Seastar Solutions HO61 Series User manual

INSTALLATION INSTRUCTIONS
AND OWNER'S MANUAL
Before you do it your way,
please try it our way
www.seastarsolutions.com
71
SEVENTY ONE
ISO 9001
Kicker Cable Tiebar
Part # HO61xx

SeaStar Hydraulic Steering
Don't compromise performance... use genuine
SeaStar parts only!
• SeaStar Helms • SeaStar Cylinders
• SeaStar Hoses • SeaStar Fluid
• SeaStar Cables
Substituting non SeaStar parts in any part of the SeaStar hydraulic
steering system, may seriously compromise system performance.
Notice to Boat Manufacturer
or Installer
Cleaning fluids containing ammonia, acids or any other corrosive
ingredients MUST NOT be used for cleaning any part of this
Hydraulic Steering System. Failure to comply will cause serious
damage to the steering system, resulting in possible loss of
steering, causing property damage, personal injury and/or death.
NOTICE
Information which
is important to
proper installation or
maintenance, but is
not hazard-related.
Immediate hazards
which WILL result
in severe personal
injury or death.
DANGER
Hazards or unsafe
practices which
COULD result in
severe personal
injury or death.
WARNING
Hazards or unsafe
practices which
COULD result in
minor injury or
product or property
damage.
CAUTION
WARNING
Throughout this publication, Warnings and Cautions (accompanied by
the International Hazard Symbol )are used to alert the manufacturer
or installer to special instructions concerning a particular service or
operation that may be hazardous if performed incorrectly or carelessly.
Observe Them Carefully!
These “safety alerts” alone, cannot eliminate the hazards that they
signal. Strict compliance to these special instructions when performing
the installation and maintenance plus “common sense” operation
are major accident prevention measures.
Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS is referred
to as SeaStar Solutions throughout this publication.
NOTICE

1
Kicker Cable Tiebar
The SeaStar Kicker Cable Tiebar has been designed for normal
pleasure use where standard rigging arrangements are used.
Before proceeding with the installation of this product, read and
understand ALL instructions thoroughly. SeaStar Solutions cannot
accept responsibility for installations where instructions have not
been followed, where substitute parts have been used, where
modifications have been made to our products. When properly
installed, this SeaStar Kicker Cable Tiebar will connect to kicker
engines with ABYC standard tilt tubes, using the engine
manufacturer's drag link arms.
INTRODUCTION
Index
Introduction .............................................................................. 1
Before Operating Your Boat........................................................ 2
Product Overview .......................................................................3
Installation ................................................................................4
Quick Connection Instructions...................................................11
Routine Maintenance............................................................... 12
Troubleshooting Guide ............................................................. 13
Replacement Parts.................................................................. 13
Statement of Limited Warranty................................................. 14
All linkages for the kicker motor (tilt tube, drag link, etc.) are to be
obtained by the installer, builder and/or owner and are required to
complete the installation of the SeaStar Kicker Cable Tiebar.
NOTICE
The Kicker Cable Tiebar Kit is designed for use with new, or
existing SeaStar Steering Cylinders, part numbers HC5345 and
HC5358 and is to be used on kicker engines up to 20HP MAX.
This kit is NOT to be used on kicker engines that exceed 20HP.
CAUTION

2SeaStar Hydraulic Steering
BEFORE OPERATING YOUR
BOAT FOR THE FIRST TIME
Ensure that the following check list is carried out.
1. Perform system pressure test by turning helm all the way hard over
and then forcing the helm another 1/4 – 1/2 turn. This must be
completed in both directions. This will pressurize the system. Any
weakness (faulty hose, leaks, etc.) will be seen at this time
2.
Confirm that there is NO interference between the steering cylinder(s),
or the Kicker Cable Tiebar with the transom, splashwell or any
other object by performing the following steps;
• With engine fully tilted, turn steering wheel from hard over to hard
over, confirming that there is no interference. If using a hydraulic
jack plate this also must be performed at the top and bottom
position of the jack plate. (If interference is present, it MUST be
eliminated with trim limiting switches and/or jack plate lift
restrictors. Contact jack plate manufacturer for advice if required).
• Confirm that the steering cylinder can be fully stroked in both
directions, as well as full tilt/trim without stretching and/or
kinking the hydraulic hoses, or, Kicker Cable Tiebar.
• Confirm that the hydraulic hoses and/or Kicker Cable Tiebar
are not subject to chafing or rubbing.
NOTE: Stretched or kinked hose/cables will fail over a period
of time.
Prior to 'every use', please refer to page 12 for important
safety checks.
Failure to comply with the above and ANY other warning, notice or
caution may lead to loss of steering control. Loss of steering control
may result in unpredictable boat behaviour leading to ejection from
boat, property damage and/or personal injury or death.
To maximize component life and performance—when the boat is
being transported on a trailer, ensure that one of the following
steps is performed.
• Turn steering wheel hard over so that the cable exiting the 'kicker
motor' is fully EXTENDED" (see figure 2, page 3 for details).
• Center the engine and use steering-stops to prevent the engine
from falling over.
• Disconnect the Kicker Cable Tiebar from the main steering
cylinder (see page 11 for details).
WARNING
WARNING
NOTICE

1
18
19
4
7
2
3
11
8
12
14
15
13
9
1
17
17
10
16 16
5
6
6
3
Kicker Cable Tiebar
ITEM DESCRIPTION QTY
1 3/8" Nut, Nyloc®2
2 3/8" HHCS Bolt 1
3 Washer 3/8" 1
4 Rod End Sleeve 1
5 Long Nut Assembly 1
6 Washer 2
7 Link Arm Assembly 1
8 FHSCS 5/16" Bolt 1
9 5/16" Nut 1
10 HHCS 5/16" Bolt 1
ITEM DESCRIPTION QTY
11 Drive Bracket 1
12 Spacer 1
13 Support Rod 1
14 Cable 1
15 Cap Seal 1
16 Connecting Clip 2
17 Brass Bushing 2
18 3/8" Nut 1
19 Rod End 1
Before starting with this installation, ensure you have the following
components, all of which will be required to complete the installation.
PRODUCT OVERVIEW
Figure 2. Additional parts required to complete installation.
Figure 1. Items included in your SeaStar
Kicker Cable Tiebar kit.
GOOD QUALITY
MARINE GREASE
DRAG LINK ARM PROVIDED
BY THE ENGINE MANUFACTURER,
AND IS REQUIRED FOR THIS
INSTALLATION
KICKER CABLE FULLY EXTENDED
WHEN TRANSPORTING OR
STORING BOAT
NOTICE

4SeaStar Hydraulic Steering
INSTALLATION
Figure 3.
STEP 1:
Existing Cylinder Installation
– Parts Removal
• Note location of ALL spacers on your current set up (refer to Figure 3).
• Remove cylinder support brackets
• After noting spacer location, remove spacers and support rod
completely. At this time you will be left with the cylinder mounting
plate attached to the steering arm only. (See Figure 4.)
STEP 2:
New Cylinder Installation –
Tiller Bolt Mounting
• Mount cylinder to engine steering arm as directed in Book #1.1
included with your steering cylinder. DO NOT INSTALL support rod,
or support brackets. (See Figure 4.)
Figure 4.
WARNING
DO NOT discard any of the
spacers, support brackets,
washers or mounting nuts as
they will be required to complete
the installation.

Kicker Cable Tiebar 5
HYDRAULIC STEERING
KICKER CABLE TIEBAR
STEP 3:
Sub-Assembly
(Rod/Bracket/Cable)
• Slide support bracket over support rod
• Hand tighten cable nut to the support rod
VIEW REVERSED
FOR CLARITY
Figure 5.
STEP 4:
Spacer Installation
• Install spacers as previously noted (existing cylinder), or, as per
your engine application as noted in Book #1.1 (new cylinder
installation).
• Using good quality marine grease, lubricate the support rod in the
area shown in Figure 6.
1.1
GOOD QUALITY
MARINE GREASE
Figure 6.

6SeaStar Hydraulic Steering
HYDRAULIC STEERING
KICKER CABLE TIEBAR
STEP 5:
Sub-Assembly Installation
(Rod/Bracket/Cable)
• Slide greased sub-assembly through main engine steering/tilt tube.
Figure 7.
STEP 6:
Spacers/Adjusting Nut
Installation
• Install spacers/adjusting nut as noted, or, as per Book #1.1.
1.1
Figure 8.

Kicker Cable Tiebar 7
HYDRAULIC STEERING
KICKER CABLE TIEBAR
Figure 9.
STEP 7:
Support Bracket/Sub-
Assembly Final Install
• Using a good quality marine grease, lubricate the telescoping,
5/16" cable rod.
• Using a 7/8" open ended wrench, and a 7/8" deep socket, tighten
support bracket nuts and torque to 50 ft-lb (see figure 9 for
placement of wrench and socket).
NOTE: cable may need to be retracted to allow the socket to reach
the threads of the nut.
• Using a 5/8" socket, tighten and torque 5/8" cylinder shaft nuts
to 33 ft-lb.
7/8"
50 ft-lb
5/8"
5/8"
7/8"
33 ft-lb
33 ft-lb
GOOD QUALITY
MARINE GREASE
CAUTION
Failure to grease cable rod may
result in premature wear, leading
to irreparable damage.

8SeaStar Hydraulic Steering
HYDRAULIC STEERING
KICKER CABLE TIEBAR
Figure 10.
STEP 8:
Drive Plate Installation
• Remove bolt and stem washer as shown in Figure 10.
• Install drive bracket onto cylinder ear as shown in Figure 10.
• Tighten and torque 1/2" bolts to 11 ft-lb.
1/2"
11 ft-lb
1/2"
11 ft-lb
REMOVE
Figure 11.
STEP 9:
Link Arm Installation
• Install drag link onto drive plate ensuring that the brass bushings
are installed on top of and below drag link, tighten and torque to
22 ft-lb (see Figure 11).
9/16"
22 ft-lb

Kicker Cable Tiebar 9
HYDRAULIC STEERING
KICKER CABLE TIEBAR
Figure 12.
STEP 10:
Link Arm Installation and
Inspection
• Install Rod End Sleeve onto 5/16" cable rod leaving 1–2 threads
visible (DO NOT tighten completely). See Figure 12a.
• Install remaining components as per Figure 12.
• Physically inspect the two shafts (kicker cable shaft and link arm)
confirming that they are Parallel with each other (not binding,
twisting or any other mechanical interference). See Figure 12b.
If the two shafts are not parallel, adjust the 3/8" nuts on the drag
link assembly until the two shafts are parallel with each other.
• Physically inspect to ensure that 1–2 threads of the 5/16" cable
rod showing.
Failure to ensure 1–2 threads are showing may lead to binding of
the Kicker Cable Tiebar.
9/16"
22 ft-lb
MUST LEAVE
1–2 THREADS
SHOWING
ROD END
SLEEVE
KICKER CABLE SHAFT AND DRAG LINK
MUST BE PARALLEL AND IN LINE WITH
EACH OTHER
1
2
ADJUTS NUTS (ITEMS 1 AND 2)
TO ENSURE THE TWO SHAFTS
ARE
PARALLEL THEN TIGHTEN
AND TORQUE
CAUTION
STEP 11:
Final Connections
• Grease and install Kicker Cable through the kicker engine steering/
tilt tube.
• Ensure the cap seal is installed to prevent contamination in the
steering/tilt tube area. (See Figure 13 on page 10.)
• Install kicker engine drag link.
NOTE: SeaStar Solutions does NOT provide the drag link required for
the final connection, contact your engine manufacturer for this item.
NOTICE
Figure 12a.
Figure 12b.

10 SeaStar Hydraulic Steering
HYDRAULIC STEERING
KICKER CABLE TIEBAR
Figure 13. Cap Seal Installation.
Figure 14.
GOOD QUALITY
MARINE GREASE
HAND
TIGHTEN
STEP 12:
System Check
• Ensure the main steering cylinder (HC5345 or HC5358) can hit
hard over in BOTH directions.
• If steering cylinder HITS HARDOVER, in BOTH DIRECTIONS,
continue with points i. and ii. shown below.
If steering cylinder DOES NOT hit hard over in BOTH Directions,
consult with Trouble Shooting details shown on page 12
i Turn steering wheel from hard over to hard over. While turning,
visually watch for any signs of binding or interference with any
other object. If interference occurs it MUST be prevented prior
to use of the vessel.
ii Complete the above noted step in ALL trim/tilt ranges and
throughout the steering arc of the engine.
CAUTION
If the main steering cylinder is
NOT fully stroking out, in BOTH
directions, stop installation and
check for mechanical interference,
contact SeaStar Solutions
Technical Support.
CAUTION
If kicker engine is mounted on an
adjustable jack plate or bracket
you MUST inspect at ALL points
in UP/DOWN range.

11
Kicker Cable Tiebar
The SeaStar Kicker Cable Tiebar is designed to allow a quick
connection/disconnection that can assist in the following areas;
• If kicker engine is bound/seized, quick disconnect will allow the
continued use of the main steering gear.
• Troubleshooting.
• When transporting boat on a trailer.
Before, during and after making a quick connection, ensure that you
do NOT lose any parts. The parts being removed will be left loose
and may fall overboard, thus, not allowing the re-connection if required.
• Line up hole in rod end with hole in link arm (both sides)
• Push connector clip straight through
• Ensure the connector is fully installed prior to use.
• Pull connector straight out.
• Store in an area where the connector will not be lost or forgotten
QUICK CONNECTION
INSTRUCTIONS
NOTICE
Connecting
Disconnecting
CONNECTING CLIP
LINK ARM ASSEMBLY
CONNECTING CLIP
Figure 15.

12 SeaStar Hydraulic Steering
Following the routine maintenance schedules below in the time
frame noted will ensure years of great service from your SeaStar
Kicker Cable Tiebar, as well as keep you and your passengers safe
from the dangers that are present while on the water.
The following schedules cover the SeaStar Kicker Cable Tiebar System
ONLY. You are required to inspect your 'main steering system' as per
your routine maintenance included with that system.
Prior to every use
• Check fluid level in helm pump
• Check for loose, worn or damaged components (helm pump,
steering cylinder(s), tiebars etc.)
• Turn steering wheel hard over to hard over to ensure response
at engine
• Turn steering wheel hard over to hard over to ensure there is
no binding or interference
First 20 hours of use
• Turn steering wheel hard over to hard over to ensure there is no
binding or interference.
• Check torque of ALL fasteners
• Check for mechanical play or slop
Every 100 hours
• ALL Points noted in #1 and #2 shown above
• Remove cable from kicker engine.
– Clean engine steering/tilt tube thoroughly
– Grease engine steering/tilt tube thoroughly
– Grease kicker cable thoroughly
• Inspect Cable Rod for any signs of
– Wear
– Scoring
REPLACE AS NEEDED.
• Grease telescoping cable end.
ROUTINE MAINTENANCE
NOTICE
1. Owner
2. Qualified Marine
Mechanic
3. Qualified Marine
Mechanic

13
Kicker Cable Tiebar
TROUBLESHOOTING GUIDE
REPLACEMENT PARTS
FAULT CAUSE SOLUTION
1. Steering is stiff • Mechanical interference.
• Cable rod and link arm are
out of alignment.
• Corrosion or debris inside the
telescoping end or cable rod.
• Normal.
• Disconnect Kicker Cable Tiebar from main
steering cylinder. If problem persists,
consult steering cylinder installation. If
problem does not persist, check ALL
areas of the Kicker Cable Installation.
• Visually inspect and correct as
required.
• Clean area and grease, or replace
cable assembly.
• It can be expected that a slight effort
increase will be noticed when using the
SeaStar Kicker Cable Tiebar. If effort is
too great when attached, consult with
all above points to ensure installation
is true and correct.
2. Steering wheel is locked
(wheel cannot be moved)
• 5/16” cable rod is binding
or bent).
• Check for binding, or bent 5/16” cable
rod. If bent, disconnect link arms, replace
cable and any other damaged part.
3. Steering remains locked
after disconnecting
link arm
• Main steering hardware
fault.
• Refer to Book #1.1 trouble shooting, or,
contact SeaStar Solutions Technical
Support.
PORT MOUNT
DRIVE PLATE KIT
PART# HP6156
LINK ARM ASSEMBLY
KIT PART# HP6157
KICKER CABLE KIT
PART# HP62xx
KIT# HP6158
SUPPORT ROD
AND NUT
HP62XX
JULIAN
DATE CODE
LENGTH OF
CABLE IN
INCHES
Figure 16.
Any damaged cable and/or kicker cable tiebar parts CANNOT be
repaired and MUST be replaced with a new part.
CAUTION

14 SeaStar Hydraulic Steering
Statement of Limited Warranty
Return Goods Procedure
We warrant to the original retail purchaser that Marine Canada
Acquisition Inc. DBA SEASTAR SOLUTIONS (herein forward referred
to as SeaStar Solutions) products have been manufactured free from
defects in materials and workmanship. This warranty is effective for
two years from date of purchase, excepting that where SeaStar
Solutions products are used commercially or in any rental or income
producing activity, then this warranty is limited to one year from the
date of purchase.
We will provide replacement product without charge, for any SeaStar
Solutions product meeting this warranty, which is returned (freight
prepaid) within the warranty period to the dealer from whom such
product were purchased, or to us at the appropriate address. In such
a case SeaStar Solutions products found to be defective and covered
by this warranty, will be replaced at SeaStar Solutions’ option, and
returned to the customer.
The above quoted statement is an extract from the complete SeaStar
Solutions products warranty statement. A complete warranty policy is
available in our SeaStar Solutions products catalogue.
Prior to returning product to SeaStar Solutions under warranty, please
obtain a Return Goods Authorization number (claim number).
Be sure to label the goods with:
a) the name and address of the sender, and
b) the return goods authorization number (claim number)
Please address the returned goods as follows:
From U.S.A.
RGA # ?
SeaStar Solutions
c/o UPS-SCS
19308 70th Ave S.
Kent, WA 98032
From Canada
RGA # ?
SeaStar Solutions
3831 No.6 Road
Richmond, B.C.
Canada V6V 1P6
Technical Support Phone: [phone]
email: [email protected]
Hours: Monday to Friday 05:00 – 15:30 PST
Web: www.seastarsolutions.com

15
Kicker Cable Tiebar
This page left intentionally blank.

16 SeaStar Hydraulic Steering
This page left intentionally blank.

FORM NO. 101202 REV. K
© 2010 MARINE CANADA ACQUISITION INC.
DBA SEASTAR SOLUTIONS
PRINTED IN CANADA 04/18
SEASTAR SOLUTIONS
3831 NO.6 ROAD
RICHMOND, B.C.
CANADA V6V 1P6
FAX [phone]
www.seastarsolutions.com
ISO 10592
Please scan
this QR code
and watch our
latest Boating
Safety video.