Power head want move

[Stephen1348]

1988 25hp evinrude. Got all bolt out from under cover an both nuts from inside cowl. Still wil not move anybody got something to try???

 

[sutor623]

Yea the exhaust gasket on the bottom of the powerhead likes to get hot and bind to the surfaces. Slap the motor with a rubber mallet. If you whack it all around eventually it will pop off. (I am also assuming that you pulled the lower unit already?)

 

[Chinewalker]

I little leverage might help, too. A large, long flat blade screwdriver, set between the base of the exhaust casting and the belly pan may pry it loose. Just gotta break that free and the rest comes easily. Go easy - you don't want to break anything.

 

[Stephen1348]

Only thing I ain't got rubber mallet lol. Oh an any ideas on how to remove broke off bolt from exhaust manifold on the side some da had put two stainless bolt in the cover. Only thing I can think of is drilling it out cause it's froze in there

 

[Chinewalker]

Yep, drill them out. I did one this spring. I used the exhaust cover as a drill guide, running a drill bit with a sleeve fitted over it.

 

[Stephen1348]

Went an bought a rubber wacker,power head finally gave up and came off. Going to jump on them rung off bolts 2mar after work.

 

[fhhuber]

If enough bolt is sticking out... you can saw/grind a slot in it and try a screwdriver.... Or center drill it and use an "Easy-Out" which is a tapered reversed thread device of hardened steel. (several variations and brands)

Aluminum will expand more than steell with heat so getting the block warm (about 180 F... not above 250 F) can make it easier to get the bolt fragment out without having to drill it out.

I would avoid drilling it completely out because the bolt is harder than the aluminum making it easy for the drill to wander off center of the hole and creating an even worse problem.

lots of experience removing broken bolts from aluminum castings.

 

[Stephen1348]

Cut slots in bolt with dermal tool and broke off with screw driver trying to turn it out

 

[Chinewalker]

DON'T use EZ-Outs! They are anything but easy to get out after they snap off on you!

 

[sutor623]

Went an bought a rubber wacker,power head finally gave up and came off.

Sweet!!

 

[Stephen1348]

Well should have got back on here now I got a dang e z-out broke off in it now

 

[Chinewalker]

Yep - nothing like trying to remove hardened steel... Time to take it to a machine shop.

 

[Stephen1348]

Small chisel and hammer will bust the easy out up and magnet to pull broke parts out. Finally drilled out little bigger an re tapped for larger bolt. Done lol

 

[Sirrobin53]

Been there, done that. Good job.

 

[Stephen1348]

Ok got it back together head,cylinders all look great good compression. Now the bad top cylinder is still pumping water got fire pull top plug no diff pull bottom she dies swap both coils out plug an cdi box. All new gaskets clean an torqued to manual specs. Lost did not see any cracks in walls or head?? Any body got any idea bout drop it in the river️

 

[AlTn]

"All new gaskets"...does this include exhaust gaskets?...did you surface the outer exhaust plate?...reuse the inner plate?.. see any warpage of that inner plate?..any gasket sealer used on the inner and outer exhaust gaskets?