Cobra 2004 King Owner's Manual
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Cobra 2004 King Owner's Manual

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2004 KING
Owners / Service / Parts
"CHAMPIONS START HERE"

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  • Page 1 2004 KING Owners / Service / Parts “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 “WARNING” THE COBRA KING IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS.

  • 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 ........................9 ENERAL MAINTENANCE ......................10 & T ......................10 CHEDULE ............11 EPLACING RANSMISSION LUTCH UBRICANT ......................13 HAIN ADJUSTMENT ..................13 RAKE AINTENANCE ....................14 ILTER...
  • Page 5 Parts – Frame - Exhaust, Radiator, & Engine Mounts ........32 Parts - Frame – Subframe, Shock, & Bodywork Mounts .........33 – F ....................34 ARTS RONT RAKES – F ....................35 ARTS RONT HEEL – P & S ................36 ARTS LASTIC ODYWORK –...

  • 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 14/39 T Chain 100 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III Quantity 235 ml (8.0oz)

  • Page 7: Optional Components

    Rear tire 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 • Carburetor jets • Sprockets...

  • Page 8: Specifications - Torque Values

    Specifications - Torque Values Torque Value Size & Fastener Remarks ft-lb in-lb Cylinder head ¼”-20 nuts Crankcase 6 x 1.0 bolts Spark plug (SP) (SP) (SP) 14 x 1.25 Stator bolts Stator cover bolts Clutch cover 6 mm bolts Clutch 10 x 1.25*** Front axle nut 12 x 1.25...

  • 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

    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

    Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number). The first two digits indicate the model and the seventh indicates the model year (MY).

  • Page 12: Replacing Transmission / Clutch Lubricant

    Grease the shaft. Replacing Transmission / Clutch Lubricant Tools needed: • 235 ml (8.0 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01), or Dexron III Automatic Transmission Fluid. • 13 mm combination wrench Procedure: 1.
  • Page 13 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, or Dexron III Automatic Transmission Fluid, thru the oil fill plug.

  • Page 14: Chain Adjustment

    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. At this point, there should be a minimum of 1” of slack. With rear wheel...

  • Page 15: Air Filter Cleaning

    Air Filter Cleaning Tools recommended for air filter maintenance: • Flat head screwdriver • Air filter oil • 5mm hex key • Foam filter oil Your Cobra comes with a pre-filter, or filter skin, to prevent the passing of water...

  • Page 16: Fork Oil Replacement

    (part # RCMU0206). When washing your bike cover the carburetor/filter with a suitable shield capable of keeping water from entering the engine. Cobra has a rubber clamp-on plug for the carburetor (part # RCMU0104). Fork Oil Replacement Tools required •...
  • Page 17 Assembly procedure 1. Fill the fork leg with 3.5 oz (105 ml) 10 wt fork oil. 2. Measure the fork oil level to the top of the fork tube with the leg collapsed, and record for tuning purposes. 3. Install the fork spring. 4.

  • Page 18: Parts

    Parts 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 THROTTLE COVER NOT SHOWN BCMU0209 ALLOY BRAKE LEVER W/BALL BAMU2002 BRAKE PERCH ASSY W/LEVER &...

  • Page 19: Parts - Carburetor

    Parts - Carburetor Carburetor REF. # PART # DESCRIPTION RCMU0305 CARB SLIDE RCMU0601 NEEDLE RCMU0002 ATOMIZER RCMU0095 MAIN JET RCMU0065 PILOT JET CHOKE JET RCMU0301 FLOAT RCMU0102 RUBBER CABLE CAP SEAL RCMU0003 CABLE ADJUSTER 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 FCMU0045 RADIATOR FCMU0047 RADIATOR CAP ECMU0024 RADIATOR HOSE LARGE, TOP, LEFT MCMUHO01 RADIATOR HOSE, SMALL, BOTTOM, RIGHT MCMUGR03 MOUNTING GROMMET (3 PER) FCMU0006 RADIATOR MOUNTING BRACKET (TEARDROP) HCBF0616 FLANGE HEAD BOLT M6X16 MCMUCL02...

  • 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 ECMU0020L BEARING, TRANSMISSION PRECISION ECKG0004 SNAP RING, WATER PUMP ZCKG2001 GASKET, CRANKCASE ECMU0106 SECONDARY SHAFT, TRANSMISSION WITH GEAR ECMU0017 SEAL, CRANKSHAFT ECMU0016...

  • Page 23: Parts - Engine - Clutch And Kick Starter

    Parts – Engine – Clutch and Kick Starter Figure 7B Engine – Clutch and Kick Starter REF # PART # DESCRIPTION ECMU0128 CLUTCH COVER WITH KICK SHAFT AND GEAR (NO LEVER) ZCMU0030 CLUTCH COVER GASKET ECMU0207 KICKSTART GEAR SMALL HCBC0608 M6X55 SHCS CLUTCH CVR SCREW LNG (2 REQD) CENTER HCBC606 M6X45 SHCS CLUTCH COVER SCREW SHORT (4 REQD)

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

    Parts – Engine – Ignition and Water Pump Figure 7C Engine – Ignition and Water Pump REF # PART # DESCRIPTION ECKG0001 IGNITION COVER ZCKG0101 IGNITION COVER GASKET HCBC0802 COVER SCREW, SHCS 802X1-3/4 ECKG0070 WATER PUMP BELT ECKG0075 WATER PUMP PULLEY, FAN TYPE - DRIVEN ECMU0080 BELT RETAINER HCBC1033...

  • Page 25: Parts - Engine - Top End

    Parts – Engine – Top Figure 7D Engine – Top End REF # PART # DESCRIPTION ECMU0052 CYLINDER ZCKG0002 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 ZCMUOR30 HEADER PIPE O-RINGS (2 REQD) XCMU0005 EXHAUST SPRING - SHORT MCMUGR06 PIPE GROMMET MALE MCMUGR07 PIPE GROMMET FEMALE MCMUSP02 PIPE GROMMET SPACER...

  • 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 REQD) HCBB0612 M6X12, BUTTON HEAD SCREW (4 REQD) FAKG0010...

  • Page 28: Parts - Forks - Leg Assembly

    Parts – Forks – Leg Assembly Figure 13 Fork Leg Assembly REF # PART # FORK DAMPER ASSEMBLY FORK SPRING STANDARD (12 LB/IN) KCKG1201 FORK SPRING OPTIONAL SOFTER (9 LB/IN) KCKG0009 FORK SPRING OPTIONAL STIFFER (15 LB/IN) SHOWN KCKG0015 FORK LEG INNER ASSEMBLY, BRAKE SIDE 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 KCKG0035...

  • 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 REQD) KCKGSH04 SHIM, 12 X .1 KCKGSH02...

  • Page 32: Parts - Frame - Brake Mounts, Plastic Shield & Footpegs

    Frame – Brake Mounts, Plastic Shield, & Footpegs REF # PART # DESCRIPTION FAKG0001 FRAME 2004 KING FAKG0009 SUB FRAME 2004 KING HCBF0620 M6x20 FLANGE HEAD CS (2 PER) BCDC0009 BRAKE PIVOT BOLT HCBH0601 M6 X 16 HEX HEAD BOLT...

  • Page 33: Parts - Frame - Exhaust, Radiator, & Engine Mounts

    Parts – Frame - Exhaust, Radiator, & Engine Mounts Figure 10 Frame – Pipe, Engine, and Radiator Mounts REF # PART # DESCRIPTION FAKG0001 FRAME 2004 KING FAKG0009 SUB FRAME 2004 KING MCMUGR06 PIPE GROMMET MALE MCMUGR07 PIPE GROMMET FEMALE MCMUSP02 PIPE GROMMET SPACER HCWF1478 PIPE GROMMET WASHER...

  • Page 34: Parts - Frame - Subframe, Shock, & Bodywork Mounts

    Frame & Subframe – Plastic and Shock Mounts REF # PART # DESCRIPTION FAKG0001 FRAME 2004 KING FAKG0009 SUB FRAME 2004 KING HCBB0802 8X20 BUTTON HEAD CAP SCREW (4 PER) HCNL0801 8MM LOCKNUT (4 PER) HCBH1001 M10X40 UPPER SHOCK MOUNT BOLT...

  • Page 35: Parts - Front Brakes

    Parts – Front Brakes Figure 18 Front Brakes REF # PART # DESCRIPTION BAMU2002 PERCH ASSEMBLY W/LEVER BCMU0209 ALLOY BRAKE LEVER BAKG0004 BRAKE HOSE WITH SHIELD BCMU0204 BRAKE CALIPER WITH PADS HCBB0612 M6X12 BUTTON HEAD BOLT (2 REQD) BCMU0206 BRAKE ROTOR W/BOLTS BCMU0207 BRAKE ROTOR MOUNTING BOLTS (6 REQD) BCMU0203...

  • Page 36: Parts - Front Wheel

    Parts – Front Wheel Figure 19 Front Wheel REF # PART # DESCRIPTION WAKG2003 FRONT WHEEL COMPLETE WCKG1200 12" FRONT TIRE WCKG1201 12" FRONT TUBE WCKG0011 FRONT AXLE WCMU0023 FRONT WHEEL SPACER, X LARGE WCMU0020 WHEEL BEARING (2 REQD) WCKG0010 WHEEL BEARING SPACER WCMU0001 FRONT WHEEL SPACER, LARGE...

  • Page 37: 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 HCBF0620 FRONT NUMBER PLATE MTG BOLT NOT SHOWN TCMU0006 FUEL TANK (NO PETCOCK OR CAP) HCBF0620...

  • Page 38: Parts - Rear Brake

    Parts – Rear Brake Figure 21 Rear Brake System REF # PART # DESCRIPTION BAKG0002 BRAKE KIT, MASTR CYLR, CALIPER, PADS AND HOSE NOT SHOWN BCKG0001 BRAKE PEDAL BCDC0009 BRAKE PIVOT BOLT HCBH0601 M6X16 HEX HEAD BOLT HCNS0601 6 MM NUT BCMUSP01 BRAKE RETURN SPRING BCDCBU01...

  • Page 39: Parts - Rear Wheel

    Parts – Rear Wheel Figure 22 Rear Wheel REF # PART # DESCRIPTION WAKG0009 REAR WHEEL COMPLETE WCMU0275 REAR TIRE, BRIDGESTONE MT320 2.75X10 WCMUTU10 TUBE, BRIDGESTONE 10" BCKG0011 BRAKE ROTOR HCBB0620 M6X20 BUTTON HEAD CAP SCREWS (5 REQD) PCMU0139 39T STEEL REAR SPROCKET PCMU0059 RUBBER DAMPERS WCMU0008...

  • Page 40: Parts - Shock

    Parts – Shock Figure 23 COBRA PART NUMBER DESCRIPTION SCKGOH01 SPRING CLIP SCKGOH02 SPACER SCKGOH03 BALL JOINT SCKGOH04 SPRING PLATFORM SCKGOH05 LOCKNUT SCKGOH06 SLEEVE SCKGOH07 BUMPER RUBBER SCKG0H08 SPRING - LIGHT SCKGOH09 SPRING-MEDIUM-STOCK SCKGOH10 SPRING-HEAVY SCKGOH11 ORING FOR BALL JOINT...

  • Page 41: Parts - Swingarm Assembly

    Parts – Swingarm Assembly Figure 24 Swingarm REF # PART # DESCRIPTION GAKG2004 SWINGARM ASSEMBLY COMPLETE HCBH1403 SWINGARM PIVOT BOLT HCNL1402 SWINGARM LOCK NUT (M14 X1) GCMU0001 SWINGARM BUSHING (4 PER) GCMU0005 TOP SWINGARM GUARD (CHAIN SLIDER) HCBF0840 FLANGE HEAD BOLT M8X40 HCWF5601 FLAT WASHER HCNL0801...

  • Page 42: 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 43: 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 44: 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 45: 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 46: Engine Assembly

    CAUTION: Take caution when handling t h e 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 47 Figure 25 Figure 26...
  • Page 48 9. Insert dowel pins in the left side case as shown in figure 27. Figure 8 10. Apply gasket sealer (ThreeBond 1104 gasket material or equivalent) to the mating surfaces of both crankcase halves. 11. Apply the crankcase gasket to the left crank case half being sure to install the gasket behind the connecting rod.
  • Page 49 16. Install the piston rings. CAUTION: Be sure to align the piston such that the arrow on the top piston surface points to the exhaust (front of bike/engine). 17. Apply gasket sealer (ThreeBond #1104, semi-drying liquid gasket material) to the cylinder deck areas around the coolant passage and cylinder studs as shown in figure 29.
  • Page 50 21. Install cylinder head insert. 22. Install O’rings as shown in figure 31. Figure 31 23. Install the cylinder head and torque to 9.2 ft-lb (12 Nm) 24. Install stator reinstalling the grommet and wires (snug the bolts). 25. Install the rotor per Rotor Installation section, under the S3: Ignition portion of this manual.

  • 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 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. You will probably have to heat the center hub again to remove the bolts. Once you get a bolt loosened, carefully remove it with the shoe and observe the way the spring washers are stacked.
  • Page 53 Clutch shoe wear: • 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 54 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 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 55: 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) or Dexron III ATF. Ignition Stator care Stator failure will result from running the bike hot.

  • Page 56: 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 57: Cooling System

    6. Set the dial indicator to zero 7. Turn the crankshaft clockwise until the dial indicator reaches 0.045” (1.14mm) from top dead center. 8. Line up the lines on the stator and the rotor (figure 37). Otherwise loosen the three 10X32 bolts to adjust the stator. 0.045”...
  • Page 58 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. Radiator fluid removal: 1. Remove the coolant drain plug (A) on the front of the engine case (figure 39).
  • Page 59 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. Remove ignition cover using a 9/64” hex key (four places) 9. Remove belt retainer screw using a 1/8” hex key. (Figure 41 - item 1) 10.
  • Page 60 Figure 43 14. Reinstall new bearings, seal and impeller. Clean all threads and use green (wicking / bearing retainer) thread locker. 15. Using a liberal amount of grease on the outside seal, bearings and inside of case, reinstall bearing assembly by using a 0.500” ID by 1.000” OD steel tube 2” long and tap on end of tube per figure 44.

  • Page 61: 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 62 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 63 have water or dirt in the carburetor bowl. Use automotive carburetor cleaner or WD-40 to clean the carburetor inside and out. STOCK CARBURETOR SETTINGS The 2003 KING stock carburetor settings from the factory are: • 65 pilot jet • 95 main jet Cleaning the carburetor: Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area;...

  • Page 64: 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 65: 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 66: Brakes

    CAUTION: This brake uses low viscosity mineral oil available from a Cobra Dealer. DO NOT USE DOT BRAKE FLUID!!! Brake Pad removal procedure:...
  • Page 67 1) Remove brake caliper using 4mm Allen wrench as shown Figure 50 2) Remove cotter key from caliper as shown and pull pads out. Figure 51...
  • Page 68 Brake pads must be checked periodically for wear. They are also available from a Cobra dealer. The brake pad must be a minimum thickness of 2.5mm. This is measuring the pad + the holder as shown below. Figure 52 Brake bleeding procedure: 1) Remove brake caliper using 4mm Allen wrench as shown in pad removal procedure.
  • Page 69 3. Remove bleed screw on caliper using a 3mm Allen wrench as shown. Figure 54 4) Attach Bleeding syringe as shown. Pump all air out of system until only clean oil runs out of reservoir. Figure 55 5) Reinstall reservoir cap. Oil will overflow in the process. This is necessary to ensure no air is in the system.

  • Page 70: 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 71 Front forks feel too stiff over small bumps. Fork oil weight If the forks feel too stiff over small bumps try decreasing the weight (increasing the viscosity) of the fork oil. Rear suspension troubleshooting. Damping Always start with standard settings and make damping changes in no more than two click increments and only make one change at a time.

  • Page 72: 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 15 Shock Damping Figure 16 Shock Length The shock on your Cobra Motorcycle has an adjustable (eye to eye) length.

  • Page 73: 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 74: Troubleshooting

    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. Troubleshooting 1) Engine operates erratically a) Carburetor top is installed backwards...
  • Page 75 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) Piston ii) Rings f) Reeds are damaged g) Ignition timing is incorrect h) Stator needs replaced 3) Engine is excessively loud...

  • Page 76: Index

    Engine won’t idle Idle knob needs adjusted b) Carburetor jets are dirty Index Front Brakes Air Filter..........14 Service ...........65 Front Wheel Parts ......35 Bars and Controls ......17 Fuel System Break-In..........8 Parts list .........60 Service ...........60 Carburetor Service ...........60 General Tips........9 Specifications ........5 Carbutetor Hardware...
  • Page 77 Forks..........26 Service ...........70 Frame ..........31 Spark Plug Front Brake........34 Recommended .......5 Front Wheel........35 Specifications ........5 Ignition & Water Pump....23 Torque Values.........7 Plastic & Seat........36 Starting ..........9 Rear Brake ........37 Stator Rear Wheel ........38 torque ..........7 Shock..........39 Suspension........70 Swingarm ........40 Swingarm Parts ........40 Top End .........24 Triple Clamps ........26 Tips ............9...

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