assembled wrong from new?

[banquo]

Had the exhaust headers off for the 1st time on 2003 FXST. Rust, rust rust...
When they came off, the flared ends of the headers were pushed directly into the port gaskets, as expected, and threaded over each pipe was the circlip, followed by the header clamp. Just to be clear, the circlips were fitted between the chrome clamps and the flared end of the header.
I was just going to slap it all together again, but checked the Clymer and the factory manuals for the torque settings (not that you can get a torque srench in there anyway). The Clymer states that the gasket goes in first, and then the circlips, which it says are to retain the gaskets, then the pipe, and then the clamp. The factory manual doesn't mention the circlip fitting at all (waste of 60 bucks then...) although it does call the circlip the gasket reatining ring, so it sounds like it is suppose dto go between the gasket and the header.....
Way I see it, if the circlips do go into the ports, before fitting the header pipe, the flared end of the pipe will bear on the circlip, and there won't be a seal between the pipe and gasket. However, if the circlips are fitted on the outside of the flared end of the header, they don't do anything at all - why not have the clamps bearing directly on the flare.....?
So the question is, do I put it back together the way it was delivered to me, with circlips on the outside, or as the Clymer says, and Factory Manual implies, with the circlips fitted in the ports, before the headers are fitted, and with only the chromed clamp on the outside...??
Am I missing something obvious here?
Comments appreciated as always!

[Helmetbolt]

Exhaust port gasket first. Header clamp onto exhaust. Then circlip retaining ring onto exhaust. Exhaust into heads, slide up retaining ring & clamp up.

The circlip / retaining ring is there because the diameter of the exhaust flange is smaller than the diameter of the clamp. (it just slips over ) The clamp uses the circlip / retaining ring to secure the exhaust flange to the head.

If you put the circlip / retaining ring into the heads before the exhaust & clamp it up. The exhaust would just fall out as there is nothing holding it there.

[banquo]

Thanx HB, but circlip slides on before clamp surely, so the clamp pushes the circlip against the flare on the header???
If I understand you rightly, take header pipe, and slide circlip on from the muffler end, up to the flared end.
Then do the same with the clamp.
Push header on to gasket, and do it all up.. Right?

If in doubt, RTFM.
Then ignore what it says in the manual, and ask the guys who know...

[Helmetbolt]

Yes you can put them on in that order.. but..

As you can see with this fishtail. you cannot slide the circlip / retaing ring or the clamp up from the muffler end.



I always put the clamp over the flange end first then twist the circlip / retaining ring on next.

Luckily I had these exhausts in my office so I took the pic as I was posting..

[Phil]

Exactly as Helmetbolt says.

[banquo]

Many thanks - that's sorted then!