Exhaust reducer

[Valzdl650]

Hello wondering what your blokes thoughts here’s a video to explain better thanks
https://youtu.be/M36yDvPCinE?si=2DjENTKTjU3bNiwR

[Rixington43]

It's not a metal reducer that's in the first pipe, it's a gasket designed the seal the joint, although they still want smearing with exhaust paste before installation in my experience.
You can see the various gaskets in the parts fiche below but you want part number 14771-32E00. I have seen after market gaskets for much less money if you know the sizes but I've only used the OEM ones simply because I know they're right.
https://www.motorcyclespareparts.eu/en/Suzuki-parts/2005-DL650-v-strom-motorcycles/muffler?_gl=1*1qh7jds*_up*MQ..*_ga*MTAyNTgxMTAxNi4xNzEzNzkzNjU4*_ga_EPD8J02JH6*MTcxMzc5MzY1Ny4xLjAuMTcxMzc5MzY1Ny4wLjAuMA..*_ga_6BMCJMKCL9*MTcxMzc5MzY1Ny4xLjAuMTcxMzc5MzY1Ny4wLjAuMA..

* When you drop the front header, you are supposed to replace the crush gasket (part No.3 in the fiche) which will probably be left/wedged inside the front exhaust port. I'm sure they can probably be re-used with exhaust paste but Suzuki do say to renew them in their service guides.

[Valzdl650]

Thanks for that 👍 but can I use this what I have?

[Rixington43]

I don't think you'll get the exhaust to seal with a metal sleeve, even if you use a lot of exhaust paste, the metal sleeve will be too rigid and the paste will crack away from it. Exhaust leaks before the lambda sensor will likely make the bike over fuel and run super rich (it did on mine) so it's worth getting a good seal if only for fuel economy let alone the potential to damage the oxygen sensor which is a big bill.

[Valzdl650]

Hhmmm well that was a waste of 6 £ OK I’ll order and I also need some paste

[Valzdl650]

Should there be something inside of these I get it almost right then starts to spinnonnitself and destroy the tread

[Rixington43]

From the parts list the 2 bolts for the clamps are different part codes. I don't know if this makes them different lengths or threads though.
Honestly, both clamps were rotted away on mine so I cut what was left away and replaced them with stainless exhaust clamps.

[Valzdl650]

What a nightmare this is becoming! 🫠🫠 so on the clamps which was on the aftermarket exhaust they have these little threads inside I think there removable although they don’t fit in the clamps on this original I was going to just swap the clamps but these clamps on the origanal have a little spot weld on them keeping them secure, I’m debating swapping them but probably going to make a mess trying to pick this weld off ! Don’t have many tools !

[Rixington43]

If the threads in the original clamps look OK then maybe the cheapest and easiest option is to buy the OEM exhaust bolts when you get the gasket(s). Did your bike come with the after market system already fitted? Perhaps they aren't the original bolts and the OEM ones were lost by the previous owner.
The parts diagram will tell you which one goes on which clamp and those welded on clamps look in pretty good condition. They rust because they're not stainless like the pipes but they're fine if you keep on top of them with corrosion blocker. Mine were already gone so I had no choice but to grind off the remains.

[Valzdl650]

Yes I took the bolts from the after market exhaust , and yes after market was fitted but he gave me the old exhaust also,

Yh the gaskets are in the hole but I’m going to put it back together without changing them and m sure in the next year I’ll get anew exhaust and I’ll change them then

[Valzdl650]

Yes I’ve ordered the oem and also the bearing bolt which goes in to the bracket on the rear cylinder 4€ 🫠 however the bolt which does the bracket from the front cylinder is different I think it’s a common size I can pick up from hardware shop for about 30c ,

I checked the drawings and these brackets are as in the picture I sent , there isn’t any washers or inside threads etc so happy days ! Yes I saw the washer was stuck like you said in the front header housing, I’m just going to reuse! So with application of the paste , shall I remove that washer clean it and put I back in or just leave it be and connect the exhaust? Do I just smear the outside of the new sleeve or where am I applying the paste :/ thanks rix

[Rixington43]

Removing it will almost definitely destroy it, they're a real wedge fit.
I'd put some paste on the face of the gasket and on the outside of the header pipe as well. You'll soon know if it's blowing but fingers crossed it reseals OK.
On the other grey coloured gaskets where the pipes sleeve together, smear paste on the inside and outside of the new gasket before assembly. Assemble everything with the bolts loose so you can check the positioning of everything front to back before going back and tightening everything up.
Good luck with it all.

[nigel s]

If you have problems with the clamp threads, and cannot get the clamp off to replace it as Rixington43 said ( the best choice), is one option is to drill out the clamp thread,and use a longer bolt passed through the now larger hole and a washer/nut on the other end.

[purplebikeunicorn]

SS exhaust clamps were £2.95 for the ACC037, that's with postage included. Delivered in a few days, top notch service.
https://www.pipewerx.co.uk/

Problem is if you're in Germany at the moment, then the postage will be far more, have a good google around for "Micalor Exhaust clamps".

[Valzdl650]

So I’ve managed to get one 1️⃣ f the bolts from the hardware store for 53c the other is a bearing bolt I just ordered it from spareoarts 4€ and also the oem reducer so then it’s done thanks for everything again!!!

[Rusty Nuts]

Agree with the unicorn on replacement clamps. The stainless steel Mikalor clamps are excellent. Like this, but obviously with the relevant number for size. Much, much better than any worm drive type clamp.

[Valzdl650]

I have 2 of these on the after market but the clamp on the origanal have a spot weld on them, I didn’t to rip them off and have a hole in that exhaust 🫠🫠🫠

[Rusty Nuts]

From memory, when I changed mine on the glee, it didn't need much of a tickle to get the weld off.

[Barbel Mick]

Mine was quite easy to remove on my gen 2. Just a bit of a wiggle with some pliers & then the 'spot' filed down.

[Valzdl650]

All done 👍 thanks for all the help