii) Intake / reed gaskets iii) Crank seals iv) Crank case gasket...
  • Page 52 b) Carburetor is dirty c) Ignition i) Spark plug fouled ii) Spark plug cap off iii) Engine Shut-off ‘kill’ switch is shorted iv) Bad electrical ground 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).

  • Page 53: Index

    Index Frame Parts ........30 Air Filter Maintenance ....12 Front Brake Parts ..........31 Bars and Controls ......16 Fuel System Base Gasket Selection....38 Parts list........40 Break-In .......... 6 Service........40 Carburetor Hardware Parts.......... 17 Frame ........30 Service ........40 Plastic ........32 Specifications ......
  • Page 54 Carburetor ......... 17 Parts ..........35 Coolant System ....15, 19 Service........47 Electrical........20 Spark Plug Exhaust ........28 Recommended ......3 Frame........30 Specifications ........3 Front Brake ....... 31 Starting..........7 Plastic & Seat ......32 Stator Rear Brake ........ 33 torque ..........5 Rear Wheel .......

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