Cobra 2003 User manual

2003 KING

Owners / Service Manual

“CHAMPIONS START HERE”

1

For parts orders contact your local dealer

To locate your closest Cobra dealer

log on to

www.cobramotorcycle.com

or call

(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.

11511 Springfield Road

North Lima, Ohio 44452

MCKG2003.3

2

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.

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 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.

3

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

Engine Service / Parts...................................................................................................15

ES1: Engine Service..................................................................................................17

E1: Engine Removal..............................................................................................18

E2: Complete Engine Disassembly Procedure .................................................19

E3: Top End Disassembly Procedure.................................................................19

E4: Splitting the Cases..........................................................................................20

E5: Engine assembly.............................................................................................21

ES3: Clutch.................................................................................................................26

ES4: Ignition................................................................................................................30

ES5: Cooling System.................................................................................................32

ES6: Fuel & Air System.............................................................................................36

ES7: Exhaust ..............................................................................................................39

Chassis Service / Parts .................................................................................................40

CS1: Wheels & Tires .................................................................................................40

CS2: Suspension........................................................................................................47

Troubleshooting..............................................................................................................50

4

General Information

Specifications - General

Items KING

Dimensions

Wheelbase 39” (991mm)

Wheel size 10” (254mm) rear, 12” (305mm) front

Seat height 26” (660mm)

Engine

Type 2-stroke, single cylinder, reed valve

Cooling system Liquid-cooled

Displacement 49.8 cc

Bore and stroke 39 mm x 41.7 mm

Ignition system Electronic

Spark plug Splitfire SF406B

Gap

0.023” – 0.025” (0.58 – 0.64 mm)

Ignition timing 0.050” (1.3 mm) Before To Dead Center (BTDC)

Fuel type Sunoco MO2

X

or 93 octane pump gasoline

OTHER RACE FUELS ARE NOT RECOMMENDED

Oil type Cobra Venom 2-cycle Race Oil

Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In is

complete)

Carburetion 19 mm Dell’Orto

Main Jet

94

Slow (Pilot) jet

65

Float Height

16mm + 0.5mm (0.63” + 0.020”

Transmission

Speed Single

Clutch Cobra 3 shoe

Final drive ratio 13/39 T

Chain 100 links 420

Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III

Quantity

235 ml (8.0oz)

5

Chassis

Front tire 2.50 - 12

Pressure

15 psi minimum

Rear tire 2.75 - 10

Pressure

15 psi min. (20 psi for hard pack or rocky conditions)

Front fork Cobra 30mm USD

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) Fork Spring Shock Spring

Less than 51 7 lb/in,

KCKG0007

SCKGOH10 (yellow, 175lb/in)

51 - 60 9 lb/in,

KCKG0009

SCKGOH85 (gray, 185 lb/in)

Greater than 60 12 lb/in,

KCKG1200

SCKG0H, (white, 195 lb/in)

• Suspension Valving

Damping Rate Fork Valving

Compression

(base valve)

Fork Valving

Rebound

(mid valve)

Shock Valving

(kit)

Soft (fast) KAKG0013 KAKG0016 SCKGOH24A

Standard KAKG0014 KAKG0017 SCKGOH24

Hard (slow) KAKG0015 KAKG0018 SCKGOH24B

• Cobra BIG AIR SX Fork Kit part #KKKG2003

6

Specifications - Torque Values

Torque Value

Fastener ft-lb in-lb Nm

Size &

Remarks

Cylinder head nuts 9.2 110 12 ¼”

Crankcase bolts 6.6 80 9 6 x 1.0

Spark plug (SP) (SP) (SP) 14 x 1.25

Stator bolts 2.1 25 2.8 #8

Stator cover bolts 1.7 20 2.3 #8

Clutch cover bolts 5.8 70 7.9 6 mm

Clutch 40 480 54 10***

Front axle nut 25 300 34 12 x 1.25

Front brake caliper

Engine mount bolts 22 265 30 8 mm

Swingarm Pivot 21 250 28 14 mm

Intake manifold bolts 4.6 55 6.2 6 mm

Rear Axle Bolt 25 300 34 12 mm

Rear Sprocket Bolts 18 216 24 7 mm

Fork cartridge rod 12 144 16

Triple clamp bolts 6 72 8 6 x 1.0

Fork cap 5 60 6.7 1.25” x 18

Ignition rotor nut 40 480 54 10 mm**

** Use green (wicking / bearing retainer) thread locker, with primer, on the

flywheel / crankshaft taper but none on the threads.

*** Use green (wicking / bearing retainer) thread locker, with primer, on the

crankshaft / clutch taper but use red (high strength) thread locker, with primer, on

the nut.

(SP) To apply the proper torque to the spark plug when inserting, one must first

screw the spark plug in until the metal gasket ring causes resistance and then

turn another 1/8 to ¼ turn.

7

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. Also, after the engine, transmission, and drive train

have been broken-in for the full 8 hours, the bike will be faster!

Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use

93 octane pump gas, or Sunoco MO2

X

, with Cobra’s specially formulated Cobra

Venom 2-cycle Race Oil. (Part # MCMUOL02)

CAUTION:

Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine

wear or damage to the machine.

Adhering to the following break-in schedule will result in long lasting high

performance machine.

• First ½ hour of operation

o Follow the starting procedure listed in this manual.

o Avoid prolonged operation at Wide Open Throttle.

• After 1 hour of operation

o Check for loose bolts and nuts on the bike and retighten as

necessary (proper toque values are listed under Specifications).

o Clean the carburetor bowl.

o Change the transmission / clutch lubricant.

• After 8 hours of operation

o Change the fork oil.

o Have a Certified Cobra Mechanic change the shock oil.

• Your bike is now ready for the highest level of competition!

NOTE:

During break-in the bike will likely loose some engine coolant through the radiator

overflow hose. Loosing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level

will cover the top of the radiator cores. Removing the radiator cap and looking

inside is the only way to check the coolant level.

Never open the radiator cap of a machine that has a hot or warm engine or one

that has recently been ridden. Burning and scalding could occur.

CAUTION:

It is important that the radiator cap is installed correctly and completely otherwise

engine damage could occur.

8

Starting Procedure

Before starting the machine inspect the following:

• Check for proper tire pressure in both tires.

• Observe the chain tension and adjust if necessary.

• Observe the coolant level and fill if necessary.

• Verify that the chain rollers do not have improper wear.

• Inspect the frame, for;

o Cracks in the metal.

o Cracking paint which might indicate overly stressed material.

• Verify that the handlebars are tight.

• Check the throttle for;

o Smooth operation and sound closing.

o Frayed strands of the cable inside the throttle housing.

• Check for loose bolts and nuts, and re-torque as necessary.

• Verify that the air filter is clean and properly saturated with oil.

• Insure that the fuel tank contains an adequate volume of fuel / oil mixture to

complete the distance required. (Sunoco MO2X or 93 octane pump gas with

Cobra’s specially formulated Cobra Venom 2-cycle Race Oil)

• Turn the fuel on by rotating the fuel petcock knob to the vertically downward

position (reserve position is horizontally forward)

CAUTION:

For best results from your Cobra Motorcycle use only the recommended fuels.

Testing has shown that most ‘race’ fuels actually degrade performance.

When your pre-ride inspection is complete the bike may be started. For a cold

engine follow this procedure.

1. 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.

2. Pull up the choke knob and turn it to lock it.

3. Kick start the engine.

4. Rev the engine in short spurts, turning the throttle no more than 1/4 open

until the engine will run without the choke.

5. Verify a functional engine shut-off switch by shutting off the engine.

6. Restart the engine and proceed with riding when the engine is sufficiently

warm (i.e. the side of the cylinder is warm to touch).

CAUTION:

Never rev an engine full throttle when it's cold or slightly warmed up. Cobra

recommends that you tell your child to take it easy the first couple of minutes in

practice until the engine comes up to full operating temperature. Make sure your

engine is properly warmed up before racing.

9

General Tips

1. Always wear a helmet and other protective riding gear.

2. 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.

3. Make sure your riders’ foot is not resting on the foot brake while they are

riding.

4. Evaluate the bikes jetting only after it has been warmed up to race

temperatures.

5. A properly maintained machine is safer, faster, and more fun to ride.

6. 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).

a. Example, ACxxxx3xxx is a 2003 MY King.

Maintenance

Schedule & Tips

It is important that you adhere to this maintenance schedule so as to promote the

longevity of your Cobra Motorcycle.

• Between each ride

o Check the air filter (clean and re-oil as necessary).

o Insure the smooth operation of the throttle cable (throttle soundly

‘clacks’ shut).

o Check for frayed strands of the throttle cable inside the throttle housing

and replace if necessary.

o Check for adequate tire pressures and adjust if necessary.

o Check all nuts and bolts for proper torque and re-torque if necessary.

o Spray all moving parts with WD40 or other light oil.

o Check drive chain for

§ Proper tension and adjust if necessary.

§ Adequate lubrication and lubricate if necessary.

o Insure that the ignition stator and rotor are clean and dry.

o Check the frame for cracks in the metal or cracks in the paint that

might indicate that the metal has been stressed beyond it’s safe limits.

Replace or get properly rewelded as necessary.

o Inspect the rear sprocket damper plate for bending or warping.

Straighten or replace if more than 1/16” (1.6 mm) from flat.

• Every 2 hours of operation

o Replace the transmission oil.

• Every 10 hours of operation

o Replace the fork oil.

o Have the shock oil replaced by a Certified Cobra Mechanic.

10

CAUTION:

1. Because of the amount of heat generated by the clutch and engine during

extended periods of riding, it is advisable to remove the ignition cover

afterward to allow the ignition to cool off. The heat transfers through the

cases and can damage the stator as it cools off because of lack of airflow

around the stator.

2. If you ever need to weld anything on the bike, disconnect the spark plug

cap, unplug the ignition, disconnect the kill switch, scrape the paint bare

near the area to be welded and put the ground clamp as close to the area

to be welded as possible.

Be sure the fuel tank and carburetor have been removed and safely located

away from the welding process.

3. 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.

4. If your kick-starter lever does not return to the rubber bumper, use WD-40

or light penetrating oil under the plastic cover behind the spring on the

shaft. The shaft is a very close fit to the case and also has an O ring in it

and is difficult to get lubrication to which may cause binding. If it does not

loosen up, remove the kick-starter cover and kicking assembly. Grease the

shaft.

M1: Replacing Transmission / Clutch

Lubricant

Tools needed:

• 225 ml (7.6 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01), or

Dexron III Automatic Transmission Fluid.

• 13 mm combination wrench

Procedure:

1. Begin this procedure with a bike that has been ridden more than 5 minutes

but less than 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.

11

2. Lean bike against something or set on stand with oil drain hole.

3. Using a 13 mm wrench, remove the oil drain bolt located on the right side of

the engine, on the clutch cover, near the brake lever (Item 2, figure 1).

Figure 1

NOTE: You may need to adjust the brake pedal (up or down) to gain access to

the drain bolt.

4. After it has drained, reinstall the bolt being sure that the copper gasket is in

place. Torque to 15 Nm (11 ft-lb).

5. Reapply oil from oil fill plug 235 cc Cobra Venom 3 Shoe Clutch Milk, or

Dexron III Automatic Transmission Fluid, thru the fill plug.

NOTE lean bike over onto it’s left hand side so that the clutch cover is up unless

you have a squeeze bottle.

6. Reapply the oil fill bolt, hand tight, being sure the fiber 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. Cobra was forced to put forth this effort because the other available

options and not adequate. Cobra’s specially developed Cobra Venom 3 Shoe

Clutch Milk (Part # MCMUGF01) is the recommended lubricant for your KING

motorcycle.

12

M2: Chain adjustment

Figure 2

1. Make sure that the rear

wheel is aligned properly.

2. Push down on the seat,

compressing the suspen-

sion down to where the

chain is tightest.

3. The chain should not be

too tight but not too

loose. A minimum of 2.5

in. of slack should be

between the swing arm

and the chain.

M3: Rear brake adjustment

Tools recommended for rear brake maintenance:

10mm open end wrench

There are 2 adjustments on the brake.

From the brake lever:

1. Loosen the 10mm nut on the back of the brake pedal.

2. Adjust the bolt to desirable position

3. Tighten the 10mm nut.

From the brake hub:

1. Adjust the wing nut up to desirable position.

CAUTION:

If you tighten the wing nut up too much, the brakes may hang up. If so, the brake

pads will burn up, and need replaced.

Figure 3, adjust brake lever free height Figure 4, adjust brake lever ‘free play’

13

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.

Make sure you change your filter after each moto. We recommend carrying 3 or

more filters in your toolbox.

1 for practice

1 for the each moto

In our testing when filters are properly oiled, no water, dirt or mud can penetrate

through the yellow or red foam to the carburetor inlet. It is important that the filter

does not touch any of the frame components in a rainy, muddy situation. We

offer two different filters. One filter for the use in sand (part # RCMU0101), and

the regular filter for regular use (part # RCMU0206).

When washing your bike cover the carburetor/filter with a suitable shield capable

of keeping water from entering the engine. Cobra has a rubber clamp-on plug for

the carburetor referred to as a carburetor condom (part # RCMU0104).

M5: Fork Oil Replacement

Tools required

• Two 19 mm wrenches or sockets

• 4 & 5 mm hex key (Allen wrench)

• 1 1/8” wrench or socket

• 5 wt fork oil

Disassembly procedure

1. Remove the front wheel (19 mm wrench).

2. Remove the brake caliber from the fork leg (4 mm hex key).

3. Loosen the fork caps (1 1/8” socket).

4. Remove the fork legs from the triple clamps (5 mm hex key).

5. One leg at a time

a. Remove the fork cap from the leg.

b. Separate the fork cap from the damper rod.

c. Pull out the fork spring.

d. Place upside down over a suitable pan, tray, or container.

14

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.

3. Install the fork spring.

4. Reconnect the damper rod to the fork cap (12 ft-lb, 16 Nm).

CAUTION:

The damper rod is hollow and will break if the nut is over tightened.

5. Reinstall the for cap into the fork leg (5 ft-lb, 6.7 Nm)

6. Reinstall the fork legs into the clamps (6 ft-lb, 8 Nm).

7. Reinstall the brake caliper.

8. Reinstall the front wheel (25 ft-lb, 34 Nm).

15

Engine Service / Parts

REF. #

PART #

DESCRIPTION

REF. #

PART #

DESCRIPTION

1

CAKG0002

Clutch, Complete

44

ZCKG0002

Gasket, Base

2

CAKG0004

Shoes, Clutch w/ Washer Springs

45

ECKG0041

Cylinder, 50cc

3

CAMU0008

Spring Set, Washer type for Clutch

46

ZCMUOR07

Oring, Exhaust Flange

4

CCMU0031

Arbor for 3 Shoe Clutch

47

ECKG0015

Exhaust Flange

5

ECMU0018

Nut, Crankshaft Starter

48

HCBC0602

Screw, 6x20

6

ECMU0033

Clutch Hub w/ Gear

49

ECMU0008

Stud, Cylinder

7

ECMU0040

Clutch to hub spacer

50

ZCMUOR03

Oring, Cylinder head, Small

8

ECDC0105

90 Degree Crankcase Vent

51

ZCMUOR05

Oring, Cylinder head, Medium

9

ECMU0017

Seal, Crankshaft

52

ECKG0121

Cylinder Head Dome-Insert

10

ECMU0016

Bearing, Crankshaft

53

ECMU0403

Spring, Kickstarter Return

11

ECMU0001

Bearing, Trans., Secondary Gear

54

HCNS1401

Nut, 1/4-20

12

ECMU0020

Bearing, Trans., Precision

55

ZCMUOR02

Oring, Cylinder head, Large

13

ECMU0105

Gear, Trans., Primary

56

ZCMUOR08

Oring, Cylinder head

14

HCNS1202

Nut, 1/2-20, Left Hand

56A

ZAKGOR02

Oring Kit, Top End

15

ECKG0018

Crankcase, Clutch side

57

ECKG0025

Cylinder Head - Outer Cap

16

ECMU0131

Water Elbow

58

HCWF1401

Washer, 1/4"

17

HCBH0805

Screw, M8x12mm

59

ICMU0006

Rotor

18

ECMU0103

Shaft, Trans., Secondary w/gear

60

ICMU0007

Stator

19

ECMU0104

Shaft, Trans., Output w/gear

60A

MCKGGR00

Grommet, Engine case

20

ECKGBR01

Bearing, Trans., Output shaft

61

ECKG0073

Impeller, Waterpump

21

ZCKG2001

Gasket, Crankcase

62

ECKG0074

Seal, Waterpump

22

HCDP1401

Dowel, for Engine Cases

63

ECKG0203

Intake Manifold

23

ECMU0038

Crankshaft, Welded and Balanced

64

ZCMU0032

Gasket, Reed to case

24

ECKG0017

Crankcase, Ignition side

65

ZCMU0031

Gasket, Intake to Reed

25

ECKG0004

Snap Ring, Int. for Water Pump

66

ECKG0202

Reed Assembly

26

ECKGSE01

Seal, Output shaft

66A

ECKG0204

Reed Kit

27

HCBC0606

Screw, M6x45

67

ZCKG0101

Gasket, Ignition Cover

28

HCBC0604

Screw, M6x35

68

ECKG0001

Cover, Ignition

28A

HCBC0603

Screw, M6x30

69

HCBC0802

Screw, 8-32x1-3/4

29

HCBC0608

Screw, M6x55

70

ECMU0043

Piston Kit

30

PCKG0013

Sprocket, 13T for output shaft

70A

ECMU0055

Piston Ring

30A

ECKGSR03

Snap Ring, Ext., for output shaft

71

ECKG0012

Wrist pin

31

HCWP0001

Washer, Stator

72

ECMU0077

Bearing, Wrist Pin

32

HCBH0803

Screw, 8-32x7/8

73

ECMUSR00

Snap Ring for Piston

33

HCBC0801

Screw, 8-32x1-1/2

74

ECMUSP01

Spring, Kick Start Dog

34

HCNS1001

Nut, 10mm

75

ECMU0207

Gear, Kickstarter, Small

35

ECKG0042

Pulley, Waterpump-Crank

76

ZCMU0030

Gasket, Clutch Cover

36

ECKG0070

Belt, Waterpump

77

ECMU0205

Kick Starter Rubber

37

HCBB0001

Screw, 10-32x1/2"

78

HCWC0000

Gasket, Copper

37A

HCBC1033

Screw, 10-32x3/4"

79

HCBH0805

Screw, M8x12mm

38

HCWL0001

Washer

80

ECMU0204

Kick Starter Dust Shield

39

ECMU0080

Belt Retainer

81

ZCMU0001

Gasket, Oil fill plug

40

ECKG0075

Pulley, Waterpump-Fan

82

ECMU0037

Oil fill plug

41

HCSS8201

Screw, 8-32x3/8

83

ECMU0202

Kickstarter Lever

42

ECKG0072

Bearing, Waterpump

84

ECMU0027

Kickstarter, complete

43

ECKG0141

Shaft, Waterpump

85

ECMU0003

Brass Clutch Bushing

2003 KING ENGINE ASSEMBLY REFERENCE DRAWING

16

Figure 5

17

Trained technicians with precision gauging and proper assembly fixtures carefully

assemble all Cobra engines to specific clearances. 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.

If you don’t feel comfortable with the service work, simply take your engine out of

the frame and sent it to:

Cobra Precision Engines

11511 Springfield Road

North Lima, Ohio 44452

Cobra has specialized mechanics that will go through the entire engine, replacing

gaskets, bolts, any old part that is worn. The engine will be rebuilt using the

same precision gauging and assembly fixtures as when it was assembled new.

Before leaving, the engines performance will be measured on a dynamometer to

ensure that your engine is operating at its highest potential. All this for one low

nominal fee. Call (330) 549-9603 for details.

ES1: Engine Service

One method for determining whether the top end of your engine needs rebuilt is

to perform a WOT (Wide Open Throttle) kicking compression test. Before

performing the procedure please read the caution notes below.

CAUTION:

• 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.

• 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.

• Length of hose on the compression tester will affect the reading. The shorter

the hose length the more accurate your reading will be.

Because of these difficulties in measuring an absolute compression value, a

useful relative value can be achieved by testing your bike’s compression with

your own particular gauge after a new top end or when the bike is new so that

you know what your particular gauge reads on a ‘fresh’ engine. When it has

dropped to 90% of its original value the engine will be down on power and would

benefit from a rebuild. When it’s dropped to 80% it really needs rebuilt! Using the

table below will help you determine monitor the condition of your top end.

18

Engine is Fresh

Measured Value

Engine Down on Power

Measured Value * 0.9

Engine NEEDS Rebuilt

Measured Value * 0.8

Example

110 psi 110 psi * 0.9 = 99 psi 110 psi * 0.8 = 88 psi

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.

E1: Engine Removal

To service the bottom end and transmission, the engine must be removed from

the frame.

Tools required

• 5/16”, 10, 14, 22 mm socket

• 10, 13, 22 mm wrench

• 10, 17 & 19 mm sockets

• 9/64”, 3,4 & 5 mm hex key (Allen wrench)

• 7 mm nut driver, flat or Phillip, screwdriver for hose clamps

• Spring remover

• Flywheel / clutch puller (#MCMUTL68)

• Clutch nut removal tool (Call local dealer for details).

Procedure

1. Remove the seat (4mm hex key).

2. Turn of the fuel at the petcock and disconnect the fuel line.

3. Remove the tank (5 mm hex key & 10 mm socket).

4. Remove the carburetor from the inlet (flat head or Phillips head screwdriver, 7

mm nut driver).

5. Remove the right side number plate (3mm hex key).

6. Remove the silencer & pipe (spring remover, 5mm hex, & 10mm wrench).

7. Disconnect the ground wire from the reed cage with a 5 mm hex key

(depending on your ultimate repair, you may want to reinstall the fastener in

the inlet.

8. Leaving the coolant lines connected to the engine, remove the radiator from

the frame (5mm hex with 10 mm wrench).

9. Remove the master link from the chain.

10. Remove front engine mount bolt (13 mm socket, 6 mm hex key).

11. To access the swingarm bolt, remove brake lever (13 mm wrench, 5 mm hex

key).

12. Remove the swingarm bolt (22mm socket & wrench).

19

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).

NOTE:

If the coolant looks to be free of contaminates it may be reused.

NOTE:

If you are merely performing a top end service skip ahead to Top End

Disassembly Procedure.

E2: Complete Engine Disassembly Procedure

1. Remove the magneto cover (9/64” hex key)

2. Remove the bolt from the water pump shaft (4mm) and slide off the belt cover

and the water pump belt

3. Using a flywheel holding tool and 14 mm socket remove the nut that secures

the flywheel.

4. Using the Cobra flywheel / clutch puller (#MCMUTL68), remove the flywheel

from the crankshaft.

5. Remove the stator (9/64” hex key).

6. Remove the nut holding the large gear to the transmission input shaft (19 mm

socket).

7. Remove the special nut / starter gear that holds on the clutch (special tool

available, contact your local dealer).

8. With the Cobra flywheel / clutch puller (#MCMUTL68), remove the clutch from

the crankshaft (details in Clutch Service portion of this manual).

E3: Top End Disassembly Procedure

1. Remove the cylinder head nuts (5/16”).

2. Remove the outer cylinder head.

3. Remove the inner cylinder head.

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