+1 on pain in the ***. you got to force it. plain and simple, make it your bitch

 

Make sure you have the front header fully seated in the exhaust port, you need every bit of room. And position the flange to allow the most clearance on the rear till it gets over the fins. Worry about getting the flange over the studs last. Don't bother with loctite, this location is too hot for blue to work and you don't want to use the red (or you'll risk having the studs come out if you ever try to remove the bolts).

I don't remember everything I tried or exactly what worked except that I was draped over the bike pulling the rear header pipe into place. All I can say is you have to keep wrestling with it and moving things a little till you finally get it to go. Maybe try with the front loose and pulled to the rear of the exhaust port (but still over the fins) to get the rear header on then put the front into the port. You could also try sliding the flanges up the pipes till you get them over the ports then slide the flanges back into place. Oh, and stop being such a puss! j/k

 

BTW, my favorite line in the instructions (as I sat alone doing the install):

 

Thanks everyone! It is in the local auto repair shop. My co-workers brother owns the shop so I think I will be in good hands.... It really sucks when you want to learn something and you do not succeed. Again, thanks to all who replied!!!!!

 

Too bad you weren't able to do it yourself, I installed mine a couple weeks ago with the help of a friend. I was pushing and pulling while he guided the flanges on the bolt studs. After they are on and you put some mileage on the pipes they come off and go on a lot easier the second time. I had to take them off to put the forward controls on. Your gunna love the sound compared to the stock pipes!