CM50

Owners / Service Manual

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 (330) 549-9600 If you need technical assistance contact your local dealer or call the Cobra Technical Support Hotline at (330) 549-9603
Cobra Motorcycle MFG., Inc. 11511 Springfield Road North Lima, Ohio 44452
MCCM2003.6

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 CM50 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. 3

Table Of Contents
Specifications - General..................................................................................................4 General Tips....................................................................................................................10 Specifications - Torque Values ......................................................................................6 Optional Components......................................................................................................7 Break-In Procedure ..........................................................................................................7 Starting Procedure ...........................................................................................................9 Maintenance....................................................................................................................1 1 Schedule & Tips .........................................................................................................11 M1: Replacing Transmission / Clutch Lubricant ....................................................12 M2: Chain adjustment................................................................................................13 M3: Front brake adjustment......................................................................................14 M4: Rear brake adjustment ......................................................................................14 M5: Air Filter Cleaning ...............................................................................................15 M6: Fork Oil Replacement ........................................................................................16 Engine Service / Parts ...................................................................................................17 ES1: Engine Service ..................................................................................................19 E1: Engine Removal..............................................................................................20 E2: Complete Engine Disassembly Procedure .................................................21 E3: Top End Disassembly Procedure .................................................................21 E4: Splitting the Cases ..........................................................................................22 E5: Engine assembly .............................................................................................23

ES3: Clutch .................................................................................................................28 ES4: Ignition................................................................................................................32 ES5: Cooling System .................................................................................................34 ES6: Fuel & Air System .............................................................................................38 ES7: Exhaust ..............................................................................................................41 Chassis Service ..............................................................................................................42 CS1: Wheels & Tires .................................................................................................42 CS2: Suspension........................................................................................................44 Troubleshooting ..............................................................................................................48 Index................................................................................................................................4 9 4

Specifications - General
Items CM 50 Dimensions Wheelbase 35.75 (908mm) Wheel size 10 (254mm) Seat height 23.9 (607 mm) Stock #TCHJ0001 22 (559 mm) Optional # TCHO0001 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 Spark plug Splitfire SF406B Gap 0.023 0.025 (0.58 0.64 mm) Ignition timing 0.050 (1.3 mm) Before To Dead Center (BTDC) Fuel type Sunoco MO2X or 93 octane pump gasoline OTHER 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 14 mm DellOrto Main Jet 92 Slow (Pilot) jet 55 Float Height 16mm + 0.5mm (0.63 + 0.020) Transmission Speed Single Clutch Cobra 3 shoe Final drive ratio 13/37 T Chain 88 links 420 Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III Quantity 235 ml (8.0oz)

5 Chassis Front tire 2.50 - 10 Pressure 15 psi minimum Rear tire 2.75 - 10 Pressure 15 psi min. (20 psi for hard pack or rocky conditions) Front fork Marzocchi 32mm Fork oil type SAE 20 weight Fork oil amount 200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild Collapsed fork oil height 70 mm (2.75) spring in, no spacer 6

Specifications - Torque Values

Torque Value Fastener ft-lb in-lb Nm Size & Remarks Cylinder head nuts 9.2 110 12 Crankcase bolts 6.6 80 9 6 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*** 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 Ignition rotor nut 40 480 54 10 mm** Rear Sprocket Bolts 18 216 24 7 mm Rear shock mounts 40 480 54 10 x 1.5 Rear Axle Bolt 25 300 34 12 mm ** 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 turn. 7

Optional Components
Carburetor jets Sprockets o Front o Rear

Seat with lower seat height, 22 (559 mm), # TCHO0001 Suspension Springs Weight of Rider (lb) Fork Spring Shock Spring Less than 38 (light) KCMZ0012A SCMU0321 (yellow, 320 lb/in) 38 45 (std) KCMZ0012 SCMU1360 (red, 260 lb/in) 46 to 55 (stiff) KCMZ0012B SCMU1380 (white, 380 lb/in) Extra stiff SCMU1400 (silver, 400 lb/in) Suspension Valving Damping Rate Fork Valving Compression (right) Fork Valving Rebound (left) Shock Valving (kit) Soft (fast) KCMZ0033A KCMZ0032A SCMU0318A Standard KCMZ0033 KCMZ0032 SCMU0318 Hard (slow) KCMZ0033B KCMZ0032B SCMU0318B 8

Break-In Procedure
Your Cobra CM50 is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The CM50 can be ridden hard after the first 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 93 octane pump gas, or Sunoco MO2X , with Cobras 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 hour of operation o Follow the starting procedure listed in this manual. o Avoid prolonged operation at Wide Open Throttle. After 1 hour of operation o Check for loose bolts and nuts on the bike and retighten as necessary (proper toque values are listed under Specifications). o Clean the carburetor bowl. o Change the transmission / clutch lubricant. After 8 hours of operation o Change the fork oil.

o Have a Certified Cobra Mechanic change the shock oil. Your bike is now ready for the highest level of competition! NOTE: During break-in the bike will likely loose some engine coolant through the radiator overflow hose. Loosing up to 4 oz (120 ml, 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. 9

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 do not have improper wear. Inspect the frame, for; o Cracks in the metal. o Cracking paint which might indicate overly stressed material. Verify that the handlebars are tight. Check the throttle for; o Smooth operation and sound closing. o Frayed strands of the cable inside the throttle housing. 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. (Sunoco MO2X or 93 octane pump gas with Cobras 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. 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. Make sure your engine is properly warmed up before racing. 10

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. 4. Evaluate the bikes jetting only after it has been warmed up to race temperatures. 5. A properly maintained machine is safer, faster, and more fun to ride. 6. When washing the bike, be careful to not directly aim the hose at the bottom edge of the seat, or water is apt to enter the airbox. 7. Your Cobra Motorcycle has a 10 digit VIN (Vehicle Identification Number). The first two digits indicate the model and the seventh indicates the model year (MY). a. Example, CMxxxx3xxx is a 2003 MY CM. 11

Maintenance
Schedule & Tips
It is important that you adhere to this maintenance schedule so as to promote the longevity of your Cobra Motorcycle. Between each ride o Check the air filter (clean and re-oil as necessary). o Insure the smooth operation of the throttle cable (throttle soundly clacks shut). o Check for frayed strands of the throttle cable inside the throttle housing and replace if necessary. o Check for adequate tire pressures and adjust if necessary. o Check all nuts and bolts for proper torque and re-torque if necessary. o Spray all moving parts with WD40 or other light oil. o Check drive chain for Proper tension and adjust if necessary. Adequate lubrication and lubricate if necessary. o Insure that the ignition stator and rotor are clean and dry. o Check the frame for cracks in the metal or cracks in the paint that

might indicate that the metal has been stressed beyond its safe limits. Replace or get properly rewelded as necessary. o Inspect the rear sprocket damper plate for bending or warping. Straighten or replace if more than 1/16 (1.6 mm) from flat. Every 2 hours of operation o Replace the transmission oil. Every 10 hours of operation o Replace the fork oil. o Have the shock oil replaced by a Certified Cobra Mechanic. CAUTION: 1. Because of the amount of heat generated by the clutch and engine during extended periods of riding, it is advisable to remove the ignition cover afterward to allow the ignition to cool off. The heat transfers through the cases and can damage the stator as it cools off because of lack of airflow around the stator. 2. 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. 12 Be sure the fuel tank and carburetor have been removed and safely located away from the welding process. 3. 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. 4. If your kick-starter lever does not return to the rubber bumper, use WD-40 or light penetrating oil under the plastic cover behind the spring on the shaft. The shaft is a very close fit to the case and also has an O ring in it and is difficult to get lubrication to which may cause binding. If it does not loosen up, remove the kick-starter cover and kicking assembly. Grease the shaft.

M1: Replacing Transmission / Clutch Lubricant

Tools needed: 225 ml (7.6 oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01), or Dexron III Automatic Transmission Fluid. 13 mm combination wrench 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 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. Lean bike against something or set on stand with oil drain hole.

3. Using a 13 mm wrench, remove the oil drain bolt located on the right side of the engine, on the clutch cover, near the brake lever (Item 2, figure 1). 13
Figure 1

NOTE: You may need to adjust the brake pedal (up or down) to gain access to the drain bolt. 4. After it has drained, reinstall the bolt being sure that the copper gasket is in place. Torque to 15 Nm (11 ft-lb). 5. Reapply oil from oil fill plug 235 cc Cobra Venom 3 Shoe Clutch Milk, or Dexron III Automatic Transmission Fluid, thru the fill plug. NOTE lean bike over onto its left hand side so that the clutch cover is up unless you have a squeeze bottle. 6. Reapply the oil fill bolt, hand tight, being sure the fiber 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 was forced to put forth this effort because the other available options and not adequate. Cobras specially developed Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01) is the recommended lubricant for your CM50 motorcycle.

M2: Chain adjustment

Figure 2

1. Make sure that the rear wheel is aligned properly. 2. Push down on the seat, compressing the suspension down to where the chain is tightest. 3. The chain should not be too tight but not too loose. A minimum of 2.5 in. of slack should be between the swing arm and the chain. 14

M3: Front brake adjustment

Tools recommended for front brake maintenance: 10mm open end wrench From the brake lever: 1. Loosen the locking nut on the brake lever. 2. Adjust the bolt to desirable position. 3. Tighten the locking nut. From the brake hub: 1. Loosen the 10mm nut on the hub. 2. Adjust the brake cable to desirable position

3. Tighten the 10mm nut. CAUTION: If you tighten the front brake up too much, the brakes may hang up causing the brake pads to wear incorrectly and prematurely.

M4: Rear brake adjustment

Tools recommended for rear brake maintenance: 10mm open end wrench There are 2 adjustments on the brake.
Figure 3, from the brake lever Figure 4, from the brake hub Figure 5, adjust brake lever free height Figure 6, adjust brake lever free play

15 From the brake lever: 4. Loosen the 10mm nut on the back of the brake pedal. 5. Adjust the bolt to desirable position 6. Tighten the 10mm nut. From the brake hub: 1. Adjust the wing nut up to desirable position. CAUTION: If you tighten the wing nut up too much, the brakes may hang up. If so, the brake pads will burn up, and need replaced.

M5: Air Filter Cleaning

Tools recommended for air filter maintenance: #2 Phillips head screwdriver 4 mm hex key (Allen) Foam filter oil Procedure 1. Removed the seat with the 4 mm hex key 2. Remove the two Phillips head screws holding the filter to the entrance of the airbox. 3. Clean the filter in a nonflammable solvent to remove the filter oil. 4. Clean the filter in hot soapy water to remove all dirt particles. 5. Allow it to dry thoroughly. 6. Saturate with filter oil and remove excess. 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. NOTE: The Cobra is equipped with a special designed Air box. It is very important to keep the air filter clean and properly oiled with high quality water-resistant foam filter oil. Its very important to oil your filter consistently each time because varied amounts of oil will change your carburetor jetting. NOTE: Make sure you change or clean your filter after each moto. We recommend carrying 3 or more filters in your toolbox. 1 for practice

1 for each moto 16

M6: Fork Oil Replacement

Tools required 5 & 6 mm Allen wrench 19 mm wrench or socket (two required) Spring clip remover Disassembly 1. Remove the front wheel. 2. Remove the fork legs from the triple clamps. 3. Perform the following on one leg at a time. 4. Using your hands, remove the black rubber plug from the top of the fork leg exposing the white plastic cap. 5. Secure the fork leg assembly in a vice by gripping the leg across the flats through which the axle bolt goes through. 6. Depress the white plastic cap inwards (down) and remove the wire spring clip from its groove. 7. Remove the white cap, the fork spring preload sleeve, and the fork spring. NOTE: Depressing the fork leg will facilitate removing the white cap. 8. The fork can now be turned upside down and drained. Assembly 1. Fill the leg with 200 cc (6.8 oz) 20 wt fork oil. 2. Standard fork oil level is 70 mm (2.75) from the top edge with the fork collapsed. NOTE: Remove the preload sleeve but leave the spring in for the measurement. 3. Install the preload sleeve. 4. Install and depress the white cap while installing the spring clip. 5. Fork may be reinstalled. 17

Engine Service / Parts

REF. # PART # DESCRIPTION REF. # PART # DESCRIPTION 1 CAKG0002 Clutch, Complete 44 ZCKG0002 Gasket, Base 2 CAKG0004 Shoes, Clutch w/ Washer Springs 45 ECKG0041 Cylinder, 50cc 3 CAMU0008 Spring Set, Washer type for Clutch 46 ZCMUOR07 Oring, Exhaust Flange 4 CCMU0031 Arbor for 3 Shoe Clutch 47 ECKG0015 Exhaust Flange 5 ECMU0018 Nut, Crankshaft Starter 48 HCBC0602 Screw, 6x20 6 ECMU0033 Clutch Hub w/ Gear 49 ECMU0008 Stud, Cylinder 7 ECMU0040 Clutch to hub spacer 50 ZCMUOR03 Oring, Cylinder head, Small 8 ECDC0105 90 Degree Crankcase Vent 51 ZCMUOR05 Oring, Cylinder head, Medium 9 ECMU0017 Seal, Crankshaft 52 ECKG1121 Cylinder Head Dome-Insert 10 ECMU0016 Bearing, Crankshaft 53 ECMU0403 Spring, Kickstarter Return 11 ECMU0001 Bearing, Trans., Secondary Gear 54 HCNS1401 Nut, 1/4-20 12 ECMU0020 Bearing, Trans., Precision 55 ZCMUOR02 Oring, Cylinder head, Large 13 ECMU0105 Gear, Trans., Primary 56 ZCMUOR08 Oring, Cylinder head 14 HCNS1202 Nut, 1/2-20, Left Hand 56A ZAKGOR02 Oring Kit, Top End 15 ECKG0018 Crankcase, Clutch side 57 ECKG0025 Cylinder Head - Outer Cap 16 ECMU0131 Water Elbow 58 HCWF1401 Washer, 1/4"

17 HCBH0805 Screw, M8x12mm, coolant drain 59 ICMU0006 Rotor 18 ECMU0103 Shaft, Trans., Secondary w/gear 60 ICMU0007 Stator 19 ECMU0104 Shaft, Trans., Output w/gear 60A MCKGGR00 Grommet, Engine case 20 ECKGBR01 Bearing, Trans., Output shaft 61 ECKG0073 Impeller, Waterpump 21 ZCKG2001 Gasket, Crankcase 62 ECKG0074 Seal, Waterpump 22 HCDP1401 Dowel, for Engine Cases 63 ECKG0203 Intake Manifold 23 ECMU0038 Crankshaft, Welded and Balanced 64 ZCMU0032 Gasket, Reed to case 24 ECKG0017 Crankcase, Ignition side 65 ZCMU0031 Gasket, Intake to Reed 25 ECKG0004 Snap Ring, Int. for Water Pump 66 ECKG0202 Reed Assembly 26 ECKGSE01 Seal, Output shaft 66A ECKG0204 Reed Kit 27 HCBC0606 Screw, M6x45 67 ZCKG0101 Gasket, Ignition Cover 28 HCBC0604 Screw, M6x35 68 ECKG0001 Cover, Ignition 28A HCBC0603 Screw, M6x30 69 HCBC0802 Screw, 8-32x1-3/4 29 HCBC0608 Screw, M6x55 70 ECMU0043 Piston Kit 30 PCKG0013 Sprocket, 13T for output shaft 70A ECMU0055 Piston Ring 30A ECKGSR03 Snap Ring, Ext., for output shaft 71 ECKG0012 Wrist pin 31 HCWP0001 Washer, Stator 72 ECMU0077 Bearing, Wrist Pin 32 HCBH0803 Screw, 8-32x7/8 73 ECMUSR00 Snap Ring for Piston 33 HCBC0801 Screw, 8-32x1-1/2 74 ECMUSP01 Spring, Kick Start Dog 34 HCNS1001 Nut, 10mm 75 ECMU0207 Gear, Kickstarter, Small 35 ECKG0042 Pulley, Waterpump-Crank 76 ZCMU0030 Gasket, Clutch Cover 36 ECKG0070 Belt, Waterpump 77 ECMU0205 Kick Starter Rubber 37 HCBB0001 Screw, 10-32x1/2" 78 HCWC0000 Gasket, Copper 37A HCBC1033 Screw, 10-32x3/4" 79 HCBH0805 Screw, M8x12mm, oil drain 38 HCWF0601 Washer, 6mm 80 ECMU0204 Kick Starter Dust Shield 39 ECMU0080 Belt Retainer 81 ZCMU0001 Gasket, Oil fill plug 40 ECKG0075 Pulley, Waterpump-Fan 82 ECMU0037 Oil fill plug 41 HCSS8201 Screw, 8-32x3/8 83 ECMU0202 Kickstarter Lever 42 ECKG0072 Bearing, Waterpump 84 ECMU0206 Kickstarter, complete 43 ECKG0141 Shaft, Waterpump 85 ECMU0003 Brass Clutch Bushing

2003 CM ENGINE ASSEMBLY REFERENCE DRAWING 18

Figure 7

19 Trained technicians with precision gauging and proper assembly fixtures carefully assemble all Cobra engines to specific clearances. If you feel you have the skills, and the appropriate tools, to perform the following service tasks please follow the instructions closely. The part numbers are listed throughout to help you when ordering parts from your local Cobra dealer. If you dont feel comfortable with the service work, simply take your engine out of the frame and sent it to: Cobra Precision Engines 11511 Springfield Road North Lima, Ohio 44452 Cobra has specialized mechanics that will go through the entire engine, replacing gaskets, bolts, any old part that is worn. The engine will be rebuilt using the same precision gauging and assembly fixtures as when it was assembled new. Before leaving, the engines performance will be measured on a dynamometer to ensure that your engine is operating at its highest potential. All this for one low nominal fee. Call (330) 549-9603 for details.

ES1: Engine Service

One method for determining whether the top end of your engine needs rebuilt is to perform a WOT (Wide Open Throttle) kicking compression test. Before performing the procedure please read the caution notes below. CAUTION: There appears to be a wide range of variability in reading compression gauges across the country. The head volume of this Cobra Motorcycle is very small and so requires many kicks ~20 before you establish the most accurate reading possible. Because of the geometry of the spark plug used in this Cobra Motorcycle, the adapter used with your compression tester must have a similar volume protruding into the combustion chamber to establish an accurate value. Length of hose on the compression tester will affect the reading. The shorter the hose length the more accurate your reading will be. Because of these difficulties in measuring an absolute compression value, a useful relative value can be achieved by testing your bikes compression with your own particular gauge after a new top end or when the bike is new so that you know what your particular gauge reads on a fresh engine. When it has dropped to 90% of its original value the engine will be down on power and would benefit from a rebuild. When its dropped to 80% it really needs rebuilt! Using the table below will help you determine monitor the condition of your top end. 20 Engine is Fresh Measured Value Engine Down on Power Measured Value * 0.9 Engine NEEDS Rebuilt Measured Value * 0.8 Example 110 psi 110 psi * 0.9 = 99 psi 110 psi * 0.8 = 88 psi Your Values Procedure for Compression Testing 1. Shut off the fuel petcock. 2. Install the compression gauge into the spark plug hole. 3. Hold the throttle to wide open, and kick repeatedly (approximately 20 times) or until the gauge reading does not increase in value with each kick.

E1: Engine Removal

To service the bottom end and transmission, the engine must be removed from the frame. Tools required 5/16, 10, 14, 22 mm socket 10, 13, 22 mm wrench 10, 17 & 19 mm sockets 9/64, 3,4 & 5 mm hex key (Allen wrench) 7 mm nut driver, flat or Phillip, screwdriver for hose clamps Spring remover

Flywheel / clutch puller (#MCMUTL68) Clutch nut removal tool (Call local dealer for details). Procedure 1. Remove the seat (4mm hex key). 2. Turn of the fuel at the petcock and disconnect the fuel line. 3. Remove the tank (5 mm hex key & 10 mm socket). 4. Remove the carburetor from the inlet (flat head or Phillips head screwdriver, 7 mm nut driver). 5. Remove the right side number plate (3mm hex key). 6. Remove the silencer & pipe (spring remover, 5mm hex, & 10mm wrench). 7. Disconnect the ground wire from the reed cage with a 5 mm hex key (depending on your ultimate repair, you may want to reinstall the fastener in the inlet. 8. Leaving the coolant lines connected to the engine, remove the radiator from the frame (5mm hex with 10 mm wrench). 9. Remove the master link from the chain. 10. Remove front engine mount bolt (13 mm socket, 6 mm hex key). 11. To access the swingarm bolt, remove brake lever (13 mm wrench, 5 mm hex key). 12. Remove the swingarm bolt (22mm socket & wrench). 21 NOTE: Only drive the swingarm bolt far enough to clear the engine, leave it holding the one side of the swingarm to the frame 13. Remove the engine from the right side of the frame. 14. Locate a suitable container for the engine coolant and remove radiator hoses from engine (coolant will drain). NOTE: If the coolant looks to be free of contaminates it may be reused. NOTE: If you are merely performing a top end service skip ahead to Top End Disassembly Procedure.

E2: Complete Engine Disassembly Procedure

1. Remove the magneto cover (9/64 hex key) 2. Remove the bolt from the water pump shaft (4mm) and slide off the belt cover and the water pump belt 3. Using a flywheel holding tool and 14 mm socket remove the nut that secures the flywheel. 4. Using the Cobra flywheel / clutch puller (#MCMUTL68), remove the flywheel from the crankshaft. 5. Remove the stator (9/64 hex key). 6. Remove the nut holding the large gear to the transmission input shaft (19 mm socket). 7. Remove the special nut / starter gear that holds