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1. Install steering wheel puller hold steering wheel firmly and tighten puller screw to detach wheel from the shaft Once steering wheel is unlocked remove steering wheel puller nut with washer and steering wheel CAUTION Do not hammer on the shaft to dis lodge the steering wheel F09K06A TYPICAL 1 Loosen this nut first 2 Use a 24 mm 15 16 in socket Be careful to keep Woodruff key no 14 for rein stallation Remove collar no 13 Disconnect steering cable and low speed system cable as described above Remove nut and screw retaining steering brace to deck as shown in the next photo LMR2002 024 06 02A FM Section 06 STEERING SYSTEM STEERING SYSTEM Subsection 02 F10KOIA 1 Disconnect steering cable 2 Disconnect low speed cable 3 Remove nut and screw Remove all 3 screws no 15 and withdraw steering helm assembly no 16 Pay attention spacer s may be present In that case note position of each spacer s for proper reinstallation Installation Reinstall removed parts and pay attention to the following When installing steering helm to boat reinstall spacer s if some were present Position screws no 15 as required in slots on steering support no 17 to keep space between helm cable and body Centering screws in slots is a good starting point F09K08A 1 Screw centered in slot Torque screws as indicated in exploded view Ensure to install Woodruff key no 14 Apply2. Loctite 271 2 8 Nem 25 Ibf in 40 Ibf in 240 Engine 7 6 Nem 70 Ibf in Loctite 243 PEE A 7 6 Nem 70 Ibf in FO9KOCS LMR2002 024_ 06 02A FM section 02 STEERING SYSTEM Loctite 243 3 7 6 Nem 70 Ibf in 8 Loctite 243 20 15 4 2 8 Nem 25 Ibf in 06 02 1 Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM Challenger 1800 Model Loctite 243 6 3 53 Ibf in 7 6 70 Ibf in i Loctite 271 gt 8 Engine g lLoctite Loctite 210 iLoctite IRI S in ngine 243 2 8 Nem Y 25 Ibf in Ds Loctite 4 20 N m 243 15 4 2 8 Nem 25 Ibf in 210 Engine 6 53 Ibf in 4 5 14 1 40 Ibf in Ve 2 2 0 15 y 16 30 13 7 22 Ibfein 41 11 0 1 3 P P amp 12 Ibf in ae 2 m d P di d we p 74 240 00 SS 1 AN 2 pane 9 Loctite 45 243 7 6Nem p 4 6 Nem j m I 42Ibf in EN EX A Loctite gt 27 243 P SN AES 2 7 6 Nem NC 7 6 Nem 70 Ibf in 7 70 Ibf in 06 02 2 L
3. CABLE THREADED ENDS MUST BE SCREWED AT LEAST 6 TURNS INTO CONNECTOR j E i E A dace ah THROTTLE SHIFTER CONTROLLER 1 Install throttle cable in this hole A Install shifter cable in this hole LMR2002 025 06 ENSURE LOCKING BRACKET TAB IS PROPERLY LOCKED IN CONNECTOR RECESS ADJUSTMENTS Cable Adjustment Ensure all on cable adjusters are set to their mid dle adjustment F10D06A TYPICAL CABLE ADJUSTER Perform throttle and shifter cable adjustment at engine and Jet pump location Refer to 210 240 M Jet Drive Service Manual tor complete detailed procedure 06 03 3 Section 06 STEERING SYSTEM Subsection 03 Levers Friction Adjustment Lever friction can be adjusted to suit operator s preferences Turn set screw clockwise to increase friction and counterclockwise to decrease it There is one screw for each lever F10KODA TYPICAL 1 Set screw of throttle lever 2 Throttle lever Shifter Lock Adjustment The locking action can be adjusted The positions Forward Neutral Reverse are notched by means of a steel ball no 5 pushed by a spring no 6 against a notch on shifter plate 06 03 4 THROTTLE SHIFTER CONTROLLER Turning the set screw no 7 clockwise will increase spring pressure and therefore hardens shifter lock action Conversely turning sc
4. F10D08A 1 Roller cam bracket 2 Vapor separator 3 Low speed cable F10D09A 1 Remove cap from roller cam bracket 2 Pull cable end out 3 Loosen cable lock nut to remove cable LMR2002 024 06 02A FM Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM 210 and 240 Engines Low Speed Cable Installation Ensure all on cable adjuster s are set to mid position before reinstalling low speed cable To reinstall low speed cable at steering helm as sembly and at engine location reverse removal procedure Pay attention to following Reinstall cable to bracket no 7 and in proper hole of pivoting plates no 3 as shown in the next photo Retighten cable stop nut no 8 and screws of piv oting plates F13K01B TYPICAL 1 Retighten these screws 2 Cable stop nut 3 Cable end in pivoting plates 210 Engine VVhen reinstalling low speed cable to carburetors link rod ensure to position its bracket as specified in the next illustration LMR2002 024 06 02A FM F10DOAB A 10 mm 3 8 in 240 Engine Reinstall low speed cable in roller cam bracket grooves as shown in the next photo Secure cable with roller cam cap Pay attention to low speed cable end position outside roller cam bracket F10D07A 1 Cable aligned with roller cam grooves 2 Cable end outside roller cam bracket 06 02 7 Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM 210 and 240 Engines Proceed with lo
5. Throttle cable 1 3 ul 2 gt Ee D 8 Nem Loctite 73 243 06 03 1 Section 06 STEERING SYSTEM Subsection 03 THROTTLE SHIFTER CONTROLLER REMOVAL Remove lever handles no 3 Unscrew retaining screws no 1 and no 2 Pull throttle shifter controller no 4 out of its re ceptacle CAUTION Use a protective mat P N 295 000 129 in shifter area when withdrawing control ler INSPECTION Check all moving parts for free movement and for excessive play Check cables for wear and oxidation REMOVE LOCK PIN Replace parts as required LUBRICATION Lubricate moving parts with synthetic grease P N 293 550 010 Where not possible apply BOMBARDIER LUBE P N 293 600 016 CABLES REMOVAL At Shifter Location USING A SCREWDRIVER SLIDE OFF LOCKING BRACKET F10K09A LOOSEN SCREW REMOVE BRACKET AND PULL CABLE OUT 1 Loosen this screw 06 03 2 LMR2002 025 06 03A FM Subsection 03 Section 06 STEERING SYSTEM THROTTLE SHIFTER CONTROLLER At Engine Location Refer to 210 240 Jet Drive Service Manual for complete detailed procedure At Jet Pump Location Detach shifter cable from reverse gate remove shifter cable retainer then loosen bellows inside engine compartment Refer to 210 240 2 Jet Drive Service Manual for complete detailed proce dure CABLES INSTALLATION Reverse removal procedure and pay attention to the following F10K0AA
6. the next illustration Adjust to 19 05 mm 750 in Install the actuators no 19 and adjust to the dis tance shown in the next illustration Clockwise steering to 24 33 mm 958 in and counterclock wise steering to 15 31 mm 603 in 06 02 10 Using an ohmmeter with an audible continuity sig nal attach meter to sensor Check that the audible signal indicating that the LSC 15 engaged activates on each side of the steering position Ensure that the signal only engages when the steering is turned fully into the rubber stop at each end to the steering travel and that the steering assist disengages from the force of the rubber stopper only As a final check slowly rotate the steering to en sure that the LSC will not stay engaged without manually holding the steering wheel into the bumpers If further adjustment is required adjust the two actuators 1 4 turn at a time on the side required until the above conditions are met F10KOLA TYPICAL LSC sensor Counterclockwise and clockwise steering actuators Torque to 0 9 1 1 Nem 8 9 7 24 33 mm 958 15 31 mm 603 in 19 05 mm 750 in OU gt Check cable hull watertightness LMR2002 024 06 02A FM Section 06 STEERING SYSTEM Subsection 03 THROTTLE SHIFTER CONTROLLER THROTTLE SHIFTER CONTROLLER Models F10K05S LMR2002 025 06 03A FM 1 3 Nem 12 Ibf in 42 Ibf in Anti seize lubricant
7. MR2002 024_ 06 02A FM Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM Challenger 2000 and X 20 EFI Models 240 T 399 243 350 53 Ibfsin 7 6 Sa 70 Ibf in x 3 yx ec a Loctite 2 8 E 1054 243 Siz 25 Ibfsin cx 2 M E i 1 em Bm Lem 25 Ibfein med Loctite D Bw 243 7 95 20 Nem 222 ER f 15 Ibf ft 2 4 55 2 8 Nem 25 Ibfein 4 5 Nem gt 14 40 S 15 d e EY 30 16 22 Ibf in 2 lt gt 13 j Pn 1 3 P 4 nd 12 Ibfein 676 e 77 2 Y 2 a 2407 OU engine 7 7 6 Nem 3 70lbfin j E Loctite 00 2919 23 1 wc K d 7 6 Nem 70 Ibfein 14 065 LMR2002 024_ 06 02A FM Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM 240 EFI Plus and 250 Optimax Engine Models 0 9 1 1 Nem 8 9 7 Ibf in F10K0KS 06 02 4 LMR2002 024 06 02A FM STEERING SYSTEM INSPECTION Models Check operation of steering It must turn easily and smoothly with a regular resistance from side to side Rotating resistance must be at a minimum No friction should be felt No frictional sound should be heard Check steering end play If some thing is wrong isolate cable from steering helm to di
8. Section 06 STEERING SYSTEM Subsection 01 TABLE OF CONTENTS TABLE OF CONTENTS STEERING SYSTEM recaia 06 02 1 STEERING SYS ENWINSPEC TION 06 02 5 STEERING CABLE N ieee 06 02 5 LOW SPEED STEERING CONTROL SYS Ges 06 02 6 STEERING HEEINIREPREAGBIVIEIN T 06 02 8 STEERING CABLE REMOVAL AND REPLACEMENT 06 02 10 THROTTLE SHIFTER 06 03 1 REMOVA tigate 06 03 2 INSPECTION 06 03 2 m 06 03 2 CABLES BEIVION AL a oie 06 03 2 INS TAEEATIO IN sacco Ex com teen vba ueniet irm te ds 06 03 3 PID STAVE 06 03 3 PROSE IVEY cee I 06 03 4 LMR2002 030 06 06 01 1 Section 06 STEERING SYSTEM Sub STEERING SYSTEM Speedster Model 6 Nem 53 Ibf in pm m o M
9. agnose faulty part Proceed as follows Visually check cable for wear and oxidation at steering helm and at nozzle Check at end of cable housing Replace as necessary Detach cable end from helm arm F13K01A TYPICAL 1 Hemove nut and detach from pivoting arm 2 Loosen this nut underneath to allow moving cable 3 Check for wear particularly brass bushing wear or oxidation in this area Check cable movement Replace as necessary Turn steering from side to side if rotation move ment is abnormal or if end play is excessive re place steering helm as an assembly WARNING Disassembly of the steering helm can lead to steering failure Replace complete assembly For cable assembly use supplied hardware only Do not use substitutes LMR2002 024_06_02A FM Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM STEERING CABLE REPLACEMENT 210 and 240 Models Steering Cable Removal Detach cable from jet pump housing and nozzle Refer to Mercury Service Manualfor complete de tailed procedure Detach cable end from pivoting arm no 1 Rotate steering wheel or shaft to release tension on throttle cable no 2 Detach throttle cable from pivoting plates no 3 Refer to LOW SPEED STEERING CONTROL SYSTEM hereinafter Detach cable housing no 4 from helm arm no 5 and unscrew cable from pivots Unscrew adjuster no 6 from cable while rotating bracket no 7 of throttle cable to allow rem
10. anti seize lubricant P N 293 800 023 on helm shaft Install steering wheel 06 02 9 Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM secure steering wheel with nut and torque as in dicated in exploded view Proceed with low speed cable adjustment as de scribed previously Proceed with steering alignment Refer to Mercury Service Manual 240 EFI Plus and 250 Optimax Models STEERING CABLE REMOVAL AND REPLACEMENT Steering Cable Removal Detach cable from jet pump housing and nozzle Refer to Mercury Service Manualtor complete de tailed procedure Detach cable end and pivot from pivoting arm no 1 detach cable housing no 4 from helm arm no 5 loosen adjuster no 6 and unscrew pivots cable Remove cable from hull Steering Cable Installation Reinstall removed parts and pay attention to the following Pass cable through transom and jet pump housing then attach to nozzle Refer to Mercury Service Manual tor complete detailed procedure secure steering cable to helm arm 5 Proceed with steering adjustment as described in Mercury Service Manual Low Speed Control Adjustments The following method applies to the adjustment of the Low Speed Control LSC for Utopia models with the Optimax power source Ensure that the bumper no 9 mounting bolt is torqued to the specification of 0 9 1 1 Nem 8 9 7 Ibfein Install the sensor no 18 and adjust to the distance shown in
11. oval of steering cable F13K02A TYPICAL 1 Unscrew adjuster while rotating bracket Remove cable from hull Steering Cable Installation Reinstall removed parts and pay attention to the following Pass cable through transom and jet pump housing then attach to nozzle Refer to Mercury Service Manual for complete detailed procedure Secure steering cable to throttle cable bracket no 7 helm arm no 5 Install throttle cable end to pivoting plates no 3 Refer to LOW SPEED STEERING CONTROL SYS TEM CABLE hereinafter Proceed with steering adjustment as described in Mercury Service Manual Check cable hull watertightness 06 02 5 Section 06 STEERING SYSTEM Subsection 02 STEERING SYSTEM LOW SPEED STEERING CONTROL SYSTEM 210 and 240 Engines Low Speed Cable Removal Loosen both screws retaining pivoting plates no 3 together just enough to release cable end cable lock nut then detach cable from throttle cable bracket no 7 F13K01B 1 Loosen these two screws 2 Loosen cable lock nut 3 Detach cable end 210 Engine Detach low speed cable end from carburetors link rod as shown in the next illustration F10D0AA 1 2 4 06 02 6 Carburetors link rod Loosen both nuts Detach low speed cable end Loosen cable lock nut 240 Engine Detach low speed cable end from roller cam brack et located under vapor separator tank as shown in the next photos
12. rew counterclockwise softens lock action set screw 15 located on the same side as shifter lever F10KOEA 1 Shifter lever 2 Set screw shifter lock ASSEMBLY When reinstalling throttle shifter controller no 4 be careful not to bend cables Ensure everything works properly LMR2002 025 06 03A FM
13. w speed steering control system cable adjustment as specified below NOTE Unit must be in water for proper loading Engine should be at operating temperature Low Speed Cable Adjustment Turn steering to port side until pivoting arm no 1 leans on rubber stopper no 9 F10K0GA 1 Pivoting arm leaning on rubber stopper Using both adjustment screws 10 adjust piv oting plate no 3 so its tab leans on pivoting arm no 1 as shown in the next photo 1 Pivoting plate tab leaning on pivoting arm 2 Use both screws to adjust 06 02 8 Start engine CAUTION Never start or run the engine even momentarily without water circulating through the cooling system to prevent damage to engine Turn steering both sides and compare engine rev vings Stop engine If revving readings are different repeat procedure using both adjustment screws no 10 to modify pivoting plate position Refer to the TECHNICAL DATA at the end of this Manual for specified low speed system RPM STEERING HELM REPLACEMENT All Models Removal To release steering cover no 11 use a small screw driver remove cap and pull cover if applicable as shown the next photo TYPICAL CAREFULLY REMOVE WITH SMALL SCREWDRIVER Loosen lock nut no 12 Use of puller tool P N 295 000 161 is recommended to ease steering wheel removal and to prevent damage LMR2002 024 06 02A FM 04
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