How to Fit a Motorcycle Exhaust: Step-by-Step Guide

by Euro Motards

Before You Start: Slip-On vs Full System

The fitting process differs significantly depending on what you're installing. A slip-on replaces only the muffler section — the midpipe and headers stay standard. It's the most common upgrade and typically takes 30–60 minutes. A full system replaces everything from the cylinder head headers back, takes 2–4 hours, and will almost certainly require a fuel remap or ECU tune to run correctly.

This guide focuses on slip-on installation, which covers the majority of aftermarket exhaust upgrades.

What You'll Need

  • New slip-on exhaust with supplied hardware
  • Socket set (typically 8mm, 10mm, 12mm, 17mm)
  • Torque wrench
  • Copper anti-seize grease
  • Heat-resistant exhaust paste or sealant (for leaks if needed)
  • Paddock stand (recommended)
  • Exhaust spring hooks or pliers
  • Gloves and eye protection

Step-by-Step: Fitting a Slip-On Exhaust

Step 1 — Let the Bike Cool Completely

Never work on a hot exhaust. Allow at least 2 hours after riding. Exhaust systems reach temperatures over 600°C in normal use — heat-soaked components are difficult to remove safely and you risk burns and damage to the new muffler if it contacts residual heat.

Step 2 — Remove the Old Muffler

Start by locating the muffler mounting bolt — typically a single bolt through a bracket on the rear subframe or footrest hanger. Remove this first. Then locate the clamp or springs connecting the muffler to the midpipe. If spring hooks are used, use an exhaust spring tool (or long-nose pliers carefully) to unhook them — they're under tension. Slide the muffler rearward off the midpipe.

Step 3 — Inspect the Midpipe Collector

With the old muffler off, check the condition of the midpipe collector — the section the new muffler will connect to. Clean off carbon deposits and rust with fine wire wool. Check for cracks. If there's any oval deformation of the pipe end, this will cause leaks with the new muffler — dress it carefully back toward round with a rubber mallet if needed.

Step 4 — Check Gaskets and Seals

Most slip-ons include a new gasket or sealing ring for the joint. If yours doesn't, and the standard one is worn or cracked, source a replacement — an exhaust leak at this joint will cause popping and potential overheating of the new muffler where it meets the pipe.

Step 5 — Fit the New Muffler

Apply a light smear of copper anti-seize grease to the midpipe collector — this prevents the joint from seizing and makes future removal easier. Slide the new muffler onto the midpipe. Don't fully tighten anything yet — leave all connections hand-tight so you can adjust position and alignment.

Step 6 — Align Before Tightening

This is the most important step most people rush. Sit on the bike, check the muffler sits level and doesn't contact the bodywork, swingarm, or tyre at any point. Check that the muffler outlet points where you want it. Adjust the clamp position if needed. Only when you're happy with the position should you tighten the mounting bolt and clamp to the torque values in the instruction sheet.

Step 7 — Refit Heat Shields

If the new exhaust came with heat shields, fit them before the first run. If your bike has a passenger footrest peg close to the new muffler position, check clearance — some slip-ons are designed for solo use only.

Step 8 — First Run Check

Start the bike and let it idle for 2 minutes. Listen for any hissing or ticking from the midpipe joint — this indicates an air leak. Check that the muffler isn't vibrating against anything. Let the exhaust go through a full heat cycle (ride for 15 minutes) before rechecking all fasteners.

Do You Need a Remap?

For a slip-on with the standard airbox, a remap isn't always necessary. However, most slip-ons will cause some off-idle richness or lean stumble because the back pressure characteristics of the exhaust system change. A professional ECU remap or self-tuning module will give you the full performance benefit and often improves rideability noticeably.

Related Guides

Browse our exhaust range in the Exhaust collection. For more guidance on selecting the right system, read our Motorcycle Exhaust Buying Guide.

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