1984 mercury 9.8 hp rebuild

[Asmusben]

While separating the powerhead I broke off one of the six bolts that make the seal joining the spark plug section to the piston section. I tried to ez out the bolt, but ended up snapping the ez out off in what was left of the bolt. It’s deep inside the bolt housing so that my only option is to grind it out ruining the threads. Can I cut new threads and use a larger bolt, or am I wasting my time on this? All 5 of the other bolts came out clean.

 

[Asmusben]

I guess what I’m asking is will I be able to get a good seal when I reassemble the power head.

 

[racerone]

That is just a cover for the water jacket.------Install a heli-coil.----A simple thread repair.

 

[Asmusben]

That is just a cover for the water jacket.------Install a heli-coil.----A simple thread repair.

Thank you very much.

 

[fitz73222]

I thought the cylinder (water) cover was held with nuts and bolts on that model?

 

[racerone]

On the newer models they were just screws.