How To Install Cobra Slip On Exhaust System Suzuki Vs800

Disclosure: As an Amazon Associate, I earn from qualifying purchases. This post may contain affiliate links, which means I may receive a small commission at no extra cost to you.

So, you’re ready to unleash a more aggressive sound and enhance the look of your Suzuki VS800 Intruder? Installing a Cobra slip-on exhaust is a fantastic way to do just that. This guide will walk you through the entire process, from gathering your tools to firing up your engine and enjoying the improved performance. Don’t worry, it’s a manageable project for most DIY enthusiasts.

We’ll cover everything from the initial prep work to the final adjustments. This is not just about bolting on a new exhaust; it’s about understanding the steps involved and ensuring a safe and successful installation. Get ready to transform your ride and enjoy a deeper, richer exhaust note that will turn heads wherever you go. Let’s get started!

Table of Contents show

What You’ll Need

Before you even think about touching your bike, gather these essential items. Having everything ready will make the installation process much smoother and more enjoyable. Trust me, running back and forth to the hardware store mid-project is no fun.

Cobra Slip-On Exhaust: Obviously! Make sure it’s specifically designed for your Suzuki VS800.
Socket Set: A good quality set with both metric and standard sockets. You’ll need various sizes.
Wrench Set: Again, metric and standard. Box-end wrenches are particularly helpful.
Torque Wrench: Crucial for tightening bolts to the correct specifications. Avoids stripping threads or overtightening.
Screwdrivers: Both Phillips head and flathead.
Penetrating Oil (e.g., PB Blaster or Liquid Wrench): For loosening stubborn bolts.
Anti-Seize Compound: To prevent future corrosion and make removal easier.
Gloves: Protect your hands.
Safety Glasses: Protect your eyes.
Jack or Lift (Optional, but Recommended): Makes accessing the exhaust much easier.
Wheel Chocks: For safety.
Shop Rags: For cleaning and wiping.
Owner’s Manual: For torque specifications and any model-specific instructions.

Step-by-Step Installation Guide

Now, let’s dive into the installation process. Follow these steps carefully, and you’ll be enjoying your new exhaust in no time. Take your time, double-check your work, and don’t hesitate to consult the Cobra exhaust instructions that came with your slip-on.

Step 1: Preparation Is Key

Before you start, ensure your VS800 is parked on a level surface. Use wheel chocks to prevent any unwanted movement. If you have a lift, use it to raise the bike for easier access to the exhaust system. If not, make sure you have enough space to work comfortably. (See Also: Won Hundred Willow Slip On Sneakers )

Safety First: Disconnect the negative (-) terminal of your battery. This is a crucial safety step to prevent accidental electrical shorts.
Cool Down: If the bike has been running recently, allow the exhaust to cool completely. Working on a hot exhaust system can lead to burns.
Locate the Exhaust: Identify the stock exhaust system components, including the muffler (slip-on).

Step 2: Removing the Old Exhaust

Now, it’s time to remove the existing exhaust. This is usually a straightforward process, but some bolts might be stubborn. Patience and penetrating oil are your friends here.

Loosen the Clamps: Locate the clamps that secure the stock muffler to the exhaust pipes. Use a socket or wrench to loosen these clamps. They might be rusty, so penetrating oil can help.
Remove the Muffler: Carefully slide the stock muffler off the exhaust pipes. You might need to wiggle it or gently tap it with a rubber mallet if it’s stuck.
Inspect and Clean: Once the muffler is off, inspect the exhaust pipes for any damage or corrosion. Clean the exhaust pipes with a wire brush if necessary to ensure a good seal with the new slip-on.

Step 3: Installing the Cobra Slip-On

This is where the magic happens! Installing the new Cobra slip-on is generally a matter of reversing the removal process. However, pay close attention to any specific instructions provided by Cobra.

Prepare the Slip-On: Inspect the new Cobra slip-on exhaust. Make sure all the necessary hardware (clamps, brackets, etc.) is included.
Apply Anti-Seize: Apply anti-seize compound to the threads of the bolts that will secure the slip-on to the exhaust pipes. This will prevent future corrosion and make removal easier.
Slide on the Slip-On: Carefully slide the Cobra slip-on onto the exhaust pipes. Align it properly, ensuring it’s seated correctly.
Secure the Clamps: Position the clamps and tighten them just enough to hold the slip-on in place. Don’t overtighten them yet, as you might need to make adjustments.
Mount the Brackets: If your Cobra exhaust uses brackets, attach them to the frame of the bike.

Step 4: Tightening and Adjusting

Now it’s time to secure the exhaust and make sure everything is aligned properly. This is where your torque wrench comes into play.

Torque the Clamps: Use your torque wrench to tighten the clamps to the manufacturer’s specified torque. Refer to the Cobra instructions or your owner’s manual for the correct torque specifications.
Tighten the Brackets: Tighten any brackets that secure the exhaust to the frame. Again, use the correct torque specifications.
Check Alignment: Ensure the exhaust is aligned properly and doesn’t interfere with any other components on the bike.
Final Inspection: Double-check all bolts and clamps to make sure they are securely tightened.

Step 5: Finishing Up and Testing

Almost there! A few final steps and you’ll be ready to enjoy the new sound of your VS800. (See Also: Will Two Brothers Slip On Exhaust Work For Rebel 300 )

Reconnect the Battery: Reconnect the negative (-) terminal of your battery.
Start the Engine: Start your engine and listen for any exhaust leaks. You might hear a slight hissing sound if there are leaks.
Check for Leaks: Run your hand (carefully!) around the exhaust joints to feel for any escaping exhaust gases.
Test Ride: Take your bike for a short test ride to ensure everything is working correctly and that the exhaust is properly seated.
Final Adjustments: Make any necessary adjustments to the exhaust position or clamps if needed.

Important Considerations and Tips

Here are some additional tips and considerations to ensure a smooth and successful installation:

Read the Instructions: Always read the instructions that come with your Cobra exhaust. They often contain specific details for your particular model of VS800.
Take Pictures: Take pictures of each step as you remove the old exhaust. This can be helpful if you get stuck during the installation.
Use Penetrating Oil: Don’t be afraid to use penetrating oil on stubborn bolts. Let it soak for a while to help loosen them.
Don’t Overtighten: Overtightening bolts can damage threads. Use a torque wrench to ensure you’re tightening them to the correct specifications.
Safety First: Wear safety glasses and gloves throughout the entire process.
Seek Help If Needed: If you’re not comfortable with any part of the installation, don’t hesitate to seek help from a qualified mechanic.
Break-In Period: Some new exhausts may require a break-in period. Refer to the Cobra instructions for details.
Check for Modifications: Ensure that the new exhaust system does not interfere with any existing modifications or accessories on your bike.
Proper Disposal: Dispose of the old exhaust system responsibly.

Troubleshooting Common Issues

Sometimes, things don’t go perfectly. Here are some common issues you might encounter and how to address them:

Difficulty Removing Bolts: Use penetrating oil and let it soak. Apply heat (carefully) with a heat gun or torch if necessary.
Exhaust Leaks: Check the clamps and ensure they are properly tightened. Inspect the joints for any damage or debris.
Exhaust Rubbing: Adjust the position of the exhaust and brackets. Check for any interference with other components.
Unusual Noise: Check all bolts and clamps. Make sure the exhaust is securely mounted.
Poor Performance: Ensure the exhaust is installed correctly. Check for any leaks or restrictions. You may need to adjust your carburetor if the exhaust significantly changes the airflow.

Maintaining Your New Exhaust

Once your new Cobra slip-on is installed, regular maintenance will keep it looking and performing its best:

Cleaning: Clean your exhaust regularly with a suitable cleaner. Avoid abrasive cleaners that can scratch the finish.
Inspection: Inspect the exhaust for any signs of damage or corrosion.
Tightening: Check the bolts and clamps periodically to ensure they are still tight.
Lubrication: Apply a light coat of lubricant to the clamps and joints to prevent corrosion.

Additional Modifications and Considerations

While installing a slip-on exhaust is a great starting point, you might consider other modifications to further enhance your VS800’s performance and aesthetics: (See Also: Will You Lose Low End With M4 Slip On Fz07 )

Air Filter Upgrade: A high-flow air filter can improve airflow and performance.
Jetting/Fuel Management: If you make significant changes to the exhaust or air intake, you might need to adjust your carburetor jetting or install a fuel management system. This ensures the engine receives the correct fuel-air mixture.
Cosmetic Upgrades: Consider other cosmetic upgrades, such as new handlebars, seats, or lighting.
Performance Upgrades: For more significant performance gains, consider upgrading other components, such as the ignition system or camshaft.

Frequently Asked Questions (faq)

Here are some common questions about installing a Cobra slip-on exhaust on a Suzuki VS800:

Do I need to rejet my carburetor after installing a slip-on exhaust? It depends. In most cases, a slip-on exhaust alone won’t require rejetting. However, if you also upgrade your air filter or notice significant performance changes, you might need to adjust your carburetor.
How long does it take to install a Cobra slip-on exhaust? The installation usually takes 1-3 hours, depending on your experience and the complexity of the installation.
What tools do I need? You’ll need a socket set, wrench set, torque wrench, screwdrivers, penetrating oil, anti-seize compound, gloves, and safety glasses.
Can I install the exhaust myself? Yes, the installation is generally straightforward and can be done by most DIY enthusiasts.
What are the benefits of installing a Cobra slip-on exhaust? Improved sound, enhanced looks, and potentially improved performance (depending on the exhaust design).
Will installing a new exhaust void my warranty? Check your warranty terms and conditions. Installing aftermarket parts can sometimes void the warranty, but it depends on the specific warranty and the parts involved.

Safety Precautions

Always prioritize safety when working on your motorcycle. Here are some important safety precautions:

Wear Safety Glasses: Protect your eyes from debris.
Wear Gloves: Protect your hands from sharp edges and heat.
Work in a Well-Ventilated Area: Avoid inhaling exhaust fumes.
Use Wheel Chocks: Prevent the bike from rolling.
Disconnect the Battery: Prevent electrical shorts.
Let the Exhaust Cool: Avoid burns.
Use Proper Lifting Equipment: If using a lift, make sure it’s rated for the weight of your bike.
Double-Check Your Work: Ensure all bolts and clamps are securely tightened.

Verdict

Installing a Cobra slip-on exhaust on your Suzuki VS800 is a rewarding project that can significantly enhance your riding experience. By following these steps and taking your time, you can easily transform the look and sound of your motorcycle. Remember to prioritize safety throughout the process and don’t hesitate to seek help if you need it.

🔥 Read More:

With your new exhaust installed, you’ll be ready to enjoy a deeper, more aggressive exhaust note and a stylish upgrade. Enjoy the ride and the satisfying feeling of a job well done! Ride safe, and enjoy the open road with your enhanced VS800.