Starter broken off in engine!!

[undecided]

Hi all, I recently removed my starter from my 2002 Sportster LE boat, I read that the removal should just take some wiggling and jiggling to get it out, well, I also used a bit of hammer and tongs!

So the housing bit that goes around the spline(the piece with the two o-rings) has broken away from the starter housing and remains in the engine bit, this is obviously fused in there to have broken off in the first place..

My question is, is there an easy way to remove this bit? Do I have to remove the engine...Can I just weld some steel onto the bit that's still in there, then heat the surrounding bit and pull it out?

Any help much appreciated!

 

[Dr Honda]

The electronics in a seadoo are to fragile to weld in the boat. I wouldn't try that.


I'm not sure how to remove the broken part... but I would start by taking the MAG cover off.

 

[chucked]

couldnt you take the mag cover off and knock it out from the inside?

 

[undecided]

MAG cover? Is that the opposing side where the starter spline connects into? I take it MAG as in magneto right...I'll have a look, it's not something I have done before but I will try and remove it. Have either of you/or anyone for that matter done this before, is it a simple job?

 

[get_real]

Could you drill into the broken piece and insert a screw? That would give you something to pull on after soaking it with some PB blaster. Post a pic if you can.

Sorry, just re-read your post and it sounds more like a sleeve, not something you could probably drill into. Need to see it!

 

[undecided]

Hopefully I've attached the pictures correctly, one showing the broken off starter collar, in the next picture...is this the mag cover? Is the one to remove to get the broken piece off? It seems that cover has an engine mount on it...am I looking at the wrong cover?

Thanks for the help!

 

[Guest_User]

wow! That is really corroded... if it were me, I`d be removing the engine and placing on the bench for further removal and inspection.
You are liable to break a few bolts and the possibility exists for further issues. even if you could hack that starter nose out of there, you would need to clean the inside perfectly...

 

[get_real]

wow! That is really corroded... if it were me, I`d be removing the engine and placing on the bench for further removal and inspection.
You are liable to break a few bolts and the possibility exists for further issues. even if you could hack that starter nose out of there, you would need to clean the inside perfectly...

Agree, need to do it right. Pull the motor, repair the starter and anything else damaged from the corrosion, clean and paint.

 

[undecided]

Thanks, I was hoping that removing the motor would be a last resort! Is there anything I can try before having to remove the motor? Like suggested earlier about the MAG cover, is that the correct one I've shown in the picture? If I do need to take the motor out, are there any gaskets or o-rings that need replacing...I think I read that you need to replcae the exhaust gasket?

 

[howie099]

If you pop off the mag cover you will need to swing a hammer and chisel to try to break that piece out. It don't think you will have enough room to try that. It will be much easier to pull the engine and do it. Either way it is going to take awhile to fix it water had to enter in the mag cover to lock the starter in place.

 

[Coastiejoe]

That does look pretty ruff...

Under the circumstances, I would pull the engine and while it is out, go over the engine pretty well. Clean and paint anything that needs to be. Take the opportunity to loosen any bolts that are normally hard to get to then tighten them to specs.

I know it is a hassle, but in the end, it will be a positive thing...

 

[undecided]

Ok, thanks for the advice guys.