Installing Exhaust Gaskets

[One For The Road]

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.

Thanks;

Steve

 

[Jack Klarich]

Look here, I have bearing driver sets, but this home made tool will work

 

[One For The Road]

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.

Steve

 

[coopernicus]

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.

Steve

Shorter bolt.

 

[Jack Klarich]

Shorter bolt.

or bend the bolt a bit
or

Go to AutoZone and rent a frost plug install tool, note the curve on the end where the adapter drivers fit

 

[dolt]

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.

 

[Jack Klarich]

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.

Don you and I are old school, but that works every time

 

[One For The Road]

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.

Steve

 

[Jack Klarich]

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.

Steve

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

 

[SoonerSoftail]

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!