Replacing Control Cables

[twsnagel]

Hi everyone:
I’m coming to the end of my 1963 Johnson 40hp project, and just need to install and adjust the control cables.

I’ve got new aftermarket cables, but I’m having trouble finding installation and adjustment instructions.

My shift box is the "newer" square-shouldered two-lever type, and I have the adjustable trunions on the motor end.

I’ve attached an instruction sheet I found for the older round-shouldered shift box, but I’m not sure if I should be cutting the cable ends as shown, or leaving them as-is.

Insight/resources? Thanks everyone!

[frankr]

They should already be cut to length. The instructions apply to replacing the inner core wire.

[Casey Lynn]

Pay close attention to the clamp screw procedure. Failure to do so can result in loss of control of the shift/throttle function! In messing with these type cables this is the most common mistake I see when I get them.

[frankr]

quote Pappy:

Pay close attention to the clamp screw procedure. Failure to do so can result in loss of control of the shift/throttle function! In messing with these type cables this is the most common mistake I see when I get them.

Yeah, and another tip: It’s been a long time since I’ve bought a new cable, so I don’t know if this still applies or not. But back in "the day", OMC cables came already annealed, but Teleflex did not. You can tell by looking at the end of the wire. If annealed, it will be discolored. If not annealed, you can’t put the proper kink in the wire and the end is apt to slip off.

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[twsnagel]

Thank you everyone!

I’ll be sure to check the anneal and crimp procedures.

Is there a resource for how to properly calibrate the cables at the motor end? I looked at the red manual on boatinfo and couldn’t find a procedure.

I can wing it, but it’s always nice to do things the proper way.

[frankr]

Assuming you are using the upgraded cables with nylon adjusting wheel, it is simplicity in itself. Just adjust the wheel to get full engagement in both forward and reverse. If you have to compromise because of worn shifter parts, favor forward gear. Another thing we didn’t mention is that the new cables with adjuster wheel use different lock clips to hold them to the motor side—that is assuming you are replacing old ones without adjuster wheels.

[twsnagel]

Great. Thank you very much. Hope to do this in the next week.

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