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Discussion Starter #3
Im wondering if it’s the exhaust wrap making it seem a tighter fit??
Or are different years XL600r headers different??
 

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I would be inclined to bolt in the right-hand side port loosely, then pull the left-hand side over and fix with the clamp. Job done.

P.S. Your engine looks lovely, mine hasn’t looked like that since the early 90’s
 

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Discussion Starter #8
Haha, thanks, had engine out, so give it a good clean and a kick of paint, not sure how long it will look like it does once I start riding it
 
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