Cobra Moto CX50 FWE User manual

F
Owners
Parts
Service
Tuning

2
For parts orders, contact your local dealer.
To locate your closest Cobra dealer, log on to
www.cobramoto.com
or call
+1 (517) 437 - 9100
Cobra MOTO, LLC
240 Uran Road
Hillsdale, MI 49242
USA

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.
MCCS2021FWE.3

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Table of Contents
GENERAL INFORMATION ..................................................................................................... 4
SPECIFICATIONS - GENERAL ........................................................................................................................ 4
OPTIONAL SUSPENSION COMPONENTS ........................................................................................................ 5
SPECIFICATIONS - TORQUE VALUES ............................................................................................................ 6
BREAK-IN PROCEDURE ............................................................................................................................... 8
STARTING PROCEDURE ............................................................................................................................... 9
MAINTENANCE ....................................................................................................................... 10
TIPS ......................................................................................................................................................... 10
SCHEDULE ............................................................................................................................................... 11
REPLACING TRANSMISSION / CLUTCH LUBRICANT ...................................................................................... 12
PROPER CHAIN ADJUSTMENT .................................................................................................................... 13
REAR BRAKE MAINTENANCE ..................................................................................................................... 14
FORK MAINTENANCE................................................................................................................................. 16
Fork Air Bleeding................................................................................................................................ 16
Fork Oil Replacement ........................................................................................................................ 17
DISASSEMBLY PROCEDURE ....................................................................................................................... 17
FRICTIONAL DRIVE (V3 CFD) .................................................................................................................... 18
PARTS – AIRBOX & INLET SYSTEM ............................................................................................................. 20
PARTS – BARS AND CONTROLS ................................................................................................................. 21
PARTS – CARBURETOR ............................................................................................................................. 22
PARTS – COOLANT SYSTEM ...................................................................................................................... 23
PARTS – ELECTRICAL SYSTEM .................................................................................................................. 24
PARTS – ENGINE – BOTTOM END AND TRANSMISSION ................................................................................ 25
PARTS – ENGINE CLUTCH AND KICK LEVER ............................................................................................... 28
PARTS – ENGINE – WATER PUMP .............................................................................................................. 30
PARTS – ENGINE – TOP END ..................................................................................................................... 31
PARTS – FORKS & TRIPLE CLAMPS ........................................................................................................... 34
PARTS – FORKS – LEG ASSEMBLY – BRAKE SIDE ....................................................................................... 36
PARTS - FORKS – LEG ASSEMBLY – NON-BRAKE SIDE ................................................................................ 38
PARTS – FRAME I ..................................................................................................................................... 40
PARTS – FRAME II .................................................................................................................................... 41
PARTS – FRONT BRAKES .......................................................................................................................... 42
PARTS – FRONT WHEEL ............................................................................................................................ 43
PARTS – PLASTIC BODYWORK & SEAT ....................................................................................................... 44
PARTS – REAR BRAKE .............................................................................................................................. 46

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PARTS – REAR WHEEL ............................................................................................................................. 48
PARTS – SHOCK ....................................................................................................................................... 49
PARTS – SHOCK - INSIDE .......................................................................................................................... 50
PARTS – SWINGARM ASSEMBLY ................................................................................................................ 51
SERVICE .................................................................................................................................... 52
ENGINE SERVICE ...................................................................................................................................... 52
Base Gasket Selection....................................................................................................................... 53
CFD Adjustment................................................................................................................................. 55
Engine Removal................................................................................................................................. 55
Complete Engine Disassembly Procedure ........................................................................................ 56
Top End Disassembly Procedure ...................................................................................................... 56
Splitting the Cases............................................................................................................................. 57
Engine assembly................................................................................................................................ 58
CLUTCH ................................................................................................................................................... 59
Clutch Assembly: ............................................................................................................................... 62
IGNITION .................................................................................................................................................. 63
COOLING SYSTEM .................................................................................................................................... 64
FUEL & AIR SYSTEM ................................................................................................................................. 65
Carburetor:......................................................................................................................................... 65
Reeds:................................................................................................................................................ 67
EXHAUST ................................................................................................................................................. 67
REAR WHEEL PULLERS .............................................................................................................................. 68
BRAKES ................................................................................................................................................... 68
FRONT FORKS .......................................................................................................................................... 68
REAR SHOCK ........................................................................................................................................... 69
TUNING ...................................................................................................................................... 69
CLUTCH ................................................................................................................................................... 69
GEARING .................................................................................................................................................. 71
Front Fork Operation.......................................................................................................................... 73
Fork Damping Adjustments................................................................................................................ 73
Rear Shock Adjustments ................................................................................................................... 74
CARBURETION .......................................................................................................................................... 75
TROUBLESHOOTING ........................................................................................................... 78
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General Information
Specifications - General
Items CX50 FWE
Dimensions
Wheelbase 41” (1041mm)
Wheel size 10” (254mm) rear, 12” (305mm) front
Seat height 26” (660mm)
Engine
Type 2-stroke, single cylinder, reed valve
Cooling system Liquid-cooled
Coolant Spectro Year-Round Super Coolant
Displacement 49.8 cc
Bore and stroke 39 mm x 41.7 mm
Ignition system PVL Analogic
Spark plug – XS61 AUTOLITE, RN6YC & 8339 CHAMPION
Gap 0.023” – 0.025” (0.58 – 0.64 mm)
Ignition timing 0.035” (0.9 mm) Before Top Dead Center (BTDC)
Fuel type High octane pump gasoline
Premix Oil type Spectro Platinum SX
2
Premix oil ratio after break-in 32:1
– 60:1
Carburetion 19 mm Dell’Orto
Slow (Pilot) Jet / Main Jet 55 / 93
Needle W7-2
Needle Clip Position 2
nd
slot from top of needle
Float Height 16mm + 0.5mm (0.63” + 0.020”)
Transmission
Speed Single
Final drive ratio 15/38 T
Chain 102 links 420
Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk
Quantity 300cc (10oz)
Chassis
Front tire 2.50 (60/100) - 12"
Pressure 16 psi minimum
Rear tire 2.75 (80/100) - 10"
Pressure 16 psi min. (20 psi for hard pack or rocky conditions)
Front fork CARD 32mm USD Fully Adjustable w/ Smart Leg
Fork oil type 5wt Spectro Fork Oil
Fork oil amount 150 ml
Std settings (turns) Smart leg: 1.5 out, Compression and rebound 2 out
Rear shock (std. settings) Compression: Low 12 clicks out, High 15 clicks out
Rebound 16 clicks out, Race sag 75mm, Free sag

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Optional Suspension Components
Weight of Rider (lb) Fork Spring Shock Spring
Less than 50 lb 0.23 kg/mm
KCCS3223
green, 2.9 kg/mm
SCKGFX29
50-60 0.25 kg/mm
KCCS3223
black, 3.1 kg/mm
SCKGFX31
60-75 0.25 kg/mm
KCCS3225
red, 3.3 kg/mm
SCKGFX33
Greater than 80 0.27 kg/mm
KCCS3227
gray, 3.5 kg/mm
SCKGFX35

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Specifications - Torque Values
Fastener Torque Value Loctite TM Size &
Remarks
ft-lb in-lb Nm
Cylinder head nuts 9 110 12 M6 x 1.0
Cylinder nuts 22 265 30 M8 x 1.25**
Crankcase bolts See the next page M6 x 1.0
Spark plug (SP) (SP) (SP) M14 x 1.25
Stator bolts 2.1 25 2.8 M5 X 0.8
Ignition rotor nut 30 400 45 243 M10 x 1.25
Stator cover bolts 1.7 20 2.3 243 M4 X 0.75
Clutch cover bolts 5.8 70 7.9 M6 X 1.0
Clutch nut 40 480 54 263 M10 x 1.25
Clutch bolts 12 144 16 263 M6 x 1.0
Engine mount bolts 22 265 30 M8 X 1.25
Swingarm pivot 21 250 28 M14 X 2.0
Shock bolt 35 420 47 243 M10 x 1.5
Water pump impeller 3 36 4 263 M5 x 0.8
Water pump pulley 10 124 14 243 M6 x 1.0
Intake manifold bolts 4.6 55 6.2 M6 X 1.0
Rear axle nuts 21 250 28 M12 X 1.25
Rear sprocket bolts 21 250 28 M7 X 1.0
Front axle aluminum bolt 18 221 25 Moly lube M10 X 1.25
Fork guard alum bolts 6 88 8 243 M6X1, ALUM
Front axle pinch bolts 7.5 88 10 M6 x 1.0
Brake caliper bolts 9 106 12 243 M6 x 1.0
Brake caliper to carrier 7 84 9.5 243 M6 x 1.0
Brake pad secure 3 36 4 M5 x 0.8
Banjo bolts – brakes 15 177 20 M8 x 1.25
Brake rotor bolts 9 108 12 243 M5 x 0.8
Triple clamp bolt (top) 8 90 10 M8 x 1.25
Steering stem pinch bolt 9.5 115 13 M8 x 1.25
Triple clamp bolts (bottom) 6 72 8 M6 x 1.0
** Use a ‘crows foot’ attachment oriented 90° to the torque wrench
(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.

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Proper case bolt torque values
Torque the engine case bolts in the pattern shown above. The upper two bolts have a different
toque value compared to the others.
Proper torquing procedure would have you lubricating the threads with 30W oil, torquing the
bolts all first to an intermediate torque value of 10-12 Nm and then once they are all at that
value, proceed back at bolt #1 and toque each bolt further up to the final value.

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Break-In Procedure
Your Cobra CX50 FWE King is a close-tolerance high performance machine and break-in time
is very important for maximum life and performance. The CX50 can be ridden hard after the first
½ hour break-in time.
Cobra recommends Spectro Platinum SX
2
premix oil with high octane
pump gas mixed at 32:1 (4 oz oil to a gallon of gas).
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.
 Start bike on stand
 First 5 minute period, operate the bike on the stand with a combination of idle and high
RPM operation. (avoid prolonged high RPM but spin the rear wheel good at least once or
twice per minute)
 Allow bike to cool
 Ride for 15 minutes maximum (avoid prolonged high RPM operation and avoid abusing the
clutch with throttle blipping.
 Cool and inspect bike for loose fasteners.
 Next ½ hour of operation, 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.
 Check CFD torque and adjust as necessary
 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 lose some engine coolant through the radiator
overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level is to the
bottom of the filler neck. 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.

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Starting Procedure
Before starting the machine inspect the following:
 Tire pressure
 Chain tension
 Coolant level
 Proper wear on chain rollers and sliders
 Handlebar tightness
 Throttle assembly movement/cable adjustment
 Air Filter
 Check for loose nuts and bolts
 Turn the fuel on by rotating the fuel petcock knob to the vertically downward position
(reserve position is horizontally forward)
NOTE: For best results from your Cobra Motorcycle use only the recommended fuels. Testing
has shown that most ‘race’ fuels actually degrade performance.
Always wear a helmet and other protective riding gear.
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 and, for best
clutch performance, warm up the bike before taking off.
This is a high performance race motorcycle. Too much application of throttle will likely land
your little racer on his or her arse. 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: Make sure your riders foot is not resting on the foot brake while they are riding.

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Maintenance
A properly maintained machine is safer, faster, and more fun to ride. It is important that you
adhere to this maintenance schedule so as to promote the longevity of your Cobra Motorcycle.
Tips
1. 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.
 Extreme temperature tolerance.
 NO frictional modifiers.
 Dispersant package to keep clutch fibers in suspension so they can be
flushed out when the oil is changed.
 Extremely low viscosity for minimal drag and ‘windage’.
b. Spectro Platinum SX2 oil is the recommended premix oil because:
 Its Ester base leaves a film on all parts at all times. No metal to metal
startups or corrosion potential.
 Exception film strength over petroleum based oils or synthetic blends.
 Easily atomizes and burns completely.
 Does not fall out of suspension from premix in cold weather.
 Produces virtually no coking deposits, leaving pistons, rings and heads
extremely clean with minimal pipe ‘spooge’.
2. Filling your transmission with more than 8.0 oz (235 cc) of lubricant may help to transfer
heat from the clutch. Filling with more than 12 oz (350 cc) will degrade performance.
3. The cylinder base gasket has been ‘fitted’ for your engine. The code number stamped
into the engine cases will guide you to what thickness base gasket is required during a
common top end service. See the service section of this manual to correspond a code
number with a base gasket part number.
4. Evaluate the bikes jetting only after it has been warmed up to race temperatures.
5. New chains will stretch on first use. Never install a new chain prior to a race. Always
‘break’ them in during practice.
6. Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number). The first three
digits indicate the model while the sixth and seventh indicates the model year.
a. Example, FWExx17xxx is a 2017 CX50 SR.
7. 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.
8. 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.

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9. The frame is 4130 Chrome Moly and it is important to weld it with the proper rod and heat
settings set as light as possible. Cobra recommends replacing the frame with a new one
if the old one becomes damaged. Use ER70S6 filler if welding on the frame.
10. If your kick-starter lever does not return properly, first try loosening the six kick/clutch
cover screws ½ turn. Hold the kick lever ½ way down while retightening the six screws
starting for the center and working out
11. Inspect CFD slip torque after the 2nd ride and then again after the 6th ride. After this follow
the recommended schedule below.
12. Check proper clutch engagement before and after each ride. If the clutch is engaging
properly DO NOT feel the need to take the clutch apart to; measure the spring stack,
clean the stack, replace the springs, etc... Cobra has worked very hard to make a clutch
that is low maintenance and so only take it apart if it NEEDS to be maintained.
Schedule
 Prior to 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 re-
welded as necessary.
o Check the rims for signs of stress; like cracks around the rim, spokes, and hub.
o Equalize the pressure in the forks with atmosphere. Release any pressure built up
inside the fork by loosening the bleed screw on the fork cap. Retightening after
pressure is released.
 Every 2 hours of operation
o Replace the transmission oil.
o Check the CFD torque.
 Every 10 hours of operation
o Replace the fork oil.
o Have the shock oil replaced by a Certified Cobra Mechanic.

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Replacing Transmission / Clutch Lubricant
Tools needed:
 5mm allen wrench
 Minimum of 300 cc (10 oz) Cobra Venom 3 Shoe Clutch Milk (Part #MCMUGF32).
Procedure:
1. Begin this procedure with a bike that has been ridden more than 5 minutes but less than 10
minutes. It is desired to have the engine warm enough so that the oil is ‘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.
2. Remove the oil drain plug located on the right side of the engine, on the clutch cover, near
the brake lever (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.
NOTE: Putting additional oil, up to 350 cc (12 oz), can help clutch life. More than 350 cc (12
oz) will degrade engine performance.
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.
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.
Figure 1

13
Proper Chain adjustment
Tools required for chain adjustment
 19 mm wrench or socket
 13 mm wrench or socket
1. Make sure that the rear wheel is aligned properly.
2. For proper adjustment, the chain should have 35mm
(1.378”) free movement just behind the chain guard
with no load on the bike (figure 2)
CAUTION:
Sit on the bike and verify that the chain has a minimum of 12mm (1/2”) free movement when the
chain is at its tightest point.
3. If the chain requires adjusting, loosen the axle
with a 19 mm wrench and tighten the chain by
rotating the adjustor bolts clockwise (CW) or
loosen the chain by rotating the adjustor bolts
(CCW).
4. Ensure proper alignment of the rear wheel by
making sure there are equal amounts of the
alignment holes (figure 4) showing on each
side of the wheel.
5. Retighten the axel bolt to 25 ft-lb (34 Nm).
6. Retighten the adjustor bolt (figure 3)
Figure 3 (top), Figure 4 (bottom)
Figure 2

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Rear Brake Maintenance
CAUTION: Too little brake pedal free-play will allow the brake pads to drag causing the pads
to wear prematurely and possible engine component failures. Too much free-play will not allow
the rider to apply the brakes quickly.
1. Set pedal height/position first, then
2. Set pedal free play.
Brake pedal height can be adjusted with the bolt located above the rear of the brake pedal.
The free-play is adjusted with the adjustable plunger on the end of the brake pedal.
CAUTION: Use New container of Spectro DOT4 Racing
Brake Fluid
Setting rear brake pedal position (see figure 2b):
1. Loosen the height adjust lock nut (10mm wrench)
2. Adjust the height adjust screw (5mm Allen
wrench) so that the lever is comfortably reachable
in both:
a. Standing riding position, and
b. Sitting riding position.
3. Tighten the height adjust lock nut.
CAUTION: Adequate pedal free play is required so that
the brake pads do not drag on the rotor.
Make sure that the free play locking clip is installed such
that one must push forward, toward the front of the bike, to remove.
Otherwise the clip is apt to come undone while riding.
To adjust freeplay (see figure 2b):
1. Loosen the lock nut (10mm).
2. Undo the free play locking clip from around the brake adjustor (plunger), with your hand
by pushing it forward.
3. Slide the pin of the locking free play locking clip from the brake lever
4. Adjust as needed by rotating the clevis on the end of the adjustor (plunger).
NOTE: Turning the clevis Clockwise will lengthen the adjustor (plunger), removing free play
from the system, and turning the clevis Counter-Clockwise will shorten the adjustor (plunger)
adding free play to the system.
Figure 2b

15
Air Filter Cleaning
Removal:
 Remove the seat
 Loosen the clamp connecting the rubber boot of the filter to
the carborator
 Push the rubber boot from the bottom up and out of the airbox
CAUTION: Pulling on the filter instead of pushing up on the boot may cause tearing of the
filter.
NOTE: Using one hand to control the filter
end while removing will help reduce the risk of
damage to the filter
 Pull the tab on the filter to remove it from
the rubber boot
 Clean the airbox of dirt.
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.
CAUTION: Cleaning the air filter with alcohol or using filter oil that
contains alcohol may cause filter glue separation.
1. Install the cover (RCMU0109) over the carburetor inlet
2. Spray out the airbox.
Do not clean the air filter with gasoline or other highly volatile petroleum product. Diesel fuel or
kerosene would be preferred but caution should still be taken. Hot soapy water works well.
1. Clean the filter in hot soapy water to remove all dirt particles.
2. Allow it to dry thoroughly.
3. Saturate with filter oil and remove excess.
NOTE: It’s very important to oil your filter consistently each time because varied amounts of oil
will change your carburetor jetting.
Carburetor Cover

16
Assembly:
1. Place the filter back onto the rubber boot.
2. With one hand on the filter, feed the rubber boot into the airbox
CAUTION: In order to avoid air filter tearing, make sure to place a hand on the filter while
feeding the boot through the airbox.
NOTE: Make sure you change or clean your filter after each moto. We recommend carrying
multiple filters in your toolbox, one for each practice session and moto.
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.
For routine maintenance, the chart below provides suggested service intervals for common
procedures:
Each Ride 10 hours 20 hours As Needed
Bleed excess air X
Change Oil X
Change
Seal/Swiper X
Change Bushings X
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. 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. Be careful not to lose or damage the sealing ring that is located
under the head of each bleed screw.

17
Fork Oil Replacement
Tools required
 32mm Fork Cap Tool (MCMUTL32)
 8mm Allen wrench
 4 & 5 mm hex key (Allen wrench)
 9/16 wrench
 Mallet
 5 wt. Spectro fork oil
Disassembly procedure
1. Remove the front wheel and axle (8mm Allen wrench).
2. Remove brake line clamp.
3. Remove the brake caliper from the fork leg (4mm hex key).
4. Loosen the top pinch bolts (6mm hex key).
5. Loosen the fork caps (32mm fork cap tool).
6. Loosen the bottom pinch bolts (5mm hex key).
7. Remove the fork legs from the triple clamps (5 and 8mm hex key).
8. One leg at a time
a. Remove the fork cap from the fork tube.
b. Pull the fork spring down to gain access to the fork cap jam nut and secure it with a
9/16 wrench.
c. Holding in one hand the 9/16 wrench use the fork cap wrench to unscrew the fork
cap from the damper rod.
d. Remove the fork spring pad, and fork spring.
e. Inside the damper rod, the rebound adjustment screw pin is resting and will fall out
of the damper rod when the fork is inverted. Try to catch it before it falls into your oil
bucket.
f. Invert the fork and allow the oil to drain completely. Working the damper rod up and
down will speed up the draining process.
Assembly procedure
1. Fill the fork with 150ml of fork oil.
2. Work the damper rod up and down to allow the fork cartridge to fill with oil.
3. Install the rebound adjustment screw pin into the damper rod.
4. Install the fork spring and spring pad.
5. Extend the damper rod completely and Compress the fork spring enough to begin
threading the fork cap back onto the damper rod.
6. Make sure that the fork cap threads onto the damper rod completely before it makes
contact with the jamnut.
7. Tighten the jamnut.
8. Tighten the fork cap to the fork leg outer
9. Install each leg back into the triple clamp. Torque each pinch bolt to 14N-m (10.3 ft-lb)
making sure both legs are set to the same height in the clamps.

18
10. Pump the fork leg several times to verify that it operates smoothly.
11. Reinstall the brake caliper.
12. Reinstall the front wheel (25 ft-lb, 34 Nm).
Frictional Drive (V3 CFD)
The Cobra Frictional Drive (CFD) is essentially an adjustable slip clutch that dissipates torque
spikes transmitted from the rear wheel to the rest of the drive line and engine. Instead of these
torque spikes potentially damaging internal components, the CFD allows the transmission to
slip with respect to the engine. For this to
occur, the CFD must function properly by
‘slipping’ above a minimum torque value.
The safe minimum slip torque of the CFD
should be checked every 2 hours of
operation, after break-in.
The slip torque value should be above 80 ft-
lb (108 Nm) measured at the sprocket with
the following process.
To properly measure the minimum
torque at which the CFD (Cobra
Frictional Drive) slips
1. Remove the oil fill plug and install the check tool/pin MCMUTL40.
2. Make sure that it is threaded in completely until it bottoms out.
3. Install the Sprocket Socket CFD torque checking tool (MCMUTL15) on the output shaft
protruding through the sprocket.
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.
5. If there is slippage below 108 Nm (80 ft-lb)
remove the cotter pin and tighten the castle nut
on the CFD one more position (it is a left hand
thread nut so you must turn it counter clockwise)
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.