Installing Pipe back on .. what gives

[DOUBLE G]

Ok, I took my pipe off to paint it a few weeks ago, and it was tight getting it off the shock but I thought nothing of it. NOW when I am going to install it I cant get it to line up. when i put the header in the head and put the bolts on the mounting bolts dont line up. off a quarter of an inch. if i try to get it on the shock mount first I cant get the pipe in the head. and my pipe is old and was rusty, i really dont want to bend and pry much. . what gives.

[HymieP]

Bolt into the head first and then pull a little bit to get it mount/install on the shock nut. It can be tricky especially for older ones. You can also drill out or bore out the hole on the muffler mounting hole if it's really tight.
Jamie

[hornetgod]

I just start the nuts on the collar on the cylinder side and work, pry, and curse the back exhaust bracket on the upper shock mount. Be certain to just start all nuts and bolts before torqueing everything down. Jamie had a good suggestion, Opening up the back hole a bit is another good option. Good Luck!

[DOUBLE G]

Thanks so much. . you guys are great. I thought I was loosing my mind or to many beers today. it was 70 degrees here in Middle Tn. My pipe was a little rusty and i hate to put on it to much in fear of it breaking on me. I might ream out the shock mount hole. Thanks again. I cant wait to post my pics, this bike has come a long ways.

[unit5alive]

Mine's the same way , always a pain to get back on!

[bjatwood]

That's Honda for you. Very tight tolerances...even for a tailpipe!

[kmcrab]

Just my .02 worth...My mechanic showed me the trick of replacing the exhaust. First take out the engine mounting bolt(s) except for the CENTER one. You will need to brace the engine on something or have someone hold it for you. After you do this, install the pipe in the engine and then lift up on the engine until the back hole of the pipe is lined up with the shock mount. Bolt it on and gently release the engine back to put the engine mounting bolts back into the frame. Done. (If your engine guard is on, you will have to remove those bolts from the frame also. You just want the engine to move up and down freely while you reinstall your pipe.)

[SS_canuck]

I've had to use the same method as kmcrab. Over almost 40 years of use and a abuse, Its not unlikely that the pipe has been tweaked from an impact or warped from multiple heat cycles. I can't imagine Honda allowing the poor assembler to wrestle the pipe into place when the bike was new.
Good luck!