KTM 790 Duke · repair cost
How much does it cost to replace slip-on exhaust on a KTM 790 Duke?
Budget $430 all-in at an independent workshop, up to $905 at a dealer with premium parts, or $335 in parts and consumables if you do the 1 h job yourself. Figures are US reference prices updated 2026-08-01.
Cost breakdown
Slip-on exhaust fitting on a naked-class bike, 1 h flat-rate labour.
| Route | Parts | Labour | Total |
|---|---|---|---|
| DIY | $335 | 60 min of your time | $335 |
| Independent shop | $335 | $95 | $430 |
| Dealer, premium parts | $765 | $140 | $905 |
Parts range $180–$750 plus $15 of consumables. Labour uses 95 USD/h independent and 140 USD/h dealer rates.
Job facts
| Job | Slip-on exhaust fitting |
|---|---|
| Bike | KTM 790 Duke (Naked) |
| Flat-rate labour | 1 h |
| DIY time | 60 min · Moderate |
| Typical interval | Replacement job, not a service item — usually rust-through or an upgrade |
| Data updated | 2026-08-01 |
Signs it is due
- Perforated or rattling baffle inside the can
- Ticking leak at the header or mid-pipe joint
- Rust bleeding through the outer skin
- Wanting less weight and a deeper note
Tools you need
- Hex and socket set with a torque wrench
- New exhaust gasket and high-temp copper grease
- Penetrating oil for seized clamp bolts
Torque figures for this job
General ranges for these fastener classes. Confirm the exact figure in the service manual for your model and year before final tightening.
| Fastener | Range | Note |
|---|---|---|
| Mid-pipe clamp bolt | 12–20 Nm | Fit a fresh gasket first, then tighten only once the can is aligned. |
| Silencer hanger bolt | 22–30 Nm | M8 into a steel bracket; leave it loose until the alignment is set. |
| Header-to-head nuts | 9–12 Nm | Only if the header comes off. Tighten evenly in two passes on a cold engine. |
| Heat shield screws | 5–7 Nm | M5 fasteners into thin brackets — very easy to snap. |
Full chart by thread size: motorcycle torque reference.
How to replace slip-on exhaust
1. Let it cool
Work on a fully cold exhaust; a hot system will burn you and warp under uneven load.
2. Release the hanger
Support the can, then undo the pillion peg or hanger bolt holding it.
3. Split the joint
Loosen the mid-pipe clamp and twist the old can free — penetrating oil first if it is seized.
4. Fit the new gasket
Always fit a fresh gasket at the joint; a reused one is the usual cause of a post-fit tick.
5. Hang and align
Slide the new can on, align it by eye against the swingarm, then torque the hanger and clamp.
6. Leak check
Run the bike and feel for escaping gas at the joint, then re-torque once after a heat cycle.
Same job, other markets
Other jobs on the KTM 790 Duke
Get the parts
FAQ
How much does a KTM 790 Duke slip-on exhaust job cost?
Around $430 at an independent workshop including parts, and up to $905 at a dealer with premium parts. Doing it yourself costs $335 in parts and consumables plus about 60 minutes.
Do I need a remap for a slip-on?
Usually no for a road slip-on with the db killer in place. A full system that removes the catalytic converter almost always needs a fuelling module.
Will a slip-on fail an inspection?
Only if it is unmarked or over the noise limit. Look for an E-mark or DOT stamp and keep the removable baffle fitted for road use.
Do I need to remap after a slip-on?
Usually no for a road slip-on with a db killer. A full system removing the catalytic converter almost always needs a fuelling module.