Dirt bike exhausts are vulnerable to damage.
Dirt bike exhausts are designed to withstand minor spills or collisions. The unexpected can happen in the dirt, and the result could be a damaged or leaky exhaust system. Exhaust pipes are made from metal alloy that's relatively easy to repair. Damaged or brittle manifold gaskets are replaced during the repair. Bent or broken manifold studs can be removed and replaced. The end product is an inexpensive home workshop repair.
Instructions
1. Allow the dirt bike and exhaust system to cool down completely. Use a socket and ratchet to remove the exhaust manifold nuts. Use an open-ended wrench to remove the bolts that hold the upper end of the exhaust pipe to the catalytic converter. Ease the exhaust pipe forward, away from the engine and out of the frame to remove it from the bike.
2. Place the exhaust on a workbench. Sand the area of repair with coarse sandpaper. For large dents, use an electric drill with a 1/16-inch drill bit and drill several holes near the center of the dent. Put flat washers on self-tapping screws and drive the screws about half way into the holes with a screwdriver. Attach the teeth of a dent puller under a flat washer and tighten the tool. Alternate screws to pull the dent out in stages.
3. Use a flat file to smooth the drilled penetrations. Complete prepping the area with sandpaper. Wipe the excess debris away with a rag.
4. Mix a batch of epoxy metal patch according to the instructions. Use a putty knife to apply the epoxy to the damaged section. Allow the patch to dry overnight. Sand the area smooth and paint it with high-heat paint.
5. Repair a broken manifold stud by drilling a 1/8-inch hole in the end of the broken stud. Insert an easy-out tap in the hole. Use an adjustable wrench to turn the tap counterclockwise and remove the broken stud.
6. Thread the nut on a new manifold stud and tighten it to the shoulder on the bolt. Thread the other end of the stud into the manifold and tighten it using an open-ended wrench on the nut. Remove the nut from the stud.
7. Install a new manifold gasket into the flange on the exhaust pipe. Insert the exhaust from the front of the bike. Align the upper end of the exhaust pipe with the catalytic converter, and push the front of the exhaust onto the manifold studs. Tighten the manifold nuts and reattach the catalytic converter.
Tags: exhaust pipe, catalytic converter, bike exhausts, broken manifold, broken stud, Dirt bike exhausts
