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Replacing an OEM Motorcycle Exhaust

A standard exhaust can rust through or clog with age. Know the signs and how to replace it properly.

An OEM (factory) exhaust is designed to balance power, sound, and emissions. With age it can rust through or clog with carbon deposits, and at that point replacement is the best option.

Signs the exhaust needs replacing

Why stay with OEM?

A genuine exhaust is certain to fit the mounting points and body lines, needs no fuel retuning, and keeps noise and emissions within standard limits. On fuel-injected bikes, the oxygen sensor also sits exactly where it should.

Replacement steps

  1. Wait until the exhaust is completely cold.
  2. Loosen the header nuts at the cylinder head, then remove the muffler mounting bolts.
  3. Remove the old exhaust and discard the old header gasket.
  4. Fit a new gasket, position the new exhaust, and start all bolts by hand first.
  5. Tighten the header nuts alternately and evenly, then the mounting bolts.
  6. Start the engine and check for leaks at the header joint.

Do not reuse the old gasket. Exhaust header gaskets are single-use. A flattened gasket will almost certainly leak and cause popping noises.

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