2003 CH2

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
MCCH2003.1

DISCLAIMER OF WARRANTY
This motorcycle is sold as is with all faults, obvious or not. There are no warranties expressed or implied, including any warranty of merchantability and warranty of fitness for any particular purpose.

WARNING
THE COBRA CH2 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.

Table Of Contents
General Information .........................................................................................................4 Specifications - General..............................................................................................4 Break-In Procedure ......................................................................................................6 Starting Procedure .......................................................................................................7 General Tips..................................................................................................................8 Maintenance......................................................................................................................9 Schedule & Tips ...........................................................................................................9 M1: Replacing Transmission / Clutch Lubricant ....................................................10 M2: Chain adjustment................................................................................................11 M3: Fork Oil Replacement ........................................................................................12 M4: Clutch Adjustment ..............................................................................................13 Engine Service / Parts ...................................................................................................14 ES1: Top End Parts ...................................................................................................15 ES2: Bottom end & transmission.............................................................................16 ES3: Clutch .................................................................................................................18 ES4: Ignition................................................................................................................19 ES5: Cooling System .................................................................................................20 ES6: Fuel & Air System .............................................................................................21 ES7: Exhaust ..............................................................................................................26 Chassis Service / Parts .................................................................................................27 CS1: Suspension........................................................................................................27 Troubleshooting ..............................................................................................................29

General Information
Specifications - General
Items Dimensions Wheelbase Wheel size Seat height Engine Type Cooling system Displacement Bore and stroke Ignition system Spark plug 2-stroke, single cylinder, reed valve Liquid-cooled 49.8 cc 39 mm x 41.7 mm Digital Electronic Champion C53, NGK B11EGV Gap 0.023 0.025 (0.58 0.64 mm) Fuel type Oil type Fuel / oil mix ratios Sunoco MO2 X or 93 octane pump gasoline
OTHER RACE FUELS ARE NOT RECOMMENDED

CH2 41 (1040 mm) 10 (254 mm) rear, 12 (305 mm) front 26 (660 mm)

Cobra Venom 2-cycle Race Oil Between 32:1 and 40:1 (after engine Break-In is complete)

Ignition timing Carburetion

Fixed 19 mm DellOrto PHBG - PS Main jet 90 Slow (Pilot) jet 48 Float height 16mm + 0.5mm (0.63 + 0.020

Transmission Speed Clutch Final drive ratio Transmission / clutch oil type Single 3 shoe centrifugal 10/39 T Cobra Venom 3 Shoe Clutch Milk, or Dexron III

Quantity 250 ml (8.5oz) 4

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 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)

Break-In Procedure
Your Cobra CH2 is a close-tolerance high performance machine and break-in time is very important for maximum life and performance. The CH2 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! Fill the fuel tank with 93 octane pump gas, or Sunoco MO2X without oil. Also, fill the oil injection reservoir with Cobras specially formulated Cobra Venom 2-cycle Race Oil. (Part # MCMUOL02) 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. 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!

Starting Procedure
Before starting the machine inspect the following: Fill the 2-stroke injector oil reservoir with Cobras specially formulated Cobra Venom 2-cycle Race Oil. 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; 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. 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. 2. 3. 4. 5. 6. 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. On the carburetor, flip the black choke knob upward from the right side of the bike. Kick start the engine by kicking the lever forward. Rev the engine in short spurts, turning the throttle no more than 1/4 open until the engine will run without the choke. Verify a functional engine shut-off switch by shutting off the engine. 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. 7

General Tips
1. 2. 3. 4. 5. 6. 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, be careful to not directly aim the hose at the bottom edge of the seat, or water is apt to enter the airbox.

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 Fill the 2-stroke injector oil reservoir. 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 Fill the 2-stroke injector oil reservoir with Cobras specially formulated Cobra Venom 2-cycle Race Oil. 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. 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. 2. 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.

M1: Replacing Transmission / Clutch Lubricant

Tools needed: 250 ml (8.5oz) Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01) or Dexron III Automatic Transmission Fluid #3 Phillips screwdriver 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.

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, remove the oil drain bolt located on the right side of the engine (figure 1).

Figure 1

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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 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 III Automatic Transmission Fluid, thru the fill plug. NOTE: Leaning the bike over onto its 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. Cobras specially developed Cobra Venom 3 Shoe Clutch Milk (Part # MCMUGF01) is the recommended lubricant for your CH2 motorcycle.

M2: Chain adjustment

Tools required for chain adjustment Two 19 mm wrenches or sockets 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)
Figure 2

CAUTION: Verify that the chain has a minimum of 6mm (1/4) free movement when the suspension is collapsed.

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3. If the chain 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: Fork Oil Replacement

Tools required 5 & 6 mm Allen wrench 19 mm wrench or socket (two required) Spring clip remover

Disassembly 1. 2. 3. 4. 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 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. 12

M4: 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).

Figure 4

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) adjustment 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-lb, 14 Nm).

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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 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 Cobras 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.

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ES1: Top End Parts

Figure 5, Top End Components

REF NO 1 2 3 4 5 6 7 9 10 11 12 13 14

PART NO ECMOTE01 ECMOTE02 HCBC0603 HCNF0601 ECMOTE05 ZCMOTE06 ECMU0026 ECMOTE09 ZCMOTE10 ZCMOTE11 ECMU0056 ECMU0076 ECMUSR04

DESCRIPTION CYLINDER - CHROME PISTON KIT - SINGLE RING 6X30 CAP SCREW FLANGED NUT 6MM CYLINDER HEAD CYLINDER HEAD O-RING 6MM DOWEL CYLINDER HEAD STUD BOLT 6MM BASE GASKET O-RING - EXHAUST FLANGE PISTON RING - CAST WRIST PIN SNAP RING-FRANCO PISTON

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ES2: Bottom end & transmission

Figure 6, bottom end components

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO ECMCBE01 ECMOBE02 ECMOBE03 ECMOBE04 ECMOBE05 ECMU0016 ECMOBE07 ECMOBE08 ECMU0077 HCBC0660 HCBC0607 ZCMOBE12 ECMOBE13 ECMOBE14

DESCRIPTION CASES - COMPLETE SET OUTPUT BEARING OUTPUT BEARING - SNAP RING PRECISION BEARING CRANK SEAL CRANK BEARING CRANKSHAFT COMPLETE FLYWHEEL KEY WRIST PIN BEARING 6X60 CAP SCREW 6X50 CAP SCREW CRANKCASE GASKET OUTPUT SEAL ROD WITH WRIST PIN AND BEARING S6 V/EC.+COM. SET OF SEAL ZKMOBE16 GASKET KIT ECMOBE17 DOWEL PIN - CASE ECMOBE18 CASE VENT PIPE

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Kick lever mechanism

Figure 7, kick mechanism

REF NO 1 2 3 4 5 6 8 9 11 12 13 14 15 16 17 18 19 20 21 22

PART NO ECMOKS01 ECMOKS02 ECMOKS03 ZCMU0001 ECMU0037 ECMOKS06 HCBC0625 ECMCKS09 HCBC0603 ZCMOKS12 ECMOKS13 ECMOKS14 ECMOKS15 ECMOKS16 ECMOKS17 ECMOKS18 ECMOKS19 ECMOKS20 ECMOKS21 ECMOKS22

DESCRIPTION CLUTCH COVER CRUSH WASHER - WATER DRAIN PLUG WATER DRAIN PLUG - 6X8 OIL FILL PLUG GASKET OIL FILL PLUG RETAINER CLIP - THRUST WASHER 6X25 CAP SCREW KICK START LEVER 6X30 CAP SCREW CLUTCH COVER GASKET THRUST WASHER SEAL - KICK START SHAFT KICK START SHAFT WITH GEAR KICK START SPRING WASHER - RETURN SPRING RETAINER RETAINER CLIP - RETURN SPRING J-SPRING KICK START DOG GEAR GASKET - ADJUSTING PLUG ADJUSTING PLUG

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ES3: Clutch

Figure 8 Clutch components

REF NO 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24

PART NO ECMOCL01 ECMCCL02 ECMOCL03 ECMOCL04 ECMOCL05 ECMOCL06 ECMOCL07 ECMOCL09 PCMOCL10 ECMOCL11 ECMOCL12 ECMOCL13 ECMOCL14 ECMOCL15 ECMOCL16 ECMOCL17 ECMOCL18 ECMOCL19 ECMOCL21 ECMOCL22 ECMOCL23 ECMOCL24

DESCRIPTION GEAR - DRIVE SNAP RING CLUTCH START NUT - LH THREAD WASHER - CLUTCH NUT BACK UP CLUTCH COMPLETE SPACER - CLUTCH TO HUB BUSHING - CLUTCH HUB WASHER - CLUTCH BASKET BACK UP SPROCKET - 10 TOOTH SNAP RING - OUTPUT SHAFT CLUTCH BASKET WITH GEAR S6 TCBEI M5X14 SCREW FOR MASS. ADJUSTING SPRING S6 D.2,5 BALL S6 SPECIAL-SCREW FEDER ATAZZA 6.2X12X0.6 DIN 2093 CLUTH WASHER CLUTCH SHOE S6 CLUTCH PAWL CLUTCH SCREW COUPLING S6 CLUTCH SPRIG BUSH 18

ES4: Ignition
CAUTION: Make sure ground wires are secure. If the bike is not grounded it will not run. Make sure connections are free of dirt.

Figure 9, ignition components

REF NO 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 18 20 21 23 24

PART NO ECMOIG01 HCWF0801 HCNS0801 HCBC0401 ECMOIG05 ECMOIG06 ECMOIG07 ECMOIG08 ECMOIG09 HCBC0502 HCBC0550 ECMOIG13 ECMOIG14 ECMOIG15 ECMOIG16 ECMOIG18 ECMOIG20 HCWF0501 ECMOIG23 ECMOIG24

DESCRIPTION FLYWHEEL 8MM WASHER 8MM NUT 4X10 CAP SCREW COIL WITHOUT SPARK PLUG CAP CDI BOX SPARK PLUG SPARK PLUG CAP RUBBER FOR CONTROL UNIT 5X20 CAP SCREW 5X50 CAP SCREW 7MM DOWEL IGNITION COVER GROMMET - OPEN IGNITION COVER GROMMET - CLOSED SPACER - FLYWHEEL IGNITION COVER FLYWHEEL GROMMET 5MM WASHER SPARK PLUG RUBBER SPARK PLUG BOOT

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ES5: Cooling System

Water pump

Figure 10 water pump

REF NO 1 2 3 4 5 6 7 9 11 12 13 14 15

PART NO ECMOWP01 ECMOWP02 ECMOWP03 ECMOWP04 ECMOWP05 ECMOWP06 ECMPWP07 ECMPWP09 ECMOWP11 ECMOWP12 ECMOWP13 ECMOWP14 ECMPWP15

DESCRIPTION WATER PUMP SHAFT RETAINER CLIP - WATER PUMP BEARING BEARING WATER PUMP SPACER - WATER PUMP BEARING CRANK PULLEY WATER PUMP BELT CLAMP FOR OIL TUBE OIL INJECTOR MOUNT PLATE WATER PUMP IMPELLER SNAP RING - TOOTHED WATER PUMP SEAL WASHER - BEARING RETAINER DOWEL PIN

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ES6: Fuel & Air System

Intake system

Figure 11, Intake components

REF NO 1 2 3 4 5 6 8 9 10

PART NO RCMU0018 ECMOIN02 HCBC0625 ECMOIN04 ZCMOIN05 ECMOIN06 ECMOIN08 ECMOIN09 ECMOIN10

DESCRIPTION 19MM DellOrto PHGB CARBURETOR CLAMP 6X25 CAP SCREW REED SPACER PLATE REED VALVE GASKET REED VALVE ASSEMBLY SCREW - REED CAGE TO SPACER PLATE RUBBER INTAKE BOOT INTAKE RETAINING PLATE

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Reeds
The reeds must lay flat on the reed cage. If the reed tips arent 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. 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)

Figure 12

The presence of light indicates that the reeds should be replaced, or possibly turned over.

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Carburetor
CH2 Carburetor Ref. Drawing
REF. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 25 26 27 28 29 30 31 33 PART # RCMU0305 RCMU0601 RCMU0002 RCMU0090 RCMU0048 RCMU0301 RCMU0102 RCMU0003 RCMU0006 RCMU0106 ZCMU0007 RCMU0004 RCMU0205 RCMU0007 RCMU0204 RCMU0009 RCMU0011 RCMU0103 RCMU0107 RCMU0012 RCMU0016 RCMU0106 RCMU0201 DESCRIPTION CARB SLIDE NEEDLE ATOMIZER MAIN JET (STOCK 90) PILOT JET (STOCK 48) CHOKE JET FLOAT RUBBER CABLE CAP SEAL CABLE ADJUSTER TOP CARB SCREW CARB TOP TOP CARB GASKET SLIDE SPRING NEEDLE RETAINER PLATE NEEDLE CLIP CHOKE ASSY. 2001 CM FUEL MIXTURE SCREW IDLE ADJUSTMENT SCREW FLOAT BOWL GASKET FLOAT NEEDLE DIFFUSER FLOAT RETAINER PIN FLOAT BOWL BOTTOM FLOAT SCREW

RCMU0269

VELOCITY STACK

Figure 13, carburetor

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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: Engine not revving out or blubbering at high RPMs. Engine will not clean out 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. 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: Engine cutting out on top end. Engine overheating and ultimately seizure. 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 24

screw. This screw will also richen and lean your engine more on the bottom and mid-range. In warmer conditions, turn the screw in. In colder conditions, turn the screw out. Be sure to keep the carburetor very clean and make sure you don't have w ater 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: 48 pilot jet 90 main jet Cleaning the carburetor:

Clean the carburetor in a well-ventilated area, and take care 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. 1. 2. 3. 4. Make sure the fuel is shut off. Remove the carburetor. Drain the fuel in the carburetor. Disassemble the carburetor.

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. 5. Immerse all the metal parts in a carburetor cleaning solution. 6. Rinse the parts in water. 7. After the parts are cleaned, dry them with compressed air. 8. Blow out the fuel passages with compressed air. 9. Assemble the carburetor 10. Install the carburetor onto the motorcycle. NOTE: The three most common problems with this carburetor are (figure 14): 1. Installing the carburetor top backwards. 2. The carburetor slide indexing pin falling out. 3. Either side vent elbow falling out.
Figure 14 Proper carburetor top installation and location of rectangular slide indexing pin and one of the elbows that has been known to fall out.

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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: 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 it is essential to clear the residue. CAUTION: It is important to repack the silencer. repacked are The bike is louder than normal. A loss of power.

Signs of your silencer needing to be

26

Chassis Service / Parts

CS1: Suspension
Front Forks

Figure 15

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.

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2003 CH2 FRONT FORK PARTS LIST

REF # 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 18A 19 20 21 22 23 25 26 27 28 29 31 32 33 PART # KCMZ0001 KCMZ0002 KCMZ0003 KCMZ0004 KCMZ0005 HCBC0806 KCMZ0007 KCMZ0008 KCMZ0009 KCMZ0011 KCMZ0012 KCMZ0013 KCMZ0014 KCMZ0015 KCMZ0016 KCMZ0017 KCMZ0018 KCMZ0018A KCMZ0019 KCMZ0020 KCMZ0021 HCWC0000 HCBC0806 KCMZ0025 KCMZ0026 KCMZ0027 KCMZ0028 KCMZ0029 KCMZ0031 HCBC0609 HCBC0525 DESCRIPTION 8 X 50 CS TOP HANDLE BAR CLAMP LOWER HANDLE BAR CLAMP FORK PLUG BLACK TRIPLE CLAMP UPPER 8 X 30 CS PINCH BOLT FOR TOP TRIPLE CLAMP SNAP RING FOR FORK CAP INNER FORK CAP - WHITE O-RING UNDER FORK CAP PRELOAD SLEEVE FORK SPRING SWIPER SNAP RING FORK SEAL WASHER SNAP RING FOR PISTON PISTON ROD - REBOUND PISTON ROD - COMPRESSION REBOUND SPRING FORK LEG OUTER LEFT FORK LEG 5 PIECE UNIT LEFT WASHER 8 X 30 CS TRIPLE CLAMP BOTTOM W/STEM FORK TUBE INNER RIGHT FORK TUBE INNER LEFT TOP OUT BUMPER FORK LEG OUTER RIGHT FORK LEG 5 PIECE UNIT RIGHT 6 X 20 CS 6 X 25 CS

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Troubleshooting
1) Engine not behaving properly a) Carburetor top is installed backwards (happens a lot) b) The carburetor slide indexing pin is missing 2) Engine is down on power a) Clutch engagement is not set properly b) Jetting is incorrect c) Silencer needs repacked d) 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 3) Engine is excessively loud a) Silencer needs repacking 4) Engine blubbers at high RPMs a) Jetting too rich 5) Engine wont start a) Fuel i) None in tank ii) Is sour or bad b) Carburetor 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 6) Engine wont idle a) Idle knob needs adjusted

b) Carburetor jets are dirty 29

Index
Bottom End Service ...........................................16 Break-In................................................6 Carburetion Specifications ..................................4 Chain Adjustment.............................. 11, 12 Chassis Specification....................................4 Clutch Parts ...............................................18 Service ...........................................18 Clutch Lubricant Replacing .......................................10 Cooling System.................................20 Engine Parts List ........................................14 Specifications ..................................4 Exhaust ..............................................26 Fork Oil Replacement .................................12 Front Forks Service ...........................................27 Front Forks: .......................................27 Fuel Petcock ............................................7 Fuel System Parts list .........................................21 Service ...........................................21 General Tips........................................8 Ignition Parts ...............................................19 Service ...........................................19 Jetting How To ...........................................24 Stock.................................................4 Kick Lever ..........................................17 Lubrication Recommended ...............................4 Maintenance Schedule ..........................................9 Tips ...................................................9 Oil Recommended ...............................4 Parts Bottom end ....................................16 Clutch .............................................18 Ignition............................................19 Inlet .................................................21 Kick mechanism ...........................17 Reeds .............................................21 Top end ..........................................15 Water pump ...................................20 Parts List Front Forks ....................................27 Petcock ................................................7 Reeds .......................................... 21, 22 Spark Plug Recommended ...............................4 Specifications ......................................4 Starting .................................................7 TIps .......................................................8 Top End Service ...........................................15 Transmission Service ...........................................16 Specifications ..................................4 Transmission Lubricant Replacing .......................................10 Troubleshooting ................................29 VIN reading .........................................8 WARNING ...........................................2 Water pump .......................................20

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