Flanges Gasket

Flanges Gasket

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need help with fitting GPZ500 exhaust gasket?

can anyone please tell me if i can replace seal with copper wire, also how would i get the new seal over the exaust flange? pleaser help as me bike is sounding awfull. and at present cant afford a new seal set

The washers are nothing more than heat resistant fiber covered with thin copper. The washer fits between the header pipe and the cylinderhead. The flange with the two studs through it shoves two half round sections against the flange on the header pipe. Try tightening the two nuts first, just make sure you don't over do it because you can strip the threads in the head. Also make sure one of the nuts hasn't vibrated off (had that happen several times).

OEM washers are more expensive than after market sources, so try one of them. Google it and you'll find some although I can't remember any of their names at present. In fact, I've seen 4 copper Kawasaki washers on ebay for $12, which is close to what the dealer will want each for OEM.

To replace the washers, you'll have to loosen the header pipes and mufflers enough to pull the headers away from the engine. Fish out the old washer and the best way to get the new one to stay in place while you fumble around trying to get everything back together is to put two small dabs of silicone sealer on the washer and stick it in the head. Slide the header pipes into place, place the two half sections around the header pipe and wrap some paper masking tape around them to hole them together. Try to space them equal distance apart. Then slide the exhaust flange over them and tighten the nuts just snug. Caution! They need very little torque to do the job!

Copper wire won't work because it's too hard. Like I said, try tightening the nuts first.