Should I put the new exhaust gaskets on the pipes as they are being installed or install them into the port? The gaskets are so flimsy they don't seem to want to go into the port easily.

 

Put them in the port.

 

I have the gaskets where they will just barely sit in the port opening. I can't push them in any further. Should I sand the outside diameter to make it fit? I am guessing that these have to fit inside the port opening before I try and fit the pipes up to them.

 

Isn't there two different sizes? I just bought gaskets and they did ask me at the parts counter which ones I wanted. I didn't know so they looked up what fit my bike. A little tight but slid right in.

 

Put them in the freezer overnight then put a little lube on 'em and then try.

 

Both of mine are the same size and the same as stock gaskets.

 

Screaming Eagle and standard stock ones.
I would use whatever the manufacturer of the pipes you bought say to use.

 

I bought the stock ones as the parts guy said there was a bigger chance that the SE ones could leak if misinstalled.

You are serious put the gaskets in the freezer? As far as lube like WD 40?

 

I agree, it's hard to get the gaskets fully seated in the exhaust port without wrinkling them. They're a bit too big to fit.

My mechanic uses a bearing race driver to seat them (Harbor Freight has them). I'm too cheap to buy a set, so I force them in, then flatten any wrinkles or high spots with a ball pein hammer (gently).

 

I just installed a set. They do seem a little to large but be patient and apply even pressure and they push in. It's a small area but I used both hands so I could hold the top while I applied pressure to the bottom. Then I just worked my way around the opening to ensure it was in all of the way and even. One of mine had a small area that got out of round and I used my finger to push it back in place. It worked out with no exhaust leaks.