1989 Jonhson 200 HP - Broken Head Bolt

[Grady19]

Darn! I was changing the thermostats, water pump, and head gaskets this weekend and broke a head bolt off in the block. There is about 3/8" of the bolt sticking up out of the block. Does anyone have any tips on how to remove the broken bolt or repair this? I can do the simple stuff on a motor but have never run in to this before.

Thank you everyone,

Grady19

 

[sheboyganjohn]

Re: 1989 Jonhson 200 HP - Broken Head Bolt

First question, was the bolt corroded causing it to snap off? If so just grab what is left with a vice grips and it should screw right out. If the bolt looked good, spray it up with some PB blaster let it sit a hour to over night then try the vice grips. You are lucky, the hard ones are when they break off 3/8" below the surface.

Once you get it out report back on how it went. If the threads are buggered up in the block we will need to move to the next step.

 

[Grady19]

Re: 1989 Jonhson 200 HP - Broken Head Bolt

Thanks for repsonding so quickly.

It was in there really tight from corrosion around the threads. Some of the others came out with salt looking deposits around the threads. I gave this one some extra pressure and snapped it.

What is PB blaster? Can I find it in automotive stores or is that a marine only item.

Thanks again,

Grady19

 

[Richman]

Re: 1989 Jonhson 200 HP - Broken Head Bolt

PB Blaster is available at any auto store.

 

[Grady19]

Re: 1989 Jonhson 200 HP - Broken Head Bolt

Update:
I let the PB Blaster soak overnight. Tried budging it with the vice grips this mornign but no luck. I sprayed more in and will try again this evening.

Grady19

 

[Grady19]

Re: 1989 Jonhson 200 HP - Broken Head Bolt

All,

I finally got this fixed but it was a mess. Mostly because of me.

I messed up what was left of the bolt with vice grips. After that I thought I would try an easy out and drilled the bolt with a cobalt bit. I messed that up too and got a bit off center but was okay. The easy out wouldn?t budge the bolt at all. I decided to try and tap the thin walls of the bolt and the block. I messed that up also. I tapped about 1" in and snapped off the tap in the whole. I suck! The tap would not drill out. I expected this. I have a friend with a Granger truck route that hooked me up with a mechanic that works on big equipment. He used 4 carbide grinding bits to grind out the tap. He then expertly over drilled the hole and inserted a helicoil and used lock tight to keep it in place. I then reassembled the engine and it runs perfectly!

This is a 20 year old engine with a lot of wear. I will be looking for a 2003 or so 2 stroke to replace this one in the next year or so.

Thanks for all your help and responses. I hope this one helps someone some day.

Best,

David

 

[jonesg]

Re: 1989 Jonhson 200 HP - Broken Head Bolt

I did that on a motorbike engine yrs ago, I never put ez outs near an engine again.

In your case I would have welded a nut to the broken stud, if using vicegrips you should grind 2 flats first. The trick getting the stud out is tighten them first, then try loosening, tighten again with some heat then try loosening.
Then try shock with an impact gun, with heat and repeat.