Hey guys,
I'm putting my new Tyga exhaust on (well, attempting to).. When trying to put the rear manifold collar on, I dropped one of the nuts that holds it in place and can't find it for the life of me. Was searching for it for an hour last night, and just spent another half an hour with a strong magnetic pickup tool and still can't find the bugger..

Then I thought it may have fell down the cylinder.. Stuck the magnetic pickup tool in the cylinder and it didn't find anything.. Neither did my fingers.. All I could find was a weird spiraling thing (not sure of its proper name.. feels like one of those big industrial mincers with blades that spin and crush food)...

I was going to just get a replacement nut and hope it's just stuck somewhere and won't affect me at all, but if it's in the engine then I'm assuming we have a big problem.. and starting the bike is the last thing I want to do..

As i said, I can't feel it, and the magnetic tool can't find anything.. There are small holes which it may have slipped down, but I don't think it could fit down there in any case.. Was just wondering.. if anyone has an NC35 engine out, if you look into the rear left cylinder, can the nut actually fit in there and go down into the cylinder?

Here's a photo of the nut I'm talking about. It has a 10mm head which is 10mm tall, and the base of the nut is a circular shape with a (approx.) 12.5mm diameter base.


I very much doubt it would fit into the cylinder, and short of somehow getting my bike to a mechanic so they can take the engine out, I very much doubt I am going to find this nut anywhere.. So assuming the nut can't fit into the cylinder, I will just have to go get a replacement nut and continue with the job, and hope the nut isn't stuck anywhere important (the wheel can spin freely so it's not stuck in the front sprocket or chain)..

Can anyone confirm whether the nut would fit into the cylinder, or give any useful advice or info?

Thanks in advance :)

Cheers

OK well I looked at the front cylinder which doesnt currently have an exhaust manifold bolted to it and it looks like there are two holes that spiral into the engine.. If the rear cylinders have the same setup for the exhaust port then maybe the nut did fall in.. But I don't see how it could have 'fallen' in UP into the holes..? But I can't find the nut anywhere for the life of me so it may be there..

Can anyone confirm the rear exhaust ports are the same as the front right one? (They don't feel the same...)

Thanks

The exhaust ports are the same all round. If it did manage to get into one it wouldn't get past the valve and into the cylinder so you would be able to fish it out.

Have another look all around the bike - there are a heap of places a nut can get caught up. Check around the swingarm pivot very carefully with a torch, you can only see some trapped parts by looking from underneath the bike (don't ask how I know! ).

OK I found the stupid nut and got the full exhaust on. The side stand hits on the exhaust a bit when it is up, but nothing major.. Maybe after I get it on completely I can fix this somehow.. (Does the side stand usually hit it a bit with the Tyga full system?)

Also, guys, last question.. For the front manifolds, I am screwing the 4 little nuts on bit by bit, and they are sitting perfectly on the gaskets. They are probably about 80% tightened but the manifold is not going up anymore.. Instead, the little 'clamps' as Tyga called them, as pictured below, are just bending (as I tighten the bolts, the middle is staying where it is, and the sides are concaving in).. and I'm scared they're going to snap if I keep going.. Is this normal? Should I leave the nuts the way they are, or keep tightening?


Thanks

My guess is that it's not sitting right while you're trying to force them in.

Take the front headers off the rest of the system and see how they fit in the exhaust ports. They should fit all the way in nicely.

It can be fiddly installing full systems. I find it easiest to not do any of the bolts up more than half way (front and rear), get it all fitted as best I can and then nip it all up gradually at each bolt a couple of turns at a time.

If you rush it then things will break.

Hey mate,
Thanks for that. OK, I just started her up and there is smoke coming from down near the back of the engine.. Radiator is connected OK.. I polished the exhaust so I'm thinking it's just the layer of polish being burnt off... Is this normal?.. (the temp gauge wasnt even reading so I doubt it was the engine..)

Also, my rearset (RHS) doesn't fit on properly! lol the mechanism that moves when the rear brake is pushed hits one of the pipes if I screw the rearset back in.. Have you ever suffered this problem before?..

Cammo wrote:My guess is that it's not sitting right while you're trying to force them in.

Take the front headers off the rest of the system and see how they fit in the exhaust ports. They should fit all the way in nicely.

It can be fiddly installing full systems. I find it easiest to not do any of the bolts up more than half way (front and rear), get it all fitted as best I can and then nip it all up gradually at each bolt a couple of turns at a time.

If you rush it then things will break.

Jonno, those brackets should fit flush against cylinders.
I know its a ballache but remove it all straighten the brackets and check that you have removed the old gaskets in the ports. it might look like you have but sometimes they are hard to budge!
then just slowly fit the rear pipes and nip the bolts up not tight. and get everything in place nicely then fit it properly!

The nuts you have pictured are for the front pipes, the rears use flanged nuts.

Also it will smoke a lot on inital start up until all the oil, sealant burns off, then it should be ok. Doont forget its a sprung system so you might need sealant on each joint to seal it. And it will feel quite loose until you get the can on and nip that up, then it should be nice and tight!!

Kris