Well i was out riding and i stop cause it seemed i lost alittle power, i look at the exhaust and theres no stud, its broken before, but now i've had it! I have 200$ it cost 300 to tear the head down and fix it, I thinking about putting a stage 1 hot cam in there while im at it. Damnit, this sucks, what else should i replace while in there? Head gasket and adjust the valves? I was like Phuq this so I raced a LE raptor with the same exhaust as me and he only beat me by one bike, and i have the header bolt missing hehehe.

 

Remove a good one and go to the dealer, have them match it up with a 2000 yamaha Grizzly 8mm stud, should be the exact lenght.

Drill em out and install em, but its best to use a drill press. Also you may have to drill out the header flanges slightly to accept the new studs.

 

let me give you ythe inside scoop, i let a duma$$ work on the stud when it broke the first time so he drilled sorta cocked, i took it to a atv shop and they couldnt drill straight and instead tapped a water jecket, O sh*t. So, he told me that when you get the denaro to take the head off and precision weld it shut the retap it and while im there install larger bolts, like you said!

 

Thats exactly what happened to my buddy, he went a little off and hand to have it welded shut and retapped... this was the second time it broke... Very expensive

The water jacket is very close, anyone could hit it..

 

oh and when you are drilling the new holes, match up the depth and put some tape around the drill bit so you know when to stop. If you have to do it by hand with a regular drill use successively bigger drill bits so it the follow the original hole.