| Author | Message | ||
     Haaken |
I ordered a set of james gasket exhaust gaskets and the were too big to actually fit in the exhaust ports. As a result they both crumpled themselves to pieces when i tried to install them and now i am left again with no exhaust gasket and my project is stalled AGAIN, and et again I have wasted money... Can someone please recommend me a set of proper exhaust gaskets and maybe some tips for instilling them? | ||
| Blackm2 |
It can be frustrating. Is it a stock header? If so the factory gasket are the ones you want. just have to feed them in a little bit at a time and work it all the way around until it is seated. | ||
| Brother_in_buells |
Make sure that the exhaust ports are perfectly clean! Scrape all the corrosion etc and clean with some fine sandpaper. Put a small bit of copper grease or so on the the port edges and tap/press the gaskets in with a wooden stick. Take it easy with those gaskets and they stay in one piece. Some did put them in the freezer but i did it without freezing them and it worked okay that way. | ||
| Haaken |
I do have the stock header. The gaskets I got wouldn't even come close to seating in. I did clean up the ports as well. IDK if the ones i purchased were produced incorrectly or what...I read that they are a pain to instal but these were literally not going in at all... o the coper ring style gaskets work at al? I would gladly pay extra if i know they will work the first time...I am tired of constant setbacks, paying for parts that don;t work, ad even worse the shipping on top of it all. | ||
| Jolly |
The stock ones DONT "FIT"...... But..... They do..... You would swear they are incorrect.... But freeze them, then proper finagling and they do fit... I buy two sets and freeze em both cause as many times as I've done this I still dork one up... I did buy the Kim's tool and it really makes it a little easier.... I justified the tool expense due to how many bikes I own. | ||
| Nitrokeeb |
I used the copper gaskets from James and they were zero fuss to install and seem to seal well. But the header sits deeper in the head because the gasket is thinner, which may cause header/muffler misalignment and cause stress on the header. I do know I had a hell of a time getting my muffler to seat on the header during installation. | ||
| Steveford |
Go to your local Harley dealer and pick up some Screamin' Chicken exhaust gaskets 17048-98 | ||
| S1owner |
Have to disagree Steveford- Stay away from the thin screamin Eagles there is not enough there to cushion the header and seal it completely. Get the stock gaskets if you need to order them contact Lance 651 on here he works for St Paul Harley and will hook you up | ||
| Ebutch |
I use These www.ebay.com/itm/COMETIC-EXHAUST-GASKET-SET-FOR-HA RLEY-1984-PRESENT-EVO-EVOLUTION-TWIN-CAM-/12193638 4582 https://www.youtube.com/watch?v=v8suwaaGFCI | ||
| Ebutch |
www.jpcycles.com/product/442-997 | ||
| Alfau |
The exhaust mounting system on these things is shit to begin with. I welded a small wire wheel the size of the gasket port to a 6" rod then cleaned the port of the black gunk (engine black) until it was shiny aluminum using a cordless drill. The exhaust gasket expands when the pipe is bolted into place. Don't snap the studs off tying to make a good seal. No more problemo. | ||
| Steveford |
I've installed dozens of the Screamin' Chickens with no problems. Maybe I've just been lucky but it was simply clean the port, pop them in and then torque the header studs in small increments. | ||
| Haaken |
Ebutch, those are the exact gaskets i just ruined. I couldn't even get them started...If i had gotten them started and then didn't press them in evenly, I would just say it was my fault, but they wouldn't even begin to set into the exhaust ports... | ||
| Ebutch |
Press https://www.youtube.com/watch?v=v8suwaaGFCI | ||
| Ebutch |
Alfau found the cat it's white and gray  | ||
| Haaken |
Watched that video way before i started this thread...If i could have even gotten them started it wouldn't be an issue...The ones i got wouldn't even get started at all. I couldn't remotely get them to stay on their own. Tried the front and back cylinder. Potentially I got a bad batch, idk. Will try a harley shop today for some OEM gaskets though. | ||
| Brother_in_buells |
Yes some of these gaskets are rubbish to begin with! Had it once ,looked like the material wasn't properly woven together. | ||
| Brother_in_buells |
Yes some of these gaskets are rubbish to begin with! Had it once ,looked like the material wasn't properly woven together. | ||
| Haaken |
I went to HD today and shelled out more then I probably should have for 4 OEM gaskets. They do at least feel better then the James gaskets i tried yesterday. Hopefully I don't end up needing all 4 of them... | ||
| Haaken |
Finally got two to go in (sort of...) and went to reinstall the header. Just to clarify as I can't remember, the flanges that bolt on should sit flush with the head, correct? I cannot get them to get anywhere near flush. The header itself didn't want to seat at all in the exhaust ports. I am fairly sure i ruined another set of exhaust gaskets (5 in total now) and my frustration level is rising to new heights. Does anyone have any suggestion? This project started as something fun to alleviate stress from work and I'm almost throwing wrenches now. | ||
| Alfau |
Does anyone have any suggestion? to alleviate stress? Yoga; I want to sleep with a sexie model OOOooooMMmmmmmmmmmm, I want to sleep with a sexie model OOOooooMMmmmmmmmmmm, Next day after a very difficult night having his wish granted.. I want to sleep with a sexie female model OOOooooMMmmmmmmmmmm, | ||
| Jolly |
the mounting bracket or flanges that basically pull the header into the gasket don't really sit flush against the head, and the header tubes don't sit truly square in the header "port" which is one reason they use a woven metal crush type header gasket. When you remove a header and inspect the gasket sitting in the port they are never evenly deformed. It's possible you are over thinking this or are trying to make HD engineering meet euro spec design/engineering specs.... Once you get the gaskets seated in the port, you very carefully align the header and slowly walk each header tube in tightening one cylinder then the other so that you are walking the header down to proper position and torque. If you fully seat one cylinder, then move to the other I don't think it will work. If you can wait a few days I'm very close to doing this on my current build and I can send photos with each step. | ||
| S1owner |
Walk away for a day! The header flange does not seat all the way to the head. Are you using manual? Did you freeze the gaskets first it makes them shrink a hair. Do you have the muffler off you should have the whole system off then install header loose then all of the exhaust loose the begin to tighten | ||
| Haaken |
I did freeze the gaskets overnight and that really didn't help at all honestly. I did get the gaskets in with only some minor deformation, so hopefully they wont leak. The problem is that there is so much gap between the exhaust flange and teh head. My understanding is that the torque spec is somewhere around 14 ft/lbs. I know for a fact I have been applying more pressure then that just to get the nuts somewhat on and tightened...Hopefully I dion't end up snapping a stud...If that happens, its done and im doing a full rebuilt at that point. I was trying to tighten each one evenly and moving from front to rear, side to side to make sure everything settles evenly, but it doesn't really seem to be making much difference. It also doesn't help that I am covered in fiberglass from header wrap, lol. | ||
| Ebutch |
Is header leaking after install ???? Is it stock header or race header ??? Are you useing Retainer rings ???? Some use 2 retainer rings per port.Race headers are prone to leak but can be modified.  The gaskets Are a Tight Fit !!!! | ||
| M2owner |
I had the same problem with the stock tapered style gaskets. Tried freezing them and still screwed them up. Went with the flat type and have not had any problems. Lance recommends the stock type but he must have a better way to squeeze them in. No problems for me getting things lined up, just had to jiggle things around a bit and tighten the headers last. They only need 5 foot pounds per the book I think. Also, replaced the flange nuts with castle nuts about an 1 1/4" tall and safety wired them. Don't have to over tighten and still seals. Good luck. | ||
| Haaken |
I believe my headers are the standard 2000 X1 lightning headers? I am running the retainer ring. It is a new james gasket ring that came with my original kit. I think at this point I am going to need to take it apart again and put in new gaskets. From what I can see myself, and what I have read, and what I am learning here, the header should go on much easier then what I am experiencing... | ||
| Jim2 |
I use the Screaming Eagle flat style gaskets and have never had a problem installing them. When I first go to seat them the outer edges don't fit so the gasket starts to bow in like a bowl. I then take a wooden dowel and lightly press the edge in just a little and walk it all around the gasket until the entire gasket is seated flush against the bottom. I've never bothered to freeze them. I originally tried using the stock cone type gaskets and I didn't really like them, I never seemed to get a good seal. | ||
| Ratbuell |
In the past, I have crushed/rounded/curved the leading "corner" of the gaskets, so they would wedge into the ports a little better. You can also grab a dremel and round the outer corner of the port in the head, so it's not a square edge. Think of a funnel. The flanges on the header never seat flat to the head - partly because of the varied seat depths mentioned above, partly to allow for thermal expansion of the gasket, head, and header. | ||
| Preybird1 |
I hated the factory set up and i found the damn studs would snap off and would not stay torqued for nothing!! After i had to grind and drill out a busted stud for the 3rd time i learned 2 things. 1. Hated the factory header and i have seen 2 cracked personally one being my own. 2. The exhaust studs are of pathetic quality! My fix was to buy an aftermarket D&D system. Fantastic by the way because it come apart into 3 pieces and i do not have to even touch the chin fairing to remove it! And i had the junk HD studs removed and my friend has motor build shop for racing bikes and he modified my heads to take 10mm studs and i have had no issues for years now. |
