Cobra CX50 SR User manual

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 CX50SR (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.
MCCS2017.0

2
Table of Contents
GENERALINFORMATION....................................................................................................4
SPECIFICATIONS‐GENERAL................................................................................................................4
OPTIONALSUSPENSIONCOMPONENTS.................................................................................................5
SPECIFICATIONS‐TORQUEVALUES......................................................................................................5
BREAK‐INPROCEDURE......................................................................................................................6
STARTINGPROCEDURE......................................................................................................................7
MAINTENANCE....................................................................................................................8
TIPS...............................................................................................................................................8
SCHEDULE.......................................................................................................................................9
REPLACINGTRANSMISSION/CLUTCHLUBRICANT.................................................................................10
PROPERCHAINADJUSTMENT............................................................................................................11
REARBRAKEMAINTENANCE............................................................................................................11
BRAKEBLEEDINGPROCEDURE..........................................................................................................13
AIRFILTERCLEANING......................................................................................................................14
FORKMAINTENANCE......................................................................................................................15
ForkAirBleeding...................................................................................................................15
ForkOilReplacement............................................................................................................16
FRICTIONALDRIVE(V3CFD)...........................................................................................................17
PARTS–AIRBOX&INLETSYSTEM.....................................................................................................19
PARTS–BARSANDCONTROLS..........................................................................................................20
PARTS–CARBURETOR....................................................................................................................21
PARTS–COOLANTSYSTEM..............................................................................................................22
PARTS–ELECTRICALSYSTEM............................................................................................................23
PARTS–ENGINE–BOTTOMENDANDTRANSMISSION..........................................................................24
PARTS–ENGINECLUTCHANDKICKLEVER..........................................................................................26
PARTS–ENGINE–WATERPUMP.....................................................................................................28
PARTS–ENGINE–TOPEND............................................................................................................29
PARTS–EXHAUSTSYSTEM...............................................................................................................30
PARTS–FORKS&TRIPLECLAMPS.....................................................................................................32
PARTS–FORKS–LEGASSEMBLY–BRAKESIDE...................................................................................34
PARTS‐FORKS–LEGASSEMBLY–NON‐BRAKESIDE............................................................................36
PARTS–FRAMEI...........................................................................................................................38
PARTS–FRAMEII..........................................................................................................................39
PARTS–FRONTBRAKES..................................................................................................................40
PARTS–FRONTWHEEL..................................................................................................................41
PARTS–PLASTICBODYWORK&SEAT................................................................................................42
PARTS–REARBRAKE.....................................................................................................................43

3
PARTS–REARWHEEL....................................................................................................................44
PARTS–SHOCK.............................................................................................................................45
PARTS–SHOCK‐INSIDE..................................................................................................................46
PARTS–SWINGARMASSEMBLY........................................................................................................47
SERVICE.............................................................................................................................48
ENGINESERVICE............................................................................................................................48
BaseGasketSelection...........................................................................................................49
EngineRemoval.....................................................................................................................51
CompleteEngineDisassemblyProcedure............................................................................52
TopEndDisassemblyProcedure...........................................................................................52
SplittingtheCases.................................................................................................................53
Engineassembly....................................................................................................................54
CLUTCH........................................................................................................................................55
ClutchAssembly....................................................................................................................59
IGNITION......................................................................................................................................60
COOLINGSYSTEM...........................................................................................................................61
FUEL&AIRSYSTEM.......................................................................................................................63
Carburetor:............................................................................................................................63
Reeds:....................................................................................................................................65
EXHAUST......................................................................................................................................65
REARWHEELPULLERS.....................................................................................................................65
BRAKES........................................................................................................................................66
FRONTFORKS................................................................................................................................66
REARSHOCK.................................................................................................................................66
TUNING.............................................................................................................................67
CLUTCH........................................................................................................................................67
GEARING......................................................................................................................................69
SUSPENSION.................................................................................................................................71
Adjustment............................................................................................................................71
FrontForkOperation............................................................................................................72
ForkDampingAdjustments..................................................................................................72
RearShockAdjustments.......................................................................................................73
CARBURETION...............................................................................................................................74
TROUBLESHOOTING..........................................................................................................77

4
General Information
Specifications - General
Items CX50 SR
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
Coolant Bel Ray Moto Chill
Displacement 49.8 cc
Bore and stroke 39 mm x 41.7 mm
Ignition system PVL Analogic
Spark plug Autolite – XS61 & 4261
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 Bel-Ray H1-R
Premix oil ratio after break-in 40:1 to 50:1
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 100 links 420
Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk
Quantity 300ml (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 2.5wt Bel-Ray Fork Oil
Fork oil amount 155 ml
Std settings Smart leg: 1.5 out, Compression and rebound 2 out
Rear shock (std. settings) Compression: Low 12 out, High 15 out
Rebound 16 out, Race sag 75mm

5
Optional Suspension Components
Weight of Rider (lb) Fork Spring Shock Spring
Less than 50 lb 0.23 kg/mm
KCCS3223 red, 3.3 kg/mm SCKGFX33
50 – 60 0.23 kg/mm
KCCS3223 gray, 3.5 kg/mm SCKGFX35
60-75 0.25 kg/mm
KCCS3225 yellow, 3.7 kg/mm SCKGFX37
Greater than 80 0.27 kg/mm
KCCS3227 gold, 3.9 kg/mm SCKGFX39
Specifications - Torque Values
Fastener Torque Value LoctiteTM 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 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 54 263 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 6 75 8 243 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
Axle nuts 25 300 34 M12 X 1.25
Rear sprocket bolts 16 195 22 243 7 mm
Rear brake rotor bolts 9 108 12 243 M6 x 1.0
Triple clamp bolts (top) 9 108 12 M6 x 1.0
Triple clamp bolts (bottom) 6 72 8 M6 x 1.0
Ignition rotor nut 30 400 45 243 M10 x 1.25
**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.

6
Break-In Procedure
Your Cobra CX50 (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 Bel-Ray H1-R premix oil with high octane pump
gas mixed at 40:1 (150 ml oil to 2 gallons of gas). Other brands of oil
should be mixed at 32:1 for break-in.
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.
Check CFD torque and adjust as necessary
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.

7
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.

8
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. Bel-Ray H1-R 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, CSRxx17xxx 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

9
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.
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
oCheck the air filter (clean and re-oil as necessary).
oInsure the smooth operation of the throttle cable (throttle soundly
‘clacks’ shut).
oCheck for frayed strands of the throttle cable inside the throttle housing
and replace if necessary.
oCheck for adequate tire pressures and adjust if necessary.
oCheck all nuts and bolts for proper torque and re-torque if necessary.
oSpray all moving parts with WD40 or other light oil.
oCheck drive chain for
Proper tension and adjust if necessary.
Adequate lubrication and lubricate if necessary.
oInsure that the ignition stator and rotor are clean and dry.
oCheck the frame for cracks in the metal or cracks in the paint that
might indicate that the metal has been stressed beyond it’s safe limits.
Replace or get properly rewelded as necessary.
oCheck the rims for signs of stress, like cracks around the rim, spokes
and hub.
oEqualize the pressure in the forks with atmosphere.
Every 2 hours of operation
oReplace the transmission oil.

10
oCheck the CFD torque.
Every 10 hours of operation
oReplace the fork oil.
oHave the shock oil replaced by a Certified Cobra Mechanic.
Replacing Transmission / Clutch Lubricant
Tools needed:
5mm allen wrench
Minimum of 300 ml (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 ml (12 oz), can help clutch life. More than
350 ml (12 oz) will degrade engine performance.
NOTE: It can be helpful to lean the bike over on its left side to add oil to the bike.
Figure 1

11
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.
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 35 mm (1 3/8”) free movement just
behind the chain block 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 it’s 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. Retighten the axel bolt to 25 ft-lb (34 Nm).
5. Retighten the adjustor bolt (figure 3)
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.
Figure 2
Figure 3

12
1. Set pedal height/position first, then
2. Set pedal free play.
Brake pedal height can be adjusted with the bolt and nut located under the rear
of the brake pedal. The free-play is adjusted with the adjustable plunger on the
end of the brake pedal.
CAUTION:
Use only DOT 4 brake fluid
Setting rear brake pedal position (see figure 2b):
1. Loosen the lock nut (10mm wrench).
2. Adjust the brake lever stop (10mm wrench) so that the lever is comfortably
reachable in both:
a. Standing riding position, and
b. Sitting riding position.
3. Tighten the lock nut
(10 mm wrench).
CAUTION:
Adequate pedal free play is
required so that the brake
pads do not drag on the
rotor. 1” MINIMUM.
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 (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

13
Brake Bleeding Procedure
Tools Required:
Front: T10 Torx bit/driver, Cobra bleed kit (BCKG0031)
Rear: 3mm hex key (Allen wrench, T10 Torx bit/driver, Cobra bleed
kit(BCKG0031)
Procedure:
Remove the brake fluid reservoir cover.
Fill the syringe half full with brake fluid.
Remove the brake caliper bleed screw.
Attach the syringe to the brake caliper bleed access. Keep the syringe
oriented as not to allow air from the syringe into the system.
Using the syringe pull fluid through the system. Use caution not to let the
fluid in the reservoir to become low and introduce air into the system.
Using the syringe push fluid back into the system until the reservoir is full.
Repeat these actions of pulling and pushing fluid through the system a few
times.
With the reservoir full, engage the brake lever/pedal and hold it there as if
engaging the brakes.
While doing this pull on the plunger of the syringe. Doing this will cause a
vacuum in the system. The vacuum will swell the air bubbles which assist
in them moving throughout the system.
Continue pulling a vacuum and release the brake lever/pedal (careful not
to allow the reservoir to become empty).
Once again engage the brakes while continuing to pull a vacuum.
When the reservoir is almost empty stop and push fluid back into the
system.
Repeat these steps with the vacuum until no more air bubbles can be
removed from the system.
Remove the syringe. Be sure to keep the caliper below the level of the
reservoir to allow the fluid to run out of the caliper and not allowing air into
the system.
Reinstall the bleed screw, being sure that the ring is in place.
Fill the reservoir with fluid (the fluid should be full enough that the fluid
spills out when placing the lid on) and replace the cover.

14
Air Filter Cleaning
Remove the seat
Squeeze the two tabs together as shown in figure A1
and pull the wire retainer up and out of the air box
The filter may now be pulled from the airbox
Clean the airbox of dirt and clean the filter sealing
surface of the old sealing grease.
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.
1. Remove the air boot
2. Install the cover (RCMU0109) over the carburetor inlet
3. 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.
4. Apply grease to the black sealing surface of the
filter and reinstall.
5. Squeeze the two finger tabs together on the wire
retainer and install into the airbox as in figure A2
6. Push the wire retainer down until it bottoms, making sure the two bottom tabs
on the retainer go through the two associated holes in the bottom of the
airbox.
7. Push the two top retainer arms out so that they properly insert into each side
hole.
Figure A1
Figure A2

15
CAUTION:
If the side arms do not align with the associated holes it is quite likely that the
legs did not make it into the holes. Realign and try again.
8. When properly installed, the filter and retainer should look like figure A4.
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
Figure A3 Figure A4

16
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.
Fork Oil Replacement
Tools required
32mm Fork Cap Tool (MCMUTL32)
19mm wrench or socket
4 & 5 mm hex key (Allen wrench)
9/16 wrench
Mallet
2.5 wt. Bel-Ray fork oil
Disassembly procedure
1. Remove the front wheel (19 mm wrench).
2. Remove the brake caliper from the fork leg (4 mm hex key).
3. Loosen the fork caps (32mm fork cap tool).
4. Remove the fork legs from the triple clamps (5 mm hex key).
5. One leg at a time
a. Remove the fork cap from the 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 155ml 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. Pump the fork leg several times to verify that it operates smoothly.

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10.Install each leg back into the triple clamp. Torque each pinch bolt to 8N-m (6
ft-lb) making sure both legs are set to the same height in the clamps.
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)

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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.
NOTE: The CFD hubs can be removed with the universal puller (MCMUTL70).
If it slips below the value, the CFD must be readjusted as per described in the
service section of this manual.
NOTE: If the bike makes a whir, whir, whir, sound coming from the clutch side
engine cover it is very probable that the CFD has slipped enough that the brass
bushing has worn sufficiently to let the gear operate off center. Time to install a
CFD refresh kit (EKMU0033).

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Parts – Airbox & Inlet System
Air Box
REF # PART # DESCRIPTION
RCMU0018 CARBURETOR
1 TCCS0002 AIRBOX
2 HCSP0004 SCREW – PLASCREW - ALUMINUM
3 RCCS0016 AIR FILTER
4 RCKG0503 RETAINER – AIR FILTER
5 TCC60008 MUDFLAP
6 MCKGHO03 HOSE CLAMP – AIRBOX TO BOOT
7 RCKG0505 AIR BOOT
8 MCKGHO01 HOSE CLAMP – BOOT TO CARB
9 MCKGHO04 HOSE CLAMP – CARB TO MANIFOLD
10 RCMU0036 INLET MANIFOLD – 2016.5
11 ECMU0246 REED CAGE ASSEMBLY WITH REEDS VFORCE
12 ZCCS0001 GASKET – REEDS TO ENGINE
13 HCBC0603 M6X30mm SOCKET HEAD CAP SCREW
14 HCWF0601 6mm FLAT WASHER
15 RCCM1301 VELOCITY STACK (SCREWS ONTO CARB)
16 ECCS0030 REED REPLACEMENT KIT

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Parts – Bars and Controls
Bars and Controls
REF # PART # DESCRIPTION
1 FAMU0014 HANDLEBAS –PRO TAPER MICROBARS –COBRA KING BEND
2 TCMU0021 GRIPS (SET OF TWO) –MICROGRIPS–RED /GRAY FEW
3 FAMU0016 THROTTLE ASSEMBLY –PRO TAPER COBRA
3A FAMU0015 TUBE ASSEMBLY –THROTTLE –2PIECE PRO TAPER MICRO
3B HCBC0525 M5 X25 SHCS –THROTTLE ASSEMBLY
3C FCMU0041 STOP RING –MICRO BAR THROTTLE
4 FCPW0004 CABLE COVER
5 FCMU0021 THROTTLE COVER
6 FCMU0019 THROTTLE CABLE
6A HCNJ0801 NUT –8MM JAM
7 BAKG0003 BRAKE ASSEMBLY FRONT
8 FCMU0033 KILL SWITCH ASSEMBLY
9 HCBC0806 M8X30mm SOCKET HEAD CAP SCREW (4 REQ’D)
10 HCBC1001 M10X45mm SOCKET HEAD CAP SCREW (2 REQ’D)
11 TKMU0404BLK BAR MOUNT KIT, SHORT (1 REQ’D) STANDARD
11A TKMU0403 BAR MOUNT KIT, TALL (1 REQ’D)
12 HCNL1001 M10 LOCK NUT
ACCESSORY BCKG0023 ALLOY BRAKE LEVER W/BALL
ACCESSORY BCKG0024 BRAKE PERCH ASSY W/LEVER & BALL
ACCESSORY MCMUAM11 GRIP DONUT – PAIR – PRO TAPER MICRO BAR