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Marine Mechanical Controls Trouble Shooting Guide

PROBLEM CAUSE SOLUTION
CONTROLS ARE HARD TO OPERATE
  1. Too many bends in cable
  2. Bent cable rod
  3. Brakes are too tight
  4. Cables are worn out
  1. Reduce the number of bends in cable. (Put in shorter cables)
  2. Check for damaged cable rods, replace cables if necessary
  3. Grease or replace control bearings
  4. Adjust brakes so they are not too tight
  5. Replace cables
THROTTLE LEVER DOES NOT STAY IN PLACE WHEN UNDERWAY
  1. Heavy return force on fuel lever at engine
  2. Throttle brake on control is too lose
  1. DO NOT tamper with or remove return springs on fuel levers
  2. Tighten throttle brakes on control
  3. Install cable brake (44386) on throttle cable jacket
THROTTLE IS SLOW IN RESPOND WHEN HAND LEVER IS MOVED
  1. Too many bends in cable
  2. Connections at control or engine are loose
  3. Cable is worn out
  1. Reduce number of bends in cable (put in shorter cables)
  2. Check all hardware and tighten if necessary
  3. Turn engine off, with hand levers at idle position, disconnect cable at fuel lever and "pull" on cable rod to take out "free play." While holding this pull force, re-adjust the cable terminalto line up with the hole in the lever
  4. Replace cable
HAND LEVERS DO NOT LINE UP WHEN AT CRUISING SETTING
  1. Too many bends in throttle cable
  2. Loose connections at contorl or engine
  1. Reduce number of bends in cable (put in shorter cables)
  2. Make sure cables are attached in the same hole in the cable output arm
  3. Adjust control stop screws so hand levers are equal at the idle position
"SPONGY" FEEL AT CONTROL. HAND LEVER DOES NOT GIVE ENOUGH STROKE
  1. Stop screws not adjusted properly
  1. Adjust stop screws on control to stop lever movement at the same time fuel lever reaches full open. Stop screws prevent over travel of cable
CANNOT FEEL NEUTRAL, FORWARD or REVERSE DETENTS
  1. Control does not have shift detent kit installed
  2. Detents are at more than one station
  3. Detents are not adjusted for feel
  4. Detents are worn
  1. Install shift detent kit
  2. In dual station systems: use detent only at most used station
  3. Adjust (tighten) detent screw for more pressure