ROYAL ENFIELD Classic 350 REborn. Fitting a full FREE FLOW polished stainless Steel exhaust System!

How to fit the Hitchcock's free flow polished stainless steel Exhaust system! Also what to do if the header stud unscrews!
Hitchcock's exhaust (stainless). accessories.hitchcocksmotorcy...
PayPal Donations. [e-mail]
PATREON. / stuartfillingham

[@johnyoung3103]

Stuart: My professional life was as an aircraft mechanic, I am retired now; The application of an anti-seize compound to all stainless steel fasteners on or off the exhaust system is highly recommended, and O2 sensors for sure. The weather here in the Great Pacific Northwest is not much different than yours.

[@RGW851]

Good advice from a professional engineer. I will take that on board on my classic 350 when I do any work. Thanks.

[@MrZap773]

A family member worked on F16/F22... Simple yet great advice

[@arealassassin]

That OEM exhaust is a psychological trick- it makes the bike look bigger than it is.

[@brianperry]

You're correct Stu, Loud isn't the same as Tone....Tone is a more soothing accompaniment to your ride.

[@philmorrow2446]

Sounds absolutely spot on during tick over! Lovely noise!

[@saikrishnathiwakarrk]

Clean and it does what is said to do ... Nothing beats that

[@stevecoppin4278]

Good Morning Stu , I do like these step by step instruction video's take care Stu

[@ruso9660]

Sounds glorious, and the bike looks impeccable!

[@michaelglynn2638]

I like the way the down-drop follows the angle of the frame. Nice kit, nice job.

[@frankysworld]

Lovely looking kit for the Reborn 350, it does look more clean "classic". It being stainless steel is a plus, the finish looks great!

[@SteveInskip]

Nice vid Stuart. I much prefer the minimalist look as well. You guidance vids are really good.

[@davidwilliamson9162]

Perfect well done,thought I would have to tell you about twisting the sensor refit,but no u got it 👍 i did notice you cleaned the down pipe with a bit more aggression 😂👍

[@MrJpb2000]

Great video…certainly brought back memories for me personally doing everything you said avoid doing back! 😂 I was literally thinking to myself, don’t do this, remember to do that & you covered everything. Historically it was the only was to learn before KZbin etc…please keep the videos coming & it would be great to see the Interceptor have a Day out again this Year. 👊😎👍

[@ScrapYardDog64]

Sounds great Stuart.

[@themechanic2036]

Good how to video Stuart!

[@stevewalker2047]

Good morning Stu. Another good video. I don’t have a 350 but I do like to watch your instructional videos. I do like the crisp sound of that exhaust.

[@leswatson8563]

Morning Steward. I enjoyed watching this as it brought back some old happy memories working with some old mates on their bikes. That copper seal, I always used copperslip spray grease that you use on the back of the disk pads. I often found this helped to keep them in place. And on things like studs, I always used that gold grease when installing them. I found it helped when dismantling later. I'm guessing that's why my uncle and his biking mates got called greasers 😂😂😂. So until the next one, safe happy cruising sir 👍😊.

[@jimstewart2141]

Looks great Uncle Stu!!! Also the yoga in the video looks very relaxing, doubt i could get up after sitting crosslegged on a concrete floor these days, well done!

[@nigehicks]

Another cracking instructional video Stuart, as an aircraft technical writer your breakdown and buildup instructions are spot on, you even include warnings and cautions. Wish I could use video in the manual, it would be a great use to people with English as a second language.

[@Lee-70ish]

As usual good info for those wanting to do this👍 Kept the cat but changed the can for an import short Punjab straight baffleless . Like the look of the free flow straight however.

[@nicholasfox3670]

Lovely pair of brown brogues Sir.

[@reinmansmith]

Looks and sounds really good 👍

[@ironcast]

Those are the exact mods I did to my 2003 Harley 883 Sportster. I found online old dyno runs done by Hot Bike Magazine. Stock, a 883 had 44 RWHP. With free flow air filter it then had 50, and with added free flow exhaust it then had 55. So it was quite easy and inexpensive to make a 25% increase in RWHP. Mine was really inexpensive as I got the new air filter kit for a discounted price from someone who had never used it plus I got the older, good condition free flow mufflers for free from one of my son's friends. I then rejetted the carb and removed the cap over the fuel mixture adjust screw and richened that adjustment. It has resulted in an impressive improvement.

[@nickmann615]

Another excellent video Stuart. As usual, very thorough. Good choice of music too. Many thanks.😊

[@stuartfillingham]

Very welcomei

[@travis-bickle-84]

I do not own a RE, never have done, nor do I ever intend to. Regardless, I watched your video to the end in awe and fascination as I do all your videos. I particularly enjoyed the bit where you fingered your flange. Keep up the good content. Loyal subscriber Travis

[@BTeamHooligan]

Great video. I’m waiting for my gunmetal grey 350 to be delivered from a few states away from Baxter Cycles (our U.S. equivalent to Hitchcoks). When I bought I got 25% off any accessories and free install. I went ahead and got the Hitchcock exhaust, Fuel X Lite, DNA, and a few other goodies. I was looking forward to doing the mods myself but free is free and they’re the top-dogs for RE in the states so I said “why not”. There will be plenty of other maintenance and work to do. I was worried the stainless exhaust would look “off” with the matte black engine, but I have some pictures and it looks really good. Still might get the silver exhaust flange ring from Hitchcocks, but I’ll wait till I can see in person. Definitely a bit unique among most Classic 350’s. Thanks as usual for the great videos and information you provide!

[@petrol_head_garage]

Again Stuart, mate, amazing video! :) Thank you so much, I am waiting for a black version of this exhaust system as I have Signals Marsh Grey edition. Cheers and I hope you will get some fine weather soon, I am interested about performance impact. Cheers!

[@SymetryofOne]

Hi Stuart. Just a quick tip. If you struggle again to get the nut off the stud, you can use 2 nuts on the threaded end and then use the nut closest to the nut you need to remove as an anchor point. Hope that makes sense. Thanks for all your content

[@johnterry804]

Looks and sounds great 👍 good video!

[@GT380man]

I like the copper gasket. I can see that it’s designed to distort to take up the space fully. The gaskets on my old Suzukis are wound wire in a fibrous material. They are pretty good at crush sealing, but I think the OEM gaskets are rather expensive, especially if I’m replacing all three. That stud, I’m sure I’d have done the same as you. It would bug me, though, and afterwards, I’d probably buy a spare stud & dome nut for my parts store, for next time 😊 Nice video, Mr Fillingham.

[@EastboundDwn]

Sold! I just ordered this exhaust from Hitch.. I, too, feel the same way about the bulky size of the OEM system. I'm looking forward to it.

[@herby4215]

Great upgrades

[@willg4944]

Aye up, I just felt the need to leave a comment. Your instructional videos are by far some of the best I have ever seen. I have personally used them to assist me in changing the seat, adding the panniers, and changing the oil. Great commentary and outstanding camera angles. Obviously you have given these a lot of fore thought. Brilliant work. Signed, a RE 350 Classic owner and Anglophile from across the pond. 👍

[@stuartfillingham]

Wow, thanks!

[@andrewmeads6136]

Seconded! It’s got to the point where the music we hear in this video plays in my head as I work on the bike. Thanks Stu.

[@johnk7814]

It does look better than the OEM , much slimmer design and saving all the weight is always a plus. I just changed my interceptor exhaust gaskets, I found using a angled pick from auto supply works much better than screw driver with no marks on the cylinder head. Also a dap of grease on the gasket will hold that gasket in place making putting on the exhaust easier grease will just burn off when you start the bike again.☺

[@martymcfly6501]

Great job!!

[@ianmcdiarmid4563]

Oh! Sounds like some road works! Probably better in person.

[@user-cj1uz3mn2l]

Usual interesting video, the exhaust looks and sounds very good. My Bullet 500 UCE has a Hitchcocks exhaust fitted (with baffles) when I bought it, next job is to fit a DNA air filter, although as far as I know there is not a modified intake available for the Bullet. I fitted the complete stage two filter and intake on my classic 350 and it certainly ran and sounded much better. Agree with the comment below regarding using anti seize grease, I use a general purpose sticky grease and wet assemble all fasteners all over the bike. Thanks for the video, Tim.

[@stuartfillingham]

Most fasteners are isolated with rubber mounts so that wouldn't be of much use Most as you may see by the blue marks are actually loctited.

[@skotty1962]

Looks great Stuart. I had the same thing with the stud bolts on my Hunter when I had to remove the exhaust to put the crash bars on. Wonder if Hitchcocks do a black version for the Hunter. Must check.

[@robertlamontweber5865]

Cool pipes

[@Vikrum_]

Nice watch Stuart

[@MyRoyalEnfieldTravels]

My C500 originally came with the upswept exhaust but when it cracked I replaced it with the oem straight exhaust cause that’s all that was available at the time and I absolutely hate the look and sound of it. As much as I want an upswept exhaust again they are hard to find so this looks like a good alternative

[@craigwilson8228]

My dark stealth exhaust completely rusted out. Now fitted decat and black widow silencer.

[@Curly-xi7dz]

Hi Stuart, Sorry for asking a question that has been answered before, regarding the MOT. I should have read all the previous comments. I am sorely tempted to get the RE Classic 350 to get the same buzz I got when I first had the freedom of biking, though we didn't need helmets then!

[@stuartfillingham]

No problem Curly!

[@electrobob1]

Hello Stuart, Today I was highly amused when driving a demo classic350 from a local dealer. Having a Guzzi Griso now, air cooled Ducatis and a Yamaha Trailway 125(12hp) before, I was expecting a bit more power than the TW125 and the classic350 deliveres should be ample and it did. I was amazed on the lack of vibrations, sit on top of the bike seat position (straight spine instead of a bend back I experienced on my Vespa gts300) and the superb gearbox! The stock version has near nothing to be complained about IMO on only 2 details: -the throttle grip needs more force to actuate as expected. -Stock sound is lovely when parked and revved, but on the move the base note gets into a monotone low, loud bass humm without hearing any "thumbing" I would expect from a single. Wether this is intake noise or exhaust leaves me clueless but this would recommend earplugs to dampen engine noise (not the wind!) for comfort which might shy me away from a purshase... Can you give some comment on this? Other than this, the lack of vibrations... not sure if this is a good thing regarding character I never drove a bike without this feature near as smooth as an EV... Love aircooled engines twins and singles and I'm quite dazzled the J engine is too good😅 kind regards, Erik

[@nathanhenry.]

Thanks!

[@stuartfillingham]

Thank You Nathan.

[@richardcrighton8079]

i had the freeflow for a while but it's just too loud. i went back to the OEM version but added the decat. now, it's perfect. i've also done the dna, fuelx and kent cam stuff so it's a bit of a rocket these days. :D

[@rossdarling5975]

Luv ya intro music taste

[@jroberthadden]

Nice looking and sounding exhaust. I'll be very interested to see if you believe if this has helped performance in a real world sense. I'm still holding out for a 500 cc version of this, or the Bullet. As I've mentioned before, I'm 220 lbs and, out here in the wild west, the 350s that I have ridden just don't have the grunt needed to pull my butt up these long grades at a decent clip.

[@ianbishop5951]

Another good video Stu thanks. I don't have a 350 classic yet but will do at some point. How will this exhaust affect emissions and MOT test?

[@Coastriderscotland]

You just need the Hitchcocks Performance Camshaft now to complete your bikes upgrades, it has been the best upgrade! 😁👍 Cheers Bruce

[@a1coyote]

Just wanted to say that your site is one I visit often , and I enjoy the scenery from your region as much as I do of what you have done with your Classic 350. Very cool to see you here too. Cheers.

[@lowersaxon]

Do what you want, you will never be able to overtake any motorized vehicles, except even smaller-heavier-more underpowered two-wheel things.

[@Coastriderscotland]

@@lowersaxon can overtake loads of other traffic! 🤣

[@simonchilli2088]

Nice little tip there of turning the ECU wire anti clockwise before re-threading it. Another YTer thinx that some subscribers who watch the videos on tv get their subscriptions turned off as they are using a remote control to navigate thru the screen functions. The subscribe button is hidden from view and possibly can be switched on or off by mistake.

[@user-yv3mu5vx7z]

Neat job Stuart. Will you be fitting a Fuel X?

[@DR-lg6xr]

when are you going to fit the performance camshaft Stuart..... i'd love to hear your thoughts on it.

[@Curly-xi7dz]

Great video Stuart. I have not ridden a motorbike for many years, but watching these videos has got me interested again. I have a question regarding the removal of the converter, how will this effect the MOT? Will the exhaust emissions be off the recommended scale?

[@stuartfillingham]

No Emissions testing at MOT.

[@mihalyesztergalyos4624]

nice ✌🏻

[@a1coyote]

Stu, was just admiring your new exhaust on this video, and I was just reminded of a fellow on my side of the pond who put the same exhaust on his Classic 350 some time ago. His turned color very fast. It is a given that stainless steel exhaust pipes generally turn a golden color over time. And that a Euro 5 engine runs lean. This guy, handle Foxxy, used a heat gun to test the before & after installation of a FuelX Lite on his Classic 350, and he claimed he found a difference of around 200 degrees F in head temp. It was tough to see due to sun glare, but I noted around 150 F or so difference. Just curious, have you ever looked into the FuelX Lite for your Classic 350?

[@rosswilliams531]

Great video thanks, but I noticed you have an engine protection plate fitted? I just took ownership of my 350 Hunter this week which sounds great at the exhaust but the engine has a very metallic booming resonance to it only when riding which is very unpleasant to the ears which Ive not heard on any video I've seen or even on the demonstrator I took out so I'm wondering if it could be caused by the fitting this steel plate? I may have to remove it to test if it's the cause of this booming noise but any ideas what could be causing it is welcome or could it just be a matter of running it in?

[@brettwicks7339]

Sounds like a HONDA BUFFALO HRU196 LAWNMOWER .

[@rajatanand9120]

Hello Mr. Stuart, great video as always. Just curious about your watch. That’s an Oyster perpetual right?

[@stuartfillingham]

Yes it is!

[@mbjsrl]

Another great video, thanks ! Can you estimate the approximate gain of weight after the switching ?

[@stuartfillingham]

I would say this is 2 to 3 kg lighter

[@hardburke4910]

Thanks a lot for this video - very easy to understand all instructions! I just have one important question: Can You change the exhaust like in this video without changing the other tuning parts (like the air filter) without damaging the bike?

[@stuartfillingham]

Yes, you can

[@hardburke4910]

@@stuartfillingham Thanks a lot for Your reply!

[@rl7881]

I particularly liked the fatherly manner in which you patted the exhaust pipe after tightening the centre clamp, did you mutter “there, there” at the same time? I hope so, for the bike’s sake. The new exhaust is much more pleasing on the eye. If it looks right, it is right.

[@antonoat]

She looks and sounds like a motorcycle, lovely!

[@johnlenart597]

When running the engine for 10 minutes would it be a good idea to place a box fan on the left side to create some cooling. This was something we did on the BMW airheads when stationary running an engine? 👍👍5🏍🙋‍♂️

[@stuartfillingham]

was only 3 degrees and a bit breezy so no problems with cooling. The whole point is to fully heat cycle the engine.

[@philthorpe4549]

Undoubtedly an improvement in tone Stu. It may be just me but the new silencer looks lower with less ground clearance on the replacement?

[@buttercupbloke]

Another great video Stu👍. One question, where do you get your workshop wipes from?

[@buttercupbloke]

Thanks Stu, but that was a sincere question mate😊, where do you get your workshop wipes from?

[@johnlegrain1064]

Good vid Stuart;how did you get on with the center stand fit after removing the cat? On my Meteor I had to fit Hitchcokcs new style center stand!! Our local dealer here in France not muchuse as they dont stock enough spares!!Agree johns comments on anti seize and galling of stainless threads.

[@stuartfillingham]

All good!

[@johnlegrain1064]

Just got to figure out how to get my decatted Meteor through the soon to be intoduced MOT for bikes here in la belle france!!!!!😡

[@georgewylie9674]

That exhaust system looks great! Besides the more pleasing exhaust note, do you feel that torque and throttle response have improved?

[@stuartfillingham]

will report on that!

[@brendonhughes4580]

Stuart you mentioned that the original down pipe is a tube within a tube, mine rattles on my meteor i would say at certain temperatures possibly due to expansion. I am considering this exhaust but would like to get the silencer welded to the down pipe and then exhaust wrap from the silencer to the head, would i still be able to remove this unit as one do you think.

[@Popoplumsi]

I personally like to stay with the original parts :) however, I understand why you changed! But from India I read a lot of posts still from the “old” UCE engine with aftermarket exhausts and sometimes they really get mechanical problems because of the “free flow”. I just think, they did test the engine for months or years and came up especially with that exhaust, so maybe it’s the best not to change that :)

[@stuartfillingham]

i have had the same exhaust fitted to my classic 500 for 4 years. no mechanical issues!

[@burtvhulberthyhbn7583]

Being a single wall pipe hopefully you can get a few inches of proper looking heat blueing

[@felipedourado5721]

Hello Stuart, I got the impression that the horizontal part of the pipe sits lower (closer to the ground) then the OEM one. Doesn't it drag on the ground more easily when the bike is on its full lean in a curve? Best regards from Brazil, thanks for another pleasant video. 👍

[@stuartfillingham]

no it doesnt.

[@luigimercure4560]

Very nice but is it homologated for road use in the UK?

[@brianperry]

From what I've seen and read, UK is pretty lax in regard to Homologation. Here in Spain that exhaust would be an instant fail at an ITV inspection...(MOT)...Stu has mentioned the fitting of after-market parts on previous videos and the fact that future legislation may prohibit the fitting of other than OEM parts.. Spain already has such, as l believe other EU countries have to varying degrees...In general once the bike reaches its road worthy inspection period it's prudent to remove part/s to pass inspection.... even a tail tidy!... l know...

[@GT380man]

I had no idea about learning ECUs. I won’t forget that.

[@richardyardley5127]

Nice work Stu. I'm thinking of fitting the same system to my Classic 500 but am aware that single skin stainless steel is far more likely to blue with the heat. For this reason I'm going to fit a Fuel X lite to help the fuel/air burn mixture create less heat with a less lean burn. I don't know if you have any thoughts on this at all mate.... 🙂

[@stuartfillingham]

It wont blue because it isnt chrome. will take on a goldish hue which is considered desirable.

[@richardyardley5127]

@@stuartfillingham Well, I didn't know that. Thank you. I feel kind of silly now as the stainless steel down pipe on my Himalayan has gone a golden colour! I'll fetch my coat 🙂

[@stuartfillingham]

@@richardyardley5127 LOL

[@KRAM-zb2vc]

Brilliant video as always Stuart and thats a very nice looking exhaust and it should give a little bit more oomph and a better sound 😊👍🏻

[@andrewroberts2213]

Any suggestions on exhaust brand? Looking at either Indian RE aftermarket exhaust or Red Rooster for my Meteor - either one better quality or better for the bike? Cheers!

[@user-up4cd6gs1j]

Hello, you might also want to look at delkevic systems. We fitted on my wife's meteor and she is very happy with it. Similar in most regards to the one in this video but with a different silencer (several styles to pick from). I forget the price but I recall it was cheaper than the hitchcocks system. They also come with a bracket for the centre stand stop. I must confess, I've not yet worked out quite where it fits so the bike is running with side stand only at present.

[@markgilson7621]

Stuart, to you think the new exhaust seems to angle down from the horizontal too much?Or is it the angle of the camera? Cheers Mark

[@stuartfillingham]

Camera angle, sorry!

[@MsDenver2]

Should I buy the full Hiscox exhaust like you or just the catalytic part that Hiscox sell ?

[@themoog3889]

2 suitable nuts locked together on the threads should have enabled you to use a spanner on the back to remove your stuck nut without damaging a thing ! Zorst sounds better ! 👍🏻

[@stuartfillingham]

unfortunately i only have a limited time to produce these videos and i didnt have any suitable nuts on hand.

[@pm8465]

I like the looks of the exhaust but does it effect the emissions test at MOT, or is that down to luck with the tester.

[@stuartfillingham]

No emissions testing for motorcycles.

[@stuartfillingham]

already answered that one.

[@pasqualinobillwilder]

Question: do Indian domestic models have the same adaptive ECU as British export bikes? I am assuming our friend Stuart here has an British export model. Would this same procedure be correct for an Indian domestic model of the same bike.

[@robinj.9329]

I've never felt comfortable riding any of todays "SUPER Bikes"! I'm not a "Speed Demon" by any means. And my idea of a "Good Time" is to cruise along on a quiet (near deserted actually!) Country road, enjoy the natural beauty of Mother Nature and just roll with the flow. But. In the mid to late 1970's a good friend got himself one of the Kawasaki 350cc "Triples" ! These were powerful two strokes with great acceleration and nimble handling. He would visit his favorite "Gal" in a city about 90 miles to our North, then come home, in the dead of night on the near deserted Freeway. It was common for him to cruise at 90 or 100 mph on these late night dashes back home! Now, I have such horrible luck that I'd have been "caught, arrested and JAILED" the very first time I tried it! But Jack was never even ticketed!! And I'm still both envious and jealous to this day 😢

[@MrMomo182]

Dealership put this pipe on my Bullet. I like the note, but I want the bent stainless header pipe. I bet the Motone Big Fin Clamp with brass dome nuts won't fit, though. Pitty.

[@GT380man]

I love seeing a brass fitting, where the manufacturer chose the material. There’ll be a good reason for their choice. They polish up beautifully.

[@user-lo9ng5jv8f]

Just a quick question. Does it matter when you install new exhaust system? Your 350 Classic did a few miles before instillation. Is it OK to change exhaust on new 350?

[@stuartfillingham]

Yep!

[@Mehtabsingh10]

Will the freeflow affect engine as it affects initial pickup and torque ?

[@MsDenver2]

What about when you need an MOT will you have to re-fit the standard exhaust to pass?

[@stuartfillingham]

Emissions are not currently tested on bikes!

[@martinowl]

Performance cam next? Lol

[@NatSatFat]

Hi Stuart, Seems a bit bonkers to remove a perfectly good exhaust? and the new one, does not have a catalytic converter? (I thought you HAD to have one on?) anyway very nice job.

[@RichardvanRens]

hi Stuart can i ask you , where is the music from you use ?

[@stuartfillingham]

KZbin library

[@ryshooter-eo7pc]

I've got a question unrelated to this video ...I own a 2017 classic 500 and I'm wondering on adjusting the valves? I can't find anything online? Thanks for your time. Nick ..canada

[@stuartfillingham]

the old classic have automatic hydraulic valve adjusters. so they never need adjusting!

[@ryshooter-eo7pc]

Wow ok, thanks so much. That's great.

[@andrewroberts2213]

Do you think keeping the baffle out can damage the engine?

[@stuartfillingham]

No

[@ianbrooker2389]

The silencer seems to hang a lot lower than the original. The silencer mounting bracket is substantially longer than the original also.

[@stuartfillingham]

optical illusion

[@themechanic2036]

If you want it to look like the old one whats the point of changing it?

[@GT380man]

@@themechanic2036Stu found the original was physically of a larger diameter and too dominant visually for his taste.

[@vick8914]

👍

[@milesrogers8314]

Would fitting this exhaust system constitute tampering with the vehicle’s emission control system rendering it unroadworthy and the owner subject to a hefty fine? Your number plate is also clearly visible identifying the registered owner. I was in the job. I know what traffic branch officers and transport inspectors are like. Anything for an easy pinch.

[@peterbennett4948]

Header ! don't you mean downpipe Stu 🤔 sorry I'm old school 👍

[@bazxl57]

Its not old school if your from these shores (England.)

[@stevenfreeman7798]

Surely the downpipe will suffer from heavy blue discoloration being single skinned?.

[@stuartfillingham]

well it wont blue because it isn't chrome! they do take on an honest golden patina though just like in the old days!

[@twowheelsoneleg5672]

I enjoyed that, your "political " content is often thought provoking but tbh I'm really here for your bike/gear content

[@NorickFZS25]

In Japan, this style of muffler is called "CABTON MUFFLER". The name comes from the muffler used in Cabton, a series of motorcycles manufactured and sold by Mizuho Motor Works (1923-1956), and came to be called "CABTON MUFFLER." "Come And Buy To Osaka Nakagawa" At that time, it was a leading manufacturer of large cars, along with Meguro (absorbed by Kawasaki). Their first machine was a 346 cc ohv single copied from a British Arie. kzbin.info/www/bejne/maetpIqQlLpnm7c

[@martinrice9190]

If you get caught altering a factory stock exhaust system in California you will be fined on the first offense & jail time and fines on the 2nd. Not sure how they feel about that type of thing in the UK??

[@stuartfillingham]

no real issues. for a start we dont really have any police on the streets these days.

[@frankmarkovcijr5459]

Stainless steel should be used for all the sheet metal on motorcycles. That or alloy. Nothing looks better than a polished alloy gas tank on a motorcycle.