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VERY difficult time trying to get 4strokeworks header on

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I've had it for about 8 years. Took it off to sand it and spray with high temp black paint. For the life of me, I cannot get this mofo on.

I didn't spray the end that goes in the exhaust port. I don't remember ANY problems putting it on when I got it in 2005.

 

Any suggestions would be appreciated.

 

2005 Kawi KXL300

Edited by goldensaber88

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No.  Only the one at '2 'o clock'. After I make the gasket, put that in, I'm going to dremel just a little bit on the flange holes. Hopefully that will do it.

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If it was on with modifications and all you did was remove and paint it and put it back on it shouldn't need anything to put it on. Mine was right but I kept it loose from the pipe to get it all lined up.

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If I remember my gasket right it was a two sided metallic ring with a compressible material sandwiched in the middle. It is pretty important to have a no leak connection.  

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