Removing and replacing mufflers

[Mackers]

Removing mufflers is one of the worst jobs when working on my Guzzi.  It is a fight against creosote glue that resists pulling, twisting and hammering. 

Does anyone have a method to clean up the muffler aperture and header pipe so that they just slip back together?

[chuck peterson]

When assembling head pipe to crossovers to mufflers while cold, slather 3-4” of each joint with anti-seize, more than necessary. Fire up the motor to heat up the exhaust joints. The anti seize will liquify and excess will drip off. Next time you take it apart it will only take a few blows with a soft face sand filled hammer. Hopefully…

[Perazzimx14]

When assembling head pipe to crossovers to mufflers while cold, slather 3-4” of each joint with anti-seize, more than necessary. Fire up the motor to heat up the exhaust joints. The anti seize will liquify and excess will drip off. Next time you take it apart it will only take a few blows with a soft face sand filled hammer. Hopefully…

I would also encourage that the OP clean the male/female exhaust joints with a compatible material (for instance do not use a carbon steel wire wheel on a stainless exhaust) prior to the slathering. As for the slathering I prefer to go with a thin schmear on the male/female parts with copper based anti-seize. Globbing on excessive amounts of slip'em is just more to clean up. Like tire lube the goal is not to see how much you can apply it is applying the right amount in the right places

[guzzisteve]

And don't forget to put that anti seize on the clamp bolt threads.

[davethewelder]

I too found reinstalling the muffler on my V7-850 Stone, damn near impossible.   Its almost like you should buy a new gasket.

[Stretch]

I use the copper-based anti-seize, and muffler removal on the big 1400
Cali is still a wrestling match. Not as bad as the first time, though.


If anyone has a better idea, and I think I can speak for the entire forum
here, we'd be appreciative!   

                                                -Stretch

[bigbikerrick]

I like to use a smear of whatever silicone rtv sealer I have around. Its heat resistant, makes removal of the mufflers later easy,and seals up any small imperfections between the pipes,as no exhaust leaks out. Someone here taught me that tip years ago,
Rick.

[Mackers]

I cleaned them up with a brillo pad and applied a smear of copper annti-seize.  They slipped together easily.  I'll see eventually how they come apart.  Thanks for the advice.

[faffi]

The mufflers on my V9 has slid off and on with ease every time. Now, if you all buy V9s, problem solved

[Moparnut72]

In the airplane radial engine shop I used to work in we used Permatex Ultra Copper on anything that needed to be sealed. A very light smear on both sides of a gasket worked well against leaks. In the event something had to be removed it would come of very easily, valve covers were the usual culprits.
kk