just bought a v & h exhaust for a 2000 x1, the pipe is 1/4" bigger diameter than the header pipe, as anyone come across this before, i think i need to make a sleeve, any suggestions or help appreciated
Get an old oil can or similar and a pair of tin snips.
Cut the can into strips and wrap them around the header pipe until the gap is taken up. Fit the end pipe and do up with an exhaust clamp and you're done.
get an old exhaust and cut the end of the part where it joins the header. Slice it down the middle so there is now a gap and it can be closed around the header on the bike but can fit inside the mufflers. Then fit the exhaust clamp...
Steve buell did a full race system which was a bigger bore pipe,sounds like you have bought a full race can. Just get a new sleeve welded in,if it is stainless Prosport engineering back of Granbys in Ilkeston will do it.They are making full stainless exhausts for a trike i am doing for a customer.
If I get time over the bank holiday will come and have a pint with you at your do.
Cheers Ian