I was taking my exhaust side cover off the other day,cause my water pump was not pumping water and the stream was weak.Anyway I thought maybe something had clogged up in there.The cover is bolted on with 16 bolts three of the 16 broke off flush.I got a EZ out screw extractor and drilled one of the bolts out.Then I tapped the EZ out in well I ended up breaking the extractor off in the bolt.So I doubt I will be able drill an tap that bolt out.The other two I am going to drill and tap them.So my question is can I bolt it on with 15 bolts put gasket sealer on and just leave out one bolt?
Find someone with an arc welder and use chrome rods to build up in the center of the studs. Once enough is built up, you can weld a nut to it and gently work it free. Might take a couple of tries but it does work.
Dont bother trying to remove the other broken off studs. Put it back together and you will be fine. Surprised you only broke off 3. FRED
Thats kinda what I figured,but it just bugged the hell out of me knowing that I broke three off,and one that would likely be hell to tap.I'm gonna go ahead and tap the other two and just leave that other one alone I reckon?Pine Island you must run in saltwater too?
Yes, my experience was on a salt water 50. Been a few years ago but I believe I broke off 5 or 7. Book I was using recommended that I remover the cover to clean things out. Will never do that again. Broke a couple of easy outs plus a few small drill bits trying to center my drilling of the studs. Did manage to tap some holes and one or two turned out to be off center but I was able to use them.
Put it back together and used hi-temp sealant. I dont remember how many bolts were missing but it worked out fine. FRED
You didn't mention what HP the motor is, and I don't know if it matters or not. I am presently in the process of cleaning out the exhaust and exhaust water jacket covers on my 1998, 90 HP Yamaha. I didn't break any bolts, thank Heaven. When I went to the dealer to pick up the new gaskets, I asked the mechanic if I had to use gasket sealer on either of those gaskets. He said no, because it will heat and pop out. (funny thing is the manual I'm using said not to use sealer also).
Looking at the gaskets, the already have a very light sticky side anyway. For what it's worth, I'm going with no sealant. Besides, the gaskets I removed could not have had any from the factory because they just peeled right off.