Tech Tips: Exhaust System Installation

One of the first things on most people's upgrade list is a full exhaust system. While most exhausts aren't too big of a project to swap out, the dual systems on the latest Hondas add a bit more work to the equation. So to show you a few tips, we're going to install a Yoshimura RS-9T system on the all-new 2017 Honda CRF450R.

Remember, if you need to get your hands on a new exhaust system; hit up Chaparral-Racing.com/DirtBikeExhaust.

For any other motorcycle parts, accessories, or gear needs, you can find them at Chaparral-Racing.com.

Transcribed version:

"Hey, this is Michael Lindsay from Vital MX, we're here at Chapparal Motorsports today. And you know, when we most of us get a new motorcycle, one of the first things we get for it is an exhaust system. Now, while that may seem like a straightforward thing to put on, when you have dual pipes such as the new Hondas, it does add a little bit of extra difficulty in it. So today we're gonna show you how to put one on the new 2017 CRF450R. Now that we got the bike here on the shop, we're gonna show you how to remove the dual cans along with the mid-pipe and head pipe system of this bike. You can usually get away with just an eight, ten, twelve, and 14 millimeter T-handle or sockets to get the plastic and pipe hardware off. So first thing we're gonna start out with here is getting our seat off. Not necessarily does the seat have to come off, but since you have to pull both the seat bolts off, I just prefer to remove the seat and get it outta your way so it's not flopping around. Next step is to remove both side panels to expose the exhaust systems and their mounting hardware. 

So of course, as most people have seen with their stock system, there is a clamp on most of your OEM models. Typically it's best to just go ahead and break these loose and get them out of the way first so they don't interfere with you down the road. Those are just nice and loose and move around, you're fine. Now on the dual exhaust system with the Honda, there is two. Most models, there's always one here from the exhaust can to the mid-pipe, but dealing with the dual system, there is one more on the other side as well. And this one is, of course, is typically found about the same place right in front of the frame rail where the mid-pipe goes to the left side can. Okay. Just loose enough to where it moves. So we're gonna start here with the bolt on the left-hand can up on the flange and to the top of the subframe, but there's also another bolt at the base of the subframe which comes off a mid-pipe mount.

Once both of these are removed and this flange is loose, we just take this little guy, just gotta give it a little bit...it's definitely a tight fit on the new Hondas. You just gotta work it back and forth a little bit. Get off the clamp and out it comes. Big thing you wanna be careful is this sleeve material here on the stock cans to make sure it doesn't get left behind on the stock system. And of course, we're gonna repeat the same steps here on the right-hand side. System is very similar on this side where there are two bolts, one actually up on the flange of the exhaust can itself. So the last thing we need to actually remove hardware-wise, is the two bolts holding the head pipe flange to the cylinder head. So this is where the new Honda differs from the previous dual pipe models. Now, with the new injector layout, they've actually produced the split before the shock. In the previous models, it used to be after the shocks you had to put the mud flap guard out to get the mid-pipe section out. Now it's one piece with the head pipe because you can just maneuver it out through the frame with the splits with it. 

So now we're gonna place in our new Yoshimura system here which follows the same layout as the stock system. So you're just gonna slide this head pipe first in and we're gonna put the front flange on. Now we're just getting our stock flange nuts back on here. We're not actually gonna crank 'em down because you want the system to be a little bit loose as you're working on it just so it makes it easier to line up everything else, so you still are able to manipulate the head pipe, but you also want it just snug enough they'll kinda hold in place as you're moving it. It just makes everything a little bit easier.

Our new system here like most aftermarkets, you'll find that the mid-pipe and can are separate. This makes it much easier to manipulate and install. So we're gonna slide the mid-pipe coupler onto the head pipe here and get our bolts lined up. We're gonna start first with the mid-pipe mount. And then we'll do the can last because as I said, it's free from the mid-pipes so you can sit here, wiggle it around, get everything just right as you put the can bolt in. So we're able to repeat the same step here, other than this side of the bike is a little bit of a tighter fit, so you wanna be really careful to make sure your mid-pipe mount is clearing the subframe as you're trying to get the mid-pipe flange over the head pipe. Same thing though, you wanna try to line up the mid-pipe mount flange first before moving up to the can itself. Once that's in place, you can manipulate the can as you need to and put this can bolt in.

Now that the entire exhaust system is lined up and complete, we can go back through and tighten everything. Once again, like to start with the cans. The mid-pipe, being that we haven't put the springs on, is still free to rotate, so then you can move down to the mid-pipe bolt and it'll suck itself right into place as needed. And now we're gonna repeat the same steps on the right side of the bike starting with the can and then moving down to the mid-pipe. Now of course, if you put in a new head pipe washer that crushes, you will wanna recheck this after you start the bike and run it for a minute. You may have to tighten back down a little bit as the washer sets in places...as the washer sets in place and crushes down.

So now that we have our entire Yoshimura RS-9T exhaust system bolted up, we're gonna throw on the pipe springs, which there are two for the head pipe flange mount and then two more that go from the head pipe to the mid-pipe on each side of the bike. After that, we're able to put on the side panels, and the seat, and then you're ready to go out and rip your new system. And make sure you jump back on vitalmx.com for more tech tips."

Credit: Joe Carlino
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