Multi-piece muffler housing

An exhaust system for use on a motorcycle having an internal combustion engine with at least one exhaust port, the exhaust system comprising:

• a first exhaust section including a header and a catalyst casing, the first exhaust section having a first end removeably coupled to the exhaust port of the internal combustion engine and a second end, opposite the first end, forming a first connector, wherein the first exhaust section also includes a catalytic element positioned within the catalyst casing;
• and
• a second exhaust section removeably coupled to the first connector of the first exhaust section, the second exhaust section having one or more baffles positioned therein,
• wherein the header and the catalyst casing are either formed from a continuous piece of material or the header is welded to the catalyst casing,
• wherein the second exhaust section includes a distal end, and the second exhaust section defines a plurality of slots proximate the distal end, wherein each slot is t-shaped.

A multi-piece muffler housing for use on a motorcycle exhaust system, the multi-piece muffler housing comprising:

• a first casing including a first substantially cylindrical body having a first end and at least one of a baffle or a catalytic element positioned therein, wherein the first substantially cylindrical body defines a plurality of t-shaped slots positioned proximate the first end;
• a second casing including a second substantially cylindrical body having a second end and the other of a baffle or a catalytic element positioned therein, and wherein the second end includes a first sealing surface, a second sealing surface, and a locking channel positioned between the first and second sealing surfaces, and wherein the first end of the first casing is configured to be removeably coupled to the second end of the second casing;
• and
• a locking ring configured to secure the second casing to the first casing.

A method of replacing a baffle casing, the method comprising:

• introducing a first end of a first casing axially onto a second end of a second casing, wherein the first casing defines a slot proximate the first end and includes one or more baffles therein, and wherein the second casing includes a locking channel and contains a catalytic element therein;
• providing a locking ring having a radially inwardly extending locking protrusion;
• aligning the locking protrusion with the slot of the first casing and the locking channel of the second casing;
• and
• coupling the first casing to the second casing with the locking ring such that each locking protrusion extends radially through the slot of the first casing and is positioned within the locking channel of the second casing.