Wow, thanks for this long PM. Yes, you guessed it correctly. 2016, I got pretty impatient and pissed so I tried pulling my cable without removing my motor first. So, the cable was somewhat bent for 1. For 2, silly me also tried to yank my steering wheel so hard to try to break loose the bind on the motor side. So, I broke some teeth in the helm side. I finally took the motor off and cleaned it. It worked ok for a few more trips but started to bind again. As I was putting the motor back I did notice the cable was bent.
I still think my tube (or sleeve as you called it) was rusted and salt got into it even though I washed the tube down after every trip, so it caused my binding after I cleaned it in 2014.
If I have to do it again, I would simply buy a tilt tube and replace the rusted tube out of the motor.
or do what the Boston whaler guy did with the cable locked (attached) to the pivot rod on the motor and avoid sliding it through the rusted tilt tube.
I brought up your post regarding the stiff steering after installing a brand new cable at our shop today. A pal bought a huge shop and it is our hangout for all of us that have boats. 10 boats amongst the 6 of us. The owner Johnny has bought no less than another 15 to work on and flip. I am not sure what you mean by "tilt tube"? Cable sleeve is what we refer to where the stainless steel shaft inserts to connect the cable to the outboard.
What the consensuses is came down to a few things. 1) the sleeve that the shaft has a burr or more than 1 burr or good size scratch in it. This would cause a new cable to bund.
2) the shaft has a good size scratch etc that will cause binding
3) The shaft was slightly bent when you installed it, It will bind for certain if the shaft has a slight bend 100% for certain. Not hard to do when fighting the thing.
4) Did you clean out the sleeve with a wire brush really well before you inserted the new shaft?
5) Did you clean off the new shaft and grease it well before inserting it, also did you grease the inside of the sleeve before you put the shaft in?
We would disconnect the cable from the sleeve (tube) and remove and inspect it for the things I mention above. I know I had a hell of a time getting in the new cable into the sleeve without removing the outboard because there wasn't enough room making the 90 degree turn from the gunnel to line up the shaft. We made it by 1/4 inch, tight. I cut away some aluminum where the boot is. I am assuming that you have a rotary or rack and pinion type steering.
How did you get the shaft (tube) and rod lined up?
