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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.
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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.
Table Of Contents General Information ....................3 Specifications - General ..................3 Specifications - Torque Values................4 Optional Suspension Components ..............5 Starting Procedure ....................8 General Tips......................9 Maintenance .......................10 Schedule & Tips ....................10 M1: Replacing Transmission Lubricant ............11 M2: Chain adjustment ..................12 M3: Air Filter Cleaning..................13 M4: Front end ....................14 Toe in adjustment ..................14 Steering .......................14...
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Parts - Engine - Ignition Side ...............24 Parts - Engine – Kick Mechanism ..............25 Parts – Engine – Shift Mechanism...............26 Parts – Engine – Top End................27 Parts - Engine - Transmission..............28 Parts – Exhaust System ..................29 Parts - Front A-Arms & Steering Upright ............30 Parts –...
Torque Value Size & CHASSIS Fastener Remarks ft-lb in-lb 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...
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(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...
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Change the transmission / clutch lubricant with Cobra Power Shift Transmission 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!
(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.
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 rear brake pedal while they...
The frame is a low carbon alloy tubing 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.
M1: Replacing Transmission Lubricant Tools needed: • 530 ml (18 oz) Cobra Power Shift Transmission Lubricant • large flat blade screwdriver • 13 mm wrench or socket Procedure: Begin this procedure with a bike that has been ridden more than 5 minutes but less than 10 minutes.
M2: Chain adjustment Tools needed: • 13 mm wrench or socket • 5mm pin (Screw driver or hex key will do) Procedure: Loosen the eccentric housing on the swingarm with two 13mm tools. Stick the 5mm pin through the sprocket into the eccentric hole. Push the quad forward or backward, turning the wheels (i.e.
M3: 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 • Foam filter oil Procedure 1. Removed the filter from the carburetor.
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.
Parts Parts – Air Inlet System Figure 4 Coolant System REF # PART # DESCRIPTION RCDC0001 AIR FILTER ASSEMBLY MCKGHO03 HOSE CLAMP – FILTER TO CARB RAEX0026 CARBURETOR 26MM MIKUNI VM MCMUCL10 HOSE CLAMP – CARB TO INLET BOOT (WIDE) ECEX0012 INLET BOOT MCMUCL03...
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...
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...
ROTOR ICMU0018 STATOR – 3 WIRE ECDC0024 SEAL, CRANKSHAFT ECDC0087 SHIFTER LEVER HCBH0620 M6 X 20 HEX HEAD BOLT ECKGSR03 SNAP RING-OUTPUT-COBRA PCKG00xx SPROCKET xx denotes number of teeth ECDC0009 SPACER,SPROCKET ECDC0025 SEAL,OUTPUT ECDC0026 SEAL,SHIFTER ICMUGR01 GROMMET-IGNITION EKEX0089 ENGINE CASE SET OF LEFT & RIGHT...
Parts – Engine – Top End Figure 16 Engine – Top End REF # PART # DESCRIPTION ECE80002 CYLINDER KIT (INCLUDES PISTON KIT) BASE GASKET 0.015” (0.4mm thick) For other Base Gaskets refer to ZCKG0501 Base Gasket Selection section of this manual ECE90002x PISTON KIT (xx denotes piston size, A, or AB, etc…) ECE90004...
Parts - Engine - Transmission Figure 17 Transmission REF # PART # DESCRIPTION ECEX0015 CRANKSHAFT, ‘09 EKEX0001 ROD KIT ACCESSORY ECDC0023 BEARING, CRANKSHAFT EKEX0089 ENGINE CASE SET OF LEFT & RIGHT EKEX0089 ENGINE CASE SET OF LEFT & RIGHT ZCEX0004 GASKET, CRANKCASE CENTER, ‘08 Left Case Screws HCBC0604...
Parts – Exhaust System Figure 18 Exhaust System REF # PART # DESCRIPTION XAEX2005 ECX70 EXHAUST PIPE ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D) XCMU0005 SPRING, EXHAUST – SHORT XCMU0030 COVER, EXHAUST SPRING NOT SHOWN PIPE GROMMET MALE (ONLY AVAILABLE IN MCMUGR02 MCMUGR02 GROMMET KIT) MCMUGR10...
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...
Parts – Front Brakes Figure 20 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...
Parts – Front Shock Figure 21 Front Shock REF # PART # DESCRIPTION SAEX2005 SHOCK ECX70 – FRONT (2 REQ’D) SCEX1080 SPRING, HELPER, 80 LB/IN (STANDARD) See Optional Components section of this manual for other springs SCEX1145 SHOCK SPRING, STANDARD (RED, 145 LB/IN) See Optional Components section of this manual for other springs SCSP0001 TRAVEL LIMITER (1.50”)
Parts – Miscellaneous If you couldn’t find it in one of the other pictures try the table below. PART # DESCRIPTION WCEX0005 REAR WHEEL WITH TIRE WCEX0004L LEFT FRONT WHEEL WITH TIRE WCEX0004R RIGHT FRONT WHEEL WITH TIRE FAEX2006 FRAME FCEX0002 CHAIN SLIDER SPLIT BUSHING HCBC1120...
Parts – Plastic Bodywork & Seat igure 22 Plastic and Bodywork REF # PART # DESCRIPTION TCEX0001Y FRONT CLIP - YELLOW 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)
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...
• 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.
• 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.
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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.
Upon completion, your final assembly squish clearance should agree with the chart below Fuel & Air System Reeds CAUTION: • The reeds must lay flat on the reed cage. • If the reed tips aren’t lying flat, replace them immediately. •...
Carburetor Cleaning Clean the carburetor in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the carburetor.
Tuning Carburetor Jetting Decisions 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.
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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 8 shows its range of adjustment and in particular what adjustable component affects what range of operation (specifically throttle position).
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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.
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...
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Index A-arms .......... 31 Parts ..........30 Air Filter ........16 Fenders .........35 Maintenance......14 Frame Parts ........34 Axle..........37 Front Brake ........32 Bars and Controls ......17 Fuel Base Gasket Selection....42 Petcock........9 Break-In .......... 8 Fuel System Bumper ......... 18 Parts list........44 Carburetion Service........44...
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Petcock ........... 9 Steering Stem .......17 Piston..........28 Steering Upright ......31 Plastic ........... 35 Swingarm Parts ......39 Radiator ........21 Throttle ..........16 Rear Brake Tie Rod..........40 Parts.......... 36 Tips ..........10 Rear Drive........37 Toe In Adjustment ......15 Rear Shock Top End Parts..........
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