Cobra 2005 King User manual

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 MCKG2005.4
1

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.
2

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...................................................................................................10
MAINTENANCE..................................................................................................10
SCHEDULE &TIPS..............................................................................................10
REPLACING TRANSMISSION /CLUTCH LUBRICANT.................................................12
CHAIN ADJUSTMENT ...........................................................................................13
REAR BRAKE MAINTENANCE...............................................................................13
AIR FILTER CLEANING ........................................................................................14
FORK OIL REPLACEMENT ...................................................................................15
PARTS................................................................................................................16
PARTS –AIRBOX &INLET SYSTEM ......................................................................16
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 Kicker................................................................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
3

PARTS –FRAME I...............................................................................................31
Parts – Frame II...........................................................................................32
PARTS –FRONT BRAKES....................................................................................33
PARTS –FRONT WHEEL.....................................................................................34
PARTS –PLASTIC BODYWORK &SEAT ................................................................35
PARTS –REAR BRAKE .......................................................................................36
PARTS –REAR WHEEL.......................................................................................37
PARTS –SHOCK ................................................................................................38
PARTS –SWINGARM ASSEMBLY..........................................................................39
SERVICE............................................................................................................40
ENGINE SERVICE ...............................................................................................40
Engine Removal ..........................................................................................41
Complete Engine Disassembly Procedure ..................................................42
Top End Disassembly Procedure ................................................................42
Splitting the Cases.......................................................................................43
Engine assembly .........................................................................................44
CLUTCH ............................................................................................................50
IGNITION ...........................................................................................................55
COOLING SYSTEM..............................................................................................57
FUEL &AIR SYSTEM ..........................................................................................61
EXHAUST ..........................................................................................................64
WHEELS &TIRES...............................................................................................65
BRAKES ............................................................................................................66
FRONT FORKS...................................................................................................67
REAR SHOCK ....................................................................................................69
TUNING..............................................................................................................70
GEARING...........................................................................................................70
SUSPENSION .....................................................................................................71
CARBURETION...................................................................................................72
TROUBLESHOOTING........................................................................................75
INDEX.................................................................................................................76
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, 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
0.040” (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
96
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
14/38 T
Chain
100 links 420
Transmission / clutch oil type
Cobra Venom 3 Shoe Clutch Milk
Quantity
235 ml (8.0oz)
5

Chassis
Front tire
2.50 - 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
Call your dealer, or the factory, for details
•Carburetor jets
•Flat clutch washers (see clutch service section)
•Pre filter for the airbox
•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
SCKGOH95, (yellow, 195 lb/in)
Greater than 60
15 lb/in,
KCKG0015
SCKGO205, (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
•Tires
•Tubes or ‘Tire Balls’
6

Specifications - Torque Values
Fastener Torque Value Size & Remarks
ft-lb in-lb Nm
Cylinder head
nuts
8.8 105 12 M6 x 1.0
Crankcase
bolts
8.8 105 12 M6 x 1.0
Spark plug (SP) (SP) (SP) M14 x 1.25
Stator bolts 2.1 25 2.8 M5 X 0.8
Stator cover
bolts
1.7 20 2.3 M4 X 0.75
Clutch cover
bolts
5.8 70 7.9 M6 X 1.0
Clutch nut 40 480 54 M10 x 1.25*
Clutch bolts 14 170 19 M6 x 1.0
Front axle nut 25 300 34 M12 x 1.25
Engine mount
bolts
22 265 30 M8 X 1.25
Swingarm
Pivot
21 250 28 M14 X 2.0
Intake manifold
bolts
4.6 55 6.2 M6 X 1.0
Rear Axle Bolt 25 300 34 M12 X 1.25
Rear Sprocket
Bolts
18 216 24 7 mm
Fork cartridge
rod
12 144 16
Triple clamp
bolts
6 72 8 M6 x 1.0
Fork cap 5 60 6.7 1.25” x 18
Ignition rotor
nut
40 480 54 M10 x 1.25*
* Apply high strength thread locking agent when installing
(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
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.
•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
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.
8

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.
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 that the fuel tank contains an adequate volume of fuel / oil mixture to
complete the distance required. (High 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. Also, for
best clutch performance, warm up the bike before taking off.
9