Hull/ControlSystems
6.14
Steering Cable Removal / Installation -- All Models
11. With the upper jam nuts and linkage accessible, remove
the eyelet assembly, jamnuts, washers, and thru--hull
locknut from the steering cable.
NOTE: Always keep the parts in the same order as you re-
moved them from the cable. These parts will be transferred
to the new steering cable.
12. With the linkage removed, pull the remainder of the
cable through the rear of the hull.
Steering Cable Installation
1. Insert the new cable through the rear thru--hull fitting from the back of the watercraft following the routing you
noted in removal.
NOTE: V erify that there are no sharp bends or kinks in the cable before proceeding to the next step.
2. Slide the black thru--hull nut onto the steering cable.
3. Apply marine--grade silicone to the thru--hull fitting threads.
4. T ighten the thru--hull fitting nut to 52 in.lbs. (6 Nm)
5. T urn locking plate flat towards thru--hull nut face. Tighten nut to 28 ft.lbs. (39 Nm)
6. Install the nut, two washers, lock washer and nut onto upper steering cable threads.
NOTE: At least four threads must be visible when installing jam nuts on steering cable.
7. Lightly grease the upper steering linkage.
8. Install the cable tube over the end of the cable. Install upper eyelet assembly. Torque assembly against tube
to 8 ft.lbs. (11 Nm) Verify that at least 3/8 in. of threadlength is engaged in the rod end.
9. Apply Loctitet 242 to jam nut threads. With at least four threads visible, install the jam nut assembly into the
steering cable mount. Hand tighten jam nuts so that cable sits in mount.
10. Turn steering column to the left. Apply Loctitet 242 to the column--to--cable mounting bolt. Tighten nut to 40
in. lbs. (5 Nm).
11. Center steering column assembly. Insert dowel into steering column. The dowel will lock the assembly in the
center position.
12. Move to the rear of the watercraft. Install the rear rod end eyelet. Verify that at least 3/8 in. of rod end is
engaged in the eyelet. Apply Loctitet 242 to threads. Tighten to 8 ft.lbs. (11 Nm)
13. Install steering steering linkage--to--nozzle mounting bolt. Verify that steering nozzle is straight. Minor
adjustments can be made at the eyelet assembly. Always maintain at least 3/8 in. rod engagement. Major
alignment adjustments can be made at the jam nuts.
14. Once the steering nozzle is aligned to center , with the help of an assistant, tighten the upper jam nuts to 22 ft.
lbs. (30 Nm). Verify that the jam nut assembly is fully engaged in the bracket with one washer on each side of
the bracket.
15. Tighten the steering nozzle bolt to 8 ft.lbs. (11 Nm) Remove the dowel locking the steering column.
16. Replace top--deck access hole plug. Loosely fit the shroud assembly to the top--deck.
17. Apply Loctitet 242 to handlebar mounting bolts. Tighten bolts to 15 ft.lbs. (21 Nm), in a criss--cross pattern.
18. Refer to appropriate shroud assembly diagrams in this chapter when assembling shroud to top--deck.
19. Reinstall the MFI and associated harnesses and pitot fittings. Reinstall front compartment bulkhead access
panel.
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