Installing Exhaust Gaskets

Discussion in 'Engine, Fuel and Exhaust' started by SteveGleckner, Aug 31, 2016.

  1. Hi All,
    I am having one heck of a time getting the wire mesh exhaust gaskets installed in my 2005 Ultra. Got the old ones out and cleaned up the port surfaces. Getting the new ones in has proven difficult. I tried to keep them square with the port but they just don't fit. It docent help they are fragile. I am afraid to tap on them very much so I don't distort them. This is on the rear port ... can't wait to try the front cylinder port (even less room to work.)

    Any of you know any tricks to make these go in easier. If I can't get them in I will order a set of high performance copper gaskets and see if they go in any better.


  2. Jack Klarich

    Jack Klarich Guest

    Look here, I have bearing driver sets, but this home made tool will work
    coopernicus likes this.
  3. Thanks Jack ... I will give it a try. Not sure how hard it will be to do the front cylinder since the frame downtube sits right in front of the port.

  4. coopernicus

    coopernicus Junior Member Contributor

    Shorter bolt.
  5. Jack Klarich

    Jack Klarich Guest

    or bend the bolt a bit
    [​IMG] Go to AutoZone and rent a frost plug install tool, note the curve on the end where the adapter drivers fit
  6. dolt

    dolt Senior Member

    Don't be afraid to tap them in; have done it many times. That will square up with the bore when bottomed out. Doesn't matter if Cometic, CYCO or OEM; same, same.
    HDDon likes this.
  7. Jack Klarich

    Jack Klarich Guest

    Don you and I are old school, but that works every time ;)
  8. Thanks guys ... If I tap them in how much distortion is acceptable. Given how tight they seem to fit I would expect to really mash up the edge. Can I smooth out the edge once they are installed. What about using a little WD-40 to lube the port before installing.

  9. Jack Klarich

    Jack Klarich Guest

    If you start them square and tap even all around with a soft blunt punch you should be good, a bit of lube may help
  10. SoonerSoftail

    SoonerSoftail Active Member

    I use the old bearing trick. Stick them in the freezer for a day or so. It shrinks them a little. And it bothers my wife. Win-win!
    Jack Klarich likes this.