1965–1984 Chrysler 35, 45 and 55 HP Outboard Service Manual (P/N OB 2803)

This Chrysler Outboard Corporation service manual, OB 2803, covers 1965–1984 Chrysler 35, 45, and 55 HP outboard motors. Printed November 1977, it details disassembly and repair of the two-cycle, twin-cylinder, alternate-firing engines and their associated assemblies.

• Powerhead repair: Short block removal and installation, crankshaft and bearing service, piston and connecting-rod disassembly, and reed plate work.

• Carburetor and fuel system: Carburetor rebuilding, float-height and throttle-pickup adjustments, plus separate Type A and Type B fuel pump procedures.

• Ignition and electrical systems: Magneto and alternator service, C-D units, rectifiers, wiring harnesses, and component wiring diagrams for ignition switches and coils.

• Starting systems: Electric starter disassembly and reassembly, plus Type A and Type B manual starters with rewind spring, rope, and interlock procedures.

• Cooling and lower unit: Water pump impeller and seal replacement, thermostat removal and installation, gear-housing leak testing, and internal gear and clutch service.

• Motor leg and steering: Stern and swivel brackets, reverse-lock mechanisms, shock mounts, driveshaft removal, and steering-handle gear and bearing replacement.

This manual suits mechanics familiar with outboard disassembly and electrical testing; several jobs require dedicated pullers, seal installers, or ignition test equipment.

Tune-Up, Carburetor, and Fuel Pump Service

Mechanical tune-up coverage includes compression checks, cylinder-head bolt checks, and lower-unit lubricant inspection. Carburetor procedures address the throttle and choke shafts and shutters, main jet and nozzle, float, and inlet needle and seat, with linkage drawings and adjustment instructions.

The Type A and Type B fuel pump sections distinguish diaphragm, sediment-bowl, screen, and valve arrangements. The Position of Valves in Pump Body illustration identifies check-valve placement, while separate procedures cover pump-body removal and primer-bulb replacement.

Ignition, Wiring, and Starter Assemblies

Electrical sections distinguish magneto, alternator-electric, C-D alternator, and single-phase alternator configurations. Stator and breaker-plate work is supported by condenser and coil tests, engine-timing instructions, and flywheel inspection and taper-lapping criteria.

Wiring Ignition Switch—Magneto Engines and the corresponding battery-ignition diagram show different terminal connections. Rectifier, terminal-block, and ignition-coil connection views support electrical routing. The separate Wiring Diagram Collection referenced in the introduction is supplementary literature and is not included in this PDF.

Electric starter procedures extend to brushes, the armature, and Bendix drive. The manual starter sections distinguish spring, rope-retainer, and interlock arrangements rather than treating both starter types as interchangeable. Observe the manual’s battery-isolation precautions during starter and ignition work.

Lower Unit, Cooling, and Motor Leg

The Lower Unit Types comparison separates Type A and Type B assemblies with different shift-rod connections and removal procedures. Matching that layout before teardown helps you select the correct lower-unit and shift-linkage instructions.

Gear-housing repair covers driveshaft and propeller-shaft seals, bearing cages, bevel gears, the clutch, yoke, and shift arm. Seal installation and bearing-cage removal reference tools T3431 and T8948-1.

Cooling coverage includes the Thermostat Assembly illustration and water pump installation views. Motor-leg instructions address bracket bearings, reverse locks, shock mounts, and the steering handle’s magneto control shaft.

Powerhead Overhaul and Assembly Checks

Powerhead procedures cover cylinder-head, exhaust-port, and transfer-port assemblies, followed by internal crankshaft, piston, piston-pin, and connecting-rod work. Assembly references distinguish matched Type A crankpin cages from Type B cages and identify revised piston-pin retaining rings.

Cylinder-head instructions warn that excessive bolt torque can distort the head or cylinder bores. Reference tables provide bore-and-stroke dimensions and torque specifications for cylinder heads, flywheels, and connecting-rod screws.

A Preview of Leak-Test and Condenser Specifications

For lower-unit leak diagnosis, the gear-housing test specifies 10 psi with a one-minute gauge observation. The manual cautions that exceeding this pressure can damage the seals.

Condenser testing uses an acceptance range of .16–.20 microfarads on a standard condenser tester.

Reading the PDF and Electrical Illustrations

Search, navigation, and wiring detail: PDF text search and embedded bookmarks are unavailable. Ignition-switch labels are legible, but some small terminal-block labels are faint or partly obscured, including at higher magnification.

A single printable, English-language 92-page PDF, including the front and back covers, a three-page index, and nine notes pages.