Chrysler 70–150 HP Outboard Service Manual, 1969–1973 (P/N OB 1565)

Chrysler service manual P/N OB 1565, Change 3, includes revision pages dated 1977. It covers the listed 1969-and-later Chrysler outboards: 70, 75, 85, and 90 HP three-cylinder models, plus 105, 115, 120, 130, 135, and 150 HP four-cylinder models.

PDF Navigation, Readability, and File Contents

Navigation and wiring detail: PDF text search and embedded bookmarks are not available. Small wire-color labels in the ignition-coil diagram need zooming. Labels over the trigger-module photographs have lower contrast but remain readable when enlarged.

The ZIP download contains one printable PDF with 166 pages. This total includes the front and rear covers, one list of effective pages, five index pages, and 14 blank pages.

Powerhead, Gearcase, and Electrical Service

These selected service topics outline the repair coverage. Additional procedures include flywheel inspection and lapping, plus anticorrosion anode replacement.

• Powerhead repair: Step-by-step procedures extend to crankshaft and piston removal, bearing replacement, and short-block disassembly and reassembly.

• Lower-unit overhaul: Covers water pumps, bevel gears, clutches, shafts, and seals, with gearcase pressure testing, shimming, and end-float checks.

• WB and TC carburetor service: Includes float adjustment, throttle-shutter synchronization, throttle pickup, and choke linkage adjustment.

• Ignition timing: Separate procedures address breaker-point, breakerless, and Magnapower II systems, with checks and adjustments matched to each ignition design.

• Delta and Motorola electrical sections: Cover alternator components, C-D unit and regulator/rectifier replacement, and relay and wiring connections.

• Type A and Type B starter repair: Covers the Bendix drive, brushes, armature, and end housings.

Its internal rebuild procedures are suited to experienced mechanics comfortable with press work and dial-indicator measurements.

Engine and Component Documentation

The specifications distinguish Electronic and Charger versions, along with Magnapower II entries for 105, 120, and 135 HP engines. Racing-engine specifications are included for 135 and 150 HP models, subject to the lower-unit limitation below.

Beyond the rotating assembly, the powerhead sections cover reed plates, carburetor adapter flanges, thermostats, exhaust and transfer-port covers, and water-bypass assemblies. The “Water By-pass Components” drawing distinguishes cylinder, cover, and spring configurations. Cylinder-head torque data also distinguish fastener configurations; a single setting does not apply to every 105 HP engine.

Fuel-system coverage separates Type A and Type B diaphragm pumps, including check valves and sediment bowls. The four-cylinder puddle-drain hose arrangement is identified for 1970-and-earlier models, while powerhead procedures identify the recirculating connections used from 1971 onward. Carburetor illustrations such as “Measuring Float Height” show the adjustment references used in the text.

Reference tables provide bore, stroke, displacement, firing order, compression ranges, spark-plug types, breaker-point settings, and component-specific torque specifications. Gearcase procedures supply the associated clearance and end-float data.

Ignition, Wiring, and Control Adjustments

Breakerless timing includes a static voltmeter method and a running timing-light method. Magnapower II procedures cover trigger, capacitor, and stator-module replacement, plus timing-ring retainer adjustment. Distributor work includes belt adjustment and breakerless preamplifier replacement.

Component wiring diagrams and connection views include “Wiring Ignition Coils” and “Connections of Lead Wire to Switch.” These accompany the component replacement procedures. Mechanical adjustments cover neutral interlock switches mounted at the distributor or shift arm, as well as the throttle towershaft and related linkages.

Gear Housings, Motor Legs, and Service Tools

Two gear-housing sections distinguish the separate upper/lower housing arrangement from the design using a removable cover and propeller-shaft bearing spool. The “Bevel Gear Rear Assembly” exploded view and “Checking End Float” illustration support the internal gear and bearing work.

The gear-clearance section explains gauge and spacer differences for 16:25, 15:26, and 15:30 gear ratios, including the T8924-1 checking gauge and T8981 spacer set. Section XIVA uses the T8997 shimming tool set. Tool references also identify the T8950 pressure tester and T2937-1 timing tool. These distinctions help match the shimming procedure and measuring tools to the gear housing being rebuilt.

The factory cautions explain why too many shims can preload bearings and cause premature failure. A displaced spacer in the propeller-shaft bearing cage can also seriously damage the gear housing during reassembly.

Motor-leg repair extends to shock mounts, stern and swivel brackets, steering tubes, reverse-lock hardware, and upper shift rods. Four-cylinder coverage also includes shock absorbers.

For racing lower-unit repair, Chrysler specifies the separate Racing Lower Unit Service Manual, P/N OB1002-1. That publication, the model-specific parts manual, owner's manual, and Wiring Diagram Collection are not included in this PDF.

Always disconnect the battery and properly support the outboard before teardown; powerhead removal requires suitable lifting equipment.

Selected Carburetor and Gearcase Measurements

The WB and TC carburetor float-height illustrations specify 13/32 ± 1/64 in., using the float position and reference surfaces shown in each drawing.

For propeller-shaft end float, the separate upper/lower gear-housing procedure in Section XIV specifies 0.005 ± 0.001 in. The removable-cover and bearing-spool design in Section XIVA specifies 0.010 ± 0.001 in.