bsw Posted December 8, 2016 Report Share Posted December 8, 2016 I am currently doing battle trying to install the mid exhaust section on an 04 Sy 250.I have 2 new rubber seals in the mid section. I have cleaned the header pipe with sand paper and greased both exhausts and still it refuses to go on. Any tips. Quote Link to comment Share on other sites More sharing options...
pauls320 Posted December 8, 2016 Report Share Posted December 8, 2016 I am guessing its the one that came off it and its not slightly crushed....You tried a successful fit-up minus Orings first?...not uncommon for substituted wrong seal thickness as Oni suggested 1 Quote Link to comment Share on other sites More sharing options...
bsw Posted December 17, 2016 Author Report Share Posted December 17, 2016 Success by polishing the header pipe,reaming some off the rubber o-ring with a die grinder, and using various pieces of timber and a rubber mallet. There is no leak from the header and the old mid box I welded. Quote Link to comment Share on other sites More sharing options...
the yukon sizzler Posted December 30, 2016 Report Share Posted December 30, 2016 i'd suggest the new rings you've used are a tad to thick. The mid box should slide on lovely with a smear of grease without the use of any encouraging impliments. On a side note, the ally mid box is easily punctured/damaged where it touches the sharp corner of the raised boss on the crankcase where the engine numbers are stamped, Dressing the sharp corner with a file or dremel is a wise move if it hasn't already been done by a previous owner. HTH. Quote Link to comment Share on other sites More sharing options...
bondy Posted December 25, 2017 Report Share Posted December 25, 2017 HI if I take my Exhaust off do I need to replace the O rings or can I reuse? Quote Link to comment Share on other sites More sharing options...
cascao Posted December 25, 2017 Report Share Posted December 25, 2017 Losen a bit front pipe to cylinder bolts. 1 Quote Link to comment Share on other sites More sharing options...
nitjay - hrc Posted August 10 Report Share Posted August 10 Resurrecting this dead thread as I just faced this exact dilemma and for anyone else who comes across this issue. in 04 there were two part numbers for the o-ring dependent on frame number. I found I was trying to fit the wrong o-ring for my bike number. So if you have 04 bike double check! Quote Link to comment Share on other sites More sharing options...
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