Replacing Your Boat Shifter: A Step-By-Step Guide

Replacing a boat shifter can be a tricky task, but with the right tools and knowledge, it is certainly achievable. Before beginning the replacement process, it is important to identify the type of engine and control head your boat has, as this will determine the appropriate control cable. There are two main types of control cables: OEM-specific cables, which have end fittings designed for your specific engine and control head, and Universal control cables, which come with threaded ends that require a connection kit. When installing a new shift and throttle control, it is crucial to measure the correct length for the control cables, taking into account the distance from the control to the engine and the shift and throttle attachment points. Additionally, it is recommended to replace shifter cables every 3-4 years to ensure smooth operation.

Identify the type of engine and control head

To identify the type of engine and control head, you need to know whether you have an OEM-specific or Universal control cable. An OEM-specific cable will have the appropriate end fittings for your specific engine and control head. For example, it could be a Mercury outboard, a Volvo engine, a Suzuki, or a Yamaha. On the other hand, a Universal control cable comes with threaded ends and requires a connection kit specific to your engine and control head.

The next step is to determine the length of the control cable you need. To do this, you can look at the plastic jacket on the cable. If it's a Teleflex cable, the model number will indicate the cable length in feet. If it's a Morse Cable, the last three digits will indicate the length in inches. Keep in mind that some OEM cables on boats may be in half-foot increments, while replacement cables are typically available in full one-foot increments. So, measure the cable from tip to tip and round up to the nearest foot to find the appropriate replacement.

Additionally, when installing a new shift and throttle control, you'll need to take three measurements. First, measure from the control back along the gunnel to the point where the gunnel and transom meet. Second, measure from the intersection of the gunnel and transom to the centerline of the engine. Third, measure from the centerline of the engine to the throttle and shift attachment points. For outboard applications, add four feet to these dimensions to ensure enough cable for the engine to move back and forth.

It's also important to understand the different types of boat engines: outboard, inboard, and stern drive. Outboard engines are mounted on the transom of the boat and are used for both power and steering. Inboard engines, on the other hand, are located inside the boat's hull and power a drive shaft connected to a propeller. Stern drive engines, sometimes called "inboard-outboards," combine features of both outboard and inboard engines. They use a four-stroke automotive engine mounted inside the hull and have a drive unit for steering.

Measure the length of the control cable

Measuring the length of the control cable is a crucial step in replacing your boat shifter. Here is a comprehensive guide to help you through the process:

First, it is important to understand the type of engine and control head your boat has. This is essential because it determines the type of control cable you need. Your boat likely has an OEM-specific control cable or a Universal control cable. OEM-specific cables have end fittings designed specifically for your engine and control head. Universal control cables, on the other hand, come with threaded ends that require a connection kit specific to your engine and control head.

Now, let's determine the length of the control cable you need. The most accurate way to do this is by examining the plastic jacket on the cable. For Teleflex cables, the model number will indicate the cable length in feet—look for the "TFX" prefix, and the last two digits will represent the length in feet. For Morse Cables, the last three digits will indicate the length in inches.

It is worth noting that some OEM cables on boats may be in half-foot increments, but replacement cables are typically available only in full one-foot increments. Therefore, it is recommended to measure the cable from tip to tip and then round up to the nearest foot when selecting a replacement.

When installing a new shift and throttle control, you will need to take three critical measurements to ensure you get the correct length for the control cables. The first measurement is from the control, along the gunnel, to the point where the gunnel and the transom meet. The second measurement is from the intersection of the gunnel and the transom to the centre line of the engine. The third and final measurement is from the centre line of the engine to the throttle attachment point and the shift attachment point. Remember to add four feet to these dimensions (A, B, and C) for outboard applications to allow for ample cable movement as the engine shifts.

By following these detailed steps, you will be able to accurately measure the length of the control cable needed for your boat shifter replacement project.

Check if you need to replace the shift cable

Before you replace your boat shifter, it's important to check if you need to replace the shift cable. Here are some signs and steps to help you determine if a shift cable replacement is necessary:

• Stiff Controls or Excessive Lever Movement: If you notice that your boat's controls are stiff or that your levers are moving too far before engaging the throttle or transmission, it could be an indication that the shift cable needs to be replaced. This usually happens when the cable is corroded or damaged.
• Difficulty Shifting: If you're experiencing difficulty shifting gears, especially if it's getting harder and harder over time, it could be a sign that the shift cable needs to be replaced. This is often due to corrosion or internal damage within the cable.
• Age of the Cable: Shift cables typically need to be replaced every 3-4 years. If it's been a while since you've replaced your shift cable, it may be time for a new one, even if you're not experiencing any noticeable problems.
• Visual Inspection: Remove the shift cable and inspect it for any signs of damage, corrosion, or wear and tear. Look for broken strands, kinks, or bends in the cable. If you notice any damage, it's best to replace the cable.
• Manual Shift Test: Disconnect the shift cable from the motor and try shifting the motor manually using a wrench or pliers. If the motor shifts freely, the issue is likely with the cable.
• Measurement: When installing a new shift cable, it's crucial to get the correct length. Measure the distance from the control, back along the gunnel to where the gunnel and transom meet. Then, measure from this intersection to the centre line of the engine, and finally, from the centre line of the engine to the throttle and shift attachment points.
• Engine and Control Head Type: Identify the type of engine and control head your boat has. This is important because it determines the type of control cable you need. You may have an OEM-specific control cable or a universal control cable. OEM-specific cables have end fittings designed for your specific engine and control head, while universal cables require a connection kit.
• Cable Length Identification: To determine the exact replacement length, check the plastic jacket on the cable. For Telefax cables, the model number will indicate the cable length in feet. For Morse Cables, the last three digits represent the length in inches.

Check if you need to replace the throttle cable

To check if you need to replace the throttle cable, there are a few key signs to look out for. Firstly, if you notice that your boat's controls are becoming too stiff or hard to operate, it may be an indication that the cable needs to be replaced. This could manifest as a shifter becoming harder and harder to move. Additionally, if you observe that your levers are moving too far before engaging the throttle or transmission, it could be indicative of a faulty throttle cable.

The longevity of a throttle cable depends on various factors, including usage and maintenance. It is recommended to replace them every 3-4 years. However, this can vary, and some cables may last longer or deteriorate faster.

Before replacing the throttle cable, it is essential to identify the type of engine and control head your boat has. This is crucial because it determines the type of control cable you need. There are two main types: OEM-specific and Universal control cables. OEM-specific cables have end fittings tailored to your specific engine and control head, whereas Universal cables come with threaded ends that require a connection kit specific to your engine and control head.

When replacing the throttle cable, it is important to get the correct length. To determine this, you can measure the old cable tip-to-tip and round up to the nearest foot. Additionally, when installing a new throttle control, you will need three measurements: from the control back along the gunnel to where the gunnel and transom meet, from this intersection to the engine's centreline, and from the centreline to the throttle and shift attachment points.

Remove the drive to pull out the shift cable

To remove the drive and pull out the shift cable, you will need to first disconnect the cable from the motor. You can then pull it through the opening into the bilge. Next, disconnect the other side and locate the rigging tube by opening the seat at the back of the cockpit. You should now be able to see the mouth of the rigging tube from inside the cabin.

At this stage, you can attach the new cable to the old one and pull it through at the same time as removing the old one. This is made easier by taping the new cable to the old one or using a threaded barrel to connect the two. By doing this, you can pull them through at the same time, making the process quicker and more efficient.

Another tip is to attach a small nylon rope to the new cable before pulling it through, so that if you need to pull a new wire in the future, you have something to tie it to. This will make future maintenance easier and is a good practice to follow.

Finally, you can fish the new cable through the transom opening and then feed the other side up through to the throttle box.

Frequently asked questions