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Cobra King 2003 Owner's Service Manual

Cobra 2003 king owners / service manual
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2003 KING
Owners / Service Manual
"CHAMPIONS START HERE"

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Summary of Contents for Cobra King 2003

  • Page 1 2003 KING Owners / Service Manual “CHAMPIONS START HERE”...
  • Page 2 To locate your closest Cobra dealer www.cobramotorcycle.com (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. log on to or call 11511 Springfield Road North Lima, Ohio 44452 MCKG2003.3...

  • Page 3: Disclaimer Of Warranty

    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 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 Specifications - General...4 Optional Components ...5 Specifications - Torque Values ...6 Break-In Procedure ...7 Starting Procedure ...8 General Tips...9 Maintenance...9 Schedule & Tips ...9 M1: Replacing Transmission / Clutch Lubricant ...10 M2: Chain adjustment...12 M3: Rear brake adjustment ...12 M4: Air Filter Cleaning ...13 M5: Fork Oil Replacement ...13...

  • Page 5: General Information

    General Information Specifications - General Items Dimensions Wheelbase Wheel size Seat height Engine Type Cooling system Displacement Bore and stroke Ignition system Spark plug Ignition timing Fuel type Oil type Fuel / oil mix ratios Carburetion Main Jet 94 Slow (Pilot) jet 65 Float Height 16mm + 0.5mm (0.63”...

  • Page 6: Optional Components

    Chassis Front tire Pressure 15 psi minimum Rear tire Pressure 15 psi min. Front fork Fork oil type SAE 5 weight Fork oil amount 118 ml (4.0 oz) Optional Components Carburetor jets Sprockets o Front o Rear Suspension Springs Weight of Rider (lb) Less than 51 51 - 60 Greater than 60...

  • Page 7: Specifications - Torque Values

    Specifications - Torque Values Fastener ft-lb Cylinder head nuts Crankcase bolts Spark plug (SP) Stator bolts Stator cover bolts Clutch cover bolts Clutch Front axle nut Front brake caliper Engine mount bolts Swingarm Pivot Intake manifold bolts Rear Axle Bolt Rear Sprocket Bolts Fork cartridge rod Triple clamp bolts...

  • Page 8: 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 9: Starting Procedure

    Place the motorcycle on a stand of sufficient strength that positions the motorcycle in a level upright position with the rear wheel off the ground. Pull up the choke knob and turn it to lock it.

  • Page 10: General Tips

    Evaluate the bikes jetting only after it has been warmed up to race temperatures. A properly maintained machine is safer, faster, and more fun to ride. 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 11: M1: Replacing Transmission / Clutch Lubricant

    10 minutes. It is desired to have the engine warm enough so that the oil ‘runny’ but not so hot that there is risk of being burned by the engine or the oil. Hot oil and hot components on the motorcycle may cause burns.
  • Page 12 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 was forced to put forth this effort because the other available options and not adequate. Cobra’s specially developed...

  • Page 13: M2: Chain Adjustment

    M2: Chain adjustment Figure 2 M3: Rear brake adjustment Tools recommended for rear brake maintenance: 10mm open end wrench There are 2 adjustments on the brake. Figure 3, adjust brake lever free height From the brake lever: 1. Loosen the 10mm nut on the back of the brake pedal. 2.

  • Page 14: M4: Air Filter Cleaning

    M4: Air Filter Cleaning Tools recommended for air filter maintenance: Flat head screwdriver Air filter oil 5mm hex key Foam filter oil The Cobra is equipped with a special designed sock filter. It is very important to keep it clean and properly oiled with high quality water-resistant foam filter oil. It’s very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting.
  • Page 15 e. Work the damper rod up and down several times. f. Allow to drain completely. Assembly procedure 1. Fill the fork leg with 4 oz (118 ml) 5 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.

  • Page 16: Engine Service / Parts

    Engine Service / Parts 2003 KING ENGINE ASSEMBLY REFERENCE DRAWING REF. # PART # DESCRIPTION CAKG0002 Clutch, Complete CAKG0004 Shoes, Clutch w/ Washer Springs CAMU0008 Spring Set, Washer type for Clutch CCMU0031 Arbor for 3 Shoe Clutch ECMU0018 Nut, Crankshaft Starter ECMU0033 Clutch Hub w/ Gear ECMU0040 Clutch to hub spacer ECDC0105 90 Degree Crankcase Vent...
  • Page 17 Figure 5...

  • Page 18: Es1: Engine 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 19: E1: Engine Removal

    Engine is Fresh Measured Value 110 psi Example Your Values Procedure for Compression Testing 1. Shut off the fuel petcock. 2. Install the compression gauge into the spark plug hole. 3. Hold the throttle to wide open, and kick repeatedly (approximately 20 times) or until the gauge reading does not increase in value with each kick.

  • Page 20: E2: Complete Engine Disassembly Procedure

    NOTE: Only drive the swingarm bolt far enough to clear the engine, leave it holding the one side of the swingarm to the frame 13. Remove the engine from the right side of the frame. 14. Locate a suitable container for the engine coolant and remove radiator hoses from engine (coolant will drain).

  • Page 21: Inspection Note

    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 22: E5: 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 and the rest of the engine.
  • Page 23 Figure 6 Figure 7...
  • Page 24 10. Insert dowel pins in the left side case as shown in figure 8. Figure 8 11. Apply gasket sealer (NAPA Aviation Form-A-Gasket #765-1210 or equivalent) to the mating surfaces of both crankcase halves. 12. Apply the crankcase gasket to the left crank case half being sure to install the gasket behind the connecting rod.
  • Page 25 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 (NAPA Aviation Form-A-Gasket #765-1210 or equal) to the cylinder deck areas around the coolant passage and cylinder studs as shown in figure 10.
  • Page 26 22. Install O’rings as shown in figure 12. 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 ES4: Ignition portion of this manual.

  • Page 27: Es3: Clutch

    ES3: Clutch Cobra clutch puller assembly: Figure 13 Tools recommended for clutch service: 22mm socket Universal clutch puller- a universal puller that pulls the clutch, main drive gear and rotor. (Part # MCMUTL70). 5mm T-handle Clutch nut removal tool (Call local dealer for details) Cobra 3 Shoe Clutch Milk (Part # MCMUGF01) CLUTCH REMOVAL: 1.
  • Page 28 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 29: Clutch Assembly

    CAUTION: Sludge build-up between the spring washers also keeps the clutch shoe from engaging fully and this will cause the clutch to start to s lip. So you will need to clean the sludge out or just replace the spring washers and bolts with new ones. How quickly this sludge builds up depends on how often you change your oil and whether your rider is a throttle ‘blipper’.
  • Page 30 CAUTION: It is also important that all three shoes are stacked the same. (See figure 15) 2. Clean the threads of the stack bolt and the clutch with contact cleaner removing all old thread locking material. 3. Apply high strength (red) thread lock material to the stack bolt and tighten as tight as possible without stripping the Allen head.

  • Page 31: Es4: Ignition

    8. Install the clutch cover taking care to put the two longer bolts in their proper locations and tightening in the order specified in figure 17. (5mm hex key, 5.8 ft-lb, 7.8 Nm). 9. Put pipe back on and add oil (225 ml (7.6 oz) Cobra 3 Shoe Clutch Milk (Part # MCMUGF01).
  • Page 32 Tools recommended for timing service: Compact motorcycle dial indicator Universal clutch puller- a universal puller that pulls the clutch, main drive gear and rotor. (Part # MCMUTL70).

  • Page 33: Rotor Installation

    5. Inspect and remove markings, scratches, and thread locker residue from the rotor and crankshaft. Figure 18, Lining up the line on the rotor with the line on the stator. ROTOR INSTALLATION: 1. Use wicking / bearing retainer (green) thread locker on the inside of the rotor, and on tapered part of crankshaft.
  • Page 34 To remove radiator cap: 1. Turn the cap counter clockwise to the first stop and wait there for a few seconds. 2. Push the cap down and turn it further in the same direction and remove the cap. NOTE: Inspect the old coolant for visual evidence of corrosion and abnormal smell. Fill the radiator up to the bottom of the radiator filler neck with coolant.
  • Page 35 8. Remove ignition cover using a 9/64” hex key (four places) 9. Remove belt retainer screw using a 1/8” hex key. (Figure 22 - item 1) 10. Remove belt retainer, water pump belt and water pump fan pulley. 11. Remove bearing retainer screw using a 3/32” hex key. (Figure 22 – item 2) 12.
  • Page 36 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 25.

  • Page 37: Es6: Fuel & Air System

    ES6: Fuel & Air System Carburetor: Tools recommended for carburetor service: Small flat head screwdriver WD-40 8mm socket KING Carburetor Ref. Drawing REF. # PART # DESCRIPTION RCMU0305 CARB SLIDE RCMU0601 NEEDLE RCMU0002 ATOMIZER MAIN JET PILOT JET CHOKE JET RCMU0301 FLOAT RCMU0102...

  • Page 38: Idle Adjustment

    Your Cobra is equipped with an adjustable carburetor. Some fine-tuning may be needed according to weather condition and altitude. 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. The larger screw with the knurled head is the idle adjustment screw.
  • Page 39 After the parts are cleaned, dry them with compressed air. Blow out the fuel passages with compressed air. Assemble the carburetor 10. Install the carburetor onto the motorcycle. NOTE: The three most common problems with this carburetor are (figure 27):...

  • Page 40: Es7: Exhaust

    The presence of light indicates that the reeds should be replaced, or possibly turned over. ES7: Exhaust The pipe is a crucial element to a motorcycle. Any kinks, dents, or damage done to the pipe will result in a major performance loss.

  • Page 41: Chassis Service / Parts

    Chassis Service / Parts CS1: Wheels & Tires Rear wheel Rear wheel dampening Tools recommended for wheel service: 13mm socket Flathead screwdriver 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.

  • Page 42: Rear Wheel Pullers

    Rear wheel pullers Disassembly: Figure 30 Rear wheel alignment: Figure 31 1. Remove back wheel assembly. 2. Pull the rear wheel pullers out of the back of the swing arm. 1. Measure from the side of the swing arm to the outer edge of the rim and make sure both sides are equal.

  • Page 43: Front Wheel Assembly

    Front wheel assembly 2003 FRONT WHEEL ASSEMBLY REF. # HCNS1201 KCKG0029 WCMU0023 WAKG0005 WCMU0001 BCKG0008 KCKG0028 WCMU0016 Figure 32 PART # DESCRIPTION 12mm AXLE NUT FORK LEG (NONBRAKE SIDE) WHEEL SPACER (LARGE) FRONT WHEEL (COMPLETE) WHEEL SPACER (SMALL) FRONT BRAKE MOUNT FORK LEG (BRAKE SIDE) REAR AXLE...

  • Page 44: Front Brakes

    CS2: Brakes Front Brakes The front brake is fully hydraulic. WARNING! Your front brake needs a break-in period to achieve maximum brake power. 30-40 stops will bring the brake to peak performance. Check before each ride: Make sure the brake does not have any leaks by holding the lever in while checking hose connections.
  • Page 45 Figure 33 2) Remove cotter key from caliper as shown and pull pads out. Figure 34...
  • Page 46 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. Brake bleeding procedure: 1) Remove brake caliper using 4mm Allen wrench as shown in pad removal procedure.
  • Page 47 4) Attach Bleeding syringe as shown. Pump all air out of system until only clean oil runs out of reservoir. 5) Reinstall reservoir cap. Oil will overflow in the process. This is necessary to ensure no air is in the system. Remove bleeding syringe and quickly reinstall bleed screw.

  • Page 48: Cs2: Suspension

    CS2: Suspension Rear Shock COBRA PART NUMBER SCKGOH01 SCKGOH02 SCKGOH03 SCKGOH04 SCKGOH05 SCKGOH06 SCKGOH07 SCKG0H08 SCKGOH09 SCKGOH10 SCKGOH11 SCKGOH12 SCKGOH13 SCKGOH14 SCKGOH15 SCKGOH16 SCKGOH17 SCKGOH18 SCKGOH19 SCKGOH20 SCKGOH21 SCKGOH22 Figure 39 DESCRIPTION SPRING CLIP SPACER BALL JOINT SPRING PLATFORM LOCKNUT SLEEVE BUMPER RUBBER SPRING - LIGHT...

  • Page 49: Front Forks

    Front forks Tools recommended for front fork service: Flat head screwdriver Hammer Snap ring pliers Seal drivers 13mm wrench 1 1/8” wrench or socket 5 wt fork oil FORK ASSEMBLY PROCEDURES: 1. Slide swiper (#6) onto lower fork leg. 2. Slide snap ring (#5) onto lower fork leg. 3.
  • Page 50 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. KING FORK Ref. KING FORK Ref. Drawing REF.

  • Page 51: Troubleshooting

    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...
  • Page 52 Index Air Filter...13 Brakes Front ...43 Break-In...7 Carburetion Specifications ...4 Carburetor ...36 Chain Adjustment...12 Chassis Specification...4 Clutch Parts List 1 ...27 Parts List 2 ...28 Service ...26 Clutch Lubricant Replacing ...10 Compression test ...18 Cooling System...32 Cylinder head torque ...6 Damper ...40 Engine Parts List ...15...

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