Cruisers Forum
 


Join CruisersForum Today

Reply
  This discussion is proudly sponsored by:
Please support our sponsors and let them know you heard about their products on Cruisers Forums. Advertise Here
 
Thread Tools Search this Thread Rate Thread Display Modes
Old 12-02-2019, 13:29   #1
Registered User

Join Date: May 2015
Location: Whangarei
Boat: Bavaria 38 Cruiser, 12meters, 2004
Posts: 168
Replacing Engine Gear Control Parts On A Bavaria 38

Since damaging my engine gear controls on our Bavaria 38 as described in "Pitfalls of Plastic- or Not" we have now imported the parts and effected a repair.

The steering pedestal with the single lever gear/throttle control on the B38 is a Whitlock design, now owned by Lewmar, the gear control I have seen described as an Edson design. Unfortunately the Lewmar website is scant on details but I found a source for the repair kit at Yacht Parts UK where Andy Salomonson was prompt and helpful. The kit contains a pair of everything you need to replace both the throttle cable and gear cable retention system at the gear lever end of the cables.

I learned the hard way how the repair should be attempted. Access to the engine control mechanism is through an inspection port on the starboard side of the pedestal. But it will also be necessary to remove the screws holding the fascia with chartplotter and instruments at the top of the pedestal. There should be sufficient cable to move these aside to access the morse control mechanism from the top.

At this point, go below and remove both the throttle cable and gear cable connecting points at the saddles (two bolts clamping outer cables) and at cable ends. On the saildrive the gear cable terminates with a cotter pin at the gear lever. At the throttle cable end, remove the bolt retaining the spring loaded cable end from the throttle lever. These are accessed from the starboard cabin engine compartment hatch, and by removing the mattress and plywood hatch directly aft of the engine compartment.

While your below open the hatch accessing the steering quadrant at the rear of the cabin and remove the bottom cover directly below the steering pedestal in the same cabin. When (not if) you drop any bits you will get them by access to this area. From the steering quadrant area, identify the two cables, (the gear cable had a red outer sleeve and the throttle control a brown one). Work some slack into the cables so that when unbolted, you can pull the engine control mechanism clear up through the top of the pedestal to facilitate any work on it.

Back in the cockpit, remove the rubber button in the base of the gear lever, carefully with a fine flat screwdriver. Take care not to lose the mushroom that sits under this button which gives you throttle control without engaging the gearbox. Naturally, all the parts go into a container in a safe place. Now you have access to the hollow bolt that retains the gear lever. Remove this and work the lever to remove it from the spline.

Now, using a Phillips screwdriver and correct socket for the locknuts on the inside of the pedestal, remove the four bolts holding the gear lever mechanism and pull it up with the slack you have got in the cables, clear of the pedestal where the instrument fascia was.

Now you can work easily with, and with clear view all of the components.

Remove cotter pins at cable ends, and take off the outer cable stainless steel retaining covers by inserting a fine flat screwdriver in little slots adjacent to the tabs which hold those covers on. Now the whole mechanism should be clear. (The gear mechanism also houses a neutral gear switch that may have electric cables attached, pull the clips off the switch and then it will be fully detached).

Take care, or take photos of attachment points of cables as there are options.

Remove the single Phillips screw that retains the plastic cable trough to the gear control arm, taking care not to lose the nut on the backside and replace with new part. When replacing the screw use a drop of medium loctite on the thread to ensure it stays put.

Remove engine gear control mechanism plastic cover by levering plastic tabs around the perimeter and apply marine grease to gears.

After testing smooth operation of mechanism and cables, replace everything in reverse order. For anyone that has already done this job, please feel free to add, amend or otherwise comment on the post, I may have missed some important points.
Attached Thumbnails
Click image for larger version

Name:	_LewmarControlMechL89400146.jpg
Views:	30
Size:	345.5 KB
ID:	185780   Click image for larger version

Name:	Gear Control.png
Views:	35
Size:	208.6 KB
ID:	185781  

Kerry1 is offline   Reply With Quote
Old 13-02-2019, 03:03   #2
Registered User

Join Date: Dec 2009
Location: Australia
Boat: building Roberts Mauritius 43ft
Posts: 901
Re: Replacing Engine Gear Control Parts On A Bavaria 38

There's actually an easier way to do it (takes about five minutes)

Clive
coopec43 is offline   Reply With Quote
Old 13-02-2019, 11:32   #3
Registered User

Join Date: May 2015
Location: Whangarei
Boat: Bavaria 38 Cruiser, 12meters, 2004
Posts: 168
Re: Replacing Engine Gear Control Parts On A Bavaria 38

Quote:
Originally Posted by coopec43 View Post
There's actually an easier way to do it (takes about five minutes)

Clive
I'm all ears Clive, or should I say eyes? Let's hear it....
Kerry1 is offline   Reply With Quote
Reply

Tags
bavaria, engine, gear, morse cable, parts

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
380 S2: Engine Control and Engine Locker Locks sy-barit Lagoon Catamarans 5 23-11-2014 17:37
Replacing Dual Lever Control with Single Lever Control ? Alecadi Engines and Propulsion Systems 47 03-12-2011 17:16
For Sale: Morse Single Lever Engine / Gear Control - $75 boatross Classifieds Archive 0 28-04-2011 07:58



Copyright 2002- Social Knowledge, LLC All Rights Reserved.

All times are GMT -7. The time now is 15:55.


Google+
Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
Social Knowledge Networks
Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2019, vBulletin Solutions, Inc.

ShowCase vBulletin Plugins by Drive Thru Online, Inc.