Cobra Cm-50 2006 Bedienungsanleitung

2006 CM-50

Owners Manual

June 2006

Allegan Motorsports - 800-475-5660

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

MCCM2006.2

DISCLAIMER OF WARRANTY

This motorcycle is sold “as is” with all faults, obvious or not. There are no warranties

expressed or implied, including any warranty of merchantability and warranty of fitness

for any particular purpose.

“WARNING”

THE COBRA CM50 IS A COMPETITION MODEL ONLY AND IS NOT

MANUFACTURED FOR, NOR SHOULD IT BE USED ON PUBLIC STREETS, ROADS

OR HIGHWAYS.

THE USE OF THIS BIKE SHOULD BE LIMITED TO PARTICIPATION IN

SANCTIONED COMPETITION EVENTS UPON A CLOSED COURSE BY A

SUFFICIENTLY SKILLED RIDER AND SHOULD NOT BE USED FOR GENERAL

OFF-ROAD RECREATIONAL RIDING.

IMPROPER USE OF THIS MOTORCYCLE CAN CAUSE INJURY OR DEATH.

THIS BIKE IS INTENDED FOR EXPERIENCED RACERS ONLY AND NOT FOR

BEGINNERS.

IT IS YOUR RESPONSIBILITY AS THE OWNER OF THIS COBRA MOTORCYCLE

OR AS THE PARENT, OR LEGAL GUARDIAN OF THE OPERATOR, TO KEEP THIS

COBRA MOTORCYCLE IN PROPER OPERATING CONDITION.

THIS BIKE WAS DESIGNED FOR RIDERS THAT WEIGH LESS THAN 80 LBS WITH

FULL RIDING GEAR AND SHOULD NOT BE OPERATED BY RIDERS THAT WEIGH

MORE THAN 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 .........................................................................................................5

Specifications - General..............................................................................................5

Specifications - Torque Values ..................................................................................6

Optional Components..................................................................................................7

Break-In Procedure......................................................................................................8

Starting Procedure .......................................................................................................9

General Tips................................................................................................................10

Maintenance....................................................................................................................11

Schedule & Tips .........................................................................................................11

Replacing Transmission / Clutch Lubricant............................................................12

Chain adjustment .......................................................................................................13

Front brake adjustment .............................................................................................14

Rear brake adjustment ..............................................................................................15

Air Filter Cleaning .......................................................................................................15

Fork Oil Replacement................................................................................................16

Service .............................................................................................................................40

Engine Service............................................................................................................40

Engine Removal .....................................................................................................41

Complete Engine Disassembly Procedure.........................................................42

Top End Disassembly Procedure ........................................................................42

Splitting the Cases .................................................................................................43

Engine assembly ....................................................................................................44

Clutch ...........................................................................................................................46

Ignition..........................................................................................................................51

Cooling System...........................................................................................................53

Fuel & Air System.......................................................................................................57

Exhaust ........................................................................................................................60

Wheels & Tires ...........................................................................................................61

Tuning ..............................................................................................................................61

Suspension..................................................................................................................61

Rear shock ..............................................................................................................63

Front Forks ..............................................................................................................63

Gearing ........................................................................................................................64

Carburetion..................................................................................................................66

Troubleshooting ..............................................................................................................68

General Information

Specifications -General

Items CM 50

Dimensions

Wheelbase 35.75” (908mm)

Wheel size 10” (254mm)

Seat height 23.9” (607 mm)

Engine

Type 2-stroke, single cylinder, reed valve

Cooling system Liquid-cooled

Coolant Liquid Performance Mini Coolant or Antifreeze

Displacement 49.8 cc

Bore and stroke 39 mm x 41.7 mm, “V” head

Ignition system Electronic, analogic advance

Spark plug Champion 8339-1, 8332-1 hotter, 8904-1 colder

Gap

0.023” –0.025” (0.58–0.64 mm)

Ignition timing 0.045” (1.14 mm) Before To Dead Center (BTDC)

Fuel type High octane pump gasoline

RACE FUELS ARE NOT RECOMMENDED

Oil type Cobra Venom 2-cycle Race Oil

Fuel / oil mix ratios Between 32:1 and 40:1 (after engine Break-In)

Carburetion 14 mm Dell’Orto

Main Jet

Slow (Pilot) jet

Float Height

16mm +0.5mm (0.63” +0.020”)

Transmission

Speed / Clutch Single / Cobra 3 shoe

Final drive ratio 13/38T or 14/38 T

Chain 420

Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk

Quantity

235 ml (8.0oz)

Chassis

Front tire 2.50 –10

Pressure

15 psi minimum

Rear tire 2.75 –10

Pressure

15 psi min. (20 psi for hard pack or rocky conditions)

Front fork Marzocchi 32mm

Fork oil type

SAE 20 weight

Fork oil amount

200 ml (6.8 oz) oil change, 220 ml (7.4 oz) rebuild

Collapsed fork oil height

70 mm (2.75”) spring in, no spacer

Specifications -Torque Values

Torque Value

Fastener ft-lb in-lb Nm

Size &

Remarks

Cylinder head nuts 8.8 105 12 M6 X 1.0

Crankcase bolts 8.8 105 12 M6 x 1.0

Spark plug (SP) (SP) (SP) M14 x 1.25

Stator bolts 2.1 25 2.8 M5 X 0.8

Stator cover bolts 1.7 20 2.3 M4 X 0.75

Clutch cover bolts 5.8 70 7.9 M6 X 1.0

Clutch nut (max.) 40 480 54 10 x 1.25*

Clutch bolts 12 144 16 M6 x 1.0

CFD nut 55 664 75 ½” x 20 LHT

Engine mount bolts 22 265 30 M8 X 1.25

Swingarm Pivot 21 250 28 M14 X 2.0

Intake manifold bolts 4.6 55 6.2 M6 X 1.0

Ignition rotor nut 40 480 54 M10 x 1.25*

Rear Sprocket Bolts 18 216 24 M7 X 1.0

Rear shock mounts 40 480 54 M10 x 1.5

Axle nuts 25 300 34 M12 X 1.25

* Apply high strength thread locking agent when installing

(SP)To apply the proper torque to the spark plugwhen inserting, one must first

screw the spark plug in until the metal gasket ring causes resistance and then

turn another 1/8 to ¼ turn.

Optional Components

Call your dealer, or the factory, for details

•Carburetor jets

•Pre-filter for the airbox

•Sprockets

oFront

oRear

•Suspension Springs

Weight of Rider (lb) Fork Spring Shock Spring

Less than 38 (light) KCMZ0012A

(12 lb/in, 2.10 N/mm))

SCMUOH04

(275 lb/in) red

38 –45 (std) KCMZ0012

(14 lb/in, 2.45 N/mm))

SCMUOH05

(285 lb/in) yellow

46 to 55 (stiff) KCMZ0012B

(16 lb/in, 2.80 N/mm)

SCMU0H06

(295 lb/in) white

•Suspension valving

Damping Rate Fork Valving

Compression

(right)

Fork Valving

Rebound

(left)

Shock Valving

(kit)

Soft (fast) KCMZ0033A KCMZ0032A SCMUOH07

Standard KCMZ0033 KCMZ0032 SCMUOH08

Hard (slow) KCMZ0033B KCMZ0032B SCMUOH09

•Tires

•Tubes or ‘Tire Balls’

Break-In Procedure

Your Cobra CM50 is a close-tolerance high performance machine and break-in

time is very important for maximum life and performance. The CM50 can be

ridden hard after the first ½ hour break-in time but it is recommended that no

adjustments are made to the carburetion or suspension until the full 8 hours of

bike break-in has elapsed. Also, after the engine, transmission, and drive train

have been broken-in for the full 8 hours, the bike will be faster!

Use a fuel / oil mixture of 32:1 for the full 8 hour break-in period. Be sure to use

high octane pump gas with Cobra’s specially formulated Cobra Venom 2-cycle

Race Oil

CAUTION:

Failure to use proper fuel, oil, or fuel/oil mixture may result in premature engine

wear or damage to the machine.

Adhering to the following break-in schedule will result in long lasting high

performance machine.

• Start bike on stand

• First 5 minute period, operate the bike on the stand with a combination of idle

and high RPM operation. (avoid prolonged high RPM but spin the rear

wheel good at least once or twice per minute)

• Allow bike to cool

• Ride for 15 minutes maximum (avoid prolonged high RPM operation and

avoid abusing the clutch with throttle blipping.

• Cool and inspect bike for loose fasteners.

• Next ½ hour of operation, avoid prolonged operation at Wide Open Throttle.

• After 1 hour of operation

oCheck for loose bolts and nuts on the bike and retighten as

necessary (proper toque values are listed under Specifications).

oClean the carburetor bowl.

oChange the transmission / clutch lubricant.

• After 8 hours of operation

oChange the fork oil.

oHave a Certified Cobra Mechanic change the shock oil.

• Your bike is now ready for the highest level of competition!

NOTE:

During break-in the bike will likely lose some engine coolant through the radiator

overflow hose. Losing up to 4 oz (120 ml, ½ cup) is normal. Proper coolant level

will cover the top of the radiator cores. Removing the radiator cap and looking

inside is the only way to check the coolant level.

June 2006

Allegan Motorsports - 800-475-5660

Never open the radiator cap of a machine that has a hot or warm engine or one

that has recently been ridden. Burning and scalding could occur.

CAUTION:

It is important that the radiator cap is installed correctly and completely otherwise

engine damage could occur.

Starting Procedure

Before starting the machine inspect the following:

•Make sure vehicle is properly maintained (seeSchedule & Tips in the

Maintenance section)

•Check the throttle for smooth operation and sound closing.

•Insure that the fuel tank contains an adequate volume of fuel / oil mixture to

complete the distance required. (High octane pump gas with Cobra’s

specially formulated Cobra Venom 2-cycle Race Oil)

•Turn the fuel on by rotating the fuel petcock knob to the vertically downward

position (reserve position is horizontally forward)

CAUTION:

For best results from your Cobra Motorcycle use only the recommended fuels.

Testing has shown that most ‘race’ fuels actually degrade performance.

When your pre-ride inspection is complete the bike may be started. For a cold

engine follow this procedure.

1. Place the motorcycle on a stand of sufficient strength that positions the

motorcycle in a level upright position with the rear wheel off the ground.

2. Pull up the choke knob and turn it to lock it.

3. Kick start the engine.

4. Rev the engine in short spurts, turning the throttle no more than 1/4 open

until the engine will run without the choke.

5. Verify a functional engine shut-off switch by shutting off the engine.

6. Restart the engine and proceed with riding when the engine is sufficiently

warm (i.e. the side of the cylinder is warm to touch).

CAUTION:

Never rev an engine full throttle when it's cold or slightly warmed up. Cobra

recommends that you tell your child to take it easy the first couple of minutes in

practice until the engine comes up to full operating temperature. Make sure your

engine is properly warmed up before racing.

This is a high performance race motorcycle. Too much application of throttle will

likely land your little racer on his or her arse. Fenders can be replaced but

bruised egos and other body parts take longer.

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