Cobra CX50FWE, Manual

Page 1: ...ED 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 80 LBS WITH FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE THAN THAT BE SURE THAT THE RIDER AL...

Page 2: ...eeding 15 Fork Oil Replacement 16 FRICTIONAL DRIVE V3 CFD 17 PARTS AIRBOX INLET SYSTEM 19 PARTS BARS AND CONTROLS 20 PARTS CARBURETOR 21 PARTS COOLANT SYSTEM 22 PARTS ELECTRICAL SYSTEM 23 PARTS ENGINE BOTTOM END AND TRANSMISSION 24 PARTS ENGINE CLUTCH AND KICK LEVER 26 PARTS ENGINE WATER PUMP 28 PARTS ENGINE TOP END 29 PARTS EXHAUST SYSTEM 30 PARTS FORKS TRIPLE CLAMPS 32 PARTS FORKS LEG ASSEMBLY B...

Page 3: ...isassembly Procedure 52 Splitting the Cases 53 Engine assembly 54 CLUTCH 55 CLUTCH ASSEMBLY 59 IGNITION 60 COOLING SYSTEM 61 FUEL AIR SYSTEM 63 Carburetor 63 Reeds 65 EXHAUST 65 REAR WHEEL PULLERS 65 BRAKES 66 FRONT FORKS 66 REAR SHOCK 66 TUNING 67 CLUTCH 67 GEARING 69 SUSPENSION 71 Adjustment 71 Front Fork Operation 72 Fork Damping Adjustments 72 Rear Shock Adjustments 73 CARBURETION 74 TROUBLESH...

Page 4: ...ter break in 40 1 to 50 1 Carburetion 19 mm Dell Orto Slow Pilot Jet Main Jet 55 93 Needle W7 2 Needle Clip Position 2nd slot from top of needle Float Height 16mm 0 5mm 0 63 0 020 Transmission Speed Single Final drive ratio 15 38 T Chain 100 links 420 Transmission clutch oil type Cobra Venom 3 Shoe Clutch Milk Quantity 300ml 10oz Chassis Front tire 2 50 60 100 12 Pressure 16 psi minimum Rear tire ...

Page 5: ...olts 5 8 70 7 9 M6 X 1 0 Clutch nut 40 480 54 263 M10 x 1 25 Clutch bolts 12 144 16 263 M6 x 1 0 Engine mount bolts 22 265 30 M8 X 1 25 Swingarm pivot 21 250 28 M14 X 2 0 Shock bolt 35 420 47 243 M10 x 1 5 Water pump impeller 6 75 8 243 M5 x 0 8 Water pump pulley 10 124 14 243 M6 x 1 0 Intake manifold bolts 4 6 55 6 2 M6 X 1 0 Axle nuts 25 300 34 M12 X 1 25 Rear sprocket bolts 16 195 22 243 7 mm R...

Page 6: ...ximum avoid prolonged high RPM operation and avoid abusing the clutch with throttle blipping Cool and inspect bike for loose fasteners Next hour of operation avoid prolonged operation at Wide Open Throttle After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary proper toque values are listed under Specifications o Clean the carburetor bowl o Change the tra...

Page 7: ... rear wheel off the ground 2 Pull up the choke knob and turn it to lock it 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 cylinde...

Page 8: ...r Produces virtually no coking deposits leaving pistons rings and heads extremely clean with minimal pipe spooge 2 Filling your transmission with more than 8 0 oz 235 cc of lubricant may help to transfer heat from the clutch Filling with more than 12 oz 350 cc will degrade performance 3 The cylinder base gasket has been fitted for your engine The code number stamped into the engine cases will guid...

Page 9: ...fter each ride If the clutch is engaging properly DO NOT feel the need to take the clutch apart to measure the spring stack clean the stack replace the springs etc Cobra has worked very hard to make a clutch that is low maintenance and so only take it apart if it NEEDS to be maintained Schedule Prior to each ride o Check the air filter clean and re oil as necessary o Insure the smooth operation of...

Page 10: ...nny 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 Remove the oil drain plug located on the right side of the engine on the clutch cover near the brake lever figure 1 3 After it has drained reinstall the plug being sure that the gasket is in place 4 Reapply oil from oil fill plug 300 cc 10 oz Cobra Venom 3 S...

Page 11: ...l is aligned properly 2 For proper adjustment the chain should have 35 mm 1 3 8 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 it s tightest point 3 If the chain requires adjusting loosen the axle with a 19 mm wrench and tighten the chain by rotating the adjus...

Page 12: ... is required so that the brake pads do not drag on the rotor 1 MINIMUM Make sure that the free play locking clip is installed such that one must push forward toward the front of the bike to remove Otherwise the clip is apt to come undone while riding To adjust see figure 2b 1 Loosen the lock nut 10mm 2 Undo the free play locking clip from around the brake adjustor plunger with your hand by pushing...

Page 13: ...l engage the brake lever pedal and hold it there as if engaging the brakes While doing this pull on the plunger of the syringe Doing this will cause a vacuum in the system The vacuum will swell the air bubbles which assist in them moving throughout the system Continue pulling a vacuum and release the brake lever pedal careful not to allow the reservoir to become empty Once again engage the brakes ...

Page 14: ...atile petroleum product Diesel fuel or kerosene would be preferred but caution should still be taken Hot soapy water works well 1 Clean the filter in hot soapy water to remove all dirt particles 2 Allow it to dry thoroughly 3 Saturate with filter oil and remove excess NOTE It s very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jettin...

Page 15: ... recommends that a professional service technician conduct all internal maintenance other than changing springs and oil This will help to ensure safe and consistent operation For routine maintenance the chart below provides suggested service intervals for common procedures Each Ride 10 hours 20 hours As Needed Bleed excess air X Change Oil X Change Seal Swiper X Change Bushings X Fork Air Bleeding...

Page 16: ...rench c Holding in one hand the 9 16 wrench use the fork cap wrench to unscrew the fork cap from the damper rod d Remove the fork spring pad and fork spring e Inside the damper rod the rebound adjustment screw pin is resting and will fall out of the damper rod when the fork is inverted Try to catch it before it falls into your oil bucket f Invert the fork and allow the oil to drain completely Work...

Page 17: ...eration after break in The slip torque value should be above 80 ft lb 108 Nm measured at the sprocket with the following process To properly measure the minimum torque at which the CFD Cobra Frictional Drive slips 1 Remove the oil fill plug and install the check tool pin MCMUTL40 2 Make sure that it is threaded in completely until it bottoms out 3 Install the Sprocket Socket CFD torque checking to...

Page 18: ...iversal puller MCMUTL70 If it slips below the value the CFD must be readjusted as per described in the service section of this manual NOTE If the bike makes a whir whir whir sound coming from the clutch side engine cover it is very probable that the CFD has slipped enough that the brass bushing has worn sufficiently to let the gear operate off center Time to install a CFD refresh kit EKMU33 ...

Page 19: ...FLAP 6 MCKGHO03 HOSE CLAMP AIRBOX TO BOOT 7 RCKG0505 AIR BOOT 8 MCKGHO01 HOSE CLAMP BOOT TO CARB 9 MCKGHO04 HOSE CLAMP CARB TO MANIFOLD 10 RCMU0036 INLET MANIFOLD 2016 5 11 ECMU0246 REED CAGE ASSEMBLY WITH REEDS VFORCE 12 ZCCS0001 GASKET REEDS TO ENGINE 13 HCBC0603 M6X30mm SOCKET HEAD CAP SCREW 14 HCWF0601 6mm FLAT WASHER 15 RCCM1301 VELOCITY STACK SCREWS ONTO CARB 16 ECCS0030 REED REPLACEMENT KIT...

Page 20: ...LY 3C FCMU0041 STOP RING MICRO BAR THROTTLE 4 FCPW0004 CABLE COVER 5 FCMU0021 THROTTLE COVER 6 FCMU0019 THROTTLE CABLE 6A HCNJ0801 NUT 8MM JAM 7 BAKG0003 BRAKE ASSEMBLY FRONT 8 FCMU0033 KILL SWITCH ASSEMBLY 9 HCBC0806 M8X30mm SOCKET HEAD CAP SCREW 4 REQ D 10 HCBC1001 M10X45mm SOCKET HEAD CAP SCREW 2 REQ D 11 TKMU0404BLK BAR MOUNT KIT SHORT 1 REQ D STANDARD 11A TKMU0403 BAR MOUNT KIT TALL 1 REQ D 1...

Page 21: ...U0009 FUEL MIXTURE SCREW 16 14 RCMU0011 IDLE ADJUSTMENT SCREW 18 15 RCMU0201 SCREW FLOAT BOWL 20 RCMU00xx PILOT JET xx denotes size 22 RCMU0262 ATOMIZER 2 62 AU STANDARD 23 RCMU0107 FLOAT NEEDLE 24 RCMU0012 DIFFUSER 20 25 RCMU0016 FLOAT RETAINER PIN 26 RCMU0301 FLOAT 7 27 RCMU0103 FLOAT BOWL GASKET 28 RCMU0043 FLOAT BOWL W THREADED HOLE 29 RCMU00xx MAIN JET xx denotes size 30 RCMU0044 MAIN JET EXT...

Page 22: ... 5A MCMUGR03 GROMMET RADIATOR MOUNTING TOP THICK ONE 5B MCC6GR01 GROMMET RADIATOR MOUNTING BOTTOM ONE 6 HCBF0616 M6X16mm FLANGE HEAD BOLT 2 REQ D 7 HCWF1478 FLAT WASHER 2 REQ D 8 MCMUCL07 HOSE CLAMP 4 REQ D 9 FCKG0214 RADIATOR OVERFLOW HOSE 22 10 MCMUCL05 HOSE CLAMP FOR OVERFLOW HOSE 11 FCCS0043 LOUVER 12 HCPP0001 PUSH PIN REMOVABLE 13 HCCN0000 5mm CLIP NUT TOOL MCMUTL16 TOOL RAD CAP REMOVAL ...

Page 23: ... HCCN0000 5mm CLIP NUT 2 REQ D 7 ICMU0023 STATOR WITH GROMMET 8 HCBC0535 M5X35mm SOCKET HEAD CAP SCREW 2 REQ D 9 HCBC0525 M5X25mm SOCKET HEAD CAP SCREW 10 HCWF0601 6MM FLAT WASHER FOR STATOR 3 REQ D 11 ICMU0042 ROTOR FEW 2016 5 12 EKMU0035 KIT PULLEYS SPACER BELT RETAINER FWE 2016 5 13 HCNS1001 NUT M10 14 ECC60166 IGNITION COVER 16 HCBC0401 M4X25mm SOCKET HEAD CAP SCREW 3 REQ D NOT SHOWN ICMU0012 ...

Page 24: ...24 Parts Engine Bottom End and Transmission ...

Page 25: ...31 BEARING TRANSMISSION SHAFT 1 EACH CASE HALF 13 HCBB0612 M6X12mm BUTTON HEAD SCREW BEARING RETAINER 2 REQ D 14 ECKGBR01 BEARING TRANSMISSION OUTPUT SHAFT 15 ECMU0236 SEAL OUTPUT SHAFT 2016 5 16 ECMU0237 SNAP RING OUTPUT BEARING 17 ECKGSR03 SNAP RING SPROCKET 2 REQ D 18 PCKG0015 SPROCKET 15 T STANDARD 13 14 16 available 19A ECMU0176 SHIM SPROCKET 2MM THICK 19B ECMU0177 SHIM SPROCKET 3MM THICK 19C...

Page 26: ...26 Parts Engine Clutch and Kick Lever ...

Page 27: ...2 REQ D 18 ECMU0249 FRICTION MATERIAL V3 CFDTHICK 2 REQ D 19 ECMU0301 GEAR V3 CFD 20 ECMU0305 BUSHING V3 CFD 7mm 21 ECMU0272BLK OIL FILL PLUG 1026 5 BLK 22 ZCMUB014 O RING OIL FILL PLUG 23 HCFH0616 M6X16mm FLANGE HEAD BOLT 24 ECMU0250 WASHER KICK LEVER MOUNTING 25 EAMU0011 KICK LEVER 26 ECDC0078 SEAL KICKSHAFT 28 HCBC0608 M6X55mm SHCS 2 REQ D 29 EAMU0018 CLUTCH COVER ASSEMBLY WITH SEAL AND PIN 201...

Page 28: ... SEAL WATER PUMP SHAFT 5 ECKG0073 IMPELLER WATER PUMP ALUMINUM 6 HCBB0512 M5X12mm BUTTON HEAD 7 ECMU0167 BEARING WATER PUMP BIG 8 EKMU0035 KIT PULLEYS SPACER BELT RETAINER FWE 2016 5 9 HCBS0009 SHOULDER BOLT 10 ECKG0170 WATER PUMP BELT 11 HCBC0408 M4X8mm SOCKET HEAD CAP SCREW 2 PLACES 12 HCWF0401 4MM FLAT WASHER 13 ECMU0274 COVER WATER PUMP 14 HCBC0412 M4 X 12 SHCS 2 REQ D ...

Page 29: ...RINGS 2 PER SET 6 ECMUSR00 SNAP RING FOR PISTON 2 REQ D 7 ECKG0012 WRIST PIN 8 ZCMUOR07 O RING EXHAUST FLANGE 9 ECMU0262 EXHAUST FLANGE 10 ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0612 M6X12 EXHAUST FLANGE SCREW 2 REQ D 12 HCNF0601 6MM FLANGE NUT 5 REQ D 13 ECC60149 CYLINDER HEAD OUTER 14 ZCC60009 O RING CYLINDER HEAD LARGE 15 ZCMUOR23 O RING CYLINDER HEAD SMALL 16 ECMU0279 CYLINDER HEAD INS...

Page 30: ...HAUST 2 REQ D 4 XCMU0033 ISOLATION MOUNT 5 HCBF0616 M6X16mm FLANGE HEAD BOLT 2 REQ D 6 HCHA0003 6mm CLIP NUT FOR FRONT PIPE MOUNT 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D 8 XCMU0032 SILENCER 9 XCC60017 PIPE SILENCER SEAL 10 MCMUGR03 MOUNTING GROMMET 2 REQ D 11 TCKG0001 SPACER 2 REQ D 12 HCBF0630 M6X30mm FLANGE HEAD BOLT 2 REQ D ACCESSORY XCMU0026 SILENCER PACKING KIT ...

Page 31: ...31 This Page Intentionally Left Blank ...

Page 32: ...32 Parts Forks Triple Clamps ...

Page 33: ...CREW 4 REQ D 13 TKMU0404BLK BAR MOUNT KIT SHORT 1 REQ D STANDARD BLK 13A TKMU0403 BAR MOUNT KIT TALL 14 HCBC1001 M10X45mm SOCKET HEAD CAP SCREW 2 REQ D 15 HCNL1001 M10 LOCK NUT 16 FCMU1103 DUST COVER 1 REQ D 17 ZCMUOR35 O RING 2 REQ D 18A FCMU0038 SPACER TOP 18B FCMU0037 SPACER BOTTOM 19 FCMU0039 SEAL 2 REQ D 20 FCMU0004 STEERING HEAD BEARING 2 REQ D 21 HCBC0603 M6X30mm SOCKET HEAD CAP SCREW 4 REQ...

Page 34: ...34 Parts Forks Leg Assembly Brake Side ...

Page 35: ...2mm 14 KCCS3227 HEAVY SPRING FORK 0 257KG MM 32mm 15 HCNJ3824 NUT JAM 3 8 24 CLASS 8 16 KCC60068 RING CLIP FORK SPRING GUIDE RETAINER 17 KAC60003 DAMPER ROD ASSEMBLY 18 KCC60058 O RING MID VALVE ADJ NEEDLE 19 KCC60050 FORK MID VALVE ADJUSTER NEEDLE 20 KCC60051 SPRING FORK ADJUSTER NEEDLE 21 KCCS0018 SEAL FORK PISTON MID VALVE 22 HCNJ0601 6MM JAM NUT 23 BCKG0033 O RING 2MMID 24 KCCS0033 ADJUSTER SC...

Page 36: ...36 Parts Forks Leg Assembly Non brake Side ...

Page 37: ...TANDARD SPRING FORK 0 25 KG MM 32mm 14 KCCS3223 LIGHT SPRING FORK 0 23 KG MM 32mm 14 KCCS3227 HEAVY SPRING FORK 0 257KG MM 32mm 15 HCNJ3824 NUT JAM 3 8 24 CLASS 8 16 KCC60068 RING CLIP FORK SPRING GUIDE RETAINER 17 KAC60003 DAMPER ROD ASSEMBLY 18 KCC60058 O RING MID VALVE ADJ NEEDLE 19 KCC60050 FORK MID VALVE ADJUSTER NEEDLE 20 KCC60051 SPRING FORK ADJUSTER NEEDLE 21 KCCS0018 SEAL FORK PISTON MID ...

Page 38: ...OUNTING 2REQ D 9 HCBF0616 M6X16mm FLANGE HEAD BOLT 2 REQ D 10 HCWF1478 FLAT WASHER 2 REQ D 11 HCBH1203 M12 SWINGARM PIVOT BOLT 12 HCNL1201 M12 SWINGARM LOCK NUT 13 HCBH0880 M8X80mm HEX HEAD BOLT 14 HCNL0801 M8 LOCK NUT 15 TAMU0005 FOOTPEGS PAIR STANDARD 16 FCMU0031 CLEVIS PIN FOOTPEG 17 HCWF0801 8mm FLAT WASHER 18 HCCP0008 COTTER PIN 1 8 X 3 4 19 XCMU0033 ISOLATION MOUNT EXHAUST 20 HCBF0616 M6X16m...

Page 39: ...14mm SOCKET HEAD CAP SCREW 2 REQ D 7 HCWP0002 WASHER BODY PANEL FLAT 2 REQ D 8 MCMUGR03 MOUNTING GROMMET 2 REQ D 9 TCKG0001 SPACER 2 REQ D 10 HCBF0630 M6X30mm FLANGE HEAD BOLT 2 REQ D 11 HCWF1478 PIPE GROMMET WASHER 2 REQ D 12 HCBF0620 M6X20mm FLANGE HEAD BOLT 2 REQ D 13 FCC60020 CHAIN ROLLER W BEAR SEALS 13A BCDC0153 WASHER NOT SHOWN 14 FCEX0018 BRAKE ADJUST ECCENTRIC 15 HCBC0612 M6X12mm SOCKET H...

Page 40: ...LUID BEL RAY DOT 4 355 ml ACCESSORY BCKG0031 BLEED KIT MULTIPLE SYRINGES FITTINGS HOSE ACCESSORY BCKG0028 LEVER ADJUSTMENT KIT ACCESSORY BCKG0027 RESERVOIR SEAL KIT ACCESSORY BCKG0025 REPLACEMENT BAR CLAMP AND SCREWS FOR MASTER CYLINDER ACCESSORY BCKG0026 PISTON REBUILD KIT FOR MASTER CYLINDER ACCESSORY BCKG0014 FITTING KIT FOR MASTER CYLINDER BOLT SET SCREW O RING ACCESSORY BCKG0017 CALIPER ORING...

Page 41: ...2 FRONT TUBE 4 WCMU0016 FRONT AXLE 5 ECMU0040 T SHIM OPTIONAL FOR BRAKE CALIPER ALIGNMENT 6 WCMU0101BLK FRONT WHEEL SPACER LARGE BLK 7 WCMU0120 WHEEL BEARING 2 REQD 8 WCMU0036 WHEEL BEARING SPACER 9 HCBC0501 BRAKE ROTOR MOUNTING BOLTS 6 REQ D 10 BCMU0503 BRAKE ROTOR 11 WCMU0123BLK FRONT WHEEL SPACER X LARGE BLK 12 HCWF1202 FRONT AXLE WASHER 13 HCNL1201 FRONT AXLE NUT 12mm ...

Page 42: ...x SHROUD LEFT x DENOTES COLOR BLK WHT YEL FLO 7A TCC60017 BODY PANEL WASHER 5MM 1 REQ D MT SHROUD TO RADIATOR 7B HCBC0514 M5X14 SHCS 1 REQ D MOUNT SHROUD TO RADIATOR 7C HCCN0000 5MM EXTRUDED U NUT 7D HCSP0004 PLASCREW SHROUD TO TANK 8 TCC60023FLL SHROUD RIGHT FLO YELLOW 8 TCC60023x SHROUD RIGHT x DENOTES COLOR BLK WHT YEL FLO 8A HCSP0004 PLASCREW SHROUD TO TANK 2 REQ D 9 TCCS0001WHT NUMBER PLATE P...

Page 43: ...E HOSE CLAMP 2 REQ D 15 HCPP0832 BRAKE HOSE CLAMP FASTENER 2 REQ D 16 BCMU0502 BRAKE ROTOR 140mm 17 HCBC0601 M6X16mm SOCKET HEAD CAP SCREWS 5 REQ D 18 HCBF0620 M6X20mm FLANGE HEAD BOLT 2 REQ D 19 BCKG0012 BRAKE MASTER CYLINDER REAR 20 BCKG0010 REPLACEMENT BRAKE HOSE 21 BCKG0013 CALIPER REAR BRAKE 22 BCMU0022 BRAKE RUBBER CAP ACCESSORY BKKG0001 BRAKE PADS WITH E CLIP ACCESSORY BCKG0031 BLEED KIT MU...

Page 44: ...5 45 PCMU0y38 SPROCKET y denotes width 1 420 2 415 7 HCBH0702 M7X30mm HEX HEAD BOLT 7A HCWF0701 7mm FLAT WASHER 4 REQ D 7B HCNL0701 M7 LOCKNUT 4REQ D 8 WCMU0016 REAR AXLE 10 WCMU0101BLK WHEEL SPACER BLACK 11 WCMU0120 WHEEL BEARING SPROCKET SIDE 12 WCMU0035 WHEEL BEARING SPACER 13 WCMU0020 WHEEL BEARING BRAKE SIDE 14 BCMU0502 BRAKE ROTOR 140mm 15 HCBC1616 M6X16mm SOCKET HEAD CAP SCREWS 5 REQ D 16 B...

Page 45: ... 4 REQ D 5 SCMU0058 SHOCK WHITE NYLON TIP SETSCREW M6 1 0 CARD 6 SCMU0056 SHOCK SLEEVE BLACK CARD 7 SCMU0100 BUMPER TAPPERED SHOCK 8 SCMU0040 SHOCK SPRING PAD CARD 9 SCMU0054 SHOCK SPRING PERCH CARD 10 SCKGFX37 SHOCK SPRING 3 7 KG MM STANDARD 10 SCKGFX35 SHOCK SPRING 3 5 KG MM LIGHT 10 SCKGFX39 SHOCK SPRING 3 9 KG MM HEAVY 11 HCBF1040 M10 X 40 HEX HEAD BOLT 2 REQ D ACCESSORY SKMU0003 REBUILD KIT C...

Page 46: ...MU0051 O RING IFP 6 SCMU0052 IFP SEAL BAND 7 SCMU0033 O RING SHOCK BASE 8 SCMU0050 RESERVOIR CAP RETAINER RING 9 SCMU0035 O RING CHARGE CAP 10 HCBB0506 M5X6mm LONG BUTTON HEAD STAINLESS STEEL 11 SCMU0044 SEAL HEAD BUMPER 12 SCMU0048 SHAFT BUSHING 13 SCMU0046 X RING SEAL 14 SCMU0034 O RING SEAL HEAD 15 SCMU0047 SPACER X RING 16 SCMU0045 DUST SEAL 17 SCC60014 PISTON BAND 18 SCMU0059 O RING REBOUND P...

Page 47: ...0000 CLAMP BRAKE HOSE 2 REQ D 10 HCPP0832 FASTNER HOSE CLAMP 2 REQ D 11 HCBF1040 M10X40mm LOWER SHOCK MOUNT BOLT 12 FCMU0203 WHEEL PULL 13 FCMU0202 WHEEL PULL ENDCAP 14 HCBH0810 M8X65mm WHEEL PULL BOLT 14A HCWL0801 8mm LOCK WASHER 15 HCWF0801 8mm WHEEL PULL WASHER 16 WCMU0016 REAR AXLE 18 HCNL1201 M12 AXLE NUT 19 HCWF1202 AXLE WASHER 20 GCMU0033 TOP CHAIN SLIDE 21 HCFH0516 FLAT HEAD SCREW 22 HCWF0...

Page 48: ... before you establish 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...

Page 49: ... at TDC and there are negative effects of either having too much 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 f...

Page 50: ...cover piston rings can be left off to ease of assembly Carefully insert the solder wire though the spark plug hole into the cylinder far enough such that the tip of the wire touches the left or right side cylinder wall not the front or back as the piston will rock more and give incorrect measurement Hold the wire at this position and rotate the crankshaft by the flywheel nut or kick lever three re...

Page 51: ...ise for you Europeans to tighten it 4 Tighten the castle nut to the next cotter pin assembly location 5 With the internal CFD gear stop tool in position check the slip torque again it is NOT necessary to have the cotter pin for the test 6 If the slip torque is below 108 Nm 80 ft lb then repeat steps 5 and 6 above 7 Once the slip torque is at the desired value install the cotter pin as shown 8 Remo...

Page 52: ... 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 ignition cover 3mm 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 holding tool and 14 mm socket remove the nut that s...

Page 53: ...apes scratches pitting etc are found replace the cylinder 2 If deposits are all are found a Clean with muriatic acid b Once the deposits are removed inspect for abrasions and missing surface coating i If there are abrasions or missing coating replace ii If all looks well the cylinder may be saved INSPECTION NOTE Inspect the cylinder head for deposits and abrasions 1 If there are deposits they shou...

Page 54: ...e faces the crank weights 3 Press in the counter shaft seal concave side faces inside of transmission 4 Press in the water pump assembly 5 Tap both ways axially then verify easy rotation 6 Inspect the crankshaft for proper true geometry no more than 0 002 0 05mm measured at bearing journal area while supported from the ends 7 Insert the case bolts with the proper lengths at locations shown 8 Torqu...

Page 55: ...t cycles 19 Leak check the engine to 20 psi to ensure proper seal 20 Install stator reinstalling the grommet and wires snug the bolts 21 Install the rotor per Rotor Installation section under the S3 Ignition portion of this manual 22 If necessary install the water pump outlet pipe apply gray Permatex gasket maker to the threads before assembly 23 Install the CFD 24 Install the clutch per Clutch In...

Page 56: ... CLUTCH REMOVAL 1 Drain the engine transmission oil and remove the clutch cover 2 Remove the clutch nut NOT left hand thread on the end of the crankshaft with the clutch nut removal tool CAUTION It is possible to cause damage to the piston when using the piston stop Care must be used when removing and installing the clutch arbor and using the piston stop 3 Attach the Universal Puller There are thr...

Page 57: ...tions CAUTION Generally reassemble the springs as you removed them from the engine or as you received them from Cobra If you are unsure call the Cobra Technical Support Group 517 437 9100 and consult the experts 5GX CLUTCH ASSEMBLY REFERENCE DRAWING REF PART DESCRIPTION 1 CAMU0009 Set of three shoes springs bolts flat washers nuts 2 CAMU0014 Set Of three springs washers bolts nuts Not Shown CAMU00...

Page 58: ...he stock washer with the proper combination of adjustment washers that delivers the desired clutch hit CAUTION It is easy to prematurely damage the clutch and other engine components with improper clutch adjustment If you are unsure of how to adjust the clutch contact the Cobra Technical Support Group before making adjustments Clutch shoe wear This can be measured by the overall diameter of the sh...

Page 59: ...ner removing all old thread locking material 3 Assemble the stacks and shoes on the arbor using high strength thread lock material to the stack bolt and tighten to 16 Nm 12 ft lb 144 in lb CAUTION Avoid allowing excess thread lock material to contact the spring washers and the clutch or the clutch is likely to malfunction 4 Clean the threads of the crank shaft and the clutch nut 5 Install the clut...

Page 60: ...t large enough There should be even clearance as the rotor rotates relative to the stator Ignition timing is not adjustable Changing the ignition timing can degrade performance Make sure connections are free of dirt CAUTION Advancing the ignition timing will cause the engine to run hotter in turn causing power loss shortened clutch life and possibly lead to premature stator failure and can also ca...

Page 61: ...ing System Radiator fluid removal Remove the coolant drain plug 10mm hex key on the bottom of the engine cases NOTE Inspect the old coolant for evidence of oil combustion byproducts black oil slick stuff or other things that may indicate a problem Tools recommended for impeller service Flat head screwdriver 2 5mm hex key 3mm hex key 4mm hex key 10mm hex key Water Pump Installation tool MCMUTL08B S...

Page 62: ...assembly into the assembly tool and align the tool with engine case making sure alignment pin is in proper hole CAUTION Damage may occur if one attempts to install the water pump assembly and it s not aligned correctly in the bore 11 Holding the tool squarely over the water pump assembly tap it firmly into place 12 The assembly is installed properly when the retaining screw can be tightened and it...

Page 63: ...ed head is the idle adjustment screw 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 Indications that the engine is running too rich too much fuel for the air are Engine not revving out or blubbering at high RPMs Engine will not clean out Wet or black spark plug NOTE Bef...

Page 64: ...the carburetor very clean and make sure you don t have water or dirt in the carburetor bowl Use automotive carburetor cleaner or WD 40 to clean the carburetor inside and out Cleaning the carburetor 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 Because of the danger of highly...

Page 65: ...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 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 essential to clear the residue NOTE If your bik...

Page 66: ...lcohol Contaminated pads must be replaced Ensure that the brake caliper is centered over the brake rotor It a correction is needed Cobra has thin brake shims to help make minor adjustments in alignment Always leave adequate free play in the lever or pedal CAUTION This brake system uses only DOT 4 or 5 1 brake fluid Front Forks The front forks are fully serviceable but it is recommended that only t...

Page 67: ...y can only be approximated by the size of the step where it sticks out of the basket h Basket has worn and is too large There is a relationship between observed characteristics and the things that can be measured If a clutch comes in too early it means that clutch spring stack is not providing enough force to keep the shoes from being thrown out to the clutch basket at the proper time with the giv...

Page 68: ...lutch life Change oil each ride Gear to the low side Avoid mud if possible Cut mud practice to 1 lap or none Stay on the gas no throttle blipping Run more air pressure to allow wheels to spin helps throttle steer Make sure wheels spin freely no bent rotors dragging brakes chain too tight etc Make sure the engines pulls cleanly and strong by having properly maintained engine with correct ignition t...

Page 69: ...time to balance the three stacks shims springs bolts etc to as close to the same length as you are willing to put effort into will result in a better performing motorcycle Q One of my two riders weighs 85 pounds and the other weighs 45 pounds Should I have their clutches adjusted differently because of their weight A No there is one best setting and it works for light or heavy riders Q If my clutc...

Page 70: ... 16 33 2 06 15 31 2 07 16 34 2 13 15 32 2 13 16 35 2 19 15 33 2 20 14 31 2 21 16 36 2 25 15 34 2 27 14 32 2 29 16 37 2 31 15 35 2 33 14 33 2 36 16 38 2 38 15 36 2 40 14 34 2 43 16 39 2 44 15 37 2 47 14 35 2 50 16 40 2 50 15 38 2 53 14 36 2 57 15 39 2 60 14 37 2 64 15 40 2 67 13 35 2 69 14 38 2 71 13 36 2 77 14 39 2 79 13 37 2 85 14 40 2 86 13 38 2 92 13 39 3 00 13 40 3 08 ...

Page 71: ...resistance to the suspension motion when the suspension is compressing 1 6 Rebound damping 1 6 1 Harder more damping slower adds resistance to the suspension motion when the suspension is returning to full length 1 6 2 Softer less damping quicker reduces resistance to the suspension motion when the suspension is returning to full length 2 Rear shock 2 1 Preload adjustment 2 1 1 More preload greate...

Page 72: ...ces significantly less mid and high speed compression until it travels into the progressive speed sensitive portion of the smart leg The speed sensitive compression component is adjustable at the top of the fork The combination of the Smart Leg and the conventional leg allows the fork to be very supple throughout all low amplitude operation and yet take punishing hits producing a progressively inc...

Page 73: ...Symptom Action Rear end feels stiff on small bumps Softer Low Speed Compression Damping Rear end sways on straights Harder Low Speed Compression Damping Bike tends to jump rear end high Harder High Speed Compression Bike tends to jump rear end low Softer High Speed Compression Frequent rear end bottoming Harder Compression Damping Bottoms after end of continuous bumps Softer rebound damping Rear e...

Page 74: ...amping or slows it down whereas out speeds up the shock or removes damping 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 Proper jetting is very important for engine performance an...

Page 75: ... Leaner Richer Very humid air Richer Leaner Low altitude Standard None High altitude Richer Leaner Low barometric pressure Richer Leaner High barometric pressure Leaner Richer NOTE Before making any carburetor jetting changes verify that o You are using the proper fuel and oil o The fuel is fresh and uncontaminated o The oil and fuel have been mixed in the proper ratio o The carburetor is clean no...

Page 76: ...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 the longest straight at the track Observe any of the lean or rich symptoms spark plug appearance and bike performance...

Page 77: ...k case gasket 2 Engine is down on power a Clutch engagement is not set properly b Jetting is incorrect c Silencer needs repacked d Exhaust pipe i Has excess carbon buildup ii Has large dent in it e Compression is low i Piston ii Rings f Reeds are damaged g Ignition timing is incorrect h Stator needs replaced 3 Engine is excessively loud a Silencer needs repacking 4 Engine blubbers at high RPMs a J...

Page 78: ...ch 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 6 Engine won t idle a Idle knob needs adjusted b Carburetor jets are dirty ...

Page 79: ... Electrical Parts 23 Engine Specifications 4 Exhaust 65 Parts 30 Fork Adjustments 72 Operation 72 Fork oil replacement 16 Forks Service 66 Frame Parts 38 Frictional Drive 17 Front Brake Parts 40 Front Wheel Parts 41 Fuel System Parts list 63 Service 63 Hardware Frame 38 Ignition Parts 28 Service 60 Timing 60 Jetting How To 63 Stock 4 Troubleshooting 74 Lubrication Recommended 4 Maintenance Schedul...

Page 80: ...ers 65 Rear Brake Adjustment 11 Parts 43 Rear Wheel Parts 44 Pullers 65 Reeds 65 Shock Adjustments 73 Parts 45 46 Slip Clutch 17 Spark Plug Recommended 4 Specifications 4 Starting 7 Stator torque 5 Suspension Adjustment 71 Swingarm Parts 47 Top End Parts 29 Service 48 Torque Values 5 Transmission Lubricant Replacing 10 Troubleshooting 77 Jetting 74 VIN reading 8 WARNING 1 Water Pump Parts 28 Wheel...