Question on removing the exhaust

[RobX-1]

I am in the process of removing my stock exhaust to install the QC-1 exhaust. Followed the steps listed in the FAQ and it did state the following:
Due to limited area, it is a very tight fit between the exhaust pipe, top of the tunnel and the rear section of the chassis. Some force may be required to remove the muffler assembly.

My question is just how much force? I have the clamp bolts pretty loosen but this darn thing does not want to budge :? I've tried to ease it up and down and side to side but no luck. Should I be concerned with stretching the stock flanges or don't worry about it and really let her have it? I've been pulling on this thing from the rear and it still won't come out. For those who have done this before, any tips you care to offer? I really don't want to drop the suspension but if I have then so be it. Also, how hard was it to line up the new exhaust to those exhaust clamps if you didn't drop the suspension?

I've got the notebook out in the garage anxiously waiting for someone's reply...

 

[MrSled]

Just give it a yank...it will pop off

 

[RobX-1]

I frickin yanked, pulled, shaked, you name it, it will simply not budge. I even dropped the suspension so that I could spray some WD-40 where the two pipes fit together and still no dice. I have one of those butane or propane torches and if it doesn't break loose, I think my only option is to heat it up and then try to break it free.

And to think everything else was going smoothly up to this point.

 

[RobX-1]

The WD-40 finally worked...it just broke free and came right out. Oh well, trying to get it out was a workout in itself. Guess I won't have to worry about going to the gym tonight and working it out...I am beat. Of course they do have a spa and lounge so maybe a nice cold is in order.

 

[Turbo Tim]

Next challenge : Getting the donuts out of the pipes !.................Unless of course you got new ones .

 

[RobX-1]

RXHaller,

With what I've been through, at this point I'm not worried about salvaging a $12 donut gasket. One of them stuck to the header pipe and was a PITA to remove. I ended up buggering it up pretty good so I called Kevin @ Port Yamaha and ordered two new ones. The one I was able to remove without damaging still seemed to be frayed up at the end when it was installed at factory so I just replaced both of them.

Oh, did I say how much fun I had removing those black exhaust covers on the sides. I would personally love to meet the ex-Sumo wrestler that screwed those bolts on so I could kick in the nuts. That should about equal the pain and frustration I had with getting two of them off. An eye for an eye, right.

 

[MrSled]

told ya...LOL, donuts are a bugger but they will come if you are careful.

 

[Mighty]

I had a harder time installing the system with new donuts, they were too fat and the pipes wouldn't go in. The edges kept peeling over and I ended up prying out the old ones and re-using them. Being that they were compressed already.