Hey Wayne I would'nt worry about it too much its only surface rust where the paint has lifted. I've got an old Suzuki 1987 vintage and the same thing has happened to it, that part of the motor is cast steel on my motor the whole arm is rusted but only surface,I hose down the motor and flush with fresh water after each use.

Kev

Give everything a spray of Lanotec every now and then. The paint has started lifting from the threaded holes so fill them up with silicone or grease. Lanotec is liquid lanolin spray available from coventrys or supercheap auto.

cheers fellas - the motor is still under warranty, do you think this is something they would replace/sort out under warranty?

theyll say its because you have damaged the paint job so the rust is inneviatable, notice also your steering arm is rusting slightly on the surface, mines a yamaha and is stainless steel (no rust) obviously mercury use a lower grade stainless or mild steel for their steering arms,...little things like that i guess is why yammys etc are more expensive.

penetrol is good drys to a tough film sealing out moisture and air

I doubt warranty will cover that. Hell of a job to change it. powerhead up, mid section off etc, to change it. clean up the flaking paint brush rust converter on it and paint it. then spray with lanox or similar after every use.

Wayene as the rest of the motor looks in good order,I know that Merc have had troubles in the distant past with the mix of metals they used on the motors,the Blue bands around 1978,but I agree with all the above,but I would certainly have a go at Merc as I personally think that any motor now days that is bought for use on the sea,should have (1) A better metal finish,were salt can come into contact.(2)Or a rubberized undercoat,that would protect that area more.but then they would charge a lot more for things to last longer. My boat trailers have all been hot dipped  galvanized but I also spray fish oil,and then rubberised paint then Lanox,over it all,The only thing I find is I get a lot KiwiS follow me jersey 

i've just emailed the photos to the service department at challenge Marine.  I'ver heard that some outboard companies have a "corrision warranty" - hopefully Merc do.  The problem is that if you look at the 4th and 5th photo you'll see that the rust goes down through - eg, not just at the end.  I don't know how I would get to those areas to rust proof and paint it without taking things apart...

 Thanks for the feedback - I'll let ya know what Challenge say on Monday!

- Wayne

Have the same thing happening to my Mariner 120 4 stroke. Again around the 2 years old mark now. I just try and keep it clean after every outing and give it a spray of lanotec when siting in the driveway. Have found that the lanotec has stopped or at leaset slowed the advance of the rust to the point it seems to be not spreading.

a few of you have mentioned using lanotec - is this good for spraying over painted areas - or should this only be used on metal areas - eg, prop, nuts n bolts etc...

just found the lanotec website - which product would you recommend? http://www.lanotec.com.au/?link=3

Do any of you use that "quicksilver lubrication" for inside the engine?  Eg, to spray over all the internals just incase moisture gets inside.  I've heard this helps...?

If anyone has any other outboard maintence tips they want to share would be good to hear them:) cheers

Wayne

That does look excessive, I have a Merc 1995 115 2stroke and it doesn't look half as bad

hi fellas - the engine is getting inspected by challenge Marine on Monday - if no "abuse" is evident LOL, then they are going to replace the rusting part under warranty:)

Wayne,hopfuly a win for the little guy,jersey

i hope you get a win mate, keen to hear how it goes

engine getting fixed free of charge under warranty:)

Good win there Wayne. That's what a warranty is all about IMO.