How to Install Cobra Speedster Long Pipes This install was for my 2006 Honda VTX 1300S Cobra Part #1929 http://www.cobrausa.com/content/index.cfm?siteaction=Exhaust&bikeID=60 Honda Exhaust Gaskets (2 needed) Part #HO‐4533972 Tools Needed •
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Penetrating Oil 5/16”, ½”, 10mm, 12mm, and 17mm Socket 4mm Hex Flat screwdriver and/or right angle screw driver Torque wrench Chrome cleaner Rags for cleanup/protection Painters tape 1 Original Exhaust Removal (see page 2‐6 in the Service Manual) 1. Spray penetrating oil on the 4 acorn joint nuts and the 2 frame mounting bolts. Let this sit for 10‐15 minutes. 2. Loosen the 2 floor board bolts with the 17mm socket 3. Tape up some of the chrome surrounding the original pipes with painters tape. (see fig 1, 2, 3) 4. Loosen the 4 acorn nuts 12mm 5. Loosen the 2 frame bolts 12mm 6. Remove the exhaust; watch for the clearance near the right footrest. (see fig 3) 7. Spray penetrating oil (I had to do this 3 times) on the exhaust gaskets. (see fig 4) 8. Use a right angle flat screwdriver to remove the 2 metal exhaust gaskets if they remained on the engine. (see fig 4) 9. Remove the two bolts for the electrical regulator and let the unit dangle. (see fig 5) 10. Remove the two 17mm bolts for the original exhaust hanger mount. (see fig 6) Fig 1 2 Fig 2 Fig 3 3 Fig 4 Fig 5 4 Fig 6 5 New Cobra Exhaust Install (original Cobra instructions attached below) Here is where the Cobra instructions need some adjustments. 1. Mount the Cobra mounting bracket to the frame (black bracket). The bracket mounts to the inside of the bike frame (towards tire) with the supplied 17mm bolt/Nut. The bolt mounts through the far hole on the frame mount with the 90 degree right angle facing towards the tire. (see fig 7) 2. Do not tighten fully; just snug enough to hold the bracket level. 3. Mount the regulator to the supplied regulator bracket and then mount that to the frame mount tube. Use the supplied ½” bolt. (see fig 7) 4. The front foot rest should still be loose (this will be needed to clear the new pipes). 5. Install the new exhaust gaskets. 6. The machined front exhaust tube will only fit into the rear muffler tube in one direction at a certain angle. The Cobra instructions say to mount the front pipe first and then slide the rear over the front pipe. I found it much easier to slide the clamp on (bolt head facing ground) and hold both pieces of the exhaust fitting them together while off the bike (this is where a friend comes in very handy). (see fig 8, 9) 7. Once the pipes are fitted together, I then slid the exhaust onto the bike, finger tightening the acorn nuts over the flanges. 8. Use the two ½” bolts to mount the mufflers to the black frame mount. Tighten all 4 acorns some more to ensure proper alignment, but DO NOT torque down. Adjust the rear of the pipes for evenness at the rear. 9. Once you are sure the 4 acorns are seated properly and the 2 bolts securing the muffler are in, torque down the main clamp that secures the front pipe to the rear muffler assembly. 10. Now torque all the acorns to 17lb‐ft per the service manual. 11. Torque down the main frame exhaust mount and 2 bolts. Remember to torque down the regulator assembly as well. (see fig 10) 6 Fig 7 Fig 8 7 Fig 9 Fig 10 8 Heat Shield Install 1. NOTE: Several of the c‐clamps are larger than the others. These will go on the rear part of the exhaust pipes around the larger diameter. C‐clamps use 5/16” sockets. 2. Unscrew all the c‐clamps and slide them into the heat shield(s) – you will see the fitted areas. Here are the direction for bolt facing: a. Large Pipe – Top clamp near engine bolt faces upwards; the 2 other clamps face towards ground. b. Smaller Pipe – All clamps face upwards (see fig 11) 3. Slide the longer heat shield onto the pipe, making sure to slide the rear part of the pipe into the enclosed end. 4. Start with the top clamp near the engine. While using one hand or a friend, push the bolt and housing flat against the pipe. Now feed the opened end of the clamp into the bolt housing and use the 5/16” socket to tighten. Once the clamp starts to feed, tighten to snug. 5. Repeat this for the other 2 clamps. 6. Now slide the shorter heat shield over the smaller pipe, sliding the end of the pipe into the open end of the shield. 7. Repeat steps 4 & 5 8. Once both heat shields are fitted properly, torque down all 6 clamps. 9. Install the rear billets into both exhaust ends, tightening down the button screw(s) with the 4mm Hex. (see fig 12) 10. Tighten the floorboard mounts 11. Recheck all bolts for tightness. 12. Wipe down the pipes/shields for smudges and finger prints. 13. Take the bike out for a test ride to get the pipes up to operating temperature. The burning smell is normal (oil inside mufflers burning in). 14. Re‐torque acorns down to ensure 17lb‐ft torque and check all bolts again (I would repeat this step after a few days of riding). 9 Fig 11 Fig 12 10 Finished! 11 12 13