I agree that you may need a lever or a piece of wood and a rubber mallet. The assembly you are trying to remove has o-rings sealing it and they can take a little force to break loose. I'm a bit concerned that the bevel gears may be jammed with that assembly being so far out of position. Normally one needs to move the pilot shaft forward to disengage the bevel gears before the upper drive assembly will lift
out. The fact thet it busted through the cover would suggest that something is seriously broken. The only thing that I can imagine that would produce enough vertical force to bust through the housing is the bevel gear on the pilot shaft. All of the other parts
rotate on the horizontal. If you busted that gear you will need to remove the pilot shaft assembly not just slide it forward. This can be done with the boat
in the water
, if neccesary, and if you have enough room to slide the engine forward about 6 inches. I had to have one rebuilt about 2.5 years ago, because it was a 3 month wait to get a new one. It only cost me $500 less than a new unit. You don't say where you are, but apparently Yanmar
doesn't ship saildrives to the US unless they are attached to a new engine. Just a sail drive had to be shipped from Japan
. That may have changed since the SD60 came out. Thinking about what you are facing you might want to haul the boat
anyway. Depending on what's broken there might be a lot of metal debris that got down into the lower unit and may have to be cleaned up.