1991 90hp lower leg cover removal problem

[QuadManiac]

I can't seem to get the $@(*!##!!!#@@% lower leg cover to come free from the rest of the leg. I've pulled all 4 top, inside the cowl bolts (had to drill a couple of them out, because the molded in nuts spun free due to bolt being corroded into nut), I've pulled all 3 bolts on both sided of the leg. Is there something else I'm missing?

On the starboard side, i can pry the leg cover out about 1/4" at the bottom, it appears as if there's a locating pin there. I can separate the edge along the top by 1/16th or so. The port side just doesn't want to move a bit. I'm afraid of cracking the fiberglass of the cover if I put any more prying force on it.

Of course, neither of my manuals show anything about the leg cover.

Any ideas or suggestions? Is this common, and if so, what is the remedy?

Thanks

 

[Frank Acampora]

Re: 1991 90hp lower leg cover removal problem

Are you sure there were only 4 bolts inside? The older Forces with the aluminum leg covers had 6--two in the rear and two on each side of the engine. And there are probably two roll pins--one on each side of the bottom of the cover. Any time you have a piece that should move and just will not, look for the one bolt you forgot or overlooked.

 

[QuadManiac]

Re: 1991 90hp lower leg cover removal problem

I've looked carefully for more bolts, but the two top corners come free, a bit. All additional screws in the cowl area appear to be going through to the front portion of the leg. I even removed the L-bracket at the rear, in case it's mounting bolts went through to the leg cover.

It's jamming up somewhere between the port roll pin and the next couple of screws going up the leg on that side... I'm perplexed. It just shouldn't be this hard to get it off... Anybody else ever had experience with this thing jamming?

 

[Frank Acampora]

Re: 1991 90hp lower leg cover removal problem

The problems I have had were with the roll pins corroding in and not coming free on the aluminum covers. What I do is to wedge in a flat tire iron--Yes, I still mount tires by hand because I am a cheap bastard-- or crowbar into the gap I have created then whack the other portion to let leverage do the work. Need to do it a few times to get enough clearance to pop off the cover. You need to be more careful with the plastic cover so you don't crack it or chew up the mating surfaces.