1. There was a stuck tilt tube, To aggravate matter even more, the steering was completely froze up so that the engine could not be moved from side to side. To remove the flywheel there are a few steps in the procedure to properly remove it and not ruin things. An alternative to fire is ice. Mark the approximate length of the bolt on the bit with a piece of tape to act as a reference point to prevent overdrilling. What is an outboard motor powerhead? It consists of a completely assembled motor. You should see the starter ratchet ring and crank nut. It practically destroyed the head of the plug but it got it off. Tack this washer to the bolt and then weld an additional nut to the washer to allow turning the bolt with a wrench or socket. Outboard motors are still the most popular type of boat engines out there. If no amount of prying, or jumping up and down on it will free it, you may need to cut the drive shaft in half to remove it and then extrude the shaft from the crank. I have patiently been able to get most of the bolts loose with heat and oil, until… I get to the aluminum transom clamp screw. A method I would use is to drill, Roto-Root with a Dremel Tool etc. Wiggle the lower unit back and forth a little to get the two sections apart. Diagnosing a Partially Seized Outboard Motor – Video Transcript. When brute force isn't enough to remove a rusted screw using just a screwdriver, try one of a number of other strategies How to Remove Broken Bolts From Cast Aluminum 1) Drill a tap into the bolt. Unfortunately, during construction, it is possible for a bolt to break. How do you remove a stuck drive shaft from an 1988 model, outboard engine. Remove the bolt that holds the zinc anode (the "zinc") to the bottom of the anti-cavitation plate -- the flat, horizontal, rectangular piece that sits above the This is not as bad even if numerous bolts become twisted off simply because once you have the extension off the motor it is easier to work on repairing/removing the broken bolts. Push down the shallow water drive lever. Remove seven (7) bolts 2 and separate gearcase 3 from Mercury-Mariner Outboard Motor Gear Oil. Replacing a Head Gasket on an Outboard Motor; Replacing a Head Gasket on an Outboard Motor In this video I'll remove the cylinder head, talk about head gaskets, get the head and block surfaces cleaned up and checked for warp. Mercury Outboard Powerhead Removal . You may want to mark the location of this bolt. There are three bolts holding it. Re: How to free a steel to Aluminum corrosion bond Originally Posted by cstevens Unlike all of the wood-related subjects on the forum, removing stuck fasteners is actually something I have a lot of experience in. This places the drive in a normal upright position, good for servicing or whatever. An outboard marine engine repair manual is a book of instructions, or handbook, for learning how to maintain, service and overhaul the 70 HP outboard motor to factory specifications. The powerhead of an outboard motor is the equivalent of an automobile's motor. Easy. DOWNLOAD 50HP Outboard Repair Manual Johnson Evinrude Mariner Suzuki Mercury INSTANTLY DOWNLOAD a 50 horsepower outboard repair manual straight to your computer in seconds. Use heaps of heat, heaps of penetrating oil and work the bolt back and forward little bits at a time and also thought out the process of all this keep hitting the head of the bolt with a hammer, the shock of the impact loosens the built up corrosion around the bolt. The PTT came away from the rest of the motor and the motor stayed with the boat held by the starboard bracket. Answers. I have the shop manual and plan on installing a new lower unit but cannot get the old one to release. A bolt is a piece of hardware typically used to hold two or more pieces of lumber in place. Chuck a 1/16-inch, titanium-nitride-coated drill bit in a drill motor. BRKT POWER TRIM AND TILT UNIT E POWER TRIM AND TILT UNIT 7 REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT Order Job/Part Q ’ty Remarks Tilt up the outboard 1 Power trim and tilt lead 2 2 Plastic locking tie 3 3 Ground lead 1 4 Circlip 3 5 Upper mounting pin 1 6 Lower mounting pin 1 7 Power trim and tilt unit 1 8 Collar 6 For installation Place the point of the extractor into your drilled hole. Outboard engine troubleshooting is an handy skill. Tilt outboard up to the shallow water drive position. Or you could change the outboard water pump yourself. The Forum is a free service, and much like the "free" content on Public Radio, we hope you will support WoodenBoat by subscribing to this fabulous magazine. This, from experience replacing rear shocks, on a rusty truck. You can change the oil and inspect its condition, in addition to whatever required you to remove the lower unit in the first place. This is a right b*****d I am going to to drill this one out and fit a helicoil ( tonight's job). Once the hole is there you get in there with a sawzall and cut the driveshaft in half. When you remove the powerhead of your outboard motor, it's like removing the engine from your car. Jan 1, 2015. If they snap off easily, remove any plastic covers from the powerhead so you can do a more-thorough rinse job. Before he knew about Salt-Away, Greg Moss, the owner and mechanic of Moss Marine, Channelview, TX, had always flushed his motors with fresh water after every use in salt water. * Impact wrench will remove bolts that a breaker bar shears off. I am just using a propane torch and light oil, but no luck. Methods of Removing Stubborn Bolts From Outboards. You can drill it with a hand power drill motor, BUT the odds are that you will not be able to hold it straight then the bit will wonder (TAKE MT WORD FOR IT). Trim the drive up so you can locate and disconnect the speedometer hose at the plastic fitting. PLEASE PLEASE help!?No need to panic,it's really not that hard. Drill through the center using a HIGH quality drill bit. Bolts should be unscrewed. I can't figure out how to drop the lower unit on a 1972 Mercury 1500(150HP) outboard. I thought most of this problem was fixed on the 90's vintage motors??? I’m assuming you have an outboard motor, mine is an I/O drive so there are a few things that are different for me. And you should also know the rust along the shank resists removal more than the rust on the threads. Their reliability and power to fish in the deep waters, namely the ocean and lakes, is undeniable. Remember to remove any shredded key bits. Use a socket and wrench to replace the spark plugs. Removing and replacing the head gasket of the Johnson 15-horsepower outboard motor means you have to remove the powerhead of the motor to make the change. The impeller will come off. You’re out board is relative self draining when it comes to water. Then, buy a new driveshaft and install it in the lower unit. 3) Remove with closed end wrench by reversing the new smaller bolt out. If this doesnt work, then you will need to take the heads of the bolts, drill a pilot hole into the bolt, then use an 'easy out' to remove it. Outboard Motor Cowling. The job's complexity varies. We’ve tried alot of products to loosen stuck bolts and nuts over the years – WD-40, TD-9 Boeschield among them – but by far the best is PB Blaster. After heating, try more tapping as well as more heating, if needed. Extract Mechanical Fasteners. 12 Steps to free a stuck piston. Cracked your cowling? Get a brand-new outboard motor cowling today from Great Lakes Skipper. Hit the back of the extractor to secure it into the broken bolt. With the 7 bolts removed it should drop down, if it's been a long time since lower ubit has been removed then the drive shaft splines may be corroded and stuck in crankshaft in which case there is no easy way to get apart. after 5-6 hours of dealing with saltwater frozen nuts and bolts, i got the tilt and trim assy out . The gasket on the left, flushed with fresh water for a year, was removed during the motor's annual overhaul. the vibration, combined with To remove a really stuck bolt, get some good penetrant—nothing works like PB Blaster—and a propane torch, available at any hardware or automotive stores. This DIY video shows a technique for extracting a broken bolt from an outboard motor. To make removing the bolts easier, tap them a few times with a hammer, spray them with PB Blaster and let them sit. Liberally spray the offending bolt, screw or nut with PB Blaster penetrating spray. On OMC, I was able to take the portside transom bracket loose from the boat, remove the bolts through the side of the bracket into the PTT, rotate the bracket up and out of the way, then take the PTT bolts out of the starboard bracket. 2003…. Reinstall the adjustment pin. How do you remove a frozen driveshaft from crankshaft. As you will usually be working on an older motor where replacing broken parts may be expensive IF you can even find the parts. An easy out is like a reverse tapered thread tap, so that as you screw it into the pilot hole, it tightens and helps remove the bolt. marvel mystery oil, a little in the cylinders, and pull the pan and spread some on the bottom of the sleeves if you can. Unfortunatly you will have to remove the powerhead as well. 1 down 3 to go. If the flywheel doesn't respond to your polite attempts to remove it, you have a problem known as a "stuck flywheel. I have an old Evinrude outboard motor from around 1977, it's 4hp, in an other question i found out that the blocked flywheel was caused by the engine, it was frozen (blocked) I have opened the engine, first i started with the spark plugs, it looked like there was oil in them. After you have the powerhead off the motor, removing the cylinder head is a straightforward process, as is replacing the gasket. Working on a little Evinrude Mate that has been sitting out in the weather and has a little rust on it. Share. 5hp fourstroke approx 6 years old. Johnson Manual Tilt Stuck common problem where outboard is seized up and the assist cylinder will not allow the engine. You could miss two or three weeks worth of boating waiting for repairs. It's the workhorse in your engine, so you need to be sure that it's functioning efficiently. After you pull off the water drop your trim down and let it drain, then give it a quick fire just for a couple of seconds and shut it back off again, raise your How to pull a flywheel from an outboard Removingomcflywheel, Pull Flywheel Off Mercury Outboard, 150 Mercury Outboard Flywheel Removal, REMOVE FLY WHEEL ON A SMALL OUTBOARD MOTOR, Removing Mercury Outboard Flywheel, FLYWEEL ON THE OUTBOARD MOTORS, Remove Flywheel Evinrude Outboard, How To Get A Stuck Flywheel Off A 90hp Merc Outboard "The best thing we ever found to break a frozen engine loose with was automatic transmission fluid. I will try to lead you in the right direction, but please realize, some engines no longer follow this design. Some maintenance tasks, like removing the powerhead from your motor, may require you to remove the flywheel as a first step. Before you crank your engine, cover the spark plug holes with a rag to keep Engine Release from blowing out of the holes. Saw him do this many times. The impeller on a 9. That motor is paired with a lower unit and then is connected with a shaft and propeller further down. 0mm drill and then taped a 6mm thead in to that 3 down 1 to go. Remove bolt and trim tab 1. Share Remove 2 small u-bolts from rear end yoke Pry drive shaft out of yoke Slide front Removing stuck piston Home › Forum › Ask A Member › Removing stuck piston This topic contains 5 replies, has 4 voices, and was last updated by bob-prock 4 years, 1 month ago . Shift the outboard into neutral or forward gear position. Penetrating fluid, torch, heating and cooling. An outboard powerhead can have different features, parts, and needs. 8 Mercury outboard boat motor can be easily changed. If they want to nick it they have to chainsaw the transom off! IMHO any engine over 15hp should be bolted through the transom, it is no big deal, far more secure than relying on a couple of clamps to hold the engine on. It should eventually free up. Then let it soak for a bit, loosening the corrosion and rust that’s holding it captive. Near the half hour, I spray fogging oil into the carb(s) with the aircleaner removed, until the motor dies. You can also use a butane torch, but it's a little cheaper and easier to go with the propane. I have removed all bolts and disconnected the clutch lever. One time my mom's drain plug was stuck on her car so tight that I used a pipe wrench to get it off. Replace the aircleaner, remove the spark plugs and spray maybe an ounce into the cylinders while hand cranking the engine. Post is for my father in law. Here’s what I used to remove it, and you can use the same procedure to Re: Removing Stuck/Corroded Bolts i use the rotary rasp bigger than the hole high speed it tapers the hole slightly but gives a center point thats shallow for drill starting i then drill the hole with side wall enough for a gouge then use the smaller rotary file to thin two opposite walls then hit the thick sides with the small gouge ps drill The motor is frozen so you know there is rust somewhere. If the motor refuses to turn, add more penetrating oil and periodically use the impact wrench to turn the crankshaft nut. lbs on the puller bolt and it will not move. Since it's hard to tell which of the pistons are stuck, fill each with enough to cover the top of the piston about a quarter to half an inch. WD-40 (or favorite penetrating oil) both sides of piston. Easy peasy. Removing and changing the water pump is another DIY solution. The first thing to look for, would be a low battery or loose wiring connections. Since you already bought a fram sure drain i'm assuming you won't need the original drain plug. Manuals contain step-by-step repair procedures, illustrations, pictures and advanced troubleshooting. The washer serves to separate your welding work area from the block or base plate and greatly reduces your chances of inadvertently welding the broken bolt to the block. If the engine is all together you may have success by running hot water through the engine. Remove the Woodruff key. Block up with combustion end up (if the rod end is up, there is a danger of melting the babbitt on the end of rod). Some smaller motors that utilize a built in fuel tank around the motor to be removed. Remove all spark plugs. Your Guide to DIY Outboard Motor Inspection and Maintenance . Attach an appropriate-sized spark plug socket to a socket wrench; then remove each spark plug by turning the wrench in a counterclockwise direction. sterndrive. Basically the bolts that Yamaha used were to long, weak, and actually would fuse to the aluminum making it impossible to remove the powerhead. I ended up drilling 2 small holes through the brackets (one hole on each side of the bracket) to access the inner thread area of the bolts which allowed the PB Blaster to work its way deeper into the entire thread area after I applied the heat. 95. Then drill a small hole thru the stud or bolt, and sharpen an old tap to a taper that will go into the hole, try to get it square, four sides, and drive it carefully, when it gets tight try turning ether way, hopefully it will come out. I have a 25hp on a fishing boat now, it is bolted through the transom with ss bolts and the nuts are welded to the bolts. It basically digs into the plug to get a good grip on it then you're able to pull it off. You can beat the remainder of the driveshaft out of the crankshaft once on the workbench. The powerhead is light enough to remove by hand. $17. On these, then remove the upper 6 bolts for access to the shift linkage coupler. I have several pages entailing the gasket replacement process for these particular Mercury Outboard Models (650 - 700). Just turning them would crack the part, or break the bolts. This is especially true if the engine has been sitting for a long time or if things locked up on you while riding and you skidded to a, hopefully upright, halt. How to remove 2005 Suzuki DF 140 outboard motor? Remove bolts and fuel pump 2. One of these is a special bolt that has the head mid way through the bolt and a separate nut to attached the ground wires too. ) One poster on the catalina 25 association forums mentioned that he was able to remove the carburetor with the boat in the water. If you’re doing the maintenance on your Mercury Marine outboard for the first time, you know that you have to remove the cover (sometimes called the “cowling” in Mercury Marine’s literature and shop manuals) to get to the powerhead, the internal combustion engine of your outboard, just as if you were opening the hood of your car to work on its engine. No matter how tightly you crank em down. The drive can be placed with the horizontal fin that is above the prop sitting on the 2 by 4's. After heating and tapping, spraying in a lubricating penetrant like those mentioned above often helps. Remove the thermostat and attach your hoses to your heating unit and pump the hot water thru the cooling system. to remove the broken bolt. Three or four days of this should do it, and then let the Engine Release soak in for a week. Evinrude Johnson 1987 Outboard Motor Engine Cover Brackets & Mounting Bolts. Now that I have the cylinder head on the bench, I can begin taking it apart to replace the outboard thermostat. The local Chap dealer seemed to think they would have to remove the motor to get to it. How to Free a Seized Engine. It also helps to tap-tap-tap the stuck bolt with a ball pein hammer. I guess it was a very common problem. I wonder what's the best/fast way to remove them, with minimum parts damage. Greenwood says it’s safe to drench anything on the motor, but take care to avoid spraying water into the throttle body or carburetor bodies, which could allow water to enter the engine. * Heat and beat works on rusted on nuts. These head gaskets came out of the same outboard motor. It worked perfectly. Use a socket wrench and a 9/16-inch socket to remove the four equally spaced visible bolts that range around the front of the flanges between the lower unit and the leg of the motor. Hot Outboard Motor Bracket up to 25HP Kicker For Boat Auxilary Trolling Mount-AM. remove the starter pawl and thread 3 1/4 20 puller bolts from your 3 jawed puller plate. For safety, disconnect the negative battery cable, if so equipped, and remove the key from the ignition. Remove the linkage with the appropriate hardware, typically a socket wrench and pliers. See website for outboard / outdrive repairs http://www. So we had a stuck tilt tube on this outboard as well as a frozen steering rod. Losing your mind because the only thing holding up your project is a seized bolt? Davin Reckow is here to show you the tools and techniques you’ll need to get those frustrating bolts out of the way. Corroded Bolts in Aluminum. The Yamaha Outboard Motor MODEL, PRE-FIX and SERIAL NUMBER are stamped on a plate attached to the transom clamp bracket. 2) Insert a smaller bolt into the tapped hole. How to Remove Corroded Metal Screws. This is the key and it can be removed by gripping the sides with pliers or wedging one end with a screwdriver. Step 5 Heat the corroded bolt by placing the neutral flame of the oxy-acetylene torch 3 to 4 inches away from the head of the bolt. FEATURES & CONTROLS ENGAGING SHALLOW WATER DRIVE Reduce engine speed to idle. Is there a manual release to get it up in the up. First remove your trim tab. All was going good until the bolt in between the motor and hull sheared off. Hold a hammer against one side of the nut, and hit the other side with a second hammer. How to Remove a Broken Bolt from a Thermostat Housing. info/ for parts, and more repair information or help. However, if you're trying to remove plastic fittings that you know were bonded with 5200, you'll get less frustrated and do less damage if you skip down to step 6 right now. Anyhow, if the bolt head snaps off tapping the housing side to side will get the housing off. I had to drill out the bolt that had the grounding strap and nut on the back side, so I am still trying to figure out how I can replace that. While this is unusual, inexperienced or rushed Start at the top and rinse down. . Since the motors are run in salt water, I decommission by running for a half hour in a barrel of fresh water. Getting to the water pump impeller requires splitting the lower unit at the two or three bolts that join it, and disconnecting the shift rod. And, like the engine of your car, the need for a powerhead repair will dictate the need for removal. When you get these 6 bolts removed, the gear case unit should drop down about 1/2”. Take flywheel nut off,remove spring washer from underneath,replace nut untill shaft is just proud,wrap arm and hand round the flywheel and take some weight(try to lift the engine)and hit it a solid smack with a 3lb engineers hammer you must hit the shaft bang on hitting the nut wont do. Once the driveshaft is cut the lower and powerhead will both pull free. Hey there Dangar Stu here. If thats the case then better to take to your dealer for them to remove. Open the oxygen valve of the oxy-acetylene torch and adjust the valve until you have a blue neutral outer flame and a bright blue inner flame that is between 3/8 and 1/2 inch in length. Remove the pull start mechanism on your motor. To remove a water pump, first locate it on your outboard engine by checking your user's manual. If that is the case, alternative and possibly damaging measures need to be taken. This takes HOT water, 180 degree or so. Begin disassembly by removing the bolts that fasten the lower unit to the midsection. First, pull each spark plug's wire off the tip of the spark plug. Remove the bolts, two on each side of the lower unit, and washers between the lower unit and the exhaust housing, with a 14mm open-end wrench. Unscrew the trim tab retaining bolt and remove the trim tab. After trying multiple times using the PB Blaster and different types of wrenches, I had to remove the housing. Pull down on the lower unit to separate it from the housing. acassidy - you have a couple of things that can work. When ordering parts and/or accessories from our Yamaha OEM Online Parts Catalog it's important to properly identify the exact model you are dealing with. Then I'll install the new head gasket and get everything torqued back up properly. What tricks are there for removing engine bolts that are starting to gall that will avoid overtorquing to the point twisting off the bolt head? My technique of working the bolt back and forth patiently hasn't worked yet. 2. * Name brand Vise Grips will remove screws, etc, that Harbor Freight brand locking pliers won't. The drive shaft fits into a splined hole in the bottom of the engine crankshaft or powerhead. Even this can be a challenge when they were originally installed with a coating of polyurethane. ?I know on my old OMC you used to have to remove the starter to get to the gear shifter pin to remove before she would drop. Outboard motor shaft puller. put molly lube on the drive shaft splines, same reason. Reverse the process to install the new impeller. puller bolt to a All that is good accurate advice, but where are the holes to screw the puller bolts to? They are the holes that hold on the starting pawl plate -- 3 surrounding the flywheel nut. The lower 6 bolts attach this extension to the lower unit which would need to also be removed to access the water pump. Like we said in the beginning, patience is a virtue. The key may be stuck. Remove the retaining bolt. Try using a "centerdrill" to start, they do not walk the way a drill does. Remove the accessory belts from the alternator, power steering pump, and any other belt-driven accessory. " Removing a stuck flywheel calls for certain tools, most of which That’s when we found out that the engine would not drop from the up position. I admit it doesn't How do I remove a lower unit that is stuck/corroded on? The motor is a Suzuki DT55. I'm trying to torque up or remove a bolt that has galled about half-way in/out. 1)Shift into forward gear. Bottle brush home is easier to get a good result if you're not experienced with a hone tool. Remove the rags and let the excess penetrating oil escape from the cylinder, while you spin the motor. Use a GOOD sharp drill bit with the hopes it will drill straight and not run out to the side. My ’72 Evinrude had been a salt water motor and the clamp bolts were frozen solid. 1/4 -20's with a 7-16th bolt head. you may also be able to remove the head and drive the pistons loose with a block and mallet, but i dont think the engine will work for you, your gonna have to do a tiny bit of repair. Source(s): My father was a tool and die maker. Read More. If the Kroil and tapping do not loosen the bolt enough to turn it out you will likely pull threads from the manifold before snapping off the bolt head but, not a guarantee. The lower unit on this engine has never been serviced and the impeller needed to be changed. Today's video proudly sponsored by MarineEngine com is about outboards, where you can turn the flywheel sort of halfway then it locks and turn it back, but you can't do a complete rotation on it. Remove the seven bolts threaded upward from the lower unit into the motor's midsection with a 5/8-inch socket wrench: three bolts are on each side of the lower unit, and the seventh is the bolt inside the cavity beneath the removed trim tab. Removing the lower unit of the Force 120-horsepower outboard motor, regardless of the reason for the removal, offers multiple maintenance opportunities. let the oil sit a few days. Try not to break the cavitation plate on the gearcase. Outboard Motor Trim/Tilt Motor Replacement There may come a time when you need to raise your outboard motor and it does not work. By continuing to use this site you consent to the use of cookies on your device as described in our cookie policy unless you have disabled them. 3. We have not used the motor for over a year and it has been laid up in the garage (sprayed with oil, covered up and stored verticle on a wall bracket before layup) On checking it over today I found that the forward/ nutral gear lever was jammed solid in nutral, the engine turns over ok on the pull cord and started on the third pull. While a fuel system problem may make it impossible to start an the engine, outboard cooling system problems have the potential to destroy an otherwise healthy motor as overheating can lead to a blown cylinder head gasket, or even complete seizure of the engine. There are 14 bolts with 7/16″ heads total to remove. Drill out the center of the bolt, making sure that you stay centered and lined up with the bolt. Most frozen engines are caused by rings being stuck to cylinder walls. Something I have seen done a few times (though I doubt I would do it to my own motor) was the ensure all bolts are out, shift shaft disconnected (if necessary) and wedges jammed in all around the lower unit to keep the tension even, place motor in down position, put something soft under skeg and start the motor. I am attempting to remove the flywheel on my Force 50 HP outboard and it will not budge! I have a puller, have tried heat, penetrating oil all the normal and proper procedures but I probably have a 150 Ft. Turn the ratchet handle to remove the bolt. That might loosen the nut so that a wrench can remove I broke off 3 of the bolts that hold the lower unit and can get the unit off - Answered by a verified Marine Mechanic We use cookies to give you the best possible experience on our website. Sometimes outboard motor water pumps give up the ghost in the middle of the season, when service technicians are swamped. Adjust the electronic trim selector or manually pull the tilt bracket pin out of the adjustment notch on the motor and set the engine to a horizontal plane. The vibration loosens the rust. 1975 Johnson 70esl75e manual tilt stuck. Loosen the exterior bolts that connect the pump to the housing. Get the crud out of the engine. Attach the 3/8th drive ratchet to the extractor. The flywheel will lift off. Going from what I remember (which might not be right) you have to remove the two big bolts from either side that secure the tilt tube. How many bolts did you take out?I have a 90 merc 45hp motor and lower unit seems to be frozen to power head. If the piston(s) are stuck put some penetrating oil down the spark plug hole(s) and try to turn the engine over using the kickstarter or wrench on the crankshaft bolt. A rubber plug covers the access hole for the shift rod. DOWNLOAD 70HP (70HP) Outboard Repair Manual Download a 70HP outboard repair manual in seconds. that is stuck in gear and I can't put it in neutral to We have a Tohatsu 3. Spray the nut with penetrating oil and let the oil sit for 10 to 15 minutes to penetrate the threads of the bolt. If you're trying to remove a nut from a bolt, you should probably apply the heat or cold to the smaller nut. He's got the 2000 50 Hp Johnson and his tilt went so it's stuck down. You are correct, the bolt holes do penetrate the water jacket on that engine. I need to remove a lot of steel bolts from an aluminum engine block, they feel like "welded" in there because the level of rust. 2)There are 7 bolts to remove. Pour one part ATF transmission oil, one part gas into cylinder (approx. The problem with doing that though, is you also have to support the motor via a hoist, or I have heard of some creative types using blocks or similar to support the motor from the bottom. Be sure the cooling water intake is submerged. On the freed pulley, locate the semicircular shape in the shaft. We have dozens of boat motor cowlings in stock now for outboard motors by Yamaha, Honda, Mercury, Suzuki, Johnson Evinrude, BRP, OMC, and more. Re: How to Unseize a seized Outboard??? At a $1000 for a box just sell the motor if there is not a very simple fix after you pop the heads Was just trying to make sure you wern't overlooking something simple with the seizure. This video is a detailed walk through of how to remove a stuck lower unit on a outboard engine. How to Remove Rusted Bolts. Any ideas? I pulled the carburetor off (it was very easy, just undo the fuel hose, the two linkage rods, and then remove two long bolts that connect the air intake to the carburetor to the engine block. Keep that in mind when heating a stuck bolt. another 2 hours drilling , retapping and rebuilding pump, motor and rams and all was good. No kidding!! stuck outboard flywheel removal info sought!!!!! procedure for removing a flywheel from an outboard motor nor any other TAPERED SHAFT fit. The safest method is to take it apart, check the bearings for rust and run a honing stone over any rusty cylinders to clean them up. Then use a wrench to try and loosen the nut. Cause the HF pliers slip off. Keywords are engine, bolt, seize, gall, remove. 2nd Ground off the studs to a little way off the casing and VERY carefully strarted with a small drill drill out he stud - I finished with a 5. Hi I just did this on a 2001 mercury 200 optimax . Outboard engines with broken bolts The WoodenBoat Forum is sponsored by WoodenBoat Publications , publisher of WoodenBoat magazine. Here's How To Remove A Broken Bolt Without Losing Your Mind leaving the hollow brass core firmly stuck in the engine. In order to replace some of those gaskets, you need to remove the powerhead. The first is to remove the lower unit and the zinc tab - then, with some of the original bolt material protruding above the lower unit, weld a stainless nut of slightly larger diameter to the bolt, let it cool a bit and then turn it out. No drama. 1965-1989 Service Manual Application How to Remove a Broken Bolt. The new lower unit will not include bolts, so reuse the old ones