thanks for ur reply
what do you mean by each pass? are you lining up one header at a time? and then going back over adjusting the header pipe next to it? are you putting the flanges on each port coming out the engine each pass or are you just ling up the pipes?
Yes do one at a time. Do not try to get any one on all at once. Get one on the threads, then the next, then the next, then try to get the last one on the threads. Not all the way butted up to the head, just closer into position than it was before. Then come back to the first one you put on and adjust it a little, try to find a little play in it, don't necessarily push it on further just try to make it feel loose. Go to the next one and then the next. Keep massaging it until it slides on freely. Again, do not force it.
I just went and looked at my spare parts, as I keep everything that I have taken off of my bike, and I could not find any gaskets. Someone else may need to chime in on this. It has been so long since I did this but I do seem to remember this being an issue...