operator’s manual - indmar

O p e r a t o r ’ s M a n u a l

Indmar Marine Engines i

Throughout this manual, specific precautions and sym-bols identify safety related information.

The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY IS INVOLVED!

Indicates the presence of a hazard whichWILL cause SEVERE injury, death or sub-stantial property damage.

Indicates the presence of a hazard whichCAN cause SEVERE injury, death or substan-tial property damage.

Indicates the presence of a hazard whichWILL or CAN cause MINOR or MODERATEpersonal injury or property damage.

NOTICEIndicates installation, operation or maintenance infor-mation which is important but not hazard-related.

The precautions listed in this manual and on the engineor boat are not all-inclusive. If a procedure, method, toolor part is not specifically recommended, you must satisfyyourself that it is safe for you and others, and that theengine or boat will not be damaged or made unsafe as aresult of your decision.

CAUTION

! WARNING

! DANGER !

IMPORTANT SAFETY INFORMATION

!

ii Indmar Marine Engines

Indmar Marine Engines iii

Dear Indmar Marine Engine Owner,

Congratulations on selecting the finest marine inboard power available for your boat; Team Indmarwelcomes you to our family of owners! Indmar proudly stands behind our products and is the firstinboard manufacturer to offer a 3-year limited warranty.

We want you to know that your engine was manufactured to surpass industry standards. Before leav-ing the factory, your engine was tested for operational performance. Operational performance datawill be retained to track product performance in the future. It’s our goal to continually improve ourproduct and deliver all the benefits of the latest power technology.

If you have any questions concerning your engine, please feel welcome to contact Indmar CustomerService at (901) 353-9930 or E-Mail us at [email protected]. You can write us at Indmar ProductsCompany, Inc., 5400 Old Millington Road, Millington, Tennessee 38053. On the Web, go to our site atwww.indmar.com.

Again, thank you for choosing Indmar. We wish you safe, trouble-free boating.

Sincerely,Team Indmar

WELCOME

iv Indmar Marine Engines

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Chapter 1: First Time Operation and Break-In . . . . . . . . . . . . . . . 1-1

Chapter 2: General Operations and Warnings . . . . . . . . . . . . . . 2-1

Chapter 3: Engine Starting Procedures . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4: Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Chapter 5: Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Chapter 6: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Chapter 7: Storage and Winter Lay-up . . . . . . . . . . . . . . . . . . . . 7-1

Chapter 8: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Appendix A – Maintenance Components and Fluids . . . . . . . . . .A-1

Appendix B – Engine Specifications . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C – Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . C-1

TABLE OF CONTENTS

Indmar Marine Engines v

This manual will acquaint you with basic informationneeded to safely operate and maintain your Indmarengine. We suggest you and all other operators read theentire manual before using your boat.

We recommend you contact your Indmar dealer for allengine service. Certified Indmar Technicians are trained.They have current specifications, parts and the specialequipment needed to service your Indmar engine anddrive line. To find your nearest Indmar dealer, please call(901) 353-9930 or visit our website at www.indmar.com.

To ensure that the proper information is available, notethe engine serial number.Your dealer should have writtenthe engine serial number on your copy of the warrantyregistration card.Your copy of the warranty registrationcard should be in this Operator’s Manual. The serialnumber is stamped on the engine block; see the diagrambelow for locations.

Figure 1.1 – Serial Number Locations

INDM-A001

INTRODUCTION

vi Indmar Marine Engines

All Indmar engine ratings are determined at specificweather and elevation conditions. Changes in elevation,heat and humidity have a noticeable effect on the powerof any engine. Some power can be regained by droppingto a lower pitch propeller but the basic problem of lowerair density will affect the power output of the engine. Ifyou are experiencing performance problems due toweather and/or elevation conditions, contact your Indmardealer for recommendations.

Send your completed warranty form today!

The Federal Boat Safety Act of 1971 requires registra-tions of marine products sold in the United States bemaintained by the manufacturer and dealers of thoseproducts.Your dealer should have completed your war-ranty registration card to comply with federal regulations.This registration enables us to contact you, if it shouldbecome necessary, to change or improve your product.The engine serial number is stamped into the block andshould also be on your warranty card. Always retain acopy of the serial number for your personal records. Ifyour dealer did not fill out the card and give you a copy,contact your dealer.

Warranty registration must be received within 10 daysafter date of purchase by the first owner. If your engine isnot registered, all warranties may be void.

To obtain enjoyment from your boat, follow recommenda-tions described in this manual. The knowledge you gainthrough careful review will help you experience lastingsatisfaction.

Further information regarding the care, operation,required equipment or specifications for your boat can beobtained from your local US Coast Guard Auxiliary, USPower Squadron, state boating authorities, or theAmerican Red Cross. Know the law and your responsibil-ities as a boat owner.

Any alteration, change, improper maintenance or abnor-mal use by you which renders the engine or any of itscomponents unreasonably dangerous will void all war-ranties and Indmar will not be liable for the resultingdamages or injuries.

Indmar Marine Engines 1-1

The following checks assumes your dealer has performedthe pre-delivery service and inspection. Complete the following pre-start check list before starting your enginefor the first time. If you have questions about any of theseprocedures, see your Indmar dealer for assistance.

FIRST TIME OPERATION1. Check the boat hull and/or garboard drain plug. Make

sure they are installed and secure. Check the boatowner’s manual for additional pre-operation checks.

2. Make sure all engine drain plugs are installed. Referto Chapter 7, Storage and Winter Layup. There areseveral drain locations:Block – Two drain plugs on each side; 5.7 Liter EFIengines have an Engine Knock Sensor (1, Figure 1-2)installed in one drain hole.

NOTICEOn the 8.1 Liter engine, removing the knock sensordoes NOT drain the block. Remove the plugs from thebrass fillings on both sides of the engine to drainwater from the block.

Exhaust – The drain hose must be connected.Transmission – The transmission oil cooler has onedrain plug. In addition, the Walters V-Drive (ifequipped) has two drain plugs.Fresh Water Cooling System – If equipped, the heatexchanger has four drain plugs; two for raw water andtwo for coolant. Refer to Chapter 7, Storage andWinter Lay-up.

Figure 1.2 – Anti Knock Sensor

IND-A005

1

Chapter 1 FIRST TIME OPERATION AND BREAK-IN

1-2 Indmar Marine Engines

3. Make sure your battery is fully charged and the cablesare clean and tight.

4. Check engine oil for correct level. Refer to Chapter 6,Maintenance.

Figure 1.3 – Engine Dipstick Level

5. Check transmission oil level for correct level. Refer toChapter 6, Maintenance.

6. If your engine is equipped with fresh water cooling,check the expansion tank for the correct level. Refer toChapter 6, Maintenance.

Do not mix antifreeze types.

7. Inspect engine mounts to make sure they aligned andtight. Make sure that the propeller shaft coupler boltsare tight.

Make sure the engine water intake is notblocked by the trailer bunk. Blocked orrestricted water flow may damage the engine.

8. Back trailer into the water. Make sure the enginewater intake is submerged.

Before starting engine operate bilge blowerat least 4 minutes and raise engine cover toventilate fumes. Inspect engine and compart-ment for any fluid or fuel leaks. Failure to doso can possibly result in fire and/or explo-sion resulting in death or serious injury toyou and your passengers.

Figure 1.4 – Raised Engine Cover

! DANGER !

! WARNING

CAUTION

ADDOPERATING RANGE SEE OWNERS MANUA

INDM-A003


NOTICEPriming the EFI FuelSystem is requiredbefore starting your

EFI engine for the first time.This allows the electric fuelpump to fill the fuel injectionlines with gasoline. Each timeyou advance the ignitionswitch to the “ON” position,the fuel pump cycles for 2seconds.

NOTICEPriming fuel systemis not necessary withcarbureted engines.

9. EFI Engines Only. Prime thefuel system by cycling the fuel pump eight to ten timesbefore the engine is started for the first time. To prime:• Turn the ignition key ON for 5 seconds.• Turn the ignition key OFF for 5 seconds.• Repeat above eight to ten times

NOTICEThe above procedure is only necessary forthe first time the engine is started or in theevent the fuel tank is run dry. If your dealer

prepares your boat for initial delivery, they will performthis procedure for you.

10. Start the engine (Refer to Chapter 2, GeneralOperation and Warnings) and allow it to reach nor-mal operating temperature; keep a close eye on thegauges. If any of the gauges indicate an engineproblem, stop the engine immediately and bring theboat to your Indmar dealer for assistance.

Do not operate starter motor for more than15 seconds without a 2 (two) minute cool-down period. Excessively long crankingtimes will permanently damage the startermotor and drain the battery.

Break-In Taking care now to break-in your new Indmar engine isVERY important. When broken in properly, your enginewill last longer, run better and require fewer repairs overits lifetime.Your new Indmar engine does not require anelaborate break-in procedure, just a little care and com-mon sense for the first 7 hours.

CAUTION

ON

STARTOFF

ACC

INDM-A006

Figure 1.5 – Engine“On” Switch


Break-in Tips• Always let engine warm up to normal operating tem-

perature before accelerating. EFI engines, includingthe LS1, are programmed with a phased warm up toensure that the engine is warm before full RPM ispossible; refer to Table 1-1.

Table 1-1. EFI Phased Warm-Up

TEMPERATURE TIME RPM LIMIT

103°F (40°C) or less ——— 3000 RPM

104° to 139°F (41° to 59°C) + 10 seconds 4200 RPM

140° (60°C) and higher + 10 seconds Full RPM

• Avoid fast accelerations and don’t carry (or pull) aheavy load during this period.

• Check engine and transmission fluid levels frequently.During the first 50 to 100 hours, an engine can usemore oil than usual. Maintain oil at proper levels at alltimes but do not overfill.

• Vary your boat speed during break-in. Do not run atthe same speed very long.

• Observe gauge readings and check for loose mount-ings, fittings, nuts, bolts and clamps.

• Report abnormal operation, noises or vibrations toyour dealer.

Break-in Steps

1. For the first hour, do not exceed 2000 RPM; varyRPM continuously.

2. For the second hour, do not exceed 3000 RPM;3. For the next five hours, do not exceed 4000 RPM.

After the first ten hours of operation, take your boat tothe dealer for its first engine and transmission oil and filter change and engine checkup.Your Indmar dealer isbest equipped to check the engine immediately afterbreak-in.

After the break-in procedure is over, your boat may beoperated continuously at any speed. Be sure to checkthe wide open throttle operating range; refer to Chapter4, Selecting A Propeller.

Do not exceed maximum RPM recommendedfor your engine. Exceeding the maximumRPM may result in damage to the engine.

CAUTION


Operating a boat is a safe and enjoyable experience.

Indmar marine engines use gasoline for fuel. The areaunder the engine and around the gasoline tank and sup-ply lines is not open to outside air. Ventilation aroundthese areas must be provided by your bilge blower sys-tem and air vents located around the boat. We recom-mend taking time out to carefully inspect your boat atleast once a day for gasoline fumes, oil leaks, and areaswhere wiring may be worn or damaged.

Explosive gasoline and battery fumes mayaccumulate in your engine compartment.Failure to properly ventilate fumes with thebilge blower may result in explosive atmos-phere resulting in death or serious injury toyou and your passengers.

Before starting engine operate bilge blowerat least 4 minutes and raise engine cover toventilate fumes. Inspect engine and compart-ment for any fluid or fuel leaks.Failure to doso can possibly result in fire and/or explo-sion resulting in death or serious injury toyou and your passengers.

When refueling, make sure to open the motor box andrun the blower during and after the re-fueling operation.Failure to do so may result in fire or explosion and maycause death or serious injury.

! WARNING

! DANGER !

Chapter 2GENERAL OPERATION AND WARNINGS


Never remove or modify any components ofthe engine’s fuel system. Tampering with fuelcomponents may cause a hazardous condi-tion that could result in severe personalinjury or death. This work must be performedby your dealer’s technicians.

Daily Pre-Start Checks

Refer to Chapter 6, Maintenance for checks and services.

Figure 2.1 – Pre-Start Check Points

1. Verify boat hull and/or garboard drain plug are inplace.

2. Carefully inspect engine compartment for signs offluid leakage and proper ventilation. Unlike autos,marine engine compartments require positive ventila-tion and air re-circulation to ensure that flammableand explosive vapors are safely dispersed in an envi-ronmentally sound manner.

3. Verify engine drain plugs are in place.4. Check engine oil level.

Figure 2.2 – Engine Oil Dipstick

5. Verify fuel lines are tight and there is no leakagepresent.

6. Inspect oil lines and oil filter. Ensure they are tightand no leakage is present.

ENGINE OIL

INDM-A008

INDM-A007

1312111098765432

15 14 161

1

! WARNING


Figure 2.3 – Engine Oil Filter

7. Check transmission fluid level. Check V-Drive fluidlevel if equipped.

8. If your engine is equipped with a fresh water coolingsystem, check coolant level in the expansion tank.

9. Check alternator belt for wear and proper tension.10. Verify that exhaust hoses are in good condition and

clamped tight.11. Ensure that the propeller shaft coupler bolts are tight.12. Verify engine mounts are tight.

13. Check electrical connections and ensure connectorsare tight. Check wiring for signs of wear and abrasion.

14. Verify throttle/shift control is functional and properlyadjusted.

15. Verify steering controls are functional and properlyadjusted.

16. Verify battery connections are clean and securelyfastened.

Figure 2.4 – Battery ConnectionsINDM-A010

INDM-A009


Explosive gasoline and battery fumes mayaccumulate in your engine compartment.Failure to properly ventilate fumes with thebilge blower may result in explosive atmos-phere resulting in death or serious injury toyou and your passengers.

Before starting engine operate bilge blowerat least 4 minutes and raise engine cover toventilate fumes. Inspect engine and compart-ment for any fluid or fuel leaks.Failure to doso can possibly result in fire and/or explo-sion resulting in death or serious injury toyou and your passengers.

When refueling, make sure to open the motor box andrun the blower during and after the re-fueling operation.Failure to do so may result in fire or explosion and maycause death or serious injury.

Never remove or modify any components ofthe engine’s fuel system. Tampering with fuelcomponents may cause a hazardous condi-tion that could result in severe personalinjury or death. This work must be performedby your dealer’s technicians.

HOW TO START YOUR ENGINE

1. Run the blower for 4 minutes to remove explosivegasoline and battery fumes from the engine compart-ment.

! WARNING

! WARNING

! DANGER !

Chapter 3ENGINE STARTING PROCEDURES


2. Perform the Daily Pre-Start checks. Refer toChapter 2, GeneralOperation and Warnings.

3. Move the shift controllever to the NEUTRALposition. Pull out the neu-tral safety lever (ifequipped). Withoutadvancing the throttlelever, turn the starter keyto START position.

NOTICEPrime cold engine by moving throttle forwardand back two or three times. Then return toidle position before starting. A hot engine

does not require priming.

NOTICEOn carbureted engines it will be necessary tofeather the throttle until the engine warms up.

NOTICEBecause of theelectronic enginecontrols, there is no

need to advance the throttleto set an automatic choke.The throttle should be in theneutral position with theneutral detent button on theshift control box pulled out.

4. After the engine starts,release the key. Theengine will gradually slowfrom a fast idle to normalidle. If engine is cold, itwill operate at a slightlyhigher idle speed untilwarm-up is complete.Make sure that when youdo shift into gear that you are at idle speed (less than1100 RPM). Let engine warm up to normal operatingtemperature before accelerating. EFI engines, includ-ing the LS1, are programmed with a phased warmup to ensure that the engine is warm before full RPMis possible; refer to Table 3-1.

Figure 3.1 – BlowerSwitch

Figure 3.2 – Start Position

ONBLOWER

OFF

INDM-A011

ON

STARTOFF

ACC

INDM-A012




103°F (40°C) or less ——— 3000 RPM



Figure 3.3 – Tachometer

Once the engine has started, immediatelycheck the oil pressure. Monitor the oil pres-sure and engine temperature closely for thefirst 10 minutes of operation.

IF ENGINE DOES NOT START

Do not operate starter motor for more than15 seconds without a 2 (two) minute cool-down period. Excessively long crankingtimes will permanently damage the startermotor and drain the battery. Damage fromoverheating the starter motor is not coveredby the warranty.

Hold key in START position for 3-5 seconds. If engine stilldoes not start, advance throttle lever about 1/4 of its totaltravel. Turn key and hold it there for 12 more secondsuntil engine starts.

If your engine does not start after several attempts, itmay have too much fuel and needs to be cleared.

HOW TO CLEAR THE ENGINE

1. Check throttle lever (1, Figure 3-4) to make sure it ispulled out (or Neutral lockout button, 2, activated) sothat boat is still in NEUTRAL.

2. Wait for 30 seconds to allow starter motor to cool.

CAUTION

CAUTION

rpm

INDM-A013

1

23

4

5

60


Figure 3.4 – Shift/Throttle Lever

3. Advance throttle lever to full throttle position andhold. Hold key in START position for no more than 10seconds to clear extra gasoline from the engine.When engine starts, immediately return throttle han-dle to IDLE position.

4. If it does not start, wait two minutes and try thesequence again.

ENGINE RESTART

1. If your engine is already warm and will not re-start,turn key to ON position and wait for about 20 sec-onds (not necessary with carbureted engine).

2. Make sure that your throttle lever is in NEUTRAL.

3. Turn key OFF. Try to start engine again. If it does notstart, advance throttle to about 1/4 while holding keyin the START position. (Remember, you should onlyhold key in start position for 12 seconds at a time.)When engine starts, release the key and immediatelyreturn throttle to IDLE position.

NOTICEYour engine is designed to work with the stan-dard electronics installed in your boat. If youadd electrical components or accessories,

you could change fuel injection controls for yourengine or could exceed the amperage capacity of thewiring and protection system. Before adding electricalequipment, consult your Indmar dealer.

INDM-A016

2

1


DAILY ROUTINE

1. Open the engine cover and check the bilge for water;pump bilge dry. Excessive amounts of water can indi-cate leakage problems from shaft/rudder logs, thru-hull fittings, loose or damaged hoses or hull damage.Excess water in the bilge will damage engine compo-nents (starters, alternators, etc.).

Do not allow excessive amounts of water toremain in the bilge. Component damage dueto water is not covered by the warranty.

2. Follow the starting procedures outlined in Chapter 3,Engine Starting Procedures.

Don’t forget to run your engine blower for atleast 4 minutes before cranking engine.Failure to do so may result in fire and/orexplosion resulting in death or serious per-sonal injury.

3. Once the engine is started, allow it to reach operat-ing temperatures of at least 120°-140° F (49˚-60˚ C)before accelerating to speeds above 3000 RPM. EFIengines, including the LS1, are programmed with aphased warm up to ensure that the engine is warmbefore full RPM is possible; refer to Table 4-1.



103°F (40°C) or less ——— 3000 RPM



! WARNING

CAUTION

Chapter 4NORMAL OPERATION


Figure 4.1 – Temperature Gauge

4. Monitor your gauges and warning lights frequently toensure that engine temperatures and pressures arewithin the proper ranges.

Figure 4.2 – Oil Pressure Gauge

OPERATING THE CONTROLS

Be sure to refer to the boat owner’s manual for additionalinformation. Should there be any difference between theinformation presented in this manual and the boatowner’s manual, the boat owner’s manual should takeprecedence.

The shift / throttle control is important to daily operation.Have your dealer check it regularly for proper adjustmentand lubrication.

NOTICEAvoid using the throttle lever during the start-ing sequence. Your electronic engine controlsshould not need any throttle movement while

starting.

Your engine has a safety feature that allows the engineto crank only in the neutral position. If during the startingprocess your engine will not turn over, make sure thatthe shift / throttle control is in the NEUTRAL position andtry again.

oil

INDM-A014

0

40

80psi

engine

INDM-A015

80 240°F

160


Most boats have an engine safe-ty switch (1, Figure 4-3) that canbe activated if the driver movesfrom the helm position. If youexperience a “no start” condition,verify that this switch has notbeen disabled. If the tether cordis pulled from the switch, it dis-ables the ignition system so theboat cannot start.

Use caution while operatingshift lever. Shift only while theengine is at idle.

Figure 4.3 – Tether Cord and Safety Switch

Avoid using the throttle when in reverse. Thiscan force water backwards into the exhaustsystem and into the engine cylinders withmajor damage.

HYDROSTATIC LOCK: If water collects in theengine cylinder for any reason, it can causehydrostatic lock, not allowing the pistons inthe engine to move properly. Hydrostatic lockcan severely damage your engine which isnot covered by your warranty.

UNUSUAL VIBRATION

If your engine is used in a direct coupled application(inboard) you need to know that damage to the drive line(propeller, shaft, strut and coupling) can cause vibration.You may feel vibration if damage is severe. Vibration inthe drive line will cause excessive wear on transmissionand engine components.

If you believe you hit something with the propeller, or ifyou notice excessive vibration, see your dealer. Damageto your engine, drive line, or transmission caused byvibration is not covered by your warranty.

CAUTION

CAUTION

INDM-A017

1


FUEL SYSTEM

The Indmar fuel system uses high quality marine gradecomponents. These components will tolerate smallamounts of water without sustaining damage.Yourengine will misfire and run poorly, however, if water is inthe fuel. Use caution when re-fueling not to allow waterto enter the fuel system. If you suspect your fuel is watercontaminated, consult your dealer and avoid that fuelsource in the future.

Do not attempt to repair or replace any compo-nents of the fuel system.They are specialmarine parts and may require special servicetools.You could damage the fuel system bynot using specified tools.This could cause afire or explosion and subsequent death or seri-ous personal injury to you or your passengers.

See your dealer for assistance with fuel system repairs.

BATTERY

Your engine uses a special 12-volt marine battery. If areplacement is needed, use only a marine battery withminimum 650 cold cranking amps at 0° F (-18° C).

Before disconnecting the battery, make sure the batteryswitch (if equipped), ignition key and all accessories arein the OFF position.

Be sure to connect cables properly:• Black cable to the negative or (-) post• Red cable to the positive or (+) post

Figure 4.4 – Marine BatteryINDM-A010

! WARNING


Use caution when connecting the batterycables. Improperly connecting the batterycables or using the wrong battery type candamage electrical components. These dam-ages are not covered by your warranty.

CHECK ENGINE LIGHT (EFI ENGINES ONLY)

Some boats are equipped with a Check Engine lightwhich alerts you when the ECM (engine control module)detects a possible engine problem. If the light goes on,return to dealer for service. When a problem is detected,EFI engines may enter a Power Reduction mode. Powerreduction limits the engine speed to a “safe maneuver-ing” speed of about 1600 RPM. This mode is intended toallow the driver to get out of harms way and to reachsafe harbor for engine service.

Figure 4.5 – Check Engine Light

The Check Engine light may activate if any of the follow-ing conditions are noted:• Low Oil Pressure• High Coolant Temperature• High Transmission Oil Temperature

Any of these conditions will also put the engine intoPower Reduction mode. If the Check Engine light should go on, or if the engine enters thePower Reduction mode, you should have your dealercheck the engine as soon as possible.

Schedule engine service at once when thislight is illuminated. Failure to have yourengine serviced when a check engine lightsignal is given, may cause damage to yourengine or your emissions system.

The ECM also provides for a tapered engine RPMreduction if engine coolant temperature approaches thehigh operating limit. If the coolant temperature exceeds176° F (80° C), the engine RPM is gradually reduceduntil a safe temperature is reached. If the engine RPMshould decrease due to high coolant temperature, stopthe engine and inspect the raw water intake, sea cockand sea strainer (if equipped) and hoses for blockage orproblems.

CAUTION

CHECKENGINE

INDM-A018

CAUTION


CHECK TRANSMISSION LIGHT

If the engine is equipped with the Walters V-Drive trans-mission, there is also a Check Transmission light. If lowoil pressure is sensed in the V-Drive, the light will go onindicating the problem. Under normal operation, the lightwill stay lit at idle and slow speed operation until enoughpressure is produced (1200 RPM ± 400 RPM). Extendedcruising or trolling at low RPM is not harmful, even if thelight is lit, provided that the V-Drive oil level is sufficient. Ifthe oil level is normal and the light stays lit above 2000RPM, take the boat to your Indmar dealer for service.

ENGINE COOLING

Raw water cooled engines have two water pumps. Onecirculates water throughout the engine. The other pumpuses water from the sea, lake or river to feed raw waterto the engine. This raw water pump is designed to usethe water it pumps to lubricate its impeller. Do not run theengine unless the boat is in water. If you run the enginewith the boat out of the water, the water pump may bedamaged, causing your engine to overheat or start a fire.

Figure 4.6 – Raw Water Pump

Running engine without adequate coolingcan cause engine to overheat and may resultin fire, explosion, death and/or personal seri-ous injury.

! WARNING

INDM-A019


Running your engine with your boat out ofwater will damage or ruin your engine.Damage to your engine caused by overheat-ing is not covered by your warranty.

Running the engine during the RPM reduc-tion phase may cause severe damage to yourengine.

• Monitor the temperature and oil gauges continuously.• If the temperature rises past 200° F (93° C), or your

oil pressure drops below 4 psi (41 kPa), STOP THEENGINE IMMEDIATELY.

Damage due to running the engine with excessive tem-perature or low oil pressure is not covered by your war-ranty.

EXHAUST HOSES

Exhaust hoses on most boats carry exhaust gases fromthe engine outside of the boat. These hoses carry waterthat has been used to cool the engine. This water keepsthe hoses cool and prevents them from melting.

Carbon monoxide gas (CO) is colorless,odorless and extremely dangerous. Allengines and fuel burning appliances produceCO as exhaust. Direct and prolonged expo-sure to CO will cause BRAIN DAMAGE orDEATH. Signs of exposure to CO includenausea, dizziness and drowsiness. Ensureadequate ventilation to prevent accumulationof CO in the boat.

Monitor the engine temperature gauge frequently. If yourengine overheats, carefully inspect the exhaust hoses fordamage. Damaged hoses can allow carbon monoxidegas to enter your boat.

SELECTING A PROPELLER

For best engine performance and longevity, the wide-open-throttle (WOT) engine operation must be near thetop of, but within, the specified WOT operating range. Toadjust the WOT operating range, you must select a pro-peller (propping) with the proper diameter and pitch. Thepropeller which was supplied with your boat was chosenby the boat builder for best all-around performance underaverage conditions.

! DANGER !

CAUTION

CAUTION


Load, weather, altitude and boat condition all affect WOTengine operation. If you use your boat for several differ-ent applications such as wakeboarding, barefooting andcruising, it may be necessary to have 2 or more pro-pellers which will allow the engine to operate in the WOTrange for each application.

Propping the boat should be done after engine break-inand the initial 10 hour dealer check. The boat should beloaded the way it would normally be for each application.For instance, if you are propping for wakeboarding, fillthe ballast tanks if equipped and add all the people andgear you would normally expect to carry in the boat. Takethe boat out and after warm-up, run it at wide-open-throt-tle and note the maximum RPM. EFI Engines areequipped with RPM limiters to prevent over-revving. Takenote if the RPM limiter is activated.

If the WOT RPM is higher than the maximum RPM inyour engine’s WOT operating range, the boat is under-propped. Install a higher pitched propeller to reduceWOT RPMs. An engine that is over-revving may quicklyexperience catastrophic damage.

If the WOT RPM is lower than the minimum RPM in yourengine’s WOT operating range, the boat is over-propped.Install a lower pitched propeller to increase WOT RPMs.

An engine that is under-revving is lugging. Luggingplaces tremendous loads on the pistons, crankshaft andbearings and can cause detonation, piston seizure andother engine damage.

Elevation and weather also have a very noticeable effecton the wide-open-throttle power of an engine. Since air(containing oxygen) gets thinner as elevation increases,the engine begins to starve for air. Humidity, barometricpressure and temperature have a noticeable effect onthe density of air since heat and humidity thin the air.This phenomenon can become particularly apparentwhen an engine is propped out on a cool dry day inspring and later, on a hot, humid day in summer, doesnot have the same performance. Although some per-formance can be regained by dropping to a lower pitchpropeller, the basic condition still exists. The propeller istoo large in diameter for the reduced power output. Anexperienced marine dealer can determine how muchdiameter to remove from a lower-pitch propeller for spe-cific high-elevation locations.

Indmar suggests that if you do require a different pro-peller, consult the dealer you bought the boat from. Thedealer is best equipped to help with the selection of thecorrect propeller for your application(s).


WHAT TYPE OF GASOLINE TO USE

All carbureted and standard EFI engines run on unlead-ed fuel of 89 Octane (R+M)/2 or higher. The LS1requires 93 octane or higher. Fuels must meet the speci-fication ASTM D4814 in the US and CGSB 3.5-92 inCanada. These fuels need no additives.

Figure 5.1 – Filling Fuel Tank

Gasoline vapors are highly flammable andexplosive.

• Never smoke while refueling. Keep sparksand flames away from fuel.

• Only refuel in well ventilated area.

• Never overfill fuel tank.

• Stop engine before fueling.

• Swallowing or inhaling gasoline or fumesis dangerous. Seek medical attention.

• Gasoline spills on your skin should bewashed immediately with soap and water.If gasoline spills on clothing, change cloth-ing immediately.

* Avoid spilling gasoline. Clean spills withdry cloth and dispose properly.

! WARNING

INDM-A021

Chapter 5FUEL


Figure 5.2 – Inspecting Fuel Lines

Frequently inspect fuel lines and connec-tions for leaks or deterioration.

Indmar recommends the regular use of Sta-Bil fuel stabi-lizer for boat users that consume less than a tank of fuelevery two weeks. Today’s fuels are more susceptible todegradation and the use of a quality stabilizer will helpensure fewer problems for the occasional boater.

If your boat has not been used for more than 30 dayswith fuel in the tank (even stabilized fuel), the enginemay run poorly until the “old” fuel is used up. Indmar willnot pay for repairs to carburetors or fuel injection compo-nents that are inoperable or damaged from old and/orpoor quality fuel.

USING OXYGENATED FUELS OR FUELS WITHALCOHOL

MBTE (methyl butyl tertiary ether) is an oxygenate andoctane enhancer. This compound may be blended withfuel. Fuel that is no more than 15% MBTE is acceptablefor use in your Indmar engine.

CAUTION

INDM-A022


Ethyl alcohol, ethanol or grain alcohol is acceptable aslong as it is a blend and the blended fuel contains nomore than 10% ethanol.

Fuels that are blended to contain methanolor wood alcohol should not be used inIndmar engines. These fuels can corrodemetal parts in your fuel system and engine.Fuels that contain methanol will damageyour engine. Damage caused by the use offuels that contain methanol is not covered byyour warranty.

FUELS IN OTHER COUNTRIES

If you operate your Indmar engine outside the USA orCanada, unleaded fuels may be difficult to obtain.Leaded fuels are not recommended as engine compo-nents will last longer using unleaded fuel.CAUTION


GENERAL SERVICE NOTES

Your Indmar dealer is your best source for engine repairand maintenance. Indmar certified technicians attendongoing service training programs and have the properdiagnostic tools plus the latest specifications for yourengine.

Electrical, ignition and fuel system compo-nents on Indmar engines comply with U.S.Coast Guard rules and regulations to mini-mize risks of fire or explosion. Use ofreplacement electrical, ignition or fuel sys-tem components, which do not comply tothese rules and regulations, could result in afire or explosion hazard and should not beused.

Your safety depends on your use of marine parts. Whenservicing the electrical, ignition and fuel systems, it isextremely important that all components are properlyinstalled and tightened. If not, any electrical or ignitioncomponent could permit sparks to ignite fuel vapors fromfuel system leaks, if they existed.

Since marine engines are expected to operate at nearfull-throttle for most of their life, and to operate in freshand salt water environments, many special parts and fas-teners are used which are quite different from standardautomotive parts. Many parts are made from special cor-rosion resistant materials while other moving parts areheavy-duty for continuous, high RPM duty. If you performminor service procedures, make sure to use genuineIndmar parts for marine use.

! DANGER !

Chapter 6MAINTENANCE


• You can be injured if you try to work on yourmarine engine without knowing enoughabout your engine.

• Be sure you have the knowledge, experienceand the correct replacement parts BEFOREyou attempt any repairs.

• Be sure all fasteners you use are approvedand rated for marine use. Use of improperparts can cause component or engine failurewhich may result in death or serious person-al injury.

Never operate engine without adequate watersupply to the raw water pump. Failure toproperly cool engine will cause severeengine damage and void your warranty.

CAUTION! WARNING


Scheduled Maintenance Chart

FIRST EVERY EVERY EVERY 300 EVERY10 50 100 HOURS or 2

ITEM SERVICE HOURS HOURS HOURS ANNUALLY YEARSEngine Oil & Filter Change X X XZF Transmission Fluid Change X XWalters V-Drive Oil Change X XEngine Coolant Change XFuel Filter Replace X X XSpark Plugs* Replace XEngine Timing* Check X XEngine* Tune Up XFlame Arrestor Clean/Change XBelts Inspect X X XShaft Alignment Check X XSpark Plug Wires* Inspect XRaw Water Pump Impeller Inspect X XBreather Hose* Clean XPCV Valve* Replace XStarter Bendix* Grease X X

* Services best accomplished by your Indmar dealer.


ENGINE OIL

Checking Oil

Figure 6.1 – Engine Oil Dipstick Location

Check the oil level with the dipstick every time you getfuel. To get an accurate reading, your engine should bewarm and the boat should be level. For best results waitabout 2 minutes after you turn off the engine to allow theoil to drain into the oil pan, giving you a more accuratereading.

Figure 6.2 – Dipstick

1. Pull dipstick from engine.2. Wipe oil off stick with clean towel/cloth.3. Insert dipstick completely into the dipstick tube.4. Remove dipstick and read oil level.5. After reading is complete, return dipstick to tube.6. Add oil if necessary.

Adding Oil

If oil level on the dipstick reads below the ADD mark, addonly enough oil to return level to FULL mark.

Figure 6.3 – Engine Oil Fill

INDM-A025

ADDOPERATING RANGE SEE OWNERS MANUA

INDM-A003

ENGINE OIL

INDM-A023


Do not overfill. If your oil level is above thefull mark on the dipstick, the engine may bedamaged.

Indmar uses and recommends Pennzoil Marine 15W-40Marine Oil API Service SJ/CG4 or equivalent. If engine isto be used on conditions below 20° F (-7˚ C), usePennzoil Marine SAE 10W-30 API Service SJ/CD orequivalent.

The use of engine oil other than 15W-40 withan API SJ/CG4 designation can cause enginedamage. Damage to your engine caused bythe use of improper oils is not covered byyour warranty.

Synthetic Oil

Synthetic oil that meets our requirements of 15W40 andAPI SJ/CG4 is acceptable to use after 100 hours ofoperation with the recommended oil. The use of syntheticoil does not change the requirement of 50 hour oilchange intervals.

Changing Oil

Change your engine oil after the first 10 hours of opera-tion. Then change oil every 50 hours or annually,whichever comes first. To maximize engine life, changethe oil filter at every oil change.

Figure 6.4 – Oil Filter

Indmar recommends all engine maintenance proceduresbe performed by your dealer, including oil changes. If youmust perform the oil change yourself, operate the engineto full operating temperature.

CAUTION

CAUTION


Engine oil is hot. Be careful not to burn yourself.

1. With the boat level on trailer, remove the hull or gar-board drain plug and insert QuickDrain through thehull opening (outside of hull).

2. Remove QuickDrain hose cap and let oil flow intoused oil container.

3. When all oil has drained, replace cap and returnQuickDrain to storage position. Replace the hull orgarboard drain plug.

4. Position a suitable container under the oil filter.Unscrew and remove the oil filter; ensure that filterseal is removed with oil filter. Wipe up any spilled oilin the bilge and dispose of properly.

5. Fill a new Pennzoil Marine oil filter about 1/2 full withclean engine oil. Lightly lubricate the oil filter gasketand “spin on” the filter until the gasket makes contact.Hand tighten filter 1/4 to 1/2 turn after contact.

6. Add the new oil through the cap located on theengine valve cover. Fill only to the FULL mark of dip-stick.

7. After initial start up, always carefully inspect oil drainplug and oil filter gasket area for leaks.

8. Stop the engine and re-check oil level. Add if neces-sary.

Oil Additives

Do not use oil additives. Indmar engines do not need oiladditives. Use of recommended oil, along with regular oiland oil filter changes, will protect your engine adequately.

Disposing

Used engine oil contains dangerous chemicals and isconsidered a hazardous waste. Do not allow used oil toremain on your skin for any length of time. Make certainto drain all free flowing oil from the filter prior to disposal.Recycle used oil by taking it to a collection center. If youhave a problem disposing of used oil, ask your Indmardealer or service station for the name of a local oil recy-cling center for proper disposal.

• Prolonged and repeated contact with usedengine oil may cause skin cancer.

• Avoid direct skin contact with used oil. If skincontact is made, wash thoroughly with soapor hand cleaner as soon as possible.

• Keep used engine oil out of reach of children.

• Used engine oil is a hazardous material.Dispose of properly.

! WARNING

CAUTION


ENGINE FLAME ARRESTOR

Your engine is equipped with a U.S. Coast Guardapproved flame arrestor. Its purpose is to contain anybackfire that may occur during the operation of yourengine. Because an inboard engine is completelyenclosed, an uncontained backfire can be extremelydangerous.

Figure 6.5 – Flame Arrestor

Periodically inspect flame arrestor to prevent clogging bydirt or corrosion. There are two types of flame arrestorsused in Indmar engines, metal and paper.

Metal TypeThe metal flame arrestor is cleaned using a mild partwashing solvent. Using solvent, clean the flame arrestor

thoroughly and blow dry. The metal flame arrestor mustdry completely before it is returned to the engine.

Paper TypeThis type of flame arrestor should be blown clean fromthe inside monthly and replaced annually. Use only gen-uine Indmar replacement parts to ensure proper fit andprotection against fire and explosion.

When cleaning or replacing the flame arrestor, clean thebreather hose and replace the PCV valve at the sametime.

Do not remove the flame arrester at any timewhen the engine is being started or run as itmay result in fire, explosion and death orserious personal injury.

ENGINE COOLING

Running engine without adequate coolingcan cause engine to overheat and may resultin fire, explosion, death and/or personal serious injury.

! WARNING

! WARNING

INDM-A027


Closed cooled engines are shipped from theIndmar factory filled with a 50/50 mix ofSierra brand antifreeze and water. This mix-ture provides freeze protection down to –26°F(-32° C). If the temperature in your area isexpected to go below this level of protection,see your Indmar dealer to have the antifreezemixture adjusted for your needs.

Running your engine with your boat out ofwater will damage or ruin your engine.Damage to your engine caused by overheat-ing is not covered by your warranty.

Most engines are cooled by the raw water outside of theboat (Open Cooling System). For this reason, do notstart the engine when the boat is out of the water withoutan engine flushing device available from your Indmardealer.

With Open Cooling Systems, if your engine is used insalt, brackish, dirty or polluted water, the cooling systemmust be flushed with clean water immediately to preventcorrosion and blockage in the cooling system.

Open Cooling Systems usually consist of a raw waterintake on the bottom of the boat, a strainer to filter weedsand debris, a raw water pump, a belt driven marine waterpump, a thermostat to regulate engine temperature, andvarious connecting hoses. The raw water pump pulls out-side water through the strainer, circulates the waterthrough the engine and then discharges it overboardthrough a hose or with the engine exhaust.

Fresh Water (Closed) Cooling Systems

Some engines have a closed fresh water cooling system.In the fresh water system the cooling water contains anti-freeze and re-circulates throughout the engine. If yourengine is equipped with a heat exchanger tank, it has afresh water cooling system. Raw water is pulled throughthe strainer and flows through chambers in the heatexchanger and then discharged overboard with theengine exhaust.

Figure 6.6 – Fresh Water Cooling System

CAUTION

! WARNING


Check coolant level every time you check your oil. Thelevel in the expansion tank should be maintained at 2/3full when the engine is at operating temperature.

To avoid possible skin burns, the enginemust be turned “OFF” and cool enough so noheat is registered on the temperature gauge.Only after the engine is completely cooled isit safe for you to remove the coolant reser-voir cap to check the level. Failure to followprocedure may result in death or serious per-sonal injury.

• Failure to maintain the coolant at the properlevel can cause engine damage.Your warran-ty will not cover engine damage due to over-heating or any other cause associated withimproper coolant levels.

• Use only propylene glycol coolant. Use ofany other coolant or mixing coolant typescan cause engine damage. Damage to yourengine from use of any other type of coolantis not covered by warranty.

• The coolant system should be flushed andcoolant replaced every two years.Thisshould be performed by a qualified Indmarservice technician.

When adding coolant, add only Sierra brand propyleneglycol in an appropriate mixture with distilled water inaccordance with the directions on the container. Do notoverfill the tank. Do not mix anti-freeze types.

If tank is completely empty, see your Indmar dealer forassistance immediately to purge system. Purging thesystem is a difficult procedure that is not recommendedfor the boat owner.

FUEL SYSTEM

The fuel system consists of a fuel filter, water separator,fuel pump, and an unused fuel recovery system. Fuel inthe system is under pressure and must be relievedbefore servicing. Because of the inherent danger of fuelleakage into the bilge, do not attempt servicing or main-taining components of the fuel system.

Your Indmar dealer has factory trained technicians andU.S. Coast Guard approved marine grade parts requiredfor fuel systems.

CAUTION

! WARNING


TRANSMISSION

Indmar engines are equipped with one of three types ofmarine transmissions:

• Midships Mount: ZF Hurth Marine In-Line• Stern Mount: ZF Hurth Marine V-Drive• Stern Mount: Walters V-Drive and ZF Hurth In-Line

A separate owner’s manual covering basic maintenanceis provided with each transmission. The transmissionfluid must be changed and the filter cleaned after the first10 hours of operation and once each year thereafter.Refer to the transmission owner's manual for information.

Figure 6.7 – ZF Hurth Transmission Dipstick LocationThe transmission is water cooled by a heat exchanger

connected to the engine coolingsystem. The transmission fluidlevel should be checked eachtime the engine oil is checked.Fluid level is to be maintained ata level between the “Full” and“Add” marks on the transmissiondipstick.

Overfilling the transmission withfluid will cause the seals to leak,and eventually lead to overheat-ing, while if there is too littlefluid, overheating will result.

If the engine uses the Walters V-Drive, it is equipped with a ZF Hurth in-line transmission for shifting. Be aware that theWalters V-Drive uses motor oilfor lubrication, while the ZFHurth transmission usesAutomatic Transmission Fluid. The Walters V-Drive alsohas a low oil pressure sensor and a dashboard mountedlight. If low oil pressure is sensed, this lamp will light indi-cating the problem. Shut down the engine and check thetransmission fluid level. Refer to Chapter 6, CheckTransmission Light for more information.

INDM-A030

HIGH

LOW

INDM-A039

Figure 6.8 – Walters V-Drive Dipstick


If transmission service is required, note the SerialNumber of the transmission stamped onto the ID plateon the top of the transmission housing. It is good practiceto note the serial number noted and keep it with otherowner related information.

Checking/Adding Transmission Fluid

Check fluid only with engine OFF and boat floating level,or level on trailer. The transmission dipstick is located onthe top of the transmission. Dipsticks may be marked“ADD” and “FULL” or “H” and “L” (high and low); maintainfluid level between the two marks.

Check level immediately after turning engineoff. Transmission fluid may be hot. Be carefulnot to burn yourself.

1. Remove the dipstick and wipe with a clean towel.2. Insert the dipstick completely (do not screw in

threaded dipstick to check fluid). Remove the dipstickand read fluid level.

3. Return dipstick after level check. Make sure it issecured in place.

4. If level is below “ADD” mark, add the proper fluid untilit reaches the full mark. Add fluid through same tubeas you removed the transmission dipstick.

Figure 6.9 – Walters V-Drive Dipstick Location

INDM-A031

CAUTION


Do not overfill the transmission. Overfillingcan damage the transmission. Damage toyour transmission due to too much or too little fluid is not covered by your warranty.

ELECTRICAL SYSTEM

All Indmar engines are equipped with a 50 A circuitbreaker (1, Figure 6-10) to protect the engine electricalsystem and components from overload. If the engine willnot crank with the battery switch in the ON position,locate the red breaker reset button (labeled “50”) at theback of the engine. Firmly push the red button until thebreaker resets (an audible click will be heard). Start theengine.

Figure 6.10 – Breaker Reset Button

INDM-A029

1

2

CAUTION

TRANSMISSION MODEL RATIO CAPACITY FLUID TYPEZF Hurth In-Line 450D 1:1 1.7 qt (1.6L) Pennzoil Dexron II, III or MERCONZF Hurth In-Line 450A 1.5:1 2.12 qt (2L) Pennzoil Dexron II, III or MERCONZF Hurth In-Line 630A 1.5:1 4.2 qt (4L) Pennzoil Dexron II, III or MERCONZF Hurth V-Drive 630V -- 4.2 qt (4L) Pennzoil Dexron II, III or MERCONWalters V-Drive RV-26D-71V -- 0.5 qt (0.5L) Pennzoil SAE 30 Motor Oil


If the breaker trips again, there is a problem with theelectrical system. Take your boat immediately to yourIndmar dealer for repair.

NOTICEIn addition to the 50 A Circuit Breaker, EFIEngines are equipped with additional compo-nent overload protection:

• Fuel Pump - 15 A ATO Fuse• Injectors - 15 A ATO Fuse• ECM - 15 A ATO Fuse

Figure 6.11 – ATO Fuse

EFI fuses are located on the holder (2, Figure 6-10)attached with the ECM. To remove or inspect a fuse,remove molded plastic cap from fuse holder/base.Inspect fuse and replace if it is defective, (Figure 6-11).

WIRING

If during maintenance or inspection, it becomes neces-sary to move or reposition any of the engine’s wiring orwire harnesses, verify that wiring is returned to its origi-nal position, and that all harnesses are routed correctly. Ifa wiring clip or retainer breaks, replace it immediately.Wiring is specifically routed to eliminate problems relatedto engine heat and spray or immersion in liquids.Electrical problems can result if wiring is moved from itsoriginal position and is not properly repositioned.

General Lubrication

STARTER

Apply a dab of Pennzoil Premium Plus multipurposegrease onto the starter bendix every month or 50 hoursof operation.Your starter has been sprayed with lubrica-tion internally to extend its longevity.

SHIFT AND THROTTLE CABLES

Spray exposed throttle cable and transmission cableends with Pennzoil Marine Z-M Corrosion Protectant andLubricant or Pennzoil Premium Plus multipurposegrease. Work the cable back and forth, then spray tocompletely lubricate. In highly corrosive locations, a com-plete cable lubrication system may be purchased throughyour Indmar dealer.

INDM-A032


Storage or winter lay-up requires preparation to preventdamage to the power package. While preparing thepower package for winter lay-up, annual maintenancetasks should also be performed.

Without proper preparation, storage over a long period oftime may cause internal engine and transmission partsto rust due to lack of lubrication. Also, if the boat is storedwhere the temperature falls below freezing, any waternot drained from the engine may freeze, resulting insevere damage. Damage that is the result of improperstorage is not covered under terms of Indmar’s limitedwarranty.

Because of the complexity of preparing yourengine for winter storage, and the danger ofcatastrophic engine damage from freezingwater in the engine, it is recommended thatyou have your dealer perform winterizationprocedures. Damage due to by improper win-terization/storage is not covered by productwarranty!

To properly winterize your engine, you MUST be able tobring the engine up to operating temperature. To accom-plish this, your boat must be in the water, or be attachedto a water supply using a hose and suitable adapter thatwill allow an uninterrupted supply of water to the engine.

! WARNING

Chapter 7STORAGE AND WINTER LAY-UP


NOTICEThis procedure covers only the power package portionof your boat. Consult your boat owner’s manual orboat manufacturer for specific boat winterizing instruc-tions.

GENERAL PREPARATIONBefore starting you will need the following supplies:• Sta-Bil Gasoline Stabilizer• 6 quarts of Pennzoil 15W40 Marine Engine Oil

(8 quarts for 8.1 Liter)• Pennzoil PZ3 Oil Filter for 5.7 Liter Carbureted and

EFI Engines• NAPA Gold 1042 Oil Filter for LS1 Engines• AC-PF454 Oil Filter for 8.1 Liter Engines• Fuel Filter (If equipped)• Low Tack Tape• 4-6 ounces of Pennzoil Marine Fogging Oil• 1 can Pennzoil Marine Z-M Corrosion Protectant and

Lubricant • Transmission Oil (As Required)• Pennzoil Premium Plus Multipurpose Grease • Short Piece of Stiff Wire (Coat hanger wire)• Pipe Thread Sealant• Anti-Freeze Tester suitable for Propylene Glycol

(Fresh Water Cooled Engines Only)• Sierra Brand Anti Freeze (As required for Fresh

Water Cooled Engines Only)

Fuel System Treatment1. If the boat is to be placed in storage with fuel in the

tank(s) that does not contain alcohol, fill the fueltank(s) with fresh fuel and a sufficient amount of Sta-Bil gasoline stabilizer to treat the entire tank. Followinstructions on the container.

2. If the boat is to be placed in storage with fuel thatcontains alcohol, the fuel tank should be drained ascompletely as possible and Sta-Bil gasoline stabilizeradded to any fuel remaining in the tank following theinstructions on the container.

3. Start the engine and operate at Idle RPM until theengine reaches normal operating temperature. (Ifusing a hose and adapter, adjust the faucet to avoidover-cooling the engine at low RPM.) Run the enginefor at least 15 minutes to ensure that the fuel stabiliz-er enters the engine’s fuel system.

Running the engine with the flame arrestorremoved increases the possibility of fire orexplosion if engine backfire occurs andgasoline fumes are present. If the engine isoperated without the flame arrestor secured,extreme care must be taken to ensure thatthe engine compartment is well ventilatedand that no fuel leaks are present.

! WARNING


4. Carefully loosen the flame arrestor and lift it farenough to insert the tube of the fogging oil can.Spray 4-6 ounces (118-177 cc) of oil into the throatof the carburetor or throttle body. Shut off the engine.Reattach the flame arrestor and seal with low tacktape.

5. Perform annual maintenance, refer to Chapter 6,Scheduled Maintenance Chart.

6. Loosen all accessory drive belts and check condition.Replace belt(s) if cracked or damaged.

7. Drain seawater section of the cooling system.

All Engines:1. Drain water from exhaust manifolds. Uncouple the

hose quick disconnect and drain the manifolds.Indmar recommends that you leave the drain plugsout, or the hose uncoupled, until spring.

2. Remove both hoses from the seawater pump on thefront of the engine. Drain any remaining water fromthe hoses.

3. Remove the raw water pump impeller from the pumphousing. Replace the impeller if it shows any signs ofdamage or wear. Lubricate the impeller with Vaselineand seal in an airtight bag.

Figure 7.1 – Quick Disconnect

INDM-A038


Figure 7.2 – Raw Water Pump Impeller

4. Remove the hose from the lower (rear) end of thetransmission cooler. Inspect the cooler for any debrissuch as weeds, plastic, etc.

Figure 7.3 – Transmission Cooler

5. On Walters V-Drive equipped units, remove the twosmall square headed drain plugs from the front andrear of the upper housing. Look for the words “WaterDrain” on the housing.

INDM-A009

INDM-A036


Figure 7.4 – V-Drive Drain Plugs

NOTICEPlacing the drain plugs, impeller, etc. in a plastic bagand attaching the bag to the steering wheel of theboat is a good reminder to reinsert the plugs whenyou recommission the boat in the spring.

Raw Water Cooled Engines

1. Remove the petcock, drain plug, or sensor from eachside of the engine. Indmar suggests removing thepetcocks completely, not just opening the petcockdrain valve.

NOTICESome 5.7 Liter engines have a knock sensorlocated in the drain location. The knock sen-sor must be carefully removed to drain that

side of the block.NOTICE

On the 8.1 Liter engine, removing the knock sensordoes NOT drain the block. Remove the plugs from thebrass fillings on both sides of the engine to drainwater from the block.

NOTICEPlacing the drain plugs in a plastic bag and attachingit to the steering wheel of the boat will act as areminder to reinstall the drain plugs during recommis-sioning in spring.

2. Use a short piece of stiff wire and poke around in thedrain hole to ensure that any rust or scale is brokenapart, and the engine drains completely.

3. Disconnect the large diameter hose that runs fromthe water-circulating pump to the thermostat housing.Make sure all of the water drains from the hose.

WATER LINE

WATER DRAIN

WATER DRAIN

INDM-A040


Fresh Water Cooled Engines (Except LS1)

1. Remove the raw water inlet and outlet hoses fromthe intake side of the heat exchanger.

2. Check the level of the coolant on the freshwater sideof the heat exchanger. Use the anti-freeze tester totest the strength of the mixture.

NOTICEA special antifreeze tester designed to be used withPropylene Glycol antifreeze is required to test thestrength of the mixture.

3. If the coolant level is low, add a sufficient amount ofcoolant/water mix to fill the heat exchanger. Use anappropriate mix of Sierra brand antifreeze and dis-tilled water, mixed in accordance with the directionson the container for the anticipated temperatures.

4. If the coolant in the heat exchanger is not strongenough to protect the engine to the lowest anticipat-ed temperature, take your boat to your Indmar dealerfor replacement of coolant.

LS1 Fresh Water Cooled Engine

1. Remove the drain plugs on each end of the heatexchanger. Do not remove center (fresh watercoolant) plug.

2. Remove the hose from the outlet side of the rawwater pump. Push the end of the hose low into thebilge using care not to kink it. Allow both coolers todrain.

3. Coat the threads of the heat exchanger drain plugswith pipe sealant and install.

4. Remove the hose from the rear elbow of one of theexhaust manifolds. Lower the hose into the bilgeusing care not to kink it. Allow both manifolds todrain.

Drive Train Preparation

1. Change the transmission fluid and clean the filterscreen following the instructions in the TransmissionOwner’s Manual.

2. Remove the attaching hardware from the propellershaft coupling. Separate the flanges and coat thesurfaces with Pennzoil Premium Plus Multipurposegrease.

General Power Package Preparation

1. Clean dirt, grime and grease from painted surfacesof the engine and drive train.

2. Touch-up painted areas of the engine and transmis-sion.

3. Lubricate throttle and shift linkages and cables withPennzoil Premium Plus Multipurpose Grease.


4. Spray the whole engine with Pennzoil Marine Z-MCorrosion Protectant and Lubricant.

5. Disconnect the battery cables from the battery andcharge the battery fully. If you remove the batteryfrom the boat, store it in a cool and dry place.

6. Leave the engine box cover propped open about 2"(50 mm) to ventilate the engine compartment.

REACTIVATING ENGINE AFTER EXTENDEDSTORAGE

Use caution when connecting the batterycables. Improperly connecting the batterycables or using the wrong battery type candamage electrical components. These dam-ages are not covered by your warranty.

1. Charge and reinstall the battery in the boat. Makesure terminals are clean and tight.

2. Coat the threads of the manifold drain plugs withpipe sealant and Install the manifold drain plugs inthe back of the exhaust manifold and/or reconnectexhaust manifold drain hoses.

3. Coat the threads of the block drains and petcockdrains with pipe sealant and install in the engineblock. EFI engines have a knock sensor located in

one of the drain holes. If your engine has a knocksensor, it must be reinstalled without using threadsealant. Do not over tighten the knock sensor. Torquespecification for the knock sensor is 14-16 lb. ft. (19to 21.5 Nom)

4. On Walter V-Drive units, coat the threads on the drainplugs with pipe sealant and reinstall on the front andrear of the transmission housing.

5. Reinstall the raw water pump impeller, be sure to usea new gasket for the housing cover. Re-attach theinlet and outlet hoses to the raw water pump.

6. Reattach the large diameter hose to the water-circu-lating pump.

7. Reattach the water hose to the transmission cooler.8. On fresh water cooled models, reattach the raw

water inlet and outlet hoses.9. Install a new set of spark plugs in the engine.10. Inspect accessory drive belts and tighten to the prop-

er tension if necessary.11. Check condition of the distributor cap and rotor, and

replace if worn, damaged or corroded.12. If the fuel tank was drained, fill tank with fresh fuel

that does not contain alcohol.13. Check all fluid, oil and coolant levels on engine and

drive train.14. Check engine compartment and bilge for nesting ani-

mals. Clean as necessary. Check for any damage orevidence of fluid leaks.

CAUTION


15. Remove tape from flame arrestor. Check alignmentbetween the output flange on the transmission andthe prop shaft flange. If the maximum feeler gaugethat can slip between the flange faces at any point is0.003" (0.08 mm), the unit is properly aligned. If athicker gauge can be inserted at any point, theengine must be readjusted until proper alignment isobtained.

Figure 7.5 – Prop Shaft Flange Alignment

NOTICEWith the boat in the water or a hose andadapter installed, cycle the key switch ON,then OFF, for five second intervals 8-10 times

before cranking the engine to allow the fuel pump toprime the fuel lines.

16. Review boat manufacturers starting procedure.

17. Start the engine. If you experience a no-start condi-tion, do not crank the engine for more than 15 sec-onds without allowing a two minute cool-down peri-od. When the engine starts, keep a close watch onthe gauge readings. Check all of the hoses and drainplugs for leaks. Listen for abnormal noises. Run theengine long enough to reach normal operating tem-perature and re-inspect for leaks. If no leaks arefound, the boat is ready for operation.

.003"

INDM-A037


Your Indmar engine is manufactured under strict qualitycontrol standards. It is tested along with a full spectrumgas analysis. It is operating at optimum levels before it isshipped. Indmar engines have the exclusive Indmar3-year limited warranty.

Difficulties can occur. Use the following problemdiagnosis charts to help pinpoint problems. In mostcases, you will need the assistance of your Indmar deal-er to correct the cause of the problem.

Poor Gas Mileage1. Fouled spark plugs2. Plugged flame arrestor3. Poor driving habits4. Closed or partially closed choke (Carbureted

Engines Only)5. Plugged positive crankcase ventilation system6. Black smoke at exhaust outlet shows rich gas mixture7. Excessive boat loads (weight)8. Damaged or dirty hull9. High altitude adjustment required10. Adjustment for temperature extremes required

Hard Cold Start1. Weak or discharged battery2. Choke held open (Carbureted Engines Only)3. Loose coil or ignition wires4. Engine Flooded5. Fouled spark plugs6. Lack of fuel at carburetor (Carbureted Engines Only)7. Battery cables loose or corroded8. Loose electrical grounds at engine9. Ignition switch problems10. Dirt or water in fuel system11. Engine needs tune-up

Poor High Speed Performance1. Fouled spark plugs, incorrect spark plug gap or heat

range2. Closed or partially closed choke (Carbureted

Engines Only)3. Dirt or water in fuel4. Lack of fuel in carburetor (Carbureted Engines Only)5. Restricted exhaust system6. Plugged flame arrestor

Chapter 8TROUBLESHOOTING


7. Insufficient air supply to engine8. Engine needs tune-up9. Damaged or incorrect propeller10. Engine needs to be adjusted for high altitude

operations11. Engine needs to be adjusted for temperature

extremes

Engine Cranks / Won’t Start1. Weak or shorted coil, no spark at plugs2. Loose engine grounds3. Lack of fuel at carburetor (Carbureted Engines Only)4. Weak or discharged battery5. Boat Engine Safety switch not attached6. Vapor lock

Idle — Misses or Runs Rough1. Spark plugs fouled or cracked2. Spark plug or distributor wires loose or shorted3. Plugged positive crankcase ventilation system4. Engine in need of tune-up5. Engine needs to be adjusted for high altitude

operations6. Engine needs to be adjusted for temperature

extremes7. Carburetor out of adjustment (Carbureted Engines

Only)

Hard Start Hot1. Flooding condition2. Loose electrical ground at engine3. Closed choke (Carbureted Engines Only)4. Plugged flame arrestor5. Fouled spark plugs6. Loose coil or ignition wires7. Battery cables loose or corroded8. Weak or discharged battery 9. Vapor lock

Engine Won’t Crank1. Weak or discharged battery; loose or corroded

battery cables2. Defective Neutral Safety Switch or adjustment needed3. Defective starter motor4. Ignition switch problems5. Hydrostatic lockup — remove spark plugs to look for

water or gasoline in cylinders6. Seized engine — turn crank pulley with socket and

ratchet

Indmar Marine Engines A-1

Engine Oil 15W-40 Pennzoil Marine, API Service SJ/CG4 Racing Oil

Engine Oil Filter All 5.7 Liter except LS1 - Pennzoil PZ3LS1 - NAPA Gold 1042

8.1 Liter - AC-PF454

Engine Coolant (for closed systems) Sierra brand propylene glycol

ZF Hurth Transmission Fluid & V-Drive Pennzoil Type A Dexron II, III or Dexron/Mercon

Walters V-Drive Oil SAE 30 Pennzoil Motor Oil

Engine Fuel (for storage) STA-BIL fuel stabilizer

Engine Cables (for corrosion protection) Pennzoil Marine Z-M Corrosion Protectant and Lubricant

Starter Bendix Pennzoil Premium Plus Multipurpose Grease

Fuel Filter In-Line - Indmar 556003Spin-on - Indmar786020

Appendix – AMAINTENANCE COMPONENTS AND FLUIDS

A-2 Indmar Marine Engines

Alternator Belt All 5.7 Liter except LS1 - Indmar 725018LS1 serpentine - Indmar 725028

8.1 Liter - Indmar 725030

Thermostat Raw water cooled - Indmar 985009Closed cooled - Indmar 986034

LS1 - Indmar 986110

Spark Plugs All 5.7 Liter except LS1 – AC Delco MR43LTSLS1 – AC Delco AC41-931

8.1 Liter – Nippon Denso TJ14R-P15

Surface Corrosion Protection Pennzoil Marine Z-M Corrosion Protectant and Lubricant

Engine Fogging Oil Pennzoil Marine Fogging Oil

5.7L Carb 5.7L TBI 5.7L MPI LS1 Corvette 8.1L MPINumber of Cylinders V-8Displacement 350 CID (5.7L) 496 CID (8.1L)Bore/Stroke 4.0012 x 3.480 in (101.63 x 88.39 mm) 3.898 x 3.622 in 4.25 x 4.37 in

(99 x 92 mm) (108 x 111 mm)Compression Ratio 9.4:1 10.1:1 9.1:1Compression Pressure (Note 1) Minimum 100 PSI (690 kPa)Idle RPM in Neutral (Note 2) 650 ± 50 RPMOperating Range at WOT 4400-4800 RPM 4600-5200 RPM 5200-5600 RPM 5000-5400 RPMOil Pressure at Idle 4PSI (41kPa) Minimum - Hot 5 PSI (34kPa) MinimumOil Pressure at 2000 RPM 18 PSI (124 kPa) Minimum Hot 10 PSI (69kPa) MinimumOil Filter Pennzoil PZ3, AC-PF25 Napa Gold 1042 AC-PF454Fuel Pump Pressure 8 PSI Max 30 PSI Min at Keyup 40 PSI Min at Keyup 50 PSI Min at Keyup

(55.2 kPa) (206.8 kPa) (275.8 kPa) (344.7 kPa)Electrical System 12 Volt DC Negative (-) GroundMinimum Battery Requirements 650 cca/700 mca/120AhFiring Order 1-8-4-3-6-5-7-2 1-8-7-2-6-5-4-3Spark Plug Type MR43LTS AC 41-931 Nippon Denso TJ14R-P15Spark Plug Gap 0.030 in (.76 mm) 0.045 in (1.1 mm) 0.050 in (1.3 mm)Base Timing at 1000 RPM (Note 3) 10˚ Before Top Dead Center Non AdjustableThermostat 160° F (71° C)

Indmar Marine Engines B-1

Appendix – BENGINE SPECIFICATIONS

B-2 Indmar Marine Engines

Fluid Capacities 5.7L Carb 5.7L TBI 5.7L MPI LS1 Corvette 8.1L MPICrankcase (With Filter)(Note 4) 5.5 Quarts (5.25 L) With Filter 8 Quarts (7.6 L)Closed Cooling System (Note 5) 12-14 Quarts (11.4-13.3 L) 14-16 Quarts (13.2-15.1 L)

In-Line Transmission (Note 4) 2.12 Quarts (2.0 L)Walters V-Drive Transmission (Note 4) 2 Pints (0.95 L) Not UsedHurth V-Drive Transmission (Note 4) 4.4 Quarts (4.16 L)

Notes1) Minimum recorded compression in any one cylinder should not be less than 70% of the highest recorded cylinder.2) Measured using an accurate shop tachometer at normal operating temperature. Idle RPM on EFI models is not

adjustable.3) Timing must be set using special procedures indicated in the appropriate service manual. Timing cannot be set

using conventional methods. Special tool(s) required.4) Always use dipstick to determine exact quantity of oil required. Do not fill above “FULL” mark.5) Do not over fill. Correct level is 3/4" below filler neck when coolant is warm.

Indmar Marine Engines C-1

What Is Covered by WarrantyAny part(s) that fails as the result of defects in material and workmanship will be replaced at no charge to the customer under theterms of the Limited Product Warranty.

What Is Not Covered by Warranty• Shop supplies used in performing warranty work (i.e. rags, sealants, lubricants, etc.).• Incidental and consequential damages (storage charges, telephone or rental charges of any type, inconvenience or loss of time

or income).• Minor adjustments and tune-ups; including checking, cleaning or adjusting spark plugs, carburetor setting, filters, belts, controls

and checking lubrication.• Failure caused by neglect, lack of maintenance, accident, abnormal operation, improper installation, improper preparation,

improper winterization, improper dealer set-up or improper service or normal wear and tear.• Haul-out, launch, towing charges; removal and/or replacement of boat partitions or material because of boat design for neces-

sary access to the Product.• Transportation charges and/or travel time.• Service requested by customer other than that necessary to satisfy the warranty obligation.• Use of other than Indmar replacement parts and labor to install these parts when making warranty repairs.• Oils, lubricants or fluids used in normal maintenance.• Participation in or preparing for racing or other competitive activity.• Starter motors and/or armatures or field coil assembly, which are damaged from excessive cranking, condensation, or submersion.• Water entering the engine via the intake or exhaust system or submersion.• Use of fuels and lubricants that are not suitable for use with or on the product.

Appendix – CLIMITED WARRANTY

C-2 Indmar Marine Engines

• Failure of any parts caused by lack of cooling water, which results from starting motor out of water or foreign materials blockingintake passages.

• Air freight, next-day or second-day air, or any special delivery fees, unless authorized by Indmar prior to ordering of parts.• Certain parts may be tested on receipt by Indmar. Parts found to be free of defects will be returned to the dealer and no credit

will be issued• Indmar reserves the right to retrieve run time/run condition data from an engines Electronic Control Module prior to granting war-

ranty coverage on the product.

Limited WarrantyIndmar Products Co., Inc., 5400 Old Millington Road, Millington, Tennessee 38053 (“Indmar”) warrants marine propulsion enginessold by it (the “Product”):

NOTICEIndmar reserves the right to retrieve run time/run condition data from an engines Electronic Control Module prior to grantingwarranty coverage on the product.

Product installed in boats manufactured by an approved manufacturer (OEM):a. For a period of thirty-six (36) months commencing from the date of purchase or the date of commencement of the product use,

whichever sooner occurs, in the case of non-commercial use.b. For a period of thirty-six (36) months commencing from the lease date if lease is for private use and is for a time period of not

less than two years. Orc. For a period of three (3) months commencing from the date of purchase or lease inception or the date of commencement of the

product use, whichever sooner occurs, in the case of commercial use.

Repowers or installation in other than boats manufactured by an approved manufacturer (OEM)a. For a period of twelve 12 months commencing from the date of purchase or the date of commencement of the product use,

whichever sooner occurs, in the case of non-commercial use. Orb. For a period of three (3) months commencing from the date of purchase or the date of commencement of the product use,

whichever sooner occurs, in the case of commercial use.

Indmar Marine Engines C-3

This limited warranty is granted SOLELY upon the following terms

a. Persons Applicable. This warranty is extended to the original retail purchaser or original lessor in the case of a leased boat. If theboat is sold or traded prior to the end of the warranty period, the remainder of the product warranty is transferable to the newowner or lessor. A fee of $200.00 will be required to transfer the warranty. Warranties of any nature to any other person are here-by specifically excluded.

b. Coverage. The product is warranted to be free from material defects in material and workmanship under normal use and serviceduring the period of this Limited Warranty. Components that are "worn-out" from use are not covered under the terms of this war-ranty. If the product or defective part thereof is, upon examination, determined to be thus defective, Indmar shall repair or, at itssole option, provide a replacement of equivalent quality (new or rebuilt, at its option.) Indmar’s sole obligation under this LimitedWarranty is to repair or at its sole option, to provide a replacement of equivalent quality (new or rebuilt, at its option).

c. Procedure. Within 10 days from the date of purchase by the original retail purchaser of the product or beginning of lease period,the Indmar Warranty Registration Card must be properly completed and mailed to Indmar. In the case of a leased boat, a copyof the lease contract showing the length of the lease must also be supplied to Indmar. In the case of a warranty transfer to a sub-sequent owner or lessor, the new owner/lessor information along with a check for $200.00 made payable to Indmar WarrantyTransfer must be sent within 60 days of transfer. Any transfer must be approved by Indmar. In the case of transfer of a leasedboat, a copy of the lease contract showing the length of the lease must also be included. No warranty claims will be honoredwithout prior receipt of the Indmar Warranty Registration Card. For warranty claims to be asserted hereunder, the Product ordefective part thereof, together with a written notice of itemized defects must be returned to the retailer from whom the productwas purchased or to any other convenient Indmar dealer. To obtain the location of an authorized Indmar dealer or service centerin your area, write to Indmar requesting such information. In the event that the local Indmar dealer is unable to remedy a war-ranted defect in the Product, the Product or defective part thereof, together with a written notice of itemized defects, must bereturned to Indmar with freight and insurance charges prepaid. All insurance and freight charges and return charges by Indmarof the Product (or its substitute) to the retail purchaser shall be paid by the purchaser. Expenses for labor incurred by Indmar inthe repair of any warranted product shall be paid by the retail purchaser or lessor to the extent that such expenses for laborexceed the specified service rates of Indmar in effect at the date of purchase by Indmar. A schedule of service rates of Indmarmay be obtained from any authorized Indmar dealer.

d. Trade Accessories. No warranty of any character is made with respect to trade accessories not manufactured by Indmar.

C-4 Indmar Marine Engines

e. Voiding Warranty. This warranty is specifically voided and shall NOT apply under the following conditions:i. When the product or any part thereof is subjected to accident, alteration, modifications, abuse, misuse, neglect,

or improper maintenance.ii. When the product is serviced by unauthorized persons; oriii. When damage to the product results from causes not arising from defects in material and/or workmanship.

THE WARRANTY STATED ABOVE IS A LIMITED WARRANTY AND IT IS THE ONLY WARRANTY MADE BY INDMAR. INDMARDOES NOT MAKE ANY OTHER WARRANTIES EXPRESS OR IMPLIED. THERE ARE EXPRESSLY EXCLUDED ALL WAR-RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. INDMAR SHALL HAVE NO LIABILITYWITH RESPECT TO ITS OBLIGATIONS UNDER THIS WARRANTY OR OTHERWISE FOR CONSEQUENTIAL, EXEMPLARY,INCIDENTAL OR PUNITIVE DAMAGES EVEN IF IT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THESTATED EXPRESS WARRANTY IS IN LIEU OF ALL LIABILITIES OR OBLIGATIONS OD INDMAR FOR DAMAGES ARISINGOUT OF OR IN CONNECTION WITH THE DEVELOPMENT, DELIVERY, USE, OR PERFORMANCE OF THE PRODUCT. IN ANYEVENT THE LIABILITY OF INDMAR FOR ANY REASON AND UPON ANY CAUSE OF ACTION WHATSOEVER SHALL BE LIM-ITED TO THE AMOUNT THEN PREVIOUSLY PAID FOR THE PRODUCT.

Indmar does not authorize any person, firm or corporation to alter this Limited Warranty or create any other obligation relating to theproduct. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Indmar Products Co., Inc.5400 Old Millington RoadMillington, Tennessee 38053

Part No. OM0502-01 Printed in U.S.A.Ken Cook Co.

5400 Old Millington RoadMillington, TN 38053www.indmar.com

SAE 15W-40

Indmar Cover 1/17/01 8:57 AM Page 4

operator’s manual - indmar

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