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38 

 

Parts – Front Brakes 

 

                          

            

 

Front Brakes 

REF # 

PART # 

DESCRIPTION 

1 

BAKG0003 

FRONT BRAKE ASSEMBLY 

2 

BCKG0030 

HOSE – BRAKE FRONT 

3 

BCKG0023 

ALLOY BRAKE LEVER 

4 

BCKG0024 

BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER 

5 

BCKG0029 

CALIPER – FRONT 

6 

BKKG0001 

KIT BRAKE PADS, WITH “E” CLIP 

7 BCMU0503 

BRAKE 

ROTOR 

8 

HCBC0514 

M5X14mm SOCKET HEAD CAP SCREW  (6 REQ’D) 

9 

HCBF0640 

M6X40mm FLANGE HEAD CAP SCREW 

10 

HCBF0620 

M6X20mm FLANGE HEAD CAP SCREW 

 

 

 

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 

ACCESSORY 

BCKG0025 REPLACEMENT

 

BAR

 

CLAMP

 

AND

 

SCREWS

 

(FOR

 

MASTER

 

CYLINDER) 

ACCESSORY 

BCKG0026 PISTON

 

&

 

REBUILD

 

KIT

 

FOR

 

MASTER

 

CYLINDER 

ACCESSORY 

BCKG0014 FITTING

 

KIT

 

FOR

 

MASTER

 

CYLINDER

 

(BOLT,

 

SET

 

SCREW

 

&

 

O’RING) 

ACCESSORY 

BCKG0017 CALIPER

 

ORING

 

&

 

BOLTS

 

(

F

&

R

) 

ACCESSORY 

BCKG0018 CALIPER

 

PISTON

 

KIT

 

(

F

&

R

) 

ACCESSORY 

BCKG0019 RETURN 

SPRING (4 FINGER SPRING) 

ACCESSORY 

ZCMUOR09 

O’RING - BANJO FITTING 

ACCESSORY 

BCMU0014 CALIPER 

ADJUSTMENT SHIMS 6mm ID 

ACCESSORY 

BCKG0033 O-RING 

- 

BLEEDER - 2mm SPECIAL 

Содержание CX50P3

Страница 1: ...NDED 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 2: ...4 Fork Air Bleeding 15 Fork Oil Replacement 15 Cobra Frictional Drive V3 CFD 16 Parts 18 Parts Airbox and Inlet System 18 Parts Bars and Controls 19 Parts Carburetor 20 Parts Coolant System 21 Parts E...

Страница 3: ...ne Removal 49 Complete Engine Disassembly Procedure 50 Top End Disassembly Procedure 50 Splitting the Cases 51 Engine assembly 52 Clutch 53 Clutch Assembly 57 Ignition 58 Cooling System 59 Fuel Air Sy...

Страница 4: ...ix oil ratio after break in 40 1 to 50 1 Carburetion 12 mm Dell Orto Slow Pilot Jet Main Jet 55 92 Needle position W7 2 Slide 50 Float Height 16mm 0 5mm 0 63 0 020 Transmission Speed Clutch Single Cob...

Страница 5: ...4 X 0 75 Clutch cover bolts 5 8 70 7 9 M6 X 1 0 Clutch nut 40 480 54 263 10 x 1 25 Clutch bolts 12 144 16 263 M6 x 1 0 Engine mount bolts 22 265 30 M8 X 1 25 Swingarm pivot 21 250 28 M14 X 2 0 Shock b...

Страница 6: ...nute Allow bike to cool Ride for 15 minutes maximum avoid prolonged high RPM operation and avoid abusing the clutch with throttle blipping Allow bike to cool and inspect bike for loose fasteners Avoid...

Страница 7: ...el upright position with the 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 op...

Страница 8: ...er Produces virtually no coking deposits leaving pistons rings and heads extremely clean with minimal pipe spooge 2 Filling your transmission with more than 8 0 oz 235 cc of lubricant will help to tra...

Страница 9: ...the recommended schedule below 12 Check proper clutch engagement before and after each ride If the clutch is engaging properly DO NOT feel the need to take the clutch apart to measure the spring stack...

Страница 10: ...rned by the engine or the oil Hot oil and hot components on the motorcycle may cause burns 2 Remove the oil drain plug located on the right side of the engine on the clutch cover near the brake lever...

Страница 11: ...3 Sit on the bike and verify that the chain has a minimum of 12mm 1 2 free movement when the chain is at its tightest point 4 If the chain requires adjusting loosen the axle with a 19 mm wrench and ti...

Страница 12: ...undone while riding To adjust see figure 2b 1 Loosen the lock nut 10mm 2 Undo the free play locking clip from around the brake adjustor plunger with your hand by pushing it forward 3 Slide the pin of...

Страница 13: ...The vacuum will swell the air bubbles which assist in them moving throughout the system Continue pulling a vacuum and release the brake lever pedal careful not to allow the reservoir to become empty O...

Страница 14: ...esigned 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 bec...

Страница 15: ...Fork Oil Replacement Tools required 32mm Fork Cap Tool MCMUTL32 19mm wrench or socket 4 5 mm hex key Allen wrench 9 16 wrench Mallet 2 5 wt Bel Ray fork oil Disassembly procedure 1 Remove the front w...

Страница 16: ...height in the clamps 11 Reinstall the brake caliper 12 Reinstall the front wheel 25 ft lb 34 Nm Cobra Frictional Drive V3 CFD The Cobra Frictional Drive CFD is essentially an adjustable slip clutch th...

Страница 17: ...ad nut so you must turn it counter clockwise NOTE This V3 CFD torque checking method is possible do to with the chain on Just put the bike on a stand so that the rear wheel can turn freely NOTE The CF...

Страница 18: ...W 6 MCKGHO04 HOSE CLAMP CARBURETOR TO MANIFOLD 7 RCCL0001 CARBURETOR 12mm DELLORTO 2016P3 8 RCCM1301 VELOCITY STACK 9 MCKGHO01 HOSE CLAMP AIR BOOT TO CARBURETOR 10 RCCJ0004 AIR FILTER WITH BOOT 11 RCM...

Страница 19: ...RO BAR THROTTLE 4 FCPW0004 CABLE COVER 5 FCMU0021 THROTTLE COVER 6 FCMU0019 THROTTLE CABLE 6A HCNJ0801 NUT 8MM JAM 7 BAKG0003 BRAKE ASSEMBLY FRONT 8 FCMU0033 KILL SWITCH ASSEMBLY 9 HCBC0806 M8X30mm SO...

Страница 20: ...ASSEMBLY 13 RCMU0009 FUEL MIXTURE SCREW 16 14 RCMU0011 IDLE ADJUSTMENT SCREW 18 15 RCMU0201 SCREW FLOAT BOWL 20 RCMU00xx PILOT JET xx denotes size 22 RCMU0262 ATOMIZER 2 62 AU STANDARD 23 RCMU0107 FLO...

Страница 21: ...6 LOCK NUT 7 MCKGGR00 GROMMET RADIATOR MOUNTING 8 FCCJ0029 HOSE RADIATOR RIGHT VENOM 9 TCCJ0001 BUMPER RAD BRACKET 10 FCMU0049 OVERFLOW HOSE 20 11 MCMUCL05 HOSE CLAMP OVERFLOW HOSE 12 ECHA0109 MOUNTIN...

Страница 22: ...3 STATOR WITH GROMMET 8 HCBC0535 M5X35mm SOCKET HEAD CAP SCREW 2 REQ D 9 HCBC0525 M5X25mm SOCKET HEAD CAP SCREW 10 HCWF0601 6MM FLAT WASHER FOR STATOR 3 REQ D 11 ICMU0042 ROTOR FEW 2016 5 12 EKMU0035...

Страница 23: ...23 This Page Intentionally Left Blank...

Страница 24: ...24 Parts Engine Bottom End and Transmission...

Страница 25: ...1 BEARING TRANSMISSION SHAFT 1 EACH CASE HALF 13 HCBB0612 M6X12mm BUTTON HEAD SCREW BEARING RETAINER 2 REQ D 14 ECKGBR01 BEARING TRANSMISSION OUTPUT SHAFT 15 ECMU0236 SEAL OUTPUT SHAFT 2016 5 16 ECMU0...

Страница 26: ...26 Parts Engine Clutch and Kick Lever...

Страница 27: ...CFD 7mm 21 ECMU0272 OIL FILL PLUG VENOM 22 ZCMUB014 O RING OIL FILL PLUG 23 HCFH0616 M6X16mm FLAT HEAD BOLT 24 ECMU0250 WASHER KICK LEVER MOUNTING 25 EAMU0011 KICK LEVER 26 ECDC0078 SEAL KICKSHAFT 28...

Страница 28: ...5 ECKG0073 IMPELLER WATER PUMP ALUMINUM 6 HCBB0512 M5X12mm BUTTON HEAD 7 ECMU0167 BEARING WATER PUMP BIG 8 EKMU0035 KIT PULLEYS SPACER BELT RETAINER FWE 2016 5 9 HCBS0009 SHOULDER BOLT 10 ECKG0170 WAT...

Страница 29: ...ECMUSR00 SNAP RING FOR PISTON 2 REQ D 7 ECKG0012 WRIST PIN 8 ZCMUOR07 O RING EXHAUST FLANGE 9 ECMU0262 EXHAUST FLANGE 10 ZCMOTE11 O RINGS PIPE TO FLANGE 2 REQ D 11 HCBC0612 M6X12 EXHAUST FLANGE SCREW...

Страница 30: ...GS 2 REQ D 3 XCMU0005 EXHAUST SPRING SHORT 2 REQ D 4 MCMUGR02 GROMMET KIT 5 XCMU0028 PIPE SILENCER SEAL 2016 6 XCMU0032 SILENCER 7 MCMUGR03 MOUNTING GROMMET 2 REQ D 8 TCKG0001 SPACER 2 REQ D 9 HCWF147...

Страница 31: ...31 This page left intentionally blank...

Страница 32: ...32 Parts Forks Triple Clamps...

Страница 33: ...6 M8X30mm SOCKET HEAD CAP SCREW 4 REQ D 13 TKMU0404 HANDLE BAR CLAMP KIT SHORT STANDARD 13A TKMU0403 HANDLE BAR CLAMP KIT TALL 14 HCBC0820 M8X20mm SOCKET HEAD CAP SCREW 4 REQ D 16 FCMU1103 DUST COVER...

Страница 34: ...34 Parts Forks Leg Assembly...

Страница 35: ...FORK SPRING GUIDE 32MM 14 KCCL0002 SPACER SPRING GUIDE EXTEND 15 KCCJ3221 STANDARD SPRING FORK 0 21 KG MM 32mm 15 KCCJ3218 LIGHT SPRING FORK 0 18 KG MM 32mm 15 KCCJ3225 HEAVY SPRING FORK 0 25 KG MM 3...

Страница 36: ...HCBB0635 M6X35mm BUTTON HEAD CAP SCREW 13 HCBF0620 M6X20mm FLANGE HEAD BOLT 14 HCNF0602 M6 NYLOC FLANGE NUT 15 HCBF0625 M6X25mm FLANGE HEAD BOLT 16 MCMUGR03 GROMMET SILENCER 2 REQ D 17 TCKG0001 SPACER...

Страница 37: ...T RADIATOR BOTTOM 3 HCBC0608 M6X55mm SOCKET HEAD CAP SCREW 4 HCNL0601 M6 LOCK NUT 5 MCKGGR00 GROMMET RADIATOR MOUNT 2 REQ D ON BOTTOM 2 ON TOP BRACKET 6 ECHA0109 MOUNTING BRACKET RADIATOR TOP 2 REQ D...

Страница 38: ...E FLUID DOT 5 1 OR HIGHER ACCESSORY BCKG0031 BLEED KIT MULTIPLE SYRINGES FITTINGS HOSE ACCESSORY BCKG0028 LEVER ADJUSTMENT KIT ACCESSORY BCKG0027 RESERVOIR SEAL KIT ACCESSORY BCKG0025 REPLACEMENT BAR...

Страница 39: ...AXLE 3 HCBC0514 M5X14mm SOCKET HEAD CAP SCREW 6 REQ D 4 BCMU0503 BRAKE ROTOR FRONT 5 WCMU0101 WHEEL SPACER LEFT SHORT 6 WCMU0120 BEARING WHEEL 2 REQ D 7 WCCJ0007 SPACER WHEEL FRONT 8 WCCJ0003 WHEEL SP...

Страница 40: ...EW 5G TCHA0004 BUSHING REAR TANK MOUNTING 6 TCHA0002 CAP FUEL TANK 7 TCHA0003 HOSE FUEL CAP 8 TCMU0151 FUEL PETCOCK 9 TCCM0007 SEAT 9A TCCM0007C SEAT COVER REPLACEMENT 9B HCBB0604 M6X35mm SHCS SEAT HO...

Страница 41: ...LT 14 HCCC0000 BRAKE HOSE CLAMP 2 REQ D 15 HCPP0832 BRAKE HOSE CLAMP FASTENER 2 REQ D 16 BCMU0502 BRAKE ROTOR 140mm 17 HCBC0601 M6X16mm SOCKET HEAD CAP SCREWS 5 REQ D 18 HCBF0620 M6X20mm FLANGE HEAD B...

Страница 42: ...34 45 7 HCBH0702 M7X30mm HEX HEAD BOLT 4 REQ D 7A HCWF0701 7mm FLAT WASHER 4 REQ D 7B HCNL0701 M7 LOCKNUT 4 REQ D 8 WCMU0016 REAR AXLE 10 WCMU0101 WHEEL SPACER 11 WCMU0120 WHEEL BEARING SPROCKET SIDE...

Страница 43: ...MU0042 BUSHING SHOCK MOUNT 4 REQ D 5 SCMU0058 SET SCREW NYLON TIP M6 1 0 6 HCFH0408 4MM FLAT HEAD SCREW 8 SCCJ0004 BUMPER P3 CARD SHOCK 9 SCMU0054 PERCH SPRING 10 HCBF1040 M10X40 FLANGE HEAD BOLT 11 S...

Страница 44: ...RGE PORT 3 SCMU0035 O RING IFP SCREW 4 SCP30002 O RING IFP 5 SCP30003 SEAL BAND IFP 6 SCC60014 PISTON BAND 7 SCMU0044 SEAL HEAD BUMPER 8 SCMU0034 O RING SEAL HEAD 9 SCMU0045 DUST SEAL 10 SCMU0047 SPAC...

Страница 45: ...10 HCBFT640 M6X40mm FLAT HEAD BOLT 2 REQ D 11 HCNL0601 M6 LOCKNUT 2 REQ D 12 FAMU0005 WHEEL PULL ASSEMBLY BLOCK CAP BOLT AND WASHER 13 FCMU0203 WHEEL PULL 14 FCMU0202 WHEEL PULL ENDCAP 15 HCWF0801 8m...

Страница 46: ...ry 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 accurate value Length...

Страница 47: ...and crankcases all have varying tolerances Cobra offers several different base gasket thickness to ensure that you can always set the squish clearance of your engine to factory specifications For bas...

Страница 48: ...that the tip of the wire touches the left or right side cylinder wall not the front or back as the piston will rock more and give incorrect measurement Hold the wire at this position and rotate the c...

Страница 49: ...5 With the internal CFD gear stop tool in position check the slip torque again it is NOT necessary to have the cotter pin for the test 6 If the slip torque is below 108 Nm 80 ft lb then repeat steps...

Страница 50: ...f the frame NOTE If you are merely performing a top end service skip ahead to Top End Disassembly Procedure Complete Engine Disassembly Procedure 1 Remove the ignition cover 3mm hex key 2 Remove the b...

Страница 51: ...pes scratches pitting etc are found replace the cylinder 2 If deposits are all are found a Clean with muriatic acid b Once the deposits are removed inspect for abrasions and missing surface coating i...

Страница 52: ...faces the crank weights 3 Press in the counter shaft seal concave side faces inside of transmission 4 Press in the water pump assembly 5 Tap both ways axially then verify easy rotation 6 Inspect the...

Страница 53: ...cycles 19 Leak check the engine to 20 psi to ensure proper seal 20 Install stator reinstalling the grommet and wires snug the bolts 21 Install the rotor per Rotor Installation section under the S3 Ig...

Страница 54: ...ch nut removal tool ECMU0078 piston stop MCMUTL03 Cobra 3 Shoe Clutch Milk Part MCMUGF32 CLUTCH REMOVAL 1 Drain the engine transmission oil and remove the clutch cover 2 Remove the clutch nut NOT left...

Страница 55: ...mer to achieve different clutch engagements hits by changing washer counts and configurations CAUTION Generally reassemble the springs as you removed them from the engine or as you received them from...

Страница 56: ...e stock washer with the proper combination of adjustment washers that delivers the desired clutch hit CAUTION It is easy to prematurely damage the clutch and other engine components with improper clut...

Страница 57: ...removing all old thread locking material 3 Assemble the stacks and shoes on the arbor using high strength thread lock material to the stack bolt and tighten to 16 Nm 12 ft lb 144 in lb CAUTION Avoid a...

Страница 58: ...large enough There should be even clearance as the rotor rotates relative to the stator Ignition timing is not adjustable Changing the ignition timing can degrade performance Make sure connections ar...

Страница 59: ...ng System Radiator fluid removal Remove the coolant drain plug 10mm hex key on the bottom of the engine cases NOTE Inspect the old coolant for evidence of oil combustion byproducts black oil slick stu...

Страница 60: ...ed 9 Lubricate the bore with grease 10 Prepare for assembly by installing the water pump assembly into the assembly tool and align the tool with engine case making sure alignment pin is in proper hole...

Страница 61: ...e can occur if not properly adjusted IDLE ADJUSTMENT On the left side of the carburetor there are two adjustment screws The larger screw with the knurled head is the idle adjustment screw To raise the...

Страница 62: ...rmer conditions turn the screw in In colder conditions turn the screw out Be sure to keep the carburetor very clean and make sure you don t have water or dirt in the carburetor bowl Use automotive car...

Страница 63: ...crucial element 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...

Страница 64: ...Clean the rotor with mild dish soap or alcohol Contaminated pads must be replaced Ensure that the brake caliper is centered over the brake rotor It a correction is needed Cobra has thin brake shims to...

Страница 65: ...n the new seal Also take care that the inner lip is not folded over when installing 4 Slide bushing 3 onto lower fork leg 5 Install the glide ring into groove on lower fork leg 6 Slide the bushing ove...

Страница 66: ...Because of different rider weights sizes and riding styles we offer various suspension options See Optional Components section of this manual for details on these and other optional components for yo...

Страница 67: ...thickness difficult to measure accurately 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 observe...

Страница 68: ...to remember If your clutch is hitting fine don t mess with it Some things to remember to aid clutch life Change oil each ride Gear to the low side Avoid mud if possible Cut mud practice to 1 lap or n...

Страница 69: ...any of the measurements A For the most part that does not matter Suffice it to say that any efforts to make the three shoes behave identically will make the best performing clutch Taking extra time t...

Страница 70: ...er Mud Sand Hills Hard Pack Throttle Blipper novice 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 5...

Страница 71: ...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...

Страница 72: ...gine performance and engine life Symptoms of improper 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...

Страница 73: ...roper measuring technique is described later in this section NOTE Perform all jetting changes on a motorcycle that has been warmed up to proper operating temperature The carburetor on your Cobra motor...

Страница 74: ...cceleration of your Cobra Motorcycle on the longest straight at the track Observe any of the lean or rich symptoms spark plug appearance and bike performance listed above and change your jetting accor...

Страница 75: ...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 is low i Pis...

Страница 76: ...round vi Stator winding damaged d Exhaust is plugged 6 Overheating a Bad stator b Water pump pulleys or belt broken c Water pump impeller broken or bolt out d Jetting too lean e Too much throttle blip...

Страница 77: ...6 Cooling System 59 Engine Specifications 4 Exhaust 63 Parts 30 Fork Operation 72 Fork oil replacement 15 Frame Parts 36 Frictional Drive 16 Front Brake Parts 38 Front Wheel Parts 39 Fuel System Servi...

Страница 78: ...Brake Adjustment 11 Parts 41 Rear Wheel Parts 42 Pullers 63 Reeds 63 Shock Parts 43 44 Slip Clutch 16 Spark Plug Recommended 4 Specifications 4 torque values 5 Starting 7 Suspension Adjustment 71 Swi...

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