Cobra PW3 2003 Owner's Service Manual
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Cobra PW3 2003 Owner's Service Manual

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2003 PW3
Owners / Service Manual
"CHAMPIONS START HERE"

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Summary of Contents for Cobra PW3 2003

  • Page 1 2003 PW3 Owners / Service Manual “CHAMPIONS START HERE”...
  • 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 ......................4 Specifications - General....................4 Specifications - Torque Values ..................5 Optional Components ....................6 Break-In Procedure ......................7 Starting Procedure .......................8 General Tips........................9 Maintenance........................10 Schedule & Tips ......................10 M1: Replacing Transmission / Clutch Lubricant ............11 M2: Chain adjustment....................12 M3: Front brake adjustment..................13 M4: Rear brake adjustment ..................14 M5: Air Filter Cleaning ....................14...

  • Page 5: General Information

    Slow (Pilot) jet 42 Float height 5 mm + 0.3mm (0.2” + 0.012”) Transmission Speed Single Clutch 3 shoe centrifugal Final drive ratio 10/46 T Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III Quantity 250 ml (8.5oz)

  • Page 6: Specifications - Torque Values

    Chassis Front tire 2.50 - 10 Pressure 15 psi minimum Rear tire 2.75 - 10 Pressure 15 psi min. (20 psi for hard pack or rocky conditions) Front fork Marzocchi 32mm Fork oil type SAE 20 weight Fork oil amount 200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild Fork oil height 70 mm (2.75”) collapsed from top with spring (no spacer) Specifications - Torque Values...

  • Page 7: Optional Components

    Optional Components • Carburetor jets o Main jets #’s 74, 76, 78, 80, 84, 86, 88 o Slow jets #’s 38, 40, 45, • Sprockets o Front sprocket, 11T o Rear sprocket, 39 T – 45 T • Seat – higher seat height 23.9” (607 mm) part # TCHJ0001 •...

  • Page 8: Break-In Procedure

    Break-In Procedure Your Cobra PW3 is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The PW3 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 9: Starting Procedure

    (i.e. the side of the cylinder is warm to touch). CAUTION: Never rev an engine full throttle when it's cold or slightly warmed up. 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.

  • Page 10: 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 11: Maintenance

    Check the frame for cracks in the metal or cracks in the paint that might indicate that the metal has been stressed beyond it’s safe limits. Replace or get properly rewelded as necessary. Fill the 2-stroke injector oil reservoir with Cobra’s specially formulated Cobra Venom 2-cycle Race Oil. •...

  • Page 12: M1: Replacing Transmission / Clutch Lubricant

    M1: Replacing Transmission / Clutch Lubricant Tools needed: • 250 ml (8.5oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01) or Dexron III Automatic Transmission Fluid • #3 Phillips screwdriver • large flat blade screwdriver or coin Procedure: 1.

  • Page 13: M2: Chain Adjustment

    4. After it has drained, reinstall the drain screw with gasket. 5. Refill oil from oil fill plug 250 ml (8.5oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01), or Dexron III Automatic Transmission Fluid, thru the fill plug.

  • Page 14: M3: Front Brake Adjustment

    3. If the chain requires adjusting, loosen the axel with a pair of 19 mm wrenches and tighten the chain by rotating the adjuster bolts clockwise (CW) or loosen the chain by rotating the adjuster bolts (CCW). 4. Retighten the axel bolt to 25 ft-lb (34 Nm). Figure 3 M3: Front brake adjustment Tools recommended for front brake maintenance:...

  • Page 15: M4: Rear Brake Adjustment

    M4: Rear brake adjustment Tools recommended for rear brake maintenance: • 10mm open end wrench There are 2 adjustments on the brake. Figure 6, adjust brake lever free height Figure 7, adjust lever ‘free play’ From the brake lever: 4. Loosen the 10mm nut on the back of the brake pedal. 5.

  • Page 16: M6: Fork Oil Replacement

    NOTE: The Cobra is equipped with a special designed 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 because varied amounts of oil will change your carburetor jetting.

  • Page 17: M7: Clutch Adjustment

    NOTE: Remove the preload sleeve but leave the spring in for the measurement. 3. Install the preload sleeve. 4. Install and depress the white cap while installing the spring clip. 5. Fork may be reinstalled. M7: Clutch Adjustment Tools required 6 mm hex key (Allen wrench) large flat blade screw driver Process...

  • Page 18: Engine Service / Parts

    Engine Service / Parts Factory trained technicians with precision gauging and proper assembly fixtures carefully assemble all Cobra engines to specific clearances. If you feel you have the skills, and the appropriate tools, to perform the following service tasks please follow the instructions closely.

  • Page 19: Es1: Top End Parts

    ES1: Top End Parts Figure 9, Top End Components REF NO PART NO DESCRIPTION ECMOTE01 CYLINDER - CHROME ECMOTE02 PISTON KIT - SINGLE RING HCBC0603 6X30 CAP SCREW HCNF0601 FLANGED NUT 6MM ECMOTE05 CYLINDER HEAD ZCMOTE06 CYLINDER HEAD O-RING ECMU0026 6MM DOWEL ECMOTE09 CYLINDER HEAD STUD BOLT 6MM...

  • Page 20: Es2: Bottom End & Transmission

    ES2: Bottom end & transmission Figure 10, bottom end components REF NO PART NO DESCRIPTION ECMOBE01 CASES - COMPLETE SET ECMOBE02 OUTPUT BEARING ECMOBE03 OUTPUT BEARING - SNAP RING ECMOBE04 PRECISION BEARING ECMOBE05 CRANK SEAL ECMU0016 CRANK BEARING ECMOBE07 CRANKSHAFT COMPLETE ECMOBE08 FLYWHEEL KEY ECMU0077 WRIST PIN BEARING HCBC0660 6X60 CAP SCREW...
  • Page 21 Do not try to true the crank yourself. Truing the crank should be done professionally. Cobra trues every crank before it leaves the factory, and also welds the pin to keep it true. If there are any problems send the engine in, or call tech support (330) 549-9603 to determine what the problem is.
  • Page 22 Kick lever mechanism Figure 11, kick mechanism REF NO PART NO DESCRIPTION ECMOKS01 CLUTCH COVER ECMOKS02 CRUSH WASHER - WATER DRAIN PLUG ECMOKS03 WATER DRAIN PLUG - 6X8 ZCMU0001 OIL FILL PLUG GASKET ECMU0037 OIL FILL PLUG ECMOKS06 RETAINER CLIP - THRUST WASHER HCBC0625 6X25 CAP SCREW ECMPKS09 KICK START LEVER HCBC0603 6X30 CAP SCREW...

  • Page 23: Es3: Clutch

    ES3: Clutch Figure 12 Clutch components REF NO PART NO DESCRIPTION ECMOCL01 GEAR - DRIVE ECMOCL03 CLUTCH START NUT - LH THREAD ECMOCL04 WASHER - CLUTCH NUT BACK UP ECMOCL05 CLUTCH COMPLETE ECMOCL06 SPACER - CLUTCH TO HUB ECMOCL07 BUSHING - CLUTCH HUB ECMOCL09 WASHER - CLUTCH BASKET BACK UP PCMOCL10 SPROCKET - 10 TOOTH ECMOCL11 SNAP RING - OUTPUT SHAFT...

  • Page 24: Es4: Ignition

    ES4: Ignition CAUTION: • Make sure ground wires are secure. If the bike is not grounded it will not run. • Make sure connections are free of dirt. Figure 13, ignition components REF NO PART NO DESCRIPTION ECMOIG01 FLYWHEEL HCWF0801 8MM WASHER HCNS0801 8MM NUT HCBC0401 4X10 CAP SCREW ECMOIG05 COIL WITHOUT SPARK PLUG CAP...

  • Page 25: Es5: Cooling System

    ES5: Cooling System Water pump Figure 14 water pump REF NO PART NO DESCRIPTION ECMOWP01 WATER PUMP SHAFT ECMOWP02 RETAINER CLIP - WATER PUMP BEARING ECMOWP03 BEARING WATER PUMP ECMOWP04 SPACER - WATER PUMP BEARING ECMOWP05 CRANK PULLEY ECMOWP06 WATER PUMP BELT ECMPWP07 CLAMP FOR OIL TUBE HCBC0501 5X12 CAP SCREW ECMPWP09 OIL INJECTOR MOUNT PLATE...

  • Page 26: Es6: Fuel & Air System

    ES6: Fuel & Air System Intake system Figure 15, Intake components REF NO PART NO DESCRIPTION ECMPIN01 12MM CARBURETOR ECMOIN02 CLAMP HCBC0625 6X25 CAP SCREW ECMOIN04 REED SPACER PLATE ZCMOIN05 REED VALVE GASKET ECMOIN06 REED VALVE ASSEMBLY ECMOIN08 SCREW - REED CAGE TO SPACER PLATE ECMOIN09 RUBBER INTAKE BOOT ECMOIN10 INTAKE RETAINING PLATE...
  • Page 27 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 28 Carburetor DESCRIPTION PART # SLIDE - 40 - STOCK RCOI 0001 SLIDE - 30 RCOI 0030 SLIDE - 50 RCOI 0050 NEEDLE FOR SLIDE RCOI 0002 ATOMIZER RCOI 0003 MAIN JET-82 STOCK RCOI 0004 PILOT JET-42 STOCK RCOI 0005 CHOKE JET RCOI 0006 TOP CARB SCREW RCOI 0007...
  • Page 29 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 30 screw. This screw will also richen and lean your engine more on the bottom and mid-range. In warmer 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.

  • Page 31: Es7: Exhaust

    ES7: Exhaust The pipe is a 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 is created from exhaust.
  • Page 32 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 pull bolt on the rear wheel puller to get the distance from the swing arm to the rim about the same.

  • Page 33: Cs2: Suspension

    STOP DISK See Optional Components section of SCMU0301 SHAFT this manual for details on these and SCMU0320 PISTON BUMPER other optional components for your SCMU0312 BUFFER DISK Cobra Motorcycle. SCMU0310 BUFFER SEAL ZCMU0114 LOADER SCMU0314 BUSHING RETAINER SCMU0306 BUSHING ZCMU0216...
  • Page 34 Rear Shock Disassembly 1. Bleed the gas pressure from the shock. Hold a rag over the bleed (Schrader) valve during this operation as the contents are at extremely high pressure. 2. Remove the spring by removing the lock nut and other nut with a large spanner.

  • Page 35: Front Forks

    Front Forks Figure 22 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 36 2003 PW3 FRONT FORK PARTS LIST REF # PART # DESCRIPTION KCMZ0001 8 X 50 CS KCMZ0002 TOP HANDLE BAR CLAMP KCMZ0003 LOWER HANDLE BAR CLAMP KCMZ0004 FORK PLUG – BLACK KCMZ0005 TRIPLE CLAMP UPPER HCBC0806 8 X 30 CS PINCH BOLT FOR TOP TRIPLE CLAMP KCMZ0007 SNAP RING FOR FORK CAP...

  • Page 37: Troubleshooting

    Troubleshooting 1) Engine not behaving properly a) Carburetor top is installed backwards (happens a lot) b) The carburetor slide indexing pin is missing 2) Engine is down on power a) Clutch engagement is not set properly b) Jetting is incorrect c) Silencer needs repacked d) Exhaust pipe Has excess carbon buildup...
  • Page 38 Index Air Filter Tips ..........10 Maintenance........14 Bottom End Recommended .......4 Service ...........19 Optional Components ......6 Break-In..........7 Parts Carburetion Bottom end ........19 Specifications ........4 Clutch ..........22 Chain Ignition..........23 Adjustment......12, 13 Inlet ..........25 Chassis Kick mechanism ......21 Specification........4 Rear shock ........32 Clutch Reeds ..........25 Parts ..........22...

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2003 ch2

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