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outboard: gap between cowl and upper unit casing

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outboard: gap between cowl and upper unit casing

Old 03-03-2020, 02:52 PM
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Default outboard: gap between cowl and upper unit casing

I have a Yamaha outboard where on one side, the cowl doesn't make a complete seal to the casing. There's a half inch gap between the rubber seal and the case.
It looks like the case is deformed or dented which is causing the gap. Can I use a heat gun to reshape the plastic casing and close the gap? What are some good ways to fix it?
Old 03-03-2020, 03:15 PM
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Do you have any pictures?
Old 03-03-2020, 04:36 PM
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I recall this topic being covered on here a couple years ago. You might try doing a search before you do anything drastic.
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Old 03-03-2020, 06:32 PM
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1/2 inch is one HUGE gap...Something is not lining up correctly. That is not normal. Pics would help
Old 03-04-2020, 09:03 PM
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It's not really "lining up", it looks like the lower casing is dented or something. I post a picture later.
Old 03-04-2020, 09:05 PM
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If you look closely you see the casing looks to be deformed
This picture is with me pressing the cowl down. The hook also clicked so this is what the cowl looks like seated!
Old 03-04-2020, 09:08 PM
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Originally Posted by chrineal View Post

If you look closely you see the casing looks to be deformed
I'm not sure the gap is your biggest issue.


Kidding aside, I believe Yamaha had a service bulletin on this problem a few years back. I'm sure someone will chime in with the details...meantime some saltaway and boatsoap with a soft wash rag is recommended!

Old 03-04-2020, 09:22 PM
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Originally Posted by signmansez View Post
I'm not sure the gap is your biggest issue.


Kidding aside, I believe Yamaha had a service bulletin on this problem a few years back. I'm sure someone will chime in with the details...meantime some saltaway and boatsoap with a soft wash rag is recommended!
It's a project boat haven't started working on it yet!
Old 03-04-2020, 10:00 PM
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doesn't look even close to a half inch, but will get a little spray in there, buy a new Yamaha rubber seal/gasket/cowling seal, whatever they call it, if the shape is off on that one you'll never get it right with a heat gun or anything else
Old 03-04-2020, 10:07 PM
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Looked through forum but couldn't find details on this specific issue. It doesn't really look to be a cowling seal misfit problem. The left and right side casing of the motor are not symmetric; plastic casing looks to be dented so would like to fix that somehow.

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