Cobra 2006 ECX70, Service Manual

Page 1: ...ECX70 Owners Parts Service Tuning...

Page 2: ...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 Motorcy...

Page 3: ...E 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 PRODU...

Page 4: ...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 Parts 16 Parts Air Inlet Sy...

Page 5: ...29 Parts Exhaust System 30 Parts Front A Arms Steering Upright 31 Parts Front Brakes 32 Parts Front Shock 33 Parts Miscellaneous 34 Parts Plastic Bodywork Seat 35 Parts Rear Brake 36 Parts Rear Drive...

Page 6: ...tem Electronic Spark plug Champion 8339 Gap 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...

Page 7: ...0 Spark Plug SP SP SP 14 x 1 25 Crank case half 5 60 6 8 6 x 1 0 Crank case cover 5 60 6 8 6 x 1 0 Flywheel rotor nut 40 480 54 10 x 1 25 G Clutch hub 40 480 54 10 x 1 25 G Units of mm unless otherwi...

Page 8: ...hread locking agent applied to the threads B designates that the application requires the use of medium strength blue thread locking agent applied to the threads Optional Suspension Components Front s...

Page 9: ...sult in premature engine wear or damage to the machine Adhering to the following break in schedule will result in long lasting high performance machine First 5 minute period operate the bike in neutra...

Page 10: ...e fuel petcock knob to the vertically downward position reserve position is horizontally inward CAUTION For best results from your Cobra ATV use only the recommended fuels Testing has shown that most...

Page 11: ...is safer faster and more fun to ride 6 When washing the bike be careful to not directly aim the hose at the air filter area 7 Keep steering stops adjusted so that the wheels do not scrape on the A arm...

Page 12: ...Check the frame for cracks in the metal or cracks in the paint that might indicate that the metal has been stressed beyond it s safe limits Replace or get properly rewelded as necessary Every 2 hours...

Page 13: ...and hot components on the motorcycle may cause burns 2 Lean bike against something or set on stand with oil drain hole 3 Using the 13 mm wrench remove the oil drain bolt located on the right side of...

Page 14: ...hole is all the way forward the chain is as tight as possible and if the pin hole is all the way back the chain is as loose as possible CAUTION Proper chain tension allows no less than 12mm free play...

Page 15: ...but caution should still be taken 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 pr...

Page 16: ...Adjust both wheels so that they have the same amount of toe in 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 c...

Page 17: ...LET BOOT 6 MCMUCL03 HOSE CLAMP BOOT TO REED MANIFOLD NARROW 7 ECDC0094 INLET MANIFOLD WITH REED ASSEMBLY REEDS REMPLACMENT STOCK ECDCRD15 REEDS SOFT 8 HCBC0602 M6 X 20 SOCKET HEAD CAP SCREW 4 REQ D 9...

Page 18: ...PLACEMENT 2 REQ D NOT SHOWN TCMU0403 BAR MOUNT KIT TALL OPTIONAL 2 REQ D 6 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 4 REQ D 7 HCBC1001 M10X45 SOCKET HEAD CAP SCREW 2 REQ D 8 HCNL1001 M10 LOCK NUT 2 REQ...

Page 19: ...8 8MM X 30 HEX HEAD BOLT FRONT MOUNT 2 PLACES NOT SHOWN HCBH0809 8MM X 50 HEX HEAD BOLT REAR MOUNT 2 PLACES NOT SHOWN HCWF0801 8MM FLAT WASHER 2 REQ D NOT SHOWN HCNL0801 8MM LOCKNUT 2 REQ D 2 FAEX0099...

Page 20: ...NUT THROTTLE CABLE ADJUSTER 5 RCEX0007 GASKET CARBURETOR BOWL 6 RCEX0008 PLUG WASHER MAIN JET 7 RCEX0009 SPRING THROTTLE VALVE 8 RCEX0010 E CLIP NEEDLE 9 RCEX0011 NEEDLE VALVE SEAT ASSEMBLY 10 RCEX00...

Page 21: ...CYLINDER 2 CCDC0001 CLUTCH LEVER 3 FCEX0020 CLUTCH LINE 4 CCDC0002 CLUTCH SLAVE CYLINDER 5 ECDC0074 CLUTCH CAP 6 M6 x 16 Bolt 7 ECDC0082 SNAP RING CLUTCH CAP 8 ECDC0020 CLUTCH PUSH ROD 9 ECDC0018 CLU...

Page 22: ...ibbed 3 ECEX0010 RADIATOR HOSE TOP 4 ECEX0011 RADIATOR HOSE BOTTOM 5 MCEXGR01 GROMMET BOTTOM RAD MOUNT 2 REQ D NOT SHOWN FCEX0026 PAD RADIATOR 2 REQ D 6 HCBF0616 FLANGE HEAD BOLT M6X16 2 REQ D 7 ECHA0...

Page 23: ...ICEX0002 TETHER IGNITION SHUT OFF 4 HCBC0516 SCREW M5 X 16 2 PER 5 HCCN0000 5MM CLIP NUT 2 PER 6 ICMU0018 STATOR 3 WIRE ANALOG 7 HCBC0535 5mm x 35 SOCKET HEAD CAP SCREW 2 REQ D 8 HCBC0525 5mm x 25 SO...

Page 24: ...UTCH PRESSURE PLATE 5 ECDC0068 CLUTCH DISC FRICTION 5 REQ D 6 ECDC0067 CLUTCH DISC STEEL 4 REQ D 7 ECDC0069 CLUTCH HUB 8 ECDC0070 SPRING CLUTCH 6 REQ D 9 ECDC0071 PLATE CLUTCH SPRING 10 HCBC0525 5X25...

Page 25: ...DC0078 SEAL KICKSTARTER DC65 9 ZCMU0001 GASKET OIL FILL PLUG 10 ECMU0037 OIL FILL PLUG 11 ZCDCOR05 ORING CLUTCH CAP DC65 13 ECDC0074 CLUTCH CAP DC65 FINISHED 14 ZCDCOR04 ORING CLUTCH SLAVE CYLINDER 15...

Page 26: ...ASHER 9 ICMU0006 ROTOR 10 ICMU0018 STATOR 3 WIRE 11 ECDC0024 SEAL CRANKSHAFT DC65 12 ECDC0087 SHIFTER LEVER DC65 13 HCBH0620 M6 X 20 HEX HEAD BOLT 14 ECKGSR03 SNAP RING OUTPUT COBRA 15 PCKG00xx SPROCK...

Page 27: ...HER KICKSTART BACKUP 6 ECDC0042 SPRING KICKSTART RAMP 7 ECDC0034 SHAFT KICK START 8 ECDC0038 RAMP GEAR KICKSTART 9 ECDC0033 GEAR KICKSTART 10 ECDC0035 SNAP RING EXTERNAL 12MM 11 ECDC0037 SNAP RING EXT...

Page 28: ...HI COLLAR 10 ECDC0057 LEVER NEUTRAL POSITIONING 11 ECDC0058 LEVER DRIVE GEAR POSITIONING 12 ECDC0098 SPRING CHANGE LEVER 13 ECDC0059 BOLT SHOULDER 14 ECDC0056 BEARING RETAINER PLATE 15 ECDC0060 6MM X...

Page 29: ...UOR07 O RING EXHAUST FLANGE 10 ECMU0074 EXHAUST FLANGE NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0602 M6X20 EXHAUST FLANGE SCREW 2 REQ D 12 HCNS0701 7MM Nut 13 HCWS1401 FLAT WASHER HARD...

Page 30: ...R 5 TH PRIMARY 23T 12 ECDC0006 GEAR 2 ND PRIMARY 16T 13 ECKGBR01 BEARING OUTPUT IGNITION SIDE 14 ECDC0007 SHAFT TRANSMISSION OUTPUT 15 ECDC0010 GEAR 2 ND OUTPUT 34T 16 ECDC0017 SHAP RING EXTERNAL 18MM...

Page 31: ...5 MCMUGR07 PIPE GROMMET FEMALE 6 MCMUSP02 PIPE GROMMET SPACER 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D 8 HCBF0635 M6X35 FLANGE HEAD BOLT NOT SHOWN HCNL0601 6MM LOCK NUT FOR FRONT PIPE MOUNT 9 XCDC0003 S...

Page 32: ...FT 4 GAEX0009 A ARM BACK BOTTOM RIGHT GAEX0008 A ARM BACK BOTTOM LEFT 5 HCBC1065 10MM X 65 SOCKET HEAD CAP SCREW BLACK OXIDE 6 MCEXBR05 BUSHING A ARM 7 GCEX0006 SPACER A ARM PIVOT TUBE 8 HCBF1070 10MM...

Page 33: ...13 HCBC0601 6MM X 16 SOCKET HEAD CAP SCREW 3 PER SIDE 14 WCEX0001 FRONT HUB WITH WHEEL STUDS 15 FRONT WHEEL STUD 4 REQ D WITH EACH HUB 16 GCEX0008 WHEEL SPINDLE SAME L R 17 HCNS1400 M14 CASTLE NUT SA...

Page 34: ...ELLOW 155 LB IN SCEXA145 SHOCK SPRING LIGHT RED 145 LB IN SCEXA165 SHOCK SPRING HEAVY BLACK 165 LB IN 4 SCSP0001 TRAVEL LIMITER 1 50 SCSP0002 TRAVEL LIMITER 1 25 SCSP0003 TRAVEL LIMITER 1 00 5 TOP SPR...

Page 35: ...RT 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 HCNL08...

Page 36: ...STIC TO GRAB BAR NOT SHOWN HCNL0601 6MM LOCK NUT 2 REQ D PLASTIC TO GRAB BAR NOT SHOWN HCBB0616 6MM BUTTON HEAD 2 REQ D AT FRONT NOT SHOWN HCWF0601 6MM FLAT WASHER 2 REQ D AT FRONT 3 TCEX0011 SEAT NOT...

Page 37: ...SCREW 14 HCBC0816 M8X16 SOCKET HEAD CAP SCREW 15 HCWF0801 M8 FLAT WASHER SPACER 4 REQ D 16 BCDC0002 CALIPER REAR BRAKE 17 BCDC0007 BRAKE PAD KIT ACCESSORY 18 BCEX0001 REAR BRAKE CARRIER NOT SHOWN WCEX...

Page 38: ...PER HUB 5 HCBH0808 M8 X 30 HEX HEAD BOLTS 4 REQ D 6 HCNL0801 M8 LOCK NUT 4 REQ D 7 PCDC00XX SPROCKET 37T 51T XX DENOTES OF TEETH 9 GCEX0016 BRAKE HUB SPACER 10 HCKW0001 HUB KEY 11 GCEX0024 REAR WHEEL...

Page 39: ...X HEAVY 3 SCEX1375 SHOCK SPRING STANDARD WHITE 375 LB IN SCEX1350 SHOCK SPRING LIGHT RED 350 LB IN SCEX0400 SHOCK SPRING HEAVY YELLOW 400 LB IN 4 SCSP0003 TRAVEL LIMITER 1 00 SCSP0001 TRAVEL LIMITER...

Page 40: ...VOT BOLT M14 X 1 HEX HEAD 5 HCNL1402 SWINGARM LOCK NUT M14 X1 6 GCEX0050 TOP SWINGARM GUARD ECX70 7 HCPP0832 SELF TAPPING SCREW 8 HCBF1040 BOLT SHOCK 9 HCCC0000 BRAKE HOSE CLAMP 2 REQ D 10 HCBH0810 EC...

Page 41: ...ssembly REF PART DESCRIPTION 1 FCEX0015 TIE ROD 2 MCEXBR02R RH TIE ROD END 3 MCEXBR02L LH TIE ROD END 4 HCNJ120L RH JAM NUT 5 HCNJ120R LH JAM NUT 6 GCEX0002 SPACER BALL JOINT 7 HCNC0010 10MM CASTLE NU...

Page 42: ...namometer to ensure that your engine is operating at its highest potential All this for one low nominal fee plus cost of parts Call 330 549 9603 for details ES1 Fuel Air System Reeds CAUTION The reeds...

Page 43: ...el is shut off 2 Remove the carburetor 3 Drain the fuel in the carburetor 4 Disassemble the carburetor CAUTION Do not use compressed air on an assembled carburetor Or the pressure may deform the float...

Page 44: ...eated from exhaust Exhaust has oils in it and the oils cling to the walls of the inside of the pipe Over a long period of time the diameter of the pipe will decrease due to carbon build up So it is es...

Page 45: ...in it e Compression is low i Piston ii Rings f Reeds are damaged g Ignition timing is incorrect 3 Engine is excessively loud a Silencer needs repacking 4 Engine blubbers at high RPMs a Jetting too ric...

Page 46: ...Electrical Parts 23 Engine Parts List 42 Specifications 5 Torque 6 Engine Mount Front 35 Exhaust 44 Parts 31 Fenders 36 Frame Parts 35 Front Brake 33 Fuel Petcock 10 Fuel System Parts list 42 Service...

Page 47: ...ed 5 Specifications 5 Torque Values 6 Spherical Steering Bearing 16 Starting 10 Steering Stem 18 Steering Upright 32 Swingarm Parts 40 Throttle 17 Tie Rod 41 Tips 11 Toe In Adjustment 16 Top End Parts...