How to Hook Up the Controls to a 1966 650 Mercury Outboard

Mercury Marine produced the Model 650 until 1976. The 1966 Mercury Model 650 outboard is a two-stroke, four-cylinder outboard that produces 65 horsepower at 5,300 rpm. Like many things on older outboards, connecting the remote control cables from your throttle and shifter remote to the throttle arm and shifter on the engine is no picnic. The process is similar, though, to making these same connections on the later 1977 Model 700 that replaced the 650. Good gloves save frustration and pain.

Things You'll Need

  • Small adjustable wrench
  • Machinist's ruler
  • Work gloves
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Instructions

    • 1

      Remove the top cover of the outboard and locate the mounting pin on the end of the shift arm. Remove the washer and locknut from the pin, using a small adjustable wrench. Move the remote shift handle to "Neutral."

    • 2

      Measure, with a machinist's ruler, the distance from the mounting pin of the shift arm and the center of the barrel holder. Don your work gloves. Push the cable into the sleeve until you encounter resistance. Now, move the cable locking barrel until it is the same distance from the mounting pin as it was when you measured it.

    • 3

      Push the barrel into the bottom slot on the barrel anchor and fasten the cable to the mounting pin, using the washer and locknut located on the pin. Move the shifter back and forth, while turning the propeller by hand, to check the shifter's operation. Move the shift handle back into "Neutral."

    • 4

      Locate the connector on the throttle lever. Remove the lock nut and the flat washer.

    • 5

      Move the cable locking barrel so it will hold the throttle arm against the carburetor throttle stop. Shift the engine into gear and ensure this action activates the throttle linkage. Turn the prop by hand, when you shift the throttle into reverse.

    • 6

      After you move through the gears, pull the remote handles so the engine is in the "Neutral-Idle" position. Slide a piece of paper between the throttle's idle stop and the throttle arm. Pull the paper out; if it drags but does not tear, the cable length is correct. Latch the cable locking barrel to the barrel holder.