95 XP striped exhaust manifold threads

[tjamzt]

So my brother and I purchased a 95 Sea Doo XP for cheap this summer without any real prior knowledge. It had issues with missing/loose exhaust manifold bolts (pointing downwards on the purple exhaust pipe) causing mass water intake. My brother who is not too mechanically inclined attempted to fix it, but ended up forcing the wrong bolts with too coarse of a thread and wrecked the existing thread in the white exhaust manifold. I was thinking of using a tap with a slightly larger diameter with some slightly larger than stock bolts but I am not sure what would be the best size, or if this is the best option. Does anyone have any suggestions? Thanks for any help.

 

[etemplet]

Use a HeilCoil and bring the threads back to the nominial size. Be careful where you purchase the HeliCoil some places are very expensive for the kit. It will come with a tap and about 10 Helicoils. The drill will be in the kit. Pay attention to the directions.. You only get one shot. Pretty neat little kit. I have hardly every used them but the work.

 

[racerxxx]

If you remove the purple pipe you can drill the holes out (with the correct size drill) and install helicoils. The original threads are M8X1.25 I use these all the time with great success. We use them in plastics all the time at work. No, they won't pull out, no you don't need to use loctite to hold them in. Again, we use them daily with great success.


I'm actually such a nice guy I made a little thread on this exact same manifold before!

717/720 Exhaust manifold repair with HeliCoil


Practice on another piece first

 

[racerxxx]

Do yourself a favor, when you remove the pipe make sure the rubber grommets are PERFECT, have the metal sleeve in them and have the heavy flat washers on both sides. The grommets have got to be complete and like new or the pipe will rattle and flex and break studs and screws. If not....you'll be fixing this same problem again.

 

[tjamzt]

Thanks for the suggestions. I found this: canadiantire(dot)ca/en/pdp/thread-repair-kit-m8-1-25-0251213p.html at my local Canadian Tire, it looks to be basically the same as the HeliCoil kit, should it be sufficient?

 

[pwgsx]

Just find a used manifold, they are a dime a dozen. Also when re-installing, keep the lower pipe bolts and mid pipe bracket kinda loose until you tighten up the upper bolts. Then tighten mid pipe bracket, then the lower 2 bushings.

 

[racerxxx]

That should do it.