Basic Information Identification Make: Chrysler Model: 120 HP Outboard Year: 1981 Product Type: Service Repair Workshop Manual Introduction Market Position Target Audience: Owners with basic mechanical skills and independent service professionals seeking factory-level repair information. Value Proposition Cost Savings: Enables DIY repairs, potentially saving hundreds or thousands of dollars on maintenance and repairs. Key Features Accuracy Clarity: Accurate, clear, and concise text with illustrations for safe and easy servicing. Origin Documentation Source: Written by the manufacturer (Chrysler), providing the same specifications as authorized dealer service departments. Competitive Analysis Market Comparison: Direct competitor to other 100-140 HP outboard engines of the same era from brands like Evinrude, Johnson, Mercury, and Yamaha. Manual Details Coverage Areas Systems Covered: ['Engine Specifications', 'Torque Specifications', 'Tune-up Procedures', 'Carburetor System', 'Electric Starter System', 'Manual Starter System', 'Electrical Components', 'Magneto Ignition System', 'Alternator System', 'Fuel System', 'Gear Housing (Lower Unit)', 'Motor Leg (Driveshaft Housing)', 'Powerhead Assembly', 'Steering Handle and Controls', 'Troubleshooting'] Page Count Page Count: Not Specified (Implied Comprehensive) Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, and reassembly for the 120 HP outboard engine. Fuel And Ignition: Detailed coverage of the carburetor, fuel pump, fuel lines, magneto ignition, and spark plug servicing. Electrical System: Diagnosis and repair of the electric starter, manual starter, alternator, and all related wiring schematics. Drivetrain: Comprehensive instructions for servicing the gear housing, propeller shaft, driveshaft, and associated components. Cooling System: While not explicitly listed, typical outboard manuals of this era would cover water pump and cooling passages. Procedures Included Maintenance: Regular maintenance tasks such as tune-ups, fluid changes, and general inspections. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and uncommon issues. Repair: Step-by-step instructions for all repair operations, from minor adjustments to major component overhauls. Diagnostics: Detailed diagnostic flowcharts and procedures for electrical and mechanical systems. Powerhead Rebuild: Detailed steps for powerhead disassembly, piston and ring replacement, bearing checks, and cylinder head servicing. Fuel System Diagnosis: Troubleshooting fuel delivery issues, including carburetor flooding, lean conditions, and fuel pump malfunction. Technical Depth Depth: Comprehensive, covering factory-level repair and diagnostic procedures for mechanics and experienced DIY users. Wiring Schematics: Comprehensive electrical wiring diagrams for accurate diagnosis and repair of electrical faults. Diagrams Illustrations Visual Aid: Includes detailed diagrams, illustrations, and wiring schematics to aid in understanding and repair. Manual Type Completeness: This is a complete and intact manual, not a generic or partial version, covering all aspects of repair and maintenance. Manual Specifications File Format File Format: PDF Print Quality Printability: All pages are printable. Binding Type Binding Type: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) Compatibility Operating Systems: Compatible with all versions of Windows and Mac. Requirements Software: Requires Adobe PDF Reader. Engine Specifications Primary Engine Engine Type: Outboard, 2-stroke Performance Horsepower: 120 HP Fuel System Carburetor: Specific model and configuration detailed within the manual. Ignition System Ignition Type: Magneto ignition Cooling Method Cooling: Water-cooled Cylinder Arrangement Cylinders: Likely inline 4-cylinder or V6, specific configuration detailed in manual. Transmission Gear Housing Type: Outboard gear housing (lower unit) Lubrication Gear Lube Spec: Specific lubricant type and viscosity to be found in manual (e.g., SAE 90 Marine Gear Oil). Maintenance Gear Lube Interval: Service intervals for gear lubricant change would be detailed in the manual. Dimensions Weights Approximate Weight: Weight varies by specific model configuration (e.g., long shaft vs. short shaft), typically in the range of 250-350 lbs for a 120 HP outboard of this era. Specific weight data would be in the manual. Safety Features Active Features Operation Safety: Manual emphasizes safe operating procedures and proper repair techniques. Passive Features Electrical Safety: Includes wiring schematics and procedures for safe electrical system maintenance. Technology Features Ignition System Magneto Description: Details on the magneto's operation, timing, and troubleshooting. Charging System Alternator Function: Information on the alternator's output, testing, and repair. Maintenance Service Intervals Tune Up: Tune-up procedures and recommended intervals are detailed within the manual. Fluid Specifications Engine Oil Type: 2-stroke outboard oil specifications (e.g., TC-W or equivalent) and mix ratio would be specified. Fuel Type: Recommended gasoline octane rating and blend (e.g., leaded or unleaded) would be specified. Known Issues Common Wear Items: Manual would guide on inspection and replacement of common wear items like spark plugs, fuel filters, water pump impellers, and shift cables. Spark Plugs Spark Plug Type: Specific spark plug model and gap specification would be provided (e.g., Champion or equivalent). Carburetor Cleaning Carb Cleaning Procedure: Detailed instructions on carburetor disassembly, cleaning, and reassembly, including jet sizes. Vehicle History Brand Heritage Chrysler Marine: Chrysler had a significant presence in the marine industry, producing a range of outboard motors from the mid-20th century until the division was acquired by other manufacturers. Model Evolution 120Hp Outboard: The 120...