help on 1995 25hp electic start Johnson

**T.C.** · 06-08-2010, 10:45 AM

ok let me try and explain this, im not sure if im gonna use the correct terminology but im gonna try. The bolt that holds my electirc starter to my motor housing sheared off last week. so now when i press the electric start button, the starter pops up, goes into place with the fly wheel on top of the motor but cant start because now nothing is holding the starter to the housing to keep it from moving, so it just pushes off. i took off the starter and ground the bolt flush to the housing. i then tried to get the bolt out using a easy out, didnt work. so, i decided to try and drill it out, that worked BUT when i did it i didnt drill it straight and now the hole is all mangled up so what i was wandering is if my aluminum housing can be tig welded up so that i could redrill and tap a new hole? i called 3 diff welding shops and they said they wouldnt touch it. its cast aluminum so im not sure either. anyone think they can tell me what to do? oh yeah and i priced switching it over to a pull start motor and i got a $500 dollar quote. i really dont wanna scrap the motor so i need some help

**sparkie51** · 06-08-2010, 03:27 PM

I don't know anything about the welding but have you given the idea of J and B Weld? You could fill the hole and tap it again.

**Barnacle Bill** · 06-08-2010, 03:44 PM

Is there enough room to drill it out a little bigge tap it and then put an oversize bolt in?

**AZfisherdude** · 06-08-2010, 04:48 PM

Originally Posted by IBNFSHN

Is there enough room to drill it out a little bigge tap it and then put an oversize bolt in?

This is what I was thinking. I have done this on my trailer for a bolt that just wouldn't come out for nothin'.

**wannabe fisherman** · 06-08-2010, 06:12 PM

or you could drill it a little bigger and get a,I think they're called, a helicoil and put in the hole then regular size bolt.

**T.C.** · 06-08-2010, 06:50 PM

i cant drill it out any bigger, its already starting to break the edge of the housing. i need it welded up or its a goner i think. can you use j and b weld for something like that? i mean will it hold up? anyway, here are some pics of it so you guys will see what im talkin about.

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**rockmike** · 06-08-2010, 07:01 PM

You might try a helical that is the size if the original bolt on the outside, and use a smaller high grade bolt in the helicoil. Use JB Weld to repair the broken area. You don't appear to have many options.

**crappiemaster4ever** · 06-09-2010, 09:18 AM

The ONLY way to weld that is take it apart. TIG welding aluminum requires it to first be heated, sometime the gun is enough, sometimes you need a torch. But anyway, you will burn/screw up stuff with that much heat if its not apart. Looks bad to me.... Heli-coil would work maybe if you drill it out deeper so you can get more thread in it. Good luck.

**T.C.** · 06-09-2010, 09:29 AM

i think its a goner, too much work for me for a 15 year old motor. im gonna try the simple fixes again, but if i have to get it welded, im not gonna spend the money i think

**fishfinder8** · 06-09-2010, 09:41 AM

Lok tite makes some good epoxy that might work. Check with a bolt company (like fastenal)

I used some years ago that you put some on the bolt and waited maybe 15 minutes then took the bolt back out. It held up really good.

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