I was wondering if anyone here was familiar with Yamaha outboard motors,
specifically from the 90's, and of the 9.9 HP (although most I think are
similar)...

Here's my story, I've had my motor just over a year now (used motor), and
the previous owner who had it had a bottom end problem where he hit
something and had to replace the gearcase... so it has a new lower unit on
it. Last winter due to various circumstances I didn't check the bottom end
for water, and it ended up freezing, thus pushing out the lower case cap
(behind the prop) and breaking it where the bolts go... after getting the
new cap with various seals, etc, I've put it all back together, and tested
it in a controlled environment. During the first test after some running I
noticed the white oily sludge all over the bottom end, so I checked and sure
enough water in the oil already. So I took the gearcase off, cleaned
everything up, and then noticed that things seemed loose in the area
surrounding the shift rod that goes down right into the gear box... Loose
was a rubber boot, and this weird plastic bracket that is suppose to hold
this boot down and keep a seal to the gearcase. The bracket was just
sitting there so I assume that was the cause. I refitted the boot into the
hole (just pushes in but not very tight) and then put the bracket back in
and the screw with expands the bracket to keep it put). My next test
included leaning the motor over as I had done before where I knew oil would
leak out of those tiny holes on the case surrounding the chamber where this
boot and bracket are (above the gearcase)... This time, no oil leaked out at
all. So I started it, and ran it at idle in both forward and reverse for a
bit. With a bit more throttle I then turned it off as I noticed a bit of
white in the water. As I tilted the motor up I noticed the tiny holes from
the chamber which houses the boot, bracket, and shift rod was leaking out
white stuff...

So, I'm suspecting now without taking off the gearcase again, that this
boot, and bracket area is where the leak is coming from. At this point
except for ordering a new boot and bracket I was wondering if there were
other options to try?

One thing I considered is some silicone around this boot as it slides into
place. Surely that would hold it in, and seal it as well right?

Else I can order the new parts and put them in. But, is there anything else
that could cause this problem? Note the lower cap has all new seals and
bearing in it, so it should be fine.

Cheers
Chris

You have prop shaft, drive shaft, shift rod and possibly water pump
seals/gaskets. You may have a seal on top of the water pump but you
definitely have one or more at the bottom (where the drive shaft goes into
the gearcase). Leaks could be coming from any of these areas and should be
repaired although silicone or 3M 5200 might work, if you have the time to
try.
LD

"Chris" wrote in message
.. .
I was wondering if anyone here was familiar with Yamaha outboard motors,
specifically from the 90's, and of the 9.9 HP (although most I think are
similar)...

Here's my story, I've had my motor just over a year now (used motor), and
the previous owner who had it had a bottom end problem where he hit
something and had to replace the gearcase... so it has a new lower unit on
it. Last winter due to various circumstances I didn't check the bottom
end
for water, and it ended up freezing, thus pushing out the lower case cap
(behind the prop) and breaking it where the bolts go... after getting the
new cap with various seals, etc, I've put it all back together, and tested
it in a controlled environment. During the first test after some running
I
noticed the white oily sludge all over the bottom end, so I checked and
sure
enough water in the oil already. So I took the gearcase off, cleaned
everything up, and then noticed that things seemed loose in the area
surrounding the shift rod that goes down right into the gear box... Loose
was a rubber boot, and this weird plastic bracket that is suppose to hold
this boot down and keep a seal to the gearcase. The bracket was just
sitting there so I assume that was the cause. I refitted the boot into
the
hole (just pushes in but not very tight) and then put the bracket back in
and the screw with expands the bracket to keep it put). My next test
included leaning the motor over as I had done before where I knew oil
would
leak out of those tiny holes on the case surrounding the chamber where
this
boot and bracket are (above the gearcase)... This time, no oil leaked out
at
all. So I started it, and ran it at idle in both forward and reverse for
a
bit. With a bit more throttle I then turned it off as I noticed a bit of
white in the water. As I tilted the motor up I noticed the tiny holes
from
the chamber which houses the boot, bracket, and shift rod was leaking out
white stuff...

So, I'm suspecting now without taking off the gearcase again, that this
boot, and bracket area is where the leak is coming from. At this point
except for ordering a new boot and bracket I was wondering if there were
other options to try?

One thing I considered is some silicone around this boot as it slides into
place. Surely that would hold it in, and seal it as well right?

Else I can order the new parts and put them in. But, is there anything
else
that could cause this problem? Note the lower cap has all new seals and
bearing in it, so it should be fine.

Cheers
Chris

amazing enough I just checked under the waterpump where I notice the
previous owner had broken something (lip from bottom part of pump housing),
and it appears that water has been leaking down through that as soon as
there's water in the water pump (lip surrounding drive shaft). I've put on
a flexible sealant and bolted her back together. Going to let it cure and
then test it out in 24 hrs... Seems the other part around the shiftter
(boot and bracket) are working good now that I've installed them
properly....


"LD" wrote in message
hlink.net...
You have prop shaft, drive shaft, shift rod and possibly water pump
seals/gaskets. You may have a seal on top of the water pump but you
definitely have one or more at the bottom (where the drive shaft goes into
the gearcase). Leaks could be coming from any of these areas and should
be
repaired although silicone or 3M 5200 might work, if you have the time to
try.
LD

"Chris" wrote in message
.. .
I was wondering if anyone here was familiar with Yamaha outboard motors,
specifically from the 90's, and of the 9.9 HP (although most I think are
similar)...

Here's my story, I've had my motor just over a year now (used motor),
and
the previous owner who had it had a bottom end problem where he hit
something and had to replace the gearcase... so it has a new lower unit
on
it. Last winter due to various circumstances I didn't check the bottom
end
for water, and it ended up freezing, thus pushing out the lower case cap
(behind the prop) and breaking it where the bolts go... after getting
the
new cap with various seals, etc, I've put it all back together, and
tested
it in a controlled environment. During the first test after some
running
I
noticed the white oily sludge all over the bottom end, so I checked and
sure
enough water in the oil already. So I took the gearcase off, cleaned
everything up, and then noticed that things seemed loose in the area
surrounding the shift rod that goes down right into the gear box...
Loose
was a rubber boot, and this weird plastic bracket that is suppose to
hold
this boot down and keep a seal to the gearcase. The bracket was just
sitting there so I assume that was the cause. I refitted the boot into
the
hole (just pushes in but not very tight) and then put the bracket back
in
and the screw with expands the bracket to keep it put). My next test
included leaning the motor over as I had done before where I knew oil
would
leak out of those tiny holes on the case surrounding the chamber where
this
boot and bracket are (above the gearcase)... This time, no oil leaked
out
at
all. So I started it, and ran it at idle in both forward and reverse
for
a
bit. With a bit more throttle I then turned it off as I noticed a bit
of
white in the water. As I tilted the motor up I noticed the tiny holes
from
the chamber which houses the boot, bracket, and shift rod was leaking
out
white stuff...

So, I'm suspecting now without taking off the gearcase again, that this
boot, and bracket area is where the leak is coming from. At this point
except for ordering a new boot and bracket I was wondering if there were
other options to try?

One thing I considered is some silicone around this boot as it slides
into
place. Surely that would hold it in, and seal it as well right?

Else I can order the new parts and put them in. But, is there anything
else
that could cause this problem? Note the lower cap has all new seals and
bearing in it, so it should be fine.

Cheers
Chris

I now have new seals on the prop shaft, new seals on the drive shaft which
relate to the water pump too, and all new seals on the water pump. The
shift rod has a stupid boot insert which I believed to be fine, but may have
to try silicone that area...$#*$( motor


"LD" wrote in message
hlink.net...
You have prop shaft, drive shaft, shift rod and possibly water pump
seals/gaskets. You may have a seal on top of the water pump but you
definitely have one or more at the bottom (where the drive shaft goes into
the gearcase). Leaks could be coming from any of these areas and should
be
repaired although silicone or 3M 5200 might work, if you have the time to
try.
LD

"Chris" wrote in message
.. .
I was wondering if anyone here was familiar with Yamaha outboard motors,
specifically from the 90's, and of the 9.9 HP (although most I think are
similar)...

Here's my story, I've had my motor just over a year now (used motor),
and
the previous owner who had it had a bottom end problem where he hit
something and had to replace the gearcase... so it has a new lower unit
on
it. Last winter due to various circumstances I didn't check the bottom
end
for water, and it ended up freezing, thus pushing out the lower case cap
(behind the prop) and breaking it where the bolts go... after getting
the
new cap with various seals, etc, I've put it all back together, and
tested
it in a controlled environment. During the first test after some
running
I
noticed the white oily sludge all over the bottom end, so I checked and
sure
enough water in the oil already. So I took the gearcase off, cleaned
everything up, and then noticed that things seemed loose in the area
surrounding the shift rod that goes down right into the gear box...
Loose
was a rubber boot, and this weird plastic bracket that is suppose to
hold
this boot down and keep a seal to the gearcase. The bracket was just
sitting there so I assume that was the cause. I refitted the boot into
the
hole (just pushes in but not very tight) and then put the bracket back
in
and the screw with expands the bracket to keep it put). My next test
included leaning the motor over as I had done before where I knew oil
would
leak out of those tiny holes on the case surrounding the chamber where
this
boot and bracket are (above the gearcase)... This time, no oil leaked
out
at
all. So I started it, and ran it at idle in both forward and reverse
for
a
bit. With a bit more throttle I then turned it off as I noticed a bit
of
white in the water. As I tilted the motor up I noticed the tiny holes
from
the chamber which houses the boot, bracket, and shift rod was leaking
out
white stuff...

So, I'm suspecting now without taking off the gearcase again, that this
boot, and bracket area is where the leak is coming from. At this point
except for ordering a new boot and bracket I was wondering if there were
other options to try?

One thing I considered is some silicone around this boot as it slides
into
place. Surely that would hold it in, and seal it as well right?

Else I can order the new parts and put them in. But, is there anything
else
that could cause this problem? Note the lower cap has all new seals and
bearing in it, so it should be fine.

Cheers
Chris

On Mon, 21 Jun 2004 17:57:37 -0400, "Chris"
wrote:

I now have new seals on the prop shaft, new seals on the drive shaft which
relate to the water pump too, and all new seals on the water pump. The
shift rod has a stupid boot insert which I believed to be fine, but may have
to try silicone that area...$#*$( motor


I have a similar problem haunting me. Here's what I will try when time
permits. Replace the oil fill plug with an adaptor so that I can pump
about 5 p.s.i. of air into the lower unit while the whole thing sits
in a pail of water. The air bubbles should indicate the weak seal.

Good Luck.

That's an excellent idea. I've just took it apart again, put gasket glue
all over and around the water pump, as well around the shifter boot (GOOP
stuff)... I'll test it out fishing next week. Then I'll try the pump.


"Derek" wrote in message
...
On Mon, 21 Jun 2004 17:57:37 -0400, "Chris"
wrote:

I now have new seals on the prop shaft, new seals on the drive shaft
which
relate to the water pump too, and all new seals on the water pump. The
shift rod has a stupid boot insert which I believed to be fine, but may
have
to try silicone that area...$#*$( motor


I have a similar problem haunting me. Here's what I will try when time
permits. Replace the oil fill plug with an adaptor so that I can pump
about 5 p.s.i. of air into the lower unit while the whole thing sits
in a pail of water. The air bubbles should indicate the weak seal.

Good Luck.

the store didn't seem to have this pressure tester I was looking for... so
with new screw seals, and all the other goop & gasket glue, I've run the
yammy in the water, and initially didn't see the white crap leaking from the
top end... perhaps she shifter boot was leaking? who knows, but I know this
for sure, I'm fishing for now, and will re-check the oil at a later date....


"Chris" wrote in message
. ..
That's an excellent idea. I've just took it apart again, put gasket glue
all over and around the water pump, as well around the shifter boot (GOOP
stuff)... I'll test it out fishing next week. Then I'll try the pump.


"Derek" wrote in message
...
On Mon, 21 Jun 2004 17:57:37 -0400, "Chris"
wrote:

I now have new seals on the prop shaft, new seals on the drive shaft
which
relate to the water pump too, and all new seals on the water pump. The
shift rod has a stupid boot insert which I believed to be fine, but may
have
to try silicone that area...$#*$( motor


I have a similar problem haunting me. Here's what I will try when time
permits. Replace the oil fill plug with an adaptor so that I can pump
about 5 p.s.i. of air into the lower unit while the whole thing sits
in a pail of water. The air bubbles should indicate the weak seal.

Good Luck.