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    Crusader Gasoline Inboard Engines 1980 Thru 1992 Service Manual (1)

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    Crusader Gasoline Inboard Engines 1980 Thru 1992 Service Manual

    Uploaded by

    Mike Jacobs

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Crusader GASOLINE INBOARD ENGINES 1980 THRU 1992 TEOM 596 Table of Contents PAGE Foreword... tl 1 Introduction «soe ceoesenneene TA 1.1 General information 13 12. Engine Breakin 16 1.3. Performance Factors w 14 Engine dentitcation 1410 2 Engine Removal and installation... 21 Engine Removal 23 22. Engine Installation 2a 23. Engine Alignment 26 24 Control Cables 29 3. Maintenance .. sosssesneensenssnee S44 34 Dive Bots 33 3.2. Fuols And Lubricants 34 3.3. Schedvled Malntenance 39 8.4 Cooling System Maintenance oat 8.5. Storage infomation 32 4 TuneUp oes ceseeseeeee At 41 General information 43 42 Tune-UpSpeciicatons ....... “7 5 Troubleshooting 5.21 Precautions 5.2. Used Spark Plug Analysis 54 5.3 Boat Performance 58 5.4 Ful-Throtle Engine RPM Problems «... 5:8 58. Engine Performance Problems. 59 56. Engine Staring Problems st 5,7 Fuel Economy 513 58. Carburetor Maltuncions 513 5.9. Charging System Problems ss 5.10 Instrument Problems 545 5.11 Radlo Noise 546 5.12 Engine Noise 57 5.13 Oi Preseure Diagnostics 5.20 5.14 Ol Preseure Problems 521 5.15 Water In Engine 522 5.18 Engine Overheating 523 5.17 Vacuum Gauge Diagnostics 5.24 6 10 " Electrical System 6.41 Genera information 62. Staner Motor 63. Distributors 6.4. Alternator 65. Inerumentation 6.8 Wring Diagrams Fuel System 7.4 Genera leformation 7.2 Fuel Delivery System 7.3. Rochester 4Barrol Quacraet Carburetor 7.4 Holley 4-Barrel Carburetor 4150 Series (Eary) 75. Holey &Barel Carburetor 4010 Series Engine Mechanical ...... 8.1 Goneratintarmation 82 V6Engine 83. SmallV-8 Engines 84 Large V8 Engines Exhaust System 9.1 Exhaust Manifold 9.2. Bows And Risers 9.2. Back Pressure Testing Cooling System .. 10.1 Frech-Water Cooling 102 Raw-Water Cooling 10.3 Water-irculating Pump 10.4 Raw.Water-Piekup Pump 40.8 Tormostat, 10.6 Wator heater ietliation 10,7 Flow Diagrams Drive System . 1 Transmission 11.2 Veraton Probleme PAGE err 655, 699 6-105 7 75 mt 735 751 ot 23 ent B62 ans on 9s o7 oo 104 104 1010 10-12 10-13 10.16 10-18 10-20 m4 113 m3 Table ot Contents i BLANK ii Table of Contents piss TEM See FOREWORD ‘The publeaton and aistibuten of tie manual by Cru ‘sade Engines does nol constte a waranty or guaran ‘woot ary kin. Ths service manualiswriten forte Use of qualied and experienced necharics ana isnot in tended asa “dit yoursei™ guide for porsons with ite ‘or no marae engine pair experience. ‘This senice manual includes comprehensive mainte- ‘anes irstructons forthe folowing Crusader marine en ces Model 229, 6 Mogel 262: v5. Model 305, v-8 Mogel350; V8 Mosel 454, V8 Model 502; 8 ‘hie manualisdvidedinto sectons accordingtothetype otinfermaton provided, and taloredto the ype of mae tenance requite. ‘Te Introduction explains the purpose ofthe manual and provides information on ie breakin of te engine, Various factors tat afectboatperormance, andengine identficaton. Engine Removal and instalation gives detailed in- sinuciors on removal, instalaton, algament, and ‘brottevansmission comols. Maintenance presents a recommended maintenance schedule uel, cl, and coolant spestetions and other periodic maintonanoe instuston Tune-Up proves thvaous ep ep speci ‘Troubleshooting uses a two-columa chante guide the service technician from symptoms, through potential ‘The sections onthe Electrical System, Fuel System, Engine Mechanical, Exhaus! System, Cooling Sys- tem and Drive System conta instructions needed to clsascomba, test and reassemble engine components for replacement oF repai. IMPORTANT: Throughout this publication, Warnings ‘and Cautions are used to alert the mechanic to spe- lal instructions concerning a particular service or ‘operation that may be hazarcous if performed incor- rectly orcarelessly ~ observe them caroful ‘These "Safety Alerts” alone cannot eliminate the hhazards that they signal. Stret compliance to these ‘pecal Instructions when rertorming the service, plus "common sense” operation, are major accident Dreventon measures. WARNING Hazards or unsafe practices which could esut nse vete persona injury or death as CAUTION Hazards or unsae practices which could resuitinm- ‘nor personal nut of product or property damage. ACKNOWLEDGEMENT Crusader Engines woud tke to hank the fotowing fms forpormissiontouse lex and ilitrations from hak ser vice Merature: AE Clevite Engine Pans Borg-Warner Champion Spark Pugs + CH Corporation ‘Chevrolet Pomiac-Canada Group Genera Motors Corporation Holley Carurator Prestolite Fochester Product Division of General Metore Corporation ++ Yamaha Motor Corporation, USA Foreword i BLANK WW Forewor vanes veo Section 1 Introduction 1.4. General Information 1-3 1.2 Engine Breakin 16 43. Performance Factors . “7 1.4 Engine Identification . Teou S96 RI Irvedueton 3-1 BLANK 4.2 induction piossaTeomse6 1 INTRODUCTION 4.1 GENERAL INFORMATION ‘This comprehensive manual writen by the Crusader Service Department powes information for dealers ‘and sorvica mechani, Because ofthe nature of ropa work, Crusader Engines ‘does not quarantee he resus any procedure outings in this manual in any partcular caso. This manual Is ‘meant to be a general Qulde tothe care, maintenance and repair of Crusader Engines forthe assistance of ‘experienced mechanics, ana Crusader Enginos makes no further representations, Maintenance and repair procedures are writen under the assumption that ine technician has been tained in servicing Crusader products or in marine engine repar {andthe use of common mechanics tale, Botore attempting maintenance and copalr task, the approriateprocedure shouisbe read theroughly to gain knowledge of proper methods and tools and to become aware of any dangers. ‘Crusader Engines could no possibly know ol and advise the service trade oa conceivable procedures by which {2 service might be performed and ofthe posse haz {ras andor results ofeach meiiod. We have not under- taken any such wide evaluation, Therefore, anyone who Uses a serves procedure andor tool which s notrecom. ‘enced by the manutactre, ret. must completely st. isfy himsel that nethor his nor he producr'ssaety wil belondangored by the service procedure selected, ‘Crusader Engines assumes no responsi foranyloss ‘occasioned faleto folow accurately andoomplotly ‘the procedures sat forth inthis man with respect 10 anyofits products, and tucher assumes naresporaily orbit forany oss or damage caused by fala to. low the procedures outined ar fe dbserve the foregoing precautions Ainormaton, lustaionsandepecicatons contained inthis manual are basod onthe latest produc informa tion avalabe atime of pobication, Specticatons, dimensions and product content are all ‘subjectto change without notes, and Crusader Engines ‘assumes no responsibly wth respect 0 notfication Persons using this marual shoul take caro to eneure thatthe procedures folomed are appicabie to the prod. el being serviced. It should bo kop in min, while working onthe produc, thatthe elecrcalsysiom and igntion system are capa- ble of violent and damaging shor circus or inficing severe oloctical shocks. When performing any work where eloctical terminals could possibly be grounded or touched bythe mechanic, the battery cables should be Ssoonnected atte batery ‘Anytime the engine's Intake or exhaust openings are ‘exposed during service, hay shoul be covered to pro tox against acedortal envance of foreign material whieh could enter the cyinders and cause extensive intra damage when the engine i state, Ikisimpocant to not that, during any maictenance pro- cecure, replacement fasteners must have the same ‘measuremonts and srongthas those removed, whether Imetrcorcustomary. Numbers on te heads of thematic bots and on surfaces of metic ruts indicate thei strength. Customary bots use rad lines for this pur ose, while most customary nuts do net have stength markings. Mematched or incorrect fasteners can resi In damage or maituncton, 0 possbiy persona inky. Thetetre fasteners removed shouldbe saved or reuse intesame locations whenever possi. Where the fas woes are not satistactory for rouse, caro should bo taken to select a replacement that maichos th original Invoduetion 1-3 Replacement Parts: WARNING ‘lec, ignition an fue system components on Crusader Engines are designed and manutacured to comply wit US. Coast Guard rules and regula- tons to minimize risks of Tre or explosion. Use of replacement elztcal,grton of uel system com ponanis whicn do not comply with tse rles and Fagulaton could resultin afr or explosion hazard land should be avoloed AN WARNING ‘When servicing the electcal, ignition and fuel sys- toms, tig extremely important that all components ‘ate properly nstaled anc tightened. If they are no {ny electrical or gniion component oponing would ‘omit sparks tonite tel vapors om possible Ue System leaks. Engine Mechanical Components: Many of the engine mecharical components are esgred for manne applcaen. Unike automotive engines, marie engines ae subjected to extended per ‘ods of eavy-load ang wide-oper-throte operation, and theretore, requie.eavy duty components. Special marine engine paris have design ahd manufacturing {peotieatione which ae required to provi ong feared ‘ependabie performance, Marine engine parts aso ‘mustbe able o resist te corosiveaction of satorbrack ‘sh water that wil ust or corade standard automotive parts win a shor perod o ime. Fall to use recommended Crusader service replace- ment parts can result n poor engine performance andlor urablty,apid cortosion of pars subjecod to saltwater ‘ane poseiay complete falure ofthe engine. Use of replacement parts other than those recom mended by Crusacer wi void the warranty on any parts damaged a a result of the use of other than recom mended pars. Directional References: “The rontof the boats the bow an he rears the stern “The starboard side Is the right sige, to por sie is the Ietede. nine maintenance manu, al drectonaleter ‘ences are gven as they appear when viewing boat rom {he stern ooking toward the bow. @ ® 4. Seroard 3. aow 2 Pon Sem Figure 1-1. Directional References {4 troduction Engine Rotation: Engine rotation is ented as “RH fight-nand) or “LH (lethang) by the model number Rotation always ‘eterminediram the ywnce endothe engine. some Instances, propeller shaft rotaon may be opposite t> {hatofthe engine. Alvays rele to engine model number for engine ‘tation. When ordering. a replacemert ‘engine, short blocks or parts for an engine, bo certain ‘check engine rotation. Be nat rly on propeller rotation indetermining engine rotation. Figure 2. Engine Rotation eomsae Risa Introduction 1-5 1.2. ENGINE BREAK-IN IMPORTANT: Proper breakin is essontial to obtain ‘minimum ollconsumption, maximum engine pertor- ‘mance ane good service lite. ‘Tho fist 25hour period of operation for anew o rebuilt cengne is called the engine breakin perod. During is peod, tis extremely important ha the engine be op Sted as outned belo ‘@ Donot operate the engine below 1500 rpm for ‘etonded periods of ime during the est 10 hours. During this period, shit iio gear as ‘soen as possible after staring engine and ‘adsarco throttle so thal engine spood & above 1500 pm (provides thal condtons permit sale operation a this speed) '. Donot operate at any one constant speed for ‘tended periods of time © Donot exceed 344 of ul throtle during the firs 10 hours of operation. During the next 15 hous, aecasional operation at ful tote (5 minutos ata time maximum f permissible. 1d. Avedtulthrotte acceleration fom the stopped position ‘2. Donet operate at ful throtle until engine reaches normal operating temperate, 1. Obverve instrumentation caretuly an abrormal reading occurs, stop engine imnedtately and determine cause 1 Frequonty check the crankcase ollovl andiadd o!# necessary. is noma for ol ‘oreumpton t Be somewhat high euting the breakin perio. IMPORTANT: To check the transmission ud loved ‘ccurately, the engine must run at 1500 rpm for 2 ‘minutes immediately prior to checking the evel. Olt must be at normal operating temperature. h._Atthe end ofthe 25-rour breakin period, {rain breakin ou tom the crankcase. Replace ‘he ol itr and i erenkease wih ol ofthe correct grade ae visosity. Use care during the st 25 hours of operation on new ‘Crusader engines or engine falure may ooour ita new ‘engine as to be waterested at fl trie before he ‘break-in pore is completo, alow ths procedure: 1. Start engine an run at 1200 rpm uni normal ‘operating temperatures reached. Fun boat upon plane. Advance engine spee in 200 rpm increments Unt engine reaches is maximum fated pm. IMPORTANT; Do not run at maximum rpm for more than 2 minutes, +16 Inedetion 1.3. PERFORMANCE FACTORS Propeller Design: Changing the dlameter or pitch of a propel wil atoct tenginerom and boa pertormarce, The bade conigura ton also wil alt performance. Twa similar proper, wn same pach and dlameter, from two. dierent ‘manulscturets wil also perform difererty It sth responsiblity of the boat manutacurer andlor selingdealer to equip te boat wiht corect propeller to alow the engine o operate within is spected rom range i mde-open tote (WOT), ‘ecause.otthe many variables of boa design and opera: tion, ony testing wil determine the best propeller fora paricdarappicaton To stforcorect propeller, operate boat (with an aver: age lozd on Boars) at W.0.T. and chock fpr wih an sour tachometer. Engine rpm should benear th op Othe spodtieg range so that, under heavy oad, engine Speed oat fal blow specications + Itengine exceeds the spectod rpm. an Increase in pich andlor clameter is required, + Hengine is below rated rm, a decrease in itch and diameters requis. ‘Normally, a change of apraximately 150 to 250 rpm wl De actievedior each singlepichchange athe propor. It apropetar i insted that does not allow engine rpmvoreachthe spcied tu-thotie pm range, the gi wil Sabor and will ot produce Tul power. (Operation uncer this condition wil cause excessive tsonaumption, angina nnehaning are poeta pisten damage (due to detonation} On the other hand, stallion ofa propeller that aiows engine o run above the spectiog fpm limi wil cause exces: ‘Svewear on intemal engine pars which may lead to ronature engine tau, CAUTION For maximum speed, a boat bottom should be as fat as possible in a fore-and aft drecion (ongidnally) for ‘approximately he lst 5. (1.5m Sorrow Figure 13. CrtealBotom Area For best speed ad minimum spray, he come between the bottom andthe transom should be sharp Figure toh. Bot Coven “The botiom is referred to as having a "hook" is con- caveinthe lore-and.at drecton.Ahook causes morelt ‘on the ttom rear the Yansom and forces the bow to ‘top. This increases watts surace ard redioes boat speed. ‘ook, however, sds in planing and reduces any por poising ythmial Bouncing) tendency sight hook is ‘ten bull m by the manulactuer A nook can also Be {caused by incoret storing of the boat win support ‘rectly under the transom. Intouetion 1-7 Figure rs. Hook ‘Avrocker isthe averse ofa hook. The bttoms convex ‘or bulged in the fore-ane-aft direction. can cause te boat to porpoise. WY Figure 6. Rocker [Any hook, rocker or surtace reughns tom, pariclalyin the alkimperant tion wil have @ negative ettect on speec, often by Sev ‘ral miles per hour ona fast boat Weight Distributio ‘Weight dstrauton is extremely important; affects a ‘boat's cunning angle or atiude. For best top speed, all movable weight cargo and passengers ~ shouldbe ae Tar aftas posse to allow tie bow to come uptoa mre efcient ange (8 to $°). On the negative side of ths ‘approach fs the problem that as weight Is moved al, some boats wil bogin an uraccepsable porpalee Secondly, a8 the weight is moved aft, planing out becomes more etic Finally the ie in choppy water bocomes more uncom- fonaple as the weight goes a With these factors in mind, each beater should seek out weight locations ‘which Dest sult hisiper needs. Weight and passenger leading placed well forward Increases the "wetted area" of the boat bottom an, in ‘some cases. vitually destoys the good perormance andhandling characteristics fhe boat. Operationinthis Configuration can produce an exemely wel Me Korn vwind-blown spray, and could even be unsate certain leather conations or where bow steering may occu. ‘Weight eistbution s not confines sty to fxe and at locations, but also apples to lateral weight distouton Uneven weight concentration to pot or etarboard ofthe longitudinalcentertne can produce a severe listing at handing ability and dng comfort In extremely rough water the safely ofthe Dot ane passengers may ben Jeoparcy 448 Introduction rasa TEOMSoE Elevation and Climate Effects: ovation has a very noticeable affect on the wide-open throtlepower ofan engin. Sincoalr(contaningoxygen) {getsthimer as elevation increases, the engine begins to Stanetorar Humid, barometric pressure andtomper- ‘ture do have a nobaabe elect onthe densiy of st Heat and humidity thin the al. This phenomenon can became partculaty annoying when an engine. Is ‘ptopoed out on a.coot, dry day in spring, ander, on & fot slr day n August, he engine may nothavelis old 2p (Figure 7), [Although some performance can be regained by arop- ing fe lower-ptch propel, the basic probe st ‘2x5, The propoter Is too lage In clamor fr the ‘eoused power output. The experiences marine dealer Can determine how much diameterto remavetrom ala. ter pic propor for specie high-elevaton locations. | own act that weather conditions exert profound lec on power output of internal combustion engines. ‘Tresor, established horsepower ratings rete to he power thatthe engin wil produce ats rated rpm uncer 8 spre combination of weather conaions “Eocs Of Weather On Engine Power Marine Fouling: Foulingis an unwantedbulé up (usualy animalvegeta- ble-derved) occuring on tho boat's botom. Fouling ‘ados to crag, which reduces bos prtormance. nfrash ‘water fouling resus rom dit, vegetable matter, lgaeor Sime, chemicals, inerals and other poltans In sat water, barnes, moss and thor marino grow ‘ten produce draratie build-up of mate qui, iz therelore importa keep he hull ascean as possible in all water Conltone to maximize Bost performance, ‘Special hull treatments, such ae antfoulng pat, ml redu08 thera of atom fouling, Water in Boat: \Wmen a boat loses performance, check bilge for water. Water can add considerable weigit othe boat, hereby secreasing the porormance and handing. Ensure that all dan passages are open for complete raring 1.4. ENGINE IDENTIFICATION ‘When ordering spare parts o* obtaining intermation, always incude the engine model and evil rune. Figures 1 8 trough 1-29 aro photos ofthe engine med ‘ls deserted inthis manual: “Typical V6 Engine Figures 1-8 twough 1-11 Typical Engine, Model 30560 CID Figures 112 through 1-13 Typical Engine, Model 305060 CID (Freshwater Cooled) Figures 1-14 tough 1-15 Typical Engine, Model 305/360 CID (Seawater Cosi) Figures 1-16 trough 1-19 “Typical Engine, Model 454/502 CID Figures 120 tough 1-23 ‘These photos will help the user to determine which engine model neshe is using. Also, each engne has 2 ‘molaltag etached othe fyueet housing hatcortains the engine model and seral number Al itustraions ate for releronce only, and in some Instances, the pars shown may vary sgh 1-10" Introduction TeoMses I-52 Inreduction 114 142 Imeduetion 4. Alt sender (argue) 4, Engine hamess connecter 2 Maur attleay 5. Smog manta) 4 Ennauetebow 6. Sram Eta rane Figure 10, ‘Typical 6 Engi Port tet View reowsee Ato Inodution 1-49 1. distin 4 Dring (en 2° eareparent tl pump uerow hose 5. rae pg (ran 3. Sram pug tater pur) 8 Miter'nount Figure 11, Typical V6 Engine Starteard “ight” View 1-14 Invodveton Pi—aiaTEow S06 Figure 1-12. Typcai Engine Model 805/360 CID — Pot Let” View Tecweo RI-S00 Intoducion 1-19, Figure 1-13. Typical Engine Wodel 305250 CID Stara Fight View 1-16. Introduction Ri-s Tec Figure 1-14. Typcal Engine Model 3051350 CID (Freshwater Cool Teowsse I-80 Irtroduction 1-17 1 9. Oran plug water pump) 2 10. Foal pomp. 5 e 1 Mote maine 4. Rama aestor (sur 12. Drm plo (erin) 8 ‘Tranterrt pup ovetow hose 12: Bran plug (marta ether 18, Stare 1, Stour ransrissin) 13. Eeraus ow 8. Rawwatee pum 18. 2noanosee Figure 1-16, Typical Engine Model 305/350 OID (Freshwater Cooled) 1418. Introduction Board Right View 40. Engine watersiowston pum 1 Themes housing 1. Flame arstr (arti 7. Fut puny 2 Fuster 1 Trandparnt ul pump overtow hse & tera ler ranemastn) é Gian Faw-water pump Figure 1-16. Typical Engine Mode! 305850 CID (Seawater Cooled) Front View recuse ats Introduction 1-19 Fame arrestor router) 8. Ol vel space (ransmision) 2 Carer 8. Shit over bac 3 Mote ot tt cap 10. Ol iter Exava abow 1. Engine nares conoctor 5 Motor mount 12, Thee ea bracket 8 Starter motor 13. Grout rear 5 Mode and scl number pte Figure 1-17. Typical Engine Mode! 305/350 C1D (Seawater Cooled) ~ Rear View 1-20, Intucton i503 Teo Fler 10. Engine ramoss Engine watecculatng pump 4 Sater moor 1 Baten goon sta 14 rai pig (mao) 15. Drain pla lens) 18. Remar 17, Rowwater pure Figure recs ay—598 Induction 1-21 uate ote 11 Thermostat novsing Panaueran 12 Ghensa foanamion) 3. Groutoeacr 18, ram pig water pre) & lgnon ca 14 Rawate pure & Sonouor 1. Foal her Esha mane 18, Voto mount 7 Tht call backot 17, ran pg engine) & 18 Oipan 6 19, Dram pg (manta) Figure 1-19._ Typical Engine Made! 305/350 CID (Seawater Cooled) ~ Starboard "ght View 1-22 Inrodueton rinses Teousoe Flare arrestor arose) Engin waleruston pump awa Re Sa lg nn Figure 120. Typical Engine Model 454/502 CID ~ Front View 2 The cable bneaet 18 Mogan seri number plata & gon cot S. Oriewe sete (ranemson) Great breaker 1a. Soitoraciet 5 oar ott eap 1 Oimter 8 Mole mount Figure 1-21. Typeal Engine Model 454/502 Ch 1-26 ntrodusion rinse Teow see 2. Engine watercelaton dk fa. Ole 4. Thermostat nous 11 State motor 3 Coburetor 412, Motor mo 5 Fame arestor 18. Baty gourd std 8 Osrburor 44 Olpraesre senaer 7 lgnton oot 18 Dram aug fran) 8 Groat treakee 48 Atemsior Figur “Typical Engine Mocel 454/802 O1D- Iredvetion 1-25 Starner moter ran plug (isa fo. TomestatFesing (i cole (engine) “Tranaparen tal pune ovation nose ‘Gilorl ipsck (engine) Dain pg mano Baty guna tos Figure 1-23. Typical Engine Model 454/502 CID - Starboard “Rgh View 1-26 introduction Section 2 Engine Removal and Installation 2.4 Engine Removal .. a 23 22. Engine Installation 24 2.3. Engine Alignment ..... = 26 24 Control Cables .... 2.28 TeoMsne 14980 Engine Removal and lstalltion 24 BLANK 22 Engine Removal and instalation rasa recuse 2 ENGINE REMOVAL AND INSTALLATION WARNING ‘Always cisconnectbatey cables trom battery. neg ‘ative terminal test, betore working on uel system ta prevent tre or explos.on, iN WARNING ‘Be caretul when changing ue system components; (gacoine is extremely flammable and highy expo Sve under curtain condilons. Be eure that griton key is “OFF Do not snake or allow sources of | Spark or lame inthe ares. Wipe up any spilled tue immediate CAUTION Ht boat i in the wator, be sure to close water it valve before removing inet hose rom pump to ee: Vent water rom draining no boat. baal ot ted with a valve, either pg inlet or raise it above water level ater removing, CAUTION 'o not operate engine without cooing water being ‘supplied ora water plewp pump or the ump in polo wilbe damaged and subsequent overeating {damage may result FASTENER TORQUE REQUIREMENTS [Fastener Location [ib (Nem) Baterycabies Securely Engine mountto stinger | Securely Hose chimps [Securely Proper shat coupling |50 (68) FTunnion bots 45 (61) Toots [22165 Mount acusting tot 24 ENGINE REMOVAL the engine needs o be replaced or requires mainte- ance on arte where access f retried bythe Boats hl the fellowing procedure shoul be alowed 1. Disconnect the battery cables from th battery ‘and remave the instrument penal names Connector pg rom the engie harness receptace. 2. Disconnect the fel ne 3. Disconnect the transmission chit cable and ‘hrotle cable inthe reverse sequence outlined In Secton 2.4, Contol Cabos. 4. Disconnect he water inlet hove and exhaust system. 5. Disconnect any ground wies or accessories that are connected ta the enghe, 6. Disconnect the propelor shat couping rom the wansmision coup, 7. Support the engin with a sutble sing through the iftng eyes onthe engine, and Temove the front and rear engine mounting bots (Figure 2-1). 8. Caretuly remove engine. 1. Engine mounteg bos Figure 2-1. Engine Mounting Bots Engine Removal and instalation 2-2 2.2 ENGINE INSTALLATION ‘To reinstall the engine ater periorming the required maintenance, orto ial a new engine, the fllewing procedure should bo flowed 1. Engure that al engine mounts (Figure 2-2}: ‘2. Arein thecorto of thor up and down adjustment b. Have the lge diameter of the tunnion fextendod a shown in Figue 22, ‘& Have the nounting base facing downward Figure 22. Proimitary Engine Mount Adjustment 2. Tighten the trunnion clamp nuts and serous Just enough se thatthe trunnion cannot move Inoroutof theciamp, but sls able fo pivot. 3. Lit tne engine nto the boat and position it ‘on the engine bed so tre transmission and propel shall couplings are visibly ages {notap can bs seen between coupling Tacos when butted together) 4, Adjust the engine bed height necessary, to ‘obtain tho proper abgnment. At this time do hot use the meunt adjustment to adjust the ‘engine's poston. NOTE: The engine bed mus position he engine sothat ‘minimum up-and-down agustment of 025 in. (mm) Stl ext on all Jour mounts aftr performing the final ‘ignmant. This isnecessar tallow orfuture engine algnment 5. Chockal fourmounts to ensure that they are sil positioned property then fasten the ‘mounts othe engine bed wit lag lis and tghton securely. 6. Disconnect and remove the sing ‘Connect the fuel ine an check or eats. 8. Connect the seawater inlet hove and tahton the lamps securely. 9. Connect the exhaust system and ighton the clamps securely. 10. Before complting the installation, align the ‘engine az ound in Section 2 3, Engine Aagament 11, Alter the alignments comect, connect the propeller shaft coupling othe transmission ‘coupling and torque the bolts and nuts to Specifications, IMPORTANT: Exhaust hoses must be connected to ‘exhaust elbows without resricting the flow of dis- ‘charge water rom the elbow (Figure2-3).Tthehoses fare connected incorrectly, discharge water from the exhaust elbow wil not flow around the entire Inside Slameter of the hose. This wilcause ahotspotin the hhose which may eventually bur through, 2-4 Engine Removaland Installation 1. Core hase instalation 2 nconet Rose ntaon Figure 23. Exhaust Hose instataton 12, Connect the instrument hamess plug tthe ‘engine hamess recepacl, 19. Connect tho transmission shit cable ard tivotle cable as outined in Section 2.4, Contol Cabs. 14, Rocennect any ground wire and accessories tat may nave buen dsconnected. 15. Conrect the battery cables tothe batty and tigen securely Engine Romoval and etalon 2.5 2.3. ENGINE ALIGNMENT CAUTION Engine must be prpety aligned or vibration, noise ‘and damage ote Fansmision output shaft ol seal and bearings may result IMPORTANT: On boats with remote V-Drives,referto ‘the V-Drive manufacturer's Instctions for the cor rect alignment ofthe driveshaft between the V-Drive ‘nd the transmission. IMPORTANT: Engine alignment must be chocked with the boat in tho water, fuel tanks filed and with ‘Sormal load on beard. ‘The engine must be aignedso thatthe transmission ang propeller shaft couping contorines are aigned andthe Coupling faces are pela. This apales fo nstallations ‘wit sold coupings, aswell asinstalabons wih exible ‘couplings. Pertrm the following procedure to earectly align and connect the propala shal tthe engine: 1 Check the mating faces onthe transmission ‘and propel shat couplings to make sure ‘hey are cles and fa. 2. Genter the propeller shat inthe shattlog as follows (Fue 2-4) ‘Push down and then lit the propeller shaft 6 far asi wil move. Then place the shat it the mile ofthe movement Move the shaft to port anc then Starboard a far asthe shat wit move ‘Than ple the shaft the mile of the movement, With the shat inthe centr ofthe shat log, align engine 1 the shat Figure 2-4. Propelor Saft Alignment Ta Engine 8. Check hate couping flange centerines align by buting the proper shat coupling agaist ine vansmisson lange (see Figue 28), Tho shoulder onthe proper ‘sal couping face should engage te vos ‘on the wansmssion flange wit no resstanco, ah aif. sean sare CouptnG FAcES ARE PARALLEL ‘Grin DISTANGE BETWEEN FADES, DUCT THE SAME RTALLPOMTS mene Figure 25. Coupling Face Alignment 26. Engine Removal ans Installation 4. Check for any angular misalignment Hold tho ‘couping faces tight together by hand and check for a gap Between the coupling faces ‘wth 0.008 in (0.07 mn) fooler gauge at 80° Imervals (see Figuee 2} Figure2-. Angular Misalignment Chock ‘5. the coupling centertnes are not agned or ithe couping faces are more than 0.003 in (0.07 mm) out of paral, adjust the engine moun as follows ‘a. Te adjust the engine up or down (Figure 27), loosen he lag screw only 1/4 ‘of tur. Use mount agusing tool oa 12 {nor 38 in. ameter od trough bath ‘ide ofthe adjusting sleve totum. Ator the adjustments complete, reighten the lag serow. IMPORTANT: Both front mounts must be adjusted ‘equally and both rear mounts must be adjusted ‘equally to keep engine level rom side to sie. ._Tomove the engine to the lt or ight, loosen the clamping screw andthe nt on alfour mounting rackets and move the fgine fo the lef oF ght, as necessary, to Botainthe proper alignment ‘Truntion "pour Figure 2-8. Engine Mount Exension IMPORTANT: The large diameter of the mount trun- rion must not extend over 1.0 in (25 mm) from the ‘mounting brackets on any of the mounts. Teowss I-59 Engine Removal and nstallaton 27 6. Afterthe engine has been propel aligned, ‘secure the engine mounts (Figure 2-9) Figure29. Securing Engine Mount 7. Connect the proplir shaft coupling to the \rananssion coupling, Torque the coupling, ataching the serews and nus oth corect Spectzations as Isted in the table 2.8 Engine Removal and Insalaion isos TeCM S06 2.4 CONTROL CABLES IMPORTANT: The remote control lever must provide total shittcable travel (vansmission end)of atleast 275 in. (70 mn). This Is necessary to position the transmission shift lever fully in the forward and re- Verse gear positions. Insufficient shift cable travel ‘wll cause the transmission to slip and eventually tal ‘Transmission Shift Lever Installation: IMPORTANT: The Warner Gear warranty is joopa lized if the shift lever poppet spring andior ball is permanently removed: tthe shiftleverischengedor Fepostioned In any manner; of ifthe linkage be- {ween the remote control and the transmission shit lever does not have sufficient travel in both aireo- tions. “The transmission shit lover and related parts must be assembled as erown i Figure 2:10 1. Lubricate poppet bal spring and holes inthe transmission shift over with 2 hightemperature grease 2. Torque the rut rom 96-182 bin (11-15 Nem) 3. Altorinstalaion, move the vanamission shit lever tough the forward, neil and reverse postions (Fegure 2-1). No more than fingertip ‘ort shouldbe required. the valve binds, the cause for binding must be found and corrected 5. Poppet oat Poppe ig Figure 210, Transmission Shit Lever Assemby “Tranamssonehtover Shi aver mut be ovr abr when prepling bomt FORWARD Shit aver must be overs lotr whan prepling boat in REVERSE 4 Poppet all rust be crtre in tet hale or tach FAVA poston (Fowaré gear pasion row) Figure 2-71. Tanemission Shit Lover Teowse6 RI-36@ Engine Removal and instalation 2-9 Attaching/Adjusting Transmission Cable: ‘Single Station Control Usothefolowingprocedurto properly attach and aust the transmission shit (Figues 2-11 and 2-12) for a single station mount 1. Pace the mote contrl shit lover in the reutal positon, laos the transmission shit lever in neta Install tho shit cable nub ito the shit cable bracket and lock the cable cp. 4 natal a cov pin ont the eable rod unt the rol ines up unt the ball ort stu, then tighten the lockout. '5. Retractthe spring look onthe clos pin and ‘ach the cable tthe ball jor stu. 1 Mounting bot 4 3. Cable anchr ep Figure 2.11. Single Saton Shit Cable Assombly— Front Mount Ciel in assembly S. Shitiever {6 Place the remote conto shit over inthe full forward gear positon. Check the postion ofthe vanemson shit over or ul engagement, 7. Place the remote contrl shit lever in the tut reverse gear poston. Check the positon ‘tthe tranemison shit ever for ul ‘engagement, 4, Ifthe tanemission shit levers positioned proper in one gear, but rat inthe otha, Fecheck the shi cable aqustment. tranemsion eit leer fot positioned propery in other gear, move the shit ver Ballot stud tothe botom Pole in tne it lover, readjust the cable and recheck fr correct engagement Icoret postioning is Stifpot achieved, the remote contrl does not provide suffer shit cable wavel and must be replaced, 1. Tote cable 2 Gable anchoreip 5 3 Brecet| Figure 2-12. Single Siaion Shi Cable Assenby — Fear Mourt 4a bal jon Shitiove 2.40. Engine Removal and instalation Dual-Station Control Use the folowing procedure to attach and adjust a dua- sation shift cable property (Figure 2-19 and 2-14 fora ‘uak-staton mount (Cae trmind Shitiover 1. Mounting bot ‘ 2 Lecasnor 5 5. Cable archer cp Figure 219. Dual Staton Shit Cable Assembly — rent Mount 1 Teo oat 4 Cable eal ot 2 Coble anche cip 5. Shitlover 5 Sracet Figure 214. Dia! Staion Shit Cable Assomby— ar Mount NOTE: The following instructions refer to Crusader at {aching kt rumbe: 22435, 1 Place the remote conta shttever and the transmission shit over inthe neal postion, IMPORTANT: The remote control lever must provide total shift cable travel of atleast 2.75 in. (70 mam). Insufficient travel wil eause the transmission to slip ‘and eventually fa 2. Retoring to Figure 2-18, atach te cable cp to the bracket Using scrows, lockwashers and ruts. ccatte cp ‘stead fesont2 in {0 lekwashor foaenexna 1 Prat pn 12 Shinty captor ato tie svacher ia 2b nace Figure 2.16. Dual Station Shit Gable Assembly 3. Remove the top transmission masiting bolt land lockwasher from the lf (vate) ede of ‘tanemiesion: postion bracket ar rplace bolt and lookwashor. 4. Fasten the pivot pn securely through hole in the adaptor plate using alocewasher and a rut 5. Insert the cable hubs into the cable ip and screw he terminals ano tho cabe rods unl the holes inthe termina ine Upith the pivot recuse At-s99 Engine Removal andinsaition 2-11 pin, Fold each terminal securely to prevent it ‘rom uring and ight the cable nut against the tein, NOTE: Be sir the transmission shift ever and there ‘mote contol ehitiover are inthe neutal postion dung the above Insalaion 6. Place terminals onthe pivot pn and secure with £5716. Exng NOTE: Shite control boxby hand andbe sure oper ‘0s freely wit no binding, 7. Place the ramote-contal shit aver inthe forward gear positon and check postion of transmission shit lever. Shiftiever must be positioned aa shown In Figue 2-1, 8, Place remote canal lever inthe reverde gear position and again check the transmission shit lever aotion. Sift lever must be postioned a5 shawn in Figure 2-1 Attaching/Adjusting Throttle Cable: Single-Station Throttle Cable Control 1. Placothe remote contol htt over inthe neuttal or ile poston. 2. Instat throte cable hub into the hota cable ‘mourting cp and secure with cable cp. 2 Gable eicer op 2 Bracket ‘Tota ever 5 Cab bal on Figure 2.17. Thott Cable Adjustment ~ Single Staton 2.12 Emin Removal ana instalation 3. Tread the bal joint lows ont te hte Catlein order tone up the bal ant stus mounted on carburetor ttle arm. Tien ‘evi am nut when positioned correctly. 4. Retiat the spring lock on the evs pin and attach the tht cable to the bal ot etd. '5. Place the remote-control hte lver in the ful- Proto poston, ard check hat the carburetor tote plates open ty arathe {trot lever contacts the coil stops, Check the ttle cable and carburetor inkage for {any binding. Return the trol ove othe ‘ural ore postion and check hat the throttle plates are closed. Figure 2-18. Romoo- Control Throttle Cable Postioning Dual-Station Throttle Cable Controt 1. laos the remote-conto thot aver inthe neutral orale postion. 2. Insalthrote cable pivot pin onthe carburetor thre am, 1 Trotle cade 4, Trott ever 2 Cabwancrorcip 5 Cable bane 3 Bracket Figure 2-18, Throte Cable Ausimont Dual Staton 4 ntl the tote cable hubs into the rote ‘cable mourting ep and secure wth cable lips. 44. Thread the cable attaching terminal onto the tote cable unt it ines Up withthe pivot pin ‘on the carouretor tote arm. Tighten cable terminal end by holding te terminal to prevent Irom tursng and tghtering the far rat 5, Place the cable terminal ends over the trate pivot pin and secure with retaining cp. Pace the remote-control lever inthe full ‘trot positon. Mako sure thal the carburetor three plates are inthe ul open position ane Sopa, Check cables and carburetor linkage for any binding. Return the trate evers tothe etal or le postion and make sure thatthe Carburetor trate arm i contacting the idle Sop, and the thot pates ae fully close. Adjust as needed, Teowses at -s0 Engine Removal and installation 243: BLANK 214 Engine Removal ad Inttiation risa TeoMso6 Section 3 Maintenance 3.1 Drive Belts. ‘| 33 3.2. Fuels And Lubricants 34 3.3. Scheduled Maintenance . 39 3.4 Cooling System Maintenance . ant 3.5 Storage Information . Teowsto Ri—589 Maintenance 3 BLANK 3:2 Maintenance Rise TEoMSS 3 MAINTENANCE ‘AllCrusader engines requreacertain amount ofmairte- nance. Suggested maintenance requirements are oon tainedinthis section. The ener should, however, deve! tp nis own maintenance schedule using the require ‘ren sted inthis manval and any other necessary re ‘uiremenis resutng from optional addons to tho en- sine stem. 3.1 DRIVE BELTS Altemator Belt Tension Adjustment: IMPORTANT: When adjusting the alternator beltten- Sion, da not apply pressure tothe sltemator’s rear fend:fame, as this may damage the alternator. 1. Chock bot tension by daprssing bet with thumb at midway point (4) (Figure $-1)- Bek should depress 1/2 in. (12m) 2. Hf adustment or placement is necessary, loasen allemator brace attaching bots and aerator mounting bo. 3. Pho altornatr inward to ropace ive bet. 4, Pivot atemator outward, as requited to obtain correct belt tension. Apply pressure © ‘Stemnator frontend fran only. Set new bets atthe hightension reading 5. Retighan alternator brace attaching aos an allernator mounting bot securely 6. Recheck atenator bl tension. Ita now crive belt has been instated, recheck bat enson ater runing for 5 minutes Raw-water Pickup Pump Belt Tension Adjustment: 1. Check belt tension by depressing bot with thumb at miway point 2) (Figure 1). Blt should depress 14. (6mm). 2. adjustment or replacements necessary, use pickup puny tlh bts 3. Side pump away tom engine, 26 recuired, ntl corel tanionf obtained 4. tor obtaining coret tension, securly retighen pump mounting bots. 5. Recheck pickup pump belt tension. ta now ‘ve belt has been stalled, recheck belt tension ater running or 5 minutes. ‘we DEFLECTION Figure 3-1. Dive Bet Deletion Teomsne Rises Maintenance 33 3.2 FUELS AND LUBRICANTS FUEL RECOMMENDATIONS ‘The ignition timing set by the factory requires the use of lead fres or leaded gasaine wih the flowing minimum lorhigher octane epocticaton: ‘+ An-Knock Index Number (AK) 87 ‘+ Research Octane Number (RON) ~ 93 i187 AKI (@1 FON) octane isnot avalabe, a gasoline (rogular leaded, premium, iow-ead or leactee) with an ‘average octane rating as low as 85 AKI(RONO) octane ‘may be used. gniton timing, however, mustbe retarded 4°16 prevent harmful detonation, Recentrogulatlonsby the US. Emvironmental Protection ‘Agency (EPA) and the Canadian goverment have re- ‘uiredthe removalotlad antknoskcompouna) tomall ‘Gasoline by 1988, ue o health hazards tom lead emis- Sion generated by the exhaust Detonation or spark knock ina marine engine isnot nec ‘essary audible, Overheating isan indication ot detona- tin in’ marine engine. I you suspect detonation or ‘park knock ane the engine propery tuned, change to ‘higher octane fue. CAUTION Useotincortest gasoline can damage the engine se- ously. Engine damage that results trom use of Corre gasoline ie considered misuse of he engine fandisnot covered under Crusader Engines warran cs ithe engine istobe operatedin foreign country, or Ifthe above recommended gasoline is natavalabo, the lonton trming wil have to be retarded so that lower octane uals can be used. When gnition timing 'sralarded, a sigh ceciease n power can be ox pected. mn CAUTION In order to maintain octane ratings, many gasoine manufacturers are adding ethyt alcohol (ethane) of ‘eth! alcahl (methano} tote gasoline replace the toad, Gasolnes containing alcohol, either methy! alcohol (methano) or ethyl alcoho! (ethanol), may cause in croased! + Comosion of meta pars + Deterioration of elastomer and plastic pats. + Fuol permeation through flexible felines. + Wear and damage o internal engine parts. + Staring and operating deus. Some. these adverse elects are due tothe tendancy ‘of gaspines containing alcohol to absorb moisture rom ‘he at esulingn aphase of water and alcohol separa Ing tem the gasoline nthe tel tank ‘The adverse eects of alcool are more severe with methanol and are heightened with increased alcohol WARNING Fe and explosion hazard: Fuel leakage tom any parol the fuel eyetom can be a fre and oxposion hazard which can cause serious bodly injury 0 dosh Carell periodic nspecton of the ene Tue Systm is mandatory particularly ater storage. Al {eleamponents including fuel anks, whether pas te,metal or fiberglass, eines ngs, fl ters, {uelpumps and carouretos shoul be inspected for leakage, ollening, hardening, sweliegocoresin. Anyi of leakage or deterioration necessitates placement belore further engine eperation, Becauseotthe possible adverse effects acohalin ‘gasoline, is fecommended tal only acoholree ‘gasoline be used where possible. If ony alcohol ontinng ves avalabe,orftheprosenteot alco. hol unknown, then more frequent inspection for leaks and abnormalities requires. Gasoline/Alcohol Blends: Many new motor vehicle owner's manuals war about the pte damage from using gasoline containing a cabal especialy methanol. They cte poste uel sys. tem damage and performance probioms, These ae just twoclthohazards thal may be causodby alcohol. These Same problems, as well as the adconal salty rik of {te and explosion fom fuel system leaks, app) to ma: fie iboara engines. Methanol is more severe in ts harmful efect than is ethanol. Alcohol is also more ‘armiulin older engines since newer engines nave ma {erat which are mare resistant to alcoho, Prermance problems, or other damage resulting ‘nom the use of gasolinealconol blended fuels, are notihe responsibilty of Crusader Engines and will note covered under our warranty Corresion of metats may result rom tho use of alcohol ‘gasoine blends. Portable or permanent installed uo 24 Maintonance tanks of metal orberlass, elites, uelines andtoat bowls maybe affectoabyaicoro ended tues. Many T= berglass fuel tanks are slowly cssolvedby alcoho, ead ing immediately to fiter- and carburetor plugging and, ‘evenly, to tank aur. ‘Alcohol containing fuels wil absorb moisture rom the ai Ati, his moisture wilremain in solution, but once {he watorcontentoftheusthasbulkup te about one-half ‘of one percent tw separa (phase separation), bring- Ingthe alcohol wiht. Ths aloohotwator mire seties {othebotiom ofthe fue tan, and, nis mnture gts nto theongine, engines canbe seriously camagodintrnaly, asitmay wash ho protctie lim ofa of tne bore of ary tyler that It enters. Baler the engine can be re. Sartod, tis necossary to remove the separated alcohol and waior ayer, tush Outhe he eyetom wah clean a, and remove and ory the spark pugs. “The-etecs of gasoline blended wih ethanol or methanol are sil belng evaluated by the United States Coast ‘Guard, the Natonal Marine Manulacturng Association (NWMA), Crusader Engines, and other engine and boat ‘manutactuer, crusader Engines has recommended pump: posting of the aleohol content of al gasoline, Crusader Engines recommends using gasoline known to contain no methar olor ethanol when posse, Teousim Fs Gasoline/Alcohol Content Te ‘The folowing an acceptable and widely used etd pxo cedure forthe detection of alcohol in gasoline, Use any ‘mal ransparet bottle or tbe that can be capped ard ‘canbe povided wit graduations or amark at about 13 {ul & pencii mark on pce of adhesive tape may be used 1. Fillthe container with water to the mark 2. Ads tel almost toil the container, leaving ‘some ai space, then cap the container. The ‘Proportions of uel to water are not ical, but {here should be 2-3 times as much fel as wate Shake container vigorously ada it ait Upright or about 3-6 minutes. the volume of water appears to have increases, alhal is present. f you are not sure, theres no need {or concer. the dvicng tne between water and uel becomes cloudy use the mccle ‘tthe cloudy band, or use a Kent Moore 4134359 Alcohol Detection Ki Maintenance 3-5 ENGINE OIL ‘ter the 25-hour break: alas boon drained crankcase ol based on tne prevaling dayime tempera {ure in the aroa in whichthe boat & operated ‘Thetable below is a guide to selecting the proper crank- ase ol and shows resommended change Irena. \Winen changin the oi ahvaye change the ol fer IMPORTANT: The use of multi-viscosit oils Is not recommended for use in Crusader engines. Oils Containing "soll" additives, nondetergent oils, o Tow-qualty oll specifically are not recommended. Prevailing Ambient | Recommended API prccecretins Above °F (10-0) [SAE 40"sGrco™ 2.50% (010°) [SAE s0“scrco™ Below 32° (0°0) [SAE 20"SGI00" Care must be taken whan chocking engine oleve. Oil level must be maintained between the "ADO" mark ard the FULL" mark onthe spstick. To ensure that you are ‘otgeting aise reading, make surethe folowing steps ‘are taken before checking the o evel. Checking/Filling Engine Oli Level: 1. Stop engin fin use, and alow boat to come toarest, 2. Allow sufcient ime (approximately S minutes) forthe oto dain back ite he oll pan. 8, Remove dipstick Wipe clean and instal Push cipsck athe way ito the dipstick ube. Remove dipstick and note te ol level (Oi level myst be between he "FULL" and "ADD" marks, 6, the oll lovelis below the ADO" mark proceed to Slaps 7 and 8 or reinstall ipstck In the cpstik ube. 7. Remove oiler cap rom te valve rocker arm 18 Add required amount of ato bring level upto, ‘bu not over, the “FULL” mark on eipstck. veriledcrankcases(oillevelbeing oo high) can cause ‘afisetuation or drop in il pressure and rocker am “la tern engines, The overt condition resus inthe en {Gne cankchat splashing and agtaing the ol causing {to foam (become aerated). The aerated ol causes the Fyerause valve Mor 0 "blood dow.” This, intr, ro- sa in rocker arm “ater and loss of engine parton: ‘nce du tothe valves ret opening propery FULL MARK, ADO MARK am Figure #2. Dipstek— Engine O1 26 Maintenance 1-803 TECH S96 Changing Engine Oil and Filter: 1. Star engine and run unlit reaches normal ‘operating temperatures. IMPORTANT: Change oll when engine is warm trom ‘operationasit flows more freely, earying away more Impurities. 2 Stopengine 3. Remove engine ol cipstok 4 Using a pume, suck engine al rom the engine trough the dipstick tube. (See directions on pump used) (Figure 2-9) 5. Remove and aiscard olfitor and ts sealing ng, 6. Coat sealing ring on new itr wih loan ‘engine all and instal now iar. Then er Securely (folowing fiter manufacturers instructions). Dont overighten Figures. Oi Removal 7. Filerankcase wa ol 18. Stat engine and check for olleaks Teowsse Rt-sn0 TRANSMISSION OIL, Dexzon!or other hydraulic transmission ols bich meet ‘the Detol Diese Alison Type C3 specications are rec: ‘ommended for use inal Velvet Drive” (Borg-Warner) manne Vanemissione Checking/Filling Transmission Oil Level 1. Remove dipstick. Check to ensure tht the oi 'S indicated onthe apstick (Figure 3). The clove! may be somewat over tho ful mark, ‘2 come ofthe al rom transmission fla Cooler and poses may have drained back into the transmission. Ifthe level isiow, ad ‘uomatcranamission fi (ATF) ur the level comes up to the “FULL! mark on tne psi Figure 3-4. Transmission OW Fil 2. ‘Star the engine and run at 1500 pm or 2 ‘minutes to alow the ot ial the hydraule routs. IMPORTANT: To accurately check the ol vel, the {engine must be un at 1500 rpm fortwo minutos im ‘mediately rior to checking level. 3. Stop the engine and quickly chock the oil level Ad ransmission fui, itpecessary. 10 bring the level upto he -FULL' mark onthe ‘pst Maintenance 97 IMPORTANT: Be sure to push dipstick all the way {down Inte dipstick tube when checking ol level. 4 Reinstall dipstick. Be sure o tighten the Thandie securely. 5. Ifthe tranamission ol ovel was extremely low, 5°2 Troubleshooting isso TeMso6 5.7 FUEL ECONOMY Poor fel economy 5.8 CARBURETOR MALFUNCTIONS ny 2. oa Te Sees Fost aks, Operator habits - proionged idling, slow acceleration, fare to cutback on thotte once boat son plane, boat overoaded, Uneven weight cistron, Engine laboring because of bert, damaged or inconect propel. ‘logged lame aresio. Inadequate ar vetiation Boat bottom ~ dry (marine growth), hook o rocker sult CCarburetor— ile micure setings, accelerator pu ‘sdustment,inkage binding, choke acjustment, carburetor flooding, main el jos Improper tue (Grankease vertlation system not working Engine needs tune-up. Engine running to col orto ho. Plugged or restricted exhaust. Low engine compression [Symptom Carburetor foading (Cause ‘Needles and soa Float adjustment ‘Saturated tat. Gaskes leaking, Cracked uel ine. Fue percolation. ‘Automate choke, 2 Rough engine DUR SP esp TM SH eS Idle rpm oe ow. ele misture sores oie passages ny “Tarot valves not closing Engine lading ‘Vacuum leak “Trot body heat passages plugged. Teowsse At —seo Troubleshooting 5:19 CARBURETOR MALFUNCTIONS (continued) [Symptom [2 Hestaton or acceleration ainess fa Engine surges. (cause fa. neoelerator pump. B. Leaking casks JC. Automatic choke, 1D. Power piston or power valve JE. Thottle valves F. Throte-body heat passages luggec. 1G. Main metering jets H. Float adusiment t Secondary ai-vave wind-up. ‘Main metering jets Leaking gaskets, Float acustment ‘Saurated fot Power piston or va. Trrotle valves 5. Lack of power or low op rpm Power piston oF valve Float agsiment Main metering ts. Leaking gaskets, Js. Poor cold-engine operation. Stating engine Tale rpm too iow {ale mixture serews ‘Tote vanes ‘Automatic choke, Engine tootng ale rp to ow Engine flooding ‘Automatic choke, Din in carburetor ‘Accelerator puro. Leaking gaskets. ee eS 5-14 Troubleshooting 5.9 CHARGING SYSTEM PROBLEMS TToaso or broken drive bol, Gauges ralcato no batoy oeaoe ‘Loose or corroded electrical connections. Fauly ammeter or batery gauge, Battery wil nt accept charge. Fauly aternatr or regular. 2. Noisy aternator {Lease mounting bots. Worn, trayed o loose dive bot. Loose clive puley Worn or dity bearings. Faulty dlode to or state. FOSS SPD ORS 5.10 INSTRUMENT PROBLEMS [Symptom (cause T_ Maloncioning instruments gauges. Faull wifing, loose or coreded lorninas ‘Bad key switch (see Soction 6, Instrumentation, Fauty gauge (see Secton 0.5, Insrumentation} Fauity sender (see Section 6.5, Insttumentaon, Tees Al-3u3 Troubleshooting 5:15 5.11 RADIO NOISE [Symptom (cause =. *Popping’nsise tat increases [A Wrong sparkpiuge. Saneaaaaa wih engine pn. B. Crackod distor cap. JC. Cracked coil tower. D. Leaking soark plug wives. Moisture on ignition components. [2 High ptches whine" inthe ado, A. Poor buch contact on the springs in the atemator. 5. A-hlesing' or cracking” radlo_[A. Instrumentation —loose connections, or antenna wire routed folse when instruments ae jared ‘a gion on, 4. Various unexplained raco noses. too dose instruments Bige pure, Bige blower. Fish finder, DDopth locator Cabin hoator motor Pepe 5:16 Trowseshootng 5.12 ENGINE NOISE No definite rule or test will positively termine source of noticeably or cisagpoars, ts lsoated to tat engine nose, therefore, Use the folowing information particular eyindor. only as a general guide to engine noise dagnoss, Ae Frisian i es asda i 1. Seta timing light to determine it noise i timed front to back, top fe bottom. This can help ‘wit engine 7pm ar one-half engine rpm ‘etermine which components are at aut Noises timed with engine rpm ae elated 10 & Scshetioas rissa canbe otised by cranks af, rods, pistons, piston pi and ‘iywhad Noles timed te one-half engine pm ‘te vaho-rain elated ‘moving pats coming in contact with other ‘components. Examples are yuhesl, ‘rankshatsiriing (pan and pan bal), rocker 2. Those ofa stethoscope can aidin locating farm sinking valve cover and loose ywhcel poise source, However because noise wll ‘over. In many cares, this is found to be the travel other metal pars not involved inthe problem, a complete engine teardown is not problem, cauton must be exercised recessary. 3. Itnciseis beloved tobe confined to one 6. When noise is isolated oa certain area and paticulareyinder, ground the sparkplug ‘camponent moval and inspection wil be feeds, one at atime noise lessens fequied. Peto o groper soctons of service ‘manval or pertint information, ‘Noise around the valve cover Rocker arm sking valve cover ein Rocker am out of adustment. Worn rocker am. Bent push od Cotapsed iter [2 Noise arcuate eynder area ‘Sticking valve Carbon buie-up. ‘Connecting ro installed wrong Bent connecting rod Piston Piston rings. Piston pin finder worn 3. Noke around eamehalt area {oss of ol pressure, (throughout engine). Valve Inors, cam beatings [4 Noise in camshatt area (rontot A. Camshafiming gear engine) Timing chain, Fuel pump. Valu iter Cam boatings recess mee Troubleshooting 597 ENGINE NOISE (continued) [Symptom (Cause 7. Engine spark knock, ‘Advanced timing. Low-octane uel Engine running het. Carbon deposits in engine. 2. Popping trough carburetor Wong ignition ting, Ccarburtor st to lean Faulty accelerator pump. Vacuum ea Valve adjustment. Valve timing, ‘Burned or stuck valve >. Noise in camsnamt area (center or | A. Fuel pump. engine. B. Vale liter. ]C. Cam bearings J6. Noein camshaft area vearot (A. Dstibutor goar. enaine). 8. Vale liter. (C._ Cam bearings 7. Nowe i crankshaft area [A Loss ool pressure {throughout engine) B. Main bearings (C._Red bearings. fo. Noise in rarkshatt area (rontot [AL Crankshait timing gear. enaine. B. Ting chan. (C. Main bearing D. Red bearing, 2. Noise in crankshaft area center ot [A Crankshaft strking pan or pan bat enaine. B. Main bearing (C. Red bearing 0. Noice in crankshaft area voar ot [A Locsetywheel cover ersine. B._ Loose yhoo. C. Dive pate, D. Main bearing IE, Rodbearing, a. B. c. p. a. B. lc. fp. E. . 6. 5-18 Troubleshooting isan TeCUSHE ENGINE NOISE (continued) 15. Sparks jumping Be[Poae > ‘Vacuum leak Fuel pump (hissing insight tube). Leaking exaust (mantotas oF pipes) Loose cylinder heads. Biown head gasket ‘Vacuum leak Dry or tight bearing in an accessory. Detective high-tension cables, Cracked col tower. Cracked alstributor cap. 76, Squeaks or squeals, SEPP P Dive bat sipping Dry or tight bearing in an accessory Parts rioting togeter Troublshoatng $19 5.13 OIL PRESSURE DIAGNOSTICS “The following table contains important nlormation forthe checking of il pressure, Measuring of pessure. ik Use a good automative al pressure test gauge. Do rt ly on the ol pressure gauge in the ost. high rpm 7. Boats with dual engines. 6. Low engine oil pressure ati or [2 Check engine olfevel with boat at [A. Ollovel shouldbe betwesn the “ADD” and FULL" watts restin the water 8. Ollevelincrantcase above A. May cause loss of engine speed ol pressure omuge, “FULL mark fuetuaton, drop nell pressure and tyoraule valve te noise alhigh tm /& Ollevelincrantcase below A. Low oll pressure, ol pressure gauge fluctuation, Intmal "ADD" marke engine noise andlor damage. 5 Change in ol pressure [A This may be @ normal conation. Ol pressure may read bighin the cooler times of the day and when engine isnot up to ‘operating temperature. AS te ar emperature warms up and ‘he engine is runing a normal operating temperature, is ‘ormal for ob pressure ta drop of sight ‘With modern engines and engine ols, ow ol pressure ‘eacings at ide donot necessary moan theo isa problem. vale liters do not cater (ate, there isa suficent volume fl to luricatealintal moving pars propery. The reason forthe crop in ol pressures that engine heat causes an ‘expansion ofthe internal tolerances inthe engine ae, leo, the ew iin out somewhat rom heat. itis nat uncommon to see diferent oll pressure readings between the two engines, 35 lg as both engines fal within spocticaions.Diferencos In ol pressure can be aintedto ferences in engine tolerances, gauges, wiring, sendos, oc 5:00 Tinuhleshoeting 5.14 OIL PRESSURE PROBLEMS [Symptom [couse 1 Lowel pressure. [A Low olleve in crankcase B. Detective ol pressure gauge andor sender. 1c. Ol broken down, contains wate or gas, wrong viscsty, engine runing too oto o0 cele, excossve dng in cole water (condensation). D. lit vave stuck open, pickup ube restcteg, wom pars ino pump, ai leak on Suton side of 08 pump or pickup We. E. Ol passage plugs leaking, cracked or porous cylinder block F._Excessive bearing doarance. a Wrong vsoosly, of ful of audge ota B. Detective oll pressure gauge andr sender. fa High o8 pressure uronTaNr: 01 pressure sgh higher than norma des nat a ways indicate a problem. Tolerance stackup In the engine, ol ‘cosy, and weather conditions could eause high oll pressure. (C. Clogged or restricted oi passage. D._ Ol pump ral vala stuck ceed 3. Excessive olleonsumption la. Otteaks. NOTE: Nocmalconsumptionis aprox: |B. OH siuted oro the wrong viscosty, ray ore aur afein='S hose! |c, ole oo sh ete D. rain holes in cylinder head plugged causing loosing of valve guides. IE. Detective valve seals F. Intake manitold gasket leaking, worn valve stom or vave guides. JG. Detective ol cooler (so equipped). 1. Glazed, scuted, wom, suck improperly installed; ing grooves wor: improper breakin; wrong end gap. L. Piston out of round, score tapered glazed excessive piston 1o-indorcearance;cracke piston. Excessive bearing earance, reowsee At -s0 Troubiesiwoling 521 5.15 WATER IN ENGINE Determine locaton of wate in engine. This information 's necessary to determine where the water came fom andhow got ito the engine. The most common prob- lems are water ontop of pistons andior water in crank cate ol 1. Alterlocating the water, remove alle water fram the engine by removing ll spark plugs and pump oylinders by cranking engine ove. Next change oll and her. Start engine and 90 problem can be duplicated. 0, there ismore than ikely a mechanscal problem prob cannot bo dupicated tis eter an Speratr error ora problem that exists ony Under ean environmental condtone, lH water is confined to ylinder(s), itis usually ‘entering trough the intake system, exhaust ‘system or head gasket. I the waters contined to crankcase, tie usualy caused by a cracked or porous block, ‘alooded bilge or condensation Ifthe waters foated in both the cyinder(s) ‘andthe crankcase, Kis usally caused by water inthe cylinders getting past the rings ‘and valves, of complete submersion, ‘Checking for ust in the intake manifold or ‘exhaust maniolds i @ good idea. Rustin {nese areas wl give cues ifthe water entered through hese areas. ‘Water found ontop ofthe pistons. [A Operator shut engine ol at high rpm Engine “diesel or tres to run backwards (engine out of tune, 00° fel, high ial rpm, timing set 100 Fgh), Rainwater runing into fame arrestor (oose hatch cover ‘Spark plugs misting ‘Backwash tough the exhaust system. Improper engine or exhaust hose instalation, (Cracked exhaust marifold, Improper manifld-to-

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