Thunderbolt 800 Control Cable Issues

[hartleck]

I received my new control cables today and went to put them on but I need a diagram of how they attach at the enging and will probably need one for the control head as well. Where should I look to find something like this?

 

[Chris1956]

Re: Thunderbolt 800 Control Cable Issues

The flat brass or stainless steel ends go to the control box. The square-ish plastic ends go to the motor. Install the control ends first. Now operate the control from neutral to forward. The cable that moves first is the shift cable. It is installed into the fitting that slides on the shift slider on the port side of the motor. a 3/8" nut holding the cast aluminum peanut-shaped fitting holds it. Set the slider about 1/2 way along the travel of the slide. It should click into neutral and stay there. Make sure the control is in neutral and adjust the barrel nut to fit the lower hole in the clamp.

The other cable is the throttle cable. It attaches to the arm just above the shift cable, that works the carbs and distributor, with a 3/8" nut. Adjust the throttle cable barrel nut to push the throttle closed, with a bit of preload. Stick the barrel into the holder and close the clamp.

 

[hartleck]

Re: Thunderbolt 800 Control Cable Issues

Thanks for the help, that got me what I needed on the engine side and adjustment. Now what I need is a diagram of the control box and how it goes together. I am having to shorten my wiring harness by almost five feet. and am wanting to make sure I get it back together correctly. I had to dissemble the box to get to the wiring.

 

[carholme]

Re: Thunderbolt 800 Control Cable Issues

hartleck;

Don S. has posted the latest Control Box manual here:

http://www.4shared.com/document/vi4Bs0m9/Outboard_SM_Index.html

About halfway down the right side of the page, you will see the list of items he has posted. You should find your box in there.

Gerry

 

[Moody Blue]

Re: Thunderbolt 800 Control Cable Issues

The previous post shows only P/N listings for service manuals for different model years of Merc outboards.

Here is the Merc service manual for the control boxes. Should have everything you need in there.

http://www.4shared.com/account/file/144897617/4cfd9e4f/Merc_Controls_Newest_manual.html

It is a big (29Mb) file. Once downloaded you can save it to your PC for future reference.

 

[carholme]

Re: Thunderbolt 800 Control Cable Issues

Moody Blue;

If you had bothered to check the link, I am sure you would have see it as:

25,541 KB | 2009-10-30 | File name: Merc Controls Newest manual.pdf | File

Just a little bit more than p/ns and I am sure Don posted it there for a reason. It is certainly the one I have on my computer.

Gerry

 

[hartleck]

Re: Thunderbolt 800 Control Cable Issues

Thanks to both of you. this is even better than I had hoped for.

hartleck;

Don S. has posted the latest Control Box manual here:

http://www.4shared.com/document/vi4Bs0m9/Outboard_SM_Index.html

About halfway down the right side of the page, you will see the list of items he has posted. You should find your box in there.

Gerry

The previous post shows only P/N listings for service manuals for different model years of Merc outboards.

Here is the Merc service manual for the control boxes. Should have everything you need in there.

http://www.4shared.com/account/file/144897617/4cfd9e4f/Merc_Controls_Newest_manual.html

It is a big (29Mb) file. Once downloaded you can save it to your PC for future reference.

 

[Moody Blue]

Re: Thunderbolt 800 Control Cable Issues

Moody Blue;

If you had bothered to check the link, I am sure you would have see it as:
Gerry

As a matter of fact I did check the link, and the only thing available was "Outboard SM Index", exactly what your link lead to. I was a little puzzled why you posted that, so I merely offered a link to the actual file location "Merc Controls Newest manual". Didn't intend to ruffle your feathers.

 

[carholme]

Re: Thunderbolt 800 Control Cable Issues

when you go to the link and follow what I said in my post;

About halfway down the right side of the page, you will see the list of items he has posted. You should find your box in there.

And lo and behold, the box is there.

No sweat, no feathers ruffled.

Gerry

 

[SeaKaye12]

Re: Thunderbolt 800 Control Cable Issues

Mayby you have to be a "member" there for the box to appear? I see no such box halfway down the right side of the page, and nowhere on the page is a link to allow me to download the file : "Merc Controls Newest Manual".

The link that Moody Blue provided worked though...so thank you all!