REF: Tools - 167

Exhaust Tools

Jims #788 Exhaust Seal Installation Tool

For use on all 1984 to present Evo Big Twin, XL, and Twin Cam models. (See the Sportsterpedia EVO Exhaust Section)
This tool installs the exhaust pipe seal H-D No. 65324-83B or Screamin’ Eagle No.17048-98 or equivalent exhaust gaskets.
It will position the gasket evenly into the head exhaust port thus preventing exhaust leaks.

Installation: 1)

  1. Position exhaust seal on tool.
    Note that the tool has a step locater to correctly position the type of seal used.
    • The tool side with the small step is for locating the H-D No. 17048-98 seal.
      Note: The thinnest edge faces tool plate. The other side of the plate is for the usage of No.65324-83B seal kit.
  2. This tool can install the seals two different ways.
    1. After the seal is in position on the tool plate, use the two exhaust flanged nuts HD (7593) to install the tool to the head.
      Alternate threading on the nuts onto the exhaust mounting studs until tool bottoms out on the head.
      Then install the pipes up to the head per the FSM.
    2. Using Jims tool handle (33416-80) -sold separately- install the small end into the center hole of 788 plate with a new seal in position.
      Place these pieces up to the head and onto the exhaust mounting studs.
      Then use a mallet to lightly tap on the end of the handle until the tool plate seats in the head.
      Then install the pipes up to the head per the FSM.

2) 3)

Homemade Exhaust Gasket Installer

You can toss the gaskets into the freezer for about a half hour to shrink them up a little before installing them.
A good hour or two works better but that still may not help much.
Then, carefully tap them into place with a 2×4 piece of wood and a hammer.
Try not to fold them over while seating them into the counterbore.

2×2 piece of wood used below… could have had better results with a 2×4.
4) 5)


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