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[navstud]

I was out enjoying a beautiful day in the old doo when I noticed some water in the hull...a lot of water. Thank God for the Bildge Pump. Anyway I noticed the water coming in from the joint between the purple tuned pipe and the manifold on the engine. It was coming in very fast. For some reason the bolts were all loose and one of them is a stud with a nut on it and the nut broke off. I bought a new gasket for ten bucks. Just wondering if anyone knows why this happened and if there is anything I need to know about putting the new gasket on. Is this a common thing?

thanks much,
steve

[tiggerman]

Lots of vibration is likely the cause- with the nut/bolts loosening over time. When you install the new gasket and stud, follow these procedures (assuming you removed the tuned pipe assembly: Make sure the gasket is on straight.
Apply Loctite 242 (the blue stuff) to the stud and bolt threads.Hand-tighten nut and top screws only and assure that tuned pipe bushing(s) rests against manifold. Use 8 mm flat washers at tuned pipe flange instead of lock washers.
Tighten first: the 2 bolts that hold the tuned pipe to the side of the manifold (they go through rubber bushings and spacers. 9 ft. lbs. is the proper torque. Next tighten the 3 bolts and nut that hold the top portion of the tuned pipe to the exhaust manifold- do this in a X pattern.. 9 ft. lbs. is the correct torque.
Retighten all bolts / nut once more to 18 ft. lbs.
I know mine leaks occasionally, and I always retighten the bolts/nut to stop it. There is just a heckuva lot of vibration going on with the Rotax.