®
23801 E. La Palma Ave., Yorba Linda, Ca 92887 Ph. 714.692.8180 Fax. 714.692.5016
www.cobrausa.com
04/10
®
1
*
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.
Items Supplied >
1
– FRONT EXHAUST / HEATSHIELD
1
– REAR EXHAUST / HEATSHIELD
1
– EXHAUST MOUNTING BRACKET
1
– EXHAUST VALVE ACTUATOR BRACKET
1
– EXHAUST VALVE ACTUATOR SOLENOID CAM
4
– CLAMP, HS 24; 2 – CLAMP, HS 28
2
– SPACER, ALUMINUM; 2 – WASHER, ¼” FLAT
2
– BOLT, 6 mm x 50 mm; 2 – NUT, NYLOCK 6 mm
4
– BOLT, FLANGE 5/16” X 5/8”; 2 – BOLT ¼” 20 X 3/8”
Application(s) >
SUZUKI M109 1800 cc
2006 & 2009
Instruction Manual >
ATTENTION: READ ALL INSTRUCTIONS CAREFULLY AND COMPLETELY BEFORE
INSTALLING YOUR NEW EXHAUST SYSTEM, AVOIDING TO DO SO MAY RESULT IN
DAMAGE TO YOUR MOTORCYCLES COMPONENTS. PRIOR TO INSTALLATION, MAKE
SURE YOUR STOCK HEADPIPE GASKETS ARE IN GOOD CONDITION. IF YOU HAVE ANY
DOUBTS AS TO THEIR CONDITION, REPLACE THEM.
1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To
remove the fairing, release the plastic peg on top by pushing the center inward and pulling
the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of
the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release
it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel
tank.
2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button
head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured
by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left
rear rubber grommet and flanged steel collar from this chrome piece, to do this press the
steel collar out of the rubber grommet first, once the collar is removed push the rubber
grommet out of the wire loop on the chrome piece, set collar and grommet aside for later
use.
3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong
electrical connector and white 2-prong electrical connector.
4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these
fasteners aside for later use in reassembly. Support the weight of the exhaust system and
remove the two 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and
exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system
as one complete unit; this includes the stock exhaust bracket, headpipes and muffler,
exhaust valve actuator solenoid and cables.
5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting
bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve
cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the
ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab.
Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket.
The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid
cables will not be used anymore with the your new Cobra Exhaust System.
3621
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DOCUMENT NO. 0017
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