I came across a 1987 Rebel 250 in great shape (Barn find) and got it running. There is one major issue... 3 of the 4 exhaust studs have been repaired improperly and is completely trashed. I expect the exhaust to fall off any day. New are extremely expensive. I found what looks like a china copy. https://www.aliexpress.com/item/33029906821.html? I wonder if it will work??? Anyone here have an original OEM head for sale?

I'm not aware of anyone on here buying one of those Alibaba heads. It looks like the right part and you won't find a used one for a better price.

It's a risk but you could become a rebel forum hero if you buy one.

Why not try drilling the studs out and re-tapping the threads?

A machine shop should be able to repair it.

I drilled and tapped the broken one. It was locked into the head, so i had to over drill and use a heli-coil. This makes the third broken stud on this bike. What causes them to snap off? Is it just age... heating/cooling over and over? Should the studs be replaced every couple of years to keep this from happening? I have two of these bikes... a 87 and a 2001.

are all your motor mounts good and tight?
do you have to muscle the exhaust into place to bolt it on?
is the exhaust secured well in all the original mounting locations?
are you using the oem exhaust with no mods - no pieces cut off?
are you over-tightening the acorn nuts?
do you have all the proper parts to mount the exhaust to the head?
any crash damage to the bike?

are all your motor mounts good and tight? Yes
do you have to muscle the exhaust into place to bolt it on? No
is the exhaust secured well in all the original mounting locations? Yes
are you using the oem exhaust with no mods - no pieces cut off? Yes
are you over-tightening the acorn nuts? This might be the cause, but would be by the previous owner. I got it with two repaired and then one snapped off before i got 50 miles on the bike.
do you have all the proper parts to mount the exhaust to the head? Yes
any crash damage to the bike? No. In fact, it is in great shape for a 87 model, besides the head.

Here is a picture. I have the original tank, which is in great condition on the outside but needs inside cleaned out. I'm waiting for the replacement blinker mount.

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