Cobra CX65 2022 User manual

DISCLAIMER OF WARRANTY
This motorcycle is sold “as is” with all faults, obvious or not. There are no warranties
expressed or implied, including any warranty of merchantability and warranty of fitness for
any particular purpose.
“WARNING”
THE COBRA CX65 IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED
FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS.
THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED
COMPETITION EVENTS UPON A CLOSED COURSE BY A SUFFICIENTLY SKILLED
RIDER AND SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL
RIDING.
IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH.
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.
THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 110 LBS WITH
FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH
MORE THAN THAT.
BE SURE THAT THE RIDER ALWAYS WEARS ADEQUATE SAFETY GEAR
EVERYTIME HE OR SHE RIDES THEIR COBRA MOTORCYCLE.
IMPORTANT SAFETY NOTICE
Failure to follow WARNING instructions could result in severe injury or death to the
machine operator, a bystander, or a person inspecting or repairing the machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the machine.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
MCC62011.2

1
Table of Contents
GENERAL INFORMATION ....................................................................................3
SPECIFICATIONS -GENERAL....................................................................................3
OPTIONAL COMPONENTS........................................................................................4
SPECIFICATIONS -TORQUE VALUES.........................................................................4
BREAK-IN PROCEDURE...........................................................................................5
STARTING PROCEDURE ..........................................................................................6
MAINTENANCE......................................................................................................7
TIPS......................................................................................................................7
SCHEDULE.............................................................................................................7
REPLACING TRANSMISSION /CLUTCH LUBRICANT.....................................................8
CHAIN ADJUSTMENT ...............................................................................................9
AIR FILTER CLEANING ..........................................................................................10
FORK OIL REPLACEMENT......................................................................................11
IGNITION TIMING...................................................................................................12
PARTS..................................................................................................................13
PARTS –AIRBOX &INLET SYSTEM.........................................................................13
PARTS –BARS AND CONTROLS.............................................................................14
PARTS -CARBURETOR .........................................................................................15
PARTS –COOLANT SYSTEM..................................................................................16
PARTS –ELECTRICAL SYSTEM ..............................................................................17
PARTS –ENGINE CLUTCH.....................................................................................18
PARTS –ENGINE –CLUTCH /KICK COVER.............................................................19
PARTS –ENGINE –IGNITION SIDE .........................................................................20
PARTS –ENGINE –KICK MECHANISM ....................................................................21
PARTS –ENGINE –SHIFT MECHANISM...................................................................22
PARTS –ENGINE –TOP END.................................................................................23
PARTS –ENGINE –TRANSMISSION ........................................................................24
PARTS –EXHAUST SYSTEM ..................................................................................25
PARTS –FORKS –LEG ASSEMBLY.........................................................................26
PARTS –FRAME &TRIPLE CLAMPS .......................................................................27
PARTS –FRONT WHEEL .......................................................................................28
PARTS –FRONT BRAKE........................................................................................29
PARTS –BODYWORK............................................................................................30
PARTS –REAR BRAKE..........................................................................................31
PARTS –REAR WHEEL .........................................................................................32
PARTS –SHOCK ..................................................................................................33
PARTS –SHOCK -INSIDE......................................................................................34
PARTS –SWINGARM ASSEMBLY ............................................................................35
SERVICE ..............................................................................................................36
ENGINE SERVICE .................................................................................................36
Base Gasket Selection...................................................................................37
FUEL &AIR SYSTEM.............................................................................................38
CARBURETOR:.....................................................................................................38
TUNING ................................................................................................................42

2
GEARING.............................................................................................................42
SUSPENSION .......................................................................................................43
CARBURETION .....................................................................................................44
TROUBLESHOOTING..........................................................................................47
INDEX...................................................................................................................49

3
General Information
Specifications - General
Items CX65
Dimensions
Wheelbase 40.9” (1040mm)
Wheel size 12” (305mm) rear, 14” (356mm) front
Seat height 29.9” (760mm)
Engine
Type 2-stroke, single cylinder, reed valve
Cooling system Liquid-cooled
Coolant 50/50 antifreeze-coolant / distilled water
Displacement 64.9 cc
Bore and stroke 43.0 mm x 44.7 mm
Ignition system Electronic, digital advance
Spark plug Champion 8339-1, 8332-1 hotter, 8904-1 colder
Gap 0.023” – 0.025” (0.58 – 0.64 mm)
Ignition timing Digital advance (set at “0” timing mark)
Fuel type High octane pump gasoline
Premix Oil type Motul 800 2T
Premix oil ratio after break-in
Motul 800 2T Off Road, 50:1 to 63:1
All other premix oil at 32:1 to 40:1
Carburetion 26 mm VM Mikuni
60Main Jet / Slow (Pilot) Jet 240 / 42.5
Needle 5I 14 - 4
Float Height 21.1 ± 1.0
Transmission 6 speed
Final drive ratio 14/45
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)
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 Compression Low 9 of 19 out, High 8 of 16 out
Rebound 26 of 29 clicks out, Race sag 87mm

4
Optional Components
Call your dealer, or the factory, for details
Carburetor jets
Pre filter for the airbox
Tires, tubes or ‘Tire Balls’
Sprockets
Suspension Springs
Weight of Rider (lb) Fork Spring Shock Spring
less than 70 lb 0.24 kg/mm
KCC60024 42 N/MM (240 lb/in) SCC60240P (white)
75-85 lb 0.26 kg/mm
KCC60026 45 N/MM (260 lb/in) SCC60260PY stock
(y
ellow
)
85-100 lb 0.28 kg/mm
KCC60028 49 N/MM (280 lb/in) SCC60280PG (gold)
Greater than 100 53 N/MM (300 lb/in)
SCEX1300 (red)
Specifications - Torque Values
Fastener Torque Value Size & Remarks
ft-lb in-lb Nm
Cylinder head nuts 12.5 150 17 M7 x 1.0
Crankcase bolts 8.8 105 12 M6 x 1.0
Exhaust Flange 5 60 6 M6x1.0
Spark plug (SP) (SP) (SP) M14 x 1.25
Stator bolts 2.1 25 2.8 M5 X 0.8
Stator cover bolts 1.7 20 2.3 M4 X 0.75
Clutch cover bolts 5.8 70 7.9 M6 X 1.0
Clutch nut 35 420 47 M10 x 1.25*
Front axle bolt 10 120 13.5 M14 x 2.0
Front axle pinch bolt 7.4 88.5 10 M6 X 1.0
Engine mount bolts 22 265 30 M8 X 1.25
Swingarm Pivot 21 250 28 M12 X 1.5
Intake manifold bolts 4.6 55 6.2 M6 X 1.0
Rear Axle Bolt 25 300 34 M14 X 1. 5
Rear Sprocket Bolts 20 240 27 M8 X 1.25
Triple clamp (top) 9 108 12 M6 x 1.0
Triple clamp (bottom) 6 72 8 M6 x 1.0
Fork cap 15 177 20
Fork Damper Nut 11 133 15
Ignition rotor nut 33 400 45 M10 x 1.25*
* Apply high strength thread locking agent when installing
(SP) To apply the proper torque to the spark plug when inserting, one must first
screw the spark plug in until the metal gasket ring causes resistance and then turn
another 1/8 to ¼ turn.

5
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.
Cobra recommends Motul 800 T2 premix oil with high octane
pump gas mixed at 50:1 (50 ml oil to 1.3 gallon of gas, or 38ml oil to 1 gallon of
gas). Other brands of oil should be mixed at 32:1 for break-in.
CAUTION:
Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine
wear or damage to the machine.
Adhering to the following break-in schedule will result in long lasting high
performance machine.
Start bike on stand
First 5 minute period, operate the bike on the stand with a combination of idle
and high RPM operation. (avoid prolonged high RPM but spin the rear wheel
good at least once or twice per minute)
Allow bike to cool
Ride for 15 minutes maximum (avoid prolonged high RPM operation and avoid
abusing the clutch).
Cool and inspect bike for loose fasteners.
Check & retighten wheel spokes
Next ½ hour of operation, avoid prolonged operation at Wide Open Throttle.
After 1 hour of operation
oCheck for loose bolts and nuts on the bike and retighten as necessary
(proper toque values are listed under Specifications).
oClean the carburetor bowl.
oChange the transmission / clutch lubricant.
After 8 hours of operation
oChange the fork oil.
oHave a Certified Cobra Mechanic change the shock oil.
Your bike is now ready for the highest level of competition!
NOTE:
During break-in the bike will likely lose some engine coolant through the radiator
overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level
will cover the top of the radiator cores. Removing the radiator cap and looking
inside is the only way to check the coolant level.
Never open the radiator cap of a machine that has a hot or warm engine or one
that has recently been ridden. Burning and scalding could occur.

6
CAUTION:
It is important that the radiator cap is installed correctly and completely otherwise
engine damage could occur.
Starting Procedure
Before starting the machine inspect the following:
Check for proper tire pressure in both tires.
Observe the chain tension and adjust if necessary.
Observe the coolant level and fill if necessary.
Verify that the chain rollers and sliders do not have improper wear.
Verify that the handlebars are tight.
Check the throttle for smooth operation and sound closing.
Check for loose bolts and nuts, and re-torque as necessary.
Verify that the air filter is clean and properly saturated with oil.
Insure that the fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required. (High octane pump gas with Cobra’s specially
formulated Cobra Venom 2-cycle Race Oil)
Turn the fuel on by rotating the fuel petcock lever to the vertically downward
position.
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.
Always wear a helmet and other protective riding gear.
When your pre-ride inspection is complete the bike may be started. For a cold
engine follow this procedure.
1. Place the motorcycle on a stand of sufficient strength that positions the
motorcycle in a level upright position with the rear wheel off the ground.
2. Engage the choke by pulling out on the choke button until it stops.
3. Kick start the engine.
4. Rev the engine in short spurts, turning the throttle no more than 1/4 open until
the engine will run without the choke.
5. Verify a functional engine shut-off switch by shutting off the engine.
6. Restart the engine and proceed with riding when the engine is sufficiently
warm (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. This may lead
to premature wear of engine components or complete cold seizure of the engine.

7
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.
Tips
1. Cobra lubricants:
a. Use only high quality transmission oil designed specifically for two-
stroke racing engines.
b. Motul 800 2T Off Road oil is the recommended premix oil because:
Its Ester base leaves a film on all parts at all times. No metal
to metal startups or corrosion potential.
Exception film strength over petroleum based oils or synthetic
blends.
Easily atomizes and burns completely.
Does not fall out of suspension from premix in cold weather.
Produces virtually no coking deposits, leaving pistons, rings
and heads extremely clean with minimal pipe ‘spooge’.
2. Fill your transmission only with the recommended amount of oil. Overfilling
may lead to premature seal failure.
3. The cylinder base gasket has been ‘fitted’ for your engine. See the service
section of this manual for instructions how to properly size a base gasket
during an engine rebuild.
4. Evaluate the bikes jetting only after it has been warmed up to race
temperatures.
5. A properly maintained machine is safer, faster, and more fun to ride.
6. New chains will stretch on first use. Never install a new chain prior to a race.
Always ‘break’ them in during practice.
7. Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number).
The first two digits indicate the model and the seventh indicates the model
year (MY).
a. Example, CXxxxx7xxx is a 2007 MY CX65.
Schedule
Between each ride
oCheck the air filter (clean and re-oil as necessary).
oInsure the smooth operation of the throttle cable (throttle soundly ‘clacks’
shut).
oCheck for frayed strands of the throttle cable inside the throttle housing
and replace if necessary.
oCheck for adequate tire pressures and adjust if necessary.
oCheck all nuts and bolts for proper torque and re-torque if necessary.
oSpray all moving parts with WD40 or other water displacing oil.
oCheck drive chain for

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Proper tension and adjust if necessary.
Adequate lubrication and lubricate if necessary.
oInsure that the ignition stator and rotor are clean and dry.
oCheck 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 re-welded as necessary.
oCheck the spokes for tightness and adjust if necessary.
oCheck the rims and hubs for signs of stress, like cracks around the rim,
spokes and hub.
Every 2 hours of operation
oReplace the transmission oil.
oCheck spoke tension
Every 10 hours of operation
oReplace the fork oil.
oHave the shock oil replaced by a Certified Cobra Mechanic.
CAUTION:
If you ever need to weld anything on the bike, disconnect the spark plug cap,
unplug the ignition, disconnect the kill switch, scrape the paint bare near the area
to be welded and put the ground clamp as close to the area to be welded as
possible.
Be sure the fuel tank and carburetor have been removed and safely located away
from the welding process.
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.
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.
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’ but not so hot that there is risk of being burned by the engine or the
oil.

9
Hot oil and hot components on the motorcycle may cause burns.
2. Lean the bike against something or set on stand with oil drain hole.
3. Using a 8mm Allen wrench, remove the oil drain bolt located on the right side of
the engine, on the clutch cover, near the brake lever (See Figure 1).
NOTE: You may need to adjust the brake pedal (up or down) to gain access to the
drain bolt.
4. After it has drained, reinstall the
bolt being sure that the rubber
gasket is in place. Torque to 11
Nm (8 ft-lb).
5. Remove oil fill plug with an 8mm
Allen wrench.
6. Carefully pour 16 oz (470 ml) of
transmission oil into the oil fill
opening.
7. Reinstall the oil fill plug making
sure the rubber gasket is in
place.
NOTE: Filling after an engine rebuild required additional transmission fluid. If the
engine is completely flushed of oil, refill with 18 oz (530ml).
Always capture and dispose of used oil properly (all auto parts stores accept used
oil). Dumping oil on the ground is illegal, inconsiderate, and can get you
disqualified from a race weekend quicker than cutting the track.
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.
2. For proper adjustment, the chain
should have 35 mm free movement
just behind the chain block with no
load on the bike (Figure 2)
CAUTION:
Sit on the bike and verify that the chain
has a minimum of 12mm (1/2”) free
movement when the chain is at its
tightest point.
Figure 1
Figure 2

10
3. If the chain requires adjusting, loosen the axle with a 22mm wrench, and loosen
the jam nut with an 11mm wrench. Tighten the chain by rotating the adjustor
bolts clockwise (CW) or loosen the chain by rotating the adjustor bolts (CCW).
4. Put a rag between the sprocket and
chain, and roll the wheel backward
to pull the chain adjustor blocks
tightly against the adjustor bolts
(Figure 3).
5. Retighten the axle bolt to 25 ft-lb (34
Nm).
6. Retighten the adjustor jam nuts.
CAUTION:
Always check rear brake adjustment
and free-play after adjusting the chain.
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.
4. Clean the filter in a nonflammable solvent to
remove the filter oil.
Do not clean the air filter with gasoline or other
highly volatile petroleum product. Diesel fuel, mineral
spirits, or kerosene would be preferred but caution
should still be taken.
5. Clean the filter in hot soapy water to remove all
dirt particles.
6. Allow it to dry thoroughly.
7. Saturate with filter oil and remove excess.
NOTE: It is very important to keep the air filter clean
and properly oiled with high quality water-resistant
foam filter oil. Apply oil consistently because varied
amounts of oil will affect carburetor jetting. Fi
g
ure 5
Figure 4
Figure 3

11
8. Reinstall the filter assembly by pushing it down and forward into the airbox
making sure the lip of the filter cage is properly seated into its receptacle (figure
5). Reinstall the air filter cap and holding wire.
CAUTION:
Double check to insure that the filter is pushed in tight at the bottom
NOTE: Make sure you change or clean your filter after each moto. We
recommend carrying multiple filters in your toolbox, one for each practice session
and moto.
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. Remove the fork legs from the triple clamps.
3. Perform the following on each fork leg:
a. Remove the fork cap from the fork tube using a 27mm wrench.
b. Lower the fork tube to expose the fork spring.
c. Pull the fork spring down from the fork cap to expose the damper rod lock
nut. Secure this nut using a 19mm wrench.
d. With a 19mm wrench on the damper rod nut, use a 27mm wrench to free
the fork cap from the damper rod.
e. Remove the 19mm wrench and allow the damper rod to fall into the damper
tube.
f. Remove the fork spring and spacer.
g. Invert the fork to allow the oil to drain. Pump the damper rod assembly
several times to help the oil drain.
Assembly
1. Completely collapse the outer fork tube onto the stanchion tube. Add enough
oil to the fork to fill the cartridge tube. Pump the damper rod up and down
slowly to help the assembly fill with oil.
2. Once the cartridge assembly is bled, continue to fill the fork with oil until it is
120mm +/- 2.5mm from the top of the fork.
3. Install the fork spring.
4. Use a flexible retrieving tool to pull the damper rod up through the fork spring.
Pull the fork spring down from the damper rod to expose the damper rod lock
nut. Secure this nut using a 19mm wrench.
5. Install the spacer and fork cap to the damper rod. Ensure that the fork cap is
completely threaded onto the damper rod before it makes contact with the lock
nut. Torque the damper rod lock nut to 15N-m (11ft-lb).

12
6. Install the fork cap to the fork tube. Torque the fork cap to 20Nm (15ft-lb).
7. Pump the fork leg several times to verify that it operates smoothly.
8. Install each leg back into the triple clamp. Torque each pinch bolt to 11N-m (8
ft-lb) making sure both legs are set to the same height in the clamps.
9. Install the front wheel, and torque the axle to 13.5N-m (10 ft-lb).
10. Drop the bike onto the ground, engage the front brake, and push up and down
on the handlebars several time to ensure that the front forks and the front wheel
are properly aligned with each other.
11.Tighten the axle pinch bolts to 10N-m (7.4 ft-lb).
Ignition Timing
The ignition timing value for the CX65 is 0° 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° advanced and retarded. The small timing marks
between 0 & 5° is 2.5°.
To change the timing, one must remove the flywheel with Cobra 65 flywheel puller
# MCMUTL05. After the flywheel has been removed, the timing can be adjusted by
loosening the stator bolts and rotating the stator to the desired position.

13
Parts
Parts – Airbox & Inlet System
Coolant System
REF # PART # DESCRIPTION
1 RCC60007 AIRBOX
2 TCC60008 MUD FLAP
3 HCSP0003 SCREW - PLASCREW
4 MCKGHO03 CLAMP, AIR BOOT TO AIR BOX
5 RCC60002 AIR FILTER
6 RCC60003 AIR FILTER CAGE
7 RCC60004 AIR FILTER WIRE
8 RCC60014 AIR BOOT, CARB TO AIRBOX
9 RCC60006 AIR FILTER CAP
10 ECC60006 REED ASSEMBLY
11 ECC60007 INLET MANIFOLD
12 HCBC0602 M6X20mm SOCKET HEAD CAP SCREW
13 MCC60003 CLAMP, MANIFOLD TO CARB
14 ZCC60021 GASKET REED
15 RCR60026 CARBURETOR 26mm MIKUNI
16 MCMUCL04 HOSE CLAMP 8mm
17 FCMU0026 FUEL LINE
18 ECC60014 REED PETALS - REPLACEMENT

14
Parts – Bars and Controls
Bars and Controls
REF # PART # DESCRIPTION
1 FAMU0011 HANDLEBAR -ALUMINUM
2 TCMU0008 GRIPS (SET OF TWO
3 FCMU0066 THROTTLE ASSEMBLY
4 FCPW0004 CABLE COVER
5 FCMU0021 THROTTLE COVER
6 CCMU0014 MASTER CYLINDER W/LEVER - CLUTCH
7 CCDC0001 CLUTCH LEVER
8 RAC60001 THROTTLE CABLE
9 TKMU0404 BAR MOUNT KIT, SHORT STANDARD
9A TKMU0403 BAR MOUNT KIT, TALL
10 HCBC1002 M10X50mm SOCKET HEAD CAP SCREW (2 REQ’D)
11 HCNL1001 M10 LOCK NUT
12 HCBC0806 M8X30mm SCOCKET HEAD CAP SCREW (4 REQ’D)
13 BCC60009
MASTER CYLINDER ASSY W/LEVER –BRAKE (OBSOLETE –
REPLACED BY BAC60010)
14 BCC60008 BRAKE LEVER (OBSOLETE -MUST PURCHASE BAC60010)
15 FCMU0033 KILL SWITCH ASSEMBLY
ACCESSORY CCMU0135 REBUILD KIT – MASTER CYLINDER - CLUTCH
ACCESSORY BCC60022 BUSHING BRAKE/CLUTCH LEVER PIVOT CX65
ACCESSORY CCMU0004 COVER – RESERVOIR (REPLACEMENT)
ACCESSORY BCC60014 CLAMP – PERCH (REPLACEMENT)
ACCESSORY CCC60001 LINE - CLUTCH (REPLACEMENT)

15
Parts - Carburetor
PILOT JET MAIN JET
30 RCEX0030 190 RCMU0190
32.5 RCEX0032 195 RCMU0195
35 RCEX0035 200 RCMU0200
37.5 RCEX0037 205 RCMU0205
40 RCEX0040 210 RCMU0210
42.5 RCEX0042 215 RCMU0215
220 RCMU0220
225 RCMU0225
230 RCMU0230
235 RCMU0235
240 RCMU0240
250 RCMU1250
260 RCMU1260
270 RCMU1270
280 RCMU1280
290 RCMU1290
300 RCMU1300
310 RCMU1310
Carburetor
REF. # PART # DESCRIPTION
1 RCR60026 CARBURETOR 26MM MIKUNI
2 RCC60017 FLOAT BOWL CHAMBER
3
4 RCMU0271 NEEDLE VALVE & SEAT ASSY
5
6 SEE BELOW MAIN JET
7
9 RCEX0026 NEEDLE JET STOCK 5L14
10 SEE BELOW PILOT JET
11 RCC60013 GASKET, FLOAT BOWL
12
13
15 RCEX0016 SPRING- IDLE ADJUST SCREW
16 RCEX0015 IDLE ADJUST SCREW
17 ZCDCOR01 O’RING BOWL PLUG
18 RCEX0012 FLOAT BOWL SCREW
20
21 RCC60016 SLIDE MASS
22 RCMU0277 CLIP - NEEDLE
23
24 RCEX0005 ADJUSTER
RCMU0415 CABLE ADJUSTER CAP (RUBBER)
25 RCEX0006 LOCK NUT
26
27
31
33
34 RCEX0014 SPRING – AIR ADJUST SCREW

16
Parts – Coolant System
Coolant System
REF # PART # DESCRIPTION
1 FCC60046 RADIATOR W/CAP - CX65
2 FCMU0022 CAP – 1.3 BAR
3 MCMUCL05 HOSE CLAMP 11-20 UNIVERSAL
4 FCKG0214 HOSE - OVERFLOW
5 FCDC0009 RADIATOR LOUVER-CX65
6 HCSP0002 PUSH PIN - PLASTIC
7 HCCN0000 5mm EXTRUDED "U" NUT
8 ECC60063 HOSE RADIATOR UPPER
9 ECC60012 HOSE RADIATOR BOTTOM
10 ECC60013 HOSE TRANSFER – CASES TO CYLINDER
11 MCMUCL07 HOSE CLAMP RADIATOR MEDIUM (4 REQ’D)
12 MCKGHO04 HOSE CLAMP RADIATOR LARGE (1 REQ’D)
13 MCC6GR01 GROMMET RADIATOR (2 REQ’D)
14 HCWF1478 6mm WASHER 22mm OD BLK ZINC (2 REQ’D)
15 HCBF0616 M6X16mm FLANGED HEX-8mm HEAD (2 REQ’D)
16 MCMUCL09 HOSE CLAMP RADIATOR SMALL (1 REQ’D)

17
Parts – Electrical System
Electrical System
REF # PART # DESCRIPTION
1 ICC60004 STATOR DIGITAL 65
2 HCBB0516 M5X16mm BUTTON HEAD (3 REQ’D)
3 HCWF0501 5mm FLAT WASHER (3 REQ’D)
4 ICC60003 ROTOR OUTER STYLE 65
5 HCWF0010 10mm FLAT WASHER
6 HCNS1001 M10mm NUT
7 ICC60006 CDI UNIT 65
8 ICMU0035 MOUNT - CDI
9 ICC60005 COIL DIGITAL 65
10 HCBC0516 M5X16mm SHCS – COIL MOUNTING (2REQ’D)
11 HCSP0002 5mm WASHER – COIL MOUNTING (2 REQ’D)
12 HCCN0000 5mm EXTRUDED "U" NUT – COIL MOUNTING (2 REQ’D)
13 ECMU0033 SPARK PLUG
14 FCMU0033 KILL SWITCH ASSEMBLY
15 ECDC0085 COVER - IGNITION
16 ZCDC0004 GASKET-IGNITION COVER
17 HCBC0402 M4X35mm SHCS – COVER MOUNTING (3 REQ’D)
18 ICMU0012 WOODRUFF KEY (NOT SHOWN)
ACCESSORY ICMU0016 SPARK PLUG CAP 5K

ACCESSORY MCKGGR00 GROMMET WIRE PROTECTION (2 PLACES)

18
Parts – Engine Clutch
Clutch components
REF. # PART # DESCRIPTION
1 ECDC0063 CLUTCH WASHER (2 PLACES)
2 ECDC0064 CLUTCH BUSHING – INNER / STEEL
3 EAEX0003 CLUTCH BASKET ASSEMBLY
4 ECDC0066 CLUTCH 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 M5X25mm SOCKET HEAD CAP SCREW (6 REQ’D)
11 ECDC0030 SPRING WASHER – CLUTCH
12 HCBF1035 M10X35mm FLANGE HEAD BOLT
13 ECDC0019 CLUTCH BEARING SEAT
14 ECDC0018 BEARING, CLUTCH THROW OUT
15 ECC60050 CLUTCH PUSH ROD
16 CKMU0001 CLUTCH KIT INCLUDING- SPRINGS, STEELS AND FIBERS
17 ECDC0167 CLUTCH BUSHING - OUTER / BRONZE (REPLACEMENT)

19
Parts – Engine – Clutch / Kick Cover
Clutch / Kick Cover Components
REF. # PART # DESCRIPTION
1 ECC60045 CLUTCH COVER
2 ZCC60007 GASKET-CLUTCHCOVER
3A HCBC0625 M6X25mm SOCKET HEAD CAP SCREW (6 REQ’D)
3B HCBC0630 M6X30mm SOCKET HEAD CAP SCREW (2 REQ’D)
4 HCFH0616 M6X16mm FLAT HEAD BOLT
5 ECMU0250 WASHER – KICK LEVER
6 ECMU0130 KICKSTARTER LEVER – ALUMINUM
7 ECDC0078 SEAL, KICKSTARTER
8 ZCMUB014 O’RING-OIL FILL PLUG
9 ECMU0168 (B, BL, OR R) OIL FILL PLUG, ALUMINUM (SUFFIX INDICATES COLOR, B – BLACK, BL – BLUE, R – RED)
10 ZCDCOR05 ORING-CLUTCH CAP
11 ECC60053 CLUTCH CAP W/SLAVE CYLINDER
12 CCC60005 PISTON – CLUTCH SLAVE CYLINDER
13 CCC60006 SPRING – SLAVE RETURN
14 ZCMUOR35 O’RING – SLAVE PISTON
15 CCEX0009 BALL, CLUTCH ACTUATOR
16 ECDC0082 SNAP RING-CLUTCH CAP
17 BCMU0018 FITTING – BLEED, CLUTCH LINE
18 ECAX0150 IMPELLER COVER
19 HCBC0601 M6X16mm SOCKET HEAD CAP SCREW
21 ECDC0075 IMPELLER, WATERPUMP
20 HCBC1512 M5X12mm SOCKET HEAD CAP SCREW STAINLESS STEEL
22 ECKG0074 SEAL, WATERPUMP
23 ECMU0218 RETAINING RING, WATER PUMP SEAL
24 CCC60010 LINE – CLUTCH REPLACEMENT
25 BCMU0021 COVER – RUBBER CLUTCH LINE END
26 BCMU0020 FITTING – THREADED CLUTCH LINE END
27 BCMU0017 FERRULE – COMPRESSION FITTING
ACCESSORY EKMU0002 PIVOT SPRING, BALL AND SET SCREW KIT