96 GTS steering cable replacement: identify tool for star-nut removal

[mokofoko]

Hello all, hopefully someone can identify the tool needed to remove the star-shaped nut (see photos) which is described as a "half-nut" in the shop manual (part# 25). Looking at the replacement cable (see post #2), it looks like this star-nut actually screws into the hull.

I'm trying to replace the steering cable. I've had it fully disassembled except for a star-shaped nut on the hull. The manual implies that no tool is needed (none listed), and should pull out in two halves. I couldn't get it to budge. Should I try and pry it out with a screwdriver? Or grip it with some pliers and pull/twist it out? It's plastic, so I imagine there's a specific tool needed.

TIA for any help.

 

[mokofoko]

Attached is a picture of the replacement steering cable (P/N 271000436) at the propulsion end. You can see that there is a half-nut that appears to sit in the inside of the hull. Clearly it's not the same type as shown in the above post--so maybe the star nut isn't on the shop part diagram?

 

[Matt Braley]

Yours is not a nut. There is a stainless ring on the hull side of it keeping the two halves together. You have to loosen the nut on the inside till it slides up the cable and then push the cable further out the back of the hull until there is room to take it apart. Then it comes out through the inside of the hull once the end is unscrewed.

 

[mokofoko]

Yours is not a nut. There is a stainless ring on the hull side of it keeping the two halves together. You have to loosen the nut on the inside till it slides up the cable and then push the cable further out the back of the hull until there is room to take it apart. Then it comes out through the inside of the hull once the end is unscrewed.

Thank you. I attempted the replacement a few years ago, had the nuts (inside hull and out) undone, and was unable to get it to move. I'll be giving it another go next week--this time I'll try using some extra force if necessary.

That ridged "nub" (if not a nut) I've photographed is just permanently affixed to the hull and has no purpose besides creating a seal?

 

[mokofoko]

I've run into the same problem as before--the hull-nut is off, and I've disconnected both ends--based on a disassembly video I found for a newer ski, this should be all there is to it:
https://youtu.be/zAsbj7yrDuw?t=3m34s

The cable simply refuses to budge. I can't push it out from inside the hull--clamping with vicegrips and and trying to turn from inside isn't working. I've tried tapping the end with a hammer from the outside--does nothing. From the video above, it looks like it can ONLY be pushed out from inside the hull, and not the other way around.

If anyone can suggest how to proceed, I'll run with it. I read somewhere that the plastic/metal ring could have sealant against the hull--could that be why it won't budge?

 

[Matt Braley]

This sounds a bit crude but I clamp a pair of vise grips on(tight) the silver solid part of the cable on the inside. Then I clamp another pair of vise grips just in front of the first pair. Then I beat it backwards(the only direction it's gonna move). On these stubborn ones you have to hit it like you DEMAND it's gonna move backwards, not like your just placing a request. It takes several blows and a single pair of those locking pliers will slide back on the cable no matter how tight I clamp it.

 

[mokofoko]

This sounds a bit crude but I clamp a pair of vise grips on(tight) the silver solid part of the cable on the inside. Then I clamp another pair of vise grips just in front of the first pair. Then I beat it backwards(the only direction it's gonna move). On these stubborn ones you have to hit it like you DEMAND it's gonna move backwards, not like your just placing a request. It takes several blows and a single pair of those locking pliers will slide back on the cable no matter how tight I clamp it.

Appreciate it, I'll give that a try if I can find another locking-type. When you're referring to "blows" and "hitting it", you do mean with something like a rubber mallet?

In the attached image, I've removed the metal washer and can apparently see the metal ring fitted inside the hull from the outside--I tried scratching it, and it's not plastic. Maybe put a screwdriver in (inside hull) and try tapping it out with a hammer? I'm not sure if it's threaded into the hull though... will that come out, or is pushing the cable out the back the only way this will work?

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[wfo speedracer]

Matt is right on point, this is exactly how I do it.

 

[mokofoko]

Thanks for the responses, I'm going to be trying this method tomorrow after picking up another locking plier.

 

[Matt Braley]

I use my trusty 3lb. hammer.

 

[1of500]

There is another way. But you will have to get a new ring and the 2 plastic half pieces. You can take a screw driver and chisel the plastic pieces until they break. Then just drive the cable back through the hole in the hull.

 

[Spimothy Leary]

I use my trusty 3lb. hammer.

amen brother.

like they say... if it doesn't come out with a hammer, your not using a big enough hammer.

I actually had the chance to use that saying with a guy in the garage the other day and he just politely smiled, until I went into the tool cart and pulled out a 3# hammer, and he said "o snap you were serious !"

 

[1of500]

this is a new one from osdparts

 

[mokofoko]

There is another way. But you will have to get a new ring and the 2 plastic half pieces. You can take a screw driver and chisel the plastic pieces until they break. Then just drive the cable back through the hole in the hull.

Hooboy, I may HAVE to resort to this method in the end. I sprayed some PB Blaster on both ends last night, got another locking plier this morning, and tried the method Matt outlined above. I used as much force as I could using a standard hammer, and maybe 50 strikes later and it STILL won't budge. I've got a sledge, but I don't even have the room to use it--there's only 12"-16" of clearance with the engine in.

I found that half-ring kit you mentioned (PN: 277000168)--only about $20 shipped. So if I do break the plastic star-ring, I can just tap that metal ring back into the hull and pull it out, easy and done?

 

[1of500]

Hooboy, I may HAVE to resort to this method in the end. I sprayed some PB Blaster on both ends last night, got another locking plier this morning, and tried the method Matt outlined above. I used as much force as I could using a standard hammer, and maybe 50 strikes later and it STILL won't budge. I've got a sledge, but I don't even have the room to use it--there's only 12"-16" of clearance with the engine in.

I found that half-ring kit you mentioned (PN: 277000168)--only about $20 shipped. So if I do break the plastic star-ring, I can just tap that metal ring back into the hull and pull it out, easy and done?

Yep that's what I had to do

 

[mokofoko]

There is another way. But you will have to get a new ring and the 2 plastic half pieces. You can take a screw driver and chisel the plastic pieces until they break. Then just drive the cable back through the hole in the hull.

I took a few more whacks with a hammer before resorting to breaking off the plastic half-rings. I dug them out, pulled off the metal ring, and pried (took a lot of effort) off the rubber stopper. Guess what? The cable STILL wouldn't move!! I put up a board against the back and took a sledgehammer to it--with some caution not to damage the hull. Still stuck! It looked like there was adhesive sealing up the cable in the hull hole. I hooked up the pliers again (inside hull) and twisted/turned, and after a great deal of effort it eventually broke free. You can see the powder/residue from what was surrounding the cable.

I'm glad I broke off the plastic half-ring as suggested, because the previous method (which likely would have worked if not for the adhesive) was getting me nowhere. I assume that there should not have been any adhesive sealing the hull, and that only the rubber stopper (from half-ring kit pictured above) is needed for that purpose? Please advise so I can do a proper reinstall.

A special thanks to all those who have commented and offered help--after several years it's finally almost done!

 

[1of500]

That white stuff looks like aluminum oxide. A small dab of silicone probably won't hurt honestly I don't remember if I put anything on the last one I did

 

[wfo speedracer]

I took a few more whacks with a hammer before resorting to breaking off the plastic half-rings. I dug them out, pulled off the metal ring, and pried (took a lot of effort) off the rubber stopper. Guess what? The cable STILL wouldn't move!! I put up a board against the back and took a sledgehammer to it--with some caution not to damage the hull. Still stuck! It looked like there was adhesive sealing up the cable in the hull hole. I hooked up the pliers again (inside hull) and twisted/turned, and after a great deal of effort it eventually broke free. You can see the powder/residue from what was surrounding the cable.

I'm glad I broke off the plastic half-ring as suggested, because the previous method (which likely would have worked if not for the adhesive) was getting me nowhere. I assume that there should not have been any adhesive sealing the hull, and that only the rubber stopper (from half-ring kit pictured above) is needed for that purpose? Please advise so I can do a proper reinstall.

A special thanks to all those who have commented and offered help--after several years it's finally almost done!

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I have spent hours before removing pumps from salt water skis , it sucks when what should be a simple 10 minute process turns into a full sale assualt with tools of mass destruction , I know your pain.