How to Replace a Motorcycle Exhaust System

By Jason Marker, eHow Contributor

 
 
 
• Print this article

Replace the exhaust system on your motorcycle yourself and save money.

One of the most obvious external engine parts on a motorcycle is its exhaust system; the exhaust pipes are typically chromed or coated in some other shiny, eye-catching compound. Replacing a motorcycle's exhaust system is one of the easiest ways to not only dress-up the bike and give it a custom look, but also to improve its engine note and overall performance. Whether choosing a pair of slip-on mufflers for a sport bike or a full-on, double-chromed open muffler exhaust for a cruiser, a good custom exhaust can make your bike stand out in a crowd.

Things You'll Need

• Shop manual specific to your motorcycle
• Ratchet
• Sockets
• Combo-wrenches
• Breaker
• Torque wrench
• New exhaust system
• Anti-seize compound
  

  Instructions

  1. • 1
       Consult your shop manual regarding the different connection points where the exhaust system is bolted to the motorcycle's frame. Loosen and remove manifold bolts and any other bolts connecting the exhaust system to the motorcycle, following the instructions in your shop manual. Remove and dispose of old exhaust gaskets. Set the old exhaust system aside for disassembly and disposal.
     • 2
       Test-fit the exhaust manifold and exhaust pipes to ensure that they line up properly. Install new exhaust gaskets, following the instructions in your shop manual. Install the new manifold by reversing the steps used to remove the old one. Tighten the exhaust manifold bolts and any exhaust pipe bolts to the torque specs outlined in your shop manual.
     • 3
       Slip the mufflers onto the exhaust pipes. Secure the mufflers both to the exhaust pipes and to the motorcycle's frame. Torque all exhaust system bolts down to the torque specifications recommended in the shop manual.

       
       

       Tips & Warnings

       • Coat all bolts and studs in the exhaust system and motorcycle cylinder head with anti-seize compound to prevent them from seizing or fusing together.
       • Make sure to test fit the exhaust system to ensure that all the pieces are there and they fit together and that the exhaust system fits the bike.
       • Do not attempt to change or remove exhaust system parts directly after the bike has been running. A motorcycle's exhaust system gets extremely hot and contact with hot parts can cause serious burns.