Exhaust system: removal and installation

Exhaust systems often need to be removed for vehicle service. The components of the exhaust system may be few and simple, but their installation and removal can be frustrating.

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With these tips from years of experience, it’s easier for technicians and ultimately creates a better experience for customers.

First, prepare to remove and install the exhaust system. Allow the component to cool sufficiently before touching it. Make sure you have all the required replacement exhaust gaskets. If the gasket fails, it will be obvious to everyone when the engine starts.

Also, plan to encounter one or two obstacles along the way. Exhaust clamps often rust and seize. To deal with these, have a permeable lubricant on hand. Thread peeling and seizure are common on exhaust fasteners. Tools such as taps, dies, easy outs, and drill bits are great for pinching, but be careful. Otherwise, small problems can be big mistakes.

If the exhaust system is for off-road vehicles, check the spark arrester. Spark arresters should be removed, inspected and cleaned according to the service manual. Spark arresters may require gaskets.

Some other items you may have to deal with are exhaust system valves and oxygen sensors. The valve may have a cable or electrical connector that must be removed before removing the exhaust pipe. Unplug the oxygen sensor before removing the exhaust system. Always reconnect these components when installing the exhaust system.

When installing the exhaust system, be sure to install the exhaust system completely in place before tightening the fasteners. If you jump forward and start tightening before the fit is established, you will have an exhaust leak or the system will not fit. After the system is installed correctly, tighten the fasteners in the order given in the service manual. Often, the tightening procedure is to start at the head and back towards the muffler.

Aftermarket exhaust system

The aftermarket exhaust system is a popular accessory for power sports vehicles. These systems can cause their own set of problems. The first item to work on is the equipment of the model. You will need the appropriate exhaust system and mounting hardware for your vehicle.

Installing the aftermarket exhaust system may change the operating condition of the engine. Owners who are hoping for a muddy roar and a little more engine power may be greeted by a bike that doesn’t work very well and can even lose power.

It may be necessary to adjust the fuel supply of the engine to compensate for the difference in exhaust gas flow. Check if the exhaust system manufacturer makes the recommended adjustments. This could be a jet kit for carburetors, or a new fuel map for fuel injectors. Not only does this improve the behavior of the tuned engine, but this work also brings additional funding to the service department.

Link: Cyclepedia Exhaust system: removal and installation

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