starboard side temp sensor broke off in head...

[Andy9236]

Hey guys,

while trying to diagnose my not restarting issue, i figured id check the temp sensors while i was also checking the spark plugs. while taking the starboard side one off, once i touched the sensor with my wrench it immediately began to move. then when i turned it it just broke off and i now have the remainder of the sensor still in the engine head. any ideas how to get it out without getting anything into the engine head? i do believe most of the sensor is still in there, i only have the nut and maybe 1/4 inch of sensor that actually came out.

also side note, could this be the issue that was causing my boat to not restart while hot? it almost looks like this whole thing is rotten...this was also the side i had an overheating problem on a few weeks ago, could it have melted the sensor?

i will be ordering two new sensors and replacing them both once i figure out how to get the broken part out without getting any debris into the head itself.

 

[Tim75]

Can you send a pic?
Most of the head sensors are just pushed into a hole in the head (Does not go into combustion chamber) and retained with a clip and screw. Retaining screw is about 8mm dia. and 12mm long.

Possibly could cause starting issues. The ECU makes fuel adjustments based on all the sensors. Have you checked the TPS?

 

[Andy9236]

Here are the pics

 

[Andy9236]

These pics are out of order, sorry just uploaded from my phone. the second to last one is the port side which is fine. the third to last and the last one are all the other side, and it broke off inside of the head next to where the cooling line goes. i do believe they were threaded though, on the little piece i have that is broken off i can see just where the thread starts .

i have not checked the TPS, where is that located at and what exactly does it look like?

 

[Tim75]

TPS is mounted on on air intake, to end of throttle shaft.

It appears that you have a newer style sensor than mine. Mine mounts in the 2 holes under the upper spark plug.

Very careful drilling is going to be required. Might be easier to remove the heads, but those rubber gasket/o-rings are expensive. The guts of the sensor are probably easier to drill than the head itself, but those heads are VERY soft. I prefer using left hand drill bits. Is there room to make a slot in the top of the sensor and use a screwdriver?

 

[Andy9236]

TPS is mounted on on air intake, to end of throttle shaft.

It appears that you have a newer style sensor than mine. Mine mounts in the 2 holes under the upper spark plug.

Very careful drilling is going to be required. Might be easier to remove the heads, but those rubber gasket/o-rings are expensive. The guts of the sensor are probably easier to drill than the head itself, but those heads are VERY soft. I prefer using left hand drill bits. Is there room to make a slot in the top of the sensor and use a screwdriver?

That was my first thought. Then I thought about tapping it and backing it out. But now that I’m thinking more the sensor is just plastic I’m wondering if I could hold a flat head to a torch for a while then press it in and melt a slot into it and unscrew it with a flat head...

Might try it...but as you said. Is the sensor actually inside of that head? Or is there a wall on the other end of the temp sensor hole?

Yeah people still tell me the engine has no temp sensors because mine are located different

 

[Sportster-2001-951C-Stock]

I think I'd buy a new sensor 1st, so you have a reference to inspect before drilling too much? Just a thought. But yeah, looks like you'll be drilling it out at least enough to get a bite.

Sorta looks like it was broken off already, so probably wasn't working.

 

[Andy9236]

Just got a screw extractor set. After looking at it I do believe the sensor is in the water jacket as I think Tim said..I’m not AS WORRIED about derby faking in anymore, but I still know to avoid it as much as I possibly can. I took the sensor out of the other side and I see how much room I have to drill into. Hopefully this extractor works, if not I plan to use a tiny tiny drill bit to make a slot for a flat head to go into and I’ll back it out that way

 

[Sportster-2001-951C-Stock]

Sounds like a good plan to me.

 

[Tim75]

If you are waiting for parts, take this time to spray your favorite penetrating oil into the hole.
Good point about having the new one in hand for reference. You can see how deep you could drill. Never-sieze on the new one!

 

[noviceskier]

I'd just make a small pinhole and use a pick and pop that sucker'out

 

[Andy9236]

I'd just make a small pinhole and use a pick and pop that sucker'out

Mines threaded in, can’t really pop it out

 

[Andy9236]

Didn’t get time to use the extractor today, but from looking at the other sensor I figure I can drill no more than 1/4 into it. Will work on it tomorrow and update

Thanks guys!

 

[noviceskier]

Mines threaded in, can’t really pop it out

angle the pick, depending how tight it is, you can unscrew it.

 

[Andy9236]

Mercury 889575 - SENSOR ASSY-TEMP | Boats.net

Mercury 885342002 - SENSOR ASSY-TEMP | Boats.net

These are the two different temp sensors...one of plastic one is brass. can they be interchanged? if so id rather go with the brass one to prevent the plastic breaking again...but if not then atleast i know i can get either one right there. once i know which one i can use i will most likely check ebay for a pair.

 

[Tim75]

If you are in salt water, there can be problems with brass in aluminum. No electrolysis with plastic into aluminum......

 

[Andy9236]

i do not plan to take it to salt water, but just to be safe ill go with the plastic again.

 

[Andy9236]

Well I got it all straight. Had to get a tap and correct the threads and the new sensors went in just fine. Putting it all back together tomorrow morning.

Unfortunately this will be the last time I come to this forum for help. I came across an unbeatable deal on a 2005 19ft chaparral runabout with a mercruiser 3.0 with only 200 hours so I’ll be listing the seadoo forsale soon along with my bassboat that I’ve barely even looked at in a year. I’ve only had the seadoo for a short time but I’ll always have a little place for it inside of me. Best way to describe it is FUN. Sad to see it go but need the bigger boat

If you guys know any good chaparral forums I’m going to need to join one soon lol

I do appreciate all of the help especially from you Tim. Anytime I posted you always helped me out.

Thanks for everything guys

 

[Tim75]

Well I got it all straight. Had to get a tap and correct the threads and the new sensors went in just fine. Putting it all back together tomorrow morning.

Unfortunately this will be the last time I come to this forum for help. I came across an unbeatable deal on a 2005 19ft chaparral runabout with a mercruiser 3.0 with only 200 hours so I’ll be listing the seadoo forsale soon along with my bassboat that I’ve barely even looked at in a year. I’ve only had the seadoo for a short time but I’ll always have a little place for it inside of me. Best way to describe it is FUN. Sad to see it go but need the bigger boat

If you guys know any good chaparral forums I’m going to need to join one soon lol

I do appreciate all of the help especially from you Tim. Anytime I posted you always helped me out.

Thanks for everything guys

Don't just leave us hanging-- HOW DOES IT RUN? lol

 

[Andy9236]

Seadoo runs ALOT better than it did before...in the process of selling it now. I’m in Baton Rouge and I get people from mobile to missouri to North Carolina calling and asking about this thing...a lot of them wanting to come pick it up and give me cash without even hearing it run or driving it. And no it’s not those scams where they are all “I’ll be giving you a cashiers check and have my mover come to get it” I’ve spoken to real people.