Well now TBR wants the muffler canister back to look at everything. I guess I'm just beyond being pissed at this point (more defeated) even though I specifically asked if I should send everything back two weeks ago -- they said no. I'm probably looking at another 3 weeks for shipping to California, their inspection and then shipping back to Florida.

At least I was able to get the stock muffler gasket so it's all together now and I'm riding.

One comment I will make, for anyone else who had problems with fitment on their 250SF, you should contact TBR and tell them. When I spoke with TBR weeks ago they said they hadn't heard about any fitment issues with the 250SF. Whether that is true or not, I do not know but they did have a point. If they don't know about it, how can they correct any issue(s)?

 

Update.

TBR is modifying the S pipe for both the S and SF.

I should be getting the new stuff in a week or so.

(It's only been about 2 months. Oh well.)

 

Got the pipe back from TBR.

A couple of things are different:

1. Mid-pipe is definitely bent differently (weld can be seen).
2. X-lite ring is now two pieces.
3. They added a spacer where you connect the canister to the top mounting point.

Installation was night and day compared to the first one. The only challenge, again, was connecting the TBR mid-pipe to the header pipe. Still took some finessing to get it to fit all the way. But from removing the rack and side cover, uninstalling the stock system, adding heat tape and then installing the new TBR and buttoning it all up – it was about an hour in time.

Some pix:

 

Phew, just spotted this thread, sounds like a major.
I fitted a Two Bros on my 09 250s.
Only problem was the "s" pipe was to short by 3/4 of an inch.
Had it extended where it joins the front pipe and all was good.
Definitely need to ensure your mid pipe is lined up and the correct length.
I found loosely bolting the cannister on first was helpful. This allowed me to position the mid pipe and check the length.

 

The new mid-pipe I received was, if anything, a tad too long. It could have been shortened by .25" or so. Then it would have lined up with the top mounting point perfectly but it was close enough to make it work.

 

Finally came over here from SMJ. I too will be getting a new can from 2BR, just as soon as I can find the time to pull it off and send back. Yes a pain in the butt. Hope the new pipe and can fit....