force 85 broken bolt with water coming out

[74bayliner]

I have a force 85, finally got the water coming through the exhaust. And i noticed water now coming from a hole were a bolt should be. i found the bolt but it was snapped off. it is one of the head cover bolts.
What do i do from here?
I tested compression on all 3 cylinders and it was fine but this is just wigging me out.

 

[kbh121956]

You will need to pull the head and drill/tap to remove the broken bolt.

 

[74bayliner]

Since this is the bolt at the bottom, i am assuming i am going to have to take the power head out ? Is there a tutorial on doing that? i was not able to find a you tube video on this particular force motor.

 

[74bayliner]

I guess it seems pretty straight forward: Fingers Crossed.

 

[jerryjerry05]

It's possible you just need to remove the head to get to the rest of the bolt??
The cowl can be loosened and lowered o get access to that area.
The mid section cover needs to be removed and the small screws holding the bottom cowl taken out.
Then it can move enough to get at the bolt.

IF??? it's got one broken off already???
Get ready for others to break too.

I use a propane torch, a can of PB Blaster or another penetrating liquid and a hammer and a 1/2" 6 point socket.

Heat the bolts, then spray with PB and let settle in, repeat 3-4 times.
As you heat and spray, tap the head of he bolts to break up any
corrosion(this is what caused the bolt to break) that has built up around the bolts.

Then after a couple time of heat and spray, gently try to remove the bolts.
They were installed with 20# of torque, if it takes a bunch to undo be careful.

The comp is good, and there is no water in the cyl?
Goop it with sillycone and go boating??

 

[74bayliner]

Thanks Jerry! I will print this out and go to the motor today when wife gets home to take on children duty. I am ready for more to break but hoping spending 4 dollars per bolt for all 14 will be worth it for new bolts. So far no water in the cylinder that i can see but i will confirm when pulling the head today.

 

[74bayliner]

Question... For the head bolts, if i am going to be replacement them all.I have seen some of the ones on ebay even the brandnew ones. They look rather old and worn. Would it make sense to go to a place like Fastenal and get some stainless steel bolts with the same spec? if so what would i be looking for in grade?

 

[Jiggz]

Stainless sounds like a great replacement for the head bolts. However, with different metals as the head and block, this causes galvanic corrosion to the softer metal, i.e. the block. Personally, carbon steel alloy in Grade 8 should be more than enough. Others probably will just stick with medium carbon steel Grade 5.

 

[74bayliner]

ok thank you. I will go to fastenal with one of these and get some new ones in carbon steel grade 8. Thank you.

 

[kbh121956]

I would first do as Jerryjerry05 said. Silicone it up. let it dry. If not leaking, Go boating!

 

[74bayliner]

Unfortunately there will be no boating in the near future
so the bolt broke off inside the engine so i will have to drill & tap it out. No biggie, have done that before, but here is the real kicker and why i "love" *sarcasm Previous Owners and their BS Stories...
The Block is cracked. I have inspected the area around the head, this is the only damaged part. Do i go about getting someone to dab a new weld in than retap that hole? or Brazing? or finding a donor block. It looks like the damage only goes as far as the bolt hole and not into the block.

 

[74bayliner]

Currently about an hour from home. Got a gentleman who is a welder for 30+ years said he can tackle it. So here i am! Pictures after its done

 

[74bayliner]

The weld is perfect! Tomorrow I will clean and put the cover back on to center the hole, punch it, drill and tap it.

 

[74bayliner]

No Exhaust Gasket? Why not... skip the 17 dollars... and use RTV
Some People...

 

[74bayliner]

kbh121956 , Jiggz or jerryjerry05 can any of you tell me in the last picture that i posted. Those two shock absorber bolts. Are they supposed to be so rusty? Or do you think because of the previous owner using RTV instead of a gasket to seal the motor and exhaust it got water in there and damaged it.
I will likely have to replace them, correct?

 

[jerryjerry05]

No gasket between the adaptor plate and the exhaust housing, sillycone the heck out of it.
The factory used silicone and the rust is normal.
Just clean up the tops and paint with a rust paint and put it back together.

 

[Jiggz]

No Exhaust Gasket? Why not... skip the 17 dollars... and use RTV
Some People...

Actually, the gasket only goes on the upper side and nothing for the bottom side.

 

[74bayliner]

Thanks guys!!! So i wonder what gasket u bought than? It looked like the right one for the application according to the drawing on marineengines website

 

[74bayliner]

You are correct the upper side gasket is what i ordered! Onto getting that bolt out and drilling & tapping the welded hole.

 

[74bayliner]

And Broken Bolt is Gone! Drilled it out, retapped the hole and bam. Perfect, New hold drilled after weld as well. But camera died before i could take a picture. Waiting on Gaskets so i can put this puppy back together again.