As your motorcycle ages, holes can develop in the muffler, causing gases to escape in more than one place and making the engine sound louder. This louder sound can also be caused by the air filter in the intake pipe or by a broken or damaged muffler packaging, called the baffle. You can easily replace the muffler and air filter of your motorcycle in an hour; or if you can remove the muffler baffle, you can replace the muffler instead of replacing the entire muffler. You can also replace your current muffler with an absorption muffler that pushes the exhaust gases through a larger chamber, reducing its noise.
Removing the old muffler
Place your motorcycle on its center stand. Remove the screws that secure the heat shield on the side of the muffler, under the seat, with a Phillips screwdriver. Your bike may also have a head cap, although if your new muffler comes with one attached, you won’t have to remove it. The heat shield should have three screws that hold it to the muffler, although this may vary depending on the make of the bike.
Use a ratchet to remove the bolts that hold the muffler to the bike. Check the muffler below to make sure you have removed all the screws. At this point the muffler should only be connected to the engine by the front pipe. Some mufflers can be removed from this tube although most will be welded to it.
Spray a lubricant on the junction between the muffler and the head tube and twist it as you pull it out of the head tube. If the muffler you are installing is attached to a new head tube, do not remove the muffler; go to step 4.
Remove the four bolts or screws that hold the header tube to the exhaust port of the motorcycle’s engine.
Pull the head tube out of the motor and remove the gasket.
Check the exhaust port of the engine to see if there is any buildup or debris that needs to be removed.
Install the new gasket and fit the new header tube, making sure it is properly aligned with the exhaust port. Fit the new muffler onto the head tube, if not already attached, securing everything snugly but not too tight.
Check that everything is lined up and installed correctly, then tighten the screws and bolts. Check all connections before replacing the heat shield.
Start your bike while it is still on the center stand and check the exhaust, placing your hand near, but not touching, the connection of the header tube with the exhaust port to feel if any of the exhaust is being pushed out of the connections. If that’s the case, you may need to separate all the pieces and work on realigning the connections.
Deflector replacement
Place your motorcycle on the center stand. Remove the heat shield with a screwdriver and then remove the screws that hold the muffler to the bike.
Remove the muffler from the head tube by loosening it with Liquid Wrench and turning it from side to side while pulling it back.
Remove the screws holding the head cover to the muffler and remove the head cover. This will give you access to the deflector.
Reach into the muffler and try to remove the baffle. If it doesn’t come off easily, spray it with a non-stick compound, let it sit for 30 minutes, and then try taking it out again. If it still doesn’t move, insert a tube expander and twist it until it sits comfortably against the baffle.
Pull the tube extender to remove the deflector.
Slide the new baffle onto the tailpipe and make sure it fits snugly. You can insert the tube expander to rotate it and make sure the baffle expands properly in the muffler.
Replace the head cap, then slide the muffler onto the head tube and screw it onto the bike, ensuring all connections fit snugly. Replace the heat shield.
Start the bike, while it is still on the center stand, to test the sound of the muffler.
Changing the air filter
Place the bike on its center stand. Locate the air filter on the opposite side of the muffler.
Remove the screw in the center of the air filter box directly under the seat. Remove the air filter case cover and set it aside.
Hold the air filter and pull it straight towards you. Check the air filter box for debris or damage. Clean it if necessary.
Press the new air filter back into the box, then replace the air filter cover.
Tips
If the muffler you have comes out of the head tube, but the muffler you purchased is permanently attached to the head pipe, don’t bother pulling the muffler out of the head tube, unless the muffler gets in your way when removing head tube.
Not all mufflers will have a removable baffle. If your muffler is welded, you will not be able to remove the baffle and will have to replace the entire muffler.
Warnings
Be careful not to scratch the paint near the parts you are removing when you are pulling them. It is best to use rags or old towels to cover the painted areas near the parts you are working with.
