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  1. #1
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    Yamaha powerhead removal - again :)

    I am currently in the process of removing the powehead from a 1985 Yamaha 200aeto. I have drilled all the bolts that broke but it will not break free. Because of the lower cowling I am unable to drill the bolts at the top. There is 1,5 - 2 inches of bolt left between where i drilled them and the powerhead. I am considering cutting the exhaust adapter plate, but to do that I will first need to cut the lower cowling. As it does not come off without removing the powerhead.

    This means replacing both lower cowling and exhaust adapterplate.

    I have tried lifting the powerhead with a forklift, and various attempts om hitting, prying and heating. But there is no sign of movement anywhere.

    Any tips?

    Also, can i use the exhaust adapterplate and lower cowling from a V4? I know they dont have the same partnumber. But can they be used still?

  2. Likes Don Dieago liked this post
  3. #2
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    Is the lower off?

  4. #3
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    are you 100 percent sure you have them all off ?

  5. #4
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    All the bolts are off, two in the back, three on the sides, and three on the front.

    Lower is still on, maybe i should try to remove the lower. But if it was stuck on the driveshaft, should it not be able to move some?

    I have now found a spare exhaust adapter plate. Maybe i should just find the grinder and be done with it.

  6. #5
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    PM message Superbender he is the Yamaha guy that could help you.

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  8. #6
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    there is 10 bolts and 2 nuts if i read your post right you said you removed two in back 3 each side and 3 front thats 11. there should be 10 bolts and two nuts thats 12.

  9. #7
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    watch this and skip to 5:50
    https://www.youtube.com/watch?v=Y3JjQAXXtHg

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  11. #8
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    You are probably going to waste the adapter plate removing the powerhead. There is one bolt on each side that is a bear to remove. You can try using a oxygen/acetylene torch to heat up the adapter plate around the bolts. I've drilled through the adapter housing/powerhead bolts to get the powerhead off. Once drilled you can use a air hammer with a punch bit to drive the bolts while lifting and hot with torch.
    Being a 1984 engine, that's a long time for the bolts to get stuck.
    Better to waste the adapter that the engine block.
    Good luck

  12. #9
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    I have decided to waste the adapter, i have a new one in the mail. I dont want to spend days fighting to get it apart, so sunday is cutting time.

    I have found 10 bolts, 2 front and rear. 3 on each side and one nut in the front. Maybe I have missed a nut in the front?

  13. #10
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    Great video don Diego! Thanks!

  14. #11
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    Before you cut lower pan, you might want to be sure there are no small parts hidden in with typical old engine pan grime. Specifically a shifter detent ball which seems to always find its way out of line of sight. Might save you a trip to the dealer for a "BB" when you go to reassemble.
    Check shift shaft for corrosion, if any replace now. You probably already know this, as this is why an awful lot of Yamaha power heads come off.

  15. #12
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    Good tip! There is always some small parts layinh around om the grime. The top og the shift shaft is rusty, so i dont think it has been changed. That is on my to do list

  16. #13
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    Most likely the front studs are broke off, common thing. You may want to look for a later year mid section in fresh water areas to replace yours with. When you try to get the adapter off more bolts will probably break......tuner, can, mounts, etc. Replace shift shaft for sure!

  17. #14
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    section 4 page five in manual for 1986 says 6 long bolts 2 medium 2 short and 2 nuts mine is 1986 150 but on the ground I also have a 175 AETO parts engine and its identical except carbs and its 1984. with the two rhardwick says are probably broke off that would make 12
    Last edited by Don Dieago; 12-15-2018 at 11:13 AM.

  18. #15
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    Last edited by Don Dieago; 12-15-2018 at 11:09 AM.

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