Cobra 2008 ECX50, Service Manual

Page 1: ......

Page 2: ...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 240 Uran Street Hillsdale Michigan 49242 ...

Page 3: ...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 THIS ATV WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 110 LBS WITH FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE THAT BE SURE THAT THE RIDER ALWAYS ...

Page 4: ...D 15 Front end 16 Parts 17 Parts Air Inlet System 17 Parts Bars and Steering 18 Parts Bumper Nerf Grab Bars 19 Parts Carburetor 20 Parts Coolant System 21 Parts Electrical System 22 Parts Engine Bottom End and Transmission 23 Parts Engine Clutch and Kicker 24 Parts Engine Water Pump 25 Parts Engine Top End 26 Parts Exhaust System 27 Parts Front A Arms Steering Upright 28 Parts Front Brakes 29 Part...

Page 5: ...y 38 Service 39 Engine Service 39 Base Gasket Selection 40 Engine Removal 42 Complete Engine Disassembly Procedure 43 Top End Disassembly Procedure 44 Splitting the Cases 45 Engine assembly 45 Clutch 47 Ignition 52 Cooling System 54 Fuel Air System 58 Exhaust 61 Tuning 62 Gearing 62 Carburetion 63 4 ...

Page 6: ...g advance Spark plug Champion 8339 1 8332 1 hotter 8904 1 colder Gap 0 023 0 025 0 58 0 64 mm Ignition timing 0 040 1 02 mm BTDC Fuel type High octane pump gasoline RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2 cycle Race Oil Fuel oil mix ratios Between 32 1 and 40 1 after engine Break In Carburetion 21 mm Dell Orto PHBG Jet Main Slow Pilot 98 55 Slide Needle 30 W 4 Float Height 16mm 0 5mm...

Page 7: ...s 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 Clutch bolts 12 144 16 M6 x 1 0 CFD nut 55 664 75 x 20 LHT Units of mm unless otherwise specified G denotes the use of wicking bearing retainer green thread locking agent to applied to the mating surfaces of the two components but not the threads SP To apply the prop...

Page 8: ... requires the use of high strength red thread 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 shock springs Weight of Rider lb Helper Main Less than 65 SCEXA145 RED 145 LB IN 65 to 100 SCEX1080 RED 80 LB IN SCEXA155 YELLOW 155 LB IN Greater than 100 SCEX1...

Page 9: ...emature 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 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 the engine to cool Ride for 15 minutes maximum avoiding prolon...

Page 10: ... results from your Cobra Motorcycle use only the recommended fuels Testing has shown that most race fuels actually degrade performance 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 Pull up the choke knob and turn it to lock it 2 Kick start the engine 3 Rev the engine in short spurts ...

Page 11: ... than 8 0 oz 235 cc of lubricant may help to transfer heat from the clutch Filling with more than 12 oz 295 cc will degrade performance 3 The cylinder base gasket has been fitted for your engine The code number stamped into the engine cases will guide you to what thickness base gasket is required during a common top end service See the service section of this manual to correspond a code number wit...

Page 12: ...ded periods of riding it is advisable to remove the ignition cover afterward to allow the ignition to cool off The heat transfers through the cases and can damage the stator as it cools off because of lack of airflow around the stator 2 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 b...

Page 13: ... performance 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 Hot oil and hot components on the motorcycle may cause burns 2 Lean bike against something or set on stand with oil drain hole 3 Re...

Page 14: ...ed to provide superior lubrication and cooling capability over extended periods of time and is the recommended lubricant for your Cobra motorcycle Chain adjustment Tools needed 13 mm wrench or socket 5mm pin Screw driver or hex key will do Procedure 1 Loosen the eccentric housing on the swingarm with two 13mm tools 2 Stick the 5mm pin through the sprocket into the eccentric hole 3 Push the quad fo...

Page 15: ...driver Foam filter oil Procedure 1 Removed the filter from the carburetor 2 Clean the filter with cleaning solvent and then again with hot soapy water 3 Allow it to dry thoroughly 4 Saturate with foam filter oil and remove excess Do not clean the air filter with gasoline or other highly volatile petroleum product Cleaning solvent diesel fuel or kerosene would be preferred but caution should still ...

Page 16: ...alue and a maximum torque value The slip torque of the CFD should be checked every 5 hours of operation Slip Torque Ft lb N m Minimum 55 75 Maximum 92 125 To properly measure the torque at which the CFD Cobra Frictional Drive slips one first access the slip clutch by draining the oil and removing the cover exposing the CFD Next brace the CFD gear from turning with a suitable device Cobra tool EAMU...

Page 17: ... in adjustment between 12mm out to 12mm in This is set by adjusting the length of the tie rod assemblies See figure 3 for direction of turn 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 call them will fall out after the first ride We have found th...

Page 18: ...04 HOSE CLAMP CARB TO MANIFOLD 6 HCBC0625 M6X25 SOCKET HEAD CAP SCREW 7 HCWF0601 6MM FLAT WASHER 8 ECKG0203 INLET MANIFOLD 9 ECKG0202 REED CAGE ASSEMBLY WITH REEDS NOT SHOWN ECKG0205 REED REPLACEMENT KIT 10 ZCMU0132 GASKET REEDS TO ENGINE 11 FCEX0016 THROTTLE QUAD THUMB STYLE 12 FCPW0004 THROTTLE CABLE END GROMMET 13 RCEX0001 CABLE THROTTLE ECX50 14 RCE50001 FUEL LINE 5 INCH 15 FCDC0093 FILTER FUE...

Page 19: ...04 BAR MOUNT KIT SHORT REPLACEMENT 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 D 9 HCWF0801 8MM FLAT WASHER 10 HCBH0810 8MM X 65 HEX HEAD BOLT 2 REQ D 11 HCNL1001 10MM LOCK NUT 12 HCWF0010 10MM FLAT WASHER 13 MCEXBR04 STEM PIVOT BUSHING LOWER 14 MCMU0001...

Page 20: ...67Y NERF NET SET YELLOW NOT SHOWN HCBH0808 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 FRONT BUMPER 3 HCBB0802 M8 X 20 BUTTON HEAD BOLT 4 REQ D 4 FCEX0003 GRAB BAR 5 HCBC0820 M8 X 20 SOCKET HEAD CAP SCREW 4 REQ D 19 ...

Page 21: ...B GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0028 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLIP 17 RCMU0204 CHOKE ASS Y 2001 CM 20 RCMU0009 FUEL MIXTURE SCREW 21 RCMU0011 IDLE ADJUSTMENT SCREW 25 RCMU0103 FLOAT BOWL GASKET 26 RCMU0107 FLOAT NEEDLE 27 RCMU0012 DIFFUSER 28 RCMU0016 FLOAT RETAINER PIN 29 RCMU0108 FLOAT BOWL 30 HCWF0401 WASHER 4MM FLAT 31 RCMU0201 SCREW FLOAT BOWL NOT SHOWN RCCM1301 VELOC...

Page 22: ...0010 RADIATOR HOSE BOTTOM 5 MCEXGR01 GROMMET BOTTOM RAD MOUNT 2 REQ D NOT SHOWN FCEX0026 PAD BOTTOM RADIATOR 2 REQ D 6 HCBF0616 FLANGE HEAD BOLT M6X16 2 REQ D 7 FCMU0049 RADIATOR OVERFLOW HOSE NOT SHOWN MCMUCL05 HOSE CLAMP OVERFLOW HOSE 8 MCMUCL07 HOSE CLAMP 4 REQ D 9 FCEXGR01 GROMMET TOP RAD MOUNT 2 REQ D NOT SHOWN MCMUGR04 GROMMET USED ALONG WITH TOP RAD MOUNT 4 PER 21 ...

Page 23: ... IKEX0001 IGNITION KILL TETHER 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 SOCKET HEAD CAP SCREW 9 HCWF0504 WASHER FOR STATOR 3 REQ D 10 ICMU0006 ROTOR 11 MCKGGR01 GROMMET STATOR LEAD 12 HCNS1001 NUT 10MM NOT SHOWN ICMU0012 WOODRUFF KEY NOT SHOWN ECKG0001 IGNITION COVER NOT SHOWN ...

Page 24: ...9 OUTPUT SHAFT TRANSMISSION WITH GEAR 12 ECMU0100 SECONDARY SHAFT TRANSMISSION WITH GEAR 13 ECMU0001 BEARING TRANMISSION SECONDARY SHAFT 14 ECKG0031 BEARING OUTPUT SHAFT RIGHT SIDE 15 HCBH0612 M6X12 HEX HEAD SCREW BEARING RETAINER 2 PLACES 16 HCWL0601 6MM LOCK WASHER 17 ECMU0020L BEARING TRANSMISSION PRECISION 18 ECKGBR01 BEARING TRANSMISSION OUTPUT SHAFT 19 ZCDCOR01 O RING SPROCKET SPACER 20 ECMU...

Page 25: ... PRESSURE PLATE WITH FRICTION MATL 08 STYLE 13 ECMU0143 FRICTION PAPER CFD 14 ECMU0161 GEAR CFD 08 STYLE 15 ECMU0159 SPRING WASHER CFD 60MM OD 16 ECMU0160 CENTERING WASHER CFD 17 HCNS1202 NUT CFD 20 LEFT HAND THREAD BLUE 18 EAMU0001 KICKSTART GEAR SHAFT 19 ECMU0116 SPRING KICKSTART 20 ZCMUB014 O RING KICK SHAFT 2 REQ D 21 HCWS1622 SHIM KICK SHAFT 22 ECDC0036 SNAP RING KICK SHAFT 23 ECDC0046 KICK L...

Page 26: ...PUMP SHAFT 5 ECKG0073 IMPELLER WATER PUMP 6 ECKG0004 RETAINER WATER PUMP ASSEMBLY 7 HCBC1512 5X12MM SHCS STAINLESS 8 HCWF0501 FLAT WASHER 9 ECKG0175 WATER PUMP PULLEY FAN TYPE DRIVEN 10 ECMU0180 BELT RETAINER 11 HCBS0003 SHOULDER BOLT 6MM 12 ECKG0170 WATER PUMP BELT 13 ECKG0042 WATER PUMP PULLEY CRANK 14 HCNS1001 NUT 10MM 15 HCBC0408 M4mm x 8 SOCKET HEAD black oxide 16 HCWF0401 4MM WASHER 25 ...

Page 27: ...ISTON 2 REQ D 7 ECKG0012 WRIST PIN 8 ECMU0077 BEARING WRIST PIN 9 ZCMUOR07 O RING EXHAUST FLANGE 10 ECMU0086 EXHAUST FLANGE NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0612 M6X12 EXHAUST FLANGE SCREW 2 REQ D 12 HCNS0601 6mm Nut 13 HCWF0601 6MM FLAT WASHER 14 ECKG0530 CYLINDER HEAD OUTER 15 ZCMUOR02 O RING CYLINDER HEAD LARGE 16 ZCMUV024 O RING CYLINDER HEAD SMALL 17 ZCMUOR10 O RING CY...

Page 28: ... 6 MCMUGR07 PIPE GROMMET FEMALE 7 HCWF1478 PIPE GROMMET WASHER NOT SHOWN MCMUGR02 GROMMET KIT 8 FCEX5003 BRACKET PIPE MOUNT 9 HCBF0620 M6 X 20 FLANGE HEAD BOLT 10 XCKG0009 PIPE SILENCER SEAL 11 TCKG0001 SPACER 12 MCMUGR03 GROMMET 13 HCBF0630 M6 X 30 FLANGE HEAD BOLT 14 HCBF0635 M6 X 35 FLANGE HEAD BOLT 15 HCNL0601 6MM LOCKNUT 16 XAMU0001 SILENCER NOT SHOWN XCMU0026 KIT SILENCER REPACKING NOT SHOWN...

Page 29: ...LEFT 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 X 70 FLANGE HEAD BOLT 9 HCNL1001 10MM LOCKNUT 10 GAEX0003 4 UPRIGHT WITH SPINDLE 03 Right 04 Left GCEX0032 GREASE FITTING 11 MCEXCL01 SNAP RING 1 3 8 INTERNAL 12 MCEXBR01 BEARING SPHERICAL 13 HCBC0...

Page 30: ...EW 2 PER SIDE 13 HCBC0601 6MM X 16 SOCKET HEAD CAP SCREW 3 PER SIDE 14 WCEX0001 FRONT HUB WITH WHEEL STUDS 16 GCEX0008 WHEEL SPINDLE SAME L R 17 HCNS1400 M14 CASTLE NUT SAME L R 18 HCCP0002 COTTER PIN SAME L R 19 GCEX0022 INNER HUB SEAL SAME L R NOT SHOWN ECKGBR01 INNER HUB BEARING 20 WCEX0301 INNER HUB BUSHING 21 WCEX0300 CENTER HUB SPACER 22 ECMU0001 OUTER HUB BEARING 23 WCEX0302 OUTER HUB BUSHI...

Page 31: ...LOW 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 SPRING PERCH 6 HCNL1001 10MM LOCK NUT 2 REQ D 7 HCWF0010 10MM FLAT WASHER 8 HCBF1040 10MM X 44 SHOCK BOLT 9 HCBC1002 10MM X 50 SOCKET HEAD CAP SCREW 10 SCKGFX04 PRELOAD RING BOTTOM 11 SCKGFX05 PRELOAD RING...

Page 32: ... REAR WHEEL WITH TIRE 6X8 WCEX0004L LEFT FRONT WHEEL WITH TIRE WCEX0004R RIGHT FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING HCBC1120 M10 X 120 FRONT ENGINE MOUNT BOLT HCWF0010 10MM FLAT WASHER 2 REQ D HCNL1001 10MM LOCK NUT FCEX0039 SPACER ENGINE MOUNT 50CC RIGHT FAE50003 ENGINE MOUNT KIT 31 ...

Page 33: ... 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 TAEX0011 SEAT NOT SHOWN HCBB0635 M6 X 35 BUTTON HEAD 1 REQ D SEAT TO PLASTIC NOT SHOWN MCMUGR04 GROMMET 1 REQ D SEAT TO PLASTIC NOT SHOWN HCWF1478 WASHER FENDER 1 REQ D SEAT TO PLASTIC NOT SHOWN HCNL0601 6MM LOCK NUT 1 REQ D SEAT TO ...

Page 34: ...CKET HEAD CAP SCREW 15 BCEX0014 CALIPER SPACER 2 REQ D 16 BCDC0002 CALIPER REAR BRAKE 17 BCDC0007 BRAKE PAD KIT ORGANIC 17 BCEX0013 BRAKE PAD KIT SINTERED METAL 18 BAEX0006 REAR BRAKE CARRIER FULL ADJUSTABLE NOT SHOWN WCEX0006 SNAP RING BRAKE CARRIER RETAINER 19 GCEX0014 BRAKE SPROCKET HUB 20 BCEX0004 BRAKE ROTOR REAR QUAD NOT SHOWN HCBC0625 6MM X 25 SOCKET HEAD CAP SCREW 2 REQ D 21 HCBB0830 8MM X...

Page 35: ... 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 HUB SPACER 2 REQ D 12 GCEX0011 REAR WHEEL HUB 2 REQ S 13 HCCP0002 COTTER PIN 2 REQ D NOT SHOWN PCMU0104 420 CHAIN 104 LINK 14 HCNC0020 15 MCEXBR03 BEARING REAR AXLE 4 TOTAL 2 PER SIDE 16 GCEX0015 ECCENTRIC UP TO TWO HUB SPACERS CAN BE ...

Page 36: ...G LIGHT WHITE 460 LB IN SCEX1530 SHOCK SPRING HEAVY GREEN 530 LB IN 4 SCKGOH04 SPRING PLATFORM 5 SCKGOH03 BALL JOIINT 6 SCKGOH02 SPACER 7 SCKGOH11 O RING FOR BALL JOINT 8 SCKGOH21 SCREW FOR KNOB 9 SCKGOH22 KNOB FOR ADJUSTMENT 10 SCKGOH05 LOCKNUT 11 HCBH1001 M10 X 40 HEX HEAD BOLT 2 REQ D 12 HCNL1001 10MM LOCKNUT 13 HCWF0010 10MM FLAT WASHER 14 HCBC1040 M10X40 SHCS 35 ...

Page 37: ...5 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 1 50 SCSP0002 TRAVEL LIMITER 1 25 5 SCEX0003 SPRING SEPARATOR 6 HCNL1001 10MM LOCKNUT 7 HCWF0010 10MM FLAT WASHER 8A HCBF1040 10MM X 44 SHOCK BOLT 8B HCBC1040 10MM X40 SHCS 9 SCKGFX04 PRELOAD RING BOTTOM 10 SCKGFX05 PR...

Page 38: ... RIGHT LONG 4 HCBH1421 SWINGARM PIVOT BOLT M14 X 1 HEX HEAD 5 HCNL1402 SWINGARM LOCK NUT M14 X1 6 GCEX0050 TOP SWINGARM GUARD ECX50 7 HCPP0832 SELF TAPPING SCREW 8 HCBF1040 BOLT SHOCK 9 HCCC0000 BRAKE HOSE CLAMP 2 REQ D 10 HCBH0810 ECCENTRIC PINCH BOLT 2 REQ D 11 HCNL0801 8MM LOCK NUT 2 REQ D 12 HCWF0801 8MM FLAT WASHER 4 REQ D 13 PAEX0001 CHAIN GUIDE ASSEMBLY COMPLETE W ALUMINUM PLATE 14 HCBF0620...

Page 39: ...embly REF PART DESCRIPTION 1 FAEX0002 TIE ROD 2 MCEXBR02R RH TIE ROD END 3 MCEXBR02L LH TIE ROD END 4 HCNJ120L LH JAM NUT 5 HCNJ120R RH JAM NUT 6 GCEX0002 SPACER BALL JOINT 7 HCNC0010 10MM CASTLE NUT 2 REQ D 8 HCCP0003 COTTERPIN 3 32 X 2 REQ D 38 ...

Page 40: ...lish the most accurate reading possible Because of the geometry of the spark plug used in this Cobra Motorcycle the adapter used with your compression tester must have a similar volume protruding into the combustion chamber to establish an accurate value Length of hose on the compression tester will affect the reading The shorter the hose length the more accurate your reading will be Because of th...

Page 41: ...ch or too little clearance Since parts like the crank connecting rod cylinder head piston and crankcases all have varying tolerances Cobra offers several different base gasket thickness to ensure that you can always set the squish clearance of your engine to factory specifications For base gasket replacement use the code see figure 21 for location along with the table on the following page reorder...

Page 42: ...e incorrect measurement Hold the wire at this position and turn the crankshaft by the flywheel nut clockwise counter clockwise can loosen the flywheel nut one revolution to smush the solder wire 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 M...

Page 43: ...0705 6 0 6 0 024 ZCMU0706 7 0 7 0 028 ZCMU0707 8 0 8 0 031 ZCMU0708 ZCMU0012 9 0 9 0 035 ZCMU0709 ZCMU0015 1 1 0 0 039 ZCMU0710 ZCMU0016 Tolerances will affect the actual gasket thicknesses Engine Removal To service the bottom end and transmission the engine must be removed from the frame Tools required 10 11 13 22 mm wrench 8 10 14 17 19 mm sockets 3 4 5 mm hex key Allen wrench 7 mm nut driver fl...

Page 44: ...t holding the one side of the swingarm to the frame 10 Remove the engine from the right side of the frame NOTE If you are merely performing a top end service skip ahead to Top End Disassembly Procedure Complete Engine Disassembly Procedure 1 Remove the magneto cover 4mm hex key 2 Remove the bolt from the water pump shaft 4mm and slide off the belt cover and the water pump belt 3 Using a flywheel h...

Page 45: ...issing chunks or indentations indicate broken hardware or ingested items replace the cylinder head 4 Remove the cylinder Muratic acid can be dangerous Follow the manufacturers instructions closely 5 Remove the piston clip with a scribe 6 Remove the piston pin with a piston pin remover INSPECTION NOTE Inspect the piston for abrasions and deposits on the top and sides and clean or replace as necessa...

Page 46: ...he needle bearing casing didn t oblong the bearing hole in the case Needle bearings should be replaced every couple months of hard racing Engine assembly CAUTION For any seals that are to be installed apply a light amount of grease to the seals ID assembly lube on all bearings and a small amount of Loctite to the OD 1 Press the three bearings into the respective holes in each case half 2 Press in ...

Page 47: ...ing rod bearing 12 Install the piston rings CAUTION Ring end gap should be no less than 0 25 mm 0 010 and no more than 0 64mm 0 025 13 Install the base gasket 14 Install the cylinder being sure that the piston rings are properly aligned with the indexing pins CAUTION Never force the cylinder If resistance is felt determine the problem and solve it Once installed slightly rotate the cylinder back a...

Page 48: ...ch Installation section in this manual 26 Install the coolant drain plug with copper washer 11 ft lb 15 Nm 27 Make sure that the exhaust spacer is on the cylinder 53 in lb 6 Nm 28 Install the spark plug with a fresh gasket 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 tur...

Page 49: ...ve the center shoulder bolt out of each clutch shoe You will probably have to heat the center hub again to remove the bolts Once you get a bolt loosened carefully remove it with the shoe and observe the way the spring washers are stacked Clean the washers and bolt if you intend to reuse The spring stacks in your 2006 Cobra clutch will contain 11 individual springs and a flat washer configured as a...

Page 50: ...ch engagement tuning Increasing the flat washer s thickness increases the engine speed for clutch engagement thus increasing the abruptness of clutch engagement harder hit Conversely decreasing the flat washer s thickness decreases the engine speed for clutch engagement thus decreasing the abruptness of clutch engagement softer hit Part Thickness mm inch HKCSM015 1 5 0 060 HKCSM012 1 2 0 047 HKCSM...

Page 51: ... rider is blipping the throttle This makes the clutch and clutch springs wear out quicker This also makes your engine tend to run hotter which decreases engine power and degrades ignition stator efficiency It is important to train your rider NOT to be a throttle blipper CAUTION Sludge build up between the spring washers also keeps the clutch shoe from engaging fully and this will cause the clutch ...

Page 52: ...old thread locking material 3 Apply high strength red thread lock material to the stack bolt and tighten to 12 ft lb 16 N m CAUTION Avoid allowing excess thread lock material to contact the spring washers and the clutch or the clutch is likely to malfunction 4 Use fine emery paper on the center hole of the clutch and on the tapered section of the crankshaft 5 Apply a small amount of wicking bearin...

Page 53: ...t 5 8 ft lb 7 8 Nm INSPECTION NOTE a There must be in out play in installed clutch 0 4mm to 1 0 mm 0 015 to 0 040 b Excess in out will cause early crank seal failure c A blue clutch drum is worn out from excessive slippage or improper lubrication NOTE To ensure proper engagement of the kick gear with the starter nut tighten the six screws only to the point of being not extremely loose Using one ha...

Page 54: ...If the engine is hot it would be helpful to take the ignition cover off to allow cooling The proper ignition timing for this model of is at 0 040 before Top Dead Center that means 0 040 before the piston reaches the highest point of it s travel in the cylinder CAUTION Advancing the ignition timing will cause the engine to run hotter in turn causing power loss shortened clutch life and possibly lea...

Page 55: ...e inside of the rotor and on tapered part of crankshaft CAUTION It is recommended that you apply the proper thread locking primer to the components that are to receive thread locking material per the manufacturers instructions 2 Eyeball the lines on the rotor and stator then press the rotor onto the crankshaft firmly figure 35 3 Torque the nut on the rotor to 40 ft lb 54 Nm with high strength red ...

Page 56: ...ducing cylinder head temperatures Radiator fluid removal 1 Remove the coolant drain plug A on the front of the engine case figure 37 Figure 37 A To remove radiator cap 1 Turn the cap counter clockwise to the first stop and wait there for a few seconds 2 Push the cap down and turn it further in the same direction and remove the cap NOTE Inspect the old coolant for visual evidence of corrosion and a...

Page 57: ...ck a 3mm hex key in the water pump shaft cross hole and remove belt retainer screw using a 4mm hex key Figure 41 item 1 10 Remove belt retainer water pump belt and water pump fan pulley 11 Remove bearing retainer screw using a 3mm hex key Figure 38 item 2 Figure 38 12 Heat engine case around area of impeller lightly with a small propane torch Using a 3 8 diameter x 8 long steel rod tap impeller as...

Page 58: ...be per figure 41 Figure 41 16 Re assemble in reverse order of disassembly CAUTION Clean all threads and use blue medium strength thread locker on the belt retainer screw NOTE Apply Ultra black Hi Temp RTV silicon or Teflon pipe sealant to the tapered pipe threads of the coolant fitting before assembly NOTE Refill the coolant system with Liquid Performance Propylene Glycol based Mini Coolant Antifr...

Page 59: ...LE ADJUSTMENT SCREW 25 RCMU0103 FLOAT BOWL GASKET 26 RCMU0107 FLOAT NEEDLE 27 RCMU0012 DIFFUSER 28 RCMU0016 FLOAT RETAINER PIN 29 RCMU0106 FLOAT BOWL 30 31 RCMU0201 BOTTOM FLOAT SCREW 33 RCMU0269 VELOCITY STACK WD 40 8mm socket Figure 42 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 f...

Page 60: ...lightly rich as opposed to slightly lean This is because an overly rich engine will just run poorly while an overly lean engine will seize potentially causing an expensive top end rebuild and a DNF To richen the carburetor 1 Change the main jet one number at a time larger 2 Lower the needle clip raising the jet needle one notch at a time until the engine starts to blubber on the top end then move ...

Page 61: ... the carburetor 4 Disassemble the carburetor 5 Immerse all the metal parts in a carburetor cleaning solution 6 After the parts are cleaned dry them with compressed air 7 Blow out the fuel passages with compressed air 8 Assemble the carburetor 9 Install the carburetor onto the motorcycle CAUTION 1 The motorcycle will only operate properly if the carburetor top is installed properly with the mountin...

Page 62: ...igure 44 The presence of light indicates that the reeds should be replaced or possibly turned over Exhaust The pipe is a crucial element to a motorcycle Any kinks dents or damage done to the pipe will result in a major performance loss NOTE Be sure to take the pipe off and any carbon that may be built up Carbon build up is created from exhaust Exhaust has oils in it and the oils cling to the walls...

Page 63: ...improper gearing Poor performance Not enough top end speed No snap Over heat clutch Premature failure of engine seals bearings electronics High clutch wear Condition Gear Taller Gear Lower Mud Sand Hills Hard Pack Throttle Blipper novice It may be helpful to set up the clutch to hit early for smooth power delivery 62 ...

Page 64: ... 2 80 13 37 2 85 14 40 2 86 13 38 2 92 14 41 2 93 13 39 3 00 14 42 3 00 13 40 3 08 13 41 3 15 13 42 3 23 Ratio Write Cobra R D 2004 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 CAUTION P...

Page 65: ... jetting a properly jetted machine will produce a spark plug that is dry and light tan in color Environmental and altitude related mixture adjustments Condition Mixture will be Required adjustment Cold air Leaner Richer Warm air Richer Leaner Dry air Leaner Richer Very humid air Richer Leaner Low altitude Standard None High altitude Richer Leaner Low barometric pressure Richer Leaner High barometr...

Page 66: ...s on the side of the carburetor and is unique with its knurled head for easy fingertip adjustment To raise the idle turn the screw in clockwise in 1 4 turn increments and rev the engine after each adjustment To lower the idle turn the screw counter clockwise TOP END JETTING Adjust for clean full throttle acceleration Jet your top end main jet based on the acceleration of your Cobra Motorcycle on t...

Page 67: ... 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 rich 5 Engine won t start a Fuel i None in tank ii Is sour or bad 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 gro...

Page 68: ...tch Lubricant Replacing 12 Compression test 39 Cooling System 54 Cylinder head torque 6 Eccentric 34 Electrical Parts 22 Engine Specifications 5 Engine Mount Front 31 Exhaust 61 Parts 27 Fenders 32 Frame Parts 31 Frictional Drive 15 Front Brake 29 Fuel System Parts list 58 Service 58 Gas Tank 32 Grab Bar 19 Hardware Frame 31 Plastic 32 Ignition Parts 25 Service 52 Timing 53 Jetting How To 58 Stock...

Page 69: ...rts 35 Service 65 Shock 30 Slip Clutch 15 Spark Plug Recommended 5 Specifications 5 Torque Values 6 Spherical Steering Bearing 16 Starting 9 Stator torque 6 Steering Stem 18 Steering Upright 28 Suspension 65 Swingarm Parts 37 Throttle 17 Tie Rod 38 Toe In Adjustment 16 Top End Parts 26 Service 39 Torque Chassis 7 Transmission Specifications 5 Transmission Lubricant Replacing 12 Troubleshooting Gen...