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TOPIC: Exhaust manifold bolts stripped

Exhaust manifold bolts stripped 06 Dec 2017 07:36 #1

  • this_guy
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Hey, looking for opinions, one of my exhaust port threads are stripped. There are some threads at the bottom of the hole to get some purchase. I'm leaning towards installing an exhaust stud with Loctite, instead of just using a bolt or installing a heli-coil. What do you guys think? And does anyone have an exhaust stud part number that they have used in the engine?

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Exhaust manifold bolts stripped 06 Dec 2017 08:01 #2

  • Makotosun
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Depending on which bike, you may want to drill and re-tap, then use a step stud to repair. Usually these are available at an Ace hardware or similar.

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Exhaust manifold bolts stripped 06 Dec 2017 08:19 #3

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Yep, that's a good idea! I'll do that when I pull top end for re-build. For now, I just wanna get her button'd up and take some chilly rides around town.

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Exhaust manifold bolts stripped 06 Dec 2017 09:55 #4

  • Giancarlo124
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I'd go for the studs too. I did the same thing and put in a heli coil which is another option but it feels like it is almost stripped as well. So the stud is probably the best way to go

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The Oil burners: 1973 DT-250, 1966 YM-1 305, 1966 YSD3, YZ-105

Exhaust manifold bolts stripped 06 Dec 2017 14:55 #5

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Me not being into originality i just tap them to 8mm & carry on. Could go to 1/4 which would only give a partial depth thread or 7mm but you'd have to make up the stud or bolt. 6mm Hellicoils work good. With 8mm you'd need a small hex nut, 12mm spanner size to clear i think. Or use an 8mm allen screw. Anyway, my rough ideas!!.

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Exhaust manifold bolts stripped 06 Dec 2017 16:49 #6

  • mdscott
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this_guy wrote: Hey, looking for opinions, one of my exhaust port threads are stripped. There are some threads at the bottom of the hole to get some purchase. I'm leaning towards installing an exhaust stud with Loctite, instead of just using a bolt or installing a heli-coil. What do you guys think? And does anyone have an exhaust stud part number that they have used in the engine?


What bike do you own, the DT250 and DT360 have a step stud, but it backwards. The 6mm part goes in the cylinder and the nut is 8mm. I installed 8mm heil coil in the cylinder, then used a 8mm stud on both ends.

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Thanks Mark
Roseville, Ca.

74 DT250
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Exhaust manifold bolts stripped 06 Dec 2017 17:29 #7

  • david.hunter
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On my dt 360 saved the option of drilling wider for later on instead drilled & tapped deeper as it was a long way till one reached piston on that unit.
They had completely stripped out.
The thinking was that with all the vibration and heat/cool cycles those studs see perhaps installing longer ones would be a little more flexible

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Exhaust manifold bolts stripped 07 Dec 2017 09:22 #8

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Hey! Great suggestions. My model is a 1973 RT3 360 and I'm going to drill and tap and use the stepped stud.

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Exhaust manifold bolts stripped 07 Dec 2017 12:15 #9

  • 1971DT250
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Something to consider. On some of mine I have to remove the exhaust manifold to get the exhaust pipe to clear the frame mount. This would be difficult with studs. When I remove and reinstall I use new bolts with anti seize compound. I loosen and tighten them once a year.

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