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Post Info TOPIC: exhaust stud stripped head thread on way out


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exhaust stud stripped head thread on way out
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so as iv heard the exhaust studs are prone to rusting. i acquired my bike over a year ago and have stripped it down resprayed the frame, stripped the engine top to bottom and now its all back together woop !

except when taking the exhaust off, first thing i did was snap one of the exhaust studs off !! argg

took it to a friend who drilled the old bolt out but bigger, to take a steel insert that the original size bolt fit into, upon tightening the bolt to its required torques the new insert thread failed pulling insert and bolt out in one, i have since tried to "fill" the hole with mig weld to re tap , but has not worked on the cast.

i think the hole is now a bit too big to tap a bigger size or not enough left? 

any ideas or am i gona have to replace the top end ? 

i will post pics asap 



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Super Guru

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You could try brazing the insert in.

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Pete. South Somerset, England.



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There's various options, i'd fit one of these, you can get them in different lengths.
www.ebay.co.uk/itm/TYPE-25-Stud-M8-exhaust-stud-repair-oversize-M8-M10-/361006777432


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2004 TTR250. White Brothers E series exhaust, modded airbox, rejetted, 13/48 c&s & many more mods..



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Sounds like there is no chance of getting a bolt in there, can you drill a couple of small holes in the fins to anchor a pair of springs ? You would need a pair of loops on the header too. KTM use a similar system

bestdualsportbikes.com/the-scary-fast-grunt-exhaust-manifold-1/

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Couple of blury pics of the situation sorry my cameras rubbish. Well I'm gona look at putting a bigger tap in and one of the bolts like locky said . and look at using the springs to try not put so much pressure on the bolt . 



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Done , just gotta charge battery and will let you know how it goes



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Will this pass mot?

IMG_20150221_134030131.jpg



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Super Guru

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As long as there are no leaks at the manifold it should be absolutely fine!

That's a pretty solid repair!

Brian



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As brian says mot man is looking at leaks which cause excessive noise ., security of the system ie not loose excessive corrosion of exhaust components and any markings that shouldnt be there eg race use only. My ktm had same set up as described above no problems .That may i say is a very nice solution credit to youwink



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Good to hear , still yet to try as havnt managed to charge battery yet. Yeah not bad repair for under £15 :)

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Woop woop just got around to starting her up and the springs worked a treat ! Mot next. thanks all for the advice !!

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