2002 90TLRA Yamaha Tilt leak repair

[panasonic]

I am assuming that is the cylinder cap at the bottom of the picture? It looks pretty corroded where the seals will sit. Are you going to replace the cap?

[pstephens46]

I am assuming that is the cylinder cap at the bottom of the picture? It looks pretty corroded where the seals will sit. Are you going to replace the cap?

That Holmen guy is not the OP. He was using the pic as an example.

[panasonic]

That Holmen guy is not the OP. He was using the pic as an example.

Paying to much attention to the pictures not the poster...lol

[nowakezone]

this is op, I was hoping that the small leak around the end cab center was going to be just a couple of o-rings and a dust seal, looks much more complicated!

[holmen78]

The seals are just 2 o-rings and a dust seal, but u have to disassemble the piston to be able to replace the dust seal and one o-ring inside the end cap. It’s not complicated just a lot of small parts inside the piston to keep track on.

[nowakezone]

I have been so frustrated trying to get a tool to open this cylinder head. The repair manual says to use YB-6175-2B - Marine Tech tools make a knock-off version part ATM0009 which came with 6mm pins. Clearly, these were too large for the holes in the cylinder head. I called them and they sent me for free replacement pins that were 5mm. These too are too big for the holes. I checked two other Yamaha motors in the boatyard and they have the same size holes as me. those motor ids are in the photos. Anyone ever use the Marine Tech tools successfully?
IMG_20180221_150239400.jpgIMG_20180221_150233099.jpgIMG_20180221_150351476.jpgIMG_20180221_150407390.jpg

[walleye1]

You may have problems getting them caps out, I would order the caps, seal wipers and orings. Use a punch and a hammer to get the caps off.

[pstephens46]

Call them back. Did you give them your model number? They seem pretty familiar with Yamaha motors. They should have a size smaller.

just had an amazing idea. Rare. Let's go with it though. You could ream those holes slightly with a drill. Please refrain from bad jokes guys. Just enough to use those last 5mm pins. Hack method for sure but beats buying new caps if it works.

[nowakezone]

Call them back. Did you give them your model number? They seem pretty familiar with Yamaha motors. They should have a size smaller.

just had an amazing idea. Rare. Let's go with it though. You could ream those holes slightly with a drill. Please refrain from bad jokes guys. Just enough to use those last 5mm pins. Hack method for sure but beats buying new caps if it works.

I thought about doing just that. If I had to replace the end cap I will be in trouble, I would have to drill out a brand new cap just to use the tool.

[rodbolt17]

punch and hammer????
OMG.
I will laugh the rest of the day.
punch an hammar.
\

[walleye1]

I've had to do that a few times after customer f.....ed the cap up. Rod do u hate your self?
Itleast you are laughing!

[pstephens46]

Call them back. Did you give them your model number? They seem pretty familiar with Yamaha motors. They should have a size smaller.

just had an amazing idea. Rare. Let's go with it though. You could ream those holes slightly with a drill. Please refrain from bad jokes guys. Just enough to use those last 5mm pins. Hack method for sure but beats buying new caps if it works.

Well it might be hard to drill straight down being so close to the tilt ram.

OP - Marinetechtools has 4 mm pins. I just looked at the website.

I would suggest calling them back before you start pounding on it. More than likely you can reuse the caps.

[panasonic]

Yes get the correct pins if possible. And would strongly recommend you follow Rodnut instructions to keep the spanner wrench down hard in the holes.See post #6.

[nowakezone]

They have 4mm pins but not for the tool that supposedly fits my end cap tool I ordered (ATM0009). I wonder now if I have the correct year of the manual that shows the tool listed for the tilt cylinder. My manual shows a YB-6175-2B for the tilt and the YB-6175-1A for the trim. The part I ordered was for the 2B and they do not make a 4mm for that size. Does someone have a shop manual for 2002 90HP 2-Stroke (90TLRA) they can check to verify the Yamaha tool part number needed to remove the end cap?

[pstephens46]

They have 4mm pins but not for the tool that supposedly fits my end cap tool I ordered (ATM0009). I wonder now if I have the correct year of the manual that shows the tool listed for the tilt cylinder. My manual shows a YB-6175-2B for the tilt and the YB-6175-1A for the trim. The part I ordered was for the 2B and they do not make a 4mm for that size. Does someone have a shop manual for 2002 90HP 2-Stroke (90TLRA) they can check to verify the Yamaha tool part number needed to remove the end cap?

OK. I see the problem now. I was under the impression all pins fit all the versions. I looked a little further. Appears you need the following. If your manual is correct.