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Honda bf 90 lower gearcase stuck!!! Help please

L

lifetimer

New member
Hi, I have been getting some great info from this forum and it was past time for me to join. I am having a really hard time dropping the bottom unit on my 2002 honda 90 and would really appreciate some help. I have the seloc manual, which provides a bit of info but not everything. I have loosened the 4 bolts from both sides of the lower unit, and removed one bolt from just forward of the skag. I allso removed the skag/trim tab and found nothing under it. The manual suggests that there could be a bolt hidden under a iregualar cover, nothing like that on my motor unless there was a cover for the bolt forward of the skag. It says the shif linkage is splined, and when i try to remove the lower unit it still shifts freely with force applied.

So, the after end will seperate easily enough to about 1/8-1/4", and i have used a mallet and a block of wood to tap around the forward (gear shift end) with no luck.

I sprayed it penetrating oil and left it overnight, still no luck. I put a small wedge in the afterend and spread it to about 1/4", and then used screwdrivers on the sides to apply more pressure.. then tapped again.

No luck, and so far no real damage to faces on the upper housing and bottom unit.

Anyone have any ideas?
 
it just seems like to much to be a dowel.. anything else that could be hanging up? 5 cap screws out.. shift rod is supposed to be splined..
 
If it is a long shaft, you will have 5 bolts. Two on each side and one just above the prop. If it is an extra long shaft, you will have 5 nuts and washers.

The shift shaft could be stuck or possibly the vertical shaft is rusted into the flywheel of the engine.

Mike
 
hondadude said:
Can you take a picture to show how far it will come apart?

Mike
Click to expand...

ill work on the pic, but it will open up about 1/8" at the back end with a bit of weight, and then open to about 1/4 inch with wood wedges. Then i very carefully tried prying a bit more on the sides and it would not seperate at all where the front dowel should be.
 
Generally a lot of wiggling and prying get them off. I am hestatant to suggest a lot more pressure. If your shift shaft was the only thing stuck, there would be more flex in the front.

How much corrosion is on the drive? Is this used in salt water?

I do not run into these that often. Normally work on fresh water engines.

Mike
 
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