With the stock pipe there was very little room between the pipe and the plastic. And it would not adjust to move away from the plastic. My HSP has a lot more room away from the plastic

 

Agreed Scrammy, I just went and looked at the pipe, and there is no way it will move away from the plastic, or anywhere really.

 

Could the metal tabs the hold the plastic out be bent in? Try loosening the exhaust and pushing it back a little and retighten, you won't know for sure till you try it.

 

I did with my stock pipe and bent the mounting tabs with no luck at all.

 

I had the same problem with my 06 and they replaced my old heat shield with the new fix ( a much larger heat shield). So there is a problem they know about and a way to repair it, yours should be covered under warranty since it was a pre existing problem, I have posted the part number for the fix in the past I'll see if I can find it

 

The part number for the heat shield repair is 2876773

 

Does that heat shield repair fit all the Sportsman models?