Customizing the exhaust system on your Everyday Motorcycles Voyager 800 is one of the most effective ways to enhance both the bike’s performance and its auditory character. A well-chosen and properly installed exhaust upgrade can transform your riding experience by improving engine efficiency, increasing horsepower, reducing weight, and producing a more satisfying sound that matches your personal style. Whether you seek a deep, throaty rumble for cruising or a sharp, aggressive roar for spirited rides, the right exhaust modifications will make a noticeable difference in how your Voyager 800 feels and sounds on the road.

Why Customize Your Exhaust System?

The stock exhaust system on the Voyager 800 is designed to meet regulatory standards and general rider needs, which sometimes limits its performance potential and sound quality. Customizing the exhaust system addresses these limitations by offering several key benefits:

  • Improved Performance: Aftermarket exhausts can significantly improve the flow of exhaust gases, reducing backpressure and allowing the engine to breathe more freely. This can lead to increases in horsepower and torque, particularly when paired with proper engine tuning.
  • Weight Reduction: Many aftermarket exhausts use lightweight materials such as titanium or carbon fiber, which reduce the overall weight of the bike. A lighter bike improves handling, acceleration, and fuel efficiency.
  • Enhanced Sound: Custom exhausts allow you to personalize the sound profile of your Voyager 800. Whether you prefer a deep, mellow growl or a loud, aggressive bark, an aftermarket system can deliver the tone and volume you desire.
  • Visual Appeal: Beyond sound and performance, exhaust upgrades can dramatically improve the aesthetic of your motorcycle. Sleek designs and premium materials add a custom look that complements the Voyager 800’s styling.

Overall, customizing your exhaust system is not just about performance gains; it is also about creating a motorcycle that reflects your personality and riding preferences.

Understanding Different Types of Exhaust Systems

Before diving into installation, it’s essential to understand the various types of exhaust systems available for the Voyager 800 and what each offers in terms of complexity, cost, and performance:

Slip-On Mufflers

Slip-on mufflers are the most straightforward and popular exhaust upgrade. These replace only the muffler section of your stock exhaust, leaving the headers and mid-pipes intact. Slip-ons are typically easier and quicker to install, require minimal modifications, and are usually more affordable. They provide a noticeable improvement in sound and a modest performance increase by reducing weight and improving exhaust flow.

Full Exhaust Systems

Full exhaust systems replace the headers, mid-pipes, and mufflers. This comprehensive upgrade offers the greatest performance gains because it optimizes exhaust flow from the engine to the tailpipe. Full systems are designed to work as a unit, maximizing horsepower, torque, and throttle response. Installation is more involved, and these systems are generally more expensive but deliver the highest level of performance enhancement.

Custom Headers

Custom headers are aftermarket exhaust manifolds that replace the stock headers. They are designed to improve exhaust scavenging and flow, which can increase power output. Headers are often part of full exhaust systems but can sometimes be installed separately, depending on compatibility. Custom headers require precise fitment and may need professional installation.

Exhaust Inserts and Baffles

For riders who want to fine-tune their exhaust sound without changing the entire system, inserts and baffles can be added or removed to adjust noise levels and tone. These components are especially useful for meeting local noise regulations while maintaining a customized sound.

Choosing the Right Exhaust for Your Voyager 800

Selecting the appropriate exhaust system depends on your performance goals, budget, and personal preferences. Here are some important factors to consider:

Performance Goals

Identify whether your priority is increased horsepower, better throttle response, sound enhancement, or a combination of these factors. For maximum power gains, a full exhaust system paired with engine tuning is ideal. If you want a better sound with minimal hassle, slip-on mufflers are a great choice.

Material Considerations

  • Stainless Steel: Durable and corrosion-resistant, stainless steel exhausts are common and provide a good balance between price and longevity.
  • Titanium: Titanium exhausts are lightweight and highly corrosion-resistant but tend to be more expensive. They also develop a unique blue or golden hue with heat, adding to the visual appeal.
  • Carbon Fiber: Often used for muffler shells, carbon fiber is extremely lightweight and offers a sleek, modern look. While not suitable for headers, it is excellent for reducing muffler weight and heat transfer.

Compatibility and Fitment

Always ensure the exhaust components are specifically designed or compatible with the Voyager 800. Using parts that do not fit correctly can cause installation issues, exhaust leaks, or even damage to the engine. Consult manufacturer specifications and forums to confirm compatibility.

Some aftermarket exhausts may not comply with local noise or emissions regulations. Before purchasing, verify that the exhaust system is street legal in your area to avoid fines or inspection failures. Consider options with removable baffles or spark arrestors if you ride off-road or in restricted zones.

Preparing for Installation

Proper preparation helps ensure a smooth installation process and optimal results. Follow these guidelines before modifying your Voyager 800’s exhaust:

  • Gather Tools and Equipment: Typical tools include socket wrenches, screwdrivers, penetrating oil, torque wrench, and safety gloves. Having a service manual for the Voyager 800 is highly recommended.
  • Work in a Safe Environment: Perform the installation in a well-ventilated, clean space with adequate lighting. Use a motorcycle stand or lift for stability.
  • Allow Exhaust to Cool: If the bike has been recently ridden, allow the exhaust system to cool completely to prevent burns.
  • Inspect Stock Exhaust: Check the stock system for damage or rust that may complicate removal. Apply penetrating oil to bolts if they appear seized.

Step-by-Step Installation Guide

While specific steps may vary depending on the exhaust brand and type, the general procedure for installing an aftermarket exhaust on the Voyager 800 is as follows:

1. Remove the Stock Exhaust

Begin by loosening and removing the mounting bolts and clamps holding the stock exhaust in place. Carefully detach the muffler and headers, taking care not to damage gaskets or exhaust flanges. Keep any reusable hardware unless the new exhaust comes with replacements.

2. Inspect and Replace Gaskets

Inspect the exhaust gaskets located between the engine ports and headers. Replace them if worn or damaged to ensure a proper seal and prevent leaks.

3. Install New Headers and Mid-Pipes (If Applicable)

If installing a full system, start by attaching the new headers to the engine exhaust ports, hand-tightening bolts to secure position. Connect the mid-pipes according to manufacturer instructions, ensuring proper alignment.

4. Attach the Muffler or Slip-On

Install the muffler or slip-on muffler onto the mid-pipe or stock pipe, depending on your system. Use supplied clamps or brackets to secure the muffler firmly but avoid overtightening, which can damage components.

5. Torque All Fasteners

Using a torque wrench, tighten all mounting bolts and clamps to the manufacturer’s specified torque values. Proper torque prevents leaks and ensures the system remains secure during operation.

6. Check for Clearance and Fitment

Verify that the exhaust system has adequate clearance from the frame, swingarm, footpegs, and other components. Adjust positioning if necessary to prevent rattling or contact during riding.

Tuning and Adjustments After Installation

Installing a custom exhaust alters the flow characteristics of your motorcycle’s engine, which often requires adjustments to maintain optimal performance and reliability. Here are essential tuning steps:

Fuel Management

Depending on your Voyager 800’s fuel system (carbureted or fuel-injected), you may need to adjust the air-fuel mixture. For carbureted models, rejetting the carburetor or adjusting pilot screws can help. Fuel-injected bikes often require a remap of the ECU or installation of a fuel management module to compensate for the increased airflow.

Ignition Timing

Some riders also adjust ignition timing to optimize combustion with the new exhaust. Consult with a professional tuner or mechanic before making timing adjustments to avoid engine damage.

Dyno Tuning

For the best results, consider taking your Voyager 800 to a professional dyno tuning shop. Dyno tuning ensures that fuel and ignition maps are customized to your specific exhaust system and riding conditions, maximizing power gains and fuel efficiency.

Break-In Period

After installation and tuning, allow a short break-in period by riding gently for the first few hundred miles. This lets the new components settle and helps detect any potential issues, such as leaks or unusual noises.

Maintenance Tips for Custom Exhaust Systems

Maintaining your upgraded exhaust system is crucial for long-term performance and appearance. Follow these maintenance tips:

  • Regular Cleaning: Clean the exhaust pipes and mufflers with appropriate cleaning products to remove dirt, grime, and road salt that can cause corrosion.
  • Inspect for Leaks: Periodically check for exhaust leaks, especially at joints and flanges. Leaks can affect performance and cause unpleasant noise.
  • Check Mounting Hardware: Vibrations from riding can loosen bolts and clamps. Inspect and tighten all hardware regularly.
  • Protective Coatings: Consider applying high-temperature protective coatings to prevent rust and discoloration, especially on stainless steel exhausts.
  • Replace Worn Components: Replace any damaged or worn gaskets, seals, or baffles to maintain optimal exhaust function.

Several reputable manufacturers offer exhaust systems compatible with the Voyager 800. Some popular choices include:

  • Akrapovič: Known for premium titanium and carbon fiber systems with excellent performance and sound quality.
  • Yoshimura: Offers a broad range of slip-on and full systems recognized for their durability and performance.
  • Vance & Hines: Renowned for their signature deep tone and quality craftsmanship, Vance & Hines exhausts are a favorite among cruiser riders.
  • FMF Racing: Provides high-performance systems focused on power gains and aggressive sound profiles.
  • Two Brothers Racing: Offers stylish designs and a variety of sound options, with a reputation for quality and durability.

When selecting a brand, consider warranty coverage, customer reviews, and the availability of tuning support.

Common Challenges and How to Overcome Them

While customizing your Voyager 800’s exhaust is rewarding, it can come with challenges. Here are some common issues and solutions:

  • Fitment Problems: If parts don’t align correctly, double-check compatibility and consult forums or dealers for advice. Custom fabrication may be necessary for some setups.
  • Excessive Noise: If the new exhaust is too loud for your preference or local laws, install removable baffles or sound-reducing inserts.
  • Engine Running Rough: This often indicates improper tuning. Revisit your fuel management settings or consult a professional tuner.
  • Exhaust Leaks: Tighten bolts, replace gaskets, or use exhaust sealant to fix leaks.
  • Overheating: Some aftermarket systems may cause heat to radiate differently; ensure adequate clearance and consider heat shields if necessary.

Final Thoughts

Customizing the exhaust system on your Everyday Motorcycles Voyager 800 is a highly effective way to improve your bike’s performance, sound, and style. By carefully selecting the right type of exhaust, ensuring proper installation, and investing in thorough tuning, you can maximize the benefits of your upgrade. Remember to prioritize quality parts, adhere to safety and legal regulations, and maintain your new system for the best long-term results.

Whether you are a seasoned mechanic or a passionate rider eager to personalize your cruiser, upgrading the Voyager 800’s exhaust system offers a satisfying project that enhances every ride.