Cobra cm-50 2006 User Manual Download

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2006 CM-50

Owners Manual

June 2006

Allegan Motorsports - 800-475-5660

Summary of Contents for cm-50 2006

Page 1: ...2006 CM 50 Owners Manual June 2006 Allegan Motorsports 800 475 5660...

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 Motorcy...

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: ...Replacing Transmission Clutch Lubricant 12 Chain adjustment 13 Front brake adjustment 14 Rear brake adjustment 15 Air Filter Cleaning 15 Fork Oil Replacement 16 Service 40 Engine Service 40 Engine Rem...

Page 5: ...4 Tuning 61 Suspension 61 Rear shock 63 Front Forks 63 Gearing 64 Carburetion 66 Troubleshooting 68...

Page 6: ...k plug 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 RECOMMEN...

Page 7: ...05 12 M6 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...

Page 8: ...Suspension Springs Weight of Rider lb Fork Spring Shock Spring Less than 38 light KCMZ0012A 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 4...

Page 9: ...he 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...

Page 10: ...e 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...

Page 11: ...een 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 ca...

Page 12: ...cks 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 Every 2 hours of operation o Replace...

Page 13: ...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 r...

Page 14: ...was formulated to provide superior lubrication and cooling capability over extended periods of time and is the recommended lubricant for your Cobra motorcycle Chain adjustment Tools required for chain...

Page 15: ...ded 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...

Page 16: ...ads 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 wi...

Page 17: ...resistant 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 pushi...

Page 18: ...wards down 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...

Page 19: ...603 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 procedu...

Page 20: ...the engine must be removed from the frame Tools required 10 11 13 22 mm wrench 8 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 Sprin...

Page 21: ...tool and 14 mm socket remove the nut that secures the flywheel 4 Using the Cobra flywheel clutch puller remove the flywheel from the crankshaft 5 Remove the stator 5mm hex key 6 Remove the nut holding...

Page 22: ...ng etc are found replace the cylinder 2 If 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 abrasio...

Page 23: ...ouple months of hard racing Engine assembly CAUTION For any seals that are to be installed apply a light amount of grease to the seals ID assembly lube on all bearings and a small amount of Loctite to...

Page 24: ...ins CAUTION Never force the cylinder If resistance is felt determine the problem and solve it Once installed slightly rotate the cylinder back and forth insuring that the rings are properly seated 15...

Page 25: ...bor shoes bolt and Belleville washers on your 2006 Cobra are similar looking but different in geometry from prior years Do not mix old and new parts as damage will occur Cobra clutch puller assembly F...

Page 26: ...washers are stacked Clean the washers and bolt if you intend to reuse The spring stacks in your 2006 Cobra clutch will contain 11 individual springs and a flat washer configured as a 5 stack See figu...

Page 27: ...tch engagement thus decreasing the abruptness of clutch engagement softer hit Part Thickness mm inch HCWS0801 1 4 0 056 HCWS0802 1 2 0 047 HCWS0803 0 79 0 031 HCWS0804 0 64 0 025 HCWS0805 0 51 0 020 H...

Page 28: ...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...

Page 29: ...the clutch is likely to malfunction 4 Use fine emery paper on the center hole of the clutch and on the tapered section of the crankshaft 5 Apply a small amount of wicking bearing retainer green thread...

Page 30: ...ated 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 da...

Page 31: ...m the ignition cover 4 Remove the water pump belt from the rotor and water pump shaft 5 Turn the crankshaft counterclockwise until it reaches top dead center 6 Set the dial indicator to zero 7 Turn th...

Page 32: ...diator fluid in circulation throughout the motor The air stream running through the radiator cools the radiator fluid Therefore dirty radiators additionally reduce the cooling effect Cobra has tested...

Page 33: ...ne transmission oil by removing drain screw using a 13mm hex wrench item 2 in the figure below 5 Remove right side radiator hose and unscrew coolant fitting with a 8mm hex key 8 Remove ignition cover...

Page 34: ...any sign of wear like a groove replace the shaft Figure 31 14 Reinstall new bearings seal open side toward impeller and impeller Clean all threads and use green wicking bearing retainer thread locker...

Page 35: ...TV silicon or Teflon pipe sealant to the tapered pipe threads of the coolant fitting before assembly NOTE Refill the coolant system with Liquid Performance Propylene Glycol based Mini Coolant Antifree...

Page 36: ...CHOKE JET 7 FLOAT 8 RUBBER CABLE CAP SEAL 9 CABLE ADJUSTOR 11 TOP CARB SCREW 12 CARB TOP 13 TOP CARB GASKET 14 SLIDE SPRING 15 NEEDLE RETAINER PLATE 16 NEEDLE CLIP 17 CHOKE ASS Y 2001 CM 20 FUEL MIXTU...

Page 37: ...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...

Page 38: ...retor 4 Disassemble the carburetor 5 Immerse all the metal parts in a carburetor cleaning solution 6 After the parts are cleaned dry them with compressed air 7 Blow out the fuel passages with compress...

Page 39: ...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 fro...

Page 40: ...g at either sprocket Tuning Suspension 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 re...

Page 41: ...m harshly more than a couple of times per lapand 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 r...

Page 42: ...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 springs d...

Page 43: ...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 44: ...2 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 1...

Page 45: ...ers 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 mixture o Pinging or ratt...

Page 46: ...ition 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...

Page 47: ...er 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 Carburetor top is...

Page 48: ...hampion to be used 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 st...

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