I'm in the midst of putting a new full system on my SV.  I've got the midpipe firmly attached to the rear header, but I've got it stuck on the front header pipe.  (seen just below the engine)

You can see the pipes need to be pushed together another 1/2 inch.
I tried using a small propane torch to heat the two up and push them together, but I think it may have only made it worse.

The midpipe wont disconnect from the rear header, so thats not an option.

Any ideas on how to bring the two pipes together?

I don't have experience installing full systems, but here's two things I can think of:

1. The midpipe doesn't look like it's going on completely straight, I can see a little gap on top between the midpipe and header in the 2nd pic.  I'm sure there's not a lot of wiggle room, but see if you can lift the midpipe or lower the header so they line up better while you're assembling

2. Maybe see if you could heat the midpipe only, since heating the header would only work to expand it, making it hard to slip the midpipe on.  This will probably be difficult though, since they are stuck together and the heat will probably conduct and radiate to the header as well

have you tried rotating the front headpipe?
I know stupid question.....

You did try and fit it all together BEFORE trying to put it on the bike, right?

Quote from: makenzie71 on March 19, 2007, 05:54:48 PM
You did try and fit it all together BEFORE trying to put it on the bike, right?

Yes, but it's such a tight fit, I didn't press the pipes all the way together before putting them on the bike..

My brother and I went in the garage tonight and tried to pull the pipes apart..  STUCK!  We can't pull the front header pipe off the midpipe.  These pipes don't want to move in either direction! 

What do I do??

can you unbolt the front header and twist it down? if you can do that, you can probably work them together, then rebolt the front header. oh, and i gotta check, whats the biggest hammer you've used so far? because i can tell you from experience, size does matter with hammers.

I think oak can fix this.....

Quote from: werase643 on March 20, 2007, 03:45:15 PM
I think oak can fix this.....

+1

Destro and I ran into this problem on one of my midpipes when we put my Jardine's on.  I seem to recall using some white penetrating lithium grease spray and a lot of grunting, twisting, and sweating.  And while that may sound like a scene from Sparticus, I assure you it was not.