Johnson (Suzuki) 90: Another midsection corrosion failure

timflan · Posted: Thu Aug 14, 2014 3:53 pm Post subject:

Hoo-boy. Got a call from Jacobsen's today. They wanted me to look at the Engine Holder casting. The one we replaced in 2008 because of corrosion around that inspection port? The one I talked about in the other thread back in 2008? THAT one!

So I stopped by to look. It has corrosion...not enough to break through, not yet. But when it does, it will be on the INSIDE, not the outside. So when it fails, it will not produce the "engine running rough because it's starved for oxygen because the engine compartment is filled with exhaust" problem. No, if it fails where it seems likely to, it will produce a DIFFERENT problem. Let's call it the "exhaust and seawater mixing with the engine oil and completely destroying the engine" problem.

So, yeah, as long as I'm already spending $1000 in labor to replace one midsection casting (Oil Pan), I've decided we should spend another $1000 to buy an additional midsection casting (Engine Holder) to ensure we don't accidentally destroy the engine in a year or two or three.

Not happy about it, but reasonably happy that Jack at Jacobsen's took the time to inspect it carefully and call me when he spotted the thin wall.

Once I get the part home I intend to put a caliper on it and measure the wall thickness there. My guess is that it's 1/8" or less, as opposed to the 3/8" or so elsewhere.

Heck, it might last three or four years without breaking through, but my fear is that I won't have any idea that it's failed if it breaks through at the beginning of a long run. I'll be leaving an oil slick behind, and the next time I check engine oil (which is every day when I'm running the boat), the oil won't be pure oil, I'll know what it is, and my trip will be over, wherever I happen to be.

But what if I've run the boat for 3 or 4 or 5 hours before I discover it? How much damage will I have done? That makes me nervous. So $1000 now for a fix I know I'll have to do within the next couple-few years anyway, saving the $1000 labor cost because I'm already incurring it for the CURRENT repair? I think it all pencils out. Do it now.

Feedback? Could I reasonably have waited? Am I overestimating the risk of waiting? Thanks, as usual!

SeaSpray · Posted: Thu Aug 14, 2014 5:17 pm Post subject:

Hi Tim,

Sorry to hear that - especially since I have the same motor including year.
How many hours on yours? I do believe your motor has seen more saltwater than mine but not sure if that makes much difference.

I have not seen a problem yet but I cannot remove the steel plug to replace it with the aluminium one.

I hope this is the end of these problems for you after the repair is done.

Steve

BrentB · Posted: Thu Aug 14, 2014 6:13 pm Post subject:

I hope the new parts are better than old

We had similar problem with Yamaha OB and the new parts looked like a coating or glaze was applied

best

Jazzmanic · Posted: Thu Aug 14, 2014 6:56 pm Post subject:

localboy · Posted: Fri Aug 15, 2014 10:34 am Post subject:

From reading thru this entire thread again, it amazes me that there is no recourse to owners. I mean a design defect/mistake/F-up (call it what you want) is just that and the manufacturer should make good to their customers IMHO.

Sorry to hear the expense, Tim. Unfortunately, I know how you feel....

BrentB · Posted: Fri Aug 15, 2014 11:20 am Post subject:

Yamaha called me about the corrosion issue for my OB.
It was out of warranty. sorry we cant help

Story was published in BoatUS by Charles Fort

SOme attorneys got involved with a class actiion suit. I didnt join bc no one locate the smoking gun that Yamaha knew about the issue early one but mechanics going to training got a different story and training on how to fully repair mid section corroisin issue. It costed me $3K to repair compared to repower with Suzuki 250 or 300 with fly by wire controls and otehr gizmos. I had it repaired

Oh well, life is full of ups and downs, and I did not let this rain on my parade. It is doubtful I will re power with Yamaha if that days comes. It runs like new now. Very quiet, very reponsive and WOT is 5800 rpm (6K limit)
Best

timflan · Posted: Fri Aug 15, 2014 1:17 pm Post subject:

I should point out that the NEW corrosion on the NEW (2008) Engine Holder casting (the one WITHOUT the troublesome inspection port/plug...the port cast shut as monolithic aluminum) does NOT have corrosion at that site. I'm seeing corrosion elsewhere in the casting. I'll post pictures when I get a chance.