Any technique on replacing the tapered exhaust gasket on a 02 RK? I've never replaced them before so do I just line it up even and bolt it in? I've tried several times now and it's getting annoying. Help please

 

The stock style can be a bear to get in, but get them started straight and push em in, then install exhaust. Use the but end of a screwdriver or something to work them in, nothing sharp or you'll wreck them.

 

For what it's worth, make sure you've pulled the old gasket out...what's worked for me is using my thumbs to carefully press the gasket in. I don't know of a tool out there that will conform to the shape without crushing the edges.

Start pressing in one side and carefully work your way around 360 degrees. Your thumbs may start getting a little sore, but it keeps your gasket from getting crushed. Use a small mirror and flashlight to make sure the gasket seats. If not seated, keep working it in the same way until it is seated.

Follow your manual for steps & torque specs on the headers install.

--Good luck!

 

Won't hurt to put a little grease or something around the edge of the gasket either. As stated, push them in with your thumbs after getting them lined up straight on.

 

The hardest thing about changing my headers was putting in the new gaskets. Too bad other things aren't that tight.

 

So when I start crushing the gasket it's starts to lay flat around the lip of the header? I know the tapered end faces the header pipe, but is the gasket curving around the lip or inside of the header itself? I'm sticking in on the header then putting the pipe on right? Man there's isn't much room to get my hands in here.

 

It is not supposed to crush inside the header or it will block exhaust flow and you will lose performance. It crushes against the edge of the header to seal it. Don't over-crush it! You might like the Cometic copper crush rings the next time you have to replace exhaust seals. They seal well and are easier to work with. You can get them from Cometic or even Kuryakyn now. Pics attached.

 

+1 on dawgs post. I like the copper ones. Dawg, aren't the stock ones restrictive just from factory install? I don't see how they can't be because of the nature in which they work. Seems to me they would crush and block exhaust flow.

 

I'm sure a majority might be if they get over crushed from the factory. Those that are trying to get every ounce out of a build don't like to use the stock crushers because of that. The majority of riders probably wouldn't know/feel the difference unless they see a dyno difference which would have to be run under the exact identical conditions except for changing the gaskets between runs.

 

After reading all the replies this really caught my eye. Are you saying you are sticking the gasket on the header and then trying to bolt the header to the engine??