Cobra 2005 King Owner's Manual

Download

Page 1

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

MCKG2005.4

Page 3

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 KING IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED FOR, NOR SHOULD IT B E USED ON PUBLIC STREETS, ROAD S 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 OPE RATED 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 c ould 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.

Page 4

Table Of Contents

GENERAL INFORMATION ................................................................................... 5

SPECIFICATIONS - GENERAL ................................................................................. 5

OPTIONAL COMPONENTS ...................................................................................... 6

SPECIFICATIONS - TORQUE VALUES ...................................................................... 7

BREAK-IN PROCEDURE......................................................................................... 8

STARTING PROCEDURE ........................................................................................ 9

GENERAL TIPS ................................................................................................... 10

MAINTENANCE .................................................................................................. 10

SCHEDULE & TIPS .............................................................................................. 10

REPLACING TRANSMISSION / CLUTCH LUBRICANT ................................................. 12

CHAIN ADJUSTMENT ........................................................................................... 13

REAR BRAKE MAINTENANCE ............................................................................... 13

AIR FILTER CLEANING ........................................................................................ 14

FORK OIL REPLACEMENT ................................................................................... 15

PARTS ................................................................................................................ 16

PARTS – AIRBOX & INLET SYSTEM ...................................................................... 16

PARTS – BARS AND CONTROLS ........................................................................... 17

PARTS - CARBURETOR ....................................................................................... 18

PARTS – COOLANT SYSTEM ................................................................................ 19

PARTS – ELECTRICAL SYSTEM ............................................................................ 20

PARTS – ENGINE – BOTTOM END AND TRANSMISSION .......................................... 21

Parts – Engine Clutch and Kicker ................................................................ 22

Parts – Engine – Ignition and Water Pump .................................................. 23

Parts – Engine – Top End ............................................................................ 24

PARTS – EXHAUST SYSTEM ................................................................................ 25

PARTS – FORKS & TRIPLE CLAMPS ..................................................................... 26

Parts – Forks – Leg Assembly ..................................................................... 27

Parts – Forks – Damper Assembly .............................................................. 28

Parts – Forks – Damper – Base Valve Assembly ........................................ 29

Parts – Forks – Damper – Mid Valve Assembly ........................................... 30

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PARTS – FRAME I ............................................................................................... 31

Parts – Frame II ........................................................................................... 32

PARTS – FRONT BRAKES .................................................................................... 33

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 ............................................................................................................ 50

IGNITION ........................................................................................................... 55

COOLING SYSTEM .............................................................................................. 57

FUEL & AIR SYSTEM .......................................................................................... 61

EXHAUST .......................................................................................................... 64

WHEELS & TIRES ............................................................................................... 65

BRAKES ............................................................................................................ 66

FRONT FORKS ................................................................................................... 67

REAR SHOCK .................................................................................................... 69

TUNING .............................................................................................................. 70

GEARING ........................................................................................................... 70

SUSPENSION ..................................................................................................... 71

CARBURETION ................................................................................................... 72

TROUBLESHOOTING ........................................................................................ 75

INDEX ................................................................................................................. 76

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General Information

Items

KING

Dimensions

Wheelbase

39” (991mm)

Wheel size

10” (254mm) rear, 12” (305mm) front

Seat height

26” (660mm)

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, analog advance

Spark plug

Champion 8339-1, 8332-1 hotter, 8904-1 colder

Gap

0.023” – 0.025” (0.58 – 0.64 mm)

Ignition timing

0.040” (1.14 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 is

Carburetion

19 mm Dell’Orto

Main Jet

Slow (Pilot) jet

Float Height

16mm + 0.5mm (0.63” + 0.020”)

Coolant

Liquid Performance Mini Coolant / Antifreeze

Transmission

Speed

Single

Final drive ratio

14/38 T

Chain

100 links 420

Transmission / clutch oil type

Cobra Venom 3 Shoe Clutch Milk

Quantity

235 ml (8.0oz)

Specifications - General

RACE FUELS ARE NOT RECOMMENDED

complete)

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Chassis

Front tire

2.50 - 12

Pressure

16 psi minimum

Rear tire

2.75 - 10

Pressure

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

Front fork

Cobra 30mm USD

Fork oil type

SAE 10 weight

Fork oil amount

105 ml (3.5oz)

Weight of Rider (lb)

Fork Spring

Shock Spring

Less than 51

9 lb/in,

KCKG0109

SCKGOH85 (gray, 185 lb/in)

51 - 60

12 lb/in,

KCKG1201

SCKGOH95, (yellow, 195 lb/in)

Greater than 60

15 lb/in,

KCKG0015

SCKGO205, (gold, 205 lb/in)

Damping Rate

Fork Valving (base valve)

Fork Valving

(mid valve)

Shock Valving

Soft (fast)

KAKG0013

KAKG0016

SCKGOH24A

Standard

KAKG0014

KAKG0017

SCKGOH24

Hard (slow)

KAKG0015

KAKG0018

SCKGOH24B

Optional Components

Call your dealer, or the factory, for details

• Carburetor jets

• Flat clutch washers (see clutch service section)

• Pre filter for the airbox

• Sprockets

o Front o Rear

• Suspension Springs

• Suspension Valving

Compression

• Tires

• Tubes or ‘Tire Balls’

Rebound

(kit)

Page 8

Specifications - Torque Value s

Cylinder head nuts

Crankcase bolts

Stator cover bolts

Clutch cover bolts

Engine mount bolts

Swingarm Pivot

Intake manifold bolts

Rear Sprocket Bolts

Fork cartridge rod

Triple clamp bolts

Ignition rotor nut

Fastener

Spark plug (SP) (SP) (SP) M14 x 1.25 Stator bolts 2.1 25 2.8 M5 X 0.8

Clutch nut 40 480 54 M10 x 1.25* Clutch bolts 14 170 19 M6 x 1.0 Front axle nut 25 300 34 M12 x 1.25

ft-lb in-lb Nm

8.8 105 12 M6 x 1.0

1.7 20 2.3 M4 X 0.75

5.8 70 7.9 M6 X 1.0

22 265 30 M8 X 1.25

Torque Value

Size & Remarks

21 250 28 M14 X 2.0

4.6 55 6.2 M6 X 1.0

Rear Axle Bolt 25 300 34 M12 X 1.25

18 216 24 7 mm 12 144 16 6 72 8 M6 x 1.0

Fork cap 5 60 6.7 1.25” x 18

40 480 54 M10 x 1.25*

* Apply high strength thread locking agent when installing

(SP) To apply the proper torque to the spark plug when inserting, one must first

screw the spark plug in until the metal gasket ring causes resistance and then turn another 1/8 to ¼ turn.

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Break-In Procedure

Your Cobra KING is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The KING 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 m ixture may result in premature engine wear or damage to the machine.

Adhering to the following break-in schedule will result in long lasting high performance machine.

• Start bike on stand

• First 5 minute period, operate the bike on the stand with a combination of idle

and high RPM operation. (avoid prolonged high RPM but spin the rear wheel good at least once or twice per minute)

• Allow bike to cool

• Ride for 15 minutes maximum (avoid prolonged high RPM operation and

avoid abusing the clutch with throttle blipping.

• Cool and inspect bike for loose fasteners.

• Next ½ 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 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 lose som e engine coolant through the radiator overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper c oolant 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.

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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 complet ely otherwise engine damage could occur.

Starting Procedure

Before starting the machine inspect the following:

• Check for proper tire pressure in both tires.

• Observe the chain tension and adjust if necessary.

• Observe the coolant level and fill if necessary.

• Verify that the chain rollers and sliders do not have improper wear.

• Verify that the handlebars are tight.

• Check the throttle for smooth operation and sound closing.

• Check for loose bolts and nuts, and re-torque as necessary.

• Verify that the air filter is clean and properly saturated with oil.

• Insure that the fuel tank contains an adequate volume of fuel / oil mixture to

complete the distance required. (High octane pump gas with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil)

• Turn the fuel on by rotating the fuel petcock 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. Also, for best clutch performance, warm up the bike before taking off.

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This is a high performance race motorcycle. Too much application of throttle will likely land your little racer on his or her arse. Fenders can be replaced but bruised egos and other body parts take longer.

General Tips

1. Always wear a helmet 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. Filling your transmission with more than 8.0 oz (235ml) of lubricant may

help to transfer heat from the clutch, but be aware that this extra oil will increase the frictional drag on the engine, thus reducing power, and will often get purged out the crankcase vent during riding.

7. New chains will stretch on first use. Never install a new chain prior to a

race. Always ‘break’ them in during practice.

8. 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, Acxxxx5xxx is a 2005 MY King.

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 t he air f ilt er (clean and re-oil as necessary). o Ins ur e the smooth operation of the throttle cable (throttle soundly

‘clacks’ shut).

o Check f or fr ayed s t rands of the throttle cable inside the throttle housing

and replace if necessary.

o Check f or adequate tire pressures and adjust if necessary. o Check al l nut s and bolt s for proper torque and re-torque if necessary. o Spray all m oving par ts with WD40 or other light oil. o Check dr ive chain for

 Proper tension and adjust if necessary.  Adequate lubrication and lubricate if necessary.

o Ins ur e that the ignition stator and rotor are clean and dry.

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o Check t he f rame 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 Ins pect the rear sprocket damper plate for bending or warping.

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

o Check t he r im s f or signs of stress, like cracks around the rim, spokes

and hub.

• 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.

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.

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Replacing Transmission / Clut ch Lubricant

Tools needed:

• 235 ml (8.0 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01).

• 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 is ‘runny’ but not so hot that there is risk of being burned by the engine or the oil.

Hot oil and hot components on the motorcycle may cause burns.

2. Lean bike against something or set on stand with oil drain hole.

3. 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).

Figure 1

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 (8.0 oz) Cobra Venom 3 Shoe Clutch Milk

thru the oil 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 plug, hand tight, being sure the fiber gasket is in place.

CAUTION: Cobra has spent considerable time and money developing t he proper lubrication to handle the harsh environment of the automat ic 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

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capability over extended periods of time and is the recommended lubricant for

1. Make sure that the rear

Push down on the seat, sion down to where the

chain is tightest. At this

e should be a

With the rear wheel a minimum of 2.5” of

slack between the swing arm and the chain.

your Cobra motorcycle.

Chain adjustment

Figure 2

Rear Brake Maintenance

CAUTION: Too little brake pedal free-play will allow the brake pads to drag causing the pads to wear prematurely and possible engine component failures. Too much free-play will not all the rider to apply the brakes quickly.

1. Set pedal height/position first, then

2. Set pedal free play.

Brake pedal height can be adjusted with the bolt and nut located under the rear of the brake pedal. The free-play is adjusted with the adjustable plunger on the end of the brake pedal.

CAUTION: Use only DOT 4 brake fluid

Setting rear brake pedal position (see figure 2b):

1. Loosen the lock nut (10mm wrench).

2. Adjust the brake lever stop (10mm wrench) so that the lever is comfortably reachable in both:

a. Standing riding position, and b. Sitting riding position.

3. Tighten the lock nut (10 mm wrench).

wheel is aligned properly.

compressing the suspen-

point, ther minimum of 1” of slack.

elevated, there should be

Page 15

Figure 2b

CAUTION: Adequate pedal free play 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 it forward.

3. Slide the pin of the locking free play locking clip from the brake lever

4. Adjust as needed by rotating the clevis on the end of the adjustor (plunger).

NOTE:

Turning the clevis Clockwise will lengthen the adjustor (plunger), removing free play from the system, and turning the clevis Counter-Clockwise will shorten the adjustor (plunger) adding free play to the system.

Air Filter Cleaning

Tools recommended for air filter maintenance:

• Filter oil

• Grease

• Proudly nothing other than that!

CAUTION: It is very important to keep it clean and properly oiled with high quality waterresistant foam filter oil. It is also very import ant to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting.

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Make sure you change your filter after each moto. We recommend carrying three or more filters in your toolbox.

1 for practice 1 for the each moto

When washing your bike, it may be handy to remove the airboot and hose out the airbox. When doing so, cover the carburetor inlet with a suitabl e shield capable of keeping water from entering the engine. Cobra has a rubber cap for the carburetor inlet (part # RCMU0109).

Fork Oil Replacement

Tools required

• Two 19 mm wrenches or sockets

• 4 & 5 mm hex key (Allen wrench)

• 1” wrench or socket

• 10 wt fork oil

Disassembly procedure

1. Remove the front wheel (19 mm wrench).

2. Remove the brake caliber from the fork leg (4 mm hex key).

3. Loosen the fork caps (1” socket).

4. Remove the fork legs from the triple clamps (5 mm hex key).

5. One leg at a time a. Remove the fork cap from the leg. b. Separate the fork cap from the damper rod. c. Pull out t he fork spring. d. Place upside down over a suitable pan, tray, or container. e. Work the damper rod up and down several times. f. Allow it to drain completely.

Assembly procedure

1. Fill the fork leg with 3.5 oz (105 ml) 10 wt fork oil.

2. Measure the fork oil level to the top of the fork tube with the leg collapsed,

and record for tuning purposes.

3. Install the fork spring.

4. Reconnect the damper rod to the fork cap (12 ft-lb, 16 Nm).

CAUTION: The damper rod is hollow and will break if the nut is over tightened.

5. Reinstall the for cap into the fork leg (5 ft-lb, 6.7 Nm)

6. Reinstall the fork legs into the clamps (6 ft-lb, 8 Nm).

7. Reinstall the brake caliper.

8. Reinstall the front wheel (25 ft-lb, 34 Nm).

Page 17

Parts

Coolant System

REF #

PART #

DESCRIPTION

RAKG0001

AIRBOX

HCBF0616

M6X16 FLANGE HEAD BOLT

RCKG0502

AIR FILTER

RCKG0503

FILTER RETAINER

TCKG0004

MUDFLAP – AIRBOX

TCKG0105

BRACKET – MUDFLAP

HCBB0612

M6X12 BUTTON HEAD BOLT

MCKGHO03

HOSE CLAMP – AIRBOX TO BOOT

RCKG0505

AIR BOOT

MCKGHO01

HOSE CLAMP – BOOT TO CARB

MCKGHO04

HOSE CLAMP – CARB TO MANIFOLD

ECKG0203

INLET MANIFOLD

ZCMU0031

GASKET – MANIFOLD TO REED

ECKG0202

REED CAGE ASSEMBLY WITH REEDS

NOT SHOWN

ECKG0205

REED REPLACEMENT KIT

ZCMU0032

GASKET – REEDS TO ENGINE

HCBC0625

M6X25 SOCKET HEAD CAP SCREW

HCWF0601

6MM FLAT WASHER

RCCM1301

VELOCITY STACK

Parts – Airbox & Inlet System

Figure 5

Page 18

Parts – Bars and Controls

Bars and Controls

REF #

PART #

DESCRIPTION

TCMU0009

HANDLEBAR - STEEL

MCMU0001

OPTIONAL CROSS BAR PAD

TCMU0008

GRIPS (SET OF TWO)

FCMU0066

THROTTLE ASSEMBLY

NOT

SHOWN

FCMU0068

THROTTLE COVER

BCKG0023

ALLOY BRAKE LEVER W/BALL

BCKG0024

BRAKE PERCH ASSY W/LEVER & BALL

NOT

SHOWN

BAKG0004

SHIELDED BRAKE HOSE ASSEMBLY

FCMU0067

THROTTLE CABLE

HCBC0806

SOCKET HEAD CAP SCREW M8 X 30 (4 PER)

TKMU0404M

BAR MOUNT KIT, SHORT (2 PER)

TKMU0403M

BAR MOUNT KIT, TALL (2 PER)

HCBC1001

M10X45 SOCKET HEAD CAP SCREW (2 REQ’D PER BIKE)

HCNL1001

M10 LOCK NUT

NOT

SHOWN

HCBH0816

M8 X 16 HEX HEAD BOLT

NOT

SHOWN

HCWF0801

8MM FLAT WASHER

FCMU0033

KILL SWITCH ASSEMBLY

Figure 3

Page 19

REF. #

PART #

DESCRIPTION

RCMU0305

CARB SLIDE

RCMU0601

NEEDLE

RCMU0002

ATOMIZER

RCMU0096

MAIN JET

CHOKE JET

RCMU0301

FLOAT

RCMU0102

RUBBER CABLE CAP SEAL

RCMU0003

CABLE ADJUSTOR

RCMU0006

TOP CARB SCREW

RCMU0106

CARB TOP

NOT

SHOWN

NOT

SHOWN

Not Shown

FCMU0026

FUEL LINE

Not Shown

MCMUCL04

HOSE CLAMPS – FUEL LINE

Parts - Carburetor

Figure 4

Carburetor

5 RCMU0065 PILOT JET

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

RCCM1301 VELOCITY STACK -05 MCKGHO01 CLAMP – CARBURETOR TO FILTER

Page 20

Parts – Coolant System

Coolant System

REF #

PART #

DESCRIPTION

FCKG0036

RADIATOR WITH CAP

FCMU0047

RADIATOR CAP (2 ears or ribbed)

MCMUHO05

RADIATOR HOSE, TOP, LEFT

MCKGHO06

RADIATOR HOSE, BOTTOM, RIGHT

MCMUGR03

MOUNTING GROMMET (3 PER)

FCMU0006

RADIATOR MOUNTING BRACKET (TEARDROP)

HCBF0616

FLANGE HEAD BOLT M6X16

MCMUCL02

HOSE CLAMP (4 REQ’D)

ECHA0002

RADIATOR VENT HOSE

Figure 5

Page 21

Parts – Electrical System

Electrical System

REF #

PART #

DESCRIPTION

IAMU0001

COIL W/SPARK PLUG CAP

ECMU0065

SPARK PLUG, CHAMPION (8339-1)

ECMU0067

OPTIONAL HOTTER PLUG (8332-1)

ECMU0066

OPTIONAL COLDER PLUG (8904-1)

FCMU0033

KILL SWITCH ASSEMBLY

HCBC0516

SCREW, M5 X 16 (2 PER)

HCCN0000

5MM CLIP NUT (2 PER)

IAMU0002

GROUND WIRE

HCWF0504

WASHER FOR STATOR (3 PER)

HCBC0525

5mm x 25 SOCKET HEAD CAP SCREW

HCBC0535

5mm x 35 SOCKET HEAD CAP SCREW (2 REQ’D)

HCNS1001

NUT 10MM

ECKG0042

PULLEY, WATERPUMP CRANK

ICMU0006

ROTOR

NOT SHOWN

ICMU0012

WOODRUFF KEY

ICMU0007

STATOR

NOT SHOWN

MCKGGR01

GROMMET - STATOR LEAD

Figure 6

Page 22

Parts – Engine – Bottom End and

Engine Bottom End and Transmission

REF #

PART #

DESCRIPTION

ECKG0017

CRANKCASE, IGNITION SIDE no bearings

ECMU0020L

BEARING, TRANSMISSION PRECISION

ECKG0004

SNAP RING, WATER PUMP

ZCMU0501

GASKET, CRANKCASE

ECMU0106

SECONDARY SHAFT, TRANSMISSION WITH GEAR

ECMU0017

SEAL, CRANKSHAFT

ECMU0016

BEARING, CRANKSHAFT

ECMU0001

BEARING, TRANMISSION SECONDARY SHAFT

ECMU0038

CRANKSHAFT

ECKGBR01

BEARING, TRANSMISSION OUTPUT SHAFT

ECDC0031

DOWEL, ENGINE CASE ALIGNEMENT

HCBH0805

M8X12 SCREW

HCWC0000

COPPER GASKET

ECMU0107

OUTPUT SHAFT, TRANSMISSION WITH GEAR

ECMU0020

BEARING, TRANSMISSION PRECISION

ECKG0018

CRANKCASE, CLUTCH SIDE, no berings

HCBH0612

M6X12 HEX HEAD SCREW - BEARING RETAINER

HCWL0601

6MM LOCK WASHER

Transmission

Figure 7A

Page 23

Parts –

Engine – Clutch and Kick Starter

REF #

PART #

DESCRIPTION

ECMU0127

CLUTCH COVER WITH KICK SHAFT, GEAR, AND LEVER

ZCMU0030

CLUTCH COVER GASKET

ECMU0207

KICKSTART GEAR SMALL

HCBC0608

M6X55 SHCS CLUTCH CVR SCREW LNG (2 REQ’D) CENTER

HCBC0606

M6X45 SHCS CLUTCH COVER SCREW SHORT (4 REQ’D)

ECMU0068

KICKSTART STOP BOLT

ECMU0037

OIL FILL PLUG

ZCMU0001

OIL FILL PLUG GASKET

HCBH0805

M8X12 OIL DRAIN SCREW

HCWC0000

COPPER GASKET

ECDC0046

KICK START LEVER

ECMU0164

KICK LEVER STOP BRACKET

HCBF0625

M6X25 FLANGE HEAD BOLT

ECMU0204

KICK STARTER DUST COVER

ECMU0063

KICK RETURN SPRING

CCMU0031

CLUTCH ARBOR

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

CCMU0129

SPRING, CLUTCH (SINGLE PIECE)

See Clutch

WASHERS, CLUTCH FLAT

NOT SHOWN

CAMU0008

SPRINGS, WASHER, & BOLT (COMPLETE SET FOR 3 SHOES)

HCBS5603

BOLT, CLUTCH CENTER (SINGLE PIECE)

ECMU0018

NUT, CLUTCH SPECIAL

ECMU0089

CLUTCH BASKET, WELDED WITH BUSHING

ECMU0110

BUSHING, CLUTCH BASKET

ECMU0040

SPACER, CLUTCH BASKET (1 - 3 REQ’D)

ECMU0132

COOLANT FITTING

ECMU0109

GEAR, PRIMARY TRANSMISSION

HCNS1202

NUT, 1/2-20 LEFT HAND THREAD

ECMU0503

FITTING, CASE VENT

NOT SHOWN

ECMU0504

HOSE – CRANKCASE VENT

ECMUSP01

KICK START DOG SPRING (PAPER CLIP)

HCWB0042

SPRING WASHER

Engine Clutch and Kicker

Figure 7B

Page 24

Parts –

Engine – Ignition and Water Pump

REF #

PART #

DESCRIPTION

ECKG0001

IGNITION COVER

ZCKG0101

IGNITION COVER GASKET

HCBC0445

M4 x 45 SOCKET HEAD (4 REQ’D)

ECKG0170

WATER PUMP BELT

ECKG0175

WATER PUMP PULLEY, FAN TYPE - DRIVEN

ECMU0180

BELT RETAINER

HCBS0003

SHOULDER BOLT 6MM

HCWF0501

FLAT WASHER

ECKG0072

BEARING, WATER PUMP

ECKG0142

SHAFT, WATER PUMP

ECKG0074

SEAL, WATER PUMP SHAFT

ECKG0073

IMPELLER, WATER PUMP

HCBB0001

IMPELLER SCREW, SHCS 10-32X1/2

HCSS8201

RETAINING SCREW, SHCS 8-32X3/8

HCBC0603

CASE SCREW, SHCS M6X30

HCBC0606

CASE SCREW, SHCS M6X45 (3 REQ’D)

HCBC0604

CASE SCREW, SHCS M6X35 (5 REQ’D)

HCWF0504

WASHER FOR STATOR (3 PER)

ICMU0007

STATOR

HCBC0535

5mm x 35 SOCKET HEAD CAP SCREW (2 REQ’D)

HCBC0525

5mm x 25 SOCKET HEAD CAP SCREW

ICMU0006

ROTOR

ECKG0042

WATER PUMP PULLEY, CRANK

HCNS1001

NUT 10MM

MCKGGR00

GROMMET

PCKG0014

SPROCKET, 14T COUNTERSHAFT

ECKGSR03

SNAP RING, COUNTERSHAFT SPROCKET

ECMU0073

SPACER, SPROCKET

ECMU0072

SEAL, COUNTERSHAFT

ZCDCOR01

O-RING, COUNTERSHAFT SPACER

ECKG0004

RETAINER, WATER PUMP ASSEMBLY

ICMU0012

WOODRUFF KEY – FLYWHEEL / CRANKSHAFT

Engine – Ignition and Water Pump

Figure 7C

Page 25

Parts –

Engine – Top End

REF #

PART #

DESCRIPTION

ECMU0052

CYLINDER

ZCKG0501

BASE GASKET

ECMU0060

PISTON KIT

ECMU0055

PISTON RINGS (2 PER SET)

ECMUSR00

SNAP RING FOR PISTON (2 REQ'D)

ECKG0012

WRIST PIN

ECMU0077

BEARING, WRIST PIN

ZCMUOR07

O-RING, EXHAUST FLANGE

ECMU0086

EXHAUST FLANGE

NOT

SHOWN

ZCMOTE11

O-RINGS – PIPE TO FLANGE (2 REQ’D)

HCBC0602

M6X20, EXHAUST FLANGE SCREW (2 REQ'D)

HCNS0601

6mm Nut

HCWF0601

6MM FLAT WASHER

ECKG0026

CYLINDER HEAD OUTER

ZCMUOR02

O-RING, CYLINDER HEAD LARGE

ZCMUV024

O-RING CYLINDER HEAD SMALL

ZCMUOR10

O-RING CYLINDER STUD (4 REQ'D )

ECMU0532

CYLINDER HEAD, INSERT

ZCMUV032

O-RING CYLINDER HEAD MEDIUM

ECMU0075

STUD, CYLINDER 6mm

Engine – Top End

Figure 7D

Page 26

Parts – Exhaust System

Exhaust System

REF #

PART #

DESCRIPTION

XCKG2004

2004 KING EXHAUST PIPE

ZCMOTE11

HEADER PIPE O-RINGS (2 REQ’D)

XCMU0005

EXHAUST SPRING - SHORT

MCMUGR06

PIPE GROMMET MALE

MCMUGR07

PIPE GROMMET FEMALE

MCMUSP02

PIPE GROMMET SPACER

HCWF1478

PIPE GROMMET WASHER (2 REQ’D)

HCBF0635

M6X35 FLANGE HEAD BOLT

NOT SHOWN

HCHA0003

6MM CLIP NUT – FOR FRONT PIPE MOUNT

XCDC0003

SILENCER

NOT SHOWN

XCMU0018

SILENCER PACKING

XCKG0009

PIPE / SILENCER SEAL

MCMUGR03

MOUNTING GROMMET (4 REQ’D TOTAL, 2 PER BOLT)

TCKG0001

SPACER (2 REQ’D)

HCBF0630

M6X30 FLANGE HEAD BOLT (2 REQ’D)

NOT SHOWN

HCNF0601

6MM FLANGE NUT (2 REQ’D) – SIL ENCER MOUNTING NUT

FCKG0028

BRACKET – RIGHT SIDE RADIATOR SHROUD

Figure 8

Page 27

Parts – Forks & Triple Clamps

Front Forks and Triple Clamp

REF #

PART #

DESCRIPTION

KAKG0010

FORK COMPLETE, NON-BRAKE SIDE

KAKG0009

FORK COMPLETE, BRAKE SIDE

KCKG0040

FORK GUARD SET

KCKG0040

FORK GUARD SET

MCMUZT04

CABLE TIE (2 REQ’D)

HCBB0612

M6X12, BUTTON HEAD SCREW (4 REQ’D)

FAKG0010

TRIPLE CLAMP BOTTOM ASSY, (1 BEARING AND DUST COVER)

FCKG0033

TRIPLE CLAMP UPPER

HCNJ0101

STEERING HEAD NUT 1X14

HCBC0625

SOCKET HEAD CS M6X25 (4 REQ’D)

HCBC0806

CAP SCREW M8X30 (4 REQ’D)

12S

TKMU0404M

BAR MOUNT KIT, SHORT (2 REQ’D)

12T

TKMU0403M

BAR MOUNT KIT, TALL (2 REQ’D)

HCBC1001

M10X45 SOCKET HEAD CAP SCREW (2 REQ’D PER BIKE)

HCNL1001

M10 LOCK NUT

NOT

SHOWN

HCBH0816

M8 X 16 HEX HEAD BOLT

NOT

SHOWN

HCWF0801

8MM FLAT WASHER

FCMU0103

DUST COVER (2 REQ’D)

FCMU0004

STEERING HEAD BEARING (2 REQ’D)

HCBC0625

SOCKET HEAD CS M6X25 (4 REQ’D)

HCBF0616

FENDER BOLT, M6X16 FLANGE HEAD (4 REQ’D)

FCKG0213

BRAKE LINE HOLDER

HCBF0620

M6X20 FLANGE HEAD BOLT (NUMBER PLATE FASTNR)

Figure 12

Page 28

Parts – Forks – Leg Assembly

Fork Leg Assembly

REF #

PART #

DESCRIPTION

FORK DAMPER ASSEMBLY

KCKG1201

FORK SPRING STANDARD (12 LB/IN)

NOT SHOWN

KCKG0009

FORK SPRING OPTIONAL SOFTER (9 LB/IN)

NOT SHOWN

KCKG0015

FORK SPRING OPTIONAL STIFFER (15 LB/IN)

3 BR

KAKG0028

FORK LEG INNER ASSEMBLY, BRAKE SIDE

3 NBR

KAKG0029

FORK LEG INNER ASEMBLY, NON-BRAKE SIDE

KCKG0004

FORK BUSHING, GLIDERING

KCMU0008

SWIPER (PART NUMBER IS A SINGLE PIECE)

KCMUSR23

SNAP RING

KCMU0007

FORK SEAL (PART NUMBER IS A SINGLE PIECE)

KCKG0020

FORK BUSHING, BRONZE

KCKG0121

OUTER FORK TUBE

KAKG0030

FORK CAP ASSEMBLY WITH RELIEF

Figure 13

Page 29

Parts – Forks – Damper Assembly

Damper Cartridge Assembly

REF #

PART #

DESCRIPTION

KCKG0027

FORK DAMPER ROD

KCKG0025

CARTRIDGE TOP

KCKG0031

TOP OUT SPRINIG

KAKG0017

MID VALVE ASSEMBLY (STANDARD)

NOT SHOWN

KAKG0016

MID VALVE ASSEMBLY (SOFT/FAST) OPTIONAL

NOT SHOWN

KAKG0018

MID VALVE ASSEMBLY (HARD/SLOW) OPTIONAL

KCKG0032

FORK SPRING GUIDE

HCNJ5601

NUT

DAMPER ROD ASSEMBLY WITH MID VALVE

KCKG0023

CARTRIDGE TUBE

KAKG0014

BASE VALVE ASSEMBLY STANDARD

NOT SHOWN

KAKG0013

BASE VALVE ASSEMBLY (SOFT/FAST) OPTIONAL

NOT SHOWN

KAKG0015

BASE VALVE ASSEMBLY (HARD/SLOW) OPTIONAL

KCKG0024

BOTTOM PLUG

ZCKGOR10

BOTTOM PLUG O-RING

Figure 14

Figure 15

Page 30

Parts – Forks – Damper – Base Valve Assembly

Forks -Valving, Base Valve Assembly – Std.

REF #

PART #

DESCRIPTION

HCBC0606

M6X45 SOCKET HEAD CAP SCREW

KCKG0011

CHECKSTOP

KCKG0038

SPRING, BASE VALVE

KCKGSH01

CHECKPLATE, 14 X .3

KCKG0026

PISTON, FORK VALVE

KCKG0013

O-RING, BASE VALVE PISTON

KCKGSH02

SHIM, 14 X .1

KCKGSH03

SHIM, 12 X .15

KCKG0036

CONICAL SPACER

KCKG0024

BOTTOM PLUG

ZCKGOR10

O-RING, BOTTOM PLUG

Figure 16

Page 31

Parts – Forks – Damper – Mid Valve Assembly

Forks – Valving, Mid Valve Assembly – Std.

REF #

PART #

DESCRIPTION

HCBC0603

M6X30 SOCKET HEAD CAP SCREW

HCWF0601

FLAT WASHER

KCKGSH05

SHIM, 8 X .15 (2 REQ’D)

KCKGSH04

SHIM, 12 X .1

KCKGSH02

SHIM, 14 X .1

KCKG0026

PISTON, FORK VALVE

KCKG0035

GLIDRING, MIDVALVE PISTON

KCKGSH01

CHECKPLATE, 14 X .3

KCKG0038

SPRING - MID VALVE

KCKG0011

CHECK STOP

Figure 17

Page 32

Parts – Frame I

Frame

REF #

PART #

DESCRIPTION

FAKG0011

FRAME 2005 KING

HCBF0616

M6X16 FLANGE HEAD BOLT

HCHA0003

6MM “U” NUT

TCKG0007

PLUG – FRAME END

MCMU0003

STRAP – HANDLE

HCBF0620

M6X20 FLANGE HEAD BOLT

HCHA0003

6MM “U” NUT

HCBF0630

M6X30 FLANGE HEAD BOLT

MCMUGR03

GROMMET (2 REQ’D PER BOLT)

TCKG0001

ALUMINUM SPACER

HCWF1478

PIPE GROMMET WASHER

HCBH0880

FRONT ENGINE MOUNT BOLT, M8X30 SHCS

HCNL0801

8MM LOCKNUT

HCBH1403

SWINGARM PIVOT BOLT

HCNL1402

SWINGARM LOCK NUT (M14 X1)

MCMUGR03

GROMMET

HCBF0616

M6X16 FLANGE HEAD BOLT

FCMU0006

RADIATOR MOUNTING BRACKET (TEARDROP)

HCHA0003

6MM “U” NUT

FCMU0057

CHAIN ROLLER

HCWF1201

WASHER FLAT, CHAIN ROLLER (2 REQ’D)

HCCP0002

COTTERPIN 3/32 X 1 (2 REQ’D)

Figure 9

Page 33

Parts – Frame II

Frame

REF #

PART #

DESCRIPTION

FAKG0011

FRAME 2005 KING

HCBF0616

M6X16 FLANGE HEAD BOLT

HCNK0001

KNOB – SEAT FASTENING

HCBB0516

M5X16 BUTTON HEAD BOLT

HCWP0002

ALUMINUM WASHER

HCBB0516

M5X16 BUTTON HEAD BOLT

HCCN0000

5 MM CLIPNUT

HCBF0620

M6X20 FLANGE HEAD BOLT

BCDC0009

BRAKE PIVOT BOLT

BCBH0601

M6 X 20 HEX HEAD BOLT

HCNS0601

6MM NUT

TCMU0110

WIDE FOOTPEGS (PAIR)

TCMU0106

FOOTPEG SPRING (2 PER)

HCBB0803

M8X40 BUTTON HEAD BOLT (2 PER)

HCNL0801

8MM LOCK NUT (2 PER)

HCWF5601

FLAT WASHER (2 PER)

HCBF0630

FLANGE HEAD BOLT, M6X30

MCMUGR06

PIPE GROMMET MALE

MCMUGR07

PIPE GROMMET FEMALE

MCMUSP02

PIPE GROMMET SPACER

FCKG0028

BRACKET – RIGHT SIDE RAD SHROUD

HCHA0003

6MM “U” NUT

HCBH0502

M5X16 HEX HEAD BOLT

HCCN0000

5 MM CLIPNUT

HCWF0601

6MM FLAT WASHER (ONLY 1 USED)

Figure 10

Page 34

Parts – Front Brakes

Front Brakes

REF #

PART #

DESCRIPTION

BAKG0003

FRONT BRAKE ASSEMBLY

BCKG0030

HOSE – BRAKE FRONT

BCKG0023

ALLOY BRAKE LEVER

BCKG0024

BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER

BCKG0029

CALIPER – FRONT

BCKG0009

BRAKE PADS, WITH “E” CLIP

BCMU0503

BRAKE ROTOR

HCBB0516

M5X16 BUTTON HEAD BOLTS WI TH THREAD LOC

BAKG0003

BRAKE CALIPER BRACKET

HCBF0635

M6 X 35 FLANGE HEAD BOLT

HCBF0616

M6 X 16 FLANGE HEAD BOLT

WCMUZT04

CABLE TIES (2 REQ’D) TO SECURE BRAKE LINE TO FORK GUARD

BCKG0031

BLEED KIT (MULTIPLE SYRINGES, FITTINGS & HOSE)

BRAKE FLUID

FCKG0213

GUIDE – FRONT BRAKE LINE

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 (BANJO BOLT, SMALL O-RING & SET SCREW)

ACCESSORY

BCKG0015

CALIPER PISTONS & SEALS

ACCESSORY

BCKG0019

RETURN SPRING (4 FINGER SPRING)

Figure 18

Page 35

Parts – Front Wheel

Front Wheel

REF #

PART #

DESCRIPTION

WAKG0021

FRONT WHEEL COMPLETE

WCKG1200

12" FRONT TIRE

WCKG1201

12" FRONT TUBE

WCKG0011

FRONT AXLE

WCMU0123

FRONT WHEEL SPACER, X LARGE

WCMU0120

WHEEL BEARING (2 REQD)

WCMU0032

WHEEL BEARING SPACER

WCMU0101

FRONT WHEEL SPACER, LARGE

BCKG0021

BRAKE CARRIER BRACKET

HCWF1202

FRONT AXLE WASHER

HCNS1201

FRONT AXLE NUT (12MM)

BCMU0207

BRAKE ROTOR MOUNTING BOLTS (6 REQD)

BCMU0503

BRAKE ROTOR

Figure 19

Page 36

Parts – Plastic Bodywork & Se at

Plastic and Seat

REF #

PART #

DESCRIPTION

TCMU0016

FRONT FENDER

NOT SHOWN

HCBF0616

FRONT FENDER MTG BOLTS (4 RE Q D)

TCMU0005

FRONT NUMBER PLATE

NOT SHOWN

HCBF0625

FRONT NUMBER PLATE MTG BOLT

TCMU0006

FUEL TANK (NO PETCOCK OR CAP)

NOT SHOWN

HCBF0616

FUEL TANK MOUNTING BOLT

TCMU1203

RADIATOR SHROUDS (RAD CAP ACCESS)

NOT SHOWN

HCBB0402

RAD SHROUD MTG BOLT, LONG (1 PER SIDE)

NOT SHOWN

HCBB0403

RAD SHROUD MTG BOLT, SHORT (1 PER SIDE)

TCMU0113

SIDE NUMBER PLATE SET

NOT SHOWN

HCBB0516

M5X16 NUMBER PLATE MTG SCREW (2 PER SIDE)

NOT SHOWN

HCWP0002

NUMBER PLATE WASHER (UPPER HOLE ONLY)

TAMU0001

REAR FENDER ASSEMBLY

NOT SHOWN

HCBH0620

REAR FENDER MTG BOLT (2 REQD)

TCMU0505

SEAT

TCMU0103

FUEL TANK CAP

TCMU0038

FUEL PETCOCK

HCNK0001

KNOB – SEAT FASTENING

FCKG0028

BRACKET – RIGHT SIDE RAD SHROUD

NOT SHOWN

HKPP0001

PUSH PINS – 10 PACK SHROUD FASTENING

NOT SHOWN

TCMU0022

GRAPHIC KIT – KING 2005

MCMU0003

STRAP HANDLE

Figure 20

Page 37

Parts – Rear Brake

Rear Brake System

REF #

PART #

DESCRIPTION

BAKG0002

BRAKE COMPLETE

BCMU0012

BRAKE PEDAL

BCDC0009

BRAKE PIVOT BOLT

HCBH0620

M6X20 HEX HEAD BOLT

HCNS0601

6 MM NUT

BCMUSP02

BRAKE RETURN SPRING

BCMU0501

SEAL – BRAKE PEDAL (2 REQ’D)

BCDC0004

PUSH ROD, REAR BRAKE

HCBF0620

M6X209 FLANGE HEAD BOLT (2 REQ’D)

HCPP0832

BRAKE HOSE CLAMP FASTENER (2 REQ’D)

HCCC0002

BRAKE HOSE CLAMP (2 REQ’D)

BCKG0010

REPLACEMENT BRAKE HOSE

HCBF0635

M6X35 FLANGE HEAD BOLT

HCBF0620

M6X20 FLANGE HEAD BOLT

BCKG0013

CALIPER – REAR BRAKE

ACCESSORY

BCKG0009

BRAKE PADS

BCKG0104

BRAKE CARRIER WITH PAD

BCKG0007

WHEEL SPACER - FLOATING CARRIER

BCKG0011

BRAKE ROTOR

HCBB0620

M6X20 BUTTON HEAD CAP S CREWS (5 REQ’D)

BCKG0012

MASTER CYLINDER - REAR

ACCESSORY

BCKG0014

FITTING KIT

ACCESSORY

BCKG0015

MASTER CYLINDER PISTON / SEAL KIT

ACCESSORY

BCKG0016

RESERVOIR SEAL KIT

ACCESSORY

BCKG0017

CALIPER BOLT / O-RING KIT

ACCESSORY

BCKG0018

CALIPER PISTON / SEAL KIT

ACCESSORY

BCKG0019

PAD RETURN SPRING (4 LEG SPRING)

Figure 21

Page 38

Parts – Rear Wheel

Rear Wheel

REF #

PART #

DESCRIPTION

WAKG0019

REAR WHEEL COMPLETE

WCMU0275

REAR TIRE, BRIDGESTONE MT320 2.75X10

WCMUTU10

TUBE, BRIDGESTONE 10"

BCMU0502

BRAKE ROTOR

HCBB0620

M6X20 BUTTON HEAD CAP S CREWS (5 REQD)

PCMU0038

38T STEEL REAR SPROCKET

PCMU0059

RUBBER DAMPERS

WCMU0008

WHEEL DAMPING PLATE

HCBH0701

M7X35 HEX HEAD BOLT

PCMU0001

MASTER LINK 420

PCMU0100

CHAIN 420 X 100

WCMU0016

REAR AXLE

HCPA0002

AXLE HEAD FIXING PLATE

BCKG0007

WHEEL SPACER - FLOATING CARRIER

BCKG0103

BRAKE CARRIER

NOT

SHOWN

BCKG0104

BRAKE CARRIER PAD

WCMU0120

WHEEL BEARING

WCMU0033

WHEEL BEARING SPACER

WCMU0101

WHEEL SPACER

HCWF1202

AXLE WASHER

HCNS1201

AXLE NUT 12MM

WCMU0006

SPACER, SPROCKET DAMPER (4 REQD)

Figure 22

Page 39

Parts – Shock

Shock

REF #

PART #

DESCRIPTION

SAKG2005

SHOCK ABSORBER 2005 KING

SCKGOH95

REPLACEMENT SHOCK SPRING (YELLOW, 195 LB/IN)

SCKGOH85

LIGHT RATE SHOCK SPRING (GRAY, 185 LB/IN)

SCKGO205

HEAVY RATE SHOCK SPRING (GOLD, 205 LB/IN)

SCKGOH05

LOCKNUT

SCKGOH04

SPRING PLATFORM

SCKGOH03

BALL JOIINT

SCKGOH02

SPACER

SCKGOH11

O-RING FOR BALL JOINT

SCKGOH21

SCREW FOR KNOB

SCKGOH22

KNOB FOR ADJUSTMENT

HCBH1001

M10 X 40 HEX HEAD BOLT

Figure 23

Page 40

Parts – Swingarm Assembly

Swingarm

REF #

PART #

DESCRIPTION

GAKG2004

SWINGARM ASSEMBLY COMPLETE

GAKG0002

SWINGARM PAINTED

HCBH1403

SWINGARM PIVOT BOLT

HCNL1402

SWINGARM LOCK NUT (M14 X1)

GCMU0001

SWINGARM BUSHING (4 PER)

GCMU0005

TOP SWINGARM GUARD (CHAIN S L IDER)

HCBB0803

M8X40 BUTTON HEAD BOLT

HCWF5601

FLAT WASHER

HCNL0801

8MM LOCK NUT

PAKG0001

CHAIN GUIDE ASSEMBLY COMPLETE

HCBF1401

1/4 X 20 X 1-1/2" FLAT HEAD SCREW (2 PER)

HCNL1401

1/4" LOCKNUT (2 PER)

HCBF0620

M6 X 20 FLANGE HEAD BOLT (2 PER)

HCCC0002

BRAKE HOSE CLAMP (2 PER)

HCPP0832

BRAKE HOSE CLAMP FASTNER (2 PER)

HCBH1001

M10 X 40 LOWER SHOCK MOUNT BOLT

FCMU0203

WHEEL PULL

FCMU0202

WHEEL PULL CAP

HCBH0810

WHEEL PULL BOLT M8X65

HCWF5601

WHEEL PULL WASHER

WCMU0016

REAR AXLE

HCPA0002

AXLE HEAD FIXING PLATE

HCNS1201

AXLE NUT, 12 MM

HCWF1202

AXLE WASHER

GCMU0017

OPTIONAL TO P CHAIN SLIDE

HCFH0516

FLAT HEAD SCREW

HCWF0501

WASHER

HCNL0501

LOCK NUT

PCKG0004

BOTTOM CHAIN SLIDER

FAMU0005

WHEEL PULL ASSEMBLY COMPLETE

NOT SHOWN

GCKG0008

SWINGARM PIVOT TUBE SPACER (2 REQ’D)

Figure 24

Page 41

Service

Trained technicians with precision gauging and prop er assembly fixtures carefully assemble all Cobra engines to specific clearances. If you feel you have the skills, and the appropriate tools, to perform t he following service t asks 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 y our 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 ent ire en gine, repl a cing 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 measur ed on a dynamometer to ensure that your engine is operating at its highest potential. All this f or one low nominal fee. Call (330) 549-9603 for details.

Engine Service

One method for determining whether the top end of your engin e 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 sm all and s o r equires many

kicks ~20 before you establish the most accurate reading possible.

• Because of the geometry of the spark plug used in this Cobra Motorcy cle, 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 readi ng. 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 po wer and would

Engine is Fresh

Measured Value

Engine Down on Power

Measured Value * 0.9

Engine NEEDS Rebuilt

Measured Value * 0.8

Example

110 psi

110 psi * 0.9 = 99 psi

110 psi * 0.8 = 88 psi

Your Values

benefit from a rebuild. When it’s dr opped to 80% it really needs rebuilt! Usin g the table below will help you determine monitor the condition of your top end.

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

• 10, 11, 13, 22 mm wrench

• 8, 10, 14, 17 & 19 mm sockets

• 3, 4 & 5 mm hex key (Allen wrench)

• 7 mm nut driver, 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.

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

3. Remove the tank (8 mm socket).

4. Remove the carburetor from the inlet (flat head or Phillips head screwdriver, 7

mm nut driver).

5. Remove the silencer & pipe (spring remover, 8mm socket).

6. Disconnect the ground wire from the cylinder head (11 mm wrench).

7. Leaving the coolant lines connected to the engine, remove the radiator from

the frame (8 mm socket).

8. Remove the master link from the chain.

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

10. Remove the swingarm bolt ( 22mm soc ket).

NOTE:

Page 43

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

11. Remove the engine from the r ight side of the frame.

12. 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 cylinder head outer.

3. Remove the cylinder head insert.

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 cylinder

head replacement, also

i. Retard the ignition timing

ii. Use a higher oc t ane 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 missing

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 t he 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 chipping & 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, assembly lube on all bearings and a small amount of Loctite to the OD.

1. Press the three bearings into the respective holes in each case half.

2. Press in 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. Inspect the crankshaft for proper true geometry (no more than 0.002 “,

0.05mm, measured at bearing journal area while supported from the ends).

8. Press crank into right case half

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

9. 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 25

Figure 26

Page 47

10. Insert dowel pins in the left side cas e as s hown in figur e 27.

Figure 8

11. Clean the gasket mating surfaces with ac et one

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

NOTE: Gasket material is only required around the crankscase, and not the transmission.

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

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

15. Insert the screws with the proper lengt hs at locations shown.

Page 48

Figure 28

16. Torque to 12 Nm (105 in-lb) in the patter n shown in figure 28.

17. Trim away any excess gasket m aterial.

NOTE: Check engine mount holes for excess material that may cause problems in engine installation.

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

CAUTION: Be sure to align the piston such that the arrow on the top piston surface points to the exhaust (front of bike/engine) and put assembly lube on the connecting rod bearing.

19. Install the piston rings.

CAUTION: Ring end gap should be no less than 0.25 mm (0.010”) and no more than

0.64mm (0.025”)

20. 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.

Page 49

Figure 29

21. Install the base gasket.

22. Apply gasket sealer to the top surface of the gasket in the same locations indicated in figure 29.

23. Install the cylinder bein g sure that the piston rings are properly aligned with the indexing pins.

CAUTION: Never force the cylinder. If resistance is felt, determine the problem and solve it. Once installed slightly rotate the cylinder back and forth insuring that the rings are properly seated.

24. Install the cylinder st uds and O-RINGs as shown in figure 30.

25. Install cylinder head inser t.

NOTE: A light application of silicone grease can help hold the O-RINGs int o position during assembly.

Figure 30

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26. Pressure test the engine insuring an acceptable leakdown rate.

27. Install O-RINGs as s hown in figure 31.

Figure 31

28. Install the cylinder head.

29. Install the washers (with flat s ide down) and nuts. Torque to 105 in-lb (12 Nm)

30. Secure the ground strap to the back left cylinder stud with an additional nut.

31. Install reed and inlet manifold with new gask et s ( 105 in-lb, 12 Nm) applying 1104 gasket sealer to both sides of all gaskets.

32. Leak check the engine to 20 ps i to ensure proper seal.

33. Install stator reinst allin g the grommet and wires (snug the bolts).

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

35. Install the water pump outlet pipe ( apply Ult r a black Hi-Tem p RTV silic on gasket maker to the threads before assembly) before installing the clutch and rotate to a vertical position with the engine resting on a bench

36. Install the clutch per Clutch I nstallation section in this manual.

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

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

39. Install the spark plug with a f resh 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).

Page 51

Clutch

Cobra clutch puller assembly:

Figure 32

Clutch puller diagram

Figure 33

Tools recommended for clutch service:

• Universal clutch puller- a universal puller t hat pulls the clutch, m ain 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).

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 t he end of the cra nkshaft 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. ( figur es 32 & 3 3) 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: 50

Page 52

Do not heat the crankshaft threads or the aluminum shoes.

CLUTCH ASSEMBLY REFERENCE DRAWING

REF #

PART #

DESCRIPTION

CAKG0004

Set of three shoes, springs, bolts, flat washers & nuts

CAMU0008

Set Of three springs, washers, bolts & nuts

CAKG0005

Set of three shoes

HCBS5603

Single center shoulder bolt

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

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

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 reass embled as it was disassembled unless new shoes are being installed then it is important to reinstall per figure 34.

Figure 34 A possible configuration of clutch spring stack. Each ‘spring’ stac k co ntains nine springs (Belleville washers) - six arranged into f our ‘ f l ying saucers’, and one turned away against the flat washer(s). Another configuration the ‘t hree stack’ is also likely. For details see Figure 34b.

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Figure 34b

Part #

Thickness mm (inch)

HCWS0801

1.4 (0.056)

HCWS0802

1.2 (0.047)

HCWS0803

0.79 (0.031)

HCWS0804

0.64 (0.025)

HCWS0805

0.51 (0.020)

HCWS0806

0.38 (0.015)

Hit

Thickness (mm)

Thickness (inch)

Softer

1.17 (0.79 + 0.38)

0.046 (0.031 + 0.015)

1.30 (0.79 + 0.51)

0.051 (0.031 + 0.020)

Stock

1.4

0.056

1.58 (1.2 + 0.38)

0.062 (0.047 + 0.015)

1.71 (1.2 + 0.51)

0.067 (0.047 + 0.020)

1.84 (1.2 + 0.64)

0.072 (0.047 + 0.025)

Harder

1.99 (1.2 + 0.79)

0.078 (0.047 + 0.031)

Clutch adjustment washers

Your Cobra comes stock with a single flat washer at the bottom of the spring washer stack. The thickness of that flat washer is 0.056” (1.4mm). Cobra offers several thicknesses of thin adjustment washers that allow clutch engagement tuning. Increasing the flat washer(s) thickness increases the engine speed for clutch engagement thus increasing the abruptness of clutch engagement ( harder hit). Conversely, decreasing the flat washer(s) thickness decreases the engine speed for clutch engagement thus decreasing the abruptness of clutch engagement (softer hit).

Use the table above to order adjustment washers. Replace the 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, by even the slightest, contact the Cobra Technical Support Group before making adjustments.

Clutch shoe wear:

Page 54

• If the clutch has been slipping and shows signs of gl azing, it is b est to replace

REF #

PART NO.

DESCRIPTION

ECMU0017

Crank seal

ECMU0040

Clutch to hub spacer

ECMU0003

Brass bushing

ECMU0033

Clutch Hub w/ brass bushing

CAKG0002

Clutch Complete w/ Arbor

ECMU0018

Clutch nut

the shoes. We have found that once the shoes are gl azed, 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 t he 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 imp ortant 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 t o start to slip. So you will need to clean the sludge out or just replace the spring washers and bolt s 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’.

Figure 35, Clutch Assembly Drawing

CLUTCH ASSEMBLY:

Page 55

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 which is 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 all old thread locking material.

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

CAUTION: Avoid allowing excess thread lock material to contact the spring washer s 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) thr ead 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.

Page 56

INSPECTION NOTE:

a. There must be in / out play in installed clutch, 0.4mm to 1.0 mm

(0.015” to 0.040”). b. Excess in/out will cause early crank seal failure. c. A blue clutch drum is worn out from excessive slippage or improper

lubrication. d. Should be no looseness in clutch shoes.

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).

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 36

Page 57

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 trans f ers 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 dr ip 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 rot or 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 t ake 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 0.040” bef ore Top Dead Center (that means 0.040” before the piston reaches the highest point of it’s trav el in the cylinder).

CAUTION: Advancing the ignition timing will cause the engine to run hot ter, 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 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

0.040”

7. Turn the crankshaft clockwise until the dial indicator reaches 0.040” (1.14mm) from top dead center.

8. Line up the lines on the stator and the rot or (figure 37). Otherwise loosen t he three 5mm bolts to adjust the stator.

before

TDC

Figure 37, Lining up the line on the rotor with the line on the stator.

Figure 38, Using a dial indicator to measure piston height for setting ignition timing.

ROTOR INSTALLATION:

1. Use wicking / bearing retainer (green) thread locker on the insi de 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) with hig h strength (red) thread locking agent.

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

Page 59

The water pump in the engine keeps the radiator fluid in circulation throughout

Radiator fluid removal:

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

Figure 39

To remove radiator cap:

1. Turn the cap counter clockwise to the first stop and wait there for a few seconds.

COBRA IMPELLER SERVICE INSTRUCTIONS

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

hex head

4. Remove foot brake.

the motor. The air stream running through the radiator cools the radiator fluid. Therefore dirty radiators additionally reduce the cooling effect. Cobra has tested numerous brand name automotive and racing coolant / antifreeze solutions and has found Liquid Perfor mance Pr opylene Glycol based Mini Coolant / Antifreeze to have the greatest effect on reducing cylinder head temperatures.

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 r adiator filler neck with coolant. Install the cap,

turning it clockwise about ¼ turn.

Tools recommended for impeller service:

• Flat head screwdriver

• 13mm- hex wrench

• 3mm hex key

• 4mm hex key

• 5mm hex key

• Propane torch

• 3/8” diameter x 8” long steel rod

• Hammer

Remove radiator cap and drain engine coolant by removing the 13mm-

coolant drain plug.

If the impeller is damaged or broken completely back flush the coolant system to

ensure no solid pieces are in the system.

Page 60

5. Drain engine transmission oil by removing drain screw using a 13mm- hex

wrench. (item 2 in the figure below).

8. Unscrew water elbow fitting. (Figure 40)

8. Remove ignition cover using a 4mm hex key (four places)

10.

11. Remove bearing retain er s crew using a 3mm hex key. (Figure 41 – item 2)

12. Heat engine case around area of impeller lig htly with a small Burnsmatic propane engine as shown in figure 42.

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

13. The shaft assembly is serviceabl e. Use a 1/8” hex key to remove impeller retainer screw. Remove impeller, seal and both bearings. Check shaft for wear in

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

Figure 40

Remove belt retainer screw using a 4mm hex key. (Figure 41 - item 1)

Remove belt retainer, water pum p belt and wat er pump fan pulley.

Figure 41

torch. Using a 3/8” diameter x 8” long steel rod, tap impeller assembly out of

Figure 42

Page 61

the area of the seal. If there is any sign of wear (like a groove) replace the shaft.

Figure 43

14. Reinstall new bearings, seal ( open s ide t oward impeller) and impeller. Clean all

15. long and tap on end of tube per figure 44.

16. Re-assemble in same order of disassembly.

CAUTION: Clean all threads and use green (wicking / bearing retai ner) thread locker on the belt retainer screw.

NOTE:

Apply Ultra black Hi-Temp RTV silicon gasket maker to the threads of the water pump 90° elbow fitting before assembly.

NOTE:

Refill the coolant system with

Propylene Glycol based Mini

Coolant / Antifreeze. CAUTION:

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

threads and use green (wicking / bearing retainer) thread locker.

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”

Figure 44

Liquid Performance

Page 62

Fuel & Air System

REF. #

PART #

DESCRIPTION

RCMU0305

CARB SLIDE

RCMU0601

NEEDLE

RCMU0002

ATOMIZER

MAIN JET

CHOKE JET

RCMU0301

FLOAT

RCMU0102

RUBBER CABLE CAP SEAL

RCMU0003

CABLE ADJUSTOR

RCMU0006

TOP CARB SCREW

RCMU0106

CARB TOP

RCMU0269

VELOCITY STACK

Carburetor:

Tools recommended for carburetor service:

• Small flat head screwdriver

• WD-40

• 8mm socket

Figure 45

KING Carburetor Ref. Drawing

5 PILOT JET

26 RCMU0107 FLOAT NEEDLE 27 RCMU0012 DIFFUSER 28 RCMU0016 FLOAT RETAINER PIN 29 RCMU0106 FLOAT BOWL 30

RCMU0201 BOTTOM FLOAT SCREW

Page 63

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 t he engine can occur if not properly adjusted.

IDLE ADJUSTMENT:

On the left side of the carburetor, there are two a djustment screws. The larger screw with the knurled head is the idle adju stment 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 en gine to run rich.

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

1. Changing the main jet to a smaller number.

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

Indications that the engine is running too lean are:

• Engine cutting out on top end.

• Engine overheating 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 u p 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 f uel mixture screw. This screw will also richen and lean your engine mor e 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 sur e you don't

Page 64

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 2005 KING stock carburetor settings from the factory are:

• 65 pilot jet

• 95 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 from the carburetor.

4. Disassemble the carburetor.

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

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

7. Blow out the fuel passages with compressed air.

8. Assemble the carburetor

9. Install the carburetor onto the motorcycle.

CAUTION:

1. The motorcycle will only operate properly if the carburetor top is installed

properly with the mounting screws, cable and choke knob oriented as shown in figure 46.

Figure 46 Proper carburetor top installation and location of rectangular slide indexing pin and vent elbows.

Page 65

Reeds:

Figure 47

• The reeds must lay flat on the reed cage.

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

• The reeds must 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 lo ok in throu gh 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)

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 oi ls 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.

Page 66

Wheels & Tires

1. Remove the four bolts with the 11mm wrench

Pop the four rubber dampers out of

r dampers into the

Place the sprocket (step facing outward) with rubber dampers, onto

Insert the 11mm bolts into the holes

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:

2. Take the backing plate off

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

Figure 48

1. the sprocket.

2. Push the rubbe sprocket.

3. the aluminum studs.

4. Place backing plate over the dampers and sprocket.

5. and tighten to 18 ft-lb (24 Nm).

Page 67

Rear wheel pullers

Figure 49

Remove axle, and

Pull the rear wheel

Disassembly:

1. back wheel assembly.

2. pullers out of the back of the swing arm.

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.

Brakes

WARNING! Your brakes need a break-in period to achieve maximum brake power. 30-40 stops will bring the brake to peak performance. Check before each ride:

• Make sure the brake does not have any leaks by holding the lever in while checking hose connections.

• Make sure the brake lever pressure is OK by pulling in on the lever and ensuring full braking performance is achieved before the lever touches the handlebar. If this is not the case, pump the lever several times until the lever feels firm.

• Always make sure the rotor and brake pads are free from oil and grease. Clean the rotor with mild dish soap or alcohol. Contaminated pads must be replaced.

• Always leave adequate free-play in the lever or pedal.

CAUTION: This brake system uses only DOT 4 or 5.1 brake fluid!

This portion will be updated shortly. Check our website

www.cobramotorcycle.com for updates.

Page 68

Front Forks

Tools recommended for front fork service:

• Flat head screwdriver

• Hammer

Snap ring pliers

•

Seal drivers

•

13mm wrench 1” wrench or socket

•

10 wt fork oil

•

FORK DISASSEMBLY PROCEDURES:

1. Using the 1” wrench, remove the fork cap.

2. Drain the fork oil into a suitable container.

3. Disconnect the fork cap from the damper rod (13mm wrench & 1” wrench).

4. Disconnect the damper assembly from the fork leg by removing the large aluminum bolt from the bottom of the fork leg (22mm wrench).

5. Pry the dust seal (swiper) from its position with a small screw driver.

6. Using snap ring pliers, remove the snap ring holding the fork seals into place.

7. ‘Pop’ the fork seal out by forcibly pulling on both ends of the fork tube assembly, thus separating the inner from the outer tube.

8. Remove the bushings

9. Clean all components to be reused.

FORK ASSEMBLY PROCEDURES:

Figure 56

CAUTION: Make sure all components are clean before assembly.

CAUTION: Be sure to apply oil to the new fork seal and other components before installing.

1. Slide dust seal (swiper) (#6) onto lower fork leg.

2. Slide snap ring (#5) onto lower fork leg.

3. CAREFULLY slide seal (#4) onto lower fork leg with spring facing away from snap ring.

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CAUTION: It is helpful to cover the sharp corners of the fork leg with tape or thin plastic before sliding on the new seal. Also take care that the inner lip is not folded over when installing.

4. Slide bronze bushing (#3) onto lower fork leg.

5. Install Teflon bushing into groove on lower fork leg.

6. Slide the bronze bushing over the Teflon bushing about 1/4" to hold the Teflon in the groove.

7. Insert the lower leg assembly into the upper fork tube about 5-6".

8. Use a seal driver to drive the seal into the upper tube.

9. Install the snap ring. Make sure it is properly seated in the groove.

10. Snap the dust seal (swiper) into the groove in t he upper tube.

11. Reinstall the damper cartridge ass em bly to the fork leg. Secure the large bolt with 22 mm wrench to 35 ft-lb with green thread locking agent.

12. Fill with 3.5 oz (105 ml) 10 wt fork oil (should measure 6 mm (0.25”) above the damper cartridge tube with spring removed.

13. Install the fork spring

14. Connect the cartridge rod to the cap and tighten to 12 ft-lb (9 Nm).

CAUTION: The damper rod is hollow and will break if the nut is over tightened (proper torque is 12 ft-lb, 16 Nm). Because of different rider weights, sizes and riding styles, we offer various suspension options:

See Optional Components section of this manual for details on these and other optional components for your Cobra Motorcycle.

Page 70

Rear Shock

The rear shock is fully serviceable. Only trained professionals should service your shock. Contact Cobra or PR2 for questions and service of your King shock.

Shock preload

Shock Damping

Figure 57

Figure 58

Page 71

Tuning

Gearing

For a bike with a centrifugal clutch, it’s better to be geared too low than too high.

What happens with improper gearing?

• Poor performance

• Not enough top end speed

• No snap

• Over heat clutch

• Premature failure of engine seals, bearings, & electronics

• High clutch wear

Condition

Gear Taller

Gear Lower

Mud

Sand

Hills

Hard Pack

Throttle Blipper (novice)

*It may be helpful to set up the clutch to hit early for smooth power delivery

Page 72

Suspension

Adjustment:

1. Front forks

1.1. Fork oil

1.1.1. Oil type

1.1.1.1. Heavier weight oil – more damping – slower responding

1.1.1.2. Lighter weight oil – less damping – quicker responding

1.1.2. Oil quantity / level

1.1.2.1. Greater quantity / higher level – greater bottoming resistance, stiffer near the end of the travel.

1.1.2.2. Smaller quantity / lower level – less bottoming resistance, less stiff near the end of the travel.

1.2. Fork spring

1.2.1. Stiffer spring (higher spring rate) – stiffer throughout the travel.

1.2.2. Less stiff spring (lower spring rate) – less stiff throughout the travel.

1.3. Gas pressure – always bleed off any pressure.

1.4. Fork height

1.4.1. Rise in clamps for quicker turning.

1.4.2. Lower in clamps for improved straight line stability.

2. Rear shock

2.1. Preload adjustment

2.1.1. More preload (greater distance) – less race sag.

2.1.2. Less preload (smaller distance) – more race sag.

2.2. Shock spring

2.2.1. Stiffer spring – stiffer throughout the travel.

2.2.2. Less stiff spring – less stiff throughout the travel.

2.3. Compression damping

2.3.1. Harder (more damping, slower) – adds resistance to the suspension motion when the suspension is compressing.

2.3.2. Softer (less damping, quicker) – reduces resistance to the suspension motion when the suspension is compressing.

2.4. Rebound damping

2.4.1. Harder (more damping, slower) – adds resistance to the suspension motion when the suspension is returning to full length.

2.4.2. Softer (less damping, quicker) - reduces resistance to the suspension motion when the suspension is returning to full length

Front Forks Bottoming Too Frequently Fork oil level

If the front forks bottom harshly more than a couple of times per lap and the fork springs are proper for the weight of rider (as detailed above), try raising the fork oil level in increments of 10mm. Raising the fork oil level, reduces the air volume, and increases the stiffness of the forks late in the travel, thus adding a progressive’ feel.

Front forks feel too stiff over small bumps. Fork oil weight

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If the forks feel too stiff over small bumps try decreasing the weight (increasing

Symptom

Action

Rear end feels stiff on small bumps

Softer compression damping

Rear end ‘sways’ on straights

Harder compression damping

Bike tends to jump ‘rear end high’

Harder rebound damping

Bike tends to jump ‘rear end low’

Softer rebound damping

Frequent rear end bottoming

Harder compression damping

Bottoms after end of continuous bumps

Softer rebound damping

Rear end ‘kicks’ over square edge bumps

1) Harder rebound, 2) Softer Compression

Situation

Actions

Sand track

Lower the rear end (increase race sag).

Sand track

Stiffer compression and rebound damping.

Long fast track

Lower the forks in the clamps by 3 mm.

Tight slow track

Raise the forks in the clamps by 3 mm.

Mud track

Lower the bike if the rider has difficulties touching the ground.

the viscosity) of the fork oil.

Rear suspension troubleshooting. Damping

Always start with standard settings and make damping changes in no more than two click increments and only make one change at a time.

Proactive Suspension Adjustments

Once you have the suspension adjusted for decent overall feel, you can make proactive adjustments when faced with different racing conditions.

Carburetion

Although your Cobra is sent from the factory with the carburetor jetted for optimal performance, you may find it necessary to adjust ment your particular jetting due to current weather conditions, altitude, fuel variations, and/or engine modifications.

CAUTION: Proper jetting is very important for engine performance and engine life. Symptoms of improper jetting are listed below.

• Symptoms of incorrect oil or oil / fuel ratio o Poor acc eleration

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o Misfire at low engine speeds

Environmental and altitude related mixture adjustments

Condition

Mixture will be

Required adjustment

Cold air

Leaner

Richer

Warm air

Richer

Leaner

Dry air

Leaner

Richer

Very humid air

Richer

Leaner

Low altitude

Standard

None

High altitude

Richer

Leaner

Low barometric pressure

Richer

Leaner

High barometric pressure

Leaner

Richer

o Excessive smoke o Spark plug fouling o Excessive black oil dripping from exhaust system

• Symptoms of too rich a fuel mixture

o Poor acceleration o Engine will not ‘rev’ out, blubbers on top o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o Wet , black, or overly dark spark plug (when removed for inspection)

• Symptoms of too lean a fuel mixture

o Pinging or rattling o Erratic acceleration o Same actions as running out of fuel o High engine temperature o Whit e spark plug (when removed for inspection)

NOTE:

When inspecting the spark plug to evaluate jetting, a properly jetted machine will produce a spark plug that is dry and light tan in color.

NOTE:

• Before making any carburetor jetting changes verify that:

o You are using the proper fuel and oil o The fuel is f resh and uncontaminated o The oil and fuel have been mixed in the proper ratio o The car bur etor is clean (no plugged jets) o The air f ilt er is properly clean and oiled o The float height is within prop er specification (pr oper measuring technique

is described later in this section)

NOTE:

Perform all jetting changes on a motorcycle that has been warmed up to proper operating temperature.

The carburetor on your Cobra motorcycle is quite adjustable. Figure 59 shows its range of adjustment and in particular what adj ustable component affects what

Page 75

range of operation (specifically throttle position).

Figure 59

FUEL SCREW ADJUSTMENT: Adjust for maximum idle speed

The fuel adjustment screw is located on the left side of the carburetor. It is the smaller of the two adjustment screws and requires t he use of a small flat blade screw driver for adjustment. After adjusting for maximum idle speed, use the idle screw to adjust the desired idle speed.

NOTE:

If the fuel screw requires more than 3 turns out, replace the pil ot jet for one that is one size richer (larger number) then readjust the fuel screw.

IDLE ADJUSTMENT: Adjust for desired idle speed

The idle speed screw is located on the left side of the carburetor. It is the larger of the two screws on the side of the carburetor and is unique with its knurled head for easy fingertip adjustment. To raise the idle, turn the screw in, clockwise, (in 1/4 turn increments) and rev the engine after each adjustment. To lower the idle, turn the screw counter-clockwise.

TOP END JETTING: Adjust for clean full throttle acceleration

Jet your top end (main j et) 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) listed above and change your jetting accordingly.

PART THROTTLE Adjust for desired acceleration

Using an area of the track that allows the rider to operate and mid throttle and transition (accelerate, or ‘roll on’) from closed, or mostly closed throttle, to a larger throttle opening. Observe the rich and lean symptoms listed above. Adjust the jet needle position by moving the clip from its current position (move the clip higher on the needle to make the bike run leaner, or move the clip lower on the needle to make the bike run richer) to one higher or lower.

Page 76

Troubleshooting

1) Engine operates erratically

a) Carburetor top is installed backwards b) The carburetor slide indexing pin is missing c) A carburetor vent elbow is plugged or has fallen out d) Faulty stator e) An air leak

i) Base gasket ii) Intake / reed gaskets iii) Crank seals iv) Crank 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) Jetting too rich b) Stator needs replaced

5) E ngine won’t start

a) Fuel

i) None in tank

Page 77

ii) Is sour or bad

b) C arburetor 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 with object of flooded fuel e) Engine is flooded f) Cracked, broken, or jammed r eed pedal g) Excessive piston or cylinder wear h) Clutch bolt or shoe dragging on basket (drum).

6) Engine won’t idle

Idle knob needs adjusted

b) Carburetor jets are dirty

Index

Air Filter ........................................ 14

Bars and Controls ......................... 17

Break-In .......................................... 8

Carburetor

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

Service ...................................... 61

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

Chain

Adjustment ................................ 13

Chassis

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

Clutch

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

Service ...................................... 50

Clutch Lubricant

Replacing .................................. 12

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

Cooling System ............................. 57

Cylinder head

torque .......................................... 7

Damper ......................................... 65

Electrical

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

Engine

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

Exhaust ......................................... 64

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

Fork oil replacement ...................... 15

Forks

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

Service ....................................... 67

Frame Parts .................................. 31

Front Brake

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

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

Fuel System

Parts list ..................................... 61

Service ....................................... 61

Page 78

General Tips ................................. 10

Hardware

Frame ........................................ 31

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

Ignition

Parts .......................................... 23

Service ...................................... 55

Timing ....................................... 56

Jetting

How To ...................................... 62

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

Troubleshooting ......................... 72

Lubrication

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

Maintenance

Schedule ................................... 10

Tips ........................................... 10

Oil

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

Optional components ...................... 6

Parts

Bars and Controls ...................... 17

Bottom End & Transmission ...... 21

Carburetor ................................. 18

Clutch & Kick Starter ................. 22

Coolant System ................... 16, 19

Electrical .................................... 20

Engine ....................................... 21

Exhaust ..................................... 25

Forks ......................................... 26

Frame ........................................ 31

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

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

Ignition & Water Pump .............. 23

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

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

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

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

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

Top End ..................................... 24

Triple Clamps ............................ 26

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

Pullers ........................................... 66

Rear Brake

Adjustment ................................. 13

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

Rear Wheel

Damper ...................................... 65

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

Pullers ........................................ 66

Reeds ............................................ 64

Shock

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

Service ....................................... 74

Spark Plug

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

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

Starting ............................................ 9

Stator

torque .......................................... 7

Suspension ................................... 74

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

Tips ............................................... 10

Top End

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

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

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

Transmission Lubricant

Replacing ................................... 12

Troubleshooting ............................ 75

Jetting ........................................ 72

VIN reading ................................... 10

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

Water Pump

Parts .......................................... 23

Wheels

Service ....................................... 65