A little over a week ago I developed an exhaust leak. It appeared the exhaust header had broken completely and perfectly just in front of the muffler pipe. Last night I finally got the last nut off the header. It looked like someone had sawed it off. When I looked at the parts diagram there is an exhaust gasket, or flange, that goes between the header and muffler pipe. There a flange inside the muffler but I couldn't get it out, at least not with my hand. It does not appear my header can reach into the muffler and I assume the piece inside the muffler is part of the broken header. Is it possible for it not to be broken and the gasket connects the header to the exhaust? This does not seem likely since there is only one clamp. Can someone describe how the gasket fits between the muffler and exhaust header? Thanks for any help.
The gasket (or flange or whatever it's properly called) is a bear to remove. Probably because the heat sort of "welds" the gasket to the inside of the muffler inlet pipe.
When I relpaced the Two Brothers exhaust (that came on the bike I bought) with the stock muffler, I had a devil of a time removing the gasket. It comes out in pieces, and even then it wasn't easy - slow and tedious. You'll need to order a new gasket/flange when you put things back together. When you do, take note of the fact that the gasket isn't symmetrical. One end of the gasket is tapered. Unfortunately, I don't have the maintenance manual with me so I can't tell you for certain which end goes which way. As I remember, the tapered end faces the header pipe.
If the header pipe did
break off (was sawed off) at the header/muffler pipe junction, there should be a section of metal pipe still inside the muffler inlet pipe in addition to the "pain-to-get-out" gasket. The header pipe does
slip into the muffler inlet pipe about the length of the gasket that's such a bear to remove. The gasket makes the seal between the two sections of pipe. And, yes, one clamp holds it all together.
I can't imagine sawing the header pipe, unless at one time the bike had an after market muffler that required the header "saw-off" modification so things would fit properly, but I'm just speculating. Hope that isn't the case - a new header system will set you back more than a few $$$.
Hopefully some of this will help.