Can I manufacture a kill switch for a 9.9?

N

nightstalker

Chief Petty Officer
Joined
Dec 10, 2003
Messages
570
My 9.9 Johnson's kill switch doesn't work. I've taken it off, cleaned it, etc. but still no go. I'm sick of shutting the engine down by pulling the choke (makes it hard to restart if it doesn't sit a while). I've looked on E-Bay, etc. for a new one with no luck. Is there a way I can rig a kill switch myself? I'm thinking of disconnecting the two wires going to the switch but not sure what to do from there.
Nightstalker
 
X

Xcusme

Commander
Joined
Apr 21, 2003
Messages
2,888
Re: Can I manufacture a kill switch for a 9.9?

Yea, you could rig a switch....have you metered the 2 wire leads with an Ohm meter to see if the wires are shorted when you press the button? Perhaps one of the wires is 'open' (broken). Meter each wire from switch to connector/ring end. Replacement switches are approx. 36.00. Have you inspected both sides of the connector for corrosion? One wire should be grounded to the lower pan or power head, the other to a connector. going to the power pack.

The switch is basically a Momentary Type -Normally Open Single Pole switch. A Single Pole Normally Open type switch will work too. Cut off old switch, connect the 2 wires to new switch..done..
You'd have to cut a mounting hole in the lower motor cover. You have options, replacement with OEM looks nicer too. Personally, I'd try grounding the lead going to the connector (when running) to confirm motor kill before I drilled any holes. This will rule out a defective power pack kill circuit, but that's just me.

BTW, that kill wire will have +/- 250 volts on it when running.....
 
guy74

guy74

Senior Chief Petty Officer
Joined
Jul 12, 2007
Messages
794
Re: Can I manufacture a kill switch for a 9.9?

On my 9.5hp johnson the two wires going to the switch are from each of the points. To kill the engine, the switch shorts the wires to each other, thus grounding each set of points thru the other. I don't know if thats how yours works, but if it has points and two wires going to the kill switch, then it's probably how it works.
 
N

nightstalker

Chief Petty Officer
Joined
Dec 10, 2003
Messages
570
Re: Can I manufacture a kill switch for a 9.9?

Thanks for the help. I'll get a meter and check everything out before I decide which way to install my own kill switch.
Nightstalker
 
samo_ott

samo_ott

Vice Admiral
Joined
Jun 18, 2006
Messages
5,125
Re: Can I manufacture a kill switch for a 9.9?

Guy74, the old engines with points work the way you described, but the 9.9 does not have points and has coil packs and works differently. I'm used to your way also :)
 
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