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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 CX50P3 IS A COMPETITION MODEL ONLY AND IS NOT
MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS
OR HIGHWAYS.
THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN
SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE BY A
SUFFICIENTLY SKILLED RIDER AND SHOULD NOT BE USED FOR GENERAL
OFF-ROAD RECREATIONAL RIDING.
IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH.
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.
THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 80 LBS WITH
FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH
MORE.
BE SURE THAT THE RIDER ALWAYS WEARS ADEQUATE SAFETY GEAR
EVERYTIME HE OR SHE RIDES THEIR COBRA MOTORCYCLE.
IMPORTANT SAFETY NOTICE
Failure to follow WARNING instructions could result in severe injury or death to
the machine operator, a bystander, or a person inspecting or repairing the
machine.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to
the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.
MCCL2017.0
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Table of Contents
Related Manuals for Cobra CX50P3
Summary of Contents for Cobra CX50P3
- Page 1 WARNING THE COBRA CX50P3 IS A COMPETITION MODEL ONLY AND IS NOT MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS OR HIGHWAYS.
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Page 2: Table Of Contents
Air Filter Cleaning ......................13 Fork Maintenance ....................... 14 Fork Air Bleeding ..................... 15 Fork Oil Replacement ..................... 15 Cobra Frictional Drive (V3 CFD) ................. 16 Parts ..........................18 Parts – Airbox and Inlet System .................. 18 Parts – Bars and Controls ................... 19 Parts - Carburetor ....................... - Page 3 Parts – Rear Brake ...................... 41 Parts – Rear Wheel ..................... 42 Parts – Shock ......................43 Parts – Shock - Internal ....................44 Parts – Swingarm Assembly ..................45 Service ..........................46 Engine Service ......................46 Base Gasket Selection .................... 47 CFD Adjustment ......................
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Page 4: General Information
Transmission Speed / Clutch Single / Cobra 3 shoe Final drive ratio 14/37 T Chain Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk Quantity 300 ml (10oz) Chassis Front tire 2.75 (80/100) – 10" Pressure 15 psi minimum Rear tire 2.75 (80/100) –... -
Page 5: Optional Suspension Components
Optional Suspension Components Weight of Rider (lb) Fork Spring Shock Spring KCCJ3218 Less than 38 (light) SCMUOH04 (275 lb/in) red (18 lb/in, 3.15 N/mm) KCCJ3221 SCMUOH05 (285 lb/in) 38 – 45 (std) (21 lb/in, 3.70 N/mm) yellow KCCJ3225 SCMUOH06 (295 lb/in) 46 to 55 (stiff) (25 lb/in, 4.40 N/mm) white... -
Page 6: Break-In Procedure
Break-In Procedure Your Cobra CX50 P3 is a close-tolerance high performance machine and break- in time is very important for maximum life and performance. The CX50 P3 can be ridden hard after the first ½ hour break-in time. Cobra recommends Bel-Ray H1-R premix oil with high octane pump gas mixed at 40:1 (150 ml oil to 2 gallons of gas). -
Page 7: Starting Procedure
Fenders can be replaced but bruised egos and other body parts take longer. 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. -
Page 8: Maintenance
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; Exceptional film strength over petroleum based oils or synthetic blends. -
Page 9: 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. -
Page 10: Replacing Transmission / Clutch Lubricant
Figure 1 3. After it has drained, reinstall the plug, being sure that the gasket is in place. 4. Reapply oil from oil fill plug 300 cc (10 oz) Cobra Venom 3 Shoe Clutch Milk thru the oil fill plug. -
Page 11: Proper Chain Adjustment
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. Cobra’s specially developed Cobra Venom 3 Shoe Clutch Milk (Part #MCMUGF32) was formulated to provide superior lubrication and cooling capability over extended periods of time and is the recommended lubricant for your Cobra motorcycle. -
Page 12: Brake Bleeding Procedure
(plunger) adding free play to the system. Brake Bleeding Procedure Tools Required: Front: T10 Torx bit/driver, Cobra bleed kit (BCKG0031) Rear: 3mm hex key (Allen wrench, T10 Torx bit/driver, Cobra bleed kit(BCKG0031) Procedure: Remove the brake fluid reservoir cover. -
Page 13: Air Filter Cleaning
Fill the syringe half full with brake fluid. Remove the brake caliper bleed screw. Attach the syringe to the brake caliper bleed access. Keep the syringe oriented as not to allow air from the syringe into the system. ... -
Page 14: Fork Maintenance
6. Allow it to dry thoroughly. 7. Saturate with filter oil and remove excess. 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. -
Page 15: Fork Air Bleeding
Each Ride 10 hours 20 hours As Needed Bleed excess air Change Oil Change Seal/Swiper Change Bushings Fork Air Bleeding Tools required 3mm hex key (Allen wrench) During normal operation, both fork legs will build up air pressure. This pressure acts as an additional spring so it must be bled on a regular basis to maintain consistent suspension operation. -
Page 16: Cobra Frictional Drive (V3 Cfd)
12. Reinstall the front wheel (25 ft-lb, 34 Nm). Cobra 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 17 CAUTION It may be necessary to remove the ECKGSR03 sprocket clip, or the sprocket entirely, to ensure good engagement between the tool and the shaft 4. Verify with a torque wrench applied to the Sprocket Socket that the V3 CFD does not slip below 108 Nm (80 ft-lb) in either direction.
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Page 18: Parts
Parts Parts – Airbox and Inlet System Airbox and Inlet System REF # PART # DESCRIPTION ZCCS0001 GASKET – REED TO CYLINDER ECMU0246 REED CAGE ASSEMBLY WITH REEDS VFORCE RCCS0002 INLET MANIFOLD HCWF0601 6mm FLAT WASHER HCBC0603 M6X30mm SOCKET HEAD CAP SCREW MCKGHO04 HOSE CLAMP –... -
Page 19: Parts - Bars And Controls
Parts – Bars and Controls Bars and Controls REF # PART # DESCRIPTION FAMU0017 HANDLEBAS – PRO TAPER MICROBARS – COBRA JR/P3 TCMU0021 GRIPS (SET OF TWO) – MICROGRIPS – RED / GRAY FEW FAMU0016 THROTTLE ASSEMBLY – PRO TAPER COBRA FAMU0015 TUBE ASSEMBLY –... -
Page 20: Parts - Carburetor
Parts - Carburetor Carburetor REF. # PART # DESCRIPTION RACP0012 CARBURETOR RCMU0003 CABLE ADJUSTOR RCCM0312 RESTRICTOR - 12MM CARB RCMU0046 TOP CARB THREAD ON RCMU0102 RUBBER CABLE CAP SEAL RCMU0004L SLIDE SPRING - LIGHT RCMU0028 NEEDLE RETAINER PLATE RCMU0007 NEEDLE CLIP RCMU0305 SLIDE - #40 RCMU0601... -
Page 21: Parts - Coolant System
Parts – Coolant System Coolant System REF # PART # DESCRIPTION FACJ0005 RADIATOR WITH CAP FCCJ0028 HOSE – RADIATOR LEFT- VENOM MCMUCL07 HOSE CLAMP EACJ0001 MOUNTING BRACKET – RADIATOR BOTTOM HCBC0608 M6X55mm SOCKET HEAD CAP SCREW HCNL0601 M6 LOCK NUT MCKGGR00 GROMMET –... -
Page 22: Parts - Electrical System
Parts – Electrical System Electrical System REF # PART # DESCRIPTION ICCJ0001 COIL/CDI W/SPARK PLUG CAP – JR/P3 ECMU0010C SPARK PLUG, AUTOLITE COPPER ECMU0010I SPARK PLUG, AUTOLITE IRIDIUM FCMU0033 KILL SWITCH ASSEMBLY HCBC0514 M5X14mm SOCKET HEAD CAP SCREW (2 REQ’D) HCWP0002 5mm WASHER POP RIVET (2 REQ’D) HCCN0000... - Page 23 This Page Intentionally Left Blank...
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Page 24: Parts - Engine - Bottom End And Transmission
Parts – Engine – Bottom End and Transmission... - Page 25 Engine Bottom End and Transmission REF # 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 ECMU0118...
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Page 26: Parts - Engine Clutch And Kick Lever
Parts – Engine Clutch and Kick Lever... - Page 27 Engine – Clutch and Kick Starter REF # PART # DESCRIPTION CAMU0002 CLUTCH COMPLETE ASSY - 5GX CAMU0009 3 SHOES & WASHER STACKS W BOLTS - 5GX CCMU0005 CLUTCH ARBOR – 3 SIDED SPLINE CAMU0014 WASHER STACKS - SET OF 3 - CLUTCH - 5GX HCBT0001 BOLT - TORX - 5GX CLUTCH - M6 X 29 CCMU0008...
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Page 28: 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 29: Parts - Engine - Top End
Parts – Engine – Top End Engine – Top End REF # PART # DESCRIPTION EKMU0015 CYLINDER KIT (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 30: Parts - Exhaust System
Parts – Exhaust System Exhaust System REF # PART # DESCRIPTION XCCJ2017 EXHAUST PIPE – JR/P3 ZCMOTE11 HEADER PIPE O-RINGS (2 REQ’D) XCMU0005 EXHAUST SPRING – SHORT (2 REQ’D) MCMUGR02 GROMMET KIT XCMU0028 PIPE / SILENCER SEAL - 2016 XCMU0032 SILENCER MCMUGR03 MOUNTING GROMMET (2 REQ’D) - Page 31 This page left intentionally blank...
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Page 32: Parts - Forks & Triple Clamps
Parts – Forks & Triple Clamps... - Page 33 Front Forks and Triple Clamps REF # PART # DESCRIPTION KACL2016 FORK ASSEMBLY P3 - FORK LEGS ONLY KCMU0011 FORK GUARD SET TCC60019 WASHER FORK GUARD (4 REQ’D) HCBC0601 M6X16mm, SOCKET HEAD CAP SCREW (4 REQ’D) BCC60015 BRAKELINE CLAMP HCBC0612 M6X12mm, SOCKET HEAD CAP SCREW (2 REQ’D) HCNL0601 M6 LOCKNUT (2 REQ’D)
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Page 34: Parts - Forks - Leg Assembly
Parts – Forks – Leg Assembly... - Page 35 REF # PART # DESCRIPTION HCBC0408 4 X 8 SHCS CLEAR ZINC ZCKG0001 GASKET, BLEED SCREW FORK KCCL0001 FORK CAP - CONVENTIONAL 32MM USD ZCMUOR18 O-RING – 3mm x 27mm ID KCCS0005 FORK - OUTER TUBE 32MM KCCS0035 RING CLIP FORK OUTER WEAR RING 32MM KCCS0006 FORK GLIDE RING BOTTOM 32MM KCCS0032...
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Page 36: Parts - Frame - Mounting Hardware I
Parts – Frame – Mounting Hardware I Frame – Engine, Swingarm, Tank, and Pipe Mounts REF # PART # DESCRIPTION HCBH1203 SWINGARM BOLT HCNL1201 M12 SWINGARM LOCK NUT HCBH0880 M8X80mm SOCKET HEAD CAP SCREW HCNL0801 M8 LOCKNUT MCMUGR02 GROMMET KIT PIPE & SPACER HCBF0635 M6X35mm FLANGE HEAD BOLT HCHA0003... -
Page 37: Parts - Frame - Mounting Hardware Ii
Parts – Frame – Mounting Hardware II Frame – Seat, Fender, Right Side Panel, Radiator & Shock Mounts REF # PART # DESCRIPTION FACJ2017 FRAME CX50 JR/P3 - 2017 EACJ0001 MOUNTING BRACKET – RADIATOR BOTTOM HCBC0608 M6X55mm SOCKET HEAD CAP SCREW HCNL0601 M6 LOCK NUT GROMMET –... -
Page 38: Parts - Front Brakes
Parts – Front Brakes Front Brakes REF # PART # DESCRIPTION BAKG0003 FRONT BRAKE ASSEMBLY BCKG0030 HOSE – BRAKE FRONT BCKG0023 ALLOY BRAKE LEVER BCKG0024 BRAKE PERCH & MASTER CYLINDER ASSY W/ LEVER BCKG0029 CALIPER – FRONT BKKG0001 KIT BRAKE PADS, WITH “E” CLIP BCMU0503 BRAKE ROTOR HCBC0514... -
Page 39: Parts - Front Wheel
Parts – Front Wheel Front Wheel REF # PART # DESCRIPTION WCKG0018BLK WHEEL WITH BEARINGS SPOKE STYLE – BLACK ANODIZE WCMU0016 FRONT AXLE HCBC0514 M5X14mm SOCKET HEAD CAP SCREW (6 REQ’D) BCMU0503 BRAKE ROTOR – FRONT WCMU0101 WHEEL SPACER LEFT (SHORT) WCMU0120 BEARING –... -
Page 40: Parts - Plastic & Seat
Parts – Plastic & Seat Plastic and Seat REF # PART # DESCRIPTION TCHA0107FLL FRONT FENDER - FLO YELLOW TCHA0107x FRONT FENDER x – DENOTES COLOR BLK, WHT, YEL, FLO HCBF0616 FENDER BOLT, M6X16mm FLANGE HEAD (4 REQ’D) TCC60002W NUMBER PLATE – FRONT TCC60002x FRONT PLATE x –... -
Page 41: Parts - Rear Brake
Parts – Rear Brake Rear Brake System REF # PART # DESCRIPTION BAKG0002 BRAKE SYSTEM – REAR (M/C-LINE-CALIPER) BCMU0027 BRAKE PIVOT BOLT BCMU0501 SEAL – BRAKE PEDAL (2 REQ’D) BCMU0029 BRAKE PEDAL – ASSEMBLY 50cc – WITH TOE PIECE BCMU0023T TOE PIECE HCBC0501 M5X 12mm SOCKET HEAD CAP SCREW... -
Page 42: Parts - Rear Wheel
Parts – Rear Wheel Rear Wheel REF # PART # DESCRIPTION WCKG0016BLK REAR WHEEL W/BEARINGS – BLACK ANODIZE WCMU1075D TIRE – REAR 10X2.75” DUNLOP MX52 WCMUTU10 TUBE, 10" PCMU0001 MASTER LINK 420 PCMU0086 CHAIN 420 X 86 PCMU0138 38T SPROCKET (STANDARD) PCMU01xx SPROCKET xx DENOTES TEETH –... -
Page 43: Parts - Shock
Parts – Shock Rear Shock REF# PART # DESCRIPTION SAP32016 SHOCK ABSORBER SCMU0043 SPHERICAL BEARING - SHOCK MOUNT – (2REQ’D) SCMU0039 O-RING – SHOCK – BUSHING (4 REQ’D) SCMU0042 BUSHING – SHOCK MOUNT (4 REQ’D) SCMU0058 SET SCREW - NYLON TIP M6-1.0 HCFH0408 4MM FLAT HEAD SCREW SCCJ0004 BUMPER –... -
Page 44: Parts - Shock - Internal
Parts – Shock - Internal Rear Shock REF# PART # DESCRIPTION SCMU0057 O-RING – SEALING SCREW – CHARGE PORT SCP30001 O-RING – FITTING – CHARGE PORT SCMU0035 O-RING – IFP SCREW SCP30002 O-RING – IFP SCP30003 SEAL BAND – IFP SCC60014 PISTON BAND SCMU0044... -
Page 45: Parts - Swingarm Assembly
Parts – Swingarm Assembly Swingarm REF # PART # DESCRIPTION GACJ2017 SWINGARM GCCS0001 SWINGARM BUSHING (SINGLE PIECE) (4 REQ’D) GCCJ0001 SPACER - PIVOT TUBE (2REQ’D) GCMU0040 CHAIN GUARD HCFH0512 M5X12mm FLAT HEAD SCREW HCWF0501 5mm FLAT WASHER HCBF0620 M6X20mm FLANGE HEAD BOLT (2 REQ’D) PAKG0001 CHAIN GUIDE –... -
Page 46: Service
CAUTION: There is a large wide range of variability in reading compression gauges. The head volume of this Cobra Motorcycle is very small and requires 20 kicks before you establish the most accurate reading possible. Because of the geometry of the spark plug used in this Cobra Motorcycle, the adapter used with your compression tester must have a similar volume protruding into the combustion chamber to establish an accurate value. -
Page 47: 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... -
Page 48: Cfd Adjustment
The easiest way to measure squish clearance is with 1mm to 1.5mm thick flexible solder wire (available through most popular electronic stores). The process is as follows: Assemble the top end of the engine with either; 1) the crankcase stamp recommended base gasket or, 2) if assembling with a new set of cases assemble with a 0.4mm (0.015”) base gasket, and torque the head nuts to the proper torque specifications leaving off the spark plug and ignition cover... -
Page 49: Engine Removal
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) 19mm socket ... -
Page 50: Complete Engine Disassembly Procedure
5. Remove the stator (4mm hex key). 6. Remove the clutch nut / starter gear that holds on the clutch (#ECMU0078). 7. With the Cobra flywheel / clutch puller (#MCMUTL70), remove the clutch from the crankshaft (details in Clutch Service portion of this manual). -
Page 51: 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 52: 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 53: Clutch
CAUTION: See base gasket selection at the beginning of service section. 13. Install the cylinder being sure that the piston rings are properly aligned with the indexing pins. 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. - Page 54 Accurate torque wrench in the range of 16 Nm (12 ft-lb, 144 in-lb). Clutch nut removal tool (ECMU0078) & piston stop (MCMUTL03). Cobra 3 Shoe Clutch Milk (Part # MCMUGF32). CLUTCH REMOVAL: 1. Drain the engine transmission oil and remove the clutch cover.
- Page 55 You should apply heat to the arbor near the clutch bolt threads or you will very likely break the Torx bit upon attempted removal. The spring stacks in your Cobra clutch will contain 11 individual springs and flat washer(s) configured as a 5 ½ stack. See figure 32. This clutch is designed such that it reconfigured by the customer to achieve different clutch engagements ‘hits’...
- Page 56 Clutch adjustment washers Your Cobra comes stock with flat washer(s) at the bottom of the spring washer stack. Cobra offers several thicknesses of thin adjustment washers that allow clutch engagement tuning. Increasing the flat washer(s) thickness increases the engine speed for clutch engagement thus increasing the abruptness of clutch engagement (harder hit).
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Page 57: Clutch Assembly
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 (295 ml (10.0 oz) Cobra 3 Shoe Clutch Milk (Part # MCMUGF32). -
Page 58: 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. -
Page 59: Cooling System
single and double hook ends for removing plastic impeller 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 60 3. Using a 3mm hex key, remove the screw in the water pump shaft stop hole. 4. Stick a 2.5mm hex key in the water pump shaft cross hole, and remove belt retainer screw using a 4mm hex key. (Figure 41 - item 1) 5.
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Page 61: 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 62 Indications that the engine is running too lean are: Engine cutting out on top end. Engine overheating and ultimately seizure. White spark plug CAUTION: It is much safer to operate the engine slightly rich as opposed to slightly lean. This is because an overly rich engine will just run poorly while an overly lean engine will seize, potentially causing an expensive top end rebuild and a DNF.
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Page 63: Reeds
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 64: Brakes
Ensure that the brake caliper is centered over the brake rotor. It a correction is needed, Cobra has thin brake shims to help make minor adjustments in alignment. Always leave adequate free-play in the lever or pedal. - Page 65 o Using a pick, remove the wire retaining ring holding the fork seals into place. o ‘Pop’ the fork seal out by forcibly pulling on both ends of the fork tube assembly, thus separating the inner from the outer tube. o Remove the bushings o Clean all components to be reused.
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Page 66: Rear Shock
See Optional Components section of this manual for details on these and other optional components for your Cobra Motorcycle. 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. -
Page 67: Tuning
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 ii) Clutch never fully engages on a reasonable straight stretch iii) Basket turns blue in short amount of time b) Clutch coming in too early i) Motorcycle moves too soon when accelerating off idle... - Page 68 1. Clutch spring stack to tall Wrong configuration Too thick a flat shim in the stack 2. Spring rate too high (wrong configuration with proper stack height) 3. Clutch arbor shoulder bolt is too short 4. Clutch shoe material has worn too thin 5.
- Page 69 A: If it is blue or purple, replace it. If it is silver or brown, you are fine. Cobra is now going to greater lengths to ensure that the clutch on your motorcycle is performing the best possible from the shop and so it may have a different clutch stack or shim washer from what you are used to.
- Page 70 Gearing Condition Gear Taller Gear Lower For a bike with a centrifugal Sand clutch, it’s better to be geared too low than too high. Hills Hard Pack What happens with improper gearing? Throttle Blipper (novice)* Poor performance *It may be helpful to set up the clutch to hit early for smooth power delivery ...
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Page 71: 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 72: Front Fork Operation
Always leave the spring perch rotated in such position so that the set screw is easily accessible. 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 73 NOTE: 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 59 shows its range of adjustment and in particular what...
- Page 74 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.
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Page 75: Troubleshooting
Troubleshooting 1) Engine not behaving properly a) Carburetor top is installed backwards (happens a lot) b) The carburetor slide indexing pin is missing c) Wrong spark plug installed (8339 Champion to be used on ’04 or later & no mods) d) Needle clip is on top of plastic not below e) Air leak –... - Page 76 Spark plug fouled ii) Wrong spark plug installed (8339 Champion to be used on ’04 or later & no mods) iii) Spark plug cap off iv) Engine Shut-off ‘kill’ switch is shorted v) Bad electrical ground vi) Stator winding damaged d) Exhaust is plugged 6) Overheating a) Bad stator...
- Page 77 Service ........61 Service ........61 Specifications ......4 Hardware and Fasteners Tuning ........72 Frame ........36 Plastic ........40 CFD Cobra Frictional Drive ... 16 Ignition Chain Service ........58 Adjustment ........ 11 Timing ........58 Chassis Jetting Specification ........
- Page 78 Exhaust ........30 Spark Plug Frame ........36 Recommended ......4 Front Brake ....... 38 Front Wheel ....... 39 Specifications ........4 Inlet ........... 18 torque values ....... 5 Plastic & Seat ......40 Rear Brake ........ 41 Starting ..........7 Rear Wheel .......
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