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Cobra CX50 2014 5R King, Owner'S Manual

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Cobra CX50 2014 5R King Owner'S Manual Download Page 20

 

  18 

Parts 

– Airbox & Inlet System 

 

 

 

Air Box 

REF # 

PART # 

DESCRIPTION 

 

RCMU0018 

CARBURETOR 

1 

TCCS0002 

AIRBOX 

2 

HCSP0003 

SCREW 

– PLASCREW  

3 

RCCS0016 

AIR FILTER  

4 

RCKG0503 

RETAINER 

– AIR FILTER 

5 

TCC61008 

MUDFLAP 

6 

MCKGHO03 

HOSE CLAMP 

– AIRBOX TO BOOT 

7 

RCKG0505 

AIR BOOT 

8 

MCKGHO01 

HOSE CLAMP 

– BOOT TO CARB 

9 

MCKGHO04 

HOSE CLAMP 

– CARB TO MANIFOLD 

10 

RCCS0002 

INLET MANIFOLD 

11 

ECMU0246 

REED CAGE ASSEMBLY WITH REEDS VFORCE 

12

 

ZCCS0001 

GASKET 

– REEDS TO ENGINE 

13 

HCBC0603 

M6X30mm SOCKET HEAD CAP SCREW 

14 

HCWF0601 

6mm FLAT WASHER 

15 

RCCM1301 

VELOCITY

 

STACK

 

(SCREWS

 

ONTO

 

CARB) 

16 

ECCS0030 

REED REPLACEMENT KIT 

Summary of Contents for CX50 2014 5R King

Page 1: ......

Page 2: ...our 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 C...

Page 3: ...ED 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...

Page 4: ...E 11 BRAKE BLEEDING PROCEDURE 13 AIR FILTER CLEANING 14 FORK MAINTENANCE 15 FRICTIONAL DRIVE V3 CFD 17 PARTS 18 PARTS AIRBOX INLET SYSTEM 18 PARTS BARS AND CONTROLS 19 PARTS CARBURETOR 20 PARTS COOLAN...

Page 5: ...GINE SERVICE 44 Base Gasket Selection 45 Engine Removal 47 Complete Engine Disassembly Procedure 47 Top End Disassembly Procedure 48 Splitting the Cases 49 Engine assembly 49 CLUTCH 51 IGNITION 55 COO...

Page 6: ...ix Oil type Bel Ray H1 R Premix oil ratio after break in 40 1 to 50 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...

Page 7: ...480 54 M10 x 1 25 Clutch bolts 12 144 16 M6 x 1 0 Engine mount bolts 22 265 30 M8 X 1 25 Swingarm pivot 21 250 28 M14 X 2 0 Shock bolt 35 420 47 M10 x 1 5 Water pump impeller 6 75 8 M5 x 0 8 Water pu...

Page 8: ...um avoid prolonged high RPM operation and avoid abusing the clutch with throttle blipping Cool and inspect bike for loose fasteners Next hour of operation avoid prolonged operation at Wide Open Thrott...

Page 9: ...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...

Page 10: ...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 stamp...

Page 11: ...o only take it apart if it NEEDS to be maintained Schedule Prior to each ride o Check the air filter clean and re oil as necessary o Insure the smooth operation of the throttle cable throttle soundly...

Page 12: ...ing sure that the gasket is in place 4 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...

Page 13: ...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 M...

Page 14: ...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...

Page 15: ...engage the brake lever pedal and hold it there as if engaging the brakes While doing this pull on the plunger of the syringe Doing this will cause a vacuum in the system The vacuum will swell the air...

Page 16: ...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 exce...

Page 17: ...gested service intervals for common procedures Each Ride 10 hours 20 hours As Needed Bleed excess air X Change Oil X Change Seal Swiper X Change Bushings X Fork Air Bleeding Tools required 3mm hex key...

Page 18: ...d Try to catch it before it falls into your oil bucket f Invert the fork and allow the oil to drain completely Working the damper rod up and down will speed up the draining process Assembly procedure...

Page 19: ...e cover exposing the CFD 2 Brace the CFD gear from turning with a suitable device Cobra tool EAMU0004 or similar 3 Install the Sprocket Socket CFD torque checking tool MCMUTL15 on the sprocket and sec...

Page 20: ...AP 6 MCKGHO03 HOSE CLAMP AIRBOX TO BOOT 7 RCKG0505 AIR BOOT 8 MCKGHO01 HOSE CLAMP BOOT TO CARB 9 MCKGHO04 HOSE CLAMP CARB TO MANIFOLD 10 RCCS0002 INLET MANIFOLD 11 ECMU0246 REED CAGE ASSEMBLY WITH REE...

Page 21: ...TTLE CABLE 7 BAKG0003 BRAKE ASSEMBLY FRONT 8 FCMU0033 KILL SWITCH ASSEMBLY 9 HCBC0806 M8X30mm SOCKET HEAD CAP SCREW 4 REQ D 10 HCBC1001 M10X45mm SOCKET HEAD CAP SCREW 2 REQ D 11 TKMU0404 BAR MOUNT KIT...

Page 22: ...ZCMU0007 TOP CARB GASKET 14 RCMU0004 SLIDE SPRING 15 RCMU0028 NEEDLE RETAINER PLATE 16 RCMU0007 NEEDLE CLIP 17 RCMU0204 CHOKE ASSEMBLY NOT SHOWN RCMU0209 O RING CHOKE ASSEMBLY 20 RCMU0009 FUEL MIXTUR...

Page 23: ...EFT 4 ECCS0010 RADIATOR HOSE BOTTOM RIGHT 5 MCC6GR01 GROMMET RADIATOR MOUNTING 2 REQ D 6 HCBF0612 M6X12mm FLANGE HEAD BOLT 2 REQ D 7 HCWF1478 FLAT WASHER 2 REQ D 8 MCMUCL07 HOSE CLAMP 4 REQ D 9 FCKG02...

Page 24: ...mm FLAT WASHER 2 REQ D 6 HCCN0000 5mm CLIP NUT 2 REQ D 7 ICMU0018 STATOR WITH GROMMET 8 HCBC0535 M5X35mm SOCKET HEAD CAP SCREW 2 REQ D 9 HCBC0525 M5X25mm SOCKET HEAD CAP SCREW 10 HCWF0504 WASHER FOR S...

Page 25: ...GEAR SUPR WIDE 12 ECMU0100 SECONDARY SHAFT TRANSMISSION WITH GEAR 13 ECMU0001 BEARING TRANMISSION SECONDARY SHAFT 14 ECKG0031 BEARING OUTPUT SHAFT RIGHT SIDE 15 HCBH0612 M6X12mm HEX HEAD SCREW BEARING...

Page 26: ...24 Parts Engine Clutch and Kick Lever...

Page 27: ...ECMU0308 BELLEVILLE SPRING V3 CFD 17 ECMU0307 NUT V3 CFD 18 HCCP0002 COTTER PIN 3 32 X 1 19 EAMU0001 KICKSTART GEAR SHAFT 20 ECMU0116 SPRING KICKSTART 21 ZCMUB014 O RING KICK SHAFT 2 REQ D 22 HCWS162...

Page 28: ...R PUMP SHAFT 5 ECKG0073 IMPELLER WATER PUMP ALUMINUM 6 HCBC1512 M5X12mm SOCKET HEAD CAP SCREW STAINLESS 7 ECMU0167 BEARING WATER PUMP BIG 8 ECKG0175 WATER PUMP PULLEY FAN TYPE DRIVEN 9 ECMU0180 BELT R...

Page 29: ...PIPE TO FLANGE 2 REQ D 5 ECMU0155 PISTON RINGS 2 PER SET 6 ECMUSR00 SNAP RING FOR PISTON 2 REQ D 7 ECKG0012 WRIST PIN 8 ECMU0077 BEARING WRIST PIN 9 ZCMUOR07 O RING EXHAUST FLANGE 10 ECMU0086 EXHAUST...

Page 30: ...4 XCMU0033 ISOLATION MOUNT 5 HCBF0612 M6X12mm FLANGE HEAD BOLT 2 REQ D 6 HCHA0003 6mm CLIP NUT FOR FRONT PIPE MOUNT 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D 8 XCMU0032 SILENCER 9 XCKG0009 PIPE SILENCER...

Page 31: ...ERING STEM 12 HCBC0806 M8X30 SOCKET HEAD CAP SCREW 4 REQ D 13 TCMU0404 BAR MOUNT KIT SHORT 1 REQ D STANDARD 13A TCMU0403 BAR MOUNT KIT TALL 14 HCBC1001 M10X45mm SOCKET HEAD CAP SCREW 2 REQ D 15 HCNL10...

Page 32: ...30 Parts Forks Leg Assembly Brake Side...

Page 33: ...2mm 15 KCCS3227 HEAVY SPRING FORK 0 257KG MM 32mm 16 HCNJ3824 NUT JAM 3 8 24 CLASS 8 17 KCC60068 RING CLIP FORK SPRING GUIDE RETAINER 18 KAC60003 DAMPER ROD ASSEMBLY 19 KCC60058 O RING MID VALVE ADJ N...

Page 34: ...32 Parts Forks Leg Assembly Non brake Side...

Page 35: ...CS3225 STANDARD SPRING FORK 0 25 KG MM 32mm 15 KCCS3223 LIGHT SPRING FORK 0 23 KG MM 32mm 15 KCCS3227 HEAVY SPRING FORK 0 257KG MM 32mm 16 HCNJ3824 NUT JAM 3 8 24 CLASS 8 17 KCC60068 RING CLIP FORK SP...

Page 36: ...D 9 HCBF0612 M6X12mm FLANGE HEAD BOLT 2 REQ D 10 HCWF1478 FLAT WASHER 2 REQ D 11 HCBH1203 M12 SWINGARM PIVOT BOLT 12 HCNL1201 M12 SWINGARM LOCK NUT 13 HCBH0890 M8X90mm HEX HEAD BOLT 14 HCNL0801 M8 LO...

Page 37: ...4mm SOCKET HEAD CAP SCREW 2 REQ D 7 HCWP0002 WASHER BODY PANEL FLAT 2 REQ D 8 MCMUGR03 MOUNTING GROMMET 2 REQ D 9 TCKG0001 SPACER 2 REQ D 10 HCBF0630 M6X30mm FLANGE HEAD BOLT 2 REQ D 11 HCWF1478 PIPE...

Page 38: ...HEAD BOLT ACCESSORY MCMUBF01 BRAKE FLUID DOT 5 1 OR HIGHER ACCESSORY BCKG0031 BLEED KIT MULTIPLE SYRINGES FITTINGS HOSE ACCESSORY BCKG0028 LEVER ADJUSTMENT KIT ACCESSORY BCKG0027 RESERVOIR SEAL KIT A...

Page 39: ...FRONT TUBE 4 WCMU0016 FRONT AXLE 5 ECMU0040 T SHIM OPTIONAL FOR BRAKE CALIPER ALIGNMENT 6 WCMU0101 FRONT WHEEL SPACER LARGE 7 WCMU0120 WHEEL BEARING 2 REQD 8 WCMU0032 WHEEL BEARING SPACER 9 HCBC0501 B...

Page 40: ...EL FLO 7A TCC60017 BODY PANEL WASHER 5MM 1 REQ D MT SHROUD TO TANK 7B HCBC0514 M5X14 SHCS 1 REQ D MOUNT SHROUD TO RADIATOR 7C HCCN0000 5MM EXTRUDED U NUT 8 TCC60023Y SHROUD RIGHT YELLOW 8 TCC60023x SH...

Page 41: ...lear cover 14 HCCC0006 BRAKE HOSE CLAMP 2 REQ D for hose with black cover 15 HCPP0832 BRAKE HOSE CLAMP FASTENER 2 REQ D 16 BCMU0502 BRAKE ROTOR 140mm 17 HCBC0601 M6X16mm SOCKET HEAD CAP SCREWS 5 REQ D...

Page 42: ...5 7 HCBH0702 M7X30mm HEX HEAD BOLT 7A HCWF0701 7mm FLAT WASHER 4 REQ D 7B HCNL0701 M7 LOCKNUT 4REQ D 8 WCMU0016 REAR AXLE 10 WCMU0101 WHEEL SPACER 11 WCMU0120 WHEEL BEARING SPROCKET SIDE 12 WCMU0034 W...

Page 43: ...RD 4 REQ D 5 SCMU0058 SHOCK WHITE NYLON TIP SETSCREW M6 1 0 CARD 6 SCMU0056 SHOCK SLEEVE BLACK CARD 7 SCMU0100 BUMPER TAPPERED SHOCK 8 SCMU0040 SHOCK SPRING PAD CARD 9 SCMU0054 SHOCK SPRING PERCH CARD...

Page 44: ...P 6 SCMU0052 IFP SEAL BAND 7 SCMU0033 O RING SHOCK BASE 8 SCMU0050 RESERVOIR CAP RETAINER RING 9 SCMU0035 O RING CHARGE CAP 10 HCBB0506 M5X6mm LONG BUTTON HEAD STAINLESS STEEL 11 SCMU0044 SEAL HEAD BU...

Page 45: ...clear cover 9B HCCC0006 BRAKE HOSE CLAMP 2 REQ D for hose with black cover 10 HCPP0832 BRAKE HOSE CLAMP FASTNER 2 REQ D 11 HCBF1040 M10X40mm LOWER SHOCK MOUNT BOLT 12 FCMU0203 WHEEL PULL 13 FCMU0202 W...

Page 46: ...ecause of the geometry of the spark plug used in this Cobra Motorcycle the adapter used with your compression tester must have a similar volume protruding into the combustion chamber to establish an a...

Page 47: ...o little clearance Since parts like the crank connecting rod cylinder head piston and crankcases all have varying tolerances Cobra offers several different base gasket thickness to ensure that you can...

Page 48: ...over piston rings can be left off to ease of assembly Carefully insert the solder wire though the spark plug hole into the cylinder far enough such that the tip of the wire touches the left or right s...

Page 49: ...nnected to the engine 8 mm socket NOTE If the coolant looks to be free of contaminates it may be reused 7 Remove the master link from the chain 8 Remove front engine mount bolt 13 mm socket 6 mm hex k...

Page 50: ...NSPECTION NOTE Inspect the cylinder bore for abrasions deposits and missing coating 1 If abrasions scrapes scratches pitting etc are found replace the cylinder 2 If deposits are all are found a Clean...

Page 51: ...case Needle bearings should be replaced every couple 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 o...

Page 52: ...mbly 15 Install O RINGs as shown in figure 29 16 Install the cylinder head 17 Install the washers with flat side down and nuts Torque to 105 in lb 12 Nm 18 Install reed and intake manifold with new ga...

Page 53: ...ure within 0 05mm 0 002 There are many variables in an automatic centrifugal clutch These variables are set to world class standards from the factory but will change over time as the components wear r...

Page 54: ...ter hub again to remove the bolts Once you get a bolt loosened carefully remove it with the shoe and observe the way the spring washers are stacked Clean the washers and bolt if you intend to reuse Th...

Page 55: ...hit Conversely decreasing the flat washer s thickness decreases the engine speed for clutch engagement thus decreasing the abruptness of clutch engagement softer hit Part Thickness mm inch HKCSM015 1...

Page 56: ...decreases engine power 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...

Page 57: ...lutch Milk Part MCMUGF32 Ignition Stator care Stator failure could result from running the bike hot Following is a list of things that will make your engine run hot 1 The timing should not exceed the...

Page 58: ...p dead center 6 Set the dial indicator to zero 7 Turn the crankshaft clockwise until the dial indicator reaches 0 035 0 9 mm from top dead center 8 At this position the line on the rotor should align...

Page 59: ...the water pump shaft cross hole and remove belt retainer screw using a 4mm hex key Figure 41 item 1 4 Remove belt retainer water pump belt and water pump fan pulley 5 Remove bearing retainer screw us...

Page 60: ...mmer until the insertion punch is needed 11 Continue driving the assembly with the punch until the head is flush NOTE The insertion punch is 0 010 0 25mm longer than the housing so as to seat the wate...

Page 61: ...s and rev the engine after each adjustment To lower the idle turn the screw counter clockwise TOP END JETTING Indications that the engine is running too rich too much fuel for the air are Engine not r...

Page 62: ...area and take care that there is 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 o...

Page 63: ...e oils cling to the walls of the inside of the pipe Over a long period of time the diameter of the pipe will decrease due to carbon build up So it is essential to clear the residue NOTE If your bike s...

Page 64: ...e fluid Front Forks Tools recommended for front fork service Flat head screwdriver Hammer Pick Seal driver MCMUTL02 9 16 loose 14 mm wrench 25mm wrench or socket 2 5 wt fork oil FORK DISASSEMBLY PROCE...

Page 65: ...the groove 10 Snap the dust seal swiper into the groove in the upper tube 11 Reinstall the damper cartridge assembly to the fork leg Secure the large bolt with 22 mm wrench to 35 ft lb with green thre...

Page 66: ...can only be approximated by the size of the step where it sticks out of the basket h Basket has worn and is too large There is a relationship between observed characteristics and the things that can...

Page 67: ...if possible Cut mud practice to 1 lap or none Stay on the gas no throttle blipping Run more air pressure to allow wheels to spin helps throttle steer Make sure wheels spin freely no bent rotors dragg...

Page 68: ...fforts to make the three shoes behave identically will make the best performing clutch Taking extra time to balance the three stacks shims springs bolts etc to as close to the same length as you are w...

Page 69: ...e clutch to hit early for smooth power delivery Front Sprocket Rear Sprocket Gear Ratio 15 33 2 20 15 34 2 27 15 35 2 33 14 33 2 36 15 36 2 40 14 34 2 43 15 37 2 47 14 35 2 50 15 38 2 53 13 33 2 54 14...

Page 70: ...esistance to the suspension motion when the suspension is compressing 1 6 Rebound damping 1 6 1 Harder more damping slower adds resistance to the suspension motion when the suspension is returning to...

Page 71: ...eed sensitive compression component is adjustable at the top of the fork The combination of the Smart Leg and the conventional leg allows the fork to be very supple throughout all low amplitude operat...

Page 72: ...ofter High Speed Compression 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...

Page 73: ...roper jetting are listed below Symptoms of incorrect oil or oil fuel ratio o Poor acceleration o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o Excessive black oil dripping from...

Page 74: ...er ratio o The carburetor is clean no plugged jets o The air filter is properly clean and oiled o The float height is within proper specification proper measuring technique is described later in this...

Page 75: ...r clean full throttle acceleration Jet your top end main jet based on the acceleration of your Cobra Motorcycle on the longest straight at the track Observe any of the lean or rich symptoms spark plug...

Page 76: ...ket 2 Engine is down on power a Clutch engagement is not set properly b Jetting is incorrect c Silencer needs repacked d Exhaust pipe i Has excess carbon buildup ii Has large dent in it e Compression...

Page 77: ...ted iv Bad electrical ground v Stator winding damaged d Exhaust is plugged with object of flooded fuel e Engine is flooded f Cracked broken or jammed reed pedal g Excessive piston or cylinder wear h C...

Page 78: ...mpression test 44 Cooling System 56 Cylinder head Torque 5 Electrical Parts 22 Engine Specifications 4 Exhaust 61 Parts 28 Forks Fork Oil Replacment 16 Parts 29 Service 62 Frame Parts 34 Front Brake B...

Page 79: ...park Plug Recommended 4 Specifications 4 Starting 7 Stator Care 55 Replacement 55 Torque 5 Suspension Adjustment 68 Swingarm Parts 43 Top End Parts 27 Service 44 Torque Values 5 Transmission Lubricant...

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