Removing the Exhaust on a KTM ATV

Driving your KTM all-terrain-vehicle can be a lot of fun, but over time all the elements like dirt and water can begin to take their toll on the various parts of the four-wheeler. The exhaust pipe and muffler are splashed on and exposed often and are susceptible to rusting out quickly. When the muffler and exhaust pipe do rust out, you can replace them easily with a few tools in your own garage.


1)ย Allow the KTM ATV to cool down for a couple hours before you work on the exhaust muffler as it is very hot when you first shut off the four-wheeler.

2)ย Fit the proper wrench on the six bolts holding the shield over the muffler. The muffler is located on the rear, right side of the ATV. Remove the bolts and pull the aluminum shield out from under the muffler.

3)ย Fit the correct wrench on the four bolts that connect the muffler to the exhaust pipe that extends from the ATV engine

4)ย Unscrew the bolts holding the muffler in place and pull the muffler off the exhaust pipe.

5)ย Follow the exhaust pipe the muffler was bolted to to where the pipe is bolted onto the exhaust port on the side of the engine block.

6)ย Unscrew the two bolts holding the exhaust pipe onto the side of the engine block with the proper wrenches. Pull the exhaust pipe out the back out the KTM ATV. Peel the gasket off of the exhaust port on the side of the engine block with your fingers.

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