Chrysler Outboard Service Manual: 35, 45, and 55 HP Motors (P/N OB 2803)

• Essential reference for workshops and DIY mechanics servicing 1965–1984 Chrysler 35, 45, and 55 HP outboard motors.
• Official 92-page Chrysler Outboard Corporation publication (OB 2803, printed November 1977).
• Includes 31 exploded-view diagrams and complete torque tables for the powerhead, gear housing, and ignition systems.
• Delivers factory-authorized specifications for the twin-cylinder alternate firing engine architectures.

Contents and Engine Systems

What exactly is inside? This 1977 edition breaks down the core components of these classic outboards, outlining the original factory blueprints for engine disassembly. It segments technical data into major assemblies so you can quickly locate details on mechanical tuning, fuel system components, and electric starter configurations for both manual and electric-start models. You get direct insight into the tune-up process, carburetor layout, and electrical routing.

Beyond the engine block, the text details critical ignition elements. This includes magneto controls, alternator systems, and C-D ignition units. To help you identify parts precisely during a teardown or rebuild, highly detailed exploded views map out the lower unit, gear housing, steering handle assembly, and motor leg.

Specification and Reference Data

Having the exact numbers on hand speeds up any job. The manual lists crucial engine specs like bore and stroke dimensions for the 35, 45, and 55 HP variants. It notes cylinder compression ranges from 95 to 155 PSI, depending on the exact model and engine hours. You will also find dedicated index tables detailing the exact torque values for cylinder heads, flywheels, and connecting rod screws to guarantee correct assembly.

Need quick ignition specs? The factory gap for spark plugs is .030 inches. Magneto ignition breaker points sit at 0.020 inches, while battery ignition setups require 0.015 inches. Keep in mind that marine environments are unforgiving, and workshop safety matters. Always treat published service data as a baseline reference and verify your specific setup before turning a wrench.