23801 E. La Palma Ave., Yorba Linda, Ca 92887 Ph. 714.692.8180 Fax. 714.692.5016
www.cobrausa.com
07/09
1
*
Cobra recommends you always wear a hel met 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.
Items Supplied >
1 – FRONT EXHAUST HEADPIPE W/ HEATSHIELD
1 – REAR EXHAUST HEADPIPE W/ HEA TSHIELD
1 – EXHAUST BRACKET
1 – EXHAUST MUFFLER
4 – CLAMPS, HS-24
2 – CLAMPS, HS-28
2 – CLAMPS, 27-61 MSC
2 – BOLT, HEX 5/16-18 x 5/8”
2 – SCREW, BUTTON ¼-20 x 3/8”
2 – BILLET MUFFLER TIPS
Application(s) >
KAWASAKI VN900 06-09
Instruction Manual >
PRIOR TO INSTALLATION, MAKE SURE YOUR STOCK HEADPIPE GASKETS ARE IN GOOD
SHAPE. IF YOU HAVE ANY DOUBTS AS TO THEIR CONDITION, REPLACE THEM.
Read all instructions carefully and completely before installing your new exhaust system
1. Remove stock exhaust system and remove stock upper and lower exhaust mounts on the right side
frame rail, retain 2 flange bolts from stock upper bracket for later reinstallation. The two stock exhaust
brackets will not be used in combination with the Cobra Exhaust System.
2. Loosen and move the right side floorboard assembly out of the way to ease installation of the exhaust.
3. Remove the exhaust bracket from the box and mount it to the motorcycle frame using the stock bolts
retained in Step 1, but
DO NOT TIGHTEN
at this time, see Figure 1.
4. Install the front and rear head pipes onto the motorcycle using the supplied Cobra flanges and stock
acorn nuts. Make sure the pipes are parallel to each other.
DO NOT TIGHTEN
.
5. Remove the muffler assembly from the box and slide two supplied 27 - 61MSC clamps onto the muffler
tubes. The clamps should be orientated as shown in Figure 1. Slide the muffler onto the head pipes by
tapping it onto the head pipes with your hand as you push the mufflers forward making sure the muffler
slides as far forward as possible. Secure the muffler to the exhaust-mounting bracket using the
supplied 5/16-18 bolts but
DO NOT TIGHTEN.
6. Make sure the muffler assembly is parallel to the ground (this is critical) then tighten the following in
order: exhaust bracket to the frame, muffler assembly to the exhaust bracket, head pipe flanges to the
motor (slowly tighten opposing acorn nut) and muffler clamps. (NOTE: If the muffler clamps are slid to
far up the muffler or past the three slots, the clamps will not tighten.)
7. On the front and rear heatshields unscrew the remaining hose clamps and feed the tail end of the
clamp through the clips on the inside. The screw end of the hose clamps should be accessible for
tightening but not visible when the heatshields are mounted to the pipes.
8. To install the front heatshield, first slide the rear portion of the heatshield over the muffler, continue to
slowly slide it forward pushing the front of the shield gently into place between the frame and motor
(Hint: Spread the hose clamps apart slightly to make it easier to slide them over the muffler assembly
and head pipes). Snug the heatshield clamps but
DO NOT TIGHTEN
.
9. Install the rear heatshield the same way as the front heatshield.
CONTINUE TO NEXT PAGE!
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DOCUMENT NO. 0017
REV. B
