1997 Seadoo GTI - Broken Cylinder Head Bolt, What to do?

[2strokenewbie]

Hi All,

I recently bought a 1997 Seadoo GTI 717. While riding a cylinder head bolt sheared off and the water that cools the piston is now able to escape through the bolt hole and pour into the bottom of the craft. I tried to remove the bolt thread in the engine block with no luck. I'm not sure if I should attempt to completely drill out the threads and tap a larger thread. The piston casing is pretty corroded and I'm afraid It will crack. Any suggestions?

Thanks for the help!

 

[clmboating]

I'd just do a top end rebuild, that's really rusty!

 

[mikidymac]

Assuming that your cylinders, rings and pistons are still within spec and your compression was good before the failure I would contact your local machine shop and/or engine rebuild shop and see what they would charge to remove the broken bolt.

The bolts are stainless so they are not the easiest to remove especially with corrosion.

The rust is just on the cooling water side of the head o-ring so I would not worry too much about that. Remove the o-ring and use a fine flat file to lightly go over the sealing surface and it will usually clean up pretty easy. Remember you are not trying to remove any material, just the corrosion. With a fine flat file you can see the high and low spots pretty quickly.

 

[Lake Sailor]

Helicoil it

 

[NIL8er]

drill and use reverse thread easy out type tool after soaking with blaster for a day. if that doesn't work when you drill hole for reverse threaded easy out make sure you have the initial drill hole precisely in the center of the bolt and keep drilling with progressively larger bits until almost to the threads, all the time increasingly attempting larger easy out tools . the heat from drilling and pressure relief of larger holes will eventually allow bolt to free up , most likely .

 

[ski-d00]

it's pretty unlikely that will come out with an EZ out. been there, done that, but a helicoil should work as long as it doesn't crack. use a good bit and go slow.

 

[Lake Sailor]

use a good bit and go slow.

(ski-d00).

YES. The thing about the stainless steel used in these fasteners, is it work-hardens rapidly. Sharp bit, slow speed, enough pressure to keep making chips. Some light oil. Let the bit spin against the metal, you've just made it harder, both the bolt and the job

 

[NIL8er]

works if done right. its the first thing to try. also the bigger the pilot hole the bigger reverse thread tool you can get in there and the more cooperative the bolt becomes. ive never met a bolt i couldnt get out . not always with this method but MANY times.

 

[Lake Sailor]

LH drill bits help also.

 

[Coastiejoe]

Most head bolts are "floating". So they don't bottom out. Once you pull the head, if there is any stud you can grab it. Kn stud, left hand drill bit is the best bet.


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[RodInEscondido]

I personally have not tried it, but saw a post here a while back suggesting to use a 50/50 mixture of acetone/ATF to soak it for a while.

I have used a center punch to center things before starting drilling and just the shock of the punch has helped me loosen things up.

Patience, patience.