[shamone79]

Hi. From UK and new to forum so please bear with me!My father-in-law and I are in the middle of re-commisioning his 96 Bayliner Capri for summer use. The engine and gearbox are all ready but we are having major troubles with the controls.The boat has Quicksilver 3000 classic controls fitted which have got extremely stiff in operation. We have checked that the cables are free and are positive that the fault lies in the control box.Can anyone give us a contact with regards to obtaining a service manual for these controls? Before we get to the point of buying a new control box we would like to have a go at sorting out these if we can. We are having trouble just getting the control lever off!! There is a grub screw which we have removed but it seems to be stuck solid.Any help/comments received will be very gratefully received. Many thanks.

[fierro]

try some graphite if you can get it into the controls and try working them. a little bit of graphite goes a long ways.

[shamone79]

Thanks for that. As soon as I can get the controls apart I will graphite grease everything up. The problem is at the moment I can't even get the lever off! Either it's seized or I'm doing something wrong! By the looks of things the handle has to come off before you can take the control box out. I'm a professional car mechanic so am pretty competent when it comes to cars but things are generally a lot cheaper if you break something on a car than a boat!

[Laotzu]

You can buy a book from this forum but the shipping cost might be prohibitive. Must be somewhere there where you could get one. Clymer has a good Merc Manual. Go on Google and ask for Clymer. They may have a European site. The book won't necessarily help you with your problem. Covers the wiring, switches, etc. However the control itself is quite simple. Just cables going around cams and out to the motor.Is there a tension knob on the front end of the unit? try turning that to free up. How about the carb linkage? Any binding evident?By the way, my son is married to a girl from Swindon. He met her there when he was in the USAF Strategic Air Command and spent some time at the RAF base in Swindon.

[shamone79]

Thanks for the suggestion Laotzu. Like you say, we have an excellent factory Mercury manual for the outboard but nothing for the controls. Can't find anything on the web either.Anyway I took the complete side panel off the boat to access the rear of the controls and all is fine inside. I disconnected the cables from the outboard and everything is as free as a bird so looks as though the stiffness is in the gearbox itself. We have adjusted the cables and greased everything up and it feels a little better. It probably needs a little use as it has been stood doing nothing all winter.It would be very interesting though to find out how you get the damn lever off. It looks as though you have to prise off the 'Throttle only' button but I can't get it to budge. Also there is a little grub screw that even when released does nothing to let you remove the lever. Hey-ho and see how we go!Laotzu- I am located in the South-West of England (Cornwall) but Swindon about 2.5 hrs drive. Can't say I have been there directly but pass it often on my way to London. Swindon is the home of Honda UK if you didn't already know. That's all I know about the place!! Thanks again

[Laotzu]

I took mine apart, but it has been several years and I didn't have any trouble so I can't make any suggestions.Jerry

[Moody Blue]

This site has lots of parts dwgs for controls. SCroll to the bottom of the page and start looking under -controls-. Many different models to choose from. Sure yours is there somewhere. http://www.mercruiserparts.com/selec...sp?type_id=*** in the address above, replace the *** with A S S (no spaces) for assembly.