Removing the Lower Unit of a 1985 V4 Johnson 90hp Outboard Motor: A Comprehensive Guide

Removing the lower unit of a 1985 V4 Johnson 90hp outboard motor is a task that can be completed with the right tools and knowledge. This guide will provide you with step-by-step instructions on how to safely and effectively remove the lower unit, ensuring that you can get your outboard back in working order quickly and efficiently.

Tools and Materials Required

Before you begin, gather the following tools and materials:

• Service manual for your specific outboard motor model
• 1/2-inch socket wrench
• 9/16-inch socket wrench
• 11/16-inch socket wrench
• Phillips head screwdriver
• Flat head screwdriver
• Hammer
• Punch
• Puller tool
• Gear puller
• Gasket scraper
• Replacement gaskets
• Marine grease

Safety Precautions

Before you start working on your outboard motor, take the following safety precautions:

• Disconnect the battery.
• Wear safety glasses.
• Work in a well-ventilated area.
• Allow the motor to cool down before touching it.

Step-by-Step Instructions

1. Preparation

1. Place the outboard motor in neutral.
2. Tilt the motor up to the full tilt position.
3. Remove the propeller and thrust washer.

2. Disconnecting the Gearcase

1. Disconnect the shift linkage from the gearcase.
2. Disconnect the water hoses from the gearcase.
3. Disconnect the electrical connections from the gearcase.

3. Removing the Gearcase

1. Remove the four bolts that hold the gearcase to the powerhead.
2. Use a puller tool to remove the gearcase from the powerhead.
3. Inspect the splines on the driveshaft and the gearcase for any damage.

4. Removing the Lower Unit

1. Remove the six bolts that hold the lower unit to the gearcase.
2. Use a gear puller to remove the lower unit from the gearcase.
3. Inspect the gears and bearings in the lower unit for any damage.

Tips and Tricks

• If you are having trouble removing the bolts, apply some penetrating oil to them and let it sit for a few minutes before trying again.
• When using the puller tools, be sure to apply even pressure to avoid damaging the components.
• If you are replacing the gaskets, be sure to apply a thin layer of marine grease to them before installing them.

Strategies for Removing a Stuck Lower Unit

• If the lower unit is stuck, you can try tapping it with a hammer to loosen it.
• You can also try using a penetrating oil to loosen the bolts.
• If all else fails, you can use a hydraulic gear puller to remove the lower unit.

Troubleshooting

• If you are having trouble removing the lower unit, check for any bolts that may be missing or damaged.
• If you are having trouble removing the gearcase, check for any electrical connections that may be loose or damaged.
• If you are having trouble removing the lower unit, check for any gears or bearings that may be damaged.

Conclusion

Removing the lower unit of a 1985 V4 Johnson 90hp outboard motor is a task that can be completed with the right tools and knowledge. By following the step-by-step instructions in this guide, you can safely and effectively remove the lower unit, allowing you to get your outboard back in working order quickly and efficiently.

Call to Action

If you have any questions or need further assistance, please consult your service manual or contact a qualified marine mechanic.