New Shift cable diameter complications at cowling rubber grommet

[havoc_squad]

I went ahead and replaced my shift cables on my VJ90TLASB 1990 V4 90 HP crossflow because I felt the shift cable slop was too much to be taken because I ran out of adjustment to remove slack after fully shifting it forward.

I'm running into an issue with SeaStar Solutions Extreme cable diameter and the brass coupling thickness causing issues where the control cables pass through the rubber cowling grommet on the outboard.

It's too much variation/thickness to trim out on the grommet to allow it to fit, does anyone know a common off the shelf item that would substitute for the cowling rubber grommet to keep most stuff out of that hole? I know it has to be stiff or ridged enough to avoid getting sucked into the motor intake possibly.

The differences I mainly noticed about the two cables in comparison:

The OEM original Teleflex cables have a cable shaft diameter of 6.6 mm and the brass coupling size of 9mm.

These SeaStars are 8.5mm on cable shaft diameter and brass coupling diameter of 10.5mm.

If no available option on the cowling grommet alternative, I'm almost inclined to re-work the entire thing if I can get similar new good quality cables closer to the originals diameter that don't cost nearly $200 a piece. Any suggestions? I'm leaning towards the TFXtreme Control Cable if I try another brand. I just hope they don't use the same diameter or thicker.

 

[havoc_squad]

Follow up, any suggestions at least for a replacement item that can substitute for a cowling grommet to keep stuff out of the outboard compartment for a typical V4 crossflow?

 

[racerone]

How much slop was there in the factory cable ?-----Factory cables are about $50 each.----Why bother with another brand ?----What other trouble shooting was done on the shifting issue ?----Was shift rod height set correctly ?---In neutral is that lever under the carburetor vertical ?----And where did you see cables at $200 each ??----I need to know !

 

[havoc_squad]

How much slop was there in the factory cable ?-----Factory cables are about $50 each.----Why bother with another brand ?----What other trouble shooting was done on the shifting issue ?----Was shift rod height set correctly ?---In neutral is that lever under the carburetor vertical ?----And where did you see cables at $200 each ??----I need to know !

Shift cable had about 1/4 inch of slack after fully tightening with controls fully in forward.

Yes, shift lever is vertical in neutral and verified lower unit in neutral by hand, not leaning forward or reverse.

Pulled lower unit and double checked the shift rod height within factory spec of 21 27/32 +/- 1 /32 inch.

Availability at the time of ordering was the primary reason and they were the primary brand being sold by one of the top US based online marine parts retailer and not ebay or Amazon which I try to avoid on such critical items.

I'll have to reference the super expensive one later when I get time today.

 

[havoc_squad]

Anyways, my assessment was correct on the aftermarket ones were WAY too thick in diameter.

Bought OEM cables and the cable diameter tolerance was with specifications and the lower cowling control cable grommet now fits correct.

For those searching the forums that stumble on this, buyer beware. The Seastar OMC 1979 and up cables were well made cables that fit in all aspects correctly and appeared well made, EXCEPT they were way too thick at least for certain OMC/BRP outboards to fit in the cowling grommet.

If it doesn't fit properly there in the grommet using the aftermarket cables, you'll possibly have to custom fabricate something up yourself to close that hole off.

Both cables fixed the shift cable being stretched too much after completing the OEM service manual shift cable installation procedure. Plenty of adjustment left over and testing of them appears 100%.

 

[racerone]

I do not think that cables stretch.----They do wear internally.