Exhaust repacking question

Hello, I bought repacking material and a quiet insert core for the Powercore silencer on my '08 WR250X. I watched some videos online, and am ready to swap it out, but I can't separate the midpipe from the header to safe my life. The slip-fit joint is just locked, and I can't get much leverage to try to pry them apart. I've beat on it with a hammer and flat edge bar, I've sprayed WD40 into the joint and twisted it, everything I can think of. I'm hesitant to put a lot of torque on the pipes by twisting with a extender bar, I don't want to bend or shear the pipes.

Any other ideas? I'm sick of the over-loud blaattt, and so are my neighbors I bet, especially at 6am.

thanks,
Dean

Stock header?
Did you put the pipe on? use high temp rtv?

Have you tried it when it's warm?

You could always just repack it with the pipe still on the header...
Take out spark arrester
Remove 4 allan screws on can
Slide can off

Yep, stock header, installed by previous owner. I've tried warm and cold. Also cold with a little torch heat on the silencer side.

I guess I could try it on the bike, thanks. I was hoping there might be a trick to separate stubborn pipes.

f3joel wrote:

You could always just repack it with the pipe still on the header...
Take out spark arrester
Remove 4 allan screws on can
Slide can off

That's what I did. Never even looked to remove it pipe and all. Only one bolt was tricky to get. Just had to roll over and stand on your head while workin behind you back to get at it that's all

I left the header on the bike. I removed the locking bolt from the slip joint, pulled the muffler mounting bolts, and then rotated the muffler and pipe to the right side of the bike. Once it started to rotate on the header I had to work it back and forth while pulling backward and it eventually came off.

+1

Worked for me, too.

Arkmage wrote:

I left the header on the bike. I removed the locking bolt from the slip joint, pulled the muffler mounting bolts, and then rotated the muffler and pipe to the right side of the bike. Once it started to rotate on the header I had to work it back and forth while pulling backward and it eventually came off.

Arkmage wrote:

I left the header on the bike. I removed the locking bolt from the slip joint, pulled the muffler mounting bolts, and then rotated the muffler and pipe to the right side of the bike. Once it started to rotate on the header I had to work it back and forth while pulling backward and it eventually came off.

That's the part that's not working for me, no matter how I try, I can't get the two pipes to separate.

I guess I'll try sewerat's yoga posture and try to repack the silencer while it's still mounted on the bike.

That should be do-able. Not ideal, but definitely do-able.

Repacking while the can was still mounted was not a problem, all done, much much better. Getting the quiet core insert lined up to allow the retaining bolt to thread was a PITA however.