Unseizing stuck bolts when performing a stator oil change procedure. Merc M2 210

[Palm Bay Chuck]

So my local boat shop is doing the CDI Switch Box replacement for me, but they said that doing the stator oil change is going to be difficult and time consuming. They said that the bolts that hold the unit in place are seized up. They suggest that under normal circumstances, the procedure takes little more than an hour, but when these bolts are seized, which is common, then it takes up to a day because they have to drop the whole unit, drill out the effected bolts, tap new bolts holes and then put everything back in place.

So, I'm going to skip the oil change for right now and research ways to unsieze those bolts! Does anyone have any suggestions?

Thanks everyone.

 

[Sportster-2001-951C-Stock]

Sometimes you can take a steel punch/drift with a 2lb hammer to pound on the bolt heads and break the galvanic bond and salt accumulation. If allen bolts, use a hex rod as opposed to a flat drift.

Changing the oil annually, or more often will help avoid stuck bolts from corrosion and salt accumulation, I like to use anti-seize compound on threads I expect might seize and in most any aluminum while others prefer a thread locking compound such as locktite blue.

 

[Dr Honda]

Yep... what he said. Heat, and penetrating oil helps too.

When it goes back together... then make sure everything gets coated in anti-seize.

 

[RiverPro]

So my local boat shop is doing the CDI Switch Box replacement for me, but they said that doing the stator oil change is going to be difficult and time consuming. They said that the bolts that hold the unit in place are seized up. They suggest that under normal circumstances, the procedure takes little more than an hour, but when these bolts are seized, which is common, then it takes up to a day because they have to drop the whole unit, drill out the effected bolts, tap new bolts holes and then put everything back in place.

So, I'm going to skip the oil change for right now and research ways to unsieze those bolts! Does anyone have any suggestions?

Thanks everyone.

Another option would be to skip dis-assembly and simply suction out the stator oil. If you decide to skip the stator oil change, I'd suggest changing the pump housing oil. Seized bolts would have no affect on changing the pump housing oil.

In addition and as stated, there's several ways to free seized bolts. I can't say I've ever broken a pump bolt in a manner that required drill and tap. I have broken bolts b/c they were darn near eaten away, however there was always enough of the bolt left protruding to grip.