How to change the muffler on your motorbike to have a more effective exhaust

How to change the muffler on your motorbike to have a more effective exhaust

How to change the muffler on your motorbike to have a more effective exhaust

Jokes aside, there are a handful of reasons why people remove stock motorcycle mufflers and replace them with aftermarket parts. From a bike repair after an OEM muffler has been damaged or worn, to the rider looking to upgrade with premium (and weight-saving) materials for performance, the fact is that replacing mufflers is a common modification. So let's get into it.

Step 1: Read the instructions!

Earning an engineering degree is difficult for a reason. It takes a lot of knowledge and skill to make something as complex as a motorcycle perform the way it does. Your bike's parts exist as they do for a reason (even if we don't always like that reason), so diving in without really understanding what you're doing is never a good idea. While this step-by-step aims to give you the broad strokes of the process, it does not replace the factory service manual or the manual that will come with your new aftermarket muffler. Read them both!

Note: Sometimes installing a new, non-factory motorcycle muffler will differ from the muffler removal process, so pay attention to the differences between the factory and aftermarket manuals.

Step 2: Loosen the connection joint

Your motorcycle's muffler will connect to your head pipes in a few ways. On our BMW F 800, the muffler is attached with a spring fastening system. On your bike, you might be looking at a standard band clamp or a gasket flange. The method differs between bike manufacturers, models, and years, so your connection is likely to be slightly different than the one shown here. Regardless, this is the point where you'll want to loosen that connection to prepare the mufflers for removal.

Step 3: Loosen the muffler bracket

As with the link joint, muffler brackets will vary depending on the bike you're working on. On the F 800, the muffler is held in place with a torx bolt. Again, your setup will likely look a little different, but the basic principle remains the same. Regardless of how the muffler bracket is constructed, it is there to support the weight of the muffler and keep it from causing a ruckus by rattling.

The main thing to keep in mind is to properly support the muffler while loosening the bracket. When the bracket loosens, the muffler itself can rattle a bit and rattle things you don't really want to rattle.

Tip: A tidy shop is a low-stress shop. Be diligent about keeping track of where you put the parts you're removing. Place the fasteners where you won't lose them!

Step 4: Remove the muffler from the motorcycle

They call them “slip-ons” for a reason. In theory, silencers should behave exactly this way. However, as with most things in this world, they don't always perform as advertised. Occasionally, when removing mufflers, you may need to use a little force to get them to dislodge from the home they have become accustomed to over the miles.

There's a fine line here, though. At this point your mufflers are still attached to your headers and your headers are attached directly to your engine. Disturbing these too much can lead to gasket problems, or worse, you could damage a cylinder head (which would suck). Be judicious with the force you apply and if you feel like you are pulling a little too hard, stop and check that all attachments are indeed completely removed.

Step 5: Slide the new muffler onto the exposed header pipe

At this point, you'll basically start doing the steps you've already completed, only in reverse and perhaps with a minor variation or two. When connecting a new muffler to the head pipe of your motorcycle, the number one rule is to proceed with caution! These pieces are precision engineered, so you shouldn't jam or slam things into place. If you find yourself struggling mightily to fit something, you're probably doing it wrong.

Step 6: Attach the new muffler

In general, there are two ways to attach your muffler to your motorcycle: via brackets or via cable ties. The brackets, like those on our F 800 example, will attach to both the muffler and the bike. Band clamps, on the other hand, act as a holster that will tighten around the silencer to keep it in place. Regardless of the style of your motorcycle, it is important to completely read the instructions that will come with your new muffler, as they may differ from the stock version you just removed. As you can see in our example, the Remus exhaust requires the addition of an O-ring which will allow you to maintain the right distance between the can and the bike.

Tip: Finger-tighten everything first to make sure it's in the right place. If something's misaligned and you tighten it all the way, you're more likely to damage the parts. At the very least, it just adds a little time and frustration to undo.

Once everything is aligned, reattach any springs, flanges, or gasket clamps needed to secure the muffler to the head tube. Excessive torque when tightening parts is a common mistake made by beginners, so be sure to consult the factory service manual and that of your aftermarket slip-on for exact specifications.

Step 7: Wait! Clean the muffler

With the new muffler installed and your bike begging to be ridden, this is the part where you no doubt want to fire things up and listen to the tune of your new slip-on. But don't do it! It would be a mistake. Throughout this entire process you handled the muffler with, well, your hands. As such (and even though you probably can't see it), your muffler is now covered in oils from your gloves and needs to be cleaned before putting it into operation. If you ride your bike before thoroughly cleaning the canister, you run the risk of permanently staining your new muffler.

Tip: Be careful around the end caps, as they are relatively delicate. Be even more careful if those end caps are carbon fiber! Be sure to always use an ultra-clean rag, as any dirt stains can scratch the carbon fiber exterior.

Step 8: Check for leaks

Now you can finally flip the switch and dial in that wonderful symphony of motorcycle exhaust sound! Before you go, though, you'll want to be sure and check for leaks around the base of the slip-on and the top of your headers. There shouldn't be any exhaust fumes coming from these areas. If there are, something's wrong.

You can use your hands to test this, but be careful! As anyone who's ever gotten too close to a hot motorcycle pipe can attest, the encounter isn't exactly ticklish and often results in a lasting scar to remember.

A note on DB killers

We often get asked about DB killers and how they should be handled. For those who don't know, DB killers are inserts that go on the end of the muffler to reduce the noise levels produced. Some exhausts ship with them, some don't. Some can be removed, some cannot. Ultimately, it all comes down to the exhaust. Since the removal and insertion process varies between different silencers, it is again imperative to follow the specific instructions listed in your sip-on manual.

The main thing here is to be very careful not to damage your DB killer when removing or manipulating it. While the idea of ​​a louder motorcycle might sound good in theory, chances are you're not actually a fan of the muffler tune without the insert. You may also encounter a variety of driving scenarios when a silenced exhaust is more desirable (e.g. long motorcycle trips, late nights in quiet neighborhoods, or passengers with sensitive ears). Damaging your DB killer or the DB killer connection on the muffler makes this process irreversible, so proceed with caution.

Oh yes… the law

So yes, there are also some legal things to consider when adding aftermarket modifications (and especially exhausts) to your bike. Be sure to consult your municipality's proverbial bylaws before making any changes. That said, we should note that the modifications shown in this article are only advisable for racing vehicles that may never be used, or registered or licensed for use, on a road

And this is all. Installing a new motorcycle muffler is a relatively simple task that doesn't require a lot of technical know-how, but offers considerable value for money when it comes to both the aesthetics and acoustics of a motorcycle. While your bike will undoubtedly be different in some way, shape, or form from our model, the general steps listed here will most likely come into play as you work your way through the process on whatever ride you own.

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