OME0502-11 CoverC_OM0502-05 Cover.qxd 4/20/10 3:34 PM Page 1 The first production inboard equipped with catalytic converters. 5400 Old Millington Road Millington, TN 38053 w w w. i n d m a r. c o m Part No. OME0502-11 Ken Cook Co. Operator ’s Manual Printed in U.S.A.
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OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page i IMPORTANT SAFETY INFORMATION Throughout this manual, specific precautions and symbols identify safety related information. ! The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! ! ! Indicates the presence of a hazard which WILL cause SEVERE injury, death or substantial property damage. Indicates the presence of a hazard which CAN cause SEVERE injury, death or substantial property damage.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page ii ENGINES COVERED The information in this manual applies to the following engine models: 5.7L Carbureted Indmar 5.7L Vortec 350 Carb Jet 5.7L Electronic Fuel Injected Axis AR335** Indmar 5.7L MPFI Indmar Assault 325 Malibu 5.7L LCR MasterCraft 5.7L RTP-1 Indmar 5.7L HO* Indmar Assault 350* Malibu Monsoon* MasterCraft MCX* 6.0L Multi Port Fuel Injected Indmar LS2* Indmar L96* MasterCraft LY6* / L96* Malibu L96* 6.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page iii WELCOME Dear Indmar Marine Engine Owner, Thank you for selecting a boat powered by an Indmar Marine Engine. Indmar is proud to provide the power to the best boat companies in the business and we hope that pride shows in the quality of our products.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page iv INDMAR MARINE ENGINES COMPANY MISSION To produce the world’s finest, most advanced and most dependable gasoline inboard marine engines at the best possible price, while respecting the needs of our employees, customers, vendors and the precious environment we share.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page v TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Chapter 1: First Time Operation and Break-In . . . . . . . . . . . . . . . 1-1 First Time Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Chapter 2: General Operations and Warnings . . . . . . . . . . . . . . . 2-1 Chapter 3: Engine Starting Procedures . . . . . . . . . . . . . . . . . . . . .
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page vi Chapter 5: Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 What Type of Gasoline to Use . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Using Oxygenated Fuels or Fuels with Alcohol . . . . . . . . . . . .5-2 Fuels in Other Countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Chapter 6: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page vii INTRODUCTION This manual will acquaint you with basic information needed to safely operate and maintain your Indmar engine. We suggest you and all other operators read the entire manual before using your boat. EMISSIONS LABEL We recommend you contact your Indmar dealer for all engine service. Certified Indmar Technicians are trained.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page viii Complete your warranty registration today! The Federal Boat Safety Act of 1971 requires registrations of marine products sold in the United States be maintained by the manufacturer and dealers of those products. Your dealer should have completed your warranty registration to comply with federal regulations. This registration enables us to contact you, if it should become necessary, to change or improve your product.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page ix Warranty Registration Transfer The remainder of the engine warranty is transferable to a second or subsequent owner. Warranty transfers must be completed within 10 days of the transfer of ownership. If the trade-in and resale is handled by an authorized Indmar dealer, the dealer must fill out the warranty registration transfer form and send it and other paperwork specified along with the warranty transfer fee (currently $200.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page x EMISSION CONTROL WARRANTY INFORMATION The inboard engine in your boat includes the Indmar Emission Control System identified as MFI or TBI or EM. Refer to the identification sticker on your engine to determine which emission control system pertains to your engine. The fuel and ignition systems on your engine meet the stringent requirements set forth by the California Air Resources Board (CARB).
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page xi Lubricant – Indmar uses and recommends Pennzoil 15W40 Marine Oil for use in all of its engines except for the 8.1 liter models which use Pennzoil 40W oil and the LS series engines which use Mobil 1 5W30 oil. If Pennzoil Marine oil is not available, any appropriate viscosity motor oil meeting the API ratings of SL/SJ, CI-4, CH-4, CG-4 is acceptable. See Chapter 6, Maintenance, for information regarding the use of synthetic oil.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page xii NOTICE The repair or replacement of any warranted part otherwise eligible for warranty coverage under the Emission Control Warranty may be excluded from such warranty coverage if Indmar demonstrates that the engine has been abused, neglected, or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page xiii NOTICE NOTICE The above procedure is valid for the transfer of the Emission Components warranty only. Refer to the Limited Warranty in Section C of this manual for information regarding warranty transfer of the remaining engine components. Ignition timing, engine idle speed and air-fuel mixture are not adjustable on this engine. NO OTHER ADJUSTMENTS NEEDED.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page xiv Emission Component Part Numbers Following are the Indmar Part numbers for the Emission Maintenance Components: Engine Model Indmar 5.7L Vortec* Indmar Assault 310* Indmar 5.7L MPFI* Indmar Assault 325* Malibu 5.7L LCR* MasterCraft 5.7L RTP-1* AXIS AR335* AXIS Raptor 400* AXIS AR335 With Catalyst AXIS Raptor 400 With Catalyst Indmar 5.7L HO Indmar 5.7L Assault 340 Malibu Monsoon 350 Malibu 383 Hammerhead MasterCraft MCX MasterCraft 6.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page xv CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Indmar Products are pleased to explain the emission control system warranty on your 2011 inboard engine. In California, new inboard engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page xvi Owner’s Warranty Responsibilities As the inboard engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Indmar Products recommends that you retain all receipts covering maintenance on your inboard engine, but Indmar Products cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 1-1 Chapter 1 FIRST TIME OPERATION AND BREAK-IN FIRST TIME OPERATION A new engine may use a more than normal amount of engine oil before it is broken in. Check your oil level hourly during the breakin period. Once the engine is broken in, check the oil level before each day’s use and more often during sustained periods of high RPM operation. Marine usage is different from automobile usage and oil consumption is expected.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 1-2 Fresh Water Cooling System – If equipped, the heat exchanger has four drain plugs; two for raw water and two for coolant. Refer to Chapter 7, Storage and Winter Lay-up. RANGE OPERATING RS MANUA SEE OWNE INDM-A003 ADD Figure 1.3 – Engine Dipstick Level 5. Check transmission oil level for correct level. Refer to Chapter 6, Maintenance. 6. If your engine is equipped with fresh water cooling, check the expansion tank for the correct level.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 1-3 8. Back trailer into the water. Make sure the engine water intake is submerged. ! ! Before starting engine operate bilge blower at least 4 minutes and raise engine cover to ventilate fumes. Inspect engine and compartment for any fluid or fuel leaks. Failure to do so can possibly result in fire and/or explosion resulting in death or serious injury to you and your passengers.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 1-4 NOTICE The above procedure is only necessary for the first time the engine is started or in the event the fuel tank is run dry. 10. Start the engine (Refer to Chapter 2, General Operation and Warnings) and allow it to reach normal operating temperature; keep a close eye on the gauges. If any of the gauges indicate an engine problem, stop the engine immediately and bring the boat to your Indmar dealer for assistance.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 1-5 Break-in Steps 1. For the first hour, do not exceed 2000 RPM; vary RPM continuously. 2. For the second hour, do not exceed 3000 RPM; vary the RPM regularly. 3. For the next five hours, do not exceed 4000 RPM; vary the RPM regularly. After the first ten hours but before 20 hours of operation, take your boat to the dealer for its first engine and transmission oil and filter change and engine checkup.
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OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 2-1 Chapter 2 GENERAL OPERATION AND WARNINGS ! The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Operating a boat is a safe and enjoyable experience. Indmar marine engines use gasoline for fuel. The area under the engine and around the gasoline tank and supply lines is not open to outside air.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 2-2 When refueling, make sure to open the motor box and run the blower during and after the re-fueling operation. Failure to do so may result in fire or explosion and may cause death or serious injury. ! ! Carbon monoxide gas (CO) is colorless, odorless and extremely dangerous. All engines and fuel burning appliances produce CO as exhaust. Direct and prolonged exposure to CO will cause BRAIN DAMAGE or DEATH.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 2-3 For more information on carbon monoxide and boats, contact the US Coast Guard Office of Boating Safety at 1-800-368-5647 or www.uscgboating.org or your state boating law administrator at 1-800-225-9487 or www.nasbla.org. Daily Pre-Start Checks Refer to Chapter 6, Maintenance for checks and services. 15 14 16 1 Never remove or modify any components of the engine’s fuel system.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 2-4 3. Verify engine drain plugs are in place. 4. Check engine oil level with the dipstick. INDM-B001 Figure 2.2 – Engine Oil Dipstick 5. Verify fuel lines are tight and there is no leakage present. 6. Inspect oil lines and oil filter. Ensure they are tight and no leakage is present. 2-4 INDM-A009 Figure 2.3 – Engine Oil Filter 7. Check transmission fluid level. Check V-Drive fluid level if equipped. 8.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 2-5 13. Check electrical connections and ensure connectors are tight. Check wiring for signs of wear and abrasion. 14. Verify throttle/shift control is functional and properly adjusted. 15. Verify steering controls are functional and properly adjusted. 16. Verify battery connections are clean and securely fastened. INDM-A010 Figure 2.
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OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 3-1 Chapter 3 ENGINE STARTING PROCEDURES ! ! Explosive gasoline and battery fumes may accumulate in your engine compartment. Failure to properly ventilate fumes with the bilge blower may result in explosive atmosphere resulting in death or serious injury to you and your passengers. Before starting engine operate bilge blower at least 4 minutes and raise engine cover to ventilate fumes. Inspect engine and compartment for any fluid or fuel leaks.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 3-2 2. Perform the Daily PreStart checks. Refer to Chapter 2, General Operation and Warnings. 3. Move the shift control lever to the NEUTRAL position. Pull out the neutral safety lever (if equipped). Without advancing the throttle lever, turn the starter key to START position. NOTICE R WE O BL ON F OF INDM-A011 Figure 3.1 – Typical Blower Switch NOTICE Prime cold engine by moving throttle forward and back two or three times.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 3-3 IF ENGINE DOES NOT START INDM-A013 Figure 3.3 – Typical Tachometer Once the engine has started, immediately check the oil pressure. Monitor the oil pressure and engine temperature closely for the first 10 minutes of operation. Do not operate starter motor for more than 15 seconds without a 2 (two) minute cooldown period. Excessively long cranking times will permanently damage the starter motor and drain the battery.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 3-4 ENGINE RESTART 2 1. If your engine is already warm and will not re-start, turn key to ON position and wait for about 20 seconds (not necessary with carbureted engine). 2. Make sure that your throttle lever is in NEUTRAL. 3. Turn key OFF. Try to start engine again. If it does not start disengage the shift interlock and advance throttle to about 1/4 while holding key in the START position.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-1 Chapter 4 NORMAL OPERATION DAILY ROUTINE 1. Open the engine cover and check the bilge for water; pump bilge dry. Excessive amounts of water can indicate leakage problems from shaft/ rudder logs, thru-hull fittings, loose or damaged hoses or hull damage. Excess water in the bilge will damage engine components (starters, alternators, transmissions, etc.). Don’t forget to run your engine blower for at least 4 minutes before cranking engine.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-2 4. Monitor your gauges and warning lights frequently to ensure that engine temperatures and pressures are within the proper ranges. INDM-A014 OPERATING THE CONTROLS Be sure to refer to the boat owner’s manual for additional information. Should there be any difference between the information presented in this manual and the boat owner’s manual, the boat owner’s manual should take precedence.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-3 Most boats have an engine safety switch (1, Figure 4-3) that can be activated if the driver moves from the helm position. If you experience a “no start” condition, verify that this switch has not been disabled. If the tether cord is pulled from the switch, it disables the ignition system so the boat cannot start.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-4 FUEL SYSTEM The Indmar fuel system uses high quality marine grade components. These components will tolerate small amounts of water without sustaining damage. Your engine will misfire and run poorly, however, if water is in the fuel. Use caution when re-fueling not to allow water to enter the fuel system. If you suspect your fuel is water contaminated, consult your dealer and avoid that fuel source in the future.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-5 Use caution when connecting the battery cables. Improperly connecting the battery cables or using the wrong battery type can damage electrical components. These damages are not covered by your warranty. “SERVICE REQUIRED” OR “CHECK ENGINE” INDICATOR (EFI ENGINES ONLY) Some boats are equipped with a digital dash which displays the words “SERVICE REQUIRED” and/or “CHECK ENGINE,” and some boats are equipped with a Check Engine light.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-6 Follow the boat manufacturer’s instructions if the sea strainer is blocked. CHECK TRANSMISSION LIGHT If the engine is equipped with the Walters V-Drive transmission, there may also be a Check Transmission light. If low oil pressure is sensed in the V-Drive, the light will go on indicating the problem. Under normal operation, the light will stay lit at idle and slow speed operation until enough pressure is produced (1200 RPM ± 400 RPM).
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-7 The rubber water pump impeller in the water pump can be damaged from running dry or by picking up sand or silt through the water intake. Inspect your water pump impeller annually or more often if you operate your boat in shallow water or run it aground. Impeller failure will result in an overheated engine. Running your engine with your boat out of water will damage or ruin your engine.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-8 ! ! Carbon monoxide gas (CO) is colorless, odorless and extremely dangerous. All engines and fuel burning appliances produce CO as exhaust. Direct and prolonged exposure to CO will cause BRAIN DAMAGE or DEATH. Signs of exposure to CO include nausea, dizziness and drowsiness. Ensure adequate ventilation to prevent accumulation of CO in the boat. Monitor the engine temperature gauge frequently.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 4-9 An engine that is under-revving is lugging. Lugging places tremendous loads on the pistons, crankshaft and bearings and can cause detonation, piston seizure and other engine damage. Elevation and weather also have a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air.
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OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 5-1 Chapter 5 FUEL WHAT TYPE OF GASOLINE TO USE All carbureted and standard EFI engines run on unleaded fuel of 89 octane or higher. The LY6, L96, LSA, LS2, LS3 and LS7 require 91 octane or higher. Indmar recommends purchasing fuel from a supplier that advertises that the fuel meets “TOP TIER” specifications. This fuel has additives and detergents that will reduce the build-up of deposits in the engine.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 5-2 Frequently inspect fuel lines and connections for leaks or deterioration. Indmar recommends the regular use of Marine Formula Sta-Bil fuel stabilizer for boat users that consume less than a tank of fuel every two weeks. Today’s fuels are more susceptible to degradation and the use of a quality stabilizer will help ensure fewer problems for the occasional boater.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-1 Chapter 6 MAINTENANCE GENERAL SERVICE NOTES Your Indmar dealer is your best source for engine repair and maintenance. Indmar certified technicians attend ongoing service training programs and have the proper diagnostic tools plus the latest specifications for your engine. ! ! Electrical, ignition and fuel system components on Indmar engines comply with U.S. Coast Guard rules and regulations to minimize risks of fire or explosion.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-2 • You can be injured if you try to work on your marine engine without knowing enough about your engine. • Be sure you have the knowledge, experience and the correct replacement parts BEFORE you attempt any repairs. • Be sure all fasteners you use are approved and rated for marine use. Use of improper parts can cause component or engine failure which may result in death or serious personal injury.
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OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-4 ENGINE OIL 1. 2. 3. 4. 5. 6. Checking Oil Pull dipstick from engine. Wipe oil off stick with clean towel/cloth. Insert dipstick completely into the dipstick tube. Remove dipstick and read oil level. After reading is complete, return dipstick to tube. Add oil if necessary. Adding Oil If oil level on the dipstick reads below the ADD mark, add only enough oil to return level to FULL mark. INDM-B001 Figure 6.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-5 Special Oil Instructions for Malibu LS7 Engine Do not overfill. If your oil level is above the full mark on the dipstick, the engine may be damaged. Indmar uses and recommends Pennzoil Marine 15W40 in all 5.7L, 6.0L and 6.2L (383) engines and Pennzoil Heavy Duty 40W in all 7.4L (454), 8.1L (496) and 8.2L (502) engines. This oil meets the API Service CI-4, CH-4, CG-4, CF-4, and CF/SL.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-6 Pull the dipstick with the yellow handle from the reservoir, and clean it with a lint-free cloth. Then push it back in all the way until it stops. Remove it again, keeping the tip down, and note the oil level on the crosshatched area. An oil level within the crosshatched area is normal. If the level is below the crosshatched area, add 1 quart (0.96 L) of 5W30 Mobil 1 synthetic oil through the black oil reservoir fill cap and take another reading.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-7 Once the oil has been removed from the engine and reservoir, fill a new PZ52 oil filter with 5W30 Mobil 1 synthetic oil and install it on the remote filter head. Tighten per instructions on the filter. Pour the remainder of the 8 Quarts of 5W30 Mobil 1 through the oil fill cap in the top of the dry sump reservoir. The total service fill, with a filter, is 8 quarts (7.57 L) of 5W30 Mobil 1 synthetic engine oil.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-8 Oil Additives Engine oil is hot. Be careful not to burn yourself. 1. With the boat level on trailer, remove the hull or garboard drain plug and insert QuickDrain through the hull opening (outside of hull). 2. Remove QuickDrain hose cap and let oil flow into used oil container. When all oil has drained, replace cap and return QuickDrain to storage position. 3. Replace the hull or garboard drain plug.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-9 ENGINE FLAME ARRESTOR dry completely before it is returned to the engine. Your engine is equipped with a U.S. Coast Guard approved flame arrestor. Its purpose is to contain any backfire that may occur during the operation of your engine. Because an inboard engine is completely enclosed, an uncontained backfire can be extremely dangerous.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-10 Fresh water cooled engines are shipped from the Indmar factory filled with a 50/50 mix of Sierra brand antifreeze and water. This mixture provides freeze protection down to –26° F (-32° C). If the temperature in your area is expected to go below this level of protection, see your Indmar dealer to have the antifreeze mixture adjusted for your needs. Running your engine with your boat out of water will damage or ruin your engine.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-11 Check coolant level daily. The level in the coolant recovery tank should be maintained at the “Full Cold” mark (1, Figure 6.6) when the engine is cold. To avoid possible skin burns, the engine must be turned “OFF” and cool enough so no heat is registered on the temperature gauge. Only after the engine is completely cooled is it safe for you to remove the coolant reservoir cap to check the level.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-12 The following engines must not be operated in brackish or salt water environments unless equipped with a closed cooling system which allows the use of antifreeze coolant in the engine instead of raw water. • Malibu Hammerhead 383, LS3 and L96 • MasterCraft LY6 and L96 • Indmar LS2 These engines use aluminum cylinder heads and/or block assemblies which will be severely damaged from salt water corrosion if operated in brackish or salt water.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-13 Even with diligent flushing, certain exhaust system components called exhaust risers or exhaust elbows will be significantly affected by salt water. These risers must be inspected by your dealer annually and replaced as required. It is not unusual to have to replace these risers every two years on boats used exclusively in salt water.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-14 Fresh Water Cooling – All Systems All fresh water cooling systems, whether they are half or full systems, must be inspected and maintained annually, usually during winterization. Heat Exchanger – Remove the end caps to drain and inspect the heat exchanger. Clean out any debris. Make sure you inspect the end caps for contour and cracks and replace the neoprene gaskets before putting the boat back in service.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-15 IGNITION TIMING All current production Indmar engines, except for carbureted models, have non-adjustable ignition timing. On carbureted models, the ignition timing is carefully adjusted at the Indmar factory. Unless the distributor hold down clamp is loosened and the distributor is turned, the engine is essentially “timed for life.” In the event that the distributor has been moved, the timing procedure for a carbureted engine is as follows: 4.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-16 CARBURETOR ADJUSTMENTS The carburetor on your engine has been carefully adjusted at the factory and has had sealing caps applied to the idle mixture screws to prevent further adjustment. Altering the original factory settings will change the emissions characteristics of your engine and may put your engine "out of compliance" with the emission standards in California.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-17 A separate owner’s manual covering basic maintenance is provided with each transmission. The transmission fluid must be changed and the filter cleaned after the first 1020 hours of operation and once each year thereafter. Refer to the transmission owner's manual for information. The transmission is water cooled by a heat exchanger connected to the engine cooling system. The transmission fluid level should be checked daily.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-18 1. Remove the dipstick and wipe with a clean towel. 2. Insert the dipstick completely (do not screw in threaded dipstick to check fluid). Remove the dipstick and read fluid level. 3. Return dipstick after level check. Make sure it is secured in place. 4. If level is below “ADD” mark, add the proper fluid until it reaches the full mark. Add fluid through same tube as you removed the transmission dipstick. INDM-A031 Figure 6.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-19 USED BY TRANSMISSION MODEL CAPACITY FLUID TYPE MB, MC, SC MC MC MC ZF ZF ZF ZF ZF ZF ZF ZF MB ZF Hurth V-Drive ZF 45IV SC Walters V-Drive RV-26D-71V MB Indmar V – 1.7 qt (1.6L) 2.12 qt (2L) 4.2 qt (4L) 4.2 qt (4L) 2.12 qt (2L) Main Gearbox 1.0 qt (1.06L) V-Drive Unit 0.5 qt (0.5L) 2.3 qt (2.18L) Main Gearbox 1.25 qt (1.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 6-20 If the breaker trips again, there is a problem with the electrical system. Take your boat immediately to your Indmar dealer for repair.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-1 Chapter 7 STORAGE AND WINTER LAY-UP Storage or winter lay-up requires preparation to prevent damage to the power package. While preparing the power package for winter lay-up, annual maintenance tasks should also be performed. Without proper preparation, storage over a long period of time may cause internal engine and transmission parts to rust due to lack of lubrication.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-2 NOTICE This procedure covers only the power package portion of your boat. Consult your boat owner’s manual or boat manufacturer for specific boat winterizing instructions. GENERAL PREPARATION Before beginning you will need the following supplies: • Sta-Bil Gasoline Stabilizer • 6 quarts of Appropriate Engine Oil (10 quarts for 8.1 Liter) • Pennzoil PZ52 Oil Filter for 5.7 and 6.0 Liter Carbureted and EFI Engines • AC-PF454 Oil Filter for 8.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-3 In catalytic converter-equipped engines, Indmar does not recommend applying fogging oil while the engine is running. The fogging oil could damage the catalytic converter. The cylinders can be protected by removing the spark plugs and applying the fogging oil directly into the cylinders. All Engines: 1. Drain water from exhaust manifolds except on salt water series engines. Uncouple the hose quick disconnect and drain the manifolds.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-4 INDM-A036 Figure 7.2 – Raw Water Pump Impeller INDM-A009 3. Remove the raw water pump impeller from the pump housing. Replace the impeller if it shows any signs of damage or wear. Lubricate the impeller with Vaseline and seal in an airtight bag. 4. Remove the hose from the lower (rear) end of the transmission cooler. Inspect the cooler for any debris such as weeds, plastic, etc. 7-4 Figure 7.3 – Transmission Cooler 5.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-5 6. On Ski-Vee equipped units, the hoses that are connected to the integral V-Drive cooler (1, Figure 7.4) must be removed to drain the hoses and cooler. The anodes (2, Figure 7.4) at the back of the cooler must be removed and inspected. Replace if they are 50% eroded. WATER LINE WATER DRAIN WATER DRAIN 1 1 INDM-A040 2 2 INDM-A041 Figure 7.4 – Ski-Vee Indmar Marine Engines Figure 7.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-6 Raw Water Cooled Engines NOTICE NOTICE Placing the drain plugs in a plastic bag and attaching it to the steering wheel of the boat will act as a reminder to reinstall the drain plugs during recommissioning in spring. Some 5.7 Liter engines have a knock sensor located in the drain locations on both sides of the engine. The knock sensor and knock sensor stud must be carefully removed to drain that side of the block. NOTICE 1.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-7 Fresh Water Cooled Engines 1. Check the level of the coolant in the coolant recovery tank. The coolant level with a cold HOT engine should be approximately 1/3 of the coolant tank capacity. (Figure 1 7.7) Use an antifreeze tester suitCOLD able for measuring the strength of propylene glycol INDM-B002 anti freeze to test Figure 7.7 – Overflow Tank the strength of the mixture. 2.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-8 Drive Train Preparation 1. Change the transmission fluid and clean the filter screen following the instructions in the Transmission Owner’s Manual. 2. Remove the attaching hardware from the propeller shaft coupling. Separate the flanges and coat the surfaces with Pennzoil Premium Plus Multipurpose grease. General Power Package Preparation 1. Clean dirt, grime and grease from painted surfaces of the engine and drive train. 2.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 7-9 12. If the fuel tank was drained, fill tank with fresh fuel that does not contain alcohol. 13. Check all fluid, oil and coolant levels on engine and drive train. 14. Check engine compartment and bilge for nesting animals. Clean as necessary. Check for any damage or evidence of fluid leaks. 15. Remove tape from flame arrestor. Check alignment between the output flange on the transmission and the prop shaft flange.
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OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 8-1 Chapter 8 TROUBLESHOOTING Your Indmar engine is manufactured under strict quality control standards. It is tested along with a full spectrum gas analysis. It is operating at optimum levels before it is shipped. Indmar engines have the exclusive Indmar 3-year limited warranty. Difficulties can occur. Use the following problem diagnosis charts to help pinpoint problems.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page 8-2 7. Insufficient air supply to engine 8. Engine needs tune-up 9. Damaged or incorrect propeller 10. Engine needs to be adjusted for high altitude operations 11. Engine needs to be adjusted for temperature extremes Engine Cranks / Won’t Start 1. 2. 3. 4. 5. 6.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page A-1 Appendix – A MAINTENANCE COMPONENTS AND FLUIDS Engine Oil All 5.7, 6.0, 383 – 15W-40 Pennzoil Marine, API Service SL/SJ/CI-4, CH-4, CG-4 All 7.4L, 8.1L, 8.2L – 40W Pennzoil Marine Service SL/SJ/CI-4, CH-4, CG-4 All LSA, LS2, LS3 and LS7 – 5W30 Mobil 1 Engine Oil Filter All 5.7 and 6.0 Liter – Pennzoil PZ52 8.1 Liter – AC-PF454 w/o Remote Oil 8.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page A-2 Alternator Belt Thermostat Spark Plugs Surface Corrosion Protection Engine Fogging Oil A-2 All Indmar 5.7 Liter – Indmar 725018 All Malibu MasterCraft 5.7L and 6.2L – Indmar 725034 LS7/6.0 serpentine – Indmar 725028 8.1 Liter – Indmar 725030 All Raw water cooled – Indmar 985009 All Closed cooled except LS7/6.0L – Indmar 986034 LS7/6.0L – Indmar 986110 All 5.7L and 383 – AC Delco 41-101 Platinum LY6, L96, LS2 and LS3 – AC Delco 41-110 8.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page B-1 Appendix – B ENGINE SPECIFICATIONS See page ii for engine models Number of Cylinders Displacement Bore/Stroke Compression Ratio Compression Pressure Idle RPM in Neutral Operating Range at WOT Oil Pressure at Idle Oil Pressure at 2000 RPM 5.7L Carbureted 5.7L MPI LS7 LS2/LS3/LY6/L96 V-8 350 CID (5.7L) 383 CID (6.3L) 427 CID (7.0L) 364 CID (6.0L) 4.0012 x 3.480 in. 4.0012 x 3.8 in 4.125 x 4.00 4.000 x 3.622 in. (101.63 x 88.39 mm) (101.63 x 96.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page B-2 Fluid Capacities Crankcase (With Filter) Closed Cooling System In-Line 1:1 Transmission In-Line Reduction Gear ZF Ski Vee Transmission ZF V-Drive Transmission Walter V-Drive B-2 5.7L Carbureted 5.7L MPI 383 LS7 LS2/LS3/LY6/L96 8.1L MPI 5.5 Quarts (5.25 L) 6.0 Quarts (5.7 L) 10 Quarts (9.5 L) 12-14 Quarts (11.4-13.3 L) 14-16 Quarts (13.2-15.1 L) 1.7 Quarts (1.6 L) Dexron 3 ATF 4.2 Quarts (4 L) 15W40 2.12 Quarts (2 L) Pennzoil 15W40 4.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page B-3 454 Carb Number of Cylinders Displacement Bore/Stroke Compression Ratio Compression Pressure (Note 1) Idle RPM in Neutral (Note 2) Operating Range at WOT Oil Pressure at Idle Oil Pressure at 2000 RPM Oil Filter Fuel Pump Pressure Electrical System Minimum Battery Requirements Firing Order Spark Plug Type Spark Plug Gap Base Timing at 1000 RPM (Note 3) Thermostat Indmar Marine Engines 502 Carb V-8 454 CID (7.4L) 502 CID (8.2L) 4.25 x 4 in. 4.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page B-4 Fluid Capacities Crankcase (With Filter)(Note 4) Closed Cooling System (Note 5) In-Line Transmission (Note 4) Walters V-Drive Transmission (Note 4) Hurth V-Drive Transmission (Note 4) 454 Carb 502 Carb 7 Quarts (6.62 L) With Filter (10 Quarts with Jet Pan) 14-16 Quarts (13.25-15.14 L) 2.12 Quarts (2.0 L) Dexron 3 ATF 2 Pints (0.95 L) 30W Motor Oil 4.4 Quarts (4.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page C-1 Appendix – C INDMAR LIMITED PRODUCT WARRANTY 1. Warranty. Indmar Products Co., Inc., 5400 Old Millington Road, Millington, Tennessee 38053 (“Indmar”), warrants that its marine propulsion engine and the parts related thereto (collectively, “Product”) are free from material defects in material and workmanship under normal use and service during the applicable warranty period as set forth herein. 2. Coverage.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page C-2 (b) Incidental and consequential damages, including, but not limited to, storage charges, telephone or rental charges of any type, inconvenience or loss of time or income. (c) Minor adjustments and tune-ups, including, but not limited to, checking, cleaning or adjusting spark plugs, carburetor setting, filters, belts, controls and checking lubrication.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page C-3 (o) Defects to the Product as determined solely by Indmar to be caused by the use of fuels and lubricants that are not suitable for use with or on the Product or its fuel system components that was damaged or rendered inoperable from stale gasoline. (p) Defects to the Product as determined solely by Indmar to be caused by the lack of cooling water resulting from the motor being started out of water or foreign materials blocking intake passages.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page C-4 In the event that more than one warranty time period may be applicable to a particular Product pursuant to this Section 6, the shortest period of time shall apply and shall be the only warranty time period allowed for that Product. The repair or replacement of parts or the performance of service under this Limited Product Warranty does not extend the applicable period of this warranty beyond its original expiration date as set forth herein. 7.
OME0502-11 Body_OM0502-05 Body.qxd 6/3/10 10:45 AM Page C-5 (b) When the Product is serviced by any individual or entity not authorized or approved by Indmar; or (c) When damage to the Product results from cases not arising from defects in material and/or workmanship and Indmar in its sole discretion determines the same. 10. Notices. Any notice to Indmar set forth pursuant to this Limited Product Warranty shall be delivered to the following address: Indmar Products Co., Inc.
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OME0502-11 Cover_OM0502-05 Cover.qxd 6/3/10 2:52 PM Page 1 The first production inboard equipped with catalytic converters. 5400 Old Millington Road Millington, TN 38053 w w w. i n d m a r. c o m Part No. OME0502-11A Ken Cook Co. Operator ’s Manual Printed in U.S.A.
