• Ciao Guest - You’ve landed at the ultimate Guzzi site. NEW FORUM REGISTRATIONS REQUIRE EMAIL ACTIVATION - CHECK YOUR SPAM FOLDER - Use the CONTACT above if you need help. New to the forum? For all new members, we require ONE post in the Introductions section at the bottom, in order to post in most of the other sections. ALWAYS TRY A SEARCH BEFORE STARTING A NEW TOPIC - Most questions you may have, have likely been already answered. DON'T BE A DRIVE-BY POSTER: As a common courtesy, check back in and reply within 24 hours, or your post will be deleted. Note there's decades of heavily experienced Guzzi professionals on this site, all whom happily give endless amounts of their VALUABLE time for free; BE COURTEOUS AND RESPECTFUL!
  • There is ZERO tolerance on personal attacks and ANY HYPERLINKS to PRODUCT(S) or other competing website(s), including personal pages, social media or other Forums. This ALSO INCLUDES ECU DIAGnostic software, questions and mapping. We work very hard to offer commercially supported products and to keep info relevant here. First offense is a note, second is a warning, third time will get you banned from the site. We don't have the time to chase repeat (and ignorant) offenders. This is NOT a social media platform; It's an ad-free, privately funded website, in small help with user donations. Be sure to see the GTM STORE link above; ALL product purchases help support the site, or you can upgrade your Forum profile or DONATE via the link above.
  • Be sure to see the GTM STORE link also above for our 700+ product inventory, including OEM parts and many of our 100% Made-in-SoCal-USA GTM products and engine kits. In SoCal? Click the SERVICE tab above for the best in service, tires, tuning and installation of our products or custom work, and don't miss our GT MotoCycles® (not) art on the BUILDS tab above. WE'RE HERE ONLINE ONLY - NO PHONE CALLS MADE OR RECEIVED - DO NOT EMAIL AND ASK QUESTIONS OR ASK TO CALL YOU.
  • Like the new V100, GuzziTech is full throttle into the future! We're now running on an all-new server and we've updated our Forum software. The visual differences are obvious, but hopefully you'll notice the super-fast speed. If you notice any glitches or have any issues, please post on the Site Support section at the bottom. If you haven't yet, please upgrade your account which is covered in the Site Support section or via the DONATE tab above, which gives you full site access including the DOWNLOADS section. We really appreciate every $ and your support to keep this site ad-free. Create an account, sign in, upgrade your account, and enjoy. See you on the road in 2024.

How to properly re-install right exhaust header w/new gasket to mid-pipe?

mohawkeye

Cruisin' Guzzisti
Joined
Oct 27, 2008
Messages
392
Location
Pasadena
Recently the stock exhaust on my '09 Stelvio 4v began sounding much louder and "tinnier." Yesterday I isolated the problem to where the right header meets the mid-pipe (exhaust pressure blowing out to the bike's right side), and went to my dealer for new gaskets (only comes as a set of 2 - $50, ouch). A gasket will fit on the end of the right header, but with the gasket on, the header will not fit inside the right end of the mid-pipe. I'm reluctant to spread open the tabs at the right end of the mid-pipe unless that's the correct procedure. :oops:

I've taken a couple of photos, one each of the right header and of the mid-pipe; unfortunately they were done on my iPhone and won't transfer to a file that'll upload here. I'll try to take a couple with my camera once its battery is charged.

If anyone knows the trick, please clue me in. TIA
 
A pair of vice grips work just as good. Gentle pry back each tab. They will re-align when you clamp it. Have had to do that 3 or 4 times with no issue.

Make sure your clamps are tight at each service (or every couple of months) and this won't happen again. Known issue with the carc bikes.
 
As long as you are careful and don't mangle the pipe it should be fine. A pipe expander is better but unless you already have one (I do) I can't see dropping the money on one, although you can get them pretty cheap.
Either way should work as long as you are careful.
 
There are many ways to do this without an expander, channel locks adjusted to fit inside when closed, then open them, work your way around the pipe, should not mark the pipe at all.

another is use the other end of the pipe with out the gasket, slip it in and roll it in a way that the pipe opens up.

i find it hard to explain in words, hopefully you see what i mean while looking at it:)
 
Better than another tool that gets used once then rusts away in the bottom drawer with the rest of the used once tools:)

I've had a set of expanders for over 30 years. I did automotive work at one time and they do come in handy when installing new exhaust systems. Just used one of mine a few weeks ago on a guys 61 Chevy pickup project. They don't get used all that often, but are the best for the job. I've found that buying the right tool for the job, even if used only once, makes for a successful project and much less aggravation for the mechanic!!
 
I have an old huge screwdriver. Gently work it back and forth in the slot and slowly pry it. That has always expanded them enough for me. It doesn't need much.

And there is a much cheaper Kawasaki gasket that fits it too.
 
Sorry, been lazy in response... Got the medium-sized (up to 2.25") expander at Harbor Freight 2 weeks ago, and it did the job. Bike's been back in business since then.

Thanks for all the suggestions! Right tool for the job, etc...
 
Back
Top