Yamaha TRX850 Enthusiasts Forum

bout year ago bought an engine with the exhaust header studs mangled by header removal.


had them taken out.


one didnt go well and had to be drilled and re tapped.

wasnt the best job in the world as was slightky off centre from the original.


what id like to know though as this has been drilled and tapped a lot deeper than original - is it possible to go through to the water jacket inside the engine as i fired her up to day and definately have coolant coming out the exhaust stud thread

if this is possible any ideas how i can resolve the issue ??

unfortunately not in a position to take it back to who did it and tell em to fix it

Very easy to go through the water jacket and probably what has happened, the engineering company that attempted to repair the broken studs on mine did exactly the same, I had mine welded and re-tapped but strangely enough the chap who skimmed my cylinder head reckoned they would have been ok with just some thread sealant around the studs as a lot of the old V8 lumps used to use this method anyway.....Don't know how true this is but might be worth a go.

Cheers cakeman

Will give that a go first as being the cheaper option

Cakeman.... that is a top tip .. I added a bit of loctite plumbers string and so far so good

JB Weld is some tough s*** & only costs a few £££. I repaired a cracked gear box casing on my trusty VW polo two years ago and it's held up fine. Maybe an option for you here