Help with 1990 90hp Force controls

[mitchbuck]

Last fall I purchased a 'new to me' 1990 90hp force to replace my 1993 90hp that blew up. For reference here is my post prior to buying the engine: http://forums.iboats.com/force-chrysler-outboards/date-force-585675.html#post4041379

Anyways, I was able to get the old engine off and the new one on ok. I hooked up the old steering cable and it works. However, the throttle cables on the boat are mercury but the 'new' engine appears to take force/crystler cables. Based on my searches it seems that I need the red jacket Universal Control Cables with a 10-32 threaded end (would appreciate it if someone could confirm). Is there anything else that I am missing here or need? It looks like that engine has the 'clamps' needed to attach the cables (photos are coming). Will these cables work with the mercury throttle control box that I have? Also, stupid question.....do I need to order 2 cables (1 for shifting, 1 for throttle) or do they come in a set? Thanks in advance!

 

[jerryjerry05]

Re: Help with 1990 90hp Force controls

Your gonna need 2 cables.
On the old cables there is a bunch of letters and numbers stamped in them.
It will be the length.Maybe in inches or feet.
Make sure the length is right,too short and it won't work right.Too long is better than too short.
The connectors on the motor are different(pics.You will need them.
The shifter, might be different.Post pics.
Some parts diagrams show Chrysler/Force shifters used on the later ones.Again pics.
Profile? Location? You might be close to someone who can help.

 

[Frank Acampora]

Re: Help with 1990 90hp Force controls

You can not use the Mercury control box. You need either a Chrysler or US Marine control box or possibly a universal Morse control box.

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

Well that is disappointing news! It turns out I have quicksilver (essentially merc) surface controls (see photo). Another thread on this site mentioned that force/Chrysler control boxes are hard to find or what is available is usually expensive (I checked ebay wow!). Any suggestions on where I can find cables and a reasonable box (new or used)? The main thing I just want to make sure that they will work with eachother and also with the motor. Lastly, are there any other components that I need besides cables and the control box? I have uploaded photos below of my engine control attachments below.

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

I hope that pic ^ came out clear enough, its hard to get a shot in this tight spot with my phone.

 

[jerryjerry05]

Re: Help with 1990 90hp Force controls

The shifter is Mercury. The connectors are Force.
You'll need a shifter and probably the connectors on the cable ends.
How about some pics of the old cable ends? ans the old motor.
Sent U a PM

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

Sent you a PM/email Jerry. Here are the pics of the old cable ends....they are just mercury cable ends. So do you guys think that my ignition switch (i think merc) will work with the force/chrysler control box?

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

I just wanted to give an update on the engine and boat. We successfully installed the universal controls for the engine. Jerry on this forum was nice enough to sell me the cable connectors and a morse control box and then give me some instructions on how to install them. In the end it wasn't too bad.

After that, I had a friend who is an electrical engineer help me install the wiring harness using the clymer manual. It took some time but in the end we got it figured out. The one confusing thing is that we haven't yet hooked up the nuetral-start wires from the ignition to the control box, however, I am not sure if they are needed because there is a already a switch on the engine that does this already. Is the nuetral-switch wiring on the shifter necessary or is it just for redundancy?

After that we tried firing up the engine and after a lot of cranking we finally got it to turn over. However, the circuit breaker/reset button on the engine kept on popping and we couldn't figure out why. Eventually we traced it to a bad choke solonoid on the engine...every time we hit the choke the breaker would trip and the solonoid wouldn't actuate. Going to order a new choke, but can live without one for now. Also, once we got the engine running we couldn't get the engine pumping water with the hose/ear muffs so looks like the water pump will be the next order of business. Getting closer and will update with progress hopefully this week.

 

[jerryjerry05]

Re: Help with 1990 90hp Force controls

The one in the shifter isn't needed.
Just make sure the one on the motor's set right.

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

The one in the shifter isn't needed.
Just make sure the one on the motor's set right.

Awesome, one less set of wires to hook up. Thanks Jerry, I'm getting close....

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

Pulled the lower unit off last night, and it was my first time doing that. It wasn't too bad honestly, the hardest part was getting exhaust hood off because one of the bolts was a 10mm head in a tight spot (must of been replaced at some point). I cleaned up all the parts, and luckily the impeller, gaskets, and water pump is the same on the 1990 as it was on the 1993 as I have spare parts from that. Hopefully it all goes back together good tonight. The only thing that I anticipate being tricky is getting the driveshaft back up the upper leg and synched with the shifting mechanism. Will report back getting closer, though I do have to replace steering too after this as it is completely frozen on the helm end.

 

[jerryjerry05]

Re: Help with 1990 90hp Force controls

Sent U a PM.

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

So I got the lower unit back on and was pretty proud of myself! It took some finagling but everything seems to be in proper order with the hardest thing getting the impeller in the pump housing. I got the engine running after some convincing with starter fluid and she began pissing water like a champ! So now on to finishing the engine tuning including a link n synch, timing check, and adjusting of the controls.

Speaking of controls, I thought I had them hooked up correctly but I noticed that the controls got stiff. I opened up the control box to check and I found the new throttle control cable end bent to my dismay, so looks like that cable is ruined and there goes another $40. I was trying to figure out how this happened and the only thing that I can think of is the control cable fitting weren't threaded on the control cable correctly. Although, I noticed that the control arm doesn't appear to be fully flush against the swivel bracket because part of the cable end overhangs the bracket (it has no where to go because this is where grove is for the clamp). So I might have to grid this swivel bracket back a little to accommodate the cable (which I find odd).

 

[jerryjerry05]

Re: Help with 1990 90hp Force controls

Youcan bend that straight.
You have the connectors on the right cable?
I think the short one is the shifter?
I'll look and get back.
Yup short one on the shifter.

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

Jerry,
The connectors are on the right cables (longer one on the throttle, shorter on shift) and the cables are hooked up properly on both the engine and control box ends. But I may have to fine tune the adjustment on the connectors on either end. Any thoughts on how I can bend the cable back?

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

UPDATE: So my local WM was nice enough to exchange the bent cable for me (they know me too well) and I was successfully able to re-install the throttle control cable. It took some time to get the throttle and shifter controls synched up properly, but I got it worked out in the end. I realized that after servicing my lower unit that I had to get the shift rod back in synch with the lower unit gears by spinning the prop rod and prop. Also, it seems that my the tach is not working properly...it says that I am idling at 2000 rpm's when it clearly is not. My tach is the one used with the mercury controls that I replaced.....so was wondering if there is a way to adjust the tach or do I have to change the Tach from Mercury brand to US Marine or ...?

^UPDATE: Looks like its time to open up the wallet again. After looking into it it seems that the older (pre-1992) Forces require a unique 20-pole Tach instead of the universal tach! I located some Teleflex and Faria 20-pin Tachs on ebay for ~$70, any difference in quality/performance between these two brands? Also, I read a bit about these Tiny Tachs that some guys are using, but have reservations about using a Tach that is wired seperate and around a spark plug wire.

 

[jerryjerry05]

Re: Help with 1990 90hp Force controls

Teleflex and Faria are both good. Get one that comes close to the same look??
The Tiny tach are a good diagnostic tool.
It's battery will eventually die. Mine I can't replace the battery.
Some time on the back of the tach. There is an adjustment knob. Look and see if yours has it and try.
You'll probably have to open the cash drawer again!!!

 

[maytheforcebewithus]

Re: Help with 1990 90hp Force controls

Mitch i just purchased this 20 pole Faria tach on Ebay for 50 bucks including shipping. hope this helps you out.

Faria Outboard Only 0 8 000 RPM Boat Tachometer Part 8000 | eBay

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

Thanks guys, I just ordered a Faria 20 pole Tach off Ebay. I can live without the speedometer, but live and die by the tach!

 

[mitchbuck]

Re: Help with 1990 90hp Force controls

Last night I was successfully able to install a new Teleflex Rotary Steering helm and cable! I was surprised how straightforward this was, the hardest part was getting the steering wheel off as I ended up having to cut the shaft and then pound it out. I am planning to do some in water testing/tuning either today or tomorrow. I still need to install the new choke solenoid that I got yesterday and the new Tach won't be here for a few days. I will update when I know more!