I've read another post about problems with these exhaust port gaskets. Since the dealers have been little to no help with this, I should have known to ask you guys first to get the fastest, most accurate information.

I installed forward controls on my '04 883 yesterday (sorry, not pictures yet). Everything went smoothly EXCEPT getting in the dern exhaust port gasket. I had to check and make sure they didn't give me the wrong gaskets. They were suppose to give me 65324-83A, which I have confirmed is correct. It seems though as if the diameter of these gaskets is a fraction off since I cannot fit it in flush. Instead, it bows up, much like trying to get that last part of a bicycle tire back into rim! It's under a lot of force and those wire-woven gaskets do NOT take pressure too well as I have already screwed up two of them. Yikes! Trying to put them in as flush and even as possible is not working.

They didn't come in a plastic bag with a part number on it, so I'm wondering if they didn't give me the wrong gaskets, even though they tried to give me 65324-83A gaskets? Either that, or I'm not the wrench monkey that I thought I was.

I have a few questions regarding this, for the pros.

1) Does the gasket go into the header FIRST or do you put the gasket on the pipe and then slip into the header? To me, the first aproach seems more logical. Still, it buckles by the time I get it into the header, as if the gasket is slightly too big.

2) In doing all of this, do I need to worry about what appears to be shavings from these gaskets getting into the exhaust port?

3) I've read about the "high performance" exhaust gaskets. Is it worth trying these instead? I did notice A LOT of carbon build up on the bottom edge, as if it was being trapped by the gasket. Does anyone have this part number??

4) It shouldn't be this difficult. Is there a TRICK to getting these in the headers or should I go back to the dealer and see if they gave me the wrong gaskets after all? The muffler interconnect gaskets fit in like a charm. I don't see any reason why this one wouldn't either. The only difference is that the interconnect gaskets came in a sealed package, with the part number on it. The exhaust port gaskets were loose.

5) Last but not least, I did NOT take the muffler off using the torca clamps. I kept the entire muffler connected as a whole and planned on putting it back that way. Any problems with doing that? I didn't feel like taking off that clamp and muffler if I didn't have to.
Suggestions? Thx!

 

I replied to your other post as well. one of mide bowed up like that and I just pushed the bow down the best I could and put the exhaust back on. pressure from the mounting bolts tightning fixes the problem and I have no exhaust leaks. so push em in and bolt her up.

 

I had the same issue and also did what Noah1980 said... I forced them in and pushed them down to smooth it out. After bolting on there was no leaks....

 

They are designed that way. That's why those gaskets are only supposed to be used once. Many times once you bolt everything down, and all is good, they are trashed for any re-install.

 

mine did the same thing when i replaced mine during a pipe swap... at first i was like wtf?

1. gasket first
2. just be careful and no shavings will fall in
3. i put in the SE gaskets.. they look way different than the stock ones - they arent tapered. per vance & hines, 17048-98 OR 65324-83A
4. they go in, but at the same time you are going to be thinking they are the wrong gaskets. take your time, use a small screwdriver and gently push them into place.
5. dunno about this one.. but it seems ok to do it that way.

good luck.

 

Sorry if I'm late to weigh in Did mine when I put my stage one kit on I put mine on themuffler side not the cross over pipe side. they did stick out some but no leaks and you really got to look to see it. Try not to reuse old gasket unless you are lucky you will be pulling the pipes off again. Also a trick I learned was to leave everything finger tight until fit-up is 100% the way you want it this will save you time too! Hope this helps