2004 KING
Owners / Service / Parts
“CHAMPIONS START HERE”
Page 1: ...2004 KING Owners Service Parts CHAMPIONS START HERE ...
Page 2: ... 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 MCKG2004 7 ...
Page 3: ...INTENDED FOR EXPERIENCED RACERS ONLY AND NOT FOR BEGINNERS IT IS YOUR RESPONSIBILITY AS THE OWNER OF THIS COBRA MOTORCYCLE OR AS THE PARENT OR LEGAL GUARDIAN OF THE OPERATOR TO KEEP THIS COBRA MOTORCYCLE IN PROPER OPERATING CONDITION THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 80 LBS WITH FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH MORE THAT BE SURE THAT THE RIDER A...
Page 4: ...ORK OIL REPLACEMENT 15 PARTS 17 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 Kick Starter 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 Fork...
Page 5: ...ARTS REAR WHEEL 38 PARTS SHOCK 39 PARTS SWINGARM ASSEMBLY 40 SERVICE 41 ENGINE SERVICE 41 Engine Removal 42 Complete Engine Disassembly Procedure 43 Top End Disassembly Procedure 43 Splitting the Cases 44 Engine assembly 45 CLUTCH 50 IGNITION 54 COOLING SYSTEM 56 FUEL AIR SYSTEM 60 EXHAUST 63 WHEELS TIRES 64 BRAKES 65 SUSPENSION 69 Rear Shock 71 Front Forks 72 TROUBLESHOOTING 73 INDEX 75 ...
Page 6: ...ap 0 023 0 025 0 58 0 64 mm Ignition timing 0 045 1 14 mm Before To Dead Center BTDC Fuel type High octane pump gasoline RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2 cycle Race Oil Fuel oil mix ratios Between 32 1 and 40 1 after engine Break In is complete Carburetion 19 mm Dell Orto Main Jet 95 Slow Pilot jet 65 Float Height 16mm 0 5mm 0 63 0 020 Coolant Liquid Performance Mini Coolant A...
Page 7: ...ront o Rear Suspension Springs 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 SCKG0H95 yellow 195 lb in Greater than 60 15 lb in KCKG0015 SCKG0205 gold 205 lb in Suspension Valving Damping Rate Fork Valving Compression base valve Fork Valving Rebound mid valve Shock Valving kit Soft fast KAKG0013 KAKG0016 SCKGOH24A Standard...
Page 8: ...le Bolt 25 300 34 12 mm Rear Sprocket Bolts 18 216 24 7 mm Fork cartridge rod 12 144 16 Triple clamp bolts 6 72 8 6 x 1 0 Fork cap 5 60 6 7 1 25 x 18 Ignition rotor nut 40 480 54 10 x 1 25 Use green wicking bearing retainer thread locker with primer on the flywheel crankshaft taper but none on the threads Use green wicking bearing retainer thread locker with primer on the crankshaft clutch taper b...
Page 9: ... First hour of operation o Follow the starting procedure listed in this manual o Avoid prolonged operation at Wide Open Throttle After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary proper toque values are listed under Specifications o Clean the carburetor bowl o Change the transmission clutch lubricant After 8 hours of operation o Change the fork oil o...
Page 10: ... 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 tur...
Page 11: ...n 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 necess...
Page 12: ...ends 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 kic...
Page 13: ...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 the proper lubrication to handle the harsh environment of the automatic clutch and transmission of this motorcycle Cobra s specially develo...
Page 14: ... 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 CAUTION Too little brake pedal free play will allow the brake pads to drag causing the pads to wear prematurely Too much free play will not all the rider to apply the brakes quickly 1 Set pedal position first then 2 Set pedal free play Setting rear brake pedal pos...
Page 15: ... adjuster 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 adjuster plunger NOTE Turning the clevis Clockwise will lengthen the adjuster plunger removing free play from the system and turning the clevis Counter Clockwise will shorten the adjuster plunger adding free pl...
Page 16: ... in a rainy muddy situation We offer two different filters One filter red in color is for use in sand and extremely dusty conditions part RCMU0101 and the regular filter yellow in color is for more non extreme conditions part RCMU0206 When washing your bike cover the carburetor filter with a suitable shield capable of keeping water from entering the engine Cobra has a rubber clamp on plug for the ...
Page 17: ...d 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 18: ...OWN THROTTLE COVER 5 BCMU0209 ALLOY BRAKE LEVER W BALL 6 BAMU2002 BRAKE PERCH ASSY W LEVER BALL NOT SHOWN BAKG0004 SHIELDED BRAKE HOSE ASSEMBLY 7 FCMU0067 THROTTLE CABLE 8 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 4 PER 9S TKMU0404 BAR MOUNT KIT SHORT 2 PER 9T TKMU0403 BAR MOUNT KIT TALL 2 PER 10 HCBC3812 SOCKET HEAD CS 3 8 16 X 1 1 2 2 PER 12 HCNL3816 LOCK NUT 3 8 16 2 PER 13 FCMU0033 KILL SWITCH AS...
Page 19: ...ER 11 RCMU0006 TOP CARB SCREW 12 RCMU0106 CARB TOP 13 ZCMU0007 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0205 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLIP 17 RCMU0204 CHOKE ASS Y 2001 CM 20 RCMU0009 FUEL MIXTURE SCREW 21 RCMU0011 IDLE ADJUSTMENT SCREW 25 RCMU0103 FLOAT BOWL GASKET 26 RCMU0107 FLOAT NEEDLE 27 RCMU0012 DIFFUSER 28 RCMU0016 FLOAT RETAINER PIN 29 RCMU0106 FLOAT BOWL 30 31 RCMU0...
Page 20: ... 1 FCMU0045 RADIATOR 2 FCMU0047 RADIATOR CAP 3 ECMU0024 RADIATOR HOSE LARGE TOP LEFT 4 MCMUHO01 RADIATOR HOSE SMALL BOTTOM RIGHT 5 MCMUGR03 MOUNTING GROMMET 3 PER 6 FCMU0006 RADIATOR MOUNTING BRACKET TEARDROP 7 HCBF0616 FLANGE HEAD BOLT M6X16 8 MCMUCL02 HOSE CLAMP 4 PER ...
Page 21: ...ER PLUG 8904 1 3 FCMU0033 KILL SWITCH ASSEMBLY 4 HCBC0516 SCREW M5 X 16 2 PER 5 HCCN0000 5MM CLIP NUT 2 PER 6 IAMU0002 GROUND WIRE 31 HCWP0001 WASHER FOR STATOR 3 PER 32 HCBC8312 SOCKET HEAD CS 8 32X1 33 HCBC0801 SOCKET HEAD CS 8 32X 1 1 2 2 PER 34 HCNS1001 NUT 10MM 35 ECKG0042 PULLEY WATERPUMP CRANK 59 ICMU0006 ROTOR 60 ICMU0007 STATOR NOT SHOWN MCKGGR00 GROMMET STATOR LEAD NOT SHOWN ICMU0012 ROT...
Page 22: ...ARING TRANMISSION SECONDAY SHAFT 9 ECMU0038 CRANKSHAFT 10 ECKGBR01 BEARING TRANSMISSION OUTPUT SHAFT 13 HCDP1401 DOWEL ENGINE CASE ALIGNEMENT 14 HCBH0805 M8X12 SCREW 15 HCWC0000 COPPER GASKET 16 ECMU0107 OUTPUT SHAFT TRANSMISSION WITH GEAR 17 ECMU0020 BEARING TRANSMISSION PRECISION 19 ECKG0018 CRANKCASE CLUTCH SIDE 20 ZCMU0032 GASKET REED TO CASE 21 ECKG0202 REED ASSEMBLY NOT SHOWN ECKG0205 REED K...
Page 23: ...ECMU0204 KICK STARTER DUST COVER 15 ECMU0063 KICK RETURN SPRING 16 CCMU0031 CLUTCH ARBOR 17 CAKG0005 CLUTCH SHOE SET OF 3 NOT SHOWN CAKG0004 SET OF 3 CLUTCH SHOES WITH SPRINGS WASHER BOLT NOT SHOWN CAKG0002 CLUTCH ASSY W ARBOR SHOES SPRINGS WSHR BOLT 18 CCMU0129 SPRING CLUTCH SINGLE PIECE 19 See Clutch WASHERS CLUTCH FLAT NOT SHOWN CAMU0008 SPRINGS WASHER BOLT COMPLETE SET FOR 3 SHOES 20 HCBS5603 ...
Page 24: ...ELLER WATER PUMP 13 HCBB0001 IMPELLER SCREW SHCS 10 32X1 2 14 HCSS8201 RETAINING SCREW SHCS 8 32X3 8 15 HCBC0603 CASE SCREW SHCS M6X30 16 HCBC0606 CASE SCREW SHCS M6X45 3 REQD 17 HCBC0604 CASE SCREW SHCS M6X35 5 REQD 18 HCWP0001 WASHER STATOR 3 REQD 19 ICMU0007 STATOR 20 HCBC0801 STATOR SCREW SHCS 8 32X1 1 2 2 REQD 21 HCBC8312 STATOR SCREW SHCS 8 32X1 22 ICMU0006 ROTOR 23 ECKG0042 WATER PUMP PULLE...
Page 25: ...G WRIST PIN 9 ZCMUOR07 O RING EXHAUST FLANGE 10 ECKG0015 EXHAUST FLANGE 11 HCBC0602 M6X20 EXHAUST FLANGE SCREW 2 REQ D 12 HCNS1401 NUT CYLINDER HEAD 1 4 20 4 REQ D 13 HCWF1401 FLAT WASHER 1 4 4 REQ D 14 ECKG0025 CYLINDER HEAD OUTER 15 ZCMUOR02 O RING CYLINDER HEAD LARGE 16 ZCMUOR08 O RING CYLINDER HEAD SMALL 17 ZCMUOR03 O RING CYLINDER STUD 8 REQ D 18 ECKG1121 CYLINDER HEAD INSERT 19 ZCMUOR05 O RI...
Page 26: ...MCMUGR06 PIPE GROMMET MALE 5 MCMUGR07 PIPE GROMMET FEMALE 6 MCMUSP02 PIPE GROMMET SPACER 7 HCWF1478 PIPE GROMMET WASHER 1 ON PIPE 2 ON SILENCER 8 HCBF0635 M6X35 FLANGE HEAD BOLT 9 XCDC0003 SILENCER NOT SHOWN XCMU0018 SILENCER PACKING 10 XCKG0009 PIPE SILENCER SEAL 11 MCMUGR03 MOUNTING GROMMET 4 REQD TOTAL 2 PER BOLT 12 TCKG0001 SPACER 2 PER 13 HCNF0601 6MM FLANGE NUT 2 REQD ...
Page 27: ...R 8 FCKG0033 TRIPLE CLAMP UPPER 9 HCNJ0101 STEERING HEAD NUT 1X14 10 HCBC0604 SOCKET HEAD CS M6X35 4 REQD 11 HCBC0806 CAP SCREW M8X30 4 REQD 12S TKMU0404 BAR MOUNT KIT SHORT 2 REQD 12T TKMU0403 BAR MOUNT KIT TALL 2 REQD 14 HCBC3812 SOCKET HEAD CS 3 8 16 X 1 1 2 2 REQD 15 HCNL3816 LOCK NUT 3 8 16 2 REQD 16 FCMU0103 DUST COVER 2 REQD 17 FCMU0004 STEERING HEAD BEARING 2 REQD 18 HCBC0604 SOCKET HEAD C...
Page 28: ...STIFFER 15 LB IN NOT SHOWN KCKG0015 FORK LEG INNER ASSEMBLY BRAKE SIDE 3 BR KAKG0028 FORK LEG INNER ASEMBLY NON BRAKE SIDE 3 NBR KAKG0029 FORK BUSHING OUTER 4 KCKG0033 SWIPER PART NUMBER IS A SINGLE PIECE 5 KCMU0008 SNAP RING 6 KCMUSR23 FORK SEAL PART NUMBER IS A SINGLE PIECE 7 KCMU0007 FORK BUSHING INNER 8 KCKG0020 OUTER FORK TUBE 9 KCKG0121 FORK CAP ASSEMBLY WITH RELIEF 10 KAKG0030 FORK DAMPER A...
Page 29: ...WN KAKG0016 MID VALVE ASSEMBLY SOFT FAST OPTIONAL NOT SHOWN KAKG0018 MID VALVE ASSEMBLY HARD SLOW OPTIONAL 5 KCKG0032 FORK SPRING GUIDE 6 HCNJ5601 NUT 7 DAMPER ROD ASSEMBLY WITH MID VALVE 8 KCKG0023 CARTRIDGE TUBE 9 KAKG0014 BASE VALVE ASSEMBLY STANDARD NOT SHOWN KAKG0013 BASE VALVE ASSEMBLY SOFT FAST OPTIONAL NOT SHOWN KAKG0015 BASE VALVE ASSEMBLY HARD SLOW OPTIONAL 10 KCKG0024 BOTTOM PLUG 11 ZCK...
Page 30: ...1 HCBC0606 M6X45 SOCKET HEAD CAP SCREW 2 KCKG0011 CHECKSTOP 3 KCKG0038 SPRING BASE VALVE 4 KCKGSH01 CHECKPLATE 14 X 3 5 KCKG0026 PISTON FORK VALVE 6 KCKG0035 PISTON SEAL RING BASE VALVE 7 KCKGSH02 SHIM 14 X 1 8 KCKGSH03 SHIM 12 X 15 9 KCKG0036 CONICAL SPACER 10 KCKG0024 BOTTOM PLUG 11 ZCKGOR10 O RING BOTTOM PLUG ...
Page 31: ...T DESCRIPTION 1 HCBC0603 M6X30 SOCKET HEAD CAP SCREW 2 HCWF0601 FLAT WASHER 3 KCKGSH05 SHIM 8 X 15 2 REQD 4 KCKGSH04 SHIM 12 X 1 5 KCKGSH02 SHIM 14 X 1 6 KCKG0026 PISTON FORK VALVE 7 KCKG0035 GLIDRING MIDVALVE PISTON 8 KCKGSH01 CHECKPLATE 14 X 3 9 KCKG0038 SPRING MID VALVE 10 KCKG0011 CHECK STOP ...
Page 32: ...FRAME 2004 KING 3 HCBF0620 M6x20 FLANGE HEAD CS 2 PER 4 BCDC0009 BRAKE PIVOT BOLT 5 HCBH0601 M6 X 16 HEX HEAD BOLT 6 HCNS0601 6 MM NUT 7 TCKG0202 MUD GUARD FRONT OF SHOCK 8 MCMUZT06 6 INCH CABLE TIE 7 PER 9 TCMU0110 WIDE FOOTPEGS PAIR 10 TCMU0106 FOOTPEG SPRING 2 PER 11 HCBB0803 M8X40 BUTTON HEAD BOLT 2 PER 12 HCNL0801 8MM LOCK NUT 2 PER 13 HCWF5601 FLAT WASHER 2 PER ...
Page 33: ...NGE HEAD BOLT M6X30 8 HCNF0601 6MM FLANGE NUT 9 FCMU0057 CHAIN ROLLER 10 HCWF1201 WASHER FLAT CHAIN ROLLER 2 REQ D 11 HCCP0002 COTTERPIN 3 32 X 1 2 REQ D 12 HCBH1403 SWINGARM PIVOT BOLT 13 HCNL1402 SWINGARM LOCK NUT M14 X1 14 HCBH0880 FRONT ENGINE MOUT BOLT M8X30 SHCS 15 HCNL0801 8MM LOCKNUT 16 HCHA0003 6MM CLIPNUT 17 FCMU0006 RADIATOR MOUNTING BRACKET TEARDROP 18 HCBF0616 FLANGE HEAD BOLT M6X16 1...
Page 34: ... FRAME 2004 KING 3 HCBB0802 8X20 BUTTON HEAD CAP SCREW 4 PER 4 HCNL0801 8MM LOCKNUT 4 PER 5 HCBH1001 M10X40 UPPER SHOCK MOUNT BOLT 6 HCNF0601 6 MM FLANGE NUT 7 HCBB0002 M5X20 BUTTON HEAD CAP SCREW 4 PER 8 HCWF0501 FLAT WASHER 2 REQD PER NUMBER PLATE 9 HCBH0502 M5 X 16 HEX HEAD CAP SCREW 2 PER 10 HCWF0601 FLAT WASHER 2 REQD 11 HCBF0620 M6X20 FLANGE HEAD BOLT ...
Page 35: ...MOUNTING BOLTS 6 REQD 8 BCMU0203 BRAKE PADS SET OF 2 9 BCKG0008 BRAKE CALIPER MOUNTING BRACKET 10 BCMU0212 BRAKE HOSE MOUNTING SCREW BANJO BOLT 11 BCMU0205 BRAKE OIL 2 OZ BOTTLE 12 BCMU0211 BRAKE OIL 500 CC BOTTLE 13 BCMU0210 SYSTEM BLEED SYRINGE 14 BKMU0200 BRAKE BLEEDING KIT 2OZ OIL SYRINGE FITTINGS ETC 15 FCKG0212 BRAKE LINE HOLDING BRACKET 16 BCMU0213 BLEED HOLE PLUG 17 WCMUZT04 CABLE TIES 2 R...
Page 36: ...E 4 WCKG0011 FRONT AXLE 5 WCMU0023 FRONT WHEEL SPACER X LARGE 6 WCMU0020 WHEEL BEARING 2 REQD 7 WCKG0010 WHEEL BEARING SPACER 8 WCMU0001 FRONT WHEEL SPACER LARGE 9 BCKG0008 BRAKE CARRIER BRACKET 10 HCWF1202 FRONT AXLE WASHER 11 HCNS1201 FRONT AXLE NUT 12MM 12 BCMU0207 BRAKE ROTOR MOUNTING BOLTS 6 REQD 13 BCMU0206 BRAKE ROTOR WITH MOUNTING BOLTS ...
Page 37: ...0402 RAD SHROUD MTG BOLT LONG 1 PER SIDE NOT SHOWN HCBB0403 RAD SHROUD MTG BOLT SHORT 1 PER SIDE 5 TCMU0013 SIDE NUMBER PLATE SET NOT SHOWN HCBB0002 NUMBER PLATE MTG SCREW 2 PER SIDE NOT SHOWN HCWF0501 NUMBER PLATE WASHER 2 PER SIDE 6 TAMU0012 REAR FENDER ASSEMBLY NOT SHOWN HCBH0502 REAR FENDER MTG BOLT 2 REQD NOT SHOWN HCWF0601 REAR FENDER WASHER 2 REQD NOT SHOWN TCMU0012 REAR FENDER NO MUD GUARD...
Page 38: ...PRING 6 BCDCBU01 BUSHING 7 BCDC0004 PUSH ROD REAR BRAKE 8 HCBF0620 M6X209 FLANGE HEAD BOLT 2 REQD 9 HCCC0002 BRAKE HOSE CLAMP 2 REQD 10 HCPP0832 BRAKE HOSE CLAMP FASTENER 2 REQD 11 BCKG0010 REPLACEMENT BRAKE HOSE 12 HCBF0635 M6X35 FLANGE HEAD BOLT 13 HCBF0620 M6X20 FLANGE HEAD BOLT 14 BCKG0009 BRAKE PADS 15 BCKG0003 BRAKE CARRIER 16 BCKG0006 WHEEL SPACER FLOATING CARRIER NOT SHOWN BCKG0011 BRAKE R...
Page 39: ...EL REAR SPROCKET 7 PCMU0059 RUBBER DAMPERS 8 WCMU0008 WHEEL DAMPING PLATE 9 HCBH0701 M7X35 HEX HEAD BOLT 10 PCMU0001 MASTER LINK 420 11 PCMU0100 CHAIN 420 X 100 12 WCMU0016 REAR AXLE 13 HCPA0002 AXLE HEAD FIXING PLATE 14 BCKG0006 WHEEL SPACER FLOATING CARRIER 15 BCKG0003 BRAKE CARRIER 16 WCMU0020 WHEEL BEARING 17 WCMU0009 WHEEL BEARING SPACER 18 WCMU0001 WHEEL SPACER 19 HCWF1202 AXLE WASHER 20 HCN...
Page 40: ...UBBER SCKG0H08 SPRING LIGHT SCKGOH09 SPRING MEDIUM STOCK SCKGOH10 SPRING HEAVY SCKGOH11 ORING FOR BALL JOINT SCKGOH12 ORING FOR REBOUND ADJUSTER SCKGOH13 ORING FOR REBOUND ADJUSTER SCKGOH14 SUPPORT SLEEVE SCKGOH15 CIRCLIP SCKGOH16 PIN FOR REBOUND ADJUST SCKGOH17 ADJUSTMENT KNOB SCKGOH18 SHAFT FOR END EYE SCKGOH19 NUT SCKGOH20 END EYE SCKGOH21 SCREW FOR KNOB SCKGOH22 KNOB FOR ADJUSTMENT ...
Page 41: ...401 1 4 LOCKNUT 2 PER 12 HCBF0620 M6 X 20 FLANGE HEAD BOLT 2 PER 13 HCCC0002 BRAKE HOSE CLAMP 2 PER 14 HCPP0832 BRAKE HOSE CLAMP FASTNER 2 PER 15 HCBH1001 M10 X 40 LOWER SHOCK MOUNT BOLT 16 FCMU0203 WHEEL PULL 17 FCMU0202 WHEEL PULL CAP 18 HCBH0810 WHEEL PULL BOLT M8X65 19 HCWF5601 WHEEL PULL WASHER 20 WCMU0016 REAR AXLE 21 HCPA0002 AXLE HEAD FIXING PLATE 22 HCNS1201 AXLE NUT 12 MM 23 HCWF1202 AXL...
Page 42: ...l fee Call 330 549 9603 for details Engine Service One method for determining whether the top end of your engine needs rebuilt is to perform a WOT Wide Open Throttle kicking compression test Before performing the procedure please read the caution notes below CAUTION There appears to be a wide range of variability in reading compression gauges across the country The head volume of this Cobra Motorc...
Page 43: ... required 5 16 10 14 mm socket 10 13 22 mm wrench 10 17 19 mm sockets 9 64 3 4 5 mm hex key Allen wrench 7 mm nut driver flat or Phillip screwdriver for hose clamps Spring remover Flywheel clutch puller MCMUTL68 Clutch nut removal tool Call local dealer for details Procedure 1 Remove the seat 4mm hex key 2 Turn of the fuel at the petcock and disconnect the fuel line 3 Remove the tank 5 mm hex key ...
Page 44: ... 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 th...
Page 45: ...f 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 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 ...
Page 46: ...placed every racing season Engine assembly CAUTION For any seals that are to be installed apply a light amount of grease to the seals ID and a small amount of Loctite to the OD 1 Press the three bearings into the respective holes in each case half 2 Press in the crank seals such that the concave side faces the crank weights 3 Press in the counter shaft seal concave side faces inside of transmissio...
Page 47: ...46 Figure 25 Figure 26 ...
Page 48: ...t to the left crank case half being sure to install the gasket behind the connecting rod 12 Assemble the two case halves together with the shim installed between the crank throws Be sure to remove the shim after assembly 13 Insert the screws with the proper lengths at locations shown Figure 28 14 Torque to 9 Nm 80 in lb in the pattern shown in figure 28 15 Install the piston with new wrist pin bea...
Page 49: ... gasket material to the cylinder deck areas around the coolant passage and cylinder studs as shown in figure 29 Figure 29 18 Install the base gasket 19 Install the cylinder being sure that the piston rings are properly aligned with the indexing pins CAUTION Never force the cylinder If resistance is felt determine the problem and solve it 20 Install the cylinder studs and o rings as shown in figure...
Page 50: ... before assembly before installing the clutch and rotate to a vertical position with the engine resting on a bench 27 Install the clutch per Clutch Installation section in this manual 28 Install the coolant drain plug with copper washer 11 ft lb 15 Nm 29 Make sure that the exhaust spacer is on the cylinder 53 in lb 6 Nm 30 Install the spark plug with a fresh gasket to apply the proper torque to th...
Page 51: ...cover on 3 Remove the clutch nut not left hand thread on the end of the crankshaft with the clutch nut removal tool 4 Attach the COBRA CLUTCH PULLER There are three 6mm clutch puller holes located on the ends of the center hub figures 32 33 You must use a draw type puller to remove the clutch CAUTION Do not use a jaw type puller or use the 6mm tapped holes as jackscrews or you are likely damage th...
Page 52: ...s are being installed then it is important to reinstall per figure 34 CLUTCH ASSEMBLY REFERENCE DRAWING REF PART DESCRIPTION 1 CAKG0004 Set of three shoes springs bolts flat washers nuts 2 CAMU0008 Set Of three springs washers bolts nuts 3 CAKG0005 Set of three shoes 4 HCBS5603 Single center shoulder bolt CAUTION The 4 stack clutch spring stack is new for 2004 Figure 34 Recommended clutch spring s...
Page 53: ...his also makes your engine tend to run hotter which decreases engine power and degrades ignition stator efficiency It is important to train your rider NOT to be a throttle blipper CAUTION Sludge build up between the spring washers also keeps the clutch shoe from engaging fully and this will cause the clutch to start to slip So you will need to clean the sludge out or just replace the spring washer...
Page 54: ... crankshaft 5 Apply a small amount of wicking bearing retainer green thread lock agent to the center tapered section of the crankshaft and taper of clutch arbor CAUTION Lean the bike engine such that any excess thread lock agent goes away from the bushing in the clutch drum 6 Put the clutch back in 7 Apply high strength red thread locking agent to the threads and install the nut and torque to 40 f...
Page 55: ...tions 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 Figure 36 9 Put pipe back on and add oil 235 ml 8 0 oz Cobra 3 Shoe Clutch Milk Part MCMUGF01 or Dexron III ATF Ignition Stator care Stator failure will result from running the bike hot Following ...
Page 56: ...the engine is hot it is EXTREMLY important to take the ignition cover off put a fan on it to let it cool and spray it with CRC 3 36 or WD 40 Proper stator care is important for the durability of the ignition system Stator Part ICMU0007 The proper ignition timing for this model of is at 0 045 before Top Dead Center that means 0 045 before the piston reaches the highest point of it s travel in the c...
Page 57: ...ines on the rotor and stator then press the rotor onto the crankshaft firmly figure 37 3 Torque the nut on the rotor to 40 ft lb 54 Nm 4 Recheck the timing following the procedure of timing your ignition 5 Install the water pump belt back on 6 Bolt the ignition cover back on 7 Put the spark plug back in and firmly stick the spark plug cap onto the spark plug Cooling System The water pump in the en...
Page 58: ...osion and abnormal smell Fill the radiator up to the bottom of the radiator filler neck with coolant Install the cap turning it clockwise about turn Tools recommended for impeller service Flat head screwdriver 5mm hex key 13mm hex wrench 1 8 hex key 9 64 hex key 3 32 hex key Propane torch 3 8 diameter x 8 long steel rod Hammer COBRA IMPELLER SERVICE INSTRUCTIONS 1 Remove exhaust pipe and gas tank ...
Page 59: ...retainer screw using a 3 32 hex key Figure 41 item 2 Figure 41 12 Heat engine case around area of impeller lightly with a small Burnsmatic propane torch Using a 3 8 diameter x 8 long steel rod tap impeller assembly out of engine as shown in figure 42 Figure 42 CAUTION Too much heat can be detrimental to the engine cases 13 The shaft assembly is serviceable Use a 1 8 hex key to remove impeller reta...
Page 60: ...igure 44 Figure 44 16 Re assemble in same order of disassembly CAUTION Clean all threads and use green wicking bearing retainer 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 Liquid Performance Propylene Glycol based Mini Coolant Antifreeze CAUTION...
Page 61: ... RUBBER CABLE CAP SEAL 9 RCMU0003 CABLE ADJUSTER 10 11 RCMU0006 TOP CARB SCREW 12 RCMU0106 CARB TOP 13 ZCMU0007 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0205 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLIP 17 RCMU0204 CHOKE ASS Y 2001 CM 20 RCMU0009 FUEL MIXTURE SCREW 21 RCMU0011 IDLE ADJUSTMENT SCREW 25 RCMU0103 FLOAT BOWL GASKET 26 RCMU0107 FLOAT NEEDLE 27 RCMU0012 DIFFUSER 28 RCMU0016 FLOA...
Page 62: ...h on the top end it should be leaned out Leaning it out can be done by 1 Changing the main jet to a smaller number 2 Raising the needle clip this lowers the jet needle one notch at a time on the slide Indications that the engine is running too lean are Engine cutting out on top end Engine overheating and ultimately seizure White spark plug CAUTION It is much safer to operate the engine slightly ri...
Page 63: ...etor 4 Disassemble the carburetor CAUTION Do not use compressed air on an assembled carburetor Or the pressure may deform the float Do not use a strong carburetor cleaning solution which could attack the parts of the carburetor instead use a mild high cleaning solution safe for plastic parts 5 Immerse all the metal parts in a carburetor cleaning solution 6 Rinse the parts in water 7 After the part...
Page 64: ...7 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 oils cling to the wa...
Page 65: ...rockets are also available Watch for bending and warping of the outside rear damper plate If it is bent or warped the rubber dampers in the sprockets do not last as long as when using a straight unit Usually you can straighten the plate with a hammer or just flip it over Changing the rubber dampers 1 Remove the four bolts with the 11mm wrench 2 Take the backing plate off 3 Observe the four rubber ...
Page 66: ...ot 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 wi...
Page 67: ...66 1 Remove brake caliper using 4mm Allen wrench as shown Figure 50 2 Remove cotter key from caliper as shown and pull pads out Figure 51 ...
Page 68: ...inimum thickness of 2 5mm This is measuring the pad the holder as shown below Figure 52 Brake bleeding procedure 1 Remove brake caliper using 4mm Allen wrench as shown in pad removal procedure Pry pads outward to fully retracted position 2 Remove reservoir cap using a Torx T25 wrench as shown Keep reservoir level Figure 53 ...
Page 69: ... Attach Bleeding syringe as shown Pump all air out of system until only clean oil runs out of reservoir Figure 55 5 Reinstall reservoir cap Oil will overflow in the process This is necessary to ensure no air is in the system Remove bleeding syringe and quickly reinstall bleed screw ...
Page 70: ...2 2 1 More preload greater distance less race sag 2 2 2 Less preload smaller distance more race sag 2 3 Shock spring 2 3 1 Stiffer spring stiffer throughout the travel 2 3 2 Less stiff spring less stiff throughout the travel 2 4 Compression damping 2 4 1 Harder more damping slower adds resistance to the suspension motion when the suspension is compressing 2 4 2 Softer less damping quicker reduces ...
Page 71: ... 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 Proactive Suspension Adjustments Once you have the suspension adjusted for decent overall feel you can make proactive adjustments when faced wit...
Page 72: ...tact Cobra or PR2 for questions and service of your King shock Shock preload Figure 15 Shock Damping Figure 16 Shock Length The shock on your Cobra Motorcycle has an adjustable eye to eye length It is not to be extended any longer than when one groove is visible below the locknut after tightening Figure 17 ...
Page 73: ...ust 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 c...
Page 74: ...ith 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 diff...
Page 75: ...cer needs repacking 4 Engine blubbers at high RPMs a Jetting too rich b Stator needs replaced 5 Engine won t start a Fuel i None in tank ii Is sour or bad b Carburetor is dirty c Ignition i Spark plug fouled ii Spark plug cap off iii Engine Shut off kill switch is shorted iv Bad electrical ground v Stator winding damaged d Exhaust is plugged with object of flooded fuel e Engine is flooded f Cracke...
Page 76: ...20 Engine Parts List 17 Specifications 5 Exhaust 63 Parts 25 Fork oil replacement 15 Forks Parts 26 Service 72 Frame Parts 31 Front Brake Parts 34 Front Brakes Service 65 Front Wheel Parts 35 Fuel System Parts list 60 Service 60 General Tips 9 Hardware Frame 31 Plastic 36 Ignition Parts 23 Service 54 Timing 55 Jetting How To 61 Stock 5 Lubrication Recommended 5 Maintenance Schedule 10 Tips 10 Oil ...
Page 77: ...36 Pullers 65 Rear Brake Adjustment 13 Parts 37 Rear Wheel Damper 64 Parts 38 Pullers 65 Reeds 63 Shock Parts 39 Service 70 Spark Plug Recommended 5 Specifications 5 Torque Values 7 Starting 9 Stator torque 7 Suspension 70 Swingarm Parts 40 Tips 9 Top End Parts 24 Service 41 Torque Values 7 Transmission Lubricant Replacing 11 Troubleshooting 73 VIN reading 9 WARNING 2 Water Pump Parts 23 Wheels Se...
