1966-1999 Chrysler Force Marine Workshop Repair manual

General Information Tools and Techniques m Tmubieshootlng Lubrication, Maintenance and Tune-up Engine Synchronization and Linkage Adjustments a Ignition and ElecMui Systems w Power Trim and Automatic Rewind Stads and Remote Control

Contents ! QUICK REFERENCE DATA .......................................................................................... IX ................................ ........................................................ .............................................. "...**..,W..3S, Delte and Motorola I (1974-1979)

CHATTER R& UIBRKMlO#r MAINTENANCE AND TUNCUP ... ...................................................... 109 . . .............................. latmwm ........................................................ 109 Oesnvleendwaterplmpduck 124 ......................................................... 1 6 - 1 system mice .............................................. 124 ' ............................................ 8 Breaker point ignition system miee ........................ 126 $@@- xt&@awe .......................... d Battery and stalter motor check .................................................... .................................. fliWq 119 (electric start models only) W lb+ ............................................................ I20 Stamr rclal/solemid check (electric sPY( mdels only) .. I31 .............................................. ............................................ Cmpmsbn Ebslr I20 Wlrisg hmess check I31 . . . . elinaol hed bdt Mgoe ...................................... I2 l%@ne syncbroaushon end adjustment l32 ...................... : ..................................................... 1 Pe&mm~eIest(onbolll ..................................... I32 CHAPTER FIVE ...................................... ENGINE SYNCHRONIZATION AND LINKAGE ADNSTMENTS 139 Er&c Iiming and syncluunization ........................... I39 Clvylkr wtbmrds 3.5 hp 11966-1969) ....................... 140 Qryslerombavds3.5hp(1980-00)aad4hp(197Pon).141 Chrya*routbods 36hp~l977)end4hp~1978)1 Chrysler wmoprds 4.4.8 hp (lnukcr point ignition) ..... 143 Chryk outkm~& 6-8 bp (CD igdtbu) .................... 145 ...................... Chrysler outbwds 9.215 hp (1966-on) W Chrysler oumoards 20 hp (1966-1976) ........................ 147 Chrysler outboards 20 hp (19794982) . 25 and 30 hp (all) and 35 hp (i976-1979 .......................... 148 Chrysla outbards 35 end 45 bp (D66m) . U) bp (1966 aad 19%Lon end 55 bp (1967-Km) ................. I51 Ch;8ler outboards 55 hp (IQ17.l980) . 60 hp (lmet976) . 65 hp (1977.1978) . end 10 5. I20 aad I35bp(l975-Imr)aritb~ni@ion ........ W Chrpskroutbouds70-USbp(disaibmlar poiDt ignitiml) ................................................ I57 CluyslCI outboards 70-140 hp (Mo(omIr elstmaic distrii ignition) ............................................ 163 Chrysler outboards 55. I25 end 140 hp ....................................... (Pmlite CD ignition) 165 Force outboards 4 . 9.9 ad l5 hp .. ........................... I66 bree outbonds 35 hp .......................................... %7 ................................ mnroutboudsuend U5hp m CmrlEuSIx FUEL SYSTEM .................................... . . . . 176 C ............. ........................................ ............................................. s PPd pnnp i... 176 Raed ralve essembly l98 Cakustma ....................................................... 183 Choke solenoid ................................................... 202 c.rknsbr d-on ................................ 183 Inre@ fwl tank ................................................. 203 CPlwaor dislsscmMylrrPembly ............................ l85l Fbmibk fucl tank ................................................ 205 Wrwrra~endiarpstio ........................... m Plwl~endprimabul ...................................... m AoladjmEad .................................................. m Plwlltximhhsydesll ....................................... m CnAm SEVEN ICNmON AND ELECTRICAL SYSTEMS .................................................................. 209 Buty ....................................................... 2 Magneto brrahr pok ignition ................................ 238 ................................. ..................................... MaDaorcbar&aygan 2l5 Bptlenbnalmpointlpnilion 242 OcPoMrebagiclg ..................................... 220 ~ismh(aCDig&m ......................................... 245 ......................................... ebmieamingsyslrm ......................................... MagmpmerUig&m 248 Mbror syamr .......................................... 220 AIk.nuWr CD ignition ........................ : ................. 254 AmDbohic~~ty ........................... 23l ~iQ.CDigoitmo .......................................... 258 &&ion systcols .................................................. 23a ..- ................. .' ...... " ... ..... ..." ..... " ..- ...... " .*. ".- aa .............................. . ** ........... ..w Pbacr ba;d 38Fa tap sild%ab ........................... a66 mala ad cm&@ md. ................................... 303 .ai6 Caractlqldrado*bbdt .............................. .................... - ....................... ...... m CglhderBbfLrdolrbrr.Irmbly *as B - j ................................. *, ....

CHAAER NINE GwmcmE .............................................. Rqwlh ......................................................... 323 Oearcase remadhi ................................. 325 aeacaae dbMe5bIyJ-y ............................ 333 Oasra &anhg and inapedion ............................. 358 Phdar gar nbhmhg and propclln end flat ............. 359 ........................................................... 323 Pnssure testing ......... . ......................... J Zinc anode ................................................... 366 Gear shift lie adjustment ................................. 367 Water pump ..................................................... 368 CHAPTER TEI -*T" ~ M A T SWERS ......................................................................... 375 .i ........................................ 3 Spool ScPner (35 hp) ........................................... 384 ........................................ ...................................... hp) 377 Flywheel mounted starter 388 hp) ........................................ 381 D TILT AND REMUTE CONTROL SYSTEMS .................................... 393 .......................... .... .......... 39 Rcmote control .................................... 4 ...... , ......................................................................................................... 403 WltAMS .............................. ................................................. d of book

SPARK W CllOMREPERENCE C W Champion 1101( AC Antolit@ I I 1. 8p.rk phtgs produd by dlffamnt manufactumn do not h.vm identical hmml mnng. c - If tha OM& dw ncannwndod bv lhr anmlnm rnmnut.otumr Is not avallmblr. usm - tM. chat to dotonnlnm'a a&bk mqulvmlont plug.- 2. ChNnDbn JU and JSJ olugo am suwrcedod by Jm no CIWS-~(~~O is avallabls for J8C. 7 - 5- 16.8 houd 18 howr 1s Mpr 4.2 hour 13 hour 26mps '> 2.4 houn 12 h w n

INTRODUCTION This Clymer shop manual covers senice and repair of all 1966-1984 Chrysler 3.5-140 hp and 1984-1988 Force 4-125 hp outboards. Step-by-step instructions and hundreds of illustrations guide you through jobs ranging from simple maintenance to complete overhaul. This manual can be used by anyone from a lirst time amateur to a professional mechanic. Easy to read type, detailed drawin@ and clear photographs give you all the information you need to do the work right. Having a wellmaintained engine will increase your enjoyment of your boat as well as assure your safety offshore. Keep this shop manual handy and use it often. It can save you hundreds of dollars in maintenance and repair bii and make yours a reliable, topperforming &at.

Chapter One General Information Jlad, comprehensive manual a&& information on main- ps, repair and overhaul, and drawings guide you rm. use &d what to do. their hands dirty, of and with some r ean perform most of the a an twls and techniques. I&&& a reference. You want to iafbmation fast. Clymer a photos* etc., in this MANUAL ORGANIZATION This chapter provides general information useful to marine owners and mechanics. Chapter Two disc- the tools and techniques for preventive maintenance, troubleshooting and repair. Chapter Three describes typical equipment problems and provides logical trouble- simple step-by-step form. concerning a specific system the end of the appropriate chapter. NOTES, CAUTIONS AND WARNINGS The terms NOTE, CAUTION easier or clearer.

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1966-1999 Chrysler Force Marine Workshop Repair manual

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