I came across this thread while doing some research in order to help me make an educated decision on the course of action on my Yamaha 9.9 that has the same issues as described above.
http://forums.iboats.com/yamaha-suzuki-outboards/9-9-yamaha-case-corrosion-468168.html
I am tiring to decide if I should take it apart weld the upper cowling and clean all the salt out. My brother specializes in all types of welding so there is no cost for the welding. The decision to fix or just to use till it dies will be made based on others experience taking it apart to the stage in the picture above. My manual won't tell me what I can expect to break due to this level of salt corrosion while taking it apart. If the back of the upper cowling is cracked from salt trapped behind it what other parts can I expect to have to replace. What parts should I factor in when estimating the cost of repair. I have experience with various boat motor repairs however I have not dismantled a 9.9 to this stage before. The replacement cost of the motor, based on what is available on the used market is about $1400 for a good runner. I also don't consider any expense for my time as I enjoy these types of projects. Any Input would be appreciated, especially tricks to overcome obstacles that I will run into taking it apart caused by excessive salt corrosion. The motor is a Yamaha FT9.9ELD The compression is good and the lower unit is in good shape.
http://forums.iboats.com/yamaha-suzuki-outboards/9-9-yamaha-case-corrosion-468168.html
I am tiring to decide if I should take it apart weld the upper cowling and clean all the salt out. My brother specializes in all types of welding so there is no cost for the welding. The decision to fix or just to use till it dies will be made based on others experience taking it apart to the stage in the picture above. My manual won't tell me what I can expect to break due to this level of salt corrosion while taking it apart. If the back of the upper cowling is cracked from salt trapped behind it what other parts can I expect to have to replace. What parts should I factor in when estimating the cost of repair. I have experience with various boat motor repairs however I have not dismantled a 9.9 to this stage before. The replacement cost of the motor, based on what is available on the used market is about $1400 for a good runner. I also don't consider any expense for my time as I enjoy these types of projects. Any Input would be appreciated, especially tricks to overcome obstacles that I will run into taking it apart caused by excessive salt corrosion. The motor is a Yamaha FT9.9ELD The compression is good and the lower unit is in good shape.
