How to Change a Motorcycle Exhaust
Replacing the factory-equipped exhaust system is one of the first modifications most motorcycles receive. Although most motorcyclists swap stock pipes for aftermarket systems to enjoy a deeper exhaust tone, these systems are usually less restricted and can provide an increase in power. Changing the exhaust systems can be a fairly simple project. However, the complexity of the installation depends largely on your motorcycle.
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Things You'll Need
- Combination wrenches
- Socket wrench and socket set
- Allen keys
- Screwdrivers
- Thread-locking adhesive
Instructions
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Installation
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1
Examine your motorcycle to determine what, if any, body components must be removed to access the exhaust system. For a full system swap, you'll need to access the exhaust headers, the pipes that connect directly to the motor, so any components that are in the way will need to be removed or worked around.
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2
Lay out the new exhaust and take an inventory of the parts included with it. In particular, look for any exhaust gaskets that may be needed. If none are supplied with the new exhaust, purchase new gaskets from your local dealership.
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3
Remove any body components that obstruct access to the exhaust. Place these components and their hardware in a safe place.
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4
Loosen the exhaust manifold flange screws and any mounting bolts that secure the exhaust to the motorcycle.
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5
Remove the muffler's mounting bolt(s) and the muffler. Next remove the mid-pipe, if any, then the headers.
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6
Clean the areas of the motorcycle that were previously obscured by the exhaust. Remove original exhaust gaskets and clean any carbon buildups in the exhaust manifold. Install fresh exhaust gaskets.
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7
Install the header onto the motorcycle. Apply a drop of thread-locking adhesive onto the threads of the mounting bolts before tightening loosely.
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8
Apply thread-locking adhesive to the threads of the mounting bolts and onto the inner sleeve of the mid-pipe and the muffler, then connect the mid-pipe and muffler to the header. Loosely tighten the mounting bolts.
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9
Align the components of the exhaust system and tighten the mounting bolts, starting from the headers and working back to the muffler.
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10
Reinstall any body components removed earlier and go for a ride.
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1
Tips & Warnings
To further improve the power and performance of your motorcycle, install a high-flow air filter and an Electronic Fuel-Injection Controller or Performance Jet kit for carbureted motorcycles.
If the muffler refuses to release from the mid-pipe, spray a penetrating release solution, such a WD40, onto the muffler joint and let it sit for a few minutes before trying again.
Read the instructions provided by the manufacturer.
Take your time. Rushing can lead to costly and time-consuming mistakes.
If you are not confident you can complete this project, have the work done by a qualified technician.
New exhausts may be filled with fiberglass packing to absorb sound. This packing may partially ignite, emitting hot sparks from the muffler for the first few minutes. Keep the area directly behind the motorcycle clear and stand back to avoid burns.
Do not reuse old exhaust gaskets. Torn or worn gaskets may create leaks in the exhaust system that will rod the motorcycle of power. Always replace them with fresh gaskets.
