June 9, 201313 yr Last night in attempting to correct an exhaust leak I stripped (yes i did) one of threaded holes on the exhaust port at the head. Has anyone corrected this situation? I am assuming it will require steel thread insert which leads me to asking if there is a danger in contacting a water jacket when drilling? I'd assume one would obviously not drill past the factory hole depth which was really quite shallow. WARNING-this stripped VERY easily and the thread depth is only about 1/4" be careful... Second Question. What does one do to get a good seal where the header pipe slips into the heavy aluminum exhaust chamber? The two O-rings that seal this connection seem to be allowing exhaust to exit and it sounds awful. Perhaps the O-rings become less supple after a couple of years and should be replaced or should one use a little RTV type sealant here in addition or even in place of the O-rings?
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