How To Install Slip On Exhaust Sv650: A Step-by-Step Guide

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So, you’re ready to upgrade your Suzuki SV650 with a new slip-on exhaust? Excellent choice! Swapping out the stock exhaust for something aftermarket is a fantastic way to improve the sound, looks, and potentially the performance of your bike. This guide will walk you through the entire process, making it easy even if you’re a beginner. We’ll cover everything from the tools you’ll need to each step of the installation, ensuring a smooth and successful project.

Before we dive in, remember to prioritize safety. Always work in a well-ventilated area, wear appropriate safety gear (gloves, eye protection), and take your time. Rushing the process can lead to mistakes and potential damage to your bike or yourself. Let’s get started and transform the sound of your SV650!

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What You’ll Need

Before you even think about touching your bike, gather all the necessary tools and supplies. Having everything ready will make the installation process much smoother and less frustrating. Here’s a comprehensive list:

New Slip-On Exhaust: Obviously! Make sure it’s specifically designed for your SV650 model year.
Socket Set: A good quality set with both metric and possibly imperial sockets. You’ll likely need sockets ranging from 8mm to 14mm, and possibly larger depending on your bike and the exhaust.
Wrench Set: Similar to the socket set, a good set of wrenches (metric).
Torque Wrench: Essential for tightening bolts to the correct specifications. Over-tightening can damage threads, while under-tightening can lead to leaks or parts falling off.
Allen Wrenches/Hex Keys: Many exhaust systems use Allen head bolts. Make sure you have a complete set.
Penetrating Oil (e.g., PB Blaster or Liquid Wrench): This is a lifesaver if any of the exhaust bolts are seized or rusty.
Anti-Seize Compound: Prevents bolts from seizing in the future.
Gloves: Protect your hands.
Safety Glasses: Protect your eyes.
Jack or Lift (Optional but Recommended): Makes accessing the exhaust much easier.
WD-40 or Similar Lubricant: For helping slide the new exhaust components together.
Shop Rags: For cleaning and wiping up spills.
Owner’s Manual: To find torque specifications for your bike.
Optional: Exhaust spring puller (makes removing and installing exhaust springs easier).

Step-by-Step Installation Guide

Now, let’s get down to the nitty-gritty of installing your new slip-on exhaust. Follow these steps carefully, and you’ll be enjoying that sweet new sound in no time.

Step 1: Preparation Is Key

Before you start, make sure your SV650 is cool. Working on a hot exhaust is a recipe for burns. Place the bike on a level surface and either put it on a stand or jack it up for easier access. Disconnect the negative (black) terminal of your battery. This is a good safety practice whenever you’re working on the electrical system. (See Also: Won Hundred Willow Slip On Sneakers )

Step 2: Removing the Old Exhaust

This is where the real work begins. Locate the stock exhaust. You’ll need to remove the bolts or clamps that secure it to the exhaust header and the mounting bracket on the frame. Often, the slip-on is held on by a clamp that secures the muffler to the mid-pipe.

Loosen the Clamp: Find the clamp that connects the stock muffler to the mid-pipe. Loosen the bolt on this clamp. You might need a wrench or socket.
Spray Penetrating Oil (if needed): If any bolts or clamps are rusty or difficult to remove, spray them with penetrating oil and let it soak for a few minutes.
Remove the Exhaust: Carefully wiggle and pull the old muffler off the mid-pipe. It might be a tight fit, so be patient and avoid forcing it. If it’s stuck, try gently tapping it with a rubber mallet.
Remove Mounting Bolts/Brackets: Remove any bolts or brackets that hold the exhaust to the frame.
Inspect and Clean: Once the old exhaust is off, inspect the exhaust header and mid-pipe for any damage or debris. Clean the mating surfaces where the new exhaust will connect.

Step 3: Installing the New Slip-on Exhaust

Now, it’s time to install your shiny new exhaust. Each exhaust system is slightly different, but the general procedure is the same.

Attach the Mid-Pipe (if applicable): Some slip-on systems require you to use the existing mid-pipe, some come with a new one. If you have a new mid-pipe, attach it to the exhaust header. Make sure the connection is snug but don’t tighten it completely yet.
Install the Slip-On Muffler: Slide the new muffler onto the mid-pipe. Again, it might be a tight fit. You can use WD-40 or a similar lubricant to help it slide on.
Align and Mount: Align the muffler with the mounting bracket on the frame. Insert the mounting bolt and hand-tighten it.
Tighten Clamps and Bolts: Now, tighten the clamp that connects the muffler to the mid-pipe and any other bolts or clamps. Use your torque wrench to tighten everything to the manufacturer’s specifications. Consult your owner’s manual or the exhaust manufacturer’s instructions for the correct torque values.
Check for Leaks: Before you start the bike, visually inspect all the connections to ensure there are no gaps or leaks.

Step 4: Final Checks and Startup

Before you fire up your SV650, double-check everything.

Torque Check: Make sure all bolts are tightened to the correct torque specifications.
Clearance Check: Ensure the exhaust isn’t touching any other parts of the bike, such as the swingarm, rear tire, or fairings.
Battery Connection: Reconnect the negative terminal of your battery.

Start the bike and listen for any exhaust leaks. You might hear a slight hissing sound if there are any leaks. If you hear a leak, shut off the engine, let it cool, and re-tighten the connections. Once everything looks and sounds good, you’re ready to ride! (See Also: Will Two Brothers Slip On Exhaust Work For Rebel 300 )

Step 5: Post-Installation Considerations

Once your new exhaust is installed and you’ve taken your first ride, there are a few things to keep in mind.

Break-In Period: Some exhaust systems require a break-in period. This allows the exhaust to fully seat and the materials to settle.
Re-Torque: After a few rides, re-check all the bolts and clamps to ensure they are still properly tightened.
Fuel Mapping (Optional but Recommended): Changing the exhaust can affect your bike’s air/fuel ratio. While not always necessary with a slip-on, consider getting your bike remapped or installing a fuel management system (like a Power Commander) to optimize performance and prevent potential engine damage.
Sound Check: Enjoy the new sound of your SV650! Be mindful of noise regulations in your area.

Specific Considerations for the Sv650

While the general steps above apply to most slip-on exhaust installations, there are a few specific things to keep in mind when working on an SV650:

Model Year Specifics: The SV650 was produced over many years, and there might be slight differences in the exhaust mounting points depending on the model year. Double-check that the exhaust you purchased is compatible with your specific year.
Exhaust Springs: Many SV650 exhaust systems use springs to secure the muffler to the mid-pipe. Use an exhaust spring puller to easily remove and install these springs. If you don’t have a puller, a pair of pliers can work, but be careful not to damage the spring or the exhaust components.
O2 Sensor (if applicable): Some SV650 models have an O2 sensor in the exhaust. Make sure to transfer the O2 sensor to the new exhaust if your new system requires it. Be careful not to damage the sensor.
Heat Shields: Consider retaining the heat shields from your stock exhaust, or purchasing aftermarket heat shields, to protect yourself and the bike’s components from the heat generated by the exhaust.

Troubleshooting Common Issues

Sometimes, things don’t go perfectly according to plan. Here are some common issues you might encounter and how to address them:

Exhaust Leaks: If you hear a hissing sound, you likely have an exhaust leak. Check all the connections and re-tighten the bolts and clamps. Make sure the gaskets are in good condition.
Difficulty Removing Bolts: If a bolt is seized or rusty, apply penetrating oil and let it soak for a while. Use the correct size socket or wrench and apply steady pressure. Avoid stripping the bolt head.
Muffler Won’t Slide On: Use WD-40 or a similar lubricant to help the muffler slide onto the mid-pipe. You might also need to gently tap it with a rubber mallet.
Vibrations: If you experience excessive vibrations, make sure all the bolts and clamps are tightened properly. Check for any contact between the exhaust and other parts of the bike.
Engine Running Poorly: If your bike runs poorly after installing the exhaust, it might need a fuel map adjustment. Consider getting your bike dyno-tuned or installing a fuel management system.

Safety First: Important Reminders

Safety is paramount when working on your motorcycle. Always follow these safety guidelines: (See Also: Will You Lose Low End With M4 Slip On Fz07 )

Wear Safety Gear: Always wear gloves, eye protection, and appropriate clothing.
Work in a Well-Ventilated Area: Exhaust fumes can be harmful.
Let the Bike Cool Down: Never work on a hot exhaust.
Use the Correct Tools: Using the right tools will make the job easier and safer.
Follow Torque Specifications: Over-tightening or under-tightening bolts can cause problems.
Double-Check Your Work: Before starting the bike, double-check all connections and ensure everything is secure.
Consult a Professional: If you’re not comfortable with any part of the installation process, consult a qualified mechanic.

Maintenance and Care

Once your new slip-on exhaust is installed, proper maintenance will ensure its longevity and performance.

Regular Inspections: Periodically inspect the exhaust system for any leaks, damage, or loose bolts.
Cleaning: Clean the exhaust periodically to remove dirt and grime. Use a suitable cleaner for your exhaust material (stainless steel, titanium, etc.).
Rust Prevention: If you live in an area with harsh weather conditions, consider applying a protectant to prevent rust.
Re-Torque Bolts: After a few rides, re-torque all the bolts and clamps.
Listen for Changes: Pay attention to the sound of your exhaust. Any changes in sound might indicate a problem.

Beyond the Slip-on: Future Upgrades

Installing a slip-on exhaust is often the first step in modifying your SV650’s exhaust system. Here are some potential future upgrades:

Full Exhaust System: A full exhaust system replaces the entire exhaust from the engine to the muffler, often providing greater performance gains than a slip-on.
Fuel Management System: To fully optimize performance, consider installing a fuel management system (like a Power Commander) or getting your bike dyno-tuned.
Air Filter Upgrade: Replacing the stock air filter with a high-flow air filter can further improve performance when combined with an exhaust upgrade.
ECU Flash: A professional ECU flash can optimize the engine’s settings for your specific modifications.

Conclusion

Installing a slip-on exhaust on your SV650 is a rewarding project that can significantly enhance your riding experience. By following this step-by-step guide, you can confidently tackle the installation yourself, saving money and gaining a deeper understanding of your bike. Remember to prioritize safety, take your time, and enjoy the process. With your new exhaust in place, you’ll not only enjoy a better sound but also potentially improved performance and a more stylish look. Now get out there and enjoy the ride!

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Always remember to double-check all connections, and if you’re ever unsure about a step, don’t hesitate to consult a professional mechanic. Proper installation is key to both performance and safety.