Cobra 2005 King Owner's Manual
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Cobra 2005 King Owner's Manual

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Summary of Contents for Cobra 2005 King

  • Page 2 For parts orders contact your local dealer To locate your closest 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 Motorcycle MFG., Inc.
  • Page 3 THIS BIKE IS INTENDED 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 PROPER OPERATING CONDITION.

  • Page 4: Table Of Contents

    Table Of Contents GENERAL INFORMATION ................... 5 ................. 5 PECIFICATIONS ENERAL ..................6 PTIONAL OMPONENTS ..............7 PECIFICATIONS ORQUE ALUES ..................8 REAK ROCEDURE ..................9 TARTING ROCEDURE ....................10 ENERAL MAINTENANCE ....................10 & T ....................10 CHEDULE ..........12 EPLACING RANSMISSION LUTCH...
  • Page 5 – F I ....................31 ARTS RAME Parts – Frame II ................... 32 – F ..................33 ARTS RONT RAKES – F ..................34 ARTS RONT HEEL – P & S ..............35 ARTS LASTIC ODYWORK – R ..................36 ARTS RAKE –...

  • Page 6: General Information

    Float Height 16mm + 0.5mm (0.63” + 0.020”) Coolant Liquid Performance Mini Coolant / Antifreeze Transmission Speed Single Final drive ratio 14/38 T Chain 100 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk Quantity 235 ml (8.0oz)

  • Page 7: Optional Components

    2.75 - 10 Pressure 16 psi min. (20 psi for hard pack or rocky conditions) Front fork Cobra 30mm USD Fork oil type SAE 10 weight Fork oil amount 105 ml (3.5oz) Optional Components Call your dealer, or the factory, for details •...

  • Page 8: Specifications - Torque Values

    Specifications - Torque Values Torque Value Size & Fastener Remarks ft-lb in-lb Cylinder head M6 x 1.0 nuts Crankcase M6 x 1.0 bolts Spark plug (SP) (SP) (SP) M14 x 1.25 Stator bolts M5 X 0.8 Stator cover M4 X 0.75 bolts Clutch cover M6 X 1.0...

  • Page 9: Break-In Procedure

    Break-In Procedure Your Cobra KING is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The KING can be ridden hard after the first ½ hour break-in time but it is recommended that no adjustments are made to the carburetion or suspension until the full 8 hours of bike break-in has elapsed.

  • Page 10: Starting Procedure

    (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 performance. When your pre-ride inspection is complete the bike may be started. For a cold engine follow this procedure.

  • Page 11: General Tips

    General Tips Always wear a helmet and other protective riding gear. Cobra recommends that you tell your child to take it easy the first couple of minutes in practice until the engine comes up to full operating temperature. Make sure your riders’ foot is not resting on the foot brake while they are...
  • Page 12 The frame is 4130 Chrome Moly and it is important to weld it with the proper rod and heat settings set as light as possible. Cobra recommends replacing the frame with a new one if the old one becomes damaged.

  • Page 13: Replacing Transmission / Clutch Lubricant

    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. Reapply oil from oil fill plug 235 cc (8.0 oz) Cobra Venom 3 Shoe Clutch Milk thru the oil fill plug.

  • Page 14: Chain Adjustment

    Cobra motorcycle. Chain adjustment 1. Make sure that the rear wheel is aligned properly. Push down on the seat, compressing the suspen- sion down to where the chain is tightest.

  • Page 15: Air Filter Cleaning

    Figure 2b CAUTION: Adequate pedal free play is required so that the brake pads do not drag on the rotor. 1” MINIMUM. Make sure that the free play locking clip is installed such that one must push forward, toward the front of the bike, to remove. Otherwise the clip is apt to come undone while riding.

  • Page 16: Fork Oil Replacement

    When washing your bike, it may be handy to remove the airboot and hose out the airbox. When doing so, cover the carburetor inlet with a suitable shield capable of keeping water from entering the engine. Cobra has a rubber cap for the carburetor inlet (part # RCMU0109). Fork Oil Replacement Tools required •...

  • Page 17: Parts

    Parts Parts – Airbox & Inlet System Figure 5 Coolant System REF # PART # DESCRIPTION RAKG0001 AIRBOX HCBF0616 M6X16 FLANGE HEAD BOLT RCKG0502 AIR FILTER RCKG0503 FILTER RETAINER TCKG0004 MUDFLAP – AIRBOX TCKG0105 BRACKET – MUDFLAP HCBB0612 M6X12 BUTTON HEAD BOLT MCKGHO03 HOSE CLAMP –...

  • Page 18: Parts - Bars And Controls

    Parts – Bars and Controls Figure 3 Bars and Controls REF # PART # DESCRIPTION TCMU0009 HANDLEBAR - STEEL MCMU0001 OPTIONAL CROSS BAR PAD TCMU0008 GRIPS (SET OF TWO) FCMU0066 THROTTLE ASSEMBLY FCMU0068 THROTTLE COVER SHOWN BCKG0023 ALLOY BRAKE LEVER W/BALL BCKG0024 BRAKE PERCH ASSY W/LEVER &...

  • Page 19: Parts - Carburetor

    Parts - Carburetor Carburetor REF. # PART # DESCRIPTION RCMU0305 CARB SLIDE RCMU0601 NEEDLE RCMU0002 ATOMIZER RCMU0096 MAIN JET RCMU0065 PILOT JET CHOKE JET RCMU0301 FLOAT RCMU0102 RUBBER CABLE CAP SEAL RCMU0003 CABLE ADJUSTOR RCMU0006 TOP CARB SCREW RCMU0106 CARB TOP ZCMU0007 TOP CARB GASKET RCMU0004...

  • Page 20: Parts - Coolant System

    Parts – Coolant System Figure 5 Coolant System REF # PART # DESCRIPTION FCKG0036 RADIATOR WITH CAP FCMU0047 RADIATOR CAP (2 ears or ribbed) MCMUHO05 RADIATOR HOSE, TOP, LEFT MCKGHO06 RADIATOR HOSE, BOTTOM, RIGHT MCMUGR03 MOUNTING GROMMET (3 PER) FCMU0006 RADIATOR MOUNTING BRACKET (TEARDROP) HCBF0616 FLANGE HEAD BOLT M6X16...

  • Page 21: Parts - Electrical System

    Parts – Electrical System Figure 6 Electrical System REF # PART # DESCRIPTION IAMU0001 COIL W/SPARK PLUG CAP ECMU0065 SPARK PLUG, CHAMPION (8339-1) ECMU0067 OPTIONAL HOTTER PLUG (8332-1) ECMU0066 OPTIONAL COLDER PLUG (8904-1) FCMU0033 KILL SWITCH ASSEMBLY HCBC0516 SCREW, M5 X 16 (2 PER) HCCN0000 5MM CLIP NUT (2 PER) IAMU0002...

  • Page 22: Parts - Engine - Bottom End And Transmission

    Parts – Engine – Bottom End and Transmission Figure 7A Engine Bottom End and Transmission REF # PART # DESCRIPTION ECKG0017 CRANKCASE, IGNITION SIDE no bearings ECMU0020L BEARING, TRANSMISSION PRECISION ECKG0004 SNAP RING, WATER PUMP ZCMU0501 GASKET, CRANKCASE ECMU0106 SECONDARY SHAFT, TRANSMISSION WITH GEAR ECMU0017 SEAL, CRANKSHAFT ECMU0016...

  • Page 23: Parts - Engine Clutch And Kicker

    Parts – Engine Clutch Kicker Figure 7B Engine – Clutch and Kick Starter REF # PART # DESCRIPTION ECMU0127 CLUTCH COVER WITH KICK SHAFT, GEAR, AND LEVER ZCMU0030 CLUTCH COVER GASKET ECMU0207 KICKSTART GEAR SMALL HCBC0608 M6X55 SHCS CLUTCH CVR SCREW LNG (2 REQ’D) CENTER HCBC0606 M6X45 SHCS CLUTCH COVER SCREW SHORT (4 REQ’D) ECMU0068...

  • Page 24: Parts - Engine - Ignition And Water Pump

    Parts – Engine – Ignition Water Pump Figure 7C Engine – Ignition and Water Pump REF # PART # DESCRIPTION ECKG0001 IGNITION COVER ZCKG0101 IGNITION COVER GASKET HCBC0445 M4 x 45 SOCKET HEAD (4 REQ’D) ECKG0170 WATER PUMP BELT ECKG0175 WATER PUMP PULLEY, FAN TYPE - DRIVEN ECMU0180 BELT RETAINER...

  • Page 25: Parts - Engine - Top End

    Parts – Engine – Top End Figure 7D Engine – Top End REF # PART # DESCRIPTION ECMU0052 CYLINDER ZCKG0501 BASE GASKET ECMU0060 PISTON KIT ECMU0055 PISTON RINGS (2 PER SET) ECMUSR00 SNAP RING FOR PISTON (2 REQ'D) ECKG0012 WRIST PIN ECMU0077 BEARING, WRIST PIN ZCMUOR07...

  • Page 26: Parts - Exhaust System

    Parts – Exhaust System Figure 8 Exhaust System REF # PART # DESCRIPTION XCKG2004 2004 KING EXHAUST PIPE ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D) XCMU0005 EXHAUST SPRING - SHORT MCMUGR06 PIPE GROMMET MALE MCMUGR07 PIPE GROMMET FEMALE MCMUSP02 PIPE GROMMET SPACER HCWF1478 PIPE GROMMET WASHER (2 REQ’D) HCBF0635...

  • Page 27: Parts - Forks & Triple Clamps

    Parts – Forks & Triple Clamps Figure 12 Front Forks and Triple Clamp REF # PART # DESCRIPTION KAKG0010 FORK COMPLETE, NON-BRAKE SIDE KAKG0009 FORK COMPLETE, BRAKE SIDE KCKG0040 FORK GUARD SET KCKG0040 FORK GUARD SET MCMUZT04 CABLE TIE (2 REQ’D) HCBB0612 M6X12, BUTTON HEAD SCREW (4 REQ’D) FAKG0010...

  • Page 28: Parts - Forks - Leg Assembly

    Parts – Forks – Leg Assembly Figure 13 Fork Leg Assembly REF # PART # DESCRIPTION FORK DAMPER ASSEMBLY KCKG1201 FORK SPRING STANDARD (12 LB/IN) KCKG0009 FORK SPRING OPTIONAL SOFTER (9 LB/IN) NOT SHOWN KCKG0015 FORK SPRING OPTIONAL STIFFER (15 LB/IN) NOT SHOWN 3 BR KAKG0028...

  • Page 29: Parts - Forks - Damper Assembly

    Parts – Forks – Damper Assembly Figure 14 Figure 15 Damper Cartridge Assembly REF # PART # DESCRIPTION KCKG0027 FORK DAMPER ROD KCKG0025 CARTRIDGE TOP KCKG0031 TOP OUT SPRINIG KAKG0017 MID VALVE ASSEMBLY (STANDARD) KAKG0016 MID VALVE ASSEMBLY (SOFT/FAST) OPTIONAL NOT SHOWN KAKG0018 MID VALVE ASSEMBLY (HARD/SLOW) OPTIONAL...

  • Page 30: Parts - Forks - Damper - Base Valve Assembly

    Parts – Forks – Damper – Base Valve Assembly Figure 16 Forks -Valving, Base Valve Assembly – Std. REF # PART # DESCRIPTION HCBC0606 M6X45 SOCKET HEAD CAP SCREW KCKG0011 CHECKSTOP KCKG0038 SPRING, BASE VALVE KCKGSH01 CHECKPLATE, 14 X .3 KCKG0026 PISTON, FORK VALVE KCKG0013...

  • Page 31: Parts - Forks - Damper - Mid Valve Assembly

    Parts – Forks – Damper – Mid Valve Assembly Figure 17 Forks – Valving, Mid Valve Assembly – Std. REF # PART # DESCRIPTION HCBC0603 M6X30 SOCKET HEAD CAP SCREW HCWF0601 FLAT WASHER KCKGSH05 SHIM, 8 X .15 (2 REQ’D) KCKGSH04 SHIM, 12 X .1 KCKGSH02...

  • Page 32: Parts - Framei

    Parts – Frame I Figure 9 Frame REF # PART # DESCRIPTION FAKG0011 FRAME 2005 KING HCBF0616 M6X16 FLANGE HEAD BOLT HCHA0003 6MM “U” NUT TCKG0007 PLUG – FRAME END MCMU0003 STRAP – HANDLE HCBF0620 M6X20 FLANGE HEAD BOLT HCHA0003 6MM “U”...

  • Page 33: Parts - Frame Ii

    Parts – Frame II Figure 10 Frame REF # PART # DESCRIPTION FAKG0011 FRAME 2005 KING HCBF0616 M6X16 FLANGE HEAD BOLT HCNK0001 KNOB – SEAT FASTENING HCBB0516 M5X16 BUTTON HEAD BOLT HCWP0002 ALUMINUM WASHER HCBB0516 M5X16 BUTTON HEAD BOLT HCCN0000...

  • Page 34: Parts - Front Brakes

    Parts – Front Brakes Figure 18 Front Brakes REF # PART # DESCRIPTION BAKG0003 FRONT BRAKE ASSEMBLY BCKG0030 HOSE – BRAKE FRONT BCKG0023 ALLOY BRAKE LEVER BCKG0024 BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER BCKG0029 CALIPER – FRONT BCKG0009 BRAKE PADS, WITH “E”...

  • Page 35: Parts - Front Wheel

    Parts – Front Wheel Figure 19 Front Wheel REF # PART # DESCRIPTION WAKG0021 FRONT WHEEL COMPLETE WCKG1200 12" FRONT TIRE WCKG1201 12" FRONT TUBE WCKG0011 FRONT AXLE WCMU0123 FRONT WHEEL SPACER, X LARGE WCMU0120 WHEEL BEARING (2 REQD) WCMU0032 WHEEL BEARING SPACER WCMU0101 FRONT WHEEL SPACER, LARGE...

  • Page 36: Parts - Plastic Bodywork & Seat

    Parts – Plastic Bodywork & Seat Figure 20 Plastic and Seat REF # PART # DESCRIPTION TCMU0016 FRONT FENDER HCBF0616 FRONT FENDER MTG BOLTS (4 REQD) NOT SHOWN TCMU0005 FRONT NUMBER PLATE HCBF0625 FRONT NUMBER PLATE MTG BOLT NOT SHOWN TCMU0006 FUEL TANK (NO PETCOCK OR CAP) HCBF0616...

  • Page 37: Parts - Rear Brake

    Parts – Rear Brake Figure 21 Rear Brake System REF # PART # DESCRIPTION BAKG0002 BRAKE COMPLETE BCMU0012 BRAKE PEDAL BCDC0009 BRAKE PIVOT BOLT HCBH0620 M6X20 HEX HEAD BOLT HCNS0601 6 MM NUT BCMUSP02 BRAKE RETURN SPRING BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D) BCDC0004 PUSH ROD, REAR BRAKE HCBF0620...

  • Page 38: Parts - Rear Wheel

    Parts – Rear Wheel Figure 22 Rear Wheel REF # PART # DESCRIPTION WAKG0019 REAR WHEEL COMPLETE WCMU0275 REAR TIRE, BRIDGESTONE MT320 2.75X10 WCMUTU10 TUBE, BRIDGESTONE 10" BCMU0502 BRAKE ROTOR HCBB0620 M6X20 BUTTON HEAD CAP SCREWS (5 REQD) PCMU0038 38T STEEL REAR SPROCKET PCMU0059 RUBBER DAMPERS WCMU0008...

  • Page 39: Parts - Shock

    Parts – Shock Figure 23 Shock REF # PART # DESCRIPTION SAKG2005 SHOCK ABSORBER 2005 KING SCKGOH95 REPLACEMENT SHOCK SPRING (YELLOW, 195 LB/IN) SCKGOH85 LIGHT RATE SHOCK SPRING (GRAY, 185 LB/IN) SCKGO205 HEAVY RATE SHOCK SPRING (GOLD, 205 LB/IN) SCKGOH05...

  • Page 40: Parts - Swingarm Assembly

    Parts – Swingarm Assembly Figure 24 Swingarm REF # PART # DESCRIPTION GAKG2004 SWINGARM ASSEMBLY COMPLETE GAKG0002 SWINGARM PAINTED HCBH1403 SWINGARM PIVOT BOLT HCNL1402 SWINGARM LOCK NUT (M14 X1) GCMU0001 SWINGARM BUSHING (4 PER) GCMU0005 TOP SWINGARM GUARD (CHAIN SLIDER) HCBB0803 M8X40 BUTTON HEAD BOLT HCWF5601...

  • Page 41: Service

    • There appears to be a wide range of variability in reading compression gauges across the country. • The head volume of this Cobra Motorcycle is very small and so requires many kicks ~20 before you establish the most accurate reading possible.

  • Page 42: Engine Removal

    dropped to 90% of its original value the engine will be down on power and would benefit from a rebuild. When it’s dropped to 80% it really needs rebuilt! Using the table below will help you determine monitor the condition of your top end. Engine is Fresh Engine Down on Power Engine NEEDS Rebuilt...

  • Page 43: Complete Engine Disassembly Procedure

    7. Remove the special nut / starter gear that holds on the clutch (special tool available, contact your local dealer). 8. With the Cobra flywheel / clutch puller (#MCMUTL68), remove the clutch from the crankshaft (details in Clutch Service portion of this manual).

  • Page 44: Splitting The Cases

    INSPECTION NOTE: Inspect the cylinder head for deposits and abrasions. 1. If there are deposits they should be removed a. Black oily deposits (indicating a rich mixture or improper oil type/quantity) can be removed with solvent b. Crusty deposits (indicating dirt ingestion) can be removed with solvent and may require some scraping.

  • Page 45: Engine Assembly

    CAUTION: Take caution when handling the crankshaft. It is the main power transfer to the rest of the engine. If it is out of alignment, it will cause premature failure of your bearings which can lead to serious damage to the cylinder and the rest of the engine.
  • Page 46 Figure 25 Figure 26...
  • Page 47 10. Insert dowel pins in the left side case as shown in figure 27. Figure 8 11. Clean the gasket mating surfaces with acetone 12. Apply gasket sealer (ThreeBond 1104 gasket material or equivalent) to the mating surfaces of both crankcase halves). NOTE: Gasket material is only required around the crankscase, and not the transmission.
  • Page 48 Figure 28 16. Torque to 12 Nm (105 in-lb) in the pattern shown in figure 28. 17. Trim away any excess gasket material. NOTE: Check engine mount holes for excess material that may cause problems in engine installation. 18. Install the piston with new wrist pin bearing and, pin and 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...
  • Page 49 Figure 29 21. Install the base gasket. 22. Apply gasket sealer to the top surface of the gasket in the same locations indicated in figure 29. 23. Install the cylinder being sure that the piston rings are properly aligned with the indexing pins.
  • Page 50 26. Pressure test the engine insuring an acceptable leakdown rate. 27. Install O-RINGs as shown in figure 31. Figure 31 28. Install the cylinder head. 29. Install the washers (with flat side down) and nuts. Torque to 105 in-lb (12 Nm) 30.

  • Page 51: Clutch

    3. Remove the clutch nut (not left hand thread) on the end of the crankshaft with the clutch nut removal tool. 4. Attach the COBRA CLUTCH PULLER. There are three 6mm clutch puller holes located on the ends of the center hub. (figures 32 & 33) You must use a draw type puller to remove the clutch.
  • Page 52 Do not heat the crankshaft threads or the aluminum shoes. 6. Keep tension on the puller as you are heating it. The clutch will often pop off under tension from the puller and it will be very hot. CLUTCH WASHER STACKUPS: Once the clutch is removed, and cool to touch, carefully put it into a vice and remove the center shoulder bolt out of each clutch shoe.
  • Page 53 Figure 34b Clutch adjustment washers Your Cobra comes stock with a single flat washer at the bottom of the spring washer stack. The thickness of that flat washer is 0.056” (1.4mm). Cobra offers several thicknesses of thin adjustment washers that allow clutch engagement tuning.
  • Page 54 • If the clutch has been slipping and shows signs of glazing, it is best to replace the shoes. We have found that once the shoes are glazed, even if deglazed with emery paper or a file, the performance is reduced. •...
  • Page 55 1. After cleaning or replacing the spring washers, reassemble the stack up of washers. CAUTION: It is important to reassemble the washer stack to that which is recommended or to your own specialized stack. CAUTION: It is also important that all three shoes are stacked the same. (See figure 34) 2.

  • Page 56: Ignition

    Prior to tightening the six clutch cover bolts, press the kick lever down to ensure proper kick gear alignment. Figure 36 9. Put pipe back on and add oil (235 ml (8.0 oz) Cobra 3 Shoe Clutch Milk (Part # MCMUGF01). Ignition Stator care Stator failure will result from running the bike hot.

  • Page 57: Ignition

    3. Improper spark plug heat range. Never run a hotter plug than the specified spark plug. 4. Clutch slippage. See “CLUTCH” section for causes of slippage. CAUTION: • Because of the amount of heat generated 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.

  • Page 58: Cooling System

    6. Set the dial indicator to zero 7. Turn the crankshaft clockwise until the dial indicator reaches 0.040” (1.14mm) from top dead center. 8. Line up the lines on the stator and the rotor (figure 37). Otherwise loosen the three 5mm bolts to adjust the stator. 0.040”...
  • Page 59 The air stream running through the radiator cools the radiator fluid. Therefore dirty radiators additionally reduce the cooling effect. Cobra has tested numerous brand name automotive and racing coolant / antifreeze solutions and has found Liquid Performance Propylene Glycol based Mini Coolant / Antifreeze to have the greatest effect on reducing cylinder head temperatures.
  • Page 60 5. Drain engine transmission oil by removing drain screw using a 13mm- hex wrench. (item 2 in the figure below). 6. Remove kick-starter cover using a 5mm hex key. (item 3 six places) 7. Remove clutch and basket. 8. Unscrew water elbow fitting. (Figure 40) Figure 40 8.
  • Page 61 the area of the seal. If there is any sign of wear (like a groove) replace the shaft. Figure 43 14. Reinstall new bearings, seal (open side toward impeller) and impeller. Clean all threads and use green (wicking / bearing retainer) thread locker. 15.

  • Page 62: Fuel & Air System

    Fuel & Air System Carburetor: Tools recommended for carburetor service: • Small flat head screwdriver KING Carburetor Ref. Drawing • WD-40 • 8mm socket REF. # PART # DESCRIPTION RCMU0305 CARB SLIDE RCMU0601 NEEDLE RCMU0002 ATOMIZER MAIN JET PILOT JET CHOKE JET RCMU0301 FLOAT...
  • Page 63 Your Cobra is equipped with an adjustable carburetor. Some fine-tuning may be needed according to weather condition and altitude. Proper jetting is very important for engine performance and engine life. Serious damage to the engine can occur if not properly adjusted.
  • Page 64 Use automotive carburetor cleaner or WD-40 to clean the carburetor inside and out. STOCK CARBURETOR SETTINGS The 2005 KING stock carburetor settings from the factory are: • 65 pilot jet • 95 main jet...

  • Page 65: Exhaust

    Reeds: • The reeds must lay flat on the reed cage. • If the reed tips aren’t lying flat, replace them immediately. • The reeds must have a tight seal on the reed cage. • If the reed is damaged in any way, replace it. This means cracks, chips, and ruptures.

  • Page 66: Wheels & Tires

    • 11mm wrench or socket • 19mm wrench The Cobra is the only 50cc to have the rear wheel damping system. This feature prevents engine impact shock caused by hard landings. This design allows the cushioned sprocket to move forward and backwards separately from the wheel.

  • Page 67: Brakes

    Rear wheel pullers Disassembly: 1. Remove axle, back wheel assembly. 2. Pull the rear wheel pullers out of the back of the swing arm. Figure 49 Rear wheel alignment: By eye, ensure that the rear sprocket is running true (in-line, planar) with the front sprocket.

  • Page 68: Front Forks

    Front Forks Tools recommended for front fork service: • Flat head screwdriver • Hammer • Snap ring pliers • Seal drivers • 13mm wrench • 1” wrench or socket • 10 wt fork oil FORK DISASSEMBLY PROCEDURES: 1. Using the 1” wrench, remove the fork cap. 2.
  • Page 69 The damper rod is hollow and will break if the nut is over tightened (proper torque is 12 ft-lb, 16 Nm). 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 your Cobra Motorcycle.

  • Page 70: Rear Shock

    Rear Shock 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 Figure 58...

  • Page 71: Tuning

    Tuning Gearing For a bike with a centrifugal clutch, it’s better to be geared too low than too high. What happens with improper gearing? • Poor performance • Not enough top end speed • No snap • Over heat clutch •...

  • Page 72: Suspension

    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 responding 1.1.2. Oil quantity / level 1.1.2.1. Greater quantity / higher level – greater bottoming resistance, stiffer near the end of the travel.

  • Page 73: Carburetion

    Lower the bike if the rider has difficulties touching the ground. Carburetion Although your Cobra is sent from the factory with the carburetor jetted for optimal performance, you may find it necessary to adjustment your particular jetting due to current weather conditions, altitude, fuel variations, and/or engine modifications.
  • Page 74 Perform all jetting changes on a motorcycle that has been warmed up to proper operating temperature. The carburetor on your Cobra motorcycle is quite adjustable. Figure 59 shows its range of adjustment and in particular what adjustable component affects what...
  • Page 75 TOP END JETTING: Adjust for 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 appearance and bike performance) listed above and change your jetting accordingly.

  • Page 76: Troubleshooting

    Troubleshooting 1) Engine operates erratically a) Carburetor top is installed backwards b) The carburetor slide indexing pin is missing c) A carburetor vent elbow is plugged or has fallen out d) Faulty stator e) An air leak i) Base gasket ii) Intake / reed gaskets iii) Crank seals iv) Crank case gasket...

  • Page 77: Index

    ii) Is sour or bad b) Carburetor is dirty c) Ignition i) Spark plug fouled ii) Spark plug cap off iii) Engine Shut-off ‘kill’ switch is shorted 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...
  • Page 78 Shock ......... 38 General Tips ......... 10 Swingarm ........39 Top End ........24 Hardware Triple Clamps ......26 Frame ........31 Plastic & Seat Parts ....... 35 Plastic ........35 Pullers ........... 66 Ignition Rear Brake Parts .......... 23 Adjustment .........

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