Cobra’s new Power Pro 2-into-1 exhaust systems feature a proprietary internal cooling design that prevents bluing.

here’s no mistaking the sound of a Harley-Davidson V-twin accelerating through the gears. No, let’s rephrase that to read “a Harley-Davidson V-twin with a free-flow exhaust system accelerating through the gears” because that is the sound that endears so many people to this all-American motorcycle engine.
     And this year Cobra ups the ante with its Harley-Davidson exhaust systems, offering two all-new custom designs. Moreover, both of Cobra’s new performance exhaust systems are available now.
The big news from Cobra is the Power Pro 2-into-1 Exhaust, a design that brings new collector-box technology to the Harley market. The Power Pro is joined by the Speedsters, a design that will improve the performance potential for all of Cobra’s current and more traditional-style 2-into-2 exhaust systems (see accompanying story for details).

The new Power Pro systems fit a wide range of Harley-Davidsons.

     Among the Power Pro’s features that separate it from other 2-into-1 V-twin exhaust systems is a proprietary internal cooling design that prevents bluing to the collector box where heat build-up can be especially bothersome. Many 2-into-1 designs have a tendency to blue their pipes at this point in the system, but through a special design in the muffler housing Cobra’s systems are able to keep exhaust gas temperatures lower and, when the engine is tuned properly, eliminate bluing.
     In addition, the Cobra Power Pro system comes with its own set of heat shields that cover the entire length of each header pipe, from the engine’s exhaust ports to the collector box area where Cobra’s distinctive collector heat shield takes over. Each shield forms a 222-degree wrap-around for the header pipe so the system’s show-quality chrome plating remains intact under all riding conditions.
     Now let’s talk about the Power Pro’s performance, another virtue in a collector box design. According to Tim McCool, president of Cobra Engineering, “the Power Pro offers substantial gains in peak horsepower, plus it helps deliver a broader powerband for improved rideability.” The gains are especially significant for Harley engines with EFI that utilize Cobra Engineering’s improved-for-2004 Fi2000 Digital Fuel Processor (see accompanying story). Likewise, Harleys with carbureted engines can take advantage of Cobra Engineering’s jet kits to harmonize the intake with the new, more efficient Power Pro exhaust system.
     As with all Cobra accessories, the Power Pro 2-into-1 Exhaust is easy to install because each system was designed for a specific Harley-Davidson model. The pipes come packaged with their own mounting hardware and detailed instructions, too. The Power Pro fits a wide range of Harley-Davidson motorcycles, so check with your Drag Specialties sales rep for order information. Then prepare for another great sound, that of your dealership’s cash register going “cha-ching!”

he Power Pro 2-into-1 Exhaust isn’t the only big news from Cobra Engineering this year. Harley-Davidson enthusiasts who prefer the timeless look of a 2-into-2 exhaust system can find even more performance for their bikes with the new Speedsters, a design that was developed especially for Cobra’s classic individual exhaust pipes.
     The secret to the Speedsters’ improved performance is found in the PowerPort, a special chamber that connects both pipes at about the mid-point of their length. The Power Port is positioned out of sight behind the pipes so it won’t distract from the bike’s looks, but you know it’s there the moment you twist the throttle for acceleration.
     “We work very hard to make sure our exhaust systems exhibit a timeless, classic appearance,” said Cobra Engineering’s president, Tim McCool, “but it’s what you don’t see on the Speedsters that makes all the difference.” In essence, the connector chamber serves as a balance tube that offers many of the performance gains associated with a collector box. So you get increased power throughout the rpm range, yet retain the classic, timeless look that 2-into-2 pipes offer Harley-Davidson owners.
     The Speedsters are available for Harley-Davidson motorcycles now from Drag Specialties. They come in two models, Longs and Shorts, and are ready to bolt on using hardware and fasteners that are supplied with each system. As with the Power Pro 2-into-1 Collector Exhaust, the Speedsters are available from Drag Specialties, so talk with your Drag rep now so you’re ready for the new riding—and selling—season.

The secret to the Speedster’s performance is the PowerPort, which is a special chamber that connects the pipes near the mid-point of their length.

nnovation with exhaust systems can take many forms. What’s innovative about the new Cobra Power Port isn’t so much the crossover itself, but how Cobra did it. Tim McCool, president of Cobra Engineering, explains. “Everyone has some sort of crossover. Even the OEM pipes,” he said. “But it’s the size and shape and where you put it that brings a bit of art to the science.”
     For the Speedsters, Cobra located the Power Port on the back side of the pipes rather than dead center from the bottom of the top pipe to the top of the bottom pipe. This placement provides a physically stronger connection between the two pipes because of a larger surface contact area, plus it gives more room for the heat shields so they do not have to be cut away to allow for the right fit. Moreover, the Power Port is installed within the muffler section itself, which makes a much more rigid tail area of the exhaust system. This allows for an easier installation because the customer can first install the head pipes, then slip on the muffler body section with the Power Port near the very front.
     So what kind of performance increase should your Harley-Davidson customers expect from the Power Port? Simply put, the Power Port helps the pipes deliver the sort of gains you expect with a traditional 2-into-1 collector system, yet it still retains the classic 2-into-2 style that is so popular among Harley owners.

The Fi2000 has an all-new housing, making it easily distinguishable from early Fi2000s.

he industry’s most user-friendly electronic fuel management system just got better. Cobra’s Fi2000, developed expressly for EFI Harley-Davidsons equipped with aftermarket exhaust pipes, now has a third pot that can be used on engines with performance modifications such as camshafts, larger pistons, things like that. Think of the third pot as the fuel injection’s electronic main jet, making it especially useful for high-performance applications.
     As you know, Cobra’s original Fi2000 design had two pots, which proved especially useful for regulating fuel disbursement during acceleration (much like a low speed jet for a carburetor) and while maintaining constant throttle at cruising speeds. These two pots remain in the new Fi2000’s makeup, so nothing’s changed there. In fact, if the bike has no modifications beyond a free-flow exhaust and air cleaner, it can still use the new three-pot Fi2000 with no problem.

Cobra’s Fi2000 EFI system now comes with a third tuning pot that can be used on engines with performance modifications.

     But the addition of the third pot gives a tuner even more flexibility, should he need it. In essence, the third pot allows the bike’s ECU to recognize the engine’s performance modifications so that it can tell the fuel injection to increase the amount of fuel as needed, and when it is needed. As you can see, this pretty much assumes the task of a carburetor’s main jet. The addition of a third pot also gives the owner the option to upgrade his Harley engine with performance modifications should he decide to do so at a later date. And, as you know, most Harley owners will do just that, sooner if not later.

The new Fi2000 is available for all Harley-Davidsons with EFI.

     The new three-pot unit is easily distinguishable from the early Fi2000, too, thanks to an all-new housing. Yet installing the new Fi2000 to a Harley-Davidson remains simple like before. The new system has the same color-coded wires that plug right into the bike’s existing wire loom as before, and it mounts to the bike using an adhesive-backed Velcro strip. And, as with the original Fi2000, all units are model-specific, and come with easy-to-follow instructions.
     Cobra offers the new three-pot Fi2000 for all Harley-Davidson motorcycles with EFI. Each unit comes pre-set for Cobra exhaust systems, too, although the Fi2000 is compatible with any aftermarket exhaust system. All systems are available through Drag Specialties, so see your rep now about this improved product for 2004.