How Do I Install Exhaust Port Gaskets in a Harley Davidson?

Written by jim murkot sr.
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How Do I Install Exhaust Port Gaskets in a Harley Davidson?
Harley-Davidson motorcycles come equipped with crush-type metallic exhaust port gaskets. (Motor image by Conny from Fotolia.com)

Harley-Davidson motorcycles come equipped with crush-type metallic exhaust port gaskets. These gaskets are designed to be used once and then replaced whenever the exhaust is disconnected from the engine head. You should also replace the gasket should you suspect that an exhaust port is leaking. The length of time to replace an exhaust port gasket on a Harley is dependent upon skill level, but should take 30 to 60 minutes.

Skill level:
Moderate

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Things you need

  • SAE socket drive set
  • SAE open-ended wrench set
  • Needle-nose pliers
  • Torque wrench

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Instructions

  1. 1

    Loosen the heat shield worm drive clamps with an SAE socket drive. Remove the nuts from the exhaust pipes at the cylinder heads with an SAE socket drive.

  2. 2

    Disconnect the mufflers by removing the bracket bolts with a socket drive or open-ended wrench. Pull the exhaust system away from the motorcycle.

  3. 3

    Remove the old gaskets from the cylinder head using needle-nose pliers. Install new exhaust port gaskets into the cylinder head. The gaskets come tapered; the thin end should point towards the exhaust pipe.

  4. 4

    Position the exhaust pipes over the cylinder head exhaust bolt studs and hand-tighten the nuts.

  5. 5

    Align the mufflers over their support brackets and hand-tighten their support bolts.

  6. 6

    Torque the cylinder stud nuts to 60 to 80 inch-pounds using a torque wrench. Be careful not to over-tighten.

  7. 7

    Torque the muffler support bolts to 19 foot-pounds. Re-tighten the heat shields.

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