Cobra 2004 cm50 Owner's Manual

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Page 1

2004 CM50

Owners / Service / Parts

“CHAMPIONS START HERE”

Page 2

For parts orders contact your local dealer

To locate your closest 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 Motorcycle MFG., Inc.

11511 Springfield Road North Lima, Ohio 44452

MCCM2004.2

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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 CM50 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 80 LBS WITH FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE 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.

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Table Of Contents

Specifications - General..................................................................................................5

Specifications - Torque Values ......................................................................................7

Optional Components......................................................................................................8

Break-In Procedure..........................................................................................................9

Starting Procedure.........................................................................................................10

General Tips ....................................................................................................................11

Maintenance....................................................................................................................12

Schedule & Tips .........................................................................................................12

M1: Replacing Transmission / Clutch Lubricant....................................................13

M2: Chain adjustment................................................................................................14

M3: Front brake adjustment......................................................................................15

M4: Rear brake adjustment ......................................................................................15

M5: Air Filter Cleaning ...............................................................................................16

M6: Fork Oil Replacement........................................................................................17

Parts.................................................................................................................................18

Parts – Airbox and Inlet System...............................................................................18

Parts - Carburetor.......................................................................................................20

Parts – Coolant System.............................................................................................21

Parts – Electrical System..........................................................................................22

Parts – Engine – Bottom End and Transmission..................................................23

Parts – Engine – Clutch and Kick Starter...........................................................24

Parts – Engine – Ignition and Water Pump........................................................25

Parts – Engine – Top End.....................................................................................26

Parts – Exhaust System............................................................................................27

Parts – Forks & Triple Clamps.................................................................................28

Parts – Forks – Leg Assembly.............................................................................29

Parts – Frame – Engine, Tank, and Pipe Mounts, Brake Snake........................30

Parts – Frame – Seat, Fender, R Side Panel, Brake Pedal, Silencer & Shock

Mounts......................................................................................................................31

Parts - Frame – Radiator, Footpeg, Chain Roller, and Airbox Mounts..........32

Parts – Front Brakes..................................................................................................33

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Parts – Front Wheel...................................................................................................34

Parts – Plastic Bodywork & Seat.............................................................................35

Parts – Rear Brake.....................................................................................................36

Parts – Rear Wheel....................................................................................................37

Parts – Shock..............................................................................................................38

Parts – Swingarm Assembly.....................................................................................39

Service.............................................................................................................................40

Engine Service............................................................................................................40

Engine Removal.....................................................................................................41

Complete Engine Disassembly Procedure.........................................................42

Top End Disassembly Procedure........................................................................42

Splitting the Cases.................................................................................................43

Engine assembly....................................................................................................44

Clutch...........................................................................................................................49

I gnition..........................................................................................................................53

Cooling System...........................................................................................................55

ES6: Fuel & Air System.............................................................................................59

Exhaust........................................................................................................................62

Wheels & Tires ...........................................................................................................63

CS2: Suspension ........................................................................................................65

Troubleshooting..............................................................................................................66

Index.................................................................................................................................67

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Specifications - General

Items CM 50

Dimensions

Wheelbase 35.75” (908mm) Wheel size 10” (254mm) Seat height 23.9” (607 mm) Stock #TCHJ0001

22” (559 mm) Option al # TCHO0001

Engine

Type 2-stroke, single cylinder, reed valve Cooling system Liquid-cooled Displacement 49.8 cc Bore and stroke 39 mm x 41.7 mm Ignition system Electronic Spark plug Champion 8339-1, 8332-1 hotter, 8904-1 colder

Gap 0.023” – 0.025” (0.58 – 0.64 mm) Ignition timing 0.050” (1.3 mm) Before To Dead Center (BTDC) Fuel type High octane pump gasoline

Oil type Cobra Venom 2-cycle Race Oil Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In) Carburetion 14 mm Dell’Orto

Main Jet 92

RACE FUELS ARE NOT RECOMMENDED

Slow (Pilot) jet 55

Float Height 16mm + 0.5mm (0.63” + 0.020”)

Transmission

Speed Single Clutch Cobra 3 shoe Final drive ratio 13/37 T Chain 88 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III

Quantity 235 ml (8.0oz)

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Chassis

Front tire 2.50 - 10

Pressure 15 psi minimum

Rear tire 2.75 - 10

Pressure 15 psi min. (20 psi for hard pack or rocky conditions)

Front fork Marzocchi 32mm

Fork oil type SAE 20 weight

Fork oil amount 200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild

Collapsed fork oil height 70 mm (2.75”) spring in, no spacer

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Specifications - Torque Values

Torque Value

Fastener ft-lb in-lb Nm

Cylinder head nuts 9.2 110 12 ¼”

Crankcase bolts 6.6 80 9 6 x 1.0

Spark plug (SP) (SP) (SP) 14 x 1.25

Stator bolts 2.1 25 2.8 #8

Stator cover bolts 1.7 20 2.3 #8

Clutch cover bolts 5.8 70 7.9 6 mm

Clutch 40 480 54 10 x 1.25***

Engine mount bolts 22 265 30 8 mm

Swingarm Pivot 21 250 28 14 mm

Intake manifold bolts 4.6 55 6.2 6 mm

Ignition rotor nut 40 480 54 10 x 1.25 mm**

Rear Sprocket Bolts 18 216 24 7 mm

Rear shock mounts 40 480 54 10 x 1.5

Size &

Remarks

Rear Axle Bolt 25 300 34 12 mm

** Use green (wicking / bearing retainer) thread locker, with primer, on the flywheel / crankshaft taper but none on the threads.

*** Use green (wicking / bearing retainer) thread locker, with primer, on the crankshaft / clutch taper but use red (high strength) thread locker, with primer, on the nut.

(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.

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Optional Components

Call your dealer, or the factory, for details

• Carburetor jets

• Sprockets

o Front o Rear

• Suspension Springs Weight of Rider (lb) Fork Spring Shock Spring

Less than 38 (light) KCMZ0012A SCMUOH04 (275 lb/in)

38 – 45 (std) KCMZ0012 SCMUOH05 (285 lb/in)

46 to 55 (stiff) KCMZ0012B SCMU0H06 (295 lb/in)

• Suspension Valving

Damping Rate Fork Valving

Compression

(right)

Soft (fast) KCMZ0033A KCMZ0032A SCMUOH07

Standard KCMZ0033 KCMZ0032 SCMUOH08

Hard (slow) KCMZ0033B KCMZ0032B SCMUOH09

Fork Valving

Rebound

(left)

Shock Valving

(kit)

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Break-In Procedure

Your Cobra CM50 is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The CM50 can be ridden hard after the first ½ hour break-in time but it is recommended that no adjustments are made to the carburetion or suspension until the full 8 hours of bike break-in has elapsed. Also, after the engine, transmission, and drive train have been broken -in for the full 8 hours, the bike will be faster!

Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use high octane pump gas with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil. (Part # MCMUOL02)

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.

• First ½ hour of operation

o Follow the starting procedu re listed in this manual. o 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 transmission / clutch lubricant.

• After 8 hours of operation

o Change the fork oil. o Have 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 loose 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.

CAUTION: It is important that the radiator cap is installed correctly and completely otherwise engine damage could occur.

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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 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 knob to the vertically downward position (reserve position is horizontally forward)

CAUTION: For best results from your Cobra Motorcycle use only the recommended fuels. Testing has shown that most ‘race’ fuels actually degrade performance.

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. 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 cylinder is warm to touch).

CAUTION: Never rev an engine full throttle when it's cold or slightly warmed up. 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. Make sure your engine is properly warmed up before racing.

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General Tips

1. Always wear a hel met and other protective riding gear.

2. 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.

3. Make sure your riders’ foot is not resting on the foot brake while they are

riding.

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. When washing the bike, be careful to not directly aim the hose at the

bottom edge of the seat, or water is apt to enter the airbox.

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, CMxxxx4xxx is a 2004 MY CM50.

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Maintenance

Schedule & Tips

It is important that you adhere to this maintenance schedule so as to promote the longevity of your Cobra Motorcycle.

• Between each ride

o Check the air filter (clean and re-oil as necessary). o Insure the smooth operation of the throttle cable (throttle soundly

‘clacks’ shut).

o Check for frayed strands of the throttle cable inside the throttle housing

and replace if necessary.

o Check for adequate tire pressures and adjust if necessary . o Check all nuts and bolts for proper torque and re-torque if necessary. o Spray all moving parts with WD40 or other light oil. o Check drive chain for

§ Proper tension and adjust if necessary.

§ Adequate lubrication and lubricate if necessary.

o Insure that the ignition stator and rotor are clean and dry. o 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.

o Inspect the rear sprocket damper plate for bending or warping.

Straighten or replace if more than 1/16” (1.6 mm) from flat.

• Every 2 hours of operation o Replace the transmission oil.

• Every 10 hours of operation

o Replace the fork oil. o Have the shock oil replaced by a Certified Cobra Mechanic.

CAUTION:

1. Because of the amount of heat generated by the clutch and engine during

extended 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 be welded and put the ground clamp as close to the area to be welded as possible.

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Be sure the fuel tank and carburetor have been removed and safely located away from the welding process.

3. The frame is 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.

4. If your kick-starter lever does not return to the rubber bumper, use WD-40

or light penetrating oil under the plastic cover behind the spring on the shaft. The shaft is a very close fit to the case and also has an O ring in it and is difficult to get lubrication to which may cause binding. If it does not loosen up, remove the kick-starter cover and kicking assembly. Grease the shaft.

M1: Replacing Transmission / Clutch Lubricant

Tools needed:

• 225 ml (7.6 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01), or

Dexron III Automatic Transmission Fluid.

• 13 mm combination wrench

Procedure:

1. Begin this procedure with a bike that has been ridden more than 5 minutes

but less than 10 minutes. It is desired to have the engine warm enough so that the oil ‘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. Using a 13 mm wrench, remove the oil drain bolt located on the right side of

the engine, on the clutch cover, near the brake lever (Item 2, figure 1).

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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 copper gasket is in

place. Torque to 15 Nm (11 ft-lb).

5. Reapply oil from oil fill plug 235 cc Cobra Venom 3 Shoe Clutch Milk, or

Dexron III Automatic Transmission Fluid, thru the fill plug.

NOTE:

Lean bike over onto it’s left hand side so that the clutch cover is up unless you have a squeeze bottle.

6. Reapply the oil fill bolt, hand tight, being sure the fiber gasket is in place.

CAUTION: Cobra has spent considerable time and money developing the proper lubrication to handle the harsh environment of the automatic clutch and transmission of this motorcycle. Cobra’s specially developed Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01) was formulated to provide superior lubrication and cooling capability over extended periods of time and is the recommended lubricant for your Cobra motorcy cle.

M2: Chain adjustment

Figure 2

1. Make sure that the rear wheel is aligned properly.

2. Push down on the seat,

compressing the suspension down to where the chain is tightest.

3. The chain should not be

too tight but not too loose. A minimum of 2.5 in. of slack should be between the swing arm and the chain.

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M3: Front brake adjustment

Tools recommended for front brake maintenance:

• 10mm open end wrench

Figure 3, from the brake lever Figure 4, from the brake hub

From the brake lever:

1. Loosen the locking nut on the brake lever.

2. Adjust the bolt to desirable position.

3. Tighten the locking nut.

From the brake hub:

1. Loosen the 10mm nut on the hub.

2. Adjust the brake cable to desirable position

3. Tighten the 10mm nut. CAUTION:

If you tighten the front brake up too much, the brakes may hang up causing the brake pads to wear incorrectly and prematurely.

M4: Rear brake adjustment

Tools recommended for rear brake maintenance:

• 10mm open end wrench There are 2 adjustments on the brake.

Figure 5, adjust brake lever free height Figure 6, adjust brake lever ‘free play’

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From the brake lever:

4. Loosen the 10mm nut on the back of the brake pedal.

5. Adjust the bolt to desirable position

6. Tighten the 10mm nut.

From the brake hub:

1. Adjust the wing nut up to desirable position. CAUTION:

If you tighten the wing nut up too much, the brakes may hang up. If so, the brake pads will burn up, and need replaced.

M5: Air Filter Cleaning

Tools recommended for air filter maintenance:

• Flat screwdriver

• 4 mm hex key (Allen)

• Foam filter oil

Procedure

1. Removed the seat with the 4 mm hex key

2. Remove the filter/air inlet boot from the back of the carburetor with a flat screwdriver

3. Pull the filter / boot assembly back, up, and out the top of the airbox.

4. Clean the filter in a nonflammable solvent to remove the filter oil.

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.

8. Reinstall the filter / boot assembly to the carburetor with the letters “CM” visible from the side.

Do not clean the air filter with gasoline or other highly volatile petroleum product. Diesel fuel or kerosene would be preferred but caution should still be taken. Hot soapy water works well.

NOTE:

The Cobra is equipped with a special designed Air box. It is very important to keep the air filter clean and properly oiled with high quality water-resistant foam filter oil. It’s very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting.

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.

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M6: Fork Oil Replacement

Tools required

• 5 & 6 mm Allen wrench

• 19 mm wrench or socket (two required)

• Spring clip remover

Disassembly

1. Remove the front wheel.

2. Remove the fork legs from the triple clamps.

3. Perform the following on one leg at a time.

4. Using your hands, remove the black rubber plug from the top of the fork leg exposing the white plastic cap.

5. Secure the fork leg assembly in a vice by gripping the leg across the flats through which the axle bolt goes through.

6. Depress the white plastic cap inwards (down) and remove the wire spring clip from its groove.

7. Remove the white cap, the fork spring preload sleeve, and the fork spring.

NOTE: Depressing the fork leg will facilitate removing the white cap.

8. The fork can now be turned upside down and drained.

Assembly

1. Fill the leg with 200 cc (6.8 oz) 20 wt fork oil.

2. Standard fork oil level is 70 mm (2.75”) from the top edge with the fork collapsed.

NOTE: Remove the preload sleeve but leave the spring in for the measurement.

3. Install the preload sleeve.

4. Install and depress the white cap while installing the spring clip.

5. Fork may be reinstalled.

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Parts

Parts – Airbox and Inlet System

Figure 7

Airbox and Inlet System

REF # PART # DESCRIPTION

1 ZCMU0032 GASKET – REED TO CYLINDER 2 ECKG0205 REED VALVE 3 ZCMU0031 GASKET – MANIFOLD TO REED 4 ECKG0203 INLET MANIFOLD 5 HCWF0601 6MM FLAT WASHER 6 HCBC0625 M6X25 SOCKET HEAD CAP SCREW 7 MCKGHO01 HOSE CLAMP – CARBURETOR TO MANIFOLD 8 RACM0002 CARBURETOR 14MM

9 FCMU0067 THROTTLE CABLE 10 RCCM1301 VELOCITY STACK 11 MCKGHO01 HOSE CLAMP – AIR BOOT TO CARBURETOR 12 RCMU0403 AIR FILTER WITH BOOT 13 RCMU0405 AIR BOX – CM 14 HCBF0416 M6X16 FLANGE HEAD BOLT (2 REQ’D) 15 RCMU1407 BRACKET – MUD FLAP 16 RCMU0406 MUD FLAP – CM

Page 20

Parts – Bars and Controls

Figure 8

Bars and Controls

REF # PART # DESCRIPTION

1 FCMU0066 THROTTLE ASSEMBLY 2 FCMU0068 THROTTLE COVER 3 TCMU0008 GRIPS (SET OF TWO) 4 FCMU0067 THROTTLE CABLE 5 FCMU0033 KILL SWITCH ASSEMBLY 6 KCMZ0001 M8X50 SOCKET HEAD CAP SCREW (4 REQ’D) 7 KCMZ0003 LOWER HANDLE BAR CLAMP (2 REQ’D) 8 KCMZ0002 TOP HANDLE BAR CLAMP (2 REQ’D)

9 TCMU0019 HANDLEBAR - ALUMINUM 11 BCMU0100 BRAKE LEVER / PERCH ASSEMBLY WITH ADJUSTER 13 BCMU0108 FRONT BRAKE CABLE

Page 21

Parts Carburetor

Figure 9

Carburetor

REF. # PART # DESCRIPTION

RCCM0001 COMPLETE CARBURETOR 14MM

1 RCMU0305 CARB SLIDE 2 RCMU0601 NEEDLE 3 RCMU0002 ATOMIZER

4 RCMU0092 MAIN JET 5 RCMU0055 PILOT JET 6 CHOKE JET

7 RCMU0301 FLOAT 8 RCMU0102 RUBBER CABLE CAP SEAL 9 RCMU0003 CABLE ADJUSTER

11 RCMU0006 TOP CARB SCREW 12 RCMU0106 CARB TOP

13 ZCMU0007 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0205 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 RCMU0106 FLOAT BOWL 30

RCMU0201 BOTTOM FLOAT SCREW

31 33 RCCM1301 VELOCITY STACK

RCCM0314 14MM CARB RESTRICTOR

Page 22

Parts – Coolant System

Figure 10

Coolant System

REF # PART # DESCRIPTION

1 ECMU0061 RADIATOR WITH CAP 2 MCMUHO02 RADIATOR HOSE LEFT 3 MCMUCL02 HOSE CLAMP 4 ECHA003 MOUNTING BRACKET – RADIATOR BOTTOM 5 HCBC0607 M6X50 SOCKET HEAD CAP SCREW 6 HCNL0601 6MM LOCK NUT 7 MCKGGR00 GROMMET – RADIATOR MOUNTING

8 MCMUHO03 RADIATOR HOSE RIGHT 10 ECHA0002 VENT HOSE 11 ECHA0109 MOUNTING BRACKET – RADIATOR TOP 12 HCBC0660 M6X60 SOCKET HEAD CAP SCREW

Page 23

Parts – Electrical System

Figure 11

Electrical System

REF # PART # DESCRIPTION

1 IAMU0001 COIL W/SPARK PLUG CAP

2 ECMU0065 SPARK PLUG, CHAMPION (8339-1) 2H ECMU0067 OPTIONAL HOTTER PLUG (8332-1) 2C ECMU0066 OPTIONAL COLDER PLUG (8904-1)

3 FCMU0033 KILL SWITCH ASSEMBLY

4 HCBC0516 SCREW, M5 X 16 (2 PER)

5 HCNL0601 6MM LOCK NUT

6 ECMU1210 BRACKET – COIL MOUNT

31 HCWP0001 WASHER FOR STATOR (3 PER) 32 HCBC8312 SOCKET HEAD CS, 8-32X1 33 HCBC0801 SOCKET HEAD CS, 8-32X 1-1/2 (2 PER) 34 HCNS1001 NUT 10MM 35 ECKG0042 PULLEY, WATERPUMP CRANK 59 ICMU0006 ROTOR 60 ICMU0007 STATOR

NOT SHOWN MCKGGR00 GROMMET - STATOR LEAD NOT SHOWN ICMU0012 ROTOR SHAFT KEY

Page 24

Parts – Engine – Bottom End and Transmission

Figure 12

Engine Bottom End and Transmission

REF # PART # DESCRIPTION

1 ECKG0017 CRANKCASE, IGNITION SIDE

2 ECMU0020L BEARING, TRANSMISSION PRECISION

3 ECKG0004 SNAP RING, WATER PUMP

4 ZCKG2001 GASKET, CRANKCASE

5 ECMU0103 SECONDARY SHAFT, TRANSMISSION WITH GEAR

6 ECMU0017 SEAL, CRANKSHAFT

7 ECMU0016 BEARING, CRANKSHAFT

8 ECMU0001 BEARING, TRANMISSION SECONDAY SHAFT

9 ECMU0038 CRANKSHAFT

10 ECKGBR01 BEARING, TRANSMISSION OUTPUT SHAFT 13 HCDP1401 DOWEL, ENGINE CASE ALIGNEMENT 14 HCBH0805 M8X12 SCREW 15 HCWC0000 COPPER GASKET 16 ECMU0104 OUTPUT SHAFT, TRANSMISSION WITH GEAR 17 ECMU0020 BEARING, TRANSMISSION PRECISION 19 ECKG0018 CRANKCASE, CLUTCH SIDE 20 ZCMU0032 GASKET, REED TO CASE 21 ECKG0205 REED ASSEMBLY

NOT SHOWN ECKG0205 REED KIT

22 ZCMU0031 GASKET, INTAKE TO REED 23 ECKG0203 INTAKE MANIFOLD 24 HCBC0625 SCREW M6X25 25 HCBB0612 M6X12 BUTTON HE AD SCREW - BEARING RETAINER 26 HCWF0601 6MM FLAT WASHER

Page 25

Parts – Engine – Clutch and Kick Starter

Figure 13

Engine – Clutch and Kick Starter

REF # PART # DESCRIPTION

1 ECMU0206 CLUT CH COVER COMPLETE WITH KICK LEVER

2 ZCMU0030 CLUTCH COVER GASKET

3 ECMU0207 KICKSTART GEAR SMALL

4 HCBC0608 M6X55 SHCS CLUTCH CVR SCREW LNG (2 REQD) CENTER

5 HCBC606 M6X45 SHCS CLUTCH COVER SCREW SHORT (4 REQD)

7 ECMUOO37 OIL FILL PLUG

8 ZCMU0001 OIL FILL PLUG GASKET

9 HCBH0805 M8X12 OIL DRAIN SCREW

10 HCWC0000 COPPER GASKET 11 ECMU0202 LEVER – KICK START 12 ECMU0205 RUBBER – KICK START LEVER 14 ECMU0204 KICK START DUST COVER 15 ECMU0403 SPRING – KICK LEVER 16 CCMU0031 CLUTCH ARBOR 17 CAKG0005 CLUTCH SHOE (SET OF 3)

NOT SHOWN CAKG0004 SET OF 3 CLUTCH SHOES WITH SPRINGS, WASHER & BOLT NOT SHOWN CAKG0002 CLUTCH ASSY W/ ARBOR, SHOES, SPRINGS, WSHR & BOLT

18 CCMU0129 SPRING, CLUTCH (SINGLE PIECE) 19 HCWS0801 WASHER, CLUTCH (SINGLE PIECE)

NOT SHOWN CAMU0008 SPRINGS, WASHER, & BOLT (COMPLETE SET FOR 3 SHOES)

20 HCBS5603 BOLT, CLUTCH CENTER (SINGLE PIECE) 21 ECMU0018 NUT, CLUTCH SPECIAL 22 ECMU0033 CLUTCH BASKET NON WELDED WITH BUSHING 23 ECMU0003 BUSHING, CLUTCH BASKET 24 ECMU0040 SPACER, CLUTCH BASKET (1 - 3 REQD) 25 ECMU0131 WATER ELBOW 26 ECMU0105 GEAR, PRIMARY TRANSMISSION 27 HCNS1202 NUT, 1/2-20 LEFT HAND THREAD 28 ECDC0105 ELBOW, CASE VENT 29 ECMUSP01 KICK START DOG SPRING (PAPER CLIP) 31 HCWB0042 SPRING WASHER

Page 26

Parts – Engine – Ignition and Water Pump

Figure 14

Engine – Ignition and Water Pump

REF # PART # DESCRIPTION

1 ECKG0001 IGNITION COVER 2 ZCKG0101 IGNITION COVER GASKET 3 HCBC0802 COVER SCREW, SHCS 802X1 -3/4 4 ECKG0070 WATER PUMP BELT 5 ECKG0075 WATER PUMP PULLEY, FAN TYPE - DRIVEN 6 ECMU0080 BELT RETAINER 7 HCBC1033 PULLEY SCREW, SHCS 10-32X3/4 8 HCWF0501 FLAT WASHER

9 ECKG0072 BEARING, WATER PUMP 10 ECKG0141 SHAFT, WATER PUMP 11 ECKG0074 SEAL, WATER PUMP SHAFT 12 ECKG0073 IMPELLER, WATER PUMP 13 HCBB0001 IMPELLER SCREW, SHCS 10-32X1/2 14 HCSS8201 RETAINING SCREW, SHCS 8-32X3/8 15 HCBC0603 CASE SCREW, SHCS M6X30 16 HCBC0606 CASE SCREW, SHCS M6X45 (3 REQD) 17 HCBC0604 CASE SCREW, SHCS M6X35 (5 REQD) 18 HCWP0001 WASHER, STATOR (3 REQD) 19 ICMU0007 STATOR 20 HCBC0801 STATOR SCREW, SHCS 8-32X1-1/2 (2 REQD) 21 HCBC8312 STATOR SCREW, SHCS 8-32X1 22 ICMU0006 ROTOR 23 ECKG0042 WATER PUMP PULLEY, CRANK 24 HCNS1001 NUT 10MM 25 MCKGGR00 GROMMET 26 PCKG0013 SPROCKET, 13T COUNTERSHAFT 27 ECKGSR03 SNAP RING, COUNTERSHAFT SPROCKET 28 HCWF0503 SPACER – WATER PUMP PULLEY 29 ECKGSE01 SEAL, COUNTERSHAFT 31 ECKG004 RETAINER, WATER PUMP ASSEMBLY

Page 27

Parts – Engin e – Top End

Figure 15

Engine – Top End

REF # PART # DESCRIPTION

1 ECKG0041 CYLINDER

2 ZCKG0002 BASE GASKET

3 ECMU0043 PISTON KIT

5 ECMU0055 PISTON RINGS (2 PER SET)

6 ECMUSR00 SNAP RING FOR PISTON (2 REQ'D)

7 ECKG0012 WRIST PIN

8 ECMU0077 BEARING, WRIST PIN

9 ZCMUOR07 O'RING, EXHAUST FLANGE 10 ECKG0015 EXHAUST FLANGE 11 HCBC0602 M6X20, EXHAUST FLANGE SCREW (2 REQ'D) 12 HCNS1401 NUT, CYLINDER HEAD 1/4-20 (4 REQ'D) 13 HCWF1401 FLAT WASHER, 1/4" (4 REQ'D) 14 ECKG0025 CYLINDER HEAD OUTER 15 ZCMUOR02 O'RING, CYLINDER HEAD LARGE 16 ZCMUOR08 O'RING CYLINDER HEAD SMALL 17 ZCMUOR03 O'RING CYLINDER STUD (8 REQ'D) 18 ECKG1121 CYLINDER HEAD, INSERT 19 ZCMUOR05 O'RING CYLINDER HEAD MEDIUM 20 ECMU0008 STUD, CYLINDER

Page 28

Parts – Exhaust System

Figure 16

Exhaust System

REF # PART # DESCRIPTION

1 XCCM2004 2004 CM EXHAUST PIPE 2 ZCMUOR30 HEADER PIPE O-RINGS (2 REQ’D) 3 XCMU0005 EXHAUST SPRING - SHORT 4 MCMUGR06 PIPE GROMMET MALE 5 MCMUGR07 PIPE GROMMET FEMALE 6 MCMUSP02 PIPE GROMMET SPACER 7 HCWF1478 PIPE GROMMET WASHER

8 HCBF0635 M6X35 FLANGE HEAD BOLT 10 XCKG0009 PIPE / SILENCER SEAL 11 XCKG0003 SILENCER

NOT SHOWN XCMU0018 SILENCER PACKING

12 HCBF0630 M6X30 FLANGE HEAD BOLT 13 MCMUGR04 GROMMET – SILENCER MOUNTING (2 REQ’D)

Page 29

Parts – Forks & Triple Clamps

Figure 17

Front Forks and Triple Clamp

REF # PART # DESCRIPTION

1 KCMZ0029 OUTER FORK LEG – RIGHT (NON BRAKE) SIDE

NOT SHOWN KCMZ0031 OUTER FORK LEG ASSY – RIGHT WITH SEAL & SWIPER

2 KCMZ0020 OUTER FORK LEG – LEFT (BRAKE) SIDE

NOT SHOWN KCMZ0021 OUTER FORK LEG ASSY – LEFT WITH SEAL & SWIPER

3 KCMZ0026 INNER FORK LEG – RIGHT (COMPRESSION) SIDE 4 KCMZ0027 INNER FORK LEG – LEFT (REBOUND) SIDE 5 HCCC0002 CLAMP – BRAKE CABLE 6 HCBC0520 M5X20 SOCKET HEAD CAP SCREW 7 HCNL0501 5MM LOCK NUT 8 HCBF0616 FENDER BOLT, M6X16 FLANGE HEAD (4 REQD) 9 KCMZ0025 TRIPLE CLAMP – LOWER WITH STEM

10 HCBC0625 M6X25 SOCKET HEAD CAP SCREW (4 REQD) 11 KCMZ0005 TRIPLE CLAMP – UPPER (NO BAR MOUNTS) 12 HCBC0806 M8X30 SOCKET HEAD CAP SCREW (2 REQD) 13 KCMZ0003 BAR MOUNT – LOWER (2 REQ’D) 14 KCMZ0002 BAR MOUNT – UPPER (2 REQ’D) 15 KCMZ0001 M8X50 SOCKET HEAD CAP SCREW 16 HCNJ0101 STEERING HEAD NUT 1X14 17 FCMU0004 STEERING HEAD BEARING (2 REQD) 18 FCMU0103 DUST COVER (2 REQD) 19 BCMU0007 BRAKE STOP 20 HCBH0808 M8X30 BUTTON HEAD SCREW

Page 30

Parts – Forks – Leg Assembly

Figure 18

REF # PART # DESCRIPTION

4 KCMZ0004 FORK PLUG – BLACK 7 KCMZ0007 SNAP RING FOR FORK CAP 8 KCMZ0008 INNER FORK CAP - WHITE

9 KCMZ0009 O-RING UNDER FORK CAP 11 KCMZ0111 PRELOAD SLEEVE 12 KCMZ0012 FORK SPRING 13 KCMZ0013 SWIPER 14 KCMZ0014 SNAP RING 15 KCMZ0015 FORK SEAL 16 KCMZ0016 WASHER 17 KCMZ0017 SEALING RING FOR REBOUND PISTON 18 KCMZ0118 PISTON ROD - REBOUND

18A KCMZ0118A PISTON ROD - COMPRESSION

19 KCMZ0019 REBOUND SPRING 20 KCMZ0020 FORK LEG OUTER LEFT 21 KCMZ0021 FORK LEG – 5 PIECE UNIT – LEFT 22 HCWC0000 WASHER 23 HCBC0806 8 X 30 CS 26 KCMZ0026 FORK TUBE – INNER RIGHT 27 KCMZ0027 FORK TUBE – INNER LEFT 28 KCMZ0028 TOP OUT BUMPER 29 KCMZ0029 FORK LEG – OUTER RIGHT 31 KCMZ0031 FORK LEG – 5 PIECE U NIT – RIGHT 32 HCBC0609 6 X 20 CS

Page 31

Parts – Frame – Engine, Tank, and Pipe Mounts, Brake Snake

Figure 19

Frame – Engine, Tank, and Pipe Mounts, Brake Snake

REF # PART # DESCRIPTION

FAMU0004 FRAME 2004 CM50 1 HCBH1403 SWINGARM BOLT 2 HCNL1402 SWINGARM LOCK NUT (M14X1) 3 HCBH0880 M8X80 SOCKET HEAD CAP SCREW 4 HCNL0801 8MM LOCKNUT 5 MCMUGR06 PIPE GROMMET MALE 6 MCMUGR07 PIPE GROMMET FEMALE 7 MCMUSP02 PIPE GROMMET SPACER 8 HCBF0630 PIPE GROMMET WASHER 9 HCHA0003 6MM CLIPNUT

10 BCMU0008 CABLE – BRAKE SNAKE 11 BCMU0009 CRIMP – BRAKE SNAKE 12 HCBC0645 M6X45 SOCKET HEAD CAP SCREW 13 TCHA0004 BUSHING – REAR TANK MOUNTING 14 HCHA0003 6MM CLIPNUT 15 HCNL0601 6MM LOCKNUT 16 TCHA0006 BUSHING – FRONT TANK MOUNT (2 REQ’D) 17 HCBF0685 M6X85 SHCS

Page 32

Parts – Frame – Seat, Fender, R Side Panel, Brake Pedal, Silencer & Shock Mounts

Figure 20

Frame – Seat, Fender, Right Side Panel, Brake Pedal, Silencer & Shock Mounts

REF # PART # DESCRIPTION

FAMU0004 FRAME 2004 CM50 1 HCBB0630 M6X30 BUTTON HEAD CAP SCREW 2 HCHA0003 6MM CLIPNUT 3 HCBF0620 M6X20 FLANGE HEAD BOLT 4 HCNF0602 6MM NYLOC FLANGE NUT 5 HCBF0630 M6X30 FLANGE HEAD BOLT 6 MCMUGR04 GROMMET – SILENCER (2 REQ’D) 7 HCBF0616 M6X16 FLANGE HEAD BOLT 8 HCBB0803 M8X40 BUTTON HEAD SCREW 9 HCNL0801 8MM LOCK NUT

10 HCBC1001 M10X45 SOCKET HEAD CAP SCREW

Page 33

Parts - Frame – Radiator, Footpeg, Chain Roller, and Airbox Mounts

Figure 21

Frame – Radiator, Footpeg, Chain Roller, and Airbox Mounts

REF # PART # DESCRIPTION

FAMU0004 FRAME 2004 CM50 1 ECHA003 MOUNTING BRACKET – RADIATOR BOTTOM 2 HCBC0607 M6X50 SOCKET HEAD CAP SCREW 3 HCNL0601 6MM LOCK NUT 4 MCKGGR00 GROMMET – RADIATOR MOUNT (2 REQ’D ON BOTTOM, 1 ON TOP BRACKET) 5 ECHA0109 MOUNTING BRACKET – RADIATOR TOP 6 HCBC0660 M6X60 SOCKET HEAD CAP SCREW 7 FCMU0057 CHAIN ROLLER 8 HCWF1201 WASHER FLAT, CHAIN ROLLER (2 REQ’D) 9 HCCP0002 COTTERPIN 3/32 X 1 (2 REQ’D)

10 TCMU0014 FOOTPEGS (SET OF 2) 11 TCMU0102 SPRINGS – FOOTPEG (SET OF 2) 12 HCBF0850 M8X50 FLANGE HEAD BOLT 13 HCWF5601 FLAT WASHER 14 HCNL0801 8MM LOCK NUT 15 HCBF0616 M6X16 FLANGE HEAD BOLT

Page 34

Parts – Front Brakes

Figure 22

Front Brakes

REF # PART # DESCRIPTION

1 BCMU0300 BRAKE HUB – FRONT 2 BCMU0113 BRAKE ARM – FRONT 3 BCMU0005 CABLE CLAMP, WASHER & NUT 4 BCMU0006 CABLE ADJUSTOR 5 BCMU0110 BRAKE SHOE (PAIR) 6 BCMU0010 SPRING – BRAKE RETURN 7 BCMU0011 PUSH NUT – BRAKE SPRING (2 REQ’D) 8 BCMU0007 BRAKE STOP

9 HCBH0808 M8X30 BUTTON HEAD SCREW 10 BCMU0100 BRAKE LEVER / PERCH ASSEMBLY WITH ADJUSTER 11 BCMU0108 BRAKE CABLE

Page 35

Parts – Front Wheel

Figure 23

Front Wheel

REF # PART # DESCRIPTION

1 WAMU0300 FRONT WHEEL COMPLETE

2 WCMU0250 FRONT TIRE 10X2.50”

3 WCMUTU10 TUBE 10”

4 WCMU0014 FRONT AXLE

5 HCWF1202 WASHER – AXLE

6 WCMU0023 FRONT WHEEL SPACER

7 WCMU0020 BEARING – WHEEL (2 REQ’D)

8 WCMU0004 SPACER – WHEEL FRONT

9 BCMU0300 BRAKE HUB – FRONT 10 HCNS1201 NUT - AXLE

Page 36

Parts – Plastic Bodywork & Seat

Figure 24

Plastic and Seat

REF # PART # DESCRIPTION

NOT SHOWN

1 TCHA0107 FRONT FENDER

NOT SHOWN

2 TCMU0005 NUMBER PLATE - FRONT

NOT SHOWN

3 TCHA0010 RADIATOR SHROUD - RIGHT 4 TCHA0011 RADIATOR SHROUD - LEFT 5 MCMUBC01 BUNGEE CORD – SHROUD HOLDING 6 TCHA0001 FUEL TANK – NOT COMPLETE

NOT SHOWN NOT SHOWN NOT SHOWN NOT SHOWN NOT SHOWN NOT SHOWN NOT SHOWN

NOT SHOWN NOT SHOWN

7 TCMU0038 FUEL PETCOCK 8 TCHO0001 SEAT

NOT SHOWN

9 TCHA0011 NUMBER PLATE – LEFT REAR

NOT SHOWN NOT SHOWN NOT SHOWN

10 TCHA0010 NUMBER PLATE – RIGHT REAR

NOT SHOWN NOT SHOWN NOT SHOWN

11 TCHA0012 FENDER – REAR

NOT SHOWN

TCMU0020 GRAPHIC KIT HCBF0616 FENDER BOLT, M6X16 FLANGE HEAD (4 REQD)

HCBF0620 M6X20 FLANGE HEAD BOLT – FRONT NUMBER PLATE MOUNT

TCHA0002 CAP – FUEL TANK TCHA0003 HOSE – FUEL CAP HCSF0620 M6X20 PHILIPS HEAD SCREW – SEAT & SHROUD HOLD TCHA0005 SPACER – SEAT & SHROUD HOLD TCHA0006 SPACER – FRONT TANK MOUNT (2 REQ’D) HCBC0685 M6X85 SHCS – FRONT TANK MOUNT HCNL0601 6MM LOCK NUT – FRONT TANK MOUNT BOLT HCBC0645 M6X45 SOCKET HEAD CAP SCREW TCHA0004 BUSHING – REAR TANK MOUNTING

HCBB0630 M6X30 BUTTON HEAD CAP SCREW – SEAT HOLDING

BCBF0616 M6X16 FLANGE HEAD BOLT – FRONT SECURE BCBF0620 M6X20 FLANGE HEAD BOLT – FENDER & REAR SECURE HCNF0602 6MM NYLOC FLANGE NUT

BCBF0616 M6X16 FLANGE HEAD BOLT – FENDER & AIRBOX SECURE

Page 37

Parts – Rear Brake

Figure 25

Rear Brake System

REF # PART # DESCRIPTION

1 BAMU0301 BRAKE PEDAL 2 BCMU0008 CABLE – BRAKE SNAKE 3 BCMU0009 CRIMP – BRAKE SNAKE 4 HCBB0803 M8X40 BUTTON HEAD SCREW 5 HCNL0801 8MM LOCK NUT 6 HCBH0602 M6X25 HEX HEAD BOLT (BRAKE STOP ADJUST) 7 HCNS0601 6MM NUT 8 BCCM0105 BRAKE ROD

9 BCMU0111 BRAKE ROD BARREL 10 HCNW0001 BRAKEROD WINGNUT 11 BCMU0109 BRAKE HUB - REAR 12 BCMU0112 BRAKE ARM – REAR 13 BCMU0010 SPRING – BRAKE RETURN 14 BCMU0110 BRAKE SHOE (PAIR) 15 BCMU0011 PUSH NUT – BRAKE SECURE (2 REQ’D) 16 HCCP0001 COTTER PIN - 3/32 X 1/2 17 HCWF0502 5MM FLAT WASHER

Page 38

Parts – Rear Wheel

Figure 26

Rear Wheel

REF # PART # DESCRIPTION

1 WACM0100 WHEEL COMPLETE – REAR 2 WCMU0275 TIRE – REAR 10X2.75” 3 WCMUTU10 TUBE – 10” 4 PCMU0137 SPROCKET – 37T 5 PCMU0059 RUBBER SPROCKET DAMPERS 6 WCMU0016 REAR AXLE 7 HCPA0002 AXLE HEAD FIXING PLATE 8 WCMU0001 REAR WHEEL SPACER (SPROCKET SIDE)

9 WCMU0020 WHEEL BEARING (2 REQ’D) 10 WCMU0003 WHEEL BEARING SPACER - REAR 11 BCMU0109 BRAKE HUB - REAR 12 WCMU0009 REAR WHEEL SPACER (BRAKE SIDE) 13 HCWF1202 WASHER – AXLE 14 HCNS1201 NUT – AXLE 15 WCMU0008 WHEEL DAMPER PLATE 16 HCBH0701 M7X35 HEX HEAD BOLT 17 PCCM0001 CHAIN –88 LINKES 420 18 PCMU0001 MASTER LINK – 420 CHAIN

Page 39

Parts – Shock

Figure 27

REAR SHOCK

REF# PART # DESCRIPTION

1 SACM2004 SHOCK ABSORBER 2 SCMUOH05 SPRING – STANDARD (285 lb/in)

SCMUOH04 SPRING – LIGHT (275 lb/in) SCMUOH06 SPRING – HEAVY (295 lb/in)

3 HCBC1001 M10X45 SHCS

Page 40

Parts – Swingarm Assembly

Figure 28

Swingarm

REF # PART # DESCRIPTION

GACM2004 SWINGARM ASSEMBLY (CONTAINS ITEMS 1 - 13) 1 GAMU0004 SWINGARM 2 GCMU0001 SWINGARM BUSHING (SINGLE PIECE) 3 GCMU0009 SPACER - PIVOT TUB E 4 GCMU0017 CHAIN GUARD 5 HCFH0516 M5X16 FLAT HEAD SCREW 6 HCWF0501 5MM FLAT WASHER 7 HCNL0501 5MM LOCK NUT 8 HCBF0620 M6X20 FLANGE HEAD BOLT 9 PCKG0000 CHAIN GUIDE - FRONT & BACK

11 PCKG0004 CHAIN GUIDE - BOTTOM SLIDER 12 HCBF1401 ¼ X 20 X 1 ½ FLAT HEAD SCREW (2 REQ’D) 13 HCNL1401 ¼ X 20 LOCK NUT 14 FAMU0005 WHEEL PULL ASSEMBLY 15 FCMU0203 WHEEL PULL 16 FCMU0202 WHEEL PULL ENDCAP 17 HCWF5601 5/16” FLAT WASHER 18 HCBH0810 M8X65 HEX HEAD BOLT (FULL THREAD) 19 HCBH1403 SWINGARM PIVOT BOLT 20 HCNL1402 14MM LOCK NUT 21 HCBC1001 M10X45 SOCKET HEAD CAP SCREW

Page 41

Service

Trained technicians with precision gauging and proper assembly fixtures carefully assemble all Cobra engines to specific clearances. If you feel you have the skills, and the appropriate tools, to perform the following service tasks please follow the instructions closely. The part numbers are listed throughout to help you when ordering parts from your local Cobra dealer.

If you don’t feel comfortable with the service work, simply take your engine out of the frame and sent it to:

Cobra Precision Engines

11511 Springfield Road North Lima, Ohio 44452

Cobra has specialized mechanics that will go through the entire engine, replacing gaskets, bolts, any old part that is worn. The engine will be rebuilt using the same precision gauging and assembly fixtures as when it was assembled new. Before leaving, the engines performance will be measured on a dynamometer to ensure that your engine is operating at its highest potential. All this for one low nominal fee. Call (330) 549-9603 for details.

Engine Service

One method for determining whether the top end of your engine needs rebuilt is to perform a WOT (Wide Open Throttle) kicking compression test. Before performing the procedure please read the caution notes below.

CAUTION:

• There appears to be a wide range of variability in reading compression gauges across the country.

• The head volume of this Cobra Motorcycle is very small and so requires many kicks ~20 before you establish the most accurate reading possible.

• 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 accu rate 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 these difficulties in measuring an absolute compression value, a useful relative value can be achieved by testing your bike’s compression with your own particular gauge after a new top end or when the bike is new so that you know what your particular gauge reads on a ‘fresh’ engine. When it has

Page 42

dropped to 90% of its original value the engine will be down on power and would benefit from a rebuild. When it’s dropped to 80% it really needs rebuilt! Using the table below will help you determine monitor the condition of your top end.

Example

Your Values

Engine is Fresh

Measured Value

110 psi 110 psi * 0.9 = 99 psi 110 psi * 0.8 = 88 psi

Engine Down on Power

Measured Value * 0.9

Engine NEEDS Rebuilt

Measured Value * 0.8

Procedure for Compression Testing

1. Shut off the fuel petcock.

2. Install the compression gauge into the spark plug hole.

3. Hold the throttle to wide open, and kick repeatedly (approximately 20 times) or until the gauge reading does not increase in value with each kick.

Engine Removal

To service the bottom end and transmission, the engine must be removed from the frame.

Tools required

• 5/16”, 10, 14, mm socket

• 10, 13, 22 mm wrench

• 10, 17 & 19 mm sockets

• 9/64”, 3,4 & 5 mm hex key (Allen wrench)

• 7 mm nut driver, flat or Phillip, screwdriver for hose clamps

• Spring remover

• Flywheel / clutch puller (#MCMUTL68)

• Clutch nut removal tool (Call local dealer for details).

Procedure

1. Remove the seat (4mm hex key).

2. Turn of the fuel at the petcock and disconnect the fuel line.

3. Remove the tank (5 mm hex key & 10 mm socket).

4. Remove the carburetor from the inlet (flat head or Phil lips head screwdriver, 7 mm nut driver).

5. Remove the right side number plate (3mm hex key).

6. Remove the silencer & pipe (spring remover, 5mm hex, & 10mm wrench).

7. Disconnect the ground wire from the reed cage with a 5 mm hex key (depending on your ultimate repair, you may want to reinstall the fastener in the inlet.

8. Leaving the coolant lines connected to the engine, remove the radiator from the frame (5mm hex with 10 mm wrench).

9. Remove the master link from the chain.

Page 43

10. Remove front engine mount bolt (13 mm socket, 6 mm hex key).

11. To access the swingarm bolt, remove brake lever (13 mm wrench, 5 mm hex key).

12. Remove the swingarm bolt (22mm socket & wrench).

NOTE: Only drive the swingarm bolt far enough to clear the engine, leave it holding the one side of the swingarm to the frame

13. Remove the engine from the right side of the frame.

14. Locate a suitable container for the engine coolant and remove radiator hoses from engine (coolant will drain).

NOTE: If the coolant looks to be free of contaminates it may be reused.

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 (9/64” 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 secures the flywheel.

4. Using the Cobra flywheel / clutch puller (#MCMUTL68), remove the flywheel from the crankshaft.

5. Remove the stator (9/64” hex key).

6. Remove the nut holding the large gear to the transmission input shaft (19 mm socket).

7. Remove the special nut / starter gear that holds on the clutch (special tool available, contact your local dealer).

8. With the Cobra flywheel / clutch puller (#MCMUTL68), remove the clutch from the crankshaft (details in Clutch Service portion of this manual).

Top End Disassembly Procedure

1. Remove the cylinder head nuts (5/16”).

2. Remove the outer cylinder head.

3. Remove the inner cylinder head.

Page 44

INSPECTION NOTE:

Inspect the cylinder head for deposits and abrasions.

1. If there are deposits they should be removed a. Black oily deposits (indicating a rich mixture or improper oil

type/quantity) can be removed with solvent

b. Crusty deposits (indicating dirt ingestion) can be removed with

solvent and may require some scraping.

2. Abrasions a. Pitting or erosion indicates detonation and may require cy linder

head replacement, also

i. Retard the ignition timing

ii. Use a higher octane fuel

b. Missing chunks or indentations indicate broken hardware or

ingested items - replace the cylinder head.

4. Remove the cylinder.

Inspect the cylinder bore for abrasions, deposits, and missing coating.

1. If abrasions: scrapes, scratches, pitting, etc… are found, replace the

cylinder.

2. If deposits are all are found a. Clean with muratic acid. b. Once the deposits are removed, inspect for abrasions and missin g

surface coating.

i. If there are abrasions or missing coating, replace.

ii. If all looks well, the cylinder may be saved.

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 necessary.

Splitting the Cases

1. Remove the fasteners holding the two halves of the crankcase together.

2. Separate the cases with a proper case splitting tool.

Page 45

CAUTION: Take caution when handling the crankshaft. It is the main power transfer to the rest of the engine. If it is out of alignment, it will cause premature failure of your bearings which can lead to serious damage to the cylinder and the rest of the engine. Do not try to true the crank yourself. Truing the crank should be done professionally.

CAUTION:

• If you split the cases, check the gear tooth faces for chapping & signs of fatigue.

• Check the small needle bearings for fatigue. If the bearings are damaged, the engine cases should be checked to make sure the needle -bearing casing didn’t oblong the bearing hole in the case.

• Needle bearings should be replaced every racing season.

Engine assembly

CAUTION: For any seals that are to be installed, apply a light amount of grease to the seals’ ID 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 the crank seals such that the concave side faces the crank weights.

3. Press in the counter shaft seal (concave side faces inside of transmission)

4. Install the water pump assembly wire ring retainer

5. Press in the water pump assembly

6. Tap both ways axially then verify easy rotation

7. Press crank into right case half

CAUTION: Insert a 7.05mm (0.278”) shim between the crank throws before pressing on the crank.

8. Insert the transmission input shaft and install large drive gear as shown in figures 25 & 26.

NOTE:

If the nut was removed from the input shaft, it will be easier to install and tighten later.

Page 46

Figure 29

Figure 30

Page 47

9. Insert dowel pins in the left side case as shown in figure 27.

Figure 31

10. Apply gasket sealer (ThreeBond 1104 gasket material or equivalent) to the mating surfaces of both crankcase halves.

11. Apply the crankcase gasket to the left crank case half being sure to install the gasket behind the connecting rod.

12. Assemble the two case halves together with the shim installed between the crank throws. Be sure to remove the shim after assembly.

13. Insert the screws with the proper lengths at locations shown.

14. Torque to 9 Nm (80 in -lb) in the pattern shown in figure 28.

15. Install the piston with new wrist pin bearing and, pin and clips.

Figure 32

Page 48

16. Install the piston rings.

CAUTION: Be sure to align the piston such that the arrow on the top piston surface points to the exhaust (front of bike/engine).

17. Apply gasket sealer (ThreeBond #1104, semi-drying liquid gasket material) to the cylinder deck areas around the coolant passage and cylinder studs as shown in figure 29.

Figure 33

18. Install the base gasket

19. 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.

20. Install the cylinder studs and o’rings as shown in figure 30.

Figure 34

Page 49

21. Install cylinder head insert.

22. Install O’rings as shown in figure 31.

Figure 35

23. Install the cylinder head and torque to 9.2 ft-lb (12 Nm)

24. Install stator reinstalling the grommet and wires (snug the bolts).

25. Install the rotor per Rotor Installation section, under the S3: Ignition portion of this manual.

26. Install the water pump outlet pipe (apply Ultra black Hi-Temp RTV silicon gasket maker to the threads before assembly) before installing the clutch and rotate to a vertical position with the engine resting on a bench

27. Install the clutch per Clutch Installation section in this manual.

28. Install the coolant drain plug with copper washer (11 ft-lb, 15 Nm).

29. Make sure that the exhaust spacer is on the cylinder (53 in -lb, 6 Nm).

30. 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 ¼ turn).

31. Install reed and inlet manifold with new gaskets (58 in -lb, 6.5 Nm).

Page 50

Clutch

Cobra clutch puller assembly:

Clutch puller diagram

Figure 36

Tools recommended for clutch service:

• Universal clutch puller- a universal puller that pulls the clutch, main drive gear and rotor. (Part # MCMUTL70).

• 5mm T-handle

• Clutch nut removal tool (Call local dealer for details)

• Cobra 3 Shoe Clutch Milk (Part # MCMUGF01)

or Dexron III ATF.

CLUTCH REMOVAL:

1. Drain the engine transmission oil.

2. Remove the pipe and remove the 6 bolts that hold the kick-starter cover on.

3. Remove the clutch nut (not left hand thread) on the end of the crankshaft with the clutch nut removal tool.

4. Attach the COBRA CLUTCH PULLER. There are three 6mm clutch puller holes located on the ends of the center hub. (figures 32 & 33) You must use a draw type puller to remove the clutch.

CAUTION: Do not use a jaw type puller or use the 6mm tapped holes as jackscrews or you are likely damage the clutch or drum.

5. If necessary apply heat to the center clutch hub.

CAUTION: Do not heat the crankshaft threads or the aluminum shoes.

6. Keep tension on the puller as you are heating it.

Figure 37

The clutch will often pop off under tension from the puller and it will be very hot.

Page 51

CLUTCH WASHER STACKUPS:

Once the clutch is removed, and cool to touch, carefully put it into a vice and remove 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.

CAUTION: It is very important that the clutch stack be reassembled as it was disassembled unless new shoes are being installed then it is important to reinstall per figure 34.

CLUTCH ASSEMBLY REFERENCE DRAWING

REF # PART # DESCRIPTION

1 CAKG0004 Set of three shoes, springs, bolts, flat washers & nuts 2 CAMU0008 Set Of three springs, washers, bolts & nuts 3 CAKG0005 Set of three shoes 4 HCBS5603 Single center shoulder bolt

CAUTION:

The ‘4 stack’ clutch spring stack is new for 2004.

Figure 34 Recommended clutch spring stack. Each ‘spring’ stack contains nine springs

(Bellville washers) - six arranged into four ‘flying saucers’, and one turned away against the flat washer(s). An optional ‘three stack’ will deliver smoother, less aggressive power. For details see Figure 34b.

Figure 34b

Page 52

Clutch shoe wear:

• If the clutch has been slipping and shows signs of glazing, it is best to replace the shoes. We have found that once the shoes are glazed, even if deglazed with emery paper or a file, the performance is reduced.

• The best way to prevent glazing is by not gearing too high, changing the oil as specified and by not blipping the throttle. Every time you blip the throttle, you are working your clutch springs.

CAUTION: The clutch produces a tremendous amount of heat and when a 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 to start to slip. So you will need to clean the sludge out or just replace the spring washers and bolts with new ones. How quickly this sludge builds up depends on how often you change your oil and whether your rider is a throttle ‘blipper’.

REF # PART NO. DESCRIPTION

1 ECMU0017 Crank seal 2 ECMU0040 Clutch to hub spacer 3 ECMU0003 Brass bushing 4 ECMU0033 Clutch Hub w/ brass bushing 5 CAKG0002 Clutch Complete w/ Arbor 6 ECMU0018 Clutch nut

Figure 39, Clutch Assembly Drawing

Page 53

CLUTCH ASSEMBLY:

1. After cleaning or replacing the spring washers, reassemble the stack up of washers.

CAUTION: It is important to reassemble the washer stack to that recommended or to your own specialized stack.

CAUTION: It is also important that all three shoes are stacked the same. (See figure 34)

2. Clean the threads of the stack bolt and the clutch with contact cleaner removing al l old thread locking material.

3. Apply high strength (red) thread lock material to the stack bolt and tighten as tight as possible without stripping the Allen head.

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 / bearing retainer (green) thread lock agent to the center tapered section of the crankshaft and taper of clutch arbor.

CAUTION: Lean the bike / engine such that any excess thread lock agent goes away from the bushing in the clutch drum.

6. Put the clutch back in.

7. Apply high strength (red) thread locking agent to the threads and install the nut and torque to 40 ft-lb (54Nm) with the special socket (see figure 35).

CAUTION: Use high strength (red) thread locker on the threads of the clutch nut. If you are using an impact socket, just zap it lightly with an air wrench to tighten it because there are only about 4 threads inside the nut and they can be easily stripped. If you are tightening it by hand, you can very carefully use a 3/4" piece of wooden dowel rod inside the exhaust port to block the piston so you can tighten the nut. Do not use something harder than your aluminum piston and do not crush the top of the piston into the ring.

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INSPECTION NOTE:

• There must be in / out play in installed clutch, 1.0 mm (0.04”)

• Should be no looseness in clutch shoes.

maximum.

• Excess in/out will cause early crank seal failure.

• A blue clutch drum is worn out from excessive slippage or improper

lubrication.

8. Install the clutch cover taking care to put the two longer bolts in their proper locations and tightening in the order specified in figure 36. (5mm hex key, 5.8 ft-lb, 7.8 Nm).

CAUTION: Prior to tightening the six clutch cover bolts, press the kick lever down to ensure proper kick gear alignment.

9. Put pipe back on and add oil (235 ml (8.0 oz) Cobra 3 Shoe Clutch Milk (Part # MCMUGF01) or Dexron III ATF.

Ignition

Stator care

Stator failure will result from running the bike hot. Following is a list of things that will make your engine run hot.

1. The timing should not exceed the maximum specifications listed.

2. Improper carburetor jetting.

Figure 40

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3. Improper spark plug heat range. Never run a hotter plug than the specified spark plug.

4. Clutch slippage. See “CLUTCH” section for causes of slippage.

CAUTION:

• Because of the amount of heat generated by the clutch and engine during extended 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. Spray the stator and rotor with CRC 3-36 or WD -40 and let it drip dry or blow it off a little with an air nozzle.

• Ignition will overheat if the gap between the rotor and stator is not large enough. There should be even clearance as the rotor rotates relative to the stator.

• Non -resistor spark plug caps should be used. Resistor caps will result in a weaker spark that will reduce performance.

• Make sure ground wires are secure.

• Make sure connections are free of dirt.

CAUTION: If the engine is hot, it is EXTREMLY important to take the ignition cover off, put a fan on it to let it cool, and spray it with CRC 3-36 or WD -40. Proper stator care is important for the durability of the ignition system. (Stator- Part # ICMU0007)

The proper ignition timing for this model of is at 0.050” before Top Dead Center (that means 0.050” (1.3mm) 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 lead to premature stator failure, and can also cause detonation which can lead to premature piston and ring failure.

Tools recommended for timing service:

• Compact motorcycle dial indicator

• Universal clutch puller- a universal puller that pulls the clutch, main drive gear

and rotor. (Part # MCMUTL70).

TIMING YOUR IGNITION:

1. Remove the spark plug cap, and sparkplug.

2. Insert the dial indicator into the spark plug hole.

3. Remove the four 8/32” X 1 ¾” bolts from the ignition cover.

4. Remove the water pump belt from the rotor and water pump shaft.

5. Turn the crankshaft counterclockwise until it reaches top dead center.

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6. Set the dial indicator to zero

7. Turn the crankshaft clockwise until the dial indicator reaches 0.05)” (1.3mm) from top dead center.

8. Line up the lines on the stator and the rotor (figure 37). Otherwise loosen the three 10X32 bolts to adjust the stator.

0.050” before

TDC

Figure 41, Lining up the line on the rotor with the line on the stator.

Figure 42, Using a dial indicator to measure piston height for setting ignition timing.

ROTOR INSTALLATION:

1. Use wicking / bearing retainer (green) thread locker on the 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 37).

3. Torque the nut on the rotor to 40 ft-lb (54 Nm).

4. Recheck the timing following the procedure of timing your ignition.

5. Install the water pump belt back on.

6. Bolt the ignition cover back on.

7. Put the spark plug back in, and firmly stick the spark plug cap onto the spark plug.

Cooling System

The water pump in the engine keeps the radiator fluid in circulation throughout the motor. The air stream running through the radiator cools the radiator fluid. Therefore dir ty radiators additionally reduce the cooling effect.

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Cobra has tested numerous brand name automotive and racing coolant / antifreeze solutions and has found Liquid Performance Propylene Glycol based Mini Coolant / Antifreeze to have the greatest effect on reducing cylinder head temperatures.

Radiator fluid removal:

1. Remove the coolant drain plug (A) on the front of the engine case (figure 39).

Figure 43

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 abnormal smell.

Fill the radiator up to the bottom of the radiator filler neck with coolant. Install the cap, turning it clockwise about ¼ turn.

Tools recommended for impeller service:

• Flat head screwdriver

• 5mm hex key

• 13mm- hex wrench

• 1/8” hex key

• 9/64” hex key

• 3/32” hex key

• Propane torch

• 3/8” diameter x 8” long steel rod

• Hammer

COBRA IMPELLER SERVICE INSTRUCTIONS

1. Remove exhaust pipe and gas tank (you will be using a propane torch in step 12.

2. Remove radiator cap and drain engine coolant by removing the 13mm- hex head coolant drain plug.

3. If the impeller is damaged or broken completely back flush the coolant system to ensure no solid pieces are in the system.

4. Remove foot brake.

5. Drain engine transmission oil by removing drain screw using a 13mm- hex wrench. (item 2 in the figure below).

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6. Remove kick-starter cover using a 5mm hex key. (item 3 six places)

7. Remove clutch and basket.

8. Unscrew water elbow fitting. (Figure 40)

Figure 44

8. Remove ignition cover using a 9/64” hex key (four places)

9. Remove belt retainer screw using a 1/8” 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 3/32” hex key. (Figure 41 – item 2)

Figure 45

12. Heat engine case around area of impeller lightly with a small Burnsmatic propane torch. Using a 3/8” diameter x 8” long steel rod, tap impeller assembly out of engine as shown in figure 42.

Figure 46

CAUTION: Too much heat can be detrimental to the engine cases.

13. The shaft assembly is serviceable. Use a 1/8” hex key to remove impeller retainer screw. Remove impeller, seal and both bearings. Check shaft for wear in the area of the seal. If there is any sign of wear (like a groove) replace the shaft.

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Figure 47

all threads and use green (wicking / bearing retainer) thread locker on the belt

Temp RTV silicon gasket maker to the threads of the water

Do not mix Propylene Glycol based coolant / antifreeze solutions with Ethylene

14. Reinstall new bearings, seal and impeller. Clean all threads and use green (wicking / bearing retainer) thread locker.

15. Using a liberal amount of grease on the outside seal, bearings and inside of case, reinstall bearing assembly by using a 0.500” ID by 1.000” OD steel tube 2” long and tap on end of tube per figure 44.

Figure 48

16. Re-assemble in same order of disassembly.

CAUTION: Clean retainer screw.

NOTE:

Apply Ultra black Hipump 90° elbow fitting before assembly.

NOTE:

Refill the coolant system with Liquid Performance Propylene Glycol based Mini Coolant / Antifreeze.

CAUTION: Glycol based coolant / antifreeze solutions.

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Fuel & AiR System

Carburetor:

Tools recommended for carburetor service:

• Small flat head screwdriver

• WD-40

• 8mm socket

Carburetor

REF. # PART # DESCRIPTION

RCCM0001 COMPLETE CARBURETOR 14MM

1 RCMU0305 CARB SLIDE 2 RCMU0601 NEEDLE 3 RCMU0002 ATOMIZER

4 RCMU0092 MAIN JET 5 RCMU0055 PILOT JET 6 CHOKE JET

7 RCMU0301 FLOAT 8 RCMU0102 RUBBER CABLE CAP SEAL

9 RCMU0003 CABLE ADJUSTER 11 RCMU0006 TOP CARB SCREW 12 RCMU0106 CARB TOP

27 RCMU0012 DIFFUSER 28 RCMU0016 FLOAT RETAINER PIN 29 RCMU0106 FLOAT BOWL 30

RCMU0201 BOTTOM FLOAT SCREW

31 33 RCCM1301 VELOCITY STACK

RCCM0314 14MM CARB RESTRICTOR

Figure 49

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Your Cobra is equipped with an adjustable carburetor. Some fine -tuning may be needed according to weather condition and altitude. Proper jetting is very important for engine performance and engine life. Serious damage to the engine can occur if not properly adjusted.

IDLE ADJUSTMENT:

On the left side of the carburetor, there are two adjustment screws. The larger screw with the knurled 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: Before changing jetting be sure that the air filter is properly cleaned and has the usual amount of air filter oil. An overly dirty air filter can cause the engine to run rich.

If the engine is running rich on the top end it should be leaned out. Leaning it out can be done by:

1. Changing the main jet to a smaller number.

2. Raising the needle clip (this lowers the jet needle) one notch at a time on the slide.

Indications that the engine is running too lean are:

• Engine cutting out on top end.

• Engine overheat ing and ultimately seizure.

• White spark plug

CAUTION: It is much safer to operate the engine slightly 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 the clip back up one notch or until you get the blubber out.

FUEL MIXTURE SCREW

The smaller brass screw that is towards the front of the engine is a fuel mixture screw. This screw will also richen and lean your engine more on the bottom and mid-range. In warmer conditions, turn the screw in. In colder conditions, turn the screw out. Be sure to keep the carburetor very clean and make sure you don't

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have water or dirt in the carburetor bowl. Use automotive carburetor cleaner or WD-40 to clean the carburetor inside and out.

STOCK CARBURETOR SETTINGS

The 2003 KING stock carburetor settings from the factory are:

• 55 pilot jet

• 92 main jet

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 flammable liquids, do not use gasoline or low flash -point solvent to clean the carburetor.

1. Make sure the fuel 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. Do not use a strong carburetor cleaning solution, which could attack the parts of the carburetor; instead, use a mild high cleaning solution safe for plastic parts.

5. Immerse all the metal parts in a carburetor cleaning solution.

6. Rinse the parts in water.

7. After the parts are cleaned, dry them with compressed air.

8. Blow out the fuel passages with compressed air.

9. Assemble the carburetor

10. Install the carburetor onto the motorcycle.

CAUTION:

1. The motorcycle will only operate

properly if the carburetor top is installed properly with the mounting screws, cable and choke knob oriented as shown in figure 46.

Figure 50 Proper carburetor top installation and location of rectangular slide indexing pin and vent elbows.

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Reeds:

• The reeds must lay flat on the reed cage.

• If the reed tips aren’t lying flat, replace them immediately.

• The reeds mu st have a tight seal on the reed cage.

• If the reed is damaged in any way, replace it. This means cracks, chips,

and ruptures. Anything abnormal, replace the reeds.

Take the reed cage out and hold it up to the light and look in through the cage. If you see light between the reed pedals and the frame, then replace the reeds. If you do not see light, then the reeds should be ok. (See figure 47)

Figure 51

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 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.

CAUTION: It is important to repack the silencer. Signs of your silencer needing to be repacked are:

• The bike is louder than normal.

• A loss of power.

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Wheels & Tires

Rear wheel

Rear wheel dampening Tools recommended for wheel service:

• 13mm socket

• Flathead screwdriver

• 11mm wrench or socket

• 19mm wrench

The Cobra is the only 50cc to have the rear wheel damping system. This feature prevents engine impact shock caused by hard landings. This design allows the cushioned sprocket to move forward and backwards separately from the wheel. After each moto, check the 4 rubber dampers, spacers and bolts for fatigue. You should keep extra rubber dampers in your toolbox (part # PCMU0059). Different sized sprockets are also available.

Watch for bending and warping of the outside rear damper plate. If it is bent or warped, the rubber dampers in the sprockets do not last as long as when using a straight unit. Usually you can straighten the plate with a hammer or just flip it over.

Changing the rubber dampers:

1. Remove the four bolts with the 11mm wrench

2. Take the backing plate off

3. Observe the four rubber dampers, and pull the sprocket upward to remove it.

1. Pop the four rubber dampers out of the sprocket.

2. Push the rubber dampers into the sprocket.

3. Place the sprocket with rubber dampers, onto the aluminum studs.

4. Place backing plate over the dampers and sprocket.

5. Insert the 11mm bolts into the holes and tighten to 18 ft-lb (24 Nm).

Figure 52

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Rear wheel pullers

Disassembly:

1. Remove axle, and back wheel assembly.

2. Pull the rear wheel pullers out of the back of the swing arm.

Figure 53

Rear wheel alignment:

By eye, ensure that the rear sprocket is running true (in-line, planar) with the front sprocket. When the sprockets are running true, the wheel is properly straightened, and the chain will run straight.

Page 66

Suspension

See the parts and optional components sections of this manual for the springs and v alving available for heavier and lighter riders.

Front forks tuning

The front forks are designed with the damping components in separate fork legs. The compression damping duties are performed in the right fork leg and the

rebound damping duties are performed in the left fork leg. This allows easy adjustment of the damping characteristics by appropriately changing the viscosity of the fork oil in the fork leg controlling the camping characteristic that need changed.

Example: If stiffer compression damping is required, switch from 20 (standard), to 25 or 30 weight fork oil in the right fork leg. If softer rebound damping is required, switch from 20 (standard) to 15 or 10 weight fork oil in the left leg.

NOTE:

Fork oil level affects bottoming harshness, and fork oil viscosity affects valving speed.

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Troubleshooting

1) Engine not behaving properly

a) Carburetor top is installed backwards (happens a lot) b) The carburetor slide indexing pin is missing

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

3) Engine is excessivel y 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 ground

v) Stator winding damaged d) Exhaust is plugged

6) Engine won’t idle

a) Idle knob needs adjusted

b) Carburetor jets are dirty

Page 68

Index

Air Filter

Maintenance..................................16

Airbox

Parts...............................................18

Bars and Controls.............................19

Break-In................................................9

Carburetor

Parts...............................................20

Service...........................................59

Specifications..................................5

Chain

Adjustment.....................................14

Chassis

Specification....................................5

Forks

Adjustment.....................................65

Parts...............................................28

Frame Parts.......................................30

Front Brake

Adjustment.....................................15

Parts...............................................33

Front Wheel Parts ............................34

Fuel System

Service...........................................59

General Tips ......................................11

Hardware and Fasteners

Frame.............................................30

Plastic.............................................35

Clutch

Parts...............................................24

Service...........................................49

Clutch Lubricant

Replacing.......................................13

Compression test.............................41

Cooling System.................................55

Damper..............................................63

Electrical

Parts...............................................22

Engine

Parts List........................................19

Specifications..................................5

Exhaust..............................................62

Parts...............................................27

Ignition

Parts...............................................25

Service...........................................53

Timing.............................................54

Jetting

How To...........................................60

Stock.................................................5

Lubrication

Recommended ...............................5

Maintenance

schedule.........................................12

tips..................................................12

Oil

Recommended ...............................5

Optional Components........................8

Fork Oil

Replacement.................................17

Parts

Airbox and Filter...........................18

Page 69

Bars and Controls.........................19

Damper..........................................63

Bottom End & Transmission.......23

Carbutetor......................................20

Clutch & Kick Starter....................24

Coolant System ............................21

Electrical........................................22

Engine ............................................23

Exhaust..........................................27

Forks...............................................28

Frame.............................................30

Front Brake....................................33

Front Wheel...................................34

Ignition & Water Pump.................25

Inlet.................................................18

Plastic & Seat................................35

Rear Brake ....................................36

Parts...............................................37

Pullers ............................................64

Reeds.................................................62

Shock

Parts...............................................38

Spark Plug

Recommended ...............................5

Specifications......................................5

torque values ...................................7

Starting...............................................10

Swingarm Parts ................................39

Tips.....................................................11

Top End

Parts...............................................26

Service...........................................40

Rear Wheel...................................37

Shock..............................................38

Swingarm.......................................39

Top End .........................................26

Triple Clamps................................28

Parts List

Engine ............................................19

Plastic & Seat Parts .........................35

Pullers ................................................64

Rear Brake

Adjustment.....................................15

Parts...............................................36

Rear Wheel

Torque Values.....................................7

Transmission

Specifications..................................5

Transmission Lubricant

Replacing.......................................13

Troubleshooting................................66

VIN reading .......................................11

WARNING ...........................................2

Water Pump

Parts...............................................25

Wheels

Service...........................................63