Dometic Marine Steering Selection Guide

MARINE STEERING SELECTION GUIDE

BayStar/SeaStar/Optimus, Marine Steering Selection Guide — 2023 EN

About this selection guide

All information, illustrations and specifications in this selection guide are based on the latest information available at the time of publishing. The illustrations used in this document are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice.

All Rights Reserved. This document, subject matter and all information herein is the sole, exclusive and confidential property of Dometic and shall not be disclosed, copied, reproduced or used in whole or in part for any purpose other than as specifically authorized in writing by Dometic.

is a registered trademark of the American Boat & Yacht Council (http://www.abycinc.org) BayStar, SeaStar, SeaStar PRO, Optimus, Optimus 360, and Capilano are all trademarks of Dometic. Loctite is a trademark of Henkel Corporation.

Table of Contents 1 Important Safety Information ............................................... 1-1 1.1 Explanation of symbols..................................................... 1-1 1.2 Safe operation................................................................ 1-2 1.3 Safety considerations for installers..................................... 1-3 2 Dometic Marine Steering ..................................................... 2-1 2.1 Hydraulic steering overview ............................................ 2-1 2.2 Electric/electronic steering overview ................................ 2-7 3 Hydraulic Outboard Steering .............................................. 3-1 3.1 BayStar front mount series................................................ 3-1 3.2 SeaStar front mount series................................................ 3-7 3.3 SeaStar PRO series........................................................ 3-16 3.4 SeaStar commercial grade outboard cylinder................... 3-19 3.5 SeaStar Tournament series............................................. 3-20 3.6 SeaStar catamaran series............................................... 3-25 3.7 SeaStar side mount series .............................................. 3-26 3.8 SeaStar splashwell mount series...................................... 3-29 3.9 SeaStar kicker cable tie bar........................................... 3-32 4 Hydraulic Inboard Steering ................................................. 4-1 4.1 BayStar inboard series..................................................... 4-1 4.2 SeaStar inboard series.................................................... 4-3 4.3 SeaStar catamaran inboard series.................................... 4-7 5 Hydraulic Sterndrive Steering ............................................. 5-1 5.1 SeaStar sterndrive series.................................................. 5-1 6 Hydraulic Power Assist and Autopilot ................................. 6-1 6.1 SeaStar power assist steering........................................... 6-1 6.2 SeaStar power assist autopilot......................................... 6-5 6.3 SeaStar autopilot pump.................................................. 6-7 6.4 SeaStar SmartStick........................................................ 6-10 7 Outboard Engine Position Control ...................................... 7-1 7.1 SeaStar Gen2 jackplates ................................................. 7-1 7.2 SeaStar Mega jackplates................................................. 7-6 . 7.3 Interact Drive ................................................................ 7- 11 8 Hydraulic Helms and Technical Information ........................ 8-1 8.1 SeaStar helms................................................................ 8-1 8.2 Tools including Power Purge Jr........................................ 8-10 8.3 Technical info/specifications.......................................... 8-13 8.4 Torque rudder data....................................................... 8-19 9 SeaStar Hydraulic Fluid ........................................................ 9-1

iii

10 Hose and Fittings .............................................................. 10-1 10.1 SeaStar hose/tube ....................................................... 10-1 10.2 SeaStar hose................................................................ 10-2 10.3 Additional stations or autopilot integration....................... 10-9 10.4 SeaStar inboard/sterndrive tubing................................. 10-10 10.5 SeaStar fittings and fitting kits ....................................... 10-12 10.6 Additional SeaStar steering station or autopilot kit ........... 10-14 11 Electric Outboard Steering ................................................. 11-1 11.1 Optimus EPS — electro/hydraulic .................................... 11-1 11.2 Optimus EPS — electric actuator .................................... 11-12 11.3 Optimus 360 — joystick control..................................... 11-20 11.4 SeaStation and SeaWays .............................................. 11-22 12 Electronic Inboard and Sterndrive Steering ...................... 12-1 12.1 3000 series .................................................................. 12-1 12.2 4000 series ................................................................. 12-5 12.3 5000 series................................................................. 12-8 12.4 5000 series — class certified......................................... 12-12 12.5 Optimus sterndrive series ............................................. 12-16 13 Trim Tabs ............................................................................ 13-1 13.1 Overview ..................................................................... 13-1 13.2 Tab and actuator installation .......................................... 13-2 13.3 Standard series ............................................................ 13-4 13.4 Adaptive/Optimus adaptive series ................................ 13-10 14 Electronic Controls ............................................................ 14-1 14.1 i7X00 series ................................................................. 14-1 15 Contact and Warranty Information .................................... 15-1 15.1 SeaStar technical service ................................................ 15-1 15.2 Locations and addresses ................................................ 15-1. 15.3 Return goods .............................................................. 15-3 15.4 Technical support ........................................................ 15-3 15.5 2-Year limited warranty .................................................. 15-4

1 Important Safety Information

Safe operation of Dometic marine steering systems depend on proper installation and maintenance of the system(s), as well as the operator’s safe judgment, boating knowledge, and expertise. The installer and operator must read and understand the safety requirements in this section along with any other manual(s) supplied before installing or using these steering systems. If you have any questions about safe installation or operation of these systems, contact Dometic Marine. Please don’t guess.

1.1 Explanation of symbols

The symbols below are used throughout this publication to alert you to potential hazards involved with the operation and installation of this product. Observe these warnings and notices carefully. The safety alerts alone cannot eliminate hazards; strict compliance with any special instructions during installation, operation, and maintenance, along with common sense operation, are important measures to prevent hazardous situations. DANGER! Safety instruction: Indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING! Safety instruction: Indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION! Safety instruction: Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE! Indicates a situation that, if not avoided, can result in property damage.

NOTE Supplementary information for operating the product.

1-1

1.2 Safe operation

General • Read and understand this manual and any other documentation provided with your steering system. • Know and obey all applicable federal, state, and municipal laws and regulations that govern boating in your area. Dometic recommends all boat operators take a boating safety course. • Never operate a boat while under the influence of drugs or alcohol. Before every use • Perform the pre-trip inspection(s) described in your operator’s manual. WARNING! Do not operate the boat if any component is not in proper working order. It may result in a loss of steering control, which could lead to a collision and/or ejection from the boat, causing property damage, personal injury, and/or death. During use • Wear a Coast Guard-approved personal flotation device (PFD). • Attach the engine shut-off lanyard to your PFD. • Do not allow anyone not familiar with the controls (steering, shift/throttle etc.) to operate the boat. After use • Rinse the steering cylinders thoroughly, using only fresh, clean water. • Do not use acetone, or cleaners containing ammonia, acids, or any other corrosive ingredients, on any steering components. • Some products formulated for cleaning fiberglass hulls are known to aggressively corrode stainless steel shafts. If using a hull cleaner, avoid overspray on the cylinders. Rinse off any overspray immediately with fresh, clean water. WARNING! The safety information below is intended to inform you of hazards that may be present when operating a boat equipped with Dometic controls. Read and understand this information.

1-2

1.3 Safety considerations for installers

Before installation • Read this selection guide and understand any other manual(s) supplied with the system. • Ensure you have all the required components on hand before you start. • Do not use a wheel-mounted trim switch with coiled cord. The cord can wrap around the steering wheel shaft and inhibit steering. During installation • Install components as instructed in the installation manual. Some component parts and kits may contain additional installation instructions – refer also to those instructions. • Do not substitute any component of the system without written authorization from Dometic. Dometic parts are rigorously engineered and tested to ensure system integrity. Substitution of components may compromise safety, performance, and reliability. • All steering components, inc. cylinder must be compatible with, and rated for, the engine(s) installed on the boat. • If an instruction is unclear, contradictory, or you are otherwise unsure how to proceed, do not guess. Contact Dometic Marine technical support at Tel: 1-800-730-4082 or email: marinetech@dometic.com. After installation • Perform the system inspection checks described in the installation manual. • Correct any interference issues before handing the boat to the owner. WARNING! Failure to comply with Dometic instructions may result in loss of steering control, which could lead to a collision and/or ejection from the boat, causing property damage, personal injury, and/or death. CAUTION! We recommend that the installation of any Dometic steering component(s) is performed by a certified marine technician.

1-3

Notes

1-4

2 Dometic Marine Steering 2.1 Hydraulic steering overview

Our manual hydraulic steering systems are simple and efficient. The basic system consists of four main components; 1) the helm pump, 2) the cylinder, 3) the hose or tubing required to connect the cylinder to the helm pump, and 4) genuine SeaStar steering fluid. These basic components are necessary in all applications. However, as the system variables increase (i.e.: multiple engines, rudders, steering stations, power assist and autopilots), additional components may be required.

Figure 2-1.

1. The helm unit The helm pump is an axial piston pump specifically designed for manual steering, it has a built-in lock valve to prevent the steering load from feeding back to the driver. The lock valve will not allow the rudder or drive unit to move until you move it with the steering wheel. The lock valve section of the helm also includes a relief valve. This relief valve provides over-pressure protection for mechanical components, hydraulic hoses and fittings. 2. The cylinder The most important differences between the variety of steering systems available is the cylinder selection. Both BayStar and SeaStar systems have a cylinder for most steering applications. 3. Hoses and tubes — important Required to provide a path for the fluid to flow under pressure from the helm pump to the cylinder. SeaStar hoses are a custom multi-layered composite design, engineered specifically for our systems. They are designed to exceed SAE and ABYC specifications and provide precise steering control not achievable with hydraulic industry standard hoses. Due to performance and safety concerns, SeaStar recommends that only SeaStar or SeaStar PRO hoses be used in SeaStar steering systems.

2-1

4. Steering fluid — important Due to the precision operation of our steering systems, Dometic recommends use of SeaStar steering fluid only in our hydraulic steering systems. SeaStar steering systems have been engineered and validated using our proprietary SeaStar hydraulic steering fluid. SeaStar steering fluid is blended with a special additive package that contains anti-foaming and anti-rust agents, anti-oxidants, viscosity stabilizers, corrosion inhibitors, wear additives as well as water emulsification adders that were formulated not to harm or degrade our components. It is highly recommended that SeaStar steering fluid be used to ensure optimum system performance and safety. The system: How it works The system is a two-line system. This makes operation very simple. 1. The steering wheel, which is attached to the helm pump, is rotated in the desired direction (ie: a turn to starboard or clockwise rotation). 2. Steering fluid is pumped out the corresponding port from the rear of the helm into the starboard line and then into the cylinder.

OUTBOARD SYSTEM

INBOARD SYSTEM

HELM STATION

WHEEL ROTATION

DIRECTION OF OIL FLOW

CYLINDER SHAFT MOVEMENT

CYLINDER BARREL MOVEMENT

TILLER ARM

STEERING CYLINDER

ENGINE

RUDDER

Figure 2-2.

2-2

3. This causes the cylinder rod, which is attached to the vessels rudder or drive unit, to move (ie: rod moves to port) thus causing the vessel to alter course. 4. Fluid displaced from the opposite end (ie: the port end) of the cylinder flows (ie: into the port line) back to the helm pump. 5. For steering in the opposite direction, simply turn the helm the other way. 6 . When no course corrections are required, the integral No-Feed-Back design holds the rudder or drive unit stationary.

2.1.1 SeaStar/BayStar hydraulic steering

The BayStar Hydraulic Steering System is designed to add safety, reliability and comfort to single outboard powered boats to a maximum 150HP. The SeaStar hydraulic steering system is designed to provide that extra margin of muscle when needed (up to a maximum of 350HP). The SeaStar system conveniently handles outboards, sterndrive and inboard boats. System selection, installation and service is substantially simplified with just four major components — helm, cylinder, hose/tube and genuine SeaStar steering fluid. SeaStar has a comprehensive range of cylinders to conveniently handle the variety of outboard, sterndrive and inboard steering applications. These are suitable for both pleasure and commercial applications. Extra steering stations and/or autopilots are easily added. SeaStar hydraulic steering is a total commitment to quality, performance and simplicity. BayStar and SeaStar, the hydraulic steering systems are; Easy to install… • Only four essential components; helm, cylinder, tube/hose and SeaStar steering fluid

• Compact and attractive helm design • Variety of helm mounting configurations • Simple tube/hose fitting connections • Clear, complete installation instructions Easy to fill and purge… • Engineered bleed fittings on the cylinders • A helm and lock valve design that enhances air removal • A no-mess filler device • A filling and purging time of normally less than 30 minutes • Easy to check for proper installation • Easy purging check via filler device • No searching for difficult-to-find air leaks Easy to turn… • Anti-friction piston points Designed to provide many years of service… • Precision built • No corrosive materials exposed to marine environment • Field replaceable helm and cylinder shaft seals • A no-hassle warranty — 2 years for pleasure use

— 1 year for commercial use (SeaStar)

BayStar and SeaStar... Simply the best!

2-3

Selecting the system The objective is to match the steering system to the requirements of the vessel. This depends on four things; 1. hull type (ie: planing or displacement), 2. type of propulsion system in the vessel (ie: inboard, outboard, sterndrive, etc.), 3. the number of engines or rudders, and 4. the total power of the engines (ie: Horsepower). Once the system and cylinder has been selected, the size of the helm pump must be determined. SeaStar systems also allow the following options to be specified; 1. the number of steering stations,

2. helm configuration (ie: standard or tilt helm), 3. additional features such as autopilots, and 4. power assist.

WARNING! Recommendations made in this selection guide are based on our experience with typical installations, applications and usage. Do not use products in applications that they were not intended for. It is the boat manufacturer and the installer’s responsibility to ensure the components selected are sufficiently validated on the boat application for safe and acceptable operation. Less wheel turns lock to lock results in more steering effort. Conversely, more wheel turns lock to lock results in less steering effort. However, additional factors that can influence steering effort are; 1. vessel speed, 2. rudder size, 3. unusual propeller selections, 4. hull type (ie: displacement, planing, etc.), 5. improperly aligned counter balance skeg, torque tab 6. trim/position, and 7. propeller height relative to water. NOTE: Steering response versus steering effort Steering wheel effort is directly proportional to the number of wheel turns lock to lock. The number of wheel turns lock to lock is dependent on three things; 1. the volume of the cylinder, 2. the displacement of the helm pump, 3. the allowable movement of the rudder or drive unit.

2-4

NOTE: www.SeaStarBOM.com The www.SeaStarBOM.com utility can be used to help select a system.

Typical boat designs that use BayStar/SeaStar steering systems 1. Inflatable Boats manufactured from waterproofed fabric which are inflated with air in order to achieve their shape. The bottom of the hull may be made of fabric and/or fiberglass. They typically have narrow transoms. Boats may be single and/or dual engine, and is generally slower than 40 mph. 2. Cruiser Cuddy/express/bridge cruiser primarily designed for cruising. It has overnight accommodations. Typically rigged with two steering stations. Boats may be single and/or dual engine, and is generally slower than 45 mph. 3. Runabout Intended for day boating. Typically a single engine, but, can be a dual engine boat. This includes tournament Ski boats and performance outboards. Boat speeds are generally slower than 60 mph. 4. Fish “N” Ski Single engine boat designed for day fishing or skiing in protected waters. Boats speeds are generally slower than 40 mph. 5. Fish Boat Boat primarily designed and equipped for offshore fishing. May be rigged with a second station and may have single and/or dual outboards. Speeds are generally slower than 50 mph. 6. Center Console Boats with the control station located on the center line of the boat. Designed specifically for fishing, may be single and/or dual engine(s). Boat speeds are generally slower than 65 mph. 7. Bass Boat Single engine designed specifically for fishing in protected waters and has a flat bottomed hull. Generally performance orientated and speeds in excess of 60 mph. 8. Pontoon Twin or triple hull boats. Single and dual engine capable. Generally speeds to not exceed 60 mph. Note: High steering loads when equipped with engines over 115 HP. 9. Catamaran Twin hull vessels. Typically twin engine boats where the use of a mechanical tie bar is not possible. Speeds to not exceed 60 mph. 10. Commercial/Work/Rescue/Race Any of the above noted boats but used in a more severe environment. Take special care when selecting a system for these boats to ensure that you have both comfortable and safe steering.

2-5

2.1.2 Optimum performance chart for outboard engines How can we help? When researching a hydraulic steering system for your boat there are several systems to choose from. The chart noted below will assist with selecting the correct system for your outboard powered boat. It is recommended that boats with high steering loads (pontoons, bass boats and larger HP four stroke engines) use the SeaStar/SeaStar PRO steering. Doing so will reduce the steering effort due to the fact that the SeaStar steering systems provide more output power, resulting in lower steering effort. If you are unsure of what system to choose, consult with your marine dealer, or Dometic technical support.

BAYSTAR

OPTIMUM PERFORMANCE

MAXIMUM RATING**

SEASTAR

OPTIMUM PERFORMANCE

MAXIMUM RATING

SEASTAR PRO*

OPTIMUM PERFORMANCE

MAXIMUM RATING

SEASTAR POWER ASSIST/ TOURNAMENT SERIES

OPTIMUM PERFORMANCE

MAXIMUM RATING

Figure 2-3.

Chart based on ‘optimum comfort’ * Ideal for single engine, high speed boats, such as bass boats. ** High performance 150HP engines, such as Mercury Optimax should use SeaStar.

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2.2 Electric/electronic steering overview

The technology behind the system The incredible feel you get when you’re behind the wheel of a boat equipped with Optimus EPS is the result of an innovative array of technology and engineering. Each component has been designed to complement the other, resulting in a seamless experience of steering control in virtually every situation on the water. The high level of engineering also extends to the reliability of the system, with quality materials, careful manufacturing and redundant systems, all to stand up to the rigors of life on the water.

2.2.1

2.2.2

System components Electronic helm — key benefits • Adjustable steering for maximum comfort • Driver comfort, control and performance as speed varies • Provides redundancy for reliable operation • No hydraulic oil at helm • Adjustable position of steering wheel for personal comfort

SmartCylinder — key benefits • System reliability and operation

• No additional RFU required for autopilot system • Fits most outboard and inboard applications Hydraulic Steering Pump — key benefits • Significantly reduces overall power consumption • No oil cooler required for hydraulic fluid • Allows user to purge system with existing components • Meets Coast Guard requirement for ignition protection • A separate autopilot pump is not required • Limp home mode on remaining functional engine(s) Pump Control Module (PCM) — key benefits • Ensures system reliability and operation • Ensures reliable cable protection from vibration • No additional autopilot pump and RFU • Ensures system operates at peak performance

CANtrak Display — key benefits • Interface to setup steering and joystick system • Installer adjustable steering settings • Real-time system status rudder direction and RPM • No additional device or computer required to get the system functional • Interface to activate both SeaStation and SeaWays

2-7

NOTE: www.OptimusBOM.com The www.OptimusBOM.com utility can be used to help select a system.

2.2.2 Applications for Optimus EPS Outboard applications

All single, twin, triple and quad outboard engine boats • Electronic and mechanical controlled • Single and multi-helm station boats • Performance powerboats, bay boats, center console, saltwater fishing vessels, RIBS, catamarans, houseboats and pontoon boats Inboard applications (40-100’+) Most single and twin inboard engine boats — electronic and mechanical controlled • Single, twin and triple helm station yachts • Performance motor yachts, express convertibles, and sport yachts Inboard & sterndrive applications (under 40’) Most single and twin inboard engine boats — electronic and mechanical controlled • Single, twin and triple helm station yachts • Competition ski boats, cruisers, and sport fishing yachts

2.2.3

Electro hydraulic compatibility information Popular engine brands: Yamaha ® , Suzuki ® BRP ® (Evinrude ® ), Mercury ® , Honda ®

OPTIMUS EPS OPTIMUS 360 JOYSTICK Single Engine Twin Engine Triple Engine Quad Engine Twin Engine Triple Engine Quad Engine JS Upgrade

POPULAR ENGINE BRANDS (MST)

✓ ✓ ✓ ✓ ✓

✓

N/A

YAMAHA EST (NON 425) YAMAHA EX (NON 425)

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

✓ ✓ ✓ ✓ ✓ ✓

✓ 1

N/A

MERCURY VERADO (L6)

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

SUZUKI SPC1

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

SUZUKI SPC2

✓ ✓

✓

OXE DIESEL

N/A

✓ ✓

COX MARINE

N/A

✓ ✓ ✓ ✓ ✓

✓

HONDA iST 2

N/A

✓ ✓ ✓ ✓ ✓ *

Mercury V6 (CMS)

N/A

✓ ✓ ✓ ✓

Mercury V8

N/A

Table 2-1.

See reference notes as per table 2-2 on page 2-9. Information is subject to change.

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2.2.4

Full electric actuator compatibility information Popular engine brands: Yamaha ® , Suzuki ® BRP ® (Evinrude ® ), Mercury ® , Honda ®

OPTIMUS EPS OPTIMUS 360 JOYSTICK Single Engine Twin Engine Triple Engine Quad Engine Twin Engine Triple Engine Quad Engine JS Upgrade

POPULAR ENGINE BRANDS (MST)

✓ ✓ ✓ ✓ ✓

✓

N/A

YAMAHA DEC (NON 425) YAMAHA EX (NON 425)

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

✓ ✓ ✓ ✓ ✓ ✓

✓ 1

N/A

MERCURY VERADO (L6)

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

SUZUKI SPC1

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

SUZUKI SPC2

OXE DIESEL

N/A

✓ ✓ ✓ ✓

COX MARINE

N/A

✓ ✓

✓

HONDA iST 2

N/A

✓ ✓ ✓ ✓ ✓ *

Mercury V6 (CMS)

N/A

✓ ✓ ✓ ✓

Mercury V8 (CMS)

N/A

Table 2-2.

Information is subject to change. 1 Twin and triple only 2 Honda iST control only (current iST control) * Available from Mercury Check Optimus BOM tool for Optimus Joystick & Mercury electronic control compatibility Optimus 360 not compatible with Mercury Next Gen control system N/A — Currently not available

MST — Mechanical Shift and Throttle Engines EST — Electronic Shift and Throttle Engines JS Upgrade — Can add joystick control to an existing Optimus EPS vessel

2.2.5 Advantages of Optimus EPS • No oil at helm • Boat that steers like a sports car

• Plug and play autopilot compatibility with drive by wire systems • No autopilot pump or rudder feedback unit • Adjustable speed sensitive wheel effort • Adjustable speed sensitive turns lock to lock • Can be retrofitted to existing mechanical controlled engines • No tie-bars (twin configuration) • No liquid tie-bar (CAT) • On demand pumps which extend battery life • Components based on existing Dometic reliability and quality • NMEA 2000 Certified. Meets or exceeds NMMA, ABYC, CE, ISO, and SAE electrical & environmental requirements

2-9

Options for Optimus EPS • Multi-station electronic helm • Heavy-duty Tournament cylinders

• Triple with tie-bar • Quad with tie-bars

Specifications Features & Benefits of the Optimus EPS System • Optimus EPS is designed to be Optimus 360 ready

• ABYC, CE, ISO and SAE compliant — adheres to established safety standards • Compatible with select autopilot models from Simrad, Garmin, and Raymarine • When adding 2nd or 3rd station helm, no oil, just electrical connection Autopilot interface The Optimus EPS electronic control system interfaces directly with the latest generation of autopilots from Garmin, Raymarine and Simrad, without the need for a second pump and the lengthy installation and purging procedure. Redundancy Optimus EPS has multiple levels of redundancy using a fault tolerant CAN network, and each component has at least 2 continually monitored sensors. Ackerman steering Intelligent programming allows the Optimus EPS system to separately control the steering angle of inner and outer outboards. This eliminates under-steer caused by the outside outboard “pushing” against the curve of the turn. Ackerman steering is especially important in power catamarans where the engines are located farther apart. Active sensitivity Lock-to-lock turns and wheel effort are programmed to change with engine RPM. At slow speeds, Optimus EPS can be set to reduce the number of turns lock-to-lock, and make it easier to steer. When you’re negotiating through traffic or in a tight spot, those smaller moves of the wheel give you precise control. When you’re running at speed in open water, Optimus EPS can be set to increase lock-to-lock turns, for example, and increase steering effort giving the driver more stability to comfortably keep on course. And through it all, Optimus EPS does the work, so you can relax and take it easy.

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3.1 BayStar front mount series 3 Hydraulic Outboard Steering

BayStar ™ hydraulic steering is brought to you by Dometic, the manufacturer of SeaStar ® , the most trusted name in pleasure boat steering. BayStar allows you to install all of the safety, reliability and comfort of hydraulic steering onto your single engine vessel with a Coast Guard approved transom/HP rating up to MAX 150 HP. Combine this with the superior design team, rigid ISO quality control and teamed with the finest materials and precision manufacturing, BayStar continues the tradition bringing comfort and safety to boating. The BayStar steering system consists of a super low friction helm for smooth comfortable steering, a balanced cylinder–featuring a compact design that fits most splashwells. The systems are easy to install with “cut-to-length” tubing. Available in complete kits or by individual components. For detailed application information go to www.dometic.com

Helm pumps and cylinders are fitted with positionable O-Ring fittings (ORB).

Figure 3-1.

NOTICE! BayStar steering systems are not recommended for vessels with high steering loads. Some examples of vessels with high steering loads include Pontoon boats, Bass boats and vessels using high performance engines or 4-3/4” hub props. Customers should then consider upgrading to SeaStar/ SeaStar PRO steering. This will reduce the steering effort due to the fact that SeaStar provides more output resulting in lower steering effort.

NOTICE! Tilt helms HH4315-3 and HH4316-3 are available separately. Currently not available in kit form.

3-1

3.1.1 Typical BayStar installation

HELM

CYLINDER

TUBING

Figure 3-2.

CAUTION! -3 helm pumps are fitted with positionable O-ring style hose fitting ports (commonly referred to as ORB). Do not attempt to install an NPT pipe fitting into a -3 helm hose fitting port. Doing so will lead to irreparable damage to the helm. Only use SeaStar O-ring style hose fittings (ORB).

3.1.2 Three easy steps to select your BayStar system 1. Check helm dimension. Both the Standard and Tilt helms require a 3” (7 6mm) cut-out hole in the dash.

Standard helm part # HH4311-3 and HH4314-3

5/8" NF THREAD

1/4" NPT FILL PORT

3/4" STANDARD TAPER

ORB PORTS (4)

3-15/16" (100 mm)

4-5/8" (118 mm)

3" DIA. (76 mm)

7-15/16" (200 mm)

(1.1 cu.in.) Gives 6.5 wheel turns lock to lock.

HH4311-3 HH4314-3

Seal kit = HP6032

(1.4 cu.in.) Gives 5.2 wheel turns lock to lock. When using BayStar outboard cylinders.

Figure 3-3. Standard helm part # HH4311-3 and HH4314-3.

3-2

Sport tilt helm part # HH4315-3

3” (76 mm)

9.2” (233.5 mm)

4.8” (122 mm)

2.4” (61 mm)

6.8” (173 mm)

3.6” (91.5 mm)

42°

6°

3.5” (89 mm)

1.3” (33 mm)

ORB PORTS (4)

Seal kit = HP6032 Tilt mechanism kit = HA6123

(1.4 cu.in.) Gives 5.2 wheel turns lock to lock. When using BayStar outboard cylinders.

HH4315-3

Figure 3-4. Sport tilt helm part # HH4315-3.

Sport Plus tilt helm part # HH4316-3

3" (76 mm)

4.8" (122 mm)

9.2" (233.5 mm)

2.4" (61 mm)

6.8" (173 mm)

3.6" (91.5 mm)

42°

6° 1 2 3

3.5" (89 mm)

1.3" (33 mm)

ORB PORTS (4)

Seal kit = HP6032 Tilt mechanism kit = HA6423

(1.4 cu.in.) Gives 5.2 wheel turns lock to lock.

HH4316-3

Figure 3-5. Sport Plus tilt helm part # HH4316-3.

2. Is the Splashwell wide enough? The HC4645-3 / 47-3 / 48-3 / 58-3 require a minimum 21” (534 mm) Splashwell width.

2.625" (67mm)

NPT seal kit = HP4600 ORB seal kit = HP4601 Tee/bleeder kit = HF4202 Support rod/nut/clip = HP6050 Pivot plate see page 3-6

21" (534mm)

Figure 3-6. BayStar cylinder part # HC4645-3 / 47-3 / 58-3.

3-3

3. Is there enough room in the splashwell for full engine tilt? Find the dimensions (B & C) of your splashwell. Check them against the minimum splashwell dimensions for full engine tilt for your engine and cylinder. Motor well dimensions required for BayStar front mount outboard steering systems

Cylinder model No.

# of engines

C Min. engine

center distance

HC4645-3 / 47-3 / 48-3 / 58-3

21” (534 mm) 6” (153 mm) 5” (127 mm) N/A

2 Twin engine applications not available

NOTES:

a) Ensure there is no interference between the BayStar cylinder rod and the splashwell boot or engine controls and cables.

b) Dimensional restrictions also apply to external motor mount brackets. c) E nsure dimension ‘A’ maintained through full trim/tilt range.

d) Maximum transom thickness 3” (76 mm). e) Engines less than 70HP may require up to an additional 1” (25 mm) of splashwell clearance.

Figure 3-7.

3.1.3 BayStar steering kits

BayStar Steering kits come complete with everything needed for an install, (some engines require additional kits and/or cylinder plate change, see application chart on page 3-6) the cylinder does not require the engine manufacturer drag link for connection. For your convenience two lengths of 20’ cut to fit tubing are supplied with the HK4200A-3 and two lengths of 30’ cut to fit tubing are supplied with the HK4230A-3 kit. NOTICE! HC4645-3 compact cylinder is included in both BayStar steering kits. If your engine requires the use of a cylinder other than HC4645-3 or HC4658-3 (refer to application guide on page 3-6) then purchase of a replacement pivot plate (noted on page 3-6) will be required.

Figure 3-8.

3-4

NOTE: Effort reduction Dometic has recently updated the BayStar cylinder. These updates include low friction main piston seals as well as low friction wiper and gland seals. If one chooses to further reduce steering effort, the following additional changes can be made: • Consider plumbing the system using SeaStar steering hoses. See page 10-1 . • Consider use of a BayStar Plus 1.4 cu.in. helm pump (HH4513-3/ HH4514-3). • Consider use of a BayStar 1.1 cu.in. helm pump (HH4311-3). NOTE : Number of wheel turns will increase to 6.6 hard over to hard over. BayStar steering kit — HK4200A-3 Includes: BayStar helm, cylinder (HC4645-3), two 20' tube assemblies, and fluid. BayStar steering kit — HK4230A-3 Includes: BayStar helm, cylinder (HC4645-3), two 30' tube assemblies, and fluid. BayStar steering kit — HK4300A-3 Includes: BayStar helm, cylinder (HC4645-3), and fluid, NO tubing. BayStar steering kit — HK4500A-3 Includes: BayStar Plus helm, cylinder (HC4645-3), and fluid, NO tubing.

BAYSTAR SYSTEM – TUBE BAYSTAR SYSTEM – HOSE BAYSTAR PLUS SYSTEM – HOSE SEASTAR SYSTEM

10%

20%

LOWER

EFFORT

HIGHER

Figure 3-9.

3-5

3.1.4 BayStar outboard steering application guide (BayStar compact cylinders HC4645-3/47-3/48-3/58-3)

MANUFACTURER

YEAR

MODEL

CYLINDER NOTES

HONDA

1992–DATE 1996–DATE 2015–DATE 1998–2010 2003–DATE 2010–DATE 1991–DATE 1997–DATE 2017–DATE 1998–DATE 1984–DATE 1998–2007 2008–DATE 2008–DATE 2000–DATE 2000–DATE 2011–2013 1986–DATE 1987–2002 1990–2000 1998–DATE 2001–DATE 1990–DATE 2014–DATE 2023–DATE 1998–DATE 1998–DATE 1986–DATE 1997–DATE 2000–DATE 2011–2014 2014–DATE

30–50 HP 4-Stroke 75–90 HP 4-Stroke 100 HP 4-Stroke 115-130 HP 4-Stroke 135–150 HP 4-Stroke 115 HP 4-Stroke 40–150 HP inc. E-Tec 115 HP Ficht 75–150 HP Ficht 40–140 HP 4-Stroke 75–150 HP 40–60 HP 2-Stroke

HC4645-3 HC4645-3 HC4645-3 HC4647-3 HC4645-3 HC4645-3 HC4645-3 HC4658-3 HC4645-3 HC4658-3 HC4645-3 HC4648-3 HC5348-3 HC4645-3 HC4648-3 HC4645-3 HC4658-3 HC4645-3 HC4645-3 HC4645-3 HC4645-3 HC4658-3 HC4645-3 HC4645-3 HC4645-3 HC4645-3 HC4645-3 HC4645-3 HC4645-3 HC4648-3 HC4658-3 HC4645-3

See note 2

JOHNSON/EVINRUDE NOTE: Johnson 115 HP 2-stroke engines, required the pivot plate to be flipped. See note 4 below.

See note 2 See note 4 See note 5 See note 1, 2, 4 See note 5 See note 1, 2 See note 1 See note 2 See note 1, 2 See note 5

MERCURY/MARINER

40 HP 4-Stroke 60 HP 4-Stroke

SELVA

25-70 HP 4-Stroke 90-150 HP 4-Stroke 115 HP 4-Stroke 150 HP 2-Stroke 115–140 HP 2-Stroke 90–100 HP 2-Stroke 40–70 HP 4-Stroke 90–140 HP 4-Stroke 40–140 HP 2-Stroke 60–150 HP 4-Stroke 75–150 HP 4-Stroke 40–50 HP 2-Stroke 60 HP 2-Stroke 70–90 HP 2-Stroke 80–150 HP 4-Stroke 25–70 HP 4-Stroke 90–115 HP inc. A Series 90–115 HP inc. B Series

SUZUKI

See note 5 See note 1

See note 1, 2 See note 1, 4

See note 2

TOHATSU

Must use Tohatsu tiller bolt 3E0-84917-0

YAMAHA

See note 2 See note 3 See note 1 See note 5 See note 1, 2, 6

4. Cylinder HC4645-3 may be used in these applications. The pivot plate will need to be flipped before installation. Instructions provided with Owner’s Manual. 5. High performance 150HP engines and any engine using a 4-3/4" gear-case such as Command Thrust MUST use SeaStar. 6. May require Yamaha hook 688-48511-12-00 and M10 x 1.25 x 30 bolts.

1. Requires Spacer kit part # HO5090 2. Engine clamp brackets must be cut or ground, and the engine through bolted onto the transom, or interference will occur, restricting engine trim and tilt. 3. Steering hook Yamaha Part # 63D-48511-00-4D must be installed

Revision Date: MAY 31st 2023

NOTICE! HC4645-3 compact cylinder is included in the BayStar Steering kits. If your engine requires the use of a cylinder other than HC4645-3 or HC4658-3 then please refer to the figure below for additional replacement pivot plate.

HA4640 Comes with cylinder HC4645-3

HA4641 Converts HC4645-3 to HC4647-3

HA4643 Converts HC4645-3 to HC4658-3

HA4642 Converts HC4645-3 to HC4648-3

Figure 3-10.

3-6

3.2 SeaStar front mount series

SeaStar outboard hydraulic steering offers many models of steering cylinders to suit most applications. The standard and most commonly used model is the Front Mount steering cylinder. Before ordering it is necessary to determine the best possible application for your boat, taking into account the hull design, speed and usage of the boat. Keep in mind that engines today have become larger, more powerful and heavier than in the past. Dometic encourages you to use the tables noted in this section and select your system accordingly or visit www.SeaStarBOM.com and use our online system builder. 3.2.1 Selecting the outboard steering system best suited for your boat 1. Using the table on page 3-9, select your system as per speed, horsepower and driving style. 2. Using the Application chart on page 3-13 choose the proper cylinder and tie bar equipment as per your outboard engine. If your engine is not noted, contact SeaStar Solutions or your distributor for details. 3. Proceed to page 2-9 for details on fitting kits and particular equipment that will be needed to add a second station and/or an autopilot.

Typical SeaStar installation

HELM

CYLINDER

HOSE

Figure 3-11. Typical SeaStar installation.

Features • Independent engine tilt for twin engine installations. • Easy steering. • 5 turns lock to lock steering response (1.7 standard system).

3-7

Applications • General purpose system. • Single and multiple engine capability. • Typical applications include center console fishboats and cruisers. How to select a front mount outboard steering system 1. From the installation recommendations on page 3-9 select the system configuration based on: a) the number of engines, b) the total power of engine(s) to be installed and c) driving use. 2. From the application guides, confirm that the front mount cylinder will fit your specific make, model and year of engine. Select the adapter kit for single engines or the tie bar kit for dual engines. 3. From section 8 select the appropriate helms and accessory hardware for each steering station. 4. From Section 10 select the fitting and hose kits required for the installation. 5. Confirm that there is sufficient space available in the splashwell and dash areas for the steering components. 6. Determine if Power Assist is desired, section 6.

Figure 3-12. HC5345-3 cylinder shown.

CAUTION! Not recommended for use in installations where; a) chopper, cleaver or surface piercing propellers are used b) the engine is highly elevated on the transom c) engine trim tabs have been removed d) the boat speed exceeds 75mph (120km/h), or e) the power exceeds the max. Coast Guard rating, or the rating provided by the vessel’s manufacturer

3-8

3.2.2 Front mount outboard installation recommendations

Outboard recommendations made in this section are based on our experience with typical installations, applications and usage. Ensure you select the system which provides the best comfort versus performance. It is the boat manufacturer and the installer’s responsibility to ensure the components selected are sufficiently validated on the boat for safe and acceptable operation. Do not use SeaStar steering in applications it is not intended for.

NORMAL USE

AGGRESSIVE USE (See note 1) SEASTAR TOURNAMENT SERIES (See note 1 – Refer to Section 3.5)

ENGINE

SEASTAR FRONT MOUNT (Refer to Section 3.2) SINGLE CYLINDER 350 HP max. 75 MPH max. HC53XX-3 cylinder (see note 2)

SINGLE ENGINE

SINGLE CYLINDER 350 HP Max.

HC63XX-3 PRO cylinder page 3-16 through page 3-18 (See notes 2 & 3) or HC6845S (Refer to Section 3.3) SINGLE CYLINDER Tournament cylinders (Refer to Section 3.5)

DUAL ENGINE NON COUNTER ROTATING SINGLE CYLINDER 450 HP max. 55 MPH max. HC53XX-3 cylinder HO60XX tie bar

DUAL CYLINDER Tournament cylinders (Refer to Section 3.5) HC53XX-3 Cylinders HO60XX tie bar

DUAL CYLINDER Tournament cylinders (Refer to Section 3.5)

DUAL ENGINE COUNTER ROTATING

SINGLE CYLINDER 600 HP max. 55 MPH max. HC53XX-3 cylinder HO60XX tie bar DUAL CYLINDER 600 HP max. 55 MPH max. HC53XX-3 cylinder HO60XX tie bar

SINGLE CYLINDER Tournament cylinders (Refer to Section 3.5)

DUAL CYLINDER SeaStar cylinder with HD tie bar Tournament cylinders (Refer to Section 3.5)

TRIPLE ENGINE ONE WITH COUNTER ROTATING

DUAL CYLINDER Tournament cylinders ( (Refer to Section 3.5)

DUAL CYLINDER Tournament cylinders (Refer to Section 3.5)

600 HP max. 55 MPH max. *MAX center engine drop <.75”

Consider Optimus EPS or 360 (Refer to Section 11)

TRIPLE CYLINDER Tournament cylinders (Refer to Section 3.5)

900 HP max. 55 MPH max. *MAX center engine drop <.75”

1. SeaStar Solutions has specific steering equipment for boats that are driven aggressively, used in severe conditions or with more than 300 HP per engine. 2. ALL ENGINES over 300 HP and all boats that are driven aggressively must use a high strength tiller bolt, kit part # HA5822. All front mount cylinders built after June 15, 2007 will have this high strength bolt included in the box. High strength tiller bolts can be identified by the marking “DOMETIC ARP” on the head of the bolt (refer to notice on page 3-14.

3. HC63xx PRO Cylinders are designed for all those critical high speed, single outboard engine boats, such as Bass, Flats combo Race/Ski and other performance orientated boats capable of speeds in excess of 65 mph. For optimal performance, the use of SeaStar PRO helms and PRO Hoses are recommended.

3-9

3.2.3 SeaStar front mount order guide (Normal and aggressive use)

Front mount cylinder part# HC5345-3 is included in the SeaStar outboard steering kits HK6400A-3/HK63XXA-3. If your engine requires the use of a cylinder other than the HC5345-3 (see application guides on page 3-13 through page 3-15) you will need to purchase the individual components (helm, cylinder, hoses, etc.) separately.

Figure 3-13.

SeaStar steering kit — HK6400A-3 Includes: Cylinder (HC5345-3), Helm (HH5271-3), two quarts of SeaStar steering fluid (HA5430[H]). SeaStar steering kit — HK63XXA-3 Includes: Hoses (HO51XX), Cylinder (HC5345-3), Helm (HH5271-3), two quarts of SeaStar steering fluid (HA5430[H]). SeaStar steering kit – Classic tilt — HK6400TC-3 Includes: Cylinder (HC5345-3), Classic Tilt Helm (HH6541-3), two quarts of SeaStar steering fluid (HA5430[H]). SeaStar steering kit – Sport tilt — HK6400TS-3 Includes: Cylinder (HC5345-3), Sport Tilt Helm (HH6191-3), two quarts of SeaStar steering fluid (HA5430[H]).

3-10

3.2.4 SeaStar tie bar kits Normal use tie bar kits

SeaStar normal use tie bar (HO6001) kits for normal use up to 600 HP in counter-rotating applications.

Figure 3-14.

Aggressive use tie bar kits SeaStar heavy duty tie bar system for aggressive use. Fully adjustable, for single cylinder and dual cylinder applications.

Figure 3-15. Twin engine, single cylinder tie bar kit part # HA5521.

3-11

NOTE Figure 3-16; if Mercury, CMS (conventional midsection) engines only.

Figure 3-16. Single engine, dual cylinder tie bar kit part # HA5522 for Mercury CMS (conventional midsection) engines or Honda outboard engines using “O-O“ style tiller arm only. Not for Suzuki.

NOTICE!

HA5522 must be used with Mercury or Honda outboard engines using this style of tiller arm and a single cylinder. In addition Honda outboards require the HA5523 bolt kit

Figure 3-17. Twin engine, dual cylinder tie bar kit part # HA5520.

3-12

CONFIGURATION

HARDWARE KIT TIE BAR

NOTES

Part #

Qty. Req.

Engine center to center distance – inches (mm) 25.0 – 25.7 (635 – 653) 25.8 – 30.7 (655 – 780) 30.8 – 39.3 (782 – 998) 39.4 – 54.5 (1000 – 1384) 25.0 – 26.2 (635 – 667) 26.3 – 31.2 (668 – 794) 31.3 – 40.0 (795 – 1016) 40.1 – 55.0 (1017 – 1397) 28.0 – 29.0 (771 – 737) 29.1 – 30.6 (739 – 777) 30.7 – 33.4 (779 – 848) 33.5 – 38.4 (850 – 975) 38.5 – 47.1 (997 – 1196) 47.2 – 62.2 (1199 – 1580)

Part #

Qty. Req.

1, 3, 4, 5 1, 3, 4, 5

1 1 1 1 1 1 1 1 1 1 1 1 1 1

HO6821 HO6822 HO6823 HO6824 HO6821 HO6822 HO6823 HO6824 HO6819 HO6820 HO6821 HO6822 HO6823 HO6824

1 1 1 1 1 1 1 1 1 1 1 1 1 1

HA5521 HA5521 HA5521 HA5521 HA5522 HA5522 HA5522 HA5522 HA5520 HA5520 HA5520 HA5520 HA5520 HA5520

TWIN ENGINE – SINGLE CYLINDER Mercury CMS and Honda

1, 3, 4 1, 3, 4

1, 3, 4, 5, 6 1, 3, 4, 5, 6

1, 3, 4, 6 1, 3, 4, 6

1, 2, 3, 4, 5 1, 2, 3, 4, 5 1, 2, 3, 4, 5

TWIN ENGINE – DUAL CYLINDER Engine centers under 28” must use HO6002

1, 2, 3, 4 1, 2, 3, 4 1, 2, 3, 4

cylinders and/or engine tilt limiting, please consult Dometic technical support. 5. Cylinder interference may occur with independent trim/tilt of the engines. 6. Mercury or Honda outboard engines using “O-O“ style tiller arm only. Revision Date: MAY 31st 2023

1. Installation may vary according to the following factors: engine mounting height, transom thickness, use of transom savers, tiller bolt location, engine tilt range, and engine size. 2. Cylinder’s must be plumbed in parallel only, no series connections.

3. Tiebar length may vary depending on toe in/toe out setup. To allow for toe, add or subtract from your nominal engine center to center distance. 4. Based on recommended engine manufacturer minimum center to center distances. Deviating from these recommendations may require stroke limiting

3.2.5 Single engine application guide (Normal use)

Prior to selecting a cylinder from this application guide, please refer to page 3-9 to ensure that you are selecting the correct cylinder for your engine/boat. NOTICE! Is your Splashwell wide enough? Check page 3-17 for space requirements.

MANUFACTURER

YEAR

MODEL

CYLINDER NOTES

2022–DATE

300 HP Diesel

HC5358-3

COX MARINE

HC5345-3 HC5347-3 HC5345-3 HC5345-3 HC5445-3 HC5345-3 HC5345-3 HC5345-3 HC5345-3 HC5345-3 HC5345-3 HC5358-3 HC5358-3 HC5345-3 HC5345-3 HC5345-3 HC5348-3 HC5345-3 HC6345-3 HC5345-3 HC5345-3 HC5345-3

60–90 HP 4-Stroke 115–130 HP 4-Stroke 30–50 HP 4-Stroke 150 HP 4-Stroke 200–250 4-Stroke 135 HP 4-Stroke 115HP 4-Stroke 100 HP 4-Stroke 200–250 4-Stroke 40–300 HP 2-Stroke 75–300 HP Ficht 40–140 HP 4-Stroke 115 HP Ficht 200–225 HP 4-Stroke 3.3L V6 200–250HP 75–300 HP 2-Stroke 30–60 HP 4-Stroke 60 HP 4-Stroke 115–300 HP XS 150–200 HP Verado

1996–DATE 1998–2009 1998–DATE 2001–DATE 2001–2022 2003–DATE 2011–DATE 2015–DATE 2023–DATE

HONDA

See note 1 See note 3

Inc. ETech engines

JOHNSON/EVINRUDE 1991–DATE 1997–DATE 1998–DATE 2000–2003 2002–DATE 2007–DATE

See note 1 See note 1

Inc. H.O. models

1989–DATE 1998–2007 2008–DATE 2004–DATE 2003–DATE 2017–DATE 2018–DATE

MERCURY

See note 1

175–225 HP 3.4L V6 4-Stroke 250–300 HP 4.6L V8 4-Stroke

See note 2 See note 2

1. Requires Spacer Kit# HO5090. 2. PRO XS MUST use HC6345-3.

3. Optional cylinder part # HC5358-3. Slight interference may occur when using the HC5358-3, with the engine in the full tilt position. 4. Must use PA1200-2HP

Revision Date: JUNE 1st 2023

3-13

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