One of the primary reasons for headers to have interference problems is the
variation and movement of the Tiger chassis after several years of use and
or damage. It is not unusual for the whole cross member to collapse by 1/8
to 1/4 inch as measured between the frame mounting holes. As the cross
member collapses, so does the frame thus leading to the fitment problems
that sometimes arise. Checking the stock frame/cross member dimensions
should be done whenever the engine is removed, and when it becomes
excessive (over 1/8 inch) both should be pushed back to the correct
locations. While your doing this, be sure to examine the frame tube nuts
connecting the crossmember to be sure that they aren't pulling down through
the frame and also the frame itself, forward of the motor mounts, for
cracking, de-lamination and other signs of damage. These two fatigue
failures are becoming very common in high use Tigers and its easier to fix
them early before the damage gets worse.
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