I have a 07 800 deluxe with dual exhaust. I need to change the donut where it goes from 2 pipes into 1 right by your right leg. I removed the plastic out of my way. Then i removed the 2 springs. I can not get the muffler to pull far enough apart to seperate it and change it out. Do i need to remove the 2 bolts at the header and remove it from the engine and pull it apart that way? That is the way it appears i need to do it but just wondering if there is a easier way. Also if I do that do i need to replace the gasket on the header? Thanks for the help in advance.

 

Has anyone ever had to do this?

 

i would do some research or call the dealer and talk 2 a mech.......good luck man

 

It sounds like you need to remove the whole header. I have the same machine and that's the way it looks to me. I do know that it is a bi*** to pull apart exhaust pipes after you've run them a while. I would ask my local mechanic like gaugedholes recommended.

 

Thanks for the replies gentelman. I will try to tackle the rest of the job this weekend. I will let you know how it goes.

 

Its not that hard to remove the headers. The hardest part is unhooking all of the springs. You will need to remove the right side foot well, but you dont need to remove any of the fenders.

 

well after stopping by my dealer today and talking to the mechanic I finished the job today. I seperated the 2 exhaust cans and unbolted the one connected to my pipe. He said it would be much easier than unbolting the header and I risked cracking it as well. It was much easier than i thought. took about 1/2 hour to take the rear can off and have it back on.while I had it apart I also replaced the donut where the pipe connects to the can just in case it was going bad as well. I now have a much quieter machine.