Fitting a Racing Exhaust to Your Motorbike

This is actually a very simple and easy project, no monstrous mechanics job, in fact we did it in five minutes, though it'll probably be slower first time round.

The bike in the photos is a Honda CB500, the exhaust is a Remus...

Tools, Materials and Issues

Well before I begin there are a few legal issues to explain about this, starting with the fact that if an exhaust states "not for road use" it's not strictly road legal, now as long as it doesn't strike the decibel levels that will get you pulled over it's fine day to day. However you will have to put the stock exhaust back on for MOT, mainly because they can point to the writing on the exhaust that says "not for road use" on it. Some people take to removing these embossings in various ways - A simpler solution would be to seek out an exhaust with a removable baffle, meaning it's road legal and you can just stick the baffle back in for MOT tests, rather than keep the old exhaust in the garage and change the whole thing every time.

As said the project's not a tricky one.

The hard bit is finding your exhaust, do your research and know what you want from it, the Remus pictured is a racing exhaust and has certain properties, it's notably lighter in comparison to the stock one, steel versus aluminium so it's not a big shock that it's lighter. It also tends to burble and crackle under normal engine braking and if you do it in a low enough gear on purpose it backfires, loudly. That's good for some and bad for others...

Anyway, Tools and such:

- Spanners, allen keys and a socket wrench, it'll vary bike to bike but those are the main things you'll need.

- Can of WD40 or a better penetrating oil

Note: Remember to let the exhaust cool down before attempting anything, it can get fairly toasty even after a short ride...

Removing the Old Exhaust

Starting with the connection to the downpipes undo the collar bolt, just like a big jubillee clip (hose clamp for those that don't know) if you find the bolts are rusted solid, give them a bit of penetrating oil and allow them a few minutes to loosen up, if desparate measures must be taken hit the bolts with the heat of a jet torch for a bit then allow to cool, hopefully unseizing them...

Removing the Old Exhaust (cntd)

Once the collar is free we undo the bolts holding the exhaust to the rear swingarm or chassis, depending on bike design, on this CB500 the bolt goes through right in front of the pillion foot peg.

New Exhaust, Link Pipe

Now we take our link pipe, if you have a two piece exhaust like this one the link pipe's first, though don't completely tighten the connection yet, leave it fairly well put on but with a little movement to make sure the can goes on easily.

On the Can... Eh on With the Can

Slide the can on the the link pipe and line it up with the bolt holes for back end, if it lines up dead on then tighten up the link pipe connection to the downpipes and bolt on the exhaust, tighten the connection between the link pipe and can.

Wrapping Up

Fire the engine up and hold your hand near the exhaust at the points of connection to check for gas leaks, though if you feel anything before taking it apart make sure there aren't holes there on purpose...

Enjoy new racing exhaust...