Hi, I’ve got a shiny new pair of Keihan exhausts to replace the, presumably original chrome plated pipes. Obviously I don’t want to snap a stud or indeed break anything. This might also be a job I leave for winter just in case anything goes wrong.
I’ve got a pair of gaskets. In your experience, will I be able to re-use old studs, nuts, collets and flanges?
Also any tips for a trouble free exhaust swap over would be very welcome.
Hope for the best .. but.. plan for the w 
orst!
Shouldn’t be a major problem unless the studs are very corroded, but if the original dome nuts are still present then they will have offered some protection. Use plenty of dismantling lubricant (PlusGas, WD40, what have you) and take it nice and easy. If you are unlucky enough to snap a stud they are easily enough removed using the double-nut method. If this happens, take the opportunity to replace the studs with stainless – you can buy S/S threaded rod from any of the usual places (I use Westfield Fasteners) and some nice stainless dome nuts to suit. Cut the studs to length and screw them in (again using the double-nut method) with some ally grease. The collets are pretty indestructible: they may be a bit rusty and pitted, in which case a wire brush attachment on the end of a drill is your friend, and ditto the flanges. I gave mine a good clean and had my friendly local paintshop cerakote them matt black – they look great.
Don’t be nervous: in the scheme of things Guzzi your project is pretty straightforward, and there’s not a lot that can go wrong. Even if it does, there’s always a remedy, and you’ll find plenty of advice on here. Best of luck!
Fantastic. Much appreciated. 
All as MandelloTractor says. My minor comment is that I prefer to use copaslip (copper grease) rather than an ally grease simply because it has a higher destruction temperature.
Well, Dai, we could have a debate about that!
Agree that Copaslip has a higher dissolution temperature, but since your exhaust is never going to reach 1000º Centigrade, then the anti-galvanic corrosion advantage of Alumslip (since aluminium is higher in the table than copper) trumps the greater heat tolerance of Copaslip in the actual temperature range likely to be encountered on a road bike breathing petrol and air (500-650º C).
The more salient question is whether you ought to install exhaust studs so that they can be easily extracted, or bake them in so they’re fixed for good!
I usually glue them in, to be truthful. Don’t ask me which Loctite glue it is because I’m in the house, it’s in the garage and it’s too cold to walk out and look!
As it happens, I also have a tin of Alumslip on the grease tins shelf which I’ve never opened…! 
Thanks again for your advice.
Always check for old exhaust gaskets. Sometimes past owners forget to take out the old ones before putting new ones in. I’m currently rebuilding an old Suzuki and dug 3 sets of gaskets out of the exhaust ports! Just because you’ve taken out one set, don’t assume there’s no more in there.
Loctite 272. Good for 232 degrees C which is a bit below what an exhaust port can reach, but so far I’ve had no trouble on Tonti Guzzis and BMW flying bricks. For anyone that may be interested:
Absolutely stellar
We’re approaching completion on a GS1000 rebuild and had exactly this, 3 layers of exhaust seal washers in each port! Same previous owner…? 
