Anyone had any problems with their 800 exhaust rubbing the motor and rattling? Today while riding I developed a very anoying rattle. I removed the side plastics, heat sheilds and can see that the pipes are hitting the block right in the bend where the pipes pass over the block. You can see evidence on the aluminum block where the pipe is rubbing. Has anyone else experienced this problem? If so what was your solution to fixing it?

 

I have not seen a problem with my 06 800, but my 02 700 rubed really bad. I finnaly had to get a new pipe. On the other hand I took off my side shields on my 800 last night and found the plastic had melted a little bit on the right side by the pipe. It looks as if the shift rod pulled it in closer when shifted in reverse. Not enough to worry about right now but I will keep a close watch as fit and finish issues on an $8000.00 machine should'nt be an issue.

 

Pics Here http://public.fotki.com/msc5195/2006...rts/page2.html

 

mine started rubbing just the other day , have no idea what happened or why , going to check the motor mounts and see if that has some thing to do with it

 

My 800 rattled rattled like crazy, mainly at speeds just off idle. I bought some header wrap at NAPA and wraped it around the pipe to insulate it from the engine block. It was kind of a pain in the butt to install since there's not much room to work in. I had to poke holes in the wrap to reinstall the heat shield bolts. The first couple times I went riding it worked awsome, no rattling and not quite as much heat coming off the pipe. However the rattle has come back a little. I'm not sure if the wrap is starting to wear through or if the rattle is coming from a new location. I'm also interested in some other solutions.

 

i have the same problem with my 06 sp800. i had it in the shop recently and they looked at the engine mounts and found they were fine but said they might be able to shim the engine to fix the problem. I decided to take it to a muffler shop instead. they said to heat it up while still installed and bend it away from the case. i dont know if that will work without burning something up. I also thought of cutting it on either side of the bend and welding a 1/2 inch piece or so on either side to raise it up. maybe some one will try this and tell me how it works.