1. Tools Required:
[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]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.
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
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.
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.
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.
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.