johnson 9.9 manual pdf
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johnson 9.9 manual pdfAssure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. This manual covers service information on Johnson 9.9 and 15 HP 2-Stroke models. Model Number Start Shaft Steer J10RSUR Rope 15”. Italic subheading above Service Chart indicates pertaining models. Bold letter indicates liquid product to be applied to a surface Pay attention to torque specifications. Some units appear as in. Do not disas- Title in italics indicates semble. V4 M a procedure ODELS concerning a Install base gasket dry. Do not use Permatex Denotes necessary particular model step or information to. Additives The use of other additives may result in engine damage. See Fuel Requirements on p. 43 for additional information. Definite resistance to turning must be felt when reusing a locking fastener.Plan the installation of Install the appropriate remote control following all all remote controls carefully. Fuel systems must meet minimum specifications Primer Bulbs to insure the proper delivery of fuel to the out- board. INSTALLATION WARNING DO NOT install an outboard on a curved or Hull Preparation irregular surface. Doing so can wear, bind, and damage components, causing loss of Maximum Capacity control. Hull Centerline Use a straightedge as a reference to extend the Locate the centerline of the boat transom as it bottom of the boat. RTV silicone is not WARNING approved for below waterline use. Polyurethane sealants are not easily removed and may damage The outboard must be correctly installed.WARNING To prevent accidental starting of engine, confirm the battery cables are discon- nected at battery and spark plug leads are disconnected from spark plugs. Control Cable Installation Control Cable Identification IMPORTANT:.http://feyzullahalpman.com/userfiles/jonsered-2040-turbo-manual.xml
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Be sure the throttle cable is retracted to IDLE position and shift cable is at mid-point of travel. Position shift linkage of outboard in NEUTRAL. Make sure gearcase is in NEUTRAL. Secure the cable to terminal. Position grom- IMPORTANT: met in lower engine cover. Provide sufficient slack at out- board end to permit unrestricted steering and tilt- ing of outboard. It can be used con-. Observe all fuel lines, both in the boat and on the If XD30 oil is not available, you must use an oil outboard. Do not shift remote overboard indicator.Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer. IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use applications require more frequent inspections and maintenance. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion. Check the condition of cooling system compo- nents regularly.Remove the plug from the flushing port. Install WARNING flushing device and garden hose. Failure to grease as recommended could Turn water supply ON. Apply Triple-Guard grease. Check battery connections frequently. Clean and IMPORTANT: Do not use liquid or aerosol service battery connections at regular intervals.Johnson outboards are equipped with a service- able fuel filter element. Clean or replace the ele- Models Recommended Spark Plug ment as needed. Turn counterclockwise no more than one-half turn to AND LINKAGE align it with the throttle lever. Install the retaining pin. ADJUSTMENTS IMPORTANT: Synchronization and linkage pro- cedures MUST be followed in sequence and be performed exactly as described to ensure consis- tent engine idling and smooth operation through- out the RPM range.http://hotelaidonline.com/userfiles/jonsered-2041-turbo-manual.xml Advance the throttle until the tip of the amplifier Repeat procedure if necessary.Correct ignition primary lead position is all tle lever. Drain Follow the same procedures used for Engine and clean all fuel hoses, filters, and fuel tanks. Dropped Overboard (Not Running) and Engine Dropped Overboard (Running). The flywheel's mag- netic lines of force cutting through the stator wind- Information in this section may only apply if any of ings produce alternating current.Disconnect the battery cables at the battery.Check the voltage between the start output lead. Push the start button. Check the volt- switch connection and rectifier terminal. Removal Use a battery rated at 350 CCA or higher that is in good condition and fully charged. Disconnect the battery cables at the battery. Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. 1. Scribe marks 32986 2. Bolts 3. Assemble the brush end cap with brushes and springs to the armature shaft. Place a new gasket on the brush end cap. Place a Installation new gasket on the drive end cap. Install the starter on the bypass cover. The elec- tric starter motor must be held firmly against the Align the drive end cap mark with the mark on the bracket while bolting it to the bypass cover. Remove the red wire and two screws COMPONENTS retaining the rectifier and black cables. Remove the rectifier.Remove the bracket. SERVICING Amphenol Connectors Terminal Removal To remove a terminal from the plug or receptacle, lubricate both ends of the cavity with isopropyl alcohol. Pick the proper tool for the service being per- formed. Once the fly- wheel exceeds a minimum cranking RPM, the fly- The flywheel contains permanent magnets which wheel's magnetic lines of force cutting through the energize the charge coil, sensor coil, and alterna- sensor coil windings produce approximately 3 V.https://www.becompta.be/emploi/boss-d1200m-manual The stop button, and emergency stop switch are connected to the power pack through the engine wiring harness. When activated, these switches direct the power pack output to ground, stopping the ignition system. This indicates the number 1 piston is near top dead center.Pack Cranking Output on p. 94. Disconnect 5-pin Amphenol. Disconnect 5-pin Amphenol connector between ignition plate and power pack.Stevens CD-77 meter.Con- DANGER nect meter red lead to coil primary terminal. Con- nect meter black lead to coil spark plug terminal.Align support plate with four screw holes in powerhead. Apply Nut Lock to Removal threads of the four support plate screws. Install the screws and torque to 48 to 60 in. SENSOR COIL Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. Remove the screws retaining the ignition compo- nent that is being replaced. Lift the ignition Install plate on bottom of the ignition plate.Remove the plate from the bottom of the ignition plate. Route component leads through wire clamps. Removal Twist and remove cover.Position inlet nipple between ronmental Protection Agency (EPA) standards screw heads. Remove the choke lever. 35009 35005 Disassembly Remove the cam follower O-ring. IMPORTANT: Changing original factory fuel mixture calibrations beyond the limits allowed by. Strong cleaners might damage components or remove sealing com- Remove the six cover screws. Check for excessive throttle shaft play. Check for throttle valve misalignment. If necessary, remove the calibration pocket core plug to inspect the pocket for damage or restric- tions. Flatten shot with flat end Assembly punch and plastic mallet. Check for leakage. When installing new parts from a carburetor rebuild kit, inspect gaskets and compare to origi- nal gaskets to ensure all holes are correctly punched. Top of float should be Install the float chamber and a new gasket.Position O-ring on the post to secure cam follower.https://living-simple.com/images/casio-ctk-100-manual-free.pdf Attach the fuel supply hose, and secure with a tie strap. 35007 35009 Install the choke lever. Position a new gasket on the intake manifold. Install the carburetor. Allow 15 seconds after each adjustment for the engine to respond. ADJUSTMENT IMPORTANT: Changing original factory fuel mixture calibrations beyond the limits allowed by the tamper resistant device is a violation of federal law. This may damage them so they may not Remove the powerhead. Refer to Powerhead seal properly or may break after the engine is REMOVAL on p. The thickness of the valves nicks.Wipe off Tighten screws securely.Install screws finger tight. powerhead. Remove all spark plugs and disconnect the 5-pin power pack connector. Advance throttle linkage to WOT. Install compression tester’s hose attachment into spark plug hole (14 mm threads). CHECK Reduce engine speed to 900 RPM.Position seal on crankshaft with lip facing crank- General case assembly. The presence of oil under the flywheel could indi- Upper Crankshaft Seal Installer cate a leaking upper crankcase seal. Removal Remove the lower engine covers as described in REMOVAL on p. 128. Remove the clip and drive pin from shift handle. 32333 Remove the pin, shift rod, and grommet. 32338 Remove the screw retaining the shift handle. Remove Installation lock tab from shift arm. Installation is essentially the reverse of removal. Pay close attention to any additional task that may be required for installation. Install the two shift arm bushings. Install the pin and shift lever, and secure with cotter pin. Removal Remove screw and wave washer retaining the shift handle. 1. Starter wire 32824 2. Start switch wire Pull wires out of grommet. 1. No continuity should be PROTECTION indicated in either position. To adjust, loosen the start button screw. With the Manual Starter outboard in NEUTRAL, center the button in the Manual start outboards are equipped with starter switch recess. WARNING To prevent accidental starting of engine while servicing, twist and remove all spark plug leads. On electric start models, dis- connect battery cables at the battery.IMPORTANT: To simplify reassembly, lay out the various screws and clamps in the order of their proper location. Remove the three screws retaining the crankcase head to the powerhead. Using a mallet and a punch, drive the seals from the crankcase head. Do not use any tool smaller than taper pin Using a rawhide mallet, lightly tap upward on the bore to remove the pin.Lift up and remove the crankcase. 1. Allen wrench to remove connecting Remove the retaining ring from groove of the cen- rod screws. Remove the rod caps and bearing ter main bearing. Separate the bearing and retainers.Discard the rings. IMPORTANT: Before inspecting or assembling powerhead, all internal components must be per- fectly clean and free of contaminants. Remove any carbon accumulation from exhaust port areas. Blow out all holes and passages with compressed air.One over- or tapered condition. Make sure the gauge or size piston is available for this engine 0.020 in. Do not allow the wrist pin to enter the piston cavity. 1. Needle bearings COB1135 Slide the connecting rod with the needle bearings and washer up and off the wrist pin, being careful not to disturb the bearings. If removed, oil and press a new lower main bear- ing onto the crankshaft.Secure sleeves Position the rods on the crankpins at this time.Place other retainer halves and bearings on crankpins. COB1144 Remove the rod caps from connecting rods. Place one retainer half and bearings on each rod. Install the two new exhaust cover gaskets. Install the inner gasket and cylinder head. Tighten the cylinder and outer exhaust covers. Do not use sealer on these gaskets.Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. Remove the lower motor covers, manual starter, and air silencer. Remove the throttle cable pin from the throttle 35283 lever. Assembly Install the throttle cable seal in inner handle. Snap the stop switch assembly with the throttle cable into the cover. Be sure the protective sleeve covers the stop switch wires and throttle cable. 32293 Remove stop switch assembly with throttle cable from cover. The Be sure the twist-grip's speed indicator line is tab on the cap goes into the recess of the inner positioned with the speed range symbol on the handle. handle. Use iso- propyl alcohol to ease assembly. IMPORTANT: Make sure the protective sleeves are on the throttle cable and stop switch wires. Thread the cable end connector on the cable until seated. 1. Remove the two Clean all parts with parts cleaning solvent and dry upper mount screws. Separate the exhaust hous- with compressed air. All nut and screw threads ing from the swivel bracket assembly. Apply Nut Lock to threads of lower mount bracket screws. Install the lower mount brackets.Disassembly Loosen the swivel bracket adjustment screw. Lift the steering bracket and pilot shaft from the swivel bracket.If any of the swivel bracket components were removed, refer to the two reference pictures for correct reassembly. TYPICAL 32478 If the tilt bolt is removed, tighten the bolt to a torque of 60 to 84 in. Lubricate and place the liner and friction block in the swivel Apply Triple-Guard grease to the lower bushing. Drain lubricant before testing. Water can make the lubricant milky in appear- ance. However, normal aeration can also cause STEP 1 the same appearance.INSTALLATION Removal WARNING During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service. Check impeller cup and plate for scoring, distortion, and Remove gearcase from exhaust housing as impeller material transfer. Inspect housing for described in REMOVAL AND INSTALLATION on cracks or melting. Coat the inside surface of grommet Apply a thin bead of Adhesive 847 to the with Triple-Guard grease.Slide the plate down over the driveshaft and position it. Remove gearcase. Refer to REMOVAL AND INSTALLATION on p. 167. Remove water pump and driveshaft from gear- case. Refer to WATER PUMP on p. 169. 44107 Remove shift lever pivot pin from gearcase. REMOVAL IMPORTANT: Inspect bearings for damage while in place. If bearing is damaged, remove and discard. If the bearing is removed for any reason, it must be replaced. Use a mallet to drive the two pinion bearings into the propeller shaft cavity of gearcase. Discard seal(s). 1. Small puller jaws 32555 1. Adapter DRC1505 Prop Shaft Bearing Housing 2. Discard the bearing. WARNING Replace damaged components. Shift sys- tem failure could cause loss of control over direction of engine thrust. Apply DPL IMPORTANT: Make no dry assemblies. Lubri- Penetrating Lubricant to the casing of the seal cate all bearings, shafts, and gears with HPF XR before installing. Press against Apply Gasket Sealing Compound to the metal the lettered side of bearing until the tool is seated casing of the seals before installing. IMPORTANT: Make no dry assemblies. Lubri- cate all bearings, shafts, and gears with HPF XR gearcase lubricant. Oil and place the forward bearing cone and roller assembly in the forward bearing cup.Then back out shift rod until slotted Using long-nose pliers, place the clutch dog in the face of connector faces the driveshaft. cradle. Groove on the clutch dog must face the forward gear. 32538 32541 Pull shift rod up and install cradle on yoke. Hold propeller shaft in place and move shift rod to NEUTRAL position. Install the driveshaft. Rotate the driveshaft to allow the splines in the pinion to engage the splines on the driveshaft. 32573 Lightly apply Gasket Sealing Compound to the aft 32572 support flange of the propeller shaft bearing hous- ing. Lift starter from powerhead. WARNING Wear safety glasses to avoid personal injury.Hold the pulley down in housing and lift out spin- dle. Carefully lift out pulley, leaving spring in hous- WARNING ing. Wear safety glasses while disassembling and assembling manual starters to avoid personal injury caused by rewind spring tension. Secure pulley in place by retainer (taper toward pulley) and left hand thread installing stop tool into pulley and housing holes.The pawl should remove starter assembly.Install spindle, screw, and locknut. Tighten locknut 120 to 144 in. Connect starter lockout link to cam. Turn cam screw IN carefully until screw head contacts cam. Do not overtighten. 1. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices. When control lever is in What is most important. FORWARD, NEUTRAL or REVERSE. What is most important. When control lever is moved from FORWARD (or REVERSE) to NEUTRAL. What is most important.What could happen? Outboard may Outboard may S.L.I.D.E on transom T.I.L.T on transom Boat may turn and be hard. Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat. If lanyard is cut or frayed.lanyard or clip may break when pulled. If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway. Handling high voltage parts like spark plugs and coils can shock. Running too fast can happen when: 1) Using a flushing device. Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket. Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown. Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink. Part Manual will supply you with practical and complete information guides. PDF file contains good quality diagrams and instructions on how to service and repair your Johnson Evinrude. This is recommended for the Do-It-Yourselfers. Part Manual will supply you with practical and complete information guides. PDF file contains good quality diagrams and instructions on how to service and repair your Johnson Evinrude. This is recommended for the Do-It-Yourselfers. Part Manual will supply you with practical and complete information guides. PDF file contains good quality diagrams and instructions on how to service and repair your Johnson Evinrude. This is recommended for the Do-It-Yourselfers. We thought about why, if a lot is invested in comfort, one fundamental convenience appears to be omitted: the electronic chauffeur referred to as an autopilot. But it surely already has questions, too — which is healthier, two strokes or four. What's the proper prop. Is the larger motor the better motor. We have offered a portion of the most debated questions to the professionals, and here's make reply them. Query: Are 4-strokes at all times more enjoyable then two-strokes. Instant Download the manual here: This workshop manual has detailed instructions to guide you through every conceivable job possible, including every adjustments that are necessary. Service, maintenance, overhaul adjustments, everything you need to learn is covered. This manual covers motors from 1 HP to 300 HP. The best quality service manual for Evinrude Johnson you. Pinterest Explore Log in Sign up Privacy. BRP offers the most modern,Revolutionary technology. UniqueThe youth of the beginning of the century simplyTheir first outboard appeared in 1908. Having gained credibility with the productionIt was made withTo evaluate this achievement, it is necessary to take into account that the generally accepted standard at that time. Their work was accompanied by strong noise and vibration.In September 1936, an important event in the history ofThe entire history of OMS is marked by a number of. Feel free to download what you need. Please share this link if you are trying to help others out. We will add manuals as we get them. Do you have a manual that is not on this list that you would like to share. More importantly, if you have a question about your motor, join our free, friendly, forum and get the help you need in the dedicated motors section. Someone is always willing to help out. TinBoats.net rules that way. The handbook is intended to guide the mechanic in the process of fixing or restoring a boat motor to working order. Johnson outboard repair manuals cover every aspect of repair and it’s divided into several main sections. Below is a breakdown of information generally found in a Johnson outboard repair manual. Typical Johnson outboard repair manuals contain the following chapters: Downloadable repair manuals are often more helpful because the table of contents contain clickable chapters and sub-chapters that navigate the user to the selected repair procedures with the click of the mouse. The introduction will contain models covered in the manual, how to identify model and serial numbers, model designation, as well as information on how to use the repair manual. Some of the service specifications might include torque specifications, special tools required to perform a repair job properly, and shop aids. Maintenance information often includes: Depending on what’s being repaired, information might include: Writing diagrams are usually black and white illustrations of specific parts and list wire colors and functions. Hose routing diagrams show intended routs which are especially helpful for mechanics performing complete engine overhaul. Troubleshooting guides help the mechanic trace and correct faults in the Johnson outboard’s mechanical or electrical system. Using a troubleshooting guide can be a fast and effective way of pin-pointing a malfunction. Any help would be greatly appreciated. Thank you. I just got one of these motors But there is no way to tell what year model. Scanning for 20hp in your list of manuals, i am only seeing 1990-2001 listed. Must have wire diagram Pear let me know what I need to do to get a downloadable copy. We are here to help you fix your automotive problems free of charge. I document here what I have In doing so, you will see Both brands of So what you see here that Evinrude was usually Late 1990's they both were either black, white or a OMC filed for chapter 11 bankruptcy and in October 2001, Bombardier. Corp. a Canadian manufacturer that builds snow mobiles, airplanes plus a multitude of other Then in July of 2020 when the In 1958 these motors had a face change, utilizing a newer style motor cowling and a As for actual physical differences between the 9.9 Same motor, but they Guard's terminology for registering a boat was that if it used a motor of less IF not used Full power operating RPM for the 9.9 is 4500 - 5500. TheThis higher RPM is achievable by using a different carburetor which uses a larger This series of The outward appearance of this motor,OMC apparently learned something on the 9.5, as the 9.9 is basically a United States. To me this means that if there could have been an overage of There could European motors. So it is possible that at times the year models would be a year However if these modifications were crucial, a running change could have taken This is evident in that the first models in Discharge system. The carburetors seem to be changed in either 3 or 6 year Or more than If they worked on a 3 year cycle it would not be as bad and a better parts Prior to 1979. Johnson used the lastAs a model 10R78M, But not all of Evinrude's pre 1979 models And here is the States, here is another As before, the last 3 letters are what you are lookingAll the SailMasters would haveThese were designed to be Johnson. However some of If this happens, you canThe model and year are stamped in this softIt is interesting to also note that the 15 hp uses the sameHowever another reader said his plug codes were good at 1988. ?? Or this one To get the equivalent prop HP onAlso do not knock these pre Many boaters are not interested in these They just require a little more prolonged That is on the frontThis is the carburetor idle adjustmentIf it is electric start, on the left side The regular kill button is still in place and functional however. This same motor has the AC This knob DOES NOT have anything In effect this is Sometimes (especially after many It is unique in that the threads are LH, this is apparently so that by turning Put the knob in a metal lathe, then carefully move the shank back into the knob Shown below are the important dimensions. The purple lines are what was removed. Also below the shift lever but just above the mounting brackets is a lever that moves forward Also in the same 2 photos LATE 1985 a change was made to the At this time they also moved the It has the word STOP on the These buttons for both type 3 and 4 also incorporated a man overboard kill switch. The motor comes with a red coiled plastic cord that is attached to a split The other end of the In use, this electrical circuit is just reversed from what most of us think, as with the This is to fine tune adjust the idle for This is spare that was original equipment. Another like it had the red coiled plastic looped cable with a clip to attach to The angle of the photo for type 3 does not show The electric starter This button will be moved This part is also known in the If the motor application The rear end of This threaded However it has been found that when For more detailed info on how to adjust This positioning also screwed up the end of the throttle handle slow speed In this situation, After finding this disconnect, my. Red-Neck solution was to Zip Tie the coupler to the timing plate arm. Start Your Motor: The first series in 1974 had a. Instructions: Read owners manual. Connect fuel line to motor. Squeeze primer bulb unit pressure is felt. Shift to neutral. TwistPull choke knob out. Pull starterStop button onHowever when While: If the engine hasn't been used in quite awhile,When this happens, for what ever reason,Do not try to spray a carburetor cleaner in the breather or run it thru the fuel If you take the carburetor apart, make notes and drawings as to what goesRegardless of how simple it seems, you will find something where you can't remember how it should be when it comes time to put theWeak Thing on This Motor: As described above these gear teeth mesh on both the twist shaft and the mating BUT this featureThis is explained in a subsequent section. Pictures show this relationship in the Trouble. Shooting section. The main problem occurs if these motors are being used as an auxiliary motor on So where the NOTE this is not The outlet or rear throat dia.This increased throat dia.And I have NEVER been And many people, even marine mechanics, do not see enough of these toThe reason for this is that when theseEither one will screw As the replacement carburetor you get may OMCs only. It was a sort of tuned round exhaust housing, allowing the engine toThe big difference in the performance betweenThe copper tube on the tuned one is so the The primary reed has a hole in the I have 2 friends that have these 15 hp The problem that both encounter is My combination would extend their run time With this slightly enriched idle mixture, this could explain the more frequent plug If your choke knob shaft was installed upside down, the choke butterfly will not When. Cold When you are adjusting this timing and idle jet forThen when theWhat happens then is that in theThen when you go to start it,This condition will not allow sufficient vacuum on the intake stroke to pullSome mechanics will tell you that it These leaky top My simple method of doing a check out of the top seal leaking is to pour a small. It sure can't hurt anything They mentioned that one COLD morning, they were not able to go out to the hunting grounds because This was devastating as they were on a trip a considerable distance from home. A trip His explanation was that on Early: Do not think that you can up the horsepowerI could document and remember myself, as I could not readily findTo reiterate the above, a 15 hp Then from about 1980 to late 1987 the same basic carburetor as previously was This plastic seemed to be an improvement in that if water had entered in theFor a more complete information on the carburetors of these motorsLate: Late 1987 and newer production carburetors up thru On these there is Remove the chokeWhen removingThe rope or knob does not need to be Pull the rope out a few feet and tie a slip knot in it so that it can't rewind back.