Owner’s Manual

VOLVOPENTA

WELCOME ABOARD Our Joint Responsibility

Please study this manual to completely understand howyour Volvo Penta stern drive operates and to enable you totake full advantage of its many built-in features.

Boating Responsibilities

Most countries have regulations controlling boating. Al-ways make sure you follow these regulations! As a boatowner, you have certain responsibilities to others. Be surethat all operators read this manual.

You are legally responsible for all occupants of your boat.Instruct at least one of your passengers in the basic funda-mentals of handling your boat in case of an emergency.Show all hands the location of emergency equipment andhow to use it. In the U.S. you are required by law to have oneU.S. Coast Guard approved life jacket for each personaboard, plus one approved throwable device for man over-board protection.

Learn the waterway rules of the locality in which you aregoing to operate your boat. Navigable waterways are con-trolled by Federal regulations while inland lakes are con-trolled by local jurisdictions. Obey these regulations toprotect yourself, your passengers and fellow boating enthu-siasts.

Thoroughly familiarize yourself with weather bureauwarning system signals and waterway traffic signs.

In the U.S. contact your local U.S. Coast Guard station andtake advantage of their seasonal boat inspections and train-ing courses.

Identification Numbers

Volvo Penta invests, annually, considerable developmen-tal resources to minimize the effects on the environmentcaused by our products. Examples of this continuous workare the improvements in exhaust emissions, sound levels,and fuel consumption.

Whether your Volvo Penta stern drive is used to power apleasure boat or is used in a commercial application it can, ifused incorrectly or maintained insufficiently, disturb ordamage the environment,

The Operators’s manual covers several service checksthat, if not performed correctly, can cause a deterioration ofthe engine affecting the environment, its service life andoperating economy. Always follow the recommended serv-ice intervals and make it a habit to check for anythingabnormal each time you use the engine. An example of thisis excessive exhaust smoke. Contact a Volvo Penta dealer ifyou cannot remedy the cause yourself.

Remember that most chemical products used to maintainyour boat and engine are harmful to the environment, ifused incorrectly. Always correctly dispose of used motor oil,vertical drive lubricant, paint, degreasing agents and wash-ing fluids, etc., so that they cannot harm the environment.

When using your boat, always adjust the speed anddistance to prevent the wake or sound level from disturbingwildlife, moored boats, pontoons, etc. Leave the waters andnatural harbors in the condition you yourself would like tofind them.

We thank you for your choice of Volvo Penta stern driveand we wish to continue to supply you with maintenanceand advice to help you get the best possible performancefrom your stern drive. Contact your nearest Volvo Pentadealer if assistance is required.

We wish you pleasant trips with your boat.

AB VOLVO PENTA

Record your engine, transom shield and drive unit model and serial numbers immediately after purchase. This willenable you to have them available for quick reference when ordering parts or literature.

Engine Model No. Serial No.

Transom Shield Model No. Serial No.

Drive Unit Model No. Serial No.

Ignition Key No.

Boat Model No.

Recommended Propeller Size

Hull Identification No. (HIN)

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Read this manual carefully before attempting to operate your engine.

GENERAL INFORMATION FEATURES

;FUEL AND LUBRICATION STARTING AND OPERATION

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SPECIFICATIONS AND MAINTENANCE

THIS PRODUCT MAY BE SERVICED BY ANY AUTHORIZEDOMC STERN DRIVE OR VOLVO PENTA SERVICING DEALER.

Printed in the U.S.A.

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GENERAL INFORMATION

Basic Safety Rules of Boating .................. 3Boater’s Responsibilities ...................... 3Illustration Symbols .......................... 2Model and Serial Numbers .................... 3Owner’s Identification Card .................... 2Product References, Illustrations and Specifications . 2

Repair Service .............................. 3Safety .................................... 2Stolen Unit ................................. 2Symbols ................................... 4Technical Literature .......................... 2Toll Free Dealer Locater Service ................ 3

SAFETY

This manual contains certain information related to thepersonal safety of you the operator, your passengers andbystanders.

The Safety symbol A~ , appears next to important infor-mation to prevent you and others from being hurt.

The Note symbol [~E], appears next to importantinformation to keep machinery from being damaged.

Observe all notes and safety warnings contained in thismanual.

PRODUCT REFERENCES, ILLUSTRATIONS ANDSPECIFICATIONS

When reference is made in this manual to a brand name,number, product or specific tool, an equivalent product maybe used in place of the product referred to unless specifi-cally stated otherwise. Equivalent products which are usedmust meet all current U.S. Coast Guard Safety Regulationsand ABYC standards to avoid hazards.

All information, illustrations and specifications containedin this manual are based on the latest product informationavailable at the time of printing. Volvo Penta Marine Prod-ucts LP reserves the right to make changes at any time,without notice, in specifications and models and also todiscontinue models. The right is also reserved to changeany specifications or parts at any time without incurringany obligation to equip same on models manufacturedprior to date of such change.

The continuing accuracy of this manual cannot be guaran-teed.

All illustrations used in this manual may not depict actualmodels or equipment and are intended as representativeviews for reference only.

STOLEN UNIT

The model and serial numbers on your engine, transomshield, and drive unit are important to you. For locations ofthese important numbers, refer to Model and Serial Num-bers in this section.

Record each of these numbers in the spaces provided onthe inside front cover of this manual and on a separate sheetof paper. Store the separate sheet of paper in a safe placeother than your boat.

In case of theft, report the model and seriam numbers toyour local authorities, your insurance agent, and VolvoPenta.

OWNER’S IDENTIFICATION CARD

When you purchased your boat, the dealer was requiredto complete a warranty and registration form for your VolvoPenta sterndrive. The owner’s portion of this form is yourOwner’s Identification Card. This card provides proof ofownership and is required to validate warranty, shouldwarranty service be necessary. Warranty coverage may bewithheld until the warranty and registration form is or= file atVolvo Penta.

TECHNICAL LITERATURE

Volvo Penta offers technical literature written specificallyfor your motor. A service manual, a parts catalog, or anextra operator’s manual can be purchased from your VolvoPenta dealer.

This manual is intended for use in the U.S. and Canadianmarkets only.

For the name and location of the nearest Volvo Pentadealer, in the U.S consult the Yellow Pages under "BoatDealers" or call 1-800-522-1959.

ILLUSTRATION SYMBOLS

Refer to the photo or drawingdescribed by that paragraph.

@®@Refer to specific items or featuresdescribed in the text and illustratedin the photo.

Refer to the general subject of the text.

.,~’~Refer to an item or feature that is notclearly visible in the photo.

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DR4282 DR2058 DR4g~7

GENERAL INFORMATION

BOATER’S RESPONSIBILITIES

The operator is responsible for the correct operation ofthe boat and for the safety of its occupants. Make sure thatall operators read this manual before operating the boat.Show your passengers the location of emergency equipmen’I and explain how to use it. Be sure one of yourpassengers knows how to handle your boat in case ofemergency. Requirements for personal flotation devicesand other safety equipment vary depending on the type ofboat.. Always comply with the regulations that apply to yourboat.

BASIC

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SAFETY RULES OF BOATING

Shut off engine when the boat is near people whoare in the water.

Avoid standing up or shifting weight suddenly insmall, lightweight boats.

Keep your passengers seated in seats. The boat’sbow, gunwale, transom, and seat backs are notintended for use as seats.

¯ insist on the use of life preservers by all passengerswhen boating conditions are hazardous, and bychildren and non-swimmers at all times.

e Know the marine traffic laws and obey them.

¯ Prevent explosion and fire by maintaining your fueldelivery system in top condition. Fuel vapor isvolatile; handle fuel with care.

¯ Keep your boat and equipment neat and in topoperating condition. Carry a selection of spare partsfor the engine.

¯ DON’T OPERATE BOAT IF YOU ARE UNDER THEINFLUENCE OF DRUGS OR ALCOHOL.

¯ If boating waters are unknown, obtain navigationaland bottom charts to avoid damage from underwa-ter objects.

MODEL AND SERIAL NUMBERS

[~ The primary mode~ and serial numbers are located onthe engine as illustrated. These numbers are required forwarranty registration, warranty service, and ordering parts.They are also referred to as engine model and serial numberbecause of their location. The sticker on the bottom of thistag shows the drive unit and transom shield model andserial numbers.

~] The model and serial numbers of the transom shieldare located on the inner transom shield plate as illustrated.

[~ The model and serial numbers for the drive unit arelocated on the drive unit behind the port trim/tilt cylinder asillustrated. These numbers are used to identify the drive unitand to match it with the engine.

REPAIR SERVICE

Always take your Volvo Penta sterndrive to an authorizedVolvo Penta servicing dealer. He has the knowledge, factorytrained technicians and special tools to take care of prob-lems that may arise. Preferably take your Volvo Pentasterndrive back to the selling dealer - he also knows youand your equipment.

m

Toll Free Dealer Locator Service

If you are away from your home waters, take yourVolvo Penta sterndrive to the nearest authorized VolvoPenta servicing dealer. To locate an authorized VolvoPenta servicing dealer, consult the Yellow Pages under"Boat Dealers" or call 1-800-522-1959.

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GENERAL INFORMATION

SYMBOLS

Certain symbols or combinations of symbols may appear on your Volvo Penta sterndrive or on its accessories. It is veryimportant that you understand their meaning or purpose. If any symbol is not clearly understood, see your Volvo Pentadealer.

"Safety Warning" Symbols

Contents under pressure

Fire hazard

"Position Indicator" Symbols

RAISE ~ LOWER

Shift positionsNEUTRAL

I"-oFORWARD REVERSE

Hour meter

Voltmeter

Water temperatu re

"Condition" Symbols

,~¯ Voltmetero Ammeter

Oil filter

A Emergency stop

E

Tachometer

(~ Fuel filter

Oil pressure

~,~o Use gasoline¯ Gasoline is present

"instructional" Symbols

~ Read Operator’s Manualbefore operating product Oil fill

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FEATURES

Circuit Breakers and Fuses ..................... 9DuoProp® Drive Unit, Rotation and Propellers ..... 10Emergency Stop Switch ....................... 8Impact Protection ............................ 5Instruments ................................ 8Engine Feature Identification ................... 6

Power Trim/Tilt .............................. 5Propellers ................................. 10Sacrificial Anodes ........................... 9Steering ................................... 5SX Drive Unit, Rotation and Propellers .......... 10

POWER TRIM/TILT

Your Volvo Penta sterndrive is equipped with a powertrim/tilt system as standard equipment. The purpose ofpower’ trim/tilt is to enable the operator to change the angleof the drive unit from the helm. Changing the angle of thedrive unit in relation to the boat bottom is called "trim-ming." Trimming provides the following benefits:

¯ Improves acceleration onto plane

,J Maintains boat on plane at reduced throttle settings

,i Increases fuel economy

.DProvides smoother and/or drier ride in choppy waterconditions

~D Increases top speed

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

STEERING

Volvo Penta sterndrives feature a power assisted steeringsystem. It consists of an engine mounted pump, hoses, andsteering cylinder. These work in conjunction with the helmand steering cable to move the tiller arm, thus moving thedrive unit.

IMPACT PROTECTION

The trim/tilt system provides impact protection for thedrive unit. Stiml, impact damage can occur in either FOR-WARD or REVERSE directions. Care must be taken:

¯ When operating in FORWARD or REVERSE

¯ When trailering boat

¯ When launching boat

Impact damage is more likely to occur when in a turn whereside loads are placed oil the drive unit.

If the drive unit strikes a solid object, throttle back andshut off engine immediately. Closely inspect the boat anddrive unit for damage, particularly the transom shield as-sembly that contains steering system components. Checkengine compartment for water leakage.

if there is obvious or suspected damage, operate boat atlow RPM and take your boat to a Volvo Penta dealer forinspection. Have necessary repairs made immediately.Operating a damaged drive unit could cause additionaldamage and could become very costly to repair.

Z~ Safety Warning: Fai|ure to inspect for damage may:

¯ Result in sudden loss of steering control.¯ Adversely affect your boat and drive unit’s ability to

resist subsequent high speed impacts.

When moving in REVERSE there is no impact protec-tion. Use CAUTION when moving in REVERSE. DO NOTEXCEED 2500 RPM.

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FEATURESB

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45997

item

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10111213

DescriptionAlternator.Anodes (Sacrificial)Backfire Flame ArrestorCarburetorCircuit BreakersDrain (Engine)Drain (Manifold).Drive Oil Level DipstickEngine Oil Level DipstickFuel Filter.Fuel Pump (Electric).Gimbal Bearing Lube FittingModel & Serial Number, Engine

Page j kem Description Page23 I 14 Model & Serial Number, Transom Shield 39,38 15 Model & Serial Number, Drive Unit ..... 326 j 16 Motor Oil Fill Cap ................... 3t27 17 Oil Filter .......................... 31 I9,25 18 Oil Withdrawal Tube ................. 31 I30 =19 J PowerSteeringPump ................ 13 I30 20 Steering Cable ..................... 13 [

32,35 21 Trim/Tilt Reservoir Cap ............... 13 I31 22 Trim/Tilt Pump Assembly ............. 13 I26 ; 23 Pivot Housing Water Drain Plug ........ 3026 i 24 ] Water Intake ....................... 29

33,36 25 I Water Supply Pump ................. 303 26

I Trim/Tilt Fuse ......................9,25 J

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iNSTRUMENTS

Before operating your Volvo Penta sterndrive, familiarizeyourself with the instruments supplied with your boat.Some boats may not have Volvo Penta instruments, read theboat’s owner’s manual to familiarize yourself with the in-struments used.

Volvo Penta Instruments

(~ Power Trim/Till Gauge - Indicates whether the boat istrimmed to a "Bow-Up" ~ or "Bow-Down" ~ condition.

(~ Tachometer - indicates the engine RPM.

© Speedometer - indicates boat speed MPH~

@ Voltmeter - With ignition on, engine not running, thevoltmeter indicates battery voltage. With engine running,the voltmeter indicates alternator voltage output.

® Oil Pressure Gauge - Indicates engine oil pressure.

® Water Temperature Gauge - indicates water tempera-ture in the engine’s cooling system.

Other Instruments

See your Volvo Penta dealer for additional Volvo Pentaaccessories specifically designed for your Volvo Pentasterndriveo

EMERGENCY STOP SWITCH

~’] An emergency stop switch (~ may be a feature of yourVolvo Penta sterndrive powered boat. Use of this switch ishighly recommended. To properly use this feature, attachthe lanyard ® securely to your clothing. Do not attach thelanyard to clothing that will tear away before the lanyard ispulled from switch to stop the engine. If the lanyard is toolong, shorten the lanyard by knotting or looping it. DO NOTcut and retie the lanyard.

36416

FEATURES

Using this switch is simple and should not interfere withnormal operation of the boat. Care must be taken to avoidaccidentally pulling the lanyard during normal operation.Unexpected loss of forward motion witt occur. This couldallow occupants to be thrown forward. In an emergencysituation, any occupant of the boat can restart the engine.Just press in and hold the emergency stop switch button,then follow normal starting procedure. When the button isreleased, the engine will stop.

Z~ Safety Warning: The emergency stop switch can onlybe effective when in good working condition. Observe thefollowing:

¯ Lanyard must aiwa~/s be free of entanglements thatcould hinder its operation.

e Once a month, check switch for proper operation.With engine running, pull lanyard, if engine doesnot stop, see your dealer.

Z~ Safety Warning: If your boat is not equipped with anemergency stop switch and it fails into one of the followingcategories, installation of an emergency stop switch isrecommended.

¯ High performance sport boats

¯ Small runabouts

¯ Boats with sensitive steering

¯ Boats where the distance from the top of thegunwale down to the driver’s seat is less than 12 in.(30,5 ¢m).

See your Volvo Penta dealer for installation of an emer-gency stop switch.

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FEATURES

372S0A

SACRIFICIAL ANODES

]~] ~D Sacrificial anodes are attached to the bottom ofthe girnbal housing O, and at the front of the gearcaseabove the anti-ventilation plate (~. Anodes are slowlyeroded away by galvanic action and require inspection.Anodes subjected to frequent wetting and drying requireperiodic scraping to remove scale and oxidation to maintaintheir effectiveness.

When replacement is required, see your Volvo Pentadealer. The material composition of Volvo Penta anodesmeets UoS. Military Specification 18001-H. If other thanVolvo Penta anodes are used, make sure they have equiva-lent specifications or gaJvanic corrosion protection will belost. if additional electronic or electrical equipment is in-stalled; each should have an individual anode or groundingdevice and all grounding devices must be interconnected.Follow equipment manufacturer’s recommendations.

[~ inspect gimbal housing and front gearcase anodesevery 14 days, or more frequently if used in extremely saltywater. If an anode is ~/3 its original size (V3 eroded), it shouldbe replaced, if a stainless steel propeller is used, additionalsacrificial anodes may be required to handle the addedcorrosion potential.

Boats that connect to an AC power source (shore power)require protection against galvanic and "stray current"corrosion. For protection, a galvanic isolator can be installedin the grounding (green) wire between the boat and theshore power outlet on the dock. The isolator blocks directcurrent (DC) flow, but permits the passage of alternatingcurrent (AC) thereby providing a path for ground faultcurrents.

If a boat is connected to an AC power source (shorepower) and it is not equipped with a galvanic isolator,additional sacrificial anodes may be required to handle theadded corrosion potential.

[~ ~ When the boat is primarily used in a fresh waterenvironment, Volvo Penta recommends replacing the zincanode 0 with a magnesium anode.

CIRCUIT BREAKERS AND FUSES

The engine and boat’s electrical system is protected bycircuit breakers and fuses against current overload. If acircuit breaker trips, it can be reset by pushing its button. Ablown fuse must be replaced. Circuit breakers or fuses thatrepeatedly fail indicate a problem requiring immediateattention. See your Volvo Penta dealer.

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DRZ031A DR202S DP,2030

FEATURES

SX DRIVE UNIT, ROTATION AND PROPELLERS

Twin Engines

Your Volvo Penta sterndrive can be set up to rotate ineither direction. The propeller, propeller shaft and verticaldriveshaft are the only parts that counter-rotate. The enginealways has standard rotation.

J~ Twin engine installations should have the starboarddrive unit set up for right-hand propshaft rotation (standardrotation) and the port drive unit set up for left-hand prop-shaft rotation (counter-rotation). Propeller rotation is asviewed from the rear.

Some boat manufacturers may set up twinsterndrives just the opposite. When propellers and/or driveunits are removed, care must be taken to attach the shift linkin the same eccentric position it was in when removed andthat the propellers are not switched.

Single Engines

All single engine installations are set up standard-rotationand use right-hand propellers.

Propellers

[] Right-hand propellers rotate clockwise to propel a boatforward. Right-hand propellers are considered standard-rotation propellers. To identify a right-hand propeller, notethe angle ® of the blade as viewed from the port side.

IT] Left-hand propellers rotate counterclockwise to propela boat forward. Left-hand propellers are considered coun-ter-rotation propellers. To identify a left-hand propeller, notethe angle ® of the blade as viewed from the port side.

¯ A drive unit set up for standard rotation must beequipped with a standard rotation (right-hand) pro-peiler.

e A drive unit set up for counter-rotation must beequipped with a counter-rotstion (left-hand) propel-ler.

Never interchange a right-hand propeller with a left-hand propeller. This would result in the boat being pro-pelled in reverse when the motors are operated in forwardgear, and forward when motors are operated in reversegear. To help you better understand and tell the differencebetween left- and right-hand propellers, see illustrations.

After having the propellers serviced, shift into FORWARDor REVERSE at idle speed and determine if the boat movesin the direction indicated by the position of the controlhandle. If the boat moves OPPOSITE the direction indicatedby control handle, the propellers are switched.

Safety Warning: Failure to perform the above test couldresult in loss of control.

DUOPROP~ DRIVE UNIT, ROTATION ANDPROPELLERS

DuoProp drive units have counter-rotating propellers andit is not necessary to change drive unit rotation. The propel-lers operate in sets. The forward propeller is left-hand androtates counter-clockwise. The rear propeller is right-handand rotates clockwise.

PROPELLERS

Your Volvo Penta sterndrive should be equipped withpropeller(s) that are designed to give top performance andmaximum economy under all operation conditions. To ob-tain peak performance, the engine RPM AT FULL THROTTLEmust fall in the specified operating range at normal loadconditions at favorable/best trim settings.

if full throttle RPM is below the recommended operatingrange, propeller(s) with less pitch should be used. Shouldfull throttle RPM exceed the recommended range, installpropeller(s) of higher pitch. Selecting the correct propel-ler(s) to allow the engine to run at full throttle in therecommended operating range will give the best engine life,fuel economy, and performance. See your Volvo Pentadealer for help in determining the correct propeller(s) foryour application.

A damaged propeller must be changed without de-lay. Operate with extreme caution if a propeller is dam-aged. Do not operate DP models with only one propeller,this can cause damage to propellor shafts.

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FUEL AND LUBRICATION

Drive Unit Lubrication ....................... 13Engine and Drive Service ..................... 12Gasoline Containing Alcohol .................. 11Gasoline Requirements ...................... 11Gimbal Bearing Lubrication ................... 13Mo:tor Oil ................................. 12

Oil Identification Symbol ..................... 12Power Steering Fluid Level .................... 13Power Trim/Tilt Fluid Level .................... 13SAE Viscosity Chart ......................... 12Steering System Lubrication .................. 13

GASOLINE REQUIREMENTS

USE ONLY UNLEADED FUEL

Z~ S~fety Warning: Gasoline is extremely flammable andhighly explosive under certain conditions. Always stopengin,s and do not smoke or allow open flames or sparksnear the boat when refueling gas tanks.

/~ Safety Warning: When filling the gas tank, ground thetank to the source of gasoline by holding the hose nozzlefirmly against the side of the deck filler plate or ground it insome other manner. This action prevents static electricitybuild-’.up which could cause sparks and ignite fuel vapors.

Maximum performance requires the use of lead-freegasoline with the following minimum or higher octanespecification:

Inside the U.S.: (R+M)/2 (AKI) Out;;ide the U.S.: (RON) -

[~ Use of gasoline with lower than 89 AKI (93 RON)octane without resetting ignition timing as specified, willresult in serious damage to your engine and will void yourengine warranty.

If fuels with 89 AKi (93 RON) octane or higher are notavailable, the ignition timing will have to be retarded solower octane fuels, with minimum 87 AKI (90 RON) octane,can be used. See your authorized Volvo Penta dealer for thisadjustment. When ignition timing is retarded, a slight de-crease in power can be expected.

[~ Engine damage resulting from the use of a loweroctane gasoline than 87 AKI (90 RON) is considered misuseof the engine and witl void your engine warranty.

Detonation or spark knock in a marine engine is notnecessarily audible. Overheating and continued running(dieseling) after ignition shut off are indications of detona-tion in a marine engine. If you suspect detonation or sparkknock, and the engine is properly tuned, change to a higheroctane fuel.

To prevent gum formation and corrosion in the fuelsystem, frequently use a fuel stabilizer in the gasoline. Fuelstabilizer is available from your Volvo Penta dealer.

GASOLINES CONTAINING ALCOHOL

Many gasolines being sold today contain alcohol. Twocommonly used alcohol additives are Ethanol (ethyl alcohol)and Methanol (methyl alcohol).

See your operator’s manual for your boat to determine ifthe boat’s fuel system is compatible with alcohol blendedfuels. If it is compatible, your engine may be operated usinggasolines blended with no more than 10% Ethanol meetingthe minimum octane specification. Do not use any gasolinewhich contains METHANOL.

Serious damage will result from the continued use offuel containing METHANOL.

If you use gasoline containing ethanol, be aware of thefollowing:

¯ The engine will operate leaner with ethanol blendedfuel. This may cause engine problems such as vaporlock, low speed stall, or hard starting.

¯ Ethanol blended fuels attract and hold moisture.Moisture inside fuel tanks can cause corrosion ofthe tank material. Inspect fuel tanks at least annu-ally. Replace fuel tanks if inspection indicates leak-age or corrosion.

¯ Inspect nonmetallic parts of fuet system frequentlyand replace if excessive stiffness, deterioration orfuel leakage is found.

Z~ Safety Warning: Fuel leakage can contribute to a fireand/or explosion.

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DR¢68~ DR1563

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FUEL AND LUBRICATION

ENGINE AND DRIVE SERVICE SAE VISCOSITY CHART

If you choose to lubricate your Volvo Penta sterndriveyourself, refer to the Lubrication and Inspection Chart inSpecifications and Maintenance section for lubricationpoints and recommended lubricants. Use only Volvo Pentarecommended lubricants or lubricants of equivalent qualityand viscosity. See your Volvo Penta dealer for recom-mended lubricants.

If you choose to have your Volvo Penta sterndrive lubri-cated, see your local Volvo Penta dealer. He will gladlylubricate it at the required intervals.

MOTOR OIL

To obtain the best engine performance and engine life,Volvo Penta DuraPlus" Premium engine oil labeled forService CE/SG is recommended, or you must use motor oilswith the recommended quality and viscosity. Motor oils arespecified by API service, letter designations and SAE viscos-ity numbers. Refer to oil identification symbol on the con-tainer.

Initial factory fill is a high quality motor oil for API ServiceCE/SG. During the break-in period (20 hours), frequentlycheck the oil level. Somewhat higher oil consumption isnormal until piston rings are seated. The oil level should bemaintained between the Add and Full marks on the dipstick.The space between the marks represents approximately 1quart (1 liter). For oil level dipstick location, refer to theFeatures section.

When you add or change motor oil, use Volvo Pentaengine oils for gasoline engines, or a good quality oil (APiService CE/SG or better) of the same viscosity that meetsGeneral Motors Specification GM-8094-M. Use the follow-ing chart to select the SAE viscosity that matches thetemperature range in which you expect to operate.

See Specifications and Maintenance section for oil filtertype and service intervals.

LOWESTANTICIPATEDTEMPERATURE

RECOMMENDEDSAE VISCOSITY OiLS

32° F (0° C) and above

0° F (-18° C) to 32° F (0° C)Below 0° F (-18° C)

SAE30~SAE 20W/50SAE 15W/50SAE 20W-20SAE 10W

¯ SAE 30 Volvo Penta DuraPlus" Synthetic Motor OilP/N 3851230-7 (U.S and Canada Only)

Use single viscosity oils in markets where aveilabne.The use of muZti-viscosity oils such as 10W-30, 10W-40 isnot recommended.

At the end of the break-in period (20 hours), change thecrankcase oil and replace the oil filter. Refer to Lubricationand inspection Chart in Specifications and Maintenancesection for recommended oil change intervals.

OiL IDENTORCATION SYMBOL

Motor oils are specified by APt service letter (CE/SG), andSAE viscosity numbers (SAE 30, SAE 20W-20, SAE 10W).These may be found on the label, top of can, or oil identifica-tion symbol.

[~ Label: Motor Oil

DE] oil Identification Symbol

~’) Label: Gear Lube

[~ Disregard eny reference to multi-viscosity oilsprinted on engine. Such reference is intended for automo-tive use only, and not for marine 8pplication.

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FUEL AND LUBRICATION

POWER TRIM/TILT FLUID LEVEL

~] Tl~e trim/tilt assembly contains an electric motor, hy-draulic pump, and reservoir. At the beginning of eachboating season, check the fluid level in the reservoir asfollows:

~ Level should be between the "MIN" and "MAX"marks on the reservoir.

¯ If necessary, add Volvo Penta DuraPlus~" PowerTrim/Tilt and Steering Fluid. Replace the cap (~ andtighten securely.

When checking fluid level, inspect the trim/tilt unit forleaks and proper operation, if service is necessary, see yourVolvo Penta dealer.

43356 33965

POWER STEERING FLUID LEVEL

r~ Whenever you check the engine oil level, also removethe power steering oil film cap and check the fluid level. Wipedipstick and note the "HOT" and "COLD" fluid level,,;.Maintain the appropriate level with Volvo Penta DuraPlus "power steering fluid available from your Volvo Penta dealer.Approved power steering fluids such as GM power steeringfluid or Dexron fl automatic transmission fluid can also beused. Do not overfill the pump reservoir.

STEERING SYSTEM LUBRICATION

[~ Every 60 days, grease the steering ram ~) with VolvoPenta dense water resistant grease as specified in theLubrication and inspection Chart in Specifications andMaintenance section.

DRIVE UNIT LUBRICATION

The drive unit is filled at the factory with Volvo PentaDuraPlus" GL 5 Synthetic Gear Lube. See Specificationsand Maintenance section for SX and DP drive unit gear lubecapacity, and draining and filling procedures.

GIMBAL BEARING LUBRICATION

See External Lubrication Points in Specifications and Main-tenance section.

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STARTING AND OPERATION

Before Starting ............................. 15Bottom Painting ............................ 22Determining the Proper Trim .................. 19Engine Break-in ............................ 17High Altitude Operation ...................... 21How to Shift and Control Speed ............... 16Operation After Break-In ..................... 18Operating in "Bow-Down" Position ............. 19Operating in "Bow-Up" Position ............... 19Operating Procedure for Freezing Temperatures ... 21Power Tilt Operation ........................ 20Power Trim Operation ....................... 18Power Trim/Tilt Switch and Gauge Location ....... 18Power Trim/Tilt Switch Operation ............... 18

Preparation for Boating After Storage ........... 14Propeller Selection .......................... 22Pumping Bilge ............................. 18Remote Control Operating Instructions .......... 14Salt Water Operation ........................ 20Shallow Water Operation ..................... 21Starting Cold Engine ........................ 16Starting Warm Engine ....................... 16Steering System ............................ 21Stopping Engine ........................... 17Trailering Your Boat ......................... 20Twin Unit Maneuvering ...................... 21Twin Unit Steering .......................... 21

PREPARATION FOR BOATING AFTER STORAGE _

1. Replace all drain plugs. Replace rubber caps and clampsor plugs. Connect hoses and check condition; tightenclamps and connections. Install boat drain plug, if removed.

2. Remove distributor cap and rotor. Wipe inside of distribu-tor cap dry with a clean cloth and spray with Volvo Pentaanti-corrosion spray or equivalent. Replace rotor and cap.

3. Clean battery terminals and check battery charge. Withignition switch in OFF position, install battery and attachbattery cables. Spray terminals with Volvo Penta anti-corro-sion spray or equivalent.

4. Open fuel shut-off valve, if so equipped, and check all fuelline connections for leaks. Check flame arrestor and clean ifnecessary.

5. Make a thorough check of boat and engine for loose ormissing nuts and screws. Pump bilge dry and air out enginecompartment. Federal, state or local regunations prohibitthe pumping of oil into any navigable waters°

6. Check, and fill as necessary, all reservoir oil levels.

REMOTE CONTROL OPERATING INSTRUCTIONS _

Familiarize yourself with remote control operation beforestarting engine.

Your boat may be equipped with one of the followingVolvo Penta remote controls:

¯ Single lever concealed side mount or binnaclemount control.

¯ Dual engine dual lever binnacle mount control.

Your boat may be equipped with remote controls otherthan those described above. If Volvo Penta controls are notused, ask your selling dealer for operating instructions forthe remote control used in your boat since operation andfunction may differ from Volvo Penta remote controls.

r~ Volvo Penta controls have the following importantfeatures:

A single lever, which allows you to select FORWARDor REVERSE gear, regulate engine speed, and en-sure shifting is done at low engine speed.

¯ A start-in-neutral-only feature, which prevents youfrom starting your Volvo Penta sterndrive in gear.

¯ Concealed side mount controls have a neutral lockbutton ~) to prevent accidental shifting. It must besqueezed to permit shifting from NEUTRAL to FOR-WARD or REVERSE. The binnacle mount controls donot have a neutral lock, but do have a neutral detent.

Z~ Safety Warning: Your boat should be equipped by themanufacturer with a remote control with protection toprevent starting in gear. Use only a remote control unitwith start-in-neutral-only feature, This feature can preventinjury resulting from unexpected turning of the propellerand sudden movement of the boat.

The shift mechanism on all Volvo Penta controls can bedisengaged to allow for easier starting and engine warm-up.

E~ Concealed Side Mount Control

¯ To disengage shift mechanism:

1. Place control handle in NEUTRAL position ~).

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STARTING AND OPERATION

2. Press both neutral lock button ~) and shift disen-gage button ©.

3. Move control handle FORWARD to increase throt-tle.

The neutral lock and shift mechanism will automaticallyengage when the control handle is returned to NEUTRALposition.

Binn=¢le Mount Control

¯ To disengage shift mechanism:

1. Push in and hold shift disengagement button.

2. Move control handle FORWARD to increase throt-tle.

[~ The shift mechanism will automatically engage whenthe control handle is returned to NEUTRAL.

@ Shift Mechanism Engaged® Shift Mechanism Disengaged(~ Reverse Shift Range(~ Reverse Throttle Range® Forward Shift Range0 Forward Throttle Range

BEFORE STARTING

Familiarize yourself with the operation of the remotecontrol supplied with your boat, then proceed as follows.

DR2891

Z~ Safety Warning: To prevent a possible explosion, oper-ate the blower as recommended by the boat manufacturerbefore starting engine. If the engine compartment is notequipped with a blower, open engine cover or hatch prior tostarting to allow any gasoline fumes that may be present todisperse. Leave hatch open until after engine is running.

1. Operate the boat’s bilge blower. Frequently check boa’£sbilge area for gasoline fumes.

2. Check the bilge for excessive water accumulation. Alwayskeep the bilge clean and dry. Never allow the water depth inthe bilge to exceed the bottom of the engine. If wateraccumulation is unavoidable, install a bilge pump with anautomatic control switch.

The water level in the boat’s bilge will increase whenthe boat is operated at a high incline before planing speed isreached. Excessive water in the bilge can cause enginedamage.

3. Check engine crankcase oil level.

4. Lower the drive unit and make sure the water intakes aresubmerged.

Do not start engine out of water unless using aflushing adaptor. Always turn water on before startingengine. Control water pressure as full water pressure maycause damage to water pump and engine. Water pump willbe damaged and engine will overheat if operated withoutcooling water.

Z~ Safety Warning: When using a flushing adaptor, re-move the propeller before starting engine to prevent acci-dental contact with moving propeller. If propeller is notremoved, personal injury could result.

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STARTING COLD ENGINE

1. The engine may require priming prior to starting. Toprime the engine, proceed as follows:

¯ Place ignition switch in the OFF position.¯ Disengage shift mechanism.¯ Move control handle to the full throttle position; this

operates accelerator pump and primes the engine.e Repeat priming, if necessary.e Return the control handle to fast idle position.

2. Turn key switch to START position and hold until enginestarts. Do not hold in START position for more than tenseconds. In colder weather, more priming may be neces-sary. However, too much priming may flood engine.

if Engine Floods:

e Disengage shift. Move handle to full throttle posi-tion.

e Turn key switch to the START position,e Immediately move the control handle to the idle

position when the engine starts.

Failure to move the control handle to the idle positionimmediately when engine starts will allow engine to over-speed and engine damage could result. Over speedingengine after off-season storage could also damage thewater pump impeller. When starting engine for the firsttime after off-season storage, always idle engine for oneminute to allow the water pump to prime.

3. As soon as engine starts:

¯ Release key to the ON or RUN position.¯ Move control handle to the fast idle position to

warm up engine. Do not exceed 1000 RPM.

STARTING WARM ENGINE

1. Move control handle to the NEUTRAL detent position.

2. Turn key switch to START position and hold until enginestarts, but do not hold in start position for more than tenseconds. If engine does not start, let go momentarily, thentry again.

3. As soon as engine starts, release key to the ON or RUNposition.

Never turn key to START position when engine isrunning.

STARTING AND OPERATION

HOW TO SHIFT AND CONTROL SPEED

If your boat is equipped with a non-Volvo Pentaremote control system, ask your dealer how to properlyoperate it.

Z~ Safety Warning: Carefully check function of all controland engine systems before leaving the dock.

1. Move control handle to the NEUTRAL detent (idle) posi-tion. This will engage neutral start switch and allow engineto start. Check in front and behind boat for people orobstructions before shifting.

2. To go FORWARD - Actuate the neutral lock mechanismand briskly move the shift handle forward. Throttle move-ment will begin after forward gear engagement.

3. To go in REVERSE - Actuate the neutral lock mechanismand briskly move the shift handle rearward. Throttle move-ment will begin after reverse gear engagement.

Do not shift if engine speed is above 800 RPM.

Z~I Safety Warning: Do not shift from FORWARD to RE-VERSE when boat is planing.

4. To go from FORWARD to REVERSE, or REVERSE toFORWARD, always pause at NEUTRAL and allow enginespeed to return to idle.

5. After shifting is completed, continue to move the controlhandle slowly in the desired direction to increase speed.

/~ Safety Warning: Any time the boat is operated, beaware of changes in shift system operation. A suddenincrease in shift effort at the remote control handle, orother abnormal operation, indicates a possible problem inthe shift system. If this occurs, the following precautionsmust be taken:

With engine running and boat securely tied to thedock, shift drive into FORWARD and REVERSE toensure there is gear engagement.

When docking the boat, all docking maneuversmust be performed at slow speed. Pay specialattention to other boaters. Passengers should beinformed of potential problems and precautionstaken.

if you suspect there is a problem, see your Volvo Pentadealer as soon as possible for proper diagnosis and re-quired service or adjustment. Continued operation couldresult in damage to the shift mechanism and loss of shiftand throttle control that cou|d result in personal injury.

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STARTING AND OPERATION

STOPPING ENGINE

1. Move control handle to the NEUTRAL position.

2. Turn ignition key to the OFF position.

~] Do not stop engine at speeds above idle or "speedup" engine while turning off ignition. Engine damage couldresult.

ENGINE BREAK-IN

~] Failure to follow the Engine Break-In procedure canresult in serious engine damage.

All Vo/vo Penta engines have been run for a short periodof time as a final test at the factory. You must follow theEngi=~e Break-in procedure during the first 20 hours ofoperation to ensure maximum performance and longestengine life.

~] To ensure proper lubrication during the break-in peri-od, do not remove factory break-in oil until after the 20-hourbreallc-in is completed.

During the break-in period, be particularly observantduring the initial running of the engine, as follows:

1. C~¢k motor oil level frequently. Maintain oil level in thesafe range, between the "add" and "full" marks on dipstick.Somewhat higher oil consumption is normal until pistonrings have seated.

~] If you have a problem getting a good oil level readingon dipstick, rotate dipstick 180° in tube.

When adding motor oil, refer to Motor Oil, in Fuel andLubrication section.

2. Watch the oil pressure gauge. If the indicator fluctuateswhenever the boat attitude (i.e. turning, climbing on plane,etc.) is changed, it may be the oil pickup screen is notcovered with oil. Check crankcase dipstick. Add oil to thecrankcase if required. DO NOT OVERFILL. If oil level iscorrect and condition still exists, see your dealer for possiblegauge or oil pump malfunction.

~] Oil pressure will rise as RPM increases, and fail asRPM decreases, in addition, cold oil will generally showhigher oil pressure for any specific RPM than hot oil. Both ofthese conditions reflect normal engine operation.

3. Watch the engine temperature indicator to be sure the~reis proper water circulation,

Failure to follow the break-in procedure will void theengine warranty.

First Two Hours

For the first five to ten minutes of operation, operateengine at a fast idle (above 1500 RPM). During the remainingfirst two hours of operation, accelerate to bring boat ontoplane quickly and bring throttle back to maintain a planingattitude. During this period, vary the engine speed fre-quently by accelerating to approximately three-fourthsthrottle for two to three minutes, then back to minimumplaning speed.

After the engine has reached operating temperature,momentarily reduce engine speed, then increase enginespeed, 1:o assist the break-in of rings and bearings. Maintainplaning attitude to avoid excessive engine load.

DO NOT RUN ENGINE AT ANY CONSTANT RPM FORPROLONGED PERIODS OF TIME FOR THIS INITIAL TWOHOURS OF BREAK-IN.

Next Eight Hours

During the next eight hours, continue to operate at ap-proximately three-fourths throttle or less (minimum planingspeed). Occasionally reduce throttle to idle speed for cooling period. During this eight hours of operation it ispermissible to operate at full throttle for periods of less thantwo minutes.

DO NOT RUN ENGINE AT A CONSTANT RPM FOR PRO-LONGED PERIODS OF TIME DURING THE BREAK-IN PERI-OD.

Final Ten Hours

During the final ten hours of break-in, it is permissible ’tooperate at full throttle for five to ten minutes at a time. Afterwarming engine to operating temperature, momentarilyreduce then increase engine speed. Occasionally reduceengine speed to idle to provide cooling periods.

DO NOT RUN ENGINE AT A CONSTANT RPM FOR PRO-LONGED PERIODS OF TIME DURING THE BREAK-IN PERI-OD.

At the end of the break-in period (20 hours), remove motoroil and replace the oil filter. Fill crankcase with recom-mended motor oil.

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DR5194

OPERATION AFTER BREAK-IN

After break-in, the engine can be operated at any RPMfrom idle to full throttle. However, cruising at 3600 RPM orless saves fuel, reduces noise, and prolongs engine life.

Be sure to check the oil level frequently during the first 50hours of operation, since the oil consumption will be highuntil the piston rings are properly seated.

PUMPING BILGE

Frequently check bilge for leaking engine, power steering,or trim system oil. Find the cause and correct it immediately.Federal, State or local regulations prohibit the pumping ofoil into am/navigable waters.

POWER TRIM/TILT SWITCH AND GAUGELOCATION

The power trim/tilt switch is located on the remote controlhandle or on the boat’s dashboard. The power trim/tiltgauges show the corresponding bow position.

[] Single Engines:

(~ Power trim/tilt switch - remote control handle@ Power trim/tilt switch - dash mounted@ Power trim/tilt gauge

[] Twin Engines:

(~ Power trim/tilt switches - remote control handle® Power trim/tilt switch - dash mounted(~ Power trim/tilt gauges

®@@

DR5195

STARTING AND OPERATION

POWER TRIM/TILT SWITCH OPERATION

[~] l~ The trim/tilt switch allows you to raise and lowerthe drive unit. Hold the trim/tilt switch in the ~ UP positionto trim up to the maximum trim position. Continue holdingthe trim/tilt switch in the ~ up position to raise the drive unitto the maximum tilt position. Hold the trim/tilt switch in the

DOWN position to lower and trim down the drive unit.

Always allow the trim/tilt switch to return to its centerposition when the drive unit reaches the maximum raised orlowered position. This will prevent your trim/tilt motor fromoverheating.

The trim/tilt motor is protected from overheating by aninternal thermal overload switch. Should the electric motorstop while tilting, release the switch and allow the overloadswitch to cool and automatically reset itself. When theoverload switch has reset, tiJting may be resumed. Makesure the drive unit is not being restrained, causing the motorto overheat. If the electric motor still does not operate, checkthe 10 amp fuse and the 50 amp circuit breaker. Refer toCircuit Breakers and Fuses, in Specifications and Mainte-nance section.

POWER TRIM OPERATION

The power trim is normally used prior to accelerating ontoplane, after reaching the desired RPM or boat speed, andwhen there is a change in water or boating conditions.Locate passengers and equipment in the boat so that theweight is balanced fore and aft, and side to side. Trimmingwill not cancel an imbatanced load.

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®@DR202

STARTING AND OPERATION

®@

[]~] F4--] To operate the trim, push and hold the switch"’bow..up" (~ or ~; "bow-down" ~ until the desired bowposition is reached. The trim may be operated at any boatspeed or at rest. Avoid operating the trim system whenrunning in reverse. Observe the trim/tilt gauge which indi-cates the bow position achieved. The midpoint of the trimgauge scale indicates the highest 9 "bow-up" position, andbottom of the trim gauge scale indicates the lowest ,~"bow-down" position.

DuoProp® Power Trim Operation

The DuoProp drive unit may be operated within the trimrange limits of -2° to +5°. When operating outside of trimrange the engine speed must be reduced to 1000 RPM.

/~ Safety Warning: Operating the DuoProp sterndrive atengines speeds higher then 1000 RPM outside of the trimlimits (-2= to +5=) could cause undesirable boat handlingcherac,~eristics resulting in the loss of control. The driveunit c~m also be damaged if the engine speed is above 1000RPM when operating in the trim/tilt angle between +5° to+30°. Never operate the engine with the drive unit tiltedmore ’then +30° or the drive will be damaged.

DETERMINING THE PROPER TRIM

The effect of the maximum 9 "bow-up" and <@ "bow-down" positions will be similar for most boats. The bowposition that is best for your operating conditions could beat any trim setting between the maximum ~ "bow-up" and

"bow-down" positions.

The boat will be properly trimmed when the trim angleprovides the best boat performance for your particularoperaling conditions. On models without power steering,the trim position that provides a balanced steering load isdesirable.

To fi~miliarize yourself with power trim, make test runs atslower speeds and at various trim positions to see the effectof trimming. Note the time it takes for the boat to plane.Watch the tachometer and speedometer readings and theride action of the boat. Read the following paragraphs underOperating in "Bow-Up" Position and Operating in "Bow-Down" Position.

DR2027

OPERATING IN "BOW-UP" POSITION

~-~ The (O) "bow-up" position is normally used for cruising,running with a choppy wave condition, or running at fullspeed, in the full ~g "bow-up" position, the boat may tend toturn. You may have to compensate with the steering wheelto keep the boat in a straight ahead path. in this position theboat’s bow will tend to raise clear of the water. Excessive (~,"bow-up" trim will cause propeller ventilation resulting inpropeller slippage. Engine RPM will also increase, however,boat speed will not increase and may even drop.

Safety Warning: Use caution when operating in roughwater or crossing another boat’s wake. Excessive ~ "bow-up" trim may result in the boat’s bow rising rapidly,possibly ejecting the occupants.

OPERATING IN "BOW-DOWN" POSITION

[~ The ~_~ "bow-down" position is normally used foracceleration onto plane, operating at slow planing speeds,and running against a choppy wave condition. In the full"bow-down" position the boat may tend to turn. You mayhave to compensate with the steering wheel to keep theboat in a straight ahead path. In this position the boat’s bowwill tend to go deeper into the water. If the boat is operatedat high speed and/or against high waves, the bow of theboat will plow into the water. The boat may tend to bowsteer or spin about rapidly and possibly eject occupants.

Z~ Safety Warning: The boat trim should be adjusted toprovide balanced steering as soon as possible each timeyou get underway. Some boat/motor/propeller combina-tions may encounter boat instability and/or high steeringtorque when operated at or near the limits of the "bow-up"or "bow-down" positions. Boat stability and steeringtorque can also vary due to changing water conditions, ifyou experience boat instability and/or high steering torque,return to port at reduced speed and see your Volvo Pentadealer to correct these conditions.

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37252

I~~ __ STA___ RTING AND OPERATION_

POWER TILT OPERATION

[~ ~ The tilting feature of the drive unit is controlled bythe trim/tilt switch. When the trim/tilt switch is held in the"bow-up" position the drive unit tilts up until the switch isreleased or the drive unit reaches the maximum tilt position.The trim/tilt gauge will indicate the "tilt" position wheneverthe drive unit is in the tilt range.

DO NOT exceed 1000 RPM when operating the driveunit in the tilted position, propeller damage can occur.Never run the engine when the drive unit is tilted more then30° or the drive will be damaged.

Tilting is normally used for raising the drive unit to obtainclearance when beaching, launching from a trailer, or moor-ing. When tilting the drive unit, the boat should be at rest orat idle speed only. Refer to Shallow Water Operation in thissection.

[~ Do not operate the drive unit out of water evenmomentarily; the water pump may be damaged or enginemay overheat.

Z~ Safety Warning:

a To avoid possible contact with the propeller, neveruse the drive unit as a ladder or as a lift to board theboat. Never board at the rear of the boat when theengine is running, even if the engine is operating inneutral. Personal injury could result from contactwith rotating engine parts and propeller.

¯ Any malfunction of the trim/tilt system could resultin a loss of impact protection. Malfunction can alsoresult in loss of reverse thrust capability, if malfunc-tion occurs, see your Volvo Penta dealer.

SALT WATER OPERATION

Your Volvo Penta sterndrive is built for operation in eitherfresh or salt water. Fresh water internal flushing is recom-mended after use in polluted or salt water. Contact yourVolvo Penta dealer for an Engine Flushing Kit that allowsflushing of the engine, when in or out of the water.

If boat is moored for long periods, tilt drive unit out of thewater (except during freezing temperatures). After remov-ing the boat from the water, lower drive unit to the run(down) position until the cooling system has drained thor-oughJy.

The entire Volvo Penta sterndrive’s exterior should berinsed with fresh water, dried, and sprayed with anti-corrosion spray, fonlowing the directions on the container.

TRAILERING YOUR BOAT

Before moving your boat, check the ground clearance ofthe drive unit. When trailering, the drive unit may be in theup or down position. There must be at least 15 in. (38,1 cm)clearance between the lower gear unit and the ground. If theclearance is less than 15 in. (38,1 cm), raise the drive unit.

Use caution when backing out of driveways or cross-ing railroad tracks, so that the lower gear unit does not hitthe ground.

It is extremely important that the boat fit the trailerproperly. Loss of performance and speed, in many cases, isdue to improper trailer support and excessive tie-downpressure which has caused the boat bottom to deform. Theboat should rest firmly on the trailer with maximum tie-down pressure applied at the bow and transom only.

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STARTING AND OPERATIONm

SHALLOW WATER OPERATION

Ti~lting the drive unit to reduce the draft for shallow waterrunning may be done providing you DO NOT EXCEED 1000RPM. Exceeding 1000 RPM is not necessary. It will onlyincrease the boat wake and will not increase boat speedappreciably.

N~,’} Exceeding 1000 RPM could damage drive train com-ponents. This type of damage is not covered by warranty.NEVER ATTEMPT TO PLANE THE BOAT OR EXCEED 1000RPM WITH THE DRIVE UNIT IN A PARTIALLY TILTED POSI-TION. ALWAYS RETURN TO THE TRIM RANGE AS SOON ASPOSSIBLE TO AVOID DAMAGE TO DRIVE TRAIN.

When operating in shallow water, be sure the waterintakes located in the lower gear unit are submerged at alltimes. Proceed at slow speed and lower drive unit immedi-ately when deeper water is reached.

N[’~] Never run the engine when the drive unit is tiltedmore then 30° or the drive will be damaged.

HIGH ALTITUDE OPERATION

A performance loss at altitudes above 5000 ft. can beexpected. If you are boating above 5000 ft. altitude for ashor~L time, a lower pitch propeller will restore some of thelost performance. Long term use above altitudes of 5000 ft.may require a change in gear ratio.

OPERATING PROCEDURE FOR FREEZINGTEMPERATURES

When freezing temperatures are forecast and the boat willbe operated and will be left in the water, the drive unit mustremain in the tilted down (submerged) position at all timesto prevent water in the drive unit from freezing. Uponcompletion of engine operation, drain the engine as de-scrib,~d in Off-Season Storage Preparations in Specifica-tions and Maintenance section.

STEERING SYSTEM

The steering system for your Volvo Penta sterndrive isoperated by a steering cable connected to the helm. Re-strictiing movement of the steering cable will limit or stopthe s~Ieering system’s hydraulic assist.

Do not interfere with or restrict steering cable move-ment through the last 90° of bend at the engine. Do not usecable retainers, clamps or tie straps. Using one or all ofthese could restrict the cable movement near the engine. Donot tie wiring harnesses or other control cables to thesteering cable. Make sure deck combing and bulkheadsallow for steering cable movement.

If the power steering system becomes inoperative, .~nincrease in steering effort will be felt. Should this conditionoccur, inspect for possible cause and correct condition ifpossible. If the power steering system cannot be correctedon board, proceed at a reduced speed. The boat will besteerable, but with increased effort. See your Volvo Pentadealer as soon as possible to correct your power steeringsystem.

At slow speeds (no wake), your boat may tend to wander.This is normal and may be overcome by anticipating bowdirection and correcting with steering wheel. A slightlyhigher throttEe and trim setting may also lessen wandertendency. Changing weight distribution, aft to forward, canalso affect slow speed steering.

TWIN UNIT STEERING

Twin engine boats may have only one engine with a fullyoperational power steering system. That power steeringsystem is on the starboard engine; therefore, when opera-ting on a single engine use the starboard engine.

Using the port engine that does not have the function-al power steering system will cause an increased effort insteering control, due to absence of power assist.

Some twin engine boats may have both engine powersteering systems coupled together with a priority valve. Thisallows the use of either engine to provide power assiststeering.

TWIN LINE MANEUVERING

When leaving or approaching the dock, or for any closemaneuvering at slow speed, place the starboard engine inNEUTRAL, on standby, and use the port engine with thecontrol nearest the operator. The use of one control is veryeffective and more convenient.

In the event that the port engine being used for maneuver-ing stops, you can immediately go to the starboard enginewhich has been on standby.

,~ Safety Warning: If maneuvering with the engine thathas the power steering pump and it stops, the powersteering assist is lost. Failure to follow the above maneu-vering procedure could result in a collision and personalinjury.

Both engines must be running during close maneu-vering or at slow speeds. Water may be forced back throughthe underwater exhaust outlet and cause serious enginedamage if only one engine is running. Do not attempt toplane boat while operating on a single engine. The propel-lers are selected for the boat with the consideration thatboth engines operate together. Operating with a singleengine could cause engine damage.

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®

lOO%

90%

80%

70%

60%

5o%

40%.

30%

PROPELLER SELECTION

E~ Your Volvo Penta dealer has chosen a propeller de-signed to deliver top performance and economy under mostconditions. To obtain the maximum percentage of availablehorsepower ~), the engine RPM at full throttle should be inthe specified full throttle operating range ~). Refer toSpecifications in Specifications and Maintenance sectionfor RPM range.

Propellers that allow wide open throttle operation(W.O.T.) at the upper end of the RPM range provide fasterplanning time for water skiing or similar activities. Propel-lers that place W.O.T. RPM in the middle of the rangeprovide improved cruising fuel economy.

If the engine’s full throttle RPM with a normal load isbelow the specified range or on the low side of the range,use propeller(s) with less pitch to increase the RPM. Shouldthe engine’s full throttle RPM exceed the specified range,use propeller(s) of higher pitch to decrease the RPM.

[~ ~ Engine damage can result from incorrect propel-ler selection which:

© ¯ Prevents engine RPM from attaining the specified"full throttle operating range." Engine is laboring.Install lower pitch propeller(s).

i Allows engine RPM above the specified "full throttleoperating range." Engine is overspeeding. Installhigher pitch propeller(s).

D-series aluminum propeller sets are not recom-mended for use on DuoProp® equipped boat and enginecombinations that are capable of speeds in excess of 40MPH. E-series stainless steel propeller sets should be usedin these applications.

I}R3A06

STARTING AND OPERATION

If using D-series aluminum propeller sets, you mustalso use an In-Trim Limiter Kit, P/N 3857598-1, availablefrom your Volvo Penta dealer

BOTTOM PAINTING

If your boat is in water where marine growth is a problem,the use of an anti-fouling paint will reduce the growth rate.Be aware of laws that may govern your paint choice and itsuse.

¯ A pure Teflon®-based agent is recommended for both theboat and drive unit.

e Copper base anti-fouling paint may be used, but willrequire more frequent inspection and replacement of sacrifi-cial anodes. DO NOT PAINT any part of the drive unit ortransom shield with copper base anti-fouling paint.

[~ Painting the drive unit and transom shield with cop-per base paint will accelerate galvanic corrosion. A 1 in.border must be left around the transom shield when paint-ing the boat bottom.

¯ Vinyl-butyl base anti-fouling paint is a recommendedalternative.

¯ DO NOT USE any graphite base anti-fouling paint.

Never paint sacrificial anodes, or their effectivenesswill be lost.

See your dealer for an EPA approved anti-fouling paintthat is suitable for your area.

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SPECIFICATIONS AND MAINTENANCE

Active Corrosion Protection System ............. 3gBackfire Flame Arrestor ...................... 26Ba’~tery ................................... 23Belt Adjustments ........................... 28Boat Bottom ............................... 30Ca~rburetor Adjustment ....................... 27Checking Crankcase Oil Level ................. 31Circuit Breakers and Fuses .................... 25Cooling System ............................ 29De;~ler Service - 20 Hour Check ................ 29DuoProp Drive Unit Section ................... 35

r)rive Unit Lubrication ...................... 35l)uoProp Propellers ........................ 38External Lubrication Points .................. 36F~ropeller Care ............................ 36Propeller Replacement ..................... 37]win Installations ......................... 36

Draining and Filling the Engine Crankcase ........ 31Draining Cooling System ..................... 30Electrical System ........................... 23Engine Alignment .......................... 25

Engine Submersion ......................... 28Exhaust System ............................ 27Fuel Filters ................................ 26Fuel Pump (Electric) ......................... 26Fuel System ............................... 26High Tension Lead Routing ................... 26Ignition System ............................ 25Maintenance Log ........................... 46Maintenance Schedule ....................... 42Off-Season Storage Preparation ................ 40Oil Filter .................................. 31Replacement Parts .......................... 39Sacrificial Anode Replacement ................. 38Specifications .............................. 41SX - Single Propeller Drive Unit Section ......... 32

Drive Unit Lubrication ...................... 32External Lubrication Points .................. 33Propeller Care ............................ 33Propeller Replacement ..................... 34

Trouble Check Chart ......................... 44Volvo Penta DuraPlus " Brand Products .......... 45

ELECTRICAL SYSTEM

The engine’s electrical system features cranking, charg-ing, ignition and trim/tilt circuits. Power is provided by abattery and all necessary wiring.

[~]1 If electrical connections are reversed, or connectionsremoved when key switch is on or engine is running, theelectrical system may immediately be damaged.

Alternator

The alternator is belt driven by the engine and will chargethe battery at all engine speeds. Idle speed output isapproximately 20 amperes and rapidly increases to themaximum output at 2000 RPM. The transistorized voltageregulator controls alternator output to protect the batteryand other accessories in the electrical circuit. The voltageregulator is an integral part of the alternator.

BATTERY

4.3 GL, GS: Use a 12 volt battery with a minimum 360Cold Cranking Amp (CCA) rating at ° F(- 18° C)and115minu’tes reserve capacity rating at 80° F (27° C) (70 ampere-hour reference).

5.0 GL: Use a 12 volt battery with a minimum 650 ColdCranking Amp (CCA) rating at ° F(-18° C)and165 minutesreserve capacity rating at 80° F (27° C).

5.7 GS: Use a 12 vott battery with a minimum 650 ColdCranking Amp (CCA) rating at ° F(- 18° C)and165 minutesresettle capacity rating at 80° F (27° C).

Z~ Safety Warning:

¯ Do not expose battery to electrical sparks or anopen flame. Do not use jumper cables and a boosterbattery to start engine. Remove battery front boatto recharge. Do not recharge battery in boat. Fumesvented during battery charging can lead to anexplosion.

¯ Battery electrolyte is a corrosive acid and should behandled with care. If electrolyte is spilled orsplashed on any part of the body, immediatelyflush the exposed area with liberal amounts ofwater and seek medical attention as soon as possi-ble.

It is important that the battery connections are cor-rect. The negative battery cable must be attached to thenegative terminal (-) on the battery and the engine’s positivecable must be attached to the positive terminal (+) on thebattery.

Inspect your battery at regular intervals for specific gravi-ty (state of charge), individual cell water level, cleanlinessand tigllt, greased connections. If the battery has becomedischarged for no apparent reason, check all electriCalsystem components for malfunction, or a switch left in theON position, before to installing a recharged battery.

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I I1¸111 I

35246

SPECIFICATIONS AND MAINTENANCEII I

/~ Safety Warning: Failure to follow the safety precautionsbelow may result in electrical sparks igniting fuel vaporscausing fire or explosion.

Operate boat’s bilge blower for at least 5 minutes.Open engine cover or hatch and check the boat’sbilge area for gasoline fun-~s. If any fumes can bedetected by smell, do not operate the boat until thesource can be found, the spil| cleaned up, and thecause corrected.

DO NOT connect cables to battery until all otherelectrical connections have been made. Make surethe ignition switch is in the OFF position beforeremoving or installing electrical equipment, check-ing any electrical connections, or insta|ling batterycables.

See your Volvo Penta dealer for recommendations oninstalling multiple batteries.

When replacing your battery, read and understandthe information supplied with it BEFORE you begin installa-tion.

Batteries must be heavy-duty and constructed for marineuse. They can be either vented/refiliabie, maintenance-free,or deep-cycle with a CCA or MCA rating. Refer to Specifica-tions in this section for battery size.

~’~ Use bolts and nuts to secure battery cables to thebattery terminals. DO NOT use wing nuts to secure batterycables, even if they were supplied with the battery.

[~ Loose battery connections can cause damage to theengine’s electrical system.

Service electrical components only while the motor isNOT running. Be careful when identifying positive andnegative battery cables and terminals, if you touch thewrong terminal with a battery cable, even briefly, themotor’s charging system could be damaged.

[~ Z~ Safety Warning: The battery terminal connectionsmust always be insulated. If the battery mounting systemdoes not cover the connections, insteU protective covers.This will help prevent shorting o¢ arcing at the batteryterminals.

Z~ Safety Warning: Battery electrolyte is an acidic solutionand should be handled with care. If electrolyte contacts anypart of the body, immediately flush the exposed area withwater and seek medical attention as soon as possible.

Multiple Batteries and Selector Switch

if your boat is equipped with multiple batteries and aselector switch, the engine should be operated with theselector switch set to the ALL position. This will providecharging system output to all batteries.

A battery isolator is recommended if batteries will beswitched for individual operation.

Battery Cables

The following are the MiNiMUM specifications forstranded copper cables from the motor to the battery for allmodels. The maximum length is 20 feet regardless of cablediameter.

[~ Do not use aluminum core battery cables. Failure touse battery cables of recommended gauge and materialcould result in poor starting and electrical componentdamage.

¯ 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 (100MWG) cable

¯ 15 to 20 ft. (4,6 to 6,1 m) require a 3/0 AWG (120MWG) cable

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DR6450

SPECIFICATIONS AND MAINTENANCE

CIRCUIT BREAKERS AND FUSES

Volvo Penta sterndrive models are protected from over-load by circuit breakers and fuses, if a circuit breaker istripped, it may be reset. A blown fuse must be replaced, ifeither continues to fail, see your Volvo Penta dealer.

[~ [’4~ The power trim/tilt motor is protected from over-load by a 50 amp circuit breaker ~). A second 50 amp circuitbreaker ® is used to protect the main wiring harness. Thesecircuit breakers are located on the starboard side of theengine. The electric fuel pump circuit is protected fromoverload by a 6 amp circuit breaker © located on the fuelpump bracket.

The power trim/tilt switch is protected by a 10 ampin-line fuse @ located in the trim/tilt pump wiring harness.

The ignition switch and instruments are protected by a 20amp fuse located in the main wiring harness under the dash(at the ignition switch).

The installation of any additional electrical accessoriesrequires the use of individual protected circuits. Powertakeoff should be made at the battery. See your Volvo Pentadealer for assistance.

Avoid sparks that will damage components. Do notattempt to connect or disconnect any part of the electricalsystem while the key switch is on or the engine is running.

ENGIINE ALIGNMENT

Engine alignment requires special tools and that the driveunit be removed. This should be done when the drive unit isremoved for lubrication during off-season storage prepara-tions. Because of the special tools required, engine align-ment must be performed by a Volvo Penta dealer.

[~ Failure to check engine alignment could result inpremature failure of engine coupler, universal joints, andgimbal bearing.

@

46OO1 47564

IGNITION SYSTEM

Z~ Safety Warning: To prevent fire and explosion, VolvoPenta ignition components meet U.S.CoG. requirements forexternal ignition proof parts. Do not substitute automotiveor other non-approved parts.

Spark Plugs

To remove spark plugs, detach spark plug lead from sparkplug by twisting rubber boot slightly and pulling off. Re-move the spark plug for inspection. Clean and check gapwith feeler gauge; replace spark plugs each season.

¯ Always clean area around spark plug before remov-ing spark plug completely.

e Before installing new spark plugs, always check forproper type and gap. Incorrect type of spark plugscan cause operational problems and possible inter-hal engine damage.

Before installing a spark plug, the spark plug seat in thecylinder head should be wiped clean. Tighten plugs only tothe recommended torque. Make sure the spark plug termi-nals are fully seated on the spark plugs.

For recommended spark plugs, plug gap and installationtorque, refer to Specifications in this section and to thetune-up decal located on the top of the circuit breakerhousing.

Z~ Safety Warning:

¯ Avoid abusive handling which could crack the sparkplug’s ceramic body. Damaged spark plugs canemit external sparks which could ignite any fuelvapors in the engine compartment.

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@ ®__--® ®

Al

--® ®

DR2448 DR2453 46002

SPECIFICATIONS AND MAINTENANCE

¯ Do not operate engine if spark plug boots or hightension leads are tom or cracked. This conditioncan allow external sparks which could ignite anyfuel vapors in the engine compartment and resultin fire or explosion causing personal injury.

Distributor Cap and Rotor

Remove, inspect and clean distributor cap and rotor.Replace these components if worn or damaged with genu-ine Volvo Penta parts. No other distributor parts requireservice or replacement.

HIGH TENSION LEAD ROUTING

/~ Safety Warning: Inspect spark plug leads and boots forcracks that would emit external sparks and possibly ignitefuel vapors in the engine compartment. Do not operateengine with damaged leads.

I-~ 4.3 GL, GS Models: Firing order 1-6-5-4-3-.2

~-] 5.0 GL Models: Firing order 1-8-4-3-6-5-7-2

I~ 5.7 GS Models: Firing order 1-8-4-3-6-5-7-2

When spark plug leads are removed, be sure they arereplaced in the correct order as shown.

FUEL SYSTEM

Z~ Safety Warning: To prevent fire and explosion, serviceprocedures are always performed with the engine stopped.After completing service procedures, start engine andcheck entire fuel system for possible leaks. Failure toinspect your work could allow fuel leakage to go unde-tected. This could become a fire or explosion hazard.

Z~ Safety Warning: To prevent fire and explosion, VolvoPentafuel system components meet U.S.C.G. requirementsfor fuel and fuel vapor containment. Do not substituteautomotive or other non-approved parts.

BACKFIRE FLAME ARRESTOR

[~ Remove the backfire flame arrestor ~) each year. Cleanin solvent, air dry, and inspect it for damage. Replace ifdamaged. Reinstall flame arrestor making sure unit is se-curely fastened.

A~ Safety warning: To prevent fire and explosion in theengine compartment, the backfire flame arrestor mustalways be in place, properly secured, and undamaged.

ELECTRIC FUEL PUMP

Z~ Safety Warning: Frequently check pump for signs offuel leakage. Should this occur, have it serviced immedi-ately by your Volvo Penta deeler.

All models are equipped with an electric fuel pumpmounted in front on the starboard side of the engine. Thefuel pump electrical circuit is protected by a 6 amp circuitbreaker ®. The electric fuel pump is activated only whenengine is running.

If the engine has stopped, or it will not start and yoususpect the fuel pump is not activated, check the circuitbreaker. Refer to Circuit Breakers and Fuses in this section.

If fuel or oil is visible in the orange overflow hose, haveyour Volvo Penta dealer replace the fuel pump immediately.

FUEL FILTERS

~] All models have a fuer filter © in the fuel line before thefuel pump.

Z~ Safety Warning: Accumulation of water and other fuelcontaminants may form corrosive compounds which candamage the fuel filter, resulting in fuel leakage. For thisreason, annual replacement of the fuel filter is required toavoid risk of explosion or fire.

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®DR3844

SPECIFICATIONS AND MAINTENANCE

Engine Fuel Filter

To clean or replace fuel pump filter:

1. Unscrew fuel filter; remove and discard.

Z~ Safety Warning: Old filter contains flammable fuel.Dis;pose of safely.

2. Lightly lubricate the gasket on new fuel filter.

3. Screw on fuel filter and hand tighten, following instruc-tions on filter.

4. Clean up any spilled fuel.

Z~ Safety Warning: 5. Run bilge blower for at least fiveminutes to vent engine compartment, then start engineand check for leakage. Smell for fuel in the bilges, if youcar= smell fuel, explosion and fire are an extreme danger.Clean up the bilges until fuel cannot be detected bysmell.

Carburetor Fuel Filter

¯ o clean carburetor fuel filter screen:

1. Disconnect fuel line at carburetor.

2. Remove fuel inlet nut ~, gasket (~) and screen (~.

3. (;lean screen with solvent and blow dry.

4. Install screen, gasket, and inlet nut. Tighten nut se-curely.

5. Connect fuel line and tighten securely.

6. Clean up any spilled fuel.

Z~ Safety Warning: 7. Start engine and check for leak-age.

CARBURETOR ADJUSTMENT

/~k Safety Warning: Engine cover is a machinery guard.Removal exposes you to moving parts. Keep hands, hair,clothing away from belts, pulleys and moving parts.

Changes in fuel, altitude and climate may make it neces-saw to adjust the idle speed and idle mixture to obtainsmooth engine operation. Before attempting to adjust car-buretor, ensure that the backfire flame arrestor is free ofdebris, dirt and grease. See Backfire Flame Arrestor in thissection.

Carburetor idle speed and mixture adjustment shouldnot be attempted until engine is warm and it is known thatignition system components (including spark plugs) are specifications. Any attempt to alter the carburetor to corn-pensate for faulty conditions elsewhere will result in re-duced fuel economy and overall performance. See yourVolvo Penta dealer for adjustment.

EXHAUST SYSTEM

Periodically inspect engine exhaust system. Check fordeteriorated or burned hoses, loose clamps, and evidem~of water leaks.

/~ Safety Warning: Replace damaged/defective compo-nents, and securely tighten all clamps, Any exhaust leakmust be repaired before boat is operated. Exhaust leaksrelease fumes that can create hazardous conditions foroperator and passengers.

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DRC43344

BELT ADJUSTMENTS

/~ Safety Warning: To prevent possible injury caused bysomeone inadvertently starting the engine, remove theignition keys from each starting location (especially if theengine room/engine compartment cannot be seen fromvarious remote starting positions such as a flybridge orendosed cabin)°

The belts used for the alternator, water supply pump,and power steering pump are heavy duty. Do NOT replacewith automotive belts.

Belt Tension

~’~ Belt tension is determined by belt deflection. Withengine stopped, the belt should be tight enough so that itwill deflect 1/4 in. (6 mm) when pressed with the finger or _ 10 lbs. (336,6 ± 44,5 N) using belt te nsion gauge atpoints @, ®, and © shown, tfthe belt is too tight, excessivebelt and bearing wear can occur. If it is too loose, slippagecan occur, resulting in belt wear, poor circuDating pump,alternator, and power steering operation. Belt tensionshould be checked after 10 hours of service and every 50hours thereafter.

Alternator Belt

With engine off, check alternator belt deflection mid-way ~) between the circulating pump pulley O and thealternator pulley @.

To increase belt tension: Loosen alternator mountingscrews and nuts, and pivot alternator away from engine toincrease belt tension. While maintaining pressure on alter-nator, retighten top screw and bottom screw and nut.Recheck belt tension.

43345

SPECIFICATIONS AND MAINTENANCE

Power Steering Pump Belt

Improper power steering belt adjustment will cause aloss of power steering assist, resulting in hard steering.

~’] With engine off, check power steering belt deflectionmidway ® between the circulating pump pulley @ and thepower steering pump pulley ®.

To increase belt tension: Loosen pump mountingscrews, insert a 1/z in. breaker bar into the square hole ~) inthe pump mounting bracket, and pivot pump away fromengine as shown. While maintaining pressure on pump,retighten all mounting screws. Recheck belt tension. Neverpry against the pump reservoir or pull filler ne¢lc

Water Pump Belt

[-~ To increase belt tension: With engine off, check waterpump belt deflection midway @ between the water pumppulley @ and the crankshaft pulley ®.

Loosen mounting bracket to water pump screws, andpivot water pump away from engine to increase belt ten-sion. While maintaining pressure on water pump, retightentop and bottom screws. Recheck belt tension.

ENGINE SUBMERSION

Remove engine from water as quickly as possible andcontact your local Vo/vo Penta dealer for service.

It is imperative that your dealer remove all water from theengine and immediately reiubricate all internal parts. Allelectrical devices must also be dried and inspected for waterdamage. Delay in completing these actions may allowextensive engine damage.

Frequently check engine compartment for gasoline fumesand excessive water accumulation; water depth in bilgeshould be kept well below flywheel housing.

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SPECIFICATIONS AND MAINTENANCEIIII II

DEALER SERVICE - 20-HOUR CHECK

To ensure your continued boating enjoyment, we recom-mend that you return your Volvo Penta sterndrive to yourVolvo Pants dealer for a 20-hour check.

Dealer 20-Hour Check:

1, Change engine oil and oil filter,

2. RepJace the fuel/filter water separator.

3. Check power trim/tilt reservoir for proper fluid level.

/~ Safety Warning: 4. Check flame arrestor for propermounting.

Z~ Safety Warning: 5. Start engine and check completefuel system for leaks.

~ Safety Warning: 6, Lubricate steering cable ram witht~)/vo Penta dense water resistant grease or equivalent.Check power steering pump reservoir for proper fluidlevel.

/~ Safety Warning: 7. Check shift system for properadjustment and operation.

Z~ Safety Warning: 8, Inspect exhaust system, tightenall hose damps and check for leaks.

9. Check tension on all drive belts,

10. Check all engine mount screws for tightness.

11. Check and adjust carburetor for correct idle mixtureand idle RPM.

12. Check engine timing.

13. Check for any deficiencies, malfunctions, signs ofabuse, etc. Correction of any problems at this time willprevent the worsening of a minor problem and helpensure a trouble-free boating season.

3725OA

I II III IIIIII

14. Make sure engine can achieve maximum rated RPM.See engine specifications.

15. Check oil level in drive unit and add as necessary withVolvo Penta DuraP/us" GL 5 Synthetic Gear Lube (ifpossible without removing the boat from the water).

This is an opportune time to discuss with your VolvoPenta dealer any questions about your Volvo Pentasterndrive which may have arisen during the first 20 hoursof operation and establish a routine preventive maintenanceschedule,

For the U.S., Canada, and Mexico, the 20-Hour Check ispaid for by the boat owner and performed by your VolvoPenta dealer at local dealer rates, in other markets, thewarranty inspection is paid for according to the warrantypolicy for importers.

COOUNG SYSTEM

[~ ~ Volvo Penta engines have a thermostatically con-trolled recirculating type cooling system. Cool water isdrawn in through the water inlets ® located on both sides ofthe lower gearcase by a water pump mounted on front of theengine. Water is pumped to the engine and circulated by theengine water pump through the cooling system.

IT] [~ A thermostat determines the amount of water 1:obe taken in, recirculsted and discharged to control engineoperating temperatures. Water is discharged through anidle exhaust relief ®, and with exhaust through the propel-ter hub @ and anti-ventilation plate ®. A temperature gaugelocated on your boat instrument panel will indicate if theengine overheats. Do not operate engine without thermo-stat. The engine may overheat if the thermostat is removed.

[~ Should engine overheat, gradually throttle back toidle position for about one minute before stopping engine.Tilt drive up and clear off any water pickup obstructions. Ifoverheating continues, return to port at low RPM to pro-vent excessive overheating and engine damage. See yourVolvo Penta dealer.

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45996

The following steps are very important in protectingyour engine and drive from damage from freezing condi-tions. If you are unsure of how to perform any of thefollowing steps, see your Volvo Penta dealer for a completeend-of-season/winterization service. Freeze damage to theengine/drive package is not covered by your Volvo Pentalimited warranty.

DRAINING COOLING SYSTEM

Perform this procedure with boat out of water, it willprevent damage to cooling system components if tempera-tures drop below freezing. When draining the engine, raiseor lower the bow of the boat to position the engine in a levelattitude. This will provide for cornpiete drainage of the blockand manifold. If the bow of the boat is higher or lower thanthe stern, some water may be trapped in the block.

Engine

[~ Front

O Disconnect and drain large hose at water pump hous-ing.

® 4.3 Litre Models On|y: Remove intake manifold drainplug and drain manifold.

~] Starboard

® Remove one cylinder block drain and clear hole with awire.(~ Loosen clamp and remove manifold hose.

~] Port

® Remove one cylinder block drain and clear hole with awire.® Loosen clamp and remove manifold hose.

Water Supply Pump

~] Loosen and slide clamps back. Remove hoses from therear of water pump and drain. Crank the engine no morethan 2 seconds (DO NOT START) to expel any water trappedin water pump. Reattach water pump hoses.

45992 45986

SPECIFICATIONS AND MAINTENANCE

Pivot Housing

[~ To drain cavity in pivot housing, tilt drive unit to the fulltilt (up) position and remove the water drain plug (~ from port side of the pivot housing. Tilt the drive unit to the full tiltdown position. Allow unit to drain. After unit has completelydrained, replace pivot housing plug. Inspect drive unit waterintake screen for obstructions.

Oin Coolers

Remove the lower water hose from the oil cooler, tf cooleris mounted horizontally, remove either hose, loosen mount-ing bolt, and tip open end of cooler down to drain.

[~ Failure to completely drain the cooling system andpivot housing will result in serious damage to the engine,exhaust manifolds, pivot housing, and drive unit whentemperatures go below freezing. To assure complete drain-age, probe all drain openings with a piece of wire to removeany blockage.

BOAT BOTTOM

The condition of the boat’s bottom can affect your boat’sperformance. Marine growth, present in fresh water as wellas salt water, will reduce boat speed. A boat bottom withevidence of marine growth can cause a reduction in topspeed of 20 percent or more. Periodically clean the bottomof your boat following the manufacturer’s recommenda-tions. Bottom painting may also be desirable; see BottomPainting in Starting and Operation section.

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42865

SPECIFICATIONS AND MAINTENANCE

CHFCKING CRANKCASE OIL LEVEL

Remove dipstick from oil withdrawal tube. The oil level mustbe between the two marks on the dipstick. Add oil asnecessary to maintain the proper level.

~l Do not allow level to go below "Add" mark. Do not fillabove "Full" mark. Overfilling results in high operatingtemperatures, foaming (air in oil), loss of power, and overallreduced engine life.

DRAINING AND FILLING THE ENGINECRANKCASE

Motor oil and the oil filter are important factors affectingengine life. They affect ease of starting, fuel economy,combustion chamber deposits and engine wear. Drain andrefill crankcase once a season or every 100 operating hours.

[~ Check the motor oil level every 4 or 5 hours of operationand add oil as necessary= When oil is to be changed, runengine to warm oil for easier removal. Remove dipstick andwithdraw oil from crankcase through the dipstick tube ®using the special fitting provided on the tube. This specialfitting is provided so oil does not have to be drained into thebilge. Withdraw oil with a suction pump. Dispose of used oilin accordance with any applicable environmental regula-tions.

Safety Warning: To prevent fire and explosion, alwaysmake sure engine compartment is free of gasoline fumesbefore using any spark=producing tools such as the electricdrill motor used with oil withdrawal pump kit.

34087 46OO5

[~ Remove oil fill cap © and fill the crankcase to thespecified capacity with a reputable brand of motor oillabeled for Service CE/SG which meets General MotorsStandard GM-6094-M. Oils conforming to this standardcontain detergent and anti-wear additives.

Volw~ Penta DuraPlus" Heavy Duty engine oil is labeledfor Service CE/SG. It exceeds General Motors StandardGM-6094-M. It can be purchased from your Volvo Pen, tadealer.

[~ Do not fill above full mark. Overfilling results in highoperating temperatures, foaming (air in oil), loss of power,and overall reduced engine life.

Crankcase Capacities - Refer to Specifications in this sec-tion.

OiL FILTER

Replace the oil filter whenever the motor oil is changed.This filter is a self-contained, screw-on type. To remove,unscrew filter canister counterclockwise and discard. Whenattaching a new filter, be sure the gasket is lightly lubricatedwith motor oil. Hand tighten only, run engine and check forleaks. Do not run engine out of water. Dispose of used filterin accordance with any applicable environmental regula-tions.

Refer to Specifications in this section for replacement oilfilter, and Features section for locations of oil withdrawaltube, dipstick, and oil filler cap.

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34O86 47117

SPECIRCATIONS AND MAINTENANCE

SX - SINGLE PROPELLER DRIVE UNIT SECTION

DRIVE UNiT LUBRICATION

The drive unit is filled at the factory with Volvo PentaDuraPlusTM GL 5 Synthetic Gear Lube.

Adding Lubricant to Drive Unit

[’~ Every week check the oil level in the drive unit (ifpossible without removing the boat from the water). Fullythread the dipstick ~) into the hole, then remove and checkthe oil level. Check to make sure that the oil level comes tothe top of the flattened portion of the dipstick. The oil shouldappear an amber color. If any moisture is present in the oil,the oil will appear milky. Also no metal flakes should appearin the oil.

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

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

The oil level in the drive unit must be checked by fullythreading the dipstick into the hole. Improper oil level mayresult in serious drive unit damage.

Draining and Filling Drive Unit

r~ [-~ When a complete change of lubricant is required inthe drive unit, proceed as follows:

¯ Place drive unit in the run (down) position.

¯ Remove the oil drain plug ® (starboard side of lowergear unit) and the oil level dipstick (~ (top of driveunit).

¯ Allow the drive unit to drain completely. Dispose ofused oil in accordance with any applicable environ-mental regulations.

[~’>’[~] To fill the drive unit, remove the three screwssecuring the rear cover to access the oil level plug ©.Remove oil level plug.

¯ Fill drive unit with Volvo Penta DuraPlusTM GL 5Synthetic Gear Lube. Fill through the oil drain pluglocation ®. Fill slowly to purge air. The drive unit isproperly filled when the oil appears at the oil levelplug hole. When filled to the proper level, install oillevel dipstick and oil level plug first to preventexcessive oil loss, then the oil drain plug. Tighten oillevel and drain plugs securely.

¯ If unable to fill drive unit through oil drain plug ®,the drive can be filled by trimming it up a fewdegrees and filling through the oil level plug ©.Reinstall oil level plug, and place drive in the run(down) position. Remove dipstick ® and check oillevel. Reinstall dipstick and tighten securely.

¯ Install rear cover and tighten screws securely.

¯ Check oil level with the dipstick, oil must appear onthe full range of dipstick. Add oil if required throughthe dipstick hole. Refer to Specifications in thissection for drive unit oil capacity.

[~ rT]’~] If drive unit was filled through the oil levelplug ©, wait 15 minutes before checking oil with dipstick.This will help ensure all air is purged from the oil cavity.Leave dipstick @ loose during waiting period.

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SPECIFICATIONS AND MAINTENANCEm III

8383

I II II I I I I I

SX ~ SINGLE PROPELLER DRIVE UNIT SECTION

EXTEIRNAL LUBRICATION POINTS

The gimbal bearing MUST be lubricated each year. Lubri-cate this component when preparing your boat for off-season storage. This requires the removal of the drive unit;theret’ore, this operation should be performed by your VolvoPenta dealer.

Failure to lubricate the gimbal bearing each year willresull in damage to the pivot housing and drive unit.

~] The gimbal bearing is lubricated by a grease fittinglocated on the side of the gimbal housing. Lubrication mustbe done with the drive unit removed. Lubricate bearing withEP wl~eel bearing grease. Apply grease until all old greasehas been removed from bearing and new grease appears. Ifthere is evidence of water, the bearing should be replaced, ifdamaged.

341O9

[~ The drive unit must be removed to lubricate the shaftsplines @ with molybdenum filled grease. Apply a light coatof motor oil to the shaft O-rings ®. Check the bellows fordamage and deterioration. Replace if necessary. Also checkengine alignment. Refer to Engine Alignment in this section.

PROPELLER CARE

A damaged or unbalanced propeller will cause excessivevibration and a loss of boat speed. Under these conditions,stop the engine and check the propeller for damage. If thepropeller appears damaged, have it checked by your Io¢~1Volvo Penta dea(er. Always carry a spare propeller andreplace the damaged propeller as soon as possible.

Never continuously run with a damaged propeller.Running with a damaged propeller can result in drive unitand engine damage.

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®\

SX - SINGLE PROPELLER DRIVE UNiT SECTION

PROPELLER REPLACEMENT

SPECIRCATIONS AND MAINTENANCE

¯ Coat the full length of the propeller shaft ® withVolvo Penta propeller shaft grease.

A rubber hub in the propeller is the shock absorber thatminimizes damage to drive unit and engine. If rubber hub ¯should begin to slip, it can be easily replaced at a VolvoPenta dealer or propeller service station.

/~ Safety Warning: The following is an emergency on-the- ¯water propeller replacement procedure. Protect your handsfrom sharp edges of the propeller blades. Wear gloveswhen removing or replacing the propeller.

r~ To Remove Propeller

¯ Safety Warning: Ignition switch must be OFF.

¯ Make sure remote control is in NEUTRAL position.

¯ Remove cotter pin Q and keeper ~.

¯ Shift the remote control into FORWARD gear to lock ¯the propeller shaft.

¯ Remove propeller nut ® using a 11/~6 in. wrench.

¯ Remove thrust washer (~, propeller ®, and thrustbushing ®.

¯ Wipe propeller shaft ® clean. Inspect for monofila-ment line; remove if present.

[~] To install Propeller

¯ Make sure remote control is in NEUTRAL position.

Place thrust bushing <~ on propeller shaft with innertaper toward gearcase to match the taper on propel-ler shaft.

Install propeller ® onto propeller shaft, aligningsplines, and push propeller onto thrust bushinguntil splines are exposed.

¯ Instalt the thrust washer (~ on propeller shaftsplines.

¯ Shift the remote control into REVERSE gear to lockthe propeller shaft.

¯ Install and tighten the propeller nut ® until itsseated against thrust washer.

Loosen nut, then turn back against thrust washeruntil finger tight. T~hten nut an additional I/3 to 1/2turn.

¯ Index keeper ® on propeller nut until aligned withcotter pin hole.

¯ Install cotter pin O and bend ends to secure (usenew cotter pin if necessary).

¯ Shift the remote control into NEUTRAL. Propellershould turn freely (control in NEUTRAL).

Before next outing, use a torque wrench to tightenpropeller to 70-80 ft. Ibs. (96-108 N.m). Thrust washer, nut,keeper and cotter pin must be installed as shown. Failure toinstall all components could result in loss of the propellerwhen boat is operated.

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34086

SPECIFICATIONS AND MAINTENANCE

37250

DUOPROP® DRIVE UNIT SECTION

DRWE UNIT LUBRICATION

The drive unit is filled at the factory with Volvo PentaDumPlus " GL 5 Synthetic Gear Lube.

Addling Lubricant to Drive Unit

!~] Every week check the oil level in the drive unit (ifpossible without removing the boat from the water). Fullythread the dipstick ® into the hole, then remove and checkthe oil level.

if oil level is low, add only enough lubricant to bring the oillevel1 within the full range of dipstick.

~ The oil level in the drive unit must be checked by fullythreading the dipstick into the hole. Improper oil level mayresult in serious drive unit damage.

Drsining and Filling Drive Unit

[~ I-~ When a complete change of lubricant is required inthe drive unit, proceed as follows:

¯ Place drive unit in the run (down) position.

¯ Remove propellers and mounting hardware.

N[’~ Removing DuoProp propellers require the use ofspecial tools. Refer to Propeller Replacement in this section.

¯ Remove the oil drain plug ® (below propeller shaft)and the oil level dipstick ® (top of drive unit).

¯ Allow the drive unit to drain completely. Dispose ofused oil in accordance with any applicable environ-mental regulations.

F2-1->’[~] To fill the drive unit, remove the three screwssecuring the rear cover to access the oil level plug (c~.Remove oil level plug.

Fill drive unit with Volvo Penta DuraPlus ~- GL 5Synthetic Gear Lube. Fill through the oil drain pluglocation ®. Fill slowly to purge air. The drive unit isproperly filled when the oil appears at the oil levelplug hole. When filled to the proper level, install oillevel dipstick and oil level plug first to preventexcessive oil loss, then the oil drain plug. Tighten oillevel and drain plugs securely.

If unable to fill the drive unit through oil drain plug(~, the drive can be filled by trimming it up a fewdegrees and filling through the oil level plug ©.Reinstall oil level plug, and place drive in the run(down) position. Remove dipstick ~) and check level. Reinstall dipstick and tighten securely.

¯ Install propellers, refer to Propeller Replacement inthis section.

¯ Install rear cover and tighten screws securely.

e Check oil level with the dipstick, oil must appear onthe full range of dipstick. Add oil if required throughthe dipstick hole. Refer to Specifications in thissection for drive unit lubricant capacity.

[~ [~’>~} If drive unit was filled through the oil levelplug ©, wait 15 minutes before checking oil with dipstick.This will help ensure all air is purged from the oil cavity.Leave dipstick ~) loose during waiting period.

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8383 34109 DR5176

SPECIFICATIONS AND MAINTENANCEII

DUOPROP~ DRIVE UNiT SECTION

EXTERNAL LUBRICATION POINTS TWIN INSTALLATIONS_

The gimbal bearing MUST be lubricated each year. Lubri-cate this component when preparing your boat for off-season storage. This requires the removal of the drive unit;therefore, this operation should be performed by yourVolvo Penta dealer.

Failure to lubricate the gimbal bearing each year willresult in damage to the pivot housing and drive unit.

The gimbal bearing is lubricated by a grease fittinglocated on the side of the gimbal housing. Lubrication mustbe done with the drive unit removed. Lubricate bearing withEP wheel bearing grease. Apply grease until a~l old greasehas been removed from bearing and new grease appears. Ifthere is evidence of water, the bearing should be replaced.

[~ The drive unit must be removed to lubricate the shaftsplines (~ with molybdenum filled grease, and apply a lightcoat of motor oil to the shaft O-rings ®. Check the bellowsfor damage and deterioration. Replace if necessary. Alsocheck engine alignment. Refer to Engine Alignment in thissection.

DuoProp drive units have counter-rotating propellers.There is no need to alter the direction of rotation of the driveunits in twin installations.

[~ In DuoProp drive unit twin installations the drive unitmust be adjusted so operation is free from ventilation. Toadjust, measure the distance © between the center line ofthe two transom shields. Adjust tie bar so the distancebetween the center of the anti-ventilation plate is equat todistance ©.

Hold the drive units when measuring.

PROPELLER CARE

A damaged or unbalanced propeller will cause excessivevibration and a loss of boat speed, Under these conditions,stop the engine and check the propellers for damage, if apropeller appears damaged, have it checked by your localVolvo Penta dealer. Always carry spare propellers andreplace a damaged propeller as soon as possible.

[~ Never continuously run with a damaged propeller.Running with a damaged propeller can result in drive unitand engine damage.

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SPECIRCATIONS AND MAINTENANCE

DR5387

DUOPROP® DRIVE UNIT SECTION

PROPELLER REPLACEMENT

A rubber hub in the propeller is the shock absorber whichminimizes damage to the drive unit and engine. If the rubberhub should begin to slip, it can be easily replaced by a VolvoPenta, dealer or propeller service station.

L~ Safety Warning: When replacing propellers, protectyour I~ands from sharp edges of the propeller blades. Weargloves when removing or replacing the propellers.

L~ S=lfety Warning: Do not attempt to hold propellers byhand when removing or installing the propellers, seriousinjury couad result.

The. following is an emergency on-the-water propellerreplacement procedure and requires the use of the specialtool kit (3855516-5).

[~ To> Remove Propellers

¯ L~ Safety Warning: Ignition switch must be OFF.

¯ Place remote control in the FORWARD position tolock propeller shafts.

¯ Remove rear propeller nut Q.

¯ Remove the rear propeller ~.

¯ Place remote control in the REVERSE position tolock propeller shafts.

¯ Remove the front propeller nut ®.

,i Remove front propeller @.

¯ Wipe propeller shafts clean. Inspect for monofila-ment line; remove if present=

~’] To Install Propellers

¯ Coat the full length of both propeller shafts withVolvo Penta propeller shaft grease.

¯ Place remote control in the FORWARD position tolock propeller shafts.

¯ Install front propeller @.

¯ Install front propeller nut ® and tighten to 45 ft. I5,s.(60 N-m).

¯ Place remote control in the REVERSE position "tolock propeller shafts.

¯ Install rear propeller ®.

¯ Install the rear propeller nut 0 and tighten to 50 ft.Ibs. (70 N-m).

Failure to install propellers as shown could result inthe loss of the rear propeller and damage to the drive unitwhen boat is operated.

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DR5382 DR5417

SPECiFiCATiONS AND MAINTENANCE

DUOPROP~ DRIVE UNiT SECTION

DUOPROP PROPELLERS

The propellers for the DuoProp drive units have applica-tion and diameter/pitch identificatior~ symbols, DO throughD9 for aluminum propellers and F4 through F9 for stainlesssteel propellers. The single number represents the diamet-er/pitch. The DuoProp propellers (forward and rear) mustoperate in sets of the matched diameters/pitches. Propellersin a set will have the same identification symbol withdifferent part numbers. These sets must be maintained, andfor twin installations both drive units must always havepropellers with the same identification symbols.

r-~ ~ The identification symbol (~ and the front and rearidentification ® are stamped on the end of the propellerhubs. When replacement of a propeller is required, either aforward or rear propeller can be purchased to maintain thematched set. Always order replacement propellers by thepart number.

Your Volvo Penta sterndrive should be equipped withpropellers designed to give top performance and maximumeconomy under all operating conditions. To obtain peakperformance, the engine RPM AT FULL THROTTLE must fallin the specified operating range at normal load conditions atfavorable/best trim settings.

if full throttle RPM is below the recommended operatingrange, propellers with less pitch should be used. Should fullthrottle RPM exceed the recommended range, install pro-pellers of higher pitch. Selecting the correct propellers toallow the engine to run at full throttle in the recommendedoperating range will give the best engine life, fuel economy,and performance. See your Volvo Penta dealer for help indetermining the correct propellers for your application.

A damaged propeller must be changed without de-Jay. Operate with extreme caution if a propeller is dam-aged. Do not operate with only one propeller, this cancause damage to the propeller shafts.

SACRiFiCiAL ANODE REPLACEMENT

[~ F~ Sacrificial anodes are attached to the bottom ofthe gimbal housing ©, and at the front of the gearcaseabove the anti-ventilation plate @. Anodes are slowlyeroded away by galvanic action and require inspection.

inspect gimbal housing and front gearcase anodesevery 14 days, or more frequently if used in extremely saltywater. If an anode is % its original size (1/3 eroded), it shouldbe replaced. If a staintess steel propeller is used, additionalsacrificial anodes may be required to handle the addedcorrosion potential.

When replacement is required, see your Volvo Pentadealer. The material composition of Volvo Penta anodesmeets U.S. Military Specification 18001-H. if other thanVolvo Penta anodes are used, make sure they have equiva-lent specifications or galvanic corrosion protection will belost. If additional electronic or electrical equipment is in-stalled; each should have an individual anode or groundingdevice and all grounding devices must be interconnected.Follow equipment manufacturer’s recommendations.

[~ r~ When the boat is primarily used in a fresh waterenvironment, Volvo Penta recommends replacing the zincanode ® with a magnesium anode.

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340e3A

SPECIFICATIONS AND MAINTENANCEII1 IIII

ACIWE CORROSION PROTECTION SYSTEM __

Your boat may be equipped with an optional Volvo PentaActive Corrosion Protection System that greatly improvesthe life of the drive unit by protecting it from corrosion, ifyou do not have this system, it is available from your VolvoPenta dealer under part number 3851984-9. This systemoperates with very little current drain from the boat’selectrical system.

The protection system’s control box has a small LEDindicator light that blinks once every one to five seconds toshow the system is operating properly. The light will blink atthe once every five second rate if the demand for protectionis very low. If the light is flashing once per second, thedemand is high and the system is operating at maximumcapacity. The Volvo Penta Active Corrosion Protection Sys-tem ;is designed to adequately protect one drive unit fromgalvanic corrosion.

The system works by keeping the voltage potential in thearea around the drive unit in a range that is not corrosive toaluminum. This is accomplished by changing the charge ofwate,r molecules so that they do not remove electrons fromthe drive unit’s metal parts to cause corrosion.

~1 This system will not provide protection from straycurrents emitted by a malfunctioning AC power source oneither your boat, the pier, or other boats in close proximityto yours. Although the zinc sacrificial anodes will last muchlonger with this system, they must still be cleaned andchecked for material condition periodically.

REPLACEMEttT PARTS

Your Volvo Penta sterndrive was designed for operating ina marine environment. This can require operating:

¯ At high RPM for long periods

¯ In salt and brackish waters

¯ In water laden with silt and minerals

37250A

iii j FI II

II~

Safety Warning: Improper parts substitution can resultin fire or explosion.

¯ When replacement parts are required, use Vo/voPentae replacement parts. Volvo Penta replacementparts are designed to meet USCG requirementsand ABYC standards for marine applications. Fail-ure to do so may result in product malfunction andpossible injury to the operator and/or passengers.

Substituting automotive or generally supplied parts andhardware will often result in less than desired performance.For this mason, you should insist on the known quality ofVolvo Penta replacement parts, and should never use par~Isof unknown quality.

See your Volvo Penta dealer; he can be depended upon tofurnish expert service and Volvo Penta parts.

In addition to the above, certain parts of the fuel andelectrical systems have been designed to comply with U.S.Coast Guard regulations. Parts or components which corn-ply with these regulations are designed so they will not emitfuel vapors or cause ignition of fuel vapors in the enginecompartment. To prevent explosion or fire - DO NOTsubstitute automotive or general hardware parts for thefollowing:

¯ Circuit breakers, alternator and related wiring.

a Starter, starter relay, trim and tilt relay and relatedwiring.

¯ Distributor, distributor cap, spark plugs, high ten,-sign leads and related ignition parts.

¯ Carburetor, fuel pump, filter and related parts.

¯ Rubber caps (manifold), hoses (water and exhaust~,and attaching clamps.

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OFF-SEASON STORAGE PREPARATIONS

1. Condition the fuel system: Add fuel Volvo Penta Dura-PlusTM Fuel Stabilizer P/N 3855832-6 to fuel system at therecommended rate stated on the container. This will stabi-lize the fuel and prevent the formation of varnish and gum inthe entire fuei system. Run engine under load so fuelconditioner reaches all fuet system components. Do thisbefore continuing with the following procedures.

2. Change motor oil and oil filter:

The engine should first be operated under Joad untilthe oil is thoroughly warmed up. If the oil is allowedto warm up before draining, a more complete drain-ing will be accornplished. In addition, the accumu-lated impurities will be held in suspension by the oiland be removed during the draining operation.

Remove the motor oil. Refer to Draining and Fillingthe Engine Crankcase in this section. Dispose ofused oil in accordance with any applicable environ-mental regulations.

¯ Install a new oil filter end fill the crankcase withrecommended oil.

¯ After changing the motor oil, with drive unit in fulldown position, run the engine at a fast idle for a fewminutes to distribute the clean oil through theengine.

[~ Drive unit must be submerged in water or an accesso-ry flushing adaptor must be used while operating engine.See your Volvo Penta dealer.

Safety Warning: When using a flushing adaptor, re-move the propeller before starting the engine to preventaccidental contact with moving propeller. If propeller is notremoved, personal injury could result.

¯ Check the oil filter gasket for leaks.

¯ Shut off the engine and check the oil level. Add oil ifnecessary to bring the oil level up to, but not over,the full mark.

3. Fog engine:

¯ Warm up engine to ensure fuel conditioner isthroughout the fuel system.

¯ Use 1/2 pint (0,25 litre) of fogging oil or 12 oz. (355 spray can to fog engine.

SPECIFICATIONS AND MAINTENANCE

Remove flame arrestor. Following instructions oncontainer, bring engine up to a fast idle and smowlydispense ~ of fogging oil into air intake.

¯ Keep engine running while adding fogging oil.

¯ Slow engine, rapidly dispense the remaining 1/3 offogging oil and allow engine to quit.

¯ Turn off ignition and replace flame arrestor.

4. Drain cooling system: Refer to Draining Cooling Systemin this section.

¯ Remove all drain plugs and make sure coolingsystem is drained, if needed, insert a small wire orsuitable object into drains to ensure openings arenot blocked.

Replace water pump impeller every two years.

5. Drain pivot housing: Refer to Draining Cooling System inthis section.

[~ Failure to completely drain the cooling system anddrive unit will result in serious damage to the engine,exhaust manifolds, and drive unit when temperatures gobelow freezing. Clear drain opening with a piece of wire toeliminate any doubt of complete drainage.

Fill the engine block, exhaust manifolds, and thermostathousing with a 50/50 mixture of anti-freeze and water toprovide added protection.

6. Change drive unit lubricant: Drain and refill with freshVolvo Penta DuraPlus TM GL 5 Synthetic Gear Lube. Refer toDrive Unit Lubrication in this section. Dispose of used oil inaccordance with any applicable environmental regulations.

7. Lubricate gimbal bearing: Refer to External LubricationPoints in this section.

8. Disconnect the battery and place in storage. Whenstorage will be for a considerable length of time, periodicallyrecharge the battery following the manufacturer’s recom-mendations.

[~ A discharged battery can be damaged by freezing.

9. Spray entire engine and drive unit with a rust preventa-tive coating, such as Volvo Penta DuraPlus Corrosion Shieldor equivalent, following the directions on the container.

10. Pump out bilge and let air dry before covering for winterstorage. Federal, State or local regulations prohibit thepumping of oil into any navigable waters.

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SPECIFICATIONS AND MAINTENANCE

SPECIFICATIONS

Models 4.3 GL, GS, 5.0 GL & 5.7 GS

Disp,|acement 4.3 GL, GS - 262 cu. in. (4,3 litres)5.0 GL - 305 cu. in. (5,0 litres)5.7 GS - 350 cu. in. (5,7 litres)

Bore and Stroke 4.3 GL, GS - 4.000 x 3.480 in. (101,60 x 88,39 rnm)5.0 GL - 3.740 x 3.480 in. (95,00 x 88,39 ram)5.7 GS - 4.000 x 3.480 in. (101,60 x 88,39 mm)

Number of Cylinders 4.3 GL, GS - 90° V-65.0 GL - 90° V-85.7 GS - 90° V-8

Firing Order 4.3 GL, GS - 1-6-5-4-3-25.0 GL - 1-8-4-3-6-5-7-25.7 GS - 1-8-4-3-6-5-7-2

Full ’Throttle Operating Range 4.3 GL - 4200-4600 RPM4.3 GS - 4400-4800 RPM5.0 GL - 4400-4800 RPM5.7 GS - 4400-4800 RPM

Idle RPM 550-650 RPM in forward gear

Ignition Timing Authorized Volvo Penta dealer service only

Recommended Spark Plugs See your Volvo Penta dealer

Charging System 65 amp alternator, with internal transistorized voltage regulator

Carburetor Adjustable idle circuitFixed main fuel jetsElectric choke

Fuel Filter See your Volvo Penta dealer

Fuel Filter Location Refer to Model in Features section

Cooling System Variable volume pump on engineRecirculating pump on engineThermostatically controlled temperature

Crankcase Capacity 4.3 GL, GS - 4.0 quarts (3,8 lives), 4.5 quarts (4,3 litres) with filter5.0 GL - 5.0 quarts (4,7 iitres), 6.0 quarts (5,7 litres) with filter5.7 GS - 5.0 quarts (4,7 litres), 6.0 quarts (5,7 litres) with filter

Oil Filter See your Volvo Penta dealer

Oil Filter Location Refer to Model in Features section

Drive Unit Oil Capacity SX - Approx. 71 oz. (2100 ml)DP - Approx. 81 oz. (2400 ml)

Volvo Penta DuraPlusTM GL 5 Synthetic Gear LubeVolvo Penta P/N 3810106-9 (U.S. and Canada Only)Volvo Penta P/N 1141572-6 (other markets)Synthetic oil (API GL 5 SAE 75w/90)See your Volvo Penta dealer

Continued

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Models

SPECIFICATIONS AND MAINTENANCE

SPECIFICATIONS - (continued)

4.3 GL, GS, 5.0 GL & 5.7 GS

Battery Size 4.3 GL, GS 360 Cold Cranking Amp (CCA) rating5.0 GL - 650 Cold Cranking Amp (CCA) rating5.7 GS - 650 Cold Cranking Amp (CCA) rating

Volvo Penta Marine Products LP reserves t~e right to make changes in weight, construction, materials or specificationswithout notice or obligation.

MAINTENANCE SCHEDULE

Items marked Z~ Safety Warning, are safety related service points to prevent mechanical failures, that could lead to aninjury. Make sure the safety related service is performed at these points and at the intervals specified.

Weekly Every 50By Operating

Operator Monthly Hours

Anodes (Sacrificial) C {14dys)

Battery and Connections - Water Level C C,T C,T

Belts - Alternator, Power Steering, Water Pump C,T C,T

Bilge Area - Clean C P

Z~I Boat Safety Equipment C C C

Z~ Emergency Stop Switch, Clip, and Lanyard C C C

Engine Alignment and Mounting Screws

Engine Crankcase Oil C,F R

Engine Oil Filter R

Z~I Exhaust System Hoses/Clamps - Leakage C,T C,T

Fasteners - Screws, Nuts, Etc. C,T C,T

Z~ Rame Arrestor - Mounting C,T

A = Adjust C = Check L = Lubricate F = Fill

P = Perform R = Replace T = Tighten or Torque ¯ = By Dealer

~< = Once a season or every 100 operating hours, whichever comes first.

Continued

Z~I Safety Warning: When replacement parts are required, we recommend that you use genuine Volvo Penta serviceparts, or parts with equivalent characteristics, including type, strength and material. Else of substandard parts couldresult in product failure and personal injury.

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SPECIFICATIONS AND MAINTENANCE

MAINTENANCE SCHEDULE - (continued)

items marked ~ Safety Warning, are safety related service points to prevent mechanical failures, that could lead to aninjury. Make sure the safety related service is performed at these points and at the intervals specified.

Weekly Every 50By Operating

Operator Monthly Hours

Fuel Filter R

/~, Fuel System - Leakage C,T C,T C,T

Gimbal Bearing

Hull - Clean P

PCV Valve C.

Power Steering - Operation/Fluid C,F C,F

Power Trim/Tilt - Operation/Fluid C,F C,F

Propeller and Shaft C,L C,L

/~k Remote Control Shift Cable - Damage C C

/~ Shift System - Operation C C,A*

Spark Plugs R

Z~ Spark Plug Wires/Boots - Deterioration C

Z~ Steering System/Cable - Operation C L L

U-Joint Shaft Splines L:~

U-Joint Bellows C

Drive Unit Oil C,F R

Water Pump impeller C R (2 yrs)

A = Adjust C = Check L = Lubricate F = Fill

P = Perform R = Replace T = Tighten or Torque ~< = By Dealer

~<* = Once a season or every 100 operating hours, whichever comes first.

/~k Safety Warning: When replacement parts are required, we recommend that you use genuine Volvo Penta serviceparts, or parts with equivalent characteristics, including type, strength and material. Use of substandard parts coukJresult in product failure and personal injury.

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