How To: Cobra Swept Exhaust Install - Yamaha Star Stryker Motorcycle Forum
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Old 08-21-2012, 06:22 PM   #1 (permalink)
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Default How To: Cobra Swept Exhaust Install

1. Tools Required:[list type=decimal]
[li]8mm Allen Wrench[/li]
[li]6mm Allen Wrench[/li]
[li]12mm socket wrench[/li]
[li]punch tool/nail/any sharp object[/li]
[li]Adjustable crescent wrench[/li]
[li]Standard screwdriver or 8mm socket wrench[/li]
[li]torque wrench[/li][/list]
Materials required:
  • [li]Cobra Swept Exhaust System[/li]
    [li] (2) Felpro Exhaust gaskets PN# 23588 (I got mine from Autozone) [/li]

1. Loosen the right side pedal bracket. Using the 12mm socket wrench, loosen the two bolts enough to have enough room to remove and install the new pipes.

2. With the 6mm Allen wrench, loosen this bolt below:


3. With the 8mm Allen wrench, remove these three bolts and the entire Catalytic/Muffler assembly can be removed by sliding it rearward.
A.
B.

4. Using the 6mm Allen wrench, loosen this bolt below:


5. Using your pointed object, press in the pin below to remove the cover and unplug the O2 Sensor
A.


B.


6. Using the 12mm socket, remove the acorn nuts on the rear and forward exhaust flanges to both cylinders. Set aside acorn nuts for reuse.


7. Grab the rear header pipe and loosen it from the front header pipe and remove.


8. Grab the front header pipe and remove.

9. Install the Cobra Exhaust bracket like shown but only hand tighten the bolts.


10. Remove O2 sensor from OEM pipe and install into the front Cobra Pipe.
A.

B.


11. Remove the old exhaust gaskets (most likely still stuck in the cylinder exhaust openings), clean mounting area and place new Felpro gaskets in their place.


12. Set Cobra front header pipe into place and hand tighten the flange nuts from before.


13. Place hose clamp onto the rear Cobra pipe as shown. Then slip the rear muffler pipe onto the front header pipe while setting the rear flange in place and hand tighten acorn nuts.
A.


B.


14. Use Cobra O2 sensor extension to connect your O2 sensor to the bike. Replace cover.

15. First, tighten the exhaust bracket to the bike frame. Next tighten the exhaust flanges. Next tighten the two bolts that attach the mufflers to the exhaust bracket. Finally, tighten the 6mm allen bolt that connects the front and the rear pipes.


16. Place the hose clamps into the sleeves inside the heat shields like so. One large one will go into the rear most sleeve for each heat shield to accommodate the mufflers. Remember to place them in a way that when the heat shields are installed, you can tuck them away while still being able to access them.




17. Begin with the front heat shield. Slip the rear on first while spreading apart the hose clamps as you slip the entire piece on. Be careful not to mar any of the surfaces at this point. Use a standard screwdriver or 8mm socket wrench to tighten the hose clamps and secure the heat shield.

18. Repeat for the rear pipe. Slip the rear on while spreading the hose clamps as you slip the entire piece on.

19. If you try bolting up the right pedal now you might find that it rubs against the forward exhaust. I used a single metal washer for each bolt between the bracket and frame. This allowed me a ~1/8" clearance between the exhaust and the foot guard on the pedal.

20. Double check that all fasteners are tight.

21. Enjoy!






Please feel free to make any comments that streamline the process or correct anything mistakes that I've made. I am after all a garage monkey and not a professional bike wrencher.
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Old 08-21-2012, 07:47 PM   #2 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

That's a serious write up!

Glad you got them in good shape, took me an hour to box up!

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Old 08-21-2012, 08:33 PM   #3 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

Just an hour? Took me two to unwrap! LOL! Seriously though, thanks for everything!
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Old 08-21-2012, 09:39 PM   #4 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

Great job on the DIY!!
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Old 08-21-2012, 09:48 PM   #5 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

What a great write up. Thanks
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Old 08-22-2012, 12:07 AM   #6 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

Thanks guys. I was up for 26 hours straight when installed it and put this together. When I get the chance I'll find the torque specs
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Old 08-22-2012, 02:18 AM   #7 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

Nice writeup. I installed my Cobra Swepts today. I already had my stock exhaust off so it only took about 15 mins to install. When I removed my stock exhaust I kept it in 1 peice so it was off in less than 10 min. Took me almost 20 mins just to get the Cobra Swepts unwrapped.


While I was doing the install I added a resistor to the O2 sensor "white wire". The Cobra Swepts come with an O2 sensor extension cable so I installed the resistor in it instead of cutting the factory wiring.






Thanks again to 8sec-z for the resistor donation!
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Old 08-22-2012, 03:32 AM   #8 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

Quote:
Originally Posted by Mr
The Cobra Swepts come with an O2 sensor extension cable so I installed the resistor in it instead of cutting the factory wiring.
See now that's a great idea!
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Old 08-22-2012, 05:12 AM   #9 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

What was that resistor size again?

BadBoysRapeOurYoungGirlsButVioletGivesWillingly
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Old 08-22-2012, 05:23 AM   #10 (permalink)
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Default Re: How To: Cobra Swept Exhaust Install

Quote:
Originally Posted by stroguy
What was that resistor size again?

BadBoysRapeOurYoungGirlsButVioletGivesWillingly
That is how I was taught to remember when I was in college over 30 years ago. LOL

1/4 watt 820k ohm resistor
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