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Exhausts Exhausts - Headers, Mid Pipes, Mufflers


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September 14th, 2016, 06:24 AM   #1
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I Ride: 99 FC600, 95 FC501, 94 FE501
Early Husaberg Exhaust Compatibility

I recently picked up a 1999 Husaberg FC600.

It has the factory head pipes, but the previous owner fabricated his own muffler. Although he did quality work, the muffler is too short and the outlet is too large - it is way too loud, and just sounds bad.

I picked up a Laser brand muffler off ebay a couple weeks ago, which said it came off a 95 501. However, after wrestling around with it for a couple hours, it just doesn't seem to fit up. There does not appear to be enough room between the shock spring and the frame, for the muffler to be in the correct position/angle to mount up to headpipes.

Prior to buying this Laser muffler, I researched the best I could and seemed as though the 90's mufflers would interchange - but now, I have some doubts. 98-99 models have a slightly different subframe, with a 2nd exhaust hanger mount, down closer to where the subframe mounts to the frame. My 99 also has the linkage-less rear suspension, which may be contributing to the issue.

Should a 95 muffler fit a 99?

I have never heard of "Laser" brand before - perhaps it is just a low-quality, poor fitting aftermarket part...
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September 14th, 2016, 06:35 AM   #2
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I Ride: "2000" FE600, 1996 FC600, 1984 Husky WR400, 2015 Beta Xtrainer
I currently have a '99 muffler mounted on a '96 FC600. I always thought they did interchange. I'd buy that Laser from you if you can't make it work.
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September 14th, 2016, 07:10 AM   #3
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I Ride: 99 FC600, 95 FC501, 94 FE501
Thanks, that is good to know, that a 99 muffler mounts up to a 96. The 99's additional exhaust mount on the subframe may be the issue. It is a "bung" welded to the bottom tube of the subframe. As much as I hate to cut it off, that may be what is preventing everything from positioning into the proper alignment. I will see what I can figure out.
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September 14th, 2016, 09:53 AM   #4
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I Ride: "2000" FE600, 1996 FC600, 1984 Husky WR400, 2015 Beta Xtrainer
Yeah, my '96 subframe doesn't have that forward mount. I'm probably going to weld one on for mine because that muffler is awfully big. Incidentally, if you're looking for quiet, the stock FE muffler from about '99 or '00 is one of the quietest I've heard.

Oh, I just remembered that I also have a 2003 chassis with a '95 501 FE engine and the exhaust is all from the '95. The muffler is the FE model and I had to grind clearance in the forward mount which is just a sort of stud-and-sleeve arrangement that's right down near where the muffler mounts to the head pipes. You might look there for interference as well.

You didn't mention if the muffler you're trying to fit up is the FC version with no spark arrester or the FE version with the spark arrester. I think both were made by Laser.

Last edited by thorgan; September 14th, 2016 at 11:43 AM.
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November 4th, 2016, 09:44 AM   #5
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I Ride: 99 FC600, 95 FC501, 94 FE501
Well, I have determined that the 99's no-link suspension is the problem. The no-link's shock position is such, that the lower shock mount is further rearward than the linkage bikes, which moves the entire shock body further rearward as well - causing the spring to rub on the muffler body.

I purchased another muffler off ebay, which has a Husaberg part #, but also says Laser on the end cap. It is the large chrome OEM looking muffler. Unfortunately, it rubs worse that the other, and overall fitment is worse also.

Once I cut the extra mount off the subframe the first muffler, which looks like maybe a 97 FC muffler (kinda like an FMF) should work ok.

On a side note, this week I picked up two more Husabergs, a 94 FE501 and a 95 FC501 for $200.
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November 4th, 2016, 11:09 AM   #6
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I Ride: "2000" FE600, 1996 FC600, 1984 Husky WR400, 2015 Beta Xtrainer
Wow! That's even better than my '96 FC600 buy for $400.
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January 13th, 2017, 05:58 AM   #7
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I Ride: 99 FC600, 95 FC501, 94 FE501
Well, I have determined that 99 was a bastard year. Not only is the muffler special to fit the PDS no-link rear suspension, but the head pipes are unique as well. I was able to get my Lazer muffler mounted to the 99, after I swapped the headers from my 95 onto the 99. I had to fabricate a custom muffler mount.

The 99 headers will not fit the 95 though. The 99 headers are low slung - so much so, that the 99 clutch cover is factory ground down for clearance. Because the 95 clutch cover is not clearanced, the 99 headers do not fit. The other problem, was the 99 header outlets, where they join the muffler, is slightly lower and oriented slightly different. That is what was causing me so much problems, attempting to mount the muffler - nothing was lining up correctly, and when forcing it into position, everything was binding up.

So, needing a set of headers to replace the ones I stole off my 95 - I found a complete exhaust system on ebay off a 93 FC 600. It arrived yesterday. Well, the 93 headers, do not fit the 95. The frame keeps them from going into proper position. After researching last night, I discovered the problem is they changed the frame design after 93. Up to 93, the downtube for the frame was a single downtube, all the way to the bottom of the engine. 94 and newer, they changed the frame, so that just above the front motor mounts, the lower cradle begins. The 93 headers wrapped around the downtube, while the 94/95 headers wrap around the cradle. The newer headers will likely work on the older bikes, but not vice versa.

I will get some pictures posted in the next few days, to demonstrate.

Not sure how many people this information helps - but I was under the impression (and I believe most others may be as well) that all the exhausts from 99 and older were interchangeable, and that is not the case. The 94+ headers would likely work on the older bikes, but 90-93 won't work with the newer frames, without some modifications.
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January 13th, 2017, 07:13 AM   #8
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I Ride: "2000" FE600, 1996 FC600, 1984 Husky WR400, 2015 Beta Xtrainer
Well, I'm certainly grateful for your efforts. Have you found that the header tubes are different between the various engine sizes? I've typically tried to keep 600 header tubes on 600's, 501 header tubes on 501's and so on. They seemed to be different to make up for the varying heights of the cylinders. Maybe the tubing diameters are different as well but I have not confirmed this.

Incidentally, I'm finding it harder and harder to find stock exhausts for the early bikes. Most guys tossed them in the bin and fitted the Big Gun. I currently have 2 Big Gun systems, both of which were originally fitted to 600's. I ran one of them on my 501 without any issues until I couldn't stand the noise any longer. So, at least in my experience between a 501 and a 600, the Big Gun system doesn't seem to be as affected by the differing cylinder heights.
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January 13th, 2017, 08:14 AM   #9
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I Ride: 99 FC600, 95 FC501, 94 FE501
The 95 501 headers have "501" stamped on them. Neither of the 600 headers (99 and 93) have any identifiers. I have not measured the ID or OD, but the 501 headers slide into the 501 and 600 heads fairly easy. While the 600 headers will fit into the 501 head, they do take some effort and twisting back and forth to get them fully seated. I will take some measurements this weekend.

As far as fitment due to cylinder height differences, all I can say is the 95 501 headers fit my 99 600 very well - but my custom mount for the muffler could play a part in the fitment.
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