Cobra 6468B User manual

® 23801 E. La Palma Ave., Yorba Linda, Ca 92887 Ph. 714.692.8180, Fax. [phone]
www.cobrausa.com
04/17 ®
1
DISCLAIMER: NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON ANY POLLUTION
CONTROLLED MOTOR VEHICLES.
Items Supplied >
1 - FRONT HEADPIPEW/ HEATSHIELD
1 - REAR HEADPIPE W/ HEATSHIELD
1 - MUFFLER ASSEMBLY
1 - BIKINI HEATSHIELD
1 - BRACKET, EXHAUST MOUNT
4 - CLAMP, HS-24 (SMALL)
1 - CLAMP, HS-28 (LARGE)
2 - CLAMP, 27-61MSC
2 - BOLT, 5/16” X 1/2” FLANGE W/ LOCK PATCH
1 - SPACER, .750”O.D. X .343”I.D. X .550”L BLACK
2 - SPACER, ALUMINUM .550”O.D. X .344”I.D. X .170”L
Application(s) >
HARLEY:
DYNA 12-17
SWITCHBACK 12-16
Instruction Manual >
PRIOR TO INSTALLATION, MAKE SURE YOUR STOCK HEAD PIPE GASKETS ARE IN GOOD CONDITION.
IF YOU HAVE ANY DOUBTS AS TO THEIR CONDITION, REPLACE THEM.
Read all instructions carefully and completely before installing your new exhaust system!
1. Apply masking tape to any surrounding parts to protect them from getting scratched.
2. For Switchback models, the right side floorboard will need to be removed from the mounts. Also remove
the forward mount bolt and loosen the rearward mount bolt so the mount will swing out of the way for
clearance.
3. Unplug O2 sensors on front and rear headpipes from motorcycle wire harnesses.
4. Remove the stock exhaust system being careful not to damage the headpipe gaskets. If the headpipe
gaskets are in good condition they do not need to be removed from the cylinders. Remove and save the
flanges, nuts, retaining rings and O2 sensors from the stock exhaust.
5. Remove the stock exhaust mount bracket.
6. Install the supplied exhaust mount bracket using the stock bolts. See FIGURE 1. Tighten the bolts to
factory specifications. If applicable, be sure to insert the large spacer between the exhaust mount and the
transmission case as shown in FIGURE 1. For Switchback models, also insert 2 of the supplied small
aluminum spacers into the large holes in the exhaust mount bracket as shown in FIGURE 2.
6468B
Page 1 of 3
DOCUMENT NO. 0017 REV. A
Continued on Page 2
STOCK BOLTS AND
WASHERS
TRANSMISSION
CASE
SUPPLIED LARGE
SPACER
EXHAUST MOUNT
BRACKET
FIGURE 2
SWITCHBACK
2X SUPPLIED SMALL
ALUMINUM SPACERS
INSERTED IN BRACKET HOLES
EXHAUST MOUNT
BRACKET
FIGURE 1
DYNA
STOCK HARDWARE
TRANSMISSION
CASE
SUPPLIED LARGE
SPACER

® 23801 E. La Palma Ave., Yorba Linda, Ca 92887 Ph. 714.692.8180, Fax. [phone]
www.cobrausa.com
04/17 ®
2
Instruction Manual >
6468B
Page 2 of 3
7. Install the stock flanges, retaining rings and O2 sensors onto the supplied front and rear headpipes.
8. Install the front headpipe (with stock gasket in place) onto the front cylinder using the stock nuts but DO
NOT TIGHTEN at this time.
9. Position the supplied #27-61 MSC muffler clamps with hex head facing the direction shown in FIGURE 3
over the inlets of the muffler.
10. Insert the rear headpipe into the top inlet tube of the muffler. Make sure to slide it in as far as possible.
11. Install the rear headpipe and muffler assembly (with stock gasket in place) onto the rear cylinder and slide
the lower muffler inlet on to the front headpipe. Rotate the rear headpipe as needed to align it with the
cylinder outlet. Use the stock nuts to fasten the rear headpipe to the cylinder but DO NOT TIGHTEN at this
time. Make sure the front and rear headpipes are pushed in as far as possible into the inlets of the muffler.
12. Secure the muffler assembly to the exhaust mount bracket using the (2) supplied 5/16"-18 bolts but DO
NOT TIGHTEN.
13. Make sure the muffler assembly, front headpipe, and rear headpipe are straight and parallel and tighten in
the following order; headpipe flanges to the cylinders (slowly tightening opposing nuts), muffler assembly to
the exhaust mount and finally the muffler clamps. (NOTE: The muffler clamps should be flush with the end
of the muffler inlets when tightened. See FIGURE 3. If the muffler clamps are slid past the slots on the
muffler inlets the clamps will not tighten properly).
14. Plug the O2sensors back into motorcycle wire harnesses.
15. Unscrew the small HS-24 clamps and feed the tail end of the clamp through the clips on the inside of the
heatshields. See FIGURE 4 for proper positioning of the clamps on the heatshields. (NOTE: The arrows
point to the positioning of the hex head of the clamps. The hex head of the clamps should be accessible for
tightening but not visible when the heatshields are mounted to the pipes.)
16. Unscrew the larger HS-28 clamp and insert the tail end through the clip on the inside of the bikini
heatshield. See FIGURE 4 for proper positioning of the clamps on the heatshields. (NOTE: The arrows
point to the positioning of the hex head of the clamps.)
17. Install the front heatshield first. (NOTE: Spread the hose clamps apart slightly to make it easier to slide
them over the muffler assembly and headpipes.) Adjust the heatshield as far back as possible on the
headpipe so that it will align properly with the bikini heatshield. Make sure the clamp on the muffler inlet
does not interfere with the heatshield and is aligned as shown in FIGURE 3. Snug the heatshield clamps
but do not tighten.
18. Install the rear heatshield the same way as the front heat shield. See FIGURE 4.
DOCUMENT NO. 0018 REV. A
Continued on Page 3
FIGURE 3
DO NOT SLIDE CLAMPS
PAST SLOTS
POSITION 27-61MSC
CLAMP WITH HEX
HEAD FACING UP
CLAMPS SHOULD BE
FLUSH WITH EDGE OF
COLLECTOR
POSITION 27-61MSC
CLAMP WITH HEX
HEAD FACING DOWN
DO NOT SLIDE CLAMPS
PAST SLOTS

® 23801 E. La Palma Ave., Yorba Linda, Ca 92887 Ph. 714.692.8180, Fax. [phone]
www.cobrausa.com
04/17 ®
3
Instruction Manual >
6468B
Page 3 of 3
19. Install the bikini heatshield over the collector area. Adjust the front and rear heatshields fore and aft on the
headpipes so that they go underneath the bikini heatshield. NOTE: If the headpipes are not inserted far
enough into the muffler inlets the heatshields will not be able to go underneath the bikini heatshield.
20. When the heatshields are aligned properly, tighten the clamps on the front and rear heatshields first. Then
tighten the bikini heatshield clamp last.
21. For Switchback models, install the right floorboard mount and floorboard. Tighten all fasteners to
manufacture’s specification.
22. Make sure all the hardware (brackets, head pipes, heatshields, and floorboards) has been tightened
appropriately.
23. IMPORTANT: Before starting your engine remove all fingerprints from all exhaust surfaces. To
clean your black exhaust system use a liquid based soap detergent, such as dishwashing soap
applied with a soft cloth and rinse with clean water. Note: Avoid abrasive cleaning methods such as
granular or dry cleansers, simple green, scotch-brite or steel wool pads. Abrasives may breach the
coating and shorten life.
IMPORTANT: It is recommended that a Cobra Fi2000®Closed Loop Digital Fuel Processor (Cobra Part
#692-1616AT, 692-1616CL, or 692-1616CL-50 for California models) be installed with the Cobra exhaust
system.
DISCLAIMER: NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON ANY POLLUTION
CONTROLLED MOTOR VEHICLES.
DOCUMENT NO. 0018 REV. A
ORIENT 27-61MSC
CLAMP WITH HEX
HS-24
CLAMP
HS-24
CLAMP
FIGURE 3
HS-28
CLAMP
NOTE: Arrows point to
the position of the hex
head of the clamps.
HS-24
CLAMP
HS-24
CLAMP