Cobra 2004 King User manual

2004 KING
Owners / Service / Parts
“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
[phone]
If you need technical assistance
contact your local dealer or call
the Cobra Technical Support Hotline at
[phone]
Cobra Motorcycle MFG., Inc.
11511 Springfield Road
North Lima, Ohio 44452 MCKG2004.7

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 USEDON 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.

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Table Of Contents
GENERAL INFORMATION............................................................................................5
SPECIFICATIONS -GENERAL...........................................................................................5
OPTIONAL COMPONENTS................................................................................................6
SPECIFICATIONS -TORQUE VALUES ..............................................................................7
BREAK-IN PROCEDURE...................................................................................................8
STARTING PROCEDURE ..................................................................................................9
GENERAL TIPS................................................................................................................9
MAINTENANCE .............................................................................................................10
SCHEDULE & TIPS.........................................................................................................10
REPLACING TRANSMISSION / CLUTCH LUBRICANT ......................................................11
CHAIN ADJUSTMENT......................................................................................................13
REAR BRAKE MAINTENANCE ........................................................................................13
AIR FILTER CLEANING...................................................................................................14
FORK OIL REPLACEMENT.............................................................................................15
PARTS .............................................................................................................................17
PARTS –BARS AND CONTROLS ...................................................................................17
PARTS -CARBURETOR .................................................................................................18
PARTS –COOLANT SYSTEM.........................................................................................19
PARTS –ELECTRICAL SYSTEM.....................................................................................20
PARTS –ENGINE –BOTTOM END AND TRANSMISSION...............................................21
Parts –Engine –Clutch and Kick Starter...........................................................22
Parts –Engine –Ignition and Water Pump........................................................23
Parts –Engine –Top End.....................................................................................24
PARTS –EXHAUST SYSTEM .........................................................................................25
PARTS –FORKS & TRIPLE CLAMPS.............................................................................26
Parts –Forks –Leg Assembly.............................................................................27
Parts –Forks –Damper Assembly......................................................................28
Parts –Forks –Damper –Base Valve Assembly.............................................29
Parts –Forks –Damper –Mid Valve Assembly................................................30
PARTS –FRAME –BRAKE MOUNTS, PLASTIC SHIELD & FOOTPEGS.........................31

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Parts –Frame -Exhaust, Radiator, & Engine Mounts.....................................32
Parts -Frame –Subframe, Shock, & Bodywork Mounts.................................33
PARTS –FRONT BRAKES..............................................................................................34
PARTS –FRONT WHEEL...............................................................................................35
PARTS –PLASTIC BODYWORK & SEAT........................................................................36
PARTS –REAR BRAKE..................................................................................................37
PARTS –REAR WHEEL.................................................................................................38
PARTS –SHOCK ...........................................................................................................39
PARTS –SWINGARM ASSEMBLY ..................................................................................40
SERVICE.........................................................................................................................41
ENGINE SERVICE...........................................................................................................41
Engine Removal.....................................................................................................42
Complete Engine Disassembly Procedure.........................................................43
Top End Disassembly Procedure........................................................................43
Splitting the Cases.................................................................................................44
Engine assembly....................................................................................................45
CLUTCH .........................................................................................................................50
IGNITION ........................................................................................................................54
COOLING SYSTEM.........................................................................................................56
FUEL & AIR SYSTEM.....................................................................................................60
EXHAUST.......................................................................................................................63
WHEELS & TIRES..........................................................................................................64
BRAKES.........................................................................................................................65
SUSPENSION.................................................................................................................69
Rear Shock..............................................................................................................71
Front Forks..............................................................................................................72
TROUBLESHOOTING ..................................................................................................73
INDEX..............................................................................................................................75

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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, analog advance
Spark plug Champion 8339-1, 8332-1 hotter, 8904-1 colder
Gap 0.023” –0.025” (0.58–0.64 mm)
Ignition timing 0.045” (1.14 mm) Before To Dead Center (BTDC)
Fuel type High octane pump gasoline
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 95
Slow (Pilot) jet 65
Float Height 16mm +0.5mm (0.63” +0.020”)
Coolant Liquid Performance Mini Coolant / Antifreeze
Transmission
Speed Single
Final drive ratio 14/39 T
Chain 100 links 420
Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III
Quantity 235 ml (8.0oz)

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Chassis
Front tire2.50 -12
Pressure 16 psi minimum
Rear tire 2.75 -10
Pressure 16 psi min. (20 psi for hard pack or rocky conditions)
Front fork Cobra 30mm USD
Fork oil type SAE 10 weight
Fork oil amount 105 ml (3.5oz)
Optional Components
•Carburetor jets
•Sprockets
oFront
oRear
•Suspension Springs
Weight of Rider (lb) Fork Spring Shock Spring
Less than 51 9 lb/in,
KCKG0109 SCKGOH85 (gray, 185 lb/in)
51 -60 12 lb/in,
KCKG1201 SCKG0H95, (yellow, 195 lb/in)
Greater than 60 15 lb/in,
KCKG0015 SCKG0205, (gold, 205 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

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Specifications -Torque Values
Torque Value
Fastener ft-lb in-lb Nm Size & Remarks
Cylinder head
nuts 9.2 110 12 ¼”-20
Crankcase
bolts 6.6 80 96 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 x 1.25***
Front axle nut 25 300 34 12 x 1.25
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 672 86 x 1.0
Fork cap 560 6.7 1.25” x 18
Ignition rotor
nut 40 480 54 10 x 1.25**
** 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.

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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
high octane pump gas, 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
oFollow the starting procedure listed in this manual.
oAvoid prolonged operation at Wide Open Throttle.
•After 1 hour of operation
oCheck for loose bolts and nuts on the bike and retighten as
necessary (proper toque values are listed under Specifications).
oClean the carburetor bowl.
oChange the transmission / clutch lubricant.
•After 8 hours of operation
oChange the fork oil.
oHave 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
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.

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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 and sliders do not have improper wear.
•Verify that the handlebars are tight.
•Check the throttle for smooth operation and sound closing.
•Check for loose bolts and nuts, and re-torque as necessary.
•Verify that the air filter is clean and properly saturated with oil.
•Insure thatthe fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required. (Highoctane 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. Also, for
best clutch performance, warm up the bike before taking off.
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.