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23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/201PRIORTOINSTALLATION,MAKESUREYOURSTOCKHEADPIPEGASKETSAREINGOODCONDITION.
IFYOUHAVEANYDOUBTSASTOTHEIRCONDITION,REPLACETHEM.
Readallinstructionscarefullyandcompletelybeforeinstallingyournewexhaustsystem!
1.
Removethesaddlebags,rightsidecover,andrightfrontfloorboardfromtheframe.
2.
UnplugtheO2sensorsonthefrontandrearheadpipesfromthemotorcyclewireharness.
3.
Removethestockexhaustsystembeingcarefulnottodamagetheheadpipegaskets.
Iftheheadpipegasketsareingoodconditiontheydonotneedtoberemovedfromthecylinders.
Removeandsavetheflanges,nuts,retainingrings,mufflerclamps,mufflermountbolts,crossoverbracketbolts,andO2sensorsfromthestockexhaust.
LabeltheO2sensorsfrontandreartoensuretheywillbeinstalledontheproperheadpipe.
4.
Removethestockexhaustmountbracket.
5.
Installthesuppliedheadpipesupportbracketusingthestocknut.
SeeFIGURE1.
LightlysnugthenutbutDONOTTIGHTENsothebracketcanbeadjusted.
Thebracketshouldbepositionedataslightangle.
SeeFIGURE1.
ItemsSupplied>1–FRONTHEADPIPEANDHEATSHIELD1–REARHEADPIPECOLLECTORASSEMBLYANDHEATSHIELD1–LEFTREARCROSSOVERPIPEANDHEATSHIELD1–BRACKET,FRONTHEADPIPESUPPORT1–BRACKET,CROSSOVERPIPESUPPORT1–FLOORBOARDMOUNTSPACERPLATE1–CLAMP,FRONTHEADPIPESUPPORT8–CLAMP,HOSEHS-241–CLAMP,HOSEHS-361–THICK3/8"WASHER2-1/4ALLENBOLTS1–THIN3/8"WASHER2-1/4FLATWASHERS1–3/8"X1"CARRIAGEBOLT2–CLAMP,27-61MSC1–3/8"NYLOCKNUTApplication(s)>HARLEY:DRESSER17-20InstructionManual>6255Page1of5DOCUMENTNO.
0017REV.
AContinuedonPage2STOCKNUTFIGURE1COBRAHEADPIPESUPPORTBRACKETDISCLAIMER:NOTLEGALFORSALEORUSEINCALIFORNIAONANYPOLLUTIONCONTROLLEDMOTORVEHICLE.
THESALE,USE,ORINSTALLATIONOFTHISPRODUCTMAYALSOBEILLEGALNATIONWIDEUNDERTHEFEDERALCLEANAIRACT(42U.
S.
C.
§7522(A)(3)).
ATTENTION!
:THESEHEADPIPESWILLNOTWORKINCOMBINATIONWITHSTOCKHARLEYDAVIDSONMUFFLERSDUETORIGHTMUFFLERSLIPDESIGN.
23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/202InstructionManual>6255Page2of56.
Installthestockflanges,retainingringsandO2sensorsontothesuppliedfrontandrearheadpipes.
BesuretoinstallthefrontO2sensoronthefrontheadpipeandtherearO2sensorontherearheadpipe.
7.
Installthefrontheadpipe(withstockgasketinplace)ontothefrontcylinderusingthestocknuts.
SnugthenutsbutDONOTTIGHTENatthistime.
8.
Slidethesuppliedpinchclampoverthefrontheadpipemakingsurethesquareholeontheclampisfacingupandtowardstheinside.
Positiontheclampoverthesupportbracketsothatthepinchclampcapturesbothsidesofthebracket.
SeeFIGURE2.
Insertthesupplied3/8"carriageboltthroughthetopofthepinchclampandsupportbracket.
Installthe3/8"thinflatwasherandnutontothebottomofthecarriageboltbutDONOTTIGHTENatthistime.
Leavethenutloosesotheheadpipecanbeadjusted.
9.
Position(2)ofthesupplied#27-61MSCmufflerclampsontotherearheadpipecollectorassemblyinletandoutlet.
Thehexheadofbothclampsshouldbeinwardanddown.
SeeFIGURE3.
(NOTE:Theclampsshouldbeflushwiththeendoftheinletandoutletwhentightened.
SeeFIGURE3.
Iftheclampsareslidpasttheslotsontheinletandoutlettheclampswillnottightenproperly).
10.
Installtherearheadpipecollectorassembly(withstockgasketinplace)ontotherearcylinderandontothefrontheadpipe.
Makesurethefrontheadpipeispushedinasfaraspossibleintotherearheadpipecollectorassemblyinlet.
Usethestocknutstofastentheheadpipetothecylinder.
SnugthenutsbutDONOTTIGHTENatthistime.
SeeFIGURE4.
11.
Installtheleftrearcrossoverpipeontotherearheadpipecollectorassemblymakingsureitslidesintotheoutletoftherearheadpipecollectorassemblyoutletasfaraspossible.
SeeFIGURE4.
DOCUMENTNO.
0018REV.
AContinuedonPage3FIGURE2FRONTHEADPIPESUPPORTBRACKETCARRIAGEBOLTPINCHCLAMP3/8"THINFLATWASHERANDNUTPOSITION27-61MSCCLAMPWITHHEXHEADFACINGINANDDOWNCLAMPSSHOULDBEFLUSHWITHEDGEOFCOLLECTORDONOTSLIDECLAMPSPASTSLOTSFIGURE3CLAMPSSHOULDBEFLUSHWITHEDGEOFCOLLECTOR(INWARDSIDEOFCOLLECTOR)23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/203InstructionManual>6255Page3of512.
Installthesuppliedcrossoversupportbrackettothestockmountinglocationusingthe(2)stockallenbolts.
LightlysnugtheboltsbutDONOTTIGHTENatthistime.
Adjustthecrossoverpipeforeandaftsothemountonthecrossoverassemblyrestsflushagainstthesupportbracket.
Thenpushuplightlyontheleftsideofthecrossoverassemblytoalignthebracketandinsertthe(2)suppliedallenboltswithflatwashers.
LightlysnugtheallenboltsbutDONOTTIGHTENatthistime.
SeeFIGURE5.
IMPORTANT:DONOTforcethecrossoverpipeforwardorbackwardorupanddowntogetitintoposition.
Ifalotofforceisneededtoalignthecrossoverpipeandsupportbracketthenadjusttherearheadpipecollectorassemblyuntilitwillalignwithonlyenoughforcetocounteracttheweightoftheleftsideofthecrossoverassembly.
Also,Makesurethecrossoverpipehasclearanceallaroundanddoesnotmakecontactwiththetransmissionpan.
Adjustasneededwhileboltsareloose.
13.
Installtheleftandrightmufflersontotheheadpipeassemblyandreinsertthe(2)stock5/16-inchboltsintoeachrearmufflermount.
Donottightenclampsorbolts.
14.
Makesurethefrontheadpipe,rearheadpipecollectorassembly,leftrearcrossoverpipe,andmufflersarealignedproperlyandtightenthe(4)allenboltsonthecrossoversupportbracket.
SeeFIGURE5.
15.
Thenfullytightentheflangenutsontheexhaustportstuds,followedbythenutforthe3/8"carriageboltonthefrontheadpipesupportclampandthenutonthefrontheadpipesupportbracket.
SeeFIGURE2.
16.
Nextfullytightenthe(2)27-61MSCclampsontherearheadpipecollectorassembly.
(NOTE:Theclampsshouldbeflushwiththeendofthecrossoverassemblyinletswhentightened.
SeeFIGURE3.
Iftheclampsareslidpasttheslotsonthecrossoverassemblyinlettheclampswillnottightenproperly).
DOCUMENTNO.
0018REV.
AContinuedonPage4FIGURE5STOCKBOLTSCROSSOVERPIPECOBRACROSSOVERSUPPORTBRACKETSUPPLIEDALLENBOLTSANDWASHERSNOTE:Arrowspointtothepositionofthehexheadoftheclamps.
FIGURE427-61MSCCLAMPFRONTHEADPIPESUPPORTREARCROSSOVERPIPE23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/204InstructionManual>6255Page4of517.
PlugtheO2sensorsbackintothemotorcyclewireharnessandroutethewiresawayfromtheexhaustinthesamemannerasstock.
18.
Removetheheatshieldsandhoseclampsfrompackaging.
Unscrewthehoseclampsandfeedthetailendoftheclampsthroughtheclipsontheinsideoftheheatshieldsothescrewsareaccessiblewithascrewdriveroncetheheatshieldisinstalled.
ThelargeHS-36hoseclampgoesontherearclipontherearheatshield.
SeeFIGURE6&8forproperpositioningoftheclampsontheheatshields.
(NOTE:Thearrowspointtothepositioningofthehexheadoftheclamps.
Thehexheadoftheclampsshouldbeaccessiblefortighteningbutnotvisiblewhentheheatshieldsaremountedtothepipes.
)19.
Installtherightrearheatshieldovertherearheadpipe.
(Hint:Spreadthehoseclampsapartslightlytomakeiteasiertoslidethemovertheheadpipes.
)Aligntheheatshieldwiththeheadpipeandthecollectorheatshield.
Thereshouldbeanevengaparoundthecollectorheatshield.
SnugtheclampsbutDONOTTIGHTENatthistime.
SeeFIGURE6&7.
20.
Installtherightfrontheatshieldovertherightfrontheadpipe.
(Hint:Spreadthehoseclampsapartslightlytomakeiteasiertoslidethemovertheheadpipes.
)Aligntheheatshieldwiththeheadpipeandthecollectorheatshield.
Thereshouldbeanevengaparoundthecollectorheatshield.
Iftheheatshielddoesnotalignwellwiththecollectorheatshieldthentherearcrossoverpipemayneedtobeloosenedandpushedforwardorbackward.
WhentheheatshieldisalignedproperlysnugtheclampsbutDONOTTIGHTENatthistime.
SeeFIGURE6&7.
21.
Iftheheatshieldswillnotalignproperlywiththecollectorheatshieldthenthecollectorheatshieldmayneedtobeloosenedandmovedforwardorbackward.
Loosenthetwobuttonheadboltstoadjustthecollectorheatshieldforwardorbackward.
SeeFIGURE7.
DOCUMENTNO.
0018REV.
AInstructionManual>ContinuedonPage5FIGURE710-24BUTTONHEADBOLT10-24BUTTONHEADBOLTCOLLECTORHEATSHIELDFIGURE6HS-24CLAMPHS-24CLAMPHS-36CLAMPNOTE:Arrowspointtothepositionofthehexheadoftheclamps.
HS-24CLAMPHS-24CLAMPHS-24CLAMP27-61CLAMP23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/205InstructionManual>6255Page5of523.
Placeleftrearheatshieldinpositiononthecrossoverassemblyontheleftsideofthemotorcycle.
(Hint:Spreadthehoseclampsapartslightlytomakeiteasiertoslidethemovertheheadpipes.
)AligntheheatshieldwiththecrossoverassemblyandsnugtheclampsbutDONOTTIGHTENatthistime.
SeeFIGURE8.
24.
Adjustthemufflersforeandafttoalignthefrontofthemufflerswiththerearoftheheatshields.
Makesurethereisasmallgapbetweenthefrontofthemufflersandtheheatshields.
Rotatethemufflerssotheyarelevelwiththegroundandthentightenthemufflermountingboltsandtheclamps.
(NOTE:Theclampsshouldbeflushwiththeendofthemufflerinletwhentightened.
Iftheclampsareslidpasttheslotsonthemufflerinlettheclampswillnottightenproperly).
SeeFIGURE9.
25.
Makesuretheheatshieldsarealignedproperlywiththecollectorheatshieldandthatthesmallgapismaintainedfromthepreviousstepandthentightenallhoseclampssecuringtheheatshields.
26.
Insertthesuppliedfloorboardspacerplatebetweentherearfloorboardmountandtheframe,thenalignthedowelpinandreinstalltheallenbolt.
Tightentofactoryspecifications.
SeeFIGURE10.
27.
Removetheallenboltfromtherightfrontfloorboardmount.
Placethesuppliedthickwasherbetweenthefrontfloorboardmountandtheframe.
Reinstallandtightentheallenbolttofactoryspecifications.
SeeFIGURE10.
28.
Reinstallanyotherpreviouslyremoveditems.
Tightentofactoryspecifications.
29.
Makesureallthehardware(brackets,headpipes,heatshields,mufflersandfloorboards)havebeentightenedappropriately.
30.
IMPORTANT:Beforestartingyourengineremoveallfingerprintsfromchromewithaqualitywaxorchromepolish.
Failuretodosocancausechromediscoloration.
Duetofluctuationsinfueldeliverysettings,timing,etc.
,CobraEngineeringdoesnotwarrantagainstchromediscoloration.
DOCUMENTNO.
0018REV.
ADISCLAIMER:NOTLEGALFORSALEORUSEINCALIFORNIAONANYPOLLUTIONCONTROLLEDMOTORVEHICLE.
THESALE,USE,ORINSTALLATIONOFTHISPRODUCTMAYALSOBEILLEGALNATIONWIDEUNDERTHEFEDERALCLEANAIRACT(42U.
S.
C.
§7522(A)(3)).
FIGURE9CLAMPSHOULDBEFLUSHWITHEDGEOFMUFFLERDONOTSLIDECLAMPSFORWARDPASTSLOTSCLAMPSPACERFIGURE10INSTALLSPACERPLATEONREARMOUNTINSTALLTHICK3/8"FLATWASHERONFRONTMOUNTFIGURE8HS-24CLAMPNOTE:Arrowspointtothepositionofthehexheadoftheclamps.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/201PRIORTOINSTALLATION,MAKESUREYOURSTOCKHEADPIPEGASKETSAREINGOODCONDITION.
IFYOUHAVEANYDOUBTSASTOTHEIRCONDITION,REPLACETHEM.
Readallinstructionscarefullyandcompletelybeforeinstallingyournewexhaustsystem!
1.
Removethesaddlebags,rightsidecover,andrightfrontfloorboardfromtheframe.
2.
UnplugtheO2sensorsonthefrontandrearheadpipesfromthemotorcyclewireharness.
3.
Removethestockexhaustsystembeingcarefulnottodamagetheheadpipegaskets.
Iftheheadpipegasketsareingoodconditiontheydonotneedtoberemovedfromthecylinders.
Removeandsavetheflanges,nuts,retainingrings,mufflerclamps,mufflermountbolts,crossoverbracketbolts,andO2sensorsfromthestockexhaust.
LabeltheO2sensorsfrontandreartoensuretheywillbeinstalledontheproperheadpipe.
4.
Removethestockexhaustmountbracket.
5.
Installthesuppliedheadpipesupportbracketusingthestocknut.
SeeFIGURE1.
LightlysnugthenutbutDONOTTIGHTENsothebracketcanbeadjusted.
Thebracketshouldbepositionedataslightangle.
SeeFIGURE1.
ItemsSupplied>1–FRONTHEADPIPEANDHEATSHIELD1–REARHEADPIPECOLLECTORASSEMBLYANDHEATSHIELD1–LEFTREARCROSSOVERPIPEANDHEATSHIELD1–BRACKET,FRONTHEADPIPESUPPORT1–BRACKET,CROSSOVERPIPESUPPORT1–FLOORBOARDMOUNTSPACERPLATE1–CLAMP,FRONTHEADPIPESUPPORT8–CLAMP,HOSEHS-241–CLAMP,HOSEHS-361–THICK3/8"WASHER2-1/4ALLENBOLTS1–THIN3/8"WASHER2-1/4FLATWASHERS1–3/8"X1"CARRIAGEBOLT2–CLAMP,27-61MSC1–3/8"NYLOCKNUTApplication(s)>HARLEY:DRESSER17-20InstructionManual>6255Page1of5DOCUMENTNO.
0017REV.
AContinuedonPage2STOCKNUTFIGURE1COBRAHEADPIPESUPPORTBRACKETDISCLAIMER:NOTLEGALFORSALEORUSEINCALIFORNIAONANYPOLLUTIONCONTROLLEDMOTORVEHICLE.
THESALE,USE,ORINSTALLATIONOFTHISPRODUCTMAYALSOBEILLEGALNATIONWIDEUNDERTHEFEDERALCLEANAIRACT(42U.
S.
C.
§7522(A)(3)).
ATTENTION!
:THESEHEADPIPESWILLNOTWORKINCOMBINATIONWITHSTOCKHARLEYDAVIDSONMUFFLERSDUETORIGHTMUFFLERSLIPDESIGN.
23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/202InstructionManual>6255Page2of56.
Installthestockflanges,retainingringsandO2sensorsontothesuppliedfrontandrearheadpipes.
BesuretoinstallthefrontO2sensoronthefrontheadpipeandtherearO2sensorontherearheadpipe.
7.
Installthefrontheadpipe(withstockgasketinplace)ontothefrontcylinderusingthestocknuts.
SnugthenutsbutDONOTTIGHTENatthistime.
8.
Slidethesuppliedpinchclampoverthefrontheadpipemakingsurethesquareholeontheclampisfacingupandtowardstheinside.
Positiontheclampoverthesupportbracketsothatthepinchclampcapturesbothsidesofthebracket.
SeeFIGURE2.
Insertthesupplied3/8"carriageboltthroughthetopofthepinchclampandsupportbracket.
Installthe3/8"thinflatwasherandnutontothebottomofthecarriageboltbutDONOTTIGHTENatthistime.
Leavethenutloosesotheheadpipecanbeadjusted.
9.
Position(2)ofthesupplied#27-61MSCmufflerclampsontotherearheadpipecollectorassemblyinletandoutlet.
Thehexheadofbothclampsshouldbeinwardanddown.
SeeFIGURE3.
(NOTE:Theclampsshouldbeflushwiththeendoftheinletandoutletwhentightened.
SeeFIGURE3.
Iftheclampsareslidpasttheslotsontheinletandoutlettheclampswillnottightenproperly).
10.
Installtherearheadpipecollectorassembly(withstockgasketinplace)ontotherearcylinderandontothefrontheadpipe.
Makesurethefrontheadpipeispushedinasfaraspossibleintotherearheadpipecollectorassemblyinlet.
Usethestocknutstofastentheheadpipetothecylinder.
SnugthenutsbutDONOTTIGHTENatthistime.
SeeFIGURE4.
11.
Installtheleftrearcrossoverpipeontotherearheadpipecollectorassemblymakingsureitslidesintotheoutletoftherearheadpipecollectorassemblyoutletasfaraspossible.
SeeFIGURE4.
DOCUMENTNO.
0018REV.
AContinuedonPage3FIGURE2FRONTHEADPIPESUPPORTBRACKETCARRIAGEBOLTPINCHCLAMP3/8"THINFLATWASHERANDNUTPOSITION27-61MSCCLAMPWITHHEXHEADFACINGINANDDOWNCLAMPSSHOULDBEFLUSHWITHEDGEOFCOLLECTORDONOTSLIDECLAMPSPASTSLOTSFIGURE3CLAMPSSHOULDBEFLUSHWITHEDGEOFCOLLECTOR(INWARDSIDEOFCOLLECTOR)23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/203InstructionManual>6255Page3of512.
Installthesuppliedcrossoversupportbrackettothestockmountinglocationusingthe(2)stockallenbolts.
LightlysnugtheboltsbutDONOTTIGHTENatthistime.
Adjustthecrossoverpipeforeandaftsothemountonthecrossoverassemblyrestsflushagainstthesupportbracket.
Thenpushuplightlyontheleftsideofthecrossoverassemblytoalignthebracketandinsertthe(2)suppliedallenboltswithflatwashers.
LightlysnugtheallenboltsbutDONOTTIGHTENatthistime.
SeeFIGURE5.
IMPORTANT:DONOTforcethecrossoverpipeforwardorbackwardorupanddowntogetitintoposition.
Ifalotofforceisneededtoalignthecrossoverpipeandsupportbracketthenadjusttherearheadpipecollectorassemblyuntilitwillalignwithonlyenoughforcetocounteracttheweightoftheleftsideofthecrossoverassembly.
Also,Makesurethecrossoverpipehasclearanceallaroundanddoesnotmakecontactwiththetransmissionpan.
Adjustasneededwhileboltsareloose.
13.
Installtheleftandrightmufflersontotheheadpipeassemblyandreinsertthe(2)stock5/16-inchboltsintoeachrearmufflermount.
Donottightenclampsorbolts.
14.
Makesurethefrontheadpipe,rearheadpipecollectorassembly,leftrearcrossoverpipe,andmufflersarealignedproperlyandtightenthe(4)allenboltsonthecrossoversupportbracket.
SeeFIGURE5.
15.
Thenfullytightentheflangenutsontheexhaustportstuds,followedbythenutforthe3/8"carriageboltonthefrontheadpipesupportclampandthenutonthefrontheadpipesupportbracket.
SeeFIGURE2.
16.
Nextfullytightenthe(2)27-61MSCclampsontherearheadpipecollectorassembly.
(NOTE:Theclampsshouldbeflushwiththeendofthecrossoverassemblyinletswhentightened.
SeeFIGURE3.
Iftheclampsareslidpasttheslotsonthecrossoverassemblyinlettheclampswillnottightenproperly).
DOCUMENTNO.
0018REV.
AContinuedonPage4FIGURE5STOCKBOLTSCROSSOVERPIPECOBRACROSSOVERSUPPORTBRACKETSUPPLIEDALLENBOLTSANDWASHERSNOTE:Arrowspointtothepositionofthehexheadoftheclamps.
FIGURE427-61MSCCLAMPFRONTHEADPIPESUPPORTREARCROSSOVERPIPE23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/204InstructionManual>6255Page4of517.
PlugtheO2sensorsbackintothemotorcyclewireharnessandroutethewiresawayfromtheexhaustinthesamemannerasstock.
18.
Removetheheatshieldsandhoseclampsfrompackaging.
Unscrewthehoseclampsandfeedthetailendoftheclampsthroughtheclipsontheinsideoftheheatshieldsothescrewsareaccessiblewithascrewdriveroncetheheatshieldisinstalled.
ThelargeHS-36hoseclampgoesontherearclipontherearheatshield.
SeeFIGURE6&8forproperpositioningoftheclampsontheheatshields.
(NOTE:Thearrowspointtothepositioningofthehexheadoftheclamps.
Thehexheadoftheclampsshouldbeaccessiblefortighteningbutnotvisiblewhentheheatshieldsaremountedtothepipes.
)19.
Installtherightrearheatshieldovertherearheadpipe.
(Hint:Spreadthehoseclampsapartslightlytomakeiteasiertoslidethemovertheheadpipes.
)Aligntheheatshieldwiththeheadpipeandthecollectorheatshield.
Thereshouldbeanevengaparoundthecollectorheatshield.
SnugtheclampsbutDONOTTIGHTENatthistime.
SeeFIGURE6&7.
20.
Installtherightfrontheatshieldovertherightfrontheadpipe.
(Hint:Spreadthehoseclampsapartslightlytomakeiteasiertoslidethemovertheheadpipes.
)Aligntheheatshieldwiththeheadpipeandthecollectorheatshield.
Thereshouldbeanevengaparoundthecollectorheatshield.
Iftheheatshielddoesnotalignwellwiththecollectorheatshieldthentherearcrossoverpipemayneedtobeloosenedandpushedforwardorbackward.
WhentheheatshieldisalignedproperlysnugtheclampsbutDONOTTIGHTENatthistime.
SeeFIGURE6&7.
21.
Iftheheatshieldswillnotalignproperlywiththecollectorheatshieldthenthecollectorheatshieldmayneedtobeloosenedandmovedforwardorbackward.
Loosenthetwobuttonheadboltstoadjustthecollectorheatshieldforwardorbackward.
SeeFIGURE7.
DOCUMENTNO.
0018REV.
AInstructionManual>ContinuedonPage5FIGURE710-24BUTTONHEADBOLT10-24BUTTONHEADBOLTCOLLECTORHEATSHIELDFIGURE6HS-24CLAMPHS-24CLAMPHS-36CLAMPNOTE:Arrowspointtothepositionofthehexheadoftheclamps.
HS-24CLAMPHS-24CLAMPHS-24CLAMP27-61CLAMP23801E.
LaPalmaAve.
,YorbaLinda,CA92887Ph.
714.
692.
8180Fax.
714.
692.
5016www.
cobrausa-vtwin.
com01/205InstructionManual>6255Page5of523.
Placeleftrearheatshieldinpositiononthecrossoverassemblyontheleftsideofthemotorcycle.
(Hint:Spreadthehoseclampsapartslightlytomakeiteasiertoslidethemovertheheadpipes.
)AligntheheatshieldwiththecrossoverassemblyandsnugtheclampsbutDONOTTIGHTENatthistime.
SeeFIGURE8.
24.
Adjustthemufflersforeandafttoalignthefrontofthemufflerswiththerearoftheheatshields.
Makesurethereisasmallgapbetweenthefrontofthemufflersandtheheatshields.
Rotatethemufflerssotheyarelevelwiththegroundandthentightenthemufflermountingboltsandtheclamps.
(NOTE:Theclampsshouldbeflushwiththeendofthemufflerinletwhentightened.
Iftheclampsareslidpasttheslotsonthemufflerinlettheclampswillnottightenproperly).
SeeFIGURE9.
25.
Makesuretheheatshieldsarealignedproperlywiththecollectorheatshieldandthatthesmallgapismaintainedfromthepreviousstepandthentightenallhoseclampssecuringtheheatshields.
26.
Insertthesuppliedfloorboardspacerplatebetweentherearfloorboardmountandtheframe,thenalignthedowelpinandreinstalltheallenbolt.
Tightentofactoryspecifications.
SeeFIGURE10.
27.
Removetheallenboltfromtherightfrontfloorboardmount.
Placethesuppliedthickwasherbetweenthefrontfloorboardmountandtheframe.
Reinstallandtightentheallenbolttofactoryspecifications.
SeeFIGURE10.
28.
Reinstallanyotherpreviouslyremoveditems.
Tightentofactoryspecifications.
29.
Makesureallthehardware(brackets,headpipes,heatshields,mufflersandfloorboards)havebeentightenedappropriately.
30.
IMPORTANT:Beforestartingyourengineremoveallfingerprintsfromchromewithaqualitywaxorchromepolish.
Failuretodosocancausechromediscoloration.
Duetofluctuationsinfueldeliverysettings,timing,etc.
,CobraEngineeringdoesnotwarrantagainstchromediscoloration.
DOCUMENTNO.
0018REV.
ADISCLAIMER:NOTLEGALFORSALEORUSEINCALIFORNIAONANYPOLLUTIONCONTROLLEDMOTORVEHICLE.
THESALE,USE,ORINSTALLATIONOFTHISPRODUCTMAYALSOBEILLEGALNATIONWIDEUNDERTHEFEDERALCLEANAIRACT(42U.
S.
C.
§7522(A)(3)).
FIGURE9CLAMPSHOULDBEFLUSHWITHEDGEOFMUFFLERDONOTSLIDECLAMPSFORWARDPASTSLOTSCLAMPSPACERFIGURE10INSTALLSPACERPLATEONREARMOUNTINSTALLTHICK3/8"FLATWASHERONFRONTMOUNTFIGURE8HS-24CLAMPNOTE:Arrowspointtothepositionofthehexheadoftheclamps.
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