Cobra Moto CX50 BW 2010, CX50 SR 2010 Owner's Manual
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 Motorcycle MFG., Inc.
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.
MCCS2010.1
Table Of Contents
GENERAL INFORMATION...................................................................................5
SPECIFICATIONS - GENERAL.................................................................................5
OPTIONAL COMPONENTS......................................................................................6
SPECIFICATIONS - TORQUE VALUES ......................................................................6
BREAK-IN PROCEDURE.........................................................................................8
STARTING PROCEDURE........................................................................................9
MAINTENANCE ..................................................................................................10
TIPS .................................................................................................................10
SCHEDULE ........................................................................................................11
REPLACING TRANSMISSION / CLUTCH LUBRICANT.................................................12
PROPER CHAIN ADJUSTMENT..............................................................................14
REAR BRAKE MAINTENANCE...............................................................................14
AIR FILTER CLEANING ........................................................................................16
FORK OIL REPLACEMENT ...................................................................................19
FRICTIONAL DRIVE (CFD) ..................................................................................20
PARTS................................................................................................................21
PARTS – AIRBOX & INLET SYSTEM......................................................................21
PARTS – BARS AND CONTROLS ..........................................................................22
PARTS - CARBURETOR.......................................................................................23
PARTS – COOLANT SYSTEM ............................................................................... 24
PARTS – ELECTRICAL SYSTEM............................................................................25
PARTS – ENGINE – BOTTOM END AND TRANSMISSION..........................................26
Parts – Engine Clutch and Kicker................................................................27
Parts – Engine – Water Pump .....................................................................28
Parts – Engine – Top End............................................................................29
PARTS – EXHAUST SYSTEM................................................................................30
PARTS – FORKS & TRIPLE CLAMPS.....................................................................31
PARTS – FORKS – LEG ASSEMBLY......................................................................32
PARTS – FRAME I ..............................................................................................33
Parts – Frame II...........................................................................................34
3
PARTS – FRONT BRAKES....................................................................................35
PARTS – FRONT WHEEL.....................................................................................36
PARTS – PLASTIC BODYWORK & SEAT ................................................................37
PARTS – REAR BRAKE .......................................................................................38
PARTS – REAR WHEEL.......................................................................................39
PARTS – SHOCK................................................................................................40
PARTS – SWINGARM ASSEMBLY..........................................................................41
SERVICE............................................................................................................42
ENGINE SERVICE ...............................................................................................42
Base Gasket Selection ................................................................................43
Engine Removal ..........................................................................................45
Complete Engine Disassembly Procedure ..................................................45
Top End Disassembly Procedure ................................................................46
Splitting the Cases.......................................................................................47
Engine assembly .........................................................................................47
CLUTCH ............................................................................................................49
IGNITION ...........................................................................................................55
COOLING SYSTEM..............................................................................................57
FUEL & AIR SYSTEM ..........................................................................................60
EXHAUST ..........................................................................................................63
BRAKES ............................................................................................................64
FRONT FORKS...................................................................................................64
REAR SHOCK ....................................................................................................66
TUNING..............................................................................................................67
CLUTCH ............................................................................................................67
GEARING...........................................................................................................69
SUSPENSION.....................................................................................................71
CARBURETION ...................................................................................................72
TROUBLESHOOTING........................................................................................75
INDEX.................................................................................................................76
4
General Information
Specifications - General
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 Champion 8339-1, 8332-1 hotter, 8904-1 colder
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
Premix oil ratio after break-in Motul 800 2T Off Road, 50:1 to 63:1
RACE FUELS ARE NOT RECOMMENDED
Motul 800 2T
All other premix oil at 32:1 to 40:1
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 14/38 T
Chain 100 links 420
Transmission / clutch oil type
Cobra Venom 3 Shoe Clutch Milk
Quantity 235 – 350 ml (8 – 12oz)
5
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 5 weight
Fork oil amount 107 ml (3.6oz)
Rear shock (std. settings) Compression 16 clicks out
Rebound 12 clicks out
Optional Components
Call your dealer, or the factory, for details
• Carburetor jets / reeds
• Flat clutch washers (see clutch service section)
• Pre filter for the airbox
• Sprockets
o Front
o Rear
• Suspension Springs
Weight of Rider (lb) Fork Spring Shock Spring
Less than 51 0.23 kg/mm
KCKG1223
51 - 60 0.25 kg/mm
KCKG1206
Greater than 60 0.27 kg/mm
KCKG1227
• Tires, tubes or ‘Tire Balls’
gray, 3.5 kg/mm
SCKGFX35
yellow, 3.7 kg/mm
SCKGFX37
gold, 3.9 kg/mm
SCKGFX39
Specifications - Torque Values
Fastener
Cylinder head
nuts
ft-lb in-lb Nm
8.8 105 12 M6 x 1.0
Torque Value
Size &
Remarks
6
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
Clutch cover
bolts
1.7 20 2.3 M4 X 0.75
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
CFD nut 55 664 75 ½” x 20 LHT
Front axle nut 25 300 34 M12 x 1.25
Engine mount
bolts
Swingarm
Pivot
22 265 30 M8 X 1.25
21 250 28 M14 X 2.0
Shock Bolt 35 420 47 M10 x 1.5**
Water Pump
Impeller
Water Pump
Pulley
Intake manifold
bolts
6 75 8 M5 x 0.8**
10 124 14 M6 x 1.0**
4.6 55 6.2 M6 X 1.0
Rear Axle Bolt 25 300 34 M12 X 1.25
Rear Sprocket
Bolts
Fork cartridge
rod
Triple clamp
bolts (bottom)
Triple clamp
bolts (top)
18 216 24 7 mm**
12 144 16
6 72 8 M6 x 1.0
9 108 12 M6 x 1.0
Fork cap 5 60 6.7 1.25” x 18
Ignition rotor
nut
35 420 47 M10 x 1.25*
* 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.
7
Break-In Procedure
Your Cobra CX50 JR is a close-tolerance high performance machine and breakin time is very important for maximum life and performance. The CX50 JR can be
ridden hard after the first ½ hour break-in time.
Cobra recommends Motul 800 T2 premix oil with high octane
pump gas mixed at 50:1 (50 ml oil to 1.3 gallon of gas, or 38ml oil to 1 gallon 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.
• 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.
8
Never open the radiator cap of a machine that has a hot or warm engine or one
that has recently been ridden. Burning and scalding could occur.
CAUTION:
It is important that the radiator cap is installed correctly and completely otherwise
engine damage could occur.
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 that it ‘clacks’ shut properly.
• 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 Motul 800 2T
premix 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.
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).
9
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.
Maintenance
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. Motul 800 2T Off Road 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’.
10
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. A properly maintained machine is safer, faster, and more fun to ride.
6. New chains will stretch on first use. Never install a new chain prior to a
race. Always ‘break’ them in during practice.
7. Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number).
The first two digits indicate the model and the seventh indicates the model
year (MY).
a. Example, ACxxxx9xxx is a 2009 MY CX50 SR.
Schedule
• Between each ride
o Check the air filter (clean and re-oil as necessary).
o Insure the smooth operation of the throttle cable (throttle soundly
‘clacks’ shut).
o Check for frayed strands of the throttle cable inside the throttle housing
and replace if necessary.
o Check for adequate tire pressures and adjust if necessary.
o Check all nuts and bolts for proper torque and re-torque if necessary.
o Spray all moving parts with WD40 or other light oil.
o Check drive chain for
Proper tension and adjust if necessary.
Adequate lubrication and lubricate if necessary.
o Insure that the ignition stator and rotor are clean and dry.
o Check the frame for cracks in the metal or cracks in the paint that
might indicate that the metal has been stressed beyond it’s safe limits.
Replace or get properly rewelded as necessary.
o Check the rims for 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
11
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 a mix of 4130 Chrome Moly and High Shrength Low Alloy
tubing. It is important to weld it with the proper filler (ER70S6) and have the
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 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.
5. Inspect CFD slip torque every 10 hours of riding or replace the friction
papers and the load spring (Bellville spring) every 20 hours.
6. 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 real hard to make a clutch that is low maintenance and so only
take it apart if it NEEDS to be maintained.
Replacing Transmission / Clutch Lubricant
Tools needed:
• Minimum of 235 ml (8 oz) Cobra Venom 3 Shoe Clutch Milk (Part #
MCMUGF01).
NOTE:
Up to 350ml (12 oz) can be applied without hurting performance.
Procedure:
1. Begin this procedure with a bike that has been ridden more than 5 minutes
but less than 10 minutes. It is desired to have the engine warm enough so
that the oil is ‘runny’ but not so hot that there is risk of being burned by the
engine or the oil.
Hot oil and hot components on the motorcycle may cause burns.
12
2. Lean bike against something or set on stand with oil drain hole.
3. 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
4. After it has drained, reinstall the plug, being sure that the gasket is in place.
5. 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:
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 gasket is in place.
CAUTION:
Cobra has spent considerable time and money developing the proper lubrication
to handle the harsh environment of the automatic clutch and transmission of this
motorcycle. Cobra’s specially developed Cobra Venom 3 Shoe Clutch Milk (Part
# MCMUGF01) was formulated to provide superior lubrication and cooling
capability over extended periods of time and is the recommended lubricant for
your Cobra motorcycle.
13
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.
CAUTION:
Always check rear brake adjustment and free-play after adjusting the chain.
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.
14
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).
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.
15
Air Filter Cleaning
Figure A1
• Remove the seat (unscrew the knob under the seat & rear fender)
• 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
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.
16
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.
Figure A2
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 A3
17
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.
8. When properly installed, the filter and retainer should look like figure A4.
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.
18
Fork Oil Replacement
Tools required
• Two 19 mm wrenches or sockets
• 4 & 5 mm hex key (Allen wrench)
• 25mm wrench or socket
• 5 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 (25mm 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 the 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 3.6oz (107 ml) 5 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).
19
Frictional Drive (CFD)
The Cobra Frictional Drive (CFD) is essentially a 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’ between a minimum torque value,
and a maximum torque value.
The slip torque of the CFD should be checked every 5 hours of operation.
Slip Torque
Minimum 55 75
Maximum 92 125
To properly measure the torque at which the CFD (Cobra Frictional Drive) slips,
one first access the slip clutch by draining the oil and removing the cover
exposing the CFD. Next, brace the CFD gear from turning with a suitable device
(Cobra tool EAMU0004 or similar).
Ft-lb N-m
Using a beam style torque wrench, turn the torque wrench counter clockwise and
observe the torque measurement when the shaft slips relative to the gear. Using
a preset value torque wrench, adjust the setting 55 ft-lb (75 Nm) and observe
whether the wrench clicks first or the shaft slips. If the shaft slips first, the slip
torque is below 55 ft-lb and the CFD needs servicing. If the wrench clicks first,
the CFD is of acceptable value.
NOTE
To loosen and tighten the blue CFD nut, use a strong wooden object (large
hammer handle) through the spokes of the rear wheel as a brace against the
swingarm to stop transmission shaft rotation.
CAUTION:
The blue CFD nut has left hand threads which require clock-wise rotation to
loosen.
20
Parts
Parts – Airbox & Inlet System
Coolant System
REF # PART # DESCRIPTION
1 TCCS0002 AIRBOX 2010
2 HCSP0003 SCREW – PLASCREW – AIRBOX TO FRAME
3 RCCS0004 AIR FILTER 2010
4 RCCS0005 BACKING PLATE – AIR FILTER
5 RCKG0503 RETAINER – AIR FILTER
6 TCC61008 MUDFLAP – 2010 SR
7 MCKGHO03 HOSE CLAMP – AIRBOX TO BOOT
8 RCKG0505 AIR BOOT
9 MCKGHO01 HOSE CLAMP – BOOT TO CARB
10 MCKGHO04 HOSE CLAMP – CARB TO MANIFOLD
11 ECKG0203 INLET MANIFOLD
12 ECKG0202 REED CAGE ASSEMBLY WITH REEDS
NOT SHOWN
13 ZCMU0132 GASKET – REEDS TO ENGINE
14 HCBC0625 M6X25 SOCKET HEAD CAP SCREW
15 HCWF0601 6MM FLAT WASHER
16 RCCM1301 VELOCITY STACK (SCREWS ONTO CARB)
ECKG0205 REED REPLACEMENT KIT
21
Parts – Bars and Controls
Bars and Controls
REF # PART # DESCRIPTION
1 FAMU0011 HANDLEBAR - ALUMINUM
MCMU0001 OPTIONAL ‘RETRO’ CROSS BAR PAD
3 TCMU0008 GRIPS (SET OF TWO)
4 FCMU0066 THROTTLE ASSEMBLY
NOT
SHOWN
5 BCKG0023 ALLOY BRAKE LEVER W/BALL
6 BCKG0024 BRAKE PERCH ASSY W/LEVER & BALL
NOT
SHOWN
7 FCMU0019 THROTTLE CABLE
8 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 (4 PER)
9S TKMU0404M BAR MOUNT KIT, SHORT (2 REQ’D)
9T TKMU0403M BAR MOUNT KIT, TALL (2 REQ’D)
10 HCBC1001 M10X45 SOCKET HEAD CAP SCREW (2 REQ’D PER BIKE)
12 HCNL1001 M10 LOCK NUT
NOT
SHOWN
NOT
SHOWN
13 FCMU0033 KILL SWITCH ASSEMBLY
FCMU0021 THROTTLE COVER
BAKG0004 SHIELDED BRAKE HOSE ASSEMBLY
HCBH0816 M8 X 16 HEX HEAD BOLT
HCWF0801 8MM FLAT WASHER
22
Parts - Carburetor
REF. # PART # DESCRIPTION
1 RCMU0305 CARB SLIDE
2 RCMU0601 NEEDLE
3 RCMU00 ATOMIZER 2.62 AU
4 RCMU00xx MAIN JET, xx denotes size
5 RCMU00xx PILOT JET, xx denotes size
Carburetor
6 CHOKE JET
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 ASS’Y. 2001 CM
20 RCMU0009 FUEL MIXTURE SCREW
21 RCMU0011 IDLE ADJUSTMENT SCREW
25 RCMU0103 FLOAT BOWL GASKET
26 RCMU0107 FLOAT NEEDLE
27 RCMU0012 DIFFUSER
28 RCMU0016 FLOAT RETAINER PIN
29 RCMU0108 FLOAT BOWL
30 HCWF0401 WASHER 4MM FLAT
31 RCMU0201 SCREW – FLOAT BOWL
NOT
SHOWN
NOT
SHOWN
Not Shown FCMU0026 FUEL LINE, 5”
Not Shown MCMUCL04 HOSE CLAMPS – FUEL LINE
Not Shown RCMU0018 CARBURETOR COMPLETE 19 mm
Not Shown RCMU0022 VENT HOSE 2” EACH
RCCM1301 VELOCITY STACK
MCKGHO01 CLAMP – CARBURETOR TO FILTER
23
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