1981 GS850 headers very tight when installing Vance and Hines pipes

[oddcycle]

I have been vacillating between new pipes and trying to find an old pair in decent shape. Your report isn't encouraging on either front. Not 10 minutes before I read this thread I had made up my mind to use an old set of used pipes. I am nervous now that any used gear I pick up may just set me in for a world of trouble hunting down difficult to diagnose leaks. The new stuff doesn't look much better but at least their customer service sounds acceptable after a little convincing on your part. Thanks for sharing.

[thewozza]

at least their customer service sounds acceptable after a little convincing on your part. Thanks for sharing.

Definitely, everyone involved has been motivated to help solve this problem. From a customer service standpoint, this has been a good experience.

[oddcycle]

I was thinking though, maybe these aren't actually flaws after-all. Maybe these little flaws wouldn't affect fitment on the other range of bikes that the V&H 12009 fits, and the 1981 GS850G just has exhaust ports that are that tiny bit small enough for it to matter. Even if that's the case, I would NOT recommend using the V&H 4 into 1 pipes on a 1981 GS850G as they don't fit properly.

If you were to do it over again from the start what would you do?

[thewozza]

If you were to do it over again from the start what would you do?

As for stock pipes, ater 30+ years I'm just not sure how many non-rusted exhaust systems are still out there. The only ones I've seen look questionable enough that I wouldn't buy them off eBay - but if you had a set that you could actually look at it might be okay if you can verify that there aren't holes.

I heard MAC makes an alternative:

http://shop.macperformance.com/MAC-Suzuki-GS-750-850-1977-1980-4-into-1-Chrome-Exhaust-003-0301.htm;jsessionid=A1FBC47F1CE3B63A195E1A5C6BA53867.m1plqscsfapp02

But since I wrote that bit about not recommending V&H on the GS850 I've softened my position a bit. the devil you know is better than than devil you don't. Knowing V&H's willingness to work with me on the issues was reassuring, and they were adamant that these pipes were supposed to fit so it's possible that it was just a bad run they had manufactured.