Modern Vespa

Hi all.
I recently went to refit my 2014 GT 200 exhaust. To do the job I purchased a new bush as recommended. The part I ordered was for the GT 200. Anyway, when it came to fitting, I used an exhaust expander to make sure I could get the bush in the exhaust without damage, and started to assemble as per hundreds of videos and posts.
This thing just didn't want to go on nicely. It was tight as hell - I did clean the end of the pipe it was due to go on - and took a lot, and I mean a lot, of persuasion. I was caught up in the moment, so persevered and did eventually get it on. I don't feel happy though. Never have I seen anyone mention this being a difficult job.
Then I had a thought. My exhaust is unlike the GT ones I have seen in the pictures, but looks like a GTS type (see pic). I have wondered if it had been swapped out in the past.
Are there different internal diameter sizes for the graphite bushes? Maybe I should be fitting a GTS bush rather than a GT, or is there some secret trick not mentioned anywhere? Would appreciate some experienced advise as form an engineering point of view, this felt wrong!
Is there a d

The chrome exhaust tip makes me think this is off a GTS300 Super. It does not look like the stock exhaust from the USA GT200 models.

Did you happen to snap any photos of the exhaust bushing fitment before install? A photo of the header pipe perhaps?

Unfortunately I didn't get a picture of the header, but I can say there was a stop ring that the exhaust should butt up to.

This is the exhaust before I tidied it up.

Por que no los dos? Both of these things can be true.

As shebalba mentioned, that chrome tip looks suspiciously like it came from a GTS 300 Super.

That said, though, getting the exhaust mounted without a leak absolutely can be a difficult task. The exhausts aren't exactly made to aircraft precision standards, and the parts (especially the graphite bushing) can be difficult to get into place correctly and without damage.

But for split exhausts in general, I don't think there are different diameters. If you have a split exhaust (exhaust plus downpipe mounted to the head of the engine) then they are probably the right diameters.

(Later exhausts had an entirely different split location, but this isn't a case you need to worry about).

Maybe didn't clean the downpipe as well as I had thought. Thanks for your help guys. As long as I know I'm getting the right size bush, I might try again.

Did you use a Vespa OE exhaust gasket? There is a part # floating around for a Yamaha gasket. It's tighter than the Vespa. Header is the same on a GTS or GT, except for O2 bung. Watch Robot:

Never had an issue with OEM bushes. Bet its a Chinese aftermarket part.

I have installed numerous genuine Piaggio bushings on multiple GTSs. If the inlet of the exhaust isn't big enough to accommodate the bushing easily, it gets mushed in the installation process.

This is common.

It was an OEM bush. I've been trying to find the receipt to check the parts number. Also did watch the Robot video before which is what made me think mine seemed excessively difficult to fit. It was nowhere like fitting it in the video.
Something else occurred to me. When I removed the exhaust, most of the old bush was still on the downpipe, so that one must have been pretty tight as well.

According to the intewebs there are two exhaust gasket bushing options. Both will fit the GT200 and GTS300 at least up to 2019.

The 'old style' which is part number 846097.

Measures: 38.5 mm OD, 32 mm ID and 31 mm long.

And the 'new style' which is part number 8263885.

Measures: 38.5 mm OD, 32 mm ID and 31 mm long.

No difference in measurements and not a clear identifier of why there is a new and old style. Could be manufacturing location or a change to spec.

Perhaps the one you received was a little misshapen and required a bit more finesse, even though you took all of the right steps to install.

Are you getting an exhaust leak?

Hi. No apparent leak. I have put my hand as close as possible and can't feel any little blasts if air pressure or see any puffs of smoke. I am going to change the bush though as I don't feel happy with the way it went on.

No harm in ordering a replacement, but if it were me I'd keep riding the installed one with the replacement as backup. Especially if there seems to be a good seal.

I recently put a slip-on exhaust onto a new low milage bike (under 400mi on the clock) and it was a real PITA to remove the gasket.

Not saying you will have the same issue, but a new slip-on would look good on your GT200 and eliminate that pesky bushing once and for all.

Interesting. Forgive my ignorance but what is a slip-on? Do you have pictures?

Aftermarket exhaust. These typically 'slip on' and do not require the bushing. They can be really spendy, but so are exhaust gaskets at $25 a pop.

I believe if you look at the new style there is a braided ring around the top of the bushing

The old style and new style are the same size. The new style has one end with more mesh (or just exposed mesh) and I think might be slightly sturdier. I've installed both -- haven't seen the old style for many years.

IMO, the new style is the way to go.

So, does anyone put the bush on the downpipe first and then fit the exhaust? My downpipe has a collar to stop the bush going too far, so is there a reason this is a bad move?

Do it exactly as Robot shows using the correct gasket, and your chance of success is pretty good,

And the "old style" is what you will get if you have it serviced at just about every shop in Italy. The main issue that I have seen when they fail between tire changes is that they some people still have the old clamp and/or put it too high. I have found that if you make sure it covers the slits at the bottom, it will hold up much better.