How to properly re-install right exhaust header w/new gasket to mid-pipe?

[mohawkeye]

Recently the stock exhaust on my '09 Stelvio 4v began sounding much louder and "tinnier." Yesterday I isolated the problem to where the right header meets the mid-pipe (exhaust pressure blowing out to the bike's right side), and went to my dealer for new gaskets (only comes as a set of 2 - $50, ouch). A gasket will fit on the end of the right header, but with the gasket on, the header will not fit inside the right end of the mid-pipe. I'm reluctant to spread open the tabs at the right end of the mid-pipe unless that's the correct procedure.

I've taken a couple of photos, one each of the right header and of the mid-pipe; unfortunately they were done on my iPhone and won't transfer to a file that'll upload here. I'll try to take a couple with my camera once its battery is charged.

If anyone knows the trick, please clue me in. TIA

 

[john zibell]

Go to your friendly neighborhood auto parts store and get an exhaust pipe expander of the appropriate size. This link shows what they look like. http://www.harborfreight.com/automotive-motorcycle/exhaust.html

 

[mohawkeye]

Thank you, John! Guess I'll have to measure the mid-pipe's diameter

 

[canuck1969]

A pair of vice grips work just as good. Gentle pry back each tab. They will re-align when you clamp it. Have had to do that 3 or 4 times with no issue.

Make sure your clamps are tight at each service (or every couple of months) and this won't happen again. Known issue with the carc bikes.

 

[john zibell]

A pair of vice grips work just as good. Gentle pry back each tab. They will re-align when you clamp it. Have had to do that 3 or 4 times with no issue.

A little primitive don't you think?

 

[canuck1969]

A little primitive don't you think?

Yup....simple is best. Works every time I have done it, especially at the side of the road.

 

[grinmaul]

A little primitive don't you think?

Better than another tool that gets used once then rusts away in the bottom drawer with the rest of the used once tools

 

[GuzziMoto]

As long as you are careful and don't mangle the pipe it should be fine. A pipe expander is better but unless you already have one (I do) I can't see dropping the money on one, although you can get them pretty cheap.
Either way should work as long as you are careful.

 

[grinmaul]

There are many ways to do this without an expander, channel locks adjusted to fit inside when closed, then open them, work your way around the pipe, should not mark the pipe at all.

another is use the other end of the pipe with out the gasket, slip it in and roll it in a way that the pipe opens up.

i find it hard to explain in words, hopefully you see what i mean while looking at it

 

[john zibell]

Better than another tool that gets used once then rusts away in the bottom drawer with the rest of the used once tools

I've had a set of expanders for over 30 years. I did automotive work at one time and they do come in handy when installing new exhaust systems. Just used one of mine a few weeks ago on a guys 61 Chevy pickup project. They don't get used all that often, but are the best for the job. I've found that buying the right tool for the job, even if used only once, makes for a successful project and much less aggravation for the mechanic!!

 

[WayneOrwig]

I have an old huge screwdriver. Gently work it back and forth in the slot and slowly pry it. That has always expanded them enough for me. It doesn't need much.

And there is a much cheaper Kawasaki gasket that fits it too.

 

[mohawkeye]

Sorry, been lazy in response... Got the medium-sized (up to 2.25") expander at Harbor Freight 2 weeks ago, and it did the job. Bike's been back in business since then.

Thanks for all the suggestions! Right tool for the job, etc...