Notice:
The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.
I had a lower unit water intrusion problem as well (on my Yamaha 9.9 fourstroke). Check the simple stuff first: the little gaskets on the fill and drain plugs can sometimes get brittle and tear. Also, after changing the gear oil try checking it again before putting the engine in the water. You may have enough residual moisture after draining so that it turns the new stuff white without any new water coming in.
If it's not the drain or fill plug gaskets, you may need to reseal the lower unit (which involves the inner seals around prop shaft, drive shaft and shift rod). This turned out to be too hairy a job for me, requiring special tools and a torch to loosen things up, so I farmed the job out to a mechanic. Quoted me between 1 and 2 boat units and get it back in a week- took 3 boat units and 3 weeks to get it done.
Have you checked internet listings for used outboard parts (for the tiller)? I found a great site once for old British Seagulls where you could order all kinds of stuff...
I just put a trottle handle on my '97 Evinrude 9.9. It's a relatively simple job if you go to a dealer to see how the cable snakes through the engine (impossible to figure out without looking at another engine). We got the handle from the engine's previous owner; however, I've seen throttle handles for sale at the local Johnson/Evinrude dealer.
Notice: The advice given on this site is based upon individual or quoted experience, yours may differ. The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.