Cobra King 2003 Owner'S Service Manual Download Page 1

Page: 1 / 52

2003 KING

Owners / Service

Manual

“CHAMPIONS START HERE”

Summary of Contents for King 2003

Page 1: ...2003 KING Owners Service Manual 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 Motorcy...

Page 3: ...NTENDED 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 MOTORCYC...

Page 4: ...adjustment 12 M3 Rear brake adjustment 12 M4 Air Filter Cleaning 13 M5 Fork Oil Replacement 13 Engine Service Parts 15 ES1 Engine Service 17 E1 Engine Removal 18 E2 Complete Engine Disassembly Procedu...

Page 5: ...58 0 64 mm Ignition timing 0 050 1 3 mm Before To Dead Center BTDC Fuel type Sunoco MO2X or 93 octane pump gasoline OTHER RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2 cycle Race Oil Fuel oil...

Page 6: ...ion Springs Weight of Rider lb Fork Spring Shock Spring Less than 51 7 lb in KCKG0007 SCKGOH10 yellow 175lb in 51 60 9 lb in KCKG0009 SCKGOH85 gray 185 lb in Greater than 60 12 lb in KCKG1200 SCKG0H w...

Page 7: ...ear Axle 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 mm Use green...

Page 8: ...hine 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 b...

Page 9: ...position reserve position is horizontally forward CAUTION For best results from your Cobra Motorcycle use only the recommended fuels Testing has shown that most race fuels actually degrade performanc...

Page 10: ...an and re oil as necessary o Insure the smooth operation of the throttle cable throttle soundly clacks shut o Check for frayed strands of the throttle cable inside the throttle housing and replace if...

Page 11: ...light as possible Cobra recommends 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 o...

Page 12: ...nom 3 Shoe Clutch Milk or Dexron III Automatic Transmission Fluid thru the 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 Reap...

Page 13: ...djustment Tools recommended for rear brake maintenance 10mm open end wrench There are 2 adjustments on the brake From the brake lever 1 Loosen the 10mm nut on the back of the brake pedal 2 Adjust the...

Page 14: ...touch any of the frame components in a rainy muddy situation We offer two different filters One filter for the use in sand part RCMU0101 and the regular filter for regular use part RCMU0206 When wash...

Page 15: ...be with the leg collapsed and record 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...

Page 16: ...se 62 ECKG0074 Seal Waterpump 22 HCDP1401 Dowel for Engine Cases 63 ECKG0203 Intake Manifold 23 ECMU0038 Crankshaft Welded and Balanced 64 ZCMU0032 Gasket Reed to case 24 ECKG0017 Crankcase Ignition s...

Page 17: ...16 Figure 5...

Page 18: ...ebuilt 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 re...

Page 19: ...ver 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 Remov...

Page 20: ...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 clut...

Page 21: ...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 abrasions or missing coating replace ii If all...

Page 22: ...the engine cases should be checked to make sure the needle bearing casing didn t oblong the bearing hole in the case Needle bearings should be replaced every racing season E5 Engine assembly CAUTION...

Page 23: ...22 Figure 6 Figure 7...

Page 24: ...th crankcase halves 12 Apply the crankcase gasket to the left crank case half being sure to install the gasket behind the connecting rod 13 Insert the screws with the three longer ones 40mm long at lo...

Page 25: ...deck areas around the coolant passage and cylinder studs as shown in figure 10 Figure 10 18 Install the base gasket 19 Install the cylinder being sure that the piston rings are properly aligned with t...

Page 26: ...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 plu...

Page 27: ...ter cover on 3 Remove the clutch nut right handed nut on the end of the crankshaft with a 22mm socket 4 Attach the COBRA CLUTCH PULLER There are three 6mm clutch puller holes located on the ends of th...

Page 28: ...Figure 15 Recommended clutch spring stack Each spring stack contains nine springs Bellville washers six arranged into three flying saucers and three arranged in a dished arrangement against the flat w...

Page 29: ...you change your oil and whether your rider is a throttle blipper REF PART NO DESCRIPTION 1 ECMU0017 Crank seal 2 ECMU0040 Clutch to hub spacer 3 ECMU0003 Brass bushing 4 ECMU0033 Clutch Hub w brass bu...

Page 30: ...tch back in 7 Apply high strength red thread locking agent to the threads and install the nut and torque to 40 ft lb 54Nm with the special socket see figure 16 CAUTION Use high strength red thread loc...

Page 31: ...park plug heat range Never run a hotter plug than t he specified spark plug 4 Clutch slippage See CLUTCH section for causes of slippage CAUTION Because of the amount of heat generated by the clutch an...

Page 32: ...ndicator Universal clutch puller a universal puller that pulls the clutch main drive gear and rotor Part MCMUTL70 TIMING YOUR IGNITION 1 Remove the spark plug cap and sparkplug 2 Insert the dial indic...

Page 33: ...4 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 spar...

Page 34: ...ch 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 you will be using a propane torch i...

Page 35: ...at 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 23 Figure 23 CAUTION...

Page 36: ...liberal amount of grease on 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 25 Figure 25 16...

Page 37: ...2 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...

Page 38: ...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 I...

Page 39: ...AUTION 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...

Page 40: ...igure 28 The presence of light indicates that the reeds should be replaced or possibly turned over ES7 Exhaust The pipe is a crucial element to a motorcycle Any kinks dents or damage done to the pipe...

Page 41: ...ent sized sprockets 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 st...

Page 42: ...eel pullers out of the back of the swing arm Rear wheel alignment Figure 31 1 Measure from the side of the swing arm to the outer edge of the rim and make sure both sides are equal 2 Adjust the wheel...

Page 43: ...HCNS1201 12mm AXLE NUT 2 KCKG0029 FORK LEG NONBRAKE SIDE 3 WCMU0023 WHEEL SPACER LARGE 4 WAKG0005 FRONT WHEEL COMPLETE 5 WCMU0001 WHEEL SPACER SMALL 6 BCKG0008 FRONT BRAKE MOUNT 7 KCKG0028 FORK LEG B...

Page 44: ...d 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 th...

Page 45: ...44 Figure 33 2 Remove cotter key from caliper as shown and pull pads out Figure 34...

Page 46: ...measuring the pad the holder as shown below Figure 35 Brake bleeding procedure 1 Remove brake caliper using 4mm Allen wrench as shown in pad removal procedure Pry pads outward to fully retracted posit...

Page 47: ...Pump all air out of system until only clean oil runs out of reservoir Figure 38 5 Reinstall reservoir cap Oil will overflow in the process This is necessary to ensure no air is in the system Remove bl...

Page 48: ...MPER RUBBER 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 SUPP...

Page 49: ...nze bushing 3 onto lower fork leg 5 Install Teflon bushing into groove on lower fork leg Figure 41 6 Slide the bronze bushing over the Teflon bushing about 1 4 to hold the Teflon in the groove 7 Inser...

Page 50: ...OUTER 4 4 KAKG0028 FORK LEG INNER BRAKE SIDE KAKG0029 FORK LEG INNER NON BRAKE SIDE 5 5 KCKG0027 DAMPER ROD 6 6 KCKG0007 FORK SPRING 7 KCKG0009 FORK SPRING 9 STOCK KCKG1200 FORK SPRING 12 7 7 KCKG0023...

Page 51: ...in it e Compression is low i Piston ii Rings f Reeds are damaged g Ignition timing is incorrect 3 Engine is excessively loud a Silencer needs repacking 4 Engine blubbers at high RPMs a Jetting too ric...

Page 52: ...uel System Parts list 36 Service 36 General Tips 9 Ignition Service 30 Timing 31 Jetting How To 37 Stock 4 Lubrication Recommended 4 Maintenance Schedule 9 Tips 9 Oil Recommended 4 Optional components...

Search results

Summary of Contents for King 2003

Reviews:

Related manuals for King 2003

Brands by name

Popular brands

Cobra King 2003, Owner'S Service Manual

Search results

Summary of Contents for King 2003

Reviews:

Related manuals for King 2003

Brands by name

Popular brands