It can be very difficult and even a two man or woman job. If you can get it in a vice the gently try separating them by moving the non gripped end backward and forwardand side to side. The way I did mine without a vice was to put wood underneath it to try to prevent damage stand it on it's end and force a small chisel or old screwdriver between the parts where they meet. You will probably have to hammer it in and wiggle it about.
There is usually a part where the header goes into the muffler and I forced a small chisel down there moving it round a bit at a time. The idea is to open up the flange to release the pipe inside.  Dont peel the outside part back too much.  I hope that helps a little
Steve

Thanks, got it off!
By the way.... Does anyone know if the clamp that snugs the gasket to the engine is supposed to be concave? I thought it was normally flat. I put it against the engine by itself, and it wobbles. Doesn't flush against it at all.

SavageWahine wrote on 12/31/69 at 16:00:10:


Uh hum! I hope you have new header gasket. Which way is it concave (outside or inside)? According to what I see on my bike (05 S40), the clamp is flat on the outside and I don't remember what shape it was on the inside! Anywho, when retighten them you have do it evenly on both side and bring them up to the TORQUE value. If not you will either strip the threat or break-off the studs

bb p/n 484442-001

it's #8 in the gasket page

oooooooooooooooH .........  RRRRRRUUUUUUUUUUSSSSSSTTTTT

NASTY NASTY NASTY

Have you thought about building your own header?  Looks like it is time to consider it.  

It is fun thing to do.   You can get a small welder for about a $100 or so ... well, maybe a bit more since you are way out there in the deep water and isolated on that rock with trees, flowers, fresh breezes and young healthy females running around the beaches with those tiny little pieces of material they call bathing suits .........   OK, back to reality, but it was a fun fantasy for a second there.

Anyway, TRY IT- YOU'LL LIKE IT !  

SavageDude wrote on 12/31/69 at 16:00:10:

Well if there is one thing I've learned, is that FREE SHIPPING does not apply to Hawaii (or Alaska for that matter).
I've learned to read the shipping policies before ordering stuff.
The only company that honors the free shipping even to Hawaii is Amazon.com.
 Just thought of something, maybe they would like to start a different branch of products!!!

I'm also gonna need #6 and #7 (totally rusted out).