Chrysler 135 H.P. Outboard Motor Parts Manuals

Manuals and User Guides for Chrysler 135 H.P. Outboard Motor Parts. We have 1 Chrysler 135 H.P. Outboard Motor Parts manual available for free PDF download: Service Manual

Chrysler 135 H.P. Service Manual (167 pages)

Three and four cylinder outboard motors

Brand: Chrysler | Category: Outboard Motor | Size: 63 MB

List of Effective Pages
3
Index
5
Introduction
11
Engine Specifications
13
Torque Specifications
19
Special Items
19
Standard Hardware
19
Tune-Up - Three Cylinder Engines
21
Mechanical
21
Checking Compression/Lower Unit Grease
21
Cylinder Head Bolt Torque
21
Electrical
22
Spark Plugs
22
Points
22
Removing Distributor/Distributor Cap
22
Timing Engine
23
Location Top Dead Center
23
Establishing 36 Gr. before Top Dead Center
23
Aligning Distributor Pulley Match Mark with Flywheel
23
Measuring Belt Deflection Using 008 Thick Feeler Gauge
24
Aligning 36 Gr. Mark on Flywheel with Timing Pointer
24
Connecting Lids of Test Light
24
Carburetor
25
Adjusting Neutral Interlock Switch Cam (Distributor/Shift Arm)
25
Synchronizing Throttle Shutters
25
Towershaft Positioned against Neutral Stop Arm
25
Adjusting Throttle Pick-Up
26
Adjusting Carburetor
26
Loosening Throttle Tie Bar Screw
26
Adjusting Point of Throttle Opening
26
Synchronizing Choke Shutters
27
Closing Choke Shutters
27
Breakerless Ignition
29
Timing
29
Locating Top Dead Center
29
Establishing 32 Gr. BTDC
29
Voltmeter
30
Timing Light
30
Adjusting Distributor Control Rod
30
Tune-Up - Four Cylinders Engines
33
Torquing Sequence
33
Connecting Leads of Test Light
37
Connection of Test Lead Wires
37
Connection of Test Light Lead Wires
38
Timing - Magnapower II Ignition System
41
Locating TDC
41
Adjusting Control Rod
42
Carburetor - WB Type
43
Removing/Installing Top Carburetor Complete (3 Cylinder Engines)
43
Removing Middle Carburetor Complete (3 Cylinder Engines)
43
Installing Middle Carburetor Complete (3 Cylinder Engines)
44
Removing/Installing Bottom Carburetor Complete (3 Cylinder Engines)
44
Disconnecting Throttle Link Assembly
44
Removing/Installing Top Carburetor Complete (4 Cylinder Engines)
45
Remove/Install Bottom Carburetor Complete (4 Cylinder Engines)
45
Removing/Installing Throttle Shaft and Shutter
46
Removing/Installing Choke Shaft and Shutter
46
Removing/Installing Fuel Bowl and Gasket
47
Removing/Insalling Mainfuel Jet
47
Removing Float/Groove Pin
47
Installing Float/Groove Pin
48
Removing/Installing Inlet Needle and Seat
48
Measuring Float Height
48
Carburetor - TC Type
49
Removing/Installing Top Carburetor Complete
49
Removing/Installing Bottom Carburetor Complete
49
Installing Shutter
50
Alternator
53
Flywheel Key/Lapping Flywheel
53
Removing Flywheel
53
Flywheel Puller
53
Installing Flywheel
54
Removing/Installing Stator
54
Electrical Components - Delta System
55
Removing/Installing Choke Solenoid
55
Removing/Installing Starter Relay
55
Removing Interlock Switch
55
Installing Interlock Switch
56
Removing/Installing Rectifier (Silicone Bridge and Selenium)
56
Rectifier with Wires Connected
56
Selenium Type Rectifier
56
Installing Rectifier (Selenium)
57
Removing/Installing Trip Regulator
57
Removing/Installing Circuit Breaker
58
Removing/Installing Terminal Block
58
Removing C-D Unit
58
Connecting Lead Wires to Terminal Block
58
Installing C-D Unit
59
Removing/Installing Ignition Coil
59
Removing Wiring Harness
59
Installing Wiring Harness
60
Removing/Installing Ignition Switch
60
Connections of Lead Wire to Switch
60
Electrical Components - Motorola System
61
Starter Relay
61
Removing Leads from Starter Relay
61
Removing/Installing Regulator - Rectifier
62
Location of Interlock Switch
62
Removing/Installing C-D Unit (404301-1,404301)
63
Removing/Installing C-D Unit (404301-2)
64
Removing C-D Unit Ignition Coil
64
Removing Lead from Distributor
64
Installing C-D Unit Ignition Coil
65
Connecting C-D Leads to Terminal Block
65
Connecting Circuit Breaker Leads
69
Removing/Installing Thermoswitch
70
Removing Timing Ring Retainer and C-D Module
70
Removing/Wiring Ignition Coils
70
Installing Timing Ring Retainer and C-D Module
71
Removing Alternator Stator Module
71
Connection Lead Wires to C-D Module
71
Adjusting Timing Ring Retainer
71
Installing Alternator Stator Module
72
Removing Capacitor Module
72
Checking Timing Ring Friction
72
Connecting Leads to Alternator Stator Module
72
Installing Capacitor Module
73
Removing/Installing Regulator-Rectifier Module
73
Connecting Capacitor Leads to C-D Module
73
Removing/Installing Trigger Module
74
Removing Timing Ring
74
Removing Trigger Assembly
74
Connecting Leads to Trigger Modules
74
Installing Timing Ring
75
Removing/Installing Wiring Harness
75
Removing Spark Control Link from Timing Ring Arm
75
Routing/Position of Wiring Harness
76
Removing/Installing Starter Motor Assembly (Type A/B)
77
Removing Retaining Ring
77
Installing Starter Motor Assembly (Type B)
78
Removing/Installing Head Assembly (Commutator End)
78
Removing Frame and Field Assembly
78
Installing Frame and Field Assembly
79
Removing Armature Brush Terminal Assembly
79
Installing Brush Plate
79
Retaining Brush in Holder
79
Removing/Installing Armature and Head Assembly (Drive End)
80
Installing Armature
80
Removing/Installing Breaker Point Set
81
Removing/Installing Distributor Belt
81
Removing/Installing Distributor Cap Assembly
81
Installing Lead Wires through Seal
81
Removing/Installing Distributor Pulley and Shaft
82
Checking Lead Wire Continuity
82
3/4-Cylinder Engines
82
Removing/Installing Distributor Bracket
83
Measuring Clearance between Housing and Bracket
83
Removing/Installing Distributor Housing
84
Removing Terminal Screw Post
84
Removing Distributor Control Rod Link Assembly
84
Distributor (Breakless)
85
Removing Preamplifier
86
Location of Leads
86
Removing Distributor Shaft
86
Installing Preamplifier
87
Removing Distributor Bracket
87
Removing Preamplifier Leads
87
Fuel System
89
Removing/Installing Sediment Bowl and Screen
89
Removing Fuel Pump Body, Gasket and Diaphragm
89
Types of Fuel Pumps
89
Installing Fuel Pump Body, Gasket and Diaphragm
90
Removing/Installing Fuel Pump Valve
90
Removing Fuel Pump Cover
90
Installing Fuel Pump Cover
91
Removing/Installing Pump Cover and Diaphragm
91
Removing Fuel Pump Body
91
Installing Fuel Pump Body
92
Removing/Installing Prime Bulb
92
Removing Puddle Drain Assembly
92
Position of Valves in Pump Body
92
Installing Puddle Drain Assembly
93
Proper Installation of Check Valve
93
Grar Housing
95
Removing/Installing Lower Unit
95
Removing/Installing Water Pump
95
Installing Driveshaft Seal
95
Removing/Installing Shift Rod (Lower)
96
Removing Gear Housing (Upper Assembly)
96
Centering Water Pump Body
96
Removing Shift Rod Seal
96
Installing Gear Housing (Upper Assembly)
97
Removing Driveshaft
97
Removing/Intsalling Bevel Pinion
98
Areas to Have Sealant
98
Tightening Retaining Nut
98
Removing/Installing Driveshaft and Bearing
99
Seating Gear Housing Bearings
99
Pressing Bearing off Driveshaft
99
Installing Driveshaft Bearing
99
Setting Proper Bevel Pinion/Bevel Gear (Rear Clearance)
100
Checking Gauge
100
Tightening Spacer Screws
101
Checking Tightness of Indicator Holder
101
Removing Propeller Shaft Bearing Cage Assembly
102
Removing Bearing Cup
102
Installing Seal Remover
102
Installing Propeller Shaft Bearing Cage Assembly
103
Removing Yoke, Clutch and Shift Pin
103
Pressing out Seal
103
Installing Bearing Cup
103
Installing Yoke, Clutch and Shift Pin
104
Removing
104
Installing Propeller Shaft Assembly
104
Removing Bevel Gear and Bearings
104
Removing/Installing Bevel Gear - Front and Bearing Cup
105
Installing Propeller Shaft Bearing
105
Removing/Installing Bearing Cup
105
Checking Propeller Shaft End Float
106
Removing/Installing Fhift Arm
106
Removing/Installing Gear Housing (Lower/Lower Complete)
107
Removing/Installing Exhaust Snout
107
Removing/Installing Gear Housing Complete
109
Removing/Installing Driveshaft Spline Seal
109
Location of Shift Rod Pin
109
Proprller Order of Assembly
109
Removing/Installing Gear Housing Cover
111
Removing Driveshaft and Gear Shift Rod Seals
111
Location of "O" Ring Seals
111
Installing Driveshaft and Gear Shift Rod Seals
112
Removing/Installing Gear Shift Rod Lower
112
Removing Anticorrosion Anode
112
Iunstalling Anticorrosion Anode
113
Removing/Installing Shaft Bearing Spool
113
Installing Puller
113
Removing/Installing Bevel Gear Rear and Bearing Cage
114
Removing/Installing Propeller Shaft
115
Bevel Gear Rear Assembly
115
Removing Clutch
115
Removing/Installing Bevel Gear Front
116
Removing/Installing Shift Arm
116
Removing Bevel Pinion Nut
116
Removing Shims
116
Removing/Installing Gear Shift Rod Coupling
117
Removing/Installing Gear Housing
117
Order of Shimming
117
Installing Master Shim
117
Torquing Pinion Nut
118
Position of Plug and Cradle
118
Reverse Gear Assembly
119
Installing Reverse Gear Assembly on Prop Shaft
119
Installing Prop Shaft Assembly
119
Installing Spool
120
Installing Dial Indicator Post
120
Position of Dial Indicator
120
Pressure Testing Gear Housing
121
Seating Forward Bearing
121
Checking End Float
121
Removing/Installong Leg Cover (Rear)
123
Removing/Installing Water Line (Upper)
123
Removing/Installing Motor Leg Assembly
123
Removing/Installing Support Plate
124
Engine Cover Latch Assembly
124
Removing/Installing Motor Leg Cover (Front)Removing/Installing Reverse Lock and Spring
125
Removing Hex Stop Nut
125
Driving out Spring Pin
125
Removing/Installing Clamp Screw and Handle
126
Removing/Installing Clamp Screw
126
Removing/Installing Stern Bracket (Port)
126
Removing Stern Bracket - Starboard and Pivot Bolt
126
Installing Stern Bracket - Starboard and Pivot Bolt
127
Removing/Installing Steering Tube
127
Removing Swivel Bracket Assembly and Kingpin
127
Installing Swivel Bracket Assembly and Kingpin
128
Driving out Kingpin
128
Removing/Installing Leg Cover (Rear)
129
Removing/Installing Motor Leg Cover (Front)
130
Removing/Installing Reverse Lock and Spring
131
Removing Shock Absorber
131
Installing Shock Absorber
132
Repositioning Retaining Ring
132
Removing/Installing Stern Bracket - Starboard and Pivot Bolt
133
Clamp Screw Assembly
133
Removing/Installing Swivel Bracket Assembly and Kingpin
134
Installing Steering Tube
134
Removing/Installing Cylinder Head Assembly
137
Removing/Installing Exhaust Port Cover, Plate and Gaskets
137
Removing/Installing N1 Cylinder Transfer Port Cover and Gasket
137
Removing N2 Cylinder Transfer Port Cover and Gasket
137
Installing N2 Cylinder Transfer Port Cover and Gasket
138
Removing/Installing N3 Cylinder Transfer Port Cover and Gasket
138
Removing/Installing Cylinder Drain Cover and Gasket
138
Removing Carburetor Adapter Flange and Reed Plate Assemblies
138
Installing Carburetor Adapter Flange and Reed Plate Assemblies
139
Removing/Installing Reed Plate Reeds
139
Carburetor Adapter Flange Screws
139
Removing/Installing Crankshaft Bearing Cage Assembly
140
Removing/Installing Towershaft
140
Removing/Installing By-Pass Cover, Valve and Spring
140
Removing/Installing Powerhead
141
Water By-Pass Components
141
Removing/Installing Short Block
142
Removing Crankshaft Assembly
142
Driving out Dowel Pins
143
Prying Crankcase Cover
143
Removing Rod Cap Screws
143
Removing Main Bearings
143
Installing Crankshaft Assembly
144
Prying Seal out of Bearing
144
Crank Pin Needle Bearing Cage
144
Match Marks on Connecting Rod
144
Removing Piston Assembly
145
Crankcase Bolt Locations
145
Removing Piston Rings
145
Installing Piston Assembly
146
Pressing out Piston Pin
146
Piston with Components and Tools
146
Removing/Installing Cylinder Assembly
147
Bevel on Piston Ring
147
Powerhead - 4 Cylinder Engines
149
Location of Cylinder Head Cover Screws
150
Areas Requiring Sealant
150
Removing/Installing N4 Cylinder Transfer Port Cover and Gasket
151
Removing Upper Cylinder Drain Cover and Gasket
151
Installing Upper Cylinder Drain Cover and Gasket
152
Removing/Installing Lower Cylinder Drain Cover and Gasket
152
Removing/Installing Top Carburetor Adapter Flange and Reed Plate Assemblies
152
Removing Bottom Carburetor Adapter Flange and Reed Plate Assemblies
152
Disconnecting Towershaft from Control Rod End
155
Grouping Parts
159

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Chrysler 135 H.P. Service Manual (167 pages)

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