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90-861327--1 OCTOBER 1999
Table of Contents
IMPORTANT INFORMATION
Section 1A - General Information
Table of Contents
1A-1
. . . . . . . . . . . . . . . . . . . . .
Introduction
1A-2
. . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use This Manual
1A-2
. . . . . . . . . . . . . . .
Page Numbering
1A-2
. . . . . . . . . . . . . . . . . . .
How to Read a Parts Manual
1A-3
. . . . . . . . . . .
Directional References
1A-4
. . . . . . . . . . . . . . . . .
Engine Rotation
1A-4
. . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number Locations
1A-5
. . . . . . . .
Propeller Information
1A-5
. . . . . . . . . . . . . . . . . .
Water Testing New Engines
1A-6
. . . . . . . . . . . .
Boat and Engine Performance
1A-6
. . . . . . . . . .
Boat Bottom
1A-6
. . . . . . . . . . . . . . . . . . . . . . .
Marine Fouling
1A-8
. . . . . . . . . . . . . . . . . . . . .
Weight Distribution
1A-9
. . . . . . . . . . . . . . . . . .
Water in Boat
1A-9
. . . . . . . . . . . . . . . . . . . . . .
Elevation and Climate
1A-9
. . . . . . . . . . . . . . .
Section 1B - Maintenance
Table of Contents
1B-1
. . . . . . . . . . . . . . . . . . .
Tools
1B-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives
1B-2
. . . . .
Maintenance Schedules
1B-3
. . . . . . . . . . . . . .
Maintenance Intervals
1B-3
. . . . . . . . . . . . .
Engine and Tune-Up Specifications
1B-7
. . . .
Fluid Capacities
1B-11
. . . . . . . . . . . . . . . . . . . . .
Sterndrive Engines
1B-11
. . . . . . . . . . . . . . .
Inboard and Ski Engines
1B-11
. . . . . . . . . . .
Sterndrives
1B-11
. . . . . . . . . . . . . . . . . . . . . .
Transmission
1B-12
. . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period
1B-13
. . . . . . . . . . . . .
After Break-in Period
1B-13
. . . . . . . . . . . . . . . .
End of First Season Checkup
1B-13
. . . . . . . . .
Specifications
1B-14
. . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations
1B-14
. . . . . . . . . . .
Vapor locking
1B-14
. . . . . . . . . . . . . . . . . . . .
Test For Alcohol Content In Gasoline
1B-16
Procedure
1B-16
. . . . . . . . . . . . . . . . . . . . . . .
Transmission Fluid
1B-16
. . . . . . . . . . . . . . . . . .
Power Steering Fluid
1B-16
. . . . . . . . . . . . . . . .
Coolant for Closed Cooling System
1B-16
. . . .
Crankcase Oil
1B-17
. . . . . . . . . . . . . . . . . . . . . .
Overfilled Crankcase Oil
1B-17
. . . . . . . . . . .
Checking Engine Oil Level / Filling
1B-18
. .
Changing Oil and Filter
1B-18
. . . . . . . . . . . . . . .
Changing Water Separating Fuel Filter
1B-19
.
MCM (Sterndrive) Models
1B-19
. . . . . . . . . .
MIE (Inboard and Ski) Models
1B-20
. . . . . .
Power Steering System
1B-21
. . . . . . . . . . . . . .
Checking Fluid Level
1B-21
. . . . . . . . . . . . . .
Engine Warm
1B-21
. . . . . . . . . . . . . . . . . . . .
Engine Cold
1B-21
. . . . . . . . . . . . . . . . . . . . .
Filling and Bleeding
1B-22
. . . . . . . . . . . . . . .
Closed Cooling System
1B-23
. . . . . . . . . . . . . .
Checking Coolant Level
1B-23
. . . . . . . . . . .
Flushing System MCM (Sterndrive)
1B-24
.
Boat Out of Water
1B-24
. . . . . . . . . . . . . . . .
Boat In Water
1B-25
. . . . . . . . . . . . . . . . . . . .
Flushing System MIE
(Inboard and Ski)
1B-26
. . . . . . . . . . . . . . . .
Transmission Fluid
1B-27
. . . . . . . . . . . . . . . . . .
Lubrication
1B-28
. . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable
1B-28
. . . . . . . . . . . . . . . . . . . .
Shift Cable and Transmission Linkage 1B-28
MCM (Sterndrive) Models
1B-28
. . . . . . . . . .
MIE (Inboard and Ski) Models
1B-29
. . . . . .
Engine Coupler/U-Joint Shaft Splines
1B-30
Sterndrive Drive Shaft
Extension Models
1B-31
. . . . . . . . . . . . . . . .
Starter Motor
1B-31
. . . . . . . . . . . . . . . . . . . . .
mie (Inboard and Ski) models
1B-31
. . . . . .
Cleaning Flame Arrestor
1B-32
. . . . . . . . . . . . .
Top Mounted Flame Arrestor
1B-32
. . . . . . .
Black Scorpion Flame Arrestor
1B-33
. . . . .
Serpentine Drive Belt
1B-34
. . . . . . . . . . . . . . . .
Component Location
1B-34
. . . . . . . . . . . . . .
Inspection
1B-36
. . . . . . . . . . . . . . . . . . . . . . .
Replacing and/or Adjusting Tension
1B-36
.
Removal
1B-36
. . . . . . . . . . . . . . . . . . . . . . . .
Installation and Adjustment
1B-36
. . . . . . . .
Ignition Timing
1B-37
. . . . . . . . . . . . . . . . . . . . . .
Thunderbolt V Models
1B-37
. . . . . . . . . . . . .
EFI/MPI Models
1B-38
. . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage
1B-39
. . . .
Precautions
1B-39
. . . . . . . . . . . . . . . . . . . . . .
Power Package Layup
1B-40
. . . . . . . . . . . .
Draining Instructions
1B-42
. . . . . . . . . . . . . .
Draining Seawater (Raw-Water)
Cooled Models
1B-42
. . . . . . . . . . . . . . . . . .
Draining Seawater Section of Closed
Cooled (Coolant) Models
1B-48
. . . . . . . . . .
Draining Seawater Section of Closed
Cooled (Coolant) Models
1B-50
. . . . . . . . . .
Draining Sterndrive
1B-52
. . . . . . . . . . . . . . .
Recommissioning
1B-53
. . . . . . . . . . . . . . . . .