Instruction/ maintenance manual of the product King 2003 Cobra
Go to page of 52
2003 KING Owners / Service Manual “CHAMPIONS START HER E”.
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.
2 DISCLAIMER OF WARRANTY This motorc ycle 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.
3 Table Of Contents General Information ......................................................................................................... 4 Specifications - General ..............................................................................
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 cyl inder, reed valve Cooling system Liquid - cooled Displacement 49.
5 Chassis Front tire 2.50 - 12 Pressure 15 psi minimum Rear tire 2.75 - 10 Pressure 15 psi min. (20 psi for hard pack or rocky conditions) Front fork Cobra 30mm USD Fork oil type SAE 5 weight Fork oil amount 118 ml (4.
6 Specifications - Torque Values Torque Value Fastener ft - lb in - lb Nm Size & Remarks Cylinder head nuts 9.2 110 12 ¼” 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.
7 Break - In Procedure Your Cobra KING is a close - tolerance high performance machine and break - in time is very i mportant for maximum life and performance.
8 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.
9 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 brak e while they are riding .
10 CAUTION: 1. Because of the amount of heat generated by the clutch and engine during extended periods of riding, it is a dvisable 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.
11 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). Figure 1 NOTE: You may need to adjust the brake pedal (up or dow n) to gain access to the drain bolt.
12 M2: Chain adjustment Figure 2 1. Make sure that the rear wheel is aligned properly. 2. Push down on the sea t, compressing the suspen - sion down to where the chain is tightest. 3. The chain should not be too tight but not too loose. A minimum of 2.
13 M4: Air Filter Cleaning Tools recommended for air filter maintenance: • Flat head screwdriver • Air filter oil • 5mm hex key • Foam filter oil The Cobra is equipped with a special designed sock filter. It is very importan t to keep it clean and properly oiled with high quality water - resistant foam filter oil.
14 e. Work the damper rod up and down several times. f. Allow to drain completely. Assembly procedure 1. Fill the fork leg with 4 oz (118 ml) 5 wt fork oil. 2. Measure the fork oil level to the top of the fork tube with the leg collapsed, and reco rd for tuning purposes.
15 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.
16 Figure 5.
17 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.
18 Engine is Fresh Measured Value Engine Down on Power Measured Value * 0.9 Engine NEEDS Rebuilt Measured Value * 0.8 Example 110 psi 11 0 psi * 0.9 = 99 psi 110 psi * 0.8 = 88 psi Your Values Procedure for Compression Testing 1. Shut off the fuel petcock.
19 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).
20 4. Remove the cylinder. Muratic acid can be dangerous. Follow the manufacturers instruct ions closely. 5. Remove the piston clip with a scribe. 6. Remove the piston pin with a piston pin remover. INSPECTION NOTE: Inspect the piston for abrasions and deposits on the top and sides and clean or replace as necessary.
21 CAUTION: Take caution when handling the crankshaft. It is the main power transfer to the rest of the engine. If it is out of alignme nt, it will cause premature failure of your bearings which can lead to serious damage to the cylinder and the rest of the engine.
22 Figure 6 Figure 7.
23 10. Insert dowel pins in the left side case as shown in figure 8. Figure 8 11. Apply gasket sealer (NAPA Aviation Form - A - Gasket #765 - 1210 or equivalent) to the mating surfaces of both crankcase halves. 12. Apply the crankcase gasket to the left crank case half being sure to install the gasket behind the connecting rod.
24 CAUTION: Be sure to align the piston such that the arrow on the top piston surface points to the exhaust (front of bike/engine). 17. Apply gasket sealer (NAPA Aviation Form - A - Gasket #765 - 1210 or equal) to the c ylinder deck areas around the coolant passage and cylinder studs as shown in figure 10.
25 22. Install O’rings as shown in figure 12. Figure 12 23. Install the cylinder head and torqu e to 9.2 ft - lb (12 Nm) 24. Install stator reinstalling the grommet and wires (snug the bolts). 25. Install the rotor per Rotor Installation section, under the ES4: Ignition portion of this manual.
26 ES3: Clutch Cobra clutch puller assembly: Figure 13 Clutch puller diagram Figure 14 Tools recommended for clutch service: • 22mm socket • Universal clutch puller - a universal puller that pulls the clutch, main drive gear and rotor. (Part # MCMUTL70).
27 CLUTCH WASHER STACKUPS: Once the clutch is removed, and cool to touch, carefully put it into a vice and remove the center shoulder bolt out of each clutch shoe.
28 CAUTION: Sludge build - up between the spring washers also keeps the clutch shoe from engaging fully and this will cause the clutch to start to s lip. So you will need to clean the sludge out or just replace the spring washers and bolts with new ones.
29 CAUTION: It is also important that all three shoes are stacked the same. (See figure 15) 2. Clean the threads of the stack bolt and the clutch with contact cleaner removing all old thread locking material. 3. Apply high strength (red) thread lock material to the stack bol t and tighten as tight as possible without stripping the Allen head.
30 8. Install the clutch cover taking care to put the two longer bolts in their proper locations and tig htening in the order specified in figure 17. (5mm hex key, 5.8 ft - lb, 7.8 Nm). Figure 17 9. Put pipe back on and add oil (225 ml (7.6 oz) Cobra 3 Shoe Clutch Milk (Part # MCMUGF01).
31 stator. • Non - resistor spark plug caps should be used. Resistor caps will result in a weaker spark that will reduce performance. • Make sure ground wires are secure. If the bike is not grounded it will not run. • Make sure connections are free of dirt.
32 5. Inspect and remove m arkings, scratches, and thread locker residue from the rotor and crankshaft. ROTOR INSTALLATION: 1. Use wicking / bearing retainer (green) thread locker on the inside of the rotor, and on tapered part of crankshaft.
33 Figure 20 To remove radiator cap: 1. Turn the cap counter clockwise to the first stop and wait there for a few seconds. 2. Push the cap down and turn it further in the same direction and remove the cap. NOTE: Inspect the old coolant for visual evidence of corrosion and abnormal smell.
34 Figure 21 8. Remove ignition cover using a 9/64” hex key (four places) 9. Remove belt retainer screw using a 1/8” hex key. (Figure 22 - item 1) 10. Remove belt retainer, water pump belt and water pump fan pulley. 11. Remove bearing retainer screw using a 3/32” hex key.
35 Figure 24 14. Reinstall new bearings, seal and impeller. Clean all threads and use green (wicking / bearing retainer) thread locker. 15. Using a liberal amount of grease on the outside seal, bearings and inside of case, reinstall bear ing assembly by using a 0.
36 ES6: Fuel & A ir System Carburetor : Tools recommended for carburetor service: • Small flat head screwdriver • WD - 40 • 8mm socket Figure 26 KING Carburetor Ref.
37 Your Cobra is equipped with an adjustable carburetor. Some fine - tuning may be needed according to weather condition and altitude. Proper jetting is very important for engine performance and engine life. Serious damage to the engine can occur if not properly adjust ed.
38 have water or dirt in the carburetor bowl. Use automotive ca rburetor cleaner or WD - 40 to clean the carburetor inside and out. STOCK CARBURETOR SETTINGS The 2003 KING stock carburetor settings fr.
39 Reeds : • The reeds must lay flat on the reed cage. • If the reed tips aren’t lying flat, replace them immediately. • The reeds must have a tight seal on the reed cage. • If the reed is damaged in any way, replace it. This means cracks, chips, and ruptures.
40 Chassis Service / Parts CS1: Wheels & Tires Rear wheel Rear wheel dampening Tools recommended for wheel service: • 13mm socket • Flathead screwdriver • 11mm wrench or socket • 19mm wrench The Cobra is the only 50cc to have the rear wheel damping system.
41 Rear wheel pullers Disassembly: Figure 30 1. Remove axle, and back wheel assembly. 2. Pull the rear wheel pullers out of the back of the swing arm. Rear wheel alignment: Figure 31 1. Measure from the side of the swing arm to the outer edge of the rim and make sure both sides are equal.
42 Front wheel assembly Figure 32 REF. # PART # DESCRIPTION 1 HCNS1201 12mm AXLE NUT 2 KCKG0029 FORK LEG (NONBRAKE SIDE) 3 WCMU0023 WHEEL SPACER (LARGE) 4 WAKG0005 FRONT WHEEL (COMPLETE) 5 WCMU0001 WH.
43 CS2: Brakes Front Brakes The front brake is fully hydraulic . WARNING! Your front brake needs a break - in period to achieve maximum brake power. 30 - 40 stops will bring the brake to peak performance. Check before each ride: • Make sure the brake does not have any leaks by holding the lever in while checking hose con nections.
44 Figure 33 2) Remove cotter key from caliper as shown and pull pads out. Figure 34.
45 3) Brake pads must be checked periodically for wear. They are also available from a Cobra dealer. The brake pad must be a minimum thickness of 2.5mm. This is measuring the pad + the holder as shown below. Figure 35 Brake bleeding procedure: 1) Remove brake caliper using 4mm Allen wrench as shown in pad removal procedure.
46 Figure 37 4) Attach Bleeding syringe as shown. Pump all air out of system until only clean oil runs out of reservoir. Figure 38 5) Rei nstall reservoir cap. Oil will overflow in the process. This is necessary to ensure no air is in the system. Remove bleeding syringe and quickly reinstall bleed screw.
47 CS2: Suspension Rear Shock Figure 39 COBRA PART NUMBER DESCRIPTION SCKGOH01 SPRING CLIP SCKGOH02 SPACER SCKGOH03 BALL JOINT SCKGOH04 SPRING PLATFORM SCKGOH05 LOCKNUT SCKGOH06 SLEEVE SCKGOH07 BUMPER.
48 Front forks Tools recommended for front fork service: • Flat head screwdriver • Hammer • Snap ring pliers • Seal drivers • 13mm wrench • 1 1/8” wrench or socket • 5 wt fork oil FORK ASSEMBLY PROCEDURES: Figure 40 1. Slide swiper (#6) onto lower fork leg.
49 13. Connect the cartridge rod to the cap and tighten to 12 ft - lb (9 Nm). CAUTION: The damper rod is hollow and will break if the nut is over tightened (proper torque is 12 ft - lb, 16 Nm).
50 Troubleshooting 1) Engine not behaving properly a) Carburetor top is installed backwards (happens a lot) b) The carburetor slide indexing pin is m issing 2) Engine is down on power a) Clutch engage.
51 Index Air Filter .............................................. 13 Brakes Front ............................................... 43 Break - In ................................................ 7 Carburetion Specifications ............................
An important point after buying a device Cobra King 2003 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Cobra King 2003 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Cobra King 2003 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Cobra King 2003 you will learn all the available features of the product, as well as information on its operation. The information that you get Cobra King 2003 will certainly help you make a decision on the purchase.
If you already are a holder of Cobra King 2003, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Cobra King 2003.
However, one of the most important roles played by the user manual is to help in solving problems with Cobra King 2003. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Cobra King 2003 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
