2002 Air Nautique Steering Cable

[toddrswenson]

I've searched and searched old posts. Do I have to take out the ballast tanks and gas tank to change the steering cable on my 2002 Air Nautique (NOT SUPER AIR)? I seem to find conflicting answers. Has anyone done this and if so how long does it take?

[s_kelley2000]

I don't know for sure but I would guess you would probably have to remove at least one ballast tank and/or the gas tank. I am not sure where the gas tank is located in an 02 Air though. You might be able to squeeze your hands in there to unhook it from the tiller arm but I am sure it will be a tight squeeze. When we did the cable on our 91 Sport we may have been able to do it without removing the gas tank but it would have been a knuckle scraping pain. Removing the gas tank isn't too bad (in a 91 at least). The hardest part was removing the gas lines from the tank but in hindsight we probably could have lefts those on and had enough slack to move the tank forward to get to the rudder once the straps holding the tank down were removed. If you lift out the back seat and remove the center floor board behind the motor you will have a decent view of what you need to get to. If you do it yourself make sure you tie a rope to the end of the old cable when you pull it out and then tie the new cable to the rope to help you pull it through.

[jbach]

just did this last night. only on a 99. should be similar

-remove rear seat/seat base
-remove starboard ballast tank
-mark where steering cable is positioned in clamp bracket so everything will be the same going back in.
-unbolt steering cable from rudder arm
-unbolt clamp block 12 inches in front of rudder
-remover center section of flooring
-cut all zip ties around steering cable from inside ski locker/ gas tank.
-remove kick panel under driver seat
-cut rudder end of steering cable off to remove the metal shaft that was connected to the rudder arm.
-unbolt steering cable "box" from steering wheel gear (4 bolts)
-pull cable from "box" at steering wheel towards rear of boat, sometimes you may also need to push the trailing part cable towards the front of the boat.
-once i got the bitter end of the cut cable into the ski locker, i connected a wire to make sure i could pull the new one back through if needed. (didn't end up needing to do that.
-i routed the new cable down through the floor fore/behind of the removed kick panel, through the ski locker and on TOP of the gas tank hold down brackets for easier replacement next time.
-replace clamp bracket on marked position, re-bolt rudder arm.
-i needed to re-center prior to the replacement, so i did and then installed the steering cable "box" at the helm.
-i installed and automatic bilge pump to keep the water out of the stern/steering cable.

not a bad job, it's easier on some boats than others. i already had everything removed doing some other work, once you have that it's literally a 30 minute job. would probably take me a couple hours from start to finish.

[toddrswenson]

You make it sound easy. Two questions... Did you remove the gas tank? It seems like everything I've read says that when removing the cable pull from the helm end of the cable towards the front of the boat. You did the reverse. Did that make it easier?

[s_kelley2000]

Nice write up JB! Is your boat an Air or a Super Air? These two steps lead me to believe you have a vdrive:

-remover center section of flooring
-cut all zip ties around steering cable from inside ski locker/ gas tank.

I still think the OP might be able to get to his rudder by just removing one of the ballast tanks and/or removing the bracing that holds the gas tank in place.

[jbach]

I did not remove the gas tank. I had a full tank and that would have been last resort. I cut the rudder end if the cable off to minimize it catching on other cables, cable ties, etc. It should pull through after cutting any zip ties. I pulled the helm end of the steering cable towards the back/stern of boat because that's the way it turns coming out of the ski locker through the floor.

[jbach]

Yes, it's a super air-v drive. BTW, I removed those tanks for the last time for simple maintenance. Bags are going back in, I've fought those things for too long.

[toddrswenson]

Well I inspected my boat this past weekend to see if I would need to take the tanks out to change the cable. It looks like there is enough room in between the two tanks that I can disconnect the rudder are (pittman arm) and unbolt the cable clamp and pull cable out from under the gas and ballast tanks. I can't disconnect the cable because it is just barely under the ballast tank. Is removing the rudder arm with the cable a bad idea? It seems like it would prevent a lot of wasted time in tank removal. My other question is when you disconnect the rudder arm from the rudder will the rudder fall out of the bottom of the boat? The attached picture is not my boat. It is just for reference. Thanks TRBenj.

[jbach]

If you remove the rudder arm, the rudder is going to drop so put a piece of wood under it if you do. I would remove the ballast tank, make your life much easier.

[charlesml3]

Do I have to take out the ballast tanks and gas tank to change the steering cable on my 2002 Air Nautique (NOT SUPER AIR)? I seem to find conflicting answers. Has anyone done this and if so how long does it take?

You have to take out at least one tank to get to the tiller-end of the cable. There's no way around that. Yesterday I replaced the steering cable on my 1999 Air. I didn't completely remove the fuel tank but it would have been much easier if I did. I disconnected it enough to get it to slide forward so I could remove the port ballast tank. I then disconnected the bottom drain hose from the starboard tank so I could lift it up a few inches and pull the floor plate out. From there I could squeeze into the ski locker (I'm kinda thin) and get to the cable and rudder connections.

I was by myself and it took around 5 hours.

-Charles

[dawn]

i just replaced the steering cable in 01 Air Nautique with the help of Rob, ridebutter. didnt have to take out ballast tanks or gas tank. took off back seat back and lifted one of the rear tanks and that was all

[charlesml3]

Please post photos of your locker/tank area. The only explanation I can come up with is your 01 does not have factory or OEM tanks. With the OEM tanks it's impossible. They will not lift more than a couple of inches before getting pinched in the gunwale at the side of the fuel tank. In addition, they had a drain in the bottom that went down to the pumps. That hose connection was just a few inches long and couldn't be reached with the fuel tank in place.

There's also a removable floorboard right under the tanks with 3 holes in it. One for the rudder stuffing box, and one each for the L and R tank drains. This floorboard has to come out because it's right over the cable connection points.