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Manuals
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Chrysler Manuals
Outboard Motor
9.9 H.P.
Service manual
Chrysler 9.9 H.P. Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Section Index
General Information
Safety
Outboard Motor Nomenclature
Starboard and Port Side Views
General Service Information: Contents
Motor Identification
Fuel and Lubricants
Fuel Use
Fuel Ratio Conversion
Fuel/Oil Mixture Requirements
Types of Lubricants Used for Complete Lubrication
Lubrication Intervals
Lubrication Points
Location of Vent and Fill Plugs
Lubricating Starter Pinion Gear
Lubricating Throttle and Choke Link
Lubricating Clamp Screws
Lubricating Shift Linkage
Lubricating Swivel Bracket
Break-In
Lubricating Steering Arm
Lubricating Stern Bracket Bolt
Lubricating Propeller Shaft
Submerged Motor
Motor Storage
Tune-Up
Troubleshooting Guide
Motor will Not Start
Loss of Power
Engine Specifications
Torque Chart
Capacities
Electrical Specifications
Fuel Jet Selection
9.9 H.P. and 250 Sailor
9.9. H.P. and 250 Sailor
15 H.p.
Fuel System and Components: Contents
Fuel System and Components: Special Tools
Fuel System Operation
Fuel System Troubleshooting
Checking Fuel Flow
No Fuel to Carburetor Bowl
No Fuel to Combustion Chamber
Flooding
Fuel Tank and Components
Gauge Cap
Prime Bulb
Fuel Tank Adapter
Fuel Line Couplers
Assembly of Check Valve in Prime Bulb
Components of Quick Disconnect Coupling
Fuel Tank and Components Overview
Fuel Pump
Fuel Pump Operation Overview
Fuel Pump Testing
Fuel Pump Servicing
Removing Fuel Pump
Unfastening Starter Support
Removing Starter Switch
Carburetor Description
Starting Choke Operation
Idle Operation
Intermediate Operation
High Speed/Idle Operation
Carburetor Adjustments
Throttle Adjustment
Idle Adjustment
Adjusting Pick-Up Point
Idle Speed Adjustment
Float Adjustment
Adjusting Float Drop
Idle Mixture Adjustment Screw
Carburetor Overhaul
Removing Carburetor
Removing Starter Support
Inspecting Idle Needle
Inspecting Float Needle
Throttle Return Spring
Positioning Throttle Valve
Position of Choke Valve
Assembling Throttle Valve to Shaft
Assembling Choke to Carburetor
Assembling Float Valve Seat
Setting Inside Dimension of Follower Arm
Installing Throttle Cam Follower and Roller
Positioning Throttle Cam Pick-Up Point and Roller
Installing Follower Arm to Cam Follower
Checking Throttle Cam Mark and Roller
Caburetor and Manifold Assembly - Exploded View
Reed Valve Assembly Servicing
Reed Valve and Manifold Removal
Removing Manifold and Reed Valve Assembly
Inspecting Reeds
Electrical System and Components: Contents
Electrical System and Components: Special Tools
Electrical System Operation
Magneto Ignition
C-D Ignition System
Generating System
C-D Ignition System Description/Troubleshooting
C-D Ignition System Components
C-D Ignition System Troubleshooting Tests
High Voltage Output
Trigger Coil Output #1 Cylinder
Trigger Coil Output #2 Cylinder
C-D Unit Output to #1 Ignition Coil Primary Winding
C-D Unit Output to #2 Ignition Coil Primary Winding
Flywheel Removal
Removing Starter Housing
Removing Coils and Starter
Removing Flywheel from Power Head
Flywheel Inspection and Repair
Stator Removal, Cleaning and Inspection
Position of Flywheel Key Prior to Assembly
Stator Installation
Trigger Stator Removal, Cleaning and Inspection
C-D Module Removal
Assembling C-D Stator to Trigger Stator
C-D Module Cleaning and Inspection
Spark Plugs, Removal
Removing C-D Module from Power Head
Connecting C-D Leads to Terminal Block
Spark Plugs Inspection, Servicing, Installation
Generating System Troubleshooting
Generating System Testing
Rectifier Removal, Installation, Cleaning and Inspection
Circuit Breaker Removal, Cleaning and Inspection, Installation
Magneto Ignition System Troubleshooting
Magneto Ignition System Preliminary Tests
Electrical Troubleshooting Guide
Magneto Ignition System Test Equipment
Flywheel Removal, Inspection
Condenser Removal
Test Condenser Capacity
Flywheel Installation
Coils
Testing Condenser
Coils Removal, Coil Power Test
Removing Coils, Coil Leads
Straightening Coil Laminations
Sparkle Cover and Spring
Testing Coil High-Speed
Testing Coil Surface Insulation
Testing Coil Continuity
Breaker Points Removal, Installation
Adjusting Breaker Point Gap
Stator Plate Removal, Installation
Checking Spring Tension
Assembling Throttle Cam and Ground Wire
Stator Hold-Down Screw Locations
Spark Plug Removal, Inspection, Servicing, Installation
Electrical Starting System Overview
Electrical Starting System Troubleshooting
Starting Circuit
Battery Activation Procedure
Battery: Slow Charge
Testing Battery
Hydrometer Test
Reading Specific Gravity with a Float-Type Hydrometer
Starter Motor: Description
Battery: Heavy Load Test
Battery Storage
Freezing Temperature Chart
Starter Motor Troubleshooting Chart
Starter Motor Removal
Testing Starter Armature Rotation
Testing Armature
Starter Motor Brush Assembly
Starter Motor Bearing Location
Field Winding Ground Test
Starter Motor Reassembly, Installation
Testing Permanent Magnets in Starter Housing
Starter Switch Removal/Installation
Interlock Switch Removal/Installation
Connecting Leads to Starter Switch
Connecting Leads to Interlock Switch
Correct Position: Interlock Switch and Interlock Lever
Steering Handle Assembly: Contents
Steering Handle Assembly: Special Tools
Steering Handle Assembly: Remove and Disassembly
Tapping Insert to Free Handle
Removing Insert
Loosening Set Screw
Steering Handle Assembly: Inspection and Repair, Reassembly and Installation
Removing Pivot Pin
Installing Stop and Spring on Bracket
Securing Magneto Control Shaft Gear
Assembling Steering Handle
Installing Magento Control Lever
Adjusting Gear Mesh
Adjusting Steering Handle Function
Steering Handle Assembly: Partial Exploded View
Manual Starter: Contents
Manual Starter: Special Tools
Manual Starter Description/Operation
Neutral Interlock
Operation of Starter Pinion Gear
Manual Starter Removal
Installing Rewind Key
Removing Interlock
Manual Starter Installation, Removal
Checking Rewind Spring
Placing Starter Rope in Insert
Manual Starter Assembly: Exploded View
Power Head: Contents
Power Head: Special Tools
Power Head Principle of Operation
Operation of the 2-Cycle Motor
Power Head Troubleshooting
Fuel Transfer Within Recirculating Passages
Compression Gauge Installed
Compression Range
Power Head Overhaul Removal
Disconnecting Stop Switch
Disconnecting Choke Link from Carburetor
Disconnecting Fuel Line
Magneto Control System
Disconnecting Interlock Link from Gear Shift Shaft Lever
Disconnecting Interlock Lever
Removing Power Head from Support Plate
Power Head Removal
Carburetor and Fuel System Components
Removing Bearing Cage and Stator Ring
Removing Exhaust Cover
Removing Crankcase Cover Screws
Removing Locating Pins
Prying off Crankcase Cover
Removing Connecting Rod and Screws
Power Head Inspection and Repair
Removing Piston Rings/Pin
Checking Flatness of Cylinder Head
Resurfacing Cylinder Head
Measuring/Honing Cylinders
Power Head Reassembly
Measuring Piston Ring Gap
Assembling Piston to Connecting Rod
Removing Piston Pin
Installing Piston Rings
Inserting Piston to Cylinder
Installing Piston Assembly in Cylinder
Installing Center Main Liner
Positioning Lower Main Bearing
Applying Sealant to Parting Line
Installing Locating Pins
Securing Lower Main Bearing Seal
Torquing Sequence for Cylinder Head
Installing Driveshaft Spline Seal
Power Head (Manual Start Models): Installation
Positioning Exhaust Cover, Gaskets, Plate
Powerhead Assembly: Exploded View
Forward and Port Side Views: Manual Start Models
Starboard and Aft. Views: Manual Start Models
Forward and Port Side Views: Electric Start Models
Starboard and Aft. Views: Electric Start Models
Lower Unit: Contents
Lower Unit: Special Tools
Motor Leg and Swivel Bracket Assembly
Shock Mounts Removal
Removing Gear Housing from Motor Leg
Disconnecting Steering Arm from Bracket
Shock Mounts: Installation
Detaching Interlock Rod
Upper Shock Mounts Installed
Removing Lower Shock Mount
Swivel Bracket Assembly: Removal, Disassembly
Proper Assembly of Gear Shift Rods
Removing King Pin from Steering Arm
Removing Spring Pin in Reverse Lock Release Lever
Removing Spring Pin in Reverse Lock Lever
Removing Spring Pin Securing Reverse Lock Link
Swivel Bracket Assembly
Replacing Clamp Screws
Installing Reverse Lock
Installing Tilt Lock Assembly
Installing Swivel Bracket Bearings
Swivel Bracket and Motor Leg Assembly - Exploded View
Gear Housing
Water Pump
Cooling System Flow
Water Pump Removal
Removing Driveshaft Seal
Gear Train
Water Pump Inspection and Repair, Reassembly, Installation
Installing Impeller
Installing Driveshaft Seal
Operating of Gear Train
Removing Bearing Cage
Lower Gear Housing: Inspection and Repair
Removing Clutch
Measuring Clutch Spring Length
Upper Gear Housing: Inspection and Repair
Rear Bevel Gear Bearing I.D.
Propeller Shaft Bearing Cage Bearing I.D.
Remove and Replace Seals
Removing Shift Rod Seal
Installing Driveshaft Seal in Upper Gear Housing
Positioning Clutch
Installing Clutch, Cam
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Table of Contents
Troubleshooting
Tune-Up
19
Fuel System Operation
31
C-D Ignition System Description/Troubleshooting
57
C-D Ignition System Troubleshooting Tests
60
Generating System Troubleshooting
71
Magneto Ignition System Troubleshooting
77
Electrical Starting System Troubleshooting
88
Starter Motor Troubleshooting Chart
92
Power Head Troubleshooting
117
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This manual is also suitable for:
15 h.p.
250 sailor
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