COBRA SPORT FG41 Best Exhaust Installation Guide

: June 16, 2024
: COBRA SPORT

Table of Contents

Instruction For Use
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COBRA SPORT FG41 Best Exhaust

Instruction For Use

Unpack your new Cobra Sport exhaust system from the box, and ensure you have the following tools to fit your performance exhaust upgrade:
- 5mm Allen Key
- 5mm Allen Key
- 17mm spanner
- 8mm socket
- Rachet
- T25 Torx
- T30 Torx
- Spring Hook Tool
Remove the plastic heat shield by removing the bolts using the T25 Torx from the outer heat shield and carefully remove from the motorcycle.
Undo the three bolts on the secondary heat shield using the T25 Torx and undo the jubilee clip with an 8mm socket and ratchet, then remove the heat shield.
Disconnect the lambda sensors from the standard exhaust system using a 17mm spanner.
Using an 8mm socket and ratchet, disconnect the clamps which connect the half system to the front sections, and use a T30 Torx to undo the bolt behind the exhaust, loosening the Half System.
Carefully remove the standard Half System from the motorcycle and store in a safe location.
Next, unbox your Cobra Sport performance exhaust ready to align the Cobra Sport system to the header pipes.
Fit the lambda sensor to the elbow section and secure tightly.

Re-fit the elbow section with the factory clamp and bolt loosely to allow some movement.

Prepare to fit the main exhaust section. Just before connecting the exhaust, fit the second lambda sensor and tighten with a 17mm spanner. It’s easier to fit this sensor before the part is attached due to the location of the lambda boss.
Some Sportsters will not be equipped with the second lambda sensor at the rear of the system from factory. For these models, fit the bolt supplied to blank the lambda sensor using a 5mm allen key.
Factory lambda sensor

Lambda sensor blank

Fit the main section of your all-new Cobra Sport system to the header pipe and new elbow section, slide the factory gasket on to the Cobra Sport system. Then, refit your factory clamp and bolt losely with the 8mm socket and rachet.

Secure the Cobra Sport exhaust to the motorcycle by refitting the bolt and tightening with the T30 Torx.
Should you want to fit the dB Killers suppled, place them inside the end of the exhaust system taking care to align the logos. If you would like the most rauccous sound from your Sportster S, skip this step
Fit the 2 Cobra Sport GP end cans on the end of the exhaust system (and dB Killers – if installed), ensuring they are lined up correctly and secure in place with the Cobra Sport spring hooks using a spring puller.
Adjust the alignment of the whole system.
Gently secure all 3 clamps to hold the exhaust in place. Once completely happy with the alignment, tighten the new Cobra Sport jubilee clamp first and then the 2 O/E clamps to fully secure the system in place.
Refit the OEM heatshield with the allen bolts supplied using a 2.5mm allen key and secure in place using a 8mm socket to tighten the jubliee clip.
Fit the outer OEM plastic heatshield using a T25 Torx on the OEM bolts.
Finally, start your engine and take a listen to the audible emotion courtesy of your new Cobra Sport performance exhaust system