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Cobra 2009 ECX50 Owner's Manual

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Summary of Contents for Cobra 2009 ECX50

  • Page 2 For parts orders contact your local dealer To locate your closest Cobra dealer log on to www.cobramotorcycle.com or call (517) 437-9100 If you need technical assistance contact your local dealer or call the Cobra Technical Support Hotline at (517) 437-9100 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 PRODUCT OR AS THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS COBRA PRODUCT IN PROPER OPERATING CONDITION.

  • Page 4: Table Of Contents

    Table Of Contents General Information ....................5 Specifications - General ..................5 Specifications - Torque Values................6 Optional Suspension Components ..............7 Spring rate chart for Cobra Fox quad shocks ............8 Break-In Procedure ...................9 Starting Procedure ..................10 Maintenance .......................11 Tips .........................11 Schedule ......................11 Replacing Transmission / Clutch Lubricant .............13 Chain adjustment ....................14...
  • Page 5 Parts – Rear Brake..................35 Parts – Rear Drive...................36 Parts – Rear Shock (Fox) ................37 Parts – Swingarm Assembly................38 Parts – Tie Rod Assembly ................39 Service........................40 Engine Service ....................40 Base Gasket Selection ................41 Engine Removal ..................43 Complete Engine Disassembly Procedure ..........44 Top End Disassembly Procedure ..............44 Splitting the Cases..................45 Engine assembly ..................46...

  • Page 6: General Information

    Slide / Needle #30 / W-4 Float Height 16mm + 0.5mm (0.63” + 0.020”) Transmission Speed / ratio Single / 14/38 T Chain 104 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk Quantity 235 – 350 ml (8 – 12oz)

  • Page 7: Specifications - Torque Values

    Chassis Tire Pressure front / rear (7 psi / 5 psi) Travel, front / rear 240mm / 247mm (9.4” / 9.7”) Race sag, front / rear 96mm / 99mm (3.8” / 3.9”) Free sag, front / rear 38mm / 40mm (1.5” / 1.6”) Specifications - Torque Values Torque Value Size &...

  • Page 8: Optional Suspension Components

    Torque Value Size & CHASSIS Fastener ft-lb in-lb Remarks Handle bar mounts 8 x 1.25 Handle bar clamps 8 x 1.25 Front engine mount 8 x 1.25 Rear brake lever pivot 13.6 8 x 1.25 Upper shock mount 10 x 1.5 Lower shock mount 10 x 1.5 Swingarm pivot...

  • Page 9: Spring Rate Chart For Cobra Fox Quad Shocks

    (rear) SCEX1300 Yellow SCEX1315 White SCEX1330 SCEX1350 White SCEX1375 Yellow SCEX1400 Blue SCEX0425P Green SCEX0450P Black SCEX0475P Purple SCEX0500P Fox 10” long main spring (rear) White SCEX2325 Yellow SCEX2350 SCEX2375 Black SCEX2400 Spring rate chart for Cobra Fox quad shocks...

  • Page 10: Break-In Procedure

    Clean the carburetor bowl. Change the transmission / clutch lubricant. Replace the fuel filter. • After 8 hours of operation have a Certified Cobra Mechanic change the shock oils. • Your bike is now ready for the highest level of competition!

  • Page 11: Starting Procedure

    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 your Cobra Motorcycle use only the recommended fuels. Testing has shown that most ‘race’ fuels actually degrade performance. Always wear a helmet and other protective riding gear.

  • Page 12: Maintenance

    CAUTION: 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. CAUTION: Make sure your riders’ foot is not resting on the foot brake while they are riding...
  • Page 13 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. Use ER70S6 filler if welding on the frame.

  • Page 14: Replacing Transmission / Clutch Lubricant

    Figure 1 4. After it has drained, reinstall the plug, being sure that the gasket is in place. 5. Reapply oil from oil fill plug 235 cc (8.0 oz) Cobra Venom 3 Shoe Clutch Milk thru the oil fill plug.

  • Page 15: Chain Adjustment

    6. Reapply the oil fill plug, hand tight, being sure the gasket is in place. CAUTION: Cobra has spent considerable time and money developing the proper lubrication to handle the harsh environment of the automatic clutch and transmission of this motorcycle.

  • Page 16: Air Filter Cleaning

    CAUTION: Be sure to remove the pin from the eccentric before riding. Air Filter Cleaning This Cobra Motorcycle comes with a unique air filter / air boot unit designed to facilitate motorcycle service. Tools recommended for air filter maintenance: • Srewdriver •...

  • Page 17: Frictional Drive (Cfd)

    Dusty conditions will require more frequent cleaning. Frictional Drive (CFD) The Cobra Frictional Drive (CFD) is essentially a slip clutch that dissipates torque spikes transmitted from the rear wheel to the rest of the drive line and engine. Instead of these torque spikes potentially damaging internal components, the CFD allows the transmission to slip with respect to the engine.

  • Page 18: Front End

    Figure 3 Steering The unique Cobra front end will exhibit some free play from the factory and that the seals (it that’s what you want to call them) will fall out after the first ride. We have found that this causes no adverse effects and that the looseness does not get significantly worse as long as the bearings are sprayed with a spray lubricant (WD40 or similar) upon each ride.

  • Page 19: Parts

    Parts Parts – Air Inlet System Figure 4 Coolant System REF # PART # DESCRIPTION FILTER ASSEMBLY RCMU0403 MCKGHO01 HOSE CLAMP – BOOT TO CARB RCCM1301 VELOCITY STACK RAEX0021 CARBURETOR, 21MM DELL’ORTO PHBG RCMU0022 VENT HOSE MCKGHO04 HOSE CLAMP – CARB TO MANIFOLD HCBC0625 M6X25 SOCKET HEAD CAP SCREW HCWF0601...

  • Page 20: Parts - Bars And Steering

    Parts – Bars and Steering Figure 5 Bars and Steering REF # PART # DESCRIPTION FAEX0020 STEERING STEM TCMU0009 HANDLEBAR - QUAD FCEX0011 STEERING STEM BLOCK (2 REQ’D) MCEXBR07 STEERING STEM BUSHING – SPLIT ZCEX0002 O’RING – STEERING STEM SEAL (2 REQ’D) NOT SHOWN HCBB0403 4MM X 8 BUTTON HEAD SCREW (2 REQ’D)

  • Page 21: Parts - Bumper, Nerf & Grab Bars

    Parts – Bumper, Nerf & Grab Bars Figure 6 BODY PROTECTION PART # DESCRIPTION REF # FCEX0024 NERF BARS (LEFT & RIGHT) FCEX0067B NERF NET SET (BLACK) FCEX0067R NERF NET SET (RED) FCEX0067Y NERF NET SET (YELLOW) HCBH0808 8MM X 30 HEX HEAD BOLT (FRONT MOUNT, 2 PLACES) NOT SHOWN NOT SHOWN HCBH0809...

  • Page 22: Parts - Carburetor

    Parts - Carburetor Carburetor REF. # PART # DESCRIPTION RCMU0031 CARB SLIDE (30 slide) RCMU0026 NEEDLE (W-4) RCMU0023 ATOMIZER 2.62 AU RCMU00xx MAIN JET (xx denotes size) RCMU00xx PILOT JET (xx denotes size) CHOKE JET RCMU0301 FLOAT RCMU0102 RUBBER CABLE CAP SEAL RCMU0003 CABLE ADJUSTOR RCMU0006...

  • Page 23: Parts - Coolant System

    Parts – Coolant System Figure 9 Coolant System REF # PART # DESCRIPTION FCEX0066 RADIATOR WITH CAP FCMU0020 RADIATOR CAP ECEX0010 RADIATOR HOSE MCEXGR01 GROMMET, RAD MOUNT (4 REQ’D) MCMUGR04 GROMMET, TOP RAD MOUNT (2 REQ’D) HCBF0620 FLANGE HEAD BOLT M6X20 (2 REQ’D) HCWF1478 WASHER RADIATOR MOUNTING MCMUCL07...

  • Page 24: Parts - Electrical System

    Parts – Electrical System Figure 10 Electrical System REF # PART # DESCRIPTION IAMU0005 COIL W/SPARK PLUG CAP (3 WIRE) ECMU0065 SPARK PLUG, CHAMPION (8339-1) ECMU0067 OPTIONAL HOTTER PLUG (8332-1) ECMU0066 OPTIONAL COLDER PLUG (8904-1) IKEX0001 IGNITION KILL TETHER HCBC0516 SCREW, M5 X 16 (2 PER) HCCN0000 5MM CLIP NUT (2 PER)

  • Page 25: Parts - Engine - Bottom End And Transmission

    Parts – Engine – Bottom End and Transmission Figure 7A Engine Bottom End and Transmission REF # PART # DESCRIPTION EKMU0023 ENGINE CASE SET W/B&S 50 07 EKMU0023 ENGINE CASE SET W/B&S 50 07 ZCMU0601 GASKET, CRANKCASE CENTER HCBC0605 6X40MM SOCKET HEAD CAP SCREW (6 REQ’D) HCBC0608 6X55MM SOCKET HEAD CAP SCREW (1 REQ’D) HCBC0606...

  • Page 26: Parts - Engine Clutch And Kicker

    Parts – Engine Clutch Kicker Figure 7B Engine – Clutch and Kick Starter REF # PART # DESCRIPTION CAMU0005 CLUTCH COMPLETE CAMU0013 CLUTCH SHOES (SET OF 3) WITH BOLT & WASHERS CCMU0029 CLUTCH ARBOR CAMU0010 SPRINGS, WASHER & BOLT (SET OF 3) HCBS0004 CLUTCH BOLT (3 REQ’D) ECMU0018...

  • Page 27: Parts - Engine - Water Pump

    Parts – Engine – Water Pump Figure 7C Engine – Ignition and Water Pump REF # PART # DESCRIPTION EKMU0001 WATER PUMP KIT ECKG0142 SHAFT, WATER PUMP ECKG0072 BEARING, WATER PUMP ECKG0074 SEAL, WATER PUMP SHAFT ECKG0073 IMPELLER, WATER PUMP (ALUMINUM) ECKG0004 RETAINER, WATER PUMP ASSEMBLY HCBC1512...

  • Page 28: Parts - Engine - Top End

    Parts – Engine – Top End Figure 7D Engine – Top End REF # PART # DESCRIPTION ECMU0129 CYLINDER KIT (INCLUDES PISTON, RINGS, PIN & CLIPS) BASE GASKET 0.015” (0.4mm thick) For other Base Gaskets refer to ZCKG0501 Base Gasket Selection section of this manual ECMU0060 PISTON KIT ECMU0155...

  • Page 29: Parts - Exhaust System

    Parts – Exhaust System Figure 18 Exhaust System REF # PART # DESCRIPTION XCEX5006 2006 ECX50 EXHAUST PIPE ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D) XCMU0005 EXHAUST SPRING - SHORT PIPE GROMMET SPACER (ONLY AVAILABLE IN MCMUGR02 MCMUGR02 GROMMET KIT) PIPE GROMMET MALE (ONLY AVAILABLE IN MCMUGR02 MCMUGR02 GROMMET KIT) MCMUGR10...

  • Page 30: Parts - Front A-Arms & Steering Upright

    Parts - Front A-Arms & Steering Upright Figure 19 A-arms & steering upright REF # PART # DESCRIPTION GAEX0001 A-ARM FRONT TOP (SAME PIECE FROM LEFT TO RIGHT) GAEX0002 A-ARM BACK TOP (SAME PIECE FROM LEFT TO RIGHT) GAEX0007 A-ARM FRONT BOTTOM RIGHT GAEX0006 A-ARM FRONT BOTOTM LEFT GAEX0009...

  • Page 31: Parts - Front Brakes (Magura)

    Parts – Front Brakes (MAGURA) Figure 20 Front Brakes REF # PART # DESCRIPTION BAEX0001 FRONT BRAKE ASSEMBLY BKEX0001 HOSE – TEE TO CALIPER BRAKE LEVER BCEX0005 BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER BCEX0005 CALIPER – FRONT RIGHT BCEX0015 CALIPER –...

  • Page 32: Parts - Front Brakes (Ajp)

    Parts – Front Brakes (AJP) Front Brakes REF # PART # DESCRIPTION BAEX0004 BRAKE SYSTEM COMPLETE BCEX0024 BANJO BOLT BCEX0025 BRAKE PADS BCEX0029 CRUSH WASHER BCDC0003 MASTER CYLINDER BCEX0026 REPLACEMENT LINE BCEX0028 CALIPER LEFT BCEX0027 CALIPER RIGHT BCEX0020 BRAKE ARM HCBC0825 M8 X 25 SHCS BCEX0021...

  • Page 33: Parts - Front Shock

    Parts – Front Shock Figure 21 Front Shock REF # PART # DESCRIPTION SAEX2005 SHOCK ECX50 – FRONT (2 REQ’D) SCEX1080 SPRING, HELPER, 80 LB/IN (STANDARD) SCEX1095 SPRING, HELPER, 95 LB/IN (HEAVY) SCEXA155 SHOCK SPRING, STANDARD (YELLOW, 155 LB/IN) SCEXA145 SHOCK SPRING, LIGHT (RED, 145 LB/IN) SCEXA165 SHOCK SPRING, HEAVY (BLACK, 165 LB/IN)

  • Page 34: Parts - Miscellaneous

    Parts – Miscellaneous If you couldn’t find it in one of the other pictures try the table below. PART # DESCRIPTION WCEX0007 REAR WHEEL WITH TIRE 6X8” WCEX0004L LEFT FRONT WHEEL WITH TIRE WCEX0004R RIGHT FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING...

  • Page 35: Parts - Plastic Bodywork & Seat

    Parts – Plastic Bodywork & Seat igure 22 Plastic and Bodywork REF # PART # DESCRIPTION TCEX0001 FRONT CLIP NOT SHOWN HCBB0616 M6 X 16 BUTTON HEAD (4 REQ’D AT BACK) NOT SHOWN HCWF0601 6 MM FLAT WASHER (4 REQ’D AT BACK) NOT SHOWN HCBB0625 M6 X 25 BUTTON HEAD (2 REQ’D AT FRONT)

  • Page 36: Parts - Rear Brake

    Parts – Rear Brake Figure 23 Rear Brake System REF # PART # DESCRIPTION BADC0001 BRAKE COMPLETE BCEX0007 BRAKE PEDAL BCDC0009 BRAKE PIVOT BOLT HCBC0601 M6X16 SOC. HEAD BOLT FCEX0018 BRAKE ADJUST ECCENTRIC BCEX0012 BRAKE RETURN SPRING BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D) BCDC0004 PUSH ROD, REAR BRAKE HCBC0601...

  • Page 37: Parts - Rear Drive

    Parts – Rear Drive Figure 24 Rear Drive REF # PART # DESCRIPTION GAEX0005 REAR AXLE WCEX0003 WHEEL LUG (8 REQ’D) HCNS1001 LUG NUT (8 REQ’D) HCWF0010 LUG WASHER (8 REQ’D) NOT SHOWN GCEX0014 BRAKE/SPROCKET HUB (2 REQ’D) HCBC0625 M6 X 25 HUB PINCH BOLT (2 PER HUB) NOT SHOWN HCBH0808 M8 X 30 HEX HEAD BOLTS (4 REQ’D)

  • Page 38: Parts - Rear Shock (Fox)

    Parts – Rear Shock (Fox) Figure 25 Rear Shock REF # PART # DESCRIPTION SAE52009 SHOCK, REAR QUAD FOX SCEX2350 SHOCK SPRING, STANDARD (350 LB/IN) SCEX2325 SHOCK SPRING, LIGHT (325 LB/IN) SCEX2400 SHOCK SPRING, HEAVY (400 LB/IN) SCKGFX04 PRELOAD RING BOTTOM SCKGFX05 PRELOAD RING TOP (LOCK RING) HCBC1050...

  • Page 39: Parts - Swingarm Assembly

    Parts – Swingarm Assembly Figure 26 Swingarm REF # PART # DESCRIPTION GAEX2009 SWINGARM (2009) GCMU0030 BUSHING, SWINGARM (4 PER) GCE50001 SPACER, SWINGARM PIVOT (RIGHT SIDED / STEPPED SPACER) GCEX5016 SPACER, SWINGARM PIVOT (LEFT SIDE / TUBE) HCBH1421 SWINGARM PIVOT BOLT (M14 X 1 HEX HEAD) HCNL1402 SWINGARM LOCK NUT (M14 X1) GCEX0050...

  • Page 40: Parts - Tie Rod Assembly

    Parts – Tie Rod Assembly Figure 27 Tie Rod Assembly REF # PART # DESCRIPTION FAEX0002 TIE ROD MCEXBR02R RH TIE ROD END MCEXBR02L LH TIE ROD END HCNJ120L LH JAM NUT HCNJ120R RH JAM NUT GCEX0002 SPACER, BALL JOINT HCNC0010 10MM CASTLE NUT (2 REQ’D) HCCP0003...

  • 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: Base Gasket Selection

    • 1mm flexible solder material • measurement calipers When rebuilding the ‘top end’ of your Cobra motorcycle, care must be taken to ensure the proper squish clearance. Squish clearance is defined as the minimum distance between cylinder head and piston at TDC, and there are negative effects of either having too much or too little clearance.
  • Page 43 Code Supplied Base Cobra # Gasket Thickness inch Part # 0.008 ZCMU0702 0.25 0.010 ZCMU0011 0.012 ZCMU0703 0.015 ZCKG0501 0.020 ZCMU0705 0.024 ZCMU0706 0.028 ZCMU0707 0.031 ZCMU0708 0.035 ZCMU0015 0.039 ZCMU0016 NOTE Tolerances will affect the actual gasket thicknesses. If during the course of the maintenance more parts than the base gasket are changed, the squish clearance should be measured, and possibly a different base gasket will be required.

  • Page 44: Engine Removal

    Upon completion, your final assembly squish clearance should agree with the chart below Engine Removal To service the bottom end and transmission, the engine must be removed from the frame. Tools required • 10, 11, 13, 22 mm wrench • 8, 10, 14, 17 &...

  • Page 45: 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 46: 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 47: 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 as well as the rest of the engine.
  • Page 48 9. Torque to 12 Nm (105 in-lb) in the pattern shown in figure 28. 10. Trim away any excess gasket material if necessary. NOTE: Check engine mount holes for excess material that may cause problems in engine installation. 11. 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: Clutch

    Clutch CAUTION: The clutch components (arbor, shoes, bolt, and belleville washers) on your 2006 Cobra are similar looking but different in geometry from prior years. Do not mix old and new parts as damage will occur. Cobra clutch puller assembly:...
  • Page 50 Generally reassemble the springs as you removed them from the engine or as you received them from Cobra. This will be either a 3, 4 ½ or, 5 stack. If you are unsure call the Cobra Technical Support Group 330 549 9600, and consult the experts.
  • Page 51 5 ½ 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 0.031” (0.79mm). Cobra offers several thicknesses of thin adjustment washers that allow clutch engagement tuning.
  • Page 52 • The best way to prevent glazing is by not gearing too high, changing the oil as specified and by not blipping the throttle. Every time you blip the throttle, you are working your clutch springs. CAUTION: The clutch produces a tremendous amount of heat and when a rider is blipping the throttle.
  • Page 53 CLUTCH ASSEMBLY: 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 32) 2.

  • Page 54: Ignition

    Using one hand rotate the kick lever to ½ stroke and hold while tightening the six screws completely with the other hand. 8. Fill with 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 55 CAUTION: Advancing the ignition timing will cause the engine to run hotter, in-turn causing power loss, shortened clutch life, and possibly lead to premature stator failure, and can also cause detonation which can lead to premature piston and ring failure. Tools recommended for timing service: •...

  • Page 56: Cooling System

    CAUTION: It is recommended that you apply the proper thread locking primer to the components that are 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 35).
  • Page 57 • Dead blow hammer COBRA IMPELLER SERVICE INSTRUCTIONS 1. Remove radiator cap and drain engine coolant as described above. NOTE: If the impeller is damaged or broken completely back flush the coolant system to ensure no solid pieces are in the system.
  • Page 58 CAUTION: Damage may occur if one attempts to install the water pump and the device is not orientated correctly. If the tool does not sit flat against the cases, the orientation of the tool to the engine is not correct. Make sure that the top alignment pin is in the 2 unthreaded hole, the bottom alignment pin is also in the 2...

  • Page 59: Fuel & Air System

    • Small flat head screwdriver • WD-40 • 8mm socket 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 60 2. Raising the needle clip (this lowers the jet needle) one notch at a time on the slide. Indications that the engine is running too lean are: • Engine cutting out on top end. • Engine overheating and ultimately seizure. •...
  • Page 61 8. Assemble the carburetor 9. Install the carburetor onto the motorcycle. CAUTION: 1. The motorcycle will only operate properly if the carburetor top is installed properly with the mounting screws, cable and choke knob oriented as shown in figure 43. Figure 43 Proper carburetor top installation location...

  • Page 62: 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 63: 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 64: Carburetion

    Ratio Write © Cobra R&D 2004 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 65 • Symptoms of incorrect oil or oil / fuel ratio o Poor acceleration o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o Excessive black oil dripping from exhaust system • Symptoms of too rich a fuel mixture o Poor acceleration o Engine will not ‘rev’...
  • Page 66 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 67: 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 68 Front Brake ........30 Specifications ......5 Fuel System Carburetor Parts list........58 Parts.......... 21 Service........58 Service ........58 Gas Tank........34 CFD Cobra Frictional Drive ... 16 Grab Bar........20 Chain Hardware Adjustment ........ 14 Frame ........33 Chassis Plastic ........34 Specification ........ 5 Ignition Torque.........
  • Page 69 Spherical Steering Bearing....17 Recommended ......5 Starting..........10 Optional Components ..... 7 Stator Parts torque ..........6 Bottom End & Transmission ..24 Steering Stem .......19 Carburetor ......... 21 Steering Upright ......29 Clutch & Kick Starter ....25 Suspension ........65 Engine ........24 Swingarm Parts ......38 Ignition &...

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