Extending Cable Throw on Transmission and Throttle Cables

[dlochner]

I replaced the single handle engine control on my Sabre 362. The new control seems to be a little different than the old and the cable throw is too large for the cable. By this I mean even with the cable jacket as close as possible to the shift lever the cable itself is too short by an inch or two.

Any suggestions? The cable jacket is long enough, it is just the cable inside the jacket that needs stretching.

 

[jssailem]

When you replaced the transmission, is the lever on the transmission in the same location as the old one?
Did you change the route of the transmission cable when you installed the new transmission?

Can you add an extension, perhaps an adjustable screw (i.e. turnbuckle) to the transmission end of the cable to give you the 2 inches you want?

 

[heritage]

Cant you carefully cut away a couple of inches of the cable jacket?

 

[dlochner]

When you replaced the transmission, is the lever on the transmission in the same location as the old one?
Did you change the route of the transmission cable when you installed the new transmission?

Can you add an extension, perhaps an adjustable screw (i.e. turnbuckle) to the transmission end of the cable to give you the 2 inches you want?

Oh the questions you ask, John. It is a long story dating back decades of things done that should have been done differently, before my time of course. Short story rather do things right, someone used a work around such that the cables are now too short when we try to do them correctly. it would take a long time and many pictures and diagrams to try to explain.

I was kind of hoping there was an extension and that one was readily available here in Key West. No luck so far.

Cant you carefully cut away a couple of inches of the cable jacket?

If this was a bicycle shift cable or brake cable that's exactly what I would do. The jacket looks to be metal and there is a metal cap at the end to keep the jacket from moving. Cutting the jacket would remove that fitting and likely affect the cable's functioning.

 

[Sailor Sue]

Without actually seeing the cable - any way you could cut a inch or so out of the middle of the cover so you retain the end fittings? Then fabricate some sort of splint to keep the two ends together.

 

[dlochner]

Without actually seeing the cable - any way you could cut a inch or so out of the middle of the cover so you retain the end fittings? Then fabricate some sort of splint to keep the two ends together.

Interesting idea. I'll have to think about it.

 

[jssailem]

Interesting idea.

That it is.
So the overall cable length is adequate. I got the sense that the cable length was short by a couple of inches.
Splitting the cable casing in a strait section where the two sections are or can be supported. Moving the cable casing together. Then securing the two ends together and assuring they stay aligned could work. If not at least you would know the possible area of concern.

 

[dlochner]

So, I am wondering if there is one standard length for the part of the cable outside of the jacket? If so then I need new cables.

 

[RoyS]

Some shifters have various cable connection holes to adjust the throw length. Some transmissions permit over-travel of the shift lever. A new correct length cable is readily available and reasonably priced. I would not attempt to modify a cable, it is not worth it.

 

[dlochner]

Some shifters have various cable connection holes to adjust the throw length. Some transmissions permit over-travel of the shift lever. A new correct length cable is readily available and reasonably priced. I would not attempt to modify a cable, it is not worth it.

I concur and I continue to learn. The term I should be using is travel, not throw. The actual length of the cable is not the issue, it is the travel of the cable, how much the inner cable can move that is the problem. The transmission and throttle have some adjustment room, time to go mess with some more.

 

[LloydB]

I recall a similar problem with an outboard motor I fought with long ago. It turned out that the throttle lever travel was restricted at low speed transmission settings by the motor somehow. It was a combination shift and throttle controller Evinrude I think, so I found somebody to explain it to me and it kind of made sense and worked after correctly adjusting it.

 

[dLj]

I concur and I continue to learn. The term I should be using is travel, not throw. The actual length of the cable is not the issue, it is the travel of the cable, how much the inner cable can move that is the problem. The transmission and throttle have some adjustment room, time to go mess with some more.

Have you figured this out?

dj

 

[dlochner]

Have you figured this out?

dj

Yes. Turns out to be a long story that began 29 years ago. Too long to write out on a cellphone. I’ll tell the story when it is done and I can use my laptop. I’ll know more tomorrow.