Well, swung by the marina this morning with boat in tow. Donnie looked at the motor & said he could fix it. He sounded confident so I dropped it off at his personal shop. According to him the method recommended by both Yamaha and Honda is to pack the affected area of the water jacket with Marine Tex. Then grind out the passage & block sand the face. Swears he's done several that way that are still running. Being kinda a dinosaur I have my doubts but we'll see.
re the 130 loopner. Motor is indeed a runner & could probly be had dirt cheap. BUT. Steering arm/bracket rotten & busted off. $700 part from BRP, plus ya gotta pull the powerhead to install it. Part's been upgraded to stainless steel btw. Gee, wonder why they did that ...?
Motor is an Ocean Pro series which means, theoretically, it's supposed to have all kinds of 'extra' corrosion resistance built in. Hmm. (See above.) However it's really very clean otherwise, but boy is that thing big. Dwarfs the crossflow. Guess it could be my imagination but it looks a heckuva lot bigger & heavier?