Here is what the shaft looks like:

http://www.monkeybutler.com/help/x1.jpg


It rots mostly at the very bottom which is not visible with the motor together:

http://www.monkeybutler.com/help/x2.jpg

Im not sure but the coupler at the bottom may be SS even on the steel shafts.

I took the LU off today and got a glimpse of the shaft and it was unfortunatly corroded. It feels like it still has some meat on it (at least thats what I'm hoping). I'd say if the shaft is around 7 millimeters diameter, the thin section due to corrosion (that I can see) is maybe 5 mm. So I'm going to pressure test it, re-seal (maybe I get lucky and its simply the crappy looking washers on the vent and drain plugs....make it nice and easy), throw it back together and run it. No funds at the moment to look for a new (used) motor. I'm just hoping it will last one more season and I can swap it out in the fall.

Anything I can do to stretch the life of the corroeded shaft for a couple of months? I guess I could throw some grease to help slow the exisiting corrosion for a while. Take it easy on shifting is another I guess. Anything else? Anybody have any ideas?

Thanks for everyones advice!

Really not much can be done. When mine started to go it was not shifting right, I had to adjust the cable to make up for the twist, after 2 adjustments the shaft broke.

Nope, I don't think that there is anything that you can do to protect the shaft from further corrosion. Too much of it is just too inaccessible to do anthing to it.

I have done a jury rig repair to a broken shaft that is still going strong after two years, but it can only be done after the shaft has broken.

Hey monkey I would love to here about the jury rig repair can you tell more about what you did ....I did some searching and found a few guys that retrofit the shaft with some sort of coupling

I'm just going to throw new washers on the vent screws, do the water pump and leave it at that....if it the shaft or LU goes, it goes and I look for a new used motor somewhere, or a new used boat. My 10 year old wont let me go a season without a boat, plus I'm paid up on my slip for the season. I'll post how things go.

Thanks