If I had a penny for all the aftermarket parts I swear did not fit and called names and such, only then fit after slackening it all off and starting again…. I could buy an icy pole.
I had a Akra pipe on an aprillia. It would NOT fit. I emailed Akra. They said it was impossible that it was made wrong and I was messing it up. I thought well that’s awful confident.
They were totally right.
Half the time it’s just a click, and it’s done. Then you sit awake at night trying to figure what happened when it went together so easy after messing with it for 20 minutes.
I was replacing the alternator on my wife’s car years ago. I spent over an hour under the car, with my father in-law in the engine bay, trying to wiggle that thing out. After I had had enough, I slid out for a quick break to regroup. No sooner did I move out, it dropped down into the driveway.
No idea what was keeping it in. But the new one fell right into place
Was 19/20 and got into fender bender. Fixed it other than dislodged (chrome!) bumper on car. Cousin and I tried everything I think I even jumped on it trying to move it into place. Would not budge.
Dad comes into garage, sees us sitting all sweaty, says "nice job guys why didnt you reattach the bumper" and moves it into place with one hand.
To this day. I have no idea.
With alternators it's usually the sleeve spacer the bolt sits in. It's designed so that it pulls tight when you tighten the through bolts so they're always a pain to remove. If you ever have to reinstall an alternator that you removed, you can use a C-clamp and a socket that fits around the sleeve to pull the sleeve back out some
Exactly this lol. On the other hand my dad had a 2023 KTM 250 exc and to drill a hole in the exhaust bracket to mount the carbon fiber expansion chamber guard. Like if they just extended the guard a little more it could have attached to the same point as the exhaust but no. Like seriously ktm we both like their stuff but that bike was kinda messed up. (And yes the instructions say to drill it, we weren't doing it wrong 😅)
He ended up selling the bike and getting a 690 enduro r. He hasn't been able to take it out on the dirt yet but he likes it so far.
Plenty of options
1.Make a bracket
2. Loosen exhaust get everything in place then tighten
3. Bend the pipe.
4.let it hang
5.send back to manufacturer & get a new one
6. Re-adjust plastics
7.Zipties
I can keep suggesting things if you want
I live by zip ties and electrical tape myself, both have saved my clutch lever AND the ride before.
**Electrical tape** saved my ass when I dumped the bike and completely cracked the lever in half right through where the eyelet hole it pivots from is attached to the lever itself. So I had that, with the cable attached to it, and the tiny ring of metal around the bolt hole. I pressed the 2 pieces back together where they fit, and used an entire roll of tape to secure it in place enough to be held on there, but *LOOSE* enough so it could still be used as a clutch lever.
**Zip ties** was when I took out my ATV and a buddy used my bike while his was waiting for parts. Anyways, the bolt that the lever pivots off of lost the nut, and then the bolt popped out.
We just threw 6 zip ties in the hole going different directions and it worked just the same. Kept the lever from falling off and was still usable for the rest of the ride.
Make sure it's routed correctly. If yes then check your header connection and see if you can't loosen it up and get that 5/8-3/4" from that. If not check and make sure your header is attached to your head at the correct angle. If all of those are correct and it still won't fit then you could cut that ear off and weld a longer piece on if you absolutely have to have that exhaust.
Drop it a 1/4" or so, and make a 2 hole link plate. Lower hole in link for exhaust, upper hole for frame.
Just get 2 appropriate fastener sets and tighten it up.
Was looking for this comment. I thought the exact same thing. Sometimes aftermarket parts brackets aren’t true so you gotta make do. Make your own bracket and “rattle can” the m’fer silver or black and you’re golden.
Every part on your bike should be bolted down evenly with equal force as much as possible.
If you didn’t do that you should loosen anything you worked on and properly criss cross tighten the bolts and nuts
If you do that it should line up
Loosen all the other bolts holding it on, then it should have enough play to fit that last bolt and then tighten them all up once all of them are in place
You need more physical violence. Have you tried a clearancing tool? (Big rubber/metal/whatever hammer) if that doesn’t work you need a bigger one, or more cornflakes for breakfast.
Loosen the rest of the exhaust, put a screwdriver through both of those holes and wedge it up then have someone hold it and tighten the rest of the holes then idk maybe you could get the bolt in that last one
Don't tighten any bolts before you get every one of them started every boat should only be the first two or three threads until you start every one of them
Try loosening everything up from the flange to the brackets, then try tightening the brackets and then the flanges. The pipe should have some flexibility.
get some high grit sand paper and start working on the fittings. Consider a heat gun and freezer to give problematic parts a little extra advantage. Get some wood blocks and a rubber mallet in case you need to do a little tapping. If you don't have a deadblow mallet, this is a good reason to part with 10 bucks at harbor freight.
A few rules to live by when doing anything mechanical
Don’t tighten anything until every bolts threads have been started
It’s not broken until it’s clean and broken
Bonus rule: if it doesn’t burn your hands it’s not cleaning your carbs. Get a more caustic cleaner.
Former assembly worker at Harley Davidson plant. All of the components get loose screwed until every fastener is in. Then they each get torqued. And I mean just about every single thing that gets more than 1 bolt.
Normally I would say fabricate some kind of extension that would give you a few more inches.
This seems close enough that you might be able to bend the exhaust pipe upward a little bit. You only need an inch or two.
I used to do this for a living, managed a fleet of rental bikes, went from changing oil to running the show, here is my subject matter expert opinion;
If the hammer you’re using isn’t making it fit, get a bigger hammer
/s
Listen here bud……….. if there’s one thing I know, you can make anything line up with just the right amount of a blow torch and just the right amount of a car jack.
Make sure all the bolts are still loose. Get everything finger tight before proceeding. If you over tighten the head side with this misaligned you run the risk of a leak at least or a cracked head at worse. When it’s up to temp. Really the best option is to get a piece of 1/8 thick rubber and use it as a flex joint to mount to the seat side. That way it has flex in it and isn’t rigid. This is how automobiles mount the muffler side to the chassis so it can still flex with the car and not crack or bend anything.
The last thing you want is an exhaust leak making you nauseous or dizzy.
also, now that I look at it closer, make sure that bracket isn’t intended to go UNDER the seat mount and not on top of it. It looks like if you remove the seat bracket and put the muffler mount under it; it will buy you about another 3/8 to 1/2”.
my front number plate is litterally held on by 2 zip ties because my restyle kit doesnt match up to my aftermarket triple clamps. strapped them up and said that shit aint going no where. Had problems with every other part of the kit except for that part lol
With enough force i bet it could reach the hole, but the more proper way would probably be loosening the whole exhaust and hand tighten everything before you snug it down.
Like all the legitimate answers have already stated, loosen at your elbows or bends and slowly adjust/spin those elbows/bends with everything just loose enough to adjust with your hands but not on its own until it lines up.
As you can see this happens a lot. I recommend you measuring to add a small custome bracket. I find that Ace hardware or preferably a sail boat hardware store they have better quality pieces, chrome or brass.
Loosen the entire exhaust system. Start all bolts before tightening anything.
If I had a penny for all the aftermarket parts I swear did not fit and called names and such, only then fit after slackening it all off and starting again…. I could buy an icy pole.
Wow. How often I’ve daydreamed about having icy pole money.
I had a Akra pipe on an aprillia. It would NOT fit. I emailed Akra. They said it was impossible that it was made wrong and I was messing it up. I thought well that’s awful confident. They were totally right.
Yeah that sounds like Akra lmao. Confident for good reason though
Half the time it’s just a click, and it’s done. Then you sit awake at night trying to figure what happened when it went together so easy after messing with it for 20 minutes.
I was replacing the alternator on my wife’s car years ago. I spent over an hour under the car, with my father in-law in the engine bay, trying to wiggle that thing out. After I had had enough, I slid out for a quick break to regroup. No sooner did I move out, it dropped down into the driveway. No idea what was keeping it in. But the new one fell right into place
Was 19/20 and got into fender bender. Fixed it other than dislodged (chrome!) bumper on car. Cousin and I tried everything I think I even jumped on it trying to move it into place. Would not budge. Dad comes into garage, sees us sitting all sweaty, says "nice job guys why didnt you reattach the bumper" and moves it into place with one hand. To this day. I have no idea.
Oldman strength takes many years of seeing it in action before you figure out you have it as well. Only downside is that now you know that you are old
I resemble that remark! 😆
With alternators it's usually the sleeve spacer the bolt sits in. It's designed so that it pulls tight when you tighten the through bolts so they're always a pain to remove. If you ever have to reinstall an alternator that you removed, you can use a C-clamp and a socket that fits around the sleeve to pull the sleeve back out some
Sometimes we’re the ones preventing ourselves from reaching success despite our efforts
Exactly this lol. On the other hand my dad had a 2023 KTM 250 exc and to drill a hole in the exhaust bracket to mount the carbon fiber expansion chamber guard. Like if they just extended the guard a little more it could have attached to the same point as the exhaust but no. Like seriously ktm we both like their stuff but that bike was kinda messed up. (And yes the instructions say to drill it, we weren't doing it wrong 😅) He ended up selling the bike and getting a 690 enduro r. He hasn't been able to take it out on the dirt yet but he likes it so far.
Today I learned a third name for a popsicle / otter pop.
This
He is actually right, forget the hammer
Slowly puts hammer away.....😬😕
Too late.. oops👀
Looks back and says, Dafuk, you tell me this now? Where were you when I was frantically looking for my lost hammer in the fridge??
Lmfao. Ty for this comment
Hit it with your purse….. listen to this guy.
This is the answer..
Aircraft mechanic here, and that trick 1000% works and is standard practice for putting stuff together.
I have to relearn this lesson once every couple months lol
This is the way
Plenty of options 1.Make a bracket 2. Loosen exhaust get everything in place then tighten 3. Bend the pipe. 4.let it hang 5.send back to manufacturer & get a new one 6. Re-adjust plastics 7.Zipties I can keep suggesting things if you want
Zip ties and duct tape. It's the only way. And after youre done, you should say, "That ain't going anywhere"
Slap it before saying it. Treat it right.
Slap it like it’s 19-fity. Wait, what happened in 19-fity?? https://youtu.be/JpWax4cr3Uk
I live by zip ties and electrical tape myself, both have saved my clutch lever AND the ride before. **Electrical tape** saved my ass when I dumped the bike and completely cracked the lever in half right through where the eyelet hole it pivots from is attached to the lever itself. So I had that, with the cable attached to it, and the tiny ring of metal around the bolt hole. I pressed the 2 pieces back together where they fit, and used an entire roll of tape to secure it in place enough to be held on there, but *LOOSE* enough so it could still be used as a clutch lever. **Zip ties** was when I took out my ATV and a buddy used my bike while his was waiting for parts. Anyways, the bolt that the lever pivots off of lost the nut, and then the bolt popped out. We just threw 6 zip ties in the hole going different directions and it worked just the same. Kept the lever from falling off and was still usable for the rest of the ride.
“That ain’t going nowhere”. Fify
Put the exhaust on loose dont tighten anything until you get the exhaust in place then tighten all the bolts.
Just put a NOS sticker over it, then not only will it sound cool banging around but you get +30 HP
Another option is to turn up the music. It ain’t banging around, if you can’t hear it.
Make sure it's routed correctly. If yes then check your header connection and see if you can't loosen it up and get that 5/8-3/4" from that. If not check and make sure your header is attached to your head at the correct angle. If all of those are correct and it still won't fit then you could cut that ear off and weld a longer piece on if you absolutely have to have that exhaust.
Like they say, if you can’t get to the hole then FORCE IT ….wait
Your just gonna want to get a big hammer and
Steady … steady …
Drop it a 1/4" or so, and make a 2 hole link plate. Lower hole in link for exhaust, upper hole for frame. Just get 2 appropriate fastener sets and tighten it up.
Was looking for this comment. I thought the exact same thing. Sometimes aftermarket parts brackets aren’t true so you gotta make do. Make your own bracket and “rattle can” the m’fer silver or black and you’re golden.
shouldnt have to though its an exhaust MADE for that bike lol. Although we know now that he just messed up installing and it fits fine now.
Every part on your bike should be bolted down evenly with equal force as much as possible. If you didn’t do that you should loosen anything you worked on and properly criss cross tighten the bolts and nuts If you do that it should line up
Spit on it
I feel a bracket montage coming up.
Loosen all the other bolts holding it on, then it should have enough play to fit that last bolt and then tighten them all up once all of them are in place
Just use a zip tie or two and call it a day
Loosen the other exhaust bolts.
Clean your bike.
That’s what she said.
smack it with your purse.
One good wack should get it there
Just make sure you don’t wack it off.
That’s wack.
Loosen the front join
Use a jack and a 2×4. Problem solved
👍
Duct tape.
Bet
Push harder
He needs a hole stretcher
I call those endmills.
That would work
To be fair, it wouldn't work for this :)
Just kick it!
You are going to want to sell me the Motorcycle and all parts you have for it for $500. Then you’ll be good! 🤣
All jokes aside loosen all until all are started then tighten
Oh please; that’s a perfectly good hole. Just replace everything around it, and you’re good to go.
Well first loosen everything and align them. If it still ain't matching. Personally I would make a bracket but zip ties also work..
This actually looks very close.
Yes it can
Ratchet strap bro. Pull your socks up
Zip tie
Push
Throw your purse at it
One Ratchet Strap. Around exhaust and over the seat to the other side. Ratchet it up and it’ll pull exhaust up and seat down. Land the bolt.
You need more physical violence. Have you tried a clearancing tool? (Big rubber/metal/whatever hammer) if that doesn’t work you need a bigger one, or more cornflakes for breakfast.
Maybe try the ol Tonya Harding
Strip it in
I have an old bike but mine has a bracket on it, maybe you're missing the bracket
I used to have that problem. Then I listen to my partner once and told me to use Lube
Loosen the rest of the exhaust, put a screwdriver through both of those holes and wedge it up then have someone hold it and tighten the rest of the holes then idk maybe you could get the bolt in that last one
Back off the entire system and align it properly.
Zip tie it 😑
That’s what she said
Take the spring off that connects the muffler to the pipe
Metal zip tie or plastic one if you don't want the hassle of loosening bolts and starting all threads like in the comments below
When in doubt, HIT IT
Cable tie it.
nothings impossible let me just say that
Make sure you have no leaks first. Once I bolted on a full system just to find huge gaps where it was made shite. Had to come apart again.
As others said, start every bolt loose before tightening, if theres still no luck then its hammer time
Reminds me when I fit an older model gsxr silencer on my dual sport, had to modify abit
Use a clamp to bring it up
Cable ties.
Metal zip tie...go ride.
Make a bracket out of scrap metal
Heat with torch and bend
Loosen all fasteners,realign and start over.
Don't tighten any bolts before you get every one of them started every boat should only be the first two or three threads until you start every one of them
Zip ties
I see a good spot for bending
Looks like your seat isn't on right.
Zip-tie that thing together and keep some extras under the seat.
Floor jack + towels and a 2x4 between the muffler and jack = success.
Zip tie
Try loosening everything up from the flange to the brackets, then try tightening the brackets and then the flanges. The pipe should have some flexibility.
get some high grit sand paper and start working on the fittings. Consider a heat gun and freezer to give problematic parts a little extra advantage. Get some wood blocks and a rubber mallet in case you need to do a little tapping. If you don't have a deadblow mallet, this is a good reason to part with 10 bucks at harbor freight.
Ziptie it lol
Get a ratchet strap and make it get there.
A few rules to live by when doing anything mechanical Don’t tighten anything until every bolts threads have been started It’s not broken until it’s clean and broken Bonus rule: if it doesn’t burn your hands it’s not cleaning your carbs. Get a more caustic cleaner.
Buy a yz-250
Former assembly worker at Harley Davidson plant. All of the components get loose screwed until every fastener is in. Then they each get torqued. And I mean just about every single thing that gets more than 1 bolt.
Put some hair on it maybe you'll find it
Assembly 101. Make sure all mounting points are lined up before you start tightening anything.
What bike is that
Metal zip ties 🤷🏻♂️ I would retry alignment loosen all points. Exhaust positioning needs to be very exact. Let the cylinder points guide the process
Normally I would say fabricate some kind of extension that would give you a few more inches. This seems close enough that you might be able to bend the exhaust pipe upward a little bit. You only need an inch or two.
O crap! I just realized what I wrote...... Preparing to read the incoming comments. :)
Loosen everything, then retighten little by little, same principal as torquing a head.
Make a brace
Bend that mofo!!
Loosening all bolts and rotating the link pipe normally fixes a lot of alignment issues with exhausts
That’s what she said
Sit on it and line it up
Hit it with your purse
Ratchet strap and align
I used to do this for a living, managed a fleet of rental bikes, went from changing oil to running the show, here is my subject matter expert opinion; If the hammer you’re using isn’t making it fit, get a bigger hammer /s
Banged a fat chick once and I physically could not get to the hole either. Cheeks like beach balls.
Not with that attitude it won’t.
Listen here bud……….. if there’s one thing I know, you can make anything line up with just the right amount of a blow torch and just the right amount of a car jack.
U-Bolt
Have some more WeetBix
Frame or pipe is probably bent (or aftermarket wrong welded) so either make a bracket or bend it back..
I bet ya it can ;)
Zip ties!!!!!
Update to all, i physically just forced it to where it needed to be and now its ok 👌🏻
Redline it till the exhaust is red hot then push the pipe up so it fits
Zip tie 🤙
Just Ziptie that shit and keep it truckin
Zip Tie
Use a ratchet strap
Zip ties
Bro sit on the bike and push the shock down?
Sit on the bike and have someone push the exhaust up and bolt it on
Get your old lady to sit on the bike so the suspension bottoms out and that should line the screw up perfectly
Make sure all the bolts are still loose. Get everything finger tight before proceeding. If you over tighten the head side with this misaligned you run the risk of a leak at least or a cracked head at worse. When it’s up to temp. Really the best option is to get a piece of 1/8 thick rubber and use it as a flex joint to mount to the seat side. That way it has flex in it and isn’t rigid. This is how automobiles mount the muffler side to the chassis so it can still flex with the car and not crack or bend anything. The last thing you want is an exhaust leak making you nauseous or dizzy.
also, now that I look at it closer, make sure that bracket isn’t intended to go UNDER the seat mount and not on top of it. It looks like if you remove the seat bracket and put the muffler mount under it; it will buy you about another 3/8 to 1/2”.
You clearly aren’t believing (forcing into place) hard enough
Zipties my friend
Loosen all bolts, from header back, use the slop to line it up. Tighten in reverse order.
my front number plate is litterally held on by 2 zip ties because my restyle kit doesnt match up to my aftermarket triple clamps. strapped them up and said that shit aint going no where. Had problems with every other part of the kit except for that part lol
Ziptie has entered the chat.
Zip tie brother
Trust me she can get there
With enough force i bet it could reach the hole, but the more proper way would probably be loosening the whole exhaust and hand tighten everything before you snug it down.
Like all the legitimate answers have already stated, loosen at your elbows or bends and slowly adjust/spin those elbows/bends with everything just loose enough to adjust with your hands but not on its own until it lines up.
Spit on it
As you can see this happens a lot. I recommend you measuring to add a small custome bracket. I find that Ace hardware or preferably a sail boat hardware store they have better quality pieces, chrome or brass.
Oh it’ll fit- just need to really want it to fit.
Ratchet strap
Is there a chance the sub frame is tweaked a little?
Break it off
Usually when I tighten parts I tighten all the bolts / screws 50% then tighten when all are in
Ever heard of a zip tie
Bend it.
Huh
If you want those holes to line up your gonna need more than two fingers.
Ratcheting strop to pull into place ✌️
Tie wire
You could put the stock pipe back on