Snapped Crank Position Sensor Bolts

[Davin]

I have a 2003 Sea-Doo Challenger 2000 (240 EFI) that I picked up used and non-running at the time. I got the thing running great after narrowing the fuel problem down to the float and needle valve in the vapor separator. Went an hour and a half 30-40 miles an hour to a restaurant on the maiden voyage without a single problem. On the way home, the boat decided to act up. It seemed to more or less instantly cut (not sputter) out if I went upwards of 3000RPM but would start right back up without a problem. After reading the forums and the tech book, I decided to check the Crank Position Sensor. One bolt was sheared and the sensor seemed a bit loose. The second bolt snapped trying to get the sensor off. The "easy-out" I used was not so easy. It snapped too. Now I'm attempting to drill and re-tap the old hole, but I have no idea how long the original bolts were and I don't want to drill too far. I have no idea how thick the block actually is and i can't see any distinguishing lines in the metals as of yet.

So I suppose my question is: Does anybody know how long the original crank position bracket bolts are supposed to be? I have the book, but I don't seem to see any part numbers or call out for these. Thanks in advance!

 

[Dr Honda]

Unfortunately... the bolts aren't listed as a separate part (Come with the sensor) so they don't list a size. Hopefully someone can chime in who owns that engine.

My official stance is... NEVER use an easy-out. They are very hard to be able to bite into the old bolt. The problem is... hard = brittle. So, a little side load, and they snap. To remove a broken bolt, just use a left handed drill. most of the time, as you start to drill... the heat generated will loosen the bolt, and the bit will bite. In turn... it just spins out the broken off part.

 

[Davin]

Unfortunately... the bolts aren't listed as a separate part (Come with the sensor) so they don't list a size. Hopefully someone can chime in who owns that engine.

My official stance is... NEVER use an easy-out. They are very hard to be able to bite into the old bolt. The problem is... hard = brittle. So, a little side load, and they snap. To remove a broken bolt, just use a left handed drill. most of the time, as you start to drill... the heat generated will loosen the bolt, and the bit will bite. In turn... it just spins out the broken off part.

Good advice with the left handed drill bit. And thanks for the quick response.

In regards to the bolts coming with the crank position sensor - the boat had an unopened mercury sensor in one of the compartments when I bought it. There were no bolts in the baggie unfortunately. Not saying all of them don't come with the bolts, it's just that mine did not. Hopefully, like you said, somebody with the part will chime in. Thanks again.

 

[Davin]

A local Merc dealer guy found the bolt somewhere in his book. 5mm x13