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  #1  
Old 09-17-2015, 06:21 PM
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Default Help With 150cc Exhaust Manifold

I was recently doing some CVT work and while i was re installing the exhaust pipe, one of the studs broke off about half way. enough to where you cant get a nut on there anymore.

its hard for me to tell as i have little XP with these smaller engines, but are the studs replaceable? i tried using a pair of vise grips and seeing if i could un screw the piece still in the manifold but no luck, i thought either i was not approaching it right or they probably are NOT replaceable.

in which case what are some opinions on ways to tackle this situation. obviously it could just be a sign to do a BB Kit but i will only do that if i have no other option than to replace the manifold.


its in a tight space, or my first thought was to cut it at the base and then tap it and use a bolt instead of the other way around, but i cant get my dremel in there, its too awkward.

thanks in advance, btw the buggy model is a tao tao atk 150 c , i looked at the parts site for tao tao but i couldnt even find the manifold for my buggy.
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Old 09-18-2015, 10:29 AM
wildbob wildbob is offline
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Every one I've seen was replaceable. Might have to head to the hardware store/autozone/etc to get a extractor. Good to have in the tool chest anyway. Either way put some bolt PB Blaster or some other bolt losener on that bad boy. I think I got an extractor for around $15 or so at autozone or napa...
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2013 Trailmaster XRX 150 Type 86 stroker
Taida 4V head with 23/22mm valves, forged 4V piston,Taida 62mm jug,forged Taida 8200 KDU stroker crank, Koso high-flow oil pump, Taida case half w/ oil cooler ports, Setrab oil cooler,TrailTec Vapor, Mikuni VM26-606, aluminum 30mm intake, Uni filter, aluminum stack, Hammerhead racing exhaust, MotoRio adjustable CDI/HO Coil, Iridium plug, Full Dr Pulley CVT kit w/ 16g sliders, JD's Mikuni slide kit

2014 Kandi 90B

Last edited by wildbob; 09-18-2015 at 10:34 AM.
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Old 09-18-2015, 12:22 PM
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ok awsome, i think i have an extractor if not i'll pick one up if i need it..

i'm gonna try the PB on it and let it sit for a lil bit then try again first.

last question, is there any disadvantage to replacing the bolt and nuts to just one way bolt? i was thinking i could get a better quality bolt instead of trying to just replace to stock.

thanks again!
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Old 09-18-2015, 12:56 PM
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With space limitations I don't know how you would drill a perfectly centered hole into a 1/4" stud . Easy outs usually break , then your really SCREWED as they're impossible to drill out = no chance of drilling & tapping to next bigger size . There are many replacement stud kits available . MAKE SURE THEY ARE TRULY GRADE EIGHT OR BETTER ! I'm SURE SCYARMS CAN HOOK YOU UP . A bolt might protrude into you inner workings . It might have had Locktite , etc. applied . GENTLY!!! heat surrounding area , and grab it with a BRAND NEW !!! set of QUALITY vice grips . It'll come out . Not to much heat , Patience .
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2011 BMS KING COBRA 150 Sold
YERF DOG SPIDERBOX's Sold
YERF DOG 3203's. Sold
MANCO SILVER FOX. Sold
2009 POLARIS 500 HO SPORTSMAN 4X4
2002 POLARIS 500 HO SPORTSMAN 4X4
2000 POLARIS MAGNUM 2X4
HALF A DOZEN CHEVY 4X4's
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Old 09-18-2015, 12:58 PM
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Sorry about that , misspelling, SYCARMS .
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2011 BMS KING COBRA 150 Sold
YERF DOG SPIDERBOX's Sold
YERF DOG 3203's. Sold
MANCO SILVER FOX. Sold
2009 POLARIS 500 HO SPORTSMAN 4X4
2002 POLARIS 500 HO SPORTSMAN 4X4
2000 POLARIS MAGNUM 2X4
HALF A DOZEN CHEVY 4X4's
NEED-MO-BUGGY
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Old 09-26-2015, 12:35 PM
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I got everything replaced..

ended up going to harbor freight and getting this little $25 variable speed dremel tool, cut the bolts about 1/8 inch from the base where metal was thicker and then cut slits in each for a flat head screw driver.

Iactually had to use a small butane torch for about 30 secs on each, tthat's what loosened them up but making the slits for the flat head was how I ended up doing it.

the replacement studs I got came with a new gasket ring too all for like $5 on ebay and they are way stronger material u can just tell by sheer weight
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Old 09-26-2015, 12:38 PM
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Oh I should add that I also got a pack of diamond cutting blade for it, they are way smaller in circumference and stronger, I did run into an over heating problem where one of the posts that the blade attaches too broke in half from pressure + heat build up, so I recommend taking it slower
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Old 09-26-2015, 03:58 PM
wildbob wildbob is offline
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Right on!!!
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2013 Trailmaster XRX 150 Type 86 stroker
Taida 4V head with 23/22mm valves, forged 4V piston,Taida 62mm jug,forged Taida 8200 KDU stroker crank, Koso high-flow oil pump, Taida case half w/ oil cooler ports, Setrab oil cooler,TrailTec Vapor, Mikuni VM26-606, aluminum 30mm intake, Uni filter, aluminum stack, Hammerhead racing exhaust, MotoRio adjustable CDI/HO Coil, Iridium plug, Full Dr Pulley CVT kit w/ 16g sliders, JD's Mikuni slide kit

2014 Kandi 90B
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Old 09-26-2015, 04:43 PM
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Hell ya, and funny enough, there was this really annoying sound that came from the back end that I could never pin down, fixed that %100

Now I just gotta keep playin with my main jet size... I live at 8800 ft elevation so it's getting tricky
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