Chrysler 250 Sailor - User Manual

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Section Index3
General Information7
Safety7
Outboard Motor Nomenclature7
Starboard and Port Side Views8
General Service Information: Contents11
Motor Identification13
Fuel and Lubricants13
Fuel Use13
Fuel Ratio Conversion14
Fuel/Oil Mixture Requirements14
Types of Lubricants Used for Complete Lubrication14
Lubrication Intervals14
Lubrication Points15
Location of Vent and Fill Plugs15
Lubricating Starter Pinion Gear15
Lubricating Throttle and Choke Link16
Lubricating Clamp Screws16
Lubricating Shift Linkage16
Lubricating Swivel Bracket16
Break-In17
Lubricating Steering Arm17
Lubricating Stern Bracket Bolt17
Lubricating Propeller Shaft17
Submerged Motor18
Motor Storage18
Tune-Up19
Troubleshooting Guide19
Motor will Not Start19
Loss of Power20
Engine Specifications21
Torque Chart22
Capacities22
Electrical Specifications22
Fuel Jet Selection23
9.9 H.P. and 250 Sailor24
9.9. H.P. and 250 Sailor25
15 H.p.26
Fuel System and Components: Contents29
Fuel System and Components: Special Tools30
Fuel System Operation31
Fuel System Troubleshooting31
Checking Fuel Flow31
No Fuel to Carburetor Bowl32
No Fuel to Combustion Chamber32
Flooding32
Fuel Tank and Components33
Gauge Cap33
Prime Bulb33
Fuel Tank Adapter33
Fuel Line Couplers34
Assembly of Check Valve in Prime Bulb34
Components of Quick Disconnect Coupling34
Fuel Tank and Components Overview35
Fuel Pump37
Fuel Pump Operation Overview37
Fuel Pump Testing38
Fuel Pump Servicing38
Removing Fuel Pump38
Unfastening Starter Support38
Removing Starter Switch39
Carburetor Description41
Starting Choke Operation41
Idle Operation41
Intermediate Operation42
High Speed/Idle Operation42
Carburetor Adjustments43
Throttle Adjustment43
Idle Adjustment43
Adjusting Pick-Up Point43
Idle Speed Adjustment44
Float Adjustment44
Adjusting Float Drop44
Idle Mixture Adjustment Screw44
Carburetor Overhaul45
Removing Carburetor45
Removing Starter Support45
Inspecting Idle Needle45
Inspecting Float Needle46
Throttle Return Spring46
Positioning Throttle Valve46
Position of Choke Valve47
Assembling Throttle Valve to Shaft47
Assembling Choke to Carburetor48
Assembling Float Valve Seat48
Setting Inside Dimension of Follower Arm48
Installing Throttle Cam Follower and Roller49
Positioning Throttle Cam Pick-Up Point and Roller49
Installing Follower Arm to Cam Follower49
Checking Throttle Cam Mark and Roller49
Caburetor and Manifold Assembly - Exploded View50
Reed Valve Assembly Servicing51
Reed Valve and Manifold Removal51
Removing Manifold and Reed Valve Assembly51
Inspecting Reeds52
Electrical System and Components: Contents53
Electrical System and Components: Special Tools54
Electrical System Operation55
Magneto Ignition55
C-D Ignition System56
Generating System56
C-D Ignition System Description/Troubleshooting57
C-D Ignition System Components57
C-D Ignition System Troubleshooting Tests60
High Voltage Output61
Trigger Coil Output #1 Cylinder62
Trigger Coil Output #2 Cylinder63
C-D Unit Output to #1 Ignition Coil Primary Winding64
C-D Unit Output to #2 Ignition Coil Primary Winding65
Flywheel Removal66
Removing Starter Housing66
Removing Coils and Starter66
Removing Flywheel from Power Head66
Flywheel Inspection and Repair67
Stator Removal, Cleaning and Inspection67
Position of Flywheel Key Prior to Assembly67
Stator Installation68
Trigger Stator Removal, Cleaning and Inspection68
C-D Module Removal68
Assembling C-D Stator to Trigger Stator68
C-D Module Cleaning and Inspection69
Spark Plugs, Removal69
Removing C-D Module from Power Head69
Connecting C-D Leads to Terminal Block69
Spark Plugs Inspection, Servicing, Installation70
Generating System Troubleshooting71
Generating System Testing72
Rectifier Removal, Installation, Cleaning and Inspection75
Circuit Breaker Removal, Cleaning and Inspection, Installation75
Magneto Ignition System Troubleshooting77
Magneto Ignition System Preliminary Tests77
Electrical Troubleshooting Guide77
Magneto Ignition System Test Equipment78
Flywheel Removal, Inspection78
Condenser Removal79
Test Condenser Capacity79
Flywheel Installation79
Coils80
Testing Condenser80
Coils Removal, Coil Power Test81
Removing Coils, Coil Leads81
Straightening Coil Laminations81
Sparkle Cover and Spring81
Testing Coil High-Speed82
Testing Coil Surface Insulation82
Testing Coil Continuity83
Breaker Points Removal, Installation84
Adjusting Breaker Point Gap84
Stator Plate Removal, Installation85
Checking Spring Tension85
Assembling Throttle Cam and Ground Wire85
Stator Hold-Down Screw Locations85
Spark Plug Removal, Inspection, Servicing, Installation86
Electrical Starting System Overview87
Electrical Starting System Troubleshooting88
Starting Circuit88
Battery Activation Procedure88
Battery: Slow Charge89
Testing Battery89
Hydrometer Test89
Reading Specific Gravity with a Float-Type Hydrometer90
Starter Motor: Description91
Battery: Heavy Load Test91
Battery Storage91
Freezing Temperature Chart91
Starter Motor Troubleshooting Chart92
Starter Motor Removal93
Testing Starter Armature Rotation93
Testing Armature94
Starter Motor Brush Assembly95
Starter Motor Bearing Location95
Field Winding Ground Test95
Starter Motor Reassembly, Installation96
Testing Permanent Magnets in Starter Housing96
Starter Switch Removal/Installation97
Interlock Switch Removal/Installation97
Connecting Leads to Starter Switch97
Connecting Leads to Interlock Switch97
Correct Position: Interlock Switch and Interlock Lever98
Steering Handle Assembly: Contents99
Steering Handle Assembly: Special Tools100
Steering Handle Assembly: Remove and Disassembly101
Tapping Insert to Free Handle102
Removing Insert102
Loosening Set Screw102
Steering Handle Assembly: Inspection and Repair, Reassembly and Installation103
Removing Pivot Pin103
Installing Stop and Spring on Bracket103
Securing Magneto Control Shaft Gear104
Assembling Steering Handle104
Installing Magento Control Lever105
Adjusting Gear Mesh105
Adjusting Steering Handle Function105
Steering Handle Assembly: Partial Exploded View106
Manual Starter: Contents107
Manual Starter: Special Tools108
Manual Starter Description/Operation109
Neutral Interlock109
Operation of Starter Pinion Gear109
Manual Starter Removal110
Installing Rewind Key110
Removing Interlock110
Manual Starter Installation, Removal111
Checking Rewind Spring111
Placing Starter Rope in Insert111
Manual Starter Assembly: Exploded View112
Power Head: Contents113
Power Head: Special Tools114
Power Head Principle of Operation115
Operation of the 2-Cycle Motor116
Power Head Troubleshooting117
Fuel Transfer Within Recirculating Passages117
Compression Gauge Installed117
Compression Range117
Power Head Overhaul Removal118
Disconnecting Stop Switch118
Disconnecting Choke Link from Carburetor118
Disconnecting Fuel Line118
Magneto Control System119
Disconnecting Interlock Link from Gear Shift Shaft Lever119
Disconnecting Interlock Lever119
Removing Power Head from Support Plate119
Power Head Removal120
Carburetor and Fuel System Components120
Removing Bearing Cage and Stator Ring121
Removing Exhaust Cover121
Removing Crankcase Cover Screws121
Removing Locating Pins122
Prying off Crankcase Cover122
Removing Connecting Rod and Screws122
Power Head Inspection and Repair123
Removing Piston Rings/Pin123
Checking Flatness of Cylinder Head123
Resurfacing Cylinder Head124
Measuring/Honing Cylinders124
Power Head Reassembly125
Measuring Piston Ring Gap125
Assembling Piston to Connecting Rod125
Removing Piston Pin126
Installing Piston Rings126
Inserting Piston to Cylinder126
Installing Piston Assembly in Cylinder127
Installing Center Main Liner127
Positioning Lower Main Bearing127
Applying Sealant to Parting Line128
Installing Locating Pins128
Securing Lower Main Bearing Seal129
Torquing Sequence for Cylinder Head129
Installing Driveshaft Spline Seal129
Power Head (Manual Start Models): Installation130
Positioning Exhaust Cover, Gaskets, Plate130
Powerhead Assembly: Exploded View132
Forward and Port Side Views: Manual Start Models134
Starboard and Aft. Views: Manual Start Models135
Forward and Port Side Views: Electric Start Models136
Starboard and Aft. Views: Electric Start Models137
Lower Unit: Contents139
Lower Unit: Special Tools140
Motor Leg and Swivel Bracket Assembly141
Shock Mounts Removal141
Removing Gear Housing from Motor Leg141
Disconnecting Steering Arm from Bracket141
Shock Mounts: Installation142
Detaching Interlock Rod142
Upper Shock Mounts Installed142
Removing Lower Shock Mount142
Swivel Bracket Assembly: Removal, Disassembly143
Proper Assembly of Gear Shift Rods143
Removing King Pin from Steering Arm143
Removing Spring Pin in Reverse Lock Release Lever144
Removing Spring Pin in Reverse Lock Lever144
Removing Spring Pin Securing Reverse Lock Link144
Swivel Bracket Assembly145
Replacing Clamp Screws145
Installing Reverse Lock145
Installing Tilt Lock Assembly146
Installing Swivel Bracket Bearings146
Swivel Bracket and Motor Leg Assembly - Exploded View147
Gear Housing149
Water Pump149
Cooling System Flow149
Water Pump Removal150
Removing Driveshaft Seal150
Gear Train151
Water Pump Inspection and Repair, Reassembly, Installation151
Installing Impeller151
Installing Driveshaft Seal151
Operating of Gear Train152
Removing Bearing Cage152
Lower Gear Housing: Inspection and Repair153
Removing Clutch153
Measuring Clutch Spring Length153
Upper Gear Housing: Inspection and Repair154
Rear Bevel Gear Bearing I.D.154
Propeller Shaft Bearing Cage Bearing I.D.154
Remove and Replace Seals155
Removing Shift Rod Seal155
Installing Driveshaft Seal in Upper Gear Housing155
Positioning Clutch156
Installing Clutch, Cam156
Gear Housing: Installation157
Install Shift Cam Detent Spring157
Installing Lower Gear Housing to Upper Gear Housing157
Gear Shift Rod Adjustment157
Connecting Gear Shift Rods158
Gear Housing - Exploded View159
Gear Housing (Sailor)161
Operation of Cooling System and Water Pump161
Removing Gear Shift Rod Screw161
Removing Water Pump, Driveshaft Seal162
Position of Impeller Pin Groove162
Gear Housing Disassembly163
Operation of Gear Train and Shift Mechanism163
Removing Bearing Cage, Propeller Shaft Seals164
Removing Nut and Lockwasher from Stud164
Removing Shift Detent Assembly164
Removing Driveshaft Seal, Gear Shift Rod Seal165
Propeller Shaft Disassembly166
Removing Gear Shift Arm Pin166
Removing Propeller Shaft Components166
Removing Bearing Cup from Gear Housing/Installing Bearing Cup in Gear Housing167
Installing Propeller Shaft Components168
Checking Propeller Shaft168
Checking Space: Rear Gear to Cage169
Checking Propeller End Float170
Installing Seal in Bearing Cage170
Installing Driveshaft Seal, Shift Rod Seal171
Assembling Shift Arm to Shift Rod171
Positioning Upper Housing to Side172
Installing Propeller Shaft Assembly172
Special Tools173
Accessories174
Installing Shift Detent Assembly175
Aligning Gear Shift Rods175

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Chrysler 250 Sailor Specifications

General

Brand	Chrysler
Model	250 Sailor
Category	Outboard Motor
Language	English

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Chrysler 250 Sailor - User Manual

Table of Contents

Chrysler 250 Sailor Specifications

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