ADB's Tech Editor Mat Boyd shows us how fitting a YZ exhaust doesn't have to be a complicated job. Here's his tricks.
The guys at Yamaha Australia have given us a bunch of GYTR parts to test on our 2024 Yamaha YZ450 long term test bike. One of those parts happens to be a Yoshimura complete exhaust system. These pipes are made from titanium and look really trick. The Yoshimura exhaust system is easy enough to fit but removing the stock Yamaha pipe can be quite frustrating. So here is how how fitting a YZ exhaust doesn’t have to be a complicated job.
#1 SET UP
Sit the bike up on a hoist or a centre stand so that the bike is solid and not rocking around. As you will be pulling and pushing on the exhaust system while how fitting a YZ exhaust you will need the bike to be sitting steady.
#2 UNCOVERING
Remove the side number plate that covers the silencer. This is held in place by three bolts, one which bolts through and secures the seat.
#3 SILENCER REMOVAL
Remove the silencer by removing the two 10mm mounting bolts and then loosening off the exhaust clamp. You will need to twist the silencer back and forth while also pulling against it for it to come loose.
#4 GUARD THAT HEADER
Remove the exhaust guard from the header pipe before loosening off the header pipe. You will need to reuse this guard and mounting screws so do not discard them.
#5 HAVE THE 10MM READY
Loosen off the exhaust clamp and then remove the 10mm mounting bolt from the front of the mid pipe. Then twist and pull the mid pipe until it comes loose then remove it by rotating it around the cylinder and out towards the clutch side of the engine. This is the part that gets tricky and frustrating. Take your time, the pipe will only come out in one particular position.
#6 EASIER ACCESS
To get easier access to the three 10mm header pipe nuts remove the aluminium engine mount brackets from each side of the engine. This will give you straight access into the nuts so you can remove them and then remove the header pipe.
#7 HEADS UP
Fit the new header pipe and mid pipe into place but leave the bolts finger tight until you have everything lined up correctly. This is crucial to fitting a YZ exhaust. The bolt in front of the cylinder that secures the mid pipe will now come in from the right hand side instead of the left like with the stock pipe. Then tighten the mounting bolt in the mid pipe before tightening the three mounting nuts on the header pipe.
#8 RETURN THE GUARD
Once you have the header pipe and mid pipe all sitting correctly and tightened you can fit the engine mounting brackets back into place and then fit the exhaust guard onto the new header pipe and fit the mounting springs to the slip joints.
#9 SILENCE IS GOLDEN
Now fit the silencer up to the bike. Then tighten the two mounting bolts into place.
#10 COVER IT UP
Refit the side number plate back into place and then start the bike up and listen to your bikes new sound. You will get steam and a new smell come off the pipe to begin with but once this burns off the pipe will change colour and no longer smell funny. And that’s how to make fitting a YZ exhaust a little easier.
DO’S
- Use WD40 on the slip joints to make them slide in easier.
- Put never seize on the exhaust bolts to prevent them from seizing up over time.
- Make sure the exhaust is sitting away from any wiring or coolant hoses.
DON’T’S
- Don’t force the exhaust into position or try to bend or manipulate the exhaust in any way.
- Over tighten any of the exhaust mounting bolts or nuts.
- Touch the exhaust system once it is hot.
TOOLS:
T-bars, spanners, spring pullers, sockets, screw drivers
WARNING:
When the exhaust heats up it will burn off a protective coating. This will produce a strong smell so it is advised that you don’t start your bike for the first time indoors.
TITANIUM OR STAINLESS
Exhaust systems can range in price due to the materials they are made of. A pipe made from titanium and carbon fiber is usually the most expensive while being the lightest. The down side is that many of these exhaust systems are not super durable and tend to fall apart from vibration or break to pieces in a crash.
A pipe made from stainless steel and aluminum is heavier but much more durable and robust. They tend to last longer and can handle crashes a little better.