Muffler removal

[Dave H]

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?

 

[Kevin.NZ]

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.

 

[Dave H]

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.

Part # 2B011893 - gasket WIRE MESH

 

[kildareman]

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.

 

[Dave H]

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.

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.

 

[kildareman]

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.

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.

 

[Dave H]

Thank you for the clarification. Will proceed with a better understanding of MG's assembly.

 

[guysat]

Part # 2B011893 - gasket WIRE MESH

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

 

[Dave H]

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

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.

 

[john zibell]

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.

Try it. If it works or not let us know.

 

[guysat]

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.

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

 

[Dave H]

Success! Sprayed Boeshield T-9 on gasket. It's a lubricant that works its way into the mesh gasket. Muffler off and will now install cat-delete.

 

[Dave H]

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.

I was able to reinstall muffler on the new de-cat system. A little grease made it slide on a little easier. Stainless against stainless needs a some form of lubrication.