For parts orders contact your local dealer
To locate your closest Cobra dealer
log on to
www.cobramotorcycle.com
or call
(517) 437-9100
If you need technical assistance
contact your local dealer or call
the Cobra Technical Support Hotline at
(517) 437-9100
Cobra Moto, LLC
240 Uran Street
Hillsdale, Michigan 49242
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 CX50SR (KING) IS A COMPETITION MODEL ONLY AND IS NOT
MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR
HIGHWAYS.
THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN SANCTIONED
COMPETITION EVENTS UPON A CLOSED COURSE BY A SUFFICIENTLY SKILLED RIDER
AND SHOULD NOT BE USED FOR GENERAL OFF-ROAD RECREATIONAL RIDING.
IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH.
THIS BIKE IS INTENDED FOR EXPERIENCED RACERS ONLY AND NOT FOR
BEGINNERS.
IT IS YOUR RESPONSIBILITY AS THE OWNER OF THIS COBRA MOTORCYCLE OR AS
THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS COBRA
MOTORCYCLE IN PROPER OPERATING CONDITION.
THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 80 LBS WITH FULL
RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE THAN
THAT.
BE SURE THAT THE RIDER ALWAYS WEARS ADEQUATE SAFETY GEAR EVERYTIME
HE OR SHE RIDES THEIR COBRA MOTORCYCLE.
IMPORTANT SAFETY NOTICE
Failure to follow WARNING instructions could result in severe injury or death to the
machine operator, a bystander, or a person inspecting or repairing the machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.
MCCS2014.0
2
Table of Contents
GENERAL INFORMATION .................................................................................. 4
SPECIFICATIONS - GENERAL ............................................................................................ 4
OPTIONAL SUSPENSION COMPONENTS ............................................................................ 5
SPECIFICATIONS - TORQUE VALUES ................................................................................. 5
BREAK-IN PROCEDURE ................................................................................................... 6
STARTING PROCEDURE ................................................................................................... 7
MAINTENANCE ................................................................................................... 8
TIPS .............................................................................................................................. 8
SCHEDULE ..................................................................................................................... 9
REPLACING TRANSMISSION / CLUTCH LUBRICANT ........................................................... 10
PROPER CHAIN ADJUSTMENT ........................................................................................ 11
REAR BRAKE MAINTENANCE.......................................................................................... 11
BRAKE BLEEDING PROCEDURE ................................ ...................................................... 13
AIR FILTER CLEANING ................................................................................................... 14
FORK MAINTENANCE .................................................................................................... 15
FRICTIONAL DRIVE (V3 CFD) ........................................................................................ 17
PARTS................................................................................................................ 18
PARTS – AIRBOX & INLET SYSTEM ................................ ................................ ................. 18
PARTS – BARS AND CONTROLS ..................................................................................... 19
PARTS – CARBURETOR ................................................................................................. 20
PARTS – COOLANT SYSTEM .......................................................................................... 21
PARTS – ELECTRICAL SYSTEM ...................................................................................... 22
PARTS – ENGINE – BOTTOM END AND TRANSMISSION ..................................................... 23
PARTS – ENGINE CLUTCH AND KICK LEVER .................................................................... 24
PARTS – ENGINE – TOP END ......................................................................................... 27
PARTS – EXHAUST SYSTEM........................................................................................... 28
PARTS – FORKS & TRIPLE CLAMPS ................................................................................ 29
PARTS – FORKS – LEG ASSEMBLY – BRAKE SIDE ........................................................... 30
PARTS - FORKS – LEG ASSEMBLY – NON-BRAKE SIDE ..................................................... 32
PARTS – FRAME I ......................................................................................................... 34
3
PARTS – FRONT BRAKES .............................................................................................. 36
PARTS – FRONT WHEEL ................................................................................................ 37
PARTS – PLASTIC BODYWORK & SEAT ........................................................................... 38
PARTS – REAR BRAKE .................................................................................................. 39
PARTS – REAR WHEEL ................................................................................................. 40
PARTS – SHOCK ........................................................................................................... 41
PARTS – SHOCK - INSIDE .............................................................................................. 42
PARTS – SWINGARM ASSEMBLY .................................................................................... 43
SERVICE ............................................................................................................ 44
ENGINE SERVICE .......................................................................................................... 44
Base Gasket Selection ........................................................................................... 45
Engine Removal ..................................................................................................... 47
Complete Engine Disassembly Procedure ............................................................. 47
Top End Disassembly Procedure ........................................................................... 48
Splitting the Cases .................................................................................................. 49
Engine assembly .................................................................................................... 49
CLUTCH ....................................................................................................................... 51
IGNITION ...................................................................................................................... 55
COOLING SYSTEM ........................................................................................................ 56
FUEL & AIR SYSTEM ..................................................................................................... 59
EXHAUST ..................................................................................................................... 61
REAR WHEEL PULLERS .................................................................................................. 61
BRAKES ....................................................................................................................... 61
FRONT FORKS .............................................................................................................. 62
REAR SHOCK ............................................................................................................... 63
TUNING .............................................................................................................. 64
CLUTCH ....................................................................................................................... 64
GEARING ..................................................................................................................... 67
SUSPENSION ................................................................................................................ 68
CARBURETION .............................................................................................................. 71
TROUBLESHOOTING ....................................................................................... 74
INDEX ................................................................................................................ 76
4
General Information
Items
CX50 SR
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
Coolant
50/50 antifreeze-coolant / distilled water
Displacement
49.8 cc
Bore and stroke
39 mm x 41.7 mm
Ignition system
PVL Analogic
Spark plug
Autolite – XS61 & 4261
Gap
0.023” – 0.025” (0.58 – 0.64 mm)
Ignition timing
0.035” (0.9 mm) Before Top Dead Center (BTDC)
Fuel type
High octane pump gasoline
Premix Oil type
Bel-Ray H1-R
Premix oil ratio after break-in
40:1 to 50:1
Carburetion
19 mm Dell’Orto
Slow (Pilot) Jet / Main Jet
60 / 96
Float Height
16mm + 0.5mm (0.63” + 0.020”)
Transmission
Speed
Single
Final drive ratio
14/37 T
Chain
100 links 420
Transmission / clutch oil type
Cobra Venom 3 Shoe Clutch Milk
Quantity
235 – 350 ml (8 – 12oz)
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
CARD 32mm USD Fully Adjustable w/ Smart Leg
Fork oil type
2.5wt Bel-Ray Fork Oil
Fork oil amount
155 ml
Std settings
Smart leg: 1.5 out, Compression and rebound 2 out
Rear shock (std. settings)
Compression: Low 12 out, High 15 out
Rebound 26 out, Race sag 75mm
Specifications - General
5
Optional Suspension Components
Weight of Rider (lb)
Fork Spring
Shock Spring
Less than 51
0.23 kg/mm
KCCS3223
gray, 3.5 kg/mm
SCKGFX35
51 - 60
0.25 kg/mm
KCCS3225
yellow, 3.7 kg/mm
SCKGFX37
Greater than 60
0.27 kg/mm
KCCS3227
gold, 3.9 kg/mm
SCKGFX39
Fastener
Torque Value
Size &
Remarks
ft-lb
in-lb
Nm
Cylinder head nuts
10.3
123
14
M7 x 1.0
Crankcase bolts
8.8
105
12
M6 x 1.0
Spark plug
(SP)
(SP)
(SP)
M14 x 1.25
Stator bolts
2.1
25
2.8
M5 X 0.8
Stator cover bolts
1.7
20
2.3
M4 X 0.75
Clutch cover bolts
5.8
70
7.9
M6 X 1.0
Clutch nut
40
480
54
M10 x 1.25*
Clutch bolts
12
144
16
M6 x 1.0
Engine mount bolts
22
265
30
M8 X 1.25
Swingarm pivot
21
250
28
M14 X 2.0
Shock bolt
35
420
47
M10 x 1.5**
Water pump impeller
6
75 8 M5 x 0.8**
Water pump pulley
10
124
14
M6 x 1.0**
Intake manifold bolts
4.6
55
6.2
M6 X 1.0
Axle nuts
25
300
34
M12 X 1.25
Rear sprocket bolts
18
216
24
7 mm**
Triple clamp bolts (top)
9
108
12
M6 x 1.0
Triple clamp bolts (bottom)
6
72 8 M6 x 1.0
Ignition rotor nut
30
400
45
M10 x 1.25**
Specifications - Torque Values
* Apply high strength thread locking agent when installing
** Apply medium 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.
6
Break-In Procedure
Your Cobra CX50 King is a close-tolerance high performance machine and break-in
time is very important for maximum life and performance. The CX50 can be ridden hard
after the first ½ hour break-in time.
Cobra recommends Bel-Ray H1-R premix oil with high octane pump
gas mixed at 40:1 (150 ml oil to 2 gallons of gas). Other brands of oil
should be mixed at 32:1 for break-in.
CAUTION:
Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine wear or
damage to the machine.
Adhering to the following break-in schedule will result in long lasting high performance
machine.
Start bike on stand
First 5 minute period, operate the bike on the stand with a combination of idle and
high RPM operation. (avoid prolonged high RPM but spin the rear wheel good at
least once or twice per minute)
Allow bike to cool
Ride for 15 minutes maximum (avoid prolonged high RPM operation and avoid
abusing the clutch 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.
Check CFD torque and adjust as necessary
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 some engine coolant through the radiator
overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level will
cover the top of the radiator cores. Removing the radiator cap and looking inside is the
only way to check the coolant level.
Never open the radiator cap of a machine that has a hot or warm engine or one that has
recently been ridden. Burning and scalding could occur.
7
Starting Procedure
Before starting the machine inspect the following:
Tire pressure
Chain tension
Coolant level
Proper wear on chain rollers and sliders
Handlebar tightness
Throttle assembly movement/cable adjustment
Air Filter
Check for loose nuts and bolts
Turn the fuel on by rotating the fuel petcock knob to the vertically downward
position (reserve position is horizontally forward)
NOTE: For best results from your Cobra Motorcycle use only the recommended fuels.
Testing has shown that most ‘race’ fuels actually degrade performance.
Always wear a helmet and other protective riding gear.
When your pre-ride inspection is complete the bike may be started. For a cold engine
follow this procedure.
1. 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 and, for best clutch
performance, warm up the bike before taking off.
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.
CAUTION:
Cobra recommends that you tell your child to take it easy the first couple of minutes in
practice until the engine comes up to full operating temperature.
CAUTION:
Make sure your riders’ foot is not resting on the foot brake while they are riding.
8
Maintenance
A properly maintained machine is safer, faster, and more fun to ride. It is important that
you adhere to this maintenance schedule so as to promote the longevity of your Cobra
Motorcycle.
Tips
1. Recommended lubricants:
a. Cobra Clutch Milk is by far the best auto clutch lubricant. It is a full
synthetic lubricant that has been specifically formulated for Cobra’s auto
clutch and has;
Exceptional film strength over petroleum based oils or synthetic
blends.
Extreme temperature tolerance.
NO frictional modifiers.
Dispersant package to keep clutch fibers in suspension so they can
be flushed out when the oil is changed.
Extremely low viscosity for minimal drag and ‘windage’.
b. Bel-Ray H1-R oil is the recommended premix oil because:
Its Ester base leaves a film on all parts at all times. No metal to
metal startups or corrosion potential.
Exception film strength over petroleum based oils or synthetic
blends.
Easily atomizes and burns completely.
Does not fall out of suspension from premix in cold weather.
Produces virtually no coking deposits, leaving pistons, rings and
heads extremely clean with minimal pipe ‘spooge’.
2. Filling your transmission with more than 8.0 oz (235 cc) of lubricant may help to
transfer heat from the clutch. Filling with more than 12 oz (350 cc) will degrade
performance.
3. The cylinder base gasket has been ‘fitted’ for your engine. The code number
stamped into the engine cases will guide you to what thickness base gasket is
required during a common top end service. See the service section of this manual
to correspond a code number with a base gasket part number.
4. Evaluate the bikes jetting only after it has been warmed up to race temperatures.
5. New chains will stretch on first use. Never install a new chain prior to a race.
Always ‘break’ them in during practice.
6. 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, ACxxxx9xxx is a 2009 MY CX50 SR.
7. 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.
8. 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.
9
Be sure the fuel tank and carburetor have been removed and safely located away
from the welding process.
9. 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. Use ER70S6 filler if welding on
the frame.
10. If your kick-starter lever does not return properly, first try loosening the six
kick/clutch cover screws ½ turn. Hold the kick lever ½ way down while retightening
the six screws starting for the center and working out
11. Inspect CFD slip torque after the 2nd ride and then again after the 6th ride. After this
follow the recommended schedule below.
12. Check proper clutch engagement before and after each ride. If the clutch is
engaging properly DO NOT feel the need to take the clutch apart to; measure the
spring stack, clean the stack, replace the springs, etc... Cobra has worked very
hard to make a clutch that is low maintenance and so only take it apart if it NEEDS
to be maintained.
Schedule
Prior to each ride
o Check the air filter (clean and re-oil as necessary).
o Insure the smooth operation of the throttle cable (throttle soundly ‘clacks’
shut).
o Check for frayed strands of the throttle cable inside the throttle housing and
replace if necessary.
o Check for adequate tire pressures and adjust if necessary.
o Check all nuts and bolts for proper torque and re-torque if necessary.
o Spray all moving parts with WD40 or other light oil.
o Check drive chain for
Proper tension and adjust if necessary.
Adequate lubrication and lubricate if necessary.
o Insure that the ignition stator and rotor are clean and dry.
o Check the frame for cracks in the metal or cracks in the paint that might
indicate that the metal has been stressed beyond it’s safe limits. Replace or
get properly rewelded as necessary.
o Check the rims for signs of stress, like cracks around the rim, spokes and
hub.
o Equalize the pressure in the forks with atmosphere.
Every 2 hours of operation
o Replace the transmission oil.
o Check the CFD torque.
Every 10 hours of operation
o Replace the fork oil.
o Have the shock oil replaced by a Certified Cobra Mechanic.
10
Replacing Transmission / Clutch Lubricant
Tools needed:
5mm allen wrench
Minimum of 235 ml (8 oz) Cobra Venom 3 Shoe Clutch Milk (Part #MCMUGF32).
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. Remove the oil drain plug located on the right side of the engine, on the clutch
cover, near the brake lever (figure 1).
Figure 1
3. After it has drained, reinstall the plug, being sure that the gasket is in place.
4. Reapply oil from oil fill plug 235 cc (8.0 oz) Cobra Venom 3 Shoe Clutch Milk thru
the oil fill plug.
NOTE: Putting additional oil, up to 350 ml (12 oz), can help clutch life. More than 350
ml (12 oz) will degrade engine performance.
NOTE: It can be helpful to lean the bike over on its left side to add oil to the bike.
5. Reapply the oil fill plug, hand tight, being sure the gasket is in place.
CAUTION:
Cobra has spent considerable time and money developing the proper lubrication to
handle the harsh environment of the automatic clutch and transmission of this
motorcycle. Cobra’s specially developed Cobra Venom 3 Shoe Clutch Milk (Part
#MCMUGF32) was formulated to provide superior lubrication and cooling capability
over extended periods of time and is the recommended lubricant for your Cobra
motorcycle.
11
Proper Chain adjustment
Tools required for chain adjustment
19 mm wrench or socket
13 mm wrench or socket
1. Make sure that the rear wheel is aligned
properly.
2. For proper adjustment, the chain should
have 35 mm (1 3/8”) free movement just
behind the chain block with no load on the
bike (figure 2) Figure 2
CAUTION:
Sit on the bike and verify that the chain has a minimum of 12mm (1/2”) free movement
when the chain is at it’s tightest point.
3. If the chain requires adjusting, loosen the axle
with a 19 mm wrench and tighten the chain by
rotating the adjustor bolts clockwise (CW) or loosen
the chain by rotating the adjustor bolts (CCW).
4. Retighten the axel bolt to 25 ft-lb (34 Nm).
5. Retighten the adjustor bolt
Figure 3
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
allow 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
12
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 Figure 2b
b. Sitting riding
position.
3. Tighten the lock nut
(10 mm wrench).
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.
13
Brake Bleeding Procedure
Tools Required:
Front: T10 Torx bit/driver, Cobra bleed kit (BCKG0031)
Rear: 3mm hex key (Allen wrench, T10 Torx bit/driver, Cobra bleed
kit(BCKG0031)
Procedure:
Remove the brake fluid reservoir cover.
Fill the syringe half full with brake fluid.
Remove the brake caliper bleed screw.
Attach the syringe to the brake caliper bleed access. Keep the syringe oriented
as not to allow air from the syringe into the system.
Using the syringe pull fluid through the system. Use caution not to let the fluid in
the reservoir to become low and introduce air into the system.
Using the syringe push fluid back into the system until the reservoir is full.
Repeat these actions of pulling and pushing fluid through the system a few times.
With the reservoir full, engage the brake lever/pedal and hold it there as if
engaging the brakes.
While doing this pull on the plunger of the syringe. Doing this will cause a
vacuum in the system. The vacuum will swell the air bubbles which assist in them
moving throughout the system.
Continue pulling a vacuum and release the brake lever/pedal (careful not to allow
the reservoir to become empty).
Once again engage the brakes while continuing to pull a vacuum.
When the reservoir is almost empty stop and push fluid back into the system.
Repeat these steps with the vacuum until no more air bubbles can be removed
from the system.
Remove the syringe. Be sure to keep the caliper below the level of the reservoir
to allow the fluid to run out of the caliper and not allowing air into the system.
Reinstall the bleed screw, being sure that the ring is in place.
Fill the reservoir with fluid (the fluid should be full enough that the fluid spills out
when placing the lid on) and replace the cover.
14
Air Filter Cleaning
Remove the seat
Squeeze the two tabs together as shown in figure A1
and pull the wire retainer up and out of the air box
The filter may now be pulled from the airbox
Clean the airbox of dirt and clean the filter sealing
surface of the old sealing grease.
CAUTION:
Pay particular attention to clean any particles from the
airbox between the filter location and the carburetor.
NOTE: Cobra has available a carburetor cover that
allows easy cleaning of the airbox.
1. Remove the air boot Figure A1
2. Install the cover (RCMU0109) over the carburetor inlet
3. Spray out the airbox.
Do not clean the air filter with gasoline or other highly volatile petroleum product. Diesel
fuel or kerosene would be preferred but caution should still be taken. Hot soapy water
works well.
1. Clean the filter in hot soapy water to remove all dirt particles.
2. Allow it to dry thoroughly.
3. Saturate with filter oil and remove excess.
NOTE: It’s very important to oil your filter consistently each time because varied
amounts of oil will change your carburetor jetting.
4. Apply grease to the black sealing surface of the
filter and reinstall.
5. Squeeze the two finger tabs together on the wire
retainer and install into the airbox as in figure A2
6. Push the wire retainer down until it bottoms,
making sure the two bottom tabs on the retainer
go through the two associated holes in the
bottom of the airbox.
7. Push the two top retainer arms out so that they
properly insert into each side hole. Figure A2
CAUTION:
If the side arms do not align with the associated holes it is quite likely that the legs did
not make it into the holes. Realign and try again.
15
Each Ride
10 hours
20 hours
As Needed
Bleed excess air
X Change Oil
X
Change
Seal/Swiper
X
Change Bushings
X
8. When properly installed, the filter and retainer should look like figure A4.
Figure A3 Figure A4
NOTE: Make sure you change or clean your filter after each moto. We recommend
carrying multiple filters in your toolbox, one for each practice session and moto.
Fork Maintenance
Cobra strongly recommends that a professional service technician conduct all internal
maintenance other than changing springs and oil. This will help to ensure safe and
consistent operation.
For routine maintenance, the chart below provides suggested service intervals for
common procedures:
Fork Air Bleeding
Tools required
3mm hex key (Allen wrench)
During normal operation, both fork legs will build up air pressure. This pressure acts as
an additional spring so it must be bled on a regular basis to maintain consistent
suspension operation. Before each ride, loosen the socket head cap screw located at
the front of each fork cap far enough so that any excess pressure in the leg is relieved.
After excess air is bled off, retighten the screw to 5 in-lb. Be careful not to lose or
damage the sealing ring that is located under the head of each bleed screw.
16
Fork Oil Replacement
Tools required
32mm Fork Cap Tool (MCMUTL32)
19mm wrench or socket
4 & 5 mm hex key (Allen wrench)
9/16 wrench
Mallet
2.5 wt. Bel-Ray fork oil
Disassembly procedure
1. Remove the front wheel (19 mm wrench).
2. Remove the brake caliper from the fork leg (4 mm hex key).
3. Loosen the fork caps (32mm fork cap tool).
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 fork tube.
b. Pull the fork spring down to gain access to the fork cap jam nut and secure it
with a 9/16 wrench.
c. Holding in one hand the 9/16 wrench use the fork cap wrench to unscrew the
fork cap from the damper rod.
d. Remove the fork spring pad, and fork spring.
e. Inside the damper rod, the rebound adjustment screw pin is resting and will
fall out of the damper rod when the fork is inverted. Try to catch it before it
falls into your oil bucket.
f. Invert the fork and allow the oil to drain completely. Working the damper rod
up and down will speed up the draining process.
Assembly procedure
1. Fill the fork with 155ml of fork oil.
2. Work the damper rod up and down to allow the fork cartridge to fill with oil.
3. Install the rebound adjustment screw pin into the damper rod.
4. Install the fork spring and spring pad.
5. Extend the damper rod completely and Compress the fork spring enough to begin
threading the fork cap back onto the damper rod.
6. Make sure that the fork cap threads onto the damper rod completely before it makes
contact with the jamnut.
7. Tighten the jamnut.
8. Tighten the fork cap to the fork leg outer
9. Pump the fork leg several times to verify that it operates smoothly.
10. Install each leg back into the triple clamp. Torque each pinch bolt to 8N-m (6 ft-lb)
making sure both legs are set to the same height in the clamps.
11. Reinstall the brake caliper.
12. Reinstall the front wheel (25 ft-lb, 34 Nm).
17
Frictional Drive (V3 CFD)
The Cobra Frictional Drive (CFD) is essentially an adjustable slip clutch that dissipates
torque spikes transmitted from the rear wheel to the rest of the drive line and engine.
Instead of these torque spikes potentially damaging internal components, the CFD
allows the transmission to slip with respect to the engine. For this to occur, the CFD
must function properly by ‘slipping’ above a minimum torque value.
The safe minimum slip torque of the CFD should be checked every 2 hours of
operation, after break-in.
The slip torque value should be above 60 ft-lb (81 Nm) measured at the sprocket.
To properly measure the minimum torque at which the
CFD (Cobra Frictional Drive) slips
1. Access the slip clutch by draining the oil and removing
the cover exposing the CFD.
2. Brace the CFD gear from turning with a suitable
device (Cobra tool EAMU0004 or similar).
3. Install the Sprocket Socket CFD torque checking tool
(MCMUTL15) on the sprocket and secure with the
supplied screw and ensure that the tool is completely up against the sprocket
4. Verify with a torque wrench applied
to the Sprocket Socket that the V3
CFD does not slip below 81 Nm (60
ft-lb) in either direction.
5. If there is slippage below 81 Nm (60
ft-lb) remove the cotter pin and
tighten the castle nut on the CFD
one more position (it is a left hand
thread nut so you must turn it
counter clockwise)
CAUTION:
Do not check earlier versions of the CFD
with this method! The torque values required at the sprocket would be much higher
HINT: This V3 CFD torque checking method is possible do to with the chain on. Just
put the bike on a stand so that the rear wheel can turn freely.
HINT: The CFD hubs can be removed with the universal puller (MCMUTL70).
18
Parts – Airbox & Inlet System
Air Box
REF #
PART #
DESCRIPTION
RCMU0018
CARBURETOR
1
TCCS0002
AIRBOX
2
HCSP0003
SCREW – PLASCREW
3
RCCS0016
AIR FILTER
4
RCKG0503
RETAINER – AIR FILTER
5
TCC61008
MUDFLAP
6
MCKGHO03
HOSE CLAMP – AIRBOX TO BOOT
7
RCKG0505
AIR BOOT
8
MCKGHO01
HOSE CLAMP – BOOT TO CARB
9
MCKGHO04
HOSE CLAMP – CARB TO MANIFOLD
10
RCCS0002
INLET MANIFOLD
11
ECMU0246
REED CAGE ASSEMBLY WITH REEDS VFORCE
12
ZCCS0001
GASKET – REEDS TO ENGINE
13
HCBC0603
M6X30mm SOCKET HEAD CAP SCREW
14
HCWF0601
6mm FLAT WASHER
15
RCCM1301
VELOCITY STACK (SCREWS ONTO CARB)
16
ECCS0030
REED REPLACEMENT KIT
19
Bars and Controls
REF #
PART #
DESCRIPTION
1
FAMU0011
HANDLEBAR - ALUMINUM
2
TCMU0008
GRIPS (SET OF TWO) – SCOTT WAFFLE
3
FCMU0066
THROTTLE ASSEMBLY
4
FCPW0004
CABLE COVER
5
FCMU0021
THROTTLE COVER
6
FCMU0019
THROTTLE CABLE
7
BAKG0003
BRAKE ASSEMBLY FRONT
8
FCMU0033
KILL SWITCH ASSEMBLY
9
HCBC0806
M8X30mm SOCKET HEAD CAP SCREW (4 REQ’D)
10
HCBC1001
M10X45mm SOCKET HEAD CAP SCREW (2 REQ’D)
11
TKMU0404
BAR MOUNT KIT, SHORT (1 REQ’D) STANDARD
11A
TKMU0403
BAR MOUNT KIT, TALL (1 REQ’D)
12
HCNL1001
M10 LOCK NUT
ACCESSORY
BCKG0023
ALLOY BRAKE LEVER W/BALL
ACCESSORY
BCKG0024
BRAKE PERCH ASSY W/LEVER & BALL
ACCESSORY
BAKG0004
SHEILDED BRAKE HOSE ASSEMBLY
Parts – Bars and Controls
20
Parts – Carburetor
48 RCMU0048 85 RCMU0085 92 RCMU0092 99 RCMU0099
50 RCMU0050 86 RCMU0086 93 RCMU0093 100 RCMU1100
52 RCMU0052 87 RCMU0087 94 RCMU0094 101 RCMU1101
55 RCMU0055 88 RCMU0088 95 RCMU0095 102 RCMU1102
60 RCMU0060 89 RCMU0089 96 RCMU0096
65 RCMU0065 90 RCMU0090 97 RCMU0097
91 RCMU0091 98 RCMU0098
PILOT JET
MAIN JET
Carburetor
REF. #
PART #
DESCRIPTION
RCMU0018
CARBURETOR
1
RCMU0305
SLIDE - #40
2
RCMU0601
NEEDLE - W7
3
RCMU0024
ATOMIZER 2.62 AU
4
RCMU00xx
MAIN JET, xx denotes size
5
RCMU00xx
PILOT JET, xx denotes size
7
RCMU0301
FLOAT
8
RCMU0102
RUBBER CABLE CAP SEAL
9
RCMU0003
CABLE ADJUSTOR
11
RCMU0006
TOP CARB SCREW
12
RCMU0106
CARB TOP
13
ZCMU0007
TOP CARB GASKET
14
RCMU0004
SLIDE SPRING
15
RCMU0028
NEEDLE RETAINER PLATE
16
RCMU0007
NEEDLE CLIP
17
RCMU0204
CHOKE ASSEMBLY
NOT SHOWN
RCMU0209
O-RING CHOKE ASSEMBLY
20
RCMU0009
FUEL MIXTURE SCREW
21
RCMU0011
IDLE ADJUSTMENT SCREW
25
RCMU0103
FLOAT BOWL GASKET
26
RCMU0107
FLOAT NEEDLE
27
RCMU0012
DIFFUSER
28
RCMU0016
FLOAT RETAINER PIN
29
RCMU0108
FLOAT BOWL
30
HCWF0401
WASHER 4MM FLAT
31
RCMU0201
SCREW – FLOAT BOWL
NOT SHOWN
RCCM1301
VELOCITY STACK
NOT SHOWN
MCKGHO01
CLAMP – CARBURETOR TO FILTER
NOT SHOWN
RCCS0006
FUEL LINE, 5”
NOT SHOWN
MCMUCL04
HOSE CLAMPS – FUEL LINE
NOT SHOWN
RCMU0018
CARBURETOR COMPLETE 19 mm
NOT SHOWN
RCMU0020
ELBOW - CARB VENT
NOT SHOWN
RAMU0001
CANNULUS - Y STYLE CARB VENTS
NOT SHOWN
RCMU0031
SLIDE - #30
NOT SHOWN
RCMU0250
SLIDE - #50
NOT SHOWN
ECKG0160
SLIDE - #60
NOT SHOWN
RCMU0026
NEEDLE - W4
NOT SHOWN
RCMU0602
NEEDLE - W16
21
Parts – Coolant System
Coolant System
REF #
PART #
DESCRIPTION
1
FCCS0031
RADIATOR WITH CAP
2
FCMU0022
CAP, 1.3 BAR
3
ECCS0014
RADIATOR HOSE, TOP, LEFT
4
ECCS0010
RADIATOR HOSE, BOTTOM, RIGHT
5
MCC6GR01
GROMMET, RADIATOR MOUNTING (2 REQ’D)
6
HCBF0612
M6X12mm FLANGE HEAD BOLT (2 REQ’D)
7
HCWF1478
FLAT WASHER (2 REQ’D)
8
MCMUCL07
HOSE CLAMP (4 REQ’D)
9
FCKG0214
RADIATOR OVERFLOW HOSE, 22”
10
MCMUCL05
HOSE CLAMP FOR OVERFLOW HOSE
11
FCCS0043
LOUVER
12
HCSP0002
PUSH PIN (2 REQ’D)
13
HCCN0000
5mm CLIP NUT
22
Parts – Electrical System
Electrical System
REF #
PART #
DESCRIPTION
1
IAMU0005
COIL/CDI W/SPARK PLUG CAP
2
ECMU0010C
SPARK PLUG, AUTOLITE COPPERLITE
2A
ECMU0010I
SPARK PLUG, AUTOLITE IRIDIUM
3
FCMU0033
KILL SWITCH ASSEMBLY
4
HCBC0516
M5X16mm SOCKET HEAD CAP SCREW (2 REQ’D)
5
HCWF0501
5mm FLAT WASHER (2 REQ’D)
6
HCCN0000
5mm CLIP NUT (2 REQ’D)
7
ICMU0018
STATOR WITH GROMMET
8
HCBC0535
M5X35mm SOCKET HEAD CAP SCREW (2 REQ’D)
9
HCBC0525
M5X25mm SOCKET HEAD CAP SCREW
10
HCWF0504
WASHER FOR STATOR (3 REQ’D)
11
ICMU0036
ROTOR – LOW INERTIA
12
ECKG0042
PULLEY, WATERPUMP CRANK
13
HCNS1001
NUT M10
14
ECCS0001
IGNITION COVER
15
ZCCS0002
GASKET – IGNITION COVER
16
HCBC0402
M4X35mm SOCKET HEAD CAP SCREW (4 REQ’D)
17
ICMU0012
WOODRUFF KEY (NOT SHOWN)
ACCESSORY
ICMU0017
SPARK PLUG CAP – 0
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