broken starter mount bolt

[nerdlinger]

99 XP Limited:

I have a broken bolt in the bottom end where the starter mounts to the engine. I tried center drilling it and using an easy out, but the easy out broke off in the hole and it appears that I am screwed.

The diagrams at the parts websites show three mounting bolts, but in actuality there are only two (top and bottom, no center bolt). Therefore, I only have one bolt available at this time.

Can I run it off of one mounting bolt?

If not, are the any suggestions aside from trying to remove the broken easy out?

Is there another way to secure the starter to the engine?

 

[89SEAPOO]

not sure if yours is the same but on my 580 there is a third support bracket and bolt on the rear of the starter. You could always drill it all the way through and try to re-tap the hole.

 

[custompartsguy]

you will need both bolts to hold it, as hard as it may be you need to drill and easy out that broken bolt, if need be you may in an extreme case have to remove the engine to do it.

 

[nerdlinger]

I tried a titanium bit first and didn't get anywhere. A cobalt bit worked better, and I was able to get it deep enough to get the easy out in there, but it took three bits to get it done since it dulled relatively quickly. Is there a better bit to use (maybe carbide)?

I'll try to drill out the easy out and see what kind of progress I can make. A seadoo dealership generously offered to remove the engine and drill it for $600. I'd like to avoid that.

There is not a third bolt on mine, just the two I mentioned, and I don't see anywhere else that would be feasible to attach it.