Modern Vespa

Hello all,

So the other day I replaced the exhaust manifold on my 2011 GTV 300ie. (And it was surprisingly easy! I figured a part so close to the engine that gets that hot would at least have a very difficult nut or something, but... nope!)

Anyway, when I reattached the exhaust to it, I could NOT slide it far enough in to align the bolts on the exhaust. It was about 1/4in. from being in the right place (as in, needed to move 1/4in. toward the front of the bike). The manifold looks/feels perfectly in place, and the front end of the exhaust is flush with the metal flange on the manifold, so it's not a problem with that gasket that everyone loves...

Has this ever happened to anyone? Ideas?

Thanks, as always!

Not sure what you are trying to describe. Did you put the exhaust manifold and muffler together and then try to install them on the scooter?

Double-check you have the right manifold (aka downpipe). Many moons ago back in the UK my X9 250 blew the downpipe, and it took Piaggio three attempts to ship the right one - all had the right part number, none were the correct one. Different lengths or different diameters. In the end they flew a complete exhaust in from Italy. Thankfully all under warranty, and kudos to my dealer at the time, John Thompson of St Albans, who badgered them continuously to get their shit together.

The muffler shouldn't slide right up to the flange on the down pipe - there should be about 1/4 inch or so before that happens.

WOW thank you Jim for that tidbit of experience. I can only assume that's exactly my problem.

I was thorough about part #'s, but apparently that doesn't apply here. Do you (or does anyone) have advice about how to end up with the right part, other than continuously order it, measure it, return it, repeat?

For the record, I got this part from SIP, whereas I've only ordered parts from ScooterWest in the past.

I would phone SIP - they have good English speakers - and explain the problem. Just be very aware of the time difference though.

Sourcing the correct head pipe for your scooter shouldn't be this difficult. Loosen everything a good solid three turns, the head nuts, the bolts holding the muffler to the swingarm and the clamp bolt. See if this gives you enough movement to make your connection.

I'm returning to this thread that I had forgotten about to give it some closure, because I appreciate seeing the solutions to people's problems!

It turns out that Abner_Bjorn, above, was closest to correct: I managed to get on the phone with a mechanic from ScooterWest (SUPER nice and informative fellow) and he gave me a rundown of how he does it, importantly emphasizing the fact that ALL connections, from the downpipe to everything on the muffler, should be nice and loose at first, and tightened together. Which seems obvious in retrospect, but I had the downpipe really secured before attaching the muffler; I shouldn't have.

Hope this helps someone someday. Cheers!