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Discussion Starter #1
My Mercury outboard throttle cable rubbed against the engine cowling which wore into the cable covering and got corrosion in the cable, and now I can hardly move the throttle.

How hard is it to replace the throttle cable as a do-it-yourself project? Are there fine tuning adjustments or does it just hook in place?
 

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There's some "tuning" involved because of neutral lockout to prevent you from starting it in gear and such, but I think if you get the exact length as the one you got, it shouldn't be much of a problem. Of course there are books like Clymer's to help you get it done................ [wink]
 

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DIY! I'm not an outboard expert by any means and I was able to mount and rig my 40hp very easily. The hardest part is routing the cable. Just take careful notes when removing the old cable.
Try not to move/adjust the lug at the motor end. You can measure this and pre-tune the new came with the same measurement. You and your wallet will appreciate it!
 

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togger
i just replaced both throttle and shift cables on my 200 black
max. it was the first time i ever done a merc ,i have changed
my johnson ones many times in the past and i'll tell you that
the merc was a piece of cake compared to the OMC [not that the omc is that bad either]. The control box [on the back side] has 2
screws that remove a lower cover that give you access to the cables their[simple once you see it]. At the mtr; i had a plastic
type retaner that snaped apart when pushed from the bottom
back, that released the cables at that point, 1 screw had to be
backed off at the end of--- i think it was the throttle cable but
all the rest of the stuff just snapped apart and the cables came
rite out. leave mtr in neutral and throttle down when installing
new and adjust barrell that fits into snap like the old one was
[there is a plastic bushing on the old cable barrell so look for it
and use bushing again]. that is how mine went and my mtr sits
on a sea drive bracket about 3 foot off the transom and i did my
work in the water at the marina. Yes i was very nerverous.
Be careful west marine tried to sell me some type of universal
cable, don't go for it get the real thing. Good Luck and GOD BLESS
 

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Discussion Starter #5
Thanks for the replies. I have definately decided to do it myself and save $$$. My old cables are longer than they should be and get in my way. I'm thinking of replacing both the throttle and shift cables while I'm at it and going with cables that are 2 ft. shorter.

Realizing that I need to get the barrel lugs adjusted exactly the same on the new cables as the old cables, going to a different cable length shouldn't cause any problem, should it? It seems to me that that the adjustment is entirely controlled by the distance from the adjustable barrel lug to the end of the cable at the motor end. Am I OK going with a different length cable or will I get myself in trouble?
 

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I think as long as you don't have any sharp bends under 8" you should be okay. Make sure you give your cables enough slack to turn and tilt motor with no kinks or extra tension. Good luck.
 

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Togger,
i'm not sure how your cable runs back to the motor but if it is routed under the deck or other tight spots do yourself a favor.
tie some heavy string to one end of the cable and pull the cable out by the other end.
this way all you have to do is tie the string to the new cable and pull it right back thru the same route.
this is especially helpful if you need to route it thru a cable chase or the like.
it will also keep you from inventing some new 4-letter words[grin]
 
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