CONTROL CABLES Car Like Steering With

MADE IN THEU.S.A.CONTROL CABLESCONTROL CABLES

CONTROL CABLESALPHABETICAL INDEXConnection Kits for Control Cables.228-232Control Cables (Jet Boats).220-221Control Cables (OEM/Engine Maker Direct Replacement Types). 213Control Cables (Universal 3300/33C Types).216-217Control Cables (Universal 4300/43 & 6400/64 Types).218-219Control Cables (Utility, Vernier & DC Control).222-223Control Cables Selection Guide Based on Engine Type.214-215Cross Reference for Other Brands of Control Cables.224-225Installation Tips. 233Introduction to Control Cables & Overview.207-209OEM Direct Replacement Type Cables. 212SeaStar Solutions Universal Control Cables Identification Guide.226-227Technical Reference / FAQs.234-238Xtreme Control Cables.210-211206 www.seastarsolutions.com

The control cable is a very important component inthe control system. It is the vital link between thecontrol head and the propulsion unit. Employing thebest cable helps insure that your shift and throttlesystem operates smoothly and efficiently. The design,technology and materials, which are used in SeaStarSolutions cables, have literally set the standard for theentire marine industry.Our control cables are environmentally testedfor marine applications. They have stainless steelterminals and conduit fittings, as well as stainless orUltraviolet stabilized high densitypolyethylene outer jacketnylon covered core wires with moisture protectiveseals for added corrosion protection and longer life.Their durable HDPE outer jackets resist abrasion andwithstand the effects of UV, salt water, chemicals,gasoline and oil. Each SeaStar Solutions cable islifetime lubricated at the factory.SeaStar Solutions pioneered the development of highefficiency control cables. Since not all cables utilizethis technology there can be significant operatingdifferences between SeaStar Solutions cables andother brands.Protective swivel sealCorrosion resistant stainlesssteel conduit fittingCONTROL CABLESSHIFT AND THROTTLE CONTROL CABLESProtective wiper sealCorrosion-resistant nickelplated brass swivel tubeCorrosion resistantstainless steel terminalHOW TO CHOOSE THE RIGHT 3300/33C CABLE:SeaStar Solutions offers several models of universal3300/33C type cables, each suited to certain operatingconditions and installation parameters. Below are keyvariables that affect how cables perform:Cable Routing: the shorter and straighter the cablerouting, the better the cable will perform. Withincreased length and bends, cable efficiency isreduced, while breakaway and backlash rise.Backlash: the lost motion between the amount ofmovement put in (input end of the cable) and theamount of movement which occurs at the outputend of the cable. Some motion is generally lost in“take up” between the inner wire (core) of the cableand the outer casing (conduit). Backlash manifestsitself as free play (slop) felt at the control handle.Environment: generally, the more rugged the cableconstruction, the longer the cable will last. In harshenvironments such as heavy salt and UV exposure,control cables with thicker conduits and stainlesssteel fittings will generally outlast those with thinnerconduits and brass or steel fittings.Efficiency: the percentage of input force that istransmitted through the cable as output force.For example, if a 10-pound force was exerted onthe cable at its input end and resulted in the cableexerting an 8-pound output force, the cable wouldbe 80% efficient.Breakaway: the “feel” of the cable when put intomotion; the breakaway threshold is the force thatmust be applied to the cable’s input end beforesomething happens at the output end. An example ofexcessive breakaway: a control that would have to bemoved to half-throttle before the engine responded.Cable design, manufacturing tolerances, length andinstallation care are additional factors to /EFFICIENCYLONG/COMPLEXHARSHROUTINGS SuperiorSuperiorSuperiorSuperior 207

CONTROL CABLESWHAT TO CONSIDER WHEN SELECTING CABLESSeaStar Solutions makes engine control cables for awide variety of applications. We recommend their usewith our controls as well as in engine manufacturers’control systems.We offer three grades of cable: standard, midrangeand.THREE PERFORMANCE GRADES:control cables can be used in any boat.They are by far the best choice for long runs, twinstations or other difficult routings with multiple cablebends.Midrange cables are recommended for somewhatlonger cable routings and heavier use than theirstandard counterparts.Standard cables are suitable for most applicationswith short, simple cable routings.FOUR APPLICATION TYPES:OEM Replacement TypeSeaStar Solutions offers a direct replacement cable foralmost every engine manufacturer's control. Most ofour OEM type cables are available in both standardandversions.Universal (3300/33C) TypeUniversal (or 3300/33C) type throttle/shift controlcables are direct replacements for many boats usingaftermarket controls or most engine manufacturer'scontrols with the correct adapter kit. Universal3300/33C cables can be connected to most engines.These cables are offered in all three grades: standard,midrange and.Universal (4300/43 6400/64) TypesHeavy duty universal type control cables are availableinversions only. These are drop-inreplacements for 43C, 43BC, 64C and 64BC stylecables.Jet Boat Gate Control CablesThree styles of drive-specificjet boat gate control cables areavailable for: Mercury Sport Jet 90 and early 120s, Sport Jet175s and OMC Turbo Jet . Our43BC cable is usedfor shifting on most other popularjet drives. Replacement throttlecontrol cables are generally anOEM or 3300/33C Universal type.SeaStar Solutions control cablesmeet OEM specifications for fit,function, reliability and quality.They are built with marine-grade,corrosion-resistant materials andfeatureeitherpremium core construction orLubri-Core lifetime internallubrication.208 www.seastarsolutions.com

FOR A NEW INSTALLATION:Measure cable routing path from control headTYPICAL OUTBOARDCABLE ROUTING:attachment point to engine connection, as follows:OUTBOARDS:Measure from control along unobstructed cablerouting to center of outboard. Add four feet toallow for loop, which provides unrestricted enginemovement. Round up to the next foot and orderrequired cable part number. (Last two digits of cablepart number equal cable length in feet.)TYPICAL STERN DRIVE (I/O) OR INBOARD CABLEROUTING:INBOARDS & STERN DRIVES:Measure from control along unobstructed cableCONTROL CABLES - Measuring CablesHOW TO MEASURE CONTROL CABLES “MEASURE TWICE. ORDER ONCE.”routing to shift and/or throttle connection. Roundthis dimension up to the next foot and order requiredcable part number. (Last two digits of cable partnumber equal cable length in feet.)FOR REPLACEMENT OF EXISTING CABLE:If you removed the old cable, measure for replacementcable as follows:Measure from tip to tip and round up to the nextfoot, if necessary (aftermarket cables are sold in footincrements up to 30 feet. After that use only evenfoot increments).The control cable part number contains its length.SeaStar Solutions cables are usually listed as CC?XX,where XX length in feet.FOR EXAMPLE:Part Number CCX63320 20 ft. CCX633Control Cableor Morse Part Number *032377-03-240.0 20 ft. 33CControl Cable(240" 20')* This cable is no longer available.Use CCX633XX as a replacementCONTROL CABLELENGTH IN FEETwww.seastarsolutions.com 209

CONTROL CABLES -REALLY DIFFERENTTraditional cables vary by the stiffness of the core wireand how tightly it fits in the casing. Thus, the classictrade-offs that have existed in control cable design:A Stiffer core/tighter fit offers less lost motion, butis harder to move. With longer and more complexruns, cable movement becomes progressively moredifficult.More flexible core/looser fit has an easier feel, butallows more lost motion. This approach leads toan overall sloppy feel, RPM loss or difficult gearengagement.THE CORE DIFFERENCE:.34” Super Tough HDPE Jacketfor Ultimate Protection Againstthe Elements.These trade-offs aren’t an issue for cables withtechnology because they are different— really different!SeaStar Solutions' uniqueincorporates a patented splined core.technologyRidges on the core allow a close fit with thecable’s inner liner, but with minimum contact,so the core glides back and forth smoothly like askater on ice.RESULT: a control cable with easy movement ANDminimum lost motion.Oil Tempered Lay Wiresfor Superior Strength &Performance.UNIQUESPLINEDCORE!Long Wearing HDPE Liner:Ultra Smooth and Lubed for Life.CROSS SECTION OFCORE AND LINER:CORE HAS 10CONTACT POINTSSPLINEDCORELINERMINIMALCORE-TO-LINERCONTACT AREA210 www.seastarsolutions.com

CONTROL CABLES -A COMPLETE FAMILY OF CABLES:CCX189XXMerc Gen II type(4000 series controls)CCX179XXMerc type (600A)CCX205XXOMC type (479)CCX630XX3600 Merc typeCCX633XX3300CC type(10-32 threaded end)CCX430XX4300/43BC type(1/4-28 threaded end)CCX433XX4300/43CC type(1/4-28 threaded end)CCX640XX6400/64BC type(5/16-24 threaded end)CCX643XX6400/64CC type(5/16-24 threaded end)SeaStar Solutionstechnology cables arethe ONLY high performance cable familywith a FULL RANGE of universal cables andALL popular direct replacement OEM type cables.www.seastarsolutions.com 211

CONTROL CABLES - OEMOEM CABLE APPLICATIONS:OEM direct-replacement type cables are designed to fit BRP , Mercury , Mariner , OMC , Volvo and similar OEMengine control heads which use a proprietary control cable connection.versions of the most popularcables are offered for demanding applications in which a smooth feel at the control is essential.FOR THESE CONTROLS:Mercury , MerCruiser , Mariner , Force , OMC ,Evinrude , Johnson , Volvo , SeaStar Solutions OspreySeries CH1700, CH7500, CH7600, CH7800 and SL-3Series.MERCURY/MARINER/FORCE/U.S. MARINE:Mercury Gen II type (standard)CC189XXMercury Gen II type (premium)CCX189XXMariner /Mercury /MerCruiser and other engines using Mercury2003-date 4000 series controls. CCX189XX is acable.Mercury 600A type (standard)CC179XXMercury 600A type (premium)Mariner /Mercury /MerCruiser (1965-date); Force CCX179XXMercury/Mariner controls (except pre-1993 40 HP & lowermodels). All 1993-date Force (US Marine) with Force/US Marine/Mercury controls. CCX179XX is acable.Mariner 630 type (standard)CC210XXMariner (pre-1993 40 HP & less) with Mariner/Mercury controls.CCX630XXMercury products (1965-date); Force (1993-date) usingcontrols which accept 10-32 threaded ends or using mostaftermarket controls. Mercury style engine end connection.US Marine L-Drive shift cable (std.)Drop-in replacement cables are engineered asreplacements for original equipment cables.Cables use the existing connection components.Stainless steel and brass fittings.Standard cables use stainless steel Lubri-Core core wire for smooth operation and long life.(8” minimum bend radius.)Premium cables have a heavy jacket and thesplined, coated core element formaximum smoothness with minimal lost motion.(4” min. bend radius.)Black HDPE outer casing for durability and bestresistance to UV and chemicals.Red conduit international only.BRP, OMC, JOHNSON, EVINRUDE, VOLVO/OMC: (1993-date) with Mercury controls. All Mariner engines withMercury 3600 type (premium)FEATURES:CC213XXU.S. Marine “L-Drive” engines with original equipment controls.400 type (standard)CC170XXPre-1979 OMC /Johnson /Evinrude with BRP/OMC controls.Exceeds engine manufacturer’s specifications.479 type (standard)CC205XX479 type (premium)CCX205XX1979-date BRP /OMC /Johnson /Evinrude /Gale with BRP/OMCcontrols. Exceeds engine manufacturer’s specifications.CCX205XX is acable.Volvo/OMC cable (premium)Volvo/OMC cable (premium)Volvo engines using top mount BRP/OMC controls.Drop-in replacement for “L-Drive” shift cables.CONTROL ENDENGINE 205/CCX205CCX214CCX740212 CCX214XXVolvo engines using BRP/OMC side mount controls.www.seastarsolutions.comCCX740XX