Hi, I am refitting the exhaust on my X1, I have new exhaust port gaskets, is there a knack for fitting these? They are too tight just to fit in, I assume I just gently & evenly tap around until they fit, hopefully without crushing them.

Maz fitted mine during rebuild. Gauze was neatly pressed back, but mostly around side wall of port and in a mirror image of header pipe shape. Maybe the header formed the tool for this? I couldn't see what happened as headers were tightened into the ports.

Assuming XBs are similar that is

Clean the exhaust port bore where the gasket will go. I put copa slip in and I copa slip the gasket, then push in with fingers carefully working my way around.

You could also put the gasket in the freezer then push in, never tried it but I would if I was struggling...

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08 Specialized Langster

Thank you both,

I would not have thought copperslip would be required, this is why I ask, if I dont ask I dont learn

It probably isn't but gives me confidence that it will come out when I want to replace it...

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08 Specialized Langster

Exhaust port gaskets are now in, exhaust is back on, I read the book for torque settings for bolts. snapped the exhaust clamp bolt, could have been worse. It felt too tight but i kept going as it had not reached the setting, I should have trusted my gut feeling. I am pleased it wasnt anything other than the clamp.

How did you do it?

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08 Specialized Langster

I'm beginning to have little faith in the torque set figures. For 8mm bolts into alloy I don't go over 18 ftlbs and squirm at the thought of 48 lbs for the front isolator bolts. Are we sure it wasn't a 38 ftlb typo? Copper slip also seems to allow more bolt stretch, but some say friction makes no difference. Gut feelings, what they say here and specs then split the diff, dig into my memory of other bikes, and add a wee bit if it feels right!

Pash, the front went in with finger pressure, the rear was tighter, a bit of 2x2 about 3 inches long to apply even pressure, the gasket did wrinkle a little bit. I thought the front was going to give trouble as that was corroded around the circumference.

Edd, I need to practice more to trust my instincts. The trouble with being a novice is relying on theory rather than practice.

I'm still just a paranoid semi-senile-novice mushroom, but I recall a caution on here about torque wrenches and accidentally following through after they reach the specified load (was that you pash?).

I would like to get an old blown engine and deliberately wind a few threads to destruction in stages just to get a feel for it!