• Ciao Guest, The owner of this website and GTMotoCycles.com lost his home completely on the morning of January 8th in the L.A. Wildfire Storm. Most of his neighborhood is gone, and a few friends were killed along with their pets. The GTM SHOP and STORE are functioning normally, but we DEMAND EXTREME PATIENCE on orders as we are a SMALL business and Todd usually has his hands on nearly every order before it goes out. You can find more info on a post named L.A. Wildfires in the USA section. Our heart and best go out to everyone in this horrific disaster.

Muffler removal

Dave H

Dave H

Tuned and Synch'ed
GT di Razza Pura
Joined
Jan 13, 2009
Messages
90
Reaction score
48
Location
Santa Barbara
On the new 2025 V85, there is a wire mesh gasket between the cat and muffler. After Loosening clamp, normally the muffler could be removed. I'm only able to move the muffler a fraction, with considerable force. I'm reluctant to start cutting.
Any thoughts?

IMG_5503.webp
 
I think you will find it is a reinforced graphite gasket, it is circular and about 50mm long. Loosen all the clamps and use a twisting motion while pulling backwards.
 
It's spot welded on (the gasket) so don't waste your time pulling it. The exhaust will twist off, it's just a tight fit. Mine did. Remove the pillion foot rest hanger for added clearance.
 
Last edited:
kildareman said:
It's spot welded on so don't waste your time pulling it. The exhaust will twist off. Mine did. Remove the pillion foot rest hanger for added clearance.
Click to expand...
That’s plain evil. When did they start doing that?
I did exert considerable twisting force, which resulted in the muffler moving down from its attachment to the frame 4 or 5 inches.
Next week I’ll try again.
Going riding tomorrow.
Thank you.
 
Dave H said:
That’s plain evil. When did they start doing that?
I did exert considerable twisting force, which resulted in the muffler moving down from its attachment to the frame 4 or 5 inches.
Next week I’ll try again.
Going riding tomorrow.
Thank you.
Click to expand...
Clarification: the gasket is spot welded (in 4 places). The exhaust is a tight fit and needed the footrest hanger removing to allow for a good twisting action but it slides off ok.
 
Thank you for the clarification. Will proceed with a better understanding of MG's assembly.
 
guysat said:
Thank you for the Part-No, I have been looking for an hour until this popped up :)
Swapping to an arrow exhaust and found the original exhaust gasket had 8 spot welds to retain it ( 2x 4 spots) so need to order one.

A quick measure showed 60-I/D and 64-O/D
Click to expand...
When you removed the stock pipe, is the gasket on the stock pipe still reusable. I am going to use to use the stock pipe with a Cat delete Y assembly.
 
Dave H said:
When you removed the stock pipe, is the gasket on the stock pipe still reusable. I am going to use to use the stock pipe with a Cat delete Y assembly.
Click to expand...
Hi, with the gasket spot welded (x8) I doubt you would be able to remove it, I have tried to find a new gasket Part-No 2B011893 but is coming up obsolete :-(

I believe the spot welding is only for the 2024 models
 
Last edited:
You must log in or register to reply here.
Back
Top