Removing stock muffler - KTM Duke 390 Forum
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post #1 of 18 Old 05-30-2014, 02:05 AM Thread Starter
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Removing stock muffler

Hey guys having a hard time removing the factory exhaust!
Anyone removed theirs? All bolts are out and it's very loose it just won't drop out!
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post #2 of 18 Old 05-30-2014, 02:50 AM
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Take your belly pan off, once you take that away it will slide down and forwards. When you mount the header pipe into your new link pipe be careful not to pinch the gasket rings, the room can be a bit restricted. Its also easier if you loosen or remove the header, just depends how much room you need. Also the long bolt in the bottom front has a big shim thats super tight, you may need to wiggle and work it out from the frame. Yep its a p***k of a job!
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post #3 of 18 Old 05-30-2014, 04:43 PM
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Quote:
Originally Posted by Dan1 View Post
Take your belly pan off, once you take that away it will slide down and forwards. When you mount the header pipe into your new link pipe be careful not to pinch the gasket rings, the room can be a bit restricted. Its also easier if you loosen or remove the header, just depends how much room you need. Also the long bolt in the bottom front has a big shim thats super tight, you may need to wiggle and work it out from the frame. Yep its a p***k of a job!
The definition of P-I-T-A !
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post #4 of 18 Old 06-03-2014, 12:44 AM Thread Starter
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Thanks guys yeah it was a pig to remove.
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post #5 of 18 Old 07-07-2014, 04:25 AM
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Hi guys. I was actually going to make a video on this. The problem is all to do with the two lower mounts that has the steel rod that sits in the middle of them that the long bolt runs through. I think what happens is when they tighten it up at the factory it squeezes these mounts together on either side which makes it near impossible to get out.

After nearly pulling my hair out I worked out what to do. I used a t-bar and put it down through the frame next to the rear master cylinder reservoir and put the end of it on top of the steel rod with the end pushed up against the left rubber mount, then get a rubber mallet and knock it out. And yes before you do this make sure you have removed the rear belly pan mount first. And bingo out it comes. You will lose bit of paint on the lower mounts but you don't see them. This also confirms they are squeezed tight.

Also make sure you use a rag or scuff proof to protect your frame where the t-bar or what ever you are using doesn't damage the frame as it will touch it when you knocking it out.

If any one wants pics on this let me know

Last edited by hardridding; 07-07-2014 at 04:29 AM.
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post #6 of 18 Old 07-09-2014, 05:29 AM
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Removal of Std. exhaust Info,
You really have to compress the rear suspension approx 3", once compressed the silencer will drop out easily. Ratchet straps over the seat connected to the swing arm do the job. Put some cloth under the straps on the seat and on the ground where the exhaust will land to stop damage. There is no clearance otherwise and you will damage paint etc.
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post #7 of 18 Old 07-09-2014, 04:39 PM
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will give that a go next time Mac, thanks for the tip.
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post #8 of 18 Old 07-09-2014, 05:22 PM
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next time around shoot a vid, someone!
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post #9 of 18 Old 06-22-2016, 05:31 AM
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videos someone!!
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post #10 of 18 Old 06-22-2016, 08:11 AM
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This thread from the RC forum has a helpful discussion and photo of stock exhaust removal.

http://www.rc390-forum.com/forum/eng...+stock+exhaust

Cheers, Will

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