How to Repair a Bike Exhaust

Written by john cook
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How to Repair a Bike Exhaust
A broken exhaust can rob your bike of performance and power. (sport bike image by ann triling from

Problems with an exhaust can rob your bike of performance and power, as well as allow hot gasses out into a potentially dangerous area. Before you start the repair you should decide whether you want it permanent or use a quick fix to hold until you can get to a repair shop.

Skill level:

Things you need

  • Sockets
  • Workbench or flat area
  • Screwdriver
  • Screws
  • Washers
  • Drill
  • Epoxy metal patch
  • High-heat paint
  • New gaskets and o-rings (if they were damaged)

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  1. 1

    Examine the exhaust pipe closely to make sure you find all the damage. There may be obvious dents in the end of the pipe, but make sure there is no damage to the joints or seals further down the pipe that may have been caused by the impact.

  2. 2

    Wait for the system to cool and remove the exhaust pipe from bike. Check all the gaskets and o-rings to make sure none have been crushed by the impact.

  3. 3

    Pop out any dents in the pipe with a dent remover. If they are too large then drill through the pipe and put a washer and screw into the hole. Use the washer as a grip point to pop the dent out.

  4. 4

    File the edges of any cracks smooth, including the edges of the holes drilled to pop out the dent.

  5. 5

    Fill any holes in the pipe with epoxy metal patch or another high temperature sealant and allow it to cure over night. Paint with high temperature paint.

  6. 6

    Reinstall the exhaust pipe on the bike and replace any of the o-rings or gaskets you identified as damaged during the initial inspection.

Tips and warnings

  • Check your fix after a few rides to make sure everything is holding as it should.
  • Wait for the exhaust to cool before starting work.
  • Wait for the epoxy to cure before painting.

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