How to Repair a Motorcycle Exhaust Pipe How to Repair a Motorcycle Exhaust Pipe

What You'll Need
Owner's manual
A wrench
A wire brush
Cold-weld compound
Wire mesh
Metal sheeting
Muffler clamps
Protective eye wear

A motorcycle exhaust pipe that is uncommonly noisy may need to be repaired. Repairing or replacing a dented exhaust pipe on a motorcycle is a fairly simple task. A pipe which has developed a hole can be temporarily fixed at home but it will need to be permanently repaired by a professional service person.

Step 1 – Safety

Park the motorcycle on a hard, flat surface. Be sure the ignition is in the off position. Allow the engine enough time to cool completely. Read the owner's manual provided by the manufacturer before you begin. Find the information regarding the exhaust pipe replacement. Be sure to put on protective eye wear before you begin working.

Step 2 – Repairing a Dent

Use a wrench to loosen and remove the bolts that secure the exhaust pipe in place. Place the bolts in a safe place until you need them again. Remove the exhaust pipe from the motorcycle. Use a garden hose to fill the exhaust pipe with water. Freeze the water inside the exhaust pipe by placing it into the freezer. When the ice freezes, the water will expand. The expansion of the frozen water will force the dent out of the pipe. Every four hours check the dent on the pipe. It should be gone within a day. If not, remove the pipe from the freezer and allow it to thaw. Refill it with water and place it back into the freezer. Continue the process until the dent is completely gone. When the repair is complete, position the pipe on the motorcycle. Secure the pipe in place with the bolts. 

Step 3 - Repairing a Small Hole

Use your wire brush to clean the small hole in the exhaust pipe. Remove all of the dirt and residue. Use a utility knife to cut out a piece of mesh. The piece will need to be somewhat larger than the small hole. Position the mesh over the hole. Read the directions provided by the manufacturer of the cold-weld compound before you begin. Following the instructions, apply the compound to the mesh. Allow the compound enough time to dry completely. Start the ignition on the motorcycle. Listen and check for any loud noises or leaks from the hole.

Step 4 - Repairing a Large Hole

For a larger hole, you will need to use the metal sheeting. Use metal snips to cut a piece of the sheeting large enough to cover the hole. Position the metal sheeting over the hole and secure it in place with muffler clamps. The clamps should fit snugly over the pipe without being too tight. Too much pressure applied to the pipe could cause more damage. Start the ignition to the motorcycle. Listen for any loud noises. This repair is only temporary. A permanent solution will need to be provided by a professional.

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