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fastjohn
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    I have removed many of these covers on Mercs. I have never had a problem with threads, and only had one that would not come off without drilling holes and breaking it out. I am sure that a good part of the reason is that I do not have to deal with motors from salt or brackish water. I made my own pin spanners to fit different covers. Coating the threads with anti-seize before reinstalling will assure easier removal next time.