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TM

23801 E. La Palma Ave., Yorba Linda, Ca 92887 Ph. 714.692.8180 Fax. 714.692.5016

www.cobrausa.com

Items Supplied >

2 – FRONT & REAR HEADPIPE AND HEATSHIELDS

1 – BRACKET, PWDR-CTD REAR HEADPIPE SUPPORT

6 – CLAMP, HOSE HS-24

1 – CLAMP, 27-59 MSC WITH M6 X 45 mm BOLT

2 – SPACER, .875” O.D. X .187” I.D. X .550” LONG

BLACK POWDERCOATED

Application(s) >

HARLEY:

FLHR (S)

FLHRC

FLHX

FLTR

FLHT

FLHTC

FLHTCU

2007 & UP

2007 & UP

2007 & UP

2007 & UP

2007 & UP

2007 & UP

2007 & UP

Instruction Manual >

6251 Page 1 of 3

WE RECOMMEND THE USE OF THE APPROPRIATE FI2000 DIGITAL FUEL-INJECTION TUNER. PRIOR TO

INSTALLATION, MAKE SURE THE STOCK HEADPIPE GASKETS ARE IN GOOD CONDITION, IF THERE IS ANY

DOUBTS ABOUT THEIR CONDITION REPLACE THEM.

Read all instructions carefully and completely before installing your new exhaust system.

1. Remove both left and right saddlebags and set them aside.

2. Remove the right side floorboard from the frame and set aside.

3. Unplug the O

2 sensors on front and rear headpipes from motorcycle wire harnesses.

4. Remove the stock exhaust system. It may be necessary to lubricate the slip joints of the exhaust with

WD-40 or similar lubricant to aid in disassembly. The stock muffler slide hangers may be left in place in the rubber mounts for later reinstallation of the mufflers.

5. Remove the stock rear headpipe support-mounting bracket by removing the two starter mounting bolts, this bracket will not be reused. Note: Use caution when removing the bolts so that any tools used do not come in contact with the positive post on the starter. Install the Cobra supplied, exhaust support-mounting bracket, see Figure 1.

6. Remove the stock exhaust flanges, retaining rings and O

2

sensors from the stock headpipes and headpipe support clamp from the front headpipe. Remove the new front headpipe from packaging and install the stock flange, retaining rings and O

2

sensor on to the pipe.

7. On the front headpipe slide the stock headpipe support clamp over it. Install the front headpipe on the motorcycle using the stock flange nuts to secure it to the exhaust port studs, but do not tighten at this time. Slide the headpipe support clamp forward on the headpipe and over the stock exhaust mount on the right side engine case, make sure the clamp’s rectangular hole is on top and the flat part of the clamp is downward, see Figure 2. Install the carriage bolt and nut to secure the tube clamp but

do not tighten at this time.

8. Reinstall the muffler onto the front headpipe using one muffler slip clamp. Reinsert two stock 5/16inch bolts into rear muffler mount, tighten to factory torque specs, do not tighten front muffler slip clamp at this time. (NOTE: On some models equipped with saddlebags the bag rail may need to be adjusted outward to allow proper clearance between muffler body and swing arm / axle nut.)

9. Tighten front headpipe flange nuts then headpipe support clamp to factory torque specifications.

10. Remove front heatshield and hose clamps from packaging. Unscrew the hose clamps and feed the tail end of the clamps through the clips on the inside of the heatshield from the bottom, so the screws are facing toward the bottom and accessible with a screw driver once the heatshield is installed.

Install the heatshield over the front headpipe. (Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly and headpipes.) Align heatshield with headpipe and snug clamps but do not tighten.

*

Cobra recommends you always wear a helmet while riding. Please never operate your motorcycle while under

the influence of alcohol and/or drugs. Enjoy the new look of your motorcycle and please ride safely.

DOCUMENT NO. 0017

10/07

REV. B

TM

TM




6251 Page 2 of 3

11. Now slide muffler forward or rearward to align rear of heatshield to front of muffler, there should be minimal gap, once aligned tighten front muffler slip clamp to headpipe. (NOTE: If the muffler clamp is slid to far up the muffler or past the slots, the clamp will not tighten properly.) Reconnect the O

2 sensor back into the wire harness. Tighten front heatshield hose clamps.

12. Remove left side passenger floorboard and mount to ease installation of rear headpipe.

13. If your motorcycle is equipped with a charcoal canister locate the rubber hose under the left side of the seat near the rear cylinder head. For better access remove left side cover. Disconnect the hard plastic hose from the rubber hose. Remove the plastic clip below the large hole in the frame and reroute the plastic hose behind the frame and back out through the large hole. Reconnect the plastic hose with the rubber hose, be sure the plastic hose does not chaff on the frame, see Figure 3.

14. Remove rear headpipe and heatshield assembly from packaging. Install the stock flange, retaining ring and O

2

sensor onto the headpipe.

15. Now from left side of motorcycle install front of rear headpipe between rear cylinder and frame. Ease pipe onto exhaust flange studs and rotate rear of headpipe downward towards rear of motorcycle to where it will be mounted with the muffler.

16. From right side of motorcycle make sure headpipe is properly seated into rear cylinder exhaust outlet.

Install the stock flange nuts removed earlier, snug but do not tighten.

17. Install left side muffler onto rear headpipe and install two stock 5/16-inch bolts onto rear muffler slide mount and tighten.

18. Locate the T-bolt clamp on underside of rear headpipe near rear headpipe support bracket which was previously installed, see Figure 4. Now slide this T-bolt clamp towards the outside of the engine. With the T-bolt clamp in this position locate the stock L-shaped support bracket with 5/16 inch stud. Slide tang of L-bracket into T-bolt clamp so that the tang locates between the headpipe and inside of clamp, see Figure 4. Now slide the bracket and T-bolt clamp together towards the headpipe support bracket and insert 5/16 Stud into slotted hole. Start 5/16 inch nut from rightside of motorcycle, do not tighten nut at this time.

19. Now from the left side of the motorcycle, sight the left exhaust muffler to the rightside muffler and align the left so it is parallel with the right side. Once the left muffler is parallel with the right align the front of the muffler with the rear heatshield and tighten slip clamp at the front of the muffler. (Note: the front of the muffler may need to be raised and held in position by another person, while the slip

clamp is being tightened.)

20. Tighten the flange bolts on the rear headpipe to factory specifications. Next tighten the 5/16 inch nut on the rear headpipe support mount. Tighten the T-bolt clamp also at this time until it firmly seats on the tang of L-bracket and headpipe see Figure 4. Be sure the gap between the rear heatshield and front of the muffler is minimal and tighten the remaining hose clamps securing the heatshield.

21. Reconnect the O

2

sensor back into the wire harness.

22. Reinstall left side passenger floorboard and mount. Reinstall the right side rider floorboard and mount by inserting the two supplied black spacers between the floorboard mount and frame then tighten the bolts to factory specifications. Reinstall the saddlebags and any other previously removed items. Tighten to factory specifications.

23. Make sure all the hardware (brackets, headpipes, heatshields, mufflers and baffles), has been tightened appropriately and cleaned before starting your motorcycle.

PLEASE REFERENCE FIGURES ON PAGE 3 IN ACCORDANCE WITH TEXT IN INSTRUCTIONS!

IMPORTANT: If your motorcycle is equipped with fuel injection it is recommended that you install a Cobra Fi2000

Digital Fuel Processor with your Cobra exhaust system, (Cobra Part# : 692-1608CL for 2007 Dresser.)

Before starting your engine remove all fingerprints from chrome with a quality wax or chrome polish. Failure

to do so can cause discoloration.


10/07

REV. B

TM


NOTE: USE

CAUTION

WHEN

REMOVING

AND

INSTALLING

STARTER

BOLTS, AVOID

CONTACT

BETWEEN

TOOLS AND

POSITIVE

STARTER

POST

FRONT

HEADPIPE

OMITTED FOR

CLARITY OF

BRACKET

INSTALLATION

TM



6251 Page 3 of 3

REAR

HEADPIPE

SUPPORT

BRACKET

BOLTED IN

PLACE

USING

STOCK

HARDWARE

FIGURE 1.

HEADPIPE

SUPPORT

CLAMP

INSTALLED

AROUND

TRUE-DUAL

FRONT

HEADPIPE

AND

SECURED TO

STOCK CASE

MOUNT

CHARCOAL

CANISTER

PLASTIC HOSE

REROUTED

THROUGH

LARGE HOLE IN

FRAME

BULKHEAD

FOR BETTER

CLEARANCE

TO EXHAUST

HEATSHIELD

FIGURE 2.

TANG OF L-BRACKET

BETWEEN HEADPIPE AND

T-BOLT CLAMP

FIGURE 3.


10/07

REV. B

FIGURE 4.

TM

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