Cobra 2006 P3-50 User Manual Download

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2006 P3-50

Owners

Parts

Service

Tuning

Summary of Contents for 2006 P3-50

Page 1: ...2006 P3 50 Owners Parts Service Tuning...

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 9600 Cobra Motorcy...

Page 3: ...TENDED 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 MOTORCYCL...

Page 4: ...rake adjustment 15 Air Filter Cleaning 15 Fork Oil Replacement 16 Exhaust Power Regulator 17 Parts 18 Parts Airbox and Inlet System I 18 Parts Bars and Controls 20 Parts Carburetor 21 Parts Coolant Sy...

Page 5: ...4 Parts Shock 41 Parts Swingarm Assembly 42 Service 43 Engine 43 Clutch 43 Reeds 44 Carburetor 46 Exhaust 49 Rear wheel pullers 49 Tuning 50 Suspension 50 Gearing 53 Carburetion 54 Troubleshooting 57...

Page 6: ...8904 1 colder Gap 0 023 0 025 0 58 0 64 mm Fuel type high octane pump gasoline RACE FUELS ARE NOT RECOMMENDED Injector oil type Cobra Venom 2 cycle Race Oil Fuel oil mix ratios Fill oil reservoir as r...

Page 7: ...spacer Specifications Torque Values Torque Value Fastener ft lb in lb Nm Size Remarks Cylinder head nuts 8 8 105 12 M6 X 1 0 Front engine mount bolts 22 264 30 M8 x 1 25 Rear engine mount bolts 22 26...

Page 8: ...of Rider lb Fork Spring Shock Spring Less than 38 light KCMZ0012A 12 lb in 2 10 N mm SCMUOH04 red 275 lb in 38 45 std KCMZ0012 14 lb in 2 45 N mm SCMUOH05 yellow 285 lb in 46 to 55 stiff KCMZ0012B 16...

Page 9: ...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...

Page 10: ...motorcycle in a level upright position with the rear wheel off the ground 2 On the carburetor flip the black choke knob upward from the right side of the bike 3 Kick start the engine by kicking the l...

Page 11: ...r when the bike is being washed 7 It is acceptable and common to run 40 1 or leaner premix in the fuel tank 8 New chains will stretch on first use Never install a new chain prior to a race Always brea...

Page 12: ...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 th...

Page 13: ...om 3 Shoe Clutch Milk Part MCMUGF01 3 Phillips screwdriver large flat blade screwdriver or coin Procedure 1 Begin this procedure with a bike that has been ridden more than 5 minutes but less than 10 m...

Page 14: ...e harsh environment of the automatic clutch and transmission of this motorcycle Cobra was forced to put forth this effort because the other available options and not adequate Cobra s specially develop...

Page 15: ...a light weight oil like Liquid Performance Chain Lube or WD40 to reduce frictional drag Front brake adjustment Tools recommended for front brake maintenance 10mm open end wrench From the brake lever 1...

Page 16: ...the brake hub 1 Adjust the wing nut to the desirable position CAUTION If you tighten the wing nut too much the brakes may remain engaged If so the brake pads will burn up and need replaced Air Filter...

Page 17: ...igned Air box It is very important to keep the air filter clean and properly oiled with high quality water resistant foam filter oil It s very important to oil your filter consistently each time becau...

Page 18: ...itate removing the white cap 8 The fork can now be turned upside down and drained Assembly 1 Fill the leg with 200 cc 6 8 oz 20 wt fork oil 2 Standard fork oil level is 70 mm 2 75 from the top edge wi...

Page 19: ...AD BOLT 2 REQ D 5 RCMU0409 CHAIN GUARD 6 HCFH0612 M6 X 12 FLAT HEAD SCREW 7 HCFH0620 M6 X 20 FLAT HEAD SCREW 8 HCNL0601 6MM LOCK NUT 9 RCMU0403 AIR FILTER WITH BOOT 10 ECMPIN01 CARBURETOR 12 MM OIL IN...

Page 20: ...UEL LINE Not Shown MCMUCL04 HOSE CLAMPS FUEL LINE 2 ECMOIN02 CLAMP 3 HCBC0625 6X25 CAP SCREW 4 ECMOIN04 REED SPACER PLATE 5 ZCMOIN05 REED VALVE GASKET 6 ECMOIN06 REED VALVE ASSEMBLY NOT SHOWN ECMOIN07...

Page 21: ...ABLE 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 CLAMP 2 REQ D 9 TCMU0019 HANDLEBAR ALUMINUM 11 B...

Page 22: ...45 PILOT 6 RCOI0006 CHOKE JET 7 RCOI0007 TOP CARB SCREW 8 RCOI0008 O RING FOR CARB TOP 9 RCOI0009 CARB TOP W O RING 10 RCOI0010 SLIDE SPRING 11 RCOI0011 NEEDLE RETAINER PLATE 12 RCOI0012 NEEDLE CLIP...

Page 23: ...CLAMP STANDARD three places 4 ECHA0003 MOUNTING BRACKET RADIATOR BOTTOM 5 HCBC0607 M6X50 SOCKET HEAD CAP SCREW 6 HCNL0601 6MM LOCK NUT 7 MCKGGR00 GROMMET RADIATOR MOUNTING 8 ECPW0003 RADIATOR HOSE RIG...

Page 24: ...0 FCMU0033 IGNITION CUT OFF SWITCH ASSEMBLY NOT SHOWN MCOIWC01 WIRE CONNECTOR MALE TO MALE PLUG 11 ECMOIG05 IGNITION COIL WITH SPARK PLUG CAP 12 HCBC0602 M6X20 SOCKET HEAD CAP SCREW 13 HCNL0601 6MM LO...

Page 25: ...EARING 5 ECMOBE05 CRANK SEAL 6 ECMU0016 CRANK BEARING 7 ECMOBE07 CRANKSHAFT COMPLETE 8 ECMOBE08 FLYWHEEL KEY 9 ECMU0077 WRIST PIN BEARING 10 HCBC0660 6X60 CAP SCREW 11 HCBC0607 6X50 CAP SCREW 12 ZCMOB...

Page 26: ...OCL30 CLUTCH COMPLETE 6 ECMOCL06 SPACER CLUTCH TO HUB 7 ECMOCL07 BUSHING CLUTCH HUB 9 ECMOCL09 WASHER CLUTCH BASKET BACK UP 10 PCMOCL10 SPROCKET 10 TOOTH 11 ECMOCL11 SNAP RING OUTPUT SHAFT 12 ECMOCL12...

Page 27: ...ER PUMP IMPELLER 12 ECMOWP12 SNAP RING TOOTHED 13 ECMOWP13 WATER PUMP SEAL 14 ECMOWP14 WASHER BEARING RETAINER 15 ECMPWP15 DOWEL PIN 16 HCWF0501 5MM WASHER 17 ECMOIG01 FLYWHEEL AND STATOR 18 HCWF0801...

Page 28: ...0625 6X25 CAP SCREW 9 ECMPKS09 KICK START LEVER 11 HCBC0603 6X30 CAP SCREW 12 ZCMOKS12 CLUTCH COVER GASKET 13 ECMOKS13 THRUST WASHER 14 ECMOKS14 SEAL KICK START SHAFT 15 ECMOKS15 KICK START SHAFT WITH...

Page 29: ...ING 3 HCBC0603 6X30 CAP SCREW 4 HCNF0601 FLANGED NUT 6MM 5 ECMOTE05 CYLINDER HEAD 6 ZCMOTE06 CYLINDER HEAD O RING 7 ECMU0026 6MM DOWEL 9 ECMOTE09 CYLINDER HEAD STUD BOLT 6MM 10 ZCMOTE10 BASE GASKET 11...

Page 30: ...T 4 XCMU0028 PIPE SILENCER SEAL 5 XCKG0003 SILENCER NOT SHOWN XCMU0018 SILENCER PACKING 6 MCMUGR04 GROMMET SILENCER MOUNTING 2 REQ D 7 HCBF0630 M6X30 FLANGE HEAD BOLT 8 MCMUGR06 PIPE GROMMET MALE 9 MC...

Page 31: ...E 4 KCMZ0027 INNER FORK LEG LEFT REBOUND SIDE 5 HCCC0001 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 TR...

Page 32: ...KCMZ0015 FORK SEAL 16 KCMZ0016 WASHER 17 KCMZ0017 SEALING RING FOR REBOUND PISTON 18 KCMZ0018 PISTON ROD REBOUND 18A KCMZ0018A PISTON ROD COMPRESSION 19 KCMZ0019 REBOUND SPRING 20 KCMZ0020 FORK LEG O...

Page 33: ...GROMMET FEMALE 7 MCMUSP02 PIPE GROMMET SPACER 8 HCWF1478 PIPE GROMMET WASHER 9 HCHA0003 6MM CLIPNUT 10 BCMU0008 CABLE BRAKE SNAKE 11 BCMU0009 CRIMP BRAKE SNAKE 12 HCBF0635 M6X35 FLANGE HEAD BOLT 13 TC...

Page 34: ...RAME 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 SILE...

Page 35: ...R 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 CHAIN ROLLER 2 REQ D 9 HCCP000...

Page 36: ...U0005 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 HCBH0808 M8X30 BUTTON...

Page 37: ...T WHEEL COMPLETE NOT SHOWN WCPW0001 RIM WITH BEARINGS 2 WCMU0018 FRONT TIRE 3 WCMUTU10 TUBE 10 4 WCMU0014 FRONT AXLE 5 HCWF1202 WASHER AXLE 6 WCPW0005 FRONT WHEEL SPACER 7 WCMU0020 BEARING WHEEL 2 REQ...

Page 38: ...rts Oil Reservoir Figure 29 Oil Reservoir REF PART DESCRIPTION TCPW0101 OIL RESERVOIR WITH FITTING TCDC0015 FITTING OIL RESERVOIR MCMUCL06 CLAMP HOSE TCPW0002 CAP OIL RESERVOIR TCPW0004 HOSE OIL INJEC...

Page 39: ...HOWN TCHA0006 SPACER FRONT TANK MOUNT 2 REQ 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 SH...

Page 40: ...HCNL0801 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 WCPW0004 BRAKE HUB REAR 12 B...

Page 41: ...R LINK 420 CHAIN 6 WCMU0016 REAR AXLE 7 HCPA0002 AXLE HEAD FIXING PLATE 8 WCMU0001 REAR WHEEL SPACER LARGE SPROCKET SIDE 9 WCMU0020 WHEEL BEARING 2 REQ D 10 WCMU0003 WHEEL BEARING SPACER REAR 11 WCPW0...

Page 42: ...ck Figure 33 REAR SHOCK REF PART DESCRIPTION 1 SAPW2004 SHOCK ABSORBER 2 SCMUOH05 SPRING STANDARD 285 lb in yellow SCMUOH04 SPRING LIGHT 275 lb in red SCMUOH06 SPRING HEAVY 295 lb in white 3 HCBC1001...

Page 43: ...M6X20 FLANGE HEAD BOLT 2 REQ D 9 PKOI 0001 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 ASSEMB...

Page 44: ...tures as when it was assembled new Before leaving the engines performance will be measured on a dynamometer to ensure that your engine is operating at its highest potential All this for one low nomina...

Page 45: ...is by not gearing too high changing the oil as specified and by not blipping the throttle Every time you blip the throttle you are working your clutch springs CAUTION The clutch produces a tremendous...

Page 46: ...45 Figure 35 The presence of light indicates that the reeds should be replaced or possibly turned over...

Page 47: ...PILOT JETS 38 45 EXAMPLE RCOI0045 FOR 45 PILOT 6 RCOI0006 CHOKE JET 7 RCOI0007 TOP CARB SCREW 8 RCOI0008 O RING FOR CARB TOP 9 RCOI0009 CARB TOP W O RING 10 RCOI0010 SLIDE SPRING 11 RCOI0011 NEEDLE RE...

Page 48: ...filter can cause the engine to run rich NOTE Also before changing jetting insure that your carburetor has a proper float height of 5 If the engine is running rich on the top end it should be leaned ou...

Page 49: ...no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clea...

Page 50: ...build up So it is essential to clear the residue CAUTION It is important to repack the silencer Signs of your silencer needing to be repacked are The bike is louder than normal A loss of power Rear wh...

Page 51: ...ng less stiff throughout the travel 2 2 Compression damping optional valve 2 2 1 Harder more damping slower adds resistance to the suspension motion when the suspension is compressing 2 2 2 Softer les...

Page 52: ...r decent overall feel you can make proactive adjustments when faced with different racing conditions Situation Actions Sand track Lower the rear end increase race sag Sand track Stiffer compression an...

Page 53: ...d the rebound damping duties are performed in the left fork leg This allows easy adjustment of the damping characteristics by appropriately changing the viscosity of the fork oil in the fork leg contr...

Page 54: ...mproper 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 Hil...

Page 55: ...cessary to adjustment your particular jetting due to current weather conditions altitude fuel variations and or engine modifications CAUTION Proper jetting is very important for engine performance and...

Page 56: ...Low altitude Standard None High altitude Richer Leaner Low barometric pressure Richer Leaner High barometric pressure Leaner Richer NOTE Before making any carburetor jetting changes verify that o You...

Page 57: ...dle turn the screw in clockwise in 1 4 turn increments and rev the engine after each adjustment To lower the idle turn the screw counter clockwise TOP END JETTING Adjust for clean full throttle accele...

Page 58: ...down on power a Clutch engagement is not set properly b Jetting is incorrect c Silencer needs repacked d e Exhaust pipe i Has excess carbon buildup ii Has large dent in it f Compression is low i Pisto...

Page 59: ...or bolt out d Jetting too lean e Too much throttle blipping f Too high gearing g Kinked radiator hose h Rear brake dragging i Chain too tight j Air leak 7 Engine won t idle a Idle knob needs adjusted...

Page 60: ...25 Exhaust 30 Forks 31 Frame 33 Front Brake 36 Front Wheel 37 Oil Reservoir 38 Plastic Seat 39 Rear Brake 40 Rear shock 51 Rear Wheel 41 Shock 42 Swingarm 43 Top end 29 Parts List Front Forks 52 Petc...

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Cobra 2006 P3-50, Owner'S Manual

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