Operators Manual

 

OPERATOR’S MANUAL 3.0GLM-C, 3.0GLP-C 4.3GL-D, 4.3GXi-E, 4.3GXi-EF 5.0GL-E, 5.0GXi-E, 5.7GL-E, 5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.0GXi-EF 5.7GXi-FF 8.1Gi-E, 8.1Gi-EF, 8.1GXi-D, 8.1GXi-DF

 

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This operator’s manual is available in English. Complete the form at the end of the operator’s manual to order a copy.

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Diese Betriebsanleitung ist auch auf Deutsch erhältlich. Ein Bestellcoupon ist am Ende der Betriebsanleitung zu finden.

Dit instructieboek kan worden besteld in het Nederlands. De bestelcoupon vindt u achter in het instructieboek.

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Ce manuel d’instructions peut être commandé en français. Vous trouverez un bon de commande à la fin du manuel d’instructions.

Denne instruktionsbog kan bestilles på dansk. Bestillingskupon findes i slutningen af instruktionsbogen. &+"

Este libro de instrucciones puede solicitarse en español. El cupón de pedido se encuentra al final

Tämän ohjekirjan voi tilata myös suomenkielisenä. Tilauskuponki on ohjekirjan

del libro.

lopussa.

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Den här instruktionsboken kan beställas på svenska. Beställningskupong finns i slutet av instruktionsboken.

Este manual de instruções pode ser encomendado em português. O talão de requerimento encontra-se no fim do manual.

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Questo manuale d’istruzioni può essere ordinato in lingua italiana. Il tagliando per l’ordinazione è riportato alla fine del manuale.

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Welcome Aboard     M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Congratulations on choosing a new boat equipped with a Volvo Penta marine engine. Volvo Penta has been building marine engines since 1907. Quality, operating reliability, reliability, and innovation have made Volvo Penta a world leader in the marine engine industry. From engineering design and manufacturing to support activities in Parts, Service, and Sales, high standards have been set to ensure your pride and satisfaction as the owner of a Volvo P Penta enta product. As owner of a Volvo Penta marine engine, we would also like to welcome you to a worldwide network of dealers and service workshops to assist you with technical advice, service requirements and replacement parts. Please contact your nearest authorized Volvo Penta dealer for assistance. We wish you many pleasant voyages.

Our Core Values: Quality, Safety, Environmental Envir onmental Care  The values and qualities that Volvo Penta expresses are what make the company unique. From the very beginning, safety and quality have stood at the heart of the development of all of our products, processes, and services. ser vices. It is on these values and qualities that the Volvo Penta corporate identity, brand position and legal status have been founded. Today’s core values of quality, safety, and care for the environment remain central to Volvo Penta. They express what we believe in as a company and will ultimately help us to survive.

Quality  is   is a value that traditionally referred to product quality but now encompasses all aspects of our products and services. In today’s competitive environment, Volvo Penta’s Penta’ s quality commitment extends beyond industrial craftsmanship and engineering ingenuity to embrace care for the customer throughout the life of the product.

Safety  will   will always be our most distinguishing core value. Historically embedded in the quality of all Volvo products, it also encompasses personal, family, business, and environmental values.

Environmental Care  in   in all operations, from design to production, distribution, service, and recycling, is an integral part of the Volvo quality commitment towards customers, employees, and the community. By embracing the environment as a core value, Volvo demonstrates its understanding of the environmental impact its products have upon nature and the shared urban and rural surroundings. Volvo Penta continually commits a considerable part of its development resources toward minimizing the environmental impact of its products. Examples of areas where we are always looking for improvements are exhaust emissions, noise levels, and fuel consumption. Regardless of whether your Volv Volvo o Penta engine is installed in a boat used for pleasure or commercial operation, incorrect operation or improper maintenance of the engine will result in disturbance or damage to the environment. In this owner’s manual there are a number of service procedures, which, if not followed, will lead to an increase in the engine’s impact on the environment, and on running costs and a reduction in service life. Always observe recommended service intervals and make a habit of checking that the engine is operating normally every time you use it. Contact an authorized Volvo Penta dealer if you cannot correct the fault yourself. Remember that most chemicals used on boats are harmful to the environment if used incorrectly incorrectly.. Volvo Penta recommends the use of biodegradable degreasing agents for all cleaning. Always dispose of engine and transmission oil waste, old paint, degreasing agents and cleaning residue etc. at proper disposal areas so that they do not harm the environment. Adapt speed and distance during your boat trips so that swell and noise generated by the boat do not disturb or harm wildlife, moored boats, docks, etc. Wherever you land or cruise, please show consideration and always leave the areas you visit as you would like to find them yourself.

 

CALIFORNIA Proposition 65 Warning Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

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Consumer Affairs Department Volvo Penta of the Americas, Inc. 1300 Volvo Penta Drive Chesapeake, Virginia 23320, USA Phone: (757) 436-5100 436-51 00 • Fax: (757) 436-5153 http://www.volvopenta.com

Volvo Action Service - North America P.O. Box 26113 Greensboro, North Carolina 27402-6113 27402-6113 Toll Free: (877) 33-PENTA • Phone: (336) 393-4966 http://myactionservice.com

World-wide Dealer Locator http://dealerlocator.penta.volvo.se/zone.asp

 

Table of Contents Table of Contents

Safety Information

3

21

General Information ..................................................4

Instrument Panel .................................................... 21

Warning Warnin g Symbols Used in this Manual .......... ................ ........... ........ ... 4

Emergency Stop Switch..............................................22 Checking Instruments .................................................23 Oil Pressure ..........................................................23 Engine Coolant Temperature................................23 Voltage/Charge .....................................................23 Engine Protection Mode .............................................24

Safety Precautions (Maintenance and Service)........5 Knowledge.............................................................. 5 Engine Decals ........................................................ 5 Stop the Engine Engine...................................................... ...................................................... 5 Lifting the Engine.................................................... 5

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Instrumentation

Before Starting the Engine ..................................... 5 Washing the Engine ............................................... 5 Fire and Explosion ....................................................... 6 Fuel and Lubrication Oil ......................................... 6 Non-Original Components ...................................... 6 Batteries ................................................................. 6 Start Spray ............................................................. 6 Hot surfaces and Fluids ............................................... 6 Carbon Monoxide Poisoning ........................................ 6 Chemicals .................................................................... 7 Cooling System ............................................................ 7 Lubrication System....................................................... 7 Fuel System ................................................................. 7 Electrical System.......................................................... 7

Safety Precautions While Operating the Boat...........8 Your New Boat ............................................................. 8 Accidents...................................................................... 8 Maneuvering ................................................................ 8 Emergency Stop Switch ............................................... 8 Daily Checklist.............................................................. 8 Refueling ...................................................................... 8 Do not Start the Engine................................................ 8 “Wagon-Back” Effect .................................................... 9

Safety Checklists.....................................................10 Replacement Parts and Tools Checklist .................... 10 Safety Equipment....................................................... 10 Safety Safet y Equip Equipment ment Checkl Checklist ist ...... ............ ............ ........... ........... .......... .... 10 Planning Your Trip ..................................................... 10 Trip Checklist........................................................ 10 Basic Safety Rules of Boating.................................... 11 High Performance Performance Boat Operation ............................. 11

Engine Control Module (ECM)....................................24 Master/Slave Arrangement .........................................24 Power Trim/Tilt............................................................25 Trim Instruments.........................................................25 Analog Trim Instrument.........................................25 Optional Digital Trim Instrument............................26 LED Display ..........................................................26 Other Instruments .......................................................26 Trim/Tilt Motor Protection ...........................................27 Impact Protection ..................................................27

Controls

29

Remote Control Unit............................................... 29 Single Lever Control Operation ..................................29 Shifting from Neutral ...................................................29 Disengaging the Shift Function...................................29 Twin Unit Maneuvering...............................................30 Maneuvering ...............................................30 How to Shift and Control Speed .................................30 Shifting between Forward and Reverse................31 Cruising Speed .....................................................31 Friction Brake..............................................................32 Side Mount Remote Controls................................32 Top Mount Remote Controls.................................32 Trim Controls ..............................................................33 Operating Trim Controls .............................................33 Control Panel ........................................................33 Remote Control Lever...........................................33 Control Lever with Catch Button (Single)..............33 Control Lever with Catch Button (Dual).................34

Operation

35

Operating Operati ng the Engine Engine ............ .................. ............. .............. ............. ............ ........ 35

13

Before Starting............................................................35 Starting the Engine (Cold Start)..................................36

Care of the Environment Environment .........................................13

GL Models.............................................................36 Gi & GXi Models....................................................36 If the Engine Floods....................................................36 GL Models.............................................................36 Gi & GXi Models....................................................37 Starting the Engine (Warm Start)................................37 Stopping the Engine ...................................................37

Introduction

Fuel and Oils .............................................................. 13 Breaking-in ................................................................. 13 Certified Engines........................................................ 14 Power Ratings............................................................ 15 Load Condition Condition (Speed of Planing Hull) ........... ............... .... 15

General Information

17

Warranty Information.................................................. 17 Warranty Registration Form ................................. 17 Volvo Action Service (VAS)..... (VAS)........................................ ................................... 17 Doing Your Own Maintenance and Repairs............... 17 Informational Decals and Identification Plates ........... 18 Identification Numbers ............................................... 19 Owner’s Identification Card ........................................ 19 Service, Replacement Parts, and Accessories .......... 20 Volvo Penta Dealer Network ...................................... 20 Toll-free Dealer Locator Service........................... 20 Volvo Penta on the Internet........................................ 20

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Operating Operati ng Remote Remote Controls Controls ...... ............. ............. ............. ............. ......... ... 38 Using the Gear Shift Release Button..........................38 Method 2 ...............................................................38

Steering Steeri ng System Operation Operation ....... ............. ............ ............ ............. ........... .... 39 Twin Unit Steering ......................................................39

Power Trim and Tilt Operat Operation ion ............. .................... .............. ........... .... 40 Power Trim Operation.................................................40 Determining the Proper Trim Trim ......................................40 Operating in “Bow-up” Position Position .............................41 Operating in “Bow-down” Position.........................41 Power Tilt Operation ...................................................42 ...................................................42 Power Trim/Tilt Switch & Gauge Location.............42

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Table of Contents

Speciall Boating Specia Boating Situations Situations ............. .................... .............. ............. .......... .... 43 Shallow Water Operation............................................43 High Altitude Operation...............................................43 Operating in Freezing Temperatures..........................43 Salt Water Operation ..................................................43 Trailering Your Boat....................................................44

Features

45

Circuit Breakers and Fuses.................................... Fuses .................................... 45 Legend of Symbols Symbols Used in Engine Diagrams ...........45

3.0GLM-C, 3.0GLP-C............................................. 46 4.3GL-D,, 5.0GL-E, 4.3GL-D 5.0GL-E, 5.7GL-E............. 5.7GL-E................... ............. .............. ......... .. 48 4.3GXi-E, 4.3GXi -E, 5.0GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F 5.7GXi-F ............. ................. .... 50 8.1Gi-E,, 8.1GXi-D 8.1Gi-E 8.1GXi-D ............ ................... ............. ............ ............. ............. ............ ...... 52 4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF......... 54 8.1Gi-EF, 8.1GXi-DF 8.1GXi-DF.............................................. .............................................. 55 SX-M Sterndrive..................................................... Sterndrive ..................................................... 56 DP-S Sterndrive Sterndrive .............. .................... ............ ............. .............. ............. ............ ........ 57    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Maintenance

59

Engine Break-in Break-in Period ............. ................... ............. ............. ............. .......... ... 59 Break-in Procedures ...................................................59 First Two Hours ..........................................................60 Next Eight Hours.........................................................60 Final Ten Hours ..........................................................61 First Service Inspection Inspection (Dealer 20-Hour Check) .......61 Operating After Break-in Period..................................61

Maintenance Schedule........................................... 62 Static Water Line.................................................... Line .................................................... 64 Static Water Line Test ................................................64 Preparing for Boating (Launching)..............................65 Off-Season Storage (Winterization)............................65

Maintenance of Boat’s Systems............................. Systems........ ..................... 66 Engine Exhaust System..............................................66 Drive Unit Bellows.......................................................66 Fuel System................................................................67 Gasoline Recommendations.................................67 Gasoline Containing Alcohol.................................68 Detonation (Spark Knock) .....................................68 Preventing Gum Formation and Corrosion ...........68 Carburetor (GL).....................................................69 Electronic Fuel Injection (Gi, GXi) GXi).........................69 .........................69 Flame Arrestor ......................................................69 Electric Fuel Fuel Pumps ..............................................70 Fuel Filter ..............................................................70 Engine Fuel Filter Replacement............................71 Fuel Filter Replacement (V6/V8 (V6/V8 Carb Engines).... 72 Fuel Screen Cleaning (3.0 Liter Carb Carb Engines) ....72 Electrical System ........................................................73 Battery Cables.......................................................73 Batteries and Connections....................................73 Battery Replacement.............................................75 Multiple Batteries and Selector Switch..................76 Distributor Cap and Rotor .....................................76 Circuit Breakers and Fuses...................................76 Spark Plugs...........................................................77 Checking and Changing S Spark park Plugs ...................77 Belt Adjustments.........................................................79 Serpentine Belt Engines........................................79

2

V-Belt Engines ...................................................... ...................................................... 80 V-Belt Tension ......................................................80 ...................................................... 80 Power Steering Pump Belt.................................... 81 Alternator Belt ....................................................... .......................................................81 81 Cooling System ..........................................................82 .......................................................... 82 Raw Water System ............................................... 82 Closed Cooling System (F-Series) ....................... 82 Engine Overheating (Gi & GXi only) only)..................... ..................... 82 Engine Overheating (All other Models)................. 83 Engine Flush .............................................................. ..............................................................83 83 Draining the Cooling System...................................... 84 Raw Water Cooled Engines.................................. Engines..................................84 84 Draining the Closed Cooling System.......................... 85 8.1 Liter Engines (F-S (F-Series) eries).................................. .................................. 85 4.3 GL Draining Only ............................................ ............................................85 85 4.3, 5.0, and 5.7 Liter Engines (F-Series) (F-Series)............. ............. 85 Impeller: Checking & Replacing .................................86 ................................. 86 Steering System .........................................................86 Power Steering Reservoir Fluid Fluid Level .................. 87 Power Trim/Tilt Fluid Level......................................... 87 Shaft Spline and Bearing Lubrication ......................... 87 Tie Rod (Twin Installations Only) ............................... 87

Lubrication System................................................. System..................... ............................ 88 Engine/Crankcase Oil................................................. 88 Checking Engine Oil Level .........................................89 ......................................... 89 Changing Engine Oil ..................................................89 Changing the Oil Filter................................................ 89

Drive Components.................................................. 90 Drive Unit Lubrication ................................................. 90 Checking the Drive Unit Lubricant ........................ 90 Draining the Drive Unit..........................................90 Unit.......................................... 90 Filling the Drive Unit.............................................. 91 Sacrificial Anodes .......................................................92 ....................................................... 92 Replacing Sacrificial Anodes ................................ 92 Active Corrosion Protection System........................... 93 Painting the Drive ....................................................... .......................................................95 95 SX and DP-S Drives .............................................95 ............................................. 95 Preparation ........................................................... 95 Paint Application ................................................... 95

Propeller Propel ler Care ...... ............. ............. ............. ............. ............. ............. ............. ........... .... 96 Propeller Replacement — SX .................................... 96 Removing the SX Propeller .................................. 96 Installing the SX Propeller .................................... 96 Propeller Replacement — DP-S................................. 97 Removing the DP-S Propeller...............................97 Propeller............................... 97 Installing the DP-S Propeller................................. 97

Boat Bottom............................................................ 98 Bottom Painting .......................................................... ..........................................................98 98

Engine Alignment ................................................... 98 Engine Submersion .................................................... ....................................................98 98

Replacement Parts................................................. Parts..... ............................................ 99

Troubleshooting

101

Troubleshooti Troubl eshooting ng - System System Isolation Isolation ....... ............. ............. ......... .. 101 Engine Troubleshoot Troubleshooting ing Guides.......... Guides................ ............. ........... .... 102

Technical Data

111

Metric Conversion Chart

119

Index

121

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Safety Information Safety Information Read this chapter carefully c arefully.. It concerns concer ns your safety. safety. This section describes descr ibes how safety information is presented in the operator’s manual and on the engine. It also gives a general account of basic safety precautions to be taken when operating the boat and maintaining the engine.

Check that you have the correct operator’s manual before you read on. If this is not the case please contact your Volvo Penta dealer.

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This symbol is used in the book and on the engine to make you aware of safety information. Always read these safety precautions very ver y carefully. Incorrectly performed operations could result in personal injury, damage to property, or harm the engine. Read the operator’s manual carefully before operating or servicing the engine. If anything is unclear, please contact your Volvo Volvo Penta dealer for assistance. In the operator’s manual warning texts have the following priority:

DANGER! Failure DANGER! Failure to comply with a danger symbol will result result in in serious serious injury injury or death to boat operator, boat occupants, and/or others. WARNING!! Failure WARNING Failure to comply with a warn warning ing may result result in injury or death to boat operator, boat occupants, and/or others. CAUTION!! Failure CAUTION Failure to compl comply y with a caution caution may may result in in failure or damage to to the equipment. impor tant information that will facilitate work or NOTE! Used to draw your attention to important operations.

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3

 

Safety Information

General Information This manual contains information you need to operate your boat engine and drive safely. safely. Check that you have the correct manual for your engine and drive. dr ive. This manual also contains a considerable amount of information concerning model identification, preven preven-tive maintenance recommendations, fuel and oil recommendations, and other important points. Please keep this book with your boat at all times.

NOTE!  It is important that this manual stays stays with the boat when it is sold. Important safety information must be passed to the new owner. The service information provided in the manual gives the owner important information about maintaining the engine and transmission.

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If you do not understand or are uncertain about any operation or information in this owner’s manual, please contact your Volvo Penta dealer. He will be able to help you with an explanation or will demonstrate the operation.

NOTE! Federal law requires manufacturers to notify owners in the event that a safety related defect is discovered on any of their products. If you are not the original owner of this engine, please notify us at our address or through an authorized Volvo Penta Penta dealer about the change in ownership. This is the only way we will be able to contact you if necessary necessar y. Carefully observe the safety alert symbols shown for dangers, warnings, and cautions. They warn you of possible dangers or important information contained in this manual. However, warnings alone do not eliminate hazards, nor are they a substitute for safe boat handling and proper accident prevention measures!

Warning Symbols Used in this Manual Following is a list of symbols used in this manual as a quick reference visual warning of the dangers and risks associated with carrying out certain activities.

High Pressure: Fluid or gas may be ejected under a great deal of pressure causing damage to metals, fabrics, or human tissue. Corrosive: Fluids, gases, or solids that can damage metals, fabrics, or human tissue through decay. Toxic: Gases or other airborne corrosives that can damage human tissue, cause ill

Poisonous:   Fluids, gases, or solids that, through a chemical reaction, can damage metals, fabrics, or human tissue. Electrical: Danger of electrical discharge or shock which can cause burns or other serious injur y.

Flammable: Fluids, gases, or solids that can–depending upon the degree of confinement–burn or explode upon ignition. Explosive:  Fluids, gases, or solids that can–depending upon the degree of confinement–burn or explode upon ignition. Fan Belts: Loose clothing, hair, fingers or a dropped tool can be caught in revolving belts and cause serious personal injury. Crushing Force: Heavy objects may break loose and fall, causing a crushing blow that can result in serious injury or death. Rotating Fan: Loose clothing, hair, fingers or a dropped tool can be caught in rotating parts and cause serious personal injury. Face Mask: Highly recommended that you wear a face shield, goggles, and/or respirator to protect face, eyes, eyes, and/or lungs. lung s. Face Wash: Wash affected body area immediately using plenty of soap and water and seek medical assistance as necessary. Gloves:   Highly recommended that you wear whilehands. engaging in activitiesprotective that maygloves harm your

Hot Surface:  Hot objects, (engine block, exhaust manifold, starter element, etc.) can cause burns and other serious injury. No Smoking:  By smoking in areas where these signs are posted, you risk starting a fire or causing an explosion. No Open Flames: By using an open flame in areas where these signs are posted, you risk starting a fire or causing an explosion.

health, or endanger life.

4

VPA 7742705 English 06-2003

 

Safety Information

Safety Precautions (Maintenance and Service) The following sections summarize the risks associated with carrying out certain activities while operating or maintaining your boat and engine and the safety precautions you should always observe while engaged in these activities.

Knowledge The operator’s manual contains instructions on how to carry general maintenance service operations safelyout and correctly. Read theand instructions carefully before starting work. Service literature covering more complicated operations is available from your Volvo Penta dealer. Never carry out any work on the engine if you are unsure of how it should be done, contact your Volvo Penta Penta dealer who will be glad to offer assistance.

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Engine Decals Check that the warning or information decals on the engine are always clearly visible. Replace decals that have been damaged or painted over. Stop the Engine

Lifting the Engine

To ensure safe handling and to avoid damaging engine components on top of the engine, use a lifting beam to raise the engine. All chains and an d cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine and any extra equipment installed. If extra equipment is installed on the engine, which alters its center of gravity, a special lifting device is required to achieve the correct balance for safe handling. Never carry out work on an engine suspended on a hoist.

Before Starting the Engine

Stop the engine before opening or removing engine hatches. Unless otherwise specified all maintenance and service must be carried out with the engine stopped. To prevent accidental start of the engine, remove the ignition key, key, turn off the t he power supply to the engine at the main switches, and lock them in the OFF position before starting work. Put up a warning sign in the control position that work on the engine is being carried out. Approaching or working on an engine that is running is dangerous. Loose clothing, hair, fingers or a dropped tool can be caught in the rotating par ts of the engine and cause serious personal injury. injury. Volvo Volvo Penta recommend that all servicing with the engine running be undertaken by an authorized Volvo Penta workshop.

VPA 7742705 English 06-2003

Reinstall all protective parts removed during service operations before starting the engine. Make a point of familiarizing yourself with other risk factors, such as rotating parts and hot surfaces (exhaust manifold, starter, etc.). Check that no tools or other items have been left on the engine. Never start a turbocharged engine without installing the air cleaner (ACL). The rotating compressor in the Turbocharger unit can cause serious personal injury. Foreign objects can also be sucked in and cause mechanical damage to the unit.

Washing the Engine

Never use a high-pressure washer when washing the engine.

5

 

Safety Information

Fire and Explosion Fuel and Lubrication Oil Incorrect connection of the battery can cause a spark, which would be sufficient to cause an explosion. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries.

All fuels, most lubricants, and many chemicals are inflammable. Read and follow the instructions on the packaging. When carrying out work on the fuel system make sure the engine is cold. A fuel spill onto a hot surface or electrical components can cause a fire. Store fuel soaked rags and other flammable material so that there is no danger of them catching fire. Fuel soaked rags can self-ignite under certain conditions.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Do not smoke when filling fuel, oil, or while in the proximity of a filling station or in the engine room. Certain engine oils are flammable. Some of them are also dangerous if inhaled. Whenever you use these agents, follow the manufacturer’s instructions on the product packaging. Ensure that ventilation in the work place is good. Use a protective mask when spraying.

Non-Original Components

Components in the electrical, ignition, and fuel systems on Volvo Penta Penta products are a re designed and constructed to minimize the risk of fire and explosion. Using non-original Volvo Penta Penta parts that do not meet the above standards can result in fire or explosion on board. Damage caused by using non-original Volvo Penta replacement parts will not be covered under any warranty provided by Volvo Penta.

Batteries

Always ensure that the positive and negative battery leads are correctly installed on the corresponding terminal posts. Incorrect installation can result in serious damage to electrical equipment. Always use protective goggles or a face mask when charging and handling batteries. Battery electrolyte contains sulphuric acid, which is highly corrosive. If battery electrolyte comes into contact with unprotected skin, wash it off immediately using plenty of water and soap. If battery acid comes in contact with the eyes, immediately flush with an abundant amount of water and obtain medical assistance.

Start Spray

Never use start spray or similar agents to start an engine. This may cause an explosion in the inlet manifold.

Hot surfaces and Fluids

There is always a risk of burns when working with a hot engine. Beware of hot surfaces. For example: the exhaust pipe, Turbo Turbo unit, oil pan, p an, charge air pipe, star ter element, hot coolant and hot oil in oil lines and hoses. Always turn off the engine before starting service procedures. Avoid hot surfaces and liquids in supply lines and hoses when the engine has just been turned off and is still hot.

Carbon Monoxide Poisoning

Never allow an open flame or electric sparks near the battery or batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which, when mixed with air, can form an explosive gas. This gas is easily ignited and highly volatile.

6

Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that there is proper ventilation in order to remove exhaust gases and crankcase ventilation emissions from the working area.

VPA 7742705 English 06-2003

 

Safety Information

Chemicals

Lubrication System

Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it. Never start or Most chemicals such as anti-freeze, rust-proofing agent, inhibiting oil, degreasing agents, etc., are hazardous to your health. Read and follow the instructions on the packaging.

operate the engine with the oil filler cap removed; hot oil could spray out.

Fuel System

Some chemicals such as inhibiting oil are flammable and toxic if breathed. Ensure good ventilation and use a protective mask when spraying.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Read and follow the instructions on the packaging. Store chemicals and other hazardous materials out of the reach of children. To protect the environment please dispose of used or leftover chemicals at a properly designated disposal site for destruction.

Cooling System

Always use protective gloves when tracing leaks. Liquids ejected under pressure can penetrate body tissue and cause serious injury. There is also a danger of blood poisoning. Always cover the generator if it is located under the fuel filter. The generator can be damaged by spilled fuel.

There is a risk of flooding when working on the seawater system. Turn off the engine and close the sea cock (where installed) before starting work on o n the system. Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out as system pressure is lost.

Fuel filter replacement should be carried out on a cold engine to avoid the risk of fire caused by fuel spilling onto the exhaust manifold.

Electrical System

If opening the filler cap or drain/venting cock, or removing a plug or engine coolant line from a hot engine, open the filler cap slowly and release coolant

Always stop the engine and break the current using the main switches before working on the electrical system. Isolate shore current to the engine block heat-

system pressure gradually; otherwise, steam or hot coolant can spray out. Note that the coolant may still be hot and can cause burns.

er, battery charger, or accessories mounted on the engine.

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7

 

Safety Information

Safety Precautions While Operating the Boat Your New Boat Read the operator’s manuals and other information supplied with your new boat. Learn to operate the engine, controls and other equipment safely and correctly. ly. If this is your first boat, or is a boat type with which you are not familiar, we recommend that you practice controlling the boat in peace and quiet. Learn how the boat behaves at different speeds, in varying weather conditions, and alternating loads before casting off for your “real” maiden voyage.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Remember that the person driving a boat is legally required to know and follow the current rules regarding traffic and safety at sea. Make sure you know the rules that apply to you and the waters you are sailing in by contacting the relevant authorities or organization. A good piece of advice is to take a course in seamanship. We recommend that you contact your local boating organization to find a suitable course.

Daily Checklist

To prevent a possible explosion or fire, make a habit of checking the engine and engine compartment visually before operating the boat (before the engine is started) and after operating the boat (after the engine has been stopped). This will help you to quickly detect fuel, coolant, or oil leaks and to spot anything else unusual that has occurred or is about to happen. If the engine compartment is not equipped with a blower,, open the engine cover or hatch before starting blower it to disperse any gasoline fumes that may be present. Leave the hatch open until after the engine is running.

Refueling

Accidents Statistics show thatofpoor maintenance of boats engines and a lack safety equipment are often and the main causes of accidents at sea. Ensure that your boat is maintained in accordance with the relevant user’s documentation and that the necessary safety equipment is on-board and is serviceable.

Maneuvering Avoid violent and unexpected changes in course and gear engagement. This could cause someone on the boat to lose their balance balan ce and fall over or overboard. A rotating propeller can cause serious seriou s injury. Chec Check k that nobody is in the water before engaging ahead or astern. Never drive near bathers or in areas where people could be in the water. Avoid trimming an outboard drive too much, as steering will be severely reduced.

Emergency Stop Switch We recommend that you install and use an emergency stop switch (accessory), especially if your boat can travel at high speeds. The emergency stop switch acts as a safety breaker and stops the engine if the driver falls down and loses control over the boat.

8

When refueling there is always a danger of fire and explosion. Smoking is forbidden and the engine must be switched off. Never overfill the tank. Close the fuel tank filler cap properly. properly. Always use fuel recommended by Volvo Penta. The use of lower quality fuels can damage the engine. Poor fuel quality can also lead to higher maintenance costs.

Do not Start the Engine

Do not start or run the engine engin e with a suspected fuel or LPG leak in the boat, nor when you are close to or in a discharge of explosive media, etc. There is risk of fire and/or explosion in explosive surroundings.

VPA 7742705 English 06-2003

 

Safety Information

“Wagon-Back” Effect

When a boat is moving forward, it will cause a certain cer tain vacuum to form behind the boat. In unfortunate circumstances, the suction from this vacuum—called “wagon-back” effect—can be so great that the exhaust gases from the boat are drawn into the cockpit or cabin, causing carbon monoxide poisoning.

Most modern boats, however, are designed in such a way that this problem is very rare. If suction should arise anyway, anyway, do not open hatches or portholes at the fore of the boat. Sur prisingly prisingly,, this will increase the suction. Try changing speed, trim, or load distribution instead. Try Try disassembling, opening, or in any other way changing the setup of the cover as well. If you suspect that your boat exhibits this “wagonback” effect, please contact your Volvo Penta dealer for help in achieving the best solution for your boat.

This problem is most prevalent on boats with sheer, broad transoms and high superstructures. In certain conditions, however, however, this suction can be a problem on other boats (e.g., when running with the cover up). Other factors that can increase the effect of the suction are wind conditions, load distribution, distr ibution, swells, trim, open hatches and portholes, and so on.

WARNING!! Do not run the engine while WARNING there are people located on or near the swim platform and transom. DAN ANGE GER! R! DO NO NOT to tow w anyo anyone ne usin using g water sports equipment (such as skis and inner tubes) closer than ten feet (10’) from the boat. DO NOT, under any circumstances, allow people to “body surf” using the swim platform as a means of being pulled along.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22770 

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Safety Information

Safety Checklists Planning Your Trip Everyone wants to have a problem-free and pleasant time when they take their boat out. To help you do do this we have provided a pre-journey pre -journey checklist below. T Take ake extra time to check the engine and its equipment and the general maintenance of the boat.

Trip Checklist

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Get up-to-date charts for the planned route.



Calculate distances and fuel consumption.



Note places where you can refuel along your planned course.



Listen to the weather reports.



Tell friends or relatives about your route (that is, file a “float plan”). Remember to inform them if your plans have changed or been delayed.

Safety Equipment The following list or recommended safety equipment can be expanded or modified as necessary because safety equipment and other requirements vary depending on the type of boat and how it is used.

Safety Equipment Checklist 

Life jackets for all passengers.



Communication equipment.



Emergency rockets.



Approved fire extinguisher, checked checked and charged. char ged.



First-aid equipment.

 

Life belt. Anchor, paddles, torches, and so on.



Tell your passengers and crew where the safety equipment is stored and how to operate it.



Make sure you are not the only person on board who knows how to start the boat and operate it safely.

Replacement Parts and Tools Checklist   

10

Impeller, fuel filters, fuses, tape, and hose clamps. Extra propeller and engine oil. Tools for any possible repairs while underway.

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Safety Information

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Basic Safety Rules of Boating

High Performance Boat Operation

We recommend that you contact your local boating organization for more detailed information on safety afloat.

High performance is not only defined by engine size, but by a combination of engine power (horsepower), hull design, and the size of the boat. Your new engine(s) produce a high power output. Depending on the boat type, the top speed may be much higher than what you are accustomed to.

•

Shut Shut off off the the engine engine when when people people who are in the the water come near the boat.

•

Propel Propellers lers are inher inherent ently ly dange dangerous rous and, as such, such, are potential safety hazards. Make sure that the propeller is not operating when people who are in the water come near the boat.

•

Av Avoid oid s stand tanding ing up up or s shift hifting ing weig weight ht sudden suddenly ly in small, lightweight boats.

•

Ke Keep ep your your passeng passengers ers s seat eated ed in seats seats.. The boat’ boat’s s bow, gunwale, gunwale, transom, and seat backs are not intended for use as seats.

•

Insist Insist on the use use of persona personall flotat flotation ion d dev evice ices s by all passengers at all times.

•

Know Know the “rules “rules of the road” road” and obey obey them. them. If If you you are not familiar with the “rules of the road,” road,” take the U.S. Coast Guard’s boater safety course. You may find information about boating safety at WWW.USCGBOATING.ORG and WWW.CGAUX.ORG/CGAUXWEB/PUBLIC/PUBFRAME.HTM.

•

Preve Prevent nt explo explosio sion n and fi fire re by main maintai tainin ning g your your fuel delivery system in top condition. Fuel vapor is volatile; handle fuel with care.

•

Ke Keep ep your your boat boat and equi equipme pment nt neat neat and and in top operating condition. Carry a selection of spare parts for the engine. (Volvo Penta’s Penta’s on-board kit contains a selection of essential items that a boat owner should carry at all times. See your Volvo Volvo Penta dealer.)

•

NEVER NEVER OPERA OPERATE TE THE THE BO BOA AT IF YOU YOU AR ARE E UNDER THE INFLUENCE OF DRUGS OR ALCOHOL.

•

If boatin boating g in water waters s that are are unfa unfamil miliar iar,, obtain obtain appropriate charts to avoid damage from underwater objects.

High speed operation requires an experienced operator who has mastered handling of high performance boats. It is advisable that you learn lear n the boat’s behavior before you take passengers on board. Inform your passengers about your boat’s characteristics and the maneuvers you intend to do. Use the boat’s performance with due consideration and care! When operating at high speeds, remember that other boaters may not realize the speed at which you are travelling, especially when you close in on another boat from astern or from ahead. Always keep a good distance to allow for the unexpected! Always be prepared for what other boaters may do unexpectedly. High speed driving requires the driver to give a high degree of attention to boat operation and surrounding conditions. A boat travelling at a speed of approximately 70 M.P.H. M.P .H. (60 knots) covers about 101 feet (30 meters) in 1 second. The faster you go the quicker things will happen. High speed driving requires a lot of water and a good distance from possible hazards! Always allow for adequate reaction time. Always reduce speed when visibility is reduced for whatever reason. When driving, make sure that all passengers are safely seated. Emphasize this especially if you have a larger, high performance cabin cruiser where one normally moves about during operation. Reduce speed considerably, or stop completely if someone needs to move about the boat. The driver should always use the safety kill switch! The kill switch lanyard which is securely connected to the driver, immediately shuts off the engine(s) should the driver be thrown from the driving position. Even if the risk of being thrown overboard is practically nonexistent in your type of boat, the risk of the driver falling and being dazed in rough seas can be even greater. Remember, even when the engine(s) is stopped in a high performance boat that is planing, it will travel approximately 325 feet (100 meters) before dropping through the planing threshold and stopping!

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Safety Information Notes

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

12

VPA 7742705 English 06-2003

 

Introduction Introduction This operator’s manual has been compiled to help you get the most from your Volvo Penta engine. It contains all the information you need in order to operate and maintain your engine safely and correctly. Please read the operator’s manual carefully and learn how to operate the engine, controls, and any other equipment safely. Always have have the operator’s manual available. Keep Keep it in a safe place and do not n ot forget to give it to the new owner if you sell your boat.

Care of the Environment We would all like to live in a clean and healthy environment—somewhere where we can breathe clean air, see healthy trees, have clean water in our lakes and oceans, and are able to enjoy the sunshine without being worried about our health. Unfortunately, this cannot be taken for granted nowadays; we must work together to achieve this vision.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

As a manufacturer of marine engines, Volvo P Penta enta has a special responsibility, where care of the environment is a core value val ue in our product produc t development. development . T Today, oday, VolVolvo Penta has a broad range of engines on which progress has been made in reducing exhaust emissions, fuel consumption, engine noise, and other detrimental side-effects. We hope you will take care in preserving these qualities. Always follow any advice given in the manual—concerning fuel grades, operation, and maintenance procedures—and you will avoid unnecessarily harming the environment. Get in touch with your Volvo Penta dealer if you notice any changes such as increased fuel consumption exhaust smoke. Adapt speed and distance to avoid wash and noise disturbing or injuring animal life, moored boats, jetties, etc. Leave islands and harbours in the same condition as you want to find them. Remember to always leave hazardous waste such as waste oil, coolant, paint and wash residue, flat batteries, and other toxic disposables at a suitable disposal site or destruction plant. Our joint efforts will make an invaluable contribution to our environment.

VPA 7742705 English 06-2003

Fuel and Oils Only use the fuel and oils recommended in the chapter entitled Technical Data . Other grades of fuel and oil can cause operating problems, increased fuel consumption and—in the long-term—a shorter engine service life. Always change oil, oil filters, and fuel filters at the recommended intervals.

Breaking-in The engine must be broken-in for its first 10 operating hours as follows:

• Operate the engine normally. • Do not operate it at full load except for short periods.

• Never run the engine at a constant engine speed for long periods during the breaking-in period.

• Check the oil level more often than is normally recommended; the engine can be expected to use more engine oil during the breaking-in period than would otherwise be normal. For a more detailed explanation of the break-in period, please refer to the appropriate section in the chapter entitled Maintenance . A First Service Inspection must be carried out after 20–50 running hours. For additional information please refer to the Warranty and Service Book .

13

 

Introduction

Certified Engines If you own an engine certified for any area where exhaust emissions are regulated by law, the following is important:

• The engine must not be modified in any way

Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer guarantees that all engines manufactured of that type correspond to the certified engine.

• No modifications to the exhaust pipes and air

except with accessories and service kits approved by Volvo Penta. supply ducts for the engine may be under taken.

• Seals may only be broken by authorized personnel.

This places special requirements for maintenance and service as follows:

Otherwise the general instructions contained in this Operator’s Manual  concerning  concerning operation, service, and maintenance must be followed.

• The maintenance and service intervals recommended by Volvo Penta Penta must be observed.

NOTE! Late or inadequate maintenance/service or the use of spare parts other than Volvo Penta original spare parts will invalidate Volvo Volvo Penta’s responsibility for the engine specification being in accordance with the certified variant.

• Only genuine Volvo Penta Penta replacement par ts may be used.

• The servicing of ignition, timing, and fuel injection systems must always be carried out by an authorized Volvo Penta workshop.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Volvo Penta accepts no responsibility or liability for any damage or costs arising due to the above.

22771

14

VPA 7742705 English 06-2003

 

Introduction

Power Ratings A great number of environmental factors, such as barometric pressure, ambient temperature, humidity, the quality of fuel, and exhaust back pressure can affect engine performance. When it comes to quoting and comparing ratings, it is important that there is a unified set of standards for measurement. In September 1989, allengine major marine engineaccording manufacturers agreed to quote power output acco rding to a common set of conditions. These conditions are referred to as ISO 8665. All Volvo Penta engines meet the ISO 8665 standard. This ISO standard outlines the following fixed values or common conditions for deterdeter mining the rating of the engine.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Condition Value Air temperature temperature ............. .................... ............25°C .....25°C (77°F) (77°F) Exhaust back pressure..............10 kPa (1.45 PSI) Barometric pressure..................100 kPa (14.504 PSI) Relative humidity.......................30% A gasoline engine operates with very little surplus air. When conditions deviate from the standard values, the result can be a loss of power at full load. It can also cause a rise in exhaust emissions due to incomplete fuel combustion.

Load Condition (Speed of Planing Hull) The overall weight of the boat is another important factor in performance. Any increase in boat weight will slow down the boat speed, particularly on boats with planing and semi-planing hulls. For example, a new boat tested with fuel and water tanks only half filled, and without any load, can easily drop 2 to 3 knots in speed when tested fully fuelled and loaded with all normal nor mal equipment and supplies for safe and comfortable cruising. This is because the propeller installed originally is frequently one that is designed to give maximum speed when the boat is new.. For this reason it is often advisable to reduce the new propeller pitch by as much as an inch or more in order to counter the effects of the increase in overall weight encountered in normal cruising, particularly in hotter climates. Although this will reduce top speed somewhat, overall ride conditions will improve and you should achieve greatly enhanced acceleration. In considering the influence of weight, it is worth remembering that fiberglass boats absorb a significant amount of water into their hulls while left afloat for any length of time and so become progressively heavier. Another negative influence on boat performance is marine growth beneath the waterline - a problem that is often overlooked.

Marine engines can be rated according to one of several power standards, but power output itself is quoted in kilowatts (KW) or horsepower (HP), for a given engine speed, usually at maximum revolutions per minute (RPM).

VPA 7742705 English 06-2003

15

 

Introduction Notes

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

16

VPA 7742705 English 06-2003

 

Generalation Information General Inform I nformation

Warranty Information

Volvo Action Service (VAS)

Volvo Penta’s warranty package can be found in the accompanying warranty booklet. Along with the warranty information you will find other checklists and reports for Volvo Volvo Penta products.

Volvo Action Service (V ( VAS) is a consumer breakdown service available 24 hours each day, 365 days per year. If your engine breaks down, the VAS coordinator will quickly locate your nearest dealer. If you need a tow,, par tow parts, ts, or mechanic, the VAS coordinator will make all arrangements necessary to get you back underway as soon as possible.

Your new Volvo Penta marine engine is covered by a limited warranty according to the conditions and instructions contained in the Warranty and Service  Book . Note that Volvo Penta’s liability is limited to that contained in the Warranty and Service Book . Read this book as soon as you take delivery of the engine. It contains important information about warranty cards, service, and maintenance which you must be aware of, check, and carry out. Liability covered in the warranty may otherwise be refused by Volvo Volvo Penta.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

The Volvo Penta International Warranty may apply outside the U.S. This warranty may contain different terms and conditions determined deter mined by prevailing national legislation and regulations. Information about these conditions can be obtained from Volvo Penta importers and dealers in those areas. Please contact your local Volvo Penta representative for a copy.

Warranty Registration Form The Warranty Registration Form should always be filled out and sent in by the dealer. Make sure that this has been done, since delay of warranty claims can occur if no proof of the delivery date can be provided. Please contact your Volvo Penta dealer if you have not received a Warranty and Service Book and a customer copy of the warranty card.

VPA 7742705 English 06-2003

Membership to Volvo Action Service is provided automatically to all Volvo Penta engine owners. As long as your Volvo Volvo Penta engine is under factory warranty, this service covers Volvo Penta-related repairs. Refer to the accompanying warranty literature for detailed information regarding coverage. Towing is not covered by the Volvo Penta warranty. warranty. Once your warranty periper iod has expired, there is a charge per p er managed breakdown, plus any additional costs incurred for towing, parts, or repairs. If you have a question about Volvo Action Service, or need additional information, please call toll-free 1877-33-PENTA.

Doing Your Own Maintenance and Repairs If you plan to do your own maintenance and an d repairs on your Volvo Volvo Penta products, you should purchase purchas e a set of service manuals that pertain to your particular engine and drive. Keep in mind, however, that there are certain tasks which should only be performed by your Volvo Penta dealer. The dealer has the tools, expertise, and most current information needed to properly perform these tasks.

17

 

General Information

Informational Decals and Identification Plates The following images provide graphical representations of various engine decals. The areas described are general locations and are intended to be guides only. Engine models and configurations do vary and, depending on the amount of space available, the exact locations of engine decals tend to vary also. The engine decal is typically located on the upper-front portion of the engine. The decal may be placed on the engine block, a pulley housing, or on any other flat surface located toward the front fro nt of the engine. 22772 

The engine plate is typically located on the port por t side of the engine flywheel housing, slightly below and aft of the exhaust manifold.

22774 

The label depicting the serpentine and “V” belt configurations is typically mounted on a flat surface located on the side of the alternator/automatic tensioner bracket or on the power steering pump/reservoir.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22777 

The California Emission sticker is located on the engine cover cover..

22773 

3.0GL Engines • Above port engine mount on side of engine block. 4.3GL Engines • On port, front face of cylinder head. 5.0GL & 5.7GL Engines • On the flat vertical surface of the inlet manifold below the carburetor pad. 22776 

4.3GXi, 5.0 GXi, & 5.7 GXi Engines • On the flat inside face of the combination bracket containing the power steering pump, alternator and serpentine belt tensioner. 8.1 Gi & 8.1 GXi Engines  • On the flat outside face of the combination bracket containing the power steering pump, alternator, and serpentine belt tensioner. The tune-up and color code decal is located on the engine cover.

22775 

18

VPA 7742705 English 06-2003

 

General Information

Identification Numbers Always provide the engine, transom shield, and drive identification numbers when ordering order ing service or replacement components. The engine identification numbers are on informational decals located in the spots shown on the previous page. Make a note of the information on the lines provided below. Make Make a copy of this page and store the information so that it is available in event of the boat being stolen.

Engine - Decal Product Designation (A) .............................................................. Serial No. (B) ............................................................................... Product No. No. (C) ........................................................................... 22772 

Engine - Plate Product No. (A) ........................................................................... Type (B) .......................................................................................    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Serial No. (C) .............................................................................. 22774 

Transom Shield Plate Product No. (A) ........................................................................... Type (B) ....................................................................................... Ratio (C) ...................................................................................... Serial No. (D) ..............................................................................

22778 

Drive Product No. (A) ........................................................................... Type (B) ....................................................................................... Ratio (C) ...................................................................................... Serial No. (D) .............................................................................. 22778 

Transom Assembly & Drive Unit Un it Stickers

22779 

Product Designation (A) .................................... ................. ................... /.................................... .................................. Model No. No. (B) .......................................... ........................... ............... /.............................................. ............................................ Serial No. (C) .......................................... ........... ............................... / ............................................ 22780 

Note! The Transom Transom Assembly & Drive Unit Stickers shown above should be b e located on the Engine Decal. Your Volvo Volvo Penta dealer will have attached these stickers at the time that the transom assembly and drive unit were mounted on your boat and attached to the engine.

Owner’s Owner’ s Identification I dentification Card When youproduct. purchased boat, the dealer was required complete a warranty and registration for your Volvo Penta Theyour owner’ owner’s s portion of this form is yourtoOwner’s Identification Card. This card form provides proof of ownership and is required to validate warranty, should warranty service become necessary. Warranty coverage may be delayed until the warranty and a nd registration form is on file at Volvo Penta. VPA 7742705 English 06-2003

19

 

General Information

Volvo Penta Dealer Network 

Service, Replacement Parts, and Accessories

The Volvo Penta worldwide network of authorized dealers are at your service. They are specialists in Volvo Penta products and have the accessories, original replacement parts, test equipment, and special tools necessary for high quality service and repair work.

Genuine Volvo Penta parts are the result of many hours of strenuous testing and fulfill Volvo Penta’s strict quality and safety requirements. Also, V Volvo olvo Penta marine engines are designed for high operational reliability and a long service life. They are manufactured to withstand the marine environment while also affecting it as little as possible. Through regular service and the use of Volvo Penta original spare parts, these qualities will be retained.

AlwaysPenta take your Volvo Penta Volvo to anOur authorized Volvo servicing dealerproduct for repair. dealers have the knowledge, factory-trained technicians, and special tools to take care of any necessary repairs. Ideally,, take your product back to your selling dealer — Ideally he also knows you and your equipment.

When replacements are required, use only Volvo PenPenta genuine parts. par ts. Always follow follow the maintenance intervals contained in the operator’s manual. Remember to state the engine/transmission identification number when ordering service and replacement parts.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Toll-free Dealer Locator Service If you are away from your home waters, take your Volvo Penta product to the nearest n earest Volv Volvo o Penta servicing dealer. For the name and location of your nearest Volvo Penta dealer, consult the Yellow Pages under Boat Dealers, or call 1-800-522-1959.

Purchase all Volvo Penta Penta replacement par ts, accessories, coolants, and lubricants lubr icants from an authorized Volvo Penta dealer. The dealer has needed parts in stock for routine maintenance, as well as the information needed to order special parts and accessories for you.

Volvo Penta on the Internet The URL address for Volvo Penta of the Americas is http://www.volvopenta.com.

Only authorized Volvo Penta dealers may purchase genuine parts and accessories directly from the factory. Volvo Penta does not sell to unauthorized dealers or retail customers.

22811

20

VPA 7742705 English 06-2003

 

Instrumentation Instrumentation

Instrument Panel The following section contains a general description of the instrument panel that comes with your Volvo Penta engine. The instrument panel for the Volvo Penta engines is equipped with a tachometer, temperature gauge, oil pressure gauge, voltmeter, 2 fuses, instrument panel lighting switch, and an ignition switch. Instruments, fuses, and ignition switch can also be supplemented with extra Volvo Penta instruments such as: synchronization tachometers, fuel gauge, fresh water gauge, clock, speed log, or rudder indicator. Note that the instrument cluster which is shown here installed in the instrument panels can be installed in other positions on some boats. If your boat is fitted with instruments not described here and you are not sure of their function, please get in touch with your boat dealer.

2

1

3

5

1. Tachometer—Shows the engine RPM rate. Multiply this value by 100 or 1000 (depending on model) for revolutions per minute. Integral “Hours run” meter (only on separately installed instrument) displays the engine’s operating time in hours and tenths of an hour. 2. Temperature Gauge—Indicates the engine coolant temperature. Normal operating temperature is 70°-90°C (158°-194°F) for all engines.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

3. Oil Pressure Gauge —Indicates the engine oil pressure. Normal operating oil pressure should be approximately 150-500 kPa (21-71 psi). Lower oil pressure is normal and should be expected at idle after a sustained cruise.

4. Voltmeter—Indicates the charge voltage from the alternator which should normally be approximately 14 Volts. With the engine stopped and the switch on, battery voltage is normally nor mally indicated as 12 Volts. 21179 

7

4

6

5. Instrument Lighting—On Volvo Penta instrument panels, turns panel lights on or off (varies, depending on product manufacturer). 6. Instrument Panel Fuses—Fuses for the starter function and system voltage (varies, depending on product manufacturer). To change fuses: Push in on the fuse holder and turn counterclockwise. Note! Always carry extra fuses on board. 7. Ignition Switch—The ignition switch has three positions (varies, depending on product manufacturer):

21180 

0 The key can be inserted or removed. I

0

I

II

Ignition is ON and engine is running. System voltage connected.

II Start position (momentary). The starter motor is engaged and starting the engine. CAUTION! Read the starting instructions in the section entitled Starting the Engine .

21181

VPA 7742705 English 06-2003

The ignition keys are marked with a code for use when ordering extra keys (varies, depending on product manufacturer). Record the code so that replacement keys can be ordered. Keep the code in a safe place where unauthorized persons do not have access to it.

21

 

Instrumentation

Emergency Stop Switch An emergency stop switch, also called a safety breaker, may be a feature of your boat. Use of this switch is highly recommended. To To properly use this feature, attach the lanyard to clothing that will NOT tear away before the lanyard is pulled from the switch to stop the engine. If the lanyard is too long, shorten it by knotting or looping it. DO NOT cut and re-tie the lanyard.

21182 

Using this switch is simple and should not interfere with normal operation of the boat. Care must be taken to avoid accidentally pulling the lanyard during boat operation. Unexpected loss of forward motion will occur. This could cause occupants to be thrown forward. In an emergency situation, any occupant of the boat can restart the engine by pressing in and holding the emergency stop switch button, followed by normal starting procedures. When the button is released, the engine will stop.

Note! The emergency stop switch can only be effective when in good working order. Observe the following:

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

must always be free of entanglements • Lanyard that could hinder its operation.

• Once a month, check the switch for proper operation. With engine running, pull lanyard. If engine does not stop, see your dealer for repairs.

Note! If your boat is not equipped equip ped with an emergency stop switch and it falls into one of the following categories, installation of an emergency stop switch is recommended.

• High performance sport boats • Small runabouts • Boats with sensitive steering • Boats where the distance from the top of the gunwale down to the driver’s seat is less than 30 cm (1 foot). Contact your Volvo Penta dealer for installation of an emergency stop switch.

22

VPA 7742705 English 06-2003

 

Instrumentation

Checking Instruments Check instruments regularly. Stop the engine if there is an abnormal reading or if the engine alarm sounds.

Oil Pressure All engines have what is considered a normal operating oil pressure range. At engine idle this is normally lower than at higher RPMs. For the normal operating oil pressure range for your model engine, please refer to the section entitled Technical Specifications . Your engine is equipped with a low oil pressure acoustic alarm. 21194 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

CAUTION! If oil pressure is too low: Stop the engine immediately and investigate. Operating the engine with oil pressure too low will damage the engine. Engine Coolant Temperature All engines have what is considered a normal operating temperature range. At engine idle this is normally lower than at higher RPMs. Normal operating temperature is 70°-90°C (158°-194°F) for all engines Your engine is equipped with an engine coolant and exhaust temperature acoustic alarm.

21195 

CAUTION! If engine coolant or exhaust temperature is too high: Idle the engine, shift to reverse and then to forward. Idle the engine for 2 - 3 minutes and shut off the engine if the temperature does not decrease. Investigate and correct the malfunction. Operating an engine with temperatures too high will damage the engine. Voltage/Charge The operating charge is approximately 14 V. V. When the engine is stopped and ignition is on, battery batter y voltage is approximately 12 V. With the ignition turned off, the voltmeter will not register a charge.

21106 

VPA 7742705 English 06-2003

23

 

Instrumentation

Engine Protection Mode In a low oil pressure, low voltage, engine overheat, or lack of exhaust cooling water situation, the Electronic Fuel Injection (EFI) system will enter an Engine Protection Mode (EPM). In such cases, if an acoustic alarm has been installed with your engine, the alarm (located beneath the dashboard) will sound to notify you of a malfunction.

21197 

Under these conditions, engine operation is limited to 2500 RPMs or less. When the EFI system switches on the EPM, one set of fuel injectors will be temporarily shut down until the problem is resolved. In this mode, ignition timing is also adjusted in response to the situation. If the engine drops below 1200 RPMs, normal injector operation and spark timing resume. The engine may now be operated normally, as long as engine speed remains below 2500 RPMs. For anything above 2500 RPMs, the engine will display poor running characteristics. If the engine is run above 2500 RPMs without any load or with the drive in neutral, the engine will exhibit surging.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Use the oil pressure and water temperature gauges to verify a problem exists, then inspect the engine eng ine crankcase for proper oil level and check the water inlets for obstructions. The low oil pressure/engine overheat problem must be corrected before the engine will return to normal operation. To reset the Engine Protection Mode after the problem is corrected, allow the engine to cool and then continue with normal operation.

Note! If the problem continues, contact your Volvo Penta dealer and have the engine inspected.

Engine Control Module (ECM) The engine control module (ECM) is designed to maintain exhaust emission levels while maintaining excellent drivability and fuel efficiency e fficiency.. The ECM controls the following conditions:

• Fuel, ignition, and idle air control. • Knock sensor system. • Various other discrete outputs. Master/Slave Arrangement For dual engine installations both engine ECMs can be tied together electronically. electronically. One engine will then be the “master“ engine and the other will be the “slave“ engine. The starboard engine or the engine with the power steering pump is always connected as the “master“ engine. If one engine has a fault that causes it to go into Engine Protection Mode (low oil pressure or engine overheat), also called Speed Limited Operator Warning (SLOW), the other engine will follow suit. 22803 

24

VPA 7742705 English 06-2003

 

Instrumentation

Power Trim/Tilt Your Volvo Penta Penta ster sterndrive ndrive is equipped e quipped with a power trim/tilt system as standard equipment. The power trim/tilt allows you to change the angle of the drive unit from the helm. Changing the angle of the drive unit in relation to the boat bottom is called trimming. Trimming provides these benefits:

• Improves acceleration to planing. • Keeps the boat on plane at reduced throttle settings. 22767 

• Improves fuel economy. • Provides smoother and/or drier ride in choppy water conditions.

• Increases maximum speed.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

If you do not wish to use this feature, you may leave the drive unit trimmed to the position that works best for you.

Trim Instruments The indicateswith thean current trim Yourtrim boatinstrument may be equipped analog orposition. a digital trim instrument. The SX drive has an analog trim instrument only. The DP-S drive may have either an analog or a digital trim instrument.

Analog Trim Instrument The analog trim instrument has three main ranges:

• Trim Rang Range e–Use trim range for maximum com22781

fort, under normal operation, from start to maximum speed.

• Beach Range–Use beach range for operating at reduced speed in shallow water, where water depth is uncertain. Also use this range when you launch and take your boat out of water onto a trailer ramp.

• Lift Range–Use lift range for lifting the drive to its maximum angle; however, however, this range cannot be used during boat operation. Use this range ONLY when you are transporting your boat. 22782 

CAUTION! Operating in beach range or lift range will cause significant loss of maneuverability. maneuverability. WARNING! The maximum safe engine speed in the Beach Range is 1000 RPMs. Operating in beach range above idle speed, or for prolonged periods of time, may cause serious drive damage. Always check that the cooling water intake is below the surface of the water when running in Beach Range. 22783 

VPA 7742705 English 06-2003

25

 

Instrumentation

Optional Digital Trim Instrument This instrument displays a figure (the angle of the drive to a stationary boat) within a range.

• Trim Rang Range e–Use trim range for maximum com-

!

fort, under normal operation, from start to maximum speed (maximum range up to 5). #$%& 

• Beach Range–Use beach range for operating at reduced speed in shallow water, where water depth is uncertain. Also use this range when you launch and take your boat out of water onto a trailer ramp. Boat speed should always be low (range from 5 to 40).

• Lift Range–Flashing red warning light. Drive up 22784 

completely (range from 41 to 51).

CAUTION! Operating in beach range or lift range will cause significant loss of maneuverability. maneuverability. Operating in beach range above idle speed, or for prolonged periods of time, may cause serious drive damage.

   M    A    6    2   :    2    2   :    3    0    1    0

LED Display Certain LEDs display at certain times for the digital trim instrument:

   2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

1 Flashes red within the range above 41. 2 Constant red within the range of 6 to 40. 3 Constant green within the range of 2 to 5. 4 Constant green within the range of 0 to 2. 22785 

5 Constant green in trimmed range up to 0. 6 Constant yellow in maximum trimmed position up to 0; flashes yellow when above 0 (drive moves, bow is lowered). 7 Constant yellow light within range of 2 to 5; flashes yellow when drive moves within trim range and bow is raised.

Other Instruments See your Volvo Penta dealer for additional accessories specifically designed for your Volvo Penta product.

26

VPA 7742705 English 06-2003

 

Instrumentation

Trim/Tilt Motor Protection CAUTION! Always allow the trim/tilt switch to return to its center position when the drive unit reaches its maximum raised or lowered position. This precaution will prevent your trim/tilt motor from overheating. Impact Protection The trim/tilt system provides impact protection in the trim/tilt cylinders. If an impact occurs, the cylinders will allow the drive to “kick up,” up,” thereby helping to minimize drive damage. However, However, impact damage can occur in either FORWARD or REVERSE directions. You must be careful when:

• You operate in FORWARD or REVERSE. • You are backing up. • You trailer your boat.    M    A    6    2   :    2    2   :    3    0    1    0

22786 

• You launch your boat. Note! Impact damage is more likely to occur when you are in a turn where side loads are placed on the drive unit.

   2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

If you strike a solid object:

• Throttle back and shut off the engine eng ine immediately.

• Closely inspect the boat and drive unit (especially the transom shield assembly that contains steering system components).

• Check the engine compartment for water leakage. If there is damage, operate the boat at low RPM and take it to a Volvo Penta dealer for inspection. Have necessary made immediately. Only operate your boat ifrepairs absolutely necessary. Operating a damaged unit could cause additional damage and could become very costly to repair.

CAUTION! Always check your boat and engine for damage. Failure to inspect for damage may:

• Result in sudden loss of steering control. • Adversely affect your boat’s capability to resist high-speed impacts. When backing-up in REVERSE, there is no impact protection. Be very careful when backing-up in REVERSE. Do not exceed 2500 RPM.

VPA 7742705 English 06-2003

27

 

Instrumentation Notes

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

28

VPA 7742705 English 06-2003

 

Controls Controls

Remote Control Unit The gear shift release, throttle lock, and engine speed control are combined in one lever. The gear shift release can be simply disengaged so that only engine engin e speed is affected. The Volvo Penta Penta controls are available for for top or side mounting. The control levers have an adjustable friction brake. A neutral position switch, available as an accessory, allows the engine to be started with the th e drive disengaged. Your boat may be equipped with remote controls other than those described below. below. If Volvo P Penta enta controls are not used, ask your dealer for operating instructions for the remote control used in your boat since operation and function may differ from Volvo Penta remote controls.

Single Lever Control Operation Both the gear shift release and engine speed control are operated using the single lever ( 1).

T T 1

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

2

N Neutral position (drive is disengaged and the engine runs at idle speed). F Drive/forward gear engaged for forward movement (ahead). R Drive/reverse gear engaged for backward movement (astern). T Engine speed control. Note! The engine can be started star ted only if the drive is in neutral.

21183 

Shifting from Neutral To move the remote control lever from the neutral detent position, depress the throttle lock (3), then move the control lever in the desired direction.

Disengaging the Shift Function

3

The gear shift can be disengaged so that the control lever affects only the engine speed. 1. Move ove tthe he lever ever (1) to the neutral position (N). 2. Press Press the the gear gear shift shift rele release ase but button ton (2) in and hold it down while moving the control lever forward to the shift position (F).

22788 

3. Release Release tthe he gear gear shift shift rrelea elease se bu button tton.. The indicator begins to flash to acknowledge that the shift function is disengaged. The lever now only affects the engine speed (RPMs). In this position the engine speed is limited to a maximum of 1500 rpm. When the lever is moved back to the neutral position it will automatically re-engage.

CAUTION! T  Take ake care not to t o engage the reverse gear/drive unintentionally unintentionally.. 1

2

21186 

VPA 7742705 English 06-2003

29

 

Controls

Twin Unit Maneuvering When leaving or approaching the dock, or for any close maneuvering at slow speed, place the starboard engine in neutral, on standby, and use the port engine with the control nearest the operator. The use of one control is very effective and more convenient. In the event that the port engine (which is being used for maneuvering) stops, you can immediately go to the starboard engine (which has been on standby).

22763 

CAUTION! Both engines must be running during close maneuvering or at slow speeds. If only one engine is running, water may be forced back through the underwater exhaust outlet and cause serious engine damage. Do not attempt to plane boat while operating on a single engine; operating with a single engine at full throttle could cause engine or transmission damage.

How to Shift and Control Speed

   M    A    6    2   :    2    2   :    3    0    1    0

Note! If your boat is equipped with a non-Volvo non-Volvo Penta remote control system, ask your dealer

   2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

how to properly operate it.

IMPORTANT! Carefully check function of all control and engine systems before leaving the dock. 1. Move Move cont contro roll handle handle (1) to the neutral detent (idle) position. Check in front and behind boat for people or obstructions before shifting. 2. To go forward forward:: Mov Move e the shift shift handle handle forwar forward d from neutral detent to forward gear engagement detent position. Throttle movement will begin after the detent position for forward gear engagement. After the throttle is activated, continue to move the control handle slowly in the desired direction to increase speed.

1

21185 

3. To go in reverse: reverse: M Move ove the shi shift ft handle handle backward backward until you reach the detent position for reverse gear engagement. Throttle movement will begin after reverse gear engagement. After the throttle is activated, continue to move the control handle slowly in the desired direction to increase speed.

CAUTION! Do not shift gears if engine speed is above 800 RPM.

30

VPA 7742705 English 06-2003

 

Controls

Shifting between Forward and Reverse • To go from forward to reverse, or reverse to forward, always pause at neutral (N) and allow engine speed to return to idle.

• After shifting is completed, continue to move the control handle slowly in the desired direction to increase speed.

CAUTION! Do not shift gears if engine speed is above 800 RPM. Do not shift from forward to reverse when boat is planing. There is a danger that water will get into the engine and cause serious damage, while causing serious damage to the drive. 22764 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

CAUTION! Any time the boat is operated, be aware of changes in shift system operation. A sudden increase in shift effort at the remote control handle, or other abnormal operation, indicates a possible problem in the shift system. If you suspect there is a problem, see your Volvo Penta dealer as soon as possible for proper diagnosis and required service or adjustment. Continued operation could result in damage to the shift mechanism and loss of shift and throttle control that could result in personal injury. Cruising Speed Operating the engine at wide open throttle (WOT) should be avoided since it is both uneconomical and uncomfortable. Volvo Penta recommends a cruising speed 25% lower than maximum rpm at WOT. Depending on hull type, choice of propeller, load and conditions, etc., the maximum engine speed at top speed can vary, but it should be within the WOT range range.. Engine

22765 

VPA 7742705 English 06-2003

WOT Range (RPM)

3.0GL-C

4200–4600

4.3GL-D 4.3GXi-E (F)

4200–4600 4400–4800

5.0GL-E

4400–4800

5.0GXi-E (F)

4600–5000

5.7GL-E

4400–4800

5.7Gi-E (F)

4600–5000

5.7GXi-F (F)

4600–5000

8.1Gi-E (F)

4200–4600

8.1GXi-D (F)

4600–5000

31

 

Controls

Friction Brake The remote control has a friction brake, which can be adjusted as necessary necessar y, to provide lighter or heavier lever action. If you are using a Volvo Penta Penta shift control and you wish to make adjustments to the friction brake, follow the instructions below to make the necessary changes.

Note! Each manufacturer has a particular method for making adjustments to the friction fr iction brake. For specific directions on how to adjust a nonVolvo Penta friction brake, please refer to your manufacturer’s manufacturer’ s manual. Side Mount Remote Controls 1. Make Make sur sure e the engin engine e is tu turned rned off off by re remov moving ing the key from the ignition switch.

1

2. Remov Remove e the the remote remote control control leve leverr (1).    M    A    6    2   :    2    2   :    3    0    1    0

3. Remove Remove tthe he plastic plastic cover cover that shields shields the remote control mechanism.

2

4. Using Using a scre screwdri wdrive verr adju adjust st the fricti friction on brake brake

   2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

screwincreases (2) as necessary. Turning screwit clockwise brake effect, whilethe turning counter clockwise provides lighter lever action. 5. Reinsta Reinstallll the pl plast astic ic cove coverr and rem remote ote contro controll lever. 22762 

Top Mount Remote Controls 1. Make Make sur sure e the engin engine e is tu turned rned off off by re remov moving ing the key from the ignition switch.

3

2. Remove Remove tthe he plastic plastic cover cover that shields shields the remote control mechanism. 3. Fo Forr single single lever lever controls controls,, mov move e the throttle throttle to the forward position. For dual lever controls, move the port side lever forward and the starboard side lever into reverse. 4. Using Using a scre screwdri wdrive verr adju adjust st the fricti friction on brake brake screw (3) as necessary. Turning the screw clockwise increases brake effect, while turning it counter clockwise provides lighter lever action.

21188 

5. Reinst Reinstall all the plasti plastic c co cover ver..

3

21189 

32

VPA 7742705 English 06-2003

 

Controls

Trim Controls Trimming (raising and lowering the drive) can be performed by using:

• A separate control panel (4) on the instrument panel.

• A control button (5) on the remote control lever. • The control buttons on the port control lever in a twin installation. The current trim position is indicated on a trim gauge located on the instrument panel or elsewhere on the dashboard.

Operating Trim Controls 4    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Control Panel The control panel has two standard buttons for tilt control with a third (optional) button:

• The center button moves the drive trim out while raising the boat’s bow bow.. lowerthe button moves • The lowering boat’s bow. the drive trim in while 22766 

• The top button (optional) disconnects a “catch” 5

so that the drive can be trimmed t rimmed into the BEACH and LIFT positions. (Press this button and the center button at the same time.)

Remote Control Lever The control button on the control lever has two functions:

• Pressing the top half of the button moves the drive trim out while raising the boat’s bow.

• Pressing the bottom half of the button moves the 6

22767 

drive trim in while lowering the boat’s boa t’s bow. bow. You must press a separate switch on the instrument panel to disconnect the “catch” (optional) so that the drive can be trimmed into the BEACH and LIFT positions.

7 Control Lever with Catch Button (Single) A switch on the control lever (6) allows you to trim the drive as follows:

• Pressing the switch up moves the drive trim out while raising the boat’s bow. bow.

• Pressing the switch down moves the drive trim in while lowering the boat’s bow bow..

• The catch button (7–optional) disconnects a “catch” that thepositions. drive can be trimmed into the BEACHso and LIFT 22768 

VPA 7742705 English 06-2003

33

 

Controls

Control Lever with Catch Button (Dual) There are two switches on the port control lever (8), which gives you the capability of individual adjustment of the drive trim.

8

• Pressing the switches up moves the drive trim out while raising the boat’s bow.

•

Pressing the switches down moves the drive trim in while lowering the th e boat’s bow. bow.

• The catch buttons (9–optional) disconnect a “catch” so that the drives can be trimmed into the BEACH and LIFT positions.

22769 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

9

34

VPA 7742705 English 06-2003

 

Operation Operation

Operating the Engine CAUTION!  Do not start star t the engine out of the th e water unless you have connected a hose with running water to the flushing adapter. Please refer to the section entitled Engine Flush  for  for instructions on attaching and running the engine out of water. Thoroughly familiarize yourself with the operation of the remote control supplied with your boat, then proceed as follows.

Before Starting DANGER!  T  To o prevent a possible explosion hazard, operate the engine compartment/bilge blower as reco recommmended by the boat manufacturer before before starting the engine. If the engine compartment is not equipped with a blower, blower, open the engine cover or hatch before starting so as to disperse any gasoline fumes that may be present. Leave the hatch open until after the engine is running. 1. Start Start the the boat’s boat’s bi bilge lge bl blower ower a and nd run as as rec recomommended by the boat manufacturer. Frequently check boat’s bilge area for gasoline fumes.

A

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

2. Check the bilge bilge for for excessi excessive ve water accum accumulaulation. Always keep the bilge clean and dr dry y.

21192 

CAUTION! The water level in the boat’s bilge will B

increase when operate your boat at a high incline before youyou reach planing speed. Excessive water in the bilge can cause engine damage. 3. Open Open th the e fue fuell c coc ock k (A). Also, ensure that the sea cock is open–if so equipped.

21190 

4. Make Make sure tthat hat there there are are no fuel, fuel, engin engine e cool coolant ant,, or oil leaks (B).

C

5. Chec Check k en engi gine ne o oilil leve levell (C).

Max

6. Switch Switch o on n the main main swit switches ches–if –if so so equipp equipped. ed.

Min

7. Insert Insert the key key into into the the ignit ignition ion s swit witch ch (O). Turn the key one step to the right ( I) to switch on engine system voltage and instrumentation.

1011021

0

I

8. Make Make sur sure e that the fuel fuel gauge gauge iis s ope operat rating ing and and that you have enough gasoline (D).

II

9. Lower Lower the drive unit; make make sure the water water intake intakes s are submerged. There should be no obstructions in the water near the propellers.

21181

D

22786  21191

VPA 7742705 English 06-2003

35

 

Operation

Starting the Engine (Cold Start) GL Models A cold engine may require priming before you can start it. To prime the engine: 1. Turn Turn tthe he igniti ignition on s swit witch ch OFF (0). 2. Disenga Disengage ge the dri drive ve mecha mechanis nism m by pre pressi ssing ng the gear shift release button (A).

B

3. Depres Depress s the thrott throttle le lock lock and mo move ve the the control control lever to FULL THROTTLE (B) in order to activate the accelerator pump and prime the engine. 4. Return Return the the rem remote ote contr control ol ha handl ndle e to a ffast ast idle idle position (about 1000 RPMs).

A

5. Turn the ignition ignition s switch witch to START START (II) and hold it there until the engine starts, but for no longer than 10 seconds.

21183 

0

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

I

II

6. Once Once the engine engine starts, starts, keep keep the the throttl throttle e at a fast fast idle (about 1000 RPMs) for 30 seconds before returning to NEUTRAL. 7. Repeat Repeat primin priming g ifif n nece ecessa ssary ry..

21181

CAUTION! Too much priming may flood the engine. If the engine fails to start after a few attempts, there may be a problem that needs to be addressed. See your authorized Volvo Penta dealer for service. Gi & GXi Models 1. Move Move the c contr ontrol ol ha handl ndle e to the N NEUT EUTRAL RAL dete detent nt position. 2. Turn the ignition ignition s switch witch to STAR START T (II) and hold, for no longer than ten seconds or until engine starts. If the engine does not start, let go momentarily, then try again. 3. As soon soon as engin engine e sta starts, rts, rele release ase k key ey to to ON or RUN (I).

If the Engine Floods GL Models 1. Disenga Disengage ge the shift shift mechan mechanism ism.. 2. Move Move the the remote remote THROTTLE (B).

contr control ol

le leve verr

to

FULL FULL

3. Turn the key key swit switch ch to ST START ART (II). 4. As soo soon n as the the eng engin ine e st starts arts::

• Return the remote control handle to IDLE. • Turn the key to ON or RUN ( I). • Move the remote control handle hand le to FAST IDLE to warm up the engine. Do not exceed 1000 RPM.

36

VPA 7742705 English 06-2003

 

Operation

Gi & GXi Models Advance the control handle to FULL THROTTLE ( C) to clear a flooded engine. In this throttle position, with the engine speed below 400 RPM ( D –cranking speed), the ECM shuts off the fuel injectors so no fuel is delivered. When the throttle position is moved from full throttle, the ECM returns to the starting mode.

C

WARNING! Be prepared to quickly move the control handle to IDLE once the engine starts. This will avoid over-speeding and possibly damaging the engine. CAUTION! Immediately after engine start-up, look at all instruments. If any readings are abnormal, stop the engine and determine the cause.

21183 

Starting the Engine (Warm Start)    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

1. Move Move the cont control rol handl handle e to th the e NEUTR NEUTRAL AL de deten tentt position. 2. Turn the ignition ignition s switch witch to START START (II) and hold, for no longer than ten seconds or until engine starts. If the engine does not start, let go momentarily, then try again.

D

3. As soon soon as engi engine ne st starts arts,, release release k key ey to ON ON or RUN (I). 22787 

0

I

II

CAUTION! Never leave the key in the ON (I) position with the engine not running. Never turn the key to START (II) when the engine is running. Either situation could damage the engine. engin e. Note! If the engine floods during a warm start, simply follow the directions provided in the section entitled If the Engine Floods  to  to restart the engine.

21181

Stopping the Engine 1. Move Move the re remot mote e control control leve leverr to NE NEUTR UTRAL. AL. 2. Let engi engine ne rretu eturn rn to to idle idle.. 3. Turn ign ignit itio ion n ke key y to OFF OFF (0).

CAUTION! Do not stop the engine at speeds above idle or “speed up” the engine while turning off the ignition. Do not stop the engine while in gear or while the boat is moving. Engine damage could result.

VPA 7742705 English 06-2003

37

 

Operation

Operating Remote Controls Familiarize yourself with remote control operations beFamiliarize fore starting the engine.

Using the Gear Shift Release Button Method 1 To disengage the gear shift mechanism on remote controls with a throttle lock: 1. Place Place th the e control control handle handle in in NEUTR NEUTRAL. AL.

1

2. Depre Depress ss tthe he thro thrott ttle le loc lock k (1) while pressing the gear shift release button (2). 3. Move Move contr control ol han handle dle in th the e desired desired direc direction tion to to increase throttle.

2

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

The throttle lock and gear shift s hift release mechanism will automatically re-engage when the control handle is returned to the NEUTRAL position.

Method 2 To disengage the gear shift mechanism on remote controls without a throttle lock: 1. Push Push in and and hold hold ge gear ar sh shift ift rele release ase b butt utton on (2). 22788 

2. Move Move contro controll handle handle FORW FORWARD to incr increase ease throttle. The gear shift release mechanism will automatically re-engage when the control lever is returned to NEUTRAL.

Note! For additional information about remote control features and operation, please refer to the chapter entitled Controls .

38

VPA 7742705 English 06-2003

 

Operation

Steering System Operation The steering system for your Volvo Volvo Penta sterndrive is operated by a steering cable connected to the helm. Restricting movement of the steering cable will limit or stop the steering system’s hydraulic assist. Do not interfere with or restrict steering cable movement through last 90°clamps, of bendorattiethe engine. Do not use cable the retainers, straps. Using one or all of these could restrict the cable movement near the engine. Do not tie wiring harnesses or other control cables to the steering cable. Make sure deck combing and bulkheads allow for steering ste ering cable movement.

21182 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

If the power steering system stops working, it will feel harder to steer. If this condition occurs, look for possible causes and fix them if possible. If the power steering system cannot be corrected on board, proceed at a reduced speed. You will be able to steer the boat, but with increased effort. effor t. See your authorized Volvo Volvo Penta dealer as soon as possible to correct your power steering system. At slow speeds (no wake), your boat may tend to wander. This is normal and may be overcome by anticipating bow direction and correcting with steering wheel. A slightly higher throttle and trim tr im setting may also lessen the tendency to “wander.” Changing weight distribution, aft to forward, can also affect slow speed steering.

Twin Unit Steering Twin engine boats may have only one engine with a fully operational power steering system. That power steering system is on the starboard s tarboard engine; therefore, when operating on a single engine use the starboard engine.  Using a port enginesystem that does have Note! functional power steering willnot cause ana increased effort in steering control, due to absence of power assist. Some twin engine boats may have both engine power steering systems coupled together with a priority valve. This allows the use of either engine to provide power assist steering.

22761

VPA 7742705 English 06-2003

39

 

Operation

Power Trim and Tilt Operation Trimming and tilting the drive is done d one from a control switch mounted on the remote contr control ol or by using the switches on the dash. When using the dash mounted switches, the bottom button lowers the bow and the top button raises the bow. The switch on the remote control lever raises and lowers the drive when its upper or lower segment is pressed.

Note! Allow the trim/tilt switch to return to its center position when the drive unit reaches the maximum raised or lowered position. This will prevent your trim/tilt motor from overheating. The trim/tilt motor is protected from overheating by an internal thermal overload switch. If the electric motor stops while tilting, release the switch and allow the overload switch to cool and automatically reset itself. When the overload switch has reset, tilting may be resumed. Make sure the drive unit is not being restrained, causing the motor to overheat. If the electric motor still does not operate, check the in-line 5-amp fuse in the remote control handle, the 10-amp fuse located on the trim/tilt pump, or the 50-amp circuit breaker on the engine.

Note! For additional information about Trim Trim and Tilt controls, please rrefer efer to the chapter entitled Controls .

Power Trim Operation The power trim is normally used before you accelerate onto plane, after you reach the desired RPM or boat speed, and when there is a change in water or boating conditions. Locate passengers and equipment in the boat so that the weight is balanced fore and aft, and side to side. Trimming will not cancel an unbalanced load.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22766 

To operate the trim, push and hold h old the switch “bow-up” or “bow-down” until the desired bow position is reached. The trim may be operated at any boat speed or at rest. Avoid operating the trim system when running in reverse. Observe the trim/tilt gauge, which indicates the bow position achieved. The upper scale (0 to 5) of the trim gauge indicates the “bow-up” positions, and lower scale (6 to 10) of the trim gauge indicates the “bowdown” positions.

Determining the Proper Trim 22767 

The effect of the maximum “bow-up” and “bow-down” positions will be similar for most boats. The bow position best for your operating conditions could be at any trim setting between the maximum “bow-up” and “bow-down” positions. The boat will be properly trimmed tr immed when the trim angle provides the best boat performance for your operating conditions. On models without power steering, the trim position that provides a balanced steering load is desirable. To familiarize yourself with the power trim, make test runs at slower speeds and at various trim positions to see the effect of trimming. tr imming. Note the time it takes for the boat to plane. Watch the tachometer and speedometer readings and the ride action of the boat. The following sections entitled Operating in “Bow-Up”  Position  and   and Operating in “Bow Down” Position  pro  provide additional information on this topic.

40

VPA 7742705 English 06-2003

 

Operation

Operating in “Bow-up” Position The “bow-up” position is normally used for cruising, running with a choppy wave condition, or running at full speed. In a full “bow-up” position the boat may tend to self-steer. You may have to compensate with the steering wheel to keep the boat in a straight-ahead path. In this position the boat’s bow will tend to raise clear of the water. Excessive “bow-up” trim will cause propeller ventilation resulting in propeller slippage. Engine RPM will also increase, but boat speed will not increase and may even drop.

!"# %&

22796 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

CAUTION! Use caution when operating in rough water or crossing another boat’s wake. Excessive “bow-up” trim may result in the boat’s bow rising rapidly and possibly throwing the boat’s occupants into the water. Operating in “Bow-down” Position The “bow-down” position is normally used for acceleration onto plane, operating at slow planing speeds, and running against a choppy wave condition. In the fully “bow-down” position the boat may tend to self-

!"# '"#(

22797 

steer. Y maythe have toincompensate with the steering wheel You toou keep boat a straight-ahead path. In this position the boat’s bow will tend to go deeper into the water. If the boat is operated at high speed and/or against high waves, the bow of the boat will plow into the water. The boat may tend to bow steer or spin about rapidly and possibly eject occupants.

CAUTION! The boat trim should be adjusted to provide balanced steering as soon as possible each time you get underway. underway. Some boat, e engine, ngine, and propeller combinations may encounter boat instability and/or high steering torque when operated at or near the limits of the “bow-up” or “bowdown” positions. Boat stability and steering torque can also vary due to changing water conditions. If you experience boat instability and/or high steering torque, tor que, see your Volvo Penta Penta dealer to correct these conditions.

VPA 7742705 English 06-2003

41

 

Operation

Power Tilt Operation Tilting is normally used for raising the drive unit to obtain clearance when beaching, launching from a trailer, or mooring. When tilting the drive unit, the boat should be at rest or o r at idle speed only. The trim/tilt switch controls the tilting feature of the drive unit. When the trim/tilt switch is held in the “bowup” position, the drive unit tilts up until the switch is released or the drive unit reaches the maximum tilt position. The trim/tilt gauge will indicate the “tilt” position whenever the drive unit is in the tilt range. 22786 

CAUTION! Never exceed 1000 RPM when operating the drive unit in the tilted position (6°-29°) because it may damage the drive dr ive system. Never RUN the engine when the drive unit is tilted more then 30° or the drive will be damaged. Never operate the engine out of water or without water supplied to the engine. The water pump may be damaged or the engine may overheat. See flushing procedures found in the maintenance section.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

 To o avoid possible contact with the WARNING! T propellers, never use the drive unit as a ladder or as a lift to board the boat. boat . Never board at the rear of the boat when the engine is running, r unning, even if the engine is operating in neutral. Personal injury could result from contact with rotating engine parts and propellers. 22781

!

Any malfunction of the trim/tilt system could result in a loss of impact protection. Malfunction can also result in loss of reverse thrust capability. If malfunction occurs, see your authorized Volvo Penta dealer.

Power Trim/Tilt Switch & Gauge Location The power trim/tilt switch is located on the remote control handle or on the boat’s dashboard. The trim indi#$%& 

cator dual displays the driveit is position in thetoTrim range. With installations, permissible individually trim the drive in Trim range. When the drive is in Beach range (7° to 10°), boat speed must be lower than planing speed. The engine must be stopped when fully tilted (Lift Range).

22784 

Note! The automatic stop function between the Trim range and Beach range is an optional feature; unless you have the automatic stop function installed on your boat, you should check the trim indicator carefully during trim operation.

22785 

42

VPA 7742705 English 06-2003

 

Operation

Special Boating Situations The following section covers scenarios that are considered special boating situations. When using the boat in the following situations, there are some special procedures to take into consideration in order to keep the engine, transmission, drive, and propeller in top working condition.

Shallow Water Operation You may tilt the drive unit (6°-29°) to reduce the draft for shallow water running as long as you do not exceed 1000 RPM. Exceeding 1000 RPM is not necessary. It will only increase the boat wake and will not increase boat speed appreciably. appreciably.

)*+,,"# !"--".

22798 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

CAUTION! Exceeding 1000 RPM with the drive dr ive unit tilted could damage drive dr ive train components. This type of damage is not covered by warranty. Never attempt to plane the boat or exceed 1000 rpm with the drive unit in a partially tilted position. Always return to the trim range as soon as possible to avoid damage to drive train. Never RUN  the engine with the drive unit tilted t ilted more than 30° or the drive will be damaged. When operating in shallow water, be sure the water intakes located in the lower gear unit are submerged at all times. Proceed at slow speed and lower drive unit immediately when deeper water is reached.

High Altitude Operation Volvo Penta EFI engines have programmed altitude compensation; however, there may be a slight performance loss at altitudes above ab ove 5000 feet due to lower air density. If you are boating above 5000 feet for a short time, a lower pitch propeller will restore some of the lost performance. Long term use above altitudes of 5000 ft. may require a change in gear ratio which is not covered under the Volvo Penta Limited Warranty. Volvo Penta carbureted engines may require mechanical modifications. See your Volvo Penta dealer for more information.

Operating in Freezing Temper Temperatures atures

22799 

When freezing temperatures are forecast and the boat will be operated and left in the water, the drive unit must remain in the tilted down (submerged) position at all times to prevent water in the drive unit from freezing. Upon completion of engine operation, drain the engine as described in the maintenance section of this manual.

Salt Water Operation You can use your Volvo Penta Penta ster sterndri ndrive ve in either fres fresh h or salt water. We recommend that you use fresh water to flush out the engine and drive as described in the maintenance section of this manual after you use it in polluted or salt water. This will prolong the service life of the manifolds and risers. VPA 7742705 English 06-2003

43

 

Operation

Traileri railering ng Your Boat If your boat will be trailered, tilt the drive dr ive unit out of the water. After you remove your boat from the water, lower the drive unit to the RUN (down) position until the cooling system drains thoroughly thoroughly.. Rinse the entire drive exterior with fresh water, then dry it and spray it with anticorrosion spray. spray.

22800 

Before trailering your boat on the road, check the ground clearance of the drive unit. When trailering, the drive unit may be in the up or down position. There must be at least 15 inches (38.1 cm) clearance between the lower gear unit and the ground. If the clearance is less than 15 inches (38.1 cm), raise the drive unit.

Note! Be very careful when you back out of driveways or cross railroad tracks, so that the sterndrive does not hit the ground. Make sure that the boat fits the trailer properly. In many cases, loss of performance and speed is due to improper trailer support and too much tie-down pressure, which causes the boat bottom to deform. The boat should rest firmly on the trailer with maximum tiedown pressure applied at the bow and transom only. only.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

44

VPA 7742705 English 06-2003

 

Features Features Your Volvo Volvo Penta product consists of three components: the engine, transom shield and the sterndrive. sterndr ive. There are certain parts pa rts on each component that you, the owner, must take care of to make sure that your Volvo Penta Penta product stays in optimum running condition. The important parts of each component are shown in the illustrations on the following “Features” pages. Explanations of these parts and systems are described below; the maintenance procedures are found in the Maintenance section.

Circuit Breakers and Fuses 4.3GXi-E, 4.3GXi-EF, 5.0GXi-E, 5.0GXi-EF, 5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.7GXi-FF, 8.1Gi-E, 8.1Gi-EF, 8.1GXi-D, 8.1GXi-DF (EFI Engines)

3.0GLM-C, 3.0GLP-C (Carb Engines)

01 02

/

3

01

02

08

09

        6         2

        6         2

        5         1

        5         1

05

0:

04

        6         2

        5         1

        6         2

22870     M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

4.3GL-D, 5.0GL-E, 5.7GL-E (Carb Engines)

7

/

!

01

/

 

!

'

02

        5         1

        5         1

        6         2

        6         2

        6         2

04

3

3 22871

A B C D E F1

        5         1

22872 

Starter Relay Fuel Pump Relay Ignition Relay Spare Relay Spare Fuses (15 & 20 Amp) 20 Amp Instrument Panel Accessory

F2 F3 F4 F5 F6 F7

20 Amp Instrument Panel Accessory 15 Amp Ignition/Fuel Fuse 15 Amp Engine Control Module (ECM) Fuse 20 Amp Spare Accessory Fuse 15 Amp EVC Fuse 7.5 Amp (Carb) or 20 Amp (EFI) Fuel Pump Fuse

Legend of Symbols Used in Engine Diagrams 1

2

3

4

5

6

7

8

22341

22874

22343

22342

22345

22372

22873

22346

9

22377  

1 2 3

Engine Oil Engine Oil Level Power Po wer Steering Fluid Flui d

5 6 7

Engine Raw Water Drain Engine Coolant Drain (Closed Cooling) Engine Coolant

4

Sterndrive Oil

8 9

Engine Flush Heat Exchanger Raw Water Drain

VPA 7742705 English 06-2003

45

 

Features

3.0GLM-C, 3.0GLP-C

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22878 

1. Circui Circuitt Break Breaker er and Fuses Fuses

9. Raw Raw Wat Water er Pum Pump p

17. 17. Fuel Fuel P Pum ump p and and Filt Filter er

2. Oil Fill ill C Cap ap

10. Raw Raw Wat Water er Outl Outlet et

18. 18. Oil Siph Siphon on Tube ube

3. Carb Carbur uret etor or

11. Raw Raw Water ater In Inle lett

19. Starte rter

4. Fl Flam ame e Arre Arrest stor or

12. Circ Circul ulat atio ion n Pu Pump mp

20. 20. Oil Oil Di Dips psti tic ck

5. Alter lterna nato torr

13 13.. Di Dist stri rib but utor or

21. 21. Ex Exha haus ustt Ris Riser er

6. Pow ower er Stee Steering ring Fluid Fluid Fill Fill1

14. Engine Engine Raw Raw Water Water Flu Flush sh

22. Exhaust Exhaust Overhe Overheat at Sensor Sensor

7. Pow ower er Steer Steerin ing g Pump Pump1

15 15.. Spar Spark k Plu Plugs gs

23. Exhaus Exhaustt Man Manif ifold old Wate Waterr Drain Drain

8. Serpe Serpent ntin ine e Belt Belt

16 16.. Oi Oill F Fil ilte terr

24. Engine Engine Raw Water Drain Drain 25. 25. Ex Exha haus ustt M Mani anifo fold ld

1. Optional

46

VPA 7742705 English 06-2003

 

Features

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22879 

22880 

47

VPA 7742705 English 06 2003

 

Features

4.3GL-D, 5.0GL-E, 5.7GL-E

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22875 

1. Exhaus Exhaustt Overh Overheat eat Sensors Sensors

11 11.. Al Alte tern rnat ator or Bel Beltt

21. 21. Fuel Fuel Pum Pump

2. Circui Circuitt Break Breaker er and Fuses Fuses

12. Power ower Stee Steering ring Fluid Fluid Fill Fill

22. 22. Di Dist stri rib but utor or

3. Fl Flam ame e Arre Arrest stor or

13. Power ower Stee Steerin ring g Pump Pump

23. 23. Spar Spark kP Plu lugs gs

4. Carb Carbur uret etor or

14. Power ower Ste Steeri ering ng Bel Beltt

24. Engine Engine Raw Water Drain Drain

5. Engi Engine ne Cov Cover

15 15.. Raw Raw Wat Water er Pum Pump p

25. Starte rter

6. Alter lterna nato torr

16. Raw Raw Wat Water er Outl Outlet et

26. Exhaus Exhaustt Man Manif ifold old Wate Waterr Drain Drain

7. Exha Exhaus ustt R Ris iser ers s

17. Raw Raw Water ater In Inle lett

27. 27. Ex Exha haus ustt M Mani anifo fold ld

8. Oil Fill ill C Cap ap 9. Oil Oil Di Dips psti tic ck

18 18.. Fue uell Fil Filte terr 19. Water Water Cir Circul culati ation on Pump Pump

28. 28. Oil Oil F Fiilter lter 29. Intake Intake Manif Manifold old Drai Drain n Pl Plug ug (4.3 GL only)

10. Oil Oil S Sip iphon hon Tube ube

20. Engine Engine Raw Raw Water Water Flu Flush sh

48

VPA 7742705 English 06 2003

 

Features

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22876 

22877 

49

VPA 7742705 English 06 2003

 

Features

4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22886 

1. Exhaus Exhaustt Overh Overheat eat Sensors Sensors

11. Au Autom tomati atic c Belt Belt T Tens ension ioner er

21. 21. Fuel Fuel Fil Filte terr

2. Circui Circuitt Break Breaker er and Fuses Fuses

12 12.. Se Serp rpen enti tine ne Bel Beltt

22. 22. Ex Exha haus ustt Ris Riser er

3. Fl Flam ame e Arre Arrest stor or

13. Power ower Stee Steering ring Fluid Fluid Fill Fill

23. 23. Spar Spark kP Plu lugs gs

4. En Engi gine ne Oil Oil Fil Filll Cap Cap

14. Power ower Stee Steerin ring g Pump Pump

24. Engine Engine Raw Water ater Flus Flush h

5. Remo Remote te Oil Oil Fil Filte terr In

15 15.. Raw Raw Wat Water er Pum Pump p

25. Engine Engine Raw Water Drain Drain

6. Remo Remote te Oil Oil Fil Filter ter Out Out

16. Raw Raw Wat Water er Outl Outlet et

26. Starte rter

7. Alter lterna nato torr

17. Raw Raw Water ater In Inle lett

27. Exhaus Exhaustt Man Manif ifold old Wate Waterr Drain Drain

8. En Engi gine ne Oil Oil F Fililte terr 9. Oil Oil Dipst Dipstic ick k (Engi (Engine ne))

18. Water Water Cir Circul culati ation on Pump Pump 19. Fuel Fuel P Pump ump (High (High Pressu Pressure) re)

28. 28. Ex Exha haus ustt M Mani anifo fold ld 29. 29. Knoc Knock k Sens Sensor or

20. Fuel Fuel P Pump ump (Low (Low Pres Pressur sure) e)

30. Engine Engine Oil Adapto Adaptorr Assem Assembly bly

10. Oil Oil S Sip iphon hon Tube ube

50

VPA 7742705 English 06 2003

 

Features

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22887 

22888 

51

VPA 7742705 English 06-2003

 

Features

8.1Gi-E, 8.1GXi-D

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22892 

1. Exha Exhaus ustt Ri Rise serr

10 10.. Se Serp rpen enti tine ne Bel Beltt

19. Fuel Fuel P Pump ump (Low (Low P Pres ressur sure) e)

2. Exhaus Exhaustt Overh Overheat eat Sensor Sensor

11. Power ower Stee Steering ring Fluid Fluid Fill Fill

20. Engine Engine Raw Water ater Flus Flush h

3. Oil Oil Fil Filll (Eng (Engin ine) e)

12. Power ower Stee Steerin ring g Pump Pump

21. Circuit Circuit Break Breaker er a and nd Fuses Fuses

4. Fl Flam ame e Arre Arrest stor or

13 13.. Raw Raw Wat Water er Pum Pump p

22. 22. Spar Spark kP Plu lugs gs

5. Alter lterna nato torr

14. Raw Raw Wat Water er Outl Outlet et

23. 23. Oil Oil Dip Dipst stic ick k (Engi (Engine) ne)

6. Remote Remote Oil Oil Filt Filter er Assem Assembl bly y

15. Raw Raw Wat Water er In Inta take ke

24. Engine Engine Raw Water Drain Drain1

7. Remo Remote te Oil Oil Fil Filter ter Out Out

16. Water Water Cir Circul culati ation on Pump Pump

25. Starte rter

8. Remo Remote te Oil Oil Fil Filte terr In

17. Fuel Fuel P Pump ump (High (High Pressu Pressure) re)

26. Exhaus Exhaustt Man Manif ifold old Wate Waterr Drain Drain

9. En Engi gine ne Oil Oil F Fililte terr

18 18.. Fue uell Fil Filte terr

27. 27. Ex Exha haus ustt M Mani anifo fold ld

1. The engine raw water drain plug on the 8.1 L Liter iter engines is a Metric M14 size bolt. Do not use an inch equivalent as you may damage the engine.

52

VPA 7742705 English 06-2003

 

Features

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22893 

22894 

53

VPA 7742705 English 06-2003

 

Features

4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22889 

1. En Engi gine ne Cool Coolan antt Fi Fillll Cap Cap

4. Raw Raw Wat Water er Inl Inlet et

7. He Heat at Ex Exch chan ange gerr

2. Engine Engine Coolan Coolantt Reserv Reservoir oir

5. Raw Raw Water ater Ou Outl tlet et

8. He Heat at E Exc xcha hange ngerr Anod Anode e

3. Raw Raw Wat Water er Pum Pump p

6. Heat Heat Exch Exchange angerr Drai Drain n Cap Cap

54

VPA 7742705 English 06-2003

 

Features

8.1Gi-EF, 8.1GXi-DF

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22891

1. En Engi gine ne Cool Coolan antt Fill Fill Cap Cap

4. Raw Raw Wat Water er Pu Pump mp

7. Heat Heat E Exch xchang anger er Dra Drain in Cap

2. Engine Engine Coolan Coolantt Reservo Reservoir ir

5. Raw Raw Wat Water er Outl Outlet et

8. Heat Heat Ex Exch chan ange gerr

3. Water Water Circul Circulati ation on Pump Pump

6. Raw Raw Wat Water er Inl Inlet et

55

VPA 7742705 English 06-2003

 

Features

SX-M Sterndrive

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22896 

1. Oil Oil Fill Fill (St (Stern erndri drive ve))

3. Anodes

5. Oil Oil Dr Drai ain n (St (Stern erndri drive ve))

2. Trim rim Se Send nder er

4. Raw Raw Water Water IIntak ntake e (Sterndr (Sterndriv ive) e)

6. Prop opel elller

56

VPA 7742705 English 06-2003

 

Features

DP-S Sterndrive

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22895 

1. Oil Oil Fill Fill (St (Stern erndri drive ve))

4. Raw Raw Wate Waterr Intak Intake e (St (Sterndr erndriv ive) e)

2. Tri rim m Send Sender er

5. Oil Oil Drai Drain n (Stern (Sterndri drive ve))

3. Anodes

6. Rear Rear Pr Prop opel elle lerr

7. Front ront Pr Prop opel elle lerr

VPA 7742705 English 06-2003

 

Notes Features

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

57

58

VPA 7742705 English 06-2003

 

Maintenance Maintenance

Engine Break-in Period Note! T  To o ensure proper lubrication lubr ication during the break-in break- in period, do not remove factory break-in oil until after the 20-hour break-in is completed. The First Service inspection should be carried out after 20 hours of operation. CAUTION!  Failure to follow engine break-in procedures can result in serious ser ious engine damage. CAUTION!  Do not run engine at a constant RPM for prolonged periods of time during the break-in period. All Volvo Volvo Penta engines have been run for a short time during a final test at the factory. You You must follow the engine break-in procedure during the first f irst 20 hours of operation to ensure maximum performance and longest engine life.

Break-in Procedur Procedures es During the break-in period, watch out for the following items during the initial engine run: 1. Check Check engi engine ne o oilil lleve evell fr frequ equent ently. ly.

Max    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Min

CAUTION! Be sure to check the oil level frequently during the first 20 hours of operation, since the oil consumption will be high until the piston rings are properly seated. The engine may use more engine oil during the breakin period than would otherwise be normal.

1011021

• Maintain oil level in the safe range, between the ADD and FULL marks on dipstick. Somewhat higher oil consumption is normal until the piston rings have seated.

• If you have a problem getting a good oil level

  # $"!  &   

   "

     !  (  

)/3 86;

$       '     

)<=>?3>@7          '        + !             /  &    

!       

)     

     "

    +

   .    + ,  , & *  (

!    *  

     -

reading on the dipstick, rotate the dipstick 180° in the dipstick tube.

• When adding engine oil, use Volvo Penta engine oils for gasoline engines, or a good quality qua lity oil (API Service CF/SH or better) of the same viscosity.. Use the following chart to select the SAE cosity viscosity that matches the temperature range in which you expect to operate.

22815 

Lowest Anticipated Temperature 32° F (0° C) — above 0° F (-18° C) — 32° F (0° C) Below 0° F (-18° C)

Recommended SAE Viscosity Oils SAE 301 SAE 20W/50 SAE 15W/50 SAE 20W-20 SAE 10W

1. Volv olvo o Penta Penta Synth Synthetic etic Mo Motor tor Oil. Oil. If the recommended recommended oi oill is not available, use pure synthetic multi-viscosity oil.

59

VPA 7742705 English 06-2003

 

Maintenance

2. Watch atch tthe he oil pres pressur sure e gauge gauge..

• Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold oil will generally show higher oil pressure for any specific RPM than hot oil. Both of these conditions reflect normal engine operation.

21194 

the oil indicator fluctuates when the boat is • Ifturning, climbing on plane, etc., the oil pickup screen may not be covered with oil. Check the oil dipstick. If required add non-synthetic oil, but do not overfill. If the oil level is correct and the condition persists, ask your Volvo Volvo Penta dealer to check for possible gauge or oil pump malfunction. 3. Watch atch the engine engine tempe temperat rature ure in indic dicato atorr to be sure there is proper coolant circulation.

21195     M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Note! Failure to follow the break-in procedure may void the engine warranty.

First Two Hours 1. For the the first first five five to ten minute minutes s of operati operation, on, run run the engine at a fast idle (above 1500 RPM). 2. During the rremaini emaining ng ffirst irst two hours of o operati peration, on, accelerate to bring the boat onto plane quickly; bring the throttle back to maintain a planing attitude.

2 HRS

22812 

During this period, vary the engine speed frequently by accelerating to approximately ¾ throttle for two to three minutes, then back to minimum cruising speed. 3. Aft After er the engin engine e has rea reached ched oper operati ating ng tem temper peraature, momentarily reduce engine speed, then increase engine speed, to assist break-in of rings and bearings. Maintain plane to avoid excessive engine load.

Note! For this initial two hour break-in, do not run the engine at any constant RPM for prolonged periods of time.

Next Eight Hours

8 HRS

22813 

1. During During th the e next eight eight hour hours, s, con continu tinue e to oper operate ate at approximately ¾ throttle or less (minimum cruising speed). Occasionally reduce throttle to idle speed for a cooling period. 2. During During this this eight eight hour hours s of operat operation ion you you may may operate at full throttle for periods of less than two minutes.

60

VPA 7742705 English 06-2003

 

Maintenance

Final Ten Hours 1. During During th the e final final te ten n hou hours rs of br break eak-in, -in, y you ou ma may y operate at full throttle for five to ten minutes at a time. 2. Aft After er warmin warming g the engine engine to oper operati ating ng tem temper peraature, momentarily increase engine speed. 3. Occasi Occasional onally ly red reduce uce engin engine e spee speed d to idle idle to provide cooling periods.

10 HRS

At the end of the 20 hour break-in period, drain the engine oil and replace the oil filter. Fill the crankcase with Volvo Penta’s synthetic engine oil labelled for API Service CF/SH.

22814 

First Service Inspection (Dealer 20-Hour Check)    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

To ensure your continued boating enjoyment, we recommend that you return your Volvo Penta product to your Volvo Penta dealer for a 20-hour check. This 20-hour check will prevent a minor problem from getting worse and helps ensure a trouble-free boating season. When servicing your engine, your Volvo Penta dealer will use the following guidelines to inspect your product. Start the engine and check that:

• No leakage of fuel, oil, water, or exhaust gases occurs.

• Engine oil pressure and temperature are within specification.

• All cables and controls operate correctly. • All gauges, instruments, and alarms operate correctly.

• Steering system operates correctly. • Engine ignition timing and idle RPM are within specifications.

• Pow Power er tr trim im system operates correctly. Stop the engine and:

• • • •

Change engine oil and oil filter. Change fuel/water separator filter. Clean seawater strainer (if equipped). Check fluid levels and fluid condition in sterndrive or inboard transmission, power steering pump, and trim pump.

• Check propeller(s) and propeller fasteners. • Check condition of battery and battery cable connections.

• Check the tension and condition of drive dr ive belt(s). • Lubricate all grease fittings and linkages following service recommendations.

• Check tightness of all water water,, fuel, exhaust clamps, fittings, drive bellows, and drains. Restart the engine and recheck that:

• No leakage of fuel, oil, water, or exhaust gases occurs.

• Engine oil pressure and temperature are within specifications. This is a perfect time to discuss with your Volvo Volvo Penta dealer any questions about your engine that may have arisen during the first 20 hours of operation and establish a routine preventive maintenance schedule.

Operating After Break-in Period After the break-in period, the engine can be operated at any RPM from idle to full throttle. Cruising at 3600 RPM or less, however, however, saves fuel, reduces noise, and prolongs engine life.

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Maintenance Schedule The operation, maintenance, and care of the Volvo Penta engine and power package as outlined in this manual are the owner’s responsibility. The owner must keep records of all maintenance services performed. This record of proper maintenance may be required to determine warranty coverage on certain repairs and should be transferred to each subsequent owner. If you are not sure of the proper maintenance procedures, contact the Volvo Penta Consumer Affairs Department at the address provided in the front of this manual. In addition to the maintenance routines outlined o utlined on these pages, p ages, we recommend that you return your Volvo Volvo Penta product to your authorized Volvo Penta Penta dealer for a 20-hour check.

WARNING! T  To o prevent fire or o r explosion, Volvo Penta Penta ignition components meet U.S. Coast Guard Gu ard requirements for external ignition proof parts. Do not substitute automotive or other non-approved parts.

Function

Adjust

Check

Lubricate

Fill

Replace  

Tighten/T  orque 

Once per day 

• • •

Anodes, sacrificial    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Cooling system (leakage) Emergency stop switch, clip, and lanyard 1

•• • • • • •

Fuel system (leakage) Oil, engine crankcase Oil, drive unit Safety equipment Shift system (operation) Steering reservoir (fluid) Steering system cable (operation)

• •

•

Monthly 

• • •

•

Battery and connections (water level)

•

•

Belts: alternator and power steering Pump (4.3GL, 5.0GL, 5.7GL)

• • • • • • • • • •

• • • • •

Battery and connections (water level) Emergency stop switch, clip, and lanyard Exhaust system hoses/clamps (leakage)

Every 50 operating hours 

Exhaust system hoses/clamps (leakage) Fasteners (screws, nuts, etc.) Flame arrestor (mounting) Fuel system (leakage) Impeller, water pump2 Power Pow er steering (operation/fluid) Power Pow er trim/tilt (operation/fluid) Propeller and shaft Remote control shift cable (damage)3

• •

• •

1. Always be c constantly onstantly aware of the fuel system; system; if you smell an any y fuel or notice any leaks leaks,, shut off the engine immediately. immediately. Thoroughly investigate investi gate the situation and make any necessary repairs before restarting the engine. 2. Check at 50-hour intervals; replace as necessary necessary or once every tw two o years, whichev whichever er comes first. first. 3. Che Check ck for for sm smoot ooth h ope operat ration ion..

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Function

Adjust

Check

Lubricate

Fill

Replace  

Tighten/T  orque 

Once per season 

• • •

Bellows and clamps, drive unit1 Exhaust manifold and risers Distributor cap and rotor

•

• •

Fuel filter, carburetor Fuel filter, engine

•

Fuel system (leakage)

• • • •

Impeller, water pump1 Oil, engine crankcase2 Oil drive unit Oil filter (engine)2 Propeller and shaft

• •

Remote control shift cable (damage)    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

• •

Spark plugs (3.0 liter models) 3 Spark plug wires/boots

•

(deterioration)4

Steering system cable (operation) Throttle cable (damage and operation)

• •

Belt: serpentine (3.0GL; all fuel-injected models) Carburetor adjustment (as needed)

• • •

Engine alignment and mounting screws Exhaust manifold and risers (corrosion/blockage)

•

Gimbal bearing PCV valve Shift system (operation) Universal joints (SX and DPS) Universal joint bellows Universal joint and shaft splines

• •

•

• • • • •

1. Check at 50-hour intervals; replace as necessary necessary or once every two years, w whicheve hicheverr comes first. first. 2. Mineral oil - once per season or every every 100 operating hours hours,, whichev whichever er comes first. Synthetic Synthetic oil - onc once e per season or 200 op operating erating hours, whichever comes first. 3. For all other other engines: Once ev every ery 3 years or 500 operatin operating g hours, whi whichever chever comes first. first. 4. Replace as needed: Once every 3 years or 500 operating hours, whiche whichever ver comes first.

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Static Water Line Check the static water line if the loading or weight distribution distr ibution in the rear of the boat has h as changed significantly from the boat manufacturers original design. This would include the addition of an auxiliary outboard on brackets, onboard generators, towers, personal water craft mounted on the rear of the boat, coolers, and bait wells, and so on.

Static Water Line Test CAUTION! The static water line height must be tested before the engine is started for the first time. Checking the static water line will help prevent the ingestion of water into the engine and the resultant damage. 1. Load the the boat boat and distrib distribute ute weig weight ht as you you would would for normal boating conditions. 2. Place Place a le level vel on on top of of transo transom, m, measu measure re from from bottom of level to top of riser ( B) and record measurement.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

4. Su Subt btra ract ct measu measurem remen entt B from measurement A  and record result (C). Measurement C should not be less than 14 in. (35.6 cm).

A–B=C 5. When When the st stati atic c water water lline ine does does not not meet meet these these specifications, contact your Volvo Penta dealer for information on high rise extension kits. Make sure one is installed before the engine is started for the first time.

Note! The addition of equipment that permits per mits water to enter the engine through the exhaust manifold(s) will not be covered by warranty, unless damage is due to defective part(s).

3. Measure Measure from bottom of the level level to static water line (A) and record measurement.

B

A C

22816 

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Preparing for Boating (Launching) When launching your boat for the first time or when starting out a new season, always carry out the steps provided in the following checklist:

21201

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Replace all drain plugs.



Replace rubber caps and clamps or plugs.



Connect hoses and check their condition; tighten clamps and connections.



Install boat drain plug, if removed.



Remove and inspect distributor cap and rotor. Replace distributor with a new one, if necessary.



Clean battery terminals and check battery charge.



With ignition switch in OFF position, install battery and attach battery cables.



Spray terminals with Volvo Penta anti corrosion spray.



Open the fuel shut-off valve and check all fuel line connections for leaks.



Check the flame arrestor and clean if necessary.



Make a thorough check of boat and engine for loose or missing nuts and screws.



Pump the bilge dry and air out engine compartment. Federal, state, and/or local regulations prohibit the pumping of oil into any navigable waters.



Check all reservoir oil levels and fill as necessary.



Check drive and transom shield anodes. Clean or replace as necessary.

Off-Season Storage (Winterization) Be sure to properly winterize your Volvo Penta equipment. Engine or drive damage can result from ignoring simple preventive maintenance steps during autumn. Winterizing gives you the assurance that your engine will run more reliably and economically in the springtime. We recommend that you have your Volvo Penta dealer “winterize” your engine and a nd drive. Your Your dealer will provide the proper servicing and maintenance to ensure that your equipment is treated and stored properly. 21199 

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Maintenance

Maintenance of Boat’s Systems The following sections provide information about the maintenance of various systems aboard your boat, including the engine, drive, transmission, steering, fuel, electrical, electr ical, and cooling systems. If you intend to do any maintenance on your engine, transmission, and drive, we urge you to be thoroughly familiar with the procedures described in this manual. Always read and follow the safety warnings provided in this manual. If you are uncertain about any procedures described in the manual, or you would like to receive a workshop manual, please contact your Volvo Penta dealer.

Engine Exhaust System

Periodically inspect the engine exhaust system. Be sure to check for:

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Deteriorated hoses.



Burned hoses.



Loose clamps.



Evidence of water leaks.



Corrosion or blockage in the th e exhaust manifold and riser(s).

22132 

WARNING! Replace damaged or defective components, and securely tighten all clamps. Any exhaust leak must be repaired before be fore you operate your boat. Exhaust leaks release fumes that can create hazardous conditions for operator and passengers.

Drive Unit Bellows WARNING! If you work on the drive bellows, secure the drive unit in a raised position in such a way that it cannot fall. A falling drive may cause serious injur y.

22821



Check the drive unit bellows for fractures and deterioration.



Check tightness of all hose clamps.



Check the drive unit bellows b ellows and clamps every 50 operating hours or every season. You You may order the bellows separately, or as part of an accessory kit. The accessory kit also includes O-rings, oils, washers, seals, and anodes.

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Fuel System

DANGER! Gasoline is extremely flammable and highly explosive. ALWAYS turn off the engine before fueling. Do not smoke or allow open flames or sparks near the boat when adding fuel. When filling the gas tank, ground the tank to the source of gasoline by holding the hose nozzle firmly against the side of the deck filler plate, or ground it in some other manner. This action prevents static electricity buildup that could cause sparks and ignite fuel vapors.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Gasoline Recommendations

22790 

USE ONLY UNLEADED FUEL. Use lead-free gasoline with the following minimum or higher octane specification: Inside the U.S.: (R+M)/2 (AKI) – 87 Outside the U.S.: (RON) – 90 If fuels with 89 AKI pump posted (93 RON) octane number or higher are used an increase in power can be expected with EFI models.

/01  (2+

Premium fuel contains injector cleaners and other additives that protect the fuel system and provide optimum performance. Gasoline will degrade over time. Always buy your gasoline from a reputable dealer.

22823 

CAUTION! Engine damage resulting from the use of a lower octane gasoline than 87 AKI (90 RON) is considered misuse of the engine. Any resulting engine damage will not be covered by the warranty.

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Maintenance

Gasoline Containing Alcohol Many brands of gasoline being sold today contain alcohol. Two Two commonly used alcohol additives are Ethanol (ethyl alcohol) and Methanol ( CH 3 OH ), also called methyl alcohol.

7? 8 A? 22824     M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

See your boat owner’s manual to see if the boat’s fuel system is compatible with alcohol blended fuels. If it is, your engine may be operated using gasoline blended with no more than 10% 1 0% Ethanol meeting the minimum octane specification.

CAUTION! Do not use any gasoline that contains METHANOL. Serious damage will result from the continued use of fuel containing METHANOL. Any resulting engine damage will not be covered by the warranty. If you use gasoline that contains ethanol, be aware of the following:

• The engine will operate leaner with ethanol blended fuel. This may cause engine problems such as vapor lock, low speed stall, or hard starting.

• Ethanol blended fuels attract and hold moisture. Moisture inside fuel tanks can cause corrosion of the tank material. Inspect fuel tanks at least annually.. Replace fuel tanks if inspection indiannually cates leakage or corrosion.

Detonation (Spark Knock) Carbureted models: Detonation, or spark knock, in a marine engine is not necessarily audible. Overheating and continued running (“dieseling”) after ignition shutoff are indications of detonation in a marine engine. If you suspect detonation or spark knock, and the engine is tuned properly proper ly,, change to a highe higherr octane fuel. EFI models: Detonation, or spark knock, is continually monitored by the electronic fuel injection (EFI) system. The EFI’s computer (ECM) will automatically alter spark advance to help prevent engine damage if knock is detected, and there will be a slight loss of power.

Preventing Gum Formation and Corrosion To prevent gum formation and corrosion in the fuel system, use a fuel stabilizer in the gasoline if it will be in the tank for more than two weeks or if the boat is being prepared for winter storage. After adding fuel stabilizer, the engine should be run for ten minutes to allow stabilized fuel to reach all points of the fuel system. Fuel stabilizer is available from your Volvo Penta dealer.

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/01  (2+

EFI models: Some marinas sell fuel with lead additives. Do not use leaded fuel, as it may block the fuel injectors and cause leakage.

DANGER! Fuel leakage can contribute to a fire and/or explosion. Frequently inspect nonmetallic parts of the engine’s fuel system and replace if 22823 

excessive is found. stiffness, deterioration, or fuel leakage To prevent fire and explosion, perform all ser service vice procedures with the th e engine turned tur ned OFF OFF.. Failure to inspect your work may allow fuel leakage to go undetected. This could become a fire or explosion hazard. After completing service procedures, start engine and check entire fuel system for possible leaks. To prevent fire and explosion, Volvo Penta fuel system components meet U.S. Coast Guard requirements for fuel and fuel vapor containment. Do not substitute automotive or other non-approved parts.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Carburetor (GL) The carburetor vaporizes fuel and mixes it with in proper quantities to suit the varying needs of theairengine. Except for changing the carburetor fuel filter screen, the carburetor requires no periodic maintenance or adjustment. If operational problems occur, see your Volvo Penta dealer.

Electronic Fuel Injection (Gi, GXi) The electronic fuel injection (EFI) fuel metering system delivers the correct amount of fuel to the engine under all operating conditions. The EFI system is controlled by a microprocessor, and requires no periodic maintenance or adjustment. If operational problems occur, see your Volvo Penta dealer.

Flame Arrestor Remove the flame arrestor every 50 operating hours.

• Clean in solvent, air dry, dry, and inspect it for damage.

• Replace if damaged. • Reinstall flame arrestor; make sure unit is securely fastened. To prevent fire and explosion in the engine compartment, the flame arrestor must always be in place, properly secured, and undamaged. 21212 

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Electric Fuel Pumps WARNING! Check fuel pumps (A and B) frequently for signs of fuel leakage. If leakage occurs, have the fuel pump serviced immediately by your Volvo Penta dealer. EFI engines have two electric fuel pumps:

• A high-pressure pump (A) to supply the fuel injectors.

• A low-pressure pump (B) to bring fuel from the boat tank to the engine. Both pumps are protected by a single 20-amp fuse. The pumps will operate only when the engine is cranking or running. If a pump does not function, check the fuses and replace them if necessary. See your Volvo Penta dealer if further service is required.

CAUTION! Do not run engine out of fuel or run the electric fuel pumps dry more than 20 seconds. Running the electric fuel pumps dry will damage the fuel pumps.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Fuel Filter All models have a fuel filter (C) in the fuel line before the fuel pump.

Note! Volv  Volvo o Penta EFI engines require a special marine filter with a 5-10 micron filtering capability. Do not substitute any other type ty pe of filter. WARNING! Accumulation of water and other fuel contaminants may form corrosive compounds that can damage the fuel filter, and result in fuel leakage. For this reason, annual replacement of the fuel filter is required to avoid risk of explosion or fire. 22825 

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Maintenance

Engine Fuel Filter Replacement DANGER! The old fuel filter contains flammable fuel. Dispose of safely.

D C

Run the bilge blower for at least five minutes to vent the engine compartment, then start the engine and check for leakage. Smell for fuel in the bilge. IF YOU CAN SMELL FUEL, TURN THE ENGINE OFF IMMEDIATELY — EXPLOSION AND FIRE ARE AN EXTREME DANGER. DANGER. Clean up the bilge until fuel cannot be detected by smell. 1. Turn Turn of offf tthe he eng engin ine. e. 2. Unscre Unscrew w fuel filte filter, r, remo remove ve,, and discard discard.. 3. Using clean engine oil, lightly lightly lu lubricate bricate the gasket gasket (C) and inner seal (D) on new fuel filter. 4. Screw on fuel fuel filter and hand-tighten, hand-tighten, following following instructions on filter.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

5. Clea Clean n up any any sp spilille led d fu fuel el.. 22839 

6. Run the bilge blowe blowerr fo forr at least least five five minutes minutes to vent theand engine compartment, engine check for leakage. then start the 7. Smel Smelll ffor or fue fuell in tthe he bil bilge ge..

DANGER! If you can smell fuel, turn the engine off immediately - EXPLOSION AND FIRE ARE AN EXTREME DANGER. 8. Clean Clean up th the e bilge bilge until until fue fuell cannot cannot be be detecte detected d by smell.

Note! A loud whining noise at idle may be due to a restricted fuel filter causing a noisy fuel pump. Operating the engine with a restricted restr icted filter may damage the pressure regulator or fuel pumps. See your Volvo Volvo Penta dealer if the pump makes an unusual noise.

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Maintenance

Fuel Filter Replacement (V6/V8 Carb Engines) 1. Turn Turn of offf tthe he eng engin ine. e. 2. Unsc Unscre rew w ffue uell ffililte terr (A), remove, and discard. 3. Lightl Lightly y lubri lubricat cate e the gaske gaskett and inner inner seal on on new fuel filter. 4. Screw Screw on fuel filter and hand-tighten, hand-tighten, following following instructions on filter. 5. Clea Clean n up any any spil spille led d fuel fuel.. 6. Run the the bilge bilge blower blower for for at least five five minutes minutes to vent the engine compartment, then start the engine and check for leakage. 7. Smel Smelll ffor or fue fuell in tthe he bil bilge ge..

DANGER!  If you can smell fuel, turn the engine off immediately - EXPLOSION AND FIRE ARE AN EXTREME DANGER.

A    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

8. Clean Clean up th the e bilge bilge until until fuel fuel cannot cannot be be detecte detected d by smell. 22900 

Fuel Screen Cleaning (3.0 Liter Carb Engines) 1. Turn Turn of offf tthe he eng engin ine. e. 2. Disconn Disconnect ect th the e fuel line line at the the carburet carburetor or.. 3. Remov Remove e the fuel fuel inlet inlet nut, g gask asket, et, and and screen screen (B). 4. Clean the screen screen with with solven solvent, t, then allow it to dry. dry. 5. Reinstall Reinstall the screen, screen, gasket, gasket, and fuel inlet nut. 6. Tighte Tighten n the fuel fuel inle inlett nut s secu ecurely rely.. 7. Reconnect Reconnect the fuel fuel line line an and d tig tighten hten it securely securely.. 8. Clea Clean n up any any spil spille led d fuel fuel.. 9. Run the the bilge bilge blower blower for for at least five five minutes minutes to vent the engine compartment, then start the engine. 10. Smell Smell for fuel fuel in the bilge. bilge.

B 22829 

DANGER!  If you can smell fuel, turn the engine off immediately - EXPLOSION AND FIRE ARE AN EXTREME DANGER. 11. Clean up the bilge bilge until fuel fuel cannot be detected detected by smell.

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Maintenance

Electrical System

The engine’s electrical system features cranking, charging, ignition, and trim/tilt circuits. A battery and all necessary wiring wir ing provide power.

CAUTION! If electrical connections are reversed, or wires are disconnected when the key switch is ON or the engine is running, sensitive electrical components may be immediately damaged. Do not turn off the main battery switch until the engine has stopped. Battery Cables

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

The following are the minimum specifications for multistrand copper cables from the motor to the battery for all models. The maximum length is 20 feet regardless of cable diameter. 18633 

• 0 to 10 ft. (3.05 m) require a 1/0 AWG (80 MWG) cable.

• 10 to 15 ft. (3.05 to 4.6 m) require a 2/0 AWG (100 MWG) cable.

• 15 to 20 ft. (4.6 to 6.1 m) require requ ire a 3/0 AWG (120 MWG) cable.

CAUTION! Do not use aluminum core battery cables. Failure Failure to use battery batter y cables of recommended gauge and material could result in poor starting and electrical component damage. Batteries and Connections Note! Whenever you replace your batter y, read and understand the information supplied with it before you begin installation. Battery Requirements: All EFI engines engines ............. ................... ...... 650 CCA non-deep cycle cycle 5.0GL, 5.7GL engines .................................. 650 CCA 22827 

3.0GL, 4.3GL engines .................................. 360 CCA 1. The batt battery ery used used to star startt the engin engine e mus mustt be a 12-volt, heavy duty marine battery, with adequate amperage for the engine model installed on your boat.

Note! It is important that the battery batter y connections are correct. The negative battery cable must be attached to the negative terminal (–) on the battery, and the engine’s positive cable must be attached to the positive terminal (+) on the battery. 22826 

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CAUTION! Do not use deep cycle batteries on EFI engines. A deep cycle battery, while it may have enough cold cranking amps (CCA), will cause problems with EFI engines. The correct starting batter y for all Volvo Penta Penta EFI engines is a standard marine battery with a minimum of 650 CCA and a minimum of 135 minutes reserve ca-

22840 

pacity. 2. All other other batt batterie eries s mu must st be heav heavy y duty a and nd conconstructed for marine use. They can be either vented/refillable, maintenance- free, or deepcycle with a CCA or INCA rating.

3. Use bol bolts ts and nuts nuts to secure secure battery cables cables to the battery battery terminals. terminals. Do not not use wing wing nuts to secure secure battery battery cables, even if they were supplied with the battery. 4. Tighten Tighten all battery connections connections.. Loose battery battery connections connections may may cause damage damage to the engine’s engine’s electrica electricall system.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

5. Service ele electrical ctrical components components only only while the engine is off. off. Be careful when identifyin identifying g positive positive and negative negative battery cables and terminals. ter minals. If you touch the wrong ter terminal minal with a battery cable, even even briefly, the motor’s motor’s charging system may be damaged. The battery terminal must always behelp insulated. the battery mounting system CAUTION! not cover the connections, installconnections protective covers. This will preventIfshorting prevent or arcing at the battery batterdoes y terminals.

WARNING! Do not expose the battery to electrical electr ical sparks or an open flame. Do not use jumper cables and a booster battery to start star t the engine. Remove the battery from the boat to recharge. Do not recharge the battery in the boat. The service life of your battery depends largely on how it is maintained.

• Keep batteries dry and clean. Oxidation or dirt on the battery and battery terminals may cause short circuits, voltage drops, and discharges (especially in damp weather).

• Clean battery terminals and leads to remove oxi•

dation. Tighten cable terminals ter minals tightly. tightly.

• Spray battery terminals and connections with an anti corrosive agent, or coat them with petroleum  jelly..  jelly

• Check that all other electrical connections are dry and free of oxidation, and that there are no loose connections.

• Always switch switch off the charging circuit before removing the battery charger connectors.

• Inspect your battery at regular intervals for specific gravity (state of charge), individual cell water level, cleanliness and tight, greased connections.

• If the battery has become discharged for no apparent reason, check all electrical system components for malfunction or a switch left ON, before installing a recharged battery.

• Electrolyte levels should be above the plates in the battery and no higher than the fill indicator level. Top off if necessary, using distilled water. After topping off, run the engine at fast idle for at least 30 minutes to charge the battery.

Note! Some maintenance-free batteries have special instructions. Make sure to follow the battery manufacturers instructions ins tructions carefully. WARNING! Battery electrolyte is a corrosive acid and should be handled with care. If you spill or splash electrolyte on any par t of the body, immediately flush the exposed area with liberal amounts of water and seek medical attention as soon as possible.

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DANGER! Failure to follow the safety precautions below may result in electrical sparks igniting fuel vapors, and thereby causing fire or explosion. 1. Operate Operate b boat’ oat’s s bilg bilge e blower blower for at least least 5 minut minutes. es. Open engine cover or hatch and check the boat’s bilge area for gasoline fumes. If any fumes can be detected by smell, do not operate the boat until the source can be found, the spill cleaned up, and the cause corrected. 2. Do not not con connect nect cabl cables es to b batt attery ery until until all all oth other er electrical connections have been made. 3. Make Make sure th the e ignitio ignition n switch switch is OFF OFF befo before re removing or installing electrical equipment, checking any electrical connections, or installing battery cables.

Battery Replacement    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Note! When replacing your battery ba ttery,, read and understand the information supplied with it before you begin installation. 1. Batter Batteries ies mu must st be hea heavyvy-dut duty y and constr construct ucted ed for marine use. They can be either vented/refillable, maintenance-free, or deep-cycle with a CCA or MICA rating. Refer to the section entitled Techni-  cal Data  for  for the correct battery sizes. 2. Use bolts bolts and nuts nuts to to secure secure batt battery ery cables cables tto o the battery terminals. Do not use wing nuts to secure battery cables, even if they were supplied with the battery. 3. Loose Loose bat battery tery conne connecti ctions ons ca can n cause cause damag damage e to the engine’s electrical system. 22840 

4. Service Service elect electrica ricall com compon ponents ents only only while while the the motor is off. Be careful when identifying positive and negative battery cables and terminals. If you touch the wrong terminal with a battery cable, even briefly, briefly, the motor’s charging system could be damaged.

WARNING! The battery terminal connections must always be insulated. If the battery mounting system does not cover the connections, install protective covers. This will help prevent shorting or arcing at the battery terminals.

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DANGER! Fumes vented during battery charging may cause an explosion. 1. Do not not expose expose batte battery ry to elect electric rical al spark sparks s or an open flame. 2. Do not not use jumpe jumperr cables cables and and a booste boosterr battery battery to start engine. 3. If the batte battery ry compartm compartment ent is is not prope properly rly vent ventiilated, remove battery from boat to recharge. rechar ge. 4. If the batte battery ry has become become disch discharg arged ed (“dead (“dead”) ”) for for no apparent reason, check all electrical system components for malfunction or a switch left ON, before installing a recharged battery.

DANGER!  Failure to follow the safety precautions below may result in electrical sparks igniting fuel vapors causing fire or explosion. 1. Operat Operate e the boat’s boat’s bilge bilge blowe blowerr for at least least 5 minminutes. 2. Open Open the en engin gine e cov cover er or hatch hatch and and check check the the boat’s areaby forsmell, gasoline fumes. If any fumes can bebilge detected do not operate the boat until you find the source, clean up the spill, and correct the cause. 3. Do not not con connec nectt cab cables les to to battery battery until until all all other other electrical connections have been made. 4. Make Make sure the the ignitio ignition n switc switch h is OFF befo before re removing or installing electrical equipment, checking any electrical connections, or installing battery cables.

Multiple Batteries and Selector Switch    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

See your Volvo Penta Penta dealer for multiple battery installation recommendations. If your boat is equipped with multiple batteries and a selector switch, the engine should be operated with the selector switch set to the ALL position. This will provide charging system output to all batteries. A battery isolator is recommended if batteries will be switched for individual operation. 22827 

Distributor Cap and Rotor Remove, inspect and clean the distributor cap and rotor. Replace these components, if worn or damaged, with genuine Volvo Penta parts. No other distributor parts require service or replacement. Be sure spark plug leads are replaced in the correct firing order. Firing order information is provided in the section entitled Technical Data .

Circuit Breakers and Fuses The engine and boat’s electrical system is protected against current overload by a circuit breaker and fuses.

• If the circuit breaker trips, push its button to reset r eset it.

• Replace any blown fuses. CAUTION! Circuit breakers or fuses that repeatedly fail indicate a problem that requires r equires immediate attention. See your Volvo Penta dealer. Note! If electrical connections are reversed, or connections removed when the key switch is on or the engine is running, the electrical system may be immediately damaged.

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Spark Plugs Before installing new spark plugs, always check for proper type and gap1. Incorrect spark plugs can cause operational problems and possible internal engine damage. Before installing a spark plug, the spark plug seat in 1. Makeclean. the cylinder head torque shouldvalue be wiped Tighten plugs to the proper sure the spark plug terminals are fully seated on the spark plugs.

When spark plug leads are removed, be sure they are replaced in the correct firing order 1.

22842 

DANGER!  A

• Avoid Avoid abusive handling that could crack the spark plug’s ceramic body ( A). Damaged spark plugs can emit external sparks that could ignite any fuel vapors in the engine compartment, resulting in fire or explosion.

   M    A    6    2   :    2    2   :    3    0

• Do not operate engine if spark plug boots or high-tension leads are torn or cracked. This con-

   1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

dition could allow external sparks which could ignite any fuel vapors in the engine compartment, resulting in fire or explosion.

Checking and Changing Spark Plugs 1. Twist Twist and pull pull only only on on the spark spark plug plug w wire ire bo boot ot (pulling on wire may cause separation of the core of the wire).

A

2. Remov Remove e spark plug plugs s usin using g a 5/8-i 5/8-inch nch spark spark plug plug socket or a 5/8-inch box wrench. Use care to avoid cracking the spark plug insulators ( A). 3. Careful Carefully ly ins inspec pectt the ins insula ulator tors s and elec electrod trodes es of all spark plugs. 

Replace any spark plug which has a cracked or broken insulator or which has loose electrodes (B).



If the insulator is worn away away around the center electrode (C), or the electrodes are burned or worn, the spark plug is worn out and should be discarded.



Spark plugs that are in good condition, except for carbon or oxide deposits, should be thoroughly cleaned and gapped.

22842 

B

C

1. Refer Refer to the sect section ion entit entitled led Technical Data  for  for additional details.

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The spark plug wires are a special resistance type. The core is carbon-impregnated linen. This type wire is superior to copper core wire in its resistance to crossfire; howev however, er, it is more easily damaged than copper core. For this reason, pull on the spark plug boots to remove the spark plug wires, rather than pulling on the wire insulation. If the wire is stretched, theon core beinsulation. broken with no evidence of damage themay outer If the core is broken, it will cause misfiring. In the case of wire damage, it is necessary to replace the complete wire assembly since a satisfactory repair cannot be made. 4. Clean igniti ignition on wi wires res with with a cloth moistened moistened in kerkerosene, and wipe dry. Bend wires to check for brittle, cracked or loose insulation. Defective insulation may result in misfiring, cross-firing, or spark to ground; therefore, defective wires must be replaced.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

5. If the wires wires are are in good good condit condition ion,, clean clean any termiterminals that are corroded. Replace any that are broken or distorted. Replace any wires with broken or deteriorated cable nipples or spark plug boots.

8. When When spark p plug lugs s hav have e been thoro thorough ughly ly cleaned cleaned,, carefully inspect them for cracks or other defects that may not have been visible before cleaning. cleaning . 9. Use a roun round d wire wire feele feelerr gaug gauge e to ch check eck the the gap gap between the spark plug electrodes. electrod es. (Flat feeler gauges will not give a correct measurement if the electrodes are worn.) Adjust gap by bending the side electrode only. Bending the center electrode will crack the insulator. Setting the spark plug gap to any other specification in an attempt to improve idle or affect engine performance is not recommended. 10. See the diagrams ffor or correct installation installation of s spark park plugs and wires. For proper engine performance it is very important that the correct spark plugs be used. When installing spark plugs, make sure that the threads in the cylinder head and all surfaces on plugs and in cylinder heads are clean. Tighten spark plugs the specified amount. All engines use tapered seat plugs plu gs without gaskets.  Do not operate if spark plug DANGER! boots or high-tension leadsengine are torn or cracked. This condition can allow external sparks, which could ignite any fuel vapors in the engine compartment.

6. Cl Clea ean n spa spark rk plu plugs gs.. Spark plugs that have carbon or oxide deposits should be cleaned in a blast type spark plug cleaner. Scraping with a pointed tool will not properly remove the deposits and may damage the insulator. If spark plugs have a wet or oily deposit, dip them in a decreasing solvent and dry thoroughly with compressed air. Oily plugs will cause the cleaning compound to pack in the shell. Carefully follow the instructions of the manufacturer of the cleaner being used. Clean each plug until the interior of shell and entire insulator is cleaned. Avoid excessive blasting. 7. Examin Examine e interior interior of plug plug in good good light light.. Remov Remove e any cleaning compound with compressed air. If traces of carbon or oxide remain in plug, finish the cleaning with a light blasting operation. Clean firing surfaces of center and side electrodes with several strokes of a fine cut file.

2

3

 

2

3

4

4

5

6

6

7

8

3

2

 

1

1

1

5

4 1 2

6

3

5

8   4

3

1 4

6 2 7

5

22843 

Spark plug wires must be arranged between the distributor cap and spark plugs in the order of firing sequence. If spark plug wires are not correctly installed, misfiring or cross-firing will result. The 8.1Gi-B/GXi-A engines use a distributorless ignition system with one coil per cylinder. Refer to the section entitled Technical Data  for   for correct firing order information.

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Belt Adjustments CAUTION! To prevent possible injury injur y caused by someone inadvertently starting the engine, remove the ignition keys from each starting location (especially if the engine room/engine compartment cannot be seen from various remote starting positions such as a flybridge or enclosed cabin).

Serpentine Belt Engines Some engine models use a serpentine belt, which is a continuous-loop belt threaded through the alternator pulley, circulating pump pulley, idler pulley, and power steering pump pulley pulley.. This single belt replaces three separate belts (alternator, circulation pump, and power steering belts). The serpentine belt tension is adjusted automatically and requires no tension adjustments. However, at least once per year, have your Volvo Penta dealer check the serpentine belt for wear. An ideal time to have this check performed is when you have the gimbal bearing

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

21203 

lubricated. Alternatively,, you may check the indicators, located on Alternatively the automatic tensioner housing, to determine the amount of wear. When tick marks C & D coincide (8.1L engines) and mark B is centered between tick marks A (all other engines), it’s time to replace the serpentine belt.

22902  22901

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V-Belt V-B elt Engines Engine s

' /

The following engines use two separate V-belts which may occasionally have to be adjusted for tension: 4.3GL, 5.0GL, and 5.7GL.

CAUTION! These belts are heavy duty. duty. Do not replace with automotive belts. Following is a description of the dual belt system:

3 !

A – Alternator Belt (arrow indicates position to be used for checking belt tension). B – Circulating Pump Pulley. C – Crankshaft Pulley. D – Alternator Pulley.

0 7

E – Power Steering Belt (arrow indicates position to be used for checking belt tension). F – Power Steering Pump Pulley.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

22844 

V-Belt Tension Belt tension is determined by belt deflection. 1. With With the eng engine ine stoppe stopped, d, the be belt lt should should be tight tight enough so that it will deflect ¼ inch (6 mm) when pressed with a finger, or 75 ± 10 pounds (333.6 ± 44.5 N) when using a belt tension gauge. 2. If the the belt is too too tight, tight, e excessi xcessive ve belt belt a and nd be bearing aring wear can occur. 3. If it is too loose, loose, slip slippage page can oc occur cur,, resulting resulting in in belt wear, poor circulating pump, alternator, altern ator, and power steering operation. Belt tension should be checked after 10 hours of service and every 5 hours thereafter. thereaft er.

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Power Steering Pump Belt Note! Improper power steering belt adjustment will result in hard steering.

5

1

With engine OFF, OFF, check power steering pump (2) belt deflection midway between the circulating pump pulley and the power steering pump pulley (position E on previous image).

9

To increase belt tension:

2

1. Loosen Loosen pum pump p mountin mounting g bracket bracket scr screws ews (posit (position ions s 1, 3, and 5). 2. With With a b break reaker er b bar ar inserte inserted d in positio position n 4, increase belt tension by moving mounting bracket to the right.

8

3. While While mainta maintaini ining ng pre pressu ssure re on the mount mounting ing bracket, tighten the screw closest to the breaker bar (position 5), then tighten the other screws.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

4. Rech Rechec eck kb bel eltt tten ensi sion. on.

Alternator Belt

22847 

With engine OFF, OFF, check alternator belt deflection midway between the circulating pump pulley and the alternator pulley (position A on image on previous page).

: 4

To increase belt tension:

B

1. Loosen Loosen al alter ternat nator or mount mounting ing screw screws s and nuts nuts (positions 6 and 8). 2. Pivo Pivott tthe he altern alternat ator or (7) away from the circulating pump pulley (9) to increase belt tension. 3. While While mai mainta ntaini ining ng pres pressur sure e on the alternat alternator or,, retighten the screws and nuts.

C

4. Rech Rechec eck kb bel eltt tten ensi sion. on.

22846 

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Cooling System

Raw Water System Various Volvo Penta engines have a thermostat-controlled cooling system. 1. Cool Cool water water is drawn drawn in throug through h raw water water inta intake ke (A) by an impeller (C) connected to the raw water pump (D) mounted on the front of the engine.

7 '

2. Water ater is pumpe pumped d to the the engine engine and and rout routed ed by circirculating water through the cooling system ( B).

/

3. A thermos thermostat tat insi inside de the e engi ngine ne de determ termine ines s the amount of water to be taken in, recirculated, recircula ted, and discharged to control the engine’s operating temperatures.

!

21205 

Closed Cooling System (F-Series) Various Volvo Penta engines have a thermostat-controlled, recirculating type cooling system.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

1. Cool Cool water water is drawn drawn in throug through h raw water water inta intake ke (E) by an impeller (F) connected to the raw water pump (G) mounted on the front of the engine.

@

F E

0

1

2. Wat ater er is pump pumped ed (H) to the heat exchanger (I), which cools the engine cooling fluid ( J). The raw water is then routed to the exhaust manifolds where it is mixed with exhaust and dumped overboard through the sterndrive exhaust port.

D

3 ? 2 21207 

3. The engin engine e cool cooling ing flu fluid id is recircu recirculat lated ed betw between een the engine and the heat exchanger by the engine circulation pump (K). 4. A thermos thermostat tat insi inside de the e engi ngine ne de determ termine ines s the amount of water to be taken in, recirculated, recircula ted, and discharged to control the engine’s operating temperatures.

Engine Overheating (Gi & GXi only) If the engine overheats at high engine speeds, the engine protection mode feature will activate and:

• Engine speed will be automatically and gradually reduced to a maximum of 2500 RPM.

• The engine will operate normally only below 2500 RPM. On some models an optional audible warning horn has been installed on or under the instrument console. The warning horn will sound if the engine enters the engine protection mode.

• The engine protection mode feature will remain activated until the engine overheating problem is corrected.

CAUTION! Do not remove the thermostat from the engine as the engine is likely to overheat.

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Engine Overheating (All other Models) If your engine overheats, the audible alarm will sound and a temperature gauge on your instrument panel will indicate your engine is overheating. 1. Turn Turn of offf tthe he eng engin ine. e. 2. Tilt Tilt the dri drive ve up up and look look for o obstr bstruct uction ions s to the water intakes (e.g., seaweed, plastic bags, etc.). 3. Lowe Lowerr tthe he drive drive unit unit.. 4. Start Start engine engine an and d run iin n NE NEUTR UTRAL AL at 1 1500 500 RPM RPM.. 5. Check Check the the engine engine gauge gauge to verif verify y the condi condition tion.. 6. If overhe overheati ating ng sti stillll occurs occurs,, do not opera operate te the engine unless it is an emergency. Only operate it until you are clear of the emergency and seek a tow to shore.

21195 

CAUTION! Continuing to operate an overheating engine will cause engine damage.

   M    A    6    2   :    2    2   :    3    0

7. See your your Volvo Volvo Penta Penta dealer dealer for assistance. assistance.

Engine Flush

   1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Volvo Penta engines incorporate an engine flushing port designed to flush the engine with fresh water while the engine is running. If flushing the engine with the boat in the water, the engine should not be run higher than idle or sea water may be drawn in with the fresh water.

1

1. If tthe he engin engine e is runnin running, g, sh shut ut itit down. down.

2

2. Remov Remove e the blue blue pla plasti stic c cap from from the hose hose that that is clamped to the starboard side of the engine. It is marked with the running engine flush symbol (1). 3. Connect Connect a wate waterr hose from from a fres fresh h water water source source to the flush connector on the engine ( 2). 4. Turn wate waterr on full full and and start start the engi engine. ne. 5. Let engine engine idle until engine temper temperature ature stabili stabilizes zes at its normal operating range. This will allow the thermostat to open and ensure the fresh water circulates throughout the engine. 6. Aft After er engine engine is is flushe flushed, d, sh shut ut engine engine tthe he do down. wn. 7. Discon Disconnec nectt wat water er hose hose and rei reinst nstall all the the cap. cap.

22347 

CAUTION! When re-installing the blue cap on the fresh water flush hose, tighten it by hand, then tighten 1/4 turn using a wrench. If the cap is too loose, air may be sucked in, causing the engine to overheat, resulting in damage. Drain the engine if freezing temperatures are expected. For details on draining the engine, please refer to the section entitled Draining the Cooling System .

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Maintenance

Draining the Cooling System CAUTION! When temperatures drop below freezing, failure to completely drain the cooling system will result in serious damage to the engine and exhaust manifolds. To To assure complete drainage, probe all drain openings with a piece of wire to remove any blockage.

Note! The following steps are very important in protecting your engine from damage in freezing conditions. If unsure of how to perform any of the following steps, see your Volvo Volvo Penta dealer for a complete end-of-season/winterization service. Freeze damage to the engine package is not covered by your Volvo Penta limited warranty.

• Perf Perform orm these procedures with the boat out of    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

the water. It will prevent damage to cooling system components if temperatures drop below freezing.

22800 

• When draining the engine, raise or lower the bowprovide of the boat to keep the engineoflevel. This will for complete drainage the block and manifold. If the bow of the boat is higher or lower than the stern, some water may be trapped in the block.

Raw Water Cooled Engines 1. With With the en engin gine e turn turned ed off, off, locat locate e and open open the the engine drain petcocks (B) located on both sides of the engine block. /

CAUTION! Be sure that all water is drained from the engine. If no water drains when the petcocks are opened, remove the petcocks and use a piece of wire to clear any obstructions from the drain hole. Failure to drain all the water from the engine may result in engine damage during freezing temperatures. 2. Remove Remove drain plugs from exhaust exhaust manifolds manifolds (A). Raise or lower the bow of the boat to ensure complete drainage. After the water has completely drained, reinstall the drain plugs and torque to t o 29 N•m (22 lb. ft.).

! 22848 

3. Note the hose hose o orientati rientation on on the raw raw water pump. pump. Loosen the hose clamps and remove the hoses from the raw water pump. Crank the engine briefly,, (1 or 2 crankshaft revolutions) but do not briefly start the engine, to clear the water from the pump. Reinstall the hoses and secure the clamps in the same orientation as removed.

CAUTION! Failure to connect the raw water pump hoses in the correct orientation may damage the raw water pump impeller.

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Maintenance

Draining the Closed Cooling System 8.1 Liter Engines (F-Series) 1. With With the e engin ngine e tur turned ned off off lo locat cate e and loose loosen n the 1 lower end cap from the heat exchanger ( ). After water has completely drained, retighten the lower end cap of the heat exchanger. 2. Note Note the hose hose orienta orientatio tion n on the raw raw wate waterr pump pump (G). Loosen the hose clamps (2) and remove the hoses (E, H, & L) from the raw water pump and heat exchanger. Crank the engine briefly, briefly, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump. Reinstall the hoses and secure the clamps in the same orientation as removed. 3. Remove Remove drain plugs from exhaust exhaust manifolds manifolds.. Change the level of the boat to ensure complete drainage. After water is completely drained, reinstall drain plugs and torque to 29 N•m (22 lb. ft.).

21207     M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

CAUTION! Be sure the engine side of the system has adequate antifreeze it from the anticipated temperatures toto beprotect encountered. Failure to maintain adequate antifreeze an tifreeze may result in engine damage during freezing temperatures.

4.3 GL Draining Only When draining the 4.3 GL carburetted engine, be sure to remove the intake manifold drain plug, located behind the alternator tensioning ten sioning bracket , to drain any remaining water in the intake manifold. Otherwise, follow the directions below. below.

4.3, 5.0, and 5.7 Liter Engines (F-Series) Check the coolant level and antifreeze concentration (check antifreeze manufacturer’s instructions). Make sure the antifreeze’s freeze point is adequate for expected temperatures. To drain the raw water system of your Volvo Penta engine (with factory installed closed cooling):

D

1. With With the e engin ngine e tur turned ned off off lo locat cate e and loose loosen n the lower end cap from the heat exchanger (1). After water has completely drained, retighten the lower end cap of the heat exchanger.

? 2

3 1 22849 

2

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Maintenance

2. Note Note the hose hose orient orientati ation on on th the e raw water water pump pump (G). Loosen the hose clamps (2) and remove the hoses (E & H) from the raw water pump. Crank the engine briefly br iefly,, (1 or 2 crankshaft revolutions) but do not start the engine, to clear the water from the pump. Reinstall the hoses and secure the clamps in the same orientation as a s removed. 3. Remove Remove drain plugs from exhaust exhaust manifolds. manifolds. Change the level of the boat to ensure complete drainage. After water is completely drained, reinstall drain plugs and torque to 29 N•m (22 lb. ft.).

CAUTION! Ensure there is sufficient antifreeze in the closed side of the cooling system to protect the engine for the anticipated temperatures. Follow the antifreeze manufacturers instructions for proper water/antifreeze ratios.

Impeller: Checking & Replacing    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

WARNING! If the engine is installed so that the seawater pump is located under the water line, there is a risk of water penetration. If you have a seacock installed, close it now. now.

1

Note! Always carry a spare impeller on board. 1. Remove Remove the the hose hose clamps clamps and and hoses hoses ffrom rom pump pump.. 2. Remov Remove e the the stati stationa onary ry brac bracke kett (1). 3. Remove Remove the ffour our screws screws and remov remove e the housing (2).

2

  21208 

8

  9

4. Insp Inspec ectt tthe he im impe pellller er (3). If there are cracks or other defects, the impeller must be replaced. Inspect the O-ring (4) for nicks, cuts, and wear. Replace as necessary. 5. Lubrica Lubricate te the pum pump p housing housing wit with h non-p non-petro etroleu leum m based lubricant, suitable for rubber, such as soapy water or glycerine 6. Reinstall Reinstall the impell impeller er.. R Reinsta einstallll tthe he housing housing (2). 7. Instal Installl th the e hoses hoses and and h hose ose cla clamps mps.. 8. Mount Mount the stationa stationary ry b brac racket ket (1).

Steering System 1. Check Check steerin steering g and thr thrott ottle le cables cables fo forr cracks cracks and wear. Check all along the length of the cable, as shown in the diagram. Replace the cables if you suspect that they are not in optimum condition. 2. Check Check ste steering ering system hoses for cracks, cracks, leaks, leaks, and wear. Replace any hoses that you suspect are not in optimum condition. 22850 

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Maintenance

Power Steering Reservoir Fluid Level Whenever you check the engine oil, also remove the steering reservoir dipstick and check the fluid level. Wipe the dipstick and note the “hot” and “cold” fluid levels. If needed, add Volvo Penta Power Trim/Tilt and Steering Fluid. Do not overfill the pump reservoir.

CAUTION! Never fill the steering system with an oil of unknown quality. Non-recommended oil may cause steering operation impairment or component damage. Do not allow contaminants to enter the reservoir reser voir when checking or filling the oil level.

Power Trim/Tilt Fluid Level The power trim and tilt assembly contains an electric motor, hydraulic pump, and reservoir reser voir..

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

At the beginning of each boating season, check the fluid level in the reservoir: 1. With With the dr drive ive unit unit trim trimme med d in (down) (down) as as far as possible, remove the fill cap.

G+H GI(

2. Check Check the the fluid fluid level. level. It s shou hould ld be betwee between n the minimum and maximum marks on the reservoir. If needed, add Volvo Penta Power Trim/Tilt and Steering Fluid. 3. Replac Replace e the fi fillll cap and and tighte tighten n securely securely..

47564 

Shaft Spline and Bearing Lubrication The primary universal joint shaft splines and bearings must be lubricated each year and whenever the drive unit is removed. This procedure requires the removal of the drive unit; therefore, your Volvo Penta dealer should do it. An ideal time to have this done is during the winterization process or in the spring when preparing to launch for the first time. Failure Failure to have primary shaft splines and bearings lubricated each year may result in damage to the drive unit.

Tie Rod (Twin Installations Only) Check the rod connecting the drive units, particularly if you hit an obstacle. If the tie rod is bent, loose, or damaged, have it serviced immediately by your Volvo Volvo Penta dealer. In the meantime, operate your boat at slow speeds only.

22853 

WARNING! The tie bar is an integral part of the steering system and is a vital safety part. A damaged tie rod may hinder steering operation or render it completely ineffective inef fective.. Always replace a damaged tie bar. Never try to straighten or weld a damaged tie rod.

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Maintenance

Lubrication System

Engine/Crankcase Engine/Crankcas e Oil

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22815     M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

To obtain the best engine performance and engine life, Volvo Penta recommends synthetic engine oil labelled for API Service CF/SH, or you may use an engine oil with the recommended quality and viscosity. Engine oils are specified by API service, letter designations, and SAE viscosity numbers. Refer to oil identification symbol on the container. Initial factory fill is a high quality motor oil for API Service CF/SH. During the break-in period (20 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated. The oil level should be maintained between the ADD and FULL marks on the dipstick. The space between the marks represents approximately one quart (one liter). For oil level dipstick location, refer to the photographs in the section entitled Features . The sections entitled Technical Data  and   and the Mainte-  nance Schedule  provide  provide detailed information about oil filter type and service intervals.

Lowest Anticipated Temperature 32° F (0° C) — above 0° F (-18° C) — 32° F (0° C) Below 0° F (-18° C)

Recommended SAE Viscosity Oils SAE 301 SAE 20W/50 SAE 15W/50 SAE 20W-20 SAE 10W

1. Volv olvo o Pent Penta a Synthetic Synthetic Motor Motor Oil. If the reco recommen mmended ded oil is not available, use pure synthetic multi-viscosity oil.

When you add or change engine oil, use Volvo Penta engine oils for gasoline engines. Use the viscosity chart to select the SAE viscosity that matches the temperature range in which you expect to operate. The 3.0GL may use a mineral-based oil. However, However, this requires an oil change at 100 hour intervals or earlier. Switching between mineral based oils and synthetic oils is not recommended. Please refer to the section entitled Maintenance Schedule  for  for additional details. Use single viscosity oils in markets where available. The use of multi-viscosity oils such as 10W-30 and 10W-40 is not recommended unless single viscosity oils are unavailable. unavailable. At the end of the break-in period (20 hours), change the crankcase oil and replace the oil filter. Refer to the Maintenance Schedule for recommended oil change intervals.

WARNING! Use only parts that are U.S.C.G. approved for marine use. Substituting automotive or generally supplied parts and hardware may result in product malfunction and possible injury to the operator and/or passengers. Never use parts of unknown quality.

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Maintenance

Checking Engine Oil Level Remove the dipstick. The oil level must be between the two marks on the dipstick. Add oil as necessary to maintain the proper level.

Max Min

Note! Do not allow the crankcase oil level to go below the ADD mark, and do not fill above the FULL mark. Overfilling results in high operating temperatures, foaming (air in oil), loss of power, and overall reduced engine life.

1011021

Changing Engine Oil Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting, fuel econeco nomy,, combustion chamber deposits, and engine wear. omy Drain and refill the engine crankcase once each season or every 100 operating hours, whichever comes first. (Also see the maintenance schedule.) 1. Run the the engine engine a att idl idle e speed speed to warm warm the the crankcrankcase oil (for easier removal).

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

2. Turn of offf tthe he engin engine. e. 3. Remove Remove oil dipstic dipstick. k. Using Using the the sp special ecial fittin fitting g provided on the tube, drain the oil from the crankcase through the dipstick tube. This special fitting is provided so that the oil does not have to be drained into the bilge. 4. Withdr Withdraw aw oil with with a s suct uction ion pump pump..

Note! You may purchase either a manual or an electric suction pump from any marine supply store or from your Volvo Penta dealer. 5. Dispos Dispose e of used o oilil accord according ing to a any ny appli applicab cable le federal, state, and local environmental regulations. 1011024 

6. Repl Replac ace e tthe he oil oil ffililte terr. 7. Remove Remove the oil oil fi fillll cap cap and fill the crankcas crankcase e to the specified capacity with Volvo Penta premium engine oil.

Changing the Oil Filter Replace the oil filter whenever the engine oil is changed. This filter is a self-contained, screw-on type. 1. To remove, remove, unscr unscrew ew filter filter canister canister counte countercl rclock ock-wise. Dispose of used filter according to any applicable federal, state, and local environmental regulations. 2. When attachi attaching ng a new new filter filter,, be sure the the gasket gasket is lightly lubricated with motor oil. 3. Hand Hand-ti -tigh ghte ten n only only.. 4. Run engine engine and check check fo forr leaks leaks.. Do not run engine out of water. 21223 

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Maintenance

Drive Components The drive unit is filled at the factory with Volvo Penta GL 5 Synthetic Gear Oil.

Drive Unit Lubrication 22342 

Checking the Drive Unit Lubricant Every week, check the oil level in the drive dr ive unit (if possible, without removing the boat from the water). CAUTION! Fully thread the oil dipstick into the oil level hole in the drive unit to properly check the oil level. An improper oil level may result in serious drive unit damage.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Fully thread the dipstick into the hole, then remove and check the oil level.



Make sure that the oil level comes to the top of the flattened portion of the dipstick ( A).

34086 

• The oil should be amber-colored. oil will appear milky if any moisture • The is present.

• No metal flakes should appear in the oil. /

Note! On both the SX and DPS drives dr ives the drain plugs (B and C) are magnetized. Any metal flakes in the drive will generally attach to the drain plugs.

33836 

!

34645 



If moisture or metal flakes appear in the drive dr ive unit oil, take the boat to your Volvo Penta dealer.



If the oil level is low, add only enough lubricant to bring the oil level within the full range of the dipstick.



You should completely drain and refill the drive unit at least once per season.

Draining the Drive Unit 1. Place Place th the e drive drive unit unit in the rrun un (down) (down) posi positio tion. n.

Note! Special tools are required to t o remove Duoprop propellers. 2. DPS only: Remove propellers and mounting hardware. 7

3. Remov Remove e the the oil oil dr drain ain plu plug g (S (SX: X: B and DPS: C) and the oil level dipstick (A). 4. Allow Allow the drive unit to to drain drain com completel pletely y. Disp Dispose ose

22854 

of used oil according to applicable environmental regulations.

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Maintenance

Filling the Drive Unit 1. Remo Remove ve the the th thre ree es scr crews ews (1) securing the rear cover to access the oil level plug. 2. Remo Remove ve the the oil oil lev level el p plu lug g (3). 2 1

3. Fill the drive drive unit with Volvo Volvo Penta Penta GL 5 Synthetic Synthetic Gear Oil. Fill through the oil drain plug location (B  and C). Fill slowly to purge air. The drive unit is properly filled when the oil appears at the oil level plug hole.

CAUTION! Overfilling the drive can cause damage and shifting problems. 4. When filled filled to to the proper proper lev level, el, in install stall the oil oil level level dipstick (2) and oil level plug first (to prevent excessive oil loss), then the oil drain plug. 22860 

5. Tighten Tighten oil level level and and dra drain in plugs plugs securely securely.. 6. Install the rear rear cover cover and tighten tighten scre screws ws securely securely..

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

8

Note! If you cannot fill the drive unit through the oil drain plug, you can fill the drive by trimming it up a few degrees and filling it through the oil level plug. Reinstall the oil level plug, and place the drive in the run (down) position. Remove the dipstick and check the oil level. Reinstall the dipstick and tighten securely. securely. DPS only: Re-install the propellers. Y You ou may refer to the section entitled Propeller Care  for  for instructions on replacing the propeller.

22855 

7. Check Check the oil lev level el with with th the e dipstic dipstick k (oil must appear on the full range of the dipstick). Add oil if required through the dipstick hole. Please refer to the section entitled Technical Data  for  for drive unit oil capacity. your drive equipped a the Drive CAUTION! Spacer, you Ifwill need toisadd more oilwith than recommended amount. We urge you to use the dipstick to check the oil level whenev whenever er you are changing or topping up the oil.

!

Note! If the drive unit was filled through the oil level plug, wait 15 minutes before checking oil with the dipstick. This will help ensure all air is purged from the oil cavity. cavity. Leave the dipstick loose during the waiting period.

34645 

7

22854 

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VPA 7742705 English 06-2003

 

Maintenance

Sacrificial Anodes Sacrificial anodes are attached to the bottom of the gimbal housing and at the front of the gearcase above the anti-ventilation plate. Anodes are slowly eroded away by galvanic action and require inspection. Additionally, anodes that are subjected to frequent wetting to and dryingscale require odic scraping with sandpaper remove andperioxidation to maintain their effectiveness. Do not paint anodes, as this will destroy their effectiveness.

22861

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

When you need to purchase new anodes, see your Volvo Penta dealer. The material composition of Volvo Penta anodes meets U.S. Military Specification 18001-H. Some after-market anodes may not meet mil-specs and are larger in size. Using after-market sterndrive anodes may cause cavitation bubbles due to poor fit, which may lead to propeller erosion. You may order the anodes separately, or as part of an accessories kit. (The accessories kit also includes orings, oils, washers, seals, and bellows.)

Replacing Sacrificial Anodes 1. Inspect Inspect a anod nodes es every every 14 days, days, or more more frequen frequently tly if used in extremely salty water. If an anode is 2/3 its original size (1/3 eroded), replace it. 22861

Note! If you use a stainless steel propeller, additional sacrificial anodes may be required to handle the added corrosion potential. 2. Remov Remove e the two two screws screws holdin holding g the ano anodes des onto onto the gearcase and/or the gimbal housing. Set the screws aside; you will use them again. 3. Pu Pullll off off tthe he old old a ano node de.. 22861

4. Inse Insert rt the the new new an anod ode. e. 5. Se Secu cure re wit with h the the two two scre screws ws.. 6. Tighte Tighten n screws screws to these these torque torque spe specif cifica icatio tions: ns:

• 12–14 ft. lb. (16 – 19 Nm) for the gimbal housing anode.

• 60–84 in. lb. (6.8 – 9.5 Nm) for the gearcase anode. If additional electronic or electrical equipment is installed, each item should have an individual anode or grounding device and all grounding devices must be interconnected. Follow equipment manufacturers recommendations.

Note! When your boating is done mostly in fresh water, magnesium anodes must be used in place of the standard zinc anodes.

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Maintenance

Active Corrosion Protection System /

Your boat may be equipped with a Volvo Penta active corrosion protection system (APC). This system operates with very little current drain from the boat’s electrical system. It keeps the voltage potential in the area around the drive unit in a range that is not corrosive to aluminum. (This is accomplished by changing the charge of water molecules so that they do not remove electrons from the drive unit’s metal parts to cause corrosion.) If you do not have an active corrosion protection system already installed, you may purchase one from your authorized Volvo Penta dealer.

22251

1

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

The protection system’s control box has both red and green LED indicator lights (A). The lights will indicate the amount of protection that the unit is providing to protect the sterndrive and transom shield. The ACP system is designed to protect one sterndrive sterndr ive and transom shield assembly. assembly. If copper based antifouling paint is used or the drive is installed on a metal hull, the unit may be inadequate to protect the drive and transom shield. 1. The The gre green en LED LED (1) indicates the unit is adequately protected.

22863 

2

2. If tthe he gree green na and nd red red LEDs LEDs (2) are illuminated, the drive is protected but the system is drawing maximum power (between 3 to 150 mA) to protect the drive unit. Check the following conditions and solutions. 

Water too severely contaminated or polluted. Install additional anode on the transom and ground to drive unit.



T oo muchshield. unpainted on theexposed dr drive ive or transom Cleanmetal and paint metal on drive and transom shield. Please refer to the section entitled Painting the Drive  for  for paint repair procedures.



Corroded, missing, or painted anodes. Service or replace anode as required.



Stray current from shore power or surrounding boats. Disconnect shore power power,, wait 8 hours and recheck. If still present, temporarily relocate boat to another area away from the marina and check again.



Loose or corroded terminals on the electronic unit or battery. Clean and tighten connectors.



Copper bottom paint used and is in contact with the transom shield. Remove paint and ensure there is a 25mm (1 in.) border between transom shield and bottom paint.

22863 

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VPA 7742705 English 06-2003

 

Maintenance

3. If only only th the e red red LED LED (3) is illuminated, the drive is not adequately protected and may have one of the following conditions: 8



Water too severely contaminated or polluted. Install additional anode on the transom and ground to drive unit.



Too much unpainted metal on the dr drive ive or transom shield. Clean and paint exposed metal on drive and transom shield. Please refer to the section entitled Painting the Drive  for  for paint repair procedures.



Corroded, missing, or painted anodes. Service or replace anode as required.



Stray current from shore power or surrounding boats. Disconnect shore shor e power, wait 8 hours and recheck. If still present, temporarily relocate boat to another anoth er area away from the marina and check again.



Loose or corroded terminals on the electronic unit or battery. Clean and tighten connectors.



Copper bottom paint used and is in contact with the transom shield. Remove paint and ensure there is a 25mm (1 in.) border between transom shield and bottom paint.

22863 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

4. If no no LEDs LEDs a are re ill illum umin inat ated ed (4), the unit is not receiving power. Check the following conditions: 9

22863 

5

22254 



Dead battery. Check battery condition and charge as necessar y.



Loose connection or corroded terminals on the electronic control unit or battery. Clean and tighten the connectors.



Blown fuse. Replace defective fuse. The fuse (5) is located near the battery connectors.



Broken anode or reference sensor unit. Replace damaged unit. Follow the installation instructions included with the replacement unit, or see your authorized Volvo Penta dealer for service.

Note! The active corrosion protection system is designed to adequately protect one drive unit from galvanic corrosion under normal operating conditions. This system will not provide protection from stray currents emitted by a malfunctioning AC power source on your boat, the pier, or other boats in close proximity to yours. Although the zinc sacrificial anodes will last much longer with this system, they must still be cleaned and checked for material condition periodically periodically.. If any of the malfunction conditions continue to exist after completing the steps above, see your authorized Volvo Penta dealer for further service.

94

VPA 7742705 English 06-2003

 

Maintenance

Painting the Drive

Paint Application

SX and DP-S Drives

1. Treat Treat any b bare are alumi aluminum num w with ith chrom chromate ate conve converrsion coating.

The SX and DP-S sterndrives and transom shield use a silicon-alloy aluminum casting process. The process requires a unique paint repair procedure.

Preparation WARNING! Always follow the manufacturers instructions regarding personal protection when handling chemicals. You should always wear eye protection and gloves as a good work habit. 1. Remo Remove ve all all mar marin ine e grow growth. th.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

2. Rinse Rinse tho thorou roughly ghly w with ith water water.. The area area must must appear “wetted” or the surface is not clean and the paint will not adhere. 3. While the s surfa urface ce is still wet ffrom rom rinsing, rinsing, treat all bare aluminum with conversion solution. Brush the chromate solution on the surface. Add additional solution as necessary for 2 to 5 minutes to prevent it from drying on the surface. Rinse the surface thoroughly with water and allow to air dry. Follow the manufacturers instructions instr uctions exactly.

2. Use sand sandpape paperr or sandb sandblas lastt to remov remove e loose loose paint and corrosion. Use a medium grit aluminum oxide sandpaper. If sandblasting use 55 - 25 grit (0.2 - 0.7mm) aluminum oxide blasting media.

• If the chromate is allowed to dry anywhere on

CAUTION!  Do not use steel wool or emery cloth. Small pieces of steel or iron oxide used to produce steel wool and emery cloth will become embedded in the aluminum and cause severe corrosion.

• Do not blow dry the part with compressed air

the bare aluminum surface, chromic acid salts will form which will prevent paint adhesion and promote corrosion. Sand the surface to bare metal. unless it is completely free of dirt, oil and water.

• Do not heat the par t above 140°F before painting.

3. Wash Wash wi with th hot water and detergent detergent to remove remove all traces of oil and grease.

• Do not touch the treated surface with bare hands

4. Roughe Roughen n any paint painted ed areas areas that that will will be re-coat re-coated ed with a medium synthetic scouring pad or equivalent (i.e. 3M Scotchbrite™).

• The part should be primed soon after it dries, or

5. Rinse with water water thoroughly thoroughly and allow allow to air air dry. dry. Do not use a rag to wipe the area as some rags may have silicone. 6. Clean Clean the the entire entire area area with with an acid acid clea cleaner ner that that does not contain fluoride fluor ide (i.e. DuPont® 5717). Scrub surface with a synthetic scouring pad until it is completely “wetted,” where no water beads on the surface. Follow all local laws and regulations when using or disposing of any chemicals used in this process.

CAUTION!  Fluorine in a cleaner causes “smut” (a dark discoloration on silicon-alloy aluminum castings), and paint will not stick to “smut”. If this happens, sand the surface and start star t over using a different acid cleaner. 7. Rinse with water water thoroughly thoroughly and allow allow to air air dry. dry.

before painting. at least within 24 hours.

• It is best to let the part air dry, but if you must wipe the surface to speed up drying, use a lint free wipe not treated with anything that may contaminate the surface. Do not scrub the surface — wipe very lightly. 4. Where Where th the e pri primer mer coat is thin thin o orr whe where re the the sursurface 11415627 is unpainted, pr ime prime with Volvo Penta Penta primer P/N or an equivalent epoxy primer (i.e. PPG® Super Koropon). Do not apply primer over a glossy hard finish coat without roughening. Primer solvents must be allowed a llowed to evaporate and the primer must harden before applying the finish coat. Follow the label instructions for method applications, drying times, and proper disposal of residual product. 5. Apply finish coat. Volvo Volvo Penta Penta P Parts arts Catalogs Catalogs and and the Volvo Volvo Penta Parts and Accessories Accessor ies Catalog list part numbers for the finishing products that apply to your Volvo Volvo Penta product.

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VPA 7742705 English 06-2003

 

Maintenance

Propeller Care A damaged or unbalanced propeller will cause excessive vibration and a loss of boat speed. Under these conditions, stop the engine and check the propeller for damage. If the propeller appears damaged, have it checked by your Volvo Volvo Penta dealer. dealer. Always carry a spare propeller and replace the damaged propeller pr opeller as soon as possible. A rubber hub in the propeller is the shock absorber that minimizes damage to drive units and engines. If the rubber hub should begin to slip, it can be easily replaced at an authorized Volvo Volvo Penta dealer or propeller service ser vice station.

WARNING! Protect your hands from the sharp edges of the propeller blades. Wear gloves whenever you you remove or replace a propeller. Do not attempt to hold propellers by hand when you remove or install propellers and propeller nuts. Serious injury could result. CAUTION! Never continuously run with a damaged propeller. Running with a damaged propeller pro peller can result in drive unit and engine damage. Installing the SX Propeller CAUTION! Failure to install all components could result in loss of propeller and damage to drive unit next time the boat is operated.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

1. Ignit Ignitio ion n sw swit itch ch mus mustt be O OFF FF.. 1

2

8

2. Make Make sure sure the remot remote e control control is in NEUT NEUTRAL RAL.. 3. Coat Coat the full full length length of the the propell propeller er sha shaft ft and th the e inside of the propeller hub with Volvo Penta propeller shaft grease P/N 828250; removal of the propeller will be difficult if this is not done.

4

:

5 9

22864 

Propeller Replacement — SX

4. Place Place the tthrus hrustt bushin bushing g on the pro propel peller ler sh shaft aft with the inner taper toward the gearcase g earcase to match the taper on the propeller shaft. 5. Install Install the the propeller propeller onto the propelle propellerr sha shaft, ft, a alignligning splines, and push the propeller onto the thrust bushing until the splines are exposed.

Removing the SX Propeller

6. Install Install th thrust rust wash washer er on prop propelle ellerr shaft splin splines. es.

1. Ignit Ignitio ion n swit switch ch mus mustt be OFF OFF..

7. Shift Shift the re remot mote e control control into into RE REVER VERSE SE gear gear to lock the propeller shaft.

2. Make Make sure tthe he remot remote e contro controll is in NEUT NEUTRAL RAL.. 3. Remo Remove ve the co cott tter er pin pin (3) and keeper ( 4). 4. Shift the remote remote control into FORW FORWARD to lock lock the propeller shaft. 5. Remo Remove ve the prope propellller er nut nut (5) using a 1-1/16 wrench. 6. Remo Remove ve the th thrus rustt wash washer er (2), propeller (1), and thrust bushing (6). 7. Wipe Wipe the the pro propel pelle lerr shaf shaftt (7) clean. Inspect for fishing line; remove if present.

8. Install Install a and nd tighte tighten n the propel propeller ler nu nutt unti untill it is seated against the thrust washer. 9. Loosen Loosen the the nut, nut, the then n turn itit bac back k against against the the thrust washer until finger tight. Tighten the nut an additional 1/3 to 1/2 turn. 10. Index Index the keeper on the propel propeller ler nut until it is aligned with the cotter pin hole. 11. Install Install the cotter pin and bend bend the ends to secure; use a new cotter pin if necessary. 12. Shift the remote remote control into into NEUTRAL. NEUTRAL. The propeller should turn tur n freely freely.. Before your next outing, use a torque wrench to tighten thewasher, propellernut, to 70 – 80 ft. lb.cotter (96 –pin 108must Nm).beThe thrust keeper, and installed as shown.

96

VPA 7742705 English 06-2003

 

Maintenance

Propeller Replacement — DP-S Removing the DP-S Propeller This procedure requires you to use special tool Volvo Penta P/N 3855516. 1. Ig Igni nitio tion n swit switch ch mus mustt be OF OFF. F. 2. Make sure the the remote remote control control is in FORW FORWARD ARD tto o lock the propeller shaft. 3. Remov Remove e the the rear rear pro propel peller ler nut (3). 4. Remo Remov ve the the rear rear p pro rope pellller er (2). 5. Change Change the the remo remote te con control trol posi positio tion n to REV REVERS ERSE E to lock the propeller shaft. 6. Remov Remove e the the front front propell propeller er n nut ut (4).

8

7. Remov Remove e th the e fron frontt pr prop opell eller er (1).

2

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

8. Wipe the propell propeller er sh shaft aft c clean. lean. Inspect for fishing fishing line; remove if present.

Installing the DP-S Propeller CAUTION! Failure to install all components could result in loss of the propeller and damage to the drive unit the next time the boat is operated.

9 1

1. Ig Igni nitio tion n swit switch ch mus mustt be OF OFF. F. 2. Make sure the re remote mote control is in FORW FORWARD. ARD.

22865 

3. Coat Coat the full full length length of th the e propell propeller er sha shaft ft and th the e inside of the propeller hub with Volvo Penta propeller shaft grease P/N 828250; removal of the propeller will be difficult if this is not done. 4. Instal Installl the the front front pro propel pelle lerr (1). 5. Instal Installl th the e front front propell propeller er nut nut (4) and tighten it to 45 ft. lb. (60 Nm). 6. Shift Shift the re remot mote e control control into into RE REVER VERSE SE to lock lock the propeller shaft. 7. Insta Installll tthe he rea rearr pr prop opel elle lerr (2). 8. Install Install the rear pro propel peller ler nut (3) and tighten it to 50 ft. lb. (70 Nm). 9. Shift Shift the re remot mote e control control into into NE NEUTR UTRAL. AL. T The he propropeller should turn tur n freely.

97

VPA 7742705 English 06-2003

 

Maintenance

Boat Bottom

Engine Alignment

The condition of the boat’s bottom can affect your boat’s performance. Marine growth, present in fresh water as well as salt water, will reduce boat speed. A boat bottom with evidence of marine growth can cause a reduction in top speed of 20 percent or more.

Because of the special tools required, a Volvo Penta dealer must do the engine alignment. This should be done during off-season storage preparations.

Periodically clean the bottom of your boat following the manufacturer’s manufacturer’ s recommendations. recommendations. Bottom painting may also be desirable.

Bottom Painting If your boat is in water where marine growth is a problem, using an antifouling paint may reduce the growth rate. Be aware of laws that may limit your paint choice and its use.

• A pure Teflon®-based Teflon®-based agent is recommended. • Copper-based antifouling paint may be used.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

CAUTION!  Do not paint transom shield or drive with copper-based paint. If you do use copperbased paint on your boat and bottom, le ave a shield. leave 1-inch border between the paint the transom Failure to follow this instruction will result in severe corrosion of the transom shield and drive d rive system.

• Vinyl-butyl based antifouling paint is a recommended alternative. See your Volvo Penta dealer for an EPA-approved antifouling paint suitable for your area.

CAUTION! Failure to periodically check engine alignment may result in premature failure of the engine coupler. If you wish to align the engine e ngine yourself, please refer to Volvo Penta publication number 7741601, entitled In-  stallation: Sterndrive Gasoline Engines .

Engine Submersion 1. Remove Remove the the engine engine ffrom rom tthe he water water as as quickly quickly a as s possible. 2. Contact your local Volv olvo o Penta Penta dealer dealer for for servic service. e.

• Your dealer will need to drain all water from the engine and immediately lubricate all internal parts. electrical must also be dried and • All inspected fordevices water damage. 3. Frequent requently ly check check eng engine ine compa compartmen rtmentt for gasogasoline fumes and excessive water accumulation. In addition, make sure that the water depth in the bilge is kept well below the flywheel housing.

CAUTION! Delay in completing the above actions will result in extensive engine damage.

98

VPA 7742705 English 06-2003

 

Maintenance

Replacement Parts WARNING! Improper parts substitution can result in fire or explosion. Use genuine Volvo Penta parts when replacement parts are needed. Volvo Penta replacement parts are

• Rubber caps (manifold), hoses (water and

designed to meet USCG requirements and ABYC standards for marine applications.

• Fuel injector O-rings, injector fuel line pressure

Failure to use genuine Volvo Penta Penta parts may result in product malfunction and possible injury to the operator and/or passengers. In your Volvo Volvo Penta product, certain fuel and electrical system components have been designed to comply with U.S. Coast Guard regulations. Parts or components that comply with these regulations are designed so they will not emit fuel vapors or cause ignition of fuel vapors in the engine compartment.    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

• Fuel pumps, relays, filter, filter, and related par parts. ts.

To prevent explosion or fire, do not substitute automotive or general hardware parts for the following:

• Circuit breakers, alternator, and related wiring. • Starter and related wiring. • Distributor, distributor cap, spark plugs, high tension leads, and related ignition parts.

exhaust), and attaching clamps. relief valve and caps, fuel reservoir vent hose and cover gasket, high pressure fuel pump mounting O-rings, fuel pressure regulator, and fuel rails. Your Volvo Penta product was designed to operate in a marine environment. This can involve operating:

• At high RPM for long periods. • In salt or brackish water. • In water laden with silt and minerals. Substituting automotive or generally supplied parts and hardware may result in product malfunction and possible injury to the operator and/or passengers. Never use parts of unknown quality. See your Volvo Penta dealer. You can depend on your dealer to furnish expert service ser vice and Volvo Volvo Penta parts.

VPA 7742705 English 06-2003

 

Notes Maintenance

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

99

100

VPA 7742705 English 06-2003

 

Troubleshooting Troubleshooting

Troubleshooting - System Isolation The following troubleshooting guide is provided to help you isolate a malfunction of one or more of your boat’s systems. After determining which systems are affected by the malfunction, refer to the individual system troubleshooting charts to isolate the specific cause.

Table 1: System Isolation Engine should crank at specified RPM. If not, not , check for:

Cranking System

1. Disc Discha harge rged d or dea dead d batte battery ry.. 2. Loose Loose or or corro corroded ded connec connectio tions. ns. 3. Cranking Cranking System System Troubl Troubleshoot eshooting ing Chart Chart in the Electrica Electricall Ignition/Fuel Service Manual. Must have good spark at spark plugs. If not, check the: 1. Dist Distri ribu buto torr ca cap. p. 2. Coil Coil a and nd spa spark rk plu plug g lead leads. s.

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Ignition System

Engine Does Not Start

3. Ig Igni niti tion on ti timi ming ng.. 4. Au Auto toma mati tic c spark spark adva advance nce.. 5. Appropriate Appropri Ignition Ignition Troubl Troubleshoot eshooting ing Chart Chart in the Electrica Electrical/Igni l/Igni-tion/Fuelate Service Manual. 6. EFI EFI Models: Models: Ref Refer er to EFI EFI Diagnost Diagnostic ic Ma Manua nual. l. EFI Models: Refer to EFI Diagnostic Manual Carbureted Models: Carburetor accelerator pump should squirt fuel into the Venturi when throttle is advanced. If not, check the: 1. Fu Fuel el tan tank, k, val valves ves,, and and line lines. s.

Fuel System

2. Fu Fuel el pump pump and fi filt lter er.. 3. Carb Carbure ureto torr and and filt filter er.. 4. Boat Boat Fuel Syste System m Trou Troubl blesh eshooti ooting ng Chart. Chart. 5. Carbu Carbureto retorr Troub Troubles leshoot hooting ing Chart. Chart. 6. Engine Fuel System Troubleshoot roubleshooting ing Chart. Check the following: 1. Comp Compre ress ssio ion. n. 2. Ig Igni niti tion on sy syst stem em.. 3. Fuel Fuel and carb carburet uretor or and inje injecti ction on sy syste stem. m.

Engine Runs Improperly

4. Lubric Lubricat atio ion n syst system em.. 5. Cool Coolin ing g sy syst stem em.. 6. St Stern erndri drive ve and and prope propellller er.. 7. PCV val alv ve. 8. Engine Engine Trou Trouble blesho shooti oting ng Gu Guide ides. s.

101

VPA 7742705 English 06-2003

 

Troubleshooting

Engine Troubleshooting Guides EFI Engines Only: Refer to EFI Diagnostic Manual . These guides were written to help you trace the symptoms of the trouble to the source, without having to read through and prove every possibility. Much of the information here will be familiar to well informed mechanics. Also, many factors will seem insignificant but when you think of it, usually the toughest problem to troubleshoot is caused by the smallest error. The greatest aid to solving a service problem is information. Start gathering information and keep a detailed record of the symptoms of the malfunction. Keep a record of pertinent facts, such as:

• When did this trouble start? • How was the boat loaded? • Did the trouble occur suddenly or did d id it become    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

apparent gradually?

Whether servicing the boat’s systems yourself or having your product serviced by a certified Volvo Penta dealer, you will need this record of information to identify potential causes of the malfunction. Analyze this information and try to match it to similar situations you have experienced in the past. Keep in mind the fundamental rules:

• COMPRESSION - Mixture inducted into cylinder and compressed.

• SP SPARK ARK - Proper in intensity tensity at the proper time. • FUEL - Proper mixture of air and fuel. These are very old rules, but necessary for the engine to run. Use the following charts and the service information to which they refer. Do not try to remember tolerances, settings, measurements, etc., as they are written in the service ser vice manual. Leave your mind free to analyze the problem.

Following is a list of the troubleshooting guides which may be found on the pages indicated.

Title

Page

Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Engine Cranks, But Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Hard Starting - Cold Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Hard Starting - Hot Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Engine Runs Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Engine Noises and Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Engine Dies Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Engine Won’t Reach Operating RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Defective Engine Lubricating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Low Battery Voltage After After Short Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

102

VPA 7742705 English 06-2003

 

Troubleshooting

Engine Will Not Crank 

Starter Circuit - Check: 

Battery condition: weak, dead, sulfated, bad cells.



Battery cables–for loose or corroded connections.



Engine Cranks, But Will Not Start    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Shorted or open ignition switch. Starter motor and solenoid–for shorts, grounds, or open circuits.



Starter assist solenoid/starter relay. relay.



Circuit breakers.



Wiring, from battery to ignition switch.



See Electrical/Ignition/Fuel Service Manual .

 Ignition Circuit - Check: 

Primary circuit wiring, from ignition switch to ignition coil/ignition module.



Secondary circuit wiring, from coil to spark plug.



Spark plugs–for proper gap, fouling, burned electrodes, or cracked/dirty insulator.



See Electrical/Ignition/Fuel Service Manual .



Low battery voltage.

Fuel System - Check: 

Quantity and condition of fuel in boat tank.



Operation and flow capacity of boat anti-siphon valve.



Fuel tank vent is unrestricted.



Fuel tank pick-up screen is clean.



Correct diameter/unrestricted boat fuel lines.



Fuel shutoff and multiple tank valves are open and operating proper-



ly ly.. Fuel pump vent hose–for signs of fuel or oil that would indicate a fuel pump failure.



Fuel pump/relay/circuit breaker operation.



External fuel filter canister and carburetor filter.



Carburetor accelerator pump.



See Electrical/Ignition/Fuel Service Manual .

103

VPA 7742705 English 06-2003

 

Troubleshooting

Hard Starting - Cold Engine Ask these questions first:

Has Engine Always Done This? Check: 

Carburetor choke operation and adjustment.



Fuel lines for obstructions.



For debris inside fuel tank.



See Electrical/Ignition/Fuel Service Manual .

Was Engine Used For A Long Time? Check: 

For clean external canister and carburetor fuel filters.



Empty carburetor float bowl due to evaporation.



Water in fuel due to condensation.



Fuel quality deterioration.



See Electrical/Ignition/Fuel Service Manual .

Is This A New N ew Condition? Check:    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Carburetor choke operation and adjustment.



Carburetor accelerator pump.



Hard Starting - Hot Engine Ask these questions first:



Fuel system–for leaks, dirt, or obstructions. Engine timing and ignition system.



See Electrical/Ignition/Fuel Service Manual .

Has Engine Always Done This? Check: 

Carburetor choke operation and adjustment.



See Electrical/Ignition/Fuel Service Manual .

Is This A New N ew Condition? Check: 

Brand, type, or octane of fuel.



Spark plugs.



Water in fuel.



Condition of battery and cables.



Starter motor–for overheat damage.

Did Engine Refuse To Start After Being Run? Check: 

Ignition system primary circuit.



Ignition coil(s) and/or ignition module.



Engine timing.



Carburetor choke operation and adjustment.



See Electrical/Ignition/Fuel Service Manual .

104

VPA 7742705 English 06-2003

 

Troubleshooting

Engine Runs Rough If Fuel Injected, see EFI Di-  agnostic Manual 

If At Slow Speed - Check: 

Idle speed and idle mixture.



Engine timing and spark plugs.



Fuel pump pressure.

 

Water or contaminants in fuel. Carburetor or manifold vacuum leak.



Internal carburetor fuel leak.



See Electrical/Ignition/Fuel Service Manual .

If At High Speed - Check:

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Engine Noises and Vibrations



Air leak on suction side of fuel system.



Too low octane fuel.



Ignition system secondary circuit.



Engine timing.



Wrong model or size carburetor, improper main jets or power valve, defective secondary fuel circuit, or secondary vacuum diaphragm



failure. External canister and carburetor fuel filters.



Fuel pump pressure.



Engine compression.



Water or contaminants in fuel, or water in cylinders.



See General Information section and Electrical/Ignition/Fuel System Service Manual .

Valves - Hydraulic Lifters 

Rapping only when starting–oil star ting–oil too heavy for prevailing weather, v vararnish on lifter, oil needs to be changed.



Intermittent rapping–leakage at lifter check ball.



Idle noise–excessive leak down rate, faulty check ball seat. Generally noisy–excessive oil in crankcase, stuck lifter plunger.

 

Loud noise at operating temperature–scored lifter plunger, fast leak down rate, oil viscosity too light for prevailing weather or operating temperatures.



See appropriate Engine section.

Ignition System (Ping or Knock) 

Improper tuning.



Incorrect spark plug wire routing.



Use higher octane fuel.



See Electrical/Ignition/Fuel Service Manual .

105

VPA 7742705 English 06-2003

 

Troubleshooting

Engine Noises and Vibrations (Cont.)

Cooling System 

Supply pump.



Loose belts and/or pulleys.



See Cooling System  section.  section.

Mountings 

Loose, broken, or worn engine mounts.



Loose lag screws holding mounts to stringer. st ringer.

Crankshaft Balancer or Flywheel 

Loose bolt(s).

Alternator Loose pulley and/or worn bearings.



Loose mounting bolts.

Sterndrive

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Engine Overheats



Failed U–joints or gimbal bearing.



Damaged internal drive components.



Worn, bent, or broken propeller hub hu b or blades.



Loose, worn, or damaged engine coupler.

 Check: 

Actual engine temperature by verifying with an accurate a ccurate thermometer.



Gauge operation and wiring circuit.



Sending unit operation and wiring circuit.



Supply pump, circulating pump, and belt(s).



Water intake screens–for blockage.



Thermostat.



Water supply hoses.



Engine timing.



Water leaks on pressure side of supply pump.



Air leaks on suction side of supply pump.



Engine compression.

106

VPA 7742705 English 06-2003

 

Troubleshooting

Engine Dies Out

Loss Of–Or Out Of–Fuel - Check: 

Fuel gauge operation and wiring.



Fuel level in tank.



Water or debris in fuel.



   M    A    6    2   :    2    2   :    3



Fuel pickup tube and screen blockage. Fuel tank vent blockage.



Plugged external canister or carburetor fuel filters.



Air leak on suction side of fuel system.



Fuel leak on pressure side of fuel system.



Inoperative, restricted, or incorrectly incorr ectly sized anti-siphon valve.



Boat fuel lines too small in diameter.



Fuel pump pressure and suction.



Carburetor cleanliness and operation.



See Electrical/Ignition/Fuel Service Manual .

Loss Of Ignition - Check:

   0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Primary and secondary ignition circuits.



Ignition switch.



Circuit breakers.



Wiring between engine and dash.



Main engine harness wiring.



See Electrical/Ignition/Fuel Service Manual .

Engine Stops Or Dies Out Due To To Seizure - Check:

Engine Won’t Reach Operating RPM



Vertical drive for internal damage.



Oil pressure gauge and crankcase oil level.



Temperature gauge and cooling system operation.



Internal engine components as required.

Check: 

Fuel type or octane.



Propeller pitch or diameter, damaged blades, or slipping hub.



Crankcase oil volume.



Marine growth on hull and drive.



Wrong Sterndrive gear ratio.



Operating at high altitude.



Restricted carburetor air intake.



Restricted exhaust outlets in engine, transom bracket, or drive.



Poor cylinder compression.

107

VPA 7742705 English 06-2003

 

Troubleshooting

Engine Won’t Reach Operating RPM (Cont.)

 (Cont.) - Check: C heck: 

Carburetor size and type correct for engine.



Fuel pump pressure and vacuum.



Boat overloaded or load improperly placed.



Defective Engine Lubricating System

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7



Engine overheating. Engine timing and ignition system operation.



Remote control cables and linkage for proper attachment and travel.

Engine Components - Check: 

Clogged or incorrect oil filter.



Worn oil pump gears, g ears, cover, cover, or shaft.



Worn or collapsed oil pump relief valve spring or foreign material caught on valve seat.



Oil pump relief valve plunger loose in cover.



Damaged filter bypass grommet.



Clogged oil pickup screen, broken tube, or housing.



Plugged crankshaft or blocked oil galleys.



Dirty or defective hydraulic lifters or clogged push rod passages.



Poor quality, quality, or incorrect viscosity or quantity of oil.



Incorrect hose routing on remote filter systems.



Water in crankcase oil from condensation, or defective head gasket, oil cooler, or cracked manifold/block manifold/block water passages.

Oil Pressure Warning System - Check: 

Oil gauge/warning horn operation and wiring.



Engine temperature.



Oil pressure gauge and warning horn sender operation and wiring.

108

VPA 7742705 English 06-2003

 

Troubleshooting

Low Battery Voltage After Short Storage

Engine/Boat Components - Check: 

All electrical accessories including ignition circuit off.



Disconnect main battery batter y negative cable from battery batter y.



Connect ammeter or voltmeter in series between negative battery cable and negative battery post:

• Meter reading of “0” indicates no draw; test battery and charging system.

• Meter movement no matter how slight indicates draw from battery. 

Disconnect main engine harness 10-Pin Connector:

• Meter drops back to “0” indicates problem caused by boat system; continue to isolate each boat electrical accessory until problem is found.

• Meter does not drop back to “0” “0 ” indicates problem caused by    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

engine electrical system; continue to isolate each engine electrical accessory until problem is found. 

Repair or replace components as necessary necessary..

VPA 7742705 English 06-2003

 

Troubleshooting Notes

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

109

110

VPA 7742705 English 06-2003

 

Technical Data Technical Data

Engine

3.0GLM-C, 3.0GLP-C

Bore and stroke. . . . . . . . . . . . . . . . . . . . Cylinders (number) . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . Full throttle operating range . . . . . . . . . .

4.00 x 3.60 inches (101.60 x 91.44 mm) 4 in-line 3.0 liters (181 Cu. In.) 1–3–4–2 4200 – 4600 RPM

Idle RPM (fixed) (fixed) . . . . . . . . . . . . . . . . . . . 650 – 750 RPM in forward gear

Fuel System Carburetor . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . Fuel filter (in fuel pump) . . . . . . . . . . . . . Fuel filter location . . . . . . . . . . . . . . . . . . Fuel type . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustable idle circuit, fixed m main ain fuel jets, electric choke Mechanical Water separating 10 micron fuel filter filter,, V Volvo olvo Penta Penta Part no. 3855104 Refer to photographs on Features pages. Inside the U.S.: 87 octane (AKI) unleaded gasoline Outside the U.S.: 90 octane (RON) unleaded gasoline

Electrical System    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 360 Cold Cranking Amp (CCA) rating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1.7kW output, planetary reduction gear

Ignition System

Distributor . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing . . . . . . . . . . . . . . . . . . . . . Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Spark plug gap . . . . . . . . . . . . . . . . . . . . Spark plug installation torque . . . . . . . . .

Delco EST 2° A ATDC, TDC, special tool Volvo Volvo Penta Penta part no. 885163 required Volvo P Penta enta Part no. 3854399 0.045 inches (1.14 mm) 27 N•m (20 ft. lb lb.) .)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Crankshaft mounted variable volum volume e flexible impell impeller er pump Recirculating pump . . . . . . . . . . . . . . . . . Fixed impel impeller ler belt driven pump on engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . 71°C (160°F) V Volvo olvo Penta Penta part no. 3853799

Oil Capacity Engine without filter. . . . . . . . . . . . . . . . . Engine with filter . . . . . . . . . . . . . . . . . . . Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter location. . . . . . . . . . . . . . . . . . . .

3.5 quarts (3.3 liters) 4 quarts (3.8 liters) Approximately 2.2 quarts (2.1 liters) Volvo Penta Penta Part no. 835440 Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . Power Pow er steering fluid U.S. U.S... . . . . . . . . . . . . Power Pow er steering fluid non non-U.S -U.S.. . . . . . . . . .

Volvo Penta Penta Premium engine oil labeled for API Service CF/SH Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Volvo P Penta enta power steering fluid Part no. 3851039 ATF oil Dexron 2 Part no. 1161941

Note! V  Volvo olvo Penta of the Americas, Inc., reserves the right to make changes in weight, construction, materials, or specifications without notice or obligation.

111

VPA 7742705 English 06-2003

 

Technical Data

Engine

4.3GL-D

Bore and stroke . . . . . . . . . . . . . . . . . . . . 4.000 x 3.480 in. (101.60 x 88.39 mm) Cylinders (number). . . . . . . . . . . . . . . . . . 90° V-6 V-6 Displacemen Displa cementt . . . . . . . . . . . . . . . . . . . . . . 4.3 liters liters (262 Cu. Cu. In.) Firing order. order . . . . . . . . . . . . . . . . . . . . . . . . 1 – 6 – 5 – 4 – 3 – 2 Full throttle throttle operating operating range range . . . . . . . . . . . 4200 – 4600 RPM Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . 550 – 650 RP RPM M in forward forward gear gear

Fuel System Carburetor . . . . . . . . . . . . . . . . . . . . . . . . Adjustable idle circuit, fixed main fuel jets, jets, electric choke Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . Electric Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Water separating 10 micron fuel filter filter,, V Volvo olvo Penta Penta Part no. 3862228 Fuel type . . . . . . . . . . . . . . . . . . . . . . . . . Inside the U.S.: 87 octane (AKI) unleaded gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside the U.S.: 90 octane (RON (RON)) unleaded gasoline

Electrical System

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 360 Cold Cranking Amp (CCA) rrating ating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1. 1.7kW 7kW output, output, planetary planetary reduction ge gear ar

Ignition System Distributor.. . . . . . . . . . . . . . . . . . . . . . . . . Delco EST Distributor Ignition timing . . . . . . . . . . . . . . . . . . . . . . 1° BTDC special tool V Volvo olvo Penta Penta part no. 885163 required Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Volvo P Penta enta Part no. 3861632 Spark plug gap . . . . . . . . . . . . . . . . . . . . . 0.060 inches (1.50 mm) Spark plug installation torque. . . . . . . . . . 27 N•m (20 ft. llb.) b.)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Crankshaft mounted variable vol volume ume flexible im impeller peller pump Recirculating pump . . . . . . . . . . . . . . . . . Fixed impeller belt driven driven pump on engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 71°C (160°F) V Volvo olvo Penta Penta part no. 3862835

Oil Capacity Engine without filter . . . . . . . . . . . . . . . . . 4 quarts (3.8 liters) Engine with with filter. . . . . . . . . . . . . . . . . . . . 4.5 quarts (4.3 liters) liters) Drive unit SX . . . . . . . . . . . . . . . . . . . . . . approximately 2.2 quarts (2.1 liters) Drive unit DP-S . . . . . . . . . . . . . . . . . . . . approximately 2.5 quarts (2.4 liters) Engine Oil filter. filter . . . . . . . . . . . . . . . . . . . . . Volvo P Penta enta Part no. 841750 Oil filter location . . . . . . . . . . . . . . . . . . . . Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. . . . . . . . . . . . . . Volvo Pe Penta nta power steering fluid Part no. 3851039 Power steering fluid non-U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

112

VPA 7742705 English 06-2003

 

Technical Data

Engine

4.3GXi-E, 4.3GXi-EF

Cylinders (number) . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . Bore and stroke. . . . . . . . . . . . . . . . . . . . Full throttle operating range . . . . . . . . . .

90° V-6 V-6 262 cubic inches (4.3 liters) 1–6–5–4–3–2 4.000 x 3.480 in. (101.60 x 88.39 mm) 4400 – 4800 RPM

Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . 600 RPM

Fuel System Fuel injection. injection . . . . . . . . . . . . . . . . . . . . . . Fuel pumps . . . . . . . . . . . . . . . . . . . . . . . Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter location . . . . . . . . . . . . . . . . . . Fuel type . . . . . . . . . . . . . . . . . . . . . . . . .

Port injection Electric Volvo Penta Penta P/N 3862228 Refer to photographs on features pages. Inside the U.S.: 87 octane (AKI) unleaded gasoline Outside the U.S.: 90 octane (RON) unleaded gasoline

Electrical System    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 650 Cold Cranking Amp (CCA) rating (135 minute reserve reser ve capacity) CAUTION! CAUTION! Do not use a deep cycle battery as the start battery. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1.7kW output, planetary reduction gear

Ignition System Distributor . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing . . . . . . . . . . . . . . . . . . . . . Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Spark plug gap . . . . . . . . . . . . . . . . . . . . Spark plug installation torque . . . . . . . . .

Delco EST 10° BTDC Fix Fixed ed Volvo P Penta enta Part no. 3861632 1.50 mm (0.060 inches) 27 N·m (20 ft. lb lb.) .)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Recirculating pump . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . GXi-EF . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft mounted variable volum volume e flexible impell impeller er pump Fixed impel impeller ler belt driven pump on engine 71°C (160°F) V Volvo olvo Penta Penta part no. 3862835 Closed cooling heat exchanger mounted on engine.

Closed Cooling System Thermostat . . . . 76°C (170°F) Volvo Volvo Penta Penta part no. 875788

Oil Capacity

Engine without filter. . . . . . . . . . . . . . . . . Engine with filter . . . . . . . . . . . . . . . . . . . Drive unit SX . . . . . . . . . . . . . . . . . . . . . . Drive unit DP-S . . . . . . . . . . . . . . . . . . . . Engine Oil filter . . . . . . . . . . . . . . . . . . . . Oil filter location. . . . . . . . . . . . . . . . . . . .

3.8 liters (4 quarts) 4.7 liters (5 quarts) 2.1 liters (2.2 quarts) 2.4 liters (2.5 quarts) Volvo P Penta enta Part no. 841750 Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. U.S... . . . . . . . . . . . . Volvo P Penta enta power steering fluid Part no. 3851039 Power Pow er steering fluid non non-U.S -U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

113

VPA 7742705 English 06-2003

 

Technical Data

Engine

5.0GL-E

Bore and stroke . . . . . . . . . . . . . . . . . . . . 3.740 x 3.480 inches (95.00 x 88.39 mm) Cylinders (number). . . . . . . . . . . . . . . . . . 90° V-8 V-8 Displacemen Displa cementt . . . . . . . . . . . . . . . . . . . . . . 305 cubic cubic inches (5.0 (5.0 liters) liters) Firing order. order . . . . . . . . . . . . . . . . . . . . . . . . 1 – 8 – 4 – 3 – 6 – 5 – 7 – 2 Full throttle throttle operating operating range range . . . . . . . . . . . 4400 – 4800 RPM Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . 550-650 RPM

Fuel System Carburetor . . . . . . . . . . . . . . . . . . . . . . . . Adjustable idle circuit, fixed main fuel jets, jets, electric choke Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . Electric Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Water separating 10 micron fuel filter filter,, V Volvo olvo Penta Penta Part no. 3862228 Fuel type . . . . . . . . . . . . . . . . . . . . . . . . . Inside the U.S.: 87 octane (AKI) unleaded gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside the U.S.: 90 octane (RON (RON)) unleaded gasoline

Electrical System

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 650 Cold Cranking Amp (CCA) rrating. ating. Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1. 1.7kW 7kW output, output, planetary planetary reduction ge gear ar

Ignition System Distributor.. . . . . . . . . . . . . . . . . . . . . . . . . Delco EST Distributor Distributor module sensor gap . . . . . . . . . 0,203 mm (0.008 inches) nonmagnetic ffeeler eeler gauge required. Ignition timing . . . . . . . . . . . . . . . . . . . . . . 10° BTDC (special tool V Volvo olvo Penta Penta part no. 885163 required) Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Volvo P Penta enta P/N 3861632 Spark plug gap . . . . . . . . . . . . . . . . . . . . . 0.060 inches (1.50 mm) Spark plug installation torque. . . . . . . . . . 27 N·m (20 ft. lb lb.) .)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Crankshaft mounted variable vol volume ume flexible im impeller peller pump Recirculating pump . . . . . . . . . . . . . . . . . Fixed impeller belt driven driven pump on engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 71°C (160°F) V Volvo olvo Penta Penta part no. 3862835

Oil Capacity Engine without filter . . . . . . . . . . . . . . . . . 5 quarts (4.7 liters) Engine with filter. . . . . . . . . . . . . . . . . . . . 6 quarts (5.7 liters) Drive unit unit . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 quarts (2.1 (2.1 liters) liters) Drive unit unit DP . . . . . . . . . . . . . . . . . . . . . . 2.5 quarts (2. (2.4 4 liters) liters) Engine Oil filter. filter . . . . . . . . . . . . . . . . . . . . . Volvo P Penta enta P/N 3850559 Oil filter location . . . . . . . . . . . . . . . . . . . . Refer to photographs on features pages. Oil filter location . . . . . . . . . . . . . . . . . . . . Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. . . . . . . . . . . . . . Volvo Pe Penta nta power steering fluid Part no. 3851039 Power steering fluid non-U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

114

VPA 7742705 English 06-2003

 

Technical Data

Engine

5.0GXi-E, 5.0GXi-EF

Bore and stroke. . . . . . . . . . . . . . . . . . . . Cylinders (number) . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . Full throttle operating range . . . . . . . . . .

3.740 x 3.480 inches (95.00 x 88.39 mm) 90° V-8 V-8 305 cubic inches (5.0 liters) 1–8–4–3–6–5–7–2 4600 – 5000 RPM

Idle RPM (fixed) . . . . . . . . . . . . . . . . . . . 600 RPM

Fuel System Fuel injection. injection . . . . . . . . . . . . . . . . . . . . . . Fuel pumps . . . . . . . . . . . . . . . . . . . . . . . Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter location . . . . . . . . . . . . . . . . . . Fuel type . . . . . . . . . . . . . . . . . . . . . . . . .

Port injection Electric Volvo Penta Penta P/N 3862228 Refer to photographs on features pages. Inside the U.S.: 87 octane (AKI) unleaded gasoline Outside the U.S.: 90 octane (RON) unleaded gasoline

Electrical System    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 650 Cold Cranking Amp (CCA) rating (135 minute reserve reser ve capacity) CAUTION! CAUTION! Do not use a deep cycle battery as the start battery. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1.7kW output, planetary reduction gear

Ignition System Distributor . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing . . . . . . . . . . . . . . . . . . . . . Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Spark plug gap . . . . . . . . . . . . . . . . . . . . Spark plug installation torque . . . . . . . . .

Delco EST 10° BTDC Fix Fixed ed Volvo P Penta enta Part no. 3861632 1.50 mm (0.060 inches) 27 N·m (20 ft. lb lb.) .)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Recirculating pump . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . GXi-EF . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft mounted variable volum volume e flexible impell impeller er pump Fixed impel impeller ler belt driven pump on engine 71°C (160°F) V Volvo olvo Penta Penta part no. 3862835 Closed cooling heat exchanger mounted on engine.

Closed Cooling System Thermostat . . . . 76°C (170°F) Volvo Volvo Penta Penta Part no. 875788

Oil Capacity

Engine without filter. . . . . . . . . . . . . . . . . Engine with filter . . . . . . . . . . . . . . . . . . . Drive unit SX . . . . . . . . . . . . . . . . . . . . . . Drive unit DP. . . . . . . . . . . . . . . . . . . . . . Engine Oil filter . . . . . . . . . . . . . . . . . . . . Oil filter location. . . . . . . . . . . . . . . . . . . .

5 quarts (4.7 liters) 6 quarts (5.7 liters) 2.2 quarts (2.1 liters) 2.5 quarts (2.4 liters) Volvo Penta Penta P/N 3850559 Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. U.S... . . . . . . . . . . . . Volvo P Penta enta power steering fluid Part no. 3851039 Power Pow er steering fluid non non-U.S -U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

115

VPA 7742705 English 06-2003

 

Technical Data

Engine

5.7GL-E

Bore and stroke . . . . . . . . . . . . . . . . . . . . 4.000 x 3.480 inches (101.60 x 88.39 mm) Cylinders (number). . . . . . . . . . . . . . . . . . 90° V-8 V-8 Displacemen Displa cementt . . . . . . . . . . . . . . . . . . . . . . 5.7 liters liters (350 cubic inches) inches) Firing order. order . . . . . . . . . . . . . . . . . . . . . . . . 1 – 8 – 4 – 3 – 6 – 5 – 7 – 2 Full throttle throttle operating operating range range . . . . . . . . . . . 4400 – 4800 RPM Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . 550 – 650 RP RPM M in forward forward gear gear

Fuel System Carburetor . . . . . . . . . . . . . . . . . . . . . . . . Adjustable idle circuit, fixed main fuel jets, jets, electric choke Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . Electric Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Water separating 10 micron fuel filter filter,, V Volvo olvo Penta Penta Part no. 3862228 Fuel type . . . . . . . . . . . . . . . . . . . . . . . . . Inside the U.S.: 87 octane (AKI) unleaded gasoline Outside the U.S.: 90 octane (RON) unleaded gasoline

Electrical System

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 650 Cold Cranking Amp (CCA) rrating. ating. Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1. 1.7kW 7kW output, output, planetary planetary reduction ge gear ar

Ignition System Distributor.. . . . . . . . . . . . . . . . . . . . . . . . . Delco EST Distributor Ignition timing . . . . . . . . . . . . . . . . . . . . . . 12° BTDC (special tool V Volvo olvo Penta Penta part no. 885163 required) Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Volvo P Penta enta part no. 3861632 Spark plug gap . . . . . . . . . . . . . . . . . . . . . 0.060 inches (1.50 mm) Spark plug installation torque. . . . . . . . . . 27 N·m (20 ft. lb lb.) .)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Crankshaft mounted variable vol volume ume flexible im impeller peller pump Recirculating pump . . . . . . . . . . . . . . . . . Fixed impeller belt driven driven pump on engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 71°C (160°F) V Volvo olvo Penta Penta part no. 3862835

Oil Capacity Engine without filter . . . . . . . . . . . . . . . . . 5 quarts (4.7 liters) Engine with filter. . . . . . . . . . . . . . . . . . . . 6 quarts (5.7 liters) Drive unit unit SX . . . . . . . . . . . . . . . . . . . . . . 2.2 quarts (2. (2.1 1 liters) liters) Drive unit unit DP . . . . . . . . . . . . . . . . . . . . . . 2.5 quarts (2. (2.4 4 liters) liters) Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Part no. 3850559 Oil filter location . . . . . . . . . . . . . . . . . . . . Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. . . . . . . . . . . . . . Volvo Pe Penta nta power steering fluid Part no. 3851039 Power steering fluid non-U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

116

VPA 7742705 English 06-2003

 

Technical Data

Engine

5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.7GXi-FF

Bore and stroke. . . . . . . . . . . . . . . . . . . . Cylinders (number) . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . Full throttle operating range . . . . . . . . . .

4.000 x 3.480 inches (101.60 x 88.39 mm) 90° V-8 V-8 5.7 liters (350 cubic inches) 1–8–4–3–6–5–7–2 4600 – 5000 RPM

Idle RPM (fixed) (fixed) . . . . . . . . . . . . . . . . . . . 600 RPM

Fuel System Fuel injection. injection . . . . . . . . . . . . . . . . . . . . . . Fuel pumps . . . . . . . . . . . . . . . . . . . . . . . Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Fuel filter location . . . . . . . . . . . . . . . . . . Fuel type . . . . . . . . . . . . . . . . . . . . . . . . .

Port injection Electric Volvo Penta Penta Part no. 3862228 Refer to photographs on features pages. Inside the U.S.: 87 octane (AKI) unleaded gasoline Outside the U.S.: 90 octane (RON) unleaded gasoline

Electrical System    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 650 Cold Cranking Amp (CCA) rating (135 minute reserve reser ve capacity) CAUTION! CAUTION! Do not use a deep cycle battery as the start battery. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1.7kW output, planetary reduction gear

Ignition System Distributor . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing . . . . . . . . . . . . . . . . . . . . . Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Spark plug gap . . . . . . . . . . . . . . . . . . . . Spark plug installation torque . . . . . . . . .

Delco EST 10°BTDC Fixed Fixed Volvo P Penta enta Part no. 3861632 1.52 mm (0.060 inches) 27 N·m (20 ft. lb lb.) .)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Recirculating pump . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . Gi-EF/GXi-FF . . . . . . . . . . . . . . . . . . . . .

Crankshaft mounted variable volum volume e flexible impell impeller er pump Fixed impel impeller ler belt driven pump on engine 71°C (160°F) V Volvo olvo Penta Penta part no. 3862835 Closed cooling heat exchanger mounted on engine.

Closed Cooling System Thermostat . . . . 76°C (170°F) Volvo Volvo Penta Penta Part no. 875788

Oil Capacity

Engine without filter. . . . . . . . . . . . . . . . . Engine with filter . . . . . . . . . . . . . . . . . . . Drive unit SX . . . . . . . . . . . . . . . . . . . . . . Drive unit DP-S . . . . . . . . . . . . . . . . . . . . Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filter location. . . . . . . . . . . . . . . . . . . .

5 quarts (4.7 liters) 6 quarts (5.7 liters) 2.2 quarts (2.1 liters) 2.5 quarts (2.4 liters) Volvo Penta Penta Part no. 3850559 Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. U.S... . . . . . . . . . . . . Volvo P Penta enta power steering fluid Part no. 3851039 Power Pow er steering fluid non non-U.S -U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

117

VPA 7742705 English 06-2003

 

Technical Data

Engine

8.1Gi-E, 8.1Gi-EF, 8.1GXi-D, 8.1GXi-DF

Bore and stroke . . . . . . . . . . . . . . . . . . . . 107.95 x 111.00mm (4.250 x 4.370 inches) Cylinders (number). . . . . . . . . . . . . . . . . . 90° V-8 V-8 Displacemen Displa cementt . . . . . . . . . . . . . . . . . . . . . . 496 cubic cubic inches (8.1 (8.1 liters) liters) Firing order. order . . . . . . . . . . . . . . . . . . . . . . . . 1 – 8 – 7 – 2 – 6 – 5 – 4 – 3 Full throttle operating range Gi. . . . . . . . . 4200 – 4600 RPM Full throttle throttle operating operating range range GXi . . . . . . . 4600 – 5000 RPM Idle RPM (fixed) . . . . . . . . . . . . . . . . . . . . 600 RPM

Fuel System Fuel injection . . . . . . . . . . . . . . . . . . . . . . Port injection Fuel pumps pumps . . . . . . . . . . . . . . . . . . . . . . . Elect Electric ric Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Part no. 3862228 Fuel filter location . . . . . . . . . . . . . . . . . . . Refer to photographs on features pages. Fuel type . . . . . . . . . . . . . . . . . . . . . . . . . Inside the U.S.: 87 octane (AKI) unleaded gasoline Outside the U.S.: 90 octane (RON) unleaded gasoline

Electrical System    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Charging system . . . . . . . . . . . . . . . . . . . 12 volt 75 amp alternator, with internal transistorized voltage regulator Battery size . . . . . . . . . . . . . . . . . . . . . . . 12 volt with 650 Cold Cranking Amp (CCA) rating (135 minute reserve reser ve capacity) CAUTION! CAUTION! Do not use a deep cycle battery as the start battery. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 1. 1.7kW 7kW output, output, planetary planetary reduction ge gear ar

Ignition System Distributorless . . . . . . . . . . . . . . . . . . . . . Crankshaft and camshaft triggered ignition sensors. Ignition timing . . . . . . . . . . . . . . . . . . . . . . 10° BTDC, fix fixed, ed, See Workshop Manual for procedure. Spark plugs . . . . . . . . . . . . . . . . . . . . . . . Volvo P Penta enta Part no. 3861325 Spark plug gap . . . . . . . . . . . . . . . . . . . . . 1.52 mm (0.060 inches) Spark plug installation torque. . . . . . . . . . 30 N•m (22 ft. llb.) b.)

Cooling System Raw water pump . . . . . . . . . . . . . . . . . . . Crankshaft mounted variable vol volume ume flexible im impeller peller pump Recirculating pump . . . . . . . . . . . . . . . . . Fixed impeller belt driven driven pump on engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 64°C (140°F) V Volvo olvo Penta Penta part no. 3853983 Gi-EF / GXi-DF. . . . . . . . . . . . . . . . . . . . . Closed cooling heat exchanger mounted on engine. Closed Cooling System Thermostat. . . . . 76°C (170°F) Volvo Volvo Penta Part Part no. 875788

Oil Capacity Engine without filter . . . . . . . . . . . . . . . . . 8 quarts (7.5 liters) Engine with filter. . . . . . . . . . . . . . . . . . . . 9 quarts (8.5 liters) Drive unit unit DP-S . . . . . . . . . . . . . . . . . . . . 2.5 quarts (2.4 lliters) iters) Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Part no. 3850559 Oil filter location . . . . . . . . . . . . . . . . . . . . Refer to photographs on features pages.

Oil Type Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta Heavy Duty Synthetic engine oil, or suitable pure synthetic oil alternative with the minimum API service rating CF/SH. Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . Volvo Penta Penta SAE 75W/90 API service GL 5 synthetic gear oil Power Pow er steering fluid U.S. . . . . . . . . . . . . . Volvo Pe Penta nta power steering fluid Part no. 3851039 Power steering fluid non-U.S.. . . . . . . . . . ATF oil Dexron 2 Part no. 1161941

118

VPA 7742705 English 06-2003

 

Metric Conversion Chart Metric Conversion Chart

  LINEAR inchesX 25.4= millimeters (mm)

foot-poundsX 1.3558= joules (j)

feetX 0.3048= meters (m)

caloriesX 4.187= joules (j)

yardsX 0.9144= meters (m)

BtuX 1055= joules (j)

milesX 1.6093= kilometers (km)

watt-hoursX 3500= joules (j)

inchesX 2.54= centimeters (cm)

kilowatt - hrsX 3.600= megajoules (MJ)

AREA

miles/galX 0.42514= kilometers/liter (km/l)

inches2X 6.452= centimeters2 (cm2)

Note:

feet2X 0.0929= meters2 (m2)

235.2/(mi/gal) = liters/100 km

yards2X 0.8361= meters2 (m2)

235.2/(Iiters/100 km) = mi/gal

miles2X 2.590= kilometers2 (km2)

   0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

FUEL ECONOMY AND FUEL CONSUMPTION

inches2X 645.16= millimeters2 (mm2)

acresX 0.4047= hectares (104 m2) (ha)

   M    A    6    2   :    2    2   :    3

ENERGY OR WORK

VOLUME

LIGHT footcandlesX 10.76= lumens/meter2 (lm/m2)

PRESSURE OR STRESS

inches3X 16387= millimeters3 (mm3)

inches HG (60°F)X 3.377= kilopascals (kPa)

inches3X 16.387= centimeters3 (cm3)

pounds/sq inX 6.895= kilopascals (kPa)

inches3X 0.01639= liters (l)

inches H2O (60°F)X 0.2488= kilopascals (kPa)

quartsX 0.94635= liters (l)

barsX 100= kilopascals (kPa)

gallonsX 3.7854= liters (l)

pounds/sq ftX 47.88= pascals (Pa)

feet3X 28.317= liters (l)

POWER

feet3X 0.02832= meters3 (m3)

horsepowerX 0.746= kilowatts (kW)

fluid ozX 29.57= milliliters (ml)

ft-lbf/minX 0.0226= watts (W)

yards3X 0.7646= meters3 (m3)

MASS

TEMPERATURE °Celsius = 0.556 X (°F -32)

ounces (av)X 28.35= grams (g)

°Fahrenheit = (1.8 X °C) +32

pounds (av)X 0.4536= kilograms (kg) tons (2000 lb)X 907.18= kilograms (kg)

TORQUE pound-inchesX 0.11299= newton-meters (N•m)

tons (2000 lb)X 0.90718= metric tons (t)

pound-feetX 1.3558= newton-meters (N•m)

FORCE

VELOCITY

ounces - f (av)X 0.278= newtons (N)

miles/hourX 1.6093= kilometers/hour (km/h)

pounds - f (av)X 4.448= newtons (N)

feet/secX 0.3048= meters/sec (m/s)

kilograms - fX 9.807= newtons (N)

kilometers/hrX 0.27778= meters/sec (m/s)

ACCELERATION feet/sec2X 0.3048= meters/sec2 (m/S2) inches/sec2X 0.0254= meters/sec2 (m/S2)

miles/hourX 0.4470= meters/sec (m/s)

VPA 7742705 English 06-2003

 

Metric Conversion Chart Notes

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!    M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

119

120

VPA 7742705 English 06-2003

 

Index Index

Numerics 4.3 GL Draining Only ....................................................... 85

A Accessories ..................................................................... 20 Accidents ........................................................................... ........................................................................... 8 ACP .................................................................. ................................................................................. ............... 93 Active Corrosion Protection System ................................ 93 Alternator Belt .................................................................. 81 Analog Trim Instrument ................................................... 25

B

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Basic Safety Rules of Boating ......................................... 11 Batteries............................................................................. 6 Batteries and Connections............................................... 73 Battery Cables ................................................................. 73 Battery Replacement ....................................................... 75 Beach Range ............................................................. 25, 26 Before Starting................................................................. 35 Belt Adjustments Adjustments.............................................................. .............................................................. 79 Boat Bottom ..................................................................... 98 Boat Transportation ......................................................... 44 Boat’s Systems Maintenance ............................................................. 66 Bottom Painting ............................................................... 98 Break-in Procedures ........................................................ ........................................................ 59 Breaking-in....................................................................... 13

C Carbon Monoxide Poisoning.............................................. 6 Carburetor (GL) ............................................................... 69 Carburetor Fuel Filter Replacement ................................ 72 Care of the Environment Environment .................................................. 13 Certified Engines ............................................................. ............................................................. 14 Changing Engine Oil ........................................................ 89 Changing Spark Plugs .................................................... ...................................................... 77 Changing the Oil Filter ..................................................... 89 Charge ................................................................... ............................................................................. .......... 23

Controls ....................................................................... ............................................................................29 .....29 Friction Brake ............................................................32 Side Mount ................................................................32 Single Lever ..............................................................29 Top Mount .................................................................32 Cooling System ............................................................7, 82 Core Value Environmental Care .....................................................i Quality .................................................................. .......................................................................... ........ i Safety ...........................................................................i Core Values.........................................................................i Cruising Speed.................................................................31

D Daily Checklist....................................................................8 Dealer 20-Hour Check......................................................61 Decals ..............................................................................18 Defective Engine Lubricating System.............................108 Determining the Proper Trim............................................40 Trim ............................................40 Detonation ........................................................................68 Disengaging the Shift Function ........................................29 Distributor Cap and Rotor.................................................76 Do not Start the Engine ......................................................8 Doing Your Own Maintenance and Repairs Repairs.....................17 .....................17 Draining the Closed Cooling System................................85 Draining the Cooling System............................................84 Draining the Drive Unit .....................................................90 .....................................................90 Draining the Engine 4.3, 5.0, and 5.7 Liter ................................................85 8.1 Liter .....................................................................85 Drive Components............................................................90 Drive Identification............................................................19 Drive Spacer.....................................................................91 Drive Unit Bellows ............................................................66 Drive Unit Lubrication....................................................... Lubrication.......................................................90 90

E ECM .................................................................................24 EFI....................................................................................24 Electric Fuel Pumps .........................................................70

Checking Instruments Engine Oil Level............................................... Engine 89 Checking ...................................................... 23 Checking the Drive Unit Lubricant ................................... 90 Checking the Spark Plugs ............................................... 77 Checklist Replacement Parts and Tools .................................. 10 Safety Equipment ..................................................... 10 Trip ........................................................................... 10 Chemicals .......................................................................... 7 Circuit Breakers and Fuses ....................................... 45, 76 Closed Cooling F-Series .................................................................... 82 Closed Cooling System ................................................... 82 Control Lever with Catch Button ...................................... 33 Dual .......................................................................... 34 Single........................................................................ 33 Control Lever with Catch Button (Dual) ........................... 34

Electrical System..........................................................7, 73 Electronic Fuel Injection (Gi, GXi) ....................................69 Emergency Stop Switch ...............................................8, 22 Engine Alignment .............................................................98 Engine Break-in Final Ten Hours.........................................................61 First Two Hours.........................................................60 Next Eight Hours .......................................................60 Engine Break-in Period ....................................................59 Engine Control Module.....................................................24 Engine Coolant Temperature ...........................................23 Engine Cranks, But Will Not Start ..................................103 Engine Decal ....................................................................19 Engine Dies Out .............................................................107 Engine Does Not Start....................................................101 Engine Exhaust System ...................................................66 Engine Flush ....................................................................83

Control Panel ............................................................ ................................................................... ....... 33

Engine Fuel Filter Replacement .......................................71 Engine Identification...................................................18, 19 Engine Noises and Vibrations Vibrations ........................................105

121

VPA 7742705 English 06-2003

 

Index

Engine Oil Changing...................................................................89 Temperature Recommendations...............................59 Engine Oil Level Checking ...................................................................89 Engine Overheating....................................................82, 83 All other Models ........................................................83 Gi & GXi only.............................................................82 Engine Overheats...........................................................106 Engine Plate .....................................................................19 Engine Protection Protection Mode ...................................................24 Engine Runs Improperly.................................................101 Engine Runs Rough .......................................................105 Engine Submersion ..........................................................98 Engine Troubleshooting Guides .....................................102 Engine Will Not Crank ....................................................103 Engine Won’t Reach Operating RPM.............................107 Engine/Crankcase Oil.......................................................88

F

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Features ...........................................................................45 ...........................................................................45 3.0GLM-C, 3.0GLP-C................................................46 4.3GL-D, 5.0GL-E, 5.7GL-E......................................48 4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F.....................50 4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF............54 8.1Gi-E, 8.1GXi-D .....................................................52 8.1Gi-EF, 8.1GXi-DF.................................................55 Circuit Breakers and Fuses.......................................45 Legend of Symbols Used in Engine Diagrams..........45 SX-M Sterndrive........................................................56 FeaturesDP-S Sterndrive .................................................57 Filling the Drive Unit .........................................................91 Fire and Explosion..............................................................6 Batteries ......................................................................6 Fuel and Lubrication Oil ..............................................6 Non-Original Components...........................................6 Start Spray ..................................................................6 First Service Service Inspection ....................................................61 Flame Arrestor..................................................................69 Forward Gear ...................................................................31 Frequency of Maintenance...............................................62 Friction Brake ...................................................................32 Fuel and Lubrication Oil .....................................................6 Fuel and Oils ....................................................................13 Fuel Filter ............................................................... .........................................................................70 ..........70 Fuel Screen Cleaning.......................................................72 Fuel System .................................................................7, 67 Fuses (8 Amp)..................................................................21

G Gasoline Containing Alcohol ............................................68 Gasoline Recommendations ............................................67 Gear Shift Release Button................................................38 General Information......................................................4, 17

H Hard Starting Starting -- Hot ColdEngine Engine.............................................104 ...........................................104 Hard High Altitude Operation ....................................................43 High Performance Performance Boat Operation ...................................11

Hot surfaces and Fluids ..................................................... .....................................................6 6 How to Shift and Control Sp Speed....................................... eed....................................... 30

I ID Tags............................................................................. Tags.............................................................................18 18 Identification Numbers ...............................................18, ............................................... 18, 19 Identification Plates ........................................................ .......................................................... .. 18 If the the Engine Engine Floods ......................................................... .........................................................36 36 Gi & GXi Models .......................................................37 ....................................................... 37 GL Models................................................................. Models.................................................................36 36 Ignition Switch ..................................................................21 .................................................................. 21 Impact Protection ............................................................. .............................................................27 27 Impeller Checking & Replacing............................................... Replacing............................................... 86 Installing the DP-S P Propeller ropeller ............................................97 Installing the SX Propeller................................................ 96 Instrument Lighting........................................................... 21 Instrument Panel ..............................................................21 .............................................................. 21 Fuses ........................................................................ ........................................................................21 21 Ignition Switch........................................................... 21 Instrument Lighting ...................................................21 ................................................... 21 Oil pressure Gauge................................................... 21 Tachometer............................................................... 21 Temperature Gauge.................................................. 21 Voltmeter...................................................................21 Voltmeter................................................................... 21 Instrumentation ................................................................ ................................................................21 21 Introduction ...................................................................... ......................................................................13 13

L Launching the Boat ............................................... .......................................................... ........... 65 LED Display .......................................................... ..................................................................... ........... 26 Lift Range................................................................... Range................................................................... 25, 26 Load Condition Speed of Planing Hull ...............................................15 Location of Informational Decals and Identification Plates .......... 18 Low Battery Voltage After Short Storage ....................... 109 Lubrication System....................................................... System....................................................... 7, 88

M Maintenance.....................................................................59 Belt Adjustments .......................................................79 ....................................................... 79 Boat Bottom .............................................................. ..............................................................98 98 Cooling System......................................................... 82 Drive Components .................................................... 90 Drive Unit Bellows..................................................... 66 Electrical System ......................................................73 ...................................................... 73 Engine Alignment...................................................... 98 Engine Exhaust System............................................ 66 Engine/Crankcase Oil ............................................... ...............................................88 88 Fuel System ..............................................................67 .............................................................. 67 Impeller ..................................................................... .....................................................................86 86 Lubrication System ................................................... ...................................................88 88 Painting the Drive...................................................... Drive...................................................... 95 Power Trim/Tilt Fluid Level .......................................87 ....................................... 87 Propeller Care........................................................... 96 Replacement Parts.....................................................92 ................................................... ...................................................99 99 Sacrificial Anodes ..................................................... 92 Steering System........................................................ System........................................................86 86 Maintenance and Service

High Performance Performance Boating ...............................................11

Special Requirements............................................... 14

122

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Index

Maintenance of Boat’s Systems ...................................... 66 Maintenance Schedule .................................................... 62 Maneuvering ...................................................................... 8 Master/Slave Installation.................................................. 24 Method............................................................................. 38 Metric Conversion Chart ................................................ 119 Multiple Batteries and Selector Switch ............................ 76

N Non-Original Components ................................................. ................................................. 6

O

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

Off-Season Storage ......................................................... ......................................................... 65 Oil Filter Changing .................................................................. 89 Oil Pressure ..................................................................... 23 Oil pressure Gauge.......................................................... 21 Oils Recommended SAE ................................................. 59 Operating After Break-in Per Period....................................... iod....................................... 61 Operating in "Bow-down" Position ................................... 41 Operating in "Bow-up" Position........................................ 41 Operating in Free Freezing zing Temper Temperatures atures............................... ............................... 43 Operating Remote Controls ............................................. 38 Operating the Engine Engine....................................................... ....................................................... 35 Operating Trim Controls .................................................. 33 Operation ......................................................................... ......................................................................... 35 Optional Digital Trim Instrument ...................................... 26 Other Instruments ........................................................... ............................................................. 26 Owner’s Identification Card.............................................. 19

P Paint Application .............................................................. .............................................................. 95 Painting the Drive ............................................................ 95 Planning Your Trip ........................................................... 10 Power Ratings ................................................................. 15 Power Steering Fluid ....................................................... 87 Power Steering Pump B Belt............................................... elt............................................... 81 Power Steering Reservoir ................................................ 87 Power Tilt Tilt Tilt......................................................................... ......................................................................... 42 Power Operation ........................................................ 42 Power Trim ...................................................................... 42 Power Trim and Tilt Operation Operation......................................... ......................................... 40 Power Trim Operation...................................................... 40 Power Trim/Tilt................................................................. 25 Power Trim/Tilt Fluid Level .............................................. 87 Preparing for Boating....................................................... 65 Preventing Gum Formation Formation and Corrosion Corrosion...................... ...................... 68 Propeller Care.................................................................. 96 Propeller Replacement — DP-S ...................................... 97 Propeller Replacement — SX.......................................... 96

R Raw Water Cooled E Engines............................................. ngines............................................. 84 Raw Water Flush ............................................................. 83 Raw Water System .......................................................... 82 Recommended SAE Viscosity Oils.................................. 59 Refueling............................................................................ 8 Remote Control Lever...................................................... 33

Remote Control Unit.........................................................29 Removing the DP-S Propeller Propeller ..........................................97 Removing the SX Propeller ..............................................96 Replacement Parts.....................................................20, 99 Replacement Parts and Tools Checklist ..........................10 Replacing Sacrificial Anodes............................................92 Reverse Gear ...................................................................31

S Sacrificial Anodes.............................................................92 Safety Emergency Stop Switch ............................................22 Safety Checklists..............................................................10 Planning Your Trip ................................................. ....................................................10 ...10 Safety Equipment .............................................................10 Safety Equipment Checklist .............................................10 Safety Information ..............................................................3 Safety Precautions Before Starting Engine................................................5 Engine ................................................5 Engine Decals .............................................................5 Lifting Engine ..............................................................5 Maintenance and Service............................................5 Operating the Boat ......................................................8 Stop Engine.................................................................5 Washing Engine ..........................................................5 Salt Water Operation........................................................43 Seasonal Maintenance.....................................................62 Serpentine Belt Engines...................................................79 Service .............................................................................20 Service, Replacement Parts, and Accessories ................20 Shaft Spline and Bearing Lubrication ...............................87 Shallow Water Operation .................................................43 Shifting between Forward and Reverse ...........................31 Shifting from Neutral.........................................................29 Side Mount Remote Controls ...........................................32 Single Lever Control Operation........................................29 Operation ........................................29 Spark Knock .....................................................................68 Spark Plugs ......................................................................77 Special Boating Situations................................................43 High Altitude Operation .............................................43 Operating in Freezing Temperatures Temperatures ........................43 Salt Water Operation.................................................43 Shallow Water Operation ..........................................43 Start Spray .........................................................................6 .........................................................................6 Starting the Engine Cold Start ..................................................................36 Gi & GXi Models........................................................36 GL Models.................................................................36 Warm Start ................................................................37 Static Water Line ..............................................................64 Static Water Line Test ......................................................64 Steering System ...............................................................86 ...............................................................86 Steering System Operation ........................................... ..............................................39 ...39 Stopping the Engine .........................................................37 Storing the Boat................................................................65

T Tachometer ......................................................................21 Technical Data ...............................................................111 ...............................................................111

123

VPA 7742705 English 06-2003

 

Index

Technical Specifications 3.0GLM-C, 3.0GLP-C..............................................111 4.3GL-D...................................................................112 4.3GXi-E, 4.3GXi-EF...............................................113 5.0GL-E...................................................................114 5.0GXi-E, 5.0GXi-EF...............................................115 5.7Gi-E, 5.7Gi-EF, 5.7GXi-F, 5.7GXi-FF.................117

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

5.7GL-E...................................................................116 8.1Gi-E, 8.1Gi-EF, 8.1GXi-D, 8.1GXi-DF................118 Temperature Gauge .........................................................21 Tensioning V-Belts ...........................................................81 Tie Rod.............................................................................87 Tie Rod (Twin Installations Only)......................................87 Toll-free Dealer Locator Service.......................................20 Top Mount Remote Controls ............................................32 Trailering Your Boat .........................................................44 Trailers ........................................................................ .............................................................................44 .....44 Transom Assembly & Drive Unit Stickers.........................19 Transom Assembly Assembly ID ......................................................19 Transom Identification ......................................................19 Transom Shield/Plate .......................................................19 Transporting the Boat.......................................................44 Trim Controls....................................................................33 Trim Instruments ..............................................................25 Trim Range.................................................................25, 26 Trim/Tilt Motor Protection .................................................27 Trip Checklist....................................................................10 Troubleshooting..............................................................101 Troubleshooting - System Isolation ........................101, 111 Twin Unit Maneuvering.....................................................30 Twin Unit Steering ............................................................39

U Using the Gear Shift Release Button Method 1 ...................................................................38 Method 2 ...................................................................38

V VAS ..................................................................................17 VAS.................................................................................. 17 V-Belt Engines .................................................................80 V-Belt Tension.................................................................. Tension..................................................................81 81 Voltage ............................................................................. .............................................................................23 23 Voltmeter.......................................................................... 21 Volvo ServiceNetwork............................................ ........................................................ 20 17 Volvo Action Penta Dealer Volvo Penta on the Internet.............................................. 20

W Wagon-Back Effect ............................................................ 9 Warning Symbols ............................................................... ...............................................................4 4 Corrosive.....................................................................4 Corrosive..................................................................... 4 Crushing Force ...........................................................4 ........................................................... 4 Electrical ..................................................................... .....................................................................4 4 Explosive..................................................................... 4 Face Mask .................................................................. 4 Face Wash.................................................................. 4 Fan Belts..................................................................... 4 Flammable .................................................................. 4 Gloves......................................................................... 4 High Pressure .............................................................4 ............................................................. 4 Hot Surface ................................................................. 4 No Open Flames......................................................... 4 No Smoking ................................................................ ................................................................4 4 Poisonous ............................................................... ................................................................... .... 4 Rotating Fan ...............................................................4 ............................................................... 4 Toxic ........................................................................... ........................................................................... 4 Warranty Information........................................................ Information........................................................17 17 Warranty Registration Form Form ............................................. ............................................. 17 Welcome ............................................................................. i Winterization ....................................................................65 .................................................................... 65

Y Your New Boat Boat ...................................................................8 ................................................................... 8

124

VPA 7742705 English 06-2003

 

 !"#

Yes please, I would like an operator’s manual in English at no charge.

Post or fax this coupon to:

Publication number: 7742705

Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg

Name

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Address

Sweden Fax: +46 31 545 772

Orders can also be placed via the Internet: h ttp ://www.vo lvo p e n ta .co m/  manual/coupon

Country NB! This offer is valid for a period of 12 months from delivery of the boat. Availability Avail ability after this period will be as far as supplies admit.

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 $!%

Ja, ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.

Schicken Sie den Coupon per Post oder als Fax an: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Schweden Fax: +46 31 545 772

Drucksachennummer: 7743112

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Name

Anschrift

       1        0        0        5        1        6        /

Die Bestellung kann auch über das Internet erfolgen: h ttp ://www.vo lvo p e n ta .co m/  manual/coupon

       0        0        2        2        4

Land Bitte beachten Sie, dass dieses Angebot für die Dauer von 12 Monaten ab dem  Lieferdatum des Bootes gilt, danach bis zum Aufbrauchen des Lagerbestandes.

 &'(

Oui merci, Je souhaite recevoir un manuel d’instructions gratuit en français.

Envoyez ou faxez le bon de commande à: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Suède Fax: +46 31 545 772

Numéro de publication: 7743113 Nom

Adresse

Vous pouvez également passer la commande par Internet: Pays

http://www.volvopenta.com/manual/coupon Notez que l’offre est valable pendant 12 mois à partir de la date de livrai-  son du bateau, ensuite seulement en fonction des stocks disponibles.

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125

VPA 7742705 English 06-2003

 



Sí gracias, deseo recibir gratuitamente un libro de instrucciones en español.

Franquear o enviar fax a:

Número de publicación: 7743114

Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg

Nombre

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Dirección

Suecia Fax: +46 31 545 772

El pedido puede hacerse también por internet: h ttp ://www.vo lvo p e n ta .co m/  manual/coupon

País Nótese que el ofrecimiento vale durante 12 meses después de la fecha de entrega  de la embarcación, y posteriormente solamente mientras duren las existencias existencias..

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 +, +,( (

Sì, grazie, desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.

Spedire il tagliando per posta o per fax a: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Svezia Fax: +46 31 545 772

Public. No.: 7743115

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Nome e Cognome

Indirizzo

L’ordinazione può essere fatta anche su Internet: http://www.volvopenta.com/manual/coupon

       0        0        2        2        4

Paese Si ricorda che l’offerta è valida per 12 mesi dalla data di consegna dell’imbarca dell’imbarcazione;  zione;  dopo il suddetto periodo l’offerta resta valida solo in base alla disposizione della  pubblicazione in oggetto.

 )*!

Ja tack,  jag vill kostnadsfritt ha en instruktionsbok på svenska.

Posta eller faxa kupongen till:

Publikationsnummer: 7743111

Dokument & Distribution Center Ordermottagningen ARU2, Avd. 64620 SE-405 08 Göteborg Sverige Fax: +46 31 545 772

Namn

Adress

Beställningen kan även göras via internet: http://www.volvopenta.com/manual/coupon

Land Observera att erbjudandet gäller i 12 månader från båtens leveransdatum, därefter endast i mån av tillgång.

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126

VPA 7742705 English 06-2003

 

 $%,

Ja graag, Ik wil kosteloos een instructieboek in het Nederlands Nederl ands ontvangen.

Stuur of fax de coupon naar:

Publicatienummer: 7743116

Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg

Naam

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Adres

Zweden Fax: +46 31 545 772

       0        0        5        1        6        /        0        0        2        2        4

U kunt ook bestellen via internet: h ttp ://www.vo lvo p e n ta .co m/  manual/coupon

Land Denk eraan dat het aanbod geldt gedurende 12 maanden na de datum  waarop de boot werd afgeleverd, daarna alleen indien nog verkrijgbaar.

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 $("

Ja tak,  jeg vil gerne gratis have en instruktionsbog på dansk.

Send kuponen med post eller fax til: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Sverige Fax: +46 31 545 772

Publikationsnummer: 7743117

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Navn

Adresse

Bestillingen kan også ske på internet: h ttp ://www.vo lvo p e n ta .co m/  manual/coupon

       0        0        2        2        4

Land Bemærk at tilbudet gælder i 12 måneder fra bådens leveringsdato leveringsdato,, Derefter  kun så længe lager haves.

 &+"

Kyllä kiitos, haluan suomenkielisen ohjekirjan veloituksetta.

Postita tai faksaa kuponki osoitteella: Document & Distribution Center Order Department ARU2, Dept. 64620 SE-405 08 Göteborg Ruotsi Fax: +46 31 545 772

Julkaisunumero: 7743118 Nimi

Osoite

Tilauksen voi tehdä myös Internetissä: Maa

http://www.volvopenta.com/manual/coupon Huomaa, että tarjous on voimassa 12 kuukautta veneen toimituspäivämäärä toimituspäivämäärästä  stä  lukien ja sen jälkeen vain niin kauan kuin kirjoja riittää.

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127

VPA 7742705 English 06-2003

 

 -.'

Envie o talão pelo correio ou um fax para: Document & Distribution Center Order Department ARU2, Dept. 64620

Sim, obrigado(a)! Gostaria de receber gratuitamente um manual de instruções em português. 7743119 Número de publicação: Nome

Endereço

SE-405 08 Göteborg Sweden Fax: +46 31 545 772

A encomenda também pode ser feita através da Internet: I nternet: h ttp ://www.vo lvo p e n ta .co m/  manual/coupon

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País Observar que esta oferta é válida durante um período de 12 meses a contar da  data de entrega do barco. Após este período, a oferta está dependente do número  de exemplares disponíveis.

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128

 

   M    A    6    2   :    2    2   :    3    0    1    0    2    /    5    /    2    1     m   o   c  .   a    t   n   e   p   o   v    l   o   v  .   w   w   w     m   o   r    f    d   e    d   a   o    l   n   w   o    D      5    0    7    2    4    7    7

VPA 7742705 English 06-2003

 

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