[Jacbo]

So I had to take the water jacket cover of my newly acquired Merc 25 2 stroke (broke a bunch of bolts... different story.) and I noticed that it doesn't really have a cylinder head. This is kinda confusing for me as I've never seen a full sized engine without a cylinder head that's removable. So I guess you can't really blow a headgasket on one of these...

Hmm, Just thought that was interesting.

Pros- No more blowing head gaskets, Water intrusion into the cylinder due to leaky water jacket seals on HG.

Cons- If you strip a spark plug hole, mess up combustion chamber somehow... You're screwed!

 

[Jacbo]

Sounds like you've done this before! ;D
Good Idea, Wouldn't have ever thought of that.

I've done a little research on helicoil. Might end up being my only option cause I doubt I'm gonna have any luck with easy outs or the like for my broken bolts.

 

[Jacbo]

Yea that's just the water jacket cover. That's why I thought it was interesting.

Excuse the pic quality, It's dark and cold out there. ;D

You can probably see the 5 broken bolts.

 

[Jacbo]

I may check mine and apply never seize Since mine is a basically new motor ...

Be careful! The bolts are imho way to small for the application and at least on my motor lower quality then I would expect from merc.

My johnson is an '82 motor with just as much or more corrosion on it and I've broken only 1 bolt on the entire motor that I can think of... same spot though.

About the broken bolts, What I'm gonna try is getting a SS nut tacked (TIGed) on to the top of each broken bolt. This basically gives me a new bolt head to work with but more importantly superheats the broken bolt without harming the threads (head applied only to SS bolt vs. heat applied to outside of block).

I've read on some forums that this has worked well for other people.