Modern Vespa

Hi all — I need some advice.

I gave my 2007 GTS to a local mechanic to replace the exhaust gasket. They mangled the gasket (tore it) and — worse — cut and rewelded the top of the exhaust. The weld looks like the angle changed slightly.

If I buy a new gasket, will it likely seal fine, or do I need to take it to a proper shop to have the weld corrected/re-welded? Attached: before/after photos.

Thanks for any tips — should I be worried about fitment or exhaust leaks?

oh boy is that ugly welding.

if you going to temp to install this loosen the head pipe first, don't have to take it off. this should allow enough slop/play to get the alignment close, otherwise you will risk cracking and or breaking the studs.

once fitted up be easy tightening everything down very evenly, a little on each at a time.

You can try to make it fit. It looks like if you turn the gasket over, it might be okay, as long as you expand the muffler so you can get the gasket in as far as possible. And put the clamp low on the muffler, so you cover the slits.

What you can do is loosen the two nuts holding the exhaust header to the engine, so it can move side to side with little resistance. Next, get the header into the muffler as straight as possible and bolt the muffler to the bike. But only tighten the bolts that hold the muffler on finger tight. Tighten the nuts at the engine, and make sure the amount of exhaust stud sticking out of each bolt is the same. Then tighten the bolts that hold on the muffler, and then the clamp. Start it. If the exhaust doesn't leak, it might be okay. Or it might break when you hit a bump. A lot will depend on if the change in position of the muffler mount puts stress on the header pipe.

Got it! so I must loosen the head pipe, the one that connects the bike to the exhaust/muffler, and then do the installing process following your indications.

One issue I had the first time (and that's why I went to the workshop), was that the gasket would not fit the exhaust, and I didn't want to use pliers to make it wider.

If you have any recommendations on how to enlarge the size or make it fit easier, that would be helpful.

Finally, in case I do all this and it keeps leaking, will I be able to fix the welding, Or should I think about getting a new exhaust?

Yeah. I give that weld the "seagull poop" rating. Ugly indeed!

I've received parts with welds like that on a few occasions. I decide whether to run-it or rework-it depending on how much stress the part is under and how badly things will go sideways if the weld was to fail while riding. At least now you know who not to take parts to for welding.

Keep an eye on ebay, craigs, marketplace for used exhaust. Routinely see mint takeoffs on there for $200 or less. Up to 2022 will fit.

Haha indeed, lack of professionals is a huge problem here. I live in Northern Chile, so it won't be easy to find the product unfortunately...

Thanks for all the recommendations anyways![/quote]

So what I feared is happening.
I tried installing the exhaust and this is the angle I'm getting.

Is this enough to try loosening the bolts in The header? Or must I think about fixing the welding?

You can give it a try, but proceed with caution. That's a big gap. Loosen each header bolt 2 full turns or so. Reassemble alternating between the swingarm bolts and the header bolts. If the gap is smoothly closing, proceed. If not, buy a new exhaust and find a new mechanic.

what you installed it WITHOUT loosening the head pipe .

well good luck with that. almost a guarantee its going to fail again.

Loosen the exhaust header bolts at the engine and see if you can make it fit. If you have to use a stack of washers to make it fit, that will work until you find another exhaust. You want it snug, but not stressed.

It might be easier to go with an aftermarket exhaust, like a Malossi, if you have to import it. They weigh a lot less and should be cheaper to ship from the US.

When I was riding in Chile, I met the Santiago Harley Owners club, and they all had stock exhausts, because of the revision tecnica. There were at least 30 of them at the gas station, and it was pleasantly quiet.

Can you use an aftermarket exhaust, or does it need to stay stock? Many aftermarket exhausts meet EU noise standards right out of the box.

You can use the exhaust off any GT 200, GTS or GTV 250 or 300 that is not an HPE.

I tried loosening the bolts but the gap is too big still.
There a welding specialist I met that suggested to cut back the bad welding. Mount both parts with its bolts (the exhaust head to the engine and the muffler to the arm) and weld 3-4 points. Then remove the muffler and weld everything back, to finally install again.
This might be the closest I get to regain the initial angle, without having to force any metallic parts.

He is the most experienced welder in my city and recommended by many, so I might go there today.

Will let you know how the soap opera continues![/quote]

now that sounds like a better plan.

And it worked!
This guy was "un capo" as we say here and saved the bike.

Thanks everyone for the tips and I think we discovered a new way of fixing this problem for the future.

I'm not sure if I installed the gasket as I should have, I could not put the softer part inside the muffler head, but it covered all the possible holes and once I started the engine it sounded softer than ever. Hopefully it swill last long and, if not, I now know how to fix this.

Back to the streets!