Cobra Moto CX50 FWE User manual
Owners
Parts
Service
Tuning
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 CX5E 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. MCCE12023.0
2
Table of Contents
GENERAL INFORMATION ..................................................................................4
SPECIFICATIONS -GENERAL......................................................................................................... 4
OPTIONAL SUSPENSION COMPONENTS......................................................................................... 5
SPECIFICATIONS -TORQUE VALUES............................................................................................. 6
POWER UP PROCEDURE ............................................................................................................... 7
MAINTENANCE ...................................................................................................9
TIPS ............................................................................................................................................. 9
SCHEDULE ................................................................................................................................. 10
REPLACING MOTOR COOLING FLUID......................................................................................... 11
PROPER CHAIN ADJUSTMENT ..................................................................................................... 11
REAR BRAKE MAINTENANCE..................................................................................................... 13
FORK MAINTENANCE................................................................................................................. 14
Fork Air Bleeding ................................................................................................................ 14
Fork Oil Replacement.......................................................................................................... 15
DISASSEMBLY PROCEDURE ........................................................................................................ 15
PARTS –BARS AND CONTROLS.................................................................................................. 17
PARTS –BATTERY ..................................................................................................................... 18
PARTS –COOLANT SYSTEM ....................................................................................................... 19
PARTS –ELECTRICAL SYSTEM................................................................................................... 20
PARTS –ELECTRONICS BOX....................................................................................................... 21
PARTS –FORKS &TRIPLE CLAMPS............................................................................................ 22
PARTS –FORKS –LEG ASSEMBLY –BRAKE SIDE ...................................................................... 24
PARTS -FORKS –LEG ASSEMBLY –NON-BRAKE SIDE............................................................... 26
.................................................................................................................................................. 26
PARTS –FRAME &SUBFRAME................................................................................................... 28
PARTS –FRONT BRAKES............................................................................................................ 29
PARTS –FRONT WHEEL............................................................................................................. 30
PARTS –MOTOR SYSTEM -INTERNALS...................................................................................... 31
PARTS –PLASTIC BODYWORK &SEAT ...................................................................................... 34
PARTS –REAR BRAKE ............................................................................................................... 36
3
PARTS –REAR WHEEL............................................................................................................... 38
PARTS –SHOCK ......................................................................................................................... 39
PARTS –SHOCK -INSIDE............................................................................................................ 40
PARTS –SWINGARM ASSEMBLY ................................................................................................ 41
SERVICE............................................................................................................42
MOTOR COOLING FLUID REPLACEMENT.................................................................................... 42
REAR WHEEL PULLERS ............................................................................................................... 42
BRAKES ..................................................................................................................................... 43
FRONT FORKS ............................................................................................................................ 43
REAR SHOCK ............................................................................................................................. 43
TUNING..............................................................................................................44
GEARING.................................................................................................................................... 44
Front Fork Operation.......................................................................................................... 45
Fork Damping Adjustments................................................................................................. 45
Rear Shock Adjustments...................................................................................................... 46
TROUBLESHOOTING........................................................................................48
4
General Information
Specifications - General
Items
CX50 FWE
Dimensions
Wheelbase
41” (1041mm)
Wheel size
10” (254mm) rear, 12” (305mm) front
Seat height
26” (660mm)
Motor
Type
Cobra –out runner
Cooling system
Liquid-cooled
Coolant
Cobra Motor Cooling Fluid, 500 ml
Final drive ratio
10/50 T
Chain
110 links 420
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 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/Free sag 75/25mm
Free sag 25mm
5
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
KCCS3225
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
6
Specifications - Torque Values
Fastener
Torque Value
LoctiteTM
Size &
Remarks
ft-lb
in-lb
Nm
Phase & power to MDU
4.4
53
6.0
No
M5 x 0.8
Phase wires to Motor
3.7
44
5.0
no
M6x1.0, copper
Motor 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
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
7
Power Up Procedure
•Before Powering Up the machine inspect the following
oTire pressure
oChain tension
oCooling fluid level
oProper wear on chain rollers and sliders
oHandlebar tightness
oThrottle assembly movement
oCheck for loose nuts and bolts
•Turn the battery on by pressing the Power Button for 2 seconds
Always wear a helmet and other protective riding gear.
CAUTION: Make sure your rider’s foot is not resting on the foot brake while they are riding.
For charging...
Ensure good AC power....if not, fast charging may produce faults.... however, slow charge is
still an option on slightly bad power until we get some software updated.
Charging Procedure:
Plug Charger into AC, then Plug into battery with Positive wire towards the back of the
bike...while turning the lock ring clockwise to lock it down. Then press the battery power button
once and wait a few seconds. The voltage indicator on the battery will start flashing
slowly(slow charge). Then hit the battery power button one more time and the voltage indicator
will not start flashing faster. Slow Charge: 2 hours, Fast Charge: 1 hour. Once all the lights on
the indicator are solid and not flashing charging is complete.
There is a new "Pre-Race" charge mode... once battery is already full. Turn battery off with
long press on the battery power button....then back on. When the battery sees that it is already
charged it will run the “Pre-Race” algorithm… and prepares the pack for maximum runtime.
This will come with the molded case battery packs.
Don'ts:
1. Don't leave battery fully charged for weeks at a time.
2. Don't leave battery with 1 light on charge indicator for weeks at a time.
3. See washing best methods.
4. Coolant is not engine Anti-Freeze!....it is mineral oil based with special additives. Anti-
Freeze is conductive and the bike will not run.
5. There is coolant in the system even though you can't see it when taking the cap off. With the
bike on the stand and powered up, apply some throttle and you should see fluid flowing in the
radiator... that is all you need to see!
Do's:
1. 2 or 3 lights on battery indicator before storing. Bike can be plugged into battery when
stored.
8
2. Check chain sliders and sprockets regularly.
3. Change cooling fluid every 3 months.
4. Lube chain each moto.
For those serious racers:
1. Warm up motor before racing for better starts. Feel radiator with hand until close to normal
running temp is reached.
2. Top off battery after warm up cycle. This is a balance as motor temp is cooling while
charging.
3. Adding a couple psi would improve top speed and runtime, but at the cost of a little initial
traction.
4. If run time is a priority, please see “Pre-Race” charge mode.
Change Bike Modes:
Bike must be disabled (“Active” light is off), before mode can be changed. Hitting the “GO”
button activates and deactivates the bike.
Add the LED light numbers to get the mode number. Hitting the upper Left Mode button cycles
through modes.
Modes:
1. Mode 1 is ~15mins of full power with a de-power at the last stage before going into turtle
mode....make sure they are aware. Applying a lot of throttle once in turtle mode will cause a
fault(with current software) stopping the bike. This is our normal race mode.
2. Mode 2 is 18mins of a gradual power reduction to increase run time....this is similar to how
competing bikes acts over a full battery run. Same peak power as mode 1.
3. Mode 3 is a lower power version of Mode 1(approx. 95%), Mode 4 is a lower power version
of Mode 2(95%)
4. Other modes are in flux, but there are slick track versions of mode 1 and 2 on Modes 5 and
6... they just have a softer feel. This probably will change based on feedback.
Holeshot Mode:
1. While not as much of a change from Holeshot to Race Stage after some recent software
updates... there is a power boost for the starting line. We are working on improvements to up
the "out of starting gate" performance even more and should have that available at LL.
2. It is automatically armed when the bike is "Active"... Once the throttle hits 100%, Holeshot
mode will engage for 8secs. If a false start happens and race restarted, then get back to the
gate and hit the "GO" button to deactivate, then reactivate with the "Go" button again. This
resets/rearms the Holeshot mode.
3. Small throttle blips will keep the bike from going to sleep as there is a 1 minute inactivity
timeout.
Washing:
1. Please pull the battery out of the bike to wash(it's just three 10mm nuts).... that would
eliminate 75-95% or more of the electrical problems ebikes tend to have either way.
2. Check for dirt/mud in main bike connector and clear with Q-tip or paper towel.
3. Wash RDU and Tank area sparingly, avoid direct pressure spray.
4. Allow ample drying time.
9
5. Be mindful of anything with wires coming out of it. Things can be waterproof, but those same
things may not be pressure washing proof.
Other:
1. While on track, if active light starts flashing....either from falling over and being tilting too
long or kill switch key falling off... when issue is resolved, one button press(1sec) of the "GO"
button will reset and allow rider to continue on.
2. If lower red fault light(Lightning bolt) comes one while riding and bike will not run... most
likely a hall sensor board issue and should be first item to replaced. Otherwise, check wiring
for pinches, etc. This fault light is also a "catch all" for other bike system issues…kill switch,
non-zero throttle, loss of CAN bus etc.
3. Lower left fault light(Battery) indicates an issue with the battery and needs to be looked at.
Check battery indicators for fault code.
4. After sitting a few weeks or from brand new... batteries will need a few runs to "Wake" up.
Performance will improve over that time.
5. We should also have other optional sprockets available soon.... a 2 tooth change is
significant. Will have 48, 50 and 52t available soon. 50t is standard. Possibly a 49t and 51t as
well.
Other issues:
1. While we feel we have taken care of the 99.5% of the issues we are aware of, there is still
the possibility of other small bugs or a parts failure(Electronics, batteries or wiring) that could
be possible. We will do our best to find any new issues and fix ASAP.
2. Doing troubleshooting remotely is no fun for anyone. We are working on options to get a
diagnostic tool in people's hands as quickly as possible. A dealer diagnostic tool will also be
available shortly.
3. Battery change can happen in under 1 min. No serial number or programing change
needed. Potential for 1 practice pack to ride bike to the line(warmup), then swap battery in
staging for race pack...so full pack and warm motor….lots of possibilities around that.
Maintenance
A properly maintained machine is safer, faster, and more fun to ride. It is important that you
adhere to this maintenance schedule to promote the longevity of your Cobra Motorcycle.
Tips
1. Cobra Motor Cooling Fluid is the ONLY cooling fluid that is compatible with high voltage
electronics and provides the necessary lubrication for the bearings.
CAUTION: Coolant designed for Internal Combustion Engines (motor coolant, engine coolant,
antifreeze, etc.…) is not compatible with the high voltage electronics in the motor and will cause
motor faults, potential damage, and an avoidable tech call and down time.
2. New chains will stretch on first use. Never install a new chain prior to a race. Always
‘break’ them in during practice.
3. 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.
10
a. Example, FWExx17xxx is a 2017 CX50 SR.
4. The frame is 4130 Chrome Moly & HSLA, 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.
Schedule
•Prior to each ride
oChain for proper tension and lubrication
oChain ‘slider’ wear on both chain sliders
oInsure the smooth operation of the electronic throttle cable.
oCheck for adequate tire pressures and adjust if necessary.
oCheck all nuts and bolts for proper torque and re-torque if necessary.
oCheck the frame for cracks in the metal or cracks in the paint that might indicate that
the metal has been stressed beyond its safe limits. Replace or get properly re-
welded as necessary.
oCheck the rims for signs of stress; like cracks around the rim, spokes, and hub.
oEqualize 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 20 hours of operation
oReplace the fork oil.
oHave the shock oil replaced by a Certified Cobra Mechanic.
•Every 50 hours of operation
oReplace the Motor Cooling Fluid.
11
Replacing Motor Cooling Fluid
Tools needed:
•8mm Allen wrench
•Minimum of 500 cc (16 oz) Cobra Motor Cooling Fluid (Part #MCMUMF32).
Procedure:
(to be completed)
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 2
12
Figure 3 (top), Figure 4 (bottom)
13
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 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 free play (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
14
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.
15
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. VP 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.
16
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).
17
Parts –Bars and Controls
Bars and Controls
REF #
PART #
DESCRIPTION
1
FAMU0014
HANDLEBAS –MICROBARS –COBRA BEND
2
TCMU0021
GRIPS (SET OF TWO) –MICROGRIPS
3
FACE50006MP
THROTTLE ASSEMBLY –TWIG -ELECTRONIC
3A
HCBC0412
M4X12 SHSC
4
FCMU0041
STOP RING –MICRO BAR THROTTLE
5
SEE FRONT BRAKE
6
NCCE50001MP
KILL SWITCH ASSEBLY -MAGNETIC
7
NCCEMU002
KEY –RED –RACER -KILL SWITCH ACTIVATE
7
NCCEMU005
KEY –YELLOW –RACER -KILL SWITCH ACTIVATE
8
HCBC0806
M8X30mm SOCKET HEAD CAP SCREW (4 REQ’D)
9
TCMU0060BLK
BAR CLAMP –BLACK (2 REQ’D)
ACCESSORY
MCMUAM11
GRIP DONUT –PAIR –PRO TAPER MICRO BAR
ACCESSORY
FKMU0004
HANDLEBAR KIT- PRO TAPER MICRO- WITH COBRA
THROTTLE AND GRIPS
ACCESSORY
TCMU00002BLK
BAR RISER KIT
18
Parts –
Battery
Battery
REF #
PART #
DESCRIPTION
1
DACE10002
BATTERY ASSY –1.0 kWh –W MOUNTING HARDWARE
2
DCCE10010
GROMMET –REAR BATTERY MOUNT 1kWh
3
DCCE10009
COMP LIMITER –REAR BATTERY MOUNT 1kWh
4
DCCE10006
STUD –FRONT BATTERY MOUNTING
5
DCCE10012
SHIELD –BATTERY EDGE –RIGHT SIDE
6
HCTF0416
M4X16MM THREAD FORMING SCREW FOR PLASTIC
7
DCCE10013
SHIELD –BATTERY EDGE –LEFT SIDE
8
DCCEMU001
BLOCK OFF –CONNECTOR –BATTERY
9
ZCCEMUOR4
O’RING – BATTERY BLOCK OFF CAP
10
BCCE10005
OVERLAY –BATTERY USER INTERFACE
11
DCCE10008
COMPRESSION LIMITER –FRONT BATTERY MOUNT
12
DCCE10007
GROMMET –FRONT BATTERY MOUNT
13
HCNF0004
6MM FLANGE LOCKNUT –DISTORTED THREADS –7.5MM TALL
Other manuals for CX50 FWE
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