HOGG Posted June 24, 2020 Report Share Posted June 24, 2020 Any hints or tips on how to fit one? Never fitted an exhaust o ring before,... When I put it on the exhaust it slides down the header and when I put it in the head it folds up. Quote Link to comment Share on other sites More sharing options...
Alex_H Posted June 24, 2020 Report Share Posted June 24, 2020 https://www.cmsnl.com/yamaha-tzr50-2004-5wx5-belgium-1c5wx-351f1_model48245/partslist/0010.html#.XvOO43XTWDY According to that the o ring should slide over a reduced section on the header, and assume slide into the cylinder. Your cylinder does look like its been in the sea for a few years which might make it more difficult though. 2 Quote Link to comment Share on other sites More sharing options...
HOGG Posted June 24, 2020 Author Report Share Posted June 24, 2020 Just seems to roll down the exhaust when I insert the exhaust into the head. Quote Link to comment Share on other sites More sharing options...
John21 Posted June 24, 2020 Report Share Posted June 24, 2020 7 minutes ago, HOGG said: Just seems to roll down the exhaust when I insert the exhaust into the head. Not the correct size O ring most probably. Quote Link to comment Share on other sites More sharing options...
lesviffer 750 Posted June 24, 2020 Report Share Posted June 24, 2020 Is that your recently acquired tzr50 resto ? if so i'd put a bit more elbow grease into it, might help the old o ring pop in easier. 1 Quote Link to comment Share on other sites More sharing options...
HOGG Posted June 24, 2020 Author Report Share Posted June 24, 2020 59 minutes ago, John21 said: Not the correct size O ring most probably. Genuine Yamaha part Quote Link to comment Share on other sites More sharing options...
DougW Posted June 26, 2020 Report Share Posted June 26, 2020 As lesviffer 750 suggests, both exhaust port and pipe will need to be properly clean. Also smooth with any corrosion marks polished out. KTM exhaust O rings sit in a groove, so are easier to fit, no rolling down the pipe. The KTM ones seal for longer with a THIN smear of high temperature silicone sealant, but they do have to cope with me repeatedly bashing the pipe around into the ground and trees, which hopefully, yours will not. I would suggest only using silicone after you have mastered getting the pipe and o ring fitted correctly in a trial run. Quote Link to comment Share on other sites More sharing options...
DougW Posted June 26, 2020 Report Share Posted June 26, 2020 On 6/24/2020 at 6:38 PM, Alex_H said: https://www.cmsnl.com/yamaha-tzr50-2004-5wx5-belgium-1c5wx-351f1_model48245/partslist/0010.html#.XvOO43XTWDY According to that the o ring should slide over a reduced section on the header, and assume slide into the cylinder. Your cylinder does look like its been in the sea for a few years which might make it more difficult though. Looking at the parts list, original set up looks like a bit of cost cutting to me. All the O ring sealed exhausts I am familiar with on the dirt bikes sit in a grooved collar. If it was mine I would be turning up a couple of steel rings and welding them to the pipe to retain the O ring like on the dirt bikes. I do have the luxury of a lathe and a mig set though. 1 Quote Link to comment Share on other sites More sharing options...
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