Chrysler 9.9 H.P. Manuals

Manuals and User Guides for Chrysler 9.9 H.P.. We have 1 Chrysler 9.9 H.P. manual available for free PDF download: Service Manual

Chrysler 9.9 H.P. Service Manual (181 pages)

Brand: Chrysler | Category: Outboard Motor | Size: 57.37 MB

Section Index
3
General Information
7
Safety
7
Outboard Motor Nomenclature
7
Starboard and Port Side Views
8
General Service Information: Contents
11
Motor Identification
13
Fuel and Lubricants
13
Fuel Use
13
Fuel Ratio Conversion
14
Fuel/Oil Mixture Requirements
14
Types of Lubricants Used for Complete Lubrication
14
Lubrication Intervals
14
Lubrication Points
15
Location of Vent and Fill Plugs
15
Lubricating Starter Pinion Gear
15
Lubricating Throttle and Choke Link
16
Lubricating Clamp Screws
16
Lubricating Shift Linkage
16
Lubricating Swivel Bracket
16
Break-In
17
Lubricating Steering Arm
17
Lubricating Stern Bracket Bolt
17
Lubricating Propeller Shaft
17
Submerged Motor
18
Motor Storage
18
Tune-Up
19
Troubleshooting Guide
19
Motor will Not Start
19
Loss of Power
20
Engine Specifications
21
Torque Chart
22
Capacities
22
Electrical Specifications
22
Fuel Jet Selection
23
9.9 H.P. and 250 Sailor
24
9.9. H.P. and 250 Sailor
25
15 H.p.
26
Fuel System and Components: Contents
29
Fuel System and Components: Special Tools
30
Fuel System Operation
31
Fuel System Troubleshooting
31
Checking Fuel Flow
31
No Fuel to Carburetor Bowl
32
No Fuel to Combustion Chamber
32
Flooding
32
Fuel Tank and Components
33
Gauge Cap
33
Prime Bulb
33
Fuel Tank Adapter
33
Fuel Line Couplers
34
Assembly of Check Valve in Prime Bulb
34
Components of Quick Disconnect Coupling
34
Fuel Tank and Components Overview
35
Fuel Pump
37
Fuel Pump Operation Overview
37
Fuel Pump Testing
38
Fuel Pump Servicing
38
Removing Fuel Pump
38
Unfastening Starter Support
38
Removing Starter Switch
39
Carburetor Description
41
Starting Choke Operation
41
Idle Operation
41
Intermediate Operation
42
High Speed/Idle Operation
42
Carburetor Adjustments
43
Throttle Adjustment
43
Idle Adjustment
43
Adjusting Pick-Up Point
43
Idle Speed Adjustment
44
Float Adjustment
44
Adjusting Float Drop
44
Idle Mixture Adjustment Screw
44
Carburetor Overhaul
45
Removing Carburetor
45
Removing Starter Support
45
Inspecting Idle Needle
45
Inspecting Float Needle
46
Throttle Return Spring
46
Positioning Throttle Valve
46
Position of Choke Valve
47
Assembling Throttle Valve to Shaft
47
Assembling Choke to Carburetor
48
Assembling Float Valve Seat
48
Setting Inside Dimension of Follower Arm
48
Installing Throttle Cam Follower and Roller
49
Positioning Throttle Cam Pick-Up Point and Roller
49
Installing Follower Arm to Cam Follower
49
Checking Throttle Cam Mark and Roller
49
Caburetor and Manifold Assembly - Exploded View
50
Reed Valve Assembly Servicing
51
Reed Valve and Manifold Removal
51
Removing Manifold and Reed Valve Assembly
51
Inspecting Reeds
52
Electrical System and Components: Contents
53
Electrical System and Components: Special Tools
54
Electrical System Operation
55
Magneto Ignition
55
C-D Ignition System
56
Generating System
56
C-D Ignition System Description/Troubleshooting
57
C-D Ignition System Components
57
C-D Ignition System Troubleshooting Tests
60
High Voltage Output
61
Trigger Coil Output #1 Cylinder
62
Trigger Coil Output #2 Cylinder
63
C-D Unit Output to #1 Ignition Coil Primary Winding
64
C-D Unit Output to #2 Ignition Coil Primary Winding
65
Flywheel Removal
66
Removing Starter Housing
66
Removing Coils and Starter
66
Removing Flywheel from Power Head
66
Flywheel Inspection and Repair
67
Stator Removal, Cleaning and Inspection
67
Position of Flywheel Key Prior to Assembly
67
Stator Installation
68
Trigger Stator Removal, Cleaning and Inspection
68
C-D Module Removal
68
Assembling C-D Stator to Trigger Stator
68
C-D Module Cleaning and Inspection
69
Spark Plugs, Removal
69
Removing C-D Module from Power Head
69
Connecting C-D Leads to Terminal Block
69
Spark Plugs Inspection, Servicing, Installation
70
Generating System Troubleshooting
71
Generating System Testing
72
Rectifier Removal, Installation, Cleaning and Inspection
75
Circuit Breaker Removal, Cleaning and Inspection, Installation
75
Magneto Ignition System Troubleshooting
77
Magneto Ignition System Preliminary Tests
77
Electrical Troubleshooting Guide
77
Magneto Ignition System Test Equipment
78
Flywheel Removal, Inspection
78
Condenser Removal
79
Test Condenser Capacity
79
Flywheel Installation
79
Coils
80
Testing Condenser
80
Coils Removal, Coil Power Test
81
Removing Coils, Coil Leads
81
Straightening Coil Laminations
81
Sparkle Cover and Spring
81
Testing Coil High-Speed
82
Testing Coil Surface Insulation
82
Testing Coil Continuity
83
Breaker Points Removal, Installation
84
Adjusting Breaker Point Gap
84
Stator Plate Removal, Installation
85
Checking Spring Tension
85
Assembling Throttle Cam and Ground Wire
85
Stator Hold-Down Screw Locations
85
Spark Plug Removal, Inspection, Servicing, Installation
86
Electrical Starting System Overview
87
Electrical Starting System Troubleshooting
88
Starting Circuit
88
Battery Activation Procedure
88
Battery: Slow Charge
89
Testing Battery
89
Hydrometer Test
89
Reading Specific Gravity with a Float-Type Hydrometer
90
Starter Motor: Description
91
Battery: Heavy Load Test
91
Battery Storage
91
Freezing Temperature Chart
91
Starter Motor Troubleshooting Chart
92
Starter Motor Removal
93
Testing Starter Armature Rotation
93
Testing Armature
94
Starter Motor Brush Assembly
95
Starter Motor Bearing Location
95
Field Winding Ground Test
95
Starter Motor Reassembly, Installation
96
Testing Permanent Magnets in Starter Housing
96
Starter Switch Removal/Installation
97
Interlock Switch Removal/Installation
97
Connecting Leads to Starter Switch
97
Connecting Leads to Interlock Switch
97
Correct Position: Interlock Switch and Interlock Lever
98
Steering Handle Assembly: Contents
99
Steering Handle Assembly: Special Tools
100
Steering Handle Assembly: Remove and Disassembly
101
Tapping Insert to Free Handle
102
Removing Insert
102
Loosening Set Screw
102
Steering Handle Assembly: Inspection and Repair, Reassembly and Installation
103
Removing Pivot Pin
103
Installing Stop and Spring on Bracket
103
Securing Magneto Control Shaft Gear
104
Assembling Steering Handle
104
Installing Magento Control Lever
105
Adjusting Gear Mesh
105
Adjusting Steering Handle Function
105
Steering Handle Assembly: Partial Exploded View
106
Manual Starter: Contents
107
Manual Starter: Special Tools
108
Manual Starter Description/Operation
109
Neutral Interlock
109
Operation of Starter Pinion Gear
109
Manual Starter Removal
110
Installing Rewind Key
110
Removing Interlock
110
Manual Starter Installation, Removal
111
Checking Rewind Spring
111
Placing Starter Rope in Insert
111
Manual Starter Assembly: Exploded View
112
Power Head: Contents
113
Power Head: Special Tools
114
Power Head Principle of Operation
115
Operation of the 2-Cycle Motor
116
Power Head Troubleshooting
117
Fuel Transfer Within Recirculating Passages
117
Compression Gauge Installed
117
Compression Range
117
Power Head Overhaul Removal
118
Disconnecting Stop Switch
118
Disconnecting Choke Link from Carburetor
118
Disconnecting Fuel Line
118
Magneto Control System
119
Disconnecting Interlock Link from Gear Shift Shaft Lever
119
Disconnecting Interlock Lever
119
Removing Power Head from Support Plate
119
Power Head Removal
120
Carburetor and Fuel System Components
120
Removing Bearing Cage and Stator Ring
121
Removing Exhaust Cover
121
Removing Crankcase Cover Screws
121
Removing Locating Pins
122
Prying off Crankcase Cover
122
Removing Connecting Rod and Screws
122
Power Head Inspection and Repair
123
Removing Piston Rings/Pin
123
Checking Flatness of Cylinder Head
123
Resurfacing Cylinder Head
124
Measuring/Honing Cylinders
124
Power Head Reassembly
125
Measuring Piston Ring Gap
125
Assembling Piston to Connecting Rod
125
Removing Piston Pin
126
Installing Piston Rings
126
Inserting Piston to Cylinder
126
Installing Piston Assembly in Cylinder
127
Installing Center Main Liner
127
Positioning Lower Main Bearing
127
Applying Sealant to Parting Line
128
Installing Locating Pins
128
Securing Lower Main Bearing Seal
129
Torquing Sequence for Cylinder Head
129
Installing Driveshaft Spline Seal
129
Power Head (Manual Start Models): Installation
130
Positioning Exhaust Cover, Gaskets, Plate
130
Powerhead Assembly: Exploded View
132
Forward and Port Side Views: Manual Start Models
134
Starboard and Aft. Views: Manual Start Models
135
Forward and Port Side Views: Electric Start Models
136
Starboard and Aft. Views: Electric Start Models
137
Lower Unit: Contents
139
Lower Unit: Special Tools
140
Motor Leg and Swivel Bracket Assembly
141
Shock Mounts Removal
141
Removing Gear Housing from Motor Leg
141
Disconnecting Steering Arm from Bracket
141
Shock Mounts: Installation
142
Detaching Interlock Rod
142
Upper Shock Mounts Installed
142
Removing Lower Shock Mount
142
Swivel Bracket Assembly: Removal, Disassembly
143
Proper Assembly of Gear Shift Rods
143
Removing King Pin from Steering Arm
143
Removing Spring Pin in Reverse Lock Release Lever
144
Removing Spring Pin in Reverse Lock Lever
144
Removing Spring Pin Securing Reverse Lock Link
144
Swivel Bracket Assembly
145
Replacing Clamp Screws
145
Installing Reverse Lock
145
Installing Tilt Lock Assembly
146
Installing Swivel Bracket Bearings
146
Swivel Bracket and Motor Leg Assembly - Exploded View
147
Gear Housing
149
Water Pump
149
Cooling System Flow
149
Water Pump Removal
150
Removing Driveshaft Seal
150
Gear Train
151
Water Pump Inspection and Repair, Reassembly, Installation
151
Installing Impeller
151
Installing Driveshaft Seal
151
Operating of Gear Train
152
Removing Bearing Cage
152
Lower Gear Housing: Inspection and Repair
153
Removing Clutch
153
Measuring Clutch Spring Length
153
Upper Gear Housing: Inspection and Repair
154
Rear Bevel Gear Bearing I.D.
154
Propeller Shaft Bearing Cage Bearing I.D.
154
Remove and Replace Seals
155
Removing Shift Rod Seal
155
Installing Driveshaft Seal in Upper Gear Housing
155
Positioning Clutch
156
Installing Clutch, Cam
156
Gear Housing: Installation
157
Install Shift Cam Detent Spring
157
Installing Lower Gear Housing to Upper Gear Housing
157
Gear Shift Rod Adjustment
157
Connecting Gear Shift Rods
158
Gear Housing - Exploded View
159
Gear Housing (Sailor)
161
Operation of Cooling System and Water Pump
161
Removing Gear Shift Rod Screw
161
Removing Water Pump, Driveshaft Seal
162
Position of Impeller Pin Groove
162
Gear Housing Disassembly
163
Operation of Gear Train and Shift Mechanism
163
Removing Bearing Cage, Propeller Shaft Seals
164
Removing Nut and Lockwasher from Stud
164
Removing Shift Detent Assembly
164
Removing Driveshaft Seal, Gear Shift Rod Seal
165
Propeller Shaft Disassembly
166
Removing Gear Shift Arm Pin
166
Removing Propeller Shaft Components
166
Removing Bearing Cup from Gear Housing/Installing Bearing Cup in Gear Housing
167
Installing Propeller Shaft Components
168
Checking Propeller Shaft
168
Checking Space: Rear Gear to Cage
169
Checking Propeller End Float
170
Installing Seal in Bearing Cage
170
Installing Driveshaft Seal, Shift Rod Seal
171
Assembling Shift Arm to Shift Rod
171
Positioning Upper Housing to Side
172
Installing Propeller Shaft Assembly
172
Special Tools
173
Accessories
174
Installing Shift Detent Assembly
175
Aligning Gear Shift Rods
175

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Chrysler 9.9 H.P. Service Manual (181 pages)

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