WTF Exhaust Gaskets, are you too good for your home!?!

[Joab]

Alright...so, I was putting the bike back together, and I go to put the exhaust gaskets in. Then put the exhaust on. Apparently, this sequence of events is just too much for me to handle, because it appears the exhaust will not go in with these freaking gaskets!







This is all I pulled out of the exhaust ports when the exhaust came off.



SO... now what??

[EricHa]

The gasket in #1 looks farther recessed than the one in #3. Are you sure that there isn't an old gasket still in #3?

Also, I would think that threading the exhaust studs in the head first would make the job much easier. I now defer to the XS gurus......

[Joab]

Yeah, it isnt pressed in all the way. The issue I am having is the flange on the end of the header will not allow the header to go past the gasket. I am pretty sure if I force it, it will just tear up the gaskets, then they will just look like those remains on the ground, if I can even force it in at all.

[EricHa]

The end of the header will meet flush with the gaskets, and the diamond flanges on each pipe will fit over the exhaust studs. Then tighten them down with the nuts. This will push the gaskets up into the head. Is this what you are wondering?

[EricHa]

OK, I may know what's going on. You need to have threaded studs sticking out of the head, like the ones in the pic below.....



Do you have the studs to thread into the head?

[Joab]

Maybe this exhaust isnt suppose to use gaskets? The flanges on the end of the header go deeper then the gaskets, pressed up against the gaskets, the diamond flanges wont even press up close enough to to tighten on the allen bolts.

[Joab]

No my exhaust was attached with allen head bolts.

[EricHa]

All XS1100 exhausts use gaskets. Your exhaust is typical, nothing special. The flanges do not need to contact the head. In fact shouldn't I believe. Heading out, but others will be here.

[natemoen]

Yeah, it isnt pressed in all the way. The issue I am having is the flange on the end of the header will not allow the header to go past the gasket. I am pretty sure if I force it, it will just tear up the gaskets, then they will just look like those remains on the ground, if I can even force it in at all.

The header seats up against the gasket, it does not go past the gasket.

The gasket gets sandwiched between the exhaust flange lip and the exhaust port.

[BA80]

Looks to me like there's 2 gaskets in the #3 port.

[Joab]

Alright, I think I see where I was getting confused. I was thinking the diamond flanges had to be flush against their mounting holes for the allen bolts, and that simply cannot be for the gaskets to rest properly against the header flange. Going back out to the garage to either mount it up or throw a motorcycle through a wall.

[crazy steve]

You definitely want studs and nuts on these, not bolts. Using bolts, you'll run a pretty good risk of tearing the threads out of the head....

[Joab]

Yeah, you and EricHA are right on that count Steve. These allen bolts are a pain, but thats what came on the bike, I didnt know any used studs...I will go out and look for some this weekend.

[skids]

You definitely want studs and nuts on these, not bolts. Using bolts, you'll run a pretty good risk of tearing the threads out of the head....

I have a 4-1 header that used one regular bolt (previous owner did that) and I believe all the others had allen nuts on the header studs. This makes an open wrench have descent access where the head pipe covers the end of where a stud would be. I liked it, so I am still using it.

[skids]

PS, you just want to seal the head pipes with the crush gaskets. There is not need to torque the heck out of it! Also, I use "never Sieze" on the bolt. I hope it doesn't cook into something like glue...