Cobra 2005 King Скачать руководство пользователя | Manualshive

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Содержание 2005 King

Страница 1: ......

Страница 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...

Страница 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...

Страница 4: ...LEANING 14 FORK OIL REPLACEMENT 15 PARTS 16 PARTS AIRBOX INLET SYSTEM 16 PARTS BARS AND CONTROLS 17 PARTS CARBURETOR 18 PARTS COOLANT SYSTEM 19 PARTS ELECTRICAL SYSTEM 20 PARTS ENGINE BOTTOM END AND T...

Страница 5: ...ASSEMBLY 39 SERVICE 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 50 IGNITION 55 COO...

Страница 6: ...er Gap 0 023 0 025 0 58 0 64 mm Ignition timing 0 040 1 14 mm Before To Dead Center BTDC Fuel type High octane pump gasoline RACE FUELS ARE NOT RECOMMENDED Oil type Cobra Venom 2 cycle Race Oil Fuel o...

Страница 7: ...ion Pre filter for the airbox Sprockets o Front o Rear Suspension Springs Weight of Rider lb Fork Spring Shock Spring Less than 51 9 lb in KCKG0109 SCKGOH85 gray 185 lb in 51 60 12 lb in KCKG1201 SCKG...

Страница 8: ...300 34 M12 x 1 25 Engine mount bolts 22 265 30 M8 X 1 25 Swingarm Pivot 21 250 28 M14 X 2 0 Intake manifold bolts 4 6 55 6 2 M6 X 1 0 Rear Axle Bolt 25 300 34 M12 X 1 25 Rear Sprocket Bolts 18 216 24...

Страница 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...

Страница 10: ...ormulated Cobra Venom 2 cycle Race Oil Turn the fuel on by rotating the fuel petcock knob to the vertically downward position reserve position is horizontally forward CAUTION For best results from you...

Страница 11: ...the crankcase vent during riding 7 New chains will stretch on first use Never install a new chain prior to a race Always break them in during practice 8 Your Cobra Motorcycle has a 10 digit VIN Vehic...

Страница 12: ...stator as it cools off because of lack of airflow around the stator 2 If you ever need to weld anything on the bike disconnect the spark plug cap unplug the ignition disconnect the kill switch scrape...

Страница 13: ...of the engine on the clutch cover near the brake lever Item 2 figure 1 Figure 1 4 After it has drained reinstall the bolt being sure that the copper gasket is in place Torque to 15 Nm 11 ft lb 5 Reapp...

Страница 14: ...ke pads to drag causing the pads to wear prematurely and possible engine component failures Too much free play will not all the rider to apply the brakes quickly 1 Set pedal height position first then...

Страница 15: ...lay locking clip from the brake lever 4 Adjust as needed by rotating the clevis on the end of the adjustor plunger NOTE Turning the clevis Clockwise will lengthen the adjustor plunger removing free pl...

Страница 16: ...caps 1 socket 4 Remove the fork legs from the triple clamps 5 mm hex key 5 One leg at a time a Remove the fork cap from the leg b Separate the fork cap from the damper rod c Pull out the fork spring d...

Страница 17: ...612 M6X12 BUTTON HEAD BOLT 8 MCKGHO03 HOSE CLAMP AIRBOX TO BOOT 9 RCKG0505 AIR BOOT 10 MCKGHO01 HOSE CLAMP BOOT TO CARB 11 MCKGHO04 HOSE CLAMP CARB TO MANIFOLD 12 ECKG0203 INLET MANIFOLD 13 ZCMU0031 G...

Страница 18: ...LEVER W BALL 6 BCKG0024 BRAKE PERCH ASSY W LEVER BALL NOT SHOWN BAKG0004 SHIELDED BRAKE HOSE ASSEMBLY 7 FCMU0067 THROTTLE CABLE 8 HCBC0806 SOCKET HEAD CAP SCREW M8 X 30 4 PER 9S TKMU0404M BAR MOUNT KI...

Страница 19: ...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 ADJUSTMENT SCREW 25 RCMU0...

Страница 20: ...AP 2 FCMU0047 RADIATOR CAP 2 ears or ribbed 3 MCMUHO05 RADIATOR HOSE TOP LEFT 4 MCKGHO06 RADIATOR HOSE BOTTOM RIGHT 5 MCMUGR03 MOUNTING GROMMET 3 PER 6 FCMU0006 RADIATOR MOUNTING BRACKET TEARDROP 7 HC...

Страница 21: ...04 1 3 FCMU0033 KILL SWITCH ASSEMBLY 4 HCBC0516 SCREW M5 X 16 2 PER 5 HCCN0000 5MM CLIP NUT 2 PER 6 IAMU0002 GROUND WIRE 31 HCWF0504 WASHER FOR STATOR 3 PER 32 HCBC0525 5mm x 25 SOCKET HEAD CAP SCREW...

Страница 22: ...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...

Страница 23: ...ER 15 ECMU0063 KICK RETURN SPRING 16 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 SHO...

Страница 24: ...SCREW SHCS 10 32X1 2 14 HCSS8201 RETAINING SCREW SHCS 8 32X3 8 15 HCBC0603 CASE SCREW SHCS M6X30 16 HCBC0606 CASE SCREW SHCS M6X45 3 REQ D 17 HCBC0604 CASE SCREW SHCS M6X35 5 REQ D 18 HCWF0504 WASHER...

Страница 25: ...CMUOR07 O RING EXHAUST 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 HCNS0601 6mm Nut 13 HCWF0601 6MM FLAT WASHE...

Страница 26: ...SPACER 7 HCWF1478 PIPE GROMMET WASHER 2 REQ D 8 HCBF0635 M6X35 FLANGE HEAD BOLT NOT SHOWN HCHA0003 6MM CLIP NUT FOR FRONT PIPE MOUNT 9 XCDC0003 SILENCER NOT SHOWN XCMU0018 SILENCER PACKING 10 XCKG0009...

Страница 27: ...ERING HEAD NUT 1X14 10 HCBC0625 SOCKET HEAD CS M6X25 4 REQ D 11 HCBC0806 CAP SCREW M8X30 4 REQ D 12S TKMU0404M BAR MOUNT KIT SHORT 2 REQ D 12T TKMU0403M BAR MOUNT KIT TALL 2 REQ D 14 HCBC1001 M10X45 S...

Страница 28: ...CKG0015 FORK SPRING OPTIONAL STIFFER 15 LB IN 3 BR KAKG0028 FORK LEG INNER ASSEMBLY BRAKE SIDE 3 NBR KAKG0029 FORK LEG INNER ASEMBLY NON BRAKE SIDE 4 KCKG0004 FORK BUSHING GLIDERING 5 KCMU0008 SWIPER...

Страница 29: ...AKG0016 MID VALVE ASSEMBLY SOFT FAST OPTIONAL NOT SHOWN KAKG0018 MID VALVE ASSEMBLY HARD SLOW OPTIONAL 5 KCKG0032 FORK SPRING GUIDE 6 HCNJ5601 NUT 7 DAMPER ROD ASSEMBLY WITH MID VALVE 8 KCKG0023 CARTR...

Страница 30: ...CBC0606 M6X45 SOCKET HEAD CAP SCREW 2 KCKG0011 CHECKSTOP 3 KCKG0038 SPRING BASE VALVE 4 KCKGSH01 CHECKPLATE 14 X 3 5 KCKG0026 PISTON FORK VALVE 6 KCKG0013 O RING BASE VALVE PISTON 7 KCKGSH02 SHIM 14 X...

Страница 31: ...SCRIPTION 1 HCBC0603 M6X30 SOCKET HEAD CAP SCREW 2 HCWF0601 FLAT WASHER 3 KCKGSH05 SHIM 8 X 15 2 REQ D 4 KCKGSH04 SHIM 12 X 1 5 KCKGSH02 SHIM 14 X 1 6 KCKG0026 PISTON FORK VALVE 7 KCKG0035 GLIDRING MI...

Страница 32: ...9 MCMUGR03 GROMMET 2 REQ D PER BOLT 10 TCKG0001 ALUMINUM SPACER 11 HCWF1478 PIPE GROMMET WASHER 12 HCBH0880 FRONT ENGINE MOUNT BOLT M8X30 SHCS 13 HCNL0801 8MM LOCKNUT 14 HCBH1403 SWINGARM PIVOT BOLT 1...

Страница 33: ...BOLT 10 BCBH0601 M6 X 20 HEX HEAD BOLT 11 HCNS0601 6MM NUT 12 TCMU0110 WIDE FOOTPEGS PAIR 13 TCMU0106 FOOTPEG SPRING 2 PER 14 HCBB0803 M8X40 BUTTON HEAD BOLT 2 PER 15 HCNL0801 8MM LOCK NUT 2 PER 16 H...

Страница 34: ...FLANGE HEAD BOLT 11 HCBF0616 M6 X 16 FLANGE HEAD BOLT 12 WCMUZT04 CABLE TIES 2 REQ D TO SECURE BRAKE LINE TO FORK GUARD 13 BCKG0031 BLEED KIT MULTIPLE SYRINGES FITTINGS HOSE 14 BRAKE FLUID 15 FCKG0213...

Страница 35: ...NT TUBE 4 WCKG0011 FRONT AXLE 5 WCMU0123 FRONT WHEEL SPACER X LARGE 6 WCMU0120 WHEEL BEARING 2 REQD 7 WCMU0032 WHEEL BEARING SPACER 8 WCMU0101 FRONT WHEEL SPACER LARGE 9 BCKG0021 BRAKE CARRIER BRACKET...

Страница 36: ...HROUD MTG BOLT LONG 1 PER SIDE NOT SHOWN HCBB0403 RAD SHROUD MTG BOLT SHORT 1 PER SIDE 5 TCMU0113 SIDE NUMBER PLATE SET NOT SHOWN HCBB0516 M5X16 NUMBER PLATE MTG SCREW 2 PER SIDE NOT SHOWN HCWP0002 NU...

Страница 37: ...Q D 11 BCKG0010 REPLACEMENT BRAKE HOSE 12 HCBF0635 M6X35 FLANGE HEAD BOLT 13 HCBF0620 M6X20 FLANGE HEAD BOLT 14 BCKG0013 CALIPER REAR BRAKE ACCESSORY BCKG0009 BRAKE PADS 15 BCKG0104 BRAKE CARRIER WITH...

Страница 38: ...0059 RUBBER DAMPERS 8 WCMU0008 WHEEL DAMPING PLATE 9 HCBH0701 M7X35 HEX HEAD BOLT 10 PCMU0001 MASTER LINK 420 11 PCMU0100 CHAIN 420 X 100 12 WCMU0016 REAR AXLE 13 HCPA0002 AXLE HEAD FIXING PLATE 14 BC...

Страница 39: ...OW 195 LB IN SCKGOH85 LIGHT RATE SHOCK SPRING GRAY 185 LB IN SCKGO205 HEAVY RATE SHOCK SPRING GOLD 205 LB IN 2 SCKGOH05 LOCKNUT 3 SCKGOH04 SPRING PLATFORM 4 SCKGOH03 BALL JOIINT 5 SCKGOH02 SPACER 6 SC...

Страница 40: ...CNL1401 1 4 LOCKNUT 2 PER 12 HCBF0620 M6 X 20 FLANGE HEAD BOLT 2 PER 13 HCCC0002 BRAKE HOSE CLAMP 2 PER 14 HCPP0832 BRAKE HOSE CLAMP FASTNER 2 PER 15 HCBH1001 M10 X 40 LOWER SHOCK MOUNT BOLT 16 FCMU02...

Страница 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...

Страница 42: ...e bottom end and transmission 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 scre...

Страница 43: ...ater 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 clutch pul...

Страница 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...

Страница 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...

Страница 46: ...Figure 25 Figure 26 45...

Страница 47: ...h crankcase halves NOTE Gasket material is only required around the crankscase and not the transmission 13 Apply the crankcase gasket to the left crank case half being sure to install the gasket behin...

Страница 48: ...clips CAUTION Be sure to align the piston such that the arrow on the top piston surface points to the exhaust front of bike engine and put assembly lube on the connecting rod bearing 19 Install the p...

Страница 49: ...the indexing pins 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 prop...

Страница 50: ...s 34 Install the rotor per Rotor Installation section under the S3 Ignition portion of this manual 35 Install the water pump outlet pipe apply Ultra black Hi Temp RTV silicon gasket maker to the threa...

Страница 51: ...ansmission oil 2 Remove the pipe and remove the 6 bolts that hold the kick starter cover on 3 Remove the clutch nut not left hand thread on the end of the crankshaft with the clutch nut removal tool 4...

Страница 52: ...washers are stacked CAUTION It is very important that the clutch stack be reassembled as it was disassembled unless new shoes are being installed then it is important to reinstall per figure 34 CLUTCH...

Страница 53: ...ch 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 HCWS0806 0 38 0 015 Use the table above to order adjustment washers Replace the stock washer with t...

Страница 54: ...engine tend to run hotter which decreases engine power and degrades ignition stator efficiency It is important to train your rider NOT to be a throttle blipper CAUTION Sludge build up between the spri...

Страница 55: ...haft 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 any exc...

Страница 56: ...proper locations 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...

Страница 57: ...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...

Страница 58: ...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 the roto...

Страница 59: ...d wait there for a few seconds 2 Push the cap down and turn it further in the same direction and remove the cap NOTE Inspect the old coolant for visual evidence of corrosion and abnormal smell Fill th...

Страница 60: ...tem 1 10 Remove belt retainer water pump belt and water pump fan pulley 11 Remove bearing retainer screw using a 3mm hex key Figure 41 item 2 Figure 41 12 Heat engine case around area of impeller ligh...

Страница 61: ...OD steel tube 2 long and tap on end of tube per figure 44 Figure 44 16 Re assemble in same order of disassembly CAUTION Clean all threads and use green wicking bearing retainer thread locker on the b...

Страница 62: ...BER CABLE CAP SEAL 9 RCMU0003 CABLE ADJUSTOR 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 NEEDL...

Страница 63: ...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...

Страница 64: ...or low flash point solvent to clean the carburetor 1 Make sure the fuel is shut off 2 Remove the carburetor 3 Drain the fuel from the carburetor 4 Disassemble the carburetor 5 Immerse all the metal pa...

Страница 65: ...gure 47 The presence of light indicates that the reeds should be replaced or possibly turned over Exhaust The pipe is a crucial element to a motorcycle Any kinks dents or damage done to the pipe will...

Страница 66: ...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...

Страница 67: ...ch ride Make sure the brake does not have any leaks by holding the lever in while checking hose connections Make sure the brake lever pressure is OK by pulling in on the lever and ensuring full brakin...

Страница 68: ...ust seal swiper from its position with a small screw driver 6 Using snap ring pliers remove the snap ring holding the fork seals into place 7 Pop the fork seal out by forcibly pulling on both ends of...

Страница 69: ...in 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 t...

Страница 70: ...ck The rear shock is fully serviceable Only trained professionals should service your shock Contact Cobra or PR2 for questions and service of your King shock Shock preload Figure 57 Shock Damping Figu...

Страница 71: ...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...

Страница 72: ...pring 2 2 1 Stiffer spring stiffer throughout the travel 2 2 2 Less stiff spring less stiff throughout the travel 2 3 Compression damping 2 3 1 Harder more damping slower adds resistance to the suspen...

Страница 73: ...active Suspension Adjustments Once you have the suspension adjusted for decent overall feel you can make proactive adjustments when faced with different racing conditions Situation Actions Sand track...

Страница 74: ...ents Condition Mixture will be Required adjustment Cold air Leaner Richer Warm air Richer Leaner Dry air Leaner Richer Very humid air Richer Leaner Low altitude Standard None High altitude Richer Lean...

Страница 75: ...ustment To raise the idle 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 clea...

Страница 76: ...se gasket 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 Compre...

Страница 77: ...ket drum 6 Engine won t idle a Idle knob needs adjusted b Carburetor jets are dirty Index Air Filter 14 Bars and Controls 17 Break In 8 Carburetor Parts 18 Service 61 Specifications 5 Chain Adjustment...

Страница 78: ...Frame 31 Front Brake 33 Front Wheel 34 Ignition Water Pump 23 Plastic Seat 35 Rear Brake 36 Rear Wheel 37 Shock 38 Swingarm 39 Top End 24 Triple Clamps 26 Plastic Seat Parts 35 Pullers 66 Rear Brake...

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