How to remove the steering cable on a Boston Whaler with an Evinrude 50 SPL?
I have an older Boston Whaler powered by a 50 hp Evinrude SPL. The steering has gone completely stiff and I need to replace the cable. How do I actually get the old cable out of the engine and the console?
Answer
To remove the steering cable on your Boston Whaler, you must disconnect it from the helm and the Evinrude tilt tube. You must also unbolt the outboard to gain clearance because the rigid output ram of a standard mechanical cable is too long to slide fully out before hitting the fibreglass gunwale.
Disconnecting the engine end
Start at the stern. Undo the nyloc nut holding the steering drag link (the short stainless arm connecting the cable to the engine steering tiller) using a 9/16-inch spanner, then disconnect the arm.
Tackle the large aluminium nut securing the cable jacket to the starboard side of the Evinrude tilt tube. Use a 1-1/8-inch spanner or a large adjustable spanner to back this nut off completely. The cable should then pull out to starboard. If the steering has gone stiff, the cable is likely seized inside this tube. Spray a penetrating oil like PlusGas into the gap. Tap the port end of the steering ram with a brass drift and a hammer to break the corrosion.
The Whaler clearance trick
On classic 13-foot and 15-foot Boston Whalers, the splashwell is extremely narrow. The rigid stainless ram of the steering cable measures about 12 inches long. This exceeds the gap between the end of the tilt tube and the starboard gunwale.
Support the engine skeg on a solid block of wood before loosening the four transom bolts to prevent the 90 kg outboard from dropping. Unbolt the Evinrude 50 SPL from the transom and remove the nuts from the mounting bolts. With a mate to help, or using a lifting eye and a block and tackle, slide the engine backwards off the transom. Pivot the powerhead towards the port side. This changes the angle of the tilt tube just enough to allow the rigid steering ram to slide completely out and clear the side of the boat.
Freeing the helm unit
Move to the centre console. Boston Whalers of this era feature a Teleflex (now SeaStar Solutions) rotary or rack-and-pinion helm. A completely new helm and cable kit costs around £120 to £150.
Look under the dash to identify your system. For a rack system, remove the four 7/16-inch bolts holding the long rectangular rack housing to the back of the steering wheel hub. The rack will drop away with the cable attached. If you have a newer rotary system like the Safe-T QC, locate the quick-connect hitch pin on the side of the round helm box, depress it, and pull the cable free. On older rotary helms, unbolt the back plate to release the cable drum.