How to Assemble Outboard Motor Controls

When maintenance, some project or disaster leads you to remove your boat's remote controls, you must reassemble them eventually. They're called remote controls because they allow you to control the throttle and gears from a place other than the front of the motor itself. They are linked to the outboard motor by cables attached to the motor's carburetor and shifting mechanism that control the speed and direction of the engine. The goal of the project is to reattach these cables to the throttle lever; most of the project, though, involves preparing the housing to hold the lever.

Things You'll Need

  • Screwdriver
  • Small adjustable wrench
  • Allen wrench
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Instructions

    • 1

      Install the spring washer and fast idle lever in the housing. Install the shift lockout cam and lever from the housing and install the spring washer and fast idle lever on the housing. Install the keeper plate screw at the top of the housing, using a screwdriver.

    • 2

      Thread the screw and lock nut that hold the shift lockout cam to the fast idle lever into place and tighten them, using the screwdriver and a small adjustable wrench.

    • 3

      Place the throttle lever assembly and spacer into the housing. Install the flat-head screw at the center of the throttle lever assembly. Fit the countersunk washer onto the lever.

    • 4

      Position the shift lever assembly into the control housing. Install the detent roller -- the pin that holds the detent, the lumpy plastic disc that bumps when you move between forward, neutral and reverse -- the shoe and spring.

    • 5

      Insert the screw and retainer plate into the top of the housing assembly. Position the neutral start switch in the assembly and secure it, using the two screws provided.

    • 6

      Push back on the cable to expose the clevis pin that holds to the bottom of the shift lever. Disconnect the shift cable. Thread the shift cable pin into the shift control clevis to the bottom of the lever.

    • 7

      Install the three housing-to-housing cover screws from the back of the housing. Push the throttle cable trunnion into the housing pocket.

    • 8

      Place the control handle on the control hub so the splines align. Thread the Allen screw into its bore in the bottom of the handle and tighten with an Allen wrench.

    • 9

      Put the face of the housing control assembly onto the housing and insert the retaining screws through the back of the housing. Tighten the retaining screws. Reinstall the control on the boat.