This work focuses on the exhaust BS6 for two-wheeler vehicles. Study included the CFD analysis and experiment have been performed on the current design of the exhaust BS6 with boundary conditions as per engines. BS6 exhaust system with layer and BS6 exhaust system without layer differences going to be obtain. The design of the BS6 exhaust system will be generated according to requirements. Exhaust gas temperatures, velocities, and back pressure have been evaluated and verified through Finite Element Analysis by using CFD module of ANSYS. Also, the modal analysis is performed to study the effect of geometric change on natural frequency of system. Actual testing has been performed by manufacturing modified exhaust BS6 and test it on the two-wheeler engine test rig for back pressure and noise. BS6 exhaust system with layer gives better results as compared to BS6 exhaust system. Without layer and also transmission loss of BS6 exhaust system with layer is net 17.52(k), which is more than requirement and satisfactory.

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