Any tips or tricks to separate / remove lower cowling from 2005 Johnson 90?

[SweetD]

I need to split the lower cowling on my 2005 Johnson 90hp 2 stroke in order to get to the tilt/trim motor wiring. I'm removing the tilt/trim unit to get it resealed.

I've never attempted to dis-assemble the lower cowling for any reason. My OEM service manual is quite vague with where the bolts are located, and the exploded views from the on-line parts source are not great for this particular job. Can't find much in the way of YouTube vids for this particular model...

Any tips would be appreciated. Again, just looking to split the lower cowling in order to be able to access the wire connectors for the tilt/trim motor. I know I can pop the connector ends off once I can get to them. Impossible without removing the lower cowling though.

Thanks!

 

[racerone]

There are 6 screws to take out I believe.-------4 at the top of the cowling ( 2 at the front and 2 at the back ) and 2 screws about half way down the cowling one at the front and one at the back.

 

[SweetD]

Thank you sir I will hopefully have not too much trouble, plan on doing the job on Sunday if the weather up here cooperates. Gonna be wicked cold starting tomorrow through Sunday morning! (RI)

 

[SweetD]

Another question, rather than dis-assemble the entire thing to get the harness out, is it acceptable to cut the green and blue motor wires just below where they enter the cowling, and then just properly connect them back together after the repair with heat shrink connectors/tubing, etc.? This would obviously be a lot easier than taking the whole thing apart. Salt water use motor.

Thanks,
Dave

 

[SweetD]

Ok well an update, I managed to get the tilt/trim unit off the boat with the motor wires intact. Had a lot of trouble with removing the blue and green wires from the plug connector. Ended up trashing the spade connectors but the plug itself is OK. I'll either need new female spade connectors that fit that plug or I guess I could just wire directly without the plug connectors using my own connectors, heat shrink, etc.

I'm sending the unit to Five Star in FL for a rebuild.

Dave

 

[oldboat1]

Include a note asking for wiring repair as well.

 

[SweetD]

Include a note asking for wiring repair as well.

Thank you I will, I had actually thought to add that in my "write up" to them.

Dave

 

[Chris1956]

Yes, now my memory returns... a bit late. The plastic connector needs to be removed from the wires, to pull the trim wires out of the cowling. There were small "tangs" that locked the wires into the plastic connector. I was able to note the position of the wires and depress the tangs with a small screwdriver to pull out the wires.

 

[Faztbullet]

Trim wires are trapped in a cutout on midsection...just remove port cowling..about a 3 minute job and 4 bolts..

 

[SweetD]

Yes thanks I was able to get the lower port cowling off with no issue. The connector plug got the best of me though. Just could not figure it out with how to depress the tab correctly. Didn't help that it was about 35 degrees out and windy.