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Page 2: ...bra 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 Motorcycl...
Page 3: ...ENDED 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...
Page 4: ...r Filter Cleaning 15 Fork Oil Replacement 16 Parts 18 Parts Airbox and Inlet System 18 Parts Bars and Controls 19 Parts Carburetor 20 Parts Coolant System 21 Parts Electrical System 22 Parts Engine Bo...
Page 5: ...ervice 40 Engine Service 40 Engine Removal 41 Complete Engine Disassembly Procedure 42 Top End Disassembly Procedure 42 Splitting the Cases 43 Engine assembly 44 Clutch 49 Ignition 54 Cooling System 5...
Page 6: ...Champion 8339 1 8332 1 hotter 8904 1 colder Gap 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...
Page 7: ...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 10 x 1 25 Clutch bolts 14 170 19 M6 x 1 0 Engine mount bolts 2...
Page 8: ...12 lb in 2 10 N mm SCMUOH04 275 lb in red 38 45 std KCMZ0012 14 lb in 2 45 N mm SCMUOH05 285 lb in yellow 46 to 55 stiff KCMZ0012B 16 lb in 2 80 N mm SCMU0H06 295 lb in white Suspension valving Dampin...
Page 9: ...eriod 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 fo...
Page 10: ...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 le...
Page 11: ...warmed up to race temperatures 5 A properly maintained machine is safer faster and more fun to ride 6 Cobra offers a carburetor inlet cover RCMU0109 to keep water and dirt from getting into the carbu...
Page 12: ...racks in the paint that might indicate that the metal has been stressed beyond it s safe limits Replace or get properly rewelded as necessary o Inspect the rear sprocket damper plate for bending or wa...
Page 13: ...he shaft Replacing Transmission Clutch Lubricant Tools needed 225 ml 7 6 oz Cobra Venom 3 Shoe Clutch Milk Part MCMUGF01 13 mm combination wrench Procedure 1 Begin this procedure with a bike that has...
Page 14: ...bra 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 lubric...
Page 15: ...for front brake maintenance 10mm open end wrench From the brake lever 1 Slide the cover out of the way 2 Loosen the locking nut on the brake lever 3 Adjust the bolt to desirable position 4 Tighten th...
Page 16: ...ds will burn up and need to be replaced Air Filter Cleaning Tools recommended for air filter maintenance 2 Phillips head screwdriver 4 mm hex key Allen Foam filter oil Procedure 1 Removed the seat wit...
Page 17: ...t foam filter oil It s very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting 8 Reinstall the filter boot assembly by pushing it dow...
Page 18: ...n and remove the wire spring clip from its groove 7 Remove the white cap the fork spring preload sleeve and the fork spring NOTE Depressing the fork leg will facilitate removing the white cap 8 The fo...
Page 19: ...6 HCBC0625 M6X25 SOCKET HEAD CAP SCREW 7 MCKGHO04 HOSE CLAMP CARBURETOR TO MANIFOLD 8 RACM0002 CARBURETOR 14MM Not Shown FCMU0026 FUEL LINE Not Shown MCMUCL04 HOSE CLAMPS FUEL LINE 9 FCMU0067 THROTTLE...
Page 20: ...TCMU0008 GRIPS SET OF TWO 4 FCMU0067 THROTTLE CABLE 5 FCMU0033 KILL SWITCH ASSEMBLY 6 KCMZ0001 M8X50 SOCKET HEAD CAP SCREW 4 REQ D 7 KCMZ0003 LOWER HANDLE BAR CLAMP 2 REQ D 8 KCMZ0002 TOP HANDLE BAR C...
Page 21: ...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...
Page 22: ...HOSE LEFT 3 MCMUCL02 HOSE CLAMP 4 ECHA0003 MOUNTING BRACKET RADIATOR BOTTOM 5 HCBC0607 M6X50 SOCKET HEAD CAP SCREW 6 HCNL0601 6MM LOCK NUT 7 MCKGGR00 GROMMET RADIATOR MOUNTING 8 MCMUHO03 RADIATOR HOS...
Page 23: ...04 1 3 FCMU0033 KILL SWITCH ASSEMBLY 4 HCBC0516 SCREW M5 X 16 2 PER 5 HCCN0000 5MM CLIP NUT 2 PER 6 IAMU0003 GROUND WIRE 31 HCWF0504 WASHER FOR STATOR 3 PER 32 HCBC0525 5mm x 25 SOCKET HEAD CAP SCREW...
Page 24: ...ION WITH GEAR 6 ECMU0017 SEAL CRANKSHAFT 7 ECMU0016 BEARING CRANKSHAFT 8 ECMU0001 BEARING TRANMISSION SECONDARY SHAFT 9 ECMU0038 CRANKSHAFT 10 ECKGBR01 BEARING TRANSMISSION OUTPUT SHAFT 13 ECDC0031 DO...
Page 25: ...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 SPRI...
Page 26: ...SHCS 10 32X1 2 14 HCBC0408 M4mm x 8 SOCKET HEAD black oxide 15 CASE SCREW SHCS M6X55 1 REQ D 16 CASE SCREW SHCS M6X45 2 REQ D 17 CASE SCREW SHCS M6X40 6 REQ D 18 HCWF0504 WASHER FOR STATOR 3 PER 19 IC...
Page 27: ...XHAUST FLANGE 10 ECMU0086 EXHAUST FLANGE NOT SHOWN ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0602 M6X20 EXHAUST FLANGE SCREW 2 REQ D 12 HCNS1401 NUT CYLINDER HEAD 1 4 20 4 REQ D 13 HCWF1401 FLAT...
Page 28: ...EXHAUST SPRING SHORT 4 MCMUGR06 PIPE GROMMET MALE 5 MCMUGR07 PIPE GROMMET FEMALE 6 MCMUSP02 PIPE GROMMET SPACER 7 HCWF1478 PIPE GROMMET WASHER 8 HCBF0635 M6X35 FLANGE HEAD BOLT 10 XCKG0009 PIPE SILENC...
Page 29: ...0001 CLAMP BRAKE CABLE 6 HCBC0502 M5X20 SOCKET HEAD CAP SCREW 7 HCNL0501 5MM LOCK NUT 8 HCBF0616 FENDER BOLT M6X16 FLANGE HEAD 4 REQ D 9 KCMZ0025 TRIPLE CLAMP LOWER WITH STEM 10 HCBC0625 M6X25 SOCKET...
Page 30: ...MZ0015 FORK SEAL 16 KCMZ0016 WASHER 17 KCMZ0017 SEALING RING FOR REBOUND PISTON 18 KCMZ0118 PISTON ROD REBOUND 18A KCMZ0118A PISTON ROD COMPRESSION 19 KCMZ0019 REBOUND SPRING 20 KCMZ0020 FORK LEG OUTE...
Page 31: ...ET HEAD CAP SCREW 4 HCNL0801 8MM LOCKNUT 5 MCMUGR06 PIPE GROMMET MALE 6 MCMUGR07 PIPE GROMMET FEMALE 7 MCMUSP02 PIPE GROMMET SPACER 8 HCWF1478 PIPE GROMMET WASHER 9 HCHA0003 6MM CLIPNUT 10 BCMU0008 CA...
Page 32: ...E 2004 CM50 1 HCBB0635 M6X35 BUTTON HEAD CAP SCREW 2 HCHA0003 6MM CLIPNUT 3 HCBF0620 M6X20 FLANGE HEAD BOLT 4 HCNF0602 6MM NYLOC FLANGE NUT 5 HCBF0630 M6X30 FLANGE HEAD BOLT 6 MCMUGR04 GROMMET SILENCE...
Page 33: ...NUT 4 MCKGGR00 GROMMET RADIATOR MOUNT 2 REQ D ON BOTTOM 1 ON TOP BRACKET 5 ECHA0109 MOUNTING BRACKET RADIATOR TOP 6 HCBC0660 M6X60 SOCKET HEAD CAP SCREW 7 FCMU0057 CHAIN ROLLER 8 HCWF1201 WASHER FLAT...
Page 34: ...ARM FRONT 3 BCMU0005 CABLE CLAMP WASHER NUT 4 BCMU0006 CABLE ADJUSTOR 5 BCMU0110 BRAKE SHOE PAIR 6 BCMU0010 SPRING BRAKE RETURN 7 BCMU0011 PUSH NUT BRAKE SPRING 2 REQ D 8 BCMU0007 BRAKE STOP 9 HCBH08...
Page 35: ...MU0300 FRONT WHEEL COMPLETE 2 WCMU0250 FRONT TIRE 10X2 50 3 WCMUTU10 TUBE 10 4 WCMU0014 FRONT AXLE 5 HCWF1202 WASHER AXLE 6 WCMU0023 FRONT WHEEL SPACER 7 WCMU0020 BEARING WHEEL 2 REQ D 8 WCMU0004 SPAC...
Page 36: ...Q D NOT SHOWN HCBC0685 M6X85 SHCS FRONT TANK MOUNT NOT SHOWN HCNL0601 6MM LOCK NUT FRONT TANK MOUNT BOLT NOT SHOWN HCBC0645 M6X45 SOCKET HEAD CAP SCREW NOT SHOWN TCHA0004 BUSHING REAR TANK MOUNTING 7...
Page 37: ...NL0801 8MM LOCK NUT 6 HCBH0602 M6X25 HEX HEAD BOLT BRAKE STOP ADJUST 7 HCNS0601 6MM NUT 8 BCCM0105 BRAKE ROD 9 BCMU0111 BRAKE ROD BARREL 10 HCNW0001 BRAKEROD WINGNUT 11 BCMU0109 BRAKE HUB REAR 12 BCMU...
Page 38: ...ACER SPROCKET DAMPER 6 WCMU0016 REAR AXLE 7 HCPA0002 AXLE HEAD FIXING PLATE 8 WCMU0001 REAR WHEEL SPACER SPROCKET SIDE 9 WCMU0020 WHEEL BEARING 2 REQ D 10 WCMU0003 WHEEL BEARING SPACER REAR 11 BCMU010...
Page 39: ...ts Shock Figure 27 REAR SHOCK REF PART DESCRIPTION 1 SACM2004 SHOCK ABSORBER 2 SCMUOH05 SPRING STANDARD 285 lb in SCMUOH04 SPRING LIGHT 275 lb in SCMUOH06 SPRING HEAVY 295 lb in 3 HCBC1001 M10X45 SHCS...
Page 40: ...620 M6X20 FLANGE HEAD BOLT 2 REQ D 9 PAKG0001 CHAIN GUIDE ASSEMBLY COMPLETE 11 PCKG0004 CHAIN GUIDE BOTTOM SLIDER 12 HCBFT640 M6 X 40 FLAT HEAD BOLT 13 HCNL0601 6MM LOCKNUT 14 FAMU0005 WHEEL PULL ASSE...
Page 41: ...e 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 perfor...
Page 42: ...mission the engine must be removed from the frame Tools required 10 11 13 22 mm wrench 10 14 17 19 mm sockets 3 4 5 mm hex key Allen wrench 7 mm nut driver flat or Phillip screwdriver for hose clamps...
Page 43: ...3mm hex key 2 Remove the bolt from the water pump shaft 3 4mm hex key 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...
Page 44: ...posits 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...
Page 45: ...apply a light amount of grease to the seals ID assembly lube on all bearings and a small amount of Loctite to the OD 1 Press the three bearings into the respective holes in each case half 2 Press in...
Page 46: ...Figure 25 Figure 26 45...
Page 47: ...th crankcase halves NOTE Gasket material is only required around the crankcase and not the transmission 13 Apply the crankcase gasket to the left crank case half being sure to install the gasket behin...
Page 48: ...e connecting rod bearing 19 Install the piston rings CAUTION Ring end gap should be no less than 0 25 mm 0 010 and no more than 0 64mm 0 025 20 Install the base gasket 21 Apply gasket sealer to the to...
Page 49: ...nut 30 Install reed and inlet manifold with new gaskets 105 in lb 12 Nm applying 1104 gasket sealer to both sides of all gaskets 31 Leak check the engine to 20 psi to ensure proper seal 32 Install st...
Page 50: ...ed for clutch service Universal clutch puller a universal puller that pulls the clutch main drive gear and rotor Part MCMUTL70 5mm T handle Clutch nut removal tool Call local dealer for details Cobra...
Page 51: ...u get a bolt loosened carefully remove it with the shoe and observe the way the spring washers are stacked CAUTION It is very important that the clutch stack be reassembled as it was disassembled unle...
Page 52: ...64 0 025 HCWS0805 0 51 0 020 HCWS0806 0 38 0 015 Use the table above to order adjustment washers Replace the stock washer with the proper combination of adjustment washers that delivers the desired c...
Page 53: ...t 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 star...
Page 54: ...e 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...
Page 55: ...ations 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 align...
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 i...
Page 57: ...at are to receive thread locking material per the manufacturers instructions 2 Eyeball the lines on the rotor and stator then press the rotor onto the crankshaft firmly figure 37 3 Torque the nut on t...
Page 58: ...39 To remove radiator cap 1 Turn the cap counter clockwise to the first stop and wait there for a few seconds 2 Push the cap down and turn it further in the same direction and remove the cap NOTE Ins...
Page 59: ...d basket 8 Unscrew water elbow fitting Figure 40 Figure 40 8 Remove ignition cover using a 4mm hex key four places 9 Remove belt retainer screw using a 4mm hex key Figure 41 item 1 10 Remove belt reta...
Page 60: ...n the outside seal bearings and inside of case reinstall bearing assembly by using a 0 500 ID by 1 000 OD steel tube 2 long and tap on end of tube per figure 44 Figure 44 16 Re assemble in same order...
Page 61: ...R 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 RCMU0205 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLI...
Page 62: ...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 Ind...
Page 63: ...he carburetor 5 Immerse all the metal parts in a carburetor cleaning solution 7 6 After the parts are cleaned dry them with compressed air 8 7 Blow out the fuel passages with compressed air 8 Assemble...
Page 64: ...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 e...
Page 65: ...so 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 ca...
Page 66: ...Adjustment 1 Front forks 1 1 Fork oil 1 1 1 Oil type 1 1 1 1 Heavier weight oil more damping slower responding 1 1 1 2 Lighter weight oil less damping quicker responding 1 1 2 Oil quantity level 1 1...
Page 67: ...the fork springs are proper for the weight of rider as detailed above try raising the fork oil level in increments of 10mm Raising the fork oil level reduces the air volume and increases the stiffnes...
Page 68: ...n the weight of your rider See the Parts Shock section or the Optional component section at the beginning of the manual for these other components Front Forks Cobra offers stiffer and softer fork spri...
Page 69: ...oper gearing Poor performance Not enough top end speed No snap Over heat clutch Premature failure of engine seals bearings electronics High clutch wear Condition Gear Taller Gear Lower Mud Sand Hills...
Page 70: ...43 15 37 2 47 14 35 2 50 15 38 2 53 13 33 2 54 14 36 2 57 15 39 2 60 13 34 2 62 14 37 2 64 15 40 2 67 13 35 2 69 14 stock 38 2 71 15 41 2 73 13 36 2 77 14 39 2 79 15 42 2 80 13 37 2 85 14 40 2 86 13 3...
Page 71: ...l not rev out blubbers on top o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o Wet black or overly dark spark plug when removed for inspection Symptoms of too lean a fuel mixtur...
Page 72: ...Figure 59 FUEL SCREW ADJUSTMENT Adjust for maximum idle speed The fuel adjustment screw is located on the left side of the carburetor It is the smaller of the two adjustment screws and requires the u...
Page 73: ...clip higher on the needle to make the bike run leaner or move the clip lower on the needle to make the bike run richer to one higher or lower Troubleshooting 1 Engine not behaving properly a Carbureto...
Page 74: ...on 04 or later no mods iii Spark plug cap off iv Engine Shut off kill switch is shorted v Bad electrical ground vi Stator winding damaged d Exhaust is plugged 6 Overheating a Bad stator b Water pump...
Page 75: ...6 Forks Parts 29 Frame Parts 31 Front Brake Adjustment 14 Parts 34 Front Forks Service 68 Front Forks 68 Front Wheel Parts 35 Fuel System Service 61 Gearing 69 General Tips 10 Hardware and Fasteners F...
Page 76: ...rs 66 Rear Brake Adjustment 15 Parts 37 Rear Wheel Damper 65 Parts 38 Pullers 66 Reeds 63 Shock 68 Parts 39 Service 73 Spark Plug Recommended 5 Specifications 5 torque values 6 Starting 9 Suspension 7...
