Johnson 9.9 Service Manual Free

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The Johnson-Evinrude Workshop manual downloads for the above listed models describes the service procedures for the complete vehicle. Follow the Maintenance Schedule recommendations to ensure that the outboard is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the outboard motor.All chapters in the Workshop Manual apply to the whole vehicle and illustrates procedures for removal/installation of components that are in detailed step-by-step fashion.Most all Workshop manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information and troubleshooting for the section.

The subsequent pages give detailed procedures. You can compare the major components of an outboard with the engineand drivetrain of your car or truck. In doing so, the powerhead is theequivalent of the engine and the gearcase is the equivalent of your drivetrain(thethe power necessary to move the'vehicle, while the gearcask is thkassembly that transmits that power via gears, shafts and a propeller (insteadof tires).Speaking in this manner, the powerhead is the 'engine' or 'motor' portionof your outboard. It is an assembly of long-life components that are protectedthrough proper maintenance.

Lubrication, the use of high-quality oils (2-stroke or 4-stroke) and proper fuelioil ratios (2-stroke) or frequent oilinspectionlchanges (4-stroke) are the most important ways to preservepowerhead condition. Similarly, proper tune-ups that help maintain properairlfuel mixture ratios and prevent pinging, knocking or other potentiallydamaging operating conditions are the next best way to preserve your motor.But, even given the best of conditions, components in a motor begin wearingthe first time the motor is started and will continue to do so over the life ofthe powerhead.Eventually, all powerheads will require some repair. The particular brokenor worn component, plus the age and overall condition of the motor may helpdictate whether a small repair or major overhaul is warranted. The complexityof the job will vary with 2 major factors.

Johnson 9.9 Service Manual Pdf Free

As much as you can generalizeabout mechanical work:transmissionltransaxle T. He powerhead is the assemblv that produces.the more difficult the repairThe larger and more complex the motor, the more difficult the repair.Again, these are generalizations and, working carefully, a skilled do-ityourselfboater can disassemble and repair aas a seasoned professional. But both DlYers and professionals must knowtheir limits.

9.9 johnson outboard

These days, many professionals will leave portions of machinework (from cylinder block and piston disassembly, clean and inspection tohoning and assembly up to a machinist). This is not because they are notcapable of the task, but because that's what a machinist does day in and dayout. A machinist is naturally going to be more experienced with theprocedures.If a complete powerhead overhaul is necessary on your outboard, werecommend that you find a local machine shop that has both an excellentreputation and that specializes in marine work. This is just as important andhandv a resource to the rofessionaal s a DIYer. If ossiblec. Onsult with themachke shop before disassembly to make sure you follow procedures ormark components, as they would desire. Some machine shops would preferto perform the disassembly themselves.

In these cases, you can usuallyremove the powerhead from the gearcase and deliver the entire unit to theshop for disassembly, inspection, machining and assembly.If you decide to perform the entire overhaul yourself, proceed slowly,taking care to following instructions closely. Consider using a digital camera(if available) to help document assemblies during the removal anddisassembly procedures. This can be especially helpful if the overhaul orrebuild is going to take place over an extended amount of time. If this is yourfirst overhaul, don't even THINK about trying to get it done in one weekend,YOU WON'T. It is better to proceed slowly, asking help when necessary fromyour trusted parts counterman or a tech with experience on these motors.Keep in mind that anytime pistons, rings and bearings have beenreplaced, the powerhead must be broken-in again, as if it were a brand-newmotor. Once a major overhaul is completed, refer to the section onPowerhead Break-In for details on how to ensure the rings set properlywithout damage or scoring to the new cylinder wall or the piston surfaces.Careful break-in or a properly overhauled motor will ensure many years ofservice for the trusty powerhead. The age of the motor (the older OR less well maintained the motor is) 70 hp EFI powerhead, as well.

+ See Figure 1The gearcase is considered that part of the outboard below themidsectioniexhaust housing. The gearcase contains the propeller shaft, thedriven and pinion gears, the driveshaft from the powerhead and the waterpump. On models equipped with shifting capabilities, the fonvard and reversegears, together with the clutch, shift assembly, and related linkage, are allhoused within the case.The single most important task for proper gearcase maintenance isinspecting it for signs of leakage after each use. If oil can get out, then watercan get in.

And, water, mixing with or replacing the oil in the gearcase willwreak havoc with the shafts and gears contained within the housinq.The second most important task for proper gearcase maintenance ischeckinq and maintainina the oil inside the case. Not onlv is it imortanttomake sire the oil is at t k proper level (not above or below), but it isimportant to check the oil for signs of contamination from moisture. Waterentering the gearcase will usually cause the oil to turn a slightly milky-whitecolor. Also, significant amounts of water mixed with the oil will give theappearance of an overfilled condition.If you suspect water in the gearcase, start by draining and closelyinspecting the fluid (refer to the procedures found in the Maintenance andTune-Up section). Then, refill the unit with fresh oil and test the outboard (byusing it!).

Watch the fluid level closely after the test, and for the first fewoutings. If any oil leaks out or water enters, either the propeller shaft sealmust be replaced or the gearcase must be disassembled, inspected andcompletely overhauled.


To be honest, a complete overhaul is recommended,because corrosion and damage may have occurred if moisture was in thegearcase long enough. But, in some cases, if the leak was caught in time,and there is no significant wear, damage or corrosion in the gearcase, thepropeller shaft seal can usually be replaced with the gearcase still installedto the outboard.The last, most important task you can perform to help keep your gearcasein top shape, is to flush the inside and outside of the aearcase after eachuse.' inseth e outside of the unit with a hose to remove any sea life, salt,chemicals or other corrosion inducing substances that you may have pickedup in the water. Cleaning the gearcase will also help you spot potentialFig.maximum efficiency, compared with a unit receiving TLC (tenderloving care) 1 A neglected lower unit cannot be expected to perform totrouble, such as gearcase oil leaks, cracks or damage that may haveoccurred during use. Remove any sand, silt or dirt that could potentiallydamage seals or clog passages. Once you've rinsed the outside, hook up aflushing device and do the same for the inside. Again, details are found inthe Maintenance and Tune-up section, look under Flushing the CoolingSystem.REMOVAL & INSTALLATIONThe most common reason for removrng and installing the gearcaseperform service (inspect or replace) the water pump impeller.

On all motorsexcept the 2.0-3.5 hp (78cc) motors, the water pump is found on the IS togearcase-to-midsectionhousing) split line. On 2.0-3.5 hp (78cc) motors the pump is mounted just infront of the propeller, so the gearcase does not have to be removed on thesesmall motors in order to service the pump.Removal and installation roceduresa re rovidedh ere for each of thegearcases used on these &nson/vinrude'motorsE.


Xploded views are alsoprovided, in case disassembly and overhaul are required. (sometimes known as the intermediate or exhaustColtiJunior (43cc) Motors + See Figures 2 and 31. For safety, disconnect the spark plug lead, then ground it to thecylinder head.2. If necessary for service or access, remove the propeller, for detailsrefer to the procedure in the Maintenance and Tune-Up section.3.

Remove the two screws securing the lower unit to the exhausthousing.4. Taking Care not to damage the driveshaft and the water tube,separate the lower unit from the exhaust housing by pulling straightdownward.5.gearcase.6. Thoroughly inspect the gearcase and exhaust housing for signs ofdamage. Make sure all mating surfaces are clean and free of debris,corrosion or damage.

If necessary for service or overhaul, drain the gear oil from theTo install:7. Apply a light coating of OMC Moly Lube, or equivalent assemblylubricant to the driveshaft splines.

Be sure to coat only the SIDES of thesplines and not the top of the shaft, as that could hydraulically prevent thedriveshaft from fully seating in the crankshaft spline.8. Apply a light coat of clean liquid soap to the water tube grommet.9. Apply a light coating of OMC Nut Lock, or equivalent threadlock tothe threads of the 2 gearcase mounting screws.10. Install the gearcase, while carefully aligning the water tube in thearommet and the driveshaft slinesto the crankshaft shaft.

If necessarv, turn?he propeller shaft slowly clockwise (when viewed from the shaft end) ioalign the splines.