How to Install an Exhaust in Vehiclesby Contributing WriterUpdated June 12, 2017
Installing the exhaust on your Vehicles Davidson Vehicles is a rather simple task, with the use of the correct tools. It is also a necessity when trying to optimize the fuel economy of your Vehicles. You may need to reinstall the stock exhaust Vehicles your Vehicles if the previous owner installed an aftermarket set of exhaust and you desire to return the bike to stock condition. Once you have completely removed the old set of exhaust, you are set to install the new exhaust.
Under The Hood:
- How to Install an Exhaust in a Honda Civic
- How to Install the Exhaust on a Harley Ultra Classic
- How to Install an Exhaust on a Yamaha Rhino 660
Removing an Old Exhaust System
Jack up your Civic to allow yourself room to work underneath the car.
Remove the bolts that hold the muffler to the exhaust B-pipe using a socket wrench.
Secure the muffler by placing a stable support underneath it, such as stacked bricks, or have someone support it for you with their hands.
Pry off the rubber hangers on the muffler, which keep the muffler from falling. If you do not have your muffler supported when you remove the rubber hangers, your muffler will fall to the ground. Remove the muffler and set it aside.
Loosen the nuts that hold the B-pipe to the catalytic converter.
Secure the exhaust system in the same manner you secured the muffler.
Pry off the rubber hangers on the exhaust system, which keep the exhaust from falling.
Remove the exhaust system from underneath your Civic.
Installing a New Exhaust System (Muffler Already Equipped)
Jack up your car to provide yourself with enough room to work underneath it.
Align the rubber hangers on your Civic with your new exhaust system's B-pipe hangers.
Attach the B-pipe to the catalytic converter with the bolts supplied with your exhaust system using a socket wrench.
Slip the band clamp over the B-pipe in the rear of your exhaust system and then slide the middle exhaust pipe into the clamp.
Attach the middle pipe to the rubber hangers that hang above.
Slip a second band clamp over the middle pipe in the rear of your exhaust system and then slide in the muffler pipe.
Attach the muffler to the rubber hangers that hang above.
Align the band clamps so the muffler fits into the muffler section on the rear of your Civic. The muffler section is the semi-circle portion of your bumper that has been cut out. Once the muffler pipe is properly aligned, tight the band clamps using your socket wrench.
Items you will need
Socket wrench set with extender
Bricks or cement blocks (optional)
Install new gaskets in the rear and front cylinder head exhaust ports. The tapered side of the gasket should be facing towards you. Install the gasket by pushing it all the way into the port with your fingers.
Install and tighten the transmission exhaust bracket onto the transmission side door. Tighten with an Allen wrench.
Install the front header pipe exhaust flange onto the front cylinder head by simply pushing it into place. Begin threading the flange nuts onto the cylinder head studs by hand.
Slide the transmission exhaust bracket clamp over the other end of the front header pipe. You may have to tighten the clamp with channel lock pliers. Tighten the clamp bolt with your fingers just enough to hold it in position.
Slide a new TORCA clamp onto the front header pipe approximately an inch away from the transmission exhaust bracket clamp.
Install one end of the rear header pipe onto the rear cylinder head located on the bike. Slide the other end onto the front header pipe through the TORCA and transmission exhaust bracket clamps. Install the rear header pipe flange by pushing it into place. Begin threading the flange nuts on the cylinder head studs by hand. Move the already installed TORCA clamp directly over where the front and rear header pipes are connected.
Install TORCA clamps at the two remaining open ends of the rear header pipe. The TORCA clamp that connects to the crossover pipe -- the pipe that crosses over to the opposite side of the bike -- is a special clamp in that it has a slot for the exhaust support bracket.
Slide the right muffler onto the rear header pipe. Loosely tighten the screws and lock washers that connect the muffler to the bottom of the saddlebag supports. Move the already installed TORCA clamp directly over where the rear header pipe and right side muffler are connected.
Install the crossover pipe onto the remaining end of the rear header pipe -- located directly above the starter. Move the already installed TORCA clamp directly over where the rear header pipe and the crossover pipe are connected; ensuring the clamp slides into the slot located on the exhaust support bracket.
Slide another TORCA clamp onto the open end of the crossover pipe. Connect the left side muffler to the crossover pipe. Move the already installed TORCA clamp directly over where the left side muffler and crossover pipe are connected. Slightly tighten the bolts of the clamp.
Tighten the exhaust into place. Tighten the top nut of the front cylinder head exhaust flange to 9 to 18 inch-pounds with a torque wrench. Tighten the bottom nut of the same flange to 100 to 120 inch-pounds. Re-tighten the top nut to 100 to 120 inch-pounds. Repeat these steps for the rear cylinder head exhaust flange. Tighten the transmission exhaust bracket bolt to 60 to 96 inch-pounds. Tighten the bolts of both the right and left mufflers with a standard wrench. Tighten the four TORCA clamps to 45 to 60 foot-pounds with the torque wrench in the following order: crossover pipe to left side muffler, rear header pipe to right side muffler, front header pipe to rear header pipe and rear header pipe to crossover pipe.
Items you will need
Channel lock pliers
4 TORCA clamps
Standard wrench set
Remove Stock Exhaust
Disconnect the rear taillight wiring by removing the screw holding the clip on using a screwdriver.
Disconnect the bed pins using your hands. Remove the bed with a partner by lifting it off of the Rhino.
Remove the stock heat shield and stock exhaust system by removing the bolts with a ratchet and socket.
Remove each gasket and inspect them for cracks. If any of the gaskets are deformed, replace them during installation.
Installing New Exhaust
Install the mount bracket that came with the kit. This mounts where the new muffler will be positioned. Do not tighten the bolt completely at this point.
Install the new head pipe into the stock header near the engine.
Place a clamp over one end of the new muffler and slide it onto the head pipe. Hand tighten the clamp.
Attach the muffler using a bolt to the factory vibration mount. Make sure the muffler is in line with the head pipe before tightening the bolt with a ratchet and socket.
Align the head pipe with the muffler and tighten the clamps using a ratchet and socket.
Items you will need