How to Install a BSA Motorcycle Exhaust

Written by william machin
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How to Install a BSA Motorcycle Exhaust
Install the BSA header clamps with the bolts facing in for a clean look. (Jupiterimages/ Images)

BSA's line of motorcycles includes a number of single-cylinder and twin-cylinder road bikes and dirt bikes. The exhausts for both types consist of a header pipe and a muffler tailpipe. Dirt bikes, like the B25 Star Fire, have scrambler exhaust with a heat shield to protect the rider's legs. BSA header clamps and exhaust clamps hold the exhaust in place at the engine's exhaust manifold and the motorcycle frame. For single-cylinder or twin-cylinder engines, you install a BSA motorcycle exhaust in a work area using standard gauge tools.

Skill level:

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Things you need

  • Exhaust kit (year and model of your motorcycle)
  • Standard gauge socket and ratchet

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  1. 1

    Park the motorcycle on the kickstand or centre stand in the work area.

  2. 2

    Organise the header pipe and muffler tailpipe on a blanket or towels to prevent scratching the chrome finish. If you are installing dual exhaust, start with one exhaust set-up.

  3. 3

    Slide the header clamp onto the straight end of the header pipe (lower end) and all the way to the flared end that attaches at the manifold. Make sure the flat side of the clamp is against the flared end of the header pipe. Lay the header pipe flat.

  4. 4

    Remove the compression bolt and nut from the muffler exhaust clamp counterclockwise with a standard-gauge socket and ratchet. Set the bolt and nut nearby.

  5. 5

    Slide the exhaust clamp onto the front (larger end) of the muffler tailpipe. Insert the front of the muffler into the lower end of the header pipe. For scrambler exhaust, rotate the muffler so the heat shield tabs are facing up. The heat shield is installed once the exhaust is mounted on the motorcycle.

  6. 6

    Lift the muffler tailpipe and header pipe into position at the motorcycle frame. Ask an assistant to hold the tailpipe section in place. If an assistant is not available, use a length of insulated electrical wire looped around the motorcycle frame and tailpipe to hold the back end of the exhaust in place.

  7. 7

    Put the provided exhaust gasket on the exhaust manifold. Push the upper end of the header pipe and header clamp against the exhaust manifold. Rotate the header clamp so the compression bolt is facing in. This gives the exhaust a tidy appearance. Tighten the compression bolt clockwise with the socket and ratchet.

  8. 8

    Align the holes on the muffler clamp with the exhaust mount on the motorcycle frame. Insert the saved bolt through the exhaust clamp and exhaust mount. Thread the saved nut on the bolt clockwise and tighten the nut with the socket and ratchet.

  9. 9

    Position the heat shield against the tabs on a scrambler exhaust muffler. Insert the provided bolts through the shield and thread each bolt clockwise onto the appropriate tab. Tighten the heat shield bolts with the socket and ratchet.

Tips and warnings

  • Some models have a pair of muffler tailpipe clamps. Align each clamp with the mounts on the frame and insert the bolts into each before tightening the nuts.

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