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Replacing Control Cables (shift and throttle)

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  • Replacing Control Cables (shift and throttle)

    Attempted to replace my cables today. My throttle cable has always been a little too stiff, so finally got around to replacing it. I have a 2000 Prostar 195.

    Here are a bunch of points that may help others:

    - To remove the driver side panel I had to remove 4 bolts with an 11 mm deep socket. You don't have to remove the throttle lever or anything on the driver facing side, just the 4 bolts in the back and the panel will move away enough that you can access the cables.

    - Definitely need to remove the driver's seat to be able to get at things, just 4 screws to do this. If you remove the seat cushion there are holes in the seat that the screw driver fits through.

    - Also needed to remove the rear seat and back, dog house (engine cover), and all the floor panels, gives you good access to help push the cables through. Its also a great time to clean the floor panels with soap and a good brush. I also took the opportunity to remove the deteriorated foam from the engine cover and put new foam in, a much easier job than the cabling. I used the "Sound-Absorbing Sheet Easy-to-Clean, Adhesive Backing, 54" WD X 1" Thickness, 8 ft. Length" (5692T49) from McMaster-Carr. I only needed 5 feet of it.

    - Look at the code on your old cables to determine the length. One end of the cable will have a marking on it with a code. The last two digits of the first code are the length on the Teleflex cables. For example, mine were "CC63324", so that means a 24 foot cable. Unfortunately I was told I needed an 18 foot cable and realized it was too short after feeding it all the way through the boat. The Prostar 195 uses a 24 foot throttle cable and a 29 foot shift cable.

    - Since I ended up feeding the new cable through and then back out again I had experience feeding cables from the helm and also from the engine end. I think it was easier to pull the cable out the helm, so I will do it this way when I get the proper 24 foot cable.

    - I used duct tape to tape the old and new cables together. I am going to look for a screw coupler and just attach that to both cable ends, that should work well.

    New cable arrives in a couple of days and I will attempt this all over again, but hopefully in half the time now that I know what I am doing.
    Last edited by airwear; 08-04-2021, 11:20 PM.

  • #2
    Any pictures?

    Sent from my SM-G955U using Tapatalk
    sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

    Comment


    • #3
      Originally posted by airwear View Post
      Attempted to replace my cables today. My throttle cable has always been a little too stiff, so finally got around to replacing it. I have a 2000 Prostar 195.

      Here are a bunch of points that may help others:

      - To remove the driver side panel I had to remove 4 bolts with an 11 mm deep socket. You don't have to remove the throttle lever or anything on the driver facing side, just the 4 bolts in the back and the panel will move away enough that you can access the cables.

      - Definitely need to remove the driver's seat to be able to get at things, just 4 screws to do this. If you remove the seat cushion there are holes in the seat that the screw driver fits through.

      - Also needed to remove the rear seat and back, dog house (engine cover), and all the floor panels, gives you good access to help push the cables through. Its also a great time to clean the floor panels with soap and a good brush. I also took the opportunity to remove the deteriorated foam from the engine cover and put new foam in, a much easier job than the cabling. I used the "Sound-Absorbing Sheet Easy-to-Clean, Adhesive Backing, 54" WD X 1" Thickness, 8 ft. Length" (5692T49) from McMaster-Carr. I only needed 5 feet of it.

      - Look at the code on your old cables to determine the length. One end of the cable will have a marking on it with a code. The last two digits of the first code are the length on the Teleflex cables. For example, mine were "CC63324", so that means a 24 foot cable. Unfortunately I was told I needed an 18 foot cable and realized it was too short after feeding it all the way through the boat. The Prostar 195 uses a 24 foot throttle cable and a 29 foot shift cable.

      - Since I ended up feeding the new cable through and then back out again I had experience feeding cables from the helm and also from the engine end. I think it was easier to pull the cable out the helm, so I will do it this way when I get the proper 24 foot cable.

      - I used duct tape to tape the old and new cables together. I am going to look for a screw coupler and just attach that to both cable ends, that should work well.

      New cable arrives in a couple of days and I will attempt this all over again, but hopefully in half the time now that I know what I am doing.
      How'd it work?

      Sent from my SM-G991U using Tapatalk

      Comment


      • #4
        Originally posted by 88falcon View Post
        How'd it work?

        Sent from my SM-G991U using Tapatalk
        The more I think about your scenario, I think "length" is your issue. It's almost a Mr. Obvious conclusion.

        Be sure and order new end connectors and cotter pins. In particular the ones at the controller end of the cables. Cables do not come with those.

        .
        Attached Files
        93 190
        (safe click)
        John 14:6
        (safe click)

        Comment


        • #5
          Originally posted by waterlogged882 View Post
          The more I think about your scenario, I think "length" is your issue. It's almost a Mr. Obvious conclusion.



          Be sure and order new end connectors and cotter pins. In particular the ones at the controller end of the cables. Cables do not come with those.



          .
          Yeah I think so as well. I was taking it all apart to clean and grease the controller and to inspect and replace the connector ends when I decided to thoroughly look into the issue of the cables. I had never really given it any thought in the passed, seemed to work well enough. But now knowing how the MV-3 controller is suppose to function their is definitely a problem. Either that or the cable has something so wrong it that it's not allowing for full travel. I plan on calling Ron Tanis tomorrow to run it by him and give him some business.

          Thanks

          Sent from my SM-G991U using Tapatalk

          Comment


          • #6
            Here is a picture of the driver side panel and where the 4 bolts are to remove. Note the 4th one just made it into the bottom of the picture frame.
            Attached Files

            Comment


            • #7
              So after replacing with the proper length new cable, throttle is smoother, but only 25% better. When the cable is not attached at the driver control end, it doesn't move smoothly, so I think the control arm mechanism is the bigger problem. I tried to grease where I could but that hasn't helped much. My brother's 205 control you could move with just 1 finger, very easy and very smooth.

              Anyone with other ideas?
              Attached Files

              Comment


              • #8
                Originally posted by airwear View Post
                So after replacing with the proper length new cable, throttle is smoother, but only 25% better.

                Anyone with other ideas?
                Ron ??? I kid.

                To be clear, you have the MV-2 or the MV-3 controller? I have manuals on both.

                Have you disassembled to clean the inside? They get nasty over the course of time.

                .
                Attached Files
                93 190
                (safe click)
                John 14:6
                (safe click)

                Comment


                • #9
                  I have not taken it fully apart, maybe that is next on my list then. Can you send me both manuals. I am not sure which controller was used in the 2000 Prostar.

                  Comment


                  • #10
                    Originally posted by airwear View Post
                    I have not taken it fully apart, maybe that is next on my list then. Can you send me both manuals. I am not sure which controller was used in the 2000 Prostar.
                    I have the MV-3 on another machine. MV-2 is attached below. I think yours is the MV-2.

                    .
                    Attached Files
                    93 190
                    (safe click)
                    John 14:6
                    (safe click)

                    Comment

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