Just take the plugs out and rebuild them they said

[Brad_Ct]

I have been fighting with these plugs for months trying to get them out and can see why now that I was finally able to get one of the tops off. The tubes are so corroded it locked them in good.

 

[Beachbummer]

What the heck is that brown stuff! That looks extremely painful. I wonder if a chemical like CLR or Vinegar to "eat" the rust away for a little while before washing it off? perhaps a thin metal blade like from a cake spatula worked around the edge? I can't imagine anything you likely haven't already tried. Best of Luck!

 

[Babin Farms]

At this point if the top is off I would start drilling holes in the bottom portion, get some tension off of it and start hammering away. If you feel that you can run a sawzall without getting into the housing I would also try that.

 

[rrmidden]

Salt water I assume?

 

[Yambers]

Seeing this reminds me that my plugs are currently in. I need to go home and pull those suckers and spray them with silicone spray.. I can imagine fighting a beast like @Brad_Ct is dealing with..

 

[Brad_Ct]

@Beachbummer The brown stuff is PB blaster mixed in with the oxidation residue.

@Babin Farms Exactly what I did, drilled a hole in the center and cut it with a sawzall. Scraped the big pieces and wire wheeled the housing and rebuilt the plug. Seems as though it will be ok.

 

[Beachbummer]

@Babin Farms Exactly what I did, drilled a hole in the center and cut it with a sawzall. Scraped the big pieces and wire wheeled the housing and rebuilt the plug. Seems as though it will be ok.

So you are good now?

 

[Brad_Ct]

So you are good now?

With that one, still need to get the other one out.

 

[2kwik4u]

I'm constantly amazed that Yamaha ever had that "pin-lock" style closure on what is essentially a pressure vessel in a marine environment. I just really don't know how the "new" style twist-lock plugs weren't the ONLY style plugs ever used.

Glad these are out. Next time try a little 50/50 mix of kerosene and diesel fuel as a penetrating agent. Works AMAZINGLY well.

 

[Brad_Ct]

I'm constantly amazed that Yamaha ever had that "pin-lock" style closure on what is essentially a pressure vessel in a marine environment. I just really don't know how the "new" style twist-lock plugs weren't the ONLY style plugs ever used.

Glad these are out. Next time try a little 50/50 mix of kerosene and diesel fuel as a penetrating agent. Works AMAZINGLY well.

I don’t know why they went to this style either. My 96 Exciter had screw in plugs that to me were a much better design.

Good idea using the mix but there will be no next time unless I buy another boat that they are stuck on lol.

 

[Brad_Ct]

I got the other one out, cleaned up the tube and rebuilt the plug. I had the clean out tray and the tubes between the housing and tray removed from when I was doing cables and after examining the first plug I got out I realized I could get a screw driver between the dog and the housing and pry up on the plug cover.