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Old 18-12-2015, 14:35   #1
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Yamaha 9.9 lower drive oil plug can not be opened.

Hey mechanics 😀

Today I wanted to change the lower leg oil of my one year old Yamaha 9.9 outboard.
I am having a really hard time getting the slotted screws out.

Is there a trick to it? Special tools maybe?I've got a fitting large screwdriver already.
The screws have a strange mark in the center.
No corrosion visible.

I'm afraid to damage the screws.

Thanks Franziska

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Old 18-12-2015, 14:37   #2
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Put the screwdriver in it then tap with a hammer...not too hard..should come out.

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Old 18-12-2015, 16:45   #3
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Yes there is a special tool. Called an impact screwdriver, you hit it with a hammer and it seats the tool and turns it slightly too.
Cheap and available most places that have tools


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Old 18-12-2015, 22:41   #4
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Great I'm sure this will help.

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Old 19-12-2015, 00:04   #5
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

I use a spanner to turn the screwdriver.
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Old 19-12-2015, 00:44   #6
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Hi Ian tried that already.Did not work this time.Thanks.

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Old 19-12-2015, 02:10   #7
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Hi Franziska,

I have a Yamaha 6 and had the same problem. For me the solution was the use of an old-fashioned brace drill (and, of course, a really good fitting screwdriver-bit).
I see you're in Harlingen but in case your not Dutch: overhere these brace drills are called "booromslag" and you might pick one up for just a couple of Euro's in a so-called "Kringloopwinkel" (second -or more-hand shop).

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Old 19-12-2015, 11:55   #8
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

I use a Snap-On impact driver set to get out things like this. But if it is not handy I have had good luck approximating one but it takes two people. Get a large slotted screwdriver that fits the screw slot as full as possible. You definitely do not want one that is too thin in the blade. Use one that has a square profile in the shank and put an adjustable wrench on it down close to the screw. Put opening pressure on the screw taking great care to keep the blade centered in the slot so it does not "pop out" and damage the screw head. While you are doing this, have your friend gently tap the top of the screw driver straight down on to the screw head, i.e. not a glancing blow. A dead blow hammer works best but any medium size will work.

Tap, tap, tap while you try to turn the screw with the wrench on the screwdriver. You need two hands on the screwdriver and the wrench to keep it steady and not strip the slot head. Alternatively, without a helper, try using that same large headed screw driver and tap on it yourself while hand turning with the hand on the screwdriver handle. Or just tap with no turning. This will sometimes work.

I have also had some luck by gently heating up (with a heat gun) and cooling down the area around the screw as that can help break the "seal" of the threads. But gently. Good luck.
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Old 19-12-2015, 12:05   #9
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

I've had excellent results with a Ryobi impact driver. The reason it's so good, I think, is because it "buzzes" the bolt- doesn't hit very hard. Also be sure to soak it in either transmission fluid mixed 50/50 with acetone or PB Blaster.
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Old 19-12-2015, 12:09   #10
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Hand impact. It is an essential boat tool. Sears has em.
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Old 19-12-2015, 14:15   #11
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Quote:
Originally Posted by sparrowhawk1 View Post
I've had excellent results with a Ryobi impact driver. The reason it's so good, I think, is because it "buzzes" the bolt- doesn't hit very hard. Also be sure to soak it in either transmission fluid mixed 50/50 with acetone or PB Blaster.

Electric impact drivers are good, but I haven't seen any large bits that would fit these plugs.
The largest hand screwdriver I could find was still a little small, an allen key plug would be better.
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Old 19-12-2015, 17:01   #12
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

I've always had success using a pointed metal punch. If the slot is considered a clock face, place the punch on the 11 side of the slot at the top and tap with a hammer. The screw should start to move and finish the job with a good screw driver. I always use the reverse procedure after installing the the plug to ensure it is tight.
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Old 19-12-2015, 17:18   #13
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Quote:
Originally Posted by Ian R View Post
Electric impact drivers are good, but I haven't seen any large bits that would fit these plugs.
The largest hand screwdriver I could find was still a little small, an allen key plug would be better.
I agree that it would be hard to find one the same width of the slot but if you find the largest width that's just as thick ( fits tightly in the slot) it should work.
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Old 20-12-2015, 06:03   #14
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Re: Yamaha 9.9 lower drive oil plug can not be opened.

Impact screw driver, only way to work aluminum. Still have mine from my motorcycle days.
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