9.9 Chrysler tiller throttle breaking

I have a 9.9 horse chrysler kicker on my boat. The throttle on the tiller is very tight and will break parts often. Does anybody know how to adjust the linkage so it is easier to twist and adjust the throttle so parts will not break. This is a very old motor but runs like a champ. The throttle tiller is also very particular on how it has to be set just so during the starting sequence. if it is off even a little bit it won't allow the ingnition to fire. once i have it started it runs and idles fine but adjusting the throttle again like i say is very hard to twist. I have broken a small piece of plastic under the tiller that holds the throttle shaft once and recently the pin that holds the rubber grip to the throttle shaft broke from twisting it so hard.

Re: 9.9 Chrysler tiller throttle breaking

Couple of hints: First check the linkage inside the engine compartment. Where the throttle arm ends it is connected by a link to a flat plate which controls both timing and carb. This flat plate is held to the block between two plastic washers and secured with a locking nut. If the nut is too tight, the plate will not be able to move easily. It should only be tight enough to take out any slop. Also check to see if your handle has a tension adjusting screw. It will be on the side of the tiller arm near the handle. If it has one, loosen it a bit.

Inside the tiller handle there is the adjustable plastic piece which you already have broken. However at the end of the tiller that connects to the engine, there is also a plastic bushing. And I forget--there might also be one at the black plastic handle end. This bushing sometimes gets hard and squeezes the throttle shaft, making it very difficult to turn. I believe there are also bushings on the link arm that goes into the engine. To check and remove this bushing I believe you must remove the throttle link, then the tiller from the engine and also remove the black handle. Slide out the throttle rod. To remove the other rod I think you must drive out the pin and remove the gear that allows the tiller to tilt.

The only other thing I can think of is to check, while the timing link is removed, to see that the timing advance plate is rotating freely.

Because of the arrangement of this throttle and tiller, tremendous leverage is built up and binding at almost any point can make it nearly impossible to twist the throttle. It will also cause the sensitivity you described