Cobra Moto CX50 FWE Manual
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Cobra Moto CX50 FWE Manual

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Summary of Contents for Cobra Moto CX50 FWE

  • Page 1 Owners Parts Service Tuning...
  • Page 2 For parts orders, contact your local dealer. To locate your closest Cobra dealer, log on to www.cobramoto.com or call +1 (517) 437 - 9100 Cobra MOTO, LLC 240 Uran Road Hillsdale, MI 49242...
  • Page 3 DISCLAIMER OF WARRANTY This motorcycle is sold “as is” with all faults, obvious or not. There are no warranties expressed or implied, including any warranty of merchantability and warranty of fitness for any particular purpose. “WARNING” THE COBRA CX50FWE (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 ..................... 4 ........................4 PECIFICATIONS ENERAL ......................5 PTIONAL USPENSION OMPONENTS ......................6 PECIFICATIONS ORQUE ALUES ..........................8 REAK ROCEDURE ..........................9 TARTING ROCEDURE MAINTENANCE ........................10 ................................. 10 ............................... 11 CHEDULE ..................12 EPLACING RANSMISSION LUTCH UBRICANT...
  • Page 5 – R ..........................48 ARTS HEEL – S ............................49 ARTS HOCK – S .......................... 50 ARTS HOCK NSIDE – S ........................ 51 ARTS WINGARM SSEMBLY SERVICE ............................ 52 ............................52 NGINE ERVICE Base Gasket Selection ........................53 CFD Adjustment ..........................55 Engine Removal ..........................

  • Page 6: General Information

    General Information Specifications - General Items CX50 FWE Dimensions Wheelbase 41” (1041mm) Wheel size 10” (254mm) rear, 12” (305mm) front Seat height 26” (660mm) Engine Type 2-stroke, single cylinder, reed valve Cooling system Liquid-cooled Coolant Spectro Year-Round Super Coolant Displacement 49.8 cc...

  • Page 7: Optional Suspension Components

    Optional Suspension Components Weight of Rider (lb) Fork Spring Shock Spring Less than 50 lb 0.23 kg/mm green, 2.9 kg/mm KCCS3223 SCKGFX29 50-60 0.25 kg/mm black, 3.1 kg/mm KCCS3223 SCKGFX31 60-75 0.25 kg/mm red, 3.3 kg/mm KCCS3225 SCKGFX33 Greater than 80 0.27 kg/mm gray, 3.5 kg/mm KCCS3227...

  • Page 8: Specifications - Torque Values

    Specifications - Torque Values Torque Value Size & Fastener Loctite Remarks ft-lb in-lb Cylinder head nuts M6 x 1.0 Cylinder nuts M8 x 1.25** Crankcase bolts See the next page M6 x 1.0 Spark plug (SP) (SP) (SP) M14 x 1.25 Stator bolts M5 X 0.8 Ignition rotor nut...
  • Page 9 Proper case bolt torque values Torque the engine case bolts in the pattern shown above. The upper two bolts have a different toque value compared to the others. Proper torquing procedure would have you lubricating the threads with 30W oil, torquing the bolts all first to an intermediate torque value of 10-12 Nm and then once they are all at that value, proceed back at bolt #1 and toque each bolt further up to the final value.

  • Page 10: Break-In Procedure

    Break-In Procedure Your Cobra CX50 FWE King is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The CX50 can be ridden hard after the first ½ hour break-in time. Cobra recommends Spectro Platinum SX premix oil with high octane pump gas mixed at 32:1 (4 oz oil to a gallon of gas).

  • Page 11: Starting Procedure

    Starting Procedure Before starting the machine inspect the following:  Tire pressure  Chain tension  Coolant level  Proper wear on chain rollers and sliders  Handlebar tightness  Throttle assembly movement/cable adjustment  Air Filter  Check for loose nuts and bolts ...

  • Page 12: Maintenance

    Maintenance A properly maintained machine is safer, faster, and more fun to ride. It is important that you adhere to this maintenance schedule so as to promote the longevity of your Cobra Motorcycle. Tips Recommended lubricants: a. Cobra Clutch Milk is by far the best auto clutch lubricant. It is a full synthetic lubricant that has been specifically formulated for Cobra’s auto clutch and has;...

  • Page 13: Schedule

    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. 10.

  • Page 14: Replacing Transmission / Clutch Lubricant

    Replacing Transmission / Clutch Lubricant Tools needed:  5mm allen wrench  Minimum of 300 cc (10 oz) Cobra Venom 3 Shoe Clutch Milk (Part #MCMUGF32). Procedure: 1. Begin this procedure with a bike that has been ridden more than 5 minutes but less than 10 minutes.

  • Page 15: Proper Chain Adjustment

    Proper Chain adjustment Tools required for chain adjustment  19 mm wrench or socket  13 mm wrench or socket 1. Make sure that the rear wheel is aligned properly. For proper adjustment, the chain should have 35mm (1.378”) free movement just behind the chain guard with no load on the bike (figure 2) Figure 2 CAUTION:...

  • Page 16: Rear Brake Maintenance

    Rear Brake Maintenance CAUTION: Too little brake pedal free-play will allow the brake pads to drag causing the pads to wear prematurely and possible engine component failures. Too much free-play will not allow the rider to apply the brakes quickly. 1.
  • Page 17 Air Filter Cleaning Removal:  Remove the seat  Loosen the clamp connecting the rubber boot of the filter to the carborator  Push the rubber boot from the bottom up and out of the airbox CAUTION: Pulling on the filter instead of pushing up on the boot may cause tearing of the filter.

  • Page 18: Fork Maintenance

    Assembly: 1. Place the filter back onto the rubber boot. 2. With one hand on the filter, feed the rubber boot into the airbox CAUTION: In order to avoid air filter tearing, make sure to place a hand on the filter while feeding the boot through the airbox.

  • Page 19: Fork Oil Replacement

    Fork Oil Replacement Tools required  32mm Fork Cap Tool (MCMUTL32)  8mm Allen wrench  4 & 5 mm hex key (Allen wrench)  9/16 wrench  Mallet  5 wt. Spectro fork oil Disassembly procedure 1. Remove the front wheel and axle (8mm Allen wrench). 2.

  • Page 20: Frictional Drive (V3 Cfd)

    10. Pump the fork leg several times to verify that it operates smoothly. 11. Reinstall the brake caliper. 12. Reinstall the front wheel (25 ft-lb, 34 Nm). Frictional Drive (V3 CFD) The Cobra Frictional Drive (CFD) is essentially an adjustable slip clutch that dissipates torque spikes transmitted from the rear wheel to the rest of the drive line and engine.
  • Page 21 NOTE: The CFD hubs can be removed with the universal puller (MCMUTL70). If it slips below the value, the CFD must be readjusted as per described in the service section of this manual. NOTE: If the bike makes a whir, whir, whir, sound coming from the clutch side engine cover it is very probable that the CFD has slipped enough that the brass bushing has worn sufficiently to let the gear operate off center.

  • Page 22: Parts - Airbox & Inlet System

    Parts – Airbox & Inlet System Air Box REF # PART # DESCRIPTION RACS0019 CARBURETOR – 19MM W/ DEEP WELL RCCS0008 AIRBOX - 2021 HCSP0004 SCREW – PLASCREW - ALUMINUM RCCS0009 AIR FILTER ASSY - 2021 TCC60008 MUDFLAP MCKGHO01 HOSE CLAMP – BOOT TO CARB MCKGHO04 HOSE CLAMP –...

  • Page 23: Parts - Bars And Controls

    Parts – Bars and Controls Bars and Controls REF # PART # DESCRIPTION FAMU0014 HANDLEBAS – PRO TAPER MICROBARS – COBRA BEND TCMU0021 GRIPS (SET OF TWO) – MICROGRIPS – RED / GRAY FAMU0016 THROTTLE ASSEMBLY – PRO TAPER COBRA FAMU0015 TUBE ASSEMBLY –...

  • Page 24: Parts - Carburetor

    Parts – Carburetor Carburetor REF. # PART # DESCRIPTION RACS0019 CARBURETOR RCMU0307 GASKET – CARB TOP RCMU0003 CABLE ADJUSTOR RCMU0046 TOP CARB THREAD ON RCMU0102 RUBBER CABLE CAP SEAL RCMU0004L SLIDE SPRING - LIGHT RCMU0028 NEEDLE RETAINER PLATE RCMU0007 NEEDLE CLIP RCMU0340 SLIDE - #40 BIG AIR RCMU0601...

  • Page 25: Parts - Coolant System

    Parts – Coolant System Coolant System REF # PART # DESCRIPTION FCMU0081 RADIATOR – (2 REQ’D) FCMU0069 LOUVER (2 REQ’D) MCMUGR12 GROMMET – RADIATOR MOUNTING (4 REQ’D) HCSP0610 FASTENER – RADIATOR MOUNTING (4 REQ’D) FCMU0020 CAP, 1.3 BAR FCKG0214 RADIATOR OVERFLOW HOSE, 22” FCMU0322 HOSE –...

  • Page 26: Parts - Electrical System

    Parts – Electrical System Electrical System REF # PART # DESCRIPTION ICMU0044 COIL/CDI W/SPARK PLUG CAP ECMU0010I SPARK PLUG, AUTOLITE IRIDIUM FCMU0171 KILL SWITCH ASSEMBLY HCBC0514 M5X14mm SOCKET HEAD CAP SCREW (2 REQ’D) HCWF0501 5mm FLAT WASHER (2 REQ’D) ICMU0023 STATOR WITH GROMMET HCBC0535 M5X35mm SOCKET HEAD CAP SCREW (2 REQ’D)
  • Page 27 This Page Left Blank Intentionally...

  • Page 28: Parts - Engine - Bottom End And Transmission

    Parts – Engine – Bottom End and Transmission...
  • Page 29 Engine Bottom End and Transmission PART # DESCRIPTION EKMU0016 CRANKCASE SET WITH BEARINGS, SEALS & GASKET ZCMU0015 GASKET, CRANKCASE CENTER HCBC0665 M6X65mm SOCKET HEAD CAP SCREW (1 REQ’D) HCBC0604 M6X35mm SOCKET HEAD CAP SCREW (12 REQ’D) ECMU0258 CRANKSHAFT - 3 SIDE SPLINE & INTERNAL W/P ECMU0016 BEARING, CRANKSHAFT (2 REQ’D) ECMU0118...

  • Page 30: Parts - Engine Clutch And Kick Lever

    Parts – Engine Clutch and Kick Lever...
  • Page 31 Engine – Clutch and Kick Starter REF # PART # DESCRIPTION CAFW0500 CLUTCH COMPLETE ASSY - 5GX CAFW0050 3 SHOES & WASHER STACKS W BOLTS - 5GX CCMU0005 CLUTCH ARBOR – 3 SIDED SPLINE CAFW0005 WASHER STACKS - SET OF 3 - CLUTCH - 5GX HCBT0001 BOLT - TORX - 5GX CLUTCH - M6 X 29 CCMU0008...

  • Page 32: Parts - Engine - Water Pump

    Parts – Engine – Water Pump Engine – Ignition and Water Pump REF # PART # DESCRIPTION EKMU0021 WATER PUMP KIT ECMU0265 SHAFT, WATER PUMP ECKG0072 BEARING, WATER PUMP ECKG0074 SEAL, WATER PUMP SHAFT ECKG0073 IMPELLER, WATER PUMP (ALUMINUM) HCBB0512 M5X12mm BUTTON HEAD ECMU0167 BEARING –...

  • Page 33: Parts - Engine - Top End

    Parts – Engine – Top End Engine – Top End REF # PART # DESCRIPTION EKMU0661 CYLINDER KIT - FWE (INCLUDES STUDS, PISTON, RINGS, PIN & CLIPS) ZCMU0102 BASE GASKET (0.20mm) THICK ZCMU0103 BASE GASKET (0.30mm) THICK ZCMU0104 BASE GASKET (0.40mm) THICK ZCMU0105 BASE GASKET (0.50mm) THICK ZCMU0106...
  • Page 34 Parts – Exhaust System Exhaust System REF # PART # DESCRIPTION XACS2021 EXHAUST PIPE ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D) XCMU0005 SPRING – EXHAUST (2 REQ’D) XCMU0033 ISOLATION MOUNT HCBF0616 M6X16mm FLANGE HEAD BOLT (2 REQ’D) HCHA0003 6mm CLIP NUT – FOR FRONT PIPE MOUNT XACS0001 SILENCER –...
  • Page 35 This Page Left Blank Intentionally...

  • Page 36: Parts - Forks & Triple Clamps

    Parts – Forks & Triple Clamps...
  • Page 37 Front Forks and Triple Clamp REF # PART # DESCRIPTION KACS2021FWE FORK COMPLETE, BRAKE & NON-BRAKE SIDE KCMU0037FLL FORK GUARD SET – 2021 HCSP0610BLK BOLT - FORK GUARD - BLACK (6 REQ’D) KCMU0036 BRAKELINE CLAMP HCSP0004 PLASTIC SCREW (2 REQ’D) FACS0009BLK TRIPLE CLAMP BOTTOM ASSY, (CLAMP &...

  • Page 38: Parts - Forks - Leg Assembly - Brake Side

    Parts – Forks – Leg Assembly – Brake Side...
  • Page 39 Parts – Forks – Leg Assembly – Brake Side REF # PART # DESCRIPTION HCBC0408 4 X 8 SHCS CLEAR ZINC ZCKG0001 GASKET, BLEED SCREW FORK KCCS0004C FORK CAP - CONVENTIONAL 32MM USD ZCMUOR18 O-RING – 3MM X 27MM ID KCCS0036 SPRING WEAR PLATE 32MM KCCS0005...

  • Page 40: Parts - Forks - Leg Assembly - Non-Brake Side

    Parts - Forks – Leg Assembly – Non-brake Side...
  • Page 41 Parts - Forks – Leg Assembly – Non-brake Side REF # PART # DESCRIPTION HCBC0408 4 X 8 SHCS CLEAR ZINC ZCKG0001 GASKET, BLEED SCREW FORK KCCS0004S FORK CAP - CONVENTIONAL 32MM USD ZCMUOR18 O-RING – 3MM X 27MM ID KCCS0036 FORK - SPRING WEAR PLATE 32MM KCCS0005...

  • Page 42: Parts - Framei

    Parts – Frame I Frame REF # PART # DESCRIPTION FACS2021 FRAME – 2021 KING & FWE HCHA0003 6mm CLIP NUT (MOUNTS TO FENDER TO HOLD SEAT) MCMUGR12 GROMMET, RADIATOR MOUNTING (4 REQ’D) GCMU0021 BOLT - TI - SWINGARM PIVOT and AXLE - CX50 HCNL1201 M12 SWINGARM LOCK NUT HCBH0880...

  • Page 43: Parts - Frame Ii

    Parts – Frame II Frame REF # PART # DESCRIPTION FACS0010 SUBFRAME 2021 HCBC0603 M6X30mm SOCKET HEAD CAP SCREW FT TANK MOUNTING HCBC0520 M5X20mm SOCKET HEAD CAP SCREW (2 REQ’D) HCCN0001 5mm CLIP NUT HCBC0516 M5X16mm SHCS TCC60017 WASHER - BODY PANEL FLAT (2 REQ’D) MCMUGR03 MOUNTING GROMMET (2 REQ’D) XCMU0051...

  • Page 44: Parts - Front Brakes

    Parts – Front Brakes Front Brakes REF# PART # DESCRIPTION BACS0001 BRAKE ASSY - FRONT CARD - KING FW - 2 PISTON 9.5 BCCS0003 HOSE – BRAKE FRONT BAMU0009 LEVER ASSEMBLY BAMU0006 MASTER CYLINDER ASSEMBLY COMPLETE W LEVER BAMU0020 CALIPER – FRONT – CARD 2 PISTON BKMU0009 KIT 505 ORGANIC BRAKE PADS, WITH BOLT AND CLIP BCMU0222...

  • Page 45: Parts - Front Wheel

    Parts – Front Wheel Front Wheel REF # PART # DESCRIPTION WACSF021BLK WHEEL WITH BEARINGS SPOKE STYLE – BLACK ANODIZE WCMU0043 FRONT AXLE - HOLLOW HCSP1016BLK BOLT – ALUMINUM AXLE PULL – BLACK ANODIZE WCMU0024 PLUG - BLACK PLASTIC HCBC0514 M5X14mm SOCKET HEAD CAP SCREW (5 REQ’D) BCMU0222 BRAKE ROTOR –...

  • Page 46: Parts - Plastic Bodywork & Seat

    Parts – Plastic Bodywork & Seat...
  • Page 47 REAR FENDER x – DENOTES COLOR BLK, WHT, YEL, FLO HCSP0610BLK BOLT – SPECIAL HCHA0003 CLIP NUT – 6mm ACCESSORY TCFW2021 GRAPHIC KIT – CX50 FWE ACCESSORY TKFW2021 BODYWORK KIT – FWE – MEGA FLO PLASTIC ACCESSORY TKFW2021BLK BODYWWORK KIT – FEW – MEGA FLO PLASTIC BLACK...

  • Page 48: Parts - Rear Brake

    Parts – Rear Brake...
  • Page 49 Parts – Rear Brake Rear Brake System REF # PART # DESCRIPTION BAMU0003 BRAKE SYSTEM – REAR (M/C-LINE-CALIPER) BCMU0027 BRAKE PIVOT BOLT BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D) BCMU0062 BRAKE PEDAL – ASSEMBLY 50cc – WITH TOE PIECE BCMU0023T TOE PIECE HCBC0501 M5X 12mm SOCKET HEAD CAP SCREW...

  • Page 50: Parts - Rear Wheel

    Parts – Rear Wheel Rear Wheel REF # PART # DESCRIPTION WAMUR021BLK REAR WHEEL W/BEARINGS – BLACK WCMU1075D32 TIRE - REAR - 70/100-10 - DUNLOP MX3S WCMUTU10 TUBE, 10" PCMU0001 MASTER LINK 420 PCMU0102 CHAIN 420 X 102 PCC50238BLK 38T SPROCKET (STANDARD) 415 PCC502xx SPROCKET xx DENOTES TEETH –...

  • Page 51: Parts - Shock

    Parts – Shock Shock REF # PART # DESCRIPTION SACS2021 SHOCK ABSORBER – KING SCMU0043 SHOCK - BEARING SPHERICAL SHOCK MOUNT–CARD (2 REQ’D) SCMU0039 O-RING - SHOCK - BUSHING – CARD (4 REQ’D) SCMU0042 SHOCK - MOUNT BUSHING – CARD (4 REQ’D) SCMU0058 SHOCK - WHITE NYLON TIP SETSCREW M6-1.0 - CARD SCMU0056...

  • Page 52: Parts - Shock - Inside

    Parts – Shock - Inside Shock REF # PART # DESCRIPTION SAMU0001 COMPRESSION ADJUSTER ASSEMBLY – COMPLETE ZCMUB020 O-RING – COMPRESSION ADJUSTER - OUTSIDE KCMU0021 O-RING - COMPRESSION ADJUSTER – PISTON SEAL ZCMUOR37 O-RING - COMPRESSION ADJUSTER - INSIDE SCMU0051 O-RING - IFP SCMU0052 IFP SEAL BAND...

  • Page 53: Parts - Swingarm Assembly

    Parts – Swingarm Assembly Swingarm REF # PART # DESCRIPTION GACS2021 SWINGARM GCMU0021 BOLT - TI - SWINGARM PIVOT and AXLE - CX50- shorter HCNL1201 M12 SWINGARM LOCK NUT GCMU0001 SWINGARM BUSHING (4 REQ’D) PAFW0001 CHAIN GUIDE ASSEMBLY COMPLETE – FACTORY WORKS EDITION HCBFT640 M6X40mm FLAT HEAD SCREW (2 REQ’D) HCNL0601...

  • Page 54: Service

    Service Trained technicians with precision gauging and proper assembly fixtures carefully assemble all Cobra engines to specific tolerances. If you feel you have the skills, and the appropriate tools, to perform the following service tasks please follow the instructions closely. The part numbers are listed throughout to help you when ordering parts from your local Cobra dealer.

  • Page 55: Base Gasket Selection

    Base Gasket Selection Tools required  17mm wrench  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 56  Carefully insert the solder wire though the spark plug hole, into the cylinder far enough such that the tip of the wire touches the left or right side cylinder wall (not the front or back as the piston will rock more and give incorrect measurement). ...

  • Page 57: Cfd Adjustment

    CFD Adjustment This section tells you what to do if you have tested and determined that the CFD requires adjustment. Tools required  5mm & 10mm hex key  Pliers to remove the old cotter key  A new cotter key (Cobra MIL spec recommended – Hardware store ones will become brittle from the hot oil and randomly fail) ...

  • Page 58: Complete Engine Disassembly Procedure

    Procedure 1. Remove the seat. 2. Turn of the fuel at the petcock and disconnect the fuel line. 3. Remove the tank (8 mm socket). 4. Remove the carburetor from the inlet (flat head or Phillips head screwdriver, 7 mm nut driver).

  • Page 59: 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 60: 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. Do not try to true the crank yourself.

  • Page 61: Clutch

    CAUTION: Never force the cylinder. If resistance is felt, determine the problem and solve it. Once installed slightly rotate the cylinder back and forth insuring that the rings are properly seated. 16. Install cylinder head insert. NOTE: A light application of silicone grease can help hold the O-rings into position during assembly.
  • Page 62 Tools recommended for clutch service:  Universal clutch puller- a universal puller that pulls the clutch, main drive gear and rotor. (Part # MCMUTL70).  5mm T-handle  T25 Torx  Accurate torque wrench in the range of 16 Nm (12 ft-lb, 144 in-lb). ...
  • Page 63 5GX CLUTCH ASSEMBLY REFERENCE DRAWING REF # PART # DESCRIPTION CAFW0050 Set of three shoes, springs, bolts, flat washers & nuts CAFW0005 Set Of three springs, washers, bolts & nuts CAFW0500 Complete assembled clutch Not Shown (Arbor, shoes and washer stacks) Clutch shoe wear: ...

  • Page 64: Clutch Assembly

    CLUTCH ASSEMBLY: 1. Start with a new set of pre-assembled washer stacks and bolts. CAUTION: It is also important that all three shoes are stacked the same. (See figure 32) 2. Clean the threads of the stack bolt and the clutch with brake cleaner removing all old thread locking material.

  • Page 65: Ignition

    Ignition Stator care Stator failure could result from running the bike hot. Following is a list of things that will make your engine run hot. 1. The timing should not exceed the maximum specifications listed. 2. Improper carburetor jetting. 3. Improper spark plug heat range. Never run a hotter plug than the specified spark plug. 4.

  • Page 66: Cooling System

    ROTOR INSTALLATION: 1. Torque the nut on the rotor to 30 ft-lb (45 Nm) with medium strength (blue) thread locking agent. 2. Recheck the timing following the procedure of timing your ignition. 3. Install the water pump belt back on. 4.

  • Page 67: Fuel & Air System

    6. Remove bearing retainer screw using a 3mm hex key. 7. Thread a slide hammer onto the end of the water pump shaft and remove the assembly. 8. Clean any debris or particles from the bore and use some light emery cloth to remove any scratches in the surface that the removal process may have created.
  • Page 68 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. IDLE ADJUSTMENT: On the left side of the carburetor, there are two adjustment screws.

  • Page 69: Reeds

    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; 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.

  • Page 70: Rear Wheel Pullers

    Rear wheel pullers 1. Remove axle, and back wheel assembly. 2. Pull the rear wheel pullers out of the back of the swing arm. Rear wheel alignment: By eye, ensure that the rear sprocket is running true (in-line, planar) with the front sprocket. When the sprockets are running true, the wheel is properly straightened, and the chain will run straight.

  • Page 71: Rear Shock

    Rear Shock The rear shock is fully serviceable but it is recommended that only trained professionals should service your shock. Contact Cobra for questions and service of your CX50 SR shock. Tuning Clutch There are performance characteristics to observe and things to measure. 1) Performance characteristics to observe a) Clutch coming in too late i) Engine rev’s to a high RPM before moving the motorcycle...
  • Page 72 If a clutch comes in too late, it means that clutch spring stack is providing too much force to keep the shoes from being thrown out to the clutch basket at the proper time with the given shoes, basket, arbor, and bolt. This can be due to: 1.

  • Page 73: Gearing

    Typically, the springs will sack at a quicker rate than the shoes will wear, meaning that an un- tampered clutch that worked fine will ultimately hit too early at some time. When this occurs, it is easily remedied with a new spring stack or a thicker flat shim. Because the shoes have worn, a thinner flat washer may be needed with the fresh new springs to allow proper clutch engagement.
  • Page 74 Front Sprocket Rear Ratio 1.94 2.00 2.06 2.07 2.13 2.13 2.19 2.20 2.21 2.25 2.27 2.29 2.31 2.33 2.36 2.38 2.40 2.43 2.44 2.47 2.50 2.50 2.53 2.57 2.60 2.64 2.67 2.69 2.71 2.77 2.79 2.85 2.86 2.92 3.00 3.08...

  • Page 75: Front Fork Operation

    Front Fork Operation The front suspension on the CX50SR works under the principals of hydraulic damping, and it features full adjustability to help tune the fork to meet each rider’s needs. The CARD fork contains MXT ‘Smart Leg’ technology that provides very progressive operation; allowing a small bike to perform well on track surfaces ripped up by larger machines.

  • Page 76: Rear Shock Adjustments

    At the base of the conventional leg is another adjustment screw that controls the amount of compression damping. Turning this screw clockwise increases damping and turning it counter- clockwise will decrease it. This is illustrated by the “HARD” and “SOFT” in the figure at the right. The Smart Leg cap is labeled “Speed Sensitive Bottoming Control”, and this adjuster provides a range of control over how progressive the fork feels.

  • Page 77: Carburetion

    Shock preload Loosen the set screw and turn the spring perch in full turn increments to get the desired sag settings. NOTE: Always leave the spring perch rotated in such position so that the set screw is easily accessible. Shock Damping The Low Speed “L”...
  • Page 78 o Misfire at low engine speeds o Excessive smoke o Spark plug fouling o Wet, black, or overly dark spark plug (when removed for inspection)  Symptoms of too lean a fuel mixture o Pinging or rattling o Erratic acceleration o Same actions as running out of fuel o High engine temperature o White spark plug (when removed for inspection)
  • Page 79 Figure 49 NOTE: If the fuel screw requires more than 3 turns out, replace the pilot jet for one that is one size richer (larger number) then readjust the fuel screw. IDLE ADJUSTMENT: Adjust for desired idle speed The idle speed screw is located on the left side of the carburetor. It is the larger of the two screws on the side of the carburetor and is unique with its knurled head for easy fingertip adjustment.

  • Page 80: Troubleshooting

    Troubleshooting 1) Engine operates erratically a) The carburetor slide indexing pin is missing b) A carburetor vent elbow is plugged or has fallen out c) Faulty stator d) An air leak i) Base gasket ii) Intake / reed gaskets iii) Crank seals iv) Crank case gasket 2) Engine is down on power a) Clutch engagement is not set properly...
  • Page 81 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/ coil 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...

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