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RS50 Tech Tips

Removing the stock exhaust

Removing the stock exhaust:
Before we can remove the cylinder to install the big bore kit, the exhaust system must be removed. 

This is a simple process, the pipe is held in only three places.  The front of the exhaust is held on by two springs which are easily removed by using a proper spring puller tool (see picture 1).  These tools are available at auto parts stores for working on drum brake set ups and are usually very inexpensive. 

The middle and rear of the exhaust system are held on by M8 bolts which are removed by using a 6mm Allen key wrench.  The middle bolt is underneath the bike (see picture 2).  The rear is the exhaust hanger bracket. These bolts go into rubber dampeners, but do occasionally need to be held from the back side by a 13mm box end wrench.  Try not to damage these dampeners, as they will keep your pipe from stress cracking as time goes on. 

Now that all the fasteners are removed, the exhaust will still be attached to the cylinder because it slips in to the cylinder.  Pull the exhaust away from the cylinder and twist it at the same time, this part can seem like it will take forever, but it will eventually come loose. 

Reinstallation of your new pipe will follow the same procedure in reverse. 

Tip: When installing a new pipe, it helps to lube the header pipe with a bit of two stroke oil to allow it to easily slide through the o-ring inside the cylinder.

 

Proceed to Step 5: Removing the Head, Cylinder, Wristpin, and Piston

Click on each picture for full size detail

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2

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