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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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They just look like they need a bit persuasion to me.
That's what i was just thinking, i'm sure i had to spring my headers into that side when i fitted them
 

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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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Discussion Starter #9
Well followed the advice and bolted up RH side loosely and the pulled left hand side into place.

the exhaust wrap was definitely making things a tighter fit.

not sure if it’s fully sealed until I get to start the bike
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