When doing the slip on about two months ago I installed new exhaust gaskets (as is recommended).  I didn't blast/paint the headers at the time, but now that I'm going naked I would like to.  Question is, given the gaskets are pretty much new, do they need to be replaced?  Is it an "every time the headers are unbolted, replace," type of thing?

You are supposed to replace them every time, that being said I have reused mine multiple times with no leaks, just put the exhaust back on and see if it leaks, if it doesn't your good to go, if it does, it is only a 5 min job to remove the header and install new ones

They're supposed to be replaced. They are crush washers, basically.  I've reused mine in the past and got away with it, but your mileage may vary.  An exhaust leak would sound like a sharp popping sound. If you get that, get some new gaskets. They're fairly cheap anyway.

Does the 'zuki dealer typically stock them, and if so, what's the part number?

Quote from: Pelikan on May 11, 2011, 08:17:51 PM
Does the 'zuki dealer typically stock them, and if so, what's the part number?

Way cheaper from ebay. Suzuki P/N 484407-001 You need two.Bike Bandit has them listed for $5.36 each.