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Related Manuals for Cobra 2008 ECX70
Summary of Contents for Cobra 2008 ECX70
- 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 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 ....................3 Specifications - General ..................3 Specifications - Torque Values................4 Optional Suspension Components ..............5 Starting Procedure ....................8 General Tips......................9 Maintenance .......................10 Schedule & Tips ....................10 M1: Replacing Transmission Lubricant ............10 M2: Chain adjustment ..................11 M3: Air Filter Cleaning..................12 M4: Front end ....................14 Toe in adjustment ..................14 Steering .......................14... - Page 5 Parts - Engine - Ignition Side ...............24 Parts - Engine – Kick Mechanism ..............25 Parts – Engine – Shift Mechanism...............26 Parts – Engine – Top End................27 Parts - Engine - Transmission..............28 Parts – Exhaust System ..................29 Parts - Front A-Arms & Steering Upright ............30 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 Remarks ft-lb in-lb 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 SCEX2125 Blue SCEX1135 SCEX1145 Yellow SCEX1155 Black SCEX1165 Fox 7” long main spring (rear) SCEX1300 Yellow SCEX1315 White SCEX1330 SCEX1350 White SCEX1375 Yellow SCEX1400 Blue SCEX0425P Green SCEX0450P Black SCEX0475P Purple SCEX0500P Spring rate chart for Cobra Fox quad shocks...
- Page 10 Change the transmission / clutch lubricant with Cobra Power Shift Transmission 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!
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Page 11: 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 12: 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 13: 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 14: M2: Chain Adjustment
Tools needed: • 530 ml (18 oz) Cobra Power Shift Transmission 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 15: 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 16 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 17: 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 18: Parts
Parts Parts – Air Inlet System Figure 4 Coolant System REF # PART # DESCRIPTION RCDC0001 AIR FILTER ASSEMBLY MCKGHO03 HOSE CLAMP – FILTER TO CARB RAEX0026 CARBURETOR 26MM MIKUNI VM MCMUCL10 HOSE CLAMP – CARB TO INLET BOOT (WIDE) ECEX0012 INLET BOOT MCMUCL03... -
Page 19: 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) MCEXBR07 STEERING STEM BUSHING – SPLIT ZCEX0002 O’RING – STEERING STEM SEAL (2 REQ’D) NOT SHOWN TCMU0404 BAR MOUNT KIT, SHORT –... -
Page 20: Parts - Bumper, Nerf & Grab Bars
Parts – Bumper, Nerf & Grab Bars Figure 6 BODY PROTECTION PART # DESCRIPTION REF # FCEX0024 NERF BARS (LEFT & RIGHT) FCEX0067B NERF NET SET (BLACK) FCEX0067R NERF NET SET (RED) FCEX0067Y NERF NET SET (YELLOW) HCBH0808 8MM X 30 HEX HEAD BOLT (FRONT MOUNT, 2 PLACES) NOT SHOWN NOT SHOWN HCBH0809... -
Page 21: Parts - Carburetor
Parts – Carburetor Figure 7 Carburetor accessories REF # PART # DESCRIPTION RAEX0026 CARBURETOR, 26MM MIKUNI VM RCEX0001 CABLE, THROTTLE RCEX0017 JET NEEDLE (5F21) STANDARD RCEX0018 JET NEEDLE (5F3) RCMU0415 CABLE ADJUSTER CAP RCEX0005 ADJUSTER, THROTTLE CABLE RCEX0006 LOCK NUT, THROTTLE CABLE ADJUSTER RCEX0007 GASKET, CARBURETOR BOWL RCEX0008... -
Page 22: 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 23: Parts - Coolant System
Parts – Coolant System Figure 9 Coolant System REF # PART # DESCRIPTION FCEX0066 RADIATOR WITH CAP FCMU0020 RADIATOR CAP ECEX0010 RADIATOR HOSE MCEXGR01 GROMMET, RAD MOUNT (4 REQ’D) MCMUGR04 GROMMET, TOP RAD MOUNT (2 REQ’D) HCBF0620 FLANGE HEAD BOLT M6X20 (2 REQ’D) HCWF1478 WASHER RADIATOR MOUNTING MCMUCL07... -
Page 24: Parts - Electrical System
Parts – Electrical System Figure 10 Electrical System REF # PART # DESCRIPTION ICMU0013 COIL (3 WIRE DIGITAL) ECMU0065 SPARK PLUG, CHAMPION (8339-1) ECMU0067 OPTIONAL HOTTER PLUG (8332-1) ECMU0066 OPTIONAL COLDER PLUG (8904-1) IKEX0001 IGNITION KILL TETHER HCBC0516 SCREW, M5 X 16 (2 PER) HCCN0000 5MM CLIP NUT (2 PER) ICMU0018... -
Page 25: Parts - Engine Clutch
Parts – Engine Clutch Figure 11 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 26: Parts - Engine - Clutch / Kick Cover
Parts – Engine – Clutch / Kick Cover Figure 12 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 ECDC0046 KICKSTARTER LEVER... -
Page 27: Parts - Engine - Ignition Side
ROTOR ICMU0018 STATOR – 3 WIRE ECDC0024 SEAL, CRANKSHAFT ECDC0087 SHIFTER LEVER 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 ECDC0026 SEAL,SHIFTER ICMUGR01 GROMMET-IGNITION EKEX0089 ENGINE CASE SET OF LEFT & RIGHT... -
Page 28: Parts - Engine - Kick Mechanism
Parts - Engine – Kick Mechanism Figure 14 Kick Mechanism REF. # PART # DESCRIPTION EKEX0089 ENGINE CASE SET OF LEFT & RIGHT 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 ECMU0135 SHAFT, KICK START... -
Page 29: Parts - Engine - Shift Mechanism
Parts – Engine – Shift Mechanism Figure 15 Clutch components REF. # PART # DESCRIPTION ECDC0054 SHIFTER SHAFT (2 COMPONENTS) 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 30: Parts - Engine - Top End
Parts – Engine – Top End Figure 16 Engine – Top End REF # PART # DESCRIPTION ECE70001 CYLINDER KIT (INCLUDES PISTON KIT) BASE GASKET 0.015” (0.4mm thick) For other Base Gaskets refer to ZCKG0501 Base Gasket Selection section of this manual ECMU0084 PISTON KIT ECE70003... -
Page 31: Parts - Engine - Transmission
Parts - Engine - Transmission Figure 17 Transmission REF # PART # DESCRIPTION ECE70002 CRANKSHAFT EKEX0001 ROD KIT ACCESSORY ECDC0023 BEARING, CRANKSHAFT EKEX0089 ENGINE CASE SET OF LEFT & RIGHT EKEX0089 ENGINE CASE SET OF LEFT & RIGHT ZCEX0004 GASKET, CRANKCASE CENTER, ‘08 Left Case Screws HCBC0604 6X35MM SOCKET HEAD CAP SCREW (4 REQ’D) -
Page 32: 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 33: 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 34: Parts - Front Brakes
Parts – Front Brakes Figure 20 Front Brakes REF # PART # DESCRIPTION BAEX0004 BRAKE SYSTEM COMPLETE BCEX0024 BANJO BOLT BCEX0025 BRAKE PADS BCEX0029 CRUSH WASHER BCDC0003 MASTER CYLINDER BCEX0026 REPLACEMENT LINE BCEX0027 CALIPER LEFT BCEX0028 CALIPER RIGHT BCEX0020 BRAKE ARM HCBC0825 M8 X 25 SHCS BCEX0021... -
Page 35: 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) See Optional Components section of this manual for other springs SCEX1145 SHOCK SPRING, STANDARD (RED, 145 LB/IN) See Optional Components section of this manual for other springs SCSP0001 TRAVEL LIMITER (1.50”) -
Page 36: 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 WCEX0004L LEFT FRONT WHEEL WITH TIRE WCEX0004R RIGHT FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING HCBC1120... -
Page 37: Parts - Plastic Bodywork & Seat
Parts – Plastic Bodywork & Seat igure 22 Plastic and Bodywork REF # PART # DESCRIPTION TCEX0001Y FRONT CLIP - YELLOW 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 HCBB0625 M6 X 25 BUTTON HEAD (2 REQ’D AT FRONT) -
Page 38: Parts - Rear Brake
Parts – Rear Brake Figure 23 Rear Brake System REF # PART # DESCRIPTION BADC0001 BRAKE COMPLETE BCEX0007 BRAKE PEDAL BCDC0009 BRAKE PIVOT BOLT HCBC0601 M6X16 SOC. HEAD BOLT FCEX0018 BRAKE ADJUST ECCENTRIC BCEX0012 BRAKE RETURN SPRING BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D) BCDC0004 PUSH ROD, REAR BRAKE HCBC0601... -
Page 39: Parts - Rear Drive
Parts – Rear Drive Figure 24 Rear Drive REF # PART # DESCRIPTION GAEX0033 REAR AXLE -SOLID WCEX0003 WHEEL LUG (8 REQ’D) HCNS1001 LUG NUT (8 REQ’D) HCWF0010 LUG WASHER (8 REQ’D) NOT SHOWN GCEX0014 BRAKE/SPROCKET HUB (2 REQ’D) HCBC0625 M6 X 25 HUB PINCH BOLT (2 PER HUB) NOT SHOWN HCBH0808... -
Page 40: Parts - Rear Shock
Parts – Rear Shock Figure 25 Rear Shock REF # PART # DESCRIPTION SAEX2007R SHOCK, REAR QUAD FOX SCEX0175P SPRING, HELPER STANDARD (BLACK, 175LB/IN) See Optional Components section of this manual for other springs SCEX0450P SHOCK SPRING, STANDARD (GREEN, 450 LB/IN) See Optional Components section of this manual for other springs SCSP0003 TRAVEL LIMITER (1.00”) -
Page 41: Parts - Swingarm Assembly
Parts – Swingarm Assembly Figure 26 Swingarm REF # PART # DESCRIPTION GAEX0100 SWINGARM GCMU0030 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 42: Parts - Tie Rod Assembly
Parts – Tie Rod Assembly Figure 27 Tie Rod Assembly REF # PART # DESCRIPTION FAEX0002 TIE ROD MCEXBR02R RH TIE ROD END MCEXBR02L LH TIE ROD END HCNJ120L LH JAM NUT HCNJ120R RH JAM NUT GCEX0002 SPACER, BALL JOINT HCNC0010 10MM CASTLE NUT (2 REQ’D) HCCP0003... -
Page 43: Engine Parts / 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 44: 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 45 • Pull out the wire and measure the solder thickness, approximately 2mm from the end of the tip, accurately with calipers. • Compare your measurement with the chart below and install the recommended base gasket. Measured Solder Required Gasket Cobra Part Number Thickness With Thickness NO GASKET (mm) (inch)
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Page 46: Fuel & Air System
Fuel & Air System 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. • If the reed is damaged in any way, replace it. -
Page 47: 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 48: Exhaust
Tuning Carburetor 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 to current weather conditions, altitude, fuel variations, and/or engine modifications. - Page 49 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...
- 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.
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Page 51: 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 52 Index A-arms .......... 32 Parts ..........31 Air Filter ........17 Fenders .........36 Maintenance......15 Frame Parts ........35 Axle..........38 Front Brake ........33 Bars and Controls ......18 Fuel Base Gasket Selection....43 Petcock........10 Break-In .......... 9 Fuel System Bumper ......... 19 Parts list........45 Carburetion Service........45...
- Page 53 Petcock ......... 10 Steering Stem .......18 Piston..........29 Steering Upright ......32 Plastic ........... 36 Swingarm Parts ......40 Radiator ........22 Throttle ..........17 Rear Brake Tie Rod..........41 Parts.......... 37 Tips ..........11 Rear Drive........38 Toe In Adjustment ......16 Rear Shock Top End Parts..........
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