There is a paper thin gasket between the headpipe and muffler at that junction. If you pull the muffler without removing the system from the bike, the gasket is junk. If you install it the same way, ditto. Gasket is available from the stealership.
-WD

If you want the gasket to work, yes. If you don't want to fight with the muffler to clear the bracket coming off the frame, yes. At the very least, loosen the head clamp, and remove the heat shield over the foot peg, allowing the system some wiggle room while you are fooling with it. I burned out 3 muffler gaskets in a month, said screw it, and left it alone until I replaced the muffler/tailpipe assembly with something that sounded/looked somewhat decent.
-WD

No gasket...I have a welder. Gaskets are an expendable item, not likely covered under warranty. My Savage shipped with a defective front brake rotor, was not covered by the warranty. Warranty is a joke, service managers/writers are encouraged to figure out a loophole so the part isn't covered.

Back in 98 when I cared about the warranty, I was told that "expendable items" aren't covered. What exactly wasn't covered: brakes (any component), wheels (rim, spokes, hubs, bearings), seals (any), fuel system (any component), bulbs, wiring, chrome, paint, belt (400 bucks at the time), starter (see belt), generator, levers, pegs, plastic.

My dealer wanted to fix a bunch of problems with my bike. He submitted a cover under warranty approval form, it was kicked back with that list on it. He fixed what he could, I figured out and fixed the rest with the help of Bert's forum (was the only game in town then).

Don't trust your dealer to fix any issues that come up. I know of one GOOD, one decent Suzuki dealership...Suzuki City in Biloxi MS and Butch's in Dyersburg TN...every other one I've been into was a sideline at a Honda shop.

F.T.F.  (if you don't know, ask, but it'll get censored)).
-WD