Yamaha AR230 assistance please.

[Benno]

Hello. I’ve just purchased my first boat Yamaha AR230. The cover/door to the fuel tank screws are seized up. I’ve tried WD40 but still no movement at all. It looks like this has been an old issue as two of the bolts have snapped due to being unable to remove.
Any ideas please. Thanks in advance.

 

[Scottintexas]

try them all, if they snap you just lift the cover over the snapped portion and get the remainder of the bolt with vice grips,

it's not fun or easy,

your profile says your boat year is 2002, is that correct ??

also, check out the link in my signature below for known issues/fixes (this is one of them) for your boat,



.

 

[FLBulldogger]

Agree with @Scottintexas I would also try and find some PB Blaster works great on seized bolts. Good Luck!

 

[Beachbummer]

So sorry, this job is extremely painful. those bolts are so seized. In addition to very good advice above, try a Heat Gun and an Impact screwdriver or high power impact driver. About half of mine came out, the other half had to be drilled out.

 

[Benno]

Tha

try them all, if they snap you just lift the cover over the snapped portion and get the remainder of the bolt with vice grips,

it's not fun or easy,

your profile says your boat year is 2002, is that correct ??

also, check out the link in my signature below for known issues/fixes (this is one of them) for your boat,



.

Thank You. I’ve been told it’s 2008. Any idea how I can confirm this. I live in Qatar so haven’t got any paperwork from Yamaha other than the manual

 

[Benno]

So sorry, this job is extremely painful. those bolts are so seized. In addition to very good advice above, try a Heat Gun and an Impact screwdriver or high power impact driver. About half of mine came out, the other half had to be drilled out.

Thanks and appreciated

 

[Benno]

Thanks

Agree with @Scottintexas I would also try and find some PB Blaster works great on seized bolts. Good Luck!
View attachment 115976

Thanks and appreciated

 

[Beachbummer]

The serial number (also known as HIN) should be stamped on the rear of the hull. That number will help identify the model year. From the rear area layout in your picture it is 2007 to 2009 for sure, so nothing to contradict the statement that it's a 2008 boat

 

[Benno]

S

try them all, if they snap you just lift the cover over the snapped portion and get the remainder of the bolt with vice grips,

it's not fun or easy,

your profile says your boat year is 2002, is that correct ??

also, check out the link in my signature below for known issues/fixes (this is one of them) for your boat,



.

sorry I can’t find the link you mentioned. Please can you assist.

 

[Beachbummer]

He means this one: https://jetboaters.net/threads/known-issues-for-boat-years-2003-2009-with-mr1-engines.15464/

 

[biglar155]

I'm afraid this is going to be a struggle.

When you put everything back together, be sure to apply anti-seize to the threads so you don't have to do this again.

 

[BlkGS]

I'm afraid this is going to be a struggle.

When you put everything back together, be sure to apply anti-seize to the threads so you don't have to do this again.

I'm like halfway through mine. I bought stainless steel bolts to replace the OEM ones.

 

[Benno]

I'm like halfway through mine. I bought stainless steel bolts to replace the OEM ones.

Thank you. Did you have to re thread for the new bolts.

 

[zipper]

Looks like an 07-09 M/Y Yamaha. The bolts can be tough to get out. They have factory sealant on them. I had success getting them all out in one piece. A #4 robertson square bit. Set the bit in the head of the bolt with a hammer. and back out the bolts with the same motion used as cutting threads with a tap/die.

https://jetboaters.net/threads/fuel-tank-deck-cover.2888/page-2#post-281518

I wonder if using Debond instead of any penetrating oil would release the thread sealant. Fawcett Boat Supplies This stuff worked great on everything else I have sprayed it on. I bet that would be a game changer, as to how this PIA task usually goes.

 

[Chillypilot]

I sprayed with penetrating oil daily for about a week before attempting to take them out. I used a impact driver and the correct bit. They all came out without breaking.

 

[Beachbummer]

My impression is that exposure to Salt Water may have an effect. I had some marinating for several weeks is a variety of lubricants and penetrants, and they still failed to release. I wish everyone better luck than I had.

 

[BlkGS]

Thank you. Did you have to re thread for the new bolts.

Not yet, I got a couple out with screw extractors, but suspect at some point I might have to.

 

[Babin Farms]

If you cant get them out use a 3/8 drill bit to drill the heads off. Drill just enough that the bolt head comes off. Once the heads are off you can remove the floor over the fuel tank & there will be at least 1/2" of shank exposed. Use vise-grips to remove the rest of the bolt. Work them back and forth & spray with penetrating oil as you SLOWLY start to remove them. They will come out, it just takes time and patience. Been there, done it.

 

[zipper]

I am pretty sure that since there is a marine sealant on the threads that spraying this on the bolts would work better than penetrating oil. I already did mine, someone else can be a pioneer here. Just a suggestion. I know how well this stuff works.

 

[Babin Farms]

You've got all of the good stuff @zipper ?