Page 3 - DISCLAIMER OF WARRANTY; “WARNING”; IMPORTANT SAFETY NOTICE
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 KING IS A COMPETITION MODEL ONLY AND IS NOT MANUFA...
Page 4 - Table Of Contents
3 Table Of Contents General Information ......................................................................................................... 4 Specifications - General .............................................................................................. 4 Optional Components .............
Page 5 - General Information; Specifications - General; Items; Sunoco; Cobra Venom; Transmission; Cobra Venom 3 Shoe Clutch Milk,
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 cylinder, reed valve Cooling system Liquid-cooled Displacement 49.8 cc Bore and stroke 39 mm x 41.7 mm Igniti...
Page 6 - Chassis
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 (4.0 oz) Optional Components • Carburetor jets • Sprockets o Front o Rear • Suspensio...
Page 7 - Specifications - Torque Values
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 2.3 #8 Clutch cover bolts 5.8 70 7.9 6 mm Clutch 40 480 ...
Page 9 - Starting Procedure
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. • Inspect the fra...
Page 10 - General Tips; Maintenance
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 brake while...
Page 12 - You may need to adjust the brake pedal (up or down) to gain access to; NOTE; (Part # MCMUGF01) is the recommended lubricant for your KING
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 down) to gain ...
Page 13 - M2: Chain adjustment; Make sure that the rear; M3: Rear brake adjustment; Tools recommended for rear brake maintenance:
12 M2: Chain adjustment Figure 2 1. Make sure that the rear wheel is aligned properly. 2. Push down on the seat, 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 2.5 in. of slack should be between the swing arm and ...
Page 14 - M4: Air Filter Cleaning; Tools recommended for air filter maintenance:; M5: Fork Oil Replacement; Tools required
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 important to keep it clean and properly oiled with high quality water-resistant foam...
Page 15 - Assembly procedure; and record for tuning purposes.
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 record for tuning purposes. 3. Install the fork spring. 4...
Page 16 - Engine Service / Parts; 003 KING ENGINE ASSEMBLY REFERENCE DRAWING
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 3 CAMU0008 Spring Set, Washer type for Clutch 46 ZCMUOR07 Oring, Exhaust Flange 4 CCMU0031 Arbor fo...
Page 19 - Example; Procedure for Compression Testing; mm nut driver, flat or Phillip, screwdriver for hose clamps; Procedure
18 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 sp...
Page 20 - E2: Complete Engine Disassembly Procedure; and the water pump belt; E3: Top End Disassembly Procedure
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). ...
Page 21 - E4: Splitting the Cases
20 4. Remove the cylinder. Muratic acid can be dangerous. Follow the manufacturers instructions 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 repla...
Page 24 - to the mating surfaces of both crankcase halves.
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 beh...
Page 27 - Cobra clutch puller assembly:; Clutch puller diagram; Tools recommended for clutch service:; Clutch nut removal tool (Call local dealer for details)
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). • 5mm T-handle • Clutch nut removal tool (Call...
Page 28 - Set of three shoes; Every time you blip the throttle, you
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. You will probably have to heat the center hub again to remove the bolts. Once you get a bolt loosened, carefully remove it with the shoe...
Page 29 - between the spring washers also keeps the clutch shoe from; change your oil; ECMU0040 Clutch to hub spacer
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 slip. So you will need to clean the sludge out or just replace the spring washers and bolts with new ones. How quickly this sludge builds up depends on ho...
Page 31 - Cobra 3 Shoe Clutch Milk
30 8. Install the clutch cover taking care to put the two longer bolts in their proper locations and tightening 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). ES4: Ignition ...
Page 32 - Tools recommended for timing service:; Compact motorcycle dial indicator; TIMING YOUR IGNITION :; from top dead center.
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. CAUTION: If the engine is hot, it is EXTREML...
Page 33 - ES5: Cooling System; TDC
32 5. Inspect and remove markings, 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. CAUTION: It is recommended that you apply the proper threa...
Page 34 - COBRA IMPELLER SERVICE INSTRUCTIONS
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. Fill the ra...
Page 35 - Too much heat can be detrimental to the engine cases.
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. (Figure 22 – item 2) Figure...
Page 37 - Tools recommended for carburetor service:; Small flat head screwdriver; KING Carburetor Ref. Drawing
36 ES6: Fuel & Air System Carburetor: Tools recommended for carburetor service: • Small flat head screwdriver • WD-40 • 8mm socket Figure 26 KING Carburetor Ref. Drawing REF. # PART # DESCRIPTION 1 RCMU0305 CARB SLIDE 2 RCMU0601 NEEDLE 3 RCMU0002 ATOMIZER 4 MAIN JET 5 PILOT JET 6 CHOKE JET 7 RCM...
Page 38 - very
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 adjusted. IDLE ADJUSTMENT: On the left...
Page 39 - not
38 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 KING stock carburetor settings from the factory are: • 65 pilot jet • 94 main jet Cleaning the carburetor: Clean the carburetor in a wel...
Page 41 - Chassis Service / Parts; Rear wheel; Rear wheel dampening
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. This feature prevents engine impact sho...
Page 42 - Rear wheel pullers; back wheel assembly.; Rear wheel alignment:; Measure from the side of
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. 2. Adjust ...
Page 43 - Front wheel assembly
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 WHEEL SPACER (SMALL) 6 BCKG0008 FRONT BRAKE MOUNT 7 KCKG0028 FORK LEG (BRAKE SIDE) 8 WCMU0016 REAR AXL...
Page 44 - Front Brakes; Your front brake needs a break-in period to achieve maximum brake
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 ...
Page 46 - Brake bleeding procedure:; procedure. Pry pads outward to fully retracted position.
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 ...
Page 48 - Rear Shock
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 RUBBER SCKG0H08 SPRING - LIGHT SCKGOH09 SPRING-MEDIUM-STOCK SCKGOH10 SPRING-HEAVY SCKGOH11 ORING FO...
Page 49 - Front forks; FORK ASSEMBLY PROCEDURES:
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. 2. Slide snap ring (#5) onto lower fork le...
Page 50 - Drawing
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). Figure 42 Because of different rider weights, sizes and riding styles, we offer various suspension options: Se...
Page 51 - Troubleshooting; b) Carburetor jets are dirty
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 engagement is not set properly b) Jetting is incorrect c) Silencer needs repacked d) Exhaust pipe i) Has e...
Page 52 - Index
51 Index Air Filter ..............................................13 Brakes Front ...............................................43 Break-In................................................ 7 Carburetion Specifications .................................. 4 Carburetor .....................................
