Stuck cleanout plugs

[smthng]

First, I've read the other threads... I'll order a rebuild kit soon. But, I need to get the cleanout plugs out first. I've tried the rope/board/4 foot bar lever trick... that left about a 1/2 indentation in my 2 x 6. Plugs didn't budge. Poured ice water in the tubes and levered them again half an hour later... Enough that I can hear the fiberglass "crackling" under my board and left another 1/2 wood dent in my board. What other options do I have? Is there any possibility that I can break the handle of the plugs off? Is there any possibility there's some other "thing" that's been done to the plugs that I might not be aware of?

 

[Bruce]

I parked the boat under my deck and used a 1" ratchet strap with one end secured to the deck and the other to the plugs handle. Then I slowly increased the tension on the strap until the plug pulled. Can you find somewhere to do similar?

Others have removed the screws from the top of the plug and disassembled it while it is installed.

 

[mark_m]

First, I've read the other threads... I'll order a rebuild kit soon. But, I need to get the cleanout plugs out first. I've tried the rope/board/4 foot bar lever trick... that left about a 1/2 indentation in my 2 x 6. Plugs didn't budge. Poured ice water in the tubes and levered them again half an hour later... Enough that I can hear the fiberglass "crackling" under my board and left another 1/2 wood dent in my board. What other options do I have? Is there any possibility that I can break the handle of the plugs off? Is there any possibility there's some other "thing" that's been done to the plugs that I might not be aware of?

I used a 3/8 inch dock line and hooked it around the Plug handle. I then used a floor jack supported by two by fours across the clean out hatch and used the jack to apply upward pressure on the rope which broke them both free.

 

[smthng]

@Bruce Not likely... Can't fit it in my garage or anyone else's that I can think of. I'm probably more interested in taking it apart if I can understand how that would help... wouldn't that just leave me with a giant rubber plug stuck with no handle to pull on? That seems worse, IMO.
@mark_m Guess that's my next attempt... I'm off to go get some lumber. :S

 

[Glassman]

WD-40, let it sit overnight

 

[Bruce]

I have not tried it but my understanding is that after you remove the expensive top portion of the plug you destroy the lower portion to get it out.

 

[Boat Crazy]

Have you verified that the dogs are retracting when pushing on the release button?

 

[mark_m]

@Bruce Not likely... Can't fit it in my garage or anyone else's that I can think of. I'm probably more interested in taking it apart if I can understand how that would help... wouldn't that just leave me with a giant rubber plug stuck with no handle to pull on? That seems worse, IMO.
@mark_m Guess that's my next attempt... I'm off to go get some lumber. :S

Don't forget the ice ... Extra can be used for beers. Seriously, I was freaking cause mine was stuck and tube full of water. One broke free the other wouldn't come out. Take your time and go slow it will break loose.

 

[mark_m]

@smthng after mine was stuck that time, I remove after each outing and lay them across the cleanout tray on their sides. Never had one stuck again, knock wood. My boat is '07 and thing the plugs are still original.

 

[txav8r]

@smthng , oh the saga of the stuck clean out plug. They seem to cling for dear life. But ironically, they are not part of the boat and they will come out. But as @Boat Crazy said, you MUST make sure the dogs have retracted, otherwise your pulling against the aluminum seat, the dogs themselves, and the upper plug. It is not likely that the tapered lower section is stuck that bad. It is probably the seal and the dogs, but may be all of them in unison. Here is the deal however, the dogs are extended and retracted from the upper half of the plug, so removing the 8 screws will open the halves, but if the dogs are still locked in the aluminum seat, the top half isn't coming off. According to @Cobra Jet Steering LLC , the slide tray and the rest of the internal locking mechanism can become corroded with sand and other grit, that will lock it up. So cleaning it occasionally is good. But the main thing you need to do, is rebuild them immediately at the first sign of them sticking. Keeping them clean and dry...and out of the hole when not in use with extend their life. Some say, including Yamaha, to use grease on the seal/gasket. I disagree with this procedure, as it attracts more grit and things to keep them from working easily. If the dogs are unlocking, you can get them out. If the dogs are not unlocked, you may break them. Either way, you have to get them out. So if you are pulling on the T handle, you need to have the button depressed at the same time if your not sure. At least that way, the tugging force may cause them to release too. Good luck!

 

[Cobra Jet Steering LLC]

believe it or not sometime you can first hit the top of the t handle with a rubber mallet give it a couple of good wacke downward then try pushing the button and pulling up the t handle. if it comes up and the plug will not come out use the ice trick or the rope and 2by4 trick to pull it out.

 

[smthng]

Alright, I have some questions about the "dogs" before I go caveman on it tomorrow...
I'm pretty sure the plugs are unlocked. The center post that connects to t-handle lifts up one or two horizontal "bars". Those two bars are hinged on the side of the plug and I'm assuming that those are the dogs that lock into the tunnel ring. I can get my fingers under those two bars in the center, so I'm assuming they're unlocked and up. Is that a safe assumption? Is there any possibility that the dogs are engaged in the lock ring if I know that the bars are up? If someone can assure me of that, or post a picture of my style plug with the handle up so I can see what I'm feeling, that would be awesome... I'll hit it with some PB blaster in the morning, tap the t-handle down to see if it locks and loosens the plug at all, unlock it, ice it and jack it out. Just gotta go get some wood in the afternoon and maybe some better rope.

 

[Cobra Jet Steering LLC]

if the handle is up the dogs are definitely unlocked. so you only need to fill the plug hole with ice let it sit a few hours and then it will probably come out easier. hitting the plug may dislodge it since sand and other stuff can be wedges between the plug and the tube at the gasket. This should show you how the inside of the plug works so you can understand that with the t handle up your dogs are released. http://youtu.be/KhsnPrWt7nU

 

[Bruce]

Can't fit it in my garage or anyone else's that I can think of.

If you can use your garage door header to attach the top of the strap then you only need to get the swim deck into the garage. A large limb would work as well. Or build a frame out of lumber. One member used his tractors front end loader to pull them out.

Do you have the rebuild kits? As hard as yours are to get out you may not be able to put them back in without the kits.

 

[aarons1k]

I hope mine come out !!!! After reading all this!!! First thing I will do tomorrow !!!

 

[rkluck]

Someone above mentioned the floor jack (or a farm jack). Just put the jack on 2x6s or something to protect the floor and spread the pressure out. I have also hit the plug down just to get some movement and that helped a lot. I use a metal rod (about 2 feet) and just tap all around the edges.

 

[Andy S]

I had to use a jack to get mine out the first time, I bought my boat used and it was not taken care of very well. Apply some pressure, let it set for a few moments, apply a little more pressure, let it set for a few moments, and repeat until the plug comes out. As others have said while you are in between applying pressure you can tap on the plug to aid in it loosing up.

 

[buckbuck]

I think that is the key. You have to create vibration or shock to get it to break loose.

 

[Cobra Jet Steering LLC]

The design of the gasket around the plug makes a good trap for sand, salt etc . the gasket expands with water pressure to form a seal when the boat is traveling at planning speeds .
People rinse their plugs but they may not realize washing out under that seal is very important.
When the plug sits the water under the seal evaporates and leaves the sediment to harden, as you try to remove the plug you are wedging it in tight with this debris. Tapping down on the plug can loosen this and allow it room to fall out clearing the way for the plug to be removed. Put the plugs in the dish washer occasionally , REALLY!

 

[smthng]

All good advice, thanks... This is my project today.

After owning an offroad Jeep, I'm well aware of the value of tapping things to get them free and to work in some kind of lube. Now that I have some light and it's dry in the tubes, I can see that the dogs are definitely not engaged, so that's a good thing.

Here's the plan...PB Blaster and tapping to get it creeping in. Go get some lumber and a short chain (less stretch than rope) for the floor jack. When I get back from the hardware store tap some more, lock the plugs, tap the handles down with a 2x4 and mallet, unlock, fill tubes with ice and water and get the jack set up. Small loop of rope around the handle, short chain between rope and bottom of the jack, a couple pumps to tighten it up, more tapping, let it sit a couple minutes, pump some more, tap some more, let it sit, repeat.

Any thoughts on PB Blaster vs WD-40? I know it shouldn't take much of either... just enough to creep in there.

Also, is there only one plug repair kit for all boats? I saw a part number somewhere, but can't find it now and I don't know if they're all the same. Those plugs aren't going back in until I get the rebuild kits. I don't mind waiting, as I'm terrified of going out in our river without a GPS with sounder (the depth finder on this boat is useless). Once I get the plugs out, I'll post up on the condition of the impellers and tunnel.