CG 125, Replacing exhaust

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

Hi, how hard is it to remove the old exhaust & fit the new one?
I have googled everything i can think of but cant find any instructions or tips.

CG-125 06 Plate

https://www.bitzforbikes.co.uk/Complete_Standard_Exhaust-ref-16496-9455-53.html

bought for £55 inc del with voucher code.

Many Thanks
Gez

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

About as easy job there it really. Unbolt old one, put new one one.

That's if nothing goes wrong, plus you should replace the gasket that sits in the exhaust outlet. Sometimes they can be tricky to see but they're in there and need to be prised out carefully and replaced. The only other thing to look out for in snapping the studs when undoing the nuts holding it on. Go easy and it should be simple job.

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

thanks m8, my current exhaust as started to blow where the weld as corroded, the shop quoted me £100 for new exhaust and fitting or £40 to fill it and weld it up.

N cee thirty · Banned Joined: 31 Jan 2010 Karma :

hardest thing is trying to keep the gasket in while getting the exhaust in place,but you'll get it after some fiddling
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

another quick question, are the two bolts that hold the exhaust to the engine just like normal screws
i.e
slacken and unscrew
replace exhaust and screw studs back in?

thx guys

N cee thirty · Banned Joined: 31 Jan 2010 Karma :

yeh
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

The Shaggy D.A. · Super Spammer Joined: 12 Sep 2008 Karma :

And don't over tighten.

(Note to self, don't do a google image search for "stretched stud".)
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gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

okey thx guys

Scotsman37 · World Chat Champion Joined: 17 Aug 2004 Karma :

Just in case it's not a single unit exhaust system but rather in two parts you may need to smear some exhaust sealant at the point where the downpipe goes into the can because you will always have very slight imperfections depending how good their manufacturing process is due to sizing/measuring is an approximate and not exact science and that's why you get a gasket at the end to seal between the downpipe and the outlet from the engine to prevent leaking of exhaust fumes and keep the compression good!

Be aware the nuts holding the exhaust collar in place to keep the downpipe in may have corroded and therefore be wary not to round off the nuts and so use a good tight fitting spanner probably be a 8mm or 10mm on whats required to the job. If it won't budge then use an impact driver instead to aid the turning of the nut and smear some copper grease to prevent it corroding.

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

just an update, got my exhaust today and fitted it but when riding it makes a blubbery sound, i took it to a mechanic who said its leaking abit from front.

do you guys think this is the problem or just a shitty exhaust lol.

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

Did you replace the gasket?

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

the old one didnt seem to have one, so i brought one and stuck it in.

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

It can often seems like there's not one in there as it sits inside the head and covered in crap. If you take off the exhaust, take out the new gasket and have a poke around gently with a small screwdriver and you'll probably find the old gasket. Gently prise it out and refit with a new gasket.

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

which is the best way to refit the exhaust because first time i screwed it in head first but then it wouldnt lineup at the silencer hole.

is there a special nack toit

fiery tupp · Trackday Trickster Joined: 24 May 2010 Karma :

I would normaly , stick gasket in the head with grease , fit the pipe hand tight to head , while supporting silencer * because most of the time,
you can't get the downpipe in the head when it is fitted to the bracket first *, fit the bolt in the bracket loose , tighten at the head , then at the bracket . * Edited *
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If you can't fix it with a hammer , use your head .

Scotsman37 · World Chat Champion Joined: 17 Aug 2004 Karma :

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

any easy way to get the gaskets out, cant get them out

..... · Quote Me Happy Joined: 15 Jan 2005 Karma :

I've just used a small screwdriver to prise them out in the past. Just don't get frustrated, be gentle but firm and get those bad boys out.

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

i got the gasket out that i put in, behind it is another round copper ring, the outta ring seems to be compressed is it a gasket?

Scotsman37 · World Chat Champion Joined: 17 Aug 2004 Karma :

Yes!

Once replaced and you've ridden the bike for a while check on the nuts again holding the downpipe in place because you may have to tighten them up a fraction bit more as the copper gasket may get a little bit compressed causing a very slight leak due to metal expanding then contracting overtime!

N cee thirty · Banned Joined: 31 Jan 2010 Karma :

yup,use a small fat head to prise it out,did one today

the exhaust is a right pig to get on with the gasket in place,would be better if you had someone hold the gasket in while you get the exhaust lined straight in Thumbs Up

____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

put old pipe on cause i need it for work tomorrow. i couldnt get the gasket out it was just breakin up.

neil. · World Chat Champion Joined: 24 Feb 2008 Karma :

Copper grease the new gasket and screws before refitting as well, which will help with later removal and create a good seal. Thumbs Up

gezza2009 · Two Stroke Sniffer Joined: 17 Feb 2009 Karma :

thx for the info guys, can someone give me some tips to remove this gasket.

it looks like the crushable type as the outta edge it crushed.

N cee thirty · Banned Joined: 31 Jan 2010 Karma :

lol heres one i did earlier

https://i825.photobucket.com/albums/zz176/robyarr/DSC00867.jpg
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once