Need 2003 Yamaha 90 Trim Cap Wrench Solution

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Author Topic:   Need 2003 Yamaha 90 Trim Cap Wrench Solution

jstarzy posted 05-25-2012 10:21 PM ET (US)
Bad timing, of course......I noticed today (Memorial day weekend) that the trim seal on the left cylinder is leaking badly on my 90 2 stroke. I have a new seal but The pins on The simple spanner wrench I tried bent as soon as I applied pressure to remove the cap. I phoned around but local shops are tied up for the start of the season.
Can anyone offer a solution I might be able to try to remove the cap so I cane get in the water soon? Is there a heavy duty wrench or socket I can buy or rent or am I stuck with having to wait for a dealer with the Yamaha tool that fits the pins in the cap and can handle the torque?
Thanks.....any help would be much appreciated. Jim.
conch posted 05-26-2012 08:48 AM ET (US)
You can use grade 8 bolts in place of the bent pins you have now. Many auto stores sell,rent,loan open face spanners.
Check with an internet search and you will find many responses for Yamaha trim cylinder wrench with homemade solutions.
One vendor selling the spanner on Ebay has a diagram with dimensions that would let you build your own.
Chuck
jstarzy posted 05-26-2012 08:37 PM ET (US)
Thanks Chuck.....I'm debating on finding a dealer to just do the work or buying the wrench on eBay. My only fear there, though, is I'll buy the wrench and not be able to crack open the cap. I have a 12" bar I can add to the handle of the eBay wrench but the spec in the service manual calls for over 100 lbs of torque and then , of course, there's the possibility its seized a bit. However, my engine is in good shape. I did a water pump on it 3 weeks ago and everything came apart nicely with no hassle at all.
Thoughts?
Thanks again...Jim.
rtk posted 05-27-2012 08:57 AM ET (US)
I replaced the trim cylinder caps on my buddies 115 Yamaha. We tried a bunch of different things to remove the caps with no sucess.
I came across Shipyard Island Marina- at the time (couple years ago) they would lend you the special tool that was needed for the job. So I ordered the parts from them and just left a credit card as security for the tool. I don't recal if there was a charge for the rental. With the correct tool the job was a breeze. Not sure if they are still lending tools. Shipyard (Andy & Lisa I believe it was)were excellent to deal with- they even spent time on the phone with advice on doing the job.
www.shipyardisland.com
Rich
conch posted 05-27-2012 09:34 AM ET (US)
Jim the factory tool grabs the trim cylinder head at three of the four holes and then uses a ratchet or breaker bar. The cap is at 110 ft lbs.
Andy at SIM is also a great idea.
I think the Yamaha dealer might be the way to go. He has the tool and the job is simple, plus you can go back if it leaks further. Might as well do both caps while you are there. The end caps if you destroy one are not that expensive.
Chuck
jstarzy posted 05-28-2012 01:19 PM ET (US)
Thanks everyone. I'm going to try 2 dealers to see what the wait time is. If Too long, I'll order the wrench on eBay and hope my 12" extension pipe and some muscle will break the caps open.
I have the packaged seals left over from at least 12 years ago.Same part number as my old 70. If the current diagram shows the same number, I'll go with them. I don't think they've been replaced by a newer, better seal but thought I read that they were in a post somewhere.
Jim.
jstarzy posted 05-30-2012 01:16 PM ET (US)
I spoke to the person who makes the wrench that is posted on EBay. He told me he didn't think his pins would hold up to the force needed to open the trim caps for an engine that's been kept in salt water. Oh well for that try. He did say that a punch and ball-peen hammer may get the cap off but will most likely ruin it for re-use. If so, still not bad at only $30 for a new cap.
Here on the Jersey Shore there are no dealers willing to rent the Yamaha tool. I have an estimate from a Yamaha dealer for the repair at 1 to 2 hours at $150/hr and $75 in parts and at least a weeks wait.
I'm waiting on a return call from another shop per a recommendation of a friend at my marina.
Such a hassle over such a simple repair.
Any other thoughts would be much appreciated.
Thanks...Jim.
jstarzy posted 06-04-2012 10:40 PM ET (US)
I heard back from S&S marine in Highlands NJ and came by their shop with the boat on the trailer on this past Saturday. They had a tool that worked and Tom fixed it while I waited. I had the parts. Very nicely done and great guys, great shop and very reasonable at one hour's shop time cost. They've earned a customer....fixed while waitng!
And.....should note that aside from the spanner needed to open the cap, a press comes in very handy to seat the new seal in the cap.
Also.....I eventually did email Shipyard Island Marine and found out that they will rent and ship the Yamaha tool for removing the trim cap. Just pay up front and they will reimburse the cost of the tool (about $145) less a $25 rental fee. I thought this was terrific as was the discounted costs for parts and a $10 flat fee for shipping. Andy was very responsive and answered my notes in minutes. This would have been a great fallback had S&S not worked out so well.
However...the saga continues but that will be a new post. The Yamaha 90 is acting up.
Thank you all for the tips and excellent advice.
Jim.

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Author	Topic: Need 2003 Yamaha 90 Trim Cap Wrench Solution
jstarzy	posted 05-25-2012 10:21 PM ET (US) Bad timing, of course......I noticed today (Memorial day weekend) that the trim seal on the left cylinder is leaking badly on my 90 2 stroke. I have a new seal but The pins on The simple spanner wrench I tried bent as soon as I applied pressure to remove the cap. I phoned around but local shops are tied up for the start of the season. Can anyone offer a solution I might be able to try to remove the cap so I cane get in the water soon? Is there a heavy duty wrench or socket I can buy or rent or am I stuck with having to wait for a dealer with the Yamaha tool that fits the pins in the cap and can handle the torque? Thanks.....any help would be much appreciated. Jim.
conch	posted 05-26-2012 08:48 AM ET (US) You can use grade 8 bolts in place of the bent pins you have now. Many auto stores sell,rent,loan open face spanners. Check with an internet search and you will find many responses for Yamaha trim cylinder wrench with homemade solutions. One vendor selling the spanner on Ebay has a diagram with dimensions that would let you build your own. Chuck
jstarzy	posted 05-26-2012 08:37 PM ET (US) Thanks Chuck.....I'm debating on finding a dealer to just do the work or buying the wrench on eBay. My only fear there, though, is I'll buy the wrench and not be able to crack open the cap. I have a 12" bar I can add to the handle of the eBay wrench but the spec in the service manual calls for over 100 lbs of torque and then , of course, there's the possibility its seized a bit. However, my engine is in good shape. I did a water pump on it 3 weeks ago and everything came apart nicely with no hassle at all. Thoughts? Thanks again...Jim.
rtk	posted 05-27-2012 08:57 AM ET (US) I replaced the trim cylinder caps on my buddies 115 Yamaha. We tried a bunch of different things to remove the caps with no sucess. I came across Shipyard Island Marina- at the time (couple years ago) they would lend you the special tool that was needed for the job. So I ordered the parts from them and just left a credit card as security for the tool. I don't recal if there was a charge for the rental. With the correct tool the job was a breeze. Not sure if they are still lending tools. Shipyard (Andy & Lisa I believe it was)were excellent to deal with- they even spent time on the phone with advice on doing the job. www.shipyardisland.com Rich
conch	posted 05-27-2012 09:34 AM ET (US) Jim the factory tool grabs the trim cylinder head at three of the four holes and then uses a ratchet or breaker bar. The cap is at 110 ft lbs. Andy at SIM is also a great idea. I think the Yamaha dealer might be the way to go. He has the tool and the job is simple, plus you can go back if it leaks further. Might as well do both caps while you are there. The end caps if you destroy one are not that expensive. Chuck
jstarzy	posted 05-28-2012 01:19 PM ET (US) Thanks everyone. I'm going to try 2 dealers to see what the wait time is. If Too long, I'll order the wrench on eBay and hope my 12" extension pipe and some muscle will break the caps open. I have the packaged seals left over from at least 12 years ago.Same part number as my old 70. If the current diagram shows the same number, I'll go with them. I don't think they've been replaced by a newer, better seal but thought I read that they were in a post somewhere. Jim.
jstarzy	posted 05-30-2012 01:16 PM ET (US) I spoke to the person who makes the wrench that is posted on EBay. He told me he didn't think his pins would hold up to the force needed to open the trim caps for an engine that's been kept in salt water. Oh well for that try. He did say that a punch and ball-peen hammer may get the cap off but will most likely ruin it for re-use. If so, still not bad at only $30 for a new cap. Here on the Jersey Shore there are no dealers willing to rent the Yamaha tool. I have an estimate from a Yamaha dealer for the repair at 1 to 2 hours at $150/hr and $75 in parts and at least a weeks wait. I'm waiting on a return call from another shop per a recommendation of a friend at my marina. Such a hassle over such a simple repair. Any other thoughts would be much appreciated. Thanks...Jim.
jstarzy	posted 06-04-2012 10:40 PM ET (US) I heard back from S&S marine in Highlands NJ and came by their shop with the boat on the trailer on this past Saturday. They had a tool that worked and Tom fixed it while I waited. I had the parts. Very nicely done and great guys, great shop and very reasonable at one hour's shop time cost. They've earned a customer....fixed while waitng! And.....should note that aside from the spanner needed to open the cap, a press comes in very handy to seat the new seal in the cap. Also.....I eventually did email Shipyard Island Marine and found out that they will rent and ship the Yamaha tool for removing the trim cap. Just pay up front and they will reimburse the cost of the tool (about $145) less a $25 rental fee. I thought this was terrific as was the discounted costs for parts and a $10 flat fee for shipping. Andy was very responsive and answered my notes in minutes. This would have been a great fallback had S&S not worked out so well. However...the saga continues but that will be a new post. The Yamaha 90 is acting up. Thank you all for the tips and excellent advice. Jim.