Owners / Service Manual
Contents
1. 2 HCBCO0603 HCNF0601 ECMOTE05 ZCMOTEO ECMU002 ECMOTE09 ZCMOTE1 ZCMOTE1 DESCRIPTION CYLINDER CHROME PISTON KIT SINGLE RING 6X30 CAP SCREW FLANGED NUT 6MM CYLINDER HEAD CYLINDER HEAD O RING 6MM DOWEL YLINDER HEAD STUD BOLT 6MM ASE GASKET O RING EXHAUST FLANGE 00056 RING CAST 00076 RIST PIN ECMUSROA SNAP RING FRANCO PISTON 00 12 13 14 ES2 Bottom end amp transmission 11 Figure 10 bottom end components 6 ECMU0016 CRANK BEARING 1 1 8 ECMOBEO08 FLYWHEELKEY 9 ECMU0077 WRIST PIN BEARING C O Z O 155 S6 WEC COM SET OF SEAL CAUTION Take caution when handling the crankshaft It is the main power transfer to he rest of the engine If it is out of alignment it will cause premature failure of your bearings which can lead to serious damage to the cylinder and the rest of the engine Do not try to true the crank yourself Truing the crank should be done professionally Cobra trues every crank before it leaves the factory and also welds the pin to keep it true If there are any problems send the engine in or call tech support 830 549 9603 to determine what the problem is CAUTION e f you split the cases check the gear tooth faces for chapping amp signs of fatigue e Check the small needle bearings for fatigue If the bearings are damaged the engine cases should be checked to make sure the needle bearing casing didn t2. 2 Raising the needle clip this lowers the jet needle one notch at a time on the slide Indications that the engine is running too lean are e Engine cutting out on top end e Engine overheating and ultimately seizure e White spark plug CAUTION It is much safer to operate the engine slightly rich as opposed to slightly lean This is because an overly rich engine will just run poorly while an overly lean engine will seize potentially causing an expensive top end rebuild and a DNF To richen the carburetor 1 Change the main jet one number at a time larger 2 Lower the needle clip raising the jet needle one notch at a time until the engine starts to blubber on the top end then move the clip back up one notch or until you get the blubber out FUEL MIXTURE SCREW The smaller brass screw that is towards the front of the engine is a fuel mixture 28 screw This screw will also richen lean your engine more the bottom mid range In warmer conditions turn the screw in In colder conditions turn the screw sure to keep the carburetor very clean and make sure you don t have water or dirt in the carburetor bowl Use automotive carburetor cleaner or WD 40 to clean the carburetor inside and out STOCK CARBURETOR SETTINGS The 2003 PW3 stock carburetor settings from the factory are e 42 pilot jet e 82 main jet Cleaning the carburetor Clean the carburetor in a well ventilated area and take car
3. Be sure to take the pipe off and any carbon that may be built up Carbon build up is created from exhaust Exhaust has oils in it and the oils cling to the walls of the inside of the pipe Over a long period of time the diameter of the pipe will decrease due to carbon build up So itis essential to clear the residue CAUTION It is important to repack the silencer Signs of your silencer needing to be repacked are The bike is louder than normal e Aloss of power Chassis Service Parts CS1 Wheels amp Tires Rear wheel pullers Disassembly 1 Remove axle and back wheel assembly 2 Pull the rear wheel pullers out of the back of the swing arm Figure 19 Rear wheel alignment 30 Figure 20 31 Measure from the side of the swing arm to the outer edge of the rim and make sure both sides are equal Adjust the wheel pull bolt on the rear wheel puller to get the distance from the swing arm to the rim about the same 52 Suspension Rear shock 24 26 REF PARTY DESCRIPTION 6 SCMUOS BUSHING 8 SCMUOS05 PISTON 9 SCMUO2 STOPDISK 27 SCMUO321 SPRING Because of different rider weights sizes and riding styles we offer various suspension options See Optional Components section of this manual for details on these and other optional components for your Cobra Motorcycle 32 Rear Shock Disassembly 1 Bleed the gas pr
4. 2 3 4 5 7 11 12 13 14 15 16 18 20 21 23 24 23 55 Cooling System Water pump Figure 14 water pump ETAINER CLIP WATER PUMP BEARING PACER WATER PUMP BEARING 7 HCBC0501 O SOOEIJS 0501 10 ECMOWP12 SNAP RING TOOTHED 13 ECMOWP13 WATER PUMP SEAL 14 14 WASHER BEARING RETAINER 15 ECMPWP15 DOWEL 16 HCWF0501 MM WASHER zo e fola OA 24 56 Fuel amp Air System Intake system REFNO PARTNO DESCRIPTION X ECMPINO1 12MM CARBURETOR 6 X ECMOINO6 8 ECMOINO8 9 s 10 ECMOIN09 10 10 INTAKE RETAINING PLATE 25 Reeds e Thereeds must lay flat on the reed cage e lfthereedtips arent lying flat replace them immediately e Thereeds must have a tight seal on the reed cage e f the reed is damaged in any way replace it This means cracks chips and ruptures Anything abnormal replace the reeds Take the reed cage out and hold it up to the light and look in through the cage If you see light between the reed pedals and the frame then replace the reeds If you do not see light then the reeds should be ok See figure 25 liiw Figure 16 The presence of light indicates that the reeds should be replaced or possibly turned over 26 Carburetor DESCRIPTION SLIDE 40 STOCK SLIDE 30 SLIDE 50 NEEDLE FOR SLIDE ATOMIZER MAIN JET 8
5. Replacing 11 Troubleshooting 36 VIN reading 9 WARNING 2 Water pump 24 37
6. be careful to not directly aim the hose at the bottom edge of the seat or water is apt to enter the airbox 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 OIxxxx3xxx is a 2003 MY PW3 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 O OO Fill the 2 stroke injector oil reservoir Check the air filter clean and re oil as necessary Insure the smooth operation of the throttle cable throttle soundly clacks shut Check for frayed strands of the throttle cable inside the throttle housing and replace if necessary Check for adequate tire pressures and adjust if necessary Check all nuts and bolts for proper torque and re torque if necessary Spray all moving parts with WD40 or other light oil Check drive chain for Proper tension and adjust if necessary Adequate lubrication and lubricate if necessary Insure that the ignition stator and rotor are clean and dry Check 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 Fill the 2 stroke injector oil reservoir with Cobra s specially formulated Cobra Venom 2 cycle Race Oil Ev
7. e After 8 hours of operation o Change the fork oil o Have a Certified Cobra Mechanic change the shock oil e Your bike is now ready for the highest level of competition Starting Procedure Before starting the machine inspect the following e Fillthe 2 stroke injector oil reservoir with Cobra s specially formulated Cobra Venom 2 cycle Race e Insure that the fuel tank contains an adequate volume of fuel to complete the distance required Sunoco MO2X or 93 octane pump gas 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 Cracks in the metal Cracking paint which might indicate overly stressed material e Verify that the handlebars are tight e Check the throttle for Smooth operation and sound closing Frayed strands of the cable inside the throttle housing e Check for loose bolts and nuts and re torque as necessary e Verify that the air filter is clean and properly saturated with oil e 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
8. oblong the bearing hole in the case e Needle bearings should be replaced every racing season 20 Kick lever mechanism 11 Figure 11 kick mechanism REFNO PARTNO DESCRIPTION 1 601 CLUTCH COVER 2 502 CRUSH WASHER WATER DRAIN PLUG 6 506 RETAINER CLIP THRUST WASHER 8 0625 6X25 CAPSCREW 1 O 9 ECMPKSO9 KICK START LEVER 21 ES3 Clutch Figure 12 Clutch components 6 ECMOCLO6 SPACER CLUTCHTOHUB 9 ECMOCLO WASHER CLUTCH BASKET BACKUP 22 54 Ignition CAUTION e Make sure ground wires are secure If the bike is not grounded it will not run Make sure connections are free of dirt oe s Pa 24 14 15 7 g 5 i Figure 13 ignition components 1 ECMOIGO1 FLYWHEEL 2 HCWF0801BMM WASHER 3 HCNSO801 8 2 4 HCBC0401 4X10 CAP SCREW _ 5 ECMOIGO5 COIL WITHOUT SPARK PLUG CAP 6 ECMOIGO6 CDIBOX gt 7 ECMOIGO7 SPARKPLUG 8 ECMOIGO8 SPARKPLUGCAP 9 ECMOIGO9 RUBBER FOR CONTROL UNIT Ep y S 820 3 14 o 05 16 _ 18 BERE TA 2 210 IO O O Ti HCBC0502 20 CAP SCREW 0550 5X50 CAP SCREW MM DOWEL GNITION COVER GROMMET OPEN ECMOIG16 SPACER FLYWHEEL 223 ECMOIG23 SPARKPLUGRUBBER 24 ECMOIG24 2 1
9. toon 21 Lubrication Recommended 4 Maintenance Scheduler sa sak 10 ne qa 10 Cil Recommended 4 Optional Components 6 Parts Bottom end 19 GIUDICE 22 Ignition 23 oan tra v 25 Kick mechanism 21 Real SNOOK 32 3121218 ONU NR S 25 end 18 Water 24 Parts List Front FORKS uias 34 Rear Shocks audi dr nons 32 PelcoGk ots dps dtt d te 8 Pullers a 30 Rear suu uuu 14 Rear Shock a etica 33 Rear Wheel Pullers 30 25 26 32 Sel VICO ISO 33 Spark Plug Recommended 4 Specifications 4 Torque Values 5 Stating u react 8 B oreet tC Esos 9 Top End OE VICE u N VARNA 18 Transmission SOVICE na ott 19 Specifications 4 Transmission Lubricant
10. 2 STOCK PILOT JET 42 STOCK CHOKE JET TOP CARB SCREW 8 ORINGFORCARBTOP RCOLO008 9 CARBTOPWORING RCOI0009 Figure 17 carburetor CHOKE ASSEMBLY 4 PIECES RCO 0022 23 REBUILD KIT RCO 0023 27 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 adjusted IDLE ADJUSTMENT On the left side of the carburetor there are 2 adjustment screws The larger screw with the knurled head is the idle adjustment screw To raise the idle turn the screw in clockwise in 1 4 turn increments and rev the engine after each adjustment To lower the idle turn the screw counter clockwise TOP END JETTING Indications that the engine is running too rich too much fuel for the air are e Engine not revving out or blubbering at high RPMs e Engine will not clean out e Wet or black spark plug NOTE Before changing jetting be sure that the air filter is properly cleaned and has the usual amount of air filter oil An overly dirty air filter can cause the engine to run rich NOTE Also before changing jetting insure that your carburetor has a proper float height of 5 If the engine is running rich on the top end it should be leaned out Leaning it out can be done by 1 Changing the main jet to a smaller number
11. 2003 PW3 Owners Service Manual CHAMPIONS START HERE 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 MCPW2003 4 1 DISCLAIMER 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 PW3 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 W
12. EIGH MORE THAT BE SURE THAT THE RIDER ALWAYS WEARS ADEQUATE SAFETY GEAR EVERYTIME HE OR SHE RIDES THEIR COBRA MOTORCYCLE IMPORTANT SAFETY NOTICE A WARNING 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 Table Of Contents General MIM ONT a y ce re en 4 Specifications General u 4 Specifications Torque Values u nana 5 Optional GOMIPONONI eT AE a plav ek re ie aloe 6 Break In Procedure si 7 Starting POC eiii m 8 General TIpes dicte uuu a aksa mamas 9 Maintenant ias tese pM UN REI B D MOD UPS 10 Schedule a TIDS a Sun agua a cessit LAE 10 M1 Replacing Transmission Clutch Lubricant 11 M2 Chain adjustment ela eda 12 M3 Front brake adis Tib oi e cni oe potett es Lees Ru ai 13 M4 Rear brake adjustment oe ee tot oes 14 M5 Air Filter GI8aning UL 14 M6 Fork Oil Replacement nana 15 M7 CI telt AdjusStmenta n 16 Engine Servi
13. T RECOMMENDED Cobra Venom 2 cycle Race Oil Fill oil reservoir as required Fixed 12 mm Dell Orto PHVA PS 82 42 5 mm 0 3mm 0 2 0 012 Single 3 shoe centrifugal 10 46 T Cobra Venom 3 Shoe Clutch Milk or Dexron III 250 ml 8 50z 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 Fork oil height 70 mm 2 75 collapsed from top with spring no spacer Specifications Torque Values Fastener Size amp Front engine mount bolts 22 264 30 8x 1 25 Rear engine mount bolts 8x 1 25 Swingarm pivot bolt 14x2 Rear sprocket bolts 7x1 Rear axle bolts 12 x 1 25 Rear shock mounts 10x 1 5 Clutch adjust access plug 12x 1 25 Units of mm unless otherwise specified Optional Components e Carburetor jets o Main jets Z s 74 76 78 80 84 86 88 o Slow jets s 38 40 45 e Sprockets o Front sprocket 11T Rear sprocket 39 T 45 T e Seat higher seat height 23 9 607 mm part TCHJ0001 e Suspension Springs Weight of Rider Ib Fork Spring Shock Spring Less than 38 light KCMZ0012A SCMUO321 yellow 320 Ib in 38 45 std KCMZ0012 SCMU1360 red 260 Ib in 46 to 55 stiff KCMZ0012B SCMU1380 white 380 Ib in e Suspension Valving Damping Rate F
14. ce Parts ere e aU tM ich laa esce ue 17 EST Top End Pallet teo Ast 18 ES2 Bottom end amp transmlissiOn cecinit 19 ES A VE teat EEA STI O 22 RE 23 COMM SYSTEM 24 ES6 Fuel amp Air System E or 25 FSZ NCC MOREM CR SO 30 Glidssis Semice PRAVI ua S Ca 30 WEB SE TITO tuta 30 CS2 DUSPONSTOM e i rau oet A ra aad aac 32 Troubleshooting rte DDR 36 General Information Specifications General Dimensions Wheelbase Wheel size Seat height Engine Type Cooling system Displacement Bore and stroke Ignition system Spark plug Fuel type Injector oil type Fuel oil mix ratios Ignition timing Carburetion Main jet Slow Pilot jet Transmission Speed Clutch Final drive ratio Float height Transmission clutch oil type Quantity 35 75 908 10 254mm 22 559 mm Stock TCHO0001 23 9 607 mm Optional TCHJ0001 2 stroke single cylinder reed valve Liquid cooled 49 8 cc 39 mm x 41 7 mm Digital Electronic Champion C53 NGK B11EGV 0 023 0 025 0 58 0 64 mm Sunoco MO2x or 93 octane pump gasoline OTHER RACE FUELS ARE NO
15. e that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the carburetor Make sure the fuel is shut off Remove the carburetor Drain the fuel in the carburetor Disassemble the carburetor N CAUTION Do not use compressed air on an assembled carburetor Or the pressure may deform the float Do not use a strong carburetor cleaning solution which could attack the parts of the carburetor instead use a mild high cleaning solution safe for plastic parts Immerse all the metal parts in a carburetor cleaning solution Rinse the parts in water After the parts are cleaned dry them with compressed air Blow out the fuel passages with compressed air Assemble the carburetor 0 Install the carburetor onto the motorcycle The three most common problems with this carburetor are figure 18 1 Installing the carburetor top backwards 2 The carburetor slide indexing pin falling out 3 Either side vent elbow falling out Figure 18 Proper carburetor top installation and location of rectangular slide indexing pin and one of the elbows that has been known to fall out 29 ES7 Exhaust The pipe is a crucial element to a motorcycle Any kinks dents or damage done to the pipe will result in a major performance loss NOTE
16. emove the oil drain bolt located on the right side of the engine figure 1 oil fill NOTE You need to adjust the brake pedal down to gain access to the drain bolt 4 After it has drained reinstall the drain screw with gasket 5 Refill oil from oil fill plug 250 ml 8 5oz Cobra Venom 3 Shoe Clutch Milk Part MCMUGF01 or Dexron Ill Automatic Transmission Fluid thru the fill plug NOTE Leaning the bike over onto it s left hand side will facilitate the oil filling procedure 6 Reapply the oil fill screw securely 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 was forced to put forth this effort because the other available options and not adequate Cobra s specially developed Cobra Venom 3 Shoe Clutch Milk Part MCMUGFO1 is the recommended lubricant for your PW3 motorcycle M2 Chain adjustment Tools required for chain adjustment e Two 19 mm wrenches or sockets e 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 38 free movement just behind the chain block with no load on the bike figure 2 Figure 2 CAUTION Verify that the chain has a minimum of 6mm 1 4 free movement when the suspension is collapsed 3 Ifthe cha
17. ery 2 hours of operation Replace the transmission oil Every 10 hours of operation Replace the fork Have the shock oil replaced by a Certified Cobra Mechanic CAUTION 1 Ifyou 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 sure the fuel tank carburetor been removed safely located away from the welding process 2 Theframe 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 M1 Replacing Transmission Clutch Lubricant Tools needed e 250 ml 8 5 2 Cobra Venom 3 Shoe Clutch Milk Part MCMUGFO1 or Dexron 11 Automatic Transmission Fluid e 3 Phillips screwdriver e large flat blade screwdriver or coin 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 A WARNING 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 Phillips screwdriver r
18. essure from the shock A WARNING Hold a rag over the bleed Schrader valve during this operation as the contents are at extremely high pressure 2 Remove the spring by removing the lock nut and other nut with a large spanner NOTE Measure the distance from the top of the spring to a feature on the top of the shock for repeatable reassembly 3 Using a Pin type spanner separate the top portion of the shock from the bottom NOTE Holding the shock in a vertical manner with the bleed valve down during separation will minimize the amount of oil that is spilled 4 Drain the oil into a suitable container for proper recycling 5 Clean the components of old oil and contaminates 6 Look for signs of wear and replace if necessary Assembly 1 If the bleed valve was removed clean the threads of both components apply some Teflon pipe sealant to the threads of the bleed valve and install torque to 10 ft Ib 14 Nm 2 With the bottom shock portion situated vertically fill with 2 5 wt often called 3 wt shock oil until 37 38 mm from the top edge 3 Install damper unit into the bottom portion of the shock taking care to not splash out shock oil in the process tighten securely 4 Holding the shock vertical with the bleed valve upward stroke the piston through its complete travel several times slowly and then bleed off any excess air 5 Charge the shock with 230 psig nitrogen 6 Reinstall the spring to the pr
19. eviously measured compressed length and secure with the lock nut 33 Front Forks bort o ta B 15 4 11 15 EA 18 E55 22 gt k Figure 22 Because of different rider weights sizes and riding styles we offer various suspension options See Optional Components section of this manual for details on these and other optional components for your Cobra Motorcycle 34 2003 PW3 FRONT PARTS LIST REFR PARE DESCHIPHON 1 85005 2 KCMZog TOPHANDLEBARCLAMP LOWER HANDLE BAR CLAMP 20005 TRIPLE CLAMP UPPER HCBC0806 8 X 30 CS PINCH BOLT FOR TOP TRIPLE CLAMP 8 70008 INNER FORK WHITE gt 9 Kmo O RING UNDER FORK CAP WASHER 35 Troubleshooting 1 2 3 4 5 6 Engine not behaving properly a Carburetor top is installed backwards happens a lot b The carburetor slide indexing pin is missing Engine is down on power a Clutch engagement is not set properly Jetting is incorrect C Silencer needs repacked Exhaust pipe i Has excess carbon buildup ii Has large dent in it e Compression is low i Piston ii Rings f Reeds are damaged g Ignition timing is incorrect Engine is excessively loud a Silencer needs repacking Engine blubbers at high RPMs a Jetting too rich Engine won t start a Fuel i None in tank ii 15 sour or bad b Ca
20. illips head screwdriver e 4mm hex key Allen e 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 Clean the filter in a nonflammable solvent to remove the filter oil Clean the filter in hot soapy water to remove all dirt particles Allow to dry thoroughly Saturate with filter oil and remove excess O Ore o 14 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 It s 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 three or more filters in your toolbox e 1 for practice e 1 for each moto M6 Fork Oil Replacement Tools required e 5 amp 6mm Allen wrench e 19 mm wrench or socket two required e Spring clip remover Disassembly Remove the front wheel Remove the fork legs from the triple clamps Perform the following on one leg at a time Using your hands remove the black rubber plug from the top of the fork leg exposing the white p
21. in requires adjusting loosen the axel with a pair of 19 mm wrenches and tighten the chain by rotating the adjuster bolts clockwise CW or loosen the chain by rotating the adjuster bolts CCW 4 Retighten the axel bolt to 25 ft lb 34 Nm Figure 3 M3 Front brake adjustment Tools recommended for front brake maintenance e 10mm open end wrench Figure 4 from the brake lever Figure 5 from the brake hub 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 4 Rear brake adjustment Tools recommended for rear brake maintenance e 10mm open end wrench There are 2 adjustments on the brake EC Figure 7 adjust lever free play 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 remain engaged If so the brake pads will burn up and need replaced M5 Air Filter Cleaning Tools recommended for air filter maintenance e 2 Ph
22. lastic cap 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 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 15 NOTE Remove the preload sleeve but leave the spring for the measurement 3 Installthe preload sleeve 4 Install and depress the white cap while installing the spring clip 5 Fork may be reinstalled M7 Clutch Adjustment Tools required 6 mm hex key Allen wrench large flat blade screw driver Process 1 Remove the clutch adjustment access plug 6mm hex key F 4 4 clutch adjust plu B Figure 8 2 Using the kick lever turn the engine over rotate the crank until one of the large flat head screws is visible through the access hole this flat head screw is one of the three adjusters NOTE Turning the adjusting screw Counter Clock Wise CCW will allow the shoe to engage at a lower RPM this is the direction you should adjust to compensate for shoe wear Alternatively a Clock Wise CW adjus
23. ork Valving Fork Valving Shock Valving Compression Rebound kit right left Soft fast KCMZ0033A KCMZ0032A SCMU0318A KCMZ0033 KCMZ0032 SCMU0318 Hard slow KCMZ0033B KCMZ0032B SCMU0318B Procedure Your Cobra PWS is close tolerance high performance machine and break in time is very important for maximum life and performance The PW3 be ridden hard after the first 1 2 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 tain have been broken in for the full 8 hours the bike will be faster Fill the fuel tank with 93 octane pump gas or Sunoco MO2x without oil Also fill the oil injection reservoir with Cobra s specially formulated Cobra Venom 2 cycle Race Oil Part MCMUOLO2 CAUTION Failure to use proper fuel or oil 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 e First 1 2 hour of operation o Follow the starting procedure listed in this manual o Avoid prolonged operation at Wide Open Throttle e 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
24. rburetor is dirty C Ignition i Spark plug fouled ii Spark plug cap off iii Engine Shut off kill switch is shorted iv Bad electrical ground v Stator winding damaged d Exhaust is plugged Engine won t idle a Idle knob needs adjusted b Carburetor jets are dirty 36 Index Air Filter Maintenance 14 Bottom End DEVICE Se aa ed 19 Break l S aa 7 Carburetion Specifications 4 Chain Adjustment 12 13 Chassis 4 22 OBI VICES 22 Clutch Lubricant Replacing 11 Cooling System 24 Engine Parts 17 Specifications 4 EXPISLISL at i aqu an uusha 30 Fork Oil Replacement 15 Front Brake Adjustment 13 Front Forks SB VICOS x Lumu u 34 Front Forks 34 Fuel P elcoO s 8 Fuel System Parts roe ciis u nas 25 SENICE s urna usu 25 General Tips 9 Ignition PAINS A 23 Sie 23 Jetting Flow TO 22 as 28 SLOG Kiran Sama a na aa 4 Kiek EVE t are
25. 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 the carburetor flip the black choke knob upward from the right side of the bike 3 Kick start the engine by kicking the lever forward 4 Revthe 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 General Tips Always wear a helmet and other protective riding gear 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 riders foot is not resting on the foot brake while they are riding Evaluate the bikes jetting only after it has been warmed up to race temperatures A properly maintained machine is safer faster and more fun to ride When washing the bike
26. tment of the screw will allow the clutch to engage at a higher RPM 3 Subsequently use the kick lever to rotate the crank and expose the other two clutch shoe adjusters and adjust them by the same amount CAUTION Be sure to adjust each of the three shoe adjustors by the same amount 4 Reinstall the clutch adjust access plug 10 ft Ib 14 Nm 16 Engine Service Parts Factory 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 don t 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 s technicians 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 plus cost of parts Call 330 549 9603 for details Figure 9 End Components PART NO 1
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