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CHECK THIS BOLT!!

JPC56 said:
Can't understand why only a very few owners have this issue.
Click to expand...

I’m positive that it has to do with a combination of mileage as well as general road conditions.

Bumpy roads will cause more metal fatigue at a faster rate.

I don’t believe this failure of this bolt is a question of “if” but rather one of “when“.

The bolt is just terribly undersized for its intended purpose in my opinion.
 
scottmastrocinque said:
I’m positive that it has to do with a combination of mileage as well as general road conditions.

Bumpy roads will cause more metal fatigue at a faster rate.

I don’t believe this failure of this bolt is a question of “if” but rather one of “when“.

The bolt is just terribly undersized for its intended purpose in my opinion.
Click to expand...
What if anything can be done to rectify the problem?
 
Redesign the bracket so that it has an integrated 8mm pin, that would eliminate the weak spot which is the thread of the cap headed bolt. The exhaust could be slid onto the pin and then assembled as normal. The bracket could be made from high strength material.
 
Hi , was at Jim Allan's, my Guzzi dealer today . Took the opportunity to have a look over the new Stelvio and interestingly the exhaust catalyst hanger brkt looks exactly the same as the V100 one , meaning the part that is supplied by parts department won't fit it either . 😳
 

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This is my second time to have this exhaust bolt brake. First time it was replaced Sept.2023 by dealership along with the complete exhaust system under warrant. Found the bolt broken again with approximately 3500 miles on it. Guzzi needs to fix this problem.
 

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Ranishdogs said:
Hi , was at Jim Allan's, my Guzzi dealer today . Took the opportunity to have a look over the new Stelvio and interestingly the exhaust catalyst hanger brkt looks exactly the same as the V100 one , meaning the part that is supplied by parts department won't fit it either . 😳
Click to expand...
Yep - it is the only common part between the assemblies. The bolt is still an M8 but is 50mm rather than 60mm, hence it is flush to the bushes which the hanger rides on rather than the bolt. IMO MG know the design on the Mandello is flawed and made it sturdier on the Stelvio.

The hanger bushes on the Stelvio will not fit the Mandello, I put calipers on the model at my dealer to check if the Mandello could be retro fitted. It can't, and the exhaust assembly also has a different part #.

My 2nd warranty fix is at 2,000 miles now, about 500 miles better than the original...but is visibly starting to bend.

T2
 
As the bolt always breaks at the thread which is only 6.77mm diameter it would make more sense to have a bolt whose shank was long enough to just enter the alloy bracket so that the weaker 6.77mm core diameter was protected from any bending/shear forces. Those forces would then be placed on the 8mm shank diameter which would have greater resistance to breakage. But if MG can't provide the same bracket as is fitted at the factory but only one that requires modification to fit, I can't see them providing an answer to this issue.
 
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