Repairing Your Dirt Bike Exhaust Pipe

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If you consider yourself a bit of a backyard mechanic and your dirt bike exhaust pipe (two stroke) has more craters in it than a teenagers face, and you don’t have the cash for a sparkling new FMF pipe… then follow these simple steps to bring her back to shape.

With a bit of effort you can increase the performance and sharpen up the look of your bike which will add to the resale price.

The process goes something like this..

You need to seal tight both ends of the pipe with some sort of plug, or bung, then apply air pressure into one end while heating up the trouble spots with a blow torch. This will push out most larger dents your pipe has to offer.

  • Find or make up a couple of plugs to block both ends of the pipe. We used a bolt and nut system with a thick rubber bush. When tightened inside one end of the pipe, it expands forming a tight seal. On one of the plugs you need to have an air valve so you can apply air pressure into the pipe. Make sure you stand clear of the plug ends. Too much air pressure and these puppies blow out like rockets!
  • Using a gas torch – apply heat directly to and around the trouble spot. You will need to get it red hot. Be careful that you don’t burn a hole right through the pipe though. Apply air pressure carefully at the same time and watch the dents pop out.
  • Once you have taken all the dents out, give your dirt bike exhaust pipe a good ol’ sanding to smooth it over and prepare it for a paint job.
  • Give her a paint job! Make sure you use heat resistant paint here, otherwise it’ll peel off. I used a matt black paint which helps to hide the smaller dents. A glossy finish will only reveal them.

And there you have it… almost as good as new!

Final Note: If you are not mechanically inclined – find someone who is who can do this. This is a potentially dangerous procedure so make sure you wear the proper protective clothing and be sensible about it.

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Jim Harmer

I'm the co-owner of Dirt Bike Planet. I live in Star, Idaho and enjoy dirt biking with my wife and two boys throughout the Idaho mountains.

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