ILMOR MARINE Please read this Owner’s Manual completely prior to operating the engine and boat for the first time. The Owner’s Manual contains information critical for safe operation, and to activate and keep the limited warranty statement in effect throughout the applicable warranty period. Continuing the appropriate maintenance and care going forward can ensure long-term enjoyment of the MV8 engine.
tronics and the all-new INDY® high-performance stern-drive were created to not only meet but exceed every requirement of the new regulations. In the first year of competition for the engines, a pair of ILMOR Marine MV-10 625 engines powered the #99 Fountain Powerboat King of Shaves to win the coveted 2007 Powerboat P1 Evolution Class World Championship. The successful first year of competition was backed up in 2008 with World Championship wins in both the largely Europeanbased Powerboat P1 series and the U.
Throughout this manual the terms “Danger,” “Warning,” and “Caution” appear, alerting the boat owner and/or operator to dangerous or potentially dangerous situations that may arise.Those terms have the following respective meanings whenever they appear herein: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Care must be taken to avoid exposure to carbon monoxide, even in small concentration. Avoid exhaust areas and the engine compartment during the venting of engine exhaust. Carbon monoxide is colorless, odorless and poisonous, and can cause serious injury or death in short periods of time! (Page 2) Gasoline is explosive.
When connecting the battery cable, always connect the positive (+) battery cable first. After the positive cable is connected, then the negative (-) battery cable can be attached. This minimizes the possibility of electrical contact. Always disconnect the negative battery cable first before disconnecting the positive battery cable. (Page 8) Do not realign the wiring or in any way alter the wiring of the MV8 engine.
Excessive exhaust temperatures will damage the exhaust hose and are symptomatic of a leak or restriction in the cooling system. The engine should be shut OFF immediately in the presence of too much heat, whether by odor, touch or sight. Failure to do so may result in more serious consequences, including but not limited to, damage to the engine, which is not covered under warranty, and/or damage to the boat that may result in personal injury as well.
Boat owners should not remove the factory break-in oil until after a minimum of ten (10) hours proper operation, but not later than twenty-five (25) hours. At that time, an oil change should be performed by an authorized ILMOR dealer, who will be able to “read” the oil and filter to determine if the proper break-in of the engine components appears to be occurring.
TABLE OF CONTENTS Safety.................................................................................................. 1 Direct Safety Concerns........................................................................... 2 Introducing the MV8............................................................................ 3 Exhaust System.................................................................................... 5 Fuel System............................................................................
Stopping the Boat.................................................................................26 Other Considerations............................................................................27 Maintenance......................................................................................28 Change the Engine Oil & Filter................................................................28 Change the Transmission Fluid/Oil and Filter...............................................
SAFETY Safety is paramount to ILMOR. Every reasonable effort has been made to provide directions to safe and thoughtful use of the ILMOR product. In most instances, adherence to common sense when operating or working around the engine will present the boat operator, all on board and other boaters on the same body of water, the proper atmosphere in which to safely enjoy the experience. Prior to operating the boat for the first time, boat operators MUST read this Owner’s Manual in its entirety.
Whenever an MV8 engine is operated within the confines of an engine compartment, it is extremely important to follow the boat manufacturer’s instructions regarding venting of the engine compartment prior to or during low-speed/idle operation. Exhaust fumes may build up inside the engine box, which can, and has, resulted in explosions. One of the most critical safety matters affecting boaters is the matter of carbon monoxide emission.
INTRODUCING THE MV8 ILMOR MV8 Owner’s Manual • Page 3
Ignition coil and rear accessory bracket neutral safety switch at transmission Use photos or drawings as necessary to designate important components, including interal; allow two pages for thermostat location these.
EXHAUST SYSTEM ILMOR MV8 engines are equipped with “wet” marine exhaust systems. In a wet marine exhaust system, raw water enters the exhaust elbows (also referred to as “downturn adapters”), where it mixes with the exhaust gases. The mixing of the water and exhaust gases is important because it provides cooling to the rubber hose that connects the exhaust elbow to the muffler. After the water-exhaust gas mixture passes through the mufflers it exits back into the body of water.
In the event that the fuel system supplying the MV8 engine requires attention, any adjustment or replacement must be done by an authorized ILMOR dealer as the lines are pressurized and can be disconnected only with specialized tools. Replacement of any part of the fuel system must be with ILMOR-authorized parts only. Failure to follow this directive can result in damage to the boat, which is not covered by the warranty, and/ or serious injury or death.
Open Cooling System Full Closed Cooling System The open cooling system was designed primarily for fresh water use only. Whenever the boat is operated in brackish or salt water, particular care, without fail, must be taken to flush the system with fresh water after every use. However, even if boating in salt-free, apparently clean fresh water, flushing the cooling system following use is recommended. This helps eliminate marine growth or fouling of the cooling system.
The electrical system on the MV8 is a 12-volt negative ground system. As a result, it is important to keep in mind that operators must avoid reverse polarity, which could lead to extensive damage of the electronics. Any damage occurring as a result of reverse polarity will not be covered by warranty. Reversed polarity also presents a serious shock risk. Turning off a breaker appears to remove power from the circuit because it turns off whatever is connected to that circuit.
Boat/Engine Interface Wiring The electrical system of the MV8 is primarily self-contained in a preassembled unit. The interface with boat wiring follows established practices and conforms to regulatory guidelines. Every reasonable effort has been made to make the electrical connection simplified and straightforward. Consumers are strongly encouraged to seek assistance from authorized ILMOR dealers when dealing with electrical issues.
the alarm will not go off again. If the alarm sounds at any other time or for any other reason, contact an authorized ILMOR dealer before re-starting the engine. The alarm appears if the engine coolant exceeds 199 F. (93 C.) in an open Water Temperature The alarm appears if the engine oil pressure falls below the recom- Oil Pressure cooled engine or 239 F. (115 C.) in a closed cooled engine.
FUELING THE MV8 The MV8 engine is being used in conjunction with an innovative fuel system that features a fuel pump that is mounted in a capsule installed directly in the fuel tank. This is similar to what is found in late model passenger cars and has proven through the years to be reliable while offering superior performance.
spark knock can cause severe engine damage. The engines have knock detection systems that offer the best engine performance by controlling knock through precise ignition timing. The higher octane fuel will cause less knock for the ignition system to process and adjust for. Poor quality or old fuels can cause problems such as loss of performance, rough idling, hard starting and hesitation.
OTHER PRE-OUTING REQUIREMENTS ILMOR blended synthetic 5W-30 is the recommended oil for use in ENGINE OIL the MV8 5.7L, 6.0L and 6.2L engines. Synthetic 5W-50 is required for the 7.4L engine only. Use of supplemental oil additives is not required. ILMOR blended synthetic contains all the necessary additives for the MV8. An oil change should be scheduled following the first 25 hours of operation and every 50 hours thereafter. Oil should also be changed if the temperature for any reason has exceeded 329 F.
BEFORE EACH USE Because this process should be completed while the engine is cool (in order to avoid burns), it is recommended that this check be completed prior to starting the engine. If checking during an outing, allow the engine to cool. Be very careful to avoid burns from contact with hot engine parts. • Ensure the engine is OFF and the engine safety starting switch is disconnected. Leave the throttle/shift control lever in neutral. Open the engine compartment and locate the raw water impeller housing.
Important:This is a critical function of routine maintenance. Even clean-appearing waterways may have debris such as pine needles or moss that can enter the cooling system and create a blockage. Failure to perform this function can result in serious overheating of the engine. Damage to the engine and/or transmission caused by overheating is not covered by warranty! Always pay attention to your temperature gauge, even if you are carefully performing this check.
• If the tank was completely or nearly empty, see your authorized ILMOR dealer for immediate assistance as the engine cooling system will likely require purging. This function should be completed only by a trained ILMOR service technician. Failure to maintain your coolant at the proper level will cause potentially serious engine damage. The warranty does not cover engine damage due to overheating or any other cause associated with improper coolant levels.
and remove the battery from the boat. Clean corrosion from the battery posts with a battery terminal cleaner. Clean the battery with a water-and-baking-soda solution. Use care to avoid allowing the solution to enter the battery vents. Rinse the battery with fresh water. Note that this is a generic cleaning method. Battery manufacturers may specify other methods of cleaning. Verify with the battery manufacturer’s website the correct cleaning method before undertaking any cleaning.
• Systematically check the entire engine for loose and missing hardware. Attempt to shake components by hand, such as the alternator and the motor mounts. If a looseness problem exists, it is important to see an authorized ILMOR dealer. Because this process should be completed while the engine is cool (in order to avoid burns), it is recommended that this check be completed prior to starting the engine. • Ensure the engine is OFF and the engine safety starting switch is disconnected.
is to allow the operator an opportunity to start the engine and permit the alternator to recharge the battery, but if the charge has fallen too low or if the battery is older or fails to hold a charge at the expected level, the boat may not start. In the event of a dead battery, charge it with a battery charger before attempting to start the engine. Jump-starting from another boat or battery is dangerous.
• Add or remove fluid/oil as necessary to maintain the level as designated. It is as important to avoid overfilling the transmission fluid/oil as it is to avoid underfilling. Use only the recommended fluid as specified in the Service Log section of this Owner’s Manual, appropriate to the correct transmission in the boat. An accurate engine oil level reading will happen only after the engine has run long enough to thoroughly warm up to at least 140 F. (60 C.
AFTER EACH USE Check Raw Water Pick-up Flush Raw Water/ Sea Pump System For all ILMOR equipped boats, a check of the raw water pick-up is necessary. Located beneath the boat, under the water line on the hull is the raw water pick-up. Even when boating on clean-appearing bodies of water, a check of this pick-up should be done after every outing to determine if there is any debris. This should be rinsed with fresh water prior to storage, even of short duration.
Since gaseous and/or fluid leaks are more likely to be apparent at the conclusion of an outing, the operator should open the engine compartment and check for any odor or discoloring of components. Any sign of leakage should be brought to the attention of an authorized ILMOR dealer immediately! Normal operations will still result in a small amount of ambient fluids.
STARTING, STOPPING AND NEW ENGINE BREAK-IN Failure to follow the break-in and operating procedures as described in this Owner’s Manual will void the warranty. Before operating the boat for the first time, you must read this Owner’s Manual completely, as well as the boat manufacturer’s Owner’s Manual. Proper break-in of the engine and transmission is critical to ensuring a long life for the drive train. The first twenty-five (25) hours, when properly completed, will ensure maximum performance as well.
Start the engine and allow it to warm up to the normal operating temperature of 140 F. (60 C.) This will require approximately fifteen (15) minutes and should be done in the low-idle (600 to 800 rpm as measured on the tachometer) mode. Move the throttle/shift control lever forward, smoothly and quickly, to planing speed. Then return the throttle back to a slower speed, but one that continues the plane. Vary the engine speed but do not exceed 3,000 rpm for the first hour, and carry only a light load.
The boat is likely to be equipped with sea strainer valves and seacocks. Ensure these are open prior to starting the engine. Any time the engine is running, an adequate amount of water as defined by ILMOR Marine MUST be flowing through the cooling system. This requires the boat to be in an operational-sized body of water or hooked up to the suction side of a raw water pump via an ILMOR-approved, water supply in a dealership.
Always be certain that there is ample room around the boat when trying to start the engine in forward position as the boat will move forward when the engine starts. Contact with other boats, docks, shallow waterway bottoms, or debris may result in damage to the boat that is not covered under warranty, and may also result in serious injury. Never operate the starter motor continuously for more than fifteen (15) seconds without at least two (2) minute resting intervals.
OTHER CONSIDERATIONS Never operate the boat at continuous wide-open-throttle. This places undue strain on the engine components. Wide-open-throttle exists to allow boaters to get out of dangerous encounters or situations, but it represents the upper limit of the engine’s capacity. See also the boat manufacturer’s Owner’s Manual for operational hints and tips that can enhance the enjoyment of the boat’s and drive train’s integration.
MAINTENANCE In addition to the routine matters addressed earlier, there are a number of other maintenance matters that require periodic attention.
ILMOR blended synthetic 5W-30 is the recommended oil for use in the MV8 5.7L, 6.0L and 6.2L engines. Synthetic 5W-50 is required for the 7.4L engine only. Use of supplemental oil additives is not required. ILMOR blended synthetic contains all the necessary additives for the MV8. • Ensure the engine is OFF and the engine safety starting switch is disconnected. Leave the throttle/shift control lever in neutral. The engine must be warm.
Failure to follow the engine oil recommendation listed in this Owner’s Manual can result in exaggerated engine wear and increase the possibility of engine component failure. Damage to your engine due to failure to follow engine oil procedures can be costly to repair and is not covered under warranty. In order to thoroughly drain all the old transmission fluid/oil, the boat engine needs to reach at least 140 F. (60 C.), which is approximately five (5) minutes idle).
Note: Access to the transmission fluid filters is somewhat difficult in the confined space in some models. Nonetheless, this maintenance is vital to long, trouble-free use of the transmission.That is why it is recommended that this service be performed by an authorized ILMOR dealer. Clean the Engine Flame Arrestor/ Air Filter ILMOR recommends that the flame arrestor be inspected and cleaned or replaced every 100 hours or annually, whichever comes first.
• Rinse off the filter with low-pressure water. Tap water is acceptable. Always flush from the clean side to the dirt side. This removes the dirt and does not drive it into the filter. • Always dry naturally. After rinsing, shake off all excess water and let the element air dry. Note: DO NOT use compressed air, open flame or heat dryers. Excess heat will shrink the cotton filter media. Compressed air will blow holes in the element. • After cleaning the air filter always re-oil before using.
Ignoring elevated temperatures on a temperature gauge or any other evidence of the engine operating at temperatures above recommended levels can result in serious damage to the engine. Any resulting damage will not be covered by the warranty. • Inspect the inside of the impeller housing. If any rubber extrusions on the end of the arm appear frayed or worn, it should be replaced. If there is not a slight bend to the paddle-wheel arms, replace it. Debris entering the impeller inevitably will damage it.
• • • • • • • • • • • • • • Drain heat exchangers of raw water. • Open cooled systems will have an oil/transmission heat exchanger. • Remove heat exchanger end caps and allow draining. • Closed cooled systems will have an oil/transmission and engine heat exchanger. • Remove heat exchanger drain plugs and allow draining. Reinstall exhaust manifold drain plugs, engine block drain plugs, and heat exchanger end caps/drain plugs after all the raw water has been drained.
• Cycle engine speed from idle to 3000 rpm in 30-second intervals until the coolant temperature reaches 169 F (76C). • Top off coolant reservoir as needed. • Check the coolant concentration level (an anti-freeze hydrometer is recommended). • Check coolant level after first complete warm-up and cool down cycle. Additional coolant may need to be added. Flush Coolers Drain heat exchangers of raw water.
Locate the engine coolant heat exchanger. It is installed vertically near the front of the engine either next to the serpentine belt (5.7L) or in front of the serpentine belt (6.0L). Using an 11/16” socket wrench, remove the zinc anode from the lower end of the heat exchanger. Inspect the anode for wear, if the anode exhibits signs of excess wear or has reduced to half of its original size it will need to be replaced.
S TORAGE & WINTERIZATION Proper storage and/or winterization preparations are as impor- tant as how a drive train is maintained in use. Since special preparations are necessary, the boat owner should have the work done by an ILMOR-authorized dealer. Damage that occurs from improper storage and/or winterization is not covered under warranty and must be avoided.
• Run the engine for at least fifteen (15) minutes while in a body of water. This allows for the circulation of the additives throughout the fuel system. • If possible during storage, the tank vents should be sealed. If the vent is sealed, the tank must NOT be completely filled. A ninety-to-ninety-five percent (90-95%) filled tank allows room for expansion, which will be required at certain times when temperatures increase.
• Drain exhaust manifolds of raw water by removing ½” NPT pipe plugs. • Drain engine block of raw water (if raw water cooled). • For 5.7L applications: remove knock sensors/drain plugs from both sides of the engine block. • For 6.0L, 6.2L and 7.4L applications: Remove drain plugs from both sides of engine drain hoses, drain fitting #6SS - part number 94MV8-1476; removal of drain plugs will require both an 11/16” and 5/8” size wrench. • Drain heat exchangers of raw water.
• • • • • • Remove the engine thermostat. If it is not removed, the antifreeze will pump through the exhaust adapters and bypass the engine. Fill a bucket with four (4) gallons of non-toxic marine/RV antifreeze. Do not dilute it. It comes pre-diluted. Add remaining 2 gallons of antifreeze during procedure.
Recommissioning After Storage/Winterization Properly preparing the engine and drive train after a period of storage and/or winterization is equally important. Equal attention must be paid to the same components during recommissioning as during the winterization process. 1. Remove raw water pump impeller and check it carefully. If it appears to have weathered or there are any doubts about its ability to function properly, replace it.
EMISSIONS It is extremely important that attention be given to the emissions throughout the life of the engine. It is the owner/operator’s responsibility to ensure that the engine maintenance is performed as described in this Owner’s Manual, in order to maintain emissions levels within the certified standards. The owner/operator(s) must never modify the engine in any manner that alters the allowable emission levels to exceed the certified specifications.
HANG TAG Each boat equipped with an ILMOR MV8 engine will have a hang tag with the Four Star box check-marked. It is the responsibility of the selling dealer to include the hang tag, and it must be marked in the correct box to match the Four Star label on the engine and the boat. The dealer must display the hang tag in a visible location on the boat prior to displaying the boat for sale in California. If only the engine is displayed, a hang tag must still be placed in a visible location on the engine.
California and U.S. EPA Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board, U.S. Environmental Protection Agency and ILMOR Marine, LLC are pleased to explain the emission control system warranty on your 2011 sterndrive/inboard engine. In the United States, new sterndrive/inboard engines must be designed, built and equipped to meet all Federally mandated anti-smog standards.
Exclusions: Failures other than those resulting from defects in material or workmanship are not covered by this warranty. This warranty does not cover damage to emission control systems or parts which are a result of owner abuse, neglect, improper maintenance, the incorporation of, or use of, add on or modified parts, or the unapproved modification of any part.
Electronic Emission-Related Control Parts Warranty: Systems Covered by this Warranty: Parts Description: Fuel Metering Fuel injectors Air/fuel ratio feedback and control system Cold start enrichment system Ignition Electronic ignition system Spark advance/retard system Miscellaneous Items Camshaft position sensor Crankshaft position sensor Engine coolant temperature sensor Intake air temperature sensor Knock sensors M
TROUBLESHOOTING The following chart is offered as assistance in identifying and correcting minor issues that may occur. Problems are listed in the order of most-likely to least-likely. Not all possible problems, causes and solutions can be listed here. When experiencing problems, check surroundings before shutting down the engine. If suddenly stopping the power would result in placing other boats and boaters in jeopardy, continue until it is safe(r) to slow or stop and analyze the situation.
ILMOR MARINE, LLC LIMITED PRODUCT WARRANT Y 1. General. ILMOR Marine, LLC (“ILMOR Marine”) provides this limited warranty to customers purchasing a MasterCraft ski or wakeboard boat equipped with an ILMOR Marine engine and power train system (the “ILMOR Products”). This warranty may be transferred to a second retail purchaser for only the unused portion of the warranty. ILMOR Marine must be notified in writing at the time the second purchaser takes possession.
gine Control Module prior to granting warranty coverage and in determining warranty eligibility.This warranty shall only apply to ILMOR Products purchased with and installed in MasterCraft ski and wakeboard boats.
(j) Defects to the starter motor, armatures, or field coil assembly determined by ILMOR to be caused by excessive cranking, condensation or submersion; (k) Defects due to water entering the ILMOR Products through the intake or exhaust system or as a result of submersion or lack of cooling resulting from engine starting outside of the water or with foreign materials blocking intake passages; (l) Any other damages to ILMOR Products which ILMOR Marine, in its sole discretion, determines are not the result of d
information regarding warranty service or to obtain information regarding the nearest authorized MasterCraft dealer, please contact MasterCraft at the following address or telephone number: MasterCraft Boat Company, LLC Attention: Warranty/Customer Service Department 100 Cherokee Cove Drive Vonore, Tennessee 37885 1-423-884-2221 ILMOR Marine may repair or replace parts under this warranty with new, remanufactured or refurbished parts, in its sole discretion.
AND ORAL, AND ANY OTHER COMMUNICATIONS RELATED TO WARRANTIES. NO PERSON OR ENTITY, INCLUDING MASTERCRAFT AND ITS DEALERS, IS AUTHORIZED TO GIVE ANY OTHER WARRANTY ON BEHALF OF ILMOR MARINE OR TO CREATE ANY OTHER OBLIGATION OF ILMOR MARINE WITH RESPECT TO THE ILMOR PRODUCTS.
SPECIFICATIONS AND SERVICE LOG ENGINE SPECS Requirements and Recommendations Engine Model Number of Cylinders Displacement Compression Ratio Valve Configuration Firing Order Fuel Type Fuel Shutoff Engine Weight (including V-drive) MATERIALS Block Cylinder Head Intake Manifold Exhaust Manifold MV-8 5.7L V-8 5.73L 9.4:1 Overhead valves 1-8-4-3-6-5-7-2 Unleaded 87-93 octane 5,200 RPM 1,012 lb (460 kg) MV-8 6.0L V-8 5.978L 9.
Transmission: Automatic transmission fluid Transmission Filter: Direct Drive (45A) - 94MV8V1173 Direct Drive (45C) - 94MV8V1174 Direct Drive (63A) - 94MV8V1176 V-Drive (63IV) - 94MV8V1175 Item Service Engine oil and filter Change Engine coolant Change Power steering fluid Check Transmission fluid Change Serpentine belt Inspect Raw water impeller/ Inspect sea pump Air filter/flamer arrestor Clean/ change Engine** Tune-up Engine timing** Check Spark plugs** Replace Spark plug wires** Inspect B
SERVICE LOG Service Date Date Engine oil and filter Engine coolant Power steering fluid Transmission fluid Walters V-drive oil Serpentine belt Raw water impeller/ Sea pump Air filter/flame arrestor Engine* Engine timing* Spark plugs* Spark plug wires* Breather hose* PCV valve* Shaft alignment Heat exchanger(s) Zinc anodes ILMOR MV8 Owner’s Manual • Page 55 Date Date Date Date
INDEX After Each Use....................................................................................... 21 After Initial Hours of Operation.................................................................. 24 After Storage/Winterization, Recommissioning............................................... 41 Air Filter, Clean the Engine Flame Arrestor/.................................................. 31 Alarm, Oil Pressure.................................................................................
Cooler, Check the Transmission................................................................... 15 Coolers, Flush........................................................................................ 35 Cooling System Storage and Winterization..................................................... 38 Cooling System........................................................................................6 Cooling System, Full Closed........................................................................
Full Closed Cooling System.........................................................................7 Fuse Box................................................................................................8 Gasoline or Gasoline Containing Alcohol, Oxygenated....................................... 12 Gears, Shifting....................................................................................... 26 General Emissions Warranty Coverage..........................................................
Pick-up, Check Raw Water........................................................................ 21 Pre-Outing Requirements, Other................................................................ 13 Prevention, Cleaning Engine Compartment and Corrosion................................. 36 Product Warranty, ILMOR Marine, LLC Limited............................................. 48 Raw Water (Sea Water) Draining and Filling....................................................
Tag, Hang............................................................................................. 43 Temperature (Alarm), Water...................................................................... 10 Throttle and Shift Cables for Kinks, Wear and Interference, Inspect the................... 18 Transmission Cooler, Check the.................................................................. 15 Transmission Fluid/Oil and Filter, Change the.................................................
