Subscribe to Our Youtube Channel
Related Manuals for Cobra 2007 CX65
Summary of Contents for Cobra 2007 CX65
- Page 1 2007 2007 CX65 CX65 2007 2007 CX65 CX65 Owners Owners Owners Owners Parts Parts Parts Parts Service Service Service Service Tuning Tuning Tuning Tuning...
- Page 2 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 3: 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 PARTS .........................14 –... - Page 4 ........................42 EARING .......................43 USPENSION ......................44 ARBURETION TROUBLESHOOTING ....................47 INDEX .........................48...
-
Page 5: General Information
Ignition timing Digital advance (set at TDC) Fuel type High octane pump gasoline Oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In) Carburetion 24 mm VM Mikuni Main Jet 230... -
Page 6: 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 7: 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 Spark plug (SP) (SP) (SP) M14 x 1.25 Stator bolts M5 X 0.8 Stator cover M4 X 0.75 bolts Clutch cover M6 X 1.0... -
Page 8: 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 9: 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 10: 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 11 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 12: Replacing Transmission / Clutch Lubricant
Replacing Transmission / Clutch Lubricant Tools needed: • High quality transmission oil • 8 mm Allen wrench Procedure: 1. 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 is ‘runny’... -
Page 13: 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 14: Air Filter Cleaning
Air Filter Cleaning Tools recommended for air filter maintenance: • 4 mm hex key (Allen) • Foam filter oil Procedure 1. Removed seat with the 4mm 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 15: 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 16: 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 17: Parts - Bars And Controls
Parts – Bars and Controls Bars and Controls REF # PART # DESCRIPTION FAMU0011 HANDLEBAR – ALUMINUM MCMU0001 OPTIONAL CROSS BAR PAD 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... -
Page 18: Parts - Carburetor
Parts - Carburetor Carburetor REF. # PART # DESCRIPTION RCC60001 CARBURETOR 24MM MIKUNI FLOAT BOWL FLOAT ARM PIN NEEDLE VALVE & SEAT ASSY WASHER, NEEDLE VALVE SEE BELOW MAIN JET NEEDLE JET JET NEEDLE SEE BELOW PILOT JET GASKET , FLOAT BOWL FLOATS VENT HOSE SPRING IDLE SCREW... -
Page 19: 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 HCCN0000 5MM EXTRUDED "U" NUT ECC60011 HOSE RADIATOR UPPER ECC60012 HOSE RADIATOR BOTTOM ECC60013... -
Page 20: Parts - Electrical System
Parts – Electrical System Figure 6 Electrical System REF # PART # DESCRIPTION ICC60004 STATOR DIGITAL 07 65 HCBC0501 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 21: 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 22: 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 23: Parts - Engine - Ignition Side
ROTOR PVL OUTER STYLE ICC60004 STATOR PVL DIGITAL 07 65 ECDC0024 SEAL, CRANKSHAFT ECDC0086 SHIFTER LEVER – CX65 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 EAC60002 ENGINE CASE LH W/B&S CX65 07... -
Page 24: Parts - Engine - Kick Mechanism
Parts - Engine – Kick Mechanism Kick Mechanism REF. # PART # DESCRIPTION EAC60003 ENGINE CASE RH W/B&S CX65 07 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 25: Parts - Engine - Shift Mechanism
Parts – Engine – Shift Mechanism Clutch components REF. # PART # DESCRIPTION ECDC0054 SHIFTER SHAFT (2 COMPONENTS) ECDC0055 SPRING, SHIFTER SHAFT ECDC0110 SPACER, CENTERING SPRING ECDC0099 SPRING, CENTERING EADC0152 SHIFT CASSETTE ASSEMBLY ECDC0053 DOWEL – SHIFT DRUM INDEX HCBC1825 8MM X 25 SHCS BLACK OXIDE HCWL0802 8MM LOCKWASHER, HI COLLAR... -
Page 26: Parts - Engine - Top End
Parts – Engine – Top End Engine – Top End REF # PART # DESCRIPTION ECC60017 CYLINDER KIT (INCLUDES PISTON KIT) ZCC60015 BASE GASKET 0.015” ZCC60010 BASE GASKET 0.010” ZCC60030 BASE GASKET 0.030” ECMU0084 PISTON KIT ECEX0005 PISTON RINGS (2 PER SET) SNAP RING FOR PISTON (2 REQ'D) WRIST PIN ECDC0061... -
Page 27: Parts - Engine - Transmission
Parts - Engine - Transmission Transmission REF # PART # DESCRIPTION ECC60001 CRANKSHAFT 07 65 ECDC0023 BEARING, CRANKSHAFT EAC60002 ENGINE CASE LH W/B&S CX65 07 EAC60003 ENGINE CASE RH W/B&S CX65 07 ZCC60001 GASKET CRANKCASE 07 65 Left Case Screws HCBC0604 6X35MM SOCKET HEAD CAP SCREW (4 REQ’D) Right Case Screws... -
Page 28: Parts - Exhaust System
Parts – Exhaust System Exhaust System REF # PART # DESCRIPTION XCC60001 EXPANSION CHAMBER 07 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 29: Parts - Forks - Leg Assembly
Parts – Forks – Leg Assembly Fork Leg Assembly REF # PART # DESCRIPTION KACX6507 FORK SET – 2007 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 30: Parts - Frame & Triple Clamps
Parts – Frame & Triple Clamps Frame REF # PART # DESCRIPTION FAC60002 SUBFRAME CX65 W/ BEARING RACES FACX6507 FRAME WELDED ASSEMBLY 07 65 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 31: Parts - Front Wheel & Brakes
Parts – Front Wheel & Brakes Front Brakes REF# PART # DESCRIPTION WAC6FR01 WHEEL 14” FRONT W BEARINGS (NO TIRE, OR TUBE,) WCDC6014 TIRE-BRDGESTNE-FRT60/100-14M39 WCC6F014 TIRE-DUNLOP WCDCHB01 HUB FOR CX65 – FRONT WCMU1400 14” RIM WCDCTU14 TUBE – 60/100-14 FRONT WCDC0009 RIM LINER 14”... -
Page 32: Parts -Bodywork
Parts –Bodywork Plastic and Seat REF # PART # DESCRIPTION TCC60013 GRAPHIC KIT NOT SHOWN TCC60001 FRONT FENDER HCBF0616 FENDER BOLT, M6X16 FLANGE HEAD (4 REQ’D) NOT SHOWN TCC60002 NUMBER PLATE – FRONT HCBF0612 M6X12 FLANGE HEAD BOLT – FRONT NUMBER PLATE MOUNT NOT SHOWN TCC60003 RADIATOR SHROUDS –... -
Page 33: Parts - Rear Brake
Parts – Rear Brake Rear Brake System REF # PART # DESCRIPTION BAC60001 BRAKE ASSEMBLY REAR FORMULA BCKG0013 CALIPER – REAR BRAKE MASTER CYLINDER – REAR BCKG0012 BCC60005 HOSE – REPLACEMENT BCC60002 CALIPER BRACKET REAR HCBC0601 6X16CS HCBC0606 6X45MM SHCS ZINC PLATED HCBF0620 6X20 FLANGE HEX-8MM HEAD HCCC0005... -
Page 34: Parts - Rear Wheel
Parts – Rear Wheel Rear Wheel REF # PART # DESCRIPTION WAC6RR01 WHEEL 12" REAR W BEARINGS (NO TIRE, TUBE, ROTOR OR SPROCKET) WCDC8012 TIRE-BRDGESTNE-RR-80/100-12M40 WCC6R012 TIRE – DUNLOP WCDCHB02 HUB FOR CX65-REAR WCMU1200 12" RIM WCDCTU12 TUBE-275-80/100-12 REAR WCDC0010 RIM LINER 12"... -
Page 35: Parts - Shock
Parts – Shock Shock REF # PART # DESCRIPTION SAAX2007 SHOCK ABSORBER - CX65 HCBF1040 10X44 ENG FAST FLANGE HEAD HCBC1055 10X55 SHCS BLACK ZINC 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 36: Parts - Swingarm Assembly
Parts – Swingarm Assembly Swingarm REF # PART # DESCRIPTION GACX6507 SWINGARM WELDED ASSY ALUMINUM WCKG0011 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 37: 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 38: 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 39 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 40 Measured Solder Required Gasket Cobra Part Number Thickness With Thickness NO GASKET (mm) (inch) (mm) (inch) With silicone bead Without silicone bead 0.008 0.030” ZCC60130 0.024 0.015” ZCC60115 0.75 0.030” 0.25 0.010” ZCC60110 - Engines may be properly assembled with gaskets thicker than 0.8mm (0.032”) although a slightly different measuring technique will be required that uses base gasket of known thickness at the starting point.
-
Page 41: Fuel & Air System
Tools recommended for carburetor service: • Small flat head screwdriver • WD-40 • 8mm 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 42 Use automotive carburetor cleaner or WD-40 to clean the carburetor inside and out. STOCK CARBURETOR SETTINGS The 2007 CX65 stock carburetor settings from the factory are: • 40 pilot jet • 230 main jet...
-
Page 43: 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 44: Tuning
Tuning Gearing Rear Gear Front Sprocket Sprocket Ratio 3.21 3.23 3.25 3.27 3.29 3.31 3.33 3.33 3.36 3.38 3.40 3.42 3.43 3.46 3.47 3.50 3.50 3.53 3.54 3.57 3.58 3.60 3.62 3.64 3.67 3.67 3.69 3.71 3.75 3.77 3.79 3.83 3.85 3.86 3.92... -
Page 45: S Uspension
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 46: C Arburetion
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 47 The float height is within proper specification (proper measuring technique is described later in this section) NOTE: 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 49 shows...
- Page 48 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 49: 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 50: Index
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 51 Parts ..........31 Jetting Rear Wheel How To ..........39 Parts ..........32 Stock ..........3 Reeds ..........41 Troubleshooting ......44 Rings..........24 Kick Mechanism ........22 shift drum...........25 shift forks ...........25 Lubrication Shift Mechanism ........23 Recommended........3 Shock Parts ..........33 Maintenance Service ...........46 Schedule...........8 Spark Plug Tips ..........8 Recommended........3 Specifications ........3 Starting..........7...
Need help?
Do you have a question about the 2007 CX65 and is the answer not in the manual?
Questions and answers