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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 CX50FWE (KING) 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 THAN THAT.
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.
MCCS2017FWE.0
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Summary of Contents for Cobra CX50FWE
- Page 1 “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.
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Page 2: Table Of Contents
Table of Contents GENERAL INFORMATION .................... 4 ‐ ........................ 4 PECIFICATIONS ENERAL .................... 5 PTIONAL USPENSION OMPONENTS ‐ ...................... 5 PECIFICATIONS ORQUE ALUES ‐I ........................ 6 REAK N ROCEDURE ........................ 7 TARTING ROCEDURE MAINTENANCE ........................ 8 ............................... 8 ............................ 9 CHEDULE ... - Page 3 – ........................ 44 ARTS EAR HEEL – .......................... 45 ARTS HOCK – ‐ ........................ 46 ARTS HOCK NSIDE – ...................... 47 ARTS WINGARM SSEMBLY SERVICE .......................... 48 .......................... 48 NGINE ERVICE Base Gasket Selection ...................... 49 Engine Removal ........................ 51 Complete Engine Disassembly Procedure ................ 52 Top End Disassembly Procedure ................... 52 Splitting the Cases ...
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Page 4: General Information
16mm + 0.5mm (0.63” + 0.020”) Transmission Speed Single Final drive ratio 15/38 T Chain 100 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk Quantity 300ml (10oz) Chassis Front tire 2.50 (60/100) - 12" Pressure 16 psi minimum Rear tire 2.75 (80/100) - 10"... -
Page 5: Optional Suspension Components
Optional Suspension Components Weight of Rider (lb) Fork Spring Shock Spring Less than 50 lb 0.23 kg/mm red, 3.3 kg/mm KCCS3223 SCKGFX33 50 – 60 0.23 kg/mm gray, 3.5 kg/mm KCCS3223 SCKGFX35 60-75 0.25 kg/mm yellow, 3.7 kg/mm KCCS3225 SCKGFX37 Greater than 80 0.27 kg/mm gold, 3.9 kg/mm... -
Page 6: 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 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. CAUTION:... -
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
5. 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 12 1. Set pedal height/position first, then 2. Set pedal free play. Brake pedal height can be adjusted with the bolt and nut located under the rear of the brake pedal. The free-play is adjusted with the adjustable plunger on the end of the brake pedal.
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Page 13: Brake Bleeding Procedure
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. Fill the syringe half full with brake fluid. -
Page 14: Air Filter Cleaning
CAUTION: Pay particular attention to clean any particles from the airbox between the filter location and the carburetor. NOTE: Cobra has available a carburetor cover that allows easy cleaning of the airbox. Figure A1 1. Remove the air boot 2. -
Page 15: Fork Maintenance
Fork Maintenance Cobra strongly recommends that a professional service technician conduct all internal maintenance other than changing springs and oil. This will help to ensure safe and consistent operation. -
Page 16: Fork Oil Replacement
consistent suspension operation. Before each ride, loosen the socket head cap screw located at the front of each fork cap far enough so that any excess pressure in the leg is relieved. After excess air is bled off, retighten the screw to 5 in-lb. -
Page 17: Frictional Drive (V3 Cfd)
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. Instead of these torque spikes potentially damaging internal components, the CFD allows the transmission to slip with respect to the engine. - Page 18 NOTE: This V3 CFD torque checking method is possible do to with the chain on. Just put the bike on a stand so that the rear wheel can turn freely. 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.
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Page 19: Parts - Airbox & Inlet System
Parts – Airbox & Inlet System Air Box REF # PART # DESCRIPTION RCMU0018 CARBURETOR TCCS0002 AIRBOX HCSP0004 SCREW – PLASCREW - ALUMINUM RCCS0016 AIR FILTER RCKG0503 RETAINER – AIR FILTER TCC60008 MUDFLAP MCKGHO03 HOSE CLAMP – AIRBOX TO BOOT RCKG0505 AIR BOOT MCKGHO01... -
Page 20: 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 FEW FAMU0016 THROTTLE ASSEMBLY – PRO TAPER COBRA FAMU0015 TUBE ASSEMBLY –... -
Page 21: Parts - Carburetor
Parts – Carburetor Carburetor REF. # PART # DESCRIPTION RACS0019 CARBURETOR RCMU0003 CABLE ADJUSTOR 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 NEEDLE –... -
Page 22: Parts - Coolant System
Parts – Coolant System Coolant System REF # PART # DESCRIPTION FCCS0058 RADIATOR WITH CAP - 2016 FCMU0052 CAP, 1.3 BAR, WITH RIBS ECCS0014 RADIATOR HOSE, TOP, LEFT ECMU0275 RADIATOR HOSE, BOTTOM MCMUGR03 GROMMET, RADIATOR MOUNTING (TOP) THICK ONE MCC6GR01 GROMMET, RADIATOR MOUNTING (BOTTOM) ONE HCBF0616 M6X16mm FLANGE HEAD BOLT (2 REQ’D) -
Page 23: Parts - Electrical System
Parts – Electrical System Electrical System REF # PART # DESCRIPTION IAMU0005 COIL/CDI W/SPARK PLUG CAP ECMU0010C SPARK PLUG, AUTOLITE COPPER ECMU0010I SPARK PLUG, AUTOLITE IRIDIUM FCMU0033 KILL SWITCH ASSEMBLY HCBC0516 M5X16mm SOCKET HEAD CAP SCREW (2 REQ’D) HCWF0501 5mm FLAT WASHER (2 REQ’D) HCCN0000 5mm CLIP NUT (2 REQ’D) ICMU0023... -
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 EKMU0020 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 30: Parts - Exhaust System
Parts – Exhaust System Exhaust System REF # PART # DESCRIPTION XACS2017FWE EXHAUST PIPE – BLACK - FACTORY WORKS 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 –... - Page 31 This Page Intentionally Left Blank...
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Page 32: Parts - Forks & Triple Clamps
Parts – Forks & Triple Clamps... - Page 33 Front Forks and Triple Clamp REF # PART # DESCRIPTION KACS2016FWE FORK COMPLETE, BRAKE & NON-BRAKE SIDE KCMU0011FLL 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) FACS0007BLK...
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Page 34: Parts - Forks - Leg Assembly - Brake Side
Parts – Forks – Leg Assembly – Brake Side... - Page 35 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...
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Page 36: Parts - Forks - Leg Assembly - Non-Brake Side
Parts - Forks – Leg Assembly – Non-brake Side... - Page 37 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...
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Page 38: Parts - Framei
Parts – Frame I Frame REF # PART # DESCRIPTION FACS2016FWE FRAME KING – CX50 SR KING VENOM TCC60018 SEAT MOUNT SPACER HCBC0625 M6X25mm SOCKET HEAD CAP SCREW HCHA0003 6mm CLIP NUT (MOUNTS TO FENDER TO HOLD SEAT) HCSP0003 PLASCREW AIRBOX MOUNTING (2 REQ’D) TCC60017 WASHER –... -
Page 39: Parts - Frame Ii
Parts – Frame II Frame REF # PART # DESCRIPTION HCBC0503 M5X30mm SOCKET HEAD CAP SCREW FT TANK MOUNTING TCC60027 SPACER – FT TANK MOUNTING HCBC0516 M5X16mm SOCKET HEAD CAP SCREW (2 REQ’D) HCWF0501 5mm FLAT WASHER (2 REQ’D) HCCN0000 5mm CLIP NUT (MAY NOT BE USED) HCBC0514 M5X14mm SOCKET HEAD CAP SCREW (2 REQ’D) -
Page 40: 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 –... -
Page 41: Parts - Front Wheel
Parts – Front Wheel Front Wheel REF # PART # DESCRIPTION WCKG0003BLK FRONT WHEEL W/BEARINGS AND SPACER – BLACK ANODIZE WCKG1200D 12" X 2.50 FRONT TIRE DUNLOP MX52 WCKG1201 12" FRONT TUBE WCMU0016 FRONT AXLE ECMU0040(T) SHIM - OPTIONAL FOR BRAKE CALIPER ALIGNMENT WCMU0101BLK FRONT WHEEL SPACER, LARGE - BLK WCMU0120... -
Page 42: Parts - Plastic Bodywork & Seat
Parts – Plastic Bodywork & Seat Plastic and Seat REF # PART # DESCRIPTION TCMU0016FLL FRONT FENDER - FLO YELLOW TCMU0016x FRONT FENDER x – DENOTES COLOR BLK, WHT, YEL, FLO HCBF0616 FRONT FENDER MTG BOLTS (4 REQD) TCC60002W FRONT NUMBER PLATE - WHITE TCC60002x FRONT NUMBER PLATE x –... -
Page 43: 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 44: Parts - Rear Wheel
Parts – Rear Wheel Rear Wheel REF # PART # DESCRIPTION WCKG0016BLK REAR WHEEL W/BEARINGS AND SPACER – BLACK ANODIZE WCMU1075D TIRE – REAR 10X2.75” DUNLOP MX52 WCMUTU10 TUBE, 10" PCMU0001 MASTER LINK 420 PCMU0100 CHAIN 420 X 100 PCMU0238 38T SPOCKET 415 BLACK (STANDARD) PCMU01xx SPROCKET - xx denotes number of teeth (35-45) -
Page 45: Parts - Shock
Parts – Shock Shock REF # PART # DESCRIPTION SACS2016 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 46: 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 47: Parts - Swingarm Assembly
Parts – Swingarm Assembly Swingarm REF # PART # DESCRIPTION GACS2017 SWINGARM HCBH1203 M12 SWINGARM PIVOT BOLT 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 M6 LOCKNUT (2 REQ’D) HCBF0620... -
Page 48: 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 49: 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 50 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. The easiest way to measure squish clearance is with 1mm to 1.5mm thick flexible solder wire (available through most popular electronic stores).
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Page 51: 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 52: 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 53: 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 54: 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 55: 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 56 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 57 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 58 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 59: 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 60: 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 61: 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 62 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 63: Fuel & Air System
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 64 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. To richen the carburetor: 1.
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Page 65: 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 66: 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 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 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. Clutch basket has worn too much and is too large of a diameter With the exceptions of component failures, generally two things will occur: 1) The clutch shoes will wear causing the clutch to engage later, and 2) The springs will sack causing the clutch to engage earlier.
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Page 69: Gearing
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 Not enough top end speed No snap Over heat clutch Premature failure of engine seals, bearings, & electronics High clutch wear 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...
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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
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;... -
Page 73: 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 74: Carburetion
“-“ speeds up the shock or removes damping. 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 75 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 49 shows its range of adjustment and in particular what adjustable component affects what range of operation Figure 49 (specifically throttle position).
- Page 76 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 77: Troubleshooting
Troubleshooting 1) Engine operates erratically a) Carburetor top is installed backwards b) The carburetor slide indexing pin is missing c) A carburetor vent elbow is plugged or has fallen out d) Faulty stator e) An air leak i) Base gasket ii) Intake / reed gaskets iii) Crank seals iv) Crank case gasket... - Page 78 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 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...
- Page 79 Parts .......... 21 Frictional Drive ......17 Service ........63 Specifications ......4 Front Brake Parts .......... 40 CFD Cobra Frictional Drive ... 17 Front Wheel Parts ......41 Chain Adjustment ........ 11 Fuel System Parts list ........63 Chassis Service ........
- Page 80 Clutch & Kick Starter ....26 Specifications ........4 Coolant System ....19, 22 Electrical ........23 Starting ..........7 Engine ........25 Exhaust ........30 Stator Frame ........38 torque .......... 5 Front Brake ....... 40 Front Wheel ....... 41 Suspension Ignition &...
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