Cobra PW3 2003 Guide d'application

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

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 PW3 IS A COMPETITION MODEL ONLY AND IS NOT

MANUFACTURED FOR, NOR SHOULD IT BE USEDON 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 aperson 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

Specifications -Torque Values ..................................................................................5

Optional Components..................................................................................................6

Break-In Procedure......................................................................................................7

Starting Procedure.......................................................................................................8

General Tips..................................................................................................................9

Maintenance....................................................................................................................10

Schedule & Tips .........................................................................................................10

M1: Replacing Transmission / Clutch Lubricant....................................................11

M2: Chain adjustment................................................................................................12

M3: Front brake adjustment......................................................................................13

M4: Rear brake adjustment ......................................................................................14

M5: Air Filter Cleaning ...............................................................................................14

M6: Fork Oil Replacement........................................................................................15

M7: Clutch Adjustment ..............................................................................................16

Engine Service / Parts...................................................................................................17

ES1: Top End Parts ...................................................................................................18

ES2: Bottom end & transmission.............................................................................19

ES3: Clutch.................................................................................................................22

ES4: Ignition................................................................................................................23

ES5: Cooling System.................................................................................................24

ES6: Fuel & Air System.............................................................................................25

ES7: Exhaust ..............................................................................................................30

Chassis Service / Parts .................................................................................................30

CS1: Wheels & Tires .................................................................................................30

CS2: Suspension........................................................................................................32

Troubleshooting..............................................................................................................36

General Information

Specifications -General

Items PW3

Dimensions

Wheelbase 35.75” (908mm)

Wheel size 10” (254mm)

Seat height 22” (559 mm) Stock #TCHO0001

23.9” (607 mm) Optional #TCHJ0001

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

Ignition system Digital Electronic

Spark plug ChampionC53, NGK B11EGV

Gap

0.023” –0.025” (0.58–0.64 mm)

Fuel type Sunoco MO2X or 93 octane pump gasoline

OTHER RACE FUELS ARE NOT RECOMMENDED

Injector oil type Cobra Venom 2-cycle Race Oil

Fuel / oil mix ratios Fill oil reservoir as required

Ignition timing Fixed

Carburetion 12 mm Dell’Orto PHVA-PS

Main jet

Slow (Pilot) jet

Float height

5 mm +0.3mm (0.2” +0.012”)

Transmission

Speed Single

Clutch 3 shoe centrifugal

Final drive ratio 10/46 T

Transmission / clutch oil type Cobra Venom 3 Shoe Clutch Milk, or Dexron III

Quantity

250 ml (8.5oz)

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

Torque ValueFastener

ft-lb in-lb Nm

Size &

Remarks

Front engine mount bolts 22 264 30 8 x 1.25

Rear engine mount bolts 22 264 30 8 x 1.25

Swingarm pivot bolt 21 250 28 14 x 2

Rear sprocket bolts 18 216 24 7 x 1

Rear axle bolts 25 300 34 12 x 1.25

Rear shock mounts 40 480 54 10 x 1.5

Clutch adjust access plug 10 124 14 12 x 1.25

Units of mm unless otherwise specified

Optional Components

•Carburetor jets

oMain jets #’s 74, 76, 78, 80, 84, 86, 88

oSlow jets #’s 38, 40, 45,

•Sprockets

oFront sprocket, 11T

oRear sprocket, 39 T –45 T

•Seat –higher seat height 23.9” (607 mm) part # TCHJ0001

•Suspension Springs

Weight of Rider (lb) Fork Spring Shock Spring

Less than 38 (light) KCMZ0012A SCMU0321 (yellow, 320 lb/in)

38 –45 (std) KCMZ0012 SCMU1360 (red, 260 lb/in)

46 to 55 (stiff) KCMZ0012B SCMU1380 (white, 380 lb/in)

Extra stiff SCMU1400 (silver, 400 lb/in)

•Suspension Valving

Damping Rate Fork Valving

Compression

(right)

Fork Valving

Rebound

(left)

Shock Valving

(kit)

Soft (fast) KCMZ0033A KCMZ0032A SCMU0318A

Standard KCMZ0033 KCMZ0032 SCMU0318

Hard (slow) KCMZ0033B KCMZ0032B SCMU0318B

Break-In Procedure

Your Cobra PW3 is a close-tolerance high performance machine and break-in

time is very important for maximum life and performance. The PW3 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!

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 #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 ½ hour of operation

oFollow the starting procedure listed in this manual.

oAvoid 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!

Starting Procedure

Before starting the machine inspect the following:

•Fill the 2-stroke injector oil reservoir with Cobra’s specially formulatedCobra

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;

oCracks in the metal.

oCracking paint which might indicate overly stressed material.

•Verify that the handlebars are tight.

•Check the throttle for;

oSmooth operation and sound closing.

oFrayed 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. 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. On 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. 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.

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 they are

riding.

4. Evaluate the bikes jetting only after it has been warmed up to race

temperatures.

5. A properly maintained machine is safer, faster, and more fun to ride.

6. 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.

7. 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.

Ce manuel convient aux modèles suivants

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