BMW R1200R R1150R/T F800 K1200R R1100R/T R1250R RnineT Message Board

I am so happy to hear I have not lost touch with my mechanical abilities...I am having trouble getting my Remus header system to fit! I have been fooling with the fit-up for over a month. I have the header pipe to the "Y" connector fitting pretty well. My problem is that the Power Cone would not clear the saddlebag. I finally had to remove the rubber mount from the rear support (supporting the muffler) and bend the chrome hanger about 10 degrees (in the direction of the muffler). Using some large washers to make sure I clear the opening in the footpeg mount and some final positioning I got it to work. I have enough clearance that with the saddlebag loaded it will not touch the muffler. Just in case I also purchased some self sticking heat shielding to make sure I don't get saddlebag meltdown. Heat shielding from a K1200LT.
To get the header pipes to fit into the "Y" I used some emery cloth to clean up the header pipes. I have a great fit on the "Y" support. Remus did send me some springs that were missing and a new Chrome support hanger but other than that nothing else. I just keep hearing that it fits and clears the bag. I could not even get any instruction sheet for the header system they keep sending me instructions for putting a hexacone on the stock headers.
I don't seem to have any appreciable vibration from the exhaust with the rubber mount removed and I feel comfortable that there will be minimal heat stress because of the slip connection between the muffler and the transition piece (the piece between the "Y" connector and muffler). I am getting ready for a 2,000 mile trip the first of May so I'll know more then.
I will say this about the exhaust...it does work. The front of the bike is off the ground through third gear under full throttle acceleration. The pipe really enhanced the performance. I can say this with some authority because I bought the bike new and put the exhaust on after I did the 12,000 mile service. The system is a good one it just has fit-up problems. In order to get it right all of the slip joints have to "slip" and as you and I found out they don't.
I find it sounds like an old Austin Healy or triumph sport car with a modified exhaust. Those that have heard my bike say it sounds good...I left the silencer in the muffler.

Hi Charlie
I started with emery paper on the Y pipe too but soon realized that they were oval shaped. That said, the pipe must have been squashed at some stage so I think my problem lays with the hanger part. I'll mess with it tomorrow. In your case it must be disappointing not to have the can fit properly when you have all Remus components. I nearly bought Laser headers but was put off by all the extra pieces to join up.
Regards Mick.