A forum for owners of Yamaha TTR250 trail and enduro bikes!

Members Login
Username 
 
Password 
    Remember Me  
The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> exhaust stud stripped head thread on way out
Post Info TOPIC: exhaust stud stripped head thread on way out
ben694


Member

Status: Offline
Posts: 17
Date:
exhaust stud stripped head thread on way out
Permalink  
 

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 



__________________
peteBLUEttr


Super Guru

Status: Offline
Posts: 1721
Date:
Permalink  
 

You could try brazing the insert in.

__________________

Pete. South Somerset, England.
locky


Guru

Status: Offline
Posts: 625
Date:
Permalink  
 

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


__________________

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


Veteran Member

Status: Offline
Posts: 32
Date:
Permalink  
 

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/

__________________
ben694


Member

Status: Offline
Posts: 17
Date:
Permalink  
 

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 . 



Attachments
__________________
ben694


Member

Status: Offline
Posts: 17
Date:
Permalink  
 

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



__________________
ben694


Member

Status: Offline
Posts: 17
Date:
Permalink  
 

Will this pass mot?

IMG_20150221_134030131.jpg



__________________
TTRfan


Super Guru

Status: Offline
Posts: 8607
Date:
Permalink  
 

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

That's a pretty solid repair!

Brian



__________________

Exeter, Devon, UK

http://www.ttr250.com  - The one and only dedicated TTR250 FAQ!  

TIP: For easy viewing bookmark the "Recent Posts" view - http://ttr250.activeboard.com/p/recent/ 
hanzo


Senior Member

Status: Offline
Posts: 216
Date:
Permalink  
 

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



__________________
ben694


Member

Status: Offline
Posts: 17
Date:
Permalink  
 

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

__________________
ben694


Member

Status: Offline
Posts: 17
Date:
Permalink  
 

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

__________________
Page 1 of 1  sorted by
 
Quick Reply

Please log in to post quick replies.
The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> exhaust stud stripped head thread on way out


Create your own FREE Forum
Report Abuse 		Powered by ActiveBoard