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→ Repairs to 1993 Yamaha T9.9 <top of page>

07/13/2009

Found a nearly new Yamaha T9.9 Lower Unit from a (1995) T9.9 EXHT on eBay.  May switch with original LU as a more permanent repair for the JB Weld repaired lower water pump section ("temporary" repair from August 2008).

10/18-24 /2009

Ran the outboard at idle speed for 20 minutes while flushing with fresh water.  Removed the thermostat and flushed for another 20 minutes.  Fogged motor in preparation for Winter storage.  Drained gas from carburetor.  Thermostat tested OK in boiling water. 

Moved outboard to basement on stand.  Drained hypoid oil from lower unit.  Looked OK.  Began disassembly of engine/lower cowling components in preparation of replacement of the bracket which holds flywheel cover and control panel.  To avoid a complete teardown to access one bolt, drilled an access path in the transom mounting bracket by enlarging an existing gap.  Had to removed the starter motor and solenoid to remove the bracket. 

Installed new panel bracket, changed motor oil, verified valves being within spec (in, 0.006; ex; 0.009), replaced starter solenoid bracket bolt, checked cooling water path on upper exhaust manifold (clear), sprayed fogging oil in cylinders through spark plug ports.

Upon inspection, found much evidence of leaks in "temporary" repair to water pump assembly in lower unit; e.g., salt built up around the repair.  The JB Weld epoxy was very friable and completely disintegrated when the housing was disassembled!  More salt built up inside water pump housing.  Hey, it did last the season.  Instead of more epoxy repairs, switched to a "almost new" lower unit from a (1995) T9.9 EXHT.  Rebuilt that water pump using new gaskets, seal, impeller, woodruff key, and wear plate.  After installing the "new" lower unit, did a LU oil change using West Marine 90W hypoid gear oil; replaced gaskets.

→ Used Nissan 3.5HP 2-stroke<top of page>

11/22/2009

Cathy gave me a lightly used Nissan NS3.5A (3.5HP) 2-stroke outboard.  It came with Water Music, and has been stored in her garage for a few years.  Took the covers off; the motor itself looked nearly new, except for some light corrosion around the head gasket.  It had spark, so I checked the plug gap (1.0 mm), and filled the tank with 50:1 gas/2-stroke oil.  Placed the prop in a tank of water.  It started after a few pulls although the water stream did not seem very strong.  Adjusted the idle speed, and ran it for about 30 minutes in then tank.  Fogged the motor and drained the fuel from the tank and carburetor.  Sprayed fogging oil into the cylinder.  Removed the impeller (which is located behind the propeller).  It had several cracked vanes.  Will order a new one.  Changed the oil in the lower unit using West Marine 90W hypoid gear oil; replaced gaskets.  Those for the T9.9 fit perfectly. The oil which drained out looked new!

12/06-09/2009

Spot cleaned the 120 with Soft Scrub and Fantastic cleaners; rinsed cleaned sections with water; allowed to dry, folded and stored.  Touched up tiller and Summer hatch boards with Sikkens Cetol Marine.

12/26/2009

Mounted a second Schaefer 90-28 2 3/4 x 3 1/2" stainless forged bail on the boom 39" from the mast as described before.  The estimated vang angle will be ~ 30° when using this attachment point.

2/27/2010

Crab Louie goes digital!  Cheryl gave me one of Jimmy's small AC/DC powered digital ATSC/NTSC TV's; a 7" Haier.  Finished construction today of a folded dipole based upon a design described here.  The ends are not electrically connected.  Cut the antenna for 190 MHz (VHF), the third harmonic falls at 570 MHz which is in the middle of the UHF TV band here in the Boston market.  The antenna consists of two 33" aluminum strips formed into a circle, and attached to two 4" lengths of fiberglass sail batten using stainless 6-40 hardware. A Z-shaped aluminum cross piece connects the battens.  The antenna is fed with 25 feet of 300 ohm ladder line.  A 4:1 balun is used at TV to match the 75 ohm TV input.  A short length of aluminum stock mounts vertically to the cross member to allow raising on a halyard while tethered to a downhaul.  Picture here.

2/28/2010

Installed new impeller on Nissan NS3.5A outboard.

Yamaha T9.9 repair parts inventory / installation history

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