advise along the way? 1991 90hp reassembly

[a1machinista1]

Im going to start the assembly of the powerhead and lower unit. I am a capable automotive engine machinist but I have never claimed to know much about 2 stroke engines. I am going to start with the L.U. as im still waiting for piston rings. all bushings,bearings,shafts and the like have been cleaned and inspected, I have L.U seal kit so I will be replacing those seals that are in the kit.. My hope is that someone who just went through this or does on a reg basis can maybe give me some heads up on things to look out for? i.e... putting components on in the correct order!!!! or anything else i should watch for?? I will post pics as i go, Im sure I will have a few questions..

 

[a1machinista1]

Re: advise along the way? 1991 90hp reassembly

I do have a force manual and im sure it will be helpful to identify parts and help me explain myself accurately. the manual seems to be close but NOT exact! This is why I may need assistance

 

[a1machinista1]

Re: advise along the way? 1991 90hp reassembly

So I started laying parts out tonight and the first thing I noticed is the fin or Keel??? on the bottom of the lower unit is bent, Is this a major issue??

Next I looked at installing the output shaft and all the components that go with it, It looks like the only issue I may have is keeping the shift yoke on the shift arm

While inserting the output shaft into the housing. any tricks on making sure that the yoke ingauges correctly???

 

[timdan94]

Re: advise along the way? 1991 90hp reassembly

When I had to put the yoke back in I used a good sized dab of grease to hold it in place. then I had my dad help look to make sure it went in properly.

 

[roscoe]

Re: advise along the way? 1991 90hp reassembly

The bent skeg is not a problem.
Its purpose is to protect the prop and gearcase from underwater obstructions and boat ramps .

 

[Frank Acampora]

Re: advise along the way? 1991 90hp reassembly

As said above, a dab of grease on the yoke. Then, as you insert it, push down on the shift rod to move the steel saddle that it sits in (another yoke) forward. Look down from the top of the lower unit while inserting.

When you do the rings, the rods are "cracked cap" technology and are the outer races of the roller bearings. They can only go on one way and must be aligned properly or service life of the assembly will suffer.

After installing the rollers, put the rod caps and bolts on FINGER tight and align the caps. Take your time and do it right. Then torque down. There are two ground flats on each rod and cap. they must be aligned so that a point or awl will pass over the crack smoothly.

If you remove the crankshaft, all center bearings and the bottom bearing are pinned to the block to prevent rotation. They must be aligned to fit over the pins before the crank will drop in fully.

Use nickel anti-seize on ALL bolts. Do not use copper--Galvanic reaction.