Yamaha TRX850 Enthusiasts Forum

I just trial fitted my OVER headers to ensure clearance and found two things...

(1) the mounting hole underneath does not line up with the mounting bracket on the headers, and;

(2) there is a markable clearance issue with the headers and the swing-arm - the right hand side has around 5-10mm gap between the pipe and the bottom outside edge of the swing-arm, whereas the left-hand side has approximately 40-50mm gap.

Is this a known problem with the OVER headers (I would assume not as they are a very popular after-market system)? And what can be done as the whole system off the bike looks very straight.

I have attached some pictures (that I took with my phone ) as a reference guide. Hope someone here can help.
Cheers,

Schmiffee

for sure sumert is not as it should be ,, has the overs been in some sort of crash ? can you swing the left side in ? the only other thing i can suggest is give it lick with the oxy and tease it back in to alignment

Youll find you can even the gap up by ajusting the clamps on the cans themselves.i.e rotating them around slightly and rebolting them to the frame brackets.

steve speed wrote:for sure sumert is not as it should be ,, has the overs been in some sort of crash ? can you swing the left side in ? the only other thing i can suggest is give it lick with the oxy and tease it back in to alignment

What i´ve heard it has been the same for at least two more, Peder had the same...
Will report after the weekend when i get mine!

This is just like I used to say:
"If it won't fit, apply more force."

Tarwetijger wrote:This is just like I used to say:
"If it won't fit, apply more force."

I think I'm with dobbo on this one. And if that doesn't work, dinnae be afeart, just bend the recalcitrant pipe out of the way of the swingarm. It's unlikely to hurt them IMO, especially if you apply lots of heat first. Or are these particularly delicate-looking headers?

Mines the same, although i think they're original headers, 2 into 2, with micron carbon race cans, left side sticks out more, big spacer pulled it in better, but still not perfect.

Dave E

It's all a matter of adjustment. I've had 2 Over systems and they both ran close to the chain. I used different length alloy spacers than what was supplied to get them to sit right.

so its still not over when its over.. Hey killer you where sayin its all over now...

OVER CCCHHHTTT....

Ok so this is a known problem. I find that the gap on the left-hand side (chain side) is not too bad - maybe a bit large. It is a very big distance, but at least it will not come in contact with the swing-arm. The one on the right however is much too close to the swing-arm for my liking. I can just see it connecting with the swing-arm and dinting my beloved pipes.

So is the consensus to heat and bend?

Adjusting the clamps? Are these the brackets at the top the headers (that tighten the headers into the outlet ports of the cylinders)? Should I tighten one first and then the other to help this alignment issue? Or should one of these be spaced out a little to help with the alignment further back?

Thanks for the help so far....

If you have had this issue I would especially love to hear (read) how you combatted the issue and the end results (performance and aesthetic).

The clamps are the chrome metal straps with the rubber strips under them. Ajust these till you even out the gap and then bolt them up to the mounting brackets. My over system is only connected to the head and the straps around the cans,it does not connect on anywhere else.

DOBBO wrote:The clamps are the chrome metal straps with the rubber strips under them. Ajust these till you even out the gap and then bolt them up to the mounting brackets. My over system is only connected to the head and the straps around the cans,it does not connect on anywhere else.

Whatcha use for exhaust gaskets??

Killerwhale Ive only taken the pipes off once and did not disturb the gaskets. Sorry mate cant help.

Schmiffe, I checked my headers and they are exactly the same as yours, clearance on none chain side between end of header and swing arm is 2 cm, whilst the chain side is 3.5 cm!!

Dave E