Step-by-step procedures serve as a detailed guide through the complete job, including necessary adjustments.

Models Covered: Chrysler Outdrives 3.5 - 140 Hp 1966 - 1984.

Table of Contents:

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Galvanic corrosion / Protection from galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Saety first / Basic hand tools / Service hints / Special tips / Mechanic's techniques

CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / Charging system / AC lighting system / DC battery charging system / Alternator charging system / Autolectic models / Ignition system / Magneto ignition system / Battery ignition system / CD ignition system / Delta and Motorola Magnapower I (1974-1979) and CD ignition (1980-on) / Magnapower II ignition system / Magnapower III ignition system / Magneto CD system / Magnapower/magneto CD ignition system / Prestolite CD ignition system / Ignition switch / Fuel system / Engine / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Storage / Complete submersion / Anti-corrosion maintenance / Engine flushing / Tune-up / Compression check / Cylinder head bolt torque / Spark plugs / Gearcase and water pump check / Fuel system service / Breaker point ignition system service / Battery and starter motor check (electric start models only) / Starter relay/solenoid check (electric start models only) / Wiring harness check / Engine synchronization and adjustment / Performance test (on boat) / Specifications

CHAPTER FIVE / ENGINE SYNCRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing and synchronization / 3.5 hp (1966-1969) / 3.5 hp (1980-on) and 4 hp (1979-on) / 3.6 hp (1970-1977) and 4 hp (1979-on) / 4.4-8 hp (breaker point ignition) / 6-8 hp (CD ignition) / 9.2-15 hp (1966-on) / 20 hp (1966-1976) / 20 hp (1979-1982), 25 and 30 hp (all) and 35 hp (1976-1979) / 35 and 45 hp (1966-on) , 50 hp (1966 and 1981-on) and 55 hp (1967-1976) / 55 hp (1977-1980), 60 hp (1974-1976), 65 hp (1977-1978), and 105, 120 and 135 hp (1975-1977) with Magnapower II ignition / 70-135 hp (distributor breaker point ignition) / 70-140 hp (Motorola electronic distributor ignition) / 55, 125 and 140 hp (Prestolite CD ignition) / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / Carburetor removal/installation / Carburetor disassembly/assembly / Carburetor cleaning and inspection / Float adjustment / Reed valve assembly / Choke solenoid / Integral fuel tank / Portable fuel tank / Fuel line and primer bulb / Fuel recirculation system / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery / Alternator charging system / Generator charging system / Electric starting system / Starter motor system / Autolectric starter-generator / Ignition systems / Magneto breaker point ignition / Battery breaker point ignition / Battery breaker point ignition / Distributor CD ignition / Magnapower II ignition / Alternator CD ignition / Prestolite CD ignition / Specifications

CHAPTER EIGHT / POWER HEAD
Engine serial number / Fasteners and torque specifications / Flywheel / Power head removal/installation / Power head disassembly / Power head cleaning/inspection / Piston and connecting rod / Connecting rod and crankshaft / Cylinder block and crankcase assembly / Specifications

CHAPTER NINE / GEARCASE
Propeller / Gearcase removal/installation / Gearcase disassembly/assembly / Gearcase cleaning and inspection / Pinion gear shimming and propeller end float / Pressure testing / Zinc anode / Gear shift linkage adjustment / Water pump / Specifications

CHAPTER TEN / AUTOMATIC REWIND STARTERS
Engine cover starter / Spool starter (4.4-8 hp) / Spool starter (9.2-15 hp) / Spool starter (35 hp) / Flywheel mounted starter / Specifications

CHAPTER ELEVEN / POWER TRIM AND TILT AND REMOTE CONTROL SYSTEMS
Power trim and tilt / Remote control / Specifications

INDEX
WIRING DIAGRAMS

Detailed Models coverage:

1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 10 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 100 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 105 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 115 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 12 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 12.9 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 120 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 125 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 130 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 135 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 140 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 15 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 20 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 25 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 3.5 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 3.6 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 30 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 35 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 4 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 4.4 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 4.5 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 4.9 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 45 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 5 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 50 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 55 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 6 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 6.6 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 60 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 65 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 7 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 7.5 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 70 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 75 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 8 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 85 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 9.2 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 9.6 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 9.9 HP
1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 Chrysler 90 HP


Clymer Manuals Chrysler 10 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 100 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 105 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 115 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 12 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 12.9 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 120 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 125 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 130 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 135 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 140 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 15 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 20 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 25 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 3.5 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 3.6 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 30 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 35 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 4 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 4.4 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 4.5 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 4.9 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 45 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 5 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 50 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 55 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 6 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 6.6 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 60 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 65 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 7 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 7.5 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 70 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 75 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 8 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 85 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 9.2 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 9.6 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 9.9 HP Repair Service Workshop Manual
Clymer Manuals Chrysler 90 HP Repair Service Workshop Manual